Owner`s Manual - Amazon Web Services
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1. rie 4 6 BU at lS Par LI GE ni EE E E EA E E quer E E E E 7 BUDES S DINEN ONS nerra i A EREA EE E AEEA NE E AEAEE I AE IE EE 8 Assembly amp Operations Bulb Eater 3 Assembly INStructions cccccccsssscscceccessusccsccessussancoessessancasccessussanccesoursane 9 10 Bulb Eater 3 Operating ProcedureS ccccccceccecceecceccuseeeeescuceeceeeseuseueeeseeeseueeeeesseeeeness 11 12 Recycling FUI FUIINS rr pe 14 Maintenance amp Trouble Shooting Dramm Chane PrO CAU ES earn EAE E EAE 13 Filter Replacement Procedure ccccceccesceeccuccecceeccuscuceeeeeeseuseeeeeeseuceeeeeueeuseuseseeeseueeess 16 18 SpIinner REpiaCenm eNEPFOCEHOF6S root e rec 18 Troubleshooting the Bulb Eater 3 caccsscscctosaiocsecaaapansensiocnsscasdeateaaiassesanaboossaaioaiteaasacexeemmssseiaas 19 Operating Tips amp Frequently Asked QuestionsS ie 19 21 Parts amp Accessories Replacement Parts amp Accessories secacccinsccossnsavonreanacansscosanaacanoearonnsaveesesaaeopeaswoaaeuennseatauanneaweanes 22 PATS UNG e EPE EEEE EE EEE aa iii 23 Maintenance amp Trouble Shooting PICK UDR GUIS FONT irren n A ira 15 MEeFCURIIATOFMArO N 24 Meray Saal OS air aio 29 Warranty INTOCMa 0 ine 30 LA 800 909 9709 n BULBE ATER l R C ki CL E www Air Cycle com with Intelli Technology IMPORTANT SAFETY INSTRUCTIONS A ATTENTION iz Inspect Bulb Eater 3 referred to as BE3 prior to any use Read all safety rule2. BULB EATER with Intelli Technology Fluorescent Lamp Crushing System i ae www AirCycle com 800 909 9709 info AirCycle com Purpose and Function of Manual The owner s user manual contains all essential information for the user to make full use of the information on the BULB EATER This manual includes Description of the Standard Safety Symbols and Safety Systems used System Functions Assembly amp Operations Maintenance amp Trouble Shooting Parts amp Accessories e Reference Materials amp Forms Step by Step Procedures Read all manuals included with this product carefully Be thoroughly familiar with the controls and the proper used of the equipment Serial Number Model Number 333 200 120 or 333 200 240 Serial Number Date of Purchase The serial number will be found on a label attached to the control box You should record both serial number and date of purchase and keep in a safe place for future reference US 800 909 9709 Outside US 708 344 7860 Fax 866 909 6725 12 04 2014 LA 800 9099709 AIRCYCLE www AirCycle com 1 BULB EATER cORPORATION with Intelli Technology Table of Contents Purpose and Function of Manual erre i Taole OTC ITS a a a a EE EE E EE E EE E E ESS 1 Important safety INStructionS ssssessssssrssessrseserreserrrseeresrrrrserreserresenreserreseresesreseseeseseeseseene 2 3 Machine amp Control Panel DiagramS
3. Crushing lamps is a regulated activity by the United States Environmental Protection Agency Air Cycle Corporation strongly urges all Bulb Eater 3 customers to thoroughly research all regulations that may apply to crushing storage shipping labeling employee training and other crushing related activities at their facility Detailed environmental and regulatory information can be found in the Mercury Information appendix beginning on page 24 Visit www bulbeater3training com to complete the Bulb Eater 3 Certified Training Program For additional online Bulb Eater resources visit www mybulbeater com For More Information on the Bulb Eater 3 and Air Cycle Corporation visit www aircycle com AA 800 909 9709 Ms al Da BULB EATER 3 www Air Cycle com with Intelli Technology Replacement Parts amp Accessories Pricing is available online at www aircycle com products bulb eater 3 parts or by contacting Air Cycle at 800 909 9709 Cartridge Filter 2 Stage O Power Cord i i Power Cord for 120v 1 Cartridge Filter HEPA Filter 3 amp 5 Stage Airlock Motor Assembly Highest Grade HEPA Filter Available Motor A L Sensor and Molex Connector rr Spinner Assembly v Bang camp Ca Clamp for Carbon Canister C 8 Loop Chain Used To Crush Lamps p V Band Clam Filter Combo Kit amp Spinner Assembly P Clamp for Airlock amp Cyclone Assembl Contains 2 2 Stage Cartridge Filter 1 3 stage p y y HEPA filt
4. Frequently Asked Questions Bulb Eater 3 users typically find the machine very easy to set up and use However we recognize that sometimes our customers have questions about their machines Below is a list of frequently asked questions that address many common inquiries that we receive If you require additional assistance please feel free to contact us at any time by phone at 800 909 9709 or 708 344 7860 through email at info aircycle com or by visiting www aircycle com resources FAQ What type of lamps can I crush with the Bulb Eater 3 All models of the Bulb Eater 3 will crush any size linear straight fluorescent lamps In addition to these the CFL U tube chute allows for crushing u tube and compact fluorescent lamps U tube and compact fluorescent lamps should only be crushed using machines designed to crush the specific lamp type What dangerous materials are in fluorescent lamps Lamps contain many different components and materials but the only one that is toxic is mercury Each lamp typically contains 10 20 mg of mercury some of which is evaporated However other components and materials of the lamp such as the glass or powdered phosphors can be contaminated by the mercury during the life of the lamp More information on mercury and disposal regulations can be found in the reference section of this manual How does the Bulb Eater 3 remove mercury while crushing lamps Your Bulb Eater 3 will remove virtually all airb
5. 3 Immediately place the spare lid on the full drum to seal the vapor Figure 4 4 Place the Bulb Eater 3 Machine on the empty drum and tighten the locking ring Figure 5 5 Place the lid locking ring on the lid with the full drum and tighten Figure 6 Note When this procedure is executed properly the drum open time should be less than 10 seconds Figure 1 Figure 2 Figure 6 A 800 909 9709 I R CYCL E www AirCycle com 13 BULB EATER with Intelli Technology Recycling Full Drums Schedule a Recycling Pickup Call Air Cycle at 800 909 9709 Schedule a pickup online at www aircycle com services Use the Pick Up Request Form Page 15 to schedule your pick up Air Cycle offers bulk pickup service to allow you to continue enjoying cost effective recycling solutions after you have crushed your lamps conserve your storage space save money over other recycling solutions and help keep our environment clean With Air Cycle s Crushed Lamp Bulk Pickups You Can Have large amounts of crushed lamps picked up nationwide Recycle various types of universal waste with a single pickup including batteries ballasts and electronics e Track your recycling progress online 24 7 with online recycling reports e Certify your progress for regulatory or management review with Recycling Certificates AA 800 909 9709 IRCYCLE www AirCycle com 14 BULB EATER 3 with Intelli Technology Pick Up Request Form Sche
6. Florida Illinois Maryland Montana New Mexico Tennessee Texas and Virginia have all passed rules that allow persons to crush lamps on site under the universal waste regulations Please verify with your state regulatory agency that these rules still apply In states that allow crushing and classify crushed lamps as universal wastes persons can generally store their waste lamps on site for up to one year can ship waste lamps off site with a bill of lading rather than a hazardous waste manifest and need not include their lamps when calculating their hazardous waste totals Under state and federal hazardous waste regulations controlled crushing is considered treatment The hazardous waste rules typically require a person who treats wastes to obtain a permit Federal and most state hazardous waste rules however exempt from the permit requirement persons who treat their wastes within a drum tank or container See 40 CFR 262 34 Air Cycle Corporation believes The Bulb Eater systems fall squarely within this exemption and many states have acknowledged in letters to Air Cycle Corporation that the accumulation tank exemption applies to The Bulb Eater 3 systems You should be aware however that the States of California Maine Massachusetts SQG and LQG generators Connecticut Rhode Island Missouri Vermont New Hampshire West Virginia Minnesota Pennsylvania Michigan and New Jersey have more narrow exemptions to the permitting r
