www.osram.com/prevaled-core 05/2016 Technical application guide PrevaLED® Core Z4 LED modules Light is OSRAM PrevaLED ® Core Z4 LED modules | Contents Contents 1 Introduction 03 4 Thermal considerations 14 1.1 System overview 03 4.1 Thermal power values 14 1.2 Nomenclature 03 4.2 TIM and other accessories 14 4.3 Cooling system and heat sink 14 2 Optical considerations 04 4.4 tc point location and temperature measurement 15 2.1 Light distribution 04 4.5 Thermocouple 15 2.2 Refl ector design 04 2.3 Theoretical considerations for possible refl ectors 05 5 Lifetime and thermal behavior 17 2.4 Refl ector mounting 06 5.1 Luminous fl ux as a function of temperature 17 2.5 Color temperature 06 5.2 Lifetime 17 2.6 Color rendering 07 18 2.7 Spectral distribution 07 6 Mechanical considerations 2.8 Luminous flux behavior 08 6.1 Outline drawing 18 6.2 3D drawing 18 3 Electrical considerations 09 6.3 Mechanical protection of the PrevaLED ® Core Z4 LED module 18 3.1 Forward voltage as a function of temperature 09 6.4 Mounting 18 3.2 LED driver/LED module combination 09 3.3 Wiring 10 7 Norms and standards 19 3.4 OTi DALI LED drivers 11 3.5 OT FIT LED drivers 11 3.6 OTe LED drivers 11 3.7 LEDset2 (LT2) 12 3.8 Maximum allowed number of LED drivers per circuit breaker 13 3.9 ESD 13 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 ® Core Z4 LED modules | Introduction 1 Introduction 1.1 System overview Building an LED-based luminaire poses a set of technical challenges, among them optical requirements, providing adequate thermal management for stable operation and lastly dealing with the ever-improving performance of LEDs. Nevertheless, LED technology also provides an unknown wealth of possibilities, opening up unprecedented levels of performance. PrevaLED® Core LED modules, which are designed according to Zhaga Book 3 standards, offer one of the best and easiest ways to outfit luminaires with LED technology. Focussing on the continuous improvement of performance and costs, OSRAM has introduced its new generation of Zhaga spotlight LED modules: PrevaLED® Core Z4. Together with the dedicated on/off and intelligent OPTOTRONIC® LED driver ranges, it offers a complete and reliable system. Future-proof concept To allow for a smooth transition to this new generation of the PrevaLED® Core series, crucial features have remained the same: — Complete portfolio in terms of luminous flux, color temperature and color rendering — Easy design-in — Same form factor and mechanical/optical interfaces as PrevaLED® Core Z3 — Compatible with off-the-shelf Zhaga Book 3 accessories — System approach — System match and 3 or 5-year guarantee (for current terms and conditions of the guarantee, please go to www.osram.com/system-guarantee) — Selection of dimmable and non-dimmable LED drivers Of course, important improvements have been realized as well: — Easy design-in — 1 reflector: 3 x LES 19 for 2 000, 3 000 and 5 000 lm — Lifetime of 50 000 hours (L70B10) — Improved poke-in connector for stranded and solid wires — Improved light quality — Small heat sink — Typical module efficacy: up to 130 lm/W — tc max: 90 °C — Thermal protection — Derating and reversible thermal shutdown built into the LED module — Price positioning Applications The PrevaLED® Core series of LED modules is ideally suited for use in reflector-based, rotation-symmetric luminaires in applications such as: — Spotlighting and tracklighting in retail stores — Downlighting and wall lighting in offices, corridors, meeting rooms and workplaces — Decorative and functional lighting in the hospitality industry — High-end museum lighting 1.2 Nomenclature PL: PrevaLED® LED module Core: Round-shaped LED module Z4: Generation 4 3000: 3000 lm 830: Color rendering index (CRI) + color temperature (CCT) = > 80 + 3000 K PL-CORE-Z4-3000-830 3 PrevaLED ® Core Z4 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 Z4 LED modules create a beam angle of 114° FWHM (full width at half maximum). C 0° 2.2 Refl ector design High luminances (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 Z4 – are required, because in such combinations, the light can be collimated particularly well with reflectors. The PrevaLED® Core Z4 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 Z4 help to avoid roughness and facets, allowing for very small total beam angles of 10° or less. 75° 60° 45° 30° 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 at www.osram.com via the “Tools & Services” portal. Note: To avoid any adverse effects on sensitive materials, it is recommended to consider the distance between the LED light source and the illuminated object, depending on the light intensity of the LED source. If in doubt, material compatibility checks should be conducted. 4 PrevaLED ® Core Z4 LED modules | Optical considerations 2.3 Theoretical considerations for possible refl ectors PrevaLED ® Core Z4, 1100 lm, LES 9, OCA A* PrevaLED ® Core Z4, 4500 lm, LES 19, OCA C* Reflector output diameter [mm] Reflector 40 height [mm] 50 60 Reflector output diameter [mm] 70 Reflector 80 height [mm] 100 100 15°; 38250 cd; 12°; 49500 cd; 11°; 63000 cd; 88 %; 9450 lx; 89 %; 12600 lx; 90 %; 15975 lx; 8.4 cd/lm 11.2 cd/lm 14.3 cd/lm 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 15°; 36000 cd; 12°; 47250 cd; 10°; 56250 cd; 89 %; 8775 lx; 91 %; 11700 lx; 92 %; 14400 lx; 7.9 cd/lm 10.4 cd/lm 12.8 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 19°; 22500 cd; 15°; 31500 cd; 12°; 40500 cd; 10°; 47250 cd; 90 %; 5850 lx; 91 %; 7875 lx; 93 %; 9900 lx; 94 %; 11700 lx; 10.5 cd/lm 5.2 cd/lm 7.0 cd/lm 8.9 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 19°; 18000 cd; 14°; 24750 cd; 11°; 27000 cd; 8°; 29250 cd; 93 %; 4725 lx; 95 %; 5850 lx; 96 %; 6975 lx; 97 %; 7425 lx; 4.2 cd/lm 5.3 cd/lm 6.1 cd/lm 6.5 cd/lm * Parabolic refl ector, 85 % specular refl ectance, lux in 2 m distance PrevaLED ® Core Z4, 2000 lm, LES 19, OCA C* Reflector output diameter [mm] Reflector 80 height [mm] 100 120 140 100 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 PrevaLED ® Core Z4, 3000 lm, LES 19, OCA C* Reflector output diameter [mm] Reflector 80 height [mm] 100 100 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 120 The above-mentioned estimations are based on the following assumptions: — 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 luminous flux of the LED module. — 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 Z4 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: 140 ACL-Lichttechnik GmbH Hans-Boeckler-Strasse 38 A 40764 Langenfeld, Germany +49 2173 9753 0 info@reflektor.com www.reflektor.com Almeco S.p.A. Via della Liberazione, 15 20098 San Giuliano Milanese (Mi), Italy +39 02 988963 1 [email protected] www.almecogroup.com 5 PrevaLED ® Core Z4 LED modules | Optical considerations Alux·Luxar GmbH & Co. KG Schneiderstrasse 76 40764 Langenfeld, Germany +49 2173 279 0 [email protected] www.alux-luxar.de Jordan Refl ektoren GmbH & Co. KG Schwelmer Strasse 161 42389 Wuppertal, Germany +49 202 60720 info@jordan-reflektoren.de www.jordan-reflektoren.de 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 Z4. PrevaLED® Core Z4 3D files including the bayonet base for design-in are available at www.osram.com/prevaled-core. 2.5 Color temperature The PrevaLED® Core Z4 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 0.45785 3000 K 0.43385 3500 K 0.40767 4000 K 0.38226 Cy 0.40919 0.40198 0.39075 0.37896 Within each available color temperature, the PrevaLED ® Core Z4 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 0.45 3000 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. 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). 