Clarus Fusion Series User manual

®
MAIL TO: P.O. BOX 16347 • Louisville, KY 40256-0347
SHIP TO: 3649 Cane Run Road • Louisville, KY 40211-1961
[phone] • 1 (800) 928-PUMP • FAX [phone]
Visit our web site:
clarusenvironmental.com
Product information presented
here reects conditions at time
of publication. Consult factory
regarding discrepancies or
inconsistencies.
© Copyright 2020. All rights reserved.
SEE LIST BELOW FOR
WARNINGS
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 1-800-928-
7867 or [phone].
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.
1. DO NOT attempt to service the Fusion®unit yourself. Contact your
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® Series
Treatment System.
Fusion®Series Treatment Systems
SECTION: C3.10.140
CL0056
0320
Supersedes
1219
OWNER'S MANUAL
Manufacturer warrants, to the purchaser and subsequent owner during the
warranty period, which is retroactive to the date of June 1, 2014 for previously
installed Fusions, the Fusion Fiberglass Tank only to be free from defects in
material and workmanship under normal use and service, when properly
installed, used and maintained, for a period of ten (10) years from date of
purchase by the end user. Tanks that fail within the warranty period that
inspections determine to be defective in material or workmanship, will be
repaired, replaced or remanufactured at Manufacturer’s option, provided
that by so doing the manufacturer will not be obligated to replace the entire
assembly or the complete unit. No allowance will be made for shipping charges,
damages, labor or other charges that may occur due to product failure, repair
or replacement.
All other Fusion components including the blower and alarm panel will be
warranted for a two-year (2) period from date of purchase by the end user.
This warranty does not apply to and there shall be no warranty for any material
or product that has been disassembled , 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: tar, hydrocarbons, hydrocarbon derivatives (oil, gasoline, solvents,
etc.), or other abrasive or corrosive substances that can damage the berglass
material. 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.
Contact Manufacturer at, 3649 Cane Run Road, Louisville, Kentucky 40211,
Attention: Customer Support Department to obtain 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.
LIMITED WARRANTY
Fusion®Model: ZF-450 ZF-800
Serial No. ____________________________________
Installing Contractor ____________________________________
Phone Number ____________________________________
Installation Date ____________________________________
Maintenance Provider’s Name ____________________________________
Phone Number ____________________________________
Limited Warranty ................................1
Process Description ..............................3
System Components and Care .......................3
Excavation and Installation..........................6
Start Up ......................................9
Blower Timer Setting ............................ 11
Operation and Maintenance ........................ 12
Aeration Chamber Cleaning ........................ 14
Fusion®Pumping................................ 15
Troubleshooting ................................ 16
TABLE OF CONTENTS


Register your
Clarus Environmental Product
on our website:
http://reg.clarusenvironmental.com/

2
© Copyright 2020. All rights reserved.
PRELIMINARY
INFLOW
RECIRCULATION BAFFLE
EFFLUENT
AERATION
(BLUE)
BACKWASH
(RED)
SLUDGE RETURN
BAFFLE
RECIRCULATION WALL OPENING
INFLOW
BAFFLE
BACKWASH MECHANISM
RECIRCULATION WALL OPENING
BAFFLE
EFFLUENT
6" (152mm) STONE OR CONCRETE PAD
W.L W.L W.L
W.L
G.L G.L
SIDE VIEW
TOP VIEW
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®utilizes a combination of anaerobic (without oxygen)
and aerobic (with oxygen) biological processes to treat wastewater.
As wastewater enters the Fusion®, it is broken down and becomes
food for biological organisms benecial to bacteria 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 CBOD5and 9mg/L TSS.
* Based on NSF Standard 40 testing.
HOW A FUSION®SERIES TREATMENT SYSTEM WORKS
Anaerobic Chamber -
Organisms adhere to xed lm
media and digest waste
Recirculation Line
Storage
Chamber
Inlet Pipe
4” PVC
SCH 40
(DN 100)
Fiberglass
Sedimentation
Chamber -
Separates bulk
solid and grease
waste
Outlet Pipe
4” PVC
SCH 40
Aeration Chamber
Floating/Circulating
Filter Media -
“Fluidized Bed”
Invigorates aerobic
bacteria
Sludge Return Line
Figure 1 - The following diagram will help you to better understand the process:
Figure 2 - Schematic diagram of the Fusion®Treatment System
SK3194
(DN 100)

3
© Copyright 2020. All rights reserved.
PRELIMINARY
The NSF mark displayed here will
be on all NSF Standard 40, Class
1 certied Fusion®systems. The
Fusion®models ZF-450 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.
Back-Wash Recirculation
Sedimentation Chamber
Anaerobic Chamber
Aeration Chamber
Storage Chamber
Effluent
Inflow
1
2
3
4
Figure 3 - Treatment Flow of the Fusion®System.
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 (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.
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 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.
The complete wastewater treatment system will typically consist of
the Fusion® treatment components and a soil absorption eld for nal
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®system. Variations to the typical system will be made
to suit your particular site and system design needs. Please contact
your authorized Fusion®installer or maintenance provider for further
information about your system design.
®
Certified to
NSF/ANSI
Standard 40
Class 1
Performance
Designation
Figure 4 NSF STANDARD 40, CLASS 1,
CERTIFICATION MARK
The Fusion®treatment unit utilizes an electronic, dual-port blower
designed specically for use with this system. The blower consists
of a linear motor and two diaphragms to generate the air ow
necessary to aerate and recirculate water within the system. This
style of blower 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.
THE FUSION®DUAL-PORT BLOWER
SYSTEM COMPONENTS
Blower Part # 5250-0050
RATING
Voltage AC120V
Frequency 60Hz
Insulation class A Rank
Operating time Continuous
CHARACTERISTICS AND PERFORMANCE
Solenoid Valve
off
Solenoid Valve on
Voltage(V) AC120V
Current (A) 1.8 or less 2.0 or less
Power consumption (W) 71 ± 20% 77 ± 20 %
Air volume (L/min) 80 ± 10%
Leak air volume(%) 1.0 or less 2.0 or less
Noice level (dBA) 43.0 or less
Valve movement (N/L) 75.0 or less
Temperature rise 60 deg or less at 30 °C room
temperature

4
© Copyright 2020. All rights reserved.
PRELIMINARY
FU S IO N TRE ATM ENT S Y ST EM
450GALLONS/DAY
800 GALLONS/ DAY
BLO WER SER VI ＣE P ART S
COMPLETE BLOWER: P/N 5250-0050-A
BLOWER DIAPHRAGM: P/N 152949-A
BLOWER FILTER: P/N 152950-A
MFG．DATE：
Manufacturer:
Clarus Environmental • 3649 Cane Run Road
Louisville, KY 40211•1-800-928-7867 toll free
ZF 450
ZF 800
□
□
P/N 018860-E
®
Certified to
NSF - ANSI
Standard 40
®
The Fusion®utilizes 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.
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®on the dataplate, such as the part number, model
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.
Figure 6
P/N
WARNING!
RED BEACON
SILENCE/TEST
SWITCH
BUZZER
FUSION
DATAPLATE
sk2649
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 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.
HIGH USE WATER DEVICES
The draining of hot tubs and swimming pools into your Fusion®system
will cause hydraulic overloading and will impair 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.
The Fusion®system is designed to continuously operate automatically 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.
ALARM PANEL
DATAPLATE
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.
Figure 5
SYSTEM CARE
sk2933
Figure 7
12 3 4 5 6 7 8
TB2
120 VAC L1
INCOMING N
POWER GND
DISNF
ALARM
HIGH WATER
ALARM
BLOWER
*FOR ILLUSTRATION PURPOSES ONLY*
REFER TO SCHEMATIC LOCATED IN
PANEL FOR INSTALLATION
BLOWER FOR ZF-450 AND ZF-800
GND LUG
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.
INTERMITTENT USE

5
© Copyright 2020. All rights reserved.
PRELIMINARY
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®treatment
system. If you have any questions concerning the use of any of
these substances, please contact your Fusion®maintenance
provider. The introduction of any substance on the “Do Not" List
into the Fusion®will void the warranty.
- THE "DO NOT" LIST -
DO NOT introduce the following substances into the Fusion®
treatment system:
• Motor oil • 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®treatment process. You should always use 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
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.
HARMFUL SUBSTANCES
WATER SOFTENERS
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 1-800 928 2731.
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®. It
may be necessary to discontinue water use until the alarm
condition has been resolved. If the buzzer continues to sound
or the red light stays on, please contact your authorized Fusion®
maintenance provider. The buzzer may be silenced by toggling
the black switch on the side of the alarm panel to “silence”.
The red beacon light will remain on until the problem has been
resolved.
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 still allow efuent to ow, and will not create a
backup in the home. You may, however, have a pump or dose tank
with a pump on the outlet of the Fusion®, which requires power to
pump the efuent to the soil absorption eld. If you have a system
such as this, please be aware of this condition and conserve water
accordingly.
Fusion® Series systems are compact, efcient, and designed to
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 CBOD5and 9 mg/L TSS.
EFFLUENT QUALITY
*Based on NSF/ANSI Standard 40 testing.
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.
An extended maintenance policy is available for purchase from
your authorized Fusion®distributor. The extended maintenance
policy will include the same system checks, schedule, and
adjustments as the initial maintenance policy. Please contact your
Fusion®distributor or maintenance provider for further information
regarding the extended maintenance policy.
EXTENDED MAINTENANCE POLICY
INITIAL SERVICE POLICY
The Fusion®models ZF-450 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.

6
© Copyright 2020. All rights reserved.
PRELIMINARY
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®. This 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).
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
openings. Riser extensions are available for deeper burial.
Make certain risers are sealed properly and watertight.
4.
CAUTION
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.
CAUTION
MAXIMUM soil burial depth over the unit is 36
inches (914 mm).
EXCAVATION AND INSTALLATION
BACKFILLING
Number AND Size of ACCeSS opeNiNgS iN fuSioN ®SerieS
ZF-450 ZF-800
20" (51 cm) Diameter 0 1
24" (61 cm) Diameter 2 2
Table 1
COLD WEATHER INSTALLATION
When installing Fusion®in cold climates, the designer may
specify insulated lids and risers. In addition, the blower must be
protected from snow drifts. If installed in a riser, the blower must
be protected from inundation and may 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®may 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®sits on, anchoring is 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®with water and add 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®, which will anchor it once the
concrete cures. Make certain to pour the concrete in a manner
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.
H
I
L
E
W
OUTLET
INLET
1) DIMESIONS "I" AND "E" ARE TO THE BOTTOM
OF THE INLET/OUTLET PIPE.
ADAPTER RING. NOT THE RISER LID.
SEPARATELY.
3) A RISER COVER COMES STANDARD. ADDITIONAL
RISERS ARE PURCHASED
2) THE OVERALL HEIGHT DIMENSION "H" IS TO
THE TOP OF THE NARROW
NOTES:
Figure 8 - Dimensions
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®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)
sk2624

7
© Copyright 2020. All rights reserved.
PRELIMINARY
4-POINT
LIFTING
LESS THAN 60°
60°
LIFTING
HOOK
LIFTING
LEVEL ACROSS TOP OF UNIT
MANHOLE
FRAME
LEVELING
Figure 9 - Lifting & Positioning
Table 3 - Concrete Anchoring Dimensions
MIN. REQUIRED
BACKFILL
UNIT SIZE Z
18"
21"
ZF-450
ZF-800
H
Z
W
CONCRETE ANCHOR
COLLAR
Figure 10 - Concrete Anchoring
sk2931
moDel Nocover 6" (15 cm) cover 12" (30 cm) cover 18" (46 cm) cover
W
iN (cm)
H
iN (cm)
coNcrete volume
Ft3(m3) (cY)
W
iN (cm)
H
iN (cm)
coNcrete volume
Ft3(m3) (cY)
W
iN (cm)
H
iN (cm)
coNcrete volume
Ft3(m3) (cY)
W
iN (cm)
H
iN (cm)
coNcrete volume
Ft3(m3) (cY)
zf-450 16
(40.6)
24
(61.0) 72 (2.0) 3 14 (40.6)
24
(61.0) 62 (1.8) 3 13 (33.0)
24
(61.0) 56 (1.6) 3 12 (30.5)
24
(61.0) 51 (1.4) 2
zf-800 20
(50.8)
24
(61.0) 109 (3.1) 4 19 (48.3)
24
(61.0) 102 (2.9) 4 40,6 (17)
24
(61.0) 90 (2.5) 4 16 (40.6)
24
(61.0) 84 (2.4) 4
moDel 24"(61 cm) cover 30"(76 cm) cover 36"(91 cm) cover
W
iN (cm)
H
iN (cm)
coNcrete volume
Ft3(m3) (cY)
W
iN (cm)
H
iN (cm)
coNcrete volume
Ft3(m3) (cY)
W
iN (cm)
H
iN (cm)
coNcrete volume
Ft3(m3) (cY)
zf-450 12
(30.5)
24
(61.0) 72 (2.0) 3 12 (30.5) 24 (61.0) 51 (1.4) 2 12 (30.5) 24 (61.0) 51 (1.4) 2
zf-800 12
(30.5)
24
(61.0) 109 (3.1) 4 14 (35.6) 24 (61.0) 72 (2.0) 3 13 (33.0) 24 (61.0) 66 (1.9) 3

8
© Copyright 2020. All rights reserved.
PRELIMINARY
WARNING!
TO DISPERSAL
SEWER LINE
FUSION ALARM PANEL
BLOWER RISER AND LID
FUSION
OPTIONAL SEPTIC TANK INSTALLATION
MAY BE REQUIRED BY LOCAL
OR STATE REGULATIONS
AIR LINES
CLEANOUT
ALARM FLOAT
CONDUIT INSTALLED
BY CONTRACTOR
WHERE APPLICABLE
Figure 11 - Typical Fusion® Layout
sk2650
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 (main) and the backwash (skim) outlet port being RED
(Figure 12).
8. The air port inlets on the Fusion®are also color-coded, BLUE for aeration and RED for
backwash (Figure 12).
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.
12. Install the Fusion®blower at an elevation where the
air line outlets are located above the elevation of the
Fusion®air line inlets (Figure 12).
BLOWER INSTALLATION AND PLACEMENT
TO PREVENT ELECTRICAL SHOCK
FROM BACK-SIPHONING, LOCATE
THE PUMP ABOVE THE WATER
LEVEL.
DECORATIVE ROCK CONFIGURATION
INTERIOR CONFIGURATION
DRILL HOLES FOR
BLOWER MAKE UP AIR
Figure 12
ELECTRICALSHOCK
HAZARD
!WARNING
DECORATIVE ROCK CONFIGURATION
INTERIOR CONFIGURATION
RED AIR
LINE
BLUE AIR
LINE
HIGH WATER FLOAT CONDUIT
TO BE INSTALLED BY
CONTRACTOR
(WHERE APPLICABLE)
FUSION UNIT
AIR LINE FROM PUMP
1/2" SCH 40 PVC
BULK HEAD FITTINGS
RUBBER
ELBOWS
POWER
CORD
RED AIR
LINE
BLUE AIR
LINE
CONDUIT TO PANEL
AIR LINE
TO PANEL
ADAPTER
BLOWER
AIR LINES
TO PANEL
SPRING
CLAMPS
DRILL HOLES FOR
BLOWER MAKE UP AIR
ALARM FLOAT
CONDUIT
SEAL AFTER LINE
INSTALLATION
AIR SENSOR LINE
1/2 X 3/4 REDUCER
INSTALL BUSHING IF AIR
LINE IS LESS THAN 17'
TO UNIT
GLUE
FITTINGS
BLOWER
sk2639

