HS-3,4,6,7 (R) Ec-Series Installation: Important! Refer To Local Code Requirements Before Wiring Machines

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1. HS-3,4,6,7(R) AND EC- SERIES INSTALLATION
GENERAL REQUIREMENTS
Operating Temperature Range 41°F to 104°F (5 to 40°C)
Storage Temperature Range -4°F to 158°F (-20 to 70°C)
Ambient Humidity: less than 90% relative humidity, non-condensing
Altitude: 0-6000 ft. (Do not operate machine in explosive atmospheres (explosive vapors and /or particulate matter)
ELECTRICITY REQUIREMENTS
IMPORTANT! REFER TO LOCAL CODE REQUIREMENTS BEFORE WIRING MACHINES.
ALL MACHINES REQUIRE:
Three phase 50 or 60Hz Delta or Wye power, except that the power source must be grounded
(e.g. leg or center leg for Delta, neutral for Wye).
Line voltage that does not fluctuate more than +/-5%.
Frequency range is 47-66 Hz.
Harmonic distortion is not to exceed 10% of the total RMS voltage.
HS-3,4,6,7 (R) Voltage Requirements High-Voltage Requirements2
(195-260V) (354-488V)
Power Supply1 125 AMP Must use an external transformer
Haas Circuit Breaker 100 AMP
If service run from elec.panel
is less than 100' use: 2 GA. WIRE
If service run from elec. panel
is more than 100' use: 0 GA. WIRE
EC-300,400,1600-3000
(195-260V) (354-488V)
Power Supply1 50AMP 8K spindle 25AMP 8K spindle
100 AMP12K spindle 50 AMP 12K spindle
Haas Circuit Breaker 40AMP 8K spindle 20AMP 8K spindle
80 AMP 12K spindle 40 AMP 12K spindle
If service run from elec.panel 8 GA. WIRE (40 AMP) 12 GA. WIRE (20 AMP)
is less than 100' use: 4 GA. WIRE (80 AMP) 8 GA. WIRE (40 AMP)
If service run from elec. panel 6 GA. WIRE (40 AMP) 10 GA. WIRE (20 AMP)
is more than 100' use: 2 GA. WIRE (80 AMP) 6 GA. WIRE (40 AMP)
WARNING!
A separate earth ground wire of the same conductor size as the input power is required to be connected to the
chassis of the machine. This ground wire is required for operator safety and for proper operation. This ground
must be supplied from the main plant ground at the service entrance, and should be routed in the same conduit
as the input power to the machine. A local cold water pipe, or ground rod adjacent to the machine cannot be
used for this purpose.
Input power to the machine must be grounded. For wye power, the neutral must be grounded. For delta power,
a central leg ground or one leg ground should be used. The machine will not function properly on ungrounded
power. (This is not a factor with the External 480V Option)
The rated horsepower of the machine may not be achieved if the imbalance of the incoming voltage is beyond
an acceptable limit. The machine may function properly, yet may not deliver the advertised power. This is
noticed more often when using phase converters. A phase converter should only be used as a last resort.
Reference Manual June 2007 Installation 1

(Horizontal)
The maximum leg-to-leg or leg-to-ground voltage should not exceed 260 volts, or 504 volts for high-voltage
machines with the Internal High Voltage Option.
1
The current requirements shown in the table reflect the circuit breaker size internal to the machine. This
breaker has an extremely slow trip time. It may be necessary to increase the size of the external service
breaker by 20-25%, as indicated by “power supply”, for proper operation.
2
The high-voltage requirements shown reflect the Internal 400V configuration which is standard on European
machines. Domestic and all other users must use the External 480V option.
AIR REQUIREMENTS
The mill requires a minimum of 100 PSI at 9 scfm at the input to the pressure regulator on the back of the
machine. This should be supplied by at least a two horsepower compressor, with a minimum 20-gallon tank,
that turns on when the pressure drops to 100 PSI.
Use a 1/2" I.D. hose for the air supply to the machine and set the main Air Regulator to 85psi. EC-400 / EC-
500 Pallet Air regulator is set to 100 psi. (1/2" hose) .
The recommended method of attaching the air hose is to the barb fitting at the back of the machine with a hose
clamp. If a quick coupler is desired, use at least a 3/8".
Excessive oil and water in the air supply will cause the machine to malfunction. The air filter/regulator has an
automatic bowl dump that should be empty before starting the machine. This must be checked for proper
operation monthly. Also, excessive contaminants in the air line may clog the dump valve and cause oil and/or
water to pass into the machine.
NOTE: The nipple between the air filter/regulator and the oil lubricator reservoir tank below the control box on
the back of the machine is for the optional rotary table (See illustration in "Air Connection" section). DO NOT
use this as a connection for an auxiliary air line. Auxiliary connections should be made on the left side of the
air filter/regulator.
WARNING!
When the machine is operating and the pressure gauge (on the ma-
chine regulator) drops by more than 10 psi during tool changes or
pallet changes, insufficient air is being supplied to the machine.
U NPACKING THE M ACHINE.
MATERIALS REQUIRED
Wire and air hose or piping as specified in the Service Requirements section
A small amount of grease
Way lube for the lubricator (See Maintenance section of the Operator's manual)
1. Remove the plastic cover
CAUTION! Do not put pressure on the top of the machine as you remove the plastic.
2. Remove the coolant tank from the pallet.

3. Remove the ¾" bolts holding the base to the pallet and the plastic thread protecting sleeve from the base.
4. Remove the nuts, on the leveling screws, holding the shipping bracket to the base casting. Remove the
shipping brackets.
5. Lift the machine off the pallet.

(Horizontal)
Set Screw
Shipping Shock Mount

Bracket Rubber Pad
All set screws are needed for
Coupler installation
Assembly
Pallet DO NOT DISCARD!
Tools Required for Installation and Leveling Procedure
Electronic differential level, precision bubble level, calibrated to show 0.0005 inch per 10"
Test indicator (0.0005")
Two ¾" hex wrenches (one open end or box and one ratchet)
Claw hammer
Forklift: HS- 3-7– Lifting more than 40,000 pounds, with forks at least 8' long by 6" wide.
EC-300 – Lifting rating more than 10,500 pounds, with forks at least 6' long by 6" wide.
EC-630 – Lifting rating more than 62,000 pounds, with forks at least 9' long by 9' wide.
Anchoring
Anchoring the EC-300 is recommended but not required. Contact the Haas Service Department for anchoring
kits.
R OUGH P LACEMENT HS-3 THROUGH 7

Ensure the anchoring preparations are in accordance with the anchoring instructions (Haas document ES-
0095) prior to setting the machine in place.
1. Prepare the table base for mating
• Remove the X-axis auger and auger trough
• Stone and clean thoroughly the mating flange surface. This is an extremely important step that must be
properly done before the bases are moved into position with respect to each other. (Failure to properly
prepare the surfaces and preserve their cleanliness may require separation of the main
components for corrective action.)
• Clean the holes in the table base.
• Ensure the air/electrical/oil lines and connectors are bundled and safely away from the mating surfaces.
2. Prepare the column base for mating
• Stone and clean thoroughly the mating flange surface. This is an extremely important step that must be
well and properly done before the bases are moved into position with respect to each other. (Failure to
properly prepare the surfaces and preserve their cleanliness may require separation of the main
components for corrective action).
• Check the thread of each hole in the column base, ensure there is no damage.
• Ensure the air/electrical/oil lines and connectors are bundled and safely away from the mating surfaces.
3. Place the table base assembly in position. Rough level by measuring from the floor to the bottom of the base
(very close to 2.5 inches). Each of the leveling screws and pads should be in place at this time and it is
advisable to take the measurement at each leveling screw location for best results. This will ensure that the
final leveling procedure will go more quickly and that the coolant tank will properly fit beneath the coolant
discharge.

(Horizontal)
Tool Changer Template
6
5
4
.
min
2.5"
3
2
1
Round Indicator Pad
1/2-13 Hex Nut
4. Place the column base assembly in position. When placing the column base in position with respect to the
table base, it is important that the two mating flanges be as parallel as possible (vertically and horizontally). Be
certain that each of the fifteen screws are engaged in the threads, and that when the column base is in place
and the mating surfaces are in contact, that each screw is free to rotate. Rough level by measuring from the
floor to the bottom of the base (very close to 2.5 inches). Each of the leveling screws and pads should be in
place at this time and it is advisable to take the measurement at each leveling screw location for best results.
This will ensure that the final leveling procedure will go more quickly. After rough leveling, fully tighten the
connecting screws to be sure the mating surfaces are in full contact, and then loosen them all approximately 3
full turns. Be certain that the connecting screws are still free to rotate (do not leave the connecting bolts tight
at this time because the machine still must be final leveled and squared).
5. Assemble a leveling foot and a ½-13 Hex Nut on the Tool Changer Template.
(Reference: Haas Tooling assembly T-2151)
6. Use 4 each 3/8-16 x 1 Socket Head Cap Screw to mount the Tool Changer Template on the Column Base.
(4X) 1/2-13 X 1.0

Socket Head Cap Screw
Tool Changer
Template Assembly Mating Flange Surface
(Ref: Fig.1) HS-3/R
Column Base
7. Place leveling pads at the locations shown in detail A and B, relative to the anchor hole and Tool Changer
Anchoring Bolt Holes patterns as shown in document (ES-0095). Trace around the leveling pads, with a
suitable marker, as shown; this will help relocate the pads if they are accidentally moved.

(Horizontal)
Machine Anchoring Holes Pattern
Leveling Pad
5.00 2.38
Mark Around
Leveling Pad Shop Floor
Detail A
5.00 2.38
Mark Around
Leveling Pad
Tool Changer Anchoring
Holes Pattern
Detail B
8. Place the Column Base by centering the leveling screws over the previously marked leveling pads. See the
figure below. Locate the front and rear leveling screws over the previously placed pads on the floor. Check and
verify the locations of the anchor bolt holes. The holes should be parallel to and approximately 7/8” from the
edge of the flange as shown on the following page. Also verify the round indicator pad on the template is
centered on the anchor bolt hole within +/- ¼”, see figure.
Shop Floor
Leveling Screw
Leveling Pad
Round
Leveling Screw
Indicator
Pad Tool Changer Anchor
Bolt Hole (+/- 1/4") Leveling Pad
9. After the column base is set, use the column base as a datum to mount the table bed to the column base
(See the following figure). After the table bed machine is seated, check and verify the locations of the anchor
bolt holes. The holes should be parallel to and approximately 7/8” from the edge of the flange as shown in the
following figure. Next, remove the tool changer template from the column base by taking off 4 each 3/8-16 x 1
Socket Head Cap Screws. The 50 taper side mount tool changer can now be installed next to the machine.

(Horizontal)
Shop Floor
Round Indicator Pad

Tool Changer
Anchoring Bolt Hole
Leveling Screw
Leveling Pad
7/8" 7/8"
7/8"
7/8"
7/8"
Mating Flanges
When placing the table base in position with respect to the column base, it is important that the two mating
flanges be as parallel as possible (vertically and horizontally). Be certain that each of the fifteen screws used to
attach the two flanges are actually engaged in the threads, and that when the column base is in place and the
mating surfaces are in contact that each screw is free to rotate. Rough level by measuring from the floor to the
bottom of the base (very close to 2.5 inches). All of the leveling screws and pads should be in place at this time
and it is advisable to take a measurement at each leveling screw location for best results. This will ensure that
the final leveling procedure will go more quickly. After rough leveling, fully tighten the connecting screws to be
sure the mating surfaces are in full contact, and then loosen them all approximately 3 full turns. Be certain that
the connecting screws are still free to rotate, if not make small adjustments to the leveling screws until the
connecting screws are free. Do not leave the connecting bolts tight at this time because the machine still must
be final leveled and squared.

(Horizontal)
S ETTING THE EC-M ILL IN P LACE
Important! Read this section in its entirety before setting the machine in place
CAUTION! Do not lift the machine any farther than necessary off the floor when moving
it, and move as slowly and cautiously as possible. Dropping the machine,
even from a height of a few inches, can cause injury, result in expensive
repairs, and void the warranty.
WARNING!
There must be approximately 6" clearance between the forklift and
the side of the machine as the machine is moved.
THIS SIDE ONLY THIS SIDE ONLY
PALLET
DUAL DRIVE
DIRECT
SPINDLE
INLINE
RPM
10,000
IPM
1000
L LUBE
EC
400
EC- 300 EC- 400 / EC-500 / EC-630
The EC-630 must be lifted on the tool changer side, using a forklift with at least a 62,000 lb. capacity and forks
at least 9 feet long, set 9.5 feet apart. When lifting the machine, the centerline between the forks should be 9
feet from the pallet load station side of the machine.
The EC-1600 – 3000 can be lifted from the rear or on either side (pendant or tool changer) of the machine.
CAUTION! Use caution when lifting the machine with a forklift not to damage the sheet
metal aprons with the forks.
1. Lift the machine until the retaining bolts clear the pallet. Pull the bolts out of the holes in the machine base.
Be sure to remove the plastic bolt covers that the retaining bolts came with.
2. Move the machine to where it will be located.
3. Apply grease to the leveling screws and thread each one down until it extends about 1.5" (38.1mm) below
the foot casting (two inches for the EC-300). Note: If a screw is excessively hard to turn, remove it, inspect the
screw, then retap the hole with a 1"-14 tap. If the screw has dings, dress the threads with a 60o V file.
4. Place a jam nut onto the bottom of each leveling screw (between the casting and the floor).
Leveling
Screw
Hex Nut
Jam nut is below the casting
5. Place the leveling pads from the tote kit on the floor, positioned as shown in the machine footprint.

