Dometic Optimus i7800 User manual

[REVISION E] Form No. 710351 | ©2021 Dometic
i7700 / i7800 Shi & Throttle System
Installation manual — Book 77
EN
SEASTAR ELECTRONIC
SHIFT & THROTTLE (EST)

All information, illustrations and specications in this manual are
based on the latest information available at the time of publishing.
The illustrations used in this manual are intended as representative
reference views only. Moreover, because of our continuous product
improvement policy, we may modify information, illustrations and/or
specications to explain and/or exemplify a product, service or
maintenance improvement. We reserve the right to make any
change at any time without notice.
©2021 Dometic.
All Rights Reserved. This document, subject matter and all information
herein is the sole, exclusive and condential property of Dometic
and shall not be disclosed, copied, reproduced or used in whole or
in part for any purpose other than as specically authorized in
writing by Dometic.
is a registered trademark of the American Boat &
Yacht Council (http://www.abycinc.org)
NMEA 2000® is a registered trademark of the National Marine
Electronics Association.
Optimus, Optimus 360, SeaStar, and BayStar are all trademarks
of Dometic.
Marine Canada Acquisition Inc. DBA SEASTAR SOLUTIONS is
referred to as Dometic throughout this publication.
NOTICE

i
IMMEDIATE HAZARDS WHICH, IF NOT ACTED UPON, WILL RESULT
IN SEVERE PERSONAL INJURY OR DEATH.
DANGER
HAZARDS OR UNSAFE PRACTICES WHICH, IF NOT ACTED UPON,
COULD RESULT IN SEVERE PERSONAL INJURY OR DEATH.
WARNING
Hazards or unsafe practices which COULD result in minor injury or
product or property damage.
CAUTION
Throughout this publication, Dangers, Warnings and Cautions
(accompanied by the International Hazard Symbol )are used to
alert the user to special instructions concerning a particular service
or operation that may be hazardous if ignored or performed
incorrectly or carelessly. Observe Them Carefully!
These safety alerts alone cannot eliminate the hazards that they
signal. Strict compliance with these special instructions during
installation, operation, and maintenance, plus common sense
operation, are important measures to prevent accidents.
This book contains the information required to install and setup the
i7X00 EST System.
It is to be delivered to the customer when installation is complete.
Thank you for choosing an i7X00 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.
Information which is important to proper use or maintenance, but is
not hazard-related.
NOTICE
About this Book
Notice to the Installer

ii
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INDEX
1.0 Safety .................................................................................... 1-1
1.1 Safety Labels ................................................................... 1-3
2.0 System Overview ..................................................................... 2-1
2.1 System Description ........................................................... 2-1
2.2 System Overview Diagram ................................................. 2-2
3.0 Installation ............................................................................. 3-1
3.1 Important Information/Technical Support Contact ............... 3-1
3.2 Installing the Control Head ................................................ 3-1
3.2.1 Control Head Trim Switch Connection ......................... 3-1
3.3 Installing the Actuators ..................................................... 3-3
3.3.1 LocationandIdentication ........................................ 3-3
3.3.2 Mounting ................................................................ 3-3
3.3.3 Mechanical Cables ....................................................3-3
3.4 Electrical Connections...................................................... 3-4
3.4.1 Power Connection ................................................... 3-4
3.4.2 Start-in-Gear Protection ........................................... 3-4
3.4.3 Ignition Source ........................................................ 3-5
3.5 CAN2 Harness Connections ............................................. 3-6
3.6 Analog Tachometer ........................................................... 3-9
3.6.1 NMEA Gateway Connection ..................................... 3-10
4.0 System Setup ......................................................................... 4-1
4.1 Actuator Setup ................................................................. 4-1
   4.1.1 ActuatorConguration .............................................. 4-1
4.1.2 Actuator Adjustment ................................................ 4-4
4.1.2.1 Shift Adjustment .......................................... 4-4
4.1.2.2 Shift Adjustment .......................................... 4-5
4.2 Control Head Setup ......................................................... 4-6
5.0 Sea Trial .............................................................................. 5-1
5.1 Shift Performance ............................................................. 5-1
5.2 Throttle Performance ........................................................ 5-1
5.3 Control Head Adjustments ................................................. 5-1
5.4 Conclusion of Sea Trial ...................................................... 5-2
6.0 System Faults & Hazards ......................................................... 6-1
6.1 Hazard Denitions ............................................................ 6-1
6.1.1 Danger .................................................................... 6-1
6.1.2 Warning .................................................................. 6-1
7.0 Warranty .............................................................................. 7-1
7.1 Statement of 2-Year Limited Warranty ................................. 7-1
7.2 Return Goods Procedure .................................................... 7-2
7.3 Technical Support .............................................................. 7-2
iii

