Lumenate · enabling you to achieve your vision. We look forward to meeting with you and hearing your needs. Thank you for making the time to read Lumenate. Are we ready for you?

Issue SixAccelerating your time-to-market

Lumenate

Making LED Lighting Solutions Simple™

Point of referenceImprove development time

with Future LightingSolutions reference designs

Pages 14-15

Replicating the warm glow ofcentury-old gaslightsLUXEON® Rebel LED shines through in acolour-critical application Pages 12-13

Lamp post LED upgradehits the streetsFrom HID to LED without rewiring;Hadco’s retrofit challenge solved Pages 8-9

Making LEDadoption easyFuture Lighting Solutions’ simpleLED®

programme accelerates your progressinto solid-state lighting markets Pages 4-7

Are you ready? We at Future Lighting Solutions have been waiting for more

than 10 years for this moment, and finally, the time has come.

The rapid adoption of LED lighting that we have been

anticipating is now upon us. Power LED technology,

performance, efficacy and value have reached the ‘tipping

point’ the general illumination market has been demanding.

2010 will be the year of rapid adoption and breathtaking growth.

Future Lighting Solutions has everything you need to

accelerate LED lighting adoption. As you read through this

issue of Lumenate, you will learn how quickly SSL adoption

can be successfully realised with the right partner. In this

issue we will show you how enabling applications is about

leveraging our reference designs and design tools to facilitate

your development time. You will also learn about our new

simpleLED® programme which comprises more than 500

different configurations of LUXEON®-based light engines,

available off-the-shelf or customised within 4 weeks.

Over the years, we have developed the tools, knowledge

and infrastructure to enable the illumination market. We

worked closely with industry leading LUXEON LED technology

from Philips Lumileds and enabled a variety of customers

who took a lead in developing with power LEDs. We learned

and grew together. Today, power LEDs are no longer an

alternative light source, they are the next light source. We

have graduated and the time has come to execute.

❞

Lawrence MadandaGeneral ManagerFuture Lighting Solutions (EMEA)

Welcome to Lumenate

Cover image:LUXEON® Rebel light engine

P O W E R • T H E R M A L • I N T E G R A T I O N • O P T I C A L F O R P R O D U C T S A N D S E R V I C E S V I S I T : W W W . F U T U R E L I G H T I N G S O L U T I O N S . C O M

F O R T E C H N I C A L A D V I C E A N D S U P P O R T E M A I L : L U M E N A T E @ F U T U R E L I G H T I N G S O L U T I O N S . C O M O R C A L L : 0 0 8 0 0 4 4 3 8 8 8 7 3

Future Lighting Solutions provides technical assistance that

simplifies the selection and analysis of the entire LED

system, from the LEDs themselves to optical, thermal and

driver solutions. We are committed to helping you get to

market faster, while optimising the performance of your LED

fixture or retrofit. By partnering with Future Lighting

Solutions, you will be connected with the most comprehensive

network of component manufacturers, and expert resources

to help you determine the best drivers, optics, connectors

and tools for your design, from concept to implementation.

We also understand the importance of reliability and

sustainability of your designs. With Philips Lumileds, we

excel at providing a consistent supply of LEDs to maintain

colour consistency from fixture to fixture and ensure you

produce a reliable and quality illumination product.

The LED revolution is here. Together we can build a

successful strategy. Future Lighting Solutions is positioned

to be your partner in accelerating your SSL designs and

enabling you to achieve your vision. We look forward to

meeting with you and hearing your needs.

Thank you for making the time to read Lumenate.

Are we ready for you? Yes we are. ❞

2 3

ContentsPages 4-7Making LED adoption easier with simpleLED®

Pages 8-9Case Study: Hadco’s quick-change LED post top upgrade

Pages 10-11Case Study: Theatrical lighting debut from Altman

Pages 12-13Case Study: Braun bring the warm glow of gaslight intoLED era

Pages 14-15Accelerating product development with Future LightingSolutions

Pages 16-17Calculating real-condition light output with Useable LightTool 2.0

Page 18Using LM-80 results to improve luminaire reliability

The programme is designed to provide tools and product solutions to help

you avoid obstacles and focus on getting your product to market quickly

and seamlessly, while adopting energy efficient, environmentally friendly,

long lifetime LED lighting technology.

The light engines are designed to accelerate the development,

prototyping and delivery of solid-state lighting applications as well as reduce

fixture development costs. The first light engines in the new simpleLED

programme are available in 12 form factors and 500-plus customisation

options, all featuring ANSI-binned LUXEON Rebel Illumination LEDs

integrated with key components.

Twelve off-the-shelf configurations – available for immediate shipment –

include linear, circular and square layouts with 1, 3, 4, 6 or 9 white 3000K,

3500K or 4000K LEDs. Each assembly incorporates circuit boards, LEDs,

Tyco Electronics connectors, and 10mm, 20mm, tri-lens or ultra-wide

Carclo optics. All these options allow optimisation of the light engine to

meet the requirements of the lighting requirements of the application.

