Seastar Solutions Optimus 360 Instruction Manual

Joystick Control System for
Outboard Powered Vessels
OPERATION INSTRUCTIONS
AND USER’S MANUAL
Before you do it your way,
please try it our way
www.seastarsolutions.com
61
SIXTY ONE
ISO 9001

All information, illustrations and specifications 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
specifications to explain and/or exemplify a product, service or
maintenance improvement. We reserve the right to make any
change at any time without notice.
©2012 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).
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
SeaStar Solutions.
Evinrude, Suzuki, Yamaha, and Yanmar are trademarks of their
respective holders.
California
Proposition 65 Warning
Battery posts, terminals, and related
accessories contain lead and lead
compounds, chemicals known to the
state of California to cause cancer
and reproductive ham.
Wash hands after handling.

© 2012 SeaStar Solutions Optimus 360 User’s Manual, Rev. C i
This User’s manual contains the information you need to safely operate
and maintain your vessel control system. It must remain on the boat.
Thank you for choosing an OptimusTM 360 Joystick Control System by
SeaStar Solutions. You have chosen a state of the art vessel control
system that will provide years of effortless and trouble free steering
performance.
About this Book
Notice to the Operator
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
Information which is important to proper use or maintenance, but is
not hazard-related.
NOTICE
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.
Failure to adhere to these notices may result in the loss of steering
and shift/throttle control, leading to possible ejection from the
vessel, causing property damage, injury and/or death.

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© 2012 SeaStar Solutions Optimus 360 User’s Manual, Rev. C iii
INDEX
Abbreviations ..................................................................... v
1.0 Safety Information........................................................... 1-1
1.1 Safety Labels ............................................................ 1-2
2.0 Introduction .................................................................... 2-1
2.1 Welcome .................................................................. 2-1
2.2 Optimus 360 System Overview................................... 2-1
2.3 Optimus 360 System Diagrams .................................. 2-2
3.0 Component Identification................................................. 3-1
3.1 Electronic Helm(s) (EPS System)................................. 3-1
3.2 Control Head (EST System) ........................................ 3-2
3.3 Joystick .................................................................... 3-3
3.4 CANtrak Display ........................................................ 3-4
3.5 Circuit Breakers for Optimus 360 System and
Shift and Throttle Control System ............................... 3-4
3.6 Pump Control Module (PCM)....................................... 3-5
3.7 Hydraulic Steering Pumps .......................................... 3-5
3.8 SmartCylinders ......................................................... 3-6
3.9 Steering Service Valves.............................................. 3-6
3.10 Shift and Throttle Actuators .................................... 3-10
4.0 Steering System Operation ................................................ 4-1
5.0 Control Head Operation...................................................... 5-1
5.1 Identification ............................................................. 5-2
6.0 Joystick Operation............................................................. 6-1
6.1 Joystick Fundamentals............................................... 6-1
6.2 Joystick Tips ............................................................. 6-5
6.3 Joystick Operation Examples ...................................... 6-6
7.0 CANtrak Display ............................................................... 7-1
7.1 Purpose.................................................................... 7-1
7.2 CANtrak Display Navigation ........................................ 7-2
7.3 CANtrak Display Map – All Helms Active ...................... 7-3
7.4 Display Screens ........................................................ 7-4
7.4.1 All Helms Active ............................................... 7-4
7.4.2 Adjust (ADJ) Screen .......................................... 7-5
7.4.3 Display (DISP) Screen ....................................... 7-6
8.0 First Time Use ................................................................... 8-1
8.1 Control Head Adjustments ......................................... 8-1

