intro
Installation Manual
PowerHive System
Figure 1 - System View
Installation Manual
Installation Manual
Version
|1 Version|1 Version|
Labels & Warnings
System Labels
System Overview
This section of the manual provides an overview of the Power Hive components.
Main System Components Installation
The installation of this system is set up such that the robot plate is located on the floor first. Once set into position, the surrounding racks are located by templates, using the robot plate as the datum. Next, the robot will be installed onto the plate and finally, the fencing will be installed to close out the cells shape. These components can be identified in Figure 2 above. Further detail can be found in the sections below.
High Voltage Power Installation
This section should be started ONLY AFTER all previous installation steps have been completed.
PowerHive Safety Fence Installation
As with PowerHive configurations, there are multiple safety fencing configurations as well. Each safety fencing configuration will have its own unique installation drawing number and will be supplied by Lion Power. An example drawing is shown in Figure 23. Follow instructions provided with the fencing kit for installation of black mesh panels to the yellow posts as well as the hinged door assembly. A quick overview of panel attachment is shown in Figure 22 below.
Electrical Cable Tray Installation
Cable trays are needed across two openings in the PowerHive: over the robot opening, and over the exit of the hallway. These trays are cut to length from a stock material and fastened to safety fence posts.
System Component Connections to Main Low Voltage Box
There are multiple components, detailed in the proceeding sections, that have cabling that route back to the main low voltage box for power and communication. These components terminate into dedicated M8 and M12 bulkheads mounted to the right side of the LV box as shown in Figure 28, Figure 29, and Figure 30. Any excess M12 and M8 cabling should be coiled up and neatly secured inside of the lower closeout panel as shown in Figure 28.
Secondary Rack Electrical Connections
Each rack is supplied with 24V power via a 6-pin 7/8-Mini cable and communication via a yellow Cat5e ethernet cable shown in Figure 31 and Figure 32. The required cable part numbers correspond to the rack position as provided in Table 4.
GL-R Keyence Light Curtain Installation
The PowerHive uses two different lengths of light curtains. The robot opening receives a tall, 1945mm curtain, whereas the hallway receives shorter 1305mm curtains on each end, connected in series. Prior to May of 2025, all systems utilized the GL-R series light curtains. Starting in August of 2025, the GL-V series light curtains became standard on all systems. The operation of both series is the same, with the GL-V series utilizing some different connectors and mounting brackets. The following sections highlight the difference between the two. There is some assembly involved with the curtains before final position installation can occur.
GL-V Keyence Light Curtain Installation
The PowerHive uses two different lengths of light curtains. The robot opening receives a tall, 1945mm curtain, whereas the hallway receives shorter 1305mm curtains on each end, connected in series. Prior to May of 2025, all systems utilized the GL-R series light curtains. Starting in August of 2025, the GL-V series light curtains became standard on all systems. The operation of both series is the same, with the GL-V series utilizing some different connectors and mounting brackets. The following sections highlight the difference between the two. There is some assembly involved with the curtains before the final position installation can occur.
Keyence Floor Scanner Installation
Floor Scanner Overview
Base of Arm (BOA) Camera Installation
The camera used to identify incoming vehicles into the hallway, among other things, is located at the base of the robot. It is screwed into the steel base plate as shown in Figure 90. The following components are used for this assembly. The subassembly shown in Figure 89 will be pre-assembled.
Hallway Person Detect Camera Installation
The hallway camera detects when someone is in the hallway and alerts the operator before starting the swap process. The following components are required for this assembly:
Robot and Hallway Red Light Installation
There are three red light assemblies, installed at the entrance and exit of the hallway, and at the robot opening.
System Health Light Tower Installation
|Lion Power PN|Description|Qty|Notes|
Parking Assist Light Installation
The parking assist light informs drivers entering the hallway when to stop via a green illuminated light bar. This section walks through the installation in its standard location; however, the power cable is long enough to accommodate any location along the hallway on either side.
Removable Panel Safety Switch Installation
Table 11: Removable Panel Safety Switch Components
Connecting Power, Air, and Communication to Robot
|Lion Power PN<br>(Supplier PN for Field ID)|Description|Qty|Notes|
Operator Pressure Pad Installation
Table 12: Operator Pad Components
Hallway Protections Installation
|Lion Power PN|Description|Qty|Notes|
External Emergency Stop Button Installation
Figure 122: External ESTOP location.
Visual Management / Signage
General Flow Signage Locations
Hallway Floor Markings Installation
Table 13: Floor Marking Components
Rack Closeout Panels Installation
|Lion Power PN|Description|Qty|Notes|
Installation of Charger Assemblies
|Lion Power PN|Description|Qty|Notes|
System Commissioning
System Installation Checklist
Troubleshooting
TODO
Appendix
Installation Checklist
Additional Support
For additional support with the product, please contact your local service provider.