Clarus Environmental 450, 600, 800 User Manual

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Page 1

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

Thank you for choosing a Fusion® Series Treatment System. High quality workmanship and easy maintenance have been incorporated into the Fusion® system. The system will provide years of trouble-free 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 1-877-244-9340.

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: C3.10.140

CL0056

0612

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 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

Excavation and Installation .............................. 6

Start Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Blower Timer Setting .................................. 11

Operation and Maintenance ............................12

Aeration Chamber Cleaning ............................14

Fusion® Pumping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Troubleshooting ...................................... 16

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 God; 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.

Fusion® Model:  ZF-450  ZF-600  ZF-800

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 specic legal rights and you may also have other

rights which vary from state to state.

Page 2

HOW A FUSION® SERIES TREATMENT SYSTEM WORKS

The Fusion® is simple in design, yet advanced in its wastewater

treatment ability. The design has been rened over many years

of intense research and development in an effort to perfect this superior treatment system. Fusion

systems are 90% -

95% efcient at treating wastewater. This is nearly twice as

effective as a traditional septic tank, which is approximately

50% efcient. This high degree of treatment helps to protect

both your personal property and the environment.

The Fusion oxygen) and aerobic (with oxygen) biological processes to treat wastewater. As wastewater enters the Fusion

Figure 1 - The following diagram will help you to better understand the process:

utilizes a combination of anaerobic (without

, it is broken

down and becomes food for biological organisms operating

within the unit. The rst chamber serves to separate 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 benecial 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 efuent leaving the system will have been treated to secondary quality efuent and

will average *9 mg/L CBOD5 and 9mg/L TSS.

* Based on NSF Standard 40 testing.

Recirculation Line

Inlet Pipe 4” PVC

SCH 40 (DN 100)

Sludge Return Line

Storage Chamber

Outlet Pipe 4” PVC

SCH 40

(DN 100)

Tank - Compression

Molded Fiber Reinforced Plastic

Sedimentation Chamber -

Separates bulk solid

and grease waste

Figure 2 - Schematic diagram of the Fusion

Re-circulation

Inflow

Baffle

Sludge return

Baffle

Backwash

Top View

Treatment System

Air-lift Pump

Effluent

Air-lift Pump

Aeration

Blower

Anaerobic Chamber -

Organisms adhere to xed lm

media and digest waste

Recirculation

6 “ (152 mm) stone or concrete pad

Wall opening

G.L.

W.L

Inflow

Baffle

Aeration Chamber Floating/Circulating Filter Media -

“Fluidized Bed”

Invigorates aerobic bacteria

W.L

Recirculation

Side View

W.L

Backwash Mechanism

G.L.

Baffle

Wall opening

Effluent

Page 3

P R E L I M I N A RY

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 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, cylindrical lter media 0.6 inch diameter

Figure 3 - Treatment Flow of the Fusion® System.

Back-Wash

(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

Sedimentation Chamber

Anaerobic Chamber

Recirculation

Aeration Chamber

Storage Chamber

Effluent

SYSTEM COMPONENTS

The complete wastewater treatment system will typically consist of the Fusion

disposal of the liquid efuent. 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 11 for a typical Fusion 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.

The Fusion® treatment unit comes with an electronic, dual-

port blower designed specically for use with this system. The

blower utilizes a linear motor and two diaphragms to generate

the air ow necessary to aerate and recirculate water within the system. This style of compressor is quieter and more efcient

than traditional rotary vane compressors. Once installed and adjusted, circuitry within the blower will automatically switch the unit from normal recirculation mode to backwash mode and back again when appropriate. In the event of a power outage, the blower will stop, but a backup battery within the unit will retain the correct time and backwash settings.

treatment components and a soil absorption eld for nal

system. Variations to the typical system

THE FUSION

DUAL-PORT BLOWER

Figure 4

Certified to

NSF/ANSI

Standard 40

Class 1

Performance

Designation

NSF STANDARD 40, CLASS 1,

CERTIFICATION MARK

The NSF mark displayed here will be on all NSF Standard

40, Class 1 certied Fusion systems. The Fusion ZF-450, ZF-600 and ZF-800 will have the mark displayed on the alarm panel. Systems not NSF

Standard 40, Class 1 certied,

will not display the mark.

models

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DATAPLATE

A dataplate similar to the one in Figure 5 is located on the blower housing and the alarm panel. There is important information about the Fusion number, serial number, and hydraulic capacity. Please make a note of this information for future reference or in case you should need to contact your Fusion® maintenance provider.

