Page 1 INSTALLATION MANUAL ELECTRONIC POWER STEERING (EPS) w w w . s e a s t a r s o l u t i o n s . c o m F I F T Y Electronic Power Steering for ISO 9001 Outboard Powered Vessels...
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 Information which is important to proper use or maintenance, but is not hazard-related. iii iii © 2014 SeaStar Solutions Optimus Installation Manual, Rev. E...
Page 5: Table Of Contents
5.5 Plumbing the System ..........5-18 5.5.1 Hose Labels ..........5-19 5.5.2 Hose Installation ........... 5-20 5.5.3 Hose Fitting Reorientation (if required) ..... 5-22 5.7 Connecting the SmartCylinder ........5-24 6.0 networks and wiring ............6-1 © 2014 SeaStar Solutions Optimus Installation Manual, Rev. E...
Page 6 A.1 Helm Templates ............A-1 A.1.1 Front Mount Helm ..........A-1 A.1.2 Rear Mount Helm ........... A-3 A.1.3 Classic Tilt Helm ..........A-5 A.1.4 Sport Tilt Helm ..........A-7 A.2 CANtrak Display ............A-9 © 2014 SeaStar Solutions Optimus Installation Manual, Rev. E...
Page 7 E.4.2 Using Datalink ..........E-5 E.5 Updating Individual Components ........ E-6 E.6 Updating the CANtrak Software ........E-6 E.7 Opening a Back-up (ECU) File ........E-7 appendix f - Bolt torque Specifications ........f-1 © 2014 SeaStar Solutions Optimus Installation Manual, Rev. E...
Page 8: Abbreviations
Rudder feedback unit. This is the position sensor on the SmartCylinder. Revolutions Per Minute STBD Starboard (right when facing forward) Switch Wide Open Throttle Note: Some abbreviations not listed here may be found in their respective sections. viii © 2014 SeaStar Solutions Optimus Installation Manual, Rev. E...
Page 9: Safety Information
3. Check that only SeaStar Pro steering hose (1500psi rating) has been used to plumb the system. © 2014 SeaStar Solutions...
Page 11: Safety Labels
Refer to User's Manual for use of valve. Prior to use check fluid level in pump reservoirs. Install OPERATION: and maintain in accordance with SeaStar Solutions installation manuals. Use SeaStar Electronic Power • TURN OFF ENGINES Steering Fluid ONLY. NEVER use brake fluid. Any •...
Page 12 (pcm) Labels Figure 1-2. PCM labels. Ignition connection Label Figure 1-3. Ignition warning decal, PID# 682300. © 2014 SeaStar Solutions Optimus Installation Manual, Rev. E...
Page 13 (click). Do not overtighten. (click). Do not overtighten. Figure 1-4. SmartCylinder labels. Steering Service To be installed close to the service valve. valve Labels Figure 1-5. Steering service valve labels. © 2014 SeaStar Solutions Optimus Installation Manual, Rev. E...
Page 15: System Overview
The PCM uses position feedback from the SmartCylinders for precise steering control and fault detection. The PCM can also respond to inputs from a certified autopilot system. © 2014 SeaStar Solutions Optimus Installation Manual, Rev. E...
Page 16 (optional) When the service valves on the power steering pumps are not easily accessible these optional remote-mounted valves can be installed in a convenient location. © 2014 SeaStar Solutions Optimus Installation Manual, Rev. E...
Page 17: Optimus Eps System Diagrams
STARBOARD POWER POWER SOURCE SOURCE COMPONENTS NOT SUPPLIED BY SEASTAR SOLUTIONS SWITCH PANEL HYDRAULIC HYDRAULIC HOSE HOSE SMART SMART CYLINDER CYLINDER Figure 2-1. Optimus EPS system diagram, single station, twin engine. © 2014 SeaStar Solutions Optimus Installation Manual, Rev. E...
Page 18 STARBOARD POWER POWER SOURCE SOURCE COMPONENTS NOT SUPPLIED BY SEASTAR SOLUTIONS SWITCH PANEL HYDRAULIC HYDRAULIC HOSE HOSE SMART SMART CYLINDER CYLINDER Figure 2-2. Optimus EPS system diagram, dual station, twin engine. © 2014 SeaStar Solutions Optimus Installation Manual, Rev. E...
Page 19 HOUSE BATTERY BATTERY SWITCH PANEL COMPONENTS NOT SUPPLIED PREFERRED CONNECTION BY SEASTAR SOLUTIONS HYDRAULIC HOSE SWITCH PANEL OPTIONAL CONNECTION SMART CYLINDER Figure 2-3. Optimus EPS system diagram, single station, single engine. © 2014 SeaStar Solutions Optimus Installation Manual, Rev. E...
Page 21: Installation Overview
• Read and understand all the safety information noted in this manual and all other installation instructions.. If you need technical assistance, or wish to report an error in our documentation, please contact SeaStar Solutions technical support: technical Support Web: www.seastarsolutions.com E-mail: seastar@@seastarsolutions.com Phone: 604.248.3858...
Page 22 Setup (Section 7) • Purge the hydraulic system. • Calibrate the SmartCylinders • System setup with CANtrak. commissioning (Section 8) • Installation checks • Sea trial • Steering adjustments • Warranty checklist © 2014 SeaStar Solutions Optimus Installation Manual, Rev. E...
Page 23: Planning
Make sure that sufficient wire of the correct gauge is available with the correct termination hardware and tie straps. Review the required hoses and fittings and check that all are available. Document the information on the system diagram. © 2014 SeaStar Solutions Optimus Installation Manual, Rev. E...
