ROMANOFF ELETTROLASER Mega 6.0 User And Maintenance Manual
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ROMANOFF ELETTROLASER Mega 6.0 User And Maintenance Manual

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SINCE 1949
1/19/24 Romanoff.com • Sales@romanoff.com • 631-842-2400

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Summary of Contents for ROMANOFF ELETTROLASER Mega 6.0

  • Page 1 SINCE 1949 1/19/24 Romanoff.com • Sales@romanoff.com • 631-842-2400...
  • Page 2 SINCE 1949 1/19/24 Romanoff.com • Sales@romanoff.com • 631-842-2400...

  • Page 3: General Index

    ElettroLaser MEGA 6.0 & MEGA 6.0 3D User Manual General index Title Page General index ..................... 3 Warranty and liability ..................4 Use of the manual ....................6 General instructions.................... 9 Characteristics and technical data ..............27 Transport and installation ................. 36 Operation ......................

  • Page 4: Warranty And Liability

    ElettroLaser MEGA 6.0 & MEGA 6.0 3D User Manual Warranty and liability Warranty This Warranty covers the product it accompanies at the �me of purchase. This Warranty guarantees the product against any material or manufacturing faults for a period of THREE YEARS from the original date of purchase.

  • Page 5: Reserved Legal Rights

    ElettroLaser MEGA 6.0 & MEGA 6.0 3D User Manual excludes or restricts its warran�es to the maximum limit allowed by applicable laws. ELETTROLASER S.R.L. Any warranty that cannot be fully excluded will be restricted (according to terms allowed by applicable laws) to the dura�on of the present Warranty.

  • Page 6: Use Of The Manual

    ElettroLaser MEGA 6.0 & MEGA 6.0 3D User Manual Use of the manual The manual This manual was prepared by the Manufacturer and is an integral part of the supply of the machinery. The informa�on featured in the MEGA 6.0 - MEGA 6.0 3D, manual addresses the staff in charge of opera�ng and maintaining the machine.

  • Page 7: Structure Of The Manual

    ElettroLaser MEGA 6.0 & MEGA 6.0 3D User Manual Structure of the manual 3.2.1 Division of the manual This manual is divided into chapters. Each chapter may in turn be divided into paragraphs. The lower external margin of each page indicates the page number and the total number of pages in the manual.

  • Page 8: Conserva�On Of The Manual

    ElettroLaser MEGA 6.0 & MEGA 6.0 3D User Manual Conserva�on of the manual 3.4.1 How to conserve the manual This manual, the original copy of the declara�on of conformity and all the technical annexes must be stored with care for the en�re lifespan of the machine, including the disassembly phase.

  • Page 9: General Instruc�Ons

    ElettroLaser MEGA 6.0 & MEGA 6.0 3D User Manual General instructions Working in safe condi�ons Safety instruc�ons included in the user and maintenance manual refer to opera�ons which can be performed on the machine. Safety symbols are included in the text to highlight items which require par�cular a�en�on. It is essen�al that these safety instruc�ons be observed at all �mes.

  • Page 10: Symbols Used

    ElettroLaser MEGA 6.0 & MEGA 6.0 3D User Manual Symbols used The following symbols are used in this manual. These symbols have been included to help understand performed / described ac�vi�es; they are generally featured in paragraphs 7.4 and 7.5 and in chapters 8 and 9.

  • Page 11: Hazard Signs

    ElettroLaser MEGA 6.0 & MEGA 6.0 3D User Manual 4.3.1 Hazard signs Generic hazard This sign is used to highlight hazardous situations which may cause damage to persons, animals and things. Failure to observe instruc�ons associated with this sign can cause danger.

  • Page 12: Prohibi�On Signs

    ElettroLaser MEGA 6.0 & MEGA 6.0 3D User Manual 4.3.2 Prohibition signs Generic prohibi�on This sign is used to highlight that certain maneuvers, opera�ons or forms of behavior are not permitted. Failure to observe instruc�ons associated with this sign can cause damage to things, animals, persons.

  • Page 13: Obliga�On Signs

    ElettroLaser MEGA 6.0 & MEGA 6.0 3D User Manual 4.3.3 Obliga�on signs Generic obliga�on This sign is used to highlight that the operator must observe the specific instructions. Failure to observe instruc�ons associated with this sign can cause damage to things, animals, persons.

  • Page 14: General Informa�On On Classifica�On Of Lasers

    ElettroLaser MEGA 6.0 & MEGA 6.0 3D User Manual General informa�on on classifica�on of lasers Classifica�on of lasers follows this standard: CEI EN 60825-1: 2014 Safety of laser products Part 1: Classifica�on of devices and requirements. • 4.4.1 Hazard poten�al of laser classes The concept of laser is insufficient to describe the hazard presented by a device emi�ing coherent electromagne�c...

  • Page 15: Effects Of Laser Radia�On On Biological �Ssues

    ElettroLaser MEGA 6.0 & MEGA 6.0 3D User Manual Effects of laser radia�on on biological �ssues General informa�on 4.5.1 The mechanism by which laser radia�on causes damage is similar for all biological systems and can lead to heat interac�ons, transitory thermoacous�c events, photochemical processes and non-linear effects.

