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Zoeller Fusion Series Owner's Manual
Zoeller Fusion Series Owner's Manual

Zoeller Fusion Series Owner's Manual

Treatment systems

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Product information presented
here reflects conditions at time
of publication. Consult factory
regarding discrepancies or
inconsistencies.
Register your
Zoeller Pump Company Product
on our website:
http://reg.zoellerpumps.com/
Thank you for choosing a Fusion
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
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 Zoeller Pump Company at 1-800-
928-7867.
Warning Labels
You will find warning labels on the Fusion
control panel. It is very important to follow the information on these labels to
ensure your safety. Please do not remove these labels.

TABLE OF CONTENTS

Limited Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Process Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
System Components and Care . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Installation and Start Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Blower Installation And Placement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Operation and Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Aeration Chamber Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Blower Inspection and Maintenence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Manufacturer warrants, to the purchaser and subsequent owner
during the warranty period, every new product to be free from defects
in material and workmanship under normal use and service, when
properly used and maintained, for a period of two years from date of
purchase by the end user. No allowance will be made for shipping
charges, damages, labor or other charges that may occur due to
product failure, repair or replacement.
This warranty does not apply to and there shall be no warranty for
any material or product that has been disassembled without prior
approval of Manufacturer, subjected to misuse, misapplication,
neglect, alteration, accident or act of nature; that has not been installed,
operated or maintained in accordance with Manufacturer's installation
instructions; that has been exposed to outside substances including
but not limited to the following: sand, gravel, cement, mud, tar,
hydrocarbons, hydrocarbon derivatives (oil, gasoline, solvents, etc.),
or other abrasive or corrosive substances, wash towels or feminine
sanitary products, etc. in all pumping applications. The warranty set
out in the paragraph above is in lieu of all other warranties expressed
or implied; and we do not authorize any representative or other person
MAIL TO: P.O. BOX 16347 • Louisville, KY 40256-0347
SHIP TO: 3649 Cane Run Road • Louisville, KY 40211-1961
TEL: (502) 778-2731 • 1 (800) 928-PUMP • FAX: (502) 774-3624
Fusion
Series Treatment Systems
®
OWNER'S MANUAL
Large Commercial Models
ZFL-2800 & ZFL-4000
Series Treatment System. High-quality
®
and follow
®
, riser lids, blower, and the alarm
®
SEE LIST AT RIGHT
FO R WAR NI N G S
LIMITED WARRANTY
© Copyright 2022. All rights reserved.
1.
DO NOT attempt to service the Fusion
authorized maintenance provider for all service related issues.
2.
There are buried electrical cables and piping near and around the
Fusion
. Please consult with your authorized maintenance provider to
®
locate these utilities before excavation.
3.
DO NOT bury or cover the Fusion
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
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
System.
Fusion
Model:  ZFL-2800  ZFL- 4000
®
Serial No.
____________________________________
Installing Contractor
____________________________________
Phone Number
____________________________________
Installation Date
____________________________________
Maintenance Provider's Name
Phone Number
____________________________________
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 any needed
repair or replacement of part(s) or additional information pertaining
to our warranty.
MANUFACTURER EXPRESSLY DISCLAIMS LIABILITY FOR
SPECIAL, CONSEQUENTIAL OR INCIDENTAL DAMAGES OR
BREACH OF EXPRESSED OR IMPLIED WARRANTY; AND ANY
IMPLIED WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE
AND OF MERCHANTABILITY SHALL BE LIMITED TO THE
DURATION OF THE EXPRESSED WARRANTY.
Some states do not allow limitations on the duration of an implied
warranty, so the above limitation may not apply to you. Some states
do not allow the exclusion or limitation of incidental or consequential
damages, so the above limitation or exclusion may not apply to you.
This warranty gives you specific legal rights and you may also have
other rights which vary from state to state.
SECTION: C3.10.142
Supersedes
Visit our website:
zoellerpumps.com
unit yourself. Contact your
®
lids with soil or other debris. This is
®
or drive heavy equipment
®
Series Treatment
®
_____________________________
CL
0169
0122
0517

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Summary of Contents for Zoeller Fusion Series

  • Page 1: Table Of Contents

    Should further necessary to allow access for operation and maintenance of the unit. assistance be necessary, please contact Zoeller Pump Company at 1-800- The Fusion blower must be unobstructed and vented for proper ®...
  • Page 2 HOW A FUSION SERIES TREATMENT SYSTEM WORKS ® The Fusion is simple in design, yet advanced in its wastewater The Fusion utilizes a combination of anaerobic (without oxygen) ® ® treatment ability. The design has been refined over many years and aerobic (with oxygen) biological processes to treat wastewater.
  • Page 3: Process Description

    PROCESS DESCRIPTION hollow, cylindrical filter media 0.6 inch diameter (15 mm) 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.
  • Page 4 SYSTEM COMPONENTS The complete wastewater treatment system will typically consist of the Fusion treatment components and a soil absorption ® field for final disposal of the liquid effluent. Some states or counties may require the addition of a septic tank before the Fusion ®...
  • Page 5 DO NOT try to reconnect power to either the blower or alarm panel once it has been submerged. Immediately If water softeners are present in the home, Zoeller Pump Company contact your authorized Fusion maintenance provider to inspect ®...
  • Page 6 EXCAVATION AND INSTALLATION Excavate an area large enough for the Fusion ® Series unit to be installed. See Figure 5 and Table 2 for the actual dimensions of the unit. In areas where high groundwater is not a concern, excavation dimensions are calculated by adding 12-18" (305-457 mm) to the length and width of the Fusion ®...
  • Page 7 RISER INSTALLATION All large Fusion units are shipped without risers attached due to size restraints, therefore all units will need to have the chosen risers attached ® in the field. Please see the riser installation instructions below. Risers are 24 inches in diameter and 6 inches in height. Do not install more than two riser heights together for a maximum of 12 inches burial depth.
  • Page 8: Blower Installation And Placement

    BLOWER INSTALLATION AND PLACEMENT CLARUS FUSION ALARM PANEL WARNING! BLOWER RISER AND LID TIMER SWITCHING VALVE AIR LINES TO TREATMENT UNIT W. L W. L W. L SEWER TO DISPERSAL CLEANOUT ALARM FLOAT CONDUIT INSTALLED BY CONTRACTOR WHERE APPLICABLE OPTIONAL SEPTIC TANK INSTALLATION MAY BE REQUIRED BY LOCAL OR STATE REGULATIONS SK2955...
  • Page 9 Figure 10 - Lifting & Positioning Figure 11 - Concrete Anchoring CONCRETE ANCHOR LESS THAN 60° COLLAR 60° 4-POINT LIFTING LIFTING HOOK LIFTING LEVEL ACROSS TOP OF UNIT LEVELING sk2931 Table 3 - Concrete Anchoring Dimensions 6" C 12" C 18"...
  • Page 10 6. The float switch cord should be installed in electrical conduit PIPING INSTALLATION connecting the control panel to the Fusion unit. The electrical ® conduit must be rated for burial. Connect house sewer pipe or septic tank outlet, if required, to 7.
  • Page 11 RECIRCULATION FLOW ADJUSTMENT BACKWASH FLOW ADJUSTMENT The recirculation flow is designed to be 1.2-1.8 times that of the In order to prevent plugging in the Aeration Chamber, the backwash cycle activates at a preset schedule. If there is no average inflow. Table 4 indicates approximate flow rates for each backwash cycle or too short of a backwash cycle, the unit’s unit.
  • Page 12: Operation And Maintenance

    FUSION OPERATION AND MAINTENANCE ® 2" RECIRCULATION RETURN LINE INLET OUTLET 3/4" AIRLINE ADAPTER 2" BACKWASH RECIRCULATION 1" AIRLINE ADAPTER RETURN LINE BACKWASH SK2801 Figure 16 - Inspection details. REQUIRED WATER QUALITY ANALYSES The following steps are to be completed during each 6-month inspection.
  • Page 13 FUSION OPERATION AND MAINTENANCE, continued ® the sample. To release the material in the unit, 1. Transparency – A transparency reading more than touch the stem extending from the bottom section 20 cm is preferred. against a hard surface such as the partition wall in 2.
  • Page 14: Aeration Chamber Cleaning

    SYSTEM DIAGRAM Refer to sections on the following pages for detailed maintenance item descriptions. Figure 17 AERATION CHAMBER CLEANING Aeration. • Rotate valve (1) back and forth from the 0% to The aeration system must be flushed every maintenance the 100% position several times to flush. visit.
  • Page 15: Troubleshooting

    For further information, reference procedure identification number Disposal pump tank downstream of the Fusion ® SOP-F-103, Zoeller Pump Company, 1-800-928-7867. Fusion discharge chamber ® * Consult local rules and regulations to determine jurisdictional Distribution Box downstream of the Fusion ®...
  • Page 16 INSPECTION AND MAINTENANCE - PUMPING AS NEEDED Perform all inspection procedures listed in 6-month inspection. Pump out sludge in the first and second chambers (if necessary). If the maximum sludge accumulation has been reached, see description in 6-month inspection. Make sure to remove the scum on top layer first, then pump out the sludge of each chamber. Step 1: Remove the scum.
  • Page 17 © Copyright 2022. All rights reserved.
  • Page 18 ALITA DIAPHRAGM CHANGE-OUT INSTRUCTIONS Remove plastic air filter cover. (See Figure 24). Flip pump upside down and unscrew 6 screws on the corners and long side of the pump. Flip pump over and proceed to lift upper housing. (See Figure 25). Rotate and slide out of the detection pin knob on top of the pump core.
  • Page 19 TECHNICAL SPECIFICATIONS Actual Values Sound Blower Details Voltage Amps Flow (L/ Weight Chambers (dB) min.) Volumes (Gallon) Alita AL-250 41.5 Model Number ZFL-2800 ZFL- 4000 Alita AL-300 48.8 Clarus P/N 5250-0027 5250-0033 Switching Valve (P/N Sedimentation Chamber 1118 1551 151438) (Gallons) Anaerobic Chamber (Gallons) 1146...
  • Page 20 MAIL TO: P.O. BOX 16347 • Louisville, KY 40256-0347 SHIP TO: 3649 Cane Run Road • Louisville, KY 40211-1961 Visit our website: (502) 778-2731 • 1 (800) 928-PUMP • FAX (502) 774-3624 zoellerpumps.com © Copyright 2022. All rights reserved.

This manual is also suitable for:

Fusion zfl-2800Fusion zfl-4000