Hubner U-ONE-SAFETY-Compact USC 42 Product guide

English
Translation of the original Operating and Assembly Instructions Issued October. 2018
ID 74445
Operating and Assembly Instructions
U-ONE®-SAFETY-Compact USC 42
Universal Encoder System
Read the operating and assembly instructions prior to
assembly, starting installation and handling!
Keep for future reference!

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Operating and Assembly Instructions
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Trademark
Brand names and product names are trademarks or registered trademarks of their respective
owner.
Protected trademarks bearing a ™ or ®symbol are not always depicted as such in the
manual.
However, the statutory rights of the respective owners remain unaffected.
Manufacturer / publisher
Johannes Hubner
Fabrik elektrischer Maschinen GmbH
Siemensstraße 7
35394 Giessen
Germany
Phone: [phone]
Fax: [phone]
Internet: www.huebner-giessen.com
E-Mail: [e-mail]
The manual has been drawn up with the utmost care and attention. Nevertheless, we cannot
exclude the possibility of errors in form and content. It is strictly forbidden to reproduce this
publication or parts of this publication in any form or by any means without the prior written
permission of
Johannes Hubner Fabrik elektrischer Maschinen GmbH.
Subject to errors and changes due to technical improvements.
Copyright © Johannes Hubner Fabrik elektrischer Maschinen GmbH.
All rights reserved.

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Table of contents
1General.......................................................................................................................... 5
1.1 Information about the Operating and Assembly Instructions................................................... 5
1.2 Scope of delivery...................................................................................................................... 5
1.3 Explanation of symbols............................................................................................................ 5
1.4 Warranty and liability................................................................................................................ 6
1.5 Organizational measures......................................................................................................... 6
1.6Copyright.................................................................................................................................. 6
1.7 Guarantee terms...................................................................................................................... 7
1.8 Customer service..................................................................................................................... 7
2Basic safety instructions............................................................................................. 7
2.1 Responsibility of the owner...................................................................................................... 7
2.2 Personnel selection and qualification; basic obligations.......................................................... 7
2.3 Intended use ............................................................................................................................ 8
2.4 Non-intended use..................................................................................................................... 8
2.5 Safety information.................................................................................................................... 9
3Assembly.....................................................................................................................10
3.1 Safety instructions.................................................................................................................. 10
3.2 Technical notes...................................................................................................................... 11
3.3 Mounting B5 type (flange)...................................................................................................... 13
3.4 Mounting of construction type B35 (flange and foot) ............................................................. 14
3.5 Dismantling............................................................................................................................. 15
3.5.1 Dismantling the USC 42 ................................................................................................. 15
3.5.2 Replacing the USC 42..................................................................................................... 15
4Installation...................................................................................................................16
4.1 Basic rules.............................................................................................................................. 16
4.2 Electrical connection.............................................................................................................. 17
5Technical Data.............................................................................................................18
5.1 Type plate............................................................................................................................... 18
5.2 Type key................................................................................................................................. 18
5.3 Mechanical data..................................................................................................................... 19
6Design and function....................................................................................................20
6.1 Basic unit (SCU C)................................................................................................................. 21
6.1.1 Electrical Data SCU C: .................................................................................................... 21
6.1.2 Operating statuses and indicators................................................................................. 22
6.1.3 Error- and status output................................................................................................ 23
6.1.4 Reset input .................................................................................................................... 24
6.1.5 Preset input ................................................................................................................... 24
6.1.6 Incremental output (non safety-related) ...................................................................... 25
6.1.7 Current output 4–20mA (not safety-oriented) ............................................................. 25
6.2 Safety Position switch module with safety relays(SRC C-R)................................................. 27
6.2.1 Electrical data safety position switch ............................................................................ 27
6.3 Safe Speed switch module with safety relay (SGS C-R)....................................................... 28
6.3.1 Electrical data safety speed switch: .............................................................................. 28
6.3.2 Switching accuracy ........................................................................................................ 29

