Technical application guide - PrevaLED Core Z3 light engines (06/14)

www.osram.com/prevaled-core
06/2014
Technical application guide
PrevaLED® Core Z3
LED modules
Light is OSRAM
PrevaLED ® Core Z3 LED modules | Contents
Contents
1 Introduction
03
5 Lifetime and thermal behavior
17
1.1 System overview
03
5.1 Flux as a function of temperature
17
1.2 Nomenclature
03
5.2 Lifetime
17
2 Optical considerations
04
6 Mechanical considerations
18
2.1 Light distribution
04
6.1 Outline drawing
18
2.2 Refl ector design
04
6.2 3D drawing
18
2.3 Theoretical considerations for possible refl ectors
05
6.3 Mechanical protection of the PrevaLED ® Core Z3 LED module
18
2.4 Refl ector mounting
06
6.4 Mounting
18
2.5 Color temperature
06
7 Norms and standards
19
2.6 Color rendering
07
2.7 Spectral distribution
07
2.8 Flux behavior
08
3 Electrical considerations
09
3.1 Forward voltage as a function of temperature
09
3.2 Electronic control gear/LED module combination
09
3.3 Wiring
10
3.4 OTi DALI electronic control gears
12
3.5 OT FIT electronic control gears
12
3.6 OTe electronic control gears
12
3.7 OT LCTS electronic control gears – LEDset GEN 1
12
3.8 Maximum allowed number of control gears per circuit breaker
13
3.9 ESD
13
4 Thermal considerations
14
4.1 Thermal power values
14
4.2 TIM and other accessories
14
4.3 Cooling system and heat sinks
14
4.4 tc point location and temperature measurement
15
4.5 Thermocouple
15
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/prevaled-core or contact your
sales partner for an updated copy of this guide.
2
PrevaLED ® Core Z3 LED modules | Introduction
1 Introduction
1.1 System overview
Building an LED-based luminaire poses a new set of technical challenges, among them new optical requirements,
providing adequate thermal management for stable
operation and lastly dealing with the ever-improving
per formance of LEDs. Nevertheless, LED technology also
provides an unknown wealth of possibilities, opening up
unprecedented levels of performance.
This technical application guide will support you in tackling
the challenges and taking full advantage of all opportunities
PrevaLED® Core LED modules have to offer.
Focussing on the continuous improvement of performance
and costs, OSRAM has introduced its new generation
of Zhaga spotlight LED modules: PrevaLED® Core Z3,
together with the dedicated on/off and intelligent
OPTOTRONIC ® electronic control gear (ECG) ranges.
Of course, important improvements have been realized
as well:
— Efficacy of the modules
— 5 000-lm package
— Price position
— Driver/LED module interface – fit for standard cables and
standard constant-current drivers (on/off and intelligent)
Applications
The PrevaLED® Core series of LED modules is ideally
suited for use in reflector-based, rotation-symmetric
luminaires (such as tracklights, cardans and downlights)
in shop, hospitality, decorative or office applications.
Future-proof concept
To allow for a smooth transition to this new generation
of the PrevaLED® Core series, crucial features have
remained the same:
— System approach with OPTOTRONIC® ECGs
— Form factor and mechanical/optical interfaces
— Compatibility with off-the-shelf accessories
according to Zhaga book 3
1.2 Nomenclature
PL: PrevaLED® LED module
Core: Round-shaped module
3000: 3000 lm
830: Color rendering index (CRI) + color
temperature (CCT) = > 80 + 3000 K
Z3: Generation 3
PL-CORE-3000-830-Z3
3
PrevaLED ® Core Z3 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 Z3 LED modules create
a beam angle of 115° FWHM (full width at half maximum).
C 0°
The PrevaLED® Core Z3 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
Z3 help to avoid roughness and facets, allowing for very
small total beam angles of 10° or less.
75°
60°
45°
30°
2.2 Refl ector design
High luminous intensities (1.5–4.5 Mcd/m2) 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 light-emitting surfaces and a high
luminous flux – as realized in the PrevaLED® Core Z3 – are
required, because in such combinations, the light can be
collimated especially well with reflectors.