  • Page 16: Hazards To The Eyes

    ElettroLaser MEGA 6.0 & MEGA 6.0 3D User Manual 4.5.2 Hazards to the eyes 4.5.2.1 Physiology of the eye Eyebrows Light Cornea (transparent front part Eyelashe Blood vessels of eye) Eyelid Aqueous humour Sclera (white part Lens Receptor cells of eye)

  • Page 17: Pathological Effects Of Laser Radia�On

    ElettroLaser MEGA 6.0 & MEGA 6.0 3D User Manual 4.5.3 Pathological effects of laser radia�on 4.5.3.1 Hazards to the eyes Fig. 4-3 features a brief descrip�on of the anatomy of the eye. The eye is par�cularly well-suited to receiving and transmit�ng op�cal radia�on.

  • Page 18: Classifica�On And Specific Hazards Of Radia�On Emi�Ed By Mega 6.0 - Mega 6.0 3D

    ElettroLaser MEGA 6.0 & MEGA 6.0 3D User Manual Studies concerning biological thresholds indicate that, with wavelengths between 1500 nm and 2600 nm, the risk of skin lesions follows a similar pa�ern to that of the eye. The EMP increases within this spectral region for exposures with a dura�on of up to 10s.
  • Page 19 ElettroLaser MEGA 6.0 & MEGA 6.0 3D User Manual WARNING!: Class 4 lasers are laser products in rela�on to which direct viewing of the beam and skin exposure are hazardous and in which the viewing of diffuse reflections can also be dangerous. These lasers o�en also represent a fire hazard.

  • Page 20: Graphic Signs And Wri�En Warnings

    ElettroLaser MEGA 6.0 & MEGA 6.0 3D User Manual Graphic signs and written warnings Please find below the graphic signs and wri�en warnings located on the machine. These signs were inserted to make the operator aware of hazards or residual poten�al sources of danger. An explanatory comment can be found next to each exclusively graphic sign.

  • Page 21: Obliga�On Graphic Signs And Wri�En Warnings

    ElettroLaser MEGA 6.0 & MEGA 6.0 3D User Manual This sign highlights the hazard (residual risk) associated with laser radia�on reflected through the blind. Warning label Fig. 4-8 – 4.7.2 Obliga�on graphic signs and wri�en warnings This sign highlights that the operator has an obliga�on to read and understand the manual before using the machine.

  • Page 22: Posi�On Of Graphic Signs And Written Warnings

    ElettroLaser MEGA 6.0 & MEGA 6.0 3D User Manual 4.7.4 Position of graphic signs and wri�en warnings Fig. 4-11 -– Le� side view Fig. 4-12 - Posi�on of CE plate, graphic signs – rear side view Fig. 4-13 - Posi�on of graphic signs and written warnings –...

  • Page 23: Physical And Intellectual Requirements Of Personnel

    ElettroLaser MEGA 6.0 & MEGA 6.0 3D User Manual Physical and intellectual requirements of personnel The personnel must be capable – also on a physical level – of performing necessary opera�ons and of familiarizing with instruc�ons and safety laws. This staff will have been trained (according to performed/assigned tasks) to be able to safely use the machine and/or to perform maintenance opera�ons on the machinery in safe condi�ons.

  • Page 24: Staff In Charge Of Extraordinary Maintenance (Support Service)

    ElettroLaser MEGA 6.0 & MEGA 6.0 3D User Manual 4.10 Staff in charge of extraordinary maintenance (support service) In terms of maintenance staff, standard EN 15628 (Maintenance – Qualifica�on of maintenance personnel) iden�fies the following three professional figures and defines their correspondent necessary skills: Maintenance manager (indica�vely referable to EQF levels 6 and 7...

  • Page 25: Laser Safety Officer

    ElettroLaser MEGA 6.0 & MEGA 6.0 3D User Manual 4.11 Laser safety officer In many countries, in case of class 3B or 4 laser products, the employer must appoint a Laser safety officer. Consult local laws in this regard. 4.12 Staff in charge of operating the machine The machine must be run by a professional operator, as described under paragraph 5.4, which also describes his/her...
  • Page 26 ElettroLaser MEGA 6.0 & MEGA 6.0 3D User Manual • Failure to observe instruc�ons concerning the installa�on, use, func�oning, maintenance, repairs of the machine or performance of any of the above by unqualified staff; Use of incorrect or incompatible materials or of auxiliary equipment;...

  • Page 27: Characteris�Cs And Technical Data

    ElettroLaser MEGA 6.0 & MEGA 6.0 3D User Manual Characteristics and technical data Descrip�on of the machine MEGA 6.0 - MEGA 6.0 3D (Fig. 5-15 and Fig. 5-16) is a welding machine for artefacts made of metallic materials that uses electromagne�c laser radia�on as an energy source for hea�ng metals to mel�ng temperature.

  • Page 28: Applicable Technical Regula�Ons And Laws

    ElettroLaser MEGA 6.0 & MEGA 6.0 3D User Manual Applicable technical regula�ons and laws The machine was designed in observance of the following Community rules on the safety of the machinery and laser system products: EN ISO 12100:2010 Safety of machinery - General principles for design - Risk assessment and risk reduc�on;...

  • Page 29: Residual Risks

    ElettroLaser MEGA 6.0 & MEGA 6.0 3D User Manual Residual risks The machine requires the prepara�on of work sta�ons as indicated in the following Tab. 5-4: Work sta�on N° of operators Opera�ons In front of the machine 1 operator Welding Tab.
  • Page 30 ElettroLaser MEGA 6.0 & MEGA 6.0 3D User Manual Risks P.P.E. * Residual risks deriving from the presence of persons unrelated to opera�ons near the machine. Risk of impact, tripping and falling: if the area where the system is installed is not sufficiently illuminated.

