Documentation consistency and technical evidence audit
Heating Rate Controller · current electrical drawings R1.2 (26 October 2026) · 14 sheets
Scope and checks completed
Reviewed all 14 A3 drawing sheets in the available R1.2 PDF, compared corresponding 14 editable PowerPoint slides, checked document hyperlinks and compared all 70 numbered wiring routes across CSV and JSON, all 48 terminal allocations and all 11 distribution groups. Reviewed the 17 main website HTML pages, 23-step SOP, 18-hazard risk assessment, 24-entry component register and Omron operator/programming pages. Selected manufacturer specifications were cross-checked independently.
Document-internal checks passed: 70 unique sequential wiring IDs, 70 matching CSV/JSON records, 48 matching terminal allocations, no oversubscribed specified blocks and consistent PDF/PPTX content across all 14 corresponding sheets.
This only establishes consistency between documents. It does not establish that the installed conductors, equipment settings or protection perform as intended. The reviewed library copy of R1.2 was not byte-compared to the deployed GitHub Pages PDF.
Findings requiring closure
| ID | Priority | Finding and required evidence |
|---|---|---|
| A01 | HIGH | Missing Murata meter circuits and input protection. The 70-route schedule and R1.2 sheets omit the two DMR20 voltmeter input circuits. Confirmed open discrepancy: neither PV1 nor PV2 has external input-wire fusing. Murata specifies 0.25 A / 300 V time-delay protection for wiring connected to TB1 (+) and (−), in addition to the internal self-resetting device. A competent electrical reviewer must select and verify the protection topology, DC ratings, fault-interruption performance and actual conductor routes for both channels before release. See technical notice PV-FUSE-01 and acceptance register. Do not amend the published R1.2 as-built status until the physical modification has been inspected. |
| A02 | HIGH | DC breaker/source coordination. The Lovato P1MB1PC16 is 16 A, C-curve, 80 V DC; a current-limited supply may not provide sufficient fault current for timely disconnection. Assess source fault energy, conductor protection, interruption and isolation. |
| A03 | HIGH | 15 A continuous-duty acceptance. Verify the Finder 62.31 and exact 92.03 socket variant, cable/connector thermal ratings, terminals and SSR operating temperature together under worst-case load. |
| A04 | HIGH | No signed commissioning evidence in the site. Record independent PE, insulation, polarity, safe RESET output, power return, fault response, external DC isolation and suitable load tests before authorisation. |
| A05 | HIGH | Risk assessment requires local authorisation. Complete residual risk scores and action owners for all 18 hazards and approve the applicable site-specific heating tests. |
| A06 | MEDIUM | R1.2 sheet 14 retains internal construction history: “Operator reported moving ACTIVE LED+”. Replace in a controlled successor issue with its factual electrical function, K1/K2:14 → EN1/EN2 → HL+. |
| A07 | MEDIUM | Sheet 01 is titled “before rebuild”. Change to a neutral service/installation heading at the next controlled issue if the arrangement is inspected. |
| A08 | MEDIUM | Omron options need nameplate verification. Register lists E1 as -000 and E2 as -003. Confirm both exact fitted names and firmware before claiming hardware-dependent programming functions. |
| A09 | MEDIUM | Power connector aliases differ. Drawings use JP1-IN/OUT and JP2-IN/OUT by channel; panel/reference listings use JP1/JP3 supply-in and JP2/JP4 heater-out. Add a controlled cross-reference with polarity and channel markings. |
| A10 | MEDIUM | Relay supply terminal notation. Confirm the Finder 13.61 fitted A1/A2 versus L/+ and N/− labels against exact device markings before servicing. |
| A11 | MEDIUM | Omron simulator qualification. The offline programme model is not a live output/safety simulator. Verify programme end, wait band, output-at-reset and power-return settings on the actual E5CC-T variants. |
| A12 | MEDIUM | R1.2 maintenance sheet is not a full commissioning record. Provide separate signed test documents and a traceable component/protection evidence register. |
Drawing set review, sheets 01–14
01–03: Distribution capacity and two-channel terminal allocation match the source tables; 48 occupied of 70 positions. 04–05: Shared mains/24 V, two independent channel selectors and common 0 V are distinguished. 06–07: EN1/EN2 are taken from Finder 13.61 terminal 14, rather than the separately gated 24 V. 08–09: Both amber ACTIVE lamp circuits follow enable plus Omron demand, not measured heater current. 10–11: Each external DC positive path passes through breaker, polarity-sensitive Finder contact and DC SSR, while negative returns separately; source fault coordination and derating remain outstanding. 12–13: Functional schedules match the numbered routes but omit the Murata meters. 14: Manufacturer reference links are preserved; internal construction wording and the missing metering/protection reference require a controlled update.
The available editable PowerPoint and PDF have 14 corresponding sheets with matching extracted vocabulary and identical counts of external links per sheet. Their content is a reference design until the installed assembly has been independently inspected and documented.
Current corrective action · PV-FUSE-01
Open / not installed: the external Murata input-wire fusing is absent on both channels. See the meter protection notice for manufacturer requirements, design/inspection hold points and the sign-off fields. Existing R1.2 drawings and 70 numbered connection routes are retained unchanged until the completed modification has been verified.
Next controlled documentation release
- Gather nameplate and internal/wiring photographs of the completed enclosure and reconcile exact terminal stamps, connector aliases and hardware suffixes.
- Engineer and inspect the Murata input fuse/voltmeter circuits, DC fault protection, isolation and 15 A load-duty limits. Update the electrical drawings and wiring data together under a new revision.
- Record competent-person electrical tests and local authorisation; close all material risk assessment actions.
- Validate representative Omron fixed temperature and ramp/soak programmes, wait-band and safe-output behaviour on the actual fitted controllers.
- Regenerate the PDF from the approved PowerPoint, check the 14 sheet illustrations, text and links, then update website, SOP, component register, search index and GitHub QA in one controlled release.
Manufacturer evidence consulted
Murata DMR20 · Lovato P1MB1PC16 · Finder 92.03 · Weidmüller 8950770000 · Omron E5C-T H185. Manufacturer specifications do not establish that the installed equipment was inspected.