carbon unit 2/2 · 2 2/2.5 carbon furler december 2001 table of contents parts 3 pictures and list...

Carbon Jib Reefing & Furling

Installation Manual

Unit 2/2.5

2 2/2.5CarbonFurler December2001

TABLEOFCONTENTS

Parts 3Pictures and list of all parts

Specifications 4Rod sizes

Clevis pin sizes

Luff tape sizes

Rigging, attachment to lower unit

Retrofits, fitting rod

Tools required

Supplies for gluing foils

Alignment splints

Headstay length

PreparationforAssembly 5-6Foil cut length

Top foil cut length

If you have a short top foil

Cutting top foil

Assembly 7-11Sliding foils onto rod

Attaching feeder

Joining foils using connectors

Preparing foil for gluing

Gluing foils using Hysol® adhesive

Gluing feeder

Aligning joined foils

Sliding halyard swivel onto foils

Capping foils with trim cap

Removing splint

Installing Navtec® eye

Installing carbon furling unit

Assembling turnbuckle

Foil height

Commissioning 12-16Tying soft attachment lines

Halyard wraps

Prevent halyard wraps

Pendants

Halyard restrainer

Halyard tension

Warranty

Warranty of Harken Carbon parts is one year from the time of purchase.

May2002 2/2.5CarbonFurler 3

PARTS

Crosspin*

Cotterpin

Toggle

Clevispin

SmalleyRing

Prefeeder

*Crosspinincludes(2)H2912Abushings.

(36)Connectorbushings

TrimCap

Feeder

LowerUnitAssembly

1Prefeeder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 947Toggle. . . . . . . . . . . . . . . . . . . . . . 5/8"(15.9mm).... H-29364CToggle. . . . . . . . . . . . . . . . . . . . . . 3/4"(19mm). . . . . . H-27385CCrossPin. . . . . . . . . . . . . . . . . . . . 5/8"(15.9mm).... H-29388ACrossPin. . . . . . . . . . . . . . . . . . . . 3/4"(19mm). . . . . . H-27407ACotterPin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . HFG344SmalleyRings . . . . . . . . . . . . . . . . 5/8"(15.9mm).... HCP1352SmalleyRings . . . . . . . . . . . . . . . . 3/4"(19mm). . . . . . HCP1062ClevisPin . . . . . . . . . . . . . . . . . . . 5/8"(15.9mm).... H-29385AClevisPin . . . . . . . . . . . . . . . . . . . 3/4"(19mm). . . . . . H-29386A2Bottom(Feeder)Connector. . . . . . . . . . . . . . . . . . . . . H-27448BFRegularConnectors . . . . . . . . . . . . . . . . . . . . . . . . . . . 1096FTopBushing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H-27508BFTorqueTubeBushing. . . . . . . . . . . . . . . . . . . . . . . . . . H-27902BF3ConnectorBushings(36) . . . . . . . . . . . . . . . . . . . . . . H-27495ATrimCap. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H-27904BFeeder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H-29238B4HalyardSwivel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H-29662C5LowerUnitAssembly. . . . . . . . . . . . . . . . . . . . . . . . . . H-27374EFLacingLines(3)1/4"(6mm)Spectra®. . . . . . . . . . . . . HFG6907

Bottom(Feeder)

Connector

RegularConnectors

TorqueTubeConnector

TopBushing

1 2

3 45Halyard

Swivel

4 2/2.5CarbonFurler May2002

SPECIFICATIONS

■RodSizeS-12,-17,-22(7.14mm,8.38mm,9.53mm)

■CLeviSPinSizeS5/8",3/4"(15.9mm,19.1mm)

■LUFFTAPeSize#6,6/32",(5mm)

■Rigging,ATTACHmenTToLoWeRUniTIfnoturnbuckleisrequired,attachtherodmarineeyedirectlytotheintegraltoggleonthe2.5.Ifaturnbuckleisrequired,itmustterminateinamarineeyethatwillfitdirectlytotheintegraltoggle.UseaNavtecC560turnbuckleorsimilarforrodwitheithera5/8"(15.9mm)pinor3/4"(19mm)pindiameter.

