AirCycler Bulb Eater 3 User manual

Fluorescent Lamp Crushing System
www.AirCycle.com | 800.909.9709 | [e-mail]



800.909.9709
www.AirCycle.com [i]
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 . This manual includes:
• Description of the Standard Safety Symbols and Safety Systems used.
• System Functions
• Assembly & Operations
• Maintenance & Trouble Shooting
• Parts & Accessories
• Reference Materials & Forms
• Step by Step Procedures
Serial Number
US-800.909.9709 Outside US-708.344.7860
Fax: [phone]
12/04/2014
Read all manuals included with this
product carefully. Be thoroughly
familiar with the controls and the
proper used of the equipment.
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.

800.909.9709
www.AirCycle.com [1]
Table of Contents
Purpose and Function of Manual ..............................................................................................i
Table of Contents.....................................................................................................................1
Important safety instructions................................................................................................2,3
Machine & Control Panel Diagrams ..................................................................................... 4-6
Bulb Eater® 3 Parts List ............................................................................................................7
Bulb Eater® 3 Dimensions ........................................................................................................8
Assembly & Operations
Bulb Eater® 3 Assembly Instructions...................................................................................9,10
Bulb Eater® 3 Operating Procedures.................................................................................11,12
Recycling Full Drums ..............................................................................................................14
Maintenance & Trouble Shooting
Drum Change Procedures ......................................................................................................13
Filter Replacement Procedures........................................................................................ 16-18
Spinner Replacement Procedures ..........................................................................................18
Troubleshooting the Bulb Eater® 3 ........................................................................................19
Operating Tips & Frequently Asked Questions................................................................. 19-21
Parts & Accessories
Replacement Parts & Accessories ..........................................................................................22
Parts List ................................................................................................................................23
Maintenance & Trouble Shooting
Pickup Request Form .............................................................................................................15
Mercury Information .............................................................................................................24
Mercury Standards ................................................................................................................29
Warranty Information............................................................................................................30

800.909.9709
www.AirCycle.com [2]
ATTENTION!
Read all safety rules carefully
before attempting to operate.
Retain for future reference.
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!
Owner/User Responsibility:
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
contents.
*The BE3 can be operated outdoors in a dry covered environment, but
MUST BE STORED indoors (when not in use) in a dry area!!*
IMPORTANT SAFETY INSTRUCTIONS
Warning indicates a potentially
hazardous situation which, if not
avoided, could result in death or
serious injury.
avoided, could result in minor or moderate injury.
Caution indicates a potentially
hazardous situation which, if not
avoided, could result in death or
serious injury.
avoided, could result in death or serious injury.
Important indicates important
information that if not followed,
may cause damage to equipment or operator.
Danger indicates an imminently
hazardous situation which, if not
potentially
hazardous situation which, if not
avoided, could result in death or
serious injury.
avoided, will result in death or serious injury.
Warning, Keep Hands out of the Machine.
Warning, Indicates Hazardous Voltage.
Important, Hearing & Vision Protection.
Important, Hand Protection Required.
Read all manuals included with this
product carefully. Be thoroughly
familiar with the controls and the
proper use of the equipment.
SAFETY SYMBOLS
MACHINE SAFETY LABELS ON BE3
Inspect Bulb Eater®3 (referred to as BE3) prior to any use.
Check for external damage that might have occurred during
transit. Be careful of moving parts . Report any damage
Meets the following standards:
UL 73: Issued: 2011/03/02 Ed: 10 UL Standard for Safety for Motor-Operated Appliances
CAN/CSA C22.2 No. 68: Issue: 2009/09/01 Ed: 7 Motor-Operated Appliances

800.909.9709
www.AirCycle.com [3]
WARNING –DO NOT LEAVE Bulb Eater®3 MACHINE UNATTENDED WHEN IT IS PLUGGED IN
AND/OR OPERATING. UNPLUG UNIT WHEN NOT IN USE.
11. Do not handle plug or machine with wet hands.
12. Close supervision is necessary when a machine is
used near children.
13. Keep hair, loose clothing, fingers and all parts of
body away from openings and moving parts.
14. Do not use without filters in place. May disperse
fine dust particles into the air.
15. Turn off all controls before unplugging.
16. Do not use in areas where combustible liquids such
as gasoline may be present.
17. Do not vacuum toxic, carcinogenic, combustible or
other hazardous materials such as asbestos,
arsenic, barium, beryllium, lead, pesticides or other
health endangering materials. Specially designed
units are available for these purposes.
18. Do not leave the cord lying on the floor when the machine
is not being operated. It can become a tripping hazard.
19. Use special care when emptying heavily loaded drums.
drums.
20. Always wear safety goggles and hearing protection when
operating the machine.
21. STAY ALERT. Watch what you are doing and use
common sense. Do not use the BE3 machine when
you are tired, distracted or under the influence of
drugs, alcohol or medication causing diminished
control.
When using an electrical appliance or machine, basic precautions
should always be followed, including the following: READ ALL
INSTRUCTIONS BEFORE USING THIS APPLIANCE/MACHINE.
WARNING –TO REDUCE THE RISK
OF FIRE, ELECTRIC SHOCK OR INJURY:
1. Do not leave machine unattended when plugged in. Unplug
from outlet when not in use and before servicing. Connect
to a properly grounded outlet only. See Grounding
instructions.
2. Do not put machine in water or other liquid.
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
manufacturer’s recommended attachments.
6. Do not use with damaged cord or plug. If machine is
not working as it should, has been dropped,
damaged, left outdoors or dropped into water, contact
Air Cycle Corporation for assistance. Replace with specific
part of machine in question.
7. Do Not: pull or carry by cord, use cord as a handle,
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.
8. Do not unplug by pulling on cord. To unplug, grasp
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
GROUNDING INSTRUCTIONS
This machine must be grounded. If it should malfunction or breakdown, grounding
provides a path of least resistance for electric current to reduce the risk of electric
shock. This machine is equipped with a cord having an equipment-grounding conductor
and grounding plug. The plug must be inserted into an appropriate outlet that is
properly installed and grounded in accordance with all local codes and ordinances.
WARNING –IMPROPER
CONNECTION OF THE MACHINE GROUNDING
CONDUCTOR CAN RESULT IN A RISK OF ELECTRIC
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
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,
and has a plug that looks like the
plug illustrated in the sketch. A
temporary adapter that looks like
the adapter illustrated in the sketch
may be used to connect
this plug to a 2-pole receptacle,
as shown, if a properly grounded
outlet is not available. The
temporary adapter should be
used only until a properly grounded
outlet (sketch) can be installed
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
place by a metal screw.
IN CANADA, THE USE OF A TEMPORARY ADAPTER IS NOT PERMITTED BY
THE CANADIAN ELECTRICAL CODE. Make sure that the machine is connected
to an outlet having the same configuration as the plug. No adapter should be
used with this machine.
IMPORTANT SAFETY INSTRUCTIONS

800.909.9709
www.AirCycle.com [4]
Control Panel
LCD Screen
Stop Button
E-Stop
Start Button
Dust Cap w/ USB Plug
AC Receptacle

800.909.9709
www.AirCycle.com [5]
The
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 & Filter
(1st stage filter system) (for U-tube/CFL chute) (see page 4 for details) (contains 2nd & 3rd stage filters)
Entry Tube Brass Plug Assembly Airlock Assembly Lid Assembly Carbon Canister Filter
(Not to scale) (At linear lamp entry) (contains 4th & 5th stage filters)
Not pictured
48” Entry Tube Spinner Assembly 2nd Stage Filter 3rd & 5th Stage Filter CFL/U-Tube Chute
(located on underside of lid) (attaches on U-Tube Flange)

800.909.9709
www.AirCycle.com [6]
The with CFL/U-Tube Chute
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 CFL/U-Tube Chute Control Panel Vacuum & Filter
(1st stage filter system) (see page 4 for details) (contains 2nd & 3rd stage filters)
Brass Plug Assembly Airlock Assembly Lid Assembly Carbon Canister Filter
(At linear lamp entry) (contains 4th & 5th stage filters)
Not pictured
48” Entry Tube Spinner Assembly 2nd Stage Filter 3rd & 5th Stage Filter
(located on underside of lid)

800.909.9709
www.AirCycle.com [7]
The Parts Included w/ Machine
The Bulb Eater®3 Parts List: Quantity
1. Airlock Assembly w/ motor (120v or 240v) 1
2. Lid Assembly 1
3. Brass Plug Assembly 1
4. Carbon Canister Assembly 1
5. Cartridge Filter 1
6. Chute Safety Cover 1
7. Control Panel Assembly 1
8. Crusher Motor, 1/5 Horsepower, 2-amp, 120v 1
9. Cyclone Assembly 1
10. HEPA Filter 2
11. Lid Open Sensor Assembly 1
12. Locking Ring & Bolt 1
13. Spinner Assembly 1
14. Vacuum Body Assembly 1
15. Vacuum Motor 120v or 240v 1
16. Plug Assembly 1
17. Safety Gloves (2 Pairs) 2
18. Safety Glasses (2 Pairs) 2
19. Ear Plugs (2 Pairs) 2
20. 48” T 12 Entry Tube 1
21. USB Drive 1
22. Bulb Eater®3 Owner’s Manual 1
*Other accessory parts are available from the parts list.
The Bulb Eater®3 Parts List for Assembly: Quantity
1. Bulb Eater®3 Lid w/ Assemblies 1
2. Carbon Canister Assembly 1
3. Clamps for Cyclone Assembly 2
4. Clamp for Carbon Canister 1
5. Cyclone w/ Vacuum Lid Assembly 1
6. O-Ring for Cyclone Assembly 2
7. O-Ring for Carbon Canister 1
8. 5g Mini-Tube of Silicone Grease 1

800.909.9709
www.AirCycle.com [8]
The Dimensions
39” (991 mm)
54” (1372 mm)
25” (635 mm)
mm)
Note:
*10’ L x 5’ W x 8’ H area required to
use the machine and crush 4 ft. lamps.
*13’ L x 5’ W x 9’ H area required to
use the machine and crush 8 ft. lamps.

