JKS-template-FAT Protocol JKS 20170825

Factory Acceptance Test Protocol
(FAT)
Project Name
Project Workorder
Customer
Customers Address
Quotation No
Customer PO No
Date of Order
Machine type
Machine Code
Quotation No
Layout
Schematics
Pneumatic Diagram
Specification Sheet
Electrical Diagram
Factory Acceptance Test Protocol (FAT)
Contents
1. Inspection Equipment used..........................................................................................2
2. Completion of scope of delivery...................................................................................3
3. General Checkpoints....................................................................................................3
4. General functional test.................................................................................................5
5. General process test..................................................................................................10
6. Safety devices............................................................................................................13
7. Machine asethetics and egronomics.........................................................................15
8. Machine Labeling.......................................................................................................16
9. Software and Control.................................................................................................17
10. Accessories / Baskets................................................................................................19
11. Documentation...........................................................................................................19
12. Delivery / Commissioning / Consumables.................................................................21
13. Trainings / Instructions...............................................................................................22
14. Work still to be accomplished / Open Points List (OPL)............................................23
15. Scheduling / Next steps.............................................................................................25
16. Remarks.....................................................................................................................26
Page 2 of 29
Y = Passed / N = Not passed / NA = Not applicable
1. Inspection Equipment used

During the FAT-acceptance test, the following inspection equipments have been used:
Type of the inspection

equipment Type / Supplier Comment
( inspection equipment)
Decibel meter PROSKIT
Multimeter
HANNA
Thermometer
INSTRUMENT
Stop watch N/A
Pressure measuring device JKS
Vacuum measuring unit N/A

Conductivity/Resistivity/pH
MYRON L
measuring unit
Tape measure Stanley
Ultrasonic Meter
Ultrasonic Meter
Online
Electrostatic Meter Field SIMCVO
PROVA
Air Flow Meter
INSTURMENT
Endoscope ADRONIC
Page 3 of 29
2. Completion of scope of delivery

Checkpoint Y N
Does the machine scope as per describe in quotation?

2.1
Remarks:
Is all accessories for the project present and completed as per
quotation (Example, basket or other supporting equipment,
2.2 such as DI systems, Chillers)
Remarks:
3. General Checkpoints
Checkpoint Y N NA
Do the machine dimensions and / or the installation

dimensions correspond to the signed layout?
3.1
Remarks:
Are the exhaust outlet location executed as per layout?
3.2
Remarks:
Are the piping inlet/outlet location and port sizes executed as
per layout?
3.3
Remarks:
Are piping executed as per schematics? Size of pipeline etc.
etc.
3.4
Remarks
Are all instrumentations and equipment present as per
schematics?
3.5
Remarks
Page 4 of 29
Visual check for potential leaks (any leaks in the tubings,

pipings or tank)?
3.6
Remarks:
Are pneumatic systems executed as per pneumatic diagram?
3.7
Remarks:
Does the specification of instrumentation and equipment as
per specification sheet?
3.8
Remarks:
Does the accessibility for maintenance is by acceptable
standard?
3.9
Remarks:
Page 5 of 29
4. General functional test

Functional test for robotic arm
Checkpoint Y N NA
Is robotic arm vertical and horizontal movements smooth

without unusual noises and vibration?
4.1
Remarks:
Robotic arm vertical and horizontal movements max speed?
Horizontal :
4.2 Vertical :
Remarks:
Robotic arm vertical and horizontal sensors in correct position
and quantity?
4.3
Remarks:
Robotic arm vertical and horizontal safety sensors functioning
and tested?
Top Overtravel :
Btm Overtravel :
Left Overtravel :
4.4
Right Overtravel :
Mishook :
Crash :
Remarks:
Robotic arm tested with rated basket load?
Please simulate robotic arm movement with rated load
4.5
Remarks:
Robotic arm movement speed profiles tested and checked?
4.6
Remarks:
Page 6 of 29
Robotic arm pick up and put down for each STN tested and
with safety tolerance?
Loading :
STN 1 :
STN 2 :
STN 3 :
4.7 STN 4 :
STN 5 :
STN 6 :
STN 7 :
STN 8 :
Unloading :
Remarks:
Functional test for agitation mechanism

