Technical application guide
www.osram.com/prevaled-core
09/2015
Technical application guide
PrevaLED® Core Z5
LED modules
Light is OSRAM
PrevaLED ® Core Z5 LED modules | Contents
Contents
1 Introduction
03
4 Thermal considerations
1.1 System overview
03
4.1 Thermal power values
14
14
1.2 Nomenclature
03
4.2 TIM and other accessories
15
4.3 Cooling system and heat sink
15
2 Optical considerations
04
4.4 tc point location and temperature measurement
16
2.1 Light distribution
04
4.5 Thermocouple
16
2.2 Refl ector design
04
2.3 Photobiological safety
04
5 Lifetime and thermal behavior
17
2.4 Theoretical considerations for possible refl ectors
05
5.1 Luminous fl ux as a function of temperature
17
2.5 Refl ector mounting
06
5.2 Lifetime
17
2.6 Color temperature
06
2.7 Color rendering
07
6 Mechanical considerations
18
2.8 Spectral distribution
07
6.1 Outline drawing
18
2.9 Luminous flux behavior
08
6.2 3D drawing
18
3 Electrical considerations
09
3.1 Forward voltage as a function of temperature
09
3.2 LED driver/LED module combination
09
3.3 Wiring
10
3.4 OTi DALI LED drivers
11
3.5 OT FIT LED drivers
11
3.6 OTe LED drivers
11
3.7 LEDset2 (LT2)
12
3.8 Maximum allowed number of LED drivers per circuit breaker
13
3.9 ESD
13
6.3 Mechanical protection of the PrevaLED ® Core Z5 LED module
18
6.4 Mounting
18
7 Norms and standards
19
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 Z5 LED modules | Introduction
1 Introduction
1.1 System overview
Building an LED-based luminaire poses a set of technical
challenges, among them optical requirements, providing
adequate thermal management for stable operation and
dealing with the improving performance of LEDs. Nevertheless, LED technology also provides an unknown number
of possibilities, opening up unprecedented levels of performance. PrevaLED® Core LED modules, which are compatible with Zhaga Book 3 standards, offer one of the best
and easiest ways to outfit luminaires with LED technology.
Focusing on the continuous improvement of performance
and costs, OSRAM has introduced its new generation of
Zhaga spotlight LED modules: PrevaLED® Core Z5. Together
with the dedicated on/off and intelligent OPTOTRONIC®
LED driver ranges, it offers a complete and reliable system.
Future-proof concept
To allow for a smooth transition to this new generation of
the PrevaLED® Core series, crucial features have remained
the same:
— Complete portfolio in terms of luminous flux, color
temperature and color rendering
— Easy upgrade from Z4 thanks to identical housing
— Same form factor and mechanical/optical interfaces
as PrevaLED® Core Z3 and Z4
— Compatible with off-the-shelf Zhaga Book 3 accessories
— High driver flexibility allows cost-effective and intelligent
systems
— 5-year guarantee (for current terms and conditions
of the guarantee, please visit www.osram.com/
system-guarantee)
— Selection of dimmable and non-dimmable LED drivers
Of course, important improvements have been realized
as well:
— Easy design-in
— Only one reflector size for 2 000, 3 000 and 5 000 lm
with 3 x LES 19
— Lifetime (L80B50) at tc = 65 °C:
50 000 hours (preliminary)
— Improved poke-in connector for stranded and solid wires
— Very good light quality
— Very high efficiencies for smaller heat sinks and easier
thermal management
— Typical module efficacy: up to 146 lm/W
— tc max: 90 °C
— Thermal protection
— Thermal derating with OTi
— Thermal shutdown
Applications
The PrevaLED® Core series of LED modules is ideally suited
for use in reflector-based, rotation-symmetric luminaires in
applications such as:
— Spotlighting and tracklighting in retail stores
— Downlighting and wall lighting in offices, corridors,
meeting rooms and workplaces
— Decorative and functional lighting in the hospitality
industry
— High-end museum lighting
1.2 Nomenclature
PL: PrevaLED® LED module
Core: Round LED module
Z5: Generation 5
3000: 3000 lm
830: Color rendering index (CRI) + color
temperature (CCT) = > 80 + 3000 K
PL-CORE-Z5-3000-830
3
PrevaLED ® Core Z5 LED modules | Optical considerations
2 Optical considerations
2.1 Light distribution
The light distribution of the LED module is shown in the
graph below. PrevaLED® Core Z5 LED modules create
a beam angle of 114° FWHM (full width at half maximum).
C 0°
2.2 Refl ector design
High luminances are the key factor for LED-based lamps
and luminaires in the area of reflector applications, such as
spotlights. For this purpose, light sources with small lightemitting surfaces and a high luminous flux – as realized in
the PrevaLED® Core Z5 – are required, because in such
combinations, the light can be collimated particularly well
with reflectors.
