Power Supply Mounting Guide

Proper power supply installation plays a key role in system reliability, whether you’re designing a new electrical system or upgrading an old one. With the right tools and resources, you can promote system longevity and optimal performance. In this power supply mounting guide, we’ll walk you through the essential processes to help you optimize your setup, protect your equipment and achieve long-term performance. 

What Is Power Supply Mounting?

Power supply mounting is the process of securely installing a power supply unit (PSU) within a system or device to help it function reliably and efficiently. It is used in almost every electrical system. Without proper mounting, the PSU’s performance and overall system’s safety will be compromised. Power supply mounting involves selecting the right location for your PSU, ensuring it has adequate ventilation and using the correct mounting hardware to minimize possible vibrations.

Importance of Proper Mounting

Proper mounting ensures that electronic devices, machines and the overall electrical system operate more reliably. It helps with:

• Safety: A properly mounted PSU reduces the chances of components shifting or loosening, causing short circuits or sparks. It also helps you better adhere to safety regulations and standards.
• System reliability: The more stable your unit, the more likely you will receive consistent power and avoid disconnections or disruptions. 
• Thermal management: Power supply mounting promotes heat dissipation by transferring heat away from its source into the surrounding equipment to prevent overheating.
• Performance and efficiency: Proper mounting keeps the PSU stable and reduces electromagnetic interference (EMI) from affecting other components. 
• Maintenance: With a properly installed unit, the power supply can be easily accessed for inspections, replacements or repairs without dismantling the whole system.

Types of Power Supply Mounting

Mounts for power supplies fall into two main categories — standard and custom:

• Standard mounts: These are pre-designed, widely used and cater to most general solutions. For example, DIN-rail mounts are popular standard mounts in industrial automation systems, while panel mounts may often be used in medical or test equipment. Standard mounts are off-the-shelf options designed for typical setups. They're great because they're straightforward, universally sized and often come with pre-drilled holes for easy installation. They're perfect for situations where everything fits into a standard configuration, like server rooms or industrial panels.
• Custom mounts: As the name suggests, these are tailored to specific needs. This option can be beneficial when space is limited, environmental conditions are demanding or specific safety and regulatory requirements need to be adhered to. Whether you need unique surface mount sizes, specialized cooling or vibration resistance, a custom mount will help you get the right specifications for your needs. 

How to Mount a Power Supply 

Mounting techniques for power supplies require careful attention to ensure the system's proper functioning, stability and safety. 

1. Choose the Right Location

It’s essential to select a location with enough ventilation to prevent overheating. This means avoiding areas with high moisture, dust or extreme vibrations unless the power supply is custom designed for those conditions. 

Mount the power supply somewhere away from components that are sensitive to EMI. If space is limited or you don’t have many options, you can use a durable EMI filter, like those from Astrodyne TDI. These filters help suppress electromagnetic noise transmitted through conduction and extract unwanted current from the wiring, enabling desirable currents to flow.

2. Inspect the Mounting Surface

A poor or unprepared surface can lead to instability, vibrations or even damage to the power supply or surrounding components. Preparing the surface involves:

• Ensuring it's flat and stable: The surface on which you mount electrical components needs to be even and steady. An uneven surface can stress the PSU and potentially cause damage. The surface must also be able to support the unit's weight without bending. 
• Assessing the environmental conditions: You want a place where the PSU will be free from moisture, corrosive chemicals or extreme temperatures.
• Cleaning the area: Remove any debris, dust or oil from the surface. These can reduce friction and cause the unit to shift or vibrate during operation. 

3. Gather Your Tools

The type of hardware you choose will depend on important factors such as the mounting method, power supply design and the installation environment. Manufacturers often include details about the size, type and material of screws, brackets or clips on the packaging or in a user manual. Using the incorrect hardware can compromise safety.

It’s also essential to match your hardware to the mounting type. Accessories for electric power equipment include:

• For DIN-rail mounts: Use brackets or clips that are designed to snap into standard DIN-rails.
• For panel mounts: Use screws or bolts that fit securely into pre-drilled mounting holes on the power supply and panel.
• For rack mounts: Choose rails designed to hold the power supply’s size for systems like servers. 

4. Position and Secure Your Power Supply

Position the power supply according to the airflow requirements that have been outlined by the manufacturer. Most units need space around vents or fans for optimal heat dissipation.

After aligning the PSU, you’ll need to fasten it using the recommended hardware and ensure it’s properly tightened. 

5. Connect the Wiring

At this step of the process, you’ll need to route the cables through the designated pathways and use cable organizers to minimize tangling or obstruction. 

6. Test Your Installation

After mounting your power supply, test it to ensure everything works properly. While testing it, you'll have to:

• Ensure that no wires or components obstruct the fan's other parts.
• Check the stability of the PSU by gently pushing it to check if it's firmly mounted.
• Ensure that it operates properly, without any unusual noise or overheating.

Thermal Management for Power Supply Mounting

Thermal management involves controlling the heat generated by the power supply to ensure safer and more operation. This is important because excessive heat can lead to reduced performance, component failure or even safety hazards. 

Multiple cooling airflow solutions can help protect your power supply effectively, including installing cooling fans to circulate air over components or adding heat sinks, which are metal components that increase the surface area of heat dissipation. 

Let Astrodyne TDI Help You Find the Perfect Power Solution

Selecting the proper power supply mounting is essential for ensuring your equipment's reliable performance and longevity. At Astrodyne TDI, we understand that every application has unique requirements and challenges. Our expert team designs custom solutions, like EMI filters, which meet industry standards and comply with EMC regulations. Contact us today to discuss your project and find the perfect power solution for your needs.