Seastar Solutions Optimus 360 User`s manual

OPERATION INSTRUCTIONS
MEMBER
AND USERS MANUAL
www.teleflexmarine.com
I S O
9 0 0 1
Joystick Control System
MANUFACTURED BY
MARINE CANADA ACQUISITION
LIMITED
PARTNERSHIP DBA TELEFLEX
CANADA
To the End User (Owner)
Thank you for choosing an OptimusTM 360 Joystick Control System
by Teleflex Marine. This User’s manual contains all of the information that you will require for safe use of your vessel control system
and must remain on the boat.
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.
For the latest information, go to www.teleflexmarine.com
All Rights Reserved:
No part of this publication may be reproduced or used in any form
by any means without the written permission of Teleflex Marine
Incorporated.
©2012 Teleflex Marine.
is a registered trademark of the American Boat & Yacht
Council (http://www.abycinc.org)
NMEA 2000® is a registered trademark of the National Marine
Electronics Association.
Optimus 360 TM is a trademark of Teleflex Marine.
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© 2012 Teleflex Marine, Inc.
Optimus 360 Users Manual, Rev. A
Notice to the Operator
Throughout this publication, Dangers, Warnings and Cautions
(accompanied by the International Hazard Symbol ) are used to
alert the user to special instructions concerning a particular service
or operation that may be hazardous if ignored, performed incorrectly,
or carelessly.
Observe Them Carefully!
These “safety alerts” alone, cannot eliminate the hazards that
they signal. Strict compliance to these special instructions when
operating and maintaining, plus “common sense” operation, are
major accident prevention measures.
Failure to adhere to these notices may result in the loss of steering
and shift/throttle control, leading to possible ejection from the
vessel, causing property damage, personal injury and/or death.
Immediate hazards which, if not acted upon, WILL result in severe
personal injury or death.
WARNING
CAUTION
Hazards or unsafe practices which, if not acted upon, COULD
result in severe personal injury or death.
Hazards or unsafe practices which COULD result in minor injury or
product or property damage.
Information which is important to proper use or maintenance, but is
not hazard-related.
© 2012 Teleflex Marine, Inc.
Optimus 360 Users Manual, Rev. A
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INDEX
1.0 Safety Instructions................................................................ 1
Safety Labels....................................................................... 3
Abbreviations....................................................................... 6
Definitions........................................................................... 7
2.0 Introduction.......................................................................... 8
2.1Welcome..................................................................... 8
2.2 Optimus 360 System Overview..................................... 8
2.3 Optimus 360 System Diagram...................................... 9
3.0 Component Identification..................................................... 10
3.1 Electronic Helm(s) (EPS System)................................. 10
3.2 Control Head (EST System)......................................... 11
3.3Joystick..................................................................... 12
3.4 CANtrak Display......................................................... 13
3.5 Circuit Breakers for Optimus 360 System
and Shift and Throttle Control System......................... 13
3.6 Pump Control Module (PCM)....................................... 14
3.7 Hydraulic Pumps........................................................ 14
3.8SmartCylinders.......................................................... 15
3.9 Steering Service Valves.............................................. 15
3.10Shift and Throttle Actuators........................................ 16
4.0 Steering System Operation.................................................. 17
5.0 Control Head Operation........................................................ 18
5.1Identification............................................................. 19
6.0 Joystick Operation............................................................... 22
6.1 Joystick Fundamentals............................................... 23
6.2 Joystick Tips.............................................................. 26
6.3 Joystick Operation Examples....................................... 27
7.0 CANtrak Display ................................................................. 31
7.1Purpose.................................................................... 32
7.2 CANtrak Display Navigation......................................... 33
7.3 CANtrak Display Map – All Helms Active....................... 34
7.4 Display Screens......................................................... 35
7.4.1 All Helms Active................................................ 35
7.4.2 Diagnostics (DIAG) Screen................................. 35
7.4.3 Adjust (ADJ) Screen........................................... 36
7.4.4 Display (DISP) Screen....................................... 38
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© 2012 Teleflex Marine, Inc.
Optimus 360 Users Manual, Rev. A
8.0 First Time Use..................................................................... 39
8.1 Control Head Adjustments.......................................... 39
8.2 Initial Start Up........................................................... 40
8.3 System Inspection..................................................... 42
8.4 Installation Checks.................................................... 44
8.5 Initial Sea Trial........................................................... 47
9.0 System Use......................................................................... 48
9.1 Before Each Use........................................................ 48
9.2 Multiple Station Boats................................................ 48
9.3 Autopilot Operation.................................................... 49
10.0 System Faults & Hazards................................................... 50
10.1 Hazard Definitions...................................................... 50
10.1.1 Danger........................................................... 50
10.1.2 Warning......................................................... 51
10.2 System Fault Handling................................................ 52
10.2.1 Danger Fault Handling..................................... 52
10.2.2 Limp Home..................................................... 53
10.2.3 Warning Fault Handling.................................... 56
10.2.4 System Fault Handling – Example..................... 58
10.2.5 CANtrak Loss of Display.................................. 58
10.3 Buzzer....................................................................... 60
10.4 Reduced Performance................................................ 60
11.0 Maintenance..................................................................... 61
12.0 Troubleshooting................................................................. 63
13.0 Replacement Parts............................................................ 64
13.1SeaStar Electronic Power Steering Fluid....................... 64
14. Warranty............................................................................. 65
14.1 Statement of Limited Warranty................................... 65
14.2 Return Goods Procedure ........................................... 65
APPENDIX A - Specifications...................................................... 66
APPENDIX B - EST Station Select Protection.............................. 67
© 2012 Teleflex Marine, Inc.
Optimus 360 Users Manual, Rev. A
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© 2012 Teleflex Marine, Inc.
Optimus 360 Users Manual, Rev. A
1.0 SAFETY INFORMATION
The safety information provided below is intended to inform you of
the dangers that may be present before, during and after use. It is
critical that you read and understand ALL the points noted.
The safe operation of the vessel control system is dependant
upon proper installation and maintenance, common sense, safe
judgement and the knowledge/expertise of the operator. Every
installer/user of the vessel control system should know the following
requirements before installing/using the vessel control system.
If you have any questions regarding any of these warnings, contact
Teleflex Marine.
To reduce risk of severe injury or death:
The Optimus 360 System MUST ONLY be installed by an authorized
Teleflex Marine dealer.
1. Always wear a Coast Guard Approved personal flotation device
(PFD) and use an engine shut-off cord (lanyard).
2. Read and understand this User’s manuals and the Quick
Reference Card provided with your vessel control components.
3. Optimus 360 components are highly engineered and safety
tested to ensure system integrity. DO NOT substitute any
component with non-Optimus 360 components, as this may
compromise system performance/reliability.
Prior to every use
Perform a system inspection as outlined below. Refer to Section 7.3
for further details.
1. Check steering fluid level in all steering pumps.
2. Verify immediate steering response when turning steering
wheel(s).
3. Inspect all steering hoses, fittings and mechanical and electrical
cables for wear, kinks, or leaks.
4. Check for binding, loose, worn or leaking steering or shift/throttle
control components.
5. Verify proper shift and throttle response for all control handles.
6. Verify that no alarms or warnings are shown on the CANtrak
display.
Do not operate boat if any component is not in proper working
condition.
© 2012 Teleflex Marine, Inc.
Optimus 360 Users Manual, Rev. A
1
1.0 Safety information (continued)
During use
1. WEAR A COAST GUARD-APPROVED PERSONAL FLOTATION
DEVICE (PFD).
2. Attach engine shut-off cord (lanyard) to your pfd.
3. Never allow anyone not familiar with the operation of the vessel
control system to operate the boat at ANY time.
4. Know and adhere to the operator restrictions for you area
including:
• Federal Laws/Regulations,
• State Laws/Regulations and
• Municipal Laws/Regulations.
DO NOT OPERATE BOAT IF ANY COMPONENT IS NOT IN PROPER
WORKING CONDITION.
After use
Rinse off SmartCylinders thoroughly using “fresh, clean water” only.
Do NOT rinse PCM, pumps, or actuators.
• Cleaning fluids containing ammonia, acids or any other corrosive
ingredients MUST NOT be used for cleaning any part of the
Optimus 360 System.
Maintenance
Maintain Optimus 360 System as directed in Section 11.0 of this
Manual.
Keep our waters clean for all current and future users. Dispose of
ALL fluids in accordance with your local regulations.
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© 2012 Teleflex Marine, Inc.
Optimus 360 Users Manual, Rev. A
Safety Labels
NOTE: The labels below should call attention to the possible
hazards associated with the equipment shown later in this manual
(see Section 3.1)
Control Head Label
Hydraulic Pump Label
CAUTION
HOT
© 2012 Teleflex Marine, Inc.
Optimus 360 Users Manual, Rev. A
3
Safety Labels (continued)
Pump Control Module
(PCM) Labels
SmartCylinder Labels
4
© 2012 Teleflex Marine, Inc.
Optimus 360 Users Manual, Rev. A
Safety Labels (continued)
Steering Service
Valve Label
TO BE INSTALLED CLOSE TO THE SERVICE VALVE
Actuators
© 2012 Teleflex Marine, Inc.
Note: Actuator labels not shown 100% of actual size.
Optimus 360 Users Manual, Rev. A
5
ABBREVIATIONS
The following abbreviations are used in this manual:
ABYC American Boat & Yacht Council
APAutopilot
AUXAuxiliary
AWG
American Wire Gauge
BATBattery
CAN
Control Area Network
CAN Bus
Control Area Network (data) Bus. (A cable of wires
that carry digital signals and power between
electronic modules)
ECU
Electronic Control Unit
EIM
Engine Interface Module
ENGEngine
EPS
Electronic Power Steering
EST
Electronic Shift and Throttle
FForward
GNDGround
GPS
Global Positioning System
HIHigh
INFOInformation
KHzKilohertz
Km/h
Kilometers Per Hour
LED
Light Emitting Diode
LoLow
mA or mAmp
Milliamp (1/1000 of an ampere)
MAGMagnetic
MPH
Miles Per Hour
NNeutral
NMEA
National Maritime Electronics Association
NMEA 2000®
The special protocol for digital communication on
a CAN Bus
Nm
Nautical Miles
NSP
Neutral Start Protection
NTW
Neutral Throttle Warmup
N/C
No Connection
PCM
Pump Control Module
PGN
Parameter Group Number
PSI
Pounds Per Square Inch
PTS
Power Train Sync
RReverse
RPM
Revolutions Per Minute
SOG
Speed Over Ground
SOW
Speed Over Water
STBD
Starboard (right when facing the front of the boat)
SWSwitch
TM
Trolling Mode
WOT
Wide Open Throttle
Note: Some abbreviations not listed here may be found in their
respective sections.
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© 2012 Teleflex Marine, Inc.
Optimus 360 Users Manual, Rev. A
DEFINITIONS
Conventional Steering This is the standard type of steering that has been used on boats for many
Control
years. The steering wheel is the only means of control.
Conventional Shift &
Throttle
The type of shift and throttle control where standard control head levers
allows the engine gear selection and throttle control.
Neutral Throttle
Warmup
This features allows the engine RPMs to be adjusted without the engine going
into gear.
Power Train Sync
This feature automatically sets both engines to the same RPM level. When
Power Train Sync is selected, the gears and the throttles are operated by one
control lever.
Trolling Mode
A control feature which limits the full throttle lever position on the control to
a percentage of the true engine maximum RPM’s; it improves forward control
of the boat at slow speeds. Default is 50% forward and may be set from 0%
to 90%.
Joystick Control
A single handle joystick control device that integrates the steering, the gear
shift, and the throttle control for multiple engines into one easy-to-use device
to provide docking control of the vessel.
© 2012 Teleflex Marine, Inc.
Optimus 360 Users Manual, Rev. A
7
2.0INTRODUCTION
2.1 Welcome
Welcome to the world of electronic joystick control. Please take
a few minutes to go through the System Overview and the First
Time Operation sections to assure your safety and to get the most
enjoyment from the Optimus 360 joystick control system.
2.2 Optimus 360 System Overview
An Optimus 360 system consists of:
a)An Electronic Power Steering (EPS) system to provide effortless
conventional steering.
b)An Electronic Shift and Throttle (EST) control system to provide
ease of shift and throttle operation and various convenience
features.
c)An Electronic Joystick control system that can combine the EPS
and the EST systems to provide complete boat control using a
single intuitive interface.
d)An electronic display to provide system status, faults, and
instructions.
The EPS system consists of an electronic helm located behind
the steering wheel that is electrically connected to a pump control
module. This module converts the steering wheel action to electrical
signals that operate hydraulic pumps. These pumps move the smart
steering cylinders (SmartCylinders) at each engine.
A position sensor is part of the SmartCylinders and provides
engine position information back to the pump control module.
service valves are installed between the hydraulic pumps and the
SmartCylinders to allow for manual positioning of the engines should
a fault occur or during servicing.
The EST system has a control head at each helm station to control
the gear selection and operate the throttle. The control head sends
electronic signals to actuators that move the shift and throttle
control cables connected to the engine’s control levers.
The Joystick Control system consists of a Joystick which interfaces
to the EPS and EST system and, when activated, controls the overall
motion of the boat. This is accomplished using electronic signals
from the joystick to take control of the shift, throttle and steering
equipment and operate them as required to totally control the boat
with one easy-to-use device.
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© 2012 Teleflex Marine, Inc.
Optimus 360 Users Manual, Rev. A
2.2 Optimus 360
System Overview (continued)
A CANtrak display shows system operation and fault warnings.
The CANtrak display also permits system sensitivity and
configuration adjustments.
The Optimus 360 system exceeds ABYC safety standards and
includes many advancements to make the system as failsafe
as possible. These include redundant sensors, fault-tolerant
communications, self-monitoring and fault communications to notify
and advise the operator in case of fault.
2.3 Optimus 360 System Diagram
© 2012 Teleflex Marine, Inc.
Optimus 360 Users Manual, Rev. A
9
3 .0 COMPONENT
IDENTIFICATION
3.1 Electronic Helm(s) (EPS System)
The electronic helm is the primary user interface for conventional
steering control. When in conventional steering control, ALL helms
on the boat are active and can steer the boat.
The steering wheel is attached to this unit and it may be located
immediately under the wheel or just behind the dash panel. The
images below show typical helms.
Refer to Section 4.0 for steering operation.
EPS Front Mount Helm
EPS Classic Tilt Helm
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© 2012 Teleflex Marine, Inc.
EPS Sport Plus Tilt Helm
EPS Rear Mount Helm
Optimus 360 Users Manual, Rev. A
3.2 Control Head (EST System)
The control head is the primary user interface for conventional shift
and throttle control.
The control head operates the gear shift and the throttle for each
engine. This is accomplished using electronic signals to direct
individual actuators for each function and each engine. The control
head also allows various features like sync and trolling to be
selected.
On single helm station boats the shift and throttle control head
takes command when the ignition is turned on and the handles are
in the neutral position. The blue Take Command light will come on
solid when active.
For more detailed control head operation, refer to Section 4.0.
© 2012 Teleflex Marine, Inc.
Optimus 360 Users Manual, Rev. A
11
3.3 Joystick
The joystick is the primary user interface for joystick control.
The joystick interfaces with the steering system and with the shift
and throttle system. It integrates the two systems together so as to
have complete boat control that is very intuitive from a single device.
The joystick can only take control of the vessel when the shift and
throttle control head is at neutral idle.
See Section 6.0 for detailed Joystick operation.
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© 2012 Teleflex Marine, Inc.
Optimus 360 Users Manual, Rev. A
3.4 CANtrak Display
There is a display at each helm station that shows the system status
and allows system adjustments.
See Section 7.0 for CANtrak usage.
3.5 Circuit Breakers for Optimus 360
System and Shift and Throttle
Control System
These are supplied by the installer and may be mounted in a variety
of locations. Check near the batteries, in the circuit breaker box, or
near the Pump Control Modules or Hydraulic Pumps. There should
be two 60 amp breakers for each PCM and a 25 amp breaker for
each pair of shift and throttle actuators.
© 2012 Teleflex Marine, Inc.
Optimus 360 Users Manual, Rev. A
13
3.6 Pump Control Module (PCM)
This is located in a dry area and can usually be found inside the
center console, in the area behind the dash, or in a compartment
near the engines or batteries. The PCM is always located close to
the Hydraulic Pumps. There will be one PCM on twin engine boats
and two PCM’s on triple or quad engine boats. The PCM controls the
steering and Joystick operation.
3.7 Hydraulic Steering Pumps
The Hydraulic Steering Pumps supply pressurized fluid to the
SmartCylinders to steer the engine and are located near the PCM.
They can usually be found in a compartment near the engines, the
center console or behind the dash. There is one pump for each
engine. Note: these pumps look a lot like the trim pumps that tilt
the engines but can be distinguished by the decal and the green/
blue SeaStar Electronic Power Steering Fluid. The pumps have the
steering fluid reservoir and this is where the fluid level is checked
and steering fluid is added.
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© 2012 Teleflex Marine, Inc.
Optimus 360 Users Manual, Rev. A
3.8 SmartCylinders
On outboard boats these are always located just below the engine
cowling and are attached to the engine tiller arm. There will be one
SmartCylinder for each engine and they provide steering.
3.9 Steering Service Valves
These are located in the hydraulic lines that go from the Hydraulic
Pumps to the SmartCylinders. There is one for each engine. These
are used for servicing and emergency operation.
The steering service valves permit the bypass of the EPS system
and allow the engines to be manually positioned. They should only
be used in the event of an EPS system failure. Instructions on how to
proceed will be supplied on the CANtrak display or in Section 10.2.
Wear a coast guard-approved personal flotation device (PFD) when
manually realigning engines.
© 2012 Teleflex Marine, Inc.
Optimus 360 Users Manual, Rev. A
15
3.10 Shift and Throttle Actuators
There is a shift actuator and a throttle actuator for each engine.
The actuators receive electronic signals from the shift and throttle
control head and position the engine control levers. There is a
manual override feature on the actuators so the engine can be
operated manually in case of a fault.
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© 2012 Teleflex Marine, Inc.
Optimus 360 Users Manual, Rev. A
4 .0 STEERING SYSTEM
OPERATION
The steering portion of the Optimus 360 system provides fingertip
steering control of multiple high-powered engines. The system
provides both power and the adjustment of a number of parameters
so the operator has perfect boat response under all conditions.
The system will power on with the ignition switch and operate
much like a conventional steering system except the feel will be
extraordinary and the effort just perfect for the conditions providing
just the right amount of response and pressure.
The CANtrak display will provide the status of the steering system
and supply information in the event of a fault.
On multiple helm station boats, all helms are active when the
steering is on just like with conventional steering.
The dealer that installs the system will make the necessary
adjustments at the time of installation to achieve exceptional
steering performance. The operator may further refine the feel using
the CANtrak display. See Section 7.4.3.
The quick reference steering guide provided with the system gives
summary and reminder information about the steering system and
should be kept at the primary helm station at all times.
The system may be connected into an autopilot to further enhance
the boating experience. See Section 9.3.
© 2012 Teleflex Marine, Inc.
Optimus 360 Users Manual, Rev. A
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5.0 CONTROL HEAD OPERATION
Be very cautious when first engaging the gears to establish that
forward is truly forward and reverse is truly reverse. A quick in-andout of gear test is recommended. Ensure that the boat is clear of all
obstacles forward and aft before conducting this test.
The control head is the primary user interface for conventional shift
and throttle controls.
On single control station boats, when the ignition is turned on, the
blue Take Command light will illuminate, indicating that the control
head is active. If the control levers are not in neutral, both neutral
indicator lamps will flash red.
On multi-control station boats, when the ignition is first turned on,
the control head “Smart Select” feature will automatically activate
the control head if the levers are moved out of the neutral position.
Alternately, pushing the Take Command button with the control
handles in the neutral position will activate the desired station.
When in joystick mode, the control head will become inactive and all
lamps will go out. The control head can be re-activated at any time
by pressing the Take Command button with the control handles in
the neutral position.
When transferring between joystick and control head, the control
head will remember any special features such as sync mode, which
may have been active prior to entering joystick mode.
The EST Quick Reference Guide provides a summary of the control
head operation and should be kept on the vessel at all times.
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© 2012 Teleflex Marine, Inc.
Optimus 360 Users Manual, Rev. A
5.1 Identification
ENGINE TRIM CONTROL:
“Switch” in the handle. Provides simultaneous
control of both engines.
LEVER POSITION
INDICATORS
NEUTRAL INDICATOR LAMPS:
When the engine is in the neutral idle
position, the lamps go steady green.
INDICATOR DIMMING FEATURE:
With the control head active, push TAKE
COMMAND button again and ALL lamps will
dim. There are five degrees of brightness from
which to choose.
NOTE: Indicator Dimming is only accessible
from the active control station. (Blue lamp on
steady.)
TAKE COMMAND BUTTON:
Press the TAKE COMMAND button to activate this control head.
NOTE: Station Protection may be turned on. See Appendix B.
A lit blue TAKE COMMAND lamp indicates a station is active.
• On single station boats, station selection is automatic.
• For multi-station boats, choose a station and then press TAKE
COMMAND button with levers in neutral.
To Change Control Head Stations (on multiple station boats):
• Move to new station and press TAKE COMMAND button. (Blue
lamp flashes.)
• Match control handle positions with those of active station. (Blue
lamp goes steady when levers match and this station is now in
control.)
© 2012 Teleflex Marine, Inc.
Optimus 360 Users Manual, Rev. A
19
5.1 Identification (continued)
NEUTRAL THROTTLE WARMUP (NTW):
A fast flashing green N (Neutral) lamp indicates NTW engaged for
Allows throttle control without gear engagement.
this engine.
TO ENGAGE Neutral Throttle Warmup:
• Move engine’s lever to the “Neutral” position. Green lamp goes
steady.
• Press the N (Neutral) button next to this lever. (the N lamp flashes
green five times per second.)
TO DISENGAGE Neutral Throttle Warmup:
• Return engine’s lever to the “Neutral” position.
• Press N (Neutral) button next to this lever. The N (Neutral)
lamp will go steady - NTW is disengaged and the engine and
transmission will now respond to lever commands.
TROLLING MODE (TM):
• Slow flashing green N lamps indicate that trolling mode is
engaged (one second on, two seconds off).
• Provides greater throttle sensitivity: moving an engine’s control
lever to FULL FORWARD will only produce a percentage of WOT.
(Default TM throttle limit is 25%).
TO ENGAGE Trolling Mode:
• Move one or both engine’s control levers to the forward idle or
reverse idle positions. The other engine’s lever must be in the
same position or in Neutral).
• Press either of the N buttons. Both N lamps will flash green slowly
– TM is engaged.
TO DISENGAGE Trolling Mode:
• Move both engines’ control levers to forward idle or reverse idle
position.
• Press either of the N buttons. The flashing green lamp will go out
– TM is disengaged.
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© 2012 Teleflex Marine, Inc.
Optimus 360 Users Manual, Rev. A
5.1 Identification (continued)
POWER TRAIN SYNC (PTS):
Automatically synchronizes engines and transmissions; the port lever
controls throttle and shift of both engines across the entire control
range.
A lit blue SYNC lamp indicates sync is engaged.
To Engage Power Train Sync:
• Press SYNC button. (Blue lamp flashes.)
• Match control handle positions within 5% of each other. (Blue lamp
goes steady when levers match – power trains are now in sync.)
To Disengage Power Train Sync:
• Press SYNC button. (Blue lamp flashes.)
• Match control handle positions within 5% of each other. (Blue
lamp goes off when levers match – PTS is now disengaged.)
ADJUSTABLE LEVER FEEL
Turning in (clockwise from front)
tightens the adjustment and backing
out (counter-clockwise from front)
loosens the adjustment.
STARBOARD
PORT
SHIFT
DETENT
THROTTLE
FRICTION
WARNING
© 2012 Teleflex Marine, Inc.
If a danger or warning is caused by the control system, the control
head neutral lights will flash red. See Section 10.
Optimus 360 Users Manual, Rev. A
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6 .0 JOYSTICK OPERATION
The joystick is the primary user interface for the Joystick Control
System. It offers the ultimate control of the vessel for docking and
maneuvering at slow speeds and is especially useful in confined
or difficult circumstances. It is quite intuitive to use as the boat
follows the actions of the handle. This section of the manual gives
a detailed description of all of its capabilities and how to get the
maximum benefit from this powerful feature. The Joystick 360 Quick
Reference Guide, provided with the system, gives summary and
reminder information on its operation and should be kept on the
vessel at all times.
