PRODUCT

SynJet PAR25 LED Cooler

with Heat Sink

Design Guide

Version 1.0
July 2009
Version History

Document Name: SynJet PAR25 LED Cooler with Heat Sink Design Guide
Document Number: MKTG-DOC-00047

Version and Date Changes

Version 1.0, July 2009 Initial release.

Nuventix, the Nuventix logo, and SynJet are trademarks or registered trademarks of Nuventix. All other brand and product names may be
trademarks of their respective companies.

Nuventix, Inc. www.nuventix.com Phone: 512-382-8100

4635 Boston Lane Copyright 2008 Nuventix Fax: 512-382-8101
Austin, TX 78735 All Rights Reserved Contact Sales: 512-382-8100
Table of Contents
Chapter 1: Introduction
Audience . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Related Documents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
SynJet PAR25 LED Cooler Driver Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
SynJet PAR25 LED Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8

Chapter 2: Thermal Design

SynJet PAR25 LED Cooler Airflow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Unrestricted Flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Example 1: Track Fixture . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Example 2: Pendant Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Restricted Flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Blocking Heat Sink Channels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Adding Ventilation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Ceiling Installations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Thermal Interface Material (TIM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Design Consultation and Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Chapter 3: Acoustic Design

Chapter 4: Mechanical Design

LED Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . .. . . 21
Mounting Surface for LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . .. . . 21
Power Wire Routing for LEDs and SynJet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . .. . . 22
SynJet PAR25 LED Cooler Attachment to Heat Sink . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . .. . . 22
Heat Sink Attachment to Luminaire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Integrating SynJet PAR25 LED Cooler with Customer-Designed Heat Sink . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Chapter 5: Electrical Design

Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Current Waveform . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Connection Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Variable Level Cooling Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Disclaimer/Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Contact Nuventix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Nuventix July 2009 Page 3

Table of Contents SynJet PAR25 LED Cooler with Heat Sink Design Guide

Page 4 Nuventix July 2009

Chapter 1
Introduction
The SynJet PAR25 LED Cooler with Heat Sink is a patented, highly adaptable,
quiet, active cooling solution for the solid state lighting industry.
Specially designed to provide active cooling, the SynJet PAR25 LED Cooler:
allows maximum lumens output for long life
provides excellent thermal management
provides low energy consumption
can double or triple lumen output over a passive cooling solution in the same
form factor.
The SynJet PAR25 LED Cooler is available in four models optimized for specific
cooling environment requirements:
SynJet PAR25 LED Cooler, Standard 28 W, provides quiet, effective cooling in
standard luminaire design environments with normal airflow and where low
acoustics are important.
SynJet PAR25 LED Cooler, High Performance 32 W, is optimized for
maximum LED cooling and/or in a restricted airflow environment such as an
enclosed box with little venting. This model provides greater cooling in areas
less sensitive to the nominal increase in acoustics that the additional flow
creates.
SynJet PAR25 LED Cooler, Silent 24 W, is optimized for LED designs where
silent acoustics are required in a compact package. This model is perfect for
slightly lower power requirements but still maintaining small designs
SynJet PAR25 LED Cooler, Variable Cooling Control, gives the designer
multiple programmable performance levels for maximum cooling and power
flexibility. The designer can apply an external control input signal to match the
SynJet cooling level to the environmental requirements. The external control
signal allow switching among any of the three performance levels described
above, plus an off state, where air flow halts, but the electronics still senses the
control signal.
This document is applicable to all four models of the SynJet PAR25 LED Cooler.

Audience The audience for this design guide is the luminaire design team to include:
thermal engineers
mechanical engineers
electrical engineers
luminaire industrial designers.

Nuventix July 2009 Page 5

Chapter 1: Introduction SynJet PAR25 LED Cooler with Heat Sink Design Guide

Sections of this document may also provide valuable SynJet PAR25 LED Cooler
application background for the luminaire marketing team and luminaire
manufacturing engineers.

