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02 / 2023 ver. 1.36 LED optics user and installation guide General information about assembling LEDiL products LEDiL LED optics user and installation guide LEDiL LED optics user and installation guide Materials Read the following instructions before using LEDiL products to ensure reliable assembly. PMMA & PC (Transparent plastic polymers in optics) Contents Materials Installation 24 PMMA & PC 3 Tape 24 Silicone (as a lens material) 3 Screw 25 General specifications for LEDiL PMMA grades 4 Glue 26 Heat durability of different materials 5 Potting 26 7 Press-fit 26 Glues / adhesives / potting / thread lock 7 Holder 26 Chemical resistance 8 Profiles 27 Silicone 8 PCB design 28 PMMA 8 LED assembly 28 PC 9 LED chip positions 29 Chemicals Stress cracking 16 LED compatibility tolerances 29 UV-Resistance 17 Distance between lenses 29 Plexiglas guarantee 17 Sealing and ingress protection of LEDiL optics 30 Silicone 17 Thermal management 31 PC 17 Heat sink machining 32 18 Thermal interface materials 32 Fire ratings 18 Thermal measurements 33 Hot Wire Ignition (HWI) 19 High Amp Arc Ignition (HAI) 19 Vacuum Evaporation PVD 35 Outdoor suitability 19 HMDS 35 LEDiL materials fire rating 20 Storage 36 Tensile strength 21 Links to useful information 36 Tolerances 22 Fire rating 2 3 Metal coating The information contained herein is the property of LEDiL Oy, Joensuunkatu 13, FI-24100 SALO, Finland and is subject to change without notice. Please visit www.ledil.com for additional information, such as the latest photometric files, 3D mechanical models, and application notes relating to handling, gluing and taping. 34 PMMA: • Rigid and hard • Average chemical resistance • Good UV-resistance (naturally UV-stable technology) • Good light transmission PC: • Very tough with excellent physical properties • Good chemical resistance • Good heat resistance • Average UV-resistance (LEDiL uses UV-stabilized clear PC-grade) In general, PMMA is harder and more fragile than PC, which has greater resistance to impact and heat. LEDiL uses many different types of PC in its products and the information given here is only valid for Makrolon 2407. Although other types of PC offer similar properties their performance should be verified separately. Transparent polymers can reflect, absorb and refract visible light. Absorption causes the temperature to increase in a lens and this should be taken into consideration during heat simulations. In general, PMMA lenses have higher light transmission rates meaning less light is absorbed. PC on the other hand has better heat resistance, but thicker parts can absorb more light resulting in increased internal temperatures. LEDiL uses UV-stabilized clear PC for optics and all materials are f1-rated (UL746C-standard is suitable for outdoor applications and meets UV and water exposure demands). Silicone (as a lens material) Silicone has excellent optical properties, great impact strength, durability and high thermal stability. Silicone’s elasticity allows complex optical and functional forms and low viscosity makes microstructural design possible. Silicone has high stability in ultraviolet light and ozone and can be used with UV LEDs where even UV stabilized plastics are unsuitable. Silicone: • Excellent optical properties with even better efficiency than glass • Elasticity allows complex optical and functional forms • High thermal and UV stability • Great impact strength • Lightweight design (lighter than glass) As part of our continuous research and improvement processes LEDiL reserves the right of changing material grades without further notice to ensure best possible quality and availability of our products. The information contained herein is the property of LEDiL Oy, Joensuunkatu 13, FI-24100 SALO, Finland and is subject to change without notice. Please visit www.ledil.com for additional information, such as the latest photometric files, 3D mechanical models, and application notes relating to handling, gluing and taping. 3 LEDiL LED optics user and installation guide LEDiL LED optics user and installation guide General specifications for LEDiL PMMA grades Heat durability of different materials All crystal clear PMMA grades we use share the same technical properties as shown in the table below. All grades have been subjected to comprehensive mechanical, environmental, and optical testing to ensure full compliance with our products. LED lighting consumes much less power compared to other light sources such as bulbs, fluorescent or energy saving lamps. These tiny light sources are at the focal point of worldwide continuous improvement constantly pushing the edge of heat resistance and luminous output. If the exact material grade used for each product is needed, please check the delivery certificate of conformity or contact us directly at tech.support@ledil.com. If in the early days of LED lighting the power consumption produced around 80°C or 90°C of heat, today the extremely large COBs can produce around 150°C. This direction has led to a situation where luminaire materials need to handle and dispose of more and more heat to ensure safe operation. To ensure the quality and availability of our products there may be possible material grade changes in our production. We therefore recommend sending product verification documents with all grade options. LEDiL standard PMMA Colour Crystal clear Transmittance (400nm - 800nm) 92 % ISO13468-2 Refractive index 1.49 ISO489 HB, 1.5 mm UL94 Outdoor suitability (IP products) f1 UL746C Relative temperature index (RTI) 90°C, 1.5 mm UL746 107°C* ISO306 Fire rating Vicat softening temperature Sources of heat Test method As a general rule 1/3 of an LED’s power consumption is turned into visible light and 2/3 into heat. There are three sources that produce heat in LED lighting: conduction, convection and radiation. All of these are extremely important when a new luminaire design is made but there are also other things to consider regarding heat generation. Some materials absorb more light than others. This means that an optic’s efficiency has a direct link to how hot the lens will get. All sorts of dirt, dust and grease on the optical surface block some of the light rays generating more heat inside the luminaire. During the product lifetime both of these effects tend to increase and therefore speed up the aging process. Every luminaire element and component that stops or reflects some of the light such as protective glass and shades, may also increase heat inside the luminaire and therefore speed up the aging process. *As a minimun and can be higher depending on the grade. Careful consideration should be given to all of these areas when designing a luminaire to ensure a safe and long product lifetime. LEDiL products are designed and manufactured to meet high efficiency values to help extend the product lifetime. Choosing the right material On the following page you can find a list of materials and recommended maximum service temperatures. Please note that because of the complex nature and numerous variables involved in luminaire design and manufacturing that affect the final product heat control, LEDiL cannot take responsibility for third party solutions and designs we can’t control. It is always the customer’s responsibility to determine and verify there is sufficient cooling and maintenance in the final product and its components. The information contained herein is the property of LEDiL Oy, Joensuunkatu 13, FI-24100 SALO, Finland and is subject to change without notice. Please visit www.ledil.com for additional information, such as the latest photometric files, 3D mechanical models, and application notes relating to handling, gluing and taping. 4 5 The information contained herein is the property of LEDiL Oy, Joensuunkatu 13, FI-24100 SALO, Finland and is subject to change without notice. Please visit www.ledil.com for additional information, such as the latest photometric files, 3D mechanical models, and application notes relating to handling, gluing and taping. LEDiL LED optics user and installation guide Colours Max recommended service temperature (°C) Specimen thickness (mm) (UL Specification) black, white, grey 70 1.5 - 3 metal 200* na clear, white 130 > 1.5 white 80** 1.5 white 105 > 1.5 PA66GF15 black, white 110 1.7 PA66GF30 black, white 110 1.5 PBT black, white 125 > 0.75 PC clear 90 (long term) 110 (short term) PMMA clear 80 1.5 HT PMMA (High temperature PMMA) clear 90 1.5 Polypropylene white 55 > 0.75 POM white 85 > 0.75 Silicone clear 150 >1 Gaskets white 150 >1 Material link to datasheets ABS Aluminium HTPC APEC (High temperature PC) (LISA2, RITA-A, RITA-B, RITA-WAS, BRITNEY-XW, BOOMMC-XW, LENINA-XW, LAURA-R-XW, LENA-X-WAS, TINA2-R-CLIP16, LEILA-R-CLIP16, LEILA, MINNIE-XW, MINNIE-LT-XW, SAGA-FRAME, MIRELLA-XW, MIRELLA40-XW, MIRELLA-50-XW, MIRELLA-50-WW-PF, REBECCARGB-HLD, BROOKE-XW, BARBARA-XW) HRPC2) (ANGELA, ANGELINA, BARBARA) Tape Glues / adhesives / potting / thread lock We strongly recommend that every customer fully tests and takes the necessary precautions to ensure there is complete chemical compatibility with each particular product, LEDs and other components. Testing and verifying adhesives, potting agents, coatings and their combinations are always the responsibility of the customer. Please also see sealing and ingress protection chapter on page 29. > 0.75 *** General instructions of use All surfaces where adhesive is applied must be clean, dry and free from grease and dirt. If the PCB surfaces need to be cleaned, please follow the LED manufacturer cleaning instructions carefully – this is important as cleaning should, under no circumstances, damage LEDs or other electronic components on the PCB. Please note optical components should not be cleaned with chemicals – only a micro fiber cloth should be used to remove fingerprints or other traces from handling. To clean silicone lenses use a low-pressure stream of water. We recommend cleaning metallized reflectors with gentle air pressure or an air ionizer. When using adhesive, please follow the detailed instructions of the adhesive manufacturer. E.g. note that different humidity and/or temperature levels may slow down the curing process of the adhesive bond or shorten its lifetime 120 Metallization methods Product families ANGELETTE-WAS, BARBARA, BLONDIE, BOOM, BOOMERANG, BRIDGET, BRITNEY, BRITNEY-TE, BROOKE, LENA, LENINA, MINNIE, MIRELLA, REGINA, VENLA 80 (same as base material) * Based on our tests, should not be run hotter. **UL nominal value. Heat deflection temperature 0.45 MPa, Unannealed 127 °C. Max recommended service temperature (°C) Max recommended service temperature (°C) 150 150 120 120 80 80 > 1> 1 55 55 150 150 85 85 > 0.75 > 0.75 80 80 > 0.75 > 0.75 110 110 1.51.5 125 125 ***Constant operation at maximum limit can cause the material to age prematurely. Specimen thickness (mm) (UL Specification) Specimen thickness (mm) (UL Specification) > 0.75 > 0.75 110 110 > 0.75 > 0.75 110 110 1.51.5 > 1.5 > 1.5 1.51.5 80 80 70 70 > 1.5 > 1.5 105 105 1.71.7 130 130 1.51.5 - 3- 3 ANGELA, ANGELETTE, ANGELINA, BARBARA-G2, BARBARA-XX-PF, BROOKE-G2, ELLA, DAISY (SHD-MET), LENINA-HMDS, MIRELLA-G2, TYRA, TYRA2, TYRA3 110 HMDS Metallization LEDiL disclaimer: Same Same as base as base material material PVD + lacquer (Metallized reflectors) 180 180 160 160 140 140 120 120 100 100 80 80 60 60 40 40 20 20 0 0 Chemicals (High reflective PC) LEDiL cannot take responsibility for the results obtained by third party methods we cannot control. It is always the customer’s responsibility to determine the chemicals suitability for their product and to take precautions for protection of property and persons against any hazards that may be involved in the handling and use such of chemicals. LEDiL disclaims all warranties, including warranties of merchantability or suitability for a particular purpose, arising from use of any adhesive product. LEDiL disclaims any liability for consequential or incidental damages of any kind, including lost profits. > 1> 1 HRPC 1) LEDiL LED optics user and installation guide More information about bonding by DELO or Henkel www.ledil.com/delo-adhesives www.ledil.com/henkel-adhesives COLD TEMPERATUES Please note that in cold temperatures plastics tend to be harder, stiffer and more brittle. Both PMMA and silicone optics can be used in -40°C, but please note that while PC optics can also be used in cold temperatures its impact strength decreases gradually. E.g. in -30°C polycarbonate impact strenght is equal to PMMA. Charpy notched impact strength (kJ/m2) PC 2407 60 40 20 0 Tested materials and test procedure by CREE www.ledil.com/cree-chemical-compatibility -30°C NOTE: These tests have been made only with LEDs and are not necessarily compatible with optical materials.Compatibility must be tested in advance by the customer. 23°C The information contained herein is the property of LEDiL Oy, Joensuunkatu 13, FI-24100 SALO, Finland and is subject to change without notice. Please visit www.ledil.com for additional information, such as the latest photometric files, 3D mechanical models, and application notes relating to handling, gluing and taping. 6 7 The information contained herein is the property of LEDiL Oy, Joensuunkatu 13, FI-24100 SALO, Finland and is subject to change without notice. Please visit www.ledil.com for additional information, such as the latest photometric files, 3D mechanical models, and application notes relating to handling, gluing and taping. LEDiL LED optics user and installation guide LEDiL LED optics user and installation guide Chemical resistance PC Silicone General chemical behaviour LEDiL silicone lenses are made of VMQ, Vinyl Methyl group, general purpose silicone. The chemical resistance of Makrolon® depends on the concentration of the substance, the temperature, contact time and internal tension level of the polycarbonate sheet depending on fabrication. The following types of damage can arise, sometimes more than one at the same time. For more information: www.ledil.com/dow_corning_fluid_resistance_guide • Dissolving / Swelling Low-molecular, aromatic, halogenated and polar components migrate into the plastic. The damage can range from a sticky surface to complete dissolving. PMMA The chemical resistance of mouldings made from Plexiglas moulding powder (tables on pages 9-14) • Stress cracking • The behaviour in the tables on pages 9 to 14 relate to a test temperature of 23°C, a relative humidity of 50% and mouldings with few internal stresses. Some chemicals migrate to a minor extend and in very low quantity into the surface, and lead to relaxation of tensions in the material. This results in stress cracking, which can be optically disturbing. Because of increased notch occurance, some mechanical properties are negatively influenced. Stress cracking is usually easy to see in transparent sheets. • The behaviour of injection mouldings made from Plexiglas moulding powder depends in practice on the internal and external stresses, the orientation in the moulding and the change of temperature in the resistance to solvents and swelling. • Plexiglas moulding powder resists all factors met in normal use such as water, perspiration, ink, lipstick, alkaline solutions and weak acids. • Molecular reduction • As a result of the chemical structure, most organic solvents, e.g. aromatics, dissolve Plexiglas moulding powder which does, however, resist aliphatic hydrocarbons. Some properties of materials are determined by the molecular weight. If a substance initiates a molecular reduction through a chemical reaction, the impact resistance and elastic properties of the material will be influenced. Electrical properties are usually not influenced, thermal properties are only slightly influenced by the molecular weight. • Do not join Plexiglas moulding powder to plasticized thermoplastics and elastomers because some plasticisers migrate at high temperatures. • Mouldings occasionally show residual stresses caused by processing or use, but this does not have a negative effect on their resistance to fracture. Inducing to solvents or swelling agents may however cause crazing. In the following tables (pages 9-14) you can find the resistance of Makrolon® to chemicals and several other substances. The test results have been obtained at samples with low internal tensions, which have been stored during 6 months in the substance at a temperature of 20°C, without any mechanical load. • The material compatibility should be tested in advance in the actual application conditions. Apart from the nature of the substances, the chemical resistance also depends on the concentration of the substance, the temperature during the contact, the contact time and the internal tension of the tested specimen. This means that our products can be resistant to a number of chemicals for short contacts, but are not resistant in the case of long exposure, such as performed in these tests. Therefore, it is always recommended to execute a test in the actual application conditions. The tested substances have been chosen according to their importance in several areas. In a lot of cases it is possible to assume similar results for other chemically comparable substances, even if these have not been tested. Our UV-protected materials (Makrolon® UV) are slightly more sensitive to chemicals in comparison to unprotected materials, but in general the results shown in the table still comply. The information contained herein is the property of LEDiL Oy, Joensuunkatu 13, FI-24100 SALO, Finland and is subject to change without notice. Please visit www.ledil.com for additional information, such as the latest photometric files, 3D mechanical models, and application notes relating to handling, gluing and taping. 8 9 The information contained herein is the property of LEDiL Oy, Joensuunkatu 13, FI-24100 SALO, Finland and is subject to change without notice. Please visit www.ledil.com for additional information, such as the latest photometric files, 3D mechanical models, and application notes relating to handling, gluing and taping. LEDiL LED optics user and installation guide Substance PC PMMA X - Acetaldehyde Substance PC PMMA Benzaldehyde X - LEDiL LED optics user and installation guide Substance PC PMMA Carbon disulphide X X Substance PC PMMA Diethylene glykol R - Acetic acid, up to 10% solution R - Benzene X - Carbon monoxide R R Diethylether X - Acetone X X Benzoic acid X - Carbon tetrachloride - X Diglycolic acid, saturated aqueous solution R - Acetylene R - Benzyl alcohol X - Castor oil R - Dimamin T, 5% O - Acid-containing combustion gasses R - BFK cleaner - R Cellux-sticking foils ® R - Dimethyl formamide X - Acrylate sealing compounds - X Bitumen emulsion - X Cement R R Dinonyl phthalate (plasticizer) O - Acrylic paints - O Bleach - R CHINOSOL, up to 1% - R Dioctyl phthalate (plasticizer) O - Acrylonitril X - Bleaching agent R - Chlor. lime paste (sas) - R Dioxane X - Ajax ® R R Blood R - CHLORAMIN, paste - X Diphyl 5,3 O - Alcohol, concentrated - X BOLIMENT - O CHLORAMIN, solution - R Dor ® R R Alcohol, up to 30% - R Borax, saturated aqueous solution R - Chlorine benzene X - DOSYL - R All purpose adhesive - O Boric acid R - Chlorine gas, dry O - DOSYLAN - R All-purpose glue O - BOTTCHERIN - R Chlorine gas, wet X - Drilling oil X - Allylalcohol O - BP Energol EM 100 ® R - Chlorine lime slurry R - E 605 ®, 0,5% (pesticide) X - Alum R - BP Energol HL 100 ® R - Chlorine lime, 2% in water R - E 605 ®, conc. X - Aluminum chloride, saturated aqueous solution R - BP H LR 65 ® R - Chlorine vapours, dry - O Electroplating baths - R Aluminum oxalate R - Brake fluid (ATE) X - Chloroamine R - ELMOCID GAMMA, up to 2% - R Aluminum sulphate, saturated aqueous solution R - Bromic benzene X - Chloroform X - Esso Estic 42-45 ® R - Ammonia X R Bromine X - Chrom alum, saturated aqueous solution R - Ether X - Ammonia solution acids - R Bromine vapours, dry - O Chromic acid, 20% in water R - Ethyl alcohol, 96% pure R - Ammoniacal liquor X - BURMAT - R CILLIT-GRON - R Ethyl amine X - Ammonium chloride, saturated aqueous solution R - BURNUS - R Citric acid R - Ethyl bromide X - Ammonium nitrate, saturated aqueous solution R - Butane (liquid or gaseous) R - Citric acid, up to 20% (sas) - R Ethylene chlorhydrine X - Ammonium sulphate, saturated aqueous solution R - Butanol R - Cleaning gasoline R - Ethylene chloride X - Ammonium sulphide, saturated aqueous solution X - Butyl acetate X - CLOPHEN T 55, A 60 - R Ethylene glykol R - Amylo acetate X - Butyl lactate - X Coal gas, natural gas - R FAKO polish - R Anfistatic plastics cleaner and preserving agent - R Butylene glycol R - Cod-liver oil R - FAKO polishing paste - R Aniline X - Butyric acid X - Contact oil 61 R - Ferritrichloride, saturated aqueous solution R - Antimony chloride, saturated aqueous solution R - Cable isolation oil IG 1402 R - Copper sulphate, saturated aqueous solution R - Ferro bisulphate R - Antistatik C, 5% X - Cable isolation oil KH 190 R - Corrosive sublimate - R Fewa ® R R Antistatikum 58 O - Calcium chloride,saturated aqueous solution, R - Cresol X - Final-photo developer (normal use concentration) R - Antistatischer Kunst-stoff-Reiniger + Pfleger - R Calcium hypochloride R - Cupric chloride, saturated aqueous solution R - Fish oil R - Aqueous solutions of pesticides - O Calcium nitrate, saturated aqueous solution R - Cuprous chloride, saturated aqueous solution R - Foam plastics - R Aral BG ® 58 R - Calcium soap, fat/pure R - Cyclo hexane X - Foam plastics, plasticise - X Arquad 18 ®, 50% O - Calciumsoap fat R - Cyclo hexanol O - Formaline, 10%ig R - Arsenic acid, 20% solution R - Calgonit ® dishwassing X - Cyclo hexanone X - Formic acid, 30% O - Baktol®, 5% R - Calgonit ® rinsing agent R - DDT X - FRAPPIN - R BAKTOLAN, conc. - X Calgonit D ®, DM, DA, R X - DEKALIN - O Freon ® TF (propellant) R - BAKTOLAN, up to 5% - R CALGONIT D, DA, S - R Dekaline R - Freon ® T-WD 602 (propellant) R - Ballpoint paste Diplomat O - Calgonit S ®, 1% R - Delegol ®, 5% R - Frigen ® 113, R113 (propellant) R - Ballpoint paste Othello O - Camphor oil X - Delu-Antistatiklösung ® R - FRIGEN A 12 (CF2 Cl2) - O Ballpoint paste V77 (Linz) R - Carbolic acid X - Diamyl phthalate X - Fuel oil O O - Basilit ® UAK, 20% in water (wood protection agent) R - Carbolic acid (sas) - X Dibutyl phthalate (plasticizer) X - FULLBOX - R Battery acid R - Carbon acid, wet R - DIEGEL liquid film 23922 - R GASOLIN, depending on the blend - O Baysilon ® Silicone oil R - Carbon dioxide - R Diesel oil O - Gasoline R - R = Resistant O = Limited resistance X = No resistance v = Vapour c = Concentrate g = Gas R = Resistant O = Limited resistance X = No resistance m = Metallic sas = Saturated aqueous solution i.w. = In water The information contained herein is the property of LEDiL Oy, Joensuunkatu 13, FI-24100 SALO, Finland and is subject to change without notice. Please visit www.ledil.com for additional information, such as the latest photometric files, 3D mechanical models, and application notes relating to handling, gluing and taping. 10 11 v = Vapour c = Concentrate g = Gas m = Metallic sas = Saturated aqueous solution i.w. = In water The information contained herein is the property of LEDiL Oy, Joensuunkatu 13, FI-24100 SALO, Finland and is subject to change without notice. Please visit www.ledil.com for additional information, such as the latest photometric files, 3D mechanical models, and application notes relating to handling, gluing and taping. LEDiL LED optics user and installation guide Substance PC PMMA Substance PC PMMA Gasoline, normal O - LAVAPLEX - R Gasoline, super X - Lead tetraethylene, 10% in gasoline O Geha stamping ink R - Lighting gas R GLYBAL A - X Ligroin (hydrocarbon compound) Glycerine O - Glycol R - Green chrom oxide (polish paste) R Green soap R LEDiL LED optics user and installation guide Substance PC PMMA Substance PC PMMA NEOMOSCAN M, M-powder - R Persil ® O R - Neutol ® photo developer (normal use concentration) - NEXION stable spray R - Persoftal ®, 2% R - - R Perspex Polish 3 ® R R - - Nickel sulphate (sas) - R Petrol ether - R Lime milk, 30% in water O Lubricant based on nafta R - Niroklar GR liquid - R Petrol, contg. aromatic substances - X - Niroklar GR powder - R Petrol, non-aromatic - R - Lubricant based on paraffin - Lubricant R2 Darina ® R - Nitric acid, 10% R - Petrol, pure - R R - Nitric acid, 10-20% O - Petroleum O O Gypsum - R Lugol solution - R Nitric acid, 20 to 70% i.w. - O Petroleum ether O - HB 155 - R LYSOFORM - X Nitric acid, 20% X - Petroleum spirit R - Heptane R - Lysoform, 2% R - Nitric acid, over 70% i.w. - X Phenol X - Hexane R - Magnesium chloride - R Nitric acid, up to 20% i.w. - O Phenols - X Horolith M ® R - Magnesium chloride, saturated aqueous solution R - Nitric Gas, dry X - Phenyl ethyl alcohol X - Hot bitumen - O Magnesium sulphate - R Nitrobenzene X - Phosphates - R Household soap R - Magnesium sulphate, saturated aqueous solution R - Nitrocellulose lacquers - X Phosphonc acid, up to 10% i.w. - R Hydraulik oil Vac HLP 16 R - Maktol ® R - Nitrogen dioxide - R Phosphor trichloride X - Hydrochloric acid (c) - R Manganous sulphate, saturated aqueous solution R - Nitrogen monoxide - R Phosphoric acid, conc. R - Hydrochloric acid, 20% R - Marlon ®, 1% (moisturizing agent) R - O Sprays (in the surroundings) - O Phosphoric oxichloride X - Hydrochloric acid, conc. X - MEFAROL, up to 1% - R Oil paints, pure - R Phosphorus trichloride - X Hydrofluoric acid, 5% R - MERCKOJOD, up to 1% - R Oktozon ®, 1% R - Phosphorus, white - X Hydrofluoric acid, conc. X - Mercuro chloride, saturated aqueous solution R - Oleic acid, conc. R - Photochemical baths - R Hydrofluorosilicic acid, 30% R - Mercury R R Omo ® R - Picric acid, 1% i.w. - R Hydrogen peroxide R - Merfen ®, 2% R R Orthozid ® 50, 0,5% (pesticide) R - Plaster R - Hydrogen peroxide, 30% R - Metasystox ®, 0,5% (pesticide) X - Oxalic acid (sas) - R Plasticiserfree glazing kit R - Hydrogen peroxide, over 40% i.w. - O Methacrylic acid-methyester (MMA) X - Oxalic acid, 10% in water R - Plexiklar ® R R Hydrogen peroxide, up to 40% i.w. - R Methane R R Oxygen R R PLEXISOL adhesive - O Hydrogen sulphide R R Methanol X - Ozone R R PLEXIT - O Impact ®, 0,2% O - Methanol, concentrated - X P3 - R PLEXTOL adhesive - R Indian ink S X - Methanol, up to 30% - O P 3 basic cleaner - O PLK 4 (wood protection agent) R - Indian ink T R - Methyl amine X - P3 Asepto ® X - Polifac grinding paste ® R - Industrial spirit - X Methyl ethyl ketone (MEK) X X PALATINOL K - R Polishing wax R - Insulating tape - R Methylene chloride X - PALATINOL O, BB neu - O Polyamide R R Into-Fensterklar ® R - Mobil DTE Oil-Light ® R - Pantex ®, 2% R - Polyethylene R R Iodine X - Mobil Special Oil 10 W 30 ® R - Paraffin oil R - Polymer plasticizer O O - Iodine tincture O - Molikote ® -Paste R - PATTEX special glue - O Polyran ® MM 25 (lubricant) R - Isoamyl alcohol O - Molikote ® -Powder R - Pelikan Royal Blue 4001 R - Polyvinylchloride (plasticizer free) R - Isolation tape R - Monobromonaphthalene - R Pentane R - Polyvinylchloride, (containing plasticizer) O - Isolation tape R - Mortar - R PERBUNAN - R Potassium aluminum sulpate, (sas) R - Isopropyl alcohol R X Motor fuel blend contg. Benzene - X Perbunan C ® R - Potassium bichromate, (sas) R - Jet engine fuel JP 4 (Kp 97-209°C) O - Motor fuel blend, free from benzene - R Perchloric acid, 10% in water R - Potassium bromide, (sas) R - Kaltron ® 113 MDR (propellant) R - Multi-Marker (Faber-Castell) O - Perchloric acid, concentrated O - Potassium carbonate, (sas) R - Kerosene (Flugbenzin) X - Nato-Turbine oil 0-250 R - Perchloro ethylene X X Potassium chloride, (sas) R - KOPPERSCHMIDT covering paste - R Natril ® R - Perhydrol R R Potassium cyanide X - Lactic acid, 10% in water R - Natural rubber R - Perhydrol, 30% R - Potassium hydroxide X - Lactic acid, up to 20% i.w. - O Nekal BX ®, 2% (moisturizing agent) R - PERODIN - R Potassium metabisulphide, 4% in water R - R = Resistant O = Limited resistance X = No resistance v = Vapour c = Concentrate g = Gas R = Resistant O = Limited resistance X = No resistance m = Metallic sas = Saturated aqueous solution i.w. = In water The information contained herein is the property of LEDiL Oy, Joensuunkatu 13, FI-24100 SALO, Finland and is subject to change without notice. Please visit www.ledil.com for additional information, such as the latest photometric files, 3D mechanical models, and application notes relating to handling, gluing and taping. 12 13 v = Vapour c = Concentrate g = Gas m = Metallic sas = Saturated aqueous solution i.w. = In water The information contained herein is the property of LEDiL Oy, Joensuunkatu 13, FI-24100 SALO, Finland and is subject to change without notice. Please visit www.ledil.com for additional information, such as the latest photometric files, 3D mechanical models, and application notes relating to handling, gluing and taping. LEDiL LED optics user and installation guide Substance PC PMMA Potassium nitrate, saturated aqueous solution R - Potassium perchlorate, 10% i.w. R Potassium permanganate, 10% i.w R Potassium persulphate, 10% i.w. Substance PC PMMA Silver nitrate (sas) - R - Skydrol 500 A ® X - Soap solution - R - Soap suds O Potassium rhodanide, (sas) R - Sod. hydroxide soln. Potassium sulphate, (sas) R - Soda Pril ® R R Soda water Propane gas R - Sodium bicarbonate, (sas) Propargyl alcohol R - Sodium bisulphate, (sas) Propionic acid, 20% R - Sodium bisulphide, (sas) Propionic acid, conc. X - Sodium bisulphite Propyl alcohol R - Sodium carbonate Propylene - R Sodium carbonate, (sas) Putty R - PVC - R LEDiL LED optics user and installation guide Substance PC PMMA Substance PC PMMA Sulphurous acid, 10% X - Turpentine - O - Sulphurous acid, (c) - O Turpentine ersatz R - R Sulphurous acid, up to 5% - R Turpentine substitute - O - Sulphuryl chloride X R Urea, (sas) R - - R Suwa ® R - VALVANOL, up to 2% - O R R Sweat, acid (pH 4,7) R - Valvoline WA 4-7 O - - R sweat, alkaline (pH 9,5) O - Varnish O R - Tanigan ® CLS, 30% O - Waste gases contg. hydrochloric acid R - Tanigan ® CV O - R - Tannic acid X - - R Tanning oil Brunofix ® R - - R Tartaric acid, 10% R - R - Tartaric acid, 50% i.w - Sodium chlorate (sas) R R TB Lysoform Sodium chloride (sas) R R TERAPIN - R Waste gases contg. sulphuric acid - R Water R - WC-00 - R Whale fat R - R Visor-Pen 7 blau R - X - WK 60 ® (Kron-Chemie) R - - R X Sprays (applied directly) - X PVC, plasticised - X Sodium hydroxide X - Terostat ® R - Xylene X X Pyridine X X Sodium hypochloride, 5% in water R - Tesafilm ® R - Zephirol ® O - RABOND stable spray - R Sodium hypochlorite - R Tesamoll ® R - ZEPHIROL, up to 5% - R Rapdosept ® O - Sodium soap fat R - Test fuel X - Zinc chloride, (sas) R - Rape oil R - Sodium sulphate - R Tetrachlorocarbon X - Zinc oxide R - Red lead - R Sodium sulphate, (sas) R - Tetrachloroethane X - Zinc sulphate, aqueous - R Register-ink DIA type U rot R - Sodium sulphide - R Tetrahydrofurane X - Zinc sulphate, (sas) R - Rei ® R R Sodium sulphide, (sas) O - Tetralin - X Zinc sulphate, solid - R Resorcin oil solution, 1% R - Somat W ® 731 O - Tetraline X - ÄTHROL, up to 5% - O Resorcinol solutions, 1% R - SPECTROL - X Texaco Regal Oil BRUO ® R - Riseptin ® R - Spirit, pure R - Texaco Regal Oil CRUO ® R - Rubber - R SPRAYLAT - O Thenocalor N R - Rubber, plasticised - X SPULI - R Thinners in general - X Sagrotan ®, 5% O O Stain remover Alkaline solutions - X Thiokol rubber (one- and two-component grades) - X SAGROTAN, up to 2% - R Stannous chloride - R Thionyl chloride - X SANGAJOL - R Starch R - Thiophene X - Sea water R - Statexan AN ® R - Tincture of iodine, 5% - X X Sealing strips, (FAKO, TEROSTAT, PRESTIK) - R Stearic acid - R Toluene X SEIFIX - R Styrene X - Trichloro acetic acid, 10% O - Sewing machine oil R - Sublimate R - Trichloroacetic acid - X Shell IP 4 (fuel) X - Sublimate, (sas) R - Trichloroethyl amine X - Shell Spirax 90 EP ® R - Sulphur R - Trichloroethyl phosphate (plasticizer) O - Shell Tellus 11-33 ® O - Sulphur (c) - R Trichloroethylene X - Shell Tellus 33 ® O - Sulphur dioxide O - Tricresyl phosphate - R Sidolin ® R X Sulphur dioxide (dry) - R Tricresyl phosphate (plasticizer) X - Silicon tetrachloride - X Sulphur dioxide, liquid - X Triethylamine - R Silicone oil R - Sulphuric acid, 50% R - Trosilin F ® extra, 2% R - Silicone rubber (acetic acid curing) - O Sulphuric acid, 70% O - Trosilin G extra ®, 1,5% R - Silicone rubber (Camino curing) - R Sulphuric acid, conc. X - Tuba ® carpet shampoo, (c) O - Siliconoil emulsion R - Sulphuric acid, up to 30% i.w. - R Turbo oil 29 R - R = Resistant O = Limited resistance X = No resistance v = Vapour c = Concentrate g = Gas R = Resistant O = Limited resistance X = No resistance m = Metallic sas = Saturated aqueous solution i.w. = In water The information contained herein is the property of LEDiL Oy, Joensuunkatu 13, FI-24100 SALO, Finland and is subject to change without notice. Please visit www.ledil.com for additional information, such as the latest photometric files, 3D mechanical models, and application notes relating to handling, gluing and taping. 14 15 v = Vapour c = Concentrate g = Gas m = Metallic sas = Saturated aqueous solution i.w. = In water The information contained herein is the property of LEDiL Oy, Joensuunkatu 13, FI-24100 SALO, Finland and is subject to change without notice. Please visit www.ledil.com for additional information, such as the latest photometric files, 3D mechanical models, and application notes relating to handling, gluing and taping. LEDiL LED optics user and installation guide Stress cracking LEDiL LED optics user and installation guide UV-resistance LEDiL products are designed and manufactured to avoid internal stress as much as possible, but this can’t be totally avoided. Common optical grade thermoplastics are vulnerable to cracking from a combination of external or internal stress sources and chemicals. Plastics degenerate differently when exposed to UV-light. Some plastics may show dramatic changes, turning yellow or losing some of their transmission properties over a long period of time. This must be considered when choosing materials for your application. Even relatively small concentrations of stress-cracking agent may be sufficient to cause the cracking, but in many cases it´s caused by a combination of several factors. LEDiL has conducted extensive UV-testing over the years for various different materials and found that even materials that tend to have very heavy yellowing will not significantly suffer from efficiency loss. However yellowing may cause the colour temperature to change to warmer tones. Possible factors that cause cracking Plexiglas guarantee • Manufacturing process PLEXIGLAS® guarantees their materials will not show yellowing and will retain a high level of light transmission for 30 years. • Temperature changes - Thermal expansion and shrinking For more information: www.ledil.com/plexiglas_guarantee • Chemical exposure - Detergents - Surface active chemicals - Lubricants - Oils - Ultra-pure water - Plating additives such as brighteners and wetting agents - Lock-thread fluids PMMA High UV-resistance with no yellowing. For better impact resistance protective glass is needed. Silicone • Screw type, torque and other fastening methods Dow Corning ® MS silicones have very high UV-resistance with no yellowing, and are highly transparent to radiation all the way down to IR-wavelengths. PC Good for applications that require higher impact resistance, but will show noticeable yellowing over time when exposed to UV-radiation. Therefore LEDiL does not recommend using products made of PC in applications where exposure to UV-radiation is high. To avoid yellowing special filtering glasses can be used to block out all the damaging UV from sunlight. After a very long period of time ultraviolet light may also cause some brittleness in the material and LEDiL recommends using plastic washers with fasteners to decrease mechanical stresses. See our video about chemicals in LED lighting https://youtu.be/lZUkBsXcnCU The information contained herein is the property of LEDiL Oy, Joensuunkatu 13, FI-24100 SALO, Finland and is subject to change without notice. Please visit www.ledil.com for additional information, such as the latest photometric files, 3D mechanical models, and application notes relating to handling, gluing and taping. 16 17 The information contained herein is the property of LEDiL Oy, Joensuunkatu 13, FI-24100 SALO, Finland and is subject to change without notice. Please visit www.ledil.com for additional information, such as the latest photometric files, 3D mechanical models, and application notes relating to handling, gluing and taping. LEDiL LED optics user and installation guide LEDiL LED optics user and installation guide Hot Wire Ignition (HWI) Test specimens are wrapped with resistance wire that dissipates a specified level of energy. HWI is the time it takes to either ignite or burn through a specimen. Performance Level Categories (PLC) were introduced to avoid excessive implied precision and bias. Fire rating HWI Mean Ignition Time (sec) PLC0 PLC1 PLC2 PLC3 PLC4 PLC5 Fire resistance testing is carried out as stated in the UL94 standard. The standard classifies plastics according to the burning rate in different positions and different-sized pieces. All LEDiL materials have UL94 standard fire rating. For metallized products UL-class confirmation tests were carried out by Tampere University of Technology. High Amp Arc Ignition (HAI) Fire ratings • HB 120 and longer 60 through 119 30 through 59 15 through 29 7 through 14 80 ± 1.6 are not applicable to extrusions, blowmoulded or foamed mouldings, deep drawn parts, sintered parts and parts produced by a chip removal machining process. ISO 3302-1 Class M3 International Standard ISO 3302-1 was prepared by Technical Committee ISO/TC 45, Rubber and rubber products, Subcommittee SC 4, Miscellaneous products. The tolerances are primarily intended for use with vulcanized rubber but may also be suitable for products made of thermoplastic rubbers. The information contained herein is the property of LEDiL Oy, Joensuunkatu 13, FI-24100 SALO, Finland and is subject to change without notice. Please visit www.ledil.com for additional information, such as the latest photometric files, 3D mechanical models, and application notes relating to handling, gluing and taping. 