installation guide

INSTALLATION GUIDE
DYNAMIC TRIM CONTROL SYSTEM
SERIES S
Drill bits
TOOLS
Power drill
Ø
Ø
Ø
Ø
Ø
2.5 mm (3/32”)
3 mm (1/8”)
3.5 mm (9/64”)
4 mm (5/32”)
5 mm (3/16”)
Sealant
Hole saw
Screw bits
Ø 76 mm (3”)
T20
Ø 19 mm (3/4”)
T10
T25
T30
Flat screwdriver Wrench
13 mm (33/64”)
Bits screwdriver
Utility knife
Hacksaw
27 mm (1 1/16”)
Antifouling
THE KIT BOX CONTAINS
INTERCEPTOR
DISTRIBUTION UNIT
1 x Distribution Unit
with Power Cable 4 m
CONTROL PANEL
1 x Control Panel
with Standard Cable 7 m
2 x Interceptors
with Cable 3 m & Cable Covers
1 x Extension Cable
1.5 m / 3 m
+
+
+
+
+
+
Operator´s Manual
Warranty Card
Installation Guide
Drill Templates
Operator´s Quick Guide
Startup Checklist
SYSTEM OVERVIEW
NMEA 2000
network
BRIDGE
CONTROL PANEL
FLYBRIDGE
CONTROL PANEL
External GPS
(optional)
Ignition key sense
3 flybridge panels
possible
DISTRIBUTION UNIT
Up to 6 interceptors
I-BUS (Can Bus)
Supply 12-32 V DC
INTERCEPTORS
INTERCEPTORS
CENTER INTERCEPTOR
Copyright © 2017 Zipwake AB, Sweden. All rights reserved. R1E, April 2017, English
INTERCEPTOR
1
MOUNTING OPTIONS
THRU-HULL CABLE FITTINGS
Depending on preference, the Interceptors can be mounted with thru-hull
cable fittings above the waterline (A) or below, concealed behind the
Interceptors (B).
A
B
ALLOWED SPRAY RAIL OVERLAP
Max Extension
E = 30 mm (1.2”)
E
Not Ok!
Ok!
INTERCEPTOR
PROPELLER CLEARANCE
If the boat has an outboard engine or sterndrive, the Interceptors must be
mounted with clearance to the propeller(s).
Min 75 mm (3”)
CONVEX BOTTOM CURVATURE
Max
5 mm (0.2”)
CONCAVE BOTTOM CURVATURE
Min
3 mm (0.1”)
Min 100 mm (4”)
INTERCEPTOR
2 PREPARE THE TRANSOM
ENSURE A FLAT SURFACE FOR EACH INTERCEPTOR
The transom must be relatively flat where the Interceptors are mounted to
ensure that they work properly.
Max 2 mm (0.08”)
between parallel
planes
DRILLING TEMPLATE
Start mounting the Interceptors as far outward as possible, although well
inside the transom. Continue inwards when installing multiple Interceptors.
Convex bottom: Place two straightedges under the bottom
parallel to the boat’s centerline. When placed on the straightedges and pressed against the transom, the template will
have the right position.
Fix the template on the transom with tape.
Convcave bottom: Place one straightedge at the
interceptor center and use one end of the
template to find its right center position.
1. Drill pilot holes
2. Remove the template
3. Drill holes
0 -15°
Only if a concealed thru-hull
fitting will be used
1. Pilot hole Ø 3 mm (1/8”)
2. Hole saw Ø 19 mm (3/4”)
Drill holes for the Interceptors
1. Pilot hole Ø 3 mm (1/8”)
2. Hole saw Ø 5 mm (3/16”)
300 S:
450 S:
600 S:
750 S:
x6
x10
x14
x18
INTERCEPTOR
3 INSTALL THE BACK PLATES
A. REMOVE THE SERVO UNIT IF A CONCEALED THRU-
HULL FITTING WILL BE USED AND CONTINUE TO STEP B. IF NOT, GO STRAIGHT TO STEP B.
