www.osram.com/prevaled 11/2015 Technical application guide PrevaLED® Cube AC DALI light engines Light is OSRAM PrevaLED ® Cube AC DALI light engines | Contents Contents 1 Introduction 03 6 Thermal considerations 1.1 System overview 03 6.1 Thermal interface material and other accessories 16 16 1.2 Nomenclature 04 6.2 Cooling systems and heat sinks 16 2 Optical considerations 05 6.3 tc point location and temperature measurement 17 6.3.1 Thermocouple 17 19 2.1 Light distribution 05 2.2 Refl ector design 05 7 Lifetime and thermal behavior 2.3 Color temperature 06 7.1 Cooling 19 2.4 Color rendering 06 7.2 Luminous flux as a function of temperature 19 2.5 Spectral distribution 06 7.3 Thermal protection mechanism 19 7.4 Lifetime as a function of temperature 20 8 Mechanical considerations 21 3 Ingress protection 07 4 Electrical considerations 07 8.1 Outline drawing 21 4.1 Wiring information 07 8.2 3D drawing 21 4.2 Insulation requirements 08 8.3 Mechanical protection of the light engine 21 4.3 Inrush current and system installation 08 8.4 Mounting 21 4.4 Electrostatic discharge (ESD) 08 8.5 Protection from corrosion 21 4.5 Controllability 08 4.6 Power as a function of voltage 08 9 Norms and standards 22 5 DALI 09 5.1 Introduction 09 5.2 Integrated DALI functions 09 5.2.1 Touch DIM ® 09 5.2.2 Corridor Function and parametrization options 11 5.2.3 SMART GRID function 13 5.3 Digital programming 14 5.4 DC operation 14 5.5 Parametrization by Tuner4TRONIC ® software 14 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 ® Cube AC DALI light engines | Introduction 1 Introduction 1.1 System overview The brightness levels of today’s LEDs are opening the door for the use of LEDs in general lighting applications that require high lumen output levels. Building an LED-based luminaire poses a new set of technical challenges, among them new optical requirements, providing adequate thermal management for stable operation and dealing with the ever-improving performance of LEDs. Nevertheless, LED technology also offers an unknown wealth of possibilities, providing access to unprecedented levels of performance and new ways of integration. OSRAM’s PrevaLED ® family of LED light engines addresses the challenges of LED-based lighting while providing users with great performance and flexibility at the same time. Enabled by the application of LED technology, PrevaLED® is aiming to push the envelope of what is possible in terms of performance and simplicity. The PrevaLED® Cube AC DALI series of light engines is ideally suited for use in a broad range of wide-reflectorbased applications such as downlights. PrevaLED® Cube AC DALI is an innovative solution. It incorporates four main features into one light engine: 1 LED module 2 LED driver 3 DALI dimmability 4 SMART GRID PrevaLED® Cube AC DALI light engines provide several specific benefits: — The first LED light engine on the market providing all functions and advantages of the DALI 2 standard! — With the LED sources and the electronic control circuitry placed on the same board and packaged into a unique compact design, they offer an integrated system solution. — Little design-in effort is required due to the integration of the electronic control circuitry into the light engine, offering a new level of simplicity. — High performance in terms of both the complete system efficiency and the quality of light (small color deviation, no recognizable light modulation). — Due to the low height of only 18.6 mm as well as the established footprint and means of mechanical fixation, a large number of existing accessories (optics, heat sinks etc.) can be easily adapted. — All in all, PrevaLED® Cube AC DALI light engines not only offer a low threshold for the adaption of LEDs, but also a significant increase in flexibility for applications already adapted to LED technology. At present, the PrevaLED® Cube AC DALI series is available as a 1 100-lm, 2 000-lm or 3 000-lm package in two light colors (3000 K and 4000 K) with a color reproduction of CRI > 80. The luminaire manufacturer benefits from reduced complexity inside the luminaire. The reduced amount of components reduces the logistical efforts and eases the manufacturing process. In addition, it enables the development of innovative miniaturized designs. The dimming behavior is on an excellent level with a dimming