Seakeeper 9 Installation Manual

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: 410-326-1590 FAX: 410-326-1199 E-MAIL: [email protected]

90222 6 1 of 20 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

90222 6 2 of 20 Section 1: MECHANICAL INSTALLATION 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).

90222 6 3 of 20 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

90222 6 4 of 20 Section 1: MECHANICAL INSTALLATION 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.

90222 6 5 of 20 Section 1: MECHANICAL INSTALLATION 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.

90222 6 6 of 20 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.

90222 6 7 of 20 Section 1: MECHANICAL INSTALLATION 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

90222 6 8 of 20 Section 1: MECHANICAL INSTALLATION 1.5 Bolt-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

90222 6 9 of 20 Section 1: MECHANICAL INSTALLATION 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.

90222 6 10 of 20 Section 1: MECHANICAL INSTALLATION 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.

90222 6 11 of 20 Section 1: MECHANICAL INSTALLATION 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.

90222 6 12 of 20 Section 1: MECHANICAL INSTALLATION 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

90222 6 13 of 20 Section 1: MECHANICAL INSTALLATION 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

90222 6 14 of 20 Section 1: MECHANICAL INSTALLATION FIGURE 7 – SADDLE INSTALLATION FIXTURE ON NOTIONAL HULL STRUCTURE

90222 6 15 of 20 Section 1: MECHANICAL INSTALLATION 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

90222 6 16 of 20 Section 1: MECHANICAL INSTALLATION 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

90222 6 17 of 20 Section 1: MECHANICAL INSTALLATION 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

90222 6 18 of 20 Section 1: MECHANICAL INSTALLATION 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

90222 6 19 of 20 Section 1: MECHANICAL INSTALLATION 5) Apply large bead of Plexus adhesive to the hull structure as shown in the figure to the right. Apply approximately ½ to 2/3rds 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 adhesive starts to cure. 6) Lower fixture and saddles over the hull structure and apply light downward pressure to each of the four saddles until the two nylon screws rest on the hull structure (SEE 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 adhesive pushes out the edges of the saddle perimeter. The intent is to pump in the adhesive working from 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.

90222 6 20 of 20 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 versus temperature prior to removing the fixture. 12) Bonding of Seakeeper saddles onto the hull is now complete. Remove installation fixture. 1.6.5 Installation of Seakeeper 1) The four areas where the feet of the Seakeeper will rest should be coplanar to within .06” (1.5 mm). See Figure 10. 2) Rig the Seakeeper for lifting and lower it into position onto top surface of four saddles. 3) Apply a small bead (approximately 4 mm wide) of sealant or caulk to the mating surfaces between the saddles and the Seakeeper foundation. Adjust position of the Seakeeper until alignment is achieved for the 16 fasteners that will attach the Seakeeper foundation frame to saddles. 4) Install Seakeeper supplied Grade 8.8, M14-2.0 x 80 mm 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. 5) Torque all fasteners to 100 ft-lbs (136 N-m). 6) Proceed to electrical and cooling portion of the installation.

Process: Plexus PC- 120 Application Instructions Rev.: 1 Process Description: Instructions for use of surface conditioner Page 1 of 4 What is Plexus PC-120? • Plexus PC-120 is a dual function primer/conditioner designed to clean surface contamination and leave a thin coating of primer on specific metal surfaces. • Although designed specifically for cleaning and priming of Aluminum and Stainless Steel, PC-120 can be used to clean other surfaces in special situations. Contact Plexus Technical Service for recommendations on any surface other than Aluminum or Stainless Steel. Plexus PC-120 works by: • Cleaning the surface of contamination using Isopropyl Alcohol to “lift” machine oils and other contamination. • Depositing a thin Phosphate based coating to retard corrosion. • Leaving a light “pink” color to assist in determining what areas have, and have not, been treated with PC-120. How should PC-120 be used? • PC-120 can be brushed, wiped or sprayed onto the surface being primed. • The PC-120 applied should then be wiped with a clean dry rag to remove any surface contamination cleaned by the PC-120 and leave only a thin, quick drying film. • Dirty or oily rags should be replaced to avoid improper cleaning. • Quality dye-free paper towels that don’t leave fibers behind are recommended. Common mistakes with PC-120 1) Using too much PC-120 2) Not removing the oils lifted off the metal surface before the PC-120 dries. 3) Not abrading corrosion that is already on the surface of the metal. 4) Using PC-120 past its shelf life.

