During the operation of the OTC DAIHEN Welding Robot, if the system experiences auxiliary system faults such as welding time timeout, welding gun limit sensor exception, welding wire adhesion, or cooling water/air pressure/transformer temperature over limit, the teach pendant will usually display a hardware and control-level alarm in the 3537 to 3546 range. If these faults are not investigated promptly, they may cause serious operational safety hazards or lead to a decline in welding quality.
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., 3537), to accurately obtain troubleshooting and processing suggestions.
I. OTC Robot Alarm Code Real-Time Quick Reference Table (3537-3546)
| Alarm Code | Fault Phenomenon | Fault Cause Analysis | Countermeasures & Solutions |
|---|---|---|---|
| 3537 | Welding Time Timeout | After the set energization wait time ends, the system still hasn’t received the “welding complete” signal from the welding machine. | Check whether the welding machine output is abnormal, confirm the signal line connection, and restart the welding process after troubleshooting. |
| 3538 | Welding Gun Remains Closed | At the end of welding, the system still detects the “fully closed” signal of the welding gun and has not completed the release action. | Check for mechanical structure jamming and communication limit status, and restart the welding process after eliminating physical interference. |
| 3539 | Welding Gun Did Not Reach Half-Release State | After the system issued the “half open” command, it did not receive the corresponding position feedback signal from the welding gun. | Check the half-open limit sensor and pneumatic/drive mechanism, and restart the welding process after troubleshooting. |
| 3540 | Welding Gun Did Not Reach Full Release State | After the system issued the “full open” command, it did not receive the corresponding position feedback signal from the welding gun. | Check the full-open limit sensor and pneumatic/drive mechanism, and restart the welding process after troubleshooting. |
| 3541 | Welding (Adhesion) Detected | At the end of the welding sequence, the system received a “welding adhesion” detection signal between the welding wire and the workpiece. | Cut off the power, clean the deposited metal, adjust the Burnback parameters, and then restart the process. |
| 3542 | Cooling Water Exception 1 Detected | The system received an external “Cooling Water Exception 1” signal (such as low water flow, insufficient water pressure). | Check the water tank water level, water pump working status, and whether the water circuit is blocked, and restart the process after troubleshooting. |
| 3543 | Cooling Water Exception 2 Detected | The system received an external “Cooling Water Exception 2” signal (such as water temperature too high, water cut-off protection). | Check whether the cooling water temperature and radiator system are operating normally, and restart the process after troubleshooting. |
| 3544 | Air Pressure Exception Detected | The system received an “Air Pressure Exception” signal, indicating the pneumatic device air pressure is insufficient or too high. | Check whether the factory air compressor output pressure and pipeline are leaking or kinked, and restart the process after troubleshooting. |
| 3545 | Transformer Temperature Exception Detected | The system received a “Transformer Temperature Exception” signal, indicating the transformer temperature exceeds the safety threshold. | Pause the operation and wait for it to cool naturally, check whether the cooling fan and load rate exceed the standard, and restart the process. |
| 3546 | Peripheral Device Exception Detected | The system received a fault signal from auxiliary peripheral equipment (such as jigs, automatic wire feeders, etc.). | Check the status of peripheral devices such as jigs and wire feeders and the PLC communication wiring, and restart the process. |
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