The joystick is spring loaded so it always returns to its center
position. When the joystick is active and in the center position, the
engines are in neutral and the throttles are at idle.
The joystick Take Command button will make the joystick active and
shut off the control head when it is pushed. The shift and throttle
controls must be in neutral to engage the joystick. When the joystick
is active, the Take Command light will be solid blue and the control
head lights will turn off.
While the joystick is active, the steering wheel will stiffen to prevent
usage and remind the user that it is disengaged.
The Boost button increases the engine RPM when pressed. It may
be activated any time the joystick is active.
Note: The A and C buttons are reserved for future use and not active
at this time.
While the joystick is active, the steering wheel will stiffen to prevent
usage and remind the user it is disengaged.
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© 2012 Teleflex Marine, Inc.
Optimus 360 Users Manual, Rev. A
6.1 Joystick Fundamentals
Handle Motion
The handle can be moved in any direction or rotated left or right.
When released the stick will always snap back to center and put the
engine in neutral idle.
Moving the handle away from center or rotating it will cause the
engines to shift into the correct gear for the desired motion. Further
handle motion in the same direction will apply throttle and provide
more thrust in the chosen direction. The joystick is proportional and
guided in each axis.
Boost Button
Increases the power the engines can apply and may be turned on or
off at any time. It can be very handy when handling the boat in wind
or current. The system will remember the boost mode status so if it
is left on, it will be on again next time the joystick is activated.
Take Command Button
Activates the joystick and allows the joystick to take control of the
vessel. The joystick can only take control of the boat when the
control head levers are both in the neutral idle position.
A and C Buttons
Reserved for future use. Not active at this time.
© 2012 Teleflex Marine, Inc.
Optimus 360 Users Manual, Rev. A
23
6.1 Joystick Fundamentals (continued)
Operation Fundamentals
The handles on the active control head must be in the neutral
position before a joystick may take command of the system.
1. The joystick has three primary operational modes (see
illustrations next page):
a) Forward/Reverse – engaged by pushing the joystick directly
fore/aft.
Causes the boat to move directly fore and aft. In this mode, the
boat can be steered by rotating the handle. Always engage the
Forward/Reverse Mode by moving the handle directly fore/aft
then rotating the handle to steer. Rotating the handle first then
pushing fore/aft would enter Rotation Mode and apply a forward
correction in rotation mode.
b) Sideways – engaged by pushing the joystick directly to port or
starboard.
Causes the boat to move directly sideways. In this mode, the
handle can then be moved fore/aft or rotated to correct the
vessel’s heading or position.
c) Rotation – engaged by twisting the joystick while it is at center
position.
Causes the boat to rotate on the spot. A fore/aft handle
movement after engaging rotation mode will cause the boat
to rotate but with a forward or reverse bias. Always engage
Rotation Mode first then apply the desired correction. Pushing
the handle fore/aft then twisting would cause the system to
enter Forward/Reverse mode with a steering correction.
2. When released, the joystick always returns to the center position,
which provides neutral-idle for engines.
3. The joystick is proportional and guided in each axis - the more
the joystick is moved, the more throttle is applied.
See the following pages for examples of each of the primary
operational modes.
WARNING
24
In the event of an engine stall, ONLY the Forward/Reverse mode
is available. Restart stalled engine or switch to conventional
controls.
© 2012 Teleflex Marine, Inc.
Optimus 360 Users Manual, Rev. A
6.1 Joystick Fundamentals (continued)
PRIMARY MOTION - FORWARD/REVERSE
CORRECTION - ROTATE TO STEER
a)
PRIMARY MOTION - SIDEWAYS
b)
PRIMARY MOTION - SIDEWAYS
CORRECTION - ROTATE TO BIAS HEADING
CORRECTION -
NEUTRAL
NEUTRAL
FORWARD/REVERSE TO DIAGONAL
OR
REVERSE
© 2012 Teleflex Marine, Inc.
Optimus 360 Users Manual, Rev. A
25
6.1 Joystick Fundamentals (continued)
PRIMARY MOTION - ROTATION
CORRECTION FORWARD/REVERSE TO BIAS ROTATION
c)
6.2 Joystick Tips
1. Plan out your joystick maneuvers before you approach your
target:
a. Keep it simple - Minimize diagonal and other complex
maneuvers. This allows for better boat correction and control.
b. Know your boat’s limitations - Be aware of wind and current,
and understand the boat’s movement delay due to its
momentum. Some conditions may prove too strong for your
engine thrust.
2. Make it clear to the system what you want to do. Do not make
slight movements off of the neutral position. For example: If you
want the boat to move to port, move the joystick well along the
port axis.
3. Moving the handle port/stbd will move the boat sideways, but
will not steer the boat (change heading). Twisting (rotating) the
handle steers and rotates the boat (see illustrations previous
page).
4. It is recommended to return to the center position when
switching between primary operational modes.
5. Practice joystick maneuvers in open water before attempting
close quarters docking. This will help you understand the primary
operational modes and how they control your boat.
26
© 2012 Teleflex Marine, Inc.
Optimus 360 Users Manual, Rev. A
6.2 Joystick Tips (continued)
6. There is a momentary shift delay built into the system when
returning from any gear activity to neutral. This allows bumping
the handle to get a little more motion in the same direction
without causing excessive engine shifting. This delay is removed
if the action passes the home area in the opposite direction so
you can stop the boat immediately if needed.
7. The control head must be active at the helm station with the
joystick that will be used and the control handles must be in
neutral and idle at that station.
6.3 Joystick Operation Examples
Example 1
Make the primary action move first and then adjust the boat motion
with a secondary joystick motion. Example: the boat is parallel to the
dock and you wish to move the boat against the dock. This is like
parallel parking a car.
1. Move the boat forward or backward with direct forward or
backward joystick motions until the boat is stopped and centered
in the location on the dock you wish to approach.
2. Return the joystick to the center position.
1
2
© 2012 Teleflex Marine, Inc.
Optimus 360 Users Manual, Rev. A
27
6.3 Joystick Operation Examples
(continued)
3. Move the joystick directly port to approach the dock.
3a. If the boat does not stay parallel due to wind or current while
holding the joystick to the side just rotate the joystick to keep
the boat parallel to the dock during the approach.
3b. If the boat does not stay centered due to wind or current while
holding the joystick to the side, just push or pull the joystick
fore/aft to correct.
4. Once close to the dock, return the joystick to the center position.
3
3a
wind
3b
4
CURRENT
28
© 2012 Teleflex Marine, Inc.
Optimus 360 Users Manual, Rev. A
6.3 Joystick Operation Examples
(continued)
Second Example
1. Move the boat forward by pushing the joystick forward.
2. With the joystick forward and the boat moving forward
rotate the joystick as needed to correct for wind or current.
Return the joystick to the home position as you near the
slip.
3. As the boat approaches the slip pull the joystick backwards
to stop the boat in front of the slip. Return the joystick to
the home position when the boat stops.
wind
1
2
3
© 2012 Teleflex Marine, Inc.
Optimus 360 Users Manual, Rev. A
29
6.3 Joystick Operation Examples
(continued)
4. Rotate the joystick to turn the boat and align it with the
slip. Use a straight port or starboard move of the joystick
if necessary to realign the boat.
5. Pull the joystick back to move the boat into the slip.
6. A short bump forward on the joystick will stop the boat in
position.
4
5
6
30
© 2012 Teleflex Marine, Inc.
Optimus 360 Users Manual, Rev. A
7.0CANtrak DISPLAY
Turning on the ignition switch will turn on the Optimus 360 system.
The CANtrak Display will turn on and the steering will become active
at ALL helms. For First Time Use, please see Section 8.0.
After reading the initial warning screen press the INFO button and
follow the prompts for a system inspection.
Splash Screen
3 SEC INTERVAL
INFO
Initial Warning
OK
NEXT
System Check 1
NEXT
System Check 2
BACK
System Check 3
BACK
OK
All Helms Active
WARNING
© 2012 Teleflex Marine, Inc.
On multiple helm station boats, all helms are active when the
Optimus 360 is turned on. This is the same you would find on a
conventional hydraulic steering system.
Optimus 360 Users Manual, Rev. A
31
7.1 Purpose
The Optimus 360 CANtrak display has an easy to navigate menu
system, adjustable backlighting for night use and includes a cover to
protect it from the sun when not in use.
The CANtrak display serves these purposes:
1.Displays the current system operating conditions.
