Seastar Solutions OPTIMUS EPS Owner's manual

Copy Part# 682147, Rev. C Page 1 of 8
Date: 02/2017
© 2015 Marine Canada Acquisition Inc. DBA SEASTAR SOLUTIONS 3831 No. 6 Road, Richmond, B.C. Canada V6V 1P6 Fax: [phone] Web: www.seastarsolutions.com
SUPPLEMENT INSTRUCTIONS
The dash panel is an alternative to the CANtrak display for indicating
steering system status and faults to the vessel operator. It consists
of a two-color LED indicator lamp, an audible buzzer, and a
pushbutton used to mute the buzzer.
Locate the dash panel where it is clearly visible to an operator
at the helm station. Ensure that the pushbutton is easily
accessible. Use the template provided in this instruction to mark
the mounting holes and the required cutouts on the dash. Before
cutting, measure the template and check the dimensions are
correct. If it is not correct it may not have been copied or printed
actual size.
Four #6-32 screws (1.75” long), flat washers, and locking nuts
are provided in the hardware kit. You may substitute different
screws for thinner or thicker dashboards if desired.
Figure B shows the general system diagram for the single-engine
Optimus EPS system with dash panel.
DASH PANEL INSTALLATION
INSTRUCTION FOR SINGLE-
ENGINE EPS
Overview
Location and Installation
System Diagram
This instruction does not replace your Optimus EPS installation
manual. Read and follow all instructions and safety information
in the installation manual(s) for your system.
WARNING
Figure A. Dash panel.

Copy Part# 682147, Rev. C Page 2 of 8
Date: 02/2017
© 2015 Marine Canada Acquisition Inc. DBA SEASTAR SOLUTIONS 3831 No. 6 Road, Richmond, B.C. Canada V6V 1P6 Fax: [phone] Web: www.seastarsolutions.com
SUPPLEMENT INSTRUCTIONS
Figure B. Optimus EPS system diagram, single station, single engine, with dash panel.
RUN
OFF
RUN
OFF
CAN1
NETWORK
CAN2
NETWORK
PCM
HELM
DASH
PANEL
BUZZER
ENGINE GATEWAY
12 VOLT POWER
CAN3 NETWORK
NMEA2000
POWER
STEERING
PUMP
HYDRAULIC
HOSE
SWITCH PANEL
AUXILIARY
SWITCH
+12V
SOURCE
SWITCH PANEL
SMART
CYLINDER
BLACK
GREY
PURPLE
2 x PURPLE
IGNITION WIRE
2 x PURPLE
IGNITION WIRE
PURPLE
RED
COMPONENTS NOT SUPPLIED
BY SEASTAR SOLUTIONS
HARNESS OPTIONS:
WITH A/P CONNECTION: CM20304
WITHOUT A/P CONNECTION: CM20032
WITH AUXILIARY SWITCH*
WITHOUT AUXILIARY SWITCH
BREAKERS
ENGINE
BATTERY
HOUSE
BATTERY
SERVICE
PORT
AUTOPILOT
CCU
OPTIONAL
THE AUXILIARY POWER SWITCH
PROVIDES BACKUP POWER TO THE
STEERING SYSTEM AND SHOULD ONLY
BE USED IN EMERGENCY SITUATIONS.
THE DASH PANEL WARNING LAMP
AND BUZZER ARE DISABLED WHEN
THIS SWITCH IS USED.
*WARNING

Copy Part# 682147, Rev. C Page 3 of 8
Date: 02/2017
© 2015 Marine Canada Acquisition Inc. DBA SEASTAR SOLUTIONS 3831 No. 6 Road, Richmond, B.C. Canada V6V 1P6 Fax: [phone] Web: www.seastarsolutions.com
SUPPLEMENT INSTRUCTIONS
RUN
OFF
CAN3 PORT
DASH
PANEL
PCM
(NOT INCLUDED
IN KIT)
HARNESS
CM20033
4 x 984822
(INC. WITH DASH
PANEL)
NOTE:
TIE-WRAP ON THIS
SIDE OF THE SPLICES
FOR STRAIN RELIEF.
CABLE TIE
TO NMEA2000
(PLUG WITH SUPPLIED
CAP IF NOT USED)
SWITCH PANEL
PURPLE
PINK
BLUE
WHITE
RED
PINK
BLUE
WHITE
RED
The dash panel harness has blunt-cut conductors that must be
spliced to the matching conductors on harness CM20033 (see
figure C). If you are installing a second station buzzer kit, see the
next page before proceeding.
Crimp instructions:
1.
Strip the wires ¼” to 3/8” (6 to 10 mm) from the end and insert
into the barrel of the butt splices (P/N 984822, included in the
dash panel kit).
2. With the wire ends properly seated, crimp the splice using a
Tyco AD-1522 tool (or equivalent).
3. Apply heat directly to the splice with a hot air gun or other
heat source. Work from the center out to the edges until the
outer sleeve shrinks, the crimp marks disappear, and the
adhesive melts onto the wire.
4. Allow the splice to cool, then check the integrity of the splice.
5. When all wires have been spliced, bundle them together and
use the supplied tie-wrap and locknut to secure them to one
of the dash panel mounting screws. See note in figure C.
The purple wire on the dash panel harness must be connected
to a 12V DC power source that it is energized when the engine
ignition switch is on.
Connections
Figure C.
NOTICE
Always use adhesive-lined, heat-
shrink splice connectors on the
Optimus EPS system.

Copy Part# 682147, Rev. C Page 4 of 8
Date: 02/2017
© 2015 Marine Canada Acquisition Inc. DBA SEASTAR SOLUTIONS 3831 No. 6 Road, Richmond, B.C. Canada V6V 1P6 Fax: [phone] Web: www.seastarsolutions.com
SUPPLEMENT INSTRUCTIONS
Dual station boats must be fitted with a buzzer kit at the second
station to notify the operator that the steering system has a fault
and needs attention. (A second dash panel cannot be installed.)
Mount the buzzer under the second station dash, near the helm.
A warning label is included in the buzzer kit and MUST be applied
to the dash in a visible location near the helm.
Refer to the wiring diagram in figure D. Connect the positive (yellow)
and negative (pink) leads of the buzzer to the positive (purple)
and negative (pink) leads on the dash panel harness at the main
station. Yellow and pink extension wire is provided in the buzzer
kit. Secure the wires adjacent to all splices for strain relief.
Second Station Buzzer Kit
Two types of splice are required:
Step-down butt splices, supplied in the buzzer
kit. The
recommended tool is Molex 064001-4500, not included.
14–16AWG self-sealing butt splices (such as Molex Perma-
Seal or TE DuraSeal). These splices are not supplied.
Refer to the manufacturer’s documentation for the correct
installation tool.
CAN3 PORT
TO
IGNITION
SOURCE
PCM
(NOT INCLUDED
IN KIT)
HARNESS
CM20033
3 x 984822
(INC. WITH
DASH PANEL)
NOTE
MARKER
(TO SMALLER
WIRE)
CABLE TIE
2ND STATION
BUZZER
PINK
YELLOW
PINK
PINK
2 x PURPLE
BLUE
WHITE
RED
BLUE
B
A
WHITE
RED
DASH
PANEL
TO NMEA2000
(PLUG WITH SUPPLIED
CAP IF NOT USED)
Figure D.
A
B

Copy Part# 682147, Rev. C Page 5 of 8
Date: 02/2017
© 2015 Marine Canada Acquisition Inc. DBA SEASTAR SOLUTIONS 3831 No. 6 Road, Richmond, B.C. Canada V6V 1P6 Fax: [phone] Web: www.seastarsolutions.com
SUPPLEMENT INSTRUCTIONS
Crimp instructions:
• Strip the wires 1/4” to 3/8” (6 to 10 mm) from the end.
• With the wire ends properly seated in the splice, crimp using
the recommended tool.
• Apply heat directly to the splice with a hot air gun or other heat
source. Work from the center out to the edges until the outer
sleeve shrinks, the crimp marks disappear, and the adhesive
melts onto the wire.
• Allow the splice to cool, then check the integrity of the splice.
For systems using Optimus EPS outboard steering cylinders, a basic
system setup, purge, and calibration can be performed with the
dash panel. Refer to the procedure below.
For all other steering cylinders, you will need to connect a CANtrak
Display setup tool (ED1700) and follow the setup procedure in
Book 65.
Procedure:
1. Turn the ignition on while pressing and holding the pushbutton
on the dash panel. Hold the button down for 3 seconds after
the ignition is switched on.
2. Release the button for 3 seconds, then press it again for at
another 3 seconds. (If you steer the helm during this setup
entry procedure you will need to start over.)
3. The dash panel lamp will flash red and the buzzer will beep
once to indicate that the system is in setup mode. The
system will automatically be configured as a single engine
system with no CANtrak display. Auto-detect parameters (see
below) are set to default values.
4. Purge the system. See instructions on the next page.
5. After the purge is completed, calibrate the system as follows:
steer in one direction until you hear a brief beep from the buzzer,
indicating that you’ve reached a hard stop. Steer in the other
direction until you hear the beep indicating the second hard
stop. The system should now be calibrated.
6. Complete the setup by cycling the system power. When you turn
on the system it should be fully operational with a steady blue
indicator light. If the red light is flashing attempt to calibrate
again by following steps 1–5 (you should not need to purge again).
If the fault persists connect to the system with a CANtrak or
Datalink to diagnose the problem.
Auto-Detect Parameters
Auto-detect parameters are changed automatically, but in one
direction only. To return to the default value you will need to
repeat the setup.
Setup, Purge and Calibration
NOTICE
All installation steps must be
completed before proceeding.
NOTICE
If the buzzer sounds continuously
during calibration it means that the
hoses are installed to the wrong
ports. Swap them at the pump and
start the setup over again.
PARAMETER DEFAULT AUTO-DETECT BEHAVIOR
Engine RPM
Source
Analog
tachometer
If a valid RPM message is seen on the NMEA2000 network, the
RPM Source will switch to NMEA2000. If NMEA2000 is then
disconnected the system will fault.
Number of
Helms
1 If two helms are detected on CAN1 the number of helms will
change to 2. If a helm is then disconnected the system will fault.

