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INSTALLATION MANUAL SUPPLEMENTAL

1. a BOTH HELMS CONNECTED b HELMS AND JOYSTICKS TO PCM PREFFERED CONNECTED TOGETHER Figure 4 4 Alternate helm joystick connections in dual station applications 2013 SeaStar Solutions Optimus 360 Installation Supplement Rev C 4 5 CAN Harness Connections The Optimus 360 system uses the same CAN2 network cables and structure as the basic Optimus EPS system In addition to the CANtrak the Optimus 360 system adds the shift and throttle actuators control head and joystick to the CAN2 network Figures 4 5 and 4 6 show the CAN2 network wiring diagram Refer also to Book 50 for CAN2 wiring harness selection and installation best FAILURE TO SECURE HARNESS practices All tees must be secured using both screw holes and the MAY RESULT IN HARNESS cable drops at each tee must be appropriately secured and strain WEAR CAUSING LOSS OF relieved to prevent any pull on the tees See Figure 4 7 for proper STEERING CONTROL PROPERTY tee installation DAMAGE PERSONAL INJURY AND OR DEATH The CAN2 network must contain two and only two terminating resistors One terminator should be installed at each end of the network backbone
2. B 23 2013 SeaStar Solutions Optimus 360 Installation Supplement Rev C 2013 SeaStar Solutions Abbreviations The following abbreviations are used in this manual ABYC AUX BAT CAN CAN bus DC ENG EPS FT LB FWD GND HI IN LB LED LO MPH NA N C Nm NMEA NMEA 2000 PCM REV ROT RPM SIDE STBD SW WOT American Boat amp Yacht Council Auxiliary Battery Controller Area Network Controller Area Network data bus A harness of wires that carry digital signals and power between electronic modules Direct current Engine Electronic Power Steering Foot pounds a US unit of torque Forward Ground High Inch pounds a US unit of torque Light emitting diode Low Miles per hour Not applicable or Not available No connection Newton meters a metric measure of torque National Marine Electronics Association A protocol for digital communication on a CAN Bus Pump control module Reverse Rotation mode joystick control Revolutions per minute Sideways mode joystick control Starboard right when facing forward Switch Wide open throttle NOTE Some abbreviations not listed here may be found in their respective sections Optimus 360 Installation Supplement Rev C 2013 SeaStar Solutions Optimus 360 Installation Supplement Rev C 1 0 SAFETY INFORMATION A WARNING THE SAFETY INFORMATION PROVIDED HERE IS INTENDED TO INFORM YOU
3. T d SHIFT THROTTLE ACTUATORS I Co T gt lt m 2 J C 5 5 gt mi N MALE TERMINATOR CM10051 5 x NETWORK TEES CM10060 OR ONE TEE PLUS SIX PORT HUB CM20064 CONTROL JOYSTICK HEAD DISPLAY 5 x gt m DP D 1 2 m gt 2 rn C DEVICENET HARNESS 4 HARNESS CM21504 FEMALE TERMINATOR CM10052 3 x NETWORK TEES CM10060 OR SIX PORT HUB CM20064 Figure 4 5 CAN2 wiring diagram single station 4 8 2013 SeaStar Solutions Optimus 360 Installation Supplement Rev C ISAN SHIFT THROTTLE ACTUATORS 705062 SS3NHVH oLNANOdWOO0 AJLNNOIN 10SNO HO HOLVH MALE TERMINATOR CM10051 9 X NETWORK TEES CM10060 OR ONE TEE PLUS SIX PORT HUB CM20064 CONTROL CONTROL JOYSTICK HEAD DISPLAY JOYSTICK HEAD DISPLAY a 2 gt m 3c P oz m gt 1 m a CJ DEVICENET HARNESS DEVICENET HARNESS HARNESS CM21504 HARNESS 3 3 PIGTAIL PIGTAIL CM21504 CI il ii TERMINATOR 6 x NETWORK TEES CM10060 OR CM10052 2 X SIX PORT HUB CM20064 See Book 50 Opt
4. 4 x 1 4 1 5 1 5 6 35 mm 38 mm 38 mm DIA 3 76 mm DIA 9 pp s err 1 71 43 5 43 5 FRONT Figure A 2 Control Head mounting template If you must photocopy this mounting template for use check ALL measurements using a measuring device prior to using as a template 2013 SeaStar Solutions Optimus 360 Installation Supplement Rev C EES 2013 SeaStar Solutions Optimus 360 Installation Supplement Rev C APPENDIX B SETUP AND TUNING WITH DATALINK B 1 Using Datalink for Optimus 360 2013 SeaStar Solutions The Optimus 360 uses the same Datalink dealer setup program as the standard Optimus EPS system However in order to communicate with the joystick and related vessel command components the computer must be connected to the system via the CAN2 network rather than the CAN1 connection outlined in the Optimus EPS manual The CAN2 programming cable P N CM21106 is provided in the Optimus dealer kit Always make sure the latest version of Datalink is installed and in use Check www optimusdealers com for latest program revision Procedure 1 Connect the notebook computer to an unused CAN2 network port using the CAN2 programming harness as shown in Figure B 1 If necessary an additional tee may be i
5. STARBOARD SHIFT ACTUATOR VOU 2 SZ SZ Na 9 o HYDRAULIC HYDRAULIC UM Dus e A PORT THROTTLE ACTUATOR STARBOARD POWER SOURCE SOURCE COMPONENTS NOT SUPPLIED BY SEASTAR SOLUTIONS STARBOARD THROTTLE ACTUATOR Lo EES M XE NETWORK TERMINATOR X 2 HYDRAULIC HYDRAULIC CYLINDER CYLINDER Figure 2 1 Optimus 360 system diagram single station 2013 SeaStar Solutions Optimus 360 Installation Supplement Rev C JOYSTICK CONTROL HEAD CANTRAK Git 5 DISPLAY Ww x 2 Sam 03 D La Al CONTROL HEAD BUZZER ps JOYSTICK v CANTRAK DISPLAY 2 PORT SHIFT STARBOARD SHIFT ACTUATOR HYDRAULIC HYDRAULIC PORT THROTTLE L int m ACTUATOR n PORT STARBOARD 9 SOURCE SOURCE COMPONENTS NOT SUPPLIED BY SEASTAR SOLUTIONS STARBOARD THROTTLE ACTUATOR a mem Oa EO 9 115 o 9 NETWORK TERMINATOR X 2 HYDRAULIC HOSE
6. 5 10 54 Control Head Setup suce ous e e peni e bte ieee bens 5 13 NS ATUS dt 6 1 Shift PEL OM AN CE ee nasa uen dus ec 6 1 6 2 Throttle PerformiafiC6 s aea auta Ra e EE Oen raies 6 1 6 3 Control Head Adjustments een nmn 6 1 6 4 Conclusion Of Seg Trials en n EE E EE oett 6 2 6 5 Complete Warranty 5 6 2 SEUD titre 1 1 7 1 Joystick Tuning OvervieW cedit eive Se 1 2 2 Joystick Tuning Procedure san 1 3 7 2 1 STEP 1 Import Engine Specific Settings 1 3 1 2 2 STEP 2 Set Throttle Limits sees 1 5 1 2 3 STEP Run Throttle Wizards eee eese 1 7 2 4 STEP 4 Set Forward Heading Correction 1 8 7 2 9 STEP 5 Balance Rotation Power 1 9 7 2 6 STEP 6 Set Sideways Rudder Angle 1 10 7 2 7 STEP 7 Balance Sideways Power 11 Optimus 360 Installation Supplement Rev 2 8 STEP 8 Adjust Power 1 13 219 STEP DO SCA Tal ices en or 1 14 2 10 STEP 10 Save the Joystick Tuning File 1 15 7 3 Importing a Joystick Tuning File 1 16 3 1 Using a template file e
7. 2013 SeaStar Solutions Optimus 360 Installation Supplement Rev C 5 11 ai Adjust Power Levels 8 Adjust Power Levels Normal Forward Power Normal Reverse Power Normal Sideways Power Normal Rotation Power Boost Forward Power Boost Reverse Power Boost Sideways Power Boost Rotation Power Figure B 18 Vessel Control Power Levels 2013 SeaStar Solutions In this step you will customize the boat s response by fine tuning power levels associated with each direction Note that large changes in these values can affect the rudder offset and FWD REV ratios calibrated in STEP 4 through STEP 8 Note When fine tuning power levels always return the joystick to center position after making any adjustment Make small changes and click Write after every change 1 Ensure boost mode is off 2 Move the joystick all the way forward and adjust Normal Forward Power until the boat s speed over water SOW is 3 4 knots 3 Move the joystick to full forward and hold until the boat is at speed Abruptly move the joystick to full reverse and hold until the boat stops its forward motion a If the boat does not stop quickly enough increase Normal Reverse Power and repeat until you are satisfied with the stopping time 4 Move the joystick all the way port and adjust Normal Sideways Power until the boat moves sideways at a comfortable close quarters docking speed 5 Rotate the joystick all the way clockwise and
8. HYDRAULIC E CYLINDER CYLINDER Figure 2 2 Optimus 360 system diagram dual station 2013 SeaStar Solutions Optimus 360 Installation Supplement Rev C 2013 SeaStar Solutions Optimus 360 Installation Supplement Rev C 3 0 INSTALLATION OVERVIEW 3 1 Important Information Technical oupport Contact To assist with the installation and maintenance of this steering system SeaStar Solutions recommends that e Installation must be performed by a SeaStar Solutions authorized installer e Read and understand all installation manuals before starting the installation process cylinders helms etc Knowing the correct order of installation and location of components will drastically reduce installation time as well as prevent common installation errors e Read and understand all safety information noted in this and all other installation manuals and instructions 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 seastarsolutions com E mail seastar seastarsolutions com Phone 604 248 3858 Fax 604 279 2202 3 2 Installation Overview Before reading this supplemental read the Optimus EPS Installation Manual Book 50 Optimus EPS User s Manual Book 51 and Optimus 360 Joystick Control System User s Manual Book 61 available at www optimusdealers com This will provide a basic workin
9. 7 Check steering fluid level in all steering pumps Verify immediate steering response when turning steering wheel s Inspect all steering hoses fittings mechanical cables and electrical harnesses for wear kinks or leaks Check for binding loose worn or leaking steering or shift throttle control components Verify proper shift and throttle response for all control handles Take control with the joystick and verify that steering shift and throttle respond to joystick movement Verify that no alarms or warnings are shown on the CANtrak display A WARNING DO NOT OPERATE BOAT IF ANY COMPONENT IS NOT IN PROPER WORKING CONDITION During use 1 WEAR A COAST GUARD APPROVED PERSONAL FLOTATION DEVICE PFD ATTACH ENGINE SHUT OFF CORD LANYARD TO YOUR PFD Never allow anyone who is not familiar with the operation of the steering system to operate the boat at any time If boat is equipped with multiple helms ensure that only one is used at a time Know and adhere to all applicable federal state and municipal laws and regulations that govern boating in your area A WARNING DO NOT OPERATE BOAT IF ANY COMPONENT IS NOT IN PROPER WORKING CONDITION After 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 a
10. From U S A From Canada RGA 2 RGA 2 SeaStar Solutions SeaStar Solutions c o UPS Supply Chain Solutions Inc 3831 No 6 Road Door A37 Richmond B C 1201 C Street NW Auburn WA Canada V6V 1P6 98001 Technical Support 2013 SeaStar Solutions Phone 604 248 3858 email seastar seastarsolutions com Hours Monday to Friday 05 00 15 30 PST Web www seastarsolutions com Optimus 360 Installation Supplement Rev C 1 19 1 20 This page left intentionally blank 2013 SeaStar Solutions Optimus 360 Installation Supplement Rev C APPENDIX A MOUNTING TEMPLATES Joystick CAUTION The helm may effect a ship s or the autopilot s compass For less than one degree of effect keep the EPS helm and the compass a minimum of 8 inches 20 5 cm apart 4 x 1 4 6 35 mm sk DIA M 3 76 mm 7 DIA LC 1 72 43 7 mm 1 72 43 7 mm Figure A 1 Joystick mounting template If you must photocopy this mounting template for use check ALL measurements using a measuring device prior to using as a template 2013 SeaStar Solutions Optimus 360 Installation Supplement Rev C ESE 2013 SeaStar Solutions Optimus 360 Installation Supplement Rev C A 2 Control Head CAUTION The helm may effect a ship s or the autopilot s compass For less than one degree of effect keep the EPS helm and the compass a minimum of 8 inches 20 5 cm apart
11. Internal nnd p A Evinrude intemal Memory Honda intemal Memory Mercury intemal Memory Suzuki Internal Memory Yamaha i4 2 8L F200 with 505 Props Internal Memory bd select wer 5 Figure 7 4 3 Scroll down the list and look for your engine manufacturer and or model If your engine is not listed use All Others Once you ve highlighted the correct item press Select 4 At the confirmation screen press Yes to confirm the import IMPORT JOYSTICK SETTINGS Are you sure you want to import the joystick settings from All Others xcu Figure 7 5 5 The settings will be imported to all joysticks connected to your system When the import is finished a completion screen will be displayed Press P to return to the Joystick Setup menu 2013 SeaStar Solutions Optimus 360 Installation Supplement Rev C 2013 SeaStar Solutions 1 2 2 1124 Set Throttle Limits In this step you will configure e the maximum throttle percent at which the engines are at idle and e the maximum throttle percent intended for joystick use Perform this step with the boat safely secured or in an open area If you are having problems getting an engine to idle or if it is idling intermittently at different RPMs confirm that your engine s throttle position sensor TPS is functioning properly 1 Go to Dealer Menu gt Initial Setup gt Joystick gt Set Throttle Limits On the menu you ll be given options for both
12. T nirg PYOCCOUIC aes ee OA eua B 10 B 5 1 General NOTES itia Pie reb ERE nimes B 11 B 9 2 Before YoU SLAM nantes arb bd CE DV CERE DI count B 11 5 3 STEP 1 Import Engine Specific Settings B 12 Bio STEP dar SVSICM B 12 5 5 STEP 2 Set Throttle Limits eere B 12 B 5 6 STEP 3 Run Throttle Wizards B 14 B 5 7 STEP 4 Set Forward Heading Correction B 15 B 5 8 STEP 5 Balance Rotation Power B 16 B 5 9 STEP 6 Set Sideways Rudder Angle B 17 B 5 10 STEP 7 Balance Sideways Engine Power B 18 5 11 STEP 8 Adjust Power Levels e B 19 B o 12 STEPS SCA Trial serien sa B 20 B 5 13 STEP 10 Saving the Joystick Tuning File B 20 B 6 Adding a Second Control B 21 B 6 1 Configure the Secondary Helm and CANtrak Display 21 B 6 2 Configure the Secondary Control Head B 21 B 6 3 Configure the Secondary Joystick B 22 Importing a Joystick Tuning File B 22 B 1 Configuring a second joystick B 22 bns UsIngauiemplate Hesse nets B 22 E 3 Replace QJOVS UC cues uua i dad B 23 B 7 4 Updating joystick B 23 B 7 5 Basic Import
13. This step will establish communication between the shift and throttle actuators and Datalink and will configure the shift and throttle actuator settings From the factory all actuators default to being Port Shift actuators This section will assign the correct function to each of the actuators A CAUTION CAUTION Ensure mechanical cables are not connected to the actuators at this point Procedure 1 in the Datalink workspace you should see four Port Shift Actuators as shown in figure B 2 below Click on the beside an actuator to view the part and serial number information associated with it 7 05 File View Control Module Tools Window Help ay H y ay R r uy pen r WorkSpace ES Interfaces 42 IXXAT V3 0 USB to CAN II HW249275 fr Port Shift Actuator Er Port Shift Actuator Product part number AC6850 Firmware part number 5 2 Bootloader part numb Manufacturing date 199 12 Manufacturer name TELEFLEX CANADA Customer product part number 111 Customer calibration number Product description ACTUATOR OPTIMUS 360 EH Port Shift Actuator lt Port Shift Actuator Ep Main Control head Hele Second Joystick 5 6 Second Control head El Main Joystick vvvvvvivvv Figure B 2 Shift Throttle actuator configuration 2013 SeaStar Solutions Optimus 360 Installation Supplement Rev C EES 2 Match the serial number shown with the serial
