TECHNICAL MANUAL

8 7 6

     

C


  

 
110 Mohr Drive 
  

Mankato, MN 56001    

 
 

1-800-458-9446 

www.pneumat.com 




A 

      
Cardox Techical Manual

We Make Bulk Flow

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 flow. 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 effort to get it to you as

1. INTRODUCTION
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 CO2 Blockage 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 filled 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 CO2 through 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 CO2 for use again.

Page 2
 Cardox Techical Manual

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 flow in cold applications. These being load
out silos, packing silos, etc.

Cardox System Components

consists of but is not limited to:
M.
A. Auto fill and activating head

B. 2 and 4 way discharge heads

C. Cardox tube
H. O.
D. Pneumat Safety Heater N.
I.

E. Copper washer P. Q.
F. Shear disk

G. Tube vise G.
H. Impact wrench

I. Filling station R.

J. Safety Heater storage maga-

zine

K. Quik-Lok base socket L.

K.
L. Quik-Lok tube clamp

M. MSHA approved blaster’s OHM

meter

N. MSHA approved blaster’s acti- D.

vator
S. F.
O. Firing cables E.

P. 1/4” hex wrench for bleeder

T.
screw

Q. 3/16” hex wrench for check B.

valve

R. Torque wrench with 7/16” deep

socket for tightening fill head A.
electrode

S. Rock drill

T. Rock drill bit and drill shaft C.

Page 3
Cardox Techical Manual

CO2
5.00 Liquid CO2 is pumped into the properly prepared tube to make the activation work.

5.01 Only liquid can be used. This is accomplished by getting the CO2 from 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 filling room should have a vent located near the
floor.

5.03 When CO2 changes state from liquid to gas it passes through a solid ordry ice state. This chills any
surface it touches. When releasing CO2 from a tube the tube may get very cold. Gloves should be
used.

2. INSTALLATION
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.

Connect
IMPACT BLOW
Compressed
WRENCH GUN Air Supply IN
SUPPLY SUPPLY

Connect
FOOT to Cardox
VALVE Fill Stand
SUPPLY

FILL
STAND COMPRESSED AIR
SUPPLY SUPPLY IN

Page 4
 Cardox Techical Manual

FILL STAND PUMP HOOK-UP AND OPERATION

Cardox tubes are “charged”­by pumping liquid CO2 from a 50

lb. bottle into the fill head of the tube until the desired amount Connect
of CO2 is contained in the tube. The Cardox Fill Station makes CO2
Bottle
this a quick and simple operation. Proper hook-up and opera-
tion of the fill station are as follows:

1. Connect the CO2 supply 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 CO2 bottle fully by

turning it counter-clockwise.

3. Purge the supply line from the pump to the fill head by
opening the fill valve on the pump stand near the fill
Connect
nipple. Compressed
Air
4. Bleed the line until liquid CO2 exits the fill nipple. The
liquid will appear as white discharge from the nipple that
quickly turns to clear gas. Close the fill 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 fill 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 fill valve.

AIR SUPPLY IN
(FROM VISE MANIFOLD)

Page 5
Cardox Techical Manual

3. REBUILDING A CARDOX TUBE

1. Center Tube in Vise 7. Remove Heater

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

Page 6
 Cardox Techical Manual

14. Inspect Tube End 20. Rotate Tube 180º in

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

Page 7
Cardox Techical Manual

4. FILLING A CARDOX TUBE

Make certain the 6. Secure Tube in Fill

Cardox firing tube has Stand
been properly rebuilt Turn the handle on the
before charging the tube clamp to securely
tube. clamp the fill head to
the fill nozzle.
1. Check Safety Bleed-
off Valve 7. Open CO2 Fill Valve
With a 1/4” hex wrench Make sure the dis-
check to make sure the charge valve is closed.
Safety Bleed Off Valve Then open the fill valve
in the fill head is closed. on the fill station to be-
gin the flow of CO2 into
2. Weigh Empty Tube the tube.
Place the EMPTY
rebuilt tube on the scale 8. Turn Air ON/OFF Valve
using the supplied plac- to ON
tic tube rest to keep the Open the Air Valve
tube from rolling off the on the pump to begin
scale. pumping.