2700 3500 4000 0.40 0.35 0.35 0.40 0.45 0.50 x Chromaticity coordinate groups: Chromaticity coordinates are measured during a current pulse of typically 25 ms, with an internal reproducibility of ±0.005 and an expanded uncertainty of ±0.01 (acc. to GUM with a coverage factor of k = 3). For testing, the chromaticity coordinate ellipses are approximated with polygons. Allowed compression: 20 N Allowed tension: 20 N Allowed torque: 1 Nm 6 PrevaLED ® Core Z4 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 Z4 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 80 89 97 80 79 86 84 61 13 75 77 71 82 98 82 CCT = 3000 K 82 89 95 82 81 86 86 66 19 75 80 70 83 97 84 CCT = 3500 K 84 90 94 84 83 85 88 70 25 75 83 70 85 96 85 CCT = 4000 K 83 88 92 84 83 84 89 71 23 72 83 67 84 95 84 CCT = 3000 K 96 95 93 95 95 94 95 91 77 88 95 86 96 95 94 2.7 Spectral distribution The typical spectral distribution of the PrevaLED® Core Z4 LED modules is shown in the following diagram. 830 Relative luminous intensity 840 930 1.00 0.80 0.60 0.40 0.20 0 380 430 480 530 580 630 680 730 780 Wavelength [nm] Values measured at tp = 65 °C 7 PrevaLED ® Core Z4 LED modules | Optical considerations 2.8 Luminous fl ux behavior The following diagrams show the luminous flux over the operating current for PrevaLED® Core Z4 modules with 2 000, 3 000 and 5 000 lm. Data related to the operating current is derived from a tp temperature of 65 °C. PL-CORE-Z4-2000-XXX Luminous flux vs. If PL-CORE-Z4-5000-XXX Luminous flux vs. If PL-CORE-Z4-2000-830 PL-CORE-Z4-2000-840 PL-CORE-Z4-2000-930 Luminous flux [lm] Luminous flux [lm] 4000 7000 3500 6000 3000 PL-CORE-Z4-5000-830 PL-CORE-Z4-5000-840 PL-CORE-Z4-5000-930 5000 2500 4000 2000 3000 1500 2000 1000 1000 500 0 100 200 300 400 500 600 700 If [mA] 0 200 400 600 800 1000 1200 1400 If [mA] PL-CORE-Z4-3000-XXX Luminous flux vs. If PL-CORE-Z4-3000-830 PL-CORE-Z4-3000-840 PL-CORE-Z4-3000-930 Luminous flux [lm] 7000 6000 5000 4000 3000 2000 1000 0 0 200 400 600 800 1000 If [mA] 8 PrevaLED ® Core Z4 LED modules | Electrical considerations 3 Electrical considerations 3.1 Forward voltage as a function of temperature PL-CORE-Z4-5000-XXX Uf vs. temperature at the tc point PL-CORE-Z4-2000-XXX Uf vs. temperature at the tc point PL-CORE-Z4-2000-830 PL-CORE-Z4-2000-840 PL-CORE-Z4-2000-930 Uf [V] PL-CORE-Z4-5000-830 PL-CORE-Z4-5000-840 PL-CORE-Z4-5000-930 Uf [V] 48 46 47.5 45.5 45 47 44.5 46.5 44 46 43.5 45.5 43 45 44.5 42.5 30 40 50 60 70 80 90 Temperature at the tc point [°C] PL-CORE-Z4-3000-XXX Uf vs. temperature at the tc point PL-CORE-Z4-3000-830 PL-CORE-Z4-3000-840 PL-CORE-Z4-3000-930 Uf [V] 47.5 47 46.5 42 30 40 50 60 70 80 90 Temperature at the tc point [°C] 3.2 LED driver/LED module combination PrevaLED® Core Z4 LED modules can either be used with non-dimmable or intelligent, dimmable OSRAM LED drivers (e.g. OTi DALI). To find the best possible LED driver/LED module combination, please refer to the Matchmaker tool, which is available at www.osram.com/oem-download in the section “LED light engines Spot- and Downlights”. With the Matchmaker tool, you can easily find out about possible system combinations and resulting electronic and photometric parameters. 46 45.5 45 44.5 44 30 40 50 60 70 80 90 Temperature at the tc point [°C] 9 PrevaLED ® Core Z4 LED modules | Electrical considerations 3.3 Wiring The input clamps used in the PrevaLED® Core Z4 can handle solid wires with a cross-section of 0.5–1.0 mm2 (AWG 21–17). Release Example: H05V-U 1x 0.5 mm 2 Wire preparation For wires with 1 mm2 (AWG 17): 5.5 mm For wires with 0.5–0.823 mm2 (AWG 21–18): 5.3 mm (±0.2 mm) Please note: — The connector is designed for three “poke-in” and release cycles. — The installation of LED modules has 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. Depending on the wire and/or cable type, other suitable preparations may also be necessary (e.g. cable end contacts). 1 Use a very slim screwdriver and push gently into the release hole 2 Push in the screwdriver below the release spring Insert and release Insert 3 Pull out the wire and afterwards the screwdriver Insert wire directly 10 PrevaLED ® Core Z4 LED modules | Electrical considerations 3.4 OTi DALI LED drivers If you use the PrevaLED® Core Z4 series in combination with the OSRAM OTi DALI LED driver series, you will get the best results and the full functionality of the LED module. 