7. No adapter should be used with this machine www AirCycle com 3 BULB EATER with Intelli Technology IN CANADA THE USE OF A TEMPORARY ADAPTER IS NOT PERMITTED BY THE CANADIAN ELECTRICAL CODE Make sure that the machine is connected S BULB EATER Control Panel with Intelli Technology LCD Screen E Stop Stop Button Start Button Dust Cap w USB Plug AC Receptacle Ans 800 909 9709 BULB E ATER S ATREYCLE www AirCycle com 4 with Intelli Technology CORPORATION The BULB EATER 3 with Intelli Technology The Bulb Eater 3 is capable of crushing any size linear straight fluorescent lamp u tube fluorescent lamp and compact fluorescent lamps Cyclone Assembly Crusher Motor Chute Safety Cover Control Panel Vacuum amp Filter 1 stage filter system for U tube CFL chute see page 4 for details contains 2 amp 3 stage filters 3 Entry Tube Brass Plug Assembly Airlock Assembly Lid Assembly Carbon Canister Filter Not to scale At linear lamp entry contains 4 amp 5 stage filters Not pictured 48 Entry Tube Spinner Assembly 2 Stage Filter 3 amp 5 Stage Filter CFL U Tube Chute located on underside of lid attaches on U Tube Flange AA 800 909 9709 BULB ATER AIRCYCLE www AirCycle com 5 with intelli Technology ORPORATION The BULB EATER 3 with CFL U Tube Chute with Intelli Technology The Bulb Eater 3 is capable of crushing any size linear
8. This warranty does not cover damage resulting from shipping negligent handling misuse or lack of reasonable care Tampering with the machine and electronics will void this warranty The Bulb Eater 3 machine can be used outdoors in a dry covered environment but MUST BE STORED indoors when not in use in a dry area Parts that prove to be defective during the one 1 year warranty period will be either repaired or replaced at the option of Air Cycle Corporation The right is also reserved by Air Cycle Corporation to replace the product in lieu thereof The full remedy for breach of this warranty and sole obligation of Air Cycle Corporation is the repair or replacement of the defective Bulb Eater 3 at Air Cycle Corporation Air Cycle Corporation shall have no liability whatsoever at any time for any personal injury or property damages or for any special indirect or consequential damages of any kind This warranty is strictly limited to its terms and is in lieu of any and all other of any kind understandings warranties and conditions written or oral whether expressed or implied Please fill out the blanks below and return to Air Cycle Corporation Upon receipt the warranty will become effective until one 1 year from purchase date Thank you for your business 12 04 2014 Company Name Name of Contact Address City State Zip Phone Fax Air Cycle Corporation 2200 Ogden Avenue Suite 100 Lisle IL 60532 US 800 909 970
9. Exempt Small Quantity Generators CESQG s are persons who generate 220 lbs per month or less of all hazardous wastes combined not just lamps These generators are exempt from most of the hazardous waste regulations which include transportation treatment and disposal requirements They must not however store more than 2200 lbs of hazardous waste on site at any time and must dispose of their hazardous waste in facilities that are permitted or authorized to accept hazardous or non hazardous wastes Many states acknowledge CESQG exemptions for paperwork but not for disposal Many states do not allow CESQG to dispose of hazardous waste in a solid waste landfill ALA 800 909 9709 BULBE ATER TIRCYCLE www AirCycle com 25 with Intelli Technology Small Quantity Generators SQG are persons who generate 220 to 2200 lbs of hazardous waste per month These generators must keep proper records of the waste report to EPA and follow accumulation requirements These generators can store up to 6 months without a storage permit Large Quantity Generators LQG generate more than 2200 Ibs of hazardous waste per month These generators are subject to the full hazardous waste management requirements These generators cannot store hazardous wastes on site for more than 90 days 3 months without obtaining a storage permit There are 2 categories of Universal Waste handlers 1 Small Quantity Handler Generator who accumulates less than 11 000 Ibs of
10. environment from human activity include coal burning power plants batteries and fluorescent and HID lamps Small amounts of mercury are a necessary component in fluorescent and HID lamps but when a lamp is broken crushed or dispensed in a landfill or incinerator mercury may be released to the air surface water or groundwater Considering this it is a good policy to keep the mercury in fluorescent and HID lamps out of the solid waste stream by recycling How do know if my waste is hazardous All generators of waste except households are responsible for determining if their waste is hazardous under current state and federal regulations Hazardous wastes can either be included on specific lists or exhibit hazardous characteristics This determination can be done by knowledge of the waste or by testing the waste ALA 800 909 9709 BULBE ATER A l R C Y C LE www AirCycle com 24 with Intelli Technology What s hazardous Persons who generate wastes are responsible for determining whether their wastes are hazardous One common method for determining whether a waste is hazardous is the Toxicity Characteristic Leaching Procedure TCLP test The TCLP test is a laboratory test that simulates the potential leaching of hazardous wastes under conditions typically found in municipal solid waste landfills If the concentration of mercury in water that is passed through a sample of crushed fluorescent lamp fragments exceeds 0 2 mg liter the crus
11. machine is is not being operated It can become a tripping hazard not working as it should has been dropped 19 Use special care when emptying heavily loaded drums damaged left outdoors or dropped into water contact drums Air Cycle Corporation for assistance Replace with specific 20 Always wear safety goggles and hearing protection when part of machine in question operating the machine 7 Do Not pull or carry by cord use cord as a handle 21 STAY ALERT Watch what you are doing and use close a door on cord or pull cord around sharp edges or corners Do not run machine over cord Keep cord away from heated surfaces common sense Do not use the BE3 machine when you are tired distracted or under the influence of drugs alcohol or medication causing diminished 8 Do not unplug by pulling on cord To unplug grasp control the plug not the cord 9 Do not put any object into openings Do not use with any openings blocked keep free of dust lint hair and anything that may reduce air flow SAVE THESE INSTRUCTIONS A WARNING DO NOT LEAVE Bulb Eater 3 MACHINE UNATTENDED WHEN IT IS PLUGGED IN AND OR OPERATING UNPLUG UNIT WHEN NOT IN USE GROUNDING INSTRUCTIONS This machine must be grounded If it should malfunction or breakdown grounding and has a plug that looks like the provides a path of least resistance for electric current to reduce the risk of electric plug illustrated in the sketch A Properly Ground
12. press the START button After crushing press the STOP button to stop the crusher motor The machine will go through 3 LCD display functions again Stopping Dumping Ready When the LCD display indicates Ready press the E STOP button and seal the entry tube Figure 1 When the machine is not in use make sure that all openings are sealed sealed entry tube and CFL chute may remain on the machine when not in operation Before removing lid Let the machine sit OFF for at least 15 minutes after the dump cycle is done to allow dust to settle before opening the lid during drum change Notes 1 Pressing the STOP button must be completed before pressing the E STOP button when finished crushing this will allow the powder to be dumped out of the cyclone into the drum 2 When crushing linear lamps insure that the CFL U Tube chute is removed and the safety cover is installed ATTENTION Drum MUST be kept closed at all times AA 800 909 9709 BU LB ATER 3 IRCYICLE www AirCycle com 11 ohh Intell Tedmalegy BULB EATER Operating Procedures for CFL S U Tube Lamps WARNING po Not TAMPER WITH ANY ELECTRICAL CONTROL DEVICES ON THIS MACHINE Before Operating the Bulb Eater 3 with CFL U Tube Chute Communicate understand potential hazards by having operators review pages 24 29 of this manual and complete online training program at www BulbEater3Training com Note The Bulb Eater 3 machine is inoperable until key personnel have c
