Factory Acceptance Testing
Go Armed, Go Ready
The infamous FAT,
Rule No.1 Organise the beers (or wine) After the FAT, not before, you are spending a lot of money start with a clear head.
This will give you a rough guide of what to look for, to ensure your ElecSpec Compliance Spec & Drawings are followed up by
a quality Switchboard.
FAT - Your Full Switchboard Checklist
Further to the manufacture and completion of the detailed project in accordance with the approved drawings and the in-house testing, already carried out (Ask for Certs), the project is now offered to you for witness testing (I'd always take this unless you have been to the manufacturer, have a rapport and 100% confidence in their design).
The purpose of the Factory Acceptance Test is to verify to you the functionality of the complete solution and to verify its compliance with the approved drawings, before delivery to site.
As a good guide if you follow below you won't go far wrong, the only advice I would give is to understand the basic requirements and control of your scheme.
Mechanical Tests
The external/internal examination of the switchboard, checking for the following has been carried out/fitted correctly:
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- Overall dimensions and layout of switchboard conforms to drawings
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- General quality and appearance check. Including paintwork and finish
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- Compare GA drawing to LV Panel Drawing. Ensuring all instrumentation and appearance has been fitted as per GA
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- Ensure switchboard is constructed to the correct form and type as designated on the drawings
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- Check to ensure product complete busbar system has three paints on each copper connection
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- Check Earth Busbar has been correctly installed and all earth bonding is carried out
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- Ensure all incoming devices are of the following:
+ Correct Frame & Trip Rating
+ Correct Accessories
+ Correct Shrouding
+ Phase Indication
8. - Ensure all outgoing devices are of the following:
+ Correct Frame & Trip Rating
+ Correct Accessories
+ Correct Shrouding
+ Phase Indication
9. - All identification & warning labels have been fitted throughout the product
10. - Ensure all internal & external control components are labelled correctly
11. - Check to ensure an adequate allowance for all incoming and outgoing cabling
12. - Continuity Test ensuring the busbar connection between incoming and outgoing devices
13. - Measure ALL the Mains Busbars and check compared to the Short Circuit Certification & Temperature Rise Documentation, ensuring the match
14. - Busbar/Connection bolt checking, ensure the torque system the implement is to your requirements (each bolt to be checked three times is my preferred but each manufacturer will have their own)
+ Torque Setting below:
Bolt Torque Settings
Bolt / Connection = Torque Setting
6MM NUT+BOLT-COPPER/BARS = 7.2 N/M
8MM NUT+BOLT-COPPER/BARS = 18 N/M
10MM NUT+BOLT-COPPER/BARS = 28 N/M
12MM NUT+BOLT-COPPER/BARS = 45 N/M
TX CLAMP M10 BOLTS = 10 N/M
TX 12MM BRASS PLATED = 20 N/M
TX 16MM BRASS PLATED = 28 N/M
Electrical Tests
The examination of the switchboards electrical operation, checking for the following has been carried out to enable 'power' to be distributed to the whole switchboard:
TRANSFORMER - INSULATION RESISTANCE TESTING
The purpose of this test is to ensure that all insulated electrical conductors (R Y & B) meet with the required insulation resistance level between each other and to earth.
The required BS specification pass, based on a 5000V D.C. applied test voltage is, 1000MΩ
Test Procedure:
+ M.V to EARTH
+ M.V to L.V
+ L.V to EARTH (2500V for 5 Seconds)
*Repeated again after the Pressure Testing*
TRANSFORMER - PRESSURE TESTING
The purpose of this test is to ensure that all-electrical clearances between each exposed electrical conductor & earth meet the BS requirements.
The test voltage applied is 16.7KV, and each test will be carried out for 60 seconds
Test Procedure:
+ M.V to L.V to EARTH
+ L.V to EARTH (Undertaken at 2500V AC for 5 seconds
L.V SWITCHBOARD BUSBARS - INSULATION RESISTANCE TESTING
The purpose of this test is to ensure that all insulated electrical conductors (L1 L2 L3 & N) meet with the required insulation resistance level between each other and to earth.
The required BS specification pass, based on a 1000V D.C. applied test voltage is, 200MΩ
Test Procedure:
+ L1/L2/L3/N to EARTH
+ L2/L3/N/EARTH to L1
+ L1/L3/N/EARTH to L2
+ L1/L2/N/EARTH to L3
+ L1/L2/L3/EARTH to N
*Repeated again after the Pressure Testing*
L.V SWITCHBOARD BUSBARS - PRESSURE TESTING
The purpose of this test is to ensure that all-electrical clearances between each exposed electrical conductor & earth meet the BS requirements.
The test voltage applied is 2.0KV, and each test will be carried out for 5 seconds
Test Procedure:
+ L1/L2/L3/N to EARTH
+ L2/L3/N/EARTH to L1
+ L1/L3/N/EARTH to L2
+ L1/L2/N/EARTH to L3
+ L1/L2/L3/EARTH to N
Functional Tests
The examination of the switchboards function operation, checking for the following has been carried out to enable functionality of the switchboard to the specification & drawings:
Description of item to be Inspected
+ Injection, Testing and demonstration of any protection relays, such as REF, Temperature Relays, etc.
+ Product to be energised through the incomer
+ Check the voltage on each meter instrumentation - Three Phase & Single Phase Voltage
+ Product incoming supplies automatic control switching operation to be proved in accordance with control philosophy documentation
+ Product incoming supplies manual control switching operation & interlocking to be proved in accordance with control philosophy documentation
+ Correct operation of the power factor correction, injecting of an inductive current through the main C.T
+ Remaining tripping/control circuits to be energised and proven
+ BMS Status signals, each to be proved for correct operation in accordance with approved drawings
+ Undertake any Secondary Injection testing of Air Circuit Breakers (ACB's)
+ Meter Primary Current Injection Testing to Ensure:
- Correct CT’s installed on Busbar
- Verifying wiring from CT’s to Digital Meter Inputs
- Verifying accuracy of Digital Meter by comparing
+ Metering Modbus Comms Address testing to each meter, simulating a BMS system.
Finally, check anything else bespoke to your product, gather all test equipment, calibration certification and once that's done, you are
ElecSpec compliant.