1. What the DWC Quickset Procedure Does

The DWC Quickset Procedure automatically locates the front-left corner of your material and sets it as the active work coordinate system origin (for example G54 when C1 is selected). During the routine, OmniControl uses the DWC Quickset Zeroing Tool block and either an endmill or the supplied 0.250" Touch Pin dowel to probe the block and calculate:

• X Work Offset – front-left X edge of the material
• Y Work Offset – front-left Y edge of the material
• Z Work Offset – top surface of the material

When the routine is complete and the block is removed, your CNC is ready to run the project with an accurate, repeatable origin.

2. When to Use the Quickset Procedure

Use the DWC Quickset Procedure when you want:

• Fast, repeatable setup of the front-left corner as your origin
• Automatic setting of X, Y, and Z work offsets
• Consistent setup for sheet goods, blocks, and jigs
• To recover a known origin after a tool change or new setup

The Quickset routine is especially helpful for new CNC users, because OmniControl guides every step and minimizes manual zeroing errors.

3. Required Setup Before Running Quickset

Before you click the Quickset button, make sure all of the following conditions are met.

3.1 Place the DWC Quickset Zeroing Tool

Position the Quickset Block on the front-left corner of your material. Align the two reference faces of the block with the front and left edges of the stock.

3.2 Install a Valid Tool (Endmill or Touch Pin)

The Quickset routine can be performed with:

• An endmill up to 2.000" diameter with a straight cutting edge, or
• The supplied 0.250" Touch Pin dowel that ships with the DWC Quickset Zeroing Tool.

If your initial cutting tool is a V-bit, tapered ball nose, form tool, or any bit that does not have a straight sidewall, you must use the Touch Pin for the Quickset operation. You will then swap to the actual cutting tool during the guided sequence.

3.3 Position the Spindle for the Start Point

Before starting the Quickset routine:

• Jog the machine so the center of the tool is directly over the corner hole in the Quickset Block.
• Ensure the tip of the tool is above the top surface of the block (not touching it).
• Verify there is enough clearance for motion in X, Y, and Z.

3.4 Model-Specific Electrical Setup

Different DWC models handle continuity and grounding for probing in different ways. Use the instructions below that match your machine.

3.4.1 DWC1824 – Requires Both Clips

On the DWC1824, the Quickset Block is not wired directly to the controller, so you must transfer the continuity circuit through the standard Z-touch system:

• Clip the Quickset Block Gator Clip to the machine’s Z-Zeroing Touch Plate.
  This transfers the Output 2 continuity signal into the Quickset Block.
• Clip the Z-Zeroing Ground Clip to the router bit shank.
  This completes the circuit back to the controller.

Both clips are required for the Quickset routine to detect contact on a DWC1824.

3.4.2 DWC2440 – Quickset Clip Only

On the DWC2440, the Quickset Block is also not wired directly to the controller, but the machine ground is handled differently:

• Clip the Quickset Block Gator Clip to the machine’s Z-Zeroing Touch Plate.
• The Z-Zeroing system’s ground lead is permanently attached to the machine leg and does not need to be moved to the router bit.

No additional ground connection to the bit is required on the DWC2440.

3.4.3 DWC2636 & DWC3648 – Direct-Wired Quickset Block

On the DWC2636 and DWC3648, the Quickset Block is hardwired directly to the controller:

• No Gator clips required.
• No grounding steps or special wiring.

Simply place the block and run the Quickset routine.

3.4.4 DWC4848 & DWC5100 – Ceramic Spindle Grounding Magnet

The DWC4848 and DWC5100 use spindles with ceramic bearings, which do not naturally conduct electricity through the spindle body. In order for the Quickset routine to detect contact, a special grounding magnet must be used:

• Attach the Grounding Magnet to either the spindle collet nut or directly to the tool shank/router bit.
• Make sure the magnet is firmly attached and the cable is safely routed away from moving parts.

The Quickset Block itself is wired directly to the controller on these machines, so only the grounding magnet is required.

3.4.5 Summary – Model Setup Matrix

4. Starting the DWC Quickset Procedure

With the Quickset Block placed, the correct tool installed, the spindle positioned over the corner hole, and the electrical setup verified for your model, you are ready to run the Quickset routine.

Click the DWC Quickset (XYZ Origin) button on the top toolbar. OmniControl opens the first dialog in the Quickset workflow.

4.1 Select the Tool Type

In the first Quickset dialog, select the tool you will use for the probing routine:

• Endmill – for straight-wall tools up to 2.000" diameter
• Touch Pin – for the 0.250" dowel pin included with the Quickset accessory

After making your choice, click the OK button (✔ in the upper-right corner) to continue.

5. Quickset Workflow – Endmill Mode

5.1 Enter the Endmill Diameter

When Endmill is selected, OmniControl displays the Endmill Offset Procedure window. Enter the exact cutting diameter:

• Use decimal format, e.g. 0.250, 0.500, 1.000, 2.000.
• The maximum allowed diameter is 2.000".

After entering the diameter, click OK (✔) to begin the motion sequence.

5.2 Endmill Touch Sequence (Z, then X, then Y)

OmniControl performs the following steps automatically:

1. Move the endmill to the center of the Quickset Block and gently touch the top surface to establish the initial Z Work Offset reference.
2. Move in X and touch the X-reference face of the block to calculate the X Work Offset.
3. Move in Y and touch the Y-reference face of the block to calculate the Y Work Offset.
4. Apply the computed X, Y, and Z Work Offsets to the currently active coordinate system (C1–C9 / G54–G59.3).

When the routine finishes, the spindle will stop at a safe location. You may remove the Quickset Block and begin machining your project.

6. Quickset Workflow – Touch Pin Mode

6.1 Enter the Tool Change Location

When Touch Pin is selected, OmniControl displays the Touch Pin Offset Procedure window. You must specify a Tool Change Location where the machine will move after probing X and Y so you can safely swap tools:

• X – Safe X position for changing tools
• Y – Safe Y position for changing tools
• Z – Clearance Z height above the work area

Choose a location that is clear of clamps, fixtures, and the Quickset Block and that provides comfortable access to the tool. Click OK (✔) to start the routine.

6.2 Touch Pin Motion Sequence (Z, then X, then Y)

With the Touch Pin installed, OmniControl runs the following sequence:

1. Move to the center of the Quickset Block and touch the top surface to establish an initial safe Z reference.
2. Move in X and touch the X-reference face of the block.
3. Move in Y and touch the Y-reference face of the block.
4. Move to the specified Tool Change Location and automatically pause.

6.3 User Tool Change

At the Tool Change Location:

• Remove the Touch Pin from the spindle.
• Install the actual cutting tool you will use for your job.
• Press the Pause button again to resume the Quickset routine.

6.4 Final Z Touch and Offset Application

After resuming, OmniControl:

1. Returns to the Quickset Block.
2. Touches the top surface again with the actual cutting tool to set the final Z Work Offset.
3. Applies the computed X, Y, and Z Work Offsets to the active coordinate system.

Once complete, remove the Quickset Block. Your origin is now fully defined and the machine is ready to run the toolpath.

7. Safety – Exiting a Quickset Dialog

8. After the Quickset Procedure

When the Quickset routine is finished:

• Remove the DWC Quickset Zeroing Tool block from the work area.
• Verify that the correct coordinate system (C1–C9) is active.
• Optionally jog to X0 Y0 Z0 in the work coordinate system to visually confirm the origin location at the lower-left corner of your material.

At this point the machine is fully set up and ready to run your project using the new work offset origin.

Set Z Zero – Resetting Z After a Manual Tool Change

The Set Z Zero button provides a fast, automated, and highly accurate method to re-establish your Z-axis work offset after a manual tool change. This routine ensures the new tool is zeroed to the exact same Z reference that was established earlier using the DWC Quickset XYZ Origin Procedure.

Use this routine anytime your project requires more than one cutting tool. Only Z is affected — X and Y remain unchanged.

1. When to Use Set Z Zero

Typical situations where this tool is required:

• Switching from a roughing bit to a finishing bit
• Changing V-bit angles (e.g., 90° → 60°)
• Changing from endmill → ball nose → tapered bit
• Any tool change where tool length differs (most cases)

The Set Z Zero function updates only the Z-axis work offset. Your X and Y origins remain exactly as they were.

2. Required Setup Before Running the Operation

For accuracy and safety, complete the following:

2.1 Place the DWC Quickset Zeroing Tool Block

Place the Quickset block in the exact same location used during the original XYZ Origin procedure. (See: DWC Quickset Procedure – XYZ Origin Button → Section 3.1)

2.2 Install Your New Tool

After the previous toolpath completes, install the next tool you intend to use and ensure it is clamped securely in the collet.

2.3 Ensure the Tool is Elevated (No Need to Move to the Block Manually)

The tool can be located anywhere on the table when you start the Set Z Zero routine. The only requirement is:

• The tool tip must be positioned higher than the top of the Quickset block
• You must ensure the spindle has clearance from clamps or fixtures during travel

When the routine begins, OmniControl automatically performs an absolute X/Y move to return the spindle directly above the Quickset block before probing begins.

3. Grounding & Electrical Contact Requirements (Model-Specific)

The Quickset block relies on continuity between the tool and the block. Certain DWC machines require different grounding configurations:

• DWC1824: Clip the Quickset block’s gator clip to the machine’s Z-Zero touch plate. Clip the machine’s touch-plate ground clip to the router bit’s shank.
• DWC2440: Clip the Quickset block’s gator clip to the machine’s Z-Zero touch plate. The machine’s ground clip attaches to the leg of the CNC frame (not the bit).
• DWC4848 & DWC5100 (ceramic-bearing spindles): Attach the included grounding magnet to the spindle’s collet nut or to the installed tool. These spindles cannot conduct through bearings, so the magnet is required.
• All other units: The Quickset block is wired directly to the controller and does not require special grounding steps.

4. Running the Set Z Zero Routine

Press the Set Z Zero button in the top toolbar. OmniControl will display a confirmation popup before beginning.

4.1 Confirmation Popup (Reset Z Axis Zero)

The popup gives the user two choices:

• Press OK (✔) — Runs the Set Z Zero procedure immediately.
• Press ESC (keyboard) — Cancels the operation safely.

4.2 What the Routine Does Automatically

After pressing OK, OmniControl will:

1. Move the spindle automatically to the Quickset block’s saved X/Y location
2. Lower the tool until it contacts the block
3. Calculate and store the new Z-axis work offset
4. Raise the tool to a safe height
5. Complete the operation

This ensures every tool in your project references the same Z origin established during your initial Quickset XYZ procedure.

5. After the Z Zero Operation Completes

• Remove the Quickset block
• Load the correct toolpath for the new tool
• Press Start to continue the project

6. Safety Notes

• Always ensure clamps and fixtures are clear of the probing path
• Never press OK unless the Quickset block is positioned correctly
• Press ESC to abort at any time before confirmation
• Verify the tool is securely tightened before running the routine

Verify Carving Area (Trace Function)

The Verify Carving Area button performs a visual “trace” of the outer boundary of your loaded toolpath. This lets you confirm:

• That your material is oriented correctly on the table
• That clamps, screws, and fixtures are clear of the carving extents
• That the toolpath fits within the machine’s travel limits

Run this routine after your project G-code is loaded and your X, Y, and Z work offset origin has been set (for example, using the DWC Quickset XYZ Origin procedure).

1. What the Verify Carving Area Routine Does

When executed, OmniControl raises the tool to the job’s G-code Safe Height (often labeled “Z Gap above Material”) and traces the X–Y extents of the toolpath. This provides a clear preview of the carving footprint before any material is cut.

2. Requirements Before Running

Before clicking the button, make sure:

• Your project G-code file is loaded in OmniControl.
• Your Work Offset Origin (X0, Y0, Z0) is correctly set.
• Material is securely clamped, and fixtures are placed where you expect them.

3. Starting the Verify Carving Area Routine

1. Click the Verify Carving Area button in the top toolbar.
2. When the confirmation popup appears:
   • Click OK (✔) to begin the trace, or
   • Press ESC on the keyboard to cancel the operation.

4. What Happens During the Trace

4.1 Lift to Safe Z Height

After confirmation, OmniControl first raises the tool to the programmed G-code Safe Height. This provides vertical clearance above your material surface for the entire trace motion.

4.2 Outline the Carving Boundary

The CNC then moves in X and Y to trace the outer extents of the loaded toolpath. This motion follows the maximum X–Y coordinates of the job, giving you a preview of the full carving footprint.