Appendix A – Mounting Templates .................................................... A-1
A.1 Control Head – Dual Lever. ................................................ A-1
A.2 Control Head – Single Lever. .............................................. A-2
A.3 Actuator – Dimensions. ..................................................... A-3
A.4 Single Lever Interface – Dimensions. ................................. A-3
Appendix B – Using the Color CANtrak Display ................................... B-1
B.1 Display Navigation ............................................................ B-1
B.2 Initial Startup ................................................................... B-2
B.4 Unlocking the Dealer Menu ............................................... B-2
B.4 Menu Structure ............................................................... B-3
B.5 First Time Service Tool Users ........................................... B-4
Appendix C – Setup with Datalink ..................................................... C-1
C.1 Dealer Tools ......................................................................C-1
C.2 Connection........................................................................C-1
C.3 Navigating Datalink ........................................................... C-3
C.4 Actuator Setup ................................................................ C-5
   C.4.1 Step1–ActuatorCongurationUsingDatalink ......... C-5
C.4.2 Step 2 – Cable Installation and Adjustment ............... C-7
C.4.3 Step 3 – Final Setup and Actuator Adjustment ........... C-7
C.5 Control Head Setup ......................................................... C-9
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
iv

1.0 SAFETY INFORMATION
THE SAFETY INFORMATION PROVIDED HERE IS INTENDED TO
INFORM YOU OF THE DANGERS THAT MAY BE PRESENT BEFORE,
DURING, AND AFTER INSTALLATION. IT IS CRITICAL THAT YOU
READ AND UNDERSTAND THIS INFORMATION.
WARNING
Safe operation of the shift and throttle system depends upon proper
installation and maintenance of the system, and the common sense,
safe judgment, knowledge, and expertise of the operator. Every
installer and operator of the i7X00 system should know the following
requirements before installing or operating the system. If you have
any questions regarding any of these warnings, contact Dometic.
1. Read and understand all installation and user's manuals provided
with the i7X00 components.
2. Ensure that all components required to complete the installation
are on hand (including cables, harnesses, and the proper tools).
3. SeaStar and i7X00 components are highly engineered and safety
tested to ensure system integrity. DO NOT substitute any component.
Substitution with non-SeaStar or non-i7X00 components may
compromise system safety, performance, and reliability.
Before installation
1. Check that there is no interference between the control head
levers and the steering wheel or any other dash-mounted
components.
2. Operate the trim/tilt switch on the control head lever and verify that
the engines tilt in the expected direction.
3. Check that the mechanical cable bends are smooth and have an
appropriate minimum radius.
After Installation
1. Install system components as directed in this manual. Some
component parts and kits may be supplied with additional
installation instructions—refer also to these instructions.
2. SeaStar and i7X00 components are highly engineered and safety
tested to ensure system integrity. DO NOT substitute any component.
Substitution with non-SeaStar or non-i7X00 components may
compromise system safety, performance, and reliability.
3. If an instruction is unclear, contradictory, or you are otherwise
uncertain how to proceed, do not guess. Call Dometic technical
support.
During Installation
1-1

Perform a system inspection as outlined below.
1. Check steering uid level.
2. Verify immediate steering response when turning steering wheel(s).
3. Inspect all steering hoses, ttings, mechanical cables, and
electrical harnesses for wear, kinks, or leaks.
4. Check for binding, loose, worn or leaking steering or shift/throttle
control components.
5. Verify proper shift and throttle response for all control handles.
Prior to every use
1. WEAR A COAST GUARD-APPROVED PERSONAL FLOTATION
DEVICE (PFD).
2. ATTACH ENGINE SHUT-OFF CORD (LANYARD) TO YOUR PFD.
3. Never allow anyone who is not familiar with the operation of the
shift and throttle system to operate the boat at any time.
4. If boat is equipped with multiple helms, ensure that only one is
used at a time.
5. Know and adhere to all applicable federal, state, and municipal laws
and regulations that govern boating in your area.
During use
The i7X00 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.
After use
DO NOT OPERATE BOAT IF ANY COMPONENT IS NOT IN PROPER
WORKING CONDITION.
WARNING
DO NOT OPERATE BOAT IF ANY COMPONENT IS NOT IN PROPER
WORKING CONDITION.
WARNING
FAILURE TO COMPLY WITH ANY WARNING, NOTICE OR CAUTION
MAY LEAD TO LOSS OF STEERING OR SHIFT/THROTTLE CONTROL
RESULTING IN A COLLISION AND/OR EJECTION FROM THE BOAT
LEADING TO PROPERTY DAMAGE, PERSONAL INJURY AND/OR
DEATH.
WARNING
1-2

