Clemco CCT User manual

© 2007 CLEMCO INDUSTRIES CORP.
One Cable Car Dr.
Washington, MO 63090
Phone [phone]
Fax [phone]
Email: [email protected]
www.clemcoindustries.com
WARNING
Do not proceed with
these instructions until
you have READ the
orange cover of 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 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.
MC FILE NUMBER: 629-1284
DATE OF ISSUE: 12-21-84
REVISION: E, 05-07
CLIMATE CONTROL TUBE
MODEL CCT
O. M. 08850

PREFACE
•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
equipment.
NOTICE TO PURCHASERS AND USERS OF OUR
PRODUCTS AND THIS INFORMATIONAL MATERIAL
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.
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
available.
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.
GENERAL INSTRUCTIONS
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.
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.
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
approval.
OPERATIONAL INSTRUCTIONS
OPERATOR SAFETY EQUIPMENT
•Blast operators and others working in the vicinity of
abrasive blasting must always wear properly-
maintained, 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
#92-102
•Inhalation of toxic dust (crystalline silica, asbestos,
lead paint and other toxins) can lead to serious or
fatal disease (silicosis, asbestosis, lead or other
poisoning).
•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
WARNING
WARNING
I

PREFACE
instrument should be used to determine when surrounding
atmosphere is clear of dust and safe to breathe.
•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
respirator.
•Clemco supplied-air respirators DO NOT REMOVE OR
PROTECT AGAINST CARBON MONOXIDE (CO) OR ANY
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.
•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).
•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.
•ALWAYS use a NIOSH-approved breathing air hose to
connect an appropriate air filter to the respirator. Use of a non-
approved 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.
•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
TO TEST THE AIR LINE MAY RESULT IN DEATH TO THE
RESPIRATOR USER.
•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
respirator.
BLAST MACHINES AND REMOTE CONTROLS
•ALWAYS equip abrasive blast machines with
remote controls.
•Abrasive blast machine operators must wear NIOSH-
approved supplied-air respirators (ref: OSHA
regulations 1910.94, 1910.132, 1910.139 and
1910.244).
•NEVER modify OR substitute remote control parts. Parts
from different manufacturers are NOT compatible with Clemco
equipment. If controls are altered, involuntary activation, which
may cause serious injury, can occur.
•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.
•UNLESS OTHERWISE SPECIFIED, maximum working
pressure of blast machines and related components MUST
NOT exceed National Board approved 125 psig (8.5 BAR).
•NEVER weld on blast machine. Welding may affect
dimensional integrity of steel wall and WILL VOID National
Board approval.
•Point nozzle ONLY at structure being blasted. High
velocity abrasive particles WILL inflict serious injury. Keep
unprotected workers OUT of blast area.
•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.
•Larger empty blast machines or ANY blast machine
containing abrasive MUST be transported by mechanical lifting
equipment.
AIR HOSE, BLAST HOSE, COUPLINGS, AND NOZZLE HOLDERS
•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
leakage IMMEDIATELY.
•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.
•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.
•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.
WARNING
II

PREFACE
MAINTENANCE
•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.
ADDITIONAL ASSISTANCE
•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.
TECHNICAL DATA AND RESEARCH COMMITTEES
•The following associations offer information, materials and
videos relating to abrasive blasting and safe operating
practices.
The Society for Protective Coatings (SSPC)
40 24th Street, Pittsburgh PA 15222-4643
Phone: [phone] • FAX [phone]
Email: [email protected] • Website: www.sspc.org
National Association of Corrosion Engineers (NACE)
1440 South Creek Drive, Houston TX 77084
Phone: [phone] • FAX [phone]
Email: [email protected] • Website: www.nace.org
American Society for Testing and Materials (ASTM)
100 Barr Harbor Dr., West Conshohocken, PA 19428
Phone [phone] • FAX [phone]
Email: [email protected] • Website: www.astm.org
NOTICE
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.
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 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
model.
