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Design-in guide Philips Fortimo LED downlight module system (DLM) - August 2009 • Philips Fortimo LED DLM1100 & 2000 in 3000 & 4000 K (New, now with improved LED efficiency for 2000lm types) • Philips Fortimo LED DLM1100 & 2000 I (with independent driver) • Philips Fortimo LED DLM1100 & 2000 TD (dimmable via Touch & DALI (new) + 12 V output) • Philips Fortimo LED DLM2000 Food (new) asimpleswitch.com

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Page 1: asimpleswitch - yunyangsh.com€¦ · Design-in guide Philips Fortimo LED downlight module system 5 Features and benefits Features Benefits Breakthrough LED L3 energy saving Patented

Design-in guidePhilips Fortimo LED downlight module system (DLM) - August 2009

• Philips Fortimo LED DLM1100 & 2000 in 3000 & 4000 K (New, now with improved LED efficiency for 2000lm types)• Philips Fortimo LED DLM1100 & 2000 I (with independent driver)• Philips Fortimo LED DLM1100 & 2000 TD (dimmable via Touch & DALI (new) + 12 V output)• Philips Fortimo LED DLM2000 Food (new)

asimpleswitch.com

Page 2: asimpleswitch - yunyangsh.com€¦ · Design-in guide Philips Fortimo LED downlight module system 5 Features and benefits Features Benefits Breakthrough LED L3 energy saving Patented

Fortimo LED DLM1100 & 2000/TD

Fortimo LED DLM1100 & 2000

Fortimo LED DLM1800 & 2000/Food

Fortimo LED DLM1100 & 2000/I

Page 3: asimpleswitch - yunyangsh.com€¦ · Design-in guide Philips Fortimo LED downlight module system 5 Features and benefits Features Benefits Breakthrough LED L3 energy saving Patented

Design-in guide Philips Fortimo LED downlight module system

Contents1. Introduction 4

Features and benefits 5Applications 5

2. LEDs, the heart of the Fortimo downlight module 6What is a LED? 6LED packaging 7Binning 7LUXEON Rebel LEDs 7Fortimo LED DLM addresses the issue of binning 8Color consistency (SDCM) 8Miniaturization 8

. Philips Fortimo LED DLM system 9Fortimo LED DLM range extensions 9Fortimo LED DLM “4000 K” 9Fortimo LED DLM “3000 K” 9Fortimo LED DLM “TD dimmable” 9Fortimo LED DLM “Independent” 9Fortimo LED DLM “Food” 9The basic principles of the Fortimo LED DLM system 10Starting characteristics 10Luminous flux during start period 10Lumen maintenance 10Dimming 10Future range extensions 10Nomenclature 11Dimensions of LED DLM module and driver 12About the Fortimo LED downlight module 13Mechanical fixation 13About the Fortimo LED driver 13About the Fortimo LED DLM cables 14Specification of the system after 100 hours 15UV and other hazards 15

4. Lighting performance characteristics 15Photobiological safety aspects 16Radiance-based 16Irradiance-based 16Measurements on the Fortimo LED DLM gave the following results: 16Dimming characteristics 17

5. Designing a luminaire 18IEC recommendations 18Electrostatic device (ESD) measures 18Installation instructions 18Wiring 18Connecting to the mains supply 18Connecting to protective ground 18Connecting to DALI 19Connecting to 12 V 19Connecting a Fortimo LED driver to a Fortimo LED module 19

Cable 19Independent operation 20Note: Fortimo LED DLM independent cable 20Outdoor luminaires 20Secondary optics 21Alux Luxar contact details 21

6. Heat sink design and temperature measurements 22General 22Test requirements 22Maximum temperature 22Critical measurement points 22Operation under built-in conditions 22Case temperature and thermal circuit 23Case temperature and LED module performance 23Operation in free air 23Heat sink design 24Size of heat sink 25Active and passive cooling 26Passive cooling 26Air flow 26Thermal design 27From the temperature test point Tc (point 1) to the side surfaces (point 2) 27From the heat sink to ambient (point 3) 27Thermal model 27Calculating your heat sink 28From the datasheet: 28Now the calculation takes place in three steps: 28Shape of heat sink 29The Fortimo LED DLM with the two connected heat sinks and three thermo couples installed: 29How to measure Tc 29SynJet cooling from Nuventix 30Nuventix contact information 30Electromagnetic compatibility 31Humidity 31Exposure to direct sunlight 31Vibration and shocks 31Standards and approvals 31IP codes, dust and moisture protection 31

7. Lighting installations and the environment 1Glow-wire test 32End-of-life behavior 32Fortimo LED DLM system disposal 32

8. Appendix Schematic luminaire with the Fortimo DLM system

9. Index of visuals 5

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Design-in guide Philips Fortimo LED downlight module system4

1. IntroductionThank you for choosing the Philips Fortimo LED DLM system.This guide tells you all about this system. If you require any further information or support please consult your local Philips office or visit:www.philips.com/support orwww.philips.com/fortimo

The advantages of LEDs have been known for 40 years:• Long life – low maintenance cost• Robustness – high reliability• Saturated colors – maximum visual effect• Cool beam – no heating of illuminated products• No UV or IR – wide application possibilities• Low-voltage operation – more safety, ease of use• Mercury-free – care for the environment

Rapid improvements in high-power LED technology mean that LEDs can now be used for the first time in ‘real’ lighting applications, providing improvements over traditional lighting systems.

The use of LEDs has implications for lighting manufacturers in terms of differences in solid-state lighting usage compared with traditional lamps: for example how to design given the constant improvements in specifications; how to provide the necessary heat sinking and how to deal with variations in flux and/or color. The Philips Fortimo LED DLM system addresses these differences and facilitates easy adoption of LED technology for high lumen packages (1000 lm+). The system is designed for integration in luminaires (system). This technical application guide addresses the relevant issues to support and facilitate the work of specifiers and lighting system designers.

The Philips Fortimo LED DLM system is, as the name suggests, designed and intended for downlight luminaires. Other applications can be explored by OEMs as long as this creates no design conflicts with the Fortimo LED DLM system and European luminaire standards are respected (EN 60598). Please consult us if you wish to deviate from the design rules as described in this application guide.

Meanwhile also complementary businesses especially for heat sink and reflector design are developing around Fortimo LED DLM systems. In the application guide you will also find references to SynJet of Nuventix (active cooling) and Alux Luxar (reflectors).

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Design-in guide Philips Fortimo LED downlight module system 5

Features and benefitsFeatures Benefits

Breakthrough LED L3 energy saving

Patented remote phosphor technology

Fortimo driver 87-92% efficiency

1st LED product suitable for functional lighting comparable to

current benchmark

Driver 15% more efficient than standard LED drivers

Superior-quality white LED light

1100 & 2000 lm modules

CRI = 80, 4000 K and 000 K

Remote phosphor

Optimized light mixing chamber

Dedicated binning strategy

An enabler for entry into general lighting

Competes with CFL systems

Meets the norms for general lighting

Very high (optical) luminaire efficiencies

Perfectly mixed light, consistent color quality and lumen output

Future-proofed, convenient modules

Fixed form factor

Fixed lumen package

Easy-to-mount heat sink/optics

Comfortable light

No heat or UV

Dimmable, instant 100% light

Easy to work with for OEMs

Fewer technical barriers

Faster time-to-market

Easy for the end user to experience

More comfortable, no damage to materials

Multiple scene-setting options

Long lifetime of 50 K hrs

Integrated lifetime-preserving method

Low-maintenance

More reliable, longer life

3000 K Now also warm color available

Independent driver For ease of installation

Dimmable via Touch & DALI

Dimmable via AM protocol

Opening even more energy saving options via lighting controls like Actilume,

OccuPlus and many others.

More energy saving because while dimming efficiency increases up to 30%

Specific version for Food

2000 lm for 4000 K 1800 lm for 000 K

Optimized spectrum

High red green and blue saturation index

Less heat and UV

Long lifetime 50K hours

Food like meat, bread and vegetables will be lighted more natural

Competes with White Son systems available in 000 K and 4000 K

Warm colour for vegetables and bread illumination, colder color for fish

Optimised to make the food more attractive

Resulting in better aspect of vegetables, meat, and fish

Enabling the luminaire to be installed closer to the merchandise

Resulting in less maintenance cost compared to White Son system

ApplicationsThe Fortimo LED DLM system is intended for general lighting applications in the professional market for offices, hospitality and retail. Examples of applications include:• Offices (representative areas such as receptions, boardrooms, restaurants, etc.)• Public buildings (cinemas, theaters, airports, exhibition halls)• High-end shops• Retail (supermarkets, bakery/butcher areas, leather goods, etc.)• Urban outdoor lighting * (ground lighting, post-top lanterns)

* Use in outdoor luminaires? Neither the Fortimo LED DLM module nor the LED driver has an IP classification. If an OEM decides to use the Fortimo system in a luminaire for outdoor application, the OEM is responsible for proper IP protection and approbation of the luminaire.

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Design-in guide Philips Fortimo LED downlight module system6

2. LEDs, the heart of the Fortimo downlight moduleThe development of Light Emitting Diodes (LEDs) is progressing at such a pace that they are rapidly gaining importance for lighting applications. To most people, the term LED still only means the small indicator lights that show whether the TV set is switched on. These tiny light sources barely emit enough light to make themselves visible. However, breakthroughs made in the last few years now allow LEDs to be used for ‘real’ lighting applications that have traditionally been the domain of incandescent lamps and discharge lamps.The Philips/Agilent joint venture Lumileds was the first to bring high power LEDs for lighting applications to the market under the Luxeon trademark. Luxeon emitters are among the highest-performance LEDs in the world, allowing us to offer the brightest solid-state lighting solutions.

What is a LED?LEDs are solid-state devices, built up from crystalline layers of semiconductor material. The light generation process makes use of the special electronic properties of crystalline semiconductors in a process called injection luminescence. In brief, this means the injection of charged particles by an electric field from one semiconductor layer into another, where they are able to relax to alower-energy state by emitting visible light. LEDs produce narrow light spectra. The bandwidth remains limited to a few tens of nanometers, and istherefore perceived by the human eye as a single, deeply saturated color. LEDs are now available in all wavelength regions of the visible spectrum; yellow is the only region in which no high-power LED is currently available. Whitelight can be produced by combining LEDs of different colors (for instance red, green and blue), or by applying phosphor coatings on blue or ultraviolet LEDs.Like many other lamps, LEDs cannot be connected directly to the mains. The LEDs have to be operated at a stabilized low voltage, which is provided by driverelectronics. However, LEDs do not need ignition and can be switched within milliseconds. LEDs do not generate nearly as much heat as many otherlamps, but that does not mean that thermal design is not important. LEDs do produce heat when they operate, and are themselves relatively sensitive to temperature. Thermal considerations are therefore very important aspects of LED lighting system design.

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Design-in guide Philips Fortimo LED downlight module system 7

LED packagingThe bare LED die is still a very sensitive and fragile device that must be handled in a clean room environment. Before bringing them outside, they must be packaged. The light flux of conventional LEDs, for example those used as indicator lights on TV sets, is severely limited by the amount of heat generated. In practice, conventional LED packages are limited to about 0.15 W at most, and emit only a few lumens. Their light is too weak to be used for illumination purposes, and they can only be used for luminance applications (i.e. when the light source is intended to be viewed directly). A breakthrough came with a new package design invented by Philips Lumileds, which guides away the heat generated at the diode junction much more efficiently. LEDs based on this package are sold under the trademark Luxeon.

Instead of an epoxy cap, the chip is encapsulated in a silicone gel covered by a polymer lens. Using two different materials for encapsulation and for the primary optics allows better optimization of material properties for heat management and lifetime. The slug is a large metal body that takes up the heat from the chip and provides a low-thermal-resistance route to the outside world. This package design now makes high-power LEDs feasible.

BinningThe subject of binning should be explained because of its importance in LED system design. As in other semiconductor manufacturing processes, in LED production the number of parameters of the epitaxy process is very large and the process window small (for example, the temperature must be controlled to within 0.5 °C (<1 °F) across the wafer at temperatures of ~800 °C/1470 °F). The difficulty of achieving such a high degree of control means that the properties of the LEDs may vary significantly within single production runs and even on the same wafer. To obtain consistency for a given application, binning (= selection in bins) is mandatory. Binning involves characterization of the LEDs by measurement and subsequently categorizing them into several specific bins. To keep the cost per LED down, LED manufacturers must sell the full production distribution. At the same time they cannot guarantee the availability of all bins at all times. There is a trade-off between logistics and cost price on the one hand, and the application requirements on the other. Setting the specification too tightly will increase the cost price and may lead to logistics problems. System design should therefore try to combine LEDs from different bins intelligently to obtain the required system performance at a reasonable price and with reasonable delivery reliability.

LUXEON Rebel LEDsLUXEON Rebel is the smallest surface mountable power LED available today. With the industry’s best lumens per package, highest light density (lumens per mm2), and the highest packing density, LUXEON Rebel is ideal for both space constrained and conventional solid lighting applications. Due to the small mounting surface we have been able to use multiple LUXEON Rebel with the Fortimo products in order to match required high lumen packages of 1100 and 2000 lumens.

LUXEO Rebel LED

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Design-in guide Philips Fortimo LED downlight module system8

Fortimo LED DLM addresses the issue of binningHigh-quality LED light is achieved by mixing the light of blue LEDs and applying a special Fortimo phosphor technology remote from the LEDs. High-quality white light is characterized by a color rendering of 80, popular CCTs in general lighting applications of 3000 K and 4000 K and a color consistency comparable with conventional CFL and HID solutions (five SDCM)).

Color consistency (SDCM)The target specification of Fortimo LED DLM systems for color consistency is 5 SDCM @ 0-hours and 6 SDCM @ 10 K hrs. This is a similar specification as for conventional CFL lamps. SDCM stands for Standard Deviation of Color Matching and the value 5 refers to the size of an ellipse around the black body locus. Staying within this ellipse results in a consistency of light that ensures that from one luminaire to another no difference can be noticed. In the visual we have plotted >3000 Fortimo LED DLM systems and you can see they all fit within the 5 SDCM ellipse. This really demonstrates the unique quality of the remote phosphor concept. We also plotted these results in a typical bin distribution sheet of Philips Lumileds. As you can see all Fortimo’s fit within 1 bin! Typically you can buy 6 to 12 bins combinations, not so precise as the 1-bin result of Fortimo.

MiniaturizationLEDs are typically much smaller than conventional light sources. Lighting designers and specifiers immediately recognized the fact that LEDs allow dramatically different lighting designs that capitalize on these tiny, unobtrusive light sources. This is understandable, but care must also be taken to deal with the heat produced by power LEDs. Proper heat management places limits on miniaturization.

Color consistency (SDCM)

0.434

0.414

0.394

0.374

0.354

0.334

0.314

0.31

8

0.33

8

0.35

8

0.37

8

0.39

8

0.41

8

0.43

8

y

CIE 1931 xy

5000

4500

4000

3500

3000

6500

7500

1000

0

x

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Design-in guide Philips Fortimo LED downlight module system 9

Fortimo LED DLM “3000K”

Fortimo LED DLM “TD dimmable”

Fortimo LED DLM “Independent”

Fortimo LED DLM range extensionsAfter the introduction of the first Fortimo LED DLM systems in 2008 the portfolio is now being extended with 4 new systems, making use and building further on the modular, future proof promise of Fortimo LED systems. The portfolio since beginning 2009 exists out of following types:

Fortimo LED DLM “4000 K”• Fortimo LED DLM1100 18W/840 220-240V• Fortimo LED DLM2000 32W/840 220-240V

Fortimo LED DLM “3000 K”• Fortimo LED DLM1100 19W/830 220-240V• Fortimo LED DLM2000 36W/830 220-240V

Fortimo LED DLM “TD dimmable”• Fortimo LED DLM1100 18W/840/TD 220-240V• Fortimo LED DLM2000 32W/840/TD 220-240V• Fortimo LED DLM1100 19W/830/TD 220-240V• Fortimo LED DLM2000 36W/830/TD 220-240V

Fortimo LED DLM “Independent”• Fortimo LED DLM1100 18W/840/I 220-240V • Fortimo LED DLM2000 32W/840/I 220-240V• Fortimo LED DLM1100 19W/830/I 220-240V• Fortimo LED DLM2000 36W/830/I 220-240V

Fortimo LED DLM “Food”• Fortimo LED DLM1800 50W/Food 30 120-277V (new)• Fortimo LED DLM2000 50W/Food 40 120-277V (new)

Fortimo LED DLM system. Left the module, right the driver

Fortimo LED DLM “Food”

3. Philips Fortimo LED DLM system

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Design-in guide Philips Fortimo LED downlight module system10

The basic principles of the Fortimo LED DLM systemThe Fortimo LED DLM system contains two products:• The Fortimo LED downlight module• The Fortimo LED driverThe Fortimo LED DLM cable can be ordered separately.

This new system is designed for downlight applications.

Starting characteristicsThe system can be switched on in milliseconds, which is a general characteristic of LEDs. In 2009 a dimmable driver will become available, making it possible to switch in milliseconds at any dimming level.

Luminous flux during start periodIn contrast to other light sources, LEDs can be switched on at full power (or at any other dimmed level) instantaneously. The Fortimo LED DLM system requires an initial burning-in time of 100 hours to reach the listed specifications because of the combination of the LEDs and the remote phosphor used in the modules.

Lumen maintenanceWhen used within specification, (Tc<65C; Ta=35C) lumen maintenance of 70% at 35,000 hours is expected for Fortimo LED DLM. At 50,000 hours lumen maintenance is 50% (average lifetime specification).

DimmingTo enable the Fortimo LED DLM system to dim, a special Fortimo LED driver is developed. The above mentioned Fortimo LED DLM “TD systems” have integrated Touch & Dali protocols. Due to the use of an AM (not PWM) protocol the efficiency of the Fortimo system will increase up to 30% while dimming.

Future range extensionsSince we feel the Fortimo familily is not complete yet the following products are foreseen:• Fortimo LED DLM upgrades: more efficient systems. LED efficiency increases

are being used for efficiency increase or cost reduction, depending the product proposition.

• Fortimo with emergency functionality.• Fortimo LED Spot.• Fortimo LED DLM mini (smaller form factor).

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Design-in guide Philips Fortimo LED downlight module system 11

NomenclatureThe names of the products are defined as follows: • Fortimo LED DLM1100 18W/840 (CRI of 80 and CCT of 4000 K) 220-240V• Fortimo LED DLM2000 32W/840 (CRI of 80 and CCT of 4000 K) 220-240V• Fortimo LED DLM1100 18W/830 (CRI of 80 and CCT of 3000 K) 220-240V• Fortimo LED DLM2000 36W/830 (CRI of 80 and CCT of 3000 K) 220-240V• Fortimo LED DLM1100 18W/840/I 220-240V (Independent)• Fortimo LED DLM2000 32W/840/I 220-240V (Independent)• Fortimo LED DLM1100 18W/830/I 220-240V (Independent)• Fortimo LED DLM2000 36W/830/I 220-240V (Independent)• Fortimo LED DLM1100 18W/840/TD 220-240V (TD = Touch & DALI)• Fortimo LED DLM2000 32W/840/TD 220-240V (TD = Touch & DALI)• Fortimo LED DLM1100 18W/830/TD 220-240V (TD = Touch & DALI)• Fortimo LED DLM2000 36W/830/TD 220-240V (TD = Touch & DALI)• Fortimo LED DLM module 1800 50W/Food 30 (CCT of 3000 K) 120-277V (new)• Fortimo LED DLM module 2000 50W/Food 40 (CCT of 4000 K) 120-277V (new)

Specification of the system after 100 hours (August 2009)Power Light

output

Efficiency Comparable

LED

efficiency

Input

voltage

CCT CRI Colour

consistency

initial &

10k hrs

Dimmable

system only:

Increase efficiency

while dimming (%)

Fixed output systems and Independent systems W lm lm/W lm/W V K Ra SDCM

Fortimo LED DLM1100 18W/840 220-240 18 1100 62 110 220-240 4000 80 5 6

Fortimo LED DLM1100 19W/830 220-240 19 1100 58 110 220-240 000 80 5 6

Fortimo LED DLM2000 32W/840 220-240 2 2000 6 110 220-240 4000 80 5 6

Fortimo LED DLM2000 36W/830 220-240 6 2000 56 110 220-240 000 80 5 6

Fortimo LED DLM1800 50W/Food 30 50 1800 6 110 120-277 000 70 5 6

Fortimo LED DLM2000 50W/Food 40 50 2000 40 110 120-277 4000 70 5 6

Dimmable systems

Fortimo LED DLM1100 18W/840 TD 220-240 18 1100 62 110 220-240 4000 80 5 6 up to 0%

Fortimo LED DLM1100 19W/830 TD 220-240 19 1100 58 110 220-240 000 80 5 6 up to 0%

Fortimo LED DLM2000 32W/840 TD 220-240 2 2000 45 110 220-240 4000 80 5 6 up to 0%

Fortimo LED DLM2000 36W/830 TD 220-240 6 2000 50 110 220-240 000 80 5 6 up to 0%

Lm main.

35k hrs

Class Power

factor

Total

harmonic

distortion

Tc life

LED

module

Tc max

LED

module

Tc life

LED

Driver

Burning

position

Dimmable

system only:

Increase efficiency

while dimming (%)% % C C C

Fixed output systems and Independent systems

Fortimo LED DLM1100 18W/840 220-240 70 I > 0.9 < 20 45 65 65 universal

Fortimo LED DLM1100 19W/830 220-240 70 I > 0.9 < 20 45 65 65 universal

Fortimo LED DLM2000 32W/840 220-240 70 I > 0.9 < 20 65 65 65 universal

Fortimo LED DLM2000 36W/830 220-240 70 I > 0.9 < 20 65 65 65 universal

Fortimo LED DLM1800 50W/Food 30 70 I > 0.9 < 20 65 65 65 universal

Fortimo LED DLM2000 50W/Food 40 70 I > 0.9 < 20 65 65 65 universal

Dimmable systems

Fortimo LED DLM1100 18W/840 TD 220-240 70 I > 0.9 < 20 45 65 65 universal up to 0%

Fortimo LED DLM1100 19W/830 TD 220-240 70 I > 0.9 < 20 45 65 65 universal up to 0%

Fortimo LED DLM2000 32W/840 TD 220-240 70 I > 0.9 < 20 65 65 65 universal up to 0%

Fortimo LED DLM2000 36W/830 TD 220-240 70 I > 0.9 < 20 65 65 65 universal up to 0%

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Design-in guide Philips Fortimo LED downlight module system12

B1A1

C1 C2

A

Fortimo LED DLM module - dimensions Fortimo LED DLM driver - dimensions

A1 A2 A3 B1 C1 C2 F1 F2 F3 G1 G2 G3 H1

81.6 - 66.8 82.8 4.7 40.2 18 128.5 124.5 74 6.6 4.5 2

F1 F2 G1 G2 H1 H2

224 206 8 n.a. 4.5 n.a.

Dimensions of LED DLM module and driver (typical data; ± 0.2 mm)

F1

H1

G1

H2

G2

F2

Fortimo LED DLM module Independent - dimensions

WeightFortimo LED DLM systems:• Fortimo LED DLM modules 290 gr.• Fortimo LED driver 1100-2000 220-240 V 293 gr.• Fortimo LED driver 1100-2000/I 220-240 V 350 gr.• Fortimo LED driver 1100-2000/TD 220-240 V 307 gr.• Fortimo LED DLM module 2000 50 W/Food 285 gr.• Fortimo LED driver 2000/Food 220-240 V 467 gr.

A1 A2 A3 B1 C1 C2 F1 F2 F3 G1 G2 G3 H1

121,6 - 206 82.8 4.7 40.2 121,5 128.5 124.5 74 6.6 4.5 2

A

C2

A1 B1

C1

Fortimo LED DLM Food module - dimensions Fortimo LED DLM Food driver - dimensions

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Design-in guide Philips Fortimo LED downlight module system 1

About the Fortimo LED downlight moduleThe LED module consists basically of four main components:

PCB with LEDs Mixing chamber Heat spreader Diffuser with remote phosphor technology

High-quality white light with high efficiencies is achieved with a plain PCB with LEDs and a remote phosphor film layer. The mixing chamber ensures perfectly mixed light, resulting in uniform colors and good color consistency. The square heat spreader facilitates optimal heat transfer in three directions and helps luminaire manufactures to design their own heat sink system. The heat spreader is equipped with screw holes for fixing the heat sink. Besides facilitating high efficiencies, the remote phosphor technology makes it relatively easy to develop virtually any fluorescent color. The first version will have a light color of 4000 K. Now we add a 3000K and a Food (specific wavelength to enhance various food) version to the Fortimo portfolio. The function of the diffuser is to shape the light distribution, resulting in a Lambertian beam. The luminaire manufacturer has the freedom to design its own secondary optics. The LED module integrates easy mounting options for secondary optics. The overall dimensions of the LED module, i.e. the combination of heat spreader and mixing chamber, are optimized for lumen packages varying from 1000 lumen to 2000 lumen.

Mechanical fixationThe Fortimo LED DLM has screw holes (M4 threaded) at the bottom and sides of the heat spreader for fixing the heat sink. As an alternative to screws the Fortimo LED DLM also has grooves at the side of the module so that a heat sink can be clicked in. 2D or 3D CAD drawings are available upon request.

About the Fortimo LED driverThe highly efficient Fortimo LED driver is specially designed to operate the Fortimo LED DLM module. It is designed to operate high-power LEDs. There are specific versions for Europe (220-240 V) and the US (120-277 V)* because of different housing requirements. There are meanwhile various Fortimo LED drivers:• Fixed output; build-in for Europe (220-240 V) and the US (120-277 V)*• Independent for Europe (220-240 V)• Dimmable for Europe (220-240 V• Specific LED driver for FOOD modules (120-277 V)Special features for the fixed output version are:• maximum current settings of 700 mA • max. 80 V enables operation of many LEDs in series• high efficiency: 92% at full load (220-240 V)• specific housings available for European and US markets• Tcase = 65 ºC• Safety Class 1 system (protective ground, no SELV system)* For the US market a separate technical application guide is available.

1.2..4.

Fortimo LED DLM module

Fortimo LED DLM module, fixing holes and grooves

Fortimo LED driver

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Design-in guide Philips Fortimo LED downlight module system14

Fortimo LED DLM cable

1 -2 Black Current Yellow Power ground4 Red NTC (thermal control)5 Blue LED module setting6 -7 Green Signal ground

About the Fortimo LED DLM cablesA standard 250 mm cable with a wire diameter of AWG24 can be ordered separately from the Fortimo LED DLM system (LED module and LED driver).

For the Fortimo LED DLM “I” we have developed a specific version of a longer length (600 mm) and includes an earth cable to facilitate easier wiring for the OEMs.

For the Fortimo Food a specific cable of 60 mm can be ordered separated from the Fortimo Food LED DLM and Fortimo Food driver.

Fortimo LED DLM cable 1100-200/l

Fortimo LED DLM cable Food

1 White VDC2 Black Not used Yellow PGND4 Red VC C5 Blue TBUS A RS-485 A6 Orange TBUS B RS-485 B7 Green SGND

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Design-in guide Philips Fortimo LED downlight module system 15

4. Lighting performance characteristicsSpecification of the system after 100 hours

Philips Fortimo LED

DLM system

Light

output

lm

Color

temperature

K

Color

rendering

index

Ra

Color

consistency

initial and at

10K hrs

SDCM

Fortimo LED DLM1100

19W/830 220-240

1,100 ,000 80 5 / 6

Fortimo LED DLM1100

19W/830/I 220-240

1,100 ,000 80 5 / 6

Fortimo LED DLM1100

19W/830/TD 220-240

1,100 ,000 80 5 / 6

Fortimo LED DLM1100

18W/840 220-240

1,100 4,000 80 5 / 6

Fortimo LED DLM1100

18W/840/I 220-240

1,100 4,000 80 5 / 6

Fortimo LED DLM1100

18W/840/TD 220-240

1,100 4,000 80 5 / 6

Fortimo LED DLM2000

36W/830 220-240

2,000 ,000 80 5 / 6

Fortimo LED DLM2000

36W/830/I 220-240

2,000 ,000 80 5 / 6

Fortimo LED DLM2000

36W/830/TD 220-240

2,000 ,000 80 5 / 6

Fortimo LED DLM2000

32W/840 220-240

2,000 4,000 80 5 / 6

Fortimo LED DLM2000

32W/840 220-240

2,000 4,000 80 5 / 6

Fortimo LED DLM2000

32W/840 220-240

2,000 4,000 80 5 / 6

Fortimo LED DLM2000

50W/Food 30

1,800 ,000 70 5 / 6

Fortimo LED DLM2000

50W/Food 40

2,000 4,000 70 5 / 6

UV and other hazardsPET value >100 hrs./Klux (zero UV)Damage factor 0.08 @ 4100 KIR (infrared) radiation As well as being free of UV radiation,

the LED modules are also free of infrared radiation in the beam.

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Design-in guide Philips Fortimo LED downlight module system16

Photobiological safety aspectsAs of March 2007, LEDs and LED-based products for general lighting are no longer included in the scope of the Eye Safety standard for lasers, IEC 60825-1 ‘Safety of laser products’. The new lamp standard, IEC 62471 ‘Photobiological safety of lamps and lamp systems’, covering incoherent light sources, is now applicable. This international standard gives guidance for evaluating the photobiological safety of lamps and lamp systems including luminaires. Specifically it specifies the exposure limits, reference measurement technique and classification scheme for the evaluation and control of photobiological hazards from all electrically powered incoherent broadband sources of optical radiation, including LEDs but excluding lasers, in the wavelength range from 200 nm through 000 nm.

In the photobiological safety standard, hazard categories are defined as follows:

Radiance-based• Blue Light LB 300 – 700 nm• Retinal Thermal LR 80 – 1400 nm• Retinal Thermal Weak Stimulus LIR 780 – 1400 nm

Irradiance-based• Actinic UV Skin & Eye ES 200 – 400 nm• Eye UVA EUVA 315 – 400 nm• Blue Light Small Sources EB 300 – 700 nm• Eye IR EIR 780 – 000 nm

Measurements on the Fortimo LED DLM gave the following results:The following should be taken into account:• The effective radiance measurement for Blue Light (LB) modules is ‘Low’, meaning

that the LED modules are categorized in Risk Group 1. For the 2000 lumen version, the permitted exposure time for Blue Light radiance (relevant when looking into the source) is limited to 1.5 hours, while for the 1100 lumen version it is 3 hours. Because of the Law of Conservation of Radiance, integrating the LED module into a luminaire results in either the same radiance or a reduced radiance. Final assessment of the luminaire is recommended.

• The measured irradiance-based values (E) for the categorized hazards are all within the exempt group (both 1100 and 2000 lumen versions).

• In general the permitted exposure time for irradiance is limited when in the ‘low’, ‘moderate’ or ‘high’ risk group. Limiting the exposure time and/or the distance to the source can reduce the hazard level. However, for the measured LED modules there are no special precautions necessary since they are ranked in the exempt group. Final assessment of the luminaire (including e.g. secondary optics) is recommended.

!Photobiological safety is not assured if the Fortimo LED module is lit up without the cover. Direct exposure to the blue LED light is dangerous for the eyes.

Hazard Category Emission Limit

LB Low (Risk Group 1)

LR Exempt*

LIR Exempt

ES Exempt

EUVA Exempt

EB Exempt

EIR Exempt

Emission limit * Exempt means ‘no risk’.

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Design-in guide Philips Fortimo LED downlight module system 17

Dimming characteristicsFortimo LED DLM “TD” makes use of a so-called amplitude (AM) dimming protocol. Where most LED systems work with PWM (pulse width modulation) where the current is cut in parts and where basically dimming levels are achieved by combining, on high frequency, on/off settings (pulses). AM dimming reduces the current through the LEDs to achieve lower light levels. And here is the big advantage: at lower currents LEDs operate more efficient (graphs on the left). Next to this, other advantages of AM dimming are:• No audible noise during dimming.• No visual interference with other lighting or video sources.

20.000 100 200 300 400

I_LED[mA]

Eff

ic. [L

m/W

]

500 600 700 800

Fortimo AM Dimmingwith heatsink

At low dimming levels the driver lossesbecome relatively dominant, but the efficiencybenefit is still very large

Fortimo PWM Dimmingwith heatsink

25.00

30.00

35.00

40.00

45.00

50.00

55.00

60.00

700 mA

100% lightlevel

LED

Cur

rent

700 mA

50% lightlevel

AM Dimming

LED

Cur

rent

700 mA

50% lightlevel

PWM Dimming

LED

Cur

rent

More then 30% efficiencyincrease during dimming

Measured with passive cooling, 2000Lm, 4000KSystem efficiency(module+driver)

20.000 100 200 300 400

I_LED[mA]

Eff

ic. [L

m/W

]

500 600 700 800

Fortimo AM Dimmingwith heatsink

At low dimming levels the driver lossesbecome relatively dominant, but the efficiencybenefit is still very large

Fortimo PWM Dimmingwith heatsink

25.00

30.00

35.00

40.00

45.00

50.00

55.00

60.00

700 mA

100% lightlevel

LED

Cur

rent

700 mA

50% lightlevel

AM Dimming

LED

Cur

rent

700 mA

50% lightlevel

PWM Dimming

LED

Cur

rent

More then 30% efficiencyincrease during dimming

Measured with passive cooling, 2000Lm, 4000KSystem efficiency(module+driver)

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Design-in guide Philips Fortimo LED downlight module system18

8...9 mm

0.5...1.0

1

2

3

4DLM

FORTIMO DLM POWER SUPPLY

Engineeringsample

Schematic wiring diagram

5. Designing a luminaireIn this chapter recommendations and values are given to enable optimal luminaire design.

IEC recommendationsThe general recommendations for luminaire design given by the IEC (IEC 60598) and the national safety regulations are also applicable to LED-based luminaires.

Electrostatic device (ESD) measuresThe Fortimo LED DLM systems do not require special ESD measures in a production environment.

Installation instructionsThe Fortimo LED DLM systems are build-in systems for integration into luminaries, except for the Fortimo LED DLM “I” version that can be used remote (stand alone / independent) from the LED luminaire).There are interfaces for:• cabling between LED module, LED driver and luminaire• secondary optics via mounting options in the LED module housing

and reflector rim• heat sink design via heat spreader

WiringConnecting to the mains supplyThe mains supply has to be connected to the power supply (L & N can be switched). Because the Fortimo LED driver is class 1, protective ground also needs to be connected.The minimum diameter for the ground cable is 1.5 mm².

Connecting to protective groundLike the Fortimo LED driver, the LED module also needs to be connected to protective ground for reasons of compliance with safety regulations and EMI. The PE symbol is shown on the product label (see below) to ensure that OEMs take proper measures in their luminaire design. The arrow points to the metal heat spreader where cabling needs to be provided.

See also the visuals in the appendix for more detailed explanation.

Label Fortimo LED DLM module

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Design-in guide Philips Fortimo LED downlight module system 19

Connecting to DALIThe Fortimo LED DLM “TD” includes connectors for DALI compatible user interfaces (controls).

Connecting to 12 VThe Fortimo LED DLM “TD” and FOOD version includes also a 12 V output that can be used for various options, like:• Active cooling of Nuventix SynJet (Universal) DLM Coolers or other

12 V operating fans.• Connection to other HP/LP LEDs to add decorative lighting effects to you

luminaire.

Connecting a Fortimo LED driver to a Fortimo LED moduleA specific cable has been developed to connect the Fortimo LED module and the LED driver; the Fortimo LED DLM cable. This 250 mm cable with a wire diameter of AWG24 can be ordered separately to the Fortimo LED DLM systems.

For the Fortimo LED DLM “I” we have developed a specific version of a longer length (600 mm) and includes an earth cable to facilitate easier wiring for the OEMs. This cable can also be ordered separately.

CableWe advise using the Fortimo LED DLM cable. However if an OEM prefers to have a cable with a different length it has to organize this itself. The cable specification should meet UL & IEC/EN requirements. However, approval of the Fortimo LED DLM module and LED driver is based on a reference luminaire with the standard cable length of 600 mm. In any case, any luminaire design needs its own approval, organized by the responsible OEM, irrespective of the length of cable used.

If an OEM prefers to have a cable with a different length it can use the following cable/connector specifications:

JST connector at cable to LED driver- housing JST PAP-07V-S- contact JST SPHD-001T-P0.5JST connector at cable to LED module: - housing JST-PHR-7- contact JST SPH-002T-P0.5S

8...9 mm

0.5...1.0

1

2

3

4DLM

DALI

FORTIMO DLM POWER SUPPLY

Engineeringsample

Fan (12V)

DALI(TD)+-

Schematic wiring diagram

Fortimo LED DLM cable

Fortimo LED DLM cable 1100-2000/l

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Design-in guide Philips Fortimo LED downlight module system20

Independent operationThe specific Fortimo LED DLM “I” versions have been developed for independent operation. The related Fortimo LED cable DLM1100-2000/I has a length of 600 mm to facilitate easier installation. Also an earth wire is added to the cable to facilitate easier wiring and assembly by the OEM.

Note: Fortimo LED DLM independent cableSpecial attention is required for the Fortimo cable for independent (stand alone) operation. Specific requirements are defined by approbation offices since it is now possible to use the electronic LED driver outside the luminaire, The Fortimo independent cable is a combination of the Fortimo LED cable 1100-2000 with specific wires and connectors combined with a wire for protective earth. For such an “exterior cable” it is prescribed that the diameter of the whole cable should be 2.25 mm². (Normally it’s a 3 wire cable (L, N, PE) each with a diameter of 0.75 mm²).

Outdoor luminairesNeither the Fortimo LED DLM module nor the LED driver has an IP classification. If an OEM decides to use the Fortimo system in a luminaire for outdoor application, it is responsible for proper IP protection and approval of the luminaire.

Fortimo DLM module “Independent”

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Design-in guide Philips Fortimo LED downlight module system 21

Polar intensity diagram

Secondary opticsThe Fortimo LED DLM module generates a Lambertian beam shape (see polar intensity diagram) which is a pragmatic starting point for secondary optic design by OEMs. Ray-set files are available upon request. The secondary optic design should not cover the exit aperture.

“It is not recommended to put a secondary optics within 70 mm of the Fortimo light exit window. When the product is installed according to the guidelines, temperature of the light exit window will be below 105 °C. When the customer decides to place a secondary optics within 70 mm of the light exit window, the customer should take care that the temperature of the material will not exceed 105 °C for performance and 115 °C for safety. The temperature of the light exit window can be measured with Infrared temperature sensing technique.”

On top of the Fortimo LED DLM there are mounting options (rim of diffuser and three mounting holes) for positioning secondary optics.

Position of secundary optics

Secondary optics are not part of the Fortimo LED DLM system offering. This is an added value area for OEMs. Meanwhile a complementary reflector business around the Fortimo LED DLM is developing. Companies like Alux Luxar, Jordan and ACL have reflector designs ready for the Fortimo systems.

The reflector portfolio for Fortimo of Alux Luxar consists out of six different designs. Three square and three round ones each with it’s own beamcharacteristics.

Alux Luxar contact detailsFor a full specification and application assistance please contact Alux Luxar directly:Alux Luxar GmbH & Co. KGSchneiderstrasse 76D-40764 LangenfeldGermany

Sales: Rene Kaiser, tel. +49 2173 279 - 224www.alux-luxar.de

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Design-in guide Philips Fortimo LED downlight module system22

GeneralFor optimum performance the Fortimo LED DLM system must operate within specified temperature limits.

Test requirementsThe Fortimo LED DLM systems have no specific measurement for minimum ambient temperature, which may be as low as -20 ºC. This minimum limit is determined by the Fortimo LED driver. Temperature measurements should only be performed when the luminaire is thermally stable, which may take 0.5 to 2 hours depending on the thermal capacity of the luminaire (see also the relevant clauses in IEC 60598). For all measurements such as temperature, luminous flux and power, a stabilization period of at least half an hour must be allowed before any reliable data can be obtained. Measurements must be performed by means of thermocouples that are firmly glued to the surface (and not, for example, secured with adhesive tape).

Maximum temperatureBecause LEDs are temperature-sensitive, LED modules require a different approach with respect to the maximum permissible component temperature. This is different to most other types of light source.

Critical measurement pointsFor LEDs the junction temperature is the critical factor for operation. Since there is a direct relation between the case temperature and the LED junction temperature it is sufficient to measure the aluminum casing of the LED module at its critical point. The critical point is on the back surface of the LED module. If the case temperature (Tc) at the critical measurement point is too high (exceeding the recommended maximum temperature), the performance of the LEDs will be adversely affected, for example in terms of light output, lifetime or lumen maintenance.

Operation under built-in conditionsThe heat produced by the LED driver and LED module in the luminaire (or similar housing) must be dissipated to the surroundings. If a luminaire is physically insulated by a ceiling, wall or insulation blanket, the heat produced cannot easily be dissipated. This will result in heating of the LED driver and the LED module in the luminaire, which in turn can have an adverse effect on system performance and lifetime. For optimum performance and lifetime it is important that:

air can flow freely around the luminaire; andairflow through the luminaire, around the modules, has a positive effect on temperature control and hence on performance and lifetime.