14. throttle and steering settings and you ve verified the tachometer input and autopilot function when required the sea trial is complete After returning the vessel to port thoroughly check all hose connections and make sure they are tight Look for any leaks in the hydraulic portion of the steering system Check that none of the electrical harnesses and wiring are exposed to water excessive temperatures or mechanical damage Check that all wire splices are properly secured sealed and dry Check that all unused CAN connectors are properly sealed with sealing plugs You must also properly secure the actuator adjustment jam nuts section 5 3 e Loosen and back off the adjuster barrel jam nuts at the actuators e Apply a drop of Loctite Threadlocker Blue 242 to the threads adjacent to the adjuster barrel e Tighten the jam nuts against the adjuster barrels e nstall the actuator cable covers Be sure to install them to the correct actuator because the labels that you applied during installation give manual override instructions specific to the actuator s type and instance Complete Warranty Checklist The warranty checklist PID 214740 included with your document package should be completed at this time It will prompt you to check several important installation points and is a valuable double check for safety and performance Once you have done an orientation with the owner and handed the vessel over return the completed
15. Idle Offset 8 0 mm Stroke 60 0 mm Figure 5 6 4 Forthe throttle actuators set the Acceleration Direction parameter to Push or Pull to match the direction the actuator is required to move to increase throttle Don t adjust the other parameters yet Port Shift Setup Shift to Forward Direction Push Forward Stroke 34 0 mm Reverse Stroke 34 0 mm Neutral Start Protection Figure 5 7 8 Remove the cable access covers see figure 5 10 on all actuators Do not connect the mechanical cables yet CAUTION The actuator contains moving parts and pinch hazards Keep away from the exposed parts while the cover is removed 9 With the covers removed move the port and starboard control head levers to the forward and reverse gear positions and verify that the shift actuator racks move accordingly 2013 SeaStar Solutions Optimus 360 Installation Supplement Rev C ES 10 Increase the throttle on each of the control head handles from idle to full throttle and check that the throttle actuator racks advance and return to accordingly 11 Apply the correct manual override decals see figure 5 8 and figure 5 9 to the cable access covers 12 Press J repeatedly to exit You will be prompted to cycle system power to save the changes For PUSH to Throttle Acceleration IDLE INCREASE PID 682049 For PULL to Throttle Acceleration INCREASE IDLE Figure 5 8 Throttle actuator manual override de
16. Import Save Read Information Tables User settings RPM Sync Forward Trolling Mode Reverse Trolling Mode Forward Throttle Curve Curve 1 v Reverse Throttle Curve Curve 1 v Dealer settings Figure B 19 Configuring the second station control head 3 Update the settings if required to match the primary control head 4 Click Write to save the change Configure the Secondary Joystick It is important that both joysticks are configured with the same tuned parameters to ensure that the boat handles correctly when controlled from either station The simplest way to do this is to import the tuning ecu file from the primary main joystick to the secondary joystick See section B 7 1 for details Optimus 360 Installation Supplement Rev C B Importing a Joystick Tuning File The Import utility in Datalink allows you to copy an existing joystick tuning file into another joystick This makes it easy to e configure a second station joystick e use a template tuning file to set up identical vessels without tuning every vessel individually e replace a joystick e update the firmware revision on a joystick B 7 1 Configuring a second joystick You will be importing the ecu tuning file that you saved in STEP 10 of the joystick tuning procedure Follow the basic import procedure shown in section B 5 Be sure to set the joystick instance number to 2 in step 4 Once you have completed t
17. Limits are found on the Setup tab 111 2 Maximum Joystick Throttle Forward a Slowly increase throttle until the engine reaches approximately 1800 RPM b Enter the throttle percentage in Port Max Forward Throttle 3 Maximum Throttle at Idle Reverse a Put the port engine in reverse gear b Very slowly increase throttle and note the maximum throttle percentage at which the engine is still at idle c Enter the value in Port Idle Reverse Throttle 4 Maximum Joystick Throttle Reverse a Slowly increase throttle until the engine reaches the maximum desired RPM for joystick operation This will be either i the maximum throttle just before cavitation or ii if cavitation does not occur the maximum throttle for comfortable use RPM Q Maximum Joystick Throttle b Enter the throttle percentage in the Port Max Reverse Throttle in reverse field Write down the corresponding RPM in the adjacent table you will use it in STEP 3 c Return the engine to neutral 5 Repeat the preceding steps for the starboard engine Be sure you are entering the throttle percentages in the correct boxes for the starboard values 6 Click Write to save the values 2013 SeaStar Solutions Optimus 360 Installation Supplement Rev C ESA 5 6 15233 Run Throttle Wizards The engine response wizards will use the values acquired in STEP 2 to develop a relationship between throttle and RPM that the joystick will use to improve its con
18. OF THE DANGERS THAT MAY BE PRESENT BEFORE DURING AND AFTER INSTALLATION IT IS CRITICAL THAT YOU READ AND UNDERSTAND THIS INFORMATION 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 Before installation 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 E During 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 c
19. TO YOUR BOATS CONTROL IT SHOULD ONLY BE USED IN AN EMERGENCY DISENGAGE DRIVE MECHANISM IF YOU ARE UNABLE TO CALL FOR ASSISTANCE ALWAYS TRY ROTATE SHIFT LEVER CLOCKWISE OR COUNTER ALTERNATIVE CONTROLLING DEVICES PROCEED WITH EXTREME CLOCKWISE TO MOVE CONTROL CABLE INTO DESIRED GEAR CAUTION READ USER S MANUAL ALWAYS WEAR A PFD amp LANYARD CONFIRM YOUR DESIRED GEAR IS ENGAGED AWARNING EU eee U S COAST GUARD REQUIRES START IN GEAR PROTECTION VERY SLOWLY ROTATE LEVER ON THROTTLE ACTUATOR IF YOUR ENGINE DOES NOT HAVE THIS FEATURE THIS CONTROL TO INCREASE RPM NO MORE THAN 1 2 TURN SHOULD SYSTEM WILL PROVIDE START IN GEAR PROTECTION MEETING BE REQUIRED U S C G REQUIREMENTS OF 33 CFR PART 183 SUB PART L KEY OFF IGNITION TO SLOW AND STOP VESSEL eee ae PID 682048 Figure 1 3 Optimus 360 actuator decal PID 682048 2013 SeaStar Solutions Optimus 360 Installation Supplement Rev C EES 2013 SeaStar Solutions Optimus 360 Installation Supplement Rev C 2 0 SYSTEM OVERVIEW 21 System Description 2013 SeaStar Solutions The Optimus 360 Joystick Control System builds on the base Optimus Electronic Power Steering EPS system It uses the same helm PCM power steering pumps service valves and smart steering cylinders It also operates using the same CANbus networks power steering The Optimus 360 system adds several components and advanced c
20. checklist to SeaStar Solutions for warranty registration 2013 SeaStar Solutions Optimus 360 Installation Supplement Rev C 2013 SeaStar Solutions 7 0 JOYSTICK SETUP How you set up the joystick will depend on your goal Use the diagram below to navigate to the appropriate section Are you tuning a joystick to a vessel for the first time Section 7 2 Are you setting up a 2nd station joystick Section B 8 1 Are you setting up a new joystick Are you replacing joystick Section 7 3 2 Do you have a template tuning file from an identical vessel Section 7 3 1 Are you updating the firmware on Section 7 3 3 a tuned joystick Figure 7 1 Joystick setup options This only applies when tuning with Datalink software When tuning with the CANtrak all joysticks are tuned at the same time Optimus 360 Installation Supplement Rev C 7 1 1 Joystick Tuning Overview The joystick s electronics manage the complex task of converting joystick input into the gear throttle and steering outputs required to move the boat in the commanded direction To accommodate a variety of hull designs and motor propeller configurations there are a large number of parameters used by the joystick control You will tune these parameters in this part of the installation Figure 7 2 shows an overview of the tuning procedure Each step is detailed in the sections that follo
21. 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 A dash cutout template is provided in Appendix A 4 2 1 Control Head Trim Switch Connection 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 5491 for twin engine configurations and connect the wiring as shown in Figure 4 1 2013 SeaStar Solutions Optimus 360 Installation Supplement Rev C ESE A WARNING ALL ELECTRICAL CONNECTIONS AND HARNESS MUST COMPLY WITH ABYC WIRING STANDARDS RATED FOR 105 C 221 F AND COMPLIANT WITH SAEJ1128 CONTROL HEAD HA5491 DUAL ENGINE TILT TRIM SWITCH KIT AVAILABLE SEPARATELY IF SUPPLIED BY OTHERS SWITCHES TO BE DP DT MOMENTARY CONTACT ON OFF ON fo OPTIONAL WIRE COLOR LEGEND TRIM UP BLUE TRIM DOWN GREEN POWER RED TRIM HARNESS 6345518 c INCLUDED IN TILT TRIM KIT HA5491 DIODE PACKS INCLUDED IN HARNESS 7 FOR TRIPLE ENGINE APPLICATIONS THE CENTER ENGINE TRIM CONNECTION b REQUIRES TRIPLE ENGINE HARNESS 6345517 ORDERED SEPARATELY VIEWED FROM REAR OF SWITCHES STBD ENGINE PORT ENGIN
22. mode change this setting to False Forward Reverse Trolling Mode sets the maximum percentage of wide open throttle when trolling mode is engaged A forward setting of 50 means that when the throttle lever is fully forward the throttle is limited to 5096 of maximum This provides greater throttle sensitivity when moving at slow speeds Forward Reverse Throttle Curve There are two throttle curves that control the response characteristics when the control lever is at or near idle Curve 1 is the default curve and is suitable for most applications Curve 2 requires more lever travel before throttle is increased Station Protect When enabled True this feature prevents accidental switching between control stations on multi station boats by requiring a specific sequence of button presses Refer to Book 61 Optimus 360 Operations Manual for more information Optimus 360 Installation Supplement Rev C B 4 System Setup B 4 1 Display Station System Type Number of Engines Number of component RPM Source Tachometer PPR Basic system configuration is set through the color CANtrak display parameters The display then broadcasts these settings to all the system devices connected to the network Access the parameters by double clicking on Main Color Display in the Datalink workspace then clicking on the Configuration tab Remember to click Write after making any changes System Parameters system Power cycle required f
23. numbers you recorded in section 4 3 1 You now know the type shift or throttle and the instance port or starboard of the actuator Double click the actuator to open its configuration file 3 Open the Parameters tab 4 Set the Actuator Type and Actuator Instance parameter as required See Figure B 3 5 Set the type specific parameters as follows Throttle actuators Set the Throttle Acceleration parameter to Push or Pull for the direction the throttle actuator is required to move to increase throttle Shift actuators Set the Shift to Forward parameter to Push or Pull for the direction the shift actuator is required to move to engage forward gear 6 Click Write to save the changes The strokes and throws will be set in section B 2 3 after the cables have been installed 7 Repeat items 1 through 6 for each actuator 8 Remove cable access covers See figure B 4 on all actuators DO NOT connect mechanical cables at this point 9 With the covers removed move the port and starboard control head handles to the forward and reverse positions and verify that the shift actuator racks both move accordingly 10 Increase the throttle on each of the control head handles from idle to the full throttle positions and verify that the throttle actuator racks advance and return to idle accordingly 11 Apply manual override direction decals as shown in section 5 figure 5 8 and figure 5 9 Dealer Actuator Type Shift vl Actuat
24. port and starboard throttle limits 2 Enter the Port Throttle Limits menu At the top of the display are two feedback items that will show the current throttle position and the current engine RPM THROTTLE LIMITS Port Throttle Position pup Read Only 6 3 30 Port Engine RPM Read TM 657 RPM Port Idle FWD Throttle 9 Yo Port Idle REV Throttle 15 1 Port Max FWD Throttle 40 Port Max REV Throttle 40 Figure 6 3 Use the control lever to put the port engine in forward gear and very slowly increase the throttle Watch the feedback display and note the maximum Port Throttle Position at which the engine is still at idle 4 Select Port Idle Fwd Throttle and use the and buttons to adjust the value to match the maximum Port Throttle Position you noted in step 3 Optimus 360 Installation Supplement Rev C THROTTLE LIMITS Port Throttle Position Read Only Port Engine RPM Read Only Port Idle FWD Throttle 13 Port Idle REV Throttle 15 Port Max FWD Throttle 40h Port Max REV Throttle 40h AN w Save Figure 7 7 5 Repeat steps 2 and 3 with the port engine in reverse gear This time change the Port Idle Rev Throttle parameter 6 Put the port engine in forward gear and slowly increase the throttle until the engine reaches approximately 1800 RPM Adjust the Port Max Fwd Throttle parameter so it matches the current Port Throttle Position 7 Put the port engine in
25. procedure is organized into eleven steps detailed in the following sections You will perform the majority of the procedure from the Setup tab of the joystick s Datalink interface Jungs r2 Set Throttle Limits Throttle Positions Click the following button and follow promptsto Portidie Forward Throttle 5 o Port Throttle 0 0 customize settings to your engine 5 Stbd Idle Forward Throttle f 5 o Stbd Throttle 0 0 76 Import Engine Specific Settings Port Max Forward Throttle Bo r 1b System Stbd Mex Forward Throttle 30 EROS Joystick Instance Mein Y Port Idle Reverse Throttle fi 5 2 ES eren RPM Stbd Idle Reverse Throttle fi 5 ensue UM m RPM Port Max Reverse Throttle 40 Sid Engine REM oe Stbd Max Reverse Throtle 40 m3 Run Engine Throttle Wizards Throttle vs Engine RPM map Run Port Engine Forward Throttle Wizard Run Port Engine Reverse Throttle Wizard Port Fwd Throttle 15 165 18 195 21 225 24 255 27 285 30 Port Fwd Engine RPM 0 500 675 850 1025 1200 1375 1550 1725 1900 2075 2250 Port Rev Throttle 24 15 175 20 225 25 275 30 325 35 375 40 Port Rev Engine RPM 0 500 750 1000 1250 1500 1750 2000 2250 2500 2750 3000 Run Stbd Engine Fonvard Throttle Wizard Run Stbd Engine Reverse Throttle Wizard Stbd Fwd Throttle 24 NUM 15 165 18 195 21 225 24 255 27 285 3
26. reverse gear and slowly increase the throttle until the engine reaches the maximum desired RPM for joystick operation This will be either a Ihe maximum throttle just before cavitation or b if cavitation does not occur the maximuxm throttle for comfortable use Adjust the Port Max Rev Throttle parameter until it matches the current Port Throttle Position 8 Press Save to save changes and return to the previous menu Repeat these steps for the starboard engine 2013 SeaStar Solutions Optimus 360 Installation Supplement Rev C 7 2 3 SELS Run Throttle Wizards The throttle wizards will use the values acquired in STEP 2 to develop a relationship between throttle and RPM that the joystick will use to improve its control of the vessel Perform this step with the boat safely secured or in an open area NOTICE If you abort any of the wizards before they finish you must run them again 1 Navigate to Dealer Menu Initial Setup Joystick Run Throttle Wizards THROTTLE WIZARDS 1 Run Port FWD Wizard 2 Run Port REV Wizard 3 Run Stbd FWD Wizard _ 4 Run Stbd REV Wizard Figure 8 2 Press Take Command on the joystick Ensure boost mode is off 3 On the display select Run Port Fwd Throttle Wizard The Throttle Wizard status screen will be displayed and the joystick s A LED will flash to indicate that the port wizard is running THROTTLE WIZARD CAUTION Ensure the boat is safely secured or in open
27. vessel you will need to set the joystick instances and locations On the CANtrak display navigate to Dealer Menu gt Initial Setup gt Select Device Locations and set the instances by matching the joystick serial number to its location Main or Second 3 Perform STEP 2 section 7 2 2 and STEP 3 section 7 2 3 of the joystick tuning procedure This is necessary because throttle response can vary from engine to engine 4 Perform a sea trial as shown in STEP 9 section 7 2 9 If the vessel s performance under joystick control is poor double check that the template file you used was for an identical vessel Replacing a joystick You will need e a copy of the original joystick s tuning file xcu on a USB drive If you do not have the tuning file you will need to tune the joystick from scratch section 7 2 e the latest firmware revision on all system components See Appendix E of Book 50 for firmware updating instructions Follow the basic import procedure shown in section 7 3 4 Once the import is complete perform a sea trial as shown in STEP 9 section 7 2 9 2013 SeaStar Solutions Optimus 360 Installation Supplement Rev C 2013 SeaStar Solutions 7 3 3 1 3 4 Updating Joystick Firmware In general system firmware should always be updated using the Update All utility described in Appendix E of the Optimus EPS Installation Manual Book 50 If you have a situation in which you feel you need to updat
28. when moving at slow speeds 2013 SeaStar Solutions Optimus 360 Installation Supplement Rev C 6 0 SEA TRIAL A WARNING ALWAYS WEAR A PFD AND CONNECT THE ENGINE LANYARD S TO THE OPERATOR DURING SEA TRIAL VVARNING PROCEED CAREFULLY TO DEEP OPEN WATER TO CONDUCT SEA TRIAL 6 1 Before conducting this sea trial you must e complete the installation and pre trip checks detailed in section 8 of the Optimus EPS Installation Manual Book 50 e check that both engines shift correctly into forward and reverse gear and that they respond to throttle inputs In addition to the steering system checks outlined in section 8 3 of Book 50 the sections below detail the checks required for the shift and throttle system Shift Performance 6 2 Check that both engines engage gears properly in both forward and reverse and that they hold in gear under load Check that they shift correctly into neutral If necessary repeat some or all of the shift actuator adjustment in section 5 3 3 Throttle Performance 6 3 Check that both engines can reach wide open throttle RPM and that both return to idle properly Check that the amount of lever travel before RPMs begin to increase is acceptable Move both levers forward together and check that the RPMs on both engines begin to increase at the same time If necessary repeat some or all of the throttle actuator adjustment in section 5 3 4 Some engine models have sensitive off idle
29. 0 Stbd Fwd Engine RPM 0 500 675 850 1025 1200 1375 1550 1725 1900 2075 2250 Stbd RevThrottle 24 W 15 175 20 225 25 275 30 325 35 375 40 Stbd Rev Engine RPM 0 500 750 1000 1250 1500 1750 2000 2250 2500 2750 3000 m4 Set Heading Correction r8 Adjust Power Levels L Rudder Correction 0 0 Normal Forward Power po o r5 Balance Rotation Engine Power Power level vs Rotation Ratio Normal Reverse Power 40 Power Level 4 65 75 100 Normal Sideways Power 65 e Rotation Rev Fwd Ratio 24 150 150 150 150 Normal Rotation Power os rs Wo 6 Set Sideways Rudder Angle Power level vs Rudder Angle map Boost Forward Power 5 Power Level 24 0 65 75 100 Boost Reverse Power 50 Sideways Rudder Angle 180 180 180 18 0 Boost Sideways Power 85 deer z Boost Rotation Power 7 Balance Sideways Engine Power Power level vs Sideways Ratio map Power Level 24 UEM 65 75 100 Sideways Rev Fwd Ratio 24 150 150 150 150 Reset Setup to Factory Defaults Figure B 8 Joystick Setup tab 2013 SeaStar Solutions Optimus 360 Installation Supplement Rev C NOTICE The joystick tuning procedure will require maneuvering of the boat Some of these procedures can be performed at dock with the boat securely restrained but others will require open water with adequate maneuv
30. BALANCE SIDEWAYS POWER Off Idle REV FWD Ratio Normal REV FWD Ratio Boost REV FWD Ratio Figure 13 3 Move the joystick sideways fully to port You can rotate the knob if necessary to keep the bow from rotating as you speed up a If the boat moves aft press to decrease the ratio If it moves forward press to increase the ratio To start adjust in increments of at least 20 Reduce the size of the increment as you get closer to zero fore aft movement b Press Save c Repeat until the boat moves directly sideways 4 Press Boost on the joystick to enable boost mode and select Boost REV FWD Ratio on the display Repeat step 3 5 Turn boost mode off on the joystick Select Off Idle REV FWD Ratio on the display and adjust the value so that it is the same as the Normal REV FWD Ratio parameter In many cases the off idle sideways power balance will be adequate at this point but you may find the vessel drifts aft at small joystick inputs especially when the joystick is tuned with higher peak power levels You can improve the off idle performance with the optional step below 6 Optional Keep an eye on your starboard engine tachometer and slowly move the joystick to port until the engine comes just off idle Hold the joystick at this point a If the boat moves aft decrease the Off Idle REV FWD Ratio b If the boat moves forward try moving the joystick a little more If the boat still doesn t move aft there is
31. E TRIM HARNESS TRIM HARNESS gt Figure 4 1 Independent trim switch wiring 2013 SeaStar Solutions Optimus 360 Installation Supplement Rev C 4 3 Installing the Actuators 4 3 1 Location Identification amp Mounting e Actuators should be mounted to allow for the shortest straightest most direct mechanical cable run e Actuators should be mounted in as dry of a location as possible e he actuators will require power and network connections and may require start in gear protection wiring connections e Shift and throttle cables require adequate clearance where they exit the actuators and enter the engines and should avoid tight bends e Actuators should be mounted where they can be accessed for manual operation if required and where manual override instruction decals are clearly visible All actuators are configured identically from the factory so they can be used interchangeably during installation Once an actuator s function has been decided apply labels from the label sheet provided to identify its type shift vs throttle and side port vs starboard then record the serial numbers in Table 4 2 below See figure 5 10 for location of serial number These serial numbers will be used when the actuators are configured electronically in Section 5 3 Serial Number Table 4 2 Actuator serial numbers The label sheet also contains labels to identify the correct override knob direction These w
32. G CORRECTION Rudder Angle Offset 0 0 Figure 10 2 Press Take Command on the joystick Ensure boost mode is off 3 Push the joystick all the way forward without rotating the knob If the boat holds a straight course no adjustment is necessary Move on to STEP 5 2013 SeaStar Solutions Optimus 360 Installation Supplement Rev C 2013 SeaStar Solutions 4 Use the display s and buttons to change the Rudder Angle Offset until the boat holds a straight course If the boat drifts to port enter a positive value If the boat drifts to starboard enter a negative value 5 Press Save to save the change and return to the Joystick Setup menu 7 2 5 1144 Balance Rotation Power In this step you will tune the power ratio between the FWD and REV engines to yield tight circles in rotation ROT mode For best results perform in an area with as little wind and current as possible 1 Bring the boat to a stop with boost mode off 2 On the display navigate to Dealer Menu Initial Setup Joystick Balance Rotation Power Select Normal REV FWD Ratio The default parameter values may be different on your installation BALANCE ROTATION POWER _ Off Idle REV FWD Ratio Normal REV FWD Ratio Boost REV FWD Ratio Figure 7 11 3 Rotate the joystick all the way clockwise CW a If the boat moves aft while rotating press to decrease the ratio If it moves forward press to increase the ratio To star
33. INSTALLATION MANUAL SUPPLEMENTAL www seastarsolutions com OPTIMUS BY GEA S TAF Joystick Control System for Outboard Powered Vessels Ww SEASTAR PX SOLUTIONS WAY Before Y udi 34 try it our WAY 2013 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 n an S aG 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 ee is a registered trademark of the American Boat amp dong Stindadis Jor Boating Yacht Council http www abycinc org NMEA 200068 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
34. OHELM iii NN Te ELECTRONIC HARNESSES MUST HELM BE STRAIN RELIEVED TO JOYSTICK MOUNTING STUD USING CABLE TIES seed FRE HARNESS MUST BE STRAIN RELIEVED TO HELM HOUSING TAB USING CABLE TIES PROVIDED T Ms CANtrak TO CAN2 NETWORK 7 NODE p CI DOC Y AQ CS CM21504 Q HARNESS 5 HARNESS MUST BE STRAIN RELIEVED TO PCM STRAIN RELIEF PLATE Figure 4 3 CAN1 harness connections ETS 2013 SeaStar Solutions Optimus 860 Installation Supplement Rev C A WARNING SEALING PLUGS MUST BE INSTALLED ON ALL UNUSED CAN1 PORTS 4 4 1 Connecting a Second Station Figure 4 4 shows the acceptable CAN1 connections when adding a second station If harness lengths allow see Section 4 3 1 in Book 50 Optimus EPS Installation Manual connect the second helm to the second CANT port as shown in a This parallel configuration makes it less likely that both helms and joysticks would be lost if a wiring harness is damaged In some cases the control station layout will require a series connection as shown in b This is allowable provided the total harness length from PCM to furthest component does not exceed 36 feet This configuration requires a wye harness 21 702 in order to have enough CANT ports available at the main station
35. 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 2013 SeaStar Solutions Optimus 360 Installation Supplement Rev C Thank you for choosing an Optimus 360 Joystick Control System 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 This book contains the information required to install and calibrate the Optimus 360 Joystick Control System Use it together with the Optimus EPS Installation Manual Book 50 PID 682100 Book 50 contains installation calibration and purging instructions for the base electronic steering system upon which the joystick control system is built This book is to be delivered to the customer when installation is complete Notice to the Installer Throughout this publication Dangers Warnings and Cautions accompanied by the International Hazard Symbol A 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 imp
36. able as follows see figure B 15 a 1st O b 2nd Normal Rotation Power from STEP 8 c 3rd Boost Rotation Power from STEP 8 minus 1096 d 4th 100 Write settings ADJUST ONLY IF RE TUNE Power Level 24 Rotation Rev Fwd Ratio 24 NORMAL MODE Y VALUES BOOST MODE Y VALUES Figure B 15 Power Level vs Rotation Ratio Bring the boat to a complete stop with boost mode off Rotate the joystick clockwise CW a If the boat moves aft while rotating decrease both normal mode Y values see figure B 15 by the same amount If the boat moves forward increase the values e To start adjust in increments of up to 50 units Decrease the increment size as the fore aft movement is reduced b Write settings c Repeat until the boat rotates on the spot with no fore aft movement Press Boost on the joystick to enable boost mode then repeat step 4 This time adjust the boost mode Y values until fore aft movement is eliminated while rotating Write settings In many vessels the Y values will all be the same 2013 SeaStar Solutions Optimus 360 Installation Supplement Rev C 2013 SeaStar Solutions B 5 9 Jii Set Sideways Rudder Angle Tip When moving sideways we don t want the boat to rotate We achieve this by tuning the Power Level vs Rotation Ratio map Perform in an area with no wind or current to remove outside interference This step only adjusts for rotation during sideways movem
37. adjust Normal Rotation Power until the boat rotates at a comfortable close quarters docking speed 6 Press Boost to enable boost mode 7 Move the joystick all the way forward and adjust Boost Forward Power until the boat s SOW is 4 5 knots 8 Move the joystick to full forward and hold until the boat is at speed Abruptly move the joystick to full reverse and hold until the boat stops its forward motion a If the boat does not stop quickly enough increase Boost Reverse Power and repeat until you are satisfied with the stopping time 9 Move the joystick all the way port and adjust Boost Sideways Power until the boat moves sideways noticeably faster than in normal mode 10 Rotate the joystick all the way clockwise and adjust Boost Rotation Power until the boat rotates noticeably faster than in Normal mode 11 Changes in these values can affect previously calibrated parameters If you changed any of these parameters by more than 5 units repeat STEPS 5 through 7 Optimus 360 Installation Supplement Rev C 5 12 5112 20 Sea Trial B 5 13 Now that the basic setup procedure is completed it is time to conduct a basic sea trial to confirm good joystick performance Perform the sea trial in an open area and pay particular attention to gear engagement boat response and stopping power Gear Engagement Perform the following actions and check that the gear shifts occur within approximately two seconds If you
