LED, xenon or halogen? Choose the right beacon for your ATEX zone

LED, xenon or halogen beacon: the choice may seem trivial to some, but it directly determines the safety, performance and compliance of your installation in an ATEX (explosive atmosphere) zone. Lighting technologies are evolving rapidly, driven by innovation from manufacturers such as Philips, Osram and GE Lighting, and the regulatory framework remains demanding. While visibility, efficiency and robustness are paramount, it is imperative to understand the technical and regulatory specificities of the industry. This guide offers a detailed analysis, practical tools and concrete examples to ensure optimal and safe installations, from product selection to maintenance, including compatibility with the most modern industrial systems.

Understand ATEX constraints and the issues involved in choosing an illuminated beacon

Signaling in ATEX environments is a crucial issue for industrial facilities exposed to the risk of explosion, such as those in the petrochemical, heavy chemicals and food industries. Every component must meet stringent safety criteria, and the beacon is no exception. This regulatory requirement is framed by ATEX Directive 2014/34/EU, imposing strict approvals for each type of device installed in Zone 1, 2, 21 or 22.

The risks are such that any error in choice, whether in terms of technology (LED, xenon or halogen), ATEX connection system or grounding compatibility, can have serious consequences. Specialized suppliers such as Nexans or Schneider Electric offer specific ranges to meet these challenges, incorporating innovations such as self-ventilated circuits or surge protection modules.

In practice, the safety standards also require that account be taken of :

• The level of illumination required on site
• Electromagnetic compatibility problems
• Reliability in the presence of explosive dusts or vapors
• Shock and vibration resistance for maximum durability

To illustrate, let’s take the example of a French distillery in zone 21: the management chose Helvar LED beacons, with waterproof Eaton connectors. The in-depth evaluation – required by the ISM-ATEX internal audit – shows that the low heat release of LEDs offers a greater safety margin than halogen models, reducing the risk of accidental ignition. Conversely, a poorly ventilated logistics warehouse equipped with xenon beacons had to rethink its installation following the detection of hot spots by infrared thermography.

Another major criterion is maintenance. Difficult access to certain areas (high storage platforms, underground galleries) makes the service life of the beacons a determining factor. A project manager at Feilo Sylvania points out that every time a halogen bulb is changed in an ATEX zone, the site is immobilized, access is at risk, and work permits are complex to manage. Hence the boom in long-life LED solutions, installed for over 50,000 hours without intervention.

The cumulative effect of these constraints is clearly guiding choices: this is no longer a time for approximation, but for finding the right balance between safety, performance and cost. In addition to simple compliance, your choice of beacon will also influence the speed of diagnosis and intervention in the event of an incident, a point that the manufacturers of 2025 can no longer afford to neglect.

Regulatory criteria and certification: how will we find our way around in 2025?

Since the latest update of European standards, all beacons installed in ATEX zones must be certified for their resistance to electrostatic discharge and their inability to generate a source of ignition. Independent laboratories such as Dekra, as well as integrated certifiers from Schneider Electric or Nexans, are now essential for validating the choice of components.

• IECEx and ATEX requirements for each model
• Traceability of the manufacturing process (batch, lot number, etc.)
• Thermal cycle simulation and risk analysis

In the era of industrial smart building, connectivity between beacon and supervision (via Modbus or profinet) is creating new needs. Manufacturers such as GE Lighting and Cree are developing plug&play modules with integrated diagnostics, facilitating predictive maintenance and remote management.

Mastering the regulatory framework and the technical choices to be made therefore determines the company’s ability to guarantee the safety of people and property, while keeping costs and deadlines under control.

LED, xenon and halogen: technical comparison and effects on safety

The lighting technology deployed on an ATEX beacon is not something to be chosen lightly. Each solution, whether LED, xenon or halogen, brings its own set of advantages and constraints, which need to be carefully assessed according to the operational context. The challenge is to ensure not only the visibility of personnel and equipment, but also compliance with contemporary safety requirements.

In 2025, LEDs will gradually become the norm, thanks to a combination of factors: low power consumption, directional light, insensitivity to vibration, and a record lifespan. The Philips, Osram and Sylvania ranges offer uniform lighting, instant start-up and easy integration of color modules for signage.

• Energy consumption 60% lower than halogen
• No warm-up time, unlike xenon
• Low heat generation, eliminating the risk of unwanted hot spots

As for xenon, their very intense blue-white light is still sought-after for areas requiring rapid detection of anomalies, particularly for wide-area surveillance. However, their increased power generates constraints: high power consumption, the need for a ballast, overheating of the optical compartment and a higher rate of side glare.

Finally, halogen technology, long the dominant choice for mobile or temporary applications, is still used in environments where cost is the main criterion. However, it has major drawbacks: shock sensitivity, frequent maintenance, low energy efficiency. Models from Feilo Sylvania and general manufacturers remain competitive, but their future appears limited compared to LEDs.

As an operator at an oil complex explains: “We switched from Sylvania halogen to Osram LED modules in high-traffic areas, and within the first six months we saw a reduction in maintenance work and the risk of burns. This kind of feedback from the field underpins the investment drive towards LEDs, which is now supported by virtually all industrial specifications.

The impact of temperature and aggressive environments

While lighting power and energy consumption are at the heart of the choice, other criteria related to the operating environment should not be overlooked:

• Temperature amplitudes: some halogen models struggle to perform at temperatures below 0°C or above 45°C ;
• Presence of explosive dusts, gases or mists that can obstruct optics or accelerate clogging;
• On/off cycle: a xenon beacon does not cope well with repeated operations, whereas an LED retains its performance.

Feedback analysis should therefore guide product selection, as recommended in this report from the National Highway Traffic Safety Administration, which highlights the structural advantage of LEDs in the face of environmental variations, thanks to their filament- and gas-free design.

At this point, it becomes clear that each technology has its own optimization scenario. The key is to make your choice according to the realities of the field, anticipating needs, constraints and regulatory changes.

ATEX light beacons: industrial applications, optimization and field feedback

Beyond the choice of technology, the integration of an illuminated beacon in an ATEX zone must be considered as part of an overall safety and signaling system. Manufacturers such as Cree and Eaton offer modular architectures for advanced customization: multicolored beacons for machine status display, synchronized flash, or coupling with audible sirens for enhanced warning.

In a recently-equipped naval workshop, the chosen solution combines high-efficiency Cree LED beacons, connected to a Schneider Electric PLC for centralized control. The system includes presence detectors and temperature sensors, triggering light signals when defined thresholds are exceeded. Post-installation analysis reveals a 27% reduction in the accident rate due to lack of visibility in high-risk areas. The result is improved regulatory compliance and the virtual disappearance of unplanned maintenance shutdowns.

• Priority use on oil rigs, chemical plants, flammable liquid handling sites
• Easy deployment thanks to compact LED modules
• Hybrid systems combining several sources for maximum adaptability

A pioneer in industrial lighting, Philips also offers combined solutions integrating crane signaling technology(see here), with high-intensity LED beacons dedicated to extreme environments. Many industrial plants appreciate the robustness and interoperability of these new devices, which are capable of communicating with the rest of their equipment (gas detectors, interlock systems, zone alarms, etc.).

Maintenance optimization in 2025: tools and methods

Reducing operating costs also means making the right choices when it comes to maintenance. ASSIST feedback from partner integrators shows that LED systems, once installed, require on average five times less intervention than their halogen equivalents. Connected supervision tools – widely deployed via Schneider Electric and Eaton modules – provide real-time alerts, facilitating predictive fault analysis.

• Automated commissioning
• Integrated test module for periodic remote checks
• Easy replacement thanks to Nexans pre-wired connectors

Optimization doesn’t stop at the installation stage: spare parts stock strategy, batch traceability and integration into a global safety management system are now essential for operators of critical infrastructures.

Focus on manufacturers and technology trends 2025

The market for ATEX beacons is driven by dynamic technological competition. Philips, Osram, GE Lighting and Cree are investing heavily in research aimed at improving luminous intensity, structural robustness and ease of connection. The major trend? The integration of “smart” functions: on-board diagnostics, remote monitoring, remote settings via secure applications.

Feilo Sylvania and Helvar stand out for their offer of multi-temperature LEDs, adapted to the differentiation of on-site signals: amber for chemical risk, blue for technical intervention, green for secure access. This flexibility culminates in modular architectures where the end-user can configure up to 8 different programs according to work configurations.

• Deployment of variable-spectrum LEDs for improved visibility in all weather conditions
• Plug and play systems based on intuitive Nexans/Eaton connectors
• Enhanced compatibility with PLCs and industrial management software

Some 2025 innovations are already in pre-production: LED modules with integrated humidity detection, or xenon with automatic dimming. Plug-and-forget solutions speed up compliance and standardize interventions, limiting human error on site.

Regulatory developments and future prospects

European regulations are becoming more stringent, with mandatory post-installation tests and periodic documented audits. Harmonized ATEX/IECEx certification, digitized maintenance records and real-time performance monitoring have become standards expected by major industrial clients.

• Standardization of audit procedures between European sites
• Mass adoption of low-maintenance solutions
• Application to new markets: lithium batteries, hydrogen, compressed gases, etc.

Anticipation is becoming the rule: investing in a “future-proof” light beacon, capable of evolving through software updates, is a guarantee for the decade to come.

Selection errors and operational recommendations for ATEX installations

Incorrectly adapting your beacon to the reality of your ATEX zone exposes you to multiple risks. Not only can compliance be compromised, but so can the entire safety chain. The main pitfall is over-standardization, with some specifiers generalizing outdated halogen references, or selecting oversized xenon modules that generate hot spots.

A case study carried out at a logistics company using Sylvania halogen beacons showed that the rate of electrical incidents fell by 60% after migration to Osram LEDs. The ISM-ATEX audit also revealed that the absence of light feedback on halogen models increased reaction time during fire drills.

• Never choose a technology without a detailed environmental analysis
• Systematically assess compatibility with the ecosystem (connected modules, PLCs, etc.)
• Check traceability, certificate of origin and ATEX compliance
• Avoid models with high thermal emissions in confined spaces
• Maintain a strategic stock to avoid any break in signal continuity

To identify and avoid such errors, we recommend systematically consulting feedback and independent comparisons published by specialist organizations or integrators such as Nexans or Eaton. Sharing hubs and test centers, accessible via these resources, will enable you to validate your choices before the final installation.

Optimum selection and commissioning procedure

In operational terms, following these main steps will help you avoid most of the pitfalls:

• Establish specific requirements for the ATEX zone sheet
• Refer to manufacturer’s manual (Philips, Osram, GE Lighting, etc.) for operating range.
• Luminous flux simulation with modeling tools
• Check integration with Schneider Electric, Cree, Helvar supervision systems
• Plan preventive maintenance after installation

There’s no need to leave anything to chance, because the battle for compliance and performance relies as much on expertise in the field as on technical catalogs. In 2025, investing in hyper-compatible, sustainable and smart signage also means responding unfailingly to the growing demand for safe industrialization – demanded today by the world’s biggest players.