The PrevaLED® Core Z5 is equipped with a surface that
emits light evenly and makes the use of diffuser materials
unnecessary due to its high level of homogeneity. The
minimized light-emitting surface (LES) and a positioning of
the reflector close to the LES allow for an improved optical
handling. Generally, the properties of the PrevaLED ® Core
Z5 help to avoid roughness and facets, allowing for very
small total beam angles of 10° or less.
75°
60°
45°
30°
15°
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-core. Ray file data are available
at www.osram.com via the “Tools & Services” portal.
2.3 Photobiological safety
According to IEC/EN 62471, all PrevaLED® Core Z5
LED modules are within risk group (RG) 1 at their nominal
operating conditions.
Note:
For the PL-CORE Z5-5000-840 module, the photobiological safety class RG 1 might not be achieved when using a
significantly higher current than the nominal module current. This may result in risk group classifications up to RG 2.
4
PrevaLED ® Core Z5 LED modules | Optical considerations
2.4 Theoretical considerations for possible refl ectors
PrevaLED ® Core Z5, 2000 lm, LES 19, OCA C*
PrevaLED ® Core Z5, 5000 lm, LES 19, OCA C*
Reflector output diameter [mm]
Reflector 80
height
[mm]
100
100
Reflector output diameter [mm]
Reflector 80
height
[mm]
100
15°; 17000 cd; 12°; 22000 cd; 11°; 28000 cd;
88 %; 4200 lx; 89 %; 5600 lx; 90 %; 7100 lx;
8.4 cd/lm
11.2 cd/lm
14.3 cd/lm
100
15°; 42500 cd; 12°; 55000 cd; 11°; 70000 cd;
88 %; 10500 lx; 89 %; 14000 lx; 90 %; 17750 lx;
8.4 cd/lm
11.2 cd/lm
14.3 cd/lm
80
15°; 16000 cd; 12°; 21000 cd; 10°; 25000 cd;
89 %; 3900 lx; 91 %; 5200 lx; 92 %; 6400 lx;
7.9 cd/lm
10.4 cd/lm
12.8 cd/lm
80
15°; 40000 cd; 12°; 42500 cd; 10°; 62500 cd;
89 %; 9750 lx; 91 %;13000 lx; 92 %; 16000 lx;
7.9 cd/lm
10.4 cd/lm
12.8 cd/lm
60
19°; 10000 cd; 15°; 14000 cd; 12°; 18000 cd; 10°; 21000 cd;
90 %; 2600 lx; 91 %; 3500 lx; 93 %; 4400 lx; 94 %; 5200 lx;
10.5 cd/lm
5.2 cd/lm
7.0 cd/lm
8.9 cd/lm
60
19°; 25000 cd; 15°; 35000 cd; 12°; 45000 cd; 10°; 52500 cd;
90 %; 6500 lx; 91 %; 8750 lx; 93 %; 11000 lx; 94 %; 13000 lx;
10.5 cd/lm
5.2 cd/lm
7.0 cd/lm
8.9 cd/lm
40
19°; 8000 cd; 14°; 11000 cd; 11°; 12000 cd; 8°; 13000 cd;
93 %; 2100 lx; 95 %; 2600 lx; 96 %; 3100 lx; 97 %; 3300 lx;
4.2 cd/lm
5.3 cd/lm
6.1 cd/lm
6.5 cd/lm
40
19°; 20000 cd; 14°; 27500 cd; 11°; 30000 cd; 8°; 32500 cd;
93 %; 5250 lx; 95 %; 6500 lx; 96 %; 7750 lx; 97 %; 8250 lx;
4.2 cd/lm
5.3 cd/lm
6.1 cd/lm
6.5 cd/lm
120
140
120
140
* Parabolic refl ector, 85 % specular refl ectance, lux in 2 m distance
PrevaLED ® Core Z5, 3000 lm, LES 19, OCA C*
Reflector output diameter [mm]
Reflector 80
height
[mm]
100
100
15°; 25000 cd; 12°; 34000 cd; 11°; 43000 cd;
88 %; 6300 lx; 89 %; 8400 lx; 90 %; 10700 lx;
8.4 cd/lm
11.2 cd/lm
14.3 cd/lm
80
15°; 24000 cd; 12°; 31000 cd; 10°; 38000 cd;
89 %; 5900 lx; 91 %; 7800 lx; 92 %; 9600 lx;
7.9 cd/lm
10.4 cd/lm
12.8 cd/lm
60
19°; 16000 cd; 15°; 21000 cd; 12°; 27000 cd; 10°; 32000 cd;
90 %; 3900 lx; 91 %; 5200 lx; 93 %; 6600 lx; 94 %; 7900 lx;
10.5 cd/lm
5.2 cd/lm
7.0 cd/lm
8.9 cd/lm
40
19°; 13000 cd; 14°; 16000 cd; 11°; 18000 cd; 8°; 20000 cd;
93 %; 3100 lx; 95 %; 4000 lx; 96 %; 4600 lx; 97 %; 4900 lx;
4.2 cd/lm
5.3 cd/lm
6.1 cd/lm
6.5 cd/lm
120
140
PrevaLED ® Core Z5, 4500 lm, LES 19, OCA C*
The above-mentioned estimations are based on the following
assumptions:
— A parabolic reflector shape is used.
— A fine facet structure is applied as it should always
be used for CoB LEDs. The impact on the narrowest
possible beam angle is small.
— A purely specular reflectance of 85 % is assumed.
— The collimation strength values (cd/lm) refer to the
luminous flux of the LED module.
— Data values in orange correspond to a reflector with an
extremely large diameter/height ratio D/H > 2 (cut-off
angle > 45°). This is not recommended with respect
to glare.
— Illuminance values are the maximum values in the spot
center in a distance of 2 m to the reflector.
The PrevaLED® Core Z5 can be used with secondary optics.
Zhaga-compliant off-the-shelf solutions can be used with
the LED module. For optics support, you can find suppliers via
OSRAM’s LED Light for You network: www.ledlightforyou.com.
Moreover, off-the-shelf solutions and support for reflector
design are available, e.g., from the following suppliers:
Reflector output diameter [mm]
Reflector 80
height
[mm]
100
100
15°; 38250 cd; 12°; 49500 cd; 11°; 63000 cd;
88 %; 9450 lx; 89 %; 12600 lx; 90 %; 15975 lx;
8.4 cd/lm
11.2 cd/lm
14.3 cd/lm
80
15°; 36000 cd; 12°; 47250 cd; 10°; 56250 cd;
89 %; 8775 lx; 91 %; 11700 lx; 92 %; 14400 lx;
7.9 cd/lm
10.4 cd/lm
12.8 cd/lm
60
19°; 22500 cd; 15°; 31500 cd; 12°; 40500 cd; 10°; 47250 cd;
90 %; 5850 lx; 91 %; 7875 lx; 93 %; 9900 lx; 94 %; 11700 lx;
10.5 cd/lm
5.2 cd/lm
7.0 cd/lm
8.9 cd/lm
40
120
140
19°; 18000 cd; 14°; 24750 cd; 11°; 27000 cd; 8°; 29250 cd;
93 %; 4725 lx; 95 %; 5850 lx; 96 %; 6975 lx; 97 %; 7425 lx;
4.2 cd/lm
6.1 cd/lm
5.3 cd/lm
6.5 cd/lm
ACL-Lichttechnik GmbH
Hans-Boeckler-Strasse 38 A
40764 Langenfeld, Germany
+49 2173 9753 0
[email protected]flektor.com
www.reflektor.com
Almeco S.p.A.
Via della Liberazione, 15
20098 San Giuliano Milanese (Mi), Italy
+39 02 988963 1
[email protected]
www.almecogroup.com
5
PrevaLED ® Core Z5 LED modules | Optical considerations
Jordan Luxar GmbH & Co. KG
Schneiderstrasse 76
40764 Langenfeld, Germany
+49 2173 279 0
[email protected]
www.jordan-luxar.de
Jordan Refl ektoren GmbH & Co. KG
Schwelmer Strasse 161
42389 Wuppertal, Germany
+49 202 60720
[email protected]flektoren.de
www.jordan-reflektoren.de
Nata Lighting Co., Ltd.
380 Jin Ou Road, Jiang Hai District
Jiang Men City, Guangdong, China
+86 750 377 0000
[email protected]
www.nata.cn
Widegerm Lighting Ltd.
Flat A, 3/F., Tak Wing Ind. Building
3 Tsun Wen Rd., Tuen Mun, N.T., Hong Kong
+85 224 655 679
[email protected]
www.widegerm.com.hk
it is recommended to stay within the OCA values of the
corresponding category (see product datasheet).
Additionally, a bayonet base option is provided, with the
help of which the reflector can be attached directly to the
PrevaLED® Core Z5.
PrevaLED® Core Z5 3D files including the bayonet base for
design-in are available at www.osram.com/prevaled-core.
2.6 Color temperature
The PrevaLED® Core Z5 series is currently available in
2 700 K, 3 000 K, 3 500 K and 4 000 K. The color coordinates
within the CIE 1931 color space are given below.
Cx
2700 K
0.4579
3000 K
0.4339
3500 K
0.4077
4000 K
0.3823
Cy
0.4092
0.4020
0.3908
0.3790
Values measured at tp = 65 °C
Within each available color temperature, the PrevaLED ®
Core Z5 series provides a maximum color variation of three
threshold value units (MacAdam steps). The following diagram shows these threshold values within the CIE 1931
color space.
y
2.5 Refl ector mounting
The LED modules have a clearly defined optical contact
area (OCA), which provides a defined surface for attaching
the reflector. In this configuration, the mounting and
mechanical support of the reflector must be ensured by the
luminaire body or by suitable structures for reflector mounting.
The following has to be considered when mounting the
reflector: Due to the creepage and clearance distances
specified in the norm (IEC 61347-1/U935, among others),
0.45
3000
0.425
3500
4000
0.40
4500
0.375
0.35
5000
0.35
0.375
0.40
0.425
0.45
x
Chromaticity coordinate groups:
Chromaticity coordinates are measured during a current
pulse of typically 25 ms, with an internal reproducibility of
±0.005 and an expanded uncertainty of ±0.01 (acc. to GUM
with a coverage factor of k = 3). For testing, the chromaticity
coordinate ellipses are approximated with polygons.
Allowed compression: 20 N
Allowed tension: 20 N
Allowed torque: 1 Nm
6
PrevaLED ® Core Z5 LED modules | Optical considerations
General CRI
Leaf green
Pink, skin color
Blue, saturated
Green, saturated
Yellow, saturated
Red, saturated
Lilac violet
Aster violet
Azure
Turquois
Light green
Dusky pink
Mustard yellow
Yellowish green
2.7 Color rendering
PrevaLED® Core Z5 LED modules provide a color rendering
index (CRI) of either > 80 or > 90. The table below shows
the individual Ra values from R1 to R14 for the available
color temperatures.
R1
R2
R3
R4
R5
R6
R7
R8
R9
R10
R11
R12
R13
R14
Ra
CCT =
2700 K
80
90
97
80
80
88
83
58
5
78
79
74
82
99
82
CCT =
3000 K
81
90
97
82
82
88
84
61
10
78
81
74
83
99
83
CCT =
3500 K
83
90
96
84
83
87
86
65
14
77
83
73
84
98
84
CCT =
4000 K
82
90
95
84
83
87
86
66
14
76
83
72
84
97
84
CCT =
3000 K
96
96
93
95
95
94
95
91
77
89
96
85
96
95
91
2.8 Spectral distribution
The typical spectral distribution of the PrevaLED® Core Z5
LED modules is shown in the following diagram.
827
Relative luminous intensity
830
835
840
930
1.00
0.80
0.60
0.40
0.20
0
380
430
480
530
580
630
680
730
780
Wavelength [nm]
Values measured at tp = 65 °C
7
PrevaLED ® Core Z5 LED modules | Optical considerations
2.9 Luminous fl ux behavior
The following diagrams show the luminous flux as a function
of the operating current for PrevaLED® Core Z5 LED modules with 2 000, 3 000 and 5 000 lm. Data related to the
operating current is derived from a tp temperature of 65 °C.
PL-CORE-Z5-2000-XXX
Luminous flux as a function of forward current (I f )
PL-CORE-Z5-2000-830
PL-CORE-Z5-2000-840
PL-CORE-Z5-2000-930
Luminous flux [lm]
PL-CORE-Z5-5000-XXX
Luminous flux as a function of forward current (I f )
Luminous flux [lm]
4000
7000
3500
6000
3000
PL-CORE-Z5-5000-830
PL-CORE-Z5-5000-840
PL-CORE-Z5-5000-930
5000
2500
4000
2000
3000
1500
2000
1000
1000
500
0
100
200
300
400
500
600
700
If [mA]
0
200
400
600
800
1000
1200
1400
If [mA]
PL-CORE-Z5-3000-XXX
Luminous flux as a function of forward current (I f )
PL-CORE-Z5-3000-830
PL-CORE-Z5-3000-840
PL-CORE-Z5-3000-930
Luminous flux [lm]
7000
6000
5000
4000
3000
2000
1000
0
0
200
400
600
800
1000
If [mA]
8
PrevaLED ® Core Z5 LED modules | Electrical considerations
3 Electrical considerations
3.1 Forward voltage as a function of temperature
PL-CORE-Z5-2000-XXX
Forward voltage (U f ) as a function of
temperature at the tc point
PL-CORE-Z5-5000-XXX
Forward voltage (U f ) as a function of
temperature at the tc point
PL-CORE-Z5-2000-830
PL-CORE-Z5-2000-840
PL-CORE-Z5-2000-930
Uf [V]
PL-CORE-Z5-5000-830
PL-CORE-Z5-5000-840
PL-CORE-Z5-5000-930
Uf [V]
48
45.5
47.5
45
47
46.5
44.5
46
44
45.5
43.5
45
43
44.5
42.5
44
43.5
30
40
50
60
70
80
90
Temperature at the tc point [°C]
PL-CORE-Z5-3000-XXX
Forward voltage (U f ) as a function of
temperature at the tc point
PL-CORE-Z5-3000-830
PL-CORE-Z5-3000-840
PL-CORE-Z5-3000-930
Uf [V]
47.5
47
42
30
40
50
60
70
80
90
Temperature at the tc point [°C]
3.2 LED driver/LED module combination
PrevaLED® Core Z5 LED modules can either be used
with non-dimmable or intelligent, dimmable OSRAM LED
drivers (e.g. OTi DALI). To find the best possible LED driver/
LED module combination, please refer to the OSRAM
Matchmaker tool, which is available at www.osram.com/
oem-download in the section “LED light engines Spot- and
Downlights”. With the OSRAM Matchmaker tool, you can
easily find out about possible system combinations and
resulting electronic and photometric parameters.