Product: ALL Document #: 90213 Process: Plexus PC- 120 Application Instructions Rev.: 1 1) Using too much PC-120 • Only a very thin coat should be left on the metal. You should be able to see a slight “pink” cast as illustrated below. Too Much PC-120 Correct Amount 2) Not removing oils once primed Wipe the surface with a dry rag • The solvents in PC-120 will clean and “lift” most machining oils, but if the metal isn’t wiped clean of these oils then they will be deposited right back onto the metal surface when the solvent in PC-120 evaporates! • While still wet, wipe the PC-120 applied to the surface with a clean dry paper towel, changing the paper towel as needed. Replace the rag when dirty • Notice how much aluminum oxide was cleaned off “clean” looking Aluminum

Product: ALL Document #: 90213 Process: Plexus PC- 120 Application Instructions Rev.: 1 3) Not abrading corroded surfaces • As good as PC-120 is, it can’t help bonding performance if applied to a surface that is already corroded! • Any surface that shows signs of corrosion should be cleaned by sanding or wire brushing to remove any scale or corrosion. • After removal of corrosion then treat the surface with PC-120 as you normally would. 4) Using PC-120 past it’s shelf life • When stored under normal conditions PC-120 has a shelf life of 12 months in an unopened, original container. • PC-120 bottles are marked with a lot number that is a simple 8 digit code that gives you the date of manufacture. o “807241” for example is 2008, 07 month (July), 24th day (the “1” refers to the first batch of PC-120 made that day). Use the lot number to make sure the material is still within shelf life. • Since it contains isopropyl alcohol, PC-120 should be tightly capped when not in use to stop evaporation.

Product: ALL Document #: 90213 Process: Plexus PC- 120 Application Instructions Rev.: 1 Remember these points! To avoid problems with Plexus PC-120: • Don’t use too much PC-120. Only a thin layer is needed. • Use a clean rag to wipe PC-120 off before it completely dries to remove surface contaminants it has cleaned. Good quality paper towels are a better choice to minimize introduction of contaminates to surface. • Any sign of corrosion already on the surface should be removed by abrading BEFORE priming. • Check the lot number for the date to make sure the PC-120 is less than a year old. Questions • Please contact Plexus Technical Service at 1-800-851-6692 or [email protected]

90222 6 1 of 11 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 & Drawings 90221 Seakeeper 9 Hardware Scope of Supply 90415 Seakeeper 7HD Hardware Scope of Supply 90223 Seakeeper 9/7HD Operation Manual 90250 2nd Helm Control Station Kit 90257 Seakeeper 9/7HD Cable Block Diagram (includes 2nd Display Kit) 90337 Color Operator Display Envelope and Mounting Details SEAKEEPER 9, Front Oblique View 24VDC Power Input Cable Terminator, Female Tee Adapter Color Display Display Interface Cable 25m Cable FIGURE 1 – ELECTRICAL EQUIPMENT FOR SEAKEEPER 9 CANvu 355 Display Interface Cable 20223 SEAKEEPER 9, Rear Oblique View

90222 6 2 of 11 Section 2: ELECTRICAL INSTALLATION 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 Seakeeper. 1. COLOR DISPLAY MOUNTING INSTRUCTIONS, SURFACE MOUNT a. Console space required: Approx. 4.57 W x 4.57 H inches (116 x 116 mm) b. Mounting Instructions, Surface Mount: See drawing 90337 for details 2. 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 Display. c. Hardware required: One mounting screw for .197” (5 mm) diameter mounting hole on Tee Adapter. Do NOT move Seakeeper mounted components from their locations or incorrect Seakeeper operation will result.

