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.

9
Other Useful Infor ation
Battery Charging
The Human Power Generator can charge any 12V battery but is most commonly used with a
low Ah (under 20 “ampere hours” of capacity) deep cycle 12-volt battery, such as the type
used in Portable Power Packs.
To charge a battery, a DC power source of a higher voltage than the battery is connected to
the battery, positive to positive and negative to negative. As long as the charging source is of
higher voltage than the battery, current will flow into the battery until it is fully charged.
If the voltage of the charging source is less than the battery voltage, current will not flow into
the battery even though the charging source may be capable of supplying power. The Human
Power Generator will not deliver a charging current to a battery until the generator is turning
fast enough to develop a voltage higher than that of the battery. Consequently, very little
effort is required to start pedaling, but as soon as the generator voltage exceeds the battery
voltage, a greater mechanical resistance is felt as power begins to be transferred into the
battery. As the battery becomes fully charged, the mechanical resistance decreases.
The average charging current with the HPG is between 3-5 amperes.
A 12V battery with lower ampere hour capacity will take less time to charge. A battery with
very high Ah, like a car battery with 200 Ah, would take a very long time to charge.

10
It is important not to overcharge the battery. Overcharging can cause the battery to
heat up and possibly release hydrogen gas. This can damage the battery and create
a hazardous condition. This is a rare occurrence and charging with the HPG is a
relatively slow process, however, it is important to monitor the level of charge in
the battery regardless.
The Power Pack has a built-in voltage indicator allowing you to monitor the charge
status of the battery. If the indicator lights show that the battery is full, stop
charging.
If you are using the Human Power Generator with your own battery, monitor the
battery voltage to prevent overcharging. A simple voltmeter can be used to
measure output and battery voltage with certainty. A fully charged 12V battery will
read between 12.7 to 13.3V.
Battery Voltages
While the Human Power Generator is primarily designed to supply 12 V DC circuits and to
charge 12 V batteries, it can also be used, without modification, to power 6V circuits and
batteries. As with 12V batteries, be careful to avoid overcharging. A 6V battery reaches 6.3-
6.8 V when fully charged. Deep cycle batteries are best suited to this application as they are
designed to withstand repeated charge and discharge cycles.

11
Battery Connections
atteries can be connected in parallel (positive to positive and negative to negative) to
increase storage capacity at the same voltage. They can also be connected in a series string
(positive of one battery to negative of the next) to provide higher voltages, such as two 6-volt
batteries combined in series to make a 12-volt battery. See the diagram below.
12V
12V
6V6V
6V
+
+
+
+
-
-
-
-
--
++
12 VOLT PARALLEL
CONNECTION OF TWO
12 VOLT BATTERIES
12 VOLT SERIES
CONNECTION OF TWO
6 VOLT BATTERIES

12
Safety Precautions
Mechanical Operation
Keep loose clothing, hair, hands, toes, fingers, and pets away from the drive chain
and sprockets of the Human Power Generator at all times.
Do not operate the Human Power Generator barefoot.
If your Human Power Generator is assembled with foot pedals, do not operate it
with your hands.
Do not allow children to operate the Human Power Generator unsupervised.
The generation of electricity requires a certain amount of physical exertion. People
with health considerations should consult with their health care practitioners
before engaging in strenuous cranking or pedaling.
Electrical Operation
As with any electrical device, use caution with the Human Power Generator.
Although the voltage generated is low, take care not to touch any exposed wires or
to allow loose wires to touch each other.
Observe the polarity - positive and negative - of all connections.
Do not expose the Human Power Generator to water or spray.
Maintenance
Cleaning and Lubrication
Maintain the Human Power Generator as you would an ordinary bicycle, by regularly cleaning
and lubricating the drive chain and sprockets, and by keeping all surfaces and components
free of dirt and oil.

13
Main Bearings
The two main ball bearings at each end of the bearing housing are identical. If the crank
makes excessive noise or offers resistance without the chain in place, the main bearings
should be inspected for excessive tightness or misalignment. If the crank rattles while turning,
the bearing assembly may be too loose. In either case, contact Windstream Power’s Service
Department at [phone]. A bicycle repair shop will also have the required tools to
remove the crank arm and inspect or change out the bearings. We use standard bicycle parts.
Chain Tension
Periodically check the drive chain tension. If the chain makes a “growling” noise, it is too tight.
If the returning loop of the chain appears floppy, the chain is too loose. To adjust the chain
tension, remove the chain guard, and using a 10mm nut driver or socket wrench, loosen the
four generator mounting nuts. Next, adjust the generator position, and then retighten the
nuts. Replace the chain guard, ensuring there is no rubbing or scraping noises between the
chain guard and the chain or pedals.
Drive Train Align ent
It is also important to periodically check that the
generator sprocket is in line with the chain and
with the drive sprocket. Over time, the 2.5 mm
set screw that holds the sprocket tight to the
shaft will loosen. Adjust the alignment of the
generator shaft by loosening the generator
sprocket set screw (with the M2.5 hex key
supplied) and sliding it along the generator shaft
or allowing the chain to position it, then
retighten the set screw onto the flat of the
generator shaft.
If the generator does not seem to be producing
power, check if the set screw has loosened
completely. If it has, the generator shaft can
become disconnected from the sprocket so the
sprocket would no longer turn the shaft
properly. When tightening the set screw, there
should be about 1.5 mm of space between the
unit’s base and the sprocket.

