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Seakeeper 7000 GYRO Operation Manual

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DOCUMENT # 90021, REV 4
MAR 2009
MODEL 7000 GYRO
OPERATION MANUAL
P.O. BOX 999
14528 SOUTH SOLOMONS ISLAND ROAD.
SOLOMONS, MARYLAND, 20688, U.S.A
PHONE: 410-326-1590
FAX: 410-326-1199
E-MAIL: customerservice@seakeeper.com

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Summary of Contents for Seakeeper 7000 GYRO

  • Page 1 DOCUMENT # 90021, REV 4 MAR 2009 MODEL 7000 GYRO OPERATION MANUAL P.O. BOX 999 14528 SOUTH SOLOMONS ISLAND ROAD. SOLOMONS, MARYLAND, 20688, U.S.A PHONE: 410-326-1590 FAX: 410-326-1199 E-MAIL: customerservice@seakeeper.com...
  • Page 2 Section 3 – Power Failures, Alarms, and Troubleshooting Section 4 – Maintenance Section 5 – Warranty, Limit of Liability, Property Rights Appendix A – Model 7000 Gyro Specs and Summary Appendix B – Technical Drawings P.O. BOX 999 14528 SOUTH SOLOMONS ISLAND ROAD.

  • Page 3: Section 1 System Overview

    DOCUMENT # 90021, REV 4 MAR 2009 MODEL 7000 GYRO OPERATION MANUAL SECTION 1 SYSTEM OVERVIEW P.O. BOX 999 14528 SOUTH SOLOMONS ISLAND ROAD. SOLOMONS, MARYLAND, 20688, U.S.A PHONE: 410-326-1590 FAX: 410-326-1199 E-MAIL: customerservice@seakeeper.com...
  • Page 4 The Seakeeper Model 7000 Gyro uses gyroscopic principals to reduce boat roll motions in waves and wakes independent of boat speed. One Model 7000 Gyro will reduce the roll motions of a boat that displaces 15 to 25 tons. Boats with higher displacement typically require multiple gyros to provide good roll reduction.
  • Page 5 The Seakeeper web site also contains videos of gyro operation and videos of several different boats operating in waves with the Model 7000 Gyro on and off. It is recommended that the reader play these videos prior to reading the remainder of this manual.
  • Page 6 DOCUMENT # 90021, REV 4 MODEL 7000 GYRO OPERATION MANUAL-MAR09 Seakeeper gyro precession is actively controlled by an electronic controller and a hydraulic brake throughout each roll cycle so the gyro supplies the maximum anti-roll torque and does not make mechanical contact with hard stops that limit the maximum gimbal angle travel to +/- 60 There is a large torque about the gimbal axis when the gyro is precessing.
  • Page 7 DOCUMENT # 90021, REV 4 MODEL 7000 GYRO OPERATION MANUAL-MAR09 GYRO ASSEMBLY The gyro assembly consists of a flywheel housed in a cast aluminum vacuum-tight sphere. The flywheel spins about a vertical axis and is supported by upper and lower pairs of bearings. A DC brushless motor mounted inside the enclosure spins the flywheel at high speed.

  • Page 8: Keypad And Display

    DOCUMENT # 90021, REV 4 MODEL 7000 GYRO OPERATION MANUAL-MAR09 1.2 KEYPAD AND DISPLAY The keypad and display shown below are the user interface to the Model 7000 Gyro and should be mounted at the primary helm station. They are used to start, operate, monitor and shutdown the Gyro.
  • Page 9 DOCUMENT # 90021, REV 4 MODEL 7000 GYRO OPERATION MANUAL-MAR09 1.3 MOTOR DRIVE J-BOX The Motor Drive Junction Box contains the electronic components that take 185-240 VAC at 50/60 Hz from the boat’s generator or shore power and supply current to the flywheel motor according to commands from the controller in the Gyro Control Junction Box.
  • Page 10 DOCUMENT # 90021, REV 4 MODEL 7000 GYRO OPERATION MANUAL-MAR09 1.4 GYRO CONTROL JUNCTION BOX The Gyro Control Junction Box contains a motion sensor package (MSP) and a controller module that is programmed with the software that monitors and automatically regulates operation of the gyro.
  • Page 11 DOCUMENT # 90021, REV 4 MODEL 7000 GYRO OPERATION MANUAL-MAR09 1.5 BRAKE The brake mechanism consists of two hydraulic cylinders which are mounted on the port side saddle beam and attach to a crank arm on the port gimbal shaft. The hydraulic cylinders are...
  • Page 12 DOCUMENT # 90021, REV 4 MODEL 7000 GYRO OPERATION MANUAL-MAR09 1.6 COOLING The cooling circuit is a closed loop that supplies a glycol/water (75% distilled water and 25% glycol) mix to: • The gyro sphere end caps to remove heat from the flywheel bearings •...

