Electrical design
D12 includes eleven schematic and connection sheets. The drawing pack is a design-review snapshot, not approved wiring instructions.
This archive contains current technical references, historical drawing issues, controller test observations and records required for safe operation. Use the operator manual for normal operation and the current R1.2 wiring documents for maintenance.
Review the cross-check of the current R1.2 drawings, 70 connection routes, 48 allocated terminals, 24 component entries, operating and programming instructions, and manufacturer data. Open items include independent meter input protection, DC load and thermal margins, restart behaviour, connector reference differences, and signed site authorisation. This technical review is separate from routine operator instructions.
Open the engineering documentation audit and issue register →
The R1.2 drawing set, 70 wiring routes, 48 terminal allocations, SOP, component register and programming guidance were reviewed for consistency. Several safety/commissioning items require recorded closure; the review does not constitute electrical sign-off.
Open the audit findings and action register → · PV-FUSE-01: confirmed missing voltmeter input-wire protection →
Use the current 14-sheet R1.2 electrical drawings, 70-route connection schedule and terminal distribution reference for electrical maintenance. The older D12/D13 records below are retained for historical comparison and are not substitutes for the current issue.
The eleven-sheet D13 PowerPoint/PDF has been generated by editing the actual original D12 PowerPoint: all original slide vector objects, wire paths, box layouts, links and diagram styling are preserved. Corrections include Finder 13.61 A1/A2 terminals, EAO COM versus ENABLE LED+, Crydom/ACTIVE/Weidmüller return, three available +24 V/0 V take-offs per channel and the cabinet-wide three Live/three Neutral outgoing distribution branches. The old D12 PowerPoint/PDF are unchanged as historical source versions. D13 is not an as-built release; inspection signoff, terminal/ferrule checks and electrical commissioning remain outstanding.
Editable revised D13 source · 11-sheet PDF · Detailed inspection register
New printable source: 22 October point-to-point register and distribution plan · 4-page draft PDF. This is a draft reconciliation supplement to original D12, not final as-built or evidence of successful tests. The D12 PDF/PPTX and full-screen legacy schematics have not themselves been reissued.
| Observed or confirmed source | Current record | Verification still required |
|---|---|---|
| Manufacturer terminal documentation | Finder 13.61.0.024.0000 uses A1/A2 for supply, 3 for impulse, 11 COM, 14 NO and 12 NC; legacy D12 L/+ and N/− were drawing power rails, not device terminals. | Read exact fitted K1 and K2 variants and stamped terminals on both devices. |
| Builder-reported Crydom positive wiring | Crydom +3/A1 shares the gated +24 V positive at the central EAO ENABLE momentary contact; this is not SB1/SB2 LED+ (the EN1/EN2 enabled net). | Identify central terminal as actual COM, confirm both channels, clamp/ferrule acceptance and polarity with power isolated. |
| Builder-reported Crydom negative wiring | Crydom −4/A2 and ACTIVE indicator − share Weidmüller W1/W2 output 13; interface output 14 returns to control 0 V. | Inspect both channel wiring branches, component polarity and state indication. Output 13 (+ collector), 14 (− emitter) confirmed from Weidmüller 8950770000 drawing page 4. |
| Available 24 V distribution positions | Builder reports three available gated +24 V and three 0 V distribution positions per channel. The number of physical wires/destinations is greater because of branches. | Confirm installed terminal-block models, occupied/incoming positions, approved cross-connectors and two-wire ferrule acceptance; keep 0 V isolated from PE unless design deliberately specifies an approved bond. |
| Mains supply design | For the whole cabinet, three outgoing Live distribution take-offs (PS1 and two selector inputs), three Neutral take-offs (PS1 and E1/E2), plus incoming L/N, two selector-to-Omron switched-Live conductors and separate PE bonds. | Confirm physically available AC rail openings, inlet fuse/pole mapping, appropriate protective devices, PE continuity, conductor size and mains terminal markings before energising. |
| EAO ENABLE LED+ / ACTIVE LED+ | ENABLE LED+ = separate Finder 13.61 NO output 14 net (EN1/EN2), shared with Finder 62.31 coil A1; ACTIVE LED+ = gated +24 V (shared with Crydom +3), not EN1/EN2. | Record actual physical jumper arrangement and rated conductors; confirm ACTIVE indicator model and that demand is not mistaken for actual current. |
D12 includes eleven schematic and connection sheets. The drawing pack is a design-review snapshot, not approved wiring instructions.
