Contact US

Log In

Come Join Us!

Are you an
Engineering professional?
Join Eng-Tips Forums!
  • Talk With Other Members
  • Be Notified Of Responses
    To Your Posts
  • Keyword Search
  • One-Click Access To Your
    Favorite Forums
  • Automated Signatures
    On Your Posts
  • Best Of All, It's Free!

*Eng-Tips's functionality depends on members receiving e-mail. By joining you are opting in to receive e-mail.

Posting Guidelines

Promoting, selling, recruiting, coursework and thesis posting is forbidden.

Students Click Here

Bystronic 6Kw Bystar "W-Axis warning error"

Bystronic 6Kw Bystar "W-Axis warning error"

Bystronic 6Kw Bystar "W-Axis warning error"

Hi all,
I am currently using a Bystronic Bystar 6kw. I have a      W-axis warning error that i cant seem to fix. I call LMC (Bystronic representative in Australia) But it seem like they dont know how to fix the problem aswell. Any one out there can help me out with this problem.?  

RE: Bystronic 6Kw Bystar "W-Axis warning error"

If you could e-mail me your contact info I could help redirecting you to the right people on this matter.


RE: Bystronic 6Kw Bystar "W-Axis warning error"

Hi KonQueR,

Is this just happening when the head lowering? Asked a bystronic service engineer about this before. The answer i got was that its down to the capacative sensing and the detected frequency being outside range. I waas none the wiser after that explanation but he didn't seem too worried about it. We're still cutting fine. Possibly an issue with the sensor board and associated equipment at the back of the head of where the sensor board "plugs" into the carriage back plate.
If your situation is similar to ours, then you should be able to cut.
Have you noticed a deterioraation in the quality of cut?
I should say that we're working off an old 3.5kW model. New machines might be different

RE: Bystronic 6Kw Bystar "W-Axis warning error"

Yes Bruno,it only happen when the head is lowering.
I try changing the bearing but it only work for a short time. The other reason LMC gives me is that the W-axis card need replacing but that would take 3-4weeks.
The machine still work fine, quality is very good. This W-axis warning error happen to alot of Bystronic Bystar and Byspeed. I have same problem with Bystar 4kw Byspeed 4.4Kw 5.2Kw. Bystronic should really have a look at this.

RE: Bystronic 6Kw Bystar "W-Axis warning error"

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

RE: Bystronic 6Kw Bystar "W-Axis warning error"

Hi All
i have worked for Bystronic for over 15years so i hope i can help. At present my role is senior service tech laser waterjet and press brake for Bystronic.

W- axis freq error is caused by the measured freq being outside the free running freq set by the controller.

Ofirst exchange all ceramics and clean the cutting nozzle holder and area with alchahol. Next check that there is no water in the d-sub connector which can leak from the above fitting. with a meter check for resistance between the nozzle and the machine. If no resistance there is a short in the cutting head or nozzle assy. Also check the rey block to make sure its clean an has less than .1 ohm between it and machine.

normally it turns out to be dirt water or faulty sensos. Small PCB in head.

RE: Bystronic 6Kw Bystar "W-Axis warning error"

Worked on Bystronic for over 12 years. Have you recently changed your ceramic nozzle body to the new type?

RE: Bystronic 6Kw Bystar "W-Axis warning error"

Cancel that suggestion as it is only relevant to the Byspeed. Captain Fantastic has the answer though. It is very easy to check over if you have a head that currently works, as all parts are interchangeable. Just be careful about the lens holder and the gas flow tube on top of the diode holder. These are head specific. I suggest changing the ceramics first then the board on the back of the head, if this fails move on to the diode block.

Red Flag This Post

Please let us know here why this post is inappropriate. Reasons such as off-topic, duplicates, flames, illegal, vulgar, or students posting their homework.

Red Flag Submitted

Thank you for helping keep Eng-Tips Forums free from inappropriate posts.
The Eng-Tips staff will check this out and take appropriate action.

Reply To This Thread

Posting in the Eng-Tips forums is a member-only feature.

Click Here to join Eng-Tips and talk with other members! Already a Member? Login


Low-Volume Rapid Injection Molding With 3D Printed Molds
Learn methods and guidelines for using stereolithography (SLA) 3D printed molds in the injection molding process to lower costs and lead time. Discover how this hybrid manufacturing process enables on-demand mold fabrication to quickly produce small batches of thermoplastic parts. Download Now
Design for Additive Manufacturing (DfAM)
Examine how the principles of DfAM upend many of the long-standing rules around manufacturability - allowing engineers and designers to place a part’s function at the center of their design considerations. Download Now
Taking Control of Engineering Documents
This ebook covers tips for creating and managing workflows, security best practices and protection of intellectual property, Cloud vs. on-premise software solutions, CAD file management, compliance, and more. Download Now

Close Box

Join Eng-Tips® Today!

Join your peers on the Internet's largest technical engineering professional community.
It's easy to join and it's free.

Here's Why Members Love Eng-Tips Forums:

Register now while it's still free!

Already a member? Close this window and log in.

Join Us             Close