Clemco Contractor Series, Contractor 4 CU. FT, Contractor 6 CU. FT Operational Instructions
BLAST MACHINE WITH MILLENNIUM PNEUMATIC
CONTRACTOR SERIES 4 AND 6 CU. FT.
PRESSURE RELEASE REMOTE CONTROLS
O. M. 21941
DATE OF ISSUE: 01/96
REVISION: L, 03/17
WARNING
Do not use this
© 2017 CLEMCO INDUSTRIES CORP.
One Cable Car Dr.
Washington, MO 63090
Phone (636) 239-4300
AX (800) 726-7559
F
Email: info@clemcoindustries.com
www.clemcoindustries.com
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.
PREFACE
• 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 ab rasi ve bla sting are con tained in the Code o f Federal Regulation s, Title 29 (29 C FR 1910 Gene ral Indust ry ;
1915 Maritime; 1926 Con s truction). The most pertinent include: 1910.94 Ventilation, 1910 .95 Occupational Noise Exposure , 1 910.132
Personal Protective Equipment, 1910.133 Eye and Face Prote cti on, 191 0.134 Respiratory Protection, 1910 .1 35 Head Protection,
1910.244 (b) Remote Controls. Consult www.osha.gov for complete information.
NOTICE
PRODUCTS AND THIS INFORMATIONAL MATERIAL
TO
PURCHASERS
AND USERS OF
OUR
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: 636 239-4300 — Fax: 800 726-7559
Email: info@clemcoindustries.com
Website: www.clemcoindustries.com
[I]
PREFACE
OPERATIONAL INSTRUCTIONS
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 Grade D,
as defined by the Compressed Gas Association
specification G-7.1, per OSHA Regulation 29 CFR
1910.134. When compressed air is the breathing air
source, a Clemco CPF (suitable sorbent bed filter)
should be used. Respirator hose connecting the
respirator to the filter must be NIOSH approved.
Non- approved hose can cause illness from
chemicals employed to manufacture the hose.
• All workers must always wear NIOSH-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.
For additional information, consult:
Occupational Safety and Health Administration (OSHA) - www.osha.gov
Compressed Gas Association (CGA) - www.cganet.com
The Society 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
OPERATOR SAFETY EQUIPMENT
• Clemco respirators DO NOT remove or protect against
carbon monoxide or any other toxic gas. Monitoring
devices must be used in conjunction with the respirator to
ensure safe breathing air. Always locate compressors and
ambient air pumps where contaminated air will not enter
the air intake.
• Always use Clemco lenses with Clemco respirators;
installing non-approved lenses voids the NIOSH approval.
Respirator lenses are designed to protect the wearer from
rebounding abrasive; they do not protect against flying
objects, heavy high-speed materials, glare, liquids, or
radiation.
INDUSTRY ORGANIZATIONS
[II]
PREFACE
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 no t equipped with properly functioning pressure relief valves.
OSHA regulation 1910.244(b) requires the use of remote controls on blast mach ines.
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 Nation al Bo ard approval and
may affect the dimensional integrity of the vessel.
Moving the blast machine. Never manually move a blast machine contain ing abrasive, any machine containing
abrasive must be moved with appropriate mechanical lifting equi pment.
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 ev ery conn ection 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
Completely read and follow all service instructions and recommended maintenance intervals. Always shut off compressor and
depressurize blast machine before performing any maintenance. At every service interval, clean all filters, screens, and alarm systems. If
spring-loaded abrasive valves are used, always cage spring before disassembly.
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 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 the
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 warrant y is conditioned upon seller’s receipt within ten (10)
days after 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 the 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 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.
[III]
PREFACE
r
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as
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Co
s
DAILYSET‐ UP CHECK LIST
2. Breathing Air Compressor for
High Pressure Respirators
or Ambient Air Pump for
Low Pressure Respirators
4. External or
Helmet Mounted
Carbon Monoxide
Monitor /Alarm
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
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
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
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
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
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
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.
worn by blast operators, and other workers exposed to blast dust.
(bearing U or UM stamp, National Board Number, and
3. NIOSH Approved
Supplied-Air Respirator
5. CPF Air Filter
sized to provide
(or oil-less ambient air pump)
installed at th e CPF filt e r or
sorbent bed filter) for
1. Air Compresso
12. Abrasive
11. Appropriately Sized Nozzle
9. Blast Hose
7. AIR LINE FILTER
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
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
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
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
should be properly sized for the job. Check material safety data sheet for freesilica, cyanide, arsenic, lead and other toxins and avoid use when these toxic,
harmful substances are present.
