Power Gems creates 40-channel LED controller for NBC Universal

November 11, 2022

Power Gems has created the world’s first 40-channel LED controller for use at high power (3kW) to control LED lighting fixtures and ribbon on a film and TV sound stage. The PWM40 was created following a special request by NBC Universal, who have received the first shipment of the new addition to the Power Gems range of LED products.

Once unpacked, most of the units will be working on NBC Universal’s state-of-the-art Sky Studios Elstree complex being built just north of London.

Artist's impression of the Sky Studios Elstree production fcacility due to open 2022 in Elstree

Image from Sky Studios Elstree

Ben Taylor, Account Manager, Universal Production Services UK– Set Lighting & Rigging, was instrumental in the initial design and development of the LED controller.

“Power Gems has been supplying Universal state-side for over 20 years, so when we decided to expand and develop our UK production facility, they were our first choice for collaborators on a controller to provide centralised LED lighting,” Ben says.

Power Gems owner and head of design, Phil Ellams’ task is to develop new products where no off-the-shelf solution exists. Specialising in designing high-power electronics, Phil recognised the technical challenges of creating a compact, high power, multi-channel controller.

“LED ribbon built into sets leaves many exposed electrical parts which increase the potential for short-circuits. This can be hazardous for the LED controller, especially as the power level rises. We focused our research efforts on designing a built-in comprehensive short-circuit protection because the new higher-power driver could produce such massive amounts of current. As a result, the PWM40s system is designed with short circuit protection, both on the supply rails and on the dimmed channels.”

The PWM40 (shown below) is a convenient solution where large numbers of LED loads need to be powered, such as driving LED ribbons on sound stage sets. The unit is fitted with lever-release terminals, which allow rapid connection of large numbers of bare-ended wires without the need even to use a screwdriver.

One of the major selling points of the PWM40 is the use of Power Gems’ innovative modular design. Phil has developed a bespoke architecture that allows output channel modules to be quickly swapped should they become damaged.

“Working with Power Gems on the PWM40 made it possible to have detailed updates and influence over the development because you have direct access to Phil, rather than passing information second hand through a sales team,” comments Ben Taylor.

The PWM40 is a combined 3kW power supply and LED PWM driver for up to 40 channels of 12V or 24V LED light source, such as ribbon or panels.