Zephyr Airdolphin Pro Z-1000 - 48 Instruction Manual
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Zephyr Airdolphin Pro Z-1000 - 48 Instruction Manual

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Airdolphin Pro Z-1000 - 48
For your internal use only.
Instruction Manual
Zephyr Corporation

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  • Page 1 Airdolphin Pro Z-1000 - 48 For your internal use only. Instruction Manual Zephyr Corporation...

  • Page 2: Table Of Contents

    Contents 1. Getting Started ............................3 . For Your Safety (Read before using.) ....................4 3. Airdolphin Features ..........................6 3-1 10 State-of-the-Art Technologies ....................6 3- Specification ..........................8 3-3 Power Output Characteristics ....................9 4. Installation Environment ........................10 5. Part Names ............................11 6.

  • Page 3: Getting Started

    Although people cannot influence wind force directly, it is possible to adapt to changes in the wind itself. Zephyr Corporation Airdolphin engineering focused on building a system that can adjust to subtle wind conditions in real time, generating the maximum amount of electricity.

  • Page 4: For Your Safety (Read Before Using.)

    2. For Your Safety (Read before using.) SAFETY WARNINGS AND SYMBOLS To ensure proper use of this product, read this section (“Safety warnings and symbols”) before attempting to install, operate, or inspect the Airdolphin (Z-1000). Throughout this manual, safety information is divided into three categories: “Danger”, “Warning”, and “Caution”.
  • Page 5 Airdolphin (Z-1000). Contact either the dealer where you purchased the Airdolphin (Z-1000) or Zephyr Corporation for repairs if the lines or cables are damaged (i.e. exposed wires, cut cables, plug damage). Continued use could result in electrocution, fire, or short circuits.

  • Page 6: Airdolphin Features

    3. Airdolphin Features 3-1 10 State-of-the-Art Technologies Extremely Low Mass The total weight of the Airdolphin is only 17.5kg. This means it weighs just 17.5g.per generated watt (when the continuous rated output is 1kW). Thus, the Airdolphin tracks wind better in turbulent flows, resulting in more efficient power generation.
  • Page 7 Data Communication System The Zephyr Communication System was recently developed, which will soon allow you to connect the Airdolphin to the internet. This way, you can check the wind strength, amount of generated power, and other information on your PC remote from the turbine’s location. You can also install a GPS receiver to the turbine for confirming the location of each unit.

  • Page 8: Specification

    3. Airdolphin Features 3-2 Specification Wind Turbine Type Horizontal axis, up-wind Control System Built-in Zephyr-Original Power Management System* (ZPMS) with: Rotor Diameter 1800mm 1. Power-Assist Function Mass 17.5kg . Stall Mode Mount Diameter 48.6mm 3. Safety Control Number of Blades 4.

  • Page 9: Power Output Characteristics

    3. Airdolphin Features 3-3 Power Output Characteristics Power output Characteristics of the Airdolphin Pro Power out put 2500 2000 1500 1000 Wind Speed (m/s) Intelligent Power Management System * Cut-in; wind speed at which the turbine begins to produce power. The intelligent power management system has succeeded in truly seamless * Cut-out;...

  • Page 10: Installation Environment

    4. Installation Environment 1. Safety Although the Airdolphin (Z-1000) has been engineered to withstand wind speeds of 65m/s, the rotating blades may be damaged by tree branches or other flying objects during strong winds. In addition, unforeseen circum- stance may cause the pole supporting the wind turbine to topple or the wind turbine itself to fall. Keep these pos- sibilities in mind when selecting a location for the installation of the Airdolphin (Z-1000).

  • Page 11: Part Names

    5. Part Names c. Screw Plug a. Tail d. Tail Shaft m. Hub  i. C Ring b. Body e. Long Nut p. Wrench f. Yaw Shaft Cover r. E-ring g. Insulator h. Cap Bolt q. Hexagonal Wrench n. Blades (3) l.
  • Page 12 “5. Part Names” to ensure that nothing is missing. * Although Zephyr Corporation verifies the quality of all our products before shipping them, damage may occur during shipping. Check the surfaces of the blades, the tail, and all other components to ensure that they are free from any damage or warping that may affect performance.