Applications range from recessed downlights to low bay, cove, wall wash,

display case, under cabinet, desk/task and street/area lighting.

simpleLED

Continued over

The use of solid-state lighting (SSL) devices is growing rapidly, and to help accelerate theadoption of LUXEON® LEDs. Future Lighting Solutions developed the simpleLED programme tohelp make it easier than ever for you to join the SSL revolution.

simpleLED® makesLED adoption easier

Left: 12 off-the-shelf configurations available immediately.500-plus customisable configurations available on request

Configuration Options

CCT Optics Size* Beam Angle* LED Spacing*

2700K3000K3500K4000K

10mm20mm

Ultra WideWideMediumNarrow

12.5mm25mm50mm

*Can be configured on selected platforms only

P O W E R • T H E R M A L • I N T E G R A T I O N • O P T I C A L F O R P R O D U C T S A N D S E R V I C E S V I S I T : W W W . F U T U R E L I G H T I N G S O L U T I O N S . C O M4 5

simpleLEDsimpleLED

simpleLED Configuration Guide

Part numbering and ordering information



Developing a lighting product with simpleLED is simple. You select the light engine platform best suited for your

application and configure the light engine to meet the lighting requirements. For larger applications, light engines can

be placed in series using the recommended connector to form a larger array. Comprehensive datasheets are

available for each series in the simpleLED range, which contain important information to help build the right lighting

solution. It includes information with regards to the power consumption of the light engines, customisation options

available and a list of compatible connectors. To ensure the light engine is achieving optimal performance, and in

operating conditions compliant with the three year warranty, the datasheet for each light engine has a dedicated

thermal management section. Here you can identify the thermal management requirements based on the operating

and ambient conditions of the application.

To add power, Future Lighting Solutions extensive line card can offer a variety of brick power modules that are suited

for your requirements and ready to use, which can be easily connected using the recommended connector cable.

Building the light engine you require couldn’t be easier. With the part number

being split into sections related to configurable parts of the light engines, you

can identify the part ideal for you. The online Light Engine Builder is a simple

tool to help you build your light engine by selecting the characteristics you

require of the light engine and then place the order online.

It is also possible to build the part number using the eight sections of the

part number are broken down so you can easily build the part you require,

subject to compatibility within the platform. This is included in the datasheet

of each platform.

More information is available online where you can view datasheets for the

light engines, and also link to the online Light Engine Builder to build the

required simpleLED product.

Visit www.futurelightingsolutions.com/simpleled

6 7

All light engines in the programme offer a three-year manufacturer’s warranty

as well as the full benefits of the LUXEON Rebel platform, including the

ability to support drive currents up to 1,000mA, compliance with ANSI

colour binning requirements, and a minimum CRI of 80. The LEDs are also

UL Recognised, eliminating the need for a full in-system LED component

investigation to obtain UL Listed status for new luminaires built with Future’s

light engines.

1. PRODUCT SERIES (05711)

Circular board withthree LEDs in series

LED TYPER – LUXEON® Rebel

2. COLOUR TEMP(AAAA)

7777 – Neutral White8888 – Warm White9999 – Cool White

3. MINIMUM CRI*(BB)

XX – No Min CRI55 – Min 5560 – Min 6065 – Min 6570 – Min 7075 – Min 7580 – Min 8085 – Min 8590 – Min 90

4. MINIMUM FLUX*(LM) (CCC)

065 – Min 65066 – Min 66067 – Min 67075 – Min 75080 – Min 80100 – Min 100

5. CONNECTOR (D)

C – ConnectorN – No Connector

6. SUPPLIERCOLLIMATOR (E)

X – No OpticsD – Carclo 10mmE – Carclo 20mm

7. OPTIC HOLDER(F)

(Carclo 20mm)X – No HolderD – Carclo Triple Black

HolderE – Carclo Triple White

Holder

8. COLLIMATOR (G)

X – No LensC – Narrow BeamD – Narrow Beam FrostedE – Medium BeamF – Medium Beam FrostedG – Wide BeamH – Wide Beam FrostedK – Elliptical BeamL – Elliptical Beam 90°

05711RAAAABBCCCDEFGPART NUMBER

1 2 3 4 5 6 7 8

*According to Philips Lumileds datasheet

Future Lighting Solutions’ online Light Engine Builder

++


With Hadco’s refractive post top fixtures installed throughout North America,

switching from HID to LED illumination must be done on-site without

rewiring. LED retrofits are always an engineering challenge, but Hadco

Lighting faced unusual complexities in developing an LED upgrade for its

widely deployed family of HID post top fixtures. With tens of thousands of

Hadco’s refractive globes installed on roadways and walkways through

North America, the company needed an LED light engine that could not only

direct light properly through the globes’ distinctive prisms but also be

quickly swapped on-site with the original HID assembly. Hadco engaged

Future Lighting Solutions engineers to help build a replacement module

using LUXEON® Rebel LEDs from Philips Lumileds. Today, Hadco’s

LumiLock™ LED retrofit fills the optical bill while also enabling road crews to

convert HID post tops to LEDs in a matter of minutes.

