Acceptance Test Procedure & Checklist for Cabinets

Acceptance Test Procedure & Checklist for Marshalling Cabinets 

A marshalling cabinet is an electrical enclosure used in industrial control systems to organize and manage wiring between field instruments and a control system like a BMS, SCADA, PLC, DCS. It acts as a central hub for grouping different types of inputs/outputs (I/O) and cross-wiring them, which simplifies maintenance, improves safety, and reduces installation time.

Key functions and purpose

·        Purpose:

To organize, protect, and terminate field wiring before connecting to the control system's I/O cards. It simplifies the wiring process and makes maintenance and troubleshooting easier.

·        Function

Signal routing: Uses "cross-wiring" to re-route signals from multi-core field cables to the correct Input/Output (I/O) modules based on signal type (analog or digital) and I/O assignments.

Signal grouping: It groups different types of signals, such as analog input, analog output, digital input, and digital output. 

Signal conditioning: Can contain signal isolators and conditioners to prepare signals for the control system.
Protection: Includes safety components like relays, fuses, circuit breakers, and surge protection.

·        Common components

Terminal blocks, relays, fuses, power supplies, signal isolators, wiring ducts, and surge protection devices.

·        Signals and voltage

Handles various industrial process signals, such as 4–20 mA, as well as digital inputs and outputs. The voltage can vary depending on the specific application.

·        Wiring organization: 

It provides a clean, organized point for all the field wiring to be terminated and connected. 

·        Typical location

Found in industrial facilities like power plants, refineries, and chemical plants, often situated in a control room or instrument technical room.

·        Cross-wiring: 

It allows field wiring signals to be cross-wired, meaning they are routed to the correct terminal on the control system's I/O module, even if the physical and logical connections are different. 

·        Simplified maintenance: 

By providing a single, organized point of contact, it makes it much easier for maintenance personnel to identify and troubleshoot issues without having to access the control system itself. 

·        Safety: 

It can include safety features like fuses and signal isolators, which protect the control system and personnel. 

·        Flexibility and expansion: 

The organized structure makes it easier to add or change connections for future system expansions and upgrades. 

The main goal of the inspection involves verifying that the marshalling cabinet satisfies project requirements as well as both industrial standards and operational performance specifications. All electrical and communication connections can operate according to design while on-site commissioning duration decreases thanks to this procedure.

Scope of the inspection Procedure for Marshalling Cabinet

This procedure defines inspection and testing standards for marshalling cabinets occurring during equipment manufacturing at manufacturer’s facilities. It includes:

·        Visual inspection

·        Mechanical verification

·        The inspections involve tests for both electrical continuity and insulation resistance.

·        Functional testing

·        Documentation verification

Inspection Procedure – Reference Standards

·        IEC 61439 – Low Voltage Switchgear and Controlgear Assemblies

·        IEC 60204 – Safety of Machinery – Electrical Equipment

·        IEEE Std. 1100 – Powering and Grounding Electronic Equipment

·        Customer project specifications

Responsibilities of Team Involved in Marshalling Cabinet FAT Procedure

·        The manufacturer must fulfill technical requirements through testing capabilities as part of their responsibilities.

·        End users must witness the FAT procedure to check compliance of the system.

·        Third-Party Inspector (if applicable): Ensures adherence to standards and specifications.

Required Tools and Equipment for Marshalling Cabinet FAT Procedure

·        Digital Multimeter

·        Insulation resistance tester (Megger)

·        Earth continuity tester

·        Function generator (for signal simulation)

·        Power supply (as per system voltage requirements)

·        Communication testing tools (as applicable)

·        Standard inspection checklist

·        Thermal imaging camera (for heat dissipation checks)

·        Users need a torque wrench to confirm proper tightening of terminals.

Step by Step Inspection Procedure for Marshalling Cabinet

Step 1: Visual Inspection

·        Check that the cabinet has proper structure integrity along with correct door alignment and appropriate ventilation openings.

·        The project requirements must be satisfied by the selected paint and its surface finish.

·        Confirm that all nameplates and identification labels as well as terminal markings remain in place.

·        All components need to have their correct grounding and bonding connections verified.

·        Check that internal components match the specifications of approved drawings.

·        Verify that installed converters contain all required signal elements including current to voltage converters and voltage to current converters as well as temperature signal converters.

·        Technical team members must establish the physical existence and correct placement of temperature transmitters alongside PLC modules together with power supply units, interface modules and communication gateways.

·        Check that ventilation fans remain in correct positions with working functionality.

