Zipwake Series E PRO Dynamic Trim Control System

1. Mounting Options

Thru-Hull Cable Fittings: Interceptors can be mounted with thru-hull cable fittings above the waterline (A) or below, concealed behind the interceptors (B).

Diagram A shows thru-hull fittings above the waterline. Diagram B shows thru-hull fittings concealed behind the interceptors.

Allowed Spray Rail Overlap: Maximum extension (E) is 60 mm (2.4").

A diagram illustrates spray rail overlap, showing the maximum allowable extension E.

NOTE! Chine interceptor: Diagrams show correct ('Ok!') and incorrect ('Not Ok!') mounting positions for chine interceptors.

Propeller Clearance

If the boat has an outboard engine or sterndrive, interceptors must be mounted with adequate clearance to the propeller(s).

Diagrams show minimum clearances: 100 mm (4") and 125 mm (5") for outboard/sterndrive propellers. For intermediate Series S interceptors (IT300-S INTER), clearances are 0 mm (0").

Convex Bottom Curvature: Maximum allowable curvature is 10 mm (0.4").

Diagram shows a convex hull section with a maximum curvature tolerance.

Concave Bottom Curvature: Minimum allowable curvature is 3 mm (0.1").

Diagram shows a concave hull section with a minimum curvature tolerance.

Optional Models: 400-E Round model for convex hulls, 600-E Tunnel models for propeller tunnels.

NOTE! Same tolerances and clearances apply to straight/chine interceptors.

2. Prepare the Transom

Ensure a Flat Surface: The transom must be relatively flat where interceptors are mounted for proper function. Maximum deviation between parallel planes is 2 mm (0.08").

Diagram shows a transom surface with a maximum flatness tolerance of 2 mm.

Drilling Template: Mount interceptors as far outward as possible. For multiple interceptors, work inwards. Place template on the transom with tape.

Diagrams illustrate template placement for convex and concave bottoms.

NOTE! Only if a concealed thru-hull fitting will be used:

• Option 1: Pilot hole Ø 3 mm (1/8"), Hole saw Ø 19 mm (3/4")
• Option 2 (threaded hole): Pilot hole Ø 3 mm (1/8"), Hole saw Ø 16 mm (5/8"), Tap M18 x 2.5

Drill Holes for Interceptors:

• IT600/800/1000-E are dual-servo (2 holes).
• IT400-E is a single-servo (1 hole).
• Steps: 1. Drill pilot holes, 2. Remove template, 3. Drill holes.
• Hole sizes: Pilot hole Ø 3 mm (1/8"), Drill Ø 6.5 mm (1/4").
• Number of holes per model: 400 E: x6, 600 E: x9, 800 E: x13, 1000 E: x17.

Diagram shows drilling steps and hole counts for different interceptor models. An angle of 0-15° is indicated.

3. Install the Back Plates

A. For Thru-Hull Fittings Above the Waterline: Proceed to Step B.

Diagram shows sliding out the cable plug to remove servo cables and removing back plugs. Servo units (T25 PT 5.0x18) are removed.

B. Mount the Back Plate:

Diagram shows applying sealant to the back plate. Screw counts for different models (400 E: x6, 600 E: x9, 800 E: x13, 1000 E: x17) are listed. For GRP hulls, use T40 (ST 8.0x45) screws. For metal hulls, machine screws (not included) are required. Excess sealant should be removed.

4A. Install Thru-Hull Fittings Above the Waterline

Mark the center of the thru-hull fitting. Drill holes (x4) for the cover base using the cover base as a template (Ø 4 mm / 5/32").

Diagram shows marking the waterline and drilling for the cover base. It distinguishes between single-servo and dual-servo fittings.

Drill holes for thru-hull fittings (1 or 2 holes):

• Option 1: Pilot hole Ø 3 mm (1/8"), Hole saw Ø 19 mm (3/4")
• Option 2 (threaded hole): Pilot hole Ø 3 mm (1/8"), Hole saw Ø 16 mm (5/8"), Tap M18 x 2.5

Diagrams illustrate the drilling process for thru-hull fittings.

Snap off the thru-hull center piece(s). Apply sealant (x4). Place the cable cover on top of the interceptor and cut it alongside the thru-hull cover base. Use the cable cover extension kit (CC-EX, optional) if necessary.

Diagrams show snapping off pieces, applying sealant, fitting the cable cover, and using an extension kit. Holes for the cover base are drilled using the cover base as a template (Ø 4 mm / 5/32").

Tighten: Use a 27 mm (1 1/16") wrench to tighten to 10 Nm (7.4 lb-ft). Hold: Use a 13 mm (33/64") wrench.

Diagrams show tightening and holding procedures, including checks for threaded holes ('OK').

Place the cable(s) inside the cable cover. Tighten thru-hull cover screws (T25 PT 5.0x18) to 2 Nm (1.5 lb-ft). Tighten cable cover screws (T25 PT 5.0x18) to 2 Nm (1.5 lb-ft).

4B. Install Concealed Thru-Hull Fittings Under the Waterline

Slide back the cable plug and press down its cantilever. Fit the cable clip in the back plate or cut it off.

Diagram shows sliding the cable plug and fitting the cable clip.

Tighten: Use a 27 mm (1 1/16") wrench to tighten to 10 Nm (7.4 lb-ft). Hold: Use a 13 mm (33/64") wrench.

Diagrams show tightening and holding procedures, including checks for threaded holes ('OK').

Servo unit(s): Install using T25 (PT 5.0x18) screws, torqued to 2 Nm (1.5 lb-ft). Note for 1 or 2 servo units.

Diagram shows servo unit installation and a note regarding 1 or 2 servo units.

5. Install the Interceptor Fronts

Interceptor front:

• 400 E: T30 (PT 6.0x60) screws (x2), 7 Nm (5.1 lb-ft)
• 600 E: T30 (PT 6.0x60) screws (x3), 7 Nm (5.1 lb-ft)
• 800 E: T30 (PT 6.0x60) screws (x5), 7 Nm (5.1 lb-ft)
• 1000 E: T30 (PT 6.0x60) screws (x7), 7 Nm (5.1 lb-ft)

Interceptor front:

• 400 E: T40 (PT 8.0x70) screws (x4), 15 Nm (11 lb-ft)
• 600 E: T40 (PT 8.0x70) screws (x6), 15 Nm (11 lb-ft)
• 800 E: T40 (PT 8.0x70) screws (x8), 15 Nm (11 lb-ft)
• 1000 E: T40 (PT 8.0x70) screws (x10), 15 Nm (11 lb-ft)

Diagrams show the installation of interceptor fronts with specific screw types and torque values for different models.

6. Paint the Interceptors with Antifouling

1. Apply antifouling paint. Best tool: Spray. 2nd Best tool: Roller.
2. Remove excess antifouling when the paint is dry. Run a thin knife or a spatula along the blades to ensure unrestrained blade motion.

Diagrams illustrate applying antifouling and the process of removing excess paint.

1. Mount the Distribution Unit

Mount the distribution unit inboard, in an accessible location for connecting to interceptors and power supply (e.g., engine room). Position the unit on a vertical (±30°) hard surface with connectors facing downward. Ensure a minimum clearance of 50 mm (2") at the top for convection cooling.

Steps:

1. Drill holes (x2) Ø 4 mm (5/32").
2. Fasten screws (x2) T25 (ST 4.8x38).

Diagrams show the mounting position, dimensions (180 mm / 7.1"), angle tolerance (±30°), and minimum clearance (50 mm / 2"). It also shows the unit connected to interceptors on the transom.

2. Connect the Distribution Unit

Connect the unit to the integrator module, power supply (battery via main switch and 15A fuse), and interceptors. The maximum combined cable length for interceptors is 6 m (standard + extension cable).

NOTE! Detailed wiring diagram is available at the end of this folder.

A wiring diagram shows the Distribution Unit (DU PRO) connected to the Integrator Module, optional DU-EX PRO, power supply (Battery, Main Switch, 15A Fuse), and Interceptors (Interceptor 1, Optional Interceptor 1).

1. Mount the Integrator Module

Mount the integrator module on a rigid surface for easy connection to the distribution unit and other equipment (e.g., under the dash). For use with mobile devices, mount for maximum signal strength. Maintain a safe distance of 0.5 m (1.6 ft) from magnetic compasses.

Steps:

1. Drill holes (x4) Ø 4 mm (5/32").
2. Fasten screws (x4) T25 (ST 4.8x38).

Diagrams show the module dimensions (162 mm / 6.4" x 46 mm / 1.8") and mounting hole locations.

Mounting Restrictions: Mount the integrator module within the specified orientation angles.

Diagrams illustrate acceptable orientation angles relative to the boat's forward direction (0°, 90°, 180°).

NOTE! Make sure the integrator module orientation angle is set as accurately as possible (within ±5°) during initial start-up.

2. Connect the Integrator Module

Route cables between the integrator module, distribution unit, and optional MFD or other equipment. Use extension cables if necessary.

A system diagram shows connections: External GPS (optional), Mobile Device, Integrator Module, Distribution Unit(s), Extension Cable (optional), Standard Cable, Mini Controller/Control Panel (optional), MFD. The system can be controlled from multiple devices.

Key Sense/Ignition Switch: Use the supplied crimp lug if the system will be connected to and turned on/off by the ignition switch.

Ethernet Connection: Always use the supplied cable gland when using the Ethernet option.

NOTE! Detailed wiring diagram is available at the end of this folder.

* IMPORTANT: The integrator module requires at least one external GPS signal via NMEA 2000, a Zipwake external GPS, or a Zipwake control panel.

3. Initial Start

Refer to the Operator's Manual for detailed information on setting up and operating the system.

Setting Up the System:

• Multifunction Display (MFD): The Zipwake application appears automatically on compatible MFDs. Consult your MFD manufacturer's manual for integration details. Follow on-screen steps for system installation.
• Mobile Device: Scan QR-code 1 on the integrator module label to connect to Wi-Fi. Scan QR-code 2 to launch the Zipwake application (APP) and add it to your device's start screen.

Diagrams show QR codes for Wi-Fi connection (ZIPWAKE-27523, Passw: 947c6b83, http://zipwake.local) and the Zipwake APP.

NOTE! Ensure the integrator module orientation angle is set accurately within ±5° relative to the boat's forward direction. Use a compass or compass app if needed.

Diagram shows an orientation angle indicator.

Interceptor Check: Perform this check after installation and before every launch.

The check involves a 5-stroke sequence where each interceptor blade extends and retracts sequentially from port to starboard. Visually confirm correct movement.

Diagrams illustrate the interceptor check sequence (1-8) and servo unit readings (Mean out, Mean in, Max. out, Max. in) which should all be green.

All readings must be green! Corrective actions are necessary for excessive torque levels. Verify transom flatness, sealant, and antifouling.

IMPORTANT: Always use controls to move interceptor blades. Never force them by hand.