Upgrade with atwistThe goal of the project was

to provide an easy transition

from traditional HID sources

to ‘greener’ LED technology

for municipalities, utilities

and commercial developers

using Hadco’s Fentress

Refractive Series of post top

fixtures. The switch would

reduce power consumption

by 55% to 60%, while also providing a typical 14-year lamp life that would

eliminate the costs associated with replacing HID bulbs every 48 months.

To accommodate the vastly different LED shape and technical requirements

of solid-state lighting, Hadco designed a replacement for the integrated

ballast and socket module at the heart of the fixture. The new LumiLock

LED module replaced the original HID lamp with four rectangular ‘light bars’

housing one or two 10-LED boards each, but retained Hadco’s patented

‘twist-lock’ mechanism for tool-less disconnect and reconnect of the wiring

system. That mechanism – previously developed for easy relamping of the

HID post tops – would now permit easy installation of the LED upgrade.

With no LED board designers on staff , Hadco sought outside help to

develop the solid-state lighting assembly itself. “We were facing complex

decisions on everything from LED selection and board configuration to optics,

thermal management and even selection of the board manufacturer,” said

Michael Riebling, Hadco Solid-State Lighting R&D Manager. “It was a

project that had to be handled with a team that

specialises in LED application development.

Refraction actionHadco turned to Future Lighting Solutions for the

firm’s extensive LED application development tools

and in-house engineering expertise, as well as its

ability to supply the necessary LEDs, components

and manufacturing referrals. Future’s first step was

to analyse Hadco’s system requirements to

Hadco


recommend the best power LED

for the job.

The team quickly zeroed in on

the cool white LUXEON Rebel

product for several reasons. The

Rebel’s ultra-compact footprint would

allow tight clustering on each 10-LED board for optimal positioning on the

LumiLock module. It also had the ability to withstand higher drive currents

and elevated junction temperatures without sacrificing lifetime or reliability,

and it offered a minimum 100-lumen part that would deliver needed light

output with the fewest emitters to minimise costs and board real estate.

Next, Future’s optics experts performed a series of optical simulations to

determine how best to replicate the light distribution of the original HID

lamp. The refractive prisms on all of Hadco’s globe shapes are cut for a

360-degree metal halide light source, bending the light horizontally for

maximum coverage, minimum light trespass, and glare control as well as

shadow reduction. Future’s challenge was to develop a board design that

filled the globe with light to provide similar refraction capabilities with the

directional LED beam.

“It was a question of doing optical modeling to determine where the LED

arrays needed to be positioned on the LumiLock module and on the boards

themselves to deliver HID-equivalent optical performance,” said Michael

Quijano, Optical Design Engineer for Future Lighting Solutions. “We knew

we needed to cluster the LEDs toward the center of each light bar so that

the light would be coming from roughly the same location as the HID bulb,

but even moving the array 1 or 2mm up or down altered the effect.”

Heat, light and lifetimeWith the optical simulations completed and several scenarios provided for

Hadco to choose from, the work torch passed to Future’s thermal and

electrical engineers.

Using proprietary Future Lighting Solutions software, the team turned its

attention to determining the most appropriate drive current to ensure

optimum light output and life span. Exclusive Future tools were also used to

calculate the expected luminous flux of various combinations of drive

current, ambient temperature and heatsink thermal resistance levels, as well

as to provide thermal guidelines to aid Hadco in developing its custom

heatsink. This made it possible to evaluate alternative designs with accurate

LED modeling – requiring no prototyping that would slow down the design

process – and thereby optimise the performance of the final light engine.

In addition, Future engineers utilised Future-developed tools to calculate

the expected lifetime of the LED system based on the LED model, drive

current and junction temperature specified in the proposed design. Future’s

analysis predicted that Hadco’s design would provide a minimum 50,000-

hour working life at 70% lumen maintenance – precisely the goal outlined in

Hadco’s design criteria.

Mission accomplishedThe final design turned out to be more versatile and flexible than even

Hadco had imagined. The same four-light-bar LumiLock LED module, for

example, is able to provide an LED retrofit for both Hadco’s 100W and

175W metal halide post tops simply by utilising one or two 10-LED boards

per light bar, respectively. The same basic module also fits narrow and wide

globes with only minor manufacturing changes. This in turn simplifies

production and inventory management. “Our distributors have to stock only

four LumiLock LED SKUs to cover all of our non-glass refractive post tops –

one- and two-board versions for narrow and wide globes,” Riebling noted.

