SeaSTAR i6800 Installation Manual
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SeaSTAR i6800 Installation Manual

Electronic shift & throttle (est)
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INSTALLATION MANUAL
ELECTRONIC SHIFT & THROTTLE (EST)
68
w w w . s e a s t a r s o l u t i o n s . c o m
S I X T Y E I G H T
ISO 9001
i6800 Shift & Throttle System

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Summary of Contents for SeaSTAR i6800

  • Page 1 . s e a s t a r s o l u t i o n s . c o m S I X T Y E I G H T ISO 9001 i6800 Shift & Throttle System...
  • Page 2 ©2014 SeaStar Solutions. All Rights Reserved. This document, subject matter and all information herein is the sole, exclusive and confidential property of SeaStar Solutions and shall not be disclosed, copied, reproduced or used in whole or in part for any purpose other than as specifically authorized in writing by Marine Canada Acquisition (DBA SEASTAR SOLUTIONS).
  • Page 3 Thank you for choosing an i6800 Electronic Shift and Throttle (EST) System. You have chosen a state of the art shift and throttle system that will provide years of effortless and trouble free performance. About this Book This book contains the information required to install and setup the i6800 EST System.
  • Page 4 This page left intentionally blank. © 2013 SeaStar Solutions i6800 Installation Supplement, Rev. C...

  • Page 5: Table Of Contents

    6.0 System Faults & Hazards ............6-1 6.1 Hazard Definitions ............6-1 6.1.1 Danger ..............6-1 6.1.2 Warning ..............6-1 7.0 Warranty ................7-1 7.1 Statement of Limited Warranty ........... 7-1 © 2013 SeaStar Solutions i6800 Installation Supplement, Rev. C...
  • Page 6 Appendix D – Updating Firmware ............. D-1 D.1 Checking Component Firmware Revision Levels....D-2 D.1.1 Using DATALINK ............D-2 D.2 Updating Actuators and Control Head ........ D-3 D.3 Updating the CANtrak Software......... D-4 © 2013 SeaStar Solutions i6800 Installation Supplement, Rev. C...

  • Page 7: Safety

    Every installer and operator of the i6800 system should know the following requirements before installing or operating the system. If you have any questions regarding any of these warnings, contact SeaStar Solutions.
  • Page 8 DO NOT OPERATE BOAT IF ANY COMPONENT IS NOT IN PROPER WORKING CONDITION. After use The i6800 system requires no special attention after use. Periodically clean the control head with a damp cloth or mild soap. DO NOT use acetone, or cleaners containing ammonia, acids, or any other corrosive ingredients.

  • Page 9: Safety Labels

    THE LABELS BELOW SHOULD CALL ATTENTION TO THE POSSIBLE HAZARDS ASSOCIATED WITH THE EQUIPMENT SHOWN LATER IN THIS MANUAL. Component labels The labels shown below are found on the i6800 actuators. WARNING PID# 682050 Figure 1-1. Start-In-Gear Advisory Decal, PID# 682050.
  • Page 10 This page left intentionally blank. © 2013 SeaStar Solutions i6800 Installation Supplement, Rev. C...

  • Page 11: System Overview

    The system supports the installation of up to three control heads. The i6800 system consists of the major components listed below. CAN Network CAN (controller area network) is a serial network protocol that is widely used in marine and automotive control systems.

  • Page 12: System Overview Diagram

    2.2 System Overview Diagram DUAL STATION/DUAL ENGINE SINGLE STATION/SINGLE ENGINE 1. Control Head 2. Throttle/Shift Actuator 3. CAN Network Bus Figure 2-1. System Overview. © 2013 SeaStar Solutions i6800 Installation Supplement, Rev. C...

  • Page 13: Installation

    Support Contact To assist with the installation and maintenance of this Electronic Shift and Throttle system SeaStar Solutions recommends that: • Installation MUST be performed by a SeaStar Solutions authorized installer. • Read and understand ALL installation manuals before starting the installation process.
  • Page 14 TILT/TRIM KIT HA5491 STBD SW PORT SW VIEWED FROM REAR OF SWITCHES STBD ENGINE PORT ENGINE TRIM HARNESS TRIM HARNESS STBD PORT ENGINE ENGINE TRIM TRIM Figure 3-1. Trim switch wiring. © 2013 SeaStar Solutions i6800 Installation Supplement, Rev. C...

  • Page 15: Installing The Actuators

    This switch may be used to interrupt the ignition start wire to the engine as start-in-gear protection if required. See Section 3.3.5 for actuator wire identification. © 2013 SeaStar Solutions i6800 Installation Supplement, Rev. C...

  • Page 16: Actuator Power Connections

    On most vessels you will have one of two options for an ignition source: a single ignition source wire, or you will have to splice into an existing ignition wire. © 2013 SeaStar Solutions i6800 Installation Supplement, Rev. C...

