SeaSTAR OPTIMUM EPS User manual

Electronic Power Steering for
Outboard Powered Vessels
INSTALLATION MANUAL
ELECTRONIC POWER STEERING (EPS)
Before you do it your way,
please try it our way
www.seastarsolutions.com
50
FIFTY
ISO 9001

© 2014 SeaStar Solutions Optimus Installation Manual, Rev. E
iiii
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.
©2014 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.
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.

© 2014 SeaStar Solutions Optimus Installation Manual, Rev. E iiiiii
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 calibrate
the Optimus EPS System.
It is to be delivered to the customer when installation is complete.
Thank you for choosing an Optimus™Electronic Power Steering (EPS)
System. You have chosen a state of the art steering system that will
provide years of effortless and trouble free steering performance.
Information which is important to proper use or maintenance, but is
not hazard-related.
NOTICE
About this Book
Notice to the Installer

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© 2014 SeaStar Solutions Optimus Installation Manual, Rev. E v
INDEX
Abbreviations ......................................................................... viii
1.0 Safety Information............................................................ 1-1
1.1 Safety Labels........................................................... 1-3
2.0 System Overview .............................................................. 2-1
2.1 System Description .................................................. 2-1
2.2 Optimus EPS System Diagrams ................................. 2-3
3.0 Installation Overview ........................................................ 3-1
3.1 Important Information/Technical Support Contact....... 3-1
3.2 Installation Summary ................................................ 3-1
4.0 Planning........................................................................... 4-1
4.1 Planning .................................................................. 4-1
4.2 Required Parts ......................................................... 4-2
4.3 Plan Your Component Placement ............................... 4-3
4.3.1 Electronic Helm(s)............................................ 4-3
4.3.2 CANtrak Display .............................................. 4-5
4.3.3 Pump Control Module (PCM)............................. 4-8
4.3.4 Power steering pump ..................................... 4-10
4.3.5 SmartCylinders.............................................. 4-11
4.3.6 Steering Service Valves.................................. 4-12
4.3.7 Circuit Breakers............................................. 4-12
4.4 Plan Your Connections ............................................ 4-13
4.4.1 Hydraulic Hoses ............................................ 4-13
4.4.2 Power Connections ........................................ 4-15
4.4.3 Ignition & Tachometer Connections..................4-19
4.4.4 Optional Autopilot Connection..........................4-19
4.5 Diagram................................................................ 4-20
5.0 Installation....................................................................... 5-1
5.1 Mounting the Helm(s)................................................ 5-1
5.1.1 EPS Front Mount Helm (EH1510) ....................... 5-2
5.1.2 EPS Sport Plus Tilt Helm (EH1530).................... 5-3
5.1.3 EPS Classic Tilt Helm (EH1550) ........................ 5-4
5.1.4 EPS Rear Mount Helm (EH1570) ....................... 5-5
5.2 CANtrak Display ....................................................... 5-6
5.3 PCM and Power Steering Pumps................................ 5-7
5.3.1 PCM Recommended Mount Hardware ............... 5-7
5.3.2 PCM Mounting Considerations.......................... 5-8
5.3.3 Power Steering Pump Mounting Considerations.... 5-9
5.3.4 Integrated Steering Service Valve.................... 5-11
5.3.5 Power Steering Pump Mounting Hardware ......... 5-11
5.4 SmartCylinder Mounting.......................................... 5-12
5.4.1 Ground Strap Installation.................................5 -17
5.5 Plumbing the System .............................................. 5-18
5.5.1 Hose Labels.................................................. 5-19
5.5.2 Hose Installation ........................................... 5-20
5.5.3 Hose Fitting Reorientation (if required)............. 5-22
5.7 Connecting the SmartCylinder ..................................5-24
6.0 Networks and Wiring ........................................................ 6-1