USB-only PV, programme persistence, RUN selection and increasing internal setpoint/programme time have been observed.
Both channels have been reported functional. Independent evidence of safe-off, restart inhibition, fault protection and maximum-duty thermal suitability must still be recorded before approval.
Two-channel front panel layout, component selections and connections captured. Confirm actual door stencil and fitted models for any dimensioned revision.
AC supply, common 24 V control, independent enable branches, SSR command and external DC load path drawn. Finder 62.31 34 (+) to 14 (−) is a directional switched-positive contact, not DC 0 V.
PV responded to thermocouple warming. Programme 1 with a 50 °C target, 2 °C/min ramp and 15-minute soak was stored and read after loss/restoration of USB setup power. The selected RUN slot and RESET state persisted. DOWN from r-r=rst selected RUN; the programme timer and displayed SV increased. No powered heater output was tested.
Thirty input-code planning choices, rate/soak/step builder, Type K training subset and 228 parameter-map entries are available. They are references, not validation of every physical input/output option.
Controller backup, hardware selection and selected guarded USB-transfer paths developed. Automated Python/Qt testing and Windows ZIP packaging succeeded; non-Type-K and analogue write paths still need real-hardware testing.
Read both Omron full nameplates (resolve E2 -000 / -003), Finder 92.03 socket variant and selector contact-block markings.
Verify 24 V enable OFF after mains loss/return, short dips and a held ENABLE button, independently of heater PSU switching.
Verify 15 A conductor/connector duty, Finder/socket derating, breaker fault coordination, SSR heat sinking and PE bonding.
Test SSR/Weidmüller polarity, ACTIVE indicator, actual current, sensor failure, RESET output and emergency isolation with a safely approved rig.
Verify ramp→soak progression, final RESET/CONTINUE, Wait Band, power-on action and controller mains-operation behaviour.
Confirm C3 write/read/return to normal, physical sensor scaling, fresh settings backup and DA meaning after global input changes.
Validate real event input/CT/RS-485 availability, menu masking and confirmed write restrictions against the full nameplate.
Document parts, terminal mapping, protection tests, persistence, final parameter backups and signed commissioning acceptance.
Only one controller is connected at a time. USB returns a model prefix, not its entire optional hardware order code. The web editor cannot write to a controller; a native app may propose changes, but hardware-dependent input changes must be applied and read back separately from programme memory transfer.
Native Studio development PR #143 · Sensor-aware website PR #144 · Interactive manual PR #145
| Parameter family | Current Windows Studio workflow |
|---|---|
| Programme memories DA (8 × 150 words) | Read/backup all eight. Edit one programme, preview specific differences, guarded RAM write and readback, SAVE, CMW OFF and later verification; only under validated configuration. |
| C3 input, limits, control mode and selected initial settings | Hardware-aware local proposal and separately confirmed setting-area-1 transfer; must re-read configuration after exit/reset. Global change never silently rescales DA programmes. |
| C1 adjustments and fixed C5 PID banks | Selected qualified values can be proposed and transferred with appropriate readback/save procedures; masked, unread or option-dependent parameters remain restricted. |
| C0 monitor values | Read only, not controller write targets. |
| Unqualified C4 context-dependent, C9 programless communications, serial-link changes, protection/password and direct output/fault forcing | Shown only when applicable for review, but USB writing remains restricted pending separate qualification. |
This is a software-capability guide, not evidence of successful physical tests for all 30 inputs or of EEPROM retention after a new sensor-range change. The previously verified Type K 50 °C exercise below remains the bench reference. Read the exact model on both installed controllers; the proposed E5CC-TQX3A5M-000 designation is a design specification until individually checked against their nameplates.
Described software capabilities are not claims of successful physical validation on every Omron hardware option.
These expandable records were formerly mixed into the operating instructions. They are retained for future testing, troubleshooting and design changes.
