Haas EC-1600 - User Manual

Need help?

Do you have a question about the Haas EC-1600 and is the answer not in the manual?

Summary

Machine Leveling Procedures

Introduction to Machine Leveling

Explains the importance of correct machine leveling for geometry and function, and potential issues from incorrect level.

Tools Required for Leveling

Lists essential precision tools for accurate machine leveling operations.

X and Z Axis Leveling Process

Details steps for correcting X and Z axis pitch and roll using leveling screws.

Leveling Verification and Final Steps

Describes final checks for X, Y, Z axes, and securing the machine after leveling.

Axis Alignment and Geometry Verification

A-axis Rotation Parallelism

Checks parallelism of the A-axis rotation to the Y-axis.

Platter Face Runout

Measures platter face runout at 90° increments.

Y-axis Tilt Relative to X-axis

Verifies Y-axis tilt against X-axis using precision tools.

Y-axis Tilt Relative to Z-axis

Verifies Y-axis tilt against Z-axis using precision tools.

Tool Changer Alignment Verification

Spindle and Tool Changer Arm Alignment

Verifies the alignment of the tool changer double arm to the spindle using a split tool.

TC Alignment Measurement and Checks

Measures and verifies TC alignment, including arm-to-tool holder distance.

Summary

Machine Leveling Procedures

Introduction to Machine Leveling

Explains the importance of correct machine leveling for geometry and function, and potential issues from incorrect level.

Tools Required for Leveling

Lists essential precision tools for accurate machine leveling operations.

X and Z Axis Leveling Process

Details steps for correcting X and Z axis pitch and roll using leveling screws.

Leveling Verification and Final Steps

Describes final checks for X, Y, Z axes, and securing the machine after leveling.

Axis Alignment and Geometry Verification

A-axis Rotation Parallelism

Checks parallelism of the A-axis rotation to the Y-axis.

Platter Face Runout

Measures platter face runout at 90° increments.

Y-axis Tilt Relative to X-axis

Verifies Y-axis tilt against X-axis using precision tools.

Y-axis Tilt Relative to Z-axis

Verifies Y-axis tilt against Z-axis using precision tools.

Tool Changer Alignment Verification

Spindle and Tool Changer Arm Alignment

Verifies the alignment of the tool changer double arm to the spindle using a split tool.

TC Alignment Measurement and Checks

Measures and verifies TC alignment, including arm-to-tool holder distance.

This document outlines the leveling and alignment procedures for Haas EC-1600/2000/3000 series machines, crucial for maintaining their precision and operational integrity. The primary function of these procedures is to ensure the correct right-angle geometry of the machine's X, Y, and Z axes and the accurate positioning of the tool changer. Incorrect leveling can lead to significant machining errors, such as out-of-round circle milling, incorrect linear interpolation, and potential tool changer malfunctions, including dropping tools.

Function Description:

The leveling process involves both rough and fine adjustments, followed by geometry checks. It addresses several critical aspects of machine setup:

Machine Leveling: This is the foundational step, ensuring the machine base is perfectly level. Factors like floor rigidity, foundation stability, nearby vibrations (trains, trucks), and seismic activity can affect the machine's level over time. Regular re-leveling checks are recommended, especially after initial installation, until a stable re-leveling frequency is established. For the EC-1600, anchoring is highly recommended for machining large, heavy, or tall parts, or if the foundation is suspect.
Roll and Pitch Adjustment: These adjustments are critical for ensuring the machine's axes are perfectly perpendicular and parallel as required. Roll refers to the tilt along an axis, while pitch refers to the tilt across an axis. Eliminating both is essential for accurate machining.
Z-axis Geometry Verification: This ensures the Z-axis is correctly aligned relative to the table or platter.
A-axis Rotation Verification: This procedure measures the parallelism of the A-axis (axis of rotation) to the Y-axis and checks the platter face runout. This is crucial for machines with rotary axes to ensure accurate rotational positioning.
Geometry Verification (Squareness Checks): These steps measure the squareness of the Y-axis to the X-axis and the Y-axis to the Z-axis. This ensures that all machine axes form perfect right angles, which is fundamental for precise multi-axis machining.
Tool Changer (TC) Alignment Verification: This is a critical safety and operational check performed before loading any tools. Any adjustment to the machine's level will affect TC alignment. Incorrect alignment can lead to dropped tools, damaged waycovers, cambox damage, excessive wear, and damage to the TC double-arm.

