Haas HS-3 User manual

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HS-3/4/6/7 VS-1/3
INSTALLATION INSTRUCTIONS
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: 20% – 95% relative humidity, non-condensing
Altitude: 0-7000 ft.
electricity requirements
IMPORTANT! REFER TO LOCAL CODE REQUIREMENTS BEFORE WIRING MACHINES.
ALL MACHINES REQUIRE:
Three phase 50 or 60Hz power supply.
Line voltage that does not uctuate more than +/-5%
40-30 HP System Voltage Requirements
(195-260V)
Power Supply 125 AMP
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
TSC-1000 Machines: Refer to the TSC-1000 installation procedure in this document for electrical require-
ments.
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 ma-
chine 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.
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 if all other methods
cannot be used.
The maximum voltage leg-to-leg or leg-to-ground should not exceed 260 volts.
The high voltage requirements shown reect the Internal 400V option which is available only in Europe. Do-
mestic and all other users must use the External 480V option.
The current requirements shown in the table reect the circuit breaker size internal to the machine. This
breaker has an extremely slow trip time. It may be necessary to size the external service breaker up by 20-
25%, as indicated by “power supply”, for proper operation.

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air requirements
The VMC requires a minimum of 100 PSI at 4 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.
The recommended method of attaching the air hose is to the barb tting at the back of the machine with a
hose clamp. If a quick coupler is desired, use at least a 3/8”.
NOTE: Excessive oil and water in the air supply will cause the machine to
malfunction. The air lter/regulator has an automatic bowl dump
that should be empty before starting the machine. This must be
checked for proper operation monthly. Also, excessive contami-
nants 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 lter/regulator and the Bijur oil lubricator
(See illustration in “Air Connection” section) reservoir tank below
the control box on the back of the machine is for the optional rotary
table. DO NOT use this as a connection for an auxiliary air line.
Auxiliary connections should be made on the left side of the air
lter/regulator.
WARNING!
When the machine is operating and the pressure gauge (on the machine regulator) drops by more
than 10 psi during tool changes or pallet changes, insufcient air is being supplied to the machine.
tools required for installation and levelinG Procedure
Electronic differential level, precision bubble level, such as one calibrated to show 0.0005 inch per 10”
Test indicator (0.0005")
Installation kit 93-0328
Two ¾” hex wrenches (one open end or box and one ratchet)
Claw hammer
A forklift capable of lifting more than 40,000 pounds, with forks at least 8’ long by 6” wide.
materials required
Wire and air hose or piping as specied in the Service Requirements section
A small amount of grease
levelinG overview
Wiring connections to power the machine must be made before the Levelling Procedure can be followed.
It is our strong recommendation that the machine be anchored in place for best and most consistent results

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while in use. The anchoring bolts (in accordance with the anchoring instructions) should be installed prior to
the machine being set in place.
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.
The installation process will be further aided if, when each base assembly is set in place, a very rough level-
ing procedure be done. The theoretical distance from the oor to the bottom of the two bases is 2 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 oor to the bottom of each base until the distance is very close to
the 2 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 fol-
lows). 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 rst.
Regardless of which assembly is placed rst, the concepts of the general outline need to be adhered to:
• Remove the column base assembly from the truck
• Remove the front shipping bracket (VS machines)
• Stone and clean the table base mating ange
• Stone and clean the column base mating ange
• Remove the table base assembly from the truck and set 12" away from the column
• Remove the X-axis auger trough
• Move the column base to mate with the table base
• Be certain that all connecting bolts are in place but not tightened
• Attach the Pendant and Pendant Arm Support Assembly to the front of the table base
• Run the Pendant electrical wires under the table and connect them in the wire covers on the back of
the table
• Rough level the column base assembly
• 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
• Power up the control
• Fine level the table base assembly
• Fine level/square the column base assembly
• Fully tighten the connecting bolts and adjust ne level/square
• Fully check machine geometry
• Replace the X-axis auger trough
• Install the coolant supply system
• Check all motors for rotation/phasing
settinG the machine in Place
Ensure the anchoring preparations are in accordance with the anchoring instructions prior to setting the ma-
chine in place.Use a small amount of grease on the leveling pads before placing the machine.
1. Prepare the table base for mating
• Remove the X-axis auger and auger trough
• Stone and clean thoroughly the mating ange 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).
• Clean the holes in the table base.
• Ensure the air/electrical/oil lines and connectors are bundled and safely away from the