·        Perform a check to verify both the presence of surge protection devices and their functional status.

·        Signal wires should be clearly separated from power cables through correct wiring practices.

Step 2: Mechanical Inspection

·        Check that all doors and panels and locking mechanisms move with normal operation.

·        Examine the integrity of cable entry points and gland plate components.

·        The inspector needs to examine the equipment for components that are loose and test for edges that are sharp or detect any problems with the assembly process.

·        The system should have operational ventilation systems with effective heat dissipation mechanisms.

Step 3: Electrical Inspection

·        Check that the electrical wiring matches the approved schematics together with the termination schedules.

·        The installation of cables and wire terminations must follow established industry protocols.

·        You must examine terminal tightness with a torque wrench.

·        The inspector must check whether all required ferrules and tags and cable markers are present.

·        Inspection must confirm that interface modules and power supplies along with converters have their grounding connections set correctly.

·        Examine the condition of fuses together with MCBs (Miniature Circuit Breakers) while assessing power distribution integrity.

·        Ensure power supply redundancy along with automated power failover system functionality delivers the required specifications.

Step 4: Continuity and Insulation Resistance Tests

·        Examine all wiring connections with the help of a multimeter during continuity tests.

·        Perform insulation tests with a megohmmeter set to apply 500V or 1000V for control circuits and 250V for communication circuits and 5kV for high-voltage circuits after applicable.

·        Check the integrity of grounding systems while measuring earth resistance values.

·        Check shield continuity for signal cables.

Step 5: Functional Testing

·        After applying power to the cabinet you should check voltage levels throughout different locations.

·        Test modules and interface modules by providing simulated signals that ensure their correct operation as well as the temperature transmitters and PLC modules.

·        Perform validation of control communication standards which include Modbus RTU, Modbus TCP/IP, Profibus DP, Foundation Fieldbus and Ethernet/IP and other protocols.

·        Check alarm and trip circuits for correct functionality.

·        Conduct verification of the system safety features by analyzing the interlocking and fail-safe mechanisms.

·        The system requires testing of power supply redundancy alongside interface module and communication gateway redundancy.

·        Check status LEDs and indicators for proper operation.

·        Test the signal isolators and converters to ensure they operate correctly.

Step 6: Communication and Signal Testing

·        Test how signals transmitted from the marshalling cabinet reach the control system.

·        The function generator together with appropriate software tools must be utilized to test analog and digital I/O signals.

·        Signal quality tests should include proofs of accuracy as well as response time measurements.

·        Test the signal conversion mechanism installed in the marshalling cabinet to verify proper operations between 4-20mA and 1-5V and RTD to 4-20mA conversion types.

·        Each signal should undergo a complete loop testing procedure.

Step 7: Power-Up and Load Test (If Required)

·        Test the cabinet operation through simulated load conditions to check for operational stability while power is active.

·        Thermal imaging cameras should be used to detect cabinet temperatures that rise above normal levels.

·        Examine the equipment by listening for abnormal noises and inspecting for fan vibrations or any abnormal device behavior.

·        Check that the system operates within specified load parameters while verifying redundancy in power supply systems.

·        Check the power consumption rates to verify they meet design requirements.

·        Throughout testing verify that each component of the cooling system operates correctly including ventilation fan functionality.

Step 8: Final Inspection and Documentation Verification

·        An inspector must examine test documentation and ensure that all test results satisfy the FAT specifications.

·        Compare as-built documentation with physical components to identify any discrepancies that need correction.

·        All recorded deviations should undergo documentation and require corrective measures for necessary adjustments.

·        Field technicians need to confirm that wiring schematics and Bill of Materials (BOM) list match the actual installed components together with termination drawings.

·        Stakeholders who include customer representatives must provide their authorization before giving their final approval.

Step 9: Acceptance Criteria

·        All marshalling cabinets must fulfill their design requirements defined in the approved drawings and specifications.

·        All electrical wiring needs to successfully complete tests for insulation resistance and continuity checks.

·        All functional testing must demonstrate component functionality.

·        Physical examination must reveal no signs of defects and installation errors together with an absence of damages.

·        The complete operation of signal converters along with interface modules and temperature transmitters should be ensured.

·        All technical documentation needs to remain complete and precise alongside its regular updating.

Step 10: Test Report and Sign-Off 

A comprehensive FAT Completion Report must be generated with documentation signatures at end of successful FAT evaluation. including:

·        Inspection checklists

·        Test data and results

·        Photographic evidence (if required)

·        The document contains all nonconforming items together with their corrective measures.

·        Measuring instruments which participated in the FAT should have their calibration certificates available.

·        Signatures from responsible parties (Manufacturer, Customer, Inspector)

Common Mistakes in Factory Acceptance Tests (FAT) and Site Loop Checking

The successful execution of a FAT minimizes system problems during commissioning thus enabling a seamless site installation process. The stakeholders need to perform thorough inspections and tests on the marshalling cabinet to confirm its reliability and functionality prior to deployment.

Multiple common errors occur during Factory Acceptance Tests (FAT) and site loop checking activities such that they trigger delays and system errors and malfunctions. The following list includes frequent mistakes identified during activities and FAT and site loop checks.

1.   Incorrect Cable Selection: Use of the wrong type of multi-pair/multi-core cables (e.g., individual shield vs. overall shield).

2.   The terminal points contain improper wire connections which lead to loose wiring.

3.   The incorrect application of ferrules, lugs and terminations leads to improper Lugging and Termination.

4.   Incorrect Cable Glands: Improper selection or installation of cable glands.

5.   Wiring mistakes occur when junction boxes and marshalling cabinets receive improper connections.

6.   A frequent error occurs when common and signal cables are mistakenly interchanged under MCC Interface termination procedures.

7.   Polarity Reversal in Analog Signals Occurs Due to Incorrect Wiring of Signals.

8.   The incorrect installation of grounding and shielding stands as a major error in marshalling cabinets.

9.   The incorrect setup of field instruments includes wrong configuration of upper/lower range settings and square root calculations together with offsets.

10.Control System Channel Misconfiguration occurs when users select improper active/passive/3-wire signal configuration settings.

11.The configuration of I/O modules can fail because users set wrong range parameters or match tags incorrectly.

12.Fuse Issues: Blown fuse, missing fuse, improper fuse rating, or open terminals.

13.Technical Failures Arise from Incorrect Digital Signal Contacts When Users Choose Between Normal Open or Normal Closed (NO/NC) Contacts.

14.Digital Output Signal errors arise from the improper selection of dry contacts instead of wet ones.

15.The presence of unwanted voltage inside dry contacts represents a Interrogation Voltage issue.

16.Incorrect component selection and improper connections cause failures in relays as well as isolators and barriers.

17.Incorrect Power Supply Module Sizing: Improper power module or MCB (Miniature Circuit Breaker) rating.

18.The use of wires with improper colors or sizes which fail to match requirements constitutes non-compliance in internal wiring.

19.External Power Supply Oversight: Lack of consideration for external power in 4-wire instruments.

20.The identification of these typical mistakes in both FAT and site loop testing leads to better system reliability and faster troubleshooting results.

ONVIF Ending Support for Profile S

ONVIF Ending Support for Profile S  

A commonly asked question is ​“what is ONVIF protocol?” This question confuses two different concepts: a standard and a protocol. ONVIF is a security standard, whereas RTSP — a key element of video and audio streaming — is a protocol.

For the avoidance of doubt, ​“ONVIF protocol” is an incorrect term, because it is a standard. The ONVIF standards are defined by several manufacturers in the video security industry, including Pelco, enabling products across brands to work together and interface seamlessly. This standard determines how a protocol like RTSP will work. 

RTSP stands for Real Time Streaming Protocol. It controls video and audio transmission between two endpoints, and enables it to happen with minimal latency (delay) over an internet connection. ONVIF IP cameras use a specific standard (known as a profile) to stream video and audio. In doing so, the standard defines certain rules about how RTSP should work and which ONVIF specifications it should follow.

Over a larger ONVIF security camera system, this means that all devices are using the same streaming protocol to transmit video to network recording devices, which are primed to receive it in that specific format.

ONVIF stands for Open Network Video Interface Forum. Its aim is to provide a standard for the interface between different IP-based physical security devices. In simple  terms, ONVIF specifications provide a consistent way for devices from multiple manufacturers to work together, where previously they would not have been able to. These standardized ONVIF specifications are like a common language that all devices can use to communicate.

The end user benefits from this interoperability because they are no longer tied to a single brand for everything to work; now, a business can use several different brands’ systems, with a single standard to communicate. Want to use the best ONVIF camera from Brand A, but you also want Brand B’s ONVIF IP cameras, and Brand C’s ONVIF NVR? No problem — because the ONVIF standard enables them all to work together.

ONVIF is ending support for Profile S on March 31, 2027. Profile S, which was introduced in 2011, specifies authentication methods that are no longer aligned with current cybersecurity standards. 

