www.osram.com/prevaled 12/2013 Technical application guide PrevaLED® Core AC light engines Light is OSRAM PrevaLED ® Core AC light engines | Contents Contents 1 Introduction 03 6 Lifetime and thermal behavior 1.1 System overview 03 6.1 Flux as a function of temperature 12 12 1.2 Ordering information 04 6.2 Lifetime as a function of temperature 12 1.3 Nomenclature 04 7 Mechanical considerations 14 2 Optical considerations 05 7.1 Outline drawing 14 2.1 Modulation of light 05 7.2 3D drawing 14 2.2 Light distribution 05 7.3 Mechanical protection of the light engine 14 2.3 Refl ector design 05 7.4 Mounting 14 2.4 Color temperature 06 15 2.5 Color rendering 06 8 Assembly in a reference luminaire 2.6 Spectral distribution 06 8.1 Preparation 15 8.2 Attachment of the thermocouple 15 3 Ingress protection 07 4 Electrical considerations 07 4.1 Wiring information 07 4.2 Insulation requirements 08 4.3 Inrush current and system installation 08 4.4 Electrostatic discharge (ESD) 08 4.5 Controllability 08 4.6 Power as a function of voltage 08 5 Thermal considerations 09 5.1 Thermal power over voltage 09 5.2 Thermal shutdown 09 5.3 Thermal interface material and other accessories 09 5.4 Cooling systems and heat sinks 09 5.5 tc point location and temperature measurement 10 5.5.1 Thermocouple 10 5.5.2 Thermal sticker 11 5.5.3 Thermal dummy 11 8.3 Mounting of the light engine 15 8.4 Wiring 16 8.5 Temperature measurement 16 9 Norms and standards 17 10 More information 17 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 or contact your sales partner for an updated copy of this guide. 2 PrevaLED ® Core AC light engines | 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 performance of LEDs. Nevertheless, LED technology also provides an unknown wealth of possibilities, opening up unprecedented levels of performance in addition to improved ways of integration. Continuing down this path of integration and innovation, OSRAM presents a revolutionary solution: PrevaLED® Core AC light engines have an integrated driver and can therefore be connected directly to line voltage. OSRAM’s PrevaLED® family of LED light engines addresses the challenges of LED-based lighting while at the same time providing the user with high levels of flexibility. Enabled by the application of LED technology, PrevaLED® aims to push the envelope of what is possible in terms of performance and simplicity. The PrevaLED® Core AC series of light engines is ideally suited for use in reflector-based, rotation-symmetric luminaires (such as spotlights and downlights) in shop, hospitality, decorative or office applications. Benefits — PrevaLED® Core AC offers an integrated system solution with the LED source and the electronic control circuitry together on the same board, packaged into a uniquely compact light engine that can be directly connected to 230 VAC. — Omitting the driver allows for smaller, simpler, slimmer and – last but not least – more cost-efficient luminaire designs. — Logistics and manufacturing will be simplified drastically thanks to the lack of the driver and cables, and also the reduced housing and fixation materials. — The PrevaLED® Core AC family is easy to integrate since the light engines are compatible with “Zhaga book 3” heat sinks and reflectors. Currently, there is no standard available for AC spotlight engines. The LES sizes, diameters and positioning of mounting holes, however, meet the Zhaga standards, similar to the PrevaLED® Core Z2 and Z3 product ranges. — The engines are outfitted with a Wago connector which allows for an easy “poke-in” of stranded and solid wires. — The protective cover glass ensures safety for installers and avoids damaging the COB. The reversible thermal shutdown protects the light engine from breaking down when overheated. — The entire PrevaLED® Core AC family is certified according to CE and VDE/ENEC standards. — COB technology ensures great homogeneity where no additional diffuser is required. Product features — PrevaLED® Core AC is available in 800 and 2 000 lm, in three color temperatures (2 700, 3 000 and 4 000 K) and CRI 83. — The LED light engine operates directly at a line voltage of 230 VAC, 50–60 Hz. — System efficacy (including driver losses) of up to 82 lm/W with a power factor of > 0.9. — Lifetime is 50 000 hours (L70B30) at tr of 65 °C, with tc max. = 80 °C. Enable 3D View PrevaLED ® Core