Clarus Environmental 450, 600, 800 User Manual

®
®
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.
© Copyright 2012. All rights reserved.
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.
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
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 -
“Fluidized Bed”
Invigorates aerobic bacteria
W.L
2
Recirculation
Side View
W.L
3
Backwash Mechanism
G.L.
Baffle
4
Wall opening
Effluent
© Copyright 2012. All rights reserved.
2
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.
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 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
© Copyright 2012. All rights reserved.
3
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
®
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
MFGDATE09/07
Manufacturer:
BL OWE R SER VI E 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
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
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.
© Copyright 2012. All rights reserved.
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.
4
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
© Copyright 2012. All rights reserved.
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.
5
, which requires power to pump the efuent to the
®
will still allow efuent 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 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).
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 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.
9.
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)
© Copyright 2012. All rights reserved.
Figure 8- Dimensions
INLET
W
H
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.
6
I
OUTLET
E
sk2624
L
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