SURFACE TO BE BLASTED
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
6. ASME Code
t Machin
Bl
8. Remote
ntrol
7. Air Line
Moisture
arato
Se
10. Hose Couplings and Safety Cables
(moisture separator) installed as close as possible to the
are required by OSHA and must be in perfect
should have an inside diameter sized to suit the blast nozzle.
should fit snugly on the hose and
must be a material specifically manufactured for blasting. It
should be examined for hazardous substances.
[IV]
CONTRACTOR SERIES BLAST MACHINE, 4 AND 6 CU. FT. Page 1
WITH MILLENNIUM PNEUMATIC, PRESSURE RELEASE REMOTE CONTROLS
1.0 INTRODUCTION
1.1 Scope of manual
1.1.1 These instructions cover set-up, operation,
maintenance, troubleshooting, and replacement parts for
the Clemco Contractor Blast Machine with Millennium
pneumatic, pressure release remote controls.
20" diameter, 4 cu. ft. capacity
24" diameter, 6 cu. ft. capacity
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; it contains important safety information about
abrasive blasting that may not be included in equipment
operation manuals. The booklet is available in both
English and Spanish; to request copies, email
info@clemcoindustries.com.
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.
© 2017 CLEMCO INDUSTRIES CORP. www.clemcoindustries.com Manual No. 21914, Rev. L
WARNING
Warning indicates a hazardous situation that, if
not avoided, could result in death or serious
injury.
DANGER
Danger indicates a hazardous situation that, if
not avoided, will result in death or serious
injury.
1.3 Components and Operating Principles
1.3.1 Components
1.3.1.1 The primary components of the Contractor
machines are shown in Figure 1. They include the blast
machine with Millennium remote controls, manuallyoperated Quantum abrasive metering valve, and frame
assembly. Blast machine systems also include optional
compressed air filter, and optional CPF particulate air
filter.
1.3.2 Instruction Maintenance Manuals
1.3.2.1 Individual manuals are included with optional
accessories: Manuals provided with blast machine
systems include:
CPF Particulate Air Filter
Apollo Respirator
Clem-Cool Air Conditioner
1.3.2.2 The front leg contains a storage area for
owner’s manuals. After reviewing all the manuals, and
startup and adjustments are completed, remove the
urethane cover plate and store manuals in the
compartment, for future reference.
1.3.3 Blast Machine
1.3.3.1 Clemco blast machines (pressure vessels) are
certified to conform to the ASME (American Society of
Mechanical Engineers) Boiler and Pressure Vessel
Code, Section VIII, Division 1. It is the owner’s
responsibility to maintain the integrity of the vessel in
accordance with the requirements of state regulations.
Regulations may include regular inspection and
hydrostatic testing as described in National Board
inspection code and jurisdictional regulations and/or
laws.
CONTRACTOR SERIES BLAST MACHINE, 4 AND 6 CU. FT. Page 2
WITH MILLENNIUM PNEUMATIC, PRESSURE RELEASE REMOTE CONTROLS
Cover
(Optional Accessory)
Lifting Eye
Screen
(**Optional Accessory)
Pop-up Seal
Inspection Door
Lifting Eye
Compression Coupling
Choke Valve
Abrasive Trap
Exhaust Muffler
Millennium Valve
Compressed Air Inlet
Air Filter (**Optional Accessory)
Pusher Line
Quantum Metering Valve
Pop-up Valve
Owner’s Manual
Storage Tube Cover
*Respirator Hose Connection
(Only with CPF Filter Option)
Bulkhead Fittings
(Control Hose Connection)
Quick Coupling
(Blast Hose Connection)
* Respirator hose connection is shown for
reference. Used only when the CPF Filter
is attached to the blast machine frame.
Breathing-Air Inlet
CPF Filter(**Optional Accessory)
** These accessories are included
with blast machine systems.
Figure 1
WARNING
Welding, grinding, or drilling on the blast
machine can weaken the vessel. Compressed
air pressure can cause a weakened blast
machine to rupture, resulting in death or
serious injury. Welding, grinding, or drilling on
the vessel, without a National Board R stamp,
voids the Clemco ASME certification.
1.3.3.2 All welding repairs to the vessel must be
performed by certified welders at shops holding a
National Board R Stamp. Welding performed by any
welder not properly qualified per the ASME code voids
the Clemco ASME certification.
