Pneumat Systems Cardox CO2 User manual

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MCH 4/5/13
DWG. NO.
DO NOT SCALE DRAWING
5780-0004
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SHEET 3 OF 3
SIZE
Cardox Vise Assy, Fixed
UNLESS OTHERWISE SPECIFIED:
TITLE:
SCALE: 1:24 WEIGHT:
NAME
REV
.010
Customer
MATERIAL
STOCK SIZE
DRAWN
CHECKED
COMMENTS:
DATE
DIMENSIONS ARE IN INCHES
TOLERANCES:
FRACTIONAL .063
ANGULAR: MACH 1° BEND 2°
TWO PLACE DECIMAL .030
THREE PLACE DECIMAL
110 Mohr Drive
Mankato, MN 56001 USA
507-345-4553
www.pneumat.com
Pneumat
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TECHNICAL MANUAL
110 Mohr Drive
Mankato, MN 56001
1-800-458-9446
www.pneumat.com

Cardox Techical Manual
Page 2
We Make Bulk Flow
The purpose of this manual is to provide the user with useful information on the Cardox Blockage
Elimination System by covering the following:
What is Cardox?
Step by Step Instructions:
- Installation
- Rebuilding a Cardox Tube
- Filling a Cardox Tube
- Firing a Cardox Tube
Troubleshooting
Exploded Parts Drawings and Lists
THE TECHNOLOGY
Cardox is a high pressure CO2Blockage Elimination System that is designed to safely and quickly
break-up material from a wide variety of areas. The system’s main component is a high strength
reusable steel tube lled with liquid CO2, a chemical energizer, a rupture disc and a gasket. When
initiated with a small electrical charge, the chemical energizer begins a reaction that develops
within milliseconds enough heat and pressure rise to shear the center out of the rupture disc. This
releases a high pressure, non-explosive blast of CO2through the discharge ports at the end of the
tube that breaks-up and dislodges the surrounding material. After each use the Cardox tube can be
rebuilt with a new energizer, rupture disc, gasket, and recharged with liquid CO2for use again.
1. INTRODUCTION
Pneumat Systems would like to thank you for your purchase of a Cardox
Blockage Elimination System. Employees’ safety will be enhanced and
steady state processes will improve due to a reduction in interruptions in
material ow. We are constantly striving to keep Cardox and our other
products the best bulk storage cleaning equipment available. One way
we can continue to do so is to listen to you. Many of the improvements
we have incorporated over the years, have come from customer input.
So please give us a call with any suggestions or questions you may have.
Included in your purchase is the commitment from us to stand behind our
product and keep you up and running. If something is needed in a timely
fashion Pneumat Systems will make the extra e󰀨ort to get it to you as

Cardox Techical Manual
Page 3
Cardox Use
3.00 The Cardox system is a good tool for dislodging build up material in a hot process vessel during operation.
3.01 The Cardox system can safely dislodge blockage that reduces material ow in cold applications. These being load
out silos, packing silos, etc.
Cardox System Components
consists of but is not limited to:
A. Auto ll and activating head
B. 2 and 4 way discharge heads
C. Cardox tube
D. Pneumat Safety Heater
E. Copper washer
F. Shear disk
G. Tube vise
H. Impact wrench
I. Filling station
J. Safety Heater storage maga-
zine
K. Quik-Lok base socket
L. Quik-Lok tube clamp
M. MSHA approved blaster’s OHM
meter
N. MSHA approved blaster’s acti-
vator
O. Firing cables
P. 1/4” hex wrench for bleeder
screw
Q. 3/16” hex wrench for check
valve
R. Torque wrench with 7/16” deep
socket for tightening ll head
electrode
S. Rock drill
T. Rock drill bit and drill shaft
A.
B.
C.
D.
E. F.
G.
H.
I.
K.
L.
M.
N. O.
P. Q.
R.
S.
T.

Cardox Techical Manual
Page 4
2. INSTALLATION
CO2
5.00 Liquid CO2is pumped into the properly prepared tube to make the activation work.
5.01 Only liquid can be used. This is accomplished by getting the CO2from a cylinder that is equipped
with a siphon tube or dip tube.
5.02 CO2 gas is heavier that air so the tube packing and lling room should have a vent located near the
oor.
5.03 When CO2changes state from liquid to gas it passes through a solid ordry ice state. This chills any
surface it touches. When releasing CO2from a tube the tube may get very cold. Gloves should be
used.
360° PNEUMATIC VISE HOOK-UP
The Pneumat Vise and Toolholder Assembly makes
rebuilding Cardox tubes much easier and more con-
venient. The tool hanger bar/shelf assembly contains
a compressed air manifold that takes a single plant
air connection and distributes compressed air power
to the foot actuator and tools you will need to quickly
teardown and rebuild Cardox Tubes. It also provides
a port for compressed air out to the Fill Stand As-
sembly.
COMPRESSED AIR
SUPPLY IN
IMPACT
WRENCH
SUPPLY
BLOW
GUN
SUPPLY
FOOT
VALVE
SUPPLY
FILL
STAND
SUPPLY
Connect
to Cardox
Fill Stand
Connect
Compressed
Air Supply IN

