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Design-in guide for OEMPhilips Fortimo LED Linear Light Module system (LLM) - May 2010

• Philips Fortimo LED LLM 1100-4500lm in 3000K and 4000K

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Design-in guide Philips Fortimo LED Linear Light Module system2

ContentsIntroduction of Philips Fortimo LED Linear system 3

Features and benefits 4Applications 4

Philips Fortimo LED LLM system 5The Fortimo LED LLM system components 5Fortimo LED Linear portfolio 5

3000K 54000K 5

Dimensions of Fortimo LED Linear system 6Precautions for mating operation 7Precaution for unamting operation 7Precautions for prying insertion and withdrawal 7Lighting performance characteristics 7

Photometric diagrams 7Spectral power distribution Fortimo LLM 8Color consistency (SDCM) 8UV and other hazards 8Photobiological safety aspects 8Measurements on the Fortimo LED LLM 9

Starting characteristics 10Constant Light Output (lumen maintenance) 10Dimming 10Dimming method 11Electromagnetic compatibility 11

Fortimo LED LLM 1100lm/1800lm 11Fortimo LED LLM 3000lm/4500lm 11

Exposure to direct sunlight 12Vibration and shocks 12Standards and approvals 12IP codes, dust and moisture protection 12Glow-wire test 12End-of-life behavior 12About the Fortimo LED Linear Light module 13About the Fortimo LLM driver 13About the Fortimo LLM cable 14About the Fortimo LLM connector 14

Precautions for mating operation 14Precaution for unmating operation 15Precautions for prying insertion and withdrawal 15Precautions for routing wire 15

Fortimo LED LLM System disposal 15

Designing a luminaire 16Introduction 16IEC recommendations 16Electrostatic device (ESD) measures 16Wiring 16Optical design (Secondary optics) 16Thermal management 17

Test requirements 17Temperature range 17Critical temperature point (Tc) 17Measurement of critical temperature point 17Operation under built-in conditions 18Heatsink design 18Calculation of thermal impedance from a system point of view 19Surface area 21Determining the size of a heat sink 21Heat sink material 23Thermal radiation and emission coefficient 25

Recommendations 26Design guidelines 26

Appendix 27Example Fortimo LED LLM solution 27Complementary partners for optics 27Complementary partners for heatsinks 27Complementary partners for thermal interface material 27

Index of visuals 28

Design-in guide Philips Fortimo LED Linear Light Module system 3

Introduction of Philips Fortimo LED Linear Light Module system (LLM)

Thank you for choosing the Philips Fortimo LED LLM 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/oem orwww.philips.com/fortimo.

The advantages of LEDs have been known for forty 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 LLM system addresses these differences and facilitates easy adoption of LED technology for high lumen packages. 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 Fortimo LED Linear system is primarily designed for luminaires in outdoor use, but can also be used in indoor applications as long as this creates no design conflicts with the Fortimo LED Linear system and the European luminaire standards are respected (EN60598). Please consult us if you wish to deviate from the design rules as described in this guide.

Fortimo LLM 1100lm/1800lm driver

Fortimo LLM module



Features and benefitsFeatures Benefits

Constant Light Output (CLO) No light depreciation

Linear shaped LED module Easily creation of uniform and retangular lightpatterns

Directed light output (batwing distribution) Reducing light polution (no sky glow)

Fortimo technology applied (RP film layer) High efficient, energy saving lighting (up to 80lm/W at system level)

Fixed form factor (Lumen packages 1000-4500) Reduced Time To Market (TTM) and related cost for OEMs

Latest LED technology inside ensuring performance and availability Reduced LED supply chain complexity for OEMS

No mercury Environmental friendly

Long lifetime (50Khrs) Reliable (system approach)

CCT 3000K & 4000K / Ra 70 and good color consistency Comfortable and safe high quality LED light

Easy replacement (not sealed for life) Upgradeable

Residential area application

City Application

Outdoor Park application

ApplicationsExamples are:• Residential.• City centre.• Square.• Park.• Wall washing.• Flood lighting.• General lighting.


The Fortimo LED LLM portfolio is a complete range. It is primarily designed for luminaires in outdoor use, but can also be used in indoor applications. Further extensions of the portfolio will be in higher lumen packages, programmable dimming features and CRI80+. The future range extensions will make use of the current form factor to build further on the future proof promise of Fortimo LED systems. As the system is future proof it will be possible to replace and upgrade the system without modifying the luminaire.

