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