Technical application guide - PrevaLED Core AC PRO light engines

Technical application guide - PrevaLED Core AC PRO light engines
www.osram.com/prevaled
01/2015
Technical application guide
PrevaLED® Core AC PRO
light engines
Light is OSRAM
PrevaLED ® Core AC PRO light engines | Contents
Contents
1 Introduction
03
5 Thermal considerations
09
1.1 System overview
03
5.1 Thermal power as a function of voltage
09
1.2 Nomenclature
04
5.2 Thermal shutdown
09
5.3 Thermal interface material and other accessories
09
2 Optical considerations
04
5.4 Cooling systems and heat sinks
09
2.1 Modulation of light
04
5.5 tc point location and temperature measurement
10
2.2 Light distribution
04
2.3 Refl ector design
05
6 Lifetime and thermal behavior
12
2.4 Color temperature
05
6.1 Flux as a function of temperature
12
2.5 Color rendering
06
6.2 Lifetime as a function of temperature
12
2.6 Spectral distribution
06
7 Mechanical considerations
13
3 Ingress protection
07
7.1 Outline drawing
13
7.2 3D drawing
13
13
4 Electrical considerations
07
7.3 Mechanical protection of the light engine
4.1 Wiring information
07
7.4 Mounting
13
4.2 Insulation requirements
08
7.5 Protection from corrosion
13
8 Norms and standards
14
4.3 Inrush current and system installation
08
4.4 Electrostatic discharge (ESD)
08
4.5 Controllability
08
4.6 Power as a function of voltage
08
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 or contact your sales partner for an updated copy of this guide. This technical application guide is
for information purposes only and aims to support you in
tackling the challenges and taking full advantage of all
opportunities the technology has to offer. Please note that
this guide is based on own measurements, tests, specific
parameters and assumptions. Individual applications may
not be covered and need different handling. Responsibility
and testing obligations remain with the luminaire manufacturer/OEM/application planner.
2
PrevaLED ® Core AC PRO light engines | Introduction
1 Introduction
1.1 System overview
Building an LED-based luminaire poses a new set of technical challenges, among them new optical requirements,
providing adequate thermal management for stable operation and lastly dealing with the ever-improving performance
of LEDs. Nevertheless, LED technology also provides an
unknown wealth of possibilities, opening up unprecedented
levels of performance in addition to improved ways of integration. Continuing down this path of integration and innovation, OSRAM presents a revolutionary solution:
PrevaLED® Core AC PRO light engines have an integrated
driver and can therefore be connected directly to line voltage.
OSRAM’s PrevaLED ® family of LED light engines addresses
the challenges of LED-based lighting while at the same time
providing the user with high levels of flexibility. Enabled by the
application of LED technology, PrevaLED® aims to push the
envelope of what is possible in terms of performance and
simplicity.
The PrevaLED® Core AC PRO series of light engines is
ideally suited for use in reflector-based luminaires (such as
spotlights and downlights) in shop, hospitality, decorative
or office applications.
Benefits
— PrevaLED® Core AC PRO offers an integrated system
solution with the LED source and the electronic control
circuitry together on the same board, packaged into a
uniquely compact light engine that can be directly
connected to 230 VAC.
— Special energy-storage components enable an increased
quality of light while at the same time managing the light
modulation to be on par with standard drivers.
— Omitting the external driver allows for smaller, simpler,
slimmer and – last but not least – more cost-efficient
luminaire designs.
— Logistics and manufacturing are drastically simplified
thanks to the lack of the external driver and special
connecting cables, and also the reduced housing and
fixation materials.
— The PrevaLED® Core AC PRO family is easy to integrate
since its mechanical and optomechanical interface is
derived from the “Zhaga book 3” guideline, which reduces
design-in effort and allows the use of standard reflectors
and heat sinks. Although there currently is no standard
available for AC spotlight engines, the LES sizes as well
as the diameters and positioning of mounting holes are
derived from the Zhaga standards, similar to the
PrevaLED® Core Z3 and Z4 product ranges.
— The engines are outfitted with a standard connector which
allows for an easy “poke-in” of stranded and solid wires.
— The protective cover glass ensures safety for installers
and avoids damaging the COB.
— The reversible thermal shutdown protects the light engine
from breaking down when overheated.
