Clemco APOLLO 100 CE User manual

Revision: 2.1
Clemco
International GmbH Carl-Zeiss-Straße 21 Tel.: [phone]
83052 Bruckmühl E-mail:[email protected]
Germany Web: www.clemco-international.com
OWNER’S MANUAL
BLAST HELMET
APOLLO 100 CE
Supplied air respirator
with continuous air flow
Cat. III
Equipment class 4 B
in acc. with DIN EN 14594:2018

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TABLE OF CONTENTS
1SCOPE OF MANUAL 4
2APPLICATION AND LIMITATIONS 4
2.1 General description 4
2.2 Restrictions and information in acc. with DIN EN 14594:2018 4
2.3 Toxic dust poisoning 7
2.4 Ear protectors 7
2.5 Expiry date of the PPE or certain of its components 7
3DESCRIPTION OF THE EQUIPMENT 7
4PREPARATION 7
5AIR SUPPLY 8
5.1 Air quality 8
5.2 Air volume, pressure and line length 9
6OPERATION 10
7SETTINGS 11
7.1 Adjusting and replacing the helmet suspension 11
8MAINTENANCE / REPLACING PARTS 12
8.1 Replacing the inner lens 13
8.2 Replacing the outer lens and cover lenses 13
8.3 Replacing the helmet suspension 14
8.4 Outer cape 14
8.5 Replacing the inner collar 15
8.6 Replacing the lens frame 15
8.7 Replacing the chin strap 15
8.8 Replacing the air line 15
9SERVICING / CLEANING 15
9.1 Filter 15

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9.2 Nylon cape 15
9.3 Leather cape 16
9.4 Inner collar 16
9.5 Sweatband/helmet suspension 16
9.6 Blast helmet 16
9.7 Inner lens 16
10 STORAGE 16
10.1 Daily storage 16
10.2 Long-term storage 16
11 REPLACEMENT PARTS 17
11.1 Air control valve 17
11.2 Helmet 18
11.3 Additional parts 19

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1 Scope of Manual
This manual covers the startup, operation, maintenance, replacement of parts and measures that ensure
the safe operation of the Apollo 100 CE blast helmet.
Read the entire manual before startup or operation of the equipment.
The following additional components may be used in conjunction with the Apollo 100 CE blast helmet:
Article no.
Description
Remarks
03580 D or
03527 D
CPF-20 or CPF-80 air filter
Installation between air supply and air supply line
23825D
Clem Cool air conditioner
In place of the pressure regulation valve to cool the
air
04411I
Climate control
In place of the pressure regulation valve to heat or
cool the air as required
These additional components are installed between the air supply and the air supply line.
100577
Leather cape for Apollo 100
In place of the nylon cape (e.g. if a lot of blast media
rebounds)
22892D
CMS-2 carbon monoxide alarm
Carbon monoxide monitor - located outside the
helmet
29766D
CMS-4 carbon monoxide alarm
Carbon monoxide monitor - integrated in the helmet
2 Application and Limitations
2.1 General description
The Apollo 100 CE blast helmet was developed especially for use in blasting operations and is approved
in accordance with DIN EN 14594:2018 (and MSHA-NIOSH).
2.2 Restrictions and information in acc. with DIN EN 14594:2018
a) The helmet enables the wearer to be supplied with breathable air, which must comply with EN
12021. The air is fed at a continuous flow rate to a mask via a breathing line. The equipment has
an adjustable air flow valve that is worn by the operator. An air supply line links the equipment
wearer with the air supply.
b) Excess and exhaled air is released to the ambient atmosphere.
The following temperatures are prescribed for:
Storage: 0°C to +30°C
Operation: -6°C to +40°C
Transport and handling: -20°C to +50°C
c) The length of the line between the filter and the control valve on the helmet must not exceed 40
m. We sell the line in pre-cut lengths of 5, 10, 20 and 40 m. A maximum of three lines can be
connected.
d) The supplied air must have a pressure between 5 and 8 bar. This pressure can be ensured by
using our CPF 20 air filter with integrated pressure regulator.
e) The pressure in the air supply line must not exceed 8 bar.
f) To ensure that the operator is supplied with sufficient oxygen, the air flow should be between 160
l/min and 200 l/min. The air indicator will be activated by the minimum amount, i.e. the flag will be
retracted.

