Troubleshooting a Pack-to-Light Station

Use this guide to troubleshoot connectivity and operational issues with your Pack-to-Light system.

Table of Contents

• Confirm the Packing App Version for Pack-to-Light
• Verify the Pack-to-Light Driver Installation
• Check Pack-to-Light Hardware Connections
• Confirm Basic Pack-to-Light Operation

Confirm the Packing App Version for Pack-to-Light

Pack-to-Light is only supported in the most recent versions of the ShipHero Packing App.

Required version (Windows): 0.7.4 or newer. This version contains the code needed to operate the Pack-to-Light hardware.

Best Practice for Installation

1. Uninstall any existing versions of the ShipHero Packing App from the machine.
2. Navigate to My Account > Apps and install the latest versioin for your operating system.

How to Verify Your Installation Version

1. Open the ShipHero Packing App.
2. Navigate to Utilities in the top menu.

3. Select Pull Logs.

   

   A log file opens, or its location is revealed. Review the log; the version number is usually listed near the beginning.

   If the version isn't visible in the log:

   • Close the log file and the Packing App.
   • Navigate to the folder where logs are stored and delete the existing log file(s).
   • Relaunch the Packing App and log in.
   • Go back to Utilities > Pull Logs. A new log file generates containing the version number.

   If you're not running version 0.7.4 or newer, follow the installation steps above.

Verify the Pack-to-Light Driver Installation

Pack-to-Light requires a specific driver to communicate with the packing station computer.

• Required driver: Silicon Labs CP210x USB to UART Bridge.
• Driver source: Silicon Labs CP210x drivers.

Verification steps:

1. Connect the ShipHero Shield Hub to the packing station via USB. The lights on the Hub should begin "breathing" (cycling through colors).
2. Open Device Manager on the Windows PC.

3. Expand the Ports (COM & LPT) section.

   

4. Look for an entry named Silicon Labs CP210x USB to UART Bridge (COM#). The COM# varies.

5. Optional: Right-click the device, select Properties, and check the Device status tab to confirm it reports "This device is working properly."

   

If the driver is missing or showing an error, download and install it from the link above.

Check Pack-to-Light Hardware Connections

Correct physical wiring is crucial for the lights to function.

Hub connection: Ensure the ShipHero Shield Hub is securely connected to the PC via USB, as verified in Verify the Pack-to-Light Driver Installation.

Light Daisy-Chaining

1. The first cable runs from the Hub to the INPUT port of the first light module in the chain.

2. A second cable runs from the OUTPUT port of the first light module to the INPUT port of the second light module.

   

Continue this pattern (OUTPUT of the previous light to INPUT of the next light) for every connected light module.

Ensure every connection is snug and that the IN/OUT sequence is followed correctly.

Confirm Basic Pack-to-Light Operation

Once the driver, app version, and hardware connections are verified, confirm the basic operational workflow:

• Ensure your Pack-to-Light system is configured in ShipHero (Force Allocate barcodes/QR codes created, locations defined). This is normally done during initial setup.
• Open the ShipHero Packing App.
• Scan the appropriate QR code to associate the packing station with the correct location prefix (Force Allocation).
• Open an order that requires picking from the Pack-to-Light locations.
• The lights corresponding to the required product locations should illuminate.