5 ways to connect a controller to a Street Luminaire

In outdoor lighting projects, one key question arises: how to connect the controller to the luminaire? We've compiled the main connection options — their pros and cons.

Built-in / PCB Connection

The controller is integrated into the luminaire housing and connected directly to the driver inside it
(soldering, terminals, or connectors).

Pros:

• No need for standardized connectors (NEMA/Zhaga);
• Lower initial costs due to the absence of a housing;
• Maximum protection from moisture, dust, temperature, and vandalism;
• High durability.

Cons: 

• To receive full warranty coverage for the luminaire, preliminary testing and integration coordination between the controller and luminaire manufacturers
is required. Without such coordination, the luminaire manufacturer may refuse warranty service;
• Difficult replacement and expensive long-term maintenance;
• Since the connection is in series, there is a luminaire
power limitation (1000W);
• Limited to PLC solution only.

NEMA Connector

Standard twist-lock connector (5 or 7 pins).
The controller is powered by ~220V AC and installed without opening the housing.

Pros:

• Plug & play — quick installation and replacement;
• Series connection, which means no special (often more expensive) luminaire driver is required that provides power for both the luminaire and the controller, as in the case of Zhaga;
• Supports radio, PLC, GSM.

Cons: 

• Higher cost than PCB due to the special housing. Additionally,
many NEMA/Zhaga controller manufacturers use regular plastic
that degrades within 2-3 years;
• Since the connection is in series, there is a luminaire power
limitation (1000W).

Zhaga-Type Connector

Compact modern connector with twist-lock mechanism. Compatible with D4i drivers and powered
by low-voltage line (up to 24–30V DC).

Pros:

• Works with any luminaire power;
• Plug & play — quick installation and replacement;
• Safer low-voltage connection;
• Supports radio, PLC, GSM.

Cons: 

• Expensive solution. Requires special drivers (Zhaga/D4i);
• Higher cost than PCB due to the special housing. Additionally, many NEMA/Zhaga controller manufacturers use regular plastic that degrades within 2-3 years.

Internal Pole Mounting

The controller has its own housing but is placed inside the lighting pole. This solution requires no additional approvals while protecting the device from external factors.

Pros:

• Maximum protection from moisture, dust, temperature, and vandalism;
• High durability;
• No warranty coordination required with luminaire manufacturers; warranties are provided separately;
• Easy access during installation and replacement.

Cons: 

• Limited to PLC technology;
• Slightly more expensive than PCB, but not as expensive
as NEMA and Zhaga, since the housing
is not a special outdoor-rated one.

External Wired Connection

A type of streetlight controller  installation where
the controller is mounted outside the luminaire,
but connected to the driver through a hole
in the luminaire or pole.

Pros:

• No need to match luminaire with a specific NEMA or Zhaga socket;
• Supports various communication protocols such as Radio, PLC, GSM;
• Can be mounted anywhere on the pole or luminaire body.

Cons: 

• Requires additional work to drill holes for cable routing;
• Slightly more labor-intensive for connection and;
replacement compared to NEMA or Zhaga
plug-and-play systems.

What to Consider When Choosing?

1. Operating conditions — how important is protection from climate and vandalism.
2. Safety — NEMA operates at ~220V AC, Zhaga at up to 30V DC.
3. Manufacturer warranty — internal connections may void it.
4. Maintenance and upgrades — NEMA and Zhaga simplify replacement and allow IoT sensor integration.
5. Project budget — embedded solutions are cheaper initially but more expensive for service.

At DITRA Solutions, we pay special attention to housing reliability: all our outdoor installation solutions (NEMA and Zhaga) use special outdoor-rated housings and materials with enhanced resistance to moisture, dust,
temperature fluctuations, and UV radiation.