www.osram.com/boxled MAY 2013 Technical application guide BoxLED Back Plus CONTENT Content 1. Product overview BoxLED Back Plus 3 6. Application overview 11 1.1. General features 3 6.1. Selection table for BoxLED Back Plus in light boxes 11 1.2. Applications 3 6.2. Luminance as a function of transmission 11 1.3. BoxLED mounting profile BX-MP 4 6.3. Luminance as a function of return depth 12 1.4. Backlighting with BoxLED Back Plus 4 6.4. Dimming matrix 13 6.5. Power output rating 13 7. Thermal properties 14 7.1. Casing temperature at the Tc point 14 1.5. Options for installing BoxLED Back Plus with the BX-MP mounting profile 1.6. Technical data at a glance 5 5 2. Product overview OPTOTRONIC power supplies 6 7.2. Measuring the Tc temperature 15 3. System combinations LED modules – OPTOTRONIC power supplies 7 8. Installation instructions 16 4. Product identifiers 8 9. Standards and regulations for LED modules and power supplies 18 5. Electrical properties 9 10. Notes 19 5.1. Electrical connections 9 10.1. General notes 19 5.2. Electrical connectors 10 10.2. Safety information 19 11. Tools and links 20 5.2.1. General 10 5.2.2. Overview of connectors 10 Disclaimer: All the information in this guide has been produced with the utmost care. However, OSRAM does not accept any liability for possible errors, changes and/or omissions. Please check www.osram.com/boxled to see whether a more recent version of this guide is available, or get in touch with your sales contact. 2 PRODUCT OVERVIEW BoxLED Back Plus 1. Product overview BoxLED Back Plus 1.1. General features • Maximum versatility for backlighting • Quick and easy installation by click-in of the module into the BoxLED mounting profile (screw connection and sticking also possible) • Flat-Ray Technology provides uniform illumination at large LED pitches • Type of protection for LED modules: IP66 • Full encapsulation protects against corrosion when applied in closed light boxes • Optimal module operation in combination with an OPTOTRONIC power supply 1.2. Applications • Signage and illuminated advertising • Backlighting of single and double-sided light boxes BoxLED Back Plus BoxLED Back Plus All figures in mm 3 PRODUCT OVERVIEW BoxLED Back Plus 1.3. BoxLED mounting profile BX-MP The universal mounting profile for all types of BoxLED modules provides the basis for quick and easy installation in single-sided and double-sided light boxes. 1.4. Backlighting with BoxLED Back Plus 1 2 3 4 Slot holes for the mounting of the profile on the rear board or side board of the light box. 2 Holes for the easy installation of a mounting grid. The constant hole spacing of 55 mm provides consistent pitches of LED modules without measuring. 3 Square holes for simple fixing of electrical cables with cable ties. 4 Embossings/edges for the easy click-in of the individual LED modules (Click & Play). 1 Single-sided backlighting Double-sided backlighting 4 PRODUCT OVERVIEW BoxLED Back Plus 1.5. Options for installing BoxLED Back Plus with the BX-MP mounting profile Possible pitches and positioning of the profiles The following graphics show the typical pitches and positioning of the profiles. Different arrangements are possible depending on the application. Be aware however that larger LED pitches mean that the depth of the light box will have to be increased. Single-sided backlighting Double-sided backlighting 3 x 55 mm = 165 mm 3 x 55 mm = 165 mm 1.6. Technical data at a glance Product reference Product number Light color No. of LED modules per chain (no. of LEDs per module) Rated output per chain (per module) [W]1) Luminous Beam flux per chain angle [°]1) (per module) [lm]1) Color temperature [K]1) DC voltage [V]1) Standard pack/ pcs. BoxLED Back Plus BX06BAW4F-765 4008321828842 White 32 (6) 115.2 (3.6) 9280 (290) 155 6500 24 1 BX06BAW4F-840 4008321828965 White 32 (6) 115.2 (3.6) 7680 (240) 155 4000 24 1 BX06BAW4F-830 4008321829047 White 32 (6) 115.2 (3.6) 7680 (240) 155 3000 24 1 – – – – – – – 24 BoxLED mounting profile BX-MP 4008321981110 Modules are perfectly matched to 24 V OSRAM OPTOTRONIC power supplies. For current photometric data and important safety, installation and application information, see www.osram.com/led-systems. 