  • Page 17: Shift Actuator Electrical Connections

    Manufacturer Wire Colors Yamaha Start circuit – brown Suzuki Short the brown wires together Evinrude Start circuit – yellow/red Mercury Start circuit – yellow/red Table 3-2. Start-in-Gear wire colors. © 2013 SeaStar Solutions i6800 Installation Supplement, Rev. C...

  • Page 18: Throttle Actuator Electrical Connections

    25A BREAKER POWER OTHER CONNECTIONS FUSE PANEL SHIFT CAN2 POWER OTHER CONNECTIONS CE20425 BLACK GREEN* THROTTLE BLACK CAN2 GREEN* POWER MAIN BATTERY OTHER CONNECTIONS GROUND Figure 3-4. CE20425 power harness connection. © 2013 SeaStar Solutions i6800 Installation Supplement, Rev. C...

  • Page 19: Can2 Harness Connections

    MALE TERMINATOR CM10051 4 x NETWORK TEES CM10060 CONTROL CANtrak SETUP HEAD TOOL EPSK1207 PIGTAIL CM20029 FEMALE TERMINATOR CM10052 CM10060 TEMPORARILY INSTALLED Figure 3-5. CAN2 wiring diagram, single station, twin engine. © 2013 SeaStar Solutions i6800 Installation Supplement, Rev. C...
  • Page 20 CM10052 * The CE42100 harness contains three flying leads with female bullet connectors. These leads are not used in the i6800 system and should be left unconnected. Figure 3-6. CAN2 wiring diagram, dual station, single engine. © 2013 SeaStar Solutions...
  • Page 21 NOTE: TEES MAY NOT LOOK ON TEES EXACTLY AS SHOWN Figure 3-7. Correct CAN2 tee installation example. CAUTION Do not connect anything other than SeaStar components to the CAN2 network. CM20064 SCREWS IN ALL MOUNT HOLES Figure 3-8. Alternative CAN2 6-port hub connection (available separately).

  • Page 22: Engine Rpm Source

    3.5 Engine RPM Source The i6800 system is designed to work without engine speed feedback. The Power Train Sync (PTS) features described in the User’s Manual simply output the same throttle percentage to each engine in order to synchronize engine speeds. In some cases this open loop control technique may result in poor synchronization performance.

  • Page 23: System Setup

    4.0 SYSTEM SETUP Before you proceed you need to have all i6800 components installed, harnesses connected, and power wiring completed. The actuator cables should not be connected yet. This section will describe the system setup using the color CANtrak display as a setup tool (P/N EPSK1207). If you prefer to use Datalink you can find instructions in Appendix C.
  • Page 24 Save. Press to return to the System Setup menu. You’ll see that the menu now has an item called Select Shift & Throttle Type. Highlight it and press >. Figure 4-3. © 2013 SeaStar Solutions i6800 Installation Supplement, Rev. C...
  • Page 25 4. Verify that SeaStar i6800 is highlighted and press Save. Press to return to the System Setup menu. Figure 4-4. 5. Choose Select Number of Devices and press >. Figure 4-5. 6. Use the + and – buttons to change the quantity of each device to match your system.

  • Page 26: Actuator Setup

    6. For the shift actuator(s), set the Shift to Forward Direction parameter to Push or Pull (see figure 4-7) to match the direction the actuator is required to move to engage forward gear. Don’t adjust the other parameters yet. © 2013 SeaStar Solutions i6800 Installation Supplement, Rev. C...
  • Page 27 9. With the covers removed, move the port and starboard control head levers to the forward and reverse gear positions and verify that the shift actuator racks move accordingly. © 2013 SeaStar Solutions i6800 Installation Supplement, Rev. C...
  • Page 28 Figure 4-9. Throttle actuator manual override decal placement. For PUSH to Shift to Forward PID# 682049 For PULL to Shift to Forward PID# 682049 Figure 4-10. Shift actuator manual override decal placement. © 2013 SeaStar Solutions i6800 Installation Supplement, Rev. C...

  • Page 29: Step 2 - Cable Installation And Adjustment

    Mercury CA27319P Table 4-1. Engine-Side cable end kits. * If longer cable ends are required, for Yamaha ONLY use SeaStar Solutions P/N CA38383P adapters ** Require only the cable ends, discard other kit components © 2013 SeaStar Solutions i6800 Installation Supplement, Rev. C...

  • Page 30: Shift Cable Installation

    3. Lay the cable into the actuator and install the dust seal (E). 4. Re-install the actuator cover (See figure 4-11). 5. Repeat for the other shift actuator, if applicable. © 2013 SeaStar Solutions i6800 Installation Supplement, Rev. C...

