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Seakeeper 12HD Installation Manual

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INSTALLATION MANUAL
Rev 1 DECEMBER 2015

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Summary of Contents for Seakeeper 12HD

  • Page 1 INSTALLATION MANUAL Rev 1 DECEMBER 2015...
  • Page 2 90370 SEAKEEPER 12HD INSTALLATION MANUAL DECEMBER 2015 The Seakeeper 12HD is closely based on the Seakeeper 16. Because of this, Seakeeper 16 drawings and part numbers are referenced in this Manual where applicable. Contents: Section 1 – Mechanical Installation & PC-120 Guide Section 2 –...

  • Page 3: Reference Drawings

    This document is intended to give details and guidance to a boat builder or equipment installer to install the Seakeeper 12HD Stabilizing Gyro. The gyro is capable of producing loads up to 24.3 KN (5,450 lbs.) at each of the four mounts and careful consideration should be given to foundation design to insure it is capable of transferring these loads into the hull.
  • Page 4 Product: Document #: Rev: Page: INSTALLATION MANUAL SEAKEEPER 12HD 90370 2 of 21 Section 1: MECHANICAL INSTALLATION Precautions  Gyro must only be lifted from the supplied lifting eyes (See Section 1.4).  Gyro flywheel is supported by precision bearings. Make certain while unpacking and lifting gyro assembly to NOT drop or impart mechanical shock as damage to bearings could result.
  • Page 5 Product: Document #: Rev: Page: INSTALLATION MANUAL SEAKEEPER 12HD 90370 3 of 21 Section 1: MECHANICAL INSTALLATION VIEWS SHOWING RECOMMENDED CLEARANCES AROUND GYRO FOR USE OF HAND TOOLS, EASE OF MAINTENANCE, INSTALLATION AND PROPER OPERATION. FIGURE 2 – INSTALLED GYRO CLEARANCE CONSIDERATIONS...
  • Page 6 Product: Document #: Rev: Page: INSTALLATION MANUAL SEAKEEPER 12HD 90370 4 of 21 Section 1: MECHANICAL INSTALLATION FIGURE 3 – TRANSVERSE BEAMS CLEARANCE CONSIDERATIONS Refer to Figure 3 for recommended clearances to transverse beams. If a transverse beam is located under the forward brace, it must be 1” (25 mm) from the edge of the gyro to provide the necessary clearance for the swing of the motor power cable during gyro precession.
  • Page 7 Noise/Soundproofing Gyro noise has been measured under steady state conditions (no wave load) in Seakeeper's lab and in our test boat. The steady state noise is typically in the range of 68-70 dB un- weighted. As the frequencies emitting the highest sound pressures are low (like other marine machinery), it is recommended that the gyro be installed in a machinery space that is already treated with soundproofing.
  • Page 8 Section 1: MECHANICAL INSTALLATION Selection of Installation Method The Seakeeper 12HD gyro can be affixed to the hull structure using two methods 1) Use bolt- in installation or 2) Bond-In installation. See figures below. OPTION 1- DIRECT FASTENING OF GYRO FOUNDATION TO SHIPS STRUCTURE (BOLT-IN) Option 1 would be applied when a metal structure is available for attachment.

