LW4D Quick Start Guide with Ever Studio

Ever Studio with LW4D Overview

This quick start guide provides an overview of using the Ever Stepper LW4D series drive with Ever Studio software. The vendor-created software manual included with Ever Studio is not applicable to the LW4D drive. For detailed documentation of the LW4D drive, please refer to the following resources:

• Ever Studio Quick Start Guide.pdf
• Manual e3PLC Studio EN.PDF
• LW4D Installation instructions
• LW4D Datasheet

The rotary switch on the LW4D drive must be set according to the motor being used. For SureStep motors sold by Automation Direct, refer to the “Preconfigured Motor and Drive Settings” section. For other motor selections, see the “Software Configurable Motor and Drive Settings” section.

LW4D Switch Settings per Motor

*The drive PPR cannot be changed when using 0-E. The encoders ship with this default PPR (no configuration necessary).

Important: For rotary switch positions 0-E, the drive must run in closed loop mode (an encoder must be used).

4-lead motors are the easiest to connect. The speed-torque of the motor depends on winding inductance. To determine the peak output current of the drive, multiply the nameplate motor phase current by 1.4. If the motor runs too hot, then multiply by 1.2 instead. A motor running in closed loop with encoder feedback will run cooler. For 6-lead and 8-lead motor wiring information, refer to the drive User Manual.

The drives are designed to operate within a specific voltage input. When selecting a power supply, choose one with an output range within the minimum and maximum of the drive, and ensure sufficient capacity for power supply fluctuation and motor back-EMF.

Wiring

Wiring the Encoder

The following example uses a SureStep motor (STP-MTR-23055E) with a premounted AMT112Q-V encoder. By default, the encoder is set to 400ppr and is line driver type. The programming cable AMT-PGRM-17C can be used to change the PPR if needed. For rotary switch selections 0 through 7, the encoder must remain at the default 400 ppr (x4 = 1600). For selections 8 through E, the encoder must remain at the default 2048 ppr (x4 = 8192).

Connect the encoder cable, STP-CBL-EBx (or AMT-17C-1-036), to the drive's encoder cable (CN4 cable) using the following diagram:

LW4D CN4 cable wire color pinout

LW4D CN4 cable wire color pinout

Wiring the Motor

Wire the motor according to the diagram below:

Note: The LW4D cable and STP-EXT cable have the same wire colors but signals of the colors do not match.

STP-EXT(x)-0xx Extension Cable Wiring Diagram

Diagram showing the wiring for STP-EXT(x)-0xx extension cables, including pinouts and wire colors.

Wiring Pulse and Direction Inputs

The diagram below provides an example for wiring a Productivity series high-speed output card (P2-HSO) pulse and direction connection to the LW4D drive. Refer to the “LW4D Installation instructions.pdf” for more wiring details for Line Driver, NPN, and PNP connections.

Diagram:

A diagram illustrating the wiring between a P2-HSO card and the LW4D drive for pulse and direction signals. It shows connections for +Step, -Step, +Dir, and -Dir, with a DC 5-24V power source.

Connecting Ever Studio

This section covers connecting to your Ever Stepper drive using Ever Studio configuration software. If using AutomationDirect SureStep motors (rotary DIP switch position 0-E), connecting Ever Studio is not necessary as all motor configuration is preset with the rotary DIP switch.

1. Step 1: Connect the computer with Ever Studio installed to the LW4D drive using an EVER-PGM-1 cable. Ensure the 4-pin square connector of the Ever-PGM-1 is plugged in correctly.
2. Step 2: Open the Ever Studio software on the connected computer.
3. Step 3: Click 'Change' to open the 'Setup Communication Interface' window.
4. Step 4: Select 'Service Serial Interface (Modbus RTU)' for the EVER-PGM-1 configuration cable kit.
5. Step 5: Click the 'Show System COM Ports' icon to open the 'System COM Ports' window. Double-click the COM port connected to the LW4D, then click 'Ok'.
6. Step 6: Click 'Connect'. The upper left of the Ever Studio window should now report the part number LW4D3070N211-00.

Initial Software Setting Changes

Unavailable Object Warning

Not all parameters and objects in Ever Studio are supported in every drive. If you encounter a non-supported parameter or object, you may receive a warning message indicating that the drive's firmware might be older than the Ever Studio release. To disable these pop-up messages, uncheck the 'Warning on Unavailable Objects' option in the 'Options' menu.

Diagram: A screenshot of the Ever Studio software showing the 'System Message' warning about unavailable objects.

Alarms and Drive Status LEDs

If any alarms need to be reset, do so in the 'Drive Status' window. The Application Execution green LED will always be on. If the rotary switch is set to 0 through E, the drive runs a preconfigured setting application for the applicable motor in pulse mode. If the rotary switch is set to F, the drive runs the user's defined settings in the software and is in pulse mode. The Drive Watchdog LED should always be active.

Check the Automation Direct website for new Application Updates. An application file is similar to a firmware file but is specific to the LW4D drive and contains settings for each rotary switch position. Firmware files are also available for download.

Diagram: A screenshot of the 'Drive Status' window showing various drive parameters and status indicators.

Preconfigured Motor and Drive Settings (Rotary Switch = 0–E)

When selecting a SureStep motor sold by Automation Direct, use the preconfigured motor settings via the rotary switch (positions 0–E). A power cycle of the drive is required for the new switch position to take effect. Ever Studio software is not needed for these settings. No motor or drive parameters can be configured with Ever Studio when the rotary switch is in position 0–E. This includes the Working, Motor, and Feedback tab settings. When selections 0-E are used, the drive operates in closed loop mode, requiring the encoder to be connected.

The DIP switches on the drive configure micro-stepping settings, motor direction (forward/reverse), and the ability to select Step/Direction or CW/CCW input signals when rotary positions 0 through E are active. AB Quadrature pulse input (Electric Gear) is only available when the rotary switch is set to F. Switch settings 0–E do not utilize software settings.

The software remains beneficial for troubleshooting and monitoring in any rotary switch position. Encoder configuration, scope, and I/O monitoring features are always available.

Using Ever Studio Software with Rotary Switch = 0–E

In rotary switch position 0–E, the following settings are hardcoded and cannot be changed via software. These parameters can be read from the drive in any rotary position by clicking the 'Read' button in the Settings window.

• Modality: Follows the setting of dip switch 6. Options are Pulse/Direction or CW/CCW. AB Quadrature following (Electric Gear) is available with rotary selection F only.
• Motor Feedback: This box is always checked and cannot be changed. The motor must be an E model stepper motor with the encoder properly wired. The encoder must be configured for 400 ppr if the rotary switch is set for 0 through 7. For selections 8 through E, the encoder must be configured for 2048 ppr. The drive uses the 4x method for these AB channel pulses, resulting in 1600 (or 8192) state changes per revolution. 400ppr is the default for encoders on E model motors. Encoders for D model motors (NEMA 34 and 42) have a default of 2048. Encoders can be reprogrammed with a configuration cable if they have been changed from their default.
• Invert Enable Input Level: This box is always unchecked and cannot be changed. When unchecked, the drive is enabled when no current flows across terminals EN-/EN+. Applying voltage to this terminal disables the drive, changing the status to “Drive is in Emergency Condition” and activating warnings in the Drive Status window.
• Open Transistor Protection: Drive is not enabled, and output transistors are off.
• Drive Protection: General message for all drive disable alarms.
• Warning “I Nominal not computed:” This alarm is normal at drive power-up if the drive is not enabled. It indicates the drive has not sent current to the motor and could not calculate the motor's R and L values. The alarm disappears at the first Enable and does not show again at the next disable.
• Invert Motor Direction: The check box follows the setting of DIP switch 5.
• Motor Stall Detection: This box is always unchecked and cannot be changed.
• Motor RL Detection: This box is always checked and cannot be changed. On drive power-up, the motor auto-checks the detected resistance and inductance of the motor windings.

After the drive is enabled, you can manually move the motor using the 'Direct Commands' window.

Software Configuration when Rotary Switch = F

When selecting rotary switch position F, the drive is configured via software. A power cycle is required for the new switch position to take effect. Ever Studio provides access to the Working, Motor, and Feedback tab settings. The DIP switches on the drive are inactive when setting F is chosen. If F is chosen, directly inputting parameters into the Motor parameters tab is easiest if you know all the parameters, rather than using the motor wizard.

The software is still beneficial for troubleshooting and monitoring in any rotary switch position. Encoder configuration, scope, and I/O monitoring features are always available.

Note: For SureStep motors from Automation Direct, pre-configured open loop .tscfg files are available for download in the Support Resources section of the LW4D item page.

Using Ever Studio Software with Rotary Switch = F

Follow these steps to configure your LW4D drive using Ever Studio software:

1. Step 1: With your computer connected to the drive, open Ever Studio and select 'Settings', then the 'Working Settings' tab.
2. Choose the pulse signal Modality: Pulse/Direction, CW/CCW, or AB Quadrature following (Electric Gear).
3. Deselect 'Motor Feedback' to allow the drive to run the motor in open loop for initial motion testing.
4. Deselect the 'Invert Enable Input Level' checkbox if no I/O is connected and you only want to test motor movements through Ever Studio.
5. Select the 'Motor RL Detection' checkbox to automatically detect the motor's resistance and inductance. Use 'Wiring Check' to manually interrogate the drive for these values if you prefer not to use automatic RL detection.
6. Click 'Write' to save the settings to the drive. Ever Studio can write the LW4D whether it is enabled or disabled.

When performing motor checks or direct movements from the software, disable the clock and direction terminal inputs in the 'Direct Commands' window. This is useful if the pulse and direction signals are not yet connected.

Diagram: A screenshot of the 'Direct Commands' window showing various movement options.

Open the 'Wiring Check' window from the Help menu.

Steps for Wiring Check:

1. Ensure 'Stepper' is selected and click 'Next'.
2. Click 'Yes' to proceed with the wiring test, acknowledging that the application will be stopped.

Diagram: A screenshot of the 'Wiring Check' process, showing the motor type selection and the system request to stop the application.

Note: The software needs to stop the running application to perform a wiring test. Each rotary dip switch position is considered a different application.

Click 'Setup' to proceed to the next step.

Diagram: A screenshot of the 'Wiring Check' setup screen showing R and L detection values.

The 'Setup' window will open.

Steps for Setup:

1. Enter the 'Nominal Current' of the motor (Amps per phase).
2. Enter the 'Rated Speed' (near the planned operating speed or at least 60 RPM).
3. Keep 'Test Speed' at a low value.
4. Enter 'Pole Pairs' (number of teeth on the rotor; for a 1.8-degree per step motor, this is 50 pole pairs).
5. Choose the 'Feedback Sensor' type if using closed-loop operation. For US Digital or CUI Encoders from Automation Direct, select '0: Incremental Encoder'. These encoders include a Z pulse, but the drive does not utilize it.
6. Click 'OK'.

Proceed with testing the resistance and inductance of the motor by pressing 'Test RL'. The drive determines the motor's winding resistance and inductance. The new R and L values are pushed to the drive but not yet stored in EEPROM.

Diagram: A screenshot of the 'Wiring Check' screen showing R and L detected values.

Click 'Next'.

Note: After clicking 'Next', the motor will begin to rotate.

Click 'Next' again if the motor is rotating correctly. This action also moves the parameters into the drive and the 'Motor Parameters' in the 'Settings' window.

Diagram: A screenshot showing the motor rotating during the wiring check.

Click 'Check' to verify that the shaft made one revolution.

Diagram: A screenshot showing the motor shaft rotation verification.

Click 'Next'.

You can click 'Show Values' to see all configured values.

Diagram: A screenshot of the 'Wiring Check' screen showing sensor selection and values.

For open-loop control, click 'End Test'. For closed-loop control, proceed to step 10.

Now is a good time to save your configuration file and write it to the drive again.

Click 'Verify Sensor'. The motor will rotate, and a pop-up window will ask if the Encoder Frequency is a positive value. If it is, the encoder A/B phases are wired correctly. Click 'Yes'.

Diagram: A screenshot of the 'Verify Sensor' pop-up window.

Click 'Start' on the next screen for the drive to run the motor and determine the encoder's PPR. The drive determines the nearest PPR divisible by 4. The example image shows the drive determined a 1600 PPR encoder was attached. The encoder defaults to 400 ppr, but the drive uses the x4 method for feedback functions.

Diagram: A screenshot of the 'Wiring Check' screen showing the encoder PPR detection.

Click 'OK' on the next window if you agree with the results.

Click 'Back' to return to the previous screen. You can click 'Show Values' to see calculated values or 'End Test'.

Ensure the 'Working Settings' are still configured as desired. Determine whether you will be using encoder feedback.

For closed loop: Adjust the following values for performance:

• Feedback_Boost_Current
• Feedback_Calibration_Current
• Feedback_Iq_Min
• Motor_R and Motor_L (if not set for auto-detection)
• Feedback_encoder_PPR (Encoder resolution multiplied by 4)

Gains for a closed-loop application can only be tuned when installed in the machine application.

For open loop: Adjust the following values for performance:

• Min_Current
• Max_Current
• Boost_Current
• Nominal_Current
• Motor_R and Motor_L (if not set for auto-detection)

Velocity objects are not used with Clock & Direction. You can set motor resolutions by changing 'Motor_Step_Angle'. Use default values for other objects.

Motor Settings

The 'Motor' tab allows direct configuration of all motor parameters without using the Wizard. Applicable settings for the LW4D include:

• Motor Type “Stepper 2P” (only)
• Motors with 50 pole pairs (only)
• Min_Current: Same as Idle current reduction; used when the motor is stopped in open loop mode. Also used in closed loop mode during an error and when closed loop mode control is disabled.
• Nominal Current: Rated phase current of the motor, usually the same as Max Current setting.
• Boost Current: Can be set slightly higher than Nominal current and is used mainly for acceleration ramps. Do not set too high to avoid excessive motor heating.
• Velocity, Accel, and Decel settings: Apply only when using 'Direct Commands' in Ever Studio.
• I2T time and current: Should only be used if absolutely necessary and not set too high to avoid excessive motor heating. If needed at a high value, the motor may be undersized.

Braking settings do not apply to the LW4D.

Feedback Settings

The 'Feedback' tab allows configuration of parameter address 2820H and is available only in closed loop mode. The value next to 'Feedback Settings' (0082H) is the address for the 'Feedback_Settings' object. More details can be found in section “8.2.5 Feedback_Type Modality” of the e3PLC manual. Additional settings are accessible via the 'Advanced' button.

Feedback Settings (0082H)

• Feedback Type: (bits 0-3) Set to 0-5 only when rotary switch is set to F. For rotary switch setting 0-E, Feedback type is Mode 1 and cannot be changed.
• Feedback Sensor: (bits 8-11) Can only be set to 0 for the LW4D.
• Calibration Options: (bit 12) Level of feedback calibration.
• Full calibration: Complete encoder calibration with slight backward and forward motor movement.
• Light calibration: Simple encoder rephasing. Used when Full calibration does not work correctly.
• AutomationDirect suggests using Full calibration when mechanics permit.
• Bit 7: Calibration performed at startup or on enable.
• Absolute Enc. Calibrated: Does not apply to the LW4D (bit 14).
• Feedback Error: Works with the first field Feedback Settings.

Feedback Type and Feedback Error

Feedback Type and Feedback Error work together in bits 0-3. Position Control is mode 1 and 2; Velocity Control is mode 3 and 4. For modes 1 and 3, feedback is disabled on position error. For modes 2 and 4, feedback remains enabled on position error. Closed loop is disabled when the Feedback_Actual_Position_Error is out of limits (following error). For mode 2, closed loop is disabled when at least one of the bits (1,3,5,8) of the Feedback_Status object is on. Following error alone does not disable closed loop.

Examples:

• Position Control mode 1: Feedback disabled on position error. Motor stops, alarm issued. Parameter 2820H shows 0081H.
• Position Control mode 2: Feedback stays enabled on position error. Motor stops, closed loop remains active. Parameter 2820H shows 0082H.
• Velocity Control mode 3: Feedback stays enabled on position error. Motor stops, alarm issued. Parameter 2820H shows 0083H.
• Velocity Control mode 4: Feedback stays enabled on position error. Motor stops, closed loop remains active. Parameter 2820H shows 0084H.

Diagrams: Screenshots illustrating Feedback Settings and Advanced Settings for Position Control modes 1 and 2, and Velocity Control modes 3 and 4.

Settings Priority

In closed loop, settings in the 'Feedback' tab take priority over identical settings in the 'Motor' tab. For example, 'Feedback_Iq_Min' is used for idle current reduction instead of 'Min_Current' from the Motor tab. This also applies to 'Feedback_Boost_Current'. In open loop control, the Feedback tab is not shown.

Diagram: A screenshot of the Ever Studio software showing the 'Feedback' tab with various parameters and values.

Feedback Status Register

The Feedback status register (Address 2822H) can be monitored in the monitoring section of EVER Studio at the bit level with descriptions. Bits correspond to the Feedback Status register. The example image shows bits 9 and 15 active, representing a value of 8200H. Values can also be monitored in the Watch window. The Calibration option to enter a calibration code is not applicable to the LW4D drive.

Diagram: A screenshot of the Ever Studio software showing the 'Feedback Status' register.

Direct Commands Window

To control the drive's motion directly from the software, disable the pulse and direction inputs. This window allows for precise position test moves and motor jogging.

Free Forward

For a continuous velocity jog, select 'Free Forward' and input the desired velocity (units can be RPM or Hz). Click 'Move'; the motor spins at the desired profile velocity until 'Stop' is pressed.

Diagram: A screenshot of the 'Direct Commands' window with 'Free Forward' selected.

Steps Forward or Backwards

To move the motor a specific amount, choose 'Steps Forward' or 'Steps Forward'. Enter the desired number of steps. The window displays the number of steps configured for one shaft revolution.

Diagram: A screenshot of the 'Direct Commands' window with 'Steps Forward' selected.

Target Move

For a 'Target' move, enter the desired position location in 'Steps/Position'. The current position is shown in 'Position_Actual_Value'. The motor moves the specified steps to reach the target position, rotating CW or CCW as needed.

Diagram: A screenshot of the 'Direct Commands' window with 'Target' move selected.

Steps Absolute

For a 'Steps Absolute' move, enter the position distance to move to in 'Steps/Position'. The current position is shown in 'Position_Actual_Value'. You can enter a negative value to move backwards.

Diagram: A screenshot of the 'Direct Commands' window with 'Steps Absolute' selected.

Auto Move

An 'Auto Move' command moves the motor back to position 0.

Diagram: A screenshot of the 'Direct Commands' window with 'Auto Move' selected.

Jog

To jog the motor forward or reverse, enable the 'Jogs' checkbox. Enter the desired speed in the 'Profile_Velocity' field. Motor motion occurs as long as 'Jog+' or 'Jog-' is held down.

Diagram: A screenshot of the 'Direct Commands' window with 'Jog' selected.

I/O Monitoring Tab

The 'I/O' tab provides tools for monitoring and troubleshooting. I/O and function assignments are shown in the table. If 'Simulate I/O' is checked, you can double-click each input to turn it on. Current DIP switch and Rotary switch positions can be read.

Diagram: A screenshot of the 'I/O Monitoring Tab' showing digital inputs and outputs.

Watch Window

The 'Watch' window in Ever Studio is useful for monitoring parameters associated with the drive. Not all objects and parameters shown are applicable to the LW4D. If a parameter is not 'read only', its value can be changed in the 'Watch' window.

• To insert a new parameter, right-click in the window and select 'Insert New'. The 'Drive Object List' window opens. Double-click any object to monitor or change. Once the list is closed, the object appears in the 'Watch' window with an updated value.
• To change an object's value, double-click it to open the 'Update Value' window. Enter the new value and click 'OK'. This updates the object in the drive and in Ever Studio. The 'Feedback Settings' shown are the same as Address 2820 hex. The value (0081H) is the current parameter value of address 2820H.

Diagram: Screenshots illustrating how to insert parameters into the 'Watch' window and update values.

Scope Monitor

The 'Scope Monitor' can trace 9 different values for troubleshooting motor performance and fine-tuning gains for closed-loop applications. Refer to the Ever Studio Quick Start Guide for more details.

Diagram: A screenshot of the 'Scope Monitor' window showing various traces and parameters.

To adjust each trace, select the 'Options' button, choose the trace, and adjust accordingly.

Diagram: A screenshot of the 'Chart Options' window for adjusting traces.

Closed Loop Tuning

For detailed tuning information, refer to page 172 of the e3PLC manual. Before tuning, ensure motor settings are accurate. When operating the LW4D in closed loop, reduce the 'Following Error' until the system performs as desired. Tuning should be done while the motor is running in the final application/machine. Adjust Kp, Kv (Kd), Ki, and Ki_Limit (anti-windup clamping).

• Kp (proportional gain): Determines how fast the motor corrects position relative to feedback error. Low Kp can lead to sluggishness; high Kp closes the error faster but may cause overshoot or oscillations. Proportional gain most influences tuning stiffness.
• Ki (integral gain): Determines how much the following error increases over time. If accurate position or speed is not attained quickly, Ki may be too low.
• Kv (velocity gain) / Kd (derivative gain): A high value can cause motor resonance. This gain determines how much the output changes in response to an error's rate of change, dampening the rate of change and error correction, and potentially reducing overshoot.

Frequently Asked Questions (FAQ)

Glossary