zipwake S Series User manual

DYNAMIC TRIM CONTROL SYSTEM
FOR INTEGRATION
SERIES S
INSTALLATION GUIDE

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 3.5 mm (9/64")
Ø 4 mm (5/32")
Ø 5 mm (3/16")
T10
T20
T25
T30
Copyright © 2023 Zipwake AB, Sweden. All rights reserved. R1A, March 2023, English
SYSTEM OVERVIEW
Ø 19 mm (3/4")
INTERCEPTOR DISTRIBUTION UNIT
INTEGRATOR MODULE
KIT BOX CONTENTS
1 x Integrator Module
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 4 m
83%45%
MANUAL FULL AUTO PITCH
83%45%
MANUAL FULL AUTO PITCH
INTEGRATOR
MODULE
MOBILE
DEVICE
MULTIFUNCTION DISPLAY
(MFD) (Zipwake MFD App)
INTERCEPTORS INTERCEPTORS
DISTRIBUTION UNIT (DU)
CONTROL
PANEL
(optional)
External GPS
(optional)
Ignition
key sense
Supply 12-32 V DC Additional control
panels (optional)
I-BUS (Can Bus)
NMEA 2000
Ethernet
KEY
SENSE
I-BUS
IN
I-BUS
OUT
NMEA
2000
EXT
CONN
ETH
10/100
1 x Standard Cable 7 m

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 = 30 mm (1.2")
E
Not Ok! Ok!
Ok!
INTERCEPTOR
1 x Standard Cable 7 m

Min
75 mm (3")
0 mm (0") 0 mm (0")
Min
3 mm (0.1")
Max
5 mm (0.2")
Min
100 mm (4")
PROPELLER CLEARANCE
CONVEX BOTTOM CURVATURE
CONCAVE BOTTOM CURVATURE
If the boat has an outboard engine or sterndrive, the Interceptors must be
mounted with clearance to the propeller(s).
NOTE! Intermediate Interceptor
INTERCEPTOR

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.
1. Drill pilot holes
2. Remove the template
3. Drill holes
2 PREPARE THE TRANSOM
ENSURE A FLAT SURFACE FOR EACH INTERCEPTOR
DRILLING TEMPLATE
The transom must be relatively flat where the Interceptors are mounted to
ensure that they work properly.
Start mounting the Interceptors as far outward as possible, although well
inside the transom. Continue inwards when installing multiple Interceptors.
Max 2 mm (0.08")
between parallel
planes
0 -15°
1. Pilot hole
2. Hole saw
Ø 3 mm (1/8")
Ø 19 mm (3/4")
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 (M18 x 2.5):Option 1:
1. Pilot hole
2. Drill
Ø 3 mm (1/8")
Ø 5 mm (3/16")
Drill holes for the Interceptors
300 S:
450 S:
600 S:
750 S:
x6
x10
x14
x18
INTERCEPTOR

Remove excess sealant
with a knife or a spatula
B. MOUNT THE BACK PLATE
12Remove back plug
3 INSTALL THE BACK PLATES
B. MOUNT THE BACK PLATE
Apply sealant
GRP hull: T30 (ST 6.3x38)
Metal hull: Machine screws
(not included)
Apply sealant
1
2
4
3
NOTE!
Sealant
Remove Servo unit:
(x3)
T25 (PT 5.0x18)
A. FOR THRU-HULL FITTINGS ABOVE THE WATERLINE
GO STRAIGHT TO STEP B.
INTERCEPTOR
300 S:
450 S:
600 S:
750 S:
x6
x10
x14
x18
300 S:
450 S:
600 S:
750 S:
x6
x10
x14
x18

4AINSTALL THRU-HULL FITTINGS
ABOVE THE WATERLINE
1
4 5 6
2
Place the cover on
the thru-hull fitting
Mark the lower edge
of the thru-hull cover
Remove the thru-
hull cover
Drill hole for thru-hull fitting
Align the hole with the
Interceptor cable
1. Pilot hole
2. Hole saw
Ø 3 mm (1/8")
Ø 19 mm (3/4")
Waterline
3
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
1. Pilot hole
2. Hole saw
3. Tap
Ø 3 mm (1/8")
Ø 16 mm (5/8")
M18 x 2.5
Option:
OK OK
NOTE!
Sealant
INTERCEPTOR