— The entire PrevaLED® Core AC PRO family is certified
according to CE and VDE/ENEC standards.
— COB technology ensures great homogeneity where no
additional diffuser is required.
Product features
— PrevaLED® Core AC PRO is available in 2 000 and
3 000 lm, in two color temperatures (3 000 and 4 000 K)
and CRI 83.
— The LED light engine operates directly at a line voltage
of 230 VAC, 50/60 Hz.
— System efficacy (including driver losses) of up to
109 lm/W with a power factor of > 0.9.
— Lifetime is 50 000* hours (L70B50) at tp of 65 °C.
— tc max. = 85 °C.
PrevaLED ® Core AC PRO
* Currently under evaluation
3
PrevaLED ® Core AC PRO light engines | Introduction | Optical considerations
1.2 Nomenclature
PL-CORE: PrevaLED® Core family
AC: AC-capable (220–240 V, 50/60 Hz)
PRO: Professional
2000: 2000 lm
830: CRI + CCT = > 80 + 3000 K
PL-CORE-AC-PRO-2000-830
2 Optical considerations
2.1 Modulation of light
Due to the improved geometry and size of the PrevaLED®
Core AC PRO, it was possible to add capacitors to the
electrical circuit which reduce the modulation of the 100-Hz
frequency down to less than 40 %. More than 60 % of the
luminous flux level are always available.
2.2 Light distribution
The light distribution of the light engine is shown in the
graph below. The PrevaLED® Core AC PRO creates a beam
angle of 110° FWHM (full width at half maximum).
Light distribution curve
Warning: This light modulation might influence the perception of moving or rotating parts. Do not use the light engine
in critical applications such as turnery. The light engine
might also cause interference with monochrome LCDs
(twisted nematic displays).
105°
105°
90°
90°
75°
75°
60°
60°
Light modulation 3000 lm
[%]
Light output [%]
200
45°
140
45°
120
300
100
80
cd/klm
30°
60
15°
0°
15°
30°
40
The light-emitting surface (LES) of the light engine is covered
by a clear glass to protect the user from mains voltage.
20
0
0.01
0.015
0.02
0.025
Time [s]
Note: Please ensure that the light engine is only used with
an undamaged cover glass.
4
PrevaLED ® Core AC PRO light engines | Optical considerations
2.3 Reflector design
The PrevaLED® Core AC PRO can also be used with secondary optics. The diameter of the light-emitting surface and
the optical contact area (OCA) are shown in the table below.
LES and OCA
2000/3000 lm
Light-emitting
surface (LES)
category [mm]
Real LES
diameter [mm]
Optical contact
area (OCA)
category [mm]
19
19
C/23
The LES dimensions of PrevaLED® Core AC PRO light
engines meet Zhaga book 3 standards. Therefore, the
PrevaLED® Core AC PRO can be used in combination with
available off-the-shelf secondary optics. For optics support,
you can find suppliers via OSRAM’s LED Light for You network:
www.ledlightforyou.com. Moreover, standard components
and support for reflector design are available, e. g., from the
following suppliers:
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 at
www.osram.com via the “Tools & Services” portal.
2.4 Color temperature
The PrevaLED® Core AC PRO series is currently available in
3 000 K and 4 000 K. The color coordinates within the CIE
1931 color space are given in the table below.
Initial color values of the CCT
3000 K
4000 K
Cx
0.432
0.378
Cy
0.399
0.374
Jordan Reflektoren GmbH & Co. KG
Schwelmer Strasse 161, 42389 Wuppertal, Germany
+49 202 60720
[email protected]flektoren.de
www.jordan-reflektoren.de
Within each available color temperature, the PrevaLED®
Core AC PRO series provides a maximum color variation of
four threshold value units (MacAdam steps). The following
diagram shows these threshold values within the CIE 1931
color space.
ACL-Lichttechnik GmbH
Hans-Boeckler-Strasse 38 A, 40764 Langenfeld, Germany
+49 2173 9753 0
[email protected]flektor.com
www.reflektor.com
Color coordinates
Alux·Luxar GmbH & Co. KG
Schneiderstrasse 76, 40764 Langenfeld, Germany
+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
4-step MacAdam ellipses
y
0.45
3000 K
2500 K
4000 K
0.40
2000 K
6000 K
0.35
0.35
0.40
0.45
0.50
x
Nata Lighting Co., Ltd.
