CLD-AP122 rev 1A application note technical article ® ® Cree XLamp CXA2530/CXA2540 LED Retail Track Light Reference Design Table of contents Introduction Introduction...........................................................1 This application note details the design of a 39‑watt Design approach/objectives......................... . . . . . . 2 equivalent The 6-step methodology............................ . . . . . . 2 CXA2530 LED. The CXA2530 is optimized to simplify 1. Define lighting requirements................. . . . . . . . 2 designs and lower system cost and can enable system- 2. Define design goals........................... . . . . . . . 5 level performance of 2000 to 5000 lumens. The XLamp 3. Estimate efficiencies of the optical, thermal & CXA2530 LED delivers high lumen output and high retail track light using Cree’s XLamp electrical systems............................. . . . . . . . 6 efficacy in a single, easy-to-use package that eliminates 4. Calculate the number of LEDs needed.. ...... . . . . . . 8 the need for reflow soldering. 5. Consider all design possibilities............... . . . . . . 9 6. Complete the final steps....................... . . . . . . 9 The XLamp CXA2530 LED highlighted in this reference Conclusions.. . . . . . . ................................... . . . . . 12 design Special thanks.. . . . ................................... . . . . . 13 traditionally use halogen, ceramic metal halide (CMH) Bill of materials. . . . ................................... . . . . . 13 and compact fluorescent lamp (CFL) technology. In this Appendix.. . . . . . . . . . .................................. . . . . . . 14 reference design, the XLamp CXA2530 LED is used in is optimized to enable applications that a retail track light that operates on direct line 120‑VAC input. The goal of the design is to enable a retail track light with a narrow beam, based on a single XLamp CXA2530 LED, delivering performance equivalent to a www.cree.com/Xlamp 39‑watt CMH lamp. Reliance on any of the information provided in this Application Note is at the user’s sole risk. Cree and its affiliates make no warranties or representations about, nor assume any liability with respect to, the information in this document or any LED-based lamp or luminaire made in accordance with this reference design, including without limitation that the lamps or luminaires will not infringe the intellectual property rights of Cree or a third party. Luminaire manufacturers who base product designs in whole or part on any Cree Application Note or Reference Design are solely responsible for the compliance of their products with all applicable laws and industry requirements. Copyright © 2010 Cree, Inc. All rights reserved. The information in this document is subject to change without notice. Cree, the Cree logo and XLamp are registered trademarks of Cree, Inc. Copyright © 2013 Cree, Inc. All rights reserved. The information in this document is subject to change without notice. Cree®, the Cree logo and XLamp® are registered trademarks and EasyWhite™ is a trademark of Cree, Inc. For product specifications, please see the data sheets available at www.cree.com. For warranty information, please contact Cree Sales at [email protected]. Cree, Inc. 4600 Silicon Drive Durham, NC 27703 USA Tel: +1.919.407.5300 XLAMP CXA2530/CXA2540 RETAIL TRACK LIGHT REFERENCE DESIGN The appendix to this reference design shows the results obtained when an XLamp CXA2540 LED was used in place of the CXA2530 LED. Design approach/objectives In the “LED Luminaire Design Guide” application note, Cree advocates a 6‑step framework for creating LED luminaires.1 All Cree reference designs use this framework, and the design guide’s summary table is reproduced below. Step Explanation 1. Define lighting requirements • The design goals can be based either on an existing fixture or on the application’s lighting requirements. 2. Define design goals • Specify design goals, which will be based on the application’s lighting requirements. • Specify any other goals that will influence the design, such as special optical or environmental requirements. 3. Estimate efficiencies of the optical, thermal & electrical systems • Design goals will place constraints on the optical, thermal and electrical systems. • Good estimations of efficiencies of each system can be made based on these constraints. • The combination of lighting goals and system efficiencies will drive the number of LEDs needed in the luminaire. 4. Calculate the number of LEDs needed • Based on the design goals and estimated losses, the designer can calculate the number of LEDs to meet the design goals. 5. Consider all design possibilities and choose the best • With any design, there are many ways to achieve the goals. • LED lighting is a new field; assumptions that work for conventional lighting sources may not apply. 