Zephyr Airdolphin Pro Z-1000 Instruction Manual
Airdolphin Pro Z-1000 - 48
Instruction Manual
For your internal use only.
Zephyr Corporation
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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 ..............................................................................................6
3-2 Specification .............................................................................................................................8
3-3 Power Output Characteristics ...................................................................................................9
4. Installation Environment .................................................................................................................... 10
5. Part Names ....................................................................................................................................... 11
6. Assembling the Airdolphin (Z-1000) ..................................................................................................12
6-1 Verify the following upon purchase .........................................................................................12
6-2 Assembly procedure ...............................................................................................................13
7. Connecting the System .....................................................................................................................19
7-1 Before connecting ...................................................................................................................
19
7-2 Length of the extension cable that leads from the Airdolphin to the battery ...........................19
7-3 D.P.D.T Blade Switch ..............................................................................................................19
7-4 Connecting the Airdolphin output cable extension ..................................................................20
7-5 Connection example ...............................................................................................................21
8. Explanation of Airdolphin Operations ................................................................................................23
9. Considerations When Choosing Peripheral Materials/Devices ........................................................24
10. Maintaining the Airdolphin System ....................................................................................................25
10-1 Daily Inspection .......................................................................................................................25
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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. 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.
We at Zephyr Cor poration hope that our products are both f un and useful, contributing to the
development of an ecological minded culture by reducing carbon dioxide emissions through the use of
natural energy, thus leaving a better Earth for future generations.
This manual provides specific information on the Airdolphin, including its features, instructions for use,
safety precautions, maintenance procedures, and peripheral equipment.
It is intended to be read by those who own or work on this product. Read this manual thoroughly and
familiarize yourself with this product before attempting to use it.
In the unlikely event that this product does not function properly, prohibit all persons except for trained
technicians from handling its internal systems and contact either the dealer from whom you purchased
it or Zephyr Corporation customer service department.
• The specifications of this product may change due to improvements without prior notice.
• For purposes of explanation, the illustrations and photographs throughout this manual may differ
from the actual product.
• "AIRDOLPHIN" and "Airdolphin" are trademarks of Zephyr Corporation.
• The serial number of the wind turbine is written at the last page of this manual. You will need this
information in the event a warranty claim.
R e a d t h e f o l l ow i n g !
u Certain Airdolphin installation procedures are dangerous. Always have a trained professional
perform installation work.
u Be aware that Zephyr Corporation assumes no responsibility for accidents or damages sus-
tained as a result of not following the procedures and warnings specified in this manual.
u Be aware that Zephyr Corporation assumes no responsibility for accidents or damage
caused by improper installation, use, or attempts to modify this product.
u This product may suffer salt erosion or other forms of corrosion if installed in a location that
places it in direct contact with salt water.
* Failure to operate this product in accordance with the content of sections labeled “Danger”,
“Warning”, and “Caution” may result in accidental death, injury, fire, or damage to the product
itself.
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2. For Your Safety (Read before using.)
DANGER:
WARNING:
CAUTION:
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”.
This symbol indicates information that could result in death or severe injur y if ignored. It is
used to indicate information of a particularly dangerous and/or urgent nature.
This symbol indicates information that could result in death or severe injury if ignored.
This symbol is used to indicate information that could result in death, severe injur y, or damage
limited to property if ignored.
SAFETY INFORMATION IS INDICATED AS
SHOWN BELOW
Do not install the Airdolphin (Z-1000) before inspecting the durability/quality of the pole to which it will be attached
and the area in which it will be installed for safety.
If the pole and the location are not suitable for the installation of this product, the pole may break or fall over,
resulting in injury or death.
Install this product so that the tips of the rotor are at least 3.5m away from locations that may be approached by
people. After installation is complete, clear away all scaffoldings, making sure that nobody goes near the rotor.
Never touch a moving rotor with your hand or any other part of the body. The rotor is as dangerous as a sword and
accidental contact can result in death or severe injury.
The body of the Airdolphin (Z-1000) will also move in accordance with wind direction once it begins to make contact
with the wind. Exercise caution if it is necessary to approach the Airdolphin (Z-1000) to per form installation or
maintenance work.
DANGER
This manual contains caution information related
to the rotors.
“Rotor” is the term u sed to describe the three
bl a d es when they are att a ched to the hub .
Caution information that describes the rotor gives
warnings about the rotating blades.
(See to page 13.)
Be awar e that failure to use the produ ct in t he
manner indicated by may, depending on
circumstances, also have severe consequences. All
of the symbols described above indicate important
safety information. Obey all safety information when
using this product.
Caution
The
symbol is intended to draw readers’ attention to
Danger/Warning/Caution information. Specific details on
the nature of the threat to safety are indicated inside or
beside the symbol.
The
symbol indi cates prohibi te d acti on s. Spe cif ic
details on the prohibited action are indicated inside or
beside the symbol.
The
sy m b o l in d i c a t e s i n s t r u c t i o n s th a t mu s t be
followed. Specific details on the mandatory instructions
are indicated inside or beside the symbol.
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Do not install the A irdolphin (Z-1000) in close proximity to electric or telephone lines. A fallen pole or c ontact
betw ee n the rotor and e le ctr ic/ telepho ne line s co ul d r esult in el ec tro cutio n, disc onnec tion, or dama ge 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. The heat could melt the insulation on electrical cables, resulting in electrocution, fire, or other
damage.
Do not instal l the Airdolphin (Z-100 0) i f t he pole to whic h it will be at tache d is not standing straig ht up. The
Airdolphin (Z-1000) could fall, causing an accident or mechanical damage/malfunction.
Do not use the Airdolphin (Z-1000) for any purpose other than generating electricity from natural wind. Do not
attempt to generate electricity by mounting the Airdolphin (Z-1000) on a moving vehicle. Do not use the Airdolphin
(Z-1000) in close proximity to an exhaust duct or in any other extremely high-temperature environment. Doing so
could result in fire, injury, or damage to the 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.
Do not pull on, excessively bend, or attempt to modify the wires/cables of the Airdolphin (Z-1000).
Doing so could result in cord damage, electrocution, or fire.
Never attempt to disassemble or modif y the Airdolphin (Z-1000). Doing so could result in electrocution, fire, or
Airdolphin (Z-1000) malfunction.
Due to conditions of use, this system may not continuously supply stable electrical power. Do not attempt to use
the electricity generated by the Airdolphin (Z-1000) to power medical devices or other equipment related to human
life systems support . Do not attempt to use the electricity generated by the Airdolphin (Z-1000) to power personal
computers not equipped with batteries or other auxiliar y power sources.
Observe all safety precautions when working on the Airdolphin (Z-1000) in high locations. Take care to ensure
that hardware and other parts do not fall from the Airdolphin (Z-1000). Falling par ts can cause injuries or other
accidents.
Before assembling the Airdolphin (Z-1000), secure adequate space to ensure that work can be completed safely.
Inadequate space can result in injuries or other accidents.
WARNING
CAUTION
2. For Your Safety
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3. Airdolphin Features
3-1 10 State-of-the-Art Technologies
u Extremely Low Mass
Th e to t a l we i g ht of the Aird o l p hin is only 17.5kg . This mea n s it we i g h s just 17.5g.p e r ge n e r ated
watt (when the c ontinuous rated output is 1kW ). Thus, the Airdolphin tr acks wind bet ter in tur bulent
flows, resulting in more efficient power generation. The light weight also allows the unit to be installed in a
wide variety of places.
u Newly-Designed Rudder
The rudder of the Airdolphin uses the newly-developed Swing Rudder System. This system ensures the turbine’s superior response to sudden changes in the direction of wind, improving the efficiency of power generation.
u Newly-Designed Rotor
The Airdolphin comes with a new rotor system consisting of:
(1) Three ultra low-mass blades, reinforced by a carbon-fiber skin for superior rigidity. (2) A hub mechanism
that uses the newly-developed Multi-Stagger System (incorporating multiple air foils and lift angles). This
technology allows the turbine to capture the wind effectively and respond flexibly to changing conditions, from
slight to stormy winds, eliminating the need for pitch controls.
u An Innovation for Low Noise Newly-Designed Rotor
The Airdolphin comes with the “Noise Disrupter Coating”. This new blades have a number of thin ridges
applied on its surface, which significantly reduces air flow noise. Our designers were inspired by the wings of
owls that enables it to fly almost silently and unnoticed while approaching its prey.
u Robust Body Structure
Bolt-less self-fitting body inspired by Japanese traditional block puzzle craftsmanship. This technique ensures
an exact fit and provides superb resistance to adverse weather conditions, greatly minimizing maintenance
requirements.
u Power-Assist Function
For 10 seconds every minute when there is no wind, the Airdolphin uses previously- generated power to spin
the rotor. This allows the rotor to reach the cut-in point more quickly--even when there is near zero wind,
allowing the unit to capture the wind effectively. The Power Assist Function also prevents freezing of the rotor
due to low temperatures.