(Horizontal)
6. Lower machine onto the leveling pads and adjust the leveling screws so that the coolant tank will fit under
the machine, with 1/2" (12.7mm) between the trough lip and the coolant tank. This must be done before the
leveling procedure begins.
EC-300 U NBLOCKING P ROCEDURE
Column Shipping
Brackets
Header Panel Shipping

Bracket
Rear Shipping
Bracket
Upper Y-Axis
Way Cover Machine Shown with Rear Cover Removed
1. Remove the four screws that hold the shipping bracket to the spindle and saddle castings.
2. Remove the screws that secure the rear panel, remove the rear shipping bracket and the two column ship-
ping brackets (there are three bolts in each one).
3. Remove the 6 screws from the header panel, pull the bottom of the header panel forward to gain access to
the way cover screws.
4. Remove the 3 screws from the top of the way cover. The way cover is now loose and can be lowered to the
top of the spindle head.
5. Remove the 2 upper and 1 lower shipping bracket screws.
6. Reinstall the way cover and header panel and replace the rear panel.
EC-400 / EC-500 U NBLOCKING P ROCEDURE
C
Shipping Bracket Tool Changer
D
60-Pocket Tool Changer Shipping Bracket
1. If equipped with a 60 pocket tool changer, remove the tool changer shipping bracket before moving any axis
of the machine. There are four bolts which hold the shipping bracket to the top of the column and the tool
changer.
2. Remove the rear panel and the panel behind the tool changer. Remove the shipping block (A).

(Horizontal)
3. Jog the column (jog without zero-return) to the home position (towards the tool changer). This will give
access to shipping block (B). Remove this shipping block (B).
4. Handle jog the column to full forward travel in the X-axis (towards the control panel). Enter the enclosure,
from the rear, and remove the spindle shipping pins (C) and (D). Ensure the machine is in E-Stop.
5. Reach in through the operator door and remove the pallet shipping bracket.
Step 5 Step 6
6. Remove the load station pallet bracket. Remove the pallet plug that is bolted to the bracket. Place the plug
in the center hole of the pallet and tap it in place with a mallet.
EC-630 UNBLOCKING P ROCEDURE

1. Remove all ballscrew cover spacers (20-1114).
2. From behind the column, remove the four column shipping pins (20-3633). See the following illustration for
location.
3. Remove the A-axis rotary shipping bracket (25-8348).
4. Remove the blocking bolt from the tool changer transfer mechanism.

(Horizontal)
P ENDANT A RM S HIPPING B RACKET R EMOVAL (EC-300 – EC-500)
1. Remove the pendant shipping bracket, there are three screws holding it in place.
2. Replace the pendant stop; orient it as shown in the illustration. Use the screws removed from the shipping
bracket.
U NBLOCKING P ROCEDURE EC-1600 – 3000

1. Remove the X-axis shipping bracket. It is located at the rear of the table.
2. Power up the machine zero return the Y-axis. Check the counter balance pressure at the top of Y-axis travel;
add nitrogen to bring the pressure back to listed pressure. Note: There are no Y-axis shipping brackets or
bolts.
3. Remove the Z-Axis shipping bolts (see figure). They are accessible from the inside of the column casting.
Axis1
Axis4
Axis1
EC
1600 Shipping
Axis1
Brackets
Axis1
Z-Axis Shipping Bolts 50-Tool Tool Changer Shipping Brackets

50-Tool Tool Changer Brackets
There are two brackets (upper and lower) that need to be removed before using the machine. Make sure that
the machine is completely turned off before removing the brackets. To remove the brackets, unscrew the
two SHCS that attach each side of each bracket to the tool changer and machine.

(Horizontal)
EC-3000 OUTRIGGERS
EC-3000 outriggers are not attached to the machine, they are secured to the pallet for shipping. Remove the
two (2) outriggers from the pallet. Attach an outrigger to each end of the machine, using the supplied fasteners.
Outrigger
U NBLOCKIN
ING THE HS- 3-7(R)
IN
CAUTION: Before unblocking machine ensure that counterbalance cylinder charging

hose is attached to nitrogen tank and nitrogen tank is fully charged to
1250psi.
The counterbalance cylinder has been removed (for overhead clearance during shipping), and it must be
reinstalled and recharged with dry nitrogen prior to enabling the Y-axis. The table is secured for shipping by
means of blocks that are bolted to the table base. The column is secured for shipping by means of blocks that
are bolted to the column base. The spindle head is not secured for shipping, but a cover has been placed over
the Y-axis ballscrew and that cover must be removed.
Shipping Blocks for Table
(2) Shipping Blocks A
(4) Shipping
A
Blocks B
B
A B
Shipping Blocks for Column

Counter Balance Tank
Y-axis Ballscrew Cover

Remove the cover from around the Y-axis ballscrew. There are two parts to the cover, a long section above the
ballnut and a short section below the ballnut. Be certain to completely remove the cover from the ballscrew to
prevent contamination after the Y-axis is later enabled. Inspect the ballscrew for any contamination that may
have gotten through the dust cover during shipping and remove if necessary.
(Horizontal)
I NSTALLING THE HYDRAULIC COUNTERBALANCE SYSTEM
The hydraulic counterbalance system has been discharged of nitrogen (but contains the correct volume of fluid)
and the hydraulic counterbalance cylinder has been removed from the column for overhead clearance in the
shipping configuration. The hose has been disconnected from the hydraulic cylinder and plugged. The hydraulic
cylinder has been placed in the Z-axis auger trough for shipping. The two shoulder screws that secure the
hydraulic cylinder to the top of the column have been stored by tightening them into the threads on the cylinder
mounting surface on top of the column. The Y-axis has been disabled for reasons of safety when initially
powering up the machine.
1. Remove the counterbalance cylinder from the auger trough and unwrap it.
2. Remove the flat washer and two jam nuts from the end of the rod.
3. Remove the two shoulder screws from the threads in the mounting surface on top of the column.
4. Remove the plug from the port of the cylinder and fully extend the cylinder rod.
5. Insert the counterbalance cylinder down through the top of the column and feed the end of the rod through
the mating hole in the back of the spindle head.
6. Place the flat washer on the rod and thread both nuts onto the end of the rod. Before jamming the nuts
together, be certain they are both high enough to allow the insertion of the cotter pin into the hole on the end of
the cylinder rod. When the nuts are in place, jam the nuts together. Insert the cotter pin into the hole on the
end of the rod.
7. Insert and tighten the hydraulic hose fitting (use teflon tape on the fitting) in the port of the counterbalance
cylinder.
8. Orient the cylinder so the hose will be away from the spindle head during operation and tighten the shoulder
screws.
9. Remove the cap plug on the end of the hydraulic hose and connect it to the fitting (use teflon tape) that is
now in the port of the cylinder.
10. Charge the counterbalance system using dry nitrogen to about 1250 psi (measure at the bottom of travel of
the axis). Use all appropriate safety precautions and a supply bottle of adequate volume. The bottle that is to
be charged is a 110 cubic foot bottle.
11. Power up the machine and enable the Y-axis.
12. Check the operation of the Y-axis limit switch in diagnostics
13. Zero return the Y-axis only. The final pressure of the system at the top of travel should be slightly more than
1250 psi. After the axis has established zero, E-stop and note whether the axis has a tendency to slowly fall.
This should be monitored in the position page of the display as well as a visual determination. If the axis falls at
all, the counterbalance pressure should be slightly increased until the head cannot move downward from the
top of travel in a servo off condition. Take care not to overcharge the system, an overcharge could cause the
spindle head to move upward when in an E-stop condition at the bottom of travel.

(Horizontal)
I NITIAL M ACHINE SETUP
WARNING!
At this point, there should be NO electrical connection to the machine.
The electrical panel should be closed and secured. When the main
switch is on, there is high voltage throughout the electrical panel
(including the circuit boards and logic circuits) and some components
operate at high temperatures. Therefore, you must exercise extreme
caution when you are working in the panel.
1. Set the main switch at the upper right of the electrical panel on the back of the machine to OFF.
2. Using a screwdriver, unlock the two latches on the panel door, unlock the cabinet with the key, and open the
door.
3. Take sufficient time to check all the components and connectors associated with the circuit boards. With
the power off, push on them gently to make sure that they are seated in their sockets. Look for any cables that
have become disconnected, look for any signs of damage and loose parts in the bottom of the cabinet. If there
are any signs that the machine was mishandled, be extremely careful in powering up the machine (be ready to
shut it off IMMEDIATELY). Or if there are obvious problems, call the factory BEFORE proceeding.
Air Connection
CAUTION! Working with the air pressure required for the mill can be hazardous. Make
sure that pressure has been removed from the air line before you connect
/disconnect it from the machine, or service parts of the air system on the
machine.
1. When the machine leaves the factory, the air filter is empty, and air lubricator and the lubricator reservoir
tank are full. However, they should be checked and serviced if required before compressed air is supplied to the
machine. (See air lube panel illustration.)
2. Connect the air blow gun to the air supply fitting on the machine. See the following figures.
3. With the pressure off in the air line, connect the air supply to the fitting next to the air filter/ regulator (below
the electrical panel). If the fitting supplied is not compatible, replace it.

(Horizontal)
EC
400
T
PALLE
DUAL
Coolant
Fitting Air Fitting Air Fitting
EC-300 EC-400
3 PSI Oil Pump Pressure

Air Filter/Regulator Gauge/Reg. Gauge
Air Nozzle
Air Line
Oil Filter Oil Reservoir

Shop Air Oil Fill
Front (To High Mark)
HS- 3-7 Shown
4. Start the compressor and set it between 100 and 150 PSI. Set the main regulator on the machine to 85 to 90
PSI. * (EC-400 pallet changer regulator is to be set to 100psi). Verify the air doubler, at the rear of the machine
is set to 40psi on EC-400s with a full fourth axis*.
5. Prime the lubricator to make sure it is working. To prime the lubrication system, pull up on the handle on top
of the reservoir tank. CAUTION! NEVER push down on the primer handle! It gradually returns to the down
position by itself, and the corresponding pressure increase can be seen on the pressure gauge.
6. Verify spindle air pressure using the gauge located behind the Air Regulator panel. This pressure regulator
should be set to 25psi. Adjust if necessary.
Electrical Connections
NOTE: The machine must have air pressure at the air gauge, or a "Low Air Pressure"
alarm will be present on power up.
CAUTION! Working with the electricity required for the mill is extremely hazardous. The
electrical power must be off and steps must be taken to ensure that it will
not turn on while working with it. In most cases this means turning off a
circuit breaker in a panel and then locking the panel door. However, if this
is not the case or are not sure how to do this, check with the appropriate
personnel and/or obtain the necessary help BEFORE you continue.

(Horizontal)
WARNING!
Keep the electrical panel closed and the latches on the door secured
at all times except during installation and service. At those times, only
qualified electricians may access to the panel. When the main circuit
breaker is on, there is high voltage throughout the electrical panel
(including the circuit boards and logic circuits) and some components
operate at high temperatures. Therefore, extreme caution is required.
Ouput
T5 Transformer Power
Ground Line
Input
Main Power
L1 L2 L3 Circuit 24 TB2
Breaker
0V
OU
T
48
8-4
58
V
45
7-4
DA 26 29V
0-2
NG INC
OM
44
V 42
8-4
ER ING
24 03V
!!! LIN
EV
O
3-2
27
2-3
40
LT V
HIG AG
E TA 22 77V
Main 12 TB1
HV
OL
TA
PS
(74,
6-2
75
11 376
, 76
)
V -3
21 54V
0-1
95
0V
OU G E V
Circuit T
DA
NG
ER
Breaker !!!
1. Secure the three power lines to the terminals on top of the main circuit breaker at upper right of electrical
panel. Connect the separate ground line to the ground bus to the left of the terminals.
NOTE: Make sure that the service wires actually go into the terminal-block clamps. (It
is easy to miss the clamp and tighten the screw. A poor connection will cause
the machine to run intermittently or have other problems, such as servo
overloads.) To check, simply pull on the wires after the screws are tightened.
2. After the line voltage is connected to the machine, make sure that main circuit breaker (at top-right of rear
cabinet) is OFF. Turn ON the power at the source. Using an accurate digital voltmeter and appropriate safety
procedures, measure the voltage between all three pair phases at the main circuit breaker and write down the
readings. The voltage must be between 195 and 260 volts (360 and 480 volts for high voltage option).
Wide voltage fluctuations are common in many industrial areas; you need to know the minimum and maximum
voltage which will be supplied to the machine while it is in operation. U.S. National Electrical Code specifies
that machines should operate with a variation of +5% to -5% around an average supply voltage. If problems with
the line voltage occur, or low line voltage is suspected, an external transformer may be required. If you suspect
voltage problems, the voltage should be checked every hour or two during a typical day to make sure that it
does not fluctuate more than +5% or -5% from an average.
CAUTION! Ensure that the main circuit breaker is OFF and the power is off at your
supply panel BEFORE you change the transformer connections. Make
sure that all three black wires are moved to the correct terminal block and
that they are tight.
3. Check the connections on the transformer at the bottom-right corner of the rear cabinet. The three black
wires labeled 74, 75, and 76 must be moved to the terminal block triple which corresponds to the average
voltage measured in step 2 above. There are four positions for the input power for the 260 volt transformer and
five positions for the 480 volt transformer. The labels showing the input voltage range for each terminal position
are as shown in the previous illustration.

