10,000-Lumen High-Bay Reference Design

Cree® XLamp® XM-L LED
10,000-Lumen High-Bay Reference Design
Table of Contents
Introduction
Introduction..................................................................................... 1
This application note details the design of a replacement
Design approach/objectives.......................................................... 2
high-bay luminaire using Cree’s XLamp® XM-L LED. The high
The 6-step methodology................................................................. 2
flux output and efficacy offered by the XM-L LED make it a
1.Define lighting requirements.................................................. 2
particularly strong candidate for use in a high-bay luminaire. The
2.Define design goals................................................................. 4
performance of the XM-L LED means that it is not necessary to
3.Estimate efficiencies of the optical, thermal & electrical
use hundreds of LEDs to match the light output of traditional
systems.................................................................................... 5
4.Calculate the number of LEDs................................................ 8
5.Consider all design possibilities............................................. 8
6.Complete the final steps: implementation and analysis....... 8
Conclusions................................................................................... 13
Special thanks............................................................................... 13
CLD-AP96 rev 0C
Application Note
metal halide and fluorescent high-bay lighting.
An XM-L LED-based high-bay luminaire not only offers
energy efficiency benefits but its long lifetime also reduces
maintenance costs in typically hard-to-reach industrial and
commercial applications.
www.cree.com/Xlamp
Bill of materials............................................................................. 13
Reliance on any of the information provided in this Application Note is at the user’s sole risk. Cree and its affiliates make no warranties or representations about, nor assume
any liability with respect to, the information in this document or any LED-based lamp or luminaire made in accordance with this reference design, including without limitation
that the lamps or luminaires will not infringe the intellectual property rights of Cree or a third party. Luminaire manufacturers who base product designs in whole or part on
any Cree Application Note or Reference Design are solely responsible for the compliance of their products with all applicable laws and industry requirements.
Copyright © 2012-2016 Cree, Inc. All rights reserved. The information in this document is subject to change without notice. Cree®, the Cree logo
and XLamp® are registered trademarks of Cree, Inc. ENERGY STAR® is a registered trademark of the U.S. Environmental Protection Agency. Other
trademarks, product, and company names are the property of their respective owners and do not imply specific product and/or vendor endorsement,
sponsorship or association. For product specifications, please see the data sheets available at www.cree.com. For warranty information, please
contact Cree Sales at [email protected]
Cree, Inc.
4600 Silicon Drive
Durham, NC 27703
USA Tel: +1.919.313.5300
1
XLamp ® xm-l LED 10,000-lumen High-bay Reference Design
Design approach/objectives
In the “LED Luminaire Design Guide” Cree advocates a six step framework for creating LED luminaires and lamps. All Cree reference
designs use this framework, and the design guide’s summary table is reproduced below.
Table 1: Cree 6-step framework
Step
Explanation
1. Define lighting requirements
•
The design goals can be based either on an existing fixture or on the application’s lighting requirements.
2. Define design goals
•
•
Specify design goals, which will be based on the application’s lighting requirements.
Specify any other goals that will influence the design, such as special optical or environmental
requirements.
3. Estimate efficiencies of the optical, thermal &
electrical systems
•
•
•
Design goals will place constraints on the optical, thermal and electrical systems.
Good estimations of efficiencies of each system can be made based on these constraints.
The combination of lighting goals and system effiiciencies will drive the number of LEDs needed in the
luminaire.
•
Based on the design goals and estimated losses, the designer can calculate the number of LEDs to meet
the design goals.
5. Consider all design possibilities and choose
the best
•
•
With any design, there are many ways to achieve the goals.
LED lighting is a new field; assumptions that work for conventional lighting sources may not apply.
6. Complete final steps
•
•
•
•
•
Complete circuit board layout.
Test design choices by building a prototype luminaire.
Make sure the design achieves all the design goals.
Use the prototype to further refine the luminaire design.
Record observations and ideas for improvement.
4. Calculate the number of LEDs needed
The 6-step methodology
The goal of the design is an LED-based high-bay luminaire that can replace high-intensity discharge (HID) and 54-watt fluorescent T5 and
T8 luminaires in commercial, industrial and warehouse applications. As a replacement luminaire, this design uses a form factor that is
similar to traditional high-bay lighting currently in use.
1. Define lighting requirements
Table 2 shows a ranked list of desirable characteristics to address in a high-bay luminaire design.