3. Airdolphin Features
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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.
Safety Control
Several technologies are applied to keep the turbine from disintegrating and allow it to control its output, even
during overheating of the power generator, excessive spinning speed, and other unfavorable situations.
High-Efficiency Operation
To maintain optimum efficiency at a variety of wind speeds, the turbine is controlled by a special computer
program coordinated with the Multi-Stagger System of the rotor. An ultra-lightweight rotor, a special propeller
design optimized for varying wind speeds, and a power generator with superior efficiency was also developed.
Battery Charge Management
Management of the rechargeable battery, optimized for using the wind turbine as an independent power supply, is controlled by a system based on a 3-step battery recharge. Charge can be managed under a variety
of conditions, from arctic to tropical weather. Management includes compensations for wire cable length and
even current (more than 50 amps of continuous power).
u New Generator
For the Airdolphin, a newly-developed heavy-duty generator is used with a max. 4.5kW power output. The
magnet used for the turbine is a neodymium iron boron magnet which boasts of an extremely high magnetic
flux.
u 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.
u Fresh Design - Winner of the Good Design Award 2005
The attractive body was designed, using nature’s animals as our inspiration. The sleek lines, high power, cleverness and playful responsiveness of this design inspired the name Airdolphin. Our turbine looks alive, eager
and ready to catch the wind.
3. Airdolphin Features
3-2 Specification
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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
Blade Mass (per piece) 380g
Blade Retention Interlock hub mounting
Body Material Aluminum diecast
Body Construction Screw-free joints (based on
traditional Japanese handi crafts)
Product Finish Teflon-based paint
Generator Sy n c h r o nous-t ype, three phase power generator with
n e o d y m i u m i r on b o r on
magnets
Protection Circuit Built-in
Data Logger Built-in
Yaw control Free yaw (360 degrees)
Direction Control
Original Swing-Rudder System
Output Control Non-stop output control
Start-up Wind Speed 0m/s (Power-Assist Function)
Cut-in Wind Speed 2.5m/s
Cut-out Wind Speed -
Survival Wind Speed 65m/s
Rated Power 1kW (12.5m/s)
Rated Rotor Speed 1000rpm
Maximum Power 2.3kW (20m/s)
Maximum Rotor Speed 1000rpm (20m/s)
Mass per Watt 17.5g/W (at rated power)
Power per Square Meter
393W/m2 (at rated power)
Output Voltage DC50V
Braking System Regenerative electro-mag netic braking system
Communication System RS-485
(Signal Output)
Recommended System
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. Data Communication System
Power Generation Features
Wind Speed Power Rotor Speed
(m/s) (mph) (W) (rpm)
3.5 7.8 27 350
6.5 14.5 170 650
10.0 22.4 620 1000
12.5 27.9 1000 1000
15.0 33.5 1500 1000
17.5 39.1 2000 1000
20.0 44.7 2300 1000
30.0 67.1 500 600
40.0 89.4 700 600
50.0 111.8 900 600
Off-grid : Deep cycle lead
acid battery,500Ah or more
3. Airdolphin Features
9
3-3 Power Output Characteristics
The intelligent power management system has succeeded in truly seamless power generating
performance for a broad spectrum of wind energy ranging from 2.5 m/s (5.6 mph) upwards, never
cutting out. The system instantly responds to sudden changes in the wind speed and adapts
by creating the most suitable power point production. At its upper potential, by incorporating
sophisticated software algorithms, the Airdolphin Pro can deliver 2.3 kW output when capturing
20 m/s (44.7 mph) gusts and winds. It then shifts to a more gradual power curve slowly increasing
output as the wind strength increases.
* Cut-in; wind speed at which the turbine begins to produce power.
* Cut-out; wind speed at which the turbine stops to produce power.
50
500
0
1000
1500
2000
2500
10 15 20 25 30 35 40 45 50 55
Power out put
(W)
Wind Speed
(m/s)
2.3kW
Power output Characteristics of the Airdolphin Pro
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