technical application guide prevaled sky module

Light is OSRAM

Technical Application GuidePrevaLED® SKY Module

www.osram.asia

DEC

2015

Technical Application Guide | PrevaLED® SKY Module

Contents

1. Introduction

1.1. System overview

1.2. System information

1.2.1. Nomenclature and marking

1.2.2. Technical data

1.2.3. Possible system combinations

2. Luminaire design

2.1. Optical considerations

2.1.1. Quality of light

2.1.2. CRI, CCT

2.2. Mechanical considerations

2.2.1. LED module & cable dimensions

2.2.2. LED power supply and cable dimensions

- OT outdoor On/Off 700mA IP65 Driver

- OT outdoor 2DIM IP64 Driver

2.3. Thermal Considerations

2.3.1. Tc location and temperature measurement.

2.3.2. Over temperature protection - OTP

2.4. Electrical considerations

2.4.1. Insulation coordination for PrevaLED® SKY LED modules

2.4.2. Wiring information

2.4.3. Electrostatic discharge (ESD)

2.4.4. Wiring in protection class I and II luminaires

3. Installation guide

3.1. Application of installation for module orientation

3.2. Application of installation sketch map for optics

3.2.1. Installation of one LED module inside a luminaire

3.2.2. Installation of more than one LED module inside a luminaire

3.3. LED module application and mounting layout.

3.4 Application of mechanical installation

4. Norms and standards

4.1 Norms and standards for PrevaLED® LED modules and light engines

4.2 Photobiological safety

Page

3

3

4

5

7

9

10

10

10

11

11

11

12

14

14

15

15

15

16

18

18

19

19

19

19

20

20

22

23

23

23

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 or contact your sales partner for an updated copy of this

guide. Please make sure you are always only using the most recent release of the application guide.

2

http://www.osram.com/


Introduction

1 Introduction

1.1. System overview

The OSRAM’s PrevaLED® SKY is a high power LED module with integrated heat sink for optimal

thermal management and tailored optical design. The modular design concept of PrevaLED® SKY

allows for design flexibility by varying the module quantity to achieve the best street lighting solution

for difference application from Road lighting to Area lighting.

The LED module is available in different color temperature (4000K and 6500K), offering very long

lifetime with minimal maintenance. PrevaLED® SKY is an IP66 unit ideal for outdoor applications.

BENEFITS

Tailored optical design

- Special designed lenses optimized the light distribution across the road for different road class

requirements and also difference application required Highbay, Lowbay and Area floodlight

illumination.

IP66 protection

- Self contained housing with heat sink for excellent thermal management, no extra protection is

needed

High energy efficiency

- Constant current driven maximizing system efficiency

Stackable & maintainable module

- Simple screw fixing module allowing multiple module configuration in luminaires

Long life time

- Optimized for extended lifetime and lumen maintenance

Module weight

- fully integrated IP66 module with optical and heat sink as less than 400g.

Additional details on optical, thermal, mechanical and electrical characteristics can be found in the

following sections. Further and updated information (IES files, CAD files and updates of this guide)

will be posted at www.osram.com.

3


Introduction

PrevaLED® SKY: Two power packages

Remark: customized requirement for different CCT and CRI on request.

+ +

OPTOTRONIC® LED

Power supply

Waterproof connector

accessories

1.2. System information

PrevaLED® SKY Module

(with or without

waterproof connector)

4

Parameter HP LP

Electrical Power @700mA (typical) 50W 25W

LightOutput

Flux [lm] 6000 6000 3000 3000

CCT [K] 6500 4000 6500 4000

CRI 70 70 70 70

Light Distribution / Beam Angle

60o x 60o, 100o x 100o, 100o x 60o, 150ox 80oT40o (C/S)

PL- SKY- HP 7 40 L150x80T40S


Introduction

1.2.1. Nomenclature and marking

The PrevaLED® product series follows a consistent naming convention for identifying key

parameters of the LED module and the LED power supply.

LED Module

Product Family

PL: PrevaLED®

Series Shape

SKY

Type

HP: High Power

LP: Lower Power

CRI

7: CRI>70

8: CRI>80

CCT info

30: 3000K

40: 4000K

50: 5000K

65: 6500K

Optic

L60x60 High bay

L100x100 Low bay

L100x60 Asymmetric Floodlight

L150x80T40S Streetlight for ME1 ME2,

Staggered / Opposite mount with 40o Tilting

L150x80T40C Streetlight for ME1 ME2,

Central mount with 40o Tilting.

5

LED power supply: OSRAM Outdoor ECG 2DIM

LED power supply: OSRAM Outdoor ECG On/OFF


Introduction

6

OT 50/120…277/700 P5

Product Family

OT: OPTOTRONIC®

Wattage:

50W

Input voltage:

120-277V AC

Max output current

700mA

P5

IP rating: IP65

Product Family

OT: OPTOTRONIC®

Wattage:

110W

Input voltage:

120-277V AC

Max output current

1400mA

2DIM

2DIM: 0-10V, Astro DIM

LT2

LEDset2 (LED module interface)

P

Humidity-protected with IP64

OT 110/120-277/1A4 2DIM LT2 P


Introduction

1.2.2. Technical data

All values regarding system efficiency and system power consumption refer to the complete

system and are measured at Ta=25oC. For the data with marker, please see the remark at the

end of the table.

7

1) Due to the special conditions of manufacturing processes of LED, the typical data of technical parameters can only

reflect statistical figures and do not necessarily correspond to the actual parameters of each single product. Actual

lumen output can be varied due to many factors like lamp factor of LED, input current/voltage, thermal conditions,

many other optical tolerance, and measurement tolerance. The data above is for reference only. Please contact

Osram sales or marketing staff for advice if customers has any specific demand on particular parameters. Ranking

at Ta = 25°.Tolerance of measurements for the colour rendering Ra is ±2.

2) The LED modules are designed for operation with OT OPTOTRONIC® ECGs or other equivalent driver. Exceeding

maximum ratings for operating and storage temperature will reduce the expected lifetime or destroy the light engine.

The temperature of the LED module must be measured with a temperature sensor at the Tc point, according to

EN60598-1 and in thermally settled conditions. For the exact location of the Tc point, see the drawing in chapter

2.3.1. Tc location and measurement.

LEDmodule1)2)

Typical / Maxinput

current[mA]

Typicalinput

voltage[V DC]

Inputvoltagerange[V DC]

Module power

[W]

Luminous flux

[lm]1)

Module efficacy[lm/W]

CCT[K]

CRIBeam Angle

[o]Ta

[oC]

Lifetime(L70/B50)at Tc point

[h]2)

PrevaLED® SKY

PL-SKY-HP 700 / 770 7066.0

to76.4

50 6000 120

4000

70

150o x 80o T40oS(For Single-

sided / Opposite mount)

150o x 80o

T40oC(For Twin-

central mount)

60o x 60o

100o x 100o

100o x 60o

-30 to +50

50000at

Tc90oC

6500

PL-SKY-LP 700 / 770 3533.0

to38.2

25 3000 120

4000

7050000

atTc90oC

6500


Introduction

8

OutdoorECG

On/OFF

Nominal outputpower

[W]

Typ.Efficiency3)

OutputCurrent

[mA]

Ta[oC]

Tc max.[oC]

Lifetime L90at Tc point

[h]4)

OT 50/120-277/700 P5 17-50 87%

700 -40 to +55

80 80000 at Tc=70oC

OT 100/120-277/700 P5 50-100 90% 85 80000 at Tc=75oC

OT 180/120-277/700 P5 80-180 90% 90 80000 at Tc=80oC

OT 250/120-277/700 P5 125-250 92% 80 80000 at Tc=70oC

3) At Full load, input voltage=230V/50Hz condition.

4) At input voltage=220-240VAC condition.

3) At Full load, input voltage=230V/50Hz condition.

4) At input voltage=220-240VAC condition.

5) AstroDIM, 0-10V, LEDset2

6) At input voltage=220-240VAC/277VAC

7) 0.13% / 1’000 h failure rate

OutdoorECG

2DIM

Nominaloutputpower

[W]

Typ.Efficiency3)

Outputcurrent

[mA]Control

Ta[oC]

Tc max.[oC]

Lifetime at Tc point

[h]7)

OT 50/120-277/800 2DIMLT2 P

11-50 86% 350-800

LEDset2 and

2DIM6)

-40 to +55 4)

85 80000 at Tc 75oC

OT 50/120-277/1A2 2DIMLT2 P

12-50 86% 600-1250 80 80000 at Tc 70oC

OT 100/120-277/800 2DIMLT2 P

45-100 90% 350-800

-40 to +55 6)

85 80000 at Tc 75oC

OT 110/120-277/1A4 2DIMLT2 P

45-110 90% 1400 85 80000 at Tc 75oC


Introduction

1.2.3. Possible system combinations

Within rated power and voltage range, PrevaLED® SKY modules and OPTOTRONIC® power

supplies can be flexibly combined. Valid and possible combinations of LED modules and ECGs

are shown in the table below.

9


System matching with OT outdoor On/Off 700mA IP65 Driver

3K lm

SKY 4 DC

– 25W

SKY 4 DC

– 50W

50W OT

6K lm 9K lm 12K lm 9K-12K lm 12K-15K lm 15K-18K lm 15K-25K lm 15K-25K lm

SKY 4 DC

– 50W

SKY 4 DC

– 25W

SKY 4 DC

– 50W

SKY 4 DC

– 50W

SKY 4 DC

– 50W

SKY 4 DC

– 50W

SKY 4 DC

– 50W

SKY 4 DC

– 50W

SKY 4 DC

– 25W

SKY 4 DC

– 50W

SKY 4 DC

– 50W

SKY 4 DC

– 50W

SKY 4 DC

– 50W

SKY 4 DC

– 50W

SKY 4 DC

– 50W

SKY 4 DC

– 25W

SKY 4 DC

– 50W

SKY 4 DC

– 50W

SKY 4 DC

– 50W

SKY 4 DC

– 50W

100W OT 180W OT 250W OT


System matching with OT outdoor 2DIM IP64 Driver

SKY 4 DC

– 50W

50W OT 100W OT 165W OT

3K lm 6K-9K lm 6K-9K lm 9K-12K lm 12K-15K lm 15K-18K lm

SKY 4 DC

– 25W

SKY 4 DC

– 25W

SKY 4 DC

– 50W

SKY 4 DC

– 50W

SKY 4 DC

– 50W

SKY 4 DC

– 50W

SKY 4 DC

– 50W

SKY 4 DC

– 50W

SKY 4 DC

– 50W

SKY 4 DC

– 50W

SKY 4 DC

– 25W

Attention:

All Combinations are affected by the maximum length of the cabling. Maximum cable length from the

OPTOTRONIC® LED power supply to all LED modules connected in series must not be longer than 10m.

Please ensure that the power supply is of adequate power to operate the total load.

PrevaLED® SKY outdoor module needs to be connected with constant current DC driver which must has

stable constant current (+/-10% tolerance suggested) output.


Luminaire Design

10

2. Luminaire Design

2.1. Optical considerations

2.1.1. Quality of light

The PrevaLED® SKY optical design has three light-emitting zone consisting of optical lens and

high power LEDs, as shown in the image above.

PrevaLED® SKY light engines are suitable for several applications (both indoor and outdoor).

Wavelength spectrum of 4000K LEDs Wavelength spectrum of 6500K LEDs


Luminaire Design

11

2.1.2. CRI, CCT

The nominal available correlated color temperatures (CCT) of LED modules are 4000K and

6500K. The color rendering Index (CRI) is >70 for all LED modules.

Color bin of PrevaLED® SKY modules with CCT:4000K Color bin of PrevaLED® SKY modules with CCT:6500K

2.2. Mechanical considerations

2.2.1. LED module and cable dimensions

The figures below provide further details on the dimensions of the available PrevaLED® SKY

LED modules.

Handle with care!Please keep the lens of module clean.

The LED module itself and all its components may not be

mechanical stressed.


Luminaire Design

12

2.2.2. LED power supply and cable dimensions

- OT outdoor On/Off 700mA IP65 Driver

OT 50/120-277/700 P5 OT 100/120-277/700 P5

OT 180/120-277/700 P5 OT 250/120-277/700 P5

Cable dimensions of driver

Item UnitValue

OT 50/120-277/700 P5 OT 100/120-277/700 P5 OT 180/120-277/700 P5 OT 250/120-277/700 P5

Input

a mm2 0.5 0.75

b mm 5.4±0.2 5.9±0.2

c mm 280 355

Output

a mm2 0.5

b mm 6.7±0.2 6.7±0.2

c mm 280 355


Luminaire Design

13

OT 50/120-277/800 2DIMLT2 P

OT 50/120-277/1A2 2DIMLT2 P OT 100/120-277/800 2DIMLT2 P

OT 110/120-277/1A4 2DIMLT2 P

LED power supply dimensions

- OT outdoor 2DIMmA IP64 Driver

Driver dimensions

Item Unit

Value

OT 50/120-277/800 2DIMLT2 P

OT 50/120-277/1A2 2DIMLT2 P

OT 100/120-277/800 2DIMLT2 P

OT 110/120-277/1A4 2DIMLT2 P

Input&

Output

a mm2 0.75

b mm 280 280

Cable dimensions of driver


Luminaire Design

14

2.3. Thermal considerations

The PrevaLED® SKY LED module has integrated heat sink providing optimal thermal management.

Customer do not need to install extra heat sink for the SKY LED module.

However, it is suggested to check the thermal condition of the PrevaLED® SKY LED module in the

luminaire. Make sure the LED module is working in environment with enough space.

2.3.1. Tc location and temperature measurement

The thermal condition of LED module has to be verified by measuring the temperature at the Tc

point. The Tc point is located on the back of the module (see figure below).

Tc point

The temperature at the Tc point can be measured by

using a thermocouple which can be glued or soldered

to the LED module.

Please make sure that the thermocouple is fixed to

the Tc point with a direct contact (a). It would be

better to paste the thermocouple on the heat sink or

luminaire by a tape (b) to prevent it dropping from Tc

point.

a

b

Note: Please keep in mind that you need a direct contact between the thermocouple and the heat sink.

Examples of recommended thermocouples are shown

below.

Illustration DescriptionTemperature range

[°C]

PVC-insulatedthermocouple

-10…+105

PFA-insulatedthermocouple

-75…+260

Sprungthermocouple

-75…+260


Luminaire Design

15

2.3.2. Over Temperature Protection (OTP).

In case the PrevaLED® SKY module working over temperature, customer can select OSRAM OT

2DIM LED driver as power supply.

With the thermal protection function of OT 2DIM LED driver, customer can use a NTC (Negative

Temperature Coefficient Thermistor) sticking on the Tc point of PrevaLED® SKY module to realize

the over temperature protection function.

Customer need to program the parameter of NTC into OT 2DIM LED driver via device of ‘OSRAM

OT Programmer’ and the software “Tuner4TRONIC®”. See below graph.

Also, a real application temperature test will be needed to verify the OTP function by customer.

With the OTP function’s help, the

OSRAM OT 2DIM driver will decrease its

output current when the NTC

temperature on the Tc point reach to the

preset parameter.

2.4. Electrical considerations

2.4.1. Insulation coordination for PrevaLED® SKY LED modules

All tests validating this kind of information were done with OPTOTRONIC® ECGs. In accordance

with EN 61347-2-13. The insulation designed working voltage U-out is 500V for this module.

The product was designed as built-in LED module which can only fulfil basic insulation. It should

be applicable to Class I luminaires. If it is used in Class II luminaires, the final user should make

sure the safety protection in final luminaires construction.


Luminaire Design

16

2.4.2. Wiring information

The PrevaLED® SKY LED module provide 2 type of input wire:

- Input wire with tin plated at the end of wire (a)

- Input wire with M15 waterproof connector (b)

a b

For the type ‘a’ wire, if module need to work in moist environment, user should add a waterproof connector or terminal

box for the wire of module and driver to fulfill the waterproof requirement. User can also use general non-waterproof

connector, but it needs to make sure the luminaire can provide sufficient IP rank for the system.

For the type ‘b’ wire, user need to confirm that the other components in system, for example driver, are using the same

M15 waterproof connector so that the system can be waterproof.

PrevaLED® SKY cable information

Item Unit Value

Input

a mm2 0.75

b mm 6.1±0.3

c mm 650

Brown: connect to LED+ of driver.

Blue: connect to LED- of driver.


Luminaire Design

17

System wiring between OT outdoor On/Off driver and PrevaLED® SKY

LED+

(red)

OT 50/120-277/700 P5

LED Driver

waterproof

connector

One driver to one LED module

LED-

(black)

PrevaLED®

SKY

OT 180/120-277/700 P5

LED Driver

LED+

(red)LED-

(black)

+(brown) -(blue)

waterproof

connector

One driver to three LED module

PrevaLED®

SKY

Attention:

Please make sure the connectors are suitable for the driver’s wire and the system

connection can meet respective IP requirement.

For the wire information, please refer to 2.2.2.

The waterproof condition for input wire of driver also need to be taken into

consideration.


Luminaire Design

18

2.4.3. Electrostatic discharge (ESD)

To protect the light engine from electrostatic damage, the module must not be opened. The light

engine fulfills the requirement of the immunity standard IEC/EN 61547. ESD Protection: contact

4kV and air 8kV.

Please pay attention to standard ESD precautions when installing the module.

If surge protection structure not within power supplier, a lightning protector should be needed

additionally for outdoor application.

2.4.4. Wiring in protection class I and II luminaires

OPTOTRONIC® LED power supplies of the OT driver are designed for different luminaires. The

EQUI connection needs to be established via the casing. Please ensure a proper electrical

connection.

For the class I luminaires, the EQUI must be connected to the heat sink of the LED module to

improve the surge withstand capability of the system and EMI in critical luminaires. The

connection of the EQUI (= casing) to protective earth is only necessary in protection class I

luminaires.

