ROTHENBERGER F60110-i5 Roxy 400L Roxy Kit Plus Instruction Manual

: September 19, 2024
: Rothenberger

Table of Contents

ROTHENBERGER F60110-i5 Roxy 400L Roxy Kit Plus
Product Usage Instructions
FAQ
Safety Notes
Technical Data
Functions
Transport and storage
Start-up
Malfunctions and maintenance
Accessories
Customer service
Documents / Resources

ROTHENBERGER F60110-i5 Roxy 400L Roxy Kit Plus

ROTHENBERGER-F60110-i5-Roxy-400L-Roxy-Kit-Plus-PRODUCT

Specifications

Model: ROXY 400L ROXY – KIT PLUS
Gas Pressure: 2.5 – 4 bar (depending on regulator or cartridge pressure)

Product Usage Instructions

Safety Instructions

Keep these instructions safe.

Technical Data

Oxygen Gas Pressure: 2.5 – 4 bar (depending on regulator or cartridge pressure)

Functional Description

Provide information on how the product functions.

Transportation and Storage

Instructions on how to assemble the product for transportation and storage.

Commissioning

Guide on how to start using the product.

Troubleshooting

List of common issues and solutions.

FAQ

Q: What should I do if the flame turns yellow?

A: If the flame turns yellow, it may indicate incomplete combustion. Check for proper gas flow and ventilation. Make sure the equipment is clean and adjust as needed.

Please read and retain these directions for use. Do not throw them away!
The warranty does not cover damage caused by incorrect use of the equipment! Subject to technical modifications!

Markings in this document:

Danger! This sign warns against the danger of personal injuries.
Caution! This sign warns against the danger of property damage and damage to the environment.
Call for action

Safety Notes

Intended use

Thank you for purchasing a Rothenberger brand product. The gas welding device you have acquired is a high-quality product.
Through the use of refillable 0.67L or 2L steel oxygen tanks, this universally applicable device allows a long welding time while being light and easy to handle.
An outstanding device for brazing.

General safety instructions

ATTENTION! All instructions must be read. Errors due to non-compliance with the instructions below can cause fire and/or severe injury.
It is mandatory to comply with the legal safety regulations and technical guidelines. Damages due to operator error void the warranty.
KEEP THESE INSTRUCTIONS AVAILABLE

Work area
- a) Keep your work area neat and clean. Messy or poorly lit work areas can lead to accidents.
- b) Do not work with the device in explosive environments containing flammable liquids, gases, or clouds of dust. Tools create sparks that can ignite dust, fumes, or gases. Make sure ventilation is adequate. If possible, do not work in closed spaces.
- c) Keep children and other people away from the tool during use. If you are distracted, you can lose control of the device.
- d) Do not misuse the hoses for carrying or hanging the device. Keep the hoses away from heat, oil, sharp edges, and moving parts of the device. Damaged or tangled hoses increase the risk of explosion.
- e) Keep the device free of oil and grease. In pure oxygen, oils and greases of any kind can explode on their own. Do not place the device near heat sources (heaters, ovens, open flames, etc.).
Personal safety
- a) Stay alert, pay attention to what you do, and work sensibly with any tool. Do not use the device if you are tired or under the influence of drugs, alcohol, or medication. A single moment of distraction when using the machine can lead to serious injury.
- b) Wear personal safety equipment and always wear safety glasses. Depending on the tool type and application, wearing personal safety equipment, such as slip-resistant safety shoes, flame-resistant clothing, and safety glasses decreases the risk of injury.
- c) Do not be overconfident. Make sure to stand securely and always keep your balance. This allows you to control the device better in unexpected situations.
- d) Wear proper clothing. Do not wear loose clothing or jewelry. Keep hair, clothing, and gloves away from moving parts. Loose clothing, jewelry, or long hair can get caught in moving parts.
Careful handling and use of tools
- a) Keep unused tools out of the reach of children. Do not allow anyone to use the device who is not familiar with it or who has not read its instructions. Tools are dangerous when used by inexperienced persons.
- b) Maintain the device with care. Check to see whether the device’s parts are operating properly and do not jam. See whether parts are broken or damaged enough to affect the device’s operation. Have the damaged parts repaired before using the device.
- Many accidents are caused by poorly maintained tools.
- c) Never leave the brazing tool unsupervised during use. There is an acute risk of fire.
- d) Make sure that the manometers are seated securely on the oxygen pressure regulators. Replace damaged manometers only with original Rothenberger replacement parts.
Service
- Have your device repaired only by qualified experts and only with original replacement parts. This ensures the continued safety of the device.