1.1 Safety Labels
THE LABELS BELOW SHOULD CALL ATTENTION TO THE POSSIBLE
HAZARDS ASSOCIATED WITH THE EQUIPMENT SHOWN LATER IN
THIS MANUAL.
WARNING
Component labels
Figure 1-1. Actuator decal, PID# 277045.
Figure 1-2. Actuator decal sheet, PID# 277044.
The labels shown below are found on the i7X00 actuators .
1-3

1-4
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2-1
SeaStar i7X00 is an electromechanical system that replaces a
traditional cable-operated engine remote control with an electronic
control. Shift and throttle settings are sent over a serial data network
to electro-mechanical actuators, where they are converted to cable
motion. The elimination of mechanical cables to the control head
simplies multi-station installations, especially when a station is
installed onto a ybridge or tower that is removed for shipping. The
system supports the installation of up to three control heads.
The i7X00 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. Each device
(node) on the network can send and receive data using specially
formatted messages. The ability to reliably communicate data between
devices is what enables the functionality of i7X00.
i7X00 implements the high-speed CAN protocol using DeviceNet
harnesses and connectors. We refer to the network as CAN2 in the
documentation to distinguish it from other CAN protocols used on
SeaStar products.
Control Head
The control head looks much like a conventional mechanical remote
control, but it is an electromechanical device that converts lever
position into digital messages that are sent over CAN2 to the shift
and throttle actuators. The control head features adjustable lever
feel, status lights, a synchronous trim switch (optional), and control
buttons for added functionality.
Shift and Throttle Actuator
The actuators are electromechanical devices that receive digital
commands on the CAN2 network and convert these commands into
movement of a mechanical cable for gear selection and throttle
control. The actuators are universal, and are easily setup for their
specic application using the CANtrak display tool. They can also
provide the start-in-gear protection required by the U.S. Coast Guard.
2.1 System Description
2.0 SYSTEM OVERVIEW

2-2
2.2 System Overview Diagram
DUAL STATION/DUAL ENGINETRIPLE STATION/DUAL ENGINE
1. Control Head
2. Throttle/Shift Actuator
3. CAN Network Bus
1
2 3
1
2222 3
1
1
1 1
3
SINGLE STATION/SINGLE ENGINE
Figure 2-1. System Overview.

3-1
To assist with the installation and maintenance of this Electronic Shift
and Throttle system Dometic recommends that:
• Installation MUST be performed by a Dometic authorized installer.
• Read and understand ALL installation manuals before starting
the installation process. Knowing the correct order of installation
and location of components will drastically reduce installation
time as well as prevent common installation errors.
• Read and understand ALL Safety Information that is noted in
this manual and ALL other Installation Manuals.
If any problems are found before, during or after the installation of the
steering system, please contact Technical Support for assistance:
Technical Support
Web: www.dometic.com
E-mail: [e-mail]
Phone: [phone]
3.1 Important Information/Technical
Support Contact
3.0 INSTALLATION
Mount the control head on the dash in an area which will allow for
convenient access during use. Whenever possible, it should be
mounted in a location to minimize water spray. Ensure that the control
handle(s) can be moved throughout the complete range of motion
in both forward and reverse without interference. ABYC standard
P-14 calls for a minimum of 2-1/2" (64 mm) clearance between the
control lever and the steering wheel rim under all possible lever
and wheel positions.
The control head requires one of the dash cutout templates in
Appendix A.
Control Head Trim Switch Connection (Optional)
The control head includes a single trim/tilt switch on the end of the
port handle. This switch can be wired to provide synchronous trim/
tilt control of all engines. If independent trim/tilt is desired use tilt/
trim kit HA5491 (for twin engine congurations) and connect the
wiring as shown in Figure 3-1.
3.2 Installing the Control Head
3.2.1

