Zira AI Vision / Lighting installation guide
Quality inspection starts with a clear image.
Create a consistent view for your AI camera with a practical four-bar lighting setup, a complete equipment list and a measured commissioning process.
Setup at a glance
Fixture specifications describe the hardware. The lux figure is a starting target you measure on your own line during commissioning.
Manufacturer data per bar: approx. 26 W, 4,500 lm, 120° emission, IP54.
Measure on site. Not a live reading and not a guarantee that four bars reach it.
01The four-bar arrangement
Light the perimeter. Keep the camera fixed.
Product size, camera resolution and the smallest defect you need to see determine the final geometry. There is no universal frame height or rail length.
Fix the camera view first
Choose working distance and optics so the whole inspection area is visible and the smallest required defect has usable detail. Mount the camera rigidly and mark the accepted position.
Place two bars along, two across
Two bars run along the conveyor and two run across it, forming a rectangle around the camera view. Aim them down and inward.
Tune edge and corner coverage
Check the center, edges and corners on your largest product. Corners and perimeter boards are where shortfalls usually show first.
Adjust lights independently of the camera
Make bar height, spacing and angle adjustable on their own, so tuning the light never moves the accepted camera view.
02Equipment list
Exact parts. Clear quantities.
The baseline for one four-bar station. Part numbers are selectable and copyable. This page does not sell or process orders.
Tick items as you source them. Ticks stay in this browser only.
| Qty | Item / part number | Installation note | Link |
|---|---|---|---|
| 4light bars | LEANLED II CLEAR light bar, 1020 mm111010-06 |
Each includes flat and swivel bracket pairs. Clear cover, non-cascadable. 24 V DC ±10%, approx. 26 W, 4,500 lm, 5700 K, CRI >85, 120°, IP54. | View product |
| 4cables | 5 m M12-A to open-lead cable, 4-wire200100-04 |
One independent feed per lamp. Do not daisy-chain. Verify the actual route length. | View product |
| 2power supplies | 24 V DC supply, 90 W / 3.8 A, NEC Class 2PIM90.245-L1 |
100-240 V AC input. Each feeds two lamps in parallel, about 52 W / 2.17 A. Keep the two outputs separate. Do not parallel the supplies. | View product |
| 1set | Rigid frame, 1515-series T-slot profile | 4 perimeter rails plus supports, anchors and matched fasteners. An existing suitable frame may be reused. The fabricator sets rail lengths, spans and loading. | View product |
| 8starter allowance | Cable-tie mounting blocks12316 |
Adjust to the actual cable route. Keep cables clear of pinch points, moving parts and the camera view. | View product |
| 1per team | Light meterLT300 |
One per commissioning team, or reuse a suitable calibrated meter. | View product |
| Sitedesigned | Electrical enclosure and protection | Enclosure, DIN rail, terminals, disconnect, circuit protection, cable glands, strain relief. Rated by qualified site electrical personnel. | Site-specific |
Power arrangement
Two separate regulated 24 V DC supplies, two lamps each. Four lamps total about 104 W, which is more than one 100 VA Class 2 output should carry, so never place all four on a single supply. Confirm polarity, connector pinout and cable capacity against the manuals. No hot-plugging.
PIM90.245-L1
PIM90.245-L1
Confirm stock, pricing and delivery with the supplier before ordering, and check the label on the delivered fixture.
03Installation
Six steps, in order.
Fit the largest product and the full inspection view before you finalize the light frame. Protect the line's required clearances and maintenance access.
Step A: Define the inspection area and largest product
Mark the exact area the camera must see and the biggest product that passes through it, including relevant product heights.
Step B: Fix camera framing and usable defect detail
Confirm the full area is in view and the smallest required defect is resolved. Avoid relying on digital zoom. Lock and mark the camera mount.
Step C: Mount and aim the bars with the supplied brackets
Use the included flat or swivel brackets and suitable frame adapters. Two bars along the conveyor, two across, aimed down and inward. Keep at least 10 cm between each emitting surface and any object.
Step D: Connect the independent 24 V supplies
Qualified electrical personnel complete isolation, protection and fixed wiring. Two supplies, two lamps each, outputs kept separate. Disconnect power before connecting; do not hot-plug.
Qualified electrical personnelStep E: Tune and lock camera settings
Set the shortest practical exposure for conveyor motion, low gain, then fix focus, exposure, gain and white balance where supported. Avoid an unverified dimmer in the baseline.
Step F: Validate with actual Zira snapshots
Review full-resolution frames at production speed before running the diagnostic trial.
Qualified electrical installation only. No hot-plugging. At least 10 cm from the emitting surface to objects. Never cover the fixture with film or cloth. IP54 does not make an installation washdown-rated.
04Commissioning and validation
Check the image. Validate the setup.
Acceptance is based on the product plane and the exact frames Zira captures, at production speed and with the intended exposure and frame rate.
Step 1
Actual-image test
Open full-resolution Zira snapshots taken at production speed with the intended exposure and frame rate. Check for:
- Motion blur on moving product
- Glare and clipped highlights
- Dark regions that hide the target, especially corners
- Banding from light or exposure interaction
- Dark and light wood, center and edge detail
Fix accepted focus, exposure, gain and white balance. Revalidate after any change to lighting, camera position or settings, or product presentation, and keep training and production imaging conditions the same.
Step 2 Diagnostic, not acceptance
Diagnostic trial
Include dark and light wood and defects at the center, edges and corners. Log each pass and review the exact frame the model judged.
This trial is diagnostic, not statistical production acceptance. Agree the final representative acceptance plan and performance targets with the Zira AI team.
05FAQ
Common questions
Is the LEANLED II CLEAR a diffuse light?
No. Part 111010-06 is the clear-cover version. It suits the general four-bar baseline. For glossy or wrapped product where glare is the problem, trial a shielded hood with diffuse light instead, and revalidate exposure afterward.
Will this setup detect raised nails?
Not on its own, and no detection is guaranteed. Strong, even fill can soften the shallow shadows that reveal slightly raised nails. Run the separate raised-nail trial with directional light and an oblique camera view on real defects before agreeing coverage.
Does this light the underside of the pallet?
No. The four-bar station lights the surface the overhead camera sees. Underside views need their own camera position and their own lighting, commissioned separately.
How do I check illumination and flicker?
Use the light meter for the nine-point illuminance grid. A lux meter does not detect camera-visible flicker, so also review snapshots at the production shutter speed and frame rate for banding or brightness changes. A two-lamp test of this fixture was reported without observed flicker; confirm the same on your four-bar installation. Leave dimmers out of the baseline unless verified.
What should we check at the start of each shift?
Lights on and stable, lenses and protective windows clean, camera view unobstructed, mounts and aim unchanged, and representative test images readable. Keep the lights on during inspection, log lighting faults and recheck after maintenance. IP54 is not a washdown rating, so clean accordingly.
Can I source these parts in my region?
Each item in the equipment list links to a product page. Order by exact part number and confirm stock, pricing and delivery for your region with the supplier.
Take the full guide to the line.
Fixture details, the equipment list, mounting and power notes, the commissioning worksheet and the diagnostic trial, in one printable PDF.