  • Page 31: Throttle Cable Installation

    (D). NOTICE If there is not enough cable protruding to install the lock nut, adjust the cable end on the engine side to lengthen the cable at the actuator side. © 2013 SeaStar Solutions i6800 Installation Supplement, Rev. C...

  • Page 32: Final Setup And Actuator Adjustment

    This is more pronounced 5. Repeat steps 3 and 4 in reverse gear, this time adjusting the with longer cables. Reverse Stroke parameter. 4-10 © 2013 SeaStar Solutions i6800 Installation Supplement, Rev. C...
  • Page 33 Adjust Port Throttle Actuator. Figure 4-15. 3. Increase the port throttle lever to the full throttle position and verify that the throttle linkage reaches the wide open throttle (WOT) position. 4-11 © 2013 SeaStar Solutions i6800 Installation Supplement, Rev. C...
  • Page 34 Idle Offset parameter (or the actuator adjuster barrels) until they are synchronized. WARNING ® AFTER FINAL ADJUSTMENT IS MADE APPLY LOCTITE 242 (BLUE) AND TIGHTEN JAM NUT ON ACTUATOR SIDE. 4-12 © 2013 SeaStar Solutions i6800 Installation Supplement, Rev. C...

  • Page 35: Control Head Setup

    Station Protection This feature prevents accidental switching between control stations on multi-station boats by requiring a specific sequence of button presses on the control head. The i6800 User’s Manual (Book 70) has more information about this feature. One Lever Sync...
  • Page 36 Shift Detent adjuster screw. The detents are meant to prevent accidental gear engagement, so bear that in mind as you make adjustments. Clockwise increases force, counter-clockwise decreases. Adjusting Screws Figure 4-17. Control Head lever positions. 4-14 © 2013 SeaStar Solutions i6800 Installation Supplement, Rev. C...

  • Page 37: Sea Trial

    On multi-engine boats engage the Power Train Sync feature and check that engine speeds are matched. If the Sync performance is unsatisfactory you may need to add an engine RPM source. See section 3.5. © 2013 SeaStar Solutions i6800 Installation Supplement, Rev. C...

  • Page 38: Conclusion Of Sea Trial

    • Install the actuator cable covers. Be sure to install them to the correct actuator, because the labels that you applied during installation give manual override instructions specific to the actuator’s type and instance © 2013 SeaStar Solutions i6800 Installation Supplement, Rev. C...

  • Page 39: System Faults & Hazards

    Indication Dual lever control: the blue Take Command lamp will flash quickly (5 times per second). Single lever control: The amber lamp will flash quickly. © 2013 SeaStar Solutions i6800 Installation Supplement, Rev. C...
  • Page 40 This page left intentionally blank. © 2013 SeaStar Solutions i6800 Installation Supplement, Rev. C...

  • Page 41: Warranty

    In such a case SeaStar Solutions products found to be defective and covered by this warranty, will be replaced at SeaStar Solutions’ option, and returned to the customer.
  • Page 42 This page left intentionally blank. © 2013 SeaStar Solutions i6800 Installation Supplement, Rev. C...

  • Page 43: Appendix A Mounting Templates

    4 x 1/4" 1.5" 1.5" (6.35 mm) DIA. (38 mm) (38 mm) 3" (76 mm) DIA. 1.71" 1.71" (43.5 mm) (43.5 mm) FRONT Figure A-1. Control head – dual lever mounting Tmemplate. © 2013 SeaStar Solutions i6800 Installation Supplement, Rev. C...

  • Page 44: Control Head - Single Lever

    If you must photocopy this mounting template for use, check ALL measurements using a measuring device prior to using as a template. 3 x 1/4" (6.35mm) DIA. 3" (76mm) DIA. 1.6" (41mm) 1.0" 1.0" (25.4mm) (25.4mm) © 2013 SeaStar Solutions i6800 Installation Supplement, Rev. C...

  • Page 45: Appendix B Using The Color Cantrak Display

    DISPLAY The color CANtrak is a powerful tool that can be used to set up the i6800 actuators and perform software updates. Note that the CANtrak is used as a display on other products, so this section will describe functionality that will not be used for i6800 setup.

  • Page 46: Documentation Conventions

    Steering on the Initial Setup screen. You will frequently need to use the up and down arrows to select menus and parameters, but these actions will not be explicitly described. © 2013 SeaStar Solutions i6800 Installation Supplement, Rev. C...

  • Page 47: Initial Startup

    All setup and configuration tools are reached from the Dealer Menu, which authorized installers can access with a four digit PIN code (if you don’t have a code contact SeaStar Solutions technical support). From the main run screen, press and hold Menu until you see the PIN entry screen.