range from 100 % down to 1 %. Enable 3D View Dummy of a PrevaLED ® Cube AC DALI light engine Move me! Movable 3D PrevaLED ® Cube AC light engine (works with Adobe Acrobat 7 or higher) 3 PrevaLED ® Cube AC DALI light engines | Introduction 1.2 Nomenclature PL: PrevaLED® light engine CUBE: Cube-shaped module AC: AC-capable (220–240 V, 50/60 Hz) 3000: 3000 lm 830: CRI + CCT = > 80 + 3000 K 230V: 230 V mains capable G3: Generation 3 of the PrevaLED® Cube family DA: DALI DALI 2 ready PL-CUBE-AC-3000-830-230V-G3-DA 4 PrevaLED ® Cube AC DALI light engines | Optical considerations 2 Optical considerations PrevaLED® Cube AC light engines can be applied in diffuse wall-mounted and ceiling-mounted luminaires without the need for further optical accessories. 2.1 Light distribution The light distribution of PrevaLED® Cube AC light engines is shown below. They create a beam angle of 110° FWHM. Light distribution curve Jordan Reflektoren GmbH & Co. KG Schwelmer Strasse 161, 42389 Wuppertal, Germany +49 202 60720 [email protected] www.jordan-reflektoren.de ACL-Lichttechnik GmbH Hans-Boeckler-Strasse 38 A, 40764 Langenfeld, Germany +49 2173 9753 0 [email protected] www.reflektor.com Jordan Luxar GmbH & Co. KG Schneiderstrasse 76 d, 40764 Langenfeld, Germany Tel.: +49 (0)2173 279-0, Fax: +49 (0)2173 279-250 [email protected] www.jordan-luxar.de The light-emitting surface of the light engines is covered by a diffuser to ensure a homogeneous, smooth light distribution. 2.2 Refl ector design PrevaLED® Cube AC light engines can also be used with secondary optics. As their optical interface has the same dimensions as common downlight modules on the market, they can be combined with available off-the-shelf secondary optics. For optics support, you can find our suppliers via OSRAM’s LED Light for You network: www.ledlightforyou.com. Moreover, standard components and support for reflector design are available e.g. through the following suppliers: Almeco S.p.A. Via della Liberazione, 15, 20098 San Giuliano Milanese (Mi), Italy +39 02 988963 1 [email protected] www.almecogroup.com Nata Lighting Co., Ltd. 380 Jinou Road, Gaoxin Zone, Jiangmen 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 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. 5 PrevaLED ® Cube AC DALI light engines | Optical considerations 2.3 Color temperature The PrevaLED® Cube AC DALI series is currently available in 3000 K and 4000 K. The color coordinates within the CIE 1931 color space are given below. 2.4 Color rendering PrevaLED® Cube AC DALI light engines provide a color rendering index (CRI) of > 80. The table below shows the individual Ra values from R1 to R14 for the available color temperatures. Initial color values of the CCT R a values Leaf green Pink, skin color Blue, saturated Green, saturated Yellow, saturated Red, saturated Lilac violet Aster violet Azure Turquois Within each available color temperature, the PrevaLED® Cube AC DALI 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. Light green 0.384 Yellowish green 0.405 Mustard yellow 0.387 Cy Dusky pink 4000 K 0.439 General CRI 3000 K Cx R a R1 R2 R3 R4 R5 R6 R7 R8 R9 R10 R11 R12 R13 R14 CCT = 85 83 90 95 84 82 85 89 70 22 75 3000 K 83 65 85 97 CCT = 83 81 89 96 83 81 86 86 64 16 75 4000 K 82 71 83 98 Color coordinates Three-step MacAdam ellipses y 2.5 Spectral distribution The typical spectral distribution of PrevaLED® Cube AC light engines is shown in the following diagram. 0.450 0.425 3000 2500 Wavelength spectrum 3500 0.400 1.00 4500 0.375 840 830 Relative spectral emission [%*100] 4000 5000 0.80 5500 0.350 0.325 0.60 0.350 0.375 0.400 0.425 0.450 0.475 x 0.40 0.20 0.00 380 430 480 530 580 630 680 730 780 Wavelength [nm] 6 PrevaLED ® Cube AC DALI light engines | Ingress protection | Electrical considerations 3 Ingress protection PrevaLED® Cube AC DALI light engines have an ingress protection rating of IP20. Please ensure that the housing of your luminaire provides the ingress protection required for your application. For further information, please have a look at the technical application guide “IP codes in accordance with IEC 60529”, which can be downloaded at www.osram.com. 4 Electrical considerations 4.1 Wiring information PrevaLED® Cube AC DALI light engines can be directly connected to mains voltage (220–240 V, 50/60 Hz). The used input clamps can handle solid or flexible wire with a cross-section of 0.2 to 0.75 mm² (AWG 24–18). The use of solid wire is recommended. Wire preparation 6–7 mm (0.24–0.28 inches) Please insert the wires in 0° orientation to the PCB. Solid wire: Plug directly. Notes: — The connector is designed for three poke-in and release cycles. — Due to the fact that you are dealing with mains voltage, you must not hot-plug the light engine. — The installation of LED light engines needs to be carried out in compliance with all applicable electrical and safety standards. Only qualified personnel should be allowed to perform installations. Flexible wire: 1. Lightly press the push button of the connection clamp. 2. Insert the flexible wire. To press/release the clamps, please use an operating tool (Wago type: 206-860) or a small screwdriver. 7 PrevaLED ® Cube AC DALI light engines | Electrical considerations 4.2 Insulation requirements PrevaLED® Cube AC DALI light engines can be used in class I luminaires without further action. The creepage distance and clearance are fulfilled. 4.4 Electrostatic discharge (ESD) It is not necessary to handle PrevaLED ® Cube AC DALI light engines in electrostatic protected areas (EPAs). In class II luminaires, additional care needs to be taken only in the area of the input connector. Between connection wires with basic insulation and touchable metal parts or the heat sink, a second insulation layer is required. The light engine itself has double/reinforced insulation. 4.3 Inrush current and system installation Due to their electronic construction, PrevaLED® Cube AC DALI light engines have a minimum inrush current. In system installations, you can connect the following numbers of PrevaLED® Cube AC DALI light engines to circuit breakers (e.g. B10 etc.) with different characteristics. To protect a PrevaLED® Cube AC DALI light engine from electrostatic damage, do not open it. The light engine fulfills the requirement of the immunity standard IEC/EN 61547. 4.5 Controllability PrevaLED® Cube AC DALI light engines are dimmable via the DALI interface in a range of 100 % to 1 %. In order to protect the light engine from damage, please do not use phase-cut dimmers. B10: 51 pcs B16: 84 pcs C16: 142 pcs 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 ® Cube AC DALI 3000 lm PrevaLED ® Cube AC DALI 2000 lm Luminous flux [lm] Power [W] Thermal power [W] Luminous flux [lm] % % 100 100 90 90 80 80 70 70 190 200 210 220 230 240 250 260 270 Voltage [V] 190 200 210 220 Power [W] 230 240 Thermal power [W] 250 260 270 Voltage [V] PrevaLED ® Cube AC DALI 1100 lm Luminous flux [lm] Power [W] Thermal power [W] % 100 90 80 70 190 200 210 220 230 240 250 260 270 Voltage [V] 8 PrevaLED ® Cube AC DALI light engines | DALI 5 DALI 5.1 Introduction Your interface to the future DALI devices for intelligent lighting solutions are powerful, efficient and multifunctional. 5.2 Integrated DALI functions 5.2.1 Touch DIM ® TOUCH DIM Creating fascinating settings with light With the right lighting solution, one can express one’s individuality in various ways and perform many different tasks: rooms are brought to life with ease, general safety is increased and the quality of workplace illumination is improved. The sophisticated and reliable solutions from OSRAM meet all these requirements and, thanks to stateof-the-art lighting control, achieve the highest levels of energy efficiency and individuality. Moreover, they also provide an optimal price-performance ratio while covering a wide spectrum – from simple applications to complex installations with light management systems. DALI standard and much more Dimmable digital power supplies with DALI interface provide optimum conditions for achieving the highest possible energy efficiency and flexibility. With the second generation of its DALI devices, OSRAM has even surpassed the common DALI standard – with cutting-edge functions that offer unique advantages in a great variety of applications: — Increase of energy efficiency in storage and production areas in the industrial sector — Brilliance and individuality in the sales and hospitality sectors — Flexibility and motivation in office areas — Multifunctional and flexible wide-area lighting, e.g. in sports halls and parking garages With the unique digital functions of OSRAM, you can meet today’s