CLEMCO CMS 3 Carbon Monoxide Monitor, Apollo 20, 60, 600 Respirator User manual

CMS-3
IN-HELMET CARBON MONOXIDE MONITOR
O. M. 24658
DATE OF ISSUE:
REVISION:
January 2011
C, 10/13
WARNING
Do not proceed with
these instructions*
until you have READ
the orange cover of
this MANUAL and YOU
UNDERSTAND its
contents.
© 2013 CLEMCO INDUSTRIES CORP.
One Cable Car Dr.
Washington, MO 63090
Phone (636) 239-4300
Fax (800) 726-7559
Email: [email protected]
www.clemcoindustries.com
These WARNINGS are
included for the health
and safety of the
operator and those in
the immediate vicinity.
*If you are using a Clemco Distributor
Maintenance and Part Guide, refer to
the orange warnings insert preceding
the Index before continuing with the
enclosed instructions.
Electronic files include a Preface
containing the same important
information as the orange cover.
PREFACE
• Employers are responsible for identifying all job site hazards, educating and training all persons who will operate and
maintain these products, and ensuring that all blast operators and their assistants understand the warnings and
information contained in these instructions relating to safe and proper operation and maintenance of this equipment.
• Serious injury or death can result from failure to comply with all Occupational Safety and Health Administration
(OSHA)regulations and all manufacturer’s instructions.
• This equipment is not intended for use in any area considered hazardous per National Electric Code NFPA 70 2011,
Article 500.
• Read this document and follow all instructions before using this equipment.
OSHA regulations relating to abrasive blasting are contained in the Code of Federal Regulations, Title 29 (29 CFR 1910 General Industry;
1915 Maritime; 1926 Construction). The most pertinent include: 1910.94 Ventilation, 1910.95 Occupational Noise Exposure, 1910.132
Personal Protective Equipment, 1910.133 Eye and Face Protection, 1910.134 Respiratory Protection, 1910.135 Head Protection,
1910.244 (b) Remote Controls. Consult www.osha.gov for complete information.
NOTICE TO PURCHASERS AND USERS OF OUR
PRODUCTS AND THIS INFORMATIONAL MATERIAL
GENERAL INSTRUCTIONS
This material describes some, but not all, of the major
requirements for safe and productive use of blast machines,
remote controls, respirator systems, and related accessories.
All equipment and accessories must be installed, tested,
operated and maintained only by trained, knowledgeable,
experienced users.
Clemco proudly provides products for the abrasive blast
industry and is confident that industry professionals will use
their knowledge and expertise for the safe and efficient use of
these products.
The blast operator and all workers in the vicinity must be
properly protected from all job site hazards including those
hazards generated by blasting.
The products described in this material, and the information
relating to these products, are intended for knowledgeable,
experienced users.
Work environments involving abrasive blasting present
numerous hazards. Hazards relate to the blast process from
many sources that include, but are not limited to, dust
generated by blasting or from material present on the surface
being blasted. The hazards from toxic materials may include,
but are not limited to, silica, cyanide, arsenic, or other toxins
in the abrasives or in the coatings, such as lead or heavy
metals. Other hazards from toxins include, but are not limited
to, fumes from coating application, carbon monoxide from
engine exhaust, contaminated water, chemicals or asbestos.
In addition, physical hazards that may be present include, but
are not limited to, uneven work surfaces, poor visibility,
excessive noise, and electricity. Employers must identify all
job site hazards and protect workers in accordance with
OSHA regulations.
No representation is intended or made as to: the suitability of
the products described here for any purpose or application, or
to the efficiency, production rate, or useful life of these
products. All estimates regarding production rates or finishes
are the responsibility of the user and must be derived solely
from the user’s experience and expertise, not from information
contained in this material.
It is possible that the products described in this material may
be combined with other products by the user for purposes
determined solely by the user. No representations are
intended or made as to the suitability of or engineering
balance of or compliance with regulations or standard practice
of any such combination of products or components the user
may employ.
Never modify Clemco equipment or components or
substitute parts from other manufacturers for any Clemco
components or parts. Any unauthorized modification or
substitution of supplied-air respirator parts violates OSHA
regulations and voids the NIOSH approval.
Abrasive blast equipment is only one component of an
abrasive blasting job. Other products, such as air
compressors, air filters and receivers, abrasives, scaffolding,
hydraulic work platforms or booms, equipment for lighting,
painting, ventilating, dehumidifying, parts handling, or
specialized respirators or other equipment, even if offered by
Clemco, may have been manufactured or supplied by others.
The information Clemco provides is intended to support the
products Clemco manufactures. Users must contact each
manufacturer and supplier of products used in the blast job for
warnings, information, training, and instruction relating to the
proper and safe use of their equipment.
IMPORTANT
Contact Clemco for free booklets:
Blast Off 2 – Guide to Safe, Productive, and Efficient Abrasive
Blasting, and Abrasive Blasting Safety Practices – Guide to Safe
Abrasive Blasting.
Clemco Industries Corp. One Cable Car Drive Washington MO 63090
Tel: 636 239-4300 — Fax: 800 726-7559
Email: [email protected]
Website: www.clemcoindustries.com
[ I ] PREFACE
OPERATIONAL INSTRUCTIONS
OPERATOR SAFETY EQUIPMENT

OSHA regulation 1910.134 requires appropriate respiratory protection for blast operators and workers in
the vicinity of blasting. These workers must wear properly-fitted, properly-maintained, NIOSH-approved,
respiratory protection that is suitable for the job site hazards. Blast respirators are to be worn only in
atmospheres not immediately dangerous to life or health from which wearers can escape without use of
the respirator.

The employer must develop and implement a written respiratory protection program with required
worksite- specific procedures and elements for required respirator use. The employer must provide
effective training to employees who are required to use respirators. The training must be comprehensive,
understandable, and recur annually, and more often if necessary.

NEVER use abrasives containing more than one percent crystalline silica. Fatal diseases, such as silicosis,
asbestosis, lead or other poisoning, can result from inhalation of toxic dusts, which include, but are not
limited to, crystalline silica, asbestos, and lead paint. Refer to NIOSH Alert 92-102; and OSHA CPL 03-00-007:
“National Emphasis Program – Crystalline Silica”, in which OSHA describes policies and procedures for
implementing a national emphasis program to identify and reduce or eliminate health hazards from exposure
to crystalline silica. Numerous topics associated with the hazards of crystalline silica in silica blasting sand
can be found on http:// osha.gov/. Clemco urges users of silica blasting sand to visit this website, and read
and heed the information it contains.