3-2
Figure 3-1. Trim switch wiring.
ALL ELECTRICAL CONNECTIONS AND HARNESS MUST COMPLY
WITH ABYC WIRING STANDARDS, BE RATED FOR 105°C (221°F),
AND COMPLIANT WITH SAEJ1128.
WARNING
CONTROL
HEAD
DIODE PACKS
(INCLUDED IN HARNESS)
GN RD BL BL / WH
RD / WH GN / WH
TO SECOND
STATION
(OPTIONAL)
SPLICE
TRIM HARNESS 6345518
(INCLUDED IN TILT/TRIM KIT HA5491)
HA5491 DUAL ENGINE
TILT/TRIM SWITCH KIT
AVAILABLE SEPARATELY
IF SUPPLIED BY OTHERS,
SWITCHES TO BE DP/DT,
MOMENTARY CONTACT
ON – OFF – ON
36
25
14
36
25
14
PORT ENGINE
TRIM HARNESS
TILT/TRIM KIT
HA5491
VIEWED FROM REAR OF SWITCHES
PORT SWSTBD SW
GN RD BL
STBD ENGINE
TRIM HARNESS
PORT
ENGINE
TRIM
GN RD BL
STBD
ENGINE
TRIM
WIRE COLOR LEGEND
TRIM UP
TRIM DOWN
POWER
BLUE
GREEN
RED

3-3
Location and Identication
Consider the following when locating and mounting the actuators:
• The mechanical cable run should be as short, straight, and direct
as possible.
• The mechanical cables need adequate clearance where they exit
the actuators and enter the engines. Be aware of the minimum
bend radius of the cables you are using.
• The mounting location should be as dry as possible.
• The actuators require power and network connections.
• The actuators need to be accessible for emergency manual
override. This means that the cover should be easily removed and
the actuator identication decals must be clearly visible.
The actuators are congured identically from the factory so they can be
used on either the port or the starboard engine. You will assign the
identity of each actuator later when you congure the actuators. Note
the serial numbers of the actuators and the engine side they control.
3.3 Installing the Actuators
3.3.1
3.3.2 Mounting
The actuator chassis has mounting holes on three surfaces to make
it easy to orient and mount. (See page A-3 for mounting dimensions.)
Use one of the following fastening methods:
• M6 machine screws with nuts and washers
• M6 machine screws into a threaded metal mounting surface
• #12 or #14 wood screws
Use four fasteners for each actuator. If you’re mounting to an uneven
surface it may be necessary to shim some mounting points to
prevent twisting of the actuator chassis when the fasteners are fully
tightened.
3.3.3
NOTICE
Mechanical Cables
Once you have located and mounted the actuators you can rough in
the mechanical cables, but don’t make any connections at this time.
The decal sheet included with each actuator contains labels to identify
the cable by engine and function. Label the cables at both ends to
simplify the cable installation later.
We recommend SeaStar Xtreme cables, P/N CCX633xx. These
cables have a minimum bend radius of 8”.
Do not connect cables to the actuators at this time.
Actuator Serial Number
Port
Starboard
Table 3-1. Actuator serial numbers.

3-4
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 system wire colors.
3.4 Electrical Connections
Power Connection
The actuator harness contains 6’ leads for power connection.
1. Connect the black wire to the battery ground, either directly to
the battery terminal or to a ground bus.
2. Connect the red wire to a 12VDC source through a 20A circuit
breaker or fuse. The preferred source is the engine battery or a
battery switch.
If you need to extend the leads, follow ABYC codes and practices.
Dometic recommends a minimum wire size of 10AWG. See the
schematic wiring diagram (gure 3-9).
3.4.1
Start-in-Gear Protection
The US Coast Guard requires start-in-gear protection to prevent an
engine from starting when forward or reverse gear is engaged. If
your engine doesn’t already have this feature, the i7X00 actuator
can provide start-ingear protection that meets the requirements of
33CFR part 183, subpart L.
If your engine already has start-in-gear protection it is recommended
to connect the i7X00 actuator's start-in-gear protection switch for
redundancy. This will also provide a redundant ignition source to the
actuator in the event of an ignition source failure.
To use the start-in-gear protection intercept the start wire between
the ignition switch and the engine start solenoid and connect the
actuator switch leads as follows:
Yellow: Connect to ignition switch
Yellow with red tracer: connect to engine start solenoid.
The polarity of the start-in-gear protection connections is important.
Do not reverse the leads.
Table 3-2 lists the ignition start system wire colors typically used
by the major outboard manufacturers. This table is a guide only;
always consult the manufacturer’s documentation for correct wire
identication.
Cap and tie back the leads if you do not need to use the actuator’s
start-in-gear protection.
3.4.2
NOTICE
NOTICE