(Horizontal)
441-480V
221-240V
T5 24 VAC
WARNING:
381-440V
190-220V MEASURE VOLTAGE AT MAIN PHASE DETECT
CIRCUIT BREAKER AND CONNECT (FOR 3 PHASE ONLY)
SUPPLIED SHORTING PLUG TO
CORRESPONDING CONNECTOR PASS FAIL
340-380V ON THIS TRANSFORMER
NE6 NE5
4. Transformer T5 supplies 24VAC used to power the main contactor. There are two versions of this transformer
for use on 240 and 400V machines (32-0964B and 32-0965B, respectively). The 240V transformer has two input
connectors located about two inches from the transformer, which allow it to be connected to either 240V or
200V. Users that have 220V-240V RMS input power should use the connector labeled 240V, while users with
190-220V input power should used the connector labeled 200V. Users with the External High Voltage Option
should use the 240V connector if they have 420V-510V 60Hz power or the 200V connector if they have 50Hz
power. Failure to use the correct input connector will result in either overheating of the main contactor or failure
to reliably engage the main contactor.
The 480V transformer has three input connectors, labeled 360V, 400V and 480V. Users with 340-380V 50Hz
power should use the 240V connector while users with 380-440V 50Hz power should use the 400V connector.
The 480V connector is not currently used.
5. Set the main circuit breaker to ON. Check for evidence of problems, such as the smell of overheating
components or smoke. If such problems are indicated, set the main circuit breaker to OFF immediately and
call the factory before proceeding.
Electrical power must be phased properly to avoid damage to your equipment. The Power Supply Assembly PC
board incorporates a "Phase Detect" circuit with neon indicators. When the orange neon is lit (NE5), the
phasing is incorrect. If the green neon is lit (NE6), the phasing is correct. If both neon indicators are lit, then
you have a loose wire; check the connections. Adjust phasing by swapping L1 and L2 of the incoming power
lines at the main circuit breaker.
Through the Spindle Coolant (TSC) pump is three phase and must be phased correctly. Improper phasing will
cause damage to the TSC pump and void the warranty. Refer to the TSC start up section if your machine is
equipped with TSC.
6. After the power is on, measure the voltage across the bottom terminals on the main circuit breaker. It should
be the same as the measurements where the input power connects to the main circuit breaker. If there are any
problems, check the wiring.

(Horizontal)
7. Apply power to the control by pressing the Power-On switch on the front panel. Check the high voltage buss
on the Vector Drive (pin 2 with respect to pin 3 on the terminal bus at the bottom of the drive). It must be
between 310 and 360 volts. If the voltage is outside these limits, turn off the power and recheck steps 2 and 3.
If the voltage is still outside these limits, call the factory. Next, check the DC voltage displayed in the second
page of the Diagnostic data on the display. It is labeled DC BUS. Verify that the displayed voltage matches the
voltage measured at pins 2 and 3 of the Vector Drive +/- 7 VDC.
8. Close the door, lock the latches, and turn the power back on.
9. Remove the key from the control cabinet and give it to the shop manager.
I NSTALLATION PROCEDURE FOR EXTERNAL 480V TRANSFORMER

Introduction
The external transformer adds to overall machine reliability and performance, however it does require extra
wiring and a place to locate it. The external transformer provides electrostatically shielded isolation. This type
of transformer acts to isolate all common mode line transients and improve EMI conducted emissions.
The external transformer has a 45 KVA rating. It is a 480V 60Hz only transformer.
Installation
The transformer should be located as close to the machine as possible. The input and output wiring of the
transformer should conform to local electrical codes and should be performed by a licensed electrician. The
following is for guidance only, and should not be construed to alter the requirements of local regulations.
The input wire should not be smaller than the 6AWG for the 45KVA transformer. Cable runs longer than 100”
will require at least one size larger wire. The output wire size should be 4 AWG.
The transformer is 480V to 240V isolation transformers with delta wound primary and secondary windings. The
primary windings offer 7 tap positions, 2 above and 4 below the nominal input voltage of 480V.
The primary side should be wired as follows:
Input Voltage Range Tap
493-510 1 (504)
481-492 2 (492)
469-480 3 (480)
457-468 4 (468)
445-456 5 (456)
433-444 6 (444)
420-432 7 (432)
This should produce a voltage on the secondary side of 234-243 V RMS L-L. Verify this and readjust the taps
as required. At the machine, connect the cables at the input of the internal 240V transformer to the 227-243V
taps. Apply power to the machine and verify that the DC voltage between pins 2 and 3 of the Vector Drive (2nd
and 3rd pins from the left) is 329-345VDC. If not, return to the 480V isolation transformer and readjust the taps
as required. Do not use the taps on the internal 240V transformer to adjust the voltage.
50Hz Installations
The external transformers are 60Hz rated, and cannot be used at 50Hz without derating the input voltage. For
these applications, the internal 240V transformer should be tapped on the lowest setting (195-210V RMS). The
external transformer should be tapped according to the following table. If these tap settings do not produce a
DC bus voltage between pins 2 and 3 on the Vector Drive between 320 and 345VDC, readjust the taps on the
external transformer as required. Do not move the taps on the internal transformer from the lowest position.
Input Voltage Range Tap Input Voltage Range Tap
423-440 1 (504) 381-390 5 (456)
412-422 2 (492) 371-380 6 (444)
401-411 3 (480) 355-370 7 (432)
391-400 4 (468)

(Horizontal)
U NBLOCKING THE T ABLE (HS - 3–7)
There is one block, bolted to the base, at each end of the table. To access the shipping blocks, both X-axis
way covers need to be fully retracted from the table. Note: The X-axis (and A-axis, if equipped) has been
disabled, using parameters, for reasons of safety on power up of the machine.
Rubber Pad Shipping

Clamp Blocks
Block
Support Block
SHCS (9)
X-Axis Chip
FHCS (4) Guard
Way Cover
1. Disconnect both X-axis way covers from the table and fully retract the way covers.
2. Remove the front and rear X-axis chip guards to ease access to the underside of the table (if necessary).
3. Remove the blocks from the table base to prevent any inadvertent damage.
WARNING!
Be certain the machine is powered off when connecting or discon-
necting servo motor cables.
4. Uncoil the X-axis servo motor cable and connect to the motor. Do not attempt to route the cable to the final
configuration at this time, but go directly from the control to the motor. This will provide power to the motor so
the machine can be jogged in the X direction without zero return.
5. After the X-axis motor cable is connected, turn the machine on and enable only the X-axis (parameter 1 bit 3)
at this time.
6. Enable jog without zero return (setting 53) and move the table toward the home position taking extreme
care that the X-axis cable does not get pinched between the table and any obstruction. Also be aware that
there may be cables on the underside of the table that could be damaged while jogging in the shipping configu-
ration.
7. When the table is moved just far enough to allow access to the two single-piece shipping blocks, stop
jogging the table and remove the two single piece shipping blocks completely from the table base.
8. Handle jog the table back to allow access to the support part of the two-piece shipping blocks and remove
them completely from the table base.
9. Continue jogging the X-axis far enough to allow access to the cable access hole. Power the machine down.
Disconnect the X-axis cable, and route the table base cables and lines through the cable access hole.

(Horizontal)
xis
X-A
Linear Scale Cable,

Disconnect at
Cable Carrier
Interpolation box
X-axis motor
cable and A-axis
motor cables are
disconnected
at the control
Limit Switch and

Lube Line Junction
a) Route the X-axis motor and encoder cable and connect.
b) If equipped with an optional A-axis, route the A-axis motor, home switch, rotary encoder cables and
the air line for the rotary brake to the connectors from the control. The connectors from the control is
near the junction of the table base and the column base. Connect the motor cables to the supply cables
from the control box and place the connectors in the cavity of the column base.
c) Route the X-axis limit switch cable to the lube air panel and terminate in the connector.
d) Route the oil line connector from the column base and connect with the oil line already in the table base.
10. Turn on the machine and check the X-axis limit switch operation in diagnostics, then zero return the X-axis.
11. Enable the A-axis (parameter 43 bit 3) and zero return.
12. Check cable clearances under the table for the full X-axis travel and secure where necessary.
13. Reinstall the front and rear X-axis chip guards. Reinstall both X-axis way covers.
U NBLOCKING THE C OLUMN (HS3–7)

There are two blocks in the front and two blocks in the rear of the column. To access the shipping blocks, both
Z-axis way covers need to be fully retracted from the column. When the front Z-axis way cover is disconnected
from the column, the lower Y-axis bellows will need to be properly supported. For that reason, the counterbal-
ance must be charged prior to the removal of the shipping blocks in the column base, permitting the spindle
head to be safely raised. The Z-axis has been disabled in parameters (parameter 29 bit 3) for reasons of safety
on power up of the machine.
Y Axis Shipping Stop Rear Access

Bellows Blocks Cover
Z Axis Chip
Guard (2)
Rubber
Pads (4)

(Horizontal)
1. Disconnect the rear Z-axis way cover from the column and fully retract. Remove the two shipping blocks and
hardware completely from the column base.
2. Raise the spindle head to the full up position to allow the lower Y-axis bellows to be collapsed upward.
3. Disconnect the lower Y-axis bellows from the front Z-axis way cover and block up to permit access to the
screws that attach the Z-axis way cover to the column. Disconnect the front Z-axis way cover from the column
and fully retract taking care to not allow the Y-axis bellows to fall. When the way cover is retracted far enough,
block the Y-axis bellows up and then continue to collapse the Z-axis way cover until it is fully retracted.
4. Enable the Z-axis in parameters (parameter 29 bit 3) but do not zero return. Ensure the Y-axis bellows will
not fall, handle jog (without zero return) the Z-axis toward the rear of the machine until access to the bolts
holding the forward shipping blocks are accessible.
5. Block the Y-axis bellows up and remove the shipping blocks completely from the column base.
6. Check that the Z-axis cables are properly routed and the cable guide is securely attached to the base.
Check the operation of the Z-axis limit switch in diagnostics. Zero return the Z-axis.
Machine Leveling / Geometry Check (HS 3-7)
At this point the machine is completely unblocked and all axes are enabled.
Cable Access Table Base

Hole Mating
Flange
Column Base
Mating Flange
SHCS (15)
Lockwasher
(15)
The following criteria should have already been met at this point:
• The machine correctly placed with respect to the anchoring points.
• The very rough leveling has taken place, ensuring that the bottom of the two bases are very close to 2 ½
inches off the floor.
• The mating flanges of the two bases have been pulled into contact.
• The screws that connect the two bases have been backed off and can rotate freely.

(Horizontal)
O VERVIEW OF L EVELING
The X-axis auger trough must be removed before mating the column base to the table base. The auger trough
will remain off the table base until the leveling and squaring procedures are completed. It is recommended that
the table base be removed from the truck and set in place before the column base to better accommodate
removal of the auger trough and keep the installation process moving smoothly.
The installation process will be further aided if, when each base assembly is set in place, a very rough leveling
procedure be done. The distance from the floor to the bottom of the two bases is 2.5 inches. The use of a
machinist scale or small gauge blocks will expedite the process. While all leveling screws and leveling pads
are in place measure from the floor to the bottom of each base until the distance is very close to the 2.5 inch
height. This will accomplish two things: First, that the machine is set to the proper height to receive the coolant
tank and, second, that the machine will be very much closer to level than without having done this procedure.
The installation procedure will necessarily follow the general outline below (a more detailed explanation follows).
Depending on the available space and equipment it may be simpler to place the column base assembly before
the table base assembly. This outline considers that it is easier to place the table base assembly first. Regard-
less of which assembly is placed first, the concepts of the general outline need to be adhered to:
• Remove the table base assembly from the truck and set in place
• Remove the X-axis auger trough and rough level the table base
• Stone and clean the table base mating flange
• Remove the column base assembly from the truck
• Stone and clean the column base mating flange
• Move the column base to mate with the table base
• Be certain that all connecting bolts are in place but not tightened
• Rough level the column base assembly
• Power up the control
• Remove the dust covers from the column assembly
• Install the counterbalance cylinder and charge the system
• Remove shipping blocks from the table base assembly
• Connect all air/electrical/oil lines between the two assemblies
• Remove shipping blocks from the column base assembly
• Fine level the table base assembly
• Fine level/square the column base assembly
• Fully tighten the connecting bolts and adjust fine level/square
• Fully check machine geometry
• Replace the X-axis auger trough
• Install the tool changer
• Install the coolant supply system
• Check all motors for rotation/phasing
Establishing the Table as the Datum Surface

1. Remove all but five of the mating flange connecting screws. The five that should be left in position are the four
that are in the corners of the mating flange and the one that is in the center of the top of the mating flange. Be
sure that the five remaining screws are able to rotate freely, indicating that no binding will occur by changing
the level of the table base. (The freedom of these screws is important to the process, and they should be
checked frequently since, if they bind, the leveling process associated with the column base could alter the
table base level). If the screws do begin to bind, the column base should be raised or lowered accordingly to
free the screws. While maintaining full face contact of the mating flange surface.

(Horizontal)
Column
casting
Step #6 Step #6
Step #5
Table casting
2. Zero return all axes.