7
8 9 10
131211
Apply sealant
Drill holes for the cable cover
Use the cover as a drill template
Extension
(optional)
Cable cover
(standard)
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
Interceptor
Apply sealant (x3)
Drill holes (x3) for the cover
Use the cover as a drill template
~5 mm
(0.2")
Ø 3.5 mm (9/64")
Ø 5 mm (3/16")
Cable cover:
Metal hull: Machine screws
(not included)
GRP hull:
T20 (ST 4.2x19)
Thru-hull cover:
Metal hull: Machine screws
(not included)
GRP hull:
T30 (ST 6.3x38) (x3)
INTERCEPTOR

2
4BINSTALL CONCEALED THRU-HULL
FITTINGS UNDER THE WATERLINE
1
Fit the cable clip
in the back plate
or cut it o
NOTE!
Sealant
Servo unit:
2 Nm (1.5 Ib-ft)
3
1
1
2
NOTE!
(x3)
T25 (PT 5.0x18)
Tighten:
27 mm (1 1/16") wrench
10 Nm (7.4 lb-ft)
Hold:
13 mm (33/64") wrench
NOTE!
M18 x 2.5
OK
OK
INTERCEPTOR

Remove excess antifouling
when the paint is dry
Run a thin knife or a
spatula along the blades
to ascertain unrestrained
blade motion
1
2
5 INSTALL THE INTERCEPTOR FRONTS
6 PAINT THE INTERCEPTORS WITH
ANTIFOULING
Best tool
Spray
2nd Best tool
Roller
Apply Antifouling
5 Nm
(3.7 lb-ft)
Interceptor front: T30 (PT 6.0x48)
INTERCEPTOR
300 S:
450 S:
600 S:
750 S:
x6
x10
x14
x18

DISTRIBUTION UNIT
Interceptor InterceptorTransom
inside view
Starboard Port
Max combined cable 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 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).
NOTE!
Detailed wiring diagram is available at the end of this folder.
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.
1. Drill holes (x2)
2. Fasten screws (x2)
Ø 4 mm (5/32")
T25 (ST 4.8x38)
Interceptor 1
Integrator
module
Power cable
Interceptor 1Interceptor
pairs 2 & 3
Battery
Main
switch
15A Fuse

INTEGRATOR MODULE
KEY
SENSE
I-BUS
IN
I-BUS
OUT
NMEA
2000
EXT
CONN
ETH
10/100
162 mm (6.4")
46 mm (1.8")
1. Drill holes (x4)
2. Fasten screws (x4)
Ø 4 mm (5/32")
T25 (ST 4.8x38)
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.
Mounting restrictions
Mount the integrator module within the angles shown in figures 1-3.
2
3
1
0˚
-45˚ 45˚
NOTE!
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.

Control panel (optional*)
Mobile device
MFD
External GPS (optional*)
Distribution unit
Standard cable (7 m)
Integrator module
Extension cable (optional)
INTEGRATOR MODULE
46 mm (1.8")
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/o by, the
ignition switch.
Key sense
(optional)
Wi-Fi/Bluetooth
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.
KEY
SENS E
I- BUS
IN
I- BUS
OUT
NMEA
2000
EXT
CONN
ETH
10/100
Ethernet
connection
Always use the
supplied cable
gland when the
ethernet option
will be used.
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.

Carry out an Interceptor Check to verify function
immediately after installation and before launching
the boat. Repeat this before every launch.
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.
INTERCEPTOR CHECK
1. Use the interface to extend the
port interceptor
2. Port side Interceptor(s) should
move out
3. Repeat for starboard side
VERIFY FUNCTION ON SHORE
Port Interceptor
INTEGRATOR MODULE
Refer to the Operator’s Manual for detailed information about setting up
and operating the system.
3 INITIAL START
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 to
connect to the Wi-Fi network. Scan the QR-code from
integrator module label 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
SETTING UP THE SYSTEM
NOTE!
Make sure the integrator module orientation
angle (mounting angle relative to the boat’s
forward direction) is set as accurately as
possible.
1
2
ZIPWAKE-137521
SSID 1
http://zipwake.local
APP
2
ORIENTATION ANGLE
Angle relative
forward direction +34o
NEXT
INTERCEPTOR CHECK
S Servo Unit P1
Serial No. 87954
Avg. out 15 mNm
Avg. in 15 mNm
Max. out 40 mNm
Max. in 38 mNm




NEXT

WIRING DIAGRAM
ACCESSORIES
Model Part No. Description
CP-S 2011238 CONTROL PANEL S WITH STANDARD CABLE 7 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
IT300-S CHINE PORT 2011702 INTERCEPTOR 300 S CHINE PORT SIDE
WITH CABLE 3 M & CABLE COVERS
IT300-S CHINE STBD 2011703 INTERCEPTOR 300 S CHINE STARBOARD SIDE
WITH CABLE 3 M & CABLE COVERS
IT450-S CHINE PORT 2011704 INTERCEPTOR 450 S CHINE PORT SIDE
WITH CABLE 3 M & CABLE COVERS
IT450-S CHINE STBD 2011705 INTERCEPTOR 450 S CHINE STARBOARD SIDE
WITH CABLE 3 M & CABLE COVERS
IT300-S INTER 2011701 INTERCEPTOR 300 S INTERMEDIATE
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
EC15-M12 2012038 M12 EXTENSION CABLE 15 M
EC20-M12 2012039 M12 EXTENSION CABLE 20 M
CC-S 2011071 CABLE COVER S KIT
GPU 2011240 GLOBAL POSITIONING UNIT WITH CABLE 5 M & MOUNT KIT

83%45%
MANUAL FULL AUTO PITCH
83%45%
MANUAL FULL AUTO PITCH
KEY
SENSE
I-BUS
IN
I-BUS
OUT
NMEA
2000
EXT
CONN
ETH
10/100
Power cable (4 m)
WIRING DIAGRAM
DISTRIBUTION UNIT (DU-S)
Standard cable (7 m)
Standard cable (7 m)
Max combined cable length (15 m)
(standard + extension cable)
EXTERNAL GPS (GPU)MULTIFUNCTION DISPLAYMOBILE DEVICEINTEGRATOR MODULE (IM)
CONTROL
PANEL (CP-S)
Ignition switch
Ignition switch
15(b)
15(b)
Connect to Key Sense input on the control panel
Connect to Key Sense input on the integrator module
Extension cable* (optional)
Extension cable* (optional)
Extension cable* (optional)
Ethernet
Wi-Fi/
Bluetooth
GPS cable (5 m)
To NMEA 2000 backbone (optional GPS source, external montitoring and/or control)
Additional control panels
(optional)
Extension cable (optional 1.5, 3, 5 or 10 m)
The external GPS can be connected to the integrator module or any control panel

83%45%
MANUAL FULL AUTO PITCH
83%45%
MANUAL FULL AUTO PITCH
KEY
SENSE
I-BUS
IN
I-BUS
OUT
NMEA
2000
EXT
CONN
ETH
10/100
WIRING DIAGRAM
POWER SUPPLY (12-32 V DC)
Battery Battery
Main
switch
15A melting
type fuse
Max combined cable length (6 m)
(standard + extension cable)
Extension cable (optional 1.5 or 3 m)
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)
NOTE!
Transom inside view
Optional: Centerline mounted interceptor connected to distribution unit port side 3
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! Do not use automatic thermal/magnetic fuse.
(1.5, 3, 5, 10, 15 and 20 m)
*Extension cable (optional)

• 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
Visit zipwake.com for additional information such as: