OSRAM PrevaLED Core Z2 User Manual

www.osram.dewww.osram.

de

www.osram.com/prevaled-core

Technical application guide

®

PrevaLED

Core Z2 light engines

JUNE

2013

CONTENTS

CONTENTS

1. Introduction 3

1.1. System overview 3

1.2. System information 6

1.2.1. Nomenclature and marking 6

1.2.2. Technical data 7

1.2.3. Accessories 7

1.3. Zhaga – interchangeability of light engines 7

2. Optical considerations 8

2.1. Refl ector 8

2.1.1. Refl ector design 9

2.1.2. Refl ector mounting 10

2.1.3. Lighting design information 10

2.2. Luminous fl ux and color stability 11

2.3. Zhaga – optical interface 11

3. Electrical considerations 12

3.1. Safety requirements 12

3.2. Wiring information 12

3.3. Wiring in class I and class II luminaires 13

3.4. Optional cable clamp 13

3.5. Electrostatic safety measures 14

3.6. Inrush current limitation 14

3.7. Connection information 14

3.8. Zhaga – electrical interface 14

4. Thermal considerations 15

4.1. Thermal interface material and other accessories 15

4.2. Heat sink 16

4.3. Temperature measurement 17

4.4. Thermal simulation 18

4.5. ECG thermal considerations 19

4.6. Thermal management and lifetime 19

4.7. Zhaga – thermal interface 19

5. Mechanical considerations 21

5.1. LED module dimensions 21

5.2. Mechanical protection of the LED module 21

5.3. ECG dimensions 22

5.4. LED module attachment 22

5.5. Zhaga – mechanical interface 22

6. Assembly in a reference luminaire 23

6.1. Preparation 23

6.2. Wiring and refl ector/cover 24

6.3. Commissioning the PrevaLED

7. Norms and standards 25

7.1. Norms and standards for PrevaLED® LED modules and light engines 25

7.2. Norms and standards for control gears 25

7.3. Photobiological safety 26

®

light engine 24

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/prevaled-core or contact your
sales partner for an updated copy of this guide.

2

INTRODUCTION

1. Introduction

1.1. System overview
Brightness levels of today’s LEDs are opening the door for
usage of LEDs in general lighting applications requiring
high lumen output levels. Building an LED-based luminaire
poses a new set of technical challenges, among them new
optical requirements, providing adequate thermal manage­ment for stable operation and lastly dealing with the ever­improving performance of LEDs.

®

OSRAM’s PrevaLED

family of LED light engines addresses
the challenges of LED-based lighting while at the same
time giving the user great performance and fl exibility.

®

The PrevaLED

Core Z2 series of light engines is ideally
suited for use in refl ector-based, rotation-symmetric
applications such as downlights or spotlights. These light
engines provide several convincing benefi ts in the
application:

®

• PrevaLED

Core Z2 light engines are available as a sys­tem of matching LED modules and ECGs and deliver
maximum performance at very high levels of effi ciency.

• These light engines provide superior optical perfor­mance, both in terms of their optical effi ciency as well
as their high quality of light (color rendering).

• A wide range of lumen packages (currently available
from 800–5000 lm) allows addressing a wide range of
applications based on a single platform. This platform
allows, for example, the operation of a sequence of
spotlights – ranging from halogen-class up to HID levels
– in a row, while at the same time creating a homoge­neous overall impression for the end user.

• Thanks to their high thermal and optical performance,
luminaires based on PrevaLED

®

Core Z2 light engines
can be realized with minimized size of required heat sink
and refl ector, giving the user greater design fl exibility.

• PrevaLED

®

Core Z2 light engines provide standardized
interfaces for the user, in particular by defi ning stable
lumen packages over time. Independent of future in­creases in LED effi cacy, the luminous fl ux of an individual
LED module will remain constant, but at lower power
consumption. In this way, a luminaire designed on the
PrevaLED

®

Core platform will automatically benefi t from
effi cacy improvements without needing a lengthy and
costly redesign of the base construction.

3

INTRODUCTION

At present, PrevaLED® Core Z2 light engines are available
as systems in different performance grades:

• Lumen packages of 800–5000 lm are available with a
good to very good color rendering (with typ. CRI 83
and typ. CRI 93).

• The lumen packages of 800–5000 lm with CRI 83 are
especially well suited for consumer applications.

Movable 3D PrevaLED® Core Z2

(works with Adobe Acrobat 7 or higher)

The high efficacy of the light engines not only results in
minimized energy consumption of the luminaire, but also
reduces the thermal load on the luminaire, allowing for
smaller and lighter designs of the heat sink.

The PrevaLED® light engine consists of an LED module,

dedicated OTp and connection cable.

Both the CRI 90 and the CRI 80 types are available with
2700 K, 3000 K, 3500 K and 4500 K CCT; in lumen
packages of 800, 1500, 2000, 3000, 4000 and 5000 lm.

®

PrevaLED
OPTOTRONIC

Core LED modules must be operated with

®

power supplies of the “OTp” type. Available
types are detailed in the next section. All possible system
configurations are listed on the latest datasheet.

Additional details on optical, thermal, mechanical and
electrical characteristics can be found in the following
sections. Additional and updated information (as well as
updates of this guide) will be posted at www.osram.com/

prevaled-core.

OSRAM also provides an extensive range of energy-saving
light management components, such as sensors and room
controllers. By use of these products, additional energy sa ­vings can be realized. For an overview of these products,
please visit www.osram.com/lms.

4

INTRODUCTION

PrevaLED® Core Z2 –
CRI 90: Six lumen packages

800 lm, 1500 lm

2000 lm

3000 lm, 4000 lm, 5000 lm

PrevaLED® Core Z2 – CRI 90: Six lumen packages

2700 K 3000 K 3500 K 4000 K

800 lm LEP-800-927-C-Z2 LEP-800-930-C-Z2 LEP-800-935-C-Z2 LEP-800-940-C-Z2

1500 lm LEP-1500-927-C-Z2 LEP-1500-930-C-Z2 LEP-1500-935-C-Z2 LEP-1500-940-C-Z2

2000 lm LEP-2000-927-C-Z2 LEP-2000-930-C-Z2 LEP-2000-935-C-Z2 LEP-2000-940-C-Z2

3000 lm LEP-3000-927-C-Z2 LEP-3000-930-C-Z2 LEP-3000-935-C-Z2 LEP-3000-940-C-Z2

4000 lm LEP-4000-927-C-Z2 LEP-4000-930-C-Z2 LEP-4000-935-C-Z2 LEP-4000-940-C-Z2

5000 lm – LEP-5000-930-C-Z2 LEP-5000-935-C-Z2 LEP-5000-940-C-Z2

®

PrevaLED

Core Z2 –

CRI 80: Six lumen packages

800 lm, 1500 lm

2000 lm

(2000 lm), 3000 lm,

4000 lm, 5000 lm

PrevaLED® Core Z2 – CRI 80: Six lumen packages

2700 K 3000 K 3500 K 4000 K

800 lm LEP-800-827-C-Z2 LEP-800-830-C-Z2 LEP-800-835-C-Z2 LEP-800-840-C-Z2

1500 lm LEP-1500-827-C-Z2 LEP-1500-830-C-Z2 LEP-1500-835-C-Z2 LEP-1500-840-C-Z2

2000 lm LEP-2000-827-C-Z2 LEP-2000-830-C-Z2 LEP-2000-835-C-Z2 LEP-2000-840-C-Z2

3000 lm LEP-3000-827-C-Z2 LEP-3000-830-C-Z2 LEP-3000-835-C-Z2 LEP-3000-840-C-Z2

4000 lm LEP-4000-827-C-Z2 LEP-4000-830-C-Z2 LEP-4000-835-C-Z2 LEP-4000-840-C-Z2

5000 lm – LEP-5000-830-C-Z2 LEP-5000-835-C-Z2 LEP-5000-840-C-Z2

5

INTRODUCTION

1.2. System information

1.2.1. Nomenclature and marking

The PrevaLED

®

family follows a consistent naming
convention for identifying key parameters of the LED
module and the power supply. The nomenclature of the
LED modules and OPTOTRONIC

®

ECGs is as follows:

LED module:

LEP = LED module PrevaLED

®

5000 = 5000 lm

930 = CRI + CCT = CRI > 90 + 3000 K

C = Core, round shape

Z2 = Product generation Z2

LEP - 5000 - 930 - C - Z2

Power supply:

OTp DALI 45 / 220-240 / 700 HD FAN

OTp: OPTOTRONIC

®

PrevaLED

®

Control protocol: DALI (if applicable)

Wattage: 45 W

Input voltage: 220–240 V

Maximum output current: 700 mA

HD = High Dynamic

FAN = Ventilator/auxiliary output 5 V

6

INTRODUCTION

1.2.2. Technical data

Technical data product family PrevaLED® Core Z2:

For current data, please see the PrevaLED

®

datasheet

at www.osram.com/prevaled-core.

PrevaLED® Core Z2

Technical data electronic control gear (ECG):

For current ECG data, please see the OPTOTRONIC
(OTp) datasheet at www.osram.com/prevaled-core.

1.2.3. Accessories

Cable kit

The cable is required for contacting and connecting the
individual PrevaLED

®

Core Z2 LED module with the power
supply. It ensures a fl exible and safe connection. This
cable kit is approved according to UL (Underwriters
Laboratories).

PrevaLED® Core Z2-

cable kit 800 lm,

1500 lm, 2000 lm, 3000 lm

PrevaLED® Core Z2-

cable kit 4000 lm

and 5000 lm

Cable clamp for OTp

This cable clamp can be clamped onto the ECG, turning
it into an ECG suitable for independent installation. It is

®

available for order for all OPTOTRONIC
OTp 45 versions.

®

OTp 35 and

ECG (OPTOTRONIC®)

Combinations of LED modules and ECGs:
For current combination possibilities, please see the
PrevaLED

®

datasheet at www.osram.COM/prevaled-core.
Within rated power, LED modules and power supplies can
be fl exibly combined, e.g. according to the favored control
option or form factor. A general requirement is that each
LED module is connected to an individual ECG.

The connection between the LED module and the ECG
should be established by means of the supplied cable kit.
Available in lengths 40 cm and 80 cm, please also refer to:

3.2. Wiring information.

Well-established form factors have been utilized for the
housings of the ECGs in order to ensure that existing
luminaire housings or accessories can be adopted to
PrevaLED

®

technology.

1.3. Zhaga – interchangeability of light engines

The Zhaga Consortium for the standardization of LED light
sources (LED light engines) is a worldwide cooperation
of luminaire and lamp manufacturers, producers of LED
modules and companies that supply the lighting industry.
The interchangeability of LED light engines is achieved
by defi ning fundamental interface parameters while still
leaving room for innovation in LED and driver technolo­gies. Zhaga interface specifi cations cover the physical
dimensions, as well as the photometric, electrical and
thermal properties of different LED light engines.

The Zhaga Consortium was established in February 2010
and includes more than 180 companies (status: April

2012). OSRAM AG is a full member. The members
meet regularly in different regions of the world in order
to jointly work out the specifi cations. Large parts of the
new PrevaLED

®

Core portfolio fulfi ll the Zhaga specifi c a­tion book 3 for “spotlight systems with separate electronic
control gear.”

®

An updated list of all currently certifi ed PrevaLED

light

engines is available at: www.osram.com/zhaga.

For more information, please go to: www.zhagastandard.org.

7

OPTICAL CONSIDERATIONS

2. Optical considerations

Chip-on-board-design (CoB)
So-called chip-on-board (CoB) light sources without
housing and with high-performance chips set very closely
next to each other have proven to be especially advanta­geous. Due to the large amount of applied chips, the size
of the light source is fl exible and scalable. In the applica­tion, the compactness, on the one hand, allows for very
high axis light and illumination levels, and, on the other
hand, a very high-contrast illumination with high brilliance.
Very good homogeneity (with a uniformity factor of 0.93) –
combined with constantly Lambertian radiation – addition­ally simplifi es refl ector design and facilitates the inter­changeability of light sources.