3. Move the table to its midpoint.
4. Place two levels at right angles to each other at the center of the table. One will show the level across the
width of the table and the other will show the level along the length of the table.
5. Focus on leveling the table only in this X-axis position to establish a primary datum for the machine. Adjust
only the four leveling screws indicated (the two on the table base closest to the column base, and the two
immediately on the other side of the table base). No other leveling screws on the table base should be in
contact with the leveling pads at this time.
6. When the table level is close to zero in both directions, the four very end leveling screws may be brought
down to touch the leveling pads.
7. Continue to level the table base until both levels on the table read zero.
Leveling the Column Base (HS 3-7)
1. Check that the mating flange screws are still free to turn so the following steps do not affect the level of the
table base primary datum.
2. Allow only the four leveling screws on the corners on the column base are to be in contact with the leveling
pads at this time.
3. With the column at approximately center of travel, lay one granite parallel across the linear guides as close
to the table as possible and another granite parallel across the linear guides as near the rear of the machine as
possible.
4. Place a level on each parallel and adjust the level of the column from side to side.
5. Check the freedom of the mating flange screws to be certain there is no binding. Raise or lower the column
base as necessary to free screws.
6. On the guide nearest the control, place one level on the linear guide in front of the column and one level on
the linear guide to the rear of the column. Adjust the level of the machine in the direction of Z-axis travel. Move
the levels to the opposite linear guide and complete the process.
Repeat steps 3-6 until the column base is level. Be certain throughout the process that the mating flange
screws are free to rotate. A binding of the screws will mean that the column base will have to be raised or
lowered as necessary and the leveling process of the column base will need to be repeated.
7. When the column base is level to earth in both directions, the six center leveling screws should be lowered
to touch the leveling pads.
8. Remove the granite parallels from the column base.

(Horizontal)
Checking the Level of the Column Base
1. Handle jog the column to the rear.
2. Place a single level on the top of the spindle head parallel with the X-axis of the machine. It is very unlikely
that this surface will read zero, do not expect it to. Note the reading that is present.
3. While monitoring the level, move the column all the way forward and check if there is a change in the level
reading. If there is no change of reading, then the column base has no twist. If there is a twist in the base, this
must be corrected.
4. Place an indicator in the special tool and touch off on the table surface. Sweep the table in the Z-axis
direction only, to determine, and correct column base flatness in the Z-axis direction. This is a very sensitive
measurement method and corrections to this level should be made in conservative steps.
NOTE: Any corrections that are made in this check of the column base level require
that a repeat of the basic leveling procedure be done and a recheck of the level
be done. All criteria must be met.
s
xi
-A
Z
Sweeping the Y-Axis (HS 3-7)

Before continuing to the final attachment of the column base to the table base the Y-axis needs to be swept.
Until now we have assumed that the geometry of the column is perfectly perpendicular to the plane of the
column base, but that may not be close enough to maintain the required machine geometry.
Y-Axis Motion Will

Be Swept Parallel X-Y Plane
To Line Of
Intersection
Y-Z Plane
Sweeping the Y-axis is accomplished using a cylinder square. The purpose of this sweep is to verify that the
line of motion of the Y-axis is perpendicular to the X-Z plane described by the motion in the Z-axis and the
motion in the X-axis. The X-Z plane, as defined by the leveling process, should be equivalent in the squaring
function as the parallel plane described by the surface of the table. The line of motion of the Y-axis will be
checked by comparing it to the line of intersection of the two most convenient relative planes, that of the X-Y
plane and the Z-Y plane. By assuring that each of these planes are perpendicular to the X-Z plane within
specification, the machine geometry will be preserved.

(Horizontal)
Final Connection of the Column Base to the Table Base
1. Completely remove the front Z-axis way cover from the machine.
2. Remove the front Z-axis way cover bottom cover and the way cover support bars to allow access for properly
tightening of the connecting screws.
3. Before inserting and tightening all the connecting screws, recheck the table level to be certain that the
leveling process of the column base did not affect table level.
4. Tighten the connecting screws with lock washers in place and loctite on the screws.
Geometry Check After Mating the Two Bases
Before continuing two fundamental geometry checks need to be made. The first is the perpendicularity of the X-
axis to the Z-axis, and the second is to verify the sweep of the Y-axis.
1. The sweep of the X-axis to the Z-axis is accomplished using a granite square. Set zero by sweeping the Z-
axis on one side of the square, and then to verify that the motion of the X-axis is perpendicular by sweeping the
adjacent side of the square. If the X-axis and Z-axis are not found to be within tolerance, there almost certainly
is contamination or damage between the mating flange surfaces that is creating this error. The unit will have to
be completely separated, the surfaces re-stoned and recleaned thoroughly, and the entire leveling/squaring
process will have to be repeated up to this point.
2. Verify the sweep of the Y-axis by repeating the previous section (“Sweeping the Y-Axis”).
Fine Leveling the Machine (HS 3-7)
Now that the preliminary leveling is done and the bases are securely mated, the machine can be treated as a
unit with confidence that the geometry will be able to be maintained as long as adequate control is maintained
in the fine leveling process. The process begins with loading the remainder of the leveling screws very lightly
and working into an equally loaded situation that does not affect the geometry already achieved.
The column base will be the first section affected, and will be fine leveled with respect to the table at the middle
of travel.
CAUTION! Do not rush the leveling process. Any drastic attempt to fine level the column
base will be propagated to the table base assembly and may not be
correctable if not addressed early in the process.
The table base is more complicated to fine level, and small steps will be taken to preserve the level to earth
established at the middle of travel. The first step of the process will be to begin to load the leveling screws over
the length of the base. The second step will be to begin to pull the overall length into earth level. The third step
will be to fully pull the base into level.
1. Begin with the column base assembly. Place the level on the spindle head parallel with the Z-axis and run
the column through the range of travel. If no deviation in the reading exists, the column base is flat in the
direction of the Z-axis. Move the level to each of the linear guide surfaces in front of the column. If the readings
are zero, the column is flat to earth in the direction of the Z-axis. Place the level on the spindle head parallel to
the X-axis. Run the column through the range of travel. If no deviation in the reading exists, the column base
exhibits no twist. Place the granite parallels across the linear guide surfaces in front and behind the column.
Place the levels on the granite. If the readings are zero, the column base is flat to earth in the X-direction.
2. Move the levels to the table and place them as close to the center as possible. One level should be parallel
to the X-axis and one level should be perpendicular to the X-axis. If the readings are still zero, then the table at
the center of travel is still level to earth.
3. If any deviations exist, they need to be corrected at this time. If the deviations are very small, the mating
flange of the two bases does not need to be unscrewed. If the deviations are very large, attempting to correct
the level may induce a large stress in the assembly that will not allow earth level to be fully achieved. It is
important for the geometry of the machine that earth level be achieved.

(Horizontal)
The table at center of travel is now known to be at earth level and the column base is also at earth level. The
process of extending that level over the travel of the X-axis may now begin by starting to load the remainder of
the leveling screws.
4. Lower the remainder of the table base leveling screws to touch off on the leveling pads below.
5. Move the table toward zero so the levels are in line with the next set of leveling screws after the primary
leveling screws. Make a very slight correction to the leveling screws at that location if the level deviates from
zero.
NOTE: Attempting to compensate for all of the deviation at any single position may
compound an otherwise small error. Do not try to final level the table base in
a single pass over the travel of the X-axis.
6. Continue moving the table toward zero, stopping at each instance where the levels are in line with the
leveling screws. Make small adjustments that begin to correct the deviation from earth level. When the end of
travel is reached, the leveling screws on the end of the table base can be slightly adjusted.
7. Return the table to the center of travel. Verify that earth level still applies to the table at that position. If it
does not, it must be attained again before continuing. Only the leveling screws that have been previously
adjusted should be used. Do not alter the position of the four primary leveling screws at this time.
8. Move the table in the same increments as before but in the direction away from zero. Repeat the very slight
adjustment procedure, beginning to make a correction in the table, level to earth.
9. Move the table back to the center of travel and verify that the primary earth zero has not been affected. If
earth zero does not exist at the center of travel, make the correction now.
The load of the table base assembly is now being shared over all of the leveling screws. The table at the center
of travel is at earth zero, and the column base is at earth zero.
Fine Leveling of the Table Base

Using the same process as loading the leveling screws in the previous steps, move the table over to line up the
levels with the leveling screws and begin to make very moderate adjustments toward earth zero. Continue the
process to the end of travel as before, then return to the center of travel and verify earth zero there. Move from
the center of travel the other direction and repeat the procedure until the table is at earth zero over the entire
travel of the X-axis.
Verify that the Z-axis has not been affected by the leveling procedure of the X-axis. If it has, use the steps
described previously to make the necessary correction and then verify that the X-axis is still correct.
Do not try to hurry this process. This is a careful, process that relies on modest adjustments for each step
along the way. If too large an adjustment is attempted, the geometry will fail and it may not be possible to
determine the corrective action and the bases may have to be disconnected to rectify the situation.
Sweeping the table

The sweep of the table should be little more than a verification of the leveling process. Using the tool for
mounting the indicator, first verify that the table is within specification as the Z-axis is moved. Then, for several
Z-axis positions where the indicator is on the table surface, run the X-axis from end to end and verify that it is
also within specification.
Geometry Check
The final step of the leveling and squaring process is to verify the overall machine geometry with respect to the
individual geometric inspection report of the machine. Every point of inspection must be verified to be within the
tolerances specified for the machine.

(Horizontal)
C OMPLETING THE I NSTALLATION (HS 3-7)
1. Replace all sheet metal removed paying particular attention to sealing any component mating surface
potentially exposed to coolant flow.
2. Install the table gutter fence. Install and verify operation of the tool changer (see the section on tool changer
installation).
3. Verify all machine functions.
Cable
Support
Clamp
Cable xis
X-A
X-Axis Auger
Trough
Cable (To X-Axis

Auger Motor)
Cable
X-Axis Auger Trough
T OOL CHANGER INSTALLATION (HS 3-7)

1. Before installing the eight leveling blocks on the bottom of the toolchanger base plate, thread in the metric
SHCS into the holes located on each side of the leveling screws.
2. Temporarily block the tool changer up on its base plate and install the eight levelling blocks on the bottom of
the base plate. Secure them with the metric SHCS installed above. The levelling blocks with center holes are
for the Main Levelling Screws in each corner; the solid levelling blocks are for the Intermediate Leveling Screws.
3. Verify that the four main leveling screws (the large hollow screws located at all four corners) and the four
intermediate leveling screws (the hex head bolts located on each of the four sides of the base plate) are
adjusted so that they are flush with the bottom of the tool changer’s base plate.
Bracket Slots
HS3 Toolchanger
Center Holes In
HS3 Base With
Vertical Slots Of
Bracket
Metric
SHCS
Bracket
(3) M16x60mm
Toolchanger
HS3
Intermediate
Leveling Screws
Leveling Blocks
Main Leveling Screws
Tool Changer and Base Plate

(Horizontal)
4. Lift the tool changer with the arm mechanism facing towards the front of the machine. Move the tool changer
over the top of the pre-installed anchor bolts and lower it such that the hollow leveling screws slide over the
anchor bolts.
5. An alignment bracket is used to provide the initial “rough” alignment of the tool changer to the horizontal mill.
Attach the alignment bracket to the base of the tool changer using three M16 X 60mm metric socket head cap
screws (Haas P/N 40-0039). Install, but do not tighten the screws at this time. In addition, it may be
necessary to move the tool changer’s base plate a small amount to bring the alignment bracket into its proper
position.
6. Place a bubble level on the tool changer’s base and using the four main leveling screws (the large 60mm hex
screws located in the corners of the base plate) bring the tool changer base plate into level. During this leveling
procedure, verify that the height of the slots on the vertical face of the alignment bracket are at the same
elevation as the threaded holes in the pad located on the side of the milling machine’s base. If necessary,
readjust the leveling screws to bring the alignment bracket to the proper elevation.
7. When the tool changer is level and the four slotted holes in the alignment bracket are lined up with the
threaded holes in the pad, attach the alignment bracket to the base of the mill using four 3/8-16 x 1¼ socket
head cap screws. Finish attaching the bracket by tightening the three M16 cap screws.
8. Next, thread the four intermediate leveling bolts (the four bolts with 30mm hex heads located near the center
of each side of the base plate) down until they just touch the leveling blocks. Further tighten the bolts approxi-
mately another 1/8 turn past this point to insure these screws are each sharing some portions of the load.
9. Complete the base plate installation by installing the nuts and washers onto the threaded ends of the tool
changer anchor bolts and tightening to 230 ft-lb. Note that these are metric threads and nuts.
10. Remove the two shipping brackets located on the tool changer’s arm assembly.
11. Install the tool changer guard around the tool changer and make the following electrical connections:
a) Connect the remote control box cable to the tool changer junction box.
b) Route and connect the cables from the tool changer junction box to the connectors located on the side
of the control box.
I NSTALLING THE H YDRAULIC P OWER U NIT (HS 3–7)

Before placing the Tools Changer, position the HPU behind the machine. This must be done before the tool
changer is installed, otherwise there may not be room to maneuver the HPU between the tool changer and any
obstacles. Once in position, install the hoses as shown.
T
Low Pressure
P
High Pressure
Air Low Press.
High Pressure High Press.
Air
Low
Pressure

(Horizontal)
Hydraulic Power Unit Information
Maximum Pressure: 1000 PSI Hydraulic Fluid: DTE 25 (Do Not Mix)
Tool Changer Maximum system pressure: 700 PSI Pressure Hose (52-0008): 1/2" JICF x 84" L
Maximum Flowrate@ 1800RPM: 10.5 GPM Return Hose (52-0000): 1/2" JICF x 90" L
Reservoir Volume: 20 Gallons
1. Check the level of the hydraulic fluid in the reservoir by inspecting the sight gage located on the side of the
reservoir. If necessary, add hydraulic fluid (DTE 25) to the reservoir until the level reaches the top of the sight
gage.
2. Connect the pressure and return hoses from the hydraulic power unit (HPU) to the tool changer. The pres-
sure hose connects the pump outlet to the middle port on the tool changer manifold; the return hose connects
the bottom port on the tool changer manifold to the filter inlet on the hydraulic power unit. NOTE: If the HPU is
operated for the first time, skip to step 7 for initial adjustment of the hydraulic system pressure and flow
settings.
3. Connect the supply airline (1/4” plastic hose) from the machine’s air-lube panel to the upper fitting on the tool
changer manifold.
4. Connect the power cord from the hydraulic power unit’s motor to the power connection located on the side of
the milling machine’s control box.
5. Check the rotation direction of the hydraulic power unit motor using the following procedure:
a) Remove the orange inspection cover from the bell housing located between the motor and the hydraulic
pump. Power-up the machine but do not clear the alarms until the next step.
b) With an observer watching the coupling inside the inspection window, push the <RESET> button on the
keypad and immediately push the <E-STOP> button. This will jog the motor on the hydraulic power unit.
c) Note the rotational direction of the power unit motor and compare with the directional arrow located on
the front of the hydraulic pump casing.
d)If the rotation matches the rotation of the directional arrow the machine is correctly wired. If the rotation
does not match then the phasing of the machine’s power must be changed by reversing any two of the
incoming three wires of the machine’s power wiring.
e) If it was necessary to change the machine phasing , recheck and verify that the motor is rotating in the
correct direction (return to Step 5b).
6. Turn the hydraulic power unit on by powering-up the machine and clearing the alarms. NOTE: The hydraulic
power unit operates any time the machine is powered-up and the alarms are cleared.
7. When the pump is to be operated for the first time, the discharge side of the pump should be in a no-load
state. This is accomplished by connecting the pump’s discharge (pressure) hose directly to the inlet of the
return filter connection.
Start and stop the motor 5 to 6 times to bleed any air from inside the pump. Verify that the pump is discharging
oil by feeling the discharge hose or cracking one of the fittings. Operate the pump for at least 10 minutes
without any load to remove any remaining air in the circuit.
8. To adjust the flow rate of the hydraulic system perform the following steps:
a) The flow rate is adjusted with the hydraulic power unit operating in a no-load state.
b) Install a hydraulic service flowmeter rated for 1 to 15 gpm in-line with the hose connecting the pump
discharge to the filter inlet of the hydraulic power unit.

(Horizontal)
c) Turn the hydraulic power unit on and adjust the pump discharge flow rate by turning the flow
adjustment screw (the horizontally oriented screw with locknut), clockwise to decrease the flow rate and
counter-clock wise to increase the flow rate. The correct flow rate for operation of the ATC 38 tool changer
is 8 gpm. Note that it may be necessary to first adjust the pump “open system” discharge pressure to
achieve 8 gpm. This is done by adjusting the vertically oriented screw. Approximately 300 to 375 psi will be
the maximum achievable pressure when in the “open system” operating mode.
Pressure Adjustment Screw

Inspection Cover
Flowrate Adjustment Screw
Hydraulic Pump Pressure and Flowrate Adjustment Screws
9. Reconnect the hydraulic hoses as described in Step 2, after the flow rate has been adjusted.
10. Turn the machine on and check the pressure gage on the HPU to verify that the system pressure is in the
range of 700 to 750 psi. This is the “blocked system” pressure.
If necessary this pressure can be adjusted by turning the pressure adjusting screw (the vertically oriented
screw with locknut), on the pump in a clockwise direction to increase pressure and counterclockwise to
decrease pressure.
The tool changer is now fully connected and ready for alignment.
NOTE: Final alignment of the toolchanger to the machine spindle must be performed
before the toolchanger can be used to change tools.
38 T OOL S IDE M OUNT T OOL C HANGER A LIGNMENT (HS-3-7)
Tool Required:
Alignment Jig
1. Level the tool changer, using a magnetic level, placed on the body of the tool changer. Set perpendicularity
to A and Z axis using the four leveling screws and jam nuts at base of the tool changer.
Leveling Screws
Leveling Screw Locations

(Horizontal)
The four hex screw that go through the hollow leveling screws are used to anchor the tool changer to the floor
after it has been leveled. Insure that the tool changer angle bracket is attached.
2. Loosen the eight sub plate bolts. Do Not press POWERUP RESTART.
3. To align the tool changer, a few preliminary steps must be done to avoid damaging the mill or the tool
changer:
a) Press <POWER ON> button.
b) Go to the PARAMETERS screen and set Parameters #211 (Y-axis) and #64
(Z-axis) to zero.
c) Press <ZERO RETURN> and <AUTO ALL AXIS> buttons.
d) Press <MDI> button then press <ORIENT SPINDLE> button.
e) Press <TOOL CHANGER RESTORE> button.
At this point the machine will ask the operator to verify the locations of any tools and the status of the tool
changer door. When the conditions asked for on the screen are met press <Y>, this will simultaneously open
the tool changer door and to move the next screen.
This screen gives a warning that tools may fall during the following process. The operator is asked to press
<Y> to continue the process.
The new screen states:
PRESS A TO ATTEMPT AUTO RECOVERY
PRESS M TO GO TO MANUAL RECOVERY
Press <M> to go into manual recovery mode.
The next screen states:
A= Arm
M= Magazine
O= Open Door
C= Close Door
Press <M> on the keypad to home the tool changer magazine. After the magazine has reached its home
position press <A> to go to the control screen for the tool changer’s arm functions.
The next screen states:
Hydraulic tool changer bump arm
Using arrow keys attempt to move the arm into its home position
Pressing the cursor keys will move the tool changer’s arm and carriage.
NOTE: The tool changer arm and carriage assembly will ‘jerk’ and ‘shake’ when it is
operated manually by using the control panel keys. Because the motion is
somewhat erratic, the safety of personnel and equipment should be taken into
consideration when operating in this mode.
WARNING!
When operated in the manual mode it is possible to move the tool
changer arm and carriage into a position that may damage the tool
changer and/or the horizontal mill. Before manually operating the tool
changer the machine operator must fully understand the motion of
the tool changer’s arm and carriage during a normal tool change cycle.
Most importantly do not attempt to swing the tool changer arm to-
wards the spindle unless the phrase “Arm Home” is displayed on the
T/C recover screen.
4. The next step in the alignment procedure is to move the tool changer arm to its HOME position by using the
cursor buttons. The following buttons are used to manually jog the tool changer:

(Horizontal)
Home Button Swing arm towards spindle
Page Down Swing arm towards magazine
Up Arrow Pull arm in
Down Arrow Push arm in
End Button Rotate arm counterclockwise
Page Up Rotate arm clockwise
Left arrow Slide arm to left
Right arrow Slide arm to right
The HOME position is defined as:
a) The arm is fully rotated towards the magazine, using the <PAGE DOWN > button.
b) The arm is fully pulled in, using the <^> up arrow button.
c) The arm is rotated fully clockwise or fully counterclockwise, using the <END>
button or the <PAGE UP> button until the arm is in a horizontal position.
d) The arm is moved fully to the right, using the <>> right arrow button.
When the tool changer arm has been moved into its HOME position the control panel screen will display a
highlighted line that states ARM HOME. Prior to reaching the HOME position the display screen will be blank
in this area. As a check, when the arm is in the HOME position, the cam follower on the bottom of the slide
mechanism will be in-line with the cam slot on the guide plate.
By using the cursor keys and the messages displayed on the TOOL RECOVERY screen, move the tool
changer’s arm into its HOME position. The tool changer arm and carriage must be moved to their full limit of
travel to achieve the HOME position. Even when it appears that the full limit of travel has been reached, push
the button several more times to ensure that, in fact, the full limit of travel has been reached.
5. Zero return all axis. Press MDI then ORIENT SPINDLE.
6. Press TOOL CHANGER RESTORE. Follow the displayed instructions until TC RECOVER screen appears.
7. Press HOME until the tool changer swings in and into hydraulic lock, this can be achieved by bumping the
key several times after the tool changer comes to a stop.
8. Press > until the tool changer double arm slides all the way in and into hydraulic lock. Place a magnetic
level on the face of double arm, plumb and level the tool changer by adjusting leveling screws at the base of
tool changer. Insure that the key tab on double arm aligns with the dog on the spindle.
Key Tab Jig
Dowel Pin
Taper
Key Tab Alignment Alignment Jig
9. Press PAGE DOWN until the tool changer is back to the stow position. Using the alignment jig dowel pin,
push the top half of the jig into the double arm fingers. Insure that it is inserted properly and that the flat side
faces the spindle. Press TOOL RELEASE and install the taper into the spindle.
10. Press HOME and swing the tool changer towards the spindle. Insure it is in hydraulic lock.

(Horizontal)
11. Press > and slide the double arm all the way to the spindle until it locks. Adjust the three transition (slide)
bolts until the jig halves are aligned by sight. Insert the dowel pin, if it goes all the way through, the alignment
is complete. Tighten the lock nuts on the slide and leveling bolts. If the dowel pin does not go through all the
way, continue with fine adjustments using the slide and leveling bolts to adjust the tool changer left, right and
perpendicular to the spindle.
12. Press ALARM MESGS, type “DEBUG” and press ENTER. Press POSIT, Press HANDLE JOG and jog the
Z axis until the air gap between the jig halves is 1.5mm (.059”) in all directions. Enter the value into Parameter
into parameter number 64 (omit the decimal point).
13. Handle jog the Y-axis moving the spindle up or down to align jig halves. Enter the value into parameter
number 211 (omit the decimal point).
14. Rotate the arm and switch the alignment jig to the other side. Adjust as necessary so that the alignment
pin inserts fully. Repeat steps 11-13 until the dowel pin inserts fully in both sides of the arm.
15. Tighten all locking nuts. Home tool changer and magazine. Exit from tool changer restore mode by press-
ing jog handle mode.
SETTING THE TOOL CHANGE POSITION P ARAMETERS

Without moving the tool changer arm, spindle or column from the position achieved in Step 15, do the following:
1. Go to the SETTINGS/GRAPH display screen by pressing the <SETNG/GRAPH> button.
2. Go to Setting #7, PARAMETER LOCK and change it to OFF by pressing <>> (right arrow) button and then
press the <WRITE/ENTER> button to save it in memory.
3. Go to the ALARMS display screen by pressing the <ALARM/MESGS> button. Type in DEBUG from the
keypad and press the <WRITE/ENTER> button.
4. Move to the POSITION display screen by pressing the <POSIT> button. Press the <PAGE UP> button to
move to the POS-RAW DAT screen.
5. Record the values shown in the ACTUAL column for the position of the Y and Z-axes.
6. Go back to the ALARMS screen, type in DEBUG and press the <WRITE/ENTER> button to exit the DEBUG
mode.
7. Press the <E-STOP> button to allow parameters to be changed.
8. Go to the PARAMETERS display screen by pressing the <PARAM/DGNOS> button. Go to Parameter #211,
Y Tool Change Offset, on the “Y PARAM B” screen. Enter the number (with the correct sign) recorded from
the POS-RAW DAT screen for the Y-axis and press the WRITE/ENTER button.
NOTE: These Parameter numbers are entered without a decimal point and must be
the same sign as that given on the POS-RAW DAT screen. For example,
-0.7094 would be entered as -7094 and -278.8854 would be entered as
-2788854.
9. Go to Parameter #64, Z Tool Change Offset, on the “Z PARAM B” screen. Enter the number (with the
correct sign) recorded from the POS-RAW DAT screen for the Z-axis and press the WRITE/ENTER button.
NOTE: Entering a value other than zero for parameter #64 creates a new “zero”
position for the machine’s Z-axis which is forward of the zero limit for the
machine. Thus, when programming the position of the Z-axis it is possible to
use both positive and negative values for the Z-axis position without using a
work offset.

(Horizontal)
10. Because of the new “ZERO” position for the machine the value for Parameter #34, Z –axis Maximum
Travel must be adjusted to reflect the new “ZERO” position. To calculate the new value use the following
formula: (Parameter #33) x (Z –axis travel distance) – (Parameter #64) = (Parameter #34), where:
(Parameter #33) is Z-axis encoder steps per unit (unit = 1 inch)
(Z-axis travel distance) is the machine’s total Z-axis travel in inches (60 in.)
(Parameter #64) is the Z Tool Change Offset value in encoder steps
(Parameter #34) is the Z-axis Maximum Travel in encoder steps
Example: (138718 steps/inch) x (60 inches) – (1052517 steps) = 7270563 steps
Go to the “Z PARAM B” screen and enter this number for Parameter #34.
11. Remove the E-STOP condition by pulling out the <E-STOP> button and press the <RESET> button twice
to return to normal machine operation.
12. Push the <TOOL CHANGE RESTORE> button and gain access to manual control of the tool changer.
13. Using the tool change manual recovery cursor buttons, move the tool changer carriage out of the machine
enclosure to its home position and remove the alignment tool from the spindle and the tool changer arm.
14. Complete the Tool Change Restore operation to close the tool changer door.
15. POWER OFF and then POWER ON the machine. Press the <RESET> button twice to clear any alarm
messages and then verify that parameters #211, #64 and #34 retain the correct offset values.
16. Push the <ATC FWD> button and visually verify that the tool changer is functioning properly and that the
tool changer arm correctly positions itself for a tool change.
17. Install a tool in the spindle and perform a live tool change. Inspect the entire sequence of operations for the
tool changer and verify that the tool changes are being made in a smooth and safe manner.