AC 800 lm PrevaLED ® Core AC 2 000 lm Move me! Movable 3D PrevaLED ® Core AC light engine (works with Adobe Acrobat 7 or higher) 3 PrevaLED ® Core AC light engines | Introduction 1.2 Ordering information PrevaLED ® Core AC Product data 800 lm, 2700 K 800 lm, 3000 K 800 lm, 4000 K 2000 lm, 2700 K 2000 lm, 3000 K 2000 lm, 4000 K Product reference PL-CORE AC800-827-G1 PL-CORE AC800-830-G1 PL-CORE AC800-840-G1 PL-CORE AC2000-827-G1 PL-CORE AC2000-830-G1 PL-CORE AC2000-840-G1 Product number EAN: 4052899050648 EAN: 4052899050662 EAN: 4052899050686 EAN: 4052899050709 EAN: 4052899050723 EAN: 4052899050747 1.3 Nomenclature PL-CORE: PrevaLED® Core family AC: AC-capable (220–240 V, 50/60 Hz) 2000: 2000 lm 830: CRI + CCT = > 80 + 3000 K G1: Generation 1 PL-CORE-AC-2000-830-G1 4 PrevaLED ® Core AC light engines | Optical considerations 2 Optical considerations The PrevaLED® Core AC can be applied in spotlights and downlights. 2.1 Modulation of light Due to the limited geometry of the PrevaLED® Core AC, there is no capacitance placed in the light engine. The result is a light modulation which has a frequency of 100 Hz. The light output goes down to 0 %. Warning: This light modulation might influence the perception of moving or rotating parts. Do not use the light engine in critical applications such as turnery. The light engine might also cause interference with monochrome LCDs (twisted nematic displays). 2.2 Light distribution The light distribution of the light engine is shown in the graph below. The PrevaLED ® Core AC creates a beam angle of 110° FWHM (full width at half maximum). Light distribution curve The LES dimensions of PrevaLED® Core AC light engines meet Zhaga book 3 standards. Therefore, the PrevaLED ® Core AC can be used in combination with available offthe-shelf secondary optics. For optics support, you can find suppliers via OSRAM’s LED Light for You network: www.ledlightforyou.com. Moreover, standard components and support for reflector design are available, e.g., from the following suppliers: Jordan Reflektoren 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 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 The light-emitting surface (LES) of the light engine is covered by a clear glass to protect the user from mains voltage. Note: Please ensure that the light engine is only used with an undamaged cover glass. 2.3 Reflector design The PrevaLED® Core AC can also be used with secondary optics. The diameter of the light-emitting surface and the optical contact area (OCA) are shown in the table below. LES and OCA Light-emitting Real LES Optical consurface (LES) diameter [mm] tact area (OCA) category [mm] category [mm] 800 lm 13.5 13 B/19 2000 lm 19 19 C/23 Nata Lighting Co., Ltd. 380 Jinou Road, Gaoxin Zone Jiangmen City, Guangdong, China +86 750 377 0000 [email protected] www.nata.cn 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. Ray file data are available upon request through your sales partner. Available ray file formats are ASAP, SPEOS, LightTools and Photopia (all binary). 5 PrevaLED ® Core AC light engines | Optical considerations Color coordinates General CRI Leaf green Blue, saturated Blue, saturated Within each available color temperature, the PrevaLED ® Core AC 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. Green, saturated 0.3797 Yellow, saturated 0.4030 Red, saturated 0.4101 Lilac violet 0.3818 Cy Aster violet 4000 K 0.4338 Azure 3000 K 0.4578 Turquois 2700 K Cx Light green R a values (note: All values measured at t c = 65 °C) Yellowish green Initial color values of the CCT Mustard yellow 2.5 Color rendering PrevaLED® Core AC light engines provide a color rendering index (CRI) of 83. The table below shows the individual Ra values from R1 to R14 for the available color temperatures. Dusky pink 2.4 Color temperature The PrevaLED® Core AC series is currently available in 2 700 K, 3 000 K and 4 000 K. The color coordinates within the CIE 1931 color space are given in the table below. R1 R2 R3 R4 R5 R6 R7 R8 R9 R10 R11 R12 R13 R14 R a CCT = 80 90 97 81 81 89 81 55 1 2700 K 78 82 74 83 99 82 CCT = 81 89 97 83 81 87 84 59 4 3000 K 75 83 69 83 98 83 CCT = 79 85 90 82 79 80 86 64 3 4000 K 65 80 57 80 94 81 MacAdam ellipses y 3000 K 2500 K 2.6 Spectral distribution The typical spectral distribution of PrevaLED® Core AC light engines is shown in the following diagram. 0.45 4000 K 2000 K 0.40 Wavelength spectrum 6000 K 0.35 2700 K Relative spectral emission 3000 K 4000 K 1.0 0.8 0.35 0.40 0.45 0.50 x 0.6 0.4 0.2 0 380 430 480 530 580 630 680 730 780 Wavelength [nm] Note: Do not stare directly into the beam or view directly with optical instruments (risk group I according to IEC 62471). 6 PrevaLED ® Core AC light engines | Ingress protection | Electrical considerations 3 Ingress protection The PrevaLED® Core AC has an ingress protection rating of IP20. Please ensure that the housing of your luminaire provides the IP protection required for your application. For further information, please have a look at the technical application guide “IP codes in accordance with IEC 60529”, which can be downloaded from www.osram.com. 4 Electrical considerations 4.1 Wiring information The PrevaLED® Core AC can be directly connected to mains voltage (220–240 V, 50/60 Hz). The used input clamps can handle solid wire or flexible wire with a cross-section of 0.2 to 0.75 mm2 (AWG24–18). The use of solid wire is recommended. Wire preparation Notes: — The connector is designed for three poke-in and release cycles. — Due to the fact that you are handling mains voltage, you must not hot-plug the light engine. — The installation of LED light engines needs to be carried out in compliance with all applicable electrical and safety standards. Only qualified personnel should be allowed to perform installations. 6–7 mm (0.24–0.28 inch) Please insert the wires in 0° orientation to the PCB. Solid wire: Plug directly. Flexible wire: 1. Lightly press the push button of the connection clamp. 2. Insert the flexible wire. To press/release the clamps, please use an operating tool (Wago type: 233-335), a ballpoint pen or a small screwdriver. 7 PrevaLED ® Core AC light engines | Electrical considerations 4.2 Insulation requirements The PrevaLED® Core AC can be used in class I luminaires without further action. The creepage distance and clearance are fulfilled. The protective cover glass is tested according to a spring hammer test and provides class I insulation. It prevents the user from touching the light-emitting surface which is connected directly to 220–240 VAC. The PrevaLED® Core AC has basic insulation. In class II luminaires, additional care needs to be taken in the area of the input connector, the metal core PCB and the metal bushings. Between connection wires with basic insulation and touchable metal parts or the heat sink, a second insulation layer is required. The light engine must be mounted in an electrically insulated way. You can, for example, use an electrically insulating thermal foil which must overlap the PrevaLED® Core AC light engine by at least 2.5 mm in all directions. To mount the light engine, you must use nonconductive screws or attach the light engine by a clamping mechanism. Please note that force must be applied to the metal bushings only. 4.5 Controllability Due to the integrated drive electronics, a good compatibility with all available phase-cut dimmers cannot be ensured. 4.6 Power as a function of voltage The nominal voltage of the light engine is 230 V. The operation range is 220–240 V. For voltage variations, the light engine is tested according to IEC/EN 61000-3-3. Please note that the power of the light engine changes over the voltage range. Please have a look at the diagrams below for the power as a function of voltage. PrevaLED ® Core AC 800 lm Flux [lm] Power Flux Thermal power Power [W] 120 % 140 % 100 % 120 % 80 % 100 % 4.3 Inrush current and system installation Due to its electronic construction, the PrevaLED® Core AC has a minimum inrush current. In system installations, the number of light engines which can be attached to one circuit is limited by the voltage drop regulations and the used diameter of the connecting wire. 60 % 80 % 40 % 60 % 20 % 40 % 0% 20% 4.4 Electrostatic discharge (ESD) It is not necessary to handle the PrevaLED® Core AC in electrostatic protected areas (EPAs). 160 170 180 To protect the light engine from electrostatic damage, the module must not be opened. The light engine fulfills the requirement of the immunity standard IEC/EN 61547. PrevaLED ® Core AC 2000 lm 190 200 210 220 230 240 250 260 270 Voltage [V] Flux [lm] Power Flux Thermal power Power [W] 120 % 140 % 100 % 120 % 80 % 100 % 60 % 80 % 40 % 60 % 20 % 40 % 0% 20% 160 170 180 190 200 210 220 230 240 250 260 270 Voltage [V] Note: According to EN 60598-1, luminaires have to be tested with 1.06 times the rated voltage or the maximum of the rated voltage range. This will also have implications on the thermal power of the light engine. 