Page 1 of 6 Issue1 05/11/2012 LEDengine-C* 15 Watt LEDengine 1490 Lumens 25 - 50 Watt LEDengine Up to 4750 lumens Fig.1 LEDengines use Sharp MegaZeni or MiniZeni LEDs Description The Lumotrix LEDengine-C* is a compact high power LED light module with integrated heat-sink, fan and control electronics. The light source of the LEDengine is a Lumotrix LEDisk which is available in a choice of color temperature and CRI with power ratings of 15W, 25W, 35W and 50W. LEDisk is available separately and has its own datasheet. The 15W LEDengine has a smaller Light emitting surface (LES) than the others. LEDengine has a very small heat-sink which is actively cooled with a fan. All LEDengines have the same size heat-sink, but fan speed can be less at lower LEDengine power ratings. This LEDengine comes in two forms LEDengine-C and LEDengine-CF. LEDengine-C requires a constant current power supply for the LED and has on board electronics to generate the supply for the fan. LEDengine-CF requires a main constant current supply for the LED and an auxiliary constant voltage supply for the fan. LEDengine-CF takes advantage of the fact that some constant current supplies are designed with an auxiliary 12VDC output. LEDengine-CF is distinguished by an additional poke-in connector for the fan supply (see Fig.2 below) LEDengine-C Fan supply on board Order code: LE-XX-XXX-C LEDengine-CF Fan supply required Order code: LE-XX-XXX-CF Fig.2 Rear of LEDengine showing the control board arrangement for LEDengine-C and LEDengine-CF There are two other types of LEDengine – type V requires a 24VDC constant voltage supply, and type D has DALI compatible control electronics and can use a DALI 24VDC constant voltage supply. There are separate datasheets for these. Preliminary Data LUMOTRIX Ltd Oakendene Estate, Cowfold, West Sussex, RH13 8AZ United Kingdom +44 1403 865914 [email protected] Page 2 of 6 Issue1 05/11/2012 LEDengine-C* Features: · High Power LED light source with heat-sink, fan and control electronics. · Over-temperature shut down. · Constant current power supply required. · Uses world class Sharp LEDs. · Low profile flat surface to fit most reflectors. · User supplies own reflector. Specification: Operating Temperature Range: -10ºC ~ +50ºC Storage Temperature Range: -40ºC ~ +70ºC Humidity: 95%RH max LED life expectancy: 40,000 hours with light output reduced to 70% Fan supply: 13.5 VDC max, 46mA @12VDC typ. Fan life expectancy: 50,000 hours @70ºC LED supply: variable constant current depending on lumens output, 37V typical for 15W, 25W, 35W, 48V typical for 50W. Recommended connection wire: 26awg, 7/0.16mm, 5A rated Electrical connection: Fig.3 LEDengine electrical connections Preliminary Data LUMOTRIX Ltd Oakendene Estate, Cowfold, West Sussex, RH13 8AZ United Kingdom +44 1403 865914 [email protected] Page 3 of 6 Issue1 05/11/2012 LEDengine-C* Dimensions: LxWxH 45.2 x 45.2 x 41.6 mm Weight: 50g Fig.4 LEDengine dimensions LEDengine Selection: Fan Supply suggested Max ambient Max LED temp Boost Lumen Lumen Boost LED Supply If (mA) Fan Supply suggested V dc 9 83 3000 1270 400 95 72 @8VDC fixed 500 1490 85 56 @8VDC fixed LE-15-830-CF 9 83 3000 1270 400 95 65 @6VDC 6 500 1490 85 66 @12VDC 25 LE-25-840-C 17 82 4000 2650 700 100 62 @8VDC fixed 950 3405 87 25 LE-25-840-CF 17 82 4000 2650 700 100 63 @8VDC 8 950 3405 35 LE-35-840-C 17 80 4000 3550 950 100 65 @12VDC fixed 1200 35 LE-35-840-CF 17 80 4000 3550 950 100 56 @10VDC 10 50 LE-50-830-C 17 83 3000 4430 950 100 52 @12VDC 50 LE-50-830-CF 17 83 3000 4430 950 100 52 @12DC LE-15-830-C 15 ºC ºC ºC ºC LED (max) If mA Sharp LED inside Recommended Power Supply 40 40 GW6BMS30HED Users choice 12 40 40 GW6BMS30HED PS-LEDP-35C 31 @8VDC fixed 40 1050 GW6DMC40NFC Users choice 87 50 @12VDC 12 40 1050 GW6DMC40NFC PS-LEDP-35C 4310 89 45 @12VDC fixed 40 1300 GW6DMD40NFC Users choice 1200 4310 89 45 @12VDC 12 40 1300 GW6DMD40NFC PS-LEDP-35C fixed 1050 4750 94 40 @12VDC fixed 55 1500 GW6DME30NFC Users choice 12 1050 4750 94 40 @12VDC 12 55 1500 GW6DME30NFC PS-LEDP-80C V dc 15 Power (W) LEDengine LED (max) Vf If (mA) Maximum Ambient CCT (K) If (mA) Max LED temp