Clemco BEACON LED BLAST LIGHT User manual

BEACON
LED BLAST LIGHT
O. M. 27765
DATE OF ISSUE: 07/14
REVISION: B, 09/17
© 2017 CLEMCO INDUSTRIES CORP.
One Cable Car Dr.
Washington, MO 63090
Phone [phone]
Fax [phone]
Email: [email protected]
www.clemcoindustries.com
Do not use this
equipment until you
have READ this
MANUAL and YOU
UNDERSTAND its
contents. *
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 Parts 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.
WARNING

PREFACE
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
[I]
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• 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.

NO T I C E TO PURCHASERS AND U SE R S OF OUR
P R ODU C T S AND T H I S I N F O R M A T I ON A L M A T E R I A L
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 products described in this material, and the information
relating to these products, are intended for knowledgeable,
experienced users.
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.
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.
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.
The blast operator and all workers in the vicinity must be
properly protected from all job site hazards including those
hazards generated by blasting.
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.
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.
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: [phone] — Fax: [phone]
Email: [email protected]
Website: www.clemcoindustries.com

PREFACE
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
[II]
OPERATIONAL INSTRUCTIONS


OPERATOR SAFETY EQUIPMENT
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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 GradeD,
as defined by the Compressed Gas Association
specification G-7.1, per OSHA Regulation 29 CFR
1910.134. When compressed air is the breathingair
source, a Clemco CPF (suitable sorbent bed filter)
should be used. Respirator hose connecting the
respirator to the filter must be NIOSH approved.
Non- approvedhose can cause illness from
chemicals employed to manufacture the hose.
• All workers must always wearNIOSH-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 removeor protect against
carbon monoxide or any other toxic gas. Monitoring
devices must be used in conjunction with the respirator to
ensure safe breathingair. Always locate compressors and
ambient air pumps where contaminatedair will not enter
the air intake.

• Always use Clemco lenses with Clemco respirators;
installing non-approvedlenses voids the NIOSH approval.
Respirator lenses aredesigned to protect the wearerfrom
rebounding abrasive; they do not protect against flying
objects, heavyhigh-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
TheSociety 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

PREFACE
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
[III]
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

Completelyreadand follow all service instructions and recommended maintenance intervals. Always shut off compressor and
depressurize blast machine beforeperforming any maintenance. At everyservice interval, clean all filters, screens, and alarm systems. If
spring-loaded abrasive valves areused, always cage spring beforedisassembly.

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 areto
be freefrom defects in workmanship and materials for a
period of one yearfrom dateof shipment to buyer, but no warranty is
madethat the products arefit 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 madeavailable to the
customer upon request.
4. Theuse 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 aredelivered freeof the
rightful claim of any third party by way of patentinfringement or the like.
6. This warranty is conditioned upon seller’s receipt within ten (10)
days afterbuyer’s discovery of a defect,of a written notice stating in
what specific material respects the product failed to meetthis
warranty. If such notice is timely given, seller will, at its option, either
modify the product or part to correct the defect,replacethe product or
part with complying products or parts, or refund the amount paid for
the defectiveproduct, any one of which will constitute the sole liability
of the seller and a full settlement of all claims. No allowance will be
madefor alterations or repairs made by other than those authorized
by seller without prior written consent of seller. Buyershall afford
seller prompt and reasonable opportunity to inspect the products for
which any claim is madeas abovestated.
Except as expressly set forth above,all warranties, express, implied
or statutory, including implied warranty of merchantability, are
herebydisclaimed.

PREFACE
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[IV]
DAILYSET‐UPCHECKLIST
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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.
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.
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.
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.

12. ABRASIVE must be a material specifically manufactured for blasting. It
should be properly sized for the job. Check material safety data sheet for free-
silica, cyanide, arsenic, lead and other toxins and avoid use when these toxic,
harmful substances are present.

