During the operation of the OTC DAIHEN Welding Robot, if the system experiences abnormalities such as motor torque limit action, command over limit, welding power source fault, or emergency stop switch disconnected, the teach pendant will usually display a hardware and control-level alarm in the 0179 to 0248 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., 0179), to accurately obtain troubleshooting and processing suggestions.
I. OTC Robot Alarm Code Real-Time Quick Reference Table (0179-0248)
| Alarm Code | Fault Phenomenon | Fault Cause Analysis | Countermeasures & Solutions |
|---|---|---|---|
| 0179 | Motor Torque Limit Action Occurred. | Exception occurring when the output torque of the motor is limited by the torque limit circuit in the drive unit during manual operation or regenerative operation. Usually occurs during interference or when conflicting with the load. | 1. Please check whether the work content has increased the load; 2. When the robot can no longer move due to interference or other reasons, use the manual operation function to move it to a safe position. If this alarm occurs frequently, the drive unit or servo board (UM221) may be malfunctioning, please contact the repair service department. After eliminating the cause of the exception, reset the exception. |
| 0201 | Main CPU Internal Monitor Timeout. | This error occurs when the main CPU internal detects that the hardware monitor has not been accessed for a certain period of time. Affected by noise, etc. | Re-plug the main board. If the power is turned on again and it still cannot recover, please contact our maintenance service department. Turn on the power again. |
| 0202 | Command Limit Occurred. | Exception issued when the motor current command value generated by the main board exceeds the upper limit of its drive unit. | When this error occurs during robot operation, it may be caused by interference (jig, etc.) during operation. In addition, this exception may occur if the drive board or servo board (UM221) malfunctions. Please confirm whether there are objects near the robot that may cause it to interfere. If this exception occurs multiple times at the same location, please contact the repair service department. After eliminating the cause of the exception, reset the exception. |
| 0203 | Out of Range Exception During Strain Control. | Motor overload occurred during strain control. | Recalibrate the position of the point subjected to overload so that it does not exceed the allowable error. After eliminating the cause of the exception, reset the exception. |
| 0243 | Welding Power Source Fault Exception Occurred. | Exception input to the control device due to an abnormality in the welding power source. (1. Temperature exception. 2. Secondary current exception. 3. Secondary voltage exception. 4. Control power exception, etc.) | Confirm the exception details on the welding machine side and eliminate the exception according to the welding machine’s instruction manual. After eliminating the cause of the exception, reset the exception. |
| 0244 | Power Cut Off Due to Welding Power Source Fault. | Because the robot has been operating and is in a state that may cause some danger during the exception input time from the welding power source to the control device, the power of the control device is cut off. | If this exception occurs, it may be caused by a fault in the welding machine. Confirm the exception details on the welding machine side and refer to the welding machine’s instruction manual to troubleshoot. After eliminating the cause of the exception, reset the exception. |
| 0245 | Emergency Stop Switch, etc. Disconnected. | Output when one of the external emergency stop contacts, control panel emergency stop switch, or teach pendant emergency stop switch is activated. Also, this display is output when the electromagnetic switch is cut off internally due to other exceptions. | Please confirm whether the door switch of the safety fence or the emergency stop switch is pressed. When the above problem has not occurred, it is also possible that the power of the robot is cut off due to other exceptions (refer to other exceptions displayed together in the history record). After eliminating the cause of the exception, reset the exception. |
| 0246 | Motor Power Cut Off Occurred. | When the safety confirmation switch on the back of the teach pendant leaves the operating state, or a malfunction causes the internal electromagnetic switch to be disconnected. | If the error is caused by releasing the safety confirmation switch, confirm the safety of the surroundings and reset the exception while pressing the first step of the safety confirmation switch. If this error occurs while the first step of the safety confirmation switch is pressed, it may be caused by the occurrence of other exceptions. Eliminate the cause of the previous exception and then reset the exception. |
| 0247 | A/D Converter Error. | This error occurs because the calibration data of the A/D converter is not correctly input. | Please contact our maintenance service department. |
| 0248 | Motor Overheat Exception. | When the motor temperature of the 7th or 8th external axis rises abnormally. The motor overheats due to heavy load. | Reduce the load applied to the axis where the exception occurred. Wait until the motor cools down before performing 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