During the operation of the OTC DAIHEN Welding Robot, if the system experiences control and communication faults such as arc welding power source communication disconnection, power source firmware version mismatch, or CAN synchronous welding not supported, the teach pendant will usually display a hardware and control-level alarm in the 4002 to 4102 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., 4002), to accurately obtain troubleshooting and processing suggestions.
I. OTC Robot Alarm Code Real-Time Quick Reference Table (4002-4102)
| Alarm Code | Fault Phenomenon | Fault Cause Analysis | Countermeasures & Solutions |
|---|---|---|---|
| 4002 | Cannot Communicate With Arc Welding Power Source | The physical communication link or logic with the arc welding power source has been disconnected. | Confirm the connection between the communication cable and the power source, and restart the robot control device and the arc welding power source. |
| 4003 | Cannot Communicate With Arc Welding Power Source | An exception occurred between the arc welding power source and the robot’s internal communication driver. | Check the power connection, confirm that the communication board is firmly plugged in, and restart the controller and power source. |
| 4004 | Error in Arc Welding Power Source Registration | The actual connected power source model is different from the system registration, or the interface board switch setting is wrong. | Check the “Welding Machine Registration” model and check the internal robot interface plug-in board switch. |
| 4005 | Welding Power Source Version Incorrect | The internal control software version of the currently connected welding power source is too old. | Contact technical support to upgrade the welding power source firmware. |
| 4006 | Power Source Version Does Not Match Servo Wire Feeding | The power source software is outdated, resulting in the inability to properly control the servo wire feeding unit. | Update the welding power source firmware, and restart the welding power source after the update is complete. |
| 4008 | Synchronous Welding Cannot Be Supported via CAN Communication | The welding power source software version is too low to execute synchronous welding via the CAN communication network. | Update the welding power source firmware, and restart the welding power source after the update is complete. |
| 4009 | Power Source Hardware Does Not Support CAN Synchronous Welding | Due to the hardware limitations of the welding power source itself, CAN synchronous welding cannot be executed. | Change the communication method of synchronous welding to RS-422 in the system, and then reset the fault. |
| 4010 | Cannot Weld (Slope Mismatch) | The current version of the welding power source does not match the welding condition slope function data of the system. | Contact technical support to upgrade the welding power source control software, and then reset the fault. |
| 4011 | Cannot Weld (Feature Data Mismatch) | The current version of the welding power source does not match the welding feature data of the system. | Contact technical support to upgrade the welding power source control software, and then reset the fault. |
| 4102 | Weaving Conditions Inconsistent | During the simultaneous weaving operation of multiple machines, the weaving parameter conditions set for each device are inconsistent. | Modify the program to keep the weaving conditions of all participating robots consistent, 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