2.Handles system faults by:
a) Displays system warnings in case of a system fault.
b) Sounds an audible alarm in case of a system fault.
c) Instructs the operator what to do in case of a system fault.
3.Permits changes to the basic system settings.
4.Provides system and diagnostic information
For details on CANtrak operation see Sections 7.2 through 7.4 of this
manual.
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© 2012 Teleflex Marine, Inc.
Optimus 360 Users Manual, Rev. A
7.2 CANtrak Display Navigation
The five buttons at the bottom of the unit are used to select various
actions. The five boxes at the bottom of the display screen will
indicate the legend for each button. These legends vary based on
what is on the screen.
WORD
OR SYMBOL
IDENTIFIES A FUNCTION OR SETTING
Moves the cursor arrow up the screen to the next item
Moves the cursor arrow down the screen to the next item
First press selects the parameter to change and
subsequent press index the selection
Takes you back one step
Reduces the setting of a selected item
Increases the setting of a selected item
OK
Accepts a given statement or condition and advances to
the next screen
Moves the unit back one level.
CANtrak display lighting
CANtrak display contrast
© 2012 Teleflex Marine, Inc.
Optimus 360 Users Manual, Rev. A
33
7.3 CANTrak Display Map –
All Helms Active (Normal Steering Mode)
The following diagram shows the progression from the Splash
Screen to the All Helms Active Screen, then illustrates the various
choices available from the All Helms Active screen.
Splash Screen
3 SEC INTERVAL
INFO
Initial Warning
NEXT
System Check 1
NEXT
System Check 2
BACK
OK
System Check 3
BACK
OK
All Helms Active
DIAGNOSTICS
Network nodes
Node Information
ADJUST*
LO Speed Helm Turns
HI Speed Helm Turns
LO Speed Helm Effort
HI Speed Helm Effort
AP Helm Effort
DISPLAY
Contrast
Brightness
*Some installations may not have this feature available. Contact
dealer.
34
© 2012 Teleflex Marine, Inc.
Optimus 360 Users Manual, Rev. A
7.4 Display Screens
7.4.1 All Helms Active (Normal Steering Mode)
The All Helms Active Mode screen will be displayed under
normal operating conditions after the startup warning has been
acknowledged.
The All Helms Active screen displays the current system operating
conditions. It shows the engine RPM, gear position, and rudder angle.
It also allows access to the Diagnostics, Adjustment and Display
menu screens.
See Section 9.3 for the autopilot display screen.
7.4.2 Diagnostics (DIAG) Screen
The Diagnostics screen allows the user the access to basic system
diagnostics tools including network node information and a CAN
message viewer.
Diagnostics Screen
© 2012 Teleflex Marine, Inc.
Optimus 360 Users Manual, Rev. A
35
7.4.3 Adjust (ADJ) Screen*
The Adjust screen allows adjustment of system parameters which
affect steering operation and feel. Specific details of each parameter
are listed below.
Changes made in the Adjust screen are saved to memory upon
exiting the Adjust screen. You will be prompted to save changes
before exiting as shown in the display.
POINTER
BUTTONS
SCROLL
BAR
*Some installations may not have this feature available. Contact
dealer.
Low Speed Turns
This setting changes the number of turns when the vessel is running
at low speeds. The adjustable range is 3.5 to 8 Turns.
High Speed Turns
This setting changes the number of turns when the vessel is running
at high speeds. The adjustable range is 3.5 to 8 Turns.
Low Speed Steering Effort
This setting changes the steering resistance when the vessel is
running at low speeds. It is adjustable between 1 and 100.
High Speed Steering Effort
This setting changes the steering resistance when the vessel is
running at high speeds. It is adjustable between 1 and 100.
Autopilot Engaged Steering Effort
This setting increases the steering resistance slightly when autopilot
is engaged to prevent accidental course corrections with the wheel.
It is adjustable between 0 and 100.
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© 2012 Teleflex Marine, Inc.
Optimus 360 Users Manual, Rev. A
7.4.3 Adjust (ADJ) Screen (continued)
The steering resistance and turns have both low speed and high
speed settings. The low speed and high speed set points may be
determined by various sources, for example: Engine RPM, Throttle
Position, etc. These are configured by your dealer and are not
adjustable.
The number of turns and steering resistance at these low and
high speeds are user adjustable. These settings will automatically
increase smoothly between the low speed and high speed points as
shown below.
Adjusting steering effort for steering turns can significantly impact
boat handling. Proceed with caution after making any changes.
© 2012 Teleflex Marine, Inc.
Optimus 360 Users Manual, Rev. A
37
7.4.4 Display (DISP) Screen
The Display screen allows adjustment of the brightness and contrast
of the CANtrak display. These should be adjusted to provide good
daytime and night time visibility of the display.
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© 2012 Teleflex Marine, Inc.
Optimus 360 Users Manual, Rev. A
8 .0 FIRST TIME USE
8.1 Control Head Adjustments
Before starting the engines for the first time, take a moment to
familiarize yourself with the shift and throttle controls. With the
engines not running and the control system turned off, move the
control levers over the full range until you are familiar with the feel.
Note that the detent pressure and drag can be adjusted using the
adjusting screw on the front surface of the control head. The top
screw sets the detent pressure; the lower screw sets the drag.
Note that the detent pressure and drag can be adjusted using the
adjusting screws on the front surface of the control head.
© 2012 Teleflex Marine, Inc.
Optimus 360 Users Manual, Rev. A
39
8.2 Initial Start Up
Turning on the ignition switch will turn on the Optimus 360 system.
The CANtrak Display will turn on and steering will become active at
ALL helms.
After reading the initial warning screen press the INFO button and
follow the prompts for a system inspection.
Splash Screen
3 SEC INTERVAL
INFO
Initial Warning
OK
NEXT
System Check 1
NEXT
System Check 2
BACK
System Check 3
BACK
OK
All Helms Active
On multiple helm station boats all helms are active when the
Optimus 360 is turned on. This is the same you would find on a
conventional hydraulic steering system.
40
© 2012 Teleflex Marine, Inc.
Optimus 360 Users Manual, Rev. A
8.2 Initial Start Up (continued)
With the system powered up, activate the desired control head or
joystick by using the Smart Select functionality on the control head
or by pressing the Take Command button on the desired device. On
single station vessels, the control head will automatically become
active.
If a control head is selected, the control head Take Command light
should illuminate solid blue and both green neutral indicator lamps
should illuminate solid green. This indicates that the control head is
now in control of shift and throttle and that the engines are in the
neutral idle position.
If a joystick is selected, the joystick Take Command light should
illuminate solid blue. The joystick now has control of the system and
is ready for use.
Refer to Sections 4.0, 5.0 and 6.0 for detailed steering, control head
and joystick operation.
© 2012 Teleflex Marine, Inc.
Optimus 360 Users Manual, Rev. A
41
8.3 System Inspection
Failure to adhere to these warnings may result in loss of boat
control, leading to possible ejection from vessel; causing property
damage, personal injury and/or death.
1. Check steering fluid level in all steering pumps.
Each Optimus 360 hydraulic pump has a steering fluid reservoir.
Ensure the fluid level is between the MIN and MAX marks on
the reservoir as shown in the figure below. Use only SeaStar
Electronic Power Steering Fluid in the Optimus 360 System.
2. Verify immediate steering response when turning steering
wheel(s).
Turn the steering wheel slowly to port and to starboard and make
sure the engines follow the commands. Watch that the hoses
harnesses, and cables move freely without any snags or hangups.
3. Inspect all steering hoses, fittings and mechanical and
electrical harness for wear, kinks, or leaks.
Check all steering hoses and fittings between the pump, service
valves and cylinders for any signs of leakage, kinking, wear or
chafing. Check all electrical harnesses and mechanical cabling
for abrasion, wear, rubbing or chafing. Check that all connections
are tight and free of corrosion.
42
© 2012 Teleflex Marine, Inc.
Optimus 360 Users Manual, Rev. A
8.3 System Inspection (continued)
4. Check for binding, loose, worn or leaking steering or shift/
throttle control components.
Check all shift and throttle cables and harnesses for signs of
wear, damage or chafing. Check that all linkages and cables
move freely and are not binding or corroded.
5. Verify proper shift and throttle response for all control handles.
Check that all shift and throttle levers operate freely and cause
the engines to shift accordingly. Put the engines in neutral
idle mode and confirm that the throttle responds correctly and
returns to idle.
