Digital Wood Carver

DWC2440

Control Box Wiring Reference

REVISION:
2.0
DOCUMENT:
DWC2440-CB-REF
ASSEMBLY & SERVICE REFERENCE

Main Power Input

120VAC single phase / 15A system

ConductorWireConnection
HotBlack 12 AWGOmron G7L rear #2 spade
NeutralWhite 12 AWGWAGO 221 neutral hub
GroundGreen 12 AWGControl 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

Omron G7L relay
TerminalConnection
Rear #2Incoming hot + blue piggy-back to E-Stop #1
Rear #1Black 14 AWG to top of 15A breaker
Rear #3Blue jumper to front right coil spade
Rear #4Blue wire to E-Stop lower #2
Front LeftNeutral from WAGO hub + fan neutral piggy-back
Front RightBlue jumper from rear #3 + Power-On #4

Breaker Assignments

15A / 10A / 5A AC distribution

BreakerBottom Terminal FeedsFunction
15ARelay module K3 + K4 common terminalsRouter / vacuum relay AC hot
10AL terminal of 36V PSUMotion power supply
5AControl box fan + L terminal of 12V PSUFan 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

Mean Well LRS-350-36 label
TerminalConnection
LBlack 14 AWG from 10A breaker
NWhite 14 AWG from neutral hub
GNDGreen 14 AWG from ground lug
V−White 14 AWG to all DM556 GND terminals
V+Black 14 AWG to all DM556 +V terminals
V−→GNDJumper wire

12V Control Power Supply

Mean Well RS-15-12

Mean Well RS-15-12 label
TerminalConnection
LBlack 14 AWG from 5A breaker
NWhite 14 AWG from neutral hub
GNDGreen 14 AWG from ground lug
V+Red wire to MK3/4 + 8–24VDC power
V−Black wire to MK3/4 − 8–24VDC power
V−→GNDJumper wire

Neutral & Ground

WAGO hub and ground lug bolt

Hub / LugConnections
Neutral HubMain neutral, 12V PSU N, 36V PSU N, duplex receptacle neutral, Omron coil neutral
Ground LugMain ground, 12V PSU GND, 36V PSU GND, duplex receptacle ground, chassis bond
FanRed 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 AxisDWC2440 Assignment
Axis 1X Driver
Axis 2Y Driver
Axis 3Z Driver
Axis 4A 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.

4-Channel Relay Module

Router and vacuum automatic power

4-channel relay module
Relay / PinConnection
K1Spare
K2Spare
K3Router hot — common from 15A breaker, NO to left outlet hot
K4Vacuum hot — common from 15A breaker, NO to right outlet hot
IN3MK3/4 Output 1
IN4MK3/4 Output 1
VCC/GNDMK3/4 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

120V duplex receptacle
ItemConnection
OrientationMounted horizontal
Hot SideTop terminals
Neutral SideBottom terminals
Hot TabRemoved to separate router/vacuum circuits
Neutral TabIntact / common neutral
GroundGreen 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

DM556 motor driver
Driver TerminalWire ColorAviation Pin
A+RedPin 1
A−WhitePin 2
B+BlackPin 3
B−GreenPin 4

Aviation Connector Reference

4-pin 16mm motor connector

4-pin aviation connector
Front Panel ConnectorPosition
XLeft-to-right position 1
YLeft-to-right position 2
ZLeft-to-right position 3
APositioned under Z on 4-axis units

Ribbon Cable Signals

10-pin ribbon / wires 1–6 used

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

Legacy DWC2440 wiring diagram
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

This page intentionally documents the DWC2440 control box. Controller pinouts and pendant wiring remain in the dedicated MK3/4 Controller Reference.
Disconnect power before servicing. Verify all AC wiring, grounding, relay wiring, and DC power supply connections before applying power.