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mating surfaces.
2. Prepare the column base for mating
• Stone and clean thoroughly the mating ange 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 safely away from the mating surfaces.
3. Place the column base assembly in position. Rough level by measuring from the oor to the bot-
tom of the base (very close to 2 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 nal leveling procedure will go more quickly and that the coolant
tank will properly t beneath the coolant discharge. Loosely screw the jam nuts onto the leveling
screws.
1
23456
2" min.
4. Place the table base assembly in position. When placing the table base in position with respect
to the column base, it is important that the two mating anges be as parallel as possible (verti-
cally and horizontally). Be certain that each of the nineteen screws 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 oor to the bottom of the base
(very close to 2 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 nal 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 nal leveled and
squared).
3.1 initial setuP
WARNING!
At this point, there should be NO electrical connection to the machine. The electrical panel should
be closed and the three latches on the door should be secured at all times except during installation
and service. At those times, only qualied electricians should have access to the panel. 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 exer-
cise 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. Unlock the cabinet with the key and open the door.

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Main
Switch
3. Take sufcient 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 sock-
ets. Look for any cables that have become disconnected, look for any signs of damage and loose
parts in the bottom of the panel box. 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 service required for the mill can be hazardous. Make sure that pressure has
been removed from the air line before you connect it to the machine, disconnect it from the machine, or service
parts of the air system on the machine.
1. When the machine leaves the factory, the air lter is empty, and air lubricator and the lubricator
reservoir tank are full. However, they should be checked and serviced if required before com-
pressed air is supplied to the machine.
2. Connect the air blow gun to the air supply tting on the machine. See gure below.
3. With the pressure off in the air line, connect the air supply to the quick-release tting next to the
air lter/ regulator (below the electrical panel). If the tting supplied is not compatible, simply
replace it.
Front
Oil Fill
(To High Mark) Oil Reservoir
Oil Pump
Oil Filter
Pressure Gauge
Air Filter/Regulator
Hose Barb
(Shop Air)
Air Nozzle
Air Line
4. Start the compressor, set it between 100 and 150 PSI. Set the regulator on the machine to 85 to
90 PSI.
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.

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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.
NOTE: Depending on the position of the cam that drives it, the lubrication
system may not activate until a few minutes after the machine is
started. However, if there is a problem with the system, an alarm
will stop the machine.
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 electrical services required for the VMC can be extremely hazardous. The electrical
power must be off and steps must be taken to ensure that it will not be turned on while you are working with it. In
most cases this means turning off a circuit breaker in a panel and then locking the panel door. However, if your
connection is different or you are not sure how to do this, check with the appropriate personnel in your organiza-
tion or otherwise obtain the necessary help BEFORE you continue.
WARNING!
The electrical panel should be closed and the three latches on the door should be secured at all
times except during installation and service. At those times, only qualied electricians should have
access to the panel. When the main circuit breaker is on, there is high voltage throughout the electri-
cal panel (including the circuit boards and logic circuits) and some components operate at high
temperatures. Therefore, extreme caution is required
Main
Circuit
Breaker
Ground
Line L1 L2 L3
1. Hook up the three power lines to the terminals on top of the main switch at upper right of electri-
cal panel and 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. The
connection looks ne but the machine runs intermittently or has
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 (rotate the shaft that connects to the breaker counterclockwise until
it snaps OFF). Turn ON the power at the source. Using an accurate digital voltmeter and appro-
priate 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).