© 2012 SeaStar Solutions Optimus 360 User’s Manual, Rev. C
iv
8.2 Initial Start Up .......................................................... 8-2
8.3 System Inspection..................................................... 8-4
8.4 Installation Checks.................................................... 8-6
8.5 Initial Sea Trial .......................................................... 8-7
9.0 System Use....................................................................... 9-1
9.1 Before Each Use ....................................................... 9-1
9.2 Multiple Station Boats ............................................... 9-1
9.3 Autopilot Operation.................................................... 9-2
10.0 System Faults & Hazards ............................................... 10-1
10.1 Hazard Definitions.................................................. 10-1
10.1.1 Danger ........................................................ 10-1
10.1.2 Warning ....................................................... 10-2
10.1.3 Caution........................................................ 10-2
10.2 System Fault Handling............................................ 10-3
10.2.1 Danger Fault Handling................................... 10-3
10.2.2 Limp Home .................................................. 10-4
10.2.3 Warning Fault Handling ................................. 10-7
10.2.4 System Fault Handling – Example .................. 10-9
10.2.5 CANtrak Loss of Display................................ 10-9
10.3 Buzzer................................................................. 10-11
10.4 Reduced Performance .......................................... 10-11
10.5 Steering Fluid Loss............................................... 10-11
11.0 Maintenance ................................................................. 11-1
12.0 Troubleshooting............................................................. 12-1
13.0 Replacement Parts........................................................ 12-2
13.1 SeaStar Electronic Power Steering Fluid................... 12-2
14. Warranty ......................................................................... 14-1
14.1 Statement of Limited Warranty................................ 14-1
14.2 Return Goods Procedure ....................................... 14-1
APPENDIX A – Specifications................................................. 14-2
APPENDIX B – Station Select Protection ................................. B-1
APPENDIX C – Trailering and Storage ....................................... B-2

© 2012 SeaStar Solutions Optimus 360 User’s Manual, Rev. C v
ABYC American Boat & Yacht Council
AP Autopilot
AUX Auxiliary
BAT Battery
CAN Controller Area Network
CAN Bus Controller Area Network (data) Bus. (A cable of wires that
carry digital signals and power between electronic modules)
ENG Engine
EPS Electronic Power Steering
EST Electronic Shift and Throttle
FWD Forward
GND Ground
HI High
LED Light Emitting Diode
Lo Low
MPH Miles Per Hour
N Neutral
NMEA National Marine Electronics Association
NMEA 2000® A protocol for digital communication on a CAN Bus
NTW Neutral Throttle Warmup
N/C No Connection
PCM Pump Control Module
PTS Power Train Sync
R Reverse
RPM Revolutions Per Minute
STBD Starboard (right when facing forward)
SW Switch
TM Trolling Mode
WOT Wide Open Throttle
Note: Some abbreviations not listed here may be found in their
respective sections.
ABBREVIATIONS
The following abbreviations are used in this manual:

© 2012 SeaStar Solutions Optimus 360 User’s Manual, Rev. C
vi
DEFINITIONS
Conventional
Steering Control
This is the standard type of steering that has
been used on boats for many years. The steering
wheel is the only means of control.
Conventional Shift
and Throttle
The type of shift and throttle control where
standard control head levers allows the
engine gear selection and throttle control.
Electronic Shift
and Throttle
There are two types of electronic shift and
throttle (EST) system:
1) On engines that use mechanical levers to
control shift and throttle, instructions from
an electronic control head are transmitted
to electric actuators, which move mechanical
control cables accordingly.
This type of EST system may also be called an
MST or remote EST system to differentiate it.
2) Many modern engines have built-in actuators
to control shift and throttle. Instructions from
an electronic control head are transmitted
directly to the engine control computer.
This type of EST system may sometimes be
called an OEM EST or integrated EST system
to differentiate it.
This manual describes the operation of the
first type of EST system. When calling for
technical support, please make it clear which
type of system you are using.
Joystick Control A single handle joystick control device that
integrates the steering, the gear shift, and the
throttle control for multiple engines into one
easy-to-use device to provide docking control
of the vessel.