Checkpoint Y N NA
Is the agitation movements smooth without unusual noises

and vibration?
4.8
Remarks:
Agitation movements speed?
Times/min :
4.9
Remarks:
Agitation height?
Height:
4.10
Remarks:
Page 7 of 29
Functional test for liftout mechanism

Checkpoint Y N NA
Is the liftout movements smooth without unusual noises and

vibration?
4.11
Remarks:
Liftout min and maxspeed?
Min :
4.12 Max :
Remarks:
Liftout mechanism safety sensors functioning and tested?
Top Overtravel :
4.13 Btm Overtravel :
Remarks:
Functional test for loading/unloading conveyor

Checkpoint Y N NA
Is the loading/unloading conveyor movements smooth without

unsual noises and vibration?
4.14
Remarks:
Loading / unloading movement speed?
Speed :
4.15
Remarks:
Loading/Unloading conveyor tested with full load?
4.16
Remarks:
Page 8 of 29
Loading/Unloading conveyor interface with Robotic arm

tested?
Loading/Robotic arm interface :
4.17
Robotic arm/Unloading interface :
Remarks:
Loading/Unloading conveyor basket pitching adjustment
done?
4.18
Remarks:
Functional test for basket IN/OUT mechanism

Checkpoint Y N NA
Is the basket IN/OUT mechanism movements smooth without

unusual noises and vibration?
4.19
Remarks:
Basket IN/OUT movement speed?
Speed :
4.20
Remarks:
Basket IN/OUT tested with full load?
4.21
Remarks:
Page 9 of 29
Functional test for shutter door mechanism

Checkpoint Y N NA
Is the shutter door mechanism movements smooth without

unusual noises and vibration?
STN 1 :
STN 2 :
STN 3 :
4.23
STN 7 :
STN 8 :
Remarks:
Shutter door movement speed?
STN 1 Speed :
4.24
Remarks:
Can the shutter door close the tank fully?
STN 1 :
STN 2 :
STN 3 :
4.25
STN 7 :
STN 8 :
Remarks:
Functional test for conveyor system

Checkpoint Y N NA
Does the conveyor mesh size and type as per quotation?

4.26
Remarks:
Does the part fit into the conveyor mesh?
4.27
Remarks:
Page 10 of 29
Does the conveyor speed range as per quotation?

Please record down Min and Max speed.
Please check actual with measuring tape
4.28
Max speed: /
Min Speed: /
Remarks:
Does all parts go through all conveyor station without any
collision?
4.29
Remarks:
Does the anti-jam sensor work?
4.30
Remarks:
Does the Torque limiter properly adjusted?
Please test by using stopping the conveyvor mesh by hand to
4.31 check if the torque limiter disengaged properlu.
Remarks:
5. General process test

Checkpoint Y N NA
Page 11 of 29
Is the Heat up time and max achievable temperature for each

station (incl. air blow and dryer STN) according to
specification?
STN 1 : / /
STN 2 : / /
STN 3 : / /
5.1 STN 4 : / /
STN 5 : / /
STN 6 : / /
STN 7 : / /
STN 8 : / /
Please fill up initial temp(°C) / max temp(°C / time(s)

Is the Recirculation / Spray pressure for each station
according to specification? If applicable
STN 1 :
STN 2 :
STN 3 :
5.2
STN 4 :
STN 5 :
STN 6 :
Please fill up operating pressure(bar)

Is the Max vacuum level for each station according to
specification? If applicable
5.3
Please fill up operating vacuum level(kPA)
Page 12 of 29
Is the Conductivity/Resistivity/pH sensor each station

calibrated according to specification? If applicable
STN 1 :
STN 2 :
5.4
STN 6 :
STN 6 :
Please compare handheld value with machine value.

