Technical application guide - PrevaLED Compact light engines (06/13)

www.osram.com
JUNE
2013
Technical application guide
PrevaLED® Compact light engines
CONTENTS
Contents
1. Introduction
3
3. Installation guide
21
1.1. System overview
3
3.1. Installation of one LED module inside a luminaire
21
1.2. System information
4
3.2. Installation of more than one LED module inside a luminaire
21
1.2.1. Nomenclature and marking
5
3.3. Creepage and clearance
22
1.2.2. Technical data
6
3.4. Constant lumen output (CLM)
23
1.2.3. Possible system combinations
7
3.5. IP rating
23
2. Luminaire design
8
4. Norms and standards
24
2.1. Optical considerations
8
4.1. Norms and standards for PrevaLED® LED modules and light engines
24
2.1.1. Quality of light
8
4.2. Photobiological safety
24
2.1.2. CRI, CCT
9
2.2. Mechanical considerations
2.2.1. LED module dimensions
9
9
2.2.2. LED power supply dimensions
10
2.2.3. Cable dimensions
10
2.3. Thermal considerations
11
2.3.1. Heat sink material and size
11
2.3.2. Thermal interface material
14
2.3.3. Tc location and temperature measurement
14
2.3.4. Overtemperature protection
16
2.4. Electrical considerations
16
2.4.1. Insulation coordination for PrevaLED® Compact LED modules
16
2.4.2. Insulation coordination for OPTOTRONIC® ECGs
16
2.4.3. Wiring information
17
2.4.4. Electrostatic discharge (ESD)
18
2.4.5. Current setting and thermal protection
18
2.4.6. Wiring in protection class I and II luminaires
20
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 guid.
Please make sure you’re always only using the most recent
release of the application guide.
2
INTRODUCTION
1. Introduction
1.1. System overview
Today, LEDs are recognized as the most cutting-edge
lighting technology, and this is especially true for the majority of outdoor lighting applications. Well-designed LED
outdoor luminaries can provide the required surface illuminance with an improved uniformity, while using less energy
compared to traditional light sources. LED luminaries usually also have a significantly longer lifetime with better lumen maintenance. The technology is improving so rapidly
in terms of luminous efficacy, color quality, thermal management and cost that choosing LEDs for general lighting
applications no longer means compromising on some of
the benefits of conventional lighting technologies.
It must be said, however, that current LED product quality
can vary significantly among manufacturers, so due diligence is required in their proper selection and use. LED
performance is highly sensitive to thermal and electrical
design weaknesses that can lead to rapid lumen depreciation or premature failure.
In order to be able to offer the best-in-class LED modules,
OSRAM capitalizes on its decades of experience in the
lighting business. OSRAM’s PrevaLED® Compact series
of LED light engines addresses the challenges of LEDbased lighting while at the same time providing great
performance and flexibility to the user.
The PrevaLED® Compact series is specifically designed for
outdoor applications such as street, urban and area lighting, or illumination of bicycle paths and pedestrian zones.
PrevaLED® Compact light engines are also well suited for
commercial and industrial high-bay lighting.
PrevaLED® Compact light engines have several convincing
benefits:
• PrevaLED® Compact LED modules are highly reliable.
The expected lifespan at which 10 % of the LED population have less than 85 % of the rated flux (L85 B10) is up
to 60000 hours (at 80 °C Tc).
• The LED modules are designed to be used in combination with OSRAM’s OPTOTRONIC® LEDset 700 series.
By installing both OSRAM LED modules and LED power
supplies, the customer is assured about safe operation
and about the achievement of target performance. The
combination of LED modules and power supplies has
been thoroughly tested and proven highly reliable.
• Because it meets the Zhaga standard, the light engine is
future-proof and interchangeable.
• The light engines provide excellent optical performance,
both in terms of efficiency and high quality of light (color
rendering).
• The wide range of lumen packages currently offered
(from 2500 lm to 10000 lm) allows for addressing a wide
range of applications based on a single platform
of light sources. Available color temperatures are 4000 K
and 5700 K, additional types are currently under consideration.
• Thanks to the excellent efficiency of the mounted
OSLON® Square LEDs, the PrevaLED® Compact LED
module achieves a high luminous flux on a relatively
small PCB, which allows for a high design flexibility.
Additional details on optical, thermal, mechanical and
electrical characteristics can be found in the following
sections. Further and updated information (ray files,
CAD files and updates of this guide) will be posted at
www.osram.com.
3
INTRODUCTION
PrevaLED® Compact: Five lumen packages
Luminous flux
2500 lm
4000 lm
6000 lm
8000 lm
10000 lm
4000 K
LEP-2500-740-CT2
LEP-4000-740-CT2
LEP-6000-740-CT3
LEP-8000-740-CT3
LEP-10000-740-CT3
5700 K
–
–
LEP-6000-657-CT3
LEP-8000-657-CT3
LEP-10000-657-CT3
Interface
LEDset 700 system: Suitable for OPTOTRONIC® LED power supplies with LEDset and a maximum output current of 700 mA.
Color
temperature
1.2. System information
+
PrevaLED® Compact
+
PrevaLED® Compact cable
OPTOTRONIC® LED power supply
4
INTRODUCTION
1.2.1. Nomenclature and marking
The PrevaLED® product series follows a consistent naming
convention for identifying key parameters of the LED module
and the LED power supply.
LED module:
LEP: Light engine PrevaLED®
6000: 6000 lm
740: CRI + CCT = CRI > 70 + 4000 K
CT3: Size 3
LEP - 6000 - 740 - CT3
LED power supply:
OT: OPTOTRONIC®
Wattage: 90 W
Input voltage: 220–240 V
Maximum output current: 700 mA
3DIM: DALI, StepDIM, AstroDIM
LT: LEDset
E: Exterior use
OT 90 / 220-240 / 700 3DIM LT E
OT: OPTOTRONIC®
Wattage: 35 W
Input voltage: 220–240 V
Maximum output current: 700 mA
LTCS: LEDset/current switch
OT 35 / 220-240 / 700 LTCS
5
INTRODUCTION
1.2.2. Technical data
All values regarding system efficiency and system power
consumption refer to the complete system and are measured at typical Tc (80 °C). For more information on Tc
measurement, see chapter 2.3.3.
LED module1), 2)
Vf max. at
Tamb -30 °C
LED module
(at Tc typ.)
+
LED power supply
(at Tc typ.)
Module power
[W]
Luminous flux
[lm]1)
Module
efficacy 3)
[lm/W]
CCT [K]
CRI
Beam angle [°]
Lifetime
(L85B10) at
Tc = 80 °C [h]2)
PrevaLED® Compact
LEP-2500740-CT2
53
21
2500
123
4000
70
120
60000
LEP-4000740-CT2
83
33
4000
122
4000
70
120
60000
LEP-6000740-CT3
108
52
6000
117
4000
70
120
60000
LEP-6000657-CT3
107
47
6000
129
5700
65
120
60000
LEP-8000740-CT3
148
69
8000
117
4000
70
120
60000
LEP-8000657-CT3
147
63
8000
130
5700
65
120
60000
LEP-10000740-CT3
188
78
10000
117
4000
70
120
60000
LEP-10000657-CT3
187
78
10000
130
5700
65
120
60000
Indoor ECG
Max. output
power [W]
Typ.
efficiency 5)
Max.
current [mA]
Control
Ta [°C]
Tc max. [°C]
Lifetime L90
at Tc point [h]
OT 35/220240/700 LTCS
35
88
700
LEDset
-25…+50
85
50000 at Tc = 75 °C
OT 45/220240/700 LTCS
45
89
700
LEDset
-25…+50
90
50000 at Tc = 80 °C
OT DALI 45/220240/700 LTCS
45
87
700
DALI and LEDset
-25…+50
85
50000 at Tc = 75 °C
Max. output
power [W]
Typ.
efficiency 5)
Max.
current [mA]
Control
Ta [°C]
Tc max. [°C]
Lifetime L90
at Tc point [h]
OT 50/220240/700 LT E
54
88
700
LEDset
-30…+60
85
85000 at Tc = 75 °C
OT 50/220240/700
3DIMLT(+) E
54
88
700
3DIM 4) and LEDset
-30…+60
85
85000 at Tc = 75 °C
OT 90/220240/700 LT E
90
90
700
LEDset
-30…+55
90
85000 at Tc = 80 °C
OT 90/220240/700
3DIMLT(+) E
90
90
700
3DIM 4) and LEDset
-30…+55
90
85000 at Tc = 80 °C
OT 150/220240/700 LT E
150
91
700
LEDset
-30…+55
85
85000 at Tc = 75 °C
OT 150/220240/700
3DIMLT+ E
150
91
700
3DIM4) and LEDset
-30…+55
85
85000 at Tc = 75 °C
Outdoor ECG
1) Target values, tolerance for optical and electrical data: ±10 %. Due to the special conditions of the manufacturing processes of LEDs, the typical data of technical parameters can only reflect statistical figures and do not necessarily correspond to the actual parameters of each single product, which could differ from the typical data.
2) The LED modules are designed for operation with OT OPTOTRONIC® ECGs. Exceeding maximum ratings for operating and storage temperature will reduce the
expected lifetime or destroy the light engine. The temperature of the LED module must be measured with a temperature sensor at the Tc point, according to
EN60598-1 and in thermally settled conditions. For the exact location of the Tc point, see the drawing in chapter 2.3.3. Tc location and measurement.