6. Verify that no faults or warnings are shown on the CANtrak
display or the Shift and Throttle Control Head.
If warnings are found on the CANtrak display, follow the
instructions on the CANtrak screen or refer to Section 10 before
proceeding. Read the System Inspection steps on the CANtrak display and
acknowledge them by pressing the right hand most button under
OK.
Do not operate the boat if any component is not in proper working
condition.
After becoming familiar with the system inspection process, the
operator can use the OK button to acknowledge that the system
inspection process was understood and completed and can then go
directly to the steering mode screen.
It is recommended the full system inspection be reviewed on a
regular basis to retain familiarity.
© 2012 Teleflex Marine, Inc.
Optimus 360 Users Manual, Rev. A
43
8.4 Installation Checks
To verify correct installation of the Optimus 360 SmartCylinder,
perform the following installation checks when the boat is
delivered and after each boat servicing.
Failure to perform these checks may result in damage to the
SmartCylinder sensor and affect the safe operation of the boat’s
steering.
1. Interference Checks - Confirm that there is no interference
between the steering cylinder(s), splashwell or outboard engine
or any combination of these parts by performing the steps below.
At the same time for each step also check that the hoses,
harnesses and cables are moving freely with no rubbing or
binding (see figures below and on right page).
a)With the engines fully tilted DOWN, turn the steering wheel from
hard over to hard over and confirm that no interference occurs.
b) With the engines fully tilted UP, turn the steering wheel from
hard over to hard over and confirm that no interference occurs.
c) Trim the port engine fully DOWN and the starboard engine fully
UP. Turn the steering wheel from hard over to hard over and
confirm that no interference occurs.
d) Trim the starboard engine fully DOWN and the port engine fully
UP. Turn the steering wheel from hard over to hard over and
confirm that no interference occurs.
If any issues are found during the installation checks, immediately
return the boat to the service dealer for those issues to be
remedied.
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© 2012 Teleflex Marine, Inc.
Optimus 360 Users Manual, Rev. A
8.4 Installation Checks (continued)
Make sure that all cables, harnesses, and hoses move freely and
that the cylinders and engines are clear at steering extremes.
ENGINE SIDE VIEW,
WHEN TILTED
© 2012 Teleflex Marine, Inc.
Optimus 360 Users Manual, Rev. A
45
8.4 Installation Checks (continued)
2. Sensor cable - Confirm that the SmartCylinder Sensor Cable
is tied securely to the hoses with gradual bends, and that the
cable will not snag on any object during motion. See the diagram
below.
Failure to perform these checks may result in damage to the
SmartCylinder Sensor and effect the safe operation of the boat’s
steering.
TIES
SECURED TO
FITTINGS
SMOOTH BEND
NO KINKING
TIES NO MORE
THAN 6” APART
46
© 2012 Teleflex Marine, Inc.
Optimus 360 Users Manual, Rev. A
8.5 Initial Sea Trial
With the engine lanyard properly connected to you and the
passengers secure, carefully proceed to a section of deep open
water at a slow to moderate speed. Use the trip to get a feel
for the steering and control response. When in open water
that is deep enough to assure you will not run aground try
various maneuvers with the boat at various speeds until you are
comfortable operating the boat.
Be sure to spend some time becoming comfortable with each of the
following:
Steering – Check at various speeds and different rate turns.
Shift and throttle – Become comfortable with the handle pressure
and the various features like Power Train Sync and Neutral Throttle
Warm up.
Joystick – Try all the various modes and using both primary and
secondary actions.
If adjustments to the system are required see Section 7.4.3 for
steering adjustments or contact your dealer.
© 2012 Teleflex Marine, Inc.
Optimus 360 Users Manual, Rev. A
47
9.0 SYSTEM USE
If this is the first-time use OR for more details, see Section 8 of this
manual. For detailed system operation see Sections 4 through 7.
9.1 Before Each Use
Prior to every use:
Perform a system inspection as outlined below, see Section 8.3 for
further details.
1. Check steering fluid level in all steering pumps.
2. Verify immediate steering response when turning steering
wheel(s).
3. Inspect all steering hoses, fittings, mechanical cables and
electrical harnesses for wear, kinks, or leaks.
4. Check for binding, loose, worn or leaking steering or shift/throttle
control components.
5. Verify proper shift and throttle response for all control handles.
6. Verify that no faults or warnings are shown on the CANtrak
display.
Do NOT operate boat if any component is not in proper working
condition.
9.2 Multiple Station Boats
On multiple helm station boats, all helms are active when the
Optimus 360 is turned on. This is the same you would find on a
conventional hydraulic steering system.
48
© 2012 Teleflex Marine, Inc.
Optimus 360 Users Manual, Rev. A
9.3 Autopilot Operation
Always read and understand the autopilot operation instruction
completely before engaging the autopilot mode.
The Optimus 360 steering system is designed to interface with many
autopilot controllers. See your Autopilot’s documentation for specific
model compatibility.
On boats with an autopilot the steering effort may be noticeably
higher when the autopilot is engaged. This resistance is user
adjustable, see Section 7.4.3 of this manual.
When any wheel is turned with the autopilot engaged, the helm will
take control of the system and manually override the autopilot. When
this happens, the steering resistance will return to normal until the
autopilot re-engages. See your autopilot user’s manuals for specific
system behavior.
The shift and throttle control head should be active when the
autopilot is operational. Do not select the joystick when the autopilot
is active.
Never leave the helm station unattended when the autopilot is
engaged.
The Title Bar will display
“Autopilot Mode” when the
autopilot is engaged.
© 2012 Teleflex Marine, Inc.
Optimus 360 Users Manual, Rev. A
49
10.0 SYSTEM FAULTS & HAZARDS
Should a fault occur, it will be communicated to the user though the
CANtrak display. Section 10.1 defines the two types of hazards you
may experience with the system and how the system will handle
each.
When a serious fault occurs, the operator should consider his or her
options. While the system has many features to allow the boat to
return to port in a slow and safe manner, local conditions or operator
skills may dictate that calling for assistance is the prudent thing to do.
10.1 Hazard Definitions
10.1.1
Danger
A danger fault is a critical system fault which will result in limited
steering and/or shift and throttle performance and requires
immediate action.
Depending on the type of fault a variety of conditions might occur all
designed to provide the safest situation for returning to port. Some
examples are:
• Steering may be restricted to one engine.
• The engines may need to be positioned manually and the boat
steered using the shift and throttle.
• The shift and throttle may require manual override with normal
steering.
• The joystick may become inactive.
The system will provide the safest alternative to normal operation.
In the case of a danger fault, the CANtrak buzzer will sound
continuously (until muted) and the CANtrak display will advise the
operator on how to proceed. See Section 10.2.1 for danger fault
handling specifics.
In the case of an EST system danger fault, in addition to the CANtrak
message and buzzer, both red lights on the control head will flash
red quickly (5 times per second).
In the case of a Joystick danger fault, in addition to the CANtrak
message and buzzer, the joystick Take Command button light will
flash red quickly (5 times per second).
50
© 2012 Teleflex Marine, Inc.
Optimus 360 Users Manual, Rev. A
10.1.2
Warning
A warning is a non-critical system fault which will either maintain full
system operation or may cause the steering and/or boat speed to be
reduced.
Although a warning does not always adversely affect steering or
shift and throttle performance, it is an indication of a problem in the
system and should be remedied.
In the case of a warning fault, the CANtrak buzzer will sound
intermittently (until muted) and the CANtrak will display the Warning
screen. See Section 10.2.3 for warning fault handling specifics.
In the case of an EST system warning fault, in addition to the
CANtrak message and buzzer, both red lights on the control head will
flash red slowly (once per second).
In the case of a Joystick warning fault, in addition to the CANtrak
message and buzzer, the joystick Take Command button light will
alternate flashing red and blue.
© 2012 Teleflex Marine, Inc.
Optimus 360 Users Manual, Rev. A
51
10.2 System Fault Handling
In case of a Danger or Warning message, the CANtrak display will
advise the operator how to proceed. If the danger or warning is
caused by the control system the control head lights will flash red.
The following sections describe what to expect in case of either
fault.
10.2.1
Danger Fault Handling
A danger fault is a critical system fault which will result in limited
steering and/or shift and throttle performance and requires
immediate action.
