zipwake E Series User manual

INSTALLATION GUIDE
DYNAMIC TRIM CONTROL SYSTEM
SERIES E

INTERCEPTOR
Copyright © 2021 Zipwake AB, Sweden. All rights reserved. R1B, January 2022, English
TOOLS
AntifoulingUtility knife Hacksaw
Sealant WrenchFlat screwdriver
Bits screwdriver
Power drill
13 mm (33/64")
27 mm (1 1/16")
Drill bits Hole saw Screw 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")
Ø 19 mm (3/4")
Ø 76 mm (3")
T10
T20
T25
T30
T40
INTERCEPTOR DISTRIBUTION UNIT
CONTROL PANEL
THE KIT BOX CONTAINS
1 x Control Panel
with Standard Cable 15 m
2 x Interceptors
with Cable 3 m & Cable Cover
+ Operator’s Manual
+ Warranty Card
+ Installation Guide
+ Drill Templates
+ Mounting Screws
+ Operator’s Quick Guide
+ Startup Checklist
1 x Distribution Unit
with Power Cable 6 m
SYSTEM OVERVIEW
BRIDGE
CONTROL PANEL
EXTERNAL
DEVICE
INTERCEPTORS INTERCEPTORS
DISTRIBUTION
UNIT
DISTRIBUTION
EXPANSION UNIT
FLYBRIDGE
CONTROL PANEL
External
GPS
Ignition
key sense
Supply 12-32 V DC
3 flybridge
panels possible
I-BUS (Can Bus)
NMEA
2000
STBD
I-BUS
OUT
PORT
12/24VDC
10A FUSE
S1
P6
S2
P5
S3
P4
P3
S4
P2
S5
P1
S6
Up to six dual-servo
interceptors or any
mix with single-servo
interceptors
1 MOUNTING OPTIONS
THRU-HULL CABLE FITTINGS
ALLOWED SPRAY RAIL OVERLAP
Depending on preference, the interceptors can be mounted with thru-hull
cable fittings above the waterline (A) or below, concealed behind the
interceptors (B).
NOTE! Chine interceptor
A
B
Max Extension
E = 60 mm (2.4")
E
Not Ok! Ok!
Ok!

INTERCEPTORINTERCEPTOR
Min
100 mm (4")
0 mm (0") 0 mm (0")
Min
3 mm (0.1")
Max
10 mm (0.4")
Min
125 mm (5")
PROPELLER CLEARANCE
CONVEX BOTTOM CURVATURE
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
CONCAVE BOTTOM CURVATURE
Max 2 mm (0.08")
between parallel
planes
0 -15°
DRILLING TEMPLATE
Start mounting the interceptors as far outward as possible, although well
inside the transom. Continue inwards when installing multiple interceptors.
1. Pilot hole
2. Drill
Ø 3 mm (1/8")
Ø 6.5 mm (1/4")
Drill holes for the interceptors
400 E:
600 E:
800 E:
1000 E:
x6
x9
x13
x17
1
2
3
1. Pilot hole
2. Hole saw
Ø 3 mm (1/8")
Ø 19 mm (3/4")
NOTE! Only if a concealed thru-hull fitting will be used
1. Pilot hole
2. Hole saw
3. Tap
Ø 3 mm (1/8")
Ø 16 mm (5/8")
M18 x 2.5
Option 2 (threaded hole):Option 1:
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.
Drill pilot holes
Remove the template
Drill holes
IT600/800/1000-E are dual-servo
interceptors (2 holes)
IT400-E is a single-servo
interceptor (1 hole)
2 PREPARE THE TRANSOM
ENSURE A FLAT SURFACE FOR EACH INTERCEPTOR
The transom must be relative-
ly flat where the interceptors
are mounted to ensure that
they work properly.

