¦ · PrevaLED® Cube G4 LED modules | Contents 2 Please note: All information in this guide has been prepared with great care. OSRAM, however, does not accept liability for

www.osram.us/ds

Technical application guide PrevaLED® Cube G4 LED modules

Light is OSRAM

PrevaLED® Cube G4 LED modules | Contents

2

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.us/ds or contact your sales partner for an updated copy of this guide. This technical application guide is for information purposes only and aims to support you in tackling the challenges and taking full advantage of all opportunities the technology has to offer. Please note that this guide is based on own measurements, tests, specific parameters and assumptions. Individual applications may not be covered and need different handling. Responsibility and testing obligations remain with the luminaire manufacturer/OEM/ application planner.

Contents

1 Introduction 03

1.1 System overview 03

1.2 Nomenclature 03

2 Optical considerations 04

2.1 Light distribution 04

2.2 Reflector design 04

2.3 Spectral distribution 05

2.4 Luminous flux behavior 06

3 Electrical considerations 07

3.1 Forward voltage as a function of temperature 07

3.2 Wiring 08

4 Thermal considerations 09

4.1 Thermal protection features 09

4.2 TIM and other accessories 09

4.3 Cooling system and heat sink 10

4.4 Tc point location and temperature measurement 10

4.5 Thermocouple 11

5 Lifetime and thermal behavior 12

5.1 Luminous flux as a function of temperature 12

5.2 Lifetime 12

6 Mechanical considerations 13

6.1 Outline drawing 13

6.2 Mechanical protection of the light engine 13

6.3 Mounting 13

7 Norms and standards 14

PrevaLED® Cube G4 LED modules | Introduction

3

1.1 System overviewBuilding an LED-based luminaire poses a set of technical challenges, among them optical requirements, providing adequate thermal management for stable operation and dealing with the improving performance of LEDs. Never-theless, LED technology also provides an unknown number of possibilities, opening up unprecedented levels of performance.

OSRAM’s PrevaLED® family of LED light engines addresses the challenges of LED-based lighting while providing users with great performance and flexibility at the same time. Enabled by the application of LED technology, PrevaLED® is aiming to push the envelope of what is possible in terms of performance and simplicity.

PrevaLED® Cube G4 LED light engines offer one of the best and easiest ways to outfit luminaires with LED technology. They are ideally suited for use in highly diffuse wall-mounted and ceiling-mounted luminaires in decorative, hospitality or domestic application as well as a broad range of wide- reflector-based luminaires such as downlights.

Future-proof conceptTo allow for a smooth transition to this new generation of the PrevaLED® Cube series, crucial features have remained the same:

— Complete portfolio in terms of luminous flux, color temperature and color rendering

— Same form factor and mechanical/optical interfaces as previous generation

— High driver flexibility allows cost-effective and intelligent systems

— 5-year system guarantee (for current terms and conditions of the guarantee, please visit https://www.osram.us/warranty

1 IntroductionOf course, important improvements have been realized as well:

High flexibility through four lumen packages and five color temperatures: The PrevaLED® Cube G4 series is available as a 1100 lm, 2000 lm, 3000 lm and 5000 lm package.

— Low height of optical contact area (OCA) of 18.6 mm for compact luminaire design

— Near Lambertian light distribution for best quality of light in diffuser as well as reflector-based applications

— Industry-standard mounting holes and light-emitting surface (LES) for use with standard heat sink and reflector accessories

— Lifetime (L70B50) at Tc = 80°C: 50,000 hours — Improved poke-in connector for stranded and solid wires

— Very high efficiencies for smaller heat sinks and easier thermal management

— Typical module efficacy: up to 151 lm/W — Tc max: 90°C — Thermal protection

— Thermal derating with on-board NTC compatible with OPTOTRONIC® compact programmable LED drivers

— Conforms to UL std 60730-1 for SREC

1.2 Nomenclature

Ordering Guide

PL – CUBE – DC – 1100 – 8 27 – G4Family Shape Direct Lumen Output CRI Color Temperature 4th Generation PL = PrevaLED® Current 1100, 2000, >80 27 = 2700K 3000, 5000 >90 30 = 3000K 35 = 3500K 40 = 4000K 50 = 5000K

PrevaLED® Cube G4 LED modules | Optical considerations

4

2 Optical considerations2.1 Light distributionThe light distribution of PrevaLED® Cube G4 light engines is shown below. They create a beam angle of 110° FWHM.

