O. M. 22925
MC FILE NUMBER: 2111-0700
E, 11/08
One Cable Car Dr.
Washington, MO 63090
Phone (636) 239-4300
Fax (800) 726-7559
Email: [email protected]
Do not proceed with
these instructions until
you have READ the
orange cover of this
contents. * These
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.
Described herein are some, BUT NOT ALL, of the major
requirements for safe and productive use of blast
machines, remote control systems, operator respirator
assemblies, and related accessories. Completely read ALL
instruction manuals prior to using equipment.
Read and follow ALL instructions before using
this equipment.
Failure to comply with ALL instructions can result
in serious injury or death.
In the event that the user, or any assistants of the
user of this equipment cannot read or cannot
completely understand the warnings and
information contained in these instructions, the
employer of the user and his assistants must
thoroughly educate and train them on the proper
operation and safety procedures of this
The user's work environment may include certain
HAZARDS related to the abrasive blasting operation.
Proper protection for the blaster, as well as anyone else
that may be EXPOSED to the hazards generated by the
blasting process, is the responsibility of the user and/or
the employer. Operators MUST consult with their employer
about what hazards may be present in the work
environment including, but not limited to, exposure to dust
that may contain TOXIC MATERIALS due to the presence
of silica, cyanide, arsenic or other toxins in the abrasive,
or materials present in the surface to be blasted such as
lead or heavy metals in coatings. The environment may
also include fumes that may be present from adjacent
coatings application, contaminated water, engine exhaust,
chemicals, and asbestos. The work area may include
PHYSICAL HAZARDS such as an uneven work surface,
poor visibility, excess noise, and electrical hazards. The
operator MUST consult with his employer on the
identification of potential hazards, and the appropriate
measures that MUST be taken to protect the blaster and
others that might be exposed to these hazards.
The products described in this material, and the information
relating to those products, is intended for knowledgeable,
experienced users of abrasive blasting equipment.
No representation is intended or made as to the suitability of
the products described herein for any particular purpose or
application. No representations are intended or made as to the
efficiency, production rate, or the useful life of the products
described herein. Any estimate regarding production rates or
production finishes are the responsibility of the user and must
be derived solely from the user’s experience and expertise,
and must not be based on information in this material.
ALL machines, components and accessories MUST be
installed, tested, operated and maintained only by trained,
knowledgeable, experienced users.
DO NOT modify or substitute any Clemco parts with other
types or brands of equipment. Unauthorized modification
and parts substitution on supplied air respirators is a
violation of OSHA regulations and voids the NIOSH
The products described in this material may be combined by
the user in a variety of ways for purposes determined solely by
the user. No representations are intended or made as to the
suitability or engineering balance of the combination of
products determined by the user in his selection, nor as to the
compliance with regulations or standard practice of such
combinations of components or products.
Abrasive Blast Equipment is only a component of the range of
equipment used in an abrasive blasting job. Other products
may include an air compressor, abrasive, scaffolding, hydraulic
work platforms or booms, paint spray equipment,
dehumidification equipment, air filters and receivers, lights,
ventilation equipment, parts handling equipment, specialized
respirators, or equipment that while offered by Clemco may
have been supplied by others. Each manufacturer and supplier
of the other products used in the abrasive blasting job must be
contacted for information, training, instruction and warnings
with regard to the proper and safe use of their equipment in the
particular application for which the equipment is being used.
The information provided by Clemco is intended to provide
instruction only on Clemco products. All operators must be
trained in the proper, safe, use of this equipment. It is the
responsibility of the users to familiarize themselves with, and
comply with, all appropriate laws, regulations, and safe
practices that apply to the use of these products. Consult with
your employer about training programs and materials that are
Blast operators and others working in the vicinity of
abrasive blasting must always wear properlymaintained, NIOSH-approved, respiratory protection
appropriate for the job site hazards.
DO NOT USE abrasives containing more than one
percent crystalline (free) silica. Ref. NIOSH Alert
Inhalation of toxic dust (crystalline silica, asbestos,
lead paint and other toxins) can lead to serious or
fatal disease (silicosis, asbestosis, lead or other
ALWAYS wear NIOSH-approved supplied-air respirators
as required by OSHA, in the presence of any dust including,
but not limited to, handling or loading abrasive; blasting or
working in the vicinity of blast jobs; and cleanup of expended
abrasive. Prior to removing respirator, an air monitoring
Our company is proud to provide a variety of products to the
abrasive blasting industry, and we have confidence that the
professionals in our industry will utilize their knowledge and
expertise in the safe efficient use of these products.
instrument should be used to determine when surrounding
atmosphere is clear of dust and safe to breathe.
equipment. If controls are altered, involuntary activation, which
may cause serious injury, can occur.
NIOSH-approved, supplied-air respirators are to be worn
ONLY in atmospheres:
• NOT IMMEDIATELY dangerous to life or health and,
• from which a user can escape WITHOUT using the
Inspect the air control orifice DAILY for cleanliness.
NEVER use welding hose in place of twinline control hose. The
internal diameter and rubber composition are UNSAFE for
remote control use.
pressure of blast machines and related components MUST
NOT exceed National Board approved 125 psig (8.5 BAR).
Clemco supplied-air respirators DO NOT REMOVE OR
OTHER TOXIC GAS. Carbon monoxide and toxic gas removal
and/or monitoring device must be used in conjunction with
respirator to insure safe breathing air.
NEVER weld on blast machine. Welding may affect
dimensional integrity of steel wall and WILL VOID National
Board approval.
Air supplied to respirator MUST BE AT LEAST GRADE D
QUALITY as described in Compressed Gas Association
Commodity Specification G-7.1, and as specified by OSHA
Regulation 1910.139 (d).
Point nozzle ONLY at structure being blasted. High
velocity abrasive particles WILL inflict serious injury. Keep
unprotected workers OUT of blast area.