1
2
Remove back plug
Remove servo unit: T25
(x3)
B. MOUNT THE BACK PLATE
Apply sealant
NOTE!
Sealant
300 S:
450 S:
600 S:
750 S:
1
Apply sealant
2
GRP hull: T30 (ST 6.3x38)
300 S: x6
450 S: x10
600 S: x14
750 S: x18
Metal hull: Machine screws
(not included)
Remove excess sealant
with a knife or a spatula
3
4
x6
x10
x14
x18
INTERCEPTOR
4AINSTALL THRU-HULL FITTINGS ABOVE THE WATERLINE
1
Drill hole for thru-hull fitting
Align the hole with the
Interceptor cable
1. Pilot hole Ø 3 mm (1/8”)
2. Hole saw Ø 19 mm (3/4”)
Waterline
Option:
1. Pilot hole Ø 3 mm (1/8”)
2. Hole saw Ø 16 mm (5/8”)
3. Tap
M18 x 2.5
OK
OK
2 NOTE!
Sealant
Tighten:
27 mm (1 1/16”) wrench
10 Nm (7.4 lb-ft)
3
Place the cable
in the clip
4
Place the cover on
the thru-hull fitting
5
Mark the lower edge
of the thru-hull cover
Hold:
13 mm (33/64”) wrench
6
Remove the thruhull cover
INTERCEPTOR
Extension
(optional)
7
Place the cable cover on top
of the Interceptor and cut it
~5 mm (0.2”) above the mark
If neccessary use the extension
and cut it to desired length
~5 mm
(0.2”)
Cable cover
(standard)
Interceptor
Drill holes for the cable cover
Use the cover as a drill template
Apply sealant
Ø 3.5 mm (9/64”)
8
9
10
Cable cover:
GRP hull:
T20 (ST 4.2x19)
Metal hull: Machine screws
(not included)
Thru-hull cover:
Drill holes (x3) for the cover
Use the cover as a drill template
Ø 5 mm (3/16”)
11
GRP hull:
T30 (ST 6.3x38) (x3)
Metal hull: Machine screws
(not included)
12
13
Apply sealant (x3)
INTERCEPTOR
4BINSTALL CONCEALED THRU-HULL
FITTINGS UNDER THE WATERLINE
1
NOTE!
Sealant
Fit the cable clip
in the back plate
or cut it off
Tighten:
27 mm (1 1/16”) wrench
10 Nm (7.4 lb-ft)
2
Hold:
13 mm (33/64”) wrench
3
NOTE!
1
2
Servo unit: T25 (x3)
2 Nm
(1.5 lb-ft)
1
INTERCEPTOR
5 INSTALL THE INTERCEPTOR FRONTS
Interceptor front: T30
5 Nm
(3.7 lb-ft)
300 S:
450 S:
600 S:
750 S:
x6
x10
x14
x18
6 PAINT THE INTERCEPTORS WITH ANTIFOULING
1
Apply Antifouling
Best tool
Spray
2
Remove excess antifouling
when the paint is dry
Run a thin knife or a
spatula along the blades
to ascertain unrestrained
blade motion
2nd Best tool
Roller
DISTRIBUTION UNIT
1
MOUNT THE DISTRIBUTION UNIT
Mount the distribution unit inboard where it is easy to connect it to both
interceptors and power supply (battery) e.g. the engineroom or other
suitable compartment.
NOTE!
The maximum cable length (including extra cable) from an interceptor to
the distribution unit is 6 m (20 ft).
180 mm (7.1”)
1. Drill holes (x2)
Ø 4 mm (5/32”)
2. Fasten screws (x2)
T25 (ST 4.8x38)
(1.5 m)
(3 m)
Max total cable length (6 m)
(standard + extension cable)
(3 m)
Interceptor
Transom
inside view
(3 m)
Interceptor
Starboard
Port
2 CONNECT THE DISTRIBUTION UNIT
NOTE!