The Fortimo LED LLM system components1100lm/1800lm system• Fortimo LED Linear Light Module• Fortimo LLM Driver• Fortimo LLM Cable 25 cm

3000lm/4500lm system• Fortimo LED Linear Light Module• Fortimo LLM Driver including 50 cm cable

Fortimo LED Linear portfolio 3000KFortimo LED LLM4500 53W/730 1-10V Fortimo LED LLM3000 34W/730 1-10V

Fortimo LED LLM1800 23W/730 220-240V Fortimo LED LLM1800 23W/730 LS-6 Fortimo LED LLM1800 23W/730 LS-8 Fortimo LED LLM1800 23W/730 LS-10


4000KFortimo LED LLM4500 50W/740 1-10V

Fortimo LED LLM3000 33W/740 1-10V



Fortimo LED Linear System

Philips Fortimo LED LLM system

Note:LS and 1-10V stand for dimming protocols. 220-240V stands for fixed output.


Dimensions of Fortimo LED Linear system

F1 F2 F3 F4 G1 G2 G3 H1

160.5 153.2 140.5 485 92 73.4 5.0 38.4

A1 B1 C1 D1 E1 F1 F3 G1 G2 G3 H1

230.0 45.0 42.0 214.5 4.5 123.0 110 79.0 67.0 4.5 33.0

Dimensions in mm.

Dimensions in mm.

Fortimo LLM module

G2

F2

G3

G1

F1

F3

F4




Polar diagrams Fortimo LED Linear

Lighting performance characteristicsPhotometric diagrams On the Fortimo website (www.philips.com/fortimo) optical files can be downloaded in the following formats; CIB, IES, LDT, PHL, including a file with ray-sets.

Spectral Power Distribution Fortimo LLM 3000 K

Batwing light distribution

Wavelength (nm)

Wavelength (nm)

800750650 700600500 550400 4503500

0.1

0.2

0.3

0.4

0.5

0.6

0.7

0.8

0.9

1

Special Power Distribution Fortimo LLM 4000 K

800750650 700600500 550400 4503500

0.1

0.2

0.3

0.4

0.5

0.6

0.7

0.8

0.9

1

Spectral Power Distribution Fortimo LLM 3000 K

Special Power Distribution Fortimo LLM 4000 K


Color consistency (SDCM)High-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 for outdoor applications is characterized by a color rendering of minimal 70, popular CCTs in general lighting applications of 3000 K and 4000 K and a color consistency comparable with conventional PLL and HID solutions (five to seven SDCM).

The target specification of Fortimo LED LLM systems for color consistency is 7 SDCM.This is a similar specification as for conventional PLL lamps. SDCM stands for Standard Deviation of Color Matching and the value 7 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 > 10k measured Fortimo LED LLM systems and as can be seen almost all fit within the circle of a 5 SDCM ellipse.This really demonstrates the unique quality of the remote phosphor concept.

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.

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 theexposure 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 3000 nm. In the photobiological safety standard, hazard categories are defined as follows:

Radiance-based:• Blue Light LB 300 – 700 nm• Retinal Thermal LR 380 – 1400 nm• Retinal Thermal Weak Stimulus LIR 780 – 1400 nmIrradiance-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 – 3000 nm

Color consistency (SDCM)

0,350

0,450

0,370 0,380 0,390 0,400 0,410 0,420 0,430 0,440 0,450 0,460 0,470

CIE

y

CIE x

0,350

0,450

0,370 0,380 0,390 0,400 0,410 0,420 0,430 0,440 0,450 0,460 0,470

CIE

y

CIE x

BBL

7 SDCM off BBL 4000K

5 SDCM off BBL 4000K

7 SDCM BBL 3000K

5 SDCM BBL 3000K

LL_NW_bins

LL_WW_bins

measurements


Measurements on the Fortimo LED LLMThe following should be taken into account: • The Measured radiance based values are all within the exempt group except

for Fortimo LLM 4500lm 51W/740. for which Blue Light (LB) falls in the low emission group. For both ‘Exempt’ and ‘Low’ it is not required to risk group label the LLM LED module or package.

• The measured irradiance-based values for the categorized hazards are all within the exempt group.

• 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. 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 Exempt*

LR Exempt

LIR Exempt

ES Exempt

EUVA Exempt

EB Exempt

EIR Exempt

Emission limit Exempt means ‘no risk’* Fortimo LLM 4500lm is ‘Low’


Starting characteristicsThe system can be switched on in milliseconds, which is a general characteristic of LEDs. In contrast to other light sources, LEDs can be switched on at full power (or at any other dimmed level) instantaneously.

Constant Light Output (lumen maintenance)The Fortimo LED Linear system has been equipped with a special feature CLO (Constant Light Output), when used within specification a lumen maintenance of 100% is expected at 50,000 hours (average lifetime specification).

