www.osram.com/prevaled 01/2015 Technical application guide PrevaLED® Core AC PRO light engines Light is OSRAM PrevaLED ® Core AC PRO light engines | Contents Contents 1 Introduction 03 5 Thermal considerations 09 1.1 System overview 03 5.1 Thermal power as a function of voltage 09 1.2 Nomenclature 04 5.2 Thermal shutdown 09 5.3 Thermal interface material and other accessories 09 2 Optical considerations 04 5.4 Cooling systems and heat sinks 09 2.1 Modulation of light 04 5.5 tc point location and temperature measurement 10 2.2 Light distribution 04 2.3 Refl ector design 05 6 Lifetime and thermal behavior 12 2.4 Color temperature 05 6.1 Flux as a function of temperature 12 2.5 Color rendering 06 6.2 Lifetime as a function of temperature 12 2.6 Spectral distribution 06 7 Mechanical considerations 13 3 Ingress protection 07 7.1 Outline drawing 13 7.2 3D drawing 13 13 4 Electrical considerations 07 7.3 Mechanical protection of the light engine 4.1 Wiring information 07 7.4 Mounting 13 4.2 Insulation requirements 08 7.5 Protection from corrosion 13 8 Norms and standards 14 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 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 AC PRO 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 PRO 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 PRO series of light engines is ideally suited for use in reflector-based luminaires (such as spotlights and downlights) in shop, hospitality, decorative or office applications. Benefits — PrevaLED® Core AC PRO 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. — Special energy-storage components enable an increased quality of light while at the same time managing the light modulation to be on par with standard drivers. — Omitting the external driver allows for smaller, simpler, slimmer and – last but not least – more cost-efficient luminaire designs. — Logistics and manufacturing are drastically simplified thanks to the lack of the external driver and special connecting cables, and also the reduced housing and fixation materials. — The PrevaLED® Core AC PRO family is easy to integrate since its mechanical and optomechanical interface is derived from the “Zhaga book 3” guideline, which reduces design-in effort and allows the use of standard reflectors and heat sinks. Although there currently is no standard available for AC spotlight engines, the LES sizes as well as the diameters and positioning of mounting holes are derived from the Zhaga standards, similar to the PrevaLED® Core Z3 and Z4 product ranges. — The engines are outfitted with a standard 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 PRO 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 PRO is available in 2 000 and 3 000 lm, in two color temperatures (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 109 lm/W with a power factor of > 0.9. — Lifetime is 50 000* hours (L70B50) at tp of 65 °C. — tc max. = 85 °C. PrevaLED ® Core AC PRO * Currently under evaluation 3 PrevaLED ® Core AC PRO light engines | Introduction | Optical considerations 1.2 Nomenclature PL-CORE: PrevaLED® Core family AC: AC-capable (220–240 V, 50/60 Hz) PRO: Professional 2000: 2000 lm 830: CRI + CCT = > 80 + 3000 K PL-CORE-AC-PRO-2000-830 2 Optical considerations 2.1 Modulation of light Due to the improved geometry and size of the PrevaLED® Core AC PRO, it was possible to add capacitors to the electrical circuit which reduce the modulation of the 100-Hz frequency down to less than 40 %. More than 60 % of the luminous flux level are always available. 2.2 Light distribution The light distribution of the light engine is shown in the graph below. The PrevaLED® Core AC PRO creates a beam angle of 110° FWHM (full width at half maximum). Light distribution curve 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). 105° 105° 90° 90° 75° 75° 60° 60° Light modulation 3000 lm [%] Light output [%] 200 45° 140 45° 120 300 100 80 cd/klm 30° 60 15° 0° 15° 30° 40 The light-emitting surface (LES) of the light engine is covered by a clear glass to protect the user from mains voltage. 20 0 0.01 0.015 0.02 0.025 Time [s] Note: Please ensure that the light engine is only used with an undamaged cover glass. 4 PrevaLED ® Core AC PRO light engines | Optical considerations 2.3 Reflector design The PrevaLED® Core AC PRO 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 2000/3000 lm Light-emitting surface (LES) category [mm] Real LES diameter [mm] Optical contact area (OCA) category [mm] 19 19 C/23 The LES dimensions of PrevaLED® Core AC PRO light engines meet Zhaga book 3 standards. Therefore, the PrevaLED® Core AC PRO can be used in combination with available off-the-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: 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 at www.osram.com via the “Tools & Services” portal. 