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Seastar Solutions OPTIMUS EPS Operation Instructions And Users Manual

Electronic power steering for outboard powered vessels
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OPERATION INSTRUCTIONS
AND USER'S MANUAL
w w w . s e a s t a r s o l u t i o n s . c o m
51
F I F T Y O N E
ISO 9001
Electronic Power Steering for
Outboard Powered Vessels

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  • Page 1 OPERATION INSTRUCTIONS AND USER’S MANUAL 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 O N E ISO 9001 Electronic Power Steering for Outboard Powered Vessels...
  • Page 2 Yacht Council (http://www.abycinc.org) NMEA 2000 is a registered trademark of the National Marine ® Electronics Association. Optimus, Optimus EPS, SeaStar, and BayStar are all trademarks of SeaStar Solutions. California Proposition 65 Warning Battery posts, terminals, and related accessories contain lead and lead...
  • Page 3 Thank you for choosing an Optimus Electronic Power Steering System by SeaStar Solutions. You have chosen a state of the art steering system that will provide years of effortless and trouble free steering performance. About this Book This User’s manual contains the information you need to safely operate and maintain your steering system.
  • Page 4 This page left intentionally blank. © 2012 SeaStar Solutions Optimus Operations Manual, Rev. D...

  • Page 5: Table Of Contents

    2.0 Introduction ..............2-1 2.1 Welcome ..............2-1 2.2 Optimus System Overview .......... 2-1 2.3 Optimus EPS Single Station System Diagram ....2-2 2.4 Optimus EPS Dual Station System Diagram ....2-3 3.0 First Time Operation ............3-1 3.1 Locate the Following Steering System Components ..3-1 3.1.1 Electronic Helm(s) ..........

  • Page 6: Abbreviations

    A protocol for digital communication on a CAN Bus Pump Control Module Revolutions Per Minute STBD Starboard (right) Note: Some abbreviations not listed here may be found in their respective sections. © 2012 SeaStar Solutions Optimus Operations Manual, Rev. D...
  • Page 7 DURING AND AFTER USE. IT IS CRITICAL THAT YOU READ AND UNDERSTAND ALL THE POINTS NOTED. WARNING THE OPTIMUS EPS SYSTEM MUST ONLY BE INSTALLED BY AN AUTHORIZED DEALER OR OEM. Safe operation of the steering system depends upon proper installation and maintenance of the system, and the common sense, safe judgment, knowledge, and expertise of the operator.
  • Page 8 Maintain your Optimus Steering as directed in Section 7 of this manual. Keep our waters clean for all current and future users. Dispose of all fluids in accordance with your local regulations. © 2012 SeaStar Solutions Optimus Operations Manual, Rev. D...

  • Page 9: Safety Labels

    6.9 MPa (1000psi) MAX. 12 Volt SERVICE VALVE WARNING Refer to User's Manual for use of valve. OPERATION: SAE J-1171 Figure 1-1. Hydraulic steering pump labels. Pump Control Module (PCM) Labels Figure 1-2. PCM labels. © 2012 SeaStar Solutions Optimus Operations Manual, Rev. D...
  • Page 10 SmartCylinder Label Figure 1-3. SmartCylinder labels. Steering Service To be installed close to the service valve. Valve Labels Figure 1-4. Steering service valve label. © 2012 SeaStar Solutions Optimus Operations Manual, Rev. D...

  • Page 11: Introduction

    Optimus EPS steering system. 2.2 Optimus EPS System Overview A typical Optimus EPS system consists of an Electronic Helm located behind the steering wheel which is electrically connected to a pump control module (PCM). The PCM converts the steering wheel action to electrical signals which operate hydraulic steering pumps.

  • Page 12: Optimus Eps Single Station System Diagram

    BREAKERS PORT 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. © 2012 SeaStar Solutions Optimus Operations Manual, Rev. D...

