NaoDec Vertex Series Coil Rev 1.0a Interactive schematic of a current-limited sixty-coil series electromagnet loop. N A O D E C VERTEX SERIES COIL - REV 1.0A 60-coil pre-release design | dual-pot XL4015 CC/CV | exact 3 A input fuse | thermal cutoff 12V INPUT / CC LOOP+ 0V / RETURN CURRENT-LIMITED POWER AND SERIES LOOP 12 V PSU DC SUPPLY 0 V +12 V F1 3 A T C1 220-470 µF ≥25 V LOW-ESR C2 100 nF X7R ≥25 V XL4015 DUAL-POT CC/CV CV 11.0 V | CC 3.0 A IN+ OUT+ IN- OUT- TCO1 70-80 °C GROUP 1 L1-L3 GROUP 2 L4-L6 . . . GROUPS 3-19 GROUP 20 L58-L60 CC-REGULATED LOOP+ | ~5.55 V LOADED | 3.0 A COMPLETE 20 AWG WIRING | ~1.30 Ω MEASURED | KEEP UNCOILED ONE GROUP - 1 OF 20 JST-F JST-M 7 T 7 T 7 T Each coil: 1 mm Cu | 12.5 mm ID | 5 cm lead + 7 cm lead | ~0.417 m copper | crystal core (non-magnetic) Connector: JST SM 2-pin, both pins paralleled | 20 connectors total | 60 coils total OPERATING POINT Cold loop estimate ~1.85 Ω Regulated output ~5.55 V | 3.0 A Total output power ~16.65 W Wiring / coils ~11.70 / 4.95 W Field per coil ~21 AT FINAL LOOP RESISTANCE MUST BE MEASURED AFTER ASSEMBLY WARNING - NEVER RUN THE STRING WITHOUT THE VERIFIED CC/CV BUCK Direct 12 V would attempt ~6.5 A / ~78 W | exact 3 A T-fuse + 70-80 °C TCO required | keep all 20 AWG runs uncoiled PRE-RELEASE - BENCH QUALIFICATION REQUIRED 1.30 Ω mock wire + ~0.56 Ω / ≥10 W resistor bank | CV 11.0 ±0.3 V | CC 3.0 ±0.1 A | 30 min burn-in SIGNAL FLOW, WIRING & CALCULATIONS POWER PATH 12 V PSU -> 3 A T fuse -> XL4015 -> TCO -> 60 coils -> return The 11.0 V CV setting is an open-load ceiling. The loaded loop operates in CC mode near 5.55 V. ELECTRICAL SUMMARY 60 coils ~0.55 Ω calculated at 20 °C 20 AWG installation wiring ~1.30 Ω measured | uncoiled Complete cold loop ~1.85 Ω estimated At 3.0 A ~5.55 V | 16.65 W Power split 11.70 W wire | 4.95 W coils PROTECTION & WIRING F1 exactly 3 A T-type | not 3-5 A Expected PSU input ~1.5-1.7 A at 12 V TCO1 70-80 °C | ≥5 A | bonded at hot spot J1-J20 JST SM 2-pin | both pins paralleled XL4015 MOCK QUALIFICATION Mock load 1.30 Ω wire + ~0.56 Ω / ≥10 W bank Open-load CV 11.0 ±0.3 V Full-load CC 3.0 ±0.1 A | steady Clamp / burn-in ≤3.1 A on 1.30 Ω | 30 minutes Reject any module with pulsing, drift, smoke, odour, or unstable current regulation. BILL OF MATERIALS & XL4015 HARNESS # QTY REF DESCRIPTION 1 1 D1 1N5819 / 1N4007 flyback (optional, only if electronically switched) 2 1 F1 Exactly 3 A slow-blow T-type | buck input 3 20 J1-J20 JST SM 2-pin | both pins paralleled 4 60 L1-L60 7 T | 1 mm Cu | 12.5 mm ID | crystal core | ~0.417 m each 5 1 U1 Dual-pot XL4015 HW-083-B | CV 11.0 V | CC 3.0 A 6 1 W1 Complete 20 AWG installation wiring | ~1.30 Ω measured 7 1 PSU1 12 V DC supply | fused isolated positive branch 8 1 C1 220-470 µF low-ESR electrolytic | ≥25 V | XL4015 input 9 1 C2 100 nF X7R ceramic | ≥25 V | parallel with C1 10 1 TCO1 70-80 °C thermal cutoff | ≥5 A | manned installation U1 XL4015 HARNESS PIN NAME NET CH IN+ VIN+ 12V_IN IN- VIN- GND OUT+ VOUT+ LOOP_POS OUT- VOUT- RETURN PROTECTION SUMMARY F1 3 A T-type TCO1 70-80 °C | ≥5 A C1 220-470 µF | ≥25 V C2 100 nF X7R | ≥25 V CC LIMIT = REGULATION FUSE + TCO = FAULT PROTECTION ONLY USE A TRUE DUAL-POT CC/CV MODULE ENGINEERING NOTES & REVISION HISTORY 1. At steady-state DC, inductive reactance tends to zero. The loop behaves as an approximately 1.85 Ω resistive load pending final assembly measurement. 2. The crystal core is non-magnetic (µ approximately air), so it provides no field boost. Each seven-turn coil produces approximately 21 ampere-turns at 3 A. 3. The XL4015 current-control loop is the operating current limiter. A CV-only or fixed-output board is not acceptable for this installation. 4. F1 must be exactly 3 A slow-blow. C1 and C2 mount directly at IN+/IN-. The 70-80 °C thermal cutoff is mandatory for manned operation. 5. Keep every 20 AWG run and all slack uncoiled. Keep bare copper apart and keep this positive branch isolated from the three LED-supply positive rails. 6. Bench-qualify each XL4015 with the documented 1.86 Ω mock load before connecting the real loop, then perform supervised commissioning and thermal inspection. 7. Do not adjust CV to force 11 V across the loaded loop. Normal operation is 3 A CC near 5.55 V for the present estimated cold resistance. REVISION HISTORY Rev 1.0a - Dark Blue-Mint theme variant (HTML_Document_Recreation_Guide palette): accent #0ff0b3, --bg #080b10, --warn #ff4f86, GND wire #4d7096. All technical content unchanged from Rev 1.0. Rev 1.0 - Strict NaoDec style rebuild with 2026-06-18 design data: 20 AWG / ~1.85 Ω loop, exact 3 A T-fuse, dual-pot XL4015, input decoupling, TCO, current calculations, and mock qualification. Document rebuild: 2026-06-19. Values remain provisional until final measurement.
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