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6.1 Network Diagrams.................................................... 6-1
6.2 Harness Connections ............................................... 6-3
6.2.1 Connecting the Helm ....................................... 6-3
6.2.2 Connecting a Second Station ........................... 6-5
6.2.3 Connecting the CANtrak ................................... 6-6
6.3 Power Wiring ............................................................ 6 -7
6.3.1 PCM Wiring ..................................................... 6-7
6.3.2 PCM Wiring Strain Relief .................................. 6-7
6.4 Ignition Sensing ....................................................... 6-8
6.4.1 Ignition Splicing.............................................. 6-9
6.5 Engine RPM Source .................................................6-10
6.5.1 NMEA 2000 CAN Bus .....................................6-10
6.5.2 Analog Tachometer ........................................ 6-13
6.6 Autopilot Connection (Optional)................................ 6-13
6.7 Buzzer Kit (Optional) ................................................6-14
7.0 Setup, Purging, and Calibration ..........................................7-1
7.1 Initial System Setup ..................................................7-1
7.2 Purging the Steering System ......................................7- 4
7.2.1 Preparation.......................................................7-4
7.2.2 The Purging Process..........................................7-5
7.3 Calibrating the SmartCylinders ...................................7-8
7.3.1 Restricting SmartCylinder Travel .........................7-9
7.4 Steering Settings.....................................................7-11
7.4.1 Adjustment.....................................................7-12
7.4.2 Available Settings ...........................................7-13
7.4.3 User Permissions............................................7-14
8.0 Commissioning................................................................. 8-1
8.1 Installation Checks ................................................... 8-1
8.2 Pre-trip Checks......................................................... 8-3
8.3 Sea Trial .................................................................. 8-5
8.3.1 Verify Tachometer Signal .................................. 8-5
8.3.2 Check Steering Performance ............................ 8-5
8.3.3 Steering Adjustments ...................................... 8-6
8.3.4 Conclusion of Sea Trial .................................... 8-6
8.4 Complete Warranty Checklist..................................... 8-6
9.0 Fault Handling .................................................................. 9-1
9.1 Danger Fault Handling ............................................... 9-1
9.2 Warning Fault Handling .............................................. 9-2
10.0 Warranty ...................................................................... 10-1
10.1 Statement of Limited Warranty ............................... 10-1
10.2 Return Goods Procedure ........................................ 10-1
Appendix A – Mounting Templates ......................................... A-1
A.1 Helm Templates ....................................................... A-1
A.1.1 Front Mount Helm ............................................ A-1
A.1.2 Rear Mount Helm ........................................... A-3
A.1.3 Classic Tilt Helm............................................. A-5
A.1.4 Sport Tilt Helm ................................................ A-7
A.2 CANtrak Display ...................................................... A-9

© 2014 SeaStar Solutions Optimus Installation Manual, Rev. E vii
A.3 PCM Mounting Dimensions ..................................... A-11
A.4 Power Steering Pump.............................................. A-12
A.4.1 Power Steering Pump Mounting Dimensions ...... A-12
A.4.2 Floor Mounting the Pumps.............................. A-13
Appendix B – CAN Network.................................................... B-1
B.1 Basic Network......................................................... B-1
B.1.1 CAN Bus Connectors....................................... B-2
B.1.2 CAN Bus Connectivity...................................... B-3
B.1.3 Electrical Harness........................................... B-3
B.1.4 Powering the Bus............................................ B-4
B.1.5 CAN Bus Power .............................................. B-4
Appendix C – Using Datalink .................................................. C-1
C.1 Dealer Tools............................................................ C-1
C.2 Connection ............................................................. C-1
C.3 Navigating Datalink.................................................. C-2
C.4 System Setup ......................................................... C-4
C.4.1 System Parameters ........................................ C-4
C.4.2 Settings Menu Access .................................... C-5
C.4.3 Second Station .............................................. C-5
C.4.4 Cycle Power to System.................................... C-5
C.5 Purge with Datalink.................................................. C-6
C.6 Calibrate with Datalink............................................. C-7
Appendix D – Using the Color CANtrak Display ....................... D-1
D.1 Display Navigation ................................................... D-1
D.2 Documentation Conventions..................................... D-2
D.3 Initial Startup .......................................................... D-3
D.4 Unlocking the Dealer Menu ...................................... D-3
D.5 Menu Structure ....................................................... D-4
Appendix E – Updating Firmware............................................ E-1
E.1 Downloading Software Update Files ........................... E-1
E.2 One-Step System Firmware Update............................ E-2
E.3 Checking Component Firmware Revision Levels ............ E-3
E.3.1 Using the CANtrak ........................................... E-3
E.3.2 Using Datalink................................................. E-3
E.4 Backing Up Component Configuration Files................... E-5
E.4.1 Using the CANtrak.............................................E-5
E.4.2 Using Datalink................................................. E-5
E.5 Updating Individual Components ................................ E-6
E.6 Updating the CANtrak Software.................................. E-6
E.7 Opening a Back-up (ECU) File ...................................... E-7
Appendix F - Bolt Torque Specifications................................... F-1

