Seastar Solutions OPTIMUS EPS Instruction Manual

Electronic Power Steering for
Outboard Powered Vessels
OPERATION INSTRUCTIONS
AND USER’S MANUAL
Before you do it your way,
please try it our way
www.seastarsolutions.com
51
FIFTY 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 EPS, SeaStar, and BayStar are all trademarks of
SeaStar Solutions.
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 Operations Manual, Rev. D i
This User’s manual contains the information you need to safely operate
and maintain your steering system. It must remain on the boat.
Thank you for choosing an OptimusTM 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
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
control, leading to possible ejection from the vessel, causing
property damage, injury and/or death.

© 2012 SeaStar Solutions Optimus Operations Manual, Rev. D
ii
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© 2012 SeaStar Solutions Optimus Operations Manual, Rev. D iii
INDEX
Abbreviations .................................................................... iv
1.0 Safety Instructions.......................................................... 1-1
1.1 Safety Labels............................................................. 1-3
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)............................................. 3-1
3.1.2 Circuit Breakers for Optimus EPS System ........... 3-1
3.1.3 Pump Control Module (PCM) ...............................3-2
3.1.4 Hydraulic Steering Pumps.................................. 3-2
3.1.5 SmartCylinders................................................. 3-3
3.1.6 Steering Service Valves..................................... 3-3
3.1.7 Cantrak Display ................................................ 3-4
3.2 Initial Start Up........................................................... 3-5
3.3 System Inspection..................................................... 3-6
3.4 Installation Checks .................................................... 3-8
3.5 Initial Sea Trial .......................................................... 3-9
4.0 System Use.................................................................... 4-1
4.1 Before Each Use ....................................................... 4-1
4.2 Multiple Stations Boats ............................................. 4-1
4.3 Autopilot Operation ................................................... 4-2
5.0 CANtrak Display ............................................................ 5-1
5.1 Purpose.....................................................................5-1
5.2 CANtrak Display Navigation .........................................5-2
5.3 CANtrak Display Map – All Helms Active ...................... 5-3
5.4 All Helms Active Screens ........................................... 5-4
5.4.1 All Helms Active (Normal Steering Mode) ........... 5-4
5.4.2 Settings Screen [ Steering ].............................. 5-5
5.4.3 Display (DISP) Screen ....................................... 5-7
6.0 System Faults & Hazards................................................. 6-1
6.1 Hazard Definitions ......................................................6-1
6.1.1 Danger ............................................................ 6-1
6.1.2 Warning ........................................................... 6-1
6.1.3 Caution............................................................ 6-1
6.2 System Fault Handling ................................................6-2
6.2.1 Danger Fault Handling....................................... 6-2
6.2.2 Limp Home ..................................................... 6-3
6.2.3 Warning Fault Handling .................................... 6-5
6.2.4 System Fault Handling – Example ...................... 6-7
6.2.5 CANtrak Loss of Display ................................... 6-8
6.3 Buzzer ...................................................................... 6-9
6.4 Reduced Performance .............................................. 6-9
6.5 Steering Fluid Loss.................................................... 6-9

© 2012 SeaStar Solutions Optimus Operations Manual, Rev. D
iv
ABYC American Boat & Yacht Council
AP Autopilot
CAN Controller Area Network
EPS Electronic Power Steering
GPS Global Positioning System
INFO Information
HI High
LO Low
MPH Miles Per Hour
NMEA National Marine Electronics Association
NMEA 2000®A protocol for digital communication on a CAN Bus
PCM Pump Control Module
RPM Revolutions Per Minute
STBD Starboard (right)
Note: Some abbreviations not listed here may be found in their
respective sections.
ABBREVIATIONS
The following abbreviations are used in this manual:
7.0 Maintenance ................................................................... 7-1
7.1 Owner(s) (End Users) .................................................. 7-1
7.2 Qualified Marine Mechanic .......................................... 7-1
8.0 Troubleshooting............................................................... 8-1
9.0 Replacement Parts.......................................................... 9-1
9.1 SeaStar Electronic Power Steering Fluid .......................9-1
10.0 Warranty....................................................................... 10-1
10.1 Statement of Limited Warranty ................................ 10-1
10.2 Return Goods Procedure ........................................ 10-1
APPENDIX A – Specifications.................................................. A-1
APPENDIX B – Trailering and Storage ...................................... A-2

© 2012 SeaStar Solutions Optimus Operations Manual, Rev. D 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 3.3
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 EPS SYSTEM MUST ONLY BE INSTALLED BY AN
AUTHORIZED DEALER OR OEM.
WARNING