Is the Ultrasonic for each station functioning and according to
specification? If applicable
STN 1 :
5.5 STN 2 :
STN 4 :
Please fill up measured kHZ and mV

Is the Bubbling feature for each station functioning and
STN 4 :
5.6
STN 5 :
STN 6 :
Please fill up operating pressure(bar)

Is the Chilling feature for each station functioning and
5.7
Please fill up operating temp(°C)

Is the Air blow/dryer function for each station functioning and
STN 7 :
5.8
STN 8 :
Please fill up air flow reading(m3/min)
Page 13 of 29
Is the Dosing function for each station functioning and

STN 1 :
5.9 STN 2 :
STN 3 :
Please manually trigger machine to dose 100ml and measure

actual value.
Is the exhaust function for each station functioning and
5.10
Please fill up air flow reading(m3/min)

Is all parts dry after drying process? If applicable.
5.11
Remarks
Page 14 of 29
6. Safety devices
Safety devices personal security
Checkpoint Y N NA
Are all required emergency buttons/pull string available?

Have they been tested and located at a suitable position.
Is the location suitable to minimised accidental triggering?
6.1
Emergency button:
Pull string:
Remarks:
Are all light curtain safety sensor functioning and tested?
6.2
Remarks
Are the necessary safety-switches, door-switches or optical
barriers of the installation (personal security) available? Have
6.3 they been tested?
Remarks:
Are all necessary machine doors and covers available? Are
the locks and key functioning as per intended?
6.4
Remarks
Is the tower light functioning and positioned in a visible
location? Is the colour of the tower light as per standard?
Please specify and test if special request.
Red - Alarm(all alarm)
6.5
Yellow -Manual Mode
Green - Automode
Remarks
Page 15 of 29
Safety elements aqueous machines

Checkpoint Y N NA
Are the required safety interlock sensor present and

functioning? (Pump/Ultrasonic dry run protection/Heater)
STN 1 :
STN 2 :
6.6 STN 3 :
STN 4 :
STN 5 :
STN 6 :
Remarks:
Are the required thermostats for heaters present and
functioning?( All wet and dryer tanks)
STN 1 :
STN 2 :
STN 3 :
6.7
STN 4 :
STN 5 :
STN 6 :
…..
Remarks:
Safety elements JKS solvent machines

Checkpoint Y N NA
Has the vacuum safety-pressure switch been installed

according to the JKS specification? if applicable
6.8
Remarks:
Page 16 of 29
Has the hot-water safety-pressure thermostat been installed

6.9
Remarks:
Has the chamber temperature thermostat been installed
6.10
Remarks:
Has the gas detector been installed according to the JKS
specification? if applicable
6.11
Remarks:
Has the hot water temperature thermostat been installed
6.12
Remarks:
Has the exhaust-air-flow-meter been installed according to
the JKS specification? If applicable
6.13
Remarks:
7. Machine aesthetics and ergonomics

Has all welding marks in the tanks and machine structure
cleaned?
7.1
Please indicate welding mark locations
Are there any scratches or damaged marks on the machine?
Please check all external and visible surface.
7.2
Please indicate problematic location

Are there any scratches or cracks on the sliding door glass/
polycarbonate cover / vacuum shutter door glass?
7.3
Please indicate problematic location
Page 17 of 29
Are all drippan / bottom on machine cleaned of all rubbish and

dirt?
7.4
Remarks
Is the touchscreen height and location suitable for ergonomic
handling?
7.5
Remarks
Is all electrical button and switches height and location
suitable for ergonomic handling?
7.6
Remarks
Is the loading/unloading position suitable for ergonomic
handling of baskets?
Please ensure that there are no obstructions to baskets
7.7 during loading/unloading operation
Remarks
Are all machine covers / sliding door handles at the location
suitable for ergonomic handling?
7.8
Remarks
8. Machine Labelling
Are all pneumatic valve properly labelled and corresponds
with schematic?
8.1
Qty of checked and correct valve
Qty of Valves on machine :
Are all instruments properly label and corresponds with
schematic?
8.2
Qty of checked and correct instruments
Qty of instruments on machine :
Page 18 of 29
Are all electrical components properly label and corresponds

with electrical diagram?
8.4
Remarks
Are all wiring components properly label and corresponds with
electrical diagram?
8.5
Remarks
Are all piping direction arrows properly labelled and
corresponds with the schematic?
8.6
Remarks
Is the machine name plate properly installed with correct
information?
8.7
Remarks
Is all warning labels properly labelled at all danger zones?
High Voltage Warning