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6.4 Error switch ............................................................................................................................ 29
6.5 Safe PROFIBUS module (SPB C) ......................................................................................... 29
6.5.1 Electrical data PROFIBUS ............................................................................................... 30
6.5.2 Bus addressing............................................................................................................... 31
6.5.3 PROFIBUS transfer technology, cable specification ...................................................... 31
6.5.4 Bus termination ............................................................................................................. 32
6.6 Saftey PROFINET module (SPN C) ...................................................................................... 33
6.6.1 Electrical data PROFINET ............................................................................................... 33
6.6.2 PROFIsafe destination address “F_Dest_Add” .............................................................. 34
6.6.3 PROFINET IO transfer technology, cable specification.................................................. 34
7Functional safety.........................................................................................................35
7.1 Safety characteristics............................................................................................................. 35
7.2 Reliability indices for the whole system USC 42.................................................................... 35
7.3 Device data ............................................................................................................................ 36
7.3.1 Timing ............................................................................................................................ 36
7.3.2 Speed-Switching accuracy ............................................................................................. 36
7.3.3 Safe state ....................................................................................................................... 36
7.4 Information about functional safety........................................................................................ 37
8Inspections..................................................................................................................38
8.1 Safety instructions.................................................................................................................. 38
8.2 Maintenance information........................................................................................................ 38
8.3 Inspection schedule ............................................................................................................... 38
8.4 Fault table............................................................................................................................... 39
8.5 Checklist................................................................................................................................. 40
9Transport, packaging and storage.............................................................................41
9.1 Safety information concerning transport ................................................................................ 41
9.2 Goods inward inspection........................................................................................................ 41
9.3 Packaging (disposal).............................................................................................................. 41
9.4 Storing packages (devices).................................................................................................... 41
9.5 Returning devices (repairs/goodwill/warranty)....................................................................... 41
9.6 Disposal.................................................................................................................................. 41
10 Accessories.................................................................................................................42
10.1 Spare parts............................................................................................................................. 42
10.2 Coupling................................................................................................................................. 43
11 Documents...................................................................................................................44
11.1 Dimension drawing................................................................................................................. 44
11.2 Connection Diagrams............................................................................................................. 45
12 Application examples..................................................................................................47
12.1 Application with safety-SPS.................................................................................................. 47
12.2 Application without safety-SPS.............................................................................................. 47

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Operating and Assembly Instructions
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1General
1.1 Information about the Operating and Assembly Instructions
These operating and assembly instructions provide important instructions for working
with the U-ONE®-SAFETY-Compact. They must be carefully read prior to starting all
tasks, and the instructions contained herein must be followed. The U-ONE®-SAFETY-
Compact is referred as USC 42 in the following documentation.
In addition, applicable local regulations for the prevention of industrial accidents and
general safety regulations must be complied with.
1.2 Scope of delivery
The scope of supply of the U-ONE®-SAFETY-Compact includes the fastening screws,
the operating and assembly instructions, the configuration instructions for further
function modules, the Software & Support CD as well as a USB programming cable.
1.3 Explanation of symbols
Warnings are indicated by symbols in these operating and assembly instructions. The
warnings are introduced by signal words that express the scope of the hazard. To
prevent accidents, personal injuries and material damage it is imperative to observe the
information provided and proceed with due care and attention at all times.
WARNING!
Indicates a possibly dangerous situation that can result in death or serious injury if
it is not avoided.
CAUTION!
Indicates a possibly dangerous situation that can result in minor injury if it is not
avoided.
CAUTION!
Indicates a possibly dangerous situation that can result in material damage if it is
not avoided.
NOTES!
Indicates useful tips and recommendations as well as information for efficient and
trouble-free operation.
NOTES!
Do not use a hammer or similar tool when installing the device due to the risk of
damage occurring to the bearings or coupling.
DANGER!
Life-threatening danger due to electric shock!
Indicates a life-threatening situation due to electric shock. If the safety instructions
are not complied with there is danger of serious injury or death. The work that must
be executed should only be performed by a qualified electrician.
!