3) Minimum module efficacy. Efficacy will improve with the next LEDs with upcoming bin flux.
4) 3DIM: DALI + StepDIM + AstroDIM
6
5) At maximum load
INTRODUCTION
1.2.3. Possible system combinations
Within rated power and voltage range, PrevaLED®
Compact LED modules and OPTOTRONIC® LEDset
power supplies can be flexibly combined. Valid and possible combinations of LED modules and ECGs for indoor
and outdoor application are shown in the table below.
The connection between the LED module and the ECG
can be established by the provided cable kit. The cable
has a length of 600 mm and its wires are colored in order
to facilitate system assembly.
Attention: In order to comply with the Zhaga
standard, we recommend not to use cables longer
than 600 mm. If it should become necessary to use
a longer cable, however, the cabling can be extended up
to two meters.
Product name
OT 35/220240/700 LTCS
OT 45/220240/700 LTCS
OT DALI 45/220240/700 LTCS
OT 50/220240/700 (3DIM)
LT E
OT 90/220240/700 (3DIM)
LT E
OT 150/220240/700 (3DIM)
LT E
Min.
1
1
1
1
2
3
Max.
1
2
2
2
4
6
Min.
1
1
1
1
1
2
Max.
1
1
1
1
2
3
Min.
–
–
–
1
1
2
Max.
–
–
–
1
1
2
Min.
–
–
–
1
1
2
Max.
–
–
–
1
1
2
Min.
–
–
–
–
1
1
Max.
–
–
–
–
1
2
Min.
–
–
–
–
1
1
Max.
–
–
–
–
1
2
Min.
–
–
–
–
1
1
Max.
–
–
–
–
1
1
Min.
–
–
–
–
1
1
Max.
–
–
–
–
1
1
PrevaLED® Compact
LEP-2500740-CT2
LEP-4000740-CT2
LEP-6000740-CT3
LEP-6000657-CT3
LEP-8000740-CT3
LEP-8000657-CT3
LEP-10000740-CT3
LEP-10000657-CT3
Attention: All combinations are affected by the
maximum length of the cabling. Maximum cable
length from the OPTOTRONIC® LED power supply
to all LED modules connected in series must not be longer
than 2 m.
7
LUMINAIRE DESIGN
2. Luminaire design
2.1. Optical considerations
LEP-6000-740-CT3
The light intensity distribution is Lambertian. Thanks to
this characteristic, PrevaLED® Compact light engines are
suitable for several applications (both indoor and outdoor).
Moreover, designing proper secondary optics is easier under these conditions. The EULUMDAT file is available for
download at www.osram.com.
Intensity
2.1.1. Quality of light
The PrevaLED® Compact optical design consists of a linear distribution of several high-power LEDs in two or more
rows, as shown in the image above.
360
400
450
500
550
600
650
Wavelength (nm)
700
750
800 830
700
750
800 830
Wavelength spectrum of 4000-K LEDs
ϕ
0° 10° 20° 30° 40° 50° 60° 70° 80° 90°
1.0 l
rel
0°
45°
-40°
0.8
-50°
Intensity
-20°
-30°
-10°
0.6
-60°
0.4
-70°
360
0.2
-80°
400
450
500
550
600
650
Wavelength (nm)
Wavelength spectrum of 5700-K LEDs
-90°
58R
0.0
-100°
Radiation pattern: Typical Lambertian beam shape
8
LUMINAIRE DESIGN
2.1.2. CRI, CCT
The nominal available correlated color temperatures
(CCTs) of the LED modules are 4000 K and 5700 K. The
color rendering index (CRI) is > 65 for all LED modules
with a color temperature of 5700 K and >70 for LED
modules that utilize 4000-K LEDs. The color variation
from module to module is inside an ANSI bin.
5000 K
2.2.1. LED module dimensions
The figures below provide further details on the dimensions of the available PrevaLED® Compact LED modules.
3D model files are available on our website:
www.osram.com
Handle with care!
Please do not mechanically stress any components of
the LED module.
0.400
0.380
2.2. Mechanical considerations
4500 K
5500 K
0.360
cx
6000 K
kg
6500 K
0.340
7000 K
0.320
8000 K
0.300
0.280
0.300
0.320
0.340
0.360
0.380
cy
Color bin of PrevaLED® Compact LED modules with CCT: 5700 K
0.430
The LED modules of the PrevaLED® Compact family have
a metal-core PCB. Its dimensions and the dimensions of
the light-emitting surface are standardized according to
the requirements listed in “Zhaga specification book 4”.
