How to install a Pick-to-Light system

In this article we explain the individual steps of the Pick-to-Light installation. You will learn which components, tools, accessories and electrical material are required for the installation. We not only show you the installation itself, but also explain in detail the various options for installation on different shelves, tables and mobile order picking trolleys.

Which components are required for the Pick-to-Light installation?

First, the Pick-to-Light displays and their types must be defined. There are two different system variants that must first be defined (height 25mm and 50mm). Both variants can be combined with each other.
You can read more about Pick-to-Light planning in a separate article. Also have a look at the list of available Pick-to-Light hardware (displays).

For an Pick-to-Light installation you need the following components:

  1. Pick-to-Light Displays
  2. Aluminium bottom profiles
  3. BUS cable for the sub-profile
  4. Terminals for connecting the cables
  5. Cover profiles and side covers
  6. Pick-to-Light Controller

Depending on the design and function of the Pick-to-Light system, additional components such as barcode readers, RFID readers, scales, batteries, etc. may be required. In this article, we will limit ourselves to the pure Pick-to-Light installation, without additional hardware.

The required installation material

Apart from the main components described, we require the following installation material for the Pick-to-Light installation:

  1. Pop rivets or screws
  2. Cable (4-wire)
  3. Wire end ferrules
  4. Cable tie
  5. Cable entry rings (possibly)
  6. Cable conduits or cable ducts (only if required)
  7. Auxiliary angles and aluminium profiles (only if required)

The necessary tools

The following machines and tools are required to carry out the Pick-to-Light installation:

  1. High-speed aluminium saw with special blades for clean cutting of aluminium profiles
  2. Drilling machine
  3. Cordless screwdriver
  4. Drill
  5. Pop rivet pliers (best battery)
  6. Wire stripper
  7. Crimping pliers
  8. Screwdriver (cross and flat various sizes)
  9. Cutter knife

Pick-to-Light Installation step by step

1. mechanical installation of the bottom profiles

We start the installation by attaching the aluminium bottom profiles to the substructure. To do this, first cut the sub-profiles to the appropriate lengths. Next, suitable holes are drilled in the sub profiles for the fastening screws or pop rivets. Depending on the type of substructure, the Pick-to-Light sub profiles can be mounted directly or with auxiliary brackets.

Tip: During mechanical installation, special attention must be paid to sharp edges and protruding screws or pop rivets. All sharp edges must be treated or secured accordingly to prevent possible injuries.

The attachment of the Pick-to-Light bottom profiles to the construction is usually done with screws or pop rivets. In some cases (e.g. heavy-duty shelving) drilling holes is not permitted. For this, we have developed another fastening option with strong magnets. You will find out more about this later below.

2. fastening the Pick-to-Light controller

Once the bottom profiles are mounted, the Pick-to-Light controllers can be attached. The controllers can be installed directly on the shelves, on columns or walls. Sometimes small special constructions made of aluminium profiles are required.

Tip: When installing the Pick-to-Light controllers, care must be taken to ensure the correct orientation for passive cooling. The controllers contain power supply units that must be cooled. Covering the controllers is not permitted.

3. cable routes between the controllers and the Pick-to-Light sub-profiles

Depending on the installation location of the controllers, cable routes may have to be constructed for routing the supply lines. Installation pipes or cable ducts can be used for this. The services should be laid separately from the power lines (separator).

4. installation of the BUS system

Next, the BUS system is installed in the installed sub-profiles.

... further steps in the near future.