Page 24: Required Parts
Figure 4-1. Other parts required (not shown): • SeaStar Pro Steering Hoses • SeaStar Electronic Power Steering Fluid (Green/blue color) • Dealer Installation Kit and Purge Hose • Electrical harnesses and wire(s) (some wire[s] not supplied by SeaStar Solutions) • Breakers – two 60 Amp (not supplied by SeaStar Solutions) • Steering wheel (not supplied by SeaStar Solutions) © 2014 SeaStar Solutions Optimus Installation Manual, Rev. E...
Page 25: Plan Your Component Placement
EPS Sport Plus Tilt Helm Part No. EH1510 Part No. EH1530 EPS Classic Tilt Helm EPS Rear Mount Helm Part No. EH1550 Part No. EH1570 Figure 4-2. For mounting templates, please see Appendix A. © 2014 SeaStar Solutions Optimus Installation Manual, Rev. E...
Page 26 36' OR LESS 36' OR LESS Two separate harness — each 36' or less multiple helm harness Lengths (optional arrangement) Two separate harnesses — total combined length of 36' or less Figure 4-3. © 2014 SeaStar Solutions Optimus Installation Manual, Rev. E...
Page 27: Cantrak Display
For mounting templates, please see Appendix A. Part No. ED1700 <60° <60° Mount vertical to hull or wall Mount at an angle less than 60° DO NOT Mount parallel to boat deck Figure 4-4. © 2014 SeaStar Solutions Optimus Installation Manual, Rev. E...
Page 28 Station Female terminator CM10052 Male terminator CM10051 DEVICENET DEVICENET HARNESS* HARNESS* NETWORK TEE NETWORK TEE NETWORK TEE CM10060 CM10060 CM10060 Figure 4-6. * Note: see next page for harness information. © 2014 SeaStar Solutions Optimus Installation Manual, Rev. E...
Page 29 30 Foot CM10030 Table 4-2. cautIon do not cut or splice devicenet harnesses. cautIon do not connect anything other than SeaStar optimus components, or SeaStar approved autopilots, to the can2 network. © 2014 SeaStar Solutions Optimus Installation Manual, Rev. E...
Page 30: Pump Control Module (Pcm)
StandardS, Be rated for 105°c (221°f), and compLIant wIth Saej1128. CAN1 CAN1 CAN3 CAN2 Figure 4-7 Part No. EM1110. © 2014 SeaStar Solutions Optimus Installation Manual, Rev. E...
Page 31 Protect from sun and elements 15° Mount vertical (parallel) to hull or wall, plus or minus 15° DO NOT Expose to vibration, shocks or excessive heat Mount parallel to boat deck Figure 4-8. © 2014 SeaStar Solutions Optimus Installation Manual, Rev. E...
Page 32: Power Steering Pump
Protect from pump housing or cylinder body elements when installing an ORB fitting. 5° Mount at vertical angle of less than 5° SEE NOTICE SEE NOTICE Figure 4-9. 4-10 © 2014 SeaStar Solutions Optimus Installation Manual, Rev. E...
Page 33: Smartcylinders
CM20918 Table 4-3. cautIon only two extension harnesses are permitted per Smartcylinder. warnInG the SmartcyLInder eLectrIcaL harneSS muSt Be attached to the hydrauLIc hoSe wIth caBLe tIeS. See SectIon 5.7.2. 4-11 © 2014 SeaStar Solutions Optimus Installation Manual, Rev. E...
Page 34: Steering Service Valves
A 60 amp circuit breaker is required for each of the two PCM power feeds. Use only circuit breakers designed for marine use, and with corrosion- resistant, stainless steel connection hardware. Refer to ABYC wiring standards for all wiring best practices. 4-12 © 2014 SeaStar Solutions Optimus Installation Manual, Rev. E...
Page 35: Plan Your Connections
2 x polished stainless steel HO89XX SeaStar Pro bulkhead hose kit, SS, double 1 x polished stainless steel XX denotes hose length in feet, with a leading zero for lengths below 10 feet. Available lengths: • 2 to 5 feet in 1 foot increments (e.g. for a 3 foot hose kit, order HO5703) •...
Page 36 InStaLL BuLkhead hoSeS BeLow the waterLIne. Bulkhead hoses BLACK ANODIZED: HO82XX POLISHED STAINLESS STEEL: HO87XX BULKHEAD PIGTAIL FITTING Figure 4-12. Single bulkhead plate. POLISHED STAINLESS STEEL ONLY Figure 4-13. Dual bulkhead plate. 4-14 © 2014 SeaStar Solutions Optimus Installation Manual, Rev. E...
Page 37: Power Connections
Awg (mm < 3.0 meters < 9.8 feet 6 (13.5) < 4.5 meters < 14.7 feet 4 (21) < 7.5 meters < 24.6 feet 2 (34) Table 4-5. 4-15 © 2014 SeaStar Solutions Optimus Installation Manual, Rev. E...
Page 38 15’ 7” (4.8 m). Checking the table results in a 2 AWG (34 mm ) wire for this connection. 4-16 © 2014 SeaStar Solutions Optimus Installation Manual, Rev. E...
Page 39 – – PORT CENTER STARBOARD ENGINE ENGINE ENGINE Breaker Breaker – – – PORT CENTER STARBOARD 12V BATTERY 12V BATTERY 12V BATTERY Figure 4-15. Sample triple engine connection with ACR. 4-17 © 2014 SeaStar Solutions Optimus Installation Manual, Rev. E...
Page 40 (inboard pair or outboard pair) the position of the battery switches is not important because one charging battery will always be connected to the PCM when connected as shown. To make your system as error-proof as possible, SeaStar recommends the use of ACRs as shown in figure 4-15. notIce For clarity only positive wire connections are shown.
Page 41: Ignition & Tachometer Connections
