Technical application guide - PrevaLED Cube AC light engines (06/13)

Technical application guide - PrevaLED Cube AC light engines (06/13)
www.osram.com/prevaled
JUNE
2013
Technical application guide
PrevaLED® Cube AC light engines
CONTENTS
Contents
1. Introduction
3
6. Lifetime and thermal behavior
12
1.1. System overview
3
6.1. Cooling
12
1.2. Ordering information
4
6.2. Flux as a function of temperature
12
1.3. Nomenclature and marking
4
6.3. Lifetime as a function of temperature
12
2. Optical considerations
5
7. Mechanical considerations
13
2.1. Light distribution
5
7.1. Outline drawing
13
2.2. Reflector design
5
7.2. 3D drawing
13
2.3. Color temperature
6
7.3. Mechanical protection of the light engine
13
2.4. Color rendering
6
7.4. Mounting
13
2.5. Spectral distribution
6
8. Assembly in a reference luminaire
14
8.1. Preparation
14
8.2. Attachment of the thermocouple
14
3. Ingress protection
7
4. Electrical considerations
7
8.3. Mounting of the light engine
14
4.1. Wiring information
7
8.4. Wiring
15
4.2. Insulation requirements
8
8.5. Temperature measurement
15
4.3. Inrush current and system installation
8
4.4. Electrostatic discharge (ESD)
8
9. Norms and standards
16
4.5. Controllability
8
5. Thermal considerations
9
5.1. Thermal interface material and other accessories
9
5.2. Cooling systems and heat sinks
9
5.3. tc point location and temperature measurement
10
5.3.1. Thermocouple
10
5.3.2. Thermal sticker
11
Please note:
All information in this guide has been prepared with great care.
OSRAM, however, does not accept liability for possible errors,
changes and/or omissions. Please check www.osram.com/
prevaled or contact your sales partner for an updated copy of
this guide.
2
INTRODUCTION
1. Introduction
1.1. System overview
The brightness levels of today’s LEDs are opening the
door for the use of LEDs in general lighting applications
that require high lumen output levels. Building an LEDbased luminaire poses a new set of technical challenges,
among them new optical requirements, providing adequate thermal management for stable operation and dealing with the ever-improving performance of LEDs. Nevertheless, LED technology also offers an unknown wealth
of possibilities, providing access to unprecedented levels
of performance and new ways of integration.
OSRAM’s PrevaLED® family of LED light engines addresses the challenges of LED-based lighting while providing
users with great performance and flexibility at the same
time. Enabled by the application of LED technology,
PrevaLED® is aiming to push the envelope of what is
possible in terms of performance and simplicity.
The PrevaLED® Cube AC series of light engines is ideally
suited for use in highly diffuse wall-mounted and ceilingmounted luminaires in decorative, hospitality or domestic
applications as well as in a broad range of wide-reflectorbased applications such as downlights.
Dummy of a PrevaLED® Cube AC light engine
The PrevaLED® Cube AC light engines provide several
specific benefits for these applications:
• With the LED sources and the electronic control circuitry
placed on the same board and packaged into a unique
compact design, they offer an integrated system solution.
• Little design-in effort is required due to the integration of
the electronic control circuitry into the light engine, offering a new level of simplicity.
• They provide high performance in terms of both the
complete system efficiency and the quality of light
(small color deviation, no recognizable light modulation).
• Due to the low height of only 18.6 mm as well as the
established footprint and means of mechanical fixation,
a large number of existing accessories (optics, heat
sinks etc.) can easily be adapted.
• All in all, PrevaLED® Cube AC light engines do not only
offer a low threshold for the adaption of LEDs, but also a
significant increase in flexibility for applications already
adapted to LED technology.
At present, the PrevaLED® Cube AC series is available as
a 1100-lm package in two light colors (3000 K and 4000 K)
with a color reproduction of Ra > 80.
Move me!