Table 2: Ranked design criteria for a high-bay luminaire
Importance
Critical
Characteristics
Units
Illuminance distribution
footcandles (fc)/lux (lx)
Electrical power
watts (W)
Lifetime
hours
Luminous flux
lumens (lm)
Manufacturability
Important
Operating temperatures
°C
Operating humidity
% RH
Correlated Color Temperature (CCT)
K
Color Rendering Index (CRI)
100-point scale
Ease of installation
Copyright © 2012-2016 Cree, Inc. All rights reserved. The information in this document is subject to change without notice. Cree®, the Cree logo and XLamp® are registered trademarks of Cree, Inc. ENERGY
STAR® is a registered trademark of the U.S. Environmental Protection Agency. Other trademarks, product, and company names are the property of their respective owners and do not imply specific product
and/or vendor endorsement, sponsorship or association. For product specifications, please see the data sheets available at www.cree.com. For warranty information, please contact Cree Sales at sales@
cree.com.
2
XLamp ® xm-l LED 10,000-lumen High-bay Reference Design
Table 3 summarizes the ENERGY STAR® requirements for solid-state luminaires.1 There are no ENERGY STAR requirements for high-bay
luminaires.
Table 3: ENERGY STAR luminaire requirements
Characteristic
Requirements
Light source life requirements: all
luminaires
The LED package(s) / LED module(s) / LED array(s), including those incorporated into LED light engines or GU24 based integrated
LED lamps, shall meet the following L70 lumen maintenance life values (refer to Lumen Maintenance Requirements in the next
section):
•
•
•
25,000 hours for residential grade indoor luminaires
35,000 hours for residential grade outdoor luminaires
35,000 hours for commercial grade luminaires
Lumen maintenance life projection claims in excess of the above requirements shall be substantiated with a TM-21 lumen
maintenance life projection report.
Lumen maintenance requirements:
directional and non-directional
luminaires
The LED package(s) / module(s) / array(s), including those incorporated into LED light engines or GU24 based integrated LED
lamps, shall meet the following
•
•
•
L70(6k) rated lumen maintenance life values, in situ:
L70(6k) ≥ 25,000 hours for residential indoor
L70(6k) ≥ 35,000 hours for residential outdoor, or commercial
Compliance with the above shall be documented with a TM-21 lumen maintenance life projection report as detailed in TM-21,
section 7. The report shall be generated using data from the LM-80 test report for the employed LED package/module/array model
(“device”), the forward drive current applied to each device, and the in situ TMPLED temperature of the hottest LED in the luminaire. In
addition to LM-80 reporting requirements, the following information shall be reported:
•
•
•
•
•
•
sampling method and sample size (per LM-80 section 4.3)
test results for each TS and drive current combination
description of device including model number and whether device is an LED package, module or array (see Definitions)
ANSI target, and calculated CCT value(s) for each device in sample set
Δ u’v’ chromaticity shift value on the CIE 1976 diagram for each device in sample set
a detailed rationale, with supporting data, for application of results to other devices (e.g. LED packages with other CCTs)
Access to the TMPLED for the hottest LED may be accomplished via a minimally sized hole in the luminaire housing, tightly resealed
with a suitable sealant if created for purposes of testing.
All thermocouple attachments and intrusions to luminaire housing shall be photographed.
CCT requirements: all indoor
luminaires
The luminaire (directional luminaires), or replaceable LED light engine or GU24 based integrated LED lamp (non-directional
luminaires) shall have one of the following nominal CCTs:
•
•
•
•
•
2700 Kelvin
3000 Kelvin
3500 Kelvin
4000 Kelvin
5000 Kelvin (commercial only)
The luminaire, LED light engine or GU24 based integrated LED lamp shall also fall within the corresponding 7-step chromaticity
quadrangles as defined in ANSI/NEMA/ANSLG C78.377-2008.
Color rendering requirements: all
indoor luminaires
The luminaire (directional luminaires), or replaceable LED light engine or GU24 based integrated LED lamp (non-directional
luminaires) shall meet or exceed Ra ≥ 80.
Color angular uniformity
requirements: directional solid state
indoor luminaires
Throughout the zonal lumen density angles detailed above, and five degrees beyond, the variation of chromaticity shall be within
0.004 from the weighted average point on the CIE 1976 (u’,v’) diagram.
Color maintenance requirements:
solid state indoor luminaires only
The change of chromaticity over the first 6,000 hours of luminaire operation shall be within 0.007 on the CIE 1976 (u’,v’) diagram, as
demonstrated by either:
•
•
•
Source start time requirement:
directional and non-directional
luminaires
1
the IES LM-80 test report for the employed LED package/array/module model, or
as demonstrated by a comparison of luminaire chromaticity data in LM-79 reports at zero and 6,000 hours, or
as demonstrated by a comparison of LED light engine or GU24 based integrated LED lamp chromaticity data in LM-82 reports
at zero and 6,000 hours.