  • Page 31: Technical Data Of The Machine

    ElettroLaser MEGA 6.0 & MEGA 6.0 3D User Manual Technical data of the machine 5.5.1 Technical data Parameter Description MEGA 6.0 MEGA 6.0 3D Dimensions Minimum length of installa�on area 2600 mm Minimum width of installa�on area 2900 mm Minimum height of installa�on area...

  • Page 32: Noise Levels

    ElettroLaser MEGA 6.0 & MEGA 6.0 3D User Manual Parameter Description MEGA 6.0 MEGA 6.0 3D Shot dura�on 25 ms �� Divergence of the laser beam 7,153° (in the output window located on the op�cal channel) Maximum emitted power or energy...

  • Page 33: Vibra�Ons

    ElettroLaser MEGA 6.0 & MEGA 6.0 3D User Manual WARNING!: The acous�c impact produced by the machine in the surrounding environment can be considered of little relevance in test conditions. In any case, it is important to keep in mind that the level of exposure of the operator in charge of running the machine will have to be assessed in the actual opera�ng conditions of the machine, in conformity with current legislation (of...

  • Page 34: Product Characteris�Cs

    ElettroLaser MEGA 6.0 & MEGA 6.0 3D User Manual Product characteris�cs 5.6.1 Technical characteris�cs of workable products The products to be processed (an example is shown in Fig. 5-17) consist of products for the goldsmith/jewelry sector, such as, for example: jewels and glasses, watches and bracelets.

  • Page 35: Weld Materials

    ElettroLaser MEGA 6.0 & MEGA 6.0 3D User Manual WARNING!: Make sure that the metals to be processed feature no impuri�es which may cause the forma�on of smoke or gas during the melting stages. 5.6.2 Weld materials If required by the type of welding in ques�on, the operator can use weld materials such as silver, monel, steel, cobalt- chromium alloy and �tanium.

  • Page 36: Transport And Installa�On

    ElettroLaser MEGA 6.0 & MEGA 6.0 3D User Manual Transport and installation Transport The machine and all the provided parts are usually supplied fully packaged in a cardboard box. During transporta�on, the box is fastened to a transport pallet; in the case of transporta�on via airplane, the box is in turn packaged within a wooden crate.

  • Page 37: Manual Handling Of Loads

    ElettroLaser MEGA 6.0 & MEGA 6.0 3D User Manual Manual handling of loads Manual handling of loads (MHL) must be carried out in safe condi�ons to avoid overloading the dorsal-lumbar tract of the spine. Please find below a series of safety instructions concerning manual handling of loads.
  • Page 38 ElettroLaser MEGA 6.0 & MEGA 6.0 3D User Manual Fig. 6-19 – Li�ing technique Avoid torsions of the bust ( • Fig. 6-20 Fig. 6-20 – Handling technique Keep the load as close as possible to your body; • Distribute the load on both sides;...
  • Page 39 ElettroLaser MEGA 6.0 & MEGA 6.0 3D User Manual Fig. 6-21 - Handling technique 1/19/24 Romanoff.com • Sales@romanoff.com • 631-842-2400 Page 37 of 122...

  • Page 40: Installa�On

    ElettroLaser MEGA 6.0 & MEGA 6.0 3D User Manual Installa�on WARNING!: Before proceeding with installation of the machine, carefully read the instruc�ons below. Failure to observe the following warnings can cause injuries, death or damage to equipment. declines any liabili�es for damage to persons or things due to installa�on in an environment ELETTROLASER S.R.L.
  • Page 41 ElettroLaser MEGA 6.0 & MEGA 6.0 3D User Manual The client is responsible for preparing the power supply network (electricity). This network must be designed and sized to guarantee correct func�oning of the machine and compliance with safety laws. The work environment must feature an independent lighting system and an adequate aspira�on system for fumes deriving from machine operations;...

  • Page 42: Assembly

    ElettroLaser MEGA 6.0 & MEGA 6.0 3D User Manual Assembly The machine is supplied fully assembled. To install the machine, proceed as follows: Place MEGA 6.0 - MEGA 6.0 3D on the work surface (please also refer to paragraph 6.5), so that: •...
  • Page 43 ElettroLaser MEGA 6.0 & MEGA 6.0 3D User Manual • Connect the control pedal of the machine: ▪ Connect the male connector of the trigger control pedal to the female DB-9 female serial port (Fig. 6-25), located on the rear of the machine;...

  • Page 44: Ligh�Ng

    ElettroLaser MEGA 6.0 & MEGA 6.0 3D User Manual Ligh�ng WARNING!: The installation site must feature sufficient ligh�ng for the performance of use and maintenance opera�ons. The op�mal ligh�ng level obviously varies according to the type of opera�ons to be performed; please refer to the EN 12464-1 standard (paragraph 5.3) for detailed informa�on concerning the type of ac�vity and the work environment.

  • Page 45: Protec�On From Electric Shocks

    ElettroLaser MEGA 6.0 & MEGA 6.0 3D User Manual 6.8.3 Protec�on from electric shocks 6.8.3.1 Direct contact Direct contact is when “persons or animals come in contact with live parts”, i.e. with dangerous voltage levels (EN 60204- All electrical devices are inserted within specific casings for electrical material, which require a tool to be opened.