  • Page 48: Menu Structure

    Control broadcast of RPM and gear selection on CAN3 (NMEA 2000) Steering Adjust steering parameters, such as helm effort and number of turns. Shift and Throttle Enable station protection and RPM sync, other settings. I6800 EST only. Yamaha EST Gateway Yamaha DEC engines only.

  • Page 49: Appendix C Setup With Datalink

    CANtrak display, experienced users may find it quicker to use Datalink for these tasks. C.1 Dealer Tools To use Datalink with an i6800 system you will need the following items, supplied with kit EPSK1206: • IXXAT USB to CAN converter, part #214720 •...
  • Page 50 TO CAN2 NETWORK TERMINATOR OTHER I6800 COMPONENTS OTHER I6800 COMPONENTS CM21106 CAN2 PROGRAMMING HARNESS CONVERTER 214720 CAN/COMPUTER HARNESS Figure C-1. Dealer Kit connection. © 2013 SeaStar Solutions i6800 Installation Supplement, Rev. C...

  • Page 51: Navigating Datalink

    Instead, you open an Interface, which is actually a database that is specially formatted on your screen. The parameter fields (any box with editable values) are cross-referenced to data tables in the devices, but it is not in real-time. © 2013 SeaStar Solutions i6800 Installation Supplement, Rev. C...
  • Page 52 Likewise, if you are prompted to save changes when you close an Interface, just click No and exit. The save function has nothing to do with whether the changes are saved on your device. © 2013 SeaStar Solutions i6800 Installation Supplement, Rev. C...

  • Page 53: Actuator Setup

    C-3 below. Click on the + beside an actuator to view the part and serial number information associated with it. Figure C-3. Shift/Throttle actuator configuration. © 2013 SeaStar Solutions i6800 Installation Supplement, Rev. C...
  • Page 54 10. Apply manual override direction decals as shown in section 4 (figure 4-9 and figure 4-10). Figure C-4. © 2013 SeaStar Solutions i6800 Installation Supplement, Rev. C...

  • Page 55: Step 2 - Cable Installation And Adjustment

    Click Write to save each change. 5. Repeat items 3 and 4 for reverse gear, modifying the Shift to Reverse Throw value as necessary to fully engage the gear. © 2013 SeaStar Solutions i6800 Installation Supplement, Rev. C...
  • Page 56 Idle Offset parameter (or the actuator adjuster barrels) until they are synchronized. WARNING ® AFTER FINAL ADJUSTMENT IS MADE APPLY LOCTITE 242 (BLUE) AND TIGHTEN JAM NUT ON ACTUATOR SIDE. © 2013 SeaStar Solutions i6800 Installation Supplement, Rev. C...

  • Page 57: Control Head Setup

    A forward setting of 50% means that when the throttle lever is fully forward the throttle is limited to 50% of maximum. This provides greater throttle sensitivity when moving at slow speeds. © 2013 SeaStar Solutions i6800 Installation Supplement, Rev. C...
  • Page 58 Manual for more information. Control Head Instance – If you are setting up a second station, change this parameter to Second. Shift and Throttle Type – Ensure this parameter is set to SeaStar i6800. C-10 © 2013 SeaStar Solutions i6800 Installation Supplement, Rev. C...

  • Page 59: Appendix D Updating Firmware

    APPENDIX D UPDATING FIRMWARE This section contains instructions for i6800 Shift and Throttle System, Optimus EPS and Optimus 360 systems. From time to time it may become necessary to update the Datalink notebook software and the i6800 component firmware as new versions become available.

  • Page 60: Checking Component Firmware Revision Levels

    D.1.1 Using DATALINK 1. Connect the computer to the i6800 system as shown in section C.2. 2. In the ‘Interfaces’ section in Datalink, click on the box to expand the component information.

  • Page 61: Updating Actuators And Control Head

    D.2 Updating Actuators and Control Head Please contact SeaStar Solutions Technical Support before attempting to update your system firmware. Not all new software releases will be compatible with your system. These instructions are provided for your information only, and assumes that you are updating your firmware under guidance.

  • Page 62: Updating The Cantrak Software

    10. Key on and power up the i6800 system. 11. Reconnect to the system using Datalink. (It may take a moment for the components to become visible in Datalink) 12. Verify that the latest revision of firmware was loaded to the component as per Section D.1.
  • Page 64 SEASTAR SOLUTIONS 3831 NO.6 ROAD RICHMOND, B.C. CANADA V6V 1P6 FAX 604-270-7172 www.seastarsolutions.com © 2014 MARINE CANADA ACQUISITION INC. DBA SEASTAR SOLUTIONS PRINTED IN CANADA 04/18 ISO 10592 Please scan FORM NO. 710100 REV. C this QR code and watch our latest Boating Safety video.

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