  • Page 13: Assembling The Airdolphin (Z-1000)

    6. Assembling the Airdolphin (Z-1000) 6-2 Assembly procedure Follow steps – below to assemble the Airdolphin (Z-1000). The assembly procedure for each part is shown on the following and subsequent pages. (outer diameter is 4 8 . 6 m m ) OBSERVE THE FOLLOWING SAFETY INSTRUCTIONS DURING ASSEMBLY AND INSTALLATION  F ailure to observe these safety instructions may result in a severe accident or damage to the Airdolphin (Z-1000) or other parts of the system.
  • Page 14 6. Assembling the Airdolphin (Z-1000) CAUTION: DO NOT CONNECT TO BATTERIES WHEN INSTALLING. Airdolphin is in brake mode when disconnected from the batteries. Fastening the pole to the body (yaw shaft) 1. The wind turbine has six cables. Connect these cables to the extension cable that passes through the pole.
  • Page 15 6. Assembling the Airdolphin (Z-1000) Attaching the tail to the body 1. Line up the attachment holes on the body 3. Install the screw plug on top of the tail and the tail. shaft and then tight it snugly into place. .
  • Page 16 6. Assembling the Airdolphin (Z-1000) Assembling the rotor * Attach the blades to hub 1 so that the c or resp onding 1. Attach the three blades to the blade attachment numbers match. Using the sections on hub 1. There are numbers on hub wind turbine with the blades a t t a c h e d i n t h e w r o n g 1 and the attachment sections of the blades.
  • Page 17 6. Assembling the Airdolphin (Z-1000) 4. Rotate hub  while holding hub 1 (to which the blades have been attached). Verify that hub  Verify that hub II rotate s smoo th ly. rotates smoothly. Hub  will come free. If it rotates, rotor assembly is complete.
  • Page 18 6. Assembling the Airdolphin (Z-1000) 7. Check the Rotor that will rotate smothly after 3. Once the rotor is in place, use the hexagonal nut to fasten it to the shaft. attaching the E-ring to the shaft. 4. The rotor will be f ixed into place once E- ri ng the gap between the body and the rotor reaches 3mm.Verify that the rotor can rotate...

  • Page 19: Connecting The System

    3). In the event of an emergency stop, the Airdolphin (Z-1000)’s power supply must be shut off for approximately 10 seconds before being restarted. In order to facilitate turning the power on/ off, Zephyr Corporation recommends the installation of a D.P.D.T. BLADE SWITCH between the Airdolphin (Z-1000) and the battery. (See next page.)

  • Page 20: Connecting The Airdolphin Output Cable Extension

    7. Connecting the System 7-4 Connecting the Airdolphin output cable extension A total of six cables extend from the Airdolphin Circuit Diagram of D.P.D.T.Blade Switch (Z-1000): four power Operate Stop cables and two data communication cables. Short cable * Each cable is 500mm long. To the Battery Use a compression sleeve to connect the extension...

  • Page 21: Connection Example

    Caution and damage the system, including this product. If you have any questions regarding Airdolphin system configuration, contact either the dealer where you purchased this product or Zephyr Corporation for more information.
  • Page 22 7. Connecting the System AT-10...

  • Page 23: Explanation Of Airdolphin Operations

    8. Explanation of Airdolphin Operations During operation, the indicator LED on the body of the Airdolphin can be used to check the operating status of the system. The indicator LED can light in solid or flashing red, green and orange (red and green). Indicator LED Operating Status List Mode...

  • Page 24: Considerations When Choosing Peripheral Materials/Devices

    Choosing peripheral materials/devices Batteries Zephyr Corporation recommends the use of a deep cycle battery (AGM) for all off-grid applications to handle the deep charge/discharge cycles in the wind turbine system. (A car battery cannot be used for repeated deep charge/discharge.) Connect four 1VDC batteries in a series circuit to attain 48VDC performance.

  • Page 25: Maintaining The Airdolphin System

    WARNING CAUTION If replacement is necessary, only use parts specified by Zephyr International. Use of other parts could cause accidents or malfunction. W hen strong winds blow, tree branches and other objects may make contact with and damage the wind turbine, its support pole, or its wiring.
  • Page 28 * This document may not be reprinted or copied without express permission from Zephyr Corporation. Zephyr Corporation American Zephyr Corporation Hatsudai Center Bldg. 1-51-1, Hatsudai 331 West 57th Street, Suite 555 Shibuya-ku, Tokyo, Japan New York, NY 10019 U.S.A. Tel + 81-3-399-1910...

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