LED failures: How to stop them dead David Scott-Maxwell Technical Director, Forge Europa.
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Transcript of LED failures: How to stop them dead David Scott-Maxwell Technical Director, Forge Europa.
LED failures: How to stop them dead
LED failures: How to stop them dead
David Scott-MaxwellTechnical Director, Forge Europa
LED failures: How to stop them dead
• Before we start – what are ‘LEDs’?:
LED failures: How to stop them dead
• Before we start – these are ‘LEDs’:
LED failures: How to stop them dead
• Before we start – these are ‘LEDs’:
‘LEDs’ ARE NOT MUCH USE ON THEIR OWN!
LED failures: How to stop them dead
• Before we start – ‘LED failures’ = ‘Whole system failures’
LED failures: How to stop them dead
• Before we start – ‘LED failures’ = ‘Whole system failures’
LED failures: How to stop them dead
• What’s in a ‘Whole system’?
LED failures: How to stop them dead
• What’s in a ‘Whole system’?
LED failures: How to stop them dead
• What’s in a ‘Whole system’?
LED
LED failures: How to stop them dead
• What’s in a ‘Whole system’?
LED
PCB
LED failures: How to stop them dead
• What’s in a ‘Whole system’?
LED
PCB
Heatsink
LED failures: How to stop them dead
• What’s in a ‘Whole system’?
LED
PCB
Heatsink
Driver/PSU
LED failures: How to stop them dead
• What’s in a ‘Whole system’?
LED
PCB
Heatsink
Driver/PSU
Enclosure
LED failures: How to stop them dead
• What’s in a ‘Whole system’?
LED
PCB
Heatsink
Driver/PSU
Enclosure
Optics
LED failures: How to stop them dead
• What’s in a ‘Whole system’?
LED
PCB
Heatsink
Driver/PSU
Enclosure
Optics
AdhesivesTIMsetc
LED failures: How to stop them dead
• What’s in a ‘Whole system’?
LED
PCB
Heatsink
Driver/PSU
Enclosure
Optics
AdhesivesTIMsetc
Testing
LED failures: How to stop them dead
• What’s in a ‘Whole system’?
LED
PCB
Heatsink
Driver/PSU
Enclosure
Optics
AdhesivesTIMsetc
Testing
Packaging
LED failures: How to stop them dead
• What’s in a ‘Whole system’?
LED
PCB
Heatsink
Driver/PSU
Enclosure
Optics
AdhesivesTIMsetc
Testing
Packaging
The user!
LED failures: How to stop them dead
• What’s in a ‘Whole system’?
LED
PCB
Heatsink
Driver/PSU
Enclosure
Optics
AdhesivesTIMsetc
Testing
Packaging
The user!
LED failures: How to stop them dead
LED failures:
LED failures: How to stop them dead
LED failures:
• Electrical Overstress (EOS)• Overheat• Chemical Contamination• Electrostatic Discharge (ESD)
LED failures: How to stop them dead
LED failures: Electrical Overstress (EOS)
Causes• ‘Hot Plugging’ #1 LED killer - VERY easily done!• …during in-factory test, luminaire installation• …can be latent• Reverse connection
Effects • Lights out (often short circuit)
Prevention• BE EOS AWARE, design-in circuit protection, lock down factory
procedures, educate
LED failures: How to stop them dead
LED failures: Electrical Overstress (EOS)
Causes• ‘Hot Plugging’ #1 LED killer - VERY easily done!• …during in-factory test, luminaire installation• …can be latent• Reverse connection
Effects • Lights out (often short circuit)
Prevention• BE EOS AWARE, design-in circuit protection, lock down factory
procedures, educate
LED failures: How to stop them dead
LED failures: Electrical Overstress (EOS)
Causes• ‘Hot Plugging’ #1 LED killer - VERY easily done!• …during in-factory test, luminaire installation• …can be latent• Reverse connection
Effects • Lights out (often short circuit)
Prevention• BE EOS AWARE, design-in circuit protection, lock down factory
procedures, educate
LED failures: How to stop them dead
LED failures: Electrical Overstress (EOS)
Causes• ‘Hot Plugging’ #1 LED killer - VERY easily done!• …during in-factory test, luminaire installation• …can be latent• Reverse connection
Effects • Lights out (often short circuit)
Prevention• BE EOS AWARE, design-in circuit protection, lock down factory
procedures, educate
LED failures: How to stop them dead
LED failures: Electrical Overstress (EOS)
Causes• ‘Hot Plugging’ #1 LED killer - VERY easily done!• …during in-factory test, luminaire installation• …can be latent• Reverse connection
Effects • Lights out (often short circuit)