38. cal placement PID 682049 For PUSH to Shift to Forward EE PID 682049 For PULL to Shift to Forward ak PID 682049 Figure 5 9 Shift actuator manual override decal placement ES 2013 SeaStar Solutions Optimus 860 Installation Supplement Rev C 2013 SeaStar Solutions 5 3 2 SERIAL NUMBER LOCATION Figure 5 10 Actuator cover removal and location of serial number Step 2 Cable Installation and Adjustment Proper cable adjustment is critical for overall system performance This section will describe how to install and adjust the shift and throttle cables Be sure to review and understand the installation goals for each section before proceeding Take into consideration when installing mechanical cables that you may not be able to shift outboard engines unless the engine is running or the prop is spun by hand Mechanical cable installation notes In most cases the engine side cable adapters supplied with the engine or by the engine manufacturer will work with the SeaStar Solutions Xtreme cables P N CCX633xx If your engines do not have cable end adapters see Table 5 1 below Use engine manufacturer s cable adapters Honda Suzuki Tohatsu CA27319P CA27320P CA27319P Table 5 1 Engine Side cable end kits If longer cable ends are required for Yamaha ONLY use SeaStar Solutions P N CA38383P adapters Require only the cable ends dis
39. card other kit components Optimus 360 Installation Supplement Rev C 9 7 5 3 2 1 Shift Cable Installation Engine Side 1 2 Position the engine s shift linkage in the neutral position Connect the cables to the engine using the appropriate adapters For new adapter kits refer to the instructions provided with the kit If reusing the existing cable ends position the cable ends approximately half way down the threaded portion of the cable Always use jam nuts to lock the cable end in place See figure 5 11 MINIMUM CABLE ENGAGEMENT 3 8 9 mm JAM NUT Figure 5 11 Cable End engine side installation A CAUTION There must always be at least 3 8 of thread engagement on the engine side cable end See figure 5 11 If correct adjustment cannot be achieved while maintaining 3 8 of thread engagement longer cable ends may be required Actuator Side 1 2 Position the U shaped steel retainer clip A into the slot on the actuator rack as shown in figure 5 12 Screw the adjustment barrel B onto the cable end to the point where the cable can be set into the actuator with the barrel engaging the steel retainer clip A and the cable housing groove C engaging the cable mount in the actuator Ensure there is enough cable sticking out of the adjustment barrel B to install and tighten the lock nut D If there is not enough cable protruding to install the lock nut adjust the cable end on the eng
40. cking speed 6 Rotate the joystick all the way clockwise and adjust Normal Rotation Power until the boat rotates at a comfortable close quarters docking speed 4 Press Boost to enable boost mode Move the joystick all the way forward and adjust Boost Forward Power until the boat s SOW is 4 5 knots 2013 SeaStar Solutions Optimus 360 Installation Supplement Rev C 1 13 7 2 9 A WARNING ALWAYS WEAR A PFD AND CONNECT THE ENGINE LANYARD S TO THE OPERATOR DURING SEA TRIAL 7 14 9 Move the joystick to full forward and hold until the boat is at speed Abruptly move the joystick to full reverse and hold until the boat stops its forward motion a If the boat does not stop quickly enough increase Boost Reverse Power and repeat until you are satisfied with the stopping time 10 Move the joystick all the way port and adjust Boost Sideways Power until the boat moves sideways noticeably faster than in normal mode 11 Rotate the joystick all the way clockwise and adjust Boost Rotation Power until the boat rotates noticeably faster than in Normal mode 12 Changes in these values can affect previously calibrated parameters If you changed any of these parameters by more than 5 units repeat STEPS 5 through 7 5112 20 Sea Trial Now that the basic setup procedure is completed it is time to conduct a basic sea trial to confirm good joystick performance Perform the sea trial in an open area and pay particular a
41. e position e hat throttle always returns to idle when handle s are moved to idle e That there is minimal handle travel before engines rev up e hat the stroke length is set to achieve wide open throttle WOT engine speed without unnecessary throttle cable movement Procedure 1 ignition on do not start engines 2 Open the starboard throttle actuator in Datalink 3 Increase the starboard throttle lever to the full throttle position and verify that the throttle linkage reaches the wide open throttle WOT position 4 Increase the Throttle Stroke value in Datalink as necessary to reach the WOT position Click Write to save each change 5 Repeat items 1 4 for the port throttle actuator 6 During sea trial verify that both engines can reach WOT RPM and that both return to idle properly On some engines the throttle levers may have to be moved forward quite a bit before any RPM increase is achieved On these engines increase the Throttle Offset value in Datalink to minimize this deadband Alternately the actuator adjuster barrels may be adjusted as necessary to remove the throttle deadband If the Throttle Offset value is modified repeat steps 2 6 to verify that WOT is still reached and that the throttle cable is not over stroking 7 During sea trial also verify that when moving both control head handles forward at the same time both engine RPMs start to increase at the same time If they do not increase or decrea
42. e the joystick firmware on its own please contact SeaStar Solutions technical support Basic Import Procedure 1 Connect all destination joysticks to the network On the CANtrak navigate to Dealer Menu Settings Joystick Import Settings 2 he display will show a list of available xcu files on your USB drive Find the one you want to use and press Select 3 Atthe confirmation prompt press Yes to continue The joystick tuning file will be imported to all connected joysticks 4 Press J repeatedly to exit You will be prompted to cycle power Turn the ignition off wait at least five seconds then turn it on again Optimus 360 Installation Supplement Rev C 1 17 1 18 8 0 POST INSTALLATION 9 0 WARRANTY CHECKLIST After completion of the system installation configuration and initial Sea Trial the Post Installation Warranty Checklist supplied with your system documentation must be filled out and returned to SeaStar Solutions as part of the Limited Warranty Registration Failure to fill out the form or incomplete information may result in loss of warranty coverage UPDATING FIRMWARE From time to time it may become necessary to update the component firmware as new versions become available Refer to Appendix E of the Optimus EPS Installation Manual Book 50 for instructions 2013 SeaStar Solutions Optimus 360 Installation Supplement Rev C 10 0 WARRANT Y 10 1 otatement of Limited Warran
43. ent Fore aft movement during sideways movement will be adjusted in STEP 7 1 If this is the initial tune skip to step 3 If you adjusted the power levels in STEP 8 and are now performing a re tune adjust the X values in the table as follows see figure B 16 1st O b 2nd Normal Sideways Power from STEP 8 c 3rd Boost Sideways Power from STEP 8 minus 1096 d 4th 100 2 Write settings ADJUST ONLY IF RE TUNE Power Level Sideways Rudder Angle NORMAL MODE Y VALUES BOOST MODE Y VALUES Figure B 16 Power Level vs Rudder Angle 3 Bring the boat to a complete stop with boost mode off 4 Move the joystick sideways fully to port without rotating the knob a If the boat rotates clockwise as it starts to move decrease both normal mode Y values see figure B 16 by up to two units If the boat rotates counterclockwise increase the values e Note The boat will rotate counterclockwise as it gains speed This is normal our objective is to remove rotation during initial movement b Write settings c Repeat until the boat s initial movement is directly sideways b Repeat step 4 with boost mode enabled This time adjust the boost mode Y values until there is no rotation during initial movement 6 Write settings In many vessels the Y values will all be the same Optimus 360 Installation Supplement Rev C B 17 18 5 10 SATA Balance Sideways Engine Power Tip In this step you wil
44. er to O Otherwise leave the default value THROTTLE Successful installation of the throttle cables should accomplish the following goals e o have throttle cables adjusted evenly so engines start to rev up at the same time given the same throttle handle position e hat throttle always returns to idle when handle s are moved to idle e That there is minimal handle travel before engines rev up e hat the stroke length is set to achieve wide open throttle WOT engine speed without unnecessary throttle cable movement Procedure 1 Turn ignition on do not start engines 2 Navigate to Dealer Menu Initial Setup Shift amp Throttle Adjust Port Throttle Actuator Port Throttle Setup Acceleration Direction Push Idle Offset 8 0 mm Stroke 60 0 mm Figure 5 14 3 Increase the port throttle lever to the full throttle position and verify that the throttle linkage reaches the wide open throttle WOT position 2013 SeaStar Solutions Optimus 360 Installation Supplement Rev C 4 Increase the Stroke parameter as necessary to reach the WOT position Press Save after each adjustment to have it take effect 5 Return Repeat steps 2 to 4 for the starboard throttle actuator 6 Tighten the actuator side lock nut see figure 5 12 for both It is not uncommon to have stroke throttle actuators Once the final adjustments are made you will length a little longer for the push need to apply Loctite 242 to the th
45. ering space B 5 1 General Notes e The joystick tuning procedure consists of several steps each of which may contain several sub steps To differentiate between these we use all capital letters to denote the main STEPS and lower case letters to indicate the sub steps Example Adjust the parameter as shown in step 7 of STEP 8 e When you change a parameter you must click Write to copy it from Datalink to the joystick Otherwise the change will not take effect e Click Read at any time to copy the joystick s saved parameters into Datalink We suggest you do this regularly to confirm that the changes you make have been correctly stored in the joystick e o return all parameters to their default settings click Reset Setup to Factory Defaults Click Read to read the default values from the joystick sersssssensrs Information essel Meters 1 Engine Specific Advanced Settings 3 Throttle Limits Throttle Feedbacks Refer to the installation manual to configure FWD Port Throttle atldle 15 Port Throttle Fbk 0 4 engine specific advanced settings FWD Stbd Max Throttle at Idle i 5 Stbd Throttle Fbk 0 1 Figure B 9 Read and Write buttons in Datalink B 5 2 Before You Start e Trim both engines down and ensure that the correct propellers are installed You will need to repeat the joystick tuning procedure if you change the propellers afterward e Warm up the engines thoroughly befo
46. ew the adjustment barrel B onto the cable end to the point where the cable can be set into the actuator with the barrel engaging the steel retainer clip A and the cable housing groove C engaging the cable mount in the actuator Ensure there is enough cable sticking out of the adjustment barrel B to install and tighten the lock nut If there is not enough cable protruding to install the lock nut adjust the cable end on the engine side to lengthen the cable at the actuator side Optimus 360 Installation Supplement Rev C 5 9 5 3 3 A DANGER THIS PROCEDURE REQUIRES TURNING A PROPELLER BY HAND WITH THE IGNITION ON USE EXTREME CAUTION NOTICE It is not uncommon to have stroke length a little longer for the push direction gear to take up the lost motion of the cable in the push direction This is more pronounced with longer cables 1 Lay the cable into the actuator and install the dust seal E 2 Re install the actuator cover See figure 5 10 3 Repeat steps 1 to 4 for the other throttle actuator Final Setup and Actuator Adjustment SHIFT Successful installation of the shift cables should accomplish the following goals e To have shift cables adjusted so neutral position of actuator represents neutral position of engine shift linkage e o set the stroke length to achieve full engagement of gear yet not interfere with physical shift linkage limit e o have both gears fully disengage when returned
47. find that gear engagement is taking longer contact SeaStar Solutions technical support 1 Engage Boost mode 2 Move the joystick all the way to port for a few seconds 3 Move the joystick all the way to starboard for a few seconds 4 Move the joystick back to port 5 Repeat pausing at the neutral position for one second when changing directions Boat Response Step through all the Joystick Modes of Operation shown on the Optimus 360 Joystick Quick Reference Guide and confirm that 1 boat response is predictable 2 speeds are safe for operation in a marina 3 boost mode gives noticeably higher thrust than normal mode If the boat performance does not meet all of these requirements return to STEP 8 and adjust the power levels according to the instructions If further adjustments do not help or if you need assistance contact SeaStar Solutions technical support Stopping Power 1 In normal mode hold the joystick all the way forward until the boat reaches its maximum speed 2 Abruptly move the joystick all the way into reverse 3 Confirm that the boat s stopping power is adequate 4 Repeat the test in boost mode If the stopping power is insufficient for safe operation return to STEP 8 and increase the REV Zone Thrust parameters as required iS MEUM Saving the Joystick Tuning File The joystick tuning ecu file should be saved as a backup in the event of a joystick failure or to facilitate setup of a seco
48. following tasks e Configure the system type e Choose the number of devices in your system e Update system software e Select device locations You will need access to the CANtrak Dealer Menu for all setup tasks See Appendix D in the Optimus EPS Installation Manual Book 50 for instructions on how to navigate the CANtrak display and access the Dealer Menu Procedure 1 On the display navigate to Dealer Menu Initial Setup System to access the System Setup menu SYSTEM SETUP 1 Select System Type 2 Select Number of Devices 3 Update System Software 4 Select Device Locations _5 Select RPM Source Figure 5 1 Optimus 360 Installation Supplement Rev C EZB 2 Press gt to enter the System Type menu SYSTEM TYPE Optimus EPS Steering Only Optimus 360 for SeaStar i6800 Optimus 360 for BRP ICON sae Figure 5 2 3 Use the down arrow button to select Optimus 360 for SeaStar 16800 then press Save or to return to the System Setup menu When you set the system type the CANtrak automatically configures the menus to show only items that relate to your system 4 Choose Select Number of Devices and press gt NUMBER OF DEVICES Number of Helms Number of Displays Number of Control Heads Number of Joysticks Figure 5 3 b Use the and buttons to change the quantity of each device to match your system Press Save or J when finished to return t