(Horizontal)
38-TOOL S IDE-M OUNT T OOL C HANGER - A DJUSTING O PERATING S PEED
The speed of the various functions on the ATC 38 tool changer can be adjusted. In general, the goal of adjusting
the tool changer speed is to achieve a high operational speed (or low tool-to-tool change time) that does not
cause undo deflection or vibration of the tool changer. In addition, consistency of motion must also be consid-
ered, that is, it is best to equalize the speed of reciprocal functions (rotate clockwise and counterclockwise,
slide left and slide right, etc.) to produce a consistent flow of motion as the tool changer operates.
1. The speed of the following nine functions on the ATC 38 tool changer can be adjusted:
• Carousel speed
• Carriage swing speed, toward carousel
• Carriage swing speed, toward spindle
• Carriage slide speed, left direction
• Carriage slide speed, right direction
• Arm speed, push-out
• Arm speed, pull-in
• Arm rotation speed, clockwise
• Arm rotation speed, counterclockwise
The carousel speed and the arm’s pull-in/push-out speed are directly controlled by the flow rate of the hydraulic
pump. Thus, increasing the flow rate will increase the speed of these functions and conversely decreasing the
flow rate will decrease their speed. The speed of the other six functions are controlled by flow control valves
located on the tool changer’s valve manifold.
Arm Slide Valve

(Mag)-(Spindle)
Arm Slide Valve

(Left)-(Right)
Arm Pull-In/
Push-Out Valve
(In)-(Out)
Arm Rotate Valve

(CW)-(CCW)
Hydraulic Pump Pressure and Flowrate Adjustment Screws
2. If it is necessary to adjust the speed of a function controlled by a valve perform the following:
a) Locate the valve that controls the function.
b) Loosen the locknut on the appropriate flow control valve.
c) Turn the flow control adjustment screw counterclockwise to increase flow (increase speed), or
turn the adjusting screw clockwise to decrease flow (speed).
NOTE: Make adjustments in ¼ turn increments as small adjustments can cause

large changes in speed.
d) After completing the adjustment, tighten the adjustment screw locknut.

(Horizontal)
TOOL CHANGER S HEETMETAL I NSTALLATION
1. Top Cover
2 1 2. Angle Bracket
3 3. Rear Guard
4 4. Guard Door
5. Hinge
5
6. J-bolt Access Cover
7. Switch Box
8. Corner Panel
6 9. Cage Panel
14 10. Left Guard
11
13 11. Cage Bracket (x3)
12. Lower Tie Plate
13. Upper Tie Plate
8 7 14. Front Guard
60 and 120-tool
tool changer guarding
12
11
8
9 10 11
1. Attach Front Guard to the mill table and column base using Cage Brackets and Upper and Lower Tie Plates.
2. Attach the Left Guard to the Front Guard.
3. Attach Rear Guard to Left Guard. Attach Rear Guard to the column base sheetmetal using Angle Brackets.
4. Use adjusters on the bottom of the Rear, Left, and Front guards to level and square the tool changer cage.
5. Attach the Top Cover to the tool changer cage. Note that this piece (1) only covers the forward area (closest
to the spindle) area of the tool cage for the 60 and 120-tool tool changers.
6. Attach the Cage Panel, Guard Door, and remaining trim pieces.
L EVELING T HE EC-300/400/500/630
Leveling of the machine is required to obtain the correct right angle geometry of the X, Y, and Z axes. Incorrect
level will result in out-of-round circle milling and incorrect linear interpolation.
Leveling is done in two steps: rough leveling to ensure the machine is level for coolant and oil drainage, and
fine leveling for axes geometry. Finally, the spindle sweep is checked.
NOTE: Many factors can affect a machine’s ability to remain level — the rigidity of the
floor, the stability of the support under the floor, trains or trucks passing nearby,
seismic activity, and so on. Therefore, until experience shows how often re-
leveling is required, check the machine’s level frequently after it is installed.
NOTE: Measurement of required tolerances in the leveling procedure requires the

use of an electronic level.

(Horizontal)
Use an electronic level with each division equal to 0.0005 inch per 10 inches, or .05 mm per meter, or 10
seconds per division. Before starting, check the accuracy of your level. Set it on the table on the X-axis and
record the reading. Then turn it 180° and the reading should be the same. If it is not, the level is out of calibra-
tion and should be adjusted before you continue.
Screw the four leveling screws at the corners through the base until the base is 3" to 3 1/2" above the floor.
NOTE: EC-630 requires 4 1/2" of clearance above the floor, as well as 78.5" of
clearance between the end of the chip conveyor and the nearest wall when
installed, to allow for coolant tank removal.
Verify that the coolant tank slides under the machine base with 1/4” to 1/2” of clearance. That translates into a
minimum of 1 3/4" of the leveling screw extending out of the bottom of the base of the machine, or one inch
between the pads and the casting. Turn each screw until the tension is about the same as the tension on the
other screws. Screw the jam nuts onto the four (4) leveling screws, but do not tighten them down.
Rough Level
1. Clean the Z-axis pallet and electronic level of debris. Center column on X-Axis and the pallet on Z-Axis.
2. Loosen right front leveling screw so there is at least 1/4" between the tip of the leveling screw and the
leveling pad. The two middle screws should not be touching the floor or the leveling pads.
3. Place level head on pallet center parallel to X-Axis. Adjust left-rear leveling screw until level reads +/-.0005".
4. Position level head on center of the pallet, parallel to Z-Axis. Adjust left-front leveling screw to read +/-.0005".
Roll
1. Jog pallet (Z-Axis) to back of the machine. Position level head on center of the pallet parallel to the X-Axis.
2. Adjust left-rear leveling screw until a reading of +/-.0002" is achieved. Note the level’s reading.
3. Jog the pallet (Z-Axis) to the front of the machine. Adjust the right front leveling screw so that readings at
both front and back of machine are within +/-.0005" of each other.
Pitch
1. Tighten the middle leveling screws until they are just touching the leveling pads (very light pressure).
2. Position the level head on the center of the table parallel to the Z-axis. Jog the Z-axis from one end to the
other. Adjust the middle screws only until a maximum pitch deviation is .0005"/10" over full travel.
3. Turn the level head 90 degrees and verify that your pitch changes have not introduced too much roll deviation
in the Z-axis. Adjust the 2 middle screws only to fix any excess roll deviation. Adjust the two screws together
by equal amounts (one up one down) to fix the roll without affecting the pitch.
Verify Column Level

1. Place the level head on the machined surface on top of column parallel to Z-axis.
2. Jog the X-axis from one side to the other, note the reading from one end of travel to the other. The maximum
allowable deviation is 0.0003".
3. Rotate the level head so it is parallel to X-axis. Jog the X-axis from one side to the other, note the reading
from one end of travel to the other. The maximum allowable deviation is 0.0005".
Electronic Level
Z-AXIS
Electronic
Level
X-Axis
EC-400 EC-300

(Horizontal)
IMPORTANT!!! Refer to the Machine Inspection Report that accompanies your machine. Check your results
with those of the report under the Pallet Flatness verification. By duplicating these results exactly, you will
obtain the same alignment specifications that were achieved at the factory.
L EVELING T HE EC-1600 / 2000 / 3000

Introduction
Leveling of the machine is required to obtain the correct right angle geometry of the machine's X, Y, and Z axes,
and to ensure the correct positioning of the tool changer. Incorrect level will result in out-of-round circle milling,
incorrect linear interpolation, and the possibility that the tool changer may drop tools.
NOTE: Many factors can affect a machine’s ability to remain level — the rigidity of the
floor, the stability of the support under the floor, trains or trucks passing nearby,
seismic activity, and so on. Therefore, until experience shows how often re-
leveling is required, check the machine’s level frequently after it is installed.
NOTE: Anchoring of the EC-1600 is highly recommended if large, heavy, or tall parts
are machined, or if the foundation is suspect.
The leveling includes fine leveling and pursuant geometry checks. The following tools are required to perform
this operation:
• .0005" bubble level • .0005" indicator
• 50T split tool/T-2089 for CT50, T-2088 for BT50 • 50T spindle lock tool/T-2080
• 24" granite parallel • 24" granite square
• Large magnetic indicator base • 1-2-3 blocks
• .0005" caliper
The machines are leveled at the factory, using an electronic level. If not available, use a precision bubble level
with each division equal to 0.0005 inch per 10 inches, or .05 mm per meter, or 10 seconds per division. Before
starting, check the accuracy of your level. Set it on the table on the X-axis and record the reading. Then turn it
180° and the reading should be the same. If it is not, the level is out of calibration and should be adjusted before
you continue.
Screw all leveling screws through the base until the base is 4" above the floor (3" pad height + 1" of screw
extending from bottom of base). Do not screw leveling screws #3, 4, 5, & 6 (and X-axis outrigger leveling
screws on the EC-3000) down on leveling pads at this point. Screw the jam nuts onto all leveling screws, but
do not tighten them down.
7 8
Z-Axis
6
5
3 4
X-Axis
Enclosure Machine Front
1 2

(Horizontal)
Leveling the EC-1600/2000/3000
1. Disconnect rear Z axis cover from column to allow access to the Z axis linear guides. Level the base
checking off of both Z axis linear guides with the level parallel to Z axis.
2. Place the level on the center of the table, parallel to the Z-axis, and note the position of the bubble.
3. Jog the table to the left, until the level is above screw 1, and note the position of the bubble.
4. Jog the table to the right, until the level is above screw 2, and note the position of the bubble.
5. Adjust for roll, by using screws 1 and 3 or screws 2 and 4 until the position of the bubble remains
constant over the full range of travel.
6. On newer EC-1600/2000 machines, X-axis pitch can be removed by adjusting the jacking screws under
the base (one on each side - see illustration).
Jack Screw
Readjustment may be needed after heavy loads are placed on the table. For the EC-3000, use the
outrigger screws for pitch adjustment by turning the screws for each outrigger by equal amounts in the
same direction so as not to affect roll.
NOTE: This adjustment is critical to the proper function of the machine. Pitch and roll
must be completely eliminated.
7. Jog the table to the center of travel.

8. Place 1-2-3 blocks (gauge blocks) on the platter or table, for machines without the A-axis platter,
(ensuring both surfaces are clean); one at the rear of the platter or inside of the table, and one at the front
of the platter, or outside edge of the table.
9. Attach a .0005" indicator to the spindle head and zero out on the block at the rear.
10. Jog the Z-axis to the front of the platter, or outside edge of the table, and indicate the 1-2-3 block at
that position.
11. Raise or lower screws 1 and 2 equally, and repeat, until readings between blocks without rotating the A-
axis platter are within .0001".
12. Remove roll from the Z-axis. Place a level on a 6" square of granite, or suitable block, inside the rear of
the column, with the level parallel to the X-axis. Shim the level as necessary. The level does not need to be
centered, just within a readable range.

(Horizontal)
Column
(Back Side)
13. Jog the column to the maximum (Z-negative) position and note position of the bubble, then jog the
column to the maximum (Z-positive) position and note position of the bubble. Adjust screws 7 and 8 by
equal mounts in opposite directions, to eliminate roll without affecting the results of Steps 6 through 10.
14. Re-verify steps 2 through 11.
15. Adjust until readings at each end of the travel are within .0001".
16. Remove the level and the block from the back of the column.
17. Repeat Steps 6 through 10 to verify the Z-axis geometry in relation to the platter or table. Keep in mind
that when repeating these steps, that Z-axis roll has already been removed, so leveling screws 7 and 8
must be adjusted up or down equally that is, both up or both down in equal amounts.
18. Remove pitch from the Z-axis. With a level placed parallel to the Z-axis (inside the column), jog the
column to the maximum (Z-negative) position and note the position of the bubble, then jog the column to
the maximum (Z-positive) position and note the position of the bubble.
19. If necessary, adjust leveling screws 5, 6, 7 and 8 to correct for Z-axis pitch.
20. With Z-axis pitch established, repeat all steps to verify X-axis roll (and pitch, if the machine has the
means for such an adjustment), Z-axis pitch and roll, and the indication in the Z-axis across the platter of
table. If all are correct, move on to A-axis rotation, geometry, and TC alignment verification. If not correct,
repeat the necessary steps to correct the error.
21. When leveling is complete, reinstall Z-axis waycovers and seal with black RTV.
Once these steps are verified to be correct, with the axes at the center of travel and the bubble level at the
center of the table checking in the X and Z plane, it is possible that the machine table surface may not be
perfectly perpendicular to earth gravity. This is acceptable, as long as the machine is square and its geometry
is correct.
NOTE: If the Z-axis pitch cannot be adjusted to an acceptable tolerance that allows
for correct geometry; it will be necessary to determine the cause for error in the
Z-axis flatness, and to take the necessary steps to correct the problem.
Normally this is due to a bow in the casting between the front and the rear of
the Z-axis portion of the base casting, and adjusting leveling screws 5 and 6
will correct this. If the pitch cannot be adjusted into tolerance with leveling
screws 5 and 6, it may be that an upward bow is present. If so, it may be
necessary to anchor the machine to bring the flatness into specification. If you
believe this condition exists, please contact Haas factory service.
A-axis Rotation Verification

These steps measure the parallelism of the A-axis (axis of rotation) to the Y-axis, and the platter face runout.
The EC-1600 geometric inspection report (GIR) is placed in the back of the operator's manual when the ma-
chine is shipped from the factory. Refer to this document for A-axis and column square verification.