3-5
Figure 3-2.
Figure 3-3.
Option 1 – single ignition source
Option 2 – splice into an existing engine ignition wire
IGNITION
SOURCE TO ACTUATOR
MOLEX PERMA-SEAL BUTT SPLICE
P/N 0191640014 OR EQUIVALENT
(NOT INCLUDED)
IGNITION
SOURCE
TO ACTUATOR
TO ENGINE
MOLEX PERMA-SEAL STEP DOWN BUTT
SPLICE P/N 0191640043 OR EQUIVALENT
(NOT INCLUDED)
TWIST WIRES
TOGETHER
Ignition Source
The actuator harness contains a violet (purple) ignition lead. Connect
this to the ignition switch for the engine the actuator is controlling.
The wire should have 12VDC when the engine is switched on.
3.4.3

3-6
Figure 3-4 and gure 3-5 show the CAN2 network wiring for single
and dual station applications. All tees must be secured using both
screw holes, and the cable drops at each tee must be appropriately
secured and strain-relieved to prevent any pull on the tees. See
gure 3-6 for proper tee installation example.
The CAN2 network must contain two, and only two, terminating
resistors. One terminator should be installed at each end of the
network backbone.
3.5 CAN2 Harness Connections
FAILURE TO SECURE HARNESS MAY RESULT IN HARNESS WEAR,
CAUSING LOSS OF THROTTLE CONTROL, PROPERTY DAMAGE,
PERSONAL INJURY AND/OR DEATH.
WARNING
Figure 3-4. CAN2 wiring diagram, triple station, twin engine.
SHIFT/THROTTLE ACTUATORS
2 x NETWORK TEES CM10060
3' PIGTAIL3' PIGTAIL
3' PIGTAIL
CM20029
CM100XX
(Where XX is the length in feet required.
6', 12' and 20' lengths are included in the kit.)
MALE
TERMINATOR
CM10051
FEMALE
TERMINATOR
CM10052
CM10060CM10060CM10060
TEMPORARILY
INSTALLED
3' PIGTAIL
MAIN STATION
CONTROL HEAD
OPTIONAL
SECOND STATION
CONTROL HEAD
OPTIONAL
THIRD STATION
CONTROL HEAD
3' PIGTAIL
CANtrak SETUP
TOOL EPSK1207
HATCH OR CONSOLE MOUNTED COMPONENTS
DASH MOUNTED COMPONENTS

3-7
Figure 3-5. CAN2 wiring diagram, triple station, single engine.
SHIFT/THROTTLE ACTUATOR
1 x NETWORK TEE CM10060
3' PIGTAIL
MALE
TERMINATOR
CM10051
FEMALE
TERMINATOR
CM10052
MAIN STATION
CONTROL HEAD
3' PIGTAIL
OPTIONAL
THIRD STATION
CONTROL HEAD
HA
TCH OR CONSOLE
MOUN
TED COMPONENTS
DASH MOUNTED COMPONENTS
CM100XX
(Where XX is the length in feet required.
6', 12' and 20' lengths are included in the kit.)
* The CE42100 harness contains three flying leads with female bullet connectors.
These leads are not used in the i7X00 system and should be left unconnected.
3' PIGTAIL
2' PIGTAIL2' PIGTAIL2' PIGTAIL
OPTIONAL
SECOND STATION
CONTROL HEAD
CE42100* CE42100* CE42100*
CM20029
TEMPORARILY
INSTALLED
CANtrak SETUP
TOOL EPSK1207
3' PIGTAIL

TIP: Once you've tightened the
nuts on the tees, mark them with
a permanent marker as shown in
gure3-6.Thismakesiteasyto
inspect them for tightness later.
3-8
SCREWS IN ALL
MOUNT HOLES
CM20064
Figure 3-7. Alternative CAN2 6-port hub connection (available separately).
Figure 3-6. Correct CAN2 tee installation example.
FAILURE TO SECURE HARNESS MAY RESULT IN HARNESS WEAR,
CAUSING LOSS OF THROTTLE CONTROL, PROPERTY DAMAGE,
PERSONAL INJURY AND/OR DEATH.
WARNING
SCREWS IN ALL
MOUNT HOLES
NOTE: TEES MAY NOT LOOK
EXACTLY AS SHOWN
EACH CABLE
APPROPRIATELY
SECURED AND
STRAIN RELIEVED
CLOSE TO TEES
NO PULLING
ON TEES
ALL NUTS DOUBLE
CHECKED FOR TIGHTNESS
AND MARKED
CAUTION Do not connect anything other than SeaStar components to the
CAN2 network.