# Z travel exceeded warning? 45w laser system **URL:** \ **Category:** General Chat\ **Tags:** lasers\ **Created:** [September 20, 2025, 5:32pm UTC](https://forum.avidcnc.com/t/z-travel-exceeded-warning-45w-laser-system/5273 "2025-09-20T17:32:11Z")\ **Posts on this page:** 20\ **Page:** 1
**Author:** ![JeffsDesign](https://yyz1.discourse-cdn.com/flex027/user_avatar/forum.avidcnc.com/jeffsdesign/32/5574_2.png) [@JeffsDesign](https://forum.avidcnc.com/u/JeffsDesign)\ **Post date:** [September 20, 2025, 5:32pm UTC](https://forum.avidcnc.com/t/z-travel-exceeded-warning-45w-laser-system/5273/1 "2025-09-20T17:32:11Z")
First little text program to test out the 45 watt laser and I keep getting a z travel exceeded warning not sure why? Am I to use the plate to set the z zero like a router bit but with the laser? I haven’t tried that cuz I didn’t want to crash I have done everything in the diode laser utilities went extremely well Adding a screenshot to show what I getting and the program stops Appreciate any help thanks ![IMG_20250920_115212680_HDR](https://canada1.discourse-cdn.com/flex027/uploads/avidcnc/original/2X/5/580c853d4485ea2708798edfa4434ba095c6bc1c.jpeg) ---
**Author:** ![Eric](https://yyz1.discourse-cdn.com/flex027/user_avatar/forum.avidcnc.com/eric/32/3220_2.png) [@Eric](https://forum.avidcnc.com/u/Eric)\ **Post date:** [September 20, 2025, 11:36pm UTC](https://forum.avidcnc.com/t/z-travel-exceeded-warning-45w-laser-system/5273/2 "2025-09-20T23:36:48Z")
You’ll find the answer here! [![](https://canada1.discourse-cdn.com/flex027/uploads/avidcnc/original/2X/6/6e5fc74f6afab0f16a0465c2fd8c0b4b879717fc.jpeg "Avid CNC Laser setup & use on EX Control") ](https://www.youtube.com/watch?v=-hA91cyZlIc) ---
**Author:** ![JeffsDesign](https://yyz1.discourse-cdn.com/flex027/user_avatar/forum.avidcnc.com/jeffsdesign/32/5574_2.png) [@JeffsDesign](https://forum.avidcnc.com/u/JeffsDesign)\ **Post date:** [September 21, 2025, 11:30pm UTC](https://forum.avidcnc.com/t/z-travel-exceeded-warning-45w-laser-system/5273/3 "2025-09-21T23:30:43Z")
Yes I followed along with the video several times and still getting the same error message. The only thing I see different that you were doing was setting up a custom laser with custom settings ---
**Author:** ![Eric](https://yyz1.discourse-cdn.com/flex027/user_avatar/forum.avidcnc.com/eric/32/3220_2.png) [@Eric](https://forum.avidcnc.com/u/Eric)\ **Post date:** [September 21, 2025, 11:58pm UTC](https://forum.avidcnc.com/t/z-travel-exceeded-warning-45w-laser-system/5273/4 "2025-09-21T23:58:38Z")
Describe the steps you take to Z zero on your material when lasering, maybe there’s a workflow issue we can figure out… ---
**Author:** ![JeffsDesign](https://yyz1.discourse-cdn.com/flex027/user_avatar/forum.avidcnc.com/jeffsdesign/32/5574_2.png) [@JeffsDesign](https://forum.avidcnc.com/u/JeffsDesign)\ **Post date:** [September 22, 2025, 12:20am UTC](https://forum.avidcnc.com/t/z-travel-exceeded-warning-45w-laser-system/5273/5 "2025-09-22T00:20:51Z")
I line up the laser to the lower left corner of the workpiece and then 0 x and y then use the 21 mm gauge to set the z zero ---
**Author:** ![Eric](https://yyz1.discourse-cdn.com/flex027/user_avatar/forum.avidcnc.com/eric/32/3220_2.png) [@Eric](https://forum.avidcnc.com/u/Eric)\ **Post date:** [September 22, 2025, 12:23am UTC](https://forum.avidcnc.com/t/z-travel-exceeded-warning-45w-laser-system/5273/6 "2025-09-22T00:23:59Z")
That’s where you’re going wrong… The 21mm block is only for initial calibration [![](https://canada1.discourse-cdn.com/flex027/uploads/avidcnc/original/2X/0/0ddb060d8d713472d599adec33fdec4a00a42b35.jpeg "Laser Z Height Setting (15W and 45W)") ](https://www.youtube.com/watch?v=YvTOOAd1L-E) After the initial calibration you have to zero to your workpiece with the tool that’s in the spindle, NOT the laser. ---