On machines equipped with homing and limit switches, if the toolpath would exceed the machine’s travel, OmniControl will stop and report a “Machine Limits Reached” error. This lets you fix the issue before any cutting begins.

4.3 Return to Work Origin at Safe Height

When the trace completes, OmniControl returns the spindle to:

• X = 0 (current work coordinate system X zero)
• Y = 0 (current work coordinate system Y zero)
• Z = G-code Safe Height (safe travel height above material)

If the spindle does not return smoothly to this position, it may indicate lost steps, mechanical binding, or a work offset mismatch that should be corrected before carving.

5. Safety Notes

• The spindle does not turn on during this routine.
• Keep hands, tools, and loose items clear of the machine while the trace runs, even though the tool is above the material.
• If anything looks wrong during the motion, press the machine’s Stop or E-Stop and investigate before continuing.

Laser Mode Overview

Laser Mode in OmniControl switches the CNC from routing or spindle carving operations to laser engraving and laser cutting. When enabled, OmniControl reroutes all spindle control commands so they safely and correctly operate your attached digital laser module instead.

1. What Laser Mode Does

When you click the Enable Laser Mode button, OmniControl will:

• Disable spindle output and activate laser PWM output
• Switch the controller into dedicated laser-engrav­ing mode
• Update the Mode tab to show Laser Mode = Active
• Convert spindle power commands into laser power commands
• Apply laser min/max power limits and start/stop timing

This ensures all laser projects run safely, consistently, and without any risk of accidentally powering the router or spindle.

2. Safety Requirements Before Enabling Laser Mode

2.1 Router-equipped Units (DWC1824 & DWC2440)

• Ensure the router’s power switch is OFF
• Remove the router bit, collet, and nut for maximum clearance
• Ensure your laser module is mounted securely

2.2 Spindle-equipped Units (DWC2636, DWC3648, DWC4848, DWC5100)

• Spindle will not turn on in Laser Mode, but still remove the collet/nut
• Verify the laser mount and bracket are tight
• Confirm water cooling is running (if applicable)

2.3 General Laser Safety

• Always wear proper wavelength laser safety glasses
• Keep a fire extinguisher or fire blanket nearby
• Never leave the CNC unattended while the laser is active
• Use proper exhaust/ventilation for smoke and fumes
• Avoid engraving toxic or unknown materials

3. Laser Mode Confirmation Popup

After clicking the Laser Mode button, OmniControl displays a confirmation popup. You must click OK (✓) to activate Laser Mode. Press ESC to cancel.

4. What Changes After Laser Mode Is Enabled

• Laser Mode = Active indicator turns green
• Spindle Mode is disabled
• Laser Min/Max power limits are displayed instead of RPM settings
• Start/stop timing applies to laser control
• Z-axis motion is minimized (laser engraving is primarily 2D)

You must now set:

1. Laser XY Zero (using the non-burning beam)
2. Laser Z Focus Height (varies for 6W vs. 45W)

These are covered in the next two chapters.

5. Before Running Any Laser Job

• Ensure the bit/collet has been removed
• Use the proper focusing tool or gauge
• Secure the material flat to the spoilboard
• Use the laser’s “non-burning” low-power beam for alignment

6. Returning to Spindle Mode

Laser Mode remains active until you manually switch back using the Spindle / Mill Mode button. Full instructions are provided in that chapter.

Laser XY & Z Work Offset Setup (Non-Burning Beam)

Before you can run any laser engraving or cutting project, you must tell OmniControl where your job starts (Laser XY Zero) and at what height the laser is in perfect focus (Laser Z Zero). Unlike spindle tools, the laser never physically touches the material. Instead, you use a very low-power non-burning beam as a pointer to aim and focus the laser safely.

This chapter explains how to:

1. Turn on the laser’s non-burning beam using the MDI bar and the M3/M5 button
2. Set Laser XY Zero at your chosen datum point
3. Set Laser Z Zero at the correct focus height
4. Verify everything before running a job

1. What Is the Non-Burning Beam?

The non-burning beam is the laser running at an extremely low power level. At this power:

• The beam is visible on the material
• It does not burn or mark the surface when used correctly
• You can safely jog the machine to position and focus the laser

On Digital Wood Carver machines, the non-burning beam is enabled manually using the MDI input bar and the M3/M5 Spindle–Laser On/Off button. This is used only for setup and alignment. It should not be written into your project’s G-code file.

2. Before You Begin

2.1 Confirm Laser Mode Is Active

Make sure the machine is in Laser Mode (see the previous chapter). On the Mode tab you should see:

• Laser Mode — active (green)
• Spindle Mode — off

2.2 Remove Router/Spindle Tooling

• Remove any router bit or endmill
• Remove the collet nut and collet, or install a blank collet with no tool
• Verify there is plenty of clearance between the router/spindle body and the material

2.3 Secure the Material

• Clamp the workpiece flat against the spoilboard
• Keep clamps and fixtures outside the planned laser area
• Avoid warped or loose stock — focus distance must stay consistent

3. Turning On the Non-Burning Beam (MDI + M3/M5)

To enable the low-power alignment beam, you will use the Manual Data Input (MDI) bar and the M3/M5 Spindle–Laser On/Off button in the PlanetCNC top toolbar.

3.1 Enter S1 in the MDI Bar

1. Click inside the MDI input bar at the bottom of the OmniControl window.
2. Type S1 (letter S followed by the number 1).
3. Press Enter on the keyboard to send the command.

This sets the controller’s current spindle/laser power value to its lowest usable level.

3.2 Toggle the Laser On with M3/M5

1. Click the M3/M5 Spindle–Laser On/Off button in the top toolbar.
2. The laser turns on at the low power level set by S1.

You should now see a faint, non-burning dot on the material. If the beam is not visible, carefully adjust your room lighting and verify you are in Laser Mode.

When you are finished aligning the laser, simply click the M3/M5 button again to turn the beam off.

4. Setting Laser XY Work Offset Zero

Once the non-burning beam is on, you can set your Laser XY Zero. Most laser jobs use either:

• The front-left corner of the design as XY zero, or
• The center of the design as XY zero

4.1 Jog to the X/Y Datum Point

1. Use the OmniControl jog controls to move the laser over your chosen datum point.
2. Jog slowly as you get close, using small step moves for accuracy.
3. Align the low-power dot precisely on the corner or center mark of your project.