Related Documents For additional information, refer to the following:

Nuventix Technology Overview
SynJet PAR25 LED Cooler with Heat Sink Assembly Instructions
SynJet PAR25 LED Cooler with Heat Sink Product Specification
SynJet PAR25 LED Cooler Variable Level Cooling Control Application Note
SynJet PAR25 LED Cooler with Heat Sink 2D Drawings
SynJet PAR25 LED Cooler with Heat Sink 3D CAD Model, STEP file format
The Nuventix web site at www.nuventix.com for:
Latest Document Updates
New Application Notes

Components The following figures illustrate the components of the SynJet PAR25 LED Cooler.

SynJet Power Wires

Mounting Screws (4)

SynJet Cooler

Heat Sink

Figure 1: SynJet PAR25 LED Cooler and Heat Sink

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SynJet PAR25 LED Cooler with Heat Sink Design Guide Chapter 1: Introduction

SynJet PAR25 LED Cooler Driver

Board

Driver
Board

Nozzles

Figure 2: SynJet PAR25 LED Cooler Driver Board

SynJet PAR25 LED Cooler

Product Label

Figure 3: SynJet PAR25 LED Cooler Product Label

Nuventix July 2009 Page 7

Chapter 1: Introduction SynJet PAR25 LED Cooler with Heat Sink Design Guide

Power and
Control Wires

Mounting
Screws (4)

Figure 4: SynJet PAR25 LED Cooler

The following table describes each component.

Table 1: Component Description

Component Description
SynJet PAR25 LED Cooler The SynJet PAR25 LED Cooler is the air mover of the cooling system. It
creates turbulent pulses of air, i.e., synthetic jets, which are directed between
heat sink fins.
Heat Sink The heat sink spreads the heat dissipated from the LEDs over a large surface
area. The heat sink is die cast aluminum and is coated with an
electro-coating for protection.
SynJet PAR25 LED Cooler Driver Board The driver board contains the components needed to operate the SynJet
PAR25 LED Cooler.
Power Leads The red and black power wires are the electrical interface to an external DC
power supply. The purple and blue wires are optional and control the cooling
level. The wires have stripped and tinned ends for easy soldering or
connection to a connector.
Mounting Screws Four screws, M2.5 x 0.45 8mm, secure the SynJet PAR25 LED Cooler to the
heat sink.
Product Label The product label contains pertinent information such as part number,
revision, operating voltage, manufacturing information, and patent
notification.

Handling The thermal, mechanical, and electrical aspects of the luminaire are key design
challenges.
The LED drive circuit, the SynJet drive circuit, and other power and control circuits
in the luminaire, are susceptible to ESD damage.

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SynJet PAR25 LED Cooler with Heat Sink Design Guide Chapter 1: Introduction

IMPORTANT! Electrostatic Discharge (ESD) is a significant cause of electronic

circuit failure. A failure may:
be immediate
occur later due to a weakened component
appear as an early service life failure.

An industry-standard assembly and test area must have proper ESD

protected work stations. In addition, the staff must have ESD
prevention education.

The SynJet PAR25 LED Cooler electronics require

industry-standard care and use of proper ESD protection during
assembly and test.

When handling the SynJet PAR25 LED Cooler, use care with the wiring and the
circuit card. The SynJet PAR25 LED Cooler is designed for normal assembly
operations. With excessive force, the wires and components can be over-stressed
and broken.
The SynJet PAR25 LED Cooler plastic housing has been designed to withstand
normal assembly forces. Clamping or force fits can create very strong local forces
that could damage or weaken the cooler housing, thus creating an early life failure
risk.
The SynJet PAR25 LED Cooler contains magnets. Small particles of iron, screws,
and other magnetic materials from secondary machining or materials that are
loose in the assembly area may be attracted to the housing or the PCBA. They
could interfere with performance or cause a failure. Process steps should be
included to be sure any particles are removed after machining. Similarly, the
assembly work area should be free of magnetic particles.
To prevent ESD or mechanical force induced failures, integrate precautions in the
design process for handling, assembly, and testing of the final product.

