Seakeeper 3 User manual

Rev 30 MAR 2017

OPERATION MANUAL


OPERATION
MANUAL
Product: Document #: Rev:
SEAKEEPER 3 90379 1



SEAKEEPER 3
OPERATION MANUAL
MARCH 2017
Contents:
Section 1 – System Overview
Section 2 – System Operation
Section 3 – Power Failures, Alarms, and Troubleshooting
Section 4 – Maintenance
Section 5 – Warranty, Limit of Liability, Property Rights
Section 6 – Specs and Summary
44425 PECAN COURT, SUITE 151
CALIFORNIA, MARYLAND, 20619, U.S.A
PHONE: [phone]
FAX: [phone]
E-MAIL: [email protected]


OPERATION
MANUAL
Product: Document #: Rev: Page:
SEAKEEPER 3 90379 1 1 of 8
Section 1: SYSTEM OVERVIEW


1.0 System Overview
The Seakeeper 3 uses gyroscopic principles to reduce boat roll motions in waves and wakes
independent of boat speed. In multiple Seakeeper installations, the Seakeepers operate
independently of each other and therefore this manual only discusses operation of a single unit.
A Seakeeper 3 consists of a Gyro assembly, a CAN communications cable, and a Display. Figure
1 illustrates the interconnection of these components and their interface with the boat.
FIGURE 1 – SEAKEEPER 3 STABILIZATION SYSTEM COMPONENTS
Technical specifications provided in Section 6 list the power consumption, total weight, and
dimensions of the major components. Gyroscopic principals that apply to boat roll control are
discussed on Seakeeper’s web site at www.seakeeper.com. The Seakeeper web site also
contains videos of Seakeeper operation and videos of several different boats operating in waves
with the Seakeeper on and off. It is recommended that the reader play these videos prior to
reading the remainder of this manual.


OPERATION
MANUAL
Product: Document #: Rev: Page:
SEAKEEPER 3 90379 1 2 of 8
Section 1: SYSTEM OVERVIEW


The gimbal angle and the rate of rotation about the gimbal axis (termed precession rate) play an
important role in its operation. These parameters are illustrated in Figure 2. At zero degree
gimbal angle, the sphere is vertical; it can precess a maximum of +/- 70 degrees about this
position. The amount of torque that the Seakeeper exerts on a boat’s hull to counter the wave
induced roll is directly proportional to the precession rate. The further the Seakeeper is from
vertical (zero degrees) the lower the anti-roll torque. The vertical arrows in Figure 2 illustrate the
direction of the forces that the Seakeeper exerts on the boat’s hull to damp roll motion.
FIGURE 2 – SEAKEEPER PRECESSION
Seakeeper precession is actively controlled by an electronic controller and a hydraulic brake
throughout each roll cycle so the Seakeeper supplies the maximum anti-roll torque and limits
mechanical contact with the hard stops that limit the maximum gimbal angle travel to +/- 70o.


OPERATION
MANUAL
Product: Document #: Rev: Page:
SEAKEEPER 3 90379 1 3 of 8
Section 1: SYSTEM OVERVIEW






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 stood on, or have anything placed on top. The covers
should always be in place during operation. If it is ever necessary to touch
the Seakeeper while the flywheel is spinning, the Seakeeper must be
locked at the display to stop the Seakeeper from precessing. Seakeeper
maintenance should not be attempted unless the Seakeeper is locked and
the flywheel has stopped spinning.















OPERATION
MANUAL
Product: Document #: Rev: Page:
SEAKEEPER 3 90379 1 4 of 8
Section 1: SYSTEM OVERVIEW


1.1 Seakeeper Assembly
The Seakeeper assembly consists of a flywheel housed in a cast aluminum vacuum-tight
enclosure. 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.
The enclosure is fastened to two gimbal shafts that are supported by gimbal bearings on either
side. These shafts establish an athwartship gimbal axis about which the flywheel and enclosure
precess or rotate up to +/- 70 degrees during operation. The gimbal bearings are supported by a
foundation which is attached to the hull structure. This foundation transfers the loads that the
Seakeeper produces to the hull structure.
An active hydraulic brake mechanism is located on the Seakeeper assembly to regulate the
Seakeeper’s precession motions about the gimbal shaft. It includes two hydraulic cylinders and
a hydraulic manifold.
A coolant pump and heat exchanger with reservoir are located near the manifold. A glycol/water
mix is circulated thru a closed loop to the motor drive box, hydraulic manifold, and the end caps
of the enclosure to remove heat.
FIGURE 3 – SEAKEEPER ASSEMBLY


