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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 materials 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 picking trolleys.

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

First of all, 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 find out more about Pick-to-Light planning in a separate article. Also take a look at the list of available Pick-to-Light hardware (displays).

You will need the following components for an Pick-to-Light installation:

  1. Pick-to-Light Displays
  2. Aluminum sub-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

In addition to 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 brackets and aluminum profiles (only if required)

The required tools

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

  1. High-speed aluminum saw with special blades for clean cutting of aluminum profiles
  2. Drill
  3. Cordless screwdriver
  4. Drill
  5. Pop rivet pliers (preferably rechargeable)
  6. Stripping pliers
  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 sub-profiles

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

Tip: During mechanical installation, particular 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 Pick-to-Light bottom profiles are usually attached to the structure using screws or pop rivets. In some cases (e.g. heavy-duty shelving), drilling holes is not permitted. We have developed another fastening option for this with strong magnets. You can find out more about this later below.

2. mounting the Pick-to-Light controller

Once the sub-profiles have been fitted, the Pick-to-Light controllers can be attached. The controllers can be installed directly on the shelves, columns or walls. Sometimes small special constructions made of aluminum profiles are required.

Tip: When installing the Pick-to-Light controller, ensure the correct alignment 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 where the controllers are installed, cable routes may need to be created for the supply cables. Installation pipes or cable ducts can be used for this purpose. The power cables should be routed separately from the power cables (separator).

4. installation of the BUS system

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

... further steps coming soon.

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