6. Complete final steps • • • • • Complete circuit board layout. Test design choices by building a prototype luminaire. Make sure the design achieves all the design goals. Use the prototype to further refine the luminaire design. Record observations and ideas for improvement. Table 1: Cree 6-step framework The 6-step methodology The goal for this project is to demonstrate an easy-to-implement, high-output lamp that can better the performance of 39‑W CMH lamps currently on the market, showing that a narrow-beam 39‑watt equivalent retail track light is possible using a single XLamp CXA2530 LED.2 1. Define lighting requirements Table 2 shows a ranked list of desirable characteristics to address in a track light. 1 2 LED Luminaire Design Guide, Application Note AP15, www.cree.com/xlamp_app_notes/luminaire_design_guide Production and cost-optimized implementations are beyond the scope of this document. Copyright © 2013 Cree, Inc. All rights reserved. The information in this document is subject to change without notice. Cree®, the Cree logo and XLamp® are registered trademarks and EasyWhite™ is a trademark of Cree, Inc. For product specifications, please see the data sheets available at www.cree.com. For warranty information, please contact Cree Sales at [email protected]. 2 XLAMP CXA2530/CXA2540 RETAIL TRACK LIGHT REFERENCE DESIGN Importance Critical Important Characteristics Units Luminous flux lumens (lm) Light intensity - center beam candle power (CBCP) candelas (cd) Beam angle - full width half maximum (FWHM) degrees (°) Luminaire efficacy lm/W Electrical power watts (W) Lifetime hours Operating temperatures °C Correlated color temperature (CCT) K Color rendering index (CRI) 100-point scale Power factor Table 2: Ranked design criteria for a track light Table 3 and Table 4 summarize the ENERGY STAR® requirements for directional commercial and residential luminaires.3 ENERGY STAR REQUIREMENTS Luminaire Type Luminaire Efficacy (Initial) Luminaire Minimum Light Output (Initial) Luminaire Zonal Lumen Density Requirement Accent Lights • includes line voltage track heads • includes directional ceiling fan light kits 35 lm/W Luminaire shall deliver a minimum of 200 lumens per head. Luminaire shall deliver a minimum of 80% of total initial lumens within the 0-40° zone (axially symmetric about the center of the beam). Table 3: ENERGY STAR luminous efficacy, output and zonal lumen density requirements Characteristic Requirements Light source life requirements: all luminaires The LED package(s) / LED module(s) / LED array(s), including those incorporated into LED light engines or GU24 based integrated LED lamps, shall meet the following L70 lumen maintenance life values (refer to Lumen Maintenance Requirements in the next section): • 25,000 hours for residential grade indoor luminaires • 35,000 hours for residential grade outdoor luminaires • 35,000 hours for commercial grade luminaires Lumen maintenance life projection claims in excess of the above requirements shall be substantiated with a TM‑21 lumen maintenance life projection report. 3 ENERGY STAR Program Requirements, Product Specification for Luminaires (Light Fixtures), Eligibility Criteria, Version 1.2, www.energystar.gov/ia/partners/product_specs/program_reqs/Final_Luminaires_V1_2.pdf?7b7d-2473 Copyright © 2013 Cree, Inc. All rights reserved. The information in this document is subject to change without notice. Cree®, the Cree logo and XLamp® are registered trademarks and EasyWhite™ is a trademark of Cree, Inc. For product specifications, please see the data sheets available at www.cree.com. For warranty information, please contact Cree Sales at [email protected]. 3 XLAMP CXA2530/CXA2540 RETAIL TRACK LIGHT REFERENCE DESIGN Characteristic Requirements Lumen maintenance requirements: directional and non-directional luminaires The LED package(s) / module(s) / array(s), including those incorporated into LED light engines or GU24 based integrated LED lamps, shall meet the following L70(6k) rated lumen maintenance life values, in situ: • L70(6k) ≥ 25,000 hours for residential indoor • L70(6k) ≥ 35,000 hours for residential outdoor, or commercial Compliance with the above shall be documented with a TM-21 lumen maintenance life projection report as detailed in TM-21, section 7. The report shall be generated using data from the LM-80 test report for the employed LED package/module/array model (“device”), the forward drive current applied to each device, and the in situ TMPLED temperature of the hottest LED in the luminaire. In addition to LM-80 reporting requirements, the following information shall be reported: • sampling method and sample size (per LM-80 section 4.3) • test results for each TS and drive current combination • description of device including model number and whether device is an LED package, module or array (see Definitions) • ANSI target, and calculated CCT value(s) for each device in sample set • Δ u’v’ chromaticity shift