Cardox Techical Manual
Page 5
FILL STAND PUMP HOOK-UP AND OPERATION
Cardox tubes are “charged” by pumping liquid CO2from a 50
lb. bottle into the ll head of the tube until the desired amount
of CO2is contained in the tube. The Cardox Fill Station makes
this a quick and simple operation. Proper hook-up and opera-
tion of the ll station are as follows:
1. Connect the CO2supply line from the inlet of the pump
to the supply bottle.
NOTE: A bottle with a siphon tube is preferred but if not
available, invert the bottle to supply liquid to the dis-
charge valve. Always use an approved bottle inverter.
2. Open the discharge valve on the CO2bottle fully by
turning it counter-clockwise.
3. Purge the supply line from the pump to the ll head by
opening the ll valve on the pump stand near the ll
nipple.
4. Bleed the line until liquid CO2 exits the ll nipple. The
liquid will appear as white discharge from the nipple that
quickly turns to clear gas. Close the ll valve.
5. Connect the air supply line to the pump air inlet valve.
Adjust regulator 80-100 psi supply to pump.
6. Test the pump, with the ll valve closed, open the ball
valve supplying air to the pump. The pump should
pump two or three cycles, after which the pump “dead-
heads” against the liquid between the pump discharge
and the ll valve.
AIR SUPPLY IN
(FROM VISE MANIFOLD)
Connect
CO
2
Bottle
Connect
Compressed
Air

Cardox Techical Manual
Page 6
1. Center Tube in Vise
Rotate the jaws of the
Rotary Air Vise so that
the Cardox Tube may
be placed horizontally
into the jaws. Center
the tube with the Fill
Head on the right.
2. Open the Manual
Bleed- o󰀨 Valve
Open the manual bleed
o󰀨 valve on the tube ll
head with a 1/4" hex
wrench.
3. Rotate Tube so Fill
Head is Facing Up
Pull up on the vise rota-
tion lock and rotate the
vise 90° counter-clock-
wise until it locks in a
vertical position so the
ll head is at the top.
Make sure the ll
head discharge hole
is pointed away from
you.
4. Loosen and Remove
Fill Head
Remove the ll head
with 1-1/2” socket and
3/4” air impact wrench.
5. Inspect Fill Head
Inspect the ll head
for buildup around the
electrode, and CO2 ll
hole. Clean with rag to
ensure proper lling if
necessary.
6. Check Electrode
Torque
Check torque of elec-
trode with torque
wrench set to 40 ft/lbs.
7. Remove Heater
Remove the spent
heater remains.
8. Blow Out Debris
Use the compressed
air nozzle to blow o󰀨
the threads and seat
area. Then wipe them
down with a clean rag.
9. Inspect Tube End
Threads and Seat
Inspect the threads
and seat area for
pitting and wear. If
acceptable, proceed;
otherwise send tubes
to Pneumat for repair.
10. Rotate Tube 180º
Rotate the tube 180º
so the discharge head
is now on top.
11. Loosen and Remove
Discharge Head
Again, using the air
impact wrench remove
the discharge head
from the tube.
12. Remove Spent Shear
Disc & Copper Gas-
ket
Remove the ruptured
shear disc and copper
washer.
13. Blow Out Debris
Again, use the com-
pressed air nozzle to
blow o󰀨 the threads
and seat area. Then
wipe them down with a
clean rag.
3. REBUILDING A CARDOX TUBE

