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Related Manuals for Harken Carbon
Summary of Contents for Harken Carbon
- Page 1 Carbon Jib Reefing & Furling Installation Manual Unit 2/2.5...
- Page 2 Installing carbon furling unit Assembling turnbuckle Foil height Commissioning 12-16 Tying 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. 2/2.5 Carbon Furler December 2001...
- Page 3 Lower Unit Assembly......H-27374EF " (6mm) Spectra ® ... . . HFG6907 Lacing Lines (3) May 2002 2/2.5 Carbon Furler...
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Page 4: Specifications
", (5mm) splint area, clear packaging tape, wood alignment stick and placemat-sized table covering. ■ Rigging, ATTACHmenT To LoWeR UniT Alignment Splints - Use 90° angle extrusion to make splints. If no turnbuckle is required, attach the rod marine eye directly Sides to be about " (19mm). Cut extrusion into 8" (203mm) to the integral toggle on the 2.5. lengths and remove burrs from cutting. If a turnbuckle is required, it must terminate in a marine eye that will fit directly to the integral toggle. Use a Navtec C560 turnbuckle or similar for rod with either a " (15.9mm) pin " (19mm) pin diameter. ■ HeAdSTAy LengTH Note: When cutting rod to length or making up new rod, make sure that you can take apart the rod terminal (usually the top eye) so that you are left with a threaded nosepiece. ■ ReTRoFiTS, FiTTing Rod If you plan to reuse the existing rod and turnbuckle: Make up the rod headstay or adjust the turnbuckle so the Harken toggle fits below the rod terminal eye. The pin-to-pin Lower end—If you are using a standard Navtec turnbuckle with integral toggle, the lower body must be replaced with a distance of the Harken toggle is 3 " (83mm). standard Navtec marine eye body. Check to make sure that Note: The 2.5 Carbon furler has an integral toggle. No this eye will mate with the Harken integral toggle. Two cross additional toggle is required below the furler. pin sizes are available. They are the same size as the clevis pin. See above. Upper end—You must take apart the marine eye so that you are left with a threaded nosepiece. Check to see if this is pos- sible. If necessary, contact Navtec or Riggarna for correct pro- cedure. You will slip carbon foils over this threaded nosepiece. If you cannot remove this fitting you will need to cut the rod. 2/2.5 Carbon Furler May 2002... -
Page 5: Preparation For Assembly
PREPARATION FOR ASSEMBLY Foil Cut Length Top Foil Cut Length Short Top Foil? Cutting Top Foil • • • ■ FoiL CUT LengTH The Carbon 2.5 furler has an integral toggle. No additional toggle is required below the unit. To check the foil length, lay foils alongside the stay before cutting top foil. Make sure that turnbuckle is set to desired length. ■ ToP FoiL CUT LengTH Instructions for worksheet below: 1 Fill in total pin-to-pin headstay length. 2 Fill in A length. 3 Adjust B length if necessary. Note: There must be enough space between top of carbon foils and bottom of rod terminal to allow for turnbuckle adjustment. As turnbuckle is adjusted, terminal is pulled down towards top of rod. If no turnbuckle is used, there only needs to be minimal space— " (12mm)–between the carbon foil and rod terminal. We have put 4" (100mm) as a starting point. This may need to be adjusted based upon how turnbuckle was set when headstay was measured. If there is less than 4" (100mm) “take-up”, less space can be left and vice versa. The space between foil trim cap and bottom of turnbuckle must be more than “take-up” on turnbuckle. 4 Add A, B, E and subtract from total pin-to-pin headstay length. SUM = _________ 5 Choose the number from foil multiplier below closest to, but not greater than, sum from step 4. Fill in D length. 6 X 72" = 432 6 X 1828.8mm = 10972.8 7 x 72" = 504 7 x 1828.8mm = 12801.6 8 x 72" = 576 8 x 1828.8mm = 14630.4... - Page 6 PREPARATION FOR ASSEMBLY Tape outside ends of all foils using blue masking tape. To make sure tape edge lines up with end of foil, extend the tape over foil end. Use a sharp razor knife to trim tape even with foil. Coat rod with mold release agent or wax to keep epoxy from adhering. Heat rod terminal and remove threaded screw and threaded nosepiece. If rod terminal has been upset (peened), follow Navtec or Riggarna procedures for removing peening. Tape threads of nosepiece and tape nosepiece so it will not slip down foil when pushing it back out. 2/2.5 Carbon Furler December 2001...
- Page 7 ASSEMBLY Assuming that installation is done from the top, slide bottom foil onto rod so end with holes is at bottom end of foil. Slide feeder over so, so rounded sail groove corners will be at the bottom end of foil. Slide full-length 72" (1.83m) foils onto the rod. Assemble connectors onto rod in preparation for glueing. Place one bushing half in socket on either side of connector, grooved side up. Bring connector up on rod and place other bushing half on rod and rotate bushing so seam is at top and bushing assembly stays in place. Place foil on bench with grooves facing up and supported on wood blocks. June 2002 2/2.5 Carbon Furler...
- Page 8 48-hours before moving. Warm Weather connector bond will fail. Surfaces must be dry. Adhesive Working Times: 75°F (24°C) - 1 hour 85°F (29°C) - 45 minutes Allow glued foils to cure undisturbed for 24-hours Remove plastic clip from Hysol ® adhesive pack. 1) Mix for five minutes in bag. 2) Pour entire contents into cup. 3) Squeegee remaining epoxy into cup. 4) Continue to thoroughly stir epoxy in cup. Use glue brush to coat the inside of the foil for one or two inches. Coat 1/2 of the outside of the connector with epoxy and slowly insert the connector into the foil. Work the con- nector in and out as you insert it to adhere the epoxy without dry spots on the inside of the foil. As excess epoxy comes off the connector, clean it up using the acid brush. Use excess to coat feeder area of connector. Clean up the end of the foil using paper towel wetted with acetone taking care that no epoxy is in the sail grooves. 2/2.5 Carbon Furler May 2002...
- Page 9 ASSEMBLY Lightly coat feeder area of connector and slip feeder into place. Use glue brush to coat inside of foil for one or two inches. Coat half the outside of connector with epoxy and slowly insert connector into foil. Work connector in and out as you insert to adhere epoxy without dry spots on inside of foil. As excess epoxy comes off connector, clean up using acid brush. Clean up end of foil using paper towel wetted with acetone, taking care that no epoxy is in sail grooves. Coat the remaining half of connector with epoxy and insert into foil as described above, cleaning up excess epoxy. Take special care to clean epoxy from sail grooves. May 2002 2/2.5 Carbon Furler...
- Page 10 ASSEMBLY Lay plastic against foil and place splint against foil. Tightly wrap clear packaging tape around splint near both ends. Insert wood alignment stick between foil and feeder and inspect to make sure that foil/feeder are aligned. Coat bottom foil reinforcement (torque tube connector) with epoxy and insert into foil as directed above. Insert plastic bushings in top connector as directed above. Coat outside of connector with epoxy as directed above and insert into top foil. Clean up excess epoxy. Slide halyard swivel onto foils. make sure swivel side is towards top of stay! Slide trim cap over threaded nosepiece. Heat cap in hot water to help it slide over nosepiece. Attach trim cap using Superglue ® Make sure foils are straight and grooves are facing up. Inspect lower unit to make sure that feeder and bottom foil are aligned correctly. Allow to cure undisturbed overnight. After curing overnight, remove splint. Use a small triangular file to clean excess epoxy while tape remains in place. Remove tape and use a razor knife to carefully remove any excess epoxy. Make sure halyard swivel passes all points. Install top rod eye using red Loctite on locking screw or ® with upset as per manufacturer's instructions. Remove eight socket-head cap-screws located on underside of lower unit and remove lower cap. Remove three set screws located at top of torque tube. 2/2.5 Carbon Furler December 2001...
- Page 11 ASSEMBLY Slide lower unit onto bottom foil. Assemble turnbuckle. Attach turnbuckle eye to toggle using cross pin with tapered ends. Secure Cross Pin using Circlip (Smalley Rings) supplied. Note: Make sure the end of the toggle with the long slot is towards the bottom. Long Slot Bring the lower unit down so that Cross Pin seats in the housing. Install cap using Blue Threadlocker on the ® eight screws. ■ FoiL HeigHT Check the clearance between the top of the foil and top terminal. TIP: Check clearance when the unit is on the ground, before raising the headstay into position. WARning: It is critical to have clearance between the top foil and the top rigging fitting when the stay adjuster is in the fully closed position. If the fittings touch, the unit will jam or in the case of a Sta-Lok fitting, the terminal may become unscrewed. This could cause catastrophic failure to the spar and a life threatening situation It is the responsibility of the rigger to check clearance. December 2001 2/2.5 Carbon Furler...
- Page 12 COMMISSIONING Tying Soft Attachment Lines You must lace line around the furler/halyard swivel three times when attaching the sail or halyard. Harken recommends us of a Hunter's Bend. This knot can be highly tensioned without slipping and like a bowline can be untied afterwards. There are other bends and knots that will also work. Lace line three times around the torque tube/halyard swivel to capture sail or halyard. After lacing line, tie ends on side opposite sail. 1 Form a loop in line that comes from left tunnel. Below this, form a second loop with line from the right tunnel. 2 Twist loop clockwise and arrange ends of line so they are below standing loops as shown. 2/2.5 Carbon Furler December 2001...
- Page 13 COMMISSIONING Tying Soft Attachment Lines 3 Take end that is now running down to right. Tuck it down under crossing lines and up through loop, towards you. 4 Pass other end up and over crossing lines and then down into loop, away from you. 5 At this point knot will not look anything like the finished bend. Set knot by gently pulling on bitter ends and then standing parts until it looks like Drawing 6. December 2001 2/2.5 Carbon Furler...
- Page 14 COMMISSIONING Tying Soft Attachment Lines 7 Finished bend drawn up and set. If your bend does not look like this untie and repeat the process. 9 If furler is installed under deck, lace tack pendant as pictured. Rigging a pendant directly from carbon tunnels will damage unit. 8 It is important to keep tack/luff as close to torque tube and as low as possible. A tack line that is too long will angle up too far and damage the carbon tunnels. When sail is bent on, check to make sure tack line is not pulling up against the carbon tunnels. 2/2.5 Carbon Furler December 2001...
- Page 15 COMMISSIONING Halyard Wraps Prevent Halyard Wraps • ■ HALyARd WRAPS The most serious problem with furling systems occurs when the jib halyard wraps around the headstay foil. Halyard wraps will prevent furling or unfurling and may cause serious dam- age to the unit and the halyard. In severe cases, halyard wraps may cause loss of the headstay. To prevent wraps, the halyard must exert a slight pull to the rear. This allows the foils to turn while the halyard remains stationary. ■ PRevenT HALyARd WRAPS WARNING: The sail must be fitted to foils before operation. 1 Halyard swivel should be within top 4" (100mm) of foil. 2 Halyard must pull slightly to rear (8 - 10°). 3 Halyard must be snug, but not too tight. 8 - 10° If a halyard wraps, do not force unit to turn. Attempt to open sail by alternately furling and unfurling sail slightly. If the sail can be unfurled, lower sail by releasing jib halyard. Severe halyard wraps can only be cleared by going aloft and freeing halyard. If the sail will not furl or unfurl, it may be possible to remove jib sheets and manually wrap/unwrap the sail around/from the headstay. Important: Testing at the dock does not indicate halyard angle is correct. In wave action, halyard may wrap if lead angle is not correct. The diverging 8-10° angle mentioned above is critical. December 2001 2/2.5 Carbon Furler...
- Page 16 You may install pendants at both head and tack of sail. ■ HALyARd ReSTRAineR To prevent wraps, the jib halyard must pull slightly to the rear. On some boats the halyard sheaves are located too close to the headstay and a halyard restrainer must be used. Use halyard restrainers only when required by the masthead geometry. Restrainers tend to limit sail luff length and may cause problems if not properly installed. Mount the restrainer as high as possible on the face of the mast. Position the restrainer so the foils will not hit it when 8 - 10° under load. The restrainer should deflect the halyard 8 - 10°. If the angle is more than 10°, you may experience difficulty in tensioning the sail luff, friction in furling and possible damage to the foils. To decrease deflection angles, shorten the luff of the sail. TIP: Boats used in charter service should consider using a halyard restrainer, regardless of masthead geometry. 2/2.5 Carbon Furler December 2001...
- Page 17 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. December 2001 2/2.5 Carbon Furler...
- Page 18 Email: polska@harken.com Harken Sweden Mjölkekilsgatan 6, Box 64 S-440 30 Marstrand, Sweden Telephone: (46) 303-618 75 Fax: (46) 303-618 76 • Web: www.harken.se Email: harken@harken.se Harken Adriatik d.o.o. Obala 107 6320 Portoroz, Slovenia Telephone/Fax: 5-6774122 Web: www.harken.si Email: info@harken.si Harken Australia, Pty, Ltd. 1B Green Street Brookvale, N.S.W. 2100, Australia Telephone: (61) 2-8978-8666 Fax: (61) 2-8978-8667 • Web: www.harken.com.au Email: info.harken.com.au Harken New Zealand, Ltd. 30-36 Fanshawe Street Auckland 1001, New Zealand Telephone: (64) 9-303-3744 Fax: (64) 9-307-7987 • Web: www.harken.co.nz Email: harken@harken.co.nz Please visit: http://www.harken.com/dealers/dealers.php...
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