  • Page 46: Shield Gas/Compressed Air Connec�On

    ElettroLaser MEGA 6.0 & MEGA 6.0 3D User Manual Shield gas/compressed air connec�on OBLIGATION!: This opera�on can only be performed by the dealer / authorized installa�on technician! MEGA 6.0 - MEGA 6.0 3D can be connected to a compressed air supply, to provide ven�la�on in the welding chamber and allow for use of an air blower to clean the product.
  • Page 47 ElettroLaser MEGA 6.0 & MEGA 6.0 3D User Manual WARNING!: All operations to connect the shield gas and compressed air supplies must be performed in the absence of • pressure in the pressurized air circuit; The input shield gas and compressed air must have a maximum pressure of 1,5 bar and a con�nuous flow rate •...

  • Page 48: Further Connec�Ons

    ElettroLaser MEGA 6.0 & MEGA 6.0 3D User Manual 6.10 Further connec�ons The machine features further connec�on points, such as: A female RJ45 port for connec�on to an Ethernet network; • An HDMI port (op�onal) for connec�on to an external monitor;...

  • Page 49: Management Of Machine Keys

    ElettroLaser MEGA 6.0 & MEGA 6.0 3D User Manual 6.11 Management of machine keys The keys of the machine (interlock bypass connector and ac�va�on key) are delivered separately. These keys must be managed by the Laser Safety Technician (LST). Before ac�va�ng the machine, the interlock contact must be connected to the safety system set up in the site where the machine is installed.

  • Page 50: Opera�On

    ElettroLaser MEGA 6.0 & MEGA 6.0 3D User Manual Operation Machine opera�on MEGA 6.0 - MEGA 6.0 3D (Fig. 7-32 and Fig. 7-33) is a welding machine for artefacts made of metallic materials that uses electromagne�c laser radia�on as an energy source for hea�ng metals to mel�ng temperature.

  • Page 51: Opera�Ng Principle

    ElettroLaser MEGA 6.0 & MEGA 6.0 3D User Manual 7.1.1 Opera�ng principle The physical principle behind the genera�on of laser electromagne�c radia�on is s�mulated light emission. LASER is indeed the acronym of Light Amplifica�on by S�mulated Emission of Radia�on. This means that lasers are light amplified by a photonic chain emission, origina�ng from a first photon (light par�cle) that –...

  • Page 52: Specific Glossary

    ElettroLaser MEGA 6.0 & MEGA 6.0 3D User Manual 7.1.2 Specific glossary The following features defini�ons of specific laser applica�on terminology, for the purpose of making the Tab. 7-11 contents of this manual more comprehensible. Term Defini�on Aperture, diaphragm Aperture means any opening in the laser device protec�ve casing through which the laser radia�on is emitted, thus...
  • Page 53 ElettroLaser MEGA 6.0 & MEGA 6.0 3D User Manual Term Defini�on Transmission factor Ra�o between the transmitted radiant flow and the incident flow in specifically set up condi�ons. Visible radia�on (light) Every op�cal radia�on capable of directly causing a visual percep�on (IEV 845-01-03).

  • Page 54: Machine Body

    ElettroLaser MEGA 6.0 & MEGA 6.0 3D User Manual 7.1.3 Machine body The body of the machine (Fig. 7-35) consists of an injec�on molded technopolymer casing. The casing is closed with screws. It contains the laser source (lamp and resonator), all power and control devices for the laser source, the coolant system, the laser channeling and focus unit and the resonator shu�er (a shu�er controlled by...
  • Page 55 ElettroLaser MEGA 6.0 & MEGA 6.0 3D User Manual All power connec�ons, as well as the power switch and cooling fans for the electronic devices, are located on the rear of the machine (Fig. 7-36). Cooling fans Fig. 7-36 – Rear side view of the machine 1/19/24 Romanoff.com •...

  • Page 56: Stereomicroscope Vision System

    ElettroLaser MEGA 6.0 & MEGA 6.0 3D User Manual 7.1.4 Stereomicroscope vision system According the machine model, the work area can be visualized via binocular (or binocular stereoscopic microscope) or 3D vision (or three-dimensional stereoscopic vision system). In both cases, the vision system consists of an op�cal magnifica�on system that allows the operator to focus on the laser target during welding opera�ons.
  • Page 57 ElettroLaser MEGA 6.0 & MEGA 6.0 3D User Manual A filter (an op�cal glass that becomes frosted at a laser wavelength of 1064 nm) is installed within the vision system (in the op�cal tube). This light grey and perfectly transparent filter becomes frosted at a laser wavelength of 1064 nm and therefore blocks entry in the oculars of the laser radia�on generated by the source.

  • Page 58: Welding Chamber

    ElettroLaser MEGA 6.0 & MEGA 6.0 3D User Manual 7.1.5 Welding chamber The welding chamber is incorporated within the welding machine casing. The access compartment of the welding chamber (Fig. 7-35), is closed by a sector curtain with the func�on of containing the laser radia�on, as this may be diffused or reflected during welding opera�ons (e.g.

  • Page 59: Control Device

    ElettroLaser MEGA 6.0 & MEGA 6.0 3D User Manual Control device The following figures (Fig. 7-43/Fig. 7-44, Fig. 7-45, Fig. 7-46, Fig. 7-47) illustrate the control and emergency devices installed on MEGA 6.0 - MEGA 6.0 3D and described in Tab. 7-12.
  • Page 60 ElettroLaser MEGA 6.0 & MEGA 6.0 3D User Manual CONTROL DEVICES Position Description Two-contact key switch (ac�va�on key) allowing the operator to select the following controls: LOCK (turn the key leftwards): machine off – procedure for turning the • Fig. 7-43 machine off.

  • Page 61: Operator Interface

    ElettroLaser MEGA 6.0 & MEGA 6.0 3D User Manual 7.2.1 Operator interface In addi�on to the devices men�oned above, the machine also features an operator interface (Fig. 7-48). The interface features a touch terminal (7” color touch screen display) which allows the operator to set the various opera�onal parameters.

  • Page 62: Safety Devices

    ElettroLaser MEGA 6.0 & MEGA 6.0 3D User Manual Safety devices The machine features a series of safety devices, illustrated in the following paragraphs. Emergency buttons 7.3.1 When pressed, the emergency bu�ons (Fig. 7-49) allow the operator to stop the machine in the event of emergencies.

  • Page 63: Interlock

    ElettroLaser MEGA 6.0 & MEGA 6.0 3D User Manual Interlock 7.3.2 The interlock (Fig. 7-50) is a safety device (that must be ac�vated before using the machine for the first �me); failure to ac�vate this device will block the laser and therefore stop MEGA 6.0 - MEGA 6.0 3D from opera�ng.

  • Page 64: Ac�Va�On Key

    ElettroLaser MEGA 6.0 & MEGA 6.0 3D User Manual Ac�va�on key 7.3.3 The ac�va�on key (Fig. 7-51) allows the operator to turn the machine on for use. The key can be removed in the LOCK posi�on, and must always be removed from the machine if le� una�ended, to avoid use by unauthorized staff.

  • Page 65: Microscope Shu�Er

    ElettroLaser MEGA 6.0 & MEGA 6.0 3D User Manual Microscope shutter 7.3.5 This device consists of a liquid crystal (LCD) filter that, when subjected to a specific tension, turns completely dark. It is located between the 45° mirror and the focus lens of the microscope.
  • Page 66 ElettroLaser MEGA 6.0 & MEGA 6.0 3D User Manual Fixed guard - case Fixed guard – smoke extraction ventilator protection grid Fixed guard – ven�la�on grid Flexible shield – segmented leather blind Fig. 7-52 – Guards Fixed guard – cooling ven�lator protection...

  • Page 67: Preliminary Opera�Ons

    ElettroLaser MEGA 6.0 & MEGA 6.0 3D User Manual Preliminary opera�ons 7.4.1 Inser�on of the cooling liquid The cooling liquid (dis�lled and deionized water) is required to cool the laser source. The machine is supplied with a container featuring the correct quan�ty of cooling liquid.
  • Page 68 ElettroLaser MEGA 6.0 & MEGA 6.0 3D User Manual ▪ Move the joys�ck rightwards and hold it in this posi�on un�l the cooling system pump starts automa�cally. Wait approximately 10 minutes; If the operator panel displays the warning message “ERROR 02 TEST FLUX H2O”, remove the ac�va�on key to ▪...

  • Page 69: Preliminary Regula�On Opera�Ons

    ElettroLaser MEGA 6.0 & MEGA 6.0 3D User Manual Preliminary regula�on opera�ons WARNING!: Failure to perform preliminary regulation opera�ons can cause damage to the machine and/or installed equipment. WARNING!: All preliminary regula�on opera�ons must be performed with the machine switched off.

  • Page 70: Safety Instruc�Ons

    ElettroLaser MEGA 6.0 & MEGA 6.0 3D User Manual Operation instructions Safety instruc�ons WARNING!: Failure to observe the following safety instructions may result in injuries, death or damage to the machine. This machine must be operated exclusively by “qualified staff”, based on the correspondent indica�ons included in this manual.

  • Page 71: Non Permissible Opera�Ons

    ElettroLaser MEGA 6.0 & MEGA 6.0 3D User Manual 8.1.4 Non permissible opera�ons The following uses of the welding machine are explicitly prohibited: The MEGA 6.0 - MEGA 6.0 3D welding machine is designed for professional use. • Use of the welding machine when it presents signs of tampering or damage (in particular cracks in the casing and •...

  • Page 72: Non-Evident Hazards

    ElettroLaser MEGA 6.0 & MEGA 6.0 3D User Manual 8.1.6 Non-evident hazards WARNING!: Both the qualified operator and the technical personnel of in charge of opera�ng on the machine must be aware of additional less evident hazards that are ELETTROLASER S.R.L.

  • Page 73: Start-Up

    ElettroLaser MEGA 6.0 & MEGA 6.0 3D User Manual Start-up 8.4.1 Operation A�er switching MEGA 6.0 - MEGA 6.0 3D on (tensioning), you need to enable its opera�on (inser�on). To enable MEGA 6.0 - MEGA 6.0 3D to operate, please follow the sequence of opera�ons described in the following Tab.
  • Page 74 ElettroLaser MEGA 6.0 & MEGA 6.0 3D User Manual Symbol Ac�on Feedback / notes Press the control pedal to weld. For pulse characteris�cs (based on the product to be welded), please refer to Tab. If the repe��on rate is deactivated (the display will show 8-16.
  • Page 75 ElettroLaser MEGA 6.0 & MEGA 6.0 3D User Manual Welding se�ings 8.4.1.1 MEGA 6.0 - MEGA 6.0 3D can store up to 100 (one hundred) different work programs. In any case, we recommend the following welding set�ngs (Tab. 8-16), based on the materials requiring welding.

