Cree XLamp MH-B LED MR16 & GU10 Reference Design

Transcription

Cree® XLamp® MH-B LED
MR16 & GU10 Reference Design
Table of Contents
Introduction
Introduction......................................................... 1
Following Cree’s previous reference designs of MR16
Design approach/objectives................................... 2
replacement lamps,1 this design demonstrates the
The 6-step methodology........................................ 2
possibility of employing the XLamp® MB-H LED as the
1. Define lighting requirements............................. 2
light source of 35-watt halogen equivalent MR16 and
2. Define design goals......................................... 4
GU10 replacement lamps for use as indoor spotlights.
CLD-AP195 rev 0
Application note
3. Estimate efficiencies of the optical, thermal &
electrical systems........................................... 4
Optimized for use in directional lamps such as the MR16
4.Calculate the number of LEDs........................... 5
and GU10, the MH-B LED offers a wide range of color
5.Consider all design possibilities......................... 5
temperatures and 2-, 4- and 5‑step binning, presenting
6. Complete the final steps: implementation and
an opportunity for lighting manufacturers to create a
analysis......................................................... 6
product line of MH-B‑based MR16 and GU10 lamps that
Conclusion..........................................................11
are constructed using nearly all the same components.
www.cree.com/XLamp
Bill of materials...................................................12
1 Cree XLamp MT-G LED MR16 Reference Design
Cree XLamp XM-L EasyWhite® LED MR16 Reference Design
Cree XLamp XP-E LED MR16 Reference Design
Cree XLamp XB-D LED MR16 Reference Design
Cree XLamp MK-R LED MR16 Reference Design
Cree XLamp XQ-D LED MR16 Reference Design
Cree XLamp High-CRI MR16 Reference Design
Reliance on any of the information provided in this Application Note is at the user’s sole risk. Cree and its affiliates make no warranties or representations
about, nor assume any liability with respect to, the information in this document or any LED-based lamp or luminaire made in accordance with this
reference design, including without limitation that the lamps or luminaires will not infringe the intellectual property rights of Cree or a third party.
Luminaire manufacturers who base product designs in whole or part on any Cree Application Note or Reference Design are solely responsible for the
compliance of their products with all applicable laws and industry requirements.
Copyright
in this
this document
document isis subject
subjecttotochange
changewithout
withoutnotice.
notice. Cree®, the Cree
Copyright©©2014
2010Cree,
Cree,Inc.
Inc.All
Allrights
rights reserved.
reserved. The
The information
information in
®
®
logo,
XLamp
andlogo
EasyWhite
areare
registered
trademarks
of of
Cree,
Inc.
ENERGY STAR® is a registered trademark of the U.S. Environmental
Cree,
the Cree
and XLamp
registered
trademarks
Cree,
Inc.
Protection Agency. Other trademarks, product and company names are the property of their respective owners and do not imply specific
product and/or vendor endorsement, sponsorship or association. For product specifications, please see the data sheets available at www.cree.
com. For warranty information, please contact Cree Sales at [email protected].
Cree, Inc.
4600 Silicon Drive
Durham, NC 27703
USA Tel: +1.919.313.5300
XLamp ® MH-B LED MR16 & GU10 Reference Design
Design approach/objectives
In the “LED Luminaire Design Guide” Cree advocates a six‑step framework for creating LED luminaires and lamps. All
Cree reference designs use this framework, and the design guide’s summary table is reproduced below.
Step
Explanation
1. Define lighting requirements
•
The design goals can be based either on an existing fixture or on the application’s lighting
requirements.
2. Define design goals
•
•
Specify design goals, which will be based on the application’s lighting requirements.
Specify any other goals that will influence the design, such as special optical or environmental
requirements.
•
•
•
Design goals will place constraints on the optical, thermal and electrical systems.
Good estimations of efficiencies of each system can be made based on these constraints.
The combination of lighting goals and system efficiencies will drive the number of LEDs needed
in the luminaire.
4. Calculate the number of LEDs needed
•
Based on the design goals and estimated losses, the designer can calculate the number of LEDs
to meet the design goals.
5. Consider all design
choose the best
•
•
With any design, there are many ways to achieve the goals.
LED lighting is a new field; assumptions that work for conventional lighting sources may not
apply.
•
•
•
•
•
Complete circuit board layout.
Test design choices by building a prototype luminaire.
Make sure the design achieves all the design goals.
Use the prototype to further refine the luminaire design.
Record observations and ideas for improvement.
3. Estimate efficiencies of the
thermal & electrical systems
optical,
possibilities
and
6. Complete final steps
Table 1: Cree 6-step framework
The 6-step methodology
The goal of this design is to create LED-based retrofit MR16 and GU10 lamps that show the performance available from
the XLamp MH-B LED and meet the ENERGY STAR® light output requirements for a 35‑watt halogen lamp.
1. Define lighting requirements
Table 2 shows a ranked list of desirable characteristics for an MR16 and GU10 lamp reference design to address.
Importance
Critical
Characteristics
Units
Light intensity - center beam candlepower (CBCP)
candelas (cd)
Beam angle - full width half maximum (FWHM)
degrees (°)
Illuminance distribution
footcandles (fc)/lux (lx)
Power
watts (W)
Luminous flux
lumens (lm)
Efficacy
lumens per watt (lm/W)
Form factor
Important
Price
$
Lifetime
hours
Operating temperature
°C
Correlated color temperature (CCT)
K
CRI
100-point scale
Manufacturability
Table 2: Ranked design criteria for an MR16 lamp
Copyright © 2014 Cree, Inc. All rights reserved. The information in this document is subject to change without notice. Cree®, the Cree logo, XLamp® and EasyWhite® are registered
trademarks of Cree, Inc. ENERGY STAR® is a registered trademark of the U.S. Environmental Protection Agency. Other trademarks, product and company names are the property of
their respective owners and do not imply specific product and/or vendor endorsement, sponsorship or association. For product specifications, please see the data sheets available
at www.cree.com. For warranty information, please contact Cree Sales at [email protected].
2
Table 3 summarizes the applicable ENERGY STAR requirements for lamps.2
Characteristic
Luminous Efficacy
Directional
ENERGY STAR Requirements
Reported values for each lamp model shall meet the applicable requirement in the table below. Additionally eight or
more units individually shall meet the requirement.
Lamp Rated Wattage (watts)
Minimum Lamp Efficacy (initial lm/W)
<20
40
≥20
50
Elevated Temperature Light
Output Ratio:
Lamp shall maintain ≥ 90% of initial light output (total luminous flux) measured at ambient temperature (25°C ± 5°C)
when tested in the same elevated temperature condition required by the Lumen Maintenance requirement.
Calculation of the elevated temperature light output ratio shall be carried out with directly measured (unrounded)
values.
Center Beam Intensity:
ANSI Standard PAR, MR
and MRX Shape Lamps
Lamp center beam intensity shall be greater than or equal to the center beam intensity value calculated by the ENERGY
STAR® Lamp Center Beam Intensity Benchmark Tool for the referenced incandescent lamp. (www.energystar.gov/
LampsCBCP)
CCT
Reported lamp model light color temperature shall correlate to one of the following nominal CCTs, additionally 9 out of
10 units shall fall within a 7-step MacAdam ellipse or ANSI quadrangle for the designated CCT, per the referenced ANSI
document:
• 2700 K
• 3000 K
• 3500 K
• 4000/4100 K
• 5000 K
• 6500 K
CRI
Lamp shall have a color rendering index (Ra) ≥ 80, and an R9 > 0. The average of units tested shall meet the
requirements and no more than 3 units shall have Ra < 77. No unit shall have Ra < 75.
Color Maintenance
Lamp change in chromaticity from 0-hour measurement, at any measurement point during the first 6,000 hours of
lamp operation, shall be within a total distance of 0.007 on the CIE 1976 u’v’ diagram. Nine or more units shall meet
the requirement.
Color Angular Uniformity
Variation of chromaticity across the beam angle of the lamp shall be within a total distance of 0.006 from the weighted
average point on the CIE 1976 (u’v’) diagram.
Rated Life
Decorative lamps shall have a rated life ≥ 15,000 hours. All other lamps shall have a rated life of ≥ 25,000 hours.
All tested units shall be operational at 3,000 hours.
≥ 90% of the tested units shall be operational at 6,000 hours.
Electrical Safety
Lamp shall comply with ANSI/UL 1993-2012, and ANSI/UL 8750-2009 as applicable
Power Factor: (Exemption:
Lamps ≤ 5 Watts)
Reported value for each lamp model shall have a power factor ≥ 0.7..
Frequency
Lamp light output shall have a frequency ≥ 120Hz.
Start Time
Reported value of time for lamp to remain continuously illuminated shall be within one second of application of
electrical power.
Transient Protection: All
Line Voltage Lamps
(Exemption: Low Voltage
Lamps)
2
Lamp shall survive 7 strikes of a 100 kHz ring wave, 2.5 kV level.
All units shall be fully operational at the completion of testing.
ENERGY STAR® Program Requirements Product Specification for Lamps (Light Bulbs) Eligibility Criteria Version 1.1
3
Characteristic
Lamp Toxics Reduction
ENERGY STAR Requirements
Lamps ≤ 23.0 rated watts shall contain ≤ 2.5 milligrams (mg) mercury per lamp
Lamps > 23.0 rated watts shall contain ≤ 3.0 milligrams (mg) mercury per lamp
When present, lamp shall contain restricted levels of the following materials, where the maximum concentration values
allowed by weight in homogeneous materials are:
• Lead: 0.1%
• Cadmium: 0.01%
• Hexavalent chromium: 0.1%
• Polybrominated biphenyls (PBB): 0.1%
• Polybrominated diphenyl ethers (PBDE): 0.1%
Exemptions:
1. Copper alloy containing up to 4% lead by weight
2. Lead in high melting temperature type solders (i.e. lead- based alloys containing 85% by weight or more lead)
3. Electrical and electronic components containing lead in a glass or ceramic other than dielectric ceramic in capacitors,
e.g. piezoelectronic devices, or in a glass or ceramic matrix compound
4. Lead in dielectric ceramic in capacitors
5. Lead in white glasses used for optical applications
6. Lead in solders to complete a viable electrical connection between semiconductor die and carrier within integrated
circuit flip chip packages
7. Lead in glass of cathode ray tubes, electronic components and fluorescent tubes
8. Cadmium and its compounds in electrical contacts
9. Cadmium in color-converting II-IV LEDs (< 10 μg Cd per mm2 of light-emitting area) for use in solid state illumination
or display systems
Lamp Shape Dimensions:
(Exemption: Non-Standard
Lamps) Directional ANSI
Standard Lamps
Lamp shall comply with ANSI minimum overall length (min OAL), maximum overall length (MOL) and maximum lamp
diameter values, where they exist.
Minimum Starting/
Operating Temperature
Lamp packaging shall state the minimum starting or operating ambient temperature and shall state any other
conditions required for reliable starting.
Table 3: ENERGY STAR requirements for lamps
2. Define design goals
The intnet of this project is to develop 35‑W halogen equivalent MR16 and GU10 lamps with an 25° beam angle using
the XLamp MH-B LED. We used the ENERGY STAR Center Beam Intensity Benchmark Tool to determine the CBCP such
lamps need to provide. Table 4 shows the design goals for this project.
Characteristic
Unit
Target Goal
Light output
lm
400
CBCP - 25° beam angle
cd
1601
lm/W
80
Efficacy
Power
W
5
CCT
K
3000
CRI
100-point scale
Power factor
80
0.5
Table 4: Design goals
3. Estimate efficiencies of the optical, thermal & electrical systems
At its binning current, 120 mA, the MH-B LED provides lumen output that meets the design goal and we used this current
value as the drive current for the design.
Thermal Requirements
As is typical for Cree’s MR16 reference designs, the heat sink must be able to dissipate the necessary heat and serve as
the mechanical housing for the other lamp components. We selected a commercially available heat sink constructed of
4
aluminum alloy AL1060 that fits the compact form factor. The heat sink is part of a kit that also includes an optic holder
and plastic base.
Driver
The drivers for these lamps are located inside the lamp base. We used off‑the‑shelf constant‑current drivers, shown in
Figure 1, that fit within the lamp base. The input voltage range for the MR16 driver is 8‑14 V; the range for the GU10
driver is 180-240 V.
Figure 1: Left and center - MR16 driver, right - GU10 driver
Secondary Optics
We used an off‑the‑shelf total internal reflection (TIR) optic, shown in Figure
2, for each lamp.
Figure 2: MR16 and GU10 optic
4. Calculate the number of LEDs
The performance of the XLamp MH-B LED enables the use of a single LED as the light source of MR16 and GU10 lamps
that meet the ENERGY STAR light output requirements for 35‑W halogen lamps.
5. Consider all design possibilities
The XLamp MH-B LED used in this reference design offer a wide range of color temperatures. As highlighted in Table 5,
we selected a warm white LED for this MR16 and GU10 lamp design.
CRI
Base Order Codes
Min. Luminous Flux
@ 120 mA
Min
Flux
Flux
Group (lm) @ (lm) @
85 °C 25 °C
CCT Range
C2
440
2-Step Order Code
Chromaticity
Region
498
80
30H
Chromaticity
Region
MHBAWT-0000000N0HC230H
C4
475
538
MHBAWT-0000000N0HC430H
A2
330
374
MHBAWT-0000000N0UA230H
A4
355
402
3000 K
90
30H
4-Step Order Code
MHBAWT-0000000N0UA430H
30F
30F
5-Step Order Code
Chromaticity
Region
MHBAWT-0000000N0HC230F
MHBAWT-0000000N0HC430F
MHBAWT-0000000N0UA230F
MHBAWT-0000000N0UA430F
30E
30E
MHBAWT-0000000N0HC230E
MHBAWT-0000000N0HC430E
MHBAWT-0000000N0UA230E
MHBAWT-0000000N0UA430E
Table 5: MH-B LED order codes
5
6. Complete the final steps: implementation and analysis
Using the methodology described above, we determined a suitable combination of components and drive conditions to
meet the design goals. This section describes how Cree assembled the MR16 and GU10 lamps and shows the results of
the design.
Prototyping Details
1. We verified the component dimensions to ensure a correct fit.
2. Following the recommendations in the MH-B Soldering and Handling Application Note3, we reflow soldered the LED to
a star board with an appropriate solder paste and reflow profile and cleaned the flux residue with isopropyl alcohol
(IPA).
3. We soldered the LED wires to the star board.
4. We attached the star board to the heat sink using thermal tape.
5. We fed the LED input wires through the heat sink and soldered them to the driver.
6. We inserted the driver into the plastic base and attached the base to the heat sink with room temperature vulcanizing
(RTV) silicone.
7. We attached the optic to the optic holder.
8. We snapped the optic holder and optic into place on the heat sink.
9. We performed final testing.
Results
Thermal Results
Cree verified the board temperature with a thermocouple to confirm that the thermal dissipation performance of the
heat sink is sufficient. Based on the measured solder‑point temperature of 67.8 °C, the junction temperatures (TJ) can
be calculated as follows.
TJ = TSP + (LED power * LED thermal resistance)
TJ = 67.8 °C + (4.3 W * 5.5 °C/W)
TJ = 91.5 °C
Optical and Electrical Results
Cree’s testing of the MR16 and GU10 lamps provided the results in Table 6.4 As the table shows, each lamp exceeds its
CBCP and light-output targets using approximately 15% of the energy of a 35‑W halogen MR16 lamp. These energy
savings produce a corresponding cost savings, making these MR16 and GU10 lamps more economical to use than their
halogen counterparts.
3
4
Cree XLamp MH-B LED Soldering and Handling Application Note
IES files for the MR16 and GU10 lamps are available on the Cree website.
6
Characteristic
Result
Unit
Light output
CBCP
MR16
GU10
lm
432.2
438.7
cd
2286
2313
degrees
21.3
21.2
lm/W
78.6
86.0
W
5.5
5.1
CCT
K
3079
3148
CRI
100-point scale
82
81
0.76
0.7
$3.55
$3.60
Beam angle
Efficacy
Power
Power factor
Estimated yearly energy savings compared to 35‑W halogen
lamp (3 hrs/day, $0.11/kWh)
$
Table 6: MH-B MR16 and GU10 lamp steady-state results
We tested the intensity distribution of the GU10 lamp. Figure 3 shows an even intensity distribution for the lamp. Figure
4 is another indication of the even light distribution of the MH-B GU10 lamp. The image is of the light pattern of the MH-B
GU10 lamp on a white wall. The lamp was mounted facing and perpendicular to the wall.
Figure 3: Angular luminous intensity distribution of MH-B
GU10 lamp - 21.2° beam angle
Figure 4: MH-B GU10 light pattern
Table 7 and Table 8 show the illuminance of the MH-B MR16 and GU10 lamps at various distances from the light source.
7
Center Beam
Illuminance
Height
Beam Width
0.5 m
1.6 ft
838.1 fc
9,021.2 lx
0.2 m
0.7 ft
1.0 m
3.3 ft
209.5 fc
2,255.0 lx
0.4 m
1.3 ft
1.5 m
4.9 ft
93.1 fc
1,002.1 lx
0.6 m
2.0 ft
2.0 m
6.6 ft
52.4 fc
564.0 lx
0.7 m
2.3 ft
2.5 m
8.2 ft
33.5 fc
360.6 lx
0.9 m
3.0 ft
3.0 m
9.8 ft
23.3 fc
250.8 lx
1.1 m
3.6 ft
Table 7: MH-B MR16 illuminance – 21.3° beam angle
Center Beam
Illuminance
Height
Beam Width
0.5 m
1.6 ft
709.9 fc
7,641.3 lx
0.2 m
0.7 ft
1.0 m
3.3 ft
177.5 fc
1,910.6 lx
0.4 m
1.3 ft
1.5 m
4.9 ft
78.9 fc
849.3 lx
0.6 m
2.0 ft
2.0 m
6.6 ft
44.4 fc
477.9 lx
0.7 m
2.3 ft
2.5 m
8.2 ft
28.4 fc
305.7 lx
0.9 m
3.0 ft
3.0 m
9.8 ft
19.7 fc
212.0 lx
1.1 m
3.6 ft
Table 8: MH-B GU10 illuminance – 21.2° beam angle
To demonstrate the range of possibilities available with just one XLamp MH-B LED, we made a number of additional
versions of the GU10 lamp, changing only the optic. Table 9 shows the results and demonstrates that it is possible for a
lighting manufacturer to offer a product line of 35-W halogen equivalent MR16 or GU10 lamps that differ in construction
by only one component.