Channel 1 controller: Type K PV responded correctly to warming by hand; Programme 1 (ramp 50 °C at 2 °C/min, soak 0.15, no repeat/link) was entered using the keys and survived a complete USB setup-power cycle. Changing Operation Level prg = 0 to prg = 1 changed the pgsg monitor to Programme 1; that selection survived another complete USB restart, with r-r = rst confirmed. A subsequent USB-only test confirmed that DOWN at r-r = rst changes the display to run (UP at RESET did not change it). The controller then showed prgt advancing and SV increasing: the internal programme clock and commanded ramp operate under USB setup power. The controller outputs themselves cannot operate from USB alone (Omron H185 §2-4 and Appendix A), and the ramp-to-soak transition, real heating, mains restoration, SSR demand and external heater safety have not been tested.
Omron H185 §§2-4 and 5-23 confirms that USB setup power supports PV display and parameter editing, but control and alarm outputs cannot operate without the rated controller terminal supply. The E5CC-T has OUT1/OUT2 control-output function indicators, not measurements of actual heater current; the larger E5EC-T/E5AC-T’s separate ramp/soak direction LEDs do not apply to this smaller model. This USB-only result does not validate heater operation or constitute commissioning.
The manufacturer confirms that the E58-CIFQ2 USB connection can display temperature and allow setting changes, but cannot operate the controller's control or auxiliary outputs. Physical testing now confirms r-r = run can be selected and the prgt timer advances while SV increases on the ramp. It has not established the end-of-ramp segment transition or end-of-programme behaviour. The following is a display-only hypothesis test, not a temperature-control or output test.
prg = 1 and r-r = rst. Note pgsg, prgt and rptm before making a change.r-r = rst, press DOWN briefly to request run. Physical result confirmed 13 October 2026: UP at RESET left rst unchanged, then DOWN selected run with E58-CIFQ2 USB setup power only. Do not connect or enable a heater, SSR power circuit or mains controller supply.r-r = run displayed, use brief MODE presses to find prgt. Physical PASS: its value changes over time and the SV increases. The clock and ramp calculation therefore work under USB-only setup power. Optionally inspect pgsg for the segment transition; do not change other settings. This validates displayed programme timing and increasing programmed setpoint only, not physical outputs or temperature tracking. If SV reaches the ramp target but the segment does not advance, configured wait/hold behaviour may be responsible when PV cannot reach SV on the unheated bench.r-r = rst before unplugging USB, using UP if the actual menu permits and verifying the displayed change (the reverse direction is not yet physically checked). Confirm RESET; re-read prg = 1 after reconnection if needed. Record any unexpected message or failure to enter RUN. Do not interpret these checks as testing electrical output or PID performance.Operation Level: with brief MODE presses, the controller displayed a-m (Auto/Manual), pgsg (programme/segment monitor), prg (RUN selection), prgt = 0 (elapsed time), rptm = 0 (execution repetitions) and r-r = rst (RESET). Which additional screens appear depends on RUN, standby, hardware and parameter masking. At a-m, do not hold LEVEL: a long hold can switch to manual output control.
Programme Setting Level: d.prg → s-no → d.seg; for a rate-mode ramp: styp → sp → pr; for a soak: styp → time. After the last active segment, d.seg = end leads to pid → al-1 → al-2 → al-3 → rpt → link → d.prg. Alarm-value screens displayed reading 0 on Programme 0, which does not prove the alarms are disabled.
PID Setting Level on our first unit: d.pid = 1 → 1.p = 8 → 1.i = 233 → 1.d = 40 → 1.olh = 100 → 1.oll = 0 → 1.aut = 1320 → d.pid. These are read-only observed values, not recommended tuning settings. 1.aut is an automatic PID selection-range limit, not the autotune command. 1.lba and mv-r were not displayed with our current configuration; never infer their actual values from a hidden screen.
Front-panel indicators: Omron H185 §3-3-1 identifies OUT1/OUT2 as control-output function indicators on the E5CC-T; they are not measurements of actual heater current. No OUT indicator operation has been checked during the USB-only test. Separate ramp/soak direction indicators illustrated on larger E5EC-T/E5AC-T controllers are not provided on E5CC-T.
run, showed prgt advancing over time and increased SV during Programme 1’s ramp. These internal-programme checks passed. They cannot commission the SSR, real heater, fail-safe cutoff or live restart inhibition.D12 is the current electrical design-review snapshot, not a signed-off installation drawing. The issues below are called out for reconciliation with the actual parts and hardware, not silently changed in the source.
