Seakeeper 7000A GYRO User manual

INSTALLATION
MANUAL
Product: Document #:Rev:
MODEL 7000A GYRO 90051 3
MODEL 7000A GYRO
INSTALLATION MANUAL
JAN 2011
Contents:
Section 1 – Mechanical Installation
Section 2 – Electrical Installation
Section 3 – Cooling Installation
Section 4 – Startup
Section 5 – Installation Checklist and Required Supplies
P.O. BOX 809
44731 ST. ANDREWS CHURCH ROAD
CALIFORNIA, MARYLAND, 20619, U.S.A
PHONE: [phone]
FAX: [phone]
E-MAIL: [e-mail]

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INSTALLATION
MANUAL
Product: Document #:Rev: Page:
MODEL 7000A GYRO 90051 3 1 of 10
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, Inc. Model 7000A Stabilizing Gyro. The gyro is capable of producing loads up to 23.5 kN
(5300 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. It will be helpful to the installer to have reviewed the
following list of reference drawings to ensure the installation procedure is fully understood.
Reference Drawings
90030 Model 7000A Gyro Hardware Scope of Supply
90031 Model 7000A Gyro Installation Details
90003 Model 7000 Gyro Cooling Schematic
90032 Model 7000A Gyro Assembly & Parts List
90023 Model 7000A Gyro Cable Block Diagram
90012 Model 7000 Gyro Installation Jig Assembly
FIGURE 1 – MODEL 7000A GYRO

INSTALLATION
MANUAL
Product: Document #:Rev: Page:
MODEL 7000A GYRO 90051 3 2 of 10
Section 1: MECHANICAL INSTALLATION
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 above) 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.
Do NOT remove forward brace (see Figure 1).
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.
•Removable overhead access or sufficient clearance for removal / re-installation of gyro for
overhaul in future years.
•Clearance for replacement of gimbal angle sensor on gyro port side (see Figure 2A below).
•Clearance for filling / purging brake hydraulic oil (see Figure 2A below).
•Clearance for filling / purging water/glycol cooling circuit (see Figure 2A below).
•Clearance for replacement of brake hydraulic cylinder (see Figure 2A below).
•Space for recommended sound / safety enclosure.

INSTALLATION
MANUAL
Product: Document #:Rev: Page:
MODEL 7000A GYRO 90051 3 3 of 10
Section 1: MECHANICAL INSTALLATION
FIGURE 2A – INSTALLED GYRO CLEARANCE CONSIDERATIONS

INSTALLATION
MANUAL
Product: Document #:Rev: Page:
MODEL 7000A GYRO 90051 3 4 of 10
Section 1: MECHANICAL INSTALLATION
Refer to Figure 2B 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.
FIGURE 2B – TRANSVERSE BEAMS CLEARANCE CONSIDERATIONS

INSTALLATION
MANUAL
Product: Document #:Rev: Page:
MODEL 7000A GYRO 90051 3 5 of 10
Section 1: MECHANICAL INSTALLATION
1.3 Preparation of Hull Structure
Refer to Seakeeper Drawing No. 90031, Model 7000A 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. 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 jig available, P/N 90012, that is intended to duplicate the gyro
foundation geometry in order to check clearances and alignment. The jig 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 jig 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 3 below.
Note: Do NOT use the installation jig to establish gyro envelope
dimensions. Refer to Drawing No. 90031 for envelope dimensions.
The hull structure supporting the gyro should be installed so the gyro is parallel to the waterplane in the
port/starboard and forward/aft directions.

INSTALLATION
MANUAL
Product: Document #:Rev: Page:
MODEL 7000A GYRO 90051 3 6 of 10
Section 1: MECHANICAL INSTALLATION
FIGURE 3 – INSTALLATION JIG

INSTALLATION
MANUAL
Product: Document #:Rev: Page:
MODEL 7000A GYRO 90051 3 7 of 10
Section 1: MECHANICAL INSTALLATION
Safety Enclosure
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. The gyro must be installed so contact is not possible while the flywheel
is spinning.
Noise/Soundproofing/Ventilation
Gyro noise has been measured under steady state conditions (no wave load) in Seakeeper's lab and in
our 43 ft Viking 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 160 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 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 Junction Box so the fan turns on and off at the same time as the controller.

INSTALLATION
MANUAL
Product: Document #:Rev: Page:
MODEL 7000A GYRO 90051 3 8 of 10
Section 1: MECHANICAL INSTALLATION
1.4 Unpacking Crate
1) Reference Seakeeper Drawing No. 90030, Model 7000A Hardware Scope of Supply for items that
ship with the gyro.
2) Remove electrical components, cables, and misc. items and set aside.
3) Remove “tray” and 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 top end of brake cylinder structure. See Figure 4
below.
FIGURE 4 – LIFTING ARRANGEMENT

INSTALLATION
MANUAL
Product: Document #:Rev: Page:
MODEL 7000A GYRO 90051 3 9 of 10
Section 1: MECHANICAL INSTALLATION
1.5 Installation of Gyro
1) Position Gyro near foundation.
2) Perform dry fit of gyro assembly over hull structure (no adhesive) to confirm that fit is good.
3) Confirm adhesive gap is within adhesive manufacturer’s requirements.
4) Mask hull area around foundation
saddles for easy clean-up and to create
outline of surface area to receive
adhesive as shown.
5) Raise gyro clear of foundation and
thoroughly clean inside surfaces of gyro
foundation saddles with the
appropriate solvent required by
adhesive as shown in Figure 5 below.
6) Check that the screws that attach
forward and aft braces are tight as
these maintain foundation alignments
during bonding process.
7) Tape off the counterbores 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 5 below.
FIGURE 5 – PREPARATION FOR BONDING

INSTALLATION
MANUAL
Product: Document #:Rev: Page:
MODEL 7000A GYRO 90051 3 10 of 10
Section 1: MECHANICAL INSTALLATION
8) Thoroughly clean hull structure with appropriate solvent where the saddles will be bonded.
9) Apply adhesive to both the saddles and the hull structure 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.
10) Allow adhesive to cure per manufacturer’s recommendations.
11) Bonding of gyro into hull is now complete. Proceed to installation of electrical components,
cables, displays, and cooling plumbing.
Skim coat on
vertical sides
Large bead of adhesive
to be forced over to
and down sides
Skim coat on
hull surfaces

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INSTALLATION
MANUAL
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Section2:ELECTRICALINSTALLATION
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2.0 Introduction
Thissectionforelectricalinstallationexplainshowtomounttheelectricalequipmentandhowto
connecttheelectricalcables.
ReferenceDrawings
90030Model7000AGyroHardwareScopeofSupply
90023Model7000AGyroCableBlockDiagram
90007Model7000GyroMotorDriveJ‐BoxEnvelope&
MountingDetails
90010Model7000GyroSerialComms6‐WayJ‐Box
Envelope&MountingDetails
90035Model7000AGyroOperatorKeypadEnvelope&
MountingDetails
90009Model7000GyroOperatorDisplayEnvelope&
MountingDetails
90018Model7000GyroSerialCommsBreakoutBox
Envelope&MountingDetails
90066Model7000ADelay‐OffTimerBoxEnvelope&
MountingDetails
ReferenceWorkInstructions
020InstallationInstructions,
24VDCPowerConnector
018InstallationInstructions,8‐Pin
ShieldedEMCConnector
019InstallationInstructions,4‐Pin
ShieldedEMCConnector
SERIAL COMMS
TERMINATOR
PCB GYRO CONTROL JUNCTION BOX
MOTOR DRIVEJUNCTION BOX
KEYPAD DISPLAY
SERIAL
COMMUNICATIONS
6-WAY JUNCTION BOX
SERIAL
COMMUNICATIONS
BREAKOUT BOX
WARNING
Hazardou s voltage
inside.
Do NOTremove cover u nless
AC p ower is disc on nected and
Gyro flywhe el is not tu rning.
!
24V DELAY-OFF
TIMER BOX
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FIGURE1–ELECTRICALEQUIPMENTFORMODEL7000AGYRO

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INSTALLATION
MANUAL
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Section2:ELECTRICALINSTALLATION
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2.1 ElectricalEquipmentMounting
Precautions
Eachitemofelectricalequipmenthasspecificmountinginstructions.Theseinstructionsshould
befollowedtoinsureproperfunctionoftheModel7000AGyro.

DoNOTmovegyroControlBoxfromitslocationorincorrectgyrooperation
willresult.
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
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1. MOTORDRIVEJUNCTIONBOXMOUNTINGINSTRUCTIONS
a. Bulkheadspacerequired:Approx.19Wx31Hinches(483x787mm);
b. Hardwarerequired:Fourmountingscrewsthroughtwomountingbracketstoprimary
vesselstructureatfourcorners.Mountingholediameter.219”(5.5mm),Seedrawing
90007forholelocations.
Location:Indryspace,optimalforcablesandtubing,within8.2ft(2.5m)
fromGyro.
c. Orientation:Notcritical.


2. PCBGYROCONTROLJUNCTIONBOXMOUNTINGINSTRUCTIONS
a. M7000APCBGyroControlBoxcomesfromthefactorymountedontheGyro;
b. Location:GyroFrontBrace
c. Orientation:RearpanelfacingGyrosphere.


3. SERIALCOMMUNICATIONS6‐WAYJUNCTIONBOXMOUNTINGINSTRUCTIONS
a. Consolespacerequired:Approx.11Wx7Hinches(280x178mm),rear
b. MountingInstructions:Rearmountonvesselconsolepanel,within3ft(1m)ofDisplay
andKeypad.
c. Hardwarerequired:Twomountingscrewsfor.28”(7.1mm)diametermountingholes,
Seedrawing90010forholelocations.
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INSTALLATION
MANUAL
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Section2:ELECTRICALINSTALLATION
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4. KEYPADMOUNTINGINSTRUCTIONS
a. Consolespacerequired:Approx.3.5Wx4Hinches(89x102mm)
b. MountingInstructions:Frontmounttovesselconsolepanel;1.25"x2.13"(31.8mmx
54.0mm)ovalholeforwireharness;two10‐32screwholes;mountwith10‐32locknuts,
provided.Seedrawing90035forholelocations.
c. HardwareRequired:none.
d. Maximumpanelthickness:.4inches(10mm)
e. Minimumpanelthickness:.04inches(1mm)

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5. DISPLAYMOUNTINGINSTRUCTIONS
a. Consolespacerequired:Approx.3Wx3Hinches(76x76mm)
b. MountingInstructions:Frontmounttovesselconsolepanel,2.125inch(54mm)hole;
withthreadedmountingcollar.Seedrawing90009fordetails.
c. Hardwarerequired:none.
d. Maximumpanelthickness:1.38inches(35mm)
e. Minimumpanelthickness:.06inches(1.6mm)

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6. SERIALCOMMUNICATIONSBREAKOUTBOX
a. Consolespacerequired:Approx.3.5Wx4Hinches(89x102mm),rear
b. MountingInstructions:Rearmountonvesselconsolepanel,within1.5ft(0.5m)of
SerialCommunications6‐WayJunctionBox.
c. Hardwarerequired:Fourmountingscrewsfor.155”(3.9mm)diametermountingholes.
Seedrawing90018forholelocations.
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7. 24VDELAY‐OFFTIMERBOX
a. Spacerequired:Approx.8Wx7Hinches(200x180mm)
b. MountingInstructions:Fourmountingscrewstoprimaryvesselstructureatfour
corners.
c. Hardwarerequired:Fourmountingscrewsfor.177”(4.5mm)diametermountingholes.
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INSTALLATION
MANUAL
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Section2:ELECTRICALINSTALLATION
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2.2 ElectricalEquipmentPowerConnections
1. 230VACPOWERSOURCEREQUIREMENTS
a. 230VAC(nominal),1Phase,50/60Hz,20Amps.
b. AseparatecircuitbreakershouldbeusedforeachMotorDriveJ‐Box.

2. 24VDCPOWERSOURCEREQUIREMENTS
a. 24VDC,10Amps.
b. AseparatebreakershouldbeusedforeachGyroControlBox.
Thevesselbreakershouldbelabeled“DoNotTurnOffExceptforService”.

3. 24VDELAY‐OFFTIMERBOX
a. The24VDelay‐OffTimerBox(SeakeeperPartNo.20115)mustbeinstalledbetweenthe
vesselbreakersandthegyrosystemasshowninFigure2.
GYRO DC
DISCONNECT
SWITCH
CUSTOMER
SUPPLIED
CIRCUIT
BREAKER
24
VDC,
10A
(-)
(+) 10 A
GYRO AC
DISCONNECT
SWITCH
CUSTOMER
SUPPLIED
CIRCUIT
BREAKER
185-240
VAC,
20A, 1Ø,
50/60 Hz
HOT
EARTH
HOT 20 A
20 A
GRN
14
S
12
11
TB8
TB9
TB7
TB6
A2
24V RTN
RED/WHT
3
1
...
TB10
24V DELAY-OFF TIMERBOX
A2
A1
SWITCHING
RELAY
TB5
TB3
TB4
TB2
TB1
TIME DELAY
RELAY
15
A1
18
16
CABLE 2
3x10AWG
CUSTOMER
SUPPLIED
+24VDC
RED/BLK
CABLE 1
2x12AWG
CUSTOMER
SUPPLIED J10
2
GRN
LINE
LINE
...
...
...
20 A
LOAD
20 A
LOAD
CB1
PCB GYRO CONTROL
JUNCTION BOX
MOTOR DRIVE
JUNCTION BOX
(NOT USED)
2x12AWG
CUSTOMER
SUPPLIED
3x10AWG
CUSTOMER
SUPPLIED

FIGURE2–24VDELAY‐OFFTIMERBOXWIRING
b. ThetimedelayrelaybetweentheDCbreakerandtheGyroControlBoxwillkeep24VDC
powertotheGyroControlBoxfor1.5hoursafterACpowerisshutoff.Thisallowsthe
glycolcoolingpumptoremoveheatfromthebearingsduringacoastdown.
c. PowertotheGyrowillbeturnedonandoffwiththeACbreaker.WhentheACbreakeris
switchedon,24VDCshouldbeavailableimmediatelytotheGyroControlBox.Whenthe
ACbreakerisswitchedoff,24VDCshouldremainontheGyroControlBoxfor1.5hours.
d. The24VDCbreakershouldremainonatalltimesexceptforservice.


INSTALLATION
MANUAL
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MODEL7000AGYRO9005135of16
Section2:ELECTRICALINSTALLATION

4. MOTORDRIVEJUNCTIONBOXPOWERCONNECTIONINSTRUCTIONS
a. 230VAC(nominal),1Phase,50/60Hz,20Amps.3x10AWG(3x5mm2CSA)customer
supplied.
i. Connect230VACwiresinCABLE2tothe“Line”sideofthedouble‐poleCircuit
Breaker.
1. Usetwofemale“QuickConnect”crimpterminalsprovided.







FIGURE3–MOTORDRIVEJ‐BOXPOWERINPUTCONNECTIONS

ii. ConnectthirdwireinCABLE2assafetygroundtoenclosurechassis.Usethering
terminalprovided.





FIGURE4–MOTORDRIVEJ‐BOXSAFETYGROUNDCONNECTION
iii. Tightencableglandnuttocompressstrainreliefontocable.Ifcableisnottight,
applysiliconetosealpenetrationintoenclosuretoprotectinternalcomponentsfrom
corrosion.SeeFigure5.

b. Electromagneticcompatibilitygroundingbytheexternalgroundstud.ConnectCable9,
4AWGGroundCable(SeakeeperP/N:20094),toMotorDriveJBfromGyrorearbrace
(factoryinstalledatrearbrace).




FIGURE5–MOTORDRIVEJ‐BOXGROUNDSTUDFIGURE6–GYROREARBRACEGROUNDSTUDS
230VAC
SAFETYGROUND
Lowercornerof
enclosure(green
wireinpicture)
GROUND
STUDS
(Drive,left;
Gyro,right)
CABLE
GLANDNUT


INSTALLATION
MANUAL
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Section2:ELECTRICALINSTALLATION
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
5. GYROCONTROLBOXPOWERCONNECTIONINSTRUCTIONS
a. 24VDC,10Amps.2x12AWG(3x4mm2CSA)customersupplied.
i. InstallSeakeeperprovidedconnectorP/N:30104(TurckP/N:B4131‐0/13,5)onCABLE
1usingWorkInstruction020.





FIGURE7–SEAKEEPERPROVIDED24VDCPOWERINPUTCONNECTOR

ii. ConnectCABLE1toJ10onPCBGyroControlBox.







FIGURE8–PCBGYROCONTROLBOXJ10

iii. ThePCBGyroControlBoxisgroundedbythemountingbracketsdirectlytotheGyro
frontbrace.ForthisreasonthegroundstudshowninFigure8isnotused.
J10
24VDC
Input


INSTALLATION
MANUAL
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MODEL7000AGYRO9005137of16
Section2:ELECTRICALINSTALLATION


2.3ElectricalEquipmentSignalConnections
1. MOTORDRIVEJUNCTIONBOXCABLE
a. ConnectcablestothereceptaclesonthebottomoftheMotorDriveJunctionBox.
Theseconnectorscomefromthefactorycompletelyinstalledonthecables.
i. J1:MotorPower,CABLE10fromGyrosphere.
ii. J2:DriveControl,CABLE14fromPCBGyroControlBox.
iii. J3:MotorInstrumentation,CABLE11fromGyrosphere.



FIGURE9–MOTORDRIVEJUNCTIONBOXCONNECTORS
A
C
Power
In
Not
Used
Ground
Stud
J1
Motor
Power
J3
Motor
Instrumentation J2
Drive
Control


INSTALLATION
MANUAL
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MODEL7000AGYRO9005138of16
Section2:ELECTRICALINSTALLATION

2. GYROCONTROLBOXCABLECONNECTIONINSTRUCTIONS
a. Somecablescomefromthefactoryalreadyconnectedtothereceptaclesonthesideof
thePCBGyroControlJunctionBox.CABLEs1,5,&8arecustomersuppliedand
assembled(J10,J8,&J9respectively).
i. J1:GyroUpperInstrumentation,CABLE12fromGyrosphere.
ii. J2:BrakeValve&GlycolPump,CABLE6(1‐2Splitter)from
Gyrorearbrace.

NOTE:ThegyroisshippedwithconnectorJ2unplugged.
Thisconnectormustremainunpluggeduntilthecoolingsystem
hasbeenfilled(section3)topreventdamagingtheglycolpump.

iii. J3:BrakePressureSwitchesandSolenoidValves,CABLE7(1‐4
Splitter)fromBrakeManifold.
1. BranchesTP‐3&TP‐4(Black)areequivalentandare
reversible.
2. BranchesDTDA‐1&DTDA‐2(Yellow)areequivalentand
arereversible
iv. J4:GimbalAngle,CABLE15fromGyroGimbalAngleSensor.
v. J5:Notused.
vi. J6:GyroLowerInstrumentation,CABLE13fromGyrosphere.
vii. J7:DriveControl,CABLE14fromMotorDriveJ‐Box.
viii. J8:SerialCommunications,CABLE5(6x20AWGw/shield,max
OD=8mm,Customersupplied)fromSerialCommunications
BreakoutBox.
1. InstallSeakeeperprovidedconnectorP/N:30076(Turck
P/N:8181‐0)onCABLE5usingWorkInstruction018.
ix. J9:SwitchedOutputs,CABLE8(4x22AWGw/shield,maxOD
=8mm,Customersupplied)toAlarm&MonitoringSystem
andSeawaterPumpControlRelay.
1. InstallSeakeeperprovidedconnectorP/N:30078
(TurckP/N:8141‐0)onCABLE8usingWorkInstruction
019.
 2.Seeconnectiondetailsonnextpage.
   x.J10:InstallationdiscussedinSection2.2.
J1J6
J10 J5
FIGURE10–PCBGYROCONTROL
JUNCTIONBOXCONNECTORS