3.6 OTe LED drivers If you want 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 LEDset2 communication standard between the LED driver and the module. A thermal derating and a luminous flux calibration are included. Therefore, please connect all three terminals of the module to the LED driver. Connection detail Connection detail Select only 1 connection terminal OTe 35/220-240/700 CS OTi DALI 50/220-240/1A4 LT2 FAN 3.5 OT FIT LED drivers It is also possible to use the PrevaLED® Core Z4 series with a constant-current driver. The OT FIT series offers different available currents. To wire the module to the LED driver, please connect the terminals 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. Connection detail OT FIT 25/220-240/500 CS 11 PrevaLED ® Core Z4 LED modules | Electrical considerations 3.7 LEDset2 (LT2) LEDset helps you to meet important market requirements: — Future-proof solutions in terms of luminous flux — Long-life operation — Luminaire customization — Energy and cost saving In combination with OSRAM LED drivers, the LEDset interface offers full flexibility and a future-proof system with the following features and benefits: — Simplified wiring for easy setting of the LED driver current, suitable for the connected LED module — Versatile connectivity of several LED modules, either in parallel or in series (or a mix of both) — Thermal protection for LED modules LEDset2 (LEDset generation 2) is the enhanced interface between OPTOTRONIC ® LED drivers and LED modules (such as OSRAM PrevaLED®). It can be identified by the product name of the LED driver, including the letters “LT2” at its end – while LEDset (generation 1) ends with “LT” only. LEDset interface behavior has been changed in order to obtain the following advantages: — To add the parallel modules operation, especially for linear and area SSL systems, while optimizing the operating range with spot and downlight systems — To simplify assembly (only one additional wire instead of three as before) LEDset2 is a low-cost analog interface based on a threewire connection between the LED driver and one or more LED modules. Only one additional wire – besides the two LED current supply wires (LED+, LED-) – is used for transferring information from the LED module/s to the LED driver. This interface is designed to allow communication between the LED module and the LED driver, performing LED current setting and thermal protection functionality. The interface supports the following functionalities: — Absolute output current setting of the constant-current LED driver (LED module self-recognition) — Handling of parallel/serial LED module connection — Thermal protection of the LED module Typical applications of this interface are single or parallel or serial LED module connections, offering a wider choice of modular capabilities and low-cost thermal protection circuits. In case of multiple module connection, all connected modules must be identical (with the same current set and with matched forward voltages). The relationship Iout vs. Rset is defined by the following formula: Iout [A] = 5V Rset [Ω] x 1000 The table below shows the improvements of the LEDset2 compared to the previous version. What’s changed in LEDset2? Current setting method LEDset (generation 1) Rset resistor LEDset2 interface wiring (block diagram) LEDset2 LED driver LED module Rset resistor with new coding LED+ Current coding Relative Absolute (within the range (in % of the of 0.1 A to 5 A) maximum output current of the LED driver) Typical number of LED modules in the system 1 From 1 up to many (series and parallel combinations) Number of wires for LEDset 3 1 Multivendor No (provided by OSRAM only) Yes (being adopted by other vendors) LEDset Current setting (Rset connection) Thermal protection LED- 12 PrevaLED ® Core Z4 LED modules | Electrical considerations LEDset2 allows a stepless selection of the output current