®
®
3649 Cane Run Road . Louisville, KY 40211-1961
877-244-9340 . Fax: 877-414-4316
www.clarusenvironmental.com
Fusion® Series Treatment Systems
OWNER'S MANUAL
Large Commercial Models ZFL-2800 – ZFL- 4000
Thank you for choosing a Fusion® Series Treatment System. Highquality workmanship and easy maintenance have been incorporated
into the Fusion® system. The system will provide years of troublefree service when maintained according to the manufacturer’s
recommendations. Please read this manual in its entirety before using
the Fusion® and follow all instructions to ensure proper operation.
Keep this manual for future reference along with other important
onsite documents. Should further assistance be necessary, please
contact Clarus Environmental at 1-800-928-7867.
Warning Labels
You will nd warning labels on the Fusion®, riser lids, blower, and the
alarm control panel. It is very important to follow the information on
these labels to ensure your safety. Please do not remove these labels.
SEE LIST AT RIGHT
FOR WARNINGS
SECTION: C3.10.142
CL0140
0313
Supersedes
New
1. DO NOT attempt to service the Fusion
authorized maintenance provider for all service related issues.
2. There are buried electrical cables and piping near and around
the Fusion®. Please consult with your authorized maintenance
provider to locate these utilities before excavation.
3. DO NOT bury or cover the Fusion® lids with soil or other debris.
This is necessary to allow access for operation and maintenance
of the unit.
4. The Fusion® blower must be unobstructed and vented for
proper operation. Care must be taken that no grass clippings or
other materials accumulate on or around the blower and block
ventilation.
5. DO NOT place heavy objects over the Fusion® or drive heavy
equipment over the Fusion®, as damage may occur. Damage of
this kind is not covered by the warranty.
6. DO NOT plant trees within 15 feet (4.6 m) of the Fusion
Treatment System.
®
unit yourself. Contact your
®
Series
TABLE OF CONTENTS
Limited Warranty ......................................1
Process Description.................................... 3
System Components and Care ...........................4
Installation and Start Up ................................6
Blower Installation And Placement........................7
Operation and Maintenance ............................ 11
Aeration Chamber Cleaning ............................13
Troubleshooting ...................................... 14
Blower Inspection and Maintenence .....................15
LIMITED WARRANTY
Manufacturer warrants, to the purchaser and subsequent owner during
the warranty period, every new product to be free from defects in material
and workmanship under normal use and service, when properly used and
maintained, for a period of two years from date of purchase by the end
user. No allowance will be made for shipping charges, damages, labor or
other charges that may occur due to product failure, repair or replacement.
This warranty does not apply to and there shall be no warranty for any
material or product that has been disassembled without prior approval of
Manufacturer, subjected to misuse, misapplication, neglect, alteration,
accident or act of nature; that has not been installed, operated or maintained
in accordance with Manufacturer's installation instructions; that has been
exposed to outside substances including but not limited to the following:
sand, gravel, cement, mud, tar, hydrocarbons, hydrocarbon derivatives (oil,
gasoline, solvents, etc.), or other abrasive or corrosive substances, wash
towels or feminine sanitary products, etc. in all pumping applications. The
warranty set out in the paragraph above is in lieu of all other warranties
expressed or implied; and we do not authorize any representative or other
person to assume for us any other liability in connection with our products.
The Fusion® Series Treatment Systems represent a collaboration with Fuji Clean Co., Ltd.
© Copyright 2013. All rights reserved.
Fusion® Model: ZFL-2800 ZFL-3200 ZFL-3600 ZFL- 4000
Serial No. ____________________________________
Installing Contractor ____________________________________
Phone Number ____________________________________
Installation Date ____________________________________
Maintenance Provider’s Name _____________________________
Phone Number ____________________________________
Contact Manufacturer at, 3649 Cane Run Road, Louisville, Kentucky 40211,
Attention: Customer Support Department to obtain any needed repair or
replacement of part(s) or additional information pertaining to our warranty.
MANUFACTURER EXPRESSLY DISCLAIMS LIABILITY FOR
SPECIAL, CONSEQUENTIAL OR INCIDENTAL DAMAGES OR
BREACH OF EXPRESSED OR IMPLIED WARRANTY; AND
ANY IMPLIED WARRANTY OF FITNESS FOR A PARTICULAR
PURPOSE AND OF MERCHANTABILITY SHALL BE LIMITED TO
THE DURATION OF THE EXPRESSED WARRANTY.
Some states do not allow limitations on the duration of an implied warranty,
so the above limitation may not apply to you. Some states do not allow
the exclusion or limitation of incidental or consequential damages, so the
above limitation or exclusion may not apply to you.
This warranty gives you specic legal rights and you may also have other
rights which vary from state to state.
HOW A FUSION® SERIES TREATMENT SYSTEM WORKS
The Fusion® is simple in design, yet advanced in its wastewater
treatment ability. The design has been rened over many years of
intense research and development in an effort to perfect this superior
treatment system. Fusion
®
systems are 90% - 95% efcient at treating
wastewater. This is nearly twice as effective as a traditional septic tank,
which is approximately 50% efcient. This high degree of treatment
helps to protect both your personal property and the environment.
Figure 1 - The following diagram will help you to better understand the process:
Tank -
Fiberglass
The Fusion® utilizes a combination of anaerobic (without oxygen) and
aerobic (with oxygen) biological processes to treat wastewater. As
wastewater enters the Fusion®, it is broken down and becomes food
for biological organisms operating within the unit. The rst chamber
serves to separate some grease and large solids from the liquid. In
the second chamber, plastic media with large surface areas are used
to increase contact between water and benecial bacteria to optimize
treatment. A small linear air blower is used to move air (oxygen) into
the third chamber for the aerobic process. The nal efuent leaving the
system will have been treated to secondary quality efuent.
Sludge Return Line
Recirculation Line
Storage
Chamber
Sedimentation
Chamber -
Separates bulk solid
and grease waste
Figure 2 - Schematic diagram of the Fusion® Treatment System
2" RECIRCULATION
RETURN LINE
INLET
2" BACKWASH
RETURN LINE
3/4" AIRLINE ADAPTER
RECIRCULATION
1" AIRLINE ADAPTER
BACKWASH
TOP VIEW SIDE VIEW
OUTLET
Anaerobic Chamber -
Organisms adhere to xed lm
media and digest waste
21
*
Aeration Chamber
Floating/Circulating
Filter Media -
“Fluidized Bed”
Invigorates aerobic bacteria
Ｗ ．ＬＷ ．Ｌ Ｗ ．Ｌ
Risers not installed
*
Ｗ ．Ｌ
28
*
© Copyright 2013. All rights reserved.
2
PROCESS DESCRIPTION
1. Sedimentation Chamber
This chamber is designed to physically separate solids from the
incoming water. Scum is the oating material and sludge is the
material that has settled at the bottom.
2. Anaerobic Chamber
This chamber contains a spherical skeleton-type of lter media,
4.3 inch diameter (109 mm). Through bacterial growth processes
on the surface of the lter media, biological anaerobic treatment
thrives while suspended solids are captured. Furthermore,
the microorganisms in this chamber convert nitrates in the
recirculated water returning from the aerobic chamber to
gaseous nitrogen. The gaseous nitrogen then escapes to the
atmosphere.
3. Aeration Chamber
The aeration chamber consists of an aerated upper section and
a lter media lower section. The chamber is lled with hollow,
Figure 3 - Treatment Flow of the Fusion® System.
cylindrical lter media 0.6 inch diameter (15 mm) and 0.55 inches
long (14 mm). Biological treatment takes place on the lter
media surface. Aeration is continuous. Residual suspended
solids are captured by the lter media circulating in this section.
