www.osram.com/prevaled-core 05/2016 Technical application guide PrevaLED® Core Z5 LED modules Light is OSRAM PrevaLED ® Core Z5 LED modules | Contents Contents 1 Introduction 03 4 Thermal considerations 1.1 System overview 03 4.1 Thermal power values 14 14 1.2 Nomenclature 03 4.2 TIM and other accessories 15 4.3 Cooling system and heat sink 15 2 Optical considerations 04 4.4 tc point location and temperature measurement 16 2.1 Light distribution 04 4.5 Thermocouple 16 2.2 Refl ector design 04 2.3 Photobiological safety 04 5 Lifetime and thermal behavior 17 2.4 Theoretical considerations for possible refl ectors 05 5.1 Luminous fl ux as a function of temperature 17 2.5 Refl ector mounting 06 5.2 Lifetime 17 2.6 Color temperature 06 2.7 Color rendering 07 6 Mechanical considerations 18 2.8 Spectral distribution 07 6.1 Outline drawing 18 2.9 Luminous flux behavior 08 6.2 3D drawing 18 3 Electrical considerations 09 3.1 Forward voltage as a function of temperature 09 3.2 LED driver/LED module combination 09 3.3 Wiring 10 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 6.3 Mechanical protection of the PrevaLED ® Core Z5 LED module 18 6.4 Mounting 18 7 Norms and standards 19 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 Z5 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 dealing with the improving performance of LEDs. Nevertheless, LED technology also provides an unknown number of possibilities, opening up unprecedented levels of performance. PrevaLED® Core LED modules, which are compatible with Zhaga Book 3 standards, offer one of the best and easiest ways to outfit luminaires with LED technology. Focusing on the continuous improvement of performance and costs, OSRAM has introduced its new generation of Zhaga spotlight LED modules: PrevaLED® Core Z5. 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 upgrade from Z4 thanks to identical housing — Same form factor and mechanical/optical interfaces as PrevaLED® Core Z3 and Z4 — Compatible with off-the-shelf Zhaga Book 3 accessories — High driver flexibility allows cost-effective and intelligent systems — 5-year guarantee (for current terms and conditions of the guarantee, please visit 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 — Only one reflector size for 2 000, 3 000 and 5 000 lm with 3 x LES 19 — Lifetime (L80B50) at tc = 65 °C: 50 000 hours (preliminary) — Improved poke-in connector for stranded and solid wires — Very good light quality — Very high efficiencies for smaller heat sinks and easier thermal management — Typical module efficacy: up to 146 lm/W — tc max: 90 °C — Thermal protection — Thermal derating with OTi — Thermal shutdown 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 LED module Z5: Generation 5 3000: 3000 lm 830: Color rendering index (CRI) + color temperature (CCT) = > 80 + 3000 K PL-CORE-Z5-3000-830 3 PrevaLED ® Core Z5 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 Z5 LED modules create a beam angle of 114° FWHM (full width at half maximum). C 0° 2.2 Refl ector design High luminances 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 lightemitting surfaces and a high luminous flux – as realized in the PrevaLED® Core Z5 – are required, because in such combinations, the light can be collimated particularly well with reflectors. The PrevaLED® Core Z5 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 Z5 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. 2.3 Photobiological safety According to IEC/EN 62471, all PrevaLED® Core Z5 LED modules are within risk group (RG) 1 at their nominal operating conditions. Note: For the PL-CORE Z5-5000-840 module, the photobiological safety class RG 1 might not be achieved when using a significantly higher current than the nominal module current. This may result in risk group classifications up to RG 2. 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 Z5 LED modules | Optical considerations 2.4 Theoretical considerations for possible refl ectors PrevaLED ® Core Z5, 2000 lm, LES 19, OCA C* PrevaLED ® Core Z5, 5000 lm, LES 19, OCA C* Reflector output diameter [mm] Reflector 80 height [mm] 100 100 Reflector output diameter [mm] Reflector 80 height [mm] 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 100 15°; 42500 cd; 12°; 55000 cd; 11°; 70000 cd; 88 %; 10500 lx; 89 %; 14000 lx; 90 %; 17750 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 80 15°; 40000 cd; 12°; 42500 cd; 10°; 62500 cd; 89 %; 9750 lx; 91 %;13000 lx; 92 %; 16000 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 