www.osram.com/prevaled 02/2016 Technical application guide PrevaLED® Cube AC G3 light engines Light is OSRAM PrevaLED ® Cube AC G3 light engines | Contents Contents 1 Introduction 03 5 Thermal considerations 09 1.1 System overview 03 5.1 Thermal interface material and other accessories 09 1.2 Nomenclature 04 5.2 Cooling systems and heat sinks 09 5.3 tc point location and temperature measurement 10 5.4 Thermocouple 10 2 Optical considerations 05 2.1 Light distribution 05 2.2 Reflector design 05 6 Lifetime and thermal behavior 12 2.3 Color temperature 06 6.1 Cooling 12 2.4 Color rendering 06 6.2 Luminous flux as a function of temperature 12 2.5 Spectral distribution 06 6.3 Thermal protection mechanism 12 6.4 Lifetime as a function of temperature 13 3 Ingress protection 07 7 Mechanical considerations 14 4 Electrical considerations 07 7.1 Outline drawing 14 4.1 Wiring information 07 7.2 3D drawing 14 4.2 Insulation requirements 08 7.3 Mechanical protection of the light engine 14 4.3 Inrush current and system installation 08 7.4 Mounting 14 4.4 Electrostatic discharge (ESD) 08 7.5 Protection from corrosion 14 4.5 Controllability 08 4.6 Power as a function of voltage 08 8 Norms and standards 15 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 manu facturer/OEM/application planner. 2 PrevaLED ® Cube AC G3 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 LEDbased luminaire poses a new set of technical challenges, among them new optical requirements, providing adequate thermal management for stable operation and dealing with the everimproving 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 LEDbased 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 G3 series of light engines is ideally suited for use in a broad range of widereflector based applications such as downlights. PrevaLED® Cube AC G3 incorporates two main features into one light engine: 1 LED module 2 LED driver PrevaLED® Cube AC G3 light engines provide several specific benefits: — With the LED sources and the electronic control circuitry placed on the same board and packaged into a com pact design, they offer an integrated system solution. — Little designin effort is required due to the integration of the electronic control circuitry into the light engine, offering a new level of simplicity. — 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 G3 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 G3 series is available as a 1 100lm, 2 000lm or 3 000lm package in two light colors (3 000 K and 4 000 K) with a color reproduction of CRI > 80. The luminaire manufacturer benefits from reduced com plexity inside the luminaire. The reduced amount of compo nents reduces the logistical efforts and eases the manufac turing process. In addition, it enables the development of innovative miniaturized designs. Dummy of a PrevaLED ® Cube AC G3 light engine 3 PrevaLED ® Cube AC G3 light engines | Introduction 1.2 Nomenclature PL: PrevaLED® light engine CUBE: Cube-shaped module AC: AC-capable (220–240 V, 50/60 Hz) 3000: 3000 lm 830: CRI + CCT = > 80 + 3000 K 230V: 230 V mains capable G3: Generation 3 of the PrevaLED® Cube family PL-CUBE-AC-3000-830-230V-G3 4 PrevaLED ® Cube AC G3 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 Jordan Luxar GmbH & Co. KG Schneiderstrasse 76 d, 40764 Langenfeld, Germany Phone: +49 (0)2173 279-0, Fax: +49 (0)2173 279-250 [email protected] www.jordan-luxar.de The light-emitting surface of the light engines is covered by a diffuser to ensure a homogeneous, smooth light distribution. 2.2 Reflector 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 second ary 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 Widegerm Lighting Ltd. Flat A, 3/F., Tak Wing Ind. Building 3 Tsun Wen Rd. Tuen Mun, N.T., Hong Kong +85 224 655 679 [email protected] www.widegerm.com.hk OSRAM provides mechanical (3D files) and optical simula tion data (ray files) to support customized reflector design. Ray file data are available upon request through your sales partner. 