1) In view of the complex manufacturing process for light-emitting diodes, the specified typical values for the technical LED parameters are merely statistical values that do not necessarily correspond to the actual technical parameters of an individual product; individual products may vary from the typical values. 5 PRODUCT OVERVIEW OPTOTRONIC POWER SUPPLIES 2. Product overview OPTOTRONIC power supplies 24 V range for BoxLED Back Plus Power supply OT 80/220-240/24 P OT 80/220-240/24 DIM P OT 120/220-240/24 P OT 120/220-240/24 DIM P OT 240/220-240/24 P OT 240/220-240/24 DIM P AC voltage, nominal 220–240 VAC 220–240 VAC 220–240 VAC Output voltage 24.0 VDC - 0.5/+ 1.0 V 24.0 VDC - 0.5/+ 1.0 V 24.0 VDC - 0.5/+ 1.0 V Protection class and IP rating (type of protection) Class II, IP67 Class I, IP67 Class I, IP67 Maximum load 80 W 120 W 240 W Power factor > 0.95 full load @ 230 VAC > 0.90 half load @ 230 VAC > 0.95 full load @ 230 VAC > 0.90 half load @ 230 VAC > 0.95 full load @ 230 VAC > 0.90 half load @ 230 VAC Ambient temperature range -25 to +55 °C -25 to +55 °C -25 to +55 °C Surge capability L-N: 3 kV L-N: 3 kV, L/N – Ground: 6 kV L-N: 3 kV, L/N – Ground: 6 kV No-load proof Yes Yes Yes Overload/short-circuit protection Automatic, reversible Automatic, reversible Automatic, reversible Overheating protection Automatic, reversible Automatic, reversible Automatic, reversible Cable length Input side/output side ~ 300 mm/~ 300 mm Input side/output side ~ 300 mm/~ 300 mm Input side/output side ~ 300 mm/~ 300 mm Dimensions (L x W x H) 250 x 50 x 34 mm 250 x 60 x 39 mm 250 x 80 x 39 mm Conformity CE, ENEC CE, ENEC CE, ENEC Product number non-dim version 4008321981684 4008321981707 4008321981721 Product number dim version 4008321981677 4008321981691 4008321981714 OT 80/220-240/24 (DIM) P OT 240/220-240/24 (DIM) P 12 34 14 39 14 50 14 16 16 80 16 241 250 241 250 All figures in mm All figures in mm OT 120/220-240/24 (DIM) P 14 39 15 60 15 241 250 All figures in mm 6 SYSTEM COMBINATIONS LED MODULES – OPTOTRONIC POWER SUPPLIES 3. System combinations LED modules – OPTOTRONIC power supplies BoxLED Back Plus Maximum no. of chains per power supply Maximum no. of modules per power supply OT 80/220-240/24 (DIM) P 2/3 21 OT 120/220-240/24 (DIM) P 1 32 OT 240/220-240/24 (DIM) P1) 2 64 Electrical connection is made by the connecting cables of the module. 1) If more than 32 LED modules (= a complete LED chain) are to be connected to a 240 W OPTOTRONIC power supply, there must be a new separate electrical feed. A common star point is also possible. 7 PRODUCT IDENTIFIERS 4. Product identifiers BoxLED Back Plus: BX = BoxLED 06 = 6 LEDs per LED module B = Back A = Version A W4F = White/4th generation/fine binning 765 = CRI + CCT = CRI 70 + 6500 K Module code Color temperature Date code Total wattage of one chain Voltage OPTOTRONIC power supplies: Output voltage Input voltage Standards and regulations Line current, IP rating nominal MM mark Power factor Primary side Input side Conformity mark of the European Community Casing temperature at the Tc point Max. casing temperature in the case of fault Secondary side Output side 8 ELECTRICAL PROPERTIES 5. Electrical properties 5.1. Electrical connections We recommend the following cable lengths and cable cross-sections for the electrical connections between the LED chains and the connections to the OPTOTRONIC power supplies. Maximum secondary cable length [m] BoxLED Back Plus 20 100 90 80 70 60 50 40 30 20 10 0 AWG16/1.23 mm2 AWG14/2.08 mm2 AWG13/2.62 mm2 1.5 mm2 2.5 mm2 10 0 57.6 W 24 modules 3/4 chain 115.2 W 32 modules 1 chain 28.8 W 57.6 W 86.4 W 115.2 W 8 modules 16 modules 24 modules 32 modules 1/4 chain 1/2 chain 3/4 chain 1 chain LED module power [W] Disclaimer: In terms of electromagnetic compatibility (EMC), the maximum permitted cable length is 10 meters (please refer to the technical data sheet of the applied OSRAM OPTOTRONIC power supply). Users are responsible to ensure EMC. Recommended cable cross-section for connecting an LED chain to other LED modules [mm2] Product Type of cable AWG A [mm2] Cable cross-section for cable extension [mm²] BoxLED Back Plus Multi-wire (stranded) 16 1.23 ≥ 1.23 Notes: We recommend to use the LED modules only in combination with OSRAM OPTOTRONIC power supplies. The maximum secondary length is the maximum cable length between power supply and the first LED module of a chain plus the wire extensions between the LED modules (see below). Power supply LED module LED module LED module Max. secondary length = power supply – first LED module + wire extension LED module – LED module + ... 9 ELECTRICAL PROPERTIES 5.2. Electrical connectors 5.2.1. General Electrical connectors are manufactured in many different versions, including screw-type terminals, wire nuts, plug connectors and joining terminals (connectors). • Use only appropriate cables and connectors to link the LED modules to the OPTOTRONIC power supplies. • Electrical terminals must not be used where they may be directly exposed to the weather without adequate protection. For outdoor applications, plug connectors (without moisture protection) must therefore be protected by IP junction boxes or light boxes. BoxLED Back Plus module BoxLED Back Plus module Correct: The terminal is raised by bending both cables up Wrong: The terminal is on the floor Light box Light box If you are using plug connectors that do not have IP protection (moisture protection), make sure that the openings are always pointing downwards. 5.2.2. Overview of connectors Among others, the following standard terminals are suitable for the electrical connections between the LED chains and the connections to the OPTOTRONIC power supplies: Manufacturer Reference Type of cable* Maximum outer diameter AWG cable cross-section Operating temperature Special properties 3M 316IR Single-wire/multi-wire 0.160" (4.064 mm) AWG22–16 (0.34–1.305 mm²) Max. 105 ºC (221 ºF) UL-listed, standard 486C, UL file E23438 3M 314 Single-wire/multi-wire 0.082" (2.08 mm) AWG22–14 (0.34–2.5 mm2) Max. 105 ºC (221 ºF) Sealed against moisture WAGO Series 222 Single-wire/multi-wire AWG28–12 (0.09–4.0 mm2) Max. 85 ºC (185 ºF) PHOENIX JBC 2.5/X Single-wire/multi-wire AWG20–14 (0.75–2.5 mm2) * Not all connectors are suitable for multi-wire and fine-wire conductors. In some cases, therefore, end sleeves must be provided. Please read the manufacturer’s instructions. 10 APPLICATION OVERVIEW 6. Application overview 6.1. Selection table for BoxLED Back Plus in light boxes1) Depth of light box [mm] 75 100 Single-sided light boxes 125 150 175 200 250 300 2752) 3302) 4002) 4002) 4002) 4002) 2752) 3302) Double-sided light boxes 350 400 4002) 4002) Optimal product performance at maximum distance between module centers Good product performance at maximum distance between module centers Good product performance at maximum distance between module centers Limited performance – risk of non-uniform backlighting Limited performance – reduced efficiency 6.2. Luminance as a function of transmission The graph on the right shows the dependency between the transmission of a light-emitting surface and the resulting luminance at constant module distances of 400 mm (i.e. the distance between the module centers of each module string as well as the distance between parallel module strings). The luminance can vary depending on the specific characteristics of the application, such as the reflectance inside the application or the dispersion parameters of the lightemitting surface. Luminance [cd/m2] – minimum return with even illumination 1) The selection can vary depending on the special characteristics of the illuminated sign, e.g. concerning front material or type of application. 2) Maximum distance between module centers in mm. 300 200 Return depth: 150 mm 200 mm 250 mm 300 mm 100 0 10 30 50 Transmission [%] Approx. 6.5 LED modules/m2 11 APPLICATION OVERVIEW 600 600 500 500 400 300 200 Transmission: 55 % 45 % 35 % 25 % 100 0 200 260 Luminance [cd/m2] Luminance [cd/m2] 6.3. Luminance as a function of return depth The graphs below show the dependency between the return depth and the resulting luminance related to different transmission values. Each graph refers to a different constant distance between parallel module strings. 400 300 200 Transmission: 55 % 45 % 35 % 25 % 100 0 300 200 Return depth [mm] 260 300 Return depth [mm] Constant distance between module centers: 400 mm (fully stretched) Constant distance between parallel module strings: Constant distance between parallel module strings: 265 mm (approx. 9.5 LED modules/m2) 320 mm (approx. 8.0 LED modules/m2) 500 500 400 400 300 200 Transmission: 55 % 45 % 35 % 25 % 100 0 200 260 Luminance [cd/m2] Luminance [cd/m2] Constant distance between module centers: 400 mm (fully stretched) 300 200 Transmission: 55 % 45 % 35 % 25 % 100 0 300 200 Return depth [mm] 260 300 Return depth [mm] Constant distance between module centers: 400 mm (fully stretched) Constant distance between parallel module strings: Constant distance between parallel module strings: 350 mm (approx. 7.0 LED modules/m2) 400 mm (approx. 6.5 LED modules/m2) Luminance [cd/m2] Constant distance between module centers: 400 mm (fully stretched) 300 200 Transmission: 55 % 45 % 35 % 25 % 100 0 260 300 Return depth [mm] Definition: Return depth: Distance between LED modules (mounting surface) and light-emitting surface (e.g. acrylic sheet, fabric) Constant distance between module centers: 400 mm (fully stretched) Constant distance between parallel module strings: 500 mm (approx. 5.0 LED modules/m2) 12 APPLICATION OVERVIEW 6.4. Dimming matrix Output Maximum Dimming devices voltage output power OPTOTRONIC EAN OT DIM1) OTi DALI DIM1) OTi DALI DIM LI1)2) 4050300943459 4008321061195 4008321624437 24 V/max. 5 A Non-dim version All-in-one version (1 … 10 V) max. 120 W 24 V/max. 4 A 1 … 10 V DALI DALI OT 80/220-240/24 P 4008321981684 24 V 80 W 1 1 1 OT 120/220-240/24 P 4008321981707 24 V 120 W 1 1 1 OT 240/220-240/24 P 4008321981721 24 V 240 W – – – OT 80/220-240/24 DIM P 4008321981677 24 V 80 W – – – OT 120/220-240/24 DIM P 4008321981691 24 V 120 W – – – OT 240/220-240/24 DIM P 4008321981714 24 V 240 W – – – max. 96 W 1) For outdoor applications, the dimming device has to be protected by an appropriate IP box. 2) For the OTi DALI DIM LI, OSRAM recommends the use of a protective housing such as the OSRAM OUTKIT (EAN: 4008321159533). 6.5. Power output rating The Φ-Uc characteristic curve in the diagram below shows a general definition of the power output depending on the control voltage of an OT DIM, OTi DALI DIM, OT 80/220-240/24 DIM P, OT 120/220-240/24 DIM P or OT 240/220-240 24 DIM P power supply. 100 90 Power output rating [%] 80 70 60 50 40 30 20 10 0 0 1 2 3 4 5 6 7 8 9 10 Control voltage Uc [V] Operation without applied control voltage (shorted) 0 % power output Operation without applied control voltage (floating) 100 % power output 13 THERMAL PROPERTIES 7. Thermal properties 7.1. Casing temperature at the Tc point The casing temperature is the temperature at a defined point on the LED casing, the Tc point. The maximum Tc temperature is the highest permitted temperature that may occur at the Tc point under the planned ambient and operating conditions in the thermally steady state. If the maximum permitted Tc temperature is exceeded, the LED module may go into a state in which the load limits