OPERATION
MANUAL
Product: Document #: Rev: Page:
SEAKEEPER 3 90379 1 5 of 8
Section 1: SYSTEM OVERVIEW


1.2 Display
The display shown below is the user interface to the Seakeeper 3 and should be mounted at the
primary helm station. It is used to start, operate, monitor and shutdown the Seakeeper. Sensors,
alarms and shutdowns are provided to allow unattended operation.
The display provides information in the event of an alarm. Alarms cause precession to stop and
the Seakeeper to start coasting down.
FIGURE 4 – OPERATOR DISPLAY






OPERATION
MANUAL
Product: Document #: Rev: Page:
SEAKEEPER 3 90379 1 6 of 8
Section 1: SYSTEM OVERVIEW


1.3 Drive Box
The glycol/water mix that cools the Seakeeper is also circulated through a cold plate inside the
Drive Box to remove heat from high-power electronic components.
The Motor Drive Box contains an electrical hazard and the
cover should not be removed while the flywheel is spinning
and the DC input voltage is present. The electrical hazard
exists even if the flywheel is coasting down and the supply
voltage has been shut off. The flywheel must be at Zero (0)
RPM and DC input power disconnected for at least 10 minutes
prior to any service work on the motor drive box.
FIGURE 5 – DRIVE BOX



OPERATION
MANUAL
Product: Document #: Rev: Page:
SEAKEEPER 3 90379 1 7 of 8
Section 1: SYSTEM OVERVIEW


1.4 Electronic Control Module
The Electronic Control Module (ECM) monitors all the system sensors and automatically regulates
operation of the Seakeeper.
The controller commands the motor speed and regulates the Seakeeper’s precession rate and
angular position. This is accomplished by commands to a high response flow control valve in the
hydraulic brake circuit that increases or decreases the precession rate.
1.5 Inertia Measurement Unit (IMU)
The motion sensor suite in the IMU measures the angular movements of the vessel and the
vertical and lateral boat movement. These signals are communicated to the ECM through the
Seakeeper’s wiring harness.
1.6 Brake
The brake mechanism consists of two hydraulic cylinders that attach to a crank arm on the
Seakeeper gimbal shaft. The Seakeeper controller modulates how fast the oil can flow through
a control valve thus controlling the precession rate of the Seakeeper.
The brake hydraulic circuit is a pre-charged closed loop – that is, there is no pump, motor or
reservoir in the circuit. An accumulator is installed in the circuit so the pre-charge pressure does
not increase as the fluid temperature rises due to the braking action. Locking solenoids are
installed in the circuit to lock the Seakeeper so it cannot precess if there is a leak in the circuit or
a mechanical problem with the Seakeeper.
FIGURE 6 – BRAKE SYSTEM COMPONENTS
Hydraulic Hand Pump Kit, P/N 10384, is required for servicing the brake system. Pressure
should never be relieved unless this tool is available.


OPERATION
MANUAL
Product: Document #: Rev: Page:
SEAKEEPER 3 90379 1 8 of 8
Section 1: SYSTEM OVERVIEW


1.7 Cooling
The cooling circuit is a closed loop that supplies a glycol/water (50% distilled water and 50%
glycol) mix to:
 The motor drive box to remove heat from the drive electronics
 The brake manifold to remove heat from the brake hydraulic circuit
 The enclosure water jackets to remove heat from the flywheel bearings
The heated fluid then passes through a heat exchanger that has seawater on the cold side. The
seawater pump output will operate for two minutes after the Seakeeper is turned on. During
operation, the seawater pump output is turned on and off based on the temperature of the
Seakeeper. The circuit also contains a coolant reservoir for coolant expansion and to make filling
easy. The reservoir contains a 7 psi (0.5 bar) pressure cap.
FIGURE 7 – COOLING SYSTEM COMPONENTS




OPERATION
MANUAL
Product: Document #: Rev: Page:
SEAKEEPER 3 90379 1 1 of 10
Section 2: SYSTEM OPERATION


2.1 Display Screens: Overview
1) When 12 VDC power is applied to the Seakeeper, the display will power up and initialize.
The splash screen will be displayed.
2) After the display has initialized, the home screen will be displayed.
3) The display uses a touch screen to allow users to select functions.
Seakeeper On/Off. The button will change from grey (Seakeeper Off) to blue
(Seakeeper On)


OPERATION
MANUAL
Product: Document #: Rev: Page:
SEAKEEPER 3 90379 1 2 of 10
Section 2: SYSTEM OPERATION


Seakeeper Stabilize On/Off. The button will change from grey (Stabilize Off) to
blue (Stabilize On)
Home screen view. These buttons toggle home screen between the Roll Angle
Gauge and the Roll Angle Graph as shown below.
4) When the menu button is pressed, the menu bar will appear or disappear at the bottom
of the screen.


OPERATION
MANUAL
Product: Document #: Rev: Page:
SEAKEEPER 3 90379 1 3 of 10
Section 2: SYSTEM OPERATION


The menu bar is used to navigate between pages. From left to right, the available pages
are home, settings, information, service and alarm history. The selected page is
highlighted in blue on the menu bar.
5) The settings page allows the user adjust the following;
Increase or decrease the brightness of the display with the brightness slider.


OPERATION
MANUAL
Product: Document #: Rev: Page:
SEAKEEPER 3 90379 1 4 of 10
Section 2: SYSTEM OPERATION


Adjust the sleep timer from 1 minutes to 60 minutes or on all of the time using sleep time
slider. Touching the screen will wake the display up after it has gone to sleep.
Change the sign of the roll angle value displayed in the roll angle gauge so the gauge
matches the motion of the boat. This will depend on installation orientation and will only
need to be adjusted once.
Change the speed of the gyro between normal operation and low power operation. The
selected speed is colored blue.
Change the display between day and night mode. The selected mode is colored blue.
Change the units of the temperatures displayed on the service page between degrees
Celsius and degrees Fahrenheit. The selected units are colored blue.
6) The information page displays the Seakeeper model, Seakeeper serial number,
Seakeeper software versions, RUN hours, and SEA hours, and other information


OPERATION
MANUAL
Product: Document #: Rev: Page:
SEAKEEPER 3 90379 1 5 of 10
Section 2: SYSTEM OPERATION


7) The service page displays operating information from the Seakeeper.
8) The alarm history page shows what alarms have occurred in the past and the associated
run hours. The scroll bar is used to move up and down through the list.



OPERATION
MANUAL
Product: Document #: Rev: Page:
SEAKEEPER 3 90379 1 6 of 10
Section 2: SYSTEM OPERATION


2.2 Start-up
1) Make sure high current and low current DC inputs to the gyro are turned on.
2) When the low DC power is turned on the Display will initialize and the Home screen will
appear.
To turn the Seakeeper on, press the On/Off button, the button will turn blue. 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.
3) 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.


OPERATION
MANUAL
Product: Document #: Rev: Page:
SEAKEEPER 3 90379 1 7 of 10
Section 2: SYSTEM OPERATION


2.3 Stabilization
To stabilize the boat after Seakeeper is on and above the minimum operating speed:
1) Press the stabilize button. The button will turn blue indicating that the Seakeeper is
stabilizing the roll motion.


OPERATION
MANUAL
Product: Document #: Rev: Page:
SEAKEEPER 3 90379 1 8 of 10
Section 2: SYSTEM OPERATION


If it is necessary to shutoff power to the flywheel motor
and slow the flywheel for any reason, press Seakeeper
On/Off button; the button will turn grey and the stabilize
button will disappear indicating the command has been
accepted. It takes approximately 8+ hours for the speed
to drop to zero rpm.



If it is necessary to stop Seakeeper motion for any reason
press the stabilize button. The stabilize button will turn
grey indicating that the Seakeeper is locked. Never
attempt to work on the Seakeeper until the flywheel has
stopped spinning. In the event that the brake system has
automatically locked the Seakeeper due to an alarm or
failure, no attempt should be made to bypass the alarm
or automatic lock.
!
!


OPERATION
MANUAL
Product: Document #: Rev: Page:
SEAKEEPER 3 90379 1 9 of 10
Section 2: SYSTEM OPERATION


2.4 Normal Shut-Down
The Seakeeper should be stopped when stabilization is no longer required.
1) Press Seakeeper On/Off button. The On/Off button will turn grey. The Seakeeper will start
coasting.
When the flywheel has stopped spinning 0 RPM will appear on the service screen
2) Once the vessel is secured in the slip, switch the high current and low current DC power
to the Seakeeper off. The flywheel will continue to spool down to zero rpm. This can take
8+ hours from full speed.
The Seakeeper should be stopped when stabilization is no longer
required. Once the vessel is secured in the slip, the high and low
current DC power to 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 Seakeeper will take
8+ hours to coast down to zero rpm from full speed.
Note: The seawater pump may run for up to 5 minutes after the
Seakeeper is switched off and is coasting (with low current DC
power applied).

!


OPERATION
MANUAL
Product: Document #: Rev: Page:
SEAKEEPER 3 90379 1 10 of 10
Section 2: SYSTEM OPERATION



2.5 Speed Adjustment
1) Press the menu button then select the settings screen.
2) Select the desired RPM button to adjust the Seakeeper’s speed. The selected RPM
button will turn blue.