D-sub-to-Gadgeteer IN adapter

IN is the host-side half of a custom nine-conductor extension. It accepts a keyed 2 × 5, 1.27 mm Gadgeteer cable and presents a male DE-9 interface for a dedicated cable to OUT. IN and OUT name the power path, not signal direction. Use one host and one OUT; the assembly is not an RS-232 interface, level converter, isolator, or general-purpose D-sub extension. It must never be connected to a computer serial port.

Development status

Baseline documentation snapshot: 2026-10-11, before the requested connector/protection/usability revision program. New revision features require their own reviewed source and qualification evidence.

This page documents an unqualified engineering study, not a released or tested product. Saved CAD, renders and automated checks do not establish a safe assembly, compatible cable, firmware support or a usable current rating.

Board-specific qualification limits: Enabled native0;header-only purchasing BOM/blank native MPNs,partial STEP,five ignored categories/physical open.

Interfaces and wiring

Connection contract

The nine DE-9 contacts carry exactly seven independent signals, one ground, and one fused +5 V conductor. Gadgeteer pin 1, the host +3.3 V rail, does not enter the DE-9 or OUT board. Gadgeteer pin 2 supplies +5 V through IN’s F1 fuse; pin 10 is the sole signal/power return. The DE-9 shell is not a tenth conductor and has no intentional connection to circuit ground.

DE-9 numbered contact 1 2 3 4 5 6 7 8 9
Gadgeteer pin 3 4 5 6 10 7 8 9 2
IN net SIG3 SIG4 SIG5 SIG6 GND SIG7 SIG8 SIG9 CABLE_5V

The OUT board uses this same numbered map. Confirm numbers from each actual mating face; male, female, and PCB solder views are mirrored. Only a tested nine-conductor straight-through cable is allowed: IN male mates a cable socket, OUT female mates its cable pins, with contact n wired to n for all nine. Maximum cable length is 1.0 m, with +5 V and ground conductors at least 26 AWG. Before first power, prove every intended contact is continuous below 0.5 Ω after test-lead compensation and all unintended contact/contact and contact/shell combinations are above 1 MΩ. Measure loaded voltage drop too. No null-modem, crossover, unidentified commercial serial cable, or hot plug.

Power off before connecting or changing jumpers. Verify pin 1, signal direction, supply voltage and ground at both ends of every cable. A mechanically fitting connector is not proof of electrical compatibility. If a host pin mapping or current allocation remains unresolved in the design record, do not connect the board until it is resolved.

Selected component architecture

Complete current review: actualv12 retains passive interface/fuse/shunts,no successor. Contract covers12 purchased/four testpad refs; purchasing BOMs are header-only and native BOM lacks MPNs. Enabled native checks0 do not close five ignored categories/partial STEP/physical gates.

Configuration and commissioning

Use the configuration and firmware contract for the exact selected revision. Do not copy another module’s socket assignments or assume that an unused pin is available. First-article work must verify source selection, reset/unplug behavior, cable orientation and the actual load or sensor interface before normal operation.

Requested connector and usability upgrades

The following are requirements for the next design iterations; this page does not claim they are already fitted:

  • On electrically suitable three/four-pin low-voltage ports, provide compact alternative 2.54 mm header/Molex-style and keyed STEMMA-family footprints. Populate one connector option per shared position and document its pin order. Use STEMMA QT only for compatible four-wire I²C; connector appearance does not make another signal protocol I²C-compatible.
  • Render each supported connector population separately. Document clearances, cable access and the exact fitted option.
  • Use uppercase titles in a consistent Montserrat-style face, labels on both sides, visible domain boundaries, a revision-specific wiring guide and this page’s URL on the silk where readable.
  • Keep mounting-hole centers on a documented 10 mm lattice; add cable-tie holes where space and electrical clearances permit. Place status LEDs near accessible edges and give every indicator its own disable solder jumper. Provide labeled test pads and a ground observation point.
  • Review applicable DC power entries for reverse-polarity cutoff with a blinking warning, overvoltage cutoff/indication, controlled startup and electronic overcurrent protection. Indicator and protection circuits must work in the fault state without defeating isolation or safe output defaults. Thermal protection belongs only where the power/thermal analysis justifies it.
  • Electronic protection does not automatically replace a required mains/branch safety fuse. Backfeed blocking and inductive-load flyback clamps are separate design functions. Do not add identity EEPROMs, fault memory, calibration storage or paid self-test hardware under this upgrade program.

Design sources

Documentation route: smoothieware.org/extensions/d-sub-to-gadgeteer-in.

Additive design studies

The 2026-10-11 upgrade program has saved additional candidates v13, v14, v15. These studies preserve the historical design described above. Their connector, LED, mechanical and protection changes are revision-specific and remain unqualified.

See the per-board changes, failures and remaining work and mandatory family specification. Use the source hash and native check for the exact candidate being reviewed; do not infer hardware ratings from a rendered population.

Upgrade candidate readback

The three additional revisions are v13, v14, v15. They are engineering studies; saved CAD and renders do not release the hardware. The latest candidate is described below. Older baseline notes above remain historical.

d-sub-to-gadgeteer-in

  • Latest PCB source, SHA-256 7a72ed48cbca355e6bc8af0c96eb76fb9f7de3b17b1e5dce11204d4df78bf25e.
  • Last native check: 19 errors, including 19 open connections. This is a CAD result, not electrical, assembly or firmware qualification.
  • Alternative connector lands recorded: J3 / PinHeader_1x04_P2.54mm_Vertical. Fit only the selected population; check its pin map and voltage in the design record.
  • normal population/render record: 6 images; source current; image hashes match; 0 unresolved models.
  • stemma population/render record: 6 images; source current; image hashes match; 0 unresolved models.
  • Changes, failed trials and remaining work.

Applicable protection, current-path, thermal, pinout, cable access and physical tests remain open wherever the linked board record has not verified them. A zero native-error count does not close those gates.

Second-round annotation readback v21 — 2026-10-13

Protected source v20; current PCB SHA-256 645c020ac2b62be9a0653f16f9d5aaa4edf8a3726437a61c551a5e04eeb9b44a. Fresh native checks: zero enabled errors, opens, schematic mismatches and ERC findings; 1 PCB warnings remain. Electrical geometry/project rules unchanged; 189 historical files, 88 model entries,17 exports and12 current population images verified. All12 populated/bare views inspected. Full documentation URL is readable in the current renders. Physical qualification remains open; no price or area savings claimed.

Trusted-power compact correction

Engineering revision v24 removes36 redundant trusted-input protection parts and restores the original23 ×29mm outline. A horizontal2.54mm alternative header and undersideSH connector share the compact bottom area. Native checks find no errors or open connections; each connector population has six renders with the fullDB9 shell framed. This remains an unqualified engineering design, not a fabrication release.

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