Here's how to install a pick-by-light system

In this article, we’ll walk you through the individual steps of installing a Pick-by-Light system. You’ll learn which components, tools, accessories, and electrical supplies are needed for the installation. We’ll not only show you the installation process itself, but also explain in detail the various installation options for different types of shelves, tables, and mobile picking carts.

What components are required for a pick-by-light system?

First, you need to define the Pick-by-Light displays and their types. There are two different system variants that must be defined first (25 mm and 50 mm in height). Both variants can be combined.
You can learn more about Pick-by-Light planning in a separate article. Be sure to check out the list of available Pick-by-Light hardware (displays).

For a Pick-by-Light installation, you will need the following components:

1. Pick-by-Light Displays
2. Aluminum sub-profiles
3. BUS cable for the sub-profile
4. Terminal blocks for connecting the cables
5. Cover profiles and side covers
6. Pick-by-Light Controller

Depending on the model and functionality of the pick-by-light system, additional components such as barcode scanners, RFID readers, scales, batteries, etc., may be required. In this article, we will focus solely on the basic pick-by-light installation, without any additional hardware.

The necessary installation materials

In addition to the main components described above, we need the following installation materials for the pick-by-light system:

1. Pop rivets or screws
2. Cable (4-wire)
3. Wire end ferrules
4. cable ties
5. Cable grommets (if needed)
6. Cable conduits or cable trays (only if needed)
7. Brackets and aluminum profiles (only if needed)

The necessary tools

The following machines and tools are required to install the Pick-by-Light system:

1. High-speed aluminum saw with special blades for clean cuts in aluminum profiles
2. Drill
3. Cordless screwdriver
4. Drill
5. Hair straightener (preferably cordless)
6. Wire stripping pliers
7. Crimping pliers
8. Screwdrivers (Phillips and flathead, various sizes)
9. utility knife

Step-by-Step Guide to Installing a Pick-by-Light System

1. Mechanical installation of the bottom rails

We begin the installation by attaching the aluminum base profiles to the substructure. To do this, we first cut the base profiles to the appropriate lengths. Next, we drill holes in the base profiles to accommodate the mounting screws or pop rivets. Depending on the type of substructure, the Pick-by-Light base profiles can be mounted directly or using mounting brackets.

Tip: During mechanical installation, pay special attention to sharp edges and protruding screws or pop rivets. All sharp edges must be properly treated or covered to prevent potential injuries.

The Pick-by-Light sub-profiles are typically attached to the structure using screws or pop rivets. In some cases (e.g., with heavy-duty racks), drilling holes is not permitted. For these situations, we have developed an alternative mounting option using strong magnets. You can learn more about this below.

2. Mounting the Pick-by-Light controllers

Once the sub-profiles are installed, the pick-by-light controllers can be mounted. The controllers can be installed directly on the shelves, on columns, or on walls. Sometimes small custom structures made of aluminum profiles are required.

Tip: When installing the Pick-by-Light controllers, ensure they are properly oriented for passive cooling. The controllers contain power supplies that must be cooled. Covering the controllers is not permitted.

3. Cable routes between the controllers and the pick-by-light sub-profiles

Depending on where the controllers are installed, cable trays or conduits may need to be installed to route the power supply cables. Conduits or cable trays can be used for this purpose. The power supply cables should be routed separately from the high-voltage cables (using a partition).

4. Installation of the BUS system

Next, the BUS system is installed into the sub-profiles that have been installed.

… more steps coming soon.