During the operation of the OTC DAIHEN Welding Robot, if the system experiences abnormalities such as failure record information limit exceeded, servo welding gun configuration conflict, large difference between actual plate thickness and set value, or RIO interface communication failure, the teach pendant will usually display a hardware and control-level alarm in the 2412 to 2528 range. If these faults are not investigated promptly, they may cause serious operational safety hazards or lead to production stagnation.
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., 2412), to accurately obtain troubleshooting and processing suggestions.
I. OTC Robot Alarm Code Real-Time Quick Reference Table (2412-2528)
| Alarm Code | Fault Phenomenon | Fault Cause Analysis | Countermeasures & Solutions |
|---|---|---|---|
| 2412 | Digital Information of Failure Record | Reminds that the digital information of the failure record has reached the set value. | After backing up and saving, execute “Clear” or reset the digital information through the failure record monitor, and then reset the exception. |
| 2413 | Digital Information of Another Storage Failure Record | The digital information of another storage failure record has reached the set value. | After backing up and saving, execute “Clear” or reset the digital information through the failure record monitor, and then reset the exception. |
| 2435 | Specified Welding Machine Cannot Be Used on This Component | The servo welding gun connected to the specified welding machine is not defined as the mechanism of this component. | Modify the settings in the program, define the servo welding gun as the mechanism of this component, and then reset the exception. |
| 2436 | Servo Welding Gun Not Connected to Specified Welding Machine | When using the servo welding gun function, a welding machine not connected to a servo welding gun was specified. | Check the equipment connection status, modify the program to specify the correct welding machine, and then reset the exception. |
| 2437 | Plate Thickness Exception | The difference between the plate thickness registered in the welding condition data and the actually detected plate thickness exceeds the “abnormal detection amount”. | Confirm whether the welding condition data matches the actual workpiece, restart, and execute from the welding function. |
| 2497 | RIO Detected Communication Error | Communication data loss or abnormality occurred on the robot’s RIO (Remote I/O) connection. | Check the physical connection of the RIO communication cable and the RIO scan configuration, and then reset the exception. |
| 2498 | RIO Interface Exception | After the main system sent a command, no response signal was received from the RIO interface module. | Re-plug or replace the damaged RIO interface module, check the power supply, and then reset the exception. |
| 2518 | Step Should Be Set | About to execute a function that cannot be executed without setting the step position data. | Reset the correct step position data in the program, and then restarting the program will clear the error. |
| 2527 | File Read or Write Exception | Occurs when the format of the storage media is inconsistent with the format required by the control device or the file is damaged. | Delete the damaged file and try writing/reading again. This fault does not require a special reset operation. |
| 2528 | Cannot Recognize Storage Media | The inserted storage media (such as a USB flash drive or floppy disk) has not been initialized by the system. | Enter the [Maintenance/File Operation/Initialize] menu to initialize the media, and press any key to release it. |
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