5. Seller makes no warranty that the products are delivered
free of the rightful claim of any third party by way of patent
infringement or the like.
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.
Except as expressly set forth above, all warranties, express,
implied or statutory, including implied warranty of
merchantability, are hereby disclaimed.
DAILY SET-UP CHECK LIST
•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.
□1. PROPERLY MAINTAINED AIR COMPRESSOR sized
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
size). FOLLOW MANUFACTURERS MAINTENANCE
INSTRUCTIONS.
□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.
WARNING
III

PREFACE
□3. Clean, properly maintained NIOSH-APPROVED
SUPPLIED-AIR RESPIRATOR. ALL components should
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.
□4. OSHA required BREATHING AIR FILTER for removal
of moisture and particulate matter from breathing air supply.
THIS DEVICE DOES NOT REMOVE OR DETECT CARBON
MONOXIDE (CO). ALWAYS USE CO MONITOR ALARM.
□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.
□6. AIR LINE FILTER installed AS CLOSE AS POSSIBLE
to machine inlet. Sized to match inlet piping or larger air supply
line. Clean filter DAILY. Drain OFTEN.
□7. REMOTE CONTROLS MUST be in PERFECT
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.
DO NOT USE WELDING HOSE.
□8. BLAST HOSE with ID 3 to 4 times the nozzle orifice.
Lines MUST be run AS STRAIGHT AS POSSIBLE from
machine to work area with NO sharp bends. Check DAILY for
internal wear and external damage.
□9. HOSE COUPLINGS, NOZZLE HOLDERS fitted
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.
□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.
□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
substances.
□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.
3. NIOSH
Approved
Supplied-Air
Respirator
11. Silica-free Abrasive 5. ASME Coded
Blast Machine
8. Blast Hose
10. Appropriately
Sized Nozzle
2. Breathing Air Compressor
4. CPF Air-Filter
6. Air Line
Filter
9. Hose Couplings and
Safety Cables
1 Air Compressor
(or)
2. Ambient Air Pump
for low pressure
respirator
7. Remote
Controls
IV

CCT CLIMATE CONTROL TUBE Page 1
© 2007 CLEMCO INDUSTRIES CORP. •www.clemcoindustries.com •Manual No. 08850
1.0 INTRODUCTION
1.1 Scope
1.1.1 This manual covers the preparation, operation,
maintenance, troubleshooting, and replacement parts for
Clemco’s CCT Climate Control Tube. The Climate Control
Tube is used to cool or warm compressed respirable air
supplying an Apollo supplied-air respirator or Comfort
Vest. Read this manual and the appropriate Apollo HP
(high pressure) respirator manual and/or Comfort Vest
manual before using the climate control tube.
1.1.2 The National Institute for Occupational Safety
and Health (NIOSH) approval and Occupational Safety &
Health Administration (OSHA) regulations cited within
this manual apply when the climate control tube is used
to provide air to a supplied-air respirator. The regulations
do not apply if the climate control tube is used with a
Comfort Vest alone. When a vest is used with a
respirator having a cape that extends over the vest, air
from the vest could be ingested by the user. For that
reason, Grade D air or higher quality, as defined in
Section 2.1 of this manual, must be provided to both the
respirator and vest.
1.2 Safety Alerts
1.2.1 Clemco uses safety alert signal words, based on
ANSI Z535.4-1998, to alert the user of a potentially
hazardous situation that may be encountered while
operating this equipment. ANSI's definitions of the signal
words are as follows:
This is the safety alert symbol. It is
used to alert the user of this equipment
of potential personal injury hazards.
Obey all safety messages that follow this symbol to
avoid possible injury or death.
CAUTION
Caution used without the safety alert symbol
indicates a potentially hazardous situation
which, if not avoided, may result in property
damage.
CAUTION
Caution indicates a potentially hazardous
situation which, if not avoided, may result in
minor or moderate injury.
WARNING
Warning indicates a potentially hazardous
situation which, if not avoided, could result in
death or serious injury.
DANGER
Danger indicatesanimminently hazardous
situation which, if not avoided, will result in
death or serious injury.
1.3 NIOSH Approval
1.3.1 The CCT Climate Control Tube is approved by
NIOSH to use with Clemco Apollo respirators.
1.3.2 The NIOSH label shown below lists the Apollo
respirator approval numbers. An X on the approval line
indicates which components are approved for the
specific respirator. Do not use any non-approved
components with the respirator.

CCT CLIMATE CONTROL TUBE Page 2
© 2007 CLEMCO INDUSTRIES CORP. •www.clemcoindustries.com •Manual No. 08850
WARNING
NIOSH approval applies to items shown on the
label when used as a complete system. Do not
make any non-approved modification, deletion,
or substitution. Non-approved components void
the NIOSH approval and may permit ingress of
toxic and hazardous dust, resulting in toxic
poisoning and respiratory disease.
1.4 OSHA Regulations
1.4.1 OSHA Regulation 29 CFR 1910.134 for
respiratory protection in General Industry is referenced
throughout this document. Respiratory protection
standards for Construction 29 CFR 1926.103 and for
Maritime 29 CFR-1915.154, 1917, and 1918 refer to
1910.134. The complete regulation is available through
the U.S. Dept. of Labor web site at www.osha.gov.
1.4.2 OSHA Regulations 29 CFR 1910.134(a) and (c)
require the employer to establish and maintain a
comprehensive, written, respiratory protection program
administered by a suitably-trained program
administrator. The program must include, but is not
limited to the following:
1. Procedures for selecting NIOSH-certified respirators.
2. Medical evaluations of employees required to use
respirators.
3. Fit testing procedures.
4. Procedures for proper use of respirator in routine
and foreseeable emergency situations.
5. Procedures and schedules for cleaning, disinfecting,
storing, inspecting, repairing, discarding and otherwise
maintaining respirators.
6. Procedures to ensure adequate air quality, quantity
and flow of breathing air for atmosphere-supplying
respirators.
7. Training of employees in the respiratory hazards to
which they are potentially exposed during routine and
emergency situations.
8. Training of employees in the proper use of the
respirators, including putting on and removing them, any
limitations on their use, and their maintenance.
9. Procedures for regularly evaluating the effectiveness
of the program.
1.4.3 It is essential that the user be properly instructed
in the use and maintenance of the respirator. The
respirator manual and this manual for the climate control
tube must be made available to all users of the
respirator, and the users must demonstrate their
understanding of its subject matter. Read the entire
manual before installing or operating the equipment.
1.4.4 The climate control tube must be supplied with
respirable air meeting requirements described herein. It
is the responsibility of the employer to provide quality
breathing-air to the respirator, and to establish a
program to ensure that the respirator and accessories
are properly used and maintained.
1.5 Description
1.5.1 The CCT Climate Control Tube is an approved
alternate air control valve, which provides the user with a
source of cool or warm air when used in conjunction with a
Clemco supplied-air respirator or Comfort Vest. The
illustration in Figure 1 shows components and controls for
the climate control tube.
Figure 1
2.0 AIR SUPPLY
2.1 Air Quality
DANGER
Never connect a breathing air line to an air
source that has not been tested for gas and
particulate contamination. The presence of
unacceptable levels of carbon monoxide (CO)
or other gases, or oxygen deficiency in
breathing air will cause death to the user.
2.1.1 The employer is responsible for ensuring that
breathing air shall meet the requirements for Grade D or
higher quality, as described in Compressed Gas
Association Commodity Specification pamphlet G-7.1.,
titled Commodity Specification For Air, published by
Compressed Gas Association Inc., Chantilly, VA.