3. Set Tare Weight to 9. After Pump Stops

Zero Close CO2 Fill Valve
Set the tare weight by Allow the pump to run
pressing the tare button until there is about
on the digital display. 5-10 seconds between
The readout should cycles of the pump, and
display a zero weight. then close the fill valve.
Fill times are normally
4. Place Tube into Fill around one minute.
Stand
Put the tube assembly 10. Open CO2 Discharge
into the fill manifold at Valve
the top of the Cardox Open the Discharge
Fill Station by entering Valve to release the
from the bottom. trapped pressure from
the fill manifold.
5. Align Fill Port & Fill
Nozzle 11. Remove Tube from Fill
Align the fill port in the Stand
tube fill head with the fill Loosen the clamp
nozzle on the fill sta- securing the tube to the
tion by rotating the tube fill nozzle and remove
assembly until the port tube.
can be fitted over the
plastic nozzle.

Page 8
 Cardox Techical Manual

12. Weigh Filled Tube 15. Put Back in Vise & Re-
Place the filled tube seal (IF LEAKS)
back on the scale to If tube is leaking clamp
check the weight of CO2 it into the vise and review
that was pumped into the troubleshooting section
tube. of this manual. Repeat fill
procedure.
13. Adjust Air Pressure &
Refill 16. Tape Over Contacts
If the tube does not If there are no leaks cover
have a sufficient CO2 the electrical contacts on
charge (see chart be- the Cardox fill head with
low) put it back into the a few wraps of electri-
fill station and repeat cal tape. The tape signi-
Steps 4 through 11. fies that the tube is now
The air pressure to the charged and ready to be
pump may need to be used.
increased to obtain a
proper fill 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.

CO2 Charge Weights (min): Series 3700 Tube Series 5700 Tube
1.3 lbs 1.8 lbs
0.60 kg 0.82 kg

Page 9
Cardox Techical Manual

5. FIRING A CARDOX TUBE - BASICS

Charged Cardox Tubes are safe to be transported and handled with reasonable care
and safety. Once a Cardox tube is filled with the proper amount of CO2 it is ready
for activation. A filled 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 effected 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 effected area and is sealed with a removable plug when not in use.
A Quik-Lok Clamp is affixed 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 flying material.

Page 10
 Cardox Techical Manual

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 firing button and the Cardox Tube
will be initiated.

Misfires
CAUTION – Misfired tubes can be partially energized and may be very hot to the
touch. Consider every misfire to be HOT until verification that it is not.
If a Cardox Tube does not fire when activated, first 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 misfire, 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 CO2 exit 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 filling, 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, filling and
activating the Cardox tube.

Page 11
Cardox Techical Manual

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,
Cooler
gypsum, clay, coal and finished cement to name a few. Throughout the preheater and
precalciner tower is an area where Cardox is used extensively and is extremely effec-
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 firing 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

D
the material build up for the
blast to be most effective. A B C
After drilling through the D = Total Depth (From Tube End to Clamp Face)
material one should use a D=A+B+C
round rod with a curve on its A = Depth into Material
B = Thickness of Refractory
end to measure the depth of C = Thickness of Wall & Quik-Lok Socket
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 EXAMPLE:
Clamp should never be any A = 10 Inches
closer than 6” beyond the B = 9 Inches
C = 3/4 inch + 2-3/4 inch = 3-1/2 ~ 4 inch
refractory. This 6” is mea-
D = 23 inches (From end of tube to Clamp Face)
sured from the end of the
tube to the surface of the

Page 12
 Cardox Techical Manual

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 firing wires should be placed in the activation auto fill head. The electrical
application is not polarity sensitive and as such no particular orientation of the firing
cable wires is needed. The opposite end of the firing 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 firing 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 firing cables.

8.12 If a blast does not occur, immediately approach the tube. Observe the location of
the relief hole in the fill 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
off 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 filling 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 off a man lift machine or off 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.

Page 13
Cardox Techical Manual

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 firing 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 firing wires should be placed in the activation auto fill head. The electrical
application is not polarity sensitive and as such no particular orientation of the firing
cable wires is needed. The opposite end of the firing 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 firing cables.

8.24 If a blast does not occur, immediately approach the tube. Observe the location of
the relief hole in the fill 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 off 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 filling 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.

