During the operation of the OTC DAIHEN Welding Robot, if the system experiences abnormalities such as welding time timeout, welding gun signal exception, welding (adhesion) alarm, or abnormal external water/gas supply pressure, the teach pendant will usually display a hardware and control-level alarm in the 2536 to 2545 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., 2536), to accurately obtain troubleshooting and processing suggestions.
I. OTC Robot Alarm Code Real-Time Quick Reference Table (2536-2545)
| Alarm Code | Fault Phenomenon | Fault Cause Analysis | Countermeasures & Solutions |
|---|---|---|---|
| 2536 | Welding Time Timeout | The “welding complete” signal of the welding power source was not received within the set energization wait time. | Check the welding power source status and control signal line, and restart the welding process after eliminating the connection fault. |
| 2537 | Welding Gun Half-Open/Full-Open Signal State Exception | The feedback limit signal of the welding gun has a logic conflict or the signal is lost. | Confirm that the welding gun limit switch operates normally and the control signal line connection is correct. |
| 2538 | Welding Gun Position Exception | After the system issued an action command, the welding gun did not reach the expected physical position. | Check the pneumatic/mechanical drive mechanism to eliminate physical interference or gas circuit faults. |
| 2539 | Welding Machine Main Fault | The welding machine control board detected a core error signal and fed it back to the robot controller. | Check the error code on the welding machine operation panel to locate the cause, and perform an exception reset after troubleshooting. |
| 2540 | Welding (Adhesion) Detected | Unexpected adhesion between the welding wire and the workpiece was detected at the end of welding. | Cut off the power, clean the deposited metal, and try again after optimizing the welding end parameters. |
| 2541 | Cooling Water Exception | Detected that the cooling water pressure or flow is lower than the set threshold. | Check the cooling water circuit, water tank, and flow sensor to ensure normal water circulation. |
| 2542 | Air Pressure Exception | Detected that the compressed air pressure is insufficient to support the welding gun action. | Check the factory compressed air supply system to ensure the pressure is stable within the rated range. |
| 2543 | Transformer Temperature Exception | The welding transformer overheated, exceeding the safety temperature setting threshold. | Pause the operation until the transformer cools down, check the ventilation and load conditions, and reset after recovery. |
| 2544 | Peripheral Device Exception | Detected a fault in peripheral welding auxiliary devices (such as automatic wire feeder, jig). | Check the power supply, communication, and status signals of peripheral devices, and eliminate connection faults. |
| 2545 | Welding Machine Communication Interrupted | The control communication link between the robot controller and the welding power source was disconnected. | Check the control communication cable plug connection and shielding layer, and restart the welding power source if necessary. |
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