During a danger fault, the CANtrak display will display DANGER
across the top, sound a continuous buzzer (until muted) and display
fault information and handling in three zones. See the figure below.
Active Fault
Description Zone
System Status Zone
Fault Handling
Instructions Zone
Will appear if multiple
faults are active to allow
user to scroll through
Active Fault Description Zone
Provides details specific to the system fault. These will include a
brief description of the fault and are primarily for troubleshooting
purposes.
System Status Zone
Displays information about the status of the system and if the
system has automatically reacted to the fault.
Fault Handling Instructions Zone
Provides detailed instructions on how to proceed. In the case of a
danger fault, this will instruct the operator what to do and how to
proceed should Limp Home mode be required.
52
© 2012 Teleflex Marine, Inc.
Optimus 360 Users Manual, Rev. A
10.2.2
Limp Home
When a Danger fault results in steering and/or shift and throttle
performance being restricted or suspended, the CANtrak may
provide instructions on how to enter Limp Home mode.
Limp home will provide instructions for the user to manually move
the engine(s), and/or control the shift and throttle, and allow the
user to “limp home” at a reduced performance.
There are three Limp Home modes depending on the nature of the
fault.
Limp home mode is an override system. It may severely limit your
boat control. It should ONLY be used in an emergency if you are
unable to call for assistance. Proceed with extreme caution.
Always wear PFDs and lanyard. Refer to the notice in Section 10.0.
Limp Home Mode 1
This mode occurs when the system can no longer provide steering
to ANY of the engines. The CANtrak will instruct the operator to
manually realign the engines using the service valves, and proceed
home immediately using the shift and throttle controls to control the
vessel as shown in the figure below.
© 2012 Teleflex Marine, Inc.
Optimus 360 Users Manual, Rev. A
53
10.2.2
Limp Home (continued)
Limp Home Mode 2
This mode occurs when the system can no longer provide steering to
ONE of the engines. The CANtrak will instruct the operator to realign
the non-responsive engine, tilt it out of the water and proceed home
immediately using the responsive engine as shown in the figure
below.
Limp Home Mode 3
This mode occurs when the shift and/or throttle is compromised on
both engines. The CANtrak will instruct the operator to use the shift
and/or throttle manual overrides. If only one engine’s shift and/or
throttle is compromised, Limp Home Mode 3 may not be required
and the CANtrak will instruct the operator how to proceed.
54
© 2012 Teleflex Marine, Inc.
Optimus 360 Users Manual, Rev. A
10.2.2
Limp Home (continued)
Engaging the Actuator(s)
In the unlikely event of a Danger warning on the shift and throttle
system that cannot be cleared the boat can be operated by using
the manual control overrides of the actuators. Proceed with caution
as follows:
1. Release the actuator engagement lever (A) by moving it to the
other end of its travel (red handle on side).
2. Rotate the control lever (B) to move the control cable to the
engine.
NOTICE
If the lever cannot be rotated it is likely the fault is in the engine not
the control system.
A. ENGAGEMENT LEVER
B. CONTROL LEVER
© 2012 Teleflex Marine, Inc.
Optimus 360 Users Manual, Rev. A
55
10.2.3
Warning Fault Handling
A warning is a non-critical system fault which will either maintain full
system operation or may cause the steering and/or boat speed to be
reduced.
During a warning fault, the CANtrak will display the same information
as with a danger fault but WARNING will appear across the top of the
screen and the buzzer will sound intermittently (until muted). See the
figure below.
Active Fault
Description Zone
System Status Zone
Fault Handling
Instructions Zone
Will appear if multiple
faults are active to allow
user to scroll through
User may exit the
Warning screen and
return to run screen
The user may choose to exit the Warning screen and return to the All
Helms Active screen by pressing the exit button, in which case the
system will flash a warning icon on the run screen as shown on the
next page. This icon will remain in place until the fault is repaired. If
the system recovers from the fault, for example if a battery runs low
and is subsequently charged, the warning screen will disappear and
the system will automatically resume normal operation.
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© 2012 Teleflex Marine, Inc.
Optimus 360 Users Manual, Rev. A
10.2.3
Warning Fault Handling (continued)
Although the system may still operate normally under many warning
faults, the vessel should still be returned to port and serviced
immediately.
RUN SCREEN WITH SYSTEM WARNING
Some system warning faults may result in a reduced steering
response and/or reduced throttle position (system will continue to
steer normally but may respond slower or limit boat speed).
© 2012 Teleflex Marine, Inc.
Optimus 360 Users Manual, Rev. A
57
10.2.4
System Fault Handling – Example
The following is an example of how the system would respond to the
warning fault hazard of a low port engine battery.
The CANtrak display will enter the warning screen mode and pulse
the system warning buzzer. The three warning screen zones will
appear as shown below.
This area shows the
active faults
Active Fault
Description Zone
Describes what system has
done to react to fault
System Status Zone
Tells the User how
to proceed
Fault Handling
Instructions Zone
In this case, the CANtrak tells the user to power off any non
essential devices and to seek technical support as fault handling
instructions. It also informs the user that the system has switched
to the starboard battery and reduced the steering speed.
The vessel should be returned to port immediately for repair.
10.2.5
CANtrak Loss of Display
In the event of a loss of CANtrak display operation proceed as
follows:
1. On a multiple helm station vessel each station should be
equipped with a CANtrak display. Proceed to navigate from
another helm station and immediately return to port for service.
2. If there are no secondary displays on board, at low speed
carefully verify that the steering system and shift and throttle
operates normally then immediately and cautiously proceed to
port for service.
58
© 2012 Teleflex Marine, Inc.
Optimus 360 Users Manual, Rev. A
10.2.5
CANtrak Loss of Display (continued)
3. In the event of a loss of steering or shift and throttle response
and CANtrak display, and you are unable to obtain assistance
and are in an emergency situation, engage Limp Home Modes 1,
2 or 3:
Limp home mode is an override system. It may severely limit your
boat control. It should ONLY be used in an emergency if you are
unable to call for assistance. Proceed with extreme caution.
Always wear PFDs and lanyard. Refer to the notice in Section 10.0.
Limp Home Mode 1
If the steering system can no longer provide steering to ANY of
the engines, proceed by using Limp Home Mode 1, as follows:
1. Always wear PFD devices.
2. Put engine(s) in Neutral.
3. Open Steering Service Valves.
4. Manually center all engines.
5. Close Steering Service Valves
6. Return to port using throttles to steer.
Limp Home Mode 2
If the steering system can no longer provide steering to ONE of
the engines, proceed by using Limp Home Mode 2, as follows:
1. Always wear PFD devices.
2. Put engine(s) in Neutral.
3. Open Steering Service Valves.
4. Turn affected engine fully away from other.
5. Close Steering Service Valves
6. Fully tilt affected engine.
7. Return to port.
In the event of loss of shift and throttle response to both engines,
proceed by using Limp Home Mode 3, as follows:
© 2012 Teleflex Marine, Inc.
Limp Home Mode 3
1. Locate and identify shift and throttle actuators. Read
labels.
2. Set all lever A(s) into manual override position.
3. Slowly turn (shift) lever B to engage gear. Then slowly turn
(throttle) lever B to raise RPM.
4. Key off ignition to slow & stop.
Optimus 360 Users Manual, Rev. A
59
10.3 Buzzer
The buzzer is used to indicate a system fault. There are two different
signals:
1.Continuously on. This indicates a danger fault. A danger fault is
a critical system fault which will result in limited steering and/or
shift and throttle performance and requires immediate action and
immediate return to the nearest port. See Section 10.1.1.
2. Alternating on and off. This indicates a warning fault. A warning is
a non-critical system fault which will either maintain full steering
system operation or cause the steering and/or boat speed to be
reduced. See Section 10.1.2.
All signals require immediate attention.
When the buzzer sounds, a screen will appear on the CANtrak
indicating the cause for the alarm. The screen will also display a
“mute” button which may be used to silence the alarm.
10.4 Reduced Performance
Under certain fault conditions the steering response and/or boat
speed will slow down. A typical cause might be a very low battery.
When this happens the CANtrak will advise the operator of the
condition, indicate the reason, and supply instructions.
Proceed with caution until the fault is corrected and normal
operation returns.
60
© 2012 Teleflex Marine, Inc.