46.5
46
45.5
45
44.5
44
43.5
43
30
40
50
60
70
80
90
Temperature at the tc point [°C]
9
PrevaLED ® Core Z5 LED modules | Electrical considerations
3.3 Wiring
The input clamps used in the PrevaLED® Core Z5 can
handle solid wires with a cross-section of 0.5–1.0 mm2
(AWG 21–17).
Release
Example: H05V-U 1x 0.5 mm 2
Wire preparation
For wires with
1 mm2 (AWG 17):
5.5 mm
For wires with
0.5–0.823 mm2
(AWG 21–18):
5.3 mm (±0.2 mm)
Please note:
— The connector is designed for three “poke-in” and
release cycles.
— The installation of LED modules has to be carried out
in compliance with all applicable electrical and safety
standards. Only qualified personnel should be allowed
to perform installations.
— If you cannot use solid wires, you can use stranded
wires with a diameter of 0.5 to 0.75 mm and tin-coat
the wire ends before inserting them into the connection
clamp. Depending on the wire and/or cable type,
other suitable preparations may also be necessary
(e.g. cable end contacts).
1
Use a suitable screwdriver and push gently into the release hole
2
Push in the screwdriver below the release spring
Insert and release
Insert
3
Pull out the wire and afterwards the screwdriver
Insert wire directly
10
PrevaLED ® Core Z5 LED modules | Electrical considerations
3.4 OTi DALI LED drivers
If you use the PrevaLED® Core Z5 series in combination
with the OSRAM OTi DALI LED driver series, you will get
the best results and the full functionality of the LED module.
3.6 OTe LED drivers
If you want to use the OSRAM OTe series, please connect
the terminal LED+ to the LED module and select the desired
current by connecting it to only one of the output terminals
21, 22 or 23.
The system includes a one-wire communication interface,
using the LEDset2 communication standard between the
LED driver and the LED module. A thermal derating and
a luminous flux calibration are included. Therefore, please
connect all three terminals of the module to the LED driver.
Connection detail
Connection detail
Select only
one connection
terminal
OTe 35/220-240/700 CS
OTi DALI 50/220-240/1A4 LT2 FAN
3.5 OT FIT LED drivers
It is also possible to use the PrevaLED® Core Z5 series
with a constant-current LED driver. The OT FIT series offers
different available currents. To wire the LED module to the
LED driver, please connect the terminals LED+ and LED- to
the LED module as shown in the image below. The current
is selected by a bridge between ports 3, 4 and 5.
Connection detail
OT FIT 25/220-240/500 CS
11
PrevaLED ® Core Z5 LED modules | Electrical considerations
3.7 LEDset2 (LT2)
LEDset helps you to meet important market requirements:
— Future-proof solutions in terms of luminous flux
— Long-life operation
— Luminaire customization
— Energy and cost saving
In combination with OSRAM LED drivers, the LEDset
interface offers full flexibility and a future-proof system with
the following features and benefits:
— Simplified wiring for easy setting of the LED driver
current, suitable for the connected LED module
— Versatile connectivity of several LED modules,
either in parallel or in series (or a mix of both)
— Thermal protection for LED modules
LEDset2 (LEDset generation 2) is the enhanced interface
between OPTOTRONIC ® LED drivers and LED modules
(such as OSRAM PrevaLED®). It can be identified by the
product name of the LED driver, including the letters “LT2”
at its end – while LEDset (generation 1) ends with “LT” only.
LEDset interface behavior has been changed in order to
obtain the following advantages:
— To add the parallel LED modules operation, especially
for linear and area SSL systems, while optimizing the
operating range with spot and downlight systems
— To simplify assembly (only one additional wire instead
of three as before)
LEDset2 is a low-cost analog interface based on a threewire connection between the LED driver and one or more
LED modules. Only one additional wire – besides the two
LED current supply wires (LED+, LED-) – is used for transferring information from the LED module/s to the LED driver.
This interface is designed to allow communication between
the LED module and the LED driver, performing LED current
setting and thermal protection functionality.
The interface supports the following functionalities:
— Absolute output current setting of the constant-current
LED driver (LED module self-recognition)
— Handling of parallel/serial LED module connection
— Thermal protection of the LED module
Typical applications of this interface are single or parallel
or serial LED module connections, offering a wider choice
of modular capabilities and low-cost thermal protection
circuits. In case of multiple module connection, all connected
LED modules must be identical (with the same current set
and with matched forward voltages).