90222 6 3 of 11 Section 2: ELECTRICAL INSTALLATION 2.2 Electrical Equipment Power Connections 1. 230 VAC POWER SOURCE REQUIREMENTS a. 230 VAC (nominal), 1 Phase, 50/60 Hz, 20 Amps. b. With installations of more than one Seakeeper, a separate circuit breaker should be used for each Seakeeper Motor Drive Box 2. DRIVE BOX AC POWER INPUT CONNECTION INSTRUCTIONS a. Cable: 3 x 10AWG (3 x 6.0 mm2 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. FIGURE 2 – DRIVE BOX AC POWER INPUT & OUTPUT CABLE GLANDS FIGURE 3 – CABLE 2 WIRE CONNECTIONS AT AC POWER DISTRIBUTION PANEL ii. Connect 230 VAC wires in CABLE 2 to a 20 Amp, double-pole Circuit Breaker at an AC power distribution panel according to Figure 3 above. OUTWARD CABLE GLAND FOR AC POWER INPUT (CABLE 2) MIDDLE CABLE GLAND FOR AC POWER OUTPUT TO SEAWATER PUMP (CABLE 5) INWARD CABLE GLAND FOR DRIVE POWER OUTPUT TO SEAKEEPER MOTOR

90222 6 4 of 11 Section 2: ELECTRICAL INSTALLATION 3. DRIVE BOX AC POWER OUTPUT TO SEAWATER PUMP CONNECTION INSTRUCTIONS a. Cable: 3 x 14AWG (3 x 2.5 mm2 CSA) cable, 10’ (3m) length, Seakeeper supplied pre-installed. b. Pumps rated at 230 VAC, 5 Amps max., Customer-supplied. i. 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.) FIGURE 4 – CABLE 5, AC OUTPUT POWER CABLE ii. Connect the 230 VAC wires in CABLE 5 to a 5 Amp maximum, Seawater Pump (approximately 1/3 horsepower or 250 W) according to Figures 4 and 5. FIGURE 5 – CABLE 5, WIRE CONNECTIONS TO SEAWATER PUMP c. If the customer-supplied Seawater Pump is not rated for 230 VAC, 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. Verify that AC power is OFF to the Drive Box before connecting CABLE 5 to a Seawater Pump.

90222 6 5 of 11 Section 2: ELECTRICAL INSTALLATION ii. The recommended wiring is shown in Figure 6. Refer to Figure 4 for Cable 5 wire connections. FIGURE 6 – RECOMMENDED WIRING FOR SEAWATER PUMPS NOT 230 VAC 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 Seakeeper operation. Do NOT cut CABLE 5 as it contains live voltage when the Seakeeper is in operation. The Seakeeper 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. Cable 5 contains live voltage when the Seakeeper is in operation. Do NOT cut Cable 5. Do not remove Cable 5 from Drive Box.

90222 6 6 of 11 Section 2: ELECTRICAL INSTALLATION 4. 24 VDC POWER SOURCE REQUIREMENTS a. 24 VDC, 10 Amps. b. A separate breaker should be used for each Seakeeper. 5. DC POWER CONNECTION INSTRUCTIONS Reversing polarity on the DC power input to the Seakeeper can result in damaging the electronics in the control system. a. 24 VDC, 10 Amps. 2 x 12AWG (3 x 4.0 mm2 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 +24 VDC. Terminate BLACK conductor to 24V Rtn or Zero VDC. ii. Before connecting CABLE 1 to Seakeeper, check for proper voltage and polarity with a DC multimeter using Figure 7 below. iii. Connect CABLE 1 to 24VDC input receptacle on the Seakeeper. When energizing DC power the first time, if display does not power up immediately then disconnect and inspect connector polarity. 2 1 FIGURE 7 – DC POWER INPUT CONNECTOR CONTACT ASSIGNMENTS (front) 2 (24V Rtn) 1 (+24VDC)