380 Jinou Road, Gaoxin Zone
Jiangmen City, Guangdong, China
+86 750 377 0000
[email protected]
www.nata.cn
5
PrevaLED ® Core AC PRO light engines | Optical considerations
3000 K
General CRI
Relative spectral emission [%]
Leaf green
Pink, skin color
Blue, saturated
Green, saturated
Yellow, saturated
Red, saturated
Lilac violet
Aster violet
Azure
Turquois
Light green
Wavelength spectrum
Yellowish green
Ra values (note: All values measured at tc = 65 °C)
Mustard yellow
2.6 Spectral distribution
The typical spectral distribution of PrevaLED® Core AC
PRO light engines is shown in the following diagram.
Dusky pink
2.5 Color rendering
PrevaLED® Core AC PRO light engines provide a color rendering index (CRI) of 83. The table below shows the individual
Ra values from R1 to R14 for the available color temperatures.
4000 K
100
80
R1 R2 R3 R4 R5 R6 R7 R8 R9 R10 R11 R12 R13 R14 Ra
60
CCT = 81 92 95 78 81 90 82 61 14 82
3000 K
76
70
84
98
83
CCT = 83 90 93 82 83 85 86 69 21 75
4000 K
80
63
85
96
84
40
20
0
380
480
580
680
780
Wavelength [nm]
Note: Do not stare directly into the beam or view directly
with optical instruments (risk group I according to IEC 62471).
6
PrevaLED ® Core AC PRO light engines | Ingress protection | Electrical considerations
3 Ingress protection
The PrevaLED® Core AC PRO has 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 from www.osram.com.
4 Electrical considerations
4.1 Wiring information
The PrevaLED® Core AC PRO can be directly connected to
mains voltage (220–240 V, 50/60 Hz).
The used input clamps can handle solid wire or flexible wire
with a cross-section of 0.2 to 0.75 mm2 (AWG24–18).
The use of solid wire is recommended.
Wire preparation
Notes:
— The connector is designed for three poke-in and release
cycles.
— Due to the fact that you are handling 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)
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 release the clamps, please use an operating tool (Wago type: 233-335) or a small screwdriver.
7
PrevaLED ® Core AC PRO light engines | Electrical considerations
4.2 Insulation requirements
The PrevaLED® Core AC PRO can be used in class I luminaires without further action. The creepage distance and
clearance are fulfilled. The protective cover glass is tested
according to a spring hammer test and provides class I
insulation. It prevents the user from touching the lightemitting surface which is connected directly to 220–240 VAC.
The PrevaLED® Core AC PRO has basic insulation. In class II
luminaires, additional care needs to be taken. The light engine
and all connected electrically conductive parts (e.g. a metal
heat sink) must be mounted in a way that they cannot be
touched by the user.
4.3 Inrush current and system installation
Due to its electronic construction, the PrevaLED® Core AC
PRO has a minimum inrush current. In system installations,
the number of light engines which can be attached to one
circuit is limited by the voltage drop regulations and the
used diameter of the connecting wire.
4.4 Electrostatic discharge (ESD)
It is not necessary to handle the PrevaLED® Core AC PRO
in electrostatic protected areas (EPAs).
To protect the light engine from electrostatic damage, the
module must not be opened. 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 any available phase-cut dimmer cannot be ensured.
4.6 Power as a function of voltage
The nominal voltage of the light engine is 230 V. The operation range is 220–240 V. For voltage variations, the light engine is tested according to IEC/EN 61000-3-3. Please note
that the power of the light engine changes over the voltage
range. Please have a look at the diagrams below for the
power as a function of voltage.
PrevaLED ® Core AC PRO 3000 830
[%]
Phi [lm]
Pel [W]
Pth [W]
130
110
90
70
50
30
10
150
170
190
210
230
250
270
Voltage [V]
PrevaLED ® Core AC PRO 2000 830
[%]
Phi [lm]
Pel [W]
Pth [W]
130
110
90
70
50
30
10
150
170
190
210
230
250
270
Voltage [V]
Note: According to EN 60598-1, luminaires have to be tested
with 1.06 times the rated voltage or the maximum of the
rated voltage range. This will also have implications on the
thermal power of the light engine.