The main benefits of a CLO system are the optimized energy consumptionand improved system reliability difference between a CLO system and a conventional system or standard LED light system is that with CLO the end-user always has the required light level; there is no overlighting (see picture Overlighting versus CLO). The CLO feature uses a predictive algorithm to increase the current to the LED over the specified lifetime of 50Khrs. As the current increases also the energy consumption increases with about 20%. By preventing overlighting, significant energy savings can be achieved compared to conventional lighting solutions and standard LED solutions. These savings can be increased even further when lumistep is used.

DimmingTo enable even further energy savings a special feature has been integrated in the Fortimo LED LLM 1100lm/1800lm system based on the lumistep protocol. This is a stand alone feature, which will dim the light level for a pre-determinend period (6, 8 or 10 hrs) per night. With the Fortimo LED LLM 3000lm/4500lm system this feature can be used by connecting the Philips Dynadimmer to the 1-10V dimming control wires. The Dynadimmer is a programmable Lumistep controller. For more information: www.philips.com/dynadimmer

• Intelligent times, works autonomous, reference-points are the switch-on and switch-off time.

• The functionality integrated in the LED driver is pre-programmed in the factory.• For Lumistep different 1100lm/1800lm drivers are available; Lumistep 6, 8 or 10

hours.

Overlighting versus CLO

1-10V dimming

Burning hours x1000

Fortimo LED Linear with CLOConventional lighting solutionStandard LED solution

100%

Requ

ired

light

leve

l

25 50

Overlighting

Energy Saving

Lumistep 8 hrs dimmingfor the Netherlands in January

12:00

Ligh

tleve

l

16:00 20:00 0:00 4:00 8:00

0 2.0

20Tcase 80C

Tcase 25C

Tcase -40C40

60

80

100

120

4.0 6.0

Iout(%) Vs Vdim(V)

Dim voltage (V)

8.0 10.0 12.0

Iout

(%)

Lumistep dimming

Fortimo LED LLM

1100lm/1800lm

Fortimo LED LLM

3000lm/4500lm

Inrush current max. 23 A 60

Half value time 220 µs 250 µs

Amount of modules on a 16A type-B MCB 24 pcs max. 12 pcs max.


The intelligent software which makes up the Lumistep protocol counts the time between the switch on and off point for three days in a row and determines the middle point on this data. As most lighting installations make use of the sun rise and sun set times the mid point of the program is around the same point during a year. From this point the software calculates at which point the dimming should start and stop. So in the summer the standard dimming period can be as long as the period between switching on and off (the night period). This is illustrated in picture: Example differences dim period January and July.

Dimming methodThe dimming characteristics of the Fortimo LED LLM makes use of a so called amplitude (AM) dimming protocol. Most LED systems use PWM (pulse width modulation), which means that the current is switched on/off at high frequency. When dimming the time between the on and off switching increases. AM dimming reduces the current through the LEDs to achieve lower light levels. Additional advantages are: • No audible noise during dimming.• No visual interference with other lighting or video sources.

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.

Fortimo LED LLM 1100lm/1800lmWhen connecting the Functional Earth (FE) of the driver the system will always be compliant to the electromagnetic compatibility requirements as laid down in European Norms EN 55022, EN 61000-3-2 and EN 61547. However, in some applications it can be that the system will also be compliant to the EMC norms even without connecting the Functional Earth. When there is no possibility to connect the FE the EMC behavior of the system might be improved by connecting the driver FE to the aluminum base of the light module.

Fortimo LED LLM 3000lm/4500lmThe system complies with the electromagnetic compatibility requirements as laid down in European Norms EN 55022, EN 61000-3-2 and EN 61547 without the need for a Functional Earth. In some applications it can be that EMC behavior will improve by connecting the case of the driver to Earth.

Energy Saving

Lumistep 8 hrs dimmingfor the Netherlands in January and July

12:00

100%

Ligh

tleve

l

16:00 20:00 0:00 4:00 8:00

JanuaryJuly

Example differences dim period January and July

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

700mA

100% lightlevel

LED

Cur

rent

700mA

50% lightlevel

AM Dimming

LED

Cur

rent

700mA

50% lightlevel

PWM Dimming

LED

Cur

rent

More then 30% efficiencyincrease during dimming

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


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 LLM systems are build-in systems, 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 3 axes) without failure.

Standards and approvalsPhilips Fortimo LED LLM systems comply with the following international rules and regulations, including:Safety EN/IEC 60598-1 & 2-2, EN 61347-1, 2-13Approvals ENEC 05Philips Fortimo LED LLM 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 LLM system carries the CE marking on the basis of compliance with the following standards: EN 61547, EN 61000-3-2, EN 55015 and EN 55022

IP codes, dust and moisture protectionThe Fortimo LED LLM systems are build-in systems and have therefore no IP classification. The Fortimo LED system is not designed for operation in free air. The OEM is responsible for proper IP classification and approbation of the luminaire.

