During the operation of the OTC DAIHEN Welding Robot, if the system experiences abnormalities such as shift register conflict, missing welding point data, illegal coordinate system call, or JW32CV self-test module communication exception, the teach pendant will usually display a hardware and control-level alarm in the 2599 to 2620 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., 2599), to accurately obtain troubleshooting and processing suggestions.
I. OTC Robot Alarm Code Real-Time Quick Reference Table (2599-2620)
| Alarm Code | Fault Phenomenon | Fault Cause Analysis | Countermeasures & Solutions |
|---|---|---|---|
| 2599 | Shift Register Number Exception | During the execution of the shift function, the referenced shift register number exceeds the maximum storage range allowed by the system. | Modify the task program, correct the shift register number to the allowable value defined by the system, and perform an exception reset. |
| 2601 | Servo Welding Gun Contact Check Failed | During the contact check process before executing the welding gun spot welding action, the correct contact resistance signal was not detected. | 1. Clean the contact surface of the welding gun contact tip and the base metal; 2. Recalibrate the contact check parameters; 3. Exception reset. |
| 2605 | User Coordinate System Number Illegal | The program attempted to call a user coordinate system number that has not been reference-calibrated or whose calibration data has been lost. | Re-execute the reference calibration of the user coordinate system, or check and replace with a legal coordinate system number, and perform an exception reset. |
| 2606 | Moving Axis Not at Zero Point | When executing a specific coordinate reset or change command, it is detected that the corresponding mechanical axis deviates from the expected zero position. | Manually return the mechanical axis to the mechanical zero point accurately, and perform a status reset. |
| 2607 | JW32CV Module Response Timeout | The communication handshake between the host computer and the JW32CV function module timed out with no response signal. | Turn off the power to check the physical bus connection between modules, eliminate interference or disconnection, and then turn on the power again to try. |
| 2608 | Module Parameter Checksum Exception | When the internal boot parameters of the JW32CV function module undergo self-test, the Checksum detection is inconsistent. | It may be a memory fault. Try to reload the module boot firmware program. If ineffective, replace the board. |
| 2609 | Module Hardware Self-Test Error | The underlying hardware (such as EEPROM or watchdog) self-test when the JW32CV module starts finds abnormal status. | Restart the control device; if the error frequency is high, it indicates that the module is damaged and you need to contact the technical department for replacement. |
| 2610 | Synchronization with Externally Connected Vision Sensor Lost | While executing vision tracking welding, the robot position feedback lost synchronization with the tracking signal sent by the vision sensor. | Check the network connection stability and ensure that the robot and the vision sensor operate under the same network synchronization clock. |
| 2611 | Vision Measurement Space Logic Conflict | The vision measurement area requested by the program does not match the logical current workspace of the system (e.g., overlap detection). | Adjust the task logic to avoid repeatedly calling different vision measurement area parameters at the same spatial node, and perform a reset. |
| 2620 | Multiple Action Commands Illegally Overlapped | While the program is executing a certain action command, a new non-interrupt control logic is triggered before the preceding command is completed. | Optimize the program logic, use logical interlocking to prevent illegal overlapping of action commands, 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