5 Pink, skin color Blue, s aturated Green, s aturated Yellow, s aturated Within each available color temperature, the PrevaLED® Cube AC G3 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. Red, s aturated 0.384 Lilac violet 0.405 Aster violet Cy Azure 0.387 Turquois 4000 K 0.439 Light green 3000 K Cx Yellowish green R a values Mustard yellow Initial color values of the CCT Dusky pink 2.4 Color rendering PrevaLED® Cube AC G3 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. General CRI 2.3 Color temperature The PrevaLED® Cube AC G3 series is currently available in 3 000 K and 4 000 K (for other CCT, please contact your sales partner). The color coordinates within the CIE 1931 color space are given below. Leaf green PrevaLED ® Cube AC G3 light engines | Optical considerations R a R1 R2 R3 R4 R5 R6 R7 R8 R9 R10 R11 R12 R13 R14 CCT = 85 83 90 95 84 82 85 89 70 22 75 3000 K 83 65 85 97 CCT = 83 81 89 96 83 81 86 86 64 16 75 4000 K 82 71 83 98 Color coordinates Three-step MacAdam ellipses y 2.5 Spectral distribution The typical spectral distribution of PrevaLED® Cube AC G3 light engines is shown in the following diagram. 0.450 0.425 3000 2500 Wavelength spectrum 3500 0.400 1.00 4500 0.375 840 830 Relative spectral emission [%*100] 4000 5000 0.80 5500 0.350 0.325 0.60 0.350 0.375 0.400 0.425 0.450 0.475 x 0.40 0.20 0.00 380 430 480 530 580 630 680 730 780 Wavelength [nm] 6 PrevaLED ® Cube AC G3 light engines | Ingress protection | Electrical considerations 3 Ingress protection PrevaLED® Cube AC G3 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 G3 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 crosssection of 0.2 to 0.75 mm² (AWG 24–18). The use of solid wire is recommended. Wire preparation 6–7 mm (0.24–0.28 inches) Please insert the wires in 0° orientation to the PCB. Solid wire: Plug directly. Notes: — The connector is designed for three pokein and release cycles. — Due to the fact that you are dealing with mains voltage, you must not hotplug 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. To press/release the clamps, please use an operating tool (Wago type: 206860) or a small screw driver. 7 PrevaLED ® Cube AC G3 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 connec tion 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. 4.3 Inrush current and system installation Due to their electronic construction, PrevaLED® Cube AC light engines have a minimum inrush current. In system installations, you can connect the following numbers of PrevaLED® Cube AC light engines to circuit breakers (e.g. B10 etc.) with different characteristics. B10: 51 pcs B16: 84 pcs C16: 142 pcs PrevaLED ® Cube AC 3000 lm 4.4 Electrostatic discharge (ESD) It is not necessary to handle PrevaLED® Cube AC light e ngines in electrostatic protected areas (EPAs). To protect a PrevaLED® Cube AC light engine from electro static damage, do not open it. The light engine fulfills the requirement of the immunity standard IEC/EN 61547. 4.5 Controllability PrevaLED® Cube AC is designed as a simple on/off device. For a fullly dimmable DALI version, please see PrevaLED® Cube AC DALI. 4.6 Power as a function of voltage The nominal voltage of the light engine is 230 V. The opera tion range is 220–240 V. For voltage variations, the light en gine 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 2000 lm Luminous flux [lm] Power [W] Thermal power [W] Luminous flux [lm] Power [W] Thermal power [W] % % 100 100 90 90 80 80 70 70 190 200 210 220 230 240 250 260 270 Voltage [V] 190 200 210 220 230 240 250 260 270 Voltage [V] PrevaLED ® Cube AC 1100 lm Luminous flux [lm] Power [W] Thermal power [W] % 100 90 80 70 190 200 210 220 230 240 250 260 270 Voltage [V] 8 PrevaLED ® Cube AC G3 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 G3 light engines, only a partial amount of the introduced electrical power has to be dissi pated through the back of the light engine. The thermal power that has to be dissipated for PrevaLED® Cube AC G3 light engines is given below. Suppliers of thermal interface materials Thermal power values 5.2 Cooling systems and heat sinks For the selection of a suitable heat sink, several points regarding thermal resistance have to be considered. Typical thermal power [W]1) Max. thermal power [W]1) Typical allowable thermal resistance R th [K/W] 2) Max. allowable thermal resistance R th [K/W] 