Copy Part# 682147, Rev. C Page 6 of 8
Date: 02/2017
© 2015 Marine Canada Acquisition Inc. DBA SEASTAR SOLUTIONS 3831 No. 6 Road, Richmond, B.C. Canada V6V 1P6 Fax: [phone] Web: www.seastarsolutions.com
SUPPLEMENT INSTRUCTIONS
Connect a purge hose kit to the SmartCylinder bleed fittings and
the steering pump bleed fitting as shown in figure E. Open all
three bleed fittings 1–1/2 to 2 turns. Make sure the service
valve on the pump is closed.
Purging
Figure E.
BOAT SPEED TURNS LOCK-TO-LOCK HELM EFFORT (%)
Low 440
High 660
Steering Settings
The default steering settings have been carefully chosen to be
satisfactory for most users. You will need a CANtrak display or
Datalink software to make changes, if required.

Copy Part# 682147, Rev. C Page 7 of 8
Date: 02/2017
© 2015 Marine Canada Acquisition Inc. DBA SEASTAR SOLUTIONS 3831 No. 6 Road, Richmond, B.C. Canada V6V 1P6 Fax: [phone] Web: www.seastarsolutions.com
SUPPLEMENT INSTRUCTIONS
2. Turn the helm one direction to start the purging process.
The pump will run as the wheel is being turned. Continue
turning the wheel until the cylinder reaches the end of travel.
Verify the pump oil level frequently.
3. Turn the wheel in the opposite direction until the cylinder
reaches the end of travel. Verify the pump oil level
frequently.
4. Repeat steps 2 & 3 until no more air bubbles appear in the
purge hose. Verify pump oil level frequently.
5. Close both cylinder bleeders. DO NOT close the pump
bleeder yet.
6. Open the service valve for the engine being purged and move
the engine by hand so that the cylinder moves about 3 inches.
7. Close the service valve.
8. Re-open the cylinder bleeders 1–1/2 to 2 turns.
9. Repeat steps 2 & 3 until no more air bubbles appear in the
purge hose. Verify pump oil level frequently.
10. Close all three bleed fittings, remove the purge hose and
replace the bleeder protective caps.
TIP: When the system is correctly purged the cylinder should have
no more than 3/8” of movement when physically shaking the
engine back and forth.
Procedure:
1. Fill the reservoir to the MAX level with Optimus EPS steering
fluid, supplied with your component kit. Do not overfill; air
coming back during purge may cause the fluid to overflow.
NOTICE When purging you will be required to turn the helm AND maintain
fluid level in the pump reservoir. The pump can empty the
reservoir quickly while purging. 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.

Copy Part# 682147, Rev. C Page 8 of 8
Date: 02/2017
© 2015 Marine Canada Acquisition Inc. DBA SEASTAR SOLUTIONS 3831 No. 6 Road, Richmond, B.C. Canada V6V 1P6 Fax: [phone] Web: www.seastarsolutions.com
SUPPLEMENT INSTRUCTIONS
.56"
(14 mm)
OVERALL NOMINAL
3.62" (92 mm)
OVERALL NOMINAL
2.0" (51 mm)
.80" (20 mm)
4 HOLES
Ø 0.19" (5 mm)
Ø 1.5" (38 mm)
(DRILL AFTER 1/2" HOLE)
Ø 0.5" (13 mm)
(DRILL BEFORE 1-1/2" HOLE)
0.2" (5 mm)
1.1" (27 mm)
1.6" (41 mm)
0.23" (6 mm)
Mounting Template
Figure F. Mounting Template
NOTICE We recommend you drill the 0.5” hole before the 1.5” hole. Its
location is more critical.
If you must photocopy this mounting template for use, check
ALL measurements using a measuring device prior to using as
a template.
NOTICE