Prevention• BE EOS AWARE, design-in circuit protection, lock down factory
procedures, educate
LED failures: How to stop them dead
LED failures: Electrical Overstress (EOS)
Causes• ‘Hot Plugging’ #1 LED killer - VERY easily done!• …during in-factory test, luminaire installation• …can be latent• Reverse connection
Effects • Lights out (often short circuit)
Prevention• BE EOS AWARE, design-in circuit protection, lock down factory
procedures, educate
LED failures: How to stop them dead
LED failures: Electrical Overstress (EOS)
Causes• ‘Hot Plugging’ #1 LED killer - VERY easily done!• …during in-factory test, luminaire installation• …can be latent• Reverse connection
Effects • Lights out (often short circuit)
Prevention• BE EOS AWARE, design-in circuit protection, lock down factory
procedures, educate
LED failures: How to stop them dead
LED failures: Electrical Overstress (EOS)
Causes• ‘Hot Plugging’ #1 LED killer - VERY easily done!• …during in-factory test, luminaire installation• …can be latent• Reverse connection
Effects • Lights out (often short circuit)
Prevention• BE EOS AWARE, design-in circuit protection, lock down factory
procedures, educate
LED failures: How to stop them dead
LED failures: Electrical Overstress (EOS)
Causes• ‘Hot Plugging’ #1 LED killer - VERY easily done!• …during in-factory test, luminaire installation• …can be latent• Reverse connection
Effects • Lights out (often short circuit)
Prevention• BE EOS AWARE, design-in circuit protection, lock down factory
procedures, Educate
LED failures: How to stop them dead
LED failures: Overheat
Causes• Modern Lighting Class LEDs can run HOT…• …but there’s a limit to how much power they can handle• …and adequate heatsinking must be provided• …and users can/will overheat products
Effects • Reduced lifetime [LM80/TM21], colour shift
Prevention• Heatsink design is tough – don’t underestimate• Educate customers
LED failures: How to stop them dead
LED failures: Overheat
Causes• Modern Lighting Class LEDs can run HOT…• …but there’s a limit to how much power they can handle• …and adequate heatsinking must be provided• …and users can/will overheat products
Effects • Reduced lifetime [LM80/TM21], colour shift
Prevention• Heatsink design is tough – don’t underestimate• Educate customers
XM-L / 105° / 2AL70>70khrs
LED failures: How to stop them dead
LED failures: Overheat
Causes• Modern Lighting Class LEDs can run HOT…• …but there’s a limit to how much power they can handle• …and adequate heatsinking must be provided• …and users can/will overheat products
Effects • Reduced lifetime [LM80/TM21], colour shift
Prevention• Heatsink design is tough – don’t underestimate• Educate customers
LED failures: How to stop them dead
LED failures: Overheat
Causes• Modern Lighting Class LEDs can run HOT…• …but there’s a limit to how much power they can handle• …and adequate heatsinking must be provided• …and users can/will overheat products
Effects • Reduced lifetime [LM80/TM21], colour shift
Prevention• Heatsink design is tough – don’t underestimate• Educate customers
LED failures: How to stop them dead
LED failures: Overheat
Causes• Modern Lighting Class LEDs can run HOT…• …but there’s a limit to how much power they can handle• …and adequate heatsinking must be provided• …and users can/will overheat products
Effects • Reduced lifetime [LM80/TM21], colour shift
Prevention• Heatsink design is tough – don’t underestimate• Educate customers
LED failures: How to stop them dead
LED failures: Overheat
Causes• Modern Lighting Class LEDs can run HOT…• …but there’s a limit to how much power they can handle• …and adequate heatsinking must be provided• …and users can/will overheat products
Effects • Reduced lifetime [LM80/TM21], colour shift
Prevention• Heatsink design is tough – don’t underestimate• Educate customers
LED failures: How to stop them dead
LED failures: Chemical Contamination
Causes• Silicones particularly vulnerable to ‘charring’• LED manufacturer’s black lists & white lists• Sometimes reversible, sometimes not…
Effects • Reduced lifetime, colour shift
Prevention• Check the lists, do your own tests, be aware of ‘hidden’ chemical
usage.