60 19°; 25000 cd; 15°; 35000 cd; 12°; 45000 cd; 10°; 52500 cd; 90 %; 6500 lx; 91 %; 8750 lx; 93 %; 11000 lx; 94 %; 13000 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 40 19°; 20000 cd; 14°; 27500 cd; 11°; 30000 cd; 8°; 32500 cd; 93 %; 5250 lx; 95 %; 6500 lx; 96 %; 7750 lx; 97 %; 8250 lx; 4.2 cd/lm 5.3 cd/lm 6.1 cd/lm 6.5 cd/lm 120 140 120 140 * Parabolic refl ector, 85 % specular refl ectance, lux in 2 m distance PrevaLED ® Core Z5, 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 120 140 PrevaLED ® Core Z5, 4500 lm, LES 19, OCA C* 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 a distance of 2 m to the reflector. The PrevaLED® Core Z5 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: Reflector output diameter [mm] 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 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 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 40 120 140 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 6.1 cd/lm 5.3 cd/lm 6.5 cd/lm 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 Z5 LED modules | Optical considerations Jordan Luxar GmbH & Co. KG Schneiderstrasse 76 40764 Langenfeld, Germany +49 2173 279 0 [email protected] www.jordan-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 Jin Ou Road, Jiang Hai District Jiang Men 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 it is recommended to stay within the OCA values of the corresponding category (see product datasheet). Additionally, a bayonet base option is provided, with the help of which the reflector can be attached directly to the PrevaLED® Core Z5. PrevaLED® Core Z5 3D files including the bayonet base for design-in are available at www.osram.com/prevaled-core. 2.6 Color temperature The PrevaLED® Core Z5 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 0.4579 3000 K 0.4339 3500 K 0.4077 4000 K 0.3823 Cy 0.4092 0.4020 0.3908 0.3790 Values measured at tp = 65 °C Within each available color temperature, the PrevaLED ® Core Z5 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 2.5 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), 0.45 3000 0.425 3500 4000 0.40 4500 0.375 0.35 5000 0.35 0.375 0.40 0.425 0.45 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 Z5 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 2.7 Color rendering PrevaLED® Core Z5 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 90 97 80 80 88 83 58 5 78 79 74 82 99 82 CCT = 3000 K 81 90 97 82 82 88 84 61 10 78 81 74 83 99 83 CCT = 3500 K 83 90 96 84 83 87 86 65 14 77 83 73 84 98 84 CCT = 4000 K 82 90 95 84 83 87 86 66 14 76 83 72 84 97 84 CCT = 3000 K 96 96 93 95 95 94 95 91 77 89 96 85 96 95 91 2.8 Spectral distribution The typical spectral distribution of the PrevaLED® Core Z5 LED modules is shown in the following diagram. 827 Relative luminous intensity 830 835 840 930 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 Z5 LED modules | Optical considerations 2.9 Luminous fl ux behavior The following diagrams show the luminous flux as a function of the operating current for PrevaLED® Core Z5 LED 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-Z5-2000-XXX Luminous flux as a function of forward current (I f ) PL-CORE-Z5-2000-830 PL-CORE-Z5-2000-840 PL-CORE-Z5-2000-930 Luminous flux [lm] PL-CORE-Z5-5000-XXX Luminous flux as a function of forward current (I f ) Luminous flux [lm] 4000 7000 3500 6000 3000 PL-CORE-Z5-5000-830 PL-CORE-Z5-5000-840 PL-CORE-Z5-5000-930 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-Z5-3000-XXX Luminous flux as a function of forward current (I f ) PL-CORE-Z5-3000-830 PL-CORE-Z5-3000-840 PL-CORE-Z5-3000-930 Luminous flux [lm] 7000 6000 5000 4000 3000 2000 1000 0 0 200 400 600 800 1000 If [mA] 8 PrevaLED ® Core Z5 LED modules | Electrical considerations 3 Electrical considerations 3.1 Forward voltage as a function of temperature PL-CORE-Z5-2000-XXX Forward voltage (U f ) as a function of temperature at the tc point PL-CORE-Z5-5000-XXX Forward voltage (U f ) as a function of temperature at the tc point PL-CORE-Z5-2000-830 PL-CORE-Z5-2000-840 PL-CORE-Z5-2000-930 Uf [V] PL-CORE-Z5-5000-830 PL-CORE-Z5-5000-840 PL-CORE-Z5-5000-930 Uf [V] 48 45.5 47.5 45 47 46.5 44.5 46 44 45.5 43.5 45 43 44.5 42.5 44 43.5 30 40 50 60 70 80 90 Temperature at the tc point [°C] PL-CORE-Z5-3000-XXX Forward voltage (U f ) as a function of temperature at the tc point PL-CORE-Z5-3000-830 PL-CORE-Z5-3000-840 PL-CORE-Z5-3000-930 Uf [V] 47.5 47 42 30 40 50 60 70 80 90 Temperature at the tc point [°C] 3.2 LED driver/LED module combination PrevaLED® Core Z5 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 OSRAM Matchmaker tool, which is available at www.osram.com/ oem-download in the section “LED light engines Spot- and Downlights”. With the OSRAM Matchmaker tool, you can easily find out about possible system combinations and resulting electronic and photometric parameters. 