8
PrevaLED ® Core AC PRO light engines | 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 the PrevaLED® Core AC PRO, 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® Core AC PRO is given below.
Thermal power values to be dissipated*
The list below is a selection of suppliers of thermal interface
materials. Additional partners for thermal management
support can also be found via OSRAM’s LED Light for You
network: www.ledlightforyou.com.
Thermal interface materials
Alfatec
www.alfatec.de
Kerafol
www.kerafol.de
Laird
www.lairdtech.com
www.bergquistcompany.com
Typical
Maximum
Bergquist
PL-CORE-AC-PRO-2000-830
12.5 W
13.8 W
Arctic Silver
www.arcticsilver.com
PL-CORE-AC-PRO-2000-840
11.9 W
13.1 W
Wakefield
www.wakefield.com
PL-CORE-AC-PRO-3000-830
24.8 W
27.3 W
PL-CORE-AC-PRO-3000-840
23.4 W
25.7 W
* Values measured at the tc point, at a reference temperature (tp) of 65 °C
5.1 Thermal power as a function of voltage
Please note that the thermal power of the module is related
to the line voltage. Please refer to the diagrams in chapter 4.6.
5.2 Thermal shutdown
To achieve the best possible performance of the module
and to protect it from damage by overheating, a thermal
protection feature has been added. The characteristics of
the thermal protection are shown in the following diagram.
5.4 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:
Define boundary
conditions
Total power dissipation of the
light engine, max. ambient
temperature ta, max. reference
temperature tr according to
lifetime requirements
Thermal shutdown
Rth =
Pel [%]
Estimate heat sink
thermal resistance on
light engine level
tr - ta
Pth
tr measured at the tc point
100
80
60
40
Select heat sink
thermal resistance
Area of active thermal protection –
not suitable for permanent operation
20
0
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
tc max. = 85
92 ± 7
110
tc [°C]
5.3 Thermal interface material and other accessories
When mounting a PrevaLED® Core AC PRO within a luminaire, it is highly 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 thermal foil can also 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 smoothness of the surface
should be optimized.
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® Core AC PRO light engine is in contact with the
solid material of the heat sink.
Note: The positioning of the mounting holes is compatible
with Zhaga book 3. Therefore, off-the-shelf heat sinks developed for these modules are also suitable for PrevaLED®
Core AC PRO light engines.
9
PrevaLED ® Core AC PRO light engines | Thermal considerations
The list below is a selection of suppliers of different cooling
solutions:
Cooling systems
Nuventix
www.nuventix.com
Sunon
www.sunoneurope.com
Cooler Master
www.coolermaster.com
AVC
www.avc-europa.de
SEPA
www.sepa-europe.com
Fischer Elektronik
www.fischerelektronik.de
Meccal
www.meccal.com
Wakefield
www.wakefield.com
R-Theta
www.r-theta.com
Cool Innovations
www.coolinnovations.com
5.5 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. tc according to IEC 62031 stands for
case temperature, which is the highest permissible temperature measured at the tc point. The tc point is the location
where the tc is measured (in the center of the back of the
light engine).
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:
K-type thermocouple with miniature connector
Miniature connector “K”
Thermo wire NiCr-Ni
Different thermocouples
Illustration
Description
Temperature range [°C]
PVC-insulated -10 … +105
thermocouple
PFA-insulated -75 … +260
thermocouple
Sprung
-75 … +260
thermocouple
Location of the tc point
tc point
tp (performance temperature) is the reference temperature
at which the datasheet values are applicable.
A correct temperature measurement can, for example, be
performed with a thermocouple.
10
PrevaLED ® Core AC PRO light engines | Thermal considerations
To measure the temperature and to ensure a good thermal
coupling between the light engine and the heat sink, drill a
hole into the heat sink and push the thermocouple through
it. To ensure a direct contact between the thermocouple
and the PCB, it is recommended to glue the thermocouple
onto the PCB. You can, for example, use an acrylic adhesive (e.g. type Loctite 3751).
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 and run the thermocouple inside the groove to the tc point.
Mounting of a thermocouple through a hole in the heat sink
Mounting of a thermocouple by means of a groove
Note: Please keep in mind that you need a direct contact
between the thermocouple and the PCB.