  • Page 9: Unpacking Crate

    7 of 21 Section 1: MECHANICAL INSTALLATION Unpacking Crate 1) Reference Seakeeper Drawing No. 90364, Seakeeper 12HD Gyro Hardware Scope of Supply for items that ship with the gyro. 2) Remove electrical components, cables, and misc. items and set aside.
  • Page 10 Bolt-In Installation 1.5.1 Check and Preparation of Hull Structure Refer to Seakeeper Drawing No. 90261, Seakeeper 16 Gyro Installation Details – Bolt in Method. Important dimensional and load information is given in this drawing that will impact the design details of the structure that will receive the gyro. It is assumed that a proper structural analysis has been performed for the hull structure to which the gyro will be fastened to insure proper strength margins for the loads the gyro will create during operation.
  • Page 11 Document #: Rev: Page: INSTALLATION MANUAL SEAKEEPER 12HD 90370 9 of 21 Section 1: MECHANICAL INSTALLATION CAUTION: Tight clearances from cable guide bands to hull structure. See above figure for dimensions and reference Seakeeper drawing NO. 90261 for complete gyro envelope.
  • Page 12 Product: Document #: Rev: Page: INSTALLATION MANUAL SEAKEEPER 12HD 90370 10 of 21 Section 1: MECHANICAL INSTALLATION 1.5.2 Transfer of Holes to Boat Structure 1) Lower assembled fixture onto hull structure. The four areas where the feet of the gyro will rest should be coplanar to within .06”...
  • Page 13 2) Lower gyro into position onto the hull foundation beams and align over drilled holes. 3) Install Seakeeper supplied M14 fasteners– apply a moderate coat of removable thread locker to the threads...
  • Page 14 1.6.1 Initial Check and Preparation of Hull Structure Refer to Seakeeper Drawing No. 90263, Seakeeper 16 Gyro Installation Details – Bond In Method. Important dimensional and load information is given in this drawing that will impact the design details of the structure that will receive the gyro as well as selection of the adhesive to bond the gyro into the hull.
  • Page 15 Note: Do NOT use the installation fixture to establish gyro envelope dimensions. Refer to Drawing No. 90263 for envelope dimensions. A 3-D model of the gyro is available on the Seakeeper website (www.seakeeper.com) to aid in designing the gyro foundation and the space around the gyro.
  • Page 16 Product: Document #: Rev: Page: INSTALLATION MANUAL SEAKEEPER 12HD 90370 14 of 21 Section 1: MECHANICAL INSTALLATION FIGURE 7 – SADDLE INSTALLATION FIXTURE ON NOTIONAL HULL STRUCTURE...
  • Page 17 Product: Document #: Rev: Page: INSTALLATION MANUAL SEAKEEPER 12HD 90370 15 of 21 Section 1: MECHANICAL INSTALLATION 1.6.2 Fiberglass Hull Preparation 1) Position installation fixture (Fig 8) on hull girders noting recommended clearances for maintenance from Figure 2. Check that the screws fastening the saddles to the installation fixture are tight (Fig 6).
  • Page 18 8) Re-position installation fixture on girders and double-check that the adhesive gap is within the adhesive manufacturer’s maximum recommended thickness. Seakeeper recommends a maximum gap of 3mm if using Plexus MA590. Note if bonding saddles to a metal structure, contact Seakeeper for hull preparation instructions.
  • Page 19 Product: Document #: Rev: Page: INSTALLATION MANUAL SEAKEEPER 12HD 90370 17 of 21 Section 1: MECHANICAL INSTALLATION 1.6.3 Gyro Saddle Preparation 1) Ensure that screws fastening saddles to the installation fixture are tight (Fig 6). 2) Check that each saddle contains 2 plastic screws which will insure an adhesive gap of .080”...
  • Page 20 Product: Document #: Rev: Page: INSTALLATION MANUAL SEAKEEPER 12HD 90370 18 of 21 Section 1: MECHANICAL INSTALLATION 1.6.4 Bonding Saddles to Hull Note: If using Plexus MA590 adhesive, the gyro saddles should be installed when PC-120 is confirmed dry. 1) Assemble Plexus cartridge into either the manual or pneumatic gun as shown. Remove cap on cartridge and attach mixing tip.
  • Page 21 Product: Document #: Rev: Page: INSTALLATION MANUAL SEAKEEPER 12HD 90370 19 of 21 Section 1: MECHANICAL INSTALLATION 5) Apply large bead of Plexus adhesive to the hull structure as shown in the figure to the right. Apply approximately 3rds 1 cartridge at each of the four locations.
  • Page 22 Adjust position of gyro until alignment is achieved for the 16 fasteners that will attach gyro foundation frame to saddles. 4) Install Seakeeper supplied M14 fasteners– apply a moderate coat of removable thread locker to the threads of each bolt and include a small bead of sealant under each washer before installation.
  • Page 23 Product: Document #: Rev: Page: INSTALLATION MANUAL SEAKEEPER 12HD 90370 21 of 21 Section 1: MECHANICAL INSTALLATION 1.7 Doc # 90213 Plexus PC-120 Application Instructions...
  • Page 24 INSTRUCTIONS Product: All Document #: 90213 Process: Plexus PC- 120 Application Instructions Rev.: 1 Process Description: Instructions for use of surface conditioner Page 1 of 4 What is Plexus PC-120? • Plexus PC-120 is a dual function primer/conditioner designed to clean surface contamination and leave a thin coating of primer on specific metal surfaces.
  • Page 25 INSTRUCTIONS Page 2 of 4 Product: ALL Document #: 90213 Process: Plexus PC- 120 Application Instructions Rev.: 1 1) Using too much PC-120 • Only a very thin coat should be left on the metal. You should be able to see a slight “pink” cast as illustrated below.
  • Page 26 INSTRUCTIONS Page 3 of 4 Product: ALL Document #: 90213 Process: Plexus PC- 120 Application Instructions Rev.: 1 3) Not abrading corroded surfaces • As good as PC-120 is, it can’t help bonding performance if applied to a surface that is already corroded! •...
  • Page 27 INSTRUCTIONS Page 4 of 4 Product: ALL Document #: 90213 Process: Plexus PC- 120 Application Instructions Rev.: 1 Remember these points! To avoid problems with Plexus PC-120: • Don’t use too much PC-120. Only a thin layer is needed. • Use a clean rag to wipe PC-120 off before it completely dries to remove surface contaminants it has cleaned.