  • Page 76: Operator Panel

    ElettroLaser MEGA 6.0 & MEGA 6.0 3D User Manual Operator panel This paragraph describes all the set�ngs that can be edited by using the operator interface (operator panel). The operator panel terminal is a “touch screen” (or tac�le terminal), allowing the operator to send commands and/or edit machine set�ngs by simply using his/her finger to press the control areas on the terminal corresponding to the...

  • Page 77: Menu Bar

    ElettroLaser MEGA 6.0 & MEGA 6.0 3D User Manual Menu bar 8.5.1 The upper part of the operator panel pages (with a few excep�ons) features a menu bar which allows the operator to promptly access the main pages. Fig. 8-59 – Menu bar When pressed, this control area allows the operator to access the “Home”...

  • Page 78: Home" Page

    ElettroLaser MEGA 6.0 & MEGA 6.0 3D User Manual “Home” page 8.5.2 Fig. 8-60 – “Home” page When pressed, this control area allows the operator to access the “Language” set�ngs page. This page (Fig. 8-61) allows the operator to set the language of all texts on the pages and on the alphanumeric keyboard for data input.

  • Page 79: Laser" Opera�On Set�Ngs Page

    ElettroLaser MEGA 6.0 & MEGA 6.0 3D User Manual “Laser” operation settings page 8.5.3 “Laser” opera�on set�ngs page Fig. 8-63 – This display area shows the power, in kilowa�s, of the welding shot set for the selected welding program; the stored ID number of the program is indicated under item 8.
  • Page 80 ElettroLaser MEGA 6.0 & MEGA 6.0 3D User Manual This display area shows the laser pulse waveform set for the selected welding program; the stored ID number of the program is indicated under item 8. Next to this area you will find the �� and� �� controls. When pressed, these controls allow the operator to select the wave form from the 5 available op�ons.

  • Page 81: Cam" Page

    ElettroLaser MEGA 6.0 & MEGA 6.0 3D User Manual “Cam” page 8.5.4 Cam” page Fig. 8-65 – “ This display area shows the power, in kilowa�s, of the currently set welding shot. When pressed, it will become selected to allow the operator to change the value by using the controls described under item 8.
  • Page 82 ElettroLaser MEGA 6.0 & MEGA 6.0 3D User Manual 8.5.4.1 “Crosshairs” page Fig. 8-66 – “Crosshairs” page When pressed, this control area allows the operator to shift the crosshairs upwards in the display area described under item 7. When pressed, this control area allows the operator to shift the crosshairs downwards in the display area described under item 7.

  • Page 83: Video" Page

    ElettroLaser MEGA 6.0 & MEGA 6.0 3D User Manual 8.5.5 “Video” page This page allows the operator to watch tutorial videos on how to use the machine or how to perform a series of maintenance opera�ons, pre-uploaded to the internal storage of the machine).

  • Page 84: Se�Ngs Page

    ElettroLaser MEGA 6.0 & MEGA 6.0 3D User Manual 8.5.6 Se�ngs page Fig. 8-68 – Se�ings page View-only area displaying: The par�al number of shots generated by the machine; • • The total number of total shots generated by the machine;...
  • Page 85 ElettroLaser MEGA 6.0 & MEGA 6.0 3D User Manual 8.5.6.1 Parameters page Fig. 8-69 – Parameters page This display area shows the idle time, in minutes, a�er which – unless the pedal is pressed – the machine will automa�cally shift into stand-by mode (the resonator shutter will ac�vate and interrupt the laser path).
  • Page 86 ElettroLaser MEGA 6.0 & MEGA 6.0 3D User Manual 8.5.6.1.1 Data logger Fig. 8-70 – Pagina data logger Selec�on area of the day to be analysed. Selec�on areas of the month to analyze. Selec�on area of the year to be analysed.
  • Page 87 ElettroLaser MEGA 6.0 & MEGA 6.0 3D User Manual 8.5.6.1.2 Alarm History Fig. 8-71 – Pagina storico allarmi Alarm log display area. Command area which, if pressed, allows you to return to the "Se�ngs" page (paragraph 8.5.6). 1/19/24 Romanoff.com • Sales@romanoff.com • 631-842-2400...
  • Page 88 ElettroLaser MEGA 6.0 & MEGA 6.0 3D User Manual 8.5.6.2 Warning messages The following table (Tab. 8-17) lists the warnings flagged by the machine. For each warning, the table includes the warning text displayed on the operator panel, the possible cause for the warning and, when applicable, the opera�ons required to restore the machine to normal condi�ons.
  • Page 89 ElettroLaser MEGA 6.0 & MEGA 6.0 3D User Manual # Warning message Possible cause Troubleshoo�ng opera�ons Error 04 TEST VENT PFC The internal power electronics a) Wait a few minutes for the thermostat has detected a high error message to disappear and...
  • Page 90 ElettroLaser MEGA 6.0 & MEGA 6.0 3D User Manual 8.5.6.3 Memory set page The machine can store up to 100 memory indexes. Fig. 8-72 – Memory set page Numeric keyboard for inpu�ng the program (memory index) number. Pressing the control areas will update the value displayed under item 3.
  • Page 91 ElettroLaser MEGA 6.0 & MEGA 6.0 3D User Manual 8.5.6.4 Date/time se�ings page Fig. 8-73 – Date/�me se�ings page This display area shows the day. Next to this area you will find the controls that, when pressed, allow the operator to increase (+) or decrease (-) the set value by one unit.
  • Page 92 ElettroLaser MEGA 6.0 & MEGA 6.0 3D User Manual 8.5.6.5 Software management page So�ware management page Fig. 8-74 – View-only area displaying the interface messages indica�ng the opera�ons required to proceed with the update. When pressed, this control area allows the operator to start a teleassistance connec�on.
  • Page 93 ElettroLaser MEGA 6.0 & MEGA 6.0 3D User Manual 8.5.6.6 Network settings page The machine can be connected to an Ethernet and/or Wi Fi network. The RJ45 socket (Fig. 6-30) is located on the rear of the machine. Fig. 8-76 – Network settings page (Wi Fi) Fig.

