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

2
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

3
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.

5
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.

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7 Settings
Air control valve
Figure 1: Air control valve
The Clemco air control valve allows the operator to increase or decrease the air flow by turning the knob
at the side while wearing the helmet. When the air supply is properly connected, the valve allows the
breathing air to be regulated between 160 l/min and 400 l/min.
7.1 Adjusting and replacing the helmet suspension
Figure 2: Helmet suspension
The following steps must be taken to adjust the helmet suspension:

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(1) Remove the cape.
Open the velcro fastener on the cape.
Slide the end of the cape as far as the opening.
Pull out one end and slide it completely out of the cape holder (see
8.4).
(2) Dismantle the helmet
suspension.
Push the four white plastic tabs out of the wedge-shaped holders on
the inner shell.
(3) Remove the vinyl sweatband.
Unfasten buttons A + B in Figure 2.
(4) Adjust the helmet suspension.
The helmet suspension fits head sizes 6.5 to 8 (marked on the
headband slits).
Push the headband tongue into the front holder until the correct fit is
achieved.
Adjust evenly on both sides.
Press the selected slits onto the pins on the front band.
(5) Reattach the vinyl sweatband.
Fasten buttons A + B in Figure 2.
(6) Check the helmet suspension.
Ensure the helmet suspension is properly adjusted.
(7) Check the suspension strap.
Check the suspension strap is in place.
(8) Reassemble the helmet
suspension.
Push the four white plastic tabs back into place (see (2)).
(9) Reattach the cape.
Reverse the procedure described in (1).
The helmet suspension ensures a sufficient distance between the head and helmet. It must be
properly installed and adjusted to provide the protection and comfort that the helmet is designed
to achieve.
8 Maintenance / Replacing Parts
The helmet, all lines, the air inlet and all connections should be inspected for the presence of dust and
debris and cleaned before use. All parts should be inspected for wear and tear.
Regularly inspect and clean the foam filter and screen filter in the air control valve and air inlet in the
helmet.
After use, the helmet should be hung by the handle in a clean place.

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8.1 Replacing the inner lens
(1) Open the lens frame.
Open the rubber latch.
(2) Remove the inner lens.
Remove the cover lenses and the outer lens.
Pull the lens gasket and inner lens off the flange.
Remove the inner lens from the lens gasket.
(3) Fit new inner lens.
Clean the lens gasket and fit a new inner lens.
From the outside place the new lens gasket with inner lens on
the opening.
Place the lens gasket with inner lens on the flange and push a
retaining slot over the respective holding tab (see figure 3).
Working from both outside and inside, push the other retaining
slots over the holding tabs.
(4) Fit other lenses and close the
lens frame.
Fit the outer lens.
Fit the three cover lenses.
8.2 Replacing the outer lens and cover lenses
Up to three perforated cover lenses can be fitted simultaneously. However, to ensure maximum visibility,
we recommend using only the number of cover lenses necessary for the specific work operation.
Follow the instructions below to ensure that the cover lenses can be easily removed by an operator
wearing heavy work gloves.
(1) Working on a smooth surface, place up to three cover lenses on the outer lens.
(2) Fold the tabs on the top two cover lenses upwards and the tab on the bottom lens downwards (see
figure 3).
(3) Open the lens frame and remove the outer lens and/or the remnants of the cover lenses.
(4) Place the cover lenses with the outer lens on the inner lens so that the cover lens tabs poke through
the lens frame.
(5) Hold the lenses and close the lens frame.

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Figure 3: Replacing inner and cover lenses
8.3 Replacing the helmet suspension
Follow the procedure described in 7.2 (see also Figure 2).
8.4 Outer cape
Figure 4: Detaching the cape
Follow this procedure if the cape is soiled or needs to be replaced.
(1) Open the velcro fastener on the
cape.
See Figure 4.

15
(2) Detach the cape.
Slide the end of the cape as far as the opening.
Pull out one end and slide the cape out of the cape holder.
(3) Attach the cape.
Open the velcro fastener.
Starting at the opening, push one end through the cape holder
and then slide the cape in. A non-toxic silicone spray will make
this easier.
(4) Close the velcro fastener on the
cape.
See figure 4.
8.5 Replacing the inner collar
The inner collar is important in ensuring the air circulation inside the helmet and preventing the ingress of
dust. To replace or wash the collar, it must be detached from the cape (see 9.4 for washing instructions).
The inner collar must be replaced if it no longer fits snugly round the neck.
8.6 Replacing the lens frame
The lens frame must be replaced if the seal is no longer guaranteed or the rubber latch no longer remains
closed. The sound insulation inside the helmet should also be replaced when replacing the lens frame.
8.7 Replacing the chin strap
Replace the chin strip when it becomes worn.
8.8 Replacing the air line
The screws on the helmet and the control valve are secured with double-sided adhesive tape to prevent
them from being loosened unintentionally. They should be resecured when the air line is replaced.
Tape should be placed around the screws and valves approx. 2 mm from their bottom end (three quarters
of the circumference is sufficient).
9 Servicing / Cleaning
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.
9.1 Filter
The filter (foam) is inside the control valve. It must be removed when it becomes soiled. Use a small
screwdriver to prise off the snap ring and remove the screen filter and the soiled foam filter. Reassemble
the components in reverse order.
9.2 Nylon cape
The cape can be machine-washed in warm water using a mild detergent. It can be dried in a tumble dryer
at the lowest temperature setting. Do not dry clean. See 8.4 for how to detach the cape.

