Seakeeper 5500 GYRO User manual

Rev2JULY2013
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INSTALLATIONMANUAL
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MODEL5500GYRO

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INSTALLATION
MANUAL
Product:Document#:Rev:
MODEL5500GYRO902142
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MODEL5500GYRO
INSTALLATIONMANUAL
JULY2013
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Contents:
Section1–MechanicalInstallation&PC‐120Guide
Section2–ElectricalInstallation&PowerConfigurations
forSeakeeperGyroStabilizers
Section3–CoolingInstallation
Section4–Startup
Section5–InstallationChecklistandRequiredSupplies
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44425PECANCOURT,SUITE151
CALIFORNIA,MARYLAND,20619,U.S.A
PHONE:410‐326‐1590
FAX:410‐326‐1199
E-MAIL: [e-mail]

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MODEL5500GYRO9021421of15
Section1:MECHANICALINSTALLATION
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1.0Introduction
Thisdocumentisintendedtogivedetailsandguidancetoaboatbuilderorequipmentinstallertoinstall
theSeakeeper,Inc.Model5500StabilizingGyro.Thegyroiscapableofproducingloadsupto14.7kN
(3300lbs.)oneachfoundationsaddleandcarefulconsiderationshouldbegiventofoundationdesignto
insureitiscapableoftransferringtheseloadsintothehull.Itisassumedthatpersonnelinvolvedin
installationarefamiliarwithGRPstructuresaswellastheuseofhighstrengthadhesivesthatwillbe
usedtobondthegyrotothehullstructure.Theinstallershouldreviewthefollowinglistofdrawingsto
ensuretheinstallationprocedureisfullyunderstood.
ReferenceDrawings
90012InstallationFixtureAssembly
90219Model5500GyroInstallationDetails
90212Model5500GyroHardwareScopeofSupply
90149GyroCableBlockDiagram
90156GyroCoolingSchematic
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FIGURE1–MODEL5500GYRO

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1.1Precautions
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.
Whilehandling/installinggyroassembly,protectexposedhydraulicbrakecylinderrods(See
Figure1)fromscratchesordamageasthiscouldleadtoprematuresealfailureandoilleaks.
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.
Exercisecaretoprotectgyropaintedfinishasdamagetofinishcouldleadtoearlyappearance
degradationofinstalledgyro.
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DoNOTremoveforwardbrace(seeFigure1).
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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.
Overheadaccessorsufficientclearanceforremoval/re‐installationofgyroenclosurefor
overhaulinfutureyears.
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Gyroshouldbeinstalledinadryspacetominimizeeffectsofcorrosion.
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Clearanceforreplacementofgimbalanglesensorongyroportside(seeFigure2).
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Clearanceforfilling/purgingbrakehydraulicoil(seeFigure2).
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Clearanceforfillingwater/glycolcoolingcircuit(seeFigure2).
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Clearanceforreplacementofbrakehydrauliccylinders(seeFigure2).
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Spaceforrecommendedsound/safetyenclosure.
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MODEL5500GYRO9021423of15
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FIGURE2–INSTALLEDGYROCLEARANCECONSIDERATIONS
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FIGURE3–TRANSVERSEBEAMSCLEARANCECONSIDERATIONS
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RefertoFigure3forrecommendedclearancestotransversebeams.Ifatransversebeamislocated
undertheforwardbrace,itmustbe3”(76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.
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SafetyEnclosure
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Thereisalargetorqueaboutthegimbalaxiswhenthegyroisprecessing.Therefore,thegyro
mustbehousedinanenclosureoracompartmentorinstalledinacagesopersonnelorgear
cannotcomeintocontactwiththegyrowhileitisprecessing.
Thegyroshouldbetreatedwiththesamerespectonegivesahighspeedrotatingpropeller
shaftorengineshaft.
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Noise/Soundproofing/Ventilation
Gyronoisehasbeenmeasuredundersteadystateconditions(nowaveload)inSeakeeper'slabandin
our43fttestboat.Thesteadystatenoiseistypicallyintherangeof70‐75dBunweighted.Asthe
frequenciesemittingthehighestsoundpressuresarelow(likeothermarinemachinery),itis
recommendedthatthegyrobeinstalledinacageinamachineryspacethatisalreadytreatedwith
soundproofing.
Ifthegyrostabilizerhastobelocatedoutsideamachineryspace,itshouldbeinstalledinasound
dampingenclosuretopreventlowfrequencynoise(approximately133Hz)fromenteringtheliving
spaces. Inthiscase,theenclosurecanbeopenatthebottombetweenthehullstringers. Asmall
exhaustfanshouldbeinstalledinthetopoftheenclosuretopullambientairthrutheenclosuresothe
airintheenclosuredoesnotheatup.Thiswillensurethattheownerdoesnotgetnuisanceshutdowns
duetotheMotorDriveandBearingtemperaturealarmsinsomeoperatingconditions(highambientair
temperature,highseawatertemperature,highseastate,etc).
Thefanshoulddeliveraminimumof35cuft/min(60cum/hr)whichshouldexchangetheairinthe
enclosureaboutonceperminute.Small,massproduced,axialandcentrifugalcoolingfansareavailable
witheitherACorDCinputpower,ballbearings,extendedtemperaturerange,lownoiseratings,long
MTBF,marinized,etc.Locatetheinletatthebottomoftheenclosureandmountthefanatthetopas
anexhaustfan.Acentrifugalfanmaybebesttominimizeoutletarea.Thefanpowerrequirements
wouldtypicallybeintherangeof20watts. WhenusingaDCfan,wireittothesamebreakerthat
providespowertotheGyroControlBoxsothefanturnsonandoffatthesametimeasthecontroller.
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INSTALLATION
MANUAL
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MODEL5500GYRO9021426of15
Section1:MECHANICALINSTALLATION
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1.3UnpackingCrate
1) ReferenceSeakeeperDrawingNo.90212,Model5500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) Attachspreaderbartothetwoliftingeyeslocatedonthetopofthegyroenclosure.Alsoattach
alevelinglinethatconnectsspreaderbartobrakegimbalshaft.Gyroweighs485kg(1069lbs).
SeeFigure4below.
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FIGURE4–LIFTINGARRANGEMENT
LevelingLine
BrakeGimbalShaft

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1.4PreparationofHullStructure
RefertoSeakeeperDrawingNo.90219,Model5500GyroInstallationDetails.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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.
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.
Acompletebondisrequiredbetweentheinsidesurfaceofthesaddlesandthehullstructure.Toaidin
determiningthequantityofadhesiverequired,thesurfaceareaofPortsaddlebondareais340in2
(2194cm2).Thestarboardsaddlebondareais310in2(2002cm2).
Seakeeperhasanoptionalinstallationfixtureavailable,P/N90012,thatisintendedtoduplicatethegyro
foundationgeometryinordertocheckclearancesandalignment.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
manufacturers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theadhesive
manufacturer’smaximumrecommendedthickness‐seeFigure5.
Thehullstructuresupportingthegyroshouldbeinstalledsothegyroisparalleltothewater‐planein
theport/starboardandforward/aftdirections.
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Note:DoNOTusetheinstallationfixturetoestablishgyroenvelope
dimensions.RefertoDrawingNo.90219forenvelopedimensions.
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INSTALLATION
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FIGURE5–INSTALLATIONFIXTURE
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1.4.1FiberglassHullPreparation
1) PositioninstallationjigonhullgirdersnotingrecommendedclearancesfromFigures2&3.
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Checklongitudinalgirdersarealignedandspacedproperly.
Confirmfixtureislevelwhenvesselislevel.
Checkfitofsaddleovergirders.
Confirmbondgapnottoosmall,nottoolarge.
Notefixtureissmallerthanactualgyro.















FIGURE6–CHECKINGFOUNDATION


INSTALLATION
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2) Maskhullareaaroundfoundationsaddlesforeasyclean‐upandtocreateoutline(highlightedin
blue)ofsurfaceareatoreceiveadhesiveasshowninred,Fig7.
3) Raisejigclearoffoundation.
4) Thoroughlycleanwithalcoholoracetoneallareas(highlightedinred,Fig7)ofgirderstobe
bondedtoremoveanycontaminates.Usenewpapertowelsforcleaning,notshoprags.
5) Removeallpaintandgel‐coatfrombondsurfacessothatadhesivewillbonddirectlytolaminate
fibersandresinasshowninFigure7.
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jigon
girdersanddouble‐checkthat
theadhesivegapiswithinthe
adhesivemanufacturer’s
maximumrecommended
thickness.(Notegapwillbe
largerduetoabsenceofgel‐
coat.)

1.4.2Aluminum/SteelHullPreparation
1) Followsteps1‐4offiberglasshullpreparation.
2) Removealloxidationviasandingwith80gritsandpaper/grinding.(IMPORTANT–BOND
STRENGTHMAYBEREDUCEDIFTHISSTEPISSKIPPED.)
3) Wipesurfacescleanfromdustwithalcoholoracetoneusingnewpapertowels,notshoprags.
4) IfusingPlexusMA590adhesive,applyPlexusPC‐120surfaceconditionertothebonding
surfaces.Theseinstructionsarelocatedattheendofthissection.
5) ThegyroshouldbeinstalledwhenPC‐120isconfirmeddry.

Notewheninstallinggyroonaluminum/steelhull,thesandingandPC‐120(if
usingPlexusMA590adhesive)applicationforbothhullandgyrosaddles
shouldbedoneasclosetothesametimeaspossible.Thiswillminimize
oxidationonbondsurfacesandhelpimproveadhesivebondstrength.
Cleanallareasof
girderstobe
bonded–no
paint,nogel‐coat
Tapegirders
aroundfixtureto
makeclean‐up
easier FIGURE7‐MASKING&CLEANINGHULL


INSTALLATION
MANUAL
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

1.5CleanGyroSaddles
1) PositionGyronearfoundation.

2) Checkthatthescrewsthatattachforward
andaftbracesaretightasthesemaintain
foundationalignmentduringbonding
process.

3) Notethateachofthesaddleshastwo
stand‐offpads(SeeFigure8)locatedon
thetopundersidesurface.DoNOT
removethesepadsastheyaremeantto
maintainasmallgapatthetopofthe
saddletoinsurethatalladhesivedoesnot
getforcedawaybytheweightofthegyro.

4) Performdryfitofgyroassemblyoverhullstructure(noadhesive)toconfirmthatfitisgood.

5) Confirmadhesivegapiswithinadhesivemanufacturer’srequirements.

6) Raisegyroclearoffoundation.

7) Thegyrocontainsholesonthesidesofthe
saddlesforinjectingadhesiveasasecondary
meansofapplyingadhesive.Thegyroshipswith
plugsintheseholes,20places.Checkthatall
plugsareinplaceasshowninFigure9.Plugs
shouldremainintheholesuntilstep1.6.2is
completed.



FIGURE9–ADHESIVEINJECTIONHOLESPLUGGED


Stand‐OffPads
FIGURE8–STANDOFFPADS


INSTALLATION
MANUAL
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
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8) Thoroughlycleanwithalcoholoracetonetheinsidesurfacesofgyrofoundationsaddles(see
Figure10)toremoveanycontaminates.Usenewpapertowelsforcleaning,notshoprags.













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





FIGURE10–FOUNDATIONPREPARATIONFORBONDING

9) Thoroughlysandallgyrobondsurfaceswith80gritsandpaper.(IMPORTANT–BOND
STRENGTHMAYBEREDUCEDIFTHISSTEPISSKIPPED.)

10) Wipesurfacescleanfromdustwithalcoholoracetoneusingnewpapertowels,notshoprags.

11) 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.

12) Tapeoffthecounter‐boresateachofthefourgimbalbearingbolts(4places)andholesfor
forwardbracemountingbolts(4places)tokeepadhesiveoutofscrewthreadsasshownin
Figure10.






INSTALLATION
MANUAL
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Section1:MECHANICALINSTALLATION


1.6InstallGyro

1) IfusingPlexusMA590adhesive,thegyroshouldbeinstalledwhenPC‐120isconfirmeddry.
Applyadhesivetothehullstructure(SeeFigure11)inamannerthatallgapsbetweenthe
saddlesandthehullstructurewillbefilledwithadhesivewhenthegyroisloweredintoposition.
ExcessadhesivewillbeneededtoinsureaCOMPLETEBOND–someadhesivewillgetsqueezed
outandmustbecleanedoffanddiscarded.IfusingthePlexusMA590AdhesiveInstallationKit
fromSeakeeper,itisrecommendedtoapply2fullcartridgestothetopofeachhullstringer.
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.
















2) Oncetheadhesivehasbeenapplied,lowergyroontohullstructure.

3) Visuallyinspecttheentireperimeterofeachsaddletoconfirmthatadhesivehasfilledallthe
gapsonthesaddlesides.Ifadhesivehas
beenappliedcorrectly,itwillsqueeze
outaroundthesidesofthesaddlesas
showninFigure12.Ifadhesivehasfilled
allthegaps,gotostep6.Ifusingthe
PlexusMA590adhesivefromSeakeeper
andtheadhesivedoesnotappearin
certainareas,injectusingtheprovided
nozzleasshowninFigure13.(Note
adhesiveshowninpictureisfor
illustrativepurposesonly.MA590colorwillbegray.)
Applylargebeadontopofgirders
FIGURE11–APPLYINGADHESIVETOHULL
FIGURE12–ADHESIVESQUEEZEOUT


INSTALLATION
MANUAL
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

4) Attachinjectionnozzlewithclamptomixingtip.













Thereareatotalof20
adhesiveinjection
holes,with5holeson
boththeinboardand
outboardsidesof
eachsaddleasshown
inFigure14.







FIGURE14–ADHESIVEINJECTIONHOLES


FIGURE13– ADHESIVEINSTALLATIONSUPPLIES
AdhesiveGun
In
j
ectionNozzle
Mixin
g
Ti
p



INSTALLATION
MANUAL
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MODEL5500GYRO90214215of15
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



5) Ifneeded,insertthetipofthe
injectionnozzleintotheappropriate
holeinthesideofthesaddleas
showninFigure15.Pumpin
adhesiveuntilitfillstheobserved
gaporareathatlacksadhesiveinthe
gapbetweenthesaddlesideandthe
hullstructure.Theinjectionprocess
isonlyusedtorecoverfrom
inadequateorun‐evenadhesive
application.Thismethodshouldnot
beusedastheprimarymeansof
applyingadhesive.


6) Discardplugsandcleanupanyexcessadhesive.Allowadhesivetocurepermanufacturer’s
recommendations.DoNOToperategyrobeforeadhesivehasfullycured.

7) Afteradhesiveiscured,itisrecommendedtosealtheedgesofsaddlewithsealantorpaintto
minimizecorrosionintrusionintobondjoint.

8) Bondingofgyrointohullisnowcomplete.Proceedtoinstallationofelectricalcomponentsand
coolingplumbing.

1.7Doc#90213PlexusPC‐120ApplicationInstructions
Removeplugandinserttipof
injectionnozzleintohole
FIGURE15 –INJECTINGADHESIVE

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