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Owner`s Manual - Air Cycle Corporation

1. 2nd Stage HEPA New Drum Date Drum Changed Filter Changed Start Date Became Full change twice perdrum change every 10 drums C yes LJ No LC yes L No Date Date Date Date Date Date Date Date C ves LJ no yes LJ No Date Date Date Date Date Date Date Date Date Date C ves LJ No yes LI No Date Date aa aa Date Date C ves LJ No L lves no Date Date Or as needed Place spent filters on top of crushed lamps in full drum for recycling Label each new drum with a Hazardous or Universal Waste Label Depending on applicable state regulations Save this form for your records j 800 909 9709 AIRCYCLE www aircycle com 24 Bulb Eater Manual Pickup Request Form Schedule a Pickup online at www aircycle com services _ Pick Up Request Form S AIRCYCLE Sa N r CORPORATI N 2200 Ogden Avenue Suite 100 Lisle i 60532 Tel 800 909 9709 e 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 Fax Contact Fax EPA ID Alternate Contact Phone PO Transportation Requirements A truck with a lift gate is required to pick up the material Material To Be Delivered A forklift available for loading the material onto the truck Quantity The mat
2. 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 As a part of staying compliant with EPA and OSHA regulations Air Cycle recommends that the operator of the Bulb Eater should be trained on how to properly operate and maintain the equipment and crush no more than one full drum of lamps per 8 hour work shift in a well ventilated work area Crushing lamps is a regulated activity by the United States Environmental Protection Agency Air Cycle Corporation strongly urges all Bulb Eater 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 18 Visit www bulbeatertraining com to complete the Bulb Eater Certified Training Program For additional online Bulb Eater resources visit www mybulbeater com For More Information on The Bulb Eater and Air Cycle C
3. com 8 Bulb Eater Manual CORPORATION CFL Premium Bulb Eater Operating Procedures Before Operating the CFL Premium Bulb Eater e Communicate understand potential hazards by having operators review pages 18 23 of this manual and complete online training program at www BulbEaterTraining com e Before crushing label drum as containing Mercury D009 and as either Hazardous Waste or Universal Waste depending on your state requirements e Crush lamps in a well ventilated area e Wear safety glasses protective gloves and ear protection e Attach and secure the CFL chute CFL chute should be attached whenever machine is operated e If crushing straight lamps screw in appropriate entry tube for lamp diameter amp remove rubber stopper Insert lamp into entry tube and then let go Do not force the lamp down the entry tube e If crushing CFLs open CFL chute safety cover and seal entry tube or entry tube hub e Crush only straight and compact fluorescent lamps 1 Release the stop switch and press green START button Confirm air flow out of carbon canister and suction at top of entry tube if crushing straight lamps before crushing lamps 2 Crush Lamps a Straight Lamps i Make sure that the CFL chute safety cover is closed li Insert a lamp into entry tube roughly 3 inches and then let go Do not force the lamp down the entry tube b CFLs i Open safety cover li Place bulbs in the CFL chute individually larger bulbs or in small
4. 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 ACGIH 30 ACGIH NAS SMAC minute Instantaneous 24 Hour Excursion Excursion Limit TWA hari mg m mg m me m 10 0 0 08 0 02 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 should be well under all applicable mercury exposure requirements AA 800 909 9709 Al R CYCLE www aircycle com 23 Bulb Eater Manual The Bulb Eater Filter Replacement Log Loacation BLUE CASE FILTER 1st Stage Filter
5. 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 Surrounding 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 mer
6. 17 Bulb Eater Manual Mercury Information Controlled Crushing Regulations Crushing lamps with the Bulb Eater 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 Florida 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 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 th