The product was designed as built-in LED module which can only fulfill basic insulation. It should

be applicable to Class I luminaires. If it is used in Class II luminaires, the final user should make

sure the safety protection in final luminaires construction.

Class I luminaires

The PE wire must be connected to touchable metal parts of the luminaire. It is highly

recommended to connect the PE of the luminaire to the equipotential of driver and module as

well.

Waterproof

Junction box

LED luminaire, protection class I


Installation Guide

19

3. Installation Guide

Note: The installation of LED systems (LED modules and ECGs) needs to be carried out in compliance with all applicable

electrical and safety standards. Only qualified personnel should perform installations.

3.1. Application of installation for module orientation

Recommended application:

Gravity

orientation

0~360° is recommended as show

3.2. Application of installation sketch map for optics.

Pole position

Lig

ht d

istrib

utio

n o

rienta

tion

Road orientation

3.2.1. Installation of one LED module inside a luminaire


Installation Guide

20

Lig

ht d

istrib

utio

n o

rienta

tion

3.2.2. Installation of more than one LED module inside a luminaire

Pole position

3.3 LED module application and mounting layout

or

a) 150º x 80º T40º S

Staggered or Opposite

b) 150º x 80º T40º C

Twin-central

6000 lm 3000 lm

6000 lm 3000 lm

Road orientation

Longitu

din

al(1

50

o)

Transverse (80o)

Longitu

din

al(1

50

o)

Transverse (80o)

Tilting (40o)

Tilting (40o)


Installation Guide

21

Pole position

c) 150º x 80º T40º S + 150º x 80º T40º C

Single Side mounting

Need combine two optics in one luminaire

d) 100º x 60º

6000 lm 3000 lm

e) 60º x 60º

Asymmetric

(Floodlight)

High bay

>5m

6000 lm 3000 lm

f) 100º x 100º

3-6m

Low bay6000 lm 3000 lm

Transverse (100o)

Longitu

din

al (6

0o)

Transverse (60o)

Longitu

din

al (6

0o)

Transverse (100o)

Longitu

din

al (1

00

o)


Installation Guide

22

3.4. Application of mechanical installation

When install more than one PrevaLED® module in

luminaire, please separate the module in order to

get better cooling.

When finish design of luminaire, please test the

temperature of Tc point on each module. Make sure the Tc

not exceed the Tc max when the luminaire is working

under max ambient temperature with max tolerance input

DC current.

Operating Tc range:

-30 … 90ºC (measure at Tc point) for HP

-30 … 90ºC (measure at Tc point) for LP

Suggested min.

clearance distance

between modules

>10mm.

The temperature

will get higher if

modules stay closer.

Please keep the module

lens clean. Any stains or

mechanical damage will

affect the optical

performance of LED

module.

It will help to decrease

module temperature

if there is opening on

the luminaire.

Suitable for M4 screw.

IP connector and adaptor

should NOT be touching

the heat sink.

Please do not remove the plastic

cover and keep the module as

original mechanical shape.

Other important note:

a) The LED module itself and all its components may

not be mechanical stressed.

b) Assembly must not damage or destroy conducting

paths on the circuit board.

c) To avoid mechanical damage to the connecting

cables, the module should be attached securely to the

fixture. Heavy vibration should be avoided.

d) Installation of LED modules with (power supplies)

needs to be made with regard to all applicable electrical

and safety standards. Only qualified personnel should

be allowed to perform installation.

e) Pay attention to standard ESD precautions when

installing the module.

f) If surge protection structure not within power supplier,

a lightning protector should be needed additionally for

outdoor application.

g) The design of the housing should be according to the

IP standards in the application..

Provision for safety

chain connection.

To reduce risk of

accidental drop during

maintenance.


Norms and Standards

23

4. Norms and standards

4.1. Norms and standards for PrevaLED ® LED modules and light engines

IP Rating IP66

Standard IEC 62471; EN 60529; EN 62031;IEC 60598-1; EN 55015; EN 61547

Flammability IEC 60598-1

Environment RoHS

4.2. Photobiological safety

The module unit has been classified as Exempt Group 2 at measurement conditions (500lx,

200mm) according to IEC 62471..

The luminaire should be positioned so that prolonged staring into the luminaire at a distance

closer than 1,86 m is not expected

www.osram.asia

OSRAM Asia Pacific Management Company

China office:

Sales and Technical Support

5/F, Hantang Building, Overseas Chinese Town,

Shennan Ave, Nan Shan District,

518053, Shenzhen, Guangdong, P.R. China

technical application guide prevaled sky module

Documents