An alarm text describes a symptom, not a cause. Treating the alarm description as the root cause, or treating “it seems fine now” as solved, are the two most common mistakes in welding robot troubleshooting. This welding robot alarm troubleshooting guide sets out a simple method, applies it to the alarms seen most often on JTCLASER programming-free workstations, and lists what to send technical support in the first message.
How do you troubleshoot a welding robot alarm?
Record before you reset: alarm screen, stopped program line with a few lines around it, whether it happened while scanning or welding, the full robot pose, the parameter pages and what was changed. Treat the alarm text as a symptom, change one thing at a time, and call a fault fixed only after a repeat test under the same conditions.
1What is the basic method for welding robot alarm troubleshooting?
- Separate what was seen from what was guessed
Alarm text and screenshots are facts. “It hit a limit” is a guess until it is checked.
- Write conclusions in three layers
Confirmed observations; best-supported direction; still-unconfirmed cause. Never present the third as the first.
- Keep layers apart
Robot motion alarms, PC software errors and procedure-match messages are different kinds of problem. Appearing one after another does not make one cause the other.
- Do not generalise one-off values
A setting that fixed one part on one machine is not a standard setting.
- Solved means repeat-tested
One good run is not proof; repeat under the same conditions.
A broader overview is in common troubleshooting methods.
2How do you handle a linear motion alarm such as EFORT 1801?
EFORT alarm 1801, Move linear error (code=-2), only says a linear move could not be executed. On its own it does not prove an axis hit a limit or that the part was misplaced.
The same seam point can be reached with different torch angles, and each angle means different joint angles. Some poses allow a straight move; others run into a joint range or pass near a singularity. That is why the same position can weld one day and alarm the next after a scan setting changes.
- Note whether it happened while scanning or welding
During scanning, the scan pose and path (scan angle, reference point, transition offsets) come first.
- Photograph the stopped program line and the full robot pose
Including torch and camera orientation.
- Record what changed and its old value
“It works after I changed a parameter” must say which one, from what to what.
- Stop rescanning if it repeats
Send the information to technical support instead.
3What does “weld procedure not matched” mean?
A message such as No procedure group for FILLET_R, Leg=3.0 under CO2 solid wire means the combination the seam asks for (joint type, leg size and wire) has no entry in the procedure library currently loaded.
- Photograph the package the seam references and what it requests
Joint type, leg size and wire.
- Open the loaded library and check for a matching entry
- Let support confirm where the difference is
Either the seam should request something else, or the library is missing a confirmed procedure.
4What should you send technical support?
Send everything in the first message to avoid several rounds of questions. Use the service request form.
| Information | Español |
|---|---|
| Alarm photo, then program position | Foto de la alarma y, tras cerrarla, foto de la posición en el programa. |
| Stopped line with lines around it | La línea donde se paró y algunas líneas antes y después. |
| Scanning or welding? | Si ocurrió durante el escaneo o la soldadura. |
| Full robot pose | Foto de la posición completa del robot. |
| Node, package and weld file pages | Fotos de la configuración del nodo, del paquete de soldadura y del archivo de soldadura. |
| Path preview | Captura de la vista previa de trayectoria. |
| What changed and the old value | Qué se cambió antes de la alarma y cuál era el valor anterior. |
For arc problems rather than alarms, see robotic welding arc start failure.
Frequently asked questions
Does EFORT alarm 1801 mean the robot hit a limit?
Not necessarily. 1801 code=-2 only says a linear move failed. Joint range, a singularity or an unreachable point are possible; judge from pose and path.
Can I fix a procedure match error by changing the leg size?
No. Leg size determines weld strength. Compare the requested values with the loaded library and set the leg size from the drawing.
If the robot seems fixed, is the fault solved?
Only after a repeat test under the same conditions confirms it.
Send us the alarm
Use the service request form with the photos listed above. Our engineers will reply with the next step.
- JTCLASER field commissioning and after-sales records, 2026