  • Page 94: How To Stop The Machine

    ElettroLaser MEGA 6.0 & MEGA 6.0 3D User Manual How to stop the machine 8.6.1 Introduc�on Please find below details on opera�ons required to stop the machine. The opera�ons described below are the only ones permitted by the manufacturer. Standby 8.6.2...

  • Page 95: Troubleshoo�Ng

    ElettroLaser MEGA 6.0 & MEGA 6.0 3D User Manual Troubleshoo�ng The following table (Tab. 8-20) lists a series of poten�al issues which may take place (due to incorrect use / opera�ons with MEGA 6.0 - MEGA 6.0 3D and/or due to machinery faults) and cause: Inadequate processing quality (and consequently insufficient quality of the product);...
  • Page 96 ElettroLaser MEGA 6.0 & MEGA 6.0 3D User Manual OBLIGATION!: Should you need to replace a fuse, use exclusively original spare parts of the same type as the one that needs to be replaced. Please contact to solve any queries.

  • Page 97: Maintenance

    ElettroLaser MEGA 6.0 & MEGA 6.0 3D User Manual Maintenance Maintenance safety rules OBLIGATION!: All EXTRAORDINARY maintenance opera�ons must be performed exclusively by qualified ELETTROLASER staff (please refer to paragraph 4.10) or staff authorized by this company, with the necessary technical know- S.R.L.

  • Page 98: Welding Chamber Infrared Filter

    ElettroLaser MEGA 6.0 & MEGA 6.0 3D User Manual Replace any damaged labels or signs. WARNING!: The absence of safety signs can expose the worker to hazards, as he/she may not perceive the presence of any residual risks. 9.2.2 Welding chamber infrared filter The infrared filter of the welding chamber inspec�on window must always be checked visually (making sure of its...

  • Page 99: Replacement Of The Special Protec�On Glass

    ElettroLaser MEGA 6.0 & MEGA 6.0 3D User Manual 9.2.4 Replacement of the special protection glass Whenever the special protection glass is “dirty”, a decrease in the power output is noted; therefore, in the presence of a strong concentra�on of metal splashes on its surface it is necessary to replace the glass itself. Periodically check the protec�ve glass of the microscope objec�ve located in the final part of the op�cal channel;...

  • Page 100: How To Align The Re�Cle Pointer Of The Binocular (Mega 6.0 Model)

    ElettroLaser MEGA 6.0 & MEGA 6.0 3D User Manual 9.2.5 How to align the reticle pointer of the binocular (MEGA 6.0 model) The re�cle pointer may sometimes not be aligned with the actual shot point. This can occur when the welding machine is moved or lifted.
  • Page 101 ElettroLaser MEGA 6.0 & MEGA 6.0 3D User Manual Progressively act on screws 1 and 3, alterna�ng the ac�on on one and the other, as many �mes as necessary to ensure that both (the aiming re�cle focused on the object and the point of focus of the shot) coincide perfectly.

  • Page 102: How To Center The Crosshairs Pointer In The 3D Visor (Mega 6.0 3D Model)

    ElettroLaser MEGA 6.0 & MEGA 6.0 3D User Manual 9.2.6 How to center the crosshairs pointer in the 3D visor (MEGA 6.0 3D model) The crosshairs pointer for welding may some�mes become misaligned in rela�on to the actual firing point. This can occur when the welding machine is moved or lifted.

  • Page 103: How To Check And Replace The Cooling Liquid

    ElettroLaser MEGA 6.0 & MEGA 6.0 3D User Manual 9.2.7 How to check and replace the cooling liquid The cooling liquid in the tank must be checked (level) every year and refilled if necessary, only with dis�lled water, and replaced every 3 years, in order to avoid the forma�on of micro-algae in the closed cooling circuit, which could decrease or impede the efficacy of the heat exchange process.

  • Page 104: Cleaning The Machine

    ElettroLaser MEGA 6.0 & MEGA 6.0 3D User Manual Cleaning the machine WARNING!: Every cleaning opera�on must be performed with the machine switched off, a�er having disconnected all sources of electrical power supply from it. This is the only way to make sure that no accidental star�ng of the machine will occur while the staff in charge of cleaning it is working.

  • Page 105: Storage Condi�Ons Of The Machine

    ElettroLaser MEGA 6.0 & MEGA 6.0 3D User Manual Storage conditions of the machine 10.1 Temporary decommissioning If the machine needs to be put out of service for short periods of �me, simply unplug it from the electrical socket. 10.2 Decommissioning for long periods of �me...

