During the operation of the OTC DAIHEN Welding Robot, if the system experiences problems such as search range, position deviation, welding current and voltage exceptions, the teach pendant will usually display a hardware and control-level alarm in the 6240 to 6297 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., 6240), to accurately obtain troubleshooting and processing suggestions.
I. OTC Robot Alarm Code Real-Time Quick Reference Table (6240-6297)
| Alarm Code | Fault Phenomenon | Fault Cause Analysis | Countermeasures & Solutions |
|---|---|---|---|
| 6240 | Exceeded ZF Search Range | The robot moved outside the search range. | Modify (increase) the search range or program to correct the error, and then perform an exception reset. |
| 6241 | Exceeded ZT Position Deviation Range | The robot moved outside the position deviation range. | Check the target position, modify (increase) the ZT parameter or program, and then perform an exception reset. |
| 6242 | Exceeded ZN Deviation Range | The set deviation exceeds the range. | Modify (increase) the ZN deviation or program to correct the error, and then perform an exception reset. |
| 6243 | Exceeded ZN Search Range | The robot moved outside the search range during ZN. | Modify (increase) the ZN search range or program to correct the error, and then perform an exception reset. |
| 6245 | Exceeded Deviation Range | The distance between the detected end point and the taught point before ZE exceeds the deviation range. | Check the detected point, modify (increase) the deviation range or program, and then perform an exception reset. |
| 6249 | Exceeded ZT Posture Deviation Range | The robot moved outside the posture deviation range. | Check the target posture, modify (increase) the ZT parameter or program, and then perform an exception reset. |
| 6294 | Adaptive Welding Current Too High | The welding current specified by the adaptive control exceeds the maximum current display value. | Check the data table via WinUser, increase the maximum current display value for adaptive control, and then reset. |
| 6295 | Adaptive Welding Current Insufficient | The welding current specified by the adaptive control is lower than the minimum current display value. | Check the data table via WinUser, decrease the minimum current display value for adaptive control, and then reset. |
| 6296 | Adaptive Welding Voltage Too High | The welding voltage specified by the adaptive control exceeds the maximum voltage display value. | Check the data table via WinUser, increase the maximum voltage display value for adaptive control, and then reset. |
| 6297 | Adaptive Welding Voltage Insufficient | The welding voltage specified by the adaptive control is lower than the minimum voltage display value. | Check the data table via WinUser, decrease the minimum voltage display value for adaptive control, and then 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
If you do not know how to handle such underlying alarms on-site, please take a picture of the error screen on the teach pendant and the on-site status, and send it to us via WhatsApp. As an OTC Designated Authorized Distributor, our professional maintenance engineers will provide you with a free technical assessment and troubleshooting solution!