Light source shall remain continuously illuminated within one second of application of electrical power.
ENERGY STAR Program Requirements, Product Specification for Luminaires (Light Fixtures), Eligibility Criteria, Version 1.1
Copyright © 2012-2016 Cree, Inc. All rights reserved. The information in this document is subject to change without notice. Cree®, the Cree logo and XLamp® are registered trademarks of Cree, Inc. ENERGY
STAR® is a registered trademark of the U.S. Environmental Protection Agency. Other trademarks, product, and company names are the property of their respective owners and do not imply specific product
and/or vendor endorsement, sponsorship or association. For product specifications, please see the data sheets available at www.cree.com. For warranty information, please contact Cree Sales at sales@
cree.com.
3
XLamp ® xm-l LED 10,000-lumen High-bay Reference Design
Characteristic
Requirements
Source run-up time requirements:
directional and non-directional
luminaires
Light source shall reach 90% of stabilized lumen output within one minute of application of electrical power.
Power factor requirements:
directional and non-directional
luminaires
Total luminaire input power less than or equal to 5 watts: PF ≥ 0.5
Transient protection requirements:
all luminaires
Ballast or driver shall comply with ANSI/IEEE C62.41.1-2002 and ANSI/IEEE C62.41.2-2002, Class A operation. The line transient
shall consist of seven strikes of a 100 kHz ring wave, 2.5 kV level, for both common mode and differential mode.
Operating frequency requirements:
directional and non-directional
luminaires
Frequency ≥ 120 Hz
Noise requirements: directional and
non-directional luminaires
All ballasts & drivers used within the luminaire shall have a Class A sound rating.
Electromagnetic and radio frequency
interference requirements:
directional and non-directional
luminaires
Power supplies and/or drivers shall meet FCC requirements:
Total luminaire input power greater than 5 watts:
Residential: PF ≥ 0.7
Commercial: PF ≥ 0.9
Note: This performance characteristic addresses problems with visible flicker due to low frequency operation and applies to steadystate as well as dimmed operation. Dimming operation shall meet the requirement at all light output levels.
Ballasts and drivers are recommended to be installed in the luminaire in such a way that in operation, the luminaire will not emit
sound exceeding a measured level of 24 BA.
•
•
Class A for power supplies or drivers that are marketed for use in a commercial, industrial or business environment, exclusive
of a device which is marketed for use by the general public or is intended to be used in the home.
Class B for power supplies or drivers that are marketed for use in a residential environment notwithstanding use in
commercial, business and industrial environments.
The DesignLights Consortium® provides requirements for a high-bay luminaire.2
Table 4: DesignLights Consortium high-bay luminaire requirements
Application
Characteristic
Minimum light output
Zonal lumen density
High-Bay and Low-Bay Fixtures for Commercial and
Industrial Buildings
High-Bay-Aisle Lighting
10,000 lm
10,000 lm
≥ 30% 20–50°
≥ 50%, 20–50°
≥ 30%, 0–20°
Minimum luminaire efficacy
70 lm/W
60 lm/W
Allowable CCTs (ANSI C78.377-2008)
< 5700 K
< 6000 K
70
70
35,000 hours
35,000 hours
5 years
5 years
Minimum CRI
L70 lumen maintenance
Minimum luminaire warranty
2. Define design goals
Table 5 shows the design goals for this project.
2
Technical Requirements Table v1.6, DesignLights Consortium Qualified Products List - Non-Residential Applications
Copyright © 2012-2016 Cree, Inc. All rights reserved. The information in this document is subject to change without notice. Cree®, the Cree logo and XLamp® are registered trademarks of Cree, Inc. ENERGY
STAR® is a registered trademark of the U.S. Environmental Protection Agency. Other trademarks, product, and company names are the property of their respective owners and do not imply specific product
and/or vendor endorsement, sponsorship or association. For product specifications, please see the data sheets available at www.cree.com. For warranty information, please contact Cree Sales at sales@
cree.com.