Glow-wire testPhilips Fortimo LED LLM 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 LLM modules are predicted to deliver an average of 100% of their initial intensity after 50,000 hours operation. This is archieved via the CLO (Constant Light Output ) feature. To compensate for the gradual degradation of the LEDs a predictive algorithm is used.


The lifetime of the system is therefore mainly influenced by the other electronic system components and soldering methods. The LEDs in the Fortimo LED LLM module are connected in series. If one LED fails, it is almost always due to an internal short-circuit (characteristic of the LEDs used). In this case it will still conduct current, so that the other LEDs will still operate.

About the Fortimo LED Linear Light moduleThe LED module consists basically of four main components:• PCB with LEDs• PCB reflector• Mixing chamber (housing)• 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 heat spreader facilitates optimal heat transfer and helps luminaire manufacturers to design their own heat sink system. The heat spreader is equipped with a hole on either side of the module for fixing. The function of the diffuser is to shape the light output, resulting in a batwing distribution. In this manner the luminaire manufacturer has the freedom to design its own secondary optics and/or reflector.

About the Fortimo LLM driverThe highly efficient Fortimo LLM drivers are especially designed to operate the Fortimo LED Linear Light Modules. They are designed to operate high-power LEDs.• Maximum current settings of 700mA.• Max. 80V (1100lm/1800lm) and 140V (3000lm/4500lm) enables operation of

many LEDs in series.• High efficiency: 90% at full load (220-240 V).• Tcase life < = 55 °C (1100lm/1800lm) and <= 75 °C (3000lm/4500lm).• Safety Class 2 system.

Exploded view Fortimo Light module

Fortimo LLM 1100lm/1800lm Driver



About the Fortimo LLM cableThe Fortimo LLM 3000lm/4500lm driver can be connected to the 3000lm or 4500lm LLM module with the cable and connector that are attached to the driver. For connecting a Fortimo LLM 1100lm/1800lm driver to a 1100lm or 1800lm LLM module a specific cable has been developed. The standard length is 250 mm. We advise to use the Fortimo LED LLM cable, if an OEM prefers to use 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 LLM module and LED driver is based on a reference luminaire with the standard 250 mm cable length. In any case, any luminaire design needs its own approval, organized by the responsible OEM, irrespective of the length of cable used. It is recommended not to use a cable longer than 10 meters to prevent the system from operating incorrectly. If an OEM prefers to have a cable with a different length it can use the following cable/connector specifications:

About the Fortimo LLM connector1100/1800lm 5-pin connector:

JST connector:Housing JST XAP-05V-1Contact JST SXA-001T-P0.6Cable:5x Wire 24 AWG UL style 1569Heat shrink tube

Pin 5: Wire 24 AWG UL style 1569 green = Signal ground

Pin 4: Wire 24 AWG UL style 1569 Blue = LED module setting

Pin 3: Wire 24 AWG UL style 1569 Red = NTC (thermal control)

Pin 2: Wire 24 AWG UL style 1569 Yellow = LED-

Pin 1: Wire 24 AWG UL style 1569 Black = LED+

3000/4500lm 6-pin connector:

JST connector:Housing JST PAP-06V-SContact JST SPHD-001T-P0.5Cable:5x Wire 24 AWG UL style 1569Heat shrink tube

Pin 6: Wire 24 AWG UL style 1569 Red = NTC (thermal control)

Pin 5: Wire 24 AWG UL style 1569 Blue = LED module setting

Pin 4: Wire 24 AWG UL style 1569 green = Signal ground

Pin 3: Blank

Pin 2: Wire 24 AWG UL style 1569 Yellow = LED-

Pin 1: Wire 24 AWG UL style 1569 Black = LED+

Pin 1

Fortimo LLM 1100/1800lm 5-pin connector

Fortimo LLM 3000/4500lm 6-pin connector


CLICK

Fixation (mechanical)The separate components (Driver and Module) of the Fortimo LED LLM systemcan be securely fastened by the mounting holes located on the module and driver.Please refer to dimensional drawing for specific details such as pitch and diameter.The 3D CAD files will be available for downloading from www.philips.com/fortimo.For fixation of the system we advise to use hexagon socket head cap screw M4(DIN 912 / ISO 4762) with a spring lock washer for screws with cylindrical headsM4 (DIN 7980) of Stainless steel A2 (DIN 1.4301 / AISI 304). It is not allowed touse screws with a head diameter larger than 8mm.

Precautions for mating operationMate connectors gently in a straight line pressing down the whole of connector. There is a “click” sound (you feel a click) when mating operation is properly completed. When there is no feeling of a click. there is a possibility that mating is not finished completely. Conduct mating operation again. (The number of mating and unmating operation shall be decreased as much as possible).

