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SG80 Operation Manual

PRODUCT OVERVIEW

System description

This gyro stabilizer contains the following units.

- SG80 gyro unit

- Control display

5

DC 24 V

6

6

4

3

1

4

2

5

AC 230 V 50-60 Hz

7

Figure 1

1.  SG80 gyro unit
2.  Control display
3.  See water pump *1
4.  Electrical connections (electronic control)

5.  Electrical connections (power)
6.  Hydraulic connections *1
7.  Sea water intake

*1. Item not included in the scope of supply.

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Summary of Contents for 108OM405

Page 1: ...Operation manual GYRO STABILIZER SG80 en English ...

Page 2: ... any time without notice Smartgyro is a registered trademark of Smartgyro s r l in the United States the European Union and the United Kingdom All Rights Reserved No part of this publication may be reproduced or used in any form by any means graphic elec tronic or mechanical including photocopying recording taping or information storage and re trieval systems without the written permission of Smar...

Page 3: ...e control display 18 Roll Angle Monitor Page 21 Alarm Log Page 22 Performance Monitor Page 24 Gyro stabilizer operation 26 Introduction 26 Safety precautions 26 Gyro Stabilizer Startup and Stabilization 27 Temperature derating 30 Gyro Stabilizer Shutdown 31 Emergency shutdown 32 Periodic maintenance 33 Introduction 33 Safety precautions 33 Precautions 34 Periodic maintenance schedule 35 Troublesho...

Page 4: ...ii SG80 Operation Manual ...

Page 5: ... please follow these rec ommendations Read and understand this Operation Manu al before you operate the gyro stabilizer to ensure that you follow safe operating prac tices and maintenance procedures Keep this Operation Manual in a convenient place for easy access If this Operation Manual is lost or dam aged order a new one from your authorized Smartgyro dealer or distributor Make sure this manual ...

Page 6: ...2 SG80 Operation Manual ...

Page 7: ...l at the same time Safety symbols These are the warning signs used in this manu al and on the product This safety alert symbol appears with most safety statements It means attention become alert your safety is involved Please read and abide by the message that follows the safety alert symbol DANGER Indicates a hazardous situation which if not avoided will result in death or serious injury WARNING ...

Page 8: ...e lessness can cause burns cuts mutilation as phyxiation other bodily injury or death This information contains general safety precau tions and guidelines that must be followed to reduce risk to personal safety Special safety precautions are listed in specific procedures Read and understand all of the safety precau tions before operation or performing repairs or maintenance Before you operate DANG...

Page 9: ...ipment including appropri ate clothing gloves work shoes and eye and hearing protection as required by the task at hand WARNING Entanglement Hazard When servicing the gyro stabi lizer make sure that the gyro system is not powered It is pos sible for someone to activate the gyro system without realizing that someone is working on the gyro unit Never operate or service the gyro stabilizer while wear...

Page 10: ...ARNING Electrical Shock Hazard Inside the gyro unit hazardous voltages are present For this reason the cover must not be opened when the gyro system is running and AC power is connected Also never disconnect the yellow green earthing grounding cable connected to the ground stud Before opening the cover be sure that the AC mains supply is disconnected from the gyro unit Before operating the gyro st...

Page 11: ...Follow the guidelines of the EPA or other gov ernmental agencies for the proper disposal of hazardous materials such as coolant and hy draulic oil Consult the local authorities or rec lamation facility Never dispose of hazardous materials by dumping them into a sewer on the ground or into groundwater or waterways Do not shut off the power or short the cables while the gyro system is running Damage...

Page 12: ... to lift it out for maintenance ensuring significant savings in time and cost For larger vessels in order to increase the anti roll torque more than one Smartgyro SG80 can operate in parallel on the same boat These units work autonomously and there is no need to synchronize them This manual therefore only outlines a single unit installation where the gyro stabilizer is controlled by its own contro...

Page 13: ...nits SG80 gyro unit Control display 5 DC 24 V 6 6 4 3 1 4 2 5 AC 230 V 50 60 Hz 7 Figure 1 1 SG80 gyro unit 2 Control display 3 See water pump 1 4 Electrical connections electronic control 5 Electrical connections power 6 Hydraulic connections 1 7 Sea water intake 1 Item not included in the scope of supply ...

Page 14: ...nerated by the combined effect of having a high inertia flywheel rotat ing inside the gyro sphere and the sphere tilting around the precession axis The preces sion movement is automatically created by the gyro when subjected to the sea roll and is dynamically adjusted by the control unit that regulates the braking effect of two hydrau lic cylinders to transmit the optimal anti roll torque to the b...

Page 15: ...Manifold 6 Vacuum sensor 7 Gyro sphere and flywheel 8 Hydraulic cylinders 9 Precession angle sensor 10 Base frame 11 Lower bearing 12 Inverter box 13 Upper bearing 14 Glycol pump 15 Control box 16 Motor sealed sleeve 17 IR sensor upper sealed sleeve 18 IR sensor lower sealed sleeve Figure 3 1 2 3 4 9 11 12 17 18 16 6 7 13 14 15 10 5 6 7 8 ...

Page 16: ...and lower bearings Because the upper and lower bearings support the flywheel rotat ing at high speed they are subjected to heavy loads and high tem peratures Therefore the glycol pump circulates coolant to reduce the temperature of these bearings Vacuum pump The vacuum pump creates a specific grade of vacuum state inside the gyro sphere to minimize air resistance generated when the fly wheel rotat...

Page 17: ...out 40 seconds since power on the Home page Figure 5 appears The home page groups and displays the most important parameters of the gyro unit Figure 4 The main purpose of the display is to activate control and monitor the gyroscope during its operation In the case of an anomaly the display unit au tomatically warns the operator of the failure which has occurred showing an anomaly mes sage on a ded...

Page 18: ...nd has not reached a minimum velocity set at 55 of top speed the precession lock toggle icon has no effect on preces sion which remains locked this condition is signalled by the presence of yellow circle around the icon Once the flywheel rotation speed has reached 55 of top speed the circle goes blue and the functionality of the icon is enabled A red circle indicates that precession is locked and ...

Page 19: ...ight depending on the angle of the sphere See Indi cation of precession angle on page 17 7 Speed indication Flywheel rotation speed given in both digital and analogue In digital form it is shown as a percentage of top speed day speed when the system is accelerating this indication goes from 0 to 100 if the system is in day mode or to 65 if in night mode In analogue form it is shown as a circular d...

Page 20: ...downward bow down Figure 8 If the roll is positive the semi circular bar on the Home page moves to the right Figure 9 Figure 9 A negative roll is observed when the port side of the vessel is angled upward port up Figure 10 A negative pitch is observed when the bow of the vessel is angled upward bow up Figure 11 If the roll is negative the semi circular bar on the Home page moves to the left Figure...

Page 21: ...n precession is negative the blue bar on the home page goes to the left Figure 16 Figure 16 Precession angle is positive when the gyro sphere is tilted toward the bow in Typical in stallation mode see the Installation manual for more information on Installation modes Typical and Reverse Figure 13 4 1 Figure 13 1 Bow When precession is positive the blue bar on the home page goes to the right Figure...

Page 22: ...or ner Figure 18 1 will return you to the Home page Pressing the icon with the padlock symbol Fig ure 18 2 will take you to a password protect ed page only accessible to service personnel for inspecting modifying some internal param eters that are typically accessed during the first time installation of the gyro SET TIME option Pressing the Set Time icon with the clock sym bol Figure 18 3 will tak...

Page 23: ...cts all the connected gyros if these are properly connected and powered i e the new date and time are sent to all the connected gyros so that one programming only is needed to set all It may happen however that for any reason some gyros are not operative for example not powered The current status of the stabilizers is shown on the bottom left of the page In this example only gyros n 1 and 2 are re...

Page 24: ...l refer to the software packages residing on the display the lowest to the Control Unit of the gyro unit Figure 22 Adjusting the brightness of the control display Pressing the brightness icon on the setting page Figure 23 1 1 Figure 23 brings up an adjusting knob on the left part of the screen Figure 24 Figure 24 The brightness level can be adjusted by turn ing the knob The knob disappears if the ...

Page 25: ...graph is autoscaled i e the upper and lower limits of the Y axis are automatically adjusted to fit the actual roll values Once the Y scale is set with the gestures it re mains fixed and does not change automati cally anymore Pressing the H icon Figure 26 2 the display visualizes the data stored in the non volatile memory of the Display as a background pro cess Using gestures left right scroll it i...

Page 26: ...he alarm log page 1 2 3 Figure 29 Anomaly messages are displayed in three dif ferent colours depending upon their state Red Anomaly still present and not ac knowledged by the operator Green Anomaly still present but acknowl edged by the operator Grey Anomaly no longer present regard less of whether it was acknowl edged If the check list icon is pressed Figure 29 2 the alarm messages will change to...

