www.osram.com/outdoor 10/2014 Technical application guide STREETLIGHT IP G1 Light is OSRAM STREETLIGHT IP G1 | Contents Contents 1 Introduction 03 4 Lumen output setting 14 2 STREETLIGHT IP product family 04 5 Standards 15 2.1 System overview 04 5.1 Norms and standards for STREETLIGHT IP LED modules 15 2.2 Nomenclature and marking 05 5.2 Photobiological safety 15 3 STREETLIGHT IP design-in 06 3.1 Optical considerations 06 3.2 Mechanical considerations 08 3.2.1 LED module dimensions 08 3.2.2 LED driver dimensions 09 3.2.3 IK rating 09 3.3 Thermal considerations 09 3.3.1 Location of the tc point and temperature measurement 10 3.3.2 Overtemperature protection 10 3.4 Electrical considerations 11 3.4.1 Insulation coordination 11 3.4.2 Insulation coordination for OPTOTRONIC ® LED drivers 11 3.4.3 Wiring information 11 3.4.4 Electrostatic discharge (ESD) 12 3.4.5 Current setting and thermal protection 12 3.4.6 Wiring in protection class I and II luminaires 13 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. Please make sure you’re always using the most recent version of the application guide. 2 STREETLIGHT IP G1 | Introduction 1 Introduction LED systems are able to exploit their inherent advantages in street lighting and outdoor lighting: They provide the required lighting level with homogeneous illumination and consume less energy than traditional lamps. The long lifetime of LEDs with only low decreases in luminous flux are also ideal for the long life cycles needed in outdoor lighting. With STREETLIGHT IP, OSRAM provides an innovative, IP66-protected LED module for street lighting, enabling extremely short luminaire development cycles. The innovative reflector concept ensures standard-compliant lighting (in accordance with EN 13201) while providing a very high quality of light and high efficiency, as well as a future-proof platform for further advancements in LED technology. Benefi ts of STREETLIGHT IP — Fast time to market thanks to easy design-in — Typical efficacy: 85–100 lm/W (including cover, even within demanding lighting applications) — High quality of light, low glare, no scattered light — Very long lifetime: 100,000 hours with L80/B10 — Very effective thermal management due to uniform heat dissipation over the complete rear surface — Plug-and-play: Via the LEDset interface, the operating current and temperature protection are automatically programmed to the right values when used with an OPTOTRONIC ® 3DIMLT+ LED driver. This technical application guide focuses on the utilization of the STREETLIGHT IP family in luminaire design. Further information (such as data sheets, EULUMDAT, CAD files) is available at www.osram.com. 3 STREETLIGHT IP G1 | STREETLIGHT IP product family 2 STREETLIGHT IP product family The following modules are currently available. Module with four refl ector clusters ME class Pedestrian crossing S class/cycleway 3000 K, 4000 K, 5000 K left or right 3000 K, 4000 K, 5000 K 4000 K Module with two refl ector clusters ME class 3000 K, 4000 K 2.1 System overview STREETLIGHT IP modules are optimized for use with OSRAM OPTOTRONIC® LED drivers equipped with the LEDset interface. In this system combination, the LED modules and the LED drivers provide maximum performance and operational safety, including automatic setting of operating current and overtemperature protection. Note: For further details on the usage of OPTOTRONIC® LED drivers, please consult the respective data sheets and guides provided at www.osram.com. 4 STREETLIGHT IP G1 | STREETLIGHT IP product family 2.2 Nomenclature and marking OSRAM products follow a consistent naming convention for identifying key parameters of the LED module and the LED driver. Note: For all technical product data and recommended system combinations, please consult the data sheets provided at www.osram.com. LED module ST IP: STREETLIGHT IP G1: First generation 6000: 6000 lm 740: CRI + CCT = CRI > 70 + 4000 K 4M: four reflector clusters, ME-class light distribution ST IP G1 6000 740 4M LED driver OT: OPTOTRONIC® Wattage: 90 W Input voltage: 220–240 V Maximum output current: 700 mA 3DIM: DALI, StepDIM, AstroDIM LT+: LEDset + NTC E: Exterior use OT 90 / 220-240 / 700 3DIM LT+ E 5 STREETLIGHT IP G1 | STREETLIGHT IP design-in 3 STREETLIGHT IP design-in By design, STREETLIGHT IP LED modules offer a very quick and relaxed luminaire development process, solving many potential issues already on module level (e.g. optics, IP, IK, heat dissipation etc.). 3.1 Optical considerations STREETLIGHT IP LED modules come with dedicated light distributions and in various color temperatures. As far as the optical concept is concerned, the module consists of several LEDs mounted in groups beneath the reflector array, guiding the light to the road surface. Once more efficient components are available, this concept allows reducing the number of LEDs without compromising the light distribution. Currently, there are three different color temperatures available: 3000 K, 4000 K and 5000 K. The nominal color rendering index (CRI) is 70 for all LED modules. The color variation from module to module is inside two ANSI bins. 6 STREETLIGHT IP G1 | STREETLIGHT IP design-in The following light distributions are currently available: ME class: ST IP G1 xxxx yyy zM S class: ST IP G1 xxxx yyy zS C0-C180 cd/1000 lm C90-C270 C0-C180 cd/1000 lm 180° 180° 380 150° 980 150° 150° 285 120° 120° 120° 245 90° 90° 90° 90° 245 95 190 60° 490 60° 30° 30° 980 0° 0° Pedestrian crossing left: ST IP G1 xxxx yyy zPL C0-C180 Pedestrian crossing right: ST IP G1 xxxx yyy zPR C90-C270 C0-C180 cd/1000 lm 180° 760 150° 150° 540 120° 120° 120° 380 180 190 90° 90° 90° 90° 190 18 180 360 60° 380 60° 540 30° 150° 570 360 60° C90-C270 180° 720 120° 30° 380 150° 60° 735 285 cd/1000 lm 120° 490 95 30° 150° 735 190 60° C90-C270 60° 570 30° 30° 30° 720 760 0° 0° EULUMDAT files for each module can be downloaded at www.osram.com. 7 STREETLIGHT IP G1 | STREETLIGHT IP design-in 3.2 Mechanical considerations STREETLIGHT IP LED modules consist of a metal-core PCB which is built into an aluminum housing and covered by a polycarbonate (PC) cover which ensures IP66 protection for the LED module and the reflector. Note: To enable an air exchange between the membrane and the ambient air, the membrane on the back surface of the module must not be firmly covered. 3.2.1 LED module dimensions Detailed CAD models can be downloaded at www.osram.com. 35 102 154 137 Membrane 27 240 310 256 Back view, size 4: ST IP G1 xxxx yyy 4zz Top view, size 4: ST IP G1 xxxx yyy 4zz 102 154 137 Membrane 104 35 27 120 174 Note: Mechanical stress can damage the module. 107 ° 40.4 5.3 32.5 Back view, size 2: ST IP G1 xxxx yyy 2zz 21.8 Top view, size 2: ST IP G1 xxxx yyy 2zz 97 123 Profile, all sizes kg In addition to the mounting holes depicted above, the LED modules have four blind holes on the back, which allow an easy connection to the heat sink using four self-cutting M4 screws. All fi gures in mm, except where indicated otherwise 8 STREETLIGHT IP G1 | STREETLIGHT IP design-in 3.3 Thermal considerations w w1 w h h 3.2.2 LED driver dimensions l1 l l1 l Note: A safe and reliable operation is possible only with sufficient thermal management. While STREETLIGHT IP LED modules operate with the smallest thermal losses possible, a substantial amount of the LED module’s power must nevertheless be dissipated through the back, as specified below. The thermal power is spread evenly over the aluminum housing of the module, so that it can be easily cooled in a passive way. For each LED module type, the thermal power has to be dissipated, as listed in the following table: OPTOTRONIC ® dimensions Thermal power LED driver l [mm] l1 [mm] w [mm] w 1 [mm] h [mm] OT 50/220-240/700 3DIMLT+ E 133 122.5 77 38.5 48 OT 90/220-240/700 3DIMLT+ E 133 122.5 77 38.5 48 OT 150/220-240/700 3DIMLT+ E 170 160 100 90 40 3.2.3 IK rating In compliance with EN 62262, STREETLIGHT IP LED modules have an IK rating of IK08 on module level. Even higher ratings can be achieved within the luminaire. STREETLIGHT IP Thermal power at I typ [W] ST IP G1 2700 730 2M 26 ST IP G1 3000 740 2M 26 ST IP G1 3700 730 4S 39 ST IP G1 4000 740 4S 39 ST IP G1 4000 750 4S 37 ST IP G1 5500 730 4M 52 ST IP G1 6000 740 4M 52 ST IP G1 6000 750 4M 50 ST IP G1 5500 740 4PL 53 ST IP G1 5500 740 4PR 53 9 STREETLIGHT IP G1 | STREETLIGHT IP design-in 3.3.1 Location of the tc point and temperature measurement The heat dissipation between the LED module and the heat sink (often the luminaire housing) has to be verified by measuring the temperature at the tc point with a temperature sensor (see figure below), according to EN 60598-1 in thermally settled conditions. Note: Exceeding maximum ratings for operating and storage temperatures will reduce the expected lifetime or destroy the LED module. 