Technical application guide PrevaLED Compact light engines

www.osram.com Technical application guide PrevaLED Compact light engines JUNE 2013

CONTENTS Contents 1. Introduction 3 1.1. System overview 3 1.2. System information 4 1.2.1. Nomenclature and marking 5 1.2.2. Technical data 6 1.2.3. Possible system combinations 7 3. Installation guide 21 3.1. Installation of one LED module inside a luminaire 21 3.2. Installation of more than one LED module inside a luminaire 21 3.3. Creepage and clearance 22 3.4. Constant lumen output (CLM) 23 3.5. IP rating 23 2. Luminaire design 8 2.1. Optical considerations 8 2.1.1. Quality of light 8 4. Norms and standards 24 4.1. Norms and standards for PrevaLED LED modules and light engines 24 4.2. Photobiological safety 24 2.1.2. CRI, CCT 9 2.2. Mechanical considerations 9 2.2.1. LED module dimensions 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. T c 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 ex perience 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 T c ). 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 Color temperature 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. 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 T c (80 C). For more information on T c measurement, see chapter 2.3.3. LED module + LED power supply (at T c typ.) (at T c typ.) 1), 2) LED module V f max. at T amb -30 C Module power [W] Luminous flux [lm] 1) Module effi cacy 3) [lm/w] CCT [K] CRI Beam angle [ ] Lifetime (L85B10) at T c = 80 C [h] 2) PrevaLED Compact LEP-2500-740-CT2 LEP-4000-740-CT2 LEP-6000-740-CT3 LEP-6000-657-CT3 LEP-8000-740-CT3 LEP-8000-657-CT3 LEP-10000-740-CT3 LEP-10000-657-CT3 53 21 2500 123 4000 70 120 60000 83 33 4000 122 4000 70 120 60000 108 52 6000 117 4000 70 120 60000 107 47 6000 129 5700 65 120 60000 148 69 8000 117 4000 70 120 60000 147 63 8000 130 5700 65 120 60000 188 78 10000 117 4000 70 120 60000 187 78 10000 130 5700 65 120 60000 Indoor ECG Max. output power [W] Typ. efficiency 5) Max. current [ma] Control T a [ C] T c max. [ C] Lifetime L90 at T c point [h] OT 35/220-240/700 LTCS OT 45/220-240/700 LTCS OT DALI 45/220-240/700 LTCS 35 88 700 LEDset -25 +50 85 50000 at T c = 75 C 45 89 700 LEDset -25 +50 90 50000 at T c = 80 C 45 87 700 DALI and LEDset -25 +50 85 50000 at T c = 75 C Outdoor ECG Max. output power [W] Typ. efficiency 5) Max. current [ma] Control T a [ C] T c max. [ C] Lifetime L90 at T c point [h] OT 50/220-240/700 LT E OT 50/220-240/700 3DIMLT(+) E OT 90/220-240/700 LT E OT 90/220-240/700 3DIMLT(+) E OT 150/220-240/700 LT E OT 150/220-240/700 3DIMLT+ E 54 88 700 LEDset -30 +60 85 85000 at T c = 75 C 54 88 700 3DIM 4) and LEDset -30 +60 85 85000 at T c = 75 C 90 90 700 LEDset -30 +55 90 85000 at T c = 80 C 90 90 700 3DIM 4) and LEDset -30 +55 90 85000 at T c = 80 C 150 91 700 LEDset -30 +55 85 85000 at T c = 75 C 150 91 700 3DIM 4) and LEDset -30 +55 85 85000 at T c = 75 C 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 35/220-240/700 LTCS OT 45/220-240/700 LTCS OT DALI 45/220-240/700 LTCS OT 50/220-240/700 (3DIM) LT E OT 90/220-240/700 (3DIM) LT E OT 150/220-240/700 (3DIM) LT E PrevaLED Compact LEP-2500-740-CT2 LEP-4000-740-CT2 LEP-6000-740-CT3 LEP-6000-657-CT3 LEP-8000-740-CT3 LEP-8000-657-CT3 LEP-10000-740-CT3 LEP-10000-657-CT3 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 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