During normal operation, a recirculation line transfers water back
to the sedimentation chamber by way of an air lift pump.
The lter media in the aeration chamber are backwashed
regularly (twice a day, 5 or 10 minute cycle) by the backwash
system located at the bottom of the chamber. The accumulated
sludge is transferred by an air lift pump back into the
sedimentation chamber for further digestion.
4. Storage Chamber
This chamber is designed to temporarily store treated water
exiting the aeration chamber. This treated water is ready for
discharge.
Inflow
Back-Wash
1
2
Sedimentation Chamber
Anaerobic Chamber
Recirculation
3
4
Aeration Chamber
Storage Chamber
Effluent
© Copyright 2013. All rights reserved.
3
SYSTEM COMPONENTS
The complete wastewater treatment system will typically consist of the Fusion® treatment components and a soil absorption eld for nal
disposal of the liquid efuent. Some states or counties may require the addition of a septic tank before the Fusion® to increase the sedimentation
chamber capacity and retain more solids. Please see Figure 9 for a typical Fusion® system. Variations to the typical system will be made to suit
your particular site and system design needs. Please contact your authorized Fusion® installer or maintenance provider for further information
about your system design.
1
2 3 4 5 6 7 8
ALARM PANEL
The Fusion
audible buzzer and red beacon light on top of the panel if there is a drop
in air pressure, if a high water alarm condition occurs, or if the blower
®
alarm panel (see Figure 4) is designed to activate an
120 VAC
INCOMING
POWER
GND
TB2
L1
N
DISNF
ALARM
GND LUG
does not cycle between recirculation and backwash modes within the
preset time. (Note: Alarm panel can only function as long as there is
electrical power supplied to the panel)
HIGH WATER
ALARM
You may from time to time check the proper operation of the alarm
panel by toggling the black switch on the side of the panel to “test”. The
buzzer will sound and the red beacon will light as long as you hold the
switch in the test position. Release the switch for normal operation.
Figure 4
BLOWER
*FOR ILLUSTRATION PURPOSES ONLY*
REFER TO SCHEMATIC LOCATED IN
PANEL FOR INSTALLATION
SK2933
SYSTEM CARE
The Fusion
blower area is recommended to ensure no debris obstructs the ventilation or intake areas of the blower. Also, periodically test the control panel
as outlined under the alarm panel section. The owner should closely monitor the types and amounts of substances and products used. Water use
should also be closely monitored to ensure proper operation of the Fusion® system.
Periodically, more extensive maintenance must be performed. Your authorized Fusion® maintenance provider will oversee this service. The name
of the maintenance provider can be recorded on the front of this document and should also be located on the alarm panel. For more information
see the Operation and Maintenance section of the manual.
The owner should only perform minimal routine maintenance on the Fusion® such as clearing debris from around blower housing (leaves, snow,
and grass clippings). The Fusion® should also be protected from excessive weight such as vehicular trafc. Trees and bushes should not be
planted in close proximity to the Fusion®. The Fusion® should be accessible to maintenance personnel and the riser lids must never be buried.
®
system is designed to continuously operate automatically with little direct maintenance from the owner. Periodically, a check of the
HIGH USE WATER DEVICES
The draining of hot tubs and swimming pools into your Fusion® system
could cause hydraulic overloading and may reduce the treatment
efciency. Please drain these devices to another location. Contact
your local regulatory authorities or authorized Fusion® maintenance
provider for more information. The use of large capacity single ll and
drain whirlpool bathtubs may also cause hydraulic overloading of your
Fusion®. Please limit the use of these types of tubs.
LEAKY FIXTURES
It is very important to monitor all water xtures in the home for leaks and
drips and repair them immediately. Excessive water use may hydraulically
overload your Fusion® system and reduce its treatment efciency.
Excessive water use may also overload your soil absorption eld and
cause failure.
HARMFUL SUBSTANCES
The Fusion® is designed to treat household type waste and can treat most
common substances introduced into the system. However, certain harmful
substances may reduce the efciency or stop the treatment process by
reducing or destroying the benecial bacterial populations responsible
for treatment. In general, if a chemical substance is considered harmful
to humans then it should also be considered harmful to the Fusion®
treatment system. If you have any questions concerning the use of any
of these substances, please contact your Fusion® maintenance provider.
The introduction of any substance on the “Do Not List” into the
Fusion® will void the warranty.
- THE "DO NOT" LIST -
DO NOT introduce the following substances into the Fusion® treatment system:
• Motor oil • Anti-freeze
• Brake uid • Paint
• Paint thinner • Gasoline
• Solvents • Pesticides
• Herbicides • Strong disinfectants
• Strong caustic drain • Toilet tank
cleaners in excess disinfection chemicals
• Excess pharmeceuticals • Chemicals & chemical waste
Not Recommended: Trash and excess food products will likely
increase frequency of pumping.
Trash
• Sanitary napkins and • Condoms
feminine products • Cat litter
• Diapers • Dental oss
• Paper products such as • Cigarette butts
paper towels & baby wipes • Plastic /rubber products
Food Products
• Coffee lters and grounds • Greases or lards
• Fruit and vegetable peels • Seeds
• Meat products • Bones
• Garbage disposal waste • Egg shells
Limited Use Products
Certain products in small or moderate amounts should not disrupt
the Fusion® treatment process. You should always use the minimum
quantities of these substances as recommended by the manufacturer.
1. Liquid laundry bleach only as needed per load
2. Liquid laundry detergents without added bleach
3. Liquid dishwashing detergents
4. Household cleaners in moderation
© Copyright 2013. All rights reserved.
4
EFFLUENT QUALITY
Fusion® Series systems are compact, efcient, and designed to be
installed in a typical residential/light commercial environment. The nal
efuent leaving the system will typically be treated to the secondary
quality strength.
WATER SOFTENERS
If water softeners are present in the home, Clarus Environmental
recommends the use of water and salt conservative models that are
installed and operated correctly. If you have questions about softeners,
contact the Water Quality Association at www.wqa.org. Contact factory
for installation details.
EXTENDED MAINTENANCE POLICY
An extended maintenance policy is available for purchase from your
authorized Fusion
include the same system checks, schedule, and adjustments as the
initial maintenance policy. Please contact your Fusion® distributor or
maintenance provider for further information regarding the extended
maintenance policy.
®
distributor. The extended maintenance policy will
POWER OUTAGE
Should you experience a power outage, the blower will not operate
and air (oxygen) will not be supplied to the Fusion®. If the blower
is off for more than 24 hours, the lack of fresh air will cause the
treatment efciency to decrease. During a power outage, the
Fusion® will still allow efuent to ow, and will not create a backup
in the home. You may, however, have a pump or dose tank with
a pump on the outlet of the Fusion®, which requires power to pump
the efuent to the soil absorption eld. If you have a system such
as this, please be aware of this condition and conserve water
accordingly.
FLOODING
If ooding of the Fusion® occurs and the blower
or the alarm panel is submerged, please disconnect power at the
circuit breaker. DO NOT try to reconnect power to either the blower
or alarm panel once it has been submerged. Immediately contact your
authorized Fusion® maintenance provider to inspect the Fusion®, the
blower, and the alarm panel. Your maintenance provider will repair or
replace the components as needed.
AUTHORIZED MAINTENANCE PROVIDER
Your authorized maintenance provider will perform many system checks
and adjustments as needed during the maintenance inspection. Two
inspections per year will be made for a total of four inspections during
the initial service policy. Please see the Operation and Maintenance
section of this manual for further details.