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
1. Air Com
p
resso
r
7. Air Line
Moisture
Se
p
arato
r
5. CPF Air Filte
r
6. ASME Code
Bl
as
t M
ac
hin
e
8. Remote
Co
ntr
o
l
s
9. Blast Hose 10. Hose Couplings and Safety Cables
11. Appropriately Sized Nozzle
12. Abrasive
4. External or
Helmet Mounted
Carbon Monoxide
Monitor /Alarm
2. Breathing Air Compressor for
High Pressure Respirators3. NIOSH Approved
Supplied-Air Respirator
or Ambient Air Pump for
Low Pressure Respirators

BEACON LED BLAST LIGHT Page 1
© 2017 CLEMCO INDUSTRIES CORP. www.clemcoindustries.com Manual No. 27765 Rev. B
1.0 INTRODUCTION
1.1 Scope of manual
1.1.1 This manual covers the setup, operation,
maintenance, and replacement parts of the Clemco
Beacon blast light.
1.1.2 These instructions contain important safety
information. All operators and personnel involved with
the abrasive blast process must read and understand
the contents of these instructions, including the orange
cover. It is equally important that the operator is trained
and qualified to safely operate the blast machine and
remote controls, and all other equipment used with the
blast machine.
1.1.3 All personnel involved with the abrasive blasting
process must be made aware of the hazards associated
with abrasive blasting. The Clemco booklet Abrasive
Blasting Safety Practicesis included with every blast
machine, and contains important safety information
about abrasive blasting that may not be included in
equipment operation manuals. To order additional
copies, visit www.clemcoindustries.com or email
[email protected].
1.2 Safety Alerts
1.2.1 Clemco uses safety alert signal words, based on
ANSI Z535.4-2011, 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 you to potential physical
injury hazards. Obey all safety
messages that follow this symbol to
avoid possible injury or death.
NOTICE
Notice indicates information that is considered
important, but not hazard-related, if not
avoided, could result in property damage.
CAUTION
Caution indicates a hazardous situation that, if
not avoided, could result in minor or moderate
injury.
W
ARNING
Warning indicates a hazardous situation that, if
not avoided, could result in death or serious
injury.
DANGER
Danger indicatesa hazardous situation that, if
not avoided, will result in death or serious
injury.
1.3 General Description
1.3.1 The Beacon is available in six models:
Three 120-volt AC models: Available with 10-foot, 50-
foot, or 100-foot power supply cables with u-ground
plug, which plug into any 120-VAC power source.
120-VAC models include an integral 12-VDC power
supply that converts 120-VAC to 12-VDC; all models
provide 12-Volt DC power to the light.
Three 12-volt DC models: Available with 10-foot, 50-
foot, or 100-foot power supply cables and color coded
spring clamps, to connect to a battery or other 12-VDC
power source.
The Beacon is a high-intensity LED light, which attaches
to a convenient location on the blast hose, nozzle holder,
or nozzle, for lighting the blasting surface. The Beacon is
ideally suited for lighting the blast surface in dimly lit
areas. It can also be attached to scaffolding, bracing, or
other surfaces as needed to provide additional lighting in
low-light blasting spaces.
1.4 Components
1.4.1 The components of the Beacon blast light are
shown in Figure 1, and include.
One of the following light assemblies:
12-volt DC assembly with 10-ft. supply cable
12-volt DC assembly with 50-ft. supply cable
12-volt DC assembly with 100-ft. supply cable
120-volt AC assembly with 10-ft. supply cable
120-volt AC assembly with 50-ft. supply cable
120-volt AC assembly with 100-ft. supply cable
Two nylon cable ties
2-ft. Adhesive-backed gasket

BEACON LED BLAST LIGHT Page 2
© 2017 CLEMCO INDUSTRIES CORP. www.clemcoindustries.com Manual No. 27765 Rev. B
Figure 1
2.0 SET-UP
2.1 Assemble Mount to Light Assembly
Refer to Figure 2
2.1.1 Slide the light mount into the slot on the light
assembly; the mount is tapered and inserts in only one
direction into the slot. Secure with the socket head screw
provided.
2.1.2 Use the cap screw provided to attach the
mounting bracket to the light mount. Secure with the lock
nut provided.
Figure 2
2.2 Assemble Light to Blast Hose
Refer to Figure 3
2.2.1 Use cable ties provided or user-supplied worm
clamps or tape to attach the light to the blast hose,
nozzle holder or nozzle, as shown in Figure 3. When
attaching the light to a slick surface, such as a nozzle or
nozzle holder, use adhesive-backed gasket to prevent
the light from slipping. To apply, cut two lengths of
gasket long enough to wrap around the holder; remove
the backing and apply the gasket around the holder,
spaced so one length of gasket is under each end of the
mounting bracket, as shown. Shorter couplings may
require the gasket strips be placed closer together.
Figure 3
2.2.2 Wrap the cable ties around each end of the
mounting bracket, as shown in Figure 3, and loosely but
secure enough to barely hold the light in position.
2.2.3 Make sure the light is aligned with the nozzle;
the pivot adjustment will be done later. If the light is
attached to the hose, and it is too far from the nozzle,
bends in the hose will direct the light beam away from
the blast stream.
Mounting Bracket Cap Screw
Lock Nut
Socket Head Screw
Light Mount
Mount Slot
* Used only with 120-volt lights
** Used only with 12-volt lights
Blast Light Assembly
**12-volt DC Supply Cable
10-ft., 50 ft., or 100 ft.
*120-volt AC Supply Cable
10-ft., 50-ft., or 100-ft.
*AC Junction Box
*4-foot Power Cord
w/120-folt AC U-ground Plug
Cable Ties (2)
5/16" x 1" Adhesive-Backed Gasket
2 feet supplied, refer to Paragraph 2.2.1.
**Clamps, (+) positive and negative (-)
Wrap cable ties
around bracket.
Cinch the ties to secure.
Mounting Bracket
Wrap adhesive-backed
gaskets around nozzle
or nozzle holder.