Movable 3D PrevaLED® Cube AC light engine
(works with Adobe Acrobat 7 or higher)
3
INTRODUCTION
1.2. Ordering information
PrevaLED® Cube AC
Product data
1100 lm, 3000 K
1100 lm, 4000 K
Product reference
LEP-CUB-AC-830-G1
LEP-CUB-AC-840-G1
Product number
EAN 10: 4052899908611
EAN 40: 4052899908079
EAN 10: 4052899908628
EAN 40: 4052899908086
1.3. Nomenclature and marking
LEP: Light engine PrevaLED®
CUB: Cube
AC: AC-capable (220–240 V, 50/60 Hz)
830: CRI + CCT = > 80 + 3000 K
G1: Generation 1
LEP-CUB-AC-830-G1
4
OPTICAL CONSIDERATIONS
2. Optical considerations
PrevaLED® Cube AC light engines can be applied in
diffuse wall-mounted and ceiling-mounted luminaires
without the need for further optical accessories.
2.1. Light distribution
The light distribution of PrevaLED® Cube AC light
engines is shown below. They create a beam angle of
110° FWHM.
Jordan Reflektoren GmbH & Co. KG
Schwelmer Strasse 161
42389 Wuppertal
Germany
+49 202 60720
[email protected]flektoren.de
www.jordan-reflektoren.de
ACL-Lichttechnik GmbH
Hans-Boeckler-Strasse 38A
40764 Langenfeld
Germany
+49 2173 9753 0
[email protected]flektor.com
www.reflektor.com
Alux·Luxar GmbH & Co. KG
Schneiderstrasse 76
40764 Langenfeld
Germany
Light distribution curve
The light-emitting surface of the light engines is covered
by a diffuser to ensure a homogeneous, smooth light
distribution. Please ensure that the temperature of the
diffuser does not exceed 120 °C.
2.2. Reflector design
PrevaLED® Cube AC light engines can also be used with
secondary optics. As their optical interface has the same
dimensions as common downlight modules in the market,
they can be combined with available off-the-shelf secondary optics.
For optics support, you can find our suppliers via OSRAM’s
LED Light for You network: www.ledlightforyou.com. Moreover, standard components and support for reflector design are available e.g. through the following suppliers:
+49 2173 279 0
[email protected]
www.alux-luxar.de
Almeco S.p.A.
Via della Liberazione, 15
20098 San Giuliano Milanese (Mi)
Italy
+39 02 988963 1
[email protected]
www.almecogroup.com
OSRAM provides mechanical (3D files) and optical
simulation data (ray files) to support customized reflector
designs. Mechanical files can be downloaded at
www.osram.com/prevaled. Ray file data are available upon
request through your sales partner. Available ray file formats
are ASAP, SPEOS, LightTools and Photopia (all binary).
5
OPTICAL CONSIDERATIONS
General CRI
Leaf green
Pink, skin color
Blue, saturated
Green, saturated
Yellow, saturated
Red, saturated
0.3767
Lilac violet
0.4041
Aster violet
Cy
Azure
0.3804
Turquois
0.4369
Light green
Cx
Yellowish green
4000 K
Mustard yellow
3000 K
2.4. Color rendering
PrevaLED® Cube AC light engines provide a color
rendering index (CRI) of > 80. The table below shows
the individual Ra values from R1 to R14 for the available
color temperatures.
Dusky pink
2.3. Color temperature
The PrevaLED® Cube AC series is currently available in
3000 K and 4000 K. The color coordinates within the CIE
1931 color space are given below.
Initial color values of the CCT
R1 R2 R3 R4 R5 R6 R7 R8 R9 R10 R11 R12 R13 R14 Ra
®
Within each available color temperature, the PrevaLED
Cube AC series provides a maximum color variation of
five 1) threshold value units (MacAdam steps). The following
diagram shows these threshold values within the CIE 1931
color space.
0.50
CCT =
3000 K
81 90 96 80 81 86 85 65 22 76 77 66 83 97 83
CCT =
4000 K
82 88 92 81 80 82 87 69 23 71 78 58 83 95 83
Ra values
0.45
3000 K
2500 K
cx
4000 K
0.40
2000 K
2.5. Spectral distribution
The typical spectral distribution of PrevaLED® Cube AC
light engines is shown in the following diagram.
