GB CO2 User Manual
IMPORTANT: RECEIVING INSTRUCTIONS: Visually inspect
all components for shipping damage. If any shipping damage is
found, notify carrier at once.
Shipping damage is NOT covered by warranty. The carrier is
responsible for all repair or replacement costs resulting from
damage in shipment.
Instruction
Sheet
CO2 CONDUIT
FISHING
SYSTEMS
IMPORTANT—USER SAFETY AND PROTECTION: In setting up systems to fit your operations, care must be taken to select the
proper components and design to insure appropriate integration with your operations and existing equipment and that all safety
measures have been taken to avoid the risk of personal injury and property damage from your application or system.
GB ELECTRICAL CANNOT BE RESPONSIBLE FOR DAMAGE OR INJURY CAUSED BY UNSAFE USE, MAINTENANCE OR
APPLICATION OF ITS PRODUCTS. Please contact GB ELECTRICAL for guidance when you are in doubt as to the proper safety
precautions to be taken in designing and setting up your particular application. To protect your warranty use only GB/Enerpac
hydraulic oil.
Model JO25C Power Pak II™ (5 lb. CO
2
System with Caddy)
Model JO25 Power Pak I™
Model JO250 Powr House™ (5 lb. CO
2
System)
(50 lb. CO
2
System)
Model JO220 Powr House™ (20 lb. CO2System) not shown.
INTRODUCTION
The GB/Jet Line Carbon Dioxide (CO
2
) Conduit Fishing Systems are high pressure tools which are used to place a pull line
in most conduit runs from
1
/2” through 6” diameter.
These systems are completely self-contained and no other
energy source is required. They are convenient to use in
remote locations and in new construction where there is no
temporary electrical power available or where only one or two
conduit runs are required.
Each system consists of five basic components:
• A high pressure gas (CO
2
) driving media.
• A control valve to start and stop the gas flow.
• Hose and seal-off to conduct the gas to the conduit and form
a seal at the conduit entrance.
• A line carrier to serve as a movable piston that supplies the
pulling force.
• Pull line for pulling wire through the conduit or to pull in a
rope or cable for large difficult runs.
A thorough understanding of all components and their function
and operating precautions is essential for safe and efficient use
of the system.
Read all of the instructions before attempting to use the system
or blow line in the Conduit.
IMPORTANT SAFETY INSTRUCTIONS
Wear a hard hat, eye
protection, and gloves.
When using a carbon dioxide
conduit fishing system basic
precautions should always
be followed. FAILURE TO OBSERVE THESE INSTRUCTIONS COULD RESULT IN SERIOUS INJURY OR DEATH.
Do not discharge a cylinder
containing carbon dioxide
(CO
2
) in a non-ventilated
manhole or other non-ventilated areas. Carbon dioxide is relatively inert, but is heavier than air and will displace it and accumulate in depressions and along the floor. Concentrations of
10% (100,000 ppm) can produce unconsciousness and death
from oxygen deficiency. Concentrations of 5% may produce
shortness of breath and headaches. Provide adequate
ventilation.
When operating a CO
2
System,
do not direct the high pressure
CO
2
stream towards any part of
the body; serious injury or possible death could occur.
All GB/Jet Line Systems are
designed to force loose debris
of all types out of the conduit by
means of a pressurized force. Serious or critical injury could
occur to anyone struck by high velocity exiting debris or the line
carrier. Warn all personnel to stand clear of the conduit exit prior
to commencing pressurization, flush-out procedures, or blowing
line into the conduit.
Do not hold the seal-off by therubber cone when discharging
CO
2
. Maintain a firm grip on
the seal-off hose and operating valve at all times while discharging CO
2
. The high velocity jet of CO2causes a recoil force, and
the free end of the hose could whip around possibly causing
injury or damage to equipment.
During use, portions of the
cylinder, valve, hose and seal-
off will become very cold as
may be noted by frost forming on these parts. Do not touch these
areas with bare hands. If bare hands become frozen to the frosted parts, do not pull away–run water over hand and metal part to
free it.