BEACON LED BLAST LIGHT Page 3
© 2017 CLEMCO INDUSTRIES CORP. www.clemcoindustries.com Manual No. 27765 Rev. B
2.2.4 Make sure the light and cable are placed so they
do not interfere with the operation of the control handle
or operator’s grip on the blast hose.
W
ARNING
When attaching the light to the blast hose,
make sure it does not restrict operation of the
control handle or reduce the grip on the blast
hose. Any interference with the operation of the
control handle or grip on the blast hose may
cause a condition that could result in injury
from the blast stream.
2.2.5 Cinch the cable ties to securely affix the light.
Once the light is firmly attached, clip the tie ends so they
will not interfere with the operators grip or operation of
the control handle.
2.2.6 Loosely wrap the power supply cable around the
end of the blast hose and attach cable ties or tape. The
cable needs to be attached with enough slack to prevent
the cable from being stretched taut when the blast hose
is moved or pulled.
NOTICE
Make sure there is enough slack in the cable to
prevent the cable from being stretched taut
when the blast hose is moved or pulled.
Damage could occur at the wire connections if
the cable is stretched taut.
2.2.7 When used in permanent blast installations, it
may be helpful to strap the cable to the blast hose every
three or four feet. When used in portable applications,
the cable may be kept loose and always detachable from
the blast hose to prevent damage to the light when
coiling the hose and moving to another worksite.
2.3 Connect Cable to Power Supply
2.3.1 Connect the cable to a suitable 120-VAC or 12-
VDC power supply. The light is ON as soon as it is
connected to a power source. NOTE for 12-VDC units
only: The red (+) cable clamp must connect to the
positive (+) terminal; if reversed, the light will not work.
2.4 Extension Cord
2.4.1 A 16-gauge or larger extension cord may be
used, but not to exceed a total length of 300 feet from
the power supply to the lamp.
3.0 ADJUSTMENTS
W
ARNING
Reposition the light and power cable as needed
to avoid entanglement or other interference
with the operation of the control handle or grip
on the blast hose that may result in a condition
causing injury from the blast stream.
3.1 Light Position on Hose
NOTE: If the light is used to illuminate parts that require
frequent repositioning of the light, use reusable worm
clamps to secure the light instead of cable ties.
3.1.1 Loosen clamps and rotate the light on the hose
to provide the best lighting to the blast surface without
interfering with the operation of the control handle or the
grip on the blast hose.
3.2 Light Angle
3.2.1 Loosen the nut on the mounting bracket bolt and
tilt the light as required to direct the light beam to provide
best lighting to the blast area. Tighten the nut to
maintain the setting.
4.0 OPERATION
W
ARNING
Use of this light in a combustible environment
could result in an explosion causing serious
injury or death.
NOTE: The light illuminates as soon as the power cable
is connected to a power supply; there is no ON/OFF
switch.
4.1 Blasting Angle
4.1.1 Whenever possible, avoid blasting 90 degrees
to the surface, as rebounding abrasive could rapidly etch
the glass outer lens. Blast at 85 degrees or less.