9
© Copyright 2020. All rights reserved.
PRELIMINARY
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.
1
2
3
4
CLEAN-OUT
FLOW RECIRC. PIPE
SLUDGETRANSF. PIPE
CLEAN-OUT
ARERATION AIR-IN
(BLUE)
BACKWASH AIR-IN
(RED)
CLEAN-OUT SLUDGETRANSF.
CLEAN-OUT RECIRC.
GREY 0 100
RED 100 100
GREY 0 100
50
BLUE 100 100
50
Figure 13 - Aeration Flow Adjustment
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.
PIPING INSTALLATION
HIGH WATER ALARM FLOAT INSTALLATION
The Fusion®alarm panel assembly includes a high water alarm
oat switch that is used to monitor the liquid level in the Fusion®
unit. The switch should be tethered to one of the gray, vertical
air lines in the aeration chamber with a 3" (76 mm) tether
length. The cord should pass through the opening in the partition
wall between the aeration and anaerobic chamber and allow
the oat to hang in the outlet bafe of the anaerobic chamber.
1. The oat switch should be tethered to one of the gray,
vertical pipes in the aeration chamber. When the oat is
in the horizontal position, the cord should be at least 1"
(25 mm) below the top of the partition wall opening in
the anaerobic chamber bafe.
2. Place the cord into the clamp and secure to gray aeration
pipe. NOTE: Do not install the cord under the clamp.
3. Position the oat with a 3" (76 mm) tether.
4. Tighten the clamp with a screwdriver. Be careful not to
overtighten as this may cause damage to the plastic clamp.
5. Make sure the oat cord is not allowed to touch the
excess clamp band during operation as this may cause
damage to the cord.
6. The oat switch cord should be installed in an electrical
conduit connecting the alarm panel to the Fusion®unit. The
electrical conduit must be rated for burial, and should be
properly sealed to prevent gases from entering the alarm
panel.
7. A 1/2" (13 mm) bulkhead tting (supplied by others) should
be used to connect the electrical conduit to the Fusion®unit.
A hole must be drilled through the wall of the Fusion®unit
between the red and blue bulkhead ttings to facilitate
this connection.
8. Please be certain that the bulkhead tting for the electrical
conduit forms a watertight connection with the FRP wall
of the Fusion®unit.
9. Electrical conduit from the Fusion®unit to the alarm
panel can be buried in the same trench as the air lines.
10. The control switch can be wired directly into the alarm
panel. See Figure 7.
1. All electrical installations must follow 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.
ELECTRICAL CONNECTIONS
START UP
An installation and start-up check list (CL0057)
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.
Valve Legend:
1. Aeration Blue 3. Backwash Red
2. Recirculation Gray 4. Sludge transfer Gray


10
© Copyright 2020. All rights reserved.
PRELIMINARY
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 flow 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 flow 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.
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 if the backwash cycle is too short, 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. The backwash initiation
time can be set for any time during a 24-hour period
to accommodate 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 in the same action.
Verify that the air ow is uniform across the
aeration chamber during a backwash cycle. If not,
adjust the red backwash valve (3) accordingly.
Setting the ow rate:
• On all HIBLOW HP series model blowers, press
the [MINUTE] button for at least 2 seconds to
switch to manual mode. The "aeration" and
"backwash" can be switched by the [MINUTE]
button.
• 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.
• Be sure to press [SET] to return the unit back to auto
mode on HIBLOW Unit.
It is important not to set the ow rate too high
because it can cause excessive agitation within the rst chamber
(Sedimentation Chamber). This could result in poor performance.
RECIRCULATION FLOW ADJUSTMENT BACKWASH FLOW ADJUSTMENT
Table 5 - Backwash Flow Rate Setting
Model Frequency ZF450 ZF800
Backwash ow
rate (sec/liter)
Twice/day 7-10 4-6
Valve open (%) Twice/day 50-55% 40-45%
Figure 15 - Flow
Controlling Valve
Figure 14 - Flow
Measurement
Model ZF450 ZF800
Recirculating ow rate (sec/liter) 29-45 14-22
Suggested Valve Opening 35-40% 30-35%
Table 4 - Recirculation Flow Rates
20
30
40
50
60
70
80
90
100
0
10
MCL
SUGGESTED
RANGE
RECIRCULATION OR BACKWASH PIPE
CONTAINER
G.L
WATER
TOTREATMENT UNIT
FAUCET
BACKFLOW PREVENTER
HOSE
BLOWER
CLAMP
EXISTING AIR LINE
BRUSH
20
30
40
50
60
70
80
90
100
0
10
MCL
SUGGESTED
RANGE
RECIRCULATION OR BACKWASH PIPE
CONTAINER
G.L
WATER
TOTREATMENT UNIT
FAUCET
BACKFLOW PREVENTER
HOSE
BLOWER
CLAMP
EXISTING AIR LINE
BRUSH