13. straight fluorescent lamp u tube fluorescent lamp and compact fluorescent lamps Cyclone Assembly Crusher Motor CFL U Tube Chute Control Panel Vacuum amp Filter 1 stage filter system see page 4 for details contains 2 amp 3 stage filters Brass Plug Assembly Airlock Assembly Lid Assembly Carbon Canister Filter At linear lamp entry contains 4 amp 5 stage filters Not pictured a A Oo E 48 Entry Tube Spinner Assembly 2 Stage Filter 3 amp 5 Stage Filter located on underside of lid LA 800 909 9709 AIRCYCLE www AirCycle com 6 BULB EATER 5 cORPORATION The BULB EATER 3 Parts Included w Machine with Intelli Technology The Bulb Eater 3 Parts List Sett Dl e Airlock Assembly w motor 120v or 240v Lid Assembly Brass Plug Assembly Carbon Canister Assembly Cartridge Filter Chute Safety Cover Control Panel Assembly Crusher Motor 1 5 Horsepower 2 amp 120v Cyclone Assembly HEPA Filter Lid Open Sensor Assembly Locking Ring amp Bolt Spinner Assembly Vacuum Body Assembly Vacuum Motor 120v or 240v Plug Assembly Safety Gloves 2 Pairs Safety Glasses 2 Pairs Ear Plugs 2 Pairs 48 T 12 Entry Tube USB Drive Bulb Eater 3 Owner s Manual Other accessory parts are available from the parts list The Bulb Eater 3 Parts List for Assembly SS Ro e Bulb Eater 3 Lid w Assemblies Carbon Canister Assembly Clam
14. universal waste batteries pesticides thermostats or lamps at any time 2 Large Quantity Handler Generator who accumulates more than 11 000 Ibs of universal waste batteries pesticides thermostats or lamps at any time Universal Waste Storage Limits Both Small and Large Quantity Generators of Universal Waste can generally store their Universal Waste for one year For more information please contact your state Environmental Protection Agency or Air Cycle Corporation Mercury Emissions The disposal of mercury containing fluorescent lamps and the potential for emissions is of concern because mercury is a highly toxic metal that bio accumulates through the food chain Mercury also has a low vapor pressure of 2 x 10 3 mm at 25 C and readily evaporates to form mercury vapor at room temperature Therefore emissions of mercury in liquid or vapor form require health and environmental consideration The volatilization is especially significant with respect to human health as it results in ambient mercury vapor that can be absorbed into the human body through various pathways These include direct inhalation ingestion through surface contamination and absorption through the skin of elemental mercury Generally excessive exposure to various forms of mercury has been shown to adversely affect the human central nervous system lungs kidneys skin and reproductive system Local Effects Mercury is a primary irritant of the skin and mucous m
15. 9 Outside US 708 344 7860 Fax 866 909 6725 Shipping Date Serial www AirCycle com AA 800 909 9709 IRCYCLE www AirCycle com 30 BULB EATER 5
16. CGIH 30 ACGIH NAS SMAC Hour minute Instantaneous 24 Hour TWA Excursion Excursion Limit TWA mg m Limit mg m mg m mg m 0 1 0 025 0 075 Skin 0 125 0 05 10 0 0 08 0 02 Skin Skin 9 1 ppb Skin Skin 12 2 ppb 3 0 ppb 15 2 ppb 6 1 ppb 1 219 ppb 9 8 ppb 2 4 ppb Table Abbreviations and Notes ACGIH American Conference of Governmental Industrial Hygienists 2002 Threshold Limit Values IDLH Immediately Dangerous To Life And Health mg m Milligrams Per Cubic Meter air NAS National Academy of Sciences NIOSH National Institute of Occupational Safety and Health PEL Permissible Exposure Limit ppb Parts per billion in air OSHA Occupational Safety and Health Administration REEL Recommended Environmental Exposure Limit Skin Percutaneous dermal exposure as route of exposure SMAC Spacecraft Maximum Allowable Concentrations for Selected Airborne Contaminants 1996 TLV Threshold Limit Value TWA Time Weighted Average Note When maintained and operated properly emissions from the Bulb Eater 3 should be well under all applicable mercury exposure requirements Test results available upon request LA 800 909 9709 BULBE ATER l R C YCL E www AirCycle com 29 with Intelli Technology Warranty Information Air Cycle Corporation warrants The Bulb Eater 3 for one 1 year from the date of Original purchase from the distributor or manufacturer against defects in workmanship and or materials under normal usage
17. LB ATER 3 AIRCYCLE www AirCycle com 22 with Intelli Technology cCcorronario n BULB EATER 3 Parts List with Intelli Technology U M 333 200 120 Bulb Eater 3 120v Machine EA A 55 304 T17 Entry Tube 48 EA 333 210 CHU U Tube CFL Removable Chute EA 333 367 Cartridge Filter EA 55 325 HEPA Filter 3 amp 5 stage 333 390 CCA Carbon Canister 4 stage amp HEPA Filter 5 Stage including Activated Carbon 333 390 SCK Filter Combo Kit 2 Cartridge Filters 1 HEPA Filter amp 1 8 Link Spinner Assemblies i PKG 333 200 120 Entry Tubes T5 Entry Tube 48 T12 Entry Tube 48 55304 O BA _333 210 CHU m gt K v G EA EA EA EA EA EA 55 400 55 Gallon Drum Epoxy lined plain lid amp bolt ring clamp 55 425 55 Gallon Transport Lid w Gasket 55 440 55 Gallon Locking Ring Heavy Duty 12 gauge w bolt EA EA EA KG EA EA EA EA EA EA EA EA EA EA EA EA EA EA EA AA 800 909 9709 n BU LB ATER S N l R C ki CL E www AirCycle com with Intelli Technology Mercury Information Controlled Crushing Regulations Crushing lamps with the Bulb Eater 3 is considered controlled crushing and is regulated under both federal and state hazardous and universal waste regulations The federal universal waste regulations do not authorize on site crushing of fluorescent lamps but do allow the states to write rules that will permit crushing on site The States of Colorado
18. Refer to page 16 of the owner s manual for filter replacement instructions ALA 800 909 9709 do BULBE ATER l R C ki CL E www AirCycle com with Intelli Technology Does the spinner assembly need to be changed The spinner chain assembly should be changed when uneven wear causes excessive vibration to the machine Refer to the Maintenance amp Troubleshooting section of the owner s manual for spinner changing instructions What do do when my drum is full First let the machine sit off for at least 15 minutes before opening the lid This allows for dust to settle inside the drum Once the Bulb Eater 3 is removed from the top of the drum it is strongly recommended that the drum be resealed as quickly as possible within 10 seconds of removal of machine from drum to minimize potential release of remaining mercury vapors present inside the drum Once your drum is full call Air Cycle at 800 909 9709 or visit www aircycle com services to schedule a pickup How can order more filters or other replacement parts Visit www aircycle com or call 800 909 9709 or 708 344 7860 to order more filters and replacement parts What safety precautions should I take when operating the Bulb Eater 3 Because of possible lamp breakage outside of the drum suitable eye protection and protective gloves must be worn at all times while the machine is in operation Proper ear protection such as the provided ear plugs should also be worn at all
19. TION Only crushed lamps and filters placed on top of the crushed lamps can be inside the drum Do not place any extraneous materials or liquids in the drum spinner Replacement Procedures Communicate understand potential hazards by having operators review pages 24 29 of this manual and complete online training program at www BulbEater3 I raining com When the Crusher Motor exhibits excessive vibration the spinner assembly should be changed Gloves and eye protection should be worn while changing the spinner With the Bulb Eater 3on a clean empty drum Carefully stand the Bulb Eater 3 on edge Figure 1 With a 5 32 Allen wrench loosen the set screw holding the spinner on the motor shaft Slide off the old spinner and replace with new spinner in the same position Figure 2 Tighten the set screw firmly to secure the spinner to the motor shaft Figure 3 Note Another option would be to remove the chute safety cover and replace the spinner assembly o e 800 909 9709 BULB E ATER S AIRCYCLE www AirCycle com 18 with intelli Technology CORPORATION Trouble shooting the BULB EATER 3 with Intelli Technology Carefully following the instructions and guidelines in this manual is tne best way to keep your Bulb Eater 3 working properly However should you encounter problems this guide will help you resolve issues that occasionally arise during normal use of the Bulb Eater 3 If you are experiencing a problem that is not addr
20. aced into the shipping container immediately upon removal from the Bulb Eater 3 Once the canister is removed a determination should be made of the waste type in accordance with applicable local state and federal regulations Also be sure to manage store and label the container accordingly Apply silicone grease on the O ring and place O ring and the clamp on the new carbon canister Figure 2 Hold the carbon canister up to the lower housing and tighten the clamp all the way 2 persons required for installation Figure 3 A new flash drive will come with your new carbon canister filter and must be installed to the control panel to reset the carbon filter lifetime Call Air Cycle Corporation 800 909 9709 for a proposal for the processing of the used carbon canister The most cost effective way to handle the canister is to include it with the pick up of your drum s of crushed lamps Ans 800 909 9709 a BULB EATER with Intelli Technology COLPronar rio n ATTENTION Only crushed lamps and filters placed on top of the crushed lamps can be inside the drum Do not place any extraneous materials or liquids in the drum Presence of these materials with the crushed lamp waste could result in very significant upcharges or potential return of the waste to your facility NOTE Bulb Eater users in the state of Tennessee are required to ship spent filters in DOT containers separate from the drums of crushed lamps ATTEN
21. alth hazards from exposure to lamps that are intact The PSDSs further disclose that no adverse effects are expected from occasional exposure to broken lamps but stated Avoid prolonged or frequent exposure to broken lamps unless there is adequate ventilation The PSDSs indicate that the major hazard from an occasional broken lamp is the possibility of sustaining glass cuts Environmental Effects Additionally mercury is harmful to the environment Mercury bio accumulates in the food chain and as such poses many of the adverse effects described on the human body during the consumption of mercury contaminated food e g predator fish swordfish tuna etc Mercury in the environment is deposited and revolatilized many times with a residence time in the atmosphere of a few days Most mercury containing fluorescent lamps must be recycled or disposed as a toxic characteristic hazardous waste as defined in the Environmental Protection Agency EPA Resource Conservation and Recovery Act RCRA This is due to the concentration of the mercury and or other toxic metal content in the waste typically exceeding EPA s Toxicity Characteristic Leaching Procedure TCLP limits quantified by TCLP analytical tests The most environmentally sound and preferred disposal method for spent fluorescent lamps is recycling Fluorescent lamp recycling allows the mercury to be separated from the other fluorescent lamp components e g glass metal etc and collecte
22. cal appliance or machine basic precautions 11 Do not handle plug or machine with wet hands should always be followed including the following READ ALL 12 Close supervision is necessary when a machine is INSTRUCTIONS BEFORE USING THIS APPLIANCE MACHINE WAR N NG TO REDUCE THE RISK 13 Keep hair loose clothing fingers and all parts of used near children body away from openings and moving parts OF FIRE ELECTRIC SHOCK OR INJURY 14 Do not use without filters in place May disperse 1 Do not leave machine unattended when plugged in Unplug fine dust particles into the air from outlet when not in use and before servicing Connect 15 Turn off all controls before unplugging to a properly grounded outlet only See Grounding 16 Do not use in areas where combustible liquids such instructions as gasoline may be present 2 Do not put machine in water or other liquid 17 Do not vacuum toxic carcinogenic combustible or 3 Do not expose to rain store indoors 4 Do not place or store machine where it can fall or be pulled into a tub or sink 5 Use only as described in this manual Use only other hazardous materials such as asbestos arsenic barium beryllium lead pesticides or other health endangering materials Specially designed units are available for these purposes manufacturer s recommended attachments 18 Do not leave the cord lying on the floor when the machine 6 Do not use with damaged cord or plug If
23. d for reutilization ALA 800 909 9709 BULBE ATER TIRCYCLE www AirCycle com 27 with Intelli Technology Table 1 Clinical Importance of Elemental and Inorganic Forms of Mercury Form Element Source Absorption Primary Effects Secondary State Effects Thermometers Liquid barometers manometers Mercury Dermal contact Poorly absorbed minimal absorption through GI tract fluorescent lamps 0 01 or switches rectifiers Ingestion poor j dermally batteries 1 absorption y Systemic toxicity is rare Mercury Salts and Compounds Medicines antiseptics Ingestion 10 Kidneys disinfectants electric absorbed GI Tract batteries industrial compounds Dermal Contact lethal doses can be absorbed by animals Mercury Industrial Inhalation 80 Lungs skin eyes CNS Vapor absorbed gingiva gums kidneys 2 Percutaneous minimal absorption Hg Hg Table Abbreviations and Notes CNS Central Nervous System GI Gastroinstestinal Hg Atomic symbol for elemental mercury In humans the biologic half life of all forms of mercury is 40 70 days P Crosses the blood brain barrier 1 Breakage of any of these devices can result in the release and volatilization of liquid mercury in air as mercury vapor 2 Mercury accumulates in many tissues but most importantly the brain and kidneys o An 800 909 9709 Pi BULB EATER 3 oy 6 a CL E www AirCycle com with Intelli Technology Mercury Standar
24. ds Occupational Safety and Health Standards The Occupational Safety and Health Administration OSHA regulation Title 29 of the Code of Federal Regulations CFR 1910 1000 Air Contaminants Table Z 2 and an OSHA Compliance Directive Interpretation of 9 September 1996 regarding mercury exposure limits has set the Permissible Exposure PEL for all forms of mercury at 0 10 milligrams per cubic meter mg m3 of air equivalent to 6 1 parts per billion ppb The Permissible Exposure Limit PEL is an eight hour Time Weighted Average TWA concentration limit in air that nearly all workers can be exposed to without adverse health effects The American Conference of Governmental Industrial Hygienists ACGIH Threshold Limit Values for Chemical Substances and Physical Agents for 2001 has set recommended air standards for the elemental and inorganic forms of mercury including inorganic mercury vapor at 0 025 milligrams per cubic meter mg m3 as an eight hour Threshold Limit Value TLV Time Weighted Average TWA concentration in air A Skin notation is also designated with the standard indicating skin eye and mucous membrane contact as a significant pathway of absorption Table 2 provides a summary of mercury vapor exposure limits by various organizations including OSHA ACGIH the National Institute of Occupational Safety and Health NIOSH and the National Academy of sciences NAS Table 2 Mercury Vapor Exposure Limits Summary OSHA PEL A
