Common Troubleshooting Methods

The program cannot be loaded (3D)

Position tracking error in 11#8: (seven-axis gantry)

1. Reset the zero point of the extra axis

Unable to record position: (hand teaching of the floor rail) Cause: The station or tool conflicts with the current program. Solution: Adjust the station or tool to match the current state.

E84 bus failure: (AOTAI welding machine) Phenomenon: Abnormal connection between the robot and the communication controller.

Water cooling anomaly E0A: (AOTAI welding machine) Cause: The water tank is empty. Solution: After adding water, simultaneously press the storage and diameter buttons of the welding wire, then press the up and down arrows to adjust up to p10. Turn the right button to put it in ono mode for two minutes, then switch it to on mode, and finally press storage to exit. 2. Restart the welding machine and the robot’s control cabinet.

No input signal on the computer: (PC) Cause: The signal cable between the central unit and the monitor is loose. Solution:

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In the computer software, you cannot change the tool or station in the (3D) positionSolution :

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Error 4903: (3D) Cause:

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Welding Torch Collision 1853: (3D) Cause: Torch Collision. Solution: Go to Welding → Equipment Settings → Torch Collision Detection, change it to Off, save, press the red X to clear the error, move the torch to a safe position, and turn torch collision detection back on.

Under Monitor → IO → Extension 2 → Input, turn off Collision Protection IO.

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Axis 1800 Movement Error (Code = -4): (3D) (Error 1801: Solution: Restart the Software) Cause: The limit has been exceeded. Solution: Press the red X to clear the error → click Stop under the program → clear the welding machine alarm and reset the welding signal → connect the software and turn it back on to move the robot to the safe point.( If there is no computer, use the teaching panel to move the torch in the direction of the robot.)

Failure to start the 3923 arc: (3D) Cause:

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Pores in welding: (3D) Cause:

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Phenomenon: Warning, red light on, no error on the display (seven-axis gantry). Cause: The program has not been fully executed. Solution: Stop the program → resets the welding signal → moves the torch position.

Emergency Stop 1802: (3D) Cause: The red emergency button has been pressed. Solution: Turn and lift the emergency stop button → press the red X. 1809

Phenomenon: When you click on tool or station on the teaching dashboard screen, there is no response. Solution: Restart the robot’s control cabinet.

4955 Welding Arc: (3D) Solution: Switches to manual mode → clears the error with the X → removes the welding alarm and resets the welding signal → switches to automatic mode → turns on the system.

3930 Welding Arc: The robot’s current motion is not Cartesian (3D) Cause: The current motion mode conflicts with the program’s execution mode. Solution: Switch to manual mode → press the red X → clear the welding alarm and reset the welding signal → switch to automatic mode → turn on the system.

Defective Vertical Weld Seam: (3D) Cause:

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955 Power off, system has rebooted (3D) Cause: Internal execution error. Effects:

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3922 Welding Arc: The arc is interrupted during the welding process (3D) Solution: Restarts after the arc interruption.

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1933 #8: Axis 8 0xFF14 — Control encoder exceeds speed (seven-axis gantry) 1. Prolonged Error Inspection Method: Check if the motor vibrates during operation. Solution: Disassemble and reassemble the motor gear.

2. Single Error Solution: Resets the zero point of the extra axis.

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4831 #7: Axle 7 0x6031 — Power Braking Resistance Overload Alarm (Seven-Axis Gantry) Solution: Resets the zero point of the additional axle.

1941 #8: Axis 8 0xFF22 — Abnormal Position Target Value (Seven-Axis Gantry) Solution: Resets the zero point of the additional axis.

4218 #8: Axis 8 0xE012 — Abnormal Fault Record 4218 #7: Axis 7 0xE012 — Abnormal Failure Historical Record (Seven-Axis Gantry) Cause:

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Phenomenon: Prolonged error in axes 7 and 8 of the seven-axis gantry. Inspection:

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Solution: Resolve according to the specific situation.

Phenomenon: The teaching panel is not responding when clicked. Cause:

Phenomenon: The ground wire in the control cabinet has burned out. Cause:

Solution:

Collision Detection Switch on Collision Detection On: May cause a shaft collision. Off: Can be used normally (collision detection off).

Cause of the phenomenon shown in the left image:

Solution:

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Problem phenomenon: The software suddenly can’t connect or turn on. Solution:

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Problem phenomenon: In the welder panel, the welding current or voltage is only half or several multiples of the welding parameter. Cause: The diameter of the welding wire was incorrectly selected. Solution: On the welder panel, adjust the diameter of the wire to match the diameter of the wire being used.

Cause: Caused by a sudden shutdown of the welder. Solution: Reconnect and continue.

Phenomenon:

Cause:

Solution: Tighten the screws on the gear or the connection between the motor and the gear. If the situation is serious: reconfigure the parameters of the driver motor).

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Phenomenon: The 3D camera lid cannot be closed.

Inspection:

Solution: Resolves based on inspection results.

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Phenomenon: The teaching panel cannot read the update file.

Inspection:

Caution: Inside the rtm_update folder there should not be another folder named rtm_update.

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Phenomenon: The torch cleaning station is unresponsive.

Inspection:

Solution: Resolves based on inspection results.

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Phenomenon: The screen on the teaching panel is not working.

Inspection:

Solution:

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Cause: The file on the higher-version card is not compatible with the lower-version software.

Phenomenon: Abnormal welding wire feeding. Analysis:

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Solution:

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Phenomenon: Missing components in the page layout.

Solution: Delete the file with the layout extension of the image and restart the software.

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