SS4544 SyncroStep Motion Control System
MECHANICAL SPECIFICATIONS
Testra Corporation  1201 N. Stadem Drive Tempe, AZ 85281 Ph:(480)560-6141 Fax:(480)907-2876
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Table of Contents

1.0 POWER INPUT CONNECTION
1.1 POWER CONNECTOR
1.2 FUSING
1.3 POWER CORD
2.0 RS-232 INTERFACE
2.1 RS-232 CONNECTOR
2.2 RS-232 CORD SET
2.3 DB-9F ADAPTOR
2.4 DB-25F ADAPTOR
3.0 RS-485 INTERFACE
3.1 RS-485 CONNECTORS
3.2 RS-485 CORD SET
4.0 INTERLOCK
5.0 LASER/PWM
6.0 AXIS ENCODER/LIMIT
7.0 TRAINING
8.0 MOTOR CONNECTORS
9.0 MOUNTING



1.0 POWER INPUT CONNECTION

    The SS4544 system power input connection is via a world standard power
connector with availability of a wide range of cord sets for various country
standards.

1.1 POWER CONNECTOR

    The input power connector is a Euro Standard 3 prong male plug. The
connector used is:

    Schurter GSF1.1101.01

    It mates with many different standard power cord sets. Cord sets should
be rated for at least 5 amps.

1.2 FUSING

    The input power line fuse holder is integrated with the power inlet
connector, and is mounted inside the case. Under normal circumstances this
fuse should not have to be replaced. The fuse being blown usually
represents some catastrophic event, meaning the unit should be returned for
servicing. If power has been applied, and the power light does not come on,
the fuse is probably blown.

    If the fuse is replaced, and blows again, the unit should be definitely
returned for service.

    The standard fuse is a 5x20mm 3.15amp 250v Fast Blow.

    Digikey WK1124-ND

1.3 POWER CORD

    The system uses a world standard cord set, depending on the country of
use. Several standard cord sets are listed below:

2.0 RS-232 INTERFACE

    The RS-232 interface is used to communicate with a PC or other computer.
The interface connector is on the bottom end plate of the box above the fan.
 

2.1 RS-232 CONNECTOR

    For the RS-232 interface, an 8 pin RJ-45 Modular connector is used. The
connector in the system is as follows:

    MOLEX 95001-2881

    Pinouts for the connector are as follows:

    1 = +5V (+5v User Power)
    2 = RTSA (Request to Send)
    3 = GND (Ground)
    4 = TXDA (Transmitter Data)
    5 = RXDA (Receive Data)
    6 = GND (Ground)
    7 = CTSA (Clear to Send)
    8 = n/c

2.2 RS-232 CORD SET

    The cord set uses standard 8 pin modular insulation displacement
connectors with standard 8 conductor flat jacked, color coded wire. The
connectors are crimped so that the cable is crossing. The following table
shows the resulting wire list for the cable:

    P1                                            P2
    ==                                            ==
    1 = +5V (+5v User Power)        =  8
    2 = RTSA (Request to Send)     =  7
    3 = GND (Ground)                   =  6
    4 = TXDA (Transmitter Data)   =  5
    5 = RXDA (Receive Data)         =  4
    6 = GND (Ground)                   =  3
    7 = CTSA (Clear to Send)         =  2
    8 = n/c                                      = 1

    The materials are as follows:

    P1,P2 RJ-45 Plug
    Wire 8 Conductor Flat Jacketed
    TOOL Crimping Tool
 

2.3 DB-9F ADAPTOR

    For connection to a personal computer (PC) you will need an adaptor going
from the 8 pin RJ-45 connector to the 9 pin DB-9 female connector. A standard
adaptor is available to accomplish this. It needs to be wired as follows:

    RJ-45                                     Color       DB-9
    =====                                   =====     ====
    1 = n/c                                    BLU          1
    2 = RTSA   (Request to Send)  ORN         7
    3 = GND                 (Ground)  BLK        n/c
    4 = TXDA (Transmitter Data)  RED          3
    5 = RXDA       (Receive Data)  GRN         2
    6 = GND                  (Ground) YEL          5
    7 = CTSA        (Clear to Send) BRN          8
    8 = n/c                                    GRY         4

    Adaptor Kit Part Number -
    Testra Part Number -

2.4 DB-25F ADAPTOR

    For connection to a personal computer (PC) you will need an adaptor going
from the 8 pin RJ-45 connector to the 25 pin DB-25 female connector. A standard
adaptor is available to accomplish this. It needs to be wired as follows:

    RJ-45                                       Color  DB-25
    =====                                     ===== ====
    1 = n/c                                      BLU      8
    2 = RTSA (Request to Send)      ORN     4
    3 = GND (Ground)                    BLK      1
    4 = TXDA (Transmitter Data)    RED      2
    5 = RXDA (Receive Data)          GRN     3
    6 = GND (Ground)                    YEL      7
    7 = CTSA (Clear to Send)          BRN     5
    8 = n/c                                      GRY    20

    Adaptor Kit Part Number -
    Testra Part Number -

3.0 RS-485 INTERFACE

    The RS-485 interface is used to communicate with one or more SS-xxxx
series motion control system, keyboard/display panel, sensor inputs, and
control outputs. These connections are made in a daisy chain manner. The
interface connectors are on the bottom end plate of the box above the fan.

3.1 RS-485 CONNECTORS

    For the RS-485 interface, an 4 pin RJ-15 Modular connectors are used. The
connectors in the system are as follows:

    MOLEX 95001-2441

    Pinouts for the connectors are as follows:

    RS-485 INPUT
   ============
    1 = TXRA (Transmit/Receive Ph A)
    2 = TXRB (Transmit/Receive Ph B)
    3 = n/c
    4 = GND (Ground)

    RS-485 OUTPUT
    =============
    1 = TXRA (Transmit/Receive Ph A)
    2 = TXRB (Transmit/Receive Ph B)
    3 = +5V (+5V  user power)
    4 = GND (Ground)

3.2 RS-485 CORD SET

    The cord set uses standard 4 pin modular insulation displacement
connectors with standard 4 conductor (2 pair twisted) jacketed, color coded
wire. The connectors are crimped so that the cable is non-crossing. The
following table shows the resulting wire list for the cable:

    P1                 P2
    ==                 ==
    1 = TXRA =   1
    2 = TXRB =   2
    3 = +5V    =   3
    4 = GND   =   4

    The materials are as follows:

    P1,P2 RJ-15 Plug
    Wire 4 Conductor Flat Jacketed
    TOOL Crimping Tool
 

4.0 INTERLOCK

    The interlock connector is used for the termination of a safety daisy
chain. This is a two pin MOLEX C-Grid SL connector located at the bottom
edge of the top panel. The two pins must be connected together to allow
operation (if programmed in the application). If the connection is broken,
the motors and laser drive can be shut down. The connector in the system is
a MOLEX 70545-0036 which is wired as follows:

    PIN  FUNCTION
    ===  ========
    1      GROUND
    2      INTERLOCK

    The mating connector parts listed as follows:

    SHELL - MOLEX 50-57-9402
    PINS    - MOLEX 16-02-1116 (70058 series)
    CRIMPER - MOLEX 11-01-0209
    WIRE - 24-28 AWG STRANDED

    An alternative is the Insulation Displacement Connector Assembly

    CONNECTOR - MOLEX 14-56-2022 (70400 series)
    DISCRETE WIRE TERMINATOR HANDGUN
        HANDLE - MOLEX 11-21-5194
        CRIMP MODULE- MOLEX 11-32-5759

    Semi-automatic and automatic assembly equipment is available from Molex for use with ribbon cable for high volume applications.

    CABLE - MOLEX (7307 series) 82-28-58028 or (24369 series - High Flex) 82-26-6202

5.0 LASER/PWM

    The LASER/PWM connector is used to output a pwm pulse train for
modulating a laser beam, or controlling a spindle motor. This is a three pin
connector located near the bottom edge of the top panel. The connector in
the system is a standard MOLEX C-Grid SL (70545-0037) which is wired as
follows:

    PIN FUNCTION
    === ========
    1      PWM
    2      GROUND
    3      SENSE

    The mating connector parts listed as follows:

    SHELL - MOLEX 50-57-9403
    PINS    - MOLEX 16-02-1116 (70058 series)
    CRIMPER - MOLEX 11-01-0209
    WIRE - 24-28 AWG STRANDED

    An alternative is the Insulation Displacement Connector Assembly

    CONNECTOR - MOLEX 14-56-2032 (70400 series)
    DISCRETE WIRE TERMINATOR HANDGUN
        HANDLE - MOLEX 11-21-5194
        CRIMP MODULE- MOLEX 11-32-5759

    Semi-automatic and automatic assembly equipment is available from Molex for use with ribbon cable for high volume applications.

    CABLE - MOLEX (7307 series) 82-28-5803 or (24369 series - High Flex) 82-26-6203

    For descrete wiring, it is recommended that the cable made up for this connector be shielded,
with the shield connected to ground on the connector.  Flat cables should be kept away from noise sources, such as the motor leads which should be shielded by themselves.
 

