Introduction

Seakeeper 35

Installation Manual

90268, Rev 7

*THIS MANUAL ALSO COVERS THE SEAKEEPER 30HD*

This document is intended to give details and guidance to a boat builder or equipment installer to install the Seakeeper 35 (SERIAL NUMBERS 35-0179 THROUGH CURRENT).

Mechanical Installation Introduction

The Seakeeper can produce loads up to 9,270 lbs (41.3 kN) at each of the four mounts and careful consideration should be given to foundation design to ensure it can transfer these loads into the hull. These loads do NOT include vessel motion accelerations, such as vertical slam loads which can be significant for high speed vessels. Seakeeper recommends a minimum safety factor of 3.0 (yielding a Safety Margin of 2.0).

There are two methods of installing the Seakeeper 35:
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 a licensed naval architect or marine engineer should be contacted to do a structural analysis.

The installer should review the following list of reference drawings to ensure the installation procedure is fully understood.

Reference Documents & Drawings:
Link to Seakeeper 35/30HD Reference Documents

• 90233 – Seakeeper 35 Hardware Scope of Supply
• 90417 – Seakeeper 30HD Hardware Scope of Supply
• 90256 – Seakeeper 35/30HD Bolt-In Installation Details
• 90255 – Seakeeper 35/30HD Bond-In Installation Details
• 90290 – Seakeeper 35/30HD Cooling Water Schematic
• 90088 – Seakeeper 35/30HD Bond-In Installation Fixture Kit
• 90089 – Seakeeper 35/30HD Bolt-In Installation Fixture Kit
• 90288 – Seakeeper 35/30HD Cable Block Diagram

Precautions

• The Seakeeper must only be lifted from the supplied lifting eyes shown in Figure 1 (see Section: Transport and Unpacking).
• The Seakeeper flywheel is supported by precision bearings. DO NOT drop or impart mechanical shock to the Seakeeper assembly when lifting or unpacking, as damage to bearings could result.
• 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.

Selection of Installation Location

Selection of mounting location of the Seakeeper should consider the following desirable features:

The Seakeeper 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. 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 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).

VIEWS SHOWING RECOMMENDED CLEARANCES AROUND THE SEAKEEPER FOR USE OF HANDTOOLS, EASE OF MAINTENANCE, INSTALLATION, AND PROPER OPERATION.

Figure 2 – Seakeeper 35 Installed Clearance Considerations

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. The cover side panels contain safety shields as shown below. Do not operate the Seakeeper without these safety shields in place.

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 Engineering Lab and in our Factory Demo 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.

Selection of Installation Method

The Seakeeper 35 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 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 contact using 32 x M16-1.0 fasteners. Depending on the structure to which the Seakeeper is fastened, blind threaded holes or thru-bolting can be utilized.

Option 2 would be commonly used on a hull constructed of glass reinforced plastic (GRP) or fiberglass. For this option, four 16 in. (406 mm) long by 8 in. (203 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 such as Plexus MA590. 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 required.

Transport and Unpacking

Transport

1. Use a Seakeeper provided shipping crate for transport. Overall dimensions of a fully packed crate are 58 L x 61 W x 53 H in. (1.32 L x 1.35 W x 1.19 H m) with a weight of 4,450 lbs (2,019 kg).
2. Do not stack Seakeeper shipping crates.
3. Both Air and Ground transport are acceptable.
4. Seakeeper shipping crates must be transported in environmental conditions between -4°F and 140°F (-20°C and 60°C).

Unpacking Crate

1. Reference Seakeeper Drawing No. 90233 – Seakeeper 35 Hardware Scope of Supply, and Drawing No. 90417 – Seakeeper 30HD Hardware Scope of Supply for items that ship with the corresponding Seakeeper model.
2. Remove electrical components, cables, and misc. items and set aside.
3. Remove packing materials that secure Seakeeper 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 Seakeeper enclosure. Stay clear of any other parts on the Seakeeper. See Figure 3 below.
6. The Seakeeper 35 weighs 3,920 lbs (1,778 kg).