standards down to the last detail, thus strengthening your position in the lighting market while being best prepared for the requirements of tomorrow. The functions that will be described in detail on the following pages include: — Touch DIM® function: Comfortable dimming with standard push-buttons — Corridor Function: Direct use of standard motion sensors — SMART GRID function: Easy monitoring of lighting systems SENSOR Often it’s the easy solutions that save costs and energy. This is also true for the Touch DIM® function: The comfortable dimming of up to 20 light engines, e.g. in conference rooms or single offices, is controlled via standard push-buttons and therefore keeps investment costs low. Connected to mains voltage, each action is triggered by short and/or long push-button pulses. In combination with a Touch DIM® sensor (see also page 10), daylight can also be used, resulting in an additional energy saving. The plus of the Touch DIM ® function The Touch DIM® function allows for free parametrization of threshold values. In a single office, for example, the lighting can be completely switched off during lunch breaks thanks to the unique stand-by operation. No other DALI device on the market offers this feature. Touch DIM ® function flow chart Light value Fixed or daylight-controlled TD max. TD min. I Fade-up II III Time- Fadeout down IV Stand-by Time Touch DIM ® LS/PD signal Factory settings: Fade-up: 0.7 s Time-out: 15 min Fade-down: 32 s Stand-by: 5 s TD min.: 1 % 9 PrevaLED ® Cube AC DALI light engines | DALI Sensors for the Touch DIM ® function The sensor Touch DIM® LS/PD LI is a light and presence sensor for luminaire integration. It is also available as a light sensor only (Touch DIM® LS LI) or as a presence and motion sensor with sensor extension (Touch DIM® PD LI 2P WOS). Touch DIM ® LS/PD LI sensor Touch DIM ® LS LI sensor Touch DIM ® PD LI 2P WOS sensor Touch DIM ® LS/PD LI sensor wiring diagram L N Pushbutton Max. signal wire length 10 m L ~ ~ DA DA Cube AC DALI ~ ~ DA DA Cube AC DALI N S Touch DIM ® sensor Max. of 4 light engines ~ ~ DA DA Cube AC DALI ~ ~ DA DA Cube AC DALI Touch DIM ® LS/PD LI sensor detection range Height [m] a [m] b [m] 1.8 4.0 2.7 2 4.4 3.0 2.2 4.9 3.3 2.4 5.3 3.6 2.6 5.8 3.9 2.8 6.2 4.2 3 6.7 4.5 3.2 7.1 4.8 3.4 7.6 5.1 Height [m] b [m] Mounting heights above 3.5 m do not lead to any signifi cant extension of the detection range a [m] 10 PrevaLED ® Cube AC DALI light engines | DALI 5.2.2 Corridor Function and parametrization options CORRIDOR FUNCTION Description of the Corridor Function It is possible to connect the PrevaLED® Cube AC DALI directly to commercially available motion sensors. The Corridor Function is triggered by a switching signal, i.e. the voltage of the supply line (220–240 V, 50/60 Hz) is switched to the DALI control line inputs (DA, DA; see the diagram below). A preset "out-of-the-box" luminous flux program launches upon triggering. This can be individually adjusted via OSRAM Tuner4TRONIC® and DALI magic. Three light value ranges and six time ranges are available for this purpose. Advantage: Development of new applications (stairwells, corridors, large storage facilities, …) with the possibility of saving energy and achieving high energy efficiency. Several PrevaLED® Cube AC DALI drivers can be synchronized in an installation via the frequency of the mains voltage (50/60 Hz). The maximum number of PrevaLED® Cube AC DALI light engines in an installation is only limited by the sum of the inrush current surges from the individual ECGs. OSRAM DALI ECG wiring diagram for Corridor Function L3 L2 L1 N Motion sensor ~ ~ DA DA Cube AC DALI ~ ~ DA DA Cube AC DALI ~ ~ DA DA Cube AC DALI Note: Default setting of PrevaLED® Cube AC DALI is the Touch DIM® mode. In order to change the parameters or to switch to the Corridor Function, please use the Tuner4TRONIC® software tool. Please note that PrevaLED® Cube AC DALI light engines in Corridor Function can only be combined with other DALI 2 LED modules or control gears. 