49. g knowledge of the base Optimus EPS and Joystick Control System The installation of the Optimus 360 system falls into two parts component installation and system calibration purging and setup 3 2 1 Part 1 Component Installation Component installation can be done in any order Table 3 1 shows where the installation information can be found for each component NOTICE Do not connect the mechanical shift and throttle cables to the actuators until the actuators have been configured in section 5 3 2013 SeaStar Solutions Optimus 360 Installation Supplement Rev C ESE Optimus EPS Installation Manual Book 50 Base EPS System Wiring Table 3 1 Component list and installation references 3 2 2 Part 2 System Calibration Purging and Setup The system calibration purging and setup must be done in the correct order as defined in Table 3 2 STEP DESCRIPTION REFERENCE DOCUMENT Initial Setup This document Section 5 Purge and Calibrate Optimus EPS Installation Manual Book 50 Actuator Setup This document Section 5 3 Optimus EPS Installation Manual Book 50 Joystick Setup This document Section 7 0 Table 3 2 Table 3 2 System setup order of operations 2013 SeaStar Solutions Optimus 360 Installation Supplement Rev C 4 0 INSTALLATION PART 1 41 Installing the Joystick Install the joystick on the dash in an area that allows convenient unobstructed access Whenever possible mount
50. h actuator to the correct type CAUTION Ensure mechanical cables are not connected to the actuators at this point Procedure 1 On the CANtrak display navigate to Dealer Menu gt Initial Setup gt System gt Select Device Locations 2 Find the four actuators in the list of devices and match their serial numbers with the serial numbers you recorded in section 4 3 1 You now know the type shift or throttle and the instance port or starboard of each actuator 3 Use the and buttons to change each actuator s configuration to match the type and instance Make sure that you have one of each type of actuator configured 4 Press Save when finished then J repeatedly to exit You will be prompted to cycle system power to save the changes 5 Navigate to Dealer Menu gt Initial Setup gt Shift amp Throttle to get to the Shift amp Throttle Setup menu SHIFT amp THROTTLE SETUP 1 Adjust Port Shift Actuator gt 2 Adjust Port Throttle Actuator 3 Adjust Stbd Shift Actuator 4 Adjust Stbd Throttle Actuator 5 Evaluate Performance Ww gt I Figure 5 5 6 For the shift actuators set the Shift to Forward Direction parameter to Push or Pull to match the direction the actuator is required to move to engage forward gear Don t adjust the other parameters yet ES 2013 SeaStar Solutions Optimus 360 Installation Supplement Rev C Port Throttle Setup Acceleration Direction Push
51. he import procedure perform a sea trial as shown in STEP 9 section B 5 12 using both joysticks Confirm that the vessel performs as expected from both stations B 7 2 Using a template file If you are setting up identical vessels you can use the tuning file from the first vessel as a template for others For vessels to be considered identical they must have the same hull model and size and the same engines model horsepower and propellers If any of these conditions are not met you will need to perform a full joystick tune When you plan to use a joystick tuning file as a template for identical vessels save it with a meaningful name in a dedicated folder Example Joystick Template Hull Model Engine Model Date ecu You will need e a copy of the template tuning file ecu on your computer e the latest firmware revision on all system components See Appendix E of Book 50 for firmware updating instructions Procedure 1 Follow the basic import procedure in section 7 5 Be sure to select the correct template file and the correct joystick instance number for the destination joystick 2 Open the joystick s interface in Datalink 3 Perform STEP 2 section B 5 5 and STEP 3 section B 5 6 of the joystick tuning procedure This is necessary because throttle response can vary from engine to engine 4 Perform a sea trial as shown in STEP 9 section B 5 12 If the vessel s performance under joystick control is poo
52. ill be applied when the actuators are configured in Section 5 3 There are two ways to mount the actuators 1 Three bolts M8 x 1 25 x 440 mm can be used for rear mount applications Bolt heads behind the mounting panel 2 Three screws and washers can be used for front mount applications 12 MAX NOTICE NN You may rough in the mechanical cables but do not connect them to the actuators at this point 4 3 2 Start In Gear Protection The US 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 33CFR part 183 sub part L The shift actuators contain a switch that is continuous electrically when the actuator is in neutral position and open circuit when in gear position This switch may be used to interrupt the ignition start wire to the engine as start in gear protection if required See Section 4 3 4 for actuator wire identification 2013 SeaStar Solutions Optimus 360 Installation Supplement Rev C 4 3 3 4 3 4 NOTICE The polarity of the start in gear protection wires is important Make the connections as described do not reverse the wires Actuator Power Connections The shift and throttle actuators for each engine are paired together and connected with a shared CE20425 power harness Each CE20425 harness includes two 4 pin power connections one for shift and one for the throt
53. imus EPS Installation Manual Figure 4 6 CAN2 wiring diagram dual station 2013 SeaStar Solutions Optimus 360 Installation Supplement Rev C ETE A WARNING FAILURE TO SECURE HARNESS MAY RESULT IN HARNESS WEAR CAUSING LOSS OF STEERING CONTROL PROPERTY DAMAGE PERSONAL INJURY AND OR DEATH ALL NUTS DOUBLE A CHECKED FOR TIGHTNESS CAUTION a D So Do not connect anything other 3 T K I SCREWS IN ALL than SeaStar Optimus components Q RI or SeaStar approved autopilots N LC to the CAN2 network a 4 SI p CS EA C L EACH CABLE VA APPROPRIATELY SECURED AND STRAIN RELIEVED CLOSE TO TEES NO PULLING ON TEES NOTE TEES MAY NOT LOOK EXACTLY AS SHOWN Figure 4 7 Correct CAN2 Tee installation example CM20064 SCREWS IN ALL MOUNT HOLES Figure 4 8 Alternative CAN2 6 port hub connection 2013 SeaStar Solutions Optimus 360 Installation Supplement Rev C 9 0 SYSTEM SETUP PURGE AND CALIBRATION 9 1 Before you proceed you need to have all Optimus EPS and Optimus 360 components installed harnesses connected and ignition sensing and power wiring completed This section will describe the system setup using the color CANtrak display If you prefer to use Datalink you can find instructions in Appendix B Initial Setup 2013 SeaStar Solutions The system setup is performed easily with the color CANtrak display It is designed to walk you through the
54. ine side to lengthen the cable at the actuator side 3 Lay the cable into the actuator and install the dust seal E 4 Re install the actuator cover See figure 5 10 5 Repeat for the other shift actuator 2013 SeaStar Solutions Optimus 360 Installation Supplement Rev C CAUTION 2013 SeaStar Solutions OWA pu VR IME OB MT NS ARR SS SD DAR Figure 5 12 Actuator cable installation 5 3 2 2 Throttle Cable Installation Engine Side 1 Put the engine s throttle linkage in the idle position against the idle hard stop 2 Connect the cables to the engine using the appropriate adapters For new adapter kits refer to the instructions provided with the kit If reusing the existing cable ends position the cable ends approximately half way down the threaded portion of the cable Always use locknuts to lock the cable end in place In most cases the original engine adapter may be re used In some cases they may not provide adequate adjustability See Table 5 1 for engine adapter kit part numbers There must always be at least 3 8 of thread engagement on the engine side cable end See figure 5 11 If correct adjustment cannot be achieved while maintaining 3 8 of thread engagement longer cable ends may be required Actuator Side 1 Position the U shaped steel retainer clip A into the slot on the actuator rack as shown in figure 5 12 2 Scr
55. l adjust the power ratio between the REV and FWD engines to eliminate fore aft movement when moving the boat sideways Perform in an area with no wind or current to remove outside interference 1 If this is the initial tune skip to step 3 If you adjusted the power levels in STEP 8 and are now performing a re tune adjust the X values in the table as follows see figure B 17 1st O b 2nd Normal Sideways Power value from STEP 8 plus 5 units c 3rd Normal Sideways Power value from STEP 8 minus 1096 d 4th 100 2 Write settings ADJUST ONLY IF RE TUNE 7 Balance Sideways Engine Power Power leyals Sideways Ratio map Power Level 24 Sideways Rev Fwd Ratio NORMAL MODE Y VALUES BOOST MODE Y VALUES Figure B 17 Sideways REV FWD Ratio Curve parameters 3 Bring the boat to a complete stop with boost mode off 4 Move the joystick sideways fully to port without rotating the knob a If the boat moves aft decrease both normal mode Y values see figure B 17 by the same amount If the boat moves forward increase the values e To start adjust in increments of up to 50 units Decrease the increment size as the fore aft movement is reduced b Write settings c Repeat until the boat moves directly sideways 5 Repeat step 4 with boost mode enabled This time adjust the boost mode Y values until the boat moves directly sideways 6 Write settings In many vessels the Y values will all be the same
56. natively you can unplug any other joysticks from the network 2 Click Import in the toolbar Use the file browser to find the ecu tuning file you wish to import Highlight it and click Open 3 You will see the following warning Click OK to continue gt Warning You are about to change the calibration Verify all parameters before writing to the module OK Figure B 20 Import warning dialog 2013 SeaStar Solutions Optimus 360 Installation Supplement Rev C B 23 4 The dialog box shown in figure 21 will be displayed Use this dialog to set the instance number of the joystick If you are configuring a second station joystick change this instance number to 2 Otherwise accept the default Click OK Joystick Station Selection Som This joystick s instance is currently set as 1 Confirm that the value below represents the correct Instance and press OK to continue 1 Main Station 2 2nd Station Figure B 21 Joystick instance setting for import 5 The following confirmation dialog will be displayed Click OK to accept DATALINK Figure B 22 Joystick import confirmation dialog 6 Click Write to save the settings At the subsequent prompt click Yes 4 The Optimus system requires a power cycle before use Turn the ignition off wait at least five seconds then turn it on again B 24 2013 SeaStar Solutions Optimus 360 Installation Supplement Rev C seas
57. nd control station You will also need to email a copy of the tuning file to SeaStar Solutions as part of the post installation warranty checklist Part 214740 Refer to Appendix E 3 in the Optimus EPS Installation Manual Book 50 for instructions 2013 SeaStar Solutions Optimus 360 Installation Supplement Rev C Adding a Second Control Station 2013 SeaStar Solutions B 6 1 B 6 2 B 6 3 At a minimum a second control station must consist of a helm a control head and an alarm buzzer A secondary joystick and CANtrak display are optional Configure the Secondary Helm and CANtrak Display If the secondary helm and CANtrak display have not already been configured refer to the Optimus EPS Installation Manual Book 50 for instructions Configure the Secondary Control Head The instance setting of the secondary control head needs to be configured and any changes to the user parameters on the primary control head need to be copied Procedure 1 If both control heads are connected to the CAN2 network you will see two Main Control Head instances in the Interfaces list Click the beside both instances to view the serial numbers associated with them then identify which of the two instances is installed as the secondary control head Connect to it by double clicking it 2 Open the Parameters tab and change the Control Head instance to Second File View Control Module Tools Window Help IA e 2 E Open
58. no adjustment to make Leave the Off Idle REV FWD Ratio the same as the Normal REV FWD Ratio It should never be higher c Press Save d Repeat until the boat moves directly sideways 7 12 2013 SeaStar Solutions Optimus 360 Installation Supplement Rev C 7 2 8 AAA Adjust Power Levels In this step you will customize the boat s response by fine tuning the power levels associated with each direction Note that large changes can affect the parameters you tuned in STEP 4 through STEP 7 Note When fine tuning power levels always return the joystick to the center position after making any adjustment Make small changes and press Save after every change 1 Ensure boost mode is off 2 Navigate to Dealer Menu Initial Setup Joystick Adjust Power Levels POWER LEVELS Normal Forward Power Boost Forward Power Boost Reverse Power W Figure 14 3 Move the joystick all the way forward and adjust Normal Forward Power until the boat s speed over water SOW is 3 4 knots 4 Move the joystick to full forward and hold until the boat is at speed Abruptly move the joystick to full reverse and hold until the boat stops its forward motion a If the boat does not stop quickly enough increase Normal Reverse Power and repeat until you are satisfied with the stopping time 5 Move the joystick all the way port and adjust Normal Sideways Power until the boat moves sideways at a comfortable close quarters do
59. nstalled but must be removed or capped after use If the spare tee is left in the system there must still be one and only one terminator at each end of the CAN2 bus 2 Turn on the notebook computer and open the Datalink program located on the desktop 3 Once Datalink opens the Interfaces section of the Workspace Should become populated with components connected to the network If not double click on Optimus CAN2 in the protocols section The components should turn green as communication is established See figure B 2 to familiarize yourself with the Datalink workspace 4 Double clicking on any of the components will enter the configuration pages for that particular component 5 Before proceeding with the setup verify that the firmware revisions are up to date for each of the components Refer to Appendix E of the Optimus EPS Installation Manual Book 50 for instructions on checking and updating firmware revisions Optimus 360 Installation Supplement Rev C SS TO CAN2 AL NETWORK HARNESS CN 2 3 TERMINATOR ON LO SU H M amp 2 K t H g OTHER OPTIMUS 360 COMPONENTS d OTHER OPTIMUS 360 COMPONENTS CM21106 CAN2 PROGRAMMING CONVERTER 214720 CAN COMPUTER HARNESS Figure B 1 Dealer Rit connection O 2013 SeaStar Solutions Optimus 360 Installation Supplement Rev B 2 Actuator Setup B 2 1 Step 1 Actuator Configuration Using Datalink