1.3.3.3 This blast machine is rated for a maximum of
150 psi (pounds per square inch); do not exceed the
maximum working pressure. The maximum pressure
rating is also stamped into ASME nameplate which is
WARNING
Excessive compressed air pressure can cause
a blast machine to rupture. To prevent serious
injury or death, do not exceed the rated
pressure of the blast machine.
1.3.3.4 OSHA does not require pressure relief valves on
blast machines when air compressors supplying air to
the blast machines are built to ASME
with OSHA
(2)
regulations. OSHA regulation 1910.169
refers to the ASME code when describing 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.
(1)
American Society of Mechanical Engineers, Boiler and Pressure
Vessel Code, Section VIII, Division 1,
(2)
Occupational Safety and Health Administration, 29 CFR 1910, 169.
(1)
code and comply
welded to the side of the vessel.
© 2017 CLEMCO INDUSTRIES CORP. www.clemcoindustries.com Manual No. 21914, Rev. L
CONTRACTOR SERIES BLAST MACHINE, 4 AND 6 CU. FT. Page 3
WITH MILLENNIUM PNEUMATIC, PRESSURE RELEASE REMOTE CONTROLS
1.3.4 Remote Controls
WARNING
Never modify or substitute remote control
parts. Parts from other manufacturers are not
compatible with Clemco equipment. If ANY part
of the remote control system is altered,
involuntary activation can occur, causing
serious injury.
1.3.4.1 A remote control system is an OSHA-required
safety device; it is required when an operator mans the
nozzle. The remote controls allow the blast operator to
pressurize the machine to start blasting, and
depressurize it to stop blasting.
1.3.4.2 The control handle, located near the blast
nozzle, is the activator for the remote control system.
When the operator intentionally or unintentionally
removes hand-held pressure from the control handle, the
machine depressurizes and blasting stops. The remote
control system "fails to safe", which means when an
interruption in the control-air circuit occurs for reasons
such as a break in the line, the compressor stops
running, or the operator drops the blast hose, the remote
control deactivates the blast machine and blasting stops.
Safety Petcock
Orifice Fitting
Outbound Air Line
Millennium Valve Outlet Segment
Millennium Valve Inlet Segment
When using a regulator to reduce
blast pressure, relocate the orifice
upstream of the regulator, and p lug
the orifice port in the inlet valve.
Refer to Section 2.1.
Return Air Line
4-Ft. Twinline Hose
1.3.4.3 Components of the Millennium remote control
system are shown in Figures 1 and 2. They include the
Millennium inlet/outlet valve, RLX control handle, 50-ft.
and 4-ft. long twinline control hoses, and abrasive trap,
shown in Figure 1.
WARNING
Moist air that freezes can cause blockage at the
control handle or in the control lines. Blockage
can cause involuntary activation of the remote
controls, or prevent the controls from
deactivating upon release of the control handle.
This situation can result in serious injury or
death. If remote controls are operated in
freezing or near-freezing weather, install a
Clemco Anti-Freeze Injector, stock no. 05537,
on the remote control air-supply line.
1.3.4.4 Millennium remote controls are pressure-
release-style systems, which control the pressurization
and depressurization of the blast machine.
Pressurization, which starts blasting, occurs when the
control handle is pressed, and depressurization, which
stops blasting, occurs when the handle is released.
Pressure Regulator
Orifice Fitting
Blast Machine Front Leg
RLX Control Handle
1/4 NPT Adaptor
Bulkhead Fitting
Blast Machine Quick Coupling
50-Ft. Twinline Hose
Nylon Ties
Blast Hose
Figure 2
© 2017 CLEMCO INDUSTRIES CORP. www.clemcoindustries.com Manual No. 21914, Rev. L
CONTRACTOR SERIES BLAST MACHINE, 4 AND 6 CU. FT. Page 4
WITH MILLENNIUM PNEUMATIC, PRESSURE RELEASE REMOTE CONTROLS
1.3.4.5 Clemco remote controls operate pneumatically
on a return-air principle. A stream of control air travels
from the orifice on the inlet valve, down the outbound
twinline (shown shaded in Figure 2) and escapes
through the opening located under the control handle
lever. The normally-closed inlet valve remains closed,
and the normally-open outlet valve remains open. As
long as air escapes through the hand le’s opening, the
remote control system remains inactive. When the
operator presses the control lever, a rubber button
seals the opening, and outbound air returns through
the inbound line to open the inlet valve and close the
outlet valve. This action pressurizes the blas t machine
and begins the blasting. Releasing the handle
exhausts the control air, which causes the inle t valve to
close, and the outlet valve to open to depressur ize the
blast machine and stop the blasting.
1.3.5 Electric Remote Control Option
1.3.5.1 Electric remote controls (electro-pneumatic) are
recommended when the nozzle and remote control
handle are farther than 100 feet from the blast machine.
Pressure drop of pneumatic systems over longer
distances increases actuation time, which prevents fast,
safe operation. Contact your local Clemco Distributor for
additional information.
1.3.6 Air Filter, Optional
1.3.6.1 The optional filter removes particles and
condensed moisture from the compressed air before it
enters the machine. Water is drained through a manual
drain located at the bottom of the filter.
1.3.7 Frame and Cart
1.3.7.1 The frame assembly provides added protection
for the piping, valves and accessories. This protection
keeps the piping aligned and tight. The wheeled cart
assists in the mobility of the machine over smooth flat
surfaces. See transporting and moving in Section 3.1.
1.3.7.2 Use lifting eyes when raising, loading, and
unloading the blast machine. Do not use a sling around
the cart handles or piping.
© 2017 CLEMCO INDUSTRIES CORP. www.clemcoindustries.com Manual No. 21914, Rev. L
1.4 Abrasive
WARNING
Abrasives and dust from blasting may contain
toxic materials (e.g., lead paint, silica) that are
hazardous to workers. Before blasting, obtain a
safety data sheet (SDS) for the blast abrasive
and identify all substances removed by the
blasting process.
• Silica sand (crystalline) can cause silicosis,
lung cancer, and breathing problems in
exposed workers.
• Slags can contain trace amounts of toxic
metals such as arsenic, beryllium, and
cadmium and have the potential to cause
lung disease.
NO DUST IS SAFE TO BREATH. DUST
PRODUCED FROM ANY ABRASIVE OR FROM
THE BLASTING PROCESS CAN CAUSE
SERIOUS LUNG DISEASE AND DEATH WHEN
INHALED. It is the employer’s responsibility to
train employees to identify hazardous
substances and to provide suitable policies,
procedures, monitoring, recordkeeping and
personal protective equipment.
NOTE: Use only abrasives specifi call y manufa ctured
for blasting that are compatible with the surface
being blasted. Abrasives produced for other
applications may be inconsistent in size and shape
and produce an unsatisfactory finish, contain
particles that could jam the abrasive metering
valve, or cause irregular wear.
1.4.1 Selection of blasting abrasive can play a
significant part in worker health risk, job productivity,
and maintenance of the blast machine. DO NOT USE
abrasives containing more than one percent crystalline
(free) silica. Obtain safety data sheets (SDS) for the
blasting abrasive prior to blasting, paying particular
attention to worker health risks and presence of any
hazardous/toxic substances.
1.4.2 Abrasive Size
1.4.2.1 The choice of abrasive size depends on the
desired profile, cleaning rate, nozzle orifice size and
availability of clean dry air. Generally, larger, denser
abrasives provide a deeper profile, while smaller
abrasives clean faster. Most abrasive blasting is done
with abrasive sizes between 16 and 80 mesh. Larger
sizes may be used if the nozzle orifice is large enough to
CONTRACTOR SERIES BLAST MACHINE, 4 AND 6 CU. FT. Page 5
WITH MILLENNIUM PNEUMATIC, PRESSURE RELEASE REMOTE CONTROLS
prevent particles to pass without jamming. Finer abrasives
are especially sensitive to moisture and requires very dry
air to prevent bridging in the metering valve.
1.4.3 Sand: Sand should never be used because of
the respiratory hazards associated with abrasives
containing free silica.
1.4.4 Slag: Slag abrasives are compatible with the
blast machine fitted with the MQV manual Quantum
metering valve. Obtain safety data sheet (SDS) to
identify hazardous substances.
1.4.5 Steel: Steel shot and steel grit may be used with
machines fitted with the MQV manual Quantum metering
valve. Shot applications may require the use of a
pneumatically-operated metering valve such as AQV
Auto-Quantum, to prevent surging at startup.
1.4.6 Silicon Carbide, Aluminum Oxide, and
Garnet: These are the most aggressive, high-volume
abrasives used in the blasting industry. These abrasives
may be used, but the service life of any equipment
components which come in contact with the abrasive will
be reduced. Use a nozzle lined with boron carbide with
these abrasives.
