Otterbine/Barebo Comet User manual

Otterbine Barebo Inc.
Concept 3
50Hz Manual










































Manual PN: 75-0077 Rev 08

CONTENTS
Safety Instructions .....................................................................................3
Inspect Equipment.....................................................................................3
Electrical/PCC Pre-Installation...................................................................4
Unit Assembly............................................................................................4-5
Physical Installation ...................................................................................7
Mooring .....................................................................................................8
Anchoring ..................................................................................................8
System Startup ..........................................................................................9
Maintenance ..............................................................................................9
Winterization..............................................................................................9
Maximum Cable Lengths...........................................................................10
Troubleshooting Guide ..............................................................................10
Sunburst Pump Chamber ..........................................................................11
Gemini Pump Chamber .............................................................................12
Saturn Pump Chamber..............................................................................13
Rocket Pump Chamber .............................................................................13
Phoenix Pump Chamber ...........................................................................14
Tri-Star Pump Chamber ............................................................................15
Constellation Pump Chamber....................................................................16
Comet Pump Chamber..............................................................................17
Genesis Pump Chamber ...........................................................................18
Equinox Pump Chamber ...........................................................................19
Omega Pump Chamber.............................................................................20
Technical Data...........................................................................................21
Otterbine Warranty ....................................................................................22














Safety Instructions
WARNING: Read this manual before installing and using this
e equipment, save it for future reference
All Electrical Work Must Be Performed By a Qualified Licensed Electrician and Conform With All
Applicable Electrical Safety Codes
CAUTION: Power to the unit must be supplied through a residual current device (RCD) having a rated
residual operating current not exceeding 30mA , all equipment must be properly grounded
CAUTION: Do not operate the equipment when people are in the water, always turn off all equipment
before servicing or performing any maintenance
CAUTION: KEEP HANDS CLEAR OF THE IMPELLER WHEN OPERATING!
WARNINGS
• The operating temperature range for this equipment is -12oto 40o C; 10oto 104o F.
• Physically disconnect equipment from the power source before entering, wading in or swimming in the water.
• If the power cord becomes damaged, it must be replaced by an authorized Otterbine distributor.



INSPECT UNIT
Inspect the equipment and verify the following: Unit - Check the nameplate located on the housing to verify
you have received the correct horsepower and voltage, Power Control Center (PCC) Motor Controls – Verify
the controls are compatible with the unit. If supplied with an Otterbine panel refer to the technical information
on the inside door of the PCC, Power Cable Assembly - Verify the correct cable gauge and length. For proper
warranty consideration return your Otterbine warranty registration card. Report any shipping damage to the
carrier that delivered your aerator.
ELECTRICAL INSTALLATION
Caution: Ground Fault Circuit Interrupter (GFCI) or Residual Current Device (RCD) Protection is
required. If GFCI or RCD protection is not used, serious or FATAL electrical shock may occur.
A. Incoming Power
1. The unit requires proper feeder circuit protection in accordance with all applicable codes.
2. Verify the proper size and type of cable is supplying power to the Power Control Center (PCC) or motor
controls. Verify the proper size of conductors to allow for no more than 5% voltage drop for the entire circuit
from the feeder source to the unit. Failure to do so may damage the aerator and void the warranty.
B. Power Control Center/Motor Control Location
1. The controls should be mounted where easily visible from the shoreline where the aerator is located. The
controls must not be accessible from the water.
C. Power Control Center (PCC) Cables & Connections
1. Only use cable that is approved by Otterbine. Do not use any junction boxes or splices. Only use power
cord gauges and lengths as specified by Otterbine.
2. Exposed cable between the PCC and the shoreline should be installed in non-metallic conduit. It is
important that the unit and lighting cables be installed in separate conduits to avoid induced interference
between cables which causes random GFCI / RCD tripping. Always use strain relief cord connectors to attach
the cable to the PCC or motor controls.
IMPORTANT! The conductor with the green/yellow insulation shall only be connected to the ground
terminal marked or .







UNIT ASSEMBLY
READ THE INSTRUCTIONS: Improper assembly may result in damage to the unit.
NOTE: *Genesis Pump Chamber; The Float MUST be
mounted before the Genesis Throat Assembly (See
page 17). The unit will be received with the pumping
chamber already mounted.
*5HP "Open Throat" Units (Sunburst, Gemini,
Saturn); If applicable, the Supplemental Float must
be mounted to the Main Float before installing on
Unit (See Below).
A. Supplemental Float Assembly
*If the Supplemental Float is already mounted to the
Main Float, continue with main float assembly below.
1. Place Main Float top face down.
2. Place the Supplemental Float on the Main Float
as shown in the photo below.
3. Ty-Rap the floats together in four places (1 in each
pocket).
4. Continue mounting Main Float.
B. Main Float Assembly
1. Stand the unit upright and place the float onto it so the holes in the float line up with the holes in the
mounting brackets.
2. Place a fender washer onto a hex bolt and insert into one of the four holes in the float making sure it also
goes through the hole in the steel mounting bracket on the unit. Repeat this for the three remaining holes.
3. Place a flat washer and a nylon locknut onto each of the four hex bolts. Tighten each nylon locknut.
CAUTION: Do not over tighten lock nuts, damage may occur to the float and/or pump chamber.






Supplemental Float Assembly
Fasten supplemental Float with Ty-Raps
C. Mounting the Stabilizers (Comet Spray Pattern Only):
Mount each of the four stabilizer plates to the top side of a bracket using a hex bolt, a fender washer, and a
nylon locknut as shown below. Mount each of the four stabilizer plate assemblies to the top side of an outer
hole in the float using an eyebolt, a fender washer, and a nylon locknut as shown. Do not over tighten.
Damage may occur to the float.





D. Screen Installation
Debris Screens help to prevent clogging of the unit and are available for all Otterbine aerators.
1. Place the unit upside down on blocks so the pump chamber does not get damaged.
2. Pull screen over motor unit until it reaches the lip on the float.
3. Make sure the cable is running through the bushing in the screen.
4. Fasten the screen to the lip on the float with the washers and screws provided, spaced evenly as shown.

PHYSICAL INSTALLATION
Concept 3 units require a minimum operating depth of 30"/75cm (40"/100cm w/ lights).
A. Attach your Otterbine power cable to the unit.
1. Align the pigtail connector (see below figure #3) on the cable to the pin configuration on the bulkhead (see
below figure #2) on the unit. Thread the nut onto the bulkhead, hand tighten only, do not use tools on the pigtail
connector nut. Do not over tighten. Over tightening may cause the connector to fracture and possibly
cause an electrical short circuit.
2. 5HP, 230V, 1 Phase units have a 3 pin bulkhead connector and a 3 pin pigtail connector on the power cable.
All other ratings use 4 pin connectors.
3. A small amount of silicon compound has been factory applied to the female end of the unit connector. The
compound is necessary to make a waterproof seal between the two connectors. DO NOT REMOVE
COMPOUND! When servicing the aerator re-apply compound. (Otterbine P/N: 48-0001).
4. Install the cable strain relief device (see below figure #1). Pass the wire hoop from the strain relief
through one of the holes in the float or around the float bracket. Reattach wire hoop to strain relief.
5. For additional protection fasten the power cable, after the strain relief, to a float hole using the cable ties
provided.

B. Pre-Startup Checks (To be performed by a qualified technician)
1. Apply power to the PCC. Verify the voltage to the PCC at the input terminals is correct and matches the
nameplate rating of the aerator.
2. With the unit on the shore check for correct motor rotation. With 3 Phase units, briefly “bump” start the unit
(turn on only long enough to establish operation and direction of rotation) while observing the motor shaft
rotation. Single Phase units come from the factory set to run in a counter clockwise rotation.
IMPORTANT! Shaft rotation MUST BE Counter Clock-wise when looking at the top end of the unit.
C. Launching the Aerator
Itisimportanttochoosethecorrectlocationforyourunit.Placementaffectshowwellyou’reyourunitwillaidinkeeping
yourpondclean.Select the method of securing your aerator, mooring (see step C1) or anchoring (see step C2).
Mooring provides for easier installation and servicing of the aerator.
1. Mooring: The following items are required to moor your Otterbine aerator. Use only brass and stainless
steel hardware. Otterbine recommends using 1/4"(0.63cm) or 1/2"(1.25cm) polypropylene rope or stainless
steel cable for mooring lines. At the mooring points you will need a wooden stake, 1/2"(1.25cm) steel bar or a
"duck bill" type earth anchor. The earth anchor allows the mooring lines to be hidden beneath the surface of
the water. Install all anchoring points. Install the first mooring point securely into the ground at the outer edge
of the pond. If you are mooring with an earth anchor position the earth anchor two feet into the pond. Fasten all
of the mooring lines securely to the outer holes in the float. Launch the aerator into the water. Walk one
mooring line around to the other side of the pond and pull the unit into the chosen location. Secure the aerator
leaving enough slack in the lines to allow the aerator to turn 90 degrees or 1/4 turn. The slack in the lines will
allow for proper start up, wave action and fluctuations in the water level.
Mooring the Aerator
2. Anchoring: Use only stainless steel and brass hardware as previously referenced in the “mooring” section.
Otterbine recommends using two 60 - 80 lb. (27 - 36 kilo) weights for anchors and a small boat. Fasten all of
the mooring lines securely to opposite outer holes in the float. Launch your unit into the water upside down with
the motor housing facing up. Place the anchors in boat and tow unit into location. Anchor location will vary
depending on the depth of your pond (See chart). Drop the anchors with lines attached into the water at
opposite locations. Secure the aerator leaving enough slack in the lines to allow the aerator to turn 90 degrees
or 1/4 turn. The slack in the lines will allow for proper start up, wave action and fluctuations in the water level.
Flip the unit over and proceed to System Startup.
Anchoring the Aerator
MAXIMUM DEPTH DISTANCE BETWEEN ANCHORS
Meters Meters
1.5 3.4
1.8 4.6
2.1 6.1
2.4 9.1
2.7 12.0
3.0 16.7
3.3 21.2
3.6 26.8
3.9 30.3
4.2 36.4
4.6 42.4