4.2 Set X = 0 and Y = 0

1. With the beam aimed at the exact datum point, press X = 0 in OmniControl.
2. Press Y = 0 in OmniControl.

This sets the current position as the Laser XY Zero for the active work coordinate system (for example G54, G55, etc.). Your job will now start from this point when you run the laser G-code.

5. Setting the Laser Z Focus Height (Z Zero)

Z Zero for laser work is defined as the height where the laser is in perfect focus, not where a tool touches the material.

The focusing method depends on your laser model:

• DWC 6-Watt Laser — uses a manual focus ring and visual sharpness of the spot.
• DWC 45-Watt Laser — uses a dedicated focusing gauge or spacer.

This chapter gives the basic Z-zero concept. The next two chapters provide detailed procedures for each laser type.

5.1 Move to Focus Height

1. With the non-burning beam still on, jog the Z axis down toward the material.
2. For the 6-Watt Laser, adjust the focus ring and Z height until the dot is as small and sharp as possible.
3. For the 45-Watt Laser, place the manufacturer’s focus gauge between the nozzle and the workpiece, jog Z until the gauge just touches, then remove the gauge.

5.2 Set Z = 0

Once you are confident the laser is at the correct focus height:

1. Press Z = 0 in OmniControl.

This tells OmniControl that the current Z height is the correct Laser Z Zero (focus height) for the job.

6. Verification Checklist Before Running a Job

Before starting your laser G-code, verify the following:

• Laser Mode is active on the Mode tab
• MDI commands are complete and the non-burning beam has been turned off (M3/M5)
• DRO shows X = 0 and Y = 0 at your chosen datum
• DRO shows Z = 0 at the correct focus height
• Material is secure and clamps are clear of the laser path
• Proper laser safety glasses are on and ventilation is running

7. What Comes Next

With Laser XY and Z Zero set, you are ready to dial in precise focus for your specific laser module:

• Next Chapter: How to Focus Your DWC 6-Watt Laser
• Then: How to Focus Your DWC 45-Watt Laser

How to Focus Your DWC 6-Watt Laser (PLH3D-XT-50)

Correct focus is the most important step for achieving clean, sharp engravings and optimal cutting performance with your DWC 6-watt laser module. This chapter walks you through a quick everyday focusing method plus an optional advanced calibration sweep for users who want maximum precision.

The information in this chapter is based on the optical specifications provided in the PLH3D-XT-50 laser head manual, with all metric values also shown in inches for convenience.

1. Working Distance (Focal Distance) Basics

Your 6-watt laser module is factory-designed to produce its tightest beam at a specific distance from the laser head to the workpiece. This is called the working distance (WD).

For the PLH3D-XT-50 used on Digital Wood Carver machines, the recommended working distance is:

• 60 mm (2.36 inches) between the bottom face of the laser head and the top surface of the material.

When the Z-axis is set so that the flat underside of the laser body (bottom face of the laser head) is approximately 60 mm (2.36 in) above the material, the beam is at its smallest diameter. This produces:

• Thinner engraving lines
• Cleaner edges with less charring
• Greater effective cutting depth
• Higher detail in raster engravings

Even small deviations from this distance can reduce beam quality. A difference of about 1 mm (0.04 in) is usually enough to make the line visibly wider and softer.

2. Safety Before Focusing

2.1 Protective Equipment

• Wear proper laser safety glasses rated for your laser’s wavelength.
• Ensure good ventilation or fume extraction.
• Remove shiny or highly reflective objects from the work area.

2.2 Machine & Workpiece Preparation

• OmniControl must be in Laser Mode (see the Laser Mode chapter).
• The router/spindle power must be off.
• No router bit or cutting tool should be installed in the collet.
• Secure the workpiece flat to the spoilboard and keep clamps clear of the beam path.

2.3 Use a Non-Burning Alignment Beam

For focusing and positioning, you should use a very low-power, “non-burning” beam. This lets you see where the laser is pointed without marking the material.

To enable the non-burning beam:

1. Click inside the MDI input bar at the bottom of OmniControl.
2. Type S1 and press Enter to set a very low power value.
3. Click the M3/M5 Spindle–Laser On/Off button in the top toolbar to turn the beam on.

You should now see a faint dot on the material. When you are done aligning or focusing, click the same M3/M5 button again to turn the beam off.

3. Quick Focus Method (Recommended)

This method is fast and accurate enough for most engraving and light cutting projects.

3.1 Move to Your Laser XY Zero

1. Enable the non-burning alignment beam as described above.
2. Jog the machine so the beam is directly over your chosen Laser XY Work Zero point (corner or center of your job).
3. Use smaller jog steps as you get close so you can aim the dot precisely.

3.2 Adjust Z to the Working Distance

1. Jog the Z-axis up or down slowly.
2. Stop when the distance from the bottom face of the laser head to the material is as close as possible to 60 mm (2.36 inches).
3. Visually confirm that the laser dot is as small and sharp as you can make it.

On many jobs, simply bringing the head to this known working distance is all that is required for a very good focus.

3.3 Set Laser Z Work Offset

Once the height looks correct:

1. With the head at the proper working distance, press Z = 0 in OmniControl (or use your normal “Set Z Zero” workflow for laser jobs).

OmniControl now treats this height as your Laser Z Zero (focus height) for the active work coordinate system.

3.4 Turn the Beam Off

When you are finished focusing:

1. Click the M3/M5 Spindle–Laser On/Off button to switch the beam off.

4. Advanced Precision Calibration (Optional)

If you need the thinnest possible lines or the cleanest cuts (for example, tiny text or high-detail engraving), you can fine-tune focus around the 60 mm working distance. This is a two-stage calibration process:

1. Coarse sweep around 60 mm (2.36 in).
2. Fine sweep around the best result from the coarse sweep.

4.1 Suggested Test Materials

For best visibility when comparing line quality, use:

• Black anodized aluminum (excellent test surface)
• Black-painted glass or microscope slide (very high contrast)
• Thin plywood or other flat, consistent material (acceptable)

On anodized aluminum, slightly tilting the material (about 4–7°) can make differences in line thickness easier to see.

4.2 Calibration Run #1 – Coarse Sweep

Goal: Find the approximate best focus around the nominal WD.

