Rock The Bike Pedal Power Utility Box User manual

TM
USER MANUAL
you pedal,
something
amazing happens

Look for the screen icon around this manual for
video tech tips on our website.
what you will need for assembly
The Utility Box allows Up to 10 people at once to convert their
Pedal Power into usable AC power, for devices rated up to 1000W.
Circuitry and wiring are safely beneath a polycarbonate panel, while
a four-line LED Pedalometer displays current power levels, so
pedalers can adjust their effort to stay within the green range.
In our humble beginnings we ran a bike-powered smoothie booth
at Northern California music festivals called “The Juice Pedaler”.
We saw the smiles and excitement as people jumped on our bike
blender and poured their heart into a thick tangy smoothie. Now
we’re excited to have you joining our quest to spread the spirit
of pedaling.
Pedaling to generate electricity may seem like a small act, but
for many people it’ll be their first time giving energy back, which
can open the door to many other personal choices that benefit
their health and fitness and our environment. So thank you! And
please keep us posted on your progress as you Rock The Bike!
Yours,
Paul Freedman,
Founder
Green and Red LED Panel: Pedalometer
Use this display to determine when the Utility
Box is ready to power devices. Connect Rock
The Bike’s Pedalomoeter accessory, via the
Large Neutrik input on the left side of the panel
face, to display these lights on a standing tower.
Red Jack (1): Mega Input / Nutrik Input
Rated for higher levels of wattage, this allows for
more than 5 pedalers at once, by connecting
with the Pedal Power Junction Box from Rock
The Bike. Support up to 10 pedalers at once
(4 from Neutrik jacks, 6 from Mega Input), or
use it as a fifth Neutrik jack.
Contents & Anatomy .................................................. 3
Assembly .................................................................. 4
Usage Tips ................................................................ 5
Activity Tips ............................................................... 7
General Information .................................................. 10
TOOLS: None needed
TIME: Allow 60 minutes
TEAM: 1-2 people
Utility Box features these components:
find rock the bike on
Orange Jacks (2): DC Output
These power 24V DC devices such as LED
lights. Simply wire a Neutrik Speakon two-way
plug to your device, or purchase an approved
24V DC device from Rock The Bike. No bike
generators are compatible with these DC jacks.
Light Green Jacks (4): Neutrik Input
XX
Dark Green Jack (1): XX
XX
3
THANK YOU!
TABLE OF CONTENTS
contents & anatomy

This video demonstartes the technique:
youtu.be/tZH213hxD3E?t=48s
(a)
(a)
(c)
(b)
(b)
(d)
4
5
Connect one or more bike generators to the Utility Box, using the
Neurtrik connector, and any of the four light green Neutrik Input
Jacks (a). Secure the connecor with a push-and-twist motion (b).
With all connections made, and the lights on the Pedalometer still
off, instruct the pedaler to begin! As the box charges up initially,
pedaling will be difficult. Soon, a red light on the Pedalometer will
begin to blink, signaling “Voltage too low: Keep pedaling (a).”
Turn the AC inverter on by flipping its switch, located on the left
side of the Utility Box (d). To keep power flowing to your devices,
adjust your effort level to keep the lights in the green. If the lights
show a white light or a blinking white light, ease off, because you
are pedaling too hard.
When the blinking red light changes to a steady red light, power
is almost ready to use (b). When a green light comes on, you can
use AC power (c). Once voltage reaches the green target range,
pedaling will feel more like riding a bike around town.
Position the Utility Box on a table so that pedalers can see the
Pedalometer, an LED panel located inside the lid of the box.
ASSEMBLY usage tips
NEUTRIK CONNECTOR
PEDALOMETER LED PANEL
PEDALOMETER LED PANEL