2.4 Color temperature The PrevaLED® Core AC PRO series is currently available in 3 000 K and 4 000 K. The color coordinates within the CIE 1931 color space are given in the table below. Initial color values of the CCT 3000 K 4000 K Cx 0.432 0.378 Cy 0.399 0.374 Jordan Reflektoren GmbH & Co. KG Schwelmer Strasse 161, 42389 Wuppertal, Germany +49 202 60720 info@jordan-reflektoren.de www.jordan-reflektoren.de Within each available color temperature, the PrevaLED® Core AC PRO series provides a maximum color variation of four threshold value units (MacAdam steps). The following diagram shows these threshold values within the CIE 1931 color space. ACL-Lichttechnik GmbH Hans-Boeckler-Strasse 38 A, 40764 Langenfeld, Germany +49 2173 9753 0 info@reflektor.com www.reflektor.com Color coordinates 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 4-step MacAdam ellipses y 0.45 3000 K 2500 K 4000 K 0.40 2000 K 6000 K 0.35 0.35 0.40 0.45 0.50 x Nata Lighting Co., Ltd. 380 Jinou Road, Gaoxin Zone Jiangmen City, Guangdong, China +86 750 377 0000 [email protected] www.nata.cn 5 PrevaLED ® Core AC PRO light engines | Optical considerations 3000 K General CRI Relative spectral emission [%] Leaf green Pink, skin color Blue, saturated Green, saturated Yellow, saturated Red, saturated Lilac violet Aster violet Azure Turquois Light green Wavelength spectrum Yellowish green Ra values (note: All values measured at tc = 65 °C) Mustard yellow 2.6 Spectral distribution The typical spectral distribution of PrevaLED® Core AC PRO light engines is shown in the following diagram. Dusky pink 2.5 Color rendering PrevaLED® Core AC PRO 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. 4000 K 100 80 R1 R2 R3 R4 R5 R6 R7 R8 R9 R10 R11 R12 R13 R14 Ra 60 CCT = 81 92 95 78 81 90 82 61 14 82 3000 K 76 70 84 98 83 CCT = 83 90 93 82 83 85 86 69 21 75 4000 K 80 63 85 96 84 40 20 0 380 480 580 680 780 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 PRO light engines | Ingress protection | Electrical considerations 3 Ingress protection The PrevaLED® Core AC PRO 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 PRO 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 release the clamps, please use an operating tool (Wago type: 233-335) or a small screwdriver. 7 PrevaLED ® Core AC PRO light engines | Electrical considerations 4.2 Insulation requirements The PrevaLED® Core AC PRO 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 lightemitting surface which is connected directly to 220–240 VAC. The PrevaLED® Core AC PRO has basic insulation. In class II luminaires, additional care needs to be taken. The light engine and all connected electrically conductive parts (e.g. a metal heat sink) must be mounted in a way that they cannot be touched by the user. 4.3 Inrush current and system installation Due to its electronic construction, the PrevaLED® Core AC PRO 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. 4.4 Electrostatic discharge (ESD) It is not necessary to handle the PrevaLED® Core AC PRO in electrostatic protected areas (EPAs). 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. 4.5 Controllability Due to the integrated drive electronics, a good compatibility with any available phase-cut dimmer 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 PRO 3000 830 [%] Phi [lm] Pel [W] Pth [W] 130 110 90 70 50 30 10 150 170 190 210 230 250 270 Voltage [V] PrevaLED ® Core AC PRO 2000 830 [%] Phi [lm] Pel [W] Pth [W] 130 110 90 70 50 30 10 150 170 190 210 230 250 270 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 PRO 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 PRO, 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 PRO is given below. Thermal power values 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 www.bergquistcompany.com Typical Maximum Bergquist PL-CORE-AC-PRO-2000-830 12.5 W 13.8 W Arctic Silver www.arcticsilver.com PL-CORE-AC-PRO-2000-840 11.9 W 13.1 W Wakefield www.wakefield.com PL-CORE-AC-PRO-3000-830 24.8 W 27.3 W PL-CORE-AC-PRO-3000-840 23.4 W 25.7 W * Values measured at the tc point, at a reference temperature (tp) of 65 °C 5.1 Thermal power as a function of 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 achieve the best possible performance of the module and to protect it from damage by overheating, a thermal protection feature has been added. The characteristics of the thermal protection are shown in the following diagram. 