In addition, a patent-pending bracket system developed by Hadco

permits rapid conversion from symmetric to

asymmetric light distribution or vice versa

simply by unscrewing and reorienting two of

the module’s four light bars. This eliminates the

need to change globes or use a house-side

shield for different illumination patterns.

With that initial project completed, Riebling’s

team of designers began the process of

building LUXEON-based LED retrofits for the

rest of Hadco’s post top line. Eventually, the

company expects to offer LED replacements

for virtually every post top fixture in its

catalogue, ideally using the same basic module

design for every globe offering in the entire line

to help fixture owners reduce energy costs,

prolong lamp life, and lower the total cost of ownership.

Stay tuned: LUXEON-driven Hadco post tops will soon shine everywhere

from streets to shopping districts, industrial parks, parking lots and college

campuses – with Future Lighting Solutions helping to light the way.

Hadco’s quick-changeLED post top upgrade

hits the streets

Quick-swap LumiLockLED retrofit module forHadco’s post top fixtures

Hadco’s original HIDLumiLock module

Converting the module from asymmetricto symmetric light distribution for differentenvironments is as simple as 1-2-3

9

Future’s technical assistance simplified the selection and analysis of the entire LEDsystem, from the LEDs themselves to optical, thermal and driver solutions. They helped

us get to market faster as well as optimise the performance of our LED retrofit.

Michael Riebling, Manager, Solid-State Ligh ng R&D, Hadco ❞

❞

Hadco’s refractive prisms create a distinct light distribution pattern that had to beconsidered in developing the LED retrofit

3. Light now shines around entire perimeter

1. Remove screws from two light bars

2. Move bars to the spaces provided

Use of 10- or 20-LED boardsenables the same LumiLock

LED module to replace 100Wor 175W HID post tops

(Hadco is a Philips group brand)

Altman debuts LEDtheatrical lighting

Altman

In mid-2008, two theatrical/architecturalLED lighting fixtures from Altman Lightingtook a bow as the first products in theirclass. The Altman Spectra CYC 100 wasthe first four-channel LED cyclorama/wallwash luminaire, featuring amber LEDsadded to RGB to enable better coloursaturation and warmer white. The AltmanSpectra PAR 100 was the first four-channelPAR spot capable of producing fourdifferent beam spreads with a simple tool-free lens change. Both are capable ofcreating over 281 trillion colours.

F O R T E C H N I C A L A D V I C E A N D S U P P O R T E M A I L : L U M E N A T E @ F U T U R E L I G H T I N G S O L U T I O N S . C O M O R C A L L : 0 0 8 0 0 4 4 3 8 8 8 7 3 1 1

For these two products, we needed to develop our own light engines for the first time. Future Lighting Solutions played an important role in

helping us optimise our design, maximise our light output, identify the best colour bins for our purposes, and in general take our LED theatrical

lighting to the next level.

Gary Raymond Leonard, Director of Technical Sales & Marketing, Altman Lighting ❞

❞

“If you have two of our Spectra CYC 100 fixtures set six feet apart and

washing the wall on a play or concert, the colour has to be even and

smooth across the backdrop,” Ryan noted. “That can only be achieved if

your supplier can guarantee tight colour bins.”

Two stars are bornThe collaboration between Altman and Future resulted in two major new

colour-changing LED theatrical/architectural lights that break new ground in

several areas.

The Spectra CYC 100 is not only the first four-channel LED

cyclorama/wall wash luminaire, with the ability to produce both deeper

tones and warmer colours via the addition of amber LEDs, but also the first

true LED cyc light by virtue of optics not used in competing products. A

patent-pending LED lens reduces pixilation, for example, and an

asymmetrical reflector controls the beam as if it were a conventional

tungsten/halogen light. Light output is equivalent to a 1,000W quartz

Altman Focusing CYC with gels.

The Spectra PAR 100 is the first solid state PAR spotlight to offer

interchangeable lenses to achieve very narrow, narrow, medium and wide

beam spreads from the same fixture. True PAR lenses replicate the light

distribution of a standard quartz PAR – including a scalloping effect with the

medium and wide lenses that is not available from any other PAR LED

product.

Colourwise, both fixtures are compatible with DMX and RDM lighting

control protocols. They ship with a library of pre-programmed single colours

and colour mixes, enable four conventional colour luminaires to be replaced

with one, allow colour changes without using gels, and offer other standard

features of solid-state entertainment lights.

In addition, both fixtures provide

the usual lifetime, maintenance and

energy savings advantages of LED

illumination. The LEDs will last for an

estimated 50,000+ hours compared

to 2,000 for standard CYC and 600 for

standard PAR solutions, and each luminaire

consumes just 100W of power – far less than

either the 575W of a comparable PAR or the massive 4,000W draw of a

conventional four CYC set. The lower power consumption also makes it

possible to run many more fixtures on a single 20-amp circuit, both

simplifying setup and amplifying the lighting options in environments with

limited electrical capacity.