Drill holes for the cover base
Use the cover base as a drill
template
4AINSTALL THRU-HULL FITTINGS
ABOVE THE WATERLINE
1
Mark the center of
the thru-hull fitting
Drill holes (x4) for the cover base
Use the cover base as a drill template
Ø 4 mm (5/32")
3
4
7 8
5 6
1. Pilot hole
2. Hole saw
Ø 3 mm (1/8")
Ø 19 mm (3/4")
Drill holes for thru-hull fittings (1 or 2 holes)
1. Pilot hole
2. Hole saw
3. Tap
Ø 3 mm (1/8")
Ø 16 mm (5/8")
M18 x 2.5
Option 2 (threaded hole):Option 1:
Apply sealant (x4)
Cover base:
Metal hull: Machine screws
(not included)
GRP hull (x4):
T25 (ST 4.8x25)
2
Ø 4 mm (5/32")
Place the cable cover
on top of the interceptor
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
Waterline
Dual-
servo Single-
servo
Snapp o
the thru-hull
center piece(s)
INTERCEPTOR INTERCEPTOR
Remove excess sealant
with a knife or a spatula
B. MOUNT THE BACK PLATE
1
3 INSTALL THE BACK PLATES
B. MOUNT THE BACK PLATE
Apply sealant
GRP hull: T40 (ST 8.0x45)
Metal hull: Machine screws
(not included)
Apply sealant
1
2
4
3
NOTE!
Remove Servo unit(s):
(x3)
T25 (PT 5.0x18)
400 E:
600 E:
800 E:
1000 E:
x6
x9
x13
x17
400 E:
600 E:
800 E:
1000 E:
x6
x9
x13
x17
A. FOR THRU-HULL FITTINGS ABOVE THE WATERLINE
GO STRAIGHT TO STEP B.
Slide out the cable
plug to remove
the servo cable(s)
2Remove the
back plug(s)

9
14
13
12
11
Cable cover base:
Metal hull: Machine screws
(not included)
GRP hull:
T25 (ST 4.8x25)
Apply sealant
Tighten:
27 mm (1 1/16") wrench
10 Nm (7.4 lb-ft)
Hold:
13 mm (33/64") wrench
Place the cable
in the clip
NOTE! Threaded hole
OK OK
Place the cable(s)
inside the cable cover
Thru-hull cover:
T25 (PT 5.0x18)
(x4)
Cable cover:
T25 (PT 5.0x18)
2 Nm (1.5 Ib-ft)
2 Nm (1.5 Ib-ft)
10
2
4BINSTALL CONCEALED THRU-HULL
FITTINGS UNDER THE WATERLINE
1
Fit the cable clip
in the back plate
or cut it o
Slide back the cable
plug and press
down its cantilever
3
(x3)
(x3)
Tighten:
27 mm (1 1/16") wrench
10 Nm (7.4 lb-ft)
Hold:
13 mm (33/64") wrench
NOTE!
Threaded hole
OK
OK
Servo unit(s):
2 Nm (1.5 Ib-ft)
T25 (PT 5.0x18)
NOTE!
1
1
2
NOTE! 1 or 2 Servo units
NOTE!
INTERCEPTORINTERCEPTOR

INTERCEPTOR
Remove excess antifouling
when the paint is dry
Run a thin knife or a
spatula along the blades
to ascertain unrestrained
blade motion
6 PAINT THE INTERCEPTORS WITH
ANTIFOULING
1
2
5 INSTALL THE INTERCEPTOR FRONTS
Best tool
Spray
2nd Best tool
Roller
Apply Antifouling
Interceptor front:
T30 (PT 6.0x60)
400 E:
600 E:
800 E:
1000 E:
x2
x3
x5
x7
7 Nm
(5.1 Ib-ft)
Interceptor front:
T40 (PT 8.0x70)
400 E:
600 E:
800 E:
1000 E:
x4
x6
x8
x10
15 Nm
(11 Ib-ft)
DISTRIBUTION UNIT
Interceptor InterceptorTransom
inside view
Starboard Port
Max combined length (6 m)
(standard + extension cable) (3 m)(3 m)
(1.5 m)
(3 m)
180 mm (7.1")
1 MOUNT THE DISTRIBUTION UNIT
2 CONNECT 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).
NOTE! Detailed wiring diagram is available at the end of this folder.
1. Drill holes (x2)
2. Fasten screws (x2)
Ø 4 mm (5/32")
T25 (ST 4.8x38)
Interceptor 1 Interceptor 1
Optional
interceptor
Control
panel
DU-EX
(optional) Power cable
Battery
Main
switch
15A Fuse

CONTROL PANEL CONTROL PANEL
Extra control panel
Flybridge (optional)
External GPS
(optional)
Standard cable (15m)
Extension cable
(optional)
Main control panel
Main bridge
1 ROUTE CABLES
Route the cables between the control panel(s), the distribution unit(s) and
optional equipment. Use optional extension cables if necessary.
A detailed wiring diagram is available on the other side of this folder.
Top view
Max
5˚
Max
5˚
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.
NOTE! Any angle betwen 0-180°
Distribution
unit(s)
0˚
180˚
Ignition switch
Distribution unit External GPS
NMEA 2000 networkExtra Control panel
1
2
4
3
3 MOUNT THE CONTROL PANEL
Connect the cables on the back of the Control panel.
Flush mount option: refer to www.zipwake.com for a drawing and 3D model.
Prepare the cables
Route the standard and
optional cables
Snap o the frame
Drill holes (x4)
Drill hole
1. Pilot hole
2. Hole saw
Ø 3 mm (1/8")
Ø 76 mm (3")
Ø 2.5 mm (3/32")

WIRING DIAGRAM
ACCESSORIES
CONTROL PANEL
Model Part No. Description
CP-E 2012032 CONTROL PANEL E WITH STANDARD CABLE 15 M
DU-E 2012033 DISTRIBUTION UNIT E WITH POWER CABLE 6 M
DU-EX 2012034 DISTRIBUTION EXPANSION UNIT E WITH POWER CABLE 6 M
IT400-E 2012215 INTERCEPTOR 400 E WITH CABLE 3 M & CABLE COVER
IT600-E 2012018 INTERCEPTOR 600 E WITH CABLE 3 M & CABLE COVER
IT800-E 2012019 INTERCEPTOR 800 E WITH CABLE 3 M & CABLE COVER
IT1000-E 2012020 INTERCEPTOR 1000 E WITH CABLE 3 M & CABLE COVER
IT600-E TUNNEL R500 2012021 INTERCEPTOR 600 E TUNNEL R500
WITH CABLE 3 M & CABLE COVER
IT600-E TUNNEL R600 2012022 INTERCEPTOR 600 E TUNNEL R600
WITH CABLE 3 M & CABLE COVER
IT600-E TUNNEL R800 2012023 INTERCEPTOR 600 E TUNNEL R800
WITH CABLE 3 M & CABLE COVER
IT400-E CHINE PORT 2012216 INTERCEPTOR 400 E CHINE PORT SIDE
WITH CABLE 3 M & CABLE COVER
IT400-E CHINE STBD 2012217 INTERCEPTOR 400 E CHINE STARBOARD SIDE
WITH CABLE 3 M & CABLE COVER
IT600-E CHINE PORT 2012024 INTERCEPTOR 600 E CHINE PORT SIDE
WITH CABLE 3 M & CABLE COVER
IT600-E CHINE STBD 2012025 INTERCEPTOR 600 E CHINE STARBOARD SIDE
WITH CABLE 3 M & CABLE COVER
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
EC15-M12 2012038 M12 EXTENSION CABLE 15 M
EC20-M12 2012039 M12 EXTENSION CABLE 20 M
SC15-M12 2012037 M12 STANDARD CABLE 15 M
CP ALU FRAME 2011281 CONTROL PANEL ALU FRAME
CP COVER 2011381-
2011385
CONTROL PANEL COVER
WHITE, LIGHT GRAY, MID GRAY, DARK GRAY, BLACK
CC-EX 2012036 CABLE COVER EXTENSION E KIT
GPU 2011240 GLOBAL POSITIONING UNIT WITH CABLE 5 M & MOUNT KIT
GB 2011622 GIMBAL BRACKET FOR CONTROL PANEL
All readings must be green!
Corrective action is always necessary when excessive 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.
5
61
2
Snap on the frame
Apply sealant (x4)
When waterproofing
is required
Control panel:
T10 (ST 2.9x19)
(x4)
INTERCEPTOR CHECK
4 INITIAL START
Press and hold the POWER/MENU button until the
Zipwake logo appears on the display and follow
the steps on the screen.
Carry out an Interceptor Check to verify function imme-
diately after installation and before launching 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).
SET UP THE SYSTEM
Refer to the Operator’s Manual for detailed information about setting up
and operating the system.
1524
678 3

WIRING DIAGRAM
POWER SUPPLY (12-32 V DC)
Battery Battery
Main
switch
15A melting
type fuse
Power cable (6 m)
Power cable (6 m)
Max combined cable length (6 m)
(standard + extension cable)
Max combined cable length (15 m)
(standard + extension cable)
STARBOARD PORT
Port
Interceptor 1
Port
Interceptor 2
Starboard
Interceptor 2
Port
Interceptor 3
Starboard
Interceptor 3
Starboard
Interceptor 1
(3 m) (3 m) (3 m) (3 m) (3 m) (3 m)
WIRING DIAGRAM
USB (upgrades etc.)
EXTERNAL GPS (GPU)EXTRA CONTROL PANEL (CP-E)MAIN CONTROL PANEL (CP-E)
Ignition
switch
15(b)
Connect to Key Sense input on the control panel
Ignition
switch
15(b)
Connect to Key Sense input on the control panel
The external GPS can be connected to any control panel
Extension cable* (optional)
Extension cable* (optional)
Extension cable (optional 1.5, 3, 5 or 10 m)
(1.5 m) (3 m) (5 m) (10 m) (15 m) (20 m)
Standard cable (15 m)
GPS cable (5 m)
Ignition switch
Distribution unit External GPS
NMEA 2000 networkExtra control panel
DISTRIBUTION
UNIT (DU-E)
DISTRIBUTION EXPANSION
UNIT (DU-EX) (optional)
To NMEA 2000 backbone (optinal GPS source, external montitoring and/or control)
Up to six dual-servo interceptors or any mix with single-servo interceptors
*Extension cable (optional)
Extension cable* (optional)
Extension cable
(optional 1.5 or 3 m)
Standard cable (15 m)
NOTE!
Transom inside view
Optional: Centerline mounted single-servo interceptor DU-E: P3 DU-E/EX: P6 Optional: Centerline mounted dual-servo interceptor DU-E: P3 & S3 DU-E/EX: P5 & P6
Auto Cleaning
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.
NOTE! Connect DU-E and DU-EX to the same power source and ground potential (grounding point).
NOTE! Do not use automatic thermal/magnetic fuse.

DU-E
STBD PORT
DU-EX
STBD PORT
DU-E
DU/INTERCEPTOR CONFIGURATIONS
NOTE!
Transom inside view
DU-E
STBD PORT
DU-E
STBD PORT
STBD PORT
DU-E DU-EX
DU-E
STBD PORT
STBD PORT
DU-EX DU-E
STBD PORT
DU-E DU-EX
STBD PORT
DU
-
ED U
-
EX
DU-E
STBD PORT
DU-EX
DU-E
STBD PORT
DU-EX

• Operator’s Manual and Installation Guide in dierent 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
• Programming Manual for external control application development
Visit www.zipwake.com for additional information such as: