D12 Electrical System · Corrected Selector Labelling
All eleven revised D12 sheets reproduced directly from the editable PowerPoint, without omitting any circuits or connection schedules. Includes explanatory logic and review observations.
Use Previous/Next or the number buttons to navigate. Click Zoom to enlarge; scroll within the image to inspect individual terminal connections. These are rendered images of the exact eleven PowerPoint sheets, not a simplified redrawing.
Functional logic — explanatory, not terminal-level wiring
These illustrations explain the D12 interlocks and demand chain. Their roles and terminal numbers come from D12 sheets 1–8; use the original diagrams above for all proposed physical connections.
Shared mains and two separately switched controllers
Schurter switched/fused L, N, PE
Shared AC buses; PE enclosure bonds
Mean Well supply stays shared
A = NO 13–14, independently switches Omron AC
Omron CH1 temperature controller
A = NO 13–14, independently switches Omron AC
Omron CH2 temperature controller
Independent 24 V enable — one per channel
Separate from external heater supply
B = NO 23–24* (IEC design); verify fitted block stamps
Impulse into K1/K2 Finder 13.61
Enables K3/K4 62.31 relay coil and switch ring
Key safety assumption, still unverified: power loss/restoration must leave K1/K2 output OFF; normal controller RESET is not sufficient as hardware isolation.
Heater demand and amber activity indication
Green input → Omron 6+/5−
Omron 1+/2− low-voltage demand
Isolated 12 V-input / DC switching interface
24 V parallel loads → switched W 13/14 return
The specified yellow ACTIVE lamp (RS 130-1086) draws max 20 mA; the Crydom SSR input draws max 15 mA, for a calculated 35 mA total per channel against the Weidmüller 100 mA DC1 output rating. Verify actual wiring and lamp operation. Neither lamp nor an Omron OUT indicator measures heater current.
External DC heater power — each channel
External 0–60 V, max 15 A intended
16 A Lovato DC protective device
Polarity 34 (+) → 14 (−)
Load terminals +1 → −2, controlled SSR
Outgoing banana jack
Separate DC negative return. Finder 14(−) and Crydom −2 remain on the SWITCHED POSITIVE side; neither connects to DC 0 V.
D12 sheet 9 — mains and shared 24 V nets
Original functional net schedule transcribed without allocating physical terminals.
| Net | Source | Destination |
|---|---|---|
AC01 | J1 switched fused L | X1:L bus |
AC02 | J1 switched N | X1:N bus |
AC03 | J1:PE | X1:PE + chassis bonds |
AC04 | X1 L / N / PE | PS1 C1 / C2 / C3 |
AC05 | X1 L → S1-A 13/14 | E1:11 L |
AC06 | X1 N bus | E1:12 N |
AC07 | X1 L → S2-A 13/14 | E2:11 L |
AC08 | X1 N bus | E2:12 N |
DC01 | PS1 A1 +Vo | X2 +24 V shared |
DC02 | PS1 A2/A3 −Vo | X2 0 V shared |
DC03 | X2 +24 → S1-B 23/24* | X3 CH1 gated +24 |
DC04 | X2 +24 → S2-B 23/24* | X4 CH2 gated +24 |
DC05 | X2 0 V shared | X3/X4 returns |
D12 sheet 10 — both channels
Each line is a functional net description. Refer to sheets 3–8 for terminal/port positions.