6.0 AXIS ENCODER/LIMIT

    There are four axis encoder/limit connectors, each associated with
one of the four motor axes. The connectors in the system are standard MOLEX
6 pin C-Grid (70545-0040) which are wired as follows:

    PIN  FUNCTION
    ===  =================
    1      +5V
    2      LIMIT
    3      INDEX
    4      GND
    5      ENCODER-Phase A
    6      ENCODER-Phase B

    The mating connectors with latches to prevent accidental extraction and
associated parts listed as follows:

    SHELL - MOLEX 50-57-9406
    PINS    - MOLEX 16-02-1116 (70058 series)
    CRIMPER - MOLEX 11-01-0209
    WIRE - 24-28 AWG STRANDED

    An alternative is the Insulation Displacement Connector Assembly

    CONNECTOR - MOLEX 14-56-2062 (70400 series)
    DISCRETE WIRE TERMINATOR HANDGUN
        HANDLE - MOLEX 11-21-5194
        CRIMP MODULE- MOLEX 11-32-5759

    Semi-automatic and automatic assembly equipment is available from Molex for use with ribbon cable for high volume applications.

    CABLE - MOLEX (7307 series) 82-28-5806 or (24369 series - High Flex) 82-26-6206

    For descrete wiring, it is recommended that the cable made up for this connector be shielded,
with the shield connected to ground on the connector.  Flat cables should be kept away from noise sources, such as the motor leads which should be shielded by themselves.

7.0 TRAINING

    There is one 8 pin training connector. The connector in the system is a
standard MOLEX C-Grid SL (70545-0042) which is wired as follows:

    PIN  FUNCTION
    ===  =================
    1      +5V
    2      ENCODER-Y Phase B
    3      ENCODER-Y Phase A
    4      GND
    5      ENCODER-X Phase B
    6      ENCODER-X Phase A
    7      INDEX-Y
    8      INDEX-X

    The mating connector parts listed as follows:

    SHELL - MOLEX 50-57-9408
    PINS    - MOLEX 16-02-1116 (70058 series)
    CRIMPER - MOLEX 11-01-0209
    WIRE - 24-28 AWG STRANDED

    An alternative is the Insulation Displacement Connector Assembly

    CONNECTOR - MOLEX 14-56-2082 (70400 series)
    DISCRETE WIRE TERMINATOR HANDGUN
        HANDLE - MOLEX 11-21-5194
        CRIMP MODULE- MOLEX 11-32-5759

    Semi-automatic and automatic assembly equipment is available from Molex for use with ribbon cable for high volume applications.

    CABLE - MOLEX (7307 series) 82-28-5808 or (24369 series - High Flex) 82-26-6208

    For descrete wiring, it is recommended that the cable made up for this connector be shielded,
with the shield connected to ground on the connector.  Flat cables should be kept away from noise sources, such as the motor leads which should be shielded by themselves.

8.0 MOTOR CONNECTORS

    There are four axis motor connectors. The connectors in the system are
five pin PHOENIX CONTACT 17 55 76 5 which are wired as follows:

    PIN    UNCTION
    ===    ========
    1        GROUND SHIELD
    2        Motor Phase B-
    3        Motor Phase B+
    4        Motor Phase A-
    5        Motor Phase A+

    NOTE: Pin one is on the left with the scallops at the back. They
               number left to right when your are looking at an edge of the box.

    The mating connector with screw terminals and latches to help prevent
accidental extraction is:

    PHOENIX CONTACT 17 57 04 8

    In making up a cable for the motor, the four motor wires should be
shielded, and the shield should be connected to the ground (pin 1) and be
grounded to the motor case. No other wires should be inside the shield.
 

9.0 MOUNTING

    The SS-4445 System was designed to mount vertically, with the power
connection at the top of the box, and the communications connections at the
bottom of the box. This will give optimum cooling, allowing convection to
move air vertically over the heat sinks. There is also an internal fan that
moves air from the bottom of the box over the motion control board, and
exits out the top from the power supply section.

    Any other mounting orientation is also OK, but additional consideration
will have to be given to surrounding air flow, and how much power will be
disapated in the particular application.

    The system requires a mounting space of approximately 8x12 inches with
a thickness of about 4 inches. This allows space for cables. The standard
mounting tabs protrude from the end plates and have two sets of mounting
holes. One set is set up for mounting to a standard 1 inch grid 1/4-20
machine plate. The other set is set up for #8 pan head phillips head
clearance slots.


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If you have comments or suggestions, email us at support@testra.com
Testra Corporation   1201 N. Stadem Drive  Tempe, AZ 85281  Ph. 480-560-6141  Fax: 480-907-2876

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