Design-in Guide ActivePAQ linear LED module VIAPAQ LIGHTING www.viapaqlighting.com1
Table of Contents Introduction & Disclaimer 4 Mechanical dimensions & connections 5 Electrical interface 7 Certificates and standards 8 Temperature management & -measurement 8 Connecting the ActivePAQ module to a heatsink 14 Light output & optics 15 Light output selection by dipswitch configuration 16 Daisy Chaining the ActivePAQ 2 ft. 4.000 lm boards 18 ElectroStatic Discharge (ESD) safety 19 Handling 19 2 DESIGN-IN GUIDE VIAPAQ LIGHTING 3
Introduction & Disclaimer This document is intended to provide guidance to OEM s and luminaire designers to integrate the ActivePAQ linear LED module into their products. Besides from mechanical conditions this document will also clarify the electrical- and environmental boundaries or attention points. By no means this design-in guide is intended to limit our customers in the options, nor can it be used to claim warranty. The design-in guide cannot be regarded as a document for official release of the luminaire. Specifically mentioned materials and/or tools from third parties are only indicative, other equivalent equipment may be used. With the ActivePAQ linear LED modules Viapaq Lighting is introducing light sources that facilitate integral cost effectiveness. While the driver is integrated with the LED module no separate bulky components need to be hosted in the luminaire and wiring can be limited to a minimum. ActivePAQ LED modules offer good quality of light and therefor can be used in various type of applications. Products described in this document: Description ActivePAQ Linear 4Ft 4.000lm ActivePAQ Linear 5Ft 6.000lm ActivePAQ Linear Basic R-set 4Ft 5.000lm ActivePAQ Linear Basic R-set 5Ft 6.000lm ActivePAQ Linear Performer 2Ft 4.000lm Mechanical dimensions & connections The ActivePAQ linear LED modules come in 3 different lengths, supporting 1.2 respectively 1.5 m and 0.56 m long luminaires. To support temperature management, the width of the module is dependent on the lumen output. This results in the next variants: Products described in this document: Description Length (mm) Width (mm) Height (mm) ActivePAQ Linear 4Ft 4.000lm 1.120 20 < 13 ActivePAQ Linear 5Ft 6.000lm 1.405 33 < 13 ActivePAQ Linear Basic R-set 4Ft 5.000lm 1.120 33 < 13 ActivePAQ Linear Basic R-set 5Ft 6.000lm 1.405 33 < 13 ActivePAQ Linear Performer 2Ft 4.000lm 560 40 < 17 Using Zhaga book 7 as guideline for the hole definition even existing luminaire designs can benefit from the advantages of the ActivePAQ LED module. When mounting ActivePAQ modules to the luminaire mechanics, special attention must be paid to the application specific creepage distance requirements. ActivePAQ modules inherently have a creepage distance of at least 2.5 mm which consists of > 1.4 mm board thickness and > 1.1 mm distance from the board edge to the tracks. Mounting of ActivePAQ modules can be done for example by using non-conductive plastic rivets or plastic screws to maintain the inherent creepage distance of the module. Another possible option is to use insulating but still heat conductive paste between the board and the luminaire mechanics. It is highly recommended in all cases to efficiently conduct the heat from the board to the luminaire mechanics, because this will have a positive effect to the performance of the ActivePAQ module. If for example conductive screws are used for mounting the ActivePAQ modules, then the necessary insulating layers must be added to fulfil the application specific creepage distance requirements. 4 DESIGN-IN GUIDE VIAPAQ LIGHTING 5
Electrical interface ActivePAQ Linear 4Ft 4.000lm dimensions 20 mm 15 125 mm 364,5mm 30 125 mm 30 391,0 mm 30 15 364,5 mm 1.120 mm 230 Vac ActivePAQ Linear 5Ft 6.000lm dimensions 33 mm 30,5 452,5 mm 500 mm 30,5 Two voltage windows have been specified: 452,5 mm 1.405 mm 1) Nominal voltage window: 220-240 Vac (within this range the module will fullfil to its specification) 2) Maximum voltage window: 230 Vac ± 10% (within this range the module will not fail, though performance within specification is no longer guaranteed) ActivePAQ Linear Basic R-Set 4t 5.000lm dimensions 28.5mm mm mm mm 33 mm ActivePAQ Linear Basic R-Set 5Ft 6.000lm dimensions 33 mm 28.5mm Inserting the wires All wires must be pushed firmly into the contact wire opening. They can be released by pushing the release button. It s important to strip the cable wire 7-9 mm. Make sure that the wires are fully inserted such that the wire insulation is surrounded by the connector housing. This prevents it can be pulled out of the connector (during operation). 1.120 mm 30,5 The ActivePAQ linear module just has one Wago 2060-852 connector on board to connect the module to mains voltage (230 Vac). 1.405 mm ActivePAQ Linear Performer 2t 4.000lm dimensions inserting solid conductors via push-in termination inserting/removing fine-stranded conductors by lightly depressing the push-button (e.g. using the optional 206-860 Operating Tool). For manual and automated Wiring systems Terminate conductors from 24 to 18 AWG (0.2-0.75 mm2) Simple push-in termination of solid conductors 6 DESIGN-IN GUIDE VIAPAQ LIGHTING strip length: 7-9 mm 7
Certificates and standards Temperature indication points ActivePAQ 1200mm, 4000lm CE / ENEC16 EN 55015:2013 / EN 547:2009 / EN 000-3-2:2014 / EN 000-3-3:2013 / EN 62031:2008 + A1:2013 + A2:2015 EN 347-1:2008 / EN 62471:2008 Ts at D86 Temperature management & -measurement Tc In order to meet the expected lifetime of the ActivePAQ linear LED module one of the critical aspects to manage is temperature. The relation of Tc (temperature reference point) to other component temperatures on the ActivePAQ module is depending on external conditions such as the material- and / or structure of the material where the product is mounted to. Therefor Viapaq Lighting has identified a few lifetime critical components on the ActivePAQ module that should be measured during design-in. As long as the maximum specified temperatures of those components are not over-exceeded the specified lifetime will be within reach. To accomplish this a heatsink is an unavoidable part of the luminaire construction. C6 C11 Q2 Note that the below measurement results are based on 230V input voltage. When increasing the input voltage, the component temperatures will rise. Also the ambient temperature of the module (so inside the luminaire and in the application) is an important factor to be taken into account. Temperature table ActivePAQ 1.200mm, 4.000lm ActivePAQ 1.200mm, 4.000lm Temp reference point FET s ELCAP s LED solder joint Environmental temperature Tc Q2 C11 C6 Ts / D86 Ta Lifetime temp ( C) +100 +115 +70 +70 +80 NA Measured on a solid aluminium +69 +76 +43 +37 +56 +22 strip* @ 230Vac Measured on a hollow aluminium profile** @230Vac +57 +67 +35 +34 +44 +22 * Aluminium strip 1120 x 40 (L x W) mm with a material thickness of 3 mm, tightly secured to the bottom of the module using thermalpaste with a resistance of 8.5 W/mK ** Aluminium rectangular profile 1120 x 70 x 10 (L x W x H) mm with a material thickness of 1,5 mm, tightly secured to the bottom of the module using thermal paste with a resistance of 8.5 W/mK. 8 DESIGN-IN GUIDE VIAPAQ LIGHTING 9
Temperature table ActivePAQ 1.500mm, 6.000lm ActivePAQ 1.500mm, 6.000lm Temp reference point FET s ELCAP s LED solder joint Tc Q2 Q4 C11 C6 Ts / D63 Ta Lifetime temp ( C) +100 +115 +115 +70 +70 +85 NA Measured on a solid aluminium +66 +74 +72 +47 +39 +49 +22 strip* @ 230Vac Measured on a hollow aluminium profile** @230Vac +44 +49 +47 +34 +29 +37 +22 Environmental temperature Temperature indication points ActivePAQ Linear Basic R-set 4Ft 5.000lm & 5Ft 6.000lm The temperature measurement points on the R-set models have been updated from the previous designs so, that all temperatures are now measured from TC points rather than directly off the components. As shown in the pictures below, TC2 and TC4 are now used for reading the temperatures from the electrolytic capacitors C11 and C6, while the FET Q2 temperature is read from TC1, and LED D63 from TC3 correspondingly. The recommended maximum temperatures for the TC points are the same as for the ActivePAQ Basic 1.500 mm 6. 000 lm. I.e. TC1 is +100 C, TC2 and TC4 are +70C and TC3 is +85C. TC 2 TC 1 * Aluminium strip 1.405 x 40 (L x W) mm with a material thickness of 3 mm, tightly secured to the bottom of the module using thermal paste with a resistance of 8.5 W/mK ** Aluminium rectangular profile 1.405 x 70 x 10 (L x W x H) mm with a material thickness of 1,5 mm, tightly secured to the bottom of the module using thermal paste with a resistance of 8.5 W/mK. Temperature indication points ActivePAQ 1.500mm, 6.000lm TS at D63 Tc Q2 TC 4 TC 3 C6 C11 Q4 10 DESIGN-IN GUIDE VIAPAQ LIGHTING 11
Temperature table ActivePAQ Linear Basic R-set 4Ft 5.000lm ActivePAQ 1.200mm, 4.000lm FETs temp reference point ELCAPs temp reference points LED solder joint Tc1 Tc2 Tc4 Tc3 Ta Lifetime temp ( C) +100 +70 +70 +85 NA Measured on a solid aluminium +58 +48 +36 +46 +22 strip* @ 230Vac Measured on a hollow aluminium profile** @230Vac +54 +39 +35 +41 +22 Environmental temperature Temperature indication points ActivePAQ Linear Performer 2Ft 4000lm As shown in the pictures below, TC2 and TC4 are used for reading the temperatures from the electrolytic capacitors C1 and C11, while the FET Q2 temperature is read from TC1, and LED D24 from TC3 correspondingly. The recommended maximum temperatures for the TC points are the following: TC1 is +100 C, TC2 and TC4 are +70C and TC3 is +85C. TC 3 TC 1 TC 2 TC 4 * Aluminium strip 1.120 x 40 (L x W) mm with a material thickness of 3 mm, tightly secured to the bottom of the module using thermal paste with a resistance of 8.5 W/mK ** Aluminium rectangular profile 1.1.20 x 70 x 10 (L x W x H) mm with a material thickness of 1,5 mm, tightly secured to the bottom of the module using thermal paste with a resistance of 8.5 W/mK. Temperature table ActivePAQ Linear Basic R-set 5Ft 6.000lm ActivePAQ 1.405mm, 6.000lm FETs temp reference point ELCAPs temp reference points LED solder joint Environmental temperature Tc1 Tc2 Tc4 Tc3 Ta Lifetime temp ( C) +100 +70 +70 +85 NA Measured on a solid aluminium strip* @ 230Vac +62 +51 +44 +48 +22 * Aluminium strip 1.405 x 40 (L x W) mm with a material thickness of 3 mm, tightly secured to the bottom of the module using thermal paste with a resistance of 8.5 W/mK. Temperature table ActivePAQ Linear Performer 2Ft 4.000lm ActivePAQ 1.200mm, 4.000lm FETs temp reference point ELCAPs temp reference points LED solder joint Environmental temperature Tc1 Tc2 Tc4 Tc3 Ta Lifetime temp ( C) +100 +70 +70 +85 NA Measured on a solid aluminium strip* @ 230Vac +60 +48 +46 +52 +22 Aluminium strip of 1.500 x 46 (L x W) mm with a material thickness of 1.5 mm tightly secured to the bottom of the two daisy chained modules using thermal paste with thermal resistance of 8.5 W/mK. 12 DESIGN-IN GUIDE VIAPAQ LIGHTING 13
Connecting the ActivePAQ module to a heatsink In order to control the temperature of lifetime critical components on the ActivePAQ module Viapaq Lighting strongly advices use of an (anodized) aluminium heatsink in the luminaire. Important factors are the size of the surface area contacting the ActivePAQ module (which can be maximized by anodizing), the volume of the heatsink, and the quality of the the connection between both components. It is highly important to select materials in the luminaire that don t have any negative effect on the LED performance or lifetime (e.g. don t use any outgassing types of tape / glue). The below steps describe how the 1500mm, 6000lm module has been connected to a very compact anodized aluminium strip with the following dimensions: 1.405 x 40mm, thickness 3 mm. In the previous table Temperature table ActivePAQ 1.500mm, 6.000lm you can find that this would already support a maximum Tamb of ~45 C inside the luminaire. Light output & optics By using best in class LED components (Samsung LM5B+ and Osram Duris S2), ActivePAQ modules are designed to support ultimate design flexibility and luminaire performance. Good thermal management however is not only essential secure the product lifetime, but to maximize the lumen output of the ActivePAQ module as well. Wide beam LED s have been implemented for superb light distribution. The ActivePAQ module is supplied without any additional optical components, because we believe that this is one of the particular area s where OEM s add significant value. For optimal light mixing and uniform colour over angle performance Viapaq Lighting advises use of a diffuse cover. Below depicted, self made profiles are solely used by Viapaq Lighting for demonstration purposes. They give an impression of the ActivePAQ performance on a simple heat distributing profile with diffuse cover. 1) ActivePAQ module & Anodized aluminium strip (heatsink) 2) Line of thermal paste over the middel line of the heatsink 3) Firmly push the module on the heatsink to spread out the thermal paste 4) Fix the module (screw connection) 14 DESIGN-IN GUIDE VIAPAQ LIGHTING 15