through the simple selection of the proper Rset resistor value and the connection of a potentiometer or a fixed standard resistor to the LEDset line. The table below shows the output current values in the entire valid LEDset range if the standard resistor series E24 is used. Output current values using standard E24 resistor values Rset E24 [Ω] Output current [mA] Rset E24 [Ω] Output current [mA] Rset E24 [Ω] Output current [mA] Rset E24 [Ω] Output current [mA] Rset E24 [Ω] Output current [mA] 51000 100 22000 227 9100 549 3900 1282 1600 3125 47000 106 20000 250 8200 610 3600 1389 1500 3333 43000 116 18000 278 7500 667 3300 1515 1300 3846 39000 128 16000 313 6800 735 3000 1667 1200 4167 36000 138 15000 333 6200 806 2700 1852 1100 4545 33000 151 13000 385 5600 893 2400 2083 1000 5000 30000 166 12000 417 5100 980 2200 2273 27000 185 11000 455 4700 1064 2000 2500 24000 208 10000 500 4300 1163 1800 2778 Two output ports (LED+ and LED-) are used for the connection of the LED string/s. LEDset2 is a one-wire interface and uses the LED- line as the reference ground. The interface is intended for the control of a single-channel, constantcurrent LED driver with a single or multiple LED string load. LED driver output terminal configuration and color code (view from above) LED driver output terminals LED+ LED- LEDset LED+ wire LED- wire LEDset wire LED(optional) More detailed information about the possibilities of LEDset2 interfaces can be found in the corresponding application guidelines of this interface. 3.8 Maximum allowed number of LED drivers per circuit breaker B16 B10 OTe 35/700 50 30 OT 35 LTCS 84 52 OT 45 LTCS 60 40 OT 45 DALI LTCS 47 18 OTe 25 CS 50 30 OTe 18 PC TBD TBD OTe 25 PC TBD TBD 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 OT FIT 50 TBD TBD 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 Z4 LED modules in electrostatic protected areas (EPAs). To protect a PrevaLED® Core Z4 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 Z4 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 Z4 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 Z4 LED modules is given below. 4.1 Thermal power values Max. allowable thermal resistance Rth [K/W]2) 4.2 TIM and other accessories When mounting a PrevaLED® Core Z4 LED module within a luminaire, it is mandatory 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 or phase-change material (PCM) because they perform better than thermal foil or pads. In order to balance possible unevenness, the material should be applied with a thickness between 0.15 and 0.30 mm (0.25 mm is recommended) and a maximum size of 25 x 25 mm. 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 roughness of the surface should be minimized and the planarity as well as the cleanness of the surface (free from burrs, chips or any other particles) should be optimized. Product Typ. thermal power [W]1) Max. thermal power [W] at nominal current1) PL-CORE-2000-827-Z4 11.9 14 2.4 PL-CORE-2000-830-Z4 10.7 12.5 2.8 PL-CORE-2000-835-Z4 9.4 11.1 3.3 PL-CORE-2000-840-Z4 8.6 10.3 3.7 PL-CORE-2000-930-Z4 13.8 15.6 2 PL-CORE-3000-827-Z4 17.4 20.5 1.5 PL-CORE-3000-830-Z4 16.2 18.9 1.7 PL-CORE-3000-835-Z4 14.7 17.4 1.9 PL-CORE-3000-840-Z4 13.9 16.4 2.1 PL-CORE-3000-930-Z4 21 24.4 1.6 PL-CORE-5000-830-Z4 27.3 27.3 1 Alfatec www.alfatec.de www.kerafol.de www.lairdtech.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 at www.ledlightforyou.com or at www.osram.com. Thermal interface materials PL-CORE-5000-835-Z4 24.5 24.5 1.1 Kerafol PL-CORE-5000-840-Z4 22.9 22.9 1.1 Laird PL-CORE-5000-930-Z4 35.2 35.2 1 Bergquist www.bergquistcompany.com Arctic Silver www.arcticsilver.com Wakefield www.wakefield.com 1) Value measured at the tc point at a reference temperature (tr) of 65 °C 2) Value measured on the back 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 has been integrated. 