  • Page 106: Disassembly Of The Machine

    ElettroLaser MEGA 6.0 & MEGA 6.0 3D User Manual Disassembly of the machine 11.1 Disassembly of the machine The machine must be disassembled by an operator authorized to perform these operations. In any case, you will need to remember to perform a series of mandatory operations before its demoli�on and a�er it has been put out of service.
  • Page 107 ElettroLaser MEGA 6.0 & MEGA 6.0 3D User Manual Actual disposal solu�ons, such as the sending of products to landfills, can be implemented only for materials which cannot be recycled. A thorough check of the entire produc�on chain of the waste producer will be required for waste products deriving from produc�on opera�ons of any sort.

  • Page 108: Support Service

    ElettroLaser MEGA 6.0 & MEGA 6.0 3D User Manual Support service To request an interven�on by our support service or to order spare parts, please cite the following data, which are also featured on the EC label on the machine: MODEL of the machine;...

  • Page 109: Table Of Contents

    ElettroLaser MEGA 6.0 & MEGA 6.0 3D User Manual Summary and index of figures 13.1 Summary General index ................................3 Warranty and liability ..............................4 Warranty ................................4 Condi�ons ................................ 4 Exclusions and restric�ons ..........................4 Reserved legal rights ............................5 Seals ................................. 5 Use of the manual ...............................6...
  • Page 110 ElettroLaser MEGA 6.0 & MEGA 6.0 3D User Manual 4.5.3 Pathological effects of laser radia�on ......................17 Classifica�on and specific hazards of radia�on emi�ed by MEGA 6.0 - MEGA 6.0 3D ........18 Graphic signs and wri�en warnings ........................ 20 4.7.1 Hazard graphic signs and written warnings ....................
  • Page 111 ElettroLaser MEGA 6.0 & MEGA 6.0 3D User Manual 6.8.3 Protec�on from electric shocks ........................45 Shield gas/compressed air connec�on ......................46 6.10 Further connec�ons ............................48 6.11 Management of machine keys ........................49 Opera�on ..................................50 Machine opera�on ............................50 7.1.1 Opera�ng principle ............................. 51 7.1.2...
  • Page 112 ElettroLaser MEGA 6.0 & MEGA 6.0 3D User Manual 8.5.1 Menu bar ..............................77 8.5.2 “Home” page ..............................78 8.5.3 “Laser” opera�on set�ngs page .........................79 8.5.4 “Cam” page ..............................81 8.5.5 “Video” page ...............................83 8.5.6 Se�ngs page ...............................84 How to stop the machine ..........................94 8.6.1...
  • Page 113 ElettroLaser MEGA 6.0 & MEGA 6.0 3D User Manual 1/19/24 Romanoff.com • Sales@romanoff.com • 631-842-2400 Page 111 of 122...

  • Page 114: Index Of Figures

    ElettroLaser MEGA 6.0 & MEGA 6.0 3D User Manual 13.2 Index of figures Fig. 3-1 - Manual ID data ..............................8 Fig. 4-2 – Examples of absorp�on of laser radia�on based on �me of exposure and dimensions of the beam ....15 Fig.
  • Page 115 ElettroLaser MEGA 6.0 & MEGA 6.0 3D User Manual Fig. 7-39 – 3D Vision ................................. 56 Fig. 7-40 – Example of operational set�ngs display through the vision system ............... 57 Fig. 7-41 – Welding chamber (without blind) ........................58 Fig. 7-42 – Op�cal channel – view from welding chamber ....................58 Fig.
  • Page 116 ElettroLaser MEGA 6.0 & MEGA 6.0 3D User Manual Fig. 9-76 – Binocular alignment ............................100 Fig. 9-77 – Prepara�on of the sleeve for the adjustment of the binocular (left side view) ..........100 Fig. 9-78 – Prepara�on of the sleeve for the adjustment of the binocular (right side view) .........100 Fig.
  • Page 117 ElettroLaser MEGA 6.0 & MEGA 6.0 3D User Manual Copy of EC Declaration of conformity 1/19/24 Romanoff.com • Sales@romanoff.com • 631-842-2400 Page 115 of 122...
  • Page 118 ElettroLaser MEGA 6.0 & MEGA 6.0 3D User Manual 1/19/24 Romanoff.com • Sales@romanoff.com • 631-842-2400 Page 116 of 122...
  • Page 119 ElettroLaser MEGA 6.0 & MEGA 6.0 3D User Manual Delivery record for the safety keys of the machine Record s�pulated upon delivering the “Laser welding machine” iden�fied by the following characteris�cs: Model: MEGA 6.0 - MEGA 6.0 3D Serial number: Year of manufacture: The individual in charge of use and maintenance of the machine, Mr./Mrs.
  • Page 120 ElettroLaser MEGA 6.0 & MEGA 6.0 3D User Manual 1/19/24 Romanoff.com • Sales@romanoff.com • 631-842-2400 Page 118 of 122...
  • Page 121 ElettroLaser MEGA 6.0 & MEGA 6.0 3D User Manual 1/19/24 Romanoff.com • Sales@romanoff.com • 631-842-2400 Page 119 of 122...
  • Page 122 ElettroLaser MEGA 6.0 & MEGA 6.0 3D User Manual 1/19/24 Romanoff.com • Sales@romanoff.com • 631-842-2400 Page 120 of 122...

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Elettrolaser mega 6.0 3dLz-6015Lz-90180

Table of Contents