Light output selection by dipswitch configuration The light output of the ActivePAQ Liner R-set models can be set using the 4 position onboard DIP switch only when the unit is powered off. See the input power, light output, and efficiency values for each combination on page 16. The numbering of the individual switches on the board matches that on the table, and the binary values 0 and 1 shown on the chart directly correspond to off and on positions on the switch. The default position for all switches is ON (1), which is also labeled on the switch. Using a small screwdriver is recommended for setting the switches to the wanted positions. The protective tape on top of the DIP switch can be removed with tweezers before using the screwdriver to adjust the switch positions. Dipswitch Dipswitch settings ActivePAQ Linear 4Ft 5.000lm R-set Measurement input power @230 Vac Dip switch # Measured Light output Efficacy 1 2 3 4 input power ActivePAQ Lm/W 0 0 0 0 21,6 3.000 138 0 0 0 1 28,1 3.760 133 0 0 1 0 27,0 3.650 134 0 0 1 1 33,1 4.350 131 0 1 0 0 26,1 3.570 136 0 1 0 1 32,1 4.220 131 0 1 1 0 31,1 4.100 131 0 1 1 1 36,9 4.750 128 1 0 0 0 24,8 3.370 135 1 0 0 1 30,9 4.100 132 1 0 1 0 29,9 3.980 132 1 0 1 1 35,7 4.600 128 1 1 0 0 28,9 3.890 134 1 1 0 1 34,8 4.540 130 1 1 1 0 33,8 4.430 130 1 1 1 1 39,3 5.000 126 ActivePAQ Linear 5Ft 6.000lm R-set Measurement input power @230 Vac Dip switch # Measured Light output Efficacy 1 2 3 4 input power ActivePAQ Lm/W 0 0 0 0 25,5 3.500 135 0 0 0 1 34,5 4.460 129 0 0 1 0 33,1 4.300 129 0 0 1 1 41,4 5.150 124 0 1 0 0 31,9 4.180 130 0 1 0 1 40,3 5.050 125 0 1 1 0 39,0 4.900 125 0 1 1 1 46,6 5.670 121 1 0 0 0 29,2 3.870 132 1 0 0 1 38,0 4.900 127 1 0 1 0 36,4 4.660 127 1 0 1 1 44,4 5.450 122 1 1 0 0 35,3 4.530 128 1 1 0 1 43,4 5.380 123 1 1 1 0 42,1 5.380 127 1 1 1 1 49,3 6.000 120 Note: ActivePAQ Linear Basic R-SET modules are default configured at maximum light output. 16 DESIGN-IN GUIDE VIAPAQ LIGHTING 17
Daisy Chaining the ActivePAQ 2 ft. 4.000 lm boards Up to 6 ActivePAQ 2 ft. 4.000 lm modules can be chained in series by utilizing the input and output connectors for easy 230V loop through. This means that you can power 12 modules from one mains input point if for example you wire 6 modules both ways in a rail from one mains input point. For visualization purposes, a chain of 3 modules is shown in figure 1 below. Additionally, an example of the ease of seamlessly connecting multiple modules together in order to build longer luminaires is shown in figure 2 below. It is recommended to leave 2 mm gap between the two boards when daisy chaining two modules due to dimensional tolerances and for Zhaga screw hole compliancy. ElectroStatic Discharge (ESD) safety It is generally recognized that electrostatic discharge can damage electronic components such as LED chips, IC s etc., potentially resulting in early product failures. Though our ActivePAQ modules have been designed as robust as possible, still a set of measures have to be taken into account when handling the products. Not only those ESD protective measures are important to be taken in the production environment, but also packing and shipping are critical processes in this aspect. Air humidity for example has an important influence on electrostatic charge build-up. In order to meet the ESD safety requirements Viapaq Lighting advices to contact an external consultancy office. Furthermore, it is highly recommended that installers are pre-informed not to touch the LED s while handling the ActivePAQ module during installation of the luminaire. AC mains 230Vac Grounding of workers ESD safe clothing Central workable Figure 1: A chain of 3 ActivePAQ modules Floor example Handling Coated floor Figure 2: Easy and minimal wiring between 2 modules ActivePAQ light engines require careful transportation and handling. Bending of the PCB (/module) may cause visible or invisible damage which can result in 0-hour defects or early failures over lifetime. In Viapaq Lighting¹s factory the boards are always in straight position, from the moment of unpacking the bare PCB s until the tested ActivePAQ light engines are slid into their final box packing. This packaging has been designed in such a way that the products fit right in with sufficient margin, though tight enough to protect the module against shocks during transportation. After arrival in the OEM factory it s evenly important to handle those boards with care during the built-in process. 18 DESIGN-IN GUIDE VIAPAQ LIGHTING 19
20 Viapaq Lighting B.V. Date: 23-09 -2016 Version: 1.5