TABLE OF CONTENTS
- Pre-Install Preparation
- Unpacking Your Machine
- Connecting the Liquid Chiller
- Connecting the Dust Collector
- Powering Up for the First Time
- Final Pre-Start Notes
Pre-Install Preparation
Milling Machine Layout
Before beginning installation, it’s important to familiarize yourself with the layout of the X-Mill 580DC. The machine has key access points at the front, rear, and right side, each of which will be used during setup and servicing.
Figure 1. X-Mill 580DC: Front, Rear, and Right Side views
Keep this orientation in mind as you proceed through the installation steps. The rear houses all major connections (power, chiller ports, vacuum interface, and network). The right side provides access to the disc changer service hatch and USB ports. The front gives access to the milling chamber and operator controls.
Pre-Install Checklist
Before beginning installation, confirm that you have the following ready:
Workspace with required clearances.
Air compressor (oil-free, water-free) meeting required specifications.
Correct electrical breaker, plug, and outlet installed.
Coolant prepared (8L of pre-diluted Asian Vehicle 50/50 Antifreeze, red/pink).
Dust collector unit and hose, with adapter cable if needed.
Tools available: hex key set, wrench, hose clamps.
TIP: Stage the chiller, hoses, coolant, and tools before uncrating the mill. This reduces downtime during setup.
Recommended Working Clearances
580DC Milling Machine
The X-Mill 580DC requires adequate space for safe operation and service access.
Dimensions: 30" × 38" footprint
Recommended Working Clearance: 48" × 52" workspace
Note: The lower-right side of the machine cabinet contains ventilation slots. If you plan to place the CW3000 chiller inside the cabinet, this area must remain unobstructed to allow proper airflow.
Figure 2. Recommended working clearance for the X-Mill 580DC Top Down View.
CW3000 Chiller
The CW3000 Industrial Chiller is used to regulate the spindle’s operating temperature during milling. It also requires adequate clearance for airflow and service access.
Dimensions: 11" × 18.5" footprint
Recommended Working Clearance: 15" × 20" workspace
Figure 3. Recommended working clearance for the CW3000 Chiller.
Note: Proper airflow is essential to keep coolant temperatures within range (27°C–33°C). Insufficient clearance may cause overheating and reduce spindle accuracy
Air Compressor with Dry Air
The 580DC requires compressed air for pneumatic actuators (tool changer, disc changer). Only use oil-free, water-free compressed air.
Specifications:
Pressure: 0.6–0.8 MPa
Flow: ≥ 60 L/min (2.12 CFM)
Tube: 8mm OD
Setup Steps:
Place the compressor within 6 feet (2m) of the mill.
Install a drying filter to remove moisture and oil.
Connect the 8mm tube to the machine’s rear air inlet.
Tighten fittings securely to avoid leaks.
Important: If pressure falls below 0.6 MPa, the machine will not initialize. Always check the compressor gauge before startup.
Power Supply
The 580DC requires a stable electrical connection.
Specifications:
Voltage: 220V AC ±5% / 60Hz
Power Consumption: 3.5kW (including vacuum)
Breaker: 20A (dedicated)
Plug/Socket: NEMA 6-20R
Setup Steps:
Confirm breaker and line are rated for 220V, 20A.
Verify your outlet is NEMA 6-20R.
Figure 4. Required outlet type: NEMA 6-20R socket.
Plug the machine’s main power cable directly into the outlet.
Warning: Do not use extension cords or multi-plug adapters. A dedicated breaker line is required.
Coolant for Liquid-Chilled Spindle
The 580DC spindle requires 8L of pre-diluted antifreeze coolant.
Coolant Requirements:
Pre-diluted 50/50 mixture of antifreeze coolant is required.
This coolant does not require you to add any water.
We highly recommend using only Asian Vehicle coolant (Red / Pink)
PEAK -50/50 Asian Vehicle Pre-Diluted Antifreeze / Coolant
Valvoline Zerex Asian Vehicle 50 / 50
Figure 5. Recommended coolants for the 580DC chiller (Valvoline Zerex & PEAK).
Setup Steps:
Remove the coolant cap on the CW3000 chiller.
Slowly pour 8L of pre-diluted coolant into the tank.
Replace the cap and check the coolant level indicator.
Self-Install Video
Refer to the installation video included with your setup package before beginning.
X-Mill 580DC Self-Install video reference:
Unpacking Your Machine
Packing Material & Foam Supports
The 580DC ships with protective foam inserts to prevent damage. These must be removed:
Open the front milling chamber door. Remove visible foam blocks.
Access the disc changer area by removing the right-side steel panel (Disc Changer Service Hatch), secured with six hex screws.
Carefully remove foam inserts from the disc changer slots.
Reinstall the steel panel once all foam has been cleared.
Figure 6. X-Mill 580DC right-side view showing service hatch.
Important: Some foam inserts may be tightly wedged in place. If you cannot remove a piece by hand:
Take note of the foam’s position.
Do not force the part out, as this may damage the robotic arm or adapters.