4
XLamp ® xm-l LED 10,000-lumen High-bay Reference Design
Table 5: Design goals
Characteristic
Light output
Power
Unit
Minimum Goal
Target Goal
lm
10,000
10,000
< 150
W
150
Luminaire efficacy
lm/W
66
70
Lifetime
hours
50,000
50,000
CCT
K
5,000
5,000
CRI
100-point scale
Power factor
75
> 75
0.9
> 0.9
3. Estimate efficiencies of the optical, thermal & electrical systems
We used Cree’s Product Characterization Tool (PCT) tool to determine the drive current for the design.
For the 10,000-lm target, we estimated 93% optical efficiency and 85% driver efficiency. We also estimated a solder point temperature of
85 °C.
LED System Comparison Rep
The PCT output highlighted in Figure 1 shows that,
at 2.4 A, sixteen XM-L LEDs provide sufficient light output to meet the design goals.
1
System:
10,000
Target Lumens :
93
Optical Efficiency:
Current (A)
LED 1
Model
Flux
LED 2
Model
Cree XLamp XM-L {CW/NW/WW}
T6 [280]
$
Price
SYS # LED SYS lm tot
Tj (ºC)
85
Tj (ºC)
$
2
-
SYS lm/W
1.500
23
10225.8
120.09
85.1
1.600
22
10313.8
123.5
83.5
1.700
21
10338.8
126.17
81.9
1.800
20
10302.9
128.1
80.4
1.900
19
10208.3
129.26
79
2.000
18
10056.9
129.65
77.6
2.200
17
10191.8
136.04
74.9
2.400
16
10200.8
140.81
72.4
2.600
15
10092.2
143.89
70.1
2.800
15
10579.7
155.62
68
3.000
14
10290.6
155.99
66
0.000
#N/A
#N/A
#N/A
#N/A
Figure 1: PCT view of the number of LEDs used and drive current
Optic
Flux
Price
SYS W
(none)
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This document is provided for informational purposes only and is not a warranty or a specification. For product specifications, please see the data
Copyright © 2009-2011 Cree, Inc. All rights reserved. The information in this document is subject to change without notice. Cree, the Cree logo a
Because this reference design is targeted as a replacement high-bay luminaire, the design has a form factor similar to incumbent
luminaires. The optic is a commercially available 16-inch diameter reflector commonly used in HID high-bay luminaires. The LED array
size and arrangement is designed to fit this reflector. To maximize the luminaire’s light output, we painted the inside of the reflector with
reflective white paint.
Copyright © 2012-2016 Cree, Inc. All rights reserved. The information in this document is subject to change without notice. Cree®, the Cree logo and XLamp® are registered trademarks of Cree, Inc. ENERGY
STAR® is a registered trademark of the U.S. Environmental Protection Agency. Other trademarks, product, and company names are the property of their respective owners and do not imply specific product
and/or vendor endorsement, sponsorship or association. For product specifications, please see the data sheets available at www.cree.com. For warranty information, please contact Cree Sales at sales@
cree.com.
5
XLamp ® xm-l LED 10,000-lumen High-bay Reference Design
Figure 2: High-bay reflector
Thermal Requirements
The thermal solution is a key factor in the success of this reference design, as the LEDs are concentrated at the center of the luminaire.
To make this design feasible, we worked with two partners to design and fabricate a custom metal core printed circuit board (MCPCB)
and heat sink.
MCPCB
As shown in Figure 4, this high-bay luminaire design has sixteen XLamp XM-L LEDs arranged in a
closely spaced 4 x 4 rectangular array. To handle the high power density we used a special copper
MCPCB from Rayben. As shown in Figure 3, where a typical MCPCB has a copper trace layer and a
dielectric layer to transfer heat to the aluminum base layer and on to the surrounding environment,
the Rayben MCPCB in this design has a “micro heat exchanger” (MHE) layer to transfer heat to the
copper base layer and offers greater heat transfer capability. The electrically neutral thermal path of
the XM-L LED makes this possible.
Figure 3: MHE thermal substrate
Figure 4: MCPCB with XM-L LEDs
Copyright © 2012-2016 Cree, Inc. All rights reserved. The information in this document is subject to change without notice. Cree®, the Cree logo and XLamp® are registered trademarks of Cree, Inc. ENERGY
STAR® is a registered trademark of the U.S. Environmental Protection Agency. Other trademarks, product, and company names are the property of their respective owners and do not imply specific product
and/or vendor endorsement, sponsorship or association. For product specifications, please see the data sheets available at www.cree.com. For warranty information, please contact Cree Sales at sales@
cree.com.
6
XLamp ® xm-l LED 10,000-lumen High-bay Reference Design
Heat Sink
This reference design uses a custom vapor-chamber heat sink by Steady Heat & Mass Transfer
Technology Academy Ltd, shown in Figure 6. As Figure 5 illustrates, the heat sink has a unique
vapor chamber design to enhance thermal conductivity and heat dissipation. A special liquid is
vacuum sealed in a chamber formed between the heat source, in this design the MCPCB, and the
heat fins. The heat from the MCPCB causes the liquid to evaporate; the vapor condenses on the
cooler part of the chamber to enhance cooling and collects on the base near the heat source to
repeat the cycle.
Figure 5: Heat sink design
Figure 6: Heat sink attached to heat sink support
We performed thermal simulations to verify this thermal design is sufficient. Figure 7 shows the thermal simulation results for the design.
The simulated solder point temperature (TSP) is 72 °C.
Figure 7: Thermal simulation of XM-L high-bay heat sink
Copyright © 2012-2016 Cree, Inc. All rights reserved. The information in this document is subject to change without notice. Cree®, the Cree logo and XLamp® are registered trademarks of Cree, Inc. ENERGY
STAR® is a registered trademark of the U.S. Environmental Protection Agency. Other trademarks, product, and company names are the property of their respective owners and do not imply specific product
and/or vendor endorsement, sponsorship or association. For product specifications, please see the data sheets available at www.cree.com. For warranty information, please contact Cree Sales at sales@
cree.com.
7
XLamp ® xm-l LED 10,000-lumen High-bay Reference Design
Driver
We used a market-ready constant-current driver that fits within the heat sink support and matches the design’s current and voltage range.
The high-bay luminaire design can also accommodate locating the driver separate from the luminaire.
Figure 8: Driver
4. Calculate the number of LEDs
Using Cree’s PCT, we determined that sixteen XLamp XM-L LEDs produce sufficient light to meet the 10,000-lm design goal.
5. Consider all design possibilities
There are many ways to design an LED-based high-bay luminaire. This reference design aims to show that the XM-L LED enables a highbay luminaire offering superior performance.
The XM-L LED offers a wide range of color temperatures. We selected a neutral white LED for this high-bay luminaire design, shown
highlighted in Table 6.
Table 6: XM-L order codes
Color
CCT Range
Min.
Neutral White
3,700 K
Max.
Base Order Codes
Min. Luminous Flux @
700 mA (lm)
Order Code
Group
Flux (lm)
T4
240
XMLAWT-00-0000-000LT40E3
T5
260
XMLAWT-00-0000-000LT50E3
T6
280
XMLAWT-00-0000-000LT60E3
5,000 K
6. Complete the final steps: implementation and analysis
Using the methodology described above, we determined a suitable combination of LEDs, components and drive conditions. This section
describes how Cree assembled the high-bay luminaire and shows the results of the design.
Prototyping Details
1. We verified the component dimensions to ensure a correct fit.
2. Following the recommendations in Cree’s Soldering and Handling Application Note for the XM-L LED, with an appropriate solder paste
and reflow profile, we reflow soldered the LEDs to the MCPCB.
Copyright © 2012-2016 Cree, Inc. All rights reserved. The information in this document is subject to change without notice. Cree®, the Cree logo and XLamp® are registered trademarks of Cree, Inc. ENERGY
STAR® is a registered trademark of the U.S. Environmental Protection Agency. Other trademarks, product, and company names are the property of their respective owners and do not imply specific product
and/or vendor endorsement, sponsorship or association. For product specifications, please see the data sheets available at www.cree.com. For warranty information, please contact Cree Sales at sales@
cree.com.
8
e Textured High Bay Reflector
NAIRE OUTPUT = 10443 LM
6 VDC and 113.7 Watts
XLamp ® xm-l LED 10,000-lumen High-bay Reference Design
3. We ran the LED DC input wires through an enclosed channel in the heat sink. The channel
runs the length of the heat sink and insulates the LED DC input wires from the heat and
moisture in the heat sink.
N.A. (absolute)
5. We tested the connection N.A.
by applying
power to the LEDs and verified the LEDs lit up.
(absolute)
6. We applied a thin layer of
thermal conductive compound to the back of MCPCB and
10463
attached it to the heat sinkN.A.
with screws.
cy
7. We secured the heat sink support to the end of the heat sink with screws.
ng (LER)
92
8. We connected the LED DC input wires to the driver DC output wires with connectors.
113.7
9. We fit the LED driver into the heat sink support. This is an optional step as the driver is a
1.00
remote standalone type. This driver can be located apart from the luminaire or a centralized
Direct
dedicated power line can be
directly wired to the luminaire.