value on the CIE 1976 diagram for each device in sample set • a detailed rationale, with supporting data, for application of results to other devices (e.g. LED packages with other CCTs) Access to the TMPLED for the hottest LED may be accomplished via a minimally sized hole in the luminaire housing, tightly resealed with a suitable sealant if created for purposes of testing. All thermocouple attachments and intrusions to luminaire housing shall be photographed. CCT requirements: all indoor luminaires The luminaire (directional luminaires), or replaceable LED light engine or GU24 based integrated LED lamp (nondirectional luminaires) shall have one of the following nominal CCTs: • • • • • 2700 3000 3500 4000 5000 Kelvin Kelvin Kelvin Kelvin Kelvin (commercial only) The luminaire, LED light engine or GU24 based integrated LED lamp shall also fall within the corresponding 7-step chromaticity quadrangles as defined in ANSI/NEMA/ANSLG C78.377-2008. Color rendering requirements: all indoor luminaires The luminaire (directional luminaires), or replaceable LED light engine or GU24 based integrated LED lamp (nondirectional luminaires) shall meet or exceed Ra ≥ 80. Color angular uniformity requirements: directional solid state indoor luminaires Throughout the zonal lumen density angles detailed above, and five degrees beyond, the variation of chromaticity shall be within 0.004 from the weighted average point on the CIE 1976 (u’,v’) diagram. Color maintenance requirements: solid state indoor luminaires only The change of chromaticity over the first 6,000 hours of luminaire operation shall be within 0.007 on the CIE 1976 (u’,v’) diagram, as demonstrated by either: • the IES LM-80 test report for the employed LED package/array/module model, or • as demonstrated by a comparison of luminaire chromaticity data in LM-79 reports at zero and 6,000 hours, or • as demonstrated by a comparison of LED light engine or GU24 based integrated LED lamp chromaticity data in LM-82 reports at zero and 6,000 hours. Source start time requirement: directional and non-directional luminaires Light source shall remain continuously illuminated within one second of application of electrical power. Dimming requirements The luminaire and its components shall provide continuous dimming from 100% to 35% of total light output. Step dimming, if employed, shall provide at least two discrete light output levels ≥ 35% of total light output and not including 100% output. Power factor requirements: directional and non-directional luminaires Total luminaire input power less than or equal to 5 watts: PF ≥ 0.5 Total luminaire input power greater than 5 watts: Residential: PF ≥ 0.7 Commercial: PF ≥ 0.9 Copyright © 2013 Cree, Inc. All rights reserved. The information in this document is subject to change without notice. Cree®, the Cree logo and XLamp® are registered trademarks and EasyWhite™ is a trademark of Cree, Inc. For product specifications, please see the data sheets available at www.cree.com. For warranty information, please contact Cree Sales at [email protected]. 4 XLAMP CXA2530/CXA2540 RETAIL TRACK LIGHT REFERENCE DESIGN Characteristic Requirements Transient protection requirements: all luminaires Ballast or driver shall comply with ANSI/IEEE C62.41.1-2002 and ANSI/IEEE C62.41.2-2002, Class A operation. The line transient shall consist of seven strikes of a 100 kHz ring wave, 2.5 kV level, for both common mode and differential mode. Operating frequency requirements: directional and non-directional luminaires Frequency ≥ 120 Hz Noise requirements: directional and non-directional luminaires All ballasts & drivers used within the luminaire shall have a Class A sound rating. Note: This performance characteristic addresses problems with visible flicker due to low frequency operation and applies to steady-state as well as dimmed operation. Dimming operation shall meet the requirement at all light output levels. Ballasts and drivers are recommended to be installed in the luminaire in such a way that in operation, the luminaire will not emit sound exceeding a measured level of 24 BA. Table 4: ENERGY STAR luminaire requirements The DesignLights™ Consortium (DLC) provides requirements for track or mono-point directional lighting fixtures, summarized in Table 5.4 Characteristic Minimum light output Unit DLC Value lm 250 Zonal lumen density ≥ 85%: 0-90° Minimum luminaire efficacy Allowable CCTs (ANSI C78.377-2008) lm/W 40 K ≤ 5000 CRI 80 L70 lumen maintenance hours 50,000 Minimum luminaire warranty years 5 Table 5: DLC track light requirements 2. Define design goals In addition to the requirements given in the above tables, we examined existing 39-W CMH lamp data sheets to develop the goals shown in Table 6. We found that the input power for luminaires using 39-W CMH lamps is 44 to 45 W, so we targeted this reference design to be at least equivalent. Table 6 shows the design goals for this