46.5 46 45.5 45 44.5 44 43.5 43 30 40 50 60 70 80 90 Temperature at the tc point [°C] 9 PrevaLED ® Core Z5 LED modules | Electrical considerations 3.3 Wiring The input clamps used in the PrevaLED® Core Z5 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 suitable 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 Z5 LED modules | Electrical considerations 3.4 OTi DALI LED drivers If you use the PrevaLED® Core Z5 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 LED 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 LED 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 one 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 Z5 series with a constant-current LED driver. The OT FIT series offers different available currents. To wire the LED module to the LED driver, please connect the terminals LED+ and LED- to the LED 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 Z5 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 LED 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 LED 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 Z5 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) 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 More detailed information about the possibilities of LEDset2 interfaces can be found in the corresponding application guidelines of this interface. 3.9 ESD It is not necessary to handle PrevaLED® Core Z5 LED modules in electrostatic protected areas (EPAs). To protect a PrevaLED® Core Z5 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 Z5 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 Z5 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 Z5 LED modules is given below. Thermal fuse characteristic Current [% of minimal LED driver current] 100 4.1 Thermal power values Product Typ. thermal power [W]1) Max. thermal power [W] at nominal current1) Max. allowable thermal resistance Rth [K/W]2) PL-CORE-Z5-2000-827 10.2 12.4 3.3 PL-CORE-Z5-2000-830 9.1 11.3 3.7 PL-CORE-Z5-2000-835 8.1 10.1 4.1 PL-CORE-Z5-2000-840 7.5 9.5 4.4 PL-CORE-Z5-2000-930 13.7 16.6 2.4 PL-CORE-Z5-3000-827 15.4 18.8 2 PL-CORE-Z5-3000-830 13.9 17.1 2.3 PL-CORE-Z5-3000-835 12.4 15.4 2.6 PL-CORE-Z5-3000-840 11.3 14.3 2.7 PL-CORE-Z5-3000-930 19.9 24.1 1.7 PL-CORE-Z5-5000-827 30 36 0.8 PL-CORE-Z5-5000-830 27.4 33.2 0.9 PL-CORE-Z5-5000-835 24.4 29.9 1.1 PL-CORE-Z5-5000-840 22.3 27.7 1.1 PL-CORE-Z5-4500-930 34.1 40.9 0.7 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 0 102 tc [°C] Thermal derating with LEDset2 Current [% of minimal LED driver current] 100 50 0 tc max To achieve the best possible lifetime of the LED module and to save it from damage by overheating, a thermal protection feature has been integrated. 110 116 105 tc [°C] The behavior below 50 % of the system current depends on the nominal system current and the applied LED driver. The thermal protection of the PrevaLED® Core Z5 LED module is divided into two parts: The first part is an onboard reversible thermal fuse that prevents the module from damage by overheating. The characteristic of the thermal fuse is shown at the top right. Note: If the thermal fuse is triggered, the module is shut off completely. The thermal fuse can be reset by disconnecting the mains and repowering the LED module. The second part of the thermal protection is a thermal derating function that works in combination with LED drivers with LEDset2 funcionality. It protects the LED module from overheating by communicating with the LED driver (the LEDset port of the LED module must be connected). The system reduces the current of the LED module if critical temperatures are reached at the tc point. This results in the best possible performance and lifetime of the LED module. The characteristic of the thermal derating function is shown at the bottom right. 14 PrevaLED ® Core Z5 LED modules | Thermal considerations 4.2 TIM and other accessories When mounting a PrevaLED® Core Z5 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. 