INSTALLATION MANUAL SEAKEEPER 5 GYRO
Contents
1. FILL WATER GLYCOL FILL m eee A jet x 762 76 03 GIMBAL ANGLE is f W Erler BRAKE CYLINDERS SENSOR 4 I 2 SEAWATER OUTLET ka NI SEAWATER l 1 INLET R Stl KEEP THIS AREA UNDER GYRO CLEAR FOR FREE MOVEMENT OF HOSES AND CABLES VIEWS SHOWING RECOMMENDED CLEARANCES AROUND GYRO FOR USE OF HAND TOOLS EASE OF MAINTENANCE INSTALLATION AND PROPER OPERATION FIGURE 2 INSTALLED GYRO CLEARANCE CONSIDERATIONS amp SEAKEEPER INSTALLATION ocument Rev Page MANUAL SEAKEEPER 5 GYRO 90245 4 of 21 Section 1 MECHANICAL INSTALLATION 851 49 33 52 BAIN BAUMA RECOMMENDED DISTANCE BETWEEN TRANSVERSE BEAMS 436 38 17 20 TOP OF SUPPORTING A i i m GA STRUCTURETOTOP A f a a on 0 rema OF GYRO COVER Au r g 101 60 101 80 ma mm um eur 4 00 4 00 MAIN MALI RECOMMENDED DETANCE KAINIKALIKA RECOMMENDED DETA NEE FROM SADDLE TO TRANSVERSE BEAR FROM SADDLE TO TRANSVERSE BEAM 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 4 102 mm from the edge of the saddle beams to provide the necessary clearance for the swing of the motor power cable during gyro precession Clearances aft of the gyro are shown to provide access for maintenance SEAKEERER INSTALLATION ocument f Rev Page MANUAL SEAKEEPER 52. See drawing 90232 for details c Hardware required none d Maximum panel thickness Flush Mount 0 120 inches 3 mm e Minimum panel thickness 120 inches 3 mm 3 SERIAL COMMUNICATIONS TEE ADAPTER AND TERMINATOR MOUNTING INSTRUCTIONS a Console space required Rear Approx 4 W x 3 H inches 102 x 76 mm rear b Mounting Instructions Rear mount on vessel console panel within 1 ft 0 3m of Displav c Hardware required One mounting screw for 197 5 mm diameter mounting hole on Tee Adapter G seameeren INSTAUATION Product _ Rev Page MANUAL SEAKEEPER 5 GYRO 90245 1 30f13 Section 2 ELECTRICAL INSTALLATION 2 2 Electrical Equipment Power Connections 1 AC INPUT POWER SOURCE REQUIREMENTS a Either of two AC input voltages are acceptable i 110 VAC nominal 1 Phase 50 60 Hz 25 Amps ii 230 VAC nominal 1 Phase 50 60 Hz 20 Amps b A separate circuit breaker should be used for each Drive Box c The Seawater Pump connected must be rated for the same AC voltage as the AC input voltage 5 Amps maximum 2 DRIVE BOX AC POWER INPUT CONNECTION INSTRUCTIONS a Cable 3 x 10AWG 3 x 6mm CSA 10 3m length Seakeeper supplied pre installed i Locate CABLE 2 for AC power input to the Drive Box at the outward of three cable glands INWARD CABLE GLAND MIDDLE CABLE GLAND OUTWARD CABLE GLAND FOR DRIVE POWER FOR AC POWER OUTPUT FOR AC POWER INPUT OUTPUT TO GYRO TO SEAWATER PUMP CABLE 2 MO
3. amp Flush Supply Mounting Details 90246 Seakeeper 5 Gyro Operation Manual 90250 2 Helm Control Station Kit 90247 Seakeeper 5 Gyro Drawing Manual 90296 Seakeeper 5 Gyro Cable Block Diagram 90231 Color Display Envelope amp Surface includes 2 Display Kit Mounting Details SEAKEEPER 5 Gyro Rear Oblique View 12VDC Power Connector Terminator Female Tee Adapter Color Display Display Interface Cable 25m Cable FIGURE 1 ELECTRICAL EQUIPMENT FOR SEAKEEPER 5 GYRO D H P O SEAKEEPER INSTALLATION Product Document Rev Page MANUAL SEAKEEPER 5 GYRO 90245 1 20f13 Section 2 ELECTRICAL INSTALLATION 2 1 Electrical Equipment Mounting Precautions e Each item of electrical equipment has specific mounting instructions These instructions should be followed to insure proper function of the SEAKEEPER 5 Gyro 1 Do NOT move Gvro mounted components from their locations or incorrect Gvro operation will result 1 COLOR DISPLAY MOUNTING INSTRUCTIONS SURFACE MOUNT a Console space required Approx 4 25 W x 4 25 H inches 108 x 108 mm b Mounting Instructions Surface Mount See drawing 90231 for details c Hardware required none d Maximum panel thickness Surface Mount 0 75 inches 19 mm e Minimum panel thickness 120 inches 3 mm 2 COLORDISPLAV MOUNTING INSTRUCTIONS FLUSH MOUNT a Console space required Approx 6 00 W x 4 25 H inches 152 x 108 mm b Mounting Instructions Flush Mount
4. GYRO 90245 5 of 21 Section 1 MECHANICAL INSTALLATION A A There is a large torque about the gimbal axis when the gyro is precessing Gyro cover panels Safety are provided to prevent personnel or equipment from contacting the gyro while it is in operation These covers should not be stepped on or have anything placed on top The covers should always be in place during operation If it is ever necessary to access the gyro while the flywheel is spinning the gyro must be locked at the display to stop the gyro from precessing Gyro maintenance should not be attempted unless the gyro is locked and the flywheel has stopped spinning The gyro should be treated with the same respect one gives a high speed rotating propeller shaft or engine shaft 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 70 75 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 Product Document Page SEAKEEPER INSTALLATION ocument Rev Page MANUAL SEAKEEPER 5 GYRO 90245 6 of 21 Section 1 MECHANICAL INSTALLATION 1 3 Selection of Installation Method The Seakeeper 5 gyro can be affixed to the hull structure using two methods 1
5. Use bolt in installation or 2 saddle installation See figures below AN EN BOLTS DIRECTLY TO SHIPS STRUCTURE OPTION 1 DIRECT FASTENING OF GYRO FOUNDATION TO SHIPS STRUCTURE Option 1 would be applied when a metal structure is available for attachment The foundation would fasten directly to hull structure using 16x M12 1 75 fasteners Depending on the structure to which the gyro is fastened blind threaded holes or thru bolting can be utilized SADDLE FITTINGS 4 BONDED TO SHIPS STRUCTURE OPTION 2 SADDLE INSTALLATION 4 PLACES Option 2 would be most commonly used on a hull constructed of glass reinforced plastic GRP or fiberglass For this option four 7 5 inch 191 mm long by 3 38 inch 85 7 mm deep saddles are bonded to properly spaced and prepared structural members that are an integral part of the hull structure Seakeeper recommends using a structural adhesive with a lap shear strength of 2000 psi 13 8 MPa or greater Careful consideration should be exercised by the installer while selecting the appropriate adhesive Compatibility with the gyro s cast aluminum A356 T6 saddles hull structure and pot life are three important factors to consider Proper surface preparation in accordance with adhesive manufacturer s recommendations prior to installation is very important amp SEAKEEPER INSTALLATION ocument Rev Page MANUAL SEAKEEPER 5 GYRO 90245 7 of 21 Section 1 MECHANICAL INSTAL
6. acetone all areas of girders to be bonded to remove any contaminates Use new paper towels for cleaning not shop rags 5 Remove any paint or gel coat from bond surfaces so that adhesive will bond directly to laminate fibers and resin as shown in Figure 8 6 Thoroughly sand girder bond surfaces with 80 grit sandpaper IMPORTANT BOND STRENGTH MAY BE REDUCED IF THIS STEP IS SKIPPED 7 Wipe surfaces clean from dust with alcohol or acetone using new paper towels not shop rags 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 amp SEAKEEPER INSTALLATION u Rev Page MANUAL SEAKEEPER 5 GYRO 90245 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 2 mm on top surface of hull as shown in Figure 11 3 Thoroughly clean with alcohol or acetone the inside surfaces of gyro foundation saddles to remove any contaminates as shown in Figure 11 Use new paper towels for cleaning not shop rags L PLASTIC SCREWS 2 PLACES Be L CLEAN INSIDE SURFACE
7. area around the gyro must be clear of personnel and equipment 4 1 Startup Instructions 1 Energize 12 VDC supply at the customer supplied electrical disconnect 2 Supply 110 230 VAC to Motor Drive Box at customer supplied electrical disconnect 3 Ifsea water pump for gyro is not supplied though cable from Motor Drive Box turn on the boat s AC or DC circuit breaker that supplies power to the sea water pump 4 With system powered up check the display for any ALARMS If there are any ALARMS present they must be corrected first G SEAKEEPER INSTAUATION Product TDocumentii Rev Pages MANUAL SEAKEEPER 5 GYRO 90245 1 2of3 Section 4 STARTUP 5 Press the GYRO ON OFF Button on Display The RED LOCK ICON and the PROGRESS BAR will appear and be RED until the GYRO is at speed then stabilization can begin 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 7 Verify that there are no ALARMS present If an ALARM is present it will be displayed 8 When the PROGRESS BAR turns GREEN from RED the GYRO can be placed in SEA mode Depress the LOCK UNLOCK Button and the GYRO will be free to move and precession can occur 9 Verify that there are no alarms If an ALARM is present it will be displayed 10 Press the LOCK UNLOCK Button to go from SEA to
8. by using this supply from motor drive to trigger an installer supplied contactor but a separate source of power must be provided e Maximum sea water pressure in heat exchanger is 20 psi 1 4 bar e Seawater flow requirement through heat exchanger is 4 GPM 15 1 LPM minimum and 8 GPM 30 3 LPM maximum under all operating conditions of the boat When sizing sea water pump installer should factor in losses for raw water plumbing In addition to initial operation at dock new gyro installations should be checked to be within the flow requirements while vessel is at speed Flows higher than 8 GPM 30 3 LPM could affect heat exchanger life 3 2 Adding Coolant 1 Cooling system is filled to proper level when shipped with a mixture of 50 ethylene glycol and 50 distilled water Clear tube between thermostat housing and reservoir should be filled with green coolant mixture If level has dropped check for evidence of leaks at all connections before adding fluid as described below If coolant is at the correct level skip to sea water connection in section 3 3 E i AS FIGURE 3 SEAKEEPER 5 COOLANT LEVEL MANUAL _ SEAKEEPER 5 GYRO 90245 1 4of5 Section 3 COOLING INSTALLATION se AKEEPER INSTALLATION ocument f Rev Page 2 Mix 50 ethylene glycol with 50 distilled water in a clean container Refer to Table 1 or glycol manufacturer s literature for freezing points Table 1 Freezing Point
9. 0242 Seakeeper 5 Gyro Hardware Scope of Supply 90296 Seakeeper 5 Gyro Cable Block Diagram 90295 Seakeeper 5 Gyro Cooling Water Schematic DT h Mr O GLYCOL WATER FILL HEAT EXCHANGER a L JF GLICO WAIER PUMP FIGURE 1 SEAKEEPER 5 GYRO 6 GEAKEEPER INSTALLATION u Rev Page MANUAL _ SEAKEEPER 5 GYRO 90245 1 2of5 Section 3 COOLING INSTALLATION COOLANT OVERFLOW GLYCOL WATER FILL HEAT EXCHANGER WTA INTEGRAL COOLANT RESERVOIR THERMOSTAT VALVE COOLANT PUMP SEAWATER OUTLET FIGURE 2 SEAKEEPER 5 GYRO COOLING COMPONENTS Product Document Page amp SEAKEEPER INSTALLATION Rev Page MANUAL _ SEAKEEPER 5 GYRO 90245 1 3of5 Section 3 COOLING INSTALLATION 3 1 Precautions e Installer is responsible for supplying a dedicated sea water pump and associated plumbing Sea water connections on the gyro heat exchanger mate with inch 19 mm hose e There is no need to disconnect hose from glycol pump except to replace the pump In this case provision will need to be made to catch draining glycol as plumbing is disconnected Use caution to avoid breaking plastic hose connections on pump casing e An output is available from motor drive to power and automatically control seawater pump This pump must operate on 110 230 VAC single phase and consume less than 5 amps Pumps requiring other voltages or higher current can still be controlled
10. AL INSTALLATION DETAIL J CALETA CATIA TI HT FLYWHEELS FIH T LEA RA H E ANE 2 Win MR TA M gt TOP OFSUPPORTIHG AS POWER CONNECTION F m STRUSTURETO TOP GIMBAL AXIS JA OF COVER ENTERLINE i 1 LELI 208 97 8 15 MIHIM LUMI RES OM MEM ED DETAHEE BETWEEN SUPPORT STR US TURE ATTENTION KEEPTHE AREA UNDER GYRO CLEAR FOR FREE MOWEMENT OF HOSES OND CABLES CAUTION Tight clearances from cable guide bands and brake side gimbal shaft to hull structure See below for brake side gimbal shaft clearance See above figure for dimensions and reference Seakeeper drawing NO 90293 for complete gyro envelope GIMBAL SHAFT AXIS JAN a Ei TEE lawa ee N N x jan NO EVA TH Le all N WHEN IN MOTION BRAKE SIDE GIMBAL SHAFT SWINGS BELOW MOUNTING SURFACE OF GYRO Product Document Page 6 SEAKEEPER INSTALLATION ocument Rev Page MANUAL SEAKEEPER 5 GYRO 90245 10 of 21 Section 1 MECHANICAL INSTALLATION 1 5 2 Transfer of Holes to Boat Structure j ALIGN FIXTURE AND TRANSFER 16 HOLE 1 Lower assembled fixture onto gyro panier KPA POSITION FIXTURE ON FOUNDATION DESIGNED FOR GYRO DIMENSIONS AND LOADS foundation 2 The four areas where the isolation mounts will rest should be coplanar to within 06 1 5mm See Figure 9 3 Align fixture in desired location and transfer holes from fixture plate to the foundation structur
11. BLE ASSY 25m TEE ADAPTER FIGURE 9 SERIAL COMMUNICATIONS LINK FOR OPERATOR STATION 2 ROUTE SERIAL COMMUNICATIONS CABLE a The CAN Cable Assembly 30243 CABLE 5 is a 25 meter shielded cable and the largest connector is a molded plug with maximum outer diameter of 58 inch 14 8mm b CABLE 5 must be routed and installed in the vessel from the Gyro female end to the Tee Adapter male end at the Operator Station D H P O SEAKEEPER INSTALLATION Product Document Rev Page MANUAL SEAKEEPER 5 GYRO 90245 1 90f13 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 4 CONNECT OPERATOR STATION EQUIPMENT a The Operator Station equipment is connected in accordance with the Cable Block Diagram 90296 SEAKEEPER 5 GYRO 90245 1 100f13 MANUAL seaxeeper NSTAUATION Product _ Document Rev Page Section 2 ELECTRICAL INSTALLATION 2 5 Second Operator Station Connection This section explains how to connect the 2 Operator Station Kit Reference Drawings 90250 Seakeeper 5 Gyro 2 Operator Station Kit 90296 Seakeeper 5 Gyro Cable Block Diagram includes detail of 2nd Operator Station 1 DETERMINE LOCATION OF 2 P OPERATOR STATION a The desired location of the 2 Operator Station must be determined wi
12. ER 5 GYRO 90245 1 50f13 Section 2 ELECTRICAL INSTALLATION CABLE 5 3x14AWG or 3x2 0mm2 SEAKEEPER SUPPLIED 3m LENGTH DRIVE BOX SEAWATER PUMP 5 shee Y UA POWER OUTPUT 110 230 VAC CUSTOMER WHITE SUPPLIED 5A 19 50 60 Hz GREEN FIGURE 5 CABLE 5 WIRE CONNECTIONS TO SEAWATER PUMP c 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 i Locate CABLE 5 for AC power output to the Seawater Pump from the Drive Box at the middle of three cable glands as shown in Figure 2 ii The recommended wiring is shown in Figure 6 Refer to Figure 4 for Cable 5 wire connections CABLE 5 3x14AWG or 3x2 0mmY SEAKEEPER SUPPLIED 3m LENGTH DRIVE BOX SEAWATER PUMP x POWER OUTPUT 110 230 VAC 5A 10 50 60 Hz BLACK SEAWATER PUMP SEAWATER PUMP POWER CABLE ii AC DISCONNECT CUSTOMER CUSTOMER RELAY l CUSTOMER SWITCH SUPPLIED SUPPLIED CUSTOMER SUPPLIED CIRCUIT BREAKER SUPPLIED SEAWATER Y PUMPX v POWER EARTH RELAY SELECTION COIL SELECT FOR INPUT VOLTAGE CONTACTS FOR SEAWATER PUMP CURRENT FIGURE 6 RECOMMENDED WIRING FOR SEAWATER PUMPS NOT MATCHING INPUT AC VOLTAGE d If CABLE 5 is not used bundle cable and secure to forward brace or other area nearby which will not come in contact with moving parts during gyro operation Do NOT cut CABLE 5 as i
13. Ethylene Glycol Solution by volume 0 10 20 30 40 50 60 32 23 14 2 13 36 70 co 0 3 8 16 25 37 55 3 Remove pressure cap on top of reservoir Pour mixture in until level reaches top of clear tube between thermostatic valve and reservoir as shown in Figure 3 Filling reservoir above this level will not cause any damage but coolant may be expelled from pressure relief port below cap due to normal thermal expansion of coolant 4 Connect 12 V to controller e At the Display check for any ALARMS e Press the POWER ON OFF button 0 e The flywheel will start to spin and the glycol pump will start e Recheck glycol level with fluid circulating in coolant circuit Sight down inside reservoir and check that coolant level is above upper port on reservoir as shown in Figure 3 Replace cap e After several minutes of running press POWER ON OFF button to turn power off to the flywheel and glycol pump The glycol pump will stop and the flywheel will coast to a stop 5 The cooling system is self purging If small amounts of air are in the system they will most likely be dislodged during the first sea trial Recheck level after sea trial and add fluid if required A Product Document Page SEAKEEPER INSTALLATION Rev Page MANUAL _ SEAKEEPER 5 GYRO 90245 1 5of5 Section 3 COOLING INSTALLATION 3 3 Connecting Seawater to Heat Exchanger 1 Connect seawater from installer supplied pu
14. LATION 1 4 Unpacking Crate 1 Reference Seakeeper Drawing No 90242 Seakeeper 5 Gyro Hardware Scope of Supply for items that ship with the gyro 2 Remove electrical components cables and misc items and set aside 3 Remove packing materials that secure gyro assembly inside the crate 4 Remove top and angled face cover panels to access lifting eyes 5 Attach spreader bar to the two lifting eyes located on the top of the gyro enclosure Stay clear of any other parts on the gyro Gyro weighs 368 kg 810 lbs See Figure 4 below Spreader Bar um Lifting Eyes FIGURE 4 LIFTING ARRANGEMENT PAGE INTENTIONALLY LEFT BLANK Product Document Page SEAKEERER INSTALLATION ocument Rev Page MANUAL SEAKEEPER 5 GYRO 90245 8 of 21 Section 1 MECHANICAL INSTALLATION 1 5 Bolt In Installation 1 5 1 Check and Preparation of Hull Structure Refer to Seakeeper Drawing No 90293 Seakeeper 5 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 The hull structure supporting the gyro should be installed so the gyro is parallel to the waterline In addition the f
15. LOCK mode Then press the GYRO ON OFF Button 0 to power the GYRO down D P l seaneeren INSTALLATION Produts Document Rev Page MANUAL _ SEAKEEPER 5 GYRO 90245 1 3of3 Section 4 STARTUP 11 During normal operation the gyro should be stopped when pulling into port and stabilization is no longer required This maximizes long term life as it allows the gyro to start the coast down cycle before cooling is shutoff Once the vessel is secured in the slip and the crew has shut down the generator and engines the AC and DC breakers that control the gyro should be switched to the OFF position The gyro will continue to spool down to zero rom No cooling is required during this time Note gyro will take 3 hours to coast down to zero rom from full speed When the flywheel has stopped the display will indicate O RPM PAGE INTENTIONALLY LEFT BLANK G SEAKEEPER INSTAUATION Product Document Rev Pages MANUAL _ SEAKEEPER 5 GYRO 90245 1 1of4 Section 5 INSTALLATION CHECKLIST AND SUPPLIES Please Complete Checklist and E mail to customerservice seakeeper com or telefax to 1 410 326 1199 5 0 Installation Checklist Mechanical Checklist reference Installation Manual Section 1 LJ Gyro Foundation Installed in Hull LJ Foundation bolts torqued to specification Electrical Checklist reference Seakeeper Drawing 90296 amp Installation Manual Section 2 Mount Components LJ Display n
16. S OF SADDLES FIGURE 11 SADDLE CLEANING 4 Thoroughly sand all saddle inside surfaces with 80 grit sandpaper IMPORTANT BOND STRENGTH MAY BE REDUCED IF THIS STEP IS SKIPPED 5 Wipe surfaces clean from dust with alcohol or acetone using new paper towels not shop rags 6 If using Plexus MA590 adhesive apply Plexus PC 120 surface conditioner to inside surfaces of gyro foundation saddles in accordance with manufacturer instructions These instructions are located at the end of this section If using an alternate adhesive check with manufacturer if any surface conditioner etch is required for the aluminum saddles Product Document Page amp SEAKEERER INSTALLATION ocument Rev Page MANUAL SEAKEEPER 5 GYRO 90245 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 For pneumatic gun start with low air pressure and increase until desired flow rate is achieved Mixing Tip Adhesive Gun FIGURE 12 ADHESIVE INSTALLATION SUPPLIES 2 Cut tip of mixing wand as shown in photo 3 Prepare a second mixing wand as shown in photo below by attaching the simple flexible nozzle to the end with provided hose clamp Set aside for now as this wi
17. S SEAKEEPER INSTALLATION MANUAL SEAKEEPER 5 GYRO Rev 1 AUGUST 2014 PAGE INTENTIONALLY LEFT BLANK 6 GEAKEEPER INSTALLATION Rev MANUAL SEAKEEPER 5 GYRO 90245 SEAKEEPER 5 GYRO INSTALLATION MANUAL AUGUST 2014 Contents Section 1 Mechanical Installation amp PC 120 Guide Section 2 Electrical Installation Section 3 Cooling Installation Section 4 Startup Section 5 Installation Checklist and Required Supplies S SEAKEEPER 44425 PECAN COURT SUITE 151 CALIFORNIA MARYLAND 20619 U S A PHONE 410 326 1590 FAX 410 326 1199 E MAIL customerservice seakeeper com PAGE INTENTIONALLY LEFT BLANK Product Document Page amp SEAKEERER INSTALLATION ocument Rev Page MANUAL SEAKEEPER 5 GYRO 90245 1 of 21 Section 1 MECHANICAL INSTALLATION 1 0 Introduction This document is intended to give details and guidance to a boat builder or equipment installer to install the Seakeeper 5 Stabilizing Gyro The gyro is capable of producing loads up to 13 3 KN 2987 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 There are two methods of installing the Seakeeper 5 gyro 1 Bolt In Installation 2 Saddle Installation It is assumed that the installer is familiar with bonding using high strength adhesives or mechanical fasteners to marine structures and has
18. S SHOULD BE USED TO ATTACH THE INSTALLATION TEMPLATE 90260 TO EITHER THE INSERT PLATE OR SADDLE TYPE FOUNDATIONS FOR ALIGNMENT en AND INSTALLATION ASSISTANCE OF THESE FOUNDATIONS ONLY THEY SHOULD NOT BE USED IN THE ACTUAL INSTALLMENT TEMPLATE KIT OF THE GYRO MOUNTING SADDLE CAN BE USED AT ANY OF THE FOUR LOCATIONS BOLT PATTERN FACES INWARD AS SHOWN 4 PLACES FIGURE 6 EXPLODED VIEW OF SADDLE INSTALLATION FIXTURE INSTALLATION Product Document Rev Page SEAKEEPER MANUAL SEAKEEPER 5 GYRO 90245 14 of 21 Section 1 MECHANICAL INSTALLATION SEAKEEPER 5 INSTALLATION KIT SADDLE 4 PLACES NOTIONAL HULL hi STRUCTURE CORRECT FOUNDATION WILL BE PARRALLEL TO AT REST WATERLINE PLANE OF THE VESSEL RADIUS SHOULD BE BETWEEN 25 AND 35 INCHES 6 4mm TO 8 9mm TO ALLOW SADDLE TO REST ON TOP OF BEAM DETAIL OF SECTION THROUGH SADDLE SECTION THROUGH FIXTURE AND HULL STRUCTURE CONFIRM GAP ON ALL VERTICAL SURFACES IS WITHIN ADHESIVE MANUF REQUIREMENTS SCREW HEADS INSTALLED IN SADDLES WILL INSURE 09 2mm BOND GAP FOR ADHESIVE ON TOP SURFACE FIGURE 7 SADDLE INSTALLATION FIXTURE ON NOTIONAL HULL STRUCTURE MANUAL SEAKEEPER 5 GYRO 90245 15 of 21 Section 1 MECHANICAL INSTALLATION Product Document Page amp SEAKEERER INSTALLATION ocument Rev Page 1 6 2 Fiberglass Hull Preparation 1 Position installation fixture Fig 8 o
19. TOR CABLE 5 FIGURE 2 DRIVE BOX AC POWER INPUT amp OUTPUT CABLE GLANDS INSTALLATION Product 0000000000 JDocumentfi Rev Page SEAKEEPER MANUAL SEAKEEPER 5 GYRO 9025 1 4013 Section 2 ELECTRICAL INSTALLATION ni HOT AC INPUT POWER 230 VAC HoT C 3x10AWG 3x 5 0mm GROUND SEAKEEPER SUPPLIED FIGURE 3 CABLE 2 WIRE CONNECTIONS AT AC POWER DISTRIBUTION PANEL ii Connect AC input conductors in CABLE 2 to a double pole Circuit Breaker at an AC power distribution panel according to Figure 3 above 1 110 VAC 25 Amp circuit breaker 2 230 VAC 20 Amp circuit breaker 3 DRIVE BOX AC POWER OUTPUT TO SEAWATER PUMP CONNECTION INSTRUCTIONS a Cable 3 x 14AWG 3 x 2 0mm CSA cable 10 3m length Seakeeper supplied pre installed b Pumps rated at 110 or 230 VAC 5 Amps max Customer supplied 1 Verifv that AC power is OFF to the Drive Box before connecting CABLE 5 to a Seawater Pump Locate CABLE 5 for AC power output to the Seawater Pump from the Drive Box at the middle of three cable glands See Figure 2 SEAWATER PUMP OUTPUT POWER 3x14AWG 3x 2 5mm SEAKEEPER SUPPLIED GROUND HOT 230 VAC FIGURE 4 CABLE 5 AC OUTPUT POWER CABLE Connect the AC output conductors in CABLE 5 to a 5 Amp maximum Seawater Pump approximately 1 3 horsepower or 250 W according to Figures 4 and 5 O seaKeeperr INSTALLATION Product ______________ Document Rev Page MANUAL SEAKEEP
20. e Note that holes in fixture plate are 80 53 13 5 mm A transfer punch is supplied FOUR AREAS WHERE ie l CO PLANAR TOLERANCE with installation template kit P N NOTIONAL HULL MUST BE WITHIN 06 1 5mm STRUCTURE 90260 4 Remove fixture and drill and tap M12X1 75 holes in foundation at marked locations to mate with holes inthe foundation Take special care to drill perpendicular to mounting surface Remove any impeding obstructions NOTIONAL HULL STRUCTURE TAP M12X1 75 HOLES 67 17mm MINIMUM THREAD ENGAGMENT 16 PLACES SEAKEEPER MANUAL Section 1 MECHANICAL INSTALLATION 1 5 3 Installation of Gvro 1 2 3 4 5 Locate and position 4 foundation spacers and 4 isolation gaskets onto hull structure NOTE Sealant or caulk is recommended to be applied Applv a small bead approximately 4mm wide of sealant silicone or caulk between all mating surfaces of each foundation spacer and each isolation gasket This will prevent water from wicking between the parts and setting up corrosion Check foundation spacers and isolation gasket alignment by test fitting bolts without any obstructions Lower gyro into position onto foundation beams and align over drilled holes supplied M12 fasteners apply a moderate coat of Install Seakeeper removable thread locker to the threads of each bolt and include a small bead of marine sealant under each washer before installation Torque all fastene
21. ear helm Connect Customer Supplied Cables L Cable 1 customer supplied Install DC Power Input Connector Kit on customer supplied 2x14AWG or 2x12AWG cable U Connect other end of Cable 1 to 12 VDC power at customer supplied connection box or directiv to circuit breaker U Plug connector of Cable 1 into mating connector on gvro wire harness Install lugs on both ends of customer supplied 4AWG ground cable L Cable 6 customer supplied U Connect one end of Cable 6 to nearest vessel ground and other end to gvro rear brace Connect Seakeeper Supplied Cables Connect Cable 2 from Drive Box to 110 230 VAC single phase at customer supplied connection box or directiv to circuit breaker L Cable 2 Seakeeper supplied Connect Cable 5 from Drive Box to customer supplied 110 230 VAC seawater pump L Cable 5 Seakeeper supplied G SEAKEEPER INSTAUATION Prode Document Rev Pages MANUAL _ SEAKEEPER 5 GYRO 90245 1 2of4 Section 5 INSTALLATION CHECKLIST AND SUPPLIES Connect female end of CAN communications Cable 3 to mating connector on gyro wire harness WI Cable 3 Seakeeper supplied U Route CAN communications Cable 3 from gyro to helm male end goes to helm O Connect male end of CAN communications Cable 3 at helm to CAN Tee Adapter U Connect Display and Seakeeper supplied Cable 4 to CAN Tee Adapter with CAN Terminator Cooling Checklist reference Installation Manual Sec
22. 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 The foundation saddles of the gyro are designed to be bonded directly to the composite hull structure of the vessel to effectively distribute gyroscopic loads A complete bond is required between the inside surface of the saddles and the hull structure Seakeeper recommends having a minimum of 7 cartridges 225mL 1 bottle Plexus PC 120 Primer Conditioner and 2 manual adhesive guns on hand for installation Two workers should apply the adhesive at the same time to finish the installation before the adhesive starts to cure To aid in determining the quantity of adhesive required the interior surface area bonding surfaces of each saddle is 58 2 in 375 cm for a total bonded surface area for all four saddles of 232 5 in 1500 cm The hull structure supporting the gyro should be installed so the gyro is parallel to the waterline In addition the four areas on top of the beams that the saddles will bond to need to be co planar within 13 inches 3 mm to minimize potential distortion of gyro support frame when installed Note that any paint or gel coat present in bond area should be removed so that adhesive will bond directly to laminate fibers and resin Seakeeper provides an installation fixture template P N 90260 that locates the saddles at the proper spacing both in the fore aft direction and
23. inder rods See Figure 1 from scratches or damage as this could lead to premature seal failure and oil leaks e While handling installing gyro assembly do not allow electrical fittings that exit bottom of gyro enclosure to come in contact with any surface or object as this could damage the fittings and potentially affect the vacuum integrity of the enclosure e Exercise care to protect gyro painted finish as damage to finish could lead to early appearance degradation of installed gyro 1 2 Selection of Gyro Installation Location Selection of mounting location of gyro should consider the following desirable features The gyro must be installed aft of amidships to minimize high acceleration loadings due to hull wave impacts during operation at high speed or in large waves e Overhead access or sufficient clearance for removal re installation of gyro for overhaul in future years e Gyro should be installed in a dry space to minimize effects of corrosion e Clearance for replacement of gimbal angle sensor on gyro gimbal shaft see Figure 2 e Clearance for filling purging brake hydraulic oil see Figure 2 e Clearance for filling water glycol cooling circuit see Figure 2 e Clearance for replacement of brake hydraulic cylinders see Figure 2 amp SEAKEERER INSTALLATION ocument Rev Page MANUAL SEAKEEPER 5 GYRO 90245 3 of 21 Section 1 MECHANICAL INSTALLATION MOTOR DRIVE BOX BRAKE MANIFOLD
24. l structure SEE OUT OF SADDLE EDGES FIG 7 The adhesive will be forced towards the forward and aft ends of each saddle and partially down the sides of the foundation beams 7 Insert full adhesive cartridge along with mixing wand nozzle assembled in step 3 above into gun 8 Begin to inject adhesive into the six holes provided on each side of each of the four saddles Follow the numbered sequence shown until the THIRD REMOVE PLUG AND SECOND REMOVE PLUG AND INJECT ADHESIVE HERE INJECT ADHESIVE HERE adhesive pushes out the edges of the UNTIL T CAN BE SEEN COMING UNTILIT CAN BE SEEN COMING OUT OF SADDLE EDGES OUT OF SADDLE EDGES saddle perimeter The intent is to pump in the adhesive working from CONTINUE IN SEQUENCE UNTIL AN EVEN AMOUNT OF ADHESIVE l IS SEEN COMING OUT OF ENTIRE PERIMETER OF SADDLE the top down and from the middle to the ends to fill the gaps and displace any air A complete bond is required excess adhesive will be needed to make sure all bond gaps are filled Product Document Page SEAKEERER INSTALLATION ocument Rev Page MANUAL SEAKEEPER 5 GYRO 90245 20 of 21 Section 1 MECHANICAL INSTALLATION 9 Repeat above step for remaining 7 sides of the saddles 10 When gaps have been completely filled clean off excess adhesive remove plugs and remove masking tape 11 Allow adhesive to cure per manufacturer s recommendations Follow adhesive guidelines for curing time ve
25. ll be used to inject adhesive into the sides of each saddle after the fixture saddles are in position MIXING TIP FLEXIBLE NOZZLE 4 Install provided rubber plugs in six holes of each saddle The plugs will limit the adhesive being forced out of the injection holes in step 6 below FIRMLY INSERT RUBBER PLUGS INTO THE THREE INJECTION HOLES ON EACH SIDE OF EACH SDDLE SIX INJECTION HOLES ON EACH SADDLE SEAKEEPER INSTALLATION u Rev Page MANUAL SEAKEEPER 5 GYRO 90245 19 of 21 Section 1 MECHANICAL INSTALLATION 5 Apply large bead of Plexus adhesive LOW ER FIXTURE SADDLES OVER FOUNDATION ONTO ADHESIVE BEAD to the hull structure as shown in the figure to the right Apply approximately Y to s 4 cartridges at each of the four locations Work deliberate and fast as it takes some time to apply the adhesive to the structure MA590 has a 90 minute working time at room temperature 23 C 73 F This working time can reduce to 40 50 minutes at elevated temperatures Two workers should apply the adhesive at the same time to finish the installation before the APPLY 2 3RDS OF A CARTRIDGE OF PLEXUS IN ONE LARGE BEAD 4 PLACES adhesive starts to cure 6 Lower fixture and saddles over the hull structure and apply light downward pressure to each of the FIRST REMOVE PLUG AND four saddles until the two nylon INJECT ADHESIVE HERE UNTIL IT CAN BE SEEN COMING screws rest on the hul
26. mp to lower 3 4 19 mm hose barb on heat exchanger Use the same practices as other below waterline seawater plumbing Required flow rate is 4 GPM 16 LPM minimum and 8 GPM 30 3 LPM maximum 2 Connect seawater discharge upper hose barb to overboard drain Use the same practices as other below waterline seawater plumbing 3 In addition to initial operation at dock new gyro installations should be checked for minimum 4 GPM 16 LPM flow while vessel is at speed and when backing down If no other method of confirming flow is available discharge line may be temporarily diverted to a bucket Flow is calculated from time to fill a known volume 4 Inspect raw water plumbing after sea trial for any signs of leakage 5 Heat exchanger contains removable end caps to provide access for cleaning the tube bundle GLYCOL WATER FILL SEAWATER INLET SEAWATER OUTLET COOLANT PUMP FIGURE 4 SEAKEEPER 5 SEAWATER CONNECTIONS PAGE INTENTIONALLY LEFT BLANK G SEAKEEPER INSTAUATION Product Document Rev Page MANUAL _ SEAKEEPER 5 GYRO 90245 1 1of3 Section 4 STARTUP 4 0 Introduction This section describes the first startup of the gyro Also reference Seakeeper Document 90246 Seakeeper 5 Gyro Operation Manual e Previous sections for mechanical electrical and cooling installation must be completed before this startup sequence is initiated e Before continuing covers must be installed and the
27. n 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 SEAKEEPER 5 INSTALLATION KIT NOTIONAL HULL FOUR MOUNTING AREAS STRUCTURE SHOULD BE CO PLANAR TO EACHOTHER WITHIN 06 1 5mm REMOVE ALL PAINT AND GELCOAT FROM BOND AREAS FIGURE 8 INSTALLING FIXTURE ON HULL 2 Mask hull area Fig 9 around foundation saddles for easy clean up and to create outline of surface area to receive adhesive as Fig 8 Insure that the bond gap is within Seakeeper s recommended thickness or 3mm if using Plexus MA590 SADDLE 4 PLACES POSITION FIXTURE IN DESIRED LOCATION AND MASK PERIMETER OF EACH SADDLE CONFIRM GAPS ON VERTICAL SURFACES ARE WITHIN ADHESIVE SPECIFICATIONS FIGURE 9 MASKING PERIMETER OF SADDLES Product Document Page amp SEAKEEPER INSTALLATION ocument Rev Page MANUAL SEAKEEPER 5 GYRO 90245 16 of 21 Section 1 MECHANICAL INSTALLATION 3 Raise fixture clear of foundation Check all four mounting areas are co planar to within 13 3 mm to each other as well as parallel to the water line plane as shown in Fig 10 PLANE PARRALLEL TO WATERLINE PLANE NOTIONAL HULL STRUCTURE SURFACES A B C amp D ON WHICH GYRO SADDLES OR BOLATION MOUNTS REST SHOULD BE CO PLANAR WATRIN 13 amm FIGURE 10 COPLANAR PROPERTIES OF FOUNDATION 4 Thoroughly clean with alcohol or
28. our areas on top of the beams on which the isolation mounts will rest need to be co planar within 06 1 5 mm to minimize potential distortion of gyro support frame when installed Seakeeper provides an installation template kit P N 90260 which contains four plates that mimic the mating surfaces of the four isolation mounts located on the gyro s foundation These plates have 4 holes located at the same centers as the holes in the isolation mounts The fixture locates the hole patterns at the proper spacing both in the fore aft direction and the port starboard direction See Figures 5 below Once assembled the fixture can be used to check clearances and alignment of the hull structure Note Do NOT use the installation fixture to establish gyro envelope dimensions Refer to Drawing No 90293 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 NOTE MAKE SURE NO OBSTRUCTIONS FROM THE HULL STRUCTURE CAN BE SEEN WITHIN THE INSIDE OF THE INSTALLATION TEMPLATE KIT INSIDE THE MARKED RED LINES SEE SECTION 1 PAGE 9 OF INSTALLATION MANUAL 1X 13 5MM DIA TRANSFER PUNCH 16 M12X1 75 40MM LG MOUNTING HARDWARE FOR TEMPLATE KIT ONLY 2 o SEAKEEPER 5 GYRO Xe INTSTALLATION TEMPLATE FIGURE 5 INSTALLATION TEMPLATE KIT P N 90260 SEAKEEPER MANUAL SEAKEEPER 5 GYRO 90245 9 of 21 Section 1 MECHANIC
29. p immediately then disconnect and inspect connector polarity 7 a D H P O SEAKEEPER INSTALLATION Product Document Rev Page MANUAL SEAKEEPER 5 GYRO 90245 1 70f13 Section 2 ELECTRICAL INSTALLATION 2 3 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 uf gt vam kl GROUND STUD FIGURE 8 GVRO GROUND STUD ON REAR OF FOUNDATION G SEAKEEPER INSTAUATION Prode Documenta Rev Page MANUAL SEAKEEPER 5 GYRO 90245 1 80f13 Section 2 ELECTRICAL INSTALLATION 2 4 Operator Station This section explains the connection between the Operator Station equipment and the Gvro Control Box Reference Drawing 90296 SEAKEEPER 5 Gvro 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 b Theoperator displav should be located on the bridge console c Figure 9 below shows the CANbus communications link for the Operator Station The Terminator goes on one the far end of the Tee Adapter from the Gvro COLOR SEAKEEPER DISPLAV FUTURE USE GYRO DISPLAY INTERFACE CABLE o0000 GYRO fm F remeron gf a a CAN CA
30. performed structural analysis to assure the structure to which the gyro mounts can properly transfer the loads the gyro creates into the hull structure If the installer has any doubt about the ability of the structure to transfer the gyro loads to the hull then he should contact a licensed naval architect or marine engineer to do a structural analysis The installer should review the following list of reference drawings to ensure the installation procedure is fully understood Reference Drawings 90242 Seakeeper 5 Gyro Hardware Scope of Supply 90260 Seakeeper 5 Gyro Installation Template Kit 90293 Seakeeper 5 Gyro Installation Details Bolt in Method 90294 Seakeeper 5 Gyro Installation Details Bond in Method 90295 Seakeeper 5 Gyro Cooling Water Schematic 90296 Seakeeper 5 Gyro Cable Block Diagram HEAT EXCHANGER LIFTING POINTS MOTOR DRIVE BOX HYDRAULIC BRAKE CYLINDERS ENCLOSURE FOUNDATION FIGURE 1 SEAKEEPER 5 GYRO G SEAKEEPER WSTAUATION Producti Document Rev Page MANUAL SEAKEEPER 5 GYRO 90245 2 of 21 Section 1 MECHANICAL INSTALLATION 1 1 Precautions e Gyro must only be lifted from the supplied lifting eyes See Section 1 4 e 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 e While handling installing gyro assembly protect exposed hydraulic brake cyl
31. rs to 65 ft lbs 88 N m Proceed to electrical and cooling portion of the installation INSTALLATION Product Document Rev Page SEAKEEPER 5 GYRO 90245 11 of 21 LOWER INTO POSITION SEAKEEPER 5 FOUNDATION SPACER 4 PLACES ISOLATION GASKET 4 PLACES NOTE SEAKEEPER 5 FOUNDATION SPACERS TO BE INSTALLED BETWEEN GYRO AND ISOLATION GASKET SOLATION GASKET TO BE INSTALLED BETWEEN FOUNDATION SPACER AND NOTIONAL HULL STRUCTURE SEE DETAIL SECTION VIEW GYRO FOUNDATION FOUNDATION SPACER ISOLATION GASKET NOTIONAL HULL STRUCTURE amp SEAKEEPER INSTALLATION ocument Rev Page MANUAL SEAKEEPER 5 GYRO 90245 12 of 21 Section 1 MECHANICAL INSTALLATION 1 6 Saddle Installation Seakeeper recommends Plexus MA590 adhesive for bonding the saddles to the GRP hull structure Plexus MA590 is a two part methacrylate structural adhesive that has characteristics conducive to this type of installation Details of the bonding procedure in this manual will involve the Plexus MA590 product but that should not exclude other suitable adhesives the installer chooses to use See Sheet 5 of Seakeeper drawing no 90294 for loads information and recommended adhesive properties 1 6 1 Initial Check and Preparation of Hull Structure Refer to Seakeeper Drawing No 90294 Seakeeper 5 Gyro Installation Details Bond In Method Important dimensional and load information is given in this drawing that will
32. rsus temperature prior to removing the fixture 12 Bonding of gyro saddles onto the hull is now complete Remove installation fixture 1 6 5 Installation of Gyro 1 Rig gyro for lifting and lower gyro into position onto top surface of four saddles 2 Apply a small bead approximately 4mm wide of sealant or caulk to the mating surfaces between the saddles and the gyro foundation Adjust position of gyro until alignment is achieved for the 16 fasteners that will attach gyro foundation frame to saddles 3 Install Seakeeper supplied M12 fasteners apply a moderate coat of removable thread locker to the threads of each bolt and include ALIGN BOLT HOLES AND LOWER GYRO ONTO SADDLES a small bead of sealant under each washer before installation 4 Torque all fasteners to 65 ft lbs 88 N m 5 Proceed to electrical and cooling portion of the installation amp SEAKEEPER INSTALLATION u Rev Page MANUAL SEAKEEPER 5 GYRO 90245 21 of 21 Section 1 MECHANICAL INSTALLATION 1 7 Doc 90213 Plexus PC 120 Application Instructions SEAKEEPER INSTALLATION u Rev Page MANUAL SEAKEEPER 5 GYRO 9025 1 10f13 Section 2 ELECTRICAL INSTALLATION 2 0 Introduction This section for electrical installation explains how to mount the electrical equipment and how to connect the electrical cables Reference Documents amp Drawings 90242 Seakeeper 5 Gyro Hardware Scope of 90232 Color Display Envelope
33. ructions in Section 2 1 5 CONNECT 2 OPERATOR STATION EQUIPMENT a The 2 Operator Station equipment is connected in accordance with the Cable Block Diagram 90296 PAGE INTENTIONALLY LEFT BLANK G SEAKEEPER INSTAUATION Product Documenta Rev Page MANUAL SEAKEEPER 5 GYRO 90245 1 120f13 Section 2 ELECTRICAL INSTALLATION 2 6 Display Installation Templates The following templates are for flush or surface mounting Before using the templates measure to ensure that the shown size is actual 2 3 4 70mm 3 4 763mm 1 3 8 3mm ER SA Ba DE FK FLAWT S SALA MAKE SURE TO CHECK MEASUREMENTS IF THIS TEMPLATE IS PRINTED FROM A COMPUTER OR PHOTUCUPIED Es Ta u a a mn mn kl SURFACE MOUNT TEMPLATE PAGE INTENTIONALLY LEFT BLANK SEAKEEPER MANUAL SEAKEEPER 5 GYRO 902455 130f13 Section 2 ELECTRICAL INSTALLATION 3 36 80mm 3 36 85mm MAKE SURE TO CHECK MEASUREMENTS IF THIS TEMPLATE IS PRINTED FROM A COMPUTER OR PHOTOCOPIED FLUSH MOUNT TEMPLATE PAGE INTENTIONALLY LEFT BLANK fa INSTALLATION Product 0000000000 Documentfii Rev Page amp SEAKEEPER MANUAL Section 3 COOLING INSTALLATION 3 0 Introduction Like the M8000 and Seakeeper 9 gyros the Seakeeper 5 is shipped with the cooling circuit filled and ready for use Only a quick confirmation of glycol level is required Reference Drawings 9
34. t contains live voltage when gyro is in operation Gyro ships with CABLE 5 permanently sealed at end of cable with protective cap in the event it is not used Do NOT remove CABLE 5 from Drive Box as moisture will be free to enter box through open cable gland and corrode internal electronic components 1 Cable 5 contains live voltage when gyro is in operation Do NOT cut Cable 5 Do not remove Cable 5 from Drive Box G SEAKEEPER INSTAUATION Prode TDocumentii Rev Page MANUAL SEAKEEPER 5 GYRO 90245 1 60f13 Section 2 ELECTRICAL INSTALLATION 4 12 VDC POWER SOURCE REQUIREMENTS a 12 VDC 15 Amps b A separate breaker should be used for each Gyro 5 GYRO DC POWER CONNECTION INSTRUCTIONS Reversing polarity on the DC power input to the gyro can result in damaging the electronics in the control system a 12 VDC 15 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 12 VDC Terminate BLACK conductor to 12V Rtn or Zero VDC ii Before connecting CABLE 1 to gyro check for proper voltage and polarity with a DC multimeter using Figure 7 below 12V Rtn 12VDC FIGURE 7 DC POWER INPUT CONNECTOR CONTACT ASSIGNMENTS front iii Connect CABLE 1 to 12VDC input receptacle on Gyro When energizing DC power the first time if Display does not power u
35. th respect to the 1 Operator Station and the vessel arrangement b Typical locations include i Flybridge ll Engine room 2 DETERMINE CABLING ARRANGEMENT a Figure 10 below shows the entire serial communications link for 2 Operator Stations The Terminator must be installed on the Tee Adapter farthest from the Gyro SEAKEEPER FUTURE USE GYRO 2nd COLOR DISPLAY 1st COLOR DISPLAY FUTURE USE GYRO DISPLAY DISPLAY INTERFACE INTERFACE CABLE CABLE l I O O O O O GYRO M M F kah ye wadhon me ja KORA TEE ADAPTER CAN CABLE ASSY 25m TEE CAN CABLE ASSY 25m ADAPTER FIGURE 10 CABLING FOR 2 OPERATOR STATIONS b The Operator Station nearest the Gyro Control Box should be connected to CABLE 5 D H P O SEAKEEPER INSTALLATION Product Document Rev Page MANUAL SEAKEEPER 5 GYRO 90245 1 110f13 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 b The additional CAN Cable Assembly must be routed in the vessel from the 1 Operator Station female end to the 2 male end Operator Station 4 INSTALL 2 OPERATOR STATION EQUIPMENT a The 2 Operator Station equipment is installed at the determined location using Electrical Equipment Mounting Inst
36. the port starboard direction See Figures 6 7 amp 8 below Once assembled with the provided saddle fittings the fixture can be used to check saddle clearances and alignment of the hull structure The fixture will allow the builder installer to lay up and adjust the foundation dimensions to create a low clearance fit between the gyro foundation saddles and the hull structure Shear strength of the adhesive will be maximized if the cured thickness between the vessel structure and gyro saddles is at the thinner end of the adhesive manufacturer s recommended range Therefore the fixture should be used to confirm that the overall dimensions of the foundations are square and level and that the adhesive gap is within Seakeeper s maximum recommended thickness of 13 or 3mm amp INSTALLATION Product Document Rev Page D SEAKEEPER MANUAL SEAKEEPER 5 GYRO 90245 13 of 21 Section 1 MECHANICAL INSTALLATION Note Do NOT use the installation fixture to establish gyro envelope dimensions Refer to Drawing No 90294 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 NOTE MAKE SURE NO OBSTRUCTIONS FROM THE HULL STRUCTURE CAN BE SEEN WITHIN THE INSIDE OF THE INSTALLATION TEMPLATE KIT INSIDE THE MARKED RED LINES SEE DRAWING NO 90294 M12 1 75 X 40MM LONG HEX HD FLANGE SCREW 16 PLACES THESE CAP SCREW
37. tion 3 U Verify coolant level in heat exchanger coolant reservoir L Connect sea water hoses open sea cocks to heat exchanger and test sea water pump LJ Verify 4 GPM 15 LPM minimum and 8 GPM 30 LPM maximum sea water flow through heat exchanger under all operating conditions of the boat Startup Checklist reference Installation Manual Section 4 and Operation Manual Section 2 LI Remove lifting bolts and Install cover panels Turn on 12 VDC circuit breaker Turn on 110 230 VAC circuit breaker Verify display works and no alarms are present U U U U Follow instructions in Section 4 1 of Installation Manual to turn on the GYRO UI Verify sea water pump turns on when the GYRO is turned ON U Verify that no ALARMS are present LJ Follow instruction in Section 4 1 of Installation Manual to turn off the Gyro U AC amp DC power and sea water pump may be turned off after the GYRO is turned off bv placing the GVRO in LOCK mode and Turning the GVRO off L Gyro takes 3 hours to coast down to zero rpm from full speed G SEAKEEPER INSTAUATION Prod TDocumentii Rev Pages MANUAL _ SEAKEEPER 5 GYRO 90245 1 3of4 Section 5 INSTALLATION CHECKLIST AND SUPPLIES 5 1 Required Supplies needed for Gyro Installation not supplied with gyro Installation Manual Other Description t System p Qty Reference Reference y Section Adhesive and cleaning supplies for bonding to hull O O NANA Mechanical Soundproofing Considera
38. tions O O 4 Mechanical Spreader bar for lifting gyro a ln Mechanical BEE Cooling Hose clamps for seawater plumbing to 3 4 19 mm hose barb 2 per hose barb Cable 2x14AWG or 2x12AWG 12 VDC power input to Gyro Dwg 90296 Electrical 76 Ms terminal lg for grounding gyro at rear brace raf 23a _ Electrical 7 Cable 4AWG for grounding gyro at rear brace to vessel AR 2 3 1 Dwg 90296 Electrical ground used with item 5 Relay for sea water pump control Not required if using gyro 1 2 2 3 Electrical output 110 230V AC pump AR As Required Dwg Drawing List of common tools that may be required for installation INSTALLATION Product 0000000000 JDocumentfi Rev Page SEAKEEPER MANUAL SEAKEEPER 5 GYRO 90245 1 4of4 Section 5 INSTALLATION CHECKLIST AND SUPPLIES kem Deseristion Joe a 25 mmnentey Gimbal ange sensor e 170 inch under Hosedampa a Unyi scoring cablejat
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