ALWAYS locate compressors to prevent contaminated air
(such as CO from engine exhaust) from entering the air intake
system. A suitable in-line air purifying sorbent bed and filter or
CO Monitor should be installed to assure breathing air quality.
NEVER attempt to manually move blast machine when it
contains abrasive. EMPTY machines, up to 6 cu. ft.(270kg)
capacity, are designed to be moved:
• on flat, smooth surfaces by AT LEAST two people;
• with the Clemco "Mule"; or
• with other specially designed machine moving devices.
ALWAYS use a NIOSH-approved breathing air hose to
connect an appropriate air filter to the respirator. Use of a nonapproved air hose can subject the operator to illness caused
by the release of chemical agents used in the manufacture of
non-approved breathing air hose.
Larger empty blast machines or ANY blast machine
containing abrasive MUST be transported by mechanical lifting
ALWAYS check to make sure air filter and respirator
system hoses are NOT CONNECTED to in-plant lines that
contain nitrogen, acetylene or any other non-breathable gas.
NEVER use oxygen with air line respirators. NEVER modify air
line connections to accommodate air filter/respirator breathing
hose WITHOUT FIRST testing content of the air line. FAILURE
Air hose, air hose fittings and connectors at compressors
and blast machines MUST be FOUR times the size of the
nozzle orifice. Air hose lengths MUST be kept as short as
possible AND in a straight line. Inspect DAILY and repair
Blast hose inside diameter MUST be THREE to FOUR
times the size of the nozzle orifice. AVOID sharp bends that
wear out hose rapidly. Use SHORTEST hose lengths possible
to reduce pressure loss. Check blast hose DAILY for soft
spots. Repair or replace IMMEDIATELY.
Respirator lenses are designed to protect against
rebounding abrasive. They do not protect against flying
objects, glare, liquids, radiation or high speed heavy materials.
Substitute lenses from sources other than the original
respirator manufacturer will void NIOSH-approval of this
ALWAYS cut loose hose ends square when installing hose
couplings and nozzle holders to allow uniform fit of hose to
coupling shoulder. NEVER install couplings or nozzle holders
that DO NOT provide a TIGHT fit on hose. ALWAYS use
manufacturers recommended coupling screws.
Replace coupling gaskets FREQUENTLY to prevent
leakage. Abrasive leakage can result in dangerous coupling
failure. ALL gaskets MUST be checked SEVERAL times during
a working day for wear, distortion and softness.
ALWAYS equip abrasive blast machines with
remote controls.
Abrasive blast machine operators must wear NIOSHapproved supplied-air respirators (ref: OSHA
regulations 1910.94, 1910.132, 1910.139 and
Install safety pins at EVERY coupling connection to
prevent accidental disengagement during hose movement.
ALWAYS attach safety cables at ALL air hose AND blast
hose coupling connections. Cables relieve tension on hose and
control whipping action in the event of a coupling blow-out.
NEVER modify OR substitute remote control parts. Parts
from different manufacturers are NOT compatible with Clemco
of the 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 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
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.
6. This warranty is conditioned upon seller’s receipt within ten
(10) days after a 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 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 the 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.
ALWAYS shut off compressor and depressurize blast
machine BEFORE doing ANY maintenance.
Always check and clean ALL filters, screens and alarm
systems when doing any maintenance.
ALWAYS cage springs BEFORE disassembling valves IF
spring-loaded abrasive control valves are used.
ALWAYS completely follow owner's manual instructions
and maintain equipment at RECOMMENDED intervals.
Training and Educational Programs.
Clemco Industries Corp. offers a booklet, Blast-Off 2,
developed to educate personnel on abrasive blast equipment
function and surface preparation techniques. Readers will learn
safe and productive use of machines, components and various
accessories, including selection of abrasive materials for
specific surface profiles and degrees of cleanliness.
The Society for Protective Coatings (SSPC) offers a video
training series on protective coatings including one entitled
"Surface Preparation." For loan or purchase information,
contact SSPC at the address shown below.
The following associations offer information, materials and
videos relating to abrasive blasting and safe operating
The Society for Protective Coatings (SSPC)
40 24th Street, Pittsburgh PA 15222-4643
Phone: (412) 281-2331 • FAX (412) 281-9992
Email: [email protected] • Website:
National Association of Corrosion Engineers (NACE)
1440 South Creek Drive, Houston TX 77084
Phone: (281) 228-6200 • FAX (281) 228-6300
Email: [email protected] • Website:
American Society for Testing and Materials (ASTM)
100 Barr Harbor Dr., West Conshohocken, PA 19428
Phone (610) 832-9500 • FAX (610) 832-9555
Email: [email protected] • Website:
Except as expressly set forth above, all warranties, express,
implied or statutory, including implied warranty of
merchantability, are hereby disclaimed.
This equipment is not intended to be used in an area that might
be considered a hazardous location as described in the
National Electric Code NFPA 70 1996, article 500.
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
ALL piping, fittings and hoses MUST be checked
DAILY for tightness and leakage.
ALL equipment and components MUST be thoroughly
checked for wear.
ALL worn or suspicious parts MUST be replaced.
ALL blast operators MUST be properly trained to
operate equipment.
ALL blast operators MUST be properly outfitted with
abrasive resistant clothing, safety shoes, leather gloves
and ear protection.
BEFORE blasting ALWAYS use the following check list.
to provide sufficient volume (cfm) for nozzle and other tools
PLUS a 50% reserve to allow for nozzle wear. Use large
compressor outlet and large air hose (4 times the nozzle orifice
2. BREATHING AIR COMPRESSOR (oil-less air pump)
capable of providing Grade D Quality air located in a dust free,
contaminant free area. If oil-lubricated air compressor is used
to supply respirator, it should have high temperature monitor
and CO monitor or both. If CO monitor is not used, air MUST
be tested FREQUENTLY to ensure proper air quality.