PrevaLED

®

Core Z2

The CoB design is characterized by a large amount of
closely set LED chips, arranged in a certain grid which is
covered with luminescent material (cf. the image above).
One of the key advantages of this design is its very homo­geneous light-emitting surface.

Pure phosphor conversion with CoB

Thanks to the use of pure phosphor conversion, the
PrevaLED

®

Core Z2 module can achieve a color rendering
quality of higher than CRI 90, while at the same time
providing a very homogeneous light output.

Phosphor conversion: By means of phosphor conversion, the blue

light of the LED chip is shifted towards the higher wavelengths of

green and red light.

2.1. Refl ector

High luminous densities (1.5–4.5 Mcd/m

2

) are the key
factor for LED-based lamps and luminaires in the area of
refl ector applications such as spotlights, for example.
For these, light sources with small light-emitting areas
and a high luminous fl ux are required (as realized with the
PrevaLED

®

Core Z2), because that way, the light can be

collimated especially well with refl ectors.

®

Thanks to CoB technology, the PrevaLED

Core Z2 has
a uniform light-emitting surface which, due to its great
homogeneity, eliminates the need to use diffuser material.
The minimized light-emitting surface (LES) and a refl ector
positioning close to the LES allows for better optical
handling. All in all, the properties of the PrevaLED

®

Core Z2
allow for the prevention of roughness and facets, which in
turn allows for minimal overall beam angles of 10° or less.

®

The high homogeneity of the PrevaLED

Core Z2 means:

• Low complexity in the surface structure of the refl ector

• Narrower beam angles <10° FWHM in combination with

minimized light-emitting surface

PrevaLED® Core Z2

8

OPTICAL CONSIDERATIONS

2.1.1. Refl ector design

OSRAM provides mechanical (3D fi les) and optical
simulation data (ray fi les) to support customized refl ector
designs. These data are available upon request through
your sales partner or for public download at:

www.osram.com/prevaled-core.

Information on the optical calculation and simulation
for refl ector designs:
a) First estimation: Assumption of the LES ∅ as an
idealized, homogeneous, Lambertian emitter
b) Simulation via raytracing software:

• Ray fi les available upon request via OSRAM sales
department

• Photopia fi les are lodged under www.lti.com

The light distribution curve (LDC) of the module (without
further refl ectors, opt. systems) is characterized by a
universally applicable Lambertian distribution. Therefore,
it is very easy to defi ne and connect further downstream
optical systems (refl ectors, lenses, …).

More partners for support in the optics area can
be found in OSRAM’s LED Light For You network:

www.ledlightforyou.com. Moreover, standard components

and support for refl ector design and refl ector brackets are
available e.g. through the following partners:

ACL-Lichttechnik GmbH

A.A.G. STUCCHI
s.r.l.u.s. (Tool-less

[phone]
info@refl ektor.com
www.refl ektor.com

re fl ector brackets)
[phone]
[e-mail]
www.aagstucchi.it

Alux·Luxar

ALMECO S.p.A.

GmbH & Co. KG

[phone]
[phone]
[e-mail]

[e-mail]

www.almecogroup.com
www.alux.de

Jordan Refl ektoren
GmbH & Co. KG

Suitable and available
refl ectors can, for example,
be found on the web pages

[phone]

of these partners.
info@jordan-refl ektoren.de
www.jordan-refl ektoren.de

C90

C0

LDC PrevaLED® Core Z2 –

without refl ector

LDC PrevaLED® Core Z2 –

with spot refl ector

PrevaLED® Core Z2

Please note that strong forces applied to the

housing can damage the LED module or the

housing, especially if the LED module isn’t
attached to a heat sink. Attach or remove the refl ector
only if the LED module is safely connected to a heat sink.

9