© 2012 SeaStar Solutions Optimus 360 User’s Manual, Rev. C 1-1
1.0 SAFETY INFORMATION
THE SAFETY INFORMATION PROVIDED BELOW IS INTENDED TO
INFORM YOU OF THE DANGERS THAT MAY BE PRESENT BEFORE,
DURING AND AFTER USE. IT IS CRITICAL THAT YOU READ AND
UNDERSTAND ALL THE POINTS NOTED.
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. Every installer and operator
of the steering system should know the following requirements before
installing or operating the steering system.
If you have any questions regarding any of these warnings, contact
SeaStar Solutions.
Perform a system inspection as outlined below. Refer to Section 8.3
for further details.
1. Check steering fluid level in all steering pumps.
2. Verify immediate steering response when turning steering
wheel(s).
3. Inspect all steering hoses, fittings and mechanical and electrical
cables 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 levers.
6. Verify that no alarms or warnings are shown on the CANtrak
display.
DO NOT OPERATE BOAT IF ANY COMPONENT IS NOT IN PROPER
WORKING CONDITION.
Prior to every use
To reduce the risk of severe injury or death:
1. Always wear a Coast Guard Approved personal flotation device
(PFD) and use an engine shut-off cord (lanyard).
2. Read and understand this User’s manual and the Quick Reference
Card provided with your vessel control components.
3.
SeaStar and Optimus components are highly engineered and safety
tested to ensure system integrity. DO NOT substitute any component.
Substitution with non-SeaStar or non-Optimus components may
compromise system safety, performance, and reliability.
WARNING
WARNING THE OPTIMUS 360 SYSTEM MUST ONLY BE INSTALLED BY AN
AUTHORIZED DEALER OR OEM.
WARNING

© 2012 SeaStar Solutions Optimus 360 User’s Manual, Rev. C
1-2
Rinse off the SmartCylinders thoroughly, using only fresh, clean water.
DO NOT rinse the PCM, pumps, actuators, or any other component
of the Optimus system.
DO NOT use acetone, or cleaners containing ammonia, acids, or any
other corrosive ingredients, on any Optimus component. Use only a
damp cloth, or a mild detergent if necessary.
Maintain your Optimus 360 System as directed in Section 11 of this
manual.
Keep our waters clean for all current and future users. Dispose of all
fluids in accordance with your local regulations.
After use
Maintenance
1. WEAR A COAST GUARD-APPROVED PERSONAL FLOTATION
DEVICE (PFD).
2. Attach engine shut-off cord (lanyard) to your pfd.
3. Never allow anyone not familiar with the operation of the vessel
control system to operate the boat at ANY time.
4. Know and adhere to all applicable federal, state, and municipal
laws and regulations that govern boating in your area.
DO NOT OPERATE BOAT IF ANY COMPONENT IS NOT IN PROPER
WORKING CONDITION.
During use
1.0 Safety information (continued)
WARNING

© 2012 SeaStar Solutions Optimus 360 User’s Manual, Rev. C 1-3
NOTE: THE LABELS BELOW SHOULD CALL ATTENTION TO THE
POSSIBLE HAZARDS ASSOCIATED WITH THE EQUIPMENT SHOWN
LATER IN THIS MANUAL (SEE SECTION 3.1)
Hydraulic Pump Labels
CAUTION
HOT
Figure 1-2. Hydraulic pump labels.
1.1 Safety Labels
WARNING
Control Head Label
WARNING
PID# 682050
Figure 1-1. Optimus 360 Start-In-Gear advisory decal.

© 2012 SeaStar Solutions Optimus 360 User’s Manual, Rev. C
1-4
Pump Control Module
(PCM) Labels
Safety Labels (continued)
Figure 1-3. PCM labels.
SmartCylinder Labels
Figure 1-4. SmartCylinder labels.