Pedalometer color indicators:
• Blinking red: Voltage too low. Power about to cut! Pedal harder.
• Solid Red: Voltage low. Pedal harder.
• Green light: Voltage in ideal range. Keep pedaling.
• Green lights: Voltage in ideal range with more reserve power.
Cruise.
• Solid white light: Voltage is above ideal range. No need to pedal
this hard. Ease off.
• Blinking white light: Voltage approaching cutoff point. Stop ped-
aling to avoid protection circuit kicking in.
• All lights blinking: Protection circuit not functioning. Voltage can
climb dangerously high if pedaling continues. Stop pedaling
and replace relay!
(ignore this section if you are using a Generator Pro or Electric
Fender Blender Pro as they only have 1 gear.)
Set the gear of the bicycle so that pedaling feels like climbing a
small hill. If pedaling feels too easy, switch to a harder gear, just
like you would on a bike. It’s normal for pedaling to feel difficult at
first, if the system has been in storage.
Pedaling will get easier as system voltage rises. It it’s too difficult at
first, try shifting the bike to an easier gear. Then when the voltage
is in the ideal range, change to a harder gear so that pedaling
feels not too hard, not too easy.
Use up all the power, until the system is in a blinking red state.
Unplug all AC power devices from the AC outlet. The connections
to the Pedal Power input jacks are twist lock.
Activity tips:
The Utility Box has an Ultracapacitor that stores power. As you use
more devices or higher-wattage devices, it will feel harder to keep
the voltage in the green.
If the pedal power going in is lower than the AC power going out
(consumption), the lights will fall until you see a blinking red light,
then you’ll hear a warning beeb from the inverter, and AC power
will eventually turn off.
If you continue to pedal after the AC power turns off, the voltage
will recover, lights will turn green again, and AC power will come
back on. There is a 20-30 second delay on the inverter before
power flows again.
If power is in the green on the Utility Box, and you want AC power
to come back on as quickly as possible, cycle the power switch
on the inverter.
Always check the device’s rating before plugging it in. Never plug
in devices rated higher than 1000W! Example: electric kettle.
Use a power-measuring device such as a Kill-A-Watt to show
pedalers how much energy they are producing.
Changing pedalers:
Always adjust the seat height for each rider so they get a comfort-
able and efficient pedaling position. The leg should have a slight
bend at the bottom.
To prevent outages, ask pedalers to raise the voltage to a double
green state before getting off. This gives you time to raise or lower
the seat for the next rider and get them started.
Always stabilize the bike when pedalers are getting on and off. Do
this by standing with the front tire between your legs and holding
the handlebars firmly.
Replacing a relay:
Call us for step by step instruction if you see the warning pattern
during an event (all lights blinking fast).
PEDALOMETER LED PANEL
GEARING
TEARDOWN
67
assembly activity tips
ACTIVITIES AND GUIDELINES

big tooth
small tooth
Don’t unscrew the strain relief. Twist the whole connector, not
just the blue part
RECTIFIER CABLE ROUND CONNECTOR
GENERATOR WHEEL BIKE INPUT SOCKET
CONNECT TO
circuit box
CONNECT TO
GENERATOR
WHEEL
strain relief
thumb tab
The Rectifier Cable connects the Generator Wheel to the circuit box.
HOW TO DISCONNECT THE ROUND CONNECTOR:
1. Slide the thumb tab back toward the cable.
2. Twist the connector 1/8 of a turn counter-clockwise, then pull.
1. Join the cables’ flat connectors. If they don’t snap in, flip one
side over and retry.
2. On the right side of the circuit box is a black socket labeled Bike
Input. Insert the round connector with a push-and-twist motion.
CONNECTING GENERATOR WHEEL
activity TIPS
LED TOWER SOCKET
activity tips
8
As you pedal vigorously, a small
light inside the circuit box will turn
on. Next, the red panel will light up,
followed by blue and green.
3. Light up all three stages and main-
tain them for a few seconds. The
panels will flash in sequence to
indiate a win on easy mode.
4. As the circuit resets following this
win, all LED panels and halogen
bulbs should light up. Watch to see
that all lights are in working order.
An adjustable difficulty knob controls the five levels of resistence.
Easier modes offer less resistence, require less effort, and cannot
light the halogen bulbs on top of the green panel. Harder modes
can light the bulbs, and will challenge even strong cyclists.
1. Turn the difficulty knob to its easiest setting.
2. Get on the bike and pedal gently at first, then increase speed.
CONNECTING TOWER
TESTING THE SYSTEM
9
On the left side of the circuit box is a larger silver socket labeled
LED Tower. Attach the cable on the red panel by inserting the large
round connector with a push-and-twist motion.