3500 K
0.410
cx
0.390
h
4500 K
5000 K
0.370
d
0.350
0.330
0.345
0.365
0.385
0.405
0.425
b1 b
0.445
cy
Color bin of PrevaLED® Compact LED modules with CCT: 4000 K
l1
s
l
LED
module
Size
b
[mm]
b1
[mm]
l
[mm]
l1
[mm]
s
[mm]
h
[mm]
d
[mm]
LEP-xxxx2
xxx-CT2
39
29
95
21
22
6.7
3.2
LEP-xxxx3
xxx-CT3
46
36
110
30
26.5
6.7
3.2
9
LUMINAIRE DESIGN
2.2.2. LED power supply dimensions
2.2.3. Cable dimensions
5
3
∅ 1.6
h
h
600
w
w1 w
15
21.8
l1
l
l1
l
OT 35/45
18
OT 50/90
8.3
w1
w
h
All figures in mm
l1
l
OT 150
ECG
l [mm]
l1 [mm]
w [mm]
w1 [mm]
h [mm]
Cable colors *
Connection to
OPTOTRONIC® LEDset ECG
OT 35/220240/700 LTCS
123
111
79
67
33
Red
LED+
OT 45/220240/700 LTCS
123
111
79
67
33
Blue
+12 Vset
OT DALI
45/220-240/
700 LTCS
123
111
79
67
33
Light gray
GNDset
Violet
Vset
OT 50/220240/700 LT E
133
122.5
77
38.5
48
Black
LED-
OT 50/220240/700
3DIMLT(+) E
133
122.5
77
38.5
48
OT 90/220240/700 LT E
133
122.5
77
38.5
48
OT 90/220240/700
3DIMLT(+) E
133
122.5
77
38.5
48
OT 150/220240/700 LT E
170
160
100
90
40
OT 150/220240/700
3DIMLT(+) E
170
160
100
90
40
* Attention: The NTCset pin (orange) of the OPTOTRONIC® (if available)
shall not be connected to the PrevaLED® Compact LED module
10
LUMINAIRE DESIGN
2.3. Thermal considerations
While PrevaLED® Compact LED modules operate with the
smallest thermal losses possible, a substantial amount of
the LED module’s power must be dissipated through the
back of the LED module as specified.
For most of the applications, passive cooling is sufficient.
In case of critical applications, an active cooling combined
with a heat sink can maximize the cooling.
2.3.1. Heat sink material and size
For the selection of a suitable heat sink, several points
regarding thermal resistance have to be considered. The
table below lists the typical thermal resistance of available
heat sinking materials.
Material
Thermal conductivity
[W/(m*K)]
For satisfactory heat transfer and good cooling, the surface of the heat sink material also has to be taken into
consideration. Depending on the location of the particular
application, it can be an advantage to use black anodized
heat sinks to achieve the best heat transfer to the ambient
air.
For each LED module type, the thermal power has to be
dissipated as listed in the following table:
LED modules
Optical power [W]
Thermal power
dissipation [W]
LEP-2500-740-CT2
6
13
LEP-4000-740-CT2
9
21
LEP-6000-740-CT3
14
33
Copper
380–401
LEP-6000-657-CT3
14
33
Aluminium
200–220
LEP-8000-740-CT3
19
44
Brass
120
LEP-8000-657-CT3
19
44
Steel
42–58
LEP-10000-740-CT3
23
55
Stainless steel
15
LEP-10000-657-CT3
23
55
Glass
1
Wood
0.13–0.18
Air (dry at 1013 mbar,
no convection)
0.0256 at 20 °C
Rth =
L
A ·␭
A
L
11
LUMINAIRE DESIGN
The selection of a suitable heat sink is usually done
through the following steps:
Total power dissipation of the light engine
Max. ambient temperature Tamb
Max. reference temperature Tc according to lifetime requirements
Define boundary
conditions
TC - TA
R thCA =
Estimate heat sink thermal resistance
on light engine level
Thermal power
LED module
Use the estimated RthCA as a target for a possible heat
sink profile and examine the performance curve in the
catalog.
Select heat sink
thermal resistance
As soon as prototype luminaires are available, thermal
measurements must be performed to confirm the design.
Warning:
A safe and reliable operation can only be realized
with sufficient thermal management.
The diagram below can be used to estimate the cooling
performance of given aluminium heat sinks of different
sizes or to determine the approximate size of a heat sink
required for given ambient temperatures. Simulations
were done without any airflow turbulence. During testing,
the PrevaLED® Compact LED modules (size 3) were facing
downwards.
Temperature difference between Ta and Tc [°C]
100
10000 lm
8000 lm
6000 lm
90
80
70
60
50
40
30
20
10
0
0.00
0.05
0.10
0.15
0.20
0.25
0.30
0.35
0.40
0.45
0.50
Heat sink surface [m2]
The data presented here show a rough approximation of a real-case
application where the dimensions, shape and orientation of the heat
sink may change.