Nuventix July 2009 Page 9

Chapter 1: Introduction SynJet PAR25 LED Cooler with Heat Sink Design Guide

Page 10 Nuventix July 2009

Chapter 2
Thermal Design
This section discusses thermal design considerations for SynJet PAR25 LED
Cooler luminaire design.
The SynJet PAR25 LED Cooler generates turbulent pulses of air which efficiently
dissipate heat from any surface. The LEDs are mounted on the face of the heat
sink and their heat spreads to the fins where the SynJet PAR25 LED Cooler
pulses along with the entrained air flow remove it. The SynJet PAR25 LED Cooler
comes with a standard heat sink and its design has been tested and qualified.

SynJet PAR25 LED Cooler SynJet PAR25 LED Cooler airflow is generated from a ring of rectangular nozzles
Airflow that are directed at the channels between the heat sink fins (see Figure 5).

Jet Nozzles

Figure 5: SynJet PAR25 LED Cooler Nozzles

The SynJet PAR25 LED Cooler nozzles:

provide for air intake
provide for exhaust
create synthetic jets.

Nuventix July 2009 Page 11

Chapter 2: Thermal Design SynJet PAR25 LED Cooler with Heat Sink Design Guide

Figure 6 illustrates air flow through the SynJet PAR25 LED Cooler to the heat
sink. In addition to the flow that is directly created by the SynJet PAR25 LED
Cooler jet nozzles (green arrows), air is also entrained (blue arrows) due to the
phenomenon known as the jet ejector effect. This is the same effect felt when a
large vehicle passes by and air rushes in to follow it. The entrained air adds to the
overall flow generated by the SynJet PAR25 LED Cooler. The SynJet PAR25 LED
Cooler jets multiply the air flow into the heat sink channels. This increases the
amount of cool air mixing with the hot air next to the fin surfaces that has been
disturbed by the synthetic jet turbulent pulse. The hot air (red arrows) then flows
out of the luminaire and mixes with the room air. These actions significantly
improve heat transfer from the fins to the ambient air. If the SynJet PAR25 LED
Cooler operates in free air with no flow restrictions, the best thermal performance
is achieved.

Figure 6: Air Flow SynJet PAR25 LED Cooler Nozzles to Heat Sink Channels

Chapter 1 described the four SynJet PAR25 LED Coolers. Each has been
optimized for specific cooling, acoustics, and power requirements. These
alternatives give the designer additional flexibility. The following sections discuss
several design constraints and examples.

Unrestricted Flow The following figures show examples of unrestricted air flow to and from the
SynJet PAR25 LED Cooler.

Example 1: Track Fixture Figure 7 shows an example of the SynJet PAR25 LED Cooler with Heat Sink and
reflector element attached to a Track Fixture. The SynJet pulses create entrained
flow between the heat sink fins and hot exit air is exhausted along the outer
surface of the reflector shell. The entire flow path has no restrictions. This
example shows one of the most effective thermal solution configurations because
the reflector diameter is the same as the heat sink diameter. The reflector does
not overlap the heat sink fin, so it does not block exit flow.

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SynJet PAR25 LED Cooler with Heat Sink Design Guide Chapter 2: Thermal Design

Unrestricted
Hot Exit Air Flow
SynJet Turbulent
Pulses
Unrestricted
Entrained Air Flow

Figure 7: SynJet PAR25 LED Cooler with Reflector - Track Fixture

Example 2: Pendant Light Figure 8 shows the SynJet PAR25 LED Cooler with Heat Sink in a pendant light
design. In this design the flow is also unrestricted.

