During the operation of the OTC DAIHEN Welding Robot, if the system experiences a corresponding fault condition, the teach pendant will usually display a hardware and control-level alarm in the 1012 to 1058 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, to accurately obtain troubleshooting and processing suggestions.
I. OTC Robot Alarm Code Real-Time Quick Reference Table (1012-1058)
| Alarm Code | Fault Phenomenon | Fault Cause Analysis | Countermeasures & Solutions |
|---|---|---|---|
| 1012 | Turned On PWM for Separated Mechanism. | This error occurs when the mechanism is separated and the PWM is not turned off after a certain period of time. The brake and PWM control circuit on the sequence PCB have failed. | Replace the sequence PCB or the drive unit. After eliminating the cause of the exception, reset the exception. |
| 1016 | Encoder Battery Voltage Drop. | Occurs when the battery voltage in the robot body drops. | 1. Refer to the “Robot Body Maintenance Manual” to replace the battery; 2. Perform encoder reset and encoder calibration. |
| 1024 | Robot Temperature Too High. | Excessively high motor current causes the temperature of the motor, encoder, wiring harness, and connector to be too high and motor speed to be abnormal. | 1. Confirm that the payload is within the rated range; 2. Refer to the “Robot Maintenance Manual” to determine the motor braking circuit; 3. Reduce the temperature in the abnormal area and the external temperature; 4. If the exception persists, reduce the operating speed of the robot. After eliminating the cause of the exception, reset the exception. |
| 1048 | Exception Occurred in Safety Module. | This error occurs when an inconsistency is detected or welding is detected in the safety module. | Turn on the control power again. When an error occurs, the wiring should be confirmed first before exchanging the safety module. After eliminating the cause of the exception, reset the exception. |
| 1049 | This IWB Does Not Support MFDC. | This error occurs when the IWB is an old version. | Replace the IWB plug-in board with a version that supports MFDC. After eliminating the cause of the exception, reset the exception. |
| 1050 | Analog Output Board Not Installed. | There is no analog output board in the control device. | Install the analog output board, and then reset the exception. |
| 1052 | Inconsistency Detected in Sequence Circuit. | This error occurs when an inconsistency or abnormality is detected in the dual signals of the Deadman switch, emergency stop, safety plug, and Mat switch. | 1. Confirm whether one of the signals of the Deadman switch, emergency stop, safety plug, and Mat switch is input or the contacts are not welded together; 2. Replace the I/O sequence board UM301. After eliminating the cause of the exception, reset the exception. |
| 1055 | Welding Machine Board Initialization Failed. | Welding machine board initialization failed. | Turn on the power again. If the error still appears, the interface printed circuit board should be exchanged, and then reset the exception. |
| 1056 | Welding Machine Board Detected Memory Error. | This error occurs when the memory of the welding machine board is damaged. | Turn on the power again after executing R930, and confirm the various parameters of the timer, and then reset the exception. |
| 1058 | Timer Control Device CPU Not Ready. | No confirmation signal was received from the timer control device CPU. | Replace the timer PCB (PMU), and then reset the exception. |
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