DWC2440 Control Box Reference v2.0

Main Power Input

120VAC single phase / 15A system

Conductor	Wire	Connection
Hot	Black 12 AWG	Omron G7L rear #2 spade
Neutral	White 12 AWG	WAGO 221 neutral hub
Ground	Green 12 AWG	Control box ground lug bolt

DWC Standard: DWC2440 control box uses a 12/3 power cord and 120VAC single-phase power.

Omron Main Relay

G7L-2A-TUB-J-CB master power relay

Terminal	Connection
Rear #2	Incoming hot + blue piggy-back to E-Stop #1
Rear #1	Black 14 AWG to top of 15A breaker
Rear #3	Blue jumper to front right coil spade
Rear #4	Blue wire to E-Stop lower #2
Front Left	Neutral from WAGO hub + fan neutral piggy-back
Front Right	Blue jumper from rear #3 + Power-On #4

Breaker Assignments

15A / 10A / 5A AC distribution

Breaker	Bottom Terminal Feeds	Function
15A	Relay module K3 + K4 common terminals	Router / vacuum relay AC hot
10A	L terminal of 36V PSU	Motion power supply
5A	Control box fan + L terminal of 12V PSU	Fan and controller PSU

Top breaker distribution: Omron switched output feeds 15A; blue 14 AWG jumpers feed 10A and 5A top terminals.

36V Motion Power Supply

Mean Well LRS-350-36

Terminal	Connection
L	Black 14 AWG from 10A breaker
N	White 14 AWG from neutral hub
GND	Green 14 AWG from ground lug
V−	White 14 AWG to all DM556 GND terminals
V+	Black 14 AWG to all DM556 +V terminals
V−→GND	Jumper wire

12V Control Power Supply

Mean Well RS-15-12

Terminal	Connection
L	Black 14 AWG from 5A breaker
N	White 14 AWG from neutral hub
GND	Green 14 AWG from ground lug
V+	Red wire to MK3/4 + 8–24VDC power
V−	Black wire to MK3/4 − 8–24VDC power
V−→GND	Jumper wire

Neutral & Ground

WAGO hub and ground lug bolt

Hub / Lug	Connections
Neutral Hub	Main neutral, 12V PSU N, 36V PSU N, duplex receptacle neutral, Omron coil neutral
Ground Lug	Main ground, 12V PSU GND, 36V PSU GND, duplex receptacle ground, chassis bond
Fan	Red hot to 5A breaker; black neutral piggy-back to Omron front-left neutral spade

Duplex receptacle ground runs directly to the ground lug bolt inside the control box.

MK3/4 Controller

DWC2440 controller platform

MK3/4 Axis	DWC2440 Assignment
Axis 1	X Driver
Axis 2	Y Driver
Axis 3	Z Driver
Axis 4	A Driver (4-Axis 3D Pro only)

Linked reference: Full MK3/4 controller pinouts and JOG pendant wiring live in the MK3/4 Controller Reference page.

Open MK3/4 Controller Reference

4-Channel Relay Module

Router and vacuum automatic power

Relay / Pin	Connection
K1	Spare
K2	Spare
K3	Router hot — common from 15A breaker, NO to left outlet hot
K4	Vacuum hot — common from 15A breaker, NO to right outlet hot
IN3	MK3/4 Output 1
IN4	MK3/4 Output 1
VCC/GND	MK3/4 5VDC and Output GND

Important: MK3/4 does not have Output 3 or Output 4 terminals. Relay module IN3 and IN4 both connect to MK3/4 Output 1.

Split Duplex Receptacle

Horizontal mounting in control box

Item	Connection
Orientation	Mounted horizontal
Hot Side	Top terminals
Neutral Side	Bottom terminals
Hot Tab	Removed to separate router/vacuum circuits
Neutral Tab	Intact / common neutral
Ground	Green wire to ground lug bolt

X Driver

DM556 / MK3-4 Axis 1

1
ON

2
ON

3
OFF

4
OFF

5
ON

6
ON

7
OFF

8
OFF

Y Driver

DM556 / MK3-4 Axis 2

1
ON

2
ON

3
OFF

4
OFF

5
ON

6
ON

7
OFF

8
OFF

Z Driver

DM556 / MK3-4 Axis 3

1
ON

2
ON

3
OFF

4
OFF

5
OFF

6
ON

7
ON

8
OFF

A Driver

DM556 / MK3-4 Axis 4 / Optional

1
ON

2
ON

3
OFF

4
OFF

5
ON

6
ON

7
OFF

8
ON

DM556 Motor Output

All axes use same motor output color map

Driver Terminal	Wire Color	Aviation Pin
A+	Red	Pin 1
A−	White	Pin 2
B+	Black	Pin 3
B−	Green	Pin 4

Aviation Connector Reference

4-pin 16mm motor connector

Front Panel Connector	Position
X	Left-to-right position 1
Y	Left-to-right position 2
Z	Left-to-right position 3
A	Positioned under Z on 4-axis units

Ribbon Cable Signals

10-pin ribbon / wires 1–6 used

DM556 Signal	Ribbon Wire
ENA+	1 — Pink wire
ENA−	2
DIR+	3
DIR−	4
PUL+	5
PUL−	6
7–10	Not used

Control Box Architecture Flow

HTML/CSS diagram — no crossing wire paths

120VAC Input12/3 power cord

Omron RelayPower ON / E-Stop

Breakers15A / 10A / 5A

Power Supplies12V + 36V

MK3/4 + DriversMotion and output control

Output 1MK3/4 controller

Relay IN3 / IN4Relay module logic

K3 / K4Router / Vacuum

Split DuplexHot tab removed

AppliancesRouter / Vacuum

Control Logic

E-Stop, Power-On, and relay behavior

Power-On Path

E-Stop NC contact must be closed.
Power-On NO button energizes Omron coil.
Omron main contacts close.

E-Stop Path

E-Stop opens the blue coil circuit.
Omron relay drops out.
Switched AC downstream is removed.

Fan / Control Power

Fan hot comes from 5A breaker.
12V PSU powers MK3/4 board.
36V PSU powers DM556 drivers.

No Motion

Check 10A breaker.
Verify 36V PSU output.
Check DM556 power LEDs.
Check ribbon cable to axis header.

Router Not Switching

Check 15A breaker.
Check relay module K3.
Verify Output 1 control wiring.
Check top hot terminal on split receptacle.

Vacuum Not Switching

Check 15A breaker.
Check relay module K4.
Verify Output 1 control wiring.
Check top hot terminal on split receptacle.

E-Stop / Power Fault

Verify E-Stop NC contact.
Check blue control circuit wires.
Verify Omron coil neutral.
Confirm switched output to 15A breaker.

Legacy Reference

Original rough wiring diagram retained for archive

Archive Note: The legacy diagram remains useful as historical source material, but this v2 HTML reference is the maintained service standard.

Related References

Linked pages in the DWC Engineering Reference Library

MK3/4 Controller Reference Engineering Reference Hub

This page intentionally documents the DWC2440 control box. Controller pinouts and pendant wiring remain in the dedicated MK3/4 Controller Reference.