The contracting installer must mark the installed model number on the dataplate, the blower housing and the alarm control panel.

on the dataplate, such as the part number, model

Figure 5

FU SI ON T REA TMEN T SYS TEM

□

ZF 450

ZF 600

□

ZF 800

□

MFG．DATE： 09/07

Manufacturer:

BL OWE R SER VI ＣE P AR TS

P/N 018860-B

450

GALLONS/DAY

600GALLONS /DAY

800GALLONS /DAY

Clarus Environmental • 3649 Cane Run Road Louisville, KY 40211•1-877-244-9340

COMPLETE BLOWER: P/N 019617

BLOWER DIAPHRAGM: P /N 018848

BLOWER FILTER: P/N 018849

toll free

Certified to NSF - ANSI

Standard 40

ALARM PANEL

The Fusion® comes with an alarm panel (see Figure 6) that is designed to activate an 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 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)

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.

SYSTEM CARE

The Fusion with little direct maintenance from the owner. Periodically, a check of the 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 trafc. 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

Figure 6

Figure 7

120 VAC

INCOMING

POWER

GND

BLOWER

FUSION DATAPLATE

TB2

RED BEACON

WARNING!

SILENCE/TEST SWITCH

P/N

BUZZER

2 3 4 5 6 7 8

DISNF

ALARM

HIGH WATER

*FOR ILLUSTRATION PURPOSES ONLY* REFER TO SCHEMATIC LOCATED IN PANEL FOR INSTALLATION

sk2649

GND LUG

ALARM

sk2933

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

efciency. 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.

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.

LEAKY FIXTURES

It is very important to monitor all water xtures in the home for leaks

and drips and repair them immediately. Leaks can cause tremendous water use and use may hydraulically overload your Fusion® system and

reduce its treatment efciency. Excessive water use may also overload your soil absorption eld and cause failure.

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.

Page 5

P R E L I M I N A RY

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 efciency or stop the treatment process by reducing or destroying the benecial 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 concerning the use of any of these substances, please contact your Fusion

substance on the “Do Not List” into the Fusion the warranty.

DO NOT introduce the following substances into the Fusion

• Motor oil • Antifreeze

• 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 the minimum quantities of these substances as recommended by the manufacturer.

• Liquid laundry bleach only as needed per load

• Liquid laundry detergents without added bleach

• Liquid dishwashing detergents

• Household cleaners

treatment system. If you have any questions

maintenance provider. The introduction of any

- THE DO NOT LIST -

treatment system:

treatment process. You should always use

will void

EFFLUENT QUALITY

Fusion be installed in a typical residential/light commercial environment.

The nal efuent leaving the system will typically be treated to the

secondary quality strength of *9 mg/L CBOD5 and 9 mg/L TSS.

If water softners 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.

Series systems are compact, efcient, and designed to

Based on NSF/ANSI Standard 40 testing.

WATER SOFTENERS

INITIAL SERVICE POLICY

The Fusion® models ZF-450, ZF-600, and ZF-800 (NSF Standard 40, Class 1 certied systems) have a two-year service policy included in the initial purchase price. The service policy will include two inspections per year for a total of four inspections. During these inspections, numerous system checks and adjustments will be made to ensure proper operation.

EXTENDED MAINTENANCE POLICY

An extended maintenance policy is available for purchase from your authorized Fusion policy will include the same system checks, schedule, and adjustments as the initial maintenance policy. Please contact your Fusion information regarding the extended maintenance policy.

distributor or maintenance provider for further

distributor. The extended maintenance

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 deciencies with your Fusion the maintenance provider will notify the owner in writing when the

deciencies will be corrected. If the maintenance provider does not correct the deciencies or the service calls are not completed,

please contact Clarus Environmental at 1-877-244-9340.

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 by removing the screw from

the cap and then pulling on the sides of the top of the blower.

Remove the foam 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 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.

. It may be

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 efciency to decrease. During a

power outage, the Fusion 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

soil absorption eld. If you have a system such as this,

please be aware of this condition and conserve water accordingly.