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1.4 Warranty and liability
In principle the "General Terms and Conditions" of Johannes Hubner Fabrik
elektrischer Maschinen GmbH apply. These are available to the operator with the
Order Confirmation or when the contract is concluded at the latest. Warranty and
liability claims in the case of personal injury or damage to property are excluded, as
well as the operating license expires if they result from one or more of the following
causes:
Non-observance of the operating and assembly instructions.
Non-intended use of the USC 42.
Improper assembly, installation, start-up and programming of the USC 42.
Work carried out incorrectly on the USC 42.
Operation of the USC 42 with technical defects.
Mechanical or electrical modifications to the USC 42 undertaken autonomously.
Repairs carried out autonomously.
Third party interference and Acts of God.
Deployment of non-qualified personnel.
Opening of the USC 42 (with the exception of terminal boxes) or modifications.
1.5 Organizational measures
The operating and assembly instructions must always be kept ready-to-hand at the
place of use of the USC 42.
In addition to the operating and assembly instructions, generally valid legal and
other binding regulations on accident prevention and environmental protection must
be observed and communicated.
The respective applicable national, local and system-specific provisions and
requirements must be observed and communicated.
The operator is obliged to inform personnel on special operating features and
requirements.
Prior to commencing work, personnel working with the measuring system must have
read and understood the chapter 2.
The nameplate and any prohibition or instruction symbols applied on the measuring
system must always be maintained in a legible state.
Do not undertake any mechanical or electrical modifications to the measuring
system, except for those expressly described in this operating and assembly
instructions.
Repairs may only be undertaken by the manufacturer or a center or person
authorized by the manufacturer.
1.6 Copyright
NOTES!
Content information, text, drawings, graphics, and other representations are
protected by copyright and are subject to commercial property rights.
It is strictly forbidden to make copies of any kind or by any means for any purpose
other than in conjunction with using the device without the prior written agreement
of the manufacturer. Any copyright infringements will be prosecuted.

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1.7 Guarantee terms
The guarantee terms are provided in the manufacturer´s terms and conditions.
1.8 Customer service
For technical information personnel is available that can be reached per telephone, fax
or email. See manufacturer´s address on page 2.
2Basic safety instructions
DANGER!
This section provides an overview of all the important safety aspects that ensure
protection of personnel, as well as safe and trouble-free device operation.
If these safety instructions are not complied with significant hazard can occur.
2.1 Responsibility of the owner
The USC 42 is used in commercial applications. Consequently the owner of the
USC 42 is subject to the legal occupational safety obligations, and subject to the
safety, accident prevention, and environmental protection regulations that are
applicable for the USC 42 area of implementation.
2.2 Personnel selection and qualification; basic obligations
All work on the USC 42 must only be carried out by qualified personnel. Qualified
personnel includes persons, who, through their training, experience and
instruction, as well as their knowledge of the relevant standards, provisions,
accident prevention regulations and operating conditions, have been authorized by
the persons responsible for the system to carry out the required work and are able
to recognize and avoid potential hazards. They are capable of identifying and
avoiding potential hazards.
The definition of “qualified personnel” also includes an understanding of the
standards VDE 0105-100 and IEC 364 (source: e.g. Beuth Verlag GmbH, VDE-
Verlag GmbH).
The responsibility for assembly, installation, commissioning and operation must be
clearly defined. The obligation exists to provide supervision for trainee personnel.