Important Technical Specifications:

The procedures rely on precise measurements and adjustments, with specific tolerances:

Leveling Accuracy: 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 is required. The level's calibration must be checked before use.
A-axis Rotation Parallelism: Readings for A-axis rotation parallelism are not to exceed 0.0005".
Platter Face Runout: Readings for platter face runout are not to exceed 0.002".
Y-axis Tilt Relative to X-axis and Z-axis: Readings for Y-axis tilt over 24" of travel are not to exceed 0.0005".
Tool Changer Alignment (Split Tool Gap): During spindle approach, there should be a maximum of 1/8" (3.2 mm) gap between the split tool halves, ensuring they do not touch.
Tool Changer Alignment (Tool Holder Distance): The distance between the double arm and the tool holder, measured with a caliper, should be +/-.010" (.254 mm).
Tool Changer Weight Preload: A 40 lb (18.2 kg) weight is hung from the pocket side of the double arm to preload it during alignment checks.
Tool Load Capacity: Maximum tool load is 30 lbs (13.6 kg) each.

Usage Features:

The manual provides a step-by-step guide for performing these critical setup and maintenance tasks:

Tool Requirements: Specific tools are needed, including a .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, and a .0005" caliper.
Initial Setup: All leveling screws are initially screwed through the base until the base is 4" above the floor (3" pad height + 1" of screw extending from the bottom of the base). This initial height may vary depending on the foundation.
Iterative Adjustments: Many steps involve iterative adjustments (e.g., raising/lowering screws, re-verifying readings) until the specified tolerances are met. This highlights the precision required.
Machine Control Interaction: The procedures involve jogging the table and column, using T/C Recovery commands for tool changer movements, and adjusting machine parameters (e.g., Parameter 257 for Spindle Orient Offset, Parameter 64 for tool holder distance).
Safety Precautions: A warning emphasizes verifying tool changer alignment before operating the mill. Emergency Stop is used during tool changer alignment to prevent the double arm from reaching the spindle. Care is advised to avoid pinch points during split tool installation.
Troubleshooting Notes: The document includes notes on potential issues, such as the need for shimming granite parallels due to table surface tolerance, and guidance on what to do if Z-axis pitch cannot be adjusted to an acceptable tolerance (e.g., anchoring the machine, contacting Haas factory service). It also clarifies that the machine table surface may not be perfectly perpendicular to earth gravity, which is acceptable as long as the machine is square and its geometry is correct.

Maintenance Features:

These procedures are primarily maintenance-related, ensuring the machine's long-term accuracy and performance:

Regular Checks: The document strongly recommends frequent level checks after initial installation until the re-leveling frequency is established, due to various environmental and operational factors affecting machine level.
Post-Anchoring Verification: If the machine is anchored, the leveling process must be repeated after the anchors are locked in and torqued, as anchoring can affect the level.
Reinstallation of Components: After leveling is complete, Z-axis waycovers must be reinstalled and sealed with black RTV.
Tool Changer Verification: TC alignment must be verified whenever the machine level is adjusted or changed, as it directly impacts tool changer operation and prevents damage.
Parameter Adjustments: The manual guides technicians on adjusting specific machine parameters (e.g., Spindle Orient Offset, tool holder distance) if alignment issues are detected, referring to the Service Manual for detailed instructions.
Final Operational Check: After all adjustments, tools are loaded (within specified weight limits), and tool changes are performed at 100% rapid speed to verify proper operation, with a caution to protect the Z-axis way cover in case of a dropped tool.

In summary, this document serves as a comprehensive guide for setting up and maintaining the geometric accuracy and tool changer functionality of Haas EC-1600/2000/3000 machines, emphasizing precision, iterative adjustments, and safety.