The PrevaLED® Cube G4 board version has an even wider beam angle of 120° FWHM.

Light distribution curve

2.2 Reflector design The light-emitting surface of the light engines is covered by a diffuser to ensure a homogenous, smooth light distribu-tion. Please ensure that the temperature of the diffuser does not exceed 120 °C.

PrevaLED® Cube G4 light engines can also be used with secondary optics. As their optical interface has the same dimensions as common downlight modules in the market, they can be combined with available off-the shelf second-ary optics.

Standard components and support for reflector design are available through the following suppliers:

Company Website

A.A.G. Stucchi www.aagstucchi.it/en/default.aspx

ACL Reflektoren www.reflektor.com

Almeco Group www.almecogroup.com

Alux Luxar www.alux-luxar-reflektoren.com

Bender + Wirth www.bender-wirth.com

Carclo Optics www.carclo-optics.com

Fraen Corporation www.fraensrl.com

Jordan www.jordanreflectors.co.uk

KHATOD www.khatod.com

LEDiL www.ledil.com

LEDLink www.ledlink-optics.com


5

2.3 Spectral distributionThe typical spectral distribution of the PrevaLED® Cube G4 LED modules is shown in the following diagrams.

0.00

0.20

0.40

0.60

0.80

80 CRI

90 CRI

400 450 500 550 600 650 700 750 800 850

Realtive emission intensity (a.u.)

2600~3700K

4700~7000K

3700~4700K

2600~3700K

4700~7000K

3700~4700K

Wavelength [nm]

0.00

0.20

0.40

0.60

0.80

1.00

400 450 500 550 600 650 700 750 800 850


Wavelength [nm]

0.00

0.20

0.40

0.60

0.80

80 CRI

90 CRI

400 450 500 550 600 650 700 750 800 850


2600~3700K

4700~7000K

3700~4700K

2600~3700K

4700~7000K

3700~4700K

Wavelength [nm]

0.00

0.20

0.40

0.60

0.80

1.00

400 450 500 550 600 650 700 750 800 850


Wavelength [nm]

80 CRI 90 CRI

Wavelength spectrum


6

PL-CUBE-DC-3000-G4 PL-CUBE-DC-5000-G4

2.4 Luminous flux behaviorThe following diagrams show the luminous flux as a func-tion of the operating current for PrevaLED® Cube G4 LED modules with 1100 lm, 2000 lm, 3000 lm and 5000 lm. The data related to the operating current is derived from a tp temperature of 75 °C.


Flux normalized at rated current [%]

PL-CUBE-DC-2000-G4

0

0

0.2

0.4

0.6

0.8

1

1.2

1.4

1.6

1.8

2

200 400 600500 700100 300 800


PL-CUBE-DC-1100-G4

0

0

1.5

2

0.5

1

2.5

100 200 400 500300 600

Forward current (mA)