Cardox Techical Manual
Page 7
14. Inspect Tube End
Threads & Seat
Again, inspect the
threads and seat area
for pitting and wear. If
acceptable, proceed;
otherwise send tubes
to Pneumat for re-
pair.
15. Install New Copper
Gasket
Place a new copper
gasket in the tube
making sure it is sitting
at down against the
seat.
16. Install New Shear
Disc
Place a new shear
disc in the tube, round-
ed edge down, so it is
resting at against the
copper washer.
17. Inspect Discharge
Head
Inspect the cutting
edge of the discharge
head looking for a
clean sharp corner. If
the edge is not sharp
send to Pneumat for
repair.
18. Oil Discharge Head
Threads
Place a small amount
of oil along threads to
lubricate them.
19. Re-install and Tight-
en Discharge Head
Start threading the
discharge head by
hand into the tube end.
Tighten securely with
the air impact wrench.
20. Rotate Tube 180º in
Vise
Again, rotate the tube
180º so the ll head
end is up.
21. Install New Cardox
Safety Heater in Tube
Place a new Cardox
Safety Heater into the
tube. Inspect the heat-
er to insure the center
contact wire is in place
and will be contacted
by the electrode in the
ll head.
22. Oil Fill Head Threads
Place a small amount
of oil along threads to
lubricate them.
23. Re-install & Tighten
Fill Head
Start threading the
ll head by hand into
the tube end. Tighten
securely with the air
impact wrench.
24. Check Continuity
Check circuit continu-
ity with the Blasters
Ohmmeter (1-3 ohms).
If not in range, remove
the ll head and check
electrode for cleanli-
ness. Replace heater
if contacts were good
and re-tighten.
25. Rotate Tube & Remove
Rotate the tube 90º in
the vise. Release pres-
sure on the vise with
the manual foot valve,
remove tube.The tube
is now ready for storage
or charging with CO2 in
the ll stand.
NOTE: Pneumat does not recommend the use of a pneumatic
rotary brush to clean the equipment. This will degrade the threads
and ultimately shorten tube and head life.

Cardox Techical Manual
Page 8
Make certain the
Cardox ring tube has
been properly rebuilt
before charging the
tube.
1. Check Safety Bleed-
o󰀨 Valve
With a 1/4” hex wrench
check to make sure the
Safety Bleed O󰀨 Valve
in the ll head is closed.
2. Weigh Empty Tube
Place the EMPTY
rebuilt tube on the scale
using the supplied plac-
tic tube rest to keep the
tube from rolling o󰀨 the
scale.
3. Set Tare Weight to
Zero
Set the tare weight by
pressing the tare button
on the digital display.
The readout should
display a zero weight.
4. Place Tube into Fill
Stand
Put the tube assembly
into the ll manifold at
the top of the Cardox
Fill Station by entering
from the bottom.
5. Align Fill Port & Fill
Nozzle
Align the ll port in the
tube ll head with the ll
nozzle on the ll sta-
tion by rotating the tube
assembly until the port
can be tted over the
plastic nozzle.
6. Secure Tube in Fill
Stand
Turn the handle on the
tube clamp to securely
clamp the ll head to
the ll nozzle.
7. Open CO2 Fill Valve
Make sure the dis-
charge valve is closed.
Then open the ll valve
on the ll station to be-
gin the ow of CO2into
the tube.
8. Turn Air ON/OFF Valve
to ON
Open the Air Valve
on the pump to begin
pumping.
9. After Pump Stops
Close CO2 Fill Valve
Allow the pump to run
until there is about
5-10 seconds between
cycles of the pump, and
then close the ll valve.
Fill times are normally
around one minute.
10. Open CO2Discharge
Valve
Open the Discharge
Valve to release the
trapped pressure from
the ll manifold.
11. Remove Tube from Fill
Stand
Loosen the clamp
securing the tube to the
ll nozzle and remove
tube.
4. FILLING A CARDOX TUBE

Cardox Techical Manual
Page 9
12. Weigh Filled Tube
Place the lled tube
back on the scale to
check the weight of CO2
that was pumped into the
tube.
13. Adjust Air Pressure &
Rell
If the tube does not
have a su󰀩cient CO2
charge (see chart be-
low) put it back into the
ll station and repeat
Steps 4 through 11.
The air pressure to the
pump may need to be
increased to obtain a
proper ll weight.
14. Check Each End of
Tube for Leaks
Dip both ends of tube in
a bucket of water at an
angle to check for leaks.
Hold under water for a
few seconds and watch
for bubbles rising up
from the tube end.
15. Put Back in Vise & Re-
seal (IF LEAKS)
If tube is leaking clamp
it into the vise and review
troubleshooting section
of this manual. Repeat ll
procedure.
16. Tape Over Contacts
If there are no leaks cover
the electrical contacts on
the Cardox ll head with
a few wraps of electri-
cal tape. The tape signi-
es that the tube is now
charged and ready to be
used.
CO2Charge Weights (min): Series 3700 Tube Series 5700 Tube
1.3 lbs 1.8 lbs
0.60 kg 0.82 kg