90222 6 7 of 11 Section 2: ELECTRICAL INSTALLATION 2.3 Electrical Equipment Ground Connections 1. SEAKEEPER TO VESSEL GROUND CONNECTION INSTRUCTIONS a. Connect the Seakeeper foundation to vessel ground. i. Install CABLE 6 (10AWG or 6.0 mm2, Customer supplied) from the M6 brass ground stud on the rear brace to a suitable vessel ground. Note: ONLY USE THIS LOCATION FOR GROUNDING THE SEAKEEPER TO THE VESSEL GROUND. FIGURE 9 – GROUND STUD ON REAR BRACE GROUND STUD

90222 6 8 of 11 Section 2: ELECTRICAL INSTALLATION 2.4 Operator Station This section explains the connection between the Operator Station equipment and the Seakeeper. Reference Drawing - 90257 Seakeeper 9/7HD 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. The operator display should be located on the bridge console. c. Figure 10 below shows the CANbus communications link for the Operator Station. The Terminator goes on one the far end of the Tee Adapter from the Seakeeper. FIGURE 10 – 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 Seakeeper (female end) to the Tee Adapter (male end) at the Operator Station. 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, 90257.

90222 6 9 of 11 Section 2: ELECTRICAL INSTALLATION 2.5 Second Operator Station Connection This section explains how to connect the 2nd Operator Station Kit. Reference Drawings 90250 Helm Display 2nd Operator Station Kit 90257 Seakeeper 9/7HD Cable Block Diagram (includes detail of 2nd Operator Station) 1. DETERMINE LOCATION OF 2ND OPERATOR STATION a. The desired location of the 2nd Operator Station must be determined with respect to the 1st Operator Station and the vessel arrangement. b. Typical locations include: i. Flybridge ii. Engine room 2. DETERMINE CABLING ARRANGEMENT a. Figure 11 below shows the entire serial communications link for 2 Operator Stations. The Terminator must be installed on the Tee Adapter farthest from the Seakeeper. FIGURE 11 – CABLING FOR 2 OPERATOR STATIONS b. The Operator Station nearest the Seakeeper should be connected to CABLE 5.

90222 6 10 of 11 Section 2: ELECTRICAL INSTALLATION 3. ROUTE 2ND 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 1st Operator Station (female end) to the 2nd (male end) Operator Station. 4. INSTALL 2ND OPERATOR STATION EQUIPMENT a. The 2nd Operator Station equipment is installed at the determined location using Electrical Equipment Mounting Instructions in Section 2.1. 5. CONNECT 2ND OPERATOR STATION EQUIPMENT a. The 2nd Operator Station equipment is connected in accordance with the Cable Block Diagram, 90257.

90222 6 11 of 11 Section 2: ELECTRICAL INSTALLATION 2.6 Display Installation Template The following template is for mounting; before using this template, measure to ensure that the shown size is actual. DISPLAY MOUNTING TEMPLATE

90222 6 1 of 5 Section 3: COOLING INSTALLATION 3.0 Introduction The Seakeeper 9 is shipped with the cooling circuit filled and ready for use. Only a quick confirmation of glycol level is required. Reference Drawings 90221 Seakeeper 9 Hardware Scope of Supply 90415 Seakeeper 7HD Hardware Scope of Supply 90257 Seakeeper 9/7HD Cable Block Diagram 90251 Seakeeper 9/7HD Cooling Water Schematic FIGURE 1 – SEAKEEPER 9

