DW077

DeWalt Calibration Procedure for DW077
For use at locations using an On-Trak Calibration Range
DW077 LASER UNIT

Note: The following procedure can be used on a customer’s complete unit, or it can be used with the
customer’s compensator installed in the special cut-away service housing. All photos and figures show the
cutaway service housing.
LASER KEYPAD
“Scan” “Spin” “Up” and “Down”
A. CALIBRATION RANGE SETUP:

1. Set up the special DW077 Calibration Tripod beside the DW073 calibration stand. This calibration
procedure will not use the DW073 calibration stand.
2. Use the Tripod’s built-in bubble level to get the Tripod head approximately level.
3. The DW077 Calibration Tripod should be approximately 6m (20 feet) from the farthest On-Trak
sensor.
4. Mount the DW077 laser in a horizontal position on the tripod, turn the laser unit on and allow it to
level itself.
5. Adjust the tripod height so the laser beam strikes the farthest On-Trak sensor approximately in the
center of its detection area.
6. Boot up the same calibration software (“Calstation”) and On-Trak sensors that are used to
calibrate the DW073.
B. SOFTWARE CHECK:
Note: The laser beam must be rotating for the On-Trak sensors to work.
1. On the computer screen, click on the green “arrow” button to start measuring the beam location.
2. Close the “Station Calibration Screen” window. This procedure only uses the “Cone Error
Adjustment Screen” window.
1
Step 1: Click on the
Green Arrow to start Step 2: Click here to
measuring close the “Station
Calibration Screen”
3. Confirm that the software is reading the beam location.

4. Try blocking the laser from reaching the farthest target. The “Far Target” box should read “No
Laser.”
Note: To fully calibrate the DW077 laser, the X, Y, and Z axis must be calibrated separately, one at a
time.
C. CHECKING THE X-AXIS CALIBRATION:

1. Align the entire laser unit on the tripod head until the “X” marking on the top housing is lined up
STRAIGHT TOWARD the farthest On-Trak. Tighten the locking knob on the tripod head so
nothing can wobble.
“X” marking to be aimed straight

toward farthest On-Trak (Step 1).
2. Turn on the laser unit, allow it to self-level, and put it in rotation mode.
3. On the computer screen, look at the value in the “Delta Position” box. As soon as it stabilizes,
write down the value, including the +/- sign and label it “+ X”.
2
Step 3: Write down value in “Delta
Position Box for +X direction
4. Rotate the laser unit on the tripod head 180 degrees, so that the “X” marking is lined up
STRAIGHT AWAY from the On-Trak targets.
5. Once the reading stabilizes, write down the new “Delta Position” value, including the +/- sign, and
label it “-X”.
Step 5: Write down value in “Delta

Position Box for -X direction
6. Subtract the “-X” value from the “+X” value, and write this down as “X Error”.
7. If the “X Error” is within the limits shown in the table below, then the unit is already calibrated.
If the “X Error” is outside of the limits, then the unit must be recalibrated.
X-AXIS AND Y-AXIS ALLOWABLE ERROR

(Equivalent to 20 arcseconds or 1/8” at 100 ft.)
Distance from On-Trak 1 to On-Trak 2 4.5m 5m 5.5m 6m

(14’9”) (16’5”) (18’) (19’8”)
Allowable Error +/- .44 +/- .48 +/- .53 +/- .58
3
D. RECALIBRATING THE X-AXIS:
1. To calculate the desired target value for “Delta Position”, take the average of the two values
previously written down for +X and –X. Write down this target value.
2. The laser unit should still be aligned with the “X” marking facing away from the On-Trak.
3. Turn the laser unit off.
4. Put the laser unit into “X” calibration mode by pushing and holding the “UP” arrow button on the
laser keypad. While still pushing the “UP” arrow, push and release the “ON” button on the laser
keypad. Release the “UP” arrow button.
5. The laser unit will automatically move through its range of X movement, then come to rest.
6. Push the rotation button (on the keypad or on the remote control) to spin the laser head.
7. Use the REMOTE CONTROL “UP” and “DOWN” arrow buttons to move the laser beam until the
“Delta Position” reading matches the target value calculated in step 1 above.
IMPORTANT NOTE: IF THE BEAM GETS TO THE END OF ITS ADJUSTMENT RANGE
BEFORE CALIBRATION REQUIREMENTS ARE MET, THEN THE UNIT CAN NOT BE
RECALIBRATED. THE COMPENSATOR WILL NEED TO BE REPLACED.
8. Allow the laser unit to stabilize for about 30 seconds.

9. Using the LASER UNIT KEYPAD (not the remote control), press and hold the “Scan” button. A
continuous tone will be heard. While holding the “Scan” button, press and release the “Down”
arrow button. This step stores the calibration settings into the laser unit’s memory, and the
continuous tone will stop.
10. Shut the laser unit off, then repeat the “X”-Axis Calibration Check (Section C, steps 1-6) to
confirm that the calibration is now correct.
E. CHECKING THE Y-AXIS CALIBRATION:

1. Align the entire laser unit on the tripod head until the “Y” marking on the top housing is lined up
STRAIGHT TOWARD the farthest On-Trak. Tighten the locking knob on the tripod head so
nothing can wobble.
2. Turn on the laser unit, allow it to self-level, and put it in rotation mode.
3. On the computer screen, look at the value in the “Delta Position” box. As soon as it stabilizes,
write down the value, including the +/- sign and label it “+ Y”.
4. Rotate the laser unit on the tripod head 180 degrees, so that the “Y” marking is lined up
STRAIGHT AWAY from the On-Trak targets.
5. Once the reading stabilizes, write down the new “Delta Position” value, including the +/- sign, and
label it “-Y”..
6. Subtract the “-Y” value from the “+Y” value, and write this down as “Y Error”..
7. If the “Y Error” is within the limits shown in the table (see Section C), then the unit is already
calibrated. If the “Y Error” is outside of the limits, then the unit must be recalibrated.
F. RECALIBRATING THE Y-AXIS:

1. To calculate the desired target value for “Delta Position,” take the average of the two values
previously written down for +Y and –Y. Write down this target value.
2. The laser unit should still be aligned with the “Y” marking facing away from the On-Trak.
3. Turn the laser unit off.
4. Put the laser unit into “Y” calibration mode by pushing and holding the “SCAN” arrow button on
the laser keypad. While still pushing the “SCAN” arrow, push and release the “ON” button on the
laser keypad. Release the “UP” arrow button.
5. The laser unit will automatically move through its range of Y movement, then come to rest.
6. Push the rotation button (on the keypad or on the remote control) to spin the laser head.
“Delta Position” reading matches the target value calculated in step 1 above.
8. IMPORTANT NOTE: IF THE BEAM GETS TO THE END OF ITS ADJUSTMENT RANGE
4

10. Using the LASER UNIT KEYPAD (not the remote control), press and hold the “SCAN” button.
A continuous tone will be heard. While holding the “SCAN” button, press and release the
“DOWN” arrow button. This step stores the calibration settings into the laser unit’s memory, and
the continuous tone will stop.
11. Shut the laser unit off, then repeat the “Y”-Axis Calibration Check (Section E, steps 1-6) to
confirm that the calibration is now correct
G. SETUP FOR THE Z-AXIS CALIBRATION:

1. Calibration of the “Z” axis uses an Optical Auto Level (Nikon or DeWalt DW096) instead of the
On-Trak system.
2. Position a tripod at least 40 feet (12 m) from a wall where a stationary laser dot can be projected.
3. Tape a piece of graph paper on the wall where the laser dot will be. The graph paper should have
1mm X 1mm grid lines.
4. Position the Optical Auto Level halfway between the tripod and the wall, almost in line with the
laser beam, but not where it will block the beam.
H. CHECKING THE Z-AXIS CALIBRATION:

1. Remove the plastic plug from the top of the laser unit’s rotary head. Use an Exacto knife to pry it
off. This will expose the laser’s vertical beam.
2. Mount the laser unit in the vertical position on the tripod, with the vertical beam pointing toward
the wall.
Laser beam
3. Turn on the laser unit and allow it to self-level.

4. Tape a piece of paper across the top of the laser unit’s rotary head so the laser beam creates a red
dot on the paper. The rotary head should not be spinning during this step.
5
A piece of paper on
the laser head allows
the beam to be sighted
with the optical level
5. Adjust the elevation of the Optical Auto Level so the horizontal cross-hair is lined up exactly on
the center of the red dot at the laser unit.
DANGER: NEVER LOOK THROUGH AN OPTICAL LEVEL DIRECTLY AT A LASER
SOURCE. SERIOUS EYE INJURY COULD RESULT.
6. Remove the paper from the laser unit’s rotary head so the beam can project a red dot on the far
wall.
7. Rotate the Optical Level around to view the dot on the graph paper mounted on the far wall.
8. Measure how far the center of the red dot is above or below the cross-hair. This is the amount of
calibration error of the laser unit’s Z axis.
9. Table of acceptable calibration error
Z-AXIS ALLOWABLE ERROR

(Equivalent to 20 arcseconds or 1/8” at 100 ft.)
Distance to Target 40 ft. (12m) 50 ft. (15m) 70 ft. (21m) 100 ft. (30m)
Allowable Error +/- 1mm +/- 1.5mm +/- 2mm +/- 3mm
If the error is greater than these acceptance limits, then the laser unit must be recalibrated
I. RECALIBRATING THE Z-AXIS:

1. Put the laser unit into the “Z” calibration mode by pushing and holding the “SCAN” button on the
laser keypad. While still pushing the “SCAN” button, push and release the “ON” button on the
laser keypad. Release the “SCAN” button.
2. The laser unit will automatically move through its range of Z movement, then come to rest.
dot on the far wall lines up with the horizontal cross-hair of the Optical Level.
IMPORTANT NOTE: IF THE BEAM GETS TO THE END OF ITS ADJUSTMENT RANGE

5. Using the LASER UNIT KEYPAD (not the remote control), press and hold the “Scan” button. A
continuous tone will be heard. While holding the “Scan” button, press and release the “Down”
arrow button. This step stores the calibration settings into the laser unit’s memory, and the
continuous tone will stop.
6. Shut the laser unit off, then repeat the “Z”-Axis Calibration Check (Section H, steps 1-9) to
confirm that the calibration is now correct.

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DeWalt Calibration Procedure for DW077

For use at locations using an On-Trak Calibration Range

DW077 LASER UNIT

“Scan” “Spin” “Up” and “Down”

A. CALIBRATION RANGE SETUP:

3. Confirm that the software is reading the beam location.

C. CHECKING THE X-AXIS CALIBRATION:

“X” marking to be aimed straight

Step 5: Write down value in “Delta

X-AXIS AND Y-AXIS ALLOWABLE ERROR

Distance from On-Trak 1 to On-Trak 2 4.5m 5m 5.5m 6m

8. Allow the laser unit to stabilize for about 30 seconds.

E. CHECKING THE Y-AXIS CALIBRATION:

F. RECALIBRATING THE Y-AXIS:

9. Allow the laser unit to stabilize for about 30 seconds.

G. SETUP FOR THE Z-AXIS CALIBRATION:

H. CHECKING THE Z-AXIS CALIBRATION:

3. Turn on the laser unit and allow it to self-level.

Z-AXIS ALLOWABLE ERROR

I. RECALIBRATING THE Z-AXIS:

4. Allow the laser unit to stabilize for about 30 seconds.

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