project. Characteristic Light output Light intensity - CBCP Unit Minimum Goal Target Goal lm 3200 > 3200 > 20,000 cd 20,000 degrees 15 15 Luminaire efficacy lm/W 75 > 75 Lifetime Beam angle - FWHM hours 35,000 50,000 CCT K 3000 3000 CRI 100-point scale 80 80 W 44 < 44 0.9 > 0.9 Power Power factor Table 6: CXA2530 retail track light design goals 4 Technical Requirements Table v1.7, DesignLights Consortium www.designlights.org/solidstate.manufacturer.requirements.php Qualified Products List - Non-Residential Applications, Copyright © 2013 Cree, Inc. All rights reserved. The information in this document is subject to change without notice. Cree®, the Cree logo and XLamp® are registered trademarks and EasyWhite™ is a trademark of Cree, Inc. For product specifications, please see the data sheets available at www.cree.com. For warranty information, please contact Cree Sales at [email protected]. 5 XLAMP CXA2530/CXA2540 RETAIL TRACK LIGHT REFERENCE DESIGN 3. Estimate efficiencies of the optical, thermal & electrical systems We used Cree’s Product Characterization Tool (PCT) tool to determine the drive current for the design.5 Figure 1 shows Comparison basic electrical data and optical output from the PCT. We estimated 90% optical efficiency,LED 85%System driver efficiency and a solder point temperature (TSP) of 70 °C. System: Rep 1 3,000 Target Lumens : 90 Optical Efficiency: Current (A) LED 1 Model Flux LED 2 Model Cree XLamp CXA2530 {EZW} Tsp (ºC) T2 [3200] $ Price SYS # LED SYS lm tot 0.900 1 3073.91 0.950 1 3184.98 1.000 1 3290.86 1.100 1 3483.93 1.200 1 3653.5 0.000 #N/A #N/A Figure 1: PCT output with Flux 70 Price SYS W 37.617 39.959 42.326 47.126 52.025 #N/A (none) Tj (ºC) $ 2 - SYS lm/W 81.7 79.7 77.8 73.9 70.2 #N/A CXA2530 flux data #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A This document is provided for informational purposes only and is not a warranty or a specification. For product specifications, please see the data Copyright © 2009-2012 Cree, Inc. All rights reserved. The information in this document is subject to change without notice. Cree, the Cree logo a The PCT output shows that, at 1 A, a single XLamp CXA2530 LED produces the desired lumen output and efficacy. Thermal Requirements Proper thermal management is a key component of any successful LED-based lamp or luminaire design. Operating at 42 W of power in this retail track light design, the XLamp CXA2530 LED requires a heat sink to dissipate this thermal load. The heat sink in this design must not only dissipate the heat generated by the LED, but also provide the mechanical frame for the LED, optic, driver and base. We used a market-ready heat sink/housing assembly, shown in Figure 2.6 The heat sink is made of anodized aluminum alloy, AA 6063, and is part of a kit that includes a cover glass, screw-on base and front optic cover ring. Figure 2: CXA2530 retail track light heat sink/housing assembly 5 PCT is available at: pct.cree.com 6Model GD120-01, Losiwang, www.loswan.cn Copyright © 2013 Cree, Inc. All rights reserved. The information in this document is subject to change without notice. Cree®, the Cree logo and XLamp® are registered trademarks and EasyWhite™ is a trademark of Cree, Inc. For product specifications, please see the data sheets available at www.cree.com. For warranty information, please contact Cree Sales at [email protected]. 6 XLAMP CXA2530/CXA2540 RETAIL TRACK LIGHT REFERENCE DESIGN We performed thermal simulation to verify that this thermal design is sufficient.7 Figure 3 shows thermal images of the lamp assembly. The simulated peak solder point temperature (TSP) is 64 °C, or 39 °C above ambient. The thermal Thermal Simulation / Measurement resistance of the XLamp CXA2530 LED is 0.8 °C/W, so at 42 W the junction temperature (TJ) will be approximately 98 °C. Tsp 63.5 T2 Thermal Simulation Tsp ~64C, Figure 3: CXA2530 retail track light thermal simulation Copyright © 2010, Cree, Inc. T3 •About 75 to heat an the heat •Thermal ~63.5C •Calculat Cree Proprietary & Confidential Drive Electronics Tsp T2 T3 Cree selected a dimmable, universal input voltage driver to supply power to the retail track light.8 The driver is a slightly 63.5℃ 60.4℃ ℃ modified version of a commercially available driver model. The driver, shown in Figure 4, is located off the track and is attached to the heat sink/housing assembly. Thermal Simulation Tsp ~64C, Copyright © 2010, Cree, Inc. Cree Proprietary & Confidential •About 75% of the 42W input power will convert to heat and need sufficient heatsink to dissipate the heat •Thermal measurement by thermal couple: Tsp ~63.5C •Calculated Tj ~94C pg. 8 Figure 4: CXA2530 retail track light driver Secondary Optics It is a challenge to create a narrow‑beam optic for a relatively large light source such as the XLamp CXA2530 LED. This design meets the challenge with a custom reflector that is about 89% optically efficient and produces a 16° beam angle.9 The reflector, shown in Figure 5, fits within the heat sink/housing assembly. 