During the operation of the OTC DAIHEN Welding Robot, if the system experiences abnormalities such as voltage adjustment method change exception, arc welding power source input undervoltage, output overcurrent, temperature exception, or inverter drive circuit fault, the teach pendant will usually display a hardware and control-level alarm in the 5022 to 5031 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., 5022), to accurately obtain troubleshooting and processing suggestions.
I. OTC Robot Alarm Code Real-Time Quick Reference Table (5022-5031)
| Alarm Code | Fault Phenomenon | Fault Cause Analysis | Countermeasures & Solutions |
|---|---|---|---|
| 5022 | Cannot Change Voltage Adjustment Method During Welding | Attempted to change the voltage adjustment method from “Individual” to “Synergic” (or vice versa) during welding. | Modify the job program to avoid changing the voltage adjustment method during welding, and execute an exception reset. |
| 5023 | General Exception Occurred in Arc Welding Power Source | The system received a “Welding Power Source Exception” signal, and the arc welding power source itself indeed has an exception. | Refer to the arc welding power source operation manual to locate the exception, and reset after eliminating the cause. |
| 5024 | Input Undervoltage Exception Occurred in Arc Welding Power Source | The primary input voltage of the arc welding power source dropped below the rated limit. | Check the factory input power circuit and voltage fluctuation, and reset after restoring normal voltage supply. |
| 5025 | Output Overcurrent Exception Occurred in Arc Welding Power Source | The average current used for internal control of the arc welding power source abnormally exceeded the specified upper limit. | Refer to the manual, troubleshoot overcurrent causes such as load short circuit or drive circuit fault, and then reset. |
| 5026 | Temperature Exception Occurred in Arc Welding Power Source | The internal temperature of the arc welding power source (such as the surface of the heat sink) is abnormally high. | Check the cooling fan, clean the dust accumulated in the vents, pause the operation, wait for the power source to cool down, and then reset. |
| 5027 | Input Overvoltage Exception Occurred in Arc Welding Power Source | The primary input voltage of the arc welding power source surged abnormally, exceeding the rated upper limit. | Check the input power voltage, install voltage stabilizing equipment or adjust the power supply circuit if necessary, and then reset. |
| 5028 | Phase Loss Exception Occurred in Arc Welding Power Source | A phase loss occurred in the primary three-phase input power of the arc welding power source (one phase is disconnected or lost voltage). | Check the input power line, circuit breaker, contactor, etc., repair the phase loss fault, and then reset. |
| 5029 | Inverter Drive Circuit Exception | The inverter IGBT drive circuit and peripheral components of the arc welding power source have failed. | Contact professionals to check the drive circuit, replace the faulty board or components, and then reset. |
| 5030 | Voltage Detection Line Exception Occurred in Arc Welding Power Source | The arc voltage feedback detection line of the arc welding power source has poor contact, disconnection, or reverse connection. | Check the connection status of the workpiece ground wire and the voltage detection line, repair the wiring problem, and then reset. |
| 5031 | Microcomputer Exception Occurred in Arc Welding Power Source | The power control section (microcomputer motherboard module) of the arc welding power source failed or the program crashed. | Try restarting the power switch of the arc welding power source. If ineffective, contact the manufacturer for repair or replace the board. |
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