Cardox Techical Manual
Page 10
Charged Cardox Tubes are safe to be transported and handled with reasonable care
and safety. Once a Cardox tube is lled with the proper amount of CO2it is ready
for activation. A lled Cardox tube should always be respected. Dropping a tube will
not cause it to activate, but it could break the copper washer seals on either end and
cause the tube to leak
Tube Placement
Drill a 2-1/8” diameter hole into the e󰀨ected material to a depth that will put the dis-
charge ports of the Cardox Tube in a position 12” – 18” from a free face. Try to take
less material with initial shots, until you learn more about the solidity and cohesive-
ness of the material.
Tube Securing
In securing a Cardox tube hold the tube into the material before initiation to prevent
ejection of the tube and to allow for retreival of the tube after initiation. There are
three basic methods for Cardox Tube retention:
1. Quik-Lok Socket and Clamp (available from Pneumat)
A Quik-Lok Socket is welded or bolted permantly to the tower, hopper or bin
wall in the e󰀨ected area and is sealed with a removable plug when not in use.
A Quik-Lok Clamp is a󰀩xed to the Cardox Tube at point that will yield the
desired tube insertion depth. The tube/clamp assembly is now inserted into
the hole through the socket on the vessel and secured with a half turn of the
bayonet-style coupling between the clamp and the socket.
2. Quik-Clamp (available from Pneumat)
A Quik-Clamp is fastened to the outside of a Cardox tube to provide an anchor
point for attaching a chain, wire rope or come-along to act as a retaining line.
Make sure the retaining line is secured to something substantial that can with-
stand the power of a Cardox tube.
3. Cardox Activating Head With Eyebolt
Cardox Activating Heads have a threaded hole that will accept an eyebolt
that can be used for tube retention and retrieval. Smaller heads have a 1/2”
threaded hole and larger heads have a 1” threaded hole. After securing an
eyebolt into the head, attach a chain, wire rope or come-along to the eyebolt
to act as a retaining line. Make sure the retaining line is secured to something
substantial that can withstand the power of a Cardox tube.
Wiring
All wiring should be done at the point of use for each tube. DO NOT pre-wire tubes
and then transport to the point of use. Wiring should be done with well-insulated 14–
18 gauge wire. . First short-circuit one end of the wires and then secure the other end
of the wires to the activating head with a few wraps of black electrical tape. Complete
wiring to the a High Energy Activating Machine when EVERYONE is safely away from
the area and behind substantial protection from ying material.
5. FIRING A CARDOX TUBE - BASICS

Cardox Techical Manual
Page 11
Activating
Proper activation of a Cardox Tube should be done with an activating machine. Dis-
connect the short-circuit and insert and tighten the leads into the screw-down connec-
tors on the activating machine.
READ the instructions on the activating machine to become familiar with its operat-
ing procedures. Verify by sight and sound that everyone is clear. Then, hold down
the charging button until the red indicator light comes on to signal that the activating
machine is now charged and ready. Depress the ring button and the Cardox Tube
will be initiated.
Misres
CAUTION – Misred tubes can be partially energized and may be very hot to the
touch. Consider every misre to be HOT until verication that it is not.
If a Cardox Tube does not re when activated, rst check for connection problems
such as loose wires and check the continuity (1-3 ohms). If a connection has been
found as the source of the misre, clear the area again and try to reactivate.
If no connection problem exists, the very FIRST thing to be done is to release the
pressure inside the Cardox Tube. Locate the release valve on the activating head
and open it with a 1/4” Hex Wrench which will let the pressurized CO2exit the tube
to atmosphere. This must be done before anything else, since once the pressure is
relieved from inside the tube, that tube can no longer discharge unexpectedly. If the
continuity is out of range the heater will need to be replaced (see page 6).
Removal
Disconnect wires from the activating machine and short-circuit them, remove wires
and tape from the activating head connections, whether a tube is charged or dis-
charged, before removal from the material. The tube can now be safely removed and
rebuilt if neccesary.
6. STANDARD OPERATING PROCEDURES -SPECIFIC AREAS
Purpose and Scope
To provide the user with the proper and most current operating procedures for safe
Cardox tube preparation, tube lling, and tube activation. Also to highlight issues of
safe operation of the Cardox system. and to provide an understanding of the Cardox
system and its usefulness as an in operation tool for reducing process blockage.
Responsible Roles
2.00 Pneumat Systems, Inc. endeavors to provide the users of the Cardox system the
proper and safe operating procedures
2.01 The user of the Cardox system is to be aware of the safe procedures and follow
them.
2.02 The user of the Cardox system is encouraged to respect the proper handling
procedures and to not take short cuts in the use of the Cardox system.
2.03 The user is encouraged to follow all the proper steps in preparation, lling and
activating the Cardox tube.