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
upon request through your sales partner. Available ray file formats are ASAP, SPEOS, LightTools and Photopia (all binary).
4
PrevaLED ® Core Z3 LED modules | Optical considerations
2.3 Theoretical considerations for possible reflectors
PrevaLED ® Core Z3, 1100 lm, LES 9, OCA A*
PrevaLED ® Core Z3, 5000 lm, LES 23, OCA D*
Reflector output diameter [mm]
Reflector 40
height
[mm]
50
60
Reflector output diameter [mm]
70
Reflector 80
height
[mm]
100
120
140
50
12°; 14000 cd; 10°; 17000 cd;
89 %; 3400 lx; 90 %; 4400 lx;
12.5 cd/lm
15.9 cd/lm
40
14°; 10000 cd; 12°; 13000 cd; 10°; 15000 cd;
89 %; 2400 lx; 91 %; 3200 lx; 92 %; 3900 lx;
8.7 cd/lm
11.5 cd/lm
14.0 cd/lm
80
18°; 27000 cd; 15°; 35000 cd; 12°; 43000 cd;
81 %; 6700 lx; 82 %; 8900 lx; 83 %; 10900 lx;
5.3 cd/lm
7.1 cd/lm
8.7 cd/lm
30
15°; 9000 cd; 12°; 11000 cd; 9°; 13000 cd;
91 %; 2100 lx; 93 %; 2700 lx; 94 %; 3100 lx;
11.4 cd/lm
7.8 cd/lm
9.9 cd/lm
60
18°; 24000 cd; 14°; 30000 cd; 11°; 36000 cd;
83 %; 6000 lx; 84 %; 7500 lx; 85 %; 8900 lx;
7.1 cd/lm
4.8 cd/lm
6.0 cd/lm
20
18°; 5000 cd; 14°; 7000 cd; 11°; 7000 cd; 9°; 7000 cd;
93 %; 1300 lx; 95 %; 1700 lx; 96 %; 1800 lx; 97 %; 1800 lx;
4.7 cd/lm
6.0 cd/lm
6.6 cd/lm
6.4 cd/lm
40
22°; 14000 cd; 16°; 18000 cd; 12°; 21000 cd; 10°; 22000 cd;
84 %; 3600 lx; 85 %; 4600 lx; 87 %; 5300 lx; 88 %; 5600 lx;
2.9 cd/lm
4.2 cd/lm
3.6 cd/lm
4.5 cd/lm
100
14°; 38000 cd; 12°; 48000 cd;
80 %; 9500 lx; 81 %; 12100 lx;
7.6 cd/lm
9.7 cd/lm
* Parabolic refl ector, 85 % specular refl ectance, lux in 2 m distance
PrevaLED ® Core Z3, 2000 lm, LES 19, OCA C*
Reflector output diameter [mm]
Reflector 80
height
[mm]
100
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
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
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
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
120
140
PrevaLED ® Core Z3, 3000 lm, LES 19, OCA C*
Reflector output diameter [mm]
Reflector 80
100
120
height
[mm]
140
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
— 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
LED module flux.
— 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 2 m distance to the reflector.
The PrevaLED® Core Z3 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:
Jordan Refl ektoren GmbH & Co. KG
Schwelmer Strasse 161
42389 Wuppertal, Germany
+49 202 60720
info@jordan-reflektoren.de
www.jordan-reflektoren.de
ACL-Lichttechnik GmbH
Hans-Boeckler-Strasse 38 A
40764 Langenfeld, Germany
+49 2173 9753 0
info@reflektor.com
www.reflektor.com
5
PrevaLED ® Core Z3 LED modules | Optical considerations
Alux·Luxar GmbH & Co. KG
Schneiderstrasse 76
40764 Langenfeld, Germany
+49 2173 279 0
[email protected]
www.alux-luxar.de
Almeco S.p.A.
Via della Liberazione, 15
20098 San Giuliano, Milanese (Mi), Italy
+39 02 988963 1
[email protected]
www.almecogroup.com
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
Additionally, a bayonet base option is provided, with the
help of which the reflector can be attached directly to the
PrevaLED® Core Z3.
PrevaLED® Core Z3 3D files including the bayonet base for
design-in are available at www.osram.com/prevaled-core.
