REV A Procedure to conduct LM-80 Measuring Lumen Maintenance of LED Light Sources

ICM37-011

Procedure to conduct LM-80 Measuring Lumen Maintenance of LED Light Sources Document No: ICM37-011 Rev: A

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REV A Procedure to conduct LM-80 Measuring Lumen Maintenance of LED Light Sources

ICM37-011

SPECIFICATION HISTORY
_____________________________________________________________
DESCRIPTION OF NOTICE First Issue Lumen Maintenance Test Procedure
ECN # DATE

REV. A

C-0193

11/2/2010

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REV A Procedure to conduct LM-80 Measuring Lumen Maintenance of LED Light Sources

ICM37-011

1. Purpose: To describe the procedure used by STS in order to conduct LM-80 testing under different conditions of temperature and humidity when these LED light sources are powered on 2. Scope 2.1. This method applies to the case temperature monitoring with respect to the light sources surrounding. The light sources include LED packages, array and modules. 2.2. The scope of this procedure does not provide guidance nor does it make any recommendations regarding predictive estimations or extrapolations for lumen maintenance beyond the limits of the lumen maintenance determined from actual measurements. 2.3. The scope of this test from STS will cover the full 6000 hour test with intermittent pull outs. 2.4. Other test duration shall be customer/manufacturers requirement. 3. References 3.1. IES LM-80 3.2. ASTM E230 for thermocouples 3.3. GCS00-006 ESD Preventive Control Process 3.4. GCS00-019 Control of Monitoring and Measuring Devices 3.5. ICS22-066 Training and Certification Requirement 3.6. GCS05-003 Atmospheric Control in Work Areas 3.7. ICM25-011 Final Visual Inspection Process 3.8. GCS22-012 Corrective and Preventive Action Procedure 3.9. ICS22-031- Incoming Inspection Of Materials, Packages Or Lots 3.10. GCA22-002 Quality Record Control 3.11. ICM36-001 Burn-In Procedure 3.12. Energy Star Manufacturers Guide for Qualifying Solid State Lighting Luminaires 3.13. Energy Star Program Requirements for Luminaires
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entertained

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REV A Procedure to conduct LM-80 Measuring Lumen Maintenance of LED Light Sources

ICM37-011

4. Equipment and Instrumentation 4.1. Hastest Chamber or equivalent, or LED test enclosure 4.2. Data logger for temperature measurement 4.3. Thermocouples 4.4. Overtemp protection with control system with auto-shutoff method using relays and internally designed electronics 4.5. Custom Labview software 4.6. Labsphere LED measurement system with 20in light measurement sphere, or equivalent 4.7. Source Meter to power DUT under measurement 5. Definitions: 5.1. Measurement Units - volt, ampere, and watts 5.2. Test Units - LED Package, array or module operated with an auxiliary driver 5.3. Lumen Maintenance - luminous flux output (expressed as a % of maximum output) at any selected elapsed operating time. 5.4. LED Light Source Failure - Failure to produce light. Early failures to function due to manufacturing are reported but are not included in the calculation of LED light source lumen maintenance. 5.5. Rated Lumen Maintenance Life (Lp) Elapsed operating time over which the LED light source will maintain the percentage p of its initial light output ex; L70(hours): time to 70% lumen maintenance L50 (hours): Time to 50% lumen maintenance 5.6. Case Temperature (Ts) temperature of thermocouple attachment point of the LED light source package as defined by customer/manufacturer. 5.7. Light Sources include LED lamps and LED modules. 6. Procedure / Requirements 6.1. Make sure proper ESD apparel is worn before entering the ESD controlled areas and ESD control process followed per GCS00-006. 6.2. Verify the calibration sticker on the equipment to ensure its validity.
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REV A Procedure to conduct LM-80 Measuring Lumen Maintenance of LED Light Sources

ICM37-011

6.3. The storage and testing of all LED sources will take place in a clean room environment. 6.4. Prior to operation, all chambers and equipments for housing these light sources shall be cleaned and purged with clean dry air to remove contamination and particles. 6.5. Identification of units must be tracked by marking directly on the unit or with the use of a label. Bar coding, ceramic ink mark or high temperature markers can be an option. 6.6. It is to be noted that the operation of the LED light sources between photometric measurements shall be at a minimum of three case temperatures Tsp or Ts. 6.7. For LED lamps, lumen maintenance is often shown as curves of relative lumen output over time for the LED under various operating conditions, such as drive current (to be maintained within 3% of the rated rms value, over the life of the test) and junction temperature. 6.8. Temperature, Ambient Air (Tair): The temperature of the air immediately surrounding the LED. In general, this temperature should be measured outside the FWHM beam angle of the LED and within the same enclosure that contains the LED. 6.9. Temperature, Junction (TJ): The temperature of the junction of the LED die inside the LED lamp. Measuring the LED die temperature by direct mechanical means is difficult and may lead to erroneous results. It is recommended measuring TJ indirectly through measurement of Tsp, VF and IF and using the following equation: TJ = Tsp + ([Rth j-sp] x [VF] x [IF]) Alternatively, TJ is provided by the customer/manufacturer where required. Note: Rth J-sp is the thermal resistance between the LED junction and the solder point of the LED lamp. This parameter is provided on all LED data sheets provided by the customer/manufacturer. 6.10. Temperature, Solder Point (Tsp): The temperature of the thermal pad on the bottom of the LED lamp. Also called case temperature (Tc). 6.11. A thermocouple measurement system complying with ASTM E230 Table 1 Special Limits shall be used to monitor Tc during life testing. Tc is measured directly at the customer/manufacturer designated temperature measurement point of the LED unit. A heat sink meeting the recommendations of the customer/manufacturer should be used.