Page 27: ...of detected anomalies As the number of anomalies gradually increas es they are added to the list Accordingly the bottom line always represents the most recent one The column Time indicates the time of occur rence of the anomaly while the column code is a numerical code for identifying the anomaly Alarms not present anymore in the system can be removed from the list Figure 32 pressing the paint bru...

Page 28: ... L Temperature of the lower bearing pack C or F 4 Precession Angle Actual precession angle expressed in degrees See Indication of precession angle on page 17 5 Sea H Number of hours during which precession has remained free unlocked 6 Roll Actual roll angle expressed in degrees See Indication of roll and pitch angles on page 16 7 Pitch Actual pitch angle expressed in degrees See Indication of roll...

Page 29: ...e and the system automatically shuts off the gyro system See TROUBLESHOOT ING on page 38 STOP SPINNING A state in which the power supply to the gyro motor is cut and the flywheel decelerates in a controlled way i e following a pre set deceleration ramp This state continues until the flywheel comes to a complete stop MAIN OUTAGE The system enters this state when AC power is disconnected When power ...

Page 30: ...n on page 3 WARNING Keep away while the gyro stabilizer is operating NOTICE If there is an anomaly while the gyro stabiliz er is operating identify the cause and fix the problem Depending on the abnormal condi tion stop the operation of the gyro stabilizer Before operating the gyro stabilizer open the seawater intake outlet of the seawater pump Also close the seawater intake outlet after the opera...

Page 31: ...the system will detect an AC power absence fault However this disappears as soon as AC power supply is supplied Figure 1 Figure 2 Note When the control display is powered on a splash screen will appear Figure 1 after about 40 seconds the Home page will be displayed on the screen Figure 2 If an anomaly is detected it is signaled by the presence of a red icon on the bottom left corner see Figure 3 F...

Page 32: ...for a no communication anomaly on the CAN line between the motor drive and the control board the cir cle around the ON OFF remains grey Check the details of the anomaly on the alarm log page see Alarm Log Page on page 25 For information about displayed anomaly messages and how to handle them see TROUBLESHOOTING on page 38 4 Make sure the seawater and glycol pumps are operating Note If the seawater...

Page 33: ...e around the precession icon Fig ure 6 1 is yellow 1 Figure 6 7 After the flywheel speed exceeds 55 of the top speed precession is allowed and the circle around the icon goes blue indi cating that precession is unlocked and the sphere is able to oscillate Figure 7 1 8 To stop the precession press the preces sion toggle icon The circle around the icon goes red indicating that the proces sion is loc...

Page 34: ...celeration state is no longer present During precession lock due to high acceler ation conditions the circle around the pre cession icon turns red as when precession is intentionally stopped Temperature derating If during normal operation an over tempera ture condition is found in the gyro in the inter nal bearings or in the Inverter Box the system automatically reduces the power supplied to the m...

Page 35: ... when the flywheel is stopped and as long as the temperature of bearings is above 45 C Figure 11 Gyro Stabilizer Shutdown 1 Go to the home page 2 Press the power ON OFF icon Figure 10 1 1 Figure 10 Note The circle around the power ON OFF icon goes grey and the circle around the preces sion lock toggle icon goes red precession is locked and the flywheel begins to deceler ate When you press the icon...

Page 36: ...the mid dle of the screen To restart the system press the power ON OFF icon Emergency shutdown Emergency shutdown is a method to stop the rotation of the flywheel by forcing the motor drive to cut power to the motor by means of a hardware circuitry and not via a software com mand as during normal shutdown This shutdown mode can be invoked by the operator for example when there is an anom aly in th...

Page 37: ...posits on gyro unit surfaces as frequently as possible possibly wiping them down with mild soap and water and rinsing This section of the instruction manual de scribes maintenance details and maintenance intervals Safety precautions Before performing any maintenance proce dures within this section read the following safety information and review the SAFETY sec tion on page 3 WARNING Crush Hazard I...

Page 38: ...og of the number of operation hours each day and a log of the daily checks per formed Also note the date type of repair and parts used for any service needed between the periodic maintenance intervals Periodic main tenance intervals are every 300 500 1000 and 2000 hours Failure to perform periodic mainte nance will shorten the life of the gyro stabilizer NOTICE Failure to perform periodic maintena...