BEACON LED BLAST LIGHT Page 4
© 2017 CLEMCO INDUSTRIES CORP. www.clemcoindustries.com Manual No. 27765 Rev. B
5.0 MAINTENANCE
NOTICE
If the outer glass protective lens breaks, stop
blasting immediately and replace it. Delaying
replacement of a broken lens will quickly frost
the inner poly lens. Continued usage with a
broken outer lens could contaminate internal
parts and require extensive cleaning and
service. Prolonged use of the light with a
broken outer lens could permanently damage
internal parts of the light.
5.1 Cleaning and Replacing the Outer Protective
Glass Lens, refer to Figure 4
5.1.1 The lens retainer attaches to the light assembly
with a bayonet-style connection. Lens replacement is
easier when the retainer is facing up. To remove the
retainer from the light, twist it counterclockwise as
viewed from the retainer end. If the retainer cannot be
turned by hand, refer to Paragraph 5.1.2.
The lens and O-ring are loose; do not drop or misplace
them. Both are included in the outer lens service kit.
Figure 4
5.1.2 If the retainer cannot be turned, loosen the four
backplate screws several turns to remove compression
from the retainer gasket, then remove retainer. NOTE:
when the gasket is compressed as described in
Paragraph 5.1.6, friction against the gasket may prevent
the retainer from turning; loosening the backplate screws
decompresses the gasket.
5.1.3 Clean the inner surface of the retainer, inner
lens, and lens housing.
5.1.4 Discard the frosted lens and inspect the O-ring.
Replace the O-ring if it is compressed or damaged.
5.1.5 Inspect the inner poly lens; if replacement is
required, proceed to Section 5.2. If no other service is
needed, reassemble as follows.
5.1.6 Place the O-ring in the recess on the lens
housing and center a new lens on the O-ring. Reattach
the retainer by aligning the grooves in the retainer with
the tabs on the lens housing, turn the retainer clockwise
to snap it in place.
5.1.7 Tighten the four backplate screws enough to
compress the retainer gasket against the retainer, but
not so tight as to prevent retainer removal by hand.
NOTE: Compressing the gasket assures a dust-tight
seal between the retainer and light assembly.
5.2 Removing and Servicing the Inner Poly Lens
and Lens Housing, refer to Figure 5
NOTE: The lens housing must be removed to access
any serviceable items within the light assembly. Service
is easier if the light assembly is removed from the blast
hose, one method is to remove the cap screw and lock
nut from the mounting bracket as shown in Figure 2.
NOTE: The inner lens service kit include all items shown
with an asterisk in Figure 5. The following instructions
assume all the service kit items will be replaced.
5.2.1 Remove the lens retainer and glass outer lens,
per Section 5.1.
5.2.2 Remove the four backplate screws, backplates,
retainer gasket, and nuts.
Figure 5
Lens Retainer
Glass Lens
O-Ring
Backplate Screws
Retainer Gasket
Turn retainer counterclockwise to remove.
Turn clockwise to snap into place. Retainer Gasket*
Backplate Halves*
Molded Gasket*
Ridged side toward light
Poly Lens* Nut*
Backplate Screws*
Gasket Ring Channel
Lens Housing*
Lens Housin
g
* Included in inner lens service kit
Light Shell