1. Set the Z height so the bottom face of the laser head is at 60 mm (2.36 in) above the material.
2. Prepare a simple G-code that engraves a series of horizontal lines, each at a different Z height.
3. For each line, change the Z height in steps of 1 mm (0.04 in), sweeping about ±5 mm (±0.20 in) around the nominal WD. This will cover roughly 55–65 mm (2.16–2.56 in).
4. Label each line with the Z height used.
5. Select the line that is thinnest, sharpest, and highest contrast.

The Z height that produced the best line is your “coarse” best working distance.

4.3 Calibration Run #2 – Fine Sweep

Goal: Refine the best focus to a very small range.

1. Use the best height found in Run #1 as your center value.
2. Create a second set of lines, adjusting Z in steps of 0.1 mm (0.004 in) above and below that center value.
3. Engrave and label each line with its exact Z height.
4. Carefully inspect the lines under good lighting. Choose the one that is clearly the narrowest and most consistent.

The Z height for that line is your precise optimal working distance for this laser and test material.

5. Saving and Reusing Your Focus Height

1. Jog the head so the bottom face of the laser is again at your optimal height above the material.
2. At this position, press Z = 0 (or run G92 Z0 in the MDI bar).

Write this height down and keep it with your machine notes. As long as you set the head to this working distance above the material, you will be at or very close to perfect focus.

6. Adjusting for Different Material Thicknesses

When you change to a thicker or thinner workpiece, your goal is to keep the distance from the bottom face of the laser head to the material the same as your calibrated working distance.

• Place the new material on the table and secure it.
• Jog Z until the head is at your known working distance above the new surface.
• Set Z = 0 again for this job.

You only need to repeat the full two-stage calibration when you make major changes, such as a different laser head, a major hardware change, or if you are chasing maximum detail on new materials.

7. Air Assist (Recommended)

If your 6-watt laser is used with an air assist nozzle, a gentle, directed airflow can:

• Reduce soot and char around engraving lines
• Improve cutting depth and edge quality
• Help keep the lens cleaner for longer periods

Use moderate air pressure aimed at the cutting point. Excessive pressure is usually not needed and may blow debris into unwanted areas.

8. Next Steps

With your 6-watt laser correctly focused, you are ready to:

• Set up and run engraving and cutting projects in Laser Mode.
• Use the Laser XY & Z Work Offset tools covered in the previous chapter.
• Move on to the next chapter: How to Focus Your DWC 45-Watt Laser for users with the higher power module.

Focusing the Legacy 6-Watt Laser (PLH3D-6W Series)

Some Digital Wood Carver machines are equipped with an older Opt Lasers PLH3D-6W module instead of the newer XT-50 head. The focusing principles are similar, but the factory working distance and recommended tuning procedure come from a different manual. This chapter explains how to quickly set focus for everyday jobs and how to perform a more advanced calibration sweep when you need maximum sharpness.

All distances are given in both metric and imperial units so you can use whichever system you prefer at the machine.

1. Working Distance for the PLH3D-6W

The working distance (WD) is the ideal distance between the laser module and the top of your material where the beam is at its smallest and most powerful.

For the legacy PLH3D-6W head used on Digital Wood Carver machines:

• Factory working distance: 60.4 mm  =  2.38 inches (approximately) from the bottom face of the laser head to the top surface of the material.
• With the factory air-assist nozzle installed, this typically leaves about 2 mm (0.08 in) between the nozzle tip and the material when the head is at the correct working distance.

2. Safety Before Focusing

2.1 Protective Gear

• Wear laser safety glasses rated for the wavelength of your 6-watt laser.
• Provide adequate ventilation or fume extraction.
• Keep reflective objects out of the beam path.

2.2 Machine & Workpiece Setup

• OmniControl must be in Laser Mode.
• The router or spindle power switch must be off.
• No router bit should be installed; remove the collet if possible for extra clearance.
• Secure your workpiece flat to the spoilboard; keep clamps outside the planned laser area.

2.3 Use a Non-Burning Alignment Beam

For focusing and XY positioning, use a very low-power, “non-burning” beam so you can see the dot without marking the material.

1. Click in the MDI bar at the bottom of OmniControl.
2. Type S1 and press Enter to set a very low power value.
3. Click the M3/M5 Spindle–Laser On/Off button in the top toolbar to turn the beam on.

When you are done focusing or positioning, click the same M3/M5 button again to turn the beam off.

3. Quick Focus Method (Recommended)

Use this method for everyday engraving and cutting. It is simple, fast, and accurate enough for most woodworking and sign projects.

3.1 Move to Your Laser XY Zero

1. Enable the non-burning beam as described above.
2. Jog the machine so the beam is directly over your chosen Laser XY Work Zero point (corner or center of the job).
3. Use smaller jog steps as you get close so you can aim the dot precisely.

3.2 Set Z to the Working Distance

1. Jog the Z-axis until the distance from the bottom face of the laser head to the material is as close as possible to 60.4 mm (2.38 inches).
2. If you have a gauge block, spacer, or focusing jig for this head, place it on the material and lower the laser until the bottom face just touches the gauge, then remove the gauge.
3. Visually confirm that the laser dot appears small and sharp at this height when the beam is on at low power.

3.3 Set Laser Z Work Offset

1. With the head at the correct distance, set Z = 0 in OmniControl (or use your standard “Set Z Zero” process for laser jobs).

OmniControl now treats this height as the Laser Z Zero (focus height) for your current work coordinate system.

3.4 Turn the Beam Off

1. Click the M3/M5 Spindle–Laser On/Off button to switch the beam off.

You are now ready to run a test pattern or your actual job with the legacy 6-watt laser at its factory working distance.

4. Advanced Precision Focus (Coarse + Fine Sweep)

If you need the thinnest possible lines and maximum detail, you can refine the focus around the factory working distance using a two-stage test pattern: a coarse sweep in 1 mm (0.039 in) steps followed by a fine sweep in 0.1 mm (0.004 in) steps.

4.1 Recommended Test Materials

• Black anodized aluminum (best contrast, very crisp lines)
• Black-painted glass or microscope slides (excellent visibility)
• Flat, consistent wood or plywood (acceptable if the others are not available)

On anodized aluminum, tilting the material slightly (about 4–7°) can make differences in line thickness easier to see.

4.2 Coarse Focus Sweep (1 mm / 0.039 in Steps)

Goal: Find the approximate best focus around the nominal 60.4 mm distance.

