Documentation and engineering consistency review

Cross-reference of the two-channel electrical drawing set, editable presentation, wiring schedules, terminal allocation, equipment component register, website operator instructions, programming guidance and selected manufacturer specifications.

This is a documentation review, not an electrical certification. Physical wiring, protective-earth continuity, DC fault clearing, maximum-current temperature rise and control-loss/restart behaviour still require inspection and recorded testing. The current R1.2 issue is a reference, not an independently signed as-built approval.

14electrical drawing sheets reviewed

70 / 48route entries / terminal allocations checked

24component-register entries cross-referenced

What the records establish

11 distribution groups48 terminals allocated22 spare ports70 route entries8 programme memories

The R1.2 distribution block capacity matches its 48 allocated conductor positions. The 70-route CSV and the browser's connection JSON agree on component source, via terminal, destination, and net for all 70 routes; four notes differ in wording only. These documentary matches do not validate the built cabinet or add missing Murata meter input protection.

Component and wiring identification

Connector-reference crosswalk: the front-panel guide uses four numbered red/black pairs while the R1.2 power-loop drawings use per-channel IN/OUT aliases. The electrical meaning is:

Channel	Panel reference	Drawing / 70-route reference	Function
1	JP1	JP1-IN	External DC supply input, upper pair
1	JP2	JP1-OUT	Heater output, lower pair
2	JP3	JP2-IN	External DC supply input, upper pair
2	JP4	JP2-OUT	Heater output, lower pair

The crosswalk resolves document nomenclature only. Before maintenance or connection, check the permanent markings and actual circuit continuity on the equipment; connector colour is not sufficient identification.

Sheet-by-sheet R1.2 review

Sheets	Section	Review scope	Document status	Remaining check
01	Distribution capacity	11 net groups; 48 used positions; 22 spare	Cross-check passed	Capacity arithmetic; physical installation not confirmed
02	Mains and common DC terminals	X1 L/N/PE; X2-24/X2-0V	Cross-check passed	48-position allocation source agrees with CSV
03	Channel terminal assignments	X3/X4 gated, enabled and demand-switched nodes	Cross-check passed	EN from Finder 13.61 terminal 14; not selector 24G
04	Mains supply	Schurter inlet, Mean Well, two Omron AC branches	Design reviewed	Site protective coordination, PE inspection outstanding
05	24 V distribution	Shared +24/0 V and two channel selectors	Design reviewed	Check built terminal positions and power-on state
06–07	Enable circuits	EAO + Finder 13.61 + 62.31 coils	Design reviewed	Check as-wired EAO terminals, RI mode, restart behaviour
08–09	Demand / amber lamps	Omron 12 V pulse to Weidmüller; 24 V Crydom input	Design reviewed	Verify actual lamp wiring and outputs on both channels
10–11	Heater DC power	0–60 V DC, breaker, directional relay and SSR	Hold for approval	15 A duty, DC protection, relay and SSR derating need tests
12–13	Summary wiring paths	Mains, 24 V, control and heater routes	Cross-check passed with limitations	Full 70-route table excludes the voltmeter circuits
14	Components and servicing	Major components, ratings and isolation	Design reviewed	Manufacturer documentation versus actual part suffixes required

Technical and documentation issue register

The priority reflects the seriousness of the potential consequence or the documentation risk, not a scored probability. Do not mark an issue closed merely because a web page has been rewritten.

Ref.	Priority	Record status	Finding	Required action
H01	Critical	Open	Murata DMR20 meters: confirmed on 9 November 2026 that neither PV1 nor PV2 has external 0.25 A / 300 V time-delay input-wire fuse protection installed. This remains OPEN.	Document both meter TB1 (+/−) supply routes, arrange manufacturer-compliant DC-rated protection and competent electrical inspection, and add the verified circuits to a future controlled drawing/schedule issue. PV-FUSE-01 action record.
H02	High	Open	15 A maximum duty is close to the 16 A rated Finder 62.31 contact and 92.03 socket; DC source fault-energy coordination and thermal duty remain unproven.	Verify actual 62.31/92.03 suffixes, wire/termination ratings, ambient derating and temperature rise at worst-case load.
H03	High	Open	Two 16 A Lovato P1MB1PC16 breakers are rated up to 80 V DC but their suitability for each actual external DC supply and fault-clearing conditions is unverified.	Document supply fault current, protective coordination, DC isolation and functional fault tests.
H04	High	Open	Heater-off behaviour after controller RESET, control mains interruption, DC supply interruption and power restoration has not been independently evidenced.	Test both channels, including held ENABLE input and short dips, with an approved low-energy rig and record outcomes.
H05	High	Open	Site-specific independent over-temperature cut-off, emergency isolation and destructive-test hazards are not established by the control diagram.	Approve risk controls for each test cell and specimen; separate routine control from emergency isolation.
D01	Medium	Website cross-reference added	Connector references differ: panel uses JP1/JP2 for channel 1 and JP3/JP4 for channel 2; R1.2 routes use JP1-IN/OUT and JP2-IN/OUT.	Use the documented cross-reference; align any reissued drawings and verify permanent physical labels.
D02	Medium	Open	The 70 numbered routes omit both Murata voltmeter inputs. External input-wire fuses are confirmed absent on PV1 and PV2.	Add a controlled supplementary drawing and route numbers after actual installation and protection are checked.
D03	Medium	Open	R1.2 reference PDF and editable presentation have historical document-property text such as D7 and 'Design review, not for construction'.	Reissue a controlled PDF/PPTX pair with matching revision, title, metadata and an authorised as-built status only after approval.
D04	Medium	Open	Older locally retained R1.2 PDF exports contain 'before rebuild', 'previous (wrong)' and operator-report commentary. A later clean source omits this wording.	Keep obsolete copies in an archive; compare the exact published PDF and PPTX bytes before certifying release consistency.
D05	Medium	Open	E1/E2 option suffixes differ (-000 and -003). USB model-prefix identification does not prove the full installed variant.	Check full nameplates and record hardware options for each channel and programming app.
D06	Medium	Open	The earlier front-panel photograph does not accurately represent the final yellow/amber lens appearance confirmed by the owner.	Use an unaltered, straight-on photograph of the finished box and verify physical panel markings.
D07	Medium	Open	The 18-hazard risk assessment remains an unsigned draft with residual-risk scoring incomplete.	Complete assessment, test-specific appendices and local signatures before treating it as authorised.
D08	Low	Reviewed	Four explanatory Note fields differ between the JSON connection data and the route CSV (IDs 033, 036, 045, 048); electrical destinations agree.	Regenerate these from one master schedule to avoid wording divergence.
D09	Low	Reviewed	Historical D12 and D13 material remains downloadable and could be mistaken for current if opened directly.	Retain explicit superseded banners and link to current R1.2 references.

Document control

The current electrical reference is R1.2 (14 drawings). D12 and D13 are superseded archives. An earlier stored R1.2 PDF export and a later clean PPTX/PDF source differ in editorial text on sheets 1, 6–9 and 14; this does not on its own establish that the PDF currently linked on GitHub differs from the linked PowerPoint. Verify the exact published files before reissuing a controlled PDF/PPTX pair. Existing slide metadata also contains an obsolete D7 design-review title/subject.

Do not change electrical nets, component values, connection order or commissioning status solely to improve presentation. Revise and approve the source document first; then export and visually check the PDF and update all website links under one document revision.

Manufacturer and primary sources

Use the manufacturer's current component data alongside the 24-entry component register, R1.2 drawing files, 70-route wiring schedule, 48-position terminal allocation, operating procedure and risk assessment.