800.909.9709
www.AirCycle.com [9]
The Assembly Instructions
What You’ll Need:
Instructions:
1. 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
2. Mount the Bulb Eater®3 onto the drum, tightening the bolt
ring with a 15/16” wrench or socket. Figure 2
3. Apply silicone grease on the two O-rings and place an O-ring
and a clamp on the airlock assembly & an O-ring and a clamp
on the mounting flange for the installation of the cyclone
assembly. Figure 3
4. Place the 2nd stage cartridge filter into the upper housing
of the vacuum housing assembly. Figure 4
5. Place the cyclone assembly on the mounting flanges with
the lid assembly attached to it, and place onto the upper
housing which holds the cartridge filter. Figure 5
6. 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 & 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
9. Unscrew the plug assembly and install the entry tube.
Figure 10
10. Finally, connect the power cord to the control panel on
your Bulb Eater®3 and plug it into an outlet. Figure 10
FIG. 2
55-Gallon Drum 15/16”wrench or socket Safety Glasses Safety Gloves
FIG. 1
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
1
FIG. 3
3
2

800.909.9709
www.AirCycle.com [10]
FIG. 4
FIG. 5
FIG. 7
FIG. 10
5
4
FIG. 9
FIG. 8
FIG. 6
6
7
8
10
9

800.909.9709
www.AirCycle.com [11]
Operating Procedures for Linear
Lamps
WARNING –DO NOT TAMPER WITH ANY ELECTRICAL CONTROL DEVICES ON THIS MACHINE
Before Operating the Bulb Eater®3
• 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
• 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
1. Plug the machine in & release the E-STOP button. The machine will go through 3 LCD display
functions –Stopping, Dumping, Ready.
2. Take the plug out of the entry tube.
3. Press the START button. When the LCD screen displays ready.
4. Insert the linear lamp into the entry tube and then let go. Do not force the lamp down the entry tube.
5. The machine will time out when the cyclone 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 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).
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.
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
FIG. 1

800.909.9709
www.AirCycle.com [12]
Operating Procedures for CFL’S/
U-Tube Lamps
WARNING –DO 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 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
• 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 & release the E-STOP button. The machine will go through 3 LCD display
functions –Stopping, Dumping, Ready.
2. Remove the chute safety cover to install the CFL/U-Tube chute. Place the plug into the entry tube.
3. Press the START button. When the LCD screen display ready.
4. 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
ii. Place bulbs in the CFL chute individually (larger bulbs) or in small batches.
5. The machine will time out when the cyclone 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.
ATTENTION:
Drum MUST be kept closed at all times
FIG. 2
FIG. 1
8
3 Latches

800.909.9709
www.AirCycle.com [13]
Drum Change Procedures
1. Loosen the lid locking bolt & 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
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 3:
Figure 4:
Figure 5:
Figure 6:

800.909.9709
www.AirCycle.com [14]
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)
• Track your recycling progress online 24/7 with online recycling reports
• Certify your progress for regulatory or management review with Recycling Certificates



800.909.9709
www.AirCycle.com [15]
Pick-Up Request Form
Schedule a Pickup online at www.aircycle.com/services or call 800.909.9709
Date:
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#:
A truck with a lift gate is required to pick up the material. Yes No
Is there a forklift available to load the material onto the truck? Yes No Quantity
The material will need to be manually loaded onto the truck. Yes No 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. Yes No 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
55 Gallon Drums of Crushed Lamps
55 Gallon Drums of Crushed CFL's Quantity
4ft. or Less Fluorescent Lamps
Steel Drums (55 Gallon)
5ft. - 8ft. Fluorescent Lamps Cardboard Boxes
9ft. or More Fluorescent Lamps
4' Fiber Drums (85 count)
U-Bend / Circular 4' Fiber Drums (185 count)
Compact w/o Ballast 8' Fiber Drums (85 count)
HID (Mercury Vapor, Metal Halide, High-pressure Sodium) Other:
Shattershield / Coated Total of Pallets:
Incandescent
UV
Other Waste for Recycling Pick Up:
Office Machinery (E-scrap):
Other Waste:
Special Instructions:
Mixed
Batteries:
Weight
Failure to complete this section may delay the scheduling of service to your facility.
Replacement Containers:
Transportation Requirements section is required.
Pick-Up Request Form
2200 Ogden Avenue, Suite 100 • Lisle, IL 60532
Generator Pick-Up Location
Generator Billing Information
Tel [phone] • Fax [phone] • www.aircycle.com
Compact w/Ballast
Weight
The Material Is Packaged In:
Poly Pails (5 Gallon)
Zinc Carbon
Alkaline
Lithium
NiMH
NiCad
Ballasts:
Non-PCB
PCB
Lead Acid
Mercury
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 [e-mail]
Have you tried our online services? Visit us at AirCycle.com/services to schedule your pickup online today!