Special Safety Instructions

MAPP gas is highly flammable, colorless, heavier than air, and has a perceptible odor. Cartridges and oxygen tanks must not be handled by children.
Store the cartridges and oxygen tanks in a well-ventilated area.
Do not smoke when working near the tanks.
Keep the cartridges and oxygen tanks away from ignition sources.
Check the screw joints’ tightness using foaming substances (e.g., soapy water, leak detection spray).
Close the tank valves during malfunctions and after work.
Do not use the device in a horizontal position. When cartridges lie flat, liquid MAPP gas enters the gas cartridge valve and the burner nozzle, and that leads to malfunctions.

Technical Data

Flame temperature . ……………Up to 3100°C
Working temperature . ………….1250°C
The usable solder and flux depend on the working temperature.
Type of gas………………………..Propane, propane/butane (Multigas 300), butane, MAPP gas
Gas pressure ……………………..2.5-4 bar (depending on the regulator or the content pressure in the cartridge).
Oxygen-returnable containers: 2L = 200 bar
Oxygen-returnable containers: 1L = 110 bar
Consumption ………………….Minimum consumption with middle-sized nozzle work duration of approx 1,0 – 2,5 hours
Operation time ……………………Oxygen tank depending on flame thickness: 2 L.max. 19 h. ca. 48 min
- 1 L.max. 14 h. ca. 18 min
workspace ………………………..0.1-5.0 mm material thickness
Oxygen working pressure ……Pre-setting 0,7 – 3 bar

Functions

Overview

Carrying frame
Oxygen tank
Maxi gas cartridge
Brazing burner
Handle
Gas hose, red
Oxygen hose, blue
Fine regulator valve
Oxygen pressure regulator
Micro nozzle adaptor
High-performance welding nozzles
Burner wrench
Welding goggles
Safety lighter

Operational description

Welding with high-performance welding nozzles:

Basically, the welding flame should burn neutrally (the gas mixture is balanced), and its size should be adjusted to the material thickness, the weld shape, the welding position, and the heat conductivity of the material.
When welding steel at greater thicknesses, open both valves wide, and when welding thinner welding steel plates close the valves somewhat.
Preheat the material and welding rod. As soon as the metal begins to melt on both sides of the seam, introduce the welding rod. Make sure that the welding area heats evenly. Run the burner in half circles around the welding rod.

Brazing:

Clean the connecting surfaces, polish them, and round off the edges. Preheat the brazing area. Place the tip of the soldering rod onto the soldering area, melt a drop of solder, and spread it under constant flame movement.

Transport and storage

For transport, the oxygen tank valve and the Maxi gas cartridge must be closed.
After finishing the soldering work: With the gas cartridge valve and oxygen tank valve closed, cut off the gas and oxygen valve at the handle, and allow the remaining gas to escape. This discharges the hoses and the oxygen pressure regulator.
Remove the oxygen pressure regulator. Screw off the gas cartridge valve of the Maxi gas cartridge. The hoses can be connected to the oxygen pressure regulator and the gas cartridge valve.
Secure the device against tilting and slipping on the loading surface. Store and transport only with the containers upright.
Reusable containers must be filled only by authorized facilities.
Refilling in an unintended manner can cause severe accidents.

Set-up

Change the gas cartridges in a well-ventilated area, preferably outdoors.
Make sure that all valves are closed before work begins.
During set-up, turn the oxygen pressure regulator tight with the wrench.
Screw the MAXIGAS one-way container rightward into the gas fine regulator valve. Make sure that the tread begins and moves correctly. Screwing it in on a slant voids the warranty.
Before igniting, make sure that the connections between the containers and the regulator. valves have no gas leaks. (Use leak detection spray or soapy water).
A Open the oxygen tank valve.
B Depending on the nozzle and the material thickness, adjust the working pressure to a setting of up to 0,7 – 3 bar.
C Opening the oxygen pressure regulator valve.
D Now opens the gas regulator valve about a half turn.
E Opening the oxygen valve hand dial and add oxygen.
F Open the fuel gas valve dial and light the gas flame.
G Setting the gas flame. The flame must already be burning visibly from the nozzle tip.
H Adjust the heating flame by opening or choking the gas and oxygen feed.
I Use only goggles that comply with DIN4646 and 58210/1.
All connections must be tightened or loosened using the wrench included. After the gas valve has been opened, ignition must occur immediately, because otherwise escaping gases can detonate.