2.5 Color temperature
The PrevaLED® Core Z3 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
0.4585
3000 K
0.4345
3500 K
0.4083
4000 K
0.3828
Cy
0.4104
0.4033
0.3921
0.3803
Within each available color temperature, the PrevaLED ®
Core Z3 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
2.4 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.
0.45
3000
2500
4000
0.40
2000
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),
it is recommended to stay within the OCA values of the
corresponding category (see product datasheet).
0.35
6000
0.35
0.40
0.45
0.50
x
Allowed compression: 20 N
Allowed tension: 20 N
Allowed torque: 1 Nm
6
PrevaLED ® Core Z3 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
2.6 Color rendering
PrevaLED® Core Z3 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
83
95
93
78
82
93
82
61
18
87
76
74
86
97
83
CCT =
3000 K
85
96
93
80
85
93
83
65
26
89
78
73
88
97
85
CCT =
3500 K
87
97
94
81
86
94
84
70
33
92
80
69
91
97
87
CCT =
4000 K
89
99
93
82
88
93
84
73
41
95
81
67
93
97
88
CCT =
3000 K
96
99
98
92
94
96
91
87
74
97
93
78
97
99
94
2.7 Spectral distribution
The typical spectral distribution of the PrevaLED® Core Z3
LED modules is shown in the following diagram.
Relative luminous intensity [%]
827
830
835
840
930
120
100
80
60
40
20
0
400
450
500
550
600
650
700
750
Wavelength [nm]
Values measured at tc = 25 °C
7
PrevaLED ® Core Z3 LED modules | Optical considerations
2.8 Flux behavior
The following diagrams show the luminous flux over
the operating current for all PrevaLED® Core Z3 modules
at a tc temperature of 65 °C.
PL-CORE-1100-8XX-Z3
PL-CORE-2000-XXX-Z3
840 65 °C
PhiV typ [lm]
830 65 °C
PhiV typ [lm]
1400
3000
1200
2500
1000
2000
800
1500
600
1000
400
500
100
150
200
250
300
350
200
250
930 65 °C
300
350
400
840 65 °C
450
500
I [mA]
550
600
I [mA]
PL-CORE-5000-XXX-Z3
PL-CORE-3000-XXX-Z3
PhiV typ [lm]
830 65 °C
930 65 °C
840 65 °C
830 65 °C
930 65 °C
PhiV typ [lm]
840 65 °C
830 65 °C
6000
5000
5000
4000
4000
3000
2000
3000
1000
0
2000
500
600
700
800
900
1000
1100
I [mA]
0
200
400
600
800
1000
1200
1400 1600
I [mA]
8
PrevaLED ® Core Z3 LED modules | Electrical considerations
3 Electrical considerations
3.1 Forward voltage as a function of temperature
Relative forward voltage
normalized at 65 °C [%]
1100 lm
3000 lm
2000 lm
5000 lm
101.5
101.0
100.5
100.0
99.5
99.0
98.5
98.0
0
20
40
60
80
100
120
Case temperature tc [°C]
3.2 Electronic control gear/LED module combination
PrevaLED® Core Z3 LED modules can either be used with
constant-current control gears or in combination with
OSRAM OTi DALI control gears. The OTi DALI control gears
provide a thermal shutdown function as well as an automatic
flux calibration. Constant-current control gears do not provide
these features. The table below shows possible combinations
of PrevaLED® Core Z3 LED modules and OSRAM ECGs.
Modules
Drivers
Typ.
OT
current 35/45
[mA]
LTCS
OT 45
DALI
LTCS
OTe
25 CS
OTe
OTe
35 CS 50 CS
OTe 50
CS FAN
OT
FIT
15 CS
OT
OT
OTi
FIT
FIT
DALI
25 CS 35 CS 25
OTi
DALI
35
OTi
DALI
50 FAN
1160
PL-CORE-1100-830-Z3
235
PL-CORE-1100-840-Z3
220
PL-CORE-2000-830-Z3
400
2070
PL-CORE-2000-840-Z3
385
2160
PL-CORE-2000-930-Z3
490
1750
PL-CORE-3000-830-Z3
590
PL-CORE-3000-840-Z3
575
PL-CORE-3000-930-Z3
730
2900
2900
PL-CORE-5000-830-Z3
950
3400
3400
PL-CORE-5000-840-Z3
885
3700
3700
PL-CORE-5000-930-Z3
1155
1210
TBD
3035
3115
2900
3240
2900
TBD
TBD
4600
4600
2300: System fi t OK; typical flux level (lm) if deviating from nominal
: System fit OK for 1 or more current settings
Preliminary data. The fl ux levels realized with fi xed-value constant-current OTe and OT FIT drivers will change as the effi cacy of the modules
evolves.
9
PrevaLED ® Core Z3 LED modules | Electrical considerations
3.3 Wiring
The input clamps used in the PrevaLED® Core Z3 can
handle solid wires with a cross-section of 0.5–1.0 mm2
(AWG21–17).
Example: H05V-U 1x 0.5 mm 2
Wire preparation
Please note:
— The connector is designed for three “poke-in” and
release cycles.
— The installation of LED modules needs 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.
For wires with
1 mm2 (AWG17):
5.5 mm
For wires with
0.5-0.823 mm2
(AWG21–18):
5.3 ± 0.2 mm
10
PrevaLED ® Core Z3 LED modules | Electrical considerations
Connect and release
Connect
Plug wire directly
Release
1
Use a very slim screwdriver and push gently into the release hole
2
Push in the screwdriver below the release spring
3
Pull out the wire and afterwards the screwdriver
11
PrevaLED ® Core Z3 LED modules | Electrical considerations
3.4 OTi DALI electronic control gears
If you use the PrevaLED® Core Z3 series in combination
with the OSRAM OTi DALI control gear series, you will get
the best results and the full functionality of the LED module.
3.6 OTe electronic control gears
If you like to use the OSRAM OTe series, please connect
the terminal LED+ to the 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 LEDset GEN 2 communication standard between
the control gear and the module. A thermal derating and a
flux calibration are included.
Therefore, please connect all three terminals of the module
to the control gear.
Connection detail
Select only
1 connection
terminal
Connection detail
3.7 OT LCTS electronic control gears – LEDset GEN 1
If you want to use PrevaLED ® Core Z3 LED modules with
LCTS control gears, you need to attach a resistor to the
ECG to adjust the required current.
3.5 OT FIT electronic control gears
It is also possible to use the PrevaLED® Core Z3 series with
a constant-current driver. The OT FIT series offers different
available currents. To wire the module to the ECG, please
connect the ports LED+ and LED- to the module as shown
in the image below. The current is selected by a bridge
between ports 3, 4 and 5.
OT 35/220-240/700 LCTS
Connection detail
You can calculate the resistor using this formula:
R set =
Iout
1 + 9 x Inom [V]
Iset
Rset = The value of the resistor in Ohm
Iout = The output current desired to operate
the LED module
Inom = 700 mA for OT 35/700 LCTS and
OT DALI 45/700 LCTS
Iset = 274 μA
12
PrevaLED ® Core Z3 LED modules | Electrical considerations
The following values result for the modules that can be
driven with LCTS drivers:
Module
PL-CORE-2000-830-Z3
I [mA]
400
R [Ohm]
22419
PL-CORE-2000-840-Z3
385
21715
PL-CORE-2000-930-Z3
490
26642
PL-CORE-3000-830-Z3
590
31335
PL-CORE-3000-840-Z3
575
30631
PL-CORE-3000-930-Z3
730
Use DIP switch for 700 mA.
Module is under-driven.
PL-CORE-5000-830-Z3
950
Use DIP switch for 700 mA.
Module is under-driven.
PL-CORE-5000-840-Z3
885
Use DIP switch for 700 mA.
Module is under-driven.
The resistor has to be placed between Vset and GNDset:
Example of wiring:
For further information on the LEDset interface, please refer
to the LEDset technical application guide at www.osram.com.
3.8 Maximum allowed number of control gears
per circuit breaker
OTe 35/700
Please note:
To activate the LEDset interface, both DIP switches of the
LED module have to be in the “OFF” position.