“After 14 years, Profile S has served its purpose of enabling basic video streaming interoperability for more than 33,000 conformant devices and clients from different vendors,” said Leo Levit, Chairman of the ONVIF Steering Committee. “As ONVIF profiles do not change to preserve the interoperability of conformant products, we recognize the need to phase it out in line with today’s security recommendations.”

ONVIF recommends the use of Profile T as a replacement for Profile S. Launched in 2018, Profile T includes virtually all Profile S features plus advanced video surveillance capabilities. End users can still use Profile S for basic video streaming between Profile S conformant devices and clients, but for security reasons, ONVIF strongly encourages customers to discontinue the use of the username token authentication method and choose instead more secure authentication mechanisms like digest authentication supported in Profile T or through TLS (HTTPS mode).

Cybersecurity Best Practices for IP-based Physical Security Products

ONVIF recommends following local regulations, industry best practices, and staying on top of updates from the marketplace. ONVIF has outlined a general, non-exhaustive set of recommendations for best practices within cybersecurity. The recommendations should not be considered as the only source or guideline to combat cybersecurity threats.

In addition to the recommendations, ONVIF supports TLS (Transport Layer Security), a secure communication protocol that allows ONVIF devices with that feature to communicate with clients across a network in a way that protects against tampering and eavesdropping.

Profile S Conformant Products

After March 31, 2027, it will not be possible for manufacturers to submit new products or older products with new firmware/software versions for Profile S conformance. Products that have already achieved Profile S conformance will always remain conformant for the specified firmware version and date of conformance. Profile S conformant products will continue to be searchable in the ONVIF conformant products database.

ONVIF conformant products and is the authoritative source for determining whether or not a product is officially ONVIF conformant and supports one or multiple ONVIF profiles. A product is registered in the database after it successfully passes the relevant ONVIF test tool and all the necessary documents have been submitted to ONVIF by the member manufacturer. Conformance is tied to a product’s specific firmware/software version and is valid indefinitely for the specific firmware/software version of that product. To ensure an existing product is conformant, the product’s firmware/software version must match the version listed for the product in the database. ONVIF releases new device and client test tools twice a year (June and December), and each test tool version is valid until a new version is released, plus a further grace period of about three months. For more information, see the Conformance FAQ page.

Note that products may use ONVIF specifications, but they may not claim to be ONVIF conformant without completing the ONVIF Conformance Process. Only ONVIF members can claim conformance, but ONVIF membership alone does not guarantee that products sold by members are ONVIF conformant.

TLS Configuration Add-on

As ONVIF adapts to new cybersecurity requirements, the specifications of the current ONVIF TLS Configuration Add-on will also be upgraded at the end of 2026. Unlike profiles, add-ons are adaptable to changing technology/specification requirements due to version handling.

Gaming PC with Home Video Surveillance

 How to Integrate Your Gaming PC with Home Surveillance CCTV

Suppose you are deep into your gaming zone with headphones on. The sound of a knock on the door or someone breaking into your home is impossible to hear. Well, you need a home surveillance CCTV system. Simply install and incorporate  cameras into your existing gaming PC setup to make your home secure.

Protecting your gaming setup and improving alertness about the surroundings can put a lot of gamers’ minds at ease. Gaming is a strict business. You must put in skill and concentration to take your game account to new heights.

A simple task such as ordering a pizza can engage your mind in constantly hearing the doorbell or ringing phone.  A gamer can easily avoid constant loss of concentration through overlay video of a  camera. To learn more about integrating your gaming PC with CCTV, read on!

Integrating Gaming PC with CCTV

Let’s start with the basics. We will use an offline setup for gamers to emphasize the concept of a closed-circuit system. In addition, we will mention methods gamers can use to broadcast their camera feed to the internet. It will make it accessible from anywhere in the world. To start the integration process, you will need a set of items. Let’s move step-by-step:

Step 1: Choose the Right CCTV Cameras

CCTV cameras come in various shapes, sizes, and technical capabilities. We typically recommend an IP CCTV camera for gamers in a home configuration. It will provide a crisp video with details ideal for a small-scale setup. There are wireless versions of IP CCTV cameras, but they are prone to interference, which can cause stuttering video or audio. In a surveillance setup, having a wired connection alongside an on-camera SD card recording is the best option.

Connecting an IP CCTV camera with the internet and offline setup is easy. They can provide up to 4K resolution depending on the requirement. Furthermore, users can opt for a camera with a microphone to receive live audio. They only need a RJ45 ethernet connection for data and a power source. However, you will not need two cables running throughout the house for the camera. A single RJ45 cable will suffice. We will explain how to achieve that in the next step.

Step 2: Collecting Necessary CCTV Surveillance Items

After you decide which camera is best for your setup, we can move on to the other items. Here is a list of things for a home surveillance CCTV setup:

·        Cameras: The number of cameras will depend on the number of places you want to perform surveillance. It will serve as a basis for the items next in line.

·        PoE Switch: After deciding the number of cameras, you need a PoE (Power over Ethernet) switch. It will serve as the basis for providing power and transmitting your video to the gaming PC. Usually, people set it up near the computer, and its ports should equal the number of cameras plus one port for computer/router connection.

·        PoE Injector and Splitter: A typical IP CCTV camera requires coaxial power and network cable. A PoE injector and splitter will convert a simple ethernet cable to a coaxial power cable and data transmitting connection. Just ensure that they are IEEE 802.3at/aft compatible.

·        Ethernet Cable: The whole system communicates using the ethernet cable. Calculate the distance between the camera and the PoE switch after routing. There are various categories of ethernet cable available. Their price depends on the quality. We recommend using a Cat5e for its price/performance ratio. Anything above the Cat5e grade is also compatible.

**Note: A typical setup will have a line running underneath the carpet alongside the edges of the wall. Make sure to take proper measurements.

·        Router: You will need a router to connect the complete setup to the internet and ensure your PC remains connected. If you are an online gamer, then you own one. We will explain how to connect all the pieces and make them start working.

Step 3: Camera Placement

Strategically placing your  camera is essential. Ensure it is not easily accessible, and you can route the wire hidden away from eyesight. Following are some of the areas where you can place your camera for surveillance:

·        Front Door Entrance

·        Back Door Entrance

·        Vulnerable Windows

·        Garage

·        Drive Way

·        Hallway

·        Common Rooms

The areas might not relate to your setup, but be sure to cover maximum entrances. Observe where you can mount the camera for complete and precise coverage.

Step 4: Complete the CCTV Setup

Let’s start connecting all the puzzles. Before we mount the camera in their respective location, check connections and equipment healthiness by performing a test. Complete the following process to complete your CCTC setup.

1.   Connect your PoE switch to the power outlet and ensure the lights are on.

2.   Now connect the ethernet cable in one of the ports of the PoE switch and connect the other end to a PoE injector and splitter.

3.   Now take a camera and connect its wires with the PoE injector and splitter. Your camera will now have power.

4.   Take a new ethernet cable, insert it into one of the ports on the PoE switch, and connect the other end with the computer router. Make sure you plug in your gaming PC to the same router.

5.   Download and install the  software from the camera manufacturer’s website. Follow the instruction to access your camera live feed.

6.   You have successfully tested your equipment if you can see the live feed.

7.   As the last step, install your CCTV cameras at their designated location, route the cable, and complete the setup.

Step 5: Start Monitoring CCTV with Gaming PC

Now that you have connected all your equipment let’s obtain the live video feed from your cameras and place an overlay on your favorite game. You will need a decent graphics card and Windows or MacOS computer.

1.   We will be using the VLC media player. Download and install the latest version. It is free to use.

2.   You will be accessing the camera through its IP address. It is usually written and provided by the manufacturer. Check the website or instruction manual.

3.   Start VLC media player.

4.   Navigate to Media > Open Network Stream

5.   Now type the address to your camera with the following settings

rtsp://admin:a1B2c4@192.168.1.5

·        Note that in the address given above, the camera username is (admin), the password is (a1B2c4), and the IP address is (192.168.1.5). Everything else will remain the same.

·        After you enter, you will start streaming your IP CCTV camera.

·        Now, right-click on the live stream, navigate to view, and always click on top.

·        Right-click on the live stream and navigate to view. Now click minimal interface.

·        Now you will have a constant stream on top of all your games.

Note: To view your surveillance streams live from anywhere around the world. Follow the camera manufacturer’s guidelines to enable the online setup. The process is easy to follow once you connect the PC to the internet router.

Conclusion:

There are tons of benefits of having a live stream over your gaming sessions. It improves spatial awareness and helps gamers concentrate on their gaming ventures. The gaming industry has reached a whopping $385 billion and still growing. It is logical to find your share within the broad field. A home surveillance CCTV can provide the comfort of security for gamers. What better than having a live view of your surroundings while gaming?

The process is easy, and anyone with a basic knowledge of computers can put a system together. To save time, you can order a pre-configured setup from an online website to immediately set up your surveillance. At last, we hope you find value in our article. So set up your watch and get gaming!