8 PrevaLED ® Core AC light engines | Thermal considerations 5 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 the PrevaLED® Core AC, only a partial amount of the introduced electrical power has to be dissipated through the back of the light engine. The thermal power that has to be dissipated for PrevaLED® Core AC is given below. Thermal power to be dissipated * The list below is a selection of suppliers of thermal interface materials. Additional partners for thermal management support can also be found via OSRAM’s LED Light for You network: www.ledlightforyou.com. Thermal interface materials Alfatec www.alfatec.de Kerafol www.kerafol.de Laird www.lairdtech.com Bergquist www.bergquistcompany.com Typical Maximum Arctic Silver www.arcticsilver.com PL-CORE AC-800-827-G1 10.9 W 13.1 W Wakefi eld www.wakefi eld.com PL-CORE AC-800-830-G1 10.2 W 12.8 W PL-CORE AC-800-840-G1 10.0 W 11.6 W PL-CORE AC-2000-827-G1 21.7 W 22.6 W PL-CORE AC-2000-830-G1 20.7 W 22.0 W PL-CORE AC-2000-840-G1 20.2 W 20.2 W 5.4 Cooling systems and heat sinks For the selection of a suitable heat sink, several points regarding thermal resistance have to be considered. * Values measured at the tc point, at a reference temperature (tr) of 65 °C The selection is usually done through the following necessary steps: 5.1 Thermal power over voltage Please note that the thermal power of the module is related to the line voltage. Please refer to the diagrams in chapter 4.6. 5.2 Thermal shutdown To ensure the best performance and a long lifetime of all components, the PrevaLED® Core AC features integrated electronics which switch off the light engine when the temperature at the tc point reaches the critical value of 83 °C (±5 °C). The light engine switches back on as soon as the temperature has cooled down below 60 °C (±5 °C). 5.3 Thermal interface material and other accessories When mounting a PrevaLED® Core AC within a luminaire, it is highly recommended to use thermal interface material (TIM) between the back of the light engine 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 light engine and the contact surfaces of the luminaire housing is achieved. For this purpose, the planarity and smoothness of the surface should be optimized. Define boundary conditions Total power dissipation of the light engine, max. ambient temperature ta, max. reference temperature tr according to lifetime requirements Rth = Estimate heat sink thermal resistance on light engine level 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. Selection of a heat sink Note: A thermal design must always be confirmed by performing a thermal measurement in steady-state condition. It is recommended that the whole area of the PCB of a PrevaLED® Core AC light engine is in contact with the solid material of the heat sink. Note: The positioning of the mounting holes is compatible with Zhaga book 3. Therefore, off-the-shelf heat sinks developed for these modules are also suitable for PrevaLED® Core AC light engines. 9 PrevaLED ® Core AC light engines | Thermal considerations Two examples of how to cool a PrevaLED® Core AC: Location of the tc point Example 1: Light engine: PL-CORE AC-800-830-G1 Heat sink: Nuventix HP30S-CALBL-001 A01 TIM: Kerafoil 86/82 tambient: 22 °C Temperature at the tc point: 65 °C Example 2: Light engine: PL-CORE AC-2000-830-G1 Heat sink: AVC ST05300001 TIM: Kerafoil 86/82 tambient: 23 °C Temperature at the tc point: 48 °C Please note that the solutions shown above 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: tc point Note: tc according to IEC 62031 stands for case temperature, which is the highest permissible temperature measured at the tc point. The tc point is the location where the tc is measured (in the center of the back of the light engine). tp (performance temperature) = tr (reference temperature) is the reference temperature at which the datasheet values are applicable. A correct temperature measurement can, for example, be performed with a thermocouple or a thermal sticker. 