Using the micro burner:

Next unscrew the flame tube with the swivel nut.
Then screw the micro nozzle adaptor directly to the torch handle using the swivel nut.
Attach the desired micro burner, and screw the safety adaptor onto the micro nozzle adaptor to secure it from coming off.
Set the flame as needed. Beware of an extremely short fuel gas flame that already burns visibly at the nozzle tip.

Shut-down:

Shut the device down in the opposite sequence, but first always turn off the gas. Always close the tank valve when work is interrupted.

Start-up

Lighting the burner

First, open the gas regulator valve and light the gas; then open the oxygen valve and then adjust the flame. The flame must already be burning visibly from the nozzle tip.
Ignite the gas/oxygen mixture by using one of the appropriate gas lighters at the burner nozzle. (It can create black soot).

Setting the flame

With the hand dial marked orange on the handle, adjust the size and appearance of the flame. If the flame cannot be ignited or is cut off, the gas pressure is too high.
In that case, choke off the gas at the torch handle (the dial marked orange) by turning it rightward.
The oxygen valve (the dial marked blue) must be completely open at the torch handle.
If the flame looks yellow, there is too much gas. Carefully choke the gas valve (the dial marked orange) at the torch handle by turning it farther leftward.
Then set it to a neutral flame. This means that the strongly glowing blue-green core of the flame must be sharply delineated from the blue border of the flame (the secondary flame.

Extinguishing the flame

To extinguish the flame, first close the gas valve (the dial marked red) and then the oxygen valve (the dial marked blue) at the torch handle by turning rightward.
Close the gas cartridge valve and the oxygen tank valve by turning them rightward. Also, close these valves during extended breaks.

Replacing the gas cartridge

Close the gas cartridge valve by turning it rightward.
Pull the Maxi gas cartridge tank with its gas cartridge valve and the hose line upward and out of the mounting.
Unscrew the Maxi gas cartridge leftward from the gas cartridge valve.
Make sure that the gasket in the gas cartridge valve is present and intact.
Only original Rothenberger Maxi gas cartridges may be used. Install a full Maxi gas cartridge into the gas cartridge valve by turning it rightward.
Insert the full Maxi gas cartridge, with the gas cartridge valve and hose line installed, into the mounting.

Replacing the oxygen tank

Close the oxygen tank valve by turning it rightward.
Screw off the oxygen pressure regulator by turning it counterclockwise with the enclosed key.
Remove the oxygen tank from the mounting. Replace the empty oxygen tank with a full one.
Screw the oxygen pressure regulator clockwise onto the oxygen tank.
Make sure that the gasket in the oxygen pressure regulator is present and intact.
In so doing, make sure that the connections are free of oil and grease.

Malfunctions and maintenance

Problem	Cause	Solution
The flame turns yellow.	Either the oxygen tank valve is closed or the oxygen
tank is empty.	Open the oxygen tank valve.

Replace the empty oxygen tank with a full one.

The flame gets smaller or lifts off the burner.| Either the gas cartridge valve is closed, or isn’t open wide enough, or the gas cartridge is empty.| Open the gas cartridge valve by turning it (farther) left, or replace the gas cartridge. If you can still hear liquid noises when you shake the gas cartridge, the ambient temperature is too low for the gas to come out in gaseous form (below -20°C).

Regularly check the hoses for cuts and leaks (visual inspection).
Replace the hose package with its single-tank fuse if the single-tank fuse has triggered after a flashback.
Hoses become porous with time. Therefore, replace the hose package as soon as small cuts appear on the hoses.

Accessories

You can find suitable accessories in the main catalog or at www.rothenberger.com

Customer service

The ROTHENBERGER service locations are available to help you (see listing in catalog or online) and replacement parts and service are also available through these same service locations.
Order your accessories and spare parts from your specialist retailer or using RO SERVICE+ online: + 49 (0) 61 95/ 800 8200 sf + 49 (0) 61 95/ 800 7491 service@rothenberger.com – www.rothenberger.com

Disposal

The components of the unit are recyclable materials and should be put into recycling. For this purpose registered and certified recycling companies are available.
For an environmentally friendly disposal of non-recyclable parts (e.g. electronic waste) please contact your local waste disposal authority

Metal parts and gas cartridges

Metals must be sorted and delivered separately to a disposal facility.
Gas cartridges must be disposed of properly.
ROTHENBERGER Werkzeuge GmbH Industriestraße 7
D-65779 Kelkheim / Germany
Telefon +49 6195 / 800 – 0
Telefax +49 6195 / 800 – 3500
info@rothenberger.com
rothenberger.com

Documents / Resources

| ROTHENBERGER F60110-i5 Roxy 400L Roxy Kit Plus [pdf] Instruction Manual
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