Contact Level Up Support for assistance. Our team can guide you in manually jogging the machine axes to safely release and remove the shipping foam.
Removing the Chuck Security Washer
During shipping, a security screw and washer are installed inside the chuck mount to lock the fixture adapter in place. This must be removed before the machine can operate.
Steps:
Open the milling chamber and locate the chuck mount.
Identify the shipping security screw and washer seated inside.
Use the provided wrench to carefully loosen and remove the screw.
Pull out the washer along with the screw.
Store the washer and screw in the original XTCERA packaging for safekeeping (do not discard).
Figure 7. Chuck security washer : shown installed (left) and removed (right).
Note: Operating the machine with the security washer still installed will prevent the chuck from functioning and may cause mechanical error.
Connecting the Liquid Chiller
The 580DC uses a liquid-chilled spindle with an industrial CW3000 chiller that circulates coolant to regulate spindle temperature during operation. Proper installation of the chiller ensures accuracy, prevents thermal expansion, and extends spindle life.
Placement of the Chiller
You may place the chiller in one of two positions:
Beside the machine on the floor (recommended for airflow and easy servicing).
Inside the machine cabinet to save space.
Important: If you place the chiller inside the cabinet, you must leave one of the front cabinet doors open or remove it entirely. This ensures proper airflow for cooling and prevents the chiller from overheating.
Connecting the Coolant Hose
Locate the two coolant hoses (coolant inlet/outlet ports) inside the lower cabinet of the 580DC.
Figure 8. Back of the 580DC showing labeled coolant inlet/outlet ports
Connect these hoses to the rear ports of the CW3000 chiller.
The chiller ships with 5 hoses and 4 adapters. Assemble these pieces before connecting them to the machine’s hoses.
Use hose clamps to secure connections and prevent leaks.
Note: Ensure the hoses are not bent or kinked. Restricted coolant flow can cause overheating.
Connecting the Chiller Power
The CW3000 receives its power directly from the 580DC and does not require a separate outlet.
Run the included chiller power cable through the rear cabinet hole.
Plug the cable into the port labeled “Chiller” on the back of the mill.
Verify the connection is firmly seated before operation.
Figure 9. Back of the 580DC showing labeled chiller power and chiller ports.
Operating Temperatures
The CW3000 stabilizes spindle temperature during continuous or heavy milling.
Normal operating range: 27°C – 33°C
Warning threshold: Above 35°C may cause milling inaccuracies.
Critical threshold: Above 40°C — stop operation immediately and check airflow and coolant level.
Tip: Monitor the chiller temperature gauge during the first few runs to confirm stable operation within range.
Connecting the Dust Collector
The 580DC Mill requires a dust collection system to manage debris generated during milling. While the machine can operate with most dust collectors, only specific models support automatic on/off control via adapter cable.
Supported Dust Collector Units
For full compatibility, we recommend the Renfert Silent PowerCAM EC dust collector. When connected with the correct adapter cable, this unit will automatically turn on and off with the milling machine.
Figure 10. Renfert Silent PowerCAM EC
Connecting the Dust Collector Hose
Locate the dust collection port at the back of the 580DC.
Route the collector hose through the rear port and up to the bottom of the milling chamber.
Secure the hose firmly to maintain suction and prevent leaks.
Using the Large Dust / Particle Catcher
The 580DC includes a Large Dust/Particle Catcher, designed to intercept larger debris before it reaches the dust collector tray. This reduces the frequency of tray cleaning and extends collector service intervals.
Figure 11. Large Dust/Particle Catcher inside the 580DC with vacuum hose connection point.
Powering Up for the First Time
Connecting to Power
Verify the air compressor and chiller are running.
Ensure the dust collector is connected.
Turn on the main power breaker for the machine.
Connecting to Network (Ethernet / WiFi)
Recommended: Wired Ethernet (stable file transfers, reliable support).
Figure 12. WiFi USB adapter included with the 580DC.
Plug Ethernet cable into the port on the back of the mill.
Optional: Use the included USB WiFi adapter (right side of machine).
Note: WiFi should only be used if Ethernet is unavailable.
Consulting the Machine Manual
For detailed machine-specific start-up procedures (e.g., spindle warmup, first calibration, or firmware checks), always refer to the official machine manual provided by XTCERA.
Link to Full Manual: X-Mill 580DC User Manual
Recommendation: Keep a digital copy of the manual accessible on the workstation PC for quick reference during startup and troubleshooting.
Final Pre-Start Notes
Before proceeding to software setup, confirm:
All foam supports and packing removed.
Chuck washer removed and stored.
Air compressor connected and at correct pressure.
Chiller connected, coolant filled, power cable secured.
Dust collector installed and hose routed correctly.
Power cable connected directly to NEMA 6-20R outlet.
Network connection established.
Manual consulted for first start-up guidance.
At this point, proceed to the “After Install: Powering Up Your Mill” guide for controller activation and first run.
Need Assistance?
You can submit a support ticket through our portal, see how to submit a ticket here.
Or email us directly at support@levelupcadcam.com.
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