Optimus 360 Users Manual, Rev. A
11.0 MAINTENANCE
Following the routine maintenance schedules as outlined below,
in the time frame noted will ensure years of service from your
Optimus 360 Joystick control system, as well as keep you and your
passengers safe from the dangers that are present on and off the
water.
1. Owner(s) (End Users)
Prior to every use (see Section 8.3 for further details):
1. Check steering fluid level in all steering pumps.
2. Verify immediate steering response when turning steering
wheel(s).
3. Inspect all steering hoses, fittings and mechanical and electrical
cables for wear, kinks, or leaks.
4. Check for binding, loose, worn or leaking steering or shift/throttle
control components.
5. Verify proper shift and throttle response to all control handles.
6. Verify that no faults or warnings are shown on the CANtrak
display or on the Shift and Throttle Control Head.
WARNING
Do not operate boat if any component is not in proper working
condition.
After every use:
1. Rinse the SmartCylinders with clean water and replace CANtrak
sun cover.
Do NOT rinse the PCM, pumps, or the actuators.
2. Qualified Marine
Mechanic
© 2012 Teleflex Marine, Inc.
After the first 20 hours, then every 100 hours or 6 months
thereafter (whichever comes first).
1. All points noted above.
2. Check tightness of ALL fasteners/fittings throughout the vessel
control system. Tighten to correct torque specifications as
required.
3. Check for mechanical play or slop throughout vessel control
system, correct as required.
4. Check for signs of corrosion. If corrosion is present contact your
dealer or Teleflex Marine.
5. Check all electrical harnesses and mechanical cables for
chaffing and wear.
Optimus 360 Users Manual, Rev. A
61
11.0 Maintenance (continued)
After the first 200 hours or 12 months thereafter (whichever
comes first).
1.All points noted above.
2.Remove support rod from engine steering/tilt tube. Clean engine
steering/tilt tube and re-grease using a good quality marine
grease.
3.Grease support rod liberally.
4.Grease all contact points shown in the figure below. DO NOT
remover the tiller bolt to re-grease.
5.Remove the steering wheel and re-grease the wheel shaft using a
good quality marine grease.
6.Inspect hydraulic oil for cleanliness; flush if required.
7.Check that the service valve is free to move and in the closed
position.
Any work being performed with the steering system MUST be
completed by a qualified mechanic with the working knowledge of
the system.
GREASE SUPPORT ROD,
TILT TUBE & SUPPORT
BRACKET HOLE
GREASE SUPPORT ROD,
TILT TUBE & SUPPORT
BRACKET HOLE
62
© 2012 Teleflex Marine, Inc.
Optimus 360 Users Manual, Rev. A
12.0 TROUBLESHOOTING GUIDE
Whenever, in the following
text, a solution calls for
removal from vessel and/
or dismantling of system
components, such work
must ONLY be carried out by
a qualified marine hydraulic
mechanic. Teleflex offers the
following as a guide only and
is not responsible for any
consequences resulting from
incorrect dismantling repairs.
Optimus 360 will provide years of safe reliable performance with a
minimum of service if properly installed.
Optimus 360 steering systems have been designed with protection
against over-pressure situations, with the inclusion of a pressure
relief valve and circuit breakers, to minimize the possibility of total
loss of steering.
Most faults occur when the installation instructions are not followed
and usually show up immediately upon filling the system. provided
below, are the most common faults encountered and their likely
cause and solution.
FAULT
CAUSE
SOLUTION
1.CANtrak does not
turn ON?
Batteries not turned ON, or in poor
working condition.
Load test batteries.
Ignition wires disconnected.
Confirm all connections are in place.
CANtrak connection damaged and/
or not connected.
Inspect wires for damage.
2.High/Low Speed
wheel turn setting
not working
Tachometer is not relaying
information.
Confirm Tachometer is operating
properly (check connections).
CANtrak NOT writing proper
information.
Confirm that your settings have
been saved. If they are not saved,
contact Tech support.
3.One engine does
not steer, but
CANtrak display is
on.
Check circuit breaker for the engine.
Reset breaker. If it immediately trips
a second time look for a shorted or
pinched wire or failed component.
4.Will not shift
Gear case jammed.
Try manual control of actuator.
If no motion, disconnect shift cable
at engine.
Check engine.
© 2012 Teleflex Marine, Inc.
Optimus 360 Users Manual, Rev. A
63
13.0 REPLACEMENT PARTS
13.1 SeaStar Electronic Power
Steering Fluid
The Optimus 360 Steering System requires genuine SeaStar
Electronic Power Steering Fluid.
In an emergency condition if SeaStar Electronic Power steering fluid
is not available, the following fluids may be used for a short period of
time:
• Sea Star Steering Fluid
• Automatic Transmission Fluid
• Motor Oil
If any of the above are used in the system, then the system should
be flushed and refilled with SeaStar Electronic Power steering fluid
when the boat is returned to port. In case of extreme emergency,
any non-toxic, non-flammable fluid may provide temporary steering.
Never use brake fluid.
SeaStar Electronic Power Steering Fluid Part Numbers
Quart HA5482
Gallon HA5483
For full listing of part numbers, please refer to the Optimus 360
Installation Manual (Book 60), part no. 682102.
64
© 2012 Teleflex Marine, Inc.
Optimus 360 Users Manual, Rev. A
14.0 WARRANTY
14.1 Statement of Limited Warranty
We warrant to the original retain purchaser that Marine Canada
Acquisition Limited Partnership DBA Teleflex Canada (herein
forward referred to as Teleflex Canada) 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 Teleflex Canada 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 and Teleflex
Canada 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, Teleflex Canada products found to be defective
and covered by this warranty will be replace at Teleflex Canada’s
option, and returned to the customer.
The above quoted statement is an extract from the complete
Teleflex Canada products warranty statement. A complete warranty
policy is available in our Teleflex Canada products catalogue.
14.2 Return Goods Procedure
Prior to returning product to Teleflex Canada 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 good authorization number (claim number).
Please address the returned goods as follows:
© 2012 Teleflex Marine, Inc.
From U.S.A.
From Canada
RGA # ?
Teleflex Canada
c/o UPS-Supply Chain Solutions, Inc.
Door A37
1201 C Street NW
Auburn, WA 98001
RGA # ?
Teleflex Canada
3831 No. 6 Road
Richmond, B.C.
Canada V6V 1P6
Optimus 360 Users Manual, Rev. A
65
A APPENDIX
Specifications
Optimus 360 SYSTEM SPECIFICATIONS
(Based on EPSK1210 Twin Engine Corepack)
Operating Voltage: 12Vdc
Maximum System Pressure: 1200 PSI
# of wheel turns: Variable from 3.5 to 8
Typical Average Current Draw: ~6 to 8 Amps
Oil Type: SeaStar Electronic Power Steering Fluid
66
© 2012 Teleflex Marine, Inc.
Optimus 360 Users Manual, Rev. A
BAPPENDIX
EST Station Select Protection
Station Select Protection prevents accidental switching between
control stations on multi-stationed boats. If turned on, a change of
control stations requires that control head buttons be pressed in a
specific sequence.
Operation
If Station Select Protection is turned on, to select or change stations
use the following button sequence:
• Go to the station you wish to make active
• Press the Take Command button
• Press the Take Command button again
• Press the Neutral or ‘N’ button
• Press the Take Command button
• The station will go active (blue light on solid) if the handles are
matched with the originally active station.
• If the blue light flashes, match the handles with the originally
active station and the blue light will go solid.
Until the blue light is on solid, the original active station retains
control of the boat.
WARNING
© 2012 Teleflex Marine, Inc.
On multiple helm station boats, all steering helms are active when
the Optimus EPS is turned on. This is the same you would find on a
conventional hydraulic steering system. Station Select only applies
to the control head.
Optimus 360 Users Manual, Rev. A
67
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© 2012 Teleflex Marine, Inc.
Optimus 360 Users Manual, Rev. A
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© 2012 Teleflex Marine, Inc.
Optimus 360 Users Manual, Rev. A
69
TELEFLEX CANADA
3831 NO. 6 ROAD
RICHMOND, B.C.
CANADA V6V 1P6
FAX 604-270-7172
www.teleflexmarine.com
ISO 10592
© 2012 MARINE CANADA ACQUISITION LIMITED PARTNERSHIP
DBA TELEFLEX CANADA
PRINTED IN CANADA
PART NO. 682103, Rev. A
09/12