Kinetix 7000 (2099) high-power servo drive fault codes: reading E codes, Drive/Comm/Bus indicators and fixes

A Kinetix 7000 high-power servo drive (Bulletin 2099) reports a fault on the seven-segment "Fault/Status" display on the front of the drive: it shows an E, then flashes the two-digit error code one digit at a time, and repeats until the error is cleared (2099-UM001G-EN-P, p. 138). E, 3, 4 means E34. At the same time the Drive status indicator turns steady red (p. 143). RSLogix 5000 shows the same fault as a fault message, such as "GroundShortFault", with the HIM text, such as "(Ground Fault)". The full code list is Table 54 (pp. 138–142); how the axis reacts to each fault is Table 61 (pp. 147–148). Rockwell lists the 2099-BM drives as discontinued; each end-of-life page, such as 2099-BM08-S, gives the replacement Rockwell lists.

The display at power-up

At power-up the display first flashes the Sercos node address, then steps through the phases until phase 4 (p. 127). Where it stops tells you where to look (p. 144):

Stuck at phase 3 with a "Pseudo Key Failure" in RSLogix 5000 usually means the motor selected in the program does not match the motor installed (p. 144).

Front-panel status indicators

Source: Tables 55–57 (p. 143). On a common-bus follower, the Bus indicator waits 2.5 seconds after DC bus voltage is applied before it flashes, so the leader can finish precharge (p. 143). The CP indicator is steady green when control power is applied at the CP terminal (p. 144); if the logic power indicator is off, check the 24 V DC control power at the CP connector (p. 126).

Common error codes

Codes not listed in the manual's Table 54 are RESERVED (p. 142). For E34 the manual also lists control-power fixes: remove the ground from the control power input, wire control power from main power as in Appendix B, or add an isolation transformer (p. 140).

Checks, step by step

1. Record before any reset: the code, the Drive, Comm and Bus states, the Sercos phase at power-up and the catalog number (2099-BM06-S to 2099-BM12-S).
2. Common DC bus: connected equipment can hold its own error data; when an 8720MC-RPS regenerative power supply provides the DC bus, check it first (p. 137).
3. Power faults (E09, E35, E37): measure AC on R (L1), S (L2), T (L3); the startup procedure prints 324…528 V AC for 460 V (p. 127), but the power specifications give 342…528 V AC rms, 380…480 V nominal (p. 150); 324 looks like a misprint, so use the p. 150 range.
4. E05 (inverter overcurrent only): with all power and motor connections removed, check continuity from the DC bus to U, V and W; if there is continuity, look for wire fibers between terminals, otherwise send the drive for repair (p. 139). E34: disconnect the motor power cable and enable with the current limit set to 0: if the fault clears, the cause is wiring or the motor (p. 140).
5. Feedback (E07, E20, E30, E63, E64): MF wiring, shields, routing, grounding; E63 and E64 are noise on the auxiliary and motor feedback cables when grounding does not follow the installation instructions (p. 141).
6. Enable, safety and Sercos (E43, E49, E38, E50): 24 V at IOD-2, SO wiring, fiber Rx/Tx, node address switches.

How the axis reacts

Fault actions are set in Axis Properties, "Fault Actions" tab: Shutdown disables the drive and opens the contactor enable relay, Disable Drive lets the motor coast, Stop Motion stops under velocity loop control, and Status Only lets the drive keep operating (p. 146). Only E04, E06, E16, E19, E23, E43, E63/E64 and E72 are programmable; E05, E09, E10, E34 and E35 are Shutdown (pp. 147–148). If an axis reports a fault but the machine does not stop, check for Status Only.

Clearing faults safely

The Kinetix 7000 is a high-power drive (22 to 149 kW, p. 150), and the DC bus is the main hazard:

• DC bus capacitors can hold hazardous voltage after input power is removed. Before working on the drive, measure the DC bus voltage, or wait the full time on the warning label on the front of the drive (p. 137).
• The specifications give a DC bus discharge time of 3 minutes after main AC is removed (p. 150); for access to the ground jumper, the manual asks for at least 5 minutes and a check that no DC bus voltage remains (p. 77). Use the longer time and always measure.
• Ground test equipment such as an oscilloscope (p. 137). Do not defeat the drive fault circuits; correct the cause first (p. 137).
• Do not cycle power repeatedly: at most 4 power cycles per minute on the AC line and 2 on the DC bus (p. 150). After a disable, the axis cannot be re-enabled for 1.5 seconds (p. 145).

Clearing a fault can restart the machine: follow the plant's permit and lockout rules.

When it is hardware

• PWR indicator off with the supply correct: internal power supply malfunction, return for repair (p. 138).
• E05 with continuity from the DC bus to U, V or W and no wire fibers: send the drive for repair (p. 139). E34 still present with the motor cable removed: contact Rockwell (p. 140).
• E54 Excessive Current Feedback Offset, if it persists: return to Rockwell (p. 141).
• E67, E71, E78: cycle power, then replace the module if it persists; E80: replace the module if it persists; E69 and E70: load defaults, save, cycle power or reset, then replace if it persists; E110 EEPROM_Fault, if it persists, and E72 with a failed fan: replace the module (p. 142).

Planning the replacement

The Kinetix 7000 is discontinued, so a fault that points to hardware is a good moment to plan the move to a current drive. The replacement Rockwell lists for each 2099-BM catalog number is on its end-of-life page; 2099-BM12-S has a migration-path page instead. The general approach is in Kinetix servo drive migration; for the Kinetix 6000 see Kinetix 6000 fault codes. For an engineer on site: breakdown support.