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 5.5 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 light engine performance. The tc point is located on the back of the light engine, in the center of the PCB (see image above). To ensure a lifetime of 50 000 hours (L70B30), the reference temperature (tr) at the tc point must not exceed 65 °C. The maximum temperature reached at the tc point must not exceed 80 °C. 5.5.1 Thermocouple Use a thermocouple that can be glued onto the light engine. Make sure that the thermocouple is fixed with direct contact to the tc point. Examples of suitable thermocouples: K-type thermocouple with miniature connector Different thermocouples Illustration Description Temperature range [°C] PVC-insulated -10 … +105 thermo couple PFA-insulated -75 … +260 thermo couple Sprung -75 … +260 thermo couple 10 PrevaLED ® Core AC light engines | Thermal considerations To measure the temperature and to ensure a good thermal coupling between the light engine and the heat sink, 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). 5.5.2 Thermal sticker You can also use thermal stickers to indicate the reference temperature (tr) at the tc point of the light engine. Attach the sticker to the light engine at the tc point (see image below). Mounting of a thermocouple through a hole in the heat sink Thermal sticker before temperature measurement 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. Note: If you use a TIM, please do not apply thermal paste to the sticker. In case you use thermal foil, please cut out the area of the sticker. 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. Mount the light engine onto the heat sink and operate it until a stable temperature has been reached. Dismount the light engine and check the thermal sticker. For the interpretation of the test result, refer to the datasheet of the thermal sticker. Mounting of a thermocouple by means of a groove Thermal sticker after temperature measurement Note: Please keep in mind that you need a direct contact between the thermocouple and the PCB. OMEGA BUA2-140/60-30 is a suitable thermal sticker, which covers a temperature range between 60 and 77 °C. 5.5.3 Thermal dummy On request, a Zhaga-specified thermal test dummy for design-in tasks is available from your sales partner. 11 PrevaLED ® Core AC light engines | Lifetime and thermal behavior 6 Lifetime and thermal behavior 6.1 Flux as a function of temperature The luminous flux of the PrevaLED® Core AC light engine depends on its temperature. 100 % of the luminous flux is achieved at the reference temperature of 65 °C (tr = 65 °C). This temperature has to be measured at the tc point. If the reference temperature increases, the light output decreases. The luminous flux changes in relation to the reference temperature according to the following diagram: Flux as a function of tc temperature Relative flux [%] 104 6.2 Lifetime as a function of temperature For the definition of the lifetime of a light engine, please refer to IEC/PAS 62717, where the following types are defined (examples): — L0C10 is the lifetime where the light output is 0 % for 10 % of the light engines. — L70F50 is the lifetime where the light output is ≥ 70 % for 50 % of the light engines. F value includes reduction of lumen output over time including abrupt degradation (flux = 0). — L70B50 is the lifetime where the light output is ≥ 70 % for 50 % of the light engines. B value includes only gradual reduction of lumen output over time (not the abrupt flux degradation). If the reference temperature (tr) of 65 °C is maintained, PrevaLED® Core AC light engines have an average lifetime of 50 000 hours (L70B30). The maximum temperature measured at the tc point must not exceed 80 °C. 102 100 98 96 10 20 30 40 50 60 70 80 tc point temperature [°C] Note: Higher tc temperatures lead to a shorter lifetime of the PrevaLED® Core AC light engines. Moreover, the failure rate will also increase. The tables on page 13 show the lifetime of a PrevaLED® Core AC light engine in relation to the temperature measured at the tc point. 