11 PrevaLED ® Cube AC DALI light engines | DALI Corridor Function phasing (general and factory setting) General curve: Factory setting: Light value 230 V A ON OFF Stand-by I B Stand-by II C I II III IV V VI DO F1 T1 F2 T2 Time Light value A Time 230 V ON B I II DO III F1 IV T1 Time OFF Three dimming ranges (1…100 %) Free parametrization of time (I…VI) using Tuner4TRONIC ® Factory-set parameters: A: 100 %, D0: 120 s, F1: 32 s B: 10 %, T1: unlimited Synchronisation of Touch DIM ® If a large number of PrevaLED® Cube AC DALI light engines with Touch DIM® is operated in a system, there is a chance that a PrevaLED® Cube AC DALI light engine will operate out of synchronism with the others (= different dimming level setting or different switching state). Sensor for the Corridor Function The DUO sensor is a motion detector suitable for ceiling installation. In addition, it can also be used as an intelligent light sensor, i.e. the lighting can be switched off when the amount of daylight increases. In areas where daylight is available, the possible energy savings are therefore significantly higher than with standard motion detectors. Synchronism can be restored as follows: Step 1: Long press of the switch (> 0.5 s) Æ all the lamps are switched on Step 2: Short press of the switch (< 0.5 s) Æ all the lamps are switched off Step 3: Long press of the switch (> 0.5 s) Æ all the lamps are switched on at minimum dimmer setting and fade up Step 4: Double-click (2x within 0.4 s) Æ store value (optional) DUO sensor After the first three steps – long-short-long – all PrevaLED® Cube AC DALI light engines will be back in synchronism. Note: Touch DIM® is designed for manual control; it is not suitable for a connection to an automation. 12 PrevaLED ® Cube AC DALI light engines | DALI DUO sensor wiring diagram Mains 220–240 V – 50/60 Hz L N F1 6 A/10 A F1 6 A/10 A To other devices 0V B 0V B L Switching contact N DUO 0V B L Switching contact N DUO Switching actuator (master) Range extension (slave) ~ ~ DA DA ~ ~ DA DA Motion signal Cube AC DALI Cube AC DALI N L1 L2 L3 DUO sensor motion detection range (circular) 2.4 m 3.7 2.7 2.1 1.5 0.9 0 0.9 1.5 2.1 2.7 3.7 m 5.2.3 SMART GRID function SMART GRID With the SMART GRID function, lighting systems can be easily monitored and successfully operated. The function increases the level of service by enabling, for example, the readout of the light sources’ operating hours as well as the current operating temperature or the detection of mains overvoltage, thus facilitating the scheduling of service intervals. Overview of supported SMART GRID functions Operation time Supported Operation temperature* Not supported Temperature time integration* Not supported Overvoltage detection Supported Power consumption Supported EOL (end of life) Not supported *Not supported means not neccessary since the module protects itself. 13 PrevaLED ® Cube AC DALI light engines | DALI 5.3 Digital programming PrevaLED® Cube AC DALI light engines can be programmed using the Tuner4TRONIC ® (T4T) software together with the hardware programmer “DALI magic”. This software consists of the following software packages: — T4T – Development — T4T – Production — T4T – Dynamic Link Library (DLL) — T4T – Command Line Version After registration, the software can be downloaded from the www.myosram.com portal. For more information on the programming of PrevaLED® Cube AC DALI, please consult the Tuner4TRONIC® manuals. Cube DALI DA DA This means it is necessary to reinterpret the data to set a certain maximum operating light level. Supply voltage DA DALI magic DA USB Features such as the Touch DIM® sensor and the Corridor Function remain exactly the same as with all other OSRAM devices. Nevertheless, due to the high integration of PrevaLED® Cube AC DALI, a transformation of input parameters for luminus flux has to be made. Tuner4TRONIC® defines current outputs of the secondary side of a typical LED driver. PrevaLED® Cube AC DALI light engines eliminate this interface for the customer as the LED driver and the LED module are integrated. Therefore, the following data will no longer be visible or useful: — Maximum rated current — Operating current — Minimum rated current Light engine programming L N 5.5 Parametrization by Tuner4TRONIC ® software Like with all other OSRAM DALI devices, it is possible to change, edit and set all DALI parameters of the PrevaLED® Cube AC DALI by use of the Tuner4TRONIC® software tool. USB PC PrevaLED® Cube AC DALI light engines need to be powered during programming. They need to be supplied with the mains input voltage. The low voltage allows for safe programming without the need for additional pre cautions during production. 