Cardox Techical Manual
Page 12
Cooler
WHERE TO USE CARDOX
Cardox can be used throughout your material handling line anywhere build-ups, hang-
ups and blockages occur. It also can be used in storage silos that contain stone,
gypsum, clay, coal and nished cement to name a few. Throughout the preheater and
precalciner tower is an area where Cardox is used extensively and is extremely e󰀨ec-
tive. Other areas include the feedshelf, kiln and cooler areas.
One feature that makes Cardox easy and safe to use is the Quik-Lok Socket and
Tube Clamp System. By placing Quik-Lok Sockets on a vessel, access points through
the wall are created that provide precise and secure tube placement. These inexpen-
sive sockets can be easily installed anywhere a problem occurs, and the adjustable
tube clamp allows consistent and controlled discharge depth into the material which
protects refractory and vessel walls.
Using Cardox in TOWER applications:
A) Get prepared completely,
B) Only put tube into the tower when prepared,
C) Only have the tube in the heat a minimum time, and
D) Keep the ring cable wires at the activator end shunted together when setting up
and dismantling the application.
8.02 In most applications the base port needs to be used for tower applications. The
base port is welded in place on the tower and sealed by the plug between tube
insertions.
8.03 With the base port a Quik-Lok Tube Clamp should be used to secure the tube while
making the blast. The Quik-Lok Tube Clamp secures to the tube and them locks the
tube into the base port.
8.04 A hole should be drilled into
the material build up for the
blast to be most e󰀨ective.
After drilling through the
material one should use a
round rod with a curve on its
end to measure the depth of
the build up.
8.05 One needs to know the
thickness of the refractory
at the point of the planned
blast. The end of the male
part of the Quik-Lok Tube
Clamp should never be any
closer than 6” beyond the
refractory. This 6” is mea-
sured from the end of the
tube to the surface of the
D
A B
C
D = Total Depth (From Tube End to Clamp Face)
D = A + B + C
A = Depth into Material
B = Thickness of Refractory
C = Thickness of Wall & Quik-Lok Socket
EXAMPLE:
A = 10 Inches
B = 9 Inches
C = 3/4 inch + 2-3/4 inch = 3-1/2 ~ 4 inch
D = 23 inches (From end of tube to Clamp Face)

Cardox Techical Manual
Page 13
male end of the clamp.
8.06 The clamp needs to be securely tightened in place on the tube. Hitting the clamp
with the wrench will verify that the clamp is in place securely.
8.07 When the base port is located close to a tower edge or corner wall only a 2-way
discharge head should be used. Mark the direction of discharge by aligning the
handle or the bolt on the clamp with the 2-way discharge outlet opening. When the
tube is locked in the base port, observe the direction the blast will go. Adjust the
positioning of the clamp so that the discharge will be in the vertical direction.
8.08 Next the ring wires should be placed in the activation auto ll head. The electrical
application is not polarity sensitive and as such no particular orientation of the ring
cable wires is needed. The opposite end of the ring cables should remain shunted
(twisted) together until the tube is placed in the base port, this prevents static elec-
tricity from the tube prematurely.
8.09 Place the tube with clamp into the base port and twist it into a locked position. Move
to the opposite end of the ring cable, which should be around a corner or out of
the line of the tube direction by 25’ – 30’. Hook up the MHSA approved blaster.
8.10 Observe that the area around the blast is secured. Hold the left button down on the
blaster until the red light comes on. Continue to hold the left button with the light on
and depress the right button to activate the safety heater inside the tube.
8.11 The blast should occur immediately. NOTE: the goal is to have the tube inside of
the tower heat for less than 5 minutes. Once the blast has occurred remove the
blaster and re-shunt that end of the ring cables.
8.12 If a blast does not occur, immediately approach the tube. Observe the location of
the relief hole in the ll head. Make certain that the relieved gas will not strike you in
the face. Open the safety bleeder valve using a 1/4” hex wrench. Let the gas bleed
o󰀨 before removing the tube. Relieving this pressure will cause the inside of the
tube to go back to equal pressure with the outside. The heater in the tube cannot
function unless it has a constant pressure around it that is greater than 275 PSI.
After relieving the gas from inside of the tube will be less than the 275 PSI.
8.13 Remove the tube. Remember that by now the discharge end of the tube is very hot;
so handle accordingly.
8.14 This failed to blast tube should be marked properly or take it to the lling room and
carefully dismantle it according to section #6.03
Cardox Activation – KILN
8.15 To properly use Cardox to break up kiln build up rings – the base ports need to be
installed in the kiln wall while shut down in the locations that the ring is expected to
be based on past experiences.
8.16 The kiln can be drilled with it “hot” or “cold”. Proper precautions need to be taken to
work the kiln hot. The work can be done o󰀨 a man lift machine or o󰀨 a catwalk. The
kiln can be stopped for 15 – 30 minutes at a time and the hole drilled in the build
up. The kiln can then be rotated for the desired number of rotations.

