WINDSTREAM Human Power Generator User manual

Rev. April 2011 1
Table of Contents
Product Description and Operating Instructions...........................................................................3
Pedal Power .......................................................................................................................4
Hand Crank Power ..............................................................................................................4
Definition of System Components ........................................................................................... 4
Assembly............................................................................................................................... 5
Attach the Foot Pedals or Hand Cranks .................................................................................5
Connect to a Power Pack or Other attery ............................................................................ 5
Precautions ........................................................................................................................... 8
Other Useful Information........................................................................................................... 9
attery Charging ....................................................................................................................9
attery Voltages ............................................................................................................... 10
attery Connections..........................................................................................................11
Safety Precautions ...............................................................................................................12
Mechanical Operation .......................................................................................................12
Electrical Operation...........................................................................................................12
Maintenance ....................................................................................................................... 12
Cleaning and Lubrication ................................................................................................... 12
Main earings................................................................................................................... 13
Chain Tension ...................................................................................................................13
Drive Train Alignment........................................................................................................13
Generator rushes ............................................................................................................14
Accessories.......................................................................................................................... 15
Equipment Return Policy .........................................................................................................16
Return Material Authorization Form ...................................................................................... 17
Conditions of Sale, Warranty, and Shipping Information ..........................................................18

3
Product Description and Operating Instructions
You have purchased a system that harnesses a readily available source of renewable energy – Human
Power. It is user friendly, portable, and available whenever you have the need for it. The power
output is directly proportional to the effort put into it. The Human Power Generator can be a
valuable tool in teaching an appreciation of the power we often take for granted.
Applications
• Emergency power generation and 12V
battery charging.
• Exercise systems that do useful work
generating power while exercising.
• Remote or off-grid power for 12-volt water
pumps and small appliances.
• Independent radio or radiotelephone
systems; emergency communications.
• Classroom projects and educational
exhibits to demonstrate the physical effort
required to generate electrical power.
The Human Power Generator is a DC power source primarily designed to charge a 12V battery. It will
charge at a rate of between 3-5 amperes. It will provide a maximum of 75 watts. Sustainable power
output over a period of time is usually around 50 watts. It is ideal for low power appliances like
laptops, radios and lighting. AC appliances can be powered by the Human Power Generator when a
DC/AC inverter, connected to the battery (often in the form of a portable power pack), is used.
Please note: It is possible to directly power certain DC appliances without using a storage battery. It
is important to observe maximum voltage ratings. An appliance rated for 12V DC will be damaged if
too much voltage is delivered. For example, a 12V lightbulb may be able to absorb 13V momentarily
but any more voltage would cause the bulb to burn out and fail. We recommend that DC Direct
applications be voltage regulated or closely monitored with a dc voltmeter or multimeter to
accurately measure output. The HPG can produce up to about 16V when connected to the load in
short bursts if the pedals or hand cranks are given a very quick turn. Note: Windstream’s 12V
Educational Light ox is voltage regulated.

4
Sustainable Power Output
The amount of power generated by the HPG is determined by the energy and length of time
available to turn the crank. The maximum output is about 75 watts.
Pedal Power
While human beings vary widely in weight, strength, and endurance, the average amount of
power that a person can generate is about 65 watts, or just under one-tenth of a horsepower.
The average sustainable output will fluctuate. For example, it may be easy to produce 65
watts continuously for twenty minutes, but that output may drop down to 30 watts as the
person pedaling becomes tired. That said, 75 watts or slightly more may be produced in short
bursts if the pedal or hand crank is whipped around very quickly (not recommended).
Hand Crank Power
The available power using hand cranks is less due to the smaller muscle mass of the upper
body. The maximum output is about 50 watts and the average sustainable output is around
35 watts.
Definition of Syste Co ponents
Generator
Power cable
Crank arm
Drive chain
Pedal
Chain guard
Hand crank
accessory
Rubber feet
Sprockets
Base

5
Asse bly
Follow these easy steps to assemble your Human Power Generator. Refer to the pictures at left and
the Definition of System Components, above.
Attach the Foot Pedals or Hand Cranks
1. oth the foot pedals and the hand cranks attach
to the Human Power Generator with screw
threads.
2. Attach each pedal or hand crank by screwing it
onto the end of the crank arm using the 15 mm
flat wrench (provided).
3. Within each pedal or hand crank set, one has a
left thread and one has a right thread. One will
attach with a counterclockwise turn and the
other with a clockwise turn.
Connect to a Power Pack or Other Battery
4. Align the tabs on the power cord with the
grooves in the port on the generator.
5. Holding the blue part of the plug, insert it and
gently turn it clockwise.

6
6. The grey collar will click into place to lock the
plug.
7. To disconnect the cable, gently pull back on the
grey collar until you can rotate it
counterclockwise, then pull the connector
straight out to remove the cable.
Connecting to a Power Pack or Simple 12V attery
All connecting cables contain a full wave bridge
diode in a sealed aluminum case (see left) to prevent
reverse current from traveling back from the battery
or motoring of the Human Power Generator.
The full wave bridge will also provide a consistent
polarity output that is not dependent on the
direction of rotation. In other words, this allows the
user to pedal in either direction safely with equal
results. All cables are 16 AWG
The only cable used with the Human Power
Generator that does not have an in-line diode is the
cable used with the 12VDC Educational Light ox or
the Power View Monitoring software, as the diode is
built into both of these products.

7
Connection Cable Options
Bare wire connecting cable for your own special application.
Ring ter inals (5/16th)
Plier Style Cable
The Anderson Connecting Cable
Note: Polarity (+ and -) must be observed. This kind of
connector is typically plugged into the jumper cable output
connector on a portable power pack or similar device. You
must be sure that the positive and negative terminals match
the positive and negative terminals on the power pack. The +
and – symbols are usually molded into the plastic at the
connector, indicating the polarity. If the polarity does not
match, the cable will short out and be permanently damaged.

8
You are now ready to start
generating power!
Optional Handcranks
Note: When the 12V Educational Light ox is ordered,
handcranks are automatically included.
Precautions
When moving the unit, hold it by the base of the
unit. Do not pick it up by the chain guard.
If you want to install the Human Power
Generator in a fixed location, the four rubber
feet can be removed from the bottom of the
base. The Generator can then be screwed to a
surface, such as a sheet of plywood, using the
screws and washers provided in the accessory
kit.