5.4 DC operation PrevaLED® Cube AC DALI light engines are capable to withstand a supply voltage of 300 VDC without causing damage to the light engine. In this operating condition, the light engine will not light up. This feature enables installations of PrevaLED® Cube AC DALI light engines within the same circuitry as LED modules used for emergency lighting. This causes a significant reduction in wiring effort in the building installation. 1 2 3 1 Maximum module input current 2 Nominal module input current 3 Minimum module input current Explanation: Module input current: The current input of the module. This parameter can be used to achieve a previously undefined light output. In the factory setting, this current is set to the nominal module input current to achieve the nominal light output under defined performance conditions. Maximum module input current: The maximum current that the module can use. PrevaLED® Cube AC DALI: Maximum input LED current = Nominal module input current. Minimum module input current: The minimum current that the module can use and still achieve a light dimming level of 1 %. 14 PrevaLED ® Cube AC DALI light engines | DALI Interactive calculation To transfer your desired light engine luminous flux into the value which has to be inserted into the Tuner4TRONIC ® input field, you can either use the diagrams shown below or insert the flux into the interactive fields below. PL-CUBE-AC-1100-8x0-230V-G3-DALI PL-CUBE-AC-2000-8x0-230V-G3-DALI Luminous flux [lm] Luminous flux [lm] 1000 2000 800 1500 600 1000 400 500 200 0 0 20 10 0 30 Target luminous flux: 40 50 60 Operating current [mA] Calculate lm Resulting operating current for T4T software (mA): 0 20 40 Target luminous flux: 60 80 lm 100 120 140 Operating current [mA] Calculate Resulting operating current for T4T software (mA): PL-CUBE-AC-3000-8x0-230V-G3-DALI Luminous flux [lm] 3000 2500 2000 1500 1000 500 0 0 20 40 Target luminous flux: 60 80 100 lm 120 140 Operating current [mA] Calculate Resulting operating current for T4T software (mA): For further information regarding Tuner4TRONIC®, please see the Tuner4TRONIC® help file which you can find in the software itself. 15 PrevaLED ® Cube AC DALI light engines | Thermal considerations 6 Thermal considerations The proper thermal design of an LED luminaire is critical for achieving the best performance and ensuring the longest lifetime of all components. Due to the high efficacy of PrevaLED® Cube AC DALI light engines, only a partial amount of the introduced electrical power has to be dissipated through the back of the light engine. The thermal power that has to be dissipated for PrevaLED® Cube AC DALI light engines is given below. Suppliers of thermal interface materials Thermal power values 6.2 Cooling systems and heat sinks For the selection of a suitable heat sink, several points regarding thermal resistance have to be considered. Typical thermal power [W]1) Max. thermal power [W]1) Typical allowable thermal resistance R th[K/W] 2) Max. allowable thermal resistance R th[K/W] 2) PL-CUBE-AC-11008XX-230V-G3-DALI 8.2 9.7 5.5 4.7 PL-CUBE-AC-20008XX-230V-G3-DALI 12.9 15.5 3.5 2.9 PL-CUBE-AC-30008XX-230V-G3-DALI 21.3 25.3 2.1 1.8 Alfatec www.alfatec.de Kerafol www.kerafol.de Laird www.lairdtech.com Bergquist www.bergquistcompany.com Wakefi eld www.wakefi eld.com The selection is usually carried out along the following necessary steps. Selection of a heat sink Define boundary conditions 6.1 Thermal interface material and other accessories When mounting a PrevaLED® Cube AC light engine within a luminaire, it is recommended to use thermal interface material (TIM) between the back of the light engine and the luminaire housing or heat sink. It is recommended to use thermal paste. In order to balance possible unevenness, the material should be applied as thinly as possible, but as thickly as necessary. In this way, air inclusions, which may otherwise occur, are replaced by TIM and the required heat conduction between the back of the light engine and the contact surfaces of the luminaire housing is achieved. For this purpose, the planarity and roughness of the surface should be optimized. The following list is a selection of suppliers of thermal interface materials. Additional suppliers for thermal management support