Chemical Warning
8.8
Hot Warning
Finger Pinching Warning.
Remarks
Page 19 of 29
9. Software and Control

Checkpoint Y N NA
Does the HMI process value corresponds with the actual

measured value?
9.1 Temperature :
Conductivity/Resistivity/pH :
Flowrate :
Remarks:
Does all the buttons in manual page function as per intended?
9.2
Remarks:
Is all the buttons labels in the manual page corresponds with
actual instrument controlled and schematic?
9.3 (Ex. Valve number )
Remarks:
Is all the light indicators functions as per intended?
(Ex. Valve ON/OFF indication)
9.3
Remarks:
Is the login feature functioning as per intended?
(Ex. Operator , Engineer , Admin restriction)
9.4
Remarks:
Is the all the process setting limits set properly as per
intended
(Ex. Process temperature max allowable temperature setting.
9.5
Slow pull speed limits)
Remarks
Page 20 of 29
Does all the manual buttons on the machine function as per

intended? (Ex. Buzzer Reset button / Alarm Reset / Fast load/
9.6 Fast unload etc...)
Remarks:
Does all water level sensor trigger and functions as per
intended?
STN1 /Max level

STN1SBT1 / Min level
9.7
STN = STATION
SBT = SUB TANK
BFT = BUFFER TANK
Remarks:
Can the machine auto-mode function without alarm for 10
baskets consecutively?
9.6
Time:
Please record time to complete all 10 basket
10. Accessories / Baskets

Checkpoint Y N NA
Does all basket fit into the machine and are according
10.1 requirements/dimensions?
Remarks:
Do the parts fit into the basket and ergonomic to load/unload?
10.2
Remarks:
Is the basket treatment done properly? Is all the welding
marks cleaned?
10.3
Remarks:
Page 21 of 29
11. Documentation
Checkpoint Y N NA
Is the complete technical documentation available?

… Number of copies on paper
11.1
Remarks:
Is the part Operations manual written in the language of the
country of destination?
11.2
Remarks:
Standard: English
Is the schematic available?
11.3
Remarks:
Is the pneumatic diagram available?
11.4
Remarks:
Is the electrical diagram available?
11.5
Remarks:
Is the BOM list available?
11.6
Remarks:
Is the Machine certification available?
11.7
Remarks:
Is the list of recommended spare parts available and has it
been discussed?
11.8
Have these spare-parts been ordered by the customer?
Remarks:
Page 22 of 29
Supplier document of components

-..
-
-
11.9 -
Available?
Certificates of the components
-..
-
-
11.9
-
-
Available?
12. Delivery / Commissioning / Consumables

Checkpoint Y N NA
Can the machine be brought into the building (dimensions and

weight) and has the customer prepared the necessary
12.1 equipment?
Remarks: None
Are the necessary consumables for start up available; who will
organize them?
12.2 Solvent
Azotes
Detergents
Page 23 of 29
13. Trainings / Instructions
The following trainings and instructions have been accomplished before

or during the FAT:
Date Participant Training level / topic Duration Instructor
According the contract / order confirmation, the following trainings / instructions at or

after the start-up at the customer side are planned / have been sold:
Date Participant Training level / topic Duration Planned?
Page 24 of 29
14. Work still to be accomplished / Open Points List (OPL)

Work to be done by / Remarks
10
Page 25 of 29
Work to be done by the customer / Remarks
10
Page 26 of 29
15. Scheduling / Next steps

Works / Activities Date Responsible
Handling of the open

issues concerning the
machine until:
Handling of open points at

Customer
the customer side
Disassembly of the
machine at the factory ;
Ready for dispatch at

Delivery of the machine
(acc. to the order
confirmation)
Positioning of the machine
(ramp to location of Customer
machine)
Preparation of infrastructure
Customer
till
Start date for the assembly

of the machine:
Connection of the machine
to the infrastructure Customer
customer side
Start date for the initial
start-up
Additional training of the
with customer
personal, technicians and
operators
SAT / Final acceptance /
with customer
hand over of the machine
Page 27 of 29
16. Remarks
Page 28 of 29
FAT / Machine Commissioning Acceptance Signature list
The machine complies in all points to the order to, as to the order confirmation dated
on ………………….and any possible supplementary agreements.
The machine has been checked thoroughly concerning functionality and completion.
No deficiencies (except the ones mentioned in the protocol) were found in
connection with the applied materials and the workmanship.
The machine is considered as accepted at the factory/customer site and is released

for delivery/to customer.
Approved/Accepted by:
JKS <Customer >
(Project Engineer) (Customer Project PIC #1)

Name: Name:
Position
(Project Electrical Engineer) (Customer Project PIC #2)

Name: Name:
Position
(Project Manager) (Customer Project PIC #2)

Name:
Name:
Position
Page 29 of 29

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Factory Acceptance Test Protocol

2. Completion of scope of delivery...................................................................................3

4. General functional test.................................................................................................5

5. General process test..................................................................................................10

7. Machine asethetics and egronomics.........................................................................15

9. Software and Control.................................................................................................17

10. Accessories / Baskets................................................................................................19

12. Delivery / Commissioning / Consumables.................................................................21

13. Trainings / Instructions...............................................................................................22

14. Work still to be accomplished / Open Points List (OPL)............................................23

15. Scheduling / Next steps.............................................................................................25

Y = Passed / N = Not passed / NA = Not applicable

1. Inspection Equipment used

Type of the inspection

Decibel meter PROSKIT

Pressure measuring device JKS

Vacuum measuring unit N/A

2. Completion of scope of delivery

Does the machine scope as per describe in quotation?

Do the machine dimensions and / or the installation

Visual check for potential leaks (any leaks in the tubings,

4. General functional test

Is robotic arm vertical and horizontal movements smooth

Functional test for agitation mechanism

Is the agitation movements smooth without unusual noises

Functional test for liftout mechanism

Is the liftout movements smooth without unusual noises and

Functional test for loading/unloading conveyor

Is the loading/unloading conveyor movements smooth without

Loading/Unloading conveyor interface with Robotic arm

Functional test for basket IN/OUT mechanism

Is the basket IN/OUT mechanism movements smooth without

Functional test for shutter door mechanism

Is the shutter door mechanism movements smooth without

Functional test for conveyor system

Does the conveyor mesh size and type as per quotation?

Does the conveyor speed range as per quotation?

5. General process test

Is the Heat up time and max achievable temperature for each

Please fill up initial temp(°C) / max temp(°C / time(s)

Please fill up operating pressure(bar)

Please fill up operating vacuum level(kPA)

Is the Conductivity/Resistivity/pH sensor each station

Please compare handheld value with machine value.

Please fill up measured kHZ and mV

Please fill up operating pressure(bar)

Please fill up operating temp(°C)

Please fill up air flow reading(m3/min)

Is the Dosing function for each station functioning and

Please manually trigger machine to dose 100ml and measure

Please fill up air flow reading(m3/min)

Are all required emergency buttons/pull string available?

Safety elements aqueous machines

Are the required safety interlock sensor present and

Safety elements JKS solvent machines

Has the vacuum safety-pressure switch been installed

Has the hot-water safety-pressure thermostat been installed

7. Machine aesthetics and ergonomics

Please indicate problematic location

Please indicate problematic location

Are all drippan / bottom on machine cleaned of all rubbish and

Are all electrical components properly label and corresponds

High Voltage Warning