Check and Preparation of Hull Structure

Refer to Seakeeper Drawing No. 90256 – Seakeeper 35/30HD Bolt-In 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 Seakeeper. It is assumed that a proper structural analysis has been performed for the hull structure to which the Seakeeper will be fastened to ensure proper strength margins for the loads the Seakeeper will create during operation.

The hull structure supporting the Seakeeper should be arranged so the Seakeeper is parallel to the waterline in the forward-aft and port-starboard directions . In addition, the four areas on top of the beams on which the isolation mounts will rest, need to be co-planar within 1/8 in. (3 mm) to minimize potential distortion of Seakeeper support frame when installed. (Similar to Figure 12).

Seakeeper provides an installation fixture assembly (P/N 90089), which contains four plates that mimic the mating surfaces of the four isolation mounts located on the Seakeeper’s foundation. These plates have 8 holes located at the same centers as the holes in the isolation mounts. These smaller holes can be used to locate the holes in the ship’s structure through use of a transfer punch or drill. The fixture locates the hole patterns at the proper spacing, both in the fore-aft direction and the port-starboard direction. See Figures 4 & 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 Seakeeper envelope dimensions. Refer to Drawing No. 90256 – Seakeeper 35/30HD Bolt-In Installation Details, 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. See Figure 6 below.

CAUTION: Tight clearances from cable guide bands to hull structure. See above figure for dimensions and reference Seakeeper Drawing No. 90256 – Seakeeper 35/30HD Bolt-In Installation Details, for complete envelope.

Transfer of Holes to Boat Structure

1. Lower assembled fixture onto hull structure.
2. The four areas where the isolation mounts will rest should be coplanar to within 1/8 in. (3 mm). See figure below. Do not use the fixture to check co-planarity as it is not stiff enough.
3. Align fixture in desired location and transfer holes from fixture plate to the hull structure. A transfer punch is recommended for this step. Note that holes in fixture plate are ø.257 in. (6.5 mm).
4. Remove fixture and drill holes in hull structure at marked locations to mate with holes in Seakeeper isolation mounts. A ø.689 in. (17.5 mm) hole is recommended for the provided M16 fasteners.

NOTE: Certain foundation designs that employ threaded blind holes in thick plates may require the installer to obtain alternate fasteners.

Installation of Seakeeper

1. Locate and position 4 isolation gaskets onto foundation beams (for metal to metal contacts only).
   NOTE: A VERY SMALL AMOUNT OF SEALANT MAY BE APPLIED TO THE GASKET TO KEEP WATER FROM WICKING INTO THE JOINT.
2. Lower Seakeeper into position onto foundation beams and align over drilled holes.
3. Install Seakeeper supplied M16 fasteners as shown in figure below – apply a moderate coat of nickel based anti-seize compound to the threads of each bolt prior to installation and a small amount of sealant to the washer faces.
4. Torque all fasteners to 100 ft-lbs (136 N-m).
5. Proceed to electrical and cooling portion of the installation.

Saddle Installation Introduction

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. 90255 – Seakeeper 35/30HD Bond-In Installation Details for loads information and recommended adhesive properties.

Check and Preparation of Hull Structure

Refer to Seakeeper Drawing No. 90255 – Seakeeper 35/30HD Bond-In 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 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 ensure a complete 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 325 in.² (2,097 cm²) for a total bonded surface area for all four saddles of 1,300 in.² (8,387 cm²).

The hull structure supporting the Seakeeper should be arranged so the Seakeeper is parallel to the waterline. In addition, the four areas on top of the beams that the saddles will bond to need to be co-planar within .13 in. (3 mm) to minimize potential distortion of Seakeeper support frame when installed, as shown in Figure 12.

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 90088), that locates the saddles at the proper spacing both in the forward-aft direction and the port-starboard direction. See Figures 7, 8 & 9 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 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 .04 in. to .13 in. (1 to 3 mm).

Note: Do NOT use the installation fixture to establish Seakeeper envelope dimensions. Refer to Drawing No. 90255 – Seakeeper 35/30HD Bond-In Installation Details, 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.

Fiberglass Hull Preparation

1. Position installation fixture (Figure 10) on hull girders noting recommended clearances for maintenance from Figure 2 (in Section: Selection of Installation Location). Check that the screws fastening the saddles to the installation fixture are tight (Figure 8).

2. Mask hull area (as shown in blue, Figure 11) around foundation saddles for easy clean-up and to create an outline of surface area to receive adhesive, as shown in brown (Figure 10). Ensure that the bond gap is within adhesive 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 in. (3 mm) to each other, as well as parallel to the water line plane, as shown in Figure 12.

4. Thoroughly clean with alcohol or acetone all areas (highlighted in brown, Figure 10) 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.
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.
9. Lift installation fixture clear of foundation. Apply Seakeeper provided adhesive backed foam strips at the eight locations shown (each end of four saddles) in Figure 13 below. These strips are to serve as a dam to minimize adhesive escaping out the ends of the saddles as they are positioned over the bond area.

Note: If bonding saddles to a metal structure, contact Seakeeper for hull preparation instructions.

Seakeeper Saddle Preparation

1. Ensure that screws fastening saddles to the installation fixture are tight.
2. Check that each saddle contains 4 plastic screws which will ensure an adhesive gap of .080 in. (2 mm) on top surface of hull as shown in Figure 14. 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 14. 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.

Bonding Saddles to Hull

Note: This is a sample if using Plexus, if using another adhesive follow manufacturer’s 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 below.

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 12 holes of each saddle. The plugs will limit the adhesive being forced out of the injection holes in step 6 below.

5. Apply large bead of Plexus adhesive to the hull structure as shown in the figure below. Apply approximately 1½ 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 (73°F / 23°C). 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 four nylon screws rest on the hull structure (see Figure 9). 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.

9. Repeat above step for remaining 7 sides of the saddles.
10. When gaps have been completely filled, clean off excess adhesive, remove foam tape, 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.

Installation of Seakeeper

1. Rig Seakeeper for lifting and lower it into position onto top surface of four saddles.
2. 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 32 fasteners that will attach the foundation frame to saddles. (Note: isolation gasket used for bolt-in installation is not required).
3. Install Seakeeper supplied M16 fasteners as shown in figure below – apply a moderate coat of nickel based anti-seize compound to the threads of each bolt prior to installation and a small amount of sealant to the washer faces.
4. Torque all fasteners to 100 ft-lbs (136 N-m).
5. Proceed to electrical and cooling portion of the installation.

Removal and Disposal

Removal

This section details basic instructions for removal of a Seakeeper from a boat. The overall basic instructions are to reverse the installation instructions:

1. Disconnect seawater pump from heat exchanger and power connector on wiring harness.
2. Drain heat exchanger of all seawater.
3. Disconnect Seakeeper input power cables.
4. Remove all installation fasteners.
5. Remove the Seakeeper unit using a spreader bar.

Disposal

DO NOT disassemble the Seakeeper to a greater degree than necessary for removal from the boat. DO NOT dispose of a Seakeeper unit in a landfill. The unit must be shipped back to Seakeeper.

Plexus PC-120 Application Instructions

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
   1. Only a very thin coat should be left on the metal. You should be able to see a slight “pink” cast as illustrated below.

2. Not removing oils once primed
   1. 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!
   2. While still wet, wipe the PC‐120 applied to the surface with a clean dry paper towel, changing the paper towel as needed.