1. Set Z-zero so that the bottom face of the laser head is at approximately 60.4 mm (2.38 in) above the test material.
2. Create or load a simple G-code file that engraves a series of straight horizontal lines. Each line will be burned at a different Z height.
3. For the first line, use your current Z-zero height as the reference. Make this line longer than the others so you can easily recognize it.
4. For the next set of lines, offset the Z height in +1 mm (+0.039 in) increments and offset each line in X by about 3 mm (0.12 in) so they do not overlap.
5. Repeat for negative offsets (–1 mm steps) so your test covers roughly ±5 mm (±0.20 in) around the starting point. This lets you explore a working distance range of about 55–65 mm (2.16–2.56 in).
6. After engraving, inspect the lines carefully under good lighting and, if possible, with magnification.
7. Identify the line that is thinnest, sharpest, and most consistent. Note the Z offset used for that line.

Example: If the best line was produced at +2 mm, then the laser is focusing best 2 mm (0.08 in) above your original zero. If it was at –3 mm, the best focus is 3 mm (0.12 in) below it.

4.3 Apply the Coarse Correction

1. Adjust your Z-zero by the measured correction amount so that Z = 0 now corresponds to the height that produced the best coarse line.

This new Z-zero is your coarse best focus height.

4.4 Fine Focus Sweep (0.1 mm / 0.004 in Steps)

Goal: Refine focus around the coarse best height with higher precision.

1. Using the updated Z-zero from the coarse sweep, create a second test pattern of lines similar to the first one.
2. This time, vary the Z height in 0.1 mm (0.004 in) steps above and below zero. Offset each line in X by about 3 mm (0.12 in) again.
3. Engrave the lines using the same material and similar power/speed settings as before.
4. Examine the lines and choose the one that is clearly the narrowest and most uniform.
5. Record the Z offset for that line and update Z-zero by that amount so that Z = 0 now matches this fine best focus height.

The Z-zero you end up with after the fine sweep is your precisely calibrated working distance for the PLH3D-6W on that machine.

5. Saving and Reusing Your Focus Height

1. Once you are satisfied with the focus, jog Z so the laser head is again at this calibrated height above a flat reference surface.
2. Set Z = 0 in OmniControl (or run G92 Z0 in the MDI bar).
3. Write down this focus height in your machine notes as “Legacy 6-Watt Focus Height”.

As long as you bring the laser head to this same working distance above the material before setting Z-zero for a job, you will be at or very close to optimal focus.

6. Adjusting for Different Material Thicknesses

When you change material thickness, your goal is to keep the distance from the bottom face of the laser head to the material equal to your calibrated working distance (factory 60.4 mm or your refined value).

• Secure the new material to the table.
• Jog Z until the head is at the calibrated working distance above the new surface.
• Set Z = 0 again for that job.

7. Air Assist Considerations

If your PLH3D-6W is equipped with an air-assist nozzle:

• At the correct working distance, the nozzle tip should be approximately 2 mm (0.08 in) above the material.
• Use moderate airflow directed at the cutting point to reduce soot and improve edge quality.
• Avoid excessive pressure that could blow debris into unwanted areas or disturb small parts.

8. When to Re-Calibrate

You should repeat the coarse + fine focusing procedure if:

• The laser head has been removed, re-mounted, or significantly bumped.
• You change to a different lens configuration or nozzle setup.
• You are chasing maximum detail on a very demanding engraving job.

For normal day-to-day work, the Quick Focus Method (Section 3) is usually all you need.

1. How the XT8 Focus System Works

The PLH3D-XT8 is a high-power, short-focus laser head. Its beam is brought to a tight focus at a specific distance below the body of the laser. When the laser is at this distance, the spot on the material is smallest and the power density is highest.

With the XT8, getting this distance correct is especially important. A small focus error can mean:

• Shallower cuts or poor engraving contrast.
• More soot and charring around the design.
• Needing much slower feed rates or higher power than necessary.

In this chapter we use a simple, repeatable method that does not require the manufacturer’s height reference tool. Instead, you will rely on the laser’s non-burning beam and a small gauge block or ruler to dial in focus.

2. XT8 Working Distance (21 mm / 0.83 in)

The XT8’s specified working distance is:

• 21 mm  ≈  0.83 inches

This is measured from the bottom face of the laser head body (not the mounting bracket above) down to the top surface of the material.

You do not need to hit this distance to the exact thousandth of an inch, but you should be very close. In practice you will:

• Visually adjust Z until the beam spot on the material is at its smallest.
• Confirm that the spacing from laser body to material is roughly 0.83 in (about 13/16 in) using a gauge block, spacer, or ruler.

3. Preparing the Machine for Focusing

Before you turn on the laser, complete these steps:

1. Install the XT8 laser head using the appropriate DWC mounting bracket and ensure all fasteners are tightened.
2. Remove any router bit and collet nut from the router or spindle. You want maximum clearance between the router/spindle and the material when the laser is at its correct Z height.
3. Enable Laser Mode in OmniControl. The Mode state panel should show Laser Mode as active and Spindle Mode disabled.
4. Home the machine so all machine coordinates are known and any limit switches are active.
5. Place a flat test board (same material and thickness as your project) on the table and secure it with clamps or fixtures that are clear of the beam path.
6. Connect and turn on air assist if available. Air assist dramatically improves cutting performance and reduces charring.

4. Turning On the Non-Burning Beam

To focus safely, you need the laser to emit a very low-power “non-burning” beam. This lets you see the spot clearly without cutting or marking the material while you jog the Z axis.

4.1 Method 1 – Using the MDI Command Bar

1. Make sure the machine is idle and the laser head is above the test board.
2. Click in the MDI (Manual Data Input) bar at the bottom of the screen.
3. Type M3 S1 and press Enter.
4. The XT8 will turn on at a very low power level. Verify that the beam is on but not burning the material.

4.2 Method 2 – S1 + Toolbar Toggle

Depending on your workflow, you can also:

1. Type S1 into the MDI bar and press Enter.
2. Click the M3/M5 Spindle–Laser On/Off button on the PlanetCNC top toolbar.
3. This combination sets the low-power value with S1 and uses the toolbar button to toggle the beam on and off.