7. 9 9709 Al R CYCLE www aircycle com 10 Bulb Eater Manual CORPORATION 5 Plug in the hose from the blue vacuum into the black grommet on top of the new carbon canister to complete the filtration system Make sure the nozzle is pushed in tightly for a good seal 6 Call Air Cycle Corporation 800 909 9709 for a proposal for the processing of the used cargon 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 ATTENTION Only 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 Adjusting the Lid Sensor Use these tools to adjust the open lid and full drum sensors e If the Open Lid light remains on while the lid is closed use the 5 32 hex wrench to adjust the black lid sensor to extend 0 1 8 amp the white lid sensor to extend 3 16 3 8 from the sensor housing e If necessary use the included screwdriver to adjust the sensitivity on the full drum sensor The factory setting is minimum sensitivity Remove control box cover to access sensitivity screw Reseal bottom of the con
8. 9 or info aircycle com for further assistance General Use Bulb Eater runs with low suction or is overheating Low suction and overheating can be an indication that your 1st stage bag filter or 2nd stage HEPA filters need to be changed In ideal conditions crushing clean bulbs 1st stage bag filters should be changed a minimum of twice per full drum of crushed lamps and the 2nd stage HEPA filters every 10 drums However dirty bulbs and various environmental conditions can cause filters to fill more quickly 1 Replace the 1st stage bag filter instructions can be found in the Maintenance amp Troubleshooting section 2 If the problem persists replace the 2nd stage HEPA filter Control Panel Lights Power light does not illuminate when machine is plugged in and is operating If your Bulb Eater functions normally when plugged in but the power light does not illuminate you likely have a faulty light The Bulb Eater will function properly with a faulty power light you can continue using The Bulb Eater with no changes Lid Open light is on when the Bulb Eater properly secured to drum The lid open sensor is a safety shut off to prevent the operation of the machine if it is not installed on a drum If the light is lit when the lid is installed properly e If your machine has a white sensor block found on the underside of the Bulb Eater lid Follow the instructions found on page 11 e If your machine has a black sens
9. Assembly amp Operations Bulb Eater Assembly INStrUCTIONS cccccceccesceececcuseecceeseuceeeeeuseuseeeeeeseeseueeeeeeseueeeeeeeseeeeeess BUND Eater Oe race Pl OCC CNNE CS aires ev ssescsinescveascuosescsesaaecaseeanescseresssaaesaseeavasueesaeevauneanevessea 8 9 Recycline FUL D OS oaren a E A EEE EA AE E E A ES Maintenance amp Trouble Shooting Filter Replacement OC OC OS acess acer aeacesreascsaneravesksecieeddswsabesdsasasesterapsiasievsessdseeaeettenis 10 11 Spinner Replacement Procedures cccccscssssesccecussusccsccessussesccessussesccessussasceseeessuseeseeesauses 11 Troubleshooting the Bulb Eater 0 0 ccccceccescsececceseeeseecenseeseeseueeeeeeeseuseeseeeseeseeeeeseeeseeees 12 Operating Tips amp Frequently Asked QUESTIONS cccsssccsccesssssasccescussancosssessascassoessanes 12 14 Parts amp Accessories Replacement Parts amp Accessories cccceccseccecceceeeceusceseeeceuseeseeeeeeseueteseeeseuseeeeeseeseeeteeeeeseaeees 15 PARTS LIS cancrcucanncasasatactonssncacusatasasucaee ce sneak E E AEE EEA 16 17 Maintenance amp Trouble Shooting Mercury WTON COUN ersten aseicetesaceyeteancencsseeaegeimecehsnsnneuneeiesceecesanaraeieecidesieamanneineeuacanareeains 18 22 Mercun SAINI aenar Er AEE E E E EEE E E EE 23 Bulb Eater Filter Replacement LOg esesessssessensrssesenrrsrrreserresrrrrserrrserreseerrseereserreserreserreseseeses 24 Pickup Request FOrM cccceecceccescceccuseeceeccus
10. The Bulb Eater Fluorescent Lamp Crushing System Models 55 VRS U Premium 55 VRS Premium and CFL Premium Fee NETE 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 e Description of the Standard Safety Symbols and Safety Systems used e System Functions e Assembly amp Operations e Maintenance amp Trouble Shooting e Parts amp Accessories e Reference Materials amp Forms e Step by Step Procedures Read all manuals included with this product carefully Be thoroughly familiar with the controls and the proper use of the equipment US 800 909 9709 Outside US 708 344 7860 Fax 866 909 6725 4 16 2013 AAA 800 909 9709 Al RCYCLE www aircycle com i Bulb Eater Manual CORPORATION Table of Contents Purpose and Function of Manual cccccceeccecceeececcuscecececeuseeceeeeeuseeeeeeeeuseueeeeeeeseuseeseeeeeseneees i TOLO CONTON lt n re Important safety INSTFUCTIONS cccccccecceececceseeeeeucceceeeeeeseueeeeeeeseeceeeeeeeeeseeeeeeeeeseeeeeeeeseeseness Machine amp Control Panel Diagrams cccccscceccsssusccsccessuscesccessussesccessussesccessusssceeseusauns 3 5 Bulb Eater Parts LiSt c cccccccsceccccccsccceccscecenccececeacsceteaescesenecesecenessetsesseneneneesenenessenecessenes