14
Generator Brushes
Inspect the generator brushes about once every two to three years. rush wear is
proportional to use. The more you use the Human Power Generator, the sooner you will need
to replace the brushes. You can reasonably expect one set of brushes to last 3 to 5 years. In
order to change the brushes, follow instructions below. If you require help with this,
Windstream will do the work free of charge – minus the cost of the new brushes and the cost
of shipping.
1. To inspect the brushes, locate the brush caps on
each side of the generator (2 total). With the
Human Power Generator, there is a hole in the
base of the frame to access one of the brush
caps. The other cap is easily accessed as it is on
top.
2. Use a coin to open each cap, and then carefully
pull out each brush.
3. If the brushes are shorter than 3mm (about 1/8
in), indicated by the wear line near the base of
the brush in the image at left, or if they are
chipped or cracked, they should be replaced
(stock # 443732).
4. Replace brushes, replace cap and tighten.

15
Accessories
Stock # 341203 - Pedal set (left & right)
Stock # 371107 – 15mm flat wrench (for attaching
pedals)
Stock # 371311 – 2.5 mm hex wrench (for adjusting
sprocket)
Stock # 301114 – M4X38 Wood screws (for attaching
base to support) and
Stock # 312506 – M4 Nylon cup washers (for screws)
Stock # 341213 – Optional padded hand crank
accessory

16
Windstrea Power, LLC
Equip ent Return Policy
This Policy refers to any equipment or parts being returned to Windstream Power, LLC (WSP)
Either:
• Unused, within 30 days of purchase, for a full refund (excluding shipping) and may be
subject to a 15% re-stocking fee depending on condition of product when returned.
Or
• For repair, both under warranty (see product warranty on Page 18) or out of warranty.
You must first contact WSP for a Return Materials Authorization nu ber (RMA) before shipping any
returns. Contact our service department at [phone] to be assigned an RMA number.
• WSP reserves the right to refuse delivery of any equipment without an RMA number clearly
displayed on the package(s).
• WSP reserves the right to refuse delivery of any equipment improperly packaged.
• Any equipment or parts shipped to WSP must be insured.
Any equipment or parts shipped to WSP must include the following documentation:
• WSP RMA/Repair Order form completed by customer, unless recorded by a WSP
representative with whom you’ve spoken.
• Description of how the equipment was used.
• Reason for return.
This policy applies to both equip ent sales and repair orders. For a Return Material
Authorization, please call our Service Depart ent at [phone].

17
Return Material Authorization For
RMA Nu ber/Repair Order __________________ Windstrea Power LLC
445 Long Point Road
North Ferrisburgh, VT 05473
Phone [phone] Fax [phone]
Date: _________________________________ WSP Contact Na e: ____________________________
Custo er Na e and Address:
______________________________________ Cust. Contact Na e: ____________________________
______________________________________
______________________________________ Product Type __________________________________
Phone Nu ber: _________________________ Part Nu ber: __________________________________
Fax Nu ber: ___________________________ Serial Nu ber:_________________________________
What type of device was being powered? ______________________________________________________
What other Windstrea Power product(s) were also being used? ___________________________________
_________________________________________________________________________________________
What other non-Windstrea Power device(s) were also being used? ________________________________
_________________________________________________________________________________________
Reason for Return:
_________________________________________________________________________________________
_________________________________________________________________________________________
_________________________________________________________________________________________
_________________________________________________________________________________________
_________________________________________________________________________________________
Signed: _____________________________________
THIS DOCUMENT MAY E REPRODUCED

