During the operation of the OTC DAIHEN Welding Robot, if the system experiences abnormalities such as welding current/voltage over limit, poor arc starting, welding wire adhesion/breakage, insufficient shielding gas, or cooling water cut-off, the teach pendant will usually display a hardware and control-level alarm in the 5010 to 5021 range. If these faults are not investigated promptly, they may cause serious operational safety hazards or lead to a decline in welding quality.
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., 5010), to accurately obtain troubleshooting and processing suggestions.
I. OTC Robot Alarm Code Real-Time Quick Reference Table (5010-5021)
| Alarm Code | Fault Phenomenon | Fault Cause Analysis | Countermeasures & Solutions |
|---|---|---|---|
| 5010 | Welding Current Exceeded Allowable Value | The actual measured welding current exceeds the allowable upper and lower limit range set in the program. | Check conditions such as the contact tip and wire extension, adjust the welding current parameters, and perform an exception reset. |
| 5011 | Welding Voltage Exceeded Allowable Value | The actual measured welding voltage exceeds the allowable upper and lower limit range set in the program. | Check the gas, ground wire, and voltage parameters, and perform an exception reset after correction. |
| 5013 | Welding Current/Voltage Over Limit | The actual current and voltage during the welding process experience severe fluctuations and exceed the limits at the same time. | Check the stability of the wire feeder and the rust removal on the surface of the base metal, adjust the parameters, and then reset. |
| 5014 | Poor Arc Starting | After multiple arc starting retries, the arc still cannot be successfully established. | Check the welding wire extension, contact tip wear, and ground wire connection, clean the workpiece, and restart. |
| 5015 | Arc Loss Detected | During the normal welding process, the arc is unexpectedly interrupted and extinguished. | Troubleshoot problems such as wire feeding blockage, unstable gas flow, or loose ground wire, repair them, and restart. |
| 5016 | Welding Wire Adhesion Detected | At the end of welding, the welding wire adheres (fuses) to the molten pool. | Cut the adhered welding wire, adjust the Burnback voltage or time parameters, and perform an exception reset. |
| 5017 | Insufficient Shielding Gas Flow | The gas flow sensor detected that the shielding gas flow is lower than the set threshold. | Check the gas cylinder margin, pressure reducing valve setting, and whether the gas pipe is leaking or kinked, restore the gas supply, and reset. |
| 5018 | Cooling Water Exception | Insufficient cooling water flow or water pressure alarm for the water-cooled welding gun. | Check the water tank level, water pump, and pipeline, eliminate the blockage, and perform an exception reset. |
| 5020 | Welding Characteristic Data Exception | The welding characteristic curve data inside the power source or called by the robot is damaged or mismatched. | Reselect the correct welding characteristic parameter file, initialize the data if necessary, and then reset. |
| 5021 | Wire Feeder Exception | Wire feeder motor overload, encoder fault, or control signal loss. | Clean the wire feed roll, replace the wire guide tube, check the communication cable connection, and perform an 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