usi SmartStep X Series User manual

USI1979
SmartStep™ Actuators
Installation, Operation, and Technical Reference Manual
100% Continuous Duty Cycle, 100% Modulation, ON/OFF,
DC Brushless, Modular, Hazardous Location Rated
Electric Actuators
X-Series & S-Series
IN DEVELOPMENT

Table of Contents
Safety Ratings 4
Certications 4
Section 1: SmartStep Introduction 5
1.1 The Actuators & Module Options 5
Section 2: Mechanical Overview 6
2.1 X-Series Mechanical and Install Dimensions 6
2.2 S-Series Mechanical and Install Dimensions 7
Section 3: Interface, Home, and Diagnostic Screens 8
3.1 XCTRL/SCTRL Interface 8
3.2 XCTRL Port/Connection Reference 9
3.3 Basic User Menu Map 10
3.4 MAIN Screen Elements 10
3.3 Super Cap Voltage Screen 11
3.4 Diagnostics 2 Screen 11
3.5 Diagnostics 3 Screen 11
3.6 Diagnostics 4 Screen 11
3.7 Diagnostics 5 Screen 11
3.8 Device Information Screen 11
3.9 Restore Defaults Screen 12
3.10 Model Setup Screen 12
Section 4: Standard Operational Modes & Wiring 13
4.1 Manual Mode 13
4.2 Auto Mode: 1-Wire Control Signal 13
4.3 Auto Mode: 2-Wire Control Signal 14
4.4 Auto Mode: 4-20mA Signal Control 15
4.5 Auto Mode: MODBUS RTU 16
4.7 Auto Mode: MODBUS TCP 17
4.7 Auto Mode: On-Off 18
4.8 Override Mode 19
4.9 Status Relay Wiring 20
Section 5: Initial Setup / End Point Calibration 21
5.1 Initial Setup 21
5.2 End Point Calibration 21
5.3 Failsafe Setup 21
6.1 Advanced Conguration Access 22
6.2 Conguration Menu Map 22
Section 6: Advanced Conguration Map 22
Section 7: Position Setup Tree 23
7.1 Position Setup Screen 23
7.2 Failsafe Setup Screen 23
7.3 Range Control Screen 23
Section 8: 4-20mA Setup Tree 24
8.1 4-20mA Control Calibration Screen 24
8.2 4-20mA DAC Calibration Screen 24
8.3 4-20mA ADC Calibration Screen 24
Section 9: Speed Control Tree 25
9.1 Speed Control Screen 25
Section 10: MODBUS Setup Tree 26
10.1 MODBUS RTU Setup Screen 26
10.2 MODBUS TCP Screen 26
10.3 MODBUS Opt Setup Screen 26
10.3 MODBUS MAC Setup Screen 26
10.3 MODBUS Register Map 27
Section 11: Status Relay Setup Tree 28
11.1 Error Status Relay Setup Screen 28
11.2 Open Status Relay Setup Screen 28
11.3 Close Status Relay Setup Screen 28
Section 12: Temperature Degree Unit Tree 29
12.1 Temperature Degree Units Screen 29
Section 13: OPEN/CLOSE Setup Tree 30
13.1 1-Wire Setup Screen 30
13.2 2-Wire Setup Screen 30
13.3 ON-OFF Setup Screen 30
13.4 OC Timer Control Setup Screen 31
13.5 OC Input Delay Setup Screen 31
Section 13: OPEN/CLOSE Setup Tree 31
Section 14: Digital Noise Input Filter Tree 32
14.1 Digital Noise Filter Screen 32
Section 15: Power Management Tree 33
15.1 Power Management Screen 33
Section 16: XCTRL Fault Codes 34
16.1 Error fault codes 34
Section 17: Troubleshooting 35
17.1 General Issues 35
17.2 J1 OPEN/CLOSE Issues 35
17.3 4-20mA/0-10VDC Issues 36
17.4 MODBUS Issues 36

Document History
Revision Date Notes
1.0 April 14, 2020 Initial Release. Support of Firmware Version 1.4.1
1.1 April 29, 2020 Added Information to support Firmware Version 1.4.2
1.2 May 12, 2020 Added Information to support Firmware Version 1.5.1
2.0 Sep 23, 2021 Added Information to support Firmware Version 3.4.1
2.1 Jan 26, 2022 Added Information to support Firmware Version 3.5.0
2.2 Sep 19, 2022 Added Information to support Firmware Version 3.8.0
3.0 Jun 23, 2023 Added Information to support Firmware Version 3.8.1. Revamped
document layout
For questions or help contact your local sales rep or reach out to us at:
314-432-3282
[email protected]
[email protected]

4
SmartStep User Guide ver 3.0
Safety Ratings
Mechanical
Cover Bolts: ¼-20 18-8 Stainless Screw (installed at factory). Should not be tightened with anything greater than 75
in-lbs of torque
Module Screws: 6-32 18-8 Stainless Screws (installed at factory). Should not be tightened with anything greater than
9.6 in-lbs of torque. Screws have threadlock applied to them before being tightened down; when removing start slow
to lessen risk of breaking screw.
F07 Valve Mounting: Holes are threaded for M8 x 1.25 screws. The bolts will be provided by distributor or end user.
Follow guidelines based on material of screw. Typical tightening torque is 48.8 newton-meters. All four bolts with lock
washers should be used to secure valve.
F10 Valve Mounting: Holes are threaded for M10 x 1.5 screws. The bolts will be provided by distributor or end user.
Follow guidelines based on material of screw. Typical tightening torque is 97.5 newton-meters. All four bolts with lock
washers should be used to secure valve.
Conduit Input: Holes are threaded for ½ - 14 conduit. Conduit should be tightened using 15 in-lbs of torque. If using
pipe thread sealant or teon tape, conduit should be tightened 2-3 turns with a wrench past nger tight for best seal.
Coupling: Coupling is designed for 27mm diameter valve stem or adapter. If adapter or valve stem do not easily slide
into coupling, do not attempt to hammer in to place as it will damage the gearbox. Either attempt a new adapter or
reach out to local distributor for assistance.
Electric/Wiring
Panel Fuse: Size fuse to respective power input. Max 4A fuse
PS048/XCTRL Power Input: 48VDC | ~1.67A max current draw (connector supplied)
PS024 (or PSUNI 24VDC Input) Module Power Input: 24VDC | ~3.3A max current draw. 12-24 AWG Input. Size wire
appropriately for length of run.
PS120 (or PSUNI 120VAC Input) Module Power Input: 100-240VAC | ~0.47A | 50/60Hz. 12-24 AWG Input. Size wire
appropriately for length of run.
XCTRL Terminal Block Inputs: Voltages vary per terminal. Refer to Section 3.2 for terminal ratings. 14-28 AWG
Input. Size wire appropriately for length of run.
Note: Full actuator has ability to draw less when not moving the valve if power is an issue. Actuator may be put into low power mode which will
turn off the holding torque of the motor after movement completes. Should only be used in low-pressure situations.
Environmental
Operating Temperature: -40°C to 60°C (-40°F to 140°F)
Certications
• CE Certied
• UL/CUL Certied. File: E352420
• UL Class 1, Div 2, Groups A, B, C, D Hazardous Location Rated. File: E511689
Failure to comply with the following limits may result in physical damage to actuator or possible harm to installation
technician. It may also result in voided warranty and incur additional repair/shipment costs.

Section 1: SmartStep Introduction
1.1 The Actuators & Module Options
The SmartStep actuator is available in two different
sized housings and ve different torque options.
The X-Series is in a larger casting that is suited for
F07 and F10 ISO mounted valves that are rated
between 500-5000 in-lbs. The S-Series is roughly
20% smaller than the X-Series and is suited for
F05 and F07 ISO mounted valves that are rated
between 400-1200 in-lbs. Note: As of the creation
of this document revision, the S-Series is in the
prototype stages and should be released by Q1 of
2024.
Both actuators use the same power input modules.
The modules may be congured for 24VAC,
24VDC, or a 24VDC & 100-240VAC universal input
module to allow stocking of a single supply.
Both power modules, if ordered with the -EPB
option may be congured with a SuperCap backup.
The capacity of the EPB currently allows any of our
modules to move 90° to their Failsafe position
during an power loss or control signal loss. The
smaller models will be capable of moving more
than that as the lower torque requires less power
draw.
The SmartStep control module (XCTRL) and the
power supply modules (PS024, PS024-VAC, and
PSUNI) are all designed to be eld replaceable. If
there is a failure on one of those modules, or if a
24VDC power input module needs to be swapped
to a 120VAC power input module, it’s as simple as
removing a few cable connections and three
screws. So if there is an issue, reach out to nd out
if a module can be replaced so that the entire
actuator doesn’t have to be sent back.
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SmartStep User Guide ver 3.0
Warranty
All SmartStepTM actuators and modules are covered by a 2-year warranty that covers standard actuator operation and
workmanship. The warranty expires 24 months from delivery date.
If an actuator is not operating in the expected manner, please reference the trouble-shooting section of this document.
If further assistance is needed contact your local distributor or [email protected]
If an actuator has failed under normal operation you may request a return material authorization through the distributor
through which the actuator was purchased.
Representation of PS024-EPB
Module
Representation of PSUNI-EPB
Module
Representation of XCTRL Module

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SmartStep User Guide ver 3.0
Section 2: Mechanical Overview
2.1 X-Series Mechanical and Install Dimensions
RearFront
Bottom X-Series Mounting Detail
8.5 [216mm]
11.25 [286mm]
3.14
[80mm]
2.88
[73mm]
1.65
[41.9mm]
8.8
[223.5mm]
4.12
[104.6mm]
3.13
[79.5mm]
1.55
[39.5mm]
4.82
[122.6mm]
1/2x14 NPT
Conduit
Entry
2 places
Note: add 3.5" [89mm] clearance for cover removal.
Cover removal also requires 3/16” Allen Wrench
2.84
[72.13mm]
1.95
[49.5mm]
2.84
[72.13mm]
1.95
[49.5mm]
1.06
[27mm]
Standard
27mm
Double
Square
1.26”
[32mm]
deep
M10x1.5 thread
18mm deep
4 places
M8x1.25 thread
18mm deep
4 places
Valve Direction reference: At any point in this
document when valve movement Clockwise or
CounterClockwise is mentioned, it is always referenced
viewing the actuator as shown in Front View.
Clockwise Counter
Clockwise

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SmartStep User Guide ver 3.0
2.2 S-Series Mechanical and Install Dimensions
9.19
[233.37mm]
8.44
[214.32mm]
3.01
[76.55]
2.89
[73.53]
2.5
[63.5]
8.03
[204]
4.93
[125.26]
1.85
[46.94]
3.84
[97.44]
1.46
[37]
M8x1.25 thread
15mm deep
4 places
M6x1 thread
15mm deep
4 places
1.95
[49.5]
1.39
[35.36]
1.39
[35.36]
1.95
[49.5]
.67
[17.1]
.67
[17.1]
Valve Direction reference: At any point in this
document when valve movement Clockwise or
CounterClockwise is mentioned, it is always referenced
viewing the actuator as shown in Front View.
Clockwise Counter
Clockwise
IN DEVELOPMENT

Section 3: Interface, Home, and Diagnostic Screens
3.1 XCTRL/SCTRL Interface
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SmartStep User Guide ver 3.0
Buttons
Use to navigate menus and set values
Store Values/Conrm
Cancel Entry/Back out of Menu
During position calibration, press to set direction valve moves to
open when in settings
Manual Mode
Hold or press to move in the direction of calibrated open position
Hold or press to move in the direction of calibrated closed position
Cycle between Automatic Modes (press once proper mode
selected)
Button Combinations
+From Main Screen, enter Calibration Mode
+In manual mode, move valve to 100% open
+In manual mode, move valve to 0% open
+On 4-20mA Calibration Screen, clear OPEN value
+ On 4-20mA Calibration Screen, clear CLOSE value
SCTRL Module KeypadXCTRL Module Keypad
IN DEVELOPMENT

3.2 XCTRL Port/Connection Reference
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SmartStep User Guide ver 3.0
Port & Functionality Port Rating Pin Pin Description
J1 - Open/Close Control: offers three modes
of operation. For more detail go to Open/
Close Mode
24-48 VDC
120-240 VAC
1A max
1OPEN: +120 VAC Signal applied when valve needs
to move to OPEN position
2,3 COMMON: 120 VAC Neutral
4CLOSED: +120 VAC Signal applied when valve
needs to move to CLOSED position
J2 - Signal Control: allows valve positioning
using 4-20mA or 0-10 VDC control
signal.
IN+ 200V 1A max
OUT+ 30V 0.2A
max protection
1IN +: +4-20mA or 0-10VDC control signal
2IN -: -4-20mA or 0-10VDC control signal
3OUT +: +4-20mA position feedback signal
4OUT -: -4-20mA position feedback signal
J3 - Manual Control: Use external Switch or
Relay to short the appropriate command
signal to MC COM. For example, to
OPEN the valve, short OPEN to MC
COM.
If OVERRIDE is shorted to MC COM, then
OPEN/CLOSE buttons may be used to
force valve into that position.
N/A - Override ,
Open, and Close
should be tied to
MC COM using
dry contacts
1OVERRIDE
2OPEN
3CLOSE
4MC COM
J4 - Status Relays: OPEN/CLOSED relays
are Make on Event. They remain open
until OPEN/CLOSED position is reached.
ERROR status relay is Break on Event. It will
remain closed until error.
Up to 350V
120mA max
1, 2 ERROR
3, 4 OPEN
5, 6 CLOSED
J5 - MODBUS N/A
1A - MODBUS Data ( - )
2B - MODBUS Data ( + )
3MB COM - Isolated common/ground for MODBUS
412 VDC - Output to power MODBUS accessory if
needed
PWR
60 VDC
15A max
1+48 VDC
2-48 VDC RETURN
Ethernet - MODBUS TCP Communication N/A N/A
MOTOR N/A Output only
1 Stepper S1A Connection
2 Stepper S1B Connection
3 Stepper S2A Connection
4 Stepper S2B Connection
USB - Used to update controller rmware N/A N/A N/A
SUPER CAP N/A
1 SCBOOT - SuperCap Boot Status
2 SCRST - SuperCap Reset
3 SCTX - Data Transmitted to SuperCap
4 SCRX - Data Received from SuperCap
5 Ground
Acceptable Wire Gauge Sizes for All Wire-to-PCB terminals: 14-28 AWG Input. Size wire appropriately for length
of run

10
SmartStep User Guide ver 3.0
3.3 Basic User Menu Map
Starting from the MAIN screen, basic status and
diagnostic information about the module may be
obtained by using the Up/Down or Right/Left Arrow
buttons as shown to the right.
The ESC button will return the unit to the home
screen any time that a parameter is not being
edited.
If a parameter is being edited, ENT will store the
new setting; ESC will cancel the input.
3.4 MAIN Screen Elements
1) Percentage that valve has opened from closed position
2) Current RUN mode selected
3) Varies on actuator status/options selected:
a) EPB Model and shaft not moving: Displays
current cycle count of actuator
b) EPB Model and shaft moving: Displays current
desired shaft position
c) Non-EPB Models: Displays current desired shaft
position
d) The entire line (elements 3 & 7) may also be
used to display faults. For a list of faults and
their explanation go to the Troubleshooting
section.
4) Varies on actuator options selected:
a) EPB Model: Displays Voltage Input detected on
PSXXX-EPB module if the SuperCap rmware is
version 3.0 or above.
b) Non-EPB models: Displays currents cycle count
of actuator.
5) Super Cap communication/charge status
6) Different RUN Mode status information is displayed here:
a) If RUN mode is set to 4-20mA, the current mA
signal value is displayed
b) If RUN mode is set to One-Wire or On-Off, then
the current J1 setting will be shown. If J1 is set
up to have CLOSE as the command signal,
J1:CLS will be displayed if not actively receiving
a command signal. Once the command signal is
detected status will be J1:+CLS+
7) Actual position of the valve
8) Displays current internal temperature of the actuator as
well as the direction the valve will always turn to go to
the OPEN position
Tip: For a simplied home screen layout press the UP arrow
while on the home screen. Press UP again to go back to the
standard view.
The simplied view shows items 1, 2, and 5 from above.
Parameter Screens that may be edited
Information Screens
Main Screen
8
XXX°C:CCW 7
A: 90.0°
6
OPN CLS 5
100%CHRG
4Vin: 24.1V
3C:--------
2RUN:2-WIRE
1100.0%OPEN
4-20mA 100%CHRG
⑤ ⑩ �⑩⑪
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