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 0919 to 1003 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 (0919-1003)
| Alarm Code | Fault Phenomenon | Fault Cause Analysis | Countermeasures & Solutions |
|---|---|---|---|
| 0919 | Exceeded Allowable Unbalanced Torque. | The robot moved to a position exceeding the allowable unbalanced torque set by the system, triggering an overload protection alarm. | 1. Enter the constant setting mode and manually move the robot to a safe position within the allowable torque range; 2. Recalibrate the teaching program and optimize the motion path to ensure that it does not exceed the allowable torque threshold throughout the process; 3. Check whether the robot installation posture is compliant to avoid abnormal torque caused by installation tilt; 4. Confirm whether the load (weight, center of gravity) of the end tool exceeds the standard, and replace/reduce the weight of the tool (if necessary); 5. After completing the above operations, perform an exception reset to clear the alarm. |
| 0956 | Communication Exception Occurred. | The internal/external communication link of the robot system is abnormal. The specific fault needs to be further located through the sub-code. | 1. View the sub-code of the communication exception on the system alarm interface to locate the specific fault cause (such as serial port/network port communication, inter-module communication, etc.); 2. Troubleshoot according to the fault point corresponding to the sub-code: check the communication cable, restart the communication module, and verify the communication parameters; 3. After eliminating the exception, perform an exception reset to clear the alarm. |
| 0957 | System Exception Detected. | Communication/hardware exception at the core system level of the robot. The specific fault needs to be confirmed by the sub-code, which belongs to a high-level system fault. | 1. Record the alarm sub-code, contact the OTC system maintenance department, and provide the sub-code and fault phenomenon; 2. Troubleshoot/repair system faults according to the guidance of the maintenance department (such as system program reinstallation, core module replacement, etc.); 3. After eliminating the exception, perform an exception reset to clear the alarm. |
| 0958 | Exception Detected During Communication Plug-in Board Self-Test. | Hardware failure of the communication plug-in board, failed the system verification during the self-test process. | 1. Restart the robot control cabinet first to troubleshoot temporary self-test failures; 2. If restarting is ineffective, unplug and plug the communication plug-in board after turning off the power, and clean the gold finger contacts; 3. If the alarm persists, it is determined that the communication plug-in board is damaged, replace it with an original communication plug-in board of the same model; 4. Restart the system after replacement and confirm that the self-test passes. |
| 0959 | Communication Plug-in Board Not Found. | The slot ID of the communication plug-in board specified in the constant setting screen does not match the actual hardware installation slot, and the system cannot recognize it. | 1. Turn off the robot power, open the control cabinet, and confirm the actual slot number where the communication plug-in board is installed; 2. Enter the constant setting screen after restarting, and verify the hardware slot ID setting value of the “Information Group Information Transfer Path”; 3. Modify the slot ID to a value consistent with the actual installation position and save the parameters; 4. Restart the system and confirm that the communication plug-in board can be recognized normally. |
| 0960 | Partial or All I/O Connections Are Stopped. | I/O device (such as remote I/O module, signal adapter board) failure, causing the robot to be unable to start the I/O communication link normally. | 1. Enter the “Information Group Information Transfer Path Monitor” interface to view the I/O device number of the specific fault; 2. Troubleshoot the I/O device: check power supply, wiring, whether hardware is damaged, repair/replace the faulty device; 3. If the fault does not recover automatically, turn off and re-power the robot control cabinet to rebuild the I/O connection; 4. After confirming that the I/O connection is restored to normal, the robot can automatically release the alarm. |
| 0967 | T/P Selector SW Is In Manual. | The selector switch of the teach pendant (T/P) is in manual mode, and the system prohibits regenerative (automatic) operation. | 1. Operate the teach pendant to switch the selector switch from the “Manual” gear to the “Auto” gear; 2. Confirm that the gear switch is in place, without jamming/poor contact; 3. Perform an exception reset to clear the alarm, and then the regenerative operation can be started normally. |
| 0973 | Regeneration Impossible Because Deadman Switch Is Not In Release Position. | A regeneration command is input while pressing the Deadman switch for emergency stop/safety confirmation, triggering a safety protection alarm. | 1. Release the Deadman switch on the teach pendant to return it to the release position; 2. Confirm that the switch resets normally, without signal exceptions caused by jamming; 3. Re-input the regeneration operation command; 4. If the alarm persists, retry after performing an exception reset. |
| 0975 | Electromagnetic Switch (MSHP) Cannot Be Turned On. | After operation preparation is input, the system does not receive the input signal feedback of the electromagnetic switch (MSHP) within the specified time. | 1. Turn off the robot power and replace the sequence plug-in board UM213 (it is recommended to use OTC original parts); 2. Re-power on after replacement and perform operation preparation; 3. Confirm that the input signal of the electromagnetic switch (MSHP) feeds back normally; 4. After eliminating the exception, perform an exception reset to clear the alarm. |
| 1003 | Analog Input Board Not Installed or Analog Output Board Not Installed. | The system executes analog input/output functions, but the corresponding analog input/output board is not actually installed in the control cabinet. | 1. Turn off the power of the robot control cabinet to ensure power-off safety; 2. Open the control cabinet, install the corresponding analog input/output board, and ensure that the wiring/slot connection is secure; 3. If analog functions are not required, modify the program to delete analog input/output commands; 4. After re-powering on, perform an exception reset to clear the alarm. |
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