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.
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.
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.
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 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 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
1
Sludge return
Baffle
2
Backwash
Top View
®
Treatment System
Air-lift Pump
4
Effluent
3
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
1
Baffle
Aeration Chamber
Floating/Circulating
Filter Media -
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.
1
2
Back-Wash
3
(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
4
Storage Chamber
Effluent
SYSTEM COMPONENTS
The complete wastewater treatment system will typically consist of
the Fusion
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 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 specically 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 efcient
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
The NSF mark displayed here
will be on all NSF Standard
®
40, Class 1 certied 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 certied,
will not display the mark.
®
models
®
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 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
Figure 6
Figure 7
120 VAC
INCOMING
POWER
L1
N
GND
BLOWER
FUSION
DATAPLATE
TB2
RED BEACON
WARNING!
SILENCE/TEST
SWITCH
P/N
BUZZER
1
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
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.
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.
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 efciency. 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.
4
PRELIMINARY
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
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.
• 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 efuent 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, efcient, and designed to
The Fusion® models ZF-450, ZF-600, and ZF-800 (NSF
Standard 40, Class 1 certied 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 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 1-877-244-9340.
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 efciency 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.
5
, which requires power to pump the efuent to the
®
will still allow efuent to ow, and
®
,
®
®
.
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 sufcient room for proper backlling.
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 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 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. If necessary, install riser extensions on the adapter rings
prior to backlling. 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. 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.
7. Tamp soil around perimeter of the unit as it is backlled to
stabilize the unit and to reduce settling.
8. 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.
9.
is 36 inches (914 mm).
Table 1
NumberaNDsizeofaccessopeNiNgsiNfusioN
20" (51 cm) Diameter
24" (61 cm) Diameter
®.
MAXIMUM soil burial depth over the unit
®
series
ZF-450ZF-600ZF-800
011
222
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
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
risers if needed.
3. Refer to Figure 10, 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
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 backlling.
6. Complete the procedures outlined in the Backlling Section,
items 5-8.
®
sits on, anchoring is
®
with water and add
®
, which will
Table 2
FUSION® DIMENSIONS
SYSTEMLWHIE
®
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
6008' (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)