Pendant Wire

Pendant Cone for LEDs

and SynJet Power Card

SynJet Cooler Heat Sink

with LEDs on Face

Shell for Optics

or Reflector

Figure 8: SynJet PAR25 LED Cooler - Pendant Light

Nuventix July 2009 Page 13

Chapter 2: Thermal Design
Restricted Flow
Blocking Heat Sink Channels
Page 14
SynJet PAR25 LED Cooler with Heat Sink Design Guide
Figure 9 shows a close-up view of the cooling flow. Note the position of the lower
reflector shell and the upper cone shell. The reflector shell attaches below the
heat sink fins and does not block exit flow. The upper cone shell's diameter is
slightly smaller than the SynJet housing so entrainment flow is not impaired.
Figure 9: Pendant Cooling Flow - SynJet PAR25 LED Cooler
As discussed in SynJet PAR25 LED Cooler Airflow on page 11, the SynJet PAR25
LED Cooler creates additional flow from entraining ambient air. If the SynJet
PAR25 LED Cooler is installed in restricted flow areas, thermal performance could
degrade. Several types of blockage that can occur are discussed in the following
sections. Usually, testing a physical model is required to determine the actual
performance. The SynJet PAR25 LED Cooler, High Performance model should be
considered for these applications.
The heat sink fin exit channel openings should not be obstructed. If the channels
are obstructed, thermal performance degrades. Mounting structures or trim rings
can create flow blockages, so the design of a luminaire to heat sink support
structure and possible trim ring should be evaluated for air flow interference. If the
assembly is held in the structure by a bracket attached to the four screws or by
screws in custom-tapped holes in the fins near the face, the bracket and fasteners
can form an additional barrier to air flow. Placing the SynJet PAR25 LED Cooler in
an unvented cylindrical shroud will also block the entrainment and/or exit flow.
Nuventix July 2009
SynJet PAR25 LED Cooler with Heat Sink Design Guide Chapter 2: Thermal Design

Chapter 4 discusses options for mechanical attachment to the luminaire in greater

detail.

Adding Ventilation If the application requires the SynJet PAR25 LED Cooler to be installed in a
restricted flow installation, better thermal performance can be achieved by adding
ventilation to enable entrainment. A vented step cylinder example is shown in
Figure 10.

Figure 10: Track Light with Louvers Added to Step Cylinder

Ceiling Installations Figure 11 shows an example of a SynJet PAR25 LED Cooler ceiling installation,
without an enclosed can, that can be used in a false ceiling spot light fixture in a
retail window display. The space above the ceiling is sufficiently open for air
exchange with the environment and air movement is not restricted. The SynJet
can create flow for the removal of hot air and exchange it with the environment.
No closed ceiling can is used and no insulation is next to the light fixture to
obstruct air flow. The figure also shows an opening around the ceiling trim ring
that can further improve air exchange.
As mentioned earlier, enclosing this fixture in a sealed can or mounting it in a
restricted flow area significantly reduces cooling.

Nuventix July 2009 Page 15

Chapter 2: Thermal Design SynJet PAR25 LED Cooler with Heat Sink Design Guide

SynJet Cooler with Reflector Air Flow Gap Between LEDs Mount on Face
Attached to Heat Sink Reflector and Trim Ring of Heat Sink

Figure 11: Ceiling Installation

Thermal Interface Material The thermal design discussion to this point has focused on improving
(TIM) forced-convection air flow to transfer heat from the heat sink to the ambient air.
Also important is good conduction of heat from the LED to the heat sink. TIM is a
critical component of the design and there are several choices available to the
designer:
thermal grease
paste
thermal epoxy
thermal pads, etc.
Selection depends on the LED/heat sink attachment design and planned
assembly process. Refer to LED Mounting on page 21 in this document for
additional information.
Because applications using the SynJet PAR25 LED Cooler vary widely, Nuventix
does not specify a TIM. Nuventix Sales can provide suggestions and consultation
regarding your unique implementation.
It is the customers responsibility for final selection of the material and verification
of its effectiveness.

Design Consultation and Nuventix Thermal/Mechanical Applications Engineers are available to review the
Support SynJet PAR25 LED Coolers thermal and mechanical integration into luminaire
concept designs. The review can also include:
thermal performance testing plan and preliminary data
acoustic testing plan and preliminary data
SynJet PAR25 LED Cooler air flow and entrainment optimization

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SynJet PAR25 LED Cooler with Heat Sink Design Guide Chapter 2: Thermal Design

SynJet PAR25 LED Cooler design and optimization is significantly different from
traditional fan cooling or passive cooling designs. To maximize the benefits of
SynJet PAR25 LED Cooler cooling, Nuventix recommends a joint consultation
and review early in the luminaire design concept development stage. This
consultation should include the luminaire design team and Nuventix Applications
Engineering.
To achieve the best cooling solution, a custom modification to the SynJet PAR25
LED Cooler or to the heat sink may be desirable. Nuventix can provide optional
custom design services. Specifications, costs, and timing are subject to mutual
agreement.
For design consultation and review of the integration process of a luminaire with
the SynJet PAR25 LED Cooler, contact Nuventix Sales.

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Chapter 2: Thermal Design SynJet PAR25 LED Cooler with Heat Sink Design Guide

Page 18 Nuventix July 2009

Chapter 3
Acoustic Design
This section discusses acoustic considerations for your SynJet PAR25 LED
Cooler installation.
The SynJet PAR25 LED Cooler and heat sink design has been optimized for
maximum cooling and minimum air flow acoustics.
Customer-added features such as housings, reflectors, ducting, attachment
structures, etc. may change the acoustic performance. These features can also
change the cooling performance as discussed in Chapter 2 Thermal Design.
When air flow is forced to change velocity, direction, or pressure; then the local
disturbance creates acoustic artifacts. The following are some examples of
features that increase acoustic air flow noise and vibration.
Narrow ducts or flow constrictions.
The velocity increases and then decreases. Local turbulences can be created.
This produces forces on walls and support structures that can cause vibration.
Each of these can be the source of acoustic wave (noise) creation.
Ducting or a cowling placed closely along or surrounding the heat sink.
Constriction and vibration issues similar to those described for narrow ducts or
flow constrictions. If the ducting or cowling are close fitting, this creates
additional noise.
Sharp turns in the flow path.
Disrupted, uneven flow causes additional noise.
Obstructions in the flow path such as posts, fins, dividers.
Obstructions can produce local turbulences and acoustics.
Loosely attached items, deflectors, metal or plastic tabs, wiring, that may
vibrate in the flow.
Additionally, the loose item may hit another part of the assembly which adds to
noise generation.
Delicate support structures that do not hold the assembly firmly.
To obtain the best acoustic performance, these considerations along with
standard engineering practices should be followed. Building mechanical models
of the design and measuring acoustic and cooling performance is recommended.
Nuventix Sales can provide suggestions and consultation.

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Chapter 3: Acoustic Design SynJet PAR25 LED Cooler with Heat Sink Design Guide

Page 20 Nuventix July 2009

Chapter 4
Mechanical Design
This chapter discusses mechanical design considerations for the SynJet PAR25
LED Cooler and LED luminaire product and its installation.

LED Mounting This section provides information on connecting the SynJet PAR25 LED Cooler
with heat sink to an LED or LED array.

Mounting Surface for LEDs To mount the SynJet PAR25 LED Cooler to an LED, there is a flat surface area on
the heat sink where contact is made. Dimensions for the area are given in the
SynJet PAR25 LED Cooler with Heat Sink 2D Drawings.
This surface is machined but not electro-coated and provides a flat surface to
make good thermal contact with the LED MCPCB or other mounting boards (see
Figure 12).

Figure 12: Heat Sink Face with LEDs Attached

The mounting surface is intentionally left without mounting features (such as

threaded holes) because it is difficult to anticipate all the applications that use this
product. The customer can either use a thermal epoxy method (if sufficient for the
design) or perform a secondary machining operation to add mounting features.
As an alternative, Nuventix can add a custom hole pattern. For example, a
three-hole pattern can be added for a Metal Core Printed Circuit Board (MCPCB)
mounted LED. Requests for specific mounting features or a custom hole pattern
should be reviewed with Nuventix Sales, and may be available as an option.

Nuventix July 2009 Page 21

Chapter 4: Mechanical Design
Power Wire Routing for LEDs and
SynJet
SynJet PAR25 LED Cooler
Attachment to Heat Sink
Page 22
SynJet PAR25 LED Cooler with Heat Sink Design Guide
The SynJet Cooler should not be attached to the heat sink during secondary
machining. This avoids damage to the circuit card or the housing.
The SynJet PAR25 LED Cooler heat sink has a clearance slot to accommodate
the power wires required to route from the LEDs through the heat sink to the LED
driver circuitry (see Figure 13.
Figure 13: Routing LED Power Leads
Figure 14 shows the routing for the SynJet power and control wires.
Exit notch in
SynJet housing
for power and
control wires
Figure 14: Routing SynJet Wires (Strain Relief, Passage, and Exit Notch)
This section discusses attachment of the heat sink to the SynJet PAR25 LED
Cooler.
The rim of the cooler has four holes that can be aligned with the four thick, wide
fins on the heat sink. One fin is notched to accept the tab located at one of the four
holes. You must align the tab and notch for proper assembly (see Figure 15). The
thick, wide fins have a hole in their upper end. It is tapped for an M 2.5 x 8 mm
screw (see Figure 16). Apply Loctite 222 MS to the threads of the four screws and
then tighten the screws to a torque value of 0.45 N-m (4 inch-lbs) 10%.
Nuventix July 2009
SynJet PAR25 LED Cooler with Heat Sink Design Guide Chapter 4: Mechanical Design

Align tab on
SynJet with
notch on heat
sink

Figure 15: SynJet Alignment Tab and Notch

The rim of the cooler also has two thin, wide fins. They are thin to help create a
wire bundle passage. The two notches on opposite sides in the body of the cooler
plastic form the other half of the passage. The passage that aligns with the LED
power wire feed-thru hole in the heat sink face is used to route external power to
the LEDs. The passage on the opposite side routes power and control wires from
the SynJet PCBA to their external connections.

Four
Screws

Tapped Hole in
the End of the
Heat Sink Fin

Figure 16: Screw Placement

Heat Sink Attachment to The SynJet PAR25 LED Cooler with Heat Sink can be attached to the luminaire
Luminaire by:
addition of a bracket using the four screws on the perimeter that also connect
the cooler with the heat sink
addition of custom tapped holes in the sides of the four wide heat sink fins and
screws to attach the luminaire
addition of custom tapped holes near the perimeter of the heat sink face

Nuventix July 2009 Page 23

Chapter 4: Mechanical Design SynJet PAR25 LED Cooler with Heat Sink Design Guide

As indicated by the four circles in Figure 16, the tapped holes for the four screws
attaching the cooler to the heat sink are in the ends of the wide fins. Stand-offs
and longer screws can be used to mount the assembly to the luminaire. This is
also a convenient location to mount a power card for the LED drive.
Figure 17 shows a close up view of two custom locations for attachment of a
mounting bracket and/or a reflector using drilled and tapped screw holes in the
heat sink face or the thick fins.

Examples:
Customer Added Holes for
Attachment of Mounting
Bracket or Reflector

Standard Heat Sink Face Exit

Hole for LED Power Wires

Figure 17: Attachments Example

If custom holes are added in the sides of the fins, they should be placed below the
ends of the housing attachment screws to avoid interference. Figure 18 shows a
section view of the SynJet and heat sink assembly. The fin material between the
bottom of the screw hole and the inner surface of the heat sink face can be used
for customer added holes. If a screw hole is placed in the face of the heat sink, the
design should ensure the screw does not interfere with the circuit card just above
the inner surface.

Space for
Customer Added
Holes

Inner Surface of Heat Sink Tallest Component on PCBA

Figure 18: Section View of Assembly

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SynJet PAR25 LED Cooler with Heat Sink Design Guide Chapter 4: Mechanical Design

The Product Specification and the 2D Drawings give further mechanical details
and dimensions.
The following two figures show examples of attachment to the thick wide fins for a
Track Light Fixture.

Figure 19: Track Light Fixture Example 1

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Chapter 4: Mechanical Design SynJet PAR25 LED Cooler with Heat Sink Design Guide

Figure 20: Track Light Fixture Example 2

The following two figures show additional examples of Track Light Fixtures.

Figure 21: Track Light Fixture Back View

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SynJet PAR25 LED Cooler with Heat Sink Design Guide
Integrating SynJet PAR25 LED
Cooler with
Customer-Designed Heat Sink
Nuventix July 2009
Chapter 4: Mechanical Design
Figure 22: SynJet PAR25 LED Cooler Completed Track Mount Assembly
As detailed above, the reflector shell can be attached to the heat sink face
perimeter with customer-determined holes drilled and tapped for the design. The
holes can alternatively be placed at the base of the four thick, wide fins.
This section outlines considerations when planning to integrate the SynJet PAR25
LED Cooler with a customer-designed heat sink.
The housing stand-offs separate the SynJet PAR25 LED Cooler housing from the
heat sink with a space that prevents excessive heat conduction from the heat sink
to the housing. The custom design should also provide this spacing.
IMPORTANT! For your customer-designed heat sink, consideration should be
given to the direction the jets enter the heat sink as well as the
spacing from the jet nozzle to the heat sink. Aim the jets so they flow
through the center of the fin spacing. Space them close to the heat
sink and above the channel so entrainment flow is maximized. Refer
to the SynJet PAR25 LED Cooler with Heat Sink 2D Drawings for
dimension details and spacing.
The standard SynJet PAR25 LED Cooler heat sink is optimized for maximum
effectiveness. Review the heat sink design, and all design comments in this
document, before developing your custom designs.
IMPORTANT! The SynJet air flow with the synthetic jets and entrainment is not the
same as a traditional fan's air flow. Traditional fan or passive cooling
design practices do not necessarily apply. Additionally, it is important
to review the custom design concept with Nuventix Sales early in the
process.
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Chapter 4: Mechanical Design SynJet PAR25 LED Cooler with Heat Sink Design Guide

Review the 3D CAD Model and the 2D Drawings for actual dimensions and
design details of the SynJet PAR25 LED Cooler with Heat Sink.

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Chapter 5
Electrical Design
This chapter discusses electrical considerations for SynJet PAR25 LED Cooler
installation.

Requirements The following table summarizes electrical specifications from the SynJet PAR25
LED Cooler with Heat Sink Product Specification.

Table 2: Electrical Requirements

Voltage, VDC Ripple Current, mA Power, W

Configuration Min Max Min Max Avg

High Performance 32 W 4.75 5.25 100 mv 10 720 1.8
Standard 28 W 4.75 5.25 100 mv 10 600 1.5
Silent 24 W 4.75 5.25 100 mv 10 400 1.0
Variable Control Cooler 4.75 5.25 100 mv 10 720 1.0 to 1.8

IMPORTANT! LEDs are typically driven using a constant-current source, but the
SynJet PAR25 LED Cooler requires a constant-voltage source.
Driving the SynJet PAR25 LED Cooler with a constant-current
source causes the input voltage to rise above the maximum allowed
value, damaging the SynJet PAR25 LED Cooler electronics and
voiding the warranty.

If the voltage source has current overload limiting built in, the level should be set
above the maximum current noted in Table 2.

Current Waveform The SynJet PAR25 LED Cooler current waveform is sinusoidal and varies
between the minimum and maximum specifications shown in Table 2. This
waveform is a sine wave, typically 80 to 160 Hz, with a DC offset. The 5-V power
source must handle this load variation and remain within specification. For
example, the SynJet PAR25 LED (Standard Model) 20W Cooler requires an
average power of 1.5 watts from the power source. This load varies from 0.050
watts (5v x 10 ma) to 3.0 watts (5v x 600 ma). This short term peak cyclic load
means the short term power required from the source is twice the average as
shown in Table 2.
When power is switched on, it also must supply sufficient current to charge input
capacitance (22 F typical) to 5 V in 10 sec to 10 msec.

