During the operation of the OTC DAIHEN Welding Robot, if the system experiences problems such as unstable wire feeding, ST/ZG1 parameter error, sensor stop signal input, or no SFM file, the teach pendant will usually display a hardware and control-level alarm in the 5254 to 5263 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., 5254), to accurately obtain troubleshooting and processing suggestions.
I. OTC Robot Alarm Code Real-Time Quick Reference Table (5254-5263)
| Alarm Code | Fault Phenomenon | Fault Cause Analysis | Countermeasures & Solutions |
|---|---|---|---|
| 5254 | Wire Feed Unstable | The wire feed status becomes unstable and the deviation exceeds the specified value. | Check the wire feed device, and then perform an exception reset. |
| 5255 | ST Parameter Error | The teaching parameters of the ST command exceed the setting range. | Confirm whether each parameter is within the setting range, and then perform an exception reset. |
| 5256 | Executed Program Without ET Command | The ET command was not taught after the ST command. | Teach the ET command, and then perform an exception reset. |
| 5257 | Exception in Basic Data Parameters | The specified basic data file does not exist or the file cannot be read. | Use the service menu to check the data file, and then perform an exception reset. |
| 5258 | Teaching Error in ZG1 Command | The ZG1 command cannot be executed in the weaving section. | Improve teaching, and then perform an exception reset. |
| 5259 | Commands Without Synchronous Teaching in Starting Point Detection/Tracking Section | In a synchronous system, movement commands are not taught as synchronous teaching (“H”). | Specify all movement commands in the specified section as synchronous teaching (“H”), and then perform an exception reset. |
| 5260 | Sensor Stop Signal Is Being Input | A stop signal is being input to the laser sensor. | Release the emergency stop button on the laser sensor and turn off the alarm input, then exception reset. |
| 5261 | Groove Not Detected | Unable to detect the groove. | Ensure the LASER power is ON; ensure the cable connection between the sensor and controller is correct. |
| 5262 | Welding Torch Movement Distance Exceeded | The distance corrected by the sensor exceeds the internal distance. | Use WinUser to adjust stability; check the cable between the control device and the laser sensor. |
| 5263 | No SFM File | The specified SFM file does not exist. | Check the SFM file number, and then 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