7 For additional information on thermal management, refer to the Thermal Management of Cree XLamp LEDs Application Note, AP05, www.cree.com/xlamp_app_notes/thermal_management 8Model ERP040W-1000-39, Energy Recovery Products (ERP), www.erppowerllc.com/ 9Model 4-1361-1, Nata Lighting Company Limited, www.nata.cn/ Copyright © 2013 Cree, Inc. All rights reserved. The information in this document is subject to change without notice. Cree®, the Cree logo and XLamp® are registered trademarks and EasyWhite™ is a trademark of Cree, Inc. For product specifications, please see the data sheets available at www.cree.com. For warranty information, please contact Cree Sales at [email protected]. 7 XLAMP CXA2530/CXA2540 RETAIL TRACK LIGHT REFERENCE DESIGN Figure 5: CXA2530 retail track light reflector 4. Calculate the number of LEDs needed The dual purpose of this reference design is to show that a single LED package can deliver equivalent lighting utility and superior performance compared to existing 39-W CMH lamps on the market and show that it is possible to produce a narrow-beam retail track light based on the XLamp CXA2530 LED. The CXA2530 LED is a multi-chip LED package that can offer the required CBCP with new levels of LED-to-LED color consistency and efficiency. The new XLamp CXA2530 LED is 34% brighter than the original CXA2011,10 which can enable superior LED lighting designs even more quickly. We selected a Warm White LED for this reference design, shown highlighted in yellow in Table 7. By choosing an LED from a mid-level flux bin, we ensured that the design uses an LED that is readily available. Color CCT Range 4000K 3500K EasyWhite 3000K 2700K Base Order Codes Min. Luminous Flux @ 800 mA 2-Step Order Code 4-Step Order Code Group Flux (lm) @ 85 °C Flux (lm) @ 25 °C* T2 3200 3609 T4 3440 3879 U2 3680 4150 CXA2530-0000-000N00U240H CXA2530-0000-000N00U240F S4 2990 3372 CXA2530-0000-000N00S435H CXA2530-0000-000N00S435F T2 3200 3609 T4 3440 3879 S4 2990 3372 T2 3200 3609 S2 2780 3135 S4 2990 3372 T2 3200 3609 Chromaticity Region Chromaticity Region CXA2530-0000-000N00T240H 40H 35H CXA2530-0000-000N00T440H CXA2530-0000-000N00T235H CXA2530-0000-000N00T240F 40F 35F CXA2530-0000-000N00T435H 30H CXA2530-0000-000N00S430H CXA2530-0000-000N00T230H CXA2530-0000-000N00S427H CXA2530-0000-000N00T227H CXA2530-0000-000N00T235F CXA2530-0000-000N00T435F 30F CXA2530-0000-000N00S227H 27H CXA2530-0000-000N00T440F CXA2530-0000-000N00S430F CXA2530-0000-000N00T230F CXA2530-0000-000N00S227F 27F CXA2530-0000-000N00S427F CXA2530-0000-000N00T227F Table 7: CXA2530 LED order codes 10Measured at 1 A, junction temperature (TJ) = 85 °C Copyright © 2013 Cree, Inc. All rights reserved. The information in this document is subject to change without notice. Cree®, the Cree logo and XLamp® are registered trademarks and EasyWhite™ is a trademark of Cree, Inc. For product specifications, please see the data sheets available at www.cree.com. For warranty information, please contact Cree Sales at [email protected]. 8 XLAMP CXA2530/CXA2540 RETAIL TRACK LIGHT REFERENCE DESIGN 5. Consider all design possibilities The design possibilities for an LED-based track light are multitudinous. There are many ways to design the necessary heat sink that can dissipate the heat and fit within the desired envelope. One such heat sink is demonstrated in this reference design. There are also many ways to drive the LED and design the reflector and optics. Carefully selecting a driver and working with a reflector manufacturer to create an appropriate reflector provided the performance necessary for a true 39-W CMH‑equivalent retail track light. There are a number of desirable performance-related benefits in this design, which are results of the XLamp CXA2530 LED package. Because the CXA2530 LED uses EasyWhite™ technology, LED-to-LED color consistency can be held to within two or four McAdam ellipses for any given CCT, depending on the order code. The CXA2530 LED is binned at 85 °C, so the CCT will be as faithful as possible to the system operating environment. These component features allow for new levels of specification accuracy. However, the primary purpose of this reference design is to show how simple and straightforward it is to design with Cree’s XLamp CXA2530 LED. This application note is not intended to show the only way to do this, but instead demonstrate the ease of implementation with this set of engineering constraints. Certainly numerous other successful solutions are possible. Track light manufacturers typically design a reflector for a particular beam angle and install the light source and reflector in multiple housings. This reference design supports such a process and in addition, the performance range of the XLamp CXA2530 LED enables a wide variety of luminaires that all use a single CXA2530 LED. For demanding retail applications, the CXA2530 LED is offered in a 90-minimum CRI option, providing even better color rendering than this reference design. CCTs from 2700 K to 5000 K and lumen output up to 5900 lm11 are possible, providing the flexibility to offer a variety of luminaires that use a single LED light source and reflector. This flexibility is enhanced by the XLamp CXA2540 LED, which has the same physical dimensions and optical source size as the CXA2530 and offers even more design possibilities. 