3.3.2 Overtemperature protection To ensure the best performance and a long lifetime of all components, STREETLIGHT IP LED modules feature an embedded electronic circuit which decreases the input current when the temperature at the tc point reaches 77 °C. The LED module switches off when a temperature of 89 °C is reached and switches back on as soon the LED module has cooled down below 84 °C. Please consider that this protection only works if the LEDset interface of the STREETLIGHT IP LED module is properly connected to an OSRAM OPTOTRONIC® LEDset driver with NTC terminal. LED module with four reflector clusters STREETLIGHT IP thermal protection via LEDset interface tc Power supply output current [%] Pre-programmed thermal protection of the STREETLIGHT IP LED module 100 % LED module with two reflector clusters 50 % tc 77 84 89 tc temperature [°C] STREETLIGHT IP, tc point location The following table provides the operating current limit for using the module without an additional heat sink, thus staying below the rated maximum tc temperature of 68 °C. Apart from the fixed temperature protection depicted above, an individual protection logic can be defined via the 3DIM Tool software. The NTC used on the STREETLIGHT IP module is "EPCOS B57423V2473H". Operation without heat sink Further information on the usage and capabilities (e.g. constant lumen function) of the 3DIM Tool software can be found at www.osram.com/3dim. STREETLIGHT IP Ambient Max. current w/o heat sink (< tc 68 °C) temperature ST IP G1 2700 730 2M ~ 550 mA ST IP G1 3000 740 2M ~ 550 mA 25 °C ST IP G1 3700 730 4S ~ 550 mA 25 °C ST IP G1 4000 740 4S ~ 550 mA 25 °C ST IP G1 4000 750 4S ~ 550 mA 25 °C ST IP G1 5500 730 4M ~ 450 mA 25 °C ST IP G1 6000 740 4M ~ 450 mA 25 °C ST IP G1 6000 750 4M ~ 450 mA 25 °C ST IP G1 5500 740 4PL ~ 450 mA 25 °C ST IP G1 5500 740 4PR ~ 450 mA 25 °C 25 °C 10 STREETLIGHT IP G1 | STREETLIGHT IP design-in 3.4 Electrical considerations 3.4.1 Insulation coordination All tests validating the information given in this chapter were done with OPTOTRONIC® LED drivers. STREETLIGHT IP LED modules are suitable for working voltages below 350 V and provide basic insulation. Regarding electromagnetic compatibility, STREETLIGHT IP LED modules show 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 also passed with performance criterion A (according to EN 61547). 3.4.3 Wiring information The STREETLIGHT IP system features the OSRAM LEDset interface. LEDset allows for automatic current setting and temperature protection. The wire cross sections which have to be used with OPTOTRONIC ® LED drivers are listed in the following table. Wire selection OPTOTRONIC ® input/output 3.4.2 Insulation coordination for OPTOTRONIC ® LED drivers OPTOTRONIC ® LED drivers fulfill the following insulation requirements according to EN 61347-2-13. These parameters have to be respected in luminaire design. For further details, please consult the data and instruction sheets. OPTOTRONIC ® output characteristics LED driver Maximum SELV output voltage [V] * Insulation (primary/ secondary) Recommended luminaire class OT 50/220-240/ 700 3DIMLT+ E 120 Yes 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 3DIMLT+ E 350 No Double Class I and class II * Maximum possible output voltage. The real maximum allowed operating voltage can be lower, see data sheet. To ensure a long lifetime and a safe handling of the LED driver and the LED module, OPTOTRONIC® LED drivers are provided with the following features: — Overtemperature protection — Short circuit protection — Overload protection For more information, please consult the corresponding OPTOTRONIC ® data sheets. Wire cross sections [mm 2] OT 50-90-150 3DIMLT+E Mains 0.25–2.5 Equipotential pin 0.25–1.5 LED+ 0.25–1.5 LED- 0.25–1.5 GNDset 0.2–0.5 Vset 0.2–0.5 +12 Vset 0.2–0.5 For an easy connection of the LED driver and the LED module, the STREETLIGHT IP LED module comes with pre-stripped cables. All five wires (for LED driver and LEDset) have the same colors as the OPTOTRONIC® output cable clamps. Ensure that the LED module is correctly connected to the LED driver. The cable is rated for an ambient temperature of -40 °C to 80 °C. Color coding Wire colors OT terminals Red LED+ Black LED- Light gray LEDset GNDset Violet LEDset Vset Orange LEDset NTCset 11 STREETLIGHT IP G1 | STREETLIGHT IP design-in Wiring one module GNDset Vset Wiring two modules Grey GNDset Violet Vset +12Vset LEDLED+ Violet +12Vset Orange NTCset Black Red STREETLIGHT IP OPTOTRONIC ® LED driver