CRI Lumen LED Supply Const.Curr Boosted Light Output L ES (mm) Standard Lumen Standard Light Output Fig.5 LEDengine selection chart Sharp LEDs can be operated to give a standard lumen output, or they may be operated with increased drive current to give a boosted lumen output. This boosted output comes at the cost of reduced efficiency and increased operating temperature of the LED. The increased operating temperature also means that the LED life will be shorter. The LEDengine selection chart Fig.5 shows the standard LED operating conditions in blue and the boosted ones in red. For lower power LEDs it is possible to operate the fan at less than the 12v rated voltage in order to reduce fan noise. For LEDengines-C, where the fan voltage is supplied internally, the fan voltage is fixed at 8V for 15W and 25W LEDs, and is fixed to 12V for 35W and 50 W LEDs. For LEDengines-CF the fan voltages are determined by the user, and looking at the blue part of the chart there are suggested fan voltages of 6, 8, 10 and 12VDC for 15W, 25W, 35W and 50W LEDengines respectively, whereas in the red (boosted) area of the chart it is suggested that the fan be operated at 12VDC because of the higher temperatures. Obviously this is only a guide, but looking at the chart will help the user determine an operating point suitable for their own conditions. They must then confirm in practice that measured temperatures are what they expect. Preliminary Data LUMOTRIX Ltd Oakendene Estate, Cowfold, West Sussex, RH13 8AZ United Kingdom +44 1403 865914 [email protected] Page 4 of 6 Issue1 05/11/2012 LEDengine-C* Standard operating current and light output in the chart are based on the datasheets of the Sharp LEDs inside, as is the maximum LED temperature. The maximum ambient temperature is based on the expected temperature rise of the LED. For example LE-50-830-C has a preset internal fan supply of 12VDC, and the expected temperature rise at 950 mA LED current is 48ºC (measured experimentally). The absolute maximum temperature allowed for the LED is 100ºC. This means that the maximum allowable ambient temperature (shown in the chart) is 52ºC (i.e.100ºC - 48ºC). Looking at the boosted output for the same LEDengine, we see a suggested increase in LED current to 1050mA. Straight away the LED maximum temperature has to be de-rated to 95ºC according to the Sharp LED datasheet and at the same time the temperature rise increases to 55ºC. This means that the maximum allowable ambient temperature has been reduced to 40ºC (shown in the chart). This is probably the lowest maximum ambient that is allowable in real world operation, and this is what determines the amount of boost current that can be applied. When we look at LE-25-840-C in the third row down on the chart, we can see that it has a fixed fan voltage of 8VDC. If we attempt to operate this in boosted mode the maximum ambient temperature that it will safely operate at is 31ºC, which may not be practical in a real application. The fan consumes about 38mV at 12VDC and 25mV at 8VDC on the LEDengine-CF. On the LEDengine-C the fan is powered by an internal buck regulator. It adds about 10mA to the power consumption at the normal operating voltages which are in excess of 35VDC. This additional current is small and has not been shown in the LED selector chart. If the fan stops during operation of the LEDengine the heat-sink temperature will rise rapidly. Unchecked, this would destroy the LED so the LEDengine incorporates a thermistor and control electronics which will shut down the LED until the fault is removed and a reset is initiated by temporarily disconnecting the power. Power supplies Lumotrix offers 35W and 85W constant current power supplies, from Power Systems GmbH, which have a current output programmable via a patented plug-in connector. These also have an auxiliary constant voltage output for the fan and are therefore suitable for use with LEDengine-CF. The arrangement is shown in Fig.6 below. LEDengine-C can be powered by standard constant current supply because it generates its own fan voltage. Connections to LEDengines are via loose wires into poke-in connectors. Preferred wire size is 26 awg e.g. 7/0.16 (7 strands of 0.16mm diameter wire). The choice of constant current power supply depends on the power requirement of the LED. Fig.6 shows the rated current and the corresponding maximum voltage required for each LED engine. This voltage varies from part to part, and the actual voltage may be a few volts less than this value. Fig.6 Programmable constant current power supply feeds LEDengine-CF Preliminary Data LUMOTRIX Ltd Oakendene Estate, Cowfold, West Sussex, RH13 8AZ United Kingdom +44 1403 865914 [email protected] Page 5 of 6 Issue1 05/11/2012 LEDengine-C* The wiring of the LEDengine poke-in connectors is negative to the left hand side and positive to the right hand side, see Fig.3. For the LED supply, maximum current ratings should be observed or overheating may occur. This will appear as black burn marks under the yellow surface of the LED phosphor. Reverse connection will not destroy the LEDengine. For the fan supply (LEDengine-CF), reverse voltage up to 15VDC will cause no damage but over-voltage will result in destruction of the electronics inside the fan. Also, the fan speed may only be controlled by a steady voltage between 6 and 12VDC. Pulse width modulation of the fan supply voltage often results in permanent damage. Mounting The LEDengine can be mounted to a surface using an M4 half nut or an M4 square nut such as RS Components 837-284 inserted in one of the T slots in the heat-sink. The T-slots can be seen at the top of the LEDengines in Fig. 1. Luminaire The LEDengine can also be mounted inside an extruded aluminium sleeve, which is available in 1 metre lengths for prototyping and cut to length 43mm (part no. SS-43) to create a luminaire for LEDengines-C*. There is a back-plate for LEDengine-C with a hole for the single poke-in connector (PRCS1) and another back-plate for LEDengine-CF with two holes (PRCS2). The LEDengine is fixed to the back-plate using the two screws that pass through the fan. These screws can be carefully removed and re-inserted. This will stop the LEDengine sliding in the sleeve. There is a trim plate (PFS1) for the front of the luminaire. Users can glue their own reflector on the luminaire after fitting the trim plate. During operation the airflow passes through holes in the back plate, through the fan and past the heat-sink. It flows between the LEDisk at the front of the LEDengine and the sleeve, and then between the trim plate and the LEDisk to the open air. The length of the sleeve is enough to leave a 6mm gap between the trim plate and the LEDisk to allow airflow. Users designing their own luminaire should consider this airflow requirement. The thermal performance of the heat-sink is not affected by the luminaire, but users should make their own tests to confirm this in their own situation. The luminaire in Fig.7 is shown red anodized, but the standard finish supplied is silver, so the user can keep it like this or make it any colour. Fig.7 Luminaire with section to show internal arrangement Preliminary Data LUMOTRIX Ltd Oakendene Estate, Cowfold, West Sussex, RH13 8AZ United Kingdom +44 1403 865914 [email protected] Page 6 of 6 Issue1 05/11/2012 LEDengine-C* LEDengine Label information Located on side of fan. Format: LE = LEDengine WW = Power e.g. 50 Watt =50 CTT = CRI + Colour Temperature e.g. CRI 82 and CCT 3000K = 830 C* = Constant current supply required + F if Fan supply required So LEDengine detailed above has code LE-50-830-C if no fan supply is needed and LE-50-830-CF if a separate fan supply is needed. LE-WW-CTT-C* 41 /2012 Week /Year The LEDisk used in the LEDengine will have its own separate label. Packing information Individually boxed. Resellers: Germany/Switzerland/Austria: UK: Power Systems GmbH+Co.KG Hauptstr. 48 74360 Ilsfeld/Germany Tel: +49 (0) 7062 6759-6 Fax: +49 (0) 7062 6759-800 www.power-systems.de Lumotrix Ltd Oakendene Estate Cowfold/West Sussex RH13 8AZ England Tel: +44 (0) 1403 865486 www.lumotrix.com Preliminary Data LUMOTRIX Ltd Oakendene Estate, Cowfold, West Sussex, RH13 8AZ United Kingdom +44 1403 865914 [email protected]