60. ny Optimus components 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 EES 2013 SeaStar Solutions Optimus 860 Installation Supplement Rev C 11 Safety Labels HAZARDS ASSOCIATED WITH THE EQUIPMENT SHOWN LATER IN THIS MANUAL Component labels The labels shown below are specific to the Optimus 360 system and are supplemental to those shown in the SeaStar Optimus EPS System Installation Manual SeaStar Solutions Book 50 PID 682100 WARNING PID 682050 U S COAST GUARD REQUIRES START IN GEAR PROTECTION IF YOUR ENGINE DOES NOT HAVE THIS FEATURE THIS CONTROL WILL PROVIDE START IN GEAR PROTECTION MEETING U S C G REQUIREMENTS OF 33 CFR PART 183 SUBPART L CONSULT INSTALLATION MANUAL Figure 1 1 Optimus 360 Start In Gear Advisory Decal PID 682050 Insert appropriate Insert appropriate IDLE or INCREASE F IDLE or INCREASE decal here Consult decal here Consult installation manual installation manual PID 682049 Figure 1 2 Optimus 360 A and B Locator Decal PID 682049 Affix PORT STARBOARD decal here Affix SHIFT THROTTLE decal here consult installation manual consult installation manual MANUAL OVERRIDE OPERATION A WARNING USING THE ACTUATOR OVERRIDE SYSTEM MAY SEVERELY LIMIT MOVE ALL LEVERS GIN THE DIRECTION OF ARROW
61. o the System Setup menu 2013 SeaStar Solutions Optimus 360 Installation Supplement Rev C 6 Review Appendix E in Book 50 and determine if your system software needs to be updated 7 Multiple helm stations only choose Select Device Locations from the System Setup menu and press The display will list the installed components along with their serial numbers Check the serial numbers and use the and buttons to toggle the components between Main and Second station Press Save to return to the System Setup menu DEVICE LOCATIONS Display S N Helm S N EHC1161200011 Actuat SIN SA1811201565 Stbd Shift Control Head SIN 189120018CH6800 Control Head S N 18812001 7 6800 Joystick S N P3 10A Figure 5 4 Note ignore the Actuators at this point We will configure them in section 5 3 5 2 Purge and Calibrate You are now ready purge and calibrate your steering system Refer to the Optimus EPS Installation Manual Book 50 for instructions Be sure to perform the steering installation checks described in Book 50 The steering portion of the system should now be fully functional 2013 SeaStar Solutions Optimus 360 Installation Supplement Rev C EE 5 3 Actuator Setup 5 3 1 STEP 1 Actuator Configuration Using the CANtrak Display The default configuration type for all actuators is Port Shift Before installing the cables and adjusting the actuator parameters you must configure eac
62. od cde ve ku reor ne 1 16 9 2 JROeDIGCIHE 1 16 7 3 3 Updating Joystick Firmware 1 17 1 3 4 Basic Import Procedure ss 1 17 8 0 Post Installation Warranty 1 18 9 0 Updating ANC t 1 18 LOLO Caec dena OY np D UAR ad 1 19 10 1 Statement of Limited 1 19 10 2 Return Goods Procedure eie vna rods x Sa E V a endi 19 10 3 TECHNIC Al SUD DONG scii ecce union 2 uisa aoa ae 1 19 Appendix A Mounting Templates 1 Bad SOV SUC 1 A2 CONTON Appendix B Setup and Tuning with B 1 B 1 Using Datalink for Optimus B 1 BZ B 3 B 2 1 Step 1 Actuator Configuration Using Datalink B 3 B 2 2 Step 2 Cable Installation and Adjustment B 5 B 2 3 Step 1 Final Setup and Actuator Adjustment B 5 Control Head DP en os e kae ee Quen B 7 BA System Selber ier til vc br aa d e oh lah ep DEF Ue DIR B 8 4 1 System Parameters esee eee enne aman aaa nun B 8 B 4 2 Settings Menu ACCOSS is B 9 B 4 3 Cycle Power to nnn B 9 B JoySHek
63. omponents 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 After 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 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 2013 SeaStar Solutions Optimus 360 Installation Supplement Rev C EE NN Prior to every use Perform a system inspection as outlined below Refer to Section 9 1 in the Optimus EPS Installation Manual Book 50 for further details 1 2 3 4 5 6
64. ontrol algorithms to enable complete vessel control Joystick The three axis joystick features on board electronics and micro processors that convert an operator s inputs into steering shift and throttle commands then sends these commands over CAN to the pump control module PCM and to the shift and throttle actuators The joystick can rotate move forward and back and side to side Combinations of these movements give the operator precise control of the vessel s direction and speed Control Head The control head looks much like a conventional mechanical remote control but it is a throttle by wire 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 and control buttons for added functionality Shift and Throttle Actuators 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 specific application using the CANtrak display Optimus 360 Installation Supplement Rev C 2 2 Optimus 360 System Diagrams wi JOYSTICK CONTROL HEAD CANTRAK DISPLAY PORT SHIFT ACTUATOR 9 Ta eee I o
65. or Instance Part Throttle amp celeration Pul gt Shift To Forward Fush rl Throttle Offset mm Throttle Stroke CCR mm Shift To Forward Throw BAD mm shift To Reverse Throw mm Neutral switch connected lw Figure B 3 Shift Throttle actuator configuration 2013 SeaStar Solutions Optimus 360 Installation Supplement Rev C B 2 2 B 2 3 DANGER THIS PROCEDURE REQUIRES TURNING A PROPELLER BY HAND WITH THE IGNITION ON USE EXTREME CAUTION 2013 SeaStar Solutions SERIAL NUMBER LOCATION Figure B 4 Actuator cover removal and location of serial number Step 2 Cable Installation and Adjustment Refer to section 5 3 2 for instructions on the mechanical installation of the cables Final Setup and Actuator Adjustment SHIFT Successful installation of the shift cables should accomplish the following goals e have shift cables adjusted so neutral position of actuator represents neutral position of engine shift linkage e o set the stroke length to achieve full engagement of gear yet not interfere with physical shift linkage limit Done in Step 4 below e have both gears fully disengage when returned to neutral Procedure 1 ignition on but do not start engines 2 Open the starboard shift actuator in Datalink 3 With an assistant spinning the prop by hand put the starboard engine into forward gear and verify that the gear engages 4 Increase
66. or changes to take effect Display Station Main system Type Steering Only Number of Engines NEN Number of Cylinders aoo Number of Helms no Number of Displays IEEE Number of Control Heads mE Number of Joysticks EN Number of Gateways E RPM Source INMEA2000 Tachometer PPR 6 Figure B 6 Color display System parameters Set the instance of the display The default is Main you only need to change the second station display instance Choose SeaStar 16800 from the drop down list At the time of printing only twin engine configurations are supported Enter the quantity of each listed component in your system Select the RPM source that you re using If the RPM Source is set to Analog Tach enter the tachometer PPR here 2013 SeaStar Solutions Optimus 360 Installation Supplement Rev C 4 2 Settings Menu Access Display Brightness settings Menu Acces Demo Mode Figure B 7 Display parameters The adjustable steering settings are limited to those with Dealer Menu access by default To allow users to adjust the steering settings change the Settings Menu Access parameter to B 4 3 Cycle Power to System Changes to system parameters will not take effect until the power has been cycled To cycle power turn the key off for several seconds and turn it on again 2013 SeaStar Solutions Optimus 360 Installation Supplement Rev C B 5 Joystick Tuning Procedure The joystick setup
67. ortant measures to prevent accidents DANGER IMMEDIATE HAZARDS WHICH IF NOT ACTED UPON WILL RESULT IN SEVERE PERSONAL INJURY OR DEATH WARNING HAZARDS OR UNSAFE PRACTICES WHICH IF NOT ACTED UPON COULD RESULT IN SEVERE PERSONAL INJURY OR DEATH CAUTION Hazards or unsafe practices which COULD result in minor injury or product or property damage NOTICE Information which is important to proper use or maintenance but is not hazard related 2013 SeaStar Solutions Optimus 360 Installation Supplement Rev C 2013 SeaStar Solutions Optimus 360 Installation Supplement Rev C 2013 SeaStar Solutions 1 0 2 0 3 0 4 0 5 0 6 0 1 0 INDEX POV OMS ieee V Sale IN OTMAUONE baa Fa 1 1 LH SAV ia Se m E rato Cose ne 1 3 System ONE VIEN cori caine rier ui Getae PD Dc v DOR eb Por e C be 2 1 2 1 System Descrip HUON iesean enan io var Cp e e ER E EE EE ED dA 2 1 2 2 Optimus 360 System Diagrams 2 2 I istallatiOr OVerVIeW 3 1 3 1 Important Information Technical Support Contact 3 1 3 2 Installation OVERVIEW ei caus ud du eli dp came patei or bata 3 1 3 2 1 Part 1 Component Installation 3 1 3 2 2 Part 2 System Calibration Purging and Setup 3 2 Installatore Part T ESS ES 4 1 AA s
68. performance and may increase RPM quickly with a small movement of the levers from the idle position The control head has an optional throttle curve that can Slow this response if necessary See section 5 4 Control Head Adjustments 2013 SeaStar Solutions During the sea trial you should test the control head features See the Quick Reference card for instructions The control head has adjustable lever friction and adjustable detents Check that the feel of both levers is the same as you shift into and out of gear and as you increase throttle Use the adjuster screws on Optimus 360 Installation Supplement Rev C 6 1 the back of the control head to make any necessary adjustments Engage the Power Train Sync feature and check that engine speeds are matched If the RPMs sound like they are oscillating you may need to disable the Sync Engine RPMs parameter on the control head section 5 4 Enter Trolling Mode and check that full throttle gives a satisfactory fraction of maximum and that the low speed control is precise Adjust the Trolling Max Throttle parameters section 5 4 if necessary If there are two control stations run the vessel from both Transfer control between control heads and verify that transfer works as it should If you can t transfer control check that the Station Protection feature is not enabled 6 4 Conclusion of Sea Trial 6 5 Once you are satisfied with the vessel s performance the shift
69. r double check that the template file you used was for an identical vessel 2013 SeaStar Solutions Optimus 360 Installation Supplement Rev C B 7 3 Replacing a joystick You will need e a copy of the original joystick s tuning file ecu on your computer If you do not have the tuning file you will need to tune the joystick from scratch section B 5 e the latest firmware revision on all system components See Appendix E of Book 50 for firmware updating instructions Follow the basic import procedure shown in section B 7 5 Once the import is complete perform a sea trial as shown in STEP 9 section B 5 12 B 7 4 Updating joystick firmware In some cases updating the joystick firmware can cause the loss of the saved tuning parameters Accordingly you should create a backup of the tuning file before updating Firmware updating instructions are found in Appendix E 2 of the Optimus EPS Installation Manual Book 50 After updating the firmware follow the basic import procedure shown in B 7 5 using the backup ecu file that you just created Once the import is complete perform a sea trial as shown in STEP 9 section B 5 12 B 7 5 Basic Import Procedure 1 Connect the destination joystick to the network and open its configuration page with Datalink If there is more than one joystick on the network identify the correct joystick by matching the serial number shown in the Workspace with the label on the joystick Alter
70. re you begin e Connect the netbook computer and open Datalink e Double click on the joystick component to access the configuration If the boat has two control stations match the serial number on the joystick with the serial number displayed in Datalink to ensure that you are accessing the correct joystick instance If you aren t sure you can disconnect the secondary joystick from the CAN2 network and it will be removed from the list of available components The secondary joystick will be configured in section B 6 NOTICE Erratic engine performance stalling or other engine control issues will affect the operation of the joystick control system Any such issues must be addressed before attempting joystick setup 2013 SeaStar Solutions Optimus 360 Installation Supplement Rev C 5 3 Import Engine Specific Settings On the Setup tab of the Joystick interface click Import Engine Specific Settings A dialog will pop up click Yes to confirm A file selector will open From the engine s listed choose the one that matches yours and click Open Click Yes at the dialog prompts to write and confirm the imported settings 1 Engine Specific Settings Click the following button and follow prompts to customize settings to your engine Import Engine Specific Settings Figure B 10 B 5 4 Kyla System Return to the Setup tab Set the Joystick Instance to either Main or Second In most cases you
71. reads but you will do this direction gear to take up the lost after the sea trial motion of the cable in the push 7 direction This is more pronounced with longer cables The Idle Offset parameter is used to fine tune throttle response and to synchronize the throttle actuation a On some engines it may take a large amount of lever travel before RPM starts to increase You can reduce this deadband by increasing the Idle Offset parameter or by adjusting the actuator adjuster barrels section 5 3 2 1 b When both levers are advanced at the same time both engines should start to increase RPM simultaneously If they do not you can adjust the Idle Offset parameter or the actuator adjuster barrels until they are synchronized A WARNING AFTER FINAL ADJUSTMENT IS MADE APPLY LOCTITE 242 BLUE AND TIGHTEN JAM NUT ON ACTUATOR SIDE 2013 SeaStar Solutions Optimus 360 Installation Supplement Rev C 5 4 Control Head Setup 2013 SeaStar Solutions The control head has several configurable parameters as shown in Figure 5 15 below The default settings will generally provide excellent performance for most boats To Access the parameters navigate to Dealer Menu gt Settings gt Shift amp Throttle on your CANtrak display SHIFT amp THROTTLE SETTINGS Station Protection Sync Engine RPMs Yes FWD Throttle Curve Curve 1 REV Throttle Curve Curve 1 Max Shift RPM 1320 RPM FWD Trolling Max Throt
