SECTION: C3.10.

140
CL0056
Product information presented 0122
here reflects conditions at time Supersedes
of publication. Consult factory
regarding discrepancies or 1220
inconsistencies.

Register your MAIL TO: P.O. BOX 16347 • Louisville, KY 40256-0347

Zoeller Pump Product on our SHIP TO: 3649 Cane Run Road • Louisville, KY 40211-1961 Visit our website:
website: TEL: (502) 778-2731 • 1 (800) 928-PUMP • FAX: (502) 774-3624 zoellerpumps.com
to Zoeller Reg page

Clarus Fusion® Series Treatment Systems

OWNER'S MANUAL
SEE LIST BELOW FOR
WARNINGS
Thank you for choosing a Fusion ® Series Treatment System. High quality 1. DO NOT attempt to service the Fusion ® unit yourself. Contact your
workmanship and easy maintenance have been incorporated into the authorized maintenance provider for all service related issues.
Fusion ® system. The system will provide years of trouble-free service 2. There are buried electrical cables and piping near and around the
when maintained according to the manufacturer’s recommendations. Fusion ®. Please consult your authorized maintenance provider to
Please read this manual in its entirety before using the Fusion ®, and follow locate these utilities before excavation.
all instructions to ensure proper operation. Keep this manual for future 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.
reference along with other important onsite documents. Should further
4. The Fusion ® blower must be unobstructed and vented for proper
assistance be necessary, please contact Clarus Fusion® at 1-800-928-7867 operation. Care must be taken that no grass clippings or other
or +1-502-778-2731. materials accumulate on or around the blower and block ventilation.
5. DO NOT place heavy objects over the Fusion ® or drive heavy
Warning Labels equipment over the Fusion ®, as damage may occur. Damage of this
You will find warning labels on the Fusion , riser lids, blower, and the alarm
®
kind is not covered by the warranty.
control panel. It is very important to follow the information on these labels 6. DO NOT plant trees within 15 feet (4.6 m) of the Fusion ® Series
to ensure your safety. Please do not remove these labels. Treatment System.

TABLE OF CONTENTS Fusion® Model:  ZF-450  ZF-800

Limited Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Process Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Serial No. ____________________________________
System Components and Care . . . . . . . . . . . . . . . . . . . . . . . 3
Excavation and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Installing Contractor ____________________________________
Start Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Phone Number ____________________________________
Blower Timer Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Operation and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . 12 Installation Date ____________________________________
Aeration Chamber Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . 14 Maintenance Provider’s Name ____________________________________
Fusion ® Pumping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Phone Number ____________________________________

LIMITED WARRANTY
Manufacturer warrants, to the purchaser and subsequent owner during the material. The warranty set out in the paragraph above is in lieu of all other
warranty period, which is retroactive to the date of June 1, 2014 for previously warranties expressed or implied; and we do not authorize any representative or
installed Fusions, the Fusion® Fiberglass Tank only to be free from defects other person to assume for us any other liability in connection with our products.
in material and workmanship under normal use and service, when properly
Contact Manufacturer at, 3649 Cane Run Road, Louisville, Kentucky 40211,
installed, used and maintained, for a period of ten (10) years from date of
Attention: Customer Support Department to obtain additional information
purchase by the end user. Tanks that fail within the warranty period that
pertaining to our warranty.
inspections determine to be defective in material or workmanship, will be
repaired, replaced or remanufactured at Manufacturer’s option, provided MANUFACTURER EXPRESSLY DISCLAIMS LIABILITY FOR SPECIAL,
that by so doing the manufacturer will not be obligated to replace the entire CONSEQUENTIAL OR INCIDENTAL DAMAGES OR BREACH OF EXPRESSED
assembly or the complete unit. No allowance will be made for shipping charges, OR IMPLIED WARRANTY; AND ANY IMPLIED WARRANTY OF FITNESS FOR A
damages, labor or other charges that may occur due to product failure, repair PARTICULAR PURPOSE AND OF MERCHANTABILITY SHALL BE LIMITED TO
or replacement. THE DURATION OF THE EXPRESSED WARRANTY.

All other Fusion® components including the blower and alarm panel will be Some states do not allow limitations on the duration of an implied warranty,
warranted for a two-year (2) period from date of purchase by the end user. so the above limitation may not apply to you. Some states do not allow the
This warranty does not apply to and there shall be no warranty for any material exclusion or limitation of incidental or consequential damages, so the above
or product that has been disassembled , subjected to misuse, misapplication, limitation or exclusion may not apply to you.
neglect, alteration, accident or act of God; that has not been installed, operated This warranty gives you specific legal rights and you may also have other rights
or maintained in accordance with Manufacturer's installation instructions; which vary from state to state.
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 fiberglass

© Copyright 2022. All rights reserved.

 HOW A FUSION® SERIES TREATMENT SYSTEM WORKS
The Fusion ® is simple in design, yet advanced in its wastewater food for biological organisms beneficial to bacteria operating
treatment ability. The design has been refined over many years within the unit. The first chamber serves to separate grease and
of intense research and development in an effort to perfect this large solids from the liquid. In the second chamber, plastic media
superior treatment system. Fusion® systems are 90% - 95% with large surface areas are used to increase contact between
efficient at treating wastewater. This is nearly twice as effective water and beneficial bacteria to optimize treatment. A small linear
as a traditional septic tank, which is approximately 50% efficient. air blower is used to move air (oxygen) into the third chamber
This high degree of treatment helps to protect both your personal for the aerobic process. The final effluent leaving the system will
property and the environment. have been treated to secondary quality effluent and will average
*9 mg/L CBOD5 and 9mg/L TSS.
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 * Based on NSF Standard 40 testing.

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

Recirculation Line Sludge Return Line

Storage
Inlet Pipe Chamber
4” PVC
SCH 40
(DN 100) Outlet Pipe
4” PVC
SCH 40 (DN 100)
Fiberglass
Aeration Chamber
Floating/Circulating
Filter Media -
“Fluidized Bed”
Invigorates aerobic
bacteria
Sedimentation
Chamber -
Separates bulk Anaerobic Chamber -
solid and grease Organisms adhere to fixed film
waste media and digest waste

Figure 2 - Schematic diagram of the Fusion ® Treatment System

RECIRCULATION WALL OPENING

RECIRCULATION BAFFLE

G.L G.L

W.L W.L W.L

W.L

INFLOW

EFFLUENT

BAFFLE
EFFLUENT
INFLOW BAFFLE

BACKWASH
(RED)
BAFFLE
RECIRCULATION WALL OPENING
AERATION
SLUDGE RETURN (BLUE) 6" (152mm) STONE OR CONCRETE PAD BACKWASH MECHANISM

TOP VIEW SIDE VIEW

SK3194
© Copyright 2022. All rights reserved.
2
 PROCESS DESCRIPTION
1. Sedimentation Chamber and 0.55 inches long (14 mm). Biological treatment takes
This chamber is designed to physically separate solids place on the filter media surface. Aeration is continuous.
from the incoming water. Scum is the floating material and Residual suspended solids are captured by the filter media
sludge is the material that has settled at the bottom. circulating in this section. During normal operation, a
recirculation line transfers water back to the sedimentation
2. Anaerobic Chamber chamber.
This chamber contains a spherical skeleton-type filter
media, 4.3 inch diameter (109 mm). Through bacterial The filter media in the aeration chamber are backwashed
growth processes on the surface of the filter media, regularly (twice a day, 5 or 10 minute cycle) by the
biological anaerobic treatment thrives while suspended backwash system located at the bottom of the chamber.
solids are captured. Furthermore, the microorganisms The accumulated sludge is transferred back into the
in this chamber convert nitrates in the recirculated water sedimentation chamber for further digestion.
returning from the aerobic chamber to gaseous nitrogen.
The gaseous nitrogen then escapes to the atmosphere. 4. Storage Chamber
This chamber is designed to temporarily store treated water
3. Aeration Chamber exiting the aeration chamber. This treated water is ready for
The aeration chamber consists of an aerated upper section discharge.
and a filter media lower section. The chamber is filled with
hollow, cylindrical filter media, 0.6 inch diameter (15 mm)
Figure 3 - Treatment Flow of the Fusion ® System. NSF STANDARD 40, CLASS 1,
Figure 4
Inflow CERTIFICATION MARK

Sedimentation Chamber The NSF mark displayed here will

1
®
be on all NSF Standard 40, Class
1 certified Fusion ® systems. The
2 Anaerobic Chamber
Fusion ® models ZF-450 and ZF-800
Back-Wash Recirculation
Certified to will have the mark displayed on
3 Aeration Chamber
NSF/ANSI the alarm panel. Systems not NSF
Standard 40 Standard 40, Class 1 certified, will not
Class 1
Performance display the mark.
4 Storage Chamber Designation

Effluent

SYSTEM COMPONENTS
The complete wastewater treatment system will typically consist of Characteristics and Performance
the Fusion ® treatment components and a soil absorption field for final
Item DUO-80 Test Method
disposal of the liquid effluent. Some states or counties may require the
addition of a septic tank before the Fusion ® to increase the sedimentation Rating
chamber capacity and retain more solids. Please see Figure 11 for a Voltage AC120V
typical Fusion ® system. Variations to the typical system will be made
to suit your particular site and system design needs. Please contact Frequency 60Hz
your authorized Fusion ® installer or maintenance provider for further Insulation class A Rank
information about your system design.
Operating time Continuous
CHARACTERISTICS AND PERFORMANCE
THE FUSION® DUAL-PORT BLOWER 60 Hz

The Fusion ® treatment unit utilizes an electronic, dual-port blower Voltage(V) AC 120V Voltmeter
designed specifically for use with this system. The blower consists Current (A) 0.88 or less Ammeter
of a linear motor and two diaphragms to generate the air flow
necessary to aerate and recirculate water within the system. This +20%
Air volume (L/min) 80 Mass Flowmeter
style of blower is quieter and more efficient than traditional rotary -10%
vane compressors. Once installed and adjusted, circuitry within the
140 F (60 °C) or less at 86 °F Thermo pen
blower will automatically switch the unit from normal recirculation Temperature rise (30 °C) room temperature recorder
mode to backwash mode and back again when appropriate. In the
event of a power outage, the blower will stop, but a backup battery Note: * The above performance is a stable state at a pressure (14.7kPa)
within the unit will retain the correct time and backwash settings. and a value at room temperature in an atmosphere 68 - 77 °F (20 to 25 °C)
* The air flow rate value refered to the amount of air flowing at a
Usage Conditions temperature of 68 °F (20 °C), an absolute pressure of 101.3 kPa, and a
relative humidity of 65% per unit time.
Item Use conditions
Continuous operation
Operation
(outdoor use)
Installation Should be level
41 °F - 104 F(5 C - 40 C) natural
Ambient Temperature
ambient temperature.
Range of pressure 5.0 - 27.5 kPa
Rated operating pressure 14.7 kPa

© Copyright 2022. All rights reserved.

3
 2.95
DATAPLATE
Figure 5 F U S IO N TRE ATM EN T SY ST EM
A dataplate similar to the one in Figure 5 is located on the blower □ ZF 450 450 GALLONS/DAY ®

housing and the alarm panel. There is important information about □ ZF 800 800 GALLONS/DAY Certified to

the Fusion ® on the dataplate, such as the part number, model

NSF - ANSI
Standard 40

number, serial number, and hydraulic capacity. Please make a note 2.36 MFG．DATE：

of this information for future reference or in case you should need to Manufacturer:

P/N 018860-G
Zoeller Pump Company • 3649 Cane Run Road ®

Louisville, KY 40211 • 1-800-928-7867 toll free

contact your Fusion ® maintenance provider.
B LO WER SER V I ＣE P ART S
The contracting installer must mark the installed model number on COMPLETE BLOWER: P/N 5250-0050-D
BLOWER DIAPHRAGM: P/N 156508-A
the dataplate, the blower housing and the alarm control panel. BLOWER FILTER: P/N 156509-A

ALARM PANEL Figure 6

RED BEACON
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 WARNING!

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 SILENCE/TEST
modes within the preset time. (Note: Alarm panel can only function SWITCH
as long as there is electrical power supplied to the panel)

You may from time to time check the proper operation of the alarm
P/N

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 BUZZER
FUSION
operation. DATAPLATE sk2649

SYSTEM CARE Figure 7 1 2 3 4 5 6 7 8

The Fusion system is designed to continuously operate automatically with

®

TB2 GND LUG

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
120 VAC L1 DISNF
the alarm panel section. The owner should closely monitor the types and ALARM
INCOMING N
amounts of substances and products used. Water use should also be closely POWER GND
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
HIGH WATER
maintenance provider can be recorded on the front of this document and should ALARM
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 traffic. 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.
sk2933
BLOWER

HIGH USE WATER DEVICES LEAKY FIXTURES

The draining of hot tubs and swimming pools into your Fusion ® system It is very important to monitor all water fixtures in the home for leaks and
will cause hydraulic overloading and will impair the treatment efficiency. drips and repair them immediately. Leaks can cause tremendous water
Please drain these devices to another location. Contact your local use and may hydraulically overload your Fusion ® system and reduce
regulatory authorities or authorized Fusion ® maintenance provider for its treatment efficiency. Excessive water use may also overload your soil
more information. The use of large capacity single fill and drain whirlpool absorption field and cause failure.
bathtubs may also cause hydraulic overloading of your Fusion ®. Please limit
the use of these types of tubs. INTERMITTENT USE
The Fusion® system is designed to function even if wastewater does not
FLOODING enter it for extended periods of time. The power to the blower must remain
If flooding of the Fusion ® occurs and the blower or the on during this time for the system to function properly. Weekend use will
alarm panel is submerged, please disconnect power at the circuit breaker. not harm the system as long as the blower is on. Should seasonal use
DO NOT try to reconnect power to either the blower or alarm panel once require a complete shut down of the property, then it is recommended that
it has been submerged. Immediately contact your authorized Fusion ® the blower be turned off. It is important to start up the system in advance of
maintenance provider to inspect the Fusion ®, the blower, and the alarm actual occupancy to allow for normal treatment to resume. Please contact
panel. Your maintenance provider will repair or replace the components as your authorized Fusion® maintenance provider for further information
needed. concerning shut down and startup of the Fusion®. You may also contact
your maintenance provider for the shut down and startup services.

© Copyright 2022. All rights reserved.

4
 HARMFUL SUBSTANCES INITIAL SERVICE POLICY
The Fusion is designed to treat household type waste and can
®
The Fusion models ZF-450 and ZF-800 (NSF Standard 40, Class
®

treat most common substances introduced into the system. 1 certified systems) have a two-year service policy included in the
However, certain harmful substances may reduce the efficiency initial purchase price. The service policy will include two inspections
or stop the treatment process by reducing or destroying the per year for a total of four inspections. During these inspections,
beneficial bacterial populations responsible for treatment. In numerous system checks and adjustments will be made to ensure
general, if a chemical substance is considered harmful to humans proper operation.
then it should also be considered harmful to the Fusion ® treatment
system. If you have any questions concerning the use of any of EXTENDED MAINTENANCE POLICY
these substances, please contact your Fusion ® maintenance
provider. The introduction of any substance on the “Do Not" List An extended maintenance policy is available for purchase from
into the Fusion ® will void the warranty. 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
- THE "DO NOT" LIST - Fusion ® distributor or maintenance provider for further information
DO NOT introduce the following substances into the Fusion ® regarding the extended maintenance policy.
treatment system:
• Motor oil • Antifreeze AUTHORIZED MAINTENANCE PROVIDER
• Brake fluid • Paint Your authorized maintenance provider will perform many system
• Paint thinner • Gasoline checks and adjustments as needed during the maintenance inspection.
Two inspections per year will be made for a total of four inspections
• Solvents • Pesticides
during the initial service policy. Please see the Operation and
• Herbicides • Strong disinfectants Maintenance section of this manual for further details.
• Strong caustic drain • Toilet tank
cleaners in excess disinfection chemicals Should there be any operational deficiencies with your Fusion ®,
the maintenance provider will notify the owner in writing when
• Excess pharmeceuticals • Chemicals & chemical
the deficiencies will be corrected. If the maintenance provider does
waste
not correct the deficiencies or the service calls are not completed,
Not Recommended: Trash and excess food products will likely please contact Clarus Fusion® at 1-800 928 2731.
increase frequency of pumping.
INSPECTION AND MAINTENANCE
Trash
FREQUENCY
• Sanitary napkins and • Condoms Fusion® Series systems are to be inspected and maintained every
feminine products • Cat litter six months under normal usage. The inspection and maintenance
• Diapers • Dental floss are only to be performed by personnel trained and authorized by
Clarus Fusion®. A Maintenance & Service Report (CL0059) is to be
• Paper products such as • Cigarette butts
completed for each inspection and maintenance visit.
paper towels & baby wipes • Plastic/rubber products

Food Products
ALARM CONDITION
• Coffee filters and grounds • Greases or lards
• Fruit and vegetable peels • Seeds If an alarm condition occurs, please check the air intake area
around the blower and make sure no debris blocks the blower
• Meat products • Bones
intake. Remove the air filter cap by removing the screw from
• Garbage disposal waste • Egg shells the cap and then pulling on the sides of the top of the blower.
Limited Use Products Remove the foam filter and gently tap against your other
hand. If it is very clogged wash it in warm, soapy water and
Certain products in small or moderate amounts should not
dry well before replacing. Reassemble filter and cap on top of
disrupt the Fusion ® treatment process. You should always use the
blower. Do not attempt to remove the blower housing or any
minimum quantities of these substances as recommended by the
other parts from the blower. If the blower is operating properly,
manufacturer.
there may be a high water condition within the Fusion ®. It
• Liquid laundry bleach only as needed per load may be necessary to discontinue water use until the alarm
• Liquid laundry detergents without added bleach condition has been resolved. If the buzzer continues to sound
• Liquid dishwashing detergents or the red light stays on, please contact your authorized Fusion ®
• Household cleaners 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
EFFLUENT QUALITY resolved.
Fusion Series systems are compact, efficient, and designed to
®

be installed in a typical residential/light commercial environment. POWER OUTAGE

The final effluent leaving the system will typically be treated to the Should you experience a power outage, the blower will not
secondary quality strength of *9 mg/L CBOD 5 and 9 mg/L TSS. 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
* Based on NSF/ANSI Standard 40 testing.
cause the treatment efficiency to decrease. During a power outage,
the Fusion® will still allow effluent to flow, and will not create a
WATER SOFTENERS backup in the home. You may, however, have a pump or dose tank
If water softners are present in the home, Clarus Fusion® with a pump on the outlet of the Fusion ®, which requires power to
recommends the use of water and salt conservative models that pump the effluent to the soil absorption field. If you have a system
are installed and operated correctly. If you have questions about such as this, please be aware of this condition and conserve water
softeners, contact the Water Quality Association at www.wqa. accordingly.
org. Contact factory for installation details.
© Copyright 2022. All rights reserved.
5
 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®. This will allow
sufficient room for proper backfilling.
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 flow 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).
6. If the Fusion Unit will be installed at grade, please contact the factory for design assistance.

BACKFILLING COLD WEATHER INSTALLATION

1. If groundwater is present, anti-flotation measures must be When installing Fusion ® in cold climates, the designer may
used to stabilize the unit prior to backfilling. Please follow the specify insulated lids and risers. In addition, the blower must be
procedures in the Anti-flotation section to properly anchor protected from snow drifts. If installed in a riser, the blower must
the Fusion ®. be protected from inundation and may have a vent pipe installed
2. Fill the unit with clean water to the normal operating depth to above the maximum snow depth with a 180 degree angle at the
prior to backfilling. Partition walls between chambers are end to prevent snow and water entry. Also, the top and sides of the
water-tight and will fill in succession beginning on the inlet side Fusion ® may be insulated with insulation sheeting or other means
of the unit. Therefore, it is best to alternate chambers when to provide a minimum insulation value of R-8. Please contact the
filling with water so the unit remains level. Check for leakage factory for further information.
around the unit.
3. If necessary, install riser extensions on the adapter rings
prior to backfilling. See Table 1 for number and size of access
ANTI-FLOTATION PROCEDURES
openings. Riser extensions are available for deeper burial. It is necessary to anchor the Fusion ® in high ground water
Make certain risers are sealed properly and watertight. conditions to prevent flotation. If groundwater rises above the rock
4. CAUTION Apply two beads of silicone fully around each or concrete pad that the Fusion ® sits on, anchoring is required.
riser section prior to securing with supplied screws. Please consult a design engineer, soil scientist or other qualified
5. Install riser covers. individual to determine high groundwater conditions.
6. Backfill with good quality granular soil around the unit that is 1. Follow the procedures outlined in the Excavation and
free of organic matter, rock, stone, tree roots, or other debris Installation Section, items 1-5, to properly prepare and level
that could damage the unit. the Fusion® excavation.
2. Follow the procedures outlined in the Backfilling Section,
7. Tamp soil around perimeter of the unit as it is backfilled to
items 1-4 to properly fill the Fusion ® with water and add risers
stabilize the unit and to reduce settling.
if needed.
8. Finalize backfill with a mounded contour so that surface water 3. Refer to Figure 10, Anchoring Schematic to determine the
is shed away from the unit. Under no circumstances should minimum amount of backfill to be placed around the Fusion ®
surface water be allowed to accumulate around unit. in the excavation. Tamp the fill to prevent settling.
9. CAUTION MAXIMUM soil burial depth over the unit is 36 4. Refer to Table 3, Concrete Anchoring Dimensions, to determine
inches (914 mm). the amount of concrete needed for the concrete anchor collar
that is poured around the entire circumference of the Fusion ®.
Pour concrete to the specified dimensions to fully engage
the mid-seam of the Fusion ®, which will anchor it once the
Table 1 concrete cures. Make certain to pour the concrete in a manner
number and size of access openings in fusion ® series
to minimize trapped air within the concrete. Agitating or lightly
mixing the concrete with a metal rod or other similar device
ZF-450 ZF-800
once poured will help release trapped air.
0 1
20" (51 cm) Diameter 5. Allow the concrete to harden before final backfilling.
24" (61 cm) Diameter 2 2 6. Complete the procedures outlined in the Backfilling Section,
items 5-8.

Table 2 Figure 8 - Dimensions OUTL

ET

INLET
E
FUSION® DIMENSIONS W
SYSTEM L W H I E
NOTES: H
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)
1) DIMESIONS "I" AND "E" ARE TO THE BOTTOM I
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) OF THE INLET/OUTLET PIPE.
L
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 SEPARATELY.
sk2624
© Copyright 2022. All rights reserved.
6
 Figure 9 - Lifting & Positioning Figure 10 - Concrete Anchoring

LESS THAN 60°

4-POINT 60° CONCRETE ANCHOR
COLLAR
LIFTING
LIFTING
HOOK

MIN. REQUIRED
BACKFILL
LIFTING UNIT SIZE Z
ZF-450 18"
LEVEL ACROSS TOP OF UNIT
ZF-800 21"

MANHOLE
H
FRAME

LEVELING
sk2931

Table 3 - Concrete Anchoring Dimensions

Model No Cover 6" (15 cm) Cover 12" (30 cm) Cover 18" (46 cm) Cover

W H Concrete Volume W H Concrete Volume W H Concrete Volume W H Concrete Volume

in (cm) in (cm) ft3 (m3) (CY) in (cm) in (cm) ft3 (m3) (CY) in (cm) in (cm) ft3 (m3) (CY) in (cm) in (cm) ft3 (m3) (CY)
16 24 14 24 13 24 12 24
ZF-450 72 (2.0) 3 62 (1.8) 3 56 (1.6) 3 51 (1.4) 2
(40.6) (61.0) (40.6) (61.0) (33.0) (61.0) (30.5) (61.0)
20 24 19 24 40,6 24 16 24
ZF-800 109 (3.1) 4 102 (2.9) 4 90 (2.5) 4 84 (2.4) 4
(50.8) (61.0) (48.3) (61.0) (17) (61.0) (40.6) (61.0)

Model 24"(61 cm) Cover 30"(76 cm) Cover 36"(91 cm) Cover

W H Concrete Volume W H Concrete Volume W H Concrete Volume

in (cm) in (cm) ft3 (m3) (CY) in (cm) in (cm) ft3 (m3) (CY) in (cm) in (cm) ft3 (m3) (CY)
12 24 24
ZF-450 72 (2.0) 3 12 (30.5) 51 (1.4) 2 12 (30.5) 24 (61.0) 51 (1.4) 2
(30.5) (61.0) (61.0)
12 24 24
ZF-800 109 (3.1) 4 14 (35.6) 72 (2.0) 3 13 (33.0) 24 (61.0) 66 (1.9) 3
(30.5) (61.0) (61.0)

© Copyright 2022. All rights reserved.

7
 Figure 11 - Typical Fusion ® Layout
FUSION ALARM PANEL

WARNING!

BLOWER RISER AND LID

TO DISPERSAL

CLEANOUT

SEWER LINE
AIR LINES

ALARM FLOAT
CONDUIT INSTALLED
BY CONTRACTOR
WHERE APPLICABLE OPTIONAL SEPTIC TANK INSTALLATION FUSION
MAY BE REQUIRED BY LOCAL sk2650
OR STATE REGULATIONS

BLOWER INSTALLATION AND PLACEMENT

DRILL HOLES FOR
1. The blower does not need to be connected to a grounded, metallic, permanent wiring BLOWER MAKE UP AIR
system, or an equipment-grounding terminal because it is double insulated, which TO PROVIDE PROPER VENTILATION
AND COOLING
provides grounding.
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 Fusion®.
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
DECORATIVE ROCK CONFIGURATION
3/4" (19 mm) diameter piping (Figure 12). If longer air lines are needed, consult the
factory.
7. The blower is provided with two discharge ports. The blower label is color-coded with the
aeration outlet port being BLUE and the backwash outlet port being RED (Figure 12).
8. The air port inlets on the Fusion® 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).
INTERIOR CONFIGURATION
10. Attach the small diameter black air tubing (included in the blower box) to barbed fitting
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
fittings in the alarm panel (Figure 12). Figure 12
11. Connect the remaining end of each PVC tee to the BULK HEAD FITTINGS FUSION UNIT
airlines installed in Step 6.
12. Install the Fusion® blower at an elevation where the
BLUE AIR
AIR LINE FROM PUMP LINE BLOWER

air line outlets are located above the elevation of the POWER
CORD

Fusion® air line inlets (Figure 12). 1/2" SCH 40 PVC

RED AIR
LINE
AIR LINE
TO PANEL
ADAPTER DRILL HOLES FOR
HIGH WATER FLOAT CONDUIT BLOWER MAKE UP AIR
TO BE INSTALLED BY ! WARNING
ELECTRICAL SHOCK
HAZARD

TO PROVIDE PROPER VENTILATION

CONTRACTOR AND COOLING
(WHERE APPLICABLE) CONDUIT TO PANEL SPRING
SEAL AFTER LINE CLAMPS
INSTALLATION

RUBBER
BLUE AIR
ELBOWS
LINE AIR LINES
TO PANEL RED AIR
LINE

ALARM FLOAT
CONDUIT DECORATIVE ROCK CONFIGURATION

TO PREVENT ELECTRICAL SHOCK AIR SENSOR LINE

BLOWER

FROM BACK-SIPHONING, LOCATE

INTERIOR CONFIGURATION
GLUE
FITTINGS
THE BLOWER ABOVE THE WATER 1/2 X 3/4 REDUCER

LEVEL.
INSTALL BUSHING IF AIR
LINE IS LESS THAN 17'
TO UNIT

sk2639

© Copyright 2022. All rights reserved.

8
 PIPING INSTALLATION ELECTRICAL CONNECTIONS
1. Connect house sewer pipe or septic tank outlet, if
1. All electrical installations must follow the
required, to the unit inlet. Make certain only household
National Electrical Code and/or your local/state electrical
waste enters the unit (no foundation drains, gutter
codes.
drains, floor drains, etc.).
2. The blower should be directly wired into the alarm panel. The
2. Connect the outlet pipe to the outlet of the unit. blower's power cord does not contain a ground wire because
it is internally grounded with double insulation. The alarm
panel must be located in a dry location that is accessible for
HIGH WATER ALARM FLOAT INSTALLATION maintenance. Please see Figure 7 and the wiring diagram
and instructions enclosed with the alarm panel.
The Fusion ® alarm panel assembly includes a high water alarm 3. Make certain the timer within the control panel is set to the
float switch that is used to monitor the liquid level in the Fusion ® proper time. The timer unit display should be set to 10 hrs.
unit. The switch should be tethered to one of the gray, vertical and the timer dial needle set to 3.6 for 36 hours. This will
air lines in the aeration chamber with a 3" (76 mm) tether activate an alarm if the blower doesn't go into backwash
length. The cord should pass through the opening in the partition cycle within a 36-hour time frame.
wall between the aeration and anaerobic chamber and allow
the float to hang in the outlet baffle of the anaerobic chamber. START UP
An installation and start-up check list (CL0057)
is furnished with the information package in the blower box.
1. The float switch should be tethered to one of the gray, Please use this as a guide and fill out all sections and return to
vertical pipes in the aeration chamber. When the float is your distributor.
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 baffle. Figure 13 - Aeration Flow Adjustment
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 float with a 3" (76 mm) tether. CLEAN-OUT CLEAN-OUT RECIRC.
4. Tighten the clamp with a screwdriver. Be careful not to
overtighten as this may cause damage to the plastic clamp. 2
FLOW RECIRC. PIPE GREY 0 100
5. Make sure the float cord is not allowed to touch the
excess clamp band during operation as this may cause
damage to the cord. 50 1
BLUE 100 100 3 50
6. The float switch cord should be installed in an electrical RED 100 100
conduit connecting the alarm panel to the Fusion® unit. The
electrical conduit must be rated for burial, and should be SLUDGE TRANSF. PIPE
4
properly sealed to prevent gases from entering the alarm GREY 0 100
panel.
CLEAN-OUT
CLEAN-OUT SLUDGE TRANSF.
7. A 1/2" (13 mm) bulkhead fitting (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 ARERATION AIR-IN BACKWASH AIR-IN
(BLUE) (RED)
between the red and blue bulkhead fittings to facilitate
this connection.
8. Please be certain that the bulkhead fitting for the electrical
SK3208
conduit forms a watertight connection with the FRP wall
of the Fusion ® unit.
9. Electrical conduit from the Fusion® unit to the alarm Valve Legend:
panel can be buried in the same trench as the air lines. 1. Aeration Blue 3. Backwash Red
10. The control switch can be wired directly into the alarm 2. Recirculation Gray 4. Sludge transfer Gray
panel. See Figure 7.

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 flow on each side of the unit to verify equal
flow. If there is an obvious discrepancy in air flow between the two
sides, adjust the valves (1 and 3) so that the flow is equal.

© Copyright 2022. All rights reserved.

9
 RECIRCULATION FLOW ADJUSTMENT BACKWASH FLOW ADJUSTMENT

The recirculation flow is designed to be 1.2-1.8 times In order to prevent plugging of the media in the
that of the average design inflow. Table 4 indicates aeration chamber, the backwash cycle activates
starting flow rates for each unit. However, fine at a preset schedule. If there is no backwash cycle
adjustments may be necessary to ensure optimum or if the backwash cycle is too short, the unit’s
performance. performance will be adversely affected. Likewise, if
the backwash cycle is too long, performance will be
Setting the flow rate: compromised.
• Adjust the flow using rates in Table 4.
The backwash cycle begins at 2:00 AM and lasts for
• The flow rate is adjusted by rotating the gray five minutes. One hour later, another five minute
recirculation valve (2) and observing the flow at the backwash cycle occurs. The backwash initiation
pipe end. time can be set for any time during a 24-hour period
• There are prescribed lines at the outlet of the to accommodate unusual water use patterns. The
recirculation pipe to aid in approximating the correct goal is to set the time when there is no flow into the
flow. unit.
The backwash cycle and sludge transfer from the
Measuring the flow rate: aeration chamber takes place in the same action.
T • The actual flow rates must be measured to verify Verify that the air flow is uniform across the
flowBACK
after adjustment
FLOW PREVENTER of the valve and observation aeration chamber during a backwash cycle. If not,
at the pipe end. adjust the red backwash valve (3) accordingly.
HOSE

WATER
• Measure the time in seconds required to fill a 1L
container.
Setting the flow rate:
• Compare the time to value ranges in Table 4.
• If necessary, adjust the valve again and collect • On all HIBLOW HP series model blowers, press
another sample to verify the correct flow rates. the [MINUTE] button for at least 2 seconds to
switch to manual mode. The "aeration" and
"backwash" can be switched by the [MINUTE]
button. BRUSH
• Set the backwash flow rate by adjusting the
BLOWER
SPIGOT It is important not to set the flow rate too high gray sludge transfer valve (4). Use Table 5 to
because itBACK
canFLOW
cause excessive agitation within the first chamber
PREVENTER determine the setting for each Fusion ® model.
(Sedimentation Chamber). This could result in poor performance. CLAMP
HOSE Measuring the flow rate:
WATER • Measure the actual backwash flow rate at the
G.L
outlet of the sludge return pipe in the first
Table 4 - Recirculation Flow Rates chamber the same way the recirculation flow rate
is measured.
Model ZF450 ZF800
EXISTING AIR LINE • Adjust the gray sludge transfer valve (4) if
Recirculating flow rate (sec/liter) 29-45 14-22 necessary to obtain the proper
BRUSH flow.

Suggested Valve Opening

BLOWER 35-40% 30-35% • Be sure to press [SET] to return the unit back to auto
mode on HIBLOW Unit.
TOCLAMP
TREATMENT UNIT

Figure 14 - Flow G.LTable 5 - Backwash Flow Rate Setting

Measurement
Model Frequency ZF450 ZF800
EXISTING AIR LINE SU
RECIRCULATION OR
BACKWASH PIPE Backwash flow Twice/day 7-10 4-6 R GGE
AN ST
rate (sec/liter) GE ED

TO TREATMENT UNIT
Valve open (%) Twice/day 50-55%
0
60
7
50
40-45%
40
30
20
80

10
90

MC
Figure 15 - Flow L
100

Controlling Valve
SU
RECIRCULATION OR G
BACKWASH PIPE RA GES
NG TE
E D
CONTAINER 50
60 40
30
70
20
80

10
90

MC
L
100

CONTAINER

SK3195
SK3195

© Copyright 2022. All rights reserved. R

PUMP COMPANY
10
 HIBLOW DU080 BLOWER Figure 16
TIMER SETTING
HiBlow Timer Settings
To Adjust Clock:
1. Remove phillips screw from top of upper housing
and then detach filter cover to access LCD screen
from the back of housing.
2. Press Select button twice and shift to Set mode.
3. Press Edit buttons plus simultaneously and
shift to adjust clock.
4. Press Up button or Down button then select AM
or PM. Press Select button and shift to hour setting
5. Press Up button or Down button then set hour.
Press Select button and shift to "min" setting.
6. Press Up button or down button then set "min".
Hold Select button for 1 second to set time. HIBLOW Blower
Backwash Cycles:
1. Port two is used for main aeration cycle and port 1 is
used for the backwash cycle.
2. The blower is factory preprogrammed with the
correct frequency and duration of backwash cycles
per day. The first backwash cycle is set to begin at
2:00 AM and end at 2:05 AM. The second backwash
cycle is set to begin at 3:00 AM and end at 3:05 AM.
Please follow steps 1-5 below to verify the correct
settings or to adjust/change them.
To Adjust/Change Backwash Settings:
1. Press Select button twice and shift to Set mode.
2. Press Up button three times until "ID 03" is
showing.
3. Press Edit buttons plus simultaneously.
4. Follow set/change clock instructions to change the
start time.
5. Enter end time and hold Enter button for 1 second
to complete.

To Switch Between "Manual" Backwash Mode and "Auto"

Backwash Mode:
1. Press Select button once and shift to manual mode.
2. Press Up button or Down button to change ports.
3. Press Select button two times to shift back to AUTO
mode.

© Copyright 2022. All rights reserved.

11
 FUSION® OPERATION AND MAINTENANCE
The following steps are to be completed during each 2. Scum – Very small amounts of scum may accumulate
6-month inspection. All information collected during the in the corners on the outlet end of the system. This
inspection is to be recorded on the Maintenance and Service is normal. Scum, should not be present elsewhere
Report (CL0059). Begin the inspection by recording the date, in the clean water storage chamber unless the
arrival time, weather conditions, purpose of the visit, water recirculation rate is too high or daily flow exceeds
use, model number, serial number, the presence or absence the design capacity. If present, use ladle to transfer
of a septic tank, and the system owner and service provider to sedimentation chamber.
information in the space provided on the report. 3. Sludge – Test the sludge depth using the sampling
GENERAL OBSERVATIONS device included in the maintenance kit. The bottom
section of the sampler includes a check valve, which
1. Are any odors present? There should be no odor opens as the unit is lowered into the liquid. When
with the lids closed, if properly sealed. With lids the sampler has reached the bottom of the chamber
removed, a septic or sewer-like odor is indicative and the liquid level equilibrated at surface level, lift
of poor treatment and is common immediately after the sampler and this action will set the check valve
startup due to hydrogen sulfide and other gases. and retain the sample in the tubing. Withdraw the
A well-operating system will have a musty, earthy sampler and note the depth of settled solids within
smell similar to wet peat moss. the sample. To release the material in the unit,
2. Is there evidence of high water? Typically indicated touch the stem extending from the bottom section
by a water level above the black wall markings against a hard surface such as the partition wall in the
and above the “0” graduation on the partition sedimentation chamber. This opens the check valve
wall stickers. May also be indicated by debris on to drain the sample. A range of 0” to 4” is preferred.
partition walls. Typically solids are brown and well flocced. More than
4” (0-102 mm) is typically due to high recirculation
3. Is there excess foam formation? Foam may be rates and sludge will appear black in color. To correct
present during an inspection. Brown foam indicates sludge depths greater than 4” (0-102 mm), decrease
bacterial buildup following startup. White foam the recirculation rate and increase the backwash rate.
is due to detergent use. Neither is a problem if
occurring intermittently. Detergent-based foam Sludge Descriptions:
will often be accompanied by low transparency Black – septic or sewer-like odor due to hydrogen
readings. sulfide and other gases
4. Is there residue build-up on piping? Typically Brown – undigested sludge is light brown, becomes
indicated by gray or black residue (dried foam) darker with digestion, lightly settled
on aeration chamber piping.
Clear – may see a clear water layer beneath solids if
5. Is there even and vigorous bubbling? Bubbles gas carries solids upwards
surfacing in the aeration chamber should be even
across the entire chamber. If uneven, cleaning steps Flocced - settled with texture similar to a tuft of wool
should resolve this issue. Grainy - gritty or sandy texture
Gray - partially digested sludge
REQUIRED WATER QUALITY ANALYSES Milky – light in color, cloudy, not transparent
PART A: Clean Water Storage Chamber – Collect samples Muddy – typically well settled, often present just after
from the clean water storage chamber to be used for startup, may be due to infiltration
the following analyses
Mustard - an off-color, remnants of digestion are often
1. Transparency – Measures the ability of the water to yellowish in color
transmit light. Using the ladle, fill the transparency White - sometimes present after new construction
tube with a water sample collected from the clean often due to drywall mud
water storage chamber. Looking down through the
water column, slowly drain the transparency tube PART B: Anaerobic Chamber - collect samples from the
using the valve on the flexible hose until you can outlet baffle of the anaerobic chamber to be used for
first distinguish between the black and white colors the following analyses:
on the secchi disk in the bottom of the tube. When 1. Transparency – A transparency reading more than
the secchi disk is visible, close the valve and read 20 cm is preferred.
the transparency (in centimeters) on the side. Dirty 2. Scum – Should not be present unless recirculation
water samples transmit less light and result in a lower and/or backwash rate is too high or daily flow exceeds
transparency. A transparency reading > 20 cm is design capacity. To correct, reduce the recirculation
preferred and 34 cm is average. Low transparency and or backwash rate.
may be due to a lack of biological activity as in a 3. Sludge – A range of 0” to 15” (0-38 cm) is preferred.
young system, a recirculation rate that is too high,
Typically brown and settled, becomes gray to black
or a system influent high in detergent concentration.
as depth and digestion increases. More than 15” (38
To correct low transparency readings not caused by
detergent, decrease the recirculation rate. Detergent cm) may require a reduction in recirculation rate. A
based problems may require consultation with owner. sludge accumulation of greater than 24” (61 cm) in

© Copyright 2022. All rights reserved.

12
 FUSION® OPERATION AND MAINTENANCE, continued
the sedimentation and 15” (38 cm) in the anaerobic
chamber requires pumping.
PART C: Sedimentation Chamber – collect samples from
the outlet baffle 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.

Figure 17 - Inspection details

RECIRCULATION WALL OPENING

RECIRCULATION BAFFLE

G.L G.L
RECIRCULATION WALL OPENING

RECIRCULATION BAFFLE
W.L W.L W.L
G.L W.L
G.L
INFLOW

EFFLUENT
W.L W.L W.L
W.L

INFLOW
BAFFLE
EFFLUENT
EFFLUENT
INFLOW BAFFLE

BAFFLE
EFFLUENT
INFLOW BAFFLE

BACKWASH
(RED)
BAFFLE
RECIRCULATION WALL OPENING
AERATION
SLUDGE RETURN (BLUE) 6" (152mm) STONE OR CONCRETE PAD BACKWASH MECHANISM
BACKWASH
(RED)
BAFFLE

TOP VIEW
SLUDGE RETURN
AERATION SIDE VIEW RECIRCULATION WALL OPENING

(BLUE) 6" (152mm) STONE OR CONCRETE PAD BACKWASH MECHANISM

TOP VIEW SIDE VIEW

SK3194

© Copyright 2022. All rights reserved.

13
 AERATION CHAMBER CLEANING
1. 
Aeration 2. Backwash
The aeration system must be flushed every maintenance The backwash system must be flushed every maintenance.
visit. There are two flushing methods: (A) Air flushing and (B) There are two flushing methods: (A) Air flushing and
Water flushing. Air flushing must be done every maintenance (B) Water flushing. Air flushing must be done every
visit. Water flushing may be done if there is a sign of maintenance visit. Water flushing must be done if there is
clogging in the aeration chamber (e.g. abnormal increase in a sign of clogging in the aeration chamber (e.g. abnormal
recirculation flow). increase in recirculation flow).
Figure 18 (A) Air flushing procedure:
• Make sure the blower is in the backwash mode.
SPIGOT
BACK FLOW PREVENTER • Close the gray sludge transfer valve (4) all the way.
HOSE

WATER
• Rotate the red backwash valve (3) back and forth from the
0% to the 100% position several times to flush.
• Set valves (3) and (4) back to the appropriate positions.
BRUSH (See Backwash System)
(B) Water flushing procedure:
BLOWER

CLAMP
Figure 19
(See Fig. 19)
G.L • Make sure the blower is off.
EXISTING AIR LINE
• Close valve (4) all the way.
•C onnect a water line to the backwash
TO TREATMENT UNIT airline as shown in Figure 18.
SK3195 • Gradually open the water faucet and
RECIRCULATION OR
SU
G
introduce water into the system.
RA GES
(A) Air flushing procedure: BACKWASH PIPE
NG TE
E D
• Rotate valve (3) back and forth from
• Make sure the blower is in the aeration mode.
50 40
60
30
70

the 0% to the 100% position several

20
80

10
90

• Make sure a check valve or backflow preventer is present MC

L
times to flush.
100

0
for water flushing procedure.
CONTAINER
• Turn off the water, remove the water line, and reconnect the
• Close gray recirculation valve (2) all the way. (0%) airline to the blower.
• Rotate blue aeration valve (1) back and forth from the 0% • Set valves (3) and (4) back to the appropriate positions. (See
to the 100% position several times to flush. Backwash System) R
R

PUMP COMPANY

• Set valves (1) and (2) back to the appropriate positions. (C) Cleaning the sludge transfer line:
(See Recirculation Flow Adjustment, pg. 10) • Make sure that the blower is in the backwash mode. If
not change the mode by pressing Manual Backwash.
(B) Water flushing procedure: (See Figure 18)
• Make sure the blower is off. • Open the gray sludge transfer valve (4) to 100%.
• Close valve (2) all the way. • Flush water through the sludge transfer line for a few
• Connect a water line to the aeration line as shown in seconds.
Figure 18. • Repeat this cleaning method three times.
• Gradually open the water faucet and introduce water • A hose or brush can also be used to clean the sludge
into the system.
transfer line. See Figure 20.
• Rotate valve (1) back and forth from the 0% to the 100%
position several times to flush. • Reset the gray valve (4) to its original position.

• Turn off the water, remove the water line, and reconnect • Return the blower to the normal aeration mode. by
the air line to the blower. pressing Manual Backwash.
• Set valves (1) and (2) back to the appropriate positions. Figure 20
(See Recirculation Flow Adjustment, pg. 10)

(C)
Cleaning the recirculation line:
• Make sure the blower is in the aeration mode. If not, BRUSH

change the mode by pressing the Manual Backwash

button. SK3195
• Open the gray recirculation valve (2) to 100%.
• Flush water through the recirculation line for several
seconds. 3. Foam formation
• Turn off the recirculation by rotating the gray valve Make sure there is not an excess amount of foam on the

(2) to 0%. surface. If excessive foam is present it may indicate high
• Make sure the blower is off. Allow the system to detergent usage. Meet with owners to inform and educate
relax for a few seconds. them concerning excessive use.
• Repeat this cleaning method three times.
4. Abnormal water level
• A hose or brush can also be used to clean the recirculation
If the water level exceeds the partition wall, clean the plastic
line. See Figure 20.
cage first with a brush, then check for possible clogging in the
• Reset the gray valve (2) to its original position.
filter 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.

© Copyright 2022. All rights reserved.

14
 FUSION ® PUMPING
Wastewater entering the Fusion ® contains organic and inorganic materials. If organic in nature, it is treated and decomposed by
microorganisms during the treatment process. If inorganic in nature, it will be stored within the Fusion ®. The stored materials accumulate
as scum (floating) 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 finished, refill both chambers with clean water to prevent the possibility of flotation.

Figure 21 - Sedimentation Chamber Pumping

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

Step 3: Remove the sludge under the media while washing the filter with tap water.
Vacuum

1) 2)

Sedimentation-separation tank

Figure 22 - Anaerobic Chamber Pumping

Vacuum Tap water
1) 2) 3)
Step 1: Remove the scum. Step 2: Remove the sludge
on the filter media.

Anaerobic filter tank

Remove the scum first. If you remove the sludge first, the water
level will decrease and the anaerobic filter will be blocked by the scum.

ALARM PANEL & BLOWER INSPECTION AND MAINTENANCE

Inspect the alarm panel for signs of water or odors inside. Toggle 2. Ensure the correct time is shown on the blower's display
the test switch on the side of the box to check that both the alarm screen, keeping in mind that the display shows a 24-
horn and the alarm beacon light are operational. hour clock (not AM/PM).
Inspect the blower for proper operation. If the blower is not 3. Engage the manual backwash cycle as instructed on page 11
functioning, refer to the troubleshooting section near the end of and ensure the blower switches into backwash. Be sure to
this guide. switch the blower back into Auto as instructed on page 11.

1. For the HiBlow DUO80 blower, inspect the air filter once power
has been disconnected by removing the phillips screw from
top of upper housing and then detach filter cover to access
filter (page 17). Remove the filter and inspect it. Remove any
dirt and dust or replace it with a new filter. The filter may
be washed in soapy water. Make certain it is completely dry
before replacing it. Remove any dust from the upper housing
before reattaching the upper cover.

© Copyright 2022. All rights reserved.

15
 TROUBLESHOOTING
1. Odor 4. Blower
Offensive odors are often the result of insufficient or Blower motor does not run, with power connected:
inappropriate bacterial growth. Causes may include a young • Check the electric supply to the panel, ensuring 120 volt service.
or unestablished system, insufficient air introduction, or the • Check that all breakers and fuses in the panels are intact.
addition of detrimental chemicals or poisons into the system. • Check the blower's safety switch mechanism (See pages 20).
Ensure the blower and air delivery systems are functioning.
Check with the owner regarding chemical use and disinfection Little or No aeration/ backwash air:
habits. Check all risers and lids to ensure an airtight seal. • Check the blower motor is running.
• Check the air line piping connections at the blower.
2. Foam Formation • Check the air filter and clean or replace if necessary.
• Check the diaphragms and replace if necessary.
Foam formation is observed in the following situations: • Check the air piping for leaks, clogs, or dislocations and correct
accordingly.
1. In the early stage of operation when the aerobic bacteria • Verify check valves (if installed) in supply lines are installed
colony is establishing itself. correctly.
2. When an excess amount of air is supplied for aeration
Blower- Manual backwash does not work.
3. When the difference between ambient temperature and
• Manually toggle between recirculation and backwash several
water temperature is great.
times, listening closely for a light click within the unit.
4. When an excessive amount of detergent is introduced.
• If the unit clicks, but the air does not switch from aeration to
In most cases, foam will disappear with proper operation.
back-wash, consult the factory.
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
first chamber and adjust recirculation flow rate as well as
backwash time, frequency and duration. (See backwash flow
adjustment)

• Check the aeration situation:

If uneven bubble generation is observed, adjust valve (1). If
aeration is weak, flush the aeration pipe with air or water.

• Check the recirculation flow rate:

If the recirculation flow rate has increased after the last
inspection, the aeration pipe may be clogged. Flush the
aeration pipe with air or water. If the recirculation flow 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 flow
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 (figure 18) may assist.

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16
 CLEANING THE HIBLOW DUO 80 FILTER (Refer to Fig.23)
• Remove screw (refer to fig.23-1). Detach filter cover from upper housing (refer to fig.23-2).
• Replace with a new filter or clean the filter. Dust off filter to remove dirt and dust in case it is soiled heavily (refer to fig.23-3).
(Filter can be washed with soap and water. Make sure that filter is dried before reattaching.)
• Remove the dust at upper housing (refer to fig.23-4).
• Install filter and make sure that all 8 projections stay in every hole of filter gasket (refer to fig.23-5).
• Attach filter cover. Insert bosses on the bottom of filter cover into flutes on upper housing (refer to fig.23-6).

Fig.23

1) 2)

3) 4)

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17
 5) 6)

Replacing Diaphram Blocks

[1) Replacing built-in block (Refer to Fig.24)
• Remove all 5 screws and remove upper housing (refer to fig.24-1).
If it is stuck, insert screwdriver between upper housing and lower housing to pry apart.
• Remove sound absorber (refer to fig.24-2).
• Pull connector out (refer to fig.24-3).
• Remove screw from cord clamp.
• Remove 4 cushion rubbers pads. Remove built-in part (refer to fig.24-4).

Fig.24

1) 2)

3) 4)

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18
[2] Replacing chamber block (Refer to Fig.25)
• Remove built-in cover. Pick part up to remove the cover (refer to fig.25-1) .
• Insert gap jig for XP (that is attached to DUO repair kit) into one side (refer to fig.25-2).
• Remove one side of casing block. Loosen casing mounting screws and remove casing as shown in fig.25-3).
Fig.25

1) 2)

3)

[3] Replacing Diaphragm block (Refer to Fig.26)

• Remove locknut and washer (refer to fig.26-1).
• Remove diaphragm ring and diaphragm (refer to fig.26-2). In case it is not easy to remove, pull with long nose pliers.
• Attach one side of diaphragm. As shown in fig.26-3), put shadowed area together. Insert new diaphragm into groove on frame.
• Attach diaphragm ring back together (refer to fig.26-4). Use new diaphragm ring (attached to diaphragm parts).
• Attach washer and tighten locknut as shown in fig.26-1.
• Make sure that the center plate is at the center of a diaphragm (refer to fig.26-5).
• Attach casing block. Tighten 4 casing mounting screws as shown in the fig.25-3).
• Exchange opposite diaphragm repeating the same steps.

Fig.26
1) 2)

3)

5)

4)

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19
[4) Resetting Safety Switch (Refer to Fig.27)
• If safety switch has tripped, please reset for operation.

Fig.27
Tripped and Inoperable Reset position

[5) Reinstalling Built-in block (Refer to Fig.28)

• Reattach built-in cover parallel to frame (refer to fig.28-1) .
• Reattach 4 cushion rubber pads to built-in part, connect power cord and terminal for built-in part. Reattach lead wire to casing as
shown in fig.28-2).
• Tighten screw on cord clamp.

Fig.28

1) 2)

MAIL TO: P.O. BOX 16347 • Louisville, KY 40256-0347

SHIP TO: 3649 Cane Run Road • Louisville, KY 40211-1961
(502) 778-2731 • 1 (800) 928-PUMP • FAX (502) 774-3624 Visit our website:
zoellerpumps.com

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