(Horizontal)
1. To check the axis of rotation, check a single point at four positions, 90° apart on a 1-2-3 block, as shown in
the illustration.
"Y" Axis
"A" Axis
Gage Block
xis
"Z" A
Platter
1 2
4 3
"X"
Axis
Rotate the platter 90° CW, then jog the X and Z axes to the indicating point. Check the block in the same
spot, record the reading, and repeat the procedure every 90°.
If the A-axis is an indexing axis, (not a full 4th rotary axis) remove the 1-2-3 block while indexing between
readings to provide clearance for platter pop-up.
NOTE: The readings are not to exceed 0.0005".
2. To check the platter face runout, check four points, 90° apart, by indicating the runout at the 0° position
(as shown in the previous illustration). To do this, jog the axis to locate the indicator at the 0° position and zero
out the indicator. Leave the indicator in this position for all four readings. Rotate the platter at 90° increments
and record the readings.
NOTE: The readings are not to exceed 0.002".
Geometry Verification
These steps measure the squareness of the Y-axis to the X-axis, and the squareness of the Y-axis to the Z-
axis.
Granite Square
Y
Y
Granite Parallel
Y-axis Tilt Relative to X-axis Y-axis Tilt Relative to Z-axis

(Horizontal)
1. Set up the granite parallel and square, as shown in the above illustration, to check Y-axis tilt relative to the
X-axis. Position the square so that its edge overhangs the parallel enough to take an indicator reading on the
underside of the square (parallel to the X-axis). Before taking this reading, adjust the square by indicating
across its vertical edge to ensure that it is parallel with the Z-axis (obtain a zero reading). Now indicate the
underside of the square to verify a zero reading. If the reading is not zero, check that all surfaces are clean.
NOTE: The granite parallel may need to be shimmed to obtain a zero reading, due to
table surface tolerance.
2. With the indicator positioned as shown in the illustration, slowly jog the Y-axis a minimum of 24" to check Y-
axis tilt relative to the X-axis.
3. Set up the granite parallel and square, as shown in the above illustration, to check Y-axis tilt relative to
the Z-axis. Position the square so that its edge overhangs the parallel enough to take an indicator reading on
the underside of the square (parallel to the Z-axis). Before taking this reading, adjust the square by indicating
across its vertical edge to ensure that it is parallel with the X-axis (obtain a zero reading). Now indicate the
underside of the square to verify a zero reading. If the reading is not zero, check that all surfaces are clean.
NOTE: The granite parallel may need to be shimmed to obtain a zero reading, due to
table surface tolerance.
4. With the indicator positioned as shown in the illustration, slowly jog the Y-axis a minimum of 24" to check
Y-axis tilt relative to the Z-axis.
NOTE: The readings in steps 2 and 4 are not to exceed 0.0005" for 24" of travel.
NOTE: If the X-axis roll, Z-axis pitch and roll, and the indication in the Z-axis across
the platter or table are correct, the column square should also be within
specification, or very close to it. Small adjustments to the leveling can be made
without compromising the overall accuracy of the machine. If excessive
adjustment is necessary to bring the column square into tolerance, or if you
have any questions, please contact the Haas factory service department for
technical support.
Tool Changer (TC) Alignment Verification

TC alignment must be verified before loading any tools. Any adjustment or change to the machine level will
affect TC alignment. Incorrect TC alignment can result in dropped tools, damaged waycovers, cambox damage,
excessive wear, and damage to the TC double-arm.
Warning
Verify tool changer alignment before operating the mill.
As a safety precaution the Service technician must ensure that the tool changer is aligned properly to the
spindle. The installation and leveling of a new machine will affect the tool changer alignment. Use the following
instructions to verify alignment. Do not load any tools into the tool changer or spindle until alignment is com-
plete.

(Horizontal)
T OOL C HANGER ALIGNMENT VERIFICATION
Tool Required: Split Tool P/N T-2088 for 50 taper, BT tooling
T-2089 for 50 taper, CT tooling
Weight
Pinch Point
Split Tool Weight hung from the tool changer double-arm
1. With no tool in the machine, command a tool change. Press Emergency Stop before the double arm reaches
the spindle. This will cause the mill to move the Y and Z axes to the ATC position.
2. Verify the spindle is free to rotate without hitting the double arm. If necessary, use the T/C Recovery com-
mands to move the arm further from the spindle.
3. Using T/C Recovery, orient the spindle.
4. Using T/C Recovery, rotate the double arm in the forward direction. Continue rotating the double arm
until it reaches the spindle, then extends approximately 6" (152.4 mm) in front of the spindle.
5. Using the dowel pin as a handle, install the tapered half of the split tool into the spindle. Be careful to not
place your hands in the pinch point between the tool and the spindle. The Tool Release button operates in a
Toggle On/Off mode during Tool Recovery. Press once to activate the Tool Release; press again to clamp.
6. Remove the dowel pin, and install the second half of the split tool into the end of the double arm in front of
the spindle. It will be necessary to manually press the tool lock plunger (near the center of the shaft as shown
in the Service manual) to allow the spilt tool to be inserted.
7. Using T/C Recovery in the reverse direction, move the double arm back toward the spindle until the halves of
the split tool are approximately 1" (25.4 mm) apart.
8. Hang a 40 lb (18.2 kg) weight from the pocket side of the arm. Hang the weight from the hole closest to the
pocket. This will preload the arm.
9. Continue to move arm toward spindle. Watch double arm as it approaches spindle. The spindle dogs and
slots in the double arm should line up. This verifies Parameter 257 (Spindle Orient Offset). If spindle and arm do
not line up, reset Parameter 257 as described in the Service Manual, and continue moving closer until there is
a maximum of 1/8" (3.2 mm) gap between the split tool halves, ensuring the halves do not touch each other.
10. Check the X and Y alignment of the double arm to the spindle by inserting the alignment dowel through
both halves of the split tool. The dowel should slide freely. If the pin does not slide freely, the direction of the
misalignment may be determined by feeling the "step" between the split tool halves, by using a steel rule,
straight edge, or similar tool.
11. If misalignment is present, correct per Engineering Bulletin (EB-0537, EC-300, EC400, EC1600-3000 Tool
Changer Alignment Instructions).
12. Using T/C Recovery, move the double arm in the forward direction, away from the spindle. Remove both
halves of the split tool.

(Horizontal)
13. Install a tool holder into the double arm, measure the distance from the front of the double arm to the front
face of the tool holder (see diagram), and record the distance.
Tool Changer
Double Arm
8 9 5 1 2 3 4 5 6 7 8 9 6 1 A Made in America
Measure This
Distance
Measure the distance from the

Tool Holder
04 03
02
05
surface of the double arm to
01
06
07
0
80 90
the surface of the tool holder
14. Remove the tool from the double arm. Using T/C Recovery, move the arm in the reverse direction to the
spindle. Continue until the arm rotates to the origin "Home" position. Once the arm is away from the spindle,
insert the same tool holder used in Step 13 into the spindle.
15. Using T/C Recovery, rotate arm in forward direction until it is very close to the tool holder. The spring-loaded
slide is depressed as arm nears the tool holder, but be sure that the arm is not touching the tool holder itself.
16. Using a caliper, measure between the same two surfaces described in Step 13. The measurement should
be the same, +/-.010" (.254 mm). Be sure that you are measuring the distance between the double arm and
the tool holder, not the spring-loaded slide and the tool holder. If adjustment is required, refer to "Setting
Parameter 64" in the Service Manual.
17. If no changes are needed, complete Tool Change Recovery.
18. Note that the same end of the double arm must be used for the caliper measurement. The two ends may
have different readings. This is normal and will not affect operation.
19. Load tools (maximum 30 lbs (13.6 kg) each) into machine, and perform tool changes to verify proper
operation. Caution: Protect the Z-axis way cover (closest to the column) in case a tool is dropped from the
spindle or tool changer arm. The tool changer should be operated at 100% rapid speed, otherwise tool changer
motion may jerk or be sluggish.
EC-630 T OOL CHANGER E NCLOSURE INSTALLATION

The EC-630 tool changer enclosure is first assembled, then it is secured to the machine on the tool changer
side.
Tool Changer Enclosure Assembly

(Horizontal)
1. Connect the first side panel to a front panel. The side panels can be identified by their opening windows.
Install the upper and lower corner braces to this assembly.
2. Attach the remaning two front panels to the assembly, including the top and bottom braces.
3. Attach the final side panel, including the top and bottom corner braces.
4. Install the two stiffener brackets to the upper inside of the three front panels.
5. Install the front drip tray panel to the inside left of the enclosure assembly. Attach the drip pan mounting
bracket to this panel.
6. Install the remaining drip tray panel.
7. Slide the assembly close to the EC-630 and attach the coolant drain hose to the drain pan. Adjust height as
necessary to align pemnuts and holes in the sheet metal. Secure the tool changer enclosure assembly to the
EC-630 and connect the tool changer remote control box to the control cabinet.
SPINDLE SWEEP
NOTE: Machine must be properly leveled for accurate spindle sweep adjustment.
1. Place an indicator on the table and insert a 6" precision test bar into the spindle.
2. Jog the Z-axis while indicating the bottom, then the side, of the test bar. The readings must be within
0.0005”/10" in both the Y/Z and X/Z planes, as stated in the inspection report supplied with the machine.
COOLANT SEPARATOR
The coolant separator is mounted in its shipping position. Remove the two screws and remount the coolant
separator in the lower mounting location. Do this for both of the coolant separators.
Cable Coolant Separator

Trough Operating Position
Coolant Pump,
coolant level sensor
and TSC cables
Coolant Trough
Route the coolant tank and TSC (optional) cables through the coolant trough. If necessary remove the trough
(2 screws) to ensure that the cables are properly routed.

(Horizontal)
COOLANT T ANK I NSTALLATION
EC-300 - The coolant pump(s) will be packed inside the machine enclosure for shipping. Remove the handle
from the underside of the coolant tank lid. Use the same hardware (screws) to secure the handle to the coolant
tank. Orient the pump(s) and lower into the coolant tank. Place the supplied cover(s) as shown. When not
using a TSC pump, install the large cover in place of the two small covers.
1. Position the coolant tank.
Electrical Sub-Panel Hose Barb Main Coolant Line

Main Pump
Power Line Hose Barb
Main
Coolant Line Male Hose
Adapter
Male Hose Main Pump
Adapter Power Line
HS 3-7 EC-300 EC-400
NOTE: It is important that the coolant tank is in place before leveling the machine to
ensure there is adequate clearance (height) between the bottom of the auger
trough and the tank.
2. The Coolant Level Float Assembly is shipped in a separate box. It consists of a housing, float and cable.
Install the Coolant Level Float Assembly by lowering the float through the tank lid. Line up the slots in the
housing with the dimples on the side of the tank and press down so the float assembly clips onto the tank.
95-Gallon coolant tank - The float can be mounted on either the edge of the coolant tank or the center.
Housing
Housing
Dimples
Float Dimples
3. Insert a plastic push wire mount into the hole in the tank lid, then route the cable to the coolant pump(s). Tie
wrap the coolant float cable to other cables, when available, when routing from the coolant tank (see figure).
55 Gallon tank shown

(Horizontal)
4. Connect the cable to the Coolant Level Gauge plug. Locations:
HS 3-7: Bulkhead on back of X-axis table.
EC-Series: Rear sheet metal below tool changer.
EC-630: Rear sheet metal on lower right-hand side.
5. Select the Current Commands screen on the operator's pendant and manually move the float up and down to
ensure that the display reflects a corresponding change in the coolant level.
6. Connect the main coolant line (3/4" O.D.) to the main pump.
7. EC-300/400/500 – Route cable to the outlet on the side of the machine. EC-1600-3000 – Route the cable,
under the machine, to the control cabinet. HS-3/4/6/7 – Route cable to sub-panel, located by the auger trough
on the tool changer side of the mill.
8. If machine includes Through the Spindle Coolant option, attach the 1/2" O.D. coolant line to the TSC pump.
NOTE: The TSC power line is hard wired to the main pump power line.
9. Route coolant/oil separator return hose as shown. The coolant return hose must slope downward to coolant
tank. When installing the coolant return hose, pour a cup of coolant through the return hose to charge the unit.
TSC Coolant
Pump Assembly
Elbow
Fitting
Oil Separator
Coolant Return
Hose
Gripper Clip
NOTE: Never reuse waste oil from the Oil/Coolant Separator; dispose of properly.
10. Fill coolant tank with coolant. Warning: Mineral cutting oils will damage rubber based components
throughout the machine.
NOTE: Before operating the coolant system, ensure the drain is positioned half way
over tank strainer.
EC-630 COOLANT T ANK I NSTALLATION

1. Remove crating and use a forklift to move the coolant tank into position to be slid into place under the
machine. IMPORTANT: Locate the two casters packaged with the coolant tank and install at the base of the
chip conveyor chute support before lowering the tank.
2. Install pumps and coolant level float into the coolant tank as shown.

(Horizontal)
3. Inside the machine, remove the splash shield (P/N 25-8144) located at the bottom of the machining area.
4. Slide the coolant tank under the base casting. Measure the distance between the base casting and the
opposite face of the pump box area of the coolant tank. This distance must be between 6 7/8" and 9" to get the
chip conveyor in the correct position within the machine.
5. Connect hoses to the correct pumps, and connect pump electrical cables to the appropriate connectors as
labeled on the enclosure.
6. Reinstall the splash shield.
7. Fill coolant tank with coolant. Warning: Mineral cutting oils will damage rubber based components
throughout the machine.
C HIP A UGER I NSTALLATION

1. Unpack the discharge tube.
2. Machines with multiple augers will have the two side augers installed at the factory. The remaining auger
(front) is installed by putting it through the discharge tube opening, then use the provided 5/16-18 x 2½” bolt to
fasten it to the motor shaft coupling.
3. Install the discharge tube into place. Attach with eight SHCS and locking washers and tighten uniformly.
EC-400: Fasten the trough extension box to the end of the auger trough using six (6) BHCS. Fasten the trough
extension covers to the top of the extension box using four (4) BHCS each.
4. After machine start-up, check the operation of the auger to ensure the direction of rotation will move the
chips toward the discharge tube. If the auger is turning so that the chips are not being moved toward the
discharge tube, change the bit switch in PARAM 209 from 1 to 0 or 0 to 1 to establish a new forward direction
End Chute
Cover Chip
Chute
Trough Extension
Cover
Front Trough
Extension Box
EC- 400 / EC-500

(Horizontal)
C HIP C ONVEYOR I NSTALLATION (O PTIONAL ) EC400 / EC-500
Conveyor
Plug Auger Guards (2)
Cable Rests
In Tray On
Side Of
Conveyor
End
Extension Wing
Cover
Side
Chip Shield Wings (2)
Extension Box
1. Unpack the chip conveyor, the chip trough extension box, and extension cover. Adjust the two casters so
that the chip conveyor will be level when it is in place.
2. Remove the two-piece auger guard. Remove the two side wings and the end wing from the chip trough. Move
the chip conveyor into the chip trough opening. Leave enough room to replace the chip shield.
3. Replace the chip shield, making sure it is behind the flange on the chip conveyor then push the chip con-
veyor in all the way until it makes contact with the back of the trough.
4. Install the two side wings and slide them outward so that they make contact with the side of the auger
trough. Fasten the end wing with two (2) BHCS.
5. Fasten the chip shield to the trough. Fasten the trough extension box to the end of the auger trough and the
extension cover to the extension box.
6. Replace auger guards, and plug the chip conveyor into the amphenol connector on the side of the machine.
7. After machine start-up, check operation of the chip conveyor to ensure direction of rotation moves the chips
toward discharge end. If chip conveyor is turning so that chips are not being moved toward discharge end,
change bit switch in PARAM 209 Reverse Conveyor from 1 to 0 or 0 to 1 to establish a new forward direction.

(Horizontal)
T HROUGH THE SPINDLE C OOLANT SYSTEM (TSC) S TARTUP
WARNING!
The TSC pump is three phase and must be phased correctly!
Improper phasing will damage the TSC pump and void the warranty.
1. Fill the coolant tank with coolant and connect all hoses and power cords. Zero Return the machine.
2. Press the MDI button and turn on TSC by pressing the AUX CLNT button. Quickly go to the back of the
machine and check if the TSC pump motor is turning and pushing coolant through the clear intake hose. If it is,
the machine is properly phased. If not immediately stop the pump by pressing the RESET button. Check that
the intake hose connection is tight, the connection must be tight for the pump to prime itself. If the motor is not
turning, check that the power cords are connected and the circuit breaker inside the control box is on.
The TSC pump will not pump if it is rotating backwards. The motor rotation should be counterclockwise when
viewed from the fan end.
CAUTION: Running The TSC pump dry for more than 60 seconds can cause serious
damage to the pump.
3. If the machine is improperly phased perform the following procedure:

a. Turn off the power to the input side (top) of the main circuit breaker. Measure the Voltage!
b. Exchange any two wires at the input side (top) of the main circuit breaker as shown.
c. Close the control box. Return to Step 2 and test for proper phasing.
Ground Line
L1 L2 L3
Main
Circuit
Breaker

(Horizontal)
O PTIONAL A UXILIARY F ILTER FOR TSC S YSTEM
Installation
1. Place filter assembly approximately six inches behind coolant tank, for tanks that pull out from the side. For
tanks that pull out from the rear, place the Auxiliary Filter beside the coolant tank next to the enclosure.
TSC Filter Assembly

100 Micron
Intake
Primary
Filter
Coolant
Assembly
Pump
Dirt
TSC Coolant Indicator
Pump Assembly Auxiliary Filter Assembly
Standard Filtration Setup Optional Auxiliary Filter setup
2. Remove the 100 mesh strainer from the inside of the TSC intake filter. Attach the hose from the top of the
TSC intake filter to the hose connector on the Auxiliary filter. The hose may be trimmed shorter if desired for
appearance.
3. Disconnect the 1/2" check valve from the 45° elbow at the base of the normal coolant pump. Install the 1/2"
street-tee from the kit between the 45° elbow and the check valve (note the orientation of the check valve).
Install the pipe reducer from the kit into the side outlet of the street-tee. Install the 1/4" push-in elbow into the
pipe reducer (See the following figure). For coolant pumps supplied with a cross fitting, remove one of the plugs
and install the reducer into the cross fitting; the street tee will not be used.
NOTE: The cap of the check valve should point upward for the check valve to function
properly.
Cable Tie
Filter
Outlet
1/4" O.D. 1/4“ O.D.

Plastic Plastic Hose
Push-in Hose
Elbow Reducer
Push-in Check
Auxiliary Filter Assembly Elbow Valve
45° Elbow
Auxiliary Filter Priming System
4. Insert the 1/4" OD plastic hose into the push-in elbow on the pump. Route the hose along the intake filter
hose and around the intake line of the auxiliary filter. Trim the plastic hose to length and insert it into the push-
in elbow at the top of the filter. Secure the plastic hose to the inlet hose with the supplied cable ties.
5. Attach the hose from the bottom of the Auxiliary Filter to the inlet of the TSC gear pump.
6. Check that the filter lid is securely closed.
7. Run the primary coolant system for ten minutes to prime the bag filter housing before using the TSC system.

(Horizontal)
1000 P SI T HROUGH THE S PINDLE C OOLANT I NSTALLATION
Place the 1000psi TSC assembly next to the coolant tank behind the machine with the hose connections
facing the back of the machine. Use the following coolant schematic as an aid for hose routing.
1. Connect the power cable for the pump assembly to an external source in order to power the motor. Note that
the CNC control does not provide power to the pump motor. Customer supplied external power must be sup-
plied at the time of installation. The power required is 208-230 volt 3-phase 50/60Hz, and have a 20-amp circuit
breaker. The pump assembly is pre-wired with a NEMA L15-20 plug.
The pump assembly can also use an alternate power source, these are:
240-230V 50/60HZ @ 20A or 480V 50/60HZ @ 10A
To power the pump assembly from an alternate source, first replace the plug at the end of the cable with an
appropriate plug for the voltage being used. Then, rewire the pump motor according to the directions on the side
of the motor.
2. Plug the TSC cable from the TSC junction box (J-box) to the TSC amphenol port on the side of the control
cabinet.
3. Connect the 1" diameter intake hose from the coolant tank to the nipple on the pressure regulator bracket.
Attach the 1/2" diameter bypass hose from the coolant tank, to the pressure regulator bypass.
4. Insert the 1/4" diameter nylon tubing from the standard coolant motor into the push in tube fitting on the
pressure regulator bracket.
5. Connect the TSC hose from the mill to the pressure regulator output fitting.
Regulator Pressure Regulator

Jam Nut Adjusting Bolt Oil
Reservoir
Filter Priming
Hose
Discharge Bypass
Hose
Hose
Intake
Hose
Bypass
Hose
CC CIA COOLANT INTAKE ASSEMBLY

MTR STANDARD COOLANT MOTOR
CP COVER PLATE
GA SUCTION GAGE, INTAKE FILTER
AF AF TANK ASSEMBLY
P/AFA COOLANT PUMP & TANK ASSEMBLY
TSC PA COOLANT PUMP
TSC CABLE
FROM J-BOX CC CONTROL CABINET
RA PRESSURE REGULATOR
P/AFA PRIMING CIA
COOLANT TUBE
RA FLOW
TO MACHINE PA AF MTR
GA INTAKE
HOSE CP
COOLANT
BYPASS HOSE TO COOLANT TANK TANK

(Horizontal)
I NITIAL S TART-U P
Ensure that a correct style tool is in place; a proper tool and pull stud for TSC.
Before using the 1000psi system the auxiliary filter must be primed. There are two ways to do this. The first is
to run the standard coolant pump for 5 minutes. This will fill the auxiliary tank, through the priming hose.
The second method, is to attach the wash down hose to the standard coolant pump. Turn on the standard
coolant system (press "MDI", then "Coolant"). It may be necessary to turn the valve(s) on the standard coolant
pump to in order to divert coolant to the hose. Open the auxiliary filter tank cover (loosen wing nuts) and use
the wash down hose to fill the auxiliary filter with coolant. Replace the auxiliary tank cover and tighten securely.
Note: To reduce wear and prolong the life of the auxiliary filter, the 1/4" nylon hose is connected between the
standard coolant pump and the auxiliary filter which will maintain the coolant level in the filter tank.
PRESSURE REGULATOR ADJUSTMENT

The pressure regulator has been set at 1000psi and tested at the factory. No further adjustment is required.
However, to change the pressure, loosen the regulator jam nut. Turn the adjusting bolt clockwise to increase
the pressure or counter clockwise to decrease the pressure. (Note, the system does not need to be running to
change pressure) Tighten the regulator nut once the pressure has been set.
PENDANT LEVELING
The pendant leveling feature allows the adjustment of the pendant angle.
1. Rotate the pendant to the position in the following figure for proper leveling. Loosen the two (2) screws on the
end cap. Use a wrench on the leveling screw to change the pendant angle.
Loosen These Two Screws,

Before Adjusting Leveling Leveling
Screw. Screw
Screw
Leveling
Monitor
Leveling
Screw Hard
Stop
Top View
2. Tighten the two (2) screws on the end cap once the pendant is level.
3. Rotate the pendant 90° forward and check the level again. Repeat the procedure if necessary.
EC1600-EC3000 S OUND S HIELD I NSTALLATION

Loosen the screws on the back of the column. Install the sound shield and tighten the screws. Note the
position of the sound shield and the hose guard. Plug the fan into the cable from the control. Use cable ties to
secure the fan wires to the other cables.
Fan Plug
Sound
Shield
Top View
Hose Guard, if equipped
Sound Shield

(Horizontal)
T OOL CHANGER ACCESS COVERS (EC-300)
Operating Position Shipping Position
The front and rear tool changer access covers are mounted inside-out on the enclosure for shipping. Remove
and reassemble during installation.
1. Remove the screws that hold on the front and rear access covers. (They can be removed as one piece.)
Remount the access covers so that they protrude out from the enclosure. The window should be toward the
front of the machine.
WASHDOWN HOSE INSTALLATION

1. Insert a washer into the female end of the nozzle and another washer in the female end of the hose.
2. Attach the nozzle to the male end of the hose.
3. Disconnect the P-cool hose from the coolant pump. Attach the “Y” connector to the coolant pump fitting,
where the P-cool hose was.
4. Attach the P-cool hose to one of the “Y” outlets and the Washdown Hose to the other.
5. Be sure the valves on the Y-connector are turned to the Open or Closed position as required.
Washdown Hose
P-Cool
hose
Y-Connector

(Horizontal)

HS-3,4,6,7 (R) Ec-Series Installation: Important! Refer To Local Code Requirements Before Wiring Machines

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1. HS-3,4,6,7(R) AND EC- SERIES INSTALLATION

Reference Manual June 2007 Installation 1

U NPACKING THE M ACHINE.

2. Remove the coolant tank from the pallet.

Reference Manual June 2007 Installation 2

Shipping Shock Mount

R OUGH P LACEMENT HS-3 THROUGH 7

Reference Manual June 2007 Installation 3

(4X) 1/2-13 X 1.0

Reference Manual June 2007 Installation 4

Reference Manual June 2007 Installation 5

Round Indicator Pad

Reference Manual June 2007 Installation 6

THIS SIDE ONLY THIS SIDE ONLY

EC- 300 EC- 400 / EC-500 / EC-630

Jam nut is below the casting

Reference Manual June 2007 Installation 7

EC-300 U NBLOCKING P ROCEDURE

Header Panel Shipping

EC-400 / EC-500 U NBLOCKING P ROCEDURE

60-Pocket Tool Changer Shipping Bracket

Reference Manual June 2007 Installation 8

EC-630 UNBLOCKING P ROCEDURE

Reference Manual June 2007 Installation 9

U NBLOCKING P ROCEDURE EC-1600 – 3000

Z-Axis Shipping Bolts 50-Tool Tool Changer Shipping Brackets

Reference Manual June 2007 Installation 10

CAUTION: Before unblocking machine ensure that counterbalance cylinder charging

Shipping Blocks for Table

(2) Shipping Blocks A

Shipping Blocks for Column

Y-axis Ballscrew Cover

Reference Manual June 2007 Installation 12

Reference Manual June 2007 Installation 13

3 PSI Oil Pump Pressure

Oil Filter Oil Reservoir

HS- 3-7 Shown

Reference Manual June 2007 Installation 14

Reference Manual June 2007 Installation 15

Reference Manual June 2007 Installation 16

I NSTALLATION PROCEDURE FOR EXTERNAL 480V TRANSFORMER

Reference Manual June 2007 Installation 17

Rubber Pad Shipping

Reference Manual June 2007 Installation 18

Linear Scale Cable,

Limit Switch and

U NBLOCKING THE C OLUMN (HS3–7)

Y Axis Shipping Stop Rear Access

Reference Manual June 2007 Installation 19

Cable Access Table Base

Reference Manual June 2007 Installation 20

Establishing the Table as the Datum Surface

Reference Manual June 2007 Installation 21

2. Zero return all axes.

Reference Manual June 2007 Installation 22

Sweeping the Y-Axis (HS 3-7)

Y-Axis Motion Will

Reference Manual June 2007 Installation 23

Reference Manual June 2007 Installation 24

Fine Leveling of the Table Base

Sweeping the table