Cooler 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.

Page 14
 Cardox Techical Manual

8.29 The firing 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 filling 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 firing wires should be placed in the activation auto fill head. The electrical
application is not polarity sensitive and as such no particular orientation of the firing
cable wires is needed. The opposite end of the firing 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 firing 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 firing cables.

8.35 If a blast does not occur, immediately approach the tube. Observe the location of the
relief hole in the fill 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 off
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 filling 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.

Page 15
Cardox Techical Manual

8.40 A regular filled tube needs to be placed firmly into that hole. This can be accom-
plished by using a #5790-0031 Adapter CDX that is threaded into the Pneumat
fill 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 fill head into the vessel.

8.42 The firing cables should be taped with electrical tape to hold them in the fill 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 firing 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 firing cables.

8.46 If a blast does not occur, immediately approach the tube. Observe the location of
the relief hole in the fill 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 off 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 filling room and
carefully dismantle it according to section #6.03

Safety Recap

9.00 Remember to respect the Cardox tube. When properly filled 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 CO2 is heavier than normal air, therefore there should be a vent located near the
floor or in the floor of the filling room.

9.02 To have success with the Cardox system the tube must be filled with liquid CO2.
CO2 is 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 CO2 released 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.

Page 16
 Cardox Techical Manual

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 fill head. DO NOT SPIN THE
HEAD LOOSE. Remove the wrench and try to loosen the fill head. If it is hard to turn
by hand note that there is still pressure inside the tube. STOP removing the fill head.
Turn the tube over and use the air impact wrench to loosen the discharge head.
Do not attempt to impact the discharge head off 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
fill 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 CO2 and then open
the bleeder screw to verify that it can be emptied. If all the gas is properly relieved
the fill 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 firing cables at the time the tube is set and activation is
ready to be made.

9.10 Keep the blaster connection end of the firing 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 efficiently and misfires 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. verifies that there is a proper fit of the compo-
nents, and the approved tube is returned for use.

Page 17
Cardox Techical Manual

6. TROUBLESHOOTING

Problem Cause Solution

Pump cycles without "deadhead- CO2 bottle may not be connected. Check CO2 supply to insure liquid
ing." Bottle may not have siphon tube. is
Bottle is empty. 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 Low air pressure to pump. Adjust air pressure to 80–100
weight. PSI. The higher the air pressure
the greater volume of CO2 will 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. Follow procedure to prime
Pump not funcitioning. 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
fill line. Connect the fill line direct
to the pump stand assembly inlet
nipple. Use the liquid CO2 in the
bottle to chill the Cardox firing
tube,
bleed CO2 into and out of the fir-
ing tube until liquid CO2 is readily
discharged from the tube (two to
four cycles). Then, weigh tube to
insure proper weight.

Page 18
 Cardox Techical Manual

Problem Cause Solution

Bubbles appear when the dis- Bad seal between discharge head The head is not tight to the body.
charge the discharge head is and tube. Use the impact wrench, rattle the
placed under water. discharge head for additional tight-
ness and retest.

Bubbles appear when the fill head Bad seal between fill head and When bubbles originate from the
is placed under water originating tube. threaded connection of the head
from the connection between the to the tube body the fill head may
fill head and tube. not be tight to the body. Use the
impact wrench and rattle the fill
head for additional tightness. If
bubbles continue the copper
seat on the heater element is not
functioning properly. Bleed off the
tube, remove the fill 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 off 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 fill head Loose valve or bad seal in bleed When bubbles originate from
is placed under water, from the valve. the bleed off valve retighten with
bleed-off valve. 1/4"hex wrench. If leakage con-
tinues replace the bleed valve
assembly, recharge the tube and
retest.

Page 19
Cardox Techical Manual

Problem Cause Soulution

Bubbles appear when the fill head Bad seal in check valve assembly. When bubbles originate from the
is placed under water, originating check valve assembly, bleed off
from the auto-fill check valve. 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 fill head Loose electrical spindle assembly When bubbles originate from the
is placed under water originating or bad seal in electrical spindle electrical contact bleed off CO2 and
from the electrical contacts. assembly. remove fill head from tube. Torque
the electrical spindle nut to 30 ft/
lbs. Tighten fill head back onto
tube, recharge and re-inspect for
leaks. If leak continues bleed off
CO2 and remove fill 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 fill 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 Short circiut between electrical Replace electrical spindle as
than 1.00 ohm of resistance. spindle and fill head body. outlined in previous solution and
recharge tube and retest.