on the module (LED, casing, chip, encapsulation materials) are reached. A thermal link between BoxLED Back Plus modules and the mounting surface is not absolutely essential. Thermo-wire NiCr–Ni Mini connector “K” 1000±15 Temperature sensors Description Temperature range Length [mm] Diameter [mm] T90 1m Powerful sensor with a magnetic holding force of 90 N -30 to +550 °C 1000 40 x 25 18 25 mm 40 x 25 mm Tube sensor with flexible hook-and-loop tape Velcro® fastener for ∅ 15–150 mm 2m -10 to +100 °C 2000 For 15 – 150 20 Flexible Teflon® wire Foil sensor, self-adhesive -50 to +250 °C 1000 10 x 20 12 L 1.2 x 0.8 mm 10 x 20 mm Possible suppliers of such temperature sensors include OMEGA: www.omega.de and B+B Thermo-Technik: www.bubthermo.de 14 THERMAL PROPERTIES 7.2. Measuring the Tc temperature The indicated lifetime can only be achieved if the permitted operating temperatures at the Tc point are maintained. After the LED modules have been installed in a light box, the Tc temperature must be measured under the planned ambient and operating conditions in the thermally steady state. To do this, attach a temperature sensor to the Tc point with suitable adhesive (cyanoacrylate-free). The illustration below shows the respective Tc reference point, marked by a small circle on the back of the LED modules. Permitted Tc temperatures Operating temperature at the Tc point* [°C] BoxLED Back Plus -25 to 90 * If the maximum temperature limits are exceeded, the lifetime of the module will be greatly reduced or the module may be destroyed. The temperature of the LED module at the Tc point should be measured in the thermally steady state by means of a temperature sensor or temperature-sensitive sticker in accordance with EN 60598-1. The Tc point is located centrally on the back of the module (see illustration below). Tc 15 INSTALLATION INSTRUCTIONS 8. Installation instructions Installation in light boxes with mounting profile 1. Measure the inside of the frame to determine the length of the mounting profiles. 2. Cut the mounting profiles to the required length. 3. Install the upper (horizontal) mounting profile. 4. Now install the lower (horizontal) mounting profile and align it using a ruler so that the vertical (perpendicular) profile can be aligned at right angles. 5. Install the vertical mounting profiles at regular intervals of, for example, 165 mm using self-cutting screws. 6. View of the installed profiles. 7. Clean the mounting profile to ensure optimum adhesion with the LED module. 8. Now remove the protective film from the adhesive strip at the back of the modules. 1 2 3 4 5a 5b 6 7 8 16 INSTALLATION INSTRUCTIONS 9. Snap the BoxLED Back Plus modules into the vertical mounting profiles. 10. Observe the predefined hole spacing of the mounting LED pitch of 165 mm = 3 x 55 mm hole grid (55 mm) spacing. 11. Form a cable loop between the individual LED modules and fix it to the mounting profile with cable ties to avoid shadows. 12. View of a mounted BoxLED Back Plus LED module. 13. Remove the insulation from the cable ends of the LED modules and power supplies using a suitable tool. 14. Use cable ties and cable tie hooks to attach the secondary feed cables to the outer mounting profile. 15. Connect the secondary side of the power supply to the LED modules, and the primary side to power cables using plug connectors. 9 10 11a 11b 11c 12 13 14 15a 15b The installation of the modules is also possible without mounting profile. Please note: All exposed metal parts (such as the mounting profile) must be grounded in accordance with the latest safety requirements. Please also read the general safety instructions on p. 19. 