11. batches 3 After crushing press STOP button to stop the crusher motor and begin purge cycle approximately 30 seconds 4 Once the purge cycle is complete seal the top of the entry tube with the rubber plug and close the CFL chute safety cover When the machine is not in use make sure that all openings are sealed sealed entry tubes and CFL chute may remain on the machine when not in operation 5 Before removing lid Let the machine sit OFF for at least 15 minutes after the purge cycle is done to allow dust to settle before opening the lid ATTENTION Drum MUST be kept closed at all times Do NOT crush more than one full drum of lamps per 8 hour period AAA 800 909 9709 Al R CYCLE www aircycle com 9 Bulb Eater Manual CORPORATION Filter Replacement Procedures 1st Stage Bag Filter must be changed a minimum of twice per full drum of crushed lamps 2nd Stage HEPA Filter must be changed at least once every 10 drums of crushed lamps 3 Stage Carbon Filter Spent filters must NEVER be left exposed Spent filters must either remain in the blue vacuum case 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 e Communicate understand potential hazards by having operators review pages 18 23 of this manual and complete online training program at www BulbEaterTraining com e Confirm that the Bulb Eater is clearly off and not opera
12. cury Including thermostats switches thermometers manometers barometers and various medical devices AA 800 909 9709 Al RCYCLE www aircycle com 19 Bulb Eater Manual CORPORATION 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 Exempt Small Quantity Generators CESQG 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 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 The
13. e accumulation tank exemption applies to The Bulb Eater 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 requirements 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
14. e air The second 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 filters mercury containing vapors through a filter of activated carbon How often should filters be changed 1st Stage Bag filter should be changed a minimum of twice with every full drum of crushed lamps Change when the drum is half full and again when it is entirely full The Bulb Eater must be operated with the bag filter in place or the HEPA filter will be ruined 1 amp 2nd Stage HEPA filter should be changed every 10 full drums Carbon filter The calculated life expectancy for the activated carbon is approximately one million T12 4 ft lamps AAA 800 909 9709 Al R CYCLE www aircycle com 13 Bulb Eater Manual CORPORATION Using the filter log included in this manual will help you keep track of when filters should be changed out 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 Refer to page 10 of the owner s manual for filter replacement instructions Does the spinner assembly need to be changed The breaking chain spinner should be changed as needed Uneven wear causes heavy vibration Refer to the Maintenance amp Troubleshooting section of the owner s manual for spinner changing instructions What do I do when my drum is full First l
15. e the lamp down the entry tube 3 After crushing press STOP button to stop the crusher motor and begin purge cycle approximately 30 seconds 4 Once the purge cycle is complete seal the top of the entry tube with the rubber plug When the machine is not in use make sure that all openings are sealed 5 Before removing lid Let the machine sit OFF for at least 15 minutes after the purge cycle is done to allow dust to settle before opening the lid ATTENTION Drum MUST be kept closed at all times Do NOT crush more than one full drum of lamps per 8 hour period Recycling Full Drums Schedule a Recycling Pickup e Call Air Cycle at 800 909 9709 e Schedule a pickup online at www aircycle com services e Use the Pickup Request Form located in the Forms amp Reference section of this manual 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 e Have large amounts of crushed lamps picked up e 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 AAA 800 909 9709 Al R CYCLE www aircycle