, which requires power to pump the efuent to the

will still allow efuent to ow, and

Page 6

EXCAVATION AND INSTALLATION

1. Excavate an area large enough for the Fusion® Series unit to be installed. See Figure 8 and Table 3 for the actual dimensions of the unit. Excavation dimensions are calculated by adding 12-18" (305-457 mm) to the length and width of the Fusion

will allow sufcient room for proper backlling.

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).

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 9).

5. Check unit to make certain it is level by placing a level at several locations on the riser. (riser covers removed) (Figure 9).

. This

BACKFILLING

1. If groundwater is present, anti-otation measures must be used to stabilize the unit prior to backlling. 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 backlling. 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. If necessary, install riser extensions on the adapter rings

prior to backlling. See Table 1 for number and size of

access opennings. Riser extensions are available for deeper burial. Make certain risers are sealed properly and watertight.

4. Apply two beads of silicone fully around each riser section prior to securing with supplied screws.

5. Install riser covers.

6. Backll 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.

7. Tamp soil around perimeter of the unit as it is backlled to stabilize the unit and to reduce settling.

8. Finalize backll 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.

is 36 inches (914 mm).

Table 1

Number aND size of access opeNiNgs iN fusioN

20" (51 cm) Diameter

24" (61 cm) Diameter

®.

MAXIMUM soil burial depth over the unit

series

ZF-450 ZF-600 ZF-800

0 1 1

2 2 2

COLD WEATHER INSTALLATION

When installing Fusion® in cold climates, the designer should specify insulated lids and risers from the factory. These are available as an option to the standard lids and risers. In addition, 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. 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 required. Please consult a design engineer, soil scientist or other

qualied 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 Backlling Section

items 1-4 to properly ll the Fusion

risers if needed.

3. Refer to Figure 10, Anchoring Schematic to determine

the minimum amount of backll 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 specied dimensions

to fully engage the mid-seam of the Fusion 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.

5. Allow the concrete to harden before nal backlling.

6. Complete the procedures outlined in the Backlling Section,

items 5-8.

sits on, anchoring is

with water and add

, which will

Table 2

FUSION® DIMENSIONS

SYSTEM L W H I E

Fusion

450 7'-1" (2.2 m) 3'-8" (1.1 m) 5'-2" (1.6 m) 4'-4" (1.3 m) 3'-10" (1.2 m)

Fusion

600 8' (2.4 m) 4'-1" (1.2 m) 5'-6" (1.7 m) 4'-8" (1.4 m) 4'-2" (1.3 m)

Fusion

800 8'-3" (2.5 m) 4'-8" (1.4 m) 6'-2" (1.9 m) 5'-4" (1.6 m) 4'-10" (1.5 m)

Figure 8- Dimensions

INLET

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

sk2624

Page 7

P R E L I M I N A RY

Figure 9, Lifting & Positioning

4-POINT LIFTING

LEVEL ACROSS TOP OF UNIT

LESS THAN 60°

LIFTING

60°

LIFTING HOOK

Figure 10, Concrete Anchoring

CONCRETE ANCHOR

COLLAR

MIN. REQUIRED

BACKFILL

UNIT SIZE Z

ZF-450

ZF-600

ZF-800

18"

19"

21"

ADAPTER RING

LEVELING

Table 2 - Concrete Anchoring Dimensions

sk2931

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)

ZF-450 1' - 4" 2' - 0" 72 3 1' - 2" 2' - 0" 62 3 1' - 1" 2' - 0" 56 3 1' - 0" 2' - 0" 51 2 ZF-600 1' - 6" 2' - 0" 91 3 1' - 4" 2' - 0" 79 3 1' - 3" 2' - 0" 73 3 1' - 2" 2' - 0" 68 3 ZF-800 1' - 8" 2' - 0" 109 4 1' - 7" 2' - 0" 102 4 1' - 5" 2' - 0" 90 4 1' - 4" 2' - 0" 84 4

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)

ZF-450 1' - 0" 2' - 0" 51 2 1' - 0" 2' - 0" 51 2 1' - 0" 2' - 0" 51 2 ZF-600 1' - 1" 2' - 0" 62 3 1' - 1" 2' - 0" 62 3 1' - 0" 2' - 0" 57 3 ZF-800 1' - 3" 2' - 0" 78 3 1' - 2" 2' - 0" 72 3 1' - 1" 2' - 0" 66 3

Page 8

Figure 11, Typical Fusion® Layout

WARNING!

