ROMANOFF ELECTROLASER MEGAHIT Configuration guide

9 Deforest Street, Amityville NY, 11701, USA
Tel: [phone]
[email protected]
Romanoff.com

Elettrolaser S.r.l. - 2 - MEGAHIT

Elettrolaser S.r.l. - 3 - MEGAHIT
LASER MEGAHIT
GENERAL MANUAL
USE AND INSTALLATION
IMPORTANT
Verify carefully the content of this manual with particular attention to the warnings
for the installation, use and the maintenance of this machine. This device and the
relative instructions are for sole rights of personnel qualified in the unit use as that
one that here will be described. Don’t allow the installation or the maintenance of
this machine to not qualified technicians. Contact directly Elettrolaser S.r.l. for every
further explanation. The customer can request to the manufacturer a copy of this
manual showing:
•Exact model of the machine
•The machine model number
•A copy of the purchase invoice
__________________________________________________________________
The erroneous application of the practice use and/or of the procedures here
described can bring the user to an exposure harmful to the laser radiations. Follow
carefully the here-described procedures.
CONTENT GUARANTEE
The informations included in this manual are subjected to modifications without notice. Elettrolaser
S.r.l. will be not responsible for errors included in this document and incidental damages or
consequent to the erroneous interpretation of this manual.
Document issues
Issue Date Approval Valid from model
n° Notes
0 01/07/2006 G.M. 01/07/06 MG01100
1 04/06/2009 G.M. 04/06/2009 MG01160
2 19/04/2010 G.M. 19/04/2010 MG01147
3 04/02/2011 G.M. 04/02/2011 MG01177
4 28/04/2014 G.M. 28/04/2014 MG01345
5 04/07/2018 G.M 04/07/2018

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USE DESTINATION
The machine MEGAHIT is destined to the welding of small size products in metallic material.
NOTE
It isn’t allowed to change the use destination for which the system has been
designed and produced. Elettrolaser S.r.l. declines every responsibility about the
non-conformance use of the equipment of its production.

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ELETTROLASER S.R.L.CONTRACTUAL GUARANTEE
The producer guarantees the defects absence, taking into consideration of the actual technological
phase, about the new equipment type and for the duration of two years from the installation date
c/o the customer included in the transportation documents. It being understood the limit of two
years, the guarantee obligation spreads also to those equipment parts not produced directly by
Elettrolaser S.r.l. with the exclusion of LED lamps for the welding room illumination, fuses,
protection glass, fire lens and all consumable material. The producer lends guarantee proceeding
at his discretion, in accordance with the technical requirements, to the repair or to the change if
faulty pieces. In the case the producer admits a guarantee right the relative intervention costs are
at his charge. The pieces that present material or working defects and those ones consequently
damaged are changed. The changed pieces become of Elettrolaser S.r.l. property. For the
changed after an intervention in guarantee, this is admitted up to the equipment guarantee
maturity.
The guarantee right doesn’t exist when the happened defect is in relation with the following cases:
The buyer hasn’t denounced the defects to the producer within eight days from the
installation date, in writing o giving job for the execution of the relative intervention.
The device or its parts have been used in different ways for the use to which have been
assigned
The device has been entrusted for the repair to an extraneous subject to Elettrolaser S.r.l. or
the device or its pieces have had some modifications not authorized by Elettrolaser S.r.l.
The prescriptions about the use and the maintenance of the machine included in this manual
have not been respected
The guarantee seals on the machine closure panels have been removed.
Besides the defects and the damages are excluded from the guarantee deriving from the normal
wear or from natural events. It being understood on behalf of the buyer the performance right in
guarantee in the terms above showed, it is excluded expressly that the buyer can request the
contract solving, the machine change or the sale price reduction and the compensation of possible
direct and indirect damages.
Possible omissions and/or negligence of the user, if provoke our technician intervention, allow the
relative expenses debit on behalf of Elettrolaser S.r.l.
If during the guarantee period there is a defect Elettrolaser S.r.l. will provide to eliminate it freely in
the full respect of the “guarantee conditions”.
Elettrolaser s.r.l. Stamp and sign for acceptance of the
“ guarantee conditions”

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INDEX
LASER MEGAHIT .................................................................................................................... 3
GENERAL MANUAL ............................................................................................................... 3
USE AND INSTALLATION ...................................................................................................... 3
CONTENT GUARANTEE......................................................................................................... 3
USE DESTINATION ................................................................................................................. 4
E
LETTROLASER S
.
R
.
L
.
CONTRACTUAL GUARANTEE
................................................................................................ 5
INDEX ......................................................................................................................... 6
CHAPTER 1 SYMBOLS ....................................................................................................... 9
CHAPTER 22 SAFTEY ............................................................................................................ 11
2.1 LASER RADIATION ABSORPTION ...................................................................................................... 12
2.2 CLASSIFICATION AND DANGEROUSNESS ....................................................................................... 13
2.3 RADIATION VISION CONDITIONS....................................................................................................... 14
2.4 RISKS FOR THE EYES AND THE SKIN............................................................................................... 15
2.5 SAFETY GENERAL PRESCRIPTIONS ................................................................................................ 15
2.6 COLLATERALI RISKS ........................................................................................................................... 15
CHAPTER 33 SEALS .............................................................................................................. 17
3.1 SAFETY LABELS................................................................................................................................... 18
3.2 LABELS POSITIONING ......................................................................................................................... 20
CHAPTER 4 TECHNICAL DATA .......................................................................................... 22
4.1 LASER SPECIFICATIONS .................................................................................................................... 22
4.2 OTHER DATA ........................................................................................................................................ 22
4.3 LAYOUT AND MACHINE DESCRIPTION ............................................................................................. 23
CHAPTER 55 CONTROLLS DESCRIPTION ........................................................................... 24
5.1 INTERNAL CONTROLS .......................................................................................................................... 1
5.2 JOYSTICK CONTROLS ........................................................................................................................ 25
CHAPTER 66 INSTALATION .................................................................................................. 27
6.1 FIRST SWITCHING ON ......................................................................................................................... 30
6.2 WELDER SWITCHING OFF .................................................................................................................. 32
CHAPTER 7 MAINTANENCE ................................................................................................ 33
7.1 CHANGE THE PROTECTION SLIDE AR/AR ....................................................................................... 35
7.2 REALIGN THE POINTING CROSS ....................................................................................................... 36
7.3 CHANGE PERIODICALLY THE REFRIGERATING LIQUID ................................................................ 38
7.4 HOW TO REMOVE THE WATER ......................................................................................................... 38
7.5 HOW TO REFILL THE COOLING SYSTEM ......................................................................................... 38
CHAPTER 8 ERROR MESSAGES AND PROBLEMS RESOLUTION ...................................39
8.1 OTHER ANOMALIES............................................................................................................................. 41

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CHAPTER 9 SAFETY SYSTEMS .......................................................................................... 42
9.1 RESONATOR SHUTTER ...................................................................................................................... 42
9.2 MICROSCOPE SHUTTER .................................................................................................................... 43
9.3 MICROSCOPE INFRARED FILTER...................................................................................................... 44
9.4 WELDING ROOM INFRARED FILTER ................................................................................................. 44
9.5 OPENINGS PROTECTION FOR HANDS INTRODUCTION ................................................................ 45
CHAPTER 10 SAFETY GENERAL PRESCRIPTIONS FOR LASER PLANTS IN WORKING
ARRANGEMENT ................................................................................................................... 46
10.1 INTRODUCTION.................................................................................................................................. 46
10.2 PROTECTION SYSTEMS ................................................................................................................... 46
10.3 PARTICULAR PRESCRIPTIONS FOR LASERS OF CLASS IV ........................................................ 48
10.4 CONTROLS POSITIONING AND PLATING ....................................................................................... 48
10.5 PRESCRIPTIONS FOR THE USER; ADMINISTRATIVE PROCEDURES AND OPERATIVE
STANDARD PROCEDURE (P.S.O.) ........................................................................................................... 48
10.6 INDIVIDUAL PROTECTION, INDIVIDUAL PROTECTION DEVICES (D.P.I.) .................................... 48
10.7 RESIDUAL RISKS THAT THE USER MUST LOCATE AND ELIMINATE .......................................... 49
CHAPTER 11 49
CONFORMANCE WITH THE CEE DIRECTIVES AND CE MARKING; ................................. 49
ADDITIONAL INSTRUCTIONS FOR THE USER................................................................... 49
11.1 CONFORMANCE DECLARATION ...................................................................................................... 51
CHAPTER 12 TECHNICAL ASSISTANCE ........................................................................... 52

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PICTURES INDEX
Picture 1:Eyeball ........................................................................................................................... 12
Picture 2: Frontal laser warning labels .......................................................................................... 20
Picture 3 : Internal laser warning labels......................................................................................... 20
Picture 4: Back laser warning labels.............................................................................................. 21
Picture 5: Internal controls ............................................................................................................ 24
Picture 6: joystick controls............................................................................................................. 25
Picture 7: Display Touch screen...................................................................................................... 1
Picture 8: Machine below sight...................................................................................................... 27
Picture 9: Protection gas connection and air connection ............................................................... 27
Picture 10: Feeding cable connection and the pedal cable............................................................ 28
Picture 11: Feeding foot pedal ...................................................................................................... 28
Picture 12: Oculars ....................................................................................................................... 29
Picture 13: Stop button ................................................................................................................. 30
Picture 14: General switch ............................................................................................................ 30
Picture 15: Switching on key ......................................................................................................... 30
Picture 16: Switching on display.................................................................................................... 31
Picture 17: General switch ............................................................................................................ 32
Picture 18:Pointing cross realignment ........................................................................................... 36
Picture 19: Fastening of the Stereomicroscope............................................................................. 37
Picture 20: Microscope infrared filter ............................................................................................. 44
Picture 21: Welding room infrared filter ......................................................................................... 44
Picture 22: Hands passage ........................................................................................................... 45

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CHAPTER 1 SYMBOLS
Generic warning:
This symbol shows the necessity of a careful reading of the manual or the necessity
of an important manoeuvre or maintenance operation.
Laser warning:
This symbol shows the exposition danger to the laser visible and invisible radiation.
This symbol can be included also on the machine in correspondence of risk zones.
In presence of this symbol so:
•Don’t introduce ever mirrors or reflecting objects in the welding room while
the machine is in function.
•Check the products exclusively from the peephole placed on the front nose.
•Don’t remove ever the curtains for the hands insertion.
During the machine use move the childs and the people of small height.
It is advised to the user to protect the hands with adequate and approved working
gloves.
Fire warning:
This symbol shows the fire danger when inflammable materials are processed. This
symbol shows the fire danger when the inflammable materials are processed. When
there is fire danger, it is indispensable to follow the indications provided from the
manufacturer during the put in service of the machine.
Don’t weld where the sparks can meet inflammable material.
Remove all the inflammable materials near to the LASER welder. If this isn’t possible
cover them carefully with fireproof material.
Fire attention: keep extinguishers in the vicinity.
Explosion warning:
This symbol shows that the gas contained in the cylinders is under pressure and can
consequently explode if the cylinders aren’t treated with the necessary cautions.
Protect the cylinder from excessive heat and mechanical stresses.
Install the cylinders in vertical position and block them with a fixed support chain or
with a proper cylinders case to avoid falls or knocks.
Maintain the cylinders far away from the welding place and from any electric circuit.
Use only regulation cylinders, pressure reducers, pipes and joints approved for the
specific use; maintain them in good conditions together with the connected parts.
Don’t expose the face towards the valve exit placed on the cylinder when this one is
opened.
Maintain the valve always covered with a correct screw hood except when the
cylinder gas is used or when the cylinder is connected to the machine.
Gas and fumes warning.
The welding processes produce fumes and gas, breath them can be dangerous for
the health.
Keep the head a long way from fumes, don’t breathe the fumes.
Don’t cover the grids placed on the machine.
Read with attention the supplied instructions about the different types of metals,

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cleaning substances and protection gas.
Prefer a wide room dedicated appropriately for the machine installation. If the room
is of reduced sizes use it only if well ventilated. The protection gas used to weld can
gradually change the air causing indisposition or death. Assure that the air that is
breathed is healthy.
Don’t weld near the degreasing, cleaning or vaporization areas. The heat could react
with the vapors forming very toxic and irritating gases.
Check that the metals haven’t impurities to provoke fumes or gases during the
melting.
Electric warning:
This symbol shows dangerous voltages associated to the laser, or however of
sufficient width to induce electric risk. This symbol can be showed also on the same
machine in correspondence of risk zones.
Touch electric parts under voltage can provoke fatal damages or serious burns. The
electric circuits are always under voltage when the machine is switched on. The not
correct installation or the machine inappropriate grounding represents a danger.
Don’t touch electric parts under voltage.
Remove the feeding plug from the net before to install or make maintenance to the
machine.
Install correctly and connect to ground this machine following the use Manual and
respecting the standards and local rules.
Switch off the machine after the use.
Don’t use the weak cables, damaged, of insufficient section or mal connected.
Pay attention to have not cables near to heat sources.
Use only equipment in perfect conditions. Repair or change immediately the
damaged parts.
Maintain all covering panels fastened and in their seats.
Important warning:
This symbol shows the necessity of a careful reading of the manual on behalf of the
operator.

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CHAPTER 2 SAFETY
In this charter are discussed matters about the individual safety.
The performed tests demonstrate the safety and the laser reliability when is used properly. It is
however necessary that the operator is informed about the precautionary standards ready to avoid
possible damages to people or to the same machine.
Laser radiations
The laser radiation is an electromagnetic emission with micrometric wavelength that is placed in
the far infrared (CO2 laser), in the near infrared (laser at Nd-YAG, Nd-YVO4), in the visible (laser
He: Ne or Argon), or in the ultraviolet (eccimers laser).
It is believed not iodizing radiation. In the lasers MEGAHIT the emission of a crystal small bar is
stimulated from the “optical pumping“ generated from a power laser lamp. The continue bounce of
the photons, between an anterior mirror and a back one, see to it that a positive reaction starts for
which their number increase step by step, up to assume the concentration necessary to produce a
beam that comes out from the anterior semi reflecting mirror. The reaction (that we can imagine as
an “invisible light beam”) is after coincided and focused with some lens in a point, in which the
intensity becomes so high to react with different materials causing a change for thermal effect.
For what described, the MEGAHIT laser radiation is invisible but, placing near the visibility
threshold, makes sure that the eye receives it almost entirely without ever offer pupillar reflex. If in
addition to this that it is generally much intense results that it can be extremely harmful or lethal for
the sight.
NOTE
The direct vision of a laser beam can provoke irreversible damages to the sight
To avoid permanent damage to the person it is necessary to follow some precautions.
All people, that can be exposed to harmful levels of laser radiations, must know when the laser is
active, and in this case must wear the protective gloves.
The laser integrated in the machine, due to the high power, causes laser light reflected from the
plane surfaces. The reflected light is potentially dangerous for the eyes and the skin. The
electromagnetic emission with micrometric wavelength places in the far infrared and it is so
invisible, it isn’t so evident where the reflected beams are addressed.
NOTE
It is indispensable to protect from the reected light beams, because they
can be sufficiently intense to create permanent damages to the eyes or to the
skin
NOTE
The laser in object comes into in class IV. Those lasers that can produce risks
belong to the class IV, not only for the direct or reflected radiation, but also for the
diffused radiation. These laser sources can present a remarkable risk for the
skin and fire risk for inflammable materials.

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2.1 LASER RADIATION ABSORPTION
The human tissue absorbs the electromagnetic radiation in different way in accordance with the
wavelength of the same radiation. Both the eye both the skin have their “presetting” to accept
some wavelengths and they are more refractory to absorb others. In the eye specific case, the
cornea and the crystalline let pass and reach up to the retina, also with different attenuations, all
the wavelengths that go from 400 to 1400 nm, or range between the light in the visible up to the
infrared IRA. So it must be noticed that the Nd:YAG lasers radiation (wavelength 1064nm), being
included in this range, requires a direct exposition of the retina.
For what concern the skin the “biological window” is different in the absorption percentages but not
different for the wavelengths. The exposition maximum values for the skin are many different, as
easily intuitable, respect to those tolerable from the eye.
Picture 1:Eyeball
For what concern the damage mechanism that the absorbed radiation can cause, depends also it
from the wavelength. The short wavelengths (ultraviolet UV-C 180-280nm, UV-B 180-280nm, UV-A
315-400nm) provoke generally photochemistry effects: cataract or crystalline opacification for the
eye, melanic coloration or reddening for the skin. Major wavelengths (infrared: IR-a 780-1400nm
IR-c 3000-10 E6nm) provoke generally thermal effects: retinal detachment and photocoagulation
for the eye, burning for the skin.
The provoked damage degree depends obviously from the quantity of absorbed radiation and
from the sudden power of the radiation source.

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2.2 CLASSIFICATION AND DANGEROUSNESS
The regulation has established different lasers dangerousness classes on the basis of their ability
to produce damages to people from laser in class I (essentially safe in every condition) to the laser
of class IV dangerous in different conditions.
The laser of class III show the label “ATTENTION” and that would not damage the eye for a
momentary vision (thanks to the palpebral reection of self-defence from a visible intense
radiation), but that can present a great danger if observed through microscopes or magnifying
glasses. Other lasers belonging to the same class but with label “DANGER” are in position to
exceed the allowed maximum exposition level, yet over 0.25 seconds of time.
The lasers that belong to the class IV can produce risks, not only for the direct or reflected
radiation, but also for the diffused radiation. These lasers source can present remarkable risk also
for the skin and fire risk for inflammable materials. For these reasons the user must prepare all
radiation excess measures to assure that it is ready at the end of its useful process. Besides the
operator must be informed of the risks deriving from the laser radiation exposure and he must be
provided with the proper D.P.I. (individual protection devices) consisting in certified protection
glasses for the laser radiation.

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2.3 RADIATION VISION CONDITIONS
The laser to the resonator exit is to be considered as a monochromatic light source highly
corresponded and intense. For these characteristics it can be seen as a “Punctiform source” of
great brightness. This allows that its “image” is after focused on the Retina in one very small spot
with power density dangerousness high! If instead the beam becomes divergent and spreads on a
not reflecting screen, then there will be a “large vision” of the image, with power density definitely
less dangerous. Then different types of radiation vision can be distinguished in relation to the
access way of the same radiation and consequently to the different dangerousness degree.
Laser beam direct vision
This type of vision is the most dangerous and can show to the laser-opening exit, after that the
optics have been removed. To avoid in every way! None protection glass can represent a valid
defence means from the beam direct vision.
Beam direct vision after speculate reflection
It can happen directing the beam on a reflecting surface.
The beam vision reflexed specularly from a plain surface is extremely dangerous equal to the
direct vision.
Beam direct vision at the optical Fiber exit
It happens if the Optical Fiber is connected to the resonator. The beam vision results dangerous up
to a remarkable distance. Filters and Glasses cannot guarantee the safety.
Beam direct vision after focusing optics
It happens if isn’t “killed” the Laser beam on an opportune absorber at the end of its useful route.
The beam vision results dangerous up to a considerable distance. Filters and protection glasses
can guarantee the safety for short expositions, on condition that are well dimensioned and certified
type.
Laser beam spread vision, after focusing optics
It is the more frequent vision condition for a device in operative way. The beam vision doesn’t
result dangerous if not on short distance, but opportune Filters and Glasses can guarantee the
safety, also for long expositions.
The Nominal Distance of D.N.R.O. Optical Risk for the laser MEGAHIT results inferior to
15m, for the direct or specularly spread radiation, and inferior to 0.5m for the spread one!
Only a suitable glass with Optical Density (D.O.) major of 4 can protect just now the sight
from the accidental vision of the harmful laser radiation!
NOTE
Use always ocular protectors of certified conformance.
Remember that none glass can protect for a long time from the direct radiation!

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2.4 RISKS FOR THE EYES AND THE SKIN
The cornea and the retina, if submitted to an intense laser radiation, also of short duration, or to a
less intense radiation but of long duration, can burn and can be damaged in irreparable way
forever. This consequence is completely realistic in case of direct vision of Class IV laser beam.
Also the skin can burn, if submitted to the focused direct radiation. Besides it is necessary to bear
that with the main radiation also a collateral radiation can coexist in the ultraviolet: a long exposure
can provoke skin carcinomas.
2.5 SAFETY GENERAL PRESCRIPTIONS
To not reduce the device safety degree occurs that the User has a conformance behaviour and is
in the possible better safety conditions. It born so the necessity to develop an Operative Standard
Procedure (P.S.O.) about the operations to perform for the starting and the out of service of the
machine. This procedure, exposed near the installation, would be a reference for the Operator and
will be written in his language.
The personnel training will be essential and it will be able to:
•familiarize with the system functioning procedures
•biological effect knowledge of the radiation on Eyes and Skin
•needs understanding of Individual Protection Devices (D.P.I.)
2.6 COLLATERALI RISKS
NOTE
If the source use destination is changed, for example for the materials process
applications, collateral risks can happen represented from the fumes and vapors
production that can be irritating or toxic, if not removed and adequately filtered
before to put back them again in the environment.
NOTE
It is recommended to not change the use destination without before have
contacted the Manufacturer
A further risk can be represented from the fire deriving from the process of materials different from
those for which the machine is foreseen.
NOTE
When inammable materials are processed, being fire danger, it is indispensable
to keep to the indications provided from the manufacturer during the machine
starting.

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NOTE
Don’t submit to the laser radiation materials different from those for which the
machine has been manufactured
The haviest collateral risk, being able to result fatal, associated to a laser device is surely
represented from the electricity.
This fact can happen when the warnings and the procedures imposed from the machine
manufacturer aren’t respected. Not authorized and unqualified personnel must not ever face any
type of intervention on the electric part. The safety devices must not ever be removed and the
efficiency must be checked periodically.
NOTE
Don’t work on the electric part if not experts. Don’t remove the protection devices.
NOTE
When inammable materials are processed, being fire danger, it is indispensable
to keep to the indications provided from the manufacturer during the machine
starting.
If for example, in the use destination of the Laser source, during the working process the material
has changes and produces fumes or irritant and/or toxic vapors, can result necessary to remove
the working fumes and filter them before to put back again in the environment.
A further risk can be represented from the fire deriving from the process of materials different from
those for which the machine is foreseen.
NOTA
Don’t submit to the laser radiation materials different from those for which the
machine has been manufactured
NOTA
When inammable materials are processed, as for example the plastic, being fire
danger, it is indispensable to keep to the indications provided from the manufacturer
during the machine starting

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CHAPTER 3 SEALS
In some points the welding system presents some seals. The seals must not be, for none reason,
broken or removed. The sealed parts in fact can be opened only and exclusively by Elettrolaser
S.r.l.
NOTE
The seals breaking or removal on behalf of the customer put from the manufacturer
on the laser system allows the guarantee immediate decay on all welding system.
ATTENTION
The manufacturer declines every responsibility about the not conformance machine
use of his production.
It is forbidden the starting of the equipment before that the machine is declared in
conformance with the actual directives
NOTE
The access to the internal parts of the electric equipment is allowed only to the
authorized personnel, qualified and trained about the electric risks!
Elettrolaser S.r.l. declines every responsibility about the interventions on active parts
on behalf of not trained personnel!
NOTE
The access to the internal parts of the laser resonator is allowed only to the
authorized personnel, qualified and trained about the optical risks!
Elettrolaser S.r.l. declines every responsibility about the interventions on behalf of not
trained personnel!

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3.1 SAFETY LABELS
The labels and the plates are applied on the equipment in conformance with the European safety
rules. They must not be removed or damaged. For possible changes you can contact Elettrolaser
S.r.l.
Laser warning labels:
Label Shape and type Sizes (mm)
Laser N. 1
Laser warning
Side 22
Side 50
Laser N. 2
Laser class information
104 x 52
52 x 26
Laser N. 3
Radiation information
104 x 52
52 x 26
Laser N. 4
Laser exposure information
56 x 40

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Laser N.5
Laser technical data
104 x 25
Laser N.6
Laser opening information
104 x 26
Electric warning labels
Label Shape and type Sizes ( mm)
Elettric N.1
Electricity warning
Side 22
Side 50
Product identification label
This label shows the data about the manufacturer (Ref A), the electric specifications (Ref B), the
generator power (Ref C) and the risk class of the laser machine (Ref D).
A
B
CD

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3.2 LABELS POSITIONING
The Laser warning labels are placed frontally, inside and outside the machine in the following way:
Picture 2: Frontal laser warning labels
Picture 3 : Internal laser warning labels
The Laser warning labels are placed behindly outside the machine in the following way:
LASER N.1
LASER N.5
LASER N.2
LASER N.6