SYSTEM STARTUP
WARNING: DO NOT ALLOW THE AERATOR TO OPERATE “DRY” OUT OF THE WATER
B. Energizing the Unit (To be performed by a qualified technician)
1. Single Phase Units: Correct motor rotation is factory determined and not field adjustable. Three Phase Units:
Verify correct motor rotation (Counter Clockwise looking at the top/impeller end of the unit). Check current
readings on each phase. Verify three phase operating currents are balanced within 5%. When correct, record
the operating voltage & amperage on the inside door of the PCC or motor controls.
To calculate the percent of current unbalance determine the Average Current: (a) Measure each of the three
phase currents. (b) Add the three phase amperage values together. (c) Divide the sum by three. (d) This is the
average current value. Determine Current Unbalance: (a) Select the phase current with the greatest difference
from the average (calculated above). (b) Determine the difference between this phase current and the average
current value. (c) Divide the difference by the average. (d) Multiply the result by 100 to determine percent of
unbalance.
3. Use connection diagram 1, 2 or 3 (below) which results in the lowest current unbalance. Roll the motor cable
leads on the aerator output terminal block in the same direction to avoid motor reversal. If the current
unbalance is not corrected by rolling leads, locate the source of the unbalance and correct it. When the phase
farthest from the average stays on the same power lead after being moved the primary cause of unbalance is
the power source. When the phase farthest from the average moves on each of the hookups with a particular
motor lead, the primary cause of unbalance is the "motor side" of the circuit. Consider: damaged cable, leaking
splice, poor connection, or a faulty motor as possible causes.
PUMP PUMP PUMP
DIAGRAM 1 DIAGRAM 2 DIAGRAM 3
MAINTENANCE
This unit requires periodic maintenance: Once a year, disconnect the unit from the power source and
physically inspect the unit and cable for any cuts, cracks or breaks. These may cause oil leaks and/or electrical
shorts. Inspect and clean the pumping chamber and screen. After every three running seasons, a simple oil
change is needed to keep your unit running smoothly. Otterbine oil must be used, contact your Otterbine
distributor to order a maintenance kit, P/N: 12-0077.
WINTERIZATION
If you are located in a region that experiences long periods of cold weather you need to remove your unit from
the water and store it in a dry, secure location where the temperature does not get below freezing. If a unit
becomes frozen-in, it could damage the unit. Damage caused by freezing conditions is not covered under
warranty.





Maximum Cable Lengths from Panel to Unit
#12 AWG #10 AWG #8AWG #6 AWG
6,530 Circular Mils 10,383 Circular Mils 16,509 Circular Mils 26,251 Circular Mils
HP Electrical Rating Meters Meters Meters Meters .
1 220/240V 1Ph 50Hz 92 152 183 *
2 220/240V 1Ph 50Hz 61 99 160 183
3 220/240V 1Ph 50Hz 61 92 152 183
3 380/415V 3Ph 50Hz 183 * * *
5 380/415V 3Ph 50Hz 183 * * *
* Longer cable lengths maybe available, please contact OTTERBINE to inquire.
TROUBLESHOOTING GUIDE
Small spray pattern
(Spray drops gradually, i.e.
minutes or hours).
Clogged intake Remove debris
Clogged screen Remove debris
Loose impeller Tighten impeller bolt
Cavitation or low spray pattern.
(Spray drops suddenly, less
than one second.)
Low line voltage Check voltage at the PCC & at the aerator.
Make sure the unit is within the specified voltage range.
Check for air bubbles surfacing
around float Make sure mooring and anchoring lines are securely tightened
Debris between slinger and
Impeller Remove debris
Motor will not start
Breaker/fuse has tripped Check circuit breaker or fuse, reset and/or replace, if necessary.
Check voltage.
Loose or broken terminals Look for loose or broken terminals.
Low voltage Measure power to starter.
Check acceptable maximum cable length (see below)
Defective power cable Check cable. If defective, call distributor.
GFCI has Tripped Reset and test GFCI device.
If device trips again call electrician or distributor
Additional technical and service information can be found on our web-site at: www.otterbine.com

SUNBURST PUMP CHAMBER

GEMINI PUMP CHAMBER

SATURN PUMP CHAMBER

ROCKET PUMP CHAMBER

PHOENIX PUMP CHAMBER

TRI-STAR PUMP CHAMBER

CONSTELLATION PUMP CHAMBER

COMET PUMP CHAMBER

GENESIS PUMP CHAMBER

EQUINOX PUMP CHAMBER
