Dell PowerEdge 4600 User manual

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Dell™ Systems
Rack-to-Tower
Conversion Guide

Notes, Notices, and Cautions
NOTE: A NOTE indicates important information that helps you make better use of your computer.
NOTICE: A NOTICE indicates either potential damage to hardware or loss of data and tells you
how to avoid the problem.
CAUTION: A CAUTION indicates a potential for property damage, personal injury,
or death.
____________________
Information in this document is subject to change without notice.
© 2002 Dell Computer Corporation. All rights reserved.
Reproduction in any manner whatsoever without the written permission of Dell Computer Corporation is strictly forbidden.
Trademarks used in this text: Dell,the DELL logo, RapidRails, and VersaRails are trademarks of Dell Computer
Corporation.
Other trademarks and trade names may be used in this document to refer to either the entities claiming the marks and
names or their products. Dell Computer Corporation disclaims any proprietary interest in trademarks and trade names
other than its own.
May 2002 P/N 4T771 Rev. A00

Contents 3
Contents
Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Rack-to-Tower Kit Contents. . . . . . . . . . . . . . . . . . . . 1-2
Before You Begin . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Recommended Tools . . . . . . . . . . . . . . . . . . . . . . 1-4
Conversion Tasks . . . . . . . . . . . . . . . . . . . . . . . 1-4
Removing the Rack Doors. . . . . . . . . . . . