INTERMO Spotlight Module

Transcription

1 November 2014 INTERMO Spotlight Module Application Note Edition 1.0 Copyright Sharp Corporation Page 1 of 19

2 Table of ContentsTable of Figures Introduction Handling Module Overview Module Types Understanding INTERMO Part Numbers Optics Light Distribution & Ray Sets Optical Characteristics Luminous Flux CIE 1931 Colour Space Chromaticity Coordinates Colour Rendering Values (CRI) Spectral Data Electronic Considerations Forward Voltage as a Function of Temperature Driving Measurements Wiring Considerations Mechanics CAD Files and technical drawings Mounting Thermal Management Temperature measurement point locations Thermal Integration Lifetime Chemical Compatibility Replacement and Repair Appendix Zhaga Copyright Sharp Corporation Page 2 of 19

3 Table of Figures Figure 1 Ray file origin location... 6 Figure 2 - INTERMO Light Distribution... 6 Figure 3 Current dependence of luminous flux... 8 Figure 4 Temperature dependence of luminous flux... 8 Figure 5 - Chromaticity Coordinates in 1931 CIE colour space, production tolerances (boxes),... 9 Figure 6 R values of CRI Figure 7 Spectral Power Distributions Figure 8 - Case Temperature vs. Forward Voltage Figure 9 Stripping and wiring the module Figure 10 Mounting an INTERMO module Figure 11 Location of temperature points T c and T r Figure 12 Example derating curve. Intermo modules must also be operated within the derating curve (green area) Figure 13 - Table of key thermal values at typical drive conditions Introduction This Application Note provides the basic information required to successfully design-in a Sharp INTERMO module. The INTERMO range is easy to integrate by design, with only 4 simple assembly steps: 1. Remove TIM protective sheet 2. Place INTERMO onto heatsink (and optional optics attachment clip if required) 3. Secure INTERMO to heatsink with M3 screws 4. Insert power wires into INTERMO 2 Handling Care must be taken when handling INTERMO modules to prevent damage. Copyright Sharp Corporation Page 3 of 19

4 Storage conditions The product should be used within a year of delivery. o Before assembly into a luminaire the modules should be stored in the sealed packaging in which they are delivered and maintained within the temperature range 0 ~ 40 o C at a relative humidity less than 90 %. o After assembly the module must be maintained within the temperature range -40 o C ~ 100 o C Do not drop or mechanically shock Intermo module. Electrostatic discharge (ESD) This can result in catastrophic damage to an LED. INTERMO modules should be handled in an ESD-safe assembly environment. Cleanliness Modules should be handled in a clean environment to avoid contamination (particulate, oil residue, moisture). Handling Do not touch the light emitting surface (LES) of the INTERMO. Pressure applied to this area can result in damage to the LED bond wires beneath. Cleaning foreign material can be removed from the LES by either blowing with dry air or wiping gently with a lint-free cloth dampened with isopropyl alcohol (IPA). TIM cover sheet the thermal interface material (TIM) is shipped with a protective cover sheet which needs to be removed before attaching the INTERMO to a heatsink. Avoid touching the TIM surface once the cover has been removed. Ensure that the TIM surface is even and that there are no bubbles or lumps that could form air gaps. Safety To avoid injury do not touch the light emitting surface when the LED is powered. It can become extremely hot. Do not look directly into the LED for long periods as this may hurt your eyes. 3 Module Overview The Sharp INTERMO LED module line-up delivers Sharp s market-leading Zenigata LED technology in easy-to-use module packages. INTERMO modules provide an excellent quality of light and high optical performance, while still delivering the energy efficiency customers expect of LED products. The INTERMO Standard and INTERMO Slim ranges are perfectly suited to spotlight and downlight applications including retail and hospitality. 3.1 Module Types There are 20 LED modules across the INTERMO range, with 10 in each of the Standard and Slim mechanical platforms. Their luminous flux ranges from 3000 to 5000lm, with Ra options of Ra80+ Copyright Sharp Corporation Page 4 of 19

5 and Ra90+. The following table lists key performance figures for the INTERMO standard range. An equivalent line-up is available for the INTERMO slim range. Module CCT (K) Current (ma) Voltage (V) Luminous Flux Category(lm) Efficacy (lm W -1 ) CRI GW7MMC30GZC GW7MMC40GZC GW7MGD30GZC GW7MGD40GZC GW7MMD30GZC GW7MMD40GZC GW7MGE30GZC GW7MGE40GZC GW7MME30GZC GW7MME40GZC Understanding INTERMO Part Numbers The part number for INTERMO modules contains some information on the module specification. GW7MME40GSC is given as an example: GW7M M : internal code for INTERMO generation : code for CRI. M = Ra80+, G = Ra90+ E : code for power consumption. E ~45W, D ~35W, C ~25W 40 : code CCT. 40 = 4000 K, 30 = 3000K GSC : code for INTERMO Slim mechanical platform. The INTERMO Standard code is GZC Copyright Sharp Corporation Page 5 of 19

6 4 Optics 4.1 Light Distribution & Ray Sets INTERMO Modules have a lambertian light distribution. Rayset files and IES files can be downloaded from sharpleds.eu (from early 2015). Raysets are available in the following formats containing 100k, 500k and 5M rays. The origin of the ray sets is the centre of the top of the light emitting surface, as depicted in Figure 1. The ray sets are measured for the LED without module housing to allow for optical designs where a reflector is positioned close to the light emitting surface. If an optic is used which fits to the top or outside of the module some high angle rays may be blocked by the module housing. Figure 1 Ray file origin location Figure 2 - INTERMO Light Distribution Copyright Sharp Corporation Page 6 of 19

7 4.2 Optical Characteristics Module Luminous Flux Φ/lm Zhaga Lumen Flux Class Category Typ. Nominal Current Chromaticity Coordinates x y CCT/K General Colour Rendering Index GW7MMC30GZC 3000 C GW7MMC40GZC 3000 C GW7MGD30GZC 3000 C GW7MGD40GZC 3000 C GW7MMD30GZC 4000 C GW7MMD40GZC 4000 C GW7MGE30GZC 4000 C GW7MGE40GZC 4000 C GW7MME30GZC 5000 C GW7MME40GZC 5000 C For more detailed information, refer to the model-specific datasheet available from sharpleds.eu (from early 2015). More information on the Zhaga flux categories is available in section Luminous Flux The relationship between Relative Luminous Flux and Forward Current is given in the following figure, assuming T j =90 o C. To estimate performance for a different value of T j, the temperature dependence of the Luminous Flux must be considered (Figure 4). The maximum Forward Current and hence Luminous Flux is dependent on T c. Further details can be found in the derating curve located in model specific specification documents. Copyright Sharp Corporation Page 7 of 19

8 Relative Luminous Flux/ Forward Current/mA GW7MMC--GZC GW7MGD--GZC GW7MMD--GZC GW7MGE--GZC GW7MME--GZC Figure 3 Current dependence of luminous flux Relative Luminous Flux/ Case Temperature/ C GW7MMC--GZC GW7MGD--GZC GW7MMD--GZC GW7MGE--GZC GW7MME--GZC Figure 4 Temperature dependence of luminous flux Copyright Sharp Corporation Page 8 of 19

9 4.2.2 CIE 1931 Colour Space Chromaticity Coordinates INTERMO modules are available with CCTs (Correlated Colour Temperatures) of 3000K and 4000K. The center point of each CCT in CIE colour space is shown in the following figure. The boxes indicate the colour bins within which all INTERMO modules lie at the time of production. The bins are within 3 SDCM (Standard Deviation of Colour Matching) giving no perceivable colour difference between INTERMO modules K y K x Figure 5 - Chromaticity Coordinates in 1931 CIE colour space, production tolerances (boxes), and 3 SDCM ellipses Copyright Sharp Corporation Page 9 of 19

10 4.2.3 Colour Rendering Values (CRI) CRI values give an indication of the ability of a light source to render colours. Typical R values for INTERMO modules are given in the table below. General CRI Light greyish red Dark greyish yellow Strong yellow green Moderate yellowish green Light bluish green Light blue Light violet Light reddish purple Strong red Strong yellow Strong green Strong blue Light yellowish pink (skin) Moderate olive green (leaf) CCT/K R a R1 R2 R3 R4 R5 R6 R7 R8 R9 R10 R11 R12 R13 R Figure 6 R values of CRI Spectral Data The spectrum of an LED determines the CCT and CRI. Typical spectra for INTERMO modules are displayed in Figure 7. Relative Intensity Wavelength/nm 3000K, Ra K, Ra K, Ra K, Ra90 Figure 7 Spectral Power Distributions Copyright Sharp Corporation Page 10 of 19

11 5 Electronic Considerations INTERMO modules are designed to be operated with a constant current source. The maximum voltage of all INTERMO modules is below 60 V (d.c.), in line with Safety Extra Low Voltage (SELV) requirements. The design of the luminaire and local safety regulations will dictate whether a SELV compliant driver must be used. Compliance with appropriate electrical safety requirements must be checked at the system/luminaire level. In systems where multiple INTERMO modules are connected to a single power source, care must be taken to ensure that each INTERMO module is supplied with the desired current, which should be kept constant at all times. This is particularly important when INTERMO modules are connected in parallel, as small variations in Forward Voltage between modules can lead to large variations in Forward Current. Sharp recommends against connecting INTERMO modules in parallel for this reason. INTERMO modules must not be connected to an energized driver (hot plugging) as this may cause irreparable damage to the LED. During the luminaire assembly process, make sure that the driver is not energized before connecting to the INTERMO module. 5.1 Forward Voltage as a Function of Temperature The Forward Voltage of a LED decreases with temperature Forward Voltage/V Case Temperature/ C GW7MMC--GZC GW7MGD--GZC GW7MMD--GZC GW7MGE--GZC GW7MME--GZC Figure 8 - Case Temperature vs. Forward Voltage Copyright Sharp Corporation Page 11 of 19

12 5.2 Driving Measurements The table below summarises electrical driving conditions for INTERMO modules. Performance parameters specified in datasheets are often given at the Typical Forward Current with a Junction Temperature (T j ) of 90 o C. It is possible to drive INTERMO modules with a Forward Current higher than the typical value, but it must not exceed the maximum value at any time. The absolute maximum Forward Current is stated in the table. It should be noted that the maximum permissible Forward Current is temperature dependent, and may be lower than the absolute maximum rating for some case temperatures. Refer to the derating curve in the datasheet for further model-specific information on the temperature dependence of the maximum Forward Current. Module Forward Current/mA Forward I F typical Typ. Max. Min. Typ. Max. GW7MMC30GZC GW7MMC40GZC GW7MGD30GZC GW7MGD40GZC GW7MMD30GZC GW7MMD40GZC GW7MGE30GZC GW7MGE40GZC GW7MME30GZC GW7MME40GZC Wiring Considerations INTERMO modules feature a poke-in connector for power cables. The cables can be stranded, solid or fused in wire sizes 22, 20 or 18 AWG. If stranded wires are used, do not twist the strands as this may result in the conductors buckling as they are inserted into the connector. When preparing a cable for the poke-in connector the conductor should be trimmed to produce a flat tip surface Copyright Sharp Corporation Page 12 of 19

13 perpendicular to the length of the cable. The insulator must be stripped to reveal 11±1 mm of conductor. When inserting cables push the conductor through the centre of the poke-in aperture and continue to feed into the connector until the end of the cable hits the internal stop-block. Figure 9 Stripping and wiring the module. 6 Mechanics INTERMO modules are designed to be attached directly to a heatsink using two customer supplied M3 screws. Modules are shipped complete with a TIM pre-attached to the underside with a protective cover. The cover must be removed prior to module being attached to the heatsink. Various adapter rings are available, allowing attachment of optical reflectors to the module housing. Adapter rings are attached to the module using the same M3 screws used to secure the module to the heatsink. Therefore, optics adapter rings must be placed before the module is secured to the heatsink. 6.1 CAD Files and technical drawings Technical drawings are included in the product specification document. CAD files are available to download from sharpleds.eu (from early 2015). Copyright Sharp Corporation Page 13 of 19

14 6.2 Mounting M3 screws should be used to mount the INTERMO module onto a heatsink. The customer must ensure that screws are of a suitable length. Screws should be tightened with a torque of between 0.4Nm and 0.6Nm in pre-tapped holes. The underside of the screw head should be flat. Ensure that the TIM protective sheet has been removed before mounting the module and avoid moving the module on the heatsink once it has made physical contact as this may cause damage to the TIM. Figure 10 Mounting an INTERMO module 7 Thermal Management 7.1 Temperature measurement point locations The case temperature, T c, measurement point is located on the top surface of the LED. A small cutout in the module housing gives access to the T c point from above. The rear temperature, T r, as specified by Zhaga is located on the back side of the module on the surface of the TIM. Figure 11 Location of temperature points T c and T r Copyright Sharp Corporation Page 14 of 19