5.4 Cooling systems and heat sinks For the selection of a suitable heat sink, several points regarding thermal resistance have to be considered. The selection is usually done through the following necessary steps: Define boundary conditions Total power dissipation of the light engine, max. ambient temperature ta, max. reference temperature tr according to lifetime requirements Thermal shutdown Rth = Pel [%] Estimate heat sink thermal resistance on light engine level tr - ta Pth tr measured at the tc point 100 80 60 40 Select heat sink thermal resistance Area of active thermal protection – not suitable for permanent operation 20 0 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 tc max. = 85 92 ± 7 110 tc [°C] 5.3 Thermal interface material and other accessories When mounting a PrevaLED® Core AC PRO 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. 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 PRO 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 PRO light engines. 9 PrevaLED ® Core AC PRO light engines | Thermal considerations The list below is a selection of suppliers of different cooling solutions: 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 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. 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). 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 Miniature connector “K” Thermo wire NiCr-Ni Different thermocouples Illustration Description Temperature range [°C] PVC-insulated -10 … +105 thermocouple PFA-insulated -75 … +260 thermocouple Sprung -75 … +260 thermocouple Location of the tc point tc point tp (performance temperature) is the reference temperature at which the datasheet values are applicable. A correct temperature measurement can, for example, be performed with a thermocouple. 10 PrevaLED ® Core AC PRO 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). 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 through a hole in the heat sink Mounting of a thermocouple by means of a groove Note: Please keep in mind that you need a direct contact between the thermocouple and the PCB. 11 PrevaLED ® Core AC PRO 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 PRO light engine depends on its temperature. 100 % of the luminous flux is achieved at the performance temperature of 65 °C (tp = 65 °C). This temperature has to be measured at the tc point. If the performance 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 2000 lm Relative flux [%] 3000 lm 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 performance temperature (tp) of 65 °C is maintained, PrevaLED® Core AC PRO light engines have an average lifetime of 50 000* hours (L70B50). The maximum temperature measured at the tc point must not exceed 85 °C. 108 106 104 102 Note: Higher tc temperatures lead to a shorter lifetime of the PrevaLED® Core AC PRO light engines. Moreover, the failure rate will also increase. 100 98 96 94 92 90 10 20 30 40 50 60 70 80 90 100 tc point temperature [°C] * Currently under evaluation 12 PrevaLED ® Core AC PRO 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 PRO light engines. For 3D files of the light engines, please go to: www.osram.com. 35 LES19 14.8 7.2 Technical drawing 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. ∅ 80 ∅ 35 kg 68 All fi gures in mm 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 PRO light engine to a heat sink, you can use M3 cylinder-head screws according to DIN 7984 or DIN EN ISO 4762. The allowed torque is 0.6 Nm (±0.1 Nm). 7.2 3D drawing Enable 3D View Move me! Movable 3D PrevaLED ® Core AC PRO light engine (works with Adobe Acrobat 7 or higher) Mount the light engine from the top 7.3 Mechanical protection of the light engine Note: The housing of a PrevaLED® Core AC PRO 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. 7.5 Protection from corrosion To protect electronic parts (such as LEDs) from corrosion, a corrosive atmosphere around the components has to be avoided. In case of LEDs, H2S, for example, is a highly corrosive substance which can lead to a drastically shortened product lifetime. The source for H2S are sulfur-crosslinked polymers, such as rubber. To ensure the absence of H2S, it is recommended to use peroxide-cross-linked materials, which are available on the market as an alternative to sulfur-cross-linked versions. Avoidance of corrosion by moisture has to be ensured by the appropriate protection of the luminaire housing (see chapter 3 “Ingress protection”). 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! 13 PrevaLED ® Core AC PRO light engines | Norms and standards 8 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 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. 14 01/15 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