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2.3 Intended use
Depending on the device configuration, the USC 42 can be used to,
to detect angular movements (SPB/SPN)
for safe, position-dependent switching of floating relay contacts (SRC C-R)
for safe, speed-dependent switching of floating relay contacts (SGS C-R)
for safe, error-dependent switching of floating relay contacts (SRC C-R/SGS C-R)
The system manufacturer must check that the characteristics of the USC 42 satisfy his
application-specific safety requirements. The responsibility or decision regarding the
use of the USC 42 lies with the system manufacturer. The USC 42 is designed for
unattended continuous operation.
Intended use also includes:
observing all instructions in this operating and assembly instructions
observing the nameplate and any prohibition or instruction symbols on the USC 42
observing the operating instructions from the machine/system manufacturer
operating the USC 42 within the limit values specified in the technical data
ensuring that the fail-safe processing unit (F-Host) fulfils all required safety
functions
safe mounting (form-closed) of the measuring system to the driving axis
Omission of a non-intended use
2.4 Non-intended use
WARNING!
Danger of death, physical injury and damage to property in case of non-intended use
of the USC 42!
The following areas of use are especially forbidden:
in environments where there is an explosive atmosphere.
use in environments with radioactive radiation.
use on ships.
for medical purposes.
fastening transport or lifting tackle to the device,for example a crane hook to lift
a motor.
fastening packaging components to the device,for example ratchet straps,
tarpaulins etc..
using the device as a step,for example by people to climb onto a motor.

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Operating and Assembly Instructions
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2.5 Safety information
WARNING! NOTICE! NOTES!
Destruction, damage and malfunction of the USC 42!
Only carry out wiring work or opening and closing of electrical connections
with the system de-energized.
Falling below or exceeding the permissible operating temperature limit values
must be prevented through an appropriate heating/cooling measure at the
place of installation.
The power adapter used must not exceed a voltage of 36 VDC even in the
event of a fault.
Potential hazards resulting from interactions with other systems and
equipment which are or will be installed in the vicinity must be checked. The
user is responsible for taking appropriate measures.
The power supply must be protected with a fuse suitable for the supply lead
cross-section.
Cables used must be suitable for the temperature range.
A defective USC 42 must not be operated.
Make sure that the installation environment is protected from aggressive
media (acids etc.).
Avoid shocks (e.g. hammer blows) to the shaft during installation.
Using the device as a step etc. is non intended.
Opening the USC 42 is forbidden (with the exception of terminal boxes).
Make sure that the access to the address switches and LEDs is locked after
the settings with the screw plug. Tighten firmly.
The type plate specifies the technical characteristics of the USC 42. If the type
plate is no longer legible or if the type plate is completely missing, the USC 42
must not be operated. Contact Hubner Service (see page 2).
NOTES!
Disposal
If disposal has to be undertaken after the lifespan of the USC 42, the respective
applicable country-specific regulations are to be observed.

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3Assembly
3.1 Safety instructions
WARNING!
At assembly, dismantling and other work to the device the basic safety
instructions to chapter 2 must be observed.
The assembly and the dismantling of the measuring system must only be carried
out by qualified personnel.
DANGER! NOTICE!
Danger of death, serious physical injury and/or damage to property due to
deactivation of safety functions, caused by an unstable shaft drive!
The system manufacturer must implement suitable design measures, so that the
drive of the USC 42 is ensured at all times through the shaft and mounting (see
chapter 3.2) of the USC 42 (fault exclusion). The specifications of DIN EN
61800-5-2:2008 "Adjustable speed electrical power drive systems, Safety
requirements - Functional, Table D.16 –Motion and position sensors" must be
observed.
In general, the requirements and acceptance conditions for the complete system
must be taken into account for mounting.
If it is not possible to use a coupling for which fatigue and design strength
calculations are available, a coupling must be used capable of withstanding 10
times the loads that occur during normal operations as stated in the data sheet.
For mounting the USC 42, we recommend our specially designed mechanical
safety components: clearance-free, torsionally rigid HKS5 coupling with fault
exclusion (see chapter 10.2 coupling) and intermediate flange with fault
exclusion.
As the installation situation is application-dependent, the following notes are
not exhaustive.
All fastening screws must be secured against unintentional loosening.
In case of applications with low operating temperatures, increased values for the
start-up torque result. This fact is to be considered when the assembling and
wave drive is performed.
A suitable coupling with positive connection must be used for the application.
The coupling manufacturer's information and installation requirements must be
observed.
In particular, you must ensure that:
the coupling is suitable for the possible axial and radial offset, as well as the
permissible speed range,
the coupling is not radially and axially loaded,
the clamping screws are tightened with the torque defined by the coupling
manufacturer and are secured against unintentional loosening, so that the
coupling cannot slip on the drive shaft or onto the USC 42 shaft.