12
LUMINAIRE DESIGN
Gravity
42
10
70
4
95
Sample heat sink dimensioning
Let’s consider, for example, a 0.3-m2 heat sink. The diagram indicates a delta temperature of approximately 40 °C
from the Tc point to the ambient temperatures (6000-lm
LED module).
In reverse direction, with the given Tc temperature of 70 °C
(max.) and an ambient temperature of 10 °C, the resulting
temperature difference of 60 °C can be used to find the
approximate needed heat sink size for stable operation.
For the given temperatures and an LEP-10000 module,
this leads to an aluminium heat sink with a surface of
approximately 0.27 m2.
If, for example, AVC is considered as a supplier, the
following AVC heat sinks could be appropriate for the
approximation above:
Cooling type
Passive
Supplier
Product code
AVC
ST03D00001
ST03B00001
ST03W00002
Illustration
The list below shows a selection of suppliers of different
cooling solutions:
Active cooling systems:
Nuventix
Sunon
Cooler Master
www.nuventix.com
www.sunoneurope.com
www.coolermaster.com
Passive cooling systems:
AVC
Fischer Elektronik
Meccal
Wakefield
R-Theta
Cool Innovations
www.avc-cooling.com
www.fischerelektronik.de
www.meccal.com
www.wakefield.com
www.r-theta.com
www.coolinnovations.com
13
LUMINAIRE DESIGN
2.3.2. Thermal interface material
A PrevaLED® Compact LED module installed within a
luminaire with a correct thermal dissipation system does
not require the use of thermal interface material (TIM).
For particular applications, however, a TIM can be applied
between the back of the LED module and the luminaire
housing. The material has to be as thin as possible and
should reach the desired thermal conduction between the
surface of the LED module and the surface of the luminaire
housing. For this purpose, the planarity and smoothness
of the surface should be optimized.
The list below shows a selection of suppliers of different
thermal interface materials.
Thermal interface materials
Alfatec
Kerafol
Laird
Bergquist
Artic Silver
Wakefield
www.alfatec.de
www.kerafol.de
www.lairdtech.com
www.bergquistcompany.com
www.articsilver.com
www.wakefield.com
The temperature at the Tc point can be measured by using
a thermocouple which can be glued or soldered to the
LED module. Please make sure that the thermocouple is
fixed to the Tc point with a direct contact. Examples of
recommended thermocouples are shown below.
K-type thermocouple with miniature connector
Illustration
Description
Temperature range [°C]
PVC-insulated thermocouple
-10…+105
PFA-insulated thermocouple
-75…+260
Sprung thermocouple
-75…+260
2.3.3. Tc location and temperature measurement
The thermal conduction between the LED module and the
heat sink (often the luminaire housing) has to be verified
by measuring the temperature at the Tc point. The Tc point
is located on the back of the PCB, centered underneath
the LED’s light-emitting surface (see figure below).
Tc point
14
LUMINAIRE DESIGN
To measure the temperature and to ensure a good thermal
coupling between the LED module and the heat sink, it is
possible to create a small groove along the top surface of
the heat sink.
If a thermal interface material is installed between the LED
module and the heat sink, it is necessary to create a small
hole on it to ensure the direct contact to the metal-core
PCB.
The best solution to measure the temperature at the Tc
point is to use a sprung thermocouple and insert it inside
the heat sink as shown in the figure below.
If it isn’t possible to reach the back of the PCB, the temperature can be measured between the NTC and the LEDs
with a thermocouple installed at 1mm from the NTC (see
figure below). The temperature measured at this point will
be 2–3 °C lower than the one measured at the Tc point.
Warning:
Do not fix the thermocouple on an electrical contact, as this could distort the measurements and
electrical functionality. Do not use glue with acrylic for
hardening.
15
LUMINAIRE DESIGN
2.3.4. Overtemperature protection
To ensure best performance and a long lifetime of all components, the PrevaLED® Compact features an embedded
electronic circuit which decreases the input current when
the temperature at the Tc point reaches the critical value of
95 °C. The LED module switches off when a temperature
of 105 °C is reached and switches back on as soon the
LED module has cooled down below 90 °C.
Please consider that this protection only works if the LEDset interface of the PrevaLED® Compact LED module is
properly connected to an OSRAM OPTOTRONIC® LEDset
power supply.
LED operating
current
100 %
Thermal derating
100 mA
60
65
70
75
80
85
90
95
100
105
110
Tc temperature [°C]
2.4. Electrical considerations
2.4.1. Insulation coordination for PrevaLED®
Compact LED modules
All tests validating this kind of information were done with
OPTOTRONIC® ECGs. In accordance with EN 61347-2-13,
PrevaLED® Compact LED modules are suitable for a working voltage below 350 V and the isolation tests can ensure
a basic insulation of the LED module.