**Author:** ![JeffsDesign](https://yyz1.discourse-cdn.com/flex027/user_avatar/forum.avidcnc.com/jeffsdesign/32/5574_2.png) [@JeffsDesign](https://forum.avidcnc.com/u/JeffsDesign)\ **Post date:** [September 22, 2025, 12:36am UTC](https://forum.avidcnc.com/t/z-travel-exceeded-warning-45w-laser-system/5273/7 "2025-09-22T00:36:41Z")
So are you using the plate then to x y and z with the workpiece? ---
**Author:** ![Eric](https://yyz1.discourse-cdn.com/flex027/user_avatar/forum.avidcnc.com/eric/32/3220_2.png) [@Eric](https://forum.avidcnc.com/u/Eric)\ **Post date:** [September 22, 2025, 12:47am UTC](https://forum.avidcnc.com/t/z-travel-exceeded-warning-45w-laser-system/5273/8 "2025-09-22T00:47:41Z")
Yes, you do NOT use the laser for XYZ zeroing at all, it’s all done with the spindle. However you arrive at your XYZ zero, as long as it’s done with the spindle it will “transfer” to the laser when you deploy it. ---
**Author:** ![JeffsDesign](https://yyz1.discourse-cdn.com/flex027/user_avatar/forum.avidcnc.com/jeffsdesign/32/5574_2.png) [@JeffsDesign](https://forum.avidcnc.com/u/JeffsDesign)\ **Post date:** [September 22, 2025, 12:56am UTC](https://forum.avidcnc.com/t/z-travel-exceeded-warning-45w-laser-system/5273/9 "2025-09-22T00:56:04Z")
Excellent thank you I’ll do!! but it’s getting a little late today 😉 ---
**Author:** ![jbaker877](https://avatars.discourse-cdn.com/v4/letter/j/a8b319/32.png) [@jbaker877](https://forum.avidcnc.com/u/jbaker877)\ **Post date:** [October 22, 2025, 12:57pm UTC](https://forum.avidcnc.com/t/z-travel-exceeded-warning-45w-laser-system/5273/10 "2025-10-22T12:57:53Z")
I have been struggling to understand how the calibration process works also - this discussion is good and the discussion finally gets to the calibration process - it would be good to place this on a video - with as much detail as possible. ---
**Author:** ![Eric](https://yyz1.discourse-cdn.com/flex027/user_avatar/forum.avidcnc.com/eric/32/3220_2.png) [@Eric](https://forum.avidcnc.com/u/Eric)\ **Post date:** [October 22, 2025, 2:00pm UTC](https://forum.avidcnc.com/t/z-travel-exceeded-warning-45w-laser-system/5273/11 "2025-10-22T14:00:16Z")
Did you see this video? [![](https://canada1.discourse-cdn.com/flex027/uploads/avidcnc/original/2X/6/6e5fc74f6afab0f16a0465c2fd8c0b4b879717fc.jpeg "Avid CNC Laser setup & use on EX Control") ](https://www.youtube.com/watch?v=-hA91cyZlIc) ---
**Author:** ![jbaker877](https://avatars.discourse-cdn.com/v4/letter/j/a8b319/32.png) [@jbaker877](https://forum.avidcnc.com/u/jbaker877)\ **Post date:** [October 22, 2025, 3:06pm UTC](https://forum.avidcnc.com/t/z-travel-exceeded-warning-45w-laser-system/5273/12 "2025-10-22T15:06:30Z")
Yes several times. THe difficult part is understanding the correlation between the tool height setting and how this relates to the laser height . The location setting is clear. I think it needs to state somewhere that you reference everything with the tool bit using the plate or other tool and the laser will take all its references from that calibration . Thanks ---
**Author:** ![Eric](https://yyz1.discourse-cdn.com/flex027/user_avatar/forum.avidcnc.com/eric/32/3220_2.png) [@Eric](https://forum.avidcnc.com/u/Eric)\ **Post date:** [October 22, 2025, 3:29pm UTC](https://forum.avidcnc.com/t/z-travel-exceeded-warning-45w-laser-system/5273/13 "2025-10-22T15:29:54Z")
That’s exactly how it works. If you try and do an XY or Z setting in the touch plate utility a message will come up telling you that you have to use a spindle tool. Rule of thumb is: Always use your spindle tool for XY setting. ---
**Author:** ![Gregpetty](https://avatars.discourse-cdn.com/v4/letter/g/6a8cbe/32.png) [@Gregpetty](https://forum.avidcnc.com/u/Gregpetty)\ **Post date:** [February 10, 2026, 1:49pm UTC](https://forum.avidcnc.com/t/z-travel-exceeded-warning-45w-laser-system/5273/14 "2026-02-10T13:49:37Z")
So I have a problem similar to this, I upgraded my system to a EX controller and deployable 45 watt laser. When I go to setup my laser and run xy calibration ( utils 5) then laser xy calibration my spindle drives up to the Z limit switch. Thinking I have to calibrate my z first, So I first calibrate my tool x,y,and z then the laser to the 21mm block using utils 5, then laser height calibration ? ---
**Author:** ![Eric](https://yyz1.discourse-cdn.com/flex027/user_avatar/forum.avidcnc.com/eric/32/3220_2.png) [@Eric](https://forum.avidcnc.com/u/Eric)\ **Post date:** [February 10, 2026, 3:19pm UTC](https://forum.avidcnc.com/t/z-travel-exceeded-warning-45w-laser-system/5273/15 "2026-02-10T15:19:14Z")
When doing the calibration your Z just goes straight up and hits the limit? It shouldn’t do that… are you able to use this machine for cutting and other non laser work? ---
**Author:** ![Gregpetty](https://avatars.discourse-cdn.com/v4/letter/g/6a8cbe/32.png) [@Gregpetty](https://forum.avidcnc.com/u/Gregpetty)\ **Post date:** [February 11, 2026, 12:01am UTC](https://forum.avidcnc.com/t/z-travel-exceeded-warning-45w-laser-system/5273/16 "2026-02-11T00:01:21Z")
Eric yes the spindle was working fine last time I used about 2 weeks ago. Yesterday I homed system and set X,Y,and Z for spindle before trying the laser ---
**Author:** ![Eric](https://yyz1.discourse-cdn.com/flex027/user_avatar/forum.avidcnc.com/eric/32/3220_2.png) [@Eric](https://forum.avidcnc.com/u/Eric)\ **Post date:** [February 11, 2026, 1:01am UTC](https://forum.avidcnc.com/t/z-travel-exceeded-warning-45w-laser-system/5273/17 "2026-02-11T01:01:42Z")
Can you walk me through the steps in detail that you take to get this error? ---
**Author:** ![Gregpetty](https://avatars.discourse-cdn.com/v4/letter/g/6a8cbe/32.png) [@Gregpetty](https://forum.avidcnc.com/u/Gregpetty)\ **Post date:** [February 11, 2026, 10:43am UTC](https://forum.avidcnc.com/t/z-travel-exceeded-warning-45w-laser-system/5273/18 "2026-02-11T10:43:14Z")
Eric I will be out in the shop on Thursday and will try it again then, After homing system and setting spindle x,y,z should I try and cal. laser height or x&y ? ---
**Author:** ![Eric](https://yyz1.discourse-cdn.com/flex027/user_avatar/forum.avidcnc.com/eric/32/3220_2.png) [@Eric](https://forum.avidcnc.com/u/Eric)\ **Post date:** [February 11, 2026, 1:43pm UTC](https://forum.avidcnc.com/t/z-travel-exceeded-warning-45w-laser-system/5273/19 "2026-02-11T13:43:10Z")
You only need to calibrate XY and Z for the laser once. Those settings are stored in there after you do it. Follow the steps I laid about above and report back, no need to re-calibrate the laser for that. ---
**Author:** ![Gregpetty](https://avatars.discourse-cdn.com/v4/letter/g/6a8cbe/32.png) [@Gregpetty](https://forum.avidcnc.com/u/Gregpetty)\ **Post date:** [February 11, 2026, 2:21pm UTC](https://forum.avidcnc.com/t/z-travel-exceeded-warning-45w-laser-system/5273/20 "2026-02-11T14:21:27Z")
Never have gotten the laser to cal or deploy let [Next page](https://forum.avidcnc.com/t/z-travel-exceeded-warning-45w-laser-system/5273.md?page=2)