Design-in guide. Fortimo LED Disk module. asimpleswitch.com

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1 Design-in guide Fortimo LED Disk module asimpleswitch.com

2 Contents Introduction 3 Designing luminaires based on the Fortimo LED Disk 3 Applications 3 Future-proof 3 Designing a luminaire 4 IEC recommendations 4 Electrostatic device measures (ESD) 4 Installation instructions 4 Over-voltage protection 4 Mechanical design 5 Range 5 The structure of the Fortimo LED Disk module 5 Dimensions of the Fortimo LED Disk module 5 Screws / wiring 5 Quality 13 Compliance and approval 13 Photobiological safety aspects 13 Emission limit 14 UV and IR radiation 14 Electromagnetic compatibility 14 Humidity 14 Exposure to direct sunlight 14 Vibration and shocks 15 IP codes, dust and moisture protection 15 Glow-wire test 15 End-of-life behavior 15 Disposal 15 Index of visuals 16 Optical design 6 Secondary optics 6 Philips Fortimo LED Disk light distribution (polar, experiment) 6 CIE-1931 (x, y) 7 Color consistency (SDCM) 7 Starting characteristics 7 Lumen maintenance 7 Thermal design 8 General 8 Test requirements 8 Maximum temperature 8 Critical measurements point 8 Operation under built-in conditions 8 Case temperature and LED module performance 9 Heat sink design 9 Size of heat sink 10 Air flow 10 Thermal model 11 Calculating your heat sink 11 Philips reference heat sink design of Fortimo LED Disk 12 Heat sink manufacturer contact 12 2

3 Introduction Thank you for choosing the. In this guide you will find all relevant information to design new luminaires based on this disk. If you require any further information or support please consult your local Philips office or visit: Designing luminaires based on the Fortimo LED Disk The use of LEDs brings additional considerations for luminaire manufacturers compared with traditional lamps. For example, how can you ensure that your new luminaire can take advantage of LED improvements without having to redesign it each time? Also, how do you ensure that your new luminaire has a sufficient heat sink, and how do you deal with variations in flux and/or color. Fortunately, the Fortimo LED Disk addresses these issues to ensure easy adoption of LED technology for high lumen packages of 800+ lm. The Fortimo LED Disk is intended for downlight- and consumer luminaires. A separate driver is not needed as this function is integrated in the disk. An external heat sink and optic can be easily attached to the module. Nowadays complementary partners are developing heat sinks (passive cooling) and reflectors around Philips LED ranges, including the Fortimo LED Disk. In this guide you will get more information on this subject. Applications The Fortimo LED Disk is intended for general lighting applications in semi professional markets such as: Hospitality, healthcare and cruise ship applications: corridors, service, areas, lobbies, lounges, restaurants, reception areas, waiting rooms Home applications: pendant and ceiling luminaires, shelf lighting, under-cabinet lighting Retail applications: corridors, changing rooms Office applications: corridors, meeting rooms Other markets can be addressed as long as this does not create design conflicts with the Fortimo LED Disk, and only if the relevant luminaire regulations are respected (e.g. EN 60598). Furthermore, the LED Disk has no IP classification, so if you would like to develop a Fortimo-based luminaire for outdoor use, you are responsible for proper IP protection and approbation. Also, please consult us if you wish to deviate from the design rules as described in this guide. Future-proof Future advances in bare LED efficacies will be incorporated into the Fortimo LED Disk. Which means you can take advantage of increasing efficacies, without changing the dimensions, shape or lumen output of the module. This is a truly future-proofed approach to enables you to plan and design new luminaire ranges that can be marketed (without redesign) for many years to come. 3

4 Designing a luminaire IEC recommendations The general recommendations for luminaire design given by the IEC (IEC 60598) and the national safety regulations are also applicable to LED-based luminaires. Electrostatic device measures (ESD) The Fortimo LED Disk does not require special ESD measures in a production environment. Installation instructions The Fortimo LED Disk modules are build-in systems for integration into luminaries. Hence, they include interfaces for: Heat sink connection to the module Mains input via wire socket connection to the input wires of the module The reflector can be connected via the heat sink (standard heat sink from Wisefull or AVC) available with holes for fixation of the reflector. We recommend adding a strain relief mechanism to make sure the mains connection cannot be removed and pulled from the module. The Fortimo LED Disk DLM module has no IP classification. If an OEM decides to use the DLM system in a luminaire for outdoor application, they shall be responsible for proper IP protection and approval of the luminaire. Over-voltage protection The LED Disk 2700K has an over-voltage protection system to prevent extreme lifetime degradation. This protection switches on when more than 264 V is used. Since 4000K and 5000K LED Disks flux stability is high, at V, there is no need for such protection system. Note: The Fortimo LED Disk is class II, and does not require protective earth connection in the luminaire. 4

5 Ø Mechanical design Range Fortimo LED Disk 2700K 800lm, 4000K 850lm and 5000K 900lm. All three are not dimmable. Fortimo LED Disk 2700K 800 lm The structure of the Fortimo LED Disk module The LED module consists of six main components: 1 Metal core PCB with four LEDs mounted 2 Driver PCB 3 Mixing chamber 4 Heat spreader 5 Micro-lens diffuser 6 Plastic housing Dimensions of the Fortimo LED Disk module Ø Side view Top view Ø 44 Screws holes to fix the module to the heat sink 3XM3 Bottom view Screws / wiring For fixation of the system we advise to use hexagon socket head cap screw M3. The length of the mains cable is 180mm and the dimension of the strand wire used in the mains cable is 18AWG. 5

6 Optical design Secondary optics The Fortimo LED Disk module generates an 85 beam angle shape (see polar diagram / intensity diagram) which is a starting point for secondary optic design by OEMs. Ray set files are available upon request. The secondary optic design should not cover the exit aperture. The aperture diameter is 39.6mm. Secondary optics are not part of the Fortimo LED Disk offering. This is an added value area for OEMs, and it is up to the OEM to decide whether secondary optics are needed depending on the end application. Philips Fortimo LED Disk light distribution (polar, experiment) Module: Philips Fortimo LED Disk LEDisk 2700K LEDisk 4000k, 5000k Light distribution of Fortimo LED Disk 6

7 CIE-1931 (x, y) k, 4sdcm 2700k, 7sdcm Color consistency (SDCM) The color consistency for the Fortimo LED Disk 2700K, 4000K and 5000K is 7 0 hours. SDCM stands for Standard Deviation of Color Matching and the value 7 refers to the size of an ellipse around the black body locus. Staying within this ellipse results in a consistency of light that ensures no difference in color can be noticed from one luminaire to another. Starting characteristics The Fortimo LED Disk 2700K is switched on in milliseconds, which is a general characteristic of LEDs. The color will start as reddish white, and tends to be stable after a few minutes. For the 4000K and 5000K, the power needs a few minutes to be stable. However, the color performance remains the same k, 7sdcm BBL Lumen maintenance When the Fortimo LED Disks are used within specification, lumen maintenance of 70% at 25,000 hours is expected. 2700K, Tc < 70 C and Ta < 35 C 4000K, Tc < 75 C and Ta < 35 C 5000K, Tc < 75 C and Ta < 35 C k, 7sdcm BBL Color consistency (color point spread) of Fortimo LED Disk 7

8 Thermal design Example of a system with passive heat sink Heat sink Module Fixation Reflector General For optimum performance the Fortimo LED Disk module must operate within specified temperature limits. But because there is no over-temperature protection in the module, a cooling methodology must be applied. Test requirements Temperature measurements should only be performed when the luminaire is thermally stable, which may take 0.5 to 2 hours depending on the thermal capacity of the luminaire (see also the relevant clauses in IEC 60598). For all measurements such as temperature, luminous flux and power, a stabilization period of at least half an hour must be allowed before any reliable data can be obtained. Measurements must be performed by means of thermocouples that are firmly glued to the surface (and not, for example, secured with adhesive tape). Maximum temperature Because LEDs are temperature-sensitive, LED modules require a different approach with respect to the maximum permissible component temperature. This is different to most other types of light source. Tc point Tc position Critical measurements point For LEDs the junction temperature is the critical factor for operation. Since there is a direct relation between the case temperature and the LED junction temperature it is sufficient to measure the under-side of the module. The critical point is on the rear surface of the LED module. If the case temperature (Tc) at the critical measurement point is too high (exceeding the recommended maximum temperature), the LED performance will be reduced in terms of light output, lifetime and/or lumen maintenance. In the reference heat sink design there is a hole which allows a thermocouple to measure the Tc. Operation under built-in conditions The heat produced by the LED module in the luminaire (or similar housing) must be dissipated to the surroundings. If a luminaire is physically insulated by a ceiling, wall or insulation blanket, the heat produced cannot be easily dissipated. This will cause the LED module in the luminaire to over-heat, which in turn can have an adverse affect on the system s performance and lifetime. For optimum performance and lifetime it is important that: air can flow freely around and through the luminaire, and around the LED modules. This airflow has a positive effect on temperature control and therefore on the performance and lifetime of the luminaire and LED module. 8