2. Luminaire design 2.1. Optical considerations LEP-6000-740-CT3 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. 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. -60-50 -40-30 -20 ϕ -10 0 10 20 30 40 50 60 70 80 90 1.0 0 45 0.8 0.6 lrel Intensity Intensity 360 400 450 500 550 600 650 700 750 800 830 Wavelength (nm) Wavelength spectrum of 4000-K LEDs -70-80 0.4 0.2 360 400 450 500 550 600 650 700 750 800 830 Wavelength (nm) -90 58R 0.0 Wavelength spectrum of 5700-K LEDs -100 Radiation pattern: Typical Lambertian beam shape 8

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. 2.2. Mechanical considerations 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 0.400 0.380 5000 K 4500 K Handle with care! Please do not mechanically stress any components of the LED module. cx cx 0.360 0.340 0.320 0.300 0.280 Color bin of PrevaLED Compact LED modules with CCT: 5700 K 0.430 0.410 0.390 0.370 8000 K 4500 K 5000 K 5500 K 6000 K 6500 K 7000 K 0.300 0.320 0.340 0.360 0.380 cy 3500 K 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. d kg h 0.350 0.330 0.345 0.365 0.385 0.405 0.425 0.445 b 1 b cy Color bin of PrevaLED Compact LED modules with CCT: 4000 K s l 1 l LED module Size b [mm] b 1 [mm] l [mm] l 1 [mm] s [mm] h [mm] d [mm] LEP-xxxxxxx-CT2 LEP-xxxxxxx-CT3 2 39 29 95 21 22 6.7 3.2 3 46 36 110 30 26.5 6.7 3.2 9

2.2.2. LED power supply dimensions 2.2.3. Cable dimensions h w 1 w w h 3 15 5 21.8 600 1.6 l 1 l l 1 l 18 OT 35/45 OT 50/90 8.3 All figures in mm w1 w h l 1 l OT 150 ECG l [mm] l 1 [mm] w [mm] w 1 [mm] h [mm] Cable colors * Connection to OPTOTRONIC LEDset ECG OT 35/220-240/700 LTCS 123 111 79 67 33 Red LED+ OT 45/220-240/700 LTCS 123 111 79 67 33 Blue +12 Vset OT DALI 45/220-240/ 700 LTCS OT 50/220-240/700 LT E OT 50/220-240/700 3DIMLT(+) E OT 90/220-240/700 LT E OT 90/220-240/700 3DIMLT(+) E OT 150/220-240/700 LT E OT 150/220-240/700 3DIMLT(+) E 123 111 79 67 33 133 122.5 77 38.5 48 133 122.5 77 38.5 48 133 122.5 77 38.5 48 133 122.5 77 38.5 48 170 160 100 90 40 170 160 100 90 40 Light gray Violet Black GNDset Vset LED- * Attention: The NTCset pin (orange) of the OPTOTRONIC (if available) shall not be connected to the PrevaLED Compact LED module 10

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 R th = L A A L 11

The selection of a suitable heat sink is usually done through the following steps: Define boundary conditions Total power dissipation of the light engine Max. ambient temperature T amb Max. reference temperature T c according to lifetime requirements Estimate heat sink thermal resistance on light engine level R thca = T C - T A Thermal power LED module Select heat sink thermal resistance Use the estimated R thca as a target for a possible heat sink profile and examine the performance curve in the catalog. As soon as prototype luminaires are available, thermal measurements must be performed to confirm the design. 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. Warning: A safe and reliable operation can only be realized with sufficient thermal management. Temperature difference between Ta and Tc [ C] 100 90 80 70 60 50 40 30 20 10 0 0.00 10000 lm 8000 lm 6000 lm 0.05 0.10 0.15 0.20 0.25 0.30 0.35 0.40 0.45 0.50 Heat sink surface [m 2 ] 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

4 10 Gravity 42 70 95 Sample heat sink dimensioning Let s consider, for example, a 0.3-m 2 heat sink. The diagram indicates a delta temperature of approximately 40 C from the T c point to the ambient temperatures (6000-lm LED module). In reverse direction, with the given T c 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 m 2. If, for example, AVC is considered as a supplier, the following AVC heat sinks could be appropriate for the approximation above: Cooling type Supplier Passive Product code ST03D00001 ST03B00001 ST03W00002 Illustration AVC The list below shows a selection of suppliers of different cooling solutions: Active cooling systems: Nuventix Sunon Cooler Master Passive cooling systems: AVC Fischer Elektronik Meccal Wakefi eld R-Theta Cool Innovations www.nuventix.com www.sunoneurope.com www.coolermaster.com www.avc-cooling.com www.fi scherelektronik.de www.meccal.com www.wakefi eld.com www.r-theta.com www.coolinnovations.com 13

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. The temperature at the T c 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 T c point with a direct contact. Examples of recommended thermocouples are shown below. K-type thermocouple with miniature connector Illustration Description Temperature range [ C] Thermal interface materials PVC-insulated thermocouple -10 +105 Alfatec www.alfatec.de Kerafol Laird www.kerafol.de www.lairdtech.com PFA-insulated thermocouple -75 +260 Bergquist www.bergquistcompany.com Artic Silver www.articsilver.com Wakefi eld www.wakefi eld.com Sprung thermocouple -75 +260 2.3.3. T c 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 T c point. The T c point is located on the back of the PCB, centered underneath the LED s light-emitting surface (see figure below). T c point 14

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 T c 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 T c 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

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 T c 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. 100 % LED operating current 100 ma Thermal derating 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 electro static 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 require ments 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 OT 35/220-240/ 700 LTCS OT 45/220-240/ 700 LTCS OT DALI 45/220-240/700 LTCS OT 50/220-240/ 700 LT E OT 50/220-240/ 700 3DIMLT(+) E OT 90/220-240/ 700 LT E OT 90/220-240/ 700 3DIMLT(+) E OT 150/220-240/ 700 LT E OT 150/220-240/ 700 3DIMLT + E Maximum output voltage [V] * SELV Insulation (primary/ secondary) 100 Yes Double 120 Yes Double 120 Yes Double 120 Yes Double 120 Yes Double 260 No Double 260 No Double 350 No Double 350 No Double Recommended luminaire class Class I and class II Class I and class II Class I and class II Class I and class II Class I and class II Class I and class II Class I and class II Class I and class II Class I and class II * 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

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 [mm 2 ] 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 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. +12 Vset 0.2 0.5 0.2 0.5 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. B B Wire colors Red OT terminals LED+ Black Violet Light gray Blue Light gray +12 Vset GNDset Blue Red Violet Vset Black LED- 5.90 0.45 All figures in mm B-B 5:1 17

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: Cable 4 (violet) Vset 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 5 (black) LED- LED module shuts down, no current in seriesconnected LEDs, current only in the LEDset circuit 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 T c value, the safety of the LED module is assured by the thermal protection. 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. 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

The flux bin can be found on the front of the LED module: 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. 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 I typ = 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 I typ values. 1.4 1.3 1.2 1.1 Required fl ux 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] Flux/Flux nom. 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

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. Warning: Excessive torque on the mounting screws may cause damage to the LED module. 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): L max. = 2 x 2 m 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 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). 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. + D1 D2 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 4.95 3.35 16.15 16.15 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. Working hours [h] OT current [%] 0 83 5000 84 10000 85 3DIM Tool DALI magic 15000 87 20000 88 25000 90 30000 91 USB Setup of the 3DIM Tool DALI Optional LED power supply 35000 92 40000 94 45000 95 50000 97 55000 98 up to 64 devices 60000 100 DA ~ Output [%] 100 % LED current Flux (no CLM) 80 % Guaranteed light level Without CLM Time [khrs] How to configure the constant lumen module in the 3DIM Tool Warning: With a set current exceeding the nominal current of the module, the warranty does not apply. Output [%] 100 % LED current Flux (with CLM) With CLM, the constant luminous flux of the LED module can be reduced down to 70 % of the nominal luminous flux (100 %). 80 % Guaranteed light level Time [khrs] 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 %. With CLM The following table helps identifying the power level that has to be set in the OPTOTRONIC 3DIM ECG: 3.5. IP rating The PrevaLED Compact has no special IP rating. 23

NORMS AND STANDARDS 4. Norms and standards 4.1. Norms and standards for PrevaLED LED modules and light engines Electromagnetic compatibility: EN 55015 EN 61547 EN 61000-4-2 EN 61000-4-3 EN 61000-4-4 EN 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

www.osram.de www.osram.com 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.