Popular Science: Ultra-complete LED lamp structure design knowledge

1. Luminaire: Any device that can distribute, illuminate, or transform light from one or more sources, and includes the components necessary to support, secure, and protect the light source (but not the light source itself), as well as the necessary circuit aids and They are connected to the power supply.

2. Ordinary luminaires: Provides protection against accidental contact with live parts, but without special dust, solid foreign objects and waterproof grades.

3. Movable luminaire: A luminaire that can be moved from one location to another when connected to a power source during normal use.

4. Fixed luminaires: luminaires that cannot be easily moved from one location to another because they are so fixed that they can only be removed with the aid of tools.

5. Recessed luminaires: Manufacturers specify luminaires that are fully or partially embedded in the mounting surface.

6. Live parts: Conductive parts that may cause electric shock during normal use. The center conductor should be considered as a live part.

7. SELV-safety extra-low voltage: The AC voltage is effective between conductors or between any conductor and ground in a circuit isolated from a power supply such as a safety isolating transformer or converter. The value does not exceed 50V.

8. UL low voltage line: The open circuit voltage does not exceed the line of the AC voltage RMS value of 30V.

9. Basic insulation (EN): Insulation that is applied to live parts to provide basic protection against electric shock. The withstand voltage should be above 2U+1000V (U: local grid voltage).

10. Supplemental insulation (EN): A separate insulation attached to the base insulation to provide protection against electric shock in the event of a basic insulation failure. The withstand voltage should be above 2U + 1750V (single layer).

11. Double-layer insulation (EN): Insulation consisting of basic insulation and supplementary insulation. The withstand voltage should be above 4U+2750V (that is, the sum of basic insulation and supplementary insulation withstand voltage).

12. Reinforced insulation (EN): A reinforced insulation that is equivalent to double insulation. Generally speaking, it is generally only one layer, but it can also be composed of multiple layers, and each layer cannot be clearly divided and measured separately. The withstand voltage should be above 4U+2750V.

13. CLASS O-class lamp (EN): A luminaire with only basic insulation as a protection against electric shock, without grounding and other protective measures.

14. CLASS Class I lamp (EN): In addition to the basic insulation for electric shock protection measures, other luminaires such as grounding and other protective measures are also used.

15. CLASS Class II luminaire (EN): A luminaire that uses double insulation or adds insulation for electric shock protection. Its insulation effect does not depend on grounding or installation conditions.

16. CLASS III Class Lamp (EN): A luminaire that uses an extra low safety voltage (SELV) for protection against electric shock.

17. Normally flammable material: The material has a ignition temperature of at least 200 ° C, and at this temperature the material does not deform or decrease in strength. For example wood and wood-based materials with a thickness greater than 2 mm.

18. Readyly flammable material: A material other than ordinary combustible materials and non-combustible materials. For example wood fibers and wood-based materials having a thickness of less than 2.

19. Non-combustible material: A material that does not support combustion. For example, metal, cement, and the like.

20. Type test: The test is carried out on the type test sample. The purpose of the test is to verify whether the design of a given product meets the requirements of the relevant standard. However, if the product after the final test meets the standard requirements in the production stage, it needs to be tested. Reports and related documents are guaranteed.

1. Tungsten bulbs, including incandescent bulbs, quartz bulbs, and halogen bulbs.

Commonly used incandescent bulbs are: Type A, B, C, G, R, T, European bulb Base – E14, E27. Among them, the United Kingdom can also use B15, B22; North American bulb Base Type – E12, E17, E26. E-Edison (Edison screw); B-Bayonet (bayonet)

A. Commonly used quartz bulbs are Type T (JC), MR, JDR-C (GU10).

2. Fluorescent tubes are commonly used in FL (T5, T8, T12...), PL-S, PL-C, 2D and energy-saving lamps.

Note: The usual representations for tungsten bulbs and FL fluorescent tubes are: letters indicating the type (Type) plus Arabic numerals, for example: A19, B10, C7, G25, S11, T8..., where Arabic numerals indicate the approximate size of the bulb The diameter, such as the diameter of the A19 bulb D = 19 * 1 / 8", multiplied by 25.4 is the diameter of the bulb in mm.

Special case: The number of the European standard R bubble is the actual size of the bulb, such as R50, R80...

Third, the lighting classification

(1) According to the installation method:

Movable lamps: table lamps, wall-mounted lamps, floor lamps, fixed lamps: ceiling lamps (ceiling lamps), chandeliers, wall lamps, recessed lamps, track lights.

(2) Use environment:

1. EN specifications

1) Indoor use: symbolized, the outer surface of the metal parts shall be treated with anti-corrosion treatment;

2) Outdoor use: symbolized, the outer surface of the metal parts should be treated with anti-corrosion treatment; Special requirements: water spray test (that is, a minimum Ф3.2mm leakage hole is required), and the inner and outer surfaces of the metal parts should be treated with anti-corrosion treatment.

2. UL/CSA specifications

1) DRY LOCATION: At most temporary humidity is large. For example, indoor environments such as living rooms, living rooms, and kitchens.

2) DAMP LOCATION: At least periodic liquefaction of moisture occurs. There are indoor humid environments such as bathrooms and cellar freezer, as well as outdoor environments with covered covers such as balcony canopies and gates.

3) WET LOCATION: At least raindrops or water splashes. For example, underground, water and all outdoor environments and car washes can be exposed to the indoor environment of water.

Note: The main requirements for tidal environment and wet environment are: water spray test (ie, the minimum leakage hole is required to be 3.2mm), the inner and outer surfaces of the metal parts should be treated with anti-corrosion treatment, and the conductive contacts of the lamp head should be corrosion-resistant (copper end piece).

(3) According to the standard category of use

1. North American system: mainly UL/CSA specification system. The voltage is AC100V ~ 127V, 60HZ, including some countries in North America, South America, and former US colonies such as Japan, the Philippines, and Taiwan.

UL Lab. The product is tested according to CSA standards and can be exported to Canada with cUL MARK.

2. IEC-International Electrotechnical Commission system: including most countries and regions in Europe, Asia, Australia, Africa, and Southeast Asia. The listed specifications are based on the EN60598 series of standards plus some special requirements (such as voltage, plug type, etc.) in the country (the region). China participated in the IEC in 1957 and is currently a member of the IEC Board of Directors, the Executive Committee and the Conformity Assessment Board. The national standard GB7000 series for the lighting industry corresponds to the IEC60598 series.

The IEC (EN) products can also be subdivided into the following categories:

(1) According to the degree of protection against electric shock:

A. CLASS 0 level light, no symbol.

Features: Power supply voltage is above 50V high voltage / single layer insulation / no grounding.

B. CLASS I class lamp, no symbol. Single-layer insulation structure, exposed metal can be grounded. Some of the CLASS I lamps can be constructed in a CLASS II structure.

Features: Power supply voltage is above 50V high voltage / single layer insulation / with grounding.

C. CLASS II class lamp, indicated by the symbol " ". Class II lamps are usually double insulated, but may have a partial structure of CLASS III structure (such as the low voltage portion after the transformer). (The built-in transformer should be designed as a Class II luminaire).

Features: Power supply voltage is above 50V high voltage / double insulation / no grounding.

D. CLASS III class lights. Expressed by the symbol " ", the power supply is a safety extra low voltage SELV (external transformer in-line luminaire)

Features: Low voltage / single layer insulation / no grounding for supply voltage below 50V.

(2) According to the IP index of dustproof and anti-solid foreign matter and moisture resistance: IPXX

The first digit: dust and solid foreign body index, divided into 0-6 seven grades. The greater the number, the stronger the ability to prevent dust and solid foreign objects.

0: no protection;

1: prevent solid foreign objects larger than 50mm;

2: prevent solid foreign matter larger than 12mm;

3: solid foreign matter greater than 2.5 mm;

4: Prevent solid foreign objects larger than 1 mm;

5: dustproof;

6: dust density

The second digit: moisture resistance index, divided into 0-8 nine grades. The greater the number, the stronger the moisture resistance;

0: no protection;

1: anti-drip (vertical);

2: anti-drip (tilt 15 degrees);

3: anti-watering (60 degree range);

4: splash water;

5: Waterproof:

6: against violent waves;

7: impact of water immersion;

8: Anti-diving effect.

Note: 1) The general luminaire protection level is IP20, generally not marked.

2) The protection level IP# of outdoor lighting is generally IP23 or above and needs to be marked.

3) According to the flammability of the installation surface:

A. Luminaires that are only suitable for direct mounting on non-combustible surfaces are indicated by the symbol " ".

B. A luminaire suitable for installation on a common flammable surface, indicated by the symbol " ".

C. It can be installed on a common flammable surface and the insulation material may cover the luminaire (ie embedded), which is indicated by “ ”.

Material requirements:

UL/cUL/CAS Specifications: The carrier (conductor) of the current must be copper, copper alloy, nickel alloy, or stainless steel.

EN specification: Current-carrying parts (conductors) shall be made of copper or a copper alloy containing at least 80% copper or at least materials having the same electrical conductivity.

1. Lamp head:

1.1 UL/cUL/CAS Specifications (AC120V 60HZ)

Specifications are E26, E17, E12, multi-purpose ceramic and bakelite heads, aluminum heads cannot be used. The E26 lamp head is mostly equipped with a switch, and the E17 and E12 lamp heads do not have a switch. UL certification is required.

1.2 EN specifications (AC220V ~ 230V 50HZ)

The specifications are E14, E27 threaded heads, mostly plastic lamp heads, ceramic heads, and less bakelite heads. The E27 lamp head is generally resistant to temperatures of 210 ° C (60 W or less) and 100 W is generally ceramic. Generally, the lamp head does not have a switch. VDE or corresponding certification is required.

1.3 SAA/BS Specifications (AC240V 50HZ)

Commonly used B22 and B15 bayonet lamp heads, regardless of polarity, also use E27, E14 threaded lamp heads, generally without switches.

1.4 GB specification (AC220V 50HZ)

Common E14, E27 threaded heads, but also B22 bayonet heads. CQC certification is required.

2. switch

2.1 UL/cUL/CAS Specifications:

A. Rotary switch: such as the lamp head switch, the base switch.

B. Midway switch: The length from the middle switch to the outlet position is not less than 20cm.

C. Rectangular pull switch: It is mostly used for quartz lamps, and some table lamps are also used. The general installation requirements are upper opening and lower closing, front opening and closing, left opening and right closing, but to meet customer requirements.

D. Dimmer: There is a rotary type: that is, gradually from dark to bright, stepless dimming. Three-position: weak light → bright → extinguish

E. Touch switch: four-position → weak light → bright → strong light → off

2.2 EN Specifications

A. Lamp push switch

B. The base pull switch is installed in the same direction as the UL requirements.

C. Square pull switch installation direction is the same as UL requirements

D. Midway switch (single knife system): Generally, the length of the switch to the outlet position is not less than 20cm; the foot switch (pressing the switch or dimmer): the distance from the general outlet to the foot switch is not less than 30cm.

2.3 SAA/BS Specifications

The SAA switch generally uses a double-knife switch, which is divided into a base switch and a mid-way switch (double-knife system), except for special requirements from the customer; BS uses a single-blade system, which is required by VDE.

2.4 GB specifications

Use CQC, CCC certified switch, table lamp, clip light with push switch, switch to the outlet line length is not less than 20cm; floor lamp with foot switch; outlet line to foot switch distance is not less than 30cm.

3. power cable:

3.1 UL/cUL/CAS specifications: Generally use SPT-2 transparent power cord size hole with hole plug, the insert material is required to be copper-plated nickel, there is a word 唛 line connected to the small leg for the L pole, the strip line with the big foot For the N pole, the switch must cut off the wire with the word 。. It also has a black plug wire, a double-footed flat plug with a large and small size. The outer diameter of the N-pole wire is thick and has a straight rib, and the outer diameter of the L-pole wire is thin and smooth. The inside of the lamp body is made of black and white leads. Generally, the black lead is connected to the L pole, and the white lead is connected to the N pole.

The length of the outlet is from the outlet position to the plug not less than 6 feet, the company's regulations are not shorter than 1.80m, and the wiring method is generally closed-end connector (nipple) and screw-in connector (toothpaste cover).

3.2 EN Specifications

Two-core double insulated wire, double-footed round plug. There are brown lines, blue lines, brown lines connected to L poles, blue lines connected to N poles; three core double insulated lines, three-legged round plugs, with brown, blue and yellow-green two-color leads, among which yellow-green The two-color line is the grounding line. When installing the switch, the fire line must be controlled. The length of the power line outlet is required to be 1.85m. The wiring method is generally the terminal block.

3.3 SAA/BS Specifications

SAA uses double insulated plug wire, the plug is two flat feet and eight shapes (regardless of size), BS is equipped with double insulated BS specification, without plug, BS plug is designed as Class I, installed by the production line or by the guest. The pins are three pieces of flat feet in the shape of "good". The inner pressure line screw of the plug is required to withstand 0.5Nm torque, and the length of the power line outlet is the same as VDE.

3.4 GB specifications

Double-insulated double-pin flat plug power cord, the pins are not divided in size, no holes, the power cord must have CCC certification mark, the length of the outlet is the same as VDE.

4. transformer

4.1 UL/cUL/CAS Specifications

The primary voltage of the UL/CSA transformer is 120V. The secondary is different according to the need, generally 12V. Because the secondary voltage is low and the current is large, the secondary pole output is thicker. Transformers are required to have UL/cUL/CAS certification.

4.2 EN Specifications

The primary input voltage is 230V, the secondary output voltage is mostly 12V, and the fuse is connected to the primary. VDE certification is required.

4.3 GB specifications

Suppliers with CQC or CCC certification are required.

1. high-pressure test:

A. UL/cUL specifications:

Ordinary fixed luminaire: 1500V/1.0mA/1 second;

Portable luminaire: 1500V/0.5mA/1 second;

B. EN specifications:

CLASS: 2U+1000V/1mA/1 second; (U is the grid voltage value)

CLASS II: 4U+2750V/1mA/1 second;

CLASS III: 500V/0.5mA/1 second;

For high voltage testing, the UL specification requires a frequency of 40 to 70 Hz, the leakage current does not exceed 0.5 mA, and the EN specification requires 50/60 Hz, and the leakage current: 0.5 mA of the Class O II lamp;

Class I movable lamp 1.0mA; Class I fixed lamp 1.0mA, rated input power greater than 1kVA Class I fixed type per 1kVA, leakage current increased by 1.0mA, maximum value 5.0mA.

2. Ground resistance test:

A. UL/cUL specification: with 12V, 25A current, the measured ground resistance is not more than 0.1Ω (100mΩ);

B. EN specification: The current with no-load voltage of not less than 12V and not less than 10A is applied between the accessible metal and the grounding terminal, and the measured ground resistance is not more than 0.5Ω (500mΩ).

3. Tensile test (the wiring point of the internal wiring when the power cord leaves the lamp body position or when the package is unpacked)

A. UL/cUL specification: 35Lbs/1 minute, the displacement should not exceed 1.6mm.

Pull-proof device: tension ring, UL knot, pressure line code, labyrinth structure

B. EN specification: 13.5Lbs, pull 25 times in 1 minute, maintain 1 second each time, the displacement should not exceed 2mm.

Pull-proof device: tension ring, pressure line code, labyrinth structure

4. Torque test

The screw connection must ensure the corresponding torque to ensure that its function and electrical performance are not affected.

The lamp head must withstand a certain torque for 1 minute.

E26, E27 and B22 bases: 2.0Nm

E14 and B15 lamp heads (except candle holders) 1.2Nm

E14 and B15 candle holders 0.5Nm.

There is a STOP position at the joint to prevent 360 ̇ rotation and to withstand a torque of 2.5 Nm per revolution;

The torque at the joint below the M10 thread is 2.5Nm, and the torque above the M10 thread is 5.0Nm.

5. Wire number:

A. UL/cUL specifications: a minimum of 18 AWG.

special case:

1) Fully covered, 2) Non-moving, 3) Transformer secondary wiring, 18AWG to 24AWG wire can be used.

Track Lighting:

1) ADAPTOR (adapter) and body part: 18AWG.

2) CONNECTOR (connector) and track section: 12AWG or cross-sectional area of ​​not less than 3.3mm2.

B. EN specifications:

Main power cord:

1) Ordinary lamps: at least 0.75mm2

2) Other lamps: at least 1.0mm2 (outdoor lights, lamps used in harsh environments)

3) When using a 10/16A socket, at least 1.0mm2

Internal leads of the lamp:

1) The normal working current is greater than 2A: at least 0.5mm2, and the insulation layer is 0.6mm thick.

2) The normal working current is less than 2A: at least 0.4mm2, and the insulation layer is 0.5mm thick.

6. Wire connection method:

A. UL/cUL specification: The connection between the power cable and the internal lead or internal lead can be closed with a closed end connector (nipple), screw-in connector (toothpaste cover), solder connection, and the same screw-in connector More than 5 roots.

B. EN Specifications: The connection between the power cord and the internal leads or internal leads can be made with terminal blocks, closed end connectors (nipples), and solder (no toothpaste cover).

Note: When the terminal block is fixed on the metal parts, it needs to pass the 8mm escape test of one of the strands. A piece of green paper is usually added between the terminal block and the metal part as a supplementary insulation. The terminal block is reserved for the user terminal and needs to be identified by L, N or L, N, and ground symbol.

7. Polarity distinction:

Fire wire (L pole): Connect the conductive contact at the center of the lamp head, and turn off the power supply L pole.

UL: wires without ridges in black and twin-core power cords;

EN: brown or red line;

Neutral line (N pole): connected to the lamp side side contact or screw sleeve;

UL: a wire with a ridge in a white or two-core power cord;

EN: blue or black line;

8. Wire open line processing:

A. UL/cUL specification: open line less than 7mm, wire end immersed in tin, immersion tin length not more than 3.2 mm

B. EN specification: When the terminal is a slingshot connection, it can be immersed in tin. Non-slingshot type, must be wrapped with copper terminals, and ≧ 5mm.

9. Over-line protection:

Wires pass through metal parts, and protective wire sleeves (such as rubber particles) or wires and sleeves (silicone tubes, yellow wax tubes, etc.) should be added at the line;

10. Anti-rotation and torque test of universal parts such as universal shaking head:

A. UL/cUL specification: movable connection point, which does not affect the insulation of the conductor when moving, the rotation should be limited to 360°, or the rotation test (6000 times). Twist 2.26Nm / 1 minute and hang 35LBS or 4 times weight / 1 minute (UL1598)

B. EN specification: Connection diameter ≦M10mm, to pass the 2.5Nm torsion test; connection diameter ≥M10mm, to be able to pass the 5.0 Nm torsion test.

11. Screw connection:

A. UL/CSA Specifications: Self-tapping screws are tested for 4 times the weight of the lamp body.

B. EN specification: If the thread diameter is less than 3.0mm, the connecting screw must be implanted in the metal. In addition, the screw should be tested by loose/tight 5 times ≦2.8mm, 0.4mm; ≦3.0mm, 0.5Nm ;≦3.2,0.6 Nm;0.8Nm...

12. Ceiling light / wall light hoisting test:

A. UL/cUL specification: The weight of the lamp body is 4 times weight / 1 hour, and the parts are not obviously deformed or damaged.

B. EN specification: The weight of the lamp body is 4 times weight / 1 hour, and the parts are not obviously deformed or damaged.

13. Dumping test (for mobile luminaires):

A. UL/cUL specifications: Mobile luminaires must pass the 8° dump test.

B. EN specifications:

1) 6° dumping test: All movable luminaires must pass this test;

2) 15° dump test: A portable luminaire that passes the 6° test but cannot pass the abnormal temperature test (the temperature of the light source is higher than 175 ° C after the lamp is dumped) must pass this test. When dumping the test, place the luminaire on the test rig in the direction that is most unfavorable for stabilizing the luminaire.

14. Clamping force (for clip light):

A. UL/cUL specifications: 1.6mm thick iron plates and 38mm thick wooden boards are respectively clamped, and the hanging lamps do not fall for one hour.

B. EN specifications:

1) Separately: a) 10mm glass, b) the thickest glass that can be clamped (20mm or 30mm..., the thickest 40mm), pull the power cord with 20N force, the clip can't move;

2) Clip the metal rod with a diameter of 20mm and pull the power cord with 20N force. The lamp should not fall. When the clamped glass plate can pass, and the clamped metal round bar cannot pass, it can be noted in the manual that it is not allowed to be clamped on the round bar.

15. Quartz lamp explosion-proof / UV-resistant UV: UV FILTER (UV filter)

A. UL/cUL specifications: Unless using a low-pressure bulb that is UV-resistant, quartz table lamp/floor lamp (except for the 5-inch high Torchiere) requires UV lens - below 100W, 2.4mm; ≥100W, 3.2mm.

B. EN specification: Unless the low-pressure bulb with its own anti-UV is used, the quartz table lamp/floor lamp needs to be equipped with an explosion-proof lens, and the explosion-proof lens should pass the impact test of 0.35Nm.

16. Clearance and CREEpage Distance

A. UL/cUL specification: 6.4mm. Note: The lamp pole, switch and CLASS II transformer secondary are not considered.

B. EN specifications:

1) Basic insulation - 50V: 0.2mm; 1.2mm; 250V: 1.7mm; 2.5mm.

2) Supplementary insulation - 250V: 3.6mm.

3) Reinforced insulation - 250V: 6.5mm.