During the operation of the OTC DAIHEN Welding Robot, if the system experiences abnormalities such as lost position data due to an encoder exception, motor overload, or servo communication interruption, the teach pendant will usually display a hardware and control-level alarm in the 0106 to 0177 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 (e.g., 0106), to accurately obtain troubleshooting and processing suggestions.
I. OTC Robot Alarm Code Real-Time Quick Reference Table (0106-0177)
| Alarm Code | Fault Phenomenon | Fault Cause Analysis | Countermeasures & Solutions |
|---|---|---|---|
| 0106 | Lost Position Data Due to Encoder Exception. | 1. This exception occurs when the encoder battery controlling the motor position signal is disconnected or the voltage drops abnormally. Since the encoder position data is lost, the operation cannot continue; 2. The built-in encoder power wiring of the robot body is damaged. | 1. Please refer to the maintenance manual of the robot or the replacement steps on the label pasted on the side of the battery to replace the battery; 2. Perform encoder reset and encoder calibration (zero adjustment); 3. Check the wiring inside the robot. After eliminating the cause of the exception, reset the exception. |
| 0116 | Exception Where Communication With Encoder Is Impossible Occurred. | This exception occurs when communication data is lost between the servo board (UM221) and the encoder in the motor. It may be due to noise or a disconnection caused by poor contact of the encoder cable. | Turn off the power. Please confirm whether the machine cable is damaged and whether the connector is loose. If no abnormalities are found after checking all these conditions, the encoder cable may be disconnected. Please confirm and replace it. Exception reset. |
| 0121 | Encoder Exception (Light Amount Decrease) | This exception occurs when the light amount of the encoder light-emitting diode decreases. | Please contact our maintenance service department. After eliminating the cause of the exception, reset the exception. |
| 0122 | Encoder Data Read Exception. | This exception occurs when the encoder signal (counter data) cannot be read. | Please contact our maintenance service department. After eliminating the cause of the exception, reset the exception. |
| 0129 | Exception Caused by Excessive Offset. | The difference between the command position and the actual robot position becomes larger. This exception occurs when the robot’s load exceeds the allowable value or when a collision accident hinders the robot’s operation. | 1. Reduce the work load, etc., to reduce the load on the axis where the exception occurred; 2. When interfering with a jig, etc., use the manual operation function to move the robot and eliminate the interference. After eliminating the cause of the exception, reset the exception. |
| 0130 | Motor Overload Exception. | Due to continuous overload on an axis, the drive unit cuts off the power to protect the robot before it overheats. It may be continuous work applying a high load above the rating (allowable load) to a specific axis. | Confirm whether the installed tool exceeds the allowable load. Reduce the work load, etc., to reduce the load on the axis where the exception occurred. After eliminating the cause of the exception, reset the exception. |
| 0131 | Motor Overspeed Exception Occurred. | This exception occurs when the movement of each axis is too fast and exceeds the maximum speed limit. Alternatively, there may be an abnormality in the encoder feedback signal or the power cable. | Please contact our maintenance service department. After eliminating the cause of the exception, reset the exception. |
| 0132 | Motor or Drive Unit Overcurrent Exception. | When excessive current flows into the motor or drive unit, this exception occurs to protect various devices. | The machine cable may be short-circuited or in poor contact. When checking without problems, it may be caused by a fault in the circuit inside the drive unit or the servo board. After eliminating the cause of the exception, reset the exception. |
| 0173 | Unable to Transmit Command Value to Servo. | This exception occurs when the communication between the main board and the servo board is interrupted. | Confirm whether the servo board (UM221) is plugged in securely; if it still cannot recover after turning off and turning on the power again, please contact the service department. |
| 0177 | Emergency Stop Due to Other Exceptions. | Other exception causes occurring at the same time cause the robot to enter an emergency stop state. | Refer to the exception code displayed earlier, eliminate the front-most alarm cause, and then reset this exception. |
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