Design of a Centralized 10kW LED Controller Unit (48V / 200A) with RF Control

Design of a Centralized 10kW LED Controller Unit (48V / 200A) with RF Control

Project Description:

I need to industrialize a control system for a fishing boat lighting setup.

Currently, I have a prototype for a single light. I want to build a single centralized control cabinet that drives 4 separate LED floodlights simultaneously.

Technical Specs (The Load):
• Total Power: 10,000W (10kW).
• Input Voltage: 48V DC (from a 227A Alternator).
• Total Current: ~210 Amps continuous.
• Outputs: 4 Channels (Each channel connects to a 2500W LED load @ ~52A).

Requirements for the Engineer:
1. Architecture: The system must be housed in one single enclosure.
• Suggestion: Use a "Master Input" busbar distributing power to 4 independent driver circuits (Mosfets/SSRs) inside the box.

2. Control (RF):
• One RF Remote Control to dim all 4 lights simultaneously (0-100%).
• Optional: If possible, a switch to turn on/off specific channels (e.g., Left Side / Right Side).

3. PCB & Power Distribution:
• Design a Control PCB (Low voltage logic).
• Design the High Current Busbar layout (Copper bars) to distribute the 210A input safely to the 4 output channels. PCB traces cannot carry this current.

4. Thermal Management: The enclosure will generate significant heat. Calculation for active cooling (high-flow fans) is mandatory.

Deliverabke:
• Electrical Schematic (Power Stage + Control Stage).
• PCB Design (Gerber).
• Mechanical Layout (Enclosure selection, component placement, busbar design).
• BOM (Bill of Materials).
Budget: $500 - $700 USD.