usi SmartStep User manual

USI1979
SmartStep™Actuator
For questions or help contact your local sales rep or reach out to us at:
314-432-3282
[email protected]
[email protected]
Full User Manual
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

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.
Nominal Electric
XCTRL Power Input: 48VDC | ~1.67A draw
PS024 Module Power Input: 24VDC | ~3.3A
PS120 Module Power Input: 100-240VAC | ~0.47A | 50/60Hz
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: -30°C to 60°C (-22°F to 140°F)
Warranty
All SmartStepTM actuators and modules are covered by a 2-year warranty that covers actuator
operation and workmanship. The warranty expires 24 months from delivery date. To request a
return material authorization, please contact your local distributor.
Certications
• CE Certied
• UL/CUL Certied.
• UL Class 1, Div 2, Groups A, B, C, D Hazardous Location Rated
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.
Safety Ratings

Quick Start
3
SmartStep User Guide ver 2.0
Device Defaults
1. Unbox and install the actuator using the ISO 5211 bolt pattern to mount the valve. Use appropriate adapter if necessary
as the SmartStep coupling is 27mm square.
2. Perform POSITION SETUP of end points:
a. Press to see the POSITION-SETUP screen
b. Use the buttons to set the direction the valve will turn to get to the OPEN position.
c. Press to clear the current setting of the end point. After pressing close the screen will ash between the following
d. Use the and buttons to move the valve to the desired close position. Hold either button down to more quickly
rotate the valve. When satised with the position press to save the position.
e. Press and repeat the previous step to set the OPEN position. If the OPEN position is exactly 90° from the
CLOSED position, instead of moving the valve to the position, press to automatically add or subtract 90° from the
current position depending on the direction to open previously set.
3. If equipped with SuperCap Module perform Failsafe Setup
a. Press the key to continue on to FailSafe Setup. There are 4 options for Failsafe:
i. CLOSE - Valve moves to closed position
ii. OPEN - Valve moves to open position
iii. PERCENT OPEN - Valve moves to X percent of open position
iv. STAYPUT - Valve doesn’t move at all
b. Press the key to enter edit mode. Use to change value. If selecting Percent Open option: Use to
move to the numeric entry eld.
c. Press to store value
To set OPEN Clockwise position →
To set OPEN Counter-clockwise position →
OPEN → CW
OPEN → CCW
POSITION-SETUP ← ↓→
Calibration Finished
OPEN → CCW CLSD
Set. 90.0° Set.
POSITION-SETUP ← ↓→
OPEN/CLOSE to move,
OPEN → CCW «CLSD»
Set. 0.0°
POSITION-SETUP ← ↓→
ENT=Set, ESC=Cancel
OPEN → CCW CLSD
Set. 0.0°
The SmartStep actuator ships with the following defaults:
Range: 0-90°
4-20mA calibrated with 20mA set as OPEN and 4mA set as CLOSED
Rotation Speed set to 70% of maximum
New calibration:

Quick Start
4
SmartStep User Guide ver 2.0
Automatic Modes of Operation
To change the current AUTO mode of the actuator:
◦ Press to cycle through the modes
◦ Press to choose the proper mode for your application as outlined below
MB-TCP
MODBUS operation using TCP service. Ensure IP address, gateway,
PORT, COM timeout, and whether DHCP will be used via MBUS-
TCP-SETUP screen. Accessed by pressing the down arrow while on
the MBUS-RTU-SETUP screen.
Wired With
4-20mA
IN + / IN - : Insert 4-20 mA or 0-10 V control signal into appropriate
terminal. Valve moves to OPEN or CLOSED based on calibrated
control signal values
OUT + / OUT - : 4-20 mA Feedback supplied for position reference.
Default 4mA out is CLOSE position and 20mA out is OPEN position.
Wiring Example
Wiring ExampleMB-RTU
Standard MODBUS operation. Ensure Device ID, Baud Rate, and
COM timeout are set up in the MBUS-RTU-SETUP screen.
Accessed via + and then press three times
Note: 12VDC Not needed for standard communication, only
accessories
ESC
ON-OFF
Only available if SuperCap Installed
No additional wiring needed. If SuperCap installed option only needs selected. Once selected,
power input onto SuperCap module controls valve position. Valve will OPEN or CLOSE based
on power input.

Quick Start
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SmartStep User Guide ver 2.0
Automatic Modes of Operation Continued
One-wire (OC1-WIRE)
Positive control wire inserted into open by default. When voltage is
applied to positive control wire, valve moves to open position. Valve
closes when signal is removed.
May be set up for closed. Option must be set in OC1-Wire setup
screen and control wire must be inserted into CLOSE instead of
OPEN.
Wiring Example
Wiring ExampleTwo-wire (OC2-WIRE)
Neutral Wire Inserted in to COM; Positive Control Wires inserted into
OPEN and CLOSE. When voltage is applied to Positive Control Wire
the valve moves to programmed OPEN or CLOSE position.
Otherwise remains stationary. If both inputs are removed, valve
moves to set FAILSAFE position in OC2-Wire setup screen.

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SmartStep User Guide ver 2.0 6 SmartStep User Guide ver 2.0
Table of Contents
Warranty 2
Certications 2
Safety Ratings 2
Device Defaults 3
New calibration: 3
Automatic Modes of Operation 4
Automatic Modes of Operation Continued 5
Section 1: Hardware Overview 7
1.1 Mechanical and Install Dimensions 7
1.2 Keypad and Button Reference 8
1.3 Connection Reference 9
Section 2: Menu Navigation and Status Screens 10
2.1 Module Conguration Screen Map 10
2.2 MAIN Screen Elements 11
2.3 Super Cap Voltage Screen 11
2.4 Diagnostics 2 Screen 12
2.5 Diagnostics 3 Screen 12
2.6 Splash Screen 12
2.7 Restore Defaults Screen 12
2.8 Model Setup Screen 13
Section 3: Position Setup Tree 13
3.1 Position Setup Screen 13
3.3 FAILSAFE Setup 14
3.4 RANGE CONTROL Setup 14
Section 4: 4-20mA Setup Tree 15
4.1 4-20mA Control Calibration Screen 15
4.2 4-20mA DAC Calibration Screen 15
4.2 4-20mA ADC Calibration Screen 16
Section 5: Speed Control Setup Tree 16
5.1 Speed Control Calibration Screen 16
Section 6: MODBUS Setup & Operation 17
6.1 MODBUS RTU Mode 17
6.2 MODBUS TCP Mode 17
6.2 MODBUS Optional Setup 17
6.3 MODBUS Register Reference 18
Section 7: Status Relay Setup 19
7.1 Error Status Relay 19
7.2 Open Status Relay 19
7.3 Closed Status Relay 19
Section 8: Temperature Degree Units 20
Section 9: Open Close Setup 20
8.1 Temp Degree Units 20
9.1 1-Wire Setup 20
9.3 ON OFF Setup 20
9.2 2-Wire Setup 20
Section 10: Digital Input Noise Filter 21
Section 11: Power Management 21
10.1 Temp Degree Units 21
11.1 Power Management Setup 21
Section 12: Software V 2.X Legacy Reference 22
Firmware V 2.X Position Setup Screen 23
Firmware V 2.X Calibration 23

Hardware Overview
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SmartStep User Guide ver 2.0
Section 1: Hardware Overview
1.1 Mechanical and Install Dimensions
RearFront
Bottom 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
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.
Direction Reference
Clockwise Counter
Clockwise

Hardware Overview
8
SmartStep User Guide ver 2.0
1.2 Keypad and Button Reference
Buttons
Use to navigate menus and set values
Store Values/Conrm
Cancel Entry/Back out of Menu
Press to set direction valve moves to open when in settings
Manual Mode
Move to calibrated open position
Move to calibrated closed position
Cycle between Automatic Modes
Button Combinations
+From Main Screen, enter Calibration Mode
+In manual mode, move valve to 100% open
+In manual mode, move valve to 0% open

Hardware Overview
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SmartStep User Guide ver 2.0
1.3 Connection Reference
Port & Functionality Port Rating(s) Pin Pin Description
J1 - Open/Close Control: offers three modes
of operation. For more detail go to Open/
Close Mode
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.
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.
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.
120-240VAC or
5-48VDC
120mA max
1, 2 ERROR
3, 4 OPEN
5, 6 CLOSED
J5 - MODBUS
1A- MODBUS Data ( - )
2B- MODBUS Data ( + )
3MB COM - Isolated common/ground for MODBUS
412 VDC - Output to power MODBUS accessory if
needed
PWR
1+48 VDC
2-48 VDC RETURN
Ethernet N/A MODBUS TCP Communication
MOTOR
1 Stepper S1A Connection
2 Stepper S1B Connection
3 Stepper S2A Connection
4 Stepper S2B Connection
USB N/A Used to update controller rmware
SUPER CAP
1 SCBOOT - SuperCap Boot Status
2 SCRST - SuperCap Reset
3 SCTX - Data Transmitted to SuperCap
4 SCRX - Data Received from SuperCap
5 Ground

Section 2: Menu Navigation and Status Screens
2.1 Module Conguration Screen Map
Menu
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SmartStep User Guide ver 2.0
MAIN
Splash
Restore
Defaults
SuperCap
Voltages
Model Setup
Failsafe
Setup
Range
Control
Position
Setup
4-20mA
DAC
Calibration
4-20mA
ADC
Calibration
4-20mA
Control
Calibration
Speed
Control
1-Wire
Setup
2-Wire
Setup
On-Off
Setup
Status
Relay
Open
Status
Relay
Closed
Status
Relay
Error
MODBUS
RTU
Setup
MODBUS
TCP
Setup
MODBUS
OPT
Setup
Temp
Units
Noise
Filter
Power
Mgmt.
Diag#2
Diag#3
Diag#4
ESC +
Starting from the MAIN screen, basic status
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.
Note: Click on any square to go to more
information related to that screen
To congure the SmartStep Actuator hold down
ESC and press the RIGHT Arrow button while on
the MAIN screen to enter the cong menu
Main Screen
Main Screen - Simplied
Information Screens
Parameter Screens that may be edited
MAIN