9 Tc of 70ºC (±5 C) assures following specifications: color temperature 2400K K 7 SDCM targeted flux lifetime 25,000 hours (APR version) Tc 75ºC, it assures following specifications: color temperature 3600K K 7 SDCM targeted flux lifetime 25,000 hours (APR version) Tc 75ºC, which assures following specifications: color temperature 4400K K 7 SDCM targeted flux lifetime 25,000 hours (APR version) Case temperature and LED module performance To ensure the specified light output, light maintenance and lifetime of the Fortimo LED Disk module we have designed-in a Tcase (Tc) measuring point on the rear surface of the LED module. The absolute maximum Tc is 100ºC and the module s lifetime will be severely reduced at this temperature. Depending on the application conditions, the heat sink can be reduced as long as the Tc typical and Tc max remain at the above stated targeted temperatures. Heat sink design To ensure that housing temperatures do not exceed the specified maximum values, a luminaire can act as an additional heat sink. The heat transport mechanisms are conduction via the heat sink and convection and thermal radiation to the surroundings. The objective of this chapter is not to define exactly how to calculate/design a heat sink, but to give some guidelines on how to improve its performance. Although a heat sink can have many (complex) shapes, the following discussion is based on a disk shape. The results for square plates, etc., are more or less the same provided the surface areas are equal. The type of material used has a relatively large influence on the final result. For example, a comparison of the thermal conductivity (k) of copper with that of corrosionresistant steel (see table) shows that a substantially smaller heat sink is possible with copper. In practice the best material for heat sinks is (soft) aluminum. The thickness (d) of the heat sink disk is also of major importance. Assuming the use of different heat sinks of the same diameter but made from different materials, the same effect in terms of temperature difference will be achieved if the product of thermal conductivity (k) and disk thickness (d) is constant. This means more or less the same result is obtained with a disk of 1 mm copper, 2 mm aluminum, 4 mm brass, 8 mm steel or 26 mm corrosion-resistant steel. Increasing the diameter, and thereby also the surface area, of the heat sink disk also leads to an improvement, but the effect is smaller for larger diameters and depends on the thermal conductivity (k) of the material and the thickness (d).thermal radiation can also form a substantial part of the total heat transfer, and is of the same order as for convection. This depends strongly on the emission coefficient (see table) of the surface, which lies between 0 and 1. For example, a polished aluminum surface has a very low emission coefficient, while that of a painted surface is very high. For passive cooling, a high emission coefficient is preferred. 9

10 Material W/mK Copper 400 Aluminum 200 Brass 100 Steel 50 Corrosion-resistant steel 15 Thermal conductivity Material Surface Emission coefficient Aluminum New/polished Oxidized Anodized 0.8 Steel Painted New/polished Emission coefficients Heavy oxidized Size of heat sink The Fortimo LED Disk 2700K module consumes 14.5 W, and the 4000K or 5000K module uses 15.2 W. All of them contain a built-in heat spreader. Every of these modules must be connected to the heat sink with a thermal interface material (TIM) in between; this ensures a perfect contact between the module and the heat sink. The 2700K module has a heat of 10.5 W, and the 4000K or 5000K creates a heat of 12 W. All these heat needs to be taken away from the module in order to maximum the module performance and its lifetime. The temperature of the test point (Tc) is important. During the thermal design process, the aim is to keep the Tc at a typical temperature of 70 C for the 2700K module, and maximum 75 C for the 4000K and 5000K modules. Although the Fortimo LED Disk module will not fail at a higher Tc (max 100 C), insufficient cooling will lead to reduced light output and lifetime. Air flow Before starting with any calculation/design, an important point to consider is the airflow. In general, hot air moves upwards at a relatively low speed. If the heat sink is horizontal, it obstructs the airflow, which reduces the efficiency of the heat sink, and obviously. This situation should be avoided. A better way to position the heat sink fins is to have them parallel to the airflow direction. Also, closing the top of the profile will reduce the heat sink s efficiency and should be avoided during design and installation. 10