4.3 Cooling system and heat sink 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 LED driver 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 Rth = Estimate heat sink thermal resistance on LED module level tr - ta Pth tr measured at the tc point Shutdown 0 90 105 tc [°C] The behavior below 50 % of the system current depends on the nominal system current and the applied LED driver Select heat sink thermal resistance 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. 14 PrevaLED ® Core Z4 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 full contact with the heat sink. Please find two examples of how to cool a PrevaLED® Core Z4 LED module below. Example 1: LED module: PL-CORE-Z4-1100-827 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-Z4-5000-830 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 To enable a lifetime of 50 000 hours (L70B10), the reference temperature (tr) at the tc point must not exceed 65 °C. The maximum temperature reached at the tc point must not exceed 90 °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.fischerelektronik.de Meccal www.meccal.com Wakefield www.wakefield.com R-Theta www.r-theta.com Cool Innovations www.coolinnovations.com MechaTronix Kaohsiung Co., Ltd www.mechatronix-asia.com 4.4 tc point location and temperature measurement The tc point is the location where 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 light-emitting surface (see following image). 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 Z4 LED modules | Thermal considerations To measure the temperature and to ensure a good thermal coupling between the LED module and the heat sink, you should 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 TIM, you should 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 Z4 LED modules | Lifetime and thermal behavior 5 Lifetime and thermal behavior 5.1 Luminous fl ux as a function of temperature The following diagram shows the behavior of the luminous flux output over the temperature at the tc point for PrevaLED® Core Z4. PL-CORE-Z4-2000-XXX Luminous flux vs. temperature at the tc point PL-CORE-Z4-5000-XXX Luminous flux vs. temperature at the tc point PL-CORE-Z4-2000-830 PL-CORE-Z4-2000-840 PL-CORE-Z4-2000-930 Luminous flux [lm] 2400 PL-CORE-Z4-5000-830 PL-CORE-Z4-5000-840 PL-CORE-Z4-5000-930 Luminous flux [lm] 5500 2200 5000 2000 1800 4500 1600 4000 1400 3500 1200 1000 35 45 55 65 75 85 Temperature at the tc point [°C] PL-CORE-Z4-3000-XXX Luminous flux vs. temperature at the tc point PL-CORE-Z4-3000-830 PL-CORE-Z4-3000-840 PL-CORE-Z4-3000-930 Luminous flux [lm] 4000 3500 3000 20 45 55 65 75 85 Temperature at the tc point [°C] 5.2 Lifetime OSRAM PrevaLED ® Core Z4 modules have a lifetime of 50 000 hours (L70B10) at a tp temperature (performance temperature) of 65 °C. This means that after 50 000 hours, a minimum of 90 % of the used modules will have at least 70 % of the initial luminous flux. If you operate the module at a lower temperature, the lifetime of the module is going to rise significantly. Note: Higher tc temperatures lead to a shorter lifetime of the PrevaLED® Core Z4 LED module. Moreover, the failure rate will also increase. 3100 2500 2000 1500 1000 35 45 55 65 75 85 Temperature at the tc point [°C] 17 PrevaLED ® Core Z4 LED modules | Mechanical considerations 6 Mechanical considerations The following schematic drawing provides further details on the dimensions of PrevaLED® Core Z4 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 Z4 LED module The housing of a PrevaLED® Core Z4 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. 6.2 3D drawing 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 rating of the luminaire housing. Please consider the luminaire standard IEC 60598-1 as well as the different requirements. 6.4 Mounting To fix a PrevaLED® Core Z4 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 using pre-tapped holes is 0.4 to 0.6 Nm. 18 PrevaLED ® Core Z4 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 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. 19 05/16 OSRAM LLS SSL-OEM-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