© 2012 SeaStar Solutions Optimus Operations Manual, Rev. D
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 components.
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.
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 Operations Manual, Rev. D 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 1-1. Hydraulic steering pump labels.
Pump Control Module
(PCM) Labels
Figure 1-2. PCM labels.
1.1 Safety Labels
WARNING
Refer to User's Manual for use of valve.
OPERATION:
UÊ/1, Ê"Ê  -
UÊ19Ê/1, Ê "Ê"1 /,-
"7-Ê/"Ê"* Ê
UÊ 19Ê"6Ê  -®Ê
/"Ê,*"-/"
UÊ19Ê/1, Ê "
"7-Ê/"Ê"-
HYDRAULIC STEERING PUMP
*ÀÀÊÌÊÕÃiÊViVÊvÕ`ÊiÛiÊÊ«Õ«ÊÀiÃiÀÛÀðÊÃÌ>Ê
>`Ê >Ì>Ê Ê >VVÀ`>ViÊ ÜÌÊ -i>-Ì>ÀÊ -ÕÌÃÊ
ÃÌ>>ÌÊ >Õ>Ã°Ê 1ÃiÊ -i>-Ì>ÀÊ iVÌÀVÊ *ÜiÀÊ
-ÌiiÀ}ÊÕ`Ê" 9°Ê 6,ÊÕÃiÊLÀ>iÊvÕ`°ÊÞÊ
>««ÀÛi`Ê vÕ`Ê >ÞÊ V>ÕÃiÊ ÀÀi«>À>LiÊ `>>}iÊ
ÀiÃÕÌ}Ê Ê ÃÃÊ vÊ ÃÌiiÀ}Ê VÌÀÊ >`Ê >ÞÊ Û`Ê
Ü>ÀÀ>ÌÞ°Ê>ÕÀiÊÌÊV«ÞÊÜÌÊÌiÊ>LÛiÊÜ>À}ÃÊ
>ÞÊ ÀiÃÕÌÊ Ê ÃÃÊ vÊ ÃÌiiÀ}Ê VÌÀ]Ê i>`}Ê ÌÊ
«ÃÃLiÊ iiVÌÊ vÀÊ ÛiÃÃiÊ V>ÕÃ}Ê «À«iÀÌÞÊ
`>>}i]Ê«iÀÃ>ÊÕÀÞÊ>`ÉÀÊ`i>Ì°
682130
--/,Ê-"1/" -
," ]Ê]Ê 
SAE J-1171
-,Ê "\
6.9 MPa (1000psi) MAX.
12 Volt
DO NOT "* Ê66Ê7/Ê
  -®Ê,1  
WARNING
STEERING
SERVICE VALVE
PART No. EP1500
WARNING
12-100001

© 2012 SeaStar Solutions Optimus Operations Manual, Rev. D
1-4
SmartCylinder Label
Figure 1-3. SmartCylinder labels.
Steering Service
Valve Labels To be installed close to the service valve.
Figure 1-4. Steering service valve label.

© 2012 SeaStar Solutions Optimus Operations Manual, Rev. D 2-1
2.0 INTRODUCTION
Welcome to the world of electronic power steering. 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 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. 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 built in to the
steering pumps and allow for manual positioning of the engines should
a fault occur, or for use by the technician during servicing. A CANtrak
display shows system operation and fault warnings. The CANtrak display
also permits system sensitivity and configuration adjustments.
The Optimus EPS system is designed and tested to exceed ABYC
safety standards, and includes many advancements to make the
system as fail-safe 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 Operations Manual, Rev. D
2-2
2.3 Optimus EPS Single Station System Diagram
Figure 2-1. Optimus EPS system diagram, single station.
RUN
OFF
CAN1 NETWORK CAN2 NETWORK
PCM
HELM
COLOR
CANtrak
BUZZER
SERVICE PORT
ENGINE GATEWAY
12 VOLT POWER
CAN3 NETWORK
NMEA2000
AUTOPILOT CCU
POWER
STEERING
PUMP
HYDRAULIC
HOSE
HYDRAULIC
HOSE
SWITCH PANEL
SMART
CYLINDER
SMART
CYLINDER
POWER
STEERING
PUMP
PS
BLACK
GREY
PURPLE
RED
COMPONENTS NOT SUPPLIED
BY SEASTAR SOLUTIONS
BREAKERS
PORT
POWER
SOURCE
STARBOARD
POWER
SOURCE

© 2012 SeaStar Solutions Optimus Operations Manual, Rev. D 2-3
2.4 Optimus EPS Dual Station System Diagram
Figure 2-2. Optimus EPS system diagram, dual station.
RUN
OFF
CAN1 NETWORK CAN2 NETWORK
PCM
HELM
HELM COLOR
CANtrak
COLOR
CANtrak
BUZZER
SERVICE PORT
ENGINE GATEWAY
12 VOLT POWER
CAN3 NETWORK
NMEA2000
AUTOPILOT CCU
SWITCH PANEL
SMART
CYLINDER
SMART
CYLINDER
PS
BLACK
GREY
PURPLE
RED
COMPONENTS NOT SUPPLIED
BY SEASTAR SOLUTIONS
BREAKERS
PORT
POWER
SOURCE
STARBOARD
POWER
SOURCE
BUZZER
POWER
STEERING
PUMP
HYDRAULIC
HOSE
HYDRAULIC
HOSE
POWER
STEERING
PUMP

© 2012 SeaStar Solutions Optimus Operations Manual, Rev. D
2-4
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© 2012 SeaStar Solutions Optimus Operations Manual, Rev. D 3-1
3.0 FIRST TIME OPERATION
The steering wheel is attached to this unit, which may be located
immediately under the wheel or just behind the dash panel. The
images below show typical helms.
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. There should be a 60 amp breaker
for each PCM power feed.
3.1.2 Circuit Breakers for Optimus EPS System
EPS Front Mount Helm EPS Rear Mount Helm
EPS Classic Tilt Helm EPS Sport Plus Tilt Helm
3.1 Locate the Following Steering System
Components
3.1.1 Electronic Helm(s)
Figure 3-1. EPS Helm configurations.
Keep magnets away from the helm. They may interfere with proper
helm operation.
CAUTION

STEERING
SERVICE
VALVE
© 2012 SeaStar Solutions Optimus Operations Manual, Rev. D
3-2
The PCM is located in a dry area and can usually be found inside the
center console, in the area behind the dash, or in a compartment
near the engines or batteries. The PCM is always located close to the
steering pumps. There will be one PCM on most boats (except for
some triple and quad engine configurations that use two PCMs).
The hydraulic steering pumps supply pressurized
fluid to the SmartCylinders to steer the engines,
and are located near the PCM. They can usually
be found in a compartment near the engines,
the center console, or behind the dash.
There is one pump for each steering
cylinder. The steering fluid reservoir is
mounted directly to the pump; it is
here that you will check the fluid
level and add steering fluid
as necessary.
Note: these pumps look
similar to
the trim pumps that
tilt the engines.
They can be
distinguished by the integrated
steering service valve.
3.1.3 Pump Control Module (PCM)
3.1.4 Hydraulic Steering Pumps
Figure 3-2. Pump control module.
Figure 3-3. Hydraulic pump and reservoir.

© 2012 SeaStar Solutions Optimus Operations Manual, Rev. D 3-3
On outboard boats these are always located just below the engine
cowling and are attached to the engine tiller arm. There will be one
SmartCylinder for each engine on twin-engine boats. Most triple- and
quad-engine boats use tie-bars to steer a pair of engines with a
single SmartCylinder.
3.1.5 SmartCylinders
3.1.6 Steering Service Valves
The steering service valves permit the bypass of the EPS system and
allow the engines to be manually positioned. They should only be used
in the event of an EPS system failure, in which case instructions will
be given on the CANtrak.
The service valves are integrated into the power steering pumps. To open
the valve, turn the knob fully counter-clockwise until it stops (about
three turns). Turn the knob fully clockwise to close it. Turn just until you
feel the valve contact the stop – do not use tools or over-tighten.
Some vessels may be fitted with
remote service valves as
shown in figure 3-5.
Figure 3-4. SmartCylinder with sensor.
Figure 3-5 Remote steering
service valve.
WEAR A COAST GUARD-
APPROVED PERSONAL
FLOTATION DEVICE (PFD)
WHEN MANUALLY
REALIGNING ENGINES.
WARNING
Figure 3-6. Service valve location.
SERVICE
VALVE
OPEN
(FULLY TURN
COUNTER-CLOCKWISE)
CLOSED
(FULLY TURN CLOCKWISE)
POWER STEERING PUMP

© 2012 SeaStar Solutions Optimus Operations Manual, Rev. D
3-4
There is a display at the main helm station that shows the system
status and allows system adjustments. A CANtrak display may also
be installed at additional helm stations.
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.
3.1.7 CANtrak Display
Figure 3-7. CANtrak Display.
Part No. ED1700

© 2012 SeaStar Solutions Optimus Operations Manual, Rev. D 3-5
3.2 Initial Start Up
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.
Turning on the ignition switch will turn on the Optimus EPS system.
The CANtrak Display will turn on and steering will become active at
all helms.
After reading the initial warning screen press the INFO button and
follow the prompts for a system inspection.
All Helms Active
Splash Screen
Initial Warning System Check 1 System Check 2
INFO NEXT
3 SEC INTERVAL
BACK
OK
System Check 3
NEXT
OK BACK
WARNING
Figure 3-9. All Helms Active screen (normal steering mode).
Figure 3-8. CANtrak initial warning screen.

© 2012 SeaStar Solutions Optimus Operations Manual, Rev. D
3-6
1. Check steering fluid level in all steering pumps.
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 EPS
steering fluid (HA5482) in the Optimus EPS System.
FAILURE TO ADHERE TO THESE WARNINGS MAY RESULT IN LOSS OF
BOAT CONTROL, LEADING TO POSSIBLE EJECTION FROM VESSEL,
CAUSING PROPERTY DAMAGE, PERSONAL INJURY AND/OR DEATH.
3.3 System Inspection
2. Verify immediate steering response when turning steering wheel(s).
Turn the steering wheel slowly to port and to starboard and make
sure the engines follow the commands. Watch that the hoses and
cables move freely without any snags or hang-ups.
3. Inspect all steering hoses, fittings and mechanical and
electrical cables for wear, kinks, or leaks.
Check all steering hoses and fittings between the pump, service
valves and cylinders for any signs of leakage, kinking, wear or
chafing. Check all electrical and mechanical cabling for abrasion,
wear, rubbing or chafing. Check that all connections are tight and
free of corrosion.
WARNING
Figure 3-10. Location of fluid level marks.