Should there be any operational deciencies with your Fusion®,
the maintenance provider will notify the owner in writing when the
deciencies will be corrected. If the maintenance provider does not
correct the deciencies or the service calls are not completed, please
contact Clarus Environmental at 1-800-928-7867.
INSPECTION AND MAINTENANCE FREQUENCY
Fusion® Series systems are to be inspected and maintained every six
months under normal usage. The inspection and maintenance are
only to be performed by personnel trained and authorized by Clarus
Environmental. A Maintenance & Service Report (CL0059) is to be
completed for each inspection and maintenance visit.
ALARM CONDITION
If an alarm condition occurs, please check the air intake area around
the blower and make sure no debris blocks the blower intake. Remove
the air lter cap. Remove the lter and gently tap against your other
hand. If it is very clogged wash it in warm, soapy water and dry well
before replacing. Reassemble lter and cap on top of blower. Do
not attempt to remove the blower housing or any other parts from
the blower. If the blower is operating properly, there may be a high
water condition within the Fusion®. It may be necessary to discontinue
water use until the alarm condition has been resolved. If the buzzer
continues to sound or the red light stays on, please contact your
authorized Fusion® maintenance provider. The buzzer may be silenced
by toggling the black switch on the side of the alarm panel to “silence”.
The red beacon light will remain on until the problem has been
resolved.
Check the circuit breaker and make sure the blower circuit is on. Reset
the breaker switch if it has been tripped. If it continues to trip or the alarm
continues to remain on, contact your Fusion® maintenance provider.
INTERMITTENT USE
The Fusion® system is designed to function even if wastewater does
not enter it for extended periods of time. The power to the blower must
remain on during this time for the system to function properly. Weekend
use will not harm the system as long as the blower is on. Should
seasonal use require a complete shut down of the property, then it is
recommended that the blower be turned off. It is important to start up the
system in advance of actual occupancy to allow for normal treatment to
resume. Please contact your authorized Fusion® maintenance provider
for further information concerning shut down and startup of the Fusion®.
You may also contact your maintenance provider for the shut down and
startup services.
© Copyright 2013. All rights reserved.
5
EXCAVATION AND INSTALLATION
1. Excavate an area large enough for the Fusion® Series unit to be installed. See Figure 5 and Table 2 for the actual dimensions of the unit. In
areas where high groundwater is not a concern, excavation dimensions are calculated by adding 12-18" (305-457 mm) to the length and width
of the Fusion®. This will allow sufcient room for proper backlling. If it is reasonable to expect a seasonally high water table, consult the AntiFlotation Procedures section below.
2. Construct a 6" (152 mm) thick stone pad of either 1/4" - 1/2" (6-13 mm) diameter stone or concrete pad and level to within 1/8" (3 mm).
3. If the unit is not level, it will cause uneven water ow as well as unbalanced aeration, which will result in poor performance.
4. Gently lift the unit at all four lifting points with a harness and install it on leveled stone pad (Figure 11).
5. Check unit to make certain it is level by placing a level at several locations on the riser. (riser covers removed) (Figure 11).
BACKFILLING
1. If groundwater is present, anti-otation measures must be used to
stabilize the unit prior to backlling. Please follow the procedures
in the Anti-otation section to properly anchor the Fusion
2. Fill the unit with clean water to the normal operating depth prior to
backlling. Partition walls between chambers are water-tight and will
ll in succession beginning on the inlet side of the unit. Therefore,
it is best to alternate chambers when lling with water so the unit
remains level. Check for leakage around the unit.
3. See riser instructions page 7. See Table 1 for number and size of
access openings. Riser extensions are available for deeper burial.
Make certain risers are sealed properly and watertight.
4. Install riser covers.
5. Backll with good quality granular soil around the unit that is free
of organic matter, rock, stone, tree roots, or other debris that could
damage the unit. Unit can be backlled partially before risers are
installed to aid in riser installation.
6. Tamp soil around perimeter of the unit as it is backlled to stabilize
the unit and to reduce settling.
7. Finalize backll with a mounded contour so that surface water is
shed away from the unit. Under no circumstances should surface
water be allowed to accumulate around unit.
8.
CAUTION
MAXIMUM soil burial depth over the unit is 36
inches (914 mm).
Table 1
NUMBER OF ACCESS RISERS IN FUSION® SERIES
ZFL-2800 ZFL-3200 ZFL-3600 ZFL-4000
24" (61 cm) Diameter 3 3 3 3
26.5" (67.3 cm) x 45" (114.3 cm) 1 1 1 1
®.
COLD WEATHER INSTALLATION
When installing Fusion® in cold climates, the blower must be protected
from snow drifts by installing it either inside a garage, home, basement,
crawlspace or riser. If installed in a riser, the blower must be protected
from inundation and must have a vent pipe installed to above the
maximum snow depth with a 180 degree angle at the end to prevent
snow and water entry. Also, the top and sides of the Fusion® must be
insulated with insulation sheeting or other means to provide a minimum
insulation value of R-8, along with the risers and lids. Please contact
the factory for further information.
ANTI-FLOTATION PROCEDURES
It is necessary to anchor the Fusion® in high ground water conditions to
prevent otation. If groundwater rises above the rock or concrete pad
that the Fusion® sits on, anchoring is required. Please consult a design
engineer, soil scientist or other qualied individual to determine high
groundwater conditions.
1. Follow the procedures outlined in the Excavation and Installation
Section items 1-5 to properly prepare and level the Fusion®
excavation.
2. Follow the procedures outlined in the Backlling Section items 1-4
to properly ll the Fusion® with water and add risers if needed.
3. Refer to Figure 12, Anchoring Schematic to determine the
minimum amount of backll to be placed around the Fusion® in the
excavation. Tamp the ll to prevent settling.
4. Refer to Table 3, Concrete Anchoring Dimensions to determine
the amount of concrete needed for the concrete anchor collar that
is poured around the entire circumference of the Fusion®. Pour
concrete to the specied dimensions to fully engage the mid-seam
of the Fusion®, which will anchor it once the concrete cures. Make
certain to pour the concrete in a manor to minimize trapped air
within the concrete. Agitating or lightly mixing the concrete with
a metal rod or other similar device once poured will help release
trapped air. Be careful not to puncture or crack the unit.
5. Allow the concrete to harden before nal backlling.
6. Complete the procedures outlined in the Backlling Section,
items 5-8.
Table 2
FUSION® DIMENSIONS
SYSTEM L W H I E
ZFL-2800 14' 8" (4.5 m) 7' 0" (2.1 m) 7' 10" (2.4 m) 6' 1" (1.9 m) 5' 7" (1.7 m)
ZFL-3200 15' 0" (4.6 m) 7' 5" (2.3 m) 7' 10" (2.4 m) 6' 1" (1.9 m) 5' 7" (1.7 m)
ZFL-3600 15' 5" (4.7 m) 7' 9" (2.4 m) 8' 0" (2.4 m) 6 '3" (1.9 m) 5' 9" (1.8 m)
ZFL-4000 15' 6" (4.7 m) 8' 0" (2.4 m) 8' 4" (2.5 m) 6' 7" (2.0 m) 6' 1" (1.9 m)
© Copyright 2013. All rights reserved.
6
Figure 5- Dimensions
INLET
W
NOTES:
1) DIMENSIONS "I" AND "E" ARE TO THE BOTTOM
OF THE INLET/OUTLET PIPE.
2) THE OVERALL HEIGHT DIMENSION "H" IS TO THE
TOP OF THE NARROW ADAPTER RING, NOT THE RISER LID.
3) A RISER COVER COMES STANDARD. ADDITIONAL RISERS ARE
PURCHASED SEPERATELY.
OUTLET
H
I
E
L
sk2624
RISER/CONVERSION KIT INSTALLATION
All large Fusion® units are shipped without risers attached due to size restraints, therefore all units will need to have the chosen riser kit attached in the
eld. Please see the riser installation instructions below. Risers come in size ranging from 6 inches to 3 feet, under no circumstances can the risers be
extended more than 3 feet.
Riser Installation Instructions – All Large Units
Install Fusion® unit in the ground and ll with water checking for any leaks. Backll with dirt up to a reasonable working level for safety and ease of
installation of hub inserts and risers. Be careful not to get any backll material into Fusion® unit.
Hub Inserts for 4” Schedule 40 PVC
The Fusion® unit will have the Japanese pipe size hub inserts. You may need to change them out to the American 4” PVC schedule 40 pipe size.
Figure 6
4" TANK ADAPTER
4" TANK ADAPTER
GASKET
4" TANK ADAPTER
NUT
INLET HUB DETAIL 'A'
PLACE A BEAD
OF SILICON ON
BACK OF ADAPTER
NUT BEFORE
INSTALLATION
4" TANK ADAPTER NUT
OUTLET HUB DETAIL 'B'
4" TANK ADAPTER
GASKET
PLACE A BEAD
OF SILICONE ON
BACK OF ADAPTER
NUT BEFORE
INSTALLATION
4" TANK ADAPTER
SK2888
24” Riser Installation Process
Verify tank opening and riser match up by placing the riser over the chosen access hole. Once it is veried that the riser ts, proceed. (if it does not t
cut tank opening to match ). Clean tank lip of any dust and dirt and apply provided tar rope seal to tank lip. Install riser by setting and pressing into the
tar rope seal adhesive. Additional fasteners may be used to attach riser if needed. If
used, seal fasteners with silicone so they are watertight. Install riser cover with included
tamper- proof screws.
Rectangular Riser Installation Process
ZFL-2800 thru ZFL-4000
Place rectangular riser over the rectangular opening, make sure the ange with
threaded inserts is facing up and the open holes side goes against the Fusion® unit.
Lineup the inside of riser opening and the inside of tank opening, riser should lay at
on tank with little over hang. Trim Fusion® opening now if necessary.
Mark and pre drill the Fusion® unit to match the supplied rectangular riser. Clean
SQUARE ALUMINUM LID
RISER EXTENSION MOUNTING BRACKETS
(OPTIONAL)
FIBERGLASS SQUARE RISER EXTENSION
THREAD INSERTS GO ON TOP SIDE FOR LID
TAR ROPE SEAL
CLEAN SEAL AREA OF
DEBRIS BEFORE APPLYING
TAR ROPE SEAL
SQUARE RISER EXTENSION AND COVER INSTALLATION 'D'
NOTE: SILICONE AROUND ALL BOLTS, NUTS AND WASHERS
WHEN ATTACHING RISER TO FUSION
®
UNIT
Figure 7
SK2888
© Copyright 2013. All rights reserved.
off any dust and
dirt and apply
tar rope seal
adhesive to the
top lip of the
Fusion® unit.
Carefully align
the riser and place into the tar rope seal adhesive and bolt down with supplied
nuts, bolts, and large fender washers being careful not to over tighten. If there
is excess overhang from the riser or it is felt that there isn’t enough support for the
riser, the use of “L” brackets ( 90 degree brackets ) may be used. Place one “L”
bracket in the center bolt hole on each side of riser, attach with nuts, bolts and large
fender washers. Mark and pre drill the Fusion® tank, apply a liberal amount silicone
around each of the pre drilled holes and attach with supplied nuts, bolts, and large
fender washers being careful not to over tighten.
Mark and pre-drill the remaining riser bolt holes into the Fusion® unit. Apply a liberal
amount of silicone around each of the pre-drilled holes and then attach with supplied
nuts, bolts and large fender washers being careful not to over tighten.
7
CHECK OPENING FOR FIT
BEFORE APPLYING TAR
OF DEBRIS BEFORE
APPLYING TAR ROPE SEAL
Figure 8
24" DIA CLARUS
RISER COVER
24" ULTRA RIB
RISER EXTENSION
RIDGE SIDE DOWN
TAR ROPE SEAL
ROPE SEAL
CLEAN SEAL AREA
RISER AND RISER COVER INSTALLATION 'C'
SK2888
BLOWER INSTALLATION AND PLACEMENT
CLARUS FUSION
ALARM PANEL
SEWER
WARNING!
CLEANOUT
ALARM FLOAT CONDUIT
INSTALLED BY CONTRACTOR
WHERE APPLICABLE
BLOWER
SWITCH BOX
AIR LINES TO
TREATMENT UNIT
OPTIONAL SEPTIC TANK INSTALLATION
MAY BE REQUIRED BY
LOCAL OR STATE REGULATIONS
Figure 9
1. This product must be connected to a grounded, metallic,
permanent wiring system, or an equipment-grounding terminal
or lead on the product.
2. Place the blower where it is easily accessible for maintenance
and inspection.
3. Install the blower in an area where it will be protected from
damage and ooding. Also make certain the location has good
ventilation. DO NOT place the blower below water level as backsiphoning can occur.
4. Install the blower on a foundation that is level and solid.
5. Excavate trench for air line from blower to the switching valve,
and trench for air lines from switching valve to Fusion® unit.
6. Install one 1" (25.4 mm) air line from the blower to the switching
valve. Piping should be less than 17' (5 m) from blower to
Fusion® unit. The recirculation line is ¾" (19 mm) and the
backwash line is 1" (25.4 mm).
RISER AND LID
Ｗ ．ＬＷ ．Ｌ Ｗ ．Ｌ
TO DISPERSAL
SK2955
7. The blower is provided with one discharge port. Install the
included air line PVC tees in the backwash and recirculation
lines.
8. Attach the small diameter black air tubing (included in the blower
box) to barbed tting on PVC tee. Black air tubing and blower
cord should be routed to the control panel through conduit.
Attach the black air tubing line to the air pressure sensor barbed
ttings in the panel. (Figure 10) If air tubing is not connected to
backwash and recirculation lines, the panel will alarm.
9. Connect the remaining end of the PVC tee to the airline installed
in Step 6.
10. The switching valve is 100V and must be connected to the panel
through the use of the supplied transformer. See included
transformer installation instructions.
(BLUE CONNECTION)
Figure 10
AERATION HOSE
SUPPLIED
BLOWER HOSE
SUPPLIED
SWITCH BOX
POWER CORD
MOUNTING BRACKET
BLUE CONNECTION
AERATION
BACKWASH HOSE
SUPPLIED
(RED CONNECTION)
CLAMP
AIR LINE SENSOR FITTING
ZFL TREATMENT UNIT
RED CONNECTION
BACKWASH
SK2930
© Copyright 2013. All rights reserved.
8
Figure 11 - Lifting & Positioning
Figure 12 - Concrete Anchoring
4-POINT
LIFTING
LESS THAN 60°
60°
LIFTING
LEVEL ACROSS TOP OF UNIT
CONCRETE ANCHOR
COLLAR
LIFTING
HOOK
W
H
LEVELING
sk2931
Table 3 - Concrete Anchoring Dimensions
MODEl NO COVEr 6" COVEr 12" COVEr 18" COVEr
W H CONCrETE VOluME W H CONCrETE VOluME W H CONCrETE VOluME W H CONCrETE VOluME
(Ft) (Ft) (Ft3) (cY) (Ft) (Ft) (Ft3) (cY) (Ft) (Ft) (Ft3) (cY) (Ft) (Ft) (Ft3) (cY)
ZFl-2800 2' - 8" 3' - 0" 432 16 2' - 7" 2' - 8" 370 14 2' - 6" 2' - 5" 323 12 2' - 3" 2' - 10" 334 13
ZFl-3200 2' - 10" 2' - 10" 451 17 2' - 8" 2' - 9" 407 15 2' - 8" 2' - 3" 333 12 2' - 4" 2' - 10" 359 13
ZFl-3600 3' - 0" 2' - 9" 482 18 2' - 10" 2' - 8" 436 16 2' - 9" 2' - 4" 368 14 2' - 5" 2' - 11" 395 15
ZFl-4000 3' - 0" 3' - 0" 531 20 3' - 0" 2' - 6" 443 16 2' - 10" 2' - 5" 400 15 2' - 6" 2' - 11" 416 16
MODEl 24" COVEr 30" COVEr 36" COVEr
W H CONCrETE VOluME W H CONCrETE VOluME W H CONCrETE VOluME
(Ft) (Ft) (Ft3) (cY) (Ft) (Ft) (Ft3) (cY) (Ft) (Ft) (Ft3) (cY)
ZFl-2800 2' - 3" 2' - 3" 265 10 2' - 2" 2' - 0" 226 9 2' - 0" 2' - 2" 223 9
ZFl-3200 2' - 4" 2' - 3" 285 11 2' - 3" 2' - 0" 243 9 2' - 1" 2' - 1" 231 9
ZFl-3600 2' - 5" 2' - 4" 316 12 2' - 4" 2' - 0" 260 10 2' - 2" 2' - 1" 249 10
ZFl-4000 2' - 6" 2' - 4" 333 13 2' - 5" 2' - 1" 286 11 2' - 3" 2' - 2" 273 10
9
PIPING INSTALLATION
1. Connect house sewer pipe or septic tank outlet, if required, to the
unit inlet. Make certain only household waste enters the unit (no
foundation drains, gutter drains, etc.).
2. Connect the outlet pipe to the outlet of the unit.
HIGH WATER ALARM FLOAT INSTALLATION
The Fusion® alarm panel assembly includes a high water alarm oat
switch that is used to monitor the liquid level in the Fusion unit. The
switch should be tethered to one of the gray, vertical air lines in the
aeration chamber. With a 3" (76 mm) tether length, the cord should
pass through the opening in the partition wall between the aeration
and anaerobic chamber, and allow the oat to hang in the outlet bafe
of the anaerobic chamber.
1. The oat switch should be tethered to one of the gray, vertical pipes in
the aeration chamber. When the oat is in the horizontal position,
the cord should be at least 1" (25 mm) below the top of the
partition wall opening in the anaerobic chamber bafe.
2. Place the cord into the clamp and secure to gray aeration pipe.
NOTE: Do not install the cord under the hose clamp.
3. Position the oat with a 3" (76 mm) tether.
4. Tighten the hose clamp with a screwdriver. Be careful not to
overtighten as this may cause damage to the plastic clamp.
5. Make sure the oat cord is not allowed to touch the excess hose
clamp band during operation as this may cause damage to the cord.
6. The oat switch cord should be installed in electrical conduit
connecting the control panel to the Fusion® unit. The electrical
conduit must be rated for burial.
7. A ½" (13 mm) bulkhead tting (supplied by others) should be used
to connect the electrical conduit to the Fusion® unit. A hole must be
drilled through the wall of the Fusion® unit between the red and blue
bulkhead ttings to facilitate this connection.
8. Please be certain that the bulkhead tting for the electrical
conduit forms a watertight connection with the FRP wall of the
Fusion® unit. Silicone may be used to create a watertight seal.
9. Electrical conduit from the Fusion® unit to the alarm panel can be
buried in the same trench as the air lines.
10. The high-water alarm oat switch is wired directly into the alarm
panel.
ELECTRICAL CONNECTIONS
1.
National Electrical Code and/or your local/state electrical codes.
2. The blower should be directly wired into the alarm panel. The
alarm panel must be located in a dry location that is accessible
for maintenance. Please see the wiring diagram and instructions
enclosed with the alarm panel.
3. Make certain the timer within the control panel is set to the proper
time. The timer unit display should be set to 10 hours and the
timer dial needle set to 3.6 for 36 hours. This will activate an
alarm if the blower doesn't go into backwash cycle within a 36hour time frame.
All electrical installations must follow the
Figure 13 - Aeration Flow Adjustment
Valve legend:
1. Aeration Blue Balance Aeration
2. Recirculation Gray See Table 2
Table 4 - Recirculation Flow Rates
Model ZFL2800 ZFL3200 ZFL3600 ZFL4000
Recirculating ow rate
(liter/min.)
Suggested Valve Opening 60-65% 55-60% 55-60% 50-55%
9.7-15 11-17 13-19 14-21
START UP
An installation and start-up check list is furnished
with the information package in the blower box. Please use this as a
guide and ll out all sections and return to your distributor.
There are two aeration systems provided within the aeration
chamber; normal aeration and backwash. Normally valves (1 and 3)
are set at 50%. Observe the air ow on each side of the unit to verify
equal ow. If there is an obvious discrepancy in air ow between the
two sides, adjust the valves (1 and 3) so that the ow is equal.
3. Backwash Red Balance Backwash
4. Sludge transfer Gray See Table 3
Table 5 - Backwash Flow Rate Setting
Model ZFL2800 ZFL3200 ZFL3600 ZFL4000
Backwash ow rate
(sec/liter)
Valve open (%) 60-70% 65-75% 60-70% 60-70%
50-70 54-75 58-81 63-89
Figure 14 - Flow Measurement
RECIRCULATION OR
BACKWASH PIPE
CONTAINER
MARKER
Figure 15 - Flow Controlling Valve
© Copyright 2013. All rights reserved.
10
DOTTED
SCALE
SUGGESTED
RANGE
VALVES
RECIRCULATION FLOW ADJUSTMENT
BACKWASH FLOW ADJUSTMENT
The recirculation ow is designed to be 1.2-1.8 times that of the average
inow. Table 4 indicates approximate ow rates for each unit. However,
ne adjustments may be necessary to ensure optimum performance.
Setting the ow rate:
• Adjust the ow using rates in Table 4.
• The ow rate is adjusted by rotating the gray recirculation valve (2)
and observing the ow at the pipe end.
• There are prescribed lines at the outlet of the recirculation pipe to aid
in approximating the correct ow.
Measuring the ow rate:
• The actual ow rates must be measured to verify ow
after adjustment of the valve and observation at the pipe end.
• Measure the time in seconds required to ll a 1000 mL container.
• Compare the time to value ranges in Table 4.
• If necessary, adjust the valve again and collect another sample to
verify the correct ow rates.
It is important not to set the flow rate too high because
it can cause excessive agitation within the first
chamber (Sedimentation Chamber). This could result in poor performance.
In order to prevent plugging in the Aeration Chamber, the backwash
cycle activates at a preset schedule. If there is no backwash cycle or
too short of a backwash cycle, the unit’s performance will be adversely
affected. Likewise, if the backwash cycle is too long, performance will
be compromised.
The backwash cycle begins at 2:00 AM and lasts for ve minutes. One
hour later, another ve minute backwash cycle occurs. Even with these
default settings, the waste water inow could be too low or too high to
optimize the performance and therefore, must be checked during each
inspection.
The backwash cycle and sludge transfer from the Aeration chamber
take place at the same time. Verify that the air ow is uniform across
the Aeration chamber between the two sides during a backwash
cycle. If not, adjust the red backwash valve (3) accordingly.
Setting the ow rate:
• Switch to a manual backwash cycle by pressing the pink "Manual
Backwash" button on the switching valve control pad.
• Set the backwash ow rate by adjusting the gray sludge transfer
valve (4). Use Table 5 to determine the typical setting for each
Fusion® model.
Measuring the ow rate:
• Measure the actual backwash ow rate at the outlet of the sludge
return pipe in the rst chamber the same way the recirculation ow
rate is measured.
• Adjust the gray sludge transfer valve (4) if necessary to obtain the
proper ow.
• Return the switching valve to normal aeration mode by pressing the
pink button on the switching valve's control pad.
SWITCHING VALVE TIMER SETTING
Reset (factory default settings):
1. Press Reset.
Clock is set to 0.00 (midnight).
Backwash Time is set to 2:00 AM.
Backwash Frequency is set to 2 per
day. Backwash Duration is set to 5 mins.
To Adjust Clock & Backwash Settings:
1. Press Mode SW. Note the blinking arrow indicating (hr.) under "Clock"
at the right of the screen.
2. Press Set SW to select the current hour of the day.
3. Press Mode SW. Note the blinking arrow indicating (min.) under
"Clock" at the right of the screen.
4. Press Set SW to select the current minute of the hour.
5. Press Mode SW. Note the blinking arrow indicating Time (hr.) under
"AUTO Back Wash" at the left of the screen.
6. Press Set SW to select the hour that the system will begin to back
wash. (A setting of 2 is standard)
7. Press Mode SW. Note the blinking arrow indicating Freq./Day under
"AUTO Back Wash" at the left of the screen.
8. Press Set SW to select either 1 or 2 back wash cycles that the system
will perform per day. A setting of 2 is standard.
9. Press Mode SW. Note the blinking arrow indicating Duration (min)
under "AUTO Back Wash" at the left of the screen.
10. Press Set SW to select either 5 or 10 minute duration for back wash
cycle. A 5-minute cycle is standard.
NOTE: A 24-hour clock is used in place of AM/PM designations.
Figure 16
© Copyright 2013. All rights reserved.
11
FUSION® OPERATION AND MAINTENANCE
2" RECIRCULATION
RETURN LINE
INLET
2" BACKWASH
RETURN LINE
3/4" AIRLINE ADAPTER
RECIRCULATION
Figure 17 - Inspection details.
The following steps are to be completed during each 6- Month
inspection. All information collected during the inspection is to be
recorded on the Maintenance and Service Report.
Begin the inspection by recording the date, arrival time, weather
conditions, purpose of the visit, water use, model number, serial number,
the presence or absence of a septic tank, and the system owner and
service provider information in the space provided on the report.
GENERAL OBSERVATIONS
1. Are any odors present? Typically there is no odor with
the lids closed, if properly sealed. With lids removed, a
septic or sewer-like odor is indicative of poor treatment and
is common immediately after startup due to hydrogen sulde
and other gases. An active system will have a musty, earthy
smell similar to wet peat moss.
2. Are any insects present? Typically, no insects are present
in the cold weather months. In warmer months, sewage ies
can be found inside risers, on the underside of lids, and larvae
can be found in the scum layer of the sedimentation chamber.
3. Is there evidence of high water? Typically indicated by
a water level above the black wall markings and above the
“0” graduation on the partition wall stickers. May also be
indicated by debris on partition walls.
4. Is there excess foam formation? Foam may be present
during an inspection. Brown foam indicates bacterial buildup
following startup. White foam is due to detergent use. Neither
is a problem if occurring intermittently. Detergent-based foam
will often be accompanied by low transparency readings.
5. Is there residue build-up on piping? Typically indicated
by gray or black residue (dried foam) on aeration chamber
piping.
6. Is there even and vigorous bubbling? Bubbles surfacing
in the aeration chamber should be even across the entire
chamber. If uneven, cleaning steps should resolve this issue.
OUTLET
1" AIRLINE ADAPTER
BACKWASH
SK2801
REQUIRED WATER QUALITY ANALYSES
PART A: Clean Water Storage Chamber – collect samples
from the clean water storage chamber to be used for the following
analyses:
1. pH – Measures the hydrogen ion-concentration and is
determined with the use of the pH test strips included in the
Fusion Maintenance Kit. Dip a test strip into the water sample
for 1 second, remove, and read by comparing to the color chart
provided on the container. A pH = 7.0 is neutral. The range suitable
for biological activity is 6.5 to 7.5. Recurring results outside this
range should be investigated – check the water source for the
home or business, chemical use, etc.
2. NO
3. Transparency – Measures the ability of the water to transmit light.
4. Scum – Very small amounts of scum may accumulate in the
-
N – Determined with the use of the nitrite test strips
2
included in the Fusion Maintenance Kit. Dip a test strip into
the water sample for 1 second, remove, allow to react for 30
seconds and read by comparing to the color chart provided
on the container. Nitrite-nitrogen is an intermediate step in the
oxidation of ammonia to nitrate and the reduction of nitrate. 0
to 3 mg/L is common and 1mg/L is average. The presence of
nitrite is indicative of biological activity. The absence of nitrite
could be due to a young system or a recirculation rate that is
too high. To correct low nitrite readings in established systems,
decrease the recirculation rate.
Using the ladle, ll the transparency tube with a water sample
collected from the clean water storage chamber. Looking down
through the water column, slowly drain the transparency tube
using the valve on the exible hose until you can rst distinguish
between the black and white colors on the secchi disk in the
bottom of the tube. When the secchi disk is visible, close the
valve and read the transparency (in centimeters) on the side.
Dirty water samples transmit less light and result in a lower
transparency. A transparency reading > 20 cm is preferred and
34 cm is average. Low transparency may be due to a lack of
biological activity as in a young system, a recirculation rate that
is too high, or a system inuent high in detergent concentration.
To correct low transparency readings not caused by detergent,
decrease the recirculation rate. Detergent based problems may
require consultation with owner.
© Copyright 2013. All rights reserved.
12
FUSION® OPERATION AND MAINTENANCE, continued
corners on the outlet end of the system. This is normal. Scum,
should not be present elsewhere in the clean water storage
chamber unless the recirculation rate is too high or daily ow
exceeds the design capacity. If present, use ladle to transfer
to sedimentation chamber.
5. Sludge – Test the sludge depth using the sampling device
included in the maintenance kit. The bottom section of the
sampler includes a check valve, which opens as the unit is
lowered into the liquid. When the sampler has reached the
bottom of the chamber and the liquid level equilibrated at surface
level, lift the sampler and this action will set the check valve and
retain the sample in the tubing. Withdraw the sampler and note
the depth of settled solids within the sample. To release the
material in the unit, touch the stem extending from the bottom
section against a hard surface such as the partition wall in the
sedimentation chamber. This opens the check valve to drain
the sample. A range of 0” to 4” is preferred. Typically solids are
brown and well occed. More than 4” (0-102 mm) is typically
due to high recirculation rates and sludge will appear black in
color. To correct sludge depths greater than 4” (0-102 mm),
decrease the recirculation rate and increase the backwash rate.
Sludge Descriptions:
Black – septic or sewer-like odor due to hydrogen sulde and
other gases
Brown – undigested sludge is light brown, becomes darker
with digestion, lightly settled
Clear – may see a clear water layer beneath solids if gas
carries solids upwards
Flocced - settled with texture similar to a tuft of wool
Grainy - gritty or sandy texture
Gray - partially digested sludge
Milky – light in color, cloudy, not transparent
Muddy – typically well settled, often present just after startup,
may be due to inltration
Mustard - an off-color, remnants of digestion are often
yellowish in color
White - sometimes present after new construction often due to
drywall mud
PART B: Anaerobic Chamber - collect samples from the outlet
bafe of the anaerobic chamber to be used for the following analyses:
1. Transparency – A transparency reading more than 20 cm
is preferred.
2. Scum – Should not be present unless recirculation and/or
backwash rate is too high or daily ow exceeds design capacity.
To correct, reduce the recirculation and or backwash rate.
3. Sludge – A range of 0” to 18” (0-46 cm) is preferred. Typically
brown and settled, becomes gray to black as depth and digestion
increases. More than 18” (46 cm) may require a reduction in
recirculation rate. A sludge accumulation of greater than 18” (46
cm) in the anaerobic chamber requires pumping.
PART C: Sedimentation Chamber – collect samples from the
outlet bafe of the sedimentation chamber for the following
analyses:
1. Scum – 0” to 12” (0-30.5 cm) is common, so long as it is not
rising above the partition wall. If so, punch down using ladle.
2. Sludge – A range of 0” to 36” (0-94 cm) is common. Typically
brown and settled, becomes gray or black as depth and
digestion increases. A sludge accumulation of > 36” (94 cm)
in the sedimentation chamber requires pumping.
OPTIONAL WATER QUALITY ANALYSES
PART D: Storage Chamber – samples should be collected as
previously described.
1. NO
2. NH
3. Dissolved oxygen – Follow the instructions included with the
4. Temperature – Most dissolved oxygen meters include a built-
PART E: Anaerobic Chamber – samples should be collected
1. pH – The range suitable for biological activity is 6.5 to 7.5.
2. NO
3. NO
4. NH
5. Dissolved oxygen – Typically < 0.5 mg/L.
6. Temperature – varies with system location.
PART F: Sedimentation Chamber - samples should be collected
1. pH – The range suitable for biological activity is 6.5 to 7.5.
2. NO
3. NO
-
N – Determined with the use of the nitrate test strips
3
included in the Fusion Maintenance Kit. Dip a test strip into
the water sample for 1 second, remove, allow to react for 60
seconds, and read by comparing to the color chart provided on
the container. Nitrate-nitrogen is the nal step in the oxidation
of ammonia. The test strips provided range from 0-50 mg/L.
Average is 7.0 mg/L. No or low nitrate concentrations are
common in systems where nitrifying microbes are absent.
To correct high nitrate concentrations in established systems
increase the recirculation rate.
-
N – Determined with the use of the ammonia test strips
3
included in the Fusion Maintenance Kit. Dip a test strip into the
water sample and move up and down for 30 seconds, remove,
allow excess water to drain, allow to react for 30 seconds, and
read by comparing to the color chart provided on the container.
Ammonia-nitrogen is measured using low range test strips,
0-6 mg/L. Average is 3.0 mg/L. Low ammonia readings are
desirable and require no changes. To correct high ammonia
readings decrease the recirculation rate.
dissolved oxygen meter. D.O. should be measured 25 inches
(635 mm) below the water level. Average is 2.0 mg/L.
in thermometer which can be used to measure temperature.
Varies with system location.
and analyses performed as previously described.
Recurring results outside this range should be investigated
– water source for the home or business, chemical use, etc.
-
N – < 3.0 mg/L is common for this chamber. Adjustments
2
should be based on water quality in the clean water storage
chamber.
-
N – < 2.0 mg/L is common for this chamber. Adjustments
3
should be based on water quality in the clean water storage
chamber.
-
N – Ammonia-nitrogen in this chamber is typically < 20.0
3
mg/L. If this test is desired, it should be conducted with test strips
suitable for the expected concentration. Adjustments should
be based on water quality in the clean water storage chamber.
and analyses performed as previously described.
Recurring results outside this range should be investigated
– water source for the home or business, chemical use, etc.
-
N – < 2.0 mg/L is common for this chamber. Adjustments
2
should be based on water quality in the clean water storage
chamber.
-
N – < 2.0 mg/L is common for this chamber. Adjustments
3
should be based on water quality in the clean water storage
chamber.
4. NH
© Copyright 2013. All rights reserved.
-
N – Ammonia-nitrogen in this chamber is typically
3
13
BRUSH
FUSION® OPERATION AND MAINTENANCE, continued
< 30 mg/L. If this test is desired, it should be conducted
with test strips suitable for the expected concentration.
Adjustments should be based on water quality in the
clean water storage chamber.
5. Transparency – Typically < 15 cm. Adjustments should be
SYSTEM DIAGRAM
Refer to sections on the following pages for detailed maintenance item descriptions.
ANAEROBIC CHAMBER
1. Scum
2. Sludge accumulation
3. Abnormal water level
SEDIMENTATION CHAMBER
1. Inflow pipe
2. Odor with manhole closed
3. Scum
4. Sludge accumulation
5. Abnormal water level
6. Insects
7. Excess amount of oil and fat
Figure 18
8. Trash accumulation
based on water quality in the clean water storage chamber.
6. Dissolved oxygen – Typically < 0.5 mg/L.
7. Temperature – varies with system location.
AERATION CHAMBER
1. Aeration
2. Foam formation
3. Abnormal water level
STORAGE CHAMBER
1. Scum
2. Sludge accumulation
3. Formation of micro
organisms
4. Transparency
5. Nitrite
6. pH
AERATION CHAMBER CLEANING
1. Aeration.
The aeration system must be ushed every maintenance
visit. There are two ushing methods; (A) Air ushing
and (B) Water ushing. Air ushing must be done every
maintenance visit. Water ushing must be done if there is
a sign of clogging in the Aeration Chamber (e.g. abnormal
increase in recirculation ow).
(A) Air ushing procedure:
• Close gray recirculation valve (2) all the way. (0%)
• Rotate blue aeration valve (1) back and forth from the
0% to the 100% position several times to ush.
• Set valves (1) and (2) back to the appropriate positions.
(See Recirculation Flow Adjustment, pg. 10)
(B) Water ushing procedure: (See Fig. 20)
• Make sure that the blower is off.
• Close valve (2) all the way.
• Connect a water line to the aeration line after the
switching valve, as shown in Fig. 20.
BACKFLOW
FAUCET
Figure 20
PREVENTER
WATER
EXISTING
AIR LINE
HOSE
BLOWER
CLAMP
.
TO TREATMENT UNIT
CLEAN OUT
AIR LIFT
PUMP
• Gradually open the water faucet and
introduce water into the system.
• Rotate valve (1) back and forth from the
0% to the 100% position several times
to ush.
• Turn off the water, remove the water line,
and reconnect the airline to the blower.
• Set valves (1) and (2) back to the
appropriate positions.
(See Recirculation Flow Adjustment, pg. 10)
Figure 19
(C) Cleaning the recirculation line:
• Open the gray recirculation valve (2) to 100%.
• Flush water through the recirculation line for several seconds.
• Turn off the recirculation by rotating the gray valve (2) to 0%.
• Make sure that the blower is off. Allow the system to relax
for a few seconds.
• Repeat this cleaning method three times.
• A hose or brush can also be used to clean the
recirculation line. See Figure 21.
• Reset the gray valve (2) to its original position.
CLEAN OUT
BRUSH
BRUSH
Figure 21
© Copyright 2013. All rights reserved.
14
ALARM PANEL & BLOWER INSPECTION AND MAINTENANCE
Inspect the alarm panel for signs of water or odors inside. Toggle the
test switch on the side of the box to check that both the alarm horn and
the alarm beacon light are operational.
Inspect the blower and switching valve for proper operation. If the
blower is not functioning, refer to the troubleshooting section near the
end of this guide.
1. Listen for any loud rattling sounds. The blower should hum softly.
If a rattle is heard, ensure that all four legs securely contact the
ground or base medium.
RECOMMENDED METHODS FOR COLLECTING EFFLUENT SAMPLES
Proper efuent sample collection technique is essential for obtaining
an accurate assessment of treatment efciency. To accurately interpret
treatment efciency, inuent as well as efuent samples should be
collected. In the event of reduced efciency, inuent composition can
be useful in determining system owner practices. Depending upon
conguration, efuent samples can be collected at:
1. Disposal pump tank downstream of the Fusion
2. Fusion® discharge chamber
3. Distribution Box downstream of the Fusion®
®
2. Inspect the lter once the power has been disconnected by
removing the lter retention screw. Then, remove the cover by
snapping the lter cover off the top of the blower. Clean the
lter by knocking the dust out or by rinsing with water to remove
accumulated particles. Be sure the lter is dry before reinstalling.
*
Samples should be obtained in clean, one liter bottles. Bottles should be
labeled appropriately to denote the sample’s original location and kept
on ice during transport. Samples should be collected to approximate
daily residential sewage ow. When opening the Fusion® lid during
sampling, try not to disturb the unit. Also, do not collect the efuent
sample from the wall of the tank.
For further information, reference procedure identication number
SOP-F-103, Clarus Environmental, 1-800-928-7867.
* Consult local rules and regulations to determine jurisdictional efuent
sampling requirements.
TROUBLESHOOTING
1. Odor
Offensive odors are often the result of insufcient or inappropriate
bacterial growth. Causes may include a young or unestablished
system, insufcient air introduction, or the addition of detrimental
chemicals or poisons into the system. Ensure the blower and
air delivery systems are functioning. Check with the homeowner
regarding chemical use and disinfection habits. Check all risers
and lids to ensure an airtight seal.
2. Foam Formation
Foam formation is observed in the following situations:
a) In the early stage of operation when the
aerobic bacteria colony is establishing itself,
b) when an excess amount of air is supplied for aeration,
c) when the difference between ambient
temperature and water temperature is great, and
d) when an excessive amount of detergent is
introduced.
In most cases, foam will disappear with proper operation. When
excessive amounts of detergent have been introduced to the
system, remind the homeowner to use appropriate amounts of
detergent.
3. Cloudy Treated Water
• Check the amount of scum and sludge: If too much scum or
sludge is observed, transfer them to the rst chamber and adjust
recirculation ow rate, frequency and duration. (See backwash
ow adjustment, pg. 10)
• Check the aeration situation:
If uneven bubble generation is observed, adjust valve (1). If
aeration is weak, ush the aeration pipe with air or water.
• Check the recirculation ow rate:
If the recirculation ow rate has increased
after the last inspection the aeration pipe may
be clogged. Flush the aeration pipe with air or
water. If the recirculation ow rate has decreased after the
last inspection, the airlift pump or recirculation pipe may be
clogged. Clean them with a brush and running water.
4. Blower
Blower Motor Does Not Run, with Power Connected:
• Check the electric supply to the panel, ensuring 120 volt
to blower power.
• Check that all breakers and fuses in the panels are on or intact.
Little or No Aeration:
• Check the blower motor is running.
• Check the air line piping connectons at the blower and
switching valve.
• Check the air lter and clean or replace if necessary.
• Check the diaphragms and replace if necessary.
• Check the air piping for leaks, clogs, or dislocations and x
accordingly.
• Verify check valves (if installed) in supply lines are installed
correctly.
© Copyright 2013. All rights reserved.
15
INSPECTION AND MAINTENANCE - PUMPING AS NEEDED
Perform all inspection procedures listed in 6-month inspection. Pump out sludge in the rst and second chambers (if necessary).
If the maximum sludge accumulation has been reached, see description in 6-month inspection.
Make sure to remove the scum on top layer rst, then pump out the sludge of each chamber.
Step 1: Remove the scum.
Vacuum
1) 2)
Sedimentation/separation tank
Figure 22 - Pump out procedures
ATTENTION: Remove the scum rst. If you remove the sludge rst, the water
level will decrease and the anaerobic lter will be blocked by the scum.
Step 2: Remove the sludge
Step 1: Remove the scum.
Vacuum
1)
Anaerobic lter tank
Figure 23 - Cleaning of anaerobic lter tank, remove all scum and sludge.
Step 2: Remove the sludge
on the lter media.
2)
© Copyright 2013. All rights reserved.
16
Step 3: Remove the sludge
under the media while washing
the lter with tap water.
3)
Tap water
TECHNICAL SPECIFICATIONS
Chambers
Actual Values
Volumes (Gallon)
Model Number
Clarus P/N
Sedimentation Chamber (Gallons) 1118 1257 1394 1551
Anaerobic Chamber (Gallons) 1146 1269 1404 1560
Aeration Chamber (Gallons) 527 569 609 673
Storage Chamber (Gallons) 241 261 297 330
Total (Gallons) 3032 3356 3704 4114
Inow in Gallons/Day 2800 3200 3600 4000
Size: Width in Inches 84 89 93 96
Length in Inches 176 180 185 186
Height in Inches 94 94 96 100
Weight in Pounds 2425 2866 3307 3748
Lids and Access
24" Diameter 3 3 3 3
26.5" x 45" 1 1 1 1
ZFL-2800 ZFL-3200 ZFL- 3600 ZFL- 4000
5250-0027 5250-0029 5250-0031 5250-0033
Blower Details
Alita AL-250 120 3.7 46 200 41.5
Alita AL-300 120 4.3 47 300 48.8
Switching Valve (P/N 151438) 100
®
Fusion
Size
ZFL2800 14' 8" 7' 0" 7' 10" 6' 1" 5' 7"
ZFL3200 15' 0" 7' 5" 7' 10" 6' 1" 5' 7"
ZFL3600 15' 5" 7' 9" 8' 0" 6' 3" 5' 9"
ZFL4000 15' 6" 8' 0" 8' 4" 6' 7" 6' 1"
Voltage Amps Sound (dB)
Length Width Height I (Inlet)
Air Flow
(L/min.)
Weight
E
(Outlet)
Blower Information
Alita AL-250 1 1
Alita AL-300 1 1
Switching Valve (P/N 151438) 1 1 1 1
Air Line Size(s)
3/4" Recirculation 1 1 1 1
1" Backwash 1 1 1 1
Inlet/Outlet Information
Inuent Invert (inches) 21 21 21 21
Efuent Invert (inches) 28 28 28 28
Inlet/Outlet Pipe Size (Inches) 4 4 4 4
© Copyright 2013. All rights reserved.
17
NOteS
© Copyright 2013. All rights reserved.
18
NOteS
© Copyright 2013. All rights reserved.
19
Your Peace of Mind is Our Top Priority
®
3649 Cane Run Rd. • Louisville, KY 40211-1961 • 877-244-9340 • FAX: 877-414-4316
www.clarusenvironmental.com
© Copyright 2013. All rights reserved.
Loading...