Website: www.cganet.com, (29 CFR 1910.134 (i)
Outlet Connecto
r
Disconnect
(Connection for
respirator supply hose)
Temperature
Control Leve
r
Heat Shield (Regulates air
tem
p
erature
)
(Connection for
res
p
irator or vest
)
Belt

CCT CLIMATE CONTROL TUBE Page 3
© 2007 CLEMCO INDUSTRIES CORP. •www.clemcoindustries.com •Manual No. 08850
2.1.2 Limiting characteristics of Grade D air, as of the
publication of this manual is as follows:
Carbon Dioxide .................... maximum of 1000 ppm
Carbon Monoxide .................... maximum of 10 ppm
Odor ........................................ *No pronounced odor
Oil (hydrocarbons) ...................maximum of 5 mg/m3
Oxygen ...................................between 19.5 - 23.5%
* Specific measurement of odor in gaseous air is
impractical. Air may have a slight odor but the presence
of a pronounced odor renders the air unsatisfactory.
2.1.3 Special care must be taken to avoid accidental
connection to any lines other than compressed air; such
as, oxygen, acetylene, or nitrogen.
2.1.4 When the climate control tube is used for
breathing air, the quality of air supplied to the climate
control tube is extremely critical to the safety of the user.
2.1.5 Any air ingested from the climate control tube
must meet the requirement for respirable air as stated
herein. If the climate control tube supplies air to a vest
that is used with a hooded respirator, air supplied to the
vest must also be respirable air meeting the
requirements for Grade D or better.
2.1.6 Prior to using the respirator, read the owner’s
manual and all instructions, labels, and warnings relating
to the compressed air source. Take special care to abide
by all warnings from the compressor manufacturer
regarding compressor use, and from the cylinder and air
supplier, for breathing air cylinders and their use.
2.1.7 A Clemco CPF filter may be installed and
regularly maintained to remove objectionable odors, oil
mist, water, pipe scale, and other particulate matter.
2.2 Breathing-Air from Cylinders
DANGER
Operators must never use or operate breathing
air cylinders, without proper pressure reducing
devices, and training on their use. Breathing
cylinders are under extremely high air pressure.
Improper use could cause cylinders or
accessories to rupture, resulting in severe
injury or death.
2.2.1 Using cylinders (high-pressure air bottles)
requires special knowledge of their use and compliance
with OSHA Regulations. Refer to 29 CFR 1910.134(h)
and (i) and 49 CFR part 173, and part 178.
2.2.2 The employer shall ensure that cylinders used to
supply breathing air to respirators meet all requirements
which may include, but are not limited to, their testing
and maintenance, a certificate of analysis for air quality
and moisture.
2.2.3 Cylinders must be equipped with a properly
maintained pressure-reducing valve that reduces
pressure to the approved pressure range as shown in
Section 2.4.3.
2.3 Breathing-Air from Compressors
2.3.1 The employer shall ensure that air from
compressors used to supply breathing air to respirators
meets the requirements in 29 CFR 1910.134.(i)(5).
2.3.2 Precautions must be taken to prevent
contaminants from entering through the compressor
intake: Ref. 29 CFR 1910.134.(i)(5)(i). The compressor
inlet must be located away from all sources of toxic
contaminants including carbon monoxide, which is found
in engine exhaust (including the exhaust from the
compressor’s engine), and in any form of combustion.
No vehicles should be allowed near the compressor
intake. Contaminants can enter respiratory equipment
through the compressor air inlet. This inlet must not be
located near any exhaust system outlet, ventilation flue,
or source of fumes or particles of any kind.
2.3.3 The compressed-air supply system must be
equipped with suitable in-line air-purifying sorbent beds
and filters, and be maintained to further ensure
breathing air quality: 29 CFR 1910.134 (iii).
2.3.4 If the breathing-air supply is from a non-oil-
lubricated compressor, the employer shall ensure that
the carbon monoxide levels in the breathing air do not
exceed 10 ppm: 29 CFR 1910.134 (i)(6).
2.3.5 If an oil-lubricated compressor is used, the
employer shall use a high-temperature alarm or carbon
monoxide (CO) 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: 29 CFR 1910.134 (i)(7).
2.4 Operating Pressure
2.4.1 Air pressure at the point of attachment (the point
of attachment is where the respirator supply hose is
connected to the respirable air source) must be
maintained at pressures between 90 to 100 psi (pounds
per square inch), as shown in the table in Section 2.4.3.
Maintaining the correct operating pressure at the point of
attachment ensures the correct air flow to the respirator.

CCT CLIMATE CONTROL TUBE Page 4
© 2007 CLEMCO INDUSTRIES CORP. •www.clemcoindustries.com •Manual No. 08850
2.4.2 The Clemco CPF Inline Particulate Filter with
regulator meets this requirement for a regulator and
gauge, provided inlet pressure does not exceed 150 psi.
DANGER
Do not connect the climate control tube, CPF
Filter, or any other regulator or filter, to bottled
air that does not have a pressure reducing
valve that reduces pressure to the maximum
operating pressure of the respirator of filter it
services. Failure to comply with this warning
will cause devices rated at lower pressures to
rupture under the high pressure of bottled air,
which could cause severe injury or death.
2.4.3 Use the following table to determine the
minimum pressure setting and maximum respirator hose
length that may be used with the climate control tube.
Adjust the pressure with the respirator hose and
respirator attached. If the regulator is adjusted with static
pressure (no air flow), pressure may drop below the
required pressure when the respirator is connected, and
may result in low air flow. Setting the pressure as shown
provides a minimum of 7 cfm (cubic feet per minute) to
the respirator. The maximum allowable pressure for use
with the climate control tube is 100 psi.
Minimum Overall hose length measured in feet
Pressure 25 50 75 100 125 150 175 200
90 psi x x x
95 psi x x x x x
The maximum overall hose length used with the climate
control tube is 200 feet when providing air to a respirator.
2.5 Dew Point
2.5.1 If exhaust air reaches temperatures at or below
freezing, excess water vapor could freeze and cause the
air tube to ice-up. Compressed air should have excess
water vapor removed to attain a dew point below the
minimum anticipated temperature of the exhausting air.
Contact a compressed-air dryer distributor for dryer
recommendations.
2.6 Air Volume
2.6.1 The climate control tube must be supplied with
20 cfm of Grade D breathing air at 90 to 100 psi.
WARNING
The compressor must provide adequate output
and the plumbing between the compressor and
the point of attaching the respirator hose must
have sufficient capacity to supply the volume of
air at the pressure required. Restricted air flow
will cause discomfort to the user, and may
result in ingress of hazardous and toxic dust,
subjecting the user to health and life
threatening toxic poisoning and long term
respiratory disease and death.
3.0 SET-UP and ADJUSTMENTS
3.1 Attach Breathing Tube Assembly
CAUTION
Note the directional flow arrows on the labels at
both ends of the breathing tube. The flow
arrows indicate the direction of air flow to the
helmet. Flow arrows must point toward the
helmet. Failure to properly attach the breathing
tube may damage the tube's acoustical foam,
which will block air flow, or it may increase
noise levels beyond OSHA limits.
3.1.1 The breathing tube has a clamped-on end and a
molded-on end. Attach the molded-on swivel connector
to the climate control tube’s outlet as shown in Figure 2.
Figure 2
3.1.2 Attach the clamped-on end to the threaded air
inlet fitting at the back of the helmet as shown in Figure
2. Do not over-tighten; hand-tight is sufficient.
3.1.3 Attach an approved Clemco respirator hose to
the quick-disconnect nipple.
Attach clamped end of
breathing tube to the respirator
Attach the molded end
of the breathing tube to
t
h
e
c
lim
ate
co
n
t
r
o
l
tube

CCT CLIMATE CONTROL TUBE Page 5
© 2007 CLEMCO INDUSTRIES CORP. •www.clemcoindustries.com •Manual No. 08850
3.2 Air Supply and Pressure
3.2.1 Initiate the air supply and regulate air pressure
between 90 and 100 psi, as shown in Section 2.4.3.
3.3 After donning the respirator, securely attach the
belt and climate control tube around the waist. Adjust the
belt size as required.
3.4 Adjust Air Temperature
3.4.1 To adjust air temperature, move the temperature
control lever (shown in Figure 3) fully toward the right,
lighter end of the indicator arrow, for maximum, or fully left,
darker end of the arrow for maximum warming. Position
the lever anyplace in between to attain the most
comfortable temperature setting.
WARMER - COOLER
WARMER - COOLER
Figure 3
4.0 PREVENTIVE MAINTENANCE
4.1 Air Filter Screen
4.1.1 Inspect and clean the air filter screen monthly. If
inadequate air flow is experienced, stop using the
climate control tube and inspect the screen for blockage.
CAUTION
Debris or abrasion on the screen is one
indication of dirty air. Dirty air will cause rapid
erosion of critical parts of the climate control
tube, which will decrease efficiency and life of
the control tube.
4.1.2 To clean the air filter screen, unscrew the quick
disconnect nipple from the inlet elbow. Turn the elbow
upside down and tap it on a solid surface to remove
loose debris. The screen can be removed by tapping the
elbow described above. If the screen is wedged in place
it may be necessary to destroy it in order to remove.
Replace the screen before reassembly.
5.0 SERVICE MAINTENANCE
5.1 Service maintenance is divided into two stages.
The first stage is to replace leaking seals and to clean the
top end when the unit is otherwise working properly. (A
small leak from around the temperature control lever is
normal, and should be the same temperature as the
expelled air.) The second stage is to service and clean the
body and tube assembly. This is usually required when the
tube loses efficiency.
NOTE: Have a 08845 seal kit on hand before servicing
either stage. Clean all parts with mild soap and water,
rinse thoroughly, and dry.
5.2 First Stage Service, Refer To Figure 4
5.2.1 Remove belt bracket, lower screw, and inlet
elbow.
5.2.2 Remove the temperature control lever and set
screw stop from upper valve plate. Make a note of the
location of each before disassembly.
5.2.3 While applying pressure on the outlet connector,
remove the second retaining screw (the first was removed
with the bracket in paragraph 5.2.1) and remove the
connector from the housing. Remove the o-ring from the
connector.
5.2.4 Remove the spring and spring support washer.
5.2.5 Remove the o-ring and upper valve plate.
5.2.6 Remove the o-ring from lower valve plate.
NOTE: If the lower plate and pin come loose, refer to
Figure 4 for reassembly.
Temperature
Control Lever
Move the control lever fully
left for maximum warming
Temperature
Control Lever
Move the control lever fully
Right for maximum cooling
Position the lever anyplace between
warm and cool to attain the most
comfortable temperature setting
Exhaust
p
ort
Warm air exhaust from this port
when the lever is in the cool mode.
Cool air exhaust in the warm mode.

CCT CLIMATE CONTROL TUBE Page 6
© 2007 CLEMCO INDUSTRIES CORP. •www.clemcoindustries.com •Manual No. 08850
Figure 4
5.2.7 If second stage service is not required, proceed to
Paragraph 5.3.21.
5.3 Second Stage Service, Refer To Figure 5.
5.3.1 Remove the lower valve plate and pin. A long-
nose pliers may be needed to remove the lower plate.
5.3.2 Slide the body assembly out the end of the tube
housing. Try not to disturb the taped-on spacer.
CAUTION
Do not use force; if the unit was disassembled
correctly, it will take very little force to remove
the body assembly.
5.3.3 Remove threaded retainer and pull out the cool
end venturi assembly (venturi, o-ring, backup washer and
spring washers). Note position of spring washers.
Reassemble the same way with convex sides facing each
other.
5.3.4 Inspect the venturi assembly for wear or erosion.
Replace if necessary. If only cleaning is required, carefully
clean the slots with a brush or small screwdriver. Clean
remaining parts of the venturi assembly and replace the o-
ring from seal kit.