Refer to the autopilot installation instructions for additional information. AUTOPILOT USE HARNESS INCLUDED WITH AUTOPILOT CAN 2 BACKBONE CAN 2 BACKBONE NETWORK TEE CM10060 Figure 4-17. Autopilot connection to CAN 2 network. 4-19 © 2014 SeaStar Solutions Optimus Installation Manual, Rev. E...
Page 42: Diagram
Use this page to make a complete diagram of the installation. The diagram should be similar to the one in Section 2.2, with the locations and correct harness and hose lengths indicated. Helm area: PCM/Pump area: SmartCylinder area: 4-20 © 2014 SeaStar Solutions Optimus Installation Manual, Rev. E...
Page 43: Installation
StatIc eLectrIcIty. a Ground Strap and hardware IS provIded wIth each heLm. faILure to do So may reSuLt In LoSS of SteerInG controL, poSSIBLy reSuLtInG In property damaGe, Injury or death. © 2014 SeaStar Solutions Optimus Installation Manual, Rev. E...
Page 44: Eps Front Mount Helm (Eh1510)
SuBStItutInG non-SeLf-LockInG faStenerS can reSuLt In LooSenInG or SeparatIon of equIpment, cauSInG LoSS of SteerInG controL, property damaGe, perSonaL Injury and or death. do not exceed 110 In-LB, (12nm) torque on heLm nutS and BoLtS. © 2014 SeaStar Solutions Optimus Installation Manual, Rev. E...
Page 45: Eps Sport Plus Tilt Helm (Eh1530)
SuBStItutInG non-SeLf-LockInG faStenerS can reSuLt In LooSenInG or SeparatIon of equIpment, cauSInG LoSS of SteerInG controL, property damaGe, perSonaL Injury and or death. do not exceed 110 In-LB, (12nm) torque on heLm nutS and BoLtS. © 2014 SeaStar Solutions Optimus Installation Manual, Rev. E...
Page 46: Eps Classic Tilt Helm (Eh1550)
SuBStItutInG non-SeLf-LockInG faStenerS can reSuLt In LooSenInG or SeparatIon of equIpment, cauSInG LoSS of SteerInG controL, property damaGe, perSonaL Injury and or death. do not exceed 110 In-LB, (12nm) torque on heLm nutS and BoLtS. © 2014 SeaStar Solutions Optimus Installation Manual, Rev. E...
Page 47: Eps Rear Mount Helm (Eh1570)
SuBStItutInG non-SeLf-LockInG faStenerS can reSuLt In LooSenInG or SeparatIon of equIpment, cauSInG LoSS of SteerInG controL, property damaGe, perSonaL Injury and or death.. do not exceed 110 In-LB, (12nm) torque on heLm nutS and BoLtS. © 2014 SeaStar Solutions Optimus Installation Manual, Rev. E...
Page 48: Cantrak Display
CANtrak. DO NOT <60° <60° Mount vertical to hull or wall Mount at an angle less than 60° Mount parallel to boat deck Figure 5-5. Figure 5-6. © 2014 SeaStar Solutions Optimus Installation Manual, Rev. E...
Page 49: Pcm And Power Steering Pumps
• The PCM is designed to fit ¼” or M6 cap screws or machine screws. Use washers between the screw head and the PCM. • Through-bolt with nuts and washers on the back the side, or drill and tap into a metal mounting surface. • You can also use a #14 wood screw and washer. © 2014 SeaStar Solutions Optimus Installation Manual, Rev. E...
Page 50: Pcm Mounting Considerations
Protect from sun and elements 15° Mount vertical (parallel) to hull or wall, plus or minus 15° DO NOT Expose to vibration, shocks or excessive heat Mount parallel to boat deck Figure 5-8. © 2014 SeaStar Solutions Optimus Installation Manual, Rev. E...
Page 51: Power Steering Pump Mounting Considerations
Be hot to the touch durInG operatIon. do not mount pumpS In an area where faBrIcS and/or other fLammaBLe materIaL may come In contact wIth the pump motor. do not cover. © 2014 SeaStar Solutions Optimus Installation Manual, Rev. E...
Page 52 Figure 5-11. note: if floor-mounting the power steering pump: • Pumps must be mounted upright to facilitate oil fill and purge. SEE MOUNDING HARDWARE RECOMMENDATIONS 3 X FLAT WASHER POWER STEERING PUMP Figure 5-12. 5-10 © 2014 SeaStar Solutions Optimus Installation Manual, Rev. E...
Page 53: Integrated Steering Service Valve
5-13 in a visible location. this decal muSt be visible! Figure 5-13. 5.3.5 Power Steering Pump Mounting Hardware Recommended Mounting Hardware: • M6 cap or machine screw and washer • 1/4” cap or machine screw and washer • #14 wood screw and washer (flat bearing surface under screw head only) 5-11 © 2014 SeaStar Solutions Optimus Installation Manual, Rev. E...
Page 54: Smartcylinder Mounting
(Item 2) into the steering arm. While holding the head of the tiller bolt with a wrench, tighten the tiller nut (Item 1) to the specified torque. 5-12 © 2014 SeaStar Solutions Optimus Installation Manual, Rev. E...
Page 55 SpecIfIcatIonS for the approprIate InStaLLatIon. faILure to correctLy InStaLL the SmartcyLInder and torque aLL ScrewS may reSuLt In SteerInG faILure, whIch couLd reSuLt In property damaGe, perSonaL Injury and/or death. 5-13 © 2014 SeaStar Solutions Optimus Installation Manual, Rev. E...
Page 56 45ft.lb. TORQUE to 33ft.lb. TORQUE to 45ft.lb. TORQUE to 22ft.lb. TORQUE * Twin engine applications only. to 33ft.lb. Consult SeaStar for triple and quad applications with tiebars. Figure 5-15. ITEM PART # qTy DESCRIPTION ITEM PART # qTy DESCRIPTION 113529 Nut, 3/8”...