Regarding electromagnetic compatibility, PrevaLED® Compact LED modules have a performance criterion A for contact electrostatic discharge of up to 4 kV and for air
electrostatic discharge of up to 8 kV (according to EN
61000-4-2). Fast transient disturbance tests were always
passed with performance criterion A (according to EN
61547). For the fixation of the LED module (see chapter
3.1.) it is mandatory to use a fixing system that maintains
the proper creepage and clearance distances from live
parts (see chapter 3.3.).
2.4.2. Insulation coordination for OPTOTRONIC® ECGs
OPTOTRONIC® LED power supplies fulfill the following insulation requirements according to IEC 61347-1-13. These
parameters have to be respected in luminaire design. For
further details, please consult the data and instruction
sheets of LED power supplies.
ECG
Maximum
output voltage [V] *
SELV
Insulation
(primary/
secondary)
OT 35/220-240/
700 LTCS
100
Yes
Double
Class I and
class II
OT 45/220-240/
700 LTCS
120
Yes
Double
Class I and
class II
OT DALI 45/220240/700 LTCS
120
Yes
Double
Class I and
class II
OT 50/220-240/
700 LT E
120
Yes
Double
Class I and
class II
OT 50/220-240/
700 3DIMLT(+) E
120
Yes
Double
Class I and
class II
OT 90/220-240/
700 LT E
260
No
Double
Class I and
class II
OT 90/220-240/
700 3DIMLT(+) E
260
No
Double
Class I and
class II
OT 150/220-240/
700 LT E
350
No
Double
Class I and
class II
OT 150/220-240/
700 3DIMLT + E
350
No
Double
Class I and
class II
Recommended
luminaire
class
* Maximum possible output voltage. The real maximum allowed operating voltage
can be lower, see datasheet.
To ensure a long lifetime and a safe handling of the
LED power supply and the LED module, OPTOTRONIC®
LED power supplies are provided with the following
features:
• Overtemperature protection
• Short circuit protection
• Overload protection
For more information, please refer to the corresponding
OPTOTRONIC® datasheets.
16
LUMINAIRE DESIGN
2.4.3. Wiring information
The recommend wire cross sections which have to be
used with OPTOTRONIC® ECGs are listed in the following
table.
OPTOTRONIC® input/output
Wire cross sections [mm2]
OT 50-90-150
3DIMLT(+)/LT E
OT 35-45
LTCS
Mains
0.25–2.5
0.2–1.5
Equipotential pole
0.25–1.5
0.2–1.5
LED +
0.25–1.5
0.2–1.5
LED -
0.25–1.5
0.2–1.5
GNDset
0.2–0.5
0.2–0.5
Vset
0.2–0.5
0.2–0.5
+12 Vset
0.2–0.5
0.2–0.5
The cable material is UL-approved (E84703) and fulfills
flammability requirements according to UL 94 V-0. The
temperature range of the cable is -55 to +125 °C. It is possible to use a further sheath to cover all the wires (not included in the kit). In this case, the minimum diameter of
the resulting cable is 5.9 mm.
The connection between the ECG and the LED module
should be established by using the provided cable kit
(length: 600 mm). For an easier connection to the ECG, the
cables are pre-stripped and all five wires have the same
colors as the OPTOTRONIC® output cable clamps.
Wire colors
B
B
Black
OT terminals
Violet
Light gray
Red
LED+
Blue
+12 Vset
Light gray
GNDset
Violet
Vset
Black
LED-
Blue
Red
∅ 5.90
0.45
All figures in mm
B-B
5:1
17
LUMINAIRE DESIGN
Ensure that the LED module is correctly connected to the
ECG. The following table can help to troubleshoot a wiring
problem if it is used with an OPTOTRONIC® ECG with
LEDset:
Disconnected wire
OSRAM
ECG pin
Behavior
Cable 1 (red)
LED+
LED module shuts down, no current in seriesconnected LEDs, current only in the LEDset
circuit
Cable 2 (blue)
+12 Vset
LED module runs at minimum current (75 mA)
Cable 3 (light gray)
GNDset
LT E version:
ECG shuts down
3DIMLT E version:
LED runs at maximum current of the ECG
(LEDset protection disabled, default)
3DIMLT E version:
ECG shuts down (LEDset protection enabled)
LTCS version:
ECG shuts down (DIP switch = LEDset)
LTCS version:
ECG runs at current selected by the DIP switch
Cable 4 (violet)
Vset
Cable 5 (black)
LED-
LED module shuts down, no current in seriesconnected LEDs, current only in the LEDset
circuit
Attention:
For 3DIMLT and 3DIMLT+, the LEDset protection
needs to be enabled via the 3DIM Tool in the
OPTOTRONIC® configuration tab. For the LT version,
the LEDset protection is enabled by default. The LEDset
protection allows to switch off the ECG in case of a broken
wire to avoid any thermal damage to the LED module due
to high currents.