••

6. Heat sink design and temperature measurements

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Design-in guide Philips Fortimo LED downlight module system 2

60% 20 25 30 35 40 45 50 55 60

Tcase (ºC)

Rel

ativ

e flu

x (%

)

70%

80%

90%

100%

110%

65 70

60% 20 25 30 35 40 45 50 55 60

Tcase (ºC)

Rel

ativ

e flu

x (%

)

70%

80%

90%

100%

110%

65 70

Temperatures Fortimo LED DLM1100

Temperatures Fortimo LED DLM2000

Case temperature and thermal circuitTo ensure the performance of the Fortimo LED DLM system we have defined a Tc at the back surface of the LED module of 65 ºC. At that case temperature the junction temperature of the LEDs is assured and the indicated performances (lifetime, light output, lumen maintenance) can be guaranteed. Above a Tc of 65 ºC, a thermal circuit will be engaged. This circuit will dim the LED module until the Tc of 65 ºC is reached again. The graphs below display the typical case temperature and relative flux as a function of ambient temperature, for a calculated heat sink performance of 1 K/W. The Fortimo LED driver also has a Tc of 65 ºC.

The above-mentioned engagement of the thermal circuit at Tc = 65 ºC is applicable to both the 1100 and the 2000 lumen versions. The performances of light output, light maintenance and lifetime are related to different Tc values like• Tc = 45 ºC for Fortimo LED DLM1100• Tc = 65 ºC for Fortimo LED DLM2000• Tc = 65 ºC for Fortimo Food DLMThis is based on the assumption that the same heat sink design is used for both Fortimo versions, where obviously the 2000 lumen version is the most critical one. However, it is possible to create a smaller specific heat sink design around 1100 lumens. The heat sink design in this case can be reduced as long as the Tc remains under 65 ºC.

Case temperature and LED module performanceThe Fortimo LED module comes in two versions, which are nominally designed for a case temperature of 45 °C/113 °F (DLM1000) and 65 °C/149 °F (DLM2000) respectively. The flux is then 100%. The graphs below show the relative light output (flux) as a % of the nominal case temperature. As you can see, if the operating condition of the Fortimo LED module is lower than the Tc point, performance will increase.

Operation in free airThe Fortimo LED DLM is not designed for operation in free air. Instead Fortimo LED DLM is a build-in concept for integration into luminaires.

Temperature test point TC

20 25 30 35 40 45 50 55 60

Ambient temperature (ºC)

Tca

se (

ºC)

65 7030

35

40

45

50

55

60

65

70

Ambient temperature (ºC)

7060%

20 25 30 35 40 45 50 55 60

Rel

ativ

e flu

x (%

)

70%

80%

90%

100%

110%

65

30 20 25 30 35 40 45 50 55 60

Ambient temperature (ºC)

Tca

se (

ºC)

65 70

35

40

45

50

55

60

65

70

Ambient temperature (ºC)

60% 20 25 30 35 40 45 50 55 60

Rel

ativ

e flu

x (%

)

70%

80%

90%

100%

110%

65 70

Tc Ø1cm

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Design-in guide Philips Fortimo LED downlight module system24

Heat sink designTo ensure that housing temperatures do not exceed the specified maximum values, a luminaire can act as an additional heat sink. The applicable heat transport mechanisms are conduction via the heat sink and convection and thermal radiation to the surroundings. The objective of this chapter is not to indicate exactly how to calculate a heat sink, but to give some guidelines on how to improve its performance. Although a heat sink can have many (complex) shapes, the following discussion is based on a disk type of heat sink. The results for square plates, etc., are more or less the same provided the surface areas are equal. The type of material used has a relatively large influence on the final result. For example, a comparison of the thermal conductivity (k) of copper with that of corrosion-resistant steel (see table left) shows that a substantially smaller heat sink can be made with copper. In practice the best material for heat sinks is (soft) aluminum.

The thickness (d) of the heat sink disk is also of major importance. Assuming the use of different heat sinks of the same diameter but made from different materials, the same effect in terms of temperature difference will be achieved if the product of thermal conductivity (k) and disk thickness (d) is constant. This means more or less the same result is obtained with a disk of 1 mm copper, 2 mm aluminum, 4 mm brass, 8 mm steel or 26 mm corrosion-resistant steel. Increasing the diameter, and thereby also the surface area, of the heat sink disk also leads to an improvement, but the effect is smaller for larger diameters and depends on the thermal conductivity (k) of the material and the thickness (d).

Thermal radiation can also form a substantial part of the total heat transfer, and is of the same order as for convection. This depends strongly on the emission coefficient (see table) of the surface, which lies between 0 and 1. For example, a polished aluminum surface has a very low emission coefficient, while that of a painted surface is very high.

Material W/mK

Copper 400

Aluminum 200

Brass 100

Steel 50

Corrosion-resistant steel 15

Thermal conductivity

Material W/mK Emission coefficient

Aluminium new/polished 0.04 - 0.06

oxidized 0.2 - 0.

anodized 0.8

Steel painted 0.8 - 0.95

new/polished 0.0 - 0.07

heavily oxidized 0.7 - 0.8

Emission coefficients

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Design-in guide Philips Fortimo LED downlight module system 25

Size of heat sinkThe first generation Fortimo LED DLM products consume 18 or 45 W and contain a built-in heat spreader. Deducting the driver efficiency and the energy that is effectively giving light leaves a heat of 15 resp. 38 W that needs to be taken away from the module. The spreader at the sides and back of the module is the contact area for the external heat sink. The heat sink transports the heat away from the module and is connected to the heat spreader, with either the use of the pre-made screw holes or the side grooves and a click design.

The performance (life time and amount of light) of the module depends heavily on the thermal management. Therefore the temperature of the test point (Tc) is important. During the thermal design process, the aim is to keep the Tc temperature below the stated maximum (65 °C). Although the Fortimo LED module will not fail due to a higher temperature, the effect of insufficient cooling will mean that the light output of the LEDs is automatically dimmed see also page 21.So the better the thermal management (low Tc of the LED module) the better the performance of the luminaire (life time and light output). Here is a differentiation opportunity for luminaire manufacturers.

The size of the heat sink needed depends on the power rating of the module. The first generation Fortimo LED DLM need 18 respectively 45 W to produce 1100 respectively 2000 lumens. The surface area of a heat sink, when passively cooled, for a 1100 lm system is ~ 0,08 m2, whilst the 2000 lm module requires a heat sink with a surface area of ~ 0,15 m2. With the introduction of improved LEDs (August 2009) the efficiency of especially the 2000 lm version is improved. This results in a power draw drop from 2 W and 36 W for resp. 4000 K and 3000 K. The related heat sink surface area reduces with 20% to ~ 0.12 m2. See drawings below.

If miniaturization is required then active cooling systems can be used, which will substantially reduce the volume of the heat sink.

Tc Ø1cm

Temperature test point Tc

Passive solution

Fortimo LED DLM1100

Passive solution

Fortimo LED DLM2000

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Design-in guide Philips Fortimo LED downlight module system26

Active and passive coolingIn principle there are two thermal solution directions.

Passive cooling systems are made such that due to the fact that hot air moves upwards, an airflow is created along the surfaces. This is called natural convection.

Active cooling. Here the airflow is forced with a fan or SynJet, which enhances the thermal capacity of the heat sink. As a result a smaller heat sink can be used and orientation of the heat sink is no issue anymore. Negative aspects of the use of a fan are that it will probably produce noise, consumes extra energy and you should ensure that its lifetime should match with the application.

There are many standard heat sinks available which are relatively cost effective. When comparing with active cooling the form factor of the total system is approximately two times larger.

Passive cooling In principle there are two passive thermal solution directions.

Left is the solution with heat sinks connected to the sides with as advantage, lower height but larger diameter. As disadvantage an extra thermal resistance from test point Tc (in the middle of the back surface) to the sides where the heat sink is connected.

Right solution is the heat sink directly connected to the backside of the LED DLM. This means that there is no extra thermal resistance, but to achieve the same thermal resistance extra height is needed.

For Fortimo LED DLM1100, the size of the required heat sink is smaller. This all depends on the application, but in general the Fortimo LED DLM1100 needs a smaller heat sink.

Air flowBefore starting with any calculation, an important point to consider is the airflow.

In general hot air is moving upwards with relatively low speed. The form and position of the heat sink is influencing the airlow. On the left picture the fins are perpendicular to the airflow which reduces the efficiency of the heat sink. This situation should be avoided.

A better way to position the fins is indicated in the middle and right picture, where the fins are parallel to the airflow direction. Closing the top of the profile will reduce the effectively of the heat sink as well, and should be avoided during design and installation.

Passive solution directions Fortimo LED DLM1100

Passive solution directions Fortimo LED DLM2000

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Design-in guide Philips Fortimo LED downlight module system 27

Thermal path basic solutions

Electrical and thermal analogy

Thermal resistance of LED DLM

Thermal designPrincipally two thermal paths are important (warming-up and dynamic behavior are not discussed here, as a static situation is normally found in lighting applications)

From the temperature test point Tc (point 1) to the side surfaces (point 2) • This is already measured by Philips and is 0.2 K/W.

From the heat sink to ambient (point 3)The thermal resistance of a heat sink is normally given in a datasheet, but it is based on a few assumptions:• a certain thermal power has to be applied, as the efficiency of the heat sink is

lower at low energy levels.• the temperature of the back side of the heat sink is homogeneous.• an air flow can freely flow over the surfaces.

Thermal modelStandard STATIC thermal situations can be modeled with so-called thermal resistances. These resistances behave like electrical resistors. Below the analogy between electrical and thermal resistors is explained. Where on the left the electrical units are mentioned, on the right the thermal equivalent is set.

With a known voltage difference at a certain current it is possible to calculate an electrical resistor with Ohm’s law. The same is possible with a thermal resistor. If the temperature difference is known and the thermal power, the thermal resistance can be calculated with thermal Ohm’s law.

In the left figures you see the two most important thermal resistances.

• From test point Tc to side surface of the LED DLM, where the heat sinks are connected.

• From side surface of Fortimo LED DLM to ambient. As we have connected two heat sinks, both will have a similar thermal resistance in parallel.

• In the specification the maximum Tc is given, in case of a Fortimo LED DLM2000 system this is 65 °C.

1

2

3 3

2

Temperatures:1= test point Tc2= heat sink @ LED DLM side= ambient

Resistances:R1 = LED DLM path 1-2R2 = heat sink path -4

Analogy between electrical and thermal

Electrical:U = voltage difference [V]I = current [A]R = resistance [Ω]Ohm’s law:U= I * R

Thermal:ΔT = temperature

difference [ºC]Pth = thermal power [W]R = thermal resistance [K/W]

or [ºC/W]

Thermal Ohm’s law:ΔT= Pth * Rth

U1

U2 T2

I

T1

Pth

1

3

3

3

21

1

2

2

Side view

Top view

Tc

Ths

Tamb

0.2 K/W

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Design-in guide Philips Fortimo LED downlight module system28

Calculating your heat sinkWe start with 3 thermal calculation formulas:• Formula 1 (f1) the relation between temperature difference, thermal power

and thermal resistance. With this formula the needed thermal resistance can be calculated when the thermal power and temperature difference are known.

• Formula 2 (f2) shows how to calculate the replacement of two parallel resistors, with one equivalent.

• Formula 3 (f3) shows the replacement equivalent of 2 resistors in series, simple add the values.

Next we gather all available information, as can be found in the datasheet, application details and design choices.

From the datasheet:Maximum test point temperature : Tc-max = 65 °CThermal power Fortimo LED DLM2000 : Pth = 0 WThermal resistance from Tc to side surface : Rth-Tc-to-side-surface = 0.2 K/WMaximum temperature in application. In this case we install the product below ceiling, which is the ambient temperature of the product. : Tambient-max = 35 °C chosen in

this case.

The maximum temperature differs per application and can be lower or higher, than the now chosen 35°C.

Below we calculate the needed thermal resistance of the heat sink, such that in worst case situations, the maximum temperature of the test point Tc, is below its maximum.

For Fortimo Food:Maximum test point temperature : Tcmax= 65 °CThermal power Fortimo Food LED DLM : Pth: 42 WThermal resistance from Tc to side surface : Rth-Tc-to-side-surface = 0.2 K/WTambient-max : 5 °C

Now the calculation takes place in three steps:• Calculation of the total thermal resistance : Rth-from-Tc-to-ambient with

formula f1. This results in 1 K/W• Calculation of the thermal resistance of both heat sinks with formula f3. This

results in subtracting 0.2 from the total value of 1 K/W, which is 0.8 K/W• Thermal resistance of a single heat sink with formula f2. We assume that both

heat sinks are identical, and results in the equation R1=R2. Using this together with formula f2 the end result shows that the thermal resistance of a single heat sink is two time the total thermal resistance of both heat sinks. This results in 1.6 K/W

Thermal resistance of heat sink 1/3

1

3

2

Thermal resistance of heat sink 1/3

1

3

2

Formulas:Thermal: ΔT = Rth x Pth f1

Parallel: Rth - R1+ R2 f2

Series: Rtot = R1+ R2 f3

Available information:Tc-max = 65˚CPth-Fortimo 2000 = 30 WRth-Tc-to-hs = 0.2 K/WTambient-max = 35ºC

To be calculated:Rth both heat sinks

11 1R1 R1

+

Tamb

Ths

Tc

0.2 K/W

1 Calculation of total maximum thermal resistance: (f1)ΔT ambient - Tc = 65-35=30ºCRth Tc - ambient = (Ttambient - Tc)/ Pth = 30 = 1 K/W

2 Calculation of thermal resistance two heat sinks: (f3)Rth hs - ambient = Rth Tc-hs + Rth hs - ambientRth hs - ambient = 1 - 0.2 = 0.8 K/W

3 Calculation of thermal resistance per identical heat sinks: (f2)R1 = R2 and Rtot-hs-amb = 1/(1/R1 + 1/R2)Rtot = 1/(2/R1) = R2/2 <> R1 = 2RtotR1 = Rth single heat sink = 2 * 0.8 = 1.6 K/W

Tambient

Ths

Tc

0.2 K/W

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Design-in guide Philips Fortimo LED downlight module system 29

4.84 in123 mm

1.57

in

6mm

0.23

in

40 m

m

0.675 100 125 150 175 200 225 250

Lenght (mm)

0.8

1.0

1.2

1.4

1.6

2.0

1.8

1.7

1.9

Thermal resistance of heat sink 3/3

Measurements

Now we know the thermal resistance of the needed heat sink. This heat sink dimension is such that at maximum power and maximum ambient temperature, the temperature of the test point Tc is at or below its maximum of 65 °C. This is the worst case situation, which means that normally the test point temperature Tc is lower. This assures lifetime and light output will be according to specifications.

Shape of heat sinkWhen looking into catalogs of heat sink suppliers, the shape is determining the thermal resistance of the heat sink. In this case the length is a design parameter.

The graph shows the thermal resistance of the heat sink, with increasing length. We need a 1.6 K/W heat sink and the red line indicates that this profile has such a value with a length of approx. 115 mm.

There are many variations in fin number, length of fins, length of heat sink and so on. With special thermal design software, a tailor made solution can be found as well.

With the use of a standard thermo couple all important temperatures can be measured and compared to theoretical values.On the left you see the standard set-up for thermal testing.

The Fortimo LED DLM with the two connected heat sinks and three thermo couples installed:• at test point Tc• at heat sink near LED DLM• ambient temperature

With this simple set-up all important values can be measured and compared to the theoretical values. It’s important to assure good thermal contact between Fortimo LED DLM and the heat sinks. We recommend to use thermal pads or thermal paste. Furthermore it’s very important that there is no moving air in the room. This will influence the measurement heavily.

How to measure TcIn case you have no direct or easy access to connect a thermo couple to the defined Tc point we recommend to connect the thermo couple to one of the sides of the Fortimo.The heat spreader that is integrated in the Fortimo LED module ensures that temperature difference for Tc point to both sides is minimal. In the visual on the left you see this difference is approx. 8 degrees with a Fortimo LED module of 2000 lumens.

Example of standard heat sink:• Needed 1.6 K/W• Heat sink: Marston 94 DN• Length @ 1.1 K/W = 115 mm (red line)• Width = 123 mm, height = 40 mm,

#fins = 13 Rth = 1.1 K/W per heat sink (data sheet)

Heat flow = 38.25 WConductivity Aluminium = 180 W/mKHeat transfer via both side walls

Temperature ºCMax: 6..538e+001Min: 5.726e+0012008/8/28 17:31

65.382

64.479

63.576

62.673

61.770

60.868

59.965

59.062

58.159

57.256

57.344

58.1

59.5265.02

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Design-in guide Philips Fortimo LED downlight module system0

SynJet cooling from NuventixNuventix has developed a cooling solution utilizing SynJet technology that offers silent operation, long life and robust cooling for Fortimo LED DLM systems. Its small size allows it to be used in tight spaces. SynJet cooling allows for universal mounting, permitting great flexibility in installation. The unit is designed for usewith 1100 and 2000 lumen Fortimo LED DLMs, providing long-term thermal solutions for LED lighting.

From March 2009 onwards Nuventix will introduce 2 standard version: • SynJet DLM Cooler with heat sink (round)• SynJet Universal DLM Cooler with heat sink (square)

For both products design guides and assembly guides are available upon request.