Page 57 TORQUE to 33ft.lb. TORQUE to 45ft.lb. TORQUE * Twin engine applications only. TORQUE to 33ft.lb. to 22ft.lb. Consult SeaStar for triple and quad applications with tiebars. SEE WARNING Figure 5-16. ITEM PART # qTy DESCRIPTION ITEM PART # qTy DESCRIPTION 113529 Nut, 3/8”...
Page 58 = TORQUE to 45ft.lb. POINT TORQUE to 33ft.lb. TORQUE to 45ft.lb. * Twin engine applications only. TORQUE to 22ft.lb. Consult SeaStar for triple and TORQUE to 33ft.lb. quad applications with tiebars. Figure 5-17. ITEM PART # qTy DESCRIPTION ITEM PART #...
Page 59: Ground Strap Installation
5.4.1 Ground Strap Installation notIce SeaStar Solutions strongly recommends use of a ground strap on any outboard hydraulic steering cylinder with an exposed shaft where FOR SALT WATER APPLICATIONS the vessel will be used in salt water. This ground strap will provide added protection against corrosion caused by stray current.
Page 60: Plumbing The System
SyStem requIreS the uSe of SeaStar pro (1500 pSI) kevLar reInforced hoSeS onLy. warnInG do not cut SeaStar pro SteerInG hoSe. there IS no meanS In the fIeLd to InStaLL a SwaGe fIttInG to the hoSe end. cautIon...
Page 61: Hose Labels
SmartCylinder cables. Place all labels so they can be easily read after the installation is complete as they are a great help when servicing the system. See illustration below. Figure 5-19. 5-19 © 2014 SeaStar Solutions Optimus Installation Manual, Rev. E...
Page 62: Hose Installation
Injury and/or death. cautIon do not remove the protective end caps until connections are ready to be made. notIce • Be sure to mark all hoses using the supplied labels to insure correct installation. • We recommend you plumb and connect hoses for each engine separately to avoid confusion. 5-20 © 2014 SeaStar Solutions Optimus Installation Manual, Rev. E...
Page 63 (provided with Kit) I.D. TAG (provided with Kit) BEND RESTRICTOR BULKHEAD TO CYLINDER PIGTAIL FITTING I.D. TAG (provided with Kit) HOSE FITTING DUST CAP Figure 5-21. 5-21 HO86xx Dual Polished Plate shown. © 2014 SeaStar Solutions Optimus Installation Manual, Rev. E...
Page 64: Hose Fitting Reorientation (If Required)
3. Re-position fitting to desired orientation by turning it counter- clockwise to a MAXIMUM of 1 full turn. 4. While holding the fitting body securely with a wrench, torque the locknut to 40–43ft-lb. 5-22 © 2014 SeaStar Solutions Optimus Installation Manual, Rev. E...
Page 65 Be sure to use the correct installation torque to avoid irreparable damage to the pump housing or cylinder body when installing an ORB fitting. Figure 5-23. Re-orientable hose fitting. Figure 5-24. 5-23 © 2014 SeaStar Solutions Optimus Installation Manual, Rev. E...
Page 66: Connecting The Smartcylinder
PORT, as you will be connecting it to the port side of the PCM). do not mix up sensor harness connections at PCM. Identification labels are provided with the kit. Starboard cable Installation (preferred method) Figure 5-25. 5-24 © 2014 SeaStar Solutions Optimus Installation Manual, Rev. E...
Page 67 Injury and or death. If additional harness length is required to reach the SmartCylinder, extension harness are available (see Section 4.3.5). Connect the SmartCylinder harness to the PCM (as shown on page 5-27). 5-25 © 2014 SeaStar Solutions Optimus Installation Manual, Rev. E...
Page 68 SmartCylinder harness can be secured to the hoses. warnInG do not InStaLL BuLkhead hoSeS BeLow the waterLIne. 1.0" THRU HOLE TO PCM BULKHEAD TO SMARTCYLINDER Figure 5-27. 5-26 © 2014 SeaStar Solutions Optimus Installation Manual, Rev. E...
Page 69 Smart- Cylinder connection (RFU1). PORT PUMP STARBOARD PUMP CONNECTION (M1) CONNECTION (M2) Figure 5-28. cautIon do not force past the marks shown below. Figure 5-29. 5-27 © 2014 SeaStar Solutions Optimus Installation Manual, Rev. E...
Page 71: Networks And Wiring
CANtrak 2 BUZZER BUZZER CM21504 CM21504 TERMINATOR CM10051 CM100XX CM100XX TERMINATOR CM10052 CM10060 OPTIMUS CAN2 CERTIFIED IGNITION SOURCE OPTIMUS CAN1 AUTOPILOT (Optional) IGNITION Figure 6-2. Network diagram — dual station, multi-engine. © 2014 SeaStar Solutions Optimus Installation Manual, Rev. E...
Page 72 CM20030 TERMINATOR CM10051 CM100XX TERMINATOR CM10052 CM10060 OPTIMUS CAN2 CERTIFIED IGNITION SOURCE OPTIMUS CAN1 AUTOPILOT (Optional) IGNITION Figure 6-4. Network diagram — dual station, single engine, with optional CAN2 for autopilot. © 2014 SeaStar Solutions Optimus Installation Manual, Rev. E...
Page 73: Harness Connections
STRAIN RELIEVED TO HELM CAN1 HARNESS TO HOUSING TAB USING PCM P1 PORT CABLE TIES PROVIDED CANTRAK TO CAN2 NETWORK NODE CM21504 HARNESS HARNESS MUST BE STRAIN RELIEVED TO PCM STRAIN-RELIEF PLATE. Figure 6-3. © 2014 SeaStar Solutions Optimus Installation Manual, Rev. E...
Page 74 1. puSh to dISenGaGe the Secondary Lock 2. LISten for the “cLIck” aS the connector LockS 2. Squeeze to unLatch the connector 3. puSh to enGaGe the Secondary Lock 3. puLL to remove Figure 6-4. © 2014 SeaStar Solutions Optimus Installation Manual, Rev. E...
