ZJ 80

Flexible placement
- Mount at bow / midship / stern; centered or offset; upright or inverted — same roll-reduction (subject to on-site space & foundation strength).
- Prioritize rigid zones (e.g., spanning two longitudinals; areas bounded by frames/bulkheads fore & aft) to diffuse alternating torque into the hull.

Compact space requirement
- Small hatch: ZJ2/ZJ4 from 610 × 780 mm (split-lift supported; larger models per spec).
- Clearances: sides 100–400 mm (service); underside 200–500 mm net.
- Ventilation: ambient ≤ 45 °C → natural; otherwise add a small fan (~300 m³/h).
- Rigidly fasten the unit; only minimal free space is required around the base.

Short installation time
- Typical 1–2 days end-to-end; no special tools; supports remote guidance.
- Fits newbuilds and refits; split-lift lowers retrofit cost and enhances vessel value.

Foundation & fastening
- Base flatness ≤ 0.5–1.5 mm.
- High-strength bolts with Loctite 243; torque 80–1,000 Nm (model-dependent).
- FRP hulls: embedded steel plates + glass-fiber reinforcement.
- Steel/Aluminum hulls: welded base frame.
- Commodity materials; no specialized welding crew required.

Cooling, power & lines
- Raw-water (outer loop): external seawater pump (recommend SEAFLO 24 V, 5–17 L/min, cost-effective).
- Closed loop (inner): automotive antifreeze, −25 °C grade.
- Power: dedicated breaker (from 16 A); shielded cable to touchscreen.
- Filtration: seawater strainer 20–100 mesh, easy to service.

Standard 6-step installation
1) Verify foundation: hole pattern & flatness; parallel to vessel centerline.
2) Lift & place: set vibration pads; use flywheel inner eyebolts; align; tighten.
3) Outer cooling: connect strainer → pump → cooler (bottom-in / top-out); leak check.
4) Electrical: route power/ground; confirm DC bus 310–560 V.
5) Inner coolant: fill to ≥ 90%; vent air; confirm no leaks.
6) Final checks: fasteners, cable routing, clearances; remove debris; remove lifting eyes.

Quick effect & low power
- Intuitive touchscreen; one-button start/stop with live parameters.
- Noticeable roll reduction in ~15–30 min after start.
- Optimized for Sea State 3 (higher levels configurable).
- Low running power; a minor share of onboard energy use.

Start-up (5–10 min prep)
1) Routine check (monthly / pre-start): cables/grounding; hoses/strainer; bolts/foundation; antifreeze ≥ 80% (quick visual).
2) Power on: close breaker; HMI self-check ~10 s; acknowledge non-critical alerts.
3) Start: press Start/Stop → status Starting; at ≥ 50% speed → Stabilizing.
4) Monitor: bus voltage, temperatures, current — automatic control within normal ranges.
5) Smart Modes:
    - Speed Mode — Effect-first response for maximum roll reduction.
    - Smart Mode — Energy-saving auto-tuning to sea state and load.

Shutdown
- Normal: press Start/Stop → Stopping; flywheel coasts down ~90–120 min.
- Emergency: power-off is non-destructive; advisable when speed ≤ 50%.

Ease-of-use highlights
- No special skills required; friendly HMI.
- Low operating cost; rapid response to sea state; boosts comfort and reduces seasickness/incident risk.

Routine checks (monthly / pre-start, 5–10 min)
- Cables/grounding & hoses/strainer: no leaks/clogs.
- Bolts/foundation: no looseness/rust; drag chain/hoses intact.
- Antifreeze ≥ 80% (top up with automotive coolant).

Minor maintenance schedule

Item	Interval	Notes
Antifreeze top-up	Monthly	Maintain ~90%; if < 60%, locate/repair leaks (user-serviceable).
Anode (zinc)	Every 6 months	Replace rod below inlet tee (simple tools; low-cost spare).
Water-cooling assembly	Every 12 months	Includes valve/anode; refill & recheck (standardized parts).
Flywheel vacuum + helium (models ≤ ZJ20)	Every 12 months	Vacuum-charge-seal under remote guidance.
Grease service (models > ZJ20)	Every 100–500 h	Bearings/geartrain with specified grease (e.g., SKF LGHP 2).
Gearbox grease replacement (all models)	Every 2000 h	MOLYWHITE RE No.00; add if noise increases.

Major service (condition-based, ~2000 h / 24 months)
- Replace aged hoses/cables/bearings if symptoms (abnormal noise/high vibration).
- Check cooler for perforation (air/water test); flush with fresh water to mitigate corrosion.