  • Page 13: Section 2 System Operation

    DOCUMENT # 90021, REV 4 MAR 2009 MODEL 7000 GYRO OPERATION MANUAL SECTION 2 SYSTEM OPERATION P.O. BOX 999 14528 SOUTH SOLOMONS ISLAND ROAD. SOLOMONS, MARYLAND, 20688, U.S.A PHONE: 410-326-1590 FAX: 410-326-1199 E-MAIL: customerservice@seakeeper.com...
  • Page 14 DOCUMENT # 90021, REV 4 MODEL 7000 GYRO OPERATION MANUAL-MAR09 SYSTEM OPERATION START-UP • Make sure AC and DC power are available • Turn “On” the boat’s AC and DC circuit breakers that supply power to the gyro. • Turn “On” the boat’s pump that supplies seawater to the Gyro heat exchanger •...
  • Page 15 DOCUMENT # 90021, REV 4 MODEL 7000 GYRO OPERATION MANUAL-MAR09 RUN – STANDBY – DISPLAY OPERATION The RPM Page of the Gyro Display will indicate 1.0 KRPM once the flywheel reaches Standby speed. The bearing, motor and drive temperatures, motor power and vacuum pressure can be checked on other display pages.
  • Page 16 DOCUMENT # 90021, REV 4 MODEL 7000 GYRO OPERATION MANUAL-MAR09 To turn on stabilization, the rpm must be above 7500 . • Depress Sea The Lock light will go out and the Sea button will illuminate indicating that the Gyro is precessing and stabilizing the boat’s roll motion.
  • Page 17 DOCUMENT # 90021, REV 4 MODEL 7000 GYRO OPERATION MANUAL-MAR09 RUN – STABILIZATION – DISPLAY OPERATION The Display has a number of individual screens. The operator depresses the Menu button (not the Up and Down buttons) to move from one screen to the next.
  • Page 18 DOCUMENT # 90021, REV 4 MODEL 7000 GYRO OPERATION MANUAL-MAR09 The Motor page on the Display indicates the temperatures and current draw of the Motor that is spinning the flywheel. The motor typically runs 20 C hotter than the bearings. Amp readings represent the DC current command to the flywheel motor not the AC line current.
  • Page 19 DOCUMENT # 90021, REV 4 MODEL 7000 GYRO OPERATION MANUAL-MAR09 For example with the Gyro in Lock, the operator can take roll rate readings with the boat in beam seas at zero speed for 5 minutes and get a quantitative measure of the boat’s uncontrolled roll motions.

  • Page 20: Normal Shutdown

    1.5 hours for the flywheel to coast down to 5000 rpm. The flywheel bearings are still generating significant heat during the first half of the coast down cycle and Seakeeper requests that this procedure be followed until we gain more experience and can issue an updated operational instruction to reduce the “power on”...

  • Page 21: Section 3 Power Failures, Alarms And Troubleshooting

    DOCUMENT # 90021, REV 4 MAR 2009 MODEL 7000 GYRO OPERATION MANUAL SECTION 3 POWER FAILURES, ALARMS AND TROUBLESHOOTING P.O. BOX 999 14528 SOUTH SOLOMONS ISLAND ROAD. SOLOMONS, MARYLAND, 20688, U.S.A PHONE: 410-326-1590 FAX: 410-326-1199 E-MAIL: customerservice@seakeeper.com...

  • Page 22: Power Failures

    • 185 - 240 Volts AC powers the Motor Drive J-Box to drive the motor inside the Gyro These are supplied on Cables 1 and 2 which are shown on Seakeeper drawing 90005, Cable Block Diagram. The Motor Drive Junction Box contains high voltage electronics and the cover should not be removed while the flywheel is spinning except by an authorized technician.
  • Page 23 DOCUMENT # 90021, REV 4 MODEL 7000 GYRO OPERATION MANUAL-MAR09 3.1.2 Momentary 230 VAC Failure (e.g. ship to shore power transfer) If the AC failure is less than thirty seconds, the Gyro Controller will automatically restart the motor and the flywheel will continue to spin. The hydraulic brake will lock stopping precession.

