Seakeeper 9 User manual

Rev 6 JAN 2017
INSTALLATION MANUAL
*THIS MANUAL ALSO COVERS THE SEAKEEPER 7HD MODEL*

INSTALLATION
MANUAL
Product:
Document #:
Rev:
SEAKEEPER 9 / 7HD
90222
6
SEAKEEPER 9 / 7HD
INSTALLATION MANUAL
JANUARY 2017
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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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 9. The Seakeeper is capable of producing loads up to 17.09KN (3,842
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. These loads do NOT include
vessel motion accelerations, such as vertical slam loads which can be high for higher speed
vessels.
There are two methods of installing the Seakeeper 9:
1) Bolt-In Installation
2) Bond-In (Saddle) 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 Seakeeper mounts can properly transfer the loads the
Seakeeper creates into the hull structure. If the installer has any doubt about the ability
of the structure to transfer the 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
90221 Seakeeper 9 Hardware Scope of Supply
90415 Seakeeper 7HD Hardware Scope of Supply
90225 Seakeeper 9/7HD Installation Details –Bolt in Method
90226 Seakeeper 9/7HD Installation Details –Bond in Method
90251 Seakeeper 9/7HD Cooling Water Schematic
90253 Seakeeper 9/7HD Installation Template Kit
90257 Seakeeper 9/7HD Cable Block Diagram
FIGURE 1 –SEAKEEPER 9
FOUNDATION

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1.1 Precautions
The Seakeeper must only be lifted from the supplied lifting eyes (See Section 1.4).
The Seakeeper flywheel is supported by precision bearings. Make certain while
unpacking and lifting the Seakeeper assembly to NOT drop or impart mechanical shock
as damage to bearings could result.
While handling / installing the Seakeeper 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 the Seakeeper assembly, do not allow electrical fittings that
exit bottom of the Seakeeper 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 the painted finish as damage to finish could lead to early
appearance degradation of the installed Seakeeper.
1.2 Selection of Seakeeper Installation Location
Selection of mounting location of the Seakeeper should consider the following desirable
features:
The Seakeeper should be installed aft of amidships to minimize high
acceleration loadings due to hull/wave impacts during operation at
high speed or in large waves. If the only possible Seakeeper location
is forward of amidships then the installer should have Seakeeper
review the installation location prior to finalizing the design.
Overhead access or sufficient clearance for removal / re-installation of the
Seakeeper for overhaul in future years.
The Seakeeper should be installed in a dry space to minimize effects of corrosion.
Clearance for replacement of gimbal angle sensor on the Seakeeper 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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Section 1: MECHANICAL INSTALLATION
VIEWS SHOWING RECOMMENDED CLEARANCES AROUND THE SEAKEEPER FOR USE OF HANDTOOLS,
EASE OF MAINTENANCE, INSTALLATION, AND PROPER OPERATION.
FIGURE 2 –INSTALLED SEAKEEPER CLEARANCE CONSIDERATIONS
ZINC ANODE
LOCATIONS

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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 2” (53 mm) from the edge of the saddle beams to
provide the necessary clearance for the swing of the motor power cable during the Seakeeper’s
precession. Clearances aft of the Seakeeper are shown to provide access for regular
scheduled maintenance.

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Safety
There is a large torque about the gimbal axis when the Seakeeper is
precessing. Seakeeper cover panels are provided to prevent personnel or
equipment from contacting the Seakeeper 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
Seakeeper while the flywheel is spinning, the Seakeeper must be locked at the
display to stop the Seakeeper from precessing. Seakeeper regular scheduled
maintenance should not be attempted unless the Seakeeper is locked and the
flywheel has stopped spinning.
The Seakeeper should be treated with the same respect one gives a high speed
rotating propeller shaft or engine shaft.
Noise/Soundproofing
Seakeeper 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 Seakeeper be installed in a machinery space
that is already treated with soundproofing.

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Section 1: MECHANICAL INSTALLATION
1.3 Selection of Installation Method
The Seakeeper 9 can be affixed to the hull structure using two methods 1) Bolt-In installation
or 2) Bond-In (Saddle) installation. See figures below.
OPTION 1- DIRECT FASTENING OF SEAKEEPER FOUNDATION TO SHIPS STRUCTURE
Option 1 would be applied when a metal structure or laminated metal plates are available for
attachment. The foundation would fasten directly to hull structure or plates using isolation
gaskets for metal to metal contacts and 16x M14X2.0 fasteners. Depending on the structure to
which the Seakeeper is fastened, blind threaded holes or thru-bolting can be utilized.
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 11 inch (280 mm) long by 4 inch( (102 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 Seakeeper’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. 90221, Seakeeper 9 Hardware Scope of Supply and
90415, Seakeeper 7HD Hardware Scope of Supply for items that ship with the
corresponding Seakeeper model.
2) Remove covers, electrical components, display, cables, and misc. items and set aside.
3) Remove packing materials that secure Seakeeper assembly inside the crate.
4) Attach spreader bar to the two lifting eyes located on the top of the Seakeeper
enclosure. Stay clear of any other parts on the Seakeeper. The Seakeeper 9 weighs
549 kg (1210 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. 90225, Seakeeper 9/7HD 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 Seakeeper. It is assumed that a proper
structural analysis has been performed for the hull structure to which the Seakeeper will be
fastened to insure proper strength margins for the loads the Seakeeper will create during
operation.
The hull structure supporting the Seakeeper should be installed so the Seakeeper is parallel to
the waterline. In addition, the four areas on top of the beams on which the feet of the
Seakeeper foundation and isolation gaskets will rest, need to be co-planar within .06”
(1.5 mm) to minimize potential distortion of Seakeeper support frame when installed. The
isolation gaskets are only used on dissimilar metal to metal contacts
Seakeeper provides an installation template kit, P/N 90253, which contains four plates that
mimic the mating surfaces of the four feet located on the Seakeeper’s foundation. These plates
have 4 holes located at the same centers as the mounting holes on the Seakeeper. 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 the Seakeeper envelope
dimensions. Refer to Drawing No. 90225 for envelope dimensions. A 3-D model of the
Seakeeper is available on the Seakeeper website (www.seakeeper.com) to aid in
designing the Seakeeper foundation and the space around the Seakeeper.
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. 90225.
FIGURE 5 –EXPLODED VIEW OF 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. 90225 for complete Seakeeper
9/7HD 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 Seakeeper will rest should be
coplanar to within .06” (1.5 mm).
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 ø0.55 (14 mm).
4) Remove fixture and drill and tap
M14X2.0 holes in hull structure at
marked locations to mate with
holes in the Seakeeper foundation.
Take special care to drill
perpendicular to mounting surface.
Remove any impeding
obstructions.

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1.5.3 Installation of Seakeeper
1) Locate and position 4 isolation gaskets
onto foundation beams (for metal to
metal contacts only). NOTE: Sealant or
caulk is recommended to be applied.
Apply a small bead (approximately 4 mm
wide) of sealant (silicone or caulk)
between both mating surfaces of each
isolation gasket where it contacts the
beam and the Seakeeper. 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 Seakeeper into position onto the
hull foundation beams and align over
drilled holes.
3) Install Seakeeper supplied M14
fasteners Or Grade 8.8, M14-2.0 bolts to
maintain a minimum thread engagement
of .68 in (17.3 mm) –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 Saddle 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. 90226 for loads information and recommended
adhesive properties.
1.6.1 Initial Check and Preparation of Hull Structure
Refer to Seakeeper Drawing No. 90226, Seakeeper 9/7HD 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 Seakeeper as well as selection of the
adhesive to bond the Seakeeper into the hull.
The foundation “saddles” of the Seakeeper are designed to be bonded directly to the composite
hull structure of the vessel to effectively distribute Seakeeper 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 106 in2(684 cm2) for a total bonded surface area for all four saddles of 424 in2
(2,736 cm2).
The hull structure supporting the Seakeeper should be installed so the Seakeeper 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 Seakeeper foundation will rest
need to be co-planar within .06” inches (1.5 mm) to minimize potential distortion of
Seakeeper 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 90253 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 Seakeeper

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foundation saddles and the hull structure. Shear strength of the adhesive will be maximized if
the cured thickness between the vessel structure and the Seakeeper 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 recommended range of 1 to 3 mm (.04” to .13”).
Note: Do NOT use the installation fixture to establish the Seakeeper envelope
dimensions. Refer to Drawing No. 90226 for envelope dimensions. A 3-D model of the
Seakeeper is available on the Seakeeper website (www.seakeeper.com) to aid in
designing the Seakeeper foundation and the space around the Seakeeper.
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. 90226.
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
manufacturer’s recommended thickness, or 3 mm 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 3 mm if using Plexus MA590.
Note if bonding saddles to a metal structure, contact the adhesive manufacturer for hull
preparation instructions.
FIGURE 10 –COPLANAR PROPERTIES OF FOUNDATION

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1.6.3 Seakeeper 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. Do not remove these screws.
3) Thoroughly clean with alcohol or acetone the inside surfaces of Seakeeper 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 Seakeeper 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: This is a sample if using Plexus, if using another adhesive follow manufacturer’
recommendations.
If using Plexus MA590 adhesive, the Seakeeper 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