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Humphree LIGHTNING Installation Manual

Interceptor
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INSTALLATION MANUAL
INTERCEPTOR
L A NG UAG E: EN G LIS H
D OC N O : 0 3 2 2 1 0 -0 2

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Summary of Contents for Humphree LIGHTNING

  • Page 1 INSTALLATION MANUAL INTERCEPTOR L A NG UAG E: EN G LIS H D OC N O : 0 3 2 2 1 0 -0 2...
  • Page 2 [This page intentionally left blank.]...
  • Page 3 © H U M P H R E E 2 0 2 3 . A l l r i g ht s re s e r ve d . No p ar t o f t h i s d o cu me n t m ay b e © HUMPHREE 2023. All rights reserved. No part of this document may be re prod u ce d i n a n y fo r m w i t ho u t p e r mi ss i o n f ro m t h e p u b l i s h e r.

  • Page 4: Table Of Contents

    CONTENTS 1. SAFETY INFORMATION 1.1 WARNINGS AND IMPORTANT NOTICES 1.2 SAFETY PRECAUTIONS 2. ABOUT THIS MANUAL 2.1 INTENDED PRODUCT USE 2.2 INTENDED AUDIENCE 3. PRODUCT OVERVIEW 3.1 STANDARD INTERCEPTOR MODELS 3.2 CHINEINTERCEPTOR MODELS 3.3 SYSTEM OVERVIEW 3.4 COMPONENTS 3.5 REQUIRED TOOLS 4.
  • Page 5 5. PREPARATIONS 6. MOUNT THE INTERCEPTOR 6.1 MOUNT THE INTERCEPTOR BRACKET 6.2 MOUNT THE INTERCEPTOR BRACKET (CHINE ONLY!) 6.3 MOUNT THE INTERCEPTOR BRACKET 6.4 ADJUST THE CABLE GLAND 6.5 MOUNT THE CABLE COVER 7. MOUNT THE CONTROL UNIT 7.1 LCU PLACEMENT GUIDELINES 7.1.1 DEFAULT ORIENTATION 7.1.2 ALTERNATIVE ORIENTATIONS 7.2 MOUNT THE LCU...
  • Page 6 1. SAFETY INFORMATION 1. SAFETY INFORMATION Please read the manual carefully before installing or operating the Humphree system. Pay extra attention to the safety notices listed under section 1.1 Warnings and Important Notices. 1.1 Warnings and Important Notices Three types of warning or notification signs are used in this manual. The signs are...

  • Page 7: About This Manual

    The system must not be used for purposes other than the intended usage. 2.2 Intended Audience This manual is aimed at the installer of the LIGHTNING by Humphree system, including ship-builders, and other authorized workshops with qualified personnel. The following installation instructions are intended for professionals only.

  • Page 8: Product Overview

    3. PRODUCT OVERVIEW 3. PRODUCT OVERVIEW 3.1 STANDARD INTERCEPTOR MODELS L300 L450 3.2 CHINE INTERCEPTOR MODELS L300C L450C NOT E! The following instructions show the installation process using the Standard model. With the exception of steps labeled “CHINE ONLY”, these instructions apply to all interceptor models.

  • Page 9: System Overview

    3. PRODUCT OVERVIEW 3.3 SYSTEM OVERVIEW CABLE GLAND BELOW THE CABLE GLAND ABOVE THE WATERLINE WATERLINE...

  • Page 10: Components

    3. PRODUCT OVERVIEW 3.4 COMPONENTS 2x INTERCEPTOR CONTROL UNIT CONTROL PANEL CABLE 2x INTERCEPTOR BRACKET CONTROL PANEL CABLE N OT E! CHINE ONLY: 2x INTERCEPTOR BRACKET ADD-ON NMEA DROP CABLE 2x CABLE COVER DRILL TEMPLATES • Control Unit & Control Panel •...

  • Page 11: Required Tools

    3. PRODUCT OVERVIEW 3.5 REQUIRED TOOLS (FOR GRP HULLS) ALLEN KEY: ANTI-CORROSIVE COMPOUND Ø 6 mm COUNTERSINK MARINE SEALANT HOLE SAW: Ø 28 mm POWER DRILL Ø 70 mm TORX: WRENCH: TORQUE WRENCH 22 mm 34 mm OPTIONAL EQUIPMENT: • M3 SCREW NUT •...

  • Page 12: Guidelines

    4. INTERCEPTOR MOUNTING GUIDELINES 4. INTERCEPTOR MOUNTING GUIDELINES 4.1 STANDARD INTERCEPTOR MODELS (L300, L450) RECOMMENDED The interceptor will work correctly. ACCEPTABLE The interceptor will work with reduced lifting force. NOT ACCEPTABLE The interceptor is in the way, hindering a clear water flow for the propeller.

  • Page 13: Stern Or Outboards

    4. INTERCEPTOR MOUNTING GUIDELINES 4.2 FOR STERN DRIVES / OUTBOARDS Mount the interceptor so that it does not disturb the water flow of the propeller. 4.3 CHINE MODELS - L300C & L450C (CHINE ONLY) RECOMMENDED Hull example 1:...

  • Page 14: Chine Interceptors

    4. INTERCEPTOR MOUNTING GUIDELINES 4.3 CHINE MODELS - L300C & L450C (CHINE ONLY) RECOMMENDED Hull example 2: NOT ACCEPTABLE Example 1: Do not use a chine interceptor model on a hull with no chine. Example 2: Do not mount the interceptor in the way of the water flow of the propeller.

  • Page 15: Interceptor Placement

    4. INTERCEPTOR MOUNTING GUIDELINES 4.4 INTERCEPTOR PLACEMENT 4.4.1 VERTICAL TRANSOM For vertical transoms, place the interceptor level with the hull bottom. 90° WATER FLOW 4.4.2 ANGLED TRANSOM IMPORTANT! For angled transoms, do not place the interceptor level with the hull bottom. Incorrect interceptor placements does the following: •...
  • Page 16 4. INTERCEPTOR MOUNTING GUIDELINES 4.4.3 INTERCEPTOR PLACEMENT WHEN THE TRANSOM ANGLE IS KNOWN If the transom angle is known, place the interceptor according to the following table: Transom Angle (a) Placement above the hull bottom (p) 0° 0 mm 5° 1.5 mm 8°...
  • Page 17 4. INTERCEPTOR MOUNTING GUIDELINES 4.4.4 INTERCEPTOR PLACEMENT WHEN THE TRANSOM ANGLE IS NOT KNOWN If the transom angle is not known, do the following: PLACE TWO WOODEN BOARDS under the hull, where the interceptor will be mounted. PLACE THE INTERCEPTOR AGAINST THE TRANSOM and move it down until the front touches the boards.
  • Page 18 4. INTERCEPTOR MOUNTING GUIDELINES MARK THE POSITION of the interceptor.
  • Page 19 4. INTERCEPTOR MOUNTING GUIDELINES 4.5 INTERCEPTOR BLADE ADJUSTMENT (CHINE ONLY) IMPORTANT! Chine models require a chine add-on to the interceptor bracket. • Attach the chine add-on to the interceptor bracket before mounting the bracket on the transom. • Mount the interceptor bracket add-on according to the following guidelines: C hi ne Ang le Dr ill Hol e no chine add-on under 8°...
  • Page 20 4. INTERCEPTOR MOUNTING GUIDELINES CHINE TYPE 2...
  • Page 21 5. PREPARATIONS 5. PREPARATIONS TWO PERSONS ARE RECOMMENDED to effectively mount the interceptor on the transom. RECOMMENDED ACCEPTABLE IMPORTANT! TRANSOM REQUIREMENTS: • Transom thickness must be between 10-70mm to fit the cable gland. • For sandwhich core transoms: the outer fiberglass layer must be minimum 10mm to fit the screws.
  • Page 22 5. PREPARATIONS CHECK THE FLATNESS of the transom surface: the surface must not exceed 1-2 mm. CHECK THAT THERE ARE NO OBSTACLES that can block the cable gland. STARBOARD OTHER EQUIPMENT...
  • Page 23 5. PREPARATIONS SAND THE SURFACE where the interceptor will be mounted to improve the adhesion of the sealand. CLEAN THE SURFACE with a hull cleaner or a similar cleaning agent.
  • Page 24 5. PREPARATIONS USE THE DRILL TEMPLATE to correctly mark the positions of the holes. IF THE CABLE GLAND HOLE IS PLACED OUTSIDE THE INTERCEPTOR: • Mark the cable gland hole using the drill template. • Use the cable cover to make sure that the cable gland hole will be covered.
  • Page 25 5. PREPARATIONS IMPORTANT! Drill the following holes at a 90° angle from the transom. VERTICAL TRANSOM 90° ANGLED TRANSOM ≠ 90° ANGLED TRANSOM 90°...
  • Page 26 5. PREPARATIONS DRILL THE CABLE GLAND HOLE with a Ø 28mm hole saw. Ø28 mm DRILL THE OTHER HOLES with a 5 - 5.5 mm* drill. 5 mm * see step 6.1.4...
  • Page 27 5. PREPARATIONS USE A COUNTERSINK on the marked holes. IMPORTANT! Drill with care to ensure that the gel coat stays intact. N OT E! REPEAT THE STEPS IN “SECTION 5 - PREPARATIONS” ON THE OTHER SIDE OF THE BOAT TO PREPARE FOR MOUNTING THE SECOND INTERCEPTOR!
  • Page 28 6. MOUNT THE INTERCEPTOR 6. MOUNT THE INTERCEPTOR 6.1 MOUNT THE INTERCEPTOR BRACKET APPLY MARINE SEALANT to the interceptor bracket holes. APPLY MARINE SEALANT to the back of the interceptor bracket as shown in the following diagram:...
  • Page 29 6. MOUNT THE INTERCEPTOR INSERT THE SCREWS (6.3 mm) to fasten the interceptor bracket. TIGHTEN THE SCREWS to 10Nm using a torque wrench. 10N m N OT E ! Depending on the hardness/density of the fiber glass/laminate/transom material a bigger hole may be needed for the screw to enter correctly.
  • Page 30 6. MOUNT THE INTERCEPTOR 6.2 MOUNT THE INTERCEPTOR BRACKET (CHINE ONLY) APPLY MARINE SEALANT to the interceptor bracket holes. ATTACH THE CHINE ADD-ON to the interceptor: • For L300C interceptors, attach the chine add-on to the innermost slot of the interceptor bracket. •...
  • Page 31 6. MOUNT THE INTERCEPTOR APPLY MARINE SEALANT to the back of the interceptor bracket and chine add-on as shown in the following diagram: INSERT THE SCREWS (6.3 mm) to fasten the interceptor bracket.
  • Page 32 6. MOUNT THE INTERCEPTOR TIGHTEN THE SCREWS to 10Nm using a torque wrench. 10Nm...
  • Page 33 6. MOUNT THE INTERCEPTOR 6.3 MOUNT THE INTERCEPTOR MOVE THE CABLE GLAND along the cable, away from the interceptor. REMOVE THE NUT from the cable. NOTE ! Make sure the O-ring stays in place. O-Ring...
  • Page 34 6. MOUNT THE INTERCEPTOR APPLY MARINE SEALANT on the cable gland. NOTE! Only apply sealant on the instructed areas. INSERT THE CABLE GLAND into the 28 mm hole on the transom. NOTE! Make sure the O-ring stays in place.
  • Page 35 6. MOUNT THE INTERCEPTOR TIGHTEN THE CABLE GLAND NUT by doing the following: • Use a 34 mm wrench to tighen the nut to 10 Nm. • Use a 22 mm wrench to hold the cable gland still while tighening the nut. NOTE ! Make sure the O-ring stays in place.
  • Page 36 6. MOUNT THE INTERCEPTOR APPLY MARINE SEALANT in the grooves on the back of the interceptor. NOTE! Only apply sealant on the instructed areas. ATTACH THE INTERCEPTOR to the grooves on the back of the interceptor. NOTE! Pull the interceptor cable from the inside when attaching the interceptor.
  • Page 37 6. MOUNT THE INTERCEPTOR APPLY AN ANTI-CORROSIVE COMPOUND (Tef-Gel) on the M8 bolts. APPLY MARINE SEALANT to the back of the M8 bolt heads.
  • Page 38 6. MOUNT THE INTERCEPTOR INSERT THE M8 BOLTS after holding the interceptor in place. TIGHTEN THE M8 BOLTS to 10 Nm with a torque wrench.
  • Page 39 6. MOUNT THE INTERCEPTOR APPLY MARINE SEALANT inside the holes. INSERT THE 6.3 MM SCREWS.
  • Page 40 6. MOUNT THE INTERCEPTOR TIGHTEN THE SCREWS to 10 Nm with a torque wrench. 10N m...
  • Page 41 6. MOUNT THE INTERCEPTOR 6.4 ADJUST THE CABLE GLAND PULL THE CABLE TIGHTLY. INSIDE THE BOAT REMOVE THE GLAND NUT from the cable gland. INSIDE THE BOAT...
  • Page 42 6. MOUNT THE INTERCEPTOR PUSH THE RUBBER SEAL all the way into the cable gland. INSIDE THE BOAT TIGHTEN THE CABLE GLAND with a 20 mm wrench. INSIDE THE BOAT TIGHTEN...
  • Page 43 6. MOUNT THE INTERCEPTOR 6.5 MOUNT THE CABLE COVER (OPTIONAL) TIGHTEN THE CABLE to the interceptor from inside of the boat. MEASURE THE CABLE COVER and mark the position to cut it.
  • Page 44 6. MOUNT THE INTERCEPTOR CUT THE CABLE COVER. NOTE! Do not saw the Cable Cover all the way through: Leave a 5-10 mm allowance on the Cable Cover sides to secure the Cable Cover to the Interceptor, as shown in Step 4. ABOVE SIDE 5-10mm...
  • Page 45 6. MOUNT THE INTERCEPTOR PLACE THE CABLE COVER on top of the cable. INSERT SCREWS in the pre-drilled holes.
  • Page 46 6. MOUNT THE INTERCEPTOR DRILL HOLES along the sides of the Cable Cover, 100mm apart. The number of holes needed depends on the length of the Cable Cover. APPLY MARINE SEALANT inside the holes.
  • Page 47 6. MOUNT THE INTERCEPTOR INSERT SCREWS in the pre-drilled holes to fasten the cable cover. N OT E ! REPEAT THE STEPS IN “SECTION 6 - MOUNT THE INTERCEPTOR” ON THE OTHER SIDE OF THE BOAT TO PREPARE FOR MOUNTING THE SECOND INTERCEPTOR!
  • Page 48 Unit is placed in any of the alternative placement orientations, orientation setup is required. STARBOARD IMPORTANT! LCU Orientation Setup is required for the Lightning system to function correctly. See the Lightning Setup Manual for instructions on how to set up the system.
  • Page 49 7. MOUNT THE CONTROL UNIT 7.2 MOUNT THE CONTROL UNIT USE THE CONTROL UNIT DRILL TEMPLATE to correctly mark the positions of the holes. DRILL THE FOUR HOLES with a 3.5 mm power drill. “Section 5 Step 8” for drilling instructions.
  • Page 50 7. MOUNT THE CONTROL UNIT INSERT THE SCREWS (four 25 mm screws) by hand. IMPORTANT! Make sure that the Control Unit is securely fastened to the boat! CONNECT THE CABLES to the Control Unit. STARBOARD PORT CABLE TO THE INTERCEPTOR INTERCEPTOR CONTROL PANEL...
  • Page 51 LANDSCAPE NOTE! FOR LANDSCAPE PLACENT OF THE CONTROL PANEL: • Place the control panel with the HUMPHREE logo facing the steering wheel. • Landscape orientation requires a Control Panel display setup. See the Lightning Setup Manual for instructions more information.
  • Page 52 8. MOUNT THE CONTROL PANEL 8.2 INSTALLATION OPTIONS TOP MOUNT INSTALLATION (see Section 8.3) FLUSH MOUNT INSTALLATION (see Section 8.4)
  • Page 53 8. MOUNT THE CONTROL PANEL 8.3 TOP MOUNT THE CONTROL PANEL USE THE CONTROL PANEL DRILL TEMPLATE to correctly mark the positions of the holes. USE A HOLE SAW to make a 70 mm diameter hole.
  • Page 54 8. MOUNT THE CONTROL PANEL DRILL FOUR HOLES using a 2.5 mm power drill. USE A COUNTERSINK ON THE HOLES.
  • Page 55 8. MOUNT THE CONTROL PANEL ROUTE THE CABLES through the large hole. REMOVE THE FRAME from the Control Panel.
  • Page 56 8. MOUNT THE CONTROL PANEL REMOVE THE PLASTIC COVER from the foam seal. PLACE THE FOAM SEAL on the back of the Control Panel.
  • Page 57 8. MOUNT THE CONTROL PANEL CONNECT THE CABLES to the Control Panel according to the following diagram: CONTROL UNIT CONTROL UNIT (LCU) (LCU) KEY SWITCH / EXTBUS PLACE THE CONTROL PANEL in the hole.
  • Page 58 8. MOUNT THE CONTROL PANEL INSERT FOUR SCREWS (2.9 x13 mm) into the holes. PLACE THE FRAME on the Control Panel.
  • Page 59 8. MOUNT THE CONTROL PANEL 8.4 FLUSH MOUNT THE CONTROL PANEL USE THE CONTROL PANEL DRILL TEMPLATE to correctly mark the control panel hole. USE AN OSCILLATING MULTI TOOL to cut the hole.
  • Page 60 8. MOUNT THE CONTROL PANEL MARK THE DRILL HOLES on the underside of the surface: use the cut hole and the Control Pannel Drill Template as guides to correctly mark the holes. DRILL FOUR HOLES using a 2.5 mm power drill. NOTE! Do not drill all the way through the surface! Measure the thickness of the surface to which the Control Panel is be...
  • Page 61 8. MOUNT THE CONTROL PANEL REMOVE THE FRAME from the Control Panel. SEPARATE THE FRAME part of the foam seal.
  • Page 62 8. MOUNT THE CONTROL PANEL REMOVE THE PLASTIC COVER from the foam seal frame. PLACE THE FOAM SEAL on the around the edges of the control panel.
  • Page 63 8. MOUNT THE CONTROL PANEL PLACE THE CONTROL PANEL INTO THE HOLE from below: the display of the Control Panel should be flush against the surface. FASTEN THE CONTROL PANEL using four M3 threaded rods and four M3 screw nuts.
  • Page 64 EXTBUS K e y Swit ch I nstalla tion The key switch puts the Humphree system in standby mode when a key is switched off (typically engine ignition). 1. Connect the remote key switch cable to a relay. Closed relay = The system is turned on.
  • Page 65 9. WIRING DIAGRAM P o we r S upply Ca b le IMPORTANT! Mount the cables high enough to avoid areas where water or other liquids may be collected. When the system is turned off by remote key switch, the system enters standby mode. The standby mode consumes power so it is important to charge the batteries continuously to avoid draining the batteries.
  • Page 66 9. WIRING DIAGRAM 9. WIRING DIAGRAM VIEW OF THE INSIDE OF THE HULL PORT STARBOARD BACK BACK SECONDARY CONTROL PANEL (OPTIONAL) MAIN CONTROL PANEL...
  • Page 67 9. WIRING DIAGRAM COMPONENTS: 1. Interceptor s • IP CODE: IP68 2 . Li gh tnin g Cont rol U nit ( LCU ) • IP CODE: IP67 3. Li gh tnin g Cont rol Pa n el (LCP) • IP CODE: IP66 •...

This manual is also suitable for:

Lightning l300Lightning l450Lightning l300cLightning l450c

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