During the operation of the OTC DAIHEN Welding Robot, if the system experiences problems such as sensor number mismatch, unconfigured signal, file error, or coordinate system mismatch, the teach pendant will usually display a hardware and control-level alarm in the 5204 to 5213 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., 5204), to accurately obtain troubleshooting and processing suggestions.
I. OTC Robot Alarm Code Real-Time Quick Reference Table (5204-5213)
| Alarm Code | Fault Phenomenon | Fault Cause Analysis | Countermeasures & Solutions |
|---|---|---|---|
| 5204 | Sensor Number Mismatch | The sensor number in the sensor step does not match the connected sensor. | Check the sensor settings and/or the teaching program, and then execute an exception reset. |
| 5205 | Input/Output Signal Not Set | The input/output signal required for the search operation is not set. | Set the input/output signal, and then execute an exception reset. |
| 5206 | Deviation File Incorrect | Unable to read the deviation file. | Check the deviation file, and then execute an exception reset. |
| 5207 | Deviation File Not Found | The specified deviation file was not found. | Modify the file number, and then execute an exception reset. |
| 5208 | Mechanism Type Mismatch | The mechanism type in the specified deviation file does not match. | Modify the file number, and then execute an exception reset. |
| 5209 | Detection Line Extension File Error | Detection line extension file reading exception. | Check the detection line extension file, and then execute an exception reset. |
| 5210 | Detection Line Extension File Not Found | Failed to find the detection line extension file. | Modify the file number, and then execute an exception reset. |
| 5211 | Coordinate System Mismatch | The coordinate system does not match the selected deviation file. | Modify the file number, and then execute an exception reset. |
| 5212 | Cannot Search | The search vector is not taught or the search vector calculation is wrong, making it impossible to specify the search direction. | 1. Specify the search vector; 2. If the search vector has been specified, modify the search vector. After completing the above operations, execute an exception reset. |
| 5213 | Gap Amount Too Large | The detected gap amount exceeds the maximum allowable value. | Check the gap amount, modify the allowable value if necessary, and then execute an exception 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