  • Page 13: Optimus Eps Dual Station System Diagram

    BREAKERS PORT 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. © 2012 SeaStar Solutions Optimus Operations Manual, Rev. D...
  • Page 14 This page left intentionally blank. © 2012 SeaStar Solutions Optimus Operations Manual, Rev. D...

  • Page 15: First Time Operation

    EPS Sport Plus Tilt Helm Figure 3-1. EPS Helm configurations. 3.1.2 Circuit Breakers for Optimus EPS System These are supplied by the installer and may be mounted in a variety of locations. Check near the batteries, in the circuit breaker box, or near the PCM or hydraulic pumps.

  • Page 16: Pump Control Module (Pcm)

    Note: these pumps look similar to the trim pumps that tilt the engines. They can be distinguished by the integrated steering service valve. Figure 3-3. Hydraulic pump and reservoir. © 2012 SeaStar Solutions Optimus Operations Manual, Rev. D...

  • Page 17: Smartcylinders

    figure 3-5. OPEN (FULLY TURN COUNTER-CLOCKWISE) POWER STEERING PUMP SERVICE VALVE CLOSED (FULLY TURN CLOCKWISE) Figure 3-5 Remote steering Figure 3-6. Service valve location. service valve. © 2012 SeaStar Solutions Optimus Operations Manual, Rev. D...

  • Page 18: Cantrak Display

    The CANtrak display is supplied with a plastic cover to protect it from the weathering effects of sunlight. Remove and stow the cover before using the boat, and replace it when finished. © 2012 SeaStar Solutions Optimus Operations Manual, Rev. D...

  • Page 19: Initial Start Up

    Figure 3-9. All Helms Active screen (normal steering mode). WARNING ON MULTIPLE HELM STATION BOATS ALL STEERING HELMS ARE ACTIVE WHEN THE OPTIMUS EPS IS TURNED ON. THIS IS THE SAME AS YOU WOULD FIND ON A CONVENTIONAL HYDRAULIC STEERING SYSTEM. © 2012 SeaStar Solutions...

  • Page 20: System Inspection

    Ensure the fluid level is between the MIN and MAX marks on the reservoir as shown in the figure below. Use only SeaStar EPS steering fluid (HA5482) in the Optimus EPS System. Figure 3-10. Location of fluid level marks. 2. Verify immediate steering response when turning steering wheel(s).
  • Page 21 CAUTION It is recommended the full system inspection be reviewed on a regular basis to retain familiarity. © 2012 SeaStar Solutions Optimus Operations Manual, Rev. D...

  • Page 22: Installation Checks

    DEALER FOR THOSE ISSUES TO BE REMEDIED. TRANSOM SMART CYLINDER CHECK FOR CLEARANCE TO BOTTOM SIDE OF SMART CYLINDER WITH ENGINE FULLY TILTED THROUGHOUT STEERNG RANGE Figure 3-11. Engine side view when tilted. © 2012 SeaStar Solutions Optimus Operations Manual, Rev. D...

  • Page 23: Initial Sea Trial

    If adjustments to the system are required, see Section 5.0 for steering adjustments or contact your dealer. CAUTION Keep magnets away from the helm. They may interfere with proper helm operation. © 2012 SeaStar Solutions Optimus Operations Manual, Rev. D...
  • Page 24 This page left intentionally blank. 3-10 © 2012 SeaStar Solutions Optimus Operations Manual, Rev. D...

  • Page 25: System Use

    On multiple helm station boats all helms are active when the Optimus EPS is turned on. The Optimus EPS system is designed to operate much like a conventional hydraulic steering system. The boat can be steered from any helm without requiring additional steps to transfer control.

  • Page 26: Autopilot Operation

    ALWAYS READ AND UNDERSTAND THE AUTOPILOT OPERATION INSTRUCTIONS COMPLETELY BEFORE ENGAGING THE AUTOPILOT MODE. The Optimus EPS steering system is designed to interface with many autopilot controllers. See your Autopilot’s documentation for specific model compatibility. On boats with an autopilot the steering effort may be noticeably higher when the autopilot is engaged.

  • Page 27: Cantrak Display

    Instructs the operator what to do in case of a system fault. 3. Permits changes to the basic system settings. 4. Provides system and diagnostic information For details on CANtrak operation see sections 5.2 through 5.4 of this manual. © 2012 SeaStar Solutions Optimus Operations Manual, Rev. D...

  • Page 28: Cantrak Display Navigation

    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. © 2012 SeaStar Solutions Optimus Operations Manual, Rev. D...

  • Page 29: Cantrak Display Map - All Helms Active

    Device List – Access product information, such as part number and serial number, for each device on the network. * Menu may be deactivated. Contact your dealer. Figure 5-2. CANtrak display map. © 2012 SeaStar Solutions Optimus Operations Manual, Rev. D...

  • Page 30: All Helms Active Screens

    The All Helms Active screen displays the current system operating conditions. It shows the engine RPM as well as the rudder angle. It also allows access to the Display & Menu screens. Figure 5-3. All Helms Active screen. © 2012 SeaStar Solutions Optimus Operations Manual, Rev. D...

  • Page 31: Settings Screen [ Steering ]

    It is adjustable between 1 and 100. * May not be available on all installations. Contact your dealer/builder. © 2012 SeaStar Solutions Optimus Operations Manual, Rev. D...
  • Page 32 Adjusting steering effort for steering turns can significantly impact boat handling. Proceed with caution after making any changes. Figure 5-5. Change of helm settings with speed. * May not be available on all installations. Contact your dealer. © 2012 SeaStar Solutions Optimus Operations Manual, Rev. D...

  • Page 33: Display (Disp) Screen

    The Display screen allows adjustment of the brightness of the CANtrak display. These should be adjusted to provide good daytime and night time visibility of the display. Figure 5-6. Display adjustment screen. © 2012 SeaStar Solutions Optimus Operations Manual, Rev. D...
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  • Page 35: System Faults & Hazards

    The yellow warning triangle will remain on the CANtrak display screen until a technician has remedied the issue. © 2012 SeaStar Solutions Optimus Operations Manual, Rev. D...

  • Page 36: System 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. © 2012 SeaStar Solutions Optimus Operations Manual, Rev. D...

  • Page 37: Limp Home

    ANY of the engines. The CANtrak will instruct the operator to manually center the engines using the service valves, then proceed to port immediately using the shift and throttle controls to steer the vessel. Figure 6-2. Limp home instructions, all steering disabled. © 2012 SeaStar Solutions Optimus Operations Manual, Rev. D...
  • Page 38 The CANtrak will instruct the operator to realign the non-responsive engine(s), tilt it out of the water and proceed to port immediately using the responsive engine(s). Figure 6-3. Limp home instructions, no steering on one engine. © 2012 SeaStar Solutions Optimus Operations Manual, Rev. D...

  • Page 39: Warning Fault Handling

    In rare cases there may be multiple Warning faults at the same time. You can view a list of all active warning faults by selecting “Active Warnings” from the Diagnostics (DIAG) screen. © 2012 SeaStar Solutions Optimus Operations Manual, Rev. D...
  • Page 40 Figure 6-5. Run screen with system warning. Some system faults may result in a reduced steering response warning. This means that the system will continue to steer normally but may respond more slowly. © 2012 SeaStar Solutions Optimus Operations Manual, Rev. D...

  • Page 41: System Fault Handling - Example

    Description Zone Describes what system has System Status Zone done to react to fault Fault Handling Tells the User how Instructions Zone to proceed Figure 6-6. Sample warning fault. © 2012 SeaStar Solutions Optimus Operations Manual, Rev. D...