3. Clean, properly maintained NIOSH-APPROVED
ALWAYS be present. NEVER operate without inner lens in
place. Thoroughly inspect ALL components DAILY for
cleanliness and wear. ANY substitution of parts voids NIOSH
approval i.e. cape, lenses, breathing hose, breathing air supply
hose, air control valve, cool air or climate control devices.
8. BLAST HOSE with ID 3 to 4 times the nozzle orifice.
machine to work area with NO sharp bends. Check DAILY for
internal wear and external damage.
SNUGLY to hose end and installed using PROPER coupling
screws. Coupling lugs MUST be snapped FIRMLY into locking
position. Gasket MUST form positive seal with safety pins
inserted through pin holes. Check gaskets and replace if ANY
sign of wear, softness or distortion. ALWAYS install safety
cables at every connection to prevent disengagement. Check
nozzle holder for worn threads. NEVER MIX DIFFERENT
BRANDS OF COMPONENTS. Check each of these
components DAILY.
4. OSHA required BREATHING AIR FILTER for removal
of moisture and particulate matter from breathing air supply.
5. ASME CODED BLAST MACHINE sized to hold 1/2
hour abrasive supply. ALWAYS ground machine to eliminate
static electricity hazard. Examine pop up valve for alignment.
Blast machine MUST be fitted with a screen to keep out foreign
objects and a cover to prevent entry of moisture overnight.
10. Inspect NOZZLE and GASKET DAILY for wear.
Replace nozzle when 1/16" larger than original size or if liner
appears cracked. Check nozzle threads for wear.
to machine inlet. Sized to match inlet piping or larger air supply
line. Clean filter DAILY. Drain OFTEN.
11. Use abrasive that is properly sized and free of harmful
substances; such as, free silica, cyanide, arsenic or lead.
Check material data sheet for presence of toxic or harmful
operating condition. ONLY use APPROVED spare parts,
including twin- line hose. DAILY: test system operation and
check button bumper and spring action of lever and lever lock.
12. Test surface to be blasted for toxic substances. Take
appropriate, and NIOSH required, protective measures for
operator and bystanders which pertain to substances found on
the surface to be blasted.
1 Air Compressor
11. Silica-free Abrasive
2. Breathing Air Compressor
2. Ambient Air Pump
for low pressure
5. ASME Coded
Blast Machine
7. Remote
6. Air Line
10. Appropriately
Sized Nozzle
4. CPF Air-Filter
8. Blast Hose
9. Hose Couplings and
Safety Cables
Scope of manual
1.1.1 These instructions cover set-up, operation,
maintenance, troubleshooting, and replacement parts for
the CMS-2 contractor series carbon monoxide (CO)
1.1.2 The CMS-2 monitor is manufactured by
Invertech Inc. for Clemco Industries Corp. The monitor is
a potential life saving instrument. To assure its
performance, the monitor must be properly installed,
tested, calibrated, and maintained. Before installing and
using the monitor, all personnel involved with the
operation and maintenance of the instrument must read
this entire manual, including the orange cover.
Page 1
Danger indicates an imminently hazardous
situation which, if not avoided, will result in
death or serious injury.
1.3.1 The primary components of the monitor are
shown in Figure 1. The instrumentation is enclosed in a
corrosion resistant polypropylene carrying case. The
monitor system includes the instrument case, ten feet of
1/8" ID x 1/4" OD tubing with fittings, a cylinder of 10
PPM (parts per million) test gas, calibration connector
which includes the connector valve, tubing and
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 used without the safety alert symbol
indicates a potentially hazardous situation
which, if not avoided, may result in property
Caution indicates a potentially hazardous
situation which, if not avoided, may result in
minor or moderate injury.
Warning indicates a potentially hazardous
situation which, if not avoided, could result in
death or serious injury.
Operating Principles
1.4.1 The CMS monitor samples respiratory air from a
breathing-air source. This enables one monitor to detect
CO and other toxic gases in the entire breathing air
system, not just for one respirator. The air to the
respirator does not actually pass through the monitor.
When the CMS is correctly installed and
maintained, it monitors the level of carbon
monoxide and other oxidizable toxic gases in
the air supply. The instrument is a monitoring
device; it DOES NOT remove or convert carbon
monoxide or any other toxic gases.
1.4.2 During operation, a small sample of air, referred
to as "sample-air", passes through the instrument, and is
continuously monitored by the broadband MOS (Metal
Oxide Substrate) sensor. Although the sensor detects
CO (carbon monoxide), it also detects other oxidizable
toxic gases (hydrocarbons). If the "sample-air" supply
fails for any reason such as air blockage, loss of
pressure, or excessively high pressure, an intermittent
audible alarm will sound and the exterior alarm light will
illuminate "yellow" to alert the user.
1.4.3 In the event the sensor detects CO in the
concentration of 10 PPM (parts per million) or above, a
continuous audible alarm will sound and the exterior
alarm light will illuminate "red" to alert the user.
© 2008 CLEMCO INDUSTRIES CORP. • • Manual No. 22925
Page 2
Calibration Connector Tube End
1/4" OD Tube Fitting (2)
This end connects to air source
Calibration Connector
Exterior Alarm Light
Test Gas
Audible Alarm
Closing Screw
Case Cover Latch
120 V Power Cord
Case Cover
Calibration Indicator
Plugged Port
for Optional Remote Alarm
Calibration Adjustment
Flow Meter
Run/Calibration Switch
Test Gas Port
Annunciator Lights and Audible Alarms and
1.5.1 Audible and visual alarms are provided on the
exterior of the instrument case and on the interior
faceplate. The exterior light illuminates "green" when
conditions are safe, or "yellow" or "red", depending on
the alarm condition. The audible alarm sounds in
conjunction with the visual alarm.
All alarm conditions require the immediate
attention of the user. Stop blasting immediately,
and remove the respirator as soon as it is safe
to do so, and check the monitor to determine
the cause for alarm.