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ABYC American Boat & Yacht Council
AUX Auxiliary
BAT Batter y
CAN Controller Area Network
CAN Bus Controller Area Network (data) bus. (A harness of
wires that carry digital signals and power between
electronic modules)
ENG Engine
EPS Electronic Power Steering
FT-LB Foot Pounds
GND Ground
HI High
IN-LB Inch Pounds
LED Light Emitting Diode
LO Low
MPH Miles Per Hour
NA Not Applicable or Not Available
N/C No Connection
Nm Newton Meters
NMEA National Marine Electronics Association
NMEA 2000®A protocol for digital communication on a CAN Bus
PCM Pump Control Module
RFU Rudder feedback unit. This is the position sensor
on the SmartCylinder.
RPM Revolutions Per Minute
STBD Starboard (right when facing forward)
SW Switch
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:

© 2014 SeaStar Solutions Optimus Installation Manual, Rev. E 1-1
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 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.
1. Read and understand all installation and user's manuals provided
with the steering components.
2. Ensure that all components required to complete the installation
are on hand (including hoses, fittings, oil, and the proper tools).
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.
4. DO NOT use a wheel-mounted, coiled cord trim switch. The cord can
wrap tight around the steering wheel shaft and inhibit steering.
Before installation
1. Check that there is no interference between the steering cylinder(s),
splashwell, outboard engine, or any combination of these parts,
by performing the following steps:
a) With the engine fully tilted DOWN, turn the steering wheel from
hard over to hard over and confirm that no interference occurs.
b) Repeat step 1a with engines tilted UP.
c) Perform step 1a with each engine in alternating DOWN/UP
positions and confirm that independent TRIM/TILT can be
done without any interference.
2. Check that the steering cylinder can be fully stroked in both
directions, as well as full tilt and trim, without stretching, chafing
rubbing, or kinking of the hydraulic hoses and electrical harnesses.
3. Check that only SeaStar Pro steering hose (1500psi rating) has
been used to plumb the system.
After Installation
1. Install system components as directed in this manual. Some
component parts and kits (such as hoses and fitting kits) are
supplied with additional installation instructions—refer also to
these instructions.
2. 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.
3. If an instruction is unclear, contradictory, or you are otherwise
uncertain how to proceed, do not guess. Call SeaStar Solutions
technical support.
During Installation

© 2014 SeaStar Solutions Optimus Installation Manual, Rev. E
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Perform a system inspection as outlined below. Refer to Section 8.2
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, 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.
6. Verify that no alarms or warnings are shown on the CANtrak display.
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
steering 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
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.
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 control resulting in a collision and/or ejection from
the boat leading to property damage, personal injury and/or death.
WARNING

© 2014 SeaStar Solutions Optimus Installation Manual, Rev. E 1-3
1.1 Safety Labels
The labels below should call attention to the possible hazards
associated with the equipment shown later in this manual.
Power steering pump
Labels
WARNING
Refer to User's Manual for use of valve.
OPERATION:
• TURN OFF ENGINES
• FULLY TURN KNOB COUNTER-
CLOCKWISE TO OPEN
• MANUALLY MOVE ENGINE(S)
TO REPOSITION
• FULLY TURN KNOB
CLOCKWISE TO CLOSE
HYDRAULIC STEERING PUMP
Prior to use check fluid level in pump reservoirs. Install
and maintain in accordance with SeaStar Solutions
installation manuals. Use SeaStar Electronic Power
Steering Fluid ONLY. NEVER use brake fluid. Any
non-approved fluid may cause irreparable damage
resulting in loss of steering control and may void
warranty. Failure to comply with the above warnings
may result in loss of steering control, leading to
possible ejection from vessel causing property
damage, personal injury and/or death.
682130
SEASTAR SOLUTIONS
RICHMOND, BC, CANADA
SAE J-1171
SERIAL NO:
6.9 MPa (1000psi) MAX.
12 Volt
DO NOT OPEN VALVE WITH
ENGINE(S) RUNNING
WARNING
STEERING
SERVICE VALVE
PART No. EP1500
WARNING
12-100001
CAUTION
HOT
Figure 1-1. Power steering pump labels.

© 2014 SeaStar Solutions Optimus Installation Manual, Rev. E
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Pump Control Module
(PCM) Labels
Figure 1-2. PCM labels.
Figure 1-3. Ignition warning decal, PID# 682300.
Ignition Connection
Label

© 2014 SeaStar Solutions Optimus Installation Manual, Rev. E 1-5
Steering Service
Valve Labels
SmartCylinder Labels
Figure 1-4. SmartCylinder labels.
WARNING WARNING
682012
Avoid steering failure: Turn
coupling clockwise to lock
(click). Do not overtighten.
Avoid steering failure: Turn
coupling clockwise to lock
(click). Do not overtighten.
To be installed close to the service valve.
Figure 1-5. Steering service valve labels.