CCT = 4000 K at ta = 25 °C
6000 K
CCT = 3000 K at ta = 25 °C
0.35
0.30
0.30
0.35
0.40
0.45
0.50
cy
Color coordinates
Relative spectral emission, r.u.
1.0
0.8
0.6
0.4
0.2
0.0
380
430
480
530
580
630
680
730
780
Wavelength (nm)
Wavelength spectrum
1) This value is subject to improvement. Please check the latest datasheet at
www.osram.com/prevaled.
6
INGRESS PROTECTION/ELECTRICAL CONSIDERATIONS
3. Ingress protection
PrevaLED® Cube AC light engines have an ingress protection rating of IP20. Please ensure that the housing of your
luminaire provides the IP protection required for your
application.
For further information, please have a look at the technical
application guide “IP codes in accordance with IEC
60529”, which can be downloaded at www.osram.com.
4. Electrical considerations
4.1. Wiring information
PrevaLED® Cube AC light engines can be directly connected to mains voltage (220–240 V, 50/60 Hz).
The used input clamps can handle solid or flexible wire
with a diameter of 0.2 to 0.75 mm² (AWG24–18). The use
of solid wire is recommended.
Notes:
• The connector is designed for three poke-in and release
cycles.
• Due to the fact that you are dealing with mains voltage,
you must not hot-plug the light engine.
• The installation of LED light engines needs to be carried
out in compliance with all applicable electrical and safety
standards. Only qualified personnel should be allowed to
perform installations.
6–7 mm
(0.24–0.28 inch)
Wire preparation
Please insert the wires in 0° orientation to the PCB.
Solid wire:
Plug directly.
Flexible wire:
1. Lightly press the push
button of the connection
clamp.
2. Insert the flexible wire.
To press/release the
clamps, please use a
small screwdriver.
7
ELECTRICAL CONSIDERATIONS
4.2. Insulation requirements
PrevaLED® Cube AC light engines can be used in class I
luminaires without further action. The creepage distance
and clearance are fulfilled.
In class II luminaires, additional care needs to be taken
only in the area of the input connector. Between connection wires with basic insulation and touchable metal parts
or the heat sink, a second insulation layer is required.
The light engine itself has double/reinforced insulation.
4.3. Inrush current and system installation
Due to their electronic construction, PrevaLED® Cube AC
light engines have a minimum inrush current. In system
installations, you can connect the following amounts of
PrevaLED® Cube AC light engines to circuit breakers with
different characteristics.
Characteristic
Max. number of light engines
B 10
30
B 16
40
C 10
40
C 16
50
4.4. Electrostatic discharge (ESD)
It is not necessary to handle PrevaLED® Cube AC light
engines in Electrostatic Protected Areas (EPAs).
To protect a PrevaLED® Cube AC light engine from electrostatic damage, do not open it. The light engine fulfills the
requirement of the immunity standard IEC/EN 61547.
4.5. Controllability
Due to the integrated drive electronics, a good compatibility with all available phase-cut dimmers cannot be ensured. For specific applications, OSRAM can validate the
dimming performance of a certain dimmer/light engine
combination. In case you have such a requirement, please
contact your sales partner.
Possible system installations
8
THERMAL CONSIDERATIONS
5. Thermal considerations
The proper thermal design of an LED luminaire is critical
for achieving the best performance and ensuring the longest
lifetime of all components. Due to the high efficacy of
PrevaLED® Cube AC light engines, only a partial amount
of the introduced electrical power has to be dissipated
through the back of the light engine. The thermal power
that has to be dissipated for PrevaLED® Cube AC light
engines is given below.
5.2. Cooling systems and heat sinks
For the selection of a suitable heat sink, several points
regarding thermal resistance have to be considered.
The selection is usually done through the following
necessary steps.
Typical thermal power to be dissipated 2)
LEP-CUB-AC-830-G1
9.8 W
LEP-CUB-AC-840-G1
9.3 W
2) Values measured at the tc point at a reference temperature (tr) of 65 °C.
