XLamp XML Lumen HighBay Reference Design.docx

APPLICATION NOTECree XLamp XM-L LED10,000-Lumen High-Bay Reference DesignTABLE OF CONTENTSIntroduction. 1Design approach/objectives . 2The 6-step methodology. 21. Define lighting requirements. 22. Define design goals . 53. Estimate efficiencies of the optical, thermal &electrical systems . 54. Calculate the number of LEDs . 85. Consider all design possibilities . 86. Complete the final steps: implementation andanalysis . 9Conclusions .14Special thanks .14INTRODUCTIONThis application note details the design of a replacementhigh-bay luminaire using Crees XLamp XM-L LED. Thehigh flux output and efficacy offered by the XM-L LEDmake it a particularly strong candidate for use in ahigh-bay luminaire. The performance of the XM-L LEDmeans that it is not necessary to use hundreds of LEDsto match the light output of traditional metal halide andfluorescent high-bay lighting.An XM-L LED-based high-bay luminaire not only offersenergy efficiency benefits but its long lifetime alsoreduces maintenance costs in typically hard-to-reachindustrial and commercial applications.Reliance on any of the information provided in this Application Note is at the users sole risk. Cree and its affiliates make no warranties or representationsabout, nor assume any liability with respect to, the information in this document or any LED-based lamp or luminaire made in accordance with thisreference design, including without limitation that the lamps or luminaires will not infringe the intellectual property rights of Cree or a third party.Luminaire manufacturers who base product designs in whole or part on any Cree Application Note or Reference Design are solely responsible for thecompliance of their products with all applicable laws and industry requirements.Copyright 2012 Cree, Inc. All rights reserved. The information in this document is subject to change without notice. Cree, the Cree logoand XLamp are registered trademarks of Cree, Inc. For product specifications, please see the data sheets available at . Forwarranty information, please contact Cree Sales at . Other trademarks, product and company names are the property of theirrespective owners and do not imply specific product and/or vendor endorsement, sponsorship or association.Cree, Inc.4600 Silicon DriveDurham, NC 27703USA Tel: +1.919.313.5300CLD-AP96 REV 0AWWW. CREE.COM/XLAMPCopyright 2010 Cree, Inc. All rights reserved. The information in this document is subject to change without notice.Cree, the Cree logo and XLamp are registered trademarks of Cree, Inc.XLAMP XM-L 10,000-LUMEN HIGH-BAY REFERENCE DESIGNDESIGN APPROACH/OBJECTIVESIn the “LED Luminaire Design Guide”1 Cree advocates a six step framework for creating LED luminaires and lamps. AllCree reference designs use this framework, and the design guides summary table is reproduced below.StepExplanation1. Define lighting requirements2. Define design goalsThe design goals can be based either on an existing fixture or on the applications lightingrequirements.Specify design goals, which will be based on the applications lighting requirements.Specify any other goals that will influence the design, such as special optical or environmentalrequirements.Design goals will place constraints on the optical, thermal and electrical systems.3. Estimate efficiencies of thethermal & electrical systemsoptical,Good estimations of efficiencies of each system can be made based on these constraints.The combination of lighting goals and system effiiciencies will drive the number of LEDs neededin the luminaire.4. Calculate the number of LEDs neededBased on the design goals and estimated losses, the designer can calculate the number of LEDsto meet the design goals.5. Consider all designchoose the bestpossibilitiesandWith any design, there are many ways to achieve the goals.LED lighting is a new field; assumptions that work for conventional lighting sources may notapply.Complete circuit board layout.Test design choices by building a prototype luminaire.6. Complete final stepsMake sure the design achieves all the design goals.Use the prototype to further refine the luminaire design.Record observations and ideas for improvement.Table 1: Cree 6-step frameworkTHE 6-STEP METHODOLOGYThe goal of the design is an LED-based high-bay luminaire that can replace high-intensity discharge (HID) and 54-wattfluorescent T5 and T8 luminaires in commercial, industrial and warehouse applications. As a replacement luminaire, thisdesign uses a form factor that is similar to traditional high-bay lighting currently in use.1. DEFINE LIGHTING REQUIREMENTSTable 2 shows a ranked list of desirable characteristics to address in a high-bay luminaire design.1LED Luminaire Design Guide, Application Note AP15, /xlamp_app_notes/luminaire_design_guideCopyright 2012 Cree, Inc. All rights reserved. The information in this document is subject to change without notice. Cree, the Cree logo and XLamp are registered trademarksof Cree, Inc. For product specifications, please see the data sheets available at . For warranty information, please