72. red 2013 SeaStar Solutions Optimus 360 Installation Supplement Rev C 2013 SeaStar Solutions 7 2 10 Save the Joystick Tuning File The joystick tuning file should be saved as a backup in the event of a joystick failure You will also need to email a copy of the tuning file to SeaStar Solutions as part of the postinstallation warranty checklist 1 Insert a USB flash drive in the USB port on the back of the CANtrak display 2 Navigate to Dealer Menu Devices Main Joystick Export Settings You will see the Export Settings menu with options for Internal Memory and USB Memory EXPORT SETTINGS Internal Memory USB Memory WW Select Figure 7 15 3 Highlight USB Memory and press Select 4 The display will save the configuration file to the USB drive and display a message when finished Notes e The display will create a folder on the USB drive called Optimus and a sub folder named Joystick into which the configuration file will be saved It will save the configuration file with the name serial number of the joystick xcu Be sure to give the file a unique meaningful name for later use You can t do this from the display you will need to insert the USB drive into a computer to rename the file See Appendix E of the Optimus EPS Installation Manual Book 50 for recommendations Configuration files exported by the display have the extension XCU This is different
73. se the Throttle Offset parameter or adjust the actuator adjuster barrels as required to achieve synchronous RPM increase 8 After final adjustment is made apply Loctite 242 blue and tighten jam nut on actuator side B 6 2013 SeaStar Solutions Optimus 360 Installation Supplement Rev C B 3 Control Head Setup 2013 SeaStar Solutions The control head has several configurable parameters as shown in figure B 5 below The default settings will generally provide excellent performance for most boats Access the parameters by double clicking on the Main Control Head in the Datalink interface list then clicking on the Parameters tab A reset function is provided so that default values can be restored at any time Remember to click Write after making any changes lo View Control Module Tools Win e e Open Import Save Read LL Information Tables Curve H User settings RPM Sync Forward Trolling Mode Reverse Trolling Mode Forward Throttle Curve Reverse Throttle Curve Dealer settings Station Protect Control Head instance Figure B 5 Control Head setup The functions of these parameters are as follows RPM Sync Controls the throttle behaviour when the Power Train Sync PTS feature is engaged When True the control system will use tachometer feedback to match engine speeds When False the control system will simply match the throttle command If engine RPMs oscillate in Sync
74. t adjust in increments of at least 2096 Reduce the size of the increment as you get closer to zero fore aft movement b Press Save c Repeat until the boat rotates on the spot with no fore aft movement 4 Press Boost on the joystick to enable boost mode and select Boost REV FWD Ratio on the display Repeat step 3 Optimus 360 Installation Supplement Rev C 5 Turn boost mode off on the joystick Select Off Idle REV FWD Ratio on the display and adjust the value so that it is the same as the Normal REV FWD Ratio parameter In many cases the off idle rotation power balance will be adequate at this point but you may find the vessel drifts aft at small joystick inputs especially when the joystick is tuned with higher peak power levels You can improve the off idle performance with the optional step below 6 Optional Keep an eye on your port engine tachometer and slowly rotate the joystick clockwise CW until the engine comes just off idle Hold the joystick at this point a If the boat moves aft decrease the Off Idle REV FWD Ratio b If the boat moves forward try rotating the joystick a little more If the boat still doesn t move aft there is no adjustment to make Leave the Off Idle REV FWD Ratio the same as the Normal REV FWD Ratio It should never be higher c Press Save d Repeat until the boat rotates on the spot with no fore aft movement 7 2 6 Set Sideways Rudder Angle When moving sideways we don
75. t isn t necessary that the port and starboard Throttle vs RPM maps are the identical The system will synchronize the engines to the same speed B 5 7 Set Forward Heading Correction In this step you will agjust the rudder angles to minimize sideways drift when piloting the boat straight ahead with the joystick Perform in an area with no wind or current 1 Press Take Command on the joystick Ensure boost mode is off 2 Push the joystick all the way forward without rotating the knob If the boat holds a straight course then no adjustment is necessary Move on to STEP 5 3 Change the Rudder Correction value until the boat holds a straight course Remember to click Write with each change a Each unit equals one degree of rudder correction If the boat drifts to port enter a positive value If the boat drifts to starboard enter a negative value m4 Set Forward Heading Correction Rudder Correction 00 Figure B 14 Rudder Correction 2013 SeaStar Solutions Optimus 360 Installation Supplement Rev C 15 5 8 ian Balance Rotation Power In this step you will tune the power ratio between the FWD and REV engines to yield tight circles in rotation ROT mode Perform in an area with no wind or current to remove outside interference Tip 1 6 If this is the initial tune skip to step 3 If you adjusted the power levels in STEP 8 and are now performing a re tune adjust the X values in the t
76. t want the boat to rotate We achieve this by tuning the Sideways Rudder Angle parameters For best results perform in an area with as little wind and current as possible This step only adjusts for rotation during sideways movement Fore aft movement during sideways motion will be adjusted in STEP 7 1 Bring the boat to a stop with boost mode off 2 On the display navigate to Dealer Menu Initial Setup Joystick Set Sideways Rudder Angle Select Normal Rudder Angle The default parameter values may be different on your installation SIDEWAYS RUDDER ANGLE Off Idle Rudder Angle Normal Rudder Angle Boost Rudder Angle Figure 12 1 10 2013 SeaStar Solutions Optimus 360 Installation Supplement Rev C 2013 SeaStar Solutions 3 Move the joystick sideways fully to port a If the boat rotates clockwise as it starts to move press to decrease the ratio by up to two units If it rotates counter clockwise press to increase the ratio Note the boat will rotate counterclockwise as it gains speed This is normal our objective is to remove rotation during initial movement b Press Save c Repeat until the boat s initial movement is directly sideways Press Boost on the joystick to enable boost mode and select Boost Rudder Angle on the display Repeat step 3 Turn boost mode off on the joystick Select Off Idle Rudder Angle on the display and adjust the value so that it is the same as
77. talling tlie 4 1 JOVStoR VDOC S desert 4 1 4 2 Installing the Control Head 4 1 4 2 1 Control Head Trim Switch Connection 4 1 4 3 Installing The Actuators od no socie 4 3 4 3 1 Location Identification amp Mounting 4 3 4 3 2 Start In Gear Protection ss 4 3 4 3 3 Actuator Power 4 4 4 3 4 Shift Actuator Electrical Connections 4 4 4 3 5 Throttle Actuator Electrical Connections 4 5 4 4 1 Harness Eo Ee arva s eor EE 4 6 4 4 1 Connecting a Second 4 7 4 5 Harness nnn nnn 4 8 System Setup Purge and Calibration 5 1 Dub INA STE 5 1 5 2 Purge and Calibrate su es 5 3 5 3 ACWALOl 5 4 5 3 1 Step 1 Actuator Configuration Using the CANAK 2180 end tonic COME a e cd OL n 5 4 5 3 2 Step 2 Cable Installation and Adjustment 5 7 5 3 2 1 Shift Cable Installation 5 8 5 3 2 2 Throttle Cable Installation 5 9 5 3 3 Final Setup and Actuator Adjustment
78. tar PR SOLUTIONS SEASTAR SOLUTIONS 3831 NO 6 ROAD RICHMOND B C CANADA V6V 1P6 FAX 604 270 7172 www seastarsolutions com ISO 10592 CE 2013 MARINE CANADA ACQUISITION INC DBA SEASTAR SOLUTIONS PRINTED IN CANADA FORM NO 682102 04 14 Rev C
79. than the ecu extension generated by Datalink Only xcu files can be imported using the CANtrak display Don t change the extension when you rename the file Optimus 360 Installation Supplement Rev C 1 15 7 3 Importing a Joystick Tuning File 1 16 7 3 1 7 3 2 The Import utility in the CANtrak display allows you to an existing joystick tuning file into another joystick This makes it easy to e use a template tuning file to set up identical vessels without tuning every vessel individually e replace a joystick Using a template file If you are setting up identical vessels you can use the tuning file from the first vessel as a template for others For vessels to be considered identical they must have the same hull model and size and the same engines model horsepower and propellers If any of these conditions are not met you will need to perform a full joystick tune When you plan to use a joystick tuning file as a template for identical vessels save it with a meaningful name in a dedicated folder Example Joystick Template Hull Model Engine Model Date xcu You will need e a copy of the template tuning file xcu on a USB drive e the latest firmware revision on all system components See Appendix E of Book 50 for firmware updating instructions Procedure 1 Follow the basic import procedure in section 7 3 4 Be sure to select the correct template file 2 f this is a multi station
80. the Normal Rudder Angle parameter In many cases the off idle rudder angle will be adequate at this point but you may find the vessel rotates clockwise at small joystick inputs especially when the joystick is tuned with higher peak power levels You can improve the off idle performance with the optional step below Optional Keep an eye on your starboard engine tachometer and slowly move the joystick to port until the engine comes just off idle Hold the joystick at this point a If the boat rotates clockwise decrease the Off Idle Rudder Angle b If the boat rotates counterclockwise try moving the joystick a little more If the boat still doesn t rotate clockwise there is no adjustment to make Leave the Off Idle Rudder Angle the same as the Normal Rudder Angle It should never be higher c Press Save d Repeat until the boat s initial movement is directly sideways 7 2 7 Balance Sideways Power In this step you will adjust the power ratio between the REV and FWD engines to eliminate fore aft movement when moving the boat sideways Perform in an area with no wind or current to remove outside interference 1 Bring the boat to a stop with boost mode off 2 On the display navigate to Dealer Menu gt Initial Setup gt Joystick gt Balance Sideways Power Select Normal REV FWD Ratio The default parameter values may be different on your installation Optimus 360 Installation Supplement Rev C 7 11
81. the Shift to Forward Throw value 1 mm at a time as necessary to fully engage the gear Click Write to save each change 5 Repeat items 3 and 4 for reverse gear modifying the Shift to Reverse Throw value as necessary to fully engage the gear Optimus 360 Installation Supplement Rev C 5 DANGER 6 Verify that the engine returns to neutral properly The propeller should freewheel in neutral If the propeller does not freewheel in neutral THIS PROCEDURE REQUIRES adjust the actuator side adjustment barrels as necessary to achieve TURNING A PROPELLER BY HAND the correct neutral position See Section 5 3 2 1 then repeat WITH THE IGNITION ON USE items 1 to 6 EXTREME CAUTION 7 Repeat items 1 to 6 for the port shift actuator 8 During sea trial verify that both engines engage both gears properly and hold the gear in both forward and reverse under load If necessary repeat items above to achieve proper gear engagement VVARNING AFTER FINAL ADJUSTMENT IS MADE APPLY LOCTITE 242 BLUE AND TIGHTEN JAM NUT ON ACTUATOR SIDE It is not uncommon to have stroke length a little longer for the push direction gear to take up the lost motion of the cable in the push direction This is more pronounced with longer cables THROTTLE Successful installation of the throttle cables should accomplish the following goals e o have throttle cables adjusted evenly so engines start to rev up at the same time given the same throttle handl
82. the joystick on a horizontal surface in a location that will minimize water spray Install the joystick using the hardware provided in the kit The joystick harnesses must be strain relieved to one of the mounting studs using the cable tie provided with the joystick hardware A dash cutout template is provided in Appendix A 4 1 1 Joystick Types There are two types of joysticks master and additional station Every installation must have at least one master joystick which comes factory configured for the number of engines in the installation The master joystick can be installed at any control station the joystick type is independent of the joystick station If there is no master joystick in the system you will get a persistent Missing Master Joystick warning on the CANtrak display Similarly if the master joystick type doesn t match the configured number of engines the CANtrak will display a persistent Invalid Joystick Configuration warning Table 4 1 lists the supported joysticks at the time of printing JOYSTICK PART NO DESCRIPTION EJ1400 Joystick Master Twin Engine EJ1401 Joystick Additional Station Table 4 1 Supported joysticks 4 2 Installing the Control Head Install the control head on the dash in a location that allows convenient and unobstructed access Whenever possible mount the control head in a location that will minimize water spray Ensure that the control levers can be moved throughout their
83. tle It is not important which connector is connected to the shift actuator and which is connected to the throttle Refer to Figure 4 2 1 Connect the 4 pin connectors to the mating connector on the shift and throttle actuators 2 Connect the black and green wires to ground 3 Connect the red wire through a 25 amp circuit breaker to a positive power source preferably direct to the vessel s batteries or to a battery switch 4 Connect the white wires to an ignition source which is live when either of the engines is in the on position If such a source does not exist use SeaStar Solutions Dual Ignition Kit P N HA1201 Shift Actuator Electrical Connections 1 To use the start in gear protection built into the actuator 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 w red tracer Connect to engine start solenoid The following table lists the ignition start system wire colors typically used by each manufacturer This table serves as a guide only always consult manufacturer s documentation for correct wire identification Manufacturer Wire Colors o BRP Table 4 3 Start in Gear wire colors 2 If not using start in gear protection cap and tie back the two yellow wires 3 Connect the round DeviceNet connector to the CAN2 network as shown in Section 4 5 4 Repeat steps 1 3 for other shift act