5.3.5 Before removing the vortex tube assembly, look
into the body and inspect the surface of the spacer for
wear; it should be flat. If it is worn, it will have to be
replaced before reassembly.
5.3.6 Carefully remove the vortex tube assembly
(spacers, venturi tube, and vortex tube).
5.3.7 On the inside of one end of the vortex tube is a
star-shaped vortex breaker. It should be intact and tight in
the tube. If the breaker is damaged or loose, replace the
tube before reassembly.
5.3.8 Remove the hot-end orifice and orifice o-ring.
5.3.9 Remove loose sealant from inside the body.
5.3.10 Clean all parts that will be reused with mild soap
and water, rinse thoroughly, and dry.
5.3.11 Replace the o-ring on the hot-end orifice and
reassemble vortex tube assembly. Make sure the hot-end
orifice is on the breaker end of the tube.
CCT Housing not shown for clarity
Outlet Connector
Upper Belt Bracket Screw
(First retaining screw)
Belt Bracket
Second Retaining Screw Lower Screw Not Shown.
To be removed for second stage service
Temperature Control Lever
Set-Screw Stop
Spring
Connector O-Ring
Support Washer
Upper Valve Plate
Upper Plate O-Ring
Lower Valve Plate
Shown for reference Lower Plate O-Ring
Pin
Shown for reference
Body
Shown for reference

CCT CLIMATE CONTROL TUBE Page 7
© 2007 CLEMCO INDUSTRIES CORP. •www.clemcoindustries.com •Manual No. 08850
5.3.12 Holding the complete vortex tube assembly in one
hand, with the hot-end orifice up, slide the body over the
assembly, guiding the end of the hot-end orifice through
the hole in the body. When the vortex tube assembly
bottoms out in the body, turn the body assembly over and
install the cool end venturi assembly.
5.3.13 Replace the threaded retainer and tighten
approximately 1/2 turn past hand tight.
5.3.14 Replace the rubber seal on the body’s inlet port
with the one from the seal kit.
5.3.15 If the spacer moved or was removed, align the
holes in the spacer with those in the body and tape the
spacer in place (Do not tape over the inlet port).
5.3.16 When reassembling the first stage, use new o-
rings from the seal kit.
5.3.17 Hold body assembly with hot end up as shown in
Figure 5. Place pin into body assembly and place the
lower valve plate onto body assembly over the pin. NOTE:
The lower valve plate is identified by the smooth outer
surface; the upper valve plate has three holes in the outer
surface.
5.3.18 Slide body assembly into housing. Align inlet port
and belt bracket holes. NOTE: It the lower valve plate is
correctly installed, it will be about 3/16" below the cutout in
the tube housing, and will not rotate. While handling the
assembly, hold the lower plate in place until the upper
plate is secured.
5.3.19 Apply a liberal amount of silicon sealant to the
male threads on the elbow and the bottom mounting screw
and Install both items. The elbow and disconnect should
point down when installed.
5.3.20 Temporarily install the lower belt bracket screw.
5.3.21 Lubricate the two valve plate o-rings with silicone
based lubricant and place one o-ring inside the housing
and push into place onto the groove of lower valve plate.
5.3.22 Insert upper valve plate (with center hole up).
Align three side ports with cutout in housing. Install
temperature control lever and set screw stop.
5.3.23 Place the remaining o-ring into the groove on the
upper valve plate.
5.3.24 Install the spring support washer and press hard
to make sure the o-ring is correctly seated.
f Figure 5
Belt Bracket
CCT Housing
Spacer
Body
Belt Bracket Screws
Belt Bracket
Shown for reference
Breaker end of tube must be
installed on hot-end orifice
Hot-end Orifice
Spacer 1, Thin
Spacer, Thick
Spacer
Belt Bracket Scre
w
Support Washer
Threaded Retainer
Orifice O-Ring
Vortex Tube
Venturi Tube
Lower Valve Plate
Venturi
Body
Venturi O-Ring
Spring Washers
Convex sides must
face each other

CCT CLIMATE CONTROL TUBE Page 8
© 2007 CLEMCO INDUSTRIES CORP. •www.clemcoindustries.com •Manual No. 08850
5.3.25 Remove the lower belt bracket screw, which was
temporarily installed. Not required for first stage only
service.