© 2012 SeaStar Solutions Optimus 360 User’s Manual, Rev. C 1-5
Safety Labels (continued)
Steering Service
Valve Labels
To be installed close to the service valve.
Figure 1-5. Steering service valve labels.
PID# 682049
A B
Insert appropriate
F, R, IDLE or INCREASE
decal here. Consult
installation manual.
Insert appropriate
F, R, IDLE or INCREASE
decal here. Consult
installation manual.
USING THE ACTUATOR OVERRIDE SYSTEM MAY SEVERELY LIMIT
YOUR BOATS CONTROL. IT SHOULD ONLY BE USED IN AN EMERGENCY
IF YOU ARE UNABLE TO CALL FOR ASSISTANCE. ALWAYS TRY
ALTERNATIVE CONTROLLING DEVICES. PROCEED WITH EXTREME
CAUTION, READ USER’S MANUAL, ALWAYS WEAR A PFD & LANYARD.
MANUAL OVERRIDE OPERATION
ACTUATOR
1. MOVE ALL LEVERS AIN THE DIRECTION OF ARROW TO
DISENGAGE DRIVE MECHANISM.
2. ROTATE "SHIFT" LEVER BCLOCKWISE, OR COUNTER-
CLOCKWISE TO MOVE CONTROL CABLE INTO DESIRED GEAR.
3. CONFIRM YOUR DESIRED GEAR IS ENGAGED
BEFORE APPLYING THROTTLE.
4. VERY SLOWLY ROTATE LEVER BON THROTTLE ACTUATOR
TO “INCREASE” RPM. NO MORE THAN 1/2 TURN SHOULD
BE REQUIRED.
5. KEY OFF IGNITION TO SLOW AND STOP VESSEL.
U.S. COAST GUARD REQUIRES START-IN-GEAR PROTECTION.
IF YOUR ENGINE DOES NOT HAVE THIS FEATURE, THIS CONTROL
SYSTEM WILL PROVIDE START-IN-GEAR PROTECTION MEETING
U.S.C.G. REQUIREMENTS OF 33 CFR PART 183, SUB PART L.
CONSULT INSTALLATION MANUAL.
PID# 682048
Affix PORT/STARBOARD decal here,
consult installation manual.
Affix SHIFT/THROTTLE decal here,
consult installation manual.
WARNING
WARNING
Figure 1-6. Actuator A and B Locator Decal, PID# 682049.
Figure 1-7. Optimus 360 Actuator decal, PID# 682048.
Actuators

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© 2012 SeaStar Solutions Optimus 360 User’s Manual, Rev. C 2-1
2.0 INTRODUCTION
Welcome to the world of electronic joystick control. Please take a few
minutes to familiarize yourself with the System Overview and the First
Time Operation sections. An understanding of the system will assure
your safety and help you get the most enjoyment from your Optimus 360
joystick control system.
2.2 Optimus 360 System Overview
An Optimus 360 system consists of:
a) An Electronic Power Steering (EPS) system to provide effortless
conventional steering.
b) An Electronic Shift and Throttle (EST) control system to provide ease
of shift and throttle operation and various convenience features.
c) An Electronic Joystick control system that can combine the EPS
and the EST systems to provide complete boat control using a
single intuitive interface.
d)
An LCD display to provide system status, faults, and instructions.
The 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 that operate hydraulic pumps. These pumps move the smart
steering cylinders (SmartCylinders) at each engine.
The SmartCylinders are equipped with position sensors that feed engine
position back to the PCM. Service valves are installed between the
hydraulic pumps and the SmartCylinders to allow for manual positioning
of the engines should a fault occur, or for use by the technician
during servicing.
The EST system has a control head at each helm station to control
the gear selection and operate the throttle. The control head sends
electronic signals to actuators that move the shift and throttle control
cables connected to the engine’s control levers.
The Joystick Control system consists of a Joystick which interfaces
with the shift, throttle, and steering equipment to control the overall
motion of the boat with one easy-to-use device.
A CANtrak display shows system operation and fault warnings. The
CANtrak display also permits system sensitivity and configuration
adjustments.
The Optimus 360 system is designed and tested to exceed ABYC
safety standards, and includes many advancements to make the
system as failsafe as possible. These include redundant sensors,
fault-tolerant communications, self-monitoring, and fault communications
to notify and advise the operator in case of fault.
2.1 Welcome