Depending on the application and the chosen light engine,
passive cooling can be sufficient. In critical applications
(e.g. small available heat sink size or highly reduced airflow), active cooling by means of a ventilator may be required. Active cooling combines a heat sink with a fan or
a similar device to maximize the thermal dissipation of the
passive heat sink.
5.1. Thermal interface material and other accessories
When mounting a PrevaLED® Cube AC light engine within
a luminaire, it is recommended to use thermal interface
material (TIM) between the back of the light engine and the
luminaire housing or heat sink. It is recommended to use
thermal paste, but also thermal foil can be used. In order
to balance possible unevenness, the material should be
applied as thinly as possible, but as thickly as necessary.
In this way, air inclusions, which may otherwise occur, are
replaced by TIM and the required heat conduction between the back of the light engine and the contact surfaces of the luminaire housing is achieved. For this purpose,
the planarity and roughness of the surface should be optimized.
The list below is a selection of suppliers of thermal interface materials. Additional suppliers for thermal management support can also be found via OSRAM’s LED Light
for You network: www.ledlightforyou.com.
Thermal interface materials
Alfatec
Kerafol
Laird
Bergquist
Arctic Silver
Wakefield
www.alfatec.de
www.kerafol.de
www.lairdtech.com
www.bergquistcompany.com
www.arcticsilver.com
www.wakefield.com
Define boundary
conditions
Estimate heat sink
thermal resistance on
light engine level
Select heat sink
thermal resistance
Total power dissipation of the light
engine, max. ambient temperature
ta, max. reference temperature tr
according to lifetime requirements
Rth =
tr - ta
Pth
tr measured at the tc point
Use the estimated Rth as a target
for a possible heat sink profile and
examine the performance curve in
the heat sink manufacturer’s catalog.
Selection of a heat sink
Note: A thermal design must always be confirmed by performing a thermal measurement in steady-state condition.
It is recommended that the whole area of the PCB of a
PrevaLED® Cube AC light engine is in contact with the
solid material of the heat sink. The minimum area of the
PCB that has to have contact with the solid material of
the heat sink is 65 x 65 mm.
In the following, you find two examples of how to cool a
PrevaLED® Cube AC light engine.
Example 1:
Light engine: LEP-CUB-AC-840-G1
Heat sink: Aluminum sheet metal (AlMg3)
Dimensions: 200 x 200 x 2 mm
TIM: Kerafoil 8620
Example 2:
Light engine: LEP-CUB-AC-830-G1
Heat sink: Fischer Elektronik SK 464
Dimensions: 100 x 84 x 40 mm
TIM: Thermal paste
9
THERMAL CONSIDERATIONS
Please note that the shown solutions are just examples.
A thermal system always depends on many factors, such
as airflow, ambient temperature etc. Please check your entire cooling system by performing a thermal measurement
in steady-state condition.
5.3.1. Thermocouple
Use a thermocouple that can be glued onto the light engine. Make sure that the thermocouple is fixed with direct
contact to the tc point.
Examples of suitable thermocouples:
The list below is a selection of suppliers of different cooling solutions.
Active cooling systems
K-type thermocouple with miniature connector
Nuventix
Sunon
Cooler Master
AVC
SEPA
www.nuventix.com
www.sunoneurope.com
www.coolermaster.com
www.avc-europa.de
www.sepa-europe.com
Illustration
Passive cooling systems
AVC
Fischer Elektronik
Meccal
Wakefield
R-Theta
Cool Innovations
www.avc-europa.de
www.fischerelektronik.de
www.meccal.com
www.wakefield.com
www.r-theta.com
www.coolinnovations.com
5.3. tc point location and temperature measurement
The tc point is the location to check if the chosen cooling
solution (heat sink and TIM) is sufficient to ensure the light
engine performance. The tc point is located on the back of
the light engine under the center of the diffuser (see image
below).
Temperature range [°C]
PVC-insulated thermocouple
-10 … +105
PFA-insulated thermocouple
-75 … +260
Sprung thermocouple
-75 … +260
Different thermocouples
To measure the temperature and to ensure a good thermal
coupling between light engine and heat sink, drill a hole
into the heat sink and push the thermocouple through the
heat sink. To ensure a direct contact between the thermocouple and the PCB, it is recommended to glue the thermocouple onto the PCB.
37.7
41.4
Description
tc point
All figures in mm
Location of the tc point
To ensure a lifetime of 40000 hours (L70B50), the reference
temperature (tr) at the tc point must not exceed 65 °C 3). The
maximum temperature reached at the tc point must not exceed 85 °C.
A correct temperature measurement can, for example, be
performed with a thermocouple or thermal sticker.
Mounting of a thermocouple through a hole in the heat sink
3) This value is subject to improvement. Please check the latest datasheet at
www.osram.com.
10
THERMAL CONSIDERATIONS
It is also possible to use a sprung thermocouple. A suitable type is: Electronic Sensor FS TE-4-KK06/09/2m.
Please note that a good thermal contact between the
thermocouple and the PCB is required. Please refer to the
datasheet and the application guideline of the manufacturer to ensure correct handling.
Another possible way is to create a small groove along the
top surface of the heat sink.
Thermal sticker before temperature measurement
Note: If you use a TIM, please do not apply thermal paste
to the sticker. In case you use a thermal foil, please cut
out the area of the sticker.
Mounting of a thermocouple by means of a groove
Afterwards, mount the light engine onto the heat sink and
operate it until a stable temperature has been reached.
Dismount the light engine and check the thermal sticker.
For the interpretation of the test result, refer to the datasheet of the thermal sticker.
Note: Please keep in mind that you need a direct contact
between the thermocouple and the PCB.
5.3.2. Thermal sticker
You can also use thermal stickers to indicate the reference
temperature (tr) at the tc point of the light engine.
Please attach the sticker to the light engine at the tc point
(see images on the right).
Thermal sticker after temperature measurement
OMEGA BUA2-140/60-30 is a suitable product, which
covers a temperature range between 60 and 77 °C.
11
LIFETIME AND THERMAL BEHAVIOR
6. Lifetime and thermal behavior
6.1. Cooling
To ensure a safe and reliable operation, the module
must be attached to a suitable cooling solution (e.g.
a heat sink).
6.2. Flux as a function of temperature
The luminous flux of PrevaLED® Cube AC light engines depends on their temperature. 100 % of the luminous flux is
achieved at the reference temperature of 65 °C (tr = 65 °C).
This temperature has to be measured at the tc point. If the
reference temperature increases, the light output decreases.
The luminous flux changes in relation to the reference temperature according to the following diagram.
140
If the reference temperature (tr) of 65 °C is maintained,
PrevaLED® Cube AC light engines have an average lifetime
of 40000 hours (L70B50). The maximum temperature measured at the tc point must not exceed 85 °C.
Note: Higher tc temperatures lead to a shorter lifetime of
the PrevaLED® Cube AC light engines. Moreover, the failure rate will also increase.
120
Relative flux [%]
6.3. Lifetime as a function of temperature
Note: For the definition of the lifetime of an LED module,
please refer to IEC/PAS 62717, where the following types
are defined (examples):
• L0C10 is the lifetime where the light output is 0 % for 10 %
of the modules.
• L70F50 is the lifetime where the light output is ≥ 70 % for
50 % of the modules. F value includes reduction of lumen
output over time including abrupt degradation (flux = 0).
• L70B50 is the lifetime where the light output is ≥ 70 % for
50 % of the modules. B value includes only gradual reduction of lumen output over time.
100
80
The following table shows the lifetime of a PrevaLED®
Cube AC light engine in relation to the temperature measured at the tc point.
60
40
20
0
20
30
40
50
60
Temperature [°C]
Flux as a function of temperature
70
80
90
C10 failure rate
Temperature at tc point
Lifetime in hours
45 °C
67000
65 °C
20000
85 °C
6000
12
MECHANICAL CONSIDERATIONS
7. Mechanical considerations
18.5
7.1. Outline drawing
The following schematic drawing provides further details
on the dimensions of PrevaLED® Cube AC light engines.
For 3D files of the light engines, please go to:
www.osram.com/prevaled.
54
68
82
61
4.5
7.3. Mechanical protection of the light engine
The housing of a PrevaLED® Cube AC light engine should
not be exposed to strong mechanical stress. Please apply
force only to the dedicated mounting positions. Strong
mechanical stress can lead to irreversible damage of the
light engine.
Note: If the diffuser material at the light-emitting surface
or any other part of the housing or the PCB is broken or
mechanically damaged, you must no longer operate the
light engine. Please replace it urgently to avoid contact
with parts of the light engine that conduct 230 V.
For operation in damp, wet or dusty environments, the
user has to make sure that an adequate ingress protection
is chosen. The light engine has to be protected by a suitable IP classification of the luminaire housing. Please consider the luminaire standard IEC 60598-1 as well as the
different requirements for indoor and outdoor application.
Note for France: Due to specific national regulations,
as defined in the standard EN 60598, it is not permitted
to expose the light engine outside a luminaire housing.
83
kg
All figures in mm
7.2. 3D drawing
Don’ts
7.4. Mounting
To fix a PrevaLED® Cube AC light engine to a heat sink,
you may use M4 cylinder head screws according to
DIN 912 or ISO 4762. The recommended torque is 0.5 Nm.
Move me!
Movable 3D PrevaLED® Cube AC light engine
(works with Adobe Acrobat 7 or higher)
Mount the light engine
from the top
Note: Make sure that the cover of the light engine cannot
be removed. Therefore, provide sufficient fixation of the
cover, e.g. by screwing it to the heat sink.
13
ASSEMBLY IN A REFERENCE LUMINAIRE
8. Assembly in a reference luminaire
To show you how easy it is to equip a luminaire with a
PrevaLED® Cube AC light engine, the following example
guides you through all necessary steps. In this case, the
luminaire housing is used as the heat sink.
8.2. Attachment of the thermocouple
Run the thermocouple through the hole under the tc point
and attach it to the PCB. In this case, the thermocouple is
glued onto the PCB.
8.1. Preparation
The first step is to position the light engine at the right
place in your luminaire and to drill the mounting holes. In
this case, M4 thread holes are used to screw the light engine directly to the housing.
For the first test luminaire, drill an additional hole exactly
at the location of the tc point to connect the thermocouple
with the PCB.
Glue the thermocouple onto the PCB and apply thermal paste
8.3. Mounting of the light engine
Before you can screw the light engine to the housing, it is
recommended to use a thermal paste to improve the thermal contact between the PCB and the housing. After applying the thermal paste, you can screw the light engine to
the housing. Use the specified screws and do not apply
more torque to them than allowed in order to protect the
light engine from being damaged.
Position the light engine
Drill the mounting holes and a hole for the thermocouple
Screw the light engine to the housing
14
ASSEMBLY IN A REFERENCE LUMINAIRE
8.4. Wiring
In this case, a protection class I luminaire is designed. All
metal parts have to be connected to earth. So the earth is
connected to the housing of the luminaire, the phase and
neutral conductors are connected to the light engine. Afterwards, you can close the luminaire and you are ready to
run the thermal test.
8.5. Temperature measurement
To check the maximum temperature at the tc point, please
operate the luminaire in the orientation of its application
(wall-mounted/ceiling-mounted) until a stable temperature
is reached. Ensure that the maximum tc temperature is not
exceeded in the ambient temperature of its application.
L
N
L
N
Wire the luminaire
Perform a steady-state thermal test
Close the luminaire
15
NORMS AND STANDARDS
9. Norms and standards
Safety:
IEC/EN 62031
IEC/EN 60598-1
Photobiological safety:
IEC/EN 62471
Risk group 2
Electromagnetic compatibility:
CISPR 15
IEC/EN 61547
IEC/EN 61000-3-2
IEC/EN 61000-3-3
EN 55015
Ingress protection:
IP20
Approval:
CE
16
OSRAM GmbH
Head Office
Marcel-Breuer-Strasse 6
80807 Munich
Germany
Phone +49 (0)89-6213-0
Fax +49 (0)89-6213-20 20
www.osram.com
06/13 Subject to change without notice. Errors and omissions excepted.
www.osram.com/prevaled
www.osram.de
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