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Application Note SubstiTUBE

ST8-SD4

Index
1. Product description 1.1 General Safety and application information 2. Installation options 2.1 Overview 2.2 Retrofitting in a CCG luminaire 2.2.1 Sample installation CCG luminaire 2.3 Direct line voltage connection 2.3.1 Direct wiring 2.3.2 Single sided direct wiring 3. Light distribution aspects 4. Power savings 5. Further information Page 3 4 5 6 7 8 10 12 13 14

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1. Product description
1. Product description 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 easy replacement of conventional fluorescent tubes in CCG luminaires, providing instant on LED-light without warm up time. The exchange of starter and the replacement of the lamp is all what needs to be done. Not enough? The rewiring of the luminaire can create additional savings by reducing the ohmic losses of the CCG. Even ECG luminaires can be equipped with SubstiTUBE when being reworked as discribed in the chapters direct wiring or single sided wiring. Due to the polycarbonate cover and the anodized aluminum profile SubstiTUBE offers a very robust and thermally optimized design. This allows the use in most luminaire types and results in a long lifetime. Temperature measurements at the reference point Tc (see figure below) will allow the analysis of proper operation. Using LED with OSRAM FineWhite/ANSI Binning results in tubes with extremely homogeneous white color coordinates, showing no distinguishable color differences within a SubstiTUBE . The internally structured cover mixes the light of the 18 LED spots and leads to a uniform mid- and far field light characteristic with 70 x 90 opening angle. The integrated ECG protects reliably from overpower, overheat, short- and open-circuit. 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 ST8-SD4-765 ST8-SD4-840 ST8-SD4-830 Product ST8-SD4-765 ST8-SD4-840 ST8-SD4-830

Color temperature 6500K 4000K 3000K Ambient temperature ta -3040C -3040C -3040C

Luminous Flux* 1550lm 1200lm 1200lm Temperature tc point max. 75C 75C 75C

Voltage UN Frequency 220-240V 220-240V 220-240V Lifetime tc<65C 50000h 50000h 50000h 50/60Hz 50/60Hz 50/60Hz Weight 420g 420g 420g

Power 23,5W 23,5W 23,5W Power factor 0,5 0,5 0,5

Beam angle 70 x 90 70 x 90 70 x 90 with CCG** 0,6 - 0,8 0,6 - 0,8 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.

tc SubstiTUBE dimensions

VDE
REG.-Nr. D457

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1. Product description
1.1 General Safety and application information SubstiTUBE safety has been tested and certified by VDE Protection class: IP20. For applications with external risk of moisture and dust a luminaire with adequate 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. 75C) 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, switches must be suitable for high inrush currents) The effective value of the energy saving depends on the efficiency of the luminaire setup to be replaced 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

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2. Installation options
2. Installation options 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 for more details.

2.1 Overview Retrofitting a CCG luminaire Advantages: - 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 wiring Advantages: - Further energy savings possible - Better powerfactor - Correct insertion of SubstiTUBE independet from orientation Disadvantages: - Luminaire certification gets void - Must be done by qualified personal only - To operate a flourescent lamp the rewiring must be undone Please refer to chapter 2.3.1 Direct wiring for more details. Single sided direct wiring Advantages: - Easier wiring of existing or new luminaires than the above mentioned direct wiring process Disadvantages: - 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.

CCG luminaire SubstiTUBE ECG luminaire noCG luminaire Overview of possible installations

Retrofitting a CCG luminaire Direct wiring Single sided direct wiring

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2. Installation options
2.2 Retrofitting in a CCG luminaire 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 lamp has to be exchanged with SubstiTUBE and the starter being replaced by SubstiTUBE Start. The built-in CCG can be used as it is and existing certifications remain valid. Its losses are reduced to ohmic losses of about 1W to 2W. If the starter has not been changed to SubstiTUBE Start the luminaire will start blinking. Please switch off immediately and change the starter, because SubstiTUBE can be damaged. SubstiTUBE can be used in luminaires with changeable starter only. Existing power factor compensation capacitors worsen the power factor, but may remain within the luminaire. In case a conventional fluorescent lamp is being inserted when the SubstiTUBE Start is in place, the lamp ends will gleam, but the lamp will not be destroyed.
CCG UN p.f. corretion capacitor SubstiTUBE Start SubstiTUBE

Circuit diagram of a retrofitted CCG luminaire

Retrofitting for common lamp holders 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

Duo circuit double lamp luminaires can be refitted analogue to single lamp luminaires.
UN CCG p.f. corretion capacitor CCG

SubstiTUBE Start SubstiTUBE

SubstiTUBE Start SubstiTUBE

Circuit diagram of a retrofitted double lamp CCG luminaire

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2. Installation options
2.2.1 Sample installation CCG luminaire Save and easy exchange of a T8 fluorescent lamp by a SubstiTUBE

Disconnect from mains

Exchange the conventional starter with SubstiTUBE Start. Here: conventionall starter marked with black cap.

Check if the luminaire is powered by a CCG (look for a starter)

Insert the SubstiTUBE Start

Remove the starter of the fluorescent lamp

Insert SubstiTUBE

Remove the fluorescent lamp

Connect to mains

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2. Installation options
2.3 Direct line If an ECG luminaire is retrofitted or the losses of CCGs should be eliminated, the luminaire must be voltage rewired, as described in 2.3.1 Direct wiring or 2.3.2 Single sided direct wiring. Analogue connection proceeding is recommended for new luminaires. Existing luminaire certificates will get void when the luminaire is modified. For new certification an accredited test institute needs to be contracted. 2.3.1 Direct wiring It is recommended to rewire a luminaire on both sides as shown below. Thus SubstiTUBE can be inserted in any direction with standardized IEC compliant G13 lamp holders. All wires need to be approved for the existing voltages and appliance class. Usually solid wires with single isolation can be used for class I, double insulation wires could be used for class II. The maximum wire crosssection for lamp holders and starters is typically 0.5mm2. Built-in control gears must not remain connected after rewiring.

SubstiTUBE Start or fuse

UN

SubstiTUBE
Direct wiring circuit diagram of a retrofitted luminaire

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

Double lamp luminaires can be refitted analogue to single lamp luminaires. The luminaires are to be UN wired as shown below.
SubstiTUBE Start or fuse

SubstiTUBE

SubstiTUBE

Direct wiring circuit diagram of a retrofitted double lamp luminaire

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2. Installation options
2.3.1.1 Direct wiring of a luminaire for SubstiTUBE (control gear removed). Sample installation direct wiring

G13 lamp holder

L, N connection to terminal

SubstiTUBE Start

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

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2. Installation options
2.3.2 Single sided direct wiring 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 operation is only possible if the wired lamp holder of the luminaire is connected to the end with the crimped pins of SubstiTUBE. Please refer to the picture next page for details. The massive pins at the other end are internally short circuited! Direct connection to mains with the massive pins will cause a short circuit. The use of SubstiTUBE Start or an adequate fuse is highly recommended for a safe operation. SubstiTUBE can be connected with standardized IEC compliant G13 lamp holders. Usually solid wires 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 further information please check DIN EN 60598. Built-in control gears must not remain connected after rewiring.

SubstiTUBE Start or fuse UN SubstiTUBE

Single sided direct wiring circuit diagram of a retrofitted luminaire

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 is inserted 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

Double lamp luminaires can be refitted analogue to single lamp luminaires. The luminaires are to be UN wired as shown below.
SubstiTUBE Start or fuse

SubstiTUBE

SubstiTUBE

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

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2. Installation options
Single sided direct wiring of a luminaire for SubstiTUBE 2.3.2.1 Sample installation single sided direct wiring

G13 lamp holder, connected

L, N connection to terminal

SubstiTUBE Start

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. crimped pins lamp marking

Inserting SubstiTUBE with the correct end (with crimped pins) into the only G13 lamphoder which is rewired.
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3. Light distribution aspects

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 is recommended to assure the conformity. To allow an application based comparison between SubstiTUBE and conventional fluorescent tube it is necessary to focus on the illuminance (Lux) at the relevant area instead of the luminous flux (Lumen) of the lamp. Due to the tight opening angle attractive Lux levels can be achieved although the total Lumen output is less than compared to fluorescent tubes. SubstiTUBE T8 reflector luminaire

650 lx 1m 160 lx 2m

700 lx

175 lx

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

Luminous Flux SubstiTUBE ST8-SD4-765 1550lm 36W batten fixture 36W reflector fixture 3350lm 3350lm

System Efficiency 66lm/W 75lm/W 75lm/W

Illuminance d=1m 650lx 300lx 700lx

Illuminance d=2m 160lx 77lx 175lx

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

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4. Power savings
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 power can also be measured with a wattmeter. Losses in CCG luminaires are caused mainly by magnetic control gears and capacitors. Within double lamped luminaires an additional capacitor is fitted for system compensation. The additional capacitor increases the system power significantly so that the overall power is more than doubled compared to single lamped luminaiers. With SubstiTUBE the losses of the magnetic control gear and additional capacitors are reduced to mainly ohmic losses. Some typical values can be found below. Single lamp luminaire Lamp power SubstiTUBE T8 FL-tube 23,5W 36W CCG dissipated power Luminaire system power* + compensation* 1W 1,5W 25W 5W13W 41W49W Possible saved energy up to 50% Double lamp luminaire CCG dissipated power Luminaire system power* + compensation* 2W3W 49W50W 17W33W 96W112W

Lamp power SubstiTUBE T8 FL-tube 47W 79W

* 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) with x = amount of retrofitted lamps Psc = system power old (T8 FL-tube + CCG losses) Pss = system power new (SubstiTUBE + reduced CCG losses) These will result in the following energy savings Esav [kWh]: Esav = Psav top with top = operation time [hours] In applications with air conditioning, additional energy savings can be achieved. As less energy is being brought into a building, less energy has to be compensated by the air condition. These power savings can be calculated when the air conditioning factor is known, which depends on the characteristics 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 to another 1W saved in airconditioning.
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www.osram.com/substitube

Further Information Brochure A new approach to light Brochure Better light in every respect. Flyer OSRAM SubstiTUBE Downloads: datasheet, eulumdat files www.osram.com/led-systems-downloads 1EZW001GB www.osram.com/led-systems-downloads 400D125GB www.osram.com/led-systems-downloads 1EBW004GB www.osram.com/downloads

OSRAM GmbH Head Office Hellabrunner Strasse 1 D - 81543 Munich Germany Phone +49 (0)89 6213-0 Fax +49 (0)89 6213-20 20 Application note SubstiTUBE | 14.02.2011 | Page 14 www.osram.com
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