| Topic | Connections as proposed in the uploaded D12 |
|---|---|
| Enable | X3/X4 gated +24 to button C and Finder 13.61 L/+ and 11; 0 V to Finder N/−, SK3/4 A2 and EAO LED−. |
| Momentary input | SB1/2 NO → K1/K2 terminal 3 impulse. |
| Finder output | K1/K2 NO terminal 14 → SK3/SK4 relay coil A1 and EAO LED+. |
| Thermocouple | Type K + → E1/E2 terminal 6; Type K − → terminal 5. |
| Omron demand | E1/E2 terminals 1 (+), 2 (−) → W1/W2 A1 (+), A2 (−). |
| SSR and amber pilot | Gated +24 to SSR input 3+ and HL LED+; SSR 4− and HL LED− to W output 13; W 14 to 0 V. |
| DC positive | Supply DC+ → QF1/2 terminals 1→2 → Finder 62.31 contact 34 (+)→14 (−) → SSR +1→−2 → heater+. |
| DC return | Heater− → corresponding external DC PSU−; Finder 14 and SSR −2 are NOT DC−. |
| Relay coil / socket | Finder 62.31 24 V coil uses SK3/SK4 A1/A2, socket family 92.03 suffix TBD; 34/14 contact polarity-sensitive. |
Engineering cross-check — open items
Based on the supplied D12 drawing set, the user’s separately recorded physical controller observations and selected manufacturer references. These are discrepancies, missing specifications or release tests, not claims that the circuit has been electrically validated.
| Review item | Finding / required validation | Priority |
|---|---|---|
| XB5AD23 two NO contact terminals | The selector has two NO contacts per Schneider data. Assign A (controller AC) = 13–14; B (gated 24 V) = 23–24 as PROVISIONAL IEC diagram identifiers only. ZBE203 double NO uses 13/14 and 23/24, while separate ZBE101 blocks can have other stamped pair numbers. Inspect the actual fitted contact-block arrangement and confirm each contact electrically before wiring. | HIGH |
| Confirm E2 model on nameplate | Sheet 1 and 6 show E5CC-TQX3A5M-003; the recent two-channel operator documentation has used -000 for both. -003 is a real distinct Omron variant with RS-485 / HB features. Record the actual fitted CH2 type before finalising terminal diagrams. | HIGH |
| Restart inhibition is still unproven | Sheets 3–4 and 11 propose Finder 13.61 impulse control and an OFF-after-supply-return state. Verify 13.61 mode and power-loss/recovery behaviour, including held button and short interruption. A programme power-on RESET does not independently break the DC heater supply. | HIGH |
| Check socket suffix and 15 A duty | Sheets 3–4 and 7–8 use Finder 62.31.9.024.4800 on an unverified 92.03-family socket; confirm A1/A2/34/14 actual terminal mapping and rated continuous current under enclosure temperature. | HIGH |
| Validate selected yellow ACTIVE lamp and 24 V SSR input | HL1/HL2 now specified as RS PRO 130-1086, 24 V DC, 20 mA max, 14 mm cutout, yellow. Crydom input 15 mA max gives 35 mA combined per channel, versus W1/W2 DC1 output max 100 mA. Verify actual fitted lamp, wiring polarity and operation; not a heater-current sensor. | MEDIUM |
| DC breaker/source/thermal coordination | Sheets 7–8 show 0–60 V / 15 A per channel, 16 A Lovato breaker, Finder DC relay and Crydom DR2220D30U. Verify available fault current, trip selection, conductor and connector rating, SSR dissipated heat and DC load limits. | HIGH |
| Fix actual terminal and connector naming | The D12 uses JP1-IN/OUT and JP2-IN/OUT for channels 1/2; the interactive operator panel assigns separate JP1/JP2 on CH1 and JP3/JP4 on CH2. These are naming differences; produce one physical identifier list before wiring. X1–X4 net IDs are logical, not ordered hardware terminals. | MEDIUM |
| Validate all protection paths | DD11 inlet fusing/selection, enclosure and door PE continuity, DC supply disconnect/E-stop strategy, sensor-fault MV, SSR-off/reset behaviour and 24 V protective circuits remain for commissioning. | HIGH |
| No proof of heater current from an indicator | ACTIVE is an intended control-demand status; rising SV, OUT1 and the amber lamp (if lit) are not measurements of externally delivered DC current. USB-only Omron trials validate programming logic, not heater outputs. | MEDIUM |