Continuity check indicatesan open Bad contact between electrical Bleed off CO2, remove fill head,
circuit (infinite resistance). spindle and heater wire lead. and inspect contacts between
the electrical spindle and heater
wire lead. Rebuild, refill tube and
retest.

Page 20
 Cardox Techical Manual

Problem Cause Solution

Tube misfires, cont. Defective Safety Heater. Bleed off CO2, remove fill head,
and remove bad heater and re-
place. Rebuild, refill tube and
retest.
Loss of continuity in circuit.
Check connections at blaster and
at fill head. If connected properly
check continuity through firing
wire. If continuity is correct see
solution for open circuit in previous
Low voltage from blasting unit. section.

Periodically test fire blaster prior to

use. If the "fire" light is dim re-
Low CO2 volume in charged tube. place the 9-volt battery and retest.

Low CO2 volume will result in

either an unburned heater or a
partially burned heater and a
unruptured shear disc. Rebuild,
recharge and reweigh to insure
correct volume of CO2. If still low
check the CO2 cylinder for a low
level. Replace cylinder if neces-
sary. If CO2 level in tank is fine
clamp the tube back into fill stand,
increase the pump input pressure
and recycle pump. Repeat this un-
til CO2 volume is above minimum
amount.

The shear disc may be bulged but

not sheared through. The cutting
shoulder on the discharge head
must be sharp and unpitted. If
edge is not sharp the shear disc
will bulge but not rupture. If cutting
shoulder is rounded send head to
Pneumat Systems for repair.

Page 21
 Cardox Techical Manual


5780-0005

Cardox Fill Stand

Assembly Parts List  

 



   

 
 
 

  
  

 
  

  

 
 
 
 
 
 
  
      
 
 
 








 
 
  
 

        


       


       



       

   

       

       

       

       

       

Page 22


 Cardox Techical Manual

8 5780-0004
7 Cardox 360° Vise
6 Diagram 5 4

13
19
D

18
14

17

1
C

21 11 10 4
20
6 15
16

12
B
9

3
8 7 6 6 5 4 3 2
5

REF PART NUMBER DESCRIPTION QTY. REF PART NUMBER DESCRIPTION QTY.
A 1 1145-0097 Body, Cardox Air Manifold (anodized) 1 12 5781-0054 Stand, CDX Vise 1
2 1215-0058 MOUNT PLATE, AIR VALVE 1 13 5781-0056 Impact Wrench Hanger 1
3 2200-0005 1/8" NPT Plug 1 14 5781-0083 Air Line-Impact Wrench 1
4 2200-0060 PLUG -6MB Plug 1 15 5781-0084 Air Line, Foot-Manifold 1
5 2500-0051 Air Valve 3-Way Foot Operated 1 16 5781-0085 Air Line Quick Exhaust 1
6 4210-0002 HHCS 3/8 x 3/4 4 17 5790-0007 1-1/2 x 3/4 Drive Socket 1
7 4210-0051 HHCS 5/8 x 2 4 18
8 7 65790-0014 3/4" Impact Wrench
5 w/Lift Assy 1 4
8 4210-0056 HHCS 5/16 x 2-1/4 2 19 5790-0015 Tool Balancer, 8' Travel 1
9 4215-0025 SHCS 1/4 x 3/4 2 20 5790-0017 Air Blowgun, with 25' hose 1
10 4230-0002 Nut, Whiz - 5/16 2 21 5780-0003 Cardox 360 Degree Vise 1
11 4230-0009 Hex Nut 5/8" 4

Page 23
Cardox Techical Manual

5780-0003 Cardox 360° Vise Parts List

8 7 6 5 4 3 2

13
12
9
20
19
24

11 7 17
5 8 3
10 14

23 16
15 20

21

6
25

26
22
27

4
1

18
UNLESS OTHERWISE SPECIFIED: NAME DATE

DIMENSIONS ARE IN INCHES DRAWN

TOLERANCES:
FRACTIONAL .063 CHECKED
7 6 5 4 3
ANGULAR: MACH 1° BEND 2° 2 1
TWO PLACE DECIMAL .030 TITLE:
THREE PLACE DECIMAL .010

Customer
Cardox 360 Degre
MATERIAL
SIZE DWG. NO.