12 PrevaLED ® Core AC light engines | Lifetime and thermal behavior Lifetime L70 BXX Lifetime L70 F XX L70B50 Lifetime [h] L70B30 L70B10 60000 60000 50000 50000 40000 40000 30000 30000 20000 20000 10000 10000 0 0 40 45 50 55 60 65 70 75 80 L70F50 Lifetime [h] 40 45 50 55 60 65 tc point temperature [°C] Lifetime L 80 BXX L80B50 L80B30 L80B10 50000 50000 40000 40000 30000 30000 20000 20000 10000 10000 0 0 55 60 65 70 75 80 tc point temperature [°C] L80F50 Lifetime [h] 60000 50 80 tc point temperature [°C] 60000 45 75 L70F10 Lifetime L 80 F XX Lifetime [h] 40 70 L70F30 40 45 50 55 60 65 70 L80F30 75 L80F10 80 tc point temperature [°C] 13 PrevaLED ® Core AC light engines | Mechanical considerations 7 Mechanical considerations 7.1 Outline drawing The following schematic drawing provides further details on the dimensions of PrevaLED® Core AC light engines. For 3D files of the light engines, please go to: www.osram.com. 7.3 Mechanical protection of the light engine Note: The housing of a PrevaLED® Core AC light engine must 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 light engine. Technical drawing Note: If the protection glass at the light-emitting surface or any other part of the housing or the PCB is broken or mechanically damaged, you must no longer operate the light engine. Please replace it immediately to avoid contact with parts of the light engine that conduct 230 V! For operation in damp, wet or dusty environments, the user has to make sure that an adequate ingress protection is chosen. The light engine 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. kg 1. Don’t connect the module when the glass cover is broken. 2. Do not mechanically stress the module. 3. The LED light engine has to be built into a luminaire. 7.4 Mounting To fix a PrevaLED® Core AC light engine 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. All fi gures in mm 7.2 3D drawing Enable 3D View Mount the light engine from the top Move me! Movable 3D PrevaLED ® Core AC light engine (works with Adobe Acrobat 7 or higher) 14 PrevaLED ® Core AC light engines | Assembly in a reference luminaire 8 Assembly in a reference luminaire To show you how easy it is to equip a luminaire with a PrevaLED® Core AC, the following example guides you through all necessary steps. In this case, the luminaire housing is used as the heat sink. 8.1 Preparation The first step is to drill the holes and threads to mount the light engine according to chapter 7.4. 8.3 Mounting of the light engine Before you can screw the light engine to the housing, you need to glue the thermocouple to the PCB at the tc point. Use the specified screws and do not apply more torque to them than allowed in order to protect the light engine from damage. For the first test luminaire, drill an additional hole exactly at the location of the tc point to connect the thermocouple with the PCB. Screw the light engine to the housing Drill the mounting holes and a hole for the thermocouple 8.2 Attachment of the thermocouple Run the thermocouple through the hole under the tc point. Here, a thermal foil is used. In this case, please cut out a hole in the area where you attach the light engine to the PCB to ensure best possible thermal contact. Run the thermocouple through the hole and cut out the TIM 15 PrevaLED ® Core AC light engines | Assembly in a reference luminaire 8.4 Wiring In this case, a protection class I luminaire is designed. All metal parts have to be connected to earth. So the earth is connected to the housing of the luminaire, the phase and neutral conductors are connected to the light engine. Then you can close the luminaire and you are ready to run the thermal test. 8.5 Temperature measurement To check the maximum temperature at the tc point, please operate the luminaire in the orientation of its application until a stable temperature is reached. Ensure that the maximum tc temperature is not exceeded in the ambient temperature of its application. Wire the luminaire Close the luminaire Perform a steady-state thermal test 16 PrevaLED ® Core AC light engines | Norms and standards | More information 9 Norms and standards Safety: IEC/EN 62031 IEC/EN 60598-1 Photobiological safety: IEC/EN 62471 Risk group 1 Electromagnetic compatibility: CISPR 15 IEC/EN 61547 IEC/EN 61000-3-2 IEC/EN 61000-3-3 EN 55015 Ingress protection: IP20 Approvals: CE, VDE, ENEC, VDE EMC mark 10 10 More information Overview of accessories suppliers: www.ledlightforyou.com Technical datasheets and downloads: www.osram.com/prevaled 17 12/13 OSRAM S-GI MK EM Subject to change without notice. Errors and omissions excepted. www.osram.com/prevaled OSRAM GmbH Head office: Marcel-Breuer-Strasse 6 80807 Munich, Germany Phone +49 89 6213-0 Fax +49 89 6213-2020 www.osram.com