  • Page 28: Section 2: Electrical Installation

    SEAKEEPER 12HD Gyro, Front Oblique View SEAKEEPER 12HD Gyro, Rear Oblique View 24VDC Power Connector Terminator, Female Tee Adapter CANvu 355 Display Interface Cable 20223 Color Display Display Interface Cable 25m Cable FIGURE 1 – ELECTRICAL EQUIPMENT FOR SEAKEEPER 12HD...
  • Page 29 Precautions  Each item of electrical equipment has specific mounting instructions. These instructions should be followed to insure proper function of the SEAKEEPER 12HD. Do NOT move Gyro mounted components from their locations or incorrect Gyro operation will result. 1. COLOR DISPLAY MOUNTING INSTRUCTIONS, SURFACE MOUNT a.
  • Page 30 230 VAC (nominal), 1 Phase, 50/60 Hz, 20 Amps. b. A separate circuit breaker should be used for each Drive Box. 2. DRIVE BOX AC POWER INPUT CONNECTION INSTRUCTIONS CSA), 10’ (3m) length, Seakeeper supplied pre- a. Cable: 3 x 10AWG (3 x 6mm installed.
  • Page 31 AC power distribution panel according to Figure 3 above. 3. DRIVE BOX AC POWER OUTPUT TO SEAWATER PUMP CONNECTION INSTRUCTIONS CSA) cable, 10’ (3m) length, Seakeeper supplied a. Cable: 3 x 16AWG (3 x 2.0mm pre-installed. b. Pumps rated at 230 VAC, 5 Amps max., Customer-supplied.
  • Page 32 Document #: Rev: Page: INSTALLATION MANUAL SEAKEEPER 12HD 90370 5 of 5 Section 2: ELECTRICAL INSTALLATION d. If the customer-supplied Seawater Pump is not rated for the applied AC input voltage, the CABLE 5 output may be used to switch a customer-supplied relay.
  • Page 33 24 VDC, 10 Amps. 2 x 12AWG (3 x 4mm CSA) Customer supplied. i. Install Seakeeper provided DC Power Input Cable, P/N: 20248 as CABLE 1. 1. Route CABLE 1 to DC Power Distribution Panel. 2. Terminate RED conductor to +24 VDC. Terminate BLACK conductor to 24V Rtn or Zero VDC.
  • Page 34 Product: Document #: Rev: Page: INSTALLATION MANUAL SEAKEEPER 12HD 90370 7 of 7 Section 2: ELECTRICAL INSTALLATION Electrical Equipment Ground Connections 1. GYRO TO VESSEL GROUND CONNECTION INSTRUCTIONS a. Connect the Gyro foundation to vessel ground. i. Install CABLE 6 (4AWG or 22.0mm , Customer supplied) from the M6 brass ground stud on the Gyro rear brace to a suitable vessel ground.
  • Page 35 This section explains the connection between the Operator Station equipment and the Gyro Control Box. Reference Drawing 90306 Seakeeper 16 Gyro Cable Block Diagram 1. DETERMINE LOCATION OF OPERATOR STATION a. The desired location of the Operator Station must be determined with respect to the vessel arrangement.
  • Page 36 Product: Document #: Rev: Page: INSTALLATION MANUAL SEAKEEPER 12HD 90370 9 of 9 Section 2: ELECTRICAL INSTALLATION 3. INSTALL OPERATOR STATION EQUIPMENT a. The Operator Station equipment is installed at the selected location using Electrical Equipment Mounting Instructions in Section 2.1.
  • Page 37 Operator Station Kit. Reference Drawings 90250 Seakeeper 16 Gyro 2 Operator Station Kit 90306 Seakeeper 16 Gyro Cable Block Diagram (includes detail of 2nd Operator Station) 1. DETERMINE LOCATION OF 2 OPERATOR STATION a. The desired location of the 2...
  • Page 38 Product: Document #: Rev: Page: INSTALLATION MANUAL SEAKEEPER 12HD 90370 11 of 11 Section 2: ELECTRICAL INSTALLATION 3. ROUTE 2 OPERATOR STATION CABLE a. A second CAN Cable Assembly (30243), also a 25 meter shielded cable, and the largest connector is a molded plug with maximum outer diameter of .58 inch (14.8mm)).
  • Page 39 Product: Document #: Rev: Page: INSTALLATION MANUAL SEAKEEPER 12HD 90370 12 of 12 Section 2: ELECTRICAL INSTALLATION Display Installation Template The following template is for mounting; before using this template, measure to ensure that the shown size is actual. DISPLAY MOUNTING TEMPLATE...
  • Page 40 1 of 5 Section 3: COOLING INSTALLATION Introduction The Seakeeper 12HD is shipped with the cooling circuit filled and ready for use. Only a quick confirmation of glycol level is required. Reference Drawings 90364 Seakeeper 12HD Gyro Hardware Scope of Supply...
  • Page 41 Product: Document #: Rev: Page: INSTALLATION MANUAL SEAKEEPER 12HD 90370 2 of 5 Section 3: COOLING INSTALLATION FIGURE 2 – SEAKEEPER 12HD GYRO COOLING COMPONENTS...

