Schleicher USP Series Modules: USP2i

Technical Dossier

Product Details And Specifications

Schleicher USP Series: Comprehensive Module Range and Technical Overview

The Schleicher USP (Universal Servo Positioning) series represents a standardized family of servo positioning and motion control modules developed by Schleicher Electronic GmbH, a German automation manufacturer later absorbed into the Moog/Animatics ecosystem. These modules have been deployed across high-demand industrial environments including chemical processing plants, nuclear facility auxiliary systems, oil refineries, paper mills, and heavy-duty packaging lines. Their modular backplane architecture and deterministic positioning logic made them a preferred choice for OEMs requiring repeatable, high-resolution axis control in safety-critical applications. Installed base across European and Asian heavy industry remains significant, driving sustained demand for spare parts and lifecycle support.

The Evolution of USP Series Architecture

The USP series was introduced in the late 1990s as a rack-mounted positioning controller designed to interface with Schleicher's proprietary SPS (Speicherprogrammierbare Steuerung) PLC platforms. Early variants such as the USP2 and USP3 operated on RS-232/RS-485 serial communication buses and supported single- or dual-axis incremental encoder feedback. The "i" suffix (e.g., USP2i, USP3i) denotes an enhanced firmware revision with improved interpolation algorithms and expanded parameter memory.

Mid-generation modules introduced CANopen and PROFIBUS-DP communication adapters, enabling integration with third-party PLCs and SCADA systems. The USP-COM1 and USP-E1/E2 variants extended fieldbus compatibility. Later revisions added onboard diagnostics, non-volatile parameter storage, and improved EMC shielding to meet EN 61800-3 Category C2 requirements. As of 2020, the entire USP series has been classified as End-of-Life (EOL) by the successor organization, with no new production runs planned. This places all USP modules firmly in the long-term maintenance and spare parts sourcing category.

USP Series Full Catalog & Functionalities (SKU List)

The following SKUs represent verified models within the Schleicher USP series, classified by functional category:

Positioning Controllers (Single/Dual Axis)

• USP2: Single-axis positioning module, RS-485 interface, incremental encoder input, 24 VDC logic supply.
• USP2i: Enhanced single-axis positioning module with improved interpolation firmware; supports teach-in programming and extended parameter set.
• USP3: Dual-axis positioning controller, synchronous operation mode, RS-485 bus, 16-bit position resolution.
• USP3i: Dual-axis enhanced variant; adds electronic gearing and cam profile functionality over USP3 baseline.
• USP4: Four-axis coordinated motion controller; supports linear and circular interpolation; rack-mount form factor.
• USP4i: Four-axis enhanced module with expanded I/O mapping and onboard PLC micro-kernel for standalone operation.
• USP5: High-speed single-axis module optimized for pick-and-place and indexing applications; 1 µs position capture input.
• USP5i: Enhanced USP5 with CANopen DS402 drive profile support and extended diagnostics buffer.
• USP6: Multi-axis master controller; coordinates up to six USP slave axes via internal backplane bus.
• USP6i: Enhanced USP6 with PROFIBUS-DP master/slave capability and extended motion program memory (256 KB).

Communication & Fieldbus Adapters

• USP-COM1: RS-232/RS-485 serial communication adapter module; bridges USP backplane to host PLC or HMI.
• USP-E1: Ethernet TCP/IP communication module for USP series; supports Modbus TCP protocol.
• USP-E2: Dual-port Ethernet module with EtherNet/IP adapter functionality; for integration with Allen-Bradley ControlLogix systems.

I/O Expansion Modules

• USP-DIO1: 16-channel digital I/O expansion module; 8 inputs (24 VDC), 8 outputs (relay, 2A); mounts on USP backplane.
• USP-A1: Analog input module; 4-channel, ±10 V / 0–20 mA selectable; 12-bit resolution; for process feedback integration.
• USP-A2: Analog output module; 4-channel, ±10 V / 4–20 mA; used for velocity reference and torque command outputs.

Specialty & Timing Modules

• USP-T3: High-resolution timer/counter module; 32-bit counter, 1 MHz input frequency; used for encoder pre-processing and registration mark detection.
• USP-T4: Extended timer module with four independent 32-bit counters and hardware latch inputs for flying shear and cut-to-length applications.

Sourcing Hard-to-Find & Obsolete USP Series Parts

With the USP series fully discontinued, OEM replacement channels are closed. DriveKNMS maintains a dedicated inventory of tested USP series modules sourced from decommissioned plant equipment, authorized surplus channels, and controlled disassembly of complete rack systems. Stock is held for all major USP variants including the USP2i, USP3i, USP4i, USP5i, USP6i, USP-COM1, USP-DIO1, USP-A1, and USP-A2.

For customers requiring long-term maintenance agreements (LTMAs), DriveKNMS offers consignment stock programs where dedicated USP module inventory is reserved against a service contract. This is particularly relevant for chemical and refinery operators running Schleicher-based motion control systems with 10–20 year remaining plant lifecycles. All sourced modules are supplied with full traceability documentation and test reports.

Quality Control for the USP Series Range

USP series modules present specific test challenges due to their proprietary backplane communication protocol and multi-axis synchronization logic. DriveKNMS applies the following verification procedures to all USP stock:

• Backplane Bus Integrity Test: Each module is seated in a reference USP rack and subjected to full backplane communication cycling to verify address decoding and data transfer integrity.
• Encoder Interface Verification: Incremental encoder simulation (A/B/Z signals at 100 kHz) is applied to confirm position capture accuracy and index pulse response.
• Parameter Memory Validation: Non-volatile parameter storage is read, cleared, and rewritten to confirm EEPROM/Flash integrity and correct firmware version retention.
• I/O Functional Test: All digital inputs and outputs are cycled under load; analog channels are calibrated against a traceable reference standard (±0.1% accuracy).
• Thermal Soak: Modules are operated at 50°C ambient for 4 hours to screen for latent component failures common in aged power supply sections.
• Communication Protocol Test: RS-485, CANopen, and PROFIBUS-DP variants are tested with protocol analyzers to confirm correct frame structure and response timing.