Calmotion USBCNC-SW Installation instructions

USBCNC-SW
USB Disk Key reader for CNC Controls
Machine Mount instructions for
Universal Switcher Version
2 15 Calmotion LLC, All rights reserved
Calmotion LLC
2172 Marilla Street
Chatsworth, CA 91311
www.calmotion.com

Introduction
This manual is intended to provide a description of the installation procedure for the Calmotion
USBCNC universal disk key reader.
Requirements
The USBCNC device will work with a CNC control with a standard DB25 S-232 serial
connection to the control box for the purposes of input/output of CNC data. Typically, the CNC
manufacturer refers this as read and punch tape functions.
Please review the instruction manual thoroughly before
beginning installation. In addition, the installer should verify
that proper space and clearance has been taken into account
prior to drilling holes in the CNC pendant. This includes
cable bending radius and cable length.

The USBCNC-INT kit includes a mounting bezel that also acts as a drill jig. Once the installer
has identified where the display should be mounted, the mark the small hole in the center and
drill a hole the same size. Mount the plate, level and tighten to the cabinet.
Figure 1
Note the orientation of the bracket. The large hole should be on the left. Place the display on the
bracket to see how the display has the J11 jack that protrudes through the large hole.
With the bracket held in place with a bolt through the smaller center hole, level the bracket and
mark the larger hole on the bracket, this will need to punched or step drilled to this same size.
Now drill the four outer holes using the bracket as a drill jig.
emove the bracket.
Step drill or punch out the larger diameter hole. The display’s J11jack connector will protrude
through this hole.
This is the smaller hole
in the center. Use this to
hold bracket in place
while drilling the outer
four mounting holes.

Figure 2
Mount the display and bracket to the control box.
Figure 3
Inside the cabinet the J11 and the potentiometer should be visible through the large diameter
hole.

Figure 4
Plug the modular cable into the J11 jack. Note the length of the cable. The USBCNC
controller board will need to be within the distance of the cable length when mounted.
Locate a good position for the USBCNC controller board. It will need to be within the distance
of the display cable, serial cable and the power plug. Secure the din rail as shown below. Use
all 6 ¼-20 nuts, by using two to secure it to the cabinet and the other 4 to stand off the din rail so
the board is clear of the screws.
Figure 5
Attach the din rail clips to the USBCNC controller and mount to the din rail. Check for spacing.
The two outer holes from the din rail clips can be used to release from the clips with a small
screwdriver.

Figure 6
Plug the modular cable from the display into the J11 connector J2 on the USBCNC controller
board.
There are two J45 plugs J3 and J4. J3 will plug into the CNC using the DB25 plug labeled
“To CNC”, see figure 8. J4 will replace the DB25 panel mounted plug that was on the CNC
cabinet going out of the machine, see figure 9. Connect the provide plug labeled “To PC” to J4,
and use the DB25 male gender changer to replace the S-232 plug going out of the CNC cabinet.
Plug the USB cable into J1 on the control board shown above. In a later step the other end of the
USB cable will plug into the panel mounted USB connector.
J2
J3
To CNC J1

Figure 7
Plug the DB25 connector removed from the cabinet panel and plug it into the DB25 to J45 plug
labeled “To CNC”.
Figure 8
Mount the included DB25 female-female plug to the cabinet. Then the DB25 to J45 connector
labeled “To PC” can be plugged into back of female-female plug on the cabinet panel.

Choose a location for the panel mounted USB plug. Its location should be chosen for convenient
connection of a USB key during normal operation of the machine. Punch a hole in the desired
location to the dimensions shown above. Insert the panel mount USB connector through the hole
and secure with the attached nut. Ensure that the gasket included with the kit is used to prevent
contaminants from entering the enclosure. The cap of the panel mount USB connector snaps
onto the connector house. (Note: the A side of the USB connector faces out of the pendant while
the square B side of the USB connector faces into the pendant). Connect the USB plug to the
controller with the USB cable provided.
Figure 9
Locate the serial port connector of the CNC. Attach one end of the CAT5 cable to the serial port
connector of the USBCNC controller. Attach the other end to one of the DB25 connectors
included with the kit. Both male and female connectors have been provided. Choose one as
appropriate. In most cases, it is best to simply pull the serial connector in from its mounting
assembly and connect inside the pendant as shown below.

Figure 1
Connect the power plug provided to the printed circuit board. The power connection is center
positive. The positive wire is identified with a white-stripe running the full length of the wire.
The solid black wire should be connected to ground. The power supply can be anywhere in the
range of 7-30 volts DC. Find a suitable power source in the cabinet and connect the flying lead
connections to a power source, if one can not be found an optional power supply can be
purchased from Calmotion. Apply power to the unit. A green LED should illuminate on the
controller indicating that power has been applied. If properly connected, the keypad will also
illuminate after a slight delay.
To Adjust the Display Contrast
An orange potentiometer (R2) located on the back of the display board can be used to adjust the
contrast of the keypad display. This potentiometer should be accessible through the large
diameter hole in the control box. (Note: the 20 on the USBCNC control board does not adjust
the contrast).

Figure 11
Please refer to the USBCNC user’s manual for operation and communication set-up of the
USBCNC.
How the RS-232 Switch Box Version Works
The USBCNC “Switch Box” version acts like having a physical A-B switch box connecting two
devices to the machine. This allows for existing computers attached to the CNC to stay in place
while adding the USBCNC functionality.
The way this USBCNC Switch Box version works is very straightforward. The USBCNC
always allows S-232 data to pass to and from the CNC. This allows computers connected to
the CNC's serial port to function normally. The USBCNC will automatically switch the serial
port to itself when using the USBCNC to transfer files in and out of the CNC. When the
USBCNC function is complete, the serial port will be returned to the external device connected
to the CNC.