Cardox Techical Manual
Page 14
8.17 The kiln can then be stopped and the tube can be placed in the clamp and into the
base port.
8.18 One needs to know the thickness of the refractory at the point of the planned blast.
The end of the male part of the Quik-Lok Tube Clamp should never be any closer
than 6” beyond the refractory. This 6” is measured from the end of the tube to the
surface of the male end of the clamp.
8.19 The clamp needs to be securely tightened in place on the tube. Hitting the clamp
with the wrench will verify that the clamp is in place securely.
8.20 Move to the opposite end of the ring cable, which should be around a corner
or out of the line of the tube direction by 25’ – 30’. Hook up the MHSA approved
blaster.
8.21 Next the ring wires should be placed in the activation auto ll head. The electrical
application is not polarity sensitive and as such no particular orientation of the ring
cable wires is needed. The opposite end of the ring cables should remain shunted
(twisted) together until the tube is placed in the base port, this prevents static elec-
tricity from the tube prematurely.
8.22 Observe that the area around the blast is secured. Hold the left button down on the
blaster until the red light comes on. Continue to hold the left button with the light on
and depress the right button to activate the safety heater inside the tube.
8.23 The blast should occur immediately. NOTE: the goal is to have the tube inside
of the kiln heat for less than 5 minutes. Once the blast has occurred remove the
blaster and re-shunt that end of the ring cables.
8.24 If a blast does not occur, immediately approach the tube. Observe the location of
the relief hole in the ll head. Make certain that the relieved gas will not strike you
in the face. Open the safety bleeder valve using a 1/4” hex wrench. Let the gas
bleed o󰀨 before removing the tube. Relieving this pressure will cause the inside
of the tube to go back to equal pressure with the outside. The heater in the tube
cannot function unless it has a constant pressure around it that is greater than 275
PSI. After relieving the gas from inside of the tube will be less than the 275 PSI.
8.25 Remove the tube. Remember that by now the discharge end of the tube is very hot;
so handle accordingly.
8.26 This failed to blast tube should be marked properly or take it to the lling room and
carefully dismantle it according to section #6.03
8.27 Please note: multiple tubes can be shot at the same time to break the ring quicker.
Please contact a Pneumat Systems, Inc. Technician to discuss this possibility if
desired.
Cardox Activation – COOLER
8.28 When blasting cooler buildups and “snowmen”; the material is usually not close
to the “wall”. This means that the set up must be made to reach out into the distant
hot material. Proper Cardox attachments should be used for this application.
Cooler

Cardox Techical Manual
Page 15
8.29 The ring head of the tube must remain outside of the heated container. To do this a
prolongation attachment is used in place of the discharge head. The tube is prepared
according to the normal procedures. When completed an attachment tube extension
is added to the prolongation attachment and the regular discharge head is added to
the attachment.
8.30 Planning and care needs to be taken for this kind of set up. Have the tube completely
assembled, make certain that enough personnel is available to lift this assembly into
the opening. Also, prepare the assembly to be secured in place. A eye bolt attach-
ment (available from Pneumat) should be threaded into the Pneumat lling head to
use to attach the hook of a cable wench. Properly plan where the cable wench will be
attached to the cooler.
8.31 Next the ring wires should be placed in the activation auto ll head. The electrical
application is not polarity sensitive and as such no particular orientation of the ring
cable wires is needed. The opposite end of the ring cables should remain shunted
(twisted) together until the tube is placed in the cooler, this prevents static electricity
from the tube prematurely.
8.32 Place the assembly in the cooler and properly secure that assembly in place. Move
to the opposite end of the ring cable, which should be around a corner or out of the
line of the tube direction by 25’ – 30’. Hook up the MHSA approved blaster.
8.33 Observe that the area around the blast is secured. Hold the left button down on the
blaster until the red light comes on. Continue to hold the left button with the light on
and depress the right button to activate the safety heater inside the tube.
8.34 The blast should occur immediately. NOTE: the goal is to have the tube inside of the
cooler heat for less than 5 minutes. Once the blast has occurred remove the blaster
and re-shunt that end of the ring cables.
8.35 If a blast does not occur, immediately approach the tube. Observe the location of the
relief hole in the ll head. Make certain that the relieved gas will not strike you in the
face. Open the safety bleeder valve using a 1/4” hex wrench. Let the gas bleed o󰀨
before removing the tube. Relieving this pressure will cause the inside of the tube to
go back to equal pressure with the outside. The heater in the tube cannot function
unless it has a constant pressure around it that is greater than 275 PSI. After reliev-
ing the gas from inside of the tube will be less than the 275 PSI.
8.36 Remove the tube. Remember that by now the discharge end of the tube is very hot;
so handle accordingly.
8.37 This failed to blast tube should be marked properly or take it to the lling room and
carefully dismantle it according to section #6.03
Cardox Activation – RAW/FINISHED SILOS
8.38 Pneumat Systems, Inc. has designed and does provide excellent attachments for the
Cardox tubes that make them very functional in all cold applications.
8.39 A hole needs to be drilled in the material chunk or the material build up. This can be
done with a Pneumat drill with extension shafts and drill bit. This hole should be deep
enough that about 1/2 of the tube can be placed into it.