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Chapter 5: Electrical Design SynJet PAR25 LED Cooler with Heat Sink Design Guide

For the most efficient conversion to 5Vdc, the power source selected is often a
switching regulator. Attention should be given to verification of its proper operation
over the minimum to maximum current load conditions. To avoid voltage
regulation and EMI problems.
If the electrical design includes LED drive current circuits and SynJet 5V regulator
circuits on the same PCBA, then the layout should include standard analog design
practices including separation of the grounds and signal traces.

Connection Specifications The SynJet PAR25 LED Cooler comes with two input power leads described in
the following table. The length includes 10 mm of the wire stripped and tinned at
the end. The total wire run length from the source to theSynJet PAR25 LED
Cooler PCBA should not exceed 300 mm. For total wire lengths beyond the 150
mm supplied with it, use 24 AWG or larger wire. For wire lengths beyond 300 mm,
consult with Nuventix Sales.
Carefully review wire routing design and check for sources of noise coupling to
see if additional filter circuitry is needed to ensure reliable operation. Do not
subject the SynJet PAR25 LED Cooler to voltage spikes greater than a 6-V peak
(5V plus 1V spike) for the 5-V when applying power through a switch or relay. A
filter/snubber may be needed when using electromechanical contacts to switch
power on or off to the SynJet PAR25 LED Cooler. This keeps the voltage spikes at
or below the specified limit.
The SynJet PAR25 LED Cooler meets applicable international specifications for
EMI (radiated, conducted, and susceptibility) when properly installed. Keep the
power wiring as short as possible to avoid the creation of potential problems.
Refer to the SynJet PAR25 LED Cooler with Heat Sink Product Specification for a
list of applicable certifications met.

Variable Level Cooling Table 3 and Figure 23 provide specifications for power and cooling control wiring.
Control

Table 3: Power and Cooling Control Wiring Specification

Signal Color Overall Length AWG (Stranded) Wire Diameter

Power +5 Vdc Red 150 mm 26 1.02 (0.04) mm
GND Black 150 mm 26 1.02 (0.04) mm
Control1 I/O 1 Blue 150 mm 26 1.02 (0.04) mm
I/O 2 Purple 150 mm 26 1.02 (0.04) mm
1. Cooling level control is an option. Wires are present only with the option.

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SynJet PAR25 LED Cooler with Heat Sink Design Guide Chapter 5: Electrical Design

Wire Signal
Blue I/O 1
Purple I/O 2
Black GND
Red +5 Vdc

Figure 23: Wiring Diagram

The following table shows the variable level cooling controls and indicates
standard settings.

Table 4: Variable Level Cooling Control

I/O 1 (Blue) I/O 2 (Purple)

Standard Performance1 12 1
High Performance 02 1
Silent 1 0
Off 0 0
1. If Level Control is not used, this is the default setting.
2. I/O 1 and I/O 2 inputs are standard CMOS logic levels:
1 = Open or High
0 = Gnd or Low

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Chapter 5: Electrical Design SynJet PAR25 LED Cooler with Heat Sink Design Guide

Page 32 Nuventix July 2009

Disclaimer/Warranty
Customers are responsible for testing products for their unique applications. Any
information furnished by Nuventix and its agents is believed to be accurate and
reliable. However, since every potential application cannot be anticipated,
Nuventix makes no warranties as to the fitness, merchantability, or suitability of
any Nuventix products for any specific or general uses. Nuventix shall not be
liable for incidental or consequential damages of any kind.

Contact Nuventix
Nuventix Inc. For company and product information:
4635 Boston Lane info@nuventix.com
Austin, TX 78735
512-382-8100 (phone) For sales information:
512-382-8101 (fax) sales@nuventix.com
www.nuventix.com