84. tle 49 Figure 5 15 Station Protection Sync Engine RPMs Max Shift RPM FWD REV Throttle Curve This feature prevents accidental switching between control stations on multi station boats by requiring a specific sequence of button presses on the control head The Optimus 360 User s Manual Book 61 has more information about this feature Controls the throttle behavior when the Power Train Sync PTS feature of the control head is engaged When set to Yes the control system will use tachometer feedback to match engine speeds When set to No the system will simply match the throttle command If you find the engine RPMs oscillate in PTS mode change this parameter to No Sets the maximum RPM at which a gear shift will be attempted by the control head It is designed to delay a shift until engine RPM reaches a safe shifting speed There are two throttle curves that control the response characteristics when the control lever is at or near idle Curve 1 is the default curve and is Suitable for most applications Curve 2 requires more lever travel before throttle is increased Optimus 360 Installation Supplement Rev C FWD REV Trolling Sets the maximum percentage of wide open Max Throttle throttle when trolling mode is engaged A forward setting of 5096 means that when the throttle lever is fully forward the throttle is limited to 5096 of maximum This provides greater throttle sensitivity
85. to neutral Procedure 1 Turn ignition on but do not start engines 2 Navigate to Dealer Menu Initial Setup Shift amp Throttle Adjust Port Shift Actuator Port Shift Setup Shift to Forward Direction Push Forward Stroke 34 0 mm Reverse Stroke 34 0 mm Neutral Start Protection Figure 5 18 3 While an assistant spins the port engine prop by hand use the control lever to put the port engine into forward gear Check that the gear engages fully If the gear does not fully engage increase the Forward Stroke parameter by 1 mm at a time press Save and repeat the test until gear engagement is satisfactory b Repeat steps 3 and 4 in reverse gear this time adjusting the Reverse Stroke parameter 2013 SeaStar Solutions Optimus 360 Installation Supplement Rev C 6 Verify that the engine returns to neutral properly from both forward and reverse gear The propeller must freewheel in neutral If it doesn t adjust the actuator side adjustment barrels until the neutral position is correct See section 5 3 2 1 for adjustment 4 Repeat steps 1 to 6 for the starboard shift actuator 8 Tighten the actuator side lock nut see figure 5 12 for both shift actuators Once the final adjustments are made you will need to apply Loctite 242 to the threads but you will do this after the sea trial 9 If your engine already has neutral start in gear protection you can change the Neutral Start Protection paramet
86. trol of the vessel Perform with boat safely secured or in an open area Forward Throttle Wizard 1 Press Take Command on the joystick Ensure boost mode is off 2 Click Run Port Engine Forward Throttle Wizard see figure B 13 SECOND Y VALUE The joystick s A LED will flash to indicate the port wizard is running m3 Run Engine Throttle Wizards hrottle qe Run Port Engine Reverse Throttle Wizard Port Fwd Throttle 24 7 15 55 Te 25 025 24 255 27 285 1 30 Port Fwd Engine RPM 1200 1375 1550 1725 1900 Port Rev Throttle UN 15 175 20 225 25 275 30 325 35 375 40 Port Rev Engine RPM 0 500 750 1000 1250 1500 1750 2000 2250 2500 2750 3000 Run Stbd Engine Forward Throttle Wizard Run Stbd Engine Reverse Thrittle Wizard Stbd Fwd Throtle 15 165 18 195 21 225 24 255 2 285 30 Stbd Fwd Engine RPM 0 500 675 850 1025 1200 1375 1550 1725 1900 2075 2250 Stbd RevThrotlle 15 175 20 225 25 275 30 325 35 375 40 SttdRevEngneRPM Y 0 500 750 1000 1250 1500 1750 2000 2250 2500 2750 3000 FINAL Y VALUE Figure B 13 The engine response configuration wizards are found on the Setup tab 3 Push and hold the joystick all the way forward The wizard will increase throttle from maximum idle throttle to maximum joystick throttle recorded in STEP 2 in increments returning to zero throttle before each increment a If necessar
87. ttention to gear engagement boat response and stopping power Gear Engagement Perform the following actions and check that the gear shifts occur within approximately two seconds If you find that gear engagement is taking longer contact SeaStar Solutions technical support Engage Boost mode Move the joystick all the way to port for a few seconds Move the joystick all the way to starboard for a few seconds Move the joystick back to port Repeat pausing at the neutral position for one second when changing directions Te ey Boat Response Step through all the Joystick Modes of Operation shown on the Optimus 360 Joystick Quick Reference Guide and confirm that 1 boat response is predictable 2 speeds are safe for operation in a marina 3 boost mode gives noticeably higher thrust than normal mode If the boat performance does not meet all of these requirements return to STEP 8 and adjust the power levels according to the instructions If further adjustments do not help or if you need assistance contact SeaStar Solutions technical support Stopping Power 1 In normal mode hold the joystick all the way forward until the boat reaches its maximum speed 2 Abruptly move the joystick all the way into reverse 3 Confirm that the boat s stopping power is adequate 4 Repeat the test in boost mode If the stopping power is insufficient for safe operation return to STEP 8 and increase the Reverse Power parameters as requi
88. ty 10 2 We warrant to the original retail purchaser that Marine Canada Acquisition Inc DBA SEASTAR SOLUTIONS herein forward referred to as SeaStar Solutions products have been manufactured free from defects in materials and workmanship This warranty is effective for two years from date of purchase excepting that where SeaStar Solutions products are used commercially or in any rental or income producing activity then this warranty is limited to one year from the date of purchase We will provide replacement product without charge for any SeaStar Solutions product meeting this warranty which is returned freight prepaid within the warranty period to the dealer from whom such product were purchased or to us at the appropriate address In such a case SeaStar Solutions products found to be defective and covered by this warranty will be replaced at SeaStar Solutions option and returned to the customer The above quoted statement is an extract from the complete SeaStar Solutions products warranty statement A complete warranty policy is available in our SeaStar Solutions products catalogue Return Goods Procedure 10 3 Prior to returning product to SeaStar Solutions under warranty please obtain a Return Goods Authorization number claim number Be sure to label the goods with a the name and address of the sender and b the return goods authorization number claim number Please address the returned goods as follows
89. uator 2013 SeaStar Solutions Optimus 360 Installation Supplement Rev C 4 3 5 Throttle Actuator Electrical Connections 1 Cap and tie back the two yellow wires these are unused for throttle actuators 2 Connect the round DeviceNet connector to the CAN2 network as shown in Section 4 5 3 Repeat steps 1 amp 2 for other throttle actuator RED AND BLACK ARE ACTUATOR POWER WHITE AND GREEN ARE CAN POWER Older CE20425 used Orange and Brown for CAN Power 25A BREAKER RED POWER OTHER CONNECTIONS WHITE CE20425 THROTTLE 29 SOURCE lt gt 25 BREAKER FUSE PANEL JJ o us om o c e BLACK CE20425 D GREEN BLACK 2I TJ MAIN BATTERY POWER OTHER CONNECTIONS GROUND Figure 4 2 CE20425 power harness connection 2013 SeaStar Solutions Optimus 360 Installation Supplement Rev C 4 5 44 Harness Connections Refer to the Optimus EPS Installation Manual Book 50 for CANT harness selection and connections In addition to this the Optimus 360 system requires a 6 pin CANT harness connection between the steering helm and the joystick Refer to book 50 for proper harness selection and strain relieving HARNESS TIE POINT X 4 CAN2 PORT fle SEE SECTION 3 5 CAN1 HARNESS 7 N 27 T
90. w STEP 1 Import engine specific settings STEP 2 Set throttle limits STEP 3 Run throttle wizards STEP 1b Set basic system parameters Datalink only STEP 7 Balance sideways power STEP 6 Set sideways rudder angle STEP 5 Balance rotation power STEP 4 Set forward heading correction YES Did you STEP 8 STEP 10 Adjust power change power STEP 9 Save copy of levels in Sea trial levels tuning file step 8 i Figure 7 2 Joystick Tuning procedure 1 2 2013 SeaStar Solutions Optimus 360 Installation Supplement Rev C 2 Joystick Tuning Procedure The joystick tuning procedure is organized into ten steps detailed in the following sections The entire procedure can be performed with either the color CANtrak display as shown in this section or with Datalink as shown in Appendix B Tuning with the CANtrak has the advantage that it will simultaneously tune all connected joysticks which makes it simpler to tune dual station boats NOTICE General Notes e The joystick tuning procedure consists of several steps each of The joystick tuning procedure will which may contain several sub steps To differentiate between require maneuvering of the boat these we use all capital letters to denote the main STEPS and Some of these procedures can be lower case letters to indicate the sub steps performed at dock with the boat securel
91. water before proceeding Moving the joystick will apply throttle INSTRUCTIONS Refer to the installation manual for the throttle wizard procedure STATUS Start Figure 7 9 2013 SeaStar Solutions Optimus 360 Installation Supplement Rev C 4 Push and hold the joystick all the way forward The wizard will increase throttle from maximum idle throttle to maximum joystick throttle recorded in STEP 2 in increments returning to zero throttle before each increment a If necessary rotate the joystick to correct the boat s heading To abort the wizard release the joystick You will need to run the wizard again b The wizard takes about one minute to run When it finishes the A LED will stop flashing the forward gear will engage and the engine speed will increase to max forward joystick Release the joystick at this point The display will return to the Throttle Wizards menu 5 Repeat this time selecting Run Port REV Wizard and holding the joystick in full reverse 6 When you ve run both forward and reverse wizards on the port engine run the starboard wizards 7 24 ii Set Forward Heading Correction In this step you will adjust the rudder angles to minimize sideways drift when piloting the boat straight ahead with the joystick For best results perform in an area with as little wind and current as possible 1 Navigate to Dealer Menu Initial Setup Joystick Set Forward Heading Correction FORWARD HEADIN
92. will be doing the setup with the main joystick 1b System Joystick Instance Main v Figure B 11 The System parameters section of the Setup tab B 5 5 Set Throttle Limits In this step you will configure e the maximum throttle percent at which the engines are at idle and e the maximum throttle percent intended for joystick use Perform this step with the boat safely secured or in an open area If you are having problems getting an engine to idle or if it is idling intermittently at different RPMs confirm that your engine s throttle position sensor TPS is functioning properly 2013 SeaStar Solutions Optimus 360 Installation Supplement Rev C 1 Maximum Throttle at Idle Forward a Use the control head to put the port engine in forward gear b Very slowly increase throttle until the engine RPM increases Note the maximum throttle percentage at which the engine is still at idle The RPM and throttle percentage are displayed in the boxes as shown in figure 9 7 c Enter the value in the Port Idle Forward Throttle 2 Set Throttle Limits Throttle Positions Port Idle Forward 1 F Port Throttle Stbd Idle Forward Throttle 15 4 Stbd Throttle 100 Port Max Forward Throttle Stbd Mex Forward Throttle Port Idle Reverse Throttle Stbd Idle Reverse Throttle Port Mex Reverse Throttle Stbd Mex Reverse Throttle Engine RPM Port Engine RPM 050 9 StbdEngine RPM 71650 RPM Figure B 12 Throttle
93. y rotate the joystick to correct the boat s heading To abort the wizard release the joystick b When the wizard finishes the LED will stop flashing This takes about one minute 4 Click Read to import the wizard values into Datalink b Examine the second Y value see figure B 13 in the table If it is more than 100 RPM higher than the engine s in gear idle RPM go back to STEP 2 and decrease FWD Port Max Throttle at Idle by 0 5 Click Write if you make a change B 14 2013 SeaStar Solutions Optimus 360 Installation Supplement Rev C 6 Examine the final Y value in the table The target value is 1800 t 200 a If itis less than 1600 go back to STEP 2 and increase FWD Port Max Joystick Throttle by 0 5 b If itis more than 2000 decrease FWD Port Max Joystick Throttle by 0 5 c Click Write if you make a change 7 If you changed the throttle parameters repeat the wizard and recheck the results until the conditions are met 8 Click Run Stbd Engine Forward Throttle Wizard to repeat this procedure for the starboard engine The C LED will flash on the joystick to indicate the starboard wizard is running Reverse Throttle Wizard Run the reverse wizards with the joystick held in full reverse The procedure is identical except that the target for the final Y value step 6 is the maximum RPM you recorded in STEP 2 Use the same adjustments to ensure the final Y value is within 200 RPM of the target BEEN NOTICE I
94. y restrained but others will require open water with Before You Start adequate maneuvering space Example Adjust the parameter as shown in step of STEP 8 e Trim both engines down and ensure that the correct propellers are installed You will need to repeat the joystick tuning procedure if you change the propellers afterward e Warm up the engines thoroughly before you begin NOTICE Erratic engine performance stalling or other engine control issues will affect the operation of the joystick control system Any such issues must be addressed before attempting joystick setup 4 2 1 ER Import Engine Specific Settings There are some system parameters that need to be set for specific engines You will do this by importing these settings with a simple wizard on the CANtrak display 1 On the display navigate to Dealer Menu Initial Setup Joystick This is your home base for the joystick tuning procedure and the numbered steps will help lead you through the tuning process JOYSTICKS SETUP 1 Import Engine Specific Settings gt gt 2 Set Throttle Limits 3 Run Throttle Wizards gt 4 Set Forward Heading Correction 5 Balance Rotation Power 6 Set Sideways Rudder Angle Figure 7 3 2013 SeaStar Solutions Optimus 360 Installation Supplement Rev C 2 Select Import Engine Specific Settings and press gt This will take you to the Import screen IMPORT JOYSTICK SETTINGS All Others

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