Nuventix contact informationA specific Synjet cooling version is being introduced for Fortimo Food DLM.For a full specification and application assistance please contact Nuventix directly:Francois Jaegle, EMEA sales managerE-mail: [email protected], direct number: +33 6 24 73 4646 orAboude Haddad , Thermal Application Engineer, tel.: +49 89 289 71587, mobile: +49 171 688 8458.www.nuventix.com

Next to Nuventix there are other active cooling suppliers. Below some references for other fan suppliers: Emb Papst, website: http://www.ebmpapst.com/de/ Emb Papst is a high-end, German based fan supplier. They cover a broad application range (including e.g. Automotive applications) and have a lot of experience in fan applications in harsh environments.Sunon, website: http://www.sunon.com/index.htm Sunon is a large Taiwan based fan supplier, mainly active in electronics cooling. They have a very interesting technology: Maglev. They use a magnetic field to stabelize the fan. This results in long lifetime and low noise. Further we would like to mention 2 Taiwanese suppliers of cooling assemblies (combinations of fan + heat sink)AVC: website http://www.avc.com.tw/CoolerMaster: website http://www.coolermaster.com/ Both suppliers are active in PC cooling solutions but are starting a business for LED solutions as well.

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Design-in guide Philips Fortimo LED downlight module system 1

Electromagnetic compatibilityElectromagnetic compatibility, EMC, is the ability of a device or system to operate satisfactorily in its electromagnetic environment without causing unacceptable interference in practical situations. Philips Fortimo LED DLM systems fulfill the requirements with regard to electromagnetic compatibility as laid down in European Norms EN 55015 and EN 55022, EN 61000--2 and EN 61547.

HumidityFortimo LED DLM modules and LED drivers have no IP classification. The OEM is responsible for proper IP classification and approbation of the luminaire.

Exposure to direct sunlightExposure to direct sunlight during operation may have severe temperature or UV effects. Where this situation is likely, extensive temperature testing is recommended. The Fortimo LED DLM systems are a build-in system (except independent versions), so this is expected to be negligible.

Vibration and shocksShock resistance: 50 g @ 6 ms semi-sinusoidal. Vibration resistance: sweep 50-150 Hz, one hour at resonance frequency (all axes) without failure.

Standards and approvalsPhilips Fortimo LED DLM systems comply with the following international rules and regulations, including:Safety EN/IEC 60598-1 & 2-2, EN 61347-1, 2-13 Approvals ENEC 05, CE

Philips Fortimo LED DLM systems carry the CE marking. CE is the abbreviation of Conformité Européenne. It expresses conformity of products to mandatory requirements of the European Community Directives. The CE mark acts as a ‘passport’ that allows goods to circulate freely throughout the European Union. Furthermore, it simplifies inspection by Market Controlling Bodies. Two European directives cover lighting products: the Electromagnetic Compatibility (EMC) Directive and the Low Voltage Directive (LVD). The Philips Fortimo LED DLM system carries the CE marking on the basis of compliance with the following standards: EN 61547, EN 61000--2, EN 55015 and EN 55022

IP codes, dust and moisture protectionPhilips Fortimo LED DLM systems are build-in systems (except independent versions) and have therefore no IP rating.

7. Lighting installations and the environment

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Design-in guide Philips Fortimo LED downlight module system2

Glow-wire testPhilips Fortimo LED DLM systems conform to the 960 degree glow-wire test. Reference test: according to additional national deviations for clause 13.3 (Annex 2c of EN 60598-1). An exception is made for France, where local regulations are more strict.End-of-life behaviorUnlike typical conventional light sources, LEDs are not subject to sudden failure or burnout. There is no time at which the light source will cease to function. Instead, the performance of LEDs shows gradual degradation over time. When used according to specification, Fortimo LED DLM modules are predicted to deliver an average of 70% of their initial intensity after 35,000 hours’ operation. The life of the system is therefore more dependent on the other electronic system components and soldering methods.

The LEDs in the Fortimo LED DLM module are connected in series. If one LED fails, this may be due to an internal short-circuit (character of blue LEDs). In this case it will still conduct current, so that the other LEDs will still operate.

Fortimo LED DLM system disposalAt the end of their (economic) lifetime, appropriate disposal of the Fortimo LED DLM or its components is recommended. The modules are basically normal pieces of electronic equipment containing components that at present are not considered to be harmful to the environment, or which can be disposed of with normal care. It is therefore recommended to dispose of these parts as normal electronic waste, according to local regulations.

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Design-in guide Philips Fortimo LED downlight module system

8...9 mm

0.5...1.0

12

3

4

DLM

FORTIMO DLM POWER SUPPLY

Engineering

sample

8. Appendix Schematic luminaire with the Fortimo DLM system

First Fortimo LED DLM systems have been designed to build the driver inside the luminaire. Added value opportunities for OEM are optic-, heat sink- and luminaire design (dotted lines)

The Fortimo LED independent driver enables stand alone operation of the Fortimo LED module. This to facilitate easier luminaire design and installation.

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Design-in guide Philips Fortimo LED downlight module system4

L N PE Terminal contacts of luminair

Screw contactIEC 60598-1,§4.12.1, §7.2

Metal head spreader screwed to heat sink(accessible)

LED Driver(class I) LED Module(class I)

Metal encasing of driver(accessible)

Seperate metal mounting babes allowed

1

2

3

8...9 mm

0.5...1.0

123

4DLM

DALI

FORTIMO DLM POWER SUPPLY

Engineeringsample

Fan (12V)DALI(TD)+-

Fortimo LED DLM systems are class 1 systems requiring proper protective earth wiring. It’s important that both the driver as well as the LED module are connected to protective earth. In the drawing below you see how to wire the Fortimo LED components in the right way.

Fortimo LED DLM “TD” (Touch & DALI) systems have connections for 12 V and Touch & DALI. The 12 V output can be used to operate the SynJet of Nuventix or any other fan that operates on 12 V. If no active cooling is required this 12 V can also be used to operate other LEDs for decorative effects. The Touch & DALI output connectors can be used to connect any DALI released user interface.

Wiring diagram also valid for Fortimo Food DLM, however no Dali output available.

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Design-in guide Philips Fortimo LED downlight module system 5

9. Index of visualsColor consistency (SDCM) 8Electrical and thermal analogy 27Emission coefficients 24Fortimo DLM module “Independent” 20Fortimo LED DLM “000K” 9Fortimo LED DLM “Food” 9Fortimo LED DLM “Independent” 9Fortimo LED DLM “TD dimmable” 9Fortimo LED DLM1100 25Fortimo LED DLM cable 14Fortimo LED DLM cable 19Fortimo LED DLM cable 1100-200/l 14Fortimo LED DLM cable 1100-2000/l 19Fortimo LED DLM cable Food 14Fortimo LED DLM driver - dimensions 12Fortimo LED DLM Food driver - dimensions 12Fortimo LED DLM Food module - dimensions 12Fortimo LED DLM module 1Fortimo LED DLM module, fixing holes and grooves 1Fortimo LED DLM module - dimensions 12Fortimo LED DLM module Independent - dimensions 12Fortimo LED DLM system. Left the module, right the driver 9Fortimo LED driver 1Label Fortimo LED DLM module 18LUXEO Rebel LED 7Measurements 29Passive solution 25Passive solution directions Fortimo LED DLM1100 26Passive solution directions Fortimo LED DLM2000 26Passive solution Fortimo LED DLM2000 25Polar intensity diagram 21Position of secundary optics 21Schematic wiring diagram 18Schematic wiring diagram 19Temperatures Fortimo LED DLM1100 2Temperatures Fortimo LED DLM2000 2Temperature test point TC 2Temperature test point Tc 25Thermal conductivity 24Thermal path basic solutions 27Thermal resistance of heat sink 1/3 28Thermal resistance of heat sink 1/3 28Thermal resistance of heat sink 3/3 29Thermal resistance of LED DLM 27

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© 2009 Koninklijke Philips Electronics N.V. All rights reserved. Reproduction in whole or in part is prohibited without the prior written consent of the copyright owner. The information presented in this document does not form part of any quotation or contract,is believed to be accurate and reliable and may be changed without notice. No liability will be accepted by the publisher for any consequence of its use. Publication thereof does not convey nor imply any license under patent or other industrial or intellectual property rights.

Document order number: 3222 635 5640108/2009

For more information please visit: www.philips.com/fortimowww.asimpleswitch.comwww.philips.com/oem