0)
10. We secured the reflector to0.64
the heat sink with screws.
11. We performed final testing0.64
70)
onal)
1.00
Circular
0)
0.00 ft
Results
0)
1.33 ft (Diameter)
Thermal Results
0.00 ft
4. We soldered the LED DC input wires to the MCPCB.
Figure 9: Assembled high-bay luminaire
ready to test
Cree verified the board temperature with a thermocouple to confirm that the thermal dissipation performance of the heat sink aligns with
our simulation. As shown in Figure 10, the measured solder point temperature was 61 °C, which shows that the heat sink is sufficient for
this design.
/sq.m)
e
Average
45-Deg
Average
90-Deg
34361
10530
10378
9654
7727
34361
10530
10378
9654
7727
TSP
Solder Point Temperature
T2
PCB Temperature
T3
Heat Sink Temperature
61 °C
56 °C
50 °C
Figure 10: Thermal measurement
nal Edition - Copyright 2002-2011 by Lighting Analysts, Inc.
Page 1
d IES Methods
and recommendations,
valuesin this
rounded
for display
purposes.
Copyright © 2012-2016
Cree, Inc. All rights reserved. The information
document is subject
to change without
notice. Cree , the Cree logo and XLamp are registered trademarks of Cree, Inc. ENERGY
STAR is a registered trademark of the U.S. Environmental Protection Agency. Other trademarks, product, and company names are the property of their respective owners and do not imply specific product
manufacturers
photometric
file.
and/or vendor endorsement,
sponsorship
or association. For product specifications, please see the data sheets available at www.cree.com. For warranty information, please contact Cree Sales at sales@
®
®
®
cree.com.
9
XLamp ® xm-l LED 10,000-lumen High-bay Reference Design
Based on the measured solder point temperature of 61 °C, the junction temperature (TJ) can be calculated as follows.
TJ = TSP + (LED power * LED thermal resistance)
TJ = 61 °C + (7.8 W * 2.5 °C/W)
TJ = 81 °C
TM-21 Lifetime Report
Estimated LED lifetime
Figure 11 shows the calculated and reported lifetimes, determined using the TM-21 projection algorithm, for the XM-L LED at a 2-A input
TM-21 Lifetime Report
current at three solder point temperatures. The duration of Cree’s XM-L HEW LM-80 data set is 6000 hours at a 2-A drive current. The TM-
LED
I
Data Set
LEDTsp
I Sample Size
Data
SetDuration
Test
Tspα
Sample
Size
β
Calculated
Test
DurationLifetime
α Reported Lifetime
XLamp XM-L White
2000 mA
2
XLamp55°C
XM-L White
2000
25 mA
6,0482 hrs
55°C
9.543E-07
25
9.887E-01
L70(6k) 6,048
= 362,000
hrs hours
L70(6k)9.543E-07
> 36,300 hours
21 methodology limits the projection to six times the duration of the LM-80 data set.
β
Calculated Lifetime
Reported Lifetime
1
45°C
25
1 hrs
6,048
45°C
1.459E-07
25
9.847E-01
L70(6k)6,048
= 2,340,000
hrs hours
L70(6k)
>
36,300
1.459E-07 hours
9.847E-01
L70(6k) = 2,340,000 hours
L70(6k) > 36,300 hours
9.887E-01
L70(6k) = 362,000 hours
L70(6k) > 36,300 hours
3
85°C
25
3
6,048 hrs
85°C
2.155E-06
25
9.834E-01
L70(6k) = 6,048
158,000
hrshours
L70(6k) >2.155E-06
36,300 hours
Reported L70
9.834E-01
L70(6k) = 158,000 hoursCalculated Lifetime
L70(6k) > 36,300 hours Reported Lifetime
Reported L70
Calculated Lifetim
Reported Lifetim
110
105
% Luminous Flux
% Luminous Flux
100
110
95
105
90
100
85
95
80
45°C (LM-80)
55°C (LM-80)
85°C (LM-80)
90 75
45°C (TM-21)
45°C (LM-80)
85 70
55°C (TM-21)
55°C (LM-80)
80 65
85°C (TM-21)
85°C (LM-80)
75 60
45°C (TM-21)
70 55
65 50
1,000
60
55
55°C (TM-21)
10,000
100,000
1,000,000
10,000,000
85°C (TM-21)
Time (hours)
Figure 11: XM-L TM-21 data
50
This document
purposes only
and is not a warranty
or a specification. For10,000,000
product specifications, please see the
1,000 is provided for informational
10,000
100,000
1,000,000
data sheets available at www.cree.com.