17 STANDARDS AND REGULATIONS FOR LED MODULES AND POWER SUPPLIES 9. Standards and regulations for LED modules and power supplies The OSRAM LED modules are perfectly matched to the electronically stabilized OSRAM OPTOTRONIC power supplies, which are protected against short-circuit, overload and overtemperature. OSRAM LED modules and OPTOTRONIC power supplies comply with all the relevant standards (see below) and ensure safe and reliable operation. LED modules Radio interference EN 55015 EMC/immunity EN 61547 Electromagnetic fields IEC 62493 Photobiological safety IEC 62471 CE Yes OPTOTRONIC power supplies Safety EN 61347-2-13 Radio interference EN 55015 Immunity EN 61547 Harmonic content EN 6100-3-2 CE Yes 18 NOTES 10. Notes 10.1. General notes • Each LED module is equipped with a pre-mounted double-sided adhesive tape which allows for optional or additional mounting. Due to varying properties of adherends and multiple external influences during the operation of the modules, OSRAM assumes no liability and provides no guarantee for a permanent adherence of the modules to the surface. OSRAM recommends fixation of the modules by means of suitable screws. • Safe operation is ensured only if the LED chains are connected in parallel. Connecting the LED chains in series is NOT recommended. Unbalanced voltage drops may lead to serious overloads and destruction of individual modules. • Make sure to take suitable ESD (electrostatic discharge) precautions when installing the modules. • If drivers other than OSRAM OPTOTRONIC power supplies are used, the output voltage must be 24 V - 0.5/+ 1.0 V for 24 VDC to ensure safe operation of the modules. • The LED chains must only be shortened by cutting the connecting cables between the LED modules. • The LED chains must not be used where they may be directly exposed to the weather without adequate protection. In outdoor applications, the LED chains must therefore be protected by suitable housings or covers. The LED chains cannot be operated in or under water. 10.2. Safety information Before you start assembly, please read this information carefully. • Caution: There is a risk of an electric shock. Disconnect the power supply before installing or maintaining the product. • To avoid mechanical damage due to vibration, the LED modules must be connected flush with the mounting surface. Avoid exposing the equipment to strong vibrations. • The LED modules, including the power supply, may only be installed by a qualified electrician in accordance with all the valid regulations and standards. • Ensure that the poles are connected correctly. No light will be emitted if the polarity is incorrect. In this case, simply reverse the polarity. Recommended properties of light boxes To ensure uniform illumination, a reflective matt white surface is generally recommended for all internal frame walls and back panels for light boxes. 19 TOOLS AND LINKS 11. Tools and links The following materials and tools relating to signage are available on various web pages: BackLED Plus BackLED MB and LB BoxLED Back Plus BoxLED Side and BoxLED Side Plus • Technical application guides • Product data sheets > www.osram.com/backled > www.osram.com/boxled Note: Please also read the product data sheets for the BoxLED Back Plus modules. These data sheets contain important information regarding safety and installation. The latest data sheets are available at www.osram.com/boxled Please also read the OPTOTRONIC technical guide and product data sheets, which are available at www.osram.com/optotronic LED deSIGNer for applications with channel letters • LED deSIGNer • Checklist – signage application > www.osram.com/led-designer OPTOTRONIC • Product data sheets • Technical guide • Operating instructions > www.osram.com/optotronic Others • Technical application guide – ESD protection for LED systems • Technical application guide – IP codes in accordance with IEC 60529 • Signage brochure including pocket guide • New standards for LED control gear 20 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 05/13 Subject to change without notice. Errors and omissions excepted. www.osram.com/boxled www.osram.de