can also be found via OSRAM’s LED Light for You network: www.ledlightforyou.com. Total power dissipation of the light engine, max. ambient temperature ta, max. reference temperature tr according to lifetime requirements Rth = Estimate heat sink thermal resistance on light engine level 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. Note: A thermal design must always be confirmed by performing a thermal measurement in steady-state condition. It is recommended that the whole area of the PCB of a PrevaLED® Cube AC DALI light engine is in contact with the solid material of the heat sink. 1) Value measured at the tc point at a reference temperature (tr) = tp of 70 °C 2) Value measured at an ambient temperature of 25 °C 3) The R th values apply to the light engine incl. the thermal interface material (TIM). 16 PrevaLED ® Cube AC DALI light engines | Thermal considerations A thermal system always depends on many factors, such as airflow, ambient temperature etc. Please check your entire cooling system by performing a thermal measurement in steady-state condition. 6.3.1 Thermocouple Use a thermocouple that can be glued onto the light engine. Make sure that the thermocouple is fixed with direct contact to the tc point. The list below is a selection of suppliers of different cooling solutions. Examples of suitable thermocouples: Suppliers of active and passive cooling systems K-type thermocouple with miniature connector 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.fi scherelektronik.de Wakefi eld www.wakefi eld.com Cooliance www.cooliance.com Different thermocouples Illustration 6.3 tc point location and temperature measurement The tc point is the location to check if the chosen cooling solution (heat sink and TIM) is sufficient to ensure the light engine performance. The tc point is located on the back of the light engine, under the center of the diffuser (see image below). Description Temperature range [°C] PVC-insulated -10 … +105 thermo couple PFA-insulated -75 … +260 thermo couple Sprung -75 … +260 thermo couple Location of the tc point 37.7 41.4 All fi gures in mm 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 (e.g. with acrylic glue, e.g. Loctite 3751). The glue shall not influence the thermal coupling. tc point A correct temperature measurement can, for example, be performed with a thermocouple. Mounting of a thermocouple through a hole in the heat sink 17 PrevaLED ® Cube AC DALI light engines | Thermal considerations It is also possible to use a sprung thermocouple. A suitable type is: Electronic Sensor FS TE-4-KK06/09/2m. Please note that a good thermal contact between the thermocouple and the PCB is required. Please refer to the datasheet and the application guideline of the manufacturer to ensure correct handling. Another possible way is to create a small groove along the top surface of the heat sink. 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. 18 PrevaLED ® Cube AC DALI light engines | Lifetime and thermal behavior 7 Lifetime and thermal behavior 7.1 Cooling To ensure a safe and reliable operation, the light engine must be attached to a suitable cooling solution (e.g. a heat sink). 7.3 Thermal protection mechanism To protect the light engine from damage by overheating, a thermal derating has been implemented. The derating starts at a tc point temperature of > 90 °C. Please see the curve in the graph at below left. 7.2 Luminous fl ux as a function of temperature The luminous flux of PrevaLED® Cube AC DALI light engines depends on their temperature. 100 % of the luminous flux is achieved at the reference temperature of 70 °C (tp = 70 °C). This temperature has to be measured at the tc point. If the reference temperature increases, the light output decreases. The luminous flux changes in relation to the reference temperature according to the following diagram. Flux as a function of temperature at nominal power Relative flux [%] 100 90 80 70 60 50 40 30 20 10 0 70 80 90 100 110 Temperature [°C] 19 PrevaLED ® Cube AC DALI light engines | Lifetime and thermal behavior 7.4 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 degradation of flux). If the performance temperature tp of 70 °C is maintained, the PrevaLED® Cube light engines have an average lifetime of 50000 hours (L70B50). The maximum temperature measured at the tc point must