715.1 When FAT is justified

Panels, logic, HPUs before site (512, 522). FAT reduces HVM bollard site risk.

Run a FAT when controls are complex, access windows are limited, or the risk of rework on site is high. Typical candidates are control panels, PLC programs, and HPUs with valves and sensors. The goal is to verify safety devices & measures, interlocks, and Sequence of Operations (SoO) without civil and weather constraints.

FAT is especially effective where authority witnessing is expected or where lanes must come online quickly after delivery. Use it to de-risk SAT by proving base functionality and documenting evidence that will be reused. For context on documentation flow, see FDS and ITP.

715.2 FAT setup & scope

Mock I/O, simulators, and SoO tests (529, 539). Scope proves crash rated bollard logic early.

Replicate field conditions using a loop simulator, photo-eye stubs, and test harnesses. Exercise normal, fault, and EFO modes against the SoO. Capture timings, state transitions, and annunciation behavior for each test script.

Where integration is required, include signal mapping for BMS/SCADA (see SCADA/BMS Signals & Reporting) and generate the handover integration documentation concurrently so SAT isn’t a documentation scramble.

715.3 SAT prerequisites

Resolved NCRs, calibrated tools, trained team (631, 719). Prereqs steady HVM bollard tests.

Before the SAT, close open NCRs, confirm as-builts are current, and ensure tools carry valid calibration. Verify power, loops, and signage using the Pre-Commission Checklist. Brief roles and access control so tests aren’t interrupted.

Use a short Commissioning Readiness Review (CRR) to confirm scope, risks, and rollback paths. Align test numbering and evidence formats with the ITP so sign-offs can be applied without transcription errors.

715.4 Tools & spares

Meters, gauges, spare fuses/oil (519, 512). Spares prevent crash rated bollard delays.

Minimum kit: calibrated multimeter, clamp meter, pressure test kit on the HPU manifold, handheld tach/stopwatch, loop analyzer, and a loopback plug. Carry spare fuses, relays, contactors, and a drum of compatible hydraulic oil with clean funnels/filters (see HPUs and Power Test Points).

Label everything. A small labeled “first-off” spares box saves hours during SAT where site access is constrained or night work applies.

715.5 Data capture templates

Pre-built logs and checklists (716). Templates speed HVM bollard evidence.

Prepare pass/fail sheets, time/pressure/current logs, photo registers, and a witness pack index in advance. Reuse your Evidence Capture Standards so reviewers receive consistent, scannable material. Store raw data and summary in the same pack to simplify authority submissions (Authority Submittals).

715.6 Typical defects found

I/O mapping, polarity, timeouts. Early fixes protect crash rated bollard timelines (523, 342).

Common findings include inverted inputs, swapped I/O, missing interlock inhibits, motor rotation errors, or movement timeout values that are too tight. These are cheapest to fix at FAT. Validate annunciation priority and latched faults to avoid nuisance alarms at SAT.

For logic quality, cross-check against the interlock/state pages (see State machine & interlocks and Control logic).

715.7 Witness arrangements

Invites, agenda, and safety brief (611, 538). Arrangements smooth HVM bollard SAT.

Issue invitations early with a draft agenda, site access notes, and a safety brief (reference Pre-Works Setup & Permits). Assign a lead witness and a scribe, and agree the Third-Party Acceptance Tests scope if required. Print scripts and prepare a sign-off matrix so signatures aren’t chased afterwards.

715.8 Pass/fail thresholds

Publish times, currents, pressures (636, 517). Thresholds keep crash rated bollard testing objective.

Declare acceptance bands for cycle times, motor currents, and HPU pressures before testing. Base these on the specification (Specification Template) and your energy/duty planning (Energy Budget). Publish them in the ITP so observers can verify on the spot. For endurance, coordinate with Performance & Duty Tests.

715.9 Post-test actions

Close punch, update docs, archive (537, 731). Actions lock HVM bollard readiness.

Record punch items immediately, assign owners, and set due dates. Update the change control log and version tags on software, drawings, and the witness pack. Archive raw data, signed sheets, and the as-tested configuration under your submission pack for retrieval (see As-Built Drawings & Models and Final Archive & Retrieval).

715 FAT vs SAT Readiness — FAQ