© 2012 SeaStar Solutions Optimus 360 User’s Manual, Rev. C
2-2
2.3 Optimus 360 System Diagrams
CAN 1 NETWORK CAN 2 NETWORKPCM
HELM
JOYSTICK
CANTRAK
DISPLAY
CONTROL HEAD
BUZZER
HYDRAULIC
PUMP
HYDRAULIC
HOSE
HYDRAULIC
HOSE
SMART
CYLINDER
SMART
CYLINDER
SERVICE
VALVE
SERVICE
VALVE
HYDRAULIC
PUMP
COMPONENTS NOT SUPPLIED
BY SEASTAR SOLUTIONS
BREAKERS
PORT
POWER
SOURCE
STARBOARD
POWER
SOURCE
NETWORK
TERMINATOR X 2
PORT SHIFT
ACTUATOR
STARBOARD SHIFT
ACTUATOR
STARBOARD THROTTLE
ACTUATOR
PORT THROTTLE
ACTUATOR
Figure 2-1. Optimus 360 system diagram, single station.

© 2012 SeaStar Solutions Optimus 360 User’s Manual, Rev. C 2-3
CAN 1 NETWORK CAN 2 NETWORKPCM
HELM
HELM
JOYSTICK
JOYSTICK
CANTRAK
DISPLAY
CONTROL HEAD
CONTROL HEAD
BUZZER
CANTRAK
DISPLAY
BUZZER
HYDRAULIC
PUMP
HYDRAULIC
HOSE
HYDRAULIC
HOSE
NETWORK
TERMINATOR X 2
PORT SHIFT
ACTUATOR
STARBOARD SHIFT
ACTUATOR
STARBOARD THROTTLE
ACTUATOR
PORT THROTTLE
ACTUATOR
SMART
CYLINDER
SMART
CYLINDER
SERVICE
VALVE
SERVICE
VALVE
HYDRAULIC
PUMP
COMPONENTS NOT SUPPLIED
BY SEASTAR SOLUTIONS
BREAKERS
PORT
POWER
SOURCE
STARBOARD
POWER
SOURCE
Figure 2-2. Optimus 360 system diagram, dual station.

© 2012 SeaStar Solutions Optimus 360 User’s Manual, Rev. C
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© 2012 SeaStar Solutions Optimus 360 User’s Manual, Rev. C 3-1
3.0 COMPONENT IDENTIFICATION
The electronic helm is the primary user interface for conventional
steering control. When in conventional steering control, all helms on
the boat are active and can steer the boat.
The steering wheel is attached to the helm, which may be located
immediately under the wheel or just behind the dash panel. The images
below show typical helms.
Refer to Section 4.0 for steering operation.
3.1 Electronic Helm(s) (EPS System)
EPS Front Mount Helm EPS Rear Mount Helm
EPS Classic Tilt Helm EPS Sport Plus Tilt Helm
Figure 3-1. EPS Helm configurations.
Keep magnets away from the helm. They may interfere with proper
helm operation.
CAUTION

© 2012 SeaStar Solutions Optimus 360 User’s Manual, Rev. C
3-2
3.2 Control Head (EST System)
The control head is the primary user interface for conventional shift
and throttle control.
The control head operates the gear shift and the throttle for each engine.
This is accomplished using electronic signals to direct individual
actuators for each function and each engine. The control head also
allows various features like sync and trolling to be selected.
On single helm station boats the shift and throttle control head takes
command when the ignition is turned on and the levers are in the
neutral position. The blue Take Command light will come on solid
when active.
For more detailed control head operation, refer to Section 4.0.
Figure 3-2. i6800 Control Head.