Always make sure the breathing air supply (respirator hose) is not connected to plant lines that supply
gases that include, but are not limited to, oxygen, nitrogen, acetylene, or other non-breathable gas. Never
modify or change respirator air line connections without first testing the content of the line for safe
breathing air. Failure to test the line may result in death to the respirator user.
• Breathing air quality must be at least Grade D,
as defined by the Compressed Gas Association
specification G-7.1, per OSHA Regulation 29 CFR
1910.134. When compressed air is the breathing air
source, a Clemco CPF (suitable sorbent bed filter)
should be used. Respirator hose connecting the
respirator to the filter must be NIOSH approved.
Non- approved hose can cause illness from
chemicals employed to manufacture the hose.
• All workers must always wear NIOSH-approved
respirators when any dust is present. Exposure to
dust can occur when handling or loading abrasive,
blasting, cleaning up abrasive, or working in the
vicinity of blasting. Before removing the respirator,
test the air with a monitoring device to ensure it is
safe to breathe.
• Clemco respirators DO NOT remove or protect against
carbon monoxide or any other toxic gas. Monitoring
devices must be used in conjunction with the respirator to
ensure safe breathing air. Always locate compressors and
ambient air pumps where contaminated air will not enter
the air intake.
• Always use Clemco lenses with Clemco respirators;
installing non-approved lenses voids the NIOSH approval.
Respirator lenses are designed to protect the wearer from
rebounding abrasive; they do not protect against flying
objects, heavy high-speed materials, glare, liquids, or
radiation.
INDUSTRY ORGANIZATIONS
For additional information, consult:
Occupational Safety and Health Administration (OSHA) - www.osha.gov
Compressed Gas Association (CGA) - www.cganet.com
The Society for Protective Coatings (SSPC) - www.sspc.org
National Association of Corrosion Engineers (NACE) - www.nace.org
American Society for Testing and Materials (ASTM) - www.astm.org
National Institute of Occupational Safety and Health (NIOSH) - www.niosh.gov
American National Standards Institute (ANSI) - www.ansi.org
[ II ] PREFACE
BLAST MACHINES AND REMOTE CONTROLS
OSHA regulation 1910.169 describes the necessity of pressure relief valves on compressed air equipment. Do not
operate blast machines with air compressors that are not equipped with properly functioning pressure relief valves.
OSHA regulation 1910.244(b) requires the use of remote controls on blast machines.
Serious injury or death can result from many sources, among them:
 Involuntary activation of the remote controls. Never modify or substitute remote control parts; parts are not
compatible among different manufacturers. Welding hose is not suitable for remote control hose. Its ID and material
composition make it unsafe for remote control use.
 Exceeding the maximum working pressure. Clemco blast machines are built to ASME-code and carry a ‘U’ or ‘UM’
stamp, and National Board/serial number. Every machine is marked with its maximum working pressure. Never
exceed the maximum working pressure limits of the blast machine.
 Uncontrolled blast stream. High-velocity abrasive particles will inflict serious injury. Always point the blast nozzle
in the direction of the blast surface only. Keep unprotected workers out of the blast area.
 Welding on the blast machine. Never weld on the blast machine; welding voids the National Board approval and
may affect the dimensional integrity of the vessel.
 Moving the blast machine. Never manually move a blast machine containing abrasive, any machine containing
abrasive must be moved with appropriate mechanical lifting equipment.
HOSES, COUPLINGS, AND NOZZLE HOLDERS
 The inside diameter (ID) of air hoses, fittings, and connections
should be at least four times larger than the nozzle orifice size. Blast
hose ID should be three to four times the size of the nozzle orifice.
Example: a #6 nozzle (3/8” diameter orifice) calls for 1-1/2” ID blast
hose and 1-1/2” ID or larger compressor hose. All hose runs should be
kept as short as possible and run in as straight a line as possible to
reduce pressure loss.
 To install, squarely cut the end of the hose so that it fits snugly
against the coupling or hose end shoulder. Always use the screws
recommended by the manufacturer ensuring that they do not
penetrate the inner wall. Make sure the couplings tightly fit the hose.
Install cotter pins at every connection or use couplings with built-in
lock-springs to prevent disengagement. Install safety cables at all
connections to prevent whipping if hoses disengage or blow out.
MAINTENANCE AND REPAIR
 Completely read and follow all service instructions and recommended maintenance intervals. Always shut off compressor and
depressurize blast machine before performing any maintenance. At every service interval, clean all filters, screens, and alarm systems. If
spring-loaded abrasive valves are used, always cage spring before disassembly.
WARRANTY
The following is in lieu of all warranties, express, implied or statutory, and in no event shall seller or its agents, successors, nominees or
assignees, or either, be liable for special or consequential damage arising out of a breach of warranty. This warranty does not apply to any damage or
defect resulting from negligent or improper assembly or use of any item by the buyer or its agent or from alteration or attempted repair by any person
other than an authorized agent of seller. All used, repaired, modified, or altered items are purchased “as is” and with all faults. In no event shall seller
be liable for consequential or incidental damages. The sole and exclusive remedy of buyer for breach of warranty by seller shall be repair or
replacement of defective parts or, at seller’s option, refund of purchase price, as set forth below
:
1. Seller makes no warranty with respect to products used other than
in accordance hereunder.
2. On products seller manufactures, seller warrants that all products are to
be free from defects in workmanship and materials for a
period of one year from date of shipment to buyer, but no warranty is
made that the products are fit for a particular purpose.
3. On products which seller buys and resells pursuant to this order, seller
warrants that the products shall carry the then standard warranties of the
manufacturers thereof, a copy of which shall be made available to the
customer upon request.
4. The use of any sample or model in connection with this order is for
illustrative purposes only and is not to be construed as a warranty that the
product will conform to the sample or model.
5. Seller makes no warranty that the products are delivered free of the
rightful claim of any third party by way of patent infringement or the like.
[ III ] 6. This warranty is conditioned upon seller’s receipt within ten (10)
days after buyer’s discovery of a defect, of a written notice stating in
what specific material respects the product failed to meet this
warranty. If such notice is timely given, seller will, at its option, either
modify the product or part to correct the defect, replace the product or
part with complying products or parts, or refund the amount paid for
the defective product, any one of which will constitute the sole liability
of the seller and a full settlement of all claims. No allowance will be
made for alterations or repairs made by other than those authorized
by seller without prior written consent of seller. Buyer shall afford
seller prompt and reasonable opportunity to inspect the products for
which any claim is made as above stated.
Except as expressly set forth above, all warranties, express, implied
or statutory, including implied warranty of merchantability, are
hereby disclaimed.
PREFACE
DAILY SET‐UP CHECK LIST 2. Breathing Air Compressor for
High Pressure Respirators 3. NIOSH Approved
Supplied-Air Respirator
1. Air Compressor
6. ASME Code
Blast Machine
8. Remote
Controls
or Ambient Air Pump for
Low Pressure Respirators 7. Air Line
Moisture
Separator
12. Abrasive
11. Appropriately Sized Nozzle
4. External or
Helmet Mounted
Carbon Monoxide
Monitor /Alarm
5. CPF Air Filter
9. Blast Hose
10. Hose Couplings and Safety Cables
Make sure all blast operators are properly trained and suitably attired with a blast suit, safety boots, leather gloves, respiratory and hearing protection. Every day before start up,
check all equipment components, including piping, fittings, and hoses, and valves, for leaks, tightness, and wear. Repair or replace as needed. Use the following checklist.
1. PROPERLY-MAINTAINED AIR COMPRESSOR sized to provide
sufficient volume (cfm) at given pressure for nozzle and other tools. ADD 50%
volume (cfm) reserve to allow for nozzle wear. Use large compressor outlet and
air hose (at least 4 times the nozzle orifice diameter). For oil-lubricated
compressors, the employer shall use a high- temperature or carbon monoxide
alarm, or both, to monitor carbon monoxide levels. If only high-temperature
alarms are used, the air supply shall be monitored at intervals sufficient to
prevent carbon monoxide in the breathing air from exceeding 10 ppm. Follow
the manufacturer’s checklist and maintenance instructions.
2. BREATHING-AIR COMPRESSOR (or oil-less ambient air pump)
capable of providing Grade D quality air, located in a dust free area. Read # 1
above.
3. CLEAN, PROPERLY-MAINTAINED NIOSH-APPROVED SUPPLIED-AIR
RESPIRATOR worn by blast operators, and other workers exposed to blast dust.
Make sure all respirator components are in place — all lenses, inner collar, and
cape. Thoroughly inspect all components for wear. The NIOSH approval (approval
number is listed in the owner’s manual) is for a complete assembly from point of
attachment on the CPF (sorbent bed) filter to the complete respirator. Substitution of
any part voids the NIOSH approval.
4. CARBON MONOXIDE MONITOR/ALARM installed at the CPF filter or
inside the supplied-air respirator for monitoring for the presence of deadly CO gas
and warning the operator(s) when the CO level reaches an unacceptable level.
When an ambient air pump is used for breathing air, a CO monitor provides a
measure of safety. Read # 1 above.
7. AIR LINE FILTER (moisture separator) installed as close as possible to the
blast machine inlet and sized to match the size of the inlet piping or larger air supply
line. Clean filter and drain often. Damp abrasive causes operational problems.
8. REMOTE CONTROLS are required by OSHA and must be in perfect
operating condition. Test and check all components to ensure all parts are present
and fully functional. Use genuine replacement parts. NEVER mix parts from different
manufacturers. Never use welding hose for remote control hose.
9. BLAST HOSE should have an inside diameter sized to suit the blast nozzle.
The ID should be three to four times the size of the nozzle orifice diameter. Blast hose
should be arranged in as straight a line as possible from the blast machine to the
work area, avoiding sharp bends.
10. COUPLINGS AND NOZZLE HOLDERS should fit snugly on the hose and
be installed with manufacturer recommended screws. Coupling lugs must snap firmly
into locking position. Gasket must always be used to form a positive seal, and cotter
pins must be installed. Replace gasket when wear, softness or distortion is detected.
Check nozzle holder for thread wear; replace at any sign of wear. Install safety cables
at all connections.
11. NOZZLE orifice size should be checked and nozzle replaced when worn
1/16” from original size. (No. 5 nozzle has 5/16” orifice diameter; replace when it
measures 3/8”). Threads should be inspected daily for wear and nozzle should be
replaced when wear is detected. Always use a nozzle washer.
5. BREATHING-AIR FILTER (OSHA-REQUIRED sorbent bed filter) for
removal of moisture and particulate matter in the compressed air breathing-air
supply. Monitor the condition of the cartridge and replace when odor is detected or
at 3 month intervals, whichever comes sooner. The breathing air filter does NOT
detect or remove carbon monoxide (CO). Always install a CO monitor/alarm.
12. ABRASIVE must be a material specifically manufactured for blasting. It
should be properly sized for the job. Check material safety data sheet for freesilica, cyanide, arsenic, lead and other toxins and avoid use when these toxic,
harmful substances are present.
6. BLAST MACHINE (bearing U or UM stamp, National Board Number, and
Maximum Working Pressure) sized to hold a 30-minute abrasive supply. Examine
pop-up valve for alignment. Check piping, fittings, screens, valves for tightness,
leaks, and wear. Always ground the machine to eliminate hazard of static shock.
Install a blast machine screen to keep out foreign objects. Use a blast machine
cover if left outdoors overnight. Never exceed the maximum working pressure of the
vessel.
SURFACE TO BE BLASTED should be examined for hazardous substances.
Take appropriate protective measures as required by OSHA to ensure the blast
operator, other workers in the vicinity, and any bystanders are properly protected.
©Clemco Industries Corp., Stock No. 20954P, 0692 Rev. F, 06/12
[ IV ] CMS-3 IN-HELMET CARBON MONOXIDE MONITOR
1.0
INTRODUCTION
1.1
Scope of Manual
1.1.1 These instructions cover operation, maintenance,
troubleshooting and replacement parts for the CMS-3
Respirator-Mounted Carbon Monoxide (CO) Monitor.
1.1.2 The monitor is intended to detect the presence
of CO inside Apollo supplied-air respirators, where the
maximum CO exposure limit in the USA is 10 parts per
million (ppm). This is the limit set to meet the
requirement for Grade D quality breathing air. The
monitor also has short-term exposure limit (STEL) and
time-weighted average (TWA) features that enable its
use as an ambient air monitor. Instructions on toggling
through the STEL and TWA are explained in Section 3.3.
WARNING
Warning indicates a potentially hazardous
situation which, if not avoided, could result in
death or serious injury.
DANGER
Danger indicates an imminently hazardous
situation which, if not avoided, will result in
death or serious injury.
1.3
Table of Contents
Topic
1.1.3 All respirator users and those responsible for
maintenance and calibration of the monitor must read
and understand this manual before using the respirator
or operating with the monitor.
1.1.4 NIOSH (National Institute of Occupational Safety
and Health) has approved the use of the CMS-3 with
Clemco respirator models Apollo 20, 60, and 600.
1.2
Safety Alerts
1.2.1 Clemco uses safety alert signal words, based on
ANSI Z535.4-1998, to alert the user of a potentially
hazardous situation that may be encountered while
operating this equipment. ANSI’s definitions of the signal
words are as follows:
This is the safety alert symbol. It is
used to alert the user of this equipment
of potential personal injury hazards.
Obey all safety messages that follow this symbol to
avoid possible injury or death.
CAUTION
Caution used without the safety alert symbol
indicates a potentially hazardous situation
which, if not avoided, may result in property
damage.
CAUTION
Caution indicates a potentially hazardous
situation which, if not avoided, may result in
minor or moderate injury.
Page 1
Page
Section
Specifications .......................................... 2 ............. 1.4
Description of Operation .......................... 2 ............. 1.5
Ancillary Equipment Requirements ......... 2 ............. 1.6
Components and Functions ................. 2 .............. 1.7
Case .................................................... 2 .......... 1.7.1
Sensor Cap and Sensor Cover ........... 2 .......... 1.7.2
Charcoal Filter Disc ............................ 2 .......... 1.7.3
Sensor ................................................ 2 .......... 1.7.4
LCD ..................................................... 3 .......... 1.7.5
Control Buttons ................................... 3 .......... 1.7.6
Alarm Lights ........................................ 3 .......... 1.7.7
Audible Alarm ..................................... 3 .......... 1.7.8
Vibrator Alarm ..................................... 3 .......... 1.7.9
Lithium Battery (a spare is included) ... 4 ........ 1.7.10
Setup, Start Up and Operation
Installation in Apollo 20 ........................ 4 ............ 2.1.1
Installation in Apollo 60 and Apollo 600 4............ 2.1.2
Turning ON and Start-up Procedure .... 5 .............. 2.2
Performing a Fresh Air Adjustment ..... 5 ........... 2.2.4
Process shown under calibration
Turning Off the CMS-3 ......................... 5 .............. 2.3
Operation
Measuring Mode .................................. 5 .............. 3.1
Displaying Peak Gas Concentrations .. 5 .............. 3.2
Displaying STEL, & TWA ..................... 6 .............. 3.3
Alarms .................................................. 6 .............. 3.4
Responding to Alarms ......................... 6 .............. 3.5
Displaying and Setting Alarm Points ... 8 .............. 3.6
Setting the Clock .................................. 9 .............. 3.7
Calibration
Setting the Fresh Air Reading ............. 9 .............. 4.1
Calibration .......................................... 10 .............. 4.2
Maintenance
Replacing the Lithium Battery ............ 10 .............. 5.1
Replacing the Sensor ........................ 11 .............. 5.2
Replacing the Sensor Cover .............. 12 .............. 5.3
Replacing the Charcoal Filter Disk .... 12 .............. 5.4
Troubleshooting ...................................... 13 .............. 6.0
Accessories and Replacement Parts ..... 14 .............. 7.0
© 2013 CLEMCO INDUSTRIES CORP.  www.clemcoindustries.com  Manual No. 24658, Rev. C
CMS-3 IN-HELMET CARBON MONOXIDE MONITOR
1.4
1.5
Specifications
Target Gas .................Carbon Monoxide (CO)
Detection Range ........................ 0 to 500 ppm
Display Increment ................................. 1 ppm
CO Sensor ...........................Electro Chemical
Alarm Point, Low ................................. 10 ppm
Alarm Point, High ................................ 10 ppm
Description of Operation
WARNING
The CMS-3 detects carbon monoxide which can
be life threatening. When using the CMS-3,
follow the instructions and warnings in this
manual to assure proper and safe operation of
the unit and to minimize the risk of personal
injury. Carbon monoxide poisoning could result
in death or serious injury.
1.5.1 The
CMS-3
respirator-mounted
carbon
monoxide monitor detects the presence of carbon
monoxide (CO) inside a supplied-air respirator.
1.5.2 The current maximum exposure limit in the USA
for carbon monoxide in Grade D compressed breathing
air is 10 parts per million (ppm). Users outside the USA
should determine their local requirements and set the
alarm threshold to their maximum PEL per Section 3.6. If
CO concentrations reach the exposure limit, three
alarms occur. The audible alarm beeps twice per
second, the alarm lights flash twice per second, and the
unit vibrates. If an alarm occurs, remove the respirator
as soon as it is safe to do so.
1.5.3 The CMS-3 offers a full range of features,
including:
 Digital liquid crystal display (LCD)
 Visual, audible, and vibrating alarms
 Low battery alarm
 Sensor fail alarm
 Current time display
 Over 3,000 hours of operation from 1 battery
 CSA classified for Class I, Division I, Groups A, B,
C, and D hazardous atmospheres
 * Peak, STEL, and TWA indication
 * STEL, TWA, and over range alarms
*Refer to notation in Paragraph 1.5.4, regarding
usage of STEL and TWA. Refer to Section 3.2 for
information on the Peak Display.
1.5.4 TWA and STEL: TWA is an acronym for timeweighted average, and it is the average reading of CO
during the last eight hours. STEL is an acronym for
short-term exposure limit, and it is the average reading
of CO during the last 15 minutes. Although some may
find TWA and STEL information useful, it is not pertinent
Page 2
for supplied-air respirator use, because the maximum
exposure limit for Grade D breathing air is 10 ppm.
1.6
Ancillary Equipment Requirements
1.6.1 In addition to the monitor, the following
equipment is required to operate and maintain the CMS3 Monitor.
 Calibration connector with tubing and calibration
cup: Stock No. 25572.
 25 PPM Test Gas: Stock No. 25573.
1.7
Components and Functions
The components include the case, sensor cap, sensor
cover, charcoal filter disk, sensor, LCD, control buttons,
printed circuit boards, alarm lights, audible alarm,
vibrator, and lithium battery. Callouts shown in Figure 1
are items needed to perform routine functions.
1.7.1 Case: The digital LCD is visible through the top
case. It displays gas concentrations, battery level, time,
and other readings including TWA, STEL, and peak gas
levels. Below the LCD are two black control buttons. The
button on the left is labeled POWER/MODE. The button
on the right is labeled AIR. To the left of the LCD is the
audible alarm, which is located inside the case. To the
right of the LCD is the sensor cap which retains the
sensor. Above the LCD is a lens through which the
alarm lights are visible. The battery cover is located on
the back of the case and is held in place by two screws.
1.7.2 Sensor Cap and Sensor Cover: The sensor
cap snaps onto the right side of the case and retains the
sensor. It also retains the sensor cover which is a round
hydrophobic disk membrane which protects the sensor
from dirt and elements. A molded gasket installed on the
sensor, seals the sensor, sensor cover, and sensor cap.
1.7.3 Charcoal Filter Disk: A charcoal filter disk is
located in a recessed area of the sensor gasket beneath
the sensor cover. The charcoal filter disk removes gases
from the sampled air that will cause a response on the CO
sensor, gases such as hydrogen sulfide (H2S) and certain
hydrocarbons. If false or elevated CO readings are
noticed, especially in the presence of H2S, change the
charcoal filter disk. Refer to the maintenance Section 5.4.
1.7.4 Sensor: The sensor is protected by the white
sensor cover which is held in place by the sensor cap
and sensor gasket. The sensor cover allows air to
diffuse past it to the sensor. A gas permeable membrane
covers the sensor face and allows gas to diffuse into the
sensor. The gas reacts in the sensor and produces a
current proportional to the concentration of carbon
monoxide. The current is amplified by the CMS-3’s
circuitry, converted to a measurement of gas
concentration, and displayed on the LCD.
© 2013 CLEMCO INDUSTRIES CORP.  www.clemcoindustries.com  Manual No. 24658, Rev. C
CMS-3 IN-HELMET CARBON MONOXIDE MONITOR
Page 3
Sensor Cap
Sensor Cover
LED Alarm Lens
LCD Display Window
Charcoal Filter
Sensor Gasket
Audible Alarm Opening
Sensor Diffusion Port
Sensor
Sensor Alignment Slots
Sensor Cap
Control Buttons
Mounting Plate and Clip
Clip not used with
respirator mounting
Velcro® Loop Fastener Tape
Velcro® Hook Fastener Tape
Figure 1
1.7.5 LCD: The LCD is visible through the top case.
CO concentrations, the time, battery condition, and
alarm indications are displayed on the LCD. Once the
monitor is "ON", pressing the Power/Mode or Air control
button, turns on the LCD backlight for 20 seconds.
Button
1.7.6 Control Buttons: Below the LCD are the two
control buttons. They are POWER/MODE and AIR. They
turn on the power to the CMS-3 and turn it off. They
control what is displayed on the LCD, including time, gas
concentrations, peak, TWA, and STEL readings, as well
as other messages. They also allow for a fresh air
adjustment, change alarm points, change the time, and
calibrate the instrument. The functions performed by the
control buttons are summarized in the table in Figure 2.
POWER/MODE



