Connecting ADR lighting: points of attention and practical tips

Installing ADR lighting involves more than installations on regular vehicles. The complete wiring harnesses must meet strict requirements to minimise the risks of accidents.

In this article, you will read:

• What to pay attention to with ADR lighting
• Which cable types are suitable for ADR vehicles
• How to avoid problems with humidity, EMC or inspections
• Attention points for mounting and IP values

What is relevant when installing from ADR legislation?

ADR regulations do not set requirements for the light itself. But chapter 9.2.2 of the European ADR Convention does require that electrical components such as cables, connectors and lighting must be used in a safe and fault-free manner.

For lighting, this means:

• Luminaires and wiring must be resistant to vibration, moisture, corrosion and mechanical stress
• No sparks or unwanted electrical effects should occur
• Lighting must be electromagnetically compatible (EMC), usually demonstrated through ECE R10
• Explosion-proof lighting (e.g. with ATEX certificate) is required in EX/II and EX/III vehicles. Read more about explosion-proof lighting in EX/II and EX/III vehicles.

Find more background on general ADR lighting requirements in our overview article.

The inspection looks at whether the lighting and accessories have been correctly applied and fitted according to these guidelines

ADR cabling: permitted cable types and mounting requirements

Cable types: PUR or H07BQ-F

For ADR lighting, it is important to choose cables that are not only mechanically robust, but also resistant to chemicals and temperature fluctuations. PUR cables and H07BQ-F are the most commonly used in practice. They are abrasion-resistant, flexible and resistant to oil and UV radiation. Avoid standard PVC cables, which age faster and are more susceptible to damage.

Routing and protection

Good cable routing prevents interference and extends the life of the installation. Make sure cables are neatly routed, properly secured and do not come into contact with moving or hot parts of the vehicle. Use vibration-resistant fixing materials and make sure cables do not hang slack or can chafe.Avoid kinks or loose loops

Cable entries and cable glands

Ensure water- and dust-proof cable entry with glands of at least IP67. For vehicles that are regularly cleaned with high pressure, IP69K is a better choice. In EX zones, ATEX-approved cable glands are mandatory. Always install glands according to the manufacturer's specifications to avoid leakage or interference.For EX zones: use ATEX-approved glands (such as Ex-e or Ex-d versions)

Connectors for ADR lighting

High-quality connectors ensure a safe, reliable connection. Common choices are:

• Deutsch
• AMP SuperSeal
• Bayonet systems

Good connectors are essential for installation reliability. Pay attention to proper sealing, sufficient strain relief and a firm locking so the connection cannot loosen during vibrations or washouts. Preferably choose connectors with at least IP67, or IP69K if the lighting is on the outside. Shrink tubing is useful as extra protection, but never replaces a sealing connector. Open wires or welding terminals are not allowed.

FL vehicles for flammable liquids often have even higher cabling and sealing requirements.

A properly fitted connector prevents moisture problems, interference and rejection on inspection.

IP values and EMC: points of attention

IP value

• Minimum: IP67 (dust- and waterproof to 1 metre)
• Recommended: IP69K (especially for FL vehicles or high-pressure cleaning)
• The IP value is valid only if correctly mounted

In chemical and gas tank transport, high IP values and EMC compliance also play a major role.

EMC certification

Lighting must comply with ECE R10 to ensure electromagnetic compatibility. Cabling also plays a role here: pay attention to good routing, shielding and correct earthing to avoid interference with other systems.

Fuses and earthing of ADR lighting

• Each luminaire must be separately fused
• Fuses preferably placed close to the luminaire
• Earthing must use good conductive, corrosion-resistant connections
• Avoid multiple mass connections without galvanic isolation

Checklist: Install ADR lighting correctly in 7 steps

1. Use PUR or H07BQ-F cabling
2. Fix cables tightly and vibration-free
3. Finish with IP67/IP69K connectors
4. Use ECE R10-approved luminaires
5. For EX vehicles: choose ATEX lighting and glands
6. Provide each light with its own fuse
7. Check mounting for damage, routing and watertightness

After going through the installation steps, you can find the required ADR-approved lighting and connectors directly with us.

Frequently asked questions on installing ADR lighting

Which cables are allowed in ADR vehicles?
PUR and H07BQ-F cables are suitable. They are resistant to heat, oil, abrasion and vibration.

Is IP69K mandatory?
No, but it is strongly recommended for tankers and high-pressure cleaning vehicles.

Should each light have its own fuse?
Yes, the ADR prescribes a separate fuse for each power circuit.

Can I use shrink tubing as a seal?
Only as additional protection. Always use a connector with an integrated seal.

Do you drive at night or under route duty? Then check out our tips for optimal visibility.

Disclaimer

At TRALERT®, we do our best to keep the information in this article as accurate and up-to-date as possible, including the regulations surrounding vehicle lighting. However, legislation can change regularly, and although we make every effort to implement these changes in a timely manner, it is possible that certain updates or adjustments have not yet been incorporated into this article. We therefore always advise our readers to check the current legislation with their local government or regulatory bodies, especially when it comes to exceptions or specific national regulations. TRALERT® is not liable for any damages or fines resulting from outdated or incomplete information in this article.

If in doubt, always contact the competent authority to ensure that your vehicle meets all legal requirements.