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]
Quick Start Guide and 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

Quick Start Guide
Custom Setup
Device Defaults
The SmartStepTM Actuator was designed to have a known zero position to make set up out of box as smooth as possible.
1. Unbox and install using the ISO 5211 bolt pattern to mount the valve to. Use appropriate adapter if necessary as the
SmartStep coupling is 27mm square.
Note: When installing power and control cabling into the actuator, both conduit openings must be lled with a device
of Type 4 or equivalent environmental rating that is tightened to 15in-lbs. (UL)
2. Perform POSITION SETUP of end points:
a. Press
b. Press as instructed to begin POSITION SETUP
c. Use the buttons to rotate the valve. A single press will turn a single degree. Hold down to rotate at a faster
speed. To ne tune as you get close to the set point, you may hold down and press either the clockwise or
counter-clockwise arrow to move 0.1°.the the desired OPEN or CLOSE position. When in the appropriate position
press OPEN or CLOSE to tell the actuator which set point that is. Repeat these steps for end point that hasn’t been
set.
Note: If retrotting an old actuator or for any other reason POSITION SETUP needs to be completed without actually
turning the valve, it may be done by pressing and then completing the POSITION SETUP as previously explained.
Arrows will blink by open and close set points to indicate motion-free setup.
1. 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
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

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
Two-wire: Neutral Wire Inserted in to COM; Positive
Control Wire inserted into OPEN or CLOSE. When
voltage is applied to Positive Control Wire the valve
moves to programmed OPEN or CLOSE position.
Otherwise remains stationary.
Wiring Example
Note: Only one COM necessary
One-wire: Neutral Wire Inserted in to COM; Positive
Control Wire inserted into OPEN or CLOSE. When
voltage is applied to Positive Control Wire the valve
moves to programmed OPEN or CLOSE position.
Otherwise remains stationary.
Wiring Examples
On-Off: Neutral Wire Inserted in to COM; Positive Control
Wire inserted into OPEN or CLOSE. The default option is
OPEN. To use close it must be congured in settings.
Control wire also supplies power to the actuator. If power
is applied, valve moves to designated position, otherwise
valve and controller are non-powered.
Note: On-Off only available if SuperCap module installed
Wiring Examples
MB-RTU: Standard MODBUS operation. If using, ensure
setup of Device ID, Baud Rate, and COM timeout are set
up in the MBUS-RTU-SETUP screen. Accessed via
+and pressing the right arrow three
times
Wiring Example
Note: 12VDC for accessories, not necessary for standard communication
MB-TCP: MODBUS operation using TCP service. If
using, ensure setup of 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:
ETHERNET
GND 12VDC B A
MODBUS
IN + IN - OUT + OUT -
SIGNAL
CONTROL
4-20mA || 0-10VDC
OPEN COM COM CLOSE
OPEN/CLOSE
CONTROL
24-48VDC || 24-240VAC
OPEN COM COM CLOSE
OPEN/CLOSE
CONTROL
24-48VDC || 24-240VAC
OPEN COM COM CLOSE
OPEN/CLOSE
CONTROL
24-48VDC || 24-240VAC
OPEN COM COM CLOSE
OPEN/CLOSE
CONTROL
24-48VDC || 24-240VAC
OPEN COM COM CLOSE
OPEN/CLOSE
CONTROL
24-48VDC || 24-240VAC
Quick Start GuideAutomatic Modes of Operation
There are six automatic modes of operation. Each are outlined below.

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SmartStep User Guide ver 1.2
Table of Contents
Section 1: Hardware Overview 3
1.1 Mechanical and Install Dimensions 3
1.2 Keypad and Button Reference 4
1.3 Wiring Reference 5
Section 2: Menu Navigation and Status Screens 6
2.1 Module Conguration Screen Map 6
2.2 MAIN Screen Elements 7
2.3 Super Cap Voltage Screen 7
2.4 Diagnostics 2 Screen 8
2.5 Diagnostics 3 Screen 8
2.6 Splash Screen 8
2.7 Restore Defaults Screen 8
2.8 Model Setup Screen 9
3.1 Position Setup Screen and Calibration 9
Section 3: Module Conguration 9
3.2 Initial Calibration 10
3.3 FAILSAFE Setup 10
3.4 RANGE CONTROL Setup 10
3.5 MODBUS Setup & Operation 11
MODBUS RTU Mode 11
MODBUS TCP Mode 11
MODBUS TCP Mode 11
3.6 MODBUS Register Reference 12
User Guide

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SmartStep User Guide ver 1.2
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 from the
zero point as shown to the left when viewing the
actuator as shown.
270° 90°
0°
180°
270° 90°
0°
180°
Direction Reference
Clockwise Counter
Clockwise

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SmartStep User Guide ver 1.2
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 rotate 1°, Hold down to rotate faster.
Manual Mode
Move to calibrated open position
Move to calibrated closed position
Cycle between Automatic Modes
Button Combinations
+In Manual Mode, press to rotate counterclockwise by 0.1°
+In Manual Mode, press to rotate clockwise by 0.1°
+From Main Screen, enter Calibration Mode
+When in Calibration Mode clears CLOSE calibration point
+When in Calibration Mode clears OPEN calibration point

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SmartStep User Guide ver 1.2
J1 - Open/Close Control, 3 Modes of operation:
• One-Wire: Neutral Wire Inserted in to COM; Positive Control Wire inserted into OPEN or CLOSE. When voltage is
applied to Positive Control Wire the valve moves to programmed OPEN or CLOSE position. Otherwise remains
stationary.
• Two-Wire: Neutral Wire(s) Inserted into COM. First Positive Control Wire inserted into Open. Second Positive
Control wire inserted into CLOSE.
• On-Off: Neutral Wire Inserted in to COM; Positive Control Wire inserted into OPEN. Functionally similar to One-
Wire. Control wire also supplies power to the actuator. If power is applied, valve moves to designated position,
otherwise valve and controller are non-powered. As this is the case, all POWER OUT errors are suppressed
J2 - Signal Control:
• IN + / IN - : Insert 4-20 mA or 0-10 V control signal into appropriate terminal.
• OUT + / OUT - : 4-20 mA Feedback supplied for position reference. Default 4mA out is CLOSE position and 20mA
out is OPEN position.
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.
J4 - Status Relays (60Vp, 600mA max):
• OPEN/CLOSED status 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.
J5 - MODBUS:
▪ A: (-) Signal
▪ B: (+) Signal
▪ MB COM: Isolated MODBUS signal ground
▪ 12VDC: +12 VDC
Ethernet:
▪ Current usage for MODBUS TCP
PWR:
▪ Power in port is located below the terminal strip on the front side of the command module. It is designed for
48VDC input. Pin 1 is input power ground. Pin 2 is +48VDC. The input is reverse voltage protected and fused.
This input is suitable for an input circuit capable of delivering not more than 5,000 rms symmetrical amperes, 240
volts maximum when protected by fuses or breakers sized in accordance with the NEC. (UL)
MOTOR:
▪ Pre-assembled 4-pin connector that supplies drive current to the stepper motor
USB:
• Used to update module rmware and communication
SUPER CAP
• Supplied communication link to Super Cap module if installed
1.3 Wiring Reference

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SmartStep User Guide ver 1.2
Section 2: Menu Navigation and Status Screens
2.1 Module Conguration Screen Map
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
Status Relay
Open
Status Relay
Closed
Status Relay
Error Setup
Accel Span
Speed
Control
MODBUS
RTU Setup Temp Units
Diag#2
Diag#3
ESC +
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
Information Screens
Parameter Screens that may be edited
MAIN
MODBUS
TCP Setup
MODBUS
OPT Setup

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SmartStep User Guide ver 1.2
2.2 MAIN Screen Elements
1
7
3
5
6
8
4
2
1) Percentage that valve has opened from closed position
2) Current RUN mode selected by pressing either the MAN or AUTO button and then pressing ENTER after the
proper RUN mode is displayed on the screen. If ENTER is not pressed, then the unit will revert back to
displaying the current RUN mode. Pressing the auto button more than once will cycle through the
following modes:
a) On-Off
b) 4-20mA
c) 1-Wire
d) 2-Wire
e) MB-TCP
f) MB-RTU
3) Desired valve position based on current control signal
a) The entire line may also be used to display faults for the current run mode. For a list of faults and
their explanation go to the Troubleshooting section. For example if in 4-20mA mode and no
signal is detected the following may be displayed:
4) Number of motor starts since the unit was commissioned
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
Accessed by pressing from the MAIN screen.
If Super Cap module is installed this screen shows
individual charge levels for each capacitor. If Super Cap
module is not installed, all levels will be shown as 0.
2.3 Super Cap Voltage Screen

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SmartStep User Guide ver 1.2
2.4 Diagnostics 2 Screen
2.5 Diagnostics 3 Screen
2.6 Splash Screen
Accessed by pressing from the Super Cap screen.
Diagnostics 2 screen shows the total stack capacitor
charge of the Super Cap if installed.
Magnet feedback is also shown on this screen. Allowing
a quick check if a new command module is installed.
Accessed by pressing from the Diagnostics 2 screen.
Diagnostics 3 shows the maximum internal temperature
recorded since commissioning.
2.7 Restore Defaults Screen
Accessed by pressing from the splash screen.
Follow prompts on screen to restore the unit to factory
default settings.
Accessed by pressing from the MAIN screen.
Model as dened in Model Setup Screen
Loaded Firmware version
Alternate message if magnet isn’t seen by command module

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SmartStep User Guide ver 1.2
2.8 Model Setup Screen
3.1 Position Setup Screen and Calibration
Press ENT to enter Edit mode. The blinking eld will be
editable. Use the LEFT and RIGHT arrows to navigate
between the elds. Use the UP and DOWN arrows to
change the eld parameter.
These should not be changed unless the control
module is being put on a different base! USI
Technologies is not responsible for potential damage
caused if the parameters are changed.
Open Position Label: The direction the valve will always rotate to
reach the calibrated open position
Closed Position Label: The direction the valve will always rotate to
reach the calibrated close position
Current Valve Position: Actual valve position in degrees.
Use the buttons to change this value. A single press of
either button will move the valve 1°. Press and hold either button for
faster movement.
Hold the button with either rotation button to move valve by 0.1°
for ne adjustment.
When valve is at proper location, press either the or
button to set the Open or Close position. Repeat for other end point.
If the desired cal point needs to be obtained WITHOUT moving the
valve, press AUTO. Two ashing arrows will appear on either side of
the Act/Desired Pos Degrees eld. To return to valve movement
mode, press MAN. The ashing arrows should disappear. This “non-
movement” mode for calibration is fast and can be useful for
calibrating a valve when the position cannot be physically seen. All
SmartStep actuators are have absolute position where 0° is always
down and Counter-clockwise direction is always increasing from 0°.
See unit circle illustration.
Range: The difference between Degrees at OPEN and Degrees at
CLOSE. If only one is set, this will be the difference between the
Actual/Desired position and the set end point. A minimum of 10° is
required for a valid calibration.
Calibrated Close Position: The CLOSED position of the valve in
degrees. If a new closed position is needed, hold the button
down and then press
Calibrated Open Position: The OPEN position of the valve in
degrees. If a new open position is needed, hold the button
down and then press
Torque Options:
• X0400 - 400 in/lb gearbox
• X1200 - 1200 in/lb gearbox
• X2500 - 2500 in/lb gearbox
• X5000 - 5000 in/lb gearbox
Power Options:
• NONE - 48VDC Supplied by
customer
• PS024 - Uses input module to boost
24VDC or 24VAC to 48VDC
• PS120 - Uses input module to
accept 120-240 VAC input
Backup Options:
• NONE - No Super Cap module
installed
• EPB - Super Cap module
installed
Current Valve
Position
Range in degrees
Between Open/Close
Closed Position
Label
Open Position
Label
Calibrated Close
position
Calibrated Open
position
Calibration has not been completed if line blank
ENT
OPEN
OPEN
CLOSE
CLOSE
Quick tip:
For a calibrated unit, if OPEN is held while
CLOSE is pressed or vice-versa, the cal points
(Degrees at OPEN and CLOSED) for OPEN and
CLOSED are swapped.
Please Note:
When calibrating, if a point is set (OPEN or CLOSED),
when moving the Act/Desired Pos Degrees for the
other set point the span will always take the shortest
path to the known endpoint. If a span of greater than
180ois desired, a smaller span must be calibrated and
the OPEN DIRECTION must be ipped by the user in
the submenu.
Section 3: Module Conguration

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SmartStep User Guide ver 1.2
3.2 Initial Calibration
- Press
- Use the
- Press
To begin calibration the below will be shown on screen
Buttons to rotate the valve to the desired end-point position. Then
Press OPEN or CLOSE when in proper position. Repeat for the other
end-point.
As instructed to show the Position Setup Screen
ESC +
ENT
3.3 FAILSAFE Setup Press the ENT button to enter edit mode. Use UP/
DOWN Arrows to change value. Use LEFT/RIGHT
Arrows when Percent Open is selected to move to the
next eld. Press ENT again to set FAILSAFE mode
when proper selection is made.
• CLOSE - Valve moves to closed position
• OPEN - Valve moves to open position
• PERCENT OPEN - Valve moves to percent open
• STAYPUT - Valve stays where it is
- Press to continue on to Failsafe Setup
- Press to continue on to RANGE CONTROL
3.4 RANGE CONTROL Setup
Press the ENT button to enter edit mode. Use UP/
DOWN Arrows to change value. Use LEFT/RIGHT
Arrows when Percent Open is selected to move to the
next eld. Press ENT again to set RANGE CONTROL
mode when proper selection is made.
• CW - Valve always moves CLOCKWISE to OPEN
position
• CCW - Valve always moves
COUNTERCLOCKWISE to OPEN position

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SmartStep User Guide ver 1.2
3.5 MODBUS Setup & Operation
MODBUS RTU Mode
Press the ENT button to enter edit mode. Use LEFT/
RIGHT Arrows to move between the three editable
elds. Use UP/DOWN Arrows to change each eld’s
value. Press ENT again to save settings.
• Device ID - Number from 1-255
• Baud rate - Standard values of 4800, 9600, 19200,
38400, 57600, or 115200
• COM Timeout - Amount of time before MODBUS
Slave Receive Timeout Trips. Select value of 1-
20 seconds or disable by selecting NONE
MODBUS TCP Mode
Press the ENT button to enter edit mode. Use LEFT/
RIGHT Arrows to move between the three editable
elds. Use UP/DOWN Arrows to change each eld’s
value. Press ENT again to save settings.
• sIP - Number from 1-255
• sGW - Standard values of 4800, 9600, 19200,
38400, 57600, or 115200
• COM Timeout - Amount of time before MODBUS
Slave Receive Timeout Trips. Select value of 1-
20 seconds or disable by selecting NONE
MODBUS TCP Mode
Press the ENT button to enter edit mode. Use UP/
DOWN Arrows to enable or disable DHCP. Press ENT
again to save settings.
Actuator control in normal operation can be set to MODBUS mode. This mode requires inputs in the J5
terminal block for MODBUS A(-), MODBUS B(+), MB COM (Signal Ground), and 12VDC. The MB COM is a
completely isolated ground connection (i.e. isolated from actuator signal ground) that may be used to
reference a single-ended master ground if desired. A full description of the MODBUS control set is given on
the following page in the MODBUS Register Reference. MODBUS registers may be queried even in AUTO
mode to get status information. See below for setting up the different MODBUS modes supported.

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SmartStep User Guide ver 1.2
Coil/Register Address Size Mode (R/W) Data Type Description
1 0 1 R/W bool OPEN/CLOSE Forced Coil output (1= “OPEN” 0 = “CLOSE”)
10001 0 1 R bool [Valve Fully Open] AUX1 Output Status (1 = "on", 0 = "off")
10002 1 1 R bool [Valve Fully Closed] AUX2 Output Status (1 = "on", 0 = "off")
10003 2 1 R bool Error Relay Output Status (1 = "on", 0 = "off")
10004 3 1 R bool FAULT: Position Calibration Needed (1 = "on", 0 = "off")
10005 4 1 R bool FAULT: Input 4-20mA Invalid (1 = "on", 0 = "off")
10006 5 1 R bool FAULT: Position Sensor (1 = "on", 0 = "off")
10007 6 1 R bool FAULT: MODBUS Slave Receive Timeout (1 = "on", 0 = "off")
10008 7 1 R bool FAULT: Open/Close Inputs Invalid (1 = "on", 0 = "off")
10009 8 1 R bool FAULT: Open/Close Interface Disconnected (1 = "on", 0 = "off")
10010 9 1 R bool FAULT: Motor Is Stalled (1 = “on”, 0 = “off”)
10011 10 1 R bool FAULT: Magnet out of range (1 = “on”, 0 = “off”)
10012-10019 11-18 8 R bool Reserved (0xFF)
10020 19 1 R bool Supercap Backup Power COM Lost (1 = “on”, 0 = “off”)
10021 20 1 R bool Supercap Backup Power ON (1 = “on”, 0 = “off”)
10022 21 1 R bool Main Power Lost (1 = “on”, 0 = “off”)
30001 0 1 R ushort Current Valve Percent Open (least signicant digit is tenth's place. (i.e.
237 = 23.7% open)
30002 1 1 R ushort Current Temperature (oC or oF based on cong)(Default: oF) (e.g. 80 =
80 oF)
30003 2 1 R ushort Maximum Temperature (oC or oF based on cong)(Default: oF) (e.g.
100 = 100oF)
30004-30005 3-4 2 R uint Number of Cycles (30004 == BITS[31…16], 30005 == BITS[15…0])
30006 5 1 R ushort Supercap Percent Charge Status [0- 100] (i.e. 100 = 100% charge)
40001 0 1 R/W ushort Desired Open Position (Tenth Percent as 0 to 1000) (i.e. 496 = 49.6%
open)
40002 1 1 R/W ushort Max Open Speed (%/10 of Max Valve Speed) (1 - 10) (Default: 7 or
70%)
40003 2 1 R/W ushort Max Close Speed (%/10 of Max Valve Speed) (1 - 10) (Default: 7 or
70%)
40004 3 1 R/W ushort Acc/Decel Span (Degree Range for Acceleration and Deceleration) (1o -
10o) (Default: 5)
3.6 MODBUS Register Reference
Table Name Coil/Register Numbers Data Addresses Type
Discrete Output Coils 1-9999 0000-270E Read/Write
Discrete Input Coils 10001-19999 0000-270E Read Only
Analog Input Registers 30001-39999 0000-270E Read Only
Analog Output Holding Registers 40001-49999 0000-270E Read/Write