The relationship Iout vs. Rset is defined by the following
formula:
Iout [A] =
5V
Rset [Ω]
x 1000
The table below shows the improvements of the LEDset2
compared to the previous version.
What’s changed in LEDset2?
Current setting
method
LEDset
(generation 1)
Rset resistor
LEDset2 interface wiring (block diagram)
LEDset2
LED driver
LED module
Rset resistor with
new coding
LED+
Current coding
Relative
Absolute (within the range
(in % of the
of 0.1 A to 5 A)
maximum output
current of the LED
driver)
Typical number
of LED modules
in the system
1
From 1 up to many (series
and parallel combinations)
Number of wires
for LEDset
3
1
Multivendor
No (provided by
OSRAM only)
Yes (being adopted by other
vendors)
LEDset
Current setting
(Rset connection)
Thermal protection
LED-
12
PrevaLED ® Core Z5 LED modules | Electrical considerations
LEDset2 allows a stepless selection of the output current
through the simple selection of the proper Rset resistor value
and the connection of a potentiometer or a fixed standard
resistor to the LEDset line. The table below shows the output current values in the entire valid LEDset range if the
standard resistor series E24 is used.
Output current values using standard E24 resistor values
Rset
E24 [Ω]
Output
current
[mA]
Rset
E24 [Ω]
Output
current
[mA]
Rset
E24 [Ω]
Output
current
[mA]
Rset
E24 [Ω]
Output
current
[mA]
Rset
E24 [Ω]
Output
current
[mA]
51000
100
22000
227
9100
549
3900
1282
1600
3125
47000
106
20000
250
8200
610
3600
1389
1500
3333
43000
116
18000
278
7500
667
3300
1515
1300
3846
39000
128
16000
313
6800
735
3000
1667
1200
4167
36000
138
15000
333
6200
806
2700
1852
1100
4545
33000
151
13000
385
5600
893
2400
2083
1000
5000
30000
166
12000
417
5100
980
2200
2273
27000
185
11000
455
4700
1064
2000
2500
24000
208
10000
500
4300
1163
1800
2778
Two output ports (LED+ and LED-) are used for the connection of the LED string/s. LEDset2 is a one-wire interface
and uses the LED- line as the reference ground. The interface is intended for the control of a single-channel, constantcurrent LED driver with a single or multiple LED string load.
LED driver output terminal configuration and color
code (view from above)
LED driver
output terminals
LED+
LED-
LEDset
LED+ wire
LED- wire
LEDset wire
LED(optional)
3.8 Maximum allowed number of LED drivers
per circuit breaker
B16
B10
OTe 35/700
50
30
OT 35 LTCS
84
52
OT 45 LTCS
60
40
OT 45 DALI LTCS
47
18
OTe 25 CS
50
30
OTe 18 PC
TBD
TBD
OTe 25 PC
TBD
TBD
OTe 35 CS S
44
28
OTe 35 CS
25
15
OTe 50/1A4 CS
25
15
OTe 50/1A0 CS
25
15
OTe 50 CS FAN
25
15
OT FIT 15 CS
28
17
OT FIT 25 CS
28
17
OT FIT 35 CS
28
17
OT FIT 50
TBD
TBD
OTi DALI 25
84*
52*
OTi DALI 35
60*
40*
OTi DALI 50 FAN
13
18
* Preliminary data
More detailed information about the possibilities of
LEDset2 interfaces can be found in the corresponding
application guidelines of this interface.
3.9 ESD
It is not necessary to handle PrevaLED® Core Z5 LED
modules in electrostatic protected areas (EPAs). To protect a
PrevaLED® Core Z5 LED module from electrostatic damage,
do not open it. The LED module fulfills the requirement of
the immunity standard IEC/EN 61547.
13
PrevaLED ® Core Z5 LED modules | Thermal considerations
4 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® Core Z5 LED modules, only a partial amount of
the introduced electrical power has to be dissipated through
the back of the LED module. The thermal power that has to
be dissipated for PrevaLED® Core Z5 LED modules is given
below.