  • Page 24: High Ac Voltage

    Stabilization will begin and the Sea button will be illuminated. 3.2 ALARMS The Model 7000 Gyro controller sends alarm messages to the Display in the event that malfunctions are detected in the Gyro Assembly, Keypad, Display, Motor Drive Box, Gyro Control Box, Brake Circuit, or Cooling Circuit.
  • Page 25 DOCUMENT # 90021, REV 4 MODEL 7000 GYRO OPERATION MANUAL-MAR09 3.2.1 GYRO ASSEMBLY ALARMS Component Alarm or Detection Alarm When Reset When Display Controller Troubleshooting Failure Indication Action Recommendations Above Below Upper Outer High Sensor 2.5 sec 5 sec Bearing 1...
  • Page 26 DOCUMENT # 90021, REV 4 MODEL 7000 GYRO OPERATION MANUAL-MAR09 3.2.2 KEYPAD AND DISPLAY ALARMS Component Alarm or Detection Alarm When Reset When Display Controller Troubleshooting Failure Indication Action Recommendations Display Power Heartbeat Display 1 sec Display 5 sec Display...
  • Page 27 DOCUMENT # 90021, REV 4 MODEL 7000 GYRO OPERATION MANUAL-MAR09 Gyro Control J-Box. Component Alarm or Detection Alarm When Reset When Display Controller Troubleshooting Failure Indication Action Recommendations Above Below Controller Software Watchdog Coast Motor 1) Turn boat’s AC and...
  • Page 28 DOCUMENT # 90021, REV 4 MODEL 7000 GYRO OPERATION MANUAL-MAR09 3.2.5 BRAKE CIRCUIT ALARMS Component Alarm or Detection Alarm When Reset When Display Controller Troubleshooting Failure Indication Action Recommendations Brake Off when Current < 0.25 A 0.5 sec >0.25 A 0.5 sec...

  • Page 29: Section 4 - Maintenance

    DOCUMENT #90021, REV 4 MAR 2009 MODEL 7000 GYRO OPERATION MANUAL SECTION 4 - MAINTENANCE P.O. BOX 999 14528 SOUTH SOLOMONS ISLAND ROAD. SOLOMONS, MARYLAND, 20688, U.S.A PHONE: 410-326-1590 FAX: 410-326-1199 E-MAIL: customerservice@seakeeper.com...
  • Page 30 DOCUMENT # 90021, REV4 MODEL 7000 GYRO OPERATION MANUAL-MAR09 MAINTENANCE The gyro system is designed to be as maintenance free as possible. However, since the system is comprised of mechanical and electrical components that operate in a marine environment some periodic inspections and maintenance are recommended.

  • Page 31: Brake Maintenance

    Seakeeper specified levels. It is anticipated that vacuum service will only be needed once every two years or longer. If it is suspected that the gyro will need vacuum service, contact customerservice@seakeeper.com...
  • Page 32 DOCUMENT # 90021, REV4 MODEL 7000 GYRO OPERATION MANUAL-MAR09 If it is discovered that the rod seal is leaking on a brake cylinder(s), contact customerservice@seakeeper.com to arrange for service or to obtain replacement parts. In the event that brake circuit has lost pressure for any reason, the damaged component must be replaced and the circuit re-filled, have the air bled out and have the system charged to the appropriate pressure.