Precaution for unmating operationPress lock working part and release lock completely. Unmate connector straightly on the mating axis with holding wire in bundles. Do not unmate connector forcibly without realising lock completely or with prying, because such handling may cause breakage and trouble, etc. of connector. Do not unmate connector with holding several wires at the end of circuits, such handling may cause breakage and trouble of contact.

Precautions for routing wireConduct wire routing carefully so that tension stemmed from excessive wire routing is not loaded on connector. Provide moderate slack for wire which makes and mating and unmating of connector easily. Fix wire so that the load generated from wire bending and pulling is not applied to connector part. When using harness at the movable part, fix wire not to travel wire moving and vibration to connecdtor regardless of angle and direction.

Fortimo LED LLM system disposal At the end of their (economic) lifetime, appropriate disposal of the Fortimo LED LLM 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.

Recommendations with respect to the Mounting area:• minimal flatness: 0,2 mm• minimal dimension: 227 x 32 mm• material: aluminium


IntroductionThe Fortimo LED Linear system is designed as a LED breakthrough in energy efficacy, comfortable and high quality light. To facilitate the integration of Fortimo LED Linear in existing luminaires and/or developing new luminaires the interface points of the system are put down, togheter with recommendation.

IEC recommendationsThe general recommendations for luminaire design by IEC and the national safety regulations (ENEC, CE, ANSI etc.) are also applicable to Fortimo LED LLM systems. The luminaire manufacturer is advised to conform to the international standards of luminaire design (IEC 60598-Luminaires).

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

WiringThe sticker on the power supply shows the connections layout for the connection to mains. The minimum diameter for the main cables is 0,2 mm and the maximum diameter is 1.5 mm². The system should not be serviced when mains voltage is connected; this includes connecting or disconnecting the Fortimo LLM cable!

Optical design (secondary optics)The Fortimo LED LLM module generates a batwing beam shape, which is a pragmatic starting point for secondary optic design by OEMs. Secondary optics are not part of the Fortimo LED LLM system offering as this is an added value area for OEMs. For support in reflector designs please check the list of complementary partners (see appendix).

Designing a luminaire

Fortimo LLM driver & connection layout mains


Thermal managementFor optimal performance, the Fortimo LED LLM system must operate within specified temperature limits. Depending on the application and luminaire design, a suitable solution for the thermal management should be applied.

Test requirementsTemperature measurements should only be performed when the luminaire is thermally stable, which may take 0.5 up to 4 hours depending on the thermal capacity of the luminaire. 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).

Temperature rangeBecause LEDs are temperature-sensitive, LED modules require a different approach with respect to thermal management. The system has been designed to operate between -20 °C and 75 °C at Tcase (start-up can be as low as -40 °C). The lower and upper limit have been determined by the application and by the components used in direct relation to the performance and reliability of the system.

Critical temperature point (Tc)For 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 Fortimo LED LLM module at its critical point. If the case temperature at the Tc point exceeds the recommended Tc life of 55 °C, the performance of the LEDs and the Fortimo LED LLM system will be adversely affected, in terms of light output, lifetime and lumen maintenance.

Measurement of critical temperature pointThe Tcase should be measured at its critical temperature point with a thermocouple at the bottom of the module, inside the left or right groove on the centre point location. Critical temperature point Tc Fortimo LED module

Center line indic for Tc position

2 options for Tc-position

Option 1 Option 2


If due to insufficient thermal management or other circumstances the Tc point reaches 75 °C (typ), a thermal circuit* will be engaged. This circuit will start dimming the LED module. The thermal circuit is only a failsafe in order to protect the module against overheating. The optimum performance is only achieved if Tc point stays below 55° C. The graph shows the effect on the relative flux as a function of Tc temperature.

*The thermal circuit is applied in all Fortimo LED LLM versions.

Operation under built-in conditionsThe heat produced by the Fortimo LED LLM driver and module in the luminaire (or similar housing) must be dissipated to the surroundings. If this is not taken care of it will have an adverse effect on system performance and lifetime.

Heatsink designTo ensure optimum performance, it is essential that the critical temperature of the module stays below 55 °C. The thermal management can be done in three ways —conduction, radiation and convection or a combination of these.

Note: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.

Two thermal design concepts are shown for passive cooling of the Fortimo LED module:• Concept A, regular heat sink design• Concept B, luminaire as part of heat sink

Relative light output

025 35 45 55 65 75 85

20

40

60

80

100

120

Temperature

Relat

ive li

ght o

utpu

t

Thermal specificationsFortimo LLM system 1100 lm LLM 1800lm LLM 3000lm LLM 4500lm LLM

Tcase of module 55 °C 55 °C 55 °C 55 °C

Ambient temperature of module (inside luminaire) 35 °C 35 °C 35 °C 35 °C

Dissipated thermal power (typical) 9 W 16 W 23 W 36 W

Dissipated thermal power (maximum) 15% 15% 15% 15%

Typical specifications under optimum operating conditions

Three types of heat transport

Luminaire

Heat sink

Radiation

ConvectionConduction

Heat sink

LED’s

Thermal interfacematerial


Luminaire

Tambient luminaire

Tambient

TC

Rthermal-luminaire

Rthermal-heat sink

Luminaire

Tambient luminaire

Rthermal-luminaire

TC

To simplify thermal management, the heat sink can be designed in such a way that it becomes one with the luminaire housing. By making the housing of the luminaire an integral part of heat management, the surface area of the (internal heat sink) can be reduced and thus also the size of the luminaire. An additional advantage is that the calculation of the heat sink can be simplified.

The main objective is to extract the heat from the module and dissipate it into the ambient air. The simplified thermal network models are depicted in figures below.

Calculation of thermal impedance from a system point of viewThe total thermal impedance (Rth tot) of the system is equal to the thermal impedance of the heat sink (Rth hs) plus the thermal impedance of the luminaire (Rth lum). For a reference calculation of the thermal network of concept A with a 1100lm Fortimo LED module, the following temperatures are used: Tc is 55 °C, T ambient inside luminaire is 35 °C and Tambient outside luminaire is 15 °C.

Note:The 35 oC ambient inside the luminaire is based on a standard luminaire and should be checked for each specific luminaire design separately.

Concept A, regular heat sink design Concept B, luminaire as part of heat sink


Rth total = Rth heatsink + Rth luminiare

The Rth heatsink is calculated by subtracting T ambient from Tc and divided by the dissipated (thermal) power of the Light module.

Rth heat sink = Tc – Tambient / Pdissipated light module

Rth heat sink = 55ºC - 35ºC/ 9W = 2.22ºC/W

The Rth luminaire is calculated similarly

Rth luminaire = Tambient - Tambient luminaire / P dissipated light module & driver

Rth luminiare = 35º C - 15º C/ (9W + 2 W) = 1.86ºC/W

The minium required Rth total is then estimated to be

Rth total = 2.22 + 1.86 = 4.08ºC/W

Similarly this can be done for the 1800lm, 3000lm and 4500lm Fortimo LED modules. Summary of the results is given below.

Concept A, regular heat sink design 1100 lm LLM 1800lm LLM 3000lm LLM 4500lm LLM


Ambient temperature of module (inside luminaire) 35 °C 35 °C 35 °C 35 °C

Ambient temperature of luminaire (outside luminaire) 15 °C 15 °C 15 °C 15 °C


Thermal dissipation driver 2 W 3 W 4 W 6 W

Thermal impedance heat sink

Rth heat sink

2.22 °C/W 1.25 °C/W 0.87 °C/W 0.56 °C/W

Thermal impedance luminaire

Rth luminaire

1.86 °C/W 1.05 °C/W 0.73 °C/W 0.47 °C/W

Total thermal impedance Rth total 4.0 °C/W 2.3 °C/W 1.6 °C/W 1.0 °C/W

Minimum required thermal performance of cooling solution for concept A, regular heat sink design


For concept B where the luminaire body is an integral part of the heat sink the same calculations can be made with one difference that the driver losses are neglected for simplicity, which is sufficient for a first order calculation. Assuming the same parameter values as above the minimum required thermal impedance for concept B are summarized below.

Surface areaAlthough a heat sink can have many (complex) shapes, the design will depend on several parameters. Depending on application of the luminaire, surface area, cost, thermal resistance and volume inside of the luminaire will all play an important part. Here is a differentiation opportunity for luminaire manufacturers.

The amount of heat (energy) that needs to be taken from the module is about 9 W for the 1100lm, 16 W for the 1800lm, 23 W for the 3000lm and 36 W for the 4500lm versions respectively. The heat sink at the back side of the module is the contact area for the external heat sink. The external heat sink transports the heat away from the module and dissipates it into the ambient air. By improving the thermal management, in other words, lowering the Tc point of the module, the system will perform better (lifetime and light output). Here is another differentiation opportunity for luminaire manufacturers. The size of the heat sink depends on the power rating of the module as well as the design and volume of the luminaire.

Determining the size of a heat sinkAs a starting point the required surface area needs to be determined. This can be done with the aid of the following relations.

Total surface area heat sink = 1/ (Rth heat sink x htc)

With htc the heat transfer coefficient (W/m2K). The typical htc value for natural convection value is between 5-10.The required surface area of a heat sink for the Fortimo LED 1100lm in a typical cooling situation as in concept A and previously assumed temperature conditions can simply be calculated.

