Luminus Devices PhlatLight DK-125M Series User manual

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PhlatLight LED
Development Kit Manual
DK-125M and DK-136M Series
Confidential © Luminus Devices, Inc - All Rights Reserved
960004 RevA
Page 1
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Table of Contents
1. Introduction
2. General Description
3. Evaluation Kit Contents
A. Heat Sink Module
B. Cable Assembly
C. Driver Card
4. Use Instructions
A. PhlatLight™ Device Mounting Instructions
B. Additional Lab Equipment Needed By User
C. Driver Card Operation Step-by-step Instructions
Appendix
A. Thermistor reading
B. Precautions for ESD (Electrostatic Sensitive Devices)
C. PhlatLight™ Window Cleanliness
D. Heat Sink Module Drawing - Top View
1. Introduction
Luminus Devices' Chipsets have been designed from the
ground up to illuminate light engines. They are the leading
solid state light source optimized for high brightness applica-
tions. This evaluation kit is intended to be used for general
evaluation of Luminus' Photonic-Lattice Technology, and to
assist with designs. The evaluation kit consists of two chipsets
of PhlatLight™ devices, heat sinks as well as electrical drivers
for continuous and pulsed operation.
2. General Description

Confidential © Luminus Devices, Inc. - All Rights Reserved
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Evaluation Kit Manual - Revision A
Each PhlatLight™ device in the kit has its own separate heat sink,
cable assembly and driver card allowing easy interfacing to a
wide variety of light engines or optical elements. This evaluation
kit is designed for general purpose evaluation of PhlatLight™ de-
vices. This kit is therefore not optimized for space or power effi-
ciency. Heat sinks and drivers included in the evaluation kit are
not intended to represent reference designs for final products.
However, they can be used as starting points for further custom-
ization and optimization. The driver boards include functionality
which is intended to make evaluation easy. Therefore, not all
functionality included on the board will be needed in a product
design.
PhlatLight™ devices can be operated in continuous (CW) mode or
pulsed mode. In continuous mode operation the device is driven
by a steady current. In pulsed mode the device is pulsed with a
peak current value for intervals of time defined by a duty cycle.
A 50% duty cycle means that the device is driven for 50% of the
time at specified peak current. A 100% duty cycle will actually be
a case of continuous operation. The driver card is designed to op-
erate in both CW and pulsed modes.
Test points are provided on the driver card so that the device for-
ward voltage, current, thermistor, and various other circuit func-
tions can be monitored. The circuit layout uses 0805 and 1206
size components to encourage modification and experimentation
as required by the user.
3. Evaluation Kit Contents
The evaluation kit contains:
1. Thermal management solution
a. Heat sinks with fans (with < 0.3 °C/W thermal resistance
from heat sink to ambient)
b. Thermal interface material (eGraf thermal pads)
2. Electrical interface to PhlatLight™ devices
a. Cables to connect tabs on devices to driver circuit
b. Driver card for controlling operation for PhlatLight™ devices
*Typically at least 2 chipsets are purchased with the evaluation
kit
A. Heat Sink Module
The heat sink module (Figure 1) consists of an air cooled heat
sink, fan, connector and mounting bracket. The module can be
bolted say to a light engine using four mounting holes on the
bracket or stand upright on the bench using the optional stand-
alone legs. All connections for driving the device, fan, and read-
outs for thermistor are made via a 10 pin Weidmuller 3.5mm
pitch Omnimate connector. The module is designed to work with
the Luminus driver card or can be used with the customers own
driver along with a +12V supply for powering the fan. The Omni-
mate connector plug has screw clamps to allow for easy wiring.
All the heat sink modules are similar and are not specific to a par-
ticular device type or color.

Confidential © Luminus Devices, Inc. - All Rights Reserved
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Evaluation Kit Manual - Revision A
Figure 1: Heat sink module
Figure 2: Heat sink module
B: Cable Assembly
Each device connects to its own driver via a 12" long cable. For
optimum performance it is best not to increase the length of the
cable. Figure 3 shows picture of the device to driver cable.
The color code for the wires is as follows:
RED 18 gauge wire: PhlatLight™ anode
BLACK18 gauge wire: PhlatLight™ cathode
WHITE/BLUE 24 gauge wire: Thermistor connections
RED 24 gauge wire: Fan +12V power
BLACK 24 gauge wire: Fan negative return (GND)
Figure 3: Device to driver cable assembly
Figure 4 and Figure 5 show how to connect the connectors of ca-
ble assembly to the connectors on the heat sink module and the
driver card. Note that the cable assembly connectors are posi-
tioned such that the screw heads are always facing towards user.
The connectors on each end of the cable are the same. Always
make sure that connection is made such that the heavy gauge
wires are hooked up to the anode and cathode of the device. Re-
versing the cable may damage the cable.

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Evaluation Kit Manual - Revision A
Figure 4: Connection to heat sink module
Figure 5: Connection to driver card (cable from device)
In addition, each driver card connects to a power supply by
means of a 36" cable. See Figure 6 for a picture of the 2 types of
connectors on the power supply cable. One end has banana plugs
to facilitate connection to a power supply and the other end has
a 2 pin socket block connector.
The color code for the wires is as follows:
RED 14 gauge wire: "+" of power supply
BLACK14 gauge wire: "-" of power supply
Figure 6: Power supply cable connectors
There is only one correct way to connect this cable to the driver
card. Figure 7 shows how to connect the cable to the driver card.
Note that the cable assembly connector is positioned such that
the screw heads are always facing towards user.
Figure 7: Power supply cable to driver card

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Evaluation Kit Manual - Revision A
C: Driver Card
A driver card is designed for operating PhlatLight™ devices up to
the recommended operating currents. For each device type,
namely, PT120/CBT120 and PT85 there is a separate driver card
designed specifically for that device. The input voltage require-
ments for a given driver card vary depending on the functionality
that is expected of the card. Table 1 gives a brief overview about
key driver card parameters and its compatibility across Phlat-
Light™ products family.
1 The output current provided by the driver card can exceed recommended operating currents for PT85 devices
2 The PT120 devices can only be operated up to 13A in CW and 22A in pulsed mode with this card
3 The CBT120 device can only be operated up to 13A in CW and 22A in pulsed mode with this card
A driver card for a device type can be used for all colors of that
particular device type. E.g. a PT85 driver card can be used for
RED, GREEN or BLUE color. However, users should refer to the
technical data sheets of a device to check the recommended op-
erating currents.
Figure 8 shows the top view of a PT120/CBT120 driver card. The
pins, switches and readouts that are commonly expected to be
used are shown. The overall layout of driver card for PT85 is sim-
ilar to the PT120/CBT120 driver card layout. However, compo-
nent values are changed to match desired operation range.
Table 1: Driver Card Configurations
Driver Card Input Voltage Output Current
(CW)
Output Current
(Pulsed)
Evaluation Options for Phlat-
Light™ Products Family
PT120/
CBT120
12V 18A 30A PT85: Yes1
PT120: Yes
CBT120: Yes
PT85 12V 13A 22A PT85: Yes
PT120: Yes2
CBT120: Yes3

Confidential © Luminus Devices, Inc. - All Rights Reserved
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Evaluation Kit Manual - Revision A
Figure 8: Driver card pin layout (example of PT120/CBT120 driver card)
4. Use Instructions
A. PhlatLight™ Device Mounting Instructions
For precautions for ESD and guidelines for device window clean-
liness, refer to Appendix B and C respectively.
Careful application of the thermal interface material (eGraf ther-
mal pad) is required to minimize thermal resistance. The follow-
ing procedure describes recommended steps for mounting of
PhlatLight™ devices on heat sink.
1. Use a thermal pad of an area slightly larger than the area of
the core board (Figure 9).
Figure 9: Thermal pad and device

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Evaluation Kit Manual - Revision A
2. Place the thermal pad on the heat sink with pre-drilled holes
matching the hole pattern on the core board of the device (Fig-
ure 11).
Figure 10: Pre-drilled holes
Figure 11: Thermal pad on heat sink
3. Carefully place the device on the thermal pad such that the
hole patterns match and also the tabs from the leads from the
device align well with the solder tabs of the PCB (Figure 12).
Figure 12: Device aligned on heat sink
4. Insert screws in the holes of the core board. Tighten the screws
with a screw driver in a pattern such that each screw is tight-
ened alternatively and there is equal pressure by all the screws
on the core board. Tighten those making sure that there are no
gaps between the core board and heat sink (Figure 13). To en-
sure this, we recommend using a torque wrench to tighten the
screws with torque settings of 40 Oz-Inches (0.2825 Newton-
meter in metric units.)
Figure 13: Device mounted on heat sink and is now
ready for electrical connections