LED failures: How to stop them dead
LED failures: Chemical Contamination
Causes• Silicones particularly vulnerable to ‘charring’• LED manufacturer’s black lists & white lists• Sometimes reversible, sometimes not…
Effects • Reduced lifetime, colour shift
Prevention• Check the lists, do your own tests, be aware of ‘hidden’ chemical
usage.
LED failures: How to stop them dead
LED failures: Chemical Contamination
Causes• Silicones particularly vulnerable to ‘charring’• LED manufacturer’s black lists & white lists• Sometimes reversible, sometimes not…
Effects • Reduced lifetime, colour shift
Prevention• Check the lists, do your own tests, be aware of ‘hidden’ chemical
usage.
LED failures: How to stop them dead
LED failures: Chemical Contamination
Causes• Silicones particularly vulnerable to ‘charring’• LED manufacturer’s black lists & white lists• Sometimes reversible, sometimes not…
Effects • Reduced lifetime, colour shift
Prevention• Check the lists, do your own tests, be aware of ‘hidden’ chemical
usage.
LED failures: How to stop them dead
LED failures: Chemical Contamination
Causes• Silicones particularly vulnerable to ‘charring’• LED manufacturer’s black lists & white lists• Sometimes reversible, sometimes not…
Effects • Reduced lifetime, colour shift
Prevention• Check the lists, do your own tests, be aware of ‘hidden’ chemical
usage.
LED failures: How to stop them dead
LED failures: Chemical Contamination
Causes• Silicones particularly vulnerable to ‘charring’• LED manufacturer’s black lists & white lists• Sometimes reversible, sometimes not…
Effects • Reduced lifetime, colour shift
Prevention• Check the lists, do your own tests, be aware of ‘hidden’ chemical
usage.
LED failures: How to stop them dead
LED failures: Chemical Contamination
Causes• Silicones particularly vulnerable to ‘charring’• LED manufacturer’s black lists & white lists• Sometimes reversible, sometimes not…
Effects • Reduced lifetime, colour shift
Prevention• Check the lists, do your own tests, be aware of ‘hidden’ chemical
usage.
LED failures: How to stop them dead
LED failures: Electrostatic Discharge
Causes• Rare due to protected LED components, good ESD handling, protection via circuitry• BUT - can be latent…
Effects • Lights out
Prevention• Install & audit ESD handling procedures, design-in circuit protection
LED failures: How to stop them dead
LED failures: Electrostatic Discharge
Causes• Rare due to protected LED components, good ESD handling, protection via circuitry• BUT - can be latent…
Effects • Lights out
Prevention• Install & audit ESD handling procedures, design-in circuit protection
LED failures: How to stop them dead
LED failures: Electrostatic Discharge
Causes• Rare due to protected LED components, good ESD handling, protection via circuitry• BUT - can be latent…
Effects • Lights out
Prevention• Install & audit ESD handling procedures, design-in circuit protection
LED failures: How to stop them dead
Driver/PSU failures:
• Electronic product reliability• Key component lifetime• Soldering
LED failures: How to stop them dead
Driver/PSU failures: Electronic Product Reliability
• Electronic products can be extremely reliable!• … but ‘you gets what you pays for’…• ‘0.2%/1000hrs’ de-facto standard for lighting electronics
LED failures: How to stop them dead
Driver/PSU failures: Electronic Product Reliability
• Electronic products can be extremely reliable!• … but ‘you gets what you pays for’…• ‘0.2%/1000hrs’ de-facto standard for lighting electronics
LED failures: How to stop them dead
Driver/PSU failures: Key Component Lifetime
Causes• Electrolytic capacitors• Freewheel diodes• Bridge rectifiers• Optocouplers• … etc etc …
Effects • Lights out, flickering, EMC non-compliance, …
Prevention• Design for product lifetime, control manufacturing
LED failures: How to stop them dead
Driver/PSU failures: Key Component Lifetime
Causes• Electrolytic capacitors• Freewheel diodes• Bridge rectifiers• Optocouplers• … etc etc …
Effects • Lights out, flickering, EMC non-compliance, …
Prevention• Design for product lifetime, control manufacturing
LED failures: How to stop them dead
Driver/PSU failures: Key Component Lifetime
Causes• Electrolytic capacitors• Freewheel diodes• Bridge rectifiers• Optocouplers• … etc etc …
Effects • Lights out, flickering, EMC non-compliance, …
Prevention• Design for product lifetime, control manufacturing
LED failures: How to stop them dead
Driver/PSU failures: Key Component Lifetime
Causes• Electrolytic capacitors• Freewheel diodes• Bridge rectifiers• Optocouplers• … etc etc …
Effects • Lights out, flickering, EMC non-compliance, …
Prevention• Design for product lifetime, control manufacturing
LED failures: How to stop them dead
Driver/PSU failures: Key Component Lifetime
Causes• Electrolytic capacitors• Freewheel diodes• Bridge rectifiers• Optocouplers• … etc etc …
Effects • Lights out, flickering, EMC non-compliance, …
Prevention• Design for product lifetime, control manufacturing
LED failures: How to stop them dead
Driver/PSU failures: Soldering
Causes• Low operator skill• Poorly controlled processes• Exotics
Effects • Lights out
Prevention• Control manufacturing, IPC-A-610-E
LED failures: How to stop them dead
Driver/PSU failures: Soldering
Causes• Low operator skill• Poorly controlled processes• Exotics
Effects • Lights out
Prevention• Control manufacturing, IPC-A-610-E
LED failures: How to stop them dead
Driver/PSU failures: Soldering
Causes• Low operator skill• Poorly controlled processes• Exotics
Effects • Lights out
Prevention• Control manufacturing, IPC-A-610-E
LED failures: How to stop them dead
Driver/PSU failures: Soldering
Causes• Low operator skill• Poorly controlled processes• Exotics
Effects • Lights out
Prevention• Control manufacturing, IPC-A-610-E
LED failures: How to stop them dead
Driver/PSU failures: Soldering
Causes• Low operator skill• Poorly controlled processes• Exotics
Effects • Lights out
Prevention• Control manufacturing, IPC-A-610-E
LED failures: How to stop them dead
Conclusion:
LED failures: How to stop them dead
Conclusion:
Don’t worry too much – LED lighting can be extremely reliable!
LED failures: How to stop them dead
Conclusion:
Don’t worry too much – LED lighting can be extremely reliable!
LED failures: How to stop them dead
Conclusion:
Don’t worry too much – LED lighting can be extremely reliable!
LED failures: How to stop them dead
Conclusion:
Don’t worry too much – LED lighting can be extremely reliable!
BUT – you need to be profoundly aware of all the issues to achieve this…
LED failures: How to stop them dead
Thank you – and good luck!
David Scott-MaxwellTechnical Director, Forge Europa