Chapter 4: Common Issues and Troubleshooting

1. Hardware Fault Handling

This troubleshooting guide lists 21 common issues encountered with robotic welding systems, including teach pendant errors, servo failures, arc faults, and encoder communication problems. Each problem is paired with a clear, actionable solution to help technicians and engineers diagnose faults quickly and restore system functionality with minimal downtime.

Robotic Welding Troubleshooting Guide: 21 Common Errors and Fixes

Identify and resolve frequent hardware and software issues affecting welding robots and teach pendants with clear, step-by-step solutions.

Serial Number	Problem Description	Solution Method
1	The teach pendant does not power on when the system is started.	Check whether the 24V power supply in the control cabinet is short-circuited (whether the short-circuit terminal block in the control cabinet is loose).
2	The teach pendant displays “Not Connected.”	Check whether the teach pendant cable is damaged. Set the corresponding IP address. Check whether the `network.cfg` file in the `fa` directory is corrupted. Change the IP address segment in the robot card file to match that of the teach pendant card file.
3	The servo cannot be powered on.	Check whether the teach pendant cable is damaged. Set the corresponding IP address. Check whether the `network.cfg` file in the `fa` directory is corrupted. Change the IP address segment in the robot card file to match that of the teach pendant card file.
4	Teach pendant safety door alarm.	Short-circuit the X12 safety door terminal block. Check whether the short-circuit jumper is loose.
5	Encoder connection error.	Check the bus wiring between the driver and the controller. Reconfigure the number of interpolated axes for the auxiliary axis: first set it to 0, shut down and restart, then reconfigure.
6	FF34: Master-slave following error too large.	Increase the maximum allowable error for the master-slave axes. Go to Position > Driver and re-record the gantry zero position. Use shielded cables for auxiliary axis wiring. Add shielding ferrite cores.
7	Arc ignition failed.	Check the welding machine ground cable. Go to Arc Welding > Welding Settings and disable Scratch Start. Insert a welding function reset command in the first line.
8	Wire explosion during welding.	Properly connect the welding machine ground cable. Check whether the P11 dual-pulse mode is enabled. Restore the welding machine to factory settings (press and hold the adjustment knob for about 5 seconds to reset parameters). Unplug the communication box, restart the welding machine, and simultaneously press the Save and Wire Diameter buttons to enter the internal settings. Adjust C04 to reduce the wire feed speed.
9	Robot Axis 1 alarm: following error too large.	Check whether the robot body cables are loose (high-flex cables must be used when routed through drag chains). Repeatedly press the enabling button and touch the first-axis motor to check whether the brake is released.
10	Arc re-ignition always fails after arc interruption during welding.	Go to Arc Welding > Welding Settings > Scratch Start and turn it ON (The scratch start switch corresponds to the arc break detection switch).
11	Arc welding function cannot be activated.	On the teach pendant main interface, open Settings > Application Selection, reselect the Arc Welding function, and click OK.
12	Wire sticking during arc ending (welding wire sticks to the weld seam).	Increase the welding machine’s P01 parameter (burnback time). The initial value is 0.08s; the recommended value is 0.15s. (After welding, observe the wire stick-out. Generally, after burnback, the stick-out should be maintained at about 10 mm.)
13	After the gantry is initially installed, the teach pendant does not report an error, but Can’t connect to the servo	Check whether the additional axis zero position is lost (Teach pendant monitoring – drive – additional axis zero position Marked in red)
14	The “Arc Welding” function of the teaching pendant cannot be turned on. Open and close automatically	Select “Settings” – “Application Selection” from the teach pendant menu, and reselect “Welding”. Save and restart the control cabinet.
15	The welding machine panel does not display current and voltage	1. Change the pulse mode to DC mode (CO2 gas does not support pulse welding mode) 2. The welder curve parameters do not match (the welder does not support PO mode)
16	Welding machine arc alarm	Take apart the communication line and connect the shielding wires at both ends to the corresponding pins. Generally, the communication line sent is only connected to the shielding wire at the welding machine end. If it is wrong, it is recommended to connect the control cabinet end shield
17	Water cooling alarm EOA	The welding machine in normal use suddenly has a water cooling alarm. After restarting the water cooling cycle for many times, the alarm still occurs. First check whether the water level has reached the minimum water level line, whether there is air or dirt in the pipe and welding gun, and whether the filter is too dirty and needs to be cleaned. Finally, check whether the hidden parameter P10 is set to automatic cycle NO. Place it on top.
18	When replacing the teaching pendant, an error message appears. Clear it normally. Global variable error	Press the white button in the controller inside the control cabinet to find the corresponding alarm and eliminate it.
19	The emergency stop error of the teaching pendant cannot be cleared	Check whether the circuit next to the emergency stop relay is loose Check the safety relay and turn the rotary knob of the safety relay
20	Robot joint motion alarm axis 1 encoder Communication abnormality	Check whether the needle in the encoder’s air plug is retracted. Push the pin forward to the right position
21	By joint, user moves robot 2 axis 0XFF8D Motor stall fault, 0X108611 Position following error is large	Re-plug the line under J2 in the driver and tighten it.

2. Software Issue Handling

This quick-reference troubleshooting table outlines key issues encountered during rib plate scanning, point cloud capture, and automatic weld programming. With each problem clearly described and paired with targeted diagnostic steps, this guide helps operators quickly identify misconfigurations in PCS parameters, camera settings, IO signals, and welding process packages.

Rib Plate Scanning and Programming Troubleshooting Guide

Resolve common issues in steel rib automation, scanning errors, missing cameras, and process package mismatches—with this focused guide.

Serial Number	Problem Description	Solution Method
1	After generating the rib plate, click Sweep Weld from Current Line Posterior movement abnormalities	Check whether the safety point under PCS is set correctly Check whether the benchmark record is successful or reasonable
2	After the ribs are generated, the node machine is scanned globally. Robot data and additional axis data are abnormal	Check whether the additional axis data superimposed axis number and direction are set correctly under PCS
3	When performing precise scanning of the rib plate, the three-way The number of cameras connected is 0	Check whether the camera name is correctly filled in under the composite vision of steel parameters
4	Click to stop scanning from the current line scanning	Check whether the continuous switch of the operating parameters in the system global parameters is turned on. Check whether the IO number at the end of the program operation in the station design is filled in normally
5	Point cloud is not displayed when collecting with large camera	Check whether the network bandwidth is Gigabit
6	After the rib plate is accurately scanned, the program is automatically created. It shows that the welding process package cannot be found	Check whether there is a corresponding welding foot process item match in the welding process package

July 16, 2025
9:47 am

Chapter 4: Common Issues and Troubleshooting