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Installation Guide for ZiPWAKE models including: Series E, Series E Dynamic Trim Control System, Dynamic Trim Control System, Trim Control System, Control System
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DocumentDocumentDYNAMIC TRIM CONTROL SYSTEM FOR INTEGR ATION SERIES E INSTALL ATION GUIDE TOOLS Power drill Drill bits Ø 2.5 mm (3/32") Ø 3 mm (1/8") Ø 4 mm (5/32") Ø 5 mm (3/16") Ø 6.5 mm (1/4") Sealant Utility knife Hole saw Ø 19 mm (3/4") Screw bits T10 T30 T20 T40 T25 Flat screwdriver Bits screwdriver Wrench 13 mm (33/64") 27 mm (11/16") Hacksaw Antifouling KIT BOX CONTENTS INTERCEPTOR 2 x Interceptors with Cable 3 m & Cable Cover DISTRIBUTION UNIT STBD PORT I-BUS S1 S2 S3 P3 P2 P1 OUT P6 P5 P4 S4 S5 S6 12/24 VDC 10A FUSE 1 x Distribution Unit with Power Cable 6 m INTEGRATOR MODULE KEY I-BUS SENSE IN I-BUS OUT NMEA EXT 2000 CONN ETH 10/100 1 x Integrator Module + Operator's Manual + Warranty Card + Installation Guide + Drill Templates + Mounting Screws + Operator's Quick Guide + Startup Checklist 1 x Standard Cable 15 m SYSTEM OVERVIEW MOBILE DEVICE MANUAL FULL AUTO PITCH INTEGRATOR MODULE MULTIFUNCTION DISPLAY (MFD) (Zipwake MFD App) MANUAL FULL AUTO PITCH External GPS (optional) 83% 45% Ignition key sense DISTRIBUTION EXPANSION UNIT (DU-EX) 83% 45% Ethernet NMEA 2000 Additional control panels (optional) DISTRIBUTION UNIT (DU) CONTROL PANEL (optional) I-BUS (Can Bus) Supply 12-32 V DC INTERCEPTORS INTERCEPTORS Copyright © 2023 Zipwake AB, Sweden. All rights reserved. R1A, March 2023, 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 = 60 mm (2.4") NOTE! Chine interceptor E Not Ok! 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). NOTE! Optional intermediate Series S interceptor IT300-S INTER Min 100 mm (4") 0 mm (0") 0 mm (0") CONVEX BOTTOM CURVATURE Min 125 mm (5") Max 10 mm (0.4") CONCAVE BOTTOM CURVATURE Min 3 mm (0.1") 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 straight-edges 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. NOTE! Only if a concealed thru-hull fitting will be used Option 1: 1. Pilot hole 2. Hole saw Ø 3 mm (1/8") Ø 19 mm (3/4") Option 2 (threaded hole): 1. Pilot hole Ø 3 mm (1/8") 2. Hole saw Ø 16 mm (5/8") 3. Tap M18 x 2.5 IT600/800/1000-E are dual-servo interceptors (2 holes) IT400-E is a single-servo interceptor (1 hole) 1 Drill pilot holes 2 Remove the template 3 Drill holes Drill holes for the interceptors 400 E: x6 1. Pilot hole Ø 3 mm (1/8") 600 E: x9 800 E: x13 2. Drill Ø 6.5 mm (1/4") 1000 E: x17 0 -15° INTERCEPTOR 3 INSTALL THE BACK PLATES A. FOR THRU-HULL FITTINGS ABOVE THE WATERLINE GO STRAIGHT TO STEP B 1 Slide out the cable 2 Remove the plug to remove back plug(s) the servo cable(s) Remove Servo unit(s): T25 (PT 5.0x18) (x3) B. MOUNT THE BACK PLATE NOTE! Apply sealant 1 400 E: x6 600 E: x9 800 E: x13 1000 E: x17 2 Apply sealant GRP hull: T40 (ST 8.0x45) 400 E: x6 600 E: x9 800 E: x13 1000 E: x17 Metal hull: Machine screws 3 (not included) Remove excess sealant with a knife or a spatula 4 INTERCEPTOR 4A INSTALL THRU-HULL FITTINGS ABOVE THE WATERLINE Mark the center of the thru-hull fitting 1 Waterline Drill holes (x4) for the cover base Use the cover base as a drill template Ø 4 mm (5/32") 2 Dual- servo Singleservo 3 Drill holes for thru-hull fittings (1 or 2 holes) Option 1: 1. Pilot hole Ø 3 mm (1/8") 2. Hole