(hours)
Copyright © 2011 Cree, Inc. All rights reserved. TheTime
information
in this document is subject to change without notice. Cree, the Cree logo and
XLamp
trademarks
of Cree, Inc.
Copyright © 2012-2016
Cree,are
Inc.registered
All rights reserved.
The information
in this document is subject to change without notice. Cree®, the Cree logo and XLamp® are registered trademarks of Cree, Inc. ENERGY
STAR® is a registered trademark of the U.S. Environmental Protection Agency. Other trademarks, product, and company names are the property of their respective owners and do not imply specific product
and/or vendor endorsement, sponsorship or association. For product specifications, please see the data sheets available at www.cree.com. For warranty information, please contact Cree Sales at sales@
cree.com.
10
This document is provided for informational purposes only and is not a warranty or a specification. For product specifications, please see the
data sheets available at www.cree.com.
XLamp ® xm-l LED 10,000-lumen High-bay Reference Design
Figure 12 shows the calculated and reported lifetimes for the XM-L LED, interpolated from the data shown in Figure 11, at the measured
61 °C TSP for the XM-L LED in this design. Although this design operates at a slightly higher current than the 2-A level of the TM-21 data
set, Cree’s experience with the XM-L LED gives us reason to expect that, with a reported L70(6k) lifetime greater than 36,300 hours and a
TM-21 Lifetime Report
calculated L70(6k) lifetime of 302,000 hours at 2 A, the high-bay luminaire to easily meet the 35,000-hour DesignLights Consortium L70
lumen maintenance requirement when operating at a measured 2.3 A.3
Ts1
XLamp XM-L White
2000 mA
Tsi (Interpolated)
Ts2
55°C
61°C
85°C
328.15 K
334.15 K
3191.23
1.5965E-02
1.136E-06
9.861E-01
L70(6k) = 302,000 hours
L70(6k) > 36,300 hours
L70(6k) = 302,000 hours
L70(6k) > 36,300 hours
358.15 K
LED
I
Tsp
Tsp
Ea/kB
A
α
β
Calculated L70
Reported L70
Calculated Lifetime
Reported Lifetime
9.543E-07
9.887E-01
L70(6k) = 362,000 hours
L70(6k) > 36,300 hours
110
45°C (LM-80)
105
% Luminous Flux
2.155E-06
9.834E-01
L70(6k) = 158,000 hours
L70(6k) > 36,300 hours
55°C (LM-80)
100
85°C (LM-80)
95
45°C (TM-21)
90
55°C (TM-21)
85°C (TM-21)
85
61°C (LM-80)
80
75
L70: 302,000hrs
70
65
60
55
50
1,000
10,000
100,000
1,000,000
10,000,000
Time (hours)
Figure 12: XM-L TM-21 data with TSP = 61 °C
3
This document is provided for informational purposes only and is not a warranty or a specification. For product specifications, please see the
data sheets available at www.cree.com.
Copyright © 2011 Cree, Inc. All rights reserved. The information in this document is subject to change without notice. Cree, the Cree logo and
That is, after 35,000 hours of operation, the LED will still deliver at least 70% of its initial luminous flux.
XLamp are registered trademarks of Cree, Inc.
Copyright © 2012-2016 Cree, Inc. All rights reserved. The information in this document is subject to change without notice. Cree®, the Cree logo and XLamp® are registered trademarks of Cree, Inc. ENERGY
STAR® is a registered trademark of the U.S. Environmental Protection Agency. Other trademarks, product, and company names are the property of their respective owners and do not imply specific product
and/or vendor endorsement, sponsorship or association. For product specifications, please see the data sheets available at www.cree.com. For warranty information, please contact Cree Sales at sales@
cree.com.
11
XLamp ® xm-l LED 10,000-lumen High-bay Reference Design
Optical and Electrical Results
We obtained the results in Table 7 by testing the luminaire in a 2-meter sphere at steady state.4 As the table shows, the luminaire meets
the 10,000-lm target goal using less than 150 W of power and compares favorably with published data for two comparison metal halide
luminaires. The XM-L high-bay luminaire also exceeds the DesignLights Consortium efficacy, CCT and CRI requirements.
