Technical application guide - PrevaLED Cube AC G2 light engines (05/14)

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