PL-CUBE-DC-3000-G4

0

0

0.2

0.4

0.6

0.8

1

1.2

1.4

1.6

1.8

200 400 600500 700100 300 800 900 1000



PL-CUBE-DC-5000-G4

0

0

0.6

0.8

0.2

0.4

1.4

1.2

1

200 400 800 1000600 1200 1400



PL-CUBE-DC-2000-G4

0

0

0.2

0.4

0.6

0.8

1

1.2

1.4

1.6

1.8

2

200 400 600500 700100 300 800


PL-CUBE-DC-1100-G4

0

0

1.5

2

0.5

1

2.5

100 200 400 500300 600




PL-CUBE-DC-3000-G4

0

0

0.2

0.4

0.6

0.8

1

1.2

1.4

1.6

1.8

200 400 600500 700100 300 800 900 1000



PL-CUBE-DC-5000-G4

0

0

0.6

0.8

0.2

0.4

1.4

1.2

1

200 400 800 1000600 1200 1400



PL-CUBE-DC-2000-G4

0

0

0.2

0.4

0.6

0.8

1

1.2

1.4

1.6

1.8

2

200 400 600500 700100 300 800


PL-CUBE-DC-1100-G4

0

0

1.5

2

0.5

1

2.5

100 200 400 500300 600




PL-CUBE-DC-3000-G4

0

0

0.2

0.4

0.6

0.8

1

1.2

1.4

1.6

1.8

200 400 600500 700100 300 800 900 1000



PL-CUBE-DC-5000-G4

0

0

0.6

0.8

0.2

0.4

1.4

1.2

1

200 400 800 1000600 1200 1400



PL-CUBE-DC-2000-G4

0

0

0.2

0.4

0.6

0.8

1

1.2

1.4

1.6

1.8

2

200 400 600500 700100 300 800


PL-CUBE-DC-1100-G4

0

0

1.5

2

0.5

1

2.5

100 200 400 500300 600




PL-CUBE-DC-3000-G4

0

0

0.2

0.4

0.6

0.8

1

1.2

1.4

1.6

1.8

200 400 600500 700100 300 800 900 1000



PL-CUBE-DC-5000-G4

0

0

0.6

0.8

0.2

0.4

1.4

1.2

1

200 400 800 1000600 1200 1400


PrevaLED® Cube G4 LED modules | Electrical considerations

7

3 Electrical considerations3.1 Forward voltage as a function of temperature

PL-CUBE-DC-3000-G4

PL-CUBE-DC-2000-G4

Forward voltage, typical (V)

PL-CUBE-DC-1100-G4

-20

37

37.5

38

38.5

39

39.5

40

0 20 60 80 10040

Tc (°C)


-20

37.5

38

38.5

39

39.5

40

40.5

0 20 60 80 10040

Tc (°C)


-20

42

42.5

43

43.5

44

44.5

45

0 20 60 80 10040

Tc (°C)


-20

37

37.5

38

38.5

39

39.5

40

0 20 60 80 10040

Tc (°C)

PL-CUBE-DC-5000-G4

PL-CUBE-DC-3000-G4

PL-CUBE-DC-2000-G4


PL-CUBE-DC-1100-G4

-20

37

37.5

38

38.5

39

39.5

40

0 20 60 80 10040

Tc (°C)


-20

37.5

38

38.5

39

39.5

40

40.5

0 20 60 80 10040

Tc (°C)


-20

42

42.5

43

43.5

44

44.5

45

0 20 60 80 10040

Tc (°C)


-20

37

37.5

38

38.5

39

39.5

40

0 20 60 80 10040

Tc (°C)

PL-CUBE-DC-5000-G4

PL-CUBE-DC-1100-G4

PL-CUBE-DC-3000-G4

PL-CUBE-DC-2000-G4

PL-CUBE-DC-5000-G4

PrevaLED® Cube G4 LED modules | Electrical considerations

8

Solid wirePlug directly.

Flexible wire1. Lightly press the push

button of the connection clamp.

2. Insert the flexible wire.

To press/release the clamps, please use an operating tool (Wago type: 206-860) or a small screwdriver.

Notes: — The connector is designed for three “poke-in” and release cycles.

— The installation of LED modules has to be carried out in compliance with all applicable electrical and safety standards. Only qualified personnel should be allowed to perform installations.

3.2 WiringThe used input clamps can handle solid or flexible wire with a cross-section of 0.2 to 0.75 mm2 (AWG 24–18). The use of solid wire is recommended.

Example: H05V-U 1x 0.5 mm2

6–7 mm(0.24–0.28 inches)

Wire preparation

9

PrevaLED® Cube G4 LED modules | Thermal considerations

Thermal interface materials

Company Website

Alfatec www.alfatec.de

Kerafol www.kerafol.de

Laird www.lairdtech.com

Bergquist www.bergquisTcompany.com

Arctic Silver www.arcticsilver.com

Wakefield www.wakefield.com

4.1 Thermal protection featuresTo achieve the best possible lifetime of the LED module and to save it from damage by overheating, thermal protection feature has been integrated. The thermal protection of the PrevaLED® Cube G4 LED module is achieved by using an on-board NTC which, when paired with an OPTOTRONIC® Compact Programmable LED driver provides a thermal foldback thus protecting it from damage by overheating.

A cULus rated NTC by Vishay (NTCS0402E3223) is used on the Cube G4 to provide thermal protection. The following curve shows the derating of the NTC with rise in temperature. This helps the final application to correlate the temperature to the output current derating. When paired with OPTOTRONIC® Compact Programmable LED Driver, OEMs can program the derating start temperature and derating end temperature using a programmable feature called "LED Thermal Protection" through the OT Programmer. The derating curve for Vishay NTC is shown below:

4 Thermal considerationsThe proper thermal design of an LED luminaire is critical for achieving the best performance and ensuring the longest lifetime of all components. Due to the high efficacy of PrevaLED® Cube G4 light engines, only a partial amount of the introduced electrical power has to be dissipated through the back of the light engine.

4.2 TIM and other accessoriesWhen mounting a PrevaLED® Cube G4 light engine within a luminaire, it is recommended to use thermal interface material (TIM) between the back of the light engine and the luminaire housing or heat sink. It is recommended to use thermal paste. In order to balance possible unevenness, the material should be applied as thinly as possible, but as thickly as necessary. In this way, air inclusions, which may otherwise occur, are replaced by TIM and the required heat conduction between the back of the light engine and the contact surfaces of the luminaire housing is achieved.For this purpose, the planarity and roughness of the surface should be optimized.

The list below is a selection of suppliers of thermal interface materials.

Programmable Range for Vishay NTCS0402E3223

Resistance (kΩ)

0

2

4

6

8

10

12

40 80 100 12060

Temperature (°C)

70 90 11050 130 150 170140 160

1

2

3

PL CUBE DC

LED -LED +

DIM +DIM -

PRG/NTCDGNDAUX+

VACInputBLK

WHT

BROWN GREEN

PURPLE GRAY

YELLOW

RED BLUE

GRN

The NTC mounted on the Cube can be connected to the OPTOTRONIC® LED driver by connecting NTC port on Cube to NTC port on the driver as shown below. For detailed information, please refer to the LED Thermal Protection Application Guide

10


4.3 Cooling system and heat sink For the selection of a suitable heat sink, several points regarding thermal resistance have to be considered.The selection is usually carried out through the following necessary steps.

Notes: A thermal design must always be confirmed by performing a thermal measurement in steady-state condition. The whole area of the PCB must be in full contact with the heat sink.

The list below is a selection of suppliers of different cooling solutions.

Supplier of active and passive cooling systems

Company Website

Nuventix www.nuventix.com

Sunon www.sunon.com

Cooliance www.cooliance.eu

AVC www.avc-europa.de

SEPA www.sepa-europe.com

Wakefield-Vette www.wakefield-vette.com

Fischer Elektronik www.fischerelektronik.de

Wakefield www.wakefield.com

MechaTronix www.mechatronix-asia.com

Define boundaryconditions

Estimate heat sink

thermal resistance on LED module level

Select heat sink thermal resistance

Total power dissipation of the LED module, max. ambient temperature ta, max. reference temperature tr according to lifetime requirements

Use the estimated Rth as a target for a possible heat sink profile and examine the perfor-mance curve in the heat sink manufacturer’s catalog.

Rth =tr - ta

Pth

tr measured at the Tc point

4.4 Tc point location and temperature measurementThe Tc point is the location where to check if the chosen cooling solution (heat sink) is sufficient to ensure the LED module performance. The Tc point is located on the back of the LED module under the center of the light-emitting surface (see following image).

To enable a lifetime of 50,000 (L70B50), the reference temperature (tr) at the Tc point must not exceed 80°C. The maximum temperature reached at the Tc point must not exceed 90°C. A correct temperature measurement can, for example, be performed with a thermocouple.

Location of the Tc pointTo measure the temperature and to ensure a good thermal coupling between the LED module and the heat sink, you should drill a hole into the heat sink and push the thermocouple through it. To ensure a direct contact between the thermocouple and the PCB, it is recommended to glue the thermocouple onto the PCB. You can, for example, use an acrylic adhesive (e.g. type Loctite 3751).

It is also possible to use a sprung thermocouple. A suitable type is: Electronic Sensor FS TE-4-KK06/09/2m. Please note that a good thermal contact between the thermocouple and the PCB is required. Please refer to the data- sheet and the application guideline of the manufacturer to ensure correct handling.

Another possible way is to create a small groove along the top surface of the heat sink and run the thermocoupleto the Tc point inside the groove.

37.3

41.4

All figures in mm

Tc point

Location of the Tc point

11


4.5 ThermocoupleUse a thermocouple that can be glued onto the LED module. Make sure that the thermocouple is fixed with direct contact to the Tc point. Examples of suitable thermocouples:

Notes:Please keep in mind that you need a direct contact between the thermocouple and the PCB. If you use TIM, you should cut out a small area where the thermocouple has direct contact to the PCB.

Different thermocouples

Illustration Description Temperature range [°C]

PVC-insulated thermo couple

-10 … +105

PFA-insulated thermo couple

-75 … +260

Sprung thermo couple

-75 … +260

K-type thermocouple with miniature connector

Mounting of a PFA-insulated thermocouple by means of a groove

Mounting of a thermocouple through a hole in the heat sink

PrevaLED® Cube G4 LED modules | Lifetime and thermal behavior

12

5 Lifetime and thermal behavior 5.1 Luminous flux as a function of temperatureThe following diagrams show the behavior of the luminous flux output as a function of the temperature at the Tc point for PrevaLED® Cube G4.

5.2 LifetimeThe performance of PrevaLED® Cube G4 light engines is measured at a typical Tc of 75°C. The maximum temperature at the Tc point must not exceed 80°C to achieve the expected lifetime (L70B50) of 50,000 hours. The maximum temperature at the Tc point to cover the operational warranty



PL-CUBE-DC-3000-G4

PL-CUBE-DC-1100-G4Flux normalized at rated current [%]

PL-CUBE-DC-5000-G4

-20

0.94

0.96

0.98

1

1.02

1.04

1.06

1.08

1.1

1.12

20 60 10080 1200 40

Tc (°C)


-20

0.94

0.96

0.98

1

1.02

1.04

1.06

1.08

1.1

1.12

20 60 10080 1200 40

Tc (°C)

PL-CUBE-DC-2000-G4


-20

0.94

0.96

0.98

1

1.02

1.04

1.06

1.08

1.1

1.12

20 60 10080 1200 40

Tc (°C)


-20

0.94

0.96

0.98

1

1.02

1.04

1.06

1.08

1.1

1.12

20 60 10080 1200 40

Tc (°C)

PL-CUBE-DC-3000-G4


PL-CUBE-DC-5000-G4

-20

0.94

0.96

0.98

1

1.02

1.04

1.06

1.08

1.1

1.12

20 60 10080 1200 40

Tc (°C)


-20

0.94

0.96

0.98

1

1.02

1.04

1.06

1.08

1.1

1.12

20 60 10080 1200 40

Tc (°C)

PL-CUBE-DC-2000-G4


-20

0.94

0.96

0.98

1

1.02

1.04

1.06

1.08

1.1

1.12

20 60 10080 1200 40

Tc (°C)


-20

0.94

0.96

0.98

1

1.02

1.04

1.06

1.08

1.1

1.12

20 60 10080 1200 40

Tc (°C)

PL-CUBE-DC-3000-G4


PL-CUBE-DC-5000-G4

-20

0.94

0.96

0.98

1

1.02

1.04

1.06

1.08

1.1

1.12

20 60 10080 1200 40

Tc (°C)


-20

0.94

0.96

0.98

1

1.02

1.04

1.06

1.08

1.1

1.12

20 60 10080 1200 40

Tc (°C)

PL-CUBE-DC-2000-G4


-20

0.94

0.96

0.98

1

1.02

1.04

1.06

1.08

1.1

1.12

20 60 10080 1200 40

Tc (°C)


-20

0.94

0.96

0.98

1

1.02

1.04

1.06

1.08

1.1

1.12

20 60 10080 1200 40

Tc (°C)

PL-CUBE-DC-3000-G4


PL-CUBE-DC-5000-G4

-20

0.94

0.96

0.98

1

1.02

1.04

1.06

1.08

1.1

1.12

20 60 10080 1200 40

Tc (°C)


-20

0.94

0.96

0.98

1

1.02

1.04

1.06

1.08

1.1

1.12

20 60 10080 1200 40

Tc (°C)

PL-CUBE-DC-2000-G4


-20

0.94

0.96

0.98

1

1.02

1.04

1.06

1.08

1.1

1.12

20 60 10080 1200 40

Tc (°C)


-20

0.94

0.96

0.98

1

1.02

1.04

1.06

1.08

1.1

1.12

20 60 10080 1200 40

Tc (°C)

of the light engine is 90°C. A warranty of 5 years can only be given if the light engine is not operated above a Tc point temperature of 85°C. Please note that as the Tc increases, the lifetime of PrevaLED Cube G4 light engines decreases. Moreover, the failure rate will also increase.

PrevaLED® Cube G4 LED modules | Mechanical considerations

13

6 Mechanical considerationsThe following schematic drawing provides further details on the dimensions of PrevaLED® Cube G4 LED modules. For 3D files of the LED modules, visit www.osram.us/ds.

6.2 Mechanical protection of the light engineThe housing of a PrevaLED® Cube G4 LED module should not be exposed to strong mechanical stress. Please apply force only to the dedicated mounting positions. Strong mechanical stress can lead to irreversible damage of the LED module.

For operation in damp, wet or dusty environments, the user has to make sure that an adequate ingress protection (IP) is chosen. The LED module has to be protected by a suitable IP rating of the luminaire housing. Please consider the luminaire standard IEC 60598-1 as well as the different requirements for indoor and outdoor application.

kg

6.3 Mounting To fix a PrevaLED® Cube G4 light engine to a heat sink, you may use M4 cylinder head screws according to DIN 912 or ISO 4762. The recommended torque is 1.0 ± 0.5 Nm.

Note:General mechanical tolerances according to ISO 2768 c.

Mount the LED module from the top

All figures in inches (mm)

center of lightemitting area

ø2.4 (61)

ø2.54 (64.4)

ø2.63 (66.9)

0.43 (11)

0.73 (18.6)

0.76 (19.4)

0.83 (21.1)

3.21 (81.6) 2.68

(68)

2.14 (54.4)

3.26 (82.8)

1.47 (37.3)

ø0.17 (4.3)TYP (3)xPLC

NTC

center of lightemitting area

ø2.4 (61)

ø2.54 (64.4)

ø2.63 (66.9)

0.43 (11)

0.73 (18.6)

0.76 (19.4)

0.83 (21.1)

3.21 (81.6) 2.68

(68)

2.14 (54.4)

3.26 (82.8)

1.47 (37.3)

ø0.17 (4.3)TYP (3)xPLC

NTC

6.1 Outline drawing

PrevaLED® Cube G4 LED modules | Norms and standards

14

7 Norms and standardsSafety: UL 8750 Class 2

Ingress protection: IP20 (no ingress protection without housing)

Approvals: UL

DisclaimerAll information contained in this document has been collected, analyzed and verified with great care by OSRAM. However, OSRAM is not responsible for the correctness and completeness of the information contained in this document and OSRAM cannot be made liable for any damage that occurs in connection with the use of and/or reliance on the content of this document. The information contained in this document reflects the current state of knowledge on the date of issue.

www.osram.us/ds

OSRAM SYLVANIA Inc.

200 Ballardvale Street

Wilmington, MA 01887 USA

877-636-5267

[email protected]

www.osram.us/ds

OSRAM, PrevaLED and OPTOTRONIC are registered trademarks. All other trademarks are those of their respective owners. Specifications subject to change without notice.

© 2018 OSRAM

LED492R3 3-18

Documents

¦ · PrevaLED® Cube G4 LED modules | Contents 2 Please note: All information in this guide has been prepared with great care. OSRAM, however, does not accept liability for