www.osram.com/prevaled 05/2014 Technical application guide PrevaLED® Cube AC G2 light engines Light is OSRAM PrevaLED ® Cube AC G2 light engines | Contents Contents 1 Introduction 03 6 Lifetime and thermal behavior 1.1 System overview 03 6.1 Cooling 12 1.2 Ordering information 04 6.2 Flux as a function of temperature 12 1.3 Nomenclature 04 6.3 Thermal protection mechanism 12 6.4 Lifetime as a function of temperature 13 14 2 Optical considerations 12 05 2.1 Light distribution 05 7 Mechanical considerations 2.2 Refl ector design 05 7.1 Outline drawing 14 2.3 Color temperature 06 7.2 3D drawing 14 2.4 Color rendering 06 7.3 Mechanical protection of the light engine 14 2.5 Spectral distribution 06 7.4 Mounting 14 7.5 Protection from corrosion 14 8 Norms and standards 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 interface material and other accessories 09 5.2 Cooling systems and heat sinks 09 5.3 tc point location and temperature measurement 10 5.3.1 Thermocouple 10 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 ® Cube AC G2 light engines | Introduction 1 Introduction 1.1 System overview The brightness levels of today’s LEDs are opening the door for the use of LEDs in general lighting applications that require high lumen output levels. 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 dealing with the ever-improving performance of LEDs. Nevertheless, LED technology also offers an unknown wealth of possibilities, providing access to unprecedented levels of performance and new ways of integration. OSRAM’s PrevaLED ® family of LED light engines addresses the challenges of LED-based lighting while providing users with great performance and flexibility at the same time. Enabled by the application of LED technology, PrevaLED® is aiming to push the envelope of what is possible in terms of performance and simplicity. The PrevaLED® Cube AC series of light engines is ideally suited for use in diffuse wall-mounted and ceiling-mounted luminaires in decorative, hospitality or domestic applications as well as in a broad range of wide-reflector-based applications such as downlights. The PrevaLED® Cube AC light engines provide several specific benefits for these applications: — With the LED sources and the electronic control circuitry placed on the same board and packaged into a unique compact design, they offer an integrated system solution. — Little design-in effort is required due to the integration of the electronic control circuitry into the light engine, offering a new level of simplicity. — They provide high performance in terms of both the complete system efficiency and the quality of light (small color deviation, no recognizable light modulation). — Due to the low height of only 18.6 mm as well as the established footprint and means of mechanical fixation, a large number of existing accessories (optics, heat sinks etc.) can be easily adapted. — All in all, PrevaLED® Cube AC light engines not only offer a low threshold for the adaption of LEDs, but also a significant increase in flexibility for applications already adapted to LED technology. At present, the PrevaLED® Cube AC series is available as a 1 100-lm, 2 000-lm or 3 000-lm package in two light colors (3000 K and 4000 K) with a color reproduction of Ra > 80. Enable 3D View Dummy of a PrevaLED ® Cube AC light engine Move me! Movable 3D PrevaLED ® Cube AC light engine (works with Adobe Acrobat 7 or higher) 3 PrevaLED ® Cube AC G2 light engines | Introduction 1.2 Ordering information PrevaLED ® Cube AC G2 Product reference Luminous fl ux [lm] Color tem perature [K] Product number PL-CUBE-AC-1100-830-G2 1100 3000 4052899150874 PL-CUBE-AC-1100-840-G2 1100 4000 4052899150898 PL-CUBE-AC-2000-830-G2 2000 3000 4052899909496 PL-CUBE-AC-2000-840-G2 2000 4000 4052899909502 PL-CUBE-AC-3000-830-G2 3000 3000 4052899909557 PL-CUBE-AC-3000-840-G2 3000 4000 4052899909564 1.3 Nomenclature PL: PrevaLED® light engine CUBE: Cube-shaped module AC: AC-capable (220–240 V, 50/60 Hz) 2000: 2000 lm 830: CRI + CCT = > 80 + 3000 K G2: Generation 2 PL-CUBE-AC-2000-830-G2 4 PrevaLED ® Cube AC G2 light engines | Optical considerations 2 Optical considerations PrevaLED® Cube AC light engines can be applied in diffuse wall-mounted and ceiling-mounted luminaires without the need for further optical accessories. 2.1 Light distribution The light distribution of PrevaLED® Cube AC light engines is shown below. They create a beam angle of 110° FWHM. Light distribution curve Jordan Reflektoren GmbH & Co. KG Schwelmer Strasse 161, 42389 Wuppertal, Germany +49 202 60720 [email protected] www.jordan-reflektoren.de ACL-Lichttechnik GmbH Hans-Boeckler-Strasse 38 A, 40764 Langenfeld, Germany +49 2173 9753 0 [email protected] www.reflektor.com Alux·Luxar GmbH & Co. KG Schneiderstrasse 76, 40764 Langenfeld, Germany +49 2173 279 0 [email protected] www.alux-luxar.de The light-emitting surface of the light engines is covered by a diffuser to ensure a homogeneous, smooth light distribution. Please ensure that the temperature of the diffuser does not exceed 120 °C. 2.2 Refl ector design PrevaLED® Cube AC light engines can also be used with secondary optics. As their optical interface has the same dimensions as common downlight modules on the market, they can be combined with available off-the-shelf secondary optics. For optics support, you can find our suppliers via OSRAM’s LED Light for You network: www.ledlightforyou.com. Moreover, standard components and support for reflector design are available e.g. through the following suppliers: Almeco S.p.A. Via della Liberazione, 15, 20098 San Giuliano Milanese (Mi), Italy +39 02 988963 1 [email protected] www.almecogroup.com Nata Lighting Co., Ltd. 380 Jinou Road, Gaoxin Zone, Jiangmen City, Guangdong, China +86 750 377 0000 [email protected] www.nata.cn 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. 5 PrevaLED ® Cube AC G2 light engines | Optical considerations 2.3 Color temperature The PrevaLED® Cube AC series is currently available in 3000 K and 4000 K. The color coordinates within the CIE 1931 color space are given below. 2.4 Color rendering PrevaLED® Cube AC light engines provide a color rendering index (CRI) of > 80. The table below shows the individual Ra values from R1 to R14 for the available color temperatures. Initial color values of the CCT R a values Leaf green Pink, skin color Blue, saturated Green, saturated Yellow, saturated Red, saturated Lilac violet Aster violet Azure Turquois Within each available color temperature, the PrevaLED® Cube 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. Light green 0.375 Yellowish green 0.398 Mustard yellow 0.385 Cy Dusky pink 4000 K 0.437 General CRI 3000 K Cx R a R1 R2 R3 R4 R5 R6 R7 R8 R9 R10 R11 R12 R13 R14 CCT = 83 81 90 96 80 80 86 85 64 20 76 3000 K 77 67 83 98 CCT = 84 82 90 90 81 82 84 88 70 25 74 4000 K 78 59 84 96 Color coordinates Three-step MacAdam ellipses y 2.5 Spectral distribution The typical spectral distribution of PrevaLED® Cube AC light engines is shown in the following diagram. 0.45 3000 K Wavelength spectrum 2500 K 840 830 Relative spectral emission [%*100] 4000 K 0.40 1.00 6000 K 0.80 0.35 0.60 0.40 0.30 0.35 0.40 0.45 0.20 0.50 x 0.00 380 430 480 530 580 630 680 730 780 Wavelength (nm) 6 PrevaLED ® Cube AC G2 light engines | Ingress protection | Electrical considerations 3 Ingress protection PrevaLED® Cube AC light engines have an ingress protection rating of IP20. Please ensure that the housing of your luminaire provides the ingress 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 at www.osram.com. 4 Electrical considerations 4.1 Wiring information PrevaLED® Cube AC light engines can be directly connected to mains voltage (220–240 V, 50/60 Hz). The used input clamps can handle solid 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 6–7 mm (0.24–0.28 inch) Please insert the wires in 0° orientation to the PCB. Solid wire: Plug directly. Notes: — The connector is designed for three poke-in and release cycles. — Due to the fact that you are dealing with 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. Flexible wire: 1. Lightly press the push button of the connection clamp. 2. Insert the flexible wire. 7 PrevaLED ® Cube AC G2 light engines | Electrical considerations 4.2 Insulation requirements PrevaLED® Cube AC light engines can be used in class I luminaires without further action. The creepage distance and clearance are fulfilled. In class II luminaires, additional care needs to be taken only in the area of the input connector. Between connection wires with basic insulation and touchable metal parts or the heat sink, a second insulation layer is required. The light engine itself has double/reinforced insulation. Note for PrevaLED ® Cube 3000-lm LED modules: In class II luminaires, due to the fact that PrevaLED ® Cube 3000-lm LED modules use metal-core PCBs (MCPCBs), an additional insulation layer between the MCPCB and the heat sink must be used. Therefore, an electrically insulating thermal interface material (TIM) is recommended. This TIM has to cover the entire surface of the MCPCB. 