11
© Copyright 2020. All rights reserved.
PRELIMINARY
HIBLOW BLOWER TIMER SETTING
To Adjust Clock:
1. Remove 2 Phillips head screws from the grey plastic
top and pull grey top off to access the timer module.
2. To switch to "Time Setting Mode", hold the [HOUR]
button for more than 2 seconds during "Auto" mode.
Adjust with the [HOUR] and [MINUTE] buttons, then
press the [SET] button to set the current time.
To Adjust Backwash Settings:
1. To set "Backwash/Skim Timer Setting Mode", hold
the [SET] button for more than 2 seconds DURING
"Time Setting Mode". Adjust the end time for
backwash with [HOUR] [MINUTE] button. Press
[SET] to set the start time. Adjust the end time with
[HOUR] [MINUTE] button, press [SET] to set 2 second
backwash end time with [HOUR] and [MINUTE]
buttons. Press [SET] to set the 2 second backwash
start time with [HOUR] and [MINUTE] buttons. Press
[SET] twice to set the backwash timer. Make sure
two 5-minute times are set from 2:00 - 2:05 and 3:00 -
3:05.
To Switch Between "Manual" Mode and "Auto" Mode:
1. To switch to "Manual" mode, press [MINUTE] button
for more than 2 seconds. The unit can be switched
between "Recirculation" and "Backwash" with the
[MINUTE] button. Press the [SET] button to switch
back to "Auto" mode.
NOTE: Unit uses a 24-hour clock.
HIBLOW Blower and Timer shown.
Figure 16

12
© Copyright 2020. All rights reserved.
PRELIMINARY
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.
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. 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.
3. Is there excess foam formation? Foam may be
present duringan inspection. Brown foamindicates
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.
4. Is there residue build-up on piping? Typically
indicated by gray or black residue (dried foam)
on aeration chamber piping.
5. 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.
1. 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.
2. 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.
3. 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:
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
GENERAL OBSERVATIONS
REQUIRED WATER QUALITY ANALYSES
FUSION®OPERATION AND MAINTENANCE

13
© Copyright 2020. All rights reserved.
PRELIMINARY
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.
INFLOW
RECIRCULATION BAFFLE
EFFLUENT
AERATION
(BLUE)
BACKWASH
(RED)
SLUDGE RETURN
BAFFLE
RECIRCULATION WALL OPENING
INFLOW
BAFFLE
BACKWASH MECHANISM
RECIRCULATION WALL OPENING
BAFFLE
EFFLUENT
6" (152mm) STONE OR CONCRETE PAD
W.L W.L W.L
W.L
G.L G.L
SIDE VIEW
TOP VIEW
Figure 17 - Inspection details
FUSION®OPERATION AND MAINTENANCE, continued
INFLOW
RECIRCULATION BAFFLE
EFFLUENT
AERATION
(BLUE)
BACKWASH
(RED)
SLUDGE RETURN
BAFFLE
RECIRCULATION WALL OPENING
INFLOW
BAFFLE
BACKWASH MECHANISM
RECIRCULATION WALL OPENING
BAFFLE
EFFLUENT
6" (152mm) STONE OR CONCRETE PAD
W.L W.L W.L
W.L
G.L G.L
SIDE VIEW
TOP VIEW
PART A: Clean Water Storage Chamber – Collect samples from the clean water storage chamber to be used for the
following analyses
1. pH – Measures the hydrogen ion-concentration and is determined with the use of the pH test strips included in the
Fusion®Maintenance Kit. Dip a test strip into the water sample for 1 second, remove, and read by comparing to the color
chart provided on the container. A pH = 7.0 is neutral. The range suitable for biological activity is 6.5 to 7.5. Recurring
results outside this range should be investigated – check the water source for the home or business, chemical use, etc.
2. NO2
- N – Determined with the use of the nitrite test strips included in the Fusion®Maintenance Kit. Dip a test strip into
the water sample for 1 second, remove, allow to react for 30 seconds and read by comparing to the color chart provided
on the container. Nitrite-nitrogen is an intermediate step in the oxidation of ammonia to nitrate and the reduction of
nitrate. 0 to 3 mg/L is common and 1mg/L is average. The presence of nitrite is indicative of biological activity. The
absence of nitrite could be due to a young system or a recirculation rate that is too high. To correct low nitrite readings
in established systems, decrease the recirculation rate.
OPTIONAL WATER QUALITY ANALYSES
SK3194