6. Complete the final steps This section describes the techniques used to create a working retail track light using the XLamp CXA2530 LED and shows the results of the design. Prototyping Details The essence of the design is to attach a Cree XLamp CXA2530 LED to a heat sink and assemble the necessary optics and driver around this to create a true 39-W CMH‑equivalent LED luminaire. The assembly steps are detailed below. 11 At 61 W, 85 °C Copyright © 2013 Cree, Inc. All rights reserved. The information in this document is subject to change without notice. Cree®, the Cree logo and XLamp® are registered trademarks and EasyWhite™ is a trademark of Cree, Inc. For product specifications, please see the data sheets available at www.cree.com. For warranty information, please contact Cree Sales at [email protected]. 9 height = 21mm •Can be use with CXA2520 as well. XLAMP CXA2530/CXA2540 RETAIL TRACK LIGHT REFERENCE DESIGN •Optical efficiency ~ 89% •Supplier: Nata (http://www.nata.cn/), Model: 4-1361-1 1. We verified the component dimensions to ensure a correct fit. 2. We attached the CXA2530 LED to the heat sink with a small amount of thermally conductive compound.12 Thermally •We also used an plastic mounting / alignment ring by: Mekoda conductive epoxy can also be used.13 3. We fed the driver output wires through the heat sink and, following the recommendations in Cree’s Soldering and Handling Application Note for the CXA family of LEDs14, soldered them onto the CXA2530 LED. 4. We tested the connection by applying power to the LED and verified that the LED lit up. 5. We placed a plastic alignment ring15 over the LED and positioned the ring so the LED was centered on the heat sink. 6. We secured the plastic alignment ring to the heat sink with screws. Copyright © 2010, Cree, Inc. Cree Proprietary & Confidential pg. 10 7. We secured each end of the driver to the heat sink with a bracket and screw. 8. We fed the driver input wires through the center hole in the screw-in base. 9. We screwed the base to the heat sink, enclosing the driver. 10. We placed the reflector in the heat sink so the opening aligned with the LED. 11. We placed the cover glass on the reflector and screwed the front optic cover ring to the heat sink to secure the cover glass and the reflector to the heat sink. 12. We attached the track adaptor bracket to the lamp assembly with decorative screws. 13. We connected the driver input wires to the track adaptor. 14. We performed final testing. 12 Dow Corning Thermally Conductive Compound, TC-5026, www.dowcorning.com/content/publishedlit/11-1689a-01.pdf 13Refer to Cree’s Chemical Compatibility application note for compounds that are safe to use with Cree LEDs. Cree XLamp LED Chemical Compatibility Application Note, AP63, www.cree.com/products/pdf/XLamp_Chemical_Comp.pdf 14 Cree XLamp CXA Family LEDs Soldering and Handling, Application Note AP74, www.cree.com/xlamp_app_notes/CXA_SH 15Model PC, Mekoda Optical Co., Ltd., www.mekoda.cn Copyright © 2013 Cree, Inc. All rights reserved. The information in this document is subject to change without notice. Cree®, the Cree logo and XLamp® are registered trademarks and EasyWhite™ is a trademark of Cree, Inc. For product specifications, please see the data sheets available at www.cree.com. For warranty information, please contact Cree Sales at [email protected]. 10 XLAMP CXA2530/CXA2540 RETAIL TRACK LIGHT REFERENCE DESIGN Results Thermal Results We measured the thermal performance of the retail track light by attaching a thermocouple to the XLamp CXA2530 LED mounted to the heat sink. The TSP of the CXA2530 retail track light was 63.5 °C. Based on the measured solder point temperature, the TJ can be calculated as follows. TJ = TSP + (LED power * LED thermal resistance) TJ = 63.5 °C + (42 W * 0.8 °C/W) TJ = 97 °C This thermal performance is in line with the thermal simulation. Estimated LED Lifetime Based on thousands of hours of long-term testing of the XLamp CXA2011 LED at higher temperatures than the measured 63.5 °C TSP in this reference design, Cree expects an L70 lifetime for this retail track light significantly longer than the 50,000‑hour goal. 39-W CMH lamps typically have lifetimes ranging from 10,000 to 12,000 hours, so the 4 to 5 times longer lifetime of the CXA2530 retail track light offers compelling maintenance cost savings. Optical and Electrical Results We obtained the results in Table 8 by testing the retail track light in a 1.5‑meter sphere and a Type A goniometer after a 60‑minute stabilization time.16 The performance meets or exceeds the project goals and accomplishes this using a single XLamp CXA2530 LED to produce a symmetric 16° beam with CBCP exceeding 20,000 cd. Characteristic Light output Light intensity - CBCP Beam angle - FWHM Unit Result lm 3211 cd 20,470 degrees 16 lm/W 75.5 CCT K 3048 CRI 100-point scale 80 W 42.6 Luminaire efficacy Power Power factor 0.95 Table 8: CXA2530 retail track light results We also tested the intensity distribution of the CXA2530 retail track light. As shown in Figure 6, the retail track light has an even intensity distribution for the narrow beam angle. 