5.3.26 Apply silicon sealant to the screw and attach the
belt bracket with the lower screw only; leave the top screw
out at this time. Not required for first stage only service.
5.3.27 Place a new o-ring on the outlet connector, and
install the spring and connector onto housing assembly.
Align the screw holes and secure with the two retaining
screws.
5.2.28 Apply additional silicone sealant around the
threads on the inlet elbow and housing. Allow sealant to
cure before testing.
5.3.29 Bench test before returning to service.
5.3.30 Attach heat shield, belt, and connect respirator
hose.
6.0 TROUBLESHOOTING
6.1 Inadequate Air Flow
6.1.1 Check filter screen for debris.
6.1.2 Make sure supply air pressure is between 90 to
100 psi. A pressure regulator and gauge must be installed
at the point of attachment (where the respirator hose is
connected to the respirable air source).
6.2 Poor Heating or Cooling Performance
6.2.1 Inadequate air flow affects cooling performance.
Refer to Paragraph 6.1.
6.2.2 The temperature of the compressed air has an
effect on the climate control tube’s discharge temperature.
Make sure that none of the lines that supply compressed
air to the climate control tube is routed near any source of
heat, such as a steam radiator, furnace, etc. When
possible avoid exposure to direct sunlight.
6.2.3 Erosion of internal parts: Compressed air moving
through the control tube will eventually wear critical
components. Dirty air accelerates wear of internal parts.
6.2.4 Vortex breaker may be loose, worn, or damaged.
Inspect the breaker per Sections 5.2 & 5.3.
6.3 Ice Forming on Air Tube
6.3.1 Water in the air line will freeze when temperature
reaches 32 degrees. To avoid icing do one of the
following:
•Lower the dew point of the compressed air below that
of the exhaust air.
•Periodically move the temperature control lever
toward the cooler position to defrost the tube
•Lower the outlet temperature enough to keep exhaust
air from freezing.

CCT CLIMATE CONTROL TUBE Page 9
© 2007 CLEMCO INDUSTRIES CORP. •www.clemcoindustries.com •Manual No. 08850
7.0 REPLACEMENT PARTS, Figure 6
Item Description Stock No.
(-) CCT Climate control tube assembly
with belt ....................................................04411
1. Cool-end venturi assembly .........................08846
2. Seal kit .........................................................08845
3. Screen ..........................................................08983
4. Disconnect nipple ........................................08449
5. Body .............................................................08825
6. Orifice, hot-end ............................................08826
7. Plug ..............................................................08827
8. Belt, 2" web ..................................................04430
9. Vortex tube with breaker..............................23030
10. Spacer 1, thin ...............................................08966
11. Venturi tube .................................................08967
12. Spacer 2, thick .............................................08968
13. Threaded retainer ........................................08829
14. Elbow, 1/4" male .........................................08869
15. Bracket, belt .................................................08974
16. Valve plate, lower ........................................08830
17. Valve plate, upper .......................................08831
18. Support washer ...........................................08832
19. Connector, outlet..........................................08833
20. Housing, body .............................................08834
21. Control lever ................................................08835
22. Spring ...........................................................08844
23. Screw, machine, 6-32 x 1/4" (each)............03870
24. Screw, set, 1/4" NC x 1/2" ..........................03072
25. Spacer ..........................................................08836
26. Pin, valve plate ............................................08838
27. Screw, machine, 10-24 x 1/2" (each)..........03886
28. Heat shield ...................................................08981
NOTE: If items 1 and 2 are ordered together, you
will receive an extra cool end venturi o-ring.
Figure 6
2
1
2
2
2
2
3
7
4
5
6
8
9
10
12 11
14
13
15
16
17
18
19
20
21
22
23
23
24
25
26 27
28