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Raw Desigh PowerPUC G4 Instructional Sheet

Wheel lighting kit
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METRICFATS.COM  
Thank  you  for  purchasing  your  new  POWER-­‐PUC™  Wheel  Lighting  Kit.  
The instructional sheets that follow are thoroughly detailed and should be studied
BEFORE picking up a tool. Take your time, work safe and you will enjoy your new
POWER-PUC™ Wheel Lights within a few hours.
ATTENTION:
You should ALWAYS disconnect your battery before performing any
electrical work.
Although the following instructions show a particular make and model of bike, virtually
every installation process will be identical regardless of bike. Also, the bike shown has a
completely flat rotor. Yours may be different. Not to worry. POWER-PUCs are made to
fit your particular bike. In some cases you may find it easier to install the rear PUC on the
drive sprocket or pulley instead of the rotor (recommended location is normally marked
on packaging). As long as you have read the following instructions and are aware of the
general operation of the system, you should have no problem. Lastly, these instructions
address installation of the PUCs themselves. Because of almost limitless combinations,
detailed instructions for installation of LEDs on the wheels is impractical. However, there
may be a future article on some simple layouts. But if you have a basic knowledge of 12
volt wiring and use some common sense you should not have any issue installing LEDs.
Just remember, ANYWHERE you will be using double-stick tape, the surface
MUST be perfectly clean. Also, all wires, LEDs etc. that are on the wheels must be
thoroughly restrained.
Let's get familiar with the kit and how it works.
(Pictures are representative only. Your PUCs may be of different sizes)

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Summary of Contents for Raw Desigh PowerPUC G4

  • Page 1 METRICFATS.COM   Thank  you  for  purchasing  your  new  POWER-­‐PUC™  Wheel  Lighting  Kit.   The instructional sheets that follow are thoroughly detailed and should be studied BEFORE picking up a tool. Take your time, work safe and you will enjoy your new POWER-PUC™...
  • Page 2 The G4 PUC Our New G4 POWER-PUC™ is a substantial advancement in RAW Design’s (Patent Pending) Wheel Lighting Systems. Below is a picture of the system. The 2 copper colored rings are the “PUCs”. The PUCs are mounted directly on the wheels (…actually rotor, pulley or sprocket) and will obviously spin with the wheels.
  • Page 3 The PUC and Brush Holder’s wiring is color coded and matched. This will become important if you are using RGB LEDs or want to experiment with some advanced effects (Don’t ask. If you’ve got the electrical experience, you’ll see the possibilities and figure it out) The order of the wires as they come out of the Brush Holder are Black, Red, Green, Blue.