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NOTE: Wide voltage uctuations 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 Elec-
trical Code species 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 uctuate more than +5% or -5% from an
average.
CAUTION! Make sure that the main breaker is set to 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.
The labels showing the input voltage range for each terminal position are as shown in the follow-
ing illustrations.
High Volt Low Volt
74
75 76 74
75 76
HIGH VOLT 488-458V 457-429V 428-403V 402-377V 376-354V
LOWVOLT ---------------- 260-244V 243-227V 226-211V 210-195V
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 connec-
tor 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 reli-
ably 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 360V connector while users with 380-440V 50Hz power should
use the 400V connector. The 480V connector is not currently used.
5. Set the main switch to ON (rotate the shaft that engages the handle on the panel door clock-
wise until it snaps into the ON position). Check for evidence of problems, such as the smell of
overheating components or smoke. If such problems are indicated, set the main switch to OFF
immediately and call the factory before proceeding

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LOW VOLT
HIGH VOLT
HIGH VOLT 488-458V 457-429V 428-403V 402-377V 376-354V
T5 Transformer
Main
Circuit
Breaker
WARNING!
Through the Spindle Coolant (TSC) pump is a three phase pump and must be phased correctly! Im-
proper 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 upper terminals on the contactor K1
(located below the main circuit breaker). It should be the same as the measurements where the
input power connects to the main breaker. If there are any problems, check the wiring.
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. Electrical power must be phased properly to avoid damage to your equipment. The Power Sup-
ply Assembly PC board incorporates a “Phase Detect” circuit with neon indicators, shown below.
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. Adjust phasing by
swapping L1 and L2 of the incoming power lines at the main circuit breaker.
PASS FAIL
PHASE DETECT
(FOR3PHASE ONLY)
NE5NE6
WARNING!
ALL POWER MUST BE TURNED OFF AT THE SOURCE PRIOR TO ADJUSTING PHASING.
9. Turn off the power (rotate the shaft that engages the handle on the panel door counterclockwise
until it snaps into the OFF position). Also, set the main switch handle on the panel door to OFF.
(Both the handle and the switch must be set to OFF before the door can be closed). Close the
door, lock the latches, and turn the power back on.

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10. Remove the key from the control cabinet and give it to the shop manager.
installation Procedure for external 480v 60hztransformer
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 should be used only in 60Hz applications.
Installation
The transformer should be located as close to the machine as possible. The input and output wiring of the
transformer should conform to the 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.
For domestic installations and all others using 60Hz power, 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 230V 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 230V transformer to adjust the voltage.
installinG the hydraulic counterbalance system
The hydraulic counterbalance system has been discharged of nitrogen (but contains the correct volume of
uid) and the hydraulic counterbalance cylinder has been removed from the column for overhead clearance in
the shipping conguration. The hoses have been disconnected from the hydraulic cylinder and plugged. The
two shoulder screws that secure the hydraulic cylinder to the top of the column have been stored by tighten-
ing them into the threads on the cylinder mounting surface on top of the column. The column axis has been
disabled for safety reasons when initially powering up the machine.
1. Remove the counterbalance cylinder from the crate and unwrap it.
2. Remove the at 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.

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6. Place the at 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. Repeat for the remaining hydraulic cylinder.
7. Orient the cylinder so the hose will be away from the spindle head during operation and tighten
the shoulder screws.
8. Insert and tighten the hydraulic hose tting (use teon tape on the tting) in the port of the coun-
terbalance cylinder.
9. Remove the cap plug on the end of the hydraulic hose and connect it to the tting that is now in
the port of the cylinder.
10. Charge the counterbalance system using dry nitrogen to about 1300 psi (measure at the bot-
tom of travel of the axis). Use all appropriate safety precautions and a supply bottle of adequate
volume. Each bottle that is to be charged is a 90 cubic foot bottle.
11. Power up the machine.
12. Zero return the column axis (Y-axis for HS machines, Z-axis for VS machines) only. The nal
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.
unblockinG the machine
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 cylinders have been removed (for overhead clearance during shipping), and they must
be reinstalled and recharged with dry nitrogen prior to enabling the column axis (Y-Axis for HS machines, Z-
axis for VS machines). 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 secured for shipping and a cover has been placed over the column axis ballscrew and that cover must be
removed.
Shipping
Blocks for
Table
Shipping Blocks A
(2) Two-Piece
Shipping Blocks for Column
Counter Balance
Tanks
Shipping
(Stop)
Block
Support
Block
Portion
Clamp
Block
Portion
(6) Shipping Blocks B
A
B
BB