  • Page 33: Cooling System Maintenance

    DOCUMENT # 90021, REV4 MODEL 7000 GYRO OPERATION MANUAL-MAR09 COOLING SYSTEM MAINTENANCE The gyro system’s cooling is accomplished by a fresh water circuit which is in turn cooled by sea water through use of a heat exchanger. See cooling circuit diagram below.
  • Page 34 DOCUMENT # 90021, REV4 MODEL 7000 GYRO OPERATION MANUAL-MAR09 Procedure for Filling / Purging Cooling System: 1 For operation in areas without risk of freezing, mix 25% glycol with 75% distilled water in fill reservoir. For colder climates, a higher percentage of glycol up to a maximum of 50% should be used to provide adequate freeze protection.
  • Page 35 DOCUMENT # 90021, REV4 MODEL 7000 GYRO OPERATION MANUAL-MAR09 Set service valves open and re-circulate valve closed: Elevate reservoir above gyro. Open glycol spigot on reservoir. OPEN Page 7 of 11...
  • Page 36 DOCUMENT # 90021, REV4 MODEL 7000 GYRO OPERATION MANUAL-MAR09 Connect glycol pump cable (17) to controller. Switch on controller breaker but do not run pump more than 5 seconds if glycol flow has not started. CABLE 15 CABLE 8 CABLE 12 CABLE 13...
  • Page 37 DOCUMENT # 90021, REV4 MODEL 7000 GYRO OPERATION MANUAL-MAR09 On Display, use MENU button to scroll to Service Brake Screen. Press up button to open brake. Gyro should now be free to precess (tilt fwd and aft). Manually precess gyro back and forth through full stroke while glycol is recirculating to reservoir.
  • Page 38 DOCUMENT # 90021, REV4 MODEL 7000 GYRO OPERATION MANUAL-MAR09 In this order, open glycol recirculation valve (A), close supply valve (B), close return valve (C). Thermal Valve should always be in fully CW position: Listen to glycol pump after gyro has reached operating temperature (minimum 1 hour at speed).

  • Page 39: Replacement Parts List

    DOCUMENT # 90021, REV4 MODEL 7000 GYRO OPERATION MANUAL-MAR09 REPLACEMENT PARTS LIST Below is a list of field serviceable parts that are most likely to need replacement due to long term operational wear. ITEM Seakeeper Part Description Quantity per Gyro...

  • Page 40: Section 5 Warranty, Limit Of Liability, Property Rights

    DOCUMENT # 90021, REV 4 MAR 2009 MODEL 7000 GYRO OPERATION MANUAL SECTION 5 WARRANTY, LIMIT OF LIABILITY, PROPERTY RIGHTS P.O. BOX 999 14528 SOUTH SOLOMONS ISLAND ROAD. SOLOMONS, MARYLAND, 20688, U.S.A PHONE: 410-326-1590 FAX: 410-326-1199 E-MAIL: customerservice@seakeeper.com...

  • Page 41: Limitation Of Liability

    24 months from the date of manufacture or 2000 hours of operation whichever event occurs first. Seakeeper warrants its Good(s) only to the original Buyer or first User. This express warranty is in lieu of and excludes all other warranties, express or implied, by...

  • Page 42: Property Rights

    Except where otherwise expressly agreed, all patterns, tools, jigs and fixtures, drawings, designs, software and other materials and data developed, fabricated by Seakeeper shall be and shall remain Seakeeper's property. Except as specifically provided for in the order, Buyer shall have no right in any technical data, Intellectual Property Rights, and computer software associated with the order.

  • Page 43: Appendix A - Model 7000 Gyro Specification & Summary

    DOCUMENT # 90021, REV4 MODEL 7000 GYRO OPERATION MANUAL-MAR09 APPENDIX A - Model 7000 Gyro Specification & Summary Rated RPM 9,700 RPM Angular Momentum at Rated RPM 7,000 N-M-S Anti-Rolling Torque at Rated RPM 15,000 N-M Spool-up Time to Rated RPM...
  • Page 44 DOCUMENT # 90021, REV4 MODEL 7000 GYRO OPERATION MANUAL-MAR09 Arrangement The Model 7000 Gyro System consists of the Gyro unit, Motor Drive Box, Gyro Control Box, Cooling Loop Components, Keypad, Display, and Cables (AC and DC power cables and CANbus cable not included).
  • Page 45 DOCUMENT # 90021, REV4 MODEL 7000 GYRO OPERATION MANUAL-MAR09 Alarm and Monitoring Sensors, alarms and shutdowns are provided to allow unattended operation. Sensors measure flywheel bearing temperatures, motor and drive temperatures, vacuum pressure, gimbal angle, brake pressure, and ship motion. The Gyro controller sends sensor values and alarm information to the display and also locks the brake and shuts down the motor drive in the event of a fault or alarm condition.

  • Page 46: Appendix B - Technical Drawings

    DOCUMENT # 90021, REV 4 MODEL 7000 GYRO OPERATION MANUAL-MAR09 APPENDIX B - TECHNICAL DRAWINGS Contents: Dwg # 90001 – Hardware Scope of Supply Dwg #90002 – Installation Details Dwg #90003 – Cooling Water Schematic Dwg #90004 – Gyro Assembly & Parts List Dwg #90005 –...

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