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REV A Procedure to conduct LM-80 Measuring Lumen Maintenance of LED Light Sources

ICM37-011

6.12. It is important that units should not go through shock or vibration during the test. 7. Exclusion for Testing 7.1. Photometric Testing is conducted by the customer/manufacturer and the data is shared with STS. However any photometric data that does not meet the LM-80 specifications must be reported. 8. Sample Size Determination 8.1. The sample selection is determined by the customer/manufacturer. 9. LM-80 Compliant Lumen Maintenance Test Configuration 9.1. The customer/manufacturer shall test LED lamps for long-term lumen maintenance consistent with LM-80 methods. The LED lamps are first mounted onto metal core printed circuit boards (MCPCBs) or typically called the stress boards. A set typically contains thirty individual LED lamps. 9.2. The boards are attached to a heat dissipation device in the test chambers. The LED lamps are powered by customer/manufacturer supplied LED constant current drivers set at specified current, with the following criteria: DC output ripple = 2%, total harmonic distortion = 3% of the fundamental, DC voltage regulation within +/- 3%. 9.3. The Tsp of the LED lamp is monitored and controlled by continuously regulating the temperature of the heat dissipation device in the test enclosure. 9.4. Ambient air temperature (Tair) in the chamber is also monitored and controlled by regulating the temperature of the air flowing through the chamber. 9.5. Tair in the test enclosure is controlled to within -5C of Tsp. Per LM-80 4.4.3, care is taken to minimize any drafts in the immediate vicinity of the devicesunder-test (DUT) . 9.6. The three Tsp shall be 55C and 85C with a third temperature selected by the customer/manufacturer. Case temperatures shall be recorded and be controlled to within -2C during life testing. 9.7. An example of temperature control is explained below. Lets assume 55C Tsp. The case temperature should not go below 53C and the surrounding temperature should not go below 50C (-5C of the case temperature).
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REV A Procedure to conduct LM-80 Measuring Lumen Maintenance of LED Light Sources

ICM37-011

9.8. The humidity shall be maintained to less than 65%RH throughout the life test. 10. Pull outs and Lumen Maintenance 10.1. The sample selection is determined by the customer/manufacturer. 10.2. The luminous flux and chromaticity of the LED lamps are initially measured in an integrating sphere before the testing begins (at t=0). 10.3. The photometric test is to be performed after each pull out until the final read point of 6000 hours, or until the customer/manufacturer specified duration is reached. 10.4. In the event of power failure and any mishap that would cause the LED unit to not properly operated at the set temperature, which would create a down time. Down time shall not be recorded as part of the total life test duration. 10.5. The LED lamp sets are placed into the active temperature controlled test enclosure with various sets of lamps being operated at various drive currents (from nominal to maximum as specified in the lamp data sheets). 10.6. At regular intervals (each pull out after 1000, 2000, 3000, 4000, 5000, 6000 hour test), the LED lamps are removed from the test enclosure and the luminous flux and chromaticity are measured with an integrating sphere and spectrometer. 10.7. The LED light sources shall be allowed to cool to room temperature (25C +/2C) before each measurement. The input current shall be within 0.5% of the rated rms value, with a 10-25ms pulsing current during photometric measurements. 10.8. Visual observation of LED light source at each measurement interval to check for catastrophic failure. Such failure shall be included in the test report.

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REV A Procedure to conduct LM-80 Measuring Lumen Maintenance of LED Light Sources

ICM37-011

Note: Air flow shall be minimized (especially around the DUTS) for proper light source starting and operation because the heat flow characteristics that differ due to variation in air flow. Some air movement is necessary to avoid thermal stratification. 11. Pass Fail Threshold 11.1. DOE has established a pass/fail threshold for lumen maintenance compliance, based on the data provided by the LM-80 test report. In some cases, customers/manufacturers continue to collect LM-80 data beyond minimum required 6000 hours. LM-80 establishes 6000 hours as a minimum test period, but recommends 10,000 hours. The lumen maintenance requirements are listed in Table 1.

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REV A Procedure to conduct LM-80 Measuring Lumen Maintenance of LED Light Sources

ICM37-011

Table 1. Lumen maintenance requirement Cumulative hours of For 25000 hour testing projected L70 life 6000 91.8% 7000 90.5% 8000 89.2% 9000 88.0% 10000 86.7% 11000 85.5% 12000 84.3% 13000 83.1% 14000 81.9% 15000 80.7%

For 35000 hour projected L70 life 94.1% 93.1% 92.2% 91.2% 90.3% 89.4% 88.5% 87.6% 86.7% 85.8%

11.2.There are three possible scenarios for determining the lumen maintenance for the product submitted to ENERGY STAR:
SCENARIO 1 The in situ measured TMPLED is greater than the highest case temperature collected according to LM-80 procedures. In this case the product cannot qualify under Option 1 as there is no test data to substantiate customer/manufacturer claims. Products that fall under this scenario must be successfully tested according to Option 2 in order to qualify. SCENARIO 2 The in situ measured TMPLED is less than the lowest case temperature (Tc) or solderjoint (Ts) temperature at which LM-80 data was collected. In this case the product must use the data from the lowest case temperature measured according to LM-80 procedures. SCENARIO 3 The in situ measured TMPLED is bounded above and below by case temperature data collected according to LM-80 procedures. In this case linear interpolation shall be used to determine the lumen maintenance for the proposed product, as follows:

LTMP = Lbelow +((Labove - Lbelow)/ (Ts, above - Ts, below)) (TMP LED - Ts, below)
Where: Lbelow = Lumen maintenance (%) below the TMPLED @ 6000 hours

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REV A Procedure to conduct LM-80 Measuring Lumen Maintenance of LED Light Sources
Labove = Lumen maintenance (%) above the TMPLED @ 6000 hours Ts, below = LM-80 case temperature (C) below the TMP LED Ts, above = LM-80 case temperature (C) above the TMP LED TMPLED = In situ measured TMP of the hottest LED within the luminaire LTMP = Calculated lumen maintenance of the hottest in situ LED within the luminaire

ICM37-011

EXAMPLE: In situ measured TMP (TMPLED) = 67C LED Customer/Manufacturer LM-80 test data for XYZ Package Case Temperature Time (hours) 25C 55C 85C 0 100% 100% 100% 6000 99% 95% 90% Applying the equation above:

LTMP = 95 +((90- 95)/(85 - 55)(67 - 55) LTMP = 93.0%

Component Performance Passing Threshold

The luminaire PASSES the Component Performance Lumen Maintenance requirements if the following three conditions are met: 1. The LM-80 test report for the package, array, or module demonstrates lumen maintenance of = 91.8% for a projected L70 of 25,000 hours (indoor residential) or = 2 94.1% for a projected L70 of 35,000 hours (outdoor residential and all commercial) . 2. The ISTMT temperature at the TMP is less than the lowest temperature that correlates to a lumen maintenance = 91.8% (residential) or = 94.1% (commercial) in the LM-80 test. Or the in-situ temperature at the TMP, when input into the linear interpolation equation, results in a lumen maintenance = 91.8% for residential products or = 94.1% for outdoor residential and commercial products. 3. The drive current measured in the fixture is less than or equal to the drive current specified in the LM-80 test report.

12. Test Report 12.1. The report should include the following items: Number of samples tested Product description Description of auxiliary equipment
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REV A Procedure to conduct LM-80 Measuring Lumen Maintenance of LED Light Sources

ICM37-011

Operating cycle Ambient conditions (airflow, temperature, humidity) Case temperature (T )

s

Drive current during life test Initial luminous flux and forward voltage at constant current Lumen maintenance for each sample and the group median value, standard deviation, minimum and maximum lumen maintenance Failure time and conditions for any failures Monitoring interval Photometric measurement uncertainty Chromaticity shift reported over the measurement time 12.2. All reported items are reported for each test. A table format shall be used to present test results. 13. Maintenance and Calibration Criteria 13.1. Calibration of the equipment shall be carried out by any qualified person as per customer/manufacturers recommendations and STS calibration guidelines per GCS00-019. 13.2. Logs and Records: Calibration records shall be maintained as required. 13.3. Calibration of equipment Any delay or elapse in calibration should be within 0.5% in time uncertainty. 14. Responsibilities: 14.1. Reliability Engineering is responsible to update and revise this specification. 14.2. Reliability Engineering is responsible for ensuring that all procedures, materials, equipment, record keeping and logs are in accordance with this specification. 14.3. Reliability Supervisor / QA to ensure that only trained and certified operators will perform this operation. 15. Quality and Calibration Records 15.1. Maintain all quality records as per specification GCA22-002. 15.2. LED lamp manufacturing guidance must be kept as records.

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