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Column Axis Ballscrew Cover
Remove the cover from around the colum 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 column axis is later enabled. Inspect the ballscrew for any con-
tamination that may have gotten through the dust cover during shipping and remove if necessary.
unblockinG the table
The table is held in place for shipping by means of blocks that are screwed into the table base. There is one block on each end of the table.These blocks must be removed before normal operation of the X-axis is possible. To access the shipping blocks, both X-axis way covers need to be fully retracted from the table. The X-axis has been disabled in parameters for reasons of safety on power up of the machine.
Rubber Pad
Support Block
SHCS (9)
FHCS (4)
Way Cover
Clamp
Block
X-Axis Chip
Guard
Shipping
Blocks
1. Disconnect both X-axis way covers from the table and fully retract the way covers.
2. Remove the blocks from the table base to prevent any inadvertent damage.
WARNING!
Be certain the machine is powered off when connecting or disconnecting servo motor cables.
3. Uncoil the X-axis servo motor cable and connect to the motor. Do not attempt to dress the cable
to the nal conguration 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.
4. After the X-axis motor cable is connected, power the machine up and enable only the X-axis at
this time.
5. Enable jog without zero return (setting 53) and move the table toward the left 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 conguration.
6. Continue jogging the X-axis far enough to allow access to the cable access hole.
7. Power the machine down. Disconnect the X-axis cable.
8. Route the table base cables and lines through the cable access hole.

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X-Axis
X-axis motor cable
is disconnected
at the control.
Linear Scale Cable,
Disconnect at
Interpolation box
Limit Switch and
Lube Line Junction
a) Route the X-axis motor and encoder cable and connect.
b) If this is a machine with a rotary axis, route the A-axis motor, home switch, and rotary encoder
cables. Also route the air line for the rotary brake. The connectors for the A-axis motor and encod-
er cables are near the junction of the table bas 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 oil line from the table base and connect with the manifold on the lube panel.
9. Power up the machine.
10. Zero return the X-axis.
11. If equipped, enable the A-axis and zero return.
12. Check cable clearances under the table for the full X-axis travel and secure where necessary.
unblockinG the column
The column is held in place for shipping by means of blocks that are screwed into the column base. There are two blocks in the front and two blocks in the rear of the column. These blocks must be removed before normal operation of the column axis is possible. To access the shipping blocks, both base way covers need to be fully retracted from the column. When the front way cover is disconnected from the column, the lower column axis bellows will need to be properly supported. For that reason, the counterbalance must be charged prior to the removal of the shipping blocks in the column base, permitting the spindle head to be safely raised. The Y-axis has been disabled in parameters for reasons of safety on power up of the machine.
Shipping Stop
Blocks
Rubber
Pads (4)
Rear Access
Cover
Z/Y Axis Chip
Guard (2)
Z/Y Axis
Bellows
1. Disconnect the rear way cover from the column and fully retract.

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2. Remove the two shipping blocks and hardware completely from the column base.
3. Raise the spindle head to the full up position and support the bellows.
4. While ensuring the lower bellows do not fall, handle jog (without zero return) the Z-axis (HS) /
Y-axis (VS) toward the rear of the machine until access to the bolts holding the forward shipping
blocks are accessible.
5. Remove the front shipping blocks completely from the column base.
6. Check that the Y-axis (HS) / Z-axis (VS) cables are properly routed and the cable guide is secure-
ly attached to the base.
7. Zero return the Y-axis (HS) / Z-axis (VS).
machine levelinG and Geometry check
At this point the machine is completely unblocked and all axes are enabled. The process of leveling can now
begin.
Lockwasher
(19)
SHCS (19)
Column Base
Mating Flange
Cable Access
Hole Table Base
Mating
Flange
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 inches off the oor.
• The mating anges of the two bases have been pulled into contact.
• The screws that connect the two bases have been backed off and can rotate freely.
overview of levelinG the machine
When leveling the machine the best results are achieved when the entire machine is leveled with respect to
the earth. For the table that means that over the entire travel of the X-axis the table is level to earth in the
direction across the table as well as along the length of the table. For the column base the same concept ap-
plies, but a slight modication may occur when checking the perpendicularity of the Z-axis to the X-Y plane of
the machine.
Leveling and squaring the machine is an iterative process where a change of level in one part of the machine
can and will affect the geometry in another part of the machine. The process is begun by establishing a known
level datum plane that is the table surface in the center of travel, and all subsequent geometry is with respect
to that plane.
The general prole of the process of leveling and squaring the machine is as follows:

ES0755 rev A 1/11 14
• The table base will be leveled to earth
• The column base will be leveled to earth
• The X-Y axes will be checked for perpendicularity
• The table will be swept for parallel to the X-Y plane of the machine
• The Z axis will be adjusted for perpendicularity to the Y axis
• The Z axis will be adjusted for perpendicularity to the X axis
• The mating ange will be completely tightened
• Final leveling, squaring, and anchoring
• Geometry check
establishinG the table as the datum surface
1. Remove all but ve of the mating ange connecting screws. The ve that should be left in position
are the four that are in the corners of the mating ange and the one that is in the center of the top
of the mating ange. Be sure that the ve 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 level-
ing 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 ange surface.
2. Zero return all axes
3. Move the X-axis to the center of travel.
4. Place two levels at right angles to each other as close as possible to 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 ma-
chine. Adjust only the four leveling screws indicated (the two on the table base closest to the col-
umn 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.
Step #5
Step #6
Column
casting
Table casting
Step #6
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.

ES0755 rev A 1/11 15
levelinG the column base
1. Check that the mating ange 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 ange 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 Y-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 ange
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.
checkinG the level of the column base
1. Handle jog the column to the rear.
2. Place a single level inside the column, 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 Y-
axis (VS) / Z-Axis (HS) direction only, to determine, and correct column base atness in the Y/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.

ES0755 rev A 1/11 16
Y-Axis
Z-Axis
sweePinG the y-axis / z-axis
Before continuing to the nal attachment of the column base to the table base the Y-axis (VS) / Z-axis (HS)
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.
Z-Axis Motion Will
Be Swept Parallel To
Line Of Intersection
Y-Z Plane
X-Y Plane
X-Z Plane
Y-Axis Motion Will
Be Swept Parallel
To Line Of
Intersection
X-Y Plane
Y-Z Plane
Sweeping the Z-axis is accomplished using a cylinder square. The purpose of this sweep is to verify that the
line of motion of the Z-axis is perpendicular to the X-Y plane described by the motion in the Y-axis and the
motion in the X-axis. The X-Y plane, as dened by the leveling process, should be equivalent in the squar-
ing function as the parallel plane described by the surface of the table. The line of motion of the Z-axis will
be checked by comparing it to the line of intersection of the two most convenient relative planes, that of the
X-Z plane and the Y-Z plane. By assuring that each of these planes are perpendicular to the X-Y plane within
specication, the machine geometry will be preserved.
final connection of the column base to the table base
1. 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.
2. Tighten the connecting screws with lock washers in place to 500 ft-lb..
Geometry check after matinG the two bases
Before continuing two fundamental geometry checks need to be made. The rst is the perpendicularity of the
X-axis to the Y-axis, and the second is to verify the sweep of the Z-axis.
1. The sweep of the X-axis to the Y-axis is accomplished using a granite square. Set zero by sweep-
ing the Y-axis on one side of the square, and then to verify that the motion of the X-axis is per-
pendicular by sweeping the adjacent side of the square. If the X-axis and Y-axis are not found to

ES0755 rev A 1/11 17
be within tolerance, there almost certainly is contamination or damage between the mating ange
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/Z-axis by repeating the previous section (“Sweeping the Y-Axis / Z-
Axis”).
fine levelinG the machine
Now that the preliminary leveling is done and the bases are securely mated, the machine can be treated as a
unit with condence that the geometry will be maintainable as long as adequate control is maintained in the
ne 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 rst section effected, and will be ne leveled with respect to the table at the
middle of travel.
CAUTION! Do not rush the leveling process. Any drastic attempt to ne level the column base will be propa-
gated to the table base assembly and may be nearly incorrectable if not addressed early in the process.
The table base is more complicated to ne level, and small steps will be taken to preserve the level to earth
established at the middle of travel. The rst 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 in the column, parallel with the Y-axis and
run the column through the range of travel. If no deviation in the reading exists, the column base
is at in the direction of the Y-axis. Move the level to each of the linear guide surfaces in front of
the column. If the readings are zero, the column is at to earth in the direction of the Y• Power
up the control-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 at to earth in the X-direc-
tion.
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 ange 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.
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 nal
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

