This came straight from Bystronic USA Service Dept:
The W axis warning is when the reported capacitive signal is not what was expected. The signal is not so far off that it generates and error, but it is far enough out of range that it will post a warning.
Most of the time the warning simply means the cutting head is dirty and needs to be cleaned up thoroughly. This means removing the 9pin print on the cutting head and removing the assembly with the nozzle adjustment screws. Inside the unit with the adjustment screws is a ring and contact print (the contact print is the flat board with the white wire connected to it). If moisture or oil gets up around the ring or behind the contact print it effects the signal. If the contact print is removed from the ring you will see a gap in the print between the solder mounted spring and the grounding surface of the print. Sometimes debris builds between this print gap and effects the signal and the contact print should be replaced. There is a small brass pin that is mounted inside a Teflon sleeve that the contact print spring pushes against. Dirt and debris builds up in that Teflon channel and can effect the signal as well. Either of the cutting head ceramics may be dirty or cracked and effecting the signal. Any, and all, of these items can cause a W axis warning.
If the head is completely and thoroughly cleaned and the W axis warning does not go away, the problem is probably third party components. I’ve seen customers using ceramics, nozzles, and nozzle bodies from third party sources that are simply garbage and can never get the W axis warning to go away. When they replace those items with Bystronic OEM materials the warning is gone. I don’t know if it is because of machining tolerances or material composition, but I’ve seen countless accounts correct the warning by using OEM parts.
Hope this helps