REF PART NUMBER DESCRIPTION QTY. REF PART NUMBER

STOCK SIZE

DESCRIPTION
B QTY.
5780-0003
DO NOT SCALE DRAWING SCALE: 1:8 WEIGHT:
1 5781-0040 Outer Ring Assy, CDX Vise 1 15 5781-0043 Indexing Pin, CDX Vise 1
8 7 6 5 4 3 2
2 5781-0041 Inner Ring Assy, CDX Vise 1 16 4235-0010 Lock Washer 3/8" 2
3 1215-0036 Back Plate, CDX Vise 1 17 4210-0005 HHCS 1/2 x 1-1/4 8
4 1215-0038 Retainer Plate, CDX Vise 4 18 4210-0022 HHCS 5/16 x 1 12
5 1415-0010 Bushing, CDX Vise 1 19 5781-0048 Push Rod, CDX Vise (All) 1
6 1345-0003 Button, CDX Vise 28 20 4210-0026 HHCS 3/8 x 1 4
7 4235-0011 Lock Washer 1/2" 8 21 4215-0021 SHCS 5/16 x 1-1/2 2
8 4110-0013 Bushing, 1-1/2ID x 1-3/4OD x 3/4 1 22 4240-0016 Dowel Pin, 5/16" x 1" 2
9 2500-0050 Air Cylinder, 12.9" Firestone Airstroke 1 23 4260-0055 Spring, Comp 1
10 4260-0057 T-Handle, Plastic 1 24 4260-0053 Rivet, Countersunk Head 2
11 4260-0054 Return Spring, CDX Vise 1 25 5781-0045A Vise Jaw, 2-1/8 dia Coated, Inside Jaw 1
12 2200-0086 Adapter, 4MP x 4MP 1 26 5781-0045B Vise Jaw, 2-1/8 dia Coated, Outside Jaw 1
13 2500-0052 Quick Exhaust Valve, 1/4" NPT 1 27 4215-0008 SHCS 3/8 x 1 1
14 5781-0042 Indexing Nut, CDX Vise 1

Page 24
 Cardox Techical Manual

5730-0003

Auto Fill Activating

Head w/

Eyebolt Parts List 




 
 

  
 
 

  
 

  
 
 

 

 
  
 
 

  
  
 
 
  
 

  

   
   


       
       
       
       
       
       
    
       
       
       
       


Page 25
Cardox Techical Manual

Series 37 Cardox Consumable Sets


Parts List
     


 





 



 

   


   

       

Series 57 Cardox Consumable Sets

Parts List
       

  



 



 

   



   

Page 26
    
 Cardox Techical Manual
    

Series 3700 Firing Head, Tube Body & Discharge Head Parts List

 

  

   

  

  

  

  

  

   

      


 
  

   

   

    
    


   

   

   

   

   

    

Page 27
 Cardox Techical Manual

Series 5700 Firing Head, Tube Body & Discharge Head Parts List
    

 








 






      

    

       

       

  
    
    

       

       

       

       

       

Page 28
 Cardox Techical Manual


Quik-Lok Tube Clamp
     

Parts List- 5750-0004







   

   

   

      

 
      
  
  
   
 

Quik-Lok Base Socket & Plug 



 

Parts List- 5750-0001 



 

       

   

   

    

 

  
  
   
Page 29
 







Cardox Techical Manual

110 Mohr Drive • Mankato, MN 56001

Toll Free:....................................... (800) 458-9446

Phone:.......................................... (507) 345-4553
Fax:.............................................. (507) 345-3639
Website: ..................www.pneumat.com

©2004 Pneumat Systems, Inc. Mod Date: 2019/05/02 - 10:30

Revision G (4/30/19) Updated BOM pg.23 & 24 Output Date: 2019/05/02 - 10:31

Page 30 File Name: \\pneumat-nas\Engineering\Manuals\Cardox Manual\Current\Cardox Manual.indd