Bystronic 6Kw Bystar "W-Axis warning error" 2

[KonQueR]

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.?
Thank-You

 

[msandoval]

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

 

[bruno77]

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

 

[KonQueR]

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.

 

[msandoval]

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

 

[captainfantastic]

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.

 

[mbaengineering]

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

 

[mbaengineering]

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.