14
© Copyright 2020. All rights reserved.
PRELIMINARY
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).
(A) Air ushing procedure:
• Make sure the blower is in the aeration mode.
• Make sure a check valve or backow preventer is present
for water ushing procedure.
• Close gray recirculation valve (2) all the way. (0%)
• Rotate blue aeration valve (1) back and forth from the 0%
to the 100% position several times to ush.
• Set valves (1) and (2) back to the appropriate positions.
(See Recirculation Flow Adjustment, pg. 10)
(B) Water ushing procedure: (See 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
Figure 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 air line to the blower.
• Set valves (1) and (2) back to the appropriate positions.
(See Recirculation Flow Adjustment, pg. 10)
(C) Cleaning the recirculation line:
• 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:
• 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)
20
30
40
50
60
70
80
90
100
0
10
MCL
SUGGESTED
RANGE
RECIRCULATION OR BACKWASH PIPE
CONTAINER
G.L
WATER
TOTREATMENT UNIT
FAUCET
BACKFLOW PREVENTER
HOSE
BLOWER
CLAMP
EXISTING AIR LINE
BRUSH
Figure 18
(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 18.
• 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)
(C) Cleaning the sludge transfer line:
• 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.
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.
Figure 19
20
30
40
50
60
70
80
90
100
0
10
MCL
SUGGESTED
RANGE
RECIRCULATION OR BACKWASH PIPE
CONTAINER
G.L
WATER
TOTREATMENT UNIT
FAUCET
BACKFLOW PREVENTER
HOSE
BLOWER
CLAMP
EXISTING AIR LINE
BRUSH
Figure 20

15
© Copyright 2020. All rights reserved.
PRELIMINARY
Step 3: Remove the sludge under the media while washing the lter with tap water.
Step 1: Remove the scum. Step 2: Remove the sludge

1)

 
2) 3)
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.
Figure 22 - Anaerobic Chamber 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®.
The stored materials accumulate as scum (oating) or sludge (solids on the bottom) and must be removed periodically to
ensure the performance of the Fusion®. Please review the Operation and Maintenance sections part B and C to determine
when the maximum depths of 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.
FUSION®PUMPING
Figure 21 - Sedimentation Chamber Pumping
Step 1: Remove the scum. Step 2: Remove the sludge
1) 2)


ALARM PANEL & BLOWER INSPECTION AND MAINTENANCE
1. Listen for loud rattling sounds. The blower should hum
softly. Ifarattleis heard, ensure thatallfourlegs securely
contact the ground or base medium.
For HIBLOW Blower, inspect the lter once the power
has been disconnected by removing the two screws
from the top cover and removing the top cover from the
unit. Remove the screw from the lter plate, and
lift off the lter plate. Clean the lter by knocking the
dust out, and then handwash in mild, soapy water. Be
sure to dry well before reinstalling lter and covers.
2. 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).
3. Press the Manual Backwash button and ensure the unit
switches into backwash mode by observing the change in
water ow in the Fusion® tankfromtherecirculationreturn
linetothesludgetransferline. Besuretoswitchthesystem
back to recirculation by pressing the Manual Backwash
button again, or pressing [SET] on HIBLOW®unit.
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.

16
© Copyright 2020. All rights reserved.
PRELIMINARY
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 forrmation is observed in the following situations:
1. In the early stage of operation when the arerobic bacteria
colony is establishing itseft.
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 amount of detergent have been introduced
to the system remind the owner to use appropriate amount 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 anaerabic 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 anaerabic chamber by
using a manual backwash tool (gure 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 intact.
• Check the blowers auto stop mechanism (See pages 17 and 18).
Little or No aeration/ backwash air:
• Check the blower motor is running.
• Check the air line piping connections 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.
• Manually toggle between recirculation and backwash 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.

17
© Copyright 2020. All rights reserved.
PRELIMINARY
HIBLOW Blower Safety Slide Switch
The blower is equipped with a safety slide switch designed to protect the motor in the event of a diaphragm rupture. If tripped, the blower
motor will not operate, but the timer will remain functional. Follow the directions below to reset the safety slide switch after the diaphragms
have been replaced. If the diaphragms are not replaced rst, resetting the safety slide switch may damage it:( pg 18)
1. Turn off the blower's circuit breaker in the control panel. Ensure that the blower motor has stopped and the unit does not have power.

 4A Reset position
Figure 1
Figure 2
Figure 3
Figure 4
Figure 2
Figure 1
2. Remove the four corner screws securing the
upper cover to the blower base and remove
the cover.(Figure 1)
3. Remove the sound absorbing felt from
around the motor.(Figure 2)
4. Pinch both sides of the safety slide switch
and slide it to the center position of the
switch base until it clicks into place. (Figure
3,3A,4,4A)
5. Check that the protrusion of the switch slide is adjusted
to the position of the “ “ mark and the switch part of the
micro switch is pressed in. (gure 4,4A)
6. The safety slide switch is now reset.
7. Install the sound absorber. (Figure 2).
8. Install the blower cover using the four corner screws
removed earlier. (Figure 1).

18
© Copyright 2020. All rights reserved.
PRELIMINARY
HIBLOW Diaphragm Replacement
1. Disconnect power to the blower and wait ve minutes before continuing with service on the unit.
2. Remove the blower upper housing by rst removing the 4 corner screws that attach the housing to the base. (Figure 1)
Figure 5
Figure 6
Figure 7
Figure 8
Figure 9
Figure 10
4. Remove chamber blocks by removing the 4 retaining screws. (Figure 6).
3. Remove the sound absorbing felt. Remove the hose band and
remove the L-tube from the chamber block. Repeat for the opposite
side. (Figure 5)
5. Remove one of the hex lock nuts and washer in the center of the
diaphragm which holds the diaphragm to the rod. (Figure 7).
6. Remove the diaphragm mounting block from the rod and pull out
the other diaphragm mounting block from the pump body together
with the rod without loosening its hex nut and washer. (Figure 8).
Remove the diaphragm mounting block from the rod by removing
the hex lock nut and washer. (Figure 9).
7. Attach a new diaphragm mounting block on one side of the rod
using a new hex lock nut and washer.
NOTE: Using old lock nuts or washers can cause the nut to loosen
and cause pump failure. (Figure 9).
8. Insert the actuating rod in accordance with the gap of the frame.
Secure the diaphragm mounting block on the other side of the
rod and tighten with the new hex lock nut and washer, (Figure
10). Make sure the gaps between the actuating rod and the
electromagnet are even.

19
© Copyright 2020. All rights reserved.
PRELIMINARY
Figure 11
Figure. 2
Figure. 1
9. Connect the L-tubes to the casing and secure with hose bands.
Secure the chamber blocks. (Figure 11).
10. Reset the safety slide switch if necessary (page 17).
11. Install the sound absorber.( Figure 2)
12. Replace the housing cover and secure it with the screws removed
earlier (Figure 1)
HIBLOW Diaphragm Replacement

PRELIMINARY
© Copyright 2019. All rights reserved.
3649 Cane Run Rd. • Louisville, KY 40211-1961 • [phone] • FAX: [phone]
clarusenvironmental.com
Trusted. Tested. Tough.®
NOTES:
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