22 23 The information contained herein is the property of LEDiL Oy, Joensuunkatu 13, FI-24100 SALO, Finland and is subject to change without notice. Please visit www.ledil.com for additional information, such as the latest photometric files, 3D mechanical models, and application notes relating to handling, gluing and taping. LEDiL LED optics user and installation guide LEDiL LED optics user and installation guide Screw The following is only general information and for more details about tightening and exceptions please download the datasheet for each product. For most of the products screws are of type M3. (DIN 7985, ISO 7045/ISO 14583 TX), with maximum tightening torque of 0.6 Nm. Installation Countersunk screws are not allowed, and self-tapping screws are not recommended. Thread forming or rolling screws are not allowed due to lack of control of the tightening torque. (Screws will most likely exceed the recommended 0.6 Nm. Make sure there is a chamfer in the screw hole to avoid rising of the hole edges.) We ask customers to check and fully test the suitability of the fastening and bonding integrity for their product. For example, mechanical stress, humidity, temperature fluctuation, vibration and holes on the surface of the circuit board can weaken the strength of the fastening and bonding. Final testing and verifying of fastening methods, adhesives and their combinations are always the customer’s responsibility. Always wear cotton gloves when handling optical parts and their accessories. LEDiL recommends using M3 nylon washers (DIN 125 / ISO 7089) between the screws and the lens to minimize stresses induced by fastening torque. DIN 7985 / ISO 7045 / SFS 2976 LEDiL products supplied with tape use double-sided high-performance acrylic, with an acrylic pressure-sensitive adhesive coating on both sides. d dk Tape k Thread Size M3 dk 6 mm d 3 mm k max 2.52 mm L 4-22 mm All surfaces where tape is applied must be straight, clean, dry and free from grease and dirt. The taped components should be firmly held for 3-5 seconds to ensure the best possible bond. The tape will reach its final strength in 24 hours. Any chemical used during the installation process may damage both the LED or the lens. Please ensure that all harmful chemicals have been fully removed before applying these components. Optical components should not be cleaned with any chemicals – only a micro fibre cloth should be used for cleaning. In extreme conditions (heavy or prolonged exposure to high ultraviolet radiation, moisture, temperature changes, constant or sudden vibrations etc.) LEDiL recommends using glue or screws to ensure reliable operation. Alternatively tapes can be used to absorb small vibrations. See specific technical properties from the document below. Adhesive tape used in LEDiL optics and assemblies (Acrylic) www.ledil.com/adhesive_tape_(acrylic) Please also see chapter about chemicals on page 7. For more information: www.ledil.com/support/#datasheets The information contained herein is the property of LEDiL Oy, Joensuunkatu 13, FI-24100 SALO, Finland and is subject to change without notice. Please visit www.ledil.com for additional information, such as the latest photometric files, 3D mechanical models, and application notes relating to handling, gluing and taping. 24 25 The information contained herein is the property of LEDiL Oy, Joensuunkatu 13, FI-24100 SALO, Finland and is subject to change without notice. Please visit www.ledil.com for additional information, such as the latest photometric files, 3D mechanical models, and application notes relating to handling, gluing and taping. LEDiL LED optics user and installation guide LEDiL LED optics user and installation guide Glue Profiles Contact your local bonding manufacturer such as DELO® or LOCTITE® for recommended adhesives for your product. Some LEDiL lenses are designed to fit existing aluminium profiles like GIZA from Klus for example. (https:// klusdesign.com/product/42) Potting Currently supported product families: Contact your local bonding manufacturer such as DELO® or LOCTITE® for recommended adhesives for your product. • FLORENCE-1R • FLORENTINA LEDiL Clips: More information about bonding by DELO or Henkel www.ledil.com/delo-adhesives www.ledil.com/henkel-adhesives Achieve a sleak and uniform luminaire exterior by connecting lenses in continuous rows with LEDiL retaining clips. Clip A and C for installation on a plate and Clip B for profile installation • C14353_FLORENCE-1R-CLIP-A for 40 mm wide PCB´s (like Philips Fortimo) and screw mount • C14409_FLORENCE-1R-CLIP-B fits straight into aluminum profile, no screws needed. • C14751_FLORENCE-1R-CLIP-C for 24 mm wide PCB´s and screw mount Press-fit Please note that LEDiL’s press-fit products are designed to be assembled only once and pins won’t withstand unfastening. C14353_FLORENCE-1R-CLIP-A BARBARA-PF C14409_FLORENCE-1R-CLIP-B Align the pins in the socket with the holes in the reflector feet and press the reflector fully into the socket. Make sure you push the reflector evenly. FLORENCE-1R assembly LEDiL’s press-fit fasteners for the FLORENCE-3R product family are designed for electrical appliances that may, for security or safety reasons, require restricted access. They feature tamper-proof luminaire assembly and class 1 light fitting. Place the lens in the aluminium profile and fasten it with the clips. Make sure the whole lens is evened out and that every hole reserved for connectors are hidden inside the profile. The fastening clips will be installed on both sides of every lens. This allows lenses to be connected in a continuous row to achieve uniform appearance. Holder LEDiL´s holders are generally very straightforward and easy to assemble. They can be fastened with either positioning pins, clips or screws. If there is a certain installation requirement, for example in some of the ROSE-lenses, it is mentioned in the corresponding datasheet or application note. LEDiL Disclaimer: Some holders may allow multiple installations after the optics are removed, but LEDiL does not guarantee this or accept liability in any circumstances where possible malfunctioning or damage to the product, component, individual or property is caused by such actions. The information contained herein is the property of LEDiL Oy, Joensuunkatu 13, FI-24100 SALO, Finland and is subject to change without notice. Please visit www.ledil.com for additional information, such as the latest photometric files, 3D mechanical models, and application notes relating to handling, gluing and taping. See our video about FLORENCE-1R assembly 26 27 https://youtu.be/ZP6QxR3hS6Q The information contained herein is the property of LEDiL Oy, Joensuunkatu 13, FI-24100 SALO, Finland and is subject to change without notice. Please visit www.ledil.com for additional information, such as the latest photometric files, 3D mechanical models, and application notes relating to handling, gluing and taping. LEDiL LED optics user and installation guide LEDiL LED optics user and installation guide PCB design LED chip positions Make sure that the LEDs optical center is aligned correctly under the lens, for it may not always be at the centre of the LEDs frame (for example in the Philips Lumileds Rebel series). The recommended tolerance for LED positioning is ±0.1mm. Please note that due to varying asymmetric chip locations, especially on mid-power LEDs, the exact source of light is not always located at the centre of the LED packet. Take this into account when making or choosing PCB designs. Many LEDiL optics have positioning pins that require holes in the PCB. The holes need to be 0.1 mm larger than the pin size with +0.1/-0 mm tolerance limits. The tolerance for the holes location is ±0.1 mm. Some LEDiL optics have position pins shaped as + and – . In these cases the + shaped pin needs to have a round hole and the – shaped pin an oblong hole. This leaves more room for thermal expansion. If maximum uniformity is required LEDiL recommends rotating such LEDs on the PCB in a regular pattern for smoother results. Some LEDiL products have clips to fasten the optics straight on to the PCB. The little claws that go under the PCB need to have enough empty space reserved for them. Note that the clips can only be used with 1.6 mm thick PCBs. In most cases the PCB needs to be 1.6 mm thick, but in some special cases this may also vary. LED compatibility tolerances Always remember to check the corresponding product datasheet for any special requirements. For an LED to be mechanically compatible with our lenses there must be 0.2 mm safety distance between the LED and the closest part of he lens design. With products that come with installation tape this safety margin must be 0.3 mm. These numbers come from the fact that the TIM or soldering paste between the LED and the heat sink is approximately 0.1 mm thick, and installation tape requires an additional 0.1 mm for natural shrinkage. LED assembly Distance between lenses We recommend LED assembly tolerance of ±0.1 mm. For accurate positioning good solder pad design is necessary. If the solder pad is not the right size and shape the LED alignment may suffer significantly. Many LEDiL products have a module based structure and can be installed next to each other without any noticeable shading. Some lenses from the same product family can even be mixed together and used inside the same luminaire. As a general guideline, we recommend lens distances follow the same pattern as the LED pitches inside one module. Usually the easiest way to calculate position to the next module is between the centre points, rather than using sides or optics. The amount of solder paste is also important. The height of the LED might vary a lot depending on the quantity of solder paste, and may even cause the LED to be askew. Please remember to visit our website www.ledil.com to see if there are more recent installation guides or application notes available for individual products. LED not aligned correctly Too much solder paste under the LED The information contained herein is the property of LEDiL Oy, Joensuunkatu 13, FI-24100 SALO, Finland and is subject to change without notice. Please visit www.ledil.com for additional information, such as the latest photometric files, 3D mechanical models, and application notes relating to handling, gluing and taping. 28 29 The information contained herein is the property of LEDiL Oy, Joensuunkatu 13, FI-24100 SALO, Finland and is subject to change without notice. Please visit www.ledil.com for additional information, such as the latest photometric files, 3D mechanical models, and application notes relating to handling, gluing and taping. LEDiL LED optics user and installation guide LEDiL LED optics user and installation guide Sealing and ingress protection of LEDiL optics Many LEDiL modules are designed to be sealed against environmental hazards with commonly available potting compounds. Sealant can be applied with a dispenser either manually or with an automated XY-table. Silicone seal of IP-2X6 module Thermal management Before adding any sealing compounds, ensure the installation surface, and the optic with its accessories are even. Modules that have an integrated silicone gasket do not need to be potted. To ensure intended level of ingress protection, please make sure that the silicone gasket is correctly in place before installation. When working with LED lighting one important issue to take into consideration is heat. Good thermal design plays a key role in the performance and lifetime of the application. There are three different ways for heat to transfer: conduction, convection and radiation. Always make sure that the thermal management is sufficient enough for the application. Only apply potting compound outside the optical areas. STRADA lenses for example are designed with barrier walls to keep the compound out of the lenses. Conduction is the transfer of heat through solid materials with direct contact. For example the heat from an LED junction to the heat sink is transferred by conduction. Convection is the transfer of heat through the movement of gases or fluids. A typical example in LED applications is the heat transferred from heat sink to air. Radiation is the transfer of thermal energy by electromagnetic radiation. This radiation causes thermal motion of charged particles in matter. In LED applications transfer through radiation is found in the light itself. This is extremely important to remember since LEDs keep getting more and more powerful. Note! In order to maintain the desired level of ingress protection, screws with thread-locking fluids should be thoroughly tested in advance for VOC (volatile organic compounds) or stress cracking, and any remaining cutting fluids used in heat sink machining must be carefully removed. Solid thread-locking screws should be used. The temperature and pressure differentials inside and outside the lens can cause seal performance to degrade over time. If more ventilation is needed inside the lens this must be done in such a way as to not compromise the ingress protection. E.g. by using ventilation solutions from 3rd party manufacturers. The best choice of optic is not always the material that can handle more heat, because some materials absorb more radiant flux than others. This basically means that an optics efficiency is directly linked to how hot the lens will get. IP ratings indicated in LEDiL product specifications are based on IEC 60598-1:2014 ed. 8.0 and are conducted internally. The final IP rating is subject to design and surface finish of luminaire parts and must be individually tested. LEDiL secondary optics are designed and manufactured to meet the highest possible efficiency rates. This not only provides good lighting results, but gives the product a longer lifetime as well. The information contained herein is the property of LEDiL Oy, Joensuunkatu 13, FI-24100 SALO, Finland and is subject to change without notice. Please visit www.ledil.com for additional information, such as the latest photometric files, 3D mechanical models, and application notes relating to handling, gluing and taping. 30 31 The information contained herein is the property of LEDiL Oy, Joensuunkatu 13, FI-24100 SALO, Finland and is subject to change without notice. Please visit www.ledil.com for additional information, such as the latest photometric files, 3D mechanical models, and application notes relating to handling, gluing and taping. LEDiL LED optics user and installation guide LEDiL LED optics user and installation guide Heat sink machining Thermal measurements All heat sink machining needs to be done before lens assembly. Some lenses need holes for wires and for fastening. For example LEDiL’s STRADA-IP-2X6 products need to be fastened to the heat sink with screws. After cable holes and threaded screw holes are machined, ensure that the anodized heat sink surface is even. Screw thread hole accuracy is ±0.1 mm. Vertical straightness tolerance for screws is ±⊥0.1 mm A. Please be sure to remove all aluminum particles from the holes and the heat sink surface. Infrared (IR) imaging and thermocouple measurement systems can be used for monitoring temperatures in LED applications, but the following must be acknowledged. • IR imaging is a preferred method for lens and reflector temperature measurements, but emissivity of the target area must be known (typical emissivity of a transparent lens is 0.88 - 0.93) • Low emissivity surfaces are challenging to measure with an IR camera because reflected temperatures can also be seen in thermal image (1) Thermal interface materials • Thermocouples cannot be placed on top of a lens or in direct light due to the absorption of the radiant flux (2) For good heat transfer, a thermal interface material must be used between the heat sink and the PCB/ COB LED. This material can be thermal pad, thermal glue, thermal paste, phase change material or double-sided thermal tape. The material choice depends on the situation and power used by the application. The thermal resistance of the thermal interface depends on the thermal conductivity of the material, material thickness, area and the pressure applied to the interface. We recommend using a thin layer of thermal interface material to minimize thermal resistance. • Tiny thermocouples (AWG 40 recommended) can be used to measure LED case, PCB and heat sink temperatures where radiant flux doesn’t interfere, and target surfaces cannot be exposed to the IR camera • A white thermal paste can be used to attach thermocouples for better accuracy and to avoid drilling, glueing or taping (2) (1) (2) It is always the customer’s responsibility to ensure reliable and sufficient cooling and heat transfer between all luminaire components. If a sufficient amount of pressure on the heat sink cannot be maintained over time we recommended using either thermal glue and/or screws for the PCB/LED fastening. While using thermal interface materials, remember that the material needs to be chemically compatible with the LEDs. Bad material choice might significantly reduce the LEDs lifetime. For example Cree has created a test method for chemical compatibility. More information about the test can be found on Cree’s web page. Lenses Method a) Switch on the light and let temperatures rise until they stabilize. Remove any obstacles (e.g. glass cover) quickly to expose the target surface and take an image on the top surface of the lens. Start to record video sequence and turn the lens over quickly to catch the maximum temperature from the bottom side of the lens. Method b) Let temperatures stabilize like in the previous method, but instead of removing or turning any parts just start the measurements and switch off the light. Do not include the first 10 seconds but take temperature values every 5 seconds to create a linear graph of the changes. (See UL standard 8750-873). Reflectors Attach a thermocouple on the surface of the reflector with a small aluminum tape and monitor temperatures until they stabilize (3). Paint the target area, attach a tape with known emissivity or remove metallization on the outer surface of the reflector and take an IR image from that area (4). COB LEDs LED case temperature, Tc, can be measured with a thermocouple (Type T) that is firmly glued/soldered to the Tc measurement point of the LED module (5). (3) The information contained herein is the property of LEDiL Oy, Joensuunkatu 13, FI-24100 SALO, Finland and is subject to change without notice. Please visit www.ledil.com for additional information, such as the latest photometric files, 3D mechanical models, and application notes relating to handling, gluing and taping. 32 33 (4) (5) The information contained herein is the property of LEDiL Oy, Joensuunkatu 13, FI-24100 SALO, Finland and is subject to change without notice. Please visit www.ledil.com for additional information, such as the latest photometric files, 3D mechanical models, and application notes relating to handling, gluing and taping. LEDiL LED optics user and installation guide LEDiL LED optics user and installation guide Vacuum evaporation PVD LEDiL uses vacuum evaporation PVD (Physical Vapor Deposition) to add a reflective aluminum coating to PC reflectors. Before aluminum can be added, adhesion between the reflectors and the aluminum coating must be improved. This is conventionally done by adding a layer of lacquer to the reflector surfaces. Metal coating • High quality both functionally and decoratively • Reflectors will not be subject to chemical of thermal stress • Good performance in cross-cut test 1) Top lacquer (to protect surface) Different materials and coatings used by LEDiL have to undergo numerous tests before being accepted. All the materials and coatings must be permanent, durable and show no signs of peeling, fingerprints, cracks, black spots, scratches, smudging or discoloration. 2) Al coat (in vacuum) 1 2 3 3) Base lacquer (to improve adhesion) We always heat test beyond our recommended limits to fully ensure our products quality. For more extreme environments some materials have been tested with diluted NaOH liquid and in an artificially created salt mist. These surfaces should be completely undamaged to pass. 4) Substrate (part to be coated) Both the HMDS and lacquer layer increase aluminium coating durability, but the reflector must be protected from water and other hazards. Weather exposure tests must be carried out during the design process. 4 HMDS HMDS is a simplified name for a glow polymerization method. Plasma treatment is first used to clean the reflector surfaces of any unfavorable materials to improve adhesion. Then the aluminum coating is added via vacuum evaporation and finally HMDS-monomers are added and a polymerization reaction takes place. • Thin and protective layer • Good optical performance • Good durability against heat 1 2 3 1) HMDS plasmapolymerisation (to protect surface) 2) Al coat (in vacuum) 4 3) Glow discharge activation of surface (to improve adhesion) 4) Substrate (part to be coated) The information contained herein is the property of LEDiL Oy, Joensuunkatu 13, FI-24100 SALO, Finland and is subject to change without notice. Please visit www.ledil.com for additional information, such as the latest photometric files, 3D mechanical models, and application notes relating to handling, gluing and taping. 34 35 The information contained herein is the property of LEDiL Oy, Joensuunkatu 13, FI-24100 SALO, Finland and is subject to change without notice. Please visit www.ledil.com for additional information, such as the latest photometric files, 3D mechanical models, and application notes relating to handling, gluing and taping. LEDiL LED optics user and installation guide Storage To maintain long-term product quality under storage, please ensure that the environment is kept at normal room temperature without too much humidity and that the products are kept in their original packaging. Links to useful information Guides documents and certificates www.ledil.com/support/ Application related guides and examples www.ledil.com/application-areas/ Product catalogue www.ledil.com/product_catalogue New products catelogue www.ledil.com/latest_products_catalogue Search for products www.ledil.com/search/ Contact Us www.ledil.com/contacts/ And for all other information, references and to subscribe LEDiL newsletter please visit www.ledil.com perfecting light Follow LEDiL in social media: The information contained herein is the property of LEDiL Oy, Joensuunkatu 13, FI-24100 SALO, Finland and is subject to change without notice. Please visit www.ledil.com for additional information, such as the latest photometric files, 3D mechanical models, and application notes relating to handling, gluing and taping. 36