USB/Serial breakout

Integrate a USB-device-to-3.3 V UART bridge between a USB-B connector and a U socket.

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: Retained native ERC/strict DRC/opens/parity and ordinary drill/mask checks zero; 130 checklist and all270 rule items unsigned. USB impedance/eye, enumeration, 3 Mbaud, backfeed, EMI and physical qualification open.

Interfaces and wiring

Inputs

  • USB 2.0 device connection.
  • U socket UART.

Outputs

  • Bidirectional USB serial link and optional U chain.

Connection contract

The selected v11 contract uses the repository-canonical connector rule: pin 1 is +3.3 V, pin 2 is +5 V, and pin 10 is GND. Actual host marking, mating face, cable continuity, and the full signal map must be checked against the target hardware before connection; this document does not resolve conflicting secondary documentation.

Pin Function Design note
1 +3.3 V Canonical fixed rail.
2 +5 V Canonical fixed rail.
3 GPIO! Board mapping; validate against current V2 hardware before layout.
4 TX Board mapping; validate against current V2 hardware before layout.
5 RX Board mapping; validate against current V2 hardware before layout.
6 GPIO/pass-through Board mapping; validate against current V2 hardware before layout.
7 UN Board mapping; validate against current V2 hardware before layout.
8 UN Board mapping; validate against current V2 hardware before layout.
9 UN Board mapping; validate against current V2 hardware before layout.
10 GND Canonical fixed rail.

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.

Electrical design requirements

The following are specification requirements or study assumptions; they are not measured operating ratings. A newer selected-revision note takes precedence over historical draft options.

  • The selected v11 prototype selects FTDI FT231XS and TXU0202DCUR. This resolves the study’s bridge/translator selection; supplier status and bench behavior remain unverified.
  • USB bus power and Gadgeteer power must not backfeed.
  • UART logic voltage must match current V2.

Protection in the design record

The design describes the following protection intent. Check the selected schematic and remaining qualification gates before relying on it:

The selected study includes USB ESD and domain-isolation components. Verify ESD return path, VBUS current limiting, decoupling placement, translator sequencing, UART series behavior, and all one-side-unpowered states on the assembled design.

Selected component architecture

See current review. Retain v11 FT231XS and already adopted TXU0202DCUR two-direction translator; no demonstrated CP2102N/CH340C benefit. Conditional V1 bypass/bias reuse, preserving actual R4 100 kΩ. No IC-stock successor. Current selected v11; retained native/stock/physical qualification limits remain explicit.

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/usb-serial-breakout.

Additive design studies

The 2026-10-11 upgrade program has saved additional candidates v12, v13, v14. 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 v12, v13, v14. 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.

usb-serial

  • Latest PCB source, SHA-256 d890670c83de883aa83f5a900cdcb288f2fa6a110365b91e8856f8ec7913ff2b.
  • Last native check: 0 errors, including 0 open connections. This is a CAD result, not electrical, assembly or firmware qualification.
  • No alternative connector population is recorded for this physical role. Any applicable connector conversion remains an explicit design-review item.
  • normal 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 v15 — 2026-10-13

Protected source v14; current PCB SHA-256 d060d8ec5a6d71a2f95d6aec38067c934b7383c1bbd31d7ec5200b79dff6bec1. Fresh checks: zero enabled errors/opens/parity/ERC findings; 16 PCB warnings. Electrical geometry, project rules and 27 historical files unchanged. Verified 23 model entries, 17 exports and 6 current population views, all inspected. Full documentation URL readable. Exact authored library/models restored; physical model seating remains unqualified Inherited native warnings and enabled-rule exclusions remain explicit Physical/thermal/current/connector-fit qualification open No priced or area savings established by annotation candidate.

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