Good reviewsBoth Altman products quickly captured the attention of the entertainment

lighting community. Early users of the Spectra PAR 100 included

Disneyland, where multiple units now light up the theme park’s parade route

as well as the exterior of the It’s A Small World ride. Early users of the

Spectra CYC 100 included lighting designers for the Food Network’s

Ultimate Recipe Showdown 2 and New York Mercedes-Benz Fashion

Week, who praised the unit for everything from brightness, colour range

and even wash to the ability to quickly set the colour and intensity on

location without receiving detailed site layout information in advance.

Based on its early success with the fixtures, Altman is in the process of

expanding the line with an outdoor version of the Spectra CYC 100 as well

as RGBW and single white colour editions. Stay tuned: Altman’s next act

promises to be as interesting as the last.

With the help of LUXEON® Rebel LEDs as well as behind-the-scenes

assistance from Future Lighting Solutions, these new fixtures are helping

Altman simplify and improve lighting on stages and buildings around the

world – including well-known theme parks, museums, TV shows and

productions of all kinds.

Altman’s new actNew York-based Altman Lighting was one

of the first entertainment/architectural

lighting manufacturers to

add solid-state

luminaires to

its product

portfolio. The

company began

producing LED-based

fixtures in 1998, not only to

deliver benefits such as long lamp life, low heat

production and low energy consumption, but also to

equip the theatrical community with never-before-possible

digital colour mixing and dimming. Altman’s LED theatrical

lights were among the first to enable a palette of 16.8 million colours to be

generated from a single fixture with no gels or dimmers.

Until the release of the Spectra CYC 100 and Spectra PAR

100, however, Altman built its solid-state fixtures with off-the-

shelf light engines that were available only in a limited

number of configurations. That was the challenge the

company faced in 2008 when it recognised the

opportunity to use a then new, higher output LUXEON®

Rebel amber LED to raise the colour bar. “We wanted to

build four-channel luminaires with the addition of amber

LEDs to give lighting designers more range of dynamic

colours, better colour rendering, and better control in

the warm colour range that is a favourite in the theater

for skin tones, but only RGB light engines were

available,” said John T. Ryan, Director of R&D for Altman Lighting. “We

realised we would have to develop our own solutions from scratch.”


Altman’s Spectra PAR 100

Inside theSpectra PAR 100

RGBA on stageBased on a relationship with Future Lighting Solutions dating back to its

earliest LED product initiatives, Altman engineers turned to Future’s solid-

state lighting application development specialists for assistance. The Future

team recommended using LUXEON Rebel LEDs because of their small

package size – particularly useful for the CYC fixture – as well as their high

flux, forward voltage and heat tolerance. Then they utilised proprietary

Future tools to help optimise the lighting assembly design.

Altman originally considered using six red, green, blue and amber LEDs

in each fixture for a total of 24, for example, but wanted to increase the light

output. Future engineers calculated that the thermal capabilities of LUXEON

Rebel LEDs as well as the use of specific printed circuit boards would make

it possible to double the number of LEDs to 12 per colour for a total of 48

without overheating. The change not only doubled the light

output per fixture but also – in combination with widening the

viewing angle – reduced the number of luminaires required to

achieve the desired wall wash or spot illumination.

Future also assisted in designing the board layout to

achieve the desired light distribution via a linear LED array

for the cyc product and a hexagonal array for the PAR;

specifying the microcontrollers and power supplies;

identifying the best colour bins for Altman’s

purposes using Future’s internally developed

colour mixing tools; and providing binning

services and inventory management to ensure

colour consistency from fixture to fixture as well as

reliable LED supply. Future’s narrow colour binning was in

fact critical to the project.

Inside the Spectra CYC 100

Altman’s Spectra CYC 100

281 trillioncolours, four beam

spreads in one energy-saving PAR fixture

Braun


improve colour rendering for better visibility of street signs and other

objects; and simplify the process of creating the desired light distribution

because of the small form factor and optical properties of the LED package.

Braun was therefore determined to create a drop-in replacement module

that would fit into the existing gas lamp head. In April 2008, he met Future

Lighting Solutions at the Light+Building show in Germany. He learned that

Future could supply LUXEON LEDs from Philips Lumileds as well as provide

engineering support to ensure that the LED retrofit would meet his

requirements. His response? “Let’s get started.”

Design assistanceThe challenge was to design an LED retrofit that would use the same four

screw base sockets as the incandescent mantles in the existing gas lamps.

Braun furnished a concept drawing showing multiple LEDs mounted on

cone-shaped copper fittings that would screw into those sockets. Future’s

assignment was to recommend the best LED product for the project as well

as an LED layout that would match the brightness and light distribution of

the gas-illuminated street lights as closely as possible.