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. 4.4 Electrostatic discharge (ESD) It is not necessary to handle PrevaLED® Cube AC light engines in electrostatic protected areas (EPAs). To protect a PrevaLED® Cube AC light engine from electrostatic damage, do not open it. 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 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 Cube AC 3000 lm Flux [lm] Power [W] Thermal power [W] % 115 110 105 100 95 90 85 80 190 200 210 220 230 240 250 Voltage [V] 8 PrevaLED ® Cube AC G2 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 PrevaLED® Cube AC light engines, 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® Cube AC light engines is given below. Thermal interface materials Alfatec www.alfatec.de Kerafol www.kerafol.de Laird www.lairdtech.com Bergquist www.bergquistcompany.com Arctic Silver www.arcticsilver.com Wakefi eld www.wakefi eld.com Thermal power values CCT Typical Maximum Max. allowable thermal thermal thermal power 1) power 1) resistance R th[K/W] 2) PL-CUBE-AC-1100-830-G2 3000 8.1 8.91 PL-CUBE-AC-1100-840-G2 4000 7.6 8.36 5.68 PL-CUBE-AC-2000-830-G2 3000 18.5 20.35 2.51 PL-CUBE-AC-2000-840-G2 4000 17.4 19.14 2.65 PL-CUBE-AC-3000-830-G2 3000 26.7 29.37 1.83 PL-CUBE-AC-3000-840-G2 4000 24.9 27.39 1.94 5.2 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. 5.35 Depending on the application and the chosen light engine, passive cooling can be sufficient. In critical applications (e.g. small available heat sink size or extremely reduced airflow), active cooling by means of a ventilator may be required. Active cooling combines a heat sink with a fan or a similar device to maximize the thermal dissipation of the passive heat sink. 5.1 Thermal interface material and other accessories When mounting a PrevaLED® Cube AC light engine within a luminaire, it is 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 roughness of the surface should be optimized. Selection of a heat sink 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. 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® Cube AC light engine is in contact with the solid material of the heat sink. The list below is a selection of suppliers of thermal interface materials. Additional suppliers for thermal management support can also be found via OSRAM’s LED Light for You network: www.ledlightforyou.com. 1) Value measured at the tc point at a reference temperature (tr) of 70 °C 2) Value measured at the rear of the luminaire at an ambient temperature of 25 °C 9 PrevaLED ® Cube AC G2 light engines | Thermal considerations 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. 5.3.1 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. The list below is a selection of suppliers of different cooling solutions. Examples of suitable thermocouples: Active and passive cooling systems K-type thermocouple with miniature connector 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 Different thermocouples Illustration Description Temperature range [°C] PVC-insulated -10 … +105 thermo couple 5.3 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, under the center of the diffuser (see image below). PFA-insulated -75 … +260 thermo couple Sprung -75 … +260 thermo couple Location of the tc point 37.7 41.4 All fi gures in mm 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 the heat sink. To ensure a direct contact between the thermocouple and the PCB, it is recommended to glue the thermocouple onto the PCB (e.g. with acrylic glue, e.g. Loctite 3751). tc point A correct temperature measurement can, for example, be performed with a thermocouple. Mounting of a thermocouple through a hole in the heat sink 10 PrevaLED ® Cube AC G2 light engines | Thermal considerations 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. 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 ® Cube AC G2 light engines | Lifetime and thermal behavior 6 Lifetime and thermal behavior 6.1 Cooling To ensure a safe and reliable operation, the module must be attached to a suitable cooling solution (e.g. a heat sink). 