Hacking an Antek power supply to reduce its footprint

[hflwaterski]

Control panel question. I'm at the point where I'm putting the control panel together however I'm a bit concerned about the amount of space in my panel. I didn't realize just how big the power supply was going to be and now it is really cramping things up in there. The DIN rail and the PMDX are not mounted, they are just sitting there.

Will I be able to get away with this panel or do you think that I will need to upgrade to a larger one?

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[Gerald D]

The major chassis plate of that power seems to serve the sole purpose of holding it all together while it is shipped to you - it is not a heatsink. I would try and tip the transformer up 90 degrees (provided that the box lid will close over the diameter) and hold it up with a single L-bracket. Then dump the chassis plate and screw the 3 heatsinks direct to the panel you have there now.

This archived thread might give you some ideas:
http://www.mechmate.com/forums/showthread.php?t=55

Whatever you do, do not sandwich the transformer between 2 brackets and then put a bolt through the center of transformer .You will burn something like this - that bolt/brackets acts as a shorted out winding.

[hflwaterski]

Whatever you do, do not sandwich the transformer between 2 brackets and then put a bolt through the center of transformer .You will burn something like this - that bolt/brackets acts as a shorted out winding.

Gerald,

There are no other brackets or areas for bolts or screws on the transformer. How do you recommend that I keep the transformer in place without using the supplied round metal plate, insulating gaskets and bolt?

Thanks,
Herb

[Gerald D]

This should explain it:

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[domino11]

If you wanted to use both brackets, you would have to use a nylon bolt and nuts to ensure no shorted turns as Gerald points out. The nylon bolt wont make an electrical connection.

[hflwaterski]

That worked out well. I was able to take the u-shaped metal appliance that the power supply came with and cut it into two pieces. I then mounted them to the back plate on the short side. That freed up quite a bit of room. It just barely fits with the cover but it does fit. I'm now going to be turning my attention to the wiring. Thanks for the advice.
- Herb

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[Gerald D]

Glad to hear that it worked. Hope you meticulously cleaned all metal filings away from the electrics . . . . (you might have been able to remove the "u-shaped metal appliance" completely before cutting?)

[hflwaterski]

Gerald,

Yes. I completely disassembled the power supply prior to cutting. I drilled all of the holes in the back panel and the u-shaped appliance and the metal was cleaned before reassembly.

- Herb