  • Page 42: Cantrak Loss Of Display

    3. Open Steering Service Valve of affected cylinder. 4. Turn affected engine(s) fully away from other(s). 5. Close Steering Service Valve. 6. Fully tilt the affected engine(s) and switch off. 7. Return to port with remaining engine(s). © 2012 SeaStar Solutions Optimus Operations Manual, Rev. D...

  • Page 43: Buzzer

    SeaStar EPS steering fluid when the boat is returned to port. In the event of an extreme emergency, any non-toxic, non-flammable fluid may provide temporary steering. WARNING NEVER USE BRAKE FLUID IN THE STEERING SYSTEM. © 2012 SeaStar Solutions Optimus Operations Manual, Rev. D...
  • Page 44 This page left intentionally blank. 6-10 © 2012 SeaStar Solutions Optimus Operations Manual, Rev. D...

  • Page 45: Maintenance

    3. Check for mechanical play or slop throughout steering system, correct as required. 4. Check for signs of corrosion. If corrosion is present contact your dealer or SeaStar Solutions. 5. Check all electrical cables for chafing and wear. © 2012 SeaStar Solutions...
  • Page 46 MUST BE COMPLETED BY A QUALIFIED MECHANIC WITH A WORKING KNOWLEDGE OF THE SYSTEM. GREASE SUPPORT ROD, TILT TUBE & SUPPORT BRACKET HOLE GREASE SUPPORT ROD, TILT TUBE & SUPPORT BRACKET HOLE Figure 7-1. Grease points on cylinder mounts. © 2012 SeaStar Solutions Optimus Operations Manual, Rev. D...

  • Page 47: Troubleshooting

    SOLUTIONS OFFERS THE FOLLOWING AS A GUIDE ONLY AND IS NOT RESPONSIBLE FOR ANY CONSEQUENCES RESULTING FROM INCORRECT DISMANTLING REPAIRS. Optimus EPS steering will provide years of safe reliable performance with a minimum of service if properly installed. Optimus steering systems have been designed with protection against over-pressure situations, with the inclusion of a pressure relief valve and circuit breakers, to minimize the possibility of total loss of steering.
  • Page 48 This page left intentionally blank. © 2012 SeaStar Solutions Optimus Operations Manual, Rev. D...

  • Page 49: Replacement Parts

    The Optimus Steering System is designed for use with genuine SeaStar Electronic Power Steering Fluid. Quart HA5482 For a comprehensive listing of part numbers, please refer to the Optimus 50 Installation Manual, part no. 682100. © 2012 SeaStar Solutions Optimus Operations Manual, Rev. D...
  • Page 50 This page left intentionally blank. © 2012 SeaStar Solutions Optimus Operations Manual, Rev. D...

  • Page 51: 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 52 This page left intentionally blank. 10-2 © 2012 SeaStar Solutions Optimus Operations Manual, Rev. D...

  • Page 53: Appendix A - Specifications

    APPENDIX A – SPECIFICATIONS OPTIMUS EPS SYSTEM SPECIFICATIONS (Based on EPSK1200 Twin Engine Core Pack) Operating Voltage: 12 VDC Maximum System Pressure: 1200 PSI # of wheel turns: Variable from 3.5 to 8 Typical Average Current Draw: ~6 to 8 Amps Oil Type: SeaStar Electronic Power Steering Fluid ©...

  • Page 54: Appendix B - Trailering And Storage

    APPENDIX B – TRAILERING AND STORAGE When trailering or storing a boat equipped with an Optimus EPS system, install the steering lock clips to all steering cylinders as shown below. These clips keep the engines from drifting, preventing contact with other components which may result in scuffing or cowling damage.
  • Page 56 SEASTAR SOLUTIONS 3831 NO. 6 ROAD RICHMOND, B.C. CANADA V6V 1P6 FAX 604-270-7172 www.seastarsolutions.com ISO 10592 © 2012 MARINE CANADA ACQUISITION INC. DBA SEASTAR SOLUTIONS PRINTED IN CANADA FORM NO. 682101 06/14 REV. D...

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