1.7.9 Vibrator Alarm: A vibrating motor mounted
inside the case vibrates momentarily during the powerup sequence and for CO gas alarms.





1.7.7 Alarm Lights: Two LED alarm lights are located
above the LCD. The red alarm lights show through the
reflective lenses. The red LED’s alert the user to CO
gas, low battery, and sensor failure.
1.7.8 Audible Alarm: An opening on the left side of
the top case allows the alarm’s sound (a beep) to
resonate from the case. The alarm sounds for CO gas,
unit malfunctions, low battery, and as an indicator during
normal use of various display options.
Function



AIR



Turns the unit on and off
Turns the LCD back light on.
(when unit is on)
Displays STEL and TWA
readings.
Displays peak (high) readings
Resets the alarm circuit (gas
alarms).
Enters Calibration Mode when
used with the AIR button.
Enters Alarm Adjustment Mode
when used with the AIR button.
Enters Time Adjustment Mode
when used with the AIR button.
Turns the LCD back light on.
(when unit is on)
Adjusts LCD readings when the
fresh air adjustment is performed.
Enters Calibration Mode when
used with POWER/MODE button.
Enters Alarm Adjustment Mode
with the POWER/MODE button.
Enters Time Adjustment Mode
with the POWER/MODE button.
Increases settings when the unit
is in Alarm Adjustment Mode,
Time Adjustment Mode, or
Calibration Mode.
Figure 2
© 2013 CLEMCO INDUSTRIES CORP.  www.clemcoindustries.com  Manual No. 24658, Rev. C
CMS-3 IN-HELMET CARBON MONOXIDE MONITOR
1.7.10 Lithium Battery: A 3.0 volt coin type lithium
battery powers the CMS-3. The battery will run the
monitor for approximately four months when no alarms
have been activated during that time period. The battery
icon on the LCD shows the charge remaining in the
battery. When the CMS-3 detects low battery voltage, a
low battery warning (the last remaining bar on the
battery icon flashes) is activated. There may be
conditions that cause rapid deterioration of a low battery.
A spare battery is provided with the monitor; keep a
new battery on hand at all times. When the battery is
too low for normal operation, a dead battery alarm
(battery icon flashes, audible alarm beeps twice per
second) is activated. Refer to Section 5.1 for instructions
on replacing the battery.
2.0
INSTALLATION, START-UP and SHUT-OFF
2.1
Installation
This section explains the initial installation of the CMS-3
inside the respirator.
2.1.1 Installation in Apollo 20 Respirator
Refer to Section 2.1.2 for installing the monitor in Apollo 60
and Apollo 600 respirators.
2.1.1.1 Open the lens frame and remove the lenses.
2.1.1.2 Don the helmet and temporarily place the monitor
on one of the side walls of the window extension, as
shown in Figure 3.
2.1.1.3 Mark the location and remove the monitor and helmet.
Mark the location anyplace
inside of the window
extension
and
attach
Velcro® hook tape. Make
sure the monitor’s alarm
lights are visible when the
helmet is donned.
Page 4
2.1.1.5 Remove the monitor and prepare it for operation.
2.1.1.6 Replace the lenses and lens frame assembly.
2.1.1.7 After the initial setup is done, remove and
reattach the monitor from inside the helmet. Remove
the monitor when taking off the respirator at the end
of the shift and to do any service or calibration,
including turning the monitor on and off. Do this to
make sure the monitor is fully functional before placing it
inside the helmet.
WARNING
Remove the monitor at the end of the shift, turn
it off and store it in a clean environment. At the
beginning of each shift, turn on the monitor and
make sure it is fully functional before installing
in the helmet. Failure to do so could result in CO
poisoning and death.
2.1.2 Installing in Apollo 60 and Apollo 600
Respirators
Refer to Section 2.1,1 for mounting the monitor in Apollo 20
respirators.
2.1.2.1 Place the transparent mounting strip on the
inside of the inner lens, and into the same window
gasket groove as the inner lens, as shown if Figure 4.
Position it so it is within peripheral vision toward the side
of the window opening.
As seen from inside the hood,
the strip is inserted into the
groove in the window gasket.
Attach Velcro® hook tape
anyplace on the inside of the
strip. Make sure the monitor’s
alarm lights are visible when
the helmet is donned.
Figure 4
Figure 3
2.1.1.4 Remove backing from the Velcro® hook tape and
adhere it at the marked location (the loop tape adheres to
the monitor). Attach the monitor so the control buttons
face toward lenses and alarm lights toward the inside of
the respirator. Don the helmet to make sure the monitor’s
alarm lights are visible from inside the helmet.
2.1.2.2 Remove backing from the Velcro® hook tape
and adhere it anyplace on the mounting strip (the loop
tape adheres to the monitor) making sure the alarm lights
are visible from inside the helmet.
2.1.2.3 Attach the monitor to the strip, with the buttons
facing toward the outer edge of the window opening and
alarm lights toward the center of the window opening.
Don the helmet to make sure the monitor alarm lights
are visible from inside the helmet.
2.1.2.4 Remove the monitor and prepare it for operation.
© 2013 CLEMCO INDUSTRIES CORP.  www.clemcoindustries.com  Manual No. 24658, Rev. C
CMS-3 IN-HELMET CARBON MONOXIDE MONITOR
2.1.2.5 After the initial setup is done, remove and
reattach the monitor from inside the helmet. Remove
the monitor when taking off the respirator at the end
of the shift and to do any service or calibration,
including turning the monitor on and off. Do this to
make sure the monitor is fully functional before placing it
inside the helmet.
WARNING
Remove the monitor at the end of the shift, turn
it off and store it in a clean environment. At the
beginning of each shift, turn on the monitor and
make sure it is fully functional before installing
in the helmet. Failure to do so could result in CO
poisoning and death.
2.2
Turning On and Start-up Procedure
This section explains how to start up the CMS-3 and to
prepare it for operation.
2.2.1 Press and hold the POWER/MODE button until the
alarm beeps. The alarm sounds briefly, the vibrator
vibrates briefly, all elements of display are activated, and
the alarm lights and LCD backlight turn on for a few
seconds.
Page 5
2.2.4.2 With the unit on and in Measuring Mode, press
and hold the AIR button for about three seconds to allow
the CMS-3 to set the fresh air reading. While pressing
the AIR button, the LCD displays “hold,” a prompt to
keep pressing the AIR button.
2.2.4.3 When the fresh air readings have been set, the
LCD displays “Adj” for 2 seconds which prompts you to
release the AIR button. The unit will set the reading to 0
ppm.
2.2.4.4 The unit then returns to normal operation and
the display indicates the current gas concentration.
2.3
Turning Off the CMS-3
2.3.1 Remove the monitor when taking off the
respirator at the end of the shift.
2.3.2 Press and hold the POWER/MODE button for
about five seconds to turn off the unit. The alarm will
beep while the POWER/MODE button is being pressed
before the unit turns off.
2.3.3 Release the button when the LCD is blank. The
unit is off.
2.3.4
Store the monitor in a clean dry area.
2.2.2 The CMS-3 then displays CO (the target gas)
and time before displaying the battery voltage.
WARNING
If the unit is in low battery warning, change the
battery as soon as possible. Do not use the
respirator if the dead battery warning is alarmed.
2.2.3 The alarm beeps again after the battery voltage
is displayed. The CMS-3 is now in the Measuring Mode,
which is the normal operating mode. The CO
concentration (ppm) is displayed and the current time is
shown at the bottom of the LCD. NOTE: When using the
CMS-3 for the first time, check the current time and
verify that it is correct for your time zone. If it is not, set
the time as described in Section 3.7 “Setting the Time”.
2.2.4 Performing a Fresh Air Adjustment
Before using the CMS-3, set the fresh air reading to
ensure accurate gas readings in the monitoring
environment. Refer to Section 4.1
2.2.4.1 Find a fresh air environment. This is an
environment free of toxic or combustible gases and of
normal oxygen content (20.9%).
3.0
OPERATION
This section describes the normal operation of the CMS3, and includes alarm indications. Ref. Figure 5
3.1
Measuring Mode
After having powered up the CMS-3 and performed a
fresh air adjustment following the instructions of the
previous section, “Turning ON and Start Up,” the CMS-3
is in Measuring Mode. In Measuring Mode the monitor is
in the normal operating mode, the battery level, time,
and CO concentration are displayed on the LCD. The
battery icon has four bars visible when the battery is full.
As the battery charge decreases, the bars disappear.
CO is displayed in parts per million (ppm). The time is
shown in military format with the hour going from 0 to 24.
3.2
Displaying the Peak CO Concentration
3.2.1 The Peak Display shows the highest
concentration of CO the monitor has detected from the
time it was last turned on.
© 2013 CLEMCO INDUSTRIES CORP.  www.clemcoindustries.com  Manual No. 24658, Rev. C
CMS-3 IN-HELMET CARBON MONOXIDE MONITOR
3.2.2 Make sure the CMS-3 is in Measuring Mode.
The current gas concentration should be displayed on
the LCD.
3.2.3 When the CMS-3 is in Measuring Mode (normal
operating mode), Press and release the POWER/MODE
button to enter Peak Display Mode. This activates the LCD
backlight and displays the Peak reading. A small Peak
symbol is displayed in the upper left corner of the LCD.
The time the spike occurred is shown in the time location.
Battery Level
Peak Alarm
Symbol
Gas Concentration
10
1 2 : 2 9 ppm
CMS-3
Time
POWER
MODE
AIR
Figure 5
3.2.4 A Peak alarm display cannot be cleared until the
monitor is turned off.
3.3
Displaying STEL, and TWA
Although some may find TWA and STEL information
useful, it is not pertinent for supplied-air respirator use,
because the maximum exposure limit for Grade D
breathing air is 10 ppm.
3.3.1 STEL is an acronym for short-term exposure
limit, and it is the average reading of CO during the last
15 minutes. TWA is an acronym for time-weighted
average, and it is the average reading for CO during the
last eight hours. If eight (8) hours has not elapsed since
the unit was turned on, the TWA is still calculated over
eight hours, with the missing time assigned a zero (0)
value for the readings. Similarly, if the unit has not been
on for 15 minutes, the missing time is assigned a 0 value
and the STEL is calculated over 15 minutes. The Peak,
STEL, and TWA readings are cleared when the unit is
turned off.
3.3.2 When the CMS-3 is in Measuring Mode (normal
operating mode), Press and release the POWER/MODE
button to enter Peak Display Mode. Press and release
the POWER/MODE button again to enter STEL Display
Mode. This will display the STEL reading. The word
“STEL” is displayed in the middle of the LCD above the
reading.
Page 6
3.3.3 Press and release the POWER/MODE button
again to enter TWA Display Mode. This will display the
TWA reading. The word “TWA” is displayed in the
middle of the LCD above the reading.
3.3.4 Press and release the POWER/MODE button
once again to return to Measuring Mode.
NOTE: If you do not press a button for 20 seconds while
displaying the Peak, STEL, or TWA readings, the unit
will return to Measuring Mode automatically and the
backlight will turn off.
3.4
Alarms
This section covers alarm indications. It also explains
how to reset the CMS-3 after an alarm has occurred and
how to respond to an alarm condition.
3.4.1 Alarm Indications
The audible alarm beeps, the unit vibrates, and the alarm
lights flash when CO concentrations rises above the low
alarm point. The CMS-3 also alarms when the high alarm
point, the STEL alarm point, or the TWA alarm point is
reached. It has a low battery warning, dead battery
alarm, an over range alarm, sensor failure alarm, and a
system failure alarm. The table in Figure 6 summarizes
the types of alarms produced by the CMS-3.
3.4.2
Resetting CO Alarms
3.4.2.1 To reset a CO carbon monoxide gas alarm, after
the CO reading falls below the low alarm point (10 ppm)
press and release the POWER/MODE button once.
NOTE: Even though the gas concentration may have
fallen below the alarm point, the alarm indications will
continue until the alarm is reset using the
MODE/POWER button as noted. A Peak alarm display
cannot be cleared until the monitor is turned off. If a TWA
or STEL alarm has been activated, it cannot be reset
unless the monitor is turned off.
3.5
Responding to Alarms
This section describes response to gas, over range,
battery, sensor failure, and system failure alarms.
3.5.1
Responding to CO Alarms
3.5.1.1 Follow an established procedure for responding
to CO gas alarms. It should include but not be limited to
removing the respirator as soon as it is safe to do so.
3.5.1.2 Reset the alarm by pressing and releasing the
POWER/MODE button once, after the CO reading falls
below the low alarm point.
© 2013 CLEMCO INDUSTRIES CORP.  www.clemcoindustries.com  Manual No. 24658, Rev. C
CMS-3 IN-HELMET CARBON MONOXIDE MONITOR
3.5.2 Responding to an Over Range Alarm
An over range alarm could indicate CO gas are above
the detection limit of 500 ppm. The CO concentration
reading is replaced by blinking brackets (ΠΠΠΠ).
WARNING
An over range condition may indicate an
extreme CO concentration. Remove the
respirator as quickly as possible when it is safe
to do so.
3.5.2.1 Follow an established procedure for responding
to CO gas alarms. It should include but not be limited to
removing the respirator as soon as it is safe to do so.
Page 7
3.5.2.2 Reset the alarm using the MODE/POWER
button once the alarm condition has cleared.
3.5.2.3 Calibrate the CMS-3 as described in Section
4.3.
3.5.2.4 Confirm the gas concentration with a different
CMS-3 or with another gas detecting device.
3.5.2.5 If the over range condition continues, the sensor
may need to be replaced.
3.5.2.6 If the over range condition continues after
replacing the sensor, contact Clemco Customer Service
at 636 239-4300 for further instructions.
Alarm Types and Indications
Alarm Type
LCD Indications

