FAQ

Problem Description:

Encoder connection error

Solution Method:

1.Check the bus wiring between the driver and the controller.
2.Reconfigure the number of additional axes for interpolation: first set it to 0, power off and restart, then set it again.

Problem Description:

Teach pendant shows “Not Connected.”

Solution Method:

1.Check if the teach pendant cable is damaged.
2.Set the corresponding IP address.
3.Check if the network.cfg file in the fa folder is corrupted.
4.Modify the IP segment in the robot card file to match the teach pendant card file

Problem Description:

Servo cannot power on.

Solution Method:

1.Use a debug cable to connect the computer to the corresponding additional axis driver, open DriveMaster.exe, then click Edit → Debug → Control Authority → Switch Control Authority.
2.Log into the software and check if the robot main body control authority has switched.
3.After ruling out the first two steps, check if any main body servo inside the control cabinet shows an alarm. If a servo alarm occurs, the teach pendant won’t display the alarm but will only show failure to power on. Swap the
driver connectors to see if the error follows.

Problem Description:

After connection,the robot does not move when position and posture control is commanded in the software.

Solution Method:

1.Check if the arc welding function is enabled.
2.Re-import the card file.

Problem Description:

After connection, the robot data does not accumulate additional axis data.

Solution Method:

Check the number of additional interpolation axes. (When the interpolation number is 0, additional axis data does not accumulate and cannot synchronize.)

Problem Description:

Arc ignition failure.

Solution Method:

Check the welder grounding wire.
Open Arc Welding → Welding Settings → Turn off Scratch Start.
Insert the welding function reset command in the first line.

Problem Description:

Welding stopped at one position.

Solution Method:

Open Arc Welding → Welding Settings → Turn off Arc Restart Detection.

Problem Description:

Arc does not extinguish at the end point after welding.

Solution Method:

Replace the arc_welding.obb file under ob_sys in the card file, then open ob.cfg to check if the values match the picture.

Problem Description:

During ground rail model drive operation, the first safety point reports a joint movement error.

Solution Method:

Set the teach pendant additional axis direction to -1.
Set the workstation design X-axis direction to 1.

Problem Description:

The rib plate is too high and hits the camera box during welding

Solution Method:

Adjust the welding process package B angle and the start and end point inward angle

Problem Description:

Abnormal right angle points in polished workpiece

Solution Method:

Modify common parameters – laser parameters – internal and external right angle calculation intersection method – intersection of the two longest straight lines on the left and right
Modify common parameters – laser node scanning – internal right angle point selection type – P1 corner seam internal intersection
Temporarily modify the Rx angle during scanning (within ±20)

Problem Description:

After the SD card is formatted, the teaching pendant shows that it is not connected and the controller screen does not display

Solution Method:

When formatting the card file, make sure to format it as FAT32.

Problem Description:

Line laser and camera conflict, causing one of them to not open.

Solution Method:

The line laser IP cannot be higher than the computer’s IP; otherwise, it will cause conflicts between the line laser and the camera, resulting in camera opening errors or failure to connect to the line laser.

Problem Description:

Opening the line laser causes an error: “CICLR.dll”.

Solution Method:

Copy the CICLR.dll file from a working SW software into the folder.
Configure the Windows system runtime environment files (this issue usually occurs on newly installed or freshly reinstalled computers).

Problem Description:

Abnormal right-angle point picking inside the H-beam submerged arc weld seam.

Solution Method:

Modify common parameters — Laser parameters — Inner and outer right-angle intersection calculation method — Intersection of the two longest left and right lines.
Modify common parameters — Laser node scanning — Inner right-angle point picking type — P1 corner seam inner intersection.

Problem Description:

Camera shows no image when taking a photo

Solution Method:

The camera takes a photo beyond the calibrated range, resulting in no image.

Problem Description:

Model driver has unassigned nodes.

Solution Method:

Modify the upper and lower limits of the additional axes in the workstation design.
Adjust the PCS working area range. Based on the actual measurements of the robot size and worktable height on site, setting the area too large may cause scanning to exceed limits, while setting it too small may cause welding to exceed limits.

Problem Description:

The point laser distance measurement always has a fixed error.

Solution Method:

Adjust the installation error between the point laser and the camera in the workstation design.
Set the correction value in the product support parameters.

Problem Description:

When welding, collision occurs from the transition point to the welding start point.

Solution Method:

In the common parameters, enable the starting point welding torch bottom transition point and set the transition height properly to avoid torch collision.
According to the working conditions, set appropriate rightward and forward offset distances.

Problem Description:

Scanning B angle always exceeds the limit

Solution Method:

In the common parameters, the laser parameters adjust the laser scanning B angle. (Note: the modification and application of the B angle requires verification of the laser. Changes in the B angle may cause inaccurate lasers. The same is true for welding. The angle is not fixed.)

Problem Description:

The error of the scanning laser Z value is too large/or the laser imaging is reversed

Solution Method:

Design of workstation – Line laser – Laser forward installation direction – Adjust direction
Design of workstation – Line laser – Laser Z direction inversion – Select the appropriate one
If the scanning space of the workpiece is too small, you can increase or decrease the Z direction offset value of the laser reference point

Problem Description:

Xiaobudian laser software has no imaging or cannot connect.

Solution Method:

Open Xiaobudian’s Shuoshu configuration file and check if the IP, port number, and MAC address correspond.
Ensure the computer firewall is turned off, and both the computer and Xiaobudian are set within the same local network.
In Xiaobudian’s built-in software backend, select external synchronization and write the parameters accordingly.

Problem Description:

Spot welding B prompts: process package not found.

Solution Method:

Select the corresponding process package and add the corresponding welding process items.
Check whether the robot folder in the setting file contains the process package file, or replace the process package file again.

Problem Description:

Robot posture changes significantly during fillet welding.

Solution Method:

Check the corresponding process package options.
Modify the B and B2 angle parameters in the fillet welding control section of the welding process package.

Problem Description:

WN11 quadrilateral flat stiffener plate joint

Solution Method:

When d1 is less than or equal to 10, complete the four flat fillet welds in one pass; pay attention to the direction of the lines.
When d1 is greater than 10, divide the four flat fillet welds into four passes to complete the welding.

Problem Description:

In auxiliary point settings, the PCS coordinate values do not read the coordinates from the current pose; the refreshed values are abnormal.

Solution Method:

Open station design, delete PCS, and re-add PCS with new coordinate points entered.

Problem Description:

Camera calibration data is not being recorded.

Solution Method:

Open the setting file and delete the camera calibration file.
Open the software, click on camera calibration, and recreate a new camera calibration file.

Problem Description:

After replacing the teach pendant, an error occurs: the global variable error cannot be cleared by normal methods.

Solution Method:

Press the white button on the controller inside the control cabinet to locate and clear the corresponding alarm.

Problem Description:

Teach pendant alarm 4208

Solution Method:

Cause: This is a CAN heartbeat error, an alarm on welding machines below version 2.1. Even after connecting the welder, the alarm cannot be cleared and requires restarting the control cabinet.
Solution: Upgrade the card file.

Problem Description:

After scanning the gantry workstation, starting welding causes an error; during verification at the robot’s C-axis 0-degree position, the line laser moves to the 180-degree direction.

Solution Method:

Open the tool coordinate system, select tool=1, and change the C-axis from 180 to 0.
(After reversing the robot tool calibration, subtract 180 from the B-axis value; set the C-axis to 0. The user coordinate system C-axis needs to be set to 180.)

Problem Description:

Robot axis 1 alarm: following error too large.

Solution Method:

Check if the robot body cables are loose (use high-flex cables when routed through drag chains).
Repeatedly press the manual hold button and feel the first-axis motor to see if the brake is releasing.

Problem Description:

Arc restart always fails after arc interruption during welding.

Solution Method:

Open Arc Welding → Welding Settings → Enable Scratching Start
(The scratching start switch corresponds to the arc break detection switch.)

Problem Description:

There is a pause between interpolation points during welding.

Solution Method:

Change Fine in the welding instructions to Z10 (for arc transition).
Do not change the final point in the welding instruction; otherwise, with Z equal to 10, the last 10mm will remain unwelded.

Problem Description:

Arc welding function cannot be opened.

Solution Method:

On the teach pendant main interface, open Settings → Application Selection, reselect the Arc Welding function, and click OK.

Problem Description:

Laser scanning points are normal, but the welding B pattern is abnormal.

Solution Method:

Ensure the tool is properly calibrated before updating the software.

Problem Description:

The scanned points are too close to the stiffener plate, increasing the risk of torch collision.

Solution Method:

Adjust the shared parameters for stiffener inward offset and flange end inward offset.
(For stiffener and flange inward offsets, ensure no torch collision and proper operation:

Distances 1 and 2 should be as small as possible.
The difference between distances 3 and 2 should be as large as possible.)

Problem Description:

The “Arc Welding” function on the teach pendant cannot be opened—it closes immediately after being opened.

Solution Method:

Select “Settings” → “Application Selection” from the teach pendant menu, reselect “Welding”, save and restart the control cabinet.

Problem Description:

After initial gantry installation, the teach pendant shows no error but the servo cannot be powered on.

Solution Method:

Check if the auxiliary axis zero position is lost (Teach pendant → Monitoring → Driver → Auxiliary axis zero position marked in red).
Re-import the auxiliary axis motor parameters.

Problem Description:

Teach pendant can power on servo normally, but software shows power-on failure.

Solution Method:

Test with another SW software package that works normally on-site.
Test using the standard version card file to see if it functions properly.

Problem Description:

OTAI welder alarm E42, communication light not lit.

Solution Method:

Press the black button on the back of the welder.

Problem Description:

The coordinate system has no data, but the robot can be moved using the teach pendant.

Solution Method:

Load a teach program or create a new teach program.

Problem Description:

Teach pendant reports DC bus undervoltage on axes 1–6.

Solution Method:

Check if the 16A fuse inside the control cabinet is normal (use a multimeter to check continuity; if no continuity, replace the fuse).
Replace the six-axis driver.

Problem Description:

Teach pendant not connected, controller reports SD file read error.

Solution Method:

Replace the SD card inside the controller.

Problem Description:

After powering the control cabinet, the controller does not operate.

Solution Method:

Check whether terminal block pins 5 (24V VP) and 7 (24V VG) on the controller have a 24V voltage difference. If not, inspect the wiring; if yes, replace the controller.

Problem Description:

The teach pendant occasionally reports an emergency stop without the emergency stop button being pressed.

Solution Method:

Check if the safety module 750105 has an HT suffix at the back; if not, the safety module needs to be replaced.
(Note: Since 2022, robot safety modules all have HT. After replacement, rotate the three red buttons’ dial switches to match the previous settings.)

Problem Description:

Controller reports “13 FPGA program fail.”

Solution Method:

Controller firmware mismatch; the controller firmware needs to be upgraded. Different controllers require matching different firmware versions.

Problem Description:

After controller replacement, alarm persists; cannot clear after IO module update.

Solution Method:

The controller did not detect the IO module; check whether the controller and IO module are properly installed.

Problem Description:

After connection, pose control moving the robot reports error or moves to incorrect position.

Solution Method:

Check whether the PCS values in pose control match the user coordinate system in the teach pendant (PCS1~5 in the software’s station design need to be the same as the wobj values in the teach pendant).

Problem Description:

After upgrading to version 3.1.1, unable to upload values from the software to the teach pendant.

Solution Method:

You need to select the robot and enter version number 3.1.1 in the station design.

Problem Description:

After software update, connection error occurs; message bar shows “Startup monitoring failed.”

Solution Method:

After software version 7.16, you need to add the positioner option in the teach pendant application, then restart the control cabinet.

Problem Description:

Abnormal welding trajectory transition points.

Solution Method:

Check whether the minimum safe transition height in the node parameters and common parameters is correctly filled.
Check if the robot orientation in the workstation matches the actual installation direction.
The minimum Z value for the transition point is -899; try to keep the Z value in the user coordinate system positive (generally, for gantry inverted robots, not setting the user coordinate system Z value causes transition point abnormalities).

Problem Description:

Line laser software camera reports an error after photo capture completion

Solution Method:

No camera calibration data in the software

Use the built-in camera software to capture an image for calibration, save it, and then proceed with calibration.
Import a camera data file that has already been calibrated from another settings file, rename the camera accordingly, and then proceed with calibration.

Problem Description:

After the card file upgrade, upon startup, hardware configuration errors such as 988 IO modules and emergency stop signal alarms occur.

Solution Method:

Click the ❌ icon in the red box or press the F1 button on the teach pendant panel to hide the alarm. Then go to IO settings to update the IO modules. After updating, wait for the controller to restart, and it will return to normal.

Problem Description:

Error 9202 reported during startup.

Solution Method:

The problem is due to the IP address in the dns-1.cfg file inside the FA folder on the SD card not matching the controller’s IP address. Adjust it to ensure they are consistent.

Problem Description:

After powering on the control cabinet, the teach pendant continuously displays “Please wait: booting.”

Solution Method:

Use a USB drive to update the teach pendant version again (the version must match; you can check the card file version by viewing the Rde_Version.cfg file under the fm folder on the SD card).

Problem Description:

When switching the teach pendant to automatic mode and pressing the power button (PWR), an alarm occurs.

Solution Method:

Locate the command line elec_man.enable_confirmbutton = 1; in the controller_config.cfg file within the FA folder on the SD card, change the number 1 to 0, and save.

Problem Description:

Teach pendant alarm 4812: fault code history abnormality.

Solution Method:

Check whether the driver in the control cabinet is alarming. This is usually caused by turning off the control cabinet power while the robot is still powered on. (Restarting the control cabinet can usually clear the error.)

Problem Description:

Dual-machine linkage program error, abnormal monitoring data

Solution Method:

Calculation anomalies caused by differing coordinate systems recorded by the main control and auxiliary control lead to limit exceedance.

Problem Description:

Teach pendant and driver alarm FF08

Solution Method:

If the error occurs occasionally and can be cleared, check whether the motor terminal cables and additional axis driver cables are securely fastened, and consider adding ferrite cores or similar measures.
If the error cannot be cleared, replace the motor or the additional axis driver.

Problem Description:

The CALL in the teach program is missing arcweld.

Solution Method:

The cause is the welding application not being added.
You need to select and add the welding application in the settings, then restart the controller.

Problem Description:

3D camera software error on startup: “VSensorSDKCLR.dll”

Solution Method:

During use, the 3D camera’s built-in SDK files are corrupted; reinstall the camera’s built-in software.
Update Windows runtime environment files.
Update the software.

Problem Description:

3D camera built-in software error, camera blue light flashing.

Solution Method:

Check if the camera’s built-in software is the latest version.
Check if the camera temperature is too high (if overheating, cool it down; generally below 55°C).
Check if the camera power adapter is 12V.

Problem Description:

After connecting the MindVision camera to the network cable, the camera cannot be detected

Solution Method:

This is caused by incompatibility between the new version of the MindVision camera and our current software version (update to the latest camera software version, available for download on the official website).

Problem Description:

Error in program auto-generated movement command.

Solution Method:

The instruction lines in our program do not correspond with those on the teach pendant (e.g., joint move speed commands only have 25%, 50%, 75%, and 100% options).

Problem Description:

After upgrading to card file version 3.1.1, moving the robot reports error: “Five-axis collision occurred.”

Solution Method:

The collision detection switch needs to be turned off in the application program.

Problem Description:

Servo cannot power on.

Solution Method:

Check if there is an alarm on the external auxiliary axis driver of the teach pendant (if yes, reset the encoder and see if it can power on normally).
Use a debug cable to connect the computer to the corresponding auxiliary axis driver, open DriveMaster.exe, and click in order: Edit → Debug → Control Authority → Switch Control Authority.

Problem Description:

Servo cannot power on, no alarm on the teach pendant.

Solution Method:

After eliminating the first two causes, check whether there are alarms on the servo of the control cabinet main unit and in the robot’s six-axis software (resolve according to the alarm type).

Problem Description:

Servo cannot power on, all six-axis drivers show red lights, no alarm on the teach pendant.

Solution Method:

Problem Description:

Servo cannot power on, one axis of the six-axis driver shows a red light, no alarm on the teach pendant.

Solution Method:

First, if the six-axis alarms but the teach pendant shows no alarm, eliminate teach pendant and communication issues.
Use DriveStarter software to read auxiliary axis alarm information (single-axis alarm).
It is most likely a driver power input abnormality. Test the power input.
Testing sequence:
Test the R, S, and T input terminals of the six-axis driver by measuring voltage between each pair. If all three wires have no voltage, check whether the external power supply from the power box to the control cabinet has 380V.
If one wire has no 220V, test the continuity of the labeled cable in that line.

Problem Description:

Teach pendant reports zero point lost, and there is no data in the coordinate system under position monitoring.

Solution Method:

Manually move the robot back to the zero position, then go to Monitoring → Driver and re-record the zero point for axes 1–6 one by one.
(If there are external auxiliary axes, also move them to zero position and re-record.)

Problem Description:

3D camera software error: unable to select process package and open station design.

Solution Method:

Replace the setting file
Reinstall or update the 3D camera software

Problem Description:

Software page layout is messed up or a certain page cannot be found.

Solution Method:

Right-click the software icon on the desktop → Open file location → Find and delete the XML file with the Layout suffix (deleting it will reset the page layout to default).

Problem Description:

Robot triggers limit alarm during movement and cannot clear it.

Solution Method:

Restart the control cabinet
Manually push the welding torch to trigger the anti-collision sensor, then clear the alarm

Problem Description:

After the welding torch collides with an object and triggers the anti-collision sensor, the alarm cannot be cleared.

Solution Method:

Turn off collision detection in device settings → clear the alarm and move the robot (collision detection must be turned back on after movement).
If the collision is severe, an X-axis overload may appear after clearing the alarm. Try clearing the alarm repeatedly; if it cannot be cleared, move the collided object to eliminate the alarm.

Problem Description:

Error occurs after upgrading card file of new six-axis drive in control cabinet

Solution Method:

Since September 2022, a new RD driver was added. This driver uses a card file partially different from the R6 driver we used before, so they must be distinguished during upgrade.
(The error reported is encoder abnormal connection error.)

Problem Description:

Robot stops and does not move at the ArcOn instruction line

Solution Method:

When the robot repeatedly runs the ArcOn instruction, it may stop and not proceed with the program.
Check if the program has duplicate ArcOn commands, then manually reset the welding signal or let the program pass through the ArcOff instruction to turn off the arc-start signal.

Problem Description:

Task displays: frequency reduced, stuck on loading continuously

Solution Method:

Locate the welding task file in the rpl folder within the card files and delete it.
Reason: The welding file fails to load

Problem Description:

Teach pendant not connected, controller alarm code 3909:

Solution Method:

(1) Check whether the 3A network port (teach pendant) indicator light is normal. If the indicator light is off:
① Check whether the teach pendant connector pins are bent.
② Swap the teach pendant to rule out pendant issues (if replacing with another teach pendant restores normal operation, it is determined to be a teach pendant problem; if alarm 3909 still occurs, consider the following causes)

Indicator light on: The card file has an issue; update it with the standard card file.
Note: When updating the card file, do not replace the files. Manually modify the IP and DH parameters. First, ensure the robot can operate normally.

Problem Description:

Teach pendant alarms for control cabinet overheating, emergency stop, and safety door alarm.

Solution Method:

Update the IO module.
If the error persists:
• Press vertically on controller and terminal block to ensure proper connection.
• Check if terminal block is powered (old version flashes red; new version’s yellow light may not light).
• Check rear bus module connection and pins.
• Confirm IO power supply wiring harness is properly connected.
• Ensure the short plug bar on the cabinet’s right end is inserted securely.

Problem Description:

Startup alarm 9001: Ambiguity in user register definition.

Solution Method:

Press and hold the alarm reset button on the controller until the alarm is cleared, then release.

Problem Description:

After card file upgrade, the teach pendant shows startup alarm 985.

Solution Method:

Reason: The elf and bin format files in the F@ folder have different version names, causing duplication.
Solution: Delete the entire F@ folder before upgrading the card file and re-import it.

Problem Description:

Software line drawing node error: incorrect string format (also occurs offline).

Solution Method:

Cause: A nested Nodelist file exists in the Nodelist folder.
Solution: Delete the nested Nodelist.

Problem Description:

Teach pendant alarm 9203

Solution Method:

Cause: Welder communication interference.
Solution:

Upgrade to version 3.2.0 or above.
Or insert “-9203” under command lines 1000–1199 in the alusr file (located in the fa folder) to suppress the alarm.

Problem Description:

After startup, the robot’s teach pendant shows fault alarm indicating loss of zero position.

Solution Method:

Go to “Monitoring >> Driver >> Zero Position Status” and check for red indicators.
Record joint axis zero positions, reset encoders, and zero axes with red lights.
Re-enter recorded joint positions with opposite values or perform zero calibration.

Problem Description:

Teach pendant alarm 4208

Solution Method:

Cause: CAN heartbeat error (seen in welders below version 2.1).
Solution: Upgrade the card file and restart the control cabinet.

Problem Description:

Teach pendant alarm 9203

Solution Method:

Cause: Welder communication interference; occasionally clears itself.
Solution: Upgrade to version 3.2.0 or above to eliminate this error, or insert “-9203” in command lines 1000 to 1199 of the alusr file located in the fa folder to suppress the alarm

Problem Description:

After powering on, the teach pendant shows fault alarm indicating zero-point position loss.

Solution Method:

Check under “Monitoring >> Driver >> Zero Position Status” for a red status
indicator. Record the current joint zero position of the axis, reset the encoder and zero the axis of the axis with the red light. Then re-enter the previously recorded joint position with the opposite value to reset the zero position or perform zero position calibration

Problem Description:

Error when opening node scanning after drawing nodes

Solution Method:

Cause: 3D camera not configured in the workstation design.

Problem Description:

Model drive running program alarm: “Program source file does not exist.”

Solution Method:

Cause: Uploaded file contains Chinese characters, symbols, or decimals.
Solution: Rename or clean the filename before upload.

Problem Description:

Servo driver FF58: excessive position deviation at power-up.

Solution Method:

Cause: Position mismatch after replacing servo or motor.
Solution: Perform encoder reset via teach pendant or DriveMaster.exe.

Problem Description:

Servo driver FF66 brake circuit error

Solution Method:

Power-on alarm:
- Check wiring between driver and relay
- Check relay power
- Check relay contact integrity and yellow driver connector wires
Driver may be damaged
Movement alarm: Slightly loosen gearbox fixing screws

Problem Description:

Welder panel does not display current or voltage

Solution Method:

Switch pulse mode to DC (CO₂ doesn’t support pulse).
Ensure welding curve parameters match; PO mode may not be supported.

Table of Contents

Problem Description:

Encoder connection error

Solution Method:

Problem Description:

Teach pendant shows “Not Connected.”

Solution Method:

Problem Description:

Servo cannot power on.

Solution Method:

Problem Description:

After connection,the robot does not move when position and posture control is commanded in the software.

Solution Method:

Problem Description:

After connection, the robot data does not accumulate additional axis data.

Solution Method:

Problem Description:

Arc ignition failure.

Solution Method:

Problem Description:

Welding stopped at one position.

Solution Method:

Problem Description:

Arc does not extinguish at the end point after welding.

Solution Method:

Problem Description:

During ground rail model drive operation, the first safety point reports a joint movement error.

Solution Method:

Problem Description:

The rib plate is too high and hits the camera box during welding

Solution Method:

Problem Description:

Abnormal right angle points in polished workpiece

Solution Method:

Problem Description:

After the SD card is formatted, the teaching pendant shows that it is not connected and the controller screen does not display

Solution Method:

Problem Description:

Line laser and camera conflict, causing one of them to not open.

Solution Method:

Problem Description:

Opening the line laser causes an error: “CICLR.dll”.

Solution Method:

Problem Description:

Abnormal right-angle point picking inside the H-beam submerged arc weld seam.

Solution Method:

Problem Description:

Camera shows no image when taking a photo

Solution Method:

Problem Description:

Model driver has unassigned nodes.

Solution Method:

Problem Description:

The point laser distance measurement always has a fixed error.

Solution Method:

Problem Description:

When welding, collision occurs from the transition point to the welding start point.

Solution Method:

Problem Description:

Scanning B angle always exceeds the limit

Solution Method:

Problem Description:

The error of the scanning laser Z value is too large/or the laser imaging is reversed

Solution Method:

Problem Description:

Xiaobudian laser software has no imaging or cannot connect.

Solution Method:

Problem Description:

Spot welding B prompts: process package not found.

Solution Method:

Problem Description:

Robot posture changes significantly during fillet welding.

Solution Method:

Problem Description:

WN11 quadrilateral flat stiffener plate joint

Solution Method:

Problem Description:

In auxiliary point settings, the PCS coordinate values do not read the coordinates from the current pose; the refreshed values are abnormal.

Solution Method: