Seakeeper 12HD User manual

Rev 1 DECEMBER 2015
INSTALLATION MANUAL

INSTALLATION
MANUAL
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SEAKEEPER 12HD
90370
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SEAKEEPER 12HD
INSTALLATION MANUAL
DECEMBER 2015
*The Seakeeper 12HD is closely based on the Seakeeper 16. Because of this,
Seakeeper 16 drawings and part numbers are referenced in this Manual where
applicable.
Contents:
Section 1 –Mechanical Installation & PC-120 Guide
Section 2 –Electrical Installation
Section 3 –Cooling Installation
Section 4 –Startup
Section 5 –Installation Checklist and Required Supplies
44425 PECAN COURT, SUITE 151
CALIFORNIA, MARYLAND, 20619, U.S.A
PHONE: [phone]
FAX: [phone]
E-MAIL: [e-mail]

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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 12HD Stabilizing Gyro. The gyro is capable of producing loads up to
24.3 KN (5,450 lbs.) at each of the four mounts and careful consideration should be given to
foundation design to insure it is capable of transferring these loads into the hull.
There are two methods of installing the Seakeeper 12HD gyro:
1) Bolt-In Installation
2) Bond-In Installation
It is assumed that the installer is familiar with bonding using high strength adhesives or
mechanical fasteners to marine structures and has 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
90364 Seakeeper 12HD Gyro Hardware Scope of Supply
90261 Seakeeper 16 Gyro Installation Details –Bolt in Method
90263 Seakeeper 16 Gyro Installation Details –Bond in Method
90305 Seakeeper 16 Gyro Cooling Water Schematic
90282 Seakeeper 16 Gyro Installation Template Kit
90306 Seakeeper 16 Gyro Cable Block Diagram
90309 Seakeeper 16 Gyro Bolt-in Installation Kit
FIGURE 1 –SEAKEEPER 12HD GYRO

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1.1 Precautions
Gyro must only be lifted from the supplied lifting eyes (See Section 1.4).
Gyro flywheel is supported by precision bearings. Make certain while unpacking and
lifting gyro assembly to NOT drop or impart mechanical shock as damage to bearings
could result.
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.
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 for
overhaul in future years.
Gyro should be installed in a dry space to minimize effects of corrosion.
Clearance for replacement of gimbal angle sensor on gyro gimbal shaft (see Figure 2).
Clearance for filling / purging brake hydraulic oil (see Figure 2).
Clearance for filling water/glycol cooling circuit (see Figure 2).
Clearance for replacement of brake hydraulic cylinders (see Figure 2).

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VIEWS SHOWING RECOMMENDED CLEARANCES AROUND GYRO FOR USE OF HAND TOOLS, EASE OF
MAINTENANCE, INSTALLATION AND PROPER OPERATION.
FIGURE 2 –INSTALLED GYRO CLEARANCE CONSIDERATIONS

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FIGURE 3 –TRANSVERSE BEAMS CLEARANCE CONSIDERATIONS
Refer to Figure 3 for recommended clearances to transverse beams. If a transverse beam is
located under the forward brace, it must be 1” (25 mm) from the edge of the gyro to provide the
necessary clearance for the swing of the motor power cable during gyro precession.
Clearances aft of the gyro are shown to provide access for maintenance.

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Safety
There is a large torque about the gimbal axis when the gyro is precessing. Gyro
cover panels 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 68-70 dB un-
weighted. As the frequencies emitting the highest sound pressures are low (like other marine
machinery), it is recommended that the gyro be installed in a machinery space that is already
treated with soundproofing.

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1.3 Selection of Installation Method
The Seakeeper 12HD gyro can be affixed to the hull structure using two methods 1) Use bolt-
in installation or 2) Bond-In installation. See figures below.
OPTION 1- DIRECT FASTENING OF GYRO FOUNDATION TO SHIPS STRUCTURE (BOLT-IN)
Option 1 would be applied when a metal structure is available for attachment. The foundation
would fasten directly to hull structure using isolation gaskets and 16x M14X2.0 fasteners.
Depending on the structure to which the gyro is fastened, blind threaded holes or thru-bolting
can be utilized.
OPTION 2- BOND-IN 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 12.9 inch (327 mm) long by 4.9 inch (125 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.

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1.4 Unpacking Crate
1) Reference Seakeeper Drawing No. 90364, Seakeeper 12HD Gyro Hardware Scope of
Supply for items that ship with the gyro.
2) Remove electrical components, cables, and misc. items and set aside.
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 996 kg (2,195 lbs). See Figure 4
below.
FIGURE 4 –LIFTING ARRANGEMENT
Spreader Bar
Lifting Eyes

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1.5Bolt-In Installation
1.5.1 Check and Preparation of Hull Structure
Refer to Seakeeper Drawing No. 90261, Seakeeper 16 Gyro Installation Details –Bolt in
Method. Important dimensional and load information is given in this drawing that will impact the
design details of the structure that will receive the gyro. It is assumed that a proper structural
analysis has been performed for the hull structure to which the gyro will be fastened to insure
proper strength margins for the loads the gyro will create during operation.
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 on which the feet of the gyro foundation
and isolation gaskets 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 90282, which contains four plates that
mimic the mating surfaces of the four feet located on the gyro’s foundation. These plates have 4
holes located at the same centers as the mounting holes on the gyro. 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. 90261 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). REFERENCE SEAKEEPER
DRAWING NO. 90261.
FIGURE 5 –INSTALLATION FIXTURE

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CAUTION: Tight clearances from cable guide bands to hull structure. See above figure
for dimensions and reference Seakeeper drawing NO. 90261 for complete gyro envelope.

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1.5.2 Transfer of Holes to Boat Structure
1) Lower assembled fixture onto
hull structure.
2) The four areas where the feet
of the gyro will rest should be
coplanar to within .06”
(1.5mm). See Figure 10.
3) Align fixture in desired location
and transfer holes from fixture
plate to the hull structure. Note
that holes in fixture plate are
ø0.61 (15 mm).
4) Remove fixture and drill and tap
M14X2.0 holes in hull structure
at marked locations to mate with
holes in the gyro foundation.
Take special care to drill
perpendicular to mounting
surface. Remove any impeding
obstructions.

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1.5.3 Installation of Gyro
1) Locate and position 4 isolation
gaskets onto foundation beams.
NOTE: Sealant or caulk is
recommended to be applied. Apply
a small bead (approximately 4mm
wide) of sealant (silicone or caulk)
between both mating surfaces of
each isolation gasket where it
contacts the beam and gyro. This
will prevent water from wicking
between the parts and setting up
corrosion. Check isolation gasket
alignment by test fitting bolts without
any obstructions.
2) Lower gyro into position onto the
hull foundation beams and align
over drilled holes.
3) Install Seakeeper supplied M14
fasteners–apply a moderate coat of
removable thread locker to the
threads of each bolt and include a
small bead of sealant under each
washer before installation.
4) Torque all fasteners to 100 ft-lbs
(136 N-m).
5) Proceed to electrical and cooling
portion of the installation.

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1.6 Bond-In Installation
Seakeeper recommends a slow curing, non-sagging structural adhesive for bonding the saddles
to the GRP hull structure. Such an adhesive is Plexus MA590 which is a two-part methacrylate
adhesive. 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 6 of Seakeeper drawing no. 90263 for loads information and recommended
adhesive properties.
1.6.1 Initial Check and Preparation of Hull Structure
Refer to Seakeeper Drawing No. 90263, Seakeeper 16 Gyro Installation Details –Bond In
Method. Important dimensional and load information is given in this drawing that will impact the
design details of the structure that will receive the gyro as well as selection of the adhesive to
bond the gyro into the hull.
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. An estimate of adhesive
volume required should be calculated for each installation based on gaps between saddles and
structural members. There is some adhesive waste as a part of the process so a good rule of
thumb is to purchase 50% more adhesive than estimated volume to bond. Depending on
conditions and adhesive used, two workers may be required to 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 164
in2(1058 cm2) for a total bonded surface area for all four saddles of 656 in2(4232 cm2).
The hull structure supporting the gyro should be installed so the gyro is parallel to the waterline.
The four areas on top of the beams that the saddles will bond to need to be co-planar
within .13” inches (3 mm) for consistent adhesive bond gap. In addition, the four areas
on top of the saddles on which the feet of the gyro foundation will rest need to be co-
planar within .06” (1.5 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 90282 that locates the saddles at the
proper spacing both in the fore-aft direction and the port-starboard direction. See Figures 6, 7 &
8 below. Once assembled with the provided saddle fittings, the fixture can be used to check
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

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that the overall dimensions of the foundations are square and level and that the adhesive gap is
within Seakeeper’s recommended range of 1 to 3mm (.04” to .13”).
Note: Do NOT use the installation fixture to establish gyro envelope dimensions. Refer
to Drawing No. 90263 for envelope dimensions. A 3-D model of the gyro is available on
the Seakeeper website (www.seakeeper.com) to aid in designing the gyro foundation and
the space around the gyro.
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). REFERENCE SEAKEEPER
DRAWING NO. 90263.
FIGURE 6 –EXPLODED VIEW OF SADDLE INSTALLATION FIXTURE

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FIGURE 7 –SADDLE INSTALLATION FIXTURE ON NOTIONAL HULL STRUCTURE

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1.6.2 Fiberglass Hull Preparation
1) Position installation fixture (Fig 8) on hull girders noting recommended clearances for
maintenance from Figure 2. Check that the screws fastening the saddles to the
installation fixture are tight (Fig 6).
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 the
adhesive manufacturer’s recommended thickness, or 3mm if using Plexus MA590.
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 8.
FIGURE 8 - INSTALLING FIXTURE ON HULL
FIGURE 9 - MASKING PERIMETER OF SADDLES

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4) Thoroughly clean with alcohol or 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.
FIGURE 10 –COPLANAR PROPERTIES OF FOUNDATION

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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.
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.
FIGURE 11 - SADDLE CLEANING

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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.
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 of the mixing tip. Set aside for now as this will be used to inject adhesive
into the sides of each saddle after the fixture / saddles are in position.
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.
Pneumatic Gun
Mixing Tip
Flexible Nozzle
Adhesive
Gun
Mixing Tip