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3.2 Technical notes
NOTES!
Do not use a hammer or similar tool during installing, disassembly or other work on
the USC 42 due to the risk of damage occurring to the bearings or coupling.
Housing surface temperature
The housing surface temperature must be within the permissible range (see chapter
5.3).
Degree of protection
The USC 42 complies with the specified degree of protection (see chapter 5.3) only
with screwed-on mating connectors or blind plugs and closed terminal boxes.
To fulfill degree of protection requirements the diameter of the connection cable must
correspond to that of the cable gland.
Connection-
thread
Sealing area
max./min. Ø mm
Sealing area
without inlet
max./min. Ø mm
Sealing area with
inlet
max./min. Ø mm
Basis
X1
M20x1,5
13,0 –9,0
-
-
M25x1,5
20,0 –11,0
20,0 –16,0
16,0 –11,0
Extensions
X2; X3; X4; X5
M20x1,5
14,0 –5,0
14,0 –9,0
9,0 –5,0
M25x1,5
20,0 –11,0
20,0 –16,0
16,0 –11,0
Deep groove ball bearings
The USC 42 are fitted with maintenance-free, greased "for-life" deep groove bearings.
Bearings must be changed by the manufacturer only.
Screw retention
All fastening screws must be secured against unintentional loosening. We recommend
using Loctite®243 (thread locker medium strength).
Required tools
Spanners: 10 mm, 13 mm, 22 mm, 24 mm 30 mm
Allen key: 5 mm, 6 mm
Flat-blade screwdriver
Assembly grease
Loctite®243 (thread locker medium strength)

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Fastening screws
To ensure the encoder is reliably mounted the following conditions must be satisfied:
Construction type
B5 flange mounting
B3 foot mounting
Screws
ISO4017 M6
ISO4017 M8
Washers
ISO7089 A6
DIN6340 A8
Number of screws
Min. 6 pcs.
4 pcs.
Property class
ISO 898-1
8.8
12.9
Length of screws
20 mm
30 mm
35 mm
Tensile strength of
internal thread
Min. 280 N/mm²
Min. 460 N/mm²
Min. 330 N/mm²
Tightening torque
6 Nm
27 Nm
Centering
85j6
-
NOTES!
Suitable measures must be taken if the minimum tensile strength of the internal
thread of the customer interface does not meet requirements (e.g. fit a threaded
insert).
Mounting preparations
1. Ensure all accessories are available.
2. Preparing the place of attachment: Clean the drive shaft, centering, bolting
surfaces and fastening threads; check for damage. Repair any damage!
Personnel
Mounting and commissioning must only be carried out by qualified personnel.
NOTES!
Observe the safety instructions contained in chapter 2when mounting or
commissioning.

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3.3 Mounting B5 type (flange)
NOTES!
For a mounting example please refer to dimension drawing (chapter 11).
The installation described below is offered as an example only and may
vary according to the coupling and flange type. It is essential to observe
the specific instructions provided by the manufacturer of the coupling.
You must be able to mount the coupling without force. Ream out the bores
of used couplings, if necessary.
If possible, fit the intermediate flange (4) in a manner that ensures the
screwed sealing plug (16) points downwards.
If possible, fit the device in a manner that ensures the cable gland points
downwards Exchange the position of the cable gland (19) and the
blanking plug (16), if necessary.
To carry out step 9, it may be necessary to turn the drive shaft (1) to the
correct position.
Intermediate disc (10), flange (4) and coupling (3) must meet the
requirements for safe mounting. See also Chapter 10.2.
1. Grease the drive shaft lightly (1).
2. Fit coupling (3) onto drive shaft (1).
3. Secure the coupling hub on the drive shaft (1) using a grub screw or a screw (12)
(depending on the coupling type).
Fig. 3-1 Example construction type B5
9
10
14
15
17
16
19
13
18
1
3
4
7
8
6
5
12
11
2