2.4.4. Electrostatic discharge (ESD)
PrevaLED® Compact LED modules require special ESDsafe handling procedures in a production environment. To
improve the ESD and surge protection of the system, a
thermal interface material can be used between the LED
module and the heat sink/luminaire housing. Details on installation can be found in chapter 3. Installation guide.
2.4.5. Current setting and thermal protection
The PrevaLED® Compact LED module features a particular
on-board electronic circuit that sets the current needed to
ensure the specific lumen output of the LED module. In
addition, this circuit monitors the temperature of the module and reduces the LEDs’ current, if required. These two
features are available only if the LED module is connected
to the OPTOTRONIC® ECG via LEDset interface.
LEDset allows:
• A faster installation since the current of the OT is set
automatically by the PrevaLED® Compact LED module
itself.
• To set the right current without any other kind of electronic device and without programming the OT.
• In case of wrong installation or working temperatures exceeding the rated Tc value, the safety of the LED module
is assured by the thermal protection.
Warning:
If the LED module is not connected to the
OPTOTRONIC® LED power supply using the LEDset interface, there is no thermal protection. All information
necessary to use this LED module with other ECGs can be
found in the PrevaLED® Compact datasheet.
Warning:
In case of LED+ or LED- disconnection, disconnect
the mains voltage and wait up to 20 seconds before reinstalling the LED module.
18
LUMINAIRE DESIGN
The flux bin can be found on the front of the LED module:
Example: The LED module LEP 6000-740 (MU) is required
to have a flux of 5400 lm instead of a nominal flux of 6000
lm (-10 %). The nominal flux is achieved at Ityp = 500 mA. By
using the graph, it can be easily checked that the LED current has to be reduced from 500 mA to about 425 mA.
Please refer to the PrevaLED® Compact datasheet for the
Ityp values.
Flux/Flux nom.
Flux bin
An output flux different from the rated value can be obtained by setting the LED current manually without using
the LEDset interface. Refer to the graph on the right for
the evaluation of the required LED supply current in order
to achieve the desired flux change. Please note that the
output flux values shown in the graph are normalized in
respect to flux at 700 mA, even if the typical current of the
LED module can be lower.
1.4
1.3
1.2
1.1
Required flux
1
reduction: 10 %
0.9
0.8
0.7
0.6
0.5
0.4
0.3
200 250 300 350 400 450 500 550 600 650 700 750 800 850 900 950 1000
I [A]
LED current has to be reduced
from 500 mA to 425 mA
Attention:
This operation mode is highly recommended only
in case of a reduction of the LED supply current in
respect to the nominal value.
19
LUMINAIRE DESIGN
2.4.6. Wiring in protection class I and II luminaires
OPTOTRONIC® LED power supplies of the 3DIMLT(+) E
and LT E family are designed for different luminaires. Independent of the luminaire class, it is always recommended to connect the equipotential pin (pink color) of the OT
50, 90 and 150 to the heat sink of the LED module. This
connection allows achieving a better protection of the LED
module in case of asymmetric over-voltages or surges on
the main supply (between L/N and earth (ground)).
LED luminaire, protection class I
Class I luminaires
The PE wire must be connected to touchable metal parts
of the luminaire. It is highly recommended to connect the
PE of the luminaire to the equipotential pin (pink color) of
the OPTOTRONIC® 3DIMLT(+)/LT E as well.
LED luminaire, protection class II
Class II luminaires
No PE wire is used in these installations. It is recommended, however, to connect the equipotential pin (pink color)
of the OPTOTRONIC® 3DIMLT(+)/LT E to the heat sink of
the LED module to improve the surge withstand capability
of the LED module.
20
INSTALLATION GUIDE
3. Installation guide
3.1. Installation of one LED module inside a luminaire
Note: The installation of LED systems (LED modules and
ECGs) needs to be carried out in compliance with all applicable electrical and safety standards. Only qualified personnel should perform installations.
To get a better understanding of the LED module concept
and the design of a luminaire, the following pages will lead
through a typical design-in. The PrevaLED® Compact LED
module is fixed by four M3 screws according to ISO 68-1.
These screws should be applied using a torque in the
range of 0.3–0.5 Nm. The usage of a TIM does not change
the torque needed.
3.2. Installation of more than one LED module
inside a luminaire
If more than one PrevaLED® Compact LED module is
installed within one luminaire using the same ECG, only
one LEDset interface can be connected to the LED power
supply. Connect the LEDset to the LED module that can
reach the highest temperature. Please isolate the cables
of the second LEDset interface (see schematic below):
Lmax. = 2 x 2 m
Warning:
Excessive torque on the mounting screws may
cause damage to the LED module.
Each wire has to be
insulated seperately
Two or more LED modules have to be connected in series
if they are installed with the same ECG.