Thermal fuse characteristic
Current [% of minimal LED driver current]
100
4.1 Thermal power values
Product
Typ.
thermal
power
[W]1)
Max. thermal
power [W]
at nominal
current1)
Max. allowable
thermal
resistance Rth
[K/W]2)
PL-CORE-Z5-2000-827
10.2
12.4
3.3
PL-CORE-Z5-2000-830
9.1
11.3
3.7
PL-CORE-Z5-2000-835
8.1
10.1
4.1
PL-CORE-Z5-2000-840
7.5
9.5
4.4
PL-CORE-Z5-2000-930
13.7
16.6
2.4
PL-CORE-Z5-3000-827
15.4
18.8
2
PL-CORE-Z5-3000-830
13.9
17.1
2.3
PL-CORE-Z5-3000-835
12.4
15.4
2.6
PL-CORE-Z5-3000-840
11.3
14.3
2.7
PL-CORE-Z5-3000-930
19.9
24.1
1.7
PL-CORE-Z5-5000-827
30
36
0.8
PL-CORE-Z5-5000-830
27.4
33.2
0.9
PL-CORE-Z5-5000-835
24.4
29.9
1.1
PL-CORE-Z5-5000-840
22.3
27.7
1.1
PL-CORE-Z5-4500-930
34.1
40.9
0.7
1) Value measured at the tc point at a reference temperature (tr) of 65 °C
2) Value measured on the back of the luminaire at an ambient temperature of 25 °C
0
102
tc [°C]
Thermal derating with LEDset2
Current [% of minimal LED driver current]
100
50
0
tc max
To achieve the best possible lifetime of the LED module
and to save it from damage by overheating, a thermal
protection feature has been integrated.
110
116
105
tc [°C]
The behavior below 50 % of the system current depends on the
nominal system current and the applied LED driver.
The thermal protection of the PrevaLED® Core Z5 LED
module is divided into two parts: The first part is an onboard reversible thermal fuse that prevents the module
from damage by overheating. The characteristic of the
thermal fuse is shown at the top right.
Note: If the thermal fuse is triggered, the module is shut off
completely. The thermal fuse can be reset by disconnecting
the mains and repowering the LED module.
The second part of the thermal protection is a thermal derating function that works in combination with LED drivers
with LEDset2 funcionality. It protects the LED module from
overheating by communicating with the LED driver (the LEDset port of the LED module must be connected). The system
reduces the current of the LED module if critical temperatures are reached at the tc point. This results in the best
possible performance and lifetime of the LED module. The
characteristic of the thermal derating function is shown at
the bottom right.
14
PrevaLED ® Core Z5 LED modules | Thermal considerations
4.2 TIM and other accessories
When mounting a PrevaLED® Core Z5 LED module within a
luminaire, it is mandatory to use thermal interface material
(TIM) between the back of the LED module and the luminaire housing or heat sink. It is recommended to use thermal paste or phase-change material (PCM) because they
perform better than thermal foil or pads. In order to balance
possible unevenness, the material should be applied with a
thickness between 0.15 and 0.30 mm (0.25 mm is recommended) and a maximum size of 25 x 25 mm. In this way,
air inclusions, which may otherwise occur, are replaced by
TIM and the required heat conduction between the back of
the LED module and the contact surfaces of the luminaire
housing is achieved. For this purpose, the roughness of the
surface should be minimized and the planarity as well as
the cleanness of the surface (free from burrs, chips or any
other particles) should be optimized.
4.3 Cooling system and heat sink
For the selection of a suitable heat sink, several points
regarding thermal resistance have to be considered.
The selection is usually carried out through the following
necessary steps.
Defi ne boundary
conditions
Total power dissipation of the
LED module, max. ambient
temperature ta, max. reference
temperature tr according to
lifetime requirements
Rth =
Estimate heat sink
thermal resistance on
LED module level
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 at www.ledlightforyou.com or at www.osram.com.
Select heat sink
thermal resistance
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.
Thermal interface materials
Alfatec
www.alfatec.de
Kerafol
www.kerafol.de
Laird
www.lairdtech.com
Bergquist
www.bergquistcompany.com
Arctic Silver
www.arcticsilver.com
Wakefield
www.wakefield.com
Please note:
A thermal design must always be confirmed by performing
a thermal measurement in steady-state condition. The whole
area of the metal-core PCB must be in full contact with the
heat sink.
The list below is a selection of suppliers of different cooling
solutions.
Cooling systems
Nuventix
www.nuventix.com
Sunon
www.sunoneurope.com
Cooliance
www.cooliance.eu
AVC
www.avc-europa.de
SEPA
www.sepa-europe.com
Fischer Elektronik
www.fischerelektronik.de
Wakefield
www.wakefield.com
MechaTronix
www.mechatronix-asia.com
15
PrevaLED ® Core Z5 LED modules | Thermal considerations
4.4 tc point location and temperature measurement
The tc point is the location where to check if the chosen
cooling solution (heat sink and TIM) is sufficient to ensure
the LED module performance. The tc point is located on the
back of the LED module under the center of the light-emitting
surface (see following image).
To measure the temperature and to ensure a good thermal
coupling between the LED module and the heat sink, you
should 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).
Location of the tc point
tc point
Mounting of a thermocouple through a hole in the heat sink
To enable a lifetime of 50 000 hours (L80B50), the reference
temperature (tr) at the tc point must not exceed 65 °C. The
maximum temperature reached at the tc point must not
exceed 90 °C. A correct temperature measurement can,
for example, be performed with a thermocouple.