Total outer surface area heat sink = 1/ 2.22 oC/W x 7 W/m2K = 0.064 m2

Concept B 1100 lm LLM 1800lm LLM 3000lm LLM 4500lm LLM


Ambient temperature of luminaire (outside luminaire) 15 °C 15 °C 15 °C 15 °C


Total thermal impedance Rth total 4.4 °C/W 2.5 °C/W 1.7 °C/W 1.1 °C/W

Minimum required thermal performance of cooling solution for concept B, luminaire as part of heat sink


The calculated surface area of 6.4 dm2 can be used as a first guideline for designing a heat sink with a similar outer surface area. For the Fortimo LED 1100lm module this can be a simple aluminum plate of 2.0 dm x 1.6 dm (assuming both sides are effective cooling surfaces).

With increasing power dissipation the required surface area increases, making a large plate heat sink less practical. In order to fit the heat sink inside the luminaire it is possible to switch from a simple plate heat sink into a fin heat sink.

Based on the calculated surface area a possible heat sink design of the Fortimo LED 1100lm module is a fin heat sink of 2.0 dm x 0.6 dm x 0.2 dm with 11 fins, the estimated outer surface area is ~ 6.5 dm2. On the left the result of a simple CFD analysis of a 1100lm module with heat sink in a rectangular luminaire with a volume of 22.5 dm3 (5 x 3 x 1.5 dm).

The simulated maximum Tcase is 52 °C in an outside ambient of 15 °C, which is in the range of what can be expected based on preliminary calculations. The ambient inside the luminaire around the module is below 35 °C which is also within optimum performance conditions for the module.

For increasing power dissipations for the 1800lm, 3000lm and 4500lm versions, the heat sink surface and luminaire volume need to increase accordingly. For some desired luminaire designs this can become impractical.

Another option is to switch from cooling concept A to cooling concept B where the luminaire body is part of the heat sink. This allows a more simplified (direct) heat path from hot Tc to cold Tambient, which in turn can help reduce the overall luminaire size.

Concept A 1100 lm LLM 1800lm LLM 3000lm LLM 4500lm LLM

Max. Tcase of module 55 °C 55 °C 55 °C 55 °C

Max. ambient temperature module (inside luminaire) 35 °C 35 °C 35 °C 35 °C


Thermal impedance heat sink

Rth heat sink

2.22 °C/W 1.25 °C/W 0.87 °C/W 0.56 °C/W

Calculated required surface area 6.4 dm2 11.4 dm2 16.4 dm2 25.7 dm2

Estimated dimensions of plate heatsink 2 x 1.6 dm 2 x 2.9 dm 2 x 4.1 dm 2 x 6.4 dm

Typical required cooling surface

CFD simulation model of module and heat sink inside a luminaire

Simulated temperature

distribution

Simulated airflow profile


Heat sink materialThe type of material used has a 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) shows that a substantially smaller heat sink can be made with copper. The best material for heat sinks is (soft) aluminum. The thickness (H) of the heat sink is also of major importance. Assuming that we would use the same heat sinks, but made from a different material, a similar effect would be archived with 1 mm copper, 2 mm aluminum, 4 mm brass, 8 mm steel or 26 mm corrosion-resistant steel.

Thermal conductivity

Material W/mK

Copper 400

Aluminium 200

Brass 100

Steel 50

Corrosion-resistant steel 15


For illustration a DoE with CFD analysis has been performed on a Fortimo LED 4500lm module directly attached to the luminaire (cooling concept B). The luminaire will be used as part of the heat sink and will act as a primary heat spreader. The same simple rectangular luminaire with a volume of 22.5dm3 (5.0dm x 3.0dm x 1.5dm) is used , the bottom side is fitted with a glass window.

With increasing thermal conductivity from 100 to 400 W/mK, the heat will be spread over a larger surface and thus help decrease Tcase. The simulated maximum Tcase temperature, in an outside ambient of 15oC, is shown in the graph on the left.

The same effect (lower temperature by better heat spreading) can also be achieved by increasing the wall thickness of the luminaire, this decreases the in plane thermal impedance and improves heat spreading.

The following graph shows the resulting Tcase temperature of a Fortimo LED 4500lm module, in the same simple rectangular luminaire (volume of 22.5 dm3, dimensions 5 x 3 x 1.5 dm), as a function it’s wall thickness. The thermal conductivity of the luminaire is taken to be 150 W/mK (industrial grade aluminum).

015

25

35

45

55

65

75

85

50 100 150 200 250 300 350 400 450

Tem

pera

ture

[C]

Conductivity [W/mK]

Tcase vs material conductivity

150 1 2 3 4 5 6 7

25

35

45

55

65

75

85

Tem

pera

ture

[C]

Thickness [mm]

Tcase as function of conductivity

Tcase as function of wall thickness


In practice increasing the wall thickness of the complete luminaire might be impractical due to weight. In this case it is also possible to only increase the thickness locally which can act as primary heat spreader for the module. The following graph shows the Tcase temperature for four different situations.