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9.3 Leather cape
The cape can be brushed or cleaned with a damp sponge. (Do not wash, dry clean, iron or use chlorine
bleach.)
9.4 Inner collar
For reasons of hygiene, the inner collar should be washed daily to remove sweat and dust.
Detach the collar from the cape (zipper) and wash in warm water and a mild detergent. The collar can be
dried in a tumble dryer at the lowest temperature setting. Do not dry clean.
9.5 Sweatband/helmet suspension
The sweatband, helmet suspension, suspension strap and chin strap can be washed in warm water and a
mild detergent. See 7.2 for how to detach the components.
9.6 Blast helmet
The helmet should be cleaned with a disinfectant. A suitable product is Indicur from Henkel*.
9.7 Inner lens
The inner lens should be replaced if it becomes soiled or scratched. It can be cleaned with warm water
and a mild detergent. Solvents such as alcohol, white spirit or ammonia must not be used. Allow the lens
to air-dry. The use of cloths or similar may scratch the lens.
10 Storage
10.1 Daily storage
During breaks or at the end of work, the helmet should be hung by the handle in a clean place.
Attention! This product has only been tested for its compatibility with our helmet. Please follow the
manufacturer’s instructions for use. We assume no liability for any skin reactions or other health problems
associated with the use of the disinfectant.
10.2 Long-term storage
After cleaning and drying the helmet, tuck the cape inside. Pack the helmet in a sealed bag or film to
protect it from dirt and moisture.

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11 Replacement parts
Figure 5: Replacement parts Apollo 100 CE
11.1 Air control valve
Item
Art. no.
Description
(-)
100042
CONTROL VALVE
100074
BREATHING VALVE LESS BELT
(-)
04381I
FILTER SET APOLLO (foam filter, screen filter, snap ring)

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11.2 Helmet
Item
Art. no.
Description
(-)
100419
APOLLO-100 WITH CONTROL VALVE, CAPE comprising:
100418 A100 CE blast helmet without accessories
90130 9 mm x 0.65 m air line with screw fittings
90331D A100 CE nylon cape
100042 control valve
(-)
100420
APOLLO-100 CE COMPL. WITH 5 M HOSE (SI) comprising:
-100419 blast helmet with control valve and cape
-100421 9mm x 5 m air line with safety coupling
(-)
100422
SAFETY-BLAST-PAKET A-100 CE comprising:
-100419 A 100 CE blast helmet with control valve and cape
-08921D blast suit, size 52
-02243D pair of leather gloves, CE-approved
-100404 9 mm x 20 m air line with safety coupling and socket
-21042I cover lenses (25 pieces)
-03580D CPF-20 R air filter
(1)
20975D
HELMET SHELL A-100 GREEN
(2)
99996D
INNER GASKET A-100
(3)
21044I
INNER LENS A-100 (polycarbonate)
(4)
21043I
OUTER LENS A-100 (plastic)
(5)
21042I
MYLAR LENS A-100 25PCS.
(6)
90291D
OUTER GASKET A-100
(7)
27308D
VISOR A-100 ASSY
(8)
90783D
HOLDER RUBBER LATCH BIG
(9)
90733D
RUBBER LATCH A-100 BIG
(10)
100361
AIR INDICATOR COMPL. A-100
(11)
08892I
HEAD SUSPENSION FOR APOLLO
(12)
04460I
CHIN STRAP ASSY
(13)
27309D
HOLDER FOR CHIN STRAP A-100 COMPL.
(14)
94260D
INNER NECK CUFF A-100/50
(15)
10534I
CAPEHOLDER FOR APOLLO
(16)
90331D
NYLONCAPE A-100/50
-
100577
LETHERCAPE A-50/60/100 KOMPL. LEATHER
(17)
100365
FITTING A-100
(18)
04370I
GASKET FOR AIR HOSE UNION A-100 6 PCS
(19)
90130D
AIR HOSE 9 MM X 0,65 FOR A-100
(20)
100042
CONTROL VALVE
-
04430I
BELT ONLY FOR BREAK VALVE APOLLO
-
100380
EAR-SAVETY PAIR

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-
100421
AIR HOSE 5 M WITH SAFETY COUPLED (SI)
-
100406
AIR HOSE 10 M WITH SAFETY COUPLING (SI)
-
100404
AIR HOSE 20 M WITH SAFETY COUPLING (SI)
-
100405
AIR HOSE 40 M WITH SAFETY COUPLING (SI)
11.3 Additional parts
23825D
CLEMCOOL
04411I
CLIMATE CONTROL CC