BEACON LED BLAST LIGHT Page 5
© 2017 CLEMCO INDUSTRIES CORP. www.clemcoindustries.com Manual No. 27765 Rev. B
5.2.3 Remove the lens housing from the light
assembly. NOTE: The lens housing is held to the light
shell by friction. Pull the housing to remove it from the
shell; cup the housing when removing it to catch the
inner lens, it is loose within the housing.
5.2.4 Remove the gasket.
5.2.5 Clean all parts to be reused.
5.3 Reassemble Inner Lens and Housing to Light
Assembly
5.3.1 Place the ridged side of the molded gasket into
the channel on the light shell.
5.3.2 Make sure the nut cutouts in the lens housing
are facing away from the light shell, and then set the
poly lens into the housing recess.
5.3.3 Align the screw holes in the light shell with the
cutouts in the housing. The locating nubs on the light
shell align with the mating holes on the lens housing.
Press the housing onto the shell to hold in place.
5.3.4 Insert the four backplate screws through the two
backplate halves, gasket, light shell, and lens housing.
5.3.5 Place a square nut into the cutouts on the
housing and tighten each backplate screw enough to
engage the nuts. NOTE: A lip on the cutouts aligns the
nut with the screw hole.
5.3.6 Place the O-ring in the recess on the lens
housing and center a new lens on the O-ring. Reattach
the retainer by aligning the grooves in the retainer with
the tabs on the lens housing; turn the retainer clockwise
to snap it in place.
5.3.7 Tighten the four backplate screws enough to
compress the retainer gasket against the retainer, but
not so tight as to prevent retainer removal by hand.
NOTE: Compressing the gasket ensures a dust tight
seal between the retainer and light assembly.
5.4 12-volt Clamp Replacement
5.4.1 If clamps are removed for replacement or if the
cable is connected to the power source by another
method, make sure the white wire goes to positive (+)
and the black wire goes to negative (-). The light will not
operate if reversed.
5.5 Periodic Inspections
5.5.1 Weekly
5.5.1.1 Check compression on the outer lens retainer
gasket. Tighten the screws or replace the gasket as
necessary to maintain a tight seal.
5.5.1.2 Inspect the inner lens; if it is dirty or otherwise
needs service, refer to Section 5.2.
6.0 TROUBLESHOOTING
6.1 LED fails to illuminate when attached to
power supply
6.1.1 Check power supply with voltmeter to verify
power.
6.1.2 Inspect cable; look for a cut, break, or other
damage.
6.1.3 12-volt operation
Make sure red clamp is connected to the
positive (+) terminal and the black clamp is
connected to the negative (-) terminal.
Inspect clamps and cable for corrosion.
Make sure clamps firmly clamp to battery or
power source.
If certain the power supply is good and the
clamps are making good contact, the cable or
light assembly is faulty. The light assembly with
cable is not serviceable, replace it.
6.1.4 120-volt operation
Inspect plug for damage.
Remove conduit cover and apply power. Use a
voltmeter to make sure power is on the AC side
of the LED driver. If no power, the 4-ft. supply
cord is damaged, replace it.
Use a voltmeter to check power on the DC side
of the LED driver.
If there is no power, the driver is faulty;
replace it.
If there is power, the cable or light assembly
is faulty. The light assembly with cable is not
serviceable; replace it.

BEACON LED BLAST LIGHT Page 6
© 2017 CLEMCO INDUSTRIES CORP. www.clemcoindustries.com Manual No. 27765 Rev. B
7.0 REPLACEMENT PARTS
7.1 Beacon Blast Light Assemblies
Description Stock No.
12-VDC blast light with 10-ft cable .........................28438
12-VDC blast light with 50-ft cable .........................27740
12-VDC blast light with 100-ft cable .......................27741
120-VAC blast light with 10-ft cable .......................28439
120-VAC blast light with 50-ft cable .......................27742
120-VAC blast light with 100-ft cable .....................27743
7.2 Service Kits
7.2.1 Lens kit, outer glass, Figure 6
Pack of three with O-ring .......................28163
Pack of 20 without O-ring........................28520
Figure 6
7.2.2 Poly inner lens kit, Figure 7 .......................28164
Quantities shown in parentheses ( )
Figure 7
7.3 Blast Light Replacement Parts, Figure 8
Item Description Stock No.
1. Retainer, outer lens ...................................27748
2. Bracket, mounting .....................................27751
3. Mount, light ................................................28161
4. Screw, light mount .....................................28162
5. Diffuser ......................................................28160
6. Screw, 1/4-NC x 1.5" hex head cap ..........03055
7. Nut, 1/4-NC lock ........................................03112
8. Tie, 14.5" long nylon ..................................02195
9 Gasket, 5/16" x 1", two ft. required ............00187
10.* Driver, 120-v to 12-v LED ..........................27758
11.* Strain relief, 3/4-NPT x 1/4" cable .............27756
12.* Strain relief, 3/4-NPT x 3/8"- 5/8" cable ....27757
13.* Cord, 4-ft 120-v power ..............................27766
14.** Clamp set, 12-volt battery .........................27763
15. Service kit, glass outer,......refer to Section 7.2.1
16. Service kit, poly inner, .......refer to Section 7.2.2
Figure 8
* Used only with 120-volt lights
** Used only with 12-volt lights
Backplate Screws (4)
Backplate (2 halves)
Retainer Gasket (1)
Molded Gasket (1)
Lens housing (1)
Nut (4)
Glass Lens
O-Ring
(
with
p
ack of three onl
y
)
Poly Lens (1)
8
9
4
7
2
6
3
*10
*11
*12
*13
**14
5
1
15
16