DIP1
DIP2
Current
Off
Off
LEDset
Off
On
700 mA
On
Off
500 mA
On
On
350 mA
B16
B10
50
30
OT 35 LCTS
84
52
OT 45 LCTS
60
40
OT 45 DALI LCTS
47
18
OTe 25 CS
50
30
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
OTi DALI 25
84*
52*
OTi DALI 35
60*
40*
OTi DALI 50 FAN
13
18
* Preliminary data
3.9 ESD
It is not necessary to handle PrevaLED® Core Z3 LED
modules in electrostatic protected areas (EPAs). To protect a
PrevaLED® Core Z3 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 Z3 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 Z3 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 Z3 LED modules is given
below.
4.1 Thermal power values
4.2 TIM and other accessories
When mounting a PrevaLED® Core Z3 LED module within
a luminaire, it is recommended 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, but thermal foil can also be used. In order to
balance possible unevenness, the material should be
applied as thinly as possible, but as thickly as necessary.
In this way, air inclusions, which may otherwise occur, are
replaced by TIM and the required heat conduction between
the back of the LED module and the contact surfaces of
the luminaire housing is achieved. For this purpose, the planarity and smoothness of the surface should be optimized.
Product
Typ.
thermal
power
[W]1)
Max. thermal
power [W] at
nominal
current1)
Max. allowable
thermal resistance Rth
[K/W]2)
PL-CORE-1100-830-Z3
7.7
8.2
4.91
PL-CORE-1100-840-Z3
6.9
7.3
5.48
PL-CORE-2000-830-Z3
11.2
12.4
3.23
PL-CORE-2000-840-Z3
10.1
11.0
3.63
PL-CORE-2000-930-Z3
14.4
15.6
2.56
PL-CORE-3000-830-Z3
15.9
17.4
2.30
PL-CORE-3000-840-Z3
15.1
16.6
2.41
Alfatec
www.alfatec.de
PL-CORE-3000-930-Z3
21.2
23.3
1.72
Kerafol
www.kerafol.de
PL-CORE-5000-830-Z3
28.6
31.3
1.28
Laird
www.lairdtech.com
www.bergquistcompany.com
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: www.ledlightforyou.com.
Thermal interface materials
PL-CORE-5000-840-Z3
25.1
27.4
1.46
Bergquist
PL-CORE-5000-930-Z3
33.7
36.8
1.09
Arctic Silver
www.arcticsilver.com
Wakefi eld
www.wakefi eld.com
1) Value measured at the tc point at a reference temperature (tr) of 65 °C
2) Value measured at the rear of the luminaire at an ambient temperature of 25 °C
To achieve the best possible lifetime of the module and to
save it from damage by overheating, a thermal protection
feature is added. This feature is only usable when operating
the module with an OSRAM OTi DALI control gear.
4.3 Cooling system and heat sinks
For the selection of a suitable heat sink, several points
regarding thermal resistance have to be considered.
The selection is usually done through the following
necessary steps.
The characteristics of the thermal protection are shown in
the following diagram.
Current [% of minimal ECG current]
Defi ne boundary
conditions
100
Total power dissipation of the
LED module, max. ambient
temperature ta, max. reference
temperature tr according to
lifetime requirements
50
R th =
Estimate heat sink
thermal resistance on
LED module level
tr - ta
P th
tr measured at the tc point
0
75
105
tc [°C]
The behavior below 50 % of the system current depends on the
nominal system current and the applied ECG
Select heat sink
thermal resistance
Use the estimated R th as a
target for a possible heat sink
profile and examine the performance curve in the heat
sink manufacturer’s catalog.
14
PrevaLED ® Core Z3 LED modules | Thermal considerations
Please note:
A thermal design must always be confirmed by performing
a thermal measurement in steady-state condition.The
whole area of the PCB must be in contact with solid material of the heat sink. In the following, you find two examples
of how to cool a PrevaLED® Core Z3 LED module.