1.4.7 Glass Bead: Most beads are treated to ensure
free-flow operation even under moderately highhumidity. Glass beads subjected to excessive moisture
may be reused after thorough drying and breaking up of
any clumps. Clean, dry air is a necessity. Glass bead
applications may require the use of a pneumaticallyoperated metering valve, such as AQV Auto-Quantum,
which can help to prevent surging at startup.
1.4.8 Lightweight Media: Plastic media and most
agricultural media may be used occasionally in a
standard blast machine. Exclusive use of plastic, and
some other lightweight media, requires a blast machine
with a 60
o
conical bottom for continuous, uninterrupted
media flow.
2.0 INITIAL SET-UP
2.1 Installation of a Pressure Regulator to
Reduce Blast Pressure.
2.1.1 When Installing a pressure regulator to reduce
blast pressure below 60 psi, install a tee upstream of the
regulator as shown in the insert in Figure 2, relocate the
orifice to the tee, and plug the orifice port in the inlet
valve. This allows the pneumatic control circuit to
operate at line pressure.
© 2017 CLEMCO INDUSTRIES CORP. www.clemcoindustries.com Manual No. 21914, Rev. L
2.2 Set Up for Multiple Blast Machines Operating
From a Common Compressed Air Supply
NOTICE
If multiple machines are operating from a
common compressed air supply, and a
machine is under pressure, when another
machine is pressurized, the sudden, increased
demand for air can reverse air flow from the
machine that is under pressure, and
contaminate the compressed air supply with
abrasive-laden air. Install check valves at the
piping inlet to prevent the reversal of air.
2.2.1 Where multiple blast machines are operating
from a single air source, install a ball-cone check valve
at the air supply on each machine. Refer to the
illustration in Figure 3 to install the check valve.
2.2.2 If the machines are placed close together, use a
receiver tank or manifold and run separate air lines from it
to each machine. The check valves may be located on the
receiver tank outlets if the air line goes directly to the blast
machine and nowhere else.
2.2.3 Use a Clemco 1-1/2-NPT cone check valve, stock
no. 02296. A smaller size valve could restrict air
movement and reduce nozzle pressure. When installing
the valve, make sure the directional arrow is pointing in
the direction of the air flow, toward the machine. N OTE:
Do not use a swing check valve, as the swing gate may
break in blast machine applications.
Millennium Valve
1-1/2-NPT Nipple
1-1/2-NPT Cone Check Valve
stock no. 02296
Figure 3
2.3 Install Optional Air Filter (Moisture
Separator) Figure 4, NOTE: The filter is included with
blast machine systems.
2.3.1 Install a compressed-air filter to the inlet valve
as shown in Figure 4. It is recommended that a filter be
installed at this location to remove moisture from air
before it enters the machine. If problems with moisture
CONTRACTOR SERIES BLAST MACHINE, 4 AND 6 CU. FT. Page 6
WITH MILLENNIUM PNEUMATIC, PRESSURE RELEASE REMOTE CONTROLS
persists after installing the filter, a dryer or aftercooler
may be required in the air-supply line.
Millennium Valve
AIR LINE RECOMMENDATIONS
Nozzle
Orifice Size
BASED ON NOZZLE SIZE
Recommended Air Supply Line
No. 3, 3/16" 3/4" ID or larger
No. 4, 1/4" 1" ID or larger
Optional Air Filter
No. 5, 5/16" 1-1/4" ID or larger
No. 6, 3/8" 1-1/2" ID or larger
No. 7, 7/16" 2" ID or larger
Figure 4
2.4 Compressed-Air Supply Hose Connection
2.4.1 Apply thread sealant to the male pipe threads of
an air fitting that is compatible with the air supply hose
fitting, as noted in Section 2.4.2, and install it onto the
1-1/2 NPT optional air filter or the Millennium inlet valve,
as shown in Figure 5. Note that the style of
connection shown in Figure 5 is for reference only.
WARNING
Hose disconnection while under pressure can
cause serious injury or death. Use safety lock
pins or safety wire to lock twist-on (claw-type)
couplings together and prevent accidental
separation while under pressure, and safety
cables to prevent hose from whipping should
separation occur.
Millennium Valve
No. 8, 1/4" 2" ID or larger
Refer to the compressed air and abrasive
consumption table in Figure 9 for approximate air
consumption.
Figure 6
2.5 Prepare Blast Hose and Remote Control
Hose Connections, Figure 2.