■ReTRoFiTS,FiTTingRodIfyouplantoreusetheexistingrodandturnbuckle:Lowerend—IfyouareusingastandardNavtecturnbucklewithintegraltoggle,thelowerbodymustbereplacedwithastandardNavtecmarineeyebody.ChecktomakesurethatthiseyewillmatewiththeHarkenintegraltoggle.Twocrosspinsizesareavailable.Theyarethesamesizeastheclevispin.Seeabove.Upperend—Youmusttakeapartthemarineeyesothatyouareleftwithathreadednosepiece.Checktoseeifthisispos-sible.Ifnecessary,contactNavtecorRiggarnaforcorrectpro-cedure.Youwillslipcarbonfoilsoverthisthreadednosepiece.Ifyoucannotremovethisfittingyouwillneedtocuttherod.

■TooLSReqUiRedSharpHacksaw,Sandpaper,SmallTriangularFile,HeatGun,RazorKnives,Sandpaper.

■SUPPLieSReqUiRedFoRgLUingFoiLSRiggingtape,bluemaskingtape,9430HysolEpoxy(supplied),Scissors,mixingcup,mixingstick,gluebrushes,acetone,papertowelscutintoquarters,plastictocoversplintarea,clearpackagingtape,woodalignmentstickandplacemat-sizedtablecovering.AlignmentSplints-Use90°angleextrusiontomakesplints.Sidestobeabout3/4"(19mm).Cutextrusioninto8"(203mm)lengthsandremoveburrsfromcutting.

■HeAdSTAyLengTHNote:Whencuttingrodtolengthormakingupnewrod,makesurethatyoucantakeaparttherodterminal(usuallythetopeye)sothatyouareleftwithathreadednosepiece.MakeuptherodheadstayoradjusttheturnbucklesotheHarkentogglefitsbelowtherodterminaleye.Thepin-to-pindistanceoftheHarkentoggleis31/4"(83mm).Note:The2.5Carbonfurlerhasanintegraltoggle.Noadditionaltoggleisrequiredbelowthefurler.

June2002 2/2.5CarbonFurler 5

PREPARATION FOR ASSEMBLY FoilCutLength • TopFoilCutLength • ShortTopFoil? • CuttingTopFoil

dimensions inches mm

ACenterofPINtobottomofterminal ______________

BBottomofterminaltotopoffoil 4 102

CTopfoil ______________ Foilsbelow8"(203mm)seenextpage

d_____x72"(1828.8mm)foils ______________

eTopoffeedertocenterofclevispin 523/4 1340

Totalpin-to-pinheadstaylength ______________

WoRKSHeeT:deTeRmineToPFoiLLengTH

C

A

D

E

■FoiLCUTLengTHTheCarbon2.5furlerhasanintegraltoggle.Noadditionaltoggleisrequiredbelowtheunit.Tocheckthefoillength,layfoilsalongsidethestaybeforecuttingtopfoil.Makesurethatturnbuckleissettodesiredlength.

■ToPFoiLCUTLengTHInstructionsforworksheetbelow:1 Fillintotalpin-to-pinheadstaylength.2 FillinAlength.3 AdjustBlengthifnecessary.Note:Theremustbeenoughspacebetweentopofcarbonfoilsandbottomofrodterminaltoallowforturnbuckleadjustment.Asturnbuckleisadjusted,terminalispulleddowntowardstopofrod.Ifnoturnbuckleisused,thereonlyneedstobeminimalspace—1/2"(12mm)–betweenthecarbonfoilandrodterminal.Wehaveput4"(100mm)asastartingpoint.Thismayneedtobeadjustedbaseduponhowturnbucklewassetwhenheadstaywasmeasured.Ifthereislessthan4"(100mm)“take-up”,lessspacecanbeleftandviceversa.Thespacebetweenfoiltrimcapandbottomofturnbucklemustbemorethan“take-up”onturnbuckle.4 AddA,B,Eandsubtractfromtotalpin-to-pinheadstaylength.SUM=_________5 Choosethenumberfromfoilmultiplierbelowclosestto,butnotgreaterthan, sumfromstep4.FillinDlength.

6X72"=432 6X1828.8mm=10972.8 7x72"=504 7x1828.8mm=12801.6 8x72"=576 8x1828.8mm=14630.4 9x72"=648 9x1828.8mm=16459.210x72"=720 10x1828.8mm=18288.011x72"=792 11x1828.8mm=20116.8

5 AddA,B,D,E.Subtractfrompin-to-pinlengthforC(topfoillength).

iFyoUHAveSHoRTToPFoiLIftopfoilislessthan8"(203mm)donotusearecessedtopconnector.Thetopfoilmustbeatleast4"(101mm).Ifitisless,shortentheupper72"(1.83m)foiltomaketheupperfoil4"(101mm).CUTTingToPFoiLOnceyouhavecheckedthetopfoillengthbylayingfoilsalongsidetherod,useasharphacksawtocuttopfoil.Tapefoilandcutalongtape.Sandbottomendofthefoilsoitissquareandtoremoveanycarbonburrs.Lightlysandinsideoffoilwhereitwillbebondedwith220grittoremoveanygreaseormoldreleaseagent.


PREPARATION FOR ASSEMBLY

Tapeoutsideendsofallfoilsusingbluemaskingtape.Tomakesuretapeedgelinesupwithendoffoil,extendthetapeoverfoilend.Useasharprazorknifetotrimtapeevenwithfoil.

Heatrodterminalandremovethreadedscrewandthreadednosepiece.Ifrodterminalhasbeenupset(peened),followNavtecorRiggarnaproceduresforremovingpeening.

Coatrodwithmoldreleaseagentorwaxtokeepepoxyfromadhering.

Tapethreadsofnosepieceandtapenosepiecesoitwillnotslipdownfoilwhenpushingitbackout.

June2002 2/2.5CarbonFurler 7

ASSEMBLY

Assumingthatinstallationisdonefromthetop,slidebottomfoilontorodsoendwithholesisatbottomendoffoil.

Slidefeederoverso,soroundedsailgroovecornerswillbeatthebottomendoffoil.Slidefull-length72"(1.83m)foilsontotherod.

Assembleconnectorsontorodinpreparationforglueing.Placeonebushinghalfinsocketoneithersideofconnector,groovedsideup.Bringconnectoruponrodandplaceotherbushinghalfonrodandrotatebushingsoseamisattopandbushingassemblystaysinplace.

Placefoilonbenchwithgroovesfacingupandsupportedonwoodblocks.

ASSEMBLY

RemoveplasticclipfromHysol®adhesivepack.1)Mixforfiveminutesinbag.2)Pourentirecontentsintocup.3)Squeegeeremainingepoxyintocup.4)Continuetothoroughlystirepoxyincup.

Usegluebrushtocoattheinsideofthefoilforoneortwoinches.Coat1/2oftheoutsideoftheconnectorwithepoxyandslowlyinserttheconnectorintothefoil.Workthecon-nectorinandoutasyouinsertittoadheretheepoxywithoutdryspotsontheinsideofthefoil.Asexcessepoxycomesofftheconnector,cleanitupusingtheacidbrush.Useexcesstocoatfeederareaofconnector.Cleanuptheendofthefoilusingpapertowelwettedwithacetonetakingcarethatnoepoxyisinthesailgrooves.

8 2/2.5CarbonFurler May2002

Adhesive Alert

Youmustfollowfour-stepmixinginstructionsshown

belowexactlyorthefoilconnectorbondwillfail.

Surfaces must be dry.