Figure 1
1.5.2 The color of the alarm light in conjunction with
the nature of the audible alarm indicates the condition
causing an alarm. Functions of the alarm annunciators
are as follows:
Interior Calibration Light
Red Light - Intermittent Audible Alarm
• The interior alarm light (calibration indicator), on the
faceplate of the instrument, responds to toxic gas
conditions only. It is for use by the technician during
calibration testing, and for calibration when the
instrument case is open.
Exterior Alarm Annunciators
Green Light - No Audible Alarm
• No Alarm, Safe Condition: Do not use the
compressed air for breathing unless the exterior light
is illuminated "green".
© 2008 CLEMCO INDUSTRIES CORP. • • Manual No. 22925
Yellow Light - Intermittent Audible Alarm
Sample-Air Failure: This alerts the user that
pressure in the test chamber is either too low or too
high. Low pressure is usually due to loss of pressure
in the sample-air air line. High pressure is an
indication that the internal regulator is set too high.
Correct flow is observed on the flow meter; the flow
ball is usually between .5 and .8 SCFH.
Calibration in process: During calibration testing and
the calibration procedure, this alarm is activated.
The alarm will terminate when the technician has
correctly returned the monitor to service.
Yellow Light - No Audible Alarm
• Warm-Up Period: During the first several minutes of
operation, the monitor goes through a warm-up
period while the sensor stabilizes. During the warmup period, the yellow light illuminates, and all other
alarms are non operational. The alarm will terminate
after the warm-up is complete.
Red Light - Continuous Audible Alarm
• Toxic Gas Detected: This alarm occurs when toxic
gas or CO in excess of 10 PPM is detected in the
breathing air line.
1.5.5 Run/Calibration Switch: The toggle should be in
the ″RUN″ position for all operations other than the
actual calibration test and calibration process. If, for any
reason, the toggle is not in the "RUN" position, the
instrument will initiate a "yellow" light and intermittent
alarm, indicating that the sample-air is not reaching the
sensor. Correctly positioning the toggle will terminate the
intermittent alarm.
Optional Accessories
1.6.1 Remote Alarm: The 12 volt DC remote alarm is
a high-intensity, red lens strobe light and high decibel
horn. Unlike external alarms, this alarm does not require
an external power source. This accessory is
recommended in high noise areas, or where the monitor
cannot be placed in a conspicuous location. The alarm
kit includes the alarm, stand, wiring connector, and 50 ft.
cable. See Accessories in Section 8.1. With additional
cable, this alarm may be used up to 150 ft. from the
monitor. Consult Clemco Industries Corp. if longer
length is required.
1.6.2 Air Line Humidifier: This accessory is used to
humidify sample-air when the instrument is used to
monitor air lines where the air has been dried to 30%
RH (relative humidity) or less.
Compressed Air Requirements
Page 3
2.1.1 Air Pressure: If the compressed air source is
between 55 psi and 120 psi, no pressure adjustment is
required. If line pressure is above 120 psi, a regulator is
required to reduce pressure within the 55 to 120 psi
operating range.
Air Connection
Do not use pipe joint compound to seal pipe
fittings. The monitor will respond to the gases
given off by these compounds. Use teflon tape
for pipe thread sealer.
Do not use any silicone based lubricants upstream of this instrument. Silicone exposure
will prematurely damage the sensor. If the instrument is used to monitor air lines
where the air has been dried to 30% RH or less, mount
an optional humidifier in an upright position between the
air supply source and monitor inlet. To ensure accurate and rapid air monitoring, the
monitor must be placed as close to the compressed air
source as practical. Ten feet of 1/8" ID tubing with two
1/4" NPT fittings are furnished, to be used between the
compressed air source and monitor inlet. Larger
diameter tubing or pipe, or longer lengths, increases the
air supply volume, and the volume determines the length
of time it takes for the sample-air to reach the monitor. Determine a suitable place to tap into the
compressed air supply. The tap location should be within
10 feet of the monitor, and the monitor placed in a
location that permits continual observance of the visual
and audible alarms.
The monitor or an auxiliary alarm must be in a
conspicuous place to ensure that any alarm
condition is observed. Using the auxiliary
terminals and a relay, the monitor may be
interlocked with other devices such as the
compressor shut-down, as an additional
safeguard against an unobserved alarm.
© 2008 CLEMCO INDUSTRIES CORP. • • Manual No. 22925
CMS-2 CARBON MONOXIDE MONITOR Place a tee in the air supply line, and use a
bushing or other adaptor, to connect one of the 1/4" NPT
tube fittings supplied. Install an isolation valve at the
source to enable depressurization to remove the
monitor. Typical set-ups are shown in Figure 2.
Page 4 The air supply line tee should face upward to
prevent water from accumulating in the sample–air line.
If the tap cannot be up, install a drop pipe and drain to
prevent water from entering the monitor. Connect the other 1/4" NPT tube fitting to the
monitor’s inlet port.
1/4" NPT Tube Fitting
To Respirator Attach the urethane tubing between the air
supply tube fitting and monitor inlet tube fitting. Remove
excess tubing.
1/8" ID Tubing
1/4" NPT
Tube Fitting
CPF Filter
Electrical Requirements
2.2.1 120-Volt AC: Monitors are supplied with a 120volt AC power cord, and can be plugged into a 120 volt
grounded electrical source.
Converted to 12 Volt
Power Cord
Battery or Relay
1/4" NPT Tube Fitting
1/8" ID Tubing
1/4" NPT
Tube Fitting
Power Cord
Isolation Valve
Compressed Air Line
2.2.2 12-Volt DC: Although monitors are supplied with
a 120-volt AC power cord, they are easily converted to
operate on 12-volt DC. The following instructions explain
the conversion. Use the supply cord provided with the
monitor, or use another 2-wire cord if a longer one is
required. Using the same process, but with 12-volt color
codes, using "red" as positive. If a new 12-volt cord is
used, splice the positive through the fuse, and use the
spade on the outlet of the fuse to connect to the positive
terminal. Refer to Figure 3. Make sure that all electrical power to the monitor
is disconnected. Open the case to access the interior faceplate. Loosen the closing screw located in the center
of the lower edge of the faceplate. See Figure 1. Swing the
the Remove the connector from the outgoing side of
the transformer (three wires) from the terminal board
connector post as shown in Figure 3. If the monitor is to
be permanently converted to 12-volts, remove the three
wires from the transformer and remove the wire.
Compressed Air Line
Isolation Valve
1/4" NPT Tube Fitting
1/8" ID Tubing
Drop Line
Power Cord Loosen the transformer mounting screws and
remove the plastic shield from the incoming side of the
transformer. Remove the "white" and "black" wire
terminal connectors from the incoming side of the
transformer, Ref. Figure 3. Tighten the transformer
mounting screws.
Figure 2
© 2008 CLEMCO INDUSTRIES CORP. • • Manual No. 22925
Page 5 A relay contact is mounted on the circuit board
(Ref. Figure 4), for use with external alarms and shutdown devices. These contacts are rated at 5 amperes.
Use the contacts to operate relays for external devices.
Circuit Board
Remove white and
black wire from inlet
side of transformer
Connector Post
Remove shield
Dry Relay Contact
Remove Connector
Remote Alarm Connector
Do not connect external
alarms to this connector.
This is for the optional
remote alarm only.
white wire to DC−
black wire to DC+
Figure 3 Plug the "black" wire connector to the "DC+"
terminal on the lower left end of the circuit board, and
the "white" wire connector to the "DC-" terminal.
Power Remove the u-ground plug from the other end of
the cord. Attach a positive (+) terminal connector to the
end of the "black" wire and a negative (-) connector to
the end of the "white" wire. Clip the green wire.
Use any terminal connectors that are
compatible with the 12-volt DC system.
However, take care to ensure that the
connectors are clearly marked positive (+) and
negative (-). Attach the positive connector to
the wire leading to the "DC+" terminal, and the
negative connector to the "DC-" terminal on the
circuit board. The monitor will not operate if
wires are reversed.
2.2.3 Connecting External Alarm and Shut-Down
Device. Ref. Figure 4. Note: External alarms require an
external power source. Do not confuse with the optional
remote alarm that does not require external power.
Auxiliary Alarm
NO When closing the faceplate, ensure that all
internal air lines are free of interference, binding or
kinks, and that all tube connections are secure. Tighten
the closing screw. Close and latch the instrument case cover.
Typical wiring for normally open alarm
Figure 4
2.3.1 The CMS-2 does not require any special
mounting, and it will operate in any position. The
carrying case handle may be used to hang the monitor
in a convenient location that is close to the compressed
air source. See Section 2.1.2.
DO NOT mount this instrument inside a blast
room. An operator inside a blast room wearing
protective clothing will not hear the alarm and
may not notice when the instrument is in an
alarm condition. The alarm case is not designed
to withstand the continual impact of abrasive
that takes place inside a blast room. Refer to
instructions within the manual for installing
auxiliary horns, lights, and safety shut-down
© 2008 CLEMCO INDUSTRIES CORP. • • Manual No. 22925
permissible contamination level, or the instrument
requires calibration. Refer to Section 4.0.
Do not use compressed air that this instrument
monitors for respiratory use unless the
instrument has been calibration-tested, and if
needed calibrated per Section 4.0. Using a
monitor that has not been calibration-tested
could permit undetected CO to enter the
respirator air lines. Breathing toxic gases could
cause death.
Set-Up For Operation
3.1.1 Position the Run/Calibration toggle switch to the
"RUN" position.
3.1.2 Open the sample-air isolation valve to supply
test air to the monitor.
3.1.3 Plug the instrument into a grounded 120-volt AC
power supply. If the monitor is converted to operate on
12 Volt, connect to a 12-volt DC power source, being
certain the positive and negative leads go to the correct
terminal. There is no on/off switch on the monitor; it will
initiate operation as soon as power is applied.
Page 6
Warm-Up Period
3.2.1 With electrical power applied and 55 to 120 psi
sample-air supplied to the inlet, the monitor will go
through a five minute warm-up period.
3.2.2 During the warm-up period, the audible alarms
are disabled and the external visual alarm is "yellow". At
the end of the warm-up period the "yellow" exterior light
turns "green", indicating that the instrument is
functioning and the sample-air does not exceed the
contamination limit.
NOTE: If the instrument has been off for a prolonged
period, it is normal for the alarms to activate for a short
period of time after the warm up cycle.
3.2.3 Insure alarms function per Section 5.5. If the
alarms function as described, proceed to place the
instrument in operating mode, per Section 3.3.
3.2.4 If the instrument goes into an alarm (exterior
light remains "red" with continuous audible alarm) after
the warm-up, re-initiate warm-up by terminating and
restarting power.
DO NOT use the respirator during the warm-up
period. The alarms are disabled and will not
warn against toxic gases.
Operating Mode
3.3.1 Following the warm-up period, with the toggle
correctly positioned to "RUN", and the sample-air flowing
through the unit, the monitor is in full operating mode.
3.3.2 Before donning the respirator, verify that the
monitor is in the operating mode; The exterior alarm light
must be "green", with no audible alarm.
Do not use compressed air monitored by this
instrument for breathing without first checking
to make sure the instrument is in full operating
mode, and the exterior alarm light is illuminated
"green". Failure to heed this warning could
cause death from the inhalation of carbon
3.4.1 If the instrument is not to be moved, and is
protected from the weather, simply shut off the isolation
valve, and unplug the power cord. If the unit is to be
transported, or if it is not protected from the weather,
proceed as follows:
3.4.2 Watch the flow meter; when air flow stops,
remove the urethane tubing from the supply line and
monitor inlet. The tubing is easily removed by pushing in
the tube fitting ring while pulling the tubing.
3.4.3 Coil the tubing and place it inside the instrument
case to keep the tubing clean.
3.4.4 Place tape or other cover over the inlet fitting to
keep instrumentation clean.
3.4.5 Transport the instrument in the passenger
compartment of the service vehicle, not in the trunk or
truck bed. See "Care and Handling" in Section 5.1
3.2.5 Continued alarm condition after several warmup periods indicates that the sample-air exceeds the
© 2008 CLEMCO INDUSTRIES CORP. • • Manual No. 22925
Note: Thoroughly review the calibration testing and the
calibration process before testing or calibrating the
This instrument must be tested and calibrated
with 10 PPM Test Gas. Do not test or calibrate
with any other test gas concentration. Doing so
will place the monitor out of calibration, and
may fail to alert the user of toxic gases.
Breathing toxic gases could cause death.
Testing and Calibration
4.1.1 It is important to understand the difference
between the calibration testing and the calibration
4.1.2 Calibration testing: Calibration testing means
applying test gas of a known concentration to the
instrument to ensure that it responds with an alarm
when CO concentrations exceed the permissible level,
and that it responds with a safe signal when impurityfree air is applied. Calibration testing does not include
any adjustment of the instrument. Calibration
(adjustments) should be done only when calibration
testing shows it is necessary.
Page 7
Prepare Calibration Connector
NOTE: Unlike ambient air, calibration test gas is bonedry. Attempts to test or calibrate the monitor without
humidifying the test gas will cause significant reading
errors of compressed air with normal levels of humidity.
4.4.1 Before connecting the calibration connector to
the test gas, dampen the humidifier media with distilled
water as follows: Ref. Figure 5.
4.4.2 Press and hold the release button and the pull
the humidifier assembly out of the release connector
4.4.3 Turn the humidifier upside down, and moisten
the sponge by putting a few drops of distilled water into
the connector, as shown in Figure 5.
Distilled Water
Humidifying Media
4.1.3 Calibration: Calibration means adjusting the
instrument. Calibration should be done only when the
instrument does not respond during calibration testing,
or remains in alarm at start-up.
Figure 5
Materials Required for Tests and Calibration
10 PPM Test Gas.............................Stock No. 22865
Impurity-Free Test Gas ...................Stock No. 11132
(when required, see Section 4.9)
Calibration Connector ......................Stock No. 22893
Distilled water
Small adjusting screwdriver
(when calibration is required)
4.4.4 Hold the tubing end of the connector and shake
out excess water. NOTE: The humidifier needs to be
dampened only; excess water must be removed so
that it does not enter the instrument plumbing.
4.4.5 Reconnect the humidifier to the connector by
pushing the humidifier into the release body. Gently pull
the connector to make sure it is correctly seated in the
4.4.6 Make sure the flow-control knob is turned fully
clockwise to the "OFF" position. Refer to Figure 6.
4.3.1 The monitor must be in operation for at least 30
minutes before calibration testing. DO NOT test the
instrument until it has gone through the warm-up period
and has been in operation with sample-air flowing
through it (See Section 3.0) for at least 30 minutes.
4.4.7 Attach the test gas connector to the cylinder of
calibration gas (Use 10 PPM CO test gas to check the
calibration or to calibrate the monitor. Use zero, impurityfree air to check if alarm is due to contaminated air or
other condition).
© 2008 CLEMCO INDUSTRIES CORP. • • Manual No. 22925
Page 8
immediately turn "yellow", and within a few seconds the
intermittent audible alarm will sound (the calibration
indicator remains "green").
Tube End Connector
Flow-Control Knob
Release Connector
Calibration Testing
4.6.1 With the flow meter vertical, slowly open the
flow-control knob to introduce test gas. Test gas is
entering the unit when the flow meter ball rises. If the
ball does not rise when the calibration valve is opened,
the test gas cylinder is probably empty.
Calibration Connector
4.6.2 Adjust the flow-control knob until the flow meter
ball remains between .5 and .8 SCFH. The valve is
extremely sensitive. Minor adjustments may be required
to correctly position the ball.
Test Gas
Figure 6
Prepare Instrument
4.5.1 Open the instrument case cover to access the
interior faceplate. Take care not to introduce blast
environment contaminants into the instrument when the
case is open. See Figure 7 for faceplate-calibration
testing and calibration callouts.
Flow meter ball
through this port
Position toggle
toward calibration
4.6.3 Allow test gas to flow through the instrument for
about one minute, or until the interior calibration
indicator light turns "red".
4.6.4 After the calibration light turns "red", the initial
phase of the calibration test is complete. Return the
instrument to operating mode per Section 4.8. If the
indicator light does not turn "red" proceed with
Paragraph 4.6.5.
4.6.5 If after one minute of operation with test gas the
calibration indicator light has not turned "red", and the
instrument has been in operation for 30 minutes,
calibrate the instrument per Section 4.7. If the instrument
has not been in operation for 30 minutes, return it to
operating mode per Section 4.8, and operate with
sample air flowing through for at least 30 more minutes.
Re-test the calibration, and if the calibration light does
not turn "red", calibrate the instrument per section 4.7.
4.7.1 Do not calibrate the instrument unless it has
gone through two stabilizing periods and calibration
tests, per Sections 4.3 and 4.6, and only if the calibration
indicator light has not turned "red".
Test Gas
Connects from test gas
Figure 7
4.5.2 Connect the calibration connector to the "Test
Gas Port", by aligning the tabs and inserting the tube
end connector into the port and turning it slightly
clockwise until it locks.
4.5.3 Place the Run/Calibration toggle toward
"CALIBRATION". The external alarm light will
4.7.2 Prepare the calibration connector per Section
4.4 and attach it to a cylinder of 10 PPM CO test gas.
4.7.3 Connect the calibration connector to the "Test
Gas Port4 on the faceplate.
4.7.4 Place the Run/Calibration toggle toward
"CALIBRATION". Slowly open the flow-control knob and
adjust the flow so the flow ball remains between .5 and
.8 SCFH.
© 2008 CLEMCO INDUSTRIES CORP. • • Manual No. 22925
Page 9
4.7.5 Allow test gas to flow through the instrument for
about one minute. Insert a small screwdriver into the
calibration adjustment port, and turn the potentiometer
as follows:
• If the potentiometer is BLUE, turn clockwise
until the calibration indicator light turns "red".
• If the potentiometer is "WHITE", turn
counterclockwise until the calibration indicator
light turns "red".
alarm condition is due to contaminated air, or monitor
4.7.6 Once the indicator is "red", turn the
potentiometer in the opposite direction until the light
turns "green". Then, slowly turn the potentiometer from
"green" to "red" several times to find the trip point. The
monitor is calibrated at the spot where the light turns
"red". Return the instrument to operating mode per
Section 4.8. If the monitor is correctly calibrated and in
working order, the alarm light will turn "green" during this
test. This means the monitor was reading contaminated
Return to Operating Mode
4.8.1 Push the connector’s slide valve to the "CLOSE"
4.8.2 To remove the calibration connector from the
monitor, grip the tube end connector, turning it slightly
counterclockwise to unlock, and pull straight out.
4.8.3 Place the calibration toggle switch to the RUN
position. The flow meter ball should rise to .5 to .8
SCFH. After several seconds the external alarm light
should change from "yellow" to "green", and the interior
light should change to "green". If the lights respond as
described, proceed with 4.8.4 to return the instrument to
operation. If after about one minute of operation, the
lights do not change to "green", do both of the following:
• Calibrate the instrument per Section 4.7.
• Test instrument function by applying impurity-free
air, per Section 4.9.
Close and latch the instrument case cover.
4.8.5 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.
Store all material in a clean, dry area.
Impurity-Free Air (zero contamination) Test
4.9.2 Follow the steps in Section 4.6 "Calibration
Testing", except use impurity-free test gas in place of the
10 PPM gas. The alarm light will either remain "red" or
turn "green". Proceed as follows:
Alarm light turns "green"
Do not use compressed air that this instrument
has identified as toxic for breathing until the
source of contamination is identified and
corrected. Breathing toxic gases could cause
death. Identify the source of contamination. Do not
overlook the possibility that contaminated air entered the
compressor intake. The contamination could be from
engine or other exhaust entering the intake. If the source
of contamination is temporary, the monitor will return to
a non-alarm (safe) condition after the contamination is
cleared from the compressed air system.
Alarm light remains "red" If the monitor is out of calibration or not in good
working order, the alarm light will remain "red". Calibrate the monitor per Section 4.7 and apply
impurity-free gas per Section 4.9. If the alarm light
remains "red", the monitor requires service. Refer
Section 6.0.
Do not use compressed air monitored by this
instrument for breathing unless the instrument
is in good working condition. Using a monitor
that is not in calibration or not working
correctly could permit undetected CO to enter
the breathing-air lines. Breathing toxic gases
could cause death.
4.9.1 This test should be done whenever the
instrument stays in an alarm condition after it is returned
to the operating mode. This test shows whether the
© 2008 CLEMCO INDUSTRIES CORP. • • Manual No. 22925
Care and handling
5.1.1 This monitor is designed for portable, field use
and is not adversely affected by normal handling that is
required of any test and measurement instrument.
5.1.2 Transport the instrument in the passenger
compartment of the service vehicle, not in the trunk or
truck bed.
Do not subject this instrument to extreme hot
or cold environments. Placing the instrument
case on the dashboard or trunk of the service
vehicle in direct sunlight or similar condition
will elevate the temperature inside the case to a
level that will damage the instrument’s
electronic components.
5.2.1 The need to open the case periodically to
calibrate the instrument exposes it to potential external
contamination. Take care not to introduce contaminants
into the instrument when the case is open.
5.2.2 Clean the exterior of the case with a solution of
water and mild detergent. Do not use solvent cleaners.
NOTE: Do not attempt to repair or replace any item that
is not listed in this section, or that requires parts not
listed in Section 8.2. Contact an authorized distributor of
Clemco products for authorization to return the
instrument for evaluation or service.
Sensor Replacement
6.1.1 Sensor life depends upon several factors, but in
most cases the sensor should last approximately two
6.1.2 The following materials are required before
replacing the sensor:
• 10 PPM Test Gas ............................Stock No. 22865
• Calibration Connector ......................Stock No. 22893
• Sensor..............................................Stock No. 22919
• Standard screwdriver
6.1.3 Open the instrument case to access the interior
faceplate. Take care not to introduce contaminants into
the instrument when the case is open.
6.1.4 Loosen the closing screw located in the center
of the lower edge of the faceplate.
6.1.5 Using the top hinge as the pivot, swing the
faceplate up to expose the instrumentation.
6.1.6 Locate the clear-plastic sensor housing, shown
in Figure 8, and while supporting the circuit board,
loosen the two mounting screws.
Calibration Schedule
5.4.1 Avoid the urge to calibrate the instrument.
Calibrate only when the calibration test shows it is
required. See Section 4.0.
in the operating mode; the exterior alarm light must
be "green", with no audible alarm.
Calibration Testing Schedule
5.3.1 Test the calibration when it is initially set-up, and
again the day after. Check it once a week for the first
month. Check it at least once a month thereafter. Refer
to Section 4.0 for test procedure.
Page 10
Sensor Housing
Alarm Tests
5.5.1 Although uncommon, alarm lights and horns do
fail. Check their function before each use by placing the
Run/Calibration toggle toward "CALIBRATION". The
external alarm light will immediately turn "yellow", and
within a few seconds the intermittent audible alarm will
sound. Placing the toggle in ″RUN″ position returns the
alarms to their normal operation. Never use the
respirator without first verifying that the monitor is
Note tab
© 2008 CLEMCO INDUSTRIES CORP. • • Manual No. 22925
Figure 8
Page 11
6.1.7 Carefully pull straight up to lift the sensor
housing off the circuit board. The sensor may come off
with the housing or stay plugged into the board.
6.1.8 If the sensor remains on the circuit board, note
the location of the small tab, as the new sensor must be
installed in the same orientation. While supporting the
circuit board, carefully pull straight up to remove the
Shorting electrical components could result in
serious electrical shocks, or could damage
equipment. All electrical troubleshooting must
be performed by a qualified electrician.
6.1.9 If the sensor comes off with the housing, note
the tab location, and remove the sensor by pulling on a
couple of the sensor pins.
6.1.10 Discard the old sensor to avoid attempts to
6.1.11 Handle the new sensor with care not to distort
the pins. Rotate the sensor so the tab is in the same
position as was the old one (as shown in Figure 8) and
plug the pins into the socket, some pin alignment may
be required, and is normal. Push firmly but carefully to
seat the sensor. The sensor will stand off the circuit
board by approximately 1/4" when seated.
6.1.12 Place the sensor housing over the sensor, align
the mounting screw holes, and while supporting the
circuit board, tighten the screws snugly. Do not overtighten the screws.
6.1.13 When closing the faceplate, ensure that all
internal air lines are free of interference, binding or
kinks, and that all tube connections are secure. Tighten
the closing screw.
6.1.14 Close the instrument case and apply sample air
and power per section 3.0, and allow the monitor to run
in operating mode for at least one hour.
6.1.15 Calibrate the monitor per Section 4.0.
6.1.16 Return the monitor to service and record sensor
replacement date.
6.1.17 Follow the calibration testing schedule per
Section 5.3.
Fuse Replacement
6.2.1 The fuse cap is located on the side of the
instrument case. To access the fuse, push the cap in
and rotate counterclockwise.
Instrument Will Not Calibrate: If the alarm
sounds when test gas is applied but does not stop
when gas is removed, or if response is very slow.
7.1.1 Calibration humidifier not moistened during
calibration. Ensure that the humidifying media is
dampened with distilled water before calibrating.
Faulty sensor, replace with new sensor.
Intermittent Alarm: A pressure switch
mounted on the circuit board monitors pressure of
the sample-air delivered to the sensor. If pressure at
the switch (which is monitored by flow through the
flow meter) drops below minimum requirement, or
rises above maximum psi, the monitor will initiate an
intermittent alarm.
7.2.1 Before doing pressure tests make sure the
Run/Calibration toggle switch is toward "RUN" position.
If for any reason the toggle is not in the "RUN" position,
the instrument will initiate an intermittent alarm,
indicating that the sample-air is not reaching the sensor.
Correctly positioning the toggle will terminate the
intermittent alarm.
7.2.2 Make sure the pressure of the sample-air is
between 55 psi and 120 psi. If the sample-air is higher
than 55 psi, the restriction is internal. Proceed as
7.2.3 Check flow through the flow meter. If the flow
ball is below .5 SCFH or above .9 SCFH adjust the
internal pressure regulator accordingly, until the ball
remains between .5 and .8 SCFH. The regulator was
factory set slightly higher than the pressure switch and
should rarely require adjustment. If the regulator
pressure was outside the limits, the alarm will disengage
as soon as the pressure is corrected. After the pressure
is correctly set, close the faceplate.
7.2.4 Check internal instrumentation lines for breaks,
kinks, or disconnection. If a line has come loose,
reconnecting it will re-establish function and the monitor
could be correctly used. NOTE: This type of failure
© 2008 CLEMCO INDUSTRIES CORP. • • Manual No. 22925
could be the result of improper service, as the
instrument is tested with pressure much higher than
operating pressure. The monitor should be returned to
the maintenance service technician for review as soon
as practical.
No annunciator lights or alarms. This
condition indicates a loss of electrical power, as it is
unlikely to have audible and visual alarms fail at the
same time.
7.3.1 Make sure the electrical power
connected to the appropriate power source.
7.3.2 Check the fuse located inside the case; make
sure it is not blown.
Check to make sure that the power supply is on.
7.3.4 For 12-volt system, Make sure the battery is fully
charged and that the charging system is operational.
Make sure the positive and negative terminals are
connected correctly.
7.3.5 Check for faulty transformer, or loose plug
connection on circuit board.
Page 12
Either alarm light or audible alarm fails.
7.4.1 Check for loose plug connections on circuit
7.4.2 To test the alarm, remove the plug connection
on the circuit board from the suspect alarm, and apply
external 12-Volt power. If the alarm fails to activate,
replace it.
7.4.3 To test the circuit board, remove the plug
connection from the faulty alarm. Use a volt meter to
check voltage across circuit board pins. Note: When
testing an audible alarm, switch the Run/Calibration
Switch to the ″Calibration″ position. This will cause an
intermittent alarm, and should register on the voltmeter
each time the alarm activates. Monitors with faulty circuit
board should be returned for service.
Stock No.
CMS-2 CO monitor package, includes:
monitor, calibration connector, and
10 PPM test gas .....................................22894
CMS-2 CO monitor (instrument only) ........22892
Calibration connector assembly ................22893
Test gas, 10 PPM ......................................22865
Test gas, impurity-free ..............................11132
Remote alarm kit, Includes: alarm, stand,
wiring connector and 50 ft. cord .............22909
Cable, remote alarm extension 50 feet .....22910
Air line humidifier .......................................03600
Replacement Parts
Description ........................................... Stock No.
Sensor ........................................................22919
Regulator /Filter .........................................22920
Filter element..............................................22921
Flow meter..................................................21376
Horn w/ wire, (audible alarm) 12-volt DC ...22922
Alarm light, exterior w/ wire & connector....22923
Fitting, 1/4" OD quick fit .............................22924
Tubing, urethane, ten feet required ...........12475
Orifice, .004 purple restrictor .....................24423
Orifice, .006 red restrictor ..........................24424
© 2008 CLEMCO INDUSTRIES CORP. • • Manual No. 22925
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