Page 75: Connecting A Second Station
STATION 2 STATION 2 STATION 1 STATION 1 WYE HARNESS CM21702 a) BOTH HELMS CONNECTED b) BOTH HELMS CONNECTED TO PCM (PREFFERED) TOGETHER Figure 6-5. Alternate helm connections in dual-station applications. © 2014 SeaStar Solutions Optimus Installation Manual, Rev. E...
Page 76: Connecting The Cantrak
MOUNT HOLES mounted securely using screws through both mounting holes. cautIon do not connect anything other than SeaStar optimus comp- onents, or SeaStar approved EACH CABLE autopilots, to the can2 network. APPROPRIATELY SECURED AND STRAIN RELIEVED...
Page 77: Power Wiring
PCM port side. Run a separate wire from the negative terminal of the starboard battery to the negative terminal of the PCM starboard side. 3. Run the positive wires as shown in the diagram. © 2014 SeaStar Solutions Optimus Installation Manual, Rev. E...
Page 78 POWER POWER SOURCE SOURCE Figure 6-8. *Breakers are not supplied as part of the SeaStar Solutions Kit. ** Battery Switch (PCM power may be connected directly to the battery or to the battery switch. Figure 6-9. © 2014 SeaStar Solutions...
Page 79: Pcm Wiring Strain Relief
Secure harneSS, aS Shown, may reSuLt In harneSS wear, cauSInG LoSS of SteerInG controL, property damaGe, perSonaL Injury and/or death. warnInG aLL unuSed connectorS requIre SeaLInG pLuGS. they wILL LIkeLy Be requIred on pcm and the heLm. © 2014 SeaStar Solutions Optimus Installation Manual, Rev. E...
Page 80: Ignition Sensing
These connection options are illustrated in figure 2-3. CAN2 NETWORK GREY/BLACK ANALOG MALE TACHOMETER TERMINATOR RED (X 1) NOT USED VIOLET (X2) IGNITION Figure 6-11. 6-10 © 2014 SeaStar Solutions Optimus Installation Manual, Rev. E...
Page 81: Ignition Splicing
2 – splice into an existing engine ignition wire TWIST WIRES TOGETHER IGNITION TO PCM SOURCE TO ENGINE MOLEX PERMA-SEAL STEP DOWN BUTT SPLICE P/N 0191640043 OR EQUIVALENT Figure 6-13. 6-11 © 2014 SeaStar Solutions Optimus Installation Manual, Rev. E...
Page 82: Engine Rpm Source
Figure 6-14. Creating an NMEA 2000 network with kit HA5492. notIce When using NMEA 2000 CAN Bus for engine RPMs ensure that the black and gray analog tachometer inputs from the CM20304 CAN2 Harness are connected together 6-12 © 2014 SeaStar Solutions Optimus Installation Manual, Rev. E...
Page 83: Analog Tachometer
6-11. 6.6 Autopilot Connection (Optional) Autopilots certified by SeaStar as compliant with the EPS system will simply connect to an available CAN2 network tee. The connection harness is supplied by the autopilot manufacturer. Refer to the manufacturer’s instructions for additional information.
Page 84: Buzzer Kit (Optional)
16awG wire has been included in the kit to power the buzzer and comply with aByc e-11. refer to the aByc e-11 for required gauge if longer wire runs are required. 6-14 © 2014 SeaStar Solutions Optimus Installation Manual, Rev. E...
Page 85: Setup, Purging, And Calibration
See Appendix D for instructions. procedure: 1. On the display, navigate to dealer menu > Initial Setup > System to access the System Setup menu. Figure 7-1. © 2014 SeaStar Solutions Optimus Installation Manual, Rev. E...
Page 86 Figure 7-3. 5. Use the + and – buttons to change the number of devices to match your system. Press Save or when finished to return to the System Setup menu. © 2014 SeaStar Solutions Optimus Installation Manual, Rev. E...
Page 87 10. Review Appendix E and determine if your system software needs Display interface. Helm instance to be updated. is found on the Configuration tab of the Helm interface. You are now ready purge your steering system. Proceed to section 7.2. © 2014 SeaStar Solutions Optimus Installation Manual, Rev. E...
Page 88: Purging The Steering System
If the inactive engine will not move manually open the service valve for that engine. OPTIONAL REMOTE SERVICE VALVE Figure 7-5. © 2014 SeaStar Solutions Optimus Installation Manual, Rev. E...
Page 89: The Purging Process
Should this accidentally occur power off the system for 3 seconds then power back on. this will stop the pump. © 2014 SeaStar Solutions Optimus Installation Manual, Rev. E...
Page 90 When the fluid level in the reservoir drops to the MIN mark, stop turning the steering wheel and refill the reservoir to the MAX mark. DO NOT ALLOW THE FLUID LEVEL TO GO BELOW THE MIN MARK. © 2014 SeaStar Solutions Optimus Installation Manual, Rev. E...
Page 91 When purging is complete the cylinder should have 3/8” or less of movement when physically trying to shake the engine back and forth. © 2014 SeaStar Solutions Optimus Installation Manual, Rev. E...
Page 92: Calibrating The Smartcylinders
The cylinder is treated as the Port cylinder on the CANtrak display and in Datalink. Figure 7-9. 3. Select calibrate port cylinder and press > to enter Calibration Mode. © 2014 SeaStar Solutions Optimus Installation Manual, Rev. E...
Page 93: Restricting Smartcylinder Travel