Cardox Techical Manual
Page 16
8.40 A regular lled tube needs to be placed rmly into that hole. This can be accom-
plished by using a #5790-0031 Adapter CDX that is threaded into the Pneumat
ll head and connects extension drill shafts (#5300-0013) to the tube. An eyebolt
#5731-0004 can be used to connect the shafts to the cable wench for securing the
assembly to the silo.
8.41 Place the tube tightly in the drilled hole and secure the assembly. Since this is a
“cold” application there is no concern with the time in the material and no concern
about having the ll head into the vessel.
8.42 The ring cables should be taped with electrical tape to hold them in the ll head as
the assembly is extended deeper into the vessel.
8.43 Place the assembly in the silo and properly secure that assembly in place. Move to
the opposite end of the ring cable, which should be around a corner or out of the
line of the tube direction by 25’ – 30’. Hook up the MHSA approved blaster.
8.44 Observe that the area around the blast is secured. Hold the left button down on the
blaster until the red light comes on. Continue to hold the left button with the light on
and depress the right button to activate the safety heater inside the tube.
8.45 The blast should occur immediately. Once the blast has occurred remove the
blaster and re-shunt that end of the ring cables.
8.46 If a blast does not occur, immediately approach the tube. Observe the location of
the relief hole in the ll head. Make certain that the relieved gas will not strike you
in the face. Open the safety bleeder valve using a 1/4” hex wrench. Let the gas
bleed o󰀨 before removing the tube completely. Relieving this pressure will cause
the inside of the tube to go back to equal pressure with the outside. The heater in
the tube cannot function unless it has a constant pressure around it that is greater
than 275 PSI. After relieving the gas from inside of the tube will be less than the
275 PSI.
8.47 Remove the tube.
8.48 This failed to blast tube should be marked properly or take it to the lling room and
carefully dismantle it according to section #6.03
Safety Recap
9.00 Remember to respect the Cardox tube. When properly lled it will have 4000-5000
PSI of pressure inside the tube. When it is activated it will exhaust out of the dis-
charge end at 27,000-30,000 PSI.
9.01 CO2is heavier than normal air, therefore there should be a vent located near the
oor or in the oor of the lling room.
9.02 To have success with the Cardox system the tube must be lled with liquid CO2.
CO2is always trying to get to its gas state. As it passes from liquid to gas, it goes
through a solid dry ice state and makes metal surfaces very cold. Gloves should be
used when handling tubes that have CO2released from inside.
9.03 When there is a failed activation the safety bleeder screw should be opened before
removing the tube from the base port.

Cardox Techical Manual
Page 17
9.04 If a tube has failed to activate special care should be taken when dismounting the
heads. Use the air impact wrench to start loosening the ll head. DO NOT SPIN THE
HEAD LOOSE. Remove the wrench and try to loosen the ll head. If it is hard to turn
by hand note that there is still pressure inside the tube. STOP removing the ll head.
Turn the tube over and use the air impact wrench to loosen the discharge head.
Do not attempt to impact the discharge head o󰀨 the tube. Use a hand wrench or a
screwdriver in the discharge openings and slowly unscrew the discharge head. While
doing this use a metal object as a hammer and tap on that end of the tube. Watch
the position of your face and be aware that you are going to eventually dislodge the
copper washer and the gas inside the tube will start escaping. When the gas starts
escaping stop un- screwing the discharge head and move from the tube until all the
gas escapes. When the pressure is gone continue to dismantle the tube. When this
ll head is removed inspect the inside to try to see what blocked the bleeder screw
opening. Reassemble the tube leaving out the heater. Fill it with CO2and then open
the bleeder screw to verify that it can be emptied. If all the gas is properly relieved
the ll head is safe to use. If not return it to Pneumat Systems, Inc. for the proper
repairs.
9.05 Make it a goal to place the tube for activation, activate it successfully, and remove the
tube in under 5 minutes in hot applications.
9.06 Be aware that the discharge head will be very hot when removed from the base port.
9.07 Never use electricians Ohmmeter or an unapproved multimeter for continuity checks.
Only use a blaster approved Ohmmeter.
9.08 Do not stand in line with the tube when rebuilding it.
9.09 Only hook the blaster to the ring cables at the time the tube is set and activation is
ready to be made.
9.10 Keep the blaster connection end of the ring cables shunted (shorted) together when
not in use.
9.11 Only use an approved blaster instrument for activation.
9.12 Never activate an unsecured tube. Secure in a base port or with a come-along.
9.13 Learn to follow all steps quickly and e󰀩ciently and misres will be non-existent and
the system will function safely.
9.14 Every 2 years the Cardox tube, Activating Head and Discharge Head should be sent
back to Pneumat Systems, Inc. for a safety review. The exposure to heat stresses
the tubes over time. Pneumat Systems Inc. has an independent lab do all the metal-
lurgical tests. Pneumat Systems Inc. veries that there is a proper t of the compo-
nents, and the approved tube is returned for use.