25. dule a Pickup online at www aircycle com services or call 800 909 9709 Pick Up Request Form I AIRCYCLE KA C oF Kk fF O RA I 2200 Ogden Avenue Suite 100 e las 7 60532 Tel 800 909 9709 Fax 866 909 6725 www aircycle com Date Generator Pick Up Location Generator Billing Information Company Company Address Address City State Zip City State Zip Contact Accounts Payable Contact Contact E mail Accounts Payable Phone Contact Phone Accounts Payable E mail Contact Fax EPA ID Alternate Contact Phone PO Transportation Requirements section is required Failure to complete this section may delay the scheduling of service to your facility A truck with a lift gate is required to pick up the material Replacement Containers Is there a forklift available to load the material onto the truck Quantity The material will need to be manually loaded onto the truck 55 Gallon Steel Drums Note manpower charges for loading may apply 4 Fiber Drums LI A full size tractor trailer can fit into the loading dock O 4 Lamp Boxes Height and length restrictions for the loading dock are 8 Lamp Boxes Where is the material stored within your facility 5 Gallon Poly Pails Available Loading Hours Failure to complete this section may delay the scheduling of service to your facility Material To Be Picked Up Lamps Quantity Batteries 55 Gallon Drums of Crushed Lamps Mixed The Material Is Packaged In 55 Gallon Drums of Crush
26. e 1 page 28 provides a summary of the clinical importance of various forms of mercury ALA 800 909 9709 BULBE ATER IRCYCLE www AirCycle com 26 ohh Intell Tedmalegy Abrasion and Cut Hazards The primary hazard resulting from handling broken lamps or crushing lamps is the potential release of airborne glass particulates resulting in skin eye and respiratory tract irritation with the possibility for cuts and lacerations to the eye skin and respiratory tract tissue upon contact The eyes and skin can also be cut or lacerated by sharp glass edges or metal components contained in the crushed lamp waste Crushing Hazards Perhaps the greatest potential for physical injury during the Bulb Eater use other than laceration from broken glass or metal components is physical injury from movement or mishandling of the 55 gallon drums Thus forklifts or other suitable lifting devices equipped with drum grabbers and drum cradles must be used for transporting moving and positioning the lamp waste collection drums when filled with crushed fluorescent lamps It is also extremely important that the manual be followed closely Failure to operate the machine properly could lead to dangerous mercury vapor exposure While boxing intact lamps intact be careful to avoid breaking the lamps When intact lamps break unfiltered vapors are released Other A review of manufacturers fluorescent lamp Product Safety Data Sheets PSDS reveal there are no known he
27. ed shock This machine is equipped with a cord having an equipment grounding conductor temporary adapter that looks like and grounding plug The plug must be inserted into an appropriate outlet that is the adapter illustrated in the sketch properly installed and grounded in accordance with all local codes and ordinances may be used to connect this plug to a 2 pole receptacle as shown if a properly grounded A wa R N l N G IMPROPER outlet is not available The CONNECTION OF THE MACHINE GROUNDING temporary adapter should be used only until a properly grounded CONDUCTOR CAN RESULT IN A RISK OF ELECTRIC outlet sketch can be installed SHOCK CHECK WITH A QUALIFIED ELECTRICIAN OR SERVICE PERSON IF YOU ARE IN DOUBT AS TO WHETHER THE OUTLET IS PROPERLY GROUNDED DO NOT MODIFY THE PLUG PROVIDED WITH THE Pepe me asa MACHINE IF IT WILL NOT FIT THE OUTLET HAVE A PROPER OUTLET INSTALLED BY A QUALIFIED ELECTRICIAN This machine is for use on a nominal 120 vac or 240 vac power A KI RECYCLE 800 909 9709 Grounding Type Plug a Grounding Prong ni Plug Adapter Ground Wire Use properly grounded receptacle cis shown by a qualified electrician The green colored rigid ear lug or the like extending from the adapter must be connected to a permanent ground such as a properly grounded outlet box cover Whenever the adapter is used it must be held in to an outlet having the same configuration as the plug
28. ed CFL s Alkaline Quantity 4ft or Less Fluorescent Lamps Lead Acid Steel Drums 55 Gallon oft 8ft Fluorescent Lamps NiCad Cardboard Boxes 9ft or More Fluorescent Lamps NiMH 4 Fiber Drums 85 count U Bend Circular Lithium 4 Fiber Drums 185 count Compact w o Ballast Mercury 8 Fiber Drums 85 count Compact w Ballast Zinc Carbon _ Poly Pails 5 Gallon HID Mercury Vapor Metal Halide High pressure Sodium Ballasts i Other Shattershield Coated Non PCB Total of Pallets Incandescent PCB UV Other Waste for Recycling Pick Up Office Machinery E scrap Other Waste Special Instructions The marked material is to be properly identified and prepared for transportation and tender in accordance with all applicable statutes ordinances permits rules and regulations of the Federal State and Local governments in whose jurisdiction such material originates passes through or is tendered for delivery certify for declare under penalty of perjury that the foregoing is true and correct Do not place any extraneous material or liquids in the drum Presence of these materials with the crushed lamp waste could result in very significant upcharges or potential return of the waste to your facility All final counts will take place at the end destination processing facility Please fill out this form completely and fax it to 866 909 6725 or e mail to pickup aircycle com Have you tried our online services Visit us at AirCycle c
29. ed to it and place onto the upper housing which holds the cartridge filter Figure 5 Fasten the lid clips on the vacuum lid and secure Tighten the clamp on the airlock assembly to the cyclone assembly until it s snug Tighten the clamp on the cyclone flange to the cyclone assembly all the way until it s tight Now re tighten the clamp on the airlock assembly to the cyclone assembly all the way Figure 6 Note This will allow the cyclone assembly to be installed correctly amp air tight 7 Apply silicone grease to the O ring and place the O ring and clamp on the carbon canister Figure 7 Hold the carbon canister up to the lower housing and tighten the clamp all the way 2 persons required Figure 8 8 Place the 3 caps on the clamps Figure 9 Unscrew the plug assembly and install the entry tube Figure 10 Finally connect the power cord to the control panel on your Bulb Eater 3 and plug it into an outlet Figure 10 IMPORTANT Electrical Requirements 120V AC Single Phase 50HZ or 60HZ OR 240V AC Single Phase 50 HZ or 60HZ Must be protected by a minimum of 15 amp fuse or circuit breaker Watch the Bulb Eater 3 Training Video at www aircycle com videos AA 800 909 9709 BU LB ATER 3 A IR E Y C L E www AirCycle com 9 with Intelli Technology I LPORLRLAT TIO N J SN 7 gtd r r FASI p Y Te a FIG 9 800 909 9709 BULB ATER AIRCYCLE www AirCycle com 10 sist nis
30. embranes It may occasionally be a skin sensitizer in some individuals Systemic Effects Acute short term poisoning due to mercury vapors adversely affects the lungs primarily in the form of acute interstitial pneumonitis bronchitis and bronchiolitis Chronic long term exposure to lower mercury levels over prolonged periods of time produces symptoms that can vary widely from individual to individual These may include weakness fatigability loss of appetite loss of weight insomnia indigestion diarrhea metallic taste in the mouth increased salivation soreness of mouth or throat inflammation of gums black line at the gums loosening of teeth irritability loss of memory and tremors of fingers eyelids lips or tongue In general chronic mercury exposure produces four classical signs gingivitis excessive salivation increased irritability and muscular tremors Rarely are all four seen together in an individual case More extensive exposures to excessive mercury levels either by daily exposures or one time can produce extreme irritability excitability anxiety delirium with hallucinations melancholia manic depressive psychosis and adverse effects on the reproductive organs Either acute or chronic exposure may produce permanent changes to affected organs and organ systems Excessive exposure to various forms of mercury has been shown to adversely affect the human central nervous system kidneys and reproductive system Tabl
31. equirements permits are often more easily obtained in Michigan and New Jersey It is Air Cycle s understanding that persons within the states not listed above as requiring a permit or as regulated under universal waste regulations are authorized to crush lamps within general hazardous waste regulations Air Cycle Corporation suggests you contact representatives of those states before proceeding with on site crushing Please note that regardless of whether the lamps are managed as universal or hazardous wastes you must properly dispose of the crushed lamps preferably by shipping the crushed lamps to a permitted recycling facility Air Cycle Corporation will continue to work with state lawmakers and the Association of Lighting and Mercury Recyclers to promote legislation which will authorize persons to crush lamps under universal waste regulations Air Cycle Corporation and its customers know that persons are able to safely crush their lamps to reduce volume minimize handling cut costs and create a safer work environment by managing their crushed lamps under either universal waste regulations or existing state hazardous waste regulations For more information on regulations in your state please visit www aircycle com resources state regulations Why is mercury an environmental concern Mercury is a metallic element that can accumulate in living tissue In sufficient concentrations mercury may cause adverse health effects Sources of mercury in the
32. er amp 1 8 Chain Spinner Assembly Impeller OOO S66 E i Jumbo Filter Combo Kit Replacement Impeller for Airlock Body m CA meg Contains 10 2 Stage Cartridge Filters 5 3 stage cees HEPA filters amp 5 8 Chain Spinner Assemblies Vacuum motor for Bulb Eater 3 120v or Carbon Canister 240v Carbon Canister w O ring amp 1 HEPA Filter Crusher Motor w Cable Carbon Canister O ring Motor for Bulb Eater 3 1 5 Horsepower 2 gt amp 120 volts Vacuum Motor Sub Assembly Replacement O ring for Carbon Canister Airlock amp Cyclone O rings E Stop Button Set of 3 O rings for Airlock amp Cyclone Replacement E Stop Button for Control Panel Xx 48 Entry Tube Start Stop Button Replacement Start Stop Button for Control Available for T5 T8 T12 amp T17 Lamps Panel U Tube CFL Chute 55 Gallon Drum Dolly Removable Chute for CFL amp U Tube Bulbs Custom Built 55 Gallon Drum Dolly Safety Glasses 800lb rating skid optimized ia Should be worn at all times when using the J GARON ETU Bulb Eater 3 Steel 55 Gallon Drum with Epoxy Lining Safety Glove for Bulb Eater 55 Gallon Drum Lid Should be worn at all times when using the Flat Steel Shipping Lid with Gasket Bulb Eater 3 ee Locking ring and Bolt for Tight Seal Ear Plugs 55 Gallon Drum Locking Ring Should be worn at all times when using the Bulb Eater 3 Heavy Duty 12 Gauge w Bolt AA 800 909 9709 BU
33. essed here or if your problem persists after following these suggested procedures do not hesitate to contact us at 800 909 9709 or info aircycle com for further assistance General Use Note If the flashing red amp green lights are displayed on the stop amp start buttons a fault code will appear on the LCD display screen Faultcodes Description Action 01 Exceeded carbon filter lifetime Replace Carbon Canister 02 Insufficient crusher motor current Check crusher motor is plugged in or bad motor 03 Excessive crusher motor current Drum is full or debris on spinner assembly 04 Crusher motor failed to reach target voltage during startup Check crusher motor is plugged in or bad motor 05 Fan pressure carbon filter didn t reach target during startup Carbon canister not installed 06 Chute safety cover opened while running Safety cover or CFL U tube chute not installed 07 Lid opened while running BE3 machine not on drum before starting 08 Very low carbon filter pressure during startup Carbon canister not installed 09 Excessive carbon filter pressure during startup Stage 5 HEPA filter needs to be changed 10 Very low HEPA filter pressure during startup Plug in entry tube or 3 stage HEPA filter not installed 11 Excessive HEPA filter pressure while running 3 stage HEPA filter needs to be changed 12 Very low cartridge filter pressure during startup 2 stage cartridge filter not installed 13 Excessive cartridge filte
34. hed lamp fragments are classified as a hazardous waste See test method 1311 in Test Methods for Evaluating Solid Waste Physical Chemical Methods EPA Publication SW846 for more information about the TCLP procedures In most cases standard fluorescent lamps and lamp fragments fail the TCLP test and are considered hazardous wastes Facilities should treat the spent lamps and lamp fragments as hazardous wastes unless they test the spent lamps and fragments and determine that the wastes are non hazardous Facilities should manage the spent lamps as hazardous waste according to applicable federal state and local requirements New low mercury lamps have been introduced into the market While these lamps may pass the TCLP test and be considered non hazardous some states like Minnesota and Vermont still prohibit persons from disposing of even these non hazardous lamps in a solid waste landfill You may want to talk with a State EPA representative to find out how you may handle spent lamps in your state Please note that regardless of whether the State in which you are located allows you to dispose of lamps in your dumpster with other non hazardous trash the lamps do contain mercury and mercury vapors are released into our environment when you throw lamps in the trash Typically the lamps break in the dumpsters during transportation or in the landfill and release mercury into the air or groundwater These hazardous releases are a risk to Surr
35. i Technology CORPORATION BULB EATER S Operating Procedures for Linear Lamps WARNING DO not TAMPER WITH ANY ELECTRICAL CONTROL DEVICES ON THIS MACHINE Before Operating the Bulb Eater 3 Oe I NO e Communicate understand potential hazards by having operators review pages 24 29 of this manual and complete online training program at www BulbEater3Training com Note The Bulb Eater 3 machine is inoperable until key personnel have completed this online training program Details to activate the Bulb Eater 3 machine will be provided immediately upon completion of the program Before crushing label drum as containing Mercury D009 and as either Hazardous Waste or Universal Waste depending on your state requirements Crush lamps in a well ventilated area e Wear safety glasses protective gloves and ear protection Screw in entry tube for crushing linear lamps Remove rubber plug from top of entry tube Crush only linear fluorescent lamps Plug the machine in amp release the E STOP button The machine will go through 3 LCD display functions Stopping Dumping Ready Take the plug out of the entry tube Press the START button When the LCD screen displays ready Insert the linear lamp into the entry tube and then let go Do not force the lamp down the entry tube The machine will time out when the cyclone counter zeros out followed by 3 LCD display functions Stopping Dumping Ready To continue crushing
