Application Note Subs Ti Tube (Gb)

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Application Note

SubstiTUBE ®

ST8-SD4

www.osram.com/substitube



Application note SubstiTUBE ® | 14.02.2011 |

PL SSL – BCT Pro-FIT

Index

Page1. Product description 3

1.1 General Safety and application information 42. Installation options 5

2.1 Overview2.2 Retrofitting in a CCG luminaire 6

2.2.1 Sample installation CCG luminaire 72.3 Direct line voltage connection 8

2.3.1 Direct wiring2.3.2 Single sided direct wiring 10

3. Light distribution aspects 124. Power savings 135. Further information 14





tc

1. Product description

1. Product

description

Product highlights• LED-retrofit for L36W fluorescent lamps (1200mm) with T8 shape and G13 socket• High switching capability• No flicker or stroboscopic effects• 18 high-performance OSLON ® LEDs• Lamp works in most luminaires without thermal problems• VDE certified safety• Up to 50000h lifetime (at 70% lumen maintenance)• Protected against overpower, overheat, short- and open-circuit• FineWhite/ANSI binning for highest homogeneity and not distinguishable color differences

within a lamp

Product Colortemperature

LuminousFlux*

Voltage UN Frequency Power Beamangle

ST8-SD4-765 6500K 1550lm 220-240V 50/60Hz 23,5W 70° x 90°

ST8-SD4-840 4000K 1200lm 220-240V 50/60Hz 23,5W 70° x 90°

ST8-SD4-830 3000K 1200lm 220-240V 50/60Hz 23,5W 70° x 90°

Product Ambienttemperature ta

Temperaturetc point max.

Lifetimetc<65°C

Weight Powerfactor λ

λ withCCG**

ST8-SD4-765 -30…40°C 75°C 50000h 420g 0,5 0,6 - 0,8

ST8-SD4-840 -30…40°C 75°C 50000h 420g 0,5 0,6 - 0,8ST8-SD4-830 -30…40°C 75°C 50000h 420g 0,5 0,6 - 0,8* Values refer to the whole system in steady state operation conditions, not to bare LED.

** Depends on luminaire, CCG and compensation capacitor. Disabling the compensation capacitor leads to a higher powerfactor.

SubstiTUBE ® is the long living replacement for 36W fluorescent lamps (1200mm) with highly

efficient OSLON ®

LED from OSRAM. The innovative LED based tube allows for the easyreplacement of conventional fluorescent tubes in CCG luminaires, providing instant on LED-lightwithout warm up time. The exchange of starter and the replacement of the lamp is all what needs tobe done. Not enough? The rewiring of the luminaire can create additional savings by reducing theohmic losses of the CCG.Even ECG luminaires can be equipped with SubstiTUBE ® when being reworked as discribed in thechapters “direct wiring” or “single sided wiring”.Due to the polycarbonate cover and the anodized aluminum profile SubstiTUBE ® offers a veryrobust and thermally optimized design. This allows the use in most luminaire types and results in along lifetime. Temperature measurements at the reference point Tc (see figure below) will allow theanalysis of proper operation. Using LED with OSRAM FineWhite/ANSI Binning results in tubes withextremely homogeneous white color coordinates, showing no distinguishable color differenceswithin a SubstiTUBE ® . The internally structured cover mixes the light of the 18 LED spots andleads to a uniform mid- and far field light characteristic with 70° x 90° opening angle. The integratedECG protects reliably from overpower, overheat, short- and open-circuit.

SubstiTUBE ® dimensions

VDEREG.-Nr. D457





1. Product description

1.1 General

Safety andapplicationinformation

• SubstiTUBE ® safety has been tested and certified by VDE•

Protection class: IP20. For applications with external risk of moisture and dust a luminaire withadequate protection has to be used• Only for use with standard IEC compliant G13 lamp holders• Lamp works in most luminaires, without thermal problems, tc point should be checked (max.

75°C) within closed luminaires or in high temperature applications• Maximum 36-66 lamps at one circuit breaker 16A, B or C characteristic (depending on

installation conditions / inrush current limitation may be necessary for more lamps, switchesmust be suitable for high inrush currents)

• The effective value of the energy saving depends on the efficiency of the luminaire setup to bereplaced and should be considered individually in each case

• The SubstiTUBE ® must not be damaged or operated in a damaged condition• Operation with CCG• Not for operation with ECG (Rewiring necessary)• Not dimmable





2. Installation options

2.

Installationoptions

Which configuration fits to what kind of luminaire? Which setup leads to which advantages and

disadvantages? Described below are the possible options. Please refer to the following chapters formore details.

2.1 Overview Retrofitting a CCG luminaireAdvantages: - Very easy and safe installation of SubstiTUBE ®

- The certification of the luminaire remains valid.- The luminaire can still be used for fluorescent lamps when the normal starter is reinstalled.Disadvantage: - Losses of CCG remain, but are significantly reduced.For more details please refer to chapter 2.2 “Retrofitting a CCG luminaire”.- Powerfactor reducing with coil and compensation condensators

Direct wiringAdvantages: - Further energy savings possible- Better powerfactor- Correct insertion of SubstiTUBE ® independet from orientationDisadvantages: - Luminaire certification gets void- Must be done by qualified personal only- To operate a flourescent lamp the rewiring must be undonePlease refer to chapter 2.3.1 “Direct wiring” for more details.

Single sided direct wiringAdvantages: - Easier wiring of existing or new luminaires than the above mentioned direct wiring processDisadvantages: - SubstiTUBE ® may be inserted with wrong orientation leading to shortcircuits- To operate a fluorescent lamp the rewiring must be undone- Please refer to chapter 2.3.2 Single sided direct wiring.

SubstiTUBE ®

CCG luminaire

ECG luminaire

noCG luminaire

Retrofitting a CCGluminaire

Direct wiring

Single sideddirect wiring

Overview of possible installations






Exchanging the starter and replacing the lamp is all what needs to be done to upgrade an existing

luminaire with conventional control gear to newest OSRAM LED-technology. The fluorescent lamphas to be exchanged with SubstiTUBE ® and the starter being replaced by SubstiTUBE ® Start. Thebuilt-in CCG can be used as it is and existing certifications remain valid. Its losses are reduced toohmic losses of about 1W to 2W.If the starter has not been changed to SubstiTUBE ® Start the luminaire will start blinking. Pleaseswitch off immediately and change the starter, because SubstiTUBE ® can be damaged.SubstiTUBE ® can be used in luminaires with changeable starter only. Existing power factorcompensation capacitors worsen the power factor, but may remain within the luminaire. In case aconventional fluorescent lamp is being inserted when the SubstiTUBE® Start is in place, the lampends will gleam, but the lamp will not be destroyed.

Installation Instructions• Make sure that the supply voltage is disconnected• Remove the conventional lamp• Replace the old starter with SubstiTUBE ® Start• Insert SubstiTUBE ® into lamp holders and check the light distribution angle

• SubstiTUBE ® Start (with fuse 250V, T2A) necessary for operation and safety

2.2

Retrofittingin a CCGluminaire

Duo circuit double lamp luminaires can be refitted analogue to single lamp luminaires.

Retrofitting for common lamp holders

Circuit diagram of a retrofitted CCG luminaire

Circuit diagram of a retrofitted double lamp CCG luminaire

SubstiTUBE ®

SubstiTUBE ® Start

CCG

UN

SubstiTUBE ®

SubstiTUBE ® Start

CCGp.f. corretion capacitor

SubstiTUBE ®

SubstiTUBE ® Start

CCG UN

p.f. corretion capacitor

http://www.rezeptewiki.org/images/3/36/Warnung.svg






Disconnect from mains

2.2.1 Sample installation CCG luminaire

Save and easy exchange of a T8 fluorescent lamp by a SubstiTUBE ®

Remove the starter of the fluorescent lamp

Remove the fluorescent lamp

Exchange the conventional starter with

SubstiTUBE ®

Start. Here: conventionall starter marked with black cap.

Insert the SubstiTUBE ® Start

Connect to mains

Check if the luminaire is powered by

a CCG (look for a starter)

Insert SubstiTUBE ®






Installation instructions

• Rework by qualified electricians only• Make sure that the supply voltage is disconnected• Remove the conventional lamp• Remove power factor correction capacitor (if installed) to improve power factor• Rewire the luminaire as shown in the circuit diagram above• Use SubstiTUBE ® Start or a fuse (250V, T2A)• Insert SubstiTUBE ® into lamp holders and check the light distribution angle

• SubstiTUBE ® Start or fuse (250V, T2A) is necessary for installation protection• Do not insert fluorescent lamps, they will be destroyed

2.3 Direct line

voltageconnection

2.3.1 Directwiring

If an ECG luminaire is retrofitted or the losses of CCGs should be eliminated, the luminaire must be

rewired, as described in 2.3.1 “Direct wiring” or 2.3.2 “Single sided direct wiring”. Analogueproceeding is recommended for new luminaires.Existing luminaire certificates will get void when the luminaire is modified. For new certification anaccredited test institute needs to be contracted.

It is recommended to rewire a luminaire on both sides as shown below. Thus SubstiTUBE ® can beinserted in any direction with standardized IEC compliant G13 lamp holders. All wires need to beapproved for the existing voltages and appliance class. Usually solid wires with single isolation canbe used for class I, double insulation wires could be used for class II. The maximum wire cross-section for lamp holders and starters is typically 0.5mm2. Built-in control gears must not remainconnected after rewiring.

SubstiTUBE ®

SubstiTUBE ® Start or fuse UN

Double lamp luminaires can be refitted analogue to single lamp luminaires. The luminaires are to be

wired as shown below.

Direct wiring circuit diagram of a retrofitted double lamp luminaire

SubstiTUBE ®

U N

SubstiTUBE ®

SubstiTUBE ® Start or fuse

Direct wiring circuit diagram of a retrofitted luminaire







Direct wiring of a luminaire for SubstiTUBE ® (control gear removed).2.3.1.1

Sampleinstallationdirect wiring

L, N connection to terminal SubstiTUBE ® Start

G13 lamp holder

Make sure to modify the wiring completely, otherwise e.g. short circuits could lead to damage.






The wiring of new or existing luminaires without control gear can also be done following the circuit

diagram below by wiring only one side of the luminaire.Please take care to insert SubstiTUBE ® with the correct side to the wired end. Successful operationis only possible if the wired lamp holder of the luminaire is connected to the end with the crimpedpins of SubstiTUBE ® . Please refer to the picture next page for details. The massive pins at theother end are internally short circuited! Direct connection to mains with the massive pins will causea short circuit. The use of SubstiTUBE ® Start or an adequate fuse is highly recommended for a safeoperation.SubstiTUBE ® can be connected with standardized IEC compliant G13 lamp holders. Usually solidwires with single isolation can be used for class I, double insulation wires could be used for class II.The maximum wire cross-section for lamp holders and starters is typically 0.5mm2. For furtherinformation please check DIN EN 60598. Built-in control gears must not remain connected afterrewiring.

2.3.2 Single

sided directwiring

Installation instructions• Rework by qualified electricians only• Make sure that the supply voltage is disconnected• Remove the conventional lamp• Remove power factor correction capacitor (if installed)• Rewire the luminaire as shown in the circuit diagram• Use SubstiTUBE ® Start or a fuse (250V, T2A)• Insert SubstiTUBE ® with the end with crimped pins (see pictures next side) into the wired lamp

holder and check the light distribution angle

• SubstiTUBE ® Start or fuse (250V, T2A) necessary for safety, in case of fluorescent lamp isinserted or SubstiTUBE ® is inserted in the wrong way with massive pins to wired luminaire end.

• Connection with the wrong end of SubstiTUBE ® with massive pins will cause short circuit• Do not insert fluorescent lamps into retrofitted luminaires, they will be destroyed

SubstiTUBE ® UN

SubstiTUBE ® Startor fuse

Single sided direct wiring circuit diagram of a retrofitted luminaire

Double lamp luminaires can be refitted analogue to single lamp luminaires. The luminaires are to bewired as shown below.

Direct single sided wiring circuit diagram of a retrofitted double lamp luminaire

SubstiTUBE ®

UN

SubstiTUBE ®

SubstiTUBE ® Start or fuse







Single sided direct wiring of a luminaire for SubstiTUBE ®

SubstiTUBE

®

only operates correctly in single sided direct wiring if it is installed as described on the previous page. The correct side to be connected to mains can be determined by taking a look at the pins and the lamp marking.

2.3.2.1

Sampleinstallationsingle sideddirect wiring

L, N connection to terminal SubstiTUBE ® Start

G13 lamp holder, connected

crimped pins lamp marking

Inserting SubstiTUBE ® with the correct end (with crimped pins) into the only G13 lamphoder which is rewired.





3. Light distribution aspects

SubstiTUBE ® T8 reflector luminaire

650 lx 700 lx

160 lx 175 lx

1 m

2 m

Luminous Flux System Efficiency Illuminance d=1m Illuminance d=2m

SubstiTUBE ® ST8-SD4-765 1550lm 66lm/W 650lx 160lx

36W batten fixture 3350lm 75lm/W 300lx 77lx

36W reflector fixture 3350lm 75lm/W 700lx 175lx

Light distribution false color display of SubstiTUBE ® in a small room

Light distribution false color display of T8 reflector luminaire in a small room

Light distribution of SubstiTUBE ® Light distribution of T8 reflector luminaire in a small room

Due to the characteristic light distribution of SubstiTUBE ® , the current luminaire light characteristic will change.

Reflectors will mostly have only little impact on the resulting beampattern.If the application is subject to certain standards, a photometric check of the installation with SubstiTUBE isrecommended to assure the conformity.To allow an application based comparison between SubstiTUBE ® and conventional fluorescent tube it is necessary tofocus on the illuminance (Lux) at the relevant area instead of the luminous flux (Lumen) of the lamp. Due to the tightopening angle attractive Lux levels can be achieved although the total Lumen output is less than compared tofluorescent tubes.

* Please refer to the datasheet, containing further information regarding illumination levels. .ldt or .ies files may be downloaded at www.osram.com





4. Power savings

Lamp powerCCG dissipated power+ compensation*

Luminaire system power*

SubstiTUBE ® 23,5W 1W – 1,5W 25W

T8 FL-tube 36W 5W–13W 41W–49W

4. Power

savings

Basic power- and energy savings realized with SubstiTUBE ® can be calculated easily. Knowing the

number of retrofitted luminaire, system power of these luminaires and operation time is sufficient.The system power consists of lamp power (e.g. 36W) plus dissipated power within the control gear.Mostly this information can be found in the datasheet of the luminaire. However the system powercan also be measured with a wattmeter.Losses in CCG luminaires are caused mainly by magnetic control gears and capacitors. Withindouble lamped luminaires an additional capacitor is fitted for system compensation. The additionalcapacitor increases the system power significantly so that the overall power is more than doubledcompared to single lamped luminaiers.With SubstiTUBE ® the losses of the magnetic control gear and additional capacitors are reduced tomainly ohmic losses. Some typical values can be found below.

* Due to the large number of variations the real values may vary.

The overall power savings Psav of a whole installation can be calculated as follows:

Psav = x ∗ (Psc - Pss)

withx = amount of retrofitted lampsPsc = system power old (T8 FL-tube + CCG losses)P

ss= system power new (SubstiTUBE ® + reduced CCG losses)

These will result in the following energy savings Esav [kWh]:

Esav = Psav ∗ top

withtop = operation time [hours]

In applications with air conditioning, additional energy savings can be achieved. As less energy isbeing brought into a building, less energy has to be compensated by the air condition. These powersavings can be calculated when the air conditioning factor is known, which depends on thecharacteristics of the building, such as thermal isolation etc. For a very rough estimation the

aircondition factor value 1 maybe assumed. So 1W saved energy for illumination could lead toanother 1W saved in airconditioning.

Lamp powerCCG dissipated power+ compensation*

Luminaire system power*

SubstiTUBE ®

47W 2W–3W 49W–50WT8 FL-tube 79W 17W–33W 96W–112W

Single lamp luminaire

Double lamp luminaire

Possible saved energy up to 50%





Further Information

OSRAM GmbH

Head OfficeHellabrunner Strasse 1

D - 81543 MunichGermanyPhone +49 (0)89 6213-0Fax +49 (0)89 6213-20 20www.osram.com

Brochure „A new approach to light“www.osram.com/led-systems-downloads

1EZW001GB

Brochure „Better light – in every respect.“www.osram.com/led-systems-downloads

400D125GB

Flyer „OSRAM SubstiTUBE ® “www.osram.com/led-systems-downloads

1EBW004GB

Downloads: datasheet, eulumdat files www.osram.com/downloads

www.osram.com/substitube

http://www.osram.com/led-systems-downloads



http://www.osram.com/downloads

http://www.osram.com/downloads




Application Note Subs Ti Tube (Gb)

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