Transit accessories are available for purchase on our website:
rockthebike.com/store/27-transit-accessories.
• Seat angle slips out of adjustment: Seat should be level when viewed
from the side, and have no play in the under-seat-clamp. If it needs
adjustment, open the seatpost lever, slide the post up to a high
position for better access, and close the lever. Using a 6mm hex key,
loosen the upwards facing bolt in the under-seat-clamp, adjust the
seat to level and very firmly re-tighten the bolt.
• Chain falls off chainring: Chain should be taught along its lower
section, or it could slip off under heavy pedaling. See page 8 to adjust
chain tension.
• If you’re having problems call Tech Support at 1-888-354-2453
(10am-5pm PST M-F)
Assembled Dimensions (Bike): 56” long, 39” tall, 31” wide
Assembled Weight (Bike): 60 lbs
Assembled Dimensions (Tower): 126” tall, 62” diameter at base
Assembled Weight (Tower): 35 lbs
Max. Rider Weight: 220 lbs
Min. Rider Leg Length: 23” inseam (roughly 7 years old)
Use: Household, Educational or Commercial
Manufacturer: Rock the Bike - Oakland, CA USA
TROUBLESHOOTING
SAFETY
SPECS
• Use the sUtility Box on a level surface.
• Do not use this product in the rain, snow, or other wet conditions
that could cause damage to you or your Rock the Bike product.
• Children should be supervised when using this product.
• Avoid contact with moving parts on the Generator Pro’s frame. This
includes, but is not limited to: fingers, hands, toes, feet, hair, clothing,
and shoes.
• Never operate the sLEDgehammer if the generator wheel, Pro frame,
tower, or LED panels appear damaged. Call Tech Support at
1-888-354-2453 for assistance.
general INFORMATION
Rock the Bike products come with a 2-year warranty against
manufacturing defects. This warranty does not cover damage due to
wear and tear, loss, overloading, misuse, abuse, incorrect assembly,
incorrect use, or anything else beyond Rock the Bike’s direct control.
The warranty is valid for the original owner, for purchases from an
approved distributor or dealer.
The use of an unauthorized attachments may cause injury or damage
and will void the warranty.
Store in a cool, dry place, away from direct sunlight.
WARRANTY
STORAGE
Whether you’re going to a classroom down the hall or a trade show
across the country, Rock the Bike has a helpful accessory or tip:
• Walkable: Easy Rolling Transport Wheels clip into your wheel
socket to help you roll the bike around effortlessly. Best used on
even ground.
• Bikeable: The Pro Trailer Kit slides into your wheel sockets to allow
towing behind your bicycle; the truest and most impressive way to
express your passion for human power.
• Drivable: You can load your bike into a vehicle or mount it onto the
rear of your vehicle with a bike rack. For pictures and details see:
rockthebike.com/transport-vehicle.
• Longer Distances: You can repack and ship your Fender Blender Pro
in the same box you received it. Our Pro Shipping Sleeves’ padding
will protect your frame during shipping, and has dedicated pockets
for small parts like bolts and screws. We recommend shipping
assembled Fender Blender Pros on a pallet with a freight carrier.
TRANSPORTATION
10 11
general information

TM
Rock the Bike
6323 San Pablo Ave.
Oakland, CA 94608
www.rockthebike.com
888-354-BIKE (2453)
510-338-3326
fax [phone]
[email protected]