contact Cree Sales at .2Importance Characteristics UnitsCriticalIlluminance distributionfootcandles (fc)/lux (lx)Electrical powerwatts (W)LifetimehoursLuminous fluxlumens (lm)ManufacturabilityXLAMP XM-L 10,000-LUMEN HIGH-BAY REFERENCE DESIGNTable 2: Ranked design criteria for a high-bay luminaireTable 3 summarizes the ENERGY STAR requirements for solid-state luminaires.2 There are no ENERGY STAR requirementsfor high-bay luminaires.2ENERGY STAR Program Requirements, Product Specification for Luminaires (Light Fixtures), Eligibility Criteria, Version 1.1, /ia/partners/prod_development/new_specs/downloads/luminaires/Final_Luminaires_Program_Requirements.pdfCopyright 2012 Cree, Inc. All rights reserved. The information in this document is subject to change without notice. Cree, the Cree logo and XLamp are registered trademarksof Cree, Inc. For product specifications, please see the data sheets available at . For warranty information, please contact Cree Sales at .3Characteristic RequirementsLight source life requirements:all luminairesThe LED package(s) / LED module(s) / LED array(s), including those incorporated into LED light engines orGU24 based integrated LED lamps, shall meet the following L70 lumen maintenance life values (refer to LumenMaintenance Requirements in the next section): 25,000 hours for residential grade indoor luminaires 35,000 hours for residential grade outdoor luminaires 35,000 hours for commercial grade luminairesLumen maintenance life projection claims in excess of the above requirements shall be substantiated with a TM-21lumen maintenance life projection report.Lumen maintenancerequirements: directional andnon-directional luminairesThe LED package(s) / module(s) / array(s), including those incorporated into LED light engines or GU24 basedintegrated LED lamps, shall meet the following L70(6k) rated lumen maintenance life values, in situ: L70(6k) 25,000 hours for residential indoor L70(6k) 35,000 hours for residential outdoor, or commercialCompliance with the above shall be documented with a TM-21 lumen maintenance life projection report as detailedin TM-21, section 7. The report shall be generated using data from the LM-80 test report for the employed LEDpackage/module/array model (“device”), the forward drive current applied to each device, and the in situ TMPLEDtemperature of the hottest LED in the luminaire. In addition to LM-80 reporting requirements, the followinginformation shall be reported: sampling method and sample size (per LM-80 section 4.3) test results for each T and drive current combinationS description of device including model number and whether device is an LED package, module or array (seeDefinitions) ANSI target, and calculated CCT value(s) for each device in sample set uv chromaticity shift value on the CIE 1976 diagram for each device in sample set a detailed rationale, with supporting data, for application of results to other devices (e.g. LED packages withother CCTs)Access to the TMP for the hottest LED may be accomplished via a minimally sized hole in the luminaire housing,LEDtightly resealed with a suitable sealant if created for purposes of testing.All thermocouple attachments and intrusions to luminaire housing shall be photographed.CCT requirements: all indoorluminairesThe luminaire (directional luminaires), or replaceable LED light engine or GU24 based integrated LED lamp (non-directional luminaires) shall have one of the following nominal CCTs: 2700 Kelvin 3000 Kelvin 3500 Kelvin 4000 Kelvin 5000 Kelvin (commercial only)The luminaire, LED light engine or GU24 based integrated LED lamp shall also fall within the corresponding 7-stepchromaticity quadrangles as defined in ANSI/NEMA/ANSLG C78.377-2008.Color rendering requirements:all indoor luminairesThe luminaire (directional luminaires), or replaceable LED light engine or GU24 based integrated LED lamp (non-directional luminaires) shall meet or exceed Ra 80.Importance Characteristics UnitsImportantOperating temperaturesCOperating humidity% RHCorrelated Color Temperature (CCT)KColor Rendering Index (CRI)100-point scaleEase of installationXLAMP XM-L 10,000-LUMEN HIGH-BAY REFERENCE DESIGNTable 3: ENERGY STAR luminaire requirementsThe DesignLights Consortium provides requirements for a high-bay luminaire.3Table 4: DesignLights Consortium high-bay luminaire requirements3Technical Requirements Table v1.6, DesignLights Consortium Qualified Products List - Non-Residential Applications, /solidstate.manufacturer.requirements.phpCopyright 2012 Cree, Inc. All rights reserved. The information in this document is subject to change without notice. Cree, the Cree logo and XLamp are registered trademarksof Cree, Inc. For product specifications, please see the data sheets available at . For warranty information, please contact Cree Sales at .4Characteristic RequirementsColor angular uniformityrequirements: directional solidstate indoor luminairesThroughout the zonal lumen density angles detailed above, and five degrees beyond, the variation of chromaticityshall be within 0.004 from the weighted average point on the