11 Analogy between electrical and thermal resistances Analogy between electrical and thermal Electrical: U = voltage difference [V] I = current [A] R = resistance [Ω] Ohm s law: U= I * R U1 I T1 Pth Thermal: ΔT = temperature difference [ºC] P th = thermal power [W] R = thermal resistance [K/W] or [ºC/W] Thermal model Standard STATIC thermal situations can be modeled with so-called thermal resistances. These resistances behave in much the same way as electrical resistors, where when the voltage and current are known, it is possible to calculate the electrical resistor with Ohm s law. The same is possible with a thermal resistor. If the temperature difference and thermal power are known, the thermal resistance can be easily calculated with the Thermal Ohm s law. Thermal model U 2 T 2 Thermal Ohm s law: ΔT= Pth * R th Calculating your heat sink We start with the thermal calculation formula: Formula (f1) describes the relation between temperature difference, thermal power, and thermal resistance. This formula enables you to calculate the required thermal resistance when the thermal power and temperature difference are known. Formulas: Thermal Ohm s law: ΔT = Rth x Pth (f1) Next we gather all available information, as can be found in the datasheet, application details and design choices. Below we calculate the required thermal resistance of the heat sink for ceiling downlight application as an example: Available information for the 2700K module: Tc - typical = 70 C Pth-Intuos LED disk 800 lm = 10.5 W Tambient - typical = 25ºC Below we calculate the required thermal resistance of the heat sink, such that performance and lifetime can be guaranteed. 11

12 Calculation of total maximum thermal resistance: (f1) ΔT = Tc - Tambient = = 35ºC Rth heatsink = ΔT /Pth = 35/10.5 = 3.33 K/W Calculation of the total thermal resistance: Rth-from-Tc-to-ambient with formula f1. This results in 3.33 K/W. Ø º Ø 3 Ø 80 Ø Ø 3.2 Ø 70 Now we know the thermal resistance of the needed heat sink. This heat sink dimension is such that at maximum power and typical ambient temperature, the temperature of the test point Tc for the 2700K module is at 70 C. For the 4000K and 5000K modules, the Tc is less or equal to 75 C. These temperatures are lower than Tc-max, which assures that lifetime, color temperature, and light output will be according to specifications. 25 Ø 44 Philips reference heat sink design of Fortimo LED Disk The drawing on the left is the Philips reference heat sink design of Fortimo 2700K LED Disk for ceiling downlight application (Ta < 35 C and Tc < 70 C). Philips reference heat sink design of Fortimo LED Disk Heat sink manufacturer contact Wisefull and AVC made the heat sink specifically for Fortimo LED Disk according to the reference heat sink design from Philips. For a ceiling mounted luminaire, the heat sink assures the 2700K s Tc < 70 C, and the 4000K or 5000K s Tc 75 C as well. However Tc measurement is necessary even when using such a heat sink since the application varies. Screw holes are pre-made on the heat sink to fix the reflector directly onto the heat sink. If you need more information regarding the heatsink, please contact either Wisefull or AVC. Thermal Products Division, Wisefull Technology LTD. weihua@wisefull.com Website: Asia Vital Components Co., LTD. Website: 12

13 Quality Compliance and approval Philips Fortimo LED Disk complies with the following international rules and regulations: Safety EN/IEC & 2-2, EN/IEC & 2-13 EN/IEC Approvals ENEC 05 Marking CE Photobiological safety aspects As of March 2007, LEDs and LED-based products for general lighting are no longer covered by the Eye Safety standard for lasers, IEC Safety of laser products. Instead, the new lamp standard, IEC Photobiological safety of lamps and lamp systems, covering incoherent light sources, is now applied. This international standard gives guidance for evaluating the photobiological safety of lamps and lamp systems including luminaries. Specifically it specifies the exposure limits, reference measurement technique, and classification scheme for the valuation and control of photobiological hazards from all electrically powered incoherent broadband sources of optical radiation, including LEDs but excluding lasers, in the wavelength range from 200 nm through 3000 nm. In the photobiological safety standard, hazard categories are defined as follows: Radiance-based Blue Light LB nm Retinal Thermal LR nm Retinal Thermal Weak Stimulus LIR nm Irradiance-based Actinic UV Skin & Eye ES nm Eye UVA EUVA nm Blue Light Small Sources EB nm Eye IR EIR nm 13