| Item | Review requirement / why it matters |
|---|---|
| Omron E2 variant | D12 sheets 01 and 06 list E5CC-TQX3A5M-003 for Channel 2, while newer operator documentation describes two -000 controllers. Omron confirms -003 is a distinct genuine variant with additional RS-485/heater-alarm capability. Inspect both physical nameplates and correct the documents once fitted models are confirmed. |
| Finder 13.61 start/reset | Both K1/K2 upper function selectors should be considered for RI step mode (single ENABLE pulse ON, next pulse OFF), not IT timed mode, RM momentary-only mode, or permanent Light ON. The orange lower adjustment is 0.5–20 min and applies to IT mode only. Read and record both fitted full model codes and selector positions. Service setup procedure. Validate OFF-after-control-power-restoration, short interruptions, and a held ENABLE button. The fact that p-on = rst was observed on an isolated USB-powered E5CC-T does not validate the heater-enable relay circuit. |
| Socket and DC continuity | Confirm installed Finder 92.03 suffix and the actual A1/A2/34/14 mapping, continuous DC current/ambient derating and mechanical terminal rating. The intended 15 A channel duty is close to a nominal 16 A switching/socket family. |
| Weidmüller and lamp | Selected HL1/HL2: RS PRO 130-1086, yellow ACTIVE LED, 24 V DC, 20 mA maximum, 14 mm mounting hole, IP67, chrome bezel, lead wires. Calculated maximum combined draw per channel: 20 mA LED + 15 mA SSR = 35 mA, below Weidmüller 8950770000's 100 mA DC1 rating. The part is identified, not confirmed installed. Verify fitted item, polarity, exact wiring, actual switching behavior and operating margin. The manual illustration depicts the manufacturer's yellow lens as amber. |
| Schneider selector contact marking — revised | Sheet 1 shows S1-A/S2-A = NO 13–14 for Omron AC live. Sheet 2 shows S1-B/S2-B = NO 23–24* for gated +24 V. *23–24 is provisional IEC notation: XB5AD23 has two NO contacts, but actual stamping depends on fitted contact-block assembly. ZBE203 double NO is 13/14 and 23/24; individual ZBE101 blocks use their own markings. Inspect and electrically identify the actual contacts before wiring. Slide 2 wires no longer obscure port numbers. |
| Connector names | D12 sheets 07–08 use JP1-IN/OUT and JP2-IN/OUT as channel-pair labels, while the front-panel manual uses separate JP1/JP2 for Channel 1 and JP3/JP4 for Channel 2. Agree a single physical designation schedule before ferrule assignment; do not modify connectivity based solely on identifiers. |
| Protection and cooling | Verify Schurter output tabs/fuses, X1–X4 stock parts/jumpers and PE, DC breaker coordination, external supply prospective fault current, 15 A conductor and connector capacity, Crydom SSR heat dissipation, emergency disconnection and independently tested sensor-fault behaviour. |
Reference manuals: Omron -003 manufacturer specification; Finder series 13; Finder series 62; Finder sockets; Crydom thermal derating.
The controller must be inspected, tested and approved before its first powered heater test. Keep the completed commissioning record with the equipment.
The two-channel vertical arrangement follows the 198 × 248 mm door-stencil layout. The finished-panel illustration is explanatory, not measured CAD and not evidence of panel-component clearances.
| Item | Design/build note to reconcile |
|---|---|
| Channel 1 / Channel 2 | Channel 1 has been partly physically populated; Channel 2 matching openings were awaiting final parts at the photo-review stage. Confirm the actual assembled state before declaring the panel finished. |
| Channel CONTROL selectors | A similar temporary rotary selector was fitted during assembly. Schneider XB5AD23 (two normally-open contacts) was selected for the final design. Verify the contact block's actual terminal markings; do not infer a 23–24 stamped pair without inspection. |
| ACTIVE indicators | Specified 24 V DC yellow RS PRO 130-1086 (20 mA maximum, 14 mm cutout) with amber appearance. The lamp is a controller demand indicator and not a load-current measurement. Confirm actual installed part, polarity and operation. |
| Omron controllers | The design lists E5CC-TQX3A5M-000. D12 also names E5CC-TQX3A5M-003 for Channel 2. Read each physical nameplate and reconcile BOM, software profile, panel labels and D12 before release. |
| Physical layout | Use the actual stencil and manufacturer's fit/cutout details. The website's front-panel SVG is illustrative, not engineering proof of dimensions or rear-door clearances. |