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4. Fasten the intermediate disc (10) on the drive side by using of the fastening screws
and washers (2).
5. Fasten the intermediate flange (4) to the intermediate disc (10) by using the fastening
screws(14) and washers (14).
6. Grease the USC 42 shaft lightly (6).
7. Fit the USC 42 (8) into both the centering (15) and coupling hub (13) at the same time.
8. Secure the USC 42 with min. 6 screws (7) and washers evenly distributed around the
circumference of the flange (4).
9. Remove the sealing plug (16) from the access bore (5) to the coupling.
10. Secure the coupling hub on the shaft with a grub screw or screw (13) (depending on
the coupling type).
11. Close access bore in the intermediate flange (4) for coupling with the sealing plug (16).
3.4 Mounting of construction type B35 (flange and foot)
NOTES!
B35 type encoders can be attached by means of a flange (B5, please refer
to chapter 3.3) or foot (B35).
For a mounting example please refer to dimension drawing (chapter 11).
The assembly procedure described below is offered as an example only and
may vary according to the type of coupling. It is essential to observe the
specific instructions provided by the manufacturer of the coupling.
You must be able to mount the coupling (3) without force! Ream the bores
of used couplings, if necessary.
Angle misalignment and parallel displacement between the (drive) shaft (1)
and the encoder shaft are mounting errors and should be kept as small as
possible.
Mounting errors
-Cause radial forces to act on the USC 42 shaft.
-Reduce the service life of the bearings and the coupling.
-Degrade the quality of the signals (harmonic content).
11
2
9
10
7
4
3
8
5
Fig. 3-2 Example construction type B35

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Operating and Assembly Instructions
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1. Grease the drive shaft lightly (1).
2. Secure the coupling hub on the drive shaft (1) with a grub screw or cheese head screw
(3) (depending on the coupling type).
3. Grease the USC 42 shaft lightly (4).
4. Align the USC 42 shaft (4) to the drive shaft (1) and insert into the coupling hub.
5. Fasten USC 42 foot with 4 screws-M8 and matching washers (7).
6. Secure the coupling hub on the USC 42 shaft with a grub screw or with a screw (8)
(depending on the coupling type).
3.5 Dismantling
Personnel
Dismantling must be carried out by qualified personnel only.
WARNING!
Observe the safety instructions contained in chapter 2 when dismantling the
USC 42.
NOTES!
Do not use a hammer or similar tool when dismantling the device due to the risk
of damage occurring to the bearings or coupling.
3.5.1 Dismantling the USC 42
Remove all electrical connection cables of the USC 42 before dismantling.
To dismantle the USC 42 follow the instructions given in chapter 3.3 or rather 3.4 in the
reverse order.
3.5.2 Replacing the USC 42
The following points must be noted when replacing the USC 42:
The new USC 42 must have the same order number (ID) as the USC 42 being
replaced.
The new USC 42 must be installed in accordance with the specifications and
requirements in chapter 4.2.
The new USC 42 must be connected in accordance with the specifications
in chapter 4.2.
The configuration of the USC 42 to be exchanged can be transferred to the new
USC 42 (see configuration manual).
When recommissioning the replaced USC 42, correct functioning must be ensured
first of all by means of a protected test run.
in addition, with USC 42 with PROFIBUS or PROFINET
With a new USC 42 ensure that the PROFIBUS address and bus termination set
via hardware switches match that of the USC 42 to be installed (applies only to
PROFIBUS).
As the F-Parameters and i-Parameters of the USC 42 are stored in the safety
program of the control, the new USC 42 is parameterized with the projected
settings in the start-up phase. (PROFIBUS and PROFINET).