Example 1:
LED module: PL-CORE-1100-827-Z3
Heat sink: Fischer SK572; height: 37.5 mm
TIM: Kerafoil 86/82
ta: 25 °C
Temperature at the tc point: 61 °C
Example 2:
LED module: PL-CORE-5000-830-Z3
Heat sink: Sunon LA003-012A82DY
(active cooling solution with 12-V fan)
TIM: Kerafoil 86/82
ta: 25 °C
Temperature at the tc point: 57 °C
Please note that the shown solutions are just examples. 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. The list below is a selection of suppliers of different cooling solutions.
Location of the tc point
tc point
2D code
To ensure a lifetime of 50 000 hours (L70B50), the reference
temperature (tr) at the tc point must not exceed 65 °C. The
maximum temperature reached at the tc point must not
exceed 85 °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:
Miniature connector “K”
Thermo wire NiCr–Ni
Cooling systems
Nuventix
www.nuventix.com
Sunon
www.sunoneurope.com
Cooler Master
www.coolermaster.com
AVC
www.avc-europa.de
SEPA
www.sepa-europe.com
Fischer Elektronik
www.fi scherelektronik.de
Meccal
www.meccal.com
Wakefi eld
www.wakefi eld.com
R-Theta
www.r-theta.com
Cool Innovations
www.coolinnovations.com
4.4 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 LED
module performance. The tc point is located on the back of
the LED module under the center of the diffuser (see image
above).
K-type thermocouple with miniature connector
Different thermocouples
Illustration
Description
Temperature range [°C]
PVC-insulated
thermocouple
-10 … +105
PFA-insulated
thermocouple
-75 … +260
Sprung
thermocouple
-75 … +260
15
PrevaLED ® Core Z3 LED modules | Thermal considerations
To measure the temperature and to ensure a good thermal
coupling between the LED module and the heat sink, drill a
hole into the heat sink and push the thermocouple through
the heat sink. 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).
Notes:
Please keep in mind that you need a direct contact
between the thermocouple and the PCB.
If you use a TIM, please cut out a small area where the
thermocouple has direct contact to the metal-core PCB.
Mounting of a thermocouple through a hole in the heat sink
It is also possible to use a sprung thermocouple. A suitable
type is: Electronic Sensor FS TE-4-KK06/09/2m. Please
note that a good thermal contact between the thermocouple and the PCB is required. Please refer to the datasheet and the application guideline of the manufacturer to
ensure correct handling.
Another possible way is to create a small groove along the
top surface of the heat sink and run the thermocouple
inside the groove to the tc point.
Mounting of a thermocouple by means of a groove
16
PrevaLED ® Core Z3 LED modules | Lifetime and thermal behavior
5 Lifetime and thermal behavior
5.1 Flux as a function of temperature
The following diagram shows the behavior of the flux output over the tc point temperature for PrevaLED® Core Z3.
PL-CORE-2000 lm/3000 lm-Z3
Relative luminous flux normalized at 65 °C [%]
108
106
104
102
100
98
96
94
92
25
45
65
85
Case temperature tc [°C]
5.2 Lifetime
OSRAM PrevaLED ® Core Z3 modules have a lifetime of
50 000 hours (L70B50) at a tc point temperature of 65 °C.
This means that after 50 000 hours, over 50 % of the used
modules will have more than 70 % of the initial luminous flux.
If you operate the module at a lower tc point temperature,
the lifetime of the module is going to rise significantly.
Note: Higher tc temperatures lead to a shorter lifetime of
the PrevaLED® Core Z3 LED modules. Moreover, the failure
rate will also increase.
17
PrevaLED ® Core Z3 LED modules | Mechanical considerations
6 Mechanical considerations
The following schematic drawing provides further details on
the dimensions of PrevaLED® Core Z3 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 Z3
LED module
The housing of a PrevaLED® Core Z3 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 surface. This could damage
the module.
2000/3000 lm
1100 lm
For operation in damp, wet or dusty environments, the user
has to make sure that an adequate ingress protection is
chosen. The LED module has to be protected by a suitable
IP classification of the luminaire housing. Please consider
the luminaire standard IEC 60598-1 as well as the different
requirements.
5000 lm
6.2 3D drawing
6.4 Mounting
To fix a PrevaLED® Core Z3 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 is 0.4 to 0.6 Nm.
Enable 3D View
18
PrevaLED ® Core Z3 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
19
06/14 OSRAM S-GI MK 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