When transporting a GB/Jet
Line 5 Ib. CO
2
System, remove
the seal-off and hose assembly, install the safety pin in the valve handle, and screw down the
handle regulating screw to hold the safety pin in place.
Always make sure the 20 Ib.
and 50 Ib. CO
2
cylinders are
securely strapped to the cart to
prevent overturning and damage to the cylinder and valve.
When not in use or while being transported, close the cylinder
valve on 20 Ib. and 50 Ib. cylinders, depressurize operating hose
assembly and remove it from the cylinder to prevent accidental
discharge. Replace the screw on valve cover on 50 Ib. cylinders.
With excessive or constant use,
the liquid CO
2
in the cylinder
may freeze solid into dry ice,
the pressure in the cylinder may drop to zero, and the gas may
not flow. If this occurs, allow the cylinder to thaw out at room temperature; the pressure will return to normal. Do not apply heat to
the cylinder to speed up thawing. This could raise the cylinder
pressure to an excessively high level, causing the cylinder valve
safety disc to rupture and discharge the cylinder contents.
If the safety disc ruptures, have it replaced at an authorized fire
extinguisher service center, or replace it with a single GB/Jet Line
safety disc.
IMPORTANT: Use commercial grade CO
2
only when refilling the
CO
2
cylinder. Never, under any circumstances, substitute any
gas other than carbon dioxide (CO
2
). The cylinder is pressure
rated for CO
2
only.
Use only a GB/Jet Line System. GB has incorporated safety features into the CO
2
system; orifice flow restrictions, adjustable flow
regulation, low temperature pressure rated hose, and a rupture
disc pressure relief system.
Do not substitute any parts or accessories not manufactured by
GB/Jet Line on your CO
2
system.
Have the cylinders hydrostatically pressure tested by a qualified
local fire extinguisher service center at two year intervals. Under
no circumstances should the hydrostatic test intervals exceed
five years.
Observe all federal, state and local codes concerning handling,
transporting and storing of compressed gas cylinders.
CARBON DIOXIDE (CO2)
Carbon dioxide may exist in three physical states; solid (dry ice at
-109° F), liquid (under pressure) or gaseous CO
2
. Only the liquid
and gaseous states are useful in conduit fishing.
Carbon dioxide is normally stored in cylinders in liquid form under
pressure (838 P.S.I. at 70°F). It will rapidly turn into a high pressure, high velocity gas when the cylinder or operating hose valve
is opened. It is this high pressure, high velocity gas that is used
to drive the line carrier through the conduit. During the expansion
process, portions of the cylinder, valve, hose, and seal-off will
become very cold as may be visibly noted by frost forming on
these components.
Wear gloves, do not touch
these areas with bare hands.
Bare hands may become
frozen to the metal parts.
GB/JET LINE CO2 CYLINDERS
GB/Jet Line supplies three sizes of CO
2
Cylinders, 5, 20, and 50
Ibs., meeting U.S. Department of Transportation (DOT) requirements for compressed gas. Each cylinder bears a neck stamp
showing a DOT number indicating the maximum allowable working pressure, serial number, manufacturers identification code,
and date of manufacture.
The 5, 20, and 50 Ib. sizes indicate the weight in pounds of liquid
CO
2
that the cylinder will hold. CO2cylinders are supplied filled
and ready for use. When a cylinder becomes empty, it may be
refilled by most authorized fire extinguisher service centers. The
5 Ib. CO
2
cylinders may be refilled from the 50 Ib. CO2cylinder.
A refill connector Model RV5 is required for this operation. See
the refilling instructions on page 6.
Do not refill the CO
2
cylinders
with air, nitrogen or other
gasses. The cylinder is pressure rated for CO
2
use only.
Hydrostatic Pressure Testing –CO2cylinders returned to GB/
Jet Line for service or repair will be hydrostatically pressure tested for safety if the latest date stamp is more than two years old.
When a cylinder passes the hydrostatic pressure test, the month
and year shall be stamped on the cylinder by the approved testing center. Cylinders failing the pressure test must be destroyed.
2
CO2 Cylinder Specifications
Model No. 1103N 1208 950
Cyl. Size 5 Ib. 20 Ib. 50 Ib.