3. Not abrading corroded surfaces
   1. As good as PC‐120 is, it can’t help bonding performance if applied to a surface that is already corroded!
   2. Any surface that shows signs of corrosion should be cleaned by sanding or wire brushing to remove any scale or corrosion.
   3. After removal of corrosion then treat the surface with PC‐120 as you normally would.
4. Using PC-120 past its shelf life
   1. When stored under normal conditions PC‐120 has a shelf life of 12 months in an unopened, original container.
   2. PC‐120 bottles are marked with a lot number that is a simple 8 digit code that gives you the date of manufacture.
      1. “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.
   3. Since it contains isopropyl alcohol, PC‐120 should be tightly capped when not in use to stop evaporation.

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 info@itwplexus.com

Electrical Installation Introduction

This section for electrical installation explains how to mount the electrical equipment and how to connect the electrical cables.

Reference Documents & Drawings:
Link to Seakeeper 35/30HD Reference Documents

• 90233 – Seakeeper 35 Hardware Scope of Supply
• 90417 – Seakeeper 30HD Hardware Scope of Supply
• 90269 – Seakeeper 35/30HD Operation Manual
• 90467 – 2^nd Helm Control Station Kit
• 90288 – Seakeeper 35/30HD Cable Block Diagram (includes 2^nd Display Kit)
• 90438 – 5″ Operator Display Envelope and Mounting Details

Figure 1 – Electrical Equipment for Seakeeper 35

Electrical Equipment Mounting

Precautions: Each item of electrical equipment has specific mounting instructions. These instructions
should be followed to ensure proper function of the Seakeeper.

Do NOT move Seakeeper mounted components from their
locations or incorrect Seakeeper operation will result.

1. Touch Display Mounting Instructions, Surface Mount
   1. Console space required: Approx. 5.24 W x 3.70 H in. (133 x 94 mm)
   2. Mounting Instructions, Surface Mount: See Drawing No. 90438 – 5″ Operator Display Envelope and Mounting Details, for details.
2. CAN Communications Tee Adapter and Terminator Mounting Instructions
   1. Console space required, Rear: Approx. 4 W x 3 H in. (102 x 76 mm)
   2. Mounting Instructions: Rear mount on vessel console panel, within 1 ft (0.3 m) of Display.
   3. Hardware required: One mounting screw for .197 in. (5 mm) diameter mounting hole on Tee Adapter.
3. USB Extension Cable Assembly Mounting Instructions
   1. Console space required: Approx. 2 W x 2 H in. (51 x 51 mm), within 6 ft (2 m) from Touch Display.
   2. Mounting Instructions, Surface Mount: Use panel cutout as shown in Section: Display Installation Template. Maximum panel thickness 1/8 in. (3.2 mm).
   3. Install sealed USB connector end of the extender cable assembly in panel from rear and secure with hex jam nut (provided) on front.
   4. Connect M12 connector end of the extender cable assembly to the rear of the Touch Display on receptacle AUX.

Electrical Equipment Power Connections

230 VAC Power Source Requirements

1. 230 VAC (nominal), 1 Phase, 50/60 Hz, 30 A
2. With installations of more than one Seakeeper, a separate circuit breaker should be used for each Seakeeper Motor Drive Box.

Drive Box AC Power Input Connection Instructions

1. Cable: 3 x 10 AWG (3 x 6 mm² CSA), 10 ft (3 m) length, Seakeeper supplied pre-installed.
   1. Locate Cable 2 for AC power input to the Motor Drive Box at the outward of three cable glands.
      
      
      <sub>Figure 2 – Motor Drive Box AC Power Input & Output Cable Glands
      
      
      
      Figure 3 – Cable 2 Wire Connections at AC Power Distribution Panel</sub>
   2. For Seakeeper 35, connect 230 VAC wires in Cable 2 to a 30 A, double-pole Circuit Breaker at an AC power distribution panel according to Figure 3 above.
   3. For Seakeeper 30HD, connect 230 VAC wires in Cable 2 to a 20 A, double-pole Circuit Breaker at an AC power distribution panel according to Figure 3 above.