16. eeeeuseuseeeeeuseuseeeeeeeeseueeeeeeseuseeeeeeseuseetesseeseneees 25 Warranty Normat se iaiiseatsadausconsdeceanedceasteaseastacaadaneicihdgisansdinesvanscanmenddasesuhdansaesdiesemaneiareeaaads 26 AA 800 909 9709 AIRCYCLE www aircycle com 1 Bulb Eater Manual CORPORATION IMPORTANT SAFETY INFORMATION A ATTENTION Read all safety rules carefully before attempting to operate Retain for future reference A DANGER 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 UNATTENDED BULB EATER SAFETY LABELS Inspect the Bulb Eater prior to any use Check for external damage that might have occurred during transit Be careful of moving parts Report any damage Danger indicates an imminently A DANGER hazardous situation which if not avoided will result in death or serious injury AWARNING Warning indicates a potentially hazardous situation which if not avoided could result in death or serious injury A CAUTION Caution indicates a potentially hazardous situation which if not avoided could result in minor or moderate injury Important indicates important information that if not followed may cause damage to equipment or operator STANDARD SAFETY SYMBOLS Warning keep hands out of the machine Warning indicates hazardous voltage Important Hearing amp Vis
17. er 1 Follow steps 1 through 7 above to remove the 1 Stage Filter 2 Locate the 2 Stage filter in the middle of the blue case 3 Rotate the filter a quarter turn counter clockwise 4 Once the HEPA cartridge is free carefully remove it from the blue filter case and place it in the full drum along with the crushed lamps and 1st Stage filters for disposal 5 Replace both filters and replace the blue door verifying that the door is secure Replacing the 3 Stage Carbon Canister filter 1 Unplug the hose from the tip of the carbon canister at the grommeted opening 2 Remove the used canister from the standoffs on the lid of the machine and place duct tape over the open grommeted hole to prevent carbon spillage 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 placed into the shipping container immediately upon removal from the Bulb Eater 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 3 Remove the carbon bag form the new beige carbon canister and slowly pour the activated carbon granules into the carbon canister 4 Hang the new carbon canister on the standoffs on the lid of the machine AA 800 90
18. erial will need to be manually loaded onto the truck 55 Gallon Steel Drums Note manpower charges for loading may apply 4 Fiber Drums A full size tractor trailer can fit into the loading dock 4 Lamp Boxes Height and length restrictions for the loading dock are 8 Lamp Boxes The material is stored 5 Gallon Poly Pails Available Loading Hours Material To Be Picked Up Lamps Quantity Batteries 55 Gallon Drums of Crushed Lamps Mixed The Material Is Packaged In 55 Gallon Drums of Crushed 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 j Other Shattershield Coated Non PCB Total of Pallets Incandescent PCB UV Other Waste for Recycling Pick Up Office Machinery E scrap Other Mercury Containing Devices Special Instructions The marked material is to be properly identi_ed 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 certif
19. et 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 is removed from the top of the drum it is strongly recommended that the drum be resealed as quickly as possible to minimize potential release of remaining mercury vapors present inside the drum well under 2 minutes Once your drum is full call Air Cycle at 800 909 9709 or visit www aircycle com services to schedule a pickup How can I order more filters or other replacement parts Visit www aircycle com or call 800 909 9709 to order more filters and replacement parts What safety precautions should I take when operating the Bulb Eater 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 times when operating the Bulb Eater 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
20. haracteristic Leaching Procedure TCLP limits quantified by TCLP analytical tests AAA 800 909 9709 Al RCYCLE www aircycle com 21 Bulb Eater Manual CORPORATION 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 collected for reutilization Table 1 Clinical Importance of Elemental and Inorganic Forms of Mercury Form Element Source Absorption Primary Effects Secondary State Effects Liquid Thermometers Dermal contact Poorly absorbed Mercury barometers manometers 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 a Crosses the blood brain ba
21. 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 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 AA 800 909 9709 Al RCYCLE www aircycle com 18 Bulb Eater Manual CORPORATION How do I 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 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 Character
22. ictured G Spinner Assembly 1 Stage Filter 2 Stage Filter located on underside of lid AAA 800 909 9709 AIRCYCLE www aircycle com 4 Bulb Eater Manual RATION y corro Premium Bulb Eater Control Panel Stop Switch Power Outlets Power On Lid Open Push to stop Vacuum amp Motor Power is present Stops system when the Twist to release when lit lid is lifted off the drum BULB EATER Start Switch Full Drum Drum Open Delay Only operates if the Stops system when the The crusher motor stops with the stop switch is released fragments reach the sensor stop button but the filtration system will continue to purge the vapors from the drum for approximately 30 seconds AAA 800 909 9709 AIRCYCLE www aircycle com 5 Bulb Eater Manual CORPORATION Premium Bulb Eater Parts Included w Machine The VRS U Premium Bulb Eater Parts List Quantity Motor Vacuum Bracket Handle with brass plug Sensor lid open amp full drum Carbon Canister Spinner Assembly Control Box Locking Ring amp Bolt 9 U Tube Chute 10 T 8 T12 Holder 11 Vacuum Assembly 12 Filter Bags 10 pack 13 Inlet Hose 14 Clean Up Hose 15 Safety Gloves 2 Pairs 16 Safety Glasses 17 Ear Plugs 2 Pairs eS ae SY NM NN a N HS HS SS SS SS SS SS SS a iM The CFL Premium Bulb Eater Parts List Quantity Motor 1 Vacuum Bracket Handle with brass plug Sensor lid open amp full drum Carbon Canister Spinne
23. ion Protection Important Hand Protection Read all manuals included with this Ba product carefully Be thoroughly familiar with the controls and the proper use of the equipment 800 909 9709 AIRCYCLE www aircycle com CORPORATION 2 Bulb Eater Manual The VRS U Premium Bulb Eater The VRS U Premium Bulb Eater is capable of crushing any size straight fluorescent lamp as well as u tube fluorescent lamps Compact fluorescent lamps cannot be crushed with the VRS U model Entry Tube Hub Crusher Motor Control Panel Vacuum amp Filters see page 5 for details contains 1 amp 2 stage filters Entry Tubes Carbon Canister U Tube Chute Flange Not pictured O Spinner Assembly 1 Stage Filter 2 Stage Filter U Tube Chute located on underside of lid attaches on U Tube Flange LA 800 909 9709 AlR CYCLE www aircycle com 3 Bulb Eater Manual CORPORATION The CFL Premium Bulb Eater The CFL Premium Bulb Eater is available in select areas of the United States and internationally and is capable of crushing any size straight fluorescent lamp as well as compact fluorescent lamps U tube lamps cannot be crushed with the CFL Premium model Entry Tube Hub Crusher Motor Control Panel Vacuum amp Filters next to crusher motor not pictured see page 5 for details contains 1 amp 2 stage filters Entry Tubes Carbon Canister Safety Cover CFL Chute on storage rack Not p
24. istic 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 crushed 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
25. ll 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 4 16 2013 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 9709 Outside US 708 344 7860 Fax 866 909 6725 Shipping Date Serial www aircycle com AAA 800 909 9709 Al R CYCLE www aircycle com 26 Bulb Eater Manual
26. n Drum Dolly CFL Chute 800lb rating skid optimized Removable Stainless Steel Chute 55 Gallon Drum Safety Glasses Steel 55 Gallon Drum with Epoxy Lining en F Should be worn at all times when using the 55 Gallon Drum Lid Bulb Eater Flat Steel Shipping Lid with Gasket Locking ring and Bolt for Tight Seal Safety Glove for Bulb Eater 55 Gallon Drum Locking Ring Should be worn at all times when using the sN Bulb Eater Heavy Duty 12 Gauge w Bolt AAA 800 909 9709 AiR CYCLE www aircycle com 15 Bulb Eater Manual CORPORATION VRS U Premium Bulb Eater Parts List Description U M 330 005 BE 55 VRS Premium Bulb Eater A 55 485 EA 55 486 T8 Entry Tube 48 55 490 EA 55 495 EA 55 487 EA 55 488 EA 55 304 T17 Entry Tube 48 55 306 EA 55 310 Filter Bags 20 disposable 1st stage filters P 55 313 Power Filter Unit w o Mounting Bracket 120v 50 60hz i m m KG EA EA EA EA E E E E E E E A A A A A A A A A EA i A A A A 330 282 Lid w U Tube Opening E AAA 800 909 9709 AIRCYCLE www aircycle com 16 Bulb Eater Manual E E E CFL Premium Bulb Eater Parts List U M Entry Tubes T8 Entry Tube 48 55 304 T17 Entry Tube 48 EA 55 305 EA 55 310 Filter Bags 20 disposable 1st stage filters P KG EA EA EA EA CFL Tube Safety Cover EA A A A A A A A E E E E E E AAA 800 909 9709 Al RCYCLE wwwaaircycle com
27. on 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 membranes It may occasionally be a skin sensitizer in some individuals AAA 800 909 9709 Al RCYCLE www aircycle com 20 Bulb Eater Manual CORPORATION 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 ext
28. or block Remove the set screw retaining the sensor and with a small screwdriver set slide the sensor out so it is flush with the end of the block Then reinstall the set screw to lightly hold the sensor in place AAA 800 909 9709 AIRCYCLE www aircycle com 12 Bulb Eater Manual CORPORATION 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 always 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 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 Still having problems Contact Air Cycle at 800 909 9709 Frequently Asked Questions Bulb Eater 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
29. orporation visit www aircycle com AA 800 909 9709 Al R CYCLE www aircycle com 14 Bulb Eater Manual CORPORATION Replacement Parts amp Accessories Pricing is available online at www aircycle com products parts or by contacting Air Cycle at 800 909 9709 Filter Bags 1 Stage Ear Plugs 20 Industrial filter bags Should be worn at all times when using HEPA Filter Cartridge 2 Stage the Bulb Eater Highest Grade HEPA Filter Available Ir U Tube Chute Storage Rack Filter Combo Kit Attaches to entry tube rack for storage of U Tube Chute Contains 20 1 Stage Filter Bags amp 1 HEPA Cartridge a S nd Spinner Assembly Ww Blue Vacuum Containing 1 amp 2 Stage a j S Filters 40 c f m 5 5 amps 120 volts Re Loop Chain Used To Crush Lamps Particulate Filtration System Outlet Filter Hose Filter Combo Kit amp Spinner Assymbly From Outlet of Blue Vacuum Housing to Contains 20 1 Stage Filter Bags 1 HEPA Beige Carbon Canister Cartridge amp Spinner Crusher Motor w Cable Motor for Premium Model Bulb Eater 1 5 f 24 Entry Tube Horsepower 2 amp 120 volts Available for T5 T8 T10 T12 amp T17 Lamps NS 48 Entry Tube f Available for T5 T8 T10 T12 amp T17 Lamps Control Panel Safety Control Panel with Start Button Stop Button and Safety Sensors F U Tube Chute 55 Gallon Drum Dolly Removable Stainless Steel Chute Custom Built 55 Gallo
30. r Assembly Control Box Locking Ring amp Bolt CFL Chute T 8 T12 Holder Vacuum Assembly Filter Bags 10 pack Inlet Hose Clean Up Hose Safety Gloves 2 Pairs Safety Glasses Ear Plugs 2 Pairs eS a a A ess es b C Oak wWNh Oo NM NN a N HS HS HS SS SS SS SS aS aS M N Other accessory parts are available from the parts list AA 800 909 9709 AIRCYCLE www aircycle com 6 Bulb Eater Manual CORPORATION Premium Bulb Eater Assembly Instructions What You ll Need erm 55 Gallon Drum 15 16 wrench or socket Safety Glasses Safety Gloves Instructions 1 Mount the Bulb Eater onto the drum tightening the bolt ring with a 15 16 wrench or socket 2 Unscrew the cap on the entry tube hub and screw the entry tube into the lid 3 Connect the vacuum hose to the drum lid by inserting the nozzle end into the black rubber grommet on the drum lid and screwing the other end into the hole on the right side of the blue filter case 4 Remove the carbon bag from the beige carbon canister and slowly pour the activated carbon granules into the carbon canister 5 Attach the lid and entry tube rack to the carbon canister Use rubber grommets between the entry tube rack and lid and align all screws before tightening 6 Hang the canister on the drum edge on the small standoffs provided as hooks 7 Plug in the hose from the blue vacuum into the black rubber grommet on
31. re 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 health 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 bioaccumulates 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 C
32. reme 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 Table 1 page 22 provides a summary of the clinical importance of various forms of mercury 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 Failu
33. require additional assistance please feel free to contact us at any time by phone at 800 909 9709 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 All models of the Bulb Eater will crush any size straight fluorescent lamps In addition to these the VRS U Premium Bulb Eater is capable of crushing u tube lamps the CFL Premium Bulb Eater is capable of crushing 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 remove mercury while crushing lamps Your Bulb Eater will remove virtually all airborne powder and mercury vapor while crushing a lamp over 99 The Bulb Eater filters the powder in two stages with a bag filter and a High Efficiency Particulate Arrestor HEPA filter The first stage bag filter removes 99 of the dust and larger particles from th
34. rrier 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 AAA 800 909 9709 Al RCYCLE www aircycle com 22 Bulb Eater Manual CORPORATION Mercury Standards 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
35. se 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 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 bioaccumlates 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 ingesti
36. ting e The operator must wear safety glasses and gloves when changing any of the three Bulb Eater filters Replacing the 1 Stage filter 1 Locate the right hand door on the blue filter case of the Bulb Eater 2 Remove black nozzle from blue door and immediately cap the end of the black nozzle to prevent dust from falling to the floor 3 Press the yellow label marked PUSH on the far most right edge of the curved blue vacuum case to open the filter case door 4 Carefully remove the door from the blue filter case 5 Immediately place a circular white label from your Bulb Eater filter kit over the center hole on the front of the 1st Stage filter This prevents mercury laden dust from escaping during the change out process 6 With the 1st Stage filter safely covered with the white label grab each side of the brown cardboard front of the filter with both hands 7 Carefully pull the 1st Stage filter slowly out of the blue vacuum case and place it on top of the full drum of crushed lamps within the drum or store in a zip top bag if drum is not yet full Avoid compression of the filter to minimize the release of mercury laden dust 8 Insert a new filter into the filter case making sure the cardboard front is securely in place and the bag portion of the filter is unfolded and beside the cartridge not rolled up in front of the cartridge 9 Replace the blue door and verify that it is latched Replacing the 2 Stage HEPA filt
37. top of the carbon canister to complete the filtration system Make sure the nozzle is pushed in deep for a good seal 8 Finally connect the power cord to the control panel on your Bulb Eater and plug it into an outlet IMPORTANT Electrical Requirements 4 120V Single Phase 50HZ or 60HZ Must be protected by a minimum of 15 amp fuse or circuit breaker Except when using a manufacturer provided 220V step down transformer Watch the Bulb Eater Training Video at www aircycle com videos AA 800 909 9709 AIRCYCLE www aircycle com 7 Bulb Eater Manual CORPORATION VRS U Premium Bulb Eater Operating Procedures Before Operating the VRS U Bulb Eater e Communicate understand potential hazards by having operators review pages 18 23 of this manual and complete online training program at www BulbEaterTraining com e Before crushing label drum as containing Mercury D009 and as either Hazardous Waste or Universal Waste depending on your state requirements e Crush lamps in a well ventilated area e Wear safety glasses protective gloves and ear protection e Screw in appropriate entry tube for lamp diameter e Remove rubber plug from top of entry tube e Crush only straight fluorescent and u tube lamps 1 Release the stop switch and press green START button Confirm suction at top of entry tube and air flow out of carbon canister before crushing lamps 2 Insert lamp into entry tube and then let go Do not forc
38. trol box when replacing Sensor set screw w 5 32 hex wrench 0 1 8 Sensor set screw w 5 32 hex wrench 3 10 3 8 use light pressure use light pressure Spinner Replacement Procedures Communicate understand potential hazards by having operators review pages 18 23 of this manual and complete online training program at www BulbEaterTraining 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 on a clean empty drum 1 Carefully stand the Bulb Eater on edge Figure 1 2 With a 5 32 allen wrench loosen the set screw holding the spinner on the motor shaft 3 Slide off the old spinner and replace with new spinner in the same position Figure 2 4 Tighten the set screw firmly to secure the spinner to the motor shaft Figure 3 AAA 800 909 9709 AiR CYCLE www aircycle com 11 Bulb Eater Manual CORPORATION Troubleshooting the Bulb Eater Carefully following the instructions and guidelines in this manual is the best way to keep your Bulb Eater working properly However should you encounter problems this guide will help you resolve issues that occasionally arise during normal use of the Bulb Eater If you are experiencing a problem that is not addressed here or if your problem persists after following these suggested procedures do not hesitate to contact us at 800 909 970
39. y for declare under penalty of perjury that the foregoing is true and correct Please fill out this form completely and fax it to 866 909 6725 or e mail to pickup aircycle com AAA 800 909 9709 AIRCYCLE www aircycle com 25 Bulb Eater Manual CORPORATION Warranty Information Air Cycle Corporation warrants The Bulb Eater 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 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 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 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 fi

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