After evaluating Braun’s requirements, Future’s engineers recommended

LUXEON Rebel LEDs based on two key factors. First, they were the

smallest surface-mountable high power LEDs on the market and therefore

well-suited to the space limitations of Braun’s application, including the

need for a low profile due to a glass housing tightly coupled to the LED

assembly. Second, they were available in high volume in specified

correlated colour temperatures through Philips Lumileds’ proprietary

manufacturing process, making it possible to have a reliable supply of LEDs

in the warm-white colour range critical to achieving a beam colour

reminiscent of gas lighting.

The Future team then supplied proof-of-concept services through a

series of optical modeling exercises. With these simulations, the Future

team demonstrated that LEDs could meet Braun’s photometric

requirements, mapped the light distribution that would be produced from

the initial sketch, and suggested modifications such as a change in the

shape of the copper mountings that guided the final design.

Future assisted in other areas as well, from recommending the

appropriate driver for the application to using its proprietary Usable Light

Tool to calculate the number of LEDs required to produce the needed light

output. The original 64-LED module proved to be too bright for the purpose

and was cut back to 48, delivering 2000 lumens of total flux like the gas

fixtures it would be replacing.

“As a company, Braun had no

experience with solid-state lighting

design. They needed technical advice

and resources to build an LED retrofit

solution that would perform to their

specifications,” said Alexander Müller,

Business Development Manager at

Future Lighting Solutions. “This is the

case with most lighting designers

because LED application

development is still an emerging field,

and it’s why we offer our tools and

expertise to the industry.”

Berlin sees the lightArmed with Future’s optical design, Braun completed development of the

LED replacement module – including transforming the aluminum disk that

formerly collected the gas into a heatsink for LED purposes – and

contracted with one of Future’s network members to assemble the LED

boards. By December 2008, he had a demo unit that was installed in Berlin

as part of a search for a less expensive alternave to natural gas lighting.

Braun’s demo design won a test over three other manufacturers for its

innovative use of LED technology as well as its near-perfect replication of

the colour, brightness and light distribution of the gas originals. Separately,

in early 2009, eight Braun LED lamps were installed on Berlin’s famous

Alexanderplatz public square in front of the Rotes Rathaus (Red Town Hall),

the city’s seat of government. Outside, they look exactly like the historic gas

fixtures. Inside, they are powered by LUXEON technology.

“From an energy point of view, gas lamps have too many negatives. They

produce more heat than light – just 2 lumens per watt compared to 50

lumens per watt for LEDs. It is just a matter of time before they will be

converted to a more efficient light source,” Braun said. “There are 100,000

gas lamps throughout Europe, and we are targeting that market with our

LED retrofit. With Future’s assistance, we have a solution that we expect will

help us secure a substantial portion of that business.”

Braun brings the warmglow of gaslightsinto LED era

1 3

We wanted to develop an LED retrofit for historic gas lamps, butwe needed LED-specific engineering advice as well as assurancethat we could get a consistent supply of LEDs at the right colour

temperature. Future Lighting Solutions was able to provide both.

André Braun, President, Braun Schaltgeräte & Service ❞❞

Braun’s LED-driven street lamps installed on Berlin’s Alexanderplatz public square

Old-world charm on the outside, LED technology on the inside

Golden glow achieved with warm-white LUXEON LEDs

New LED module fits old gaslight formfactor

Vintage look without the high cost ofnatural gas lighting

Gas street lamps have largely gone the way of the horse and buggy, but

cities like Berlin, Prague and Warsaw and even a few towns and

neighbourhoods in the U.S. have clung to their historic gas lights

because of their old-time charm. Berlin-based Braun Schaltgeräte &

Service caters exclusively to this market, maintaining existing gas

lamps as well as manufacturing new ones that duplicate the older

designs. Now Braun is expanding into LED retrofit systems

that cut energy costs as well as multiplying lamp life

by a factor of more than 10. With Future Lighting

Solutions supplying LUXEON® Rebel LEDs and

providing vital support services such as optical modeling

to achieve the proper light distribution, Braun installed

eight ‘LED-Gaslights’ on a well-known public square in

Berlin in early 2009 and began approaching municipalities

looking for gas lamp retrofits.

Colour-critical projectAs Europe’s biggest manufacturer of gas-illuminated street

lights, Braun has long recognised the need to use a more

energy-efficient, longer-lasting light source in the existing gas

fixtures to assist municipalities dealing with ever tightening

budgets. The company began offering electrified inserts with

conventional compact fluorescent and mercury vapor lighting to

satisfy customers’ environmental demands over the short term,

but president André Braun was convinced that the future lay in

power LEDs. One critical reason was the quality of light.

“Gas lighting has a colour temperature of less than

2900K. This produces a distinctive golden glow that is

so tied into the character of cities like Berlin

that the public won’t accept anything else, and

that glow cannot be reproduced with cooler light

sources like mercury vapor and sodium vapor,”

Braun noted. “The only way to achieve a

comparable colour tone in a street lamp is with

warm-white LEDs.”

The usual solid-state efficiency and engineering

advantages applied as well. After retrofitting from gas-

driven lamps to Braun-LED-Gaslight, energy

consumption and related costs would be reduced by

more than 90%. The new lamps would also last more

than 50,000 hours compared to 4,000 for gas and an

average 16,000 for standard electrical illumination;


With LED technology rapidly improving light output and light quality, lighting companies are now looking to invest in a solid-statelighting strategy.


F O R T E C H N I C A L A D V I C E A N D S U P P O R T E M A I L : L U M E N A T E @ F U T U R E L I G H T I N G S O L U T I O N S . C O M O R C A L L : 0 0 8 0 0 4 4 3 8 8 8 7 31 4 1 5

FR4 board populated with nine LUXEON Rebel LEDs and 10mm Carclo optics form the lightengine. This is available through the simpleLED programme

Thermal simulations have been done at 350mA, 500mA and 700mA so that designers canimmediately see the different options available when designing the fixture

Custom reflector provides a widedistribution of light to replicate afluorescent tube in refrigeration application

Light measurements show that the light distribution and average lux achieved across thelit area meets the requirements for car parks

Moving from designing with conventional lamp sources to a rapidly evolving

technology such as high power LEDs can seem daunting. To help speed up

the learning and product concept development stages, Future Lighting

Solutions has developed a series of reference designs leveraging LUXEON®

Rebel LEDs. These designs will provide a

complete system solution to enable

applications in key market

segments, such as indoor general

lighting, car park lighting, and

commercial refrigeration lighting.

4-inch recesseddownlightThe reference designs makes use

of standard product offerings and

include detailed performance

information on the optical, thermal, and

power solutions,

which reduce time and

cost to market by

assisting customers in

meeting light output,

efficacy and lifetime

targets specified by

Energy Star. The

solution uses six

LUXEON LEDs with

the total power

consumption of the

system being 7.56W

after losses, providing

a total 398 lumens

with a system efficacy of 52.72 lm/W. All proposed power solutions,

whether they are module or IC based, support Triac dimming in order to

leverage existing lighting infrastructure.

Commercial refrigerationGenerating up to 75% in energy savings, the commercial refrigeration

lighting reference design provides a cost effective solution that is simple to

implement. The custom aluminum extrusion is designed to eliminate the need

for additional secondary optics and also provides the thermal management

required whilst also precisely directing the light from the LEDs with high level

of uniformity in the refrigeration unit. The extrusion is required to maintain

the 70% lumen maintenance at 50k hours.

Low-bay lightingThe low-bay light reference design was developed to generate an average

illumination of 75 lux with a very high level of uniformity leveraging 48

LUXEON Rebel LEDs and ultra wide optics. The concept produces 4311

lumens (after thermal and optical losses) and consumes only 57.77W of

power. The result is an illuminated area measuring 7.5m x 7.5m and with a

uniform illuminance of 75 lux.

To arrange a demonstration of the reference design demos and read further

information in the Applications Notes, please visit

www.futurelightingsolutions.com/services/referencedesigns.aspFR4 board populated with six LUXEON Rebel LEDs and Carclo 10mm optics to form the

light engine. The light engine is part of the simpleLED product program availableexclusively from Future Lighting Solutions

QLED thermal simulation shows how hot the LEDs will getin a real life situation. LEDs are tested at 350mA in ambientconditions of 20ºC. The junction temperature is maintainedat 88.7ºC, which means thermal management could bereduced to lower cost or the LUXEON Rebel could bedriven harder to maximise light output

6-inch recesseddownlight

The nine LED 6-inch

recessed downlight

reference design provides

two possible solutions to

meet Energy Star

requirements. The first is

to place a single optic

per LED, whilst the

second more flexible

option is to leverage a 9-LED

optic where the viewing angle

changes depending on the optic

mounting distance from the LED. The

system produces 751 lumens after thermal and optical losses, with a

system efficacy of 46.94lm/W.

Thermal simulation showing how thecustom reflector also acts as a heatsinkand allows the LEDs to run cooler

Accelerate product developmentwith Future Lighting Solutionsreference designs



The Usable Light Tool (ULT) was initially launched in 2007 and proved to be

a very useful and popular tool with its many users. Following feedback from

various types of users, Future Lighting Solutions developed ULT 2.0, which

significantly enhances the ability of users to make informed decisions on

selecting the appropriate LUXEON® Rebel LED, LED count, LED drive

current, and heatsink. This allowed users to determine the usable light that

will be generated under real world conditions for solid-state lighting

applications.

For the first time, users are able to easily visualise the LED system safe

operating area and how parameters such as flux, efficacy, forward voltage,

power consumption and junction temperature can be impacted by changes

in ambient temperature, heatsink thermal resistance and LED forward

voltage bin range.

One of the important ULT 2.0 enhancements is the addition of new

variables to be considered in the output calculations; circuit board type and

heatsink selection. The addition of these two new variables makes it easier

to approximate the thermal management of the solution, but more

importantly will provide more accurate performance data allowing users

higher confidence in the results.

Usable Light Tool 2.0

1 7

New thermal management section allows users to approximate the heatsink that be will used

Graphs from ULT 2.0 showing how changes in heatsink thermal resistance can affectusable flux and usable efficacy

Another new feature incorporated into Usable Light Tool 2.0 is the ability to

generate up to 40 parametric output charts as a function of:

• LED drive current

• Ambient temperature

• Heat sink thermal resistance

• LED forward voltage bin range

• LED flux bin range

“By leveraging the various output charts from ULT 2.0, users can dramatically

reduce the number of iterative scenarios they need to run to make clear

design tradeoff decisions,” said Patrick Durand, Future Lighting Solutions

Worldwide Technical Director. “These charts also facilitate validation and

justification of these decisions to colleagues and management to further

decrease time to market.”

Other new features include full compatibility with Future’s SSL Designer,

which has been developed to assist in designing the luminaire. When used

together they will allow the user to input data from ULT 2.0 into SSL Designer

to help develop the luminaire itself.

Usable Light Tool 2.0 is available at: www.futurelightingsolutions.com/ult.

Registered users can login with their existing Future Lighting Solutions

online tool username and password. New users can register at the same

location.

Usable Light Tool 2.0 makes it even easierto calculate real-condition light output

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F O R P R O D U C T S A N D S E R V I C E S V I S I T : W W W . F U T U R E L I G H T I N G S O L U T I O N S . C O M

Using LM-80 results to improveluminaire reliability

Understanding how lumen maintenance is affected by drive current andjunction temperature is key to developing a reliable luminaire. In theillumination industry, IES LM-80 is the standard that describes howlumen maintenance testing should be conducted for LEDs and how theLM-80 report should be formatted.

Philips Lumileds has taken the step to make publically available its LM-80

test reports for LUXEON® Rebel so that lighting manufacturers can have

access to its data to become more familiar with this important subject. This

allows luminaire manufacturers to compare the amount of light produced

from a light source when it is brand new to the amount of light output at a

specific time in the future.

The LM80 specifies that LEDs must be tested in real life application

conditions as opposed to datasheet measurements which are done at a

junction temperature of 25°C. LM80 requires to show the data of LEDs

tested at 55°C, 85°C and a third manufacturer selected case temperature at

nominal datasheet drive current to represent typical real life conditions.

Philips Lumileds also provide additional test data at higher drive currents

(700mA and 1,000mA) to reflect the broad operating range of LUXEON

Rebel and help its customers further.

The data shows all LEDs in the test population and how light output

changed over the course of 6,000 hours. A summary of the data is

provided at the end of each test so that you can see the average

performance in the test conditions.

Lighting manufacturers can then use this data to extend warranties on

their products or, where applicable, to submit for approval by Energy Star.

The graphs below show the results of the LM-80 tests at 350mA and

700mA, and they show LUXEON exceeds the Energy Star requirements for

commercial and residential required lifetime. The data requires a minimum

of 6,000 hours of testing and the lumen depreciation is recorded and

displayed as an average of a sample of LEDs.

The test data is then extrapolated to six times the test time to give an

expected L70 figure. Lumileds strongly recommend using six times the test

time to ensure credibility of the data. With Lumileds having over 10,000

hours of LUXEON Rebel test data they can confidently state a Lumen

Maintenance figure of 70% Lumen Maintenance after 60k hours.

The LM-80 tests are an easy way to understand how light sources react

under certain conditions, thus allowing confidence in selecting the right light

source for the right application. The data also highlights how LUXEON

Rebel is the ideal high power LED choice for solid-state lighting.

Details of test conditions to meet LM-80 tests criteria, and additional tests to show the capabilities of LUXEON Rebel

Lumen Maintenance projection for White LXM3-PWx1 LUXEON Rebel under theseconditions, 55°C, 0.35A (Tjunction 68°C) Normalised to 1 at 24 hours

LM-80 TESTS

Required LM-80 Test Temperature IF Actual TS Actual TA

Actual Δ[TA – TS]

Actual RelativeHumidity

Average lumen output @ 6,000 hrs

55°C 350mA 60° 64°C +4°C 18% 0.992

85°C 350mA 85°C 84°C -1°C 7% 0.962

108°C* 350mA 128°C 103°C -25°C TBD 0.979

*Third temperature chosen by the manufacturer and adjusted to meet -5°CTA – TS requirement

Documents

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