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If the project does not support a neighbourhood detection, in case of a device
replacement it must be ensured that the device name assigned before also is
assigned to the new USC 42. When the system boots up the device name is
detected again and the new MAC-Address and IP-Address is assigned to the
device name automatically (only PROFINET).
4Installation
4.1 Basic rules
WARNING!
The power supplies used must not cut out in the event of a fault in the energy
supply (safe under single fault conditions). Observe SELV and PELV requirements
(IEC 60364-4-41).
Equipotential bonding measures must be provided throughout the entire
processing chain of the plant.
Route power and signal cables separately.
Observe the manufacturer's instructions for the installation of converters and for
shielding power cables between frequency converter and motor.
Ensure adequate dimensioning of the energy supply.
The line cross-section of the voltage supply line must be designed in such a way
that the max. Voltage drop is < 3V
PROFIBUS
All devices used on the bus must have a PROFIBUS –certificate or must have a
corresponding declaration of the manufacturer.
All safety devices must also have a certificate from a "Notified Body" (e.g. TÜV,
BIA, HSE, INRS, UL, etc.).
Only use M12 connectors for connecting the measuring system, which guarantee
good contact between the cable shield and connector housing. The cable shield
must be connected to the connector housing over a large area.
PROFINET
All PROFIsafe devices used on the bus must have a PROFINET and a PROFIsafe
–certificate.

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4.2 Electrical connection
1. Open the terminal box cover (9) (Fig. 3-2).
CAUTION!
Do not allow moisture to enter the terminal box when the terminal cover is open.
2. Remove the cap of the cable gland (10) (Fig. 3-2).
3. Feed the cable into the terminal box trough the cable gland.
NOTES! (only SCU C)
The signal cable shielding can be connected directly to the housing via the EMC
cable gland. A coil spring integrated in the cable gland ensures all-round contact is
made with the bare cable shielding to ensure a good shield connection. This type
of shield connection should be preferred.
To achieve an effective shielding the cable shield must also be connected in the
electrical cabinet. Ensure no equipotential bonding currents are able to flow across
the shielding.
4. Tighten the cable gland and blanking plugs using a spanner.
NOTES!
Prior to delivery cable glands and blanking plugs are tightened finger tight only. To
ensure that the terminal box is reliably sealed tighten all cable glands and blanking
plugs before starting up for the first time.
5. Use a spanner to tighten the cable gland until the cable is securely clamped and
properly sealed.
NOTES!
Prevent lateral pulling forces acting on the cable and plugs so as not to impair the
degree of protection of the cable gland.
6. Strip cable insulation, crimp wire-end ferrules. Connect the supply voltage and
signal cable (see connection diagrams, chapter 11.2).
CAUTION!
Do not apply supply voltage to the signal outputs, as this will destroy the USC 42.
7. Close the terminal box cover.
NOTES!
Before closing the terminal box cover check the sealing surface is clean and that
the seal is in a good condition; clean or replace damaged seals as necessary.
CAUTION!
Ensure when closing the terminal box cover that no cable becomes jammed.
!
!
!

U-ONE®-SAFETY-Compact USC 42
Operating and Assembly Instructions
18
USC42_Manual-en_R7
5Technical Data
5.1 Type plate
The figure below shows an example of a type plate.
The type plate is located on the side of the
housing and contains the following
information:
Manufacturer, address
Type, year of construction
CE-mark
Serial number S/N)
Number of pulses
Degree of protection
Supply voltage
ID number
Maximum speed
Current output
Certification information
5.2 Type key
USC 42 I - function modules (see table)
U-ONE®-SAFETY-Compact
I: Current output 4 … 20 mA
G: Current output + incremental output
Housing modules:
The individual housing modules may contain 1 or 2 functional modules , they are separated
by „-“ (eg. USC 42I-DD-A). and listed in the sequence they are installed after the basic unit.
Identification
Description
USC 42I
Safety Control Unit (SCU C) with 2 digital inputs (reset, preset) and 2
digital outputs (status, error) as well as
current output 4 … 20 mA (identification: I)
A
3 safe speed switches (SGS C-R)
(1 function module - max. switching voltage: 230 V AC / DC)
AA
6 safe speed switches (SGS C-R)
(2 function modules - max. switching voltage: 230 V AC / DC)
D
3 safe position switches (SRC C-R)
(1 function module - max. switching voltage: 230 V AC / DC)
DD
6 safe position switches (SRC C-R)
(2 function modules - max. switching voltage: 230 V AC / DC)
P
PROFIsafe via PROFIBUS
R
PROFIsafe via PROFINET
Fig. 5-1: type plate (example)

U-ONE®-SAFETY-Compact USC 42
Operating and Assembly Instructions
USC42_Manual-en_R7
19
5.3 Mechanical data
Specification
Value
Max. encoder shaft load
100 N axial, 120 N radial
Shaft end
Ø 14j6 x 30 mm
Mech. permissible speed
max. 2800 rpm
Temperature range
-25°C … + 70° C
Vibration resistance
5 g (DIN EN 60068-2-6 (8,7 … 500 Hz))
Shock resistance
25 g (DIN EN 60068-2-27 (6 ms))
Bearing life time L10
-speed
-operating temperature
1.1 * 1011 revolutions at
2800 rpm
70 °C
Bearing grease life time
-max. speed
-max. operating temperature
20 years at
2800 rpm
65 °C
Rotor moment of inertia
approx. 330 gcm²
Permissible angular
acceleration
104rad/s²
Breakaway torque
approx. 3,5 Ncm
Degree of protection acc. to
DIN EN 60529
IP66 with axial shaft seal
Max. operating hight above sea
level
3000 m
Weight
Construction type B35 (basic unit + 1
module)
Construction type B5 (basic unit)
for each additional module
approx.5 kg
approx.3.6 kg
+ approx 0.8 kg
Calculations pertaining to the service life were carried out using data from the
manufacturer of the bearings. The stated service lifetimes are based on the modified
rating life L10 in accordance with ISO 281. That means, the probability that the bearings
will attain or exceed the specified service lifetime is 90%.
The following factors influence the service life of the bearings
Operating temperature
Mechanical loads from vibration and shock
Drive dynamics
The influence of transport and storage (bearing grease ageing)
Installation errors

U-ONE®-SAFETY-Compact USC 42
Operating and Assembly Instructions
20
USC42_Manual-en_R7
6Design and function
The USC 42 consists of a basic unit as well as maximum 4 housing modules in which it
is possible to integrate a maximum of 6 function modules.
In Fig. 6-2, the basic unit with a position switch module (SRC C-R) is shown.
It is possible to utilize max. 6 function modules, which are connected to the system
bus.
The base unit consists of:
Two-channel scanning system, for generation of safe measured data through
internal channel comparison
Channel 1, master system:
optical Single-Turn scanning via code disk with transmitted light and magnetic
Multi-Turn scanning
Channel 2, inspection system:
magnetic Single and Multi-Turn scanning
A common drive shaft
Due to its technology the optical system possesses greater accuracy; therefore it is
used as master system. The data of the master system are unevaluated in the non-
safety-oriented process data channel with a short cycle time.
The magnetic scanning system serves for the internal safety check The "safe data" is
obtained through two-channel data comparison.
System2
SCU C
System1
Encoder shaft
SCU C
Logic2
SCU C
Logic1
Control
Current
output
Incremental
output
Status
Error
SRC C-R
Logic1
SRC C-R
Logic2
Control
SRC C-R
System Bus
The USC 42 is configured using a Laptop/PC running a Windows® operating system
(version XP SP3, Vista, 7, 8, 8.1, 10) in conjunction with the programming software
US42Pro included in the scope of supply. The physical interface is USB.2.0 in the
terminal box of the basic unit SCU C.
Fig. 6-1: Basic unit with 3 housing modules
Fig. 6-2: Block diagram USC 42