WARNING
Where two or more blast machines are used,
carefully trace control lines and blast hose
when making connections. Cross-connecting
control hose or blast hose can lead to serious
injury, death, or property damage from
unintentional actuation of a blast machine. To
prevent cross connections, hoses should be of
equal lengths, and the hoses and blast machine
couplings clearly marked. Use optional hose
identification kits, stock no. 15890 for use with
two blast machines, or stock no. 15891 for up
to four machines. Mark each hose and
connection per the instructions supplied with
the kit, and carefully trace and verify each
Hose Fitting
Safety Lock Pin
connection before operating.
WARNING
Air Supply Hose
Safety Cable
Figure 5
2.4.2 Attach an air line from the compressor to the
hose fitting installed on the blast machine inlet. For best
blasting performance, refer to the table in Figure 6 for
the minimum recommended hose size based on the
nozzle orifice size. A smaller diameter hose could result
in a reduction in nozzle pressure.
© 2017 CLEMCO INDUSTRIES CORP. www.clemcoindustries.com Manual No. 21914, Rev. L
Moist air that freezes can cause blockage at the
control handle or in the control lines. Blockage
can cause involuntary activation of the remote
controls, or prevent the controls from
deactivating upon release of the control handle.
This situation can result in serious injury or
death. If remote controls are operated in
freezing or near freezing weather, install a
Clemco Anti-Freeze Injector, stock no. 05537,
on the remote control air supply line.
CONTRACTOR SERIES BLAST MACHINE, 4 AND 6 CU. FT. Page 7
WITH MILLENNIUM PNEUMATIC, PRESSURE RELEASE REMOTE CONTROLS
2.5.1 Uncoil the blast hose, and lay the 50-ft. twinline
hose alongside it. Hoses should be of equal lengths.
2.5.2 Band the control handle to the blast hose close
to the nozzle holder, as shown in Figure 7, using the two
nylon ties provided. Once the control is firmly attached,
clip the tie ends to avoid snags or interference with the
operation of the control handle.
2.5.3 Attach the 50-ft. twinline hose to the two fittings
on the control handle. Either side of the hose can be
attached to either fitting.
2.5.4 Working from the control handle back, band the
twinline hose to the blast hose every four to six feet, and
as close to the couplings as possible.
NOTE: Control hoses come with reusable hose ends.
Excess hose may be cut-to-fit and recoupled, refer to
Section 6.11.
Nozzle Holder
RLX Control Handle
WARNING
Air supply to the respirator system is critical to
the safety of the user. Read the CPF Filter and
Apollo Respirator manuals carefully. Poor
quality air will cause serious respiratory injury
or death to the user.
2.6.1 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
2.6.2 Apply thread sealant to the male threads of an air
fitting that is compatible with the air supply hose fitting, as
noted in Section 2.6.3, and install it onto the 1-NPT port
located at the side of the filter, as shown in Figure 8. Note
that the style of connection shown is for reference only.
Respirator Lead Hose Fitting
(29 CFR 1910.134 (i)).
Blast Hose
Nylon Ties
CPF Filter
Air Fitting
Hose from
respirable air supply
Figure 7
2.5.5 Place the nozzle washer in the nozzle holder,
and screw the nozzle into the holder. The nozzle must
seat tightly against the nozzle washer.
2.6 Breathing Air Connection, Opt ional CPF Filter,
Refer to the CPF Owner’s Manual 04143 before
operating the filter.
DANGER
Do not connect the CPF Filter, or any other
regulator or filter, to bottled air or any other air
source that does not have a pressure-reducing
valve that reduces pressure to maximum of 150
psi. Failure to comply with this warning will
cause low-pressure devices to explode under
the high pressure of bottled air. Such an
explosion can cause severe injury or death.
Figure 8
2.6.3 Refer to the CPF air filter owner’s manual and
attach an air supply hose from an air source that meets
OSHA requirements for respirable air, to the fitting
installed on the CPF filter inlet, as shown in Figure 8 and
noted in the CPF air filter owner’s manual.
2.6.4 For models with CPF filter attached, Refer to
Page 27, Figure 35 and connect a hose union to one
end of the 5-ft. respirator lead hose and connect the
other end of the hose to the fitting at the top of the CPF
filter
2.6.5 Refer to the Apollo Respirator and CPF Filter
manuals for instructions concerning their operation.
Use safety lock pins
to secure couplings.
© 2017 CLEMCO INDUSTRIES CORP. www.clemcoindustries.com Manual No. 21914, Rev. L
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