36. om services to schedule your pickup online today AA 800 909 9709 BU LB ATER 3 A l Ri I Y C LE www Air Cycle com 15 with Intelli Technology Filter Replacement Directions 1 stage Cyclone Filter will never need to be changed 2 stage Cartridge Filter required to be changed when the fault code 13 is displayed on the LCD screen 3 stage HEPA Filter required to be changed when the fault code 11 is displayed on the LCD screen 4 stage Carbon Filter The carbon filter will require changing when filter life times out 1 500 hrs Fault code 01 will be displayed on the LCD screen 5 stage final HEPA Filter required to be changed when the fault code 09 is displayed on the screen Spent Filters must NEVER be left exposed Spent filters must either remain in the vacuum housing attached to the unit be sealed in a full drum of crushed lamps or bagged in a zip top bag to avoid mercury release DO NOT DISPOSE OF FILTERS IN THE TRASH Communicate understand potential hazards by having operators review pages 24 29 of this manual and complete online training program at www BulbEater3Training com e Confirm that the Bulb Eater 3 is clearly off and not operating e The operator must wear safety glasses and gloves when changing any of the three Bulb Eater 3 filters Replacing the 2 Stage Cartridge Filter Remove the lid from the upper housing of the vacuum body Figure 1 Remove the used 2 stage cartridge filter from the u
37. ompleted this online training program Details to activate the Bulb Eater 3 machine will be provided immediately upon completion of the program Before crushing label drum as containing Mercury D009 and as either Hazardous Waste or Universal Waste depending on your state requirements Crush lamps in a well ventilated area e Wear safety glasses protective gloves and ear protection Attach and secure the CFL U Tube chute by first removing the safety cover Insert the CFL U Tube chute and be certain to engage the three latches Figure 1 CFL U tube chute should be attached whenever machine is crushing CFL s U Tubes Linear entry tube can remain on the machine as long as it is plugged If crushing CFLs open CFL chute safety cover and seal entry tube or entry tube hub Crush only U Tube lamps or CFL bulbs 1 Plug the machine in amp release the E STOP button The machine will go through 3 LCD display functions Stopping Dumping Ready Remove the chute safety cover to install the CFL U Tube chute Place the plug into the entry tube Press the START button When the LCD screen display ready Crush Lamps a U Tube Lamps i Make sure that the CFL chute safety cover is closed ii Insert the u tube lamp into the chute and then let go Do not force the lamp down the chute b CFLs Bulbs i Open safety cover li Place bulbs in the CFL chute individually larger bulbs or in small batches 5 The machine will time out when the c
38. orne powder and mercury vapor while crushing a lamp over 99 The Bulb Eater 3 filters the exhaust air in five stages with a cyclone filter a cartridge filter two High Efficiency Particulate Arrestor HEPA filters and an activated carbon filter The first stage cyclonic filter removes about 90 of the dust and larger particles from the air The second stage cartridge filter removes 99 of the dust and larger particles from the air The third stage HEPA filters out the remaining small particles The HEPA has been shown to capture at least 99 97 of powder with particle sizes of 0 3 microns or greater The Bulb Eater 3 filters mercury containing vapors through a filter of activated carbon How will know when to change filters 2 Stage Cartridge filter required to be changed when the fault code 13 is displayed on the LCD screen The Bulb Eater 3 must be operated with the cartridge filter in place or the HEPA filter will be prematurely plugged 3 Stage HEPA filter required to be changed when the fault code 11 is displayed on the LCD screen 4 Stage Carbon filter The carbon filter will require changing when filter life times out 1 500 hrs Fault code 01 will be displayed on the LCD screen 5 Stage HEPA filter required to be changed when the fault code 09 is displayed on the LCD screen Keep in mind crushing bulbs with heavy dust or other materials on them may require filters to be changed more often than the guidelines above
39. ounding communities Facilities that throw their spent lamps in the trash thinking they are saving money may be mistaken Throwing spent lamps in the trash may result in the person being held responsible for the cleanup of a remote and costly Superfund site Because of the potential liability under Superfund Air Cycle Corporation believes facilities that decide to recycle their soent lamps are making a smart decision that benefits not only the environment but also the bottom line What are universal wastes Universal wastes are specific hazardous waste streams that facilities can choose to manage in an alternative manner in place of the more complex hazardous waste requirements These wastes are typically generated by many facilities and are often not properly managed under hazardous waste regulations Universal Wastes include Lamps Including fluorescent high intensity discharge HID sodium vapor mercury vapor neon and incandescent lamps Batteries Including spent dry cell and lead acid batteries Pesticides Including certain suspended canceled or unused pesticides Devices containing elemental mercury Including thermostats switches thermometers manometers barometers and various medical devices Does quantity matter Yes RCRA hazardous waste requirements differ according to the amounts of hazardous waste generated per month by the facility There are three main categories of hazardous waste generators Conditionally
40. pper housing Figure 2 Figure 3 Replace the new 2 stage cartridge filter in the upper housing Figure 3 Replace the lid on the upper housing of the vacuum body and secure with the 4 clips Figure 4 ee Figure 1 Figure 3 Figure 4 LA 800 909 9709 AIRCYCLE www AirCycle com 16 BULB EATER with Intelli Technology cC ga gk a ti ON Replacing the 3 Stage HEPA Filter R R 1 AIRCYCLE www AirCycle com 1 Follow steps 1 through 2 above to remove the 2 stage cartridge filter 2 Rotate the 3 stage HEPA filter counter clockwise to remove Figure 5 3 Place the new 3 stage HEPA filter into the upper housing and rotate clockwise to lock Figure 6 4 Follow steps 3 through 4 above to replace the 2 stage cartridge filter Figure 6 Figure 5 eplacing the 5 Stage HEPA Filter 1 Reach under the bottom housing of the carbon canister and rotate clockwise to remove Figure 7 8 2 Place the new HEPA filter into the bottom housing and turn counterclockwise to lock Figure 7 8 Figure 7 ee eplacing the 4 Stage Carbon filter Loosen the nut on the clamp of the carbon canister Figure 1 and remove the used canister from the lower housing It is recommended that the canister be placed into a DOT approved appropriately sized container and sealed A 55 gallon DOT metal drum may be the most convenient and cost effective The used carbon canister should be pl
41. ps for Cyclone Assembly Clamp for Carbon Canister Cyclone w Vacuum Lid Assembly O Ring for Cyclone Assembly O Ring for Carbon Canister 5g Mini Tube of Silicone Grease AA 800 909 9709 x IRCYCLE www AirCycle com 7 Quantity Quantity BULB EATER with Intelli Technology S AA R FQRk ATt I ON The BULB EATER with Intelli Technology 800 909 9709 www AirCycle com 8 BULB EATER with Intelli Technology 3 Dimensions 25 635 mm 0 Te uuu kk LA ALA 4 54 1372 mm Note 10 Lx 5 W x8 H area required to use the machine and crush 4 ft lamps 13 Lx 5 W x9 H area required to use the machine and crush 8 ft lamps The BULB EATER S Assembly Instructions What You ll Need with Intelli Technology 55 Gallon Drum 15 16 wrench or socket Instructions C Attach the plug assembly to the handle and install the handle to the lid assembly using 2 1 4 20 x 3 4 screws Figure 1 Mount the Bulb Eater 3 onto the drum tightening the bolt ring with a 15 16 wrench or socket Figure 2 Apply silicone grease on the two O rings and place an O ring and a clamp on the airlock assembly amp an O ring and a clamp on the mounting flange for the installation of the cyclone assembly Figure 3 Place the 2 stage cartridge filter into the upper housing of the vacuum housing assembly Figure 4 Place the cyclone assembly on the mounting flanges with the lid assembly attach