11
PrevaLED ® Core AC PRO light engines | Lifetime and thermal behavior
6 Lifetime and thermal behavior
6.1 Flux as a function of temperature
The luminous flux of the PrevaLED® Core AC PRO light engine
depends on its temperature. 100 % of the luminous flux is
achieved at the performance temperature of 65 °C (tp = 65 °C).
This temperature has to be measured at the tc point. If the
performance temperature increases, the light output decreases.
The luminous flux changes in relation to the reference
temperature according to the following diagram:
Flux as a function of tc temperature
2000 lm
Relative flux [%]
3000 lm
6.2 Lifetime as a function of temperature
For the definition of the lifetime of a light engine, 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 light engines.
— L70F50 is the lifetime where the light output is ≥ 70 % for
50 % of the light engines. 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 light engines. B value includes only gradual
reduction of lumen output over time (not the abrupt flux
degradation).
If the performance temperature (tp) of 65 °C is maintained,
PrevaLED® Core AC PRO light engines have an average
lifetime of 50 000* hours (L70B50). The maximum temperature
measured at the tc point must not exceed 85 °C.
108
106
104
102
Note: Higher tc temperatures lead to a shorter lifetime of
the PrevaLED® Core AC PRO light engines. Moreover, the
failure rate will also increase.
100
98
96
94
92
90
10
20
30
40
50
60
70
80
90
100
tc point temperature [°C]
* Currently under evaluation
12
PrevaLED ® Core AC PRO light engines | Mechanical considerations
7 Mechanical considerations
7.1 Outline drawing
The following schematic drawing provides further details
on the dimensions of PrevaLED® Core AC PRO light engines.
For 3D files of the light engines, please go to:
www.osram.com.
35
LES19
14.8
7.2
Technical drawing
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.
∅ 80
∅ 35
kg
68
All fi gures in mm
1. Don’t connect the module when the glass cover is broken.
2. Do not mechanically stress the module.
3. The LED light engine has to be built into a luminaire.
7.4 Mounting
To fix a PrevaLED® Core AC PRO light engine to a heat
sink, you can use M3 cylinder-head screws according to
DIN 7984 or DIN EN ISO 4762. The allowed torque is
0.6 Nm (±0.1 Nm).
7.2 3D drawing
Enable 3D View
Move me!
Movable 3D PrevaLED ® Core AC PRO light engine
(works with Adobe Acrobat 7 or higher)
Mount the light engine from the top
7.3 Mechanical protection of the light engine
Note: The housing of a PrevaLED® Core AC PRO light
engine must 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.
7.5 Protection from corrosion
To protect electronic parts (such as LEDs) from corrosion,
a corrosive atmosphere around the components has to be
avoided. In case of LEDs, H2S, for example, is a highly
corrosive substance which can lead to a drastically shortened product lifetime. The source for H2S are sulfur-crosslinked polymers, such as rubber. To ensure the absence of
H2S, it is recommended to use peroxide-cross-linked
materials, which are available on the market as an alternative
to sulfur-cross-linked versions. Avoidance of corrosion by
moisture has to be ensured by the appropriate protection of
the luminaire housing (see chapter 3 “Ingress protection”).
Note: If the protection glass 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 immediately to avoid contact with
parts of the light engine that conduct 230 V!
13
PrevaLED ® Core AC PRO light engines | Norms and standards
8 Norms and standards
Safety:
IEC/EN 62031
IEC/EN 60598-1
Photobiological safety:
IEC/EN 62471
Risk group 1
Electromagnetic compatibility:
CISPR 15
IEC/EN 61547
IEC/EN 61000-3-2
IEC/EN 61000-3-3
EN 55015
Ingress protection:
IP20
Approvals:
CE, VDE, ENEC, VDE EMC mark
10
Disclaimer
All information contained in this document has been collected,
analyzed and verified with great care by OSRAM. However,
OSRAM is not responsible for the correctness and completeness of the information contained in this document and
OSRAM cannot be made liable for any damage that occurs
in connection with the use of and/or reliance on the content
of this document. The information contained in this document
reflects the current state of knowledge on the date of issue.
14
01/15 OSRAM S-GI MK EM Subject to change without notice. Errors and omissions excepted.
www.osram.com/prevaled
OSRAM GmbH
Head office:
Marcel-Breuer-Strasse 6
80807 Munich, Germany
Phone +49 89 6213-0
Fax
+49 89 6213-2020
www.osram.com
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