CLEAN - OUT

SEWER LINE

FUSION CONTROL PANEL

AIR LINE

BLOWER

RISER AND LID

TO DRAIN FIELD

OPTIONAL SEPTIC TANK INSTALLATION MAY BE REQUIRED BY LOCAL OR STATE REGULATIONS

BLOWER INSTALLATION AND PLACEMENT

1. The blower 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 inundation. Also make certain the location has good ventilation.

4. Install the blower on a foundation that is level and solid.

5. Excavate trenches for two air lines from blower to the unit.

6. Install two separate 1/2" (13 mm) air lines from the blower to the unit. Length of piping must be less than 17' (5 m). If distances from 17' (5 m) to 33' (10 m) are required, use 3/4" (19 mm) diameter piping (Figure 12). If longer air lines are needed, consult the factory.

7. The blower is provided with two discharge ports. The blower label is color-coded with the aeration outlet port being BLUE and the backwash outlet port being RED (Figure 12).

8. The air port inlets on the Fusion for backwash (Figure12).

9. Attach the barbed end of each PVC tee (included in the blower box) to the blower using the rubber elbows (Figure 12).

10. Attach the small diameter black air tubing (included in the blower box) to barbed tting on PVC tee. Black air tubing and blower power cord should be routed to the alarm panel through conduit. Attach the two black air tubing lines to the two air pressure

sensor barbed ttings in the alarm panel (Figure 12).

11. Connect the remaining end of each PVC tee to the airlines installed in Step 6.

are also color-coded, BLUE for aeration and RED

FUSION

RISER CONFIGURATION

DECORATIVE ROCK CONFIGURATION

INTERIOR CONFIGURATION

RED AIR

LINE

POWER

CORD

AIR LINE

TO PANEL

ADAPTER

sk2650

BLOWER

TO PREVENT ELECTRICAL SHOCK FROM BACK-SIPHONING, LOCATE THE PUMP ABOVE THE WATER LEVEL.

Figure 12

BLUE AIR

LINE

RED AIR LINE

CONDUIT TO

PANEL

TO PANEL

AIR LINE

BLUE AIR LINE

sk2639

RUBBER ELBOWS

Page 9

P R E L I M I N A RY

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, oor 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 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 bafe of the anaerobic chamber.

1. The oat switch should be tethered to one of the gray,

2. Place the cord into the clamp and secure to gray aeration

3. Position the oat with a 3" (76 mm) tether.

4. Tighten the clamp with a screwdriver. Be careful not

5. Make sure the oat cord is not allowed to touch the

6. The oat switch cord should be installed in an electrical

7. A ½" (13 mm) bulkhead tting (supplied by others)

8. Please be certain that the bulkhead tting for the

9. Electrical conduit from the Fusion

10. The control switch can be wired directly into the alarm

unit. The switch should be tethered to one of

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 bafe.

pipe. NOTE: Do not install the cord under the clamp.

to overtighten as this may cause damage to the plastic clamp.

excess clamp band during operation as this may cause damage to the cord.

conduit connecting the alarm panel to the Fusion The electrical conduit must be rated for burial, and should be properly sealed to prevent gases from entering the alarm panel.

should be used to connect the electrical conduit to the

Fusion the Fusion

ttings to facilitate this connection.

electrical conduit forms a watertight connection with the FRP wall of the Fusion

panel can be buried in the same trench as the air lines.

panel. See Figure 7.

unit. A hole must be drilled through the wall of

unit between the red and blue bulkhead

unit.

unit to the alarm

unit.

ELECTRICAL CONNECTIONS

the 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 Figure 7 and 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 hrs. 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 36-hour time frame.

All electrical installations must follow

START UP

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.

Figure 13- Aeration Flow Adjustment

Valve Legend:

1. Aeration Blue 3. Backwash Red

2. Recirculation Gray 4. Sludge transfer Gray

There are two aeration systems provided within the aeration chamber: normal aeration and backwash. 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.

An installation and start-up check list (CL0057)

Page 10

RECIRCULATION FLOW ADJUSTMENT

BACKWASH FLOW ADJUSTMENT

The recirculation ow is designed to be 1.2-1.8 times that of the average design inow. Table 4 indicates starting 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 1L

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 of the media 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 inow could be too low or too high to optimize

the performance and therefore, must be checked during each inspection. The backwash initiation time can be set for any time during a 24-hour period to accomodate unusual water use patterns. The goal is to set the time when there is no

ow into the unit.

The backwash cycle and sludge transfer from the Aeration Chamber takes 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 blower control pad.

• Set the backwash ow rate by adjusting the gray sludge transfer valve (4). Use Table 5 to determine the 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 blower to normal aeration mode by

pressing the pink button on the blower's control pad.

Table 4 - Recirculation Flow Rates

Model ZF450 ZF600 ZF800

Recirculating ow rate

(sec/liter)

Suggested Valve Opening 35-40% 30-35% 30-35%

Figure 14 - Flow Measurement

RECIRCULATION OR BACKWASH PIPE

CONTAINER

29-45 21-32 14-22

MARKER

Table 5 - Backwash Flow Rate Setting

Model Frequency ZF450 ZF600 ZF800

Backwash ow rate

(sec/liter)

Valve open (%) Twice/day 50-55 40-45 40-45

Figure 15 - Flow Controlling Valve

Twice/day 7-10 5-7 4-6

DOTTED

SCALE

SUGGESTED

RANGE

VALVES

Page 11

P R E L I M I N A RY

Figure 16

BLOWER TIMER SETTING

Reset (factory default settings):

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.

Page 12

FUSION® OPERATION AND MAINTENANCE

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 (CL0059). 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? There should be 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 sulde and other gases. A

well-operating 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.

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 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

N – Determined with the use of the nitrite test strips

included in the Fusion 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.

Maintenance Kit. Dip a test strip into the

Maintenance Kit. Dip a test strip

3. Transparency – Measures the ability of the water to

transmit light. 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

inuent 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.

4. Scum – Very small amounts of scum may accumulate

in the 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 sulde

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 inltration

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 bafe of the anaerobic chamber to be used for the

following analyses:

Page 13

P R E L I M I N A RY

FUSION® OPERATION AND MAINTENANCE, continued

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 15” (0-38 cm) is preferred.

Typically brown and settled, becomes gray to black as depth and digestion increases. More than 15” (38 cm) may require a reduction in recirculation rate. A sludge accumulation of greater than 24” (61 cm) in the sedimentation and 15” (38 cm) in the anaerobic chamber requires pumping.

PART C: Sedimentation Chamber – collect samples

from the outlet bafe 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 24” (0-61 cm) is common.

Typically brown and settled, becomes gray or black as depth and digestion increases. A sludge accumulation of > 24” (61 cm) in the sedimentation chamber and 15” (38 cm) in the anaerobic chamber requires pumping.

OPTIONAL WATER QUALITY ANALYSES

PART D: Clean Water Storage Chamber – samples should be collected as previously described.

1. NO

2. NH

strips 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.

N – Determined with the use of the nitrate test strips

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 7.0mg/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

3. Dissolved oxygen – Follow the instructions included

with the dissolved oxygen meter. D.O. should be measured 25 inches (635 mm) below the water level. Average is 2.0 mg/L.

4. Temperature – Most dissolved oxygen meters include a built-in thermometer which can be used to measure temperature. Varies with system location.

PART E: Anaerobic Chamber – samples should be collected and analyses performed as previously described

1. pH – The range suitable for biological activity is 6.5

to 7.5. Recurring results outside this range should be investigated – water source for the home or business, chemical use, etc.

2. NO

3. NO

4. NH

N – < 3.0 mg/L is common for this chamber.

Adjustments should be based on water quality in the clean water storage chamber.

N – < 2.0 mg/L is common for this chamber.

Adjustments should be based on water quality in the clean water storage chamber.

N – Ammonia-nitrogen in this chamber is typically <

20.0 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. Dissolved oxygen – Typically < 0.5 mg/L.

6. Temperature – varies with system location.

PART F: Sedimentation Chamber - samples should be

collected and analyses performed as previously described.

1. pH – The range suitable for biological activity is 6.5

to 7.5. Recurring results outside this range should be investigated – water source for the home or business, chemical use, etc.

2. NO

3. NO

4. NH

N – < 2.0 mg/L is common for this chamber.

Adjustments should be based on water quality in the clean water storage chamber.

N – < 2.0 mg/L is common for this chamber.

Adjustments should be based on water quality in the clean water storage chamber.

N – Ammonia-nitrogen in this chamber is

typically < 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 based on water quality in the clean water storage chamber.

6. Dissolved Oxygen – Typically < 0.5 mg/L

7. Temperature – Varies with system location

Figure 17 - Inspection details

RECIRCULATION SYSTEM

1. Measure the recirculation flow

2. Cleaning

BACKWASH SYSTEM

1. Measure the current backwash flow

2. Cleaning

3. Alternating backwash time and frequency

BLOWER AND CONTROL PANEL

1. Power failure

2. Blower timer setting

3. Noise and vibration

4. Air filter replacement

5. Diaphragm replacement

Page 14

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 may be done if there is

a sign of clogging in the Aeration Chamber (e.g. abnormal

increase in recirculation ow).

Figure 18

FAUCET

BACKFLOW PREVENTER

WATER

BLOWER

EXISTING AIR LINE

HOSE

CLAMP

TO TREATMENT UNIT

(A) Air ushing procedure:

• Make sure the blower is in the aeration mode.

• 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 Figure 18)

• Make sure the blower is off.

• Close valve (2) all the way.

• Connect a water line to the aeration line as shown in Fig. 18.

• 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)

• Make sure the blower is in the aeration mode. If not,

change the mode by pressing the Manual Backwash button.

• 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 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 20.

• Reset the gray valve (2) to its original position.

2. Backwash

The backwash system must be ushed every maintenance 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:

Figure 19

• Make sure the blower is in the

backwash mode.

• Close the gray sludge transfer

valve (4) all the way.

• Rotate the red backwash valve

(3) back and forth from the 0% to the 100% position several

times to ush.

• Set valves (3) and (4) back to

the appropriate positions.

(See Backwash System) (B) Water ushing procedure: (See Fig. 19)

• Make sure the blower is off.

• Close valve (4) all the way.

• Connect a water line to the backwash airline as shown in

Figure 16.

• Gradually open the water faucet and introduce water into

the system.

• Rotate valve (3) 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 (3) and (4) back to the appropriate positions.

(See Backwash System)

• Make sure that the blower is in the backwash mode. If

not change the mode by pressing Manual Backwash.

• Open the gray sludge transfer valve (4) to 100%.

• Flush water through the sludge transfer line for a few

seconds.

• Repeat this cleaning method three times.

• A hose or brush can also be used to clean the sludge

transfer line. See Figure 20.

• Reset the gray valve (4) to its original position.

• Return the blower to the normal aeration mode. by

pressing Manual Backwash.

Figure 20

BRUSH

3. Foam formation

Make sure there is not an excess amount of foam on the

surface. If excessive foam is present it may indicate high detergent usage. Meet with owners to inform and educate them concerning excessive use.

4. Abnormal water level

If the water level exceeds the partition wall, clean the

plastic cage rst with a brush, then check for possible clogging in the lter media section. Clogs may be cleared

by using a manual backwash tool. The manual backwash tool may also be used to eliminate a clog in the anaerobic chamber media as well.

Page 15

P R E L I M I N A RY

FUSION® PUMPING

Wastewater entering the Fusion® contains organic and inorganic materials. If organic in nature, it is treated and decomposed by microorganisms during the treatment process. If inorganic in nature, it will be stored within the Fusion

accumulate as scum (oating) or sludge (solids on the bottom) and must be removed periodically to ensure the performance of

the Fusion scum and sludge have been reached and pumping is required. Follow the procedures in Figures 21 and 22 to remove scum and

sludge from the sedimentation and anaerobic chambers only. When nished, rell both chambers with clean water to prevent the possibility of otation.

Figure 21 - Sedimentation Chamber Pumping

. Please review the Operation and Maintenance sections part B and C to determine when the maximum depths of

Step 1: Remove the scum. Step 2: Remove the sludge

Step 3: Remove the sludge under the media while washing the lter with tap water.

Vacuum

1) 2)

. The stored materials

Sedimentation-separation tank

Figure 22 - Anaerobic Chamber Pumping

Step 1: Remove the scum.

Anaerobic lter tank

Vacuum

: 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.

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 for proper operation. If the blower is not functioning, refer to the troubleshooting section near the end of this guide.

1. Listen for 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.

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.

Step 2: Remove the sludge

on the lter media.

3. Ensure the correct time is shown on the blower's display screen, keeping in mind that the display shows a 24-hour clock (not AM/PM).

4. Press the Manual Backwash button and ensure the unit switches into backwash mode by observing the change in water ow in the Fusion return line to the sludge transfer line. Be sure to switch the system back to recirculation by pressing the Manual Backwash button again.

Tap water

tank from the recirculation

Page 16

TROUBLESHOOTING

1. Odor

Offensive odors are often the result of insufcient or

inappropriate bacterial growth. Causes may include

a young or unestablished system, insufcient 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 owner 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:

1. In the early stage of operation when the aerobic bacteria colony is establishing itself.

2. When an excess amount of air is supplied for aeration.

3. When the difference between ambient temperature and water temperature is great.

4. 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 owner 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 as well as backwash time, frequency and duration.

(See backwash ow adjustment)

• 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.

• Check the color of the returning sludge from the

backwash pipe: If the color is abnormally dark, decrease the

recirculation ow rate accordingly. If the TSS of

the water from Anaerobic to Aeration Chamber is high, check the sludge accumulation. If the sludge accumulation reaches the upper limit, pump out the sludge. If not, backwashing the Anaerobic Chamber by using a manual backwash tool (Figure 18) may assist.

4. Blower

Blower motor does not run, with power connected:

• Check the electric supply to the panel, ensuring 120

volt service.

• Check that all breakers and fuses in the panels are

on and intact.

• Check the blower's Auto Stop Mechanism

(see Figure 24).

Little or No Aeration / Backwash Air:

• Check the blower motor is running.

• Check the air line piping connectons at the blower.

• 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

correct accordingly.

• Verify check valves (if installed) in supply lines are

installed correctly.

Blower - manual backwash does not work:

• Push the manual backwash button several times,

listening closely for a light click within the unit.

• If the unit clicks, but the air does not switch from

aeration to back wash, consult the factory.

Page 17

P R E L I M I N A RY

Auto Stop Mechanism

The Fusion® blower is equipped with an Auto Stop Mechanism designed to protect the motor in the event of a diaphragm rupture. If tripped, the screen display on the blower will remain functional, but the blower motor will not operate. Follow the directions below (Figure 24) to check and reset the Auto Stop Mechanism:

1. Turn off the blower's breaker in the control panel. Ensure that the blower motor has stopped and the unit does not have power.

2. Remove the four screws securing the blower cover to the blower base and remove the cover.

3. Remove the insulation felt from around the motor.

4. Observe the position of the auto stop break bar. If the arrow on the auto stop break bar does not line up with the arrow on the auto stop base plate, then a trip has occured. IMPORTANT: IF THE AUTO STOP HAS TRIPPED, DO NOT REINSTALL THE AUTO STOP BREAK BAR UNTIL THE DIAPHRAGMS HAVE BEEN INSPECTED OR REPLACED!

5. To remove the auto stop break bar, rotate the piece 90°, couter-clockwise and lift out.

6. To reinstall the auto stop break bar, line up the arrows on both the bar and the base, insert the tip of the bar through the plate, and push the bar straight down to snap it in place.

Figure 23

Rotate the auto-stop bar to one side.

Turn until the mark is inline with the opening in the plastic handle.

Remove the auto-stop bar.

Align the marks on each piece and slide the piece into the holder.

Push in until it clicks. Ready for use.

Page 18

DIAPHRAGM REPLACEMENT

1. Disconnect power to the blower and wait 5 minutes before continuing with service on the unit.

2. Remove the top to the blower (4 Allen head or Phillips head screws attach the top to the base).

3. Remove one of the diaphragm covers (4 Phillips head screws attach the cover to the motor). The cover should easily pull out of

the base.

4. Remove the lock nut holding the diaphragm on (7/32” socket).

5. Replace diaphragm with new diaphragm. The diaphragm can only go on one way. The smaller screw hole spacing must go to the top

of the unit. Any other way and the screw holes will not line up.

6. Replace lock nut.

7. Replace diaphragm cover ensuring that the cover is seated back in the grommet on the base plate, and the four screw holes line up.

8. Repeat procedure for the other diaphragm.

9. Replace the top to the blower and tighten the 4 screws removed earlier.

10. Reconnect power to the unit.

Figure 24

Diaphram Cover (removed)

Diaphram (removed)

Diaphram Cover

Diaphram

Page 19

P R E L I M I N A RY

NOTES

Page 20

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