This functional Factory Acceptance Testing (FAT) Protocol & Live Execution Script builds directly upon the pre-FAT cold check sign-off. It provides a step-by-step procedure for controlled first-time energisation, safety system trip validation under BS EN 60204-1 / BS EN ISO 13849-1, and systematic PLC I/O loop checks.

Factory Acceptance Testing (FAT) Protocol & Live Script

Document Reference: FAT-PROT-[YEAR]-[001]

Panel Reference: [e.g., MCC-L3-001]

Associated SOW: [SOW-Reference-No]

Test Location: [Workshop / Test Bay Name]

Date of Test: [DD/MM/YYYY]

Test Personnel:

Lead Electrical Wireman / Commissioning Engineer: [Contractor Representative]
Lead Controls / Software Engineer: [Software Engineer Name]
Client / Technical Witness: [Client Representative Name]

1. Safety Prerequisites & Pre-Energisation Sign-Off

SAFETY NOTICE: Prior to connecting temporary test supplies, verify that the Pre-FAT Cold Inspection Sheet is signed off, all trunking lids are closed, bare copper is shrouded, and test bay barriers/signage are erected.

[ ] Section 1–6 Cold Checks completed and signed off.
[ ] Calibration certificates verified for digital multimeter (CAT III/IV) and phase-rotation meter.
[ ] Temporary 3-phase/neutral/earth supply isolated, locked out, and tagged out (LOTO).
[ ] Fire protection equipment suitable for electrical fires ($CO_2$) within reach.

2. Stage 1: Initial Controlled Energisation Script

┌──────────────────────────────────────────────────────────────────────────────┐
│                    CONTROLLED ENERGISATION SEQUENCE                          │
├──────────────────────────────────────────────────────────────────────────────┤
│ 1. Isolate all branch MCBs/MPCBs/fuses on the chassis.                       │
│ 2. Close main incoming switch-disconnector (door isolator).                  │
│ 3. Prove incoming voltage (L-L, L-N, L-PE) and phase sequence (L1-L2-L3).    │
│ 4. Step-energise auxiliary transformers and 24V DC Switch Mode Power Supply. │
│ 5. Sequentially energise downstream field distribution breakers.             │
└──────────────────────────────────────────────────────────────────────────────┘

Step	Action / Procedure	Expected Result	Measured / Observed	Pass / Fail	Initials
1.1	Open all internal outgoing MCBs, MPCBs, and auxiliary fuses. Leave only the main incoming line switch closed.	Incoming terminals live; all internal load circuits isolated.	Complete isolation confirmed	`[ ]`
1.2	Connect supply. Measure incoming supply voltage at main isolator terminals `L1-L2`, `L2-L3`, `L3-L1`.	$400\text{V AC} \pm 10\%$ ($360\text{V} – 440\text{V}$) balanced across phases.	`L1-L2:` ______ V `L2-L3:` ______ V `L3-L1:` ______ V	`[ ]`
1.3	Measure incoming neutral to earth `N-PE`.	$< 5\text{V AC}$ under normal workshop supply conditions.	`N-PE:` ______ V	`[ ]`
1.4	Check phase rotation using calibrated meter.	Clockwise (standard L1-L2-L3 sequence).	Clockwise confirmed	`[ ]`
1.5	Close 24V DC Power Supply primary circuit protection.	PSU powers up; “DC OK” LED illuminated.	Green LED ON	`[ ]`
1.6	Measure regulated DC output at main distribution terminals (`+24V` to `0V`).	$24.0\text{V DC} \pm 0.4\text{V}$ (range $23.6\text{V} – 24.4\text{V}$).	`Measured:` ______ V	`[ ]`
1.7	Measure DC reference rail to earth (`0V` to `PE`).	Matches grounding philosophy: $0.0\text{V}$ (grounded SELV) or high-impedance floating (PELV).	`0V-PE:` ______ V	`[ ]`

3. Stage 2: Functional Safety Circuits & E-Stop Trip Validation

Tested in accordance with BS EN ISO 13849-1 (PLr architecture) and BS EN 60204-1.

Step	Safety Device Under Test	Test Method / Operator Action	Expected Reaction	Observed Reaction	Pass / Fail
2.1	Safety Relay Reset	Ensure all E-Stops released. Press panel door “Safety Reset” pushbutton.	Safety Relay energises; safety contactors pull in; channel LEDs illuminate steady green.		`[ ]`
2.2	Door Emergency Stop (S1)	Depress panel door E-Stop mushroom pushbutton.	Instant drop-out of safety relay and dual redundant contactors ($< 50\text{ ms}$). HMI/Beacon indicates “E-Stop Tripped”.		`[ ]`
2.3	Safety Relay Anti-Tie-Down	Hold Reset button pressed while releasing E-Stop S1.	Relay MUST NOT automatically reset (fault-lockout mode). Manual re-press required.		`[ ]`
2.4	Dual-Channel Cross-Fault Check	Disconnect one channel (Channel A) at safety gate/terminal while relay is active.	Safety relay trips immediately; cross-monitoring detects discrepancy; relay inhibits re-energisation.		`[ ]`
2.5	Safety Interlock Switches (Door Switches)	Actuate guard door magnetic/RFID interlock switch while safety is active.	Safety circuit de-energises; auxiliary contact flags open safety guard on PLC input.		`[ ]`
2.6	Orange Core Foreign Interlocks	Turn main door isolator OFF. Check voltage on designated orange control cores.	Interlock terminals remain active (indicated by orange wire and external supply warning label).		`[ ]`

4. Stage 3: PLC I/O Loop Testing & Software Verification

Connect programming terminal via industrial Ethernet/Profinet. Verify individual hardware states against the master engineering I/O list.

Digital Inputs (DI) Verification

Method: Apply local 24V DC test signal / operate field switch sim.

Channel / Address	Terminal Ref	Description / Signal Name	Hardware State	PLC Monitor Tag	Result
`%I0.0`	`X2:1`	Main Air Pressure Switch OK	`ON / 24V DC`	`DI_AirPress_OK = TRUE`	`[ ]`
`%I0.1`	`X2:2`	Cell Safety Guard Closed	`ON / 24V DC`	`DI_Guard_Closed = TRUE`	`[ ]`
`%I0.2`	`X2:3`	Master Start Pushbutton	`Depressed`	`DI_Master_Start = TRUE`	`[ ]`
`%I0.3`	`X2:4`	VFD 1 Fault Healthy Contact	`Simulate Trip`	`DI_VFD1_Trip = TRUE`	`[ ]`

Digital Outputs (DO) Verification

Method: Force output through PLC engineering software / HMI manual mode.

Channel / Address	Terminal Ref	Description / Signal Name	Software Force	Physical Reaction	Result
`%Q0.0`	`X3:1`	Beacon Green (Running)	`FORCE HIGH`	Green stack light element illuminated.	`[ ]`
`%Q0.1`	`X3:2`	Beacon Red (Fault/Trip)	`FORCE HIGH`	Red element illuminated + sounder pulse.	`[ ]`
`%Q0.2`	`X3:3`	Main Contactor 1 Enable	`FORCE HIGH`	Contactor coil pulls in; auxiliary closes.	`[ ]`
`%Q0.3`	`X3:4`	Pneumatic Solenoid Dump Valve	`FORCE HIGH`	24V DC measured at field connector terminals.	`[ ]`

Analogue I/O Checks (AI / AO)

Method: Calibrated 4–20mA / 0–10V process loop calibrator.

Channel	Signal Type	Test Point	0% Input	50% Input	100% Input	Linear Scaled Value	Result
`%IW64`	`4–20 mA`	Pressure Transducer	$4.00\text{ mA}$	$12.00\text{ mA}$	$20.00\text{ mA}$	$0.0 – 10.0\text{ bar}$	`[ ]`
`%QW64`	`0–10 V`	VFD Speed Reference	$0.00\text{ V}$	$5.00\text{ V}$	$10.00\text{ V}$	$0.0 – 50.0\text{ Hz}$	`[ ]`

5. Live Snagging & Punch-List Log

Item #	System / Component	Defect Observed	Remedial Action Required	Target Rectification	Cleared (Initials)
1	`[e.g., Beacon Sounder]`	`No audible tone when forced`	`Check 0V return on terminal X3:5`	`Pre-dispatch`	`[ ]`
2	`[e.g., MPCB 2 Aux]`	`Aux contact normally open instead of NC`	`Swap terminal connections on block`	`Pre-dispatch`	`[ ]`

6. FAT Certification Sign-Off

Conditional Acceptance:

The panel assembly described herein has been tested in accordance with the FAT functional protocol. Subject to the clearance of any minor non-conformances listed in Section 5 above, the panel is certified for dispatch and site delivery.

Lead Commissioning Engineer / Contractor:

Name: ___________________________________

Signature: ________________________________

Date: [DD/MM/YYYY]

Client Witness / Technical Representative: