Ethercat Communication breaking
my problem is I have an AC500 (PM590Eth) processor and I'm using CM579 ETHCAT with a 55 microflex e150.
1-) In the uncertain times ethercat line breaks occur.
2-) When ethercat is disconnected or there is communication, the drive generates errors such as 10005 (Follow error), 10022 (Encoder lost) and 10000 (Motion aborted). This error occurs even when the servos are inactive. Promlematic cables changed.
it is not easy to suggest a solution, maybe I can suggest some more checks.
Has the problem always occurred on this application or is it only for some time?
If it is a recent event, what changes have been made in your plant / machine?
Do you have power cables close to the signal cables that can induce communication disturbances?
Do you have the possibility to try to insert a short filter of time out communication protocol, to understand if there are disturbances in the network?
Since you say you've already changed the cables, we need to eliminate this possible cause.
Fortunately for me, I have never - yet - experienced such a problem and therefore the suggestions I can give you are limited.
The errors you see 10005 (Follow error), 10022 (Encoder lost) and 10000 (Motion aborted) are all consistent with motor control issues / big changes in demand - not communication errors. If you look in the drive error history its possible you get them in conjunction with" 10026 PDO data is not present" (drive detecting a comms error)? If you don't see this problem then the drive is not seeing a loss of comms with the master! That being said these errors must come from somewhere so presuming that the system is healthy any big step changes in demand from the master (ie go from 0 -100000 units in 0 seconds) could give the errors you describe so its worth monitoring the position demand and actual position on the drive to get more information on what happening.
Furthermore (and probably more importantly) 55 drives on one bus coupler seems like quite a lot. I seem to recall an advised limit of 44 drives per coupler. So this might be part of the problem. Official advice would be to use 2 couplers for this many drives!