6.3 Thermal protection mechanism To protect the LED module from damage by overheating, a thermal derating has been implemented. The derating starts at a tc point temperature of 90 °C (±5 °C). Please see the curve in the graph at below left. 6.2 Flux as a function of temperature The luminous flux of PrevaLED® Cube AC light engines depends on their temperature. 100 % of the luminous flux is achieved at the reference temperature of 70 °C (tr = 70 °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 temperature Relative flux [%] 100 90 80 70 60 50 40 30 20 10 0 25 35 45 55 65 75 85 95 105 Temperature [°C] 12 PrevaLED ® Cube AC G2 light engines | Lifetime and thermal behavior 6.4 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 degradation of flux). If the performance temperature tp of 70 °C is maintained, the PrevaLED® Cube light engines have an average lifetime of 50000 hours (L70B50). The maximum temperature measured at the tc point must not exceed 85 °C. Note: Higher temperatures lead to a shorter lifetime of the PrevaLED® Cube AC light engines. Moreover, the failure rate will also increase. The tables below show the lifetime of PrevaLED® Cube light engines according to IEC/PAS 62717. PL-CUBE-1100-G2, PL-CUBE-2000-G2 L70B10 L70B50 L80B10 L80B50 L0C10 L0C50 L70F10 L70F50 L80F10 L80F50 Lifetime [h] at t p = 60 °C 50000 50000 29000 50000 50000* 50000* 43000 50000 24000 50000 Lifetime [h] at t p = 65 °C 45000 50000 20000 50000 50000* 50000* 32000 50000 17000 50000 Lifetime [h] at t p = 70 °C 33000 50000 14000 45000 49000 47000 24000 47000 12000 41000 Lifetime [h] at t p = 80 °C 18000 23000 7000 23000 23000 23000 14000 23000 6000 23000 Lifetime [h] at t p = 85 °C 12000 14500 5000 14500 14500 14500 9000 14500 4000 14500 L80F50 PL-CUBE-3000-G2 L70B10 L70B50 L80B10 L80B50 L0C10 L0C50 L70F10 L70F50 L80F10 Lifetime [h] at t p = 60 °C 50000 50000 50000 50000 50000* 50000* 50000 50000 50000 50000 Lifetime [h] at t p = 65 °C 50000 50000 50000 50000 50000* 50000* 50000 50000 39000 50000 Lifetime [h] at t p = 70 °C 50000 50000 37000 50000 50000* 50000* 45000 50000 28000 50000 Lifetime [h] at t p = 80 °C 40000 50000 18000 50000 39000 43000 25000 43000 14000 43000 * Expected to be higher. 13 PrevaLED ® Cube AC G2 light engines | Mechanical considerations 7 Mechanical considerations Outline drawing Note for France: Due to specific national regulations as defined in the standard EN 60598, it is not permitted to expose the light engine outside a luminaire housing. 54 18.5 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 code of the luminaire housing. Please consider the luminaire standard IEC 60598-1 as well as the different requirements for indoor and outdoor application. 61 68 82 7.1 Outline drawing The following schematic drawing provides further details on the dimensions of PrevaLED® Cube AC light engines. For 3D files of the light engines, please go to: www.osram.com/prevaled. kg Don’ts 83 4.5 All fi gures in mm 7.4. Mounting To fix a PrevaLED® Cube AC light engine to a heat sink, use M4 cylinder head screws according to DIN 912 or ISO 4762. The required torque is 1.5 (±0.5) Nm. 7.2 3D drawing Enable 3D View Mount the light engine from the top Move me! Movable 3D PrevaLED ® Cube AC light engine (works with Adobe Acrobat 7 or higher) 7.3 Mechanical protection of the light engine The housing of a PrevaLED® Cube AC light engine 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 light engine. Note: If the diffuser material 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. 7.5 Protection from corrosion To avoid corrosion of electronic parts (such as LEDs), it is necessary to avoid a corrosive atmosphere around the components. In case of LEDs, e.g. H2S is a highly corrosive substance which could lead to a drastically shortened product lifetime. The source for H2S are sulfur-cross-linked polymers – such as rubber. To ensure the absence of H2S, we recommend using peroxide cross-linked materials, which are available on the market as an alternative to sulfur-cross-linked versions. The general topic corrosion by moisture has to be ensured within the appropriate luminaire housing (see chapter 3: Ingress protection). 14 PrevaLED ® Cube AC G2 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 Approval: CE 15 05/14 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