Page 39: ...nd are difficult to es tablish clearly The following should be treated only as a general guideline System Item Periodic Maintenance Interval Every 300 hours or 6 months 1 Every 6 months or 500 hours 1 Every 12 months or 1000 hours 1 Every 24 months or 2000 hours 1 Mechanical assembly Check the metal outer surface for corrosion If there is corrosion remove the corrosion and touch up with paint Chec...

Page 40: ...ses and the manifold Check that the gyro sphere is locked when precession is not permitted If it is not locked perform air purging of the hydraulic circuit and in case flush and refill the hydraulic circuit AW 46 oil Flush and refill the hydraulic circuit AW 46 Check the cylinder bushing and spacers for wear and damage Replace the cylinder bushing and spacers Every 2000 hours Grease up the cylinde...

Page 41: ...for wear and damage When the parts are replaced the air purge of the cooling circuit is performed and the coolant is replenished with a mixing ratio of 50 ethylene glycol to 50 soft water Every 12 months Check that the seawater inlet outlet hoses of the heat exchanger are securely connected and that the relevant hose clamps are not corroded and securely fastened Every 6 months Check that the seawa...

Page 42: ... repair and re placement require specialized expertise If you do not have the specialized expertise contact your authorized Smartgyro dealer or distribu tor Supply the authorized Smartgyro dealer or dis tributor with the following information Model name and serial number of your gyro stabilizer Total number of operation hours Displayed alarm log if alarm log is detected Anomaly status gyro stabili...

Page 43: ...ame way in the Alarm Log page In the occurrence of a low level anomaly the gyro system will continue to operate but in the occurrence of a high level anomaly it will lock the precession and stop the motor In addition alert icons Figure 1 1 flash on the home page to notify you of the occurrence of the high level anomaly The alert icons disappear automatically when the anomaly is cleared 1 Figure 1 ...

Page 44: ... associated with the inverter box are securely connected Contact Smartgyro dealer or distributor if the fault remains Mains Outage Motor drive disabled flywheel deceleration 2 AC power is not being supplied to the gyro unit Check that the AC breaker has not tripped Contact Smartgyro dealer or distributor if the fault remains IMU Absence IMU Corrupted Motor drive disabled flywheel deceleration Prec...

Page 45: ...ted Normal operation One of the two connections with the pressure sensors is disconnected or its value is invalid Check that the connector is securely connected to the pressure sensor on the manifold Contact Smartgyro dealer or distributor if the fault remains Upp Bearings Ovt Lwr Bearings Ovt Motor drive disabled flywheel deceleration Precession is not allowed Overtemperature detected on either o...

Page 46: ...dealer or distributor if the fault remains U Temp Sens Fail L Temp Sens Fail both detected Motor drive disabled flywheel deceleration Precession is not allowed Both connections with the temperature sensors are disconnected or their value is invalid Check that the IR sensors located on the gyro sphere are securely mated to the corresponding connectors of the gyro unit wiring Contact Smartgyro deale...

Page 47: ...uum circuit are securely fastened to the quick connect couplings on the gyro sphere and on the vacuum pump Contact Smartgyro dealer or distributor if the fault remains RTC Fail Normal operation In case an anomaly is detected in the real time circuitry inside the control box Contact Smartgyro dealer or distributor if the fault remains Mainboard Temp Fail Normal operation In case an anomaly temperat...

Page 48: ...44 SG80 Operation Manual SPECIFICATIONS Introduction Specifications are subject to change without prior notice Specifications ...

Page 49: ...Hz single phase Input voltage DC 24 V Spool up AC power 4 9 kW Operating AC power 2 4 4 0 kW sea state dependent DC power Spool up and operating 150 W including display Seawater supply 15 min 30 max LPM 4 min 8 max GPM Operating temperature 0 60 C 32 140 F Envelope dimensions 1 08 x 1 11 x 0 87 m 42 4 x 43 7 x 24 3 in Weight 980 kg 2160 lbs Noise output 62 64 dBC 1 meter Control display Display ty...

Page 50: ...46 SG80 Operation Manual ...

Page 51: ... 47 SG80 Operation Manual ...

Page 52: ...Issued by Smartgyro s r l Edited by Smartgyro s r l 700102 01 Smartgyro s r l Via Privata O T O 11 19136 La Spezia ITALY Phone 39 0 187 1859146 www smartgyro com Rev 2 0 August 2022 ...

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