During the operation of the OTC DAIHEN Welding Robot, if the system experiences a corresponding fault condition, the teach pendant will usually display a hardware and control-level alarm in the 0040-0055 range. If these faults are not investigated promptly, they may cause serious operational safety hazards or damage to core components such as the reducer.
To help on-site engineers and mechanics quickly locate problems, we have organized the diagnostic terminology from the official maintenance manual to provide you with the following intuitive fault quick reference table. We recommend using the search function, entering the error code, to accurately obtain troubleshooting and processing suggestions.
I. OTC Robot Alarm Code Real-Time Quick Reference Table (0040-0055)
| Alarm Code | Fault Phenomenon | Fault Cause Analysis | Countermeasures & Solutions |
|---|---|---|---|
| 0040 | Software Exception Instruction Error. | A malfunction may have occurred in the main board. An error may have occurred due to the influence of noise, etc. | If it occurs frequently, turn off the power. Please re-plug the main board. If this still does not work, please contact our maintenance service department. Turn on the power again. |
| 0042 | Software Error Occurred. | A malfunction may have occurred in the main board. An error may have occurred due to the influence of noise, etc. | If it occurs frequently, turn off the power. Please re-plug the main board. If this still does not work, please contact our maintenance service department. Turn on the power again. |
| 0043 | Infinite Calculation Loop Error. | The action to be performed by the robot cannot be calculated, etc. | If it occurs during manual operation, restart to recover. Also, in automatic operation, reduce the operating speed at which this error occurs. If it occurs frequently, please contact the repair service department. After eliminating the cause of the exception, reset the exception. |
| 0044 | Soft Limit Overtravel Occurred. | This error is output when the operating range limit of each operating axis defined by the software is exceeded. After this exception is displayed during automatic operation, the drive unit is cut off (servo turned on) and in a stopped state. | As long as the exception release key is pressed, the soft limit is released. Therefore, at this time, manual operation (joint interpolation motion) should be used to move the robot into the normal range (within the soft limit). Note that reverse overtravel is not allowed at this time. |
| 0046 | Hardware Is Not Working Properly. | An exception was detected during the internal self-test when the main power was turned on. | It may be that the main CPU printed circuit board, auxiliary equipment board, or other boards inside the control device are damaged. Contact our repair service department. Turn on the power again. |
| 0050 | Encoder Exception or Disconnection Detected. | The servo board (UM221) did not receive the encoder signal. Or power, disconnection, etc. | Turn off the power. Confirm whether the connectors at each end of the machine cable are loose, and whether the pins inside the connectors are bent. Re-plug the servo board (UM221). If the same exception occurs when the power is turned on again after this processing, it may be that the encoder cable is disconnected. At this time, replace the encoder cable. Exception reset. |
| 0051 | Exception Detected by Watchdog Timer. | Occurs when a state such as a stopped microprocessor (CPU) in the drive unit is detected. It may be caused by interference such as noise. | Turn off the power and re-plug the servo board (UM221). If this exception still occurs after turning on the power again after the above processing, contact our repair service department. Exception reset. |
| 0052 | System Parameter Range Error Occurred. | A system parameter range error occurred. | Turn on the power again. |
| 0054 | Record Data Has Been Destroyed. | The record data of the control motor position signal may have been destroyed. If used directly in this state, mechanical devices may be damaged because the soft limit does not work. If you continue to use it like this, encoder position information will be lost. | Refer to [Setting of Soft Limit], this error can be released after resetting. Press any key to release the error. |
| 0055 | Exception Where Communication With Encoder Is Impossible Occurred. | An error detected during data communication between various encoders built into the robot body, etc., and the servo board (UM221). mostly occurs when the cable is in poor contact or disconnected. | Re-plug the machine cables (both the body and the control device), or re-plug the connectors behind the motors of each axis. If recovery is still impossible after this processing, please replace the machine cable (encoder cable). Exception reset. |
II. Get Professional Technical Support and Maintenance Services
When the robot frequently displays the above hardware-level alarms, and routine reset attempts are ineffective, do not forcefully pull the robot arm or repeatedly force restarts, so as not to cause secondary irreversible damage.
Contact Anhui Oujie for Technical Guidance
- System Recovery & Hardware Repair: Manager Fang
- Service Hotline (WhatsApp): 180-9663-1656
- Official Email: ahojotc@gmail.com