Low Alarm
and
High Alarm

Gas reading flashes.
Back light turns on.
Other Alarm Indications



Concentration of CO
rises above the alarm
point.
Note: Low and High
Alarms are both set at
the maximum exposure
limit of 10 ppm.

TWA or STEL
Concentration of CO
rises above the TWA or
STEL alarm point.


Over Range
An over range condition
may indicate an extreme
CO concentration.

Low Battery Warning

Dead Battery Alarm

Back light turns on.
TWA or STEL blinks to the left of the battery
icon.
If the unit is in both TWA alarm and STEL
alarm, both TWA and STEL will be displayed.

Gas reading replaced by blinking brackets
(ΠΠΠΠ).
Back light turns on.





Last remaining bar on the right in battery icon
flashes.
Audible alarm beeps twice per
second.
Unit vibrates twice per second.
Alarm lights flash twice per second.
Audible alarm beeps once per
second (Single Pulse).
Unit vibrates once per second.
Alarm lights flash once per second
(Single Pulse).
Audible alarm beeps once per
second (Single Pulse).
Unit vibrates once per second.
Alarm lights flash once per second
(Single Pulse).

None.
• Gas reading replaced by FAIL.
• Battery icon flashes.

Audible alarm beeps twice per
second (Double Pulse).
Sensor Failure
• Gas reading replaced by FAIL.

Audible alarm beeps twice per
second (Double Pulse).
System Failure
• Gas reading replaced by FAIL.
• Time replaced by SYS below FAIL

Audible alarm beeps twice per
second (Double Pulse).
Figure 6
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CMS-3 IN-HELMET CARBON MONOXIDE MONITOR
3.5.3
Responding to Battery Alarms
WARNING
The CMS-3 is not operational during a dead
battery alarm. Do not use the respirator until the
battery is replaced.
3.5.3.1 The CMS-3 is fully functional in a low battery
warning condition. However, only a couple of days of
operation may remain depending on certain conditions
such as alarm occurrences. Change the battery as soon
as possible when a low battery warning occurs. Refer to
Section 5.1 “Replacing the Lithium Battery.”
NOTE: Alarms and the back light feature consume
battery power and reduce the amount of operating time
remaining.
3.5.4
Responding to a Sensor Failure Alarm
3.5.4.1 Perform a calibration as described in Section 4.3.
3.5.4.2 If the sensor failure alarm continues, replace the
sensor as described in Section 5.2.
3.5.4.3 If the sensor failure alarm continues after
replacing the sensor, contact Clemco Customer Service
at 636 239-4300 for further instructions.
3.5.5
Responding to a System Failure Alarm
3.5.5.1 If a system failure occurs, turn off the unit and
turn it on again.
3.5.5.2 If the unit is still in system failure, contact
Clemco Customer Service at 636 239-4300 for further
instructions.
3.6
Setting the Alarm Points
3.6.1 There is a low-alarm point, a high-alarm point,
and STEL and TWA alarm points. The alarm points and
their factory settings are summarized below:
 Low Alarm (displayed (LO): is triggered when CO
concentrations reach 10 ppm, which is the maximum
exposure limit for Grade D compressed air. Remove
the respirator as soon as it is safe to do so.
 High Alarm (displayed (HI): Because the maximum
exposure limit for grade D breathing air is 10 ppm of
CO, the high alarm is also set to alarm when CO
concentration reaches 10 ppm. This alarm is a rapid,
twice per second beep and stresses the urgency to
remove the respirator as soon as it is safe to do so.
Page 8
 *TWA Alarm: TWA is an acronym for time-weighted
average; it is the average reading of CO during the
last eight hours.
 *STEL Alarm: STEL is an acronym for short-term
exposure limit; it is the average reading of CO
during the last 15 minutes.
* Although some may find TWA and STEL information
useful, it is not pertinent for supplied-air respirator use,
because the maximum exposure limit for Grade D
breathing air is 10 ppm.
3.6.2 To begin, make sure the CMS-3 is turned off.
The LCD should be blank.
3.6.3 Press and hold the AIR button, then press and
hold the POWER/MODE button.
3.6.4 As soon as segments appear on the display
(approximately one second), release the AIR button.
When the unit “beeps,” release the POWER/MODE button
to put the CMS-3 into Alarm Point Adjustment Mode.
3.6.5 The LCD should display the Low (LO) Alarm
setting (10 ppm), the battery level, and peak alarm
symbol as Shown in Figure 5. NOTE: If the LCD shows
“CAL” in the lower left corner, the CMS-3 is in
Calibration Mode. Press and hold the POWER/MODE
button to turn off the unit. Repeat the process beginning
with Paragraph 3.6.2.
NOTE: You can only cycle through the alarm points in
the sequence noted in paragraph 3.6.1 once before the
monitor goes into its startup sequence followed by
Measuring Mode (operating mode). To cycle through the
alarm points again, press and hold the POWER/MODE
button to turn off the unit. Then repeat the process
beginning with Paragraph 3.6.2 to put the unit back into
Alarm Point Adjustment Mode.
3.6.6 To change the alarm point, press and release
the POWER/MODE button to cycle through the alarms.
NOTE: If you press and hold the POWER/MODE button
the monitor may turn off.
3.6.7 When an alarm point is displayed, use the AIR
button to increase the alarm point. If you pass the
desired setting, continue increasing the alarm point until
it reaches the maximum setting (50 for low alarm, and
500 for high alarm) and it will “wrap around” to the
minimum setting (0 for low alarm and 10 for high alarm).
3.6.8 If the alarm setting has been changed, press the
POWER/MODE button to save the new setting. The next
alarm point will be displayed.
3.6.9 When finished viewing or adjusting the alarm
point settings, press and release the POWER button
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CMS-3 IN-HELMET CARBON MONOXIDE MONITOR
repeatedly until the ROM number for the unit appears on
the LCD. (The ROM is the component that contains the
software that runs the CMS-3.) The CMS-3 will then go
into its startup sequence followed by Measuring Mode.
3.7
4.0
CALIBRATION
This section covers the calibration of the CMS-3. Setting
the fresh air reading is described first followed by setting
the calibration value.
Setting the Clock
3.7.1 Make sure the CMS-3 is on and in Measuring
Mode.
3.7.2 Press and hold the Air button, then press and
hold the POWER/MODE button to put the monitor into
Time Adjustment Mode. Release the buttons when the
word “SEt” appears on the LCD as noted in Figure 7.
Below “SEt”, the time will be displayed and the hour in
the time will be flashing.
Page 9
WARNING
Use a 0.5 LPM (liters per minute) fixed flow
calibration connector (Clemco Stock No. 25572)
when calibrating. Use of a different flow rate
may adversely affect the accuracy of the
calibration.
4.1
3.7.3 Use the AIR button to increase the hour to the
desired setting. If you pass the desired setting, continue
to increase the hour until it reaches 23 and then wraps
around to 0, then set to the desired setting.
Calibration schedule
 Calibrate daily for the first week of operation.
 Calibrate weekly for the first month of
operation.
 Calibrate at least monthly thereafter.
 Calibrate before use if the monitor was out of
service for more than one week.
4.2
Setting the Fresh Air Reading
Fresh-air settings must be done in a fresh air
environment, free of toxic or combustible gases and of
normal oxygen content (20.9%). The usual method is to
set it in fresh ambient air. If fresh, ambient air cannot be
assured, set the fresh air reading with impurity free test
gas, as described in Section 4.2.2.
Time Set
Display
SEt
12:29
CMS-3
POWER
MODE
4.2.1
AIR
Figure 7
3.7.4 Press the POWER/MODE button to accept the
hour setting. The minute starts flashing.
3.7.5 Use the Air button to increase the minute setting
to the desired setting.
3.7.6 Press the POWER/MODE button to accept the
minute setting and return to Measuring Mode.
Setting the fresh air reading with ambient air
4.2.1.1 Turn on the CMS-3 by pressing and holding the
POWER/MODE button for one second. Allow the unit to
finish its warm-up sequence.
4.2.1.2 Press and hold the AIR button. While pressing
the AIR button, the LCD displays “Hold,” a prompt to
keep pressing the AIR button.
4.2.1.3 When the fresh air reading has been set, the
LCD displays “Adj,” a prompt to release the AIR button.
It will set the reading to 0 ppm.
4.2.2 Setting the fresh air reading with impurity
free test gas
The following is required to set the fresh air setting with
impurity free test gas.
• Impurity free test gas, Stock No. 11132
• Calibration connector with tubing and calibration cup.
4.2.2.1 Make sure the monitor is off.
4.2.2.2 Make sure the calibration connector valve is
closed, and then attach the connector to the test gas
cylinder.
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CMS-3 IN-HELMET CARBON MONOXIDE MONITOR
4.2.2.3 Attach the calibration cup to the sensor cap, as
shown in Figure 8. The cup opens up like a clothes pin
to fit over the sensor cap and locks onto the cap.
4.2.2.4 Turn on the CMS-3 by pressing and holding the
POWER/MODE button for one second. Allow the unit to
finish its warm-up sequence.
4.2.2.5 Open the connector by sliding the regulator
valve to the "OPEN" position.
4.2.2.6 Press and hold the AIR button. While pressing
the AIR button, the LCD displays “Hold,” a prompt to
keep pressing the AIR button.
4.2.2.7 When the fresh air reading has been set, the
LCD displays “Adj,” a prompt to release the AIR button.
It will set the reading to 0 ppm.
Page 10
4.3.5 Press and hold the AIR button, then press and
hold the POWER/MODE button. Release both buttons
when you hear a “beep.” The unit is in calibration mode
and the LCD displays “CAL” in the lower left and the
battery level in the upper right. It also displays the gas
concentration that is to be used to calibrate the unit.
Calibration Cup
Pinch ends to open retainer
Tubing to
Calibration Connector
Sensor Cap
Bottom of Sensor
Cap Tab
4.2.2.8 Close the connector by sliding the regulator
valve to the "CLOSE" position.
4.2.2.9 Carefully remove the calibration cup from the
unit, being careful not to misplace the gasket on the
bottom of the cup.
4.2.2.10 Remove the calibration connector from the test
gas cylinder. The test gas cylinder has a positive seal,
whereas the calibration connector valve does not. If the
connector is not removed from the test gas cylinder, over
a period of time the cylinder will empty.
Do not plug open vent
on calibration cup
Make sure retainers are fully
set under sensor cap tabs
Sensor end view of monitor
Figure 8
4.3
Calibration (setting the span adjustment)
Calibrate the CMS-3 in a non-hazardous environment,
as used to set the fresh air reading.
The following is required to calibrate the CMS-3
• Test gas with 25 ppm concentration of CO,
Stock No. 25573.
• Calibration connector with tubing and calibration cup.
4.3.1 Make sure the fresh air reading was set per
Section 4.2.
4.3.2
4.3.6 If necessary, use the AIR button to adjust the
calibration value (the value shown on the display) to
match the gas concentration in the calibration cylinder.
4.3.7 Press the POWER/MODE button to accept the
calibration value and proceed to the calibration screen.
The current gas reading is displayed and the “CAL”
display blinks.
4.3.8 Open the connector by sliding the regulator
valve to the "OPEN" position.
Make sure the monitor is off.
4.3.3 Make sure the calibration connector valve is
closed, and then attach the connector to the test gas
cylinder.
4.3.4 Attach the calibration cup to the sensor cap, as