Temperatureshouldbehigherthan60°F(15°C).Ifyouglueatalowertemperature:

50°F(10°C)minimumgentlywarmjointswithahairdryertonomorethan:

100°F(38°C),atemperatureatwhichyoucanstillholdthefoilcomfortablyinyourhand.

If glued in temperature less than 60°F (15°C, allow glued foils to cure undisturbed for 48-hours before moving.

AdhesiveWorkingTimes:75°F(24°C)-1hour

85°F(29°C)-45minutesAllow glued foils to cure undisturbed for 24-hours

CoolWeather

WarmWeather

May2002 2/2.5CarbonFurler 9

ASSEMBLY

Lightlycoatfeederareaofconnectorandslipfeederintoplace.

Usegluebrushtocoatinsideoffoilforoneortwoinches.Coathalftheoutsideofconnectorwithepoxyandslowlyinsertconnectorintofoil.Workconnectorinandoutasyouinserttoadhereepoxywithoutdryspotsoninsideoffoil.Asexcessepoxycomesoffconnector,cleanupusingacidbrush.

Cleanupendoffoilusingpapertowelwettedwithacetone,takingcarethatnoepoxyisinsailgrooves.Coattheremaininghalfofconnectorwithepoxyandinsertintofoilasdescribedabove,cleaningupexcessepoxy.Takespecialcaretocleanepoxyfromsailgrooves.


ASSEMBLY

Layplasticagainstfoilandplacesplintagainstfoil.Tightlywrapclearpackagingtapearoundsplintnearbothends.Insertwoodalignmentstickbetweenfoilandfeederandinspecttomakesurethatfoil/feederarealigned.

Coatbottomfoilreinforcement(torquetubeconnector)withepoxyandinsertintofoilasdirectedabove.Insertplasticbushingsintopconnectorasdirectedabove.Coatoutsideofconnectorwithepoxyasdirectedaboveandinsertintotopfoil.Cleanupexcessepoxy.Slidehalyardswivelontofoils.makesureswivelsideistowardstopofstay!Slidetrimcapoverthreadednosepiece.Heatcapinhotwatertohelpitslideovernosepiece.AttachtrimcapusingSuperglue®.Makesurefoilsarestraightandgroovesarefacingup.Inspectlowerunittomakesurethatfeederandbottomfoilarealignedcorrectly.Allowtocureundisturbedovernight.

Aftercuringovernight,removesplint.Useasmalltriangularfiletocleanexcessepoxywhiletaperemainsinplace.Removetapeandusearazorknifetocarefullyremoveanyexcessepoxy.Makesurehalyardswivelpassesallpoints.

InstalltoprodeyeusingredLoctite®onlockingscreworwithupsetaspermanufacturer'sinstructions.Removeeightsocket-headcap-screwslocatedonundersideoflowerunitandremovelowercap.Removethreesetscrewslocatedattopoftorquetube.

ASSEMBLY

December2001 2/2.5CarbonFurler 11

Slidelowerunitontobottomfoil.

Assembleturnbuckle.Attachturnbuckleeyetotoggleusingcrosspinwithtaperedends.SecureCrossPinusingCirclip(SmalleyRings)supplied.Note:Makesuretheendofthetogglewiththelongslotistowardsthebottom.

BringthelowerunitdownsothatCrossPinseatsinthehousing.InstallcapusingBlueThreadlocker®ontheeightscrews.

LongSlot

■FoiLHeigHTChecktheclearancebetweenthetopofthefoilandtopterminal.

WARning:Itiscriticaltohaveclearancebetweenthetopfoilandthetopriggingfittingwhenthestayadjusterisinthefullyclosedposition.Ifthefittingstouch,theunitwilljamorinthecaseofaSta-Lokfitting,theterminalmaybecomeunscrewed.ThiscouldcausecatastrophicfailuretothesparandalifethreateningsituationItistheresponsibilityoftheriggertocheckclearance.

TIP: Check clearance when the unit is on the ground, before raising the headstay into position.


COMMISSIONING TyingSoftAttachmentLines

Youmustlacelinearoundthefurler/halyardswivelthreetimeswhenattachingthesailorhalyard.HarkenrecommendsusofaHunter'sBend.Thisknotcanbehighlytensionedwithoutslippingandlikeabowlinecanbeuntiedafterwards.Thereareotherbendsandknotsthatwillalsowork.Lacelinethreetimesaroundthetorquetube/halyardswiveltocapturesailorhalyard.Afterlacingline,tieendsonsideoppositesail.

1 Formaloopinlinethatcomesfromlefttunnel.Belowthis,formasecondloopwithlinefromtherighttunnel.

2 Twistloopclockwiseandarrangeendsoflinesotheyarebelowstandingloopsasshown.



4 Passotherendupandovercrossinglinesandthendownintoloop,awayfromyou.

5 Atthispointknotwillnotlookanythinglikethefinishedbend.SetknotbygentlypullingonbitterendsandthenstandingpartsuntilitlookslikeDrawing6.

3 Takeendthatisnowrunningdowntoright.Tuckitdownundercrossinglinesandupthroughloop,towardsyou.



7 Finishedbenddrawnupandset.Ifyourbenddoesnotlooklikethisuntieandrepeattheprocess.

8 Itisimportanttokeeptack/luffasclosetotorquetubeandaslowaspossible.Atacklinethatistoolongwillangleuptoofaranddamagethecarbontunnels.Whensailisbenton,checktomakesuretacklineisnotpullingupagainstthecarbontunnels.

6

9 Iffurlerisinstalledunderdeck,lacetackpendantaspictured.Riggingapendantdirectlyfromcarbontunnelswilldamageunit.

COMMISSIONING HalyardWraps • PreventHalyardWraps


■HALyARdWRAPSThemostseriousproblemwithfurlingsystemsoccurswhenthejibhalyardwrapsaroundtheheadstayfoil.Halyardwrapswillpreventfurlingorunfurlingandmaycauseseriousdam-agetotheunitandthehalyard.Inseverecases,halyardwrapsmaycauselossoftheheadstay.Topreventwraps,thehalyardmustexertaslightpulltotherear.Thisallowsthefoilstoturnwhilethehalyardremainsstationary.

■PRevenTHALyARdWRAPSWARNING:Thesailmustbefittedtofoilsbeforeoperation.1 Halyardswivelshouldbewithintop4"(100mm)offoil.2 Halyardmustpullslightlytorear(8-10°).3 Halyardmustbesnug,butnottootight.Ifahalyardwraps,donotforceunittoturn.Attempttoopensailbyalternatelyfurlingandunfurlingsailslightly.Ifthesailcanbeunfurled,lowersailbyreleasingjibhalyard.Severehalyardwrapscanonlybeclearedbygoingaloftandfreeinghalyard.Ifthesailwillnotfurlorunfurl,itmaybepossibletoremovejibsheetsandmanuallywrap/unwrapthesailaround/fromtheheadstay.Important:Testingatthedockdoesnotindicatehalyardangleiscorrect.Inwaveaction,halyardmaywrapifleadangleisnotcorrect.Thediverging8-10°anglementionedaboveiscritical.

8-10°

COMMISSIONING Pendants • HalyardRestrainer


■PendAnTSIfyoursailisnotlongenoughtopositionhalyardswivelproperly,youmustaddapendanttosail.Pendantsshouldbeplastic-coatedwirepermanentlyattachedtotheheadofsailsoheightwillbecorrect.Adjustablelengthpendantsarenotacceptableastheymightnotbeadjustedcorrectlyduringasailchange.■INSTALLAPENDANT1 Raisesail,butdonotattachtackshackle.2 Positionhalyardswivelcorrectlyneartopofheadstay andsecurehalyard.3 Secureapieceofropetosailtack.Leadlinethrough tackshackleonfurlingdrumandtensionsail.4 Measuredistancefromtackshackletosailtackand haveapendantofthislengthpermanentlyattachedto headofsail.5 Repeatthisprocedureforeveryjib.

TIP: Pendants are used at head of sail. Short pendants may be added at tack to improve visibility under genoa, but remember that visibility is already improved by shackling to tack swivel. Tack pendants increase heeling moment by raising sailplan. You may install pendants at both head and tack of sail.

■HALyARdReSTRAineRTopreventwraps,thejibhalyardmustpullslightlytotherear.Onsomeboatsthehalyardsheavesarelocatedtooclosetotheheadstayandahalyardrestrainermustbeused.Usehalyardrestrainersonlywhenrequiredbythemastheadgeometry.Restrainerstendtolimitsaillufflengthandmaycauseproblemsifnotproperlyinstalled.Mounttherestrainerashighaspossibleonthefaceofthemast.Positiontherestrainersothefoilswillnothititwhenunderload.Therestrainershoulddeflectthehalyard8-10°.Iftheangleismorethan10°,youmayexperiencedifficultyintensioningthesailluff,frictioninfurlingandpossibledamagetothefoils.Todecreasedeflectionangles,shortentheluffofthesail.

TIP: Boats used in charter service should consider using a halyard restrainer, regardless of masthead geometry.

8-10°

COMMISSIONING HalyardTension


■HALyARdTenSionThejibhalyardshouldbefirm,butnottootight.

TIP: The luff foil system supports the sail along its entire length so halyard tension is required only to shape sails, not to support them. Use only enough halyard tension to remove some wrinkles along the luff. Do not tension the halyard enough to cause vertical wrinkles in the luff. Use halyard tension to adjust draft position of the sail to suit sailing conditions. Your halyard should be firm but not tight. If in doubt, release halyard tension. To protect the sail, ease the halyard when the boat is not in use.

Corporate Headquarters1251EastWisconsinAvenue,Pewaukee,Wisconsin53072USA

Telephone:(262)691-3320•Fax:(262)691-3008•Cable:HarkenPewaukeeWeb:www.harken.com•OnlineCatalog:www.harkenstore.com

Email:[email protected] France

ZA.PortdesMinimes,BP3064,17032-LaRochelleCedex1,FranceTelephone:(33)05.46.44.51.20•Fax:(33)05.46.44.25.70

Web:www.harken.frEmail:[email protected]

Harken Italy S.P.A.ViaMarcoBiagi,14,22070LimidoComasco,(CO),ItalyTelephone:(39)031.3523511•Fax:(39)031.3520031

Web:www.harken.itEmail:[email protected]

Harken UK Ltd.BearingHouse,AmpressLane

Lymington,HampshireS0418LW,EnglandTelephone:(44)01590-689122•Fax:(44)01590-610274

Web:www.harken.co.ukEmail:[email protected]

Harken Polandul.LisaKuli4Lok.1,01-512Warszawa,Polska

Telephone:+48607979747Web:www.harken.com

Email:[email protected] Sweden

Mjölkekilsgatan6,Box64S-44030Marstrand,Sweden

Telephone:(46)303-61875•Fax:(46)303-61876Web:www.harken.se

Email:[email protected] Adriatik d.o.o.

Obala1076320Portoroz,Slovenia

Telephone/Fax:5-6774122Web:www.harken.siEmail:[email protected]

Harken Australia, Pty, Ltd.1BGreenStreet

Brookvale,N.S.W.2100,AustraliaTelephone:(61)2-8978-8666•Fax:(61)2-8978-8667

Web:www.harken.com.auEmail:info.harken.com.auHarken New Zealand, Ltd.

30-36FanshaweStreetAuckland1001,NewZealand

Telephone:(64)9-303-3744•Fax:(64)9-307-7987Web:www.harken.co.nz

Email:[email protected]

Pleasevisit:http://www.harken.com/dealers/dealers.phpforanup-to-datelistofHarkendealersanddistributors

4362/9-08

carbon unit 2/2 · 2 2/2.5 carbon furler december 2001 table of contents parts 3 pictures and list...

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