14 Measurements on the Fortimo LED Disk gave the following results: The following should be taken into account: The effective radiance measurement for Blue Light (LB) modules is Low, meaning that the LED modules are categorized in Risk Group 1. The permitted exposure time for Blue Light radiance (relevant when looking into the source) is limited to 3 hours. Because of the Law of Conservation of Radiance, integrating the LED module into a luminaire results in either the same or reduced radiance. Final assessment of the luminaire is recommended. The measured irradiance-based values (E) for the categorized hazards are all within the exempt group. In general the permitted exposure time for irradiance is limited when in the low, moderate or high risk group. Limiting the exposure time and/or the distance to the source can reduce the hazard level. However, for the measured LED modules there are no special precautions necessary since they are ranked in the exempt group. Final assessment of the luminaire (including e.g. secondary optics) is recommended. Emission limit Hazard category Emission Limit LB Low (Risk group I) ES Exempt EUVA Exempt EB Exempt EIR Exempt * Exempt means no risk. UV and IR radiation The LED Disk is free of UV and IR radiation in the beam. Electromagnetic compatibility Electromagnetic compatibility, EMC, is the ability of a device or system to operate satisfactorily in its electromagnetic environment without causing unacceptable interference in practical situations. Philips Fortimo LED Disks fulfill the requirements with regard to electromagnetic compatibility as laid down in European Norms EN and EN/IEC 55022, EN and EN/IEC Humidity Fortimo LED Disk modules and LED drivers have no IP classification. The OEM is responsible for proper IP classification and approbation for the luminaire. Exposure to direct sunlight Exposure to direct sunlight during operation may have severe temperature or UV effects. Where this situation is likely, extensive temperature testing is recommended. The Fortimo LED Disk modules are to be built into luminaires so this is expected to be negligible. 14

15 Vibration and shocks Shock resistance: ms half-sine and 11ms half-sine Vibration resistance: sweep Hz 1 octave/minute 0.35 mm peak Cycle: 10 /axes Radom Vibration resistance: G2/Hz dB/Oct G2/Hz IP codes, dust and moisture protection Philips Fortimo LED Disks are built-in systems and have therefore no IP rating. Glow-wire test s conform to the 650 degree glow- wire test. Reference test: according to additional national deviations for clause 13.3 (Annex 2c of EN ). An exception is made for France, where local regulations are stricter. End-of-life behavior Unlike typical conventional light sources, LEDs are not subject to sudden failure or burnout. There is no time at which the light source will cease to function. Instead, the performance of LEDs shows gradual degradation over time. When used according to specification: Fortimo LED Disk modules are predicted to deliver an average of 70% of their initial intensity after 25,000 hours operation at Tcase 70 C. Disposal At the end of their (economic) lifetime, appropriate disposal of the Fortimo LED Disk is recommended. The modules are basically normal pieces of electronic equipment containing components that at present are not considered to be harmful to the environment, or which can be disposed of with normal care. It is therefore recommended to dispose of these parts as normal electronic waste, according to local regulations. 15

16 Index of visuals Fortimo LED Disk 2700K 800 lm 5 Light distribution of Fortimo LED Disk 6 Color consistency (color point spread) of Fortimo LED Disk 7 Example of a system with passive heat sink 8 Tc point 8 Thermal conductivity 10 Emission coefficients 10 Thermal model 11 Philips reference heat sink design of Fortimo LED Disk 12 16

17 For more information please visit: Koninklijke Philips Electronics N.V. All rights reserved. Reproduction in whole or in part is prohibited without the prior written consent of the copyright owner. The information presented in this document does not form part of any quotation or contract,is believed to be accurate and reliable and may be changed without notice. No liability will be accepted by the publisher for any consequence of its use. Publication thereof does not convey nor imply any license under patent or other industrial or intellectual property rights. Document order number: /2011