42. r pressure while running 2 stage cartridge filter needs to be changed 14 Fan exhaust temperature too high Call Air Cycle for guidance 15 Insufficient fan carbon filter pressure while running Carbon filter not installed 16 VBUS voltage below set threshold Call Air Cycle for guidance 17 Heat sink temperature too high Call Air Cycle for guidance 18 Airlock Failed to rotate or rotation not sensed Check airlock motor is plugged in 19 Parameter values in EEPROM doesn t match expectation Call Air Cycle for guidance 20 Parameter revision code in EEPROM does not match Call Air Cycle for guidance 21 Corrupt or uninitialized parameter date in EEPROM Call Air Cycle for guidance 22 Transient loss of mains power detected Call Air Cycle for guidance 23 System tilted too far from level Change spinner assembly or BE3 machine is not on a flat surface to operate 24 Start switch active at power up Call Air Cycle for guidance 25 Crusher motor current indicates high drag condition Full drum Chute Open The chute sensor is not sensing the chute safety cover Move the safety cover to the left Lid Open Machine has not been activated complete training program to download the parameter file Still having problems Contact Air Cycle at 800 909 9709 or 708 344 7860 Operating Tips 1 Do not force lamps down the entry tube The Bulb Eater s vacuum suction should be sufficient to pull the lamps into the machine 2 Ensure that you alwa
43. s carefully before attempting to operate Retain for future reference Owner User Responsibility DANGER i a Warning information should be emphasized by the operator If the operator is not fluent in the languages of the written manual the manufacturer s instructions and warnings shall be read to and discussed with the operator in the operator s native language by the purchaser owner making sure that the operator comprehends its Check for external damage that might have occurred during transit Be careful of moving parts Report any damage Never operate this unit when flammable materials or vapors are present because electrical devices produce arcs or sparks that can cause a fire or explosion NEVER OPERATE e The BE3 can be operated outdoors in a dry covered environment but UNATTENDED MUST BE STORED indoors when not in use in a dry area DANGER hazardous situation which if not avoided will result in death or serious injury Warning indicates a potentially hazardous situation which if not avoided could result in death or serious injury Caution indicates a potentially hazardous situation which if not avoided could result in minor or moderate injury Important indicates important IMPORTANT information that if not followed Mantenga las manos fuera may cause damage to equipment or operator de la m quina SAFETY SYMBOLS Two persons required to lift machine Deux personnes
44. sont requises pour lever la machine Keep hands out of machine Ne pas mettre les mains dans la machine Se requieren dos personas para levantar la m quina IMPORTANT Align Arrows When Replacing Cover Risk of electric shock Do not expose to rain store indoors Les Warning Keep Hands out of the Machine Pronta e entreposer a l int rieur Riesgo de descarga el ctrica No se exponga a la lluvia guardese en interiores Warning Indicates Hazardous Voltage Hazardous Voltage Disconnect electric power ee before opening Important Hearing amp Vision Protection iil e D brancher l lectricit avant d ouvrir Voltaje peligroso Desconecte la energia Important Hand Protection Required albutiiia sco da i IMPORTANT Read all manuals included with this product carefully Be thoroughly Hearing Vision and Hand Machine Will Shut Down When Cover is Removed Te SE gt PERI familiar with the CO ntrols and the La machine s arr tera lorsque la eer PORGE emer he e pen rene Meets the following standards clitici l CONFORMS TO UL 73 Issued 2011 03 02 Ed 10 UL Standard for Safety for Motor Operated Appliances Nit PaA CAN CSA C22 2 No 68 Issue 2009 09 01 Ed 7 Motor Operated Appliances Intertek 4006905 STD C22 2 No 68 AA 800 909 9709 A IRCYCLE www AirCycle com 2 BULB EATER S with Intelli Technology IMPORTANT SAFETY INSTRUCTIONS When using an electri
45. times when operating the Bulb Eater 3 Wearing steel toed safety shoes and disposal overalls is recommended when changing out drums or moving full drums around for storage or pickup Take care when lifting and moving drums of crushed lamps as a full drum can weigh over 500 Ibs Before using the machine it is extremely important for the operator to review and understand all instructions and safety precautions Refer to the Operation Instructions in this manual for detailed information and procedures How should I clean up broken bulbs 1 Carefully scoop up glass fragments and powder using stiff paper or cardboard DO NOT use a traditional vacuum or broom as these may spread the mercury bearing phosphor powder 2 Place fragments and powder in the drum with crushed lamps 3 Use tape or a wet paper towel to clean up remaining fragments and powder 4 Place tape or paper towel in a securely sealed zip top bag and place bag on top of full drum of crushed lamps with spent filters What regulatory restrictions apply to operating the Bulb Eater 3 As a part of staying compliant with EPA and OSHA regulations Air Cycle recommends that the operator of the Bulb Eater 3 should be trained on how to properly operate and maintain the equipment and crush no more than two full drums of lamps per 8 hour work shift in a well ventilated work area Users operators of the Bulb Eater 3 may opt to process more lamps given that appropriate monitoring is performed
46. yclone counter zeros out followed by 3 LCD display functions Stopping Dumping Ready 6 To continue crushing press the START button 7 After crushing press the STOP button to stop the crusher motor The machine will go through 3 LCD display functions again Stopping Dumping Ready 8 When the LCD display indicates Ready press the E STOP button seal the top of the entry tube with the rubber plug then remove the CFL U Tube chute and attach the chute safety cover Figure 2 When the machine is not in use make sure that all openings are sealed sealed entry tube and CFL chute may remain on the machine when not in operation 9 Before removing lid Let the machine sit OFF for at least 15 minutes after the dump cycle is done to allow dust to settle before opening the lid during drum change Note Pressing the STOP button must be completed before pressing the E STOP button when finished crushing this will allow the powder to be dumped out of the cyclone into the drum PS ATTENTION a z Drum MUST be kept closed at all times gt 3 Latches Da Le AA 800 909 9709 na BU LB ATER 3 R C ki CL E www Air Cycle com with Intelli Technology Drum Change Procedures 1 Loosen the lid locking bolt amp ring on the Bulb Eater 3 machine and remove the lid locking ring on the spare lid Figure 1 2 Lift the Bulb Eater 3 machine straight up with the spare lid in hand requires 2 person for lid change Figure 2 3
47. ys crush lamps using appropriately sized entry tubes to minimize external breakage Entry tubes are available at www aircycle com for a wide variety of lamp sizes 3 If you are crushing lamps with significantly blackened ends feed the lamps blackened end first These portions of glass are slightly weaker and more prone to breakage outside the machine 4 Crushing lamps that have previously been taped together can result in a buildup of adhesive in the Bulb Eater 3 entry tubes and cause breakage Remove the entry tube from the machine and clean the inside of the tube with a rag soaked in an appropriate solvent like paint thinner 800 909 9709 BU LB ATER 3 IRCYCLE www AirCycle com 19 with Intelli Technology Control Panel Lights Blinking red light on the STOP button will be displayed after the E STOP button is released on the Bulb Eater 3 The solid red light will appear on the stop button when the machine is ready Press the START button to start the machine A flashing green light will appear on the START button when the machine starts The solid green light will appear on the START button when the Bulb Eater 3 is ready for crushing The machine will time out when the cyclone counter zeros out and a flashing red light will appear on the STOP button Once the flashing red light on the STOP button turns solid the Bulb Eater 3 will be ready to start again Press the START button to go through the process of starting the machine again
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