5. Focusing the XT8 – DWC Method

With the non-burning beam on and the test board in place, you can now dial in focus:

1. Jog to a safe starting height.
   Use small Z jogs to bring the laser to a point where the nozzle is comfortably above the board (for example, 1–2 inches). The spot on the material will be large and soft.
2. Slowly jog Z downward in small steps.
   Move the Z axis down in small increments (for example, 0.01 in per jog). Watch the spot closely – it should become smaller and brighter as you approach the correct distance.
3. Find the smallest, sharpest spot.
   When you reach a point where the spot stops getting smaller and begins to grow again, you have passed through the focus point. Move slightly back up until the spot is at its smallest and most concentrated.
4. Fine-tune around the focus point.
   Jog a few steps above and below this height and “split the difference” until you are confident you have the best possible focus.
5. Verify the working distance.
   With the Z axis at best focus, measure from the bottom face of the laser body down to the material. It should be approximately 0.83 inches (21 mm), roughly the same as a 13/16 in gauge block. If you are significantly off, re-check your visual focus.
6. Turn the beam off.
   Use M5 in the MDI bar or click the M3/M5 toolbar button again to ensure the laser is completely off before you continue.

6. Setting Z Zero at the Focus Height

Once you are satisfied with the focus:

1. Make sure the beam is off (M5 or toolbar toggle).
2. Without moving the Z axis, set your Z Work Offset at this height. Use the same Z-zero method you prefer for normal OmniControl operations (for example, setting Z = 0 in the active work coordinate system for engraving).
3. Record this Z focus height in your notes for that material and fixture setup. If you later change material thickness or table spacing, you can return to this workflow to re-establish focus.

7. Engraving vs. Cutting – Focus Guidelines

The “perfect” focus depends on whether you are engraving the surface or trying to cut through thicker material.

7.1 Surface Engraving

• Use the sharpest possible focus at the material surface.
• This produces crisp details and good contrast for logos, text, and photos.
• Start with moderate power and higher speeds, then adjust based on test results.

7.2 Cutting Through Material

• For thin stock (for example, 1/8 in), you can generally use the same focus as surface engraving.
• For thicker material (for example, 1/4 in or more), you may get better results by focusing slightly below the surface – roughly in the middle of the material’s thickness – so the beam has good power density deeper into the cut.
• Make a few test cuts with different focus depths and note which setting gives you the cleanest edge with the least charring.

8. Troubleshooting Focus Issues

• Wide or fuzzy beam spot – Re-focus using the visual method above and verify the 0.83 in working distance.
• Material scorches heavily but doesn’t cut deeply – Check that focus is not too far above the surface; ensure air assist is on and unobstructed.
• Beam seems oval or streaked – Inspect the lens for dust or smoke residue and clean it according to the manufacturer’s instructions.
• Frequent flare-ups or small flames – Reduce power, increase movement speed, and ensure air assist is working. Confirm the material is suitable for laser cutting.
• Focus changes during a job – Check that the laser mount and Z axis are rigid and that the workpiece is firmly clamped and not warping from heat.

1. What These Buttons Do

When a digital laser is mounted on your CNC, its beam is offset from the center of the router/spindle by some fixed X/Y distance. These two buttons use that offset to move one tool to the other tool’s position and automatically re-zero the work offsets:

• Move Laser to Spindle Position – Moves the laser to where the router/spindle is currently located and sets the laser’s X/Y work offset to that point.
• Move Spindle to Laser Position – Moves the router/spindle to where the laser is currently located and sets the spindle’s X/Y work offset to that point.

This is ideal for combo projects, such as carving a pocket or profile, then laser engraving artwork in the exact same location.

2. Before You Calibrate

Make sure that:

• Your laser is solidly mounted and will not move on the bracket.
• The router/spindle is installed and able to hold a V-bit.
• OmniControl is configured for your machine profile (for example, 2440_OmniControl) and can switch between Spindle Mode and Laser Mode.
• You are comfortable jogging the machine, setting work offsets, and using the Work Offset state tab.

3. Step 1 – Mark the Spindle Center with a V-Bit

1. Place a flat piece of scrap material on the table and secure it with clamps that are clear of your working area.
2. Install a sharp V-bit in the spindle/router. Do not turn the spindle on for this procedure.
3. Jog the machine so the V-bit is roughly over the center of your scrap material.
4. Slowly jog Z down until the V-bit just dimples the material to leave a small, clear mark.
5. Open the Offset state tab and zero the X and Y work offsets. This locks in the dimple location as X = 0, Y = 0 in your current work coordinate system.
6. Raise Z to a safe height and remove the V-bit from the collet.

4. Step 2 – Move the Laser Over the Dimple and Record the Offset

1. Enable Laser Mode in OmniControl and make sure the router bit, collet, and nut are removed so they cannot hit the material.
2. Set the laser to its proper focus height above the material and then zero the Z work offset for the laser.
3. Turn on the laser’s non-burning beam (for example, using M3 S1 or S1 plus the M3/M5 toolbar button) so you can see the spot without cutting.
4. Jog X and Y until the beam is perfectly centered over the V-bit dimple you made earlier.
5. On the Offset tab, record the current X and Y work offset values. These numbers represent how far the laser is from the spindle’s center when the spindle was at X = 0, Y = 0.

Example (your values will be different):

• X = 2.1699
• Y = -2.4501

Write your actual X and Y values down carefully. You will enter these into two user command script files in the next step.

5. Step 3 – Edit the “Move Laser to Spindle Position” Script

The laser-to-spindle move is stored in a user command G-code file. The path for a DWC2440 profile looks like this:

C:\Program Files\PlanetCNC\Profiles\2440_OmniControl\UserCmd

Your exact profile folder name may differ (for example, 1824_OmniControl, 4848_OmniControl, etc.).

1. Download and install Notepad++ if you have not already. It is highly recommended for editing OmniControl scripts.
2. Navigate to the UserCmd folder and open:
   User_Enable_Laser_to_Router_code.gcode in Notepad++.
3. Locate the section that defines the laser offset variables:

   (name,11 - Move Laser To Spindle Position)
   
   #<laser_offset_x> = -2.1699
   #<laser_offset_y> =  2.4501
   

4. Replace the example numbers with your X and Y values from Step 2, but pay attention to the signs:
   • Use the X value with the sign needed to move the laser to the spindle (often the negative of what you read when the laser was over the dimple).
   • Use the Y value with the sign needed to move the laser to the spindle.
   In the example above, the laser must move X = -2.1699, Y = 2.4501 to reach the spindle center.
5. Save the file. Notepad++ may prompt you to reopen in administrative mode; click Yes, then save again.