90222 6 2 of 5 Section 3: COOLING INSTALLATION FIGURE 2 – SEAKEEPER 9 COOLING COMPONENTS

90222 6 3 of 5 Section 3: COOLING INSTALLATION 3.1 Precautions  Installer is responsible for supplying a dedicated sea water pump and associated plumbing. Sea water connections on the Seakeeper heat exchanger mate with ¾ inch (19 mm) hose.  An output is available from motor drive to power and automatically control seawater pump. This pump must operate on 230 VAC single phase and consume less than 5 amps. Pumps requiring other voltages or higher current can still be controlled by using this supply from motor drive to trigger an installer-supplied contactor but a separate source of power must be provided.  A self-priming sea water pump (customer/installer supplied) may be required due to installation location to maintain water flow in all underway conditions where cavitation near the intake may occur and potentially cause an air-lock condition restricting sea water flow to the heat exchanger.  Maximum sea water pressure in heat exchanger is 20 psi (1.4 bar)  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 Seakeeper 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. FIGURE 3 – SEAKEEPER 9 COOLANT LEVEL Correct Coolant Level

90222 6 4 of 5 Section 3: COOLING INSTALLATION 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 Ethylene Glycol Solution (% by volume) 0 10 20 30 40 50 60 Temperature (oF) 32 23 14 2 -13 -36 -70 (oC) 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 24 V to controller.  At the Display check for any ALARMS  Press the POWER ON/OFF button  The flywheel will start to spin and the glycol pump will start.  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.  After several minutes of running, press POWER ON/OFF button to turn power off to the flywheel.

90222 6 5 of 5 Section 3: COOLING INSTALLATION 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. 3.3 Connecting Seawater to Heat Exchanger 1) Connect seawater from installer supplied pump 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 Seakeeper 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. A self-priming sea water pump (customer/installer supplied) may be required due to installation location to maintain water flow in all underway conditions where cavitation near the intake may occur and potentially cause an air-lock condition restricting sea water flow to the heat exchanger. 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. FIGURE 4 – SEAKEEPER 9 SEAWATER CONNECTIONS

90222 6 1 of 2 Section 4: STARTUP 4.0 Introduction This section describes the first startup of the Seakeeper. Also reference Seakeeper Document # 90223, Seakeeper 9 / 7HD Operation Manual.  Previous sections for mechanical, electrical and cooling installation must be completed before this startup sequence is initiated.  Before continuing, covers must be installed unless the Seakeeper is inaccessible and there is no risk to injury. Also, the area around the Seakeeper must be clear of personnel and equipment. 4.1 Startup Instructions 1) Energize 24 VDC supply at the customer supplied electrical disconnect. 2) Supply 208-230 VAC to Motor Drive Box at customer supplied electrical disconnect. 3) If sea water pump for the Seakeeper is not supplied though cable from Motor Drive Box, turn on the boat’s AC or DC dedicated 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. 5) Press the Seakeeper ON/OFF Button on Display. The RED LOCK ICON and the PROGRESS BAR will appear and be RED until the Seakeeper is at speed, then stabilization can begin.

90222 6 2 of 2 Section 4: STARTUP 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 Seakeeper can be placed in SEA mode. Depress the LOCK/UNLOCK Button and the Seakeeper 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 LOCK mode. Then press the Seakeeper ON/OFF Button to power the Seakeeper down. 11) During normal operation, the Seakeeper should be stopped when stabilization is no longer required. This maximizes long term life as it allows the Seakeeper 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 Seakeeper should be switched to the OFF position. The Seakeeper will continue to spool down to zero rpm. No cooling is required during this time. Note the Seakeeper 9 will take 4+ hours to coast down to zero rpm from full speed. When the flywheel has stopped the display will indicate 0 RPM.

90222 6 1 of 3 Section 5: INSTALLATION CHECKLIST AND SUPPLIES Please Complete Checklist and E-mail to [email protected] or telefax to +1.410.326.1199 5.0 Installation Checklist Mechanical Checklist (reference Installation Manual Section 1)  Seakeeper Foundation Installed in Hull  Foundation bolts torqued to specification Electrical Checklist (reference Seakeeper Drawing 90257 & Installation Manual Section 2) Mount Components  Display (near helm) Connect Customer Supplied Cables  Cable 1 (Seakeeper supplied) – Connect Cable 1 from Seakeeper 24VDC power at customer supplied connection box, or directly to a circuit breaker.  – Plug connector of Cable 1 into mating connector on the Seakeeper wire harness  Cable 6 (customer supplied) – Install lugs on both ends of customer supplied 10 AWG ground cable  – Connect one end of Cable 6 to nearest vessel ground and other end to Seakeeper rear brace Connect Seakeeper Supplied Cables  Cable 2 (Seakeeper supplied) – Connect Cable 2 from Drive Box to 230 VAC single phase at customer supplied connection box or directly to circuit breaker  Cable 5 (Seakeeper supplied) – Connect Cable 5 from Drive Box to customer supplied 230 VAC seawater pump

90222 6 2 of 3 Section 5: INSTALLATION CHECKLIST AND SUPPLIES  Cable 3 (Seakeeper supplied) – Connect female end of CAN communications Cable 3 to mating connector on the Seakeeper wire harness  – Route CAN communications Cable 3 from the Seakeeper to helm (male end goes to helm)  – Connect male end of CAN communications Cable 3 at helm to CAN Tee Adapter  – Connect Display and Seakeeper supplied Cable 4 to CAN Tee Adapter with CAN Terminator Cooling Checklist (reference Installation Manual Section 3)  Verify coolant level in heat exchanger coolant reservoir.  Connect sea water hoses / open sea cocks to heat exchanger and test sea water pump.  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 & Operation Manual Sect. 2)  Remove lifting bolts and Install cover panels  Turn on 24 VDC circuit breaker  Turn on 230 VAC circuit breaker  Verify display works and no alarms are present 1. If display does not work, turn off both circuit breakers immediately 2. Check polarity of 24VDC power per Section 2.2.5  Follow instructions in Section 4.1 of Installation Manual to turn on the Seakeeper  Verify sea water pump turns on when the Seakeeper is turned ON  Verify that no ALARMS are present  Follow instruction in Section 4.1 of Installation Manual to turn off the Seakeeper  AC & DC power and sea water pump may be turned off after the Seakeeper is turned off by placing the Seakeeper in LOCK mode and Turning the Seakeeper off  Seakeeper 9 takes 4+ hours to coast down to zero rpm from full speed

90222 6 3 of 3 Section 5: INSTALLATION CHECKLIST AND SUPPLIES 5.1 Required Supplies needed for Seakeeper Installation (not supplied with the Seakeeper) Item Description Qty Installation Manual Reference Section Other Reference System 1 Adhesive and cleaning supplies for bonding to hull 1 Mechanical 2 Soundproofing Considerations 1 Mechanical 3 Spreader bar for lifting the Seakeeper 1 Mechanical 4 Hose clamps for seawater plumbing to 3/4" (19 mm) hose barb (2 per hose barb) 4 3 Cooling 5 M6 terminal lug for grounding Seakeeper at rear brace 1 2.3.1 Electrical 6 Cable, 10 AWG, for grounding Seakeeper at rear brace to vessel ground (used with item 5) AR 2.3.1 Dwg 90257 Electrical 7 Sea water pump, 230V AC 1 2.2.3 Electrical 8 Relay for sea water pump control (Not required if using 230V AC pump) 1 2.2.3 Electrical AR = As Required Dwg = Drawing List of common tools that may be required for installation Item Description Use 1 Wire cutter DC Power, AC Power cables 2 Wire stripper DC Power, AC Power cables 3 3 mm hex key Gimbal sensor mount plate 4 2.5 mm hex key Gimbal angle sensor 5 1/4 inch nutdriver Hose clamps 6 Terminal or quick disconnect crimper Power cables 7 Utility knife Scoring cable jackets