not exceed 90 °C. Note: Higher temperatures lead to a shorter lifetime of the PrevaLED® Cube AC light engines. Moreover, the failure rate will also increase. The tables below show the lifetime of PrevaLED® Cube AC DALI light engines according to IEC/PAS 62717. PL-CUBE-AC-1100-8x0-230V-G3-DALI L70B50 L80B10 L80B50 L0C10 L0C50 L70F10 L70F50 L80F10 L80F50 Lifetime [h] at t c point = 65 °C 41000 L70B10 50000 26000 36000 104000 104000 39000 50000 26000 35000 Lifetime [h] at t c point = 70 °C 38000 50000 24000 33000 73000 73000 36000 50000 23000 32000 Lifetime [h] at t c point = 75 °C 35000 48000 23000 31000 52000 52000 33000 47000 22000 30000 Lifetime [h] at t c point = 80 °C 33000 45000 21000 28000 36000 36000 30000 44000 20000 27000 Lifetime [h] at t c point = 90 °C 31000 43000 20000 27000 18000 18000 28000 41000 18000 26000 PL-CUBE-AC-2000-8x0-230V-G3-DALI L70B50 L80B10 L80B50 L0C10 L0C50 L70F10 L70F50 L80F10 L80F50 Lifetime [h] at t c point = 65 °C 50000 L70B10 50000 35000 50000 82000 82000 48000 50000 33000 50000 Lifetime [h] at t c point = 70 °C 47000 50000 31000 44000 58000 58000 41000 50000 29000 44000 Lifetime [h] at t c point = 75 °C 41000 50000 27000 39000 41000 41000 36000 50000 25000 38000 Lifetime [h] at t c point = 80 °C 36000 50000 24000 34000 29000 29000 31000 50000 22000 33000 Lifetime [h] at t c point = 90 °C 28000 41000 18000 26000 14000 14000 23000 40000 16000 26000 PL-CUBE-AC-3000-8x0-230V-G3-DALI L70B50 L80B10 L80B50 L0C10 L0C50 L70F10 L70F50 L80F10 L80F50 Lifetime [h] at t c point = 65 °C 42000 L70B10 50000 28000 41000 82000 82000 38000 50000 26000 40000 Lifetime [h] at t c point = 70 °C 37000 50000 24000 36000 58000 58000 33000 50000 23000 35000 Lifetime [h] at t c point = 75 °C 33000 49000 21000 31000 41000 41000 28000 47000 20000 31000 Lifetime [h] at t c point = 80 °C 29000 43000 19000 28000 29000 29000 24000 42000 17000 27000 Lifetime [h] at t c point = 90 °C 23000 34000 15000 22000 14000 14000 18000 33000 13000 21000 20 PrevaLED ® Cube AC DALI light engines | Mechanical considerations 8 Mechanical considerations 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 code of the luminaire housing. Please consider the luminaire standard IEC 60598-1 as well as the different requirements for indoor and outdoor application. Outline drawing Note for France: Due to specific national regulations as defined in the standard EN 60598, it is not permitted to expose the light engine outside a luminaire housing. 54.4 82.8 68 81.6 61 6.2 (screw contact area) kg 41.4 Tc 37.3 18.6 21.1 8.1 Outline drawing The following schematic drawing provides further details on the dimensions of PrevaLED® Cube AC DALI light engines. For 3D files of the light engines, please go to: www.osram.com/prevaled. 4.3 Don’ts 8.4. Mounting To fix a PrevaLED® Cube AC DALI light engine to a heat sink, use M4 cylinder head screws according to DIN 912 or ISO 4762. All fi gures in mm 8.2 3D drawing Enable 3D View Mount the light engine from the top Move me! Movable 3D PrevaLED ® Cube AC DALI light engine Note: Good experiences were made with a torque of 1.0 ± 0.5 Nm, higher torque levels do not necessarily lead to significantly better heat transfer but may lead to damage of the light engine. (works with Adobe Acrobat 7 or higher) 8.3 Mechanical protection of the light engine The housing of a PrevaLED® Cube AC DALI light engine should not be exposed to strong mechanical stress. Please apply force only to the dedicated mounting positions. Strong mechanical stress can lead to irreversible damage of the light engine. Note: If the diffuser material at the light-emitting surface or any other part of the housing or the PCB is broken or mechanically damaged, you must no longer operate the light engine. Please replace it immediately to avoid contact with parts of the light engine that conduct 230 V. 8.5 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-cross-linked 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"). 21 PrevaLED ® Cube AC DALI light engines | Norms and standards 9 Norms and standards Safety: IEC/EN 62031 IEC/EN 60598-1 IEC 61347-1 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 Approval: CE, ENEC, VDE, CB VDE DALI 2: IEC 62386-101:2014 IEC 62386-102:2014 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. 22 11/15 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