4.5 Thermocouple
Use a thermocouple that can be glued onto the LED module.
Make sure that the thermocouple is fixed with direct contact
to the tc point. Examples of suitable thermocouples:
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
to the tc point inside the groove.
Miniature connector “K”
Thermo wire NiCr–Ni
K-type thermocouple with miniature connector
Different thermocouples
Illustration
Description
Temperature range [°C]
PVC-insulated
thermocouple
-10 … +105
PFA-insulated
thermocouple
-75 … +260
Notes:
Please keep in mind that you need a direct contact
between the thermocouple and the PCB.
Sprung
thermocouple
-75 … +260
If you use TIM, you should cut out a small area where the
thermocouple has direct contact to the metal-core PCB.
Mounting of a thermocouple by means of a groove
16
PrevaLED ® Core Z5 LED modules | Lifetime and thermal behavior
5 Lifetime and thermal behavior
5.1 Luminous fl ux as a function of temperature
The following diagrams show the behavior of the luminous
flux output as a function of the temperature at the tc point for
PrevaLED® Core Z5.
PL-CORE-Z5-2000-XXX
Luminous flux as a function of
temperature at the tc point
PL-CORE-Z5-5000-XXX
Luminous flux as a function of
temperature at the tc point
PL-CORE-Z5-2000-830
PL-CORE-Z5-2000-840
PL-CORE-Z5-2000-930
Luminous flux [lm]
2500
PL-CORE-Z5-5000-830
PL-CORE-Z5-5000-840
PL-CORE-Z5-5000-930
Luminous flux [lm]
7500
2400
6500
2300
2200
5500
2000
2000
4500
1900
3500
1800
1700
2500
1600
1500
35
45
55
65
75
85
Temperature at the tc point [°C]
PL-CORE-Z5-3000-XXX
Luminous flux as a function of
temperature at the tc point
PL-CORE-Z5-3000-830
PL-CORE-Z5-3000-840
PL-CORE-Z5-3000-930
Luminous flux [lm]
4000
1500
35
45
55
65
75
85
Temperature at the tc point [°C]
5.2 Lifetime
OSRAM PrevaLED ® Core Z5 LED modules have a lifetime
of 50 000 hours (L80B50) at a tp temperature (performance
temperature) of 65 °C. This means that after 50 000 hours,
a minimum of 50 % of the utilized LED modules will have
at least 80 % of the initial luminous flux. If you operate the
module at a lower temperature, the lifetime of the module
is going to rise significantly. For more details, please refer
to the product datasheet.
3500
Note: Higher tc temperatures lead to a shorter lifetime of
the PrevaLED® Core Z5 LED module. Moreover, the failure
rate will also increase.
3000
2500
2000
1500
35
45
55
65
75
85
Temperature at the tc point [°C]
17
PrevaLED ® Core Z5 LED modules | Mechanical considerations
6 Mechanical considerations
The following schematic drawing provides further details on
the dimensions of PrevaLED® Core Z5 LED modules. For
3D files of the LED modules, please go to www.osram.com.
6.1 Outline drawing
6.3 Mechanical protection of the PrevaLED ® Core Z5
LED module
The housing of a PrevaLED® Core Z5 LED module 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
LED module.
Note: Please do not touch or mechanically stress the
yellow chip-on-board (CoB) surface. This could damage
the module.
6.2 3D drawing
For operation in damp, wet or dusty environments, the user
has to make sure that an adequate ingress protection (IP) is
chosen. The LED module has to be protected by a suitable IP
rating of the luminaire housing. Please consider the luminaire
standard IEC 60598-1 as well as the different requirements.
6.4 Mounting
To fix a PrevaLED® Core Z5 LED module to a heat sink, you
can use M3 cylinder head screws according to DIN 7984. If
you cannot use DIN screws, please use the following specification: Height of head not more than 2.6 mm, diameter of
head below 5.5 mm. The allowed torque using pre-tapped
holes is 0.4 to 0.6 Nm.
Move me!
Movable 3D PrevaLED ® Core Z5 LED module
(works with Adobe Acrobat 7 or higher)
18
PrevaLED ® Core Z5 LED modules | Norms and standards
7 Norms and standards
Safety:
Photobiological safety:
Risk group:
Electromagnetic compatibility:
Ingress protection:
Flammability of plastics:
Approvals:
IEC/EN 62031
IEC/EN 60598-1
IEC/EN 62471
1
CISPR 15
IEC/EN 61547
IEC/EN 61000-3-2
IEC/EN 61000-3-3
EN 55015
IP10
UL 8750 Class 2/UL 94 850 °C glow wire test
CE, UL, VDE ENEC
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.
19
09/15 OSRAM LLS SSL-OEM-EM Subject to change without notice. Errors and omissions excepted.
www.osram.com/prevaled-core
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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