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g) Warning: The helmet is intended for use in an atmosphere that does not represent an imminent
danger to human life or health and contains at least 19.5 % by volume oxygen. The operator
should be able to escape from this atmosphere without needing to use the helmet.
The Apollo 100CE blast helmet will not provide adequate protection in certain highly toxic
atmospheres caused by e.g. lead-contaminated dust that results from removing lead-containing
paints or other paints, asbestos, heavy metals etc. In such cases, there may be a risk to human
life and health.
Lead poisoning may cause death. The maximum workplace concentration has been defined as
0.1 mg/m³ of air (TRGS 900). For this reason, the blasting contractor must always determine
which type of paint is to be removed and, if necessary, ensure that operators wear a blast hood
or helmet that is approved for use with these substances or an additional respirator. In
accordance with DGUV Regulation 112-190, Class 4B blast protection equipment can be used at
up to 500 times the threshold value.
h) Warning: During a period of very high use, peak respiration may produce negative pressure in the
helmet.
i) Warning: The air supply must comply with EN 12021.
j) Warning: The moisture content in the breathing air must be kept within the limits specified in EN
12021 to prevent the supplied air respirator with continuous air flow from freezing. If the
equipment is used at a temperature below 4°C, the moisture content must be limited to prevent
freezing.
k) Warning: The equipment must not be operated with pure oxygen or oxygen-enriched air.
l) Warning: Each operator connected to the air supply system must check that the capacity of the
system is adequate as described in the information provided by Clemco.
m) It is imperative that operators follow the instructions for donning the equipment as provided by
Clemco. These are contained in Sections 4 (Preparation) and 6 (Operation) of this owner's
manual.
n) The air supply line is not resistant to contact with hot surfaces or boiling water and is therefore
not labelled accordingly.
o) The air supply line is not antistatic and is therefore not labelled accordingly.
p) Do not use aggressive chemicals or solvents to clean the equipment. This may irritate or harm
the operator and alter the properties of the material used. Please also consult the instructions
concerning cleaning products and disinfectants in Section 9 of this owner’s manual.
q) No assistance is required when using the respirator because the operator will be warned if the air
supply falls to inadequate levels by the flag of the air indicator dropping in his field of vision. If the
operator is wearing ear protection or soundproofed communications equipment, there is therefore
no need for any further measures to be taken.
r) Warning: Particular attention must be paid to ensuring that the apparatus is not accidentally
connected to other gas supplies, e.g. oxygen, acetylene or nitrogen. Never connect the breathing
air line to an air source that has not been tested for gas or particulate contamination.

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s) The operator must assess the risk of potentially dangerous substances (e.g. nitrogen) at the
workplace.
t) The blast helmet is labelled in the customary manner. This label is clearly visible and durable.
Explanation of the respirator label (Section 7, EN 14594:2018):
Line 1: Type designation Apollo 100
Line 2: Serial number of the blast helmet currently a five-digit number
Line 3: Number and year of the European standard and equipment class EN 14594: 2018
4B
Line 4: left - Storage temperatures to which the respirator is resistant –symbol acc. to EN132
0°C to +30°C
Line 4: middle –Month and year of manufacture (MM-YYYY) (example: 04 –2019)
Line 4: right –Symbol: “See information provided by manufacturer” open book with “i”
Line 5: Name of manufacturer Clemco International GmbH
Line 6: Address of manufacturer Clemco International GmbH, Carl-Zeiss Str. 21, 83052
Bruckmühl
Line 7: Country of manufacture Made in Germany
Line 8: CE symbol and number of the notified monitoring body CE symbol and number of the
notified monitoring body
u) The cape and cape fastener are also labelled. The blast helmet is not suitable for use for other
operations such as welding or painting.
-The helmet is not suitable for use in flammable atmospheres.
-The helmet can be worn with the head in the usual vertical or slightly inclined position.
-The air indicator will not function in forced postures, e.g. with the head in a horizontal position
when lying down.
-The helmet also protects the skin on the operator’s head and neck from grazing caused by
rebounding blast media.
-The quality of the air supply is critical and very important for ensuring the safety and wellbeing of
the operator.
-Do not use a piston compressor (oil bath) to generate the breathing air as there is a strong risk it
may produce high carbon monoxide concentrations.
-The presence of excessive carbon monoxide concentrations may result in the operator’s death.
-If special air sources are used, e.g. a cylinder trolley or portable air tanks, these must be
equipped with warning devices in accordance with EN14594:2018.
v) A maximum of four operators can be connected simultaneously to the CPF filter.

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2.3 Toxic dust poisoning
The following applies for model 1 and model 2 protective clothing in accordance with DIN EN ISO
14877:2003 (D):
Research has identified the potential risks of lead poisoning to unprotected operators and other
personnel who may be exposed to lead-containing abrasive dust in the vicinity of abrasive blasting
operations. This dust is primarily the result of removing lead-containing paints. A risk to human life and
health may also result from paints containing heavy metals, asbestos or other toxic dust. Lead
poisoning may cause death. The maximum workplace concentration has been defined as 0.1 mg/m³ of
air (TRGS 900).
For this reason, the blasting contractor must always determine which type of paint is to be removed
and, if necessary, ensure that operators wear a blast hood or helmet that is approved for use with
these substances or an additional respirator.
In accordance with DGUV Regulation 112-190, Class 4B blast protection equipment can be used at up
to 500 times the threshold value.
2.4 Ear protectors
Ear protectors must be worn when using the blast helmet.
2.5 Expiry date of the PPE or certain of its components
The equipment must be properly serviced, maintained and stored. All rubber components must be
replaced at the latest 5 years after the date of manufacture. It is recommended that the blast helmet is
replaced after a maximum of 10 years.
3 Description of the equipment
The minimal version of the blast helmet consists of the following components:
Helmet with chin strap, suspension and cape
Breathing air line (length approx. 700 mm)
Air supply line (length 10 m) with quick coupling (female)
Air control valve
4 Preparation
Check and/or prepare the following components:
(1) Adjust the helmet
suspension.
Remove the cape (see 8.4).
Detach and adjust the helmet suspension (see 7.2).
(2) Check that the lens
system is in place.
Inner lens (replacement, see 8.1)
Outer lens (replacement, see 8.2)