8
Beam
Angle
(°)
ENERGY
STAR MR16
Line Voltage
Requirement
(cd)
CBCP
(cd)
Light
Output
(lm)
Power
(W)
Efficacy
(lm/W)
Nata 1298-E
16.4
1060
2644
407.5
5.2
78.9
LedLink LL01EDAK25L06
17.3
987
2077
434.9
5.2
84.3
LedLink LL01XPDG20L06-M2
22.9
669
1629
439.2
5.2
85.1
Nata 1293-E
31.6
420
999.1
409.3
5.2
79.3
LedLink LL01CRWI40L02-M2
47.2
266
566.2
433.7
5.2
84.0
Optic
Table 9: Steady-state results for additional MH-B GU10 lamps
Table 10 shows the angular luminous intensity distribution and light pattern of the additional GU10 lamps.
9
Optic
Intensity Distribution
Light Pattern
Nata 1298-E
LedLink LL01EDAK25L06
LedLink LL01XPDG20L06-M2
10
Optic
Intensity Distribution
Light Pattern
Nata 1293-E
LedLink LL01CRWI40L02-M2
Table 10: Intensity distributions and light patterns for additional MH-B GU10 lamps
Conclusion
This reference design demonstrates the simplicity of using a single XLamp MH-B LED as the light source of 35‑W halogen
equivalent MR16 and GU10 lamps that conform to ENERGY STAR requirements. The performance of the MH-B LED
enables a product line of MR16 and GU10 lamps that provides a variety of color temperatures and beam angles. The
excellent performance of the Cree XLamp MH-B LED makes it a serious candidate to serve as the basis for LED‑based
MR16 and GU10 lamps.
11
Bill of materials
Company
Order Code/
Model Number
Web Link
Shenzhen Technology Co., Ltd.
MR16
www.sz-wnd.com
Optoelectronics Technology Co.,
Ltd. Xiamen Fang
GU10
sgqsz.cn.gongchang.com
Heat sink/housing,
optic holder, base
Dah Sing Metal Products Co.,
Ltd. Huizhou
GU10/MR16
www.hztaisun.com
LED
Cree, Inc.
MHBAWT-0000-000N0HC230F
MH-B product page
LedLink
LL01XP-DG30L06-M2
LL01ED-AK25L06
LL01XP-DG20L06-M2
LL01CR-WI40L02-M2
www.ledlink-optics.com/ProductsHomeLED.aspx
Nata Lighting Company Limited
1298-E
1293-E
www.nata.cn/miniCatalog.php?level1=CA_0000009&level2=
CA_00019
Dow Corning Corporation
SE 9185 White
www4.dowcorning.com/DataFiles/090007c8802d7bdc.pdf
Star board
t-Global Technology
LP0001-01
www.tglobaltechnology.com/die-cut-datasheet/LP0001-01Li2000A-02.pdf
Thermal tape
t-Global Technology
Li-2000
www.tglobaltechnology.com/thermal-management-products/
li-2000a-thermal-tape.php/
Component
Driver
Optic
RTV silicone
Table 11: Bill of materials for MH-B MR16 and GU10 lamps
Reliance on any of the information provided in this Application Note is at the user’s sole risk. Cree and its affiliates make no warranties or representations
about, nor assume any liability with respect to, the information in this document or any LED-based lamp or luminaire made in accordance with this
reference design, including without limitation that the lamps or luminaires will not infringe the intellectual property rights of Cree or a third party.
Luminaire manufacturers who base product designs in whole or part on any Cree Application Note or Reference Design are solely responsible for the
compliance of their products with all applicable laws and industry requirements.
12

Cree XLamp MH-B LED MR16 & GU10 Reference Design

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Cree XLamp MH-B LED MR16 &amp; GU10 Reference Design

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Cree XLamp MH-B LED MR16 & GU10 Reference Design