18
Conditions of Sale, Warranty, and Shipping Infor ation
1. PRICES
The prices shown on the published price lists are subject to change at any
time, without notice.
The product list price includes all the most commonly ordered products.
Other products, and variations on listed products, are also available. If you
need any renewable energy products not listed, write or call for availability
and prices.
Spare parts and component prices shown are on the individual parts list for
each product, available upon request.
2. ORDERS
Orders must be prepaid, and can be accepted verbally or in writing by mail,
fax, or e-mail. Confirmations, if requested, are sent promptly, indicating any
special instructions or terms, factory lead time, and planned shipping date.
Changes or cancellation: orders for catalog products cannot be cancelled or
changed after shipment. Special orders are noncancellable, and are subject
to repricing if changes are requested.
3. DISCOUNTS
Discounts are available on catalog products to quantity purchasers, dealers,
distributors, and manufacturers (OEM). For details, please contact the
company.
4. PAYMENTS
Payments may be made by money order, MasterCard or Visa, American
Express, interbank transfer (wire), or cash (factory pickup only). Payments
by check are welcome, but are subject to normal bank clearance delays.
Payments for international orders may be made by U.S. dollar bank drafts
or checks, payable on a U.S. bank; interbank transfers, or bank credit
cards.
5. DELIVERY LEAD TIMES
Orders for goods in stock are normally shipped within five working days.
Goods not in stock at the time of order will be shipped within 30 days of
order, failing which the customer will be advised.
Shipment dates of special orders are subject to arrangements made at the
time of the order.
6. SHIPPING
Shipments within continental USA and Canada are normally made by
prepaid UPS, freight or mail. Puerto Rico, Hawaii and Alaska are served by
UPS (air service only) or mail.
Express same-day, next-day and second-day air delivery service is
available on request. Factory pickup by customer may also be arranged.
International shipments are made by mail, air, or ocean freight; or air
express, as requested.
7. SHIPPING CHARGES
Shipping and insurance are charged to the customer at cost.
Nominal handling charges may be included in shipping charges.
Supplementary charges will be made for special packaging, such as export
crating, or repackaging to comply with size, weight or dimensional weight
restrictions.
8. INSURANCE
Shipments are normally insured up to the full invoice value, unless
insurance coverage is waived at the customer’s request.
The company will advise the customer before shipment in those instances
where insurance is limited or unavailable.
The receiver of the shipment is responsible to inspect the goods upon
arrival, and in the event of damage, to file a claim with the delivering
carrier, as well as to notify Windstream.
In the case of a missing shipment, the customer must advise
Windstream within thirty days of the expected arrival date. The
company cannot be responsible for loss or damage claims made after
expiration of the carrier’s or insurer’s period of liability.
9. GUARANTEE OF SATISFACTION
If a customer is not fully satisfied with a product purchased from
Windstream, the product may be returned, and the company will
refund the purchase price, subject to the following conditions:
A product returned for refund must be received within thirty days of the
date of shipment, unused and in its original condition, duly authorized
(see returns), freight prepaid, accompanied by a copy of the
customer’s invoice, and on inspection by the company confirmed to be
in unused condition.
Shipping charges are not refundable. All return shipments must be
insured, as the company cannot provide a refund if, on receipt, the
goods have sustained any damage.
ALL SALES ARE FINAL THIRTY DAYS AFTER THE DATE OF
SHIPMENT. NO REFUNDS CAN BE MADE AFTER THAT TIME.
10. PRODUCT WARRANTY
All products manufactured by Windstream are warranted against
defects in materials or workmanship for one year from the date of
purchase from the company.
This warranty does not cover damages due to shipping, improper
handling or installation, accident, misuse, acts of nature, omitted
maintenance or inspections called for in the owner’s manual, or
unauthorized service. The warranty also does not cover expenses
incurred in the removal, shipping or reinstallation of the product.
Windstream shall not be liable for any incidental or consequential
damage arising from the use of its products. Windstream makes no
warranty of merchantability or fitness for any particular purpose of any
of its products.
Products sold by Windstream but manufactured by others may be
subject to longer or shorter warranties, and such warranty terms will
supersede the general conditions shown on this page.
11. RETURNS
All returns must be securely packed, shipped freight prepaid, and must
be marked with a return material authorization number (RMA #) which
must be obtained by contacting the company. The customer’s name,
address, telephone number and written instructions must accompany
any return shipment. Customers are advised to insure return
shipments. Unauthorized returns will not be accepted.
Goods returned for exchange or refund may be subject to restocking
charges.
12. SERVICING
The company will repair or overhaul customer’s equipment, shipped
prepaid or delivered to the factory. Equipment is inspected and repair
estimates are provided without charge, prior to performing the repair.
Warranty claims should be so indicated at the time of the return
material authorization. Equipment subject to warranty will be specially
inspected to determine eligibility for warranty service.
Repairs performed by company technicians are warranted for three
months.
13. SPARE PARTS AND COMPONENTS
Spare parts, original equipment components and assembly drawings
are available for all company-manufactured products, for use in
maintenance, repairs, or for home construction – not for resale.