During the operation of the OTC DAIHEN Welding Robot, if the system experiences abnormalities such as multiple measurement process conflict, vision shift value over limit, vision measurement timeout, or seam welding command conflict, the teach pendant will usually display a hardware and control-level alarm in the 2589 to 2598 range. If these faults are not investigated promptly, they may cause serious operational safety hazards or lead to welding forming failure.
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., 2589), to accurately obtain troubleshooting and processing suggestions.
I. OTC Robot Alarm Code Real-Time Quick Reference Table (2589-2598)
| Alarm Code | Fault Phenomenon | Fault Cause Analysis | Countermeasures & Solutions |
|---|---|---|---|
| 2589 | Multiple Measurements Occurred | The current measurement process has not been completed, and the system was issued a measurement command again, resulting in an operation logic conflict. | Adjust the task program logic to ensure that the current measurement is completed before sending the next trigger command, and perform an exception reset. |
| 2590 | Shift Range Exceeded | The shift value measured by the vision sensor exceeds the shift range threshold set in the system parameters. | Check whether the workpiece positioning deviation is too large; if the positioning is normal, the upper limit of the shift range set in the parameters can be appropriately relaxed. |
| 2591 | Vision Sensor Exception | The vision sensor internal self-test reports an error, or the communication/calibration parameters between it and the robot controller are abnormal. | Restart the sensor device; if the fault persists, troubleshoot the power supply, communication cable, and calibration parameters, and reset the exception. |
| 2592 | Multiple Shift Fault | Multiple mutually exclusive shift operations were triggered simultaneously within the same time period in the program, resulting in a function logic conflict. | Modify the task program logic to ensure that only one type of shift operation is executed at the same time, and perform a fault reset. |
| 2593 | Measurement Time Exceeded | The vision sensor measurement process executed slowly, exceeding the task execution time window specified by the system. | Check and optimize the trigger/exposure logic, clear interference objects if necessary to improve recognition speed, and perform an exception reset. |
| 2594 | Cannot Execute Seam Welding Function | In the seam welding work mode, a function command not supported by the current control level was called, or the configuration was wrong. | According to the seam welding control requirements, delete unsupported function commands in the program or correct the wrong constant configuration. |
| 2595 | Function Command Not Allowed to Execute | In seam welding mode, attempted to call illegal commands restricted by the system such as CALLFAR (remote function). | Move the disabled function to be executed outside the seam welding operation process, or find an alternative command, and perform an exception reset. |
| 2596 | No Set Basic Position Data | When the shift function is triggered, the basic position data in the corresponding register read by the system is empty or not entered. | Enter the system basic setting menu, accurately enter and save the calibrated basic position data, and perform a fault reset. |
| 2597 | Measurement Point Data Exception | The number of collected valid measurement points is insufficient, the data format is damaged, or the position points conflict, and the shift cannot be resolved. | Ensure that enough valid measurement points are collected; if the basic position data is correct, re-execute the vision calibration process and perform an exception reset. |
| 2598 | Measurement Type Exception | The measurement type configured in the robot system is 2D mode, but the program executed an algorithm that only supports 3D functions. | Enter the parameter interface to confirm the robot vision measurement configuration (upgrade the configuration if 3D is required), or replace it with a dedicated function that supports 2D. |
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