OPTOTRONIC ® LED driver NTCset Grey LEDLED+ DA DA DA DA SD SD N N L L Orange Black Red STREETLIGHT IP STREETLIGHT IP Note: The LEDset protection has to be enabled via the 3DIM Tool in the OPTOTRONIC® configuration tab. The LEDset protection automatically switches off the LED driver in case of a broken wire to avoid any damages to the LED module due to overheating. In case LED+ or LED- is disconnected during operation, disconnect the mains voltage and wait at least 20 seconds before reconnecting the LED module. In general, the maximum cable length from the OPTOTRONIC® LED driver to all LED modules connected in series must not be longer than 2 m. In case investigations on longer cables are needed, please contact OSRAM application engineering for support. 3.4.4 Electrostatic discharge (ESD) STREETLIGHT IP LED modules require special ESD-safe handling procedures in a production environment. 3.4.5 Current setting and thermal protection STREETLIGHT IP LED modules feature an on-board electronic circuit that sets the current needed to ensure the nominal lumen output of the LED module. In addition, an NTC monitors the temperature of the module and causes a reduction of the current, if required. Both features are available only if the LED module is connected to an OPTOTRONIC ® LED driver via LEDset interface with NTC terminal. Note: Thermal protection won’t be active if the LED module is not connected to the NTC terminal of the OPTOTRONIC® LED driver. All information necessary to use the LED module with other drivers can be found in the STREETLIGHT IP data sheet. 12 STREETLIGHT IP G1 | STREETLIGHT IP design-in 3.4.6 Wiring in protection class I and II luminaires OPTOTRONIC ® LED drivers of the 3DIMLT+ E family are designed to fit protection class I and II luminaires. Independent of the luminaire class, it is always recommended to connect the equipotential pin (pink color) to the heat sink of the LED module. This connection allows achieving a better protection of the LED module in case of asymmetric overvoltages or surges on the main supply (between L/N and earth (ground)). Class I luminaires The PE wire must be connected to touchable metal parts of the luminaire. It is strictly recommended to connect the PE of the luminaire to the equipotential pin (pink color) of the OPTOTRONIC ® 3DIMLT+ E as well. Connect equipotential pin to heat sink and PE STREETLIGHT IP LED module OPTOTRONIC ® LED driver 3DIMLT+ LED luminaire class I Class II luminaires No PE wire is used in these installations. It is strictly recommended to connect the equipotential pin (pink color) of the OPTOTRONIC ® 3DIMLT+ E to the heat sink of the LED module to improve the surge withstand capability of the LED module. Connect equipotential pin to heat sink STREETLIGHT IP LED module OPTOTRONIC ® LED driver 3DIMLT+ LED luminaire class II 13 STREETLIGHT IP G1 | Lumen output setting 4 Lumen output setting In some applications, it will be mandatory to lower the lumen output of the module. This can be achieved by reprogramming the output current of the OPTOTRONIC® LED driver. Reprogramming is carried out via the 3DIM Tool software, while connecting the LED driver to a computer, using the DALI magic hardware interface. DALI magic 3DIM Tool USB DALI Optional LED driver Setup of the 3DIM Tool Up to 64 DA ~ devices 3DIM Tool and DALI magic setup Further information on the usage and capabilities (e.g. constant lumen function) of the 3DIM Tool software can be found at www.osram.com/3dim. 14 STREETLIGHT IP G1 | Standards 5 Standards 5.1 Norms and standards for STREETLIGHT IP LED modules 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 IEC/TR 62471-2 LED module safety: EN 62031 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 Degree of protection provided by enclosure: EN 60529 EN 62262 5.2 Photobiological safety The evaluation of photobiological safety is carried out according to IEC 62471:2006 (“Photobiological safety of lamps and lamp systems”). With regard to photobiological safety, the module can be classified in Risk Group (RG) 1, low risk according to EN 62471. This product shall be positioned so that prolonged staring into the module at a distance closer than 0.35 m is not to be expected. 15 10/14 OSRAM S-GI MK EM Subject to change without notice. Errors and omissions excepted. www.osram.com/outdoor OSRAM GmbH Head office: Marcel-Breuer-Strasse 6 80807 Munich, Germany Phone +49 89 6213-0 Fax +49 89 6213-2020 www.osram.com