During daily welding operations, the OTC DAIHEN welding robot may halt and display alarm codes due to issues with system communication, brakes, or drive power. To assist engineers and equipment maintenance personnel in quickly troubleshooting problems, we have systematically compiled the core alarm codes in the 9144 to 9213 range.
This guide simplifies the lengthy maintenance manual into a structured quick reference table. We recommend using the search box below to directly input the alarm code displayed on your equipment for one-click access to accurate fault causes and troubleshooting countermeasures.
I. OTC Robot Alarm Code Real-Time Quick Reference Table (9144-9213)
| Alarm Code | Fault Phenomenon | Fault Cause | Countermeasures & Solutions |
|---|---|---|---|
| 9144 | System Error (Communication Timeout) | A communication timeout is detected internally in the system. | 1. Turn the power back on; 2. Check and reconnect the CPU board or system CF card; 3. Reinstall the system; 4. If it still cannot be resolved, please replace the CPU board and turn the power back on. |
| 9151 | Interpolation Calculation Stopped Due to System Busy | Interpolation calculation is stopped in the motion control section. | Please contact the original factory service department, back up the files to an external CF memory card, and perform an error reset. |
| 9152 | “Sleep” Not Enabled | An exception occurred when creating the “Sleep” file. Possible causes: 1. D drive device opened abnormally; 2. Unable to create the “Sleep” file; 3. Unable to close the D drive; 4. Unable to unmount the D drive; 5. Unable to open the D drive. |
Turn the power back on; if the exception persists, contact the service department, back up files to an external CF memory card, and reset the fault. |
| 9200 | Unrecognized Dynamics | Unable to recognize dynamic parameters. | Turn the power back on; if the error cannot be cleared, reinstall the system and turn the power back on. |
| 9204 | Unrecognized I/O System | Unable to recognize the I/O system and communication module. | Turn the power back on; if the error cannot be cleared, reinstall the system and turn the power back on. |
| 9208 | Communication Start Error | Unable to start communication between the CPU board and the drive unit (servo board). | 1. Confirm whether the connectors of the drive unit (RIX: CNUSB, RKX: CNCOM) are connected correctly; 2. Confirm whether the power voltage of the drive unit is the standard 5V (only for RIX: CNP5V); 3. Replace the drive unit; 4. Replace the CPU board. After eliminating the cause of the exception, turn the power back on. |
| 9209 | Brake Fuse Blown | Fuse F1-1, F1-2, or F1-3 on the brake control board UM222 is blown. | Replace the brake fuse, check for short circuits or other exceptions, and reset the exception after processing. |
| 9210 | Brake Fuse Blown (Additional Axis) | Fuse F1-1 or F1-2 on the brake control board UM226 for the additional axis amplifier is blown. | Replace the brake fuse, troubleshoot the exception of the additional axis, and reset the exception after processing. |
| 9211 | Brake Power Control Relay Contact Welded | The contact of the brake power control relay CRBC1 on the brake control board UM222 has welded. | Refer to the “AX Controller Maintenance Manual”, replace the brake control board UM222, and turn the power back on after eliminating the cause. |
| 9213 | Drive Unit Power Supply Error | Power supply PG15 (+15V) inside the drive unit is not being supplied properly. | Directly replace the drive unit, eliminate the external power supply exception causes, and reset the exception. |
II. Robot Motherboard and Servo Drive Repair Services
When hardware-level damages such as 9208 (Communication Error), 9209 (Board Blown), or 9213 (Power Error) occur, it is usually necessary to replace the CPU board or brake control board. If you lack the relevant spare parts, do not blindly short-circuit the fuses to avoid secondary burning of the servo motor.
Contact Anhui Oujie for Technical Support
- Spare Parts Procurement & Board Repair: Manager Fang
- Service Hotline (WhatsApp): +86-180-9663-1656
- Official Email: ahojotc@gmail.com
If you encounter difficulties during on-site troubleshooting, please take a picture of the error screen on the teach pendant and send it to us via WhatsApp. As an OTC Designated Authorized Distributor, our professional repair engineers will provide you with a free preliminary fault diagnosis!