Weight (full) * 14 Ibs. 55 Ibs. 154 Ibs.
Weight (empty) * 9 Ibs. 35 Ibs. 104 Ibs.
Weight (CO
2
) 5 Ibs. 20 Ibs. 50 Ibs.
Diameter * 5” 8” 9”
Height* 17
1
/2” 27” 51”
Valve Type Squeeze Rotary Rotary
Valve Coupling Ball Lock Threaded Threaded
Pressure (70°F) 838 P.S.I. 838 P.S.I. 838 P.S.I.
Maximum Cylinder See DOT 3 AA rating
Working Pressure stamped on cylinder neck
* Dimensions and empty weight of the cylinder may vary slightly,
depending on cylinder manufacturer.
Model 1103N 5 Ib. CO2 Cylinder – The 1103N, 5 Ib. CO
2
cylinder, is used in both Power Pak I and Power Pak ll conduit fishing
kits.
The cylinder is equipped with a "squeeze to operate" hand valve.
A thumb screw is used to limit the operating handle movement
and regulate the amount of CO
2
dispensed. Adjusting the screw
will permit a mere trickle of CO
2
and backing out further will permit full handle travel and
a full flow of CO
2
(Refer
to Figure 1).
A safety pin inserted
through the handle and
valve body prevents the
handle from being
depressed accidentally. The
pin should always
be in place when the cylinder is not in use or when
the cylinder is being
transported.
A ball lock quick coupling is
provided for attaching sealoff Model 1215 or 1216.
Model 1208 20 Ib. CO2 Cylinder –
The model 1208, 20 Ib. cylinder, is
a cart-transported cylinder weighing approximately 55 Ibs. when
fully charged with 20 Ibs. of CO
2
.
This cylinder should always remain
strapped in the cart to prevent
overturning and damage to the
cylinder or valve.
The cylinder has a rotary hand
valve with a special port thread.
The valve requires a matching coupling nut and stem with an O-ring
face seal as supplied on Model
1105 CO
2
Operating Valve and
Hose Assembly (Refer to Figure 2
and 9).
Model 950 50 Ib. CO2 Cylinder– The model 950, 50 Ib. CO
2
cylinder, is a cart transported
cylinder weighing approximately
154 Ibs. when fully charged with
50 Ibs. of liquid CO
2
(Refer to
Figures 3 and 9).
The cylinder is equipped with a
rotary hand valve with a special
port thread. The valve requires
a matching coupling nut and
stem with an O-ring face seal
as supplied on the Model 1105
CO
2
Operating Valve and Hose
Assembly.
A screw on valve safety cover is
supplied with the cylinder and
should always be in place when
the cylinder is not in use or while
the cylinder is being transported.
The 50 Ib. cylinder may be used
as a field refilling supply tank for
the 5 Ib. cylinder if desired. See
refilling instructions on page 6.
USE AND OPERATION
With the GB/Jet Line CO
2
system, gas generated from the liquid
CO
2
stored in the cylinder is used to propel the line carrier
and pull line through the conduit.
When using the CO
2
system, adjust the flow regulating screw on
the “squeeze to operate” valve handle on the 5 Ib. cylinder or on
the 1105 valve and hose assembly. Regulate the flow to a moderate amount sufficient to keep the line carrier moving and the
line flowing into the conduit. Develop a light touch and conserve
CO
2
(Refer to Figure 4).
The valve handle is very easy to
operate when the regulating
screw is backed out. Do not
attempt to force the handle or damage to the screw and handle
could occur.
There is substantial force when
the valve is operated and CO
2
is
discharged in open air. Point the
nozzle in a safe direction and maintain a firm grip on the seal-off
frost guard and valve.
Where conduit is run under
ground; it may contain water or
be subjected to flooding. It may
be desirable to blow the water out before blowing a line in the
conduit. Because the water will be blown out ahead of the line
carrier, take precautions to protect nearby equipment that could
be damaged by moisture and sludge (Refer to Figure 16).
3
Figure 1
1103N 5 Lb. CO
2
Cylinder
Figure 2
1208 20 Lb. CO
2
Cylinder
Figure 3
950 50 Lb. CO
2
Cylinder
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