Detailed wiring diagram is available at the end of this folder.
Control panel
15A Fuse
Power cable
Main
switch
Battery
Interceptor 1
Interceptor
pairs 2 & 3
Interceptor 1
NOTE! The system allows an unpaired Interceptor mounted on the center of
the transom. A centerline mounted Interceptor should always be connected
to port side 3 to work properly.
CONTROL PANEL
1
ROUTE CABLES
Route the cables between the control panel(s), the distribution unit and
optional equipment. Use optional extension cables if necessary.
A detailed wiring diagram is available on the other side of this folder.
External GPS
(optional)
Extra control panel
Flybridge (optional)
Main control panel
Main bridge
Distribution unit
Standard cable (7m)
Extension cable (optional)
2 PREPARE THE DASH
The control panel must be mounted within certain angles relative to the
boat’s axes for the built-in sensors to deliver reliable output.
Locate a free area on the dash suitable for mounting the control panel.
Use the control panel’s template as a guide to see if it will fit next to other
instruments.
NOTE! 0.5 m (1.6 ft) safe distance to magnetic compass.
180˚
Top view
Max
5˚
0˚
NOTE! Any angle betwen 0-180°
Max
5˚
CONTROL PANEL
3 MOUNT THE CONTROL PANEL
Drill holes (x4)
1
Ø 2.5 mm (3/32”)
Drill hole
1. Pilot hole Ø 3 mm (1/8”)
2. Hole saw Ø 76 mm (3”)
Flush mount option: refer to www.zipwake.com for a drawing and 3D model.
2
Prepare the cables
Route the standard and
optional cables
3
4
Snap off the frame
Connect the cables on the back of the Control panel.
Ignition switch
Distribution unit
Extra Control panel
External GPS
NMEA 2000 network
CONTROL PANEL
5
Control panel:
T10 (ST 2.9x19)
(x4)
6
Apply sealant (x4)
When waterproofing is required
1
Snap on the frame
2
4 INITIAL START
Refer to the Operator´s Manual for detailed information about setting up
and operating the system.
SET UP THE SYSTEM
Press and hold the POWER/MENU button until the
Zipwake logo appears on the display and follow
the steps on the screen.
INTERCEPTOR CHECK
It is recommended that a first check is always made right
after installing the interceptors, before launching the
boat. If an interceptor then shows excessive servo motor
torque, the prime suspect is the flatness of the transom
behind the interceptor and/or excess antifouling between
its blades.
NOTE! Corrective actions are always necessary in the event that too high
torque levels are observed. All readings must be green!
VERIFY FUNCTION ON SHORE
1.Turn the Roll wheel clockwise
2.Port side Interceptor(s) should
move out
3.Reverse direction for starboard
IMPORTANT
Always use the controls to move the
Interceptor blades. Never try to force
the Interceptor blades by hand.
Port Interceptor
WIRING DIAGRAM
SERIES S
ACCESSORIES AND SPARE PARTS
Model
Part No.
Description
CP-S
2011238
CONTROL PANEL S WITH STANDARD CABLE 7 M
DU-S
2011239
DISTRIBUTION UNIT S WITH POWER CABLE 4 M
IT300-S
2011232
INTERCEPTOR 300 S WITH CABLE 3 M & CABLE COVERS
IT450-S
2011233
INTERCEPTOR 450 S WITH CABLE 3 M & CABLE COVERS
IT600-S
2011234
INTERCEPTOR 600 S WITH CABLE 3 M & CABLE COVERS
IT750-S
2011235
INTERCEPTOR 750 S WITH CABLE 3 M & CABLE COVERS
IT450-S V13
2011482
INTERCEPTOR 450 S V13 WITH CABLE 3 M & CABLE COVERS
IT450-S V16
2011483
INTERCEPTOR 450 S V16 WITH CABLE 3 M & CABLE COVERS
IT450-S V19
2011484
INTERCEPTOR 450 S V19 WITH CABLE 3 M & CABLE COVERS
IT450-S V22
2011485
INTERCEPTOR 450 S V22 WITH CABLE 3 M & CABLE COVERS
EC1.5-M12
2011258
M12 EXTENSION CABLE 1.5 M
EC3-M12
2011259
M12 EXTENSION CABLE 3 M
EC5-M12
2011260
M12 EXTENSION CABLE 5 M
EC10-M12
2011261
M12 EXTENSION CABLE 10 M
SC7-M12
2011257
M12 STANDARD CABLE 7 M
CP-S ALU FRAME
2011281
CONTROL PANEL S ALU FRAME
2011381-
CONTROL PANEL S COVER
2011385
WHITE, LIGHT GRAY, MID GRAY, DARK GRAY, BLACK
CC-S
2011071
CABLE COVER S
GPU
2011240
GLOBAL POSITIONING UNIT WITH CABLE 5 M & MOUNT KIT
SU-S
2011230
SERVO UNIT S WITH CABLE 3 M
IT300-S FRONT
2011252
INTERCEPTOR 300 S FRONT
IT450-S FRONT
2011253
INTERCEPTOR 450 S FRONT
IT600-S FRONT
2011254
INTERCEPTOR 600 S FRONT
IT750-S FRONT
2011255
INTERCEPTOR 750 S FRONT
IT450-S V13 FRONT
2011492
INTERCEPTOR 450 S V13 FRONT
IT450-S V16 FRONT
2011493
INTERCEPTOR 450 S V16 FRONT
IT450-S V19 FRONT
2011494
INTERCEPTOR 450 S V19 FRONT
IT450-S V22 FRONT
2011495
INTERCEPTOR 450 S V22 FRONT
CP-S COVER
To NMEA 2000 backbone
(optional GPS source)
Ignition switch
Extension cable (1.5 m)
(optional)
(3 m)
(5 m)
Ignition
switch
Extra control panel
Distribution unit
Standard cable (7 m)
Extension cable
(optional)
(1.5 m)
(3 m)
(5 m)
(10 m)
(1.5 m)
(3 m)
Extension cable (5 m)
(optional)
(10 m)
Connect to Key Sense input
on the control panel
15(b)
NMEA 2000 network
External GPS
USB
(upgrades etc.)
MAIN CONTROL PANEL (CP-S)
15(b)
Power cable
(4 m)
Standard cable (7 m)
Extension cable (1.5 m)
(optional)
(3 m)
(5 m)
(10 m)
Connect to Key Sense input
on the control panel
DISTRIBUTION UNIT (DU-S)
Ignition
switch
EXTRA CONTROL PANEL (CP-S)
The external GPS
can be connected
to any control panel
GPS cable (5 m)
EXTERNAL GPS (GPU)
WIRING DIAGRAM
(3 m)
Starboard
Interceptor 1
STARBOARD
Starboard
Interceptor 2
(3 m)
Max total cable length (6 m)
(standard + extension cable)
Starboard
Interceptor 3
(3 m)
Optional:
Centerline mounted
interceptor connected
to distribution unit
port side 3
Extension cable (1.5 m)
(optional)
(3 m)
NOTE!
Transom inside view
Port
Interceptor 3
(3 m)
Battery
Auto Cleaning
Port
Interceptor 2
(3 m)
Port
Interceptor 1
(3 m)
PORT
NOTE! Connect power directly to the positive
battery terminal if interceptor Auto Cleaning will
be used. Refer to the Operator’s Manual on how
to turn on the interceptor Auto Cleaning function.
Battery
Main
switch
15A melting
type fuse
NOTE! Do not use automatic thermal/magnetic fuse.
POWER SUPPLY (12-32 V DC)
WIRING DIAGRAM
Visit www.zipwake.com for additional information such as:
•Operator’s Manual and Installation Guide in different languages
•Product specifications, including a list of accessories and spare parts
•Application examples and Interceptor mounting options
•Drawings and 3D models of system components
•Software upgrades for your Dynamic Trim Control System

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