  • Page 4: Installation

    Installation Part 1: locating the PUC In general, it will be easier to work if you get the wheel slightly off the ground. Because it was easier to photograph, these instructions show the system being mounted to the “profile” side of the bike. This means it is the right side (as seated) of the bike that is easiest to see when it is on the kickstand.
  • Page 5 Next, you’ll need to create a small gap between the wheel spacer and fork in order to install the Universal Mount. To do this, loosen the axle bolts / clamps just a few turns. Sometimes, the side you loosen will be where the gap naturally shows up. Other times it will be the opposite side.
  • Page 6 Pick up one of the PUCs and examine it. You will see it has a split as shown below. There is an interlocking notch on either side of the split. Forget about double stick or Velcro for now. Take the split ring and “screw” it over the fork like is shown in the lower left picture.
  • Page 7 It’s very important that the ring be concentric, or centered, on the wheel within about 1/16”. On most bikes there is an existing feature of the wheel that will substantially help you with this. It can be an existing bolt pattern, shoulder of some sort, or other natural feature on the wheel.
  • Page 8 If you can mount your PUC with one of the “natural” alignment features mentioned above - great. On rare occasions where no natural features exist, you can create your own. It will be like putting a Dime on top of a Quarter and just making sure the dime is centered.
  • Page 9 PART 2: Mounting the PUC Cut lengths of the included velcro strip into sections that are about 1/8” longer than the width of the PUC. A good pair of scissors works well. Do this while the 2 halfs of the Velcro strips are together - and keep them that way.
  • Page 10 There is a foil pack of adhesive promoter included in your kit. Once you know where the Velcro will mount, tear off a corner of the pack and pull a section of the applicator out without removing it. Wipe the entire area with the promoter, peel the protective film from the double-stick on one side of the Velcro and apply to the rotor.
  • Page 11 For the moment, get the PUC wires out of the way so you will be able to spin the wheel without them getting caught anywhere. Tuck them inside and add a piece of tape to hold them there. Step 3. Checking concentricity (alignment). Making sure the PUC is concentric with the wheel is very important.
  • Page 12 First, draw lines at the 12, 3, 6 & 9 o’clock positions. Put the mounting bracket back on and make sure it’s seated against the axle. Pick a tooth on the mount and use it as a guide again to mark a line as you rotate the wheel.
  • Page 13 New line showing misalignment...
  • Page 14 At the 9 o’clock position, the line we drew is on the inside edge of the outermost ring. The 3 o’clock position in the right picture shows the line on the inside edge of the second ring. Notice Difference. They need to be the same. We can see the PUC needs to move towards the 9 o’clock position, so we’ve marked the rotor at the edge of the PUC to again use as a reference.
  • Page 15 Slide the Universal Mount off again just to make it easier to work. CAREFULLY work your way around the PUC and use your fingertips to separate the Velcro halves while making sure not to separate the velcro from the rotor or PUC. Do a little at a time to prevent bending the PUC.
  • Page 16 In this picture, notice the wider space to the left of the most recent reference mark we put on the rotor. That’s because we moved the PUC slightly (one ring width) towards the 9 o’clock position and put the mount back in place to check everything. Notice how the mounts’...
  • Page 17 Alignment check, 12 o’clock position (Good)
  • Page 18 Alignment check, 9 o’clock position (Still good)
  • Page 19 Step 4. Mounting the Brush Housing Now it’s time to mount the Brush Housing. Let’s take a closer look for a minute and see exactly how it works. If you understand what you are working with it’s less likely you will make a mistake.
  • Page 20 The universal bracket fits every bike we’ve run across so far. “Universal” means you have to do a little work to fit your particular bike (Very little though. About 15 minutes worth.) Here’s how. Since the Brush Housing contains spring-loaded brushes, there needs to be a consistent space between the housing and PUC.
  • Page 21 With your 3 hand, draw a line where the mount touches the Brush Housing. This will give you the offset the mount needs to be bent to. Now on some bikes, it will have gone just as described. On others the bracket will have fit perfectly, as-is. And still others, the bracket would have missed completely.
  • Page 22 Using a vice is the easiest way to do this, as it will help make straight and even bends. In a pinch, 2 pairs of pliers held parallel on either side of the bend line will work. First clamp the bracket with the “Y” in the jaws and the end of the slots even with the top of the jaws.
  • Page 23 Place the mark you made on the housing on the line between the jaws of the vice. Now bend the bracket back towards the vertical position until the mount is about 1/8” (or the width of the wire tire) beyond the housing. Get this as close as possible. Some minor, final adjustment will most likely be necessary after final assembly anyway.
  • Page 24 Snug the axle bolt / clamps. Each brush must contact ONLY ONE copper ring. Test for this by slowly spinning the wheel while keeping an eye on the contact points. If the brushes are consistently off in one direction, you can adjust the housing with the 2 mounting screws. If they move from off in one direction to off in another, you will have to adjust the PUC as described earlier in these instructions.
  • Page 25 The following are GENERIC instructions for remotes. Instructions that come with your remote should supersede the below. If you are using an On / Off remote, or a Multi-Function remote: 1) Connect the red, green and blue wires from the Brush Housing (BH) together with the “12V OUT”...
  • Page 26 The following are GENERIC instructions for remotes. Instructions that come with your remote should supersede the below. If you are using a Color Changing (RGB) remote: 1) Connect the blue wire from the Brush Housing (BH) to the blue wire from the remote.