TCP Force Exceeded User Limit

When error [2.9015] occurs, the robot stops with the error message below.

• The robot stops when the tool touches something, or at the same point of a program every time.
• Sometimes it stops even though nothing is touching the tool — for example during jogging, or at a certain posture.

[2.9015] Control algorithm category

TCP force has exceeded user limit.
Param 1: Detailed cause

This is a safety function. The robot estimates the external force acting on the tool (TCP), and stops when that force exceeds the TCP force limit set in the safety settings.

• Real contact — the tool or workpiece touches a jig, a conveyor, a cable or a person.
• Wrong tool settings — the tool weight or center of gravity in the settings does not match the real tool and workpiece, so the robot reads the difference as an external force.
• Aggressive motion — high acceleration, or motion close to a singular posture, produces a large estimated force.
• Limit set too low — the TCP force limit is lower than the task needs.
• Sensor drift or a fault in a joint — the force is misread even without contact. This needs service.

• Look for anything the tool, workpiece or cables could touch at the point where the robot stops, and remove it.
• Check that the tool weight and center of gravity in the tool settings match the real tool, including the workpiece when it is held. Make sure the correct tool is selected in the program.
• If the error happens at the same motion every time, lower the acceleration and speed of that motion. If the robot passes close to a singular posture there, change the waypoint.
• If the limit is too low for the task, raise the TCP force limit in the safety settings, within what your risk assessment allows. In a collaborative zone, the limit for the reduced mode applies.
• With nothing touching the tool, check the TCP force shown on the teach pendant. If it is far from zero while the robot is still, the sensors need attention — contact your distributor.

• Robot model and serial number
• Software version of the controller
• The error code with its Param value, all codes shown with it, and the date and time
• The tool weight and center of gravity settings, and a photo of the tool
• The TCP force shown on the teach pendant with the robot standing still and nothing touching it
• The controller log exported right after the error

• 2.9011 Collision has been detected
• 2.9010 Joint torque has exceeded user limit in at least one joint
• 5.7064 TCP force has exceeded user limit (safety controller)
• 5.7060 Collision has been detected (safety controller)
• 2.3509 Commanded motion can be unstable in the vicinity of singular configuration