6. Step 4 – Edit the “Move Spindle to Laser Position” Script

Now update the reverse move, which sends the spindle to the laser position.

1. In the same UserCmd folder, open:
   User_Enable_Router_to_Laser_code.gcode in Notepad++.
2. Find the offset definitions:

   (name,14 - Move Spindle To Laser Position)
   
   #<laser_offset_x> =  2.1699
   #<laser_offset_y> = -2.4501
   

3. Enter the same magnitudes you used in Step 3, but with the signs reversed. The negative move in “Laser to Router” becomes a positive move in “Router to Laser,” and vice versa.

   Using the example:

   • Laser to Spindle: X = -2.1699, Y = 2.4501
   • Spindle to Laser: X = 2.1699, Y = -2.4501
4. Save the file (again allowing Notepad++ to restart in admin mode if requested).

7. Step 5 – Test the Buttons

Before using this in a real job, perform a dry run:

1. Set up a scrap board and repeat the basic V-bit + laser steps, but with the spindle and laser well above the surface (air moves only).
2. With the spindle active and X/Y work offsets set at the dimple position, click Move Laser to Spindle Position. The laser should move directly over the dimple location.
3. Switch back to Spindle Mode, and with the laser’s X/Y offset active, click Move Spindle to Laser Position. The spindle should return to the same point.
4. If either move is off, re-check your recorded X/Y values and the signs in both script files.

8. Typical Workflow – Carve First, Then Laser

Once calibrated, here’s how a combined carve + laser project might look:

1. Set the project origin.
   With the router/spindle installed, set your project’s X, Y, and Z work offset origin for the carving portion (for example, lower-left corner of the material, top surface).
2. Run the carving toolpath(s).
   When complete, the router should be back at the project’s X/Y/Z zero position.
3. Prepare for laser.
   Enable Laser Mode, remove the router bit, collet, and nut, set the laser’s Z focus height, and zero the Z work offset for the laser.
4. Click “Move Laser to Spindle Position”.
   The laser moves to the project origin and the X/Y work offsets are automatically re-zeroed for the laser at that same location.
5. Load the laser G-code for the engraving portion and run the job.

9. Reverse Workflow – Laser First, Then Carve

The process also works in reverse:

1. Set up and focus the laser, then set the X/Y/Z origin for the engraving.
2. Run the laser engraving portion first.
3. Switch to Spindle Mode, install the appropriate bit, and set Z zero for carving (keeping X/Y the same).
4. Click Move Spindle to Laser Position to bring the spindle exactly to the laser’s origin, then run the carving toolpaths.

1. Spindle Mode vs Laser Mode

OmniControl can operate in two primary modes: Spindle Mode for routing/milling and Laser Mode for engraving or cutting with an attached digital laser. Only one mode is active at a time.

To see which mode is currently active, open the Mode tab in the State Panel.

• Spindle Mode ON
  
  • Spindle Mode indicator: green (enabled)
  • Laser Mode indicator: red (disabled)
• Laser Mode ON
  
  • Spindle Mode indicator: red (disabled)
  • Laser Mode indicator: green (enabled)

The Enable Spindle Mode button is your “back to normal carving” switch. After any laser work, enabling Spindle Mode ensures that future M3 / M5 commands control the router or spindle instead of the laser.

2. Where to Find the Button

The Enable Spindle Mode button is located on the top toolbar. When you hover over it, OmniControl displays a tooltip such as “Enable Spindle Mode” or “Engage Spindle Mode Settings.”

3. When to Use Enable Spindle Mode

Use the Enable Spindle Mode button whenever:

• You’ve finished a laser job and are returning to routing or milling.
• You want to ensure the CNC behaves like a standard router: the spindle starts and stops according to the G-code (M3, M5), and all laser outputs remain disabled.
• You’re ending your work day and want the machine ready for normal carving at the next startup.

In short: if your next operation uses a cutting bit in the spindle, you should be in Spindle Mode.

4. Safety Checklist Before Enabling Spindle Mode

Before you confirm the Enable Spindle Mode popup, walk through this quick checklist:

4.1 Correct Tool Installed

• Install the router bit or endmill you plan to use for the job.
• Verify the bit is seated properly and the collet and nut are securely tightened.

4.2 Dust Collection & Workholding

• Confirm clamps, screws, tape, or fixtures are secure and clear of the cutting path.
• Attach and position the dust shoe or dust collection system if used.

4.3 Spindle Power & Cooling

• For routers: make sure the physical router power switch is set according to Digital Wood Carver’s recommendations so the controller can safely start and stop the router.
• For water-cooled spindles: confirm coolant flow is active and circulating before any cutting operation.

4.4 Laser Hardware (If Attached) — Important!

• If a digital laser module is currently mounted, ensure it is powered OFF and the beam is not armed.
• Best Practice: remove the laser module entirely when it is not in use. This prevents dust and debris from collecting on the diode, lens, and internal optics during carving operations, and it protects the laser from accidental bumps.
• Store the laser in a clean, dust-free, and protected location, with its lens cap or cover installed.

5. Running the Enable Spindle Mode Routine

1. Click the Enable Spindle Mode button.
   OmniControl opens the Enable Spindle Mode popup dialog with a spindle illustration.
2. Review the dialog.
   This is a confirmation step, not a calibration wizard. Think of it as OmniControl asking: “Are you sure you are done with laser and ready for routing?”
3. Choose how to proceed:
   • Press OK (✓) in the upper-right of the popup.
     OmniControl:
     • Enables Spindle Mode and disables Laser Mode.
     • Updates the Mode tab to show Spindle Mode (green) and Laser Mode (red).
     • Ensures future M3/M5 commands control the spindle.
   • Press ESC on the keyboard.
     This cancels the operation and leaves the current mode unchanged.

6. End-of-Day Best Practice

When you finish your last job of the day, it’s a good habit to leave the machine in a safe, predictable state:

1. Stop any running program and move the Z-axis up to a safe height.
2. Jog the spindle away from clamps and fixtures if needed.
3. Click Enable Spindle Mode and press OK (✓) so:
   • Spindle Mode = ON
   • Laser Mode = OFF
4. Power down the CNC, computer, and accessories per your normal shutdown routine.

Doing this at the end of each day means that the next time the system is powered up, OmniControl is already in a known-safe default configuration ready for normal carving.