5V 60A Industrial SMPS Design

Job ID: 40467919

Budget: $250 – $750 USD

I need a reliable switch-mode power supply that can accept any mains voltage from 100 VAC to 240 VAC and deliver a rock-solid 5 V at 60 A (≈300 W) for a outdoor /indoor LED system application Because the unit will live inside industrial control cabinets, low ripple, high efficiency, and rugged protection features (short-circuit, over-current, over-temperature, and over-voltage) are critical. EMI has to be kept well within the typical limits you would expect for industrial gear, but I’m not chasing any formal UL or CE paperwork right now.

What I’m looking for:

• Complete schematic with part numbers that are actually obtainable
• Optimised PCB layout and Gerber files ready for fabrication
• A vetted BOM, costed if possible, plus transformer design data
• Basic thermal and efficiency estimates so I know it will stay cool in a sealed panel
• Startup and functional test procedure I can repeat on my bench

Experience with flyback or forward topologies at this power level, proper grounding practices, and familiarity with controller ICs from TI, Infineon, or similar will help you hit the ground running.

If you have already designed something comparable for industrial automation, show me—seeing a proven track record will speed up the selection process.