  • Page 42: Adding Coolant

    If level has dropped, check evidence leaks connections before adding fluid as described below. If coolant is at the correct level, skip to sea water connection in section 3.3. FIGURE 3 – SEAKEEPER 12HD COOLANT LEVEL...
  • Page 43 Product: Document #: Rev: Page: INSTALLATION MANUAL SEAKEEPER 12HD 90370 4 of 5 Section 3: COOLING INSTALLATION Mix 50% ethylene glycol with 50% distilled water in a clean container. Refer to Table 1 or glycol manufacturer’s literature for freezing points.
  • Page 44 Flow is calculated from time to fill a known volume. Inspect raw water plumbing after sea trial for any signs of leakage. Heat exchanger contains removable end-caps to provide access for cleaning the tube bundle. FIGURE 4 – SEAKEEPER 12HD SEAWATER CONNECTIONS...

  • Page 45: Section 4: Startup

    Section 4: STARTUP Introduction This section describes the first startup of the gyro. Also reference Seakeeper Document # 90371, Seakeeper 12HD Gyro Operation Manual. • Previous sections for mechanical, electrical and cooling installation must be completed before this startup sequence is initiated.
  • Page 46 Document #: Rev: Page: INSTALLATION MANUAL SEAKEEPER 12HD 90370 2 of 2 Section 4: STARTUP 6) The sea water pump should have started when the ON/OFF button on the display was depressed. Confirm pump operation and flow rate, if practical. Required flow is 4 GPM (15 LPM) minimum and 8 GPM (30 LPM) maximum.
  • Page 47 Mechanical Checklist (reference Installation Manual Section 1)  Gyro Foundation Installed in Hull  Foundation bolts torqued to specification Electrical Checklist (reference Seakeeper Drawing 90306 & Installation Manual Section Mount Components  Display (near helm) Connect Customer Supplied Cables ...
  • Page 48 Connect male end of CAN communications Cable 3 at helm to CAN Tee Adapter  – Connect Display and Seakeeper supplied Cable 4 to CAN Tee Adapter with CAN Terminator Cooling Checklist (reference Installation Manual Section 3)  Verify coolant level in heat exchanger coolant reservoir.
  • Page 49 Product: Document #: Rev: Page: INSTALLATION MANUAL SEAKEEPER 12HD 90370 3 of 4 Section 5: INSTALLATION CHECKLIST AND SUPPLIES Required Supplies needed for Gyro Installation (not supplied with gyro) Installation Manual Other Item Description System Reference Reference Section Adhesive and cleaning supplies for bonding to hull...
  • Page 50 Product: Document #: Rev: Page: INSTALLATION MANUAL SEAKEEPER 12HD 90370 4 of 4 Section 5: INSTALLATION CHECKLIST AND SUPPLIES List of common tools that may be required for installation Item Description Wire cutter DC Power, AC Power cables Wire stripper...