Module directly attached to a luminaire with 1.5mm thick walls.Module attached to the luminiare with locally an increased wall thickness over an area of 1.6dm2 (rectangular plate of 0.1dm thickness and 2.0dm x 0.8dm).Module attached to the luminiare with locally an increased wall thickness over an area of 2.9dm2 (rectangular plate of 0.1dm thickness and 2.4dm x 1.2dm).Module attached to the luminiare with locally an increased wall thickness over an area of 6.0dm2 (rectangular plate of 0.1dm thickness and 3.0dm x 2.0dm).

Thermal radiation and emission coefficientThermal 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.

Thermal emissivity coefficients of common materials

Material Emission coefficient

Aluminium new/polished 0.04 - 0.06

oxidized 0.2 - 0.3

anodized 0.8

Steel painted 0.8 - 0.95

new/polished 0.03 - 0.07

heavely oxidized 0.7 - 0.8

Tcase as function of primary heat spreading area

15

25

35

45

55

65

75

85

Tem

pera

ture

[C]

0 1 2 3 4 5 6Area [dm2]

(no local increase in thicknes)

(2.0dm x 0.8dm)(2.4dm x 1.2dm)

(3.0dm x 2.0dm)


RecommendationsDesign guidelinesFinally an overview of general thermal design guidelines to improve the thermal management and performance of a luminaire.

• Simplify the heat path from hot Tcase to cold ambient air.• Use good thermal conductive materials in the primary heat path i.e. aluminum.• Limit the number of thermal interfaces in the primary heat path towards the

ambient air.• If thermal interfaces are inevitable use thermal grease to ensure proper thermal

contact i.e. between module and heat sink.• Ensure proper heat spreading by using good conductive materials or sufficient

thickness to increase effective use of the available cooling surfaces.• For increased heat transfer via thermal radiation, anodized, painted surfaces are

always preferred over blank surfaces.

If you require further support for thermal interface material we suggest that youcontact one of our complementary partners as listed in the appendix.


Example Fortimo LED LLM solutionTo proof the Fortimo Led Linear concept a reference design has been made with the Fortimo LLM 1800lm.The luminaire is made from plastic and has an inner volume of 7 dm2Based on a typical residential street of 8 meters and a poleheight of 6 metersa poledistance of 30 meters can be archived while complying with the international S5 residential lighting norm as stated in theEuropean BS EN 13201-2.

It is possible of course to comply with higher norms by moving the poles closer together or reducing the pole height.

Complementary partners for optics

Appendix

Example of luminaire with Fortimo LED LLM system

Jordan : www. ordanreflectors.co.ukAlux Luxar : www.alux.de

Complementary partners for heatsinks Nuventix : www. nuventix.comAVC : www.avc.com.tw

Complementary partners for thermal interface materialLaird : www.lairdtech.comBergquist : www.bergquistcompany.comChomerics : www.chomerics.com


Index of visualsBatwing light distribution 7CFD simulation model of module and heat sink inside a luminaire 22City Application 4Color consistency (SDCM) 8Concept A, regular heat sink design 19Concept B, luminaire as part of heat sink 19Critical temperature point Tc Fortimo LED module 17Example differences dim period January and July 11Example of luminaire with Fortimo LED LLM system 27Exploded view Fortimo Light module 13Fortimo LED Linear System 5Fortimo LLM 1100/1800lm 5-pin connector 14Fortimo LLM 1100lm/1800lm driver 3Fortimo LLM 1100lm/1800lm driver 6Fortimo LLM 1100lm/1800lm Driver 13Fortimo LLM 3000/4500lm 6-pin connector 14Fortimo LLM 3000lm/4500lm driver 3Fortimo LLM 3000lm/4500lm driver 6Fortimo LLM 3000lm/4500lm driver 13Fortimo LLM driver & connection layout mains 16Fortimo LLM module 3Fortimo LLM module 6Lumistep dimming 10Outdoor Park application 4Overlighting versus CLO 10Polar diagrams Fortimo LED Linear 7Relative light output 18Residential area application 4Simulated airflow profile 22Simulated temperature distribution 22Special Power Distribution Fortimo LLM 4000 K 7Spectral Power Distribution Fortimo LLM 3000 K 7Tcase as function of conductivity 24Tcase as function of primary heat spreading area 25Tcase as function of wall thickness 24*The thermal circuit is applied in all Fortimo LED LLM versions. 18Three types of heat transport 18Typical specifications under optimum operating conditions 18

© 2010 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 7266105/2010

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

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