shown in Figure 8. The cup opens up like a clothes pin
to fit over the sensor cap and locks onto the cap.
NOTE: To cancel the span adjustment process, press
and hold the AIR button for about 3 seconds. The unit
will cancel the adjustment and begin its startup
sequence.
4.3.9 Let the gas flow for one minute and then press
the POWER/MODE button. The unit will adjust the span
based on the calibration value that was saved as
described in Paragraphs 4.2.5 through 4.2.7.
© 2013 CLEMCO INDUSTRIES CORP.  www.clemcoindustries.com  Manual No. 24658, Rev. C
CMS-3 IN-HELMET CARBON MONOXIDE MONITOR
Page 11
4.3.10 Close the connector by sliding the regulator
valve to the "CLOSE" position.
held captive in the battery cover if they are not
unscrewed too far.
4.3.11 Immediately and carefully remove the calibration
cup from the unit, being careful not to misplace the
gasket on the bottom of the cup. The monitor goes into
the start up and measuring mode as soon as the
calibrations is complete. If the cup is not immediately
removed, residual gas may cause the monitor to alarm.
Refer to Paragraph 4.3.13.
5.1.3
5.1.4 Carefully install the new battery, noting the
polarity indications on the underside of the battery cover
and in the battery compartment. The negative (-) side of
the battery goes in first.
4.3.12 Remove the calibration connector from the test
gas cylinder. The test gas cylinder has a positive seal,
whereas the calibration connector valve does not. If the
connector is not removed from the test gas cylinder, over
a period of time the cylinder will empty.
Battery Cover
4.3.13 As soon as the unit makes the calibration
adjustment, it will begin its startup sequence and then
enter the Measuring Mode. NOTE: If the gas reading is
high enough when the unit enters Measuring Mode, an
alarm condition will occur. Reset the alarm using the
POWER/MODE button when the gas reading falls below
the alarm point.
5.0
Carefully remove the old battery.
Battery
Positive (+) toward cover
Back View of CMS-3 Case
MAINTENANCE
Figure 9
WARNING
Service, calibration, and repair of the
instruments should be performed by personnel
properly trained for this work. Improper service
could result in malfunction and loss of life.
NOTE: The printed circuit boards contain no user
serviceable parts.
5.1
Replacing the Lithium Battery,
Refer to Figure 9
Always keep a spare lithium battery on hand, and
replace it when the battery icon indicates that the unit is
in low battery warning. When in low battery warning, only
one battery level indication bar remains and it is flashing.
Use a CR 2450 battery manufactured by Sony,
Eveready, Maxell, Hitachi, or Toshiba.
5.1.1
Make sure the monitor is off.
5.1.2 From the back of the unit, unscrew the two
screws that retain the battery cover far enough to pull
the cover away from the bottom case. The screws are
5.1.5
Reinstall the battery cover.
NOTE: All power to the unit is lost when the old battery
is removed. The clock is reset to 0:00 when the new
battery is installed. The clock must be set to the correct
time after the battery is changed. Refer to Section 3.7 to
reset the clock.
5.2
Replacing the Sensor, Ref Figures 10 and 11
Replace the sensor in a clean, non-hazardous
environment.
5.2.1
Make sure the monitor is off.
5.2.2 The sensor cap snaps onto the case with two
tabs. With a small flat blade screw driver, gently expand
the two tabs to pry off the sensor cap.
5.2.3 Remove the sensor gasket, cover, and charcoal
filter from the sensor.
5.2.4 Carefully remove the old sensor from the sensor
socket. NOTE: The sensor is keyed and can only be
© 2013 CLEMCO INDUSTRIES CORP.  www.clemcoindustries.com  Manual No. 24658, Rev. C
CMS-3 IN-HELMET CARBON MONOXIDE MONITOR
inserted in the socket one way. Note the orientation of
the old sensor, as shown in Figure 11 before removing it.
Sensor Cap
Sensor Cap Tabs
Sensor Cover
Page 12
5.2.6 Reinstall the sensor gasket; install a new
charcoal filter, and sensor cover into the recess in the
sensor gasket.
5.2.7 Reinstall the sensor cap, making sure both tabs
snap into place.
5.2.8 Calibrate the new sensor as described in
Section 4.3.
Charcoal Filter
Sensor Gasket
Sensor
Sensor Alignment
Key Slots
Sensor Cap
Retaining Clip
Figure 10
5.2.5 Carefully insert the replacement sensor in the
socket. Make sure the sensor face with the colored ring
is facing up, and that the sensor key slots are properly
aligned with the key tabs in the socket as shown in
Figure 11, before inserting.
CAUTION
Do not force the sensor into the socket; when
correctly aligned, the sensor easily fits into the
socket. Forcing it could damage the sensor or
the socket.
Top View of Sensor
Alignment arrows
show location of
key slots
Sensor Alignment
Key Slots
Bottom View of Sensor
5.3
Replacing the Sensor Cover
Replace the sensor cover in a non-hazardous
environment.
5.3.1
Make sure the CMS-3 is off.
5.3.2 The sensor cap snaps onto the case with two
tabs. With a small flat blade screw driver, gently expand
the two tabs to pry off the sensor cap.
5.3.3 Remove the old sensor cover from its recess in
the sensor gasket.
5.3.4 Install the new sensor cover into the recess in
the sensor gasket.
5.3.5 Reinstall the sensor cap, making sure both tabs
snap into place.
5.4
Replacing the Charcoal Filter Disk
Replace the charcoal filter disk in a non-hazardous
environment.
5.4.1
Make sure the CMS-3 is off.
5.4.2 The sensor cap snaps onto the case with two
tabs. With a small flat blade screw driver, gently expand
the two tabs to pry off the sensor cap.
5.4.3 Remove the old sensor cover from its recess in
the sensor gasket.
5.4.4 Remove the old charcoal filter from its recess in
the sensor gasket.
Sensor Alignment
Key Tabs
5.4.5 Install the new charcoal filter into its recess in
the sensor gasket.
5.4.6 Install a new sensor cover into its recess in the
sensor gasket.
Figure 11
5.4.7 Reinstall the sensor cap, making sure both tabs
snap into place.
© 2013 CLEMCO INDUSTRIES CORP.  www.clemcoindustries.com  Manual No. 24658, Rev. C
CMS-3 IN-HELMET CARBON MONOXIDE MONITOR
Page 13
6.0
TROUBLESHOOTING
The troubleshooting table describes error messages,
symptoms, probable causes, and recommended action
for problems encountered with the CMS-3.
SYMPTOMS
PROBABLE CAUSES
The LCD is blank.
The LCD shows
abnormally high or
low readings but
other gas detection
instruments do not.
“FAIL” displays
during span or zero
adjustment.
RECOMMENDED ACTION
The unit may be turned off.
1. To turn on the unit, press and hold the
MODE/POWER button.
The battery may need to be replaced.
1.
If the unit does not turn on, replace the battery.
2.
If the difficulties continue, contact an authorized
Clemco distributor for further instructions.
The unit may need to be recalibrated.
1.
Recalibrate the unit. Review Section 4.0.
The sensor may need replacement.
1.
Replace the sensor and calibrate the unit.
2.
If the difficulties continue, contact an authorized
Clemco distributor for further instructions.
The calibration value may not match
the cylinder gas concentration.
Make sure the calibration value matches the
cylinder gas. Refer to Section 4.0.
CMS-3 not
calibration.
Make sure the CMS-3 has been properly set up
for calibration per Section 4.0.
correctly
set
up
for
The sample gas is not reaching the
sensor because of a bad connection.
1.
Check all calibration tubing for leaks or for any
bad connections.
2.
Make sure the calibration cup is correctly
clipped to the sensor cap. Review Section 4.3.
The calibration cylinder may be out of
gas or is outdated.
The sensor may need replacement.
“FAIL SYS” is
indicated on the
LCD.
A microprocessor failure has occurred.
Make sure the calibration cylinder contains an
adequate supply of fresh test sample.
1.
If the fail condition continues, replace the
sensor.
2.
If the difficulties continue, contact an authorized
Clemco distributor for further instructions.
1.
Turn off the unit and turn it on again.
2.
If the difficulties continue, contact an authorized
Clemco distributor for further instructions.
Figure 12
© 2013 CLEMCO INDUSTRIES CORP.  www.clemcoindustries.com  Manual No. 24658, Rev. C
CMS-3 IN-HELMET CARBON MONOXIDE MONITOR
7.0
ACCESSORIES and REPLACEMENT PARTS
7.1
System and Accessories, Figure 13
Item
Description
(-)
1.
2.
3.
4.
5.
6.
7.
Stock No.
CMS-3 CO Monitor Package
Includes items shown with asterisk (*) .... 24612
* CMS-3 CO monitor, instrument only .......... 24613
* Calibration connector assembly ................. 24614
Test gas,
* 25 ppm CO .............................................. 25573
Impurity free ............................................ 11132
Calibration connector valve ........................ 25572
Calibration cup ........................................... 24615
Tubing, 3/16 ID, 2-feet required ................. 13074
* Mounting strip assembly,
used with Apollo 60 and 600 only
Included with kit 25577 shown in Figure 14.
7.2
Replacement Parts, Figure 14
NOTE: The printed circuit boards contain no user
serviceable parts.
Item
(-).
1.
2.
3.
4.
5.
6.
7.
5
Page 14
Description
Stock No.
CMS-3 CO Monitor only ............................ 24613
Sensor ....................................................... 24616
Service kit, includes
Items 3, 4 and 5 ....................................... 24617
Kit, screws and seal and mounting strip .... 25577
3a Cap, sensor
3b Gasket, sensor
3c Screw set, (8) case and (4) battery cover
3d O-ring, battery cover
3e Velcro® tape, loop side, 1" x 1-1/4"
3f Velcro® tape, hook side, 1" x 2" (qty. of 2)
3g Mounting strip (qty. of 2)
3h Spring pin (qty. of 2)
Discs, sensor cover, pack of 10 ................ 25563
Filter, charcoal, pack of 5 .......................... 25564
Mounting plate ........................................... 25575
Battery, Lithium, ......................................... 24619
or purchase locally ................... Model CR2450
2
6
4
3c
OP E N
CL O S E
3d
1
3a
CLEMCO
STK# 24613
7
3
4
5
7
3b
3c
Figure 13
3h
1
3e
3f
3g
6
Figure 14
© 2013 CLEMCO INDUSTRIES CORP.  www.clemcoindustries.com  Manual No. 24658, Rev. C
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