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Three perforated cover lenses (replacement, see 8.2)
The blast helmet should never be used without the inner lens, outer lens and
cover lenses in place.
(3) Belt
Attach the air control valve to the belt.
(4) Breathing air line
Screw the breathing air line coupling to the air inlet of the helmet.
Attach the other end to the air control valve.
Never carry the blast helmet by the air line but always use the handle to avoid
damage to the air line.
(5) Air supply line
Attach the air supply line to the air control valve using the quick coupling.
Attach the other end of the line to the air filter, either CPF-20 or CPF-80 (more
than one operator).
5 Air Supply
The air supply to the blast helmet is a critical element of operator safety and is not included in the
scope of delivery. Please read this section with particular care. Poor air quality may result in
illness or death of the operator (see 2.2).
5.1 Air quality
The quality of the air supply is critical and very important for ensuring the safety and wellbeing of the
operator. Particular attention must be paid to ensuring that the equipment is not accidentally connected to
other gas supplies, e.g. oxygen, acetylene or nitrogen.
Never connect the breathing air line to an air source that has not been tested for gas or particulate
contamination.
Do not use a piston compressor (oil bath) to generate the breathing air as there is a strong risk it
may produce high carbon monoxide concentrations.
The presence of excessive carbon monoxide concentrations may result in the operator’s death.
The breathing air must meet the following requirements:
The air supply must comply with EN 12021.
The breathing air for the blast helmet must contain at least 19.5 % by volume oxygen.
Before using the helmet, please read the owner’s manual, all instructions and labels, and all
warnings concerning the compressed air source. Please observe the compressor
manufacturer’s statements/warnings concerning the use of the compressor.
If using an oil-lubricated compressor for the air supply, a high temperature monitor and/or a
carbon monoxide alarm should be fitted. If only a high temperature monitor is fitted, the air
must be regularly tested for the presence of carbon monoxide. The user is responsible for
testing the breathing air, the compressor, the carbon monoxide alarm, the air filter and
the wearing parts. An overheated or poorly maintained compressor may produce carbon

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monoxide or an unpleasant smell. It is also possible to use systems to remove or convert
carbon monoxide in order to ensure good breathing air quality. The maximum permissible
carbon monoxide concentration in the breathing air is 10 ppm (parts per million).
When using a compressor, the air intake must be positioned to prevent the intake of
contaminants, e.g. carbon monoxide and oil components found in exhaust gases. This applies
especially when using portable compressors. For this reason, no vehicles or motor-powered
equipment should be operated in the vicinity of the compressor.
An appropriate filter (e.g. CPF 20, Art. no. 03580I) must be fitted and regularly serviced to
remove unpleasant smells, oil mist, condensation, rust from pipes and other constituents.
We recommend the use of our CMS-2 or CMS-4 carbon monoxide alarm.
5.2 Air volume, pressure and line length
To ensure that the operator is supplied with sufficient oxygen, the air flow
should be between 160 l/min and 200l/min.
The air indicator will be activated by the minimum amount, i.e. the flag will be retracted.
Only CE-approved supply lines with safety couplings should be used to connect the air filter and the
regulating valve (see Section 11: Replacement Parts).
The length of the line between the filter and the control valve on the helmet must not exceed 40 m. If it is
necessary to use a longer line, please contact the manufacturer to define suitable measures.
The pressure in the supply line must not exceed 8 bar.

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6 Operation
Prior to operation, the helmet, breathing air line, air supply line, air intake and all connections
must be thoroughly inspected and cleaned of all dust and debris. The helmet suspension should
also be inspected and adjusted if necessary (see 7.2 - Adjustments).
The following steps must be taken before operating the helmet:
(1) Air supply
Start the compressor.
Open the service valve to pressurise the air supply line.
(2) Check the air pressure.
Make adjustments at the air filter.
(3) Check the equipment.
Protective equipment
Helmet
Breathing air supply
(4) Check for leaks and fit.
Supply lines
Connections
(5) Put on the equipment.
Put the helmet on, ensuring as far as possible that no blast media
gets inside it.
Correctly position the chin strap and inner collar.
Pull the cape down and fix below the arms using the two rubber
straps on each side.
Put on the belt with the air control valve and tighten it well.