First, mount the PrevaLED® Compact LED module
(perhaps, if needed, with an additional heat sink) and the
ECG into the luminaire. To fixate the ECG, use the screws
recommended in the datasheet of the OPTOTRONIC® LED
power supply. Connect the cable between the ECG and
the PrevaLED® Compact.
Warning:
Never wire PrevaLED® Compact LED modules
with different lumen packages to the same ECG
as this might destroy the modules.
21
INSTALLATION GUIDE
+
D2
D1
D3
D1
+
LED cluster (all copper areas in blue)
LED
module
D1 [mm]
D2 [mm]
D3 [mm]
LEP-xxxx-xxx-CT2
9.4
11.8
7.7
LEP-xxxx-xxx-CT3
9.4
13.3
10
16.15
3.35
4.95
The green-marked regions on the PrevaLED® Compact
LED module below are the live parts of the module.
Please maintain the needed creepage and clearance
distances to any accessible live part.
Warning:
All metal contacts of the electronic components,
all test points and also the copper traces covered
with solder mask have to be considered live parts. When
fixing the light engine to the luminaire, consider that the
distances D1, D2 and D3 between live parts have the value shown in the table below.
16.15
3.3. Creepage and clearance
In order to meet safety requirements during luminaire design with PrevaLED® Compact LED modules, particular attention must be paid to creepage and clearance distances
(consider IEC 60598).
Electronic circuit
22
INSTALLATION GUIDE
3.4. Constant lumen module (CLM)
In some applications, it can be useful to compensate the
normal lumen output degradation of LED modules with a
programmed current increase. Through the 3DIM Tool
software, the operating current can be set to compensate
the lumen degradation over the lifetime.
DALI magic
3DIM Tool
USB
DALI
Optional LED
power supply
Setup of the 3DIM Tool
up to 64 devices
Working hours [h]
OT current [%]
0
83
5000
84
10000
85
15000
87
20000
88
25000
90
30000
91
35000
92
40000
94
45000
95
50000
97
55000
98
60000
100
DA ~
LED current
Flux (no CLM)
Output [%]
100 %
80 %
Guaranteed light level
How to configure the constant lumen module in the 3DIM Tool
Time [kHrs]
Warning:
With a set current exceeding the nominal current of
the module, the warranty does not apply.
Without CLM
LED current
Flux (with CLM)
Output [%]
100 %
80 %
Guaranteed light level
Time [kHrs]
With CLM
With CLM, the constant luminous flux of the LED module
can be reduced down to 70 % of the nominal luminous flux
(100 %).
The initial current of an LEP 4000-740-CT2 with an active
CLM and an ensured light level of 3400 lm, for instance,
is 17 % lower than the typical nominal value, therefore
requiring a constant lumen module (CLM) starting value
of 83 %.
3.5. IP rating
The PrevaLED® Compact has no special IP rating.
The following table helps identifying the power level that
has to be set in the OPTOTRONIC® 3DIM ECG:
23
NORMS AND STANDARDS
4. Norms and standards
4.1. Norms and standards for PrevaLED® LED modules and light engines
Electromagnetic compatibility:
EN
EN
EN
EN
EN
EN
55015
61547
61000-4-2
61000-4-3
61000-4-4
61000-4-6
Photobiological safety:
IEC 62471
LED module safety:
EN 62031
UL 8750
Vibration, tensile strength:
EN 60068-2-6
EN 60068-2-21
Temperature, corrosion stress:
JESD22-A105-C
JESD22-A103
JESD22-A101-C
EN 60068-2-2
EN 60068-2-11
4.2. Photobiological safety
The evaluation of photobiological safety is carried out according to the standard IEC 62471:2006
(“Photobiological safety of lamps and lamp systems”). Following the definition of the risk grouping
system of the mentioned IEC standard, the LEDs mounted on PrevaLED® Compact light engines
fall into the class “Moderate risk (RG2 – max. exposure time: 59 s)”.
Under real circumstances (regarding exposure time, pupils, observation distance), it is assumed that
there is no endangerment to the eye from these devices. As a matter of principle, however, it should
be mentioned that intense light sources have a high secondary exposure potential due to their blinding
effect.
For this kind of product, the marking “Caution! Possibly hazardous optical radiation emitted
from this product” is necessary.
Important note: OSRAM products must never be directly exposed to external influences.
Always provide adequate protection for relevant outdoor applications (covers, housings etc.)
and never operate the products in or under water. For more information on ingress protection,
please see the technical application guide “IP codes in accordance with IEC 60529” at www.osram.com
24
OSRAM GmbH
Head Office
Marcel-Breuer-Strasse 6
80807 Munich
Germany
Phone +49 (0)89-6213-0
Fax +49 (0)89-6213-20 20
www.osram.com
06/13 Subject to change without notice. Errors and omission excepted.
www.osram.com
www.osram.de