Confidential © Luminus Devices, Inc. - All Rights Reserved
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Evaluation Kit Manual - Revision A
B. Additional Lab Equipment Needed By User
Table 2 suggests additional lab equipment needed for evaluating
PhlatLight™ devices.
The Lambda power supply recommended in Table 2 assumes op-
eration of one device at a time.
C. Driver Card Operation Step-by-step Instructions
Arrange the evaluation kit, required lab power supplies and mea-
surement equipment (e.g. digital multimeters, oscilloscope)
preferably on one table. Refer to Figure 16 for an example of
equipment set up for evaluation (no wire connections shown). It
is recommended that the table is equipped with ESD (Electro-
static Sensitive Device) safe arrangement. Please refer to Appen-
dix for ESD precautions.
Table 2: Additional lab equipment
Lab Equipment Luminus Recommendation
12V Lab Power Supply Lambda ZUP20-20
Oscilloscope Tektronix TDS 3024B
Waveform Generator Agilent 33220A
Multimeter Fluke 187
Photodetector Thorlabs PDA10A

Confidential © Luminus Devices, Inc. - All Rights Reserved
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Evaluation Kit Manual - Revision A
Figure 16: Equipment set up for PhlatLight™ evaluation (example)
Mount the devices on heat sinks as discussed in section A. Then
go through the following steps to evaluate the devices.
1. Make sure power supply is OFF and the power switch (ON/
OFF switch in Figure 8) on the driver card is OFF.
2. Connect driver card to heat sink module on which device is
mounted.
3. Connect power supply to driver card using the cable supplied
with the kit.
4. Turn the Current Control Knob on the driver card all the way
counter clockwise.
5. Set middle switch (Current Control/Manual Control switch in
Figure 8) to "Manual".
6. Set right switch (CW/Pulsed switch in Figure 8) to "CW" for
continuous operation.
7. Turn on power supply and set to correct output voltage, 12V,
as specified for the driver card.
8. Turn power switch on driver card to "ON". The device may be
slightly lit at this point.
9. Check to make sure that the two fans, one on driver card and
one on heat sink module, are running.
10. Using a digital voltmeter (DVM) check that the supply voltage
on the driver card is correct. You should use the test point
"TP4" which is labeled "VIN" at lower right corner of card. If
this voltage is zero check to see if the fuse is blown.
11. Connect DVM to "GND" and "LED CURRENT" test points to
Waveform
Generator
Power
Supply
Driver Card
Oscilloscope Digital
Multimeter
Heat Sink
Module
Photodetector

Confidential © Luminus Devices, Inc. - All Rights Reserved
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Evaluation Kit Manual - Revision A
monitor current through the device. The output is 10mV/
Amp. It is good practice to always monitor this output to
make sure that the device is always driven within its limits.
12. Turn the knob on the driver card clockwise while monitoring
the current. This will drive more current in the device.
13. To operate in pulse mode, connect a pulse generator to
"Pulse Input" BNC. Pulse Generator should have an output
signal set to TTL levels or 0-5V. Using an oscilloscope, moni-
tor the pulse generator output at the "PULSE INPUT" test
point.
14. Turn the current control knob all the way counter clockwise
and set the right switch to "PULSE". The driver card is now op-
erating the device in pulse mode. The "Current Control" knob
sets the amplitude of the current and the pulse generator
sets the width of the pulse. Proper operation is best moni-
tored by using a photodetector to monitor device's light out-
put. Current amplitude can still be monitored using the "LED
CURRENT" test point.
16. Device current amplitude can also be controlled using an ex-
ternal signal. Connect a signal source (0-5V max) to the
"CURRENT CONTROL INPUT" BNC. Monitor using the "CUR-
RENT CONTROL" test point. Switch the middle switch to
"CURRENT CONTROL" and the driver now uses the input signal
instead of the current control knob to set the LED current
amplitude. This input can be used both in CW and Pulse
mode. Note that the max output current corresponds to 5V
input and is the maximum level specified for the specific
driver card regardless of whether operation is CW or Pulse.
Note 1: Due to the high amount of current generated by the driv-
er card, there is some audible noise created by the circuit. This
issue is known and is being worked on for next revision of the
driver card.
Note 2: Always refer to the technical data sheet of the device for
recommended operating current values.
Figures 17, 18 and 19 show oscilloscope traces for a GREEN Phlat-
Light™ PT120 device operated at 30A, 50% duty cycle and 2.88kHz
frequency. The pink trace is the input pulse and the green trace
is the photodetector output. These traces are shown for refer-
ence. Actual waveforms may depend on individual driver boards,
devices and settings.
Figure 17 shows the input and output pulse.
Figure 17: Input and output pulse (example)
Figure 18 shows the rise time of the output pulse (rise time 1 µs).
Figure 19 shows the fall time of the output pulse (fall time 1 to 2
µs).
Figure 18: Rise time (example)

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Figure 19: Fall time (example)

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Appendix
A. Thermistor Reading
The thermistor on the core-board of a PhlatLight™ device facili-
tates measurement of core-board temperature during operation.
The procedure to calculate the thermistor temperature for a de-
vice is in operation is as follows.
1. Measure the voltage (VOUT) at the "THERMISTOR" test point on
the driver card using a DVM.
2. Use the chart in Figure 20 to calculate the thermistor temper-
ature.
Figure 20: Thermistor temperature calculation chart
0
0.2
0.4
0.6
0.8
1
1.2
1.4
1.6
1.8
2
2.2
2.4
2.6
2.8
3
3.2
3.4
3.6
3.8
4
0 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100
The rmistor Te mpe rature (°C)
VOUT (volts)

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Evaluation Kit Manual - Revision A
B. Precautions for ESD (Electrostatic Sensitive Devices)
PhlatLight™ devices are electrostatic sensitive. Static Electricity
is generated by the simple contact and separation of materials,
by movement of people and by air currents. ESD-type damage can
create hidden failures. This means that the failure may not actu-
ally show up until the device is used for a period of time. The fol-
lowing procedures are essential in minimizing the risk of damage
to PhlatLight™ devices due to electrostatic discharge.
1. When a person carries a PhlatLight™ device (in conductive car-
riers or trays) to another bench, prior to placing the units on a
static dissipative/conductive surface, he/she must first touch
the surface with his/her bare hand in order to drain any static
electricity from their body.
2. Handling all PhlatLight™ devices shall be done at ESD con-
trolled work station. All ESD workstations shall have conduc-
tive/static dissipative work surfaces to prevent generation and
build-up of static charges. Each mat/laminate surface shall be
connected by a grounding wire to ground.
3. Personnel grounding is required prior to handling any Phlat-
Light™ devices. This can be done by using wrist straps or
ground cords.
4. Tweezers, gloves or finger cots must be worn when handling
all PhlatLight™ devices.
5. PhlatLight™ devices should be stored in covered conductive
trays whenever possible.
C. PhlatLight™ Window Cleanliness
The glass window in a PhlatLight™ device serves as a protection
for the die and also for the wire bonds. It is important that the
window is clean to ensure optimum brightness when the device is
in operation. The following can be done to keep the window
clean:
1. Do not touch the window with bare fingers.
2. Always use tweezers, gloves or finger cots while handling de-
vices.
3. If there is any debris on top of the window (e.g. caused by the
thermal interface material), first saturate Texwipes Tx 609 (or
equivalent) cloth or Q-Tips in Isopropanol and then clean the
affected surface.

Confidential © Luminus Devices, Inc. - All Rights Reserved
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Evaluation Kit Manual - Revision A
D. Heat Sink Module Drawing - Top View
Figure 21: Heat sink module drawing - top view

Confidential © Luminus Devices, Inc. - All Rights Reserved
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Evaluation Kit Manual - Revision A
The products, their specifications and other information appearing in this document are subject to change by Luminus Devices without
notice. Luminus Devices assumes no liability for errors that may appear in this document, and no liability otherwise arising from the
application or use of the product or information contained herein. None of the information provided herein should be considered to be
a representation of the fitness or suitability of the product for any particular application or as any other form of warranty. Luminus
Devices’ product warranties are limited to only such warranties as accompany a purchase contract or purchase order for such products.
Nothing herein is to be construed as constituting an additional warranty. No information contained in this publication may be consid-
ered as a waiver by Luminus Devices of any intellectual property rights that Luminus Devices may have in such information. PhlatLight™
is a registered trademark of Luminus Devices, Inc., all rights reserved.
Luminus Devices
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Woburn, MA 01801 781-932-7835 (F)
Email: [email protected] www.luminus.com