16 Testing was performed at Cree’s Shenzhen Technology Center. An IES file for the retail track light is available on the Cree website: www.cree.com/xlamp_app_notes/CXA2530_track_ies Copyright © 2013 Cree, Inc. All rights reserved. The information in this document is subject to change without notice. Cree®, the Cree logo and XLamp® are registered trademarks and EasyWhite™ is a trademark of Cree, Inc. For product specifications, please see the data sheets available at www.cree.com. For warranty information, please contact Cree Sales at [email protected]. 11 灯 具 内 系 源 数 只 上上系实上 实系额源额额 下上系实上 平发平平平平系室室单单 XLAMP RETAIL TRACK LIGHT REFERENCE DESIGN 室CXA2530/CXA2540 内灯具室系室室 平平系平保系 系光 安安安系 Figure 6: Goniometric intensity polar plot of CXA2530 retail track light Table 9 shows the center beam illuminance of the CXA2530 retail track light at various distances from the light source. Height Center Beam Illuminance 0.5 m 1.7 ft 1.0 m 3.3 ft 1.5 m 5.0 ft 2.0 m C保系角角: 0系 360系 360系 C保系角角: 15. 15.0系 7,371 fc 系系测系: 79,337 快测 lx 环环环系:23℃ 23℃ 系系测测:CANDY WONG 1,843 19,834 lx29 系系fc 测测:2012 10 2012 10 Beam Width Vertical Spread Horizontal Spread γ保系角角: 0系 180系 180系 γ保 系 角 角 : 1.0系 15.2 cm ft 15.2 cm 0.5 ft 系 系系测: 0.5 远远 (EVERFINE) )GO A_V1系 测 V2. EVERFINE GO2000A 2000 环环环系:50% 50% 系系测测:5.000米 =1.0000] 000米 [K= = 0000] 30.5 ft 测测实 27.4 0.9 ft 备 备cm : 系系1.0 系系 测cm 819 fc 8,815 lx 42.7 cm 1.4 ft 42.7 cm 1.4 ft 6.6 ft 461 fc 4,959 lx 57.9 cm 1.9 ft 57.9 cm 1.9 ft 2.5 m 8.3 ft 295 fc 3,173 lx 73.2 cm 2.4 ft 73.2 cm 2.4 ft 3.0 m 9.9 ft 205 fc 2,204 lx 88.4 cm 2.9 ft 88.3 cm 2.8 ft C:\Documents and Settings\ Settings\ledit\ ledit\Desktop\ Desktop\胡胡系\cxa2530 cxa2530TRACK 2530TRACK_ TRACK_20121029. 20121029.GOS Table 9: CXA2530 retail track light center beam illuminance – 16° beam angle Conclusions This reference design demonstrates the ease of integrating the Cree XLamp CXA2530 LED into a retail track light with excellent results. Such a luminaire is useful in both retail and residential spot light applications, where enhancing the appearance of merchandise or artwork is desirable. The performance of this retail track light makes it an attractive alternative to CMH-based luminaires and could form the basis for a broad product line of CXA2530 LED based track Copyright © 2013 Cree, Inc. All rights reserved. The information in this document is subject to change without notice. Cree®, the Cree logo and XLamp® are registered trademarks and EasyWhite™ is a trademark of Cree, Inc. For product specifications, please see the data sheets available at www.cree.com. For warranty information, please contact Cree Sales at [email protected]. 12 XLAMP CXA2530/CXA2540 RETAIL TRACK LIGHT REFERENCE DESIGN lights. This document is meant to show that this level of performance is achievable with a single XLamp CXA2530 LED component, and is meant to suggest that the CXA2530 LED can be the basis of numerous successful track light designs. To further demonstrate this point, the appendix describes the even better results obtained when we subsequently replaced the XLamp CXA2530 LED in this retail track light with the XLamp CXA2540 LED. Special thanks Cree would like to acknowledge and thank the following partner companies for collaborating in the successful prototyping of this track light. • Energy Recovery Products - www.erppowerllc.com • Nata Lighting Company Limited - www.nata.cn Bill of materials Component Order Code/Model Number Company Web Link Alignment ring PC Mekoda Optical Co., Ltd. www.mekoda.cn Driver ERP040W-1000-39 Energy Recovery Products, Inc. www.erppowerllc.com Heat sink/housing, cover glass, screw‑on base, front optic cover ring kit GD120-01 Losiwang www.loswan.cn LED CXA2530-0000-000N00T230H Cree, Inc. www.cree.com/cxa2530 Reflector 4-1361-1 Nata Lighting Company Limited www.nata.cn Thermally conductive compound TC-5026 Dow Corning Corporation www.dowcorning.com/content/ publishedlit/11-1689a-01.pdf Table 10: Bill of materials for CXA2530 retail track light Copyright © 2013 Cree, Inc. All rights reserved. The information in this document is subject to change without notice. Cree®, the Cree logo and XLamp® are registered trademarks and EasyWhite™ is a trademark of Cree, Inc. For product specifications, please see the data sheets available at www.cree.com. For warranty information, please contact Cree Sales at [email protected]. 