Table 7: XM-L high-bay luminaire steady-state results
Characteristic
Unit
DesignLights Consortium
High-Bay Requirement
Comparison Metal Halide
High-Bay Luminaire
Comparison Pulse Start
Metal Halide High-Bay
Luminaire
XM-L High-Bay Luminaire
Result
Luminous flux
lm
10,000
10,427
9,676
10,737
Power
W
-
175
150
125
lm/W
70
64
66
86
CCT
K
< 5,700 K
~ 5,000
~ 5,000
5,154
CRI
100-point scale
70
65
65
75
A
-
Luminaire efficacy
Current
2.3
Goniometric measurements show a consistent beam shape and light distribution for the XM-L high-bay luminaire.5
8802
6602
4401
2201
Figure 13: Angular luminous intensity distribution of XM-L high-bay luminaire
The light intensity and distribution data in Table 8 show the XM-L high-bay luminaire effectively illuminates the area in which it is installed.
4
5
Testing was performed at Cree’s Durham Technology Center.
Ibid. IES files for the high-bay luminaire are available.
Copyright © 2012-2016 Cree, Inc. All rights reserved. The information in this document is subject to change without notice. Cree®, the Cree logo and XLamp® are registered trademarks of Cree, Inc. ENERGY
STAR® is a registered trademark of the U.S. Environmental Protection Agency. Other trademarks, product, and company names are the property of their respective owners and do not imply specific product
and/or vendor endorsement, sponsorship or association. For product specifications, please see the data sheets available at www.cree.com. For warranty information, please contact Cree Sales at sales@
cree.com.
12
XLamp ® xm-l LED 10,000-lumen High-bay Reference Design
Table 8: XM-L high-bay light intensity and distribution
Height
Illuminance
Diameter
1.3 m
4.2 ft
507.0 fc
5457.4 lx
1.3 m
4.3 ft
2.5 m
8.3 ft
126.8 fc
1374.3 lx
2.6 m
8.5 ft
3.8 m
12.5 ft
56.3 fc
606.3 lx
3.9 m
12.8 ft
5.7 m
16.7 ft
31.7 fc
341.0 lx
5.2 m
17.1 ft
6.3 m
20.8 ft
20.3 fc
218.3 lx
6.5 m
21.4 ft
7.6 m
25.0 ft
14.1 fc
151.6 lx
7.8 m
25.6 ft
Conclusions
This reference design illustrates the excellent performance of a high-bay luminaire based on the Cree XLamp XM-L LED. The efficacy of
the XM-L LED allows a relatively small number of LEDs to match the light output of comparison luminaires with better color consistency
without the metal halide’s slow start-up times and ultraviolet light. The lighting-class performance of the Cree XLamp XM-L LED makes it
an attractive design option for an LED-based high-bay luminaire.
Special thanks
Cree would like to acknowledge and thank the following partner companies that collaborated in the successful prototyping of this
luminaire.
•
Rayben
•
Steady Heat & Mass Transfer Technology Academy Ltd.
Bill of materials
Table 9: Bill of materials for XM-L high-bay luminaire
Component
Order Code/Model Number
Company
Web Link
Driver
HLG-150-54A
Mean Well USA, Inc.
www.meanwellusa.com
Heat sink
HBEXC-98D160L200-S
Steady Heat & Mass Transfer Technology
Academy Ltd.
www.cnvc.cc
LED
XMLAWT-00-0000-000LT60E3
Cree, Inc.
XM-L product page
MCPCB
MHE 301
Rayben
www.rayben.com/English/contact/contact.asp
Thermal epoxy
ASTA-7G
Arctic Silver, Inc.
www.arcticsilver.com/arctic_silver_thermal_adhesive.htm
Reliance on any of the information provided in this Application Note is at the user’s sole risk. Cree and its affiliates make no warranties or representations about, nor assume any
liability with respect to, the information in this document or any LED-based lamp or luminaire made in accordance with this reference design, including without limitation that
the lamps or luminaires will not infringe the intellectual property rights of Cree or a third party. Luminaire manufacturers who base product designs in whole or part on any Cree
Application Note or Reference Design are solely responsible for the compliance of their products with all applicable laws and industry requirements.
Copyright © 2012-2016 Cree, Inc. All rights reserved. The information in this document is subject to change without notice. Cree®, the Cree logo and XLamp® are registered trademarks of Cree, Inc. ENERGY
STAR® is a registered trademark of the U.S. Environmental Protection Agency. Other trademarks, product, and company names are the property of their respective owners and do not imply specific product
and/or vendor endorsement, sponsorship or association. For product specifications, please see the data sheets available at www.cree.com. For warranty information, please contact Cree Sales at sales@
cree.com.
13