ES0755 rev A 1/11 18
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 posi-
tion. 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 pri-
mary 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 af-
fected. 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 cen-
ter 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 Y-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, repetitive, 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 pos-
sible to determine the corrective action and the bases may have to be disconnected to rectify the situation.
When ne leveling is completed, tighten the jam nuts on the leveling screws.
sweePinG the table
The sweep of the table should be little more than a verication of the leveling process. Using the special tool
for mounting the indicator, rst verify that the table is within specication as the Y-axis (VS) / Z-axis (HS) is
moved. Then, for several Y-axis (VS) / Z-axis (HS) positions where the indicator is on the table surface, run
the X-axis from end to end and verify that it is also within specication.
Geometry check
The nal 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 veried to be
within the tolerances specied for the machine.
comPletinG the installation
1. Seal the shipping bracket bolt holes to prevent oil leaks.
2. Replace all sheet metal removed paying particular attention to sealing any component mating
surface potentially exposed to coolant ow.
3. Install the table gutter fence.
4. Install and verify operation of the tool changer (see the section on tool changer installation and
alignment for the specic toolchanger).
5. Verify all machine functions.

ES0755 rev A 1/11 19
Cable
Support
Clamp
Cable
Cable
X-Axis
X-Axis Auger
Trough
Cable (To X-Axis
Auger Motor)
X-Axis Auger Trough
condition exists, please contact Haas factory service.
tool chanGer installation/aliGnment
Installing the Hydraulic Power Unit (HPU)
Before placing the Tool 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.
High Pressure
Low
Pressure
High Press.
Low Press.
Air
Air
T
P
High Pressure
Low Pressure
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 level of hydraulic uid in reservoir by inspecting the sight gage located on the side of the reservoir. If
necessary, add hydraulic uid (DTE 25) to the reservoir until the level reaches the top of the sight gage.
2. Connect pressure and return hoses from the hydraulic power unit (HPU) to the tool changer. The pressure
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 lter inlet on the hydraulic power unit. Note that if the HPU is
operated for the rst time, skip to step 7 for initial adjustment of hydraulic system pressure and ow settings.
3. Connect the supply airline (1/4” plastic hose) from the machine’s air-lube panel to the upper tting on the
tool changer manifold.

ES0755 rev A 1/11 20
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 hydrau-
lic power unit.
c. Note the rotational direction of the power unit motor and compare with the directional arrow lo-
cated 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 that 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 rst 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 lter 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 ttings. Operate the pump for at least 10
minutes without any load to remove any remaining air in the circuit.
8. To adjust the ow rate of the hydraulic system perform the following steps:
a. The ow rate is adjusted with the hydraulic power unit operating in a no-load state.
b. Install a hydraulic service owmeter rated for 1 to 15 gpm in-line with the hose connecting the
pump discharge to the lter inlet of the hydraulic power unit.
c. Turn the hydraulic power unit on and adjust the pump discharge ow rate by turning the ow ad-
justment screw (the horizontally oriented screw with locknut), clockwise to decrease the ow rate
and counter-clock wise to increase the ow rate. The correct ow rate for operation of the ATC
38 tool changer is 8 gpm. Note that it may be necessary to rst adjust the pump “open system”
discharge pressure to achieve 8 gpm. This is done by adjusting the vertically oriented screw. Ap-
proximately 300 to 375 psi will be the maximum achievable pressure when in the “open system”
operating mode.
Inspection Cover
Flowrate Adjustment Screw
Pressure Adjustment Screw
Hydraulic Pump Pressure and Flowrate Adjustment Screws
9. Reconnect the hydraulic hoses as described in Step 2, after the ow 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