Cardox Techical Manual
Page 18
Problem Cause Solution
Pump cycles without "deadhead-
ing."
CO2 bottle may not be connected.
Bottle may not have siphon tube.
Bottle is empty.
Check CO2supply to insure liquid
is
supplied to the pump.
Invert bottle for gravity feed of
liquid or replace with siphon tube
bottle.
Replace empty bottle.
Tubes do not reach minimum
weight.
Low air pressure to pump. Adjust air pressure to 80–100
PSI. The higher the air pressure
the greater volume of CO2will be
conveyed to the tube. Adjust air
regulator at pump inlet to maximize
application of available plant air.
Pump will not operate. Pump not primed.
Pump not funcitioning.
Follow procedure to prime
pump.
Pump will need to be repaired. Call
Pneumat and a loner pump will be
sent overnight to your facility.
If Cardox is required while the
pump is out of service, bypass the
pump with the bottle discharge
ll line. Connect the ll line direct
to the pump stand assembly inlet
nipple. Use the liquid CO2in the
bottle to chill the Cardox ring
tube,
bleed CO2 into and out of the r-
ing tube until liquid CO2is readily
discharged from the tube (two to
four cycles). Then, weigh tube to
insure proper weight.
6. TROUBLESHOOTING

Cardox Techical Manual
Page 19
Problem Cause Solution
Bubbles appear when the dis-
charge the discharge head is
placed under water.
Bad seal between discharge head
and tube.
The head is not tight to the body.
Use the impact wrench, rattle the
discharge head for additional tight-
ness and retest.
Bubbles appear when the ll head
is placed under water originating
from the connection between the
ll head and tube.
Bad seal between ll head and
tube.
When bubbles originate from the
threaded connection of the head
to the tube body the ll head may
not be tight to the body. Use the
impact wrench and rattle the ll
head for additional tightness. If
bubbles continue the copper
seat on the heater element is not
functioning properly. Bleed o󰀨 the
tube, remove the ll head, remove
the heater element and inspect for
damage, clean the threads, seating
shoulder in the tube and seating
surface on the head, replace the
heater element, lubricate, as-
semble and tighten with the impact
wrench. Recharge the tube and
retest.
If bubbles continue following re-
tightening, inspect the washer and
shear disk assembly to ensure it to
be seated properly. Bleed o󰀨 the
CO2, remove the discharge head,
remove the shear disk and copper
washer, inspect components for
possible explanation, re-clean the
seat and threads, reassemble with
new washer and disk, re-torque us-
ing the impact wrench. Recharge
the tube and retest.
Bubbles appear when the ll head
is placed under water, from the
bleed-o󰀨 valve.
Loose valve or bad seal in bleed
valve.
When bubbles originate from
the bleed o󰀨 valve retighten with
1/4"hex wrench. If leakage con-
tinues replace the bleed valve
assembly, recharge the tube and
retest.

Cardox Techical Manual
Page 20
Problem Cause Soulution
Bubbles appear when the ll head
is placed under water, originating
from the auto-ll check valve.
Bad seal in check valve assembly. When bubbles originate from the
check valve assembly, bleed o󰀨
CO2
and remove assembly from head.
Replace parts as required. Often
times only the o-rings need re-
placement. Inspect the seat and
plunger and replace as required.
Recharge the tube and retest.
Bubbles appear when the ll head
is placed under water originating
from the electrical contacts.
Loose electrical spindle assembly
or bad seal in electrical spindle
assembly.
When bubbles originate from the
electrical contact bleed o󰀨 CO2and
remove ll head from tube. Torque
the electrical spindle nut to 30 ft/
lbs. Tighten ll head back onto
tube, recharge and re-inspect for
leaks. If leak continues bleed o󰀨
CO2 and remove ll head from
tube. Replace the electrical spin-
dle assembly with a new assembly.
Be sure the insulating and sealing
washers are in the correct loca-
tion. The insulating washer must
be placed between the electrical
spindle and the spindle nut. The
sealing washer must be placed
between the electrical spindle and
the seat in the ll head. Recharge
tube and retest. Torquing the
spindle nut above 30 ft/lbs. may
result in the crushing of the insulat-
ing washer and the loss of torque
or dielectric seal.
Continuity check indicates less
than 1.00 ohm of resistance.
Short circiut between electrical
spindle and ll head body.
Replace electrical spindle as
outlined in previous solution and
recharge tube and retest.
Continuity check indicatesan open
circuit (innite resistance).
Bad contact between electrical
spindle and heater wire lead.
Bleed o󰀨 CO2, remove ll head,
and inspect contacts between
the electrical spindle and heater
wire lead. Rebuild, rell tube and
retest.