15 November Thermal Integration Temperature is a key factor in determining the performance and lifetime of an INTERMO module. Derating curve Forward Current, IF Operating window Case Temperature T c Max Operating Temperature Figure 12 Example derating curve. Intermo modules must also be operated within the derating curve (green area).. Running a module outside of its derating curve can result in irreversible damage to the module and a drastic reduction in its lifetime. It is important to note that the operating temperature can significantly limit the allowable forward current, and vice-versa. INTERMO modules are supplied with an integrated TIM which reduces the complexity of luminaire thermal design. However customers must still ensure that luminaire thermal design is adequate to maintain an INTERMO module within the specified operating conditions. Worst case operating conditions should be considered during the thermal design process, giving allowance for degradation of system thermal performance over time. If an INTERMO module is incorrectly mounted on the heatsink, or the heatsink is inadequate or damaged, the thermal path from LED junction to LED case may change. In this situation, T c may no longer be a suitable metric for determining whether the LED is operating within safe conditions. An alternative measurement point T r is detailed in this application note which is located on the back side of the TIM in the centre of the module. T r is less susceptible to changes in thermal path and so it is recommended that during design and testing of a luminaire both T r and T c are monitored. A luminaire of suitable thermal design should result in a strong correlation between T r and T c. It is Copyright Sharp Corporation Page 15 of 19

16 highly recommended that long term testing is conducted while measuring both T c and T r, as issues with thermal integration may not manifest immediately. The heatsink surface onto which the INTERMO is attached should be smooth, flat and clean. A non-flat surface can result in damage or cracking of the module when it is screwed down. Foreign material, excessive roughness and non-flatness can each result in air gaps between the TIM and heatsink, significantly increasing thermal resistance and potentially leading to overheating and premature failure of the LED. T c thermocouple attachment: Use thermal epoxy to attach thermocouple tip to T c point. Ensure that thermocouple is as thin as possible. Take care with thermocouple routing. If a thermocouple is in the light path of the LED, its insulating jacket can absorb enough light to cause heating sufficient to corrupt the measurement. Using thermocouples with thin stainless steel outer sheaths can help to reduce this effect. Module Max Thermal Power/W Calculaed Thermal Power/W Junction-to- Case Thermal Resistance R ΘJ-C / C W -1 Max. Case Temperature T CMAX / C GW7MMC30GZC GW7MMC40GZC GW7MGD30GZC GW7MGD40GZC GW7MMD30GZC GW7MMD40GZC GW7MGE30GZC GW7MGE40GZC GW7MME30GZC GW7MME40GZC Figure 13 - Table of key thermal values at typical drive conditions. Max thermal power assumes all electrical power is converted into heat. Calculated thermal power is the difference between electrical and optical power. Copyright Sharp Corporation Page 16 of 19

17 8 Lifetime LM80 reports are available for Sharp ZENIGATA LEDs used in INTERMO Modules. Talk to your local Sharp INTERMO sales representative for more information. 9 Chemical Compatibility Careful attention should be made to the nature of compounds outgassed by materials and components within an LED lighting fixture specifically their compatibility with the LED device. If such compounds are prone to photo-degradation, the degradation products must also be considered. The closed nature of many lighting fixtures means that such compounds can become trapped, potentially resulting in high concentrations close to the LED. Sharp recommends that INTERMO modules are allowed to ventilate to the atmosphere. The chemicals listed in below table have potential risks to react with chip, silicone resin or other materials in the LED device and may cause quality problems for the LED device. Therefore, the materials which contain or generate these chemicals should not be used in the vicinity of the LED device. If they are necessary to use around the LED device, please evaluate and check the effect of these chemicals on the LED device performance and reliability. Copyright Sharp Corporation Page 17 of 19

18 10 Replacement and Repair Intermo modules are not designed to be repairable or end user replaceable. If a defective or damaged unit must be replaced only a qualified person should do so using the following procedure: Remove power to the luminaire and give time for electrical charge held in control gear to dissipate. Unscrew the two customer supplied screws that attach the module to the heatsink. Disconnect module power cables from the control gear. Heat the module and heatsink to above 50 o C. Remove the module. Copyright Sharp Corporation Page 18 of 19

19 Clean heatsink to remove TIM residue. Install new module. 11 Appendix 11.1 Zhaga The following table lists the Zhaga Luminous Flux categories relevant to INTERMO modules. See zhagastandard.org for further information on Zhaga. Flux Category Luminous Flux Φ/lm Min. Max. C C C Notice The values in this document can change without notice. Always consult the latest specification document which can be found on sharpleds.eu (from early 2015). Copyright Sharp Corporation Page 19 of 19