2) PL-CUBE-AC-11008XX-230V-G3 8.2 9.7 5.5 4.7 PL-CUBE-AC-20008XX-230V-G3 12.9 15.5 3.5 2.9 PL-CUBE-AC-30008XX-230V-G3 21.3 25.3 2.1 1.8 Alfatec www.alfatec.de Kerafol www.kerafol.de Laird www.lairdtech.com Bergquist www.bergquistcompany.com Wakefield www.wakefield.com The selection is usually carried out along the following necessary steps. Selection of a heat sink Define boundary conditions 5.1 Thermal interface material and other accessories When mounting a PrevaLED® Cube AC G3 light engine within a luminaire, it is recommended to use thermal inter face m aterial (TIM) between the back of the light engine and the luminaire housing or heat sink. It is recommended to use thermal paste. In order to balance possible uneven ness, 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 e ngine and the contact surfaces of the luminaire housing is achieved. For this purpose, the planarity and roughness of the surface should be optimized. The following list is a selection of suppliers of thermal inter face materials. Additional suppliers for thermal manage ment support can also be found via OSRAM’s LED Light for You network: www.ledlightforyou.com. 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 perfor mance curve in the heat sink manufacturer’s catalog. Note: A thermal design must always be confirmed by per forming a thermal measurement in steady-state condition. It is recommended that the whole area of the PCB of a PrevaLED® Cube AC G3 light engine is in contact with the solid material of the heat sink. 1) Value measured at the tc point at a reference temperature (tr) = tp of 70 °C 2) V alue measured at an ambient temperature of 25 °C; the R th values apply to the light engine incl. the thermal interface material (TIM) 9 PrevaLED ® Cube AC G3 light engines | Thermal considerations A thermal system always depends on many factors, such as airflow, ambient temperature etc. Please check your en tire cooling system by performing a thermal measurement in steadystate condition. 5.4 Thermocouple Use a thermocouple that can be glued onto the light en gine. 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: Suppliers of 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.avceuropa.de SEPA www.sepaeurope.com Fischer Elektronik www.fi scherelektronik.de Wakefi eld www.wakefi eld.com Cooliance www.cooliance.com Different thermocouples Illustration 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). Description Temperature range [°C] PVCinsulated 10 … +105 thermo couple PFAinsulated 75 … +260 thermo couple Sprung 75 … +260 thermo couple Location of the tc point 37.3 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 it. 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). The glue shall not influence the thermal coupling. 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 G3 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 thermo couple and the PCB is required. Please refer to the data sheet 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 G3 light engines | Lifetime and thermal behavior 6 Lifetime and thermal behavior 6.1 Cooling To ensure a safe and reliable operation, the light engine must be attached to a suitable cooling solution (e.g. a heat sink). 6.3 Thermal protection mechanism To protect the light engine from damage by overheating, a thermal derating has been implemented. The derating starts at a tc point temperature of > 90 °C. Please see the curve in the graph on the left. 6.2 Luminous flux as a function of temperature The luminous flux of PrevaLED® Cube AC G3 light engines depends on their temperature. 100 % of the lumi nous flux is achieved at the reference temperature of 70 °C (tp = 70 °C). This temperature has to be measured at the tc point. If the reference temperature increases, the light output decreases. Flux as a function of temperature at nominal power Relative flux [%] 100 90 80 70 60 50 40 30 20 10 0 70 80 90 100 110 Temperature [°C] 12 PrevaLED ® Cube AC G3 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 AC G3 light engines have an average lifetime of 50 000 hours (L70B50). The maximum tempera ture measured at the tc point must not exceed 90 °C. Note: Higher temperatures lead to a shorter lifetime of the PrevaLED® Cube AC G3 light engines. Moreover, the failure rate will also increase. The tables below show the lifetime of PrevaLED® Cube AC G3 light engines according to IEC 62717. PL-CUBE-AC-1100-8x0-230V-G3 L70B50 L80B10 L80B50 L0C10 L0C50 L70F10 L70F50 L80F10 L80F50 Lifetime [h] at t c point = 65 °C 41000 L70B10 50000 26000 36000 104000 104000 39000 50000 26000 35000 Lifetime [h] at t c point = 70 °C 38000 50000 24000 33000 73000 73000 36000 50000 23000 32000 Lifetime [h] at t c point = 75 °C 35000 48000 23000 31000 52000 52000 33000 47000 22000 30000 Lifetime [h] at t c point = 80 °C 33000 45000 21000 28000 36000 36000 30000 44000 20000 27000 Lifetime [h] at t c point = 90 °C 31000 43000 20000 27000 18000 18000 28000 41000 18000 26000 PL-CUBE-AC-2000-8x0-230V-G3 L70B50 L80B10 L80B50 L0C10 L0C50 L70F10 L70F50 L80F10 L80F50 Lifetime [h] at t c point = 65 °C 50000 L70B10 50000 35000 50000 82000 82000 48000 50000 33000 50000 Lifetime [h] at t c point = 70 °C 47000 50000 31000 44000 58000 58000 41000 50000 29000 44000 Lifetime [h] at t c point = 75 °C 41000 50000 27000 39000 41000 41000 36000 50000 25000 38000 Lifetime [h] at t c point = 80 °C 36000 50000 24000 34000 29000 29000 31000 50000 22000 33000 Lifetime [h] at t c point = 90 °C 28000 41000 18000 26000 14000 14000 23000 40000 16000 26000 PL-CUBE-AC-3000-8x0-230V-G3 L70B50 L80B10 L80B50 L0C10 L0C50 L70F10 L70F50 L80F10 L80F50 Lifetime [h] at t c point = 65 °C 42000 L70B10 50000 28000 41000 82000 82000 38000 50000 26000 40000 Lifetime [h] at t c point = 70 °C 37000 50000 24000 36000 58000 58000 33000 50000 23000 35000 Lifetime [h] at t c point = 75 °C 33000 49000 21000 31000 41000 41000 28000 47000 20000 31000 Lifetime [h] at t c point = 80 °C 29000 43000 19000 28000 29000 29000 24000 42000 17000 27000 Lifetime [h] at t c point = 90 °C 23000 34000 15000 22000 14000 14000 18000 33000 13000 21000 13 PrevaLED ® Cube AC G3 light engines | Mechanical considerations 7 Mechanical considerations 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 suit able IP code of the luminaire housing. Please consider the luminaire standard IEC 605981 as well as the different requirements for indoor and outdoor application. 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. 18.6 21.1 7.1 Outline drawing The following schematic drawing provides further details on the dimensions of PrevaLED® Cube AC G3 light engines. For 3D files of the light engines, please go to: www.osram.com/prevaled. 54.4 6.2 (screw contact area) 41.4 kg Tc 82.8 37.3 68 81.6 61 4.3 All fi gures in mm Don’ts 7.4 Mounting To fix a PrevaLED® Cube AC G3 light engine to a heat sink, use M4 cylinder head screws according to DIN 912 or ISO 4762. Note: General mechanical tolerances according to ISO 2768 c. 7.2 3D drawing Enable 3D View Mount the light engine from the top Move me! Movable 3D PrevaLED ® Cube AC G3 light engine Note: Good experiences were made with a torque of 1.0 ± 0.5 Nm, higher torque levels do not necessarily lead to significantly better heat transfer but may lead to damage of the light engine. (works with Adobe Acrobat 7 or higher) 7.3 Mechanical protection of the light engine The housing of a PrevaLED® Cube AC G3 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 lightemitting 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 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 cor rosive substance which can lead to a drastically shortened product lifetime. The source for H2S are sulfurcrosslinked polymers, such as rubber. To ensure the absence of H2S, it is recommended to use peroxidecrosslinked materials, which are available on the market as an alternative to sul furcrosslinked versions. Avoidance of corrosion by mois ture has to be ensured by the appropriate protection of the luminaire housing (see chapter 3 “Ingress protection”). 14 PrevaLED ® Cube AC G3 light engines | Norms and standards 8 Norms and standards Safety: IEC/EN 62031 IEC 61347-1 Photobiological safety: IEC/EN 62471 Risk group 1 Ingress protection: IP20 Approval: CE, ENEC, VDE, CB VDE 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. 15 02/16 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