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© 2014 SeaStar Solutions Optimus Installation Manual, Rev. E 2-1
2.0 SYSTEM OVERVIEW
Optimus EPS is a steer-by-wire system that replaces a traditional
hydraulic helm with electronic components that communicate over a
serial data network. This state-of-the-art system incorporates many
advanced features to make it safe and reliable. These features
include redundant sensors, fault-tolerant communications, extensive
self-monitoring, and fault communications to notify and advise the
operator in case of a system fault.
The Optimus EPS system consists of several major components,
listed below. Refer to figures 2-1 and 2-2 to see these components
in a schematic system diagram.
CAN Networks
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 steer-by-wire functionality of Optimus EPS.
Optimus EPS uses up to three independent CAN networks, designated
CAN1, CAN2, and CAN3.
•CAN1 is a low-speed, fault-tolerant network with two pairs of signal
wires in each cable. It is used for safety-critical communications.
•CAN2 is a high-speed network that is well-suited for non-critical
tasks such as passing data to and from the CANtrak display.
•CAN3 is a public network using the NMEA 2000 protocol. The
Optimus system broadcasts public messages onto this network,
and can also monitor the network for engine RPM. Use of this
network is optional.
More information about CAN may be found in Appendix B.
Electronic helm
The helm converts steering wheel movement into digital messages
that are sent over CAN1 to the pump control module (PCM). A
system of friction plates in the helm allow the steering effort to be
adjusted according to a setpoint received from the PCM. (A steering
wheel is not included with the Optimus EPS system.)
CANtrak display
The CANtrak display is a small color LCD that displays system status
and fault information to the operator. It is also used to make changes
to user-adjustable steering settings. Authorized installers have access
to additional menus with system setup and calibration tools.
Pump control module (PCM)
The PCM receives wheel movement messages from the helm(s) and
operates the hydraulic steering pumps to steer the vessel as
required. The PCM uses position feedback from the SmartCylinders
for precise steering control and fault detection. The PCM can also
respond to inputs from a certified autopilot system.
2.1 System Description

© 2014 SeaStar Solutions Optimus Installation Manual, Rev. E
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Power steering pumps
The power steering pumps supply pressurized fluid to the
SmartCylinders in order to steer the boat. The PCM controls a 12V
DC motor that drives a small gear pump. The pump assembly has
an integral fluid reservoir and pressure relief valves.
The steering pumps have an integral service valve that can be opened
to bypass the pumps and allow the engines to be manually repositioned.
They are used for service or in the case of an emergency.
SmartCylinders
The SmartCylinder is a hydraulic steering cylinder fitted with a
magnet and a position sensor. Each SmartCylinder can steer up
to two outboard engines.
Remote-mounted steering service valves (optional)
When the service valves on the power steering pumps are not
easily accessible these optional remote-mounted valves can be
installed in a convenient location.

© 2014 SeaStar Solutions Optimus Installation Manual, Rev. E 2-3
2.2 Optimus EPS System Diagrams
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
P S
BLACK
GREY
PURPLE
RED
COMPONENTS NOT SUPPLIED
BY SEASTAR SOLUTIONS
BREAKERS
PORT
POWER
SOURCE
STARBOARD
POWER
SOURCE
Figure 2-1. Optimus EPS system diagram, single station, twin engine.

© 2014 SeaStar Solutions Optimus Installation Manual, Rev. E
2-4
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
P S
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
Figure 2-2. Optimus EPS system diagram, dual station, twin engine.

© 2014 SeaStar Solutions Optimus Installation Manual, Rev. E 2-5
Figure 2-3. Optimus EPS system diagram, single station, single engine.
RUN
OFF
RUN
OFF
CAN1
NETWORK
CAN2
NETWORK
PCM
HELM
COLOR
CANtrak
BUZZER
SERVICE
PORT
ENGINE GATEWAY
12 VOLT POWER
CAN3 NETWORK
NMEA2000
AUTOPILOT
CCU
OPTIONAL
POWER
STEERING
PUMP
HYDRAULIC
HOSE
SWITCH PANEL
SWITCH
+12V
SOURCE
SWITCH PANEL
SMART
CYLINDER
BLACK
GREY
PURPLE PURPLE
RED
COMPONENTS NOT SUPPLIED
BY SEASTAR SOLUTIONS PREFERRED CONNECTION
OPTIONAL CONNECTION
BREAKERS
ENGINE
BATTERY
HOUSE
BATTERY

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