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Selden FURLEX 500TDH Manual

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597-599-E
2024-04-04
500TDH
500TDH
Manual
1

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Summary of Contents for Selden FURLEX 500TDH

  • Page 1 597-599-E 2024-04-04 500TDH 500TDH Manual...

  • Page 2: Table Of Contents

    Contents Page Page 1 Introduction 5 Rigging 1.1 Key features 5.1 Fitting the Furlex to a stepped mast 1.2 What’s included? 5.2 Fitting the Furlex to an un-stepped 1.3 Main dimensions mast 23 1.4 Safety precautions 5.3 Routing the furling line 1.5 Sail measurements 5.4 Fitting the stanchion blocks 2 Assembly preparations 6 The Sail 2.1. Tools needed 6.1 Adapting the sail to the Furlex system 2.2 Mast attachment 6.2 Adjusting the forestay length 2.3 Hull attachment 6.3 Check list 2.4 Location of the through-deck hole 6.4 Hoisting the sail 2.5 Calculating the length of the forestay 6.5 Unfurling the sail wire 6.6 Furling the sail 2.6 Calculating the length of the luff 6.7 Reefing the sail extrusion 6.7 Furlex for racing 3 Fitting the lower bearing assembly...

  • Page 3: Introduction

    Fore stay options and termination. Furlex 500TDH uses a short adjuster with a 100mm stroke. The adjuster is designed for Seldén rod seats in dimensions -40/-48 and -60. The adjuster is integrated in the torque tube and does not affect the tack height of the sail.

  • Page 4: Main Dimensions

    1.3 Main dimensions All dimensions are given in millimeters. Fig. 1.3.a ALLOW 100mm EMERGENCY LINEDRIVER Furlex model Furlex 500TDH 430-560 ø28.6 (1 1/8”)

  • Page 5: Safety Precautions

    1.4 Safety precautions The information in this manual must be followed carefully Fig. 1.4.a to avoid damage to the system and to aviod the risk of personal injury. The warranty is only valid if the system is assembled and operated according to this manual. 10-15°...

  • Page 6: Sail Measurements

    1.5 Sail measurements Your sailmaker has all the necessary information through the Seldén Sailmakers Guide. The Sailmakers Guide can be downloaded from www.seldenmast.com Note that if you want to use an existing sail, it will need some modifications. • The luff length needs to be adjusted. •...

  • Page 7: Assembly Preparations

    2 Assembly preparations 2.1. Tools No special tools are needed for the assembly. Examples of tools needed: • Socket set. • Set of spanners (or adjustable). • Set of Hex(Allen) keys • Set of Torx keys. • Knife • File •...

  • Page 8: Hull Attachment

    2.3 Hull attachment The lower bearing assembly of the Furlex TD system is to be considered as an extension of the forestay fitting inside the hull. As it is locked horizontally at deck level, there is a toggle fitted between the lower bearing assembly and the forestay/luff section. This toggle, together with the universal joint function of the torque tube, will create the required articulation.

  • Page 9: Location Of The Through-Deck Hole

    2.4 Location of the through-deck hole The bearing of the through-deck fitting has a spherical surface which compensates for smal- Fig. 2.4.a ler angle discrepancies between forestay and through-deck fitting. However, it is important to minimize the discrepancies to achieve maximum furling performance.

  • Page 10: Calculating The Length Of The Forestay

    2.5 Calculating the length of the forestay If a Sta-lok terminal (with or without rigging screw) is included, the wire is supplied over-length. The wire has a swaged eye terminal on one end while the other end is open (= without terminal). If your Furlex is supplied with a rod forestay (supplied by the rod manufacturer complete with joining sleeves and end terminals) -go directly to chapt.

  • Page 11: Wire

    2.6 Calculating the length of the luff extrusion The Furlex luff extrusion consists of a number of shorter sections. Starting from the bottom there is a 580 mm luff extrusion connected to the lower. This extrusion has a sail inlet at the upper end. Then, from the sail feeder and up there are a number of full length luff extrusions (L=4800 mm) and finally there is a 2000 mm top extrusion that has to be cut to length to suite the actual forestay length.
  • Page 12 WL=27395 Finished rod forestay. Note that the quantity of short joining sleeves is equal to the number of 4800mm extrusions. Lower bearing and rod seat at lower end. Fig. 2.6.a...
  • Page 13 3 Assembly of the Furlex system 3.1 Making deck hole and fitting of through-deck fitting The best way to decide the location of the through-deck fitting is to step the mast with a forestay, which passes through a smaller hole in the deck. 1.
  • Page 14 8. Fit the through deck fitting. The markings (A), fore and aft of the fitting, will help to center the fitting in the longitudinal direction. The deck fitting has a compartment for sealing compound which can be used if required. Check that the through deck fitting rests against the aft edge of the hole when the the screws are tightened.
  • Page 15 7. Pull the tack ring shackle upwards ensuring there is is a gap to the deck fitting and that tack ring turns freely. Note that adjustments can still bemade by turning the toggle but the whole drive unit will turn provided there is enough space. Otherwise-remove the screws and turn the toggle (C) acc.
  • Page 16 4 Assembly Prior to the assembly of the luff extrusion, the top extrusion and the top distance tube shall be cut according to table 2. 4.1 Assembly of the luf f section Luff assembly should be carried out on a clean, flat surface. Make sure there is enough space for the entire forestay length to be stretched out.
  • Page 17 5. Release a short joining sleeve and move down to the first extrusion. Add the next 4800mm extrusion and fit a connecting plate. 6. Insert distance tube halves in the second extrusion. Use the next short joining sleeve to push in the distance tube halves. The joining sleeve should be pushed in approximately half its length (150mm).

  • Page 18: Rigging

    5 Rigging The Furlex system is best transported and rigged together with the mast. 5.1 Fitting the Furlex on a stepped mast 1. Slacken the backstay as much as possible, but make sure that any rigging screw is not unscrewed so far that the threads are no longer visible ”on the inside”. 2.
  • Page 19 Remove the locking plates from the lower bearing bearing assembly. Slide the torque tube down and fit it to the lower bearing assembly. Align the marking (A) on the torque tube with the allen screw (B) on the bearing assembly. Apply locking adhesive to the screws and fit the locking plates attaching the torque tube to the bearing assembly.

  • Page 20: Installation

    6 Installation Hydraulic motor • The drive unit and hydraulic motor are tested before delivery. • The hydraulic motor is a Danfoss OMM 20 cm3/revolution. Maximum recommended pressure, p=140 bar. • The oil flow, Q=20 litres/min. gives a nominal speed n=40 rpm. The normal working load when reefing or unfurling is p=40 bar when Q is 19 litres/min.

  • Page 21: Hydraulic Hoses

    Hydraulic hoses 1. Hydraulic hoses for installation below deck are not supplied. (See fig. 12.1). 2. Connecting threads are G 3/8”. (See fig. 11.1). 3. Use hydraulic hoses of good quality corresponding so SAE 100R7/-ISO3949. Minimum dimension 1/2”. Minimum working pressure 140 bar. Minimum recommended bending radius 150 mm (6”). Important! Blow through all new hoses with compressed air to clean them from possible dust and dirt before fitting. Check the system very thoroughly during assembly to ensure that no impurities are present.

  • Page 22: The Sail

    7 The sail Adapting the sail to the Furlex system To fit the Furlex system, an existing sail may need a number of modifications. The maximum luff length is calculated as shown in Table 1 page 6 FLD-(F+E). Existing forestay length FLD as per Table 2, page 11.

  • Page 23: Adjusting The Forestay Length

    7.2 Adjusting the forestay leng th The Furlex system is supplied with a simple adjuster Stroke is +-50mm. The adjuster is only for adjustining the forestay length. Tensioning the forestay, is done by tensioning the cap shrouds and/or the backstay, and not by tensioning the forestay adjuster. The sail must be removed or unfurled and halyard slackened before the forestay length can be adjusted.

  • Page 24: Checklist

    7.3 Checklist Go through the checklist below and make sure that all the important steps have been carried out. This will ensure that the Furlex system functions safely and reliably for many years and in all conditions. • Check that the angle between the halyard and forestay is 10–15° when the sail is hoisted. •...

  • Page 25: Unfurling The Sail

    7.5 Unfurling the sail Haul in on the sheet while pressing the unfurling switch. By doing this, the sail will not flap and be subjected to excessive wear. Stop the reefing gear when the sail is fully open and the luff extrusion has a suitable angle to the apparent wind.

  • Page 26: Emergency Operation

    7.8 Racing The Furlex system can be converted from a furling system to a twin-groove racing headfoil by lowe- ring the halyard swivel below the sailfeeder. The twin grooves now makes swift sail changes possible. 7.9 Emergency operation If power is lost the system can be manually operated using the emergency line driver supplied with the system.

  • Page 27: Maintenance

    Maintenance 8.1 Inspection • To ensure that the system rotates easily and functions satisfactorily year after year, regular inspection and maintenance should be carried out once a year. Maintenance is simple, even with the Furlex rigged on the boat. • Check for damages on the luff extrusion.

  • Page 28: Storage

    8.3 Storage The stay is preferably stored with the mast when the mast is down. Make sure that no aluminium surfaces are in contact with steel parts. Under no circumstances should an unwashed or damp Furlex system be wrapped in plastic or any other impervious material.

  • Page 29: Luf F Extrusion

    8.6 Luf f extrusion Place the stay on a flat surface and make sure that the luff extrusion is kept straight. Remove the top guard and top eye terminal. Pry out the bushings from the lower bearing with a screw driver or a similar tool. Be careful not damaging the holes in the luff section.

  • Page 30: Spare Parts And Accessories

    9 Spare parts and accessories...

  • Page 31: Spare Parts

    9.1 Spare parts list Motor unit Description Dimension Item Assembly number-> 539-822-11 Motor unit 500TDH 539-822-11 Locking screws 153-208 Toggle terminal Description Dimension Item Assembly number-> 308-627-01 Toggle terminal 1 ¼” RH 308-627-01 Clevis pin ø1 1/8” 165-592 Split pin Ø5.9x41 301-058 Deck fitting...
  • Page 32 Luff extrusion lower (sail feeder) Item Description Dimension Assembly number-> 549-509-01 Luff extrusion L=580 549-509 Joint sleeve L=700 549-510 Bearing plug 50x40 539-193 Bush ø12/10-12 306-562 Luff extrusion 4800mm Item Description Dimension Assembly number-> 539-423-01 Luff extrusion L=4800 539-423 Joint sleeve L=300 539-427 Distance tube half...

  • Page 33: Warranty

    7 Warranty Seldén Mast AB guarantees the Furlex-system for 2 years. The guarantee covers faults arising from defective design, materials or workmanship. The guarantee is only valid if the Furlex-system is assembled, operated and maintained in accordance with this manual and is not subjected to loads in excess of those indicated in the brochure and instructions.
  • Page 34 DINGHIESKEELBOATSYACHTS Seldén Mast AB, Sweden The Seldén Group is the world’s leading manufacturer of Tel +46 (0)31 69 69 00 mast and rigging systems in carbon and aluminium for e-mail info@seldenmast.com dinghies, keelboats and yachts. Seldén Mast Limited, UK Tel +44 (0) 1329 504000 e-mail info@seldenmast.co.uk Our well known brands are Seldén and Furlex.

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