Drive Box AC Power Output to Seawater Pump Connection Instructions

1. Cable: 3 x 10 AWG (3 x 6 mm² CSA), 10 ft (3 m) length, Seakeeper supplied pre-installed.
2. Pumps rated at 230 VAC, 5 A max., Customer-supplied.
   
   Verify that AC power is OFF to the Drive Box before connecting Cable 5 to a Seawater Pump.
   
   1. 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}
   2. Connect the 230 VAC wires in Cable 5 to a 5 A 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}

3. 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.
   1. 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.
   2. The recommended wiring is shown in Figure 6. Refer to Figure 4 for Cable 5 wire connections.

4. If Cable 5 is not used, bundle cable and secure to Seakeeper frame 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 Seakeeper is in operation. 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 Seakeeper is in operation. Do
NOT cut Cable 5. Do not remove Cable 5 from Drive Box.

24 VDC Power Source Requirements

1. 24 VDC, 15 A
2. A separate breaker should be used for each Seakeeper.

DC Power Connection Instructions

Reversing polarity on the DC power input to the Seakeeper can result in damaging the electronics in the control system.

1. 24 VDC, 15 A, 2 x 12 AWG (3 x 4 mm² CSA) Seakeeper supplied.
   1. 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 24 V Rtn or 0 VDC.
   2. Before connecting Cable 1 to Seakeeper, check for proper voltage and polarity with a DC multimeter using Figure 7 below.
   3. Connect Cable 1 to 24 VDC input receptacle on Seakeeper.

When energizing DC power for the first time, if Display does not power up immediately then disconnect and inspect connector polarity.

Electrical Equipment Ground Connections

Seakeeper to Vessel Ground Connection Instructions

1. Connect the Seakeeper foundation to vessel ground.
   1. Install Cable 6 (4 AWG or 22.0 mm², Customer supplied) from the M6 brass ground stud on the Seakeeper rear foundation to a suitable vessel ground. Cable 6 should be installed on the inside rear of the foundation as shown below. If possible, install Cable 6 prior to installing the Seakeeper into the vessel. If there is no access to the ground stud from below the rear of the Seakeeper once installed, the rear cover, upper rear cover, and ECM bracket will need to be removed to access the ground stud from above the Seakeeper.

Operator Station

This section explains the connection between the Operator Station equipment and the Seakeeper.

Reference Documents & Drawings

• 90288 – Seakeeper 35/30HD Cable Block Diagram

Determine Location of Operator Station

1. The desired location of the Operator Station must be determined with respect to the vessel arrangement.
2. The operator display should be located on the bridge console.
3. Figure 9 below shows the CAN bus communications link for the Operator Station. The Terminator goes on the far end of the Tee Adapter from the Seakeeper.

Route Serial Communications Cable

1. The CAN Cable Assembly (P/N 30243, Cable 3) is a 25 m shielded cable and the largest connector is a molded plug with maximum outer diameter of .58 in. (14.8 mm).
2. Cable 3 must be routed and installed in the vessel from the Seakeeper (female end) to the Tee Adapter (male end) at the Operator Station.

Install Operator Station Equipment

1. The Operator Station equipment is installed at the selected location using instructions found in Section: Electrical Equipment Mounting.

Connect Operator Station Equipment

1. The Operator Station equipment is connected in accordance with Drawing No. 90288 – Seakeeper 35/30HD Cable Block Diagram.

Second Operator Station Connection

This section explains how to connect the 2^nd Operator Station Kit.

Reference Documents & Drawings

• 90467 – Helm Display 2^nd Operator Station Kit
• 90288 – Seakeeper 35/30HD Cable Block Diagram (includes detail of 2^nd Operator Station)

Determine Location of 2^nd Operator Station

1. The desired location of the 2^nd Operator Station must be determined with respect to the 1^st Operator Station and the vessel arrangement.
2. Typical locations include:
   1. Flybridge
   2. Engine room

Determine Cabling Arrangement

1. Figure 10 below shows the entire serial communications link for 2 Operator Stations. The Terminator must be installed on the Tee Adapter farthest from the Seakeeper.

2. The Operator Station nearest the Seakeeper should be connected to Cable 3.

Route 2^nd Operator Station Cable

1. A second CAN Cable Assembly (P/N 30243), also a 25 m shielded cable, and the largest connector is a molded plug with maximum outer diameter of .58 in. (14.8 mm).
2. The additional CAN Cable Assembly must be routed in the vessel from the 1^st Operator Station (female end) to the 2^nd (male end) Operator Station.

Install 2^nd Operator Station Equipment

1. The 2^nd Operator Station equipment is installed at the determined location using instructions found in Section: Electrical Equipment Mounting.

Connect 2^nd Operator Station Equipment

1. The 2^nd Operator Station equipment is connected in accordance with Drawing No. 90288 – Seakeeper 35/30HD Cable Block Diagram.

Display Installation Template

The following template is for mounting. Before using this template, measure to ensure that the shown size is actual.

Cooling Installation Introduction

The Seakeeper 35 is shipped with the cooling circuit filled and ready for use. Only a quick confirmation of glycol level is required.

Reference Documents & Drawings:
Link to Seakeeper 35/30HD Reference Documents

• 90233 – Seakeeper 35 Hardware Scope of Supply
• 90417 – Seakeeper 30HD Hardware Scope of Supply
• 90288 – Seakeeper 35/30HD Cable Block Diagram
• 90290 – Seakeeper 35/30HD Cooling Water Schematic

Precautions

1. Installer is responsible for supplying a dedicated seawater pump and associated plumbing. Seawater connections on the heat exchanger mate with 1 in. (25.4 mm) hose.
2. There is no need to disconnect hose from glycol pump except to replace the pump. In this case, provision will need to be made to catch draining glycol as plumbing is disconnected. Use caution to avoid breaking plastic hose connections on pump casing.
3. An output is available from motor drive box to power and automatically control seawater pump. This pump must operate on 230 VAC single phase and consume less than 5 A. 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.
4. Maximum seawater pressure in heat exchanger is 20 psi (1.4 bar).
5. Seawater flow requirement through heat exchanger is 10 GPM (38 LPM) minimum and 14 GPM (53 LPM) maximum under all operating conditions of the boat. When sizing seawater 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 14 GPM (53 LPM) could affect heat exchanger life.

Adding Coolant

1. Cooling system is filled to proper level when shipped, with a mixture of 50% ethylene glycol and 50% distilled water. The clear tube between the 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 Section: Connecting Seawater to Heat Exchanger.

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.

3. Remove pressure cap on top of reservoir. Pour mixture in until level is 1 – 2 inches from top of 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.
   1. At the Display check for any ALARMS
      
      
   2. Press the POWER ON/OFF button.
   3. The flywheel will start to spin and the glycol pump will start.
   4. 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.
   5. After several minutes of running, press POWER ON/OFF button to turn power off to the flywheel and glycol pump.
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. Re-check level after sea trial and add fluid if required.

Connecting Seawater to Heat Exchanger

1. Connect seawater from installer-supplied pump to lower 1 in. (25.4 mm) hose barb on heat exchanger. Use the same practices as other below waterline seawater plumbing. Required flow rate is 10 GPM (38 LPM) minimum and 14 GPM (53 LPM) maximum.
2. Connect seawater discharge (upper hose barb) to overboard drain. Use the same practices as typical below waterline seawater plumbing.
3. In addition to initial operation at dock, new installations should be checked with a flow meter for minimum 10 GPM (38 LPM) flow under all normal operating conditions. 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 seawater 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 seawater 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.

Start Up Introduction

This section describes the first start up of the Seakeeper.

Reference Documents & Drawings:
Link to Seakeeper 35/30HD Reference Documents

• 90269 – Seakeeper 35/30HD Operation Manual

• Previous sections for mechanical, electrical and cooling installation must be completed before this start up 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.

Start Up 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 seawater pump for the Seakeeper is not supplied through cable from Motor Drive Box, turn on the boat’s AC or DC circuit breaker that supplies power to the seawater 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 progress bar will appear and indicate how soon the Seakeeper will be available for stabilization. When the Seakeeper is initialized and up to minimum operating speed, the stabilize button will appear. At this point, the Seakeeper is available for stabilization.

6. The seawater 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 10 GPM (38 LPM) minimum and 14 GPM (53 LPM) maximum.
7. Verify that there are no ALARMS present. If an ALARM is present it will be displayed.
8. When the Seakeeper reaches its maximum operating speed where maximum stabilization is available, the progress bar will disappear and the Seakeeper is available for maximum stabilization. Press the stabilize button. The button will turn blue indicating that the Seakeeper is stabilizing the roll motion.

9. Verify that there are no ALARMS. If an ALARM is present it will be displayed.
10. Press the STABILIZE Button to turn stabilization off. 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 0 RPM. No cooling is required during this time. Note the Seakeeper 35 will take 5+ hours to coast down to 0 RPM from full speed. When the flywheel has stopped the Display will indicate 0 RPM.

Installation Checklist

Please Complete Checklist and E-mail to customerservice@seakeeper.com or telefax to +1.410.326.1199

Mechanical Checklist
(Reference Installation Manual Section: Mechanical Installation)

• Seakeeper foundation installed in hull
• Foundation bolts torqued to specification

Electrical Checklist
(Reference Seakeeper Drawing No. 90288 – Seakeeper 35/30HD Cable Block Diagram & Installation Manual Section: Electrical Installation)

Mount Components

• Display (near helm)

Connect Customer Supplied Cables

• 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 foundation frame

Connect Seakeeper Supplied Cables

• Cable 1
  • Connect Cable 1 from Seakeeper to 24 VDC power at customer-supplied connection box or directly to circuit breaker
  • Plug connector of Cable 1 into mating connector on Seakeeper wire harness
• 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
• Cable 3 (Seakeeper Supplied)
  • Connect female end of CAN communications Cable 3 to mating connector on Seakeeper wire harness
  • Route CAN communications Cable 3 from 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: Cooling Installation)

• Verify coolant level in heat exchanger coolant reservoir.
• Connect seawater hoses / open sea cocks to heat exchanger and test seawater pump.
• Verify 10 GPM (38 LPM) minimum and 14 GPM (53 LPM) maximum seawater flow through heat exchanger under all operating conditions of the boat.

Start Up Checklist
(Reference Installation Manual Section: Start Up & Operation Manual Section: System Operation)

• Remove lifting eyes, install sealing fasteners in lifting holes, and install cover panels
• Turn on 24 VDC circuit breaker
• Turn on 230 VAC circuit breaker
• Verify display works and no ALARMS are present
  • If display does not work, turn off both circuit breakers immediately.
  • Check polarity of 24 VDC power per Section: Electrical Equipment Power Connections – DC Power Connection Instructions.
• Follow instructions in Section: Start Up Instructions to turn on the Seakeeper
• Verify seawater pump turns on when the Seakeeper is turned ON
• Verify that no ALARMS are present
• Follow instructions in Section: Start Up Instructions to turn off the Seakeeper
• AC & DC power and seawater pump may be turned off after the Seakeeper is turned off by placing the Seakeeper in LOCK mode and turning the Seakeeper off.
• Seakeeper 35 takes 5+ hours to coast down to 0 RPM from full speed

Required Supplies Needed for Seakeeper Installation

Required Supplies Needed for Seakeeper Installation
(Not Supplied With the Seakeeper)

List of Common Tools That May Be Required for Installation