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 carried out through the following necessary steps. Defi ne boundary conditions Total power dissipation of the LED module, max. ambient temperature ta, max. reference temperature tr according to lifetime requirements Rth = Estimate heat sink thermal resistance on LED module level 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. Select heat sink thermal resistance tr - ta Pth tr measured at the tc point Use the estimated Rth as a target for a possible heat sink profile and examine the performance curve in the heat sink manufacturer’s catalog. Thermal interface materials Alfatec www.alfatec.de Kerafol www.kerafol.de Laird www.lairdtech.com Bergquist www.bergquistcompany.com Arctic Silver www.arcticsilver.com Wakefield www.wakefield.com Please note: A thermal design must always be confirmed by performing a thermal measurement in steady-state condition. The whole area of the metal-core PCB must be in full contact with the heat sink. The list below is a selection of suppliers of different cooling solutions. Cooling systems Nuventix www.nuventix.com Sunon www.sunoneurope.com Cooliance www.cooliance.eu AVC www.avc-europa.de SEPA www.sepa-europe.com Fischer Elektronik www.fischerelektronik.de Wakefield www.wakefield.com MechaTronix www.mechatronix-asia.com 15 PrevaLED ® Core Z5 LED modules | Thermal considerations 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). 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 it. 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). Location of the tc point tc point Mounting of a thermocouple through a hole in the heat sink To enable a lifetime of 50 000 hours (L80B50), 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: 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 to the tc point inside the groove. Miniature connector “K” Thermo wire NiCr–Ni K-type thermocouple with miniature connector Different thermocouples Illustration Description Temperature range [°C] PVC-insulated thermocouple -10 … +105 PFA-insulated thermocouple -75 … +260 Notes: Please keep in mind that you need a direct contact between the thermocouple and the PCB. Sprung thermocouple -75 … +260 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 by means of a groove 16 PrevaLED ® Core Z5 LED modules | Lifetime and thermal behavior 5 Lifetime and thermal behavior 5.1 Luminous fl ux as a function of temperature The following diagrams show the behavior of the luminous flux output as a function of the temperature at the tc point for PrevaLED® Core Z5. PL-CORE-Z5-2000-XXX Luminous flux as a function of temperature at the tc point PL-CORE-Z5-5000-XXX Luminous flux as a function of temperature at the tc point PL-CORE-Z5-2000-830 PL-CORE-Z5-2000-840 PL-CORE-Z5-2000-930 Luminous flux [lm] 2500 PL-CORE-Z5-5000-830 PL-CORE-Z5-5000-840 PL-CORE-Z5-5000-930 Luminous flux [lm] 7500 2400 6500 2300 2200 5500 2000 2000 4500 1900 3500 1800 1700 2500 1600 1500 35 45 55 65 75 85 Temperature at the tc point [°C] PL-CORE-Z5-3000-XXX Luminous flux as a function of temperature at the tc point PL-CORE-Z5-3000-830 PL-CORE-Z5-3000-840 PL-CORE-Z5-3000-930 Luminous flux [lm] 4000 1500 35 45 55 65 75 85 Temperature at the tc point [°C] 5.2 Lifetime OSRAM PrevaLED ® Core Z5 LED modules have a lifetime of 50 000 hours (L80B50) at a tp temperature (performance temperature) of 65 °C. This means that after 50 000 hours, a minimum of 50 % of the utilized LED modules will have at least 80 % of the initial luminous flux. If you operate the module at a lower temperature, the lifetime of the module is going to rise significantly. For more details, please refer to the product datasheet. 3500 Note: Higher tc temperatures lead to a shorter lifetime of the PrevaLED® Core Z5 LED module. Moreover, the failure rate will also increase. 3000 2500 2000 1500 35 45 55 65 75 85 Temperature at the tc point [°C] 17 PrevaLED ® Core Z5 LED modules | Mechanical considerations 6 Mechanical considerations The following schematic drawing provides further details on the dimensions of PrevaLED® Core Z5 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 Z5 LED module The housing of a PrevaLED® Core Z5 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 (CoB) 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 (IP) 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 Z5 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. Move me! Movable 3D PrevaLED ® Core Z5 LED module (works with Adobe Acrobat 7 or higher) 18 PrevaLED ® Core Z5 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, VDE ENEC 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