CIE 1976 (u,v) diagram.Color maintenancerequirements: solid state indoorluminaires onlyThe change of chromaticity over the first 6,000 hours of luminaire operation shall be within 0.007 on the CIE 1976(u,v) diagram, as demonstrated by either: the IES LM-80 test report for the employed LED package/array/module model, or as demonstrated by a comparison of luminaire chromaticity data in LM-79 reports at zero and 6,000 hours, or as demonstrated by a comparison of LED light engine or GU24 based integrated LED lamp chromaticity datain LM-82 reports at zero and 6,000 hours.Source start time requirement:directional and non-directionalluminairesLight source shall remain continuously illuminated within one second of application of electrical power.Source run-up timerequirements: directional andnon-directional luminairesLight source shall reach 90% of stabilized lumen output within one minute of application of electrical power.Power factor requirements:directional and non-directionalluminairesTotal luminaire input power less than or equal to 5 watts: PF 0.5Total luminaire input power greater than 5 watts:Residential: PF 0.7Commercial: PF 0.9Transient protectionrequirements: all luminairesBallast or driver shall comply with ANSI/IEEE C62.41.1-2002 and ANSI/IEEE C62.41.2-2002, Class A operation.The line transient shall consist of seven strikes of a 100 kHz ring wave, 2.5 kV level, for both common mode anddifferential mode.Operating frequencyrequirements: directional andnon-directional luminairesFrequency 120 HzNote: This performance characteristic addresses problems with visible flicker due to low frequency operation andapplies to steady-state as well as dimmed operation. Dimming operation shall meet the requirement at all lightoutput levels.Noise requirements: directionaland non-directional luminairesAll ballasts & drivers used within the luminaire shall have a Class A sound rating.Ballasts and drivers are recommended to be installed in the luminaire in such a way that in operation, theluminaire will not emit sound exceeding a measured level of 24 BA.Electromagnetic and radiofrequency interferencerequirements: directional andnon-directional luminairesPower supplies and/or drivers shall meet FCC requirements: Class A for power supplies or drivers that are marketed for use in a commercial, industrial or businessenvironment, exclusive of a device which is marketed for use by the general public or is intended to be usedin the home. Class B for power supplies or drivers that are marketed for use in a residential environment notwithstandinguse in commercial, business and industrial environments.CharacteristicApplicationHigh-Bay and Low-Bay Fixtures forHigh-Bay-Aisle LightingCommercial and Industrial BuildingsMinimum light output10,000 lm10,000 lmZonal lumen density 30% 2050 50%, 2050 30%, 020Minimum luminaire efficacy70 lm/W60 lm/WAllowable CCTs (ANSI C78.377-2008) 5700 K 6000 KMinimum CRI7070L70 lumen maintenance35,000 hours35,000 hoursMinimum luminaire warranty5 years5 yearsXLAMP XM-L 10,000-LUMEN HIGH-BAY REFERENCE DESIGN2. DEFINE DESIGN GOALSTable 5 shows the design goals for this project.Table 5: Design goals3. ESTIMATE EFFICIENCIES OF THE OPTICAL, THERMAL & ELECTRICAL SYSTEMSWe used Crees Product Characterization Tool (PCT) tool to determine the drive current for the design.4For the 10,000-lm target, we estimated 93% optical efficiency and 85% driver efficiency. We also estimated a solderpoint temperature of 85 C.LED System Comparison RepThe PCT output highlighted in Figure 1 shows that, at 2.4 A, sixteen XM-L LEDs provide sufficient light output to meetthe design goals.System:1Target Lumens :10,000Optical Efficiency:93LED 1LED 2ModelCree XLamp XM-L CW/NW/WWModel(none)FluxT6 280Tj (C)85FluxTj (C)2Price$-Price$-SYS # LED SYS lm totSYS WSYS lm/W1.5001.6001.7001.8001.9002.0002.2002.4002.6002.8003.000232221201918171615151410225.810313.810338.810302.910208.310056.910191.810200.810092.210579.710290.6120.09123.5126.17128.1129.26129.65136.04140.81143.89155.62155.9985.183.581.980.47977.674.972.470.16866#N/A#N/A#N/A#N/A#N/A#N/A#N/A#N/A#N/A#N/A#N/A#N/A#N/A#N/A#N/A#N/A#N/A#N/A#N/A#N/A#N/A#N/A#N/A#N/A#N/A#N/A#N/A#N/A#N/A#N/A#N/A#N/A#N/A#N/A#N/A#N/A#N/A#N/A#N/A#N/A#N/A#N/A#N/A#N/AFigure 1:number ofLEDs usedand#N/A#N/A#N/AThis document is provided for informational purposes only and is not a warranty or a specification. For product specifications, please see the dataOpticCopyright 2009-2011 Cree, Inc. All rights reserved. The information in this document is subject to change without notice. Cree, the Cree logo aBecause this reference design is targeted as a replacement high-bay luminaire, the design has a form factor similar toincumbent luminaires. The optic is a commercially available 16-inch diameter reflector commonly used in HID high-bay4PCT is available at Copyright 2012 Cree, Inc. All rights reserved. The information in this document is subject to change without notice. Cree, the Cree logo and XLamp are registered trademarksof Cree, Inc. For product specifications, please see the data sheets available at . For warranty