Rack System

The Rack System is the grouping of racks and their components. This system includes the voltage systems, battery chargers, and material responsible for holding the batteries and other components.

Rack systems may differ in layout, ranging from 1 to 3 racks, based on each customer’s needs, but the parts and servicing methods remain the same across different rack kits.

Racks

There are several types of racks. Each rack will have the same frame but may have different components depending on the intended functions and location of that rack.

Each Hive has a “Primary Rack.” The Primary Rack contains a special high voltage panel to support 8 chargers, a robot, and a low voltage system. The Primary Rack also includes a low voltage panel which houses the safety system and main system controller.

The servicing on the Primary Rack does not differ from the generic racks except for additional space claims used to provide tool clearances to work around the other subassemblies contained in the Primary Rack.

Figure 28: Primary Rack (Rack 1) Exploded View

Subassemblies	Part #	Quantity
Main Low Voltage Box	101847	1
Low Voltage Distribution Plate	101777/103234	1
High Voltage Box	Varies by number of breakers	1
Robot Controller Assembly	101099	1
Pneumatic Sub-Assembly	101877	1
Charger Sub-Assembly	101878	Varies
Battery Charging Bay Assembly	Standard: 102719, XL: 102723	Varies
Battery Storage Bay Assembly	Standard: 103190, XL: 103189	Varies
Low Voltage Side – Closeout Panels	102162	1
High Voltage Side – Closeout Panels	102165	1
Door Assembly	102160	1

Rack Replacement

Full rack replacement is unlikely, and any rack damage should be reviewed on a case-bycase basis with the Concentric service team.

• The Primary Rack includes the robot controller. If the robot controller sustains damage, Kawasaki USA should be consulted for evaluation and next steps.

Rack Doors

Subassemblies	Part #	Quantity
Left Door	101916	1
Right Door	101915	1
Door Magnet	101963	1

Door Installation

Doors are supported on the rack with four (4) hinge pins (2 on upper door and 2 on lower door). The doors are then locked using electromagnets located along the centerline of the rack. Finally, the door is held tightly to the rack at the top and bottom edges using the flex of the door against rubber bumpers. To install these doors:

1. Locate the upper and lower portion of the pre-assembled doors. Starting with the top, slide the door onto the mating hinges and install one pin per hinge.

2. The upper pin on each door section must be installed from the underside due to space constraints.

Figure 29: Rack Door Assembly

3. These underside pins are secured into place with snap-in retaining rings (see image for clarity).

4. Close the doors and ensure the top and bottom edges are engaging with the

Figure 30: Hinge Pins and Snap Rings - Locations and Orientations

rubber bumpers when the magnets engage.

• a. Adjust threaded rubber bumpers in or out accordingly to provide sufficient resistive force for the doors.

• b. The magnets have a small amount natural holding force that you can hear engage when the doors get close enough to the rack. The system is designed such that these magnets will not secure the door when power is cut. The doors will pop open.

Door Replacement

1. Open the door to expose the removable hinge pins on the inside.

2. Doors can be removed as a single piece or split into two for easier removal.

   • a. To split doors, remove the five (5) - M6x10mm SHC screws at the center seam of the door. They both can hang from the rack independently.

3. Remove the snap rings from the upper pins installed from the underside of the hinge.

4. Slide the upper and lower pins out of the hinges.

5. The door is now free to remove from the rack and a new one can be installed using the above steps in reverse.

Hinge Installation

Rack door hinges have two (2) individual PNs, 101185 for the door side and 101186 for the rack side. There is also an aluminum spacer (PN 101129), that gets installed underneath the rack side hinge to space the door appropriately off the rack.

To install a door hinge:

1. Install the rack side hinge and spacer using two (2) – M5x20mm button head screws.

2. To install the door side hinge, first slide the hinge leaf onto the M5 door studs and secure using two (2) – M5 flanged nuts.

a. The door side hinge comes from the vendor with the hinge pin installed. Pay special attention not to lose this pin. Hinge Replacement The door of the affected hinge will need to be removed first to replace the hinges. See Door Replacement instructions above.

Replacement instructions above.
To replace the hinges (after door is removed):
1.<br>Remove the 5 - M6x10mm SHC screws at the center seam of the door to split the
doors into two (2) sections.
2. Remove snap rings from the door pins and set aside.
3. Remove the hinge pins from the portion of the door to be removed.
4. With the door section removed from the rack:
a. For the door-side hinge, remove the two (2) M5 flanged nuts from the door
studs.
b. For the rack-side hinge, remove the two (2) – M5x20mm button head screws
from the rack.
5. Reinstallation is opposite of the steps above.
Handle Installation
The door handle is secured to the door using two (2) – M4x6mm SHC screws. To install a
handle:
1.<br>Open the doorsto gain access to the inside of the door.
a. For technician access to the system, follow the instructions in section 6.1
2. With the handle lined up with the screw holes on the door, install the two (2) - M4
screws to secure the handle.
Handle Replacement
1.<br>Open the door to gain access to the screws.
2. Remove the two (2) - M4 screws to free the handle from the door.
3. Procced with steps from “Handle Installation” above.
Magnetic Lock Installation
The magnet is secured to the door using 2 – M4 nuts. To install a new magnet:
1.<br>Open the door to gain access to the inside of the door.
2. Slide the magnet onto the M4 studs installed into the door. Holding the magnet in
the middle of the slot travel, install the 2 - M4 nuts to secure the magnet.
3. Close the door and ensure that magnet is mating with electromagnet unit installed
on the rack.
Magnetic Lock Replacement
1.<br>Open the door to gain access to the M4 nuts.
2. Remove the M4 nuts to free the magnet from the door.
3. Proceed with steps from magnetic lock installation above.
Door Bumper Installation
Rubber door bumpers are molded over an M6 stud. These bumpers are threaded into a
dedicated location at the top, middle and bottom of the rack along the centerline such that
both doors will contact each bumper. To install a bumper:
1.<br>Open the doors to gain access to the rack frame.
2. Install bumper into threaded M6 hole located at the top, middle, or bottom bracket
along the centerline of the rack frame.

3. Close the door and ensure the door is contacting the bumper.

Door Bumper Adjustment

This service piece is for adjusting the rubber bumper, so that the rack doors close and open with appropriate pressure and spring. With properly adjusted bumpers, the door should spring open when prompted via the service page of the HMI screen.

Door Bumper Replacement

To replace a bumper:

4. Open the doors to gain access to the rack frame.

5. Take note of the bumper gap from the bracket.

6. Unscrew the affected bumper from the threaded bracket.

7. Install a new bumper using the same gap as the original.

8. Confirm that the doors spring open when prompted.

Battery Charger

Figure 31: Battery Charger Assembly

Subassemblies	Part #	Quantity
Charger	101878	1
Right Bracket	101801	1
Left Bracket	101800	1
Alternative: Single shelf to replace right and left brackets	103343	1
M5x10 SHC Screws	101925	4

• Charger Installation The charger is suspended underneath the battery charging bay using two (2) hanger straps and a rear support channel. If a charger needs to be replaced, follow steps below: 1. Locate the HV panel supplying power to the charger. 2. Shut off power to the rack via the disconnect handle on the front of the HV panel. a. Follow all applicable lockout/tagout procedures.

• 3. Locate the charger in need of replacement and disconnect the following connectors: a. Battery cable assembly (Anderson connector with two (2) – 2/0 cables)- front surface.

• b. M12 screw connection beside battery cable connection – front surface.

• If equipped with a blue ethernet cable routing to the back of the charger, disconnect the RJ45 connection – back surface.

  4. The connections at the back of the charger can be accessed from the top (via the access port in the battery support plates) or from underneath the charger through the middle of the charger support brackets. In either case, the battery above or below will need to be removed to gain sufficient access to connectors. a. Quarter turn NEMA power plug at back of charger b. If equipped with a blue ethernet cable routing to the back of the charger, disconnect the RJ45 connection – back surface.

  5. Once all cables are disconnected, support the front of charger and slide charger brackets out of the hanger slots. a. Once out of the slot, rotate hangers out of the way.

  6. Lift charger assembly up and out of the back slots supporting the rear of the charger.

  7. Pull charger assembly out of rack. 8. Place the charger on its side and remove the four (4) M5x10mm SHC screws holding the two mounting brackets to the bottom of the charger.

  8. Move the mounting brackets to the new charger to be installed. 10. Lift charger assembly back into place, starting by sliding the rear of the charger into the slots on the back support.

  9. Supporting the front of the charger, rotate the hangers back vertically and pull out slightly to reinstall bracket hooks into hanger slots. a. At this point, the charger is fully supported.

  10. Proceed to reconnecting electrical connections: a. NEMA 480V power connection at back of charger b. Blue ethernet cable at back of charger (if equipped) c. Anderson battery cable at front of charger d. Threaded M12 CAN connector at front of charger.

  11. Once all connections have been confirmed secure, power can be restored to rack via the HV Panel disconnect handle.

Brush Bracket Assembly for Charging Bay

) WS<br>a		J
Subassemblies	Part #	Quantity
Charge Bay Brush Assembly	101709	1

Brush Assembly Removal

The brush assembly at each charging bay is secured to the horizontal rack member via two (2) – M8x16mm flanged hex head screws. To remove this assembly:

1. Remove the yellow ethernet cable providing power to the assembly.

2. Remove the blue ethernet cable communicating with the charger (if equipped)

3. Disconnect the two (2) – 2 pin Molex connectors for brush temperature monitoring. 4. Disconnect the main 23 -pin Ampseal Connector at the back of the assembly.

4. Cut the zip ties securing the harness to the back of the assembly.

5. Lay the harness down and out of the way.

6. Remove the two (2) – M8x16mm flanged hex head screws holding the assembly to the rack.

7. Lift the assembly out of the rack.

• a. The assembly has a metal support bracket that sits on top of the plastic bracket to protect the plastic during fastener tightening. Pay attention not to lose this part as it will be reused for reinstallation of a new brush assembly.

• Brush Assembly Installation 1. Place the brush assembly into position at the back of the charging bay, lining up the assembly with the holes in the horizontal rack member. a. Ensure metal support bracket is installed over top of plastic bracket before fastener tightening.

Brush Assembly Installation

2. Install two (2) – M8x16mm screws into dedicated holes and torque t

• XX N-m. 3. Reconnect the following electrical connections: a. Yellow ethernet cable provides power to the assembly. b. Blue ethernet cable communicating with the charger (if equipped)

• c. Two (2) – 2 pin Molex connectors for brush temperature monitoring d. Main 23 -pin Ampseal connector

• 4. Resecure harness to the assembly using zip ties at the dedicated securement points.

Brush Bracket Assembly for Storage Bay

Figure 32: Storage Bay Bracket Assembly

Subassemblies	Part #	Quantity
Storage Bay Brush Assembly	101880	1

Storage Bay Assembly Removal

The storage bay assembly is best identified by its lack of charge brushes. Each storage bay assembly is secured to the horizontal rack member via two (2) – M8x16mm flanged hex head screws. To remove this assembly:

1. Remove the yellow ethernet cable providing power to the assembly.

2. Disconnect the main 23 -pin Ampseal Connector at the back of the assembly.

3. Cut the zip ties securing the harness to the back of the assembly.

4. Lay the harness down and out of the way.

5. Remove the two (2) – M8x16mm flanged hex head screws holding the assembly to the rack.

6. Lift the assembly out of the rack.

   • a. The assembly has a metal support bracket that sits on top of the plastic bracket to protect the plastic during fastener tightening. Pay attention not to lose this part as it will be reused for reinstallation of a new brush assembly.

Storage Bay Assembly Installation

1. Place the brush assembly into position at the back of the storage bay, lining up the assembly with the holes in the horizontal rack member.

   • a. Ensure metal support bracket is installed over top of plastic bracket before fastener tightening.

2. Install two (2) – M8x16mm screws into dedicated holes and torque t

• XX N-m.

3. Reconnect the following electrical connections:

   • a. Yellow ethernet cable provides power to the assembly.

   • b. Main 23-pin Ampseal connector

4. Resecure harness to the assembly using zip ties at the dedicated securement points.

Brush Replacement (Rack and Cradle)

Part Description	Part #	Quantity
SCREW, FHT, M5 X 18 THREAD FORMING	101744	4
LID, BRUSH ENCLOSURE	101705	1
BRUSH, CARBON	102060	1
PLATE, SPRING	102068	1
SLEEVE, SPRING	102820	4
SPRING, COMPRESSION, 78LBS/IN	102821	4
THERMISTOR	102032	1

5. Remove the 4 screws holding the brush enclosure lid in place.

Figure 33: Brush Enclosure Lid Removal

6. Locate the back of the assembly and disconnect the temperature thermistor connector from the main harness.

7. Next, remove the M8 fastener and locknut holding the brush cable to the bulkhead.

8. Slide the brush and temperature thermistor out through the front opening.

9. Before installing a new brush, ensure the rear metal frame, spring sleeves, and springs are installed as shown below.

   • Ensure slot for temperature thermistor service in the metal frame lines up with the opening in the plastic main bracket. Also ensure notches of the plastic spring sleeves line up with the notches in the main brush bracket.

10. If the thermistor is not damaged, remove it from the old brush and install onto the new brush.

11. When installing the new brush, ensure the tabs on the back of the brush fit inside of the mating springs.

12. Reinstall the front lid with 4 screws.

13. Reconnect the temperature thermistor into the main harness.

14. Reconnect the brush cable/shunt into the bottom of the bulkhead using the existing M8 stainless screw. Torque to 6.8 N-m (60 in-lbs).

Front Rack Securement Lip

Subassemblies	Part #	Quantity
STANDARD BATTERY FRONT LIP	102151	1
XL BATTERY FRONT LIP	102585	1
XL LIP – PLASTIC PLANE MARKER	102881	1

Front Rack Lip Removal (Standard and XL)

The front rack lip keeps the battery in position when the robot releases from the pin. To remove this lip:

1. Remove the two (2) – M8x16mm flanged hex head screws holding the assembly to the rack.

Front Rack Lip Installation (Standard and XL)

1. Place the lip over the front screw holes and secure to the horizontal rack member with two (2) – M8x16mm flanged hex head screws.

XL Battery Front Lip Assembly

The lip for the XL battery requires an additional plastic “plane marker” to be installed if damaged.

1. Line the plastic marker, 102881, up with the mating area of the XL front lip, 102585.

2. Push the plastic into place until the plastic bottoms out on the metal.