• Check with the engine(s) tilted up and down. If you find interference towards the end of the cylinder travel, you will need to adjust the maximum steering angle. Follow the instructions below. © 2014 SeaStar Solutions Optimus Installation Manual, Rev. E...
Page 94 5. Check again for interference and adjust the Max Steering Angle found on the Configuration tab as necessary. For the best steering performance, restrict the of the PCM interface. travel as little as possible. 7-10 © 2014 SeaStar Solutions Optimus Installation Manual, Rev. E...
Page 95: Steering Settings
Both of these parameters are set for low and high speed operation, and the system smoothly transitions them as boat speed changes. Figure 7-12 shows how these parameters change with speed. Figure 7-12. 7-11 © 2014 SeaStar Solutions Optimus Installation Manual, Rev. E...
Page 96: Adjustment
Changes will not take effect until you exit the Steering Settings menu and confirm that you want to save the changes. cautIon make adjustments in small increments and then trial them. Large changes may introduce unexpected steering behavior. 7-12 © 2014 SeaStar Solutions Optimus Installation Manual, Rev. E...
Page 97: Available Settings
Helm Effort in Auto- Sets the helm effort when the vessel 1 to 100 Pilot is in autopilot. Set it high enough to prevent accidental movement of the helm. Table 7-1. Steering Settings 7-13 © 2014 SeaStar Solutions Optimus Installation Manual, Rev. E...
Page 98: User Permissions
You will be prompted to save the setting on exit. For Datalink users: this parameter is available in the Configuration tab of the Color Display interface. Figure 7-14. 7-14 © 2014 SeaStar Solutions Optimus Installation Manual, Rev. E...
Page 99: Commissioning
UP. Turn the steering wheel from hard over to hard over and confirm that no interference occurs. 2. Sensor cable – Confirm that the SmartCylinder Sensor Cable is tied securely to the hoses with gradual bends as shown figure 8-2. © 2014 SeaStar Solutions Optimus Installation Manual, Rev. E...
Page 100 PORT EXIT CABLE (ALTERNATE METHOD) 6" STARBOARD 6" EXIT CABLE (PREFERRED METHOD) 6" SMOOTH BEND TIE SECURED (NO KINKING) TO FITTING 6" 6" Figure 8-2. Sensor cable and hose routing checks. © 2014 SeaStar Solutions Optimus Installation Manual, Rev. E...
Page 101: Pre-Trip Checks
Each Optimus hydraulic pump has a steering fluid reservoir. Ensure the fluid level is between the MIN and MAX marks on the reservoir as shown in the figure below. Use only SeaStar Electronic Power Steering Fluid in the Optimus EPS System.
Page 102 Read the System Inspection steps on the CANtrak display and acknowledge them by pressing the right hand most button under OK. 7. verify that installation checks have been performed per Section 8.1. © 2014 SeaStar Solutions Optimus Installation Manual, Rev. E...
Page 103: Sea Trial
(Note: it will take an effort to “break” the helm free.) The autopilot’s override behavior will depend on the manufacturer; refer to the instructions supplied with the autopilot. © 2014 SeaStar Solutions Optimus Installation Manual, Rev. E...
Page 104: Steering Adjustments
Once you have done an orientation with the owner and handed the vessel over, return the completed checklist to SeaStar Solutions for warranty registration. © 2014 SeaStar Solutions...
Page 105: Fault Handling
Provides detailed instructions on how to proceed. In the case of a danger fault, this will instruct the operator what to do and how to proceed should Limp Home mode be required. © 2014 SeaStar Solutions Optimus Installation Manual, Rev. E...
Page 106: Warning Fault Handling
If the system recovers from the fault, for example if a battery runs low and is subsequently charged, the warning screen will disappear and the system will automatically resume normal operation. © 2014 SeaStar Solutions Optimus Installation Manual, Rev. E...
Page 107 Some system faults may result in a reduced steering response warning. This means that the system will continue to steer normally but may respond slower. notIce Additional fault handling information is provided in the User’s Manual. © 2014 SeaStar Solutions Optimus Installation Manual, Rev. E...
Page 109: Warranty
SeaStar SoLutIonS) products have been manufactured free from defects in materials and workmanship. This warranty is effective for two years from date of purchase, excepting that where SeaStar SoLutIonS products are used commercially or in any rental or income producing activity, then this warranty is limited to one year from the date of purchase.
Page 111: Appendix A Mounting Templates
Front Mount Helm notIce If this template has been downloaded electronically or copied from another document, please verify all template dimensions prior to cutting. Print/copy reproductions may be scaled differently. Figure A-1. © 2014 SeaStar Solutions Optimus Installation Manual, Rev. E...
Page 113: Rear Mount Helm
Rear Mount Helm notIce If this template has been downloaded electronically or copied from another document, please verify all template dimensions prior to cutting. Print/copy reproductions may be scaled differently. Figure A-2. © 2014 SeaStar Solutions Optimus Installation Manual, Rev. E...
Page 115: Classic Tilt Helm
Classic Tilt Helm notIce If this template has been downloaded electronically or copied from another document, please verify all template dimensions prior to cutting. Print/copy reproductions may be scaled differently. Figure A-3. © 2014 SeaStar Solutions Optimus Installation Manual, Rev. E...
Page 117: Sport Tilt Helm
Sport Tilt Helm notIce If this template has been downloaded electronically or copied from another document, please verify all template dimensions prior to cutting. Print/copy reproductions may be scaled differently. Figure A-4. © 2014 SeaStar Solutions Optimus Installation Manual, Rev. E...
Page 119: Cantrak Display
If this template has been downloaded electronically or copied from another document, please verify all template dimensions prior to cutting. Print/copy reproductions may be scaled differently. 3.38" – 3.5" DIA. (86 –89 mm) Figure A-5. © 2014 SeaStar Solutions Optimus Installation Manual, Rev. E...
Page 121: Pcm Mounting Dimensions
A.3 PCM Mounting Dimensions Figure A-6. A-11 © 2014 SeaStar Solutions Optimus Installation Manual, Rev. E...
Page 122: Power Steering Pump
Power Steering Pump Mounting Dimensions 8 X .28 DIA. MOUNTING HOLES (ONLY FOUR FASTENERS REQUIRED) 10.5" (267 mm) 3 x 1.1" (28 mm) 7.9" (200 mm) 8.6" (218 mm) Figure A-7. A-12 © 2014 SeaStar Solutions Optimus Installation Manual, Rev. E...
Page 123: Floor Mounting The Pumps
Floor Mounting the Pumps Recommended Mounting Hardware: • M6 x 1 cap or machine screw and washer • 1/4”– 20 cap or machine screw and washer • #14 wood screw and washer (flat bearing surface under screw head only) 8.6" (218 mm) 2.06" (52 mm) 2.0" 6.4" (51 mm) (163 mm) 7.9" (201 mm) Figure A-8. A-13 © 2014 SeaStar Solutions Optimus Installation Manual, Rev. E...
Page 125: Appendix B Can Network
Any manufacturer may use their own harness but to adhere to the standard they must have an adaptor harness that allows easy connection to the approved harness. All SEASTAR SOLUTIONS CAN Bus harness meet the NMEA 2000 standard and ®...
Page 126: Can Bus Connectors
(whichever applies). • Hand-tighten after the connection is made. do not tightly tie down the tee connectors, as this will create stress. © 2014 SeaStar Solutions Optimus Installation Manual, Rev. E...
Page 127: Can Bus Connectivity
• The harness ends are male and female. To avoid a mismatch it is best to work from one end toward the other. If you must work from both ends toward the middle assure that the mating point will be a male/female connection. © 2014 SeaStar Solutions Optimus Installation Manual, Rev. E...
Page 128: Powering The Bus
CAN Bus. This requires the CAN Bus to have adequate sources of power. Figure B-5. © 2014 SeaStar Solutions Optimus Installation Manual, Rev. E...
Page 129: Appendix C Using Datalink
PCM as shown in figure C-1. If you don’t have any spare ports an optional wye harness (CM21702) is available that can convert a single port into two. warnInG aLwayS reInStaLL the can1 SeaLInG pLuGS when you dISconnect the proGrammInG harneSS. © 2014 SeaStar Solutions Optimus Installation Manual, Rev. E...
Page 130: Navigating Datalink
If you are connected to CAN1, double-click on ‘Optimus CAN1’ to bring up the connected devices. On an EPS system you should see only the Main PCM, your helm(s), and your display(s). © 2014 SeaStar Solutions Optimus Installation Manual, Rev. E...
Page 131 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. © 2014 SeaStar Solutions Optimus Installation Manual, Rev. E...
Page 132: System Setup
Optimus EPS system. rpm Source Set to the appropriate RPM source. tachometer ppr If you’re using an analog tachometer, you may need to adjust the PPR setting. © 2014 SeaStar Solutions Optimus Installation Manual, Rev. E...
Page 133: Settings Menu Access
Cycle Power to System Changes to system parameters will not take effect until the power has been cycled. To cycle power, turn the key off for several seconds and turn it on again. © 2014 SeaStar Solutions Optimus Installation Manual, Rev. E...
Page 134: Purge With Datalink
In step 8 of the purge procedure (section 7.2) use the radio buttons to set the mode into either ‘Purge port cylinder’ or ‘Purge starboard cylinder’. To take the system out of purge mode, click the radio button next to ‘Off’. © 2014 SeaStar Solutions Optimus Installation Manual, Rev. E...
Page 135: Calibrate With Datalink
10. Power up the system and turn the helm. The engines should align automatically, and the steering should operate normally. You may see a window in Datalink asking you if you wish to save changes. Click no and exit. © 2014 SeaStar Solutions Optimus Installation Manual, Rev. E...
Page 137: Appendix D Using The Color Cantrak Display
Increases the setting of the selected item. Accepts a given statement or condition and advances to the next screen. Returns to previous menu. Save Saves change and returns to previous menu. © 2014 SeaStar Solutions Optimus Installation Manual, Rev. E...
Page 138: 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. © 2014 SeaStar Solutions Optimus Installation Manual, Rev. E...
Page 139: 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 140: Menu Structure
Lists all devices. From submenus you can find product serial suppressed during setup and numbers, configure and calibrate the device, monitor inputs and system updates. outputs, update firmware, and export or import device settings. tools Import and export system settings. © 2014 SeaStar Solutions Optimus Installation Manual, Rev. E...
Page 141: Appendix E Updating Firmware
Figure E-1. Desktop\Optimus Firmware – Folder Structure. note: The installer only loads the required files to the computer; it does NOT perform the actual component updates. Refer to Section E.2 for detailed component updating instructions. © 2014 SeaStar Solutions Optimus Installation Manual, Rev. E...
Page 142: One-Step System Firmware Update
7. You will still need to update the CANtrak display firmware separately. See section E.6 for instructions. There is currently no ability to perform an automatic update using the CANtrak display. © 2014 SeaStar Solutions Optimus Installation Manual, Rev. E...
Page 143: Checking Component Firmware Revision Levels
See Figure E-4. (In an EPS system you will see only the PCM and Helm in the component list.) 2. Firmware revision can be found under the ‘Firmware Part Number’ field. © 2014 SeaStar Solutions Optimus Installation Manual, Rev. E...
Page 144 DATALINk VERSION CLICk TO EXPAND COMPONENT INfORMATION fIRMWARE REVISION Figure E-4. Datalink Workspace. © 2014 SeaStar Solutions Optimus Installation Manual, Rev. E...
Page 145: Backing Up Component Configuration Files
1. Connect to the Optimus system using Datalink as shown in Appendix C. 2. Double click the component name in the Interfaces list to access the component configuration pages. © 2014 SeaStar Solutions Optimus Installation Manual, Rev. E...
Page 146: Updating Individual Components
In general, system firmware should always be updated using the ‘Update All’ utility described in section E.2 If you have a situation in which you feel you need to update the joystick firmware on its own, please contact SeaStar Solutions technical support. E.6 Updating the CANtrak Software The CANtrak software can only be updated from the display.
Page 147: Opening A Back-Up (Ecu) File
3. The backup file will open. It can be identified at the top of the Datalink screen by a different name and icon. WhITE ShEET ICON INDICATES AN ECU fILE IS OPEN Figure E-6. ECU File Icon. © 2014 SeaStar Solutions Optimus Installation Manual, Rev. E...
Page 149 104.0 (141.00) 1/2"-20 45.0 (61.01) 37.0 (50.17) 3/4"-16 124.0 (168.12) 102.0 (138.29) 9/16"-12 57.0 (77.28) 47.0 (63.72) 7/8"-9 194.0 (236.03) 159.0 (215.58) 9/16"-18 63.0 (85.42) 51.0 (69.15) 7/8"-14 193.0 (261.67) 158.0 (214.22) © 2014 SeaStar Solutions Optimus Installation Manual, Rev. E...
Page 150 _______________________________________________ notes _______________________________________________ _______________________________________________ _______________________________________________ _______________________________________________ _______________________________________________ _______________________________________________ _______________________________________________ _______________________________________________ _______________________________________________ _______________________________________________ _______________________________________________ _______________________________________________ _______________________________________________ _______________________________________________ _______________________________________________ _______________________________________________ _______________________________________________ _______________________________________________ _______________________________________________ © 2014 SeaStar Solutions Optimus Installation Manual, Rev. E...
Page 152 SEASTAR SOLUTIONS 3831 NO.6 ROAD RICHMOND, B.C. CANADA V6V 1P6 FAX 604-270-7172 www.seastarsolutions.com ISo 10592 © 2014 MARINE CANADA ACQUISITION INC. DBA SEASTAR SOLUTIONS PRINTED IN CANADA FORM NO. 682100 REV. E 10/14...

SeaSTAR OPTIMUM EPS Installation Manual

Abbreviations

1 Safety Information

2 System Overview

3 Installation Overview

4 Planning

5 Installation

6 Networks and Wiring

7 Setup, Purging, and Calibration

8 Commissioning

9 Fault Handling

10 Warranty

Appendix A Mounting Templates

Appendix B CAN Network

Appendix C USING Datalink

Appendix D USING the COLOR Cantrak Display

Appendix E UPDATING Firmware

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Summary of Contents for SeaSTAR OPTIMUM EPS

Table of Contents