saw Ø 19 mm (3/4") Option 2 (threaded hole): 1. Pilot hole Ø 3 mm (1/8") 2. Hole saw Ø 16 mm (5/8") 3. Tap M18 x 2.5 4 5 6 Snapp off the thru-hull center piece(s) Apply sealant (x4) Cover base: GRP hull (x4): T25 (ST 4.8x25) Metal hull: Machine screws (not included) Place the cable cover 7 on top of the interceptor 8 and and cut it alongside the thru-hull cover base. If neccessary use the cable cover extension kit (CC-EX, optional) and cut it to desired length Drill holes for the cover base Use the cover base as a drill template Ø 4 mm (5/32") INTERCEPTOR 9 10 Apply sealant 11 NOTE! Cable cover base: GRP hull: T25 (ST 4.8x25) Metal hull: Machine screws (not included) 12 Tighten: 27 mm (11/16") wrench 10 Nm (7.4 lb-ft) Place the cable Hold: in the clip 13 mm (33/64") wrench NOTE! Threaded hole OK OK 13 Place the cable(s) inside the cable cover 14 Thru-hull cover: T25 (PT 5.0x18) (x4) 2 Nm (1.5 Ib-ft) Cable cover: T25 (PT 5.0x18) 2 Nm (1.5 Ib-ft) INTERCEPTOR 4B INSTALL CONCEALED THRU-HULL FITTINGS UNDER THE WATERLINE 1 NOTE! Slide back the cable plug and press down its cantilever Fit the cable clip in the back plate or cut it off 2 Tighten: NOTE! 27 mm (11/16") wrench 10 Nm (7.4 lb-ft) Threaded hole OK OK Hold: 13 mm (33/64") wrench 3 Servo unit(s): T25 (PT 5.0x18) 2 Nm (1.5 Ib-ft) NOTE! 1 or 2 Servo units (x3) 1 2 1 (x3) INTERCEPTOR 5 INSTALL THE INTERCEPTOR FRONTS Interceptor front: T30 (PT 6.0x60) 400 E: x2 600 E: x3 800 E: x5 1000 E: x7 7 Nm (5.1 Ib-ft) Interceptor front: T40 (PT 8.0x70) 400 E: x4 600 E: x6 800 E: x8 1000 E: x10 15 Nm (11 Ib-ft) 6 PAINT THE INTERCEPTORS WITH ANTIFOULING 1 Apply antifouling 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 ascertain unrestrained blade motion 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 engine room or other suitable compartment. NOTE! The maximum cable length (including extra cable) from an interceptor to the distribution unit is 6 m (20 ft). 1. Drill holes (x2) Ø 4 mm (5/32") 2. Fasten screws (x2) T25 (ST 4.8x38) 180 mm (7.1") (1.5 m) (3 m) (3 m) Max combined length (6 m) (standard + extension cable) (3 m) Interceptor Transom inside view Interceptor Starboard Port 2 CONNECT THE DISTRIBUTION UNIT NOTE! Detailed wiring diagram is available at the end of this folder. Integrator module DU-EX (optional) Power cable 15A Fuse Main switch Interceptor 1 Optional interceptor Interceptor 1 Battery INTEGRATOR MODULE 1 MOUNT THE INTEGRATOR MODULE Mount the integrator module on a rigid surface where it is easy to connect it to the distribution unit and other equipment e.g. under the dash or another suitable compartment. If the system will be used with mobile devices, mount the integrator module for maximum signal strength. NOTE! 0.5 m (1.6 ft) safe distance to magnetic compass. 1. Drill holes (x4) Ø 4 mm (5/32") 162 mm (6.4") 46 mm (1.8") 2. Fasten screws (x4) T25 (ST 4.8x38) KEY I-BUS SENSE IN I-BUS OUT NMEA 2000 EXT CONN ETH 10/100 Mounting restrictions Mount the integrator module within the angles shown in figures 1-3. 1 2 3 0° NOTE! -45° 45° Make sure the integrator module orientation angle (mounting angle relative the boat's forward direction) is set as accurately as possible (±5°) during initial start-up. INTEGRATOR MODULE 2 CONNECT THE INTEGRATOR MODULE Route the cables between the integrator module, the distribution unit and optional multifunction display (MFD) and/or other equipment. Use optional extension cables if necessary. External GPS (optional*) Mobile device Integrator module Distribution unit(s) Standard cable (15 m) MFD Control panel (optional*) Extension cable (optional) With the integrator module connected, the system can be controlled from one or several sources e.g. an MFD, a mobile device or a Zipwake control panel. NOTE! Detailed wiring diagram is available at the end of this folder. Key sense/ Ignition switch Use the crimp lug supplied if the system will be connected to, and turned on/off by, the ignition switch. Wi-Fi/Bluetooth KEY I-BUS SENSE IN I- BUS OUT NMEA 2000 EX T CONN ETH 10/100 Ethernet connection Always use the supplied cable gland when the ethernet option will be used. Key sense (optional) Ethernet MFD Distribution unit Control panel (optional*) NMEA 2000 (optional*) External GPS (optional*) * IMPORTANT The integrator module requires at least one external GPS signal via MFD, NMEA 2000, Zipwake control panel or Zipwake external GPS. INTEGRATOR MODULE 3 INITIAL START Refer to the Operator's Manual for detailed information about setting up and operating the system. SETTING UP THE SYSTEM MULTIFUNCTION DISPLAY (MFD) The Zipwake application automatically appears on a connected (compatible) MFD. Refer to the MFD manufacturer or manual for detailed information on compatible models and how to launch integration applications such as the Zipwake Integrator Module interface on your MFD model. At first start-up, follow the steps on the MFD to complete system installation. MOBILE DEVICE Scan the QR-code from integrator module label 1 to connect to the Wi-Fi network. Scan the QR-code from integrator module label 2 to install the Zipwake App and add it to the device start screen for future use. Follow the steps in the app to complete system installation SSID 1 ZIPWAKE-137521 2 APP http://zipwake.local NOTE! Make sure the integrator module orientation angle (mounting angle relative to the boat's forward direction) is set as accurately as possible. ORIENTATION ANGLE Angle relative forward direction +34o INTERCEPTOR CHECK Carry out an Interceptor Check to verify function immediately after installation and before launching NEXT the boat. Repeat this before every launch. NOTE! Interceptor Check will not start if no interceptor configuration has been saved to the system (refer to the Operator's Manual). The check repeats a 5 stroke sequence, where each interceptor blade is extended, one by one, from port to starboard and then retracted in the same order. Visually confirm that the interceptors move accordingly during the check. This confirms that the interceptors are correctly connected to the distribution unit(s). 15 26 37 48 INTERCEPTOR CHECK E Servo Unit P1 Serial No. 36598 Avg. out Avg. in Max. out Max. in 15 mNm 15 mNm 40 mNm 38 mNm NEXT All readings must be green! Corrective action is always necessary when excessive servo torque levels are observed. The root cause is usually the flatness of the transom behind the interceptor and/or excess antifouling between its blades. IMPORTANT Always use the controls to move the interceptor blades. Never try to force the interceptor blades by hand. WIRING DIAGRAM ACCESSORIES Model CP-E DU-EX IT400-E IT600-E IT800-E IT1000-E IT600-E TUNNEL R500 IT600-E TUNNEL R600 IT600-E TUNNEL R800 IT400-E CHINE PORT IT400-E CHINE STBD IT600-E CHINE PORT IT600-E CHINE STBD EC1.5-M12 EC3-M12 EC5-M12 EC10-M12 EC15-M12 EC20-M12 CC-EX GPU Part No. Description 2012032 CONTROL PANEL E WITH STANDARD CABLE 15 M 2012034 DISTRIBUTION EXPANSION UNIT E WITH POWER CABLE 6 M 2012215 INTERCEPTOR 400 E WITH CABLE 3 M & CABLE COVER 2012018 INTERCEPTOR 600 E WITH CABLE 3 M & CABLE COVER 2012019 INTERCEPTOR 800 E WITH CABLE 3 M & CABLE COVER 2012020 INTERCEPTOR 1000 E WITH CABLE 3 M & CABLE COVER 2012021 INTERCEPTOR 600 E TUNNEL R500 WITH CABLE 3 M & CABLE COVER 2012022 INTERCEPTOR 600 E TUNNEL R600 WITH CABLE 3 M & CABLE COVER 2012023 INTERCEPTOR 600 E TUNNEL R800 WITH CABLE 3 M & CABLE COVER 2012216 INTERCEPTOR 400 E CHINE PORT SIDE WITH CABLE 3 M & CABLE COVER 2012217 INTERCEPTOR 400 E CHINE STARBOARD SIDE WITH CABLE 3 M & CABLE COVER 2012024 INTERCEPTOR 600 E CHINE PORT SIDE WITH CABLE 3 M & CABLE COVER 2012025 INTERCEPTOR 600 E CHINE STARBOARD SIDE WITH CABLE 3 M & CABLE COVER 2011258 M12 EXTENSION CABLE 1.5 M 2011259 M12 EXTENSION CABLE 3 M 2011260 M12 EXTENSION CABLE 5 M 2011261 M12 EXTENSION CABLE 10 M 2012038 M12 EXTENSION CABLE 15 M 2012039 M12 EXTENSION CABLE 20 M 2012036 CABLE COVER EXTENSION E KIT 2011240 GLOBAL POSITIONING UNIT WITH CABLE 5 M & MOUNT KIT WIRING DIAGRAM INTEGRATOR MODULE (IM) MOBILE DEVICE MANUAL FULL AUTO PITCH KEY I-BUS SENSE IN I-BUS OUT NMEA 2000 EXT CONN ETH 10/100 Wi-Fi/ Bluetooth 83% 45% Ethernet MULTIFUNCTION DISPLAY MANUAL FULL AUTO PITCH EXTERNAL GPS (GPU) 83% 45% The external GPS can be connected to the integrator module or any control panel Extension cable (optional 1.5, 3, 5 or 10 m) Max combined cable length (15 m) (standard + extension cable) GPS cable (5 m) Extension cable* (optional) Extension cable* (optional) To NMEA 2000 backbone (optional GPS source, external montitoring and/or control) Extension cable* (optional) DISTRIBUTION EXPANSION UNIT (DU-EX) (optional) Ignition switch DISTRIBUTION UNIT (DU-E) Ignition switch CONTROL PANEL (CP-E) (optional) 15(b) Connect to Key Sense input on the control panel 15(b) Connect to Key Sense input on the integrator module Power cable (6 m) Extension cable* (optional) Standard cable (15 m) Standard cable (7 m) Power cable (6 m) Additional control panels NOTE! Connect DU-E and DU-EX to the same power source and ground potential (grounding point). WIRING DIAGRAM * Extension cable (optional) (1.5, 3, 5, 10, 15 and 20 m) NOTE! Transom inside view Extension cable (optional 1.5 or 3 m) Max combined cable length (6 m) (standard + extension cable) Up to six dual-servo interceptors or any mix with single-servo interceptors Optional: Centerline mounted dual-servo interceptor DU-E: P3 & S3 DU-E/EX: P5 & P6 POWER SUPPLY (12-32 V DC) 15A melting NOTE! Do not use automatic type fuse thermal/magnetic fuse. Auto Cleaning Main switch Battery Battery 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. STARBOARD (3 m) (3 m) Starboard Interceptor 1 Starboard Interceptor 2 (3 m) Optional: Centerline mounted single-servo interceptor DU-E: P3 DU-E/EX: P6 (3 m) (3 m) Starboard Interceptor 3 Port Interceptor 3 Port Interceptor 2 (3 m) PORT Port Interceptor 1 DU/INTERCEPTOR CONFIGURATIONS NOTE! Transom inside view DU-E STBD DU-EX PORT DU-E STBD DU-E PORT DU-EX STBD DU-E PORT DU-EX STBD DU-E PORT STBD PORT DU-E STBD DU-E PORT DU-EX STBD DU-E PORT DU-EX STBD DU-E PORT STBD DU-E PORT DU-EX STBD DU-E PORT DU-EX STBD PORT Visit 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