13 XLAMP CXA2530/CXA2540 RETAIL TRACK LIGHT REFERENCE DESIGN Appendix The introduction of the Cree XLamp CXA2540 LED expands the possibilities for this retail track light. To demonstrate the performance available from the CXA2540 LED, we replaced only the LED in the CXA2530 retail track light. The LED in the original track light was from the highest CXA2530 3000 K flux bin and its replacement, shown in Table 11, was from the highest CXA2540 3000 K flux bin. Color CCT Range 4000K 3500K EasyWhite 3000K 2700K Base Order Codes Min. Luminous Flux @ 1100 mA 2-Step Order Code 4-Step Order Code Group Flux (lm) @ 85 °C Flux (lm) @ 25 °C* V2 4230 4730 V4 4545 5083 W2 4860 5435 CXA2540-0000-000N00W240H CXA2540-0000-000N00W240F U4 3955 4423 CXA2540-0000-000N00U435H CXA2540-0000-000N00U435F V2 4230 4730 V4 4545 5083 CXA2540-0000-000N00V435H CXA2540-0000-000N00V435F U4 3955 4423 CXA2540-0000-000N00U430H CXA2540-0000-000N00U430F V2 4230 4730 V4 4545 5083 CXA2540-0000-000N00V430H CXA2540-0000-000N00V430F U2 3680 4115 CXA2540-0000-000N00U227H CXA2540-0000-000N00U227F U4 3955 4423 V2 4230 4730 Chromaticity Region Chromaticity Region CXA2540-0000-000N00V240H 40H 35H 30H 27H CXA2540-0000-000N00V440H CXA2540-0000-000N00V235H CXA2540-0000-000N00V230H CXA2540-0000-000N00U427H CXA2540-0000-000N00V227H CXA2540-0000-000N00V240F 40F 35F 30F 27F CXA2540-0000-000N00V440F CXA2540-0000-000N00V235F CXA2540-0000-000N00V230F CXA2540-0000-000N00U427F CXA2540-0000-000N00V227F Table 11: CXA2540 LED order codes Testing of the CXA2540 retail track light yielded the results shown in Table 12. Operating at the same 1 A current as the CXA2530 track light, the CXA2540 track light provides a 16% increase in lumen output and a 14% increase in light intensity. Its 21% increase in luminaire efficacy makes it excellent at highlighting merchandise in retail displays. Occupying the same footprint as the CXA2530, the CXA2540 offers an even broader range to a retail track light product line based on CXA2530 and CXA2540 LEDs. Characteristic Unit Result Light output lm 3740 Light intensity - CBCP cd 23,367 degrees 17 Beam angle - FWHM lm/W 91 CCT Luminaire efficacy K 3000 CRI 100-point scale 80 W 41 Power Power factor 0.95 Table 12: CXA2540 retail track light results Copyright © 2013 Cree, Inc. All rights reserved. The information in this document is subject to change without notice. Cree®, the Cree logo and XLamp® are registered trademarks and EasyWhite™ is a trademark of Cree, Inc. For product specifications, please see the data sheets available at www.cree.com. For warranty information, please contact Cree Sales at [email protected]. 14 XLAMP CXA2530/CXA2540 RETAIL TRACK LIGHT REFERENCE DESIGN We also tested the intensity distribution of the CXA2540 retail track light. As shown in Figure 7, the retail track light has an even intensity distribution for the narrow beam angle. Figure 7: Goniometric intensity polar plot of CXA2540 retail track light Table 13 shows the center beam illuminance of the CXA2540 retail track light at various distances from the light source. The beam width is nearly identical to the CXA2530 retail track light beam width, with 14% greater center beam illuminance. Height Center Beam Illuminance Beam Width Vertical Spread Horizontal Spread 0.5 m 1.7 ft 8,378 fc 90,180 lx 15.2 cm 0.5 ft 15.2 cm 0.5 ft 1.0 m 3.3 ft 2,094 fc 22,540 lx 30.5 cm 1.0 ft 30.5 cm 1.0 ft 1.5 m 5.0 ft 931 fc 10,021 lx 45.7 cm 1.5 ft 45.7 cm 1.5 ft 2.0 m 6.6 ft 524 fc 5,640 lx 61.0 cm 2.0 ft 61.0 cm 2.0 ft 2.5 m 8.3 ft 335 fc 3,606 lx 76.2 cm 2.5 ft 73.2 cm 2.4 ft 3.0 m 9.9 ft 233 fc 2,508 lx 88.4 cm 2.9 ft 88.4 cm 2.9 ft Table 13: CXA2540 retail track light center beam illuminance – 17° beam angle Reliance on any of the information provided in this Application Note is at the user’s sole risk. Cree and its affiliates make no warranties or representations about, nor assume any liability with respect to, the information in this document or any LED-based lamp or luminaire made in accordance with this reference design, including without limitation that the lamps or luminaires will not infringe the intellectual property rights of Cree or a third party. Luminaire manufacturers who base product designs in whole or part on any Cree Application Note or Reference Design are solely responsible for the compliance of their products with all applicable laws and industry requirements. Copyright © 2013 Cree, Inc. All rights reserved. The information in this document is subject to change without notice. Cree®, the Cree logo and XLamp® are registered trademarks and EasyWhite™ is a trademark of Cree, Inc. For product specifications, please see the data sheets available at www.cree.com. For warranty information, please contact Cree Sales at [email protected]. 15