Z SPARS Z400 - User Manual

GENINS05 Page 1 28/08/2014
Z SPARS UK
GENOA FURLING SYSTEM
SYSTEM MANUAL
Documents in this manual:
Title Document/File Name
Genoa Furling System – Instructions GENINS05.doc
Z400F, Z500F, Z600F Dimensions Form FS-1/456
Z700F, Z800F, Dimensions Form FS-1/780
Z1000F, Z1200F Dimensions Form FS-1/1012
Halyard Diverter – Method 1 FS-3/gendiv01.skd
Halyard Diverter – Method 2 FS-3a/gendiv02.skd
Halyard Diverter – Method 3 FS-3b/gendiv03.skd
System Forestay
No. Size (mm)
Z400F 4mm
Z500F 5mm
Z600F 6mm
Z700F 7mm
Z800F 8mm
Z1000F 10mm
Z1200F 12mm

Summary

Manual Document Overview

System Instructions and Forms

Lists main system instructions and dimension forms included in the manual.

Halyard Diverter Guides

Provides methods for installing the Halyard Diverter.

List of Components

Component Visuals

General Component Drawings

Illustrative drawings of the furling system components.

Model-Specific Component Drawings

Detailed component drawings for Z456, Z780, and Z1012 models.

Assembly Procedures

Luff Foil Assembly

Steps for assembling the luff foil, including trimming and connecting sections.

Swivel and Foil End Cap Assembly

Guidance on fitting the swivel and multi-part foil end cap.

Furling Drum Assembly

Details on assembling the furling drum, including tubes and capscrews.

Mast Assembly and Diverter Fitting

Instructions for mounting the system on the mast and fitting the halyard diverter.

System Operation and Maintenance

System Operation

Guide on how to furl and unfurl the sail using the Genoa Furling System.

Maintenance and Forestay Tension

Procedure for flushing parts with fresh water and adjusting forestay tension.

Troubleshooting Guide

Foresail Unfurling Issues

Causes and actions for when the foresail will not unfurl.

Foresail Furling Issues

Causes and actions for when the foresail will not furl.

Hoisting and Tensioning Problems

Solutions for difficult hoisting or insufficient luff tension.

Lowering Issues

Causes and actions when the sail cannot be lowered.

Overview

1. Function Description
2. Important Technical Specifications
3. Usage Features
4. Maintenance Features

The Z Spars Genoa Furling System is a marine device designed to facilitate the furling and unfurling of a boat's foresail. It allows for easy adjustment of sail area from the cockpit, enhancing convenience and safety for sailors. The system is compatible with various boat sizes, offering models from Z400 to Z1200, which correspond to different forestay sizes.

Function Description:

The primary function of the Genoa Furling System is to wrap the foresail around a luff foil, effectively reducing or increasing the sail area. This is achieved by pulling on a drum rope, which rotates a drum assembly at the base of the forestay. This rotation, in turn, twists the luff foil, causing the sail to furl. To unfurl the sail, the drum rope is released, and the foresail sheet is pulled.

A crucial component of the system is the halyard diverter, which is essential to prevent the foresail halyard from wrapping around the furling mechanism. Without a diverter, the halyard could jam the system, potentially causing damage to the forestay. The diverter ensures that the halyard maintains an optimal angle (15° to 20°) with the forestay, preventing entanglement during furling and unfurling operations.

The system is designed to be installed with a new forestay, typically featuring a rigging screw at the base for tension adjustment. The luff foil, which is the core around which the sail furls, can be composed of multiple aluminium sections connected by foil connector sleeves and secured with socket set screws. Loctite 638 is recommended for securing these screws.

The drum assembly consists of an upper (torque) tube, two flanges, and a lower tube, through which the rigging screw passes. The foil connects to the upper tube via socket capscrews that engage both the foil and a double-hole threaded stainless steel plate. A bottom plastic stopper is inserted into the foil to prevent the PVC sleeving from falling down.

Important Technical Specifications:

• Models: Z400F, Z500F, Z600F, Z700F, Z800F, Z1000F, Z1200F.
• Forestay Sizes:
  • Z400F: 4mm
  • Z500F: 5mm
  • Z600F: 6mm
  • Z700F: 7mm
  • Z800F: 8mm
  • Z1000F: 10mm
  • Z1200F: 12mm
• Luff Foil Material: Aluminium.
• Foil Connection Screws: M6 x 8 socket set screws (for connecting foil sections).
• Lower Drum Bolt Sizes:
  • Z400F-Z600F: M10 x 60
  • Z700F-Z800F: M12 x 75
  • Z1000F-Z1200F: M16 x 100
• Sail Luff Slot Dimensions: All Z Spars luff foils have a 5.5mm internal diameter sail slot with a minimum slot width of 2.5mm. Sailmakers need to be aware of these dimensions for proper sail construction.
• Adhesive: 3ml tube Loctite 638 for securing foil connection screws.
• Rivets: 2 Alloy Rivets for Foil End Cap.

Usage Features:

• Ease of Operation: The system allows for partial or complete furling of the foresail by simply pulling on the drum rope. Unfurling is achieved by releasing the drum rope and pulling the foresail sheet.
• Adjustable Sail Area: Sailors can easily adjust the amount of sail set from the cockpit, adapting to changing wind conditions without needing to go to the foredeck.
• Safety: The halyard diverter is a critical safety feature, preventing the halyard from wrapping around the furling mechanism, which could lead to system failure or damage to the forestay. Maintaining tension in both the forestay and halyard is crucial for the diverter's effectiveness.
• Installation Flexibility: The system accommodates various forestay top terminals. If the Foil End Cap does not fit over the terminal, it can be fed onto the forestay from the bottom.
• Component List: A comprehensive list of components (Halyard Diverter, PVC Sleeving, Swivel, Head Shackle, Aluminium Luff Foil, Drum Screws, Tack Eye, Guard, Drum, Guard Attachment, Locking Joint, Locking Screw, Bushing for Lower Drum Bolt, Lower Drum Bolt, Foil Connecting Screws, Foil Connector, Bottom Plastic Stopper, Bottom Foil with sail entry, Top Foil, Foil End Cap, Inner Half Bearings for 21, Double Hole Toggle, Lower Drum Tube, Upper Drum Tube) is provided for easy identification and assembly.

Maintenance Features:

• Fresh Water Rinse: All parts exposed to salt water should be flushed with fresh water to prevent corrosion and maintain optimal performance.
• Forestay Tension Adjustment: The system allows for adjustment of forestay tension or length. This involves removing the sail, connecting the halyard to the Drum Tack Eye, tensioning a spinnaker halyard for safety, disconnecting the foil from the drum assembly, removing the Lower Drum Bolt, and then hoisting the drum assembly to access the rigging screw for adjustment.
• Troubleshooting Guide: The manual includes a detailed troubleshooting section to address common issues such as the foresail not unfurling or furling, difficulty hoisting or lowering the sail, and insufficient luff tension. This guide provides causes and recommended actions for each problem, including checking for wrapped halyards, fouled furling lines, slack forestays, and incorrect halyard tension.
• Loctite Application: Loctite 638 is used for securing foil connection screws, ensuring a durable and reliable assembly. Users are advised to observe the manufacturer's handling and usage instructions for the adhesive.
• Sail Luff Rope Compatibility: The system specifies a maximum sail luff rope thickness of 5mm. If the luff rope is too thick, it can cause difficulty in hoisting the sail, requiring consultation with a sailmaker.
• Drum Screw Taping: After refitting the drum, it is advisable to tape over the socket-headed Drum Screws (7) to prevent them from coming undone and being lost.

Z SPARS Z400 Specifications

General

Brand	Z SPARS
Model	Z400
Category	Boating Equipment
Language	English