Airdolphin Pro Z-1000 - 48 Instruction Manual Zephyr Corporation For your internal use only.
Contents 1. Getting Started.....................................................................................................................................3 2. For Your Safety (Read before using.)...................................................................................................4 3. Airdolphin Features..............................................................................................................................6 3-1 10 State-of-the-Art Technologies.......................
1. Getting Started Thank you for purchasing the Airdolphin (Z-1000). The Airdolphin's creation is the culmination of Zephyr Corporation’s years of experience and technical expertise with small wind turbines. This turbine is powered by wind, which it harnesses to generate electricity. Since wind is a natural energy source, its output varies in accordance with time, date, and the seasons. Wind conditions may not always be optimal, and can range from no breeze to raging gusts.
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”. DANGER: This symbol indicates information that could result in death or severe injury if ignored.
2. For Your Safety WARNING Do not install the Airdolphin (Z-1000) in close proximity to electric or telephone lines. A fallen pole or contact between the rotor and electric/telephone lines could result in electrocution, disconnection, or damage to/ malfunction of the Airdolphin (Z-1000). Do not install the Airdolphin (Z-1000) in close proximity to structures such as smokestacks that attain extremely high temperatures.
3. Airdolphin Features 3-1 10 State-of-the-Art Technologies u 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. The light weight also allows the unit to be installed in a wide variety of places.
3. Airdolphin Features u New Power Management System The newly-developed Power Management System is aimed at optimizing the safety and efficiency of power generation. Non-Stop Operation with Continuous Output At its upper potential, the Airdolphin can deliver a 2.3kW output (at 20m/s). During strong winds (at 20m/s or more), the Airdolphin automatically moderates its spinning speed and continues working at a reduced output.
3. Airdolphin Features 3-2 Specification Wind Turbine Type Horizontal axis, up-wind Rotor Diameter 1800mm Mass 17.5kg Mount Diameter 48.6mm Number of Blades 3 Blade Material Carbon-fiber laminate over foam core Control System Built-in Zephyr-Original Power Management System* (ZPMS) with: 1. Power-Assist Function 2. Stall Mode 3. Safety Control 4. Battery Charge Management 5.
3. Airdolphin Features 3-3 Power Output Characteristics Power output Characteristics Power out put (W) 2500 of the Airdolphin Pro 2.3kW 2000 1500 1000 500 0 0 5 10 15 20 25 30 35 40 45 50 55 Wind Speed (m/s) Intelligent Power Management System * Cut-in; wind speed at which the turbine begins to produce power. Thewind intelligent power management system * Cut-out; speed at which the turbine stops to produce power.
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 circumstance may cause the pole supporting the wind turbine to topple or the wind turbine itself to fall. Keep these possibilities in mind when selecting a location for the installation of the Airdolphin (Z-1000).
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 l. Hub 1 q. Hexagonal Wrench (8mm / 6mm) n. Blades (3) j. Hexagonal Nut (for Hub use) o. Instruction Manual k.
6. Assembling the Airdolphin (Z-1000) 6-1 Verify the following upon purchase n The Airdolphin consists of the items listed below. Upon opening the package, check the parts against the list shown above in “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.
6. Assembling the Airdolphin (Z-1000) 6-2 Assembly procedure Follow steps j–m 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 ailure to observe these safety instructions may result in a severe accident or damage to the Airdolphin (Z-1000) or F other parts of the system.
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) j 1. The wind turbine has six cables. Connect these cables to the extension cable that passes through the pole. (See page 20.) 2. Connect the pole to the body (yaw shaft). Lower the yaw shaft until the end of the pole fastens inside the yaw shaft.
6. Assembling the Airdolphin (Z-1000) k Attaching the tail to the body 1. Line up the attachment holes on the body and the tail. 2. Make sure you have the tail shaft right side up and then insert it into the attachment hole on the body until it makes contact with the bottom as shown in the figure below. 3. Install the screw plug on top of the tail shaft and then tight it snugly into place.
6. Assembling the Airdolphin (Z-1000) l Assembling the rotor 1. Attach the three blades to the blade attachment sections on hub 1. There are numbers on hub 1 and the attachment sections of the blades. Make sure that these numbers match when attaching the blades. Blade Attachment Section 000001 There is a protrusion on this part of the blade attachment face. 00000 01 * The rotor is tuned so that it is dynamically balanced.
0 6. Assembling the Airdolphin (Z-1000) 4. Rotate hub 2 while holding hub 1 (to which the blades have been attached). Hub 2 will come free. If it rotates, rotor assembly is complete. In the event that Hub 2 does not rotate smoothly, return to step 2 above, make certain that the blades are securely fastened, and repeat the assembly procedures. Verify thathub hub II Verify that 2 rotate s smoo thly. rotates smoothly. The blades are The blades are 1.I attached hub 1.
6. Assembling the Airdolphin (Z-1000) 7. Check the Rotor that will rotate smothly after attaching the E-ring to the shaft. 3. Once the rotor is in place, use the hexagonal nut to fasten it to the shaft. 4. The rotor will be f ixed into place once the gap between the body and the rotor reaches 3mm.Verify that the rotor can rotate smoothly. E- ri ng Rotor 8. Slide the nose cone onto the end of the rotor.
7. Connecting the System 7-1 Before connecting The Airdolphin 48V model is used as a standalone system(Off-grid system). A 48V battery is required for the system. The following explains how to connect the Airdolphin power cable (approx. 500mm long) and provides a typical example of a wind turbine system connection. *P ay attention to the + and – terminals when connecting the power cable to the battery. Reverse connection will cause serious damage.
7. Connecting the System 7-4 Connecting the Airdolphin output cable extension A total of six cables extend from the Airdolphin (Z-1000): four power cables and two data communication cables. Circuit Diagram of D.P.D.T.Blade Switch Operate Stop Short cable * Each cable is 500mm long. To the Battery Use a compression sleeve to connect the extension cable (15m) that leads to the blade switch. Use electrical tape or a shrink tube to insulate the connections.
7. Connecting the System 7-5 Connection example The Airdolphin can be used in a multitude of configurations. This section shows a typical connection example recommended by Zephyr Corporation. Caution This manual is intended for individuals who have the knowledge and technical skill needed to work with batteries and electrical wiring. If the Airdolphin is used in an inappropriate configuration or wired incorrectly, its use could cause a severe accident and damage the system, including this product.
7. Connecting the System AT-10 RM-1000 TH-5 LAN PC AM-10 (Anemometer and thermometer) Standalone System (Off Grid) Airdolphin D.P.D.
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).
9. 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 12VDC batteries in a series circuit to attain 48VDC performance.
9. Considerations When Choosing Peripheral Materials/Devices Inverters Since batteries are a direct current power source, a DC-AC inverter is needed to convert direct current (DC) to alternating current (AC) when an alternating current device is used to manage the electrical load. Verify the capacity and type of your inverter to ensure that it is appropriate for the load you are using. * Always use 48VDC inverters. * Always use inverters equipped with an overvoltage protection circuit. 10.
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* 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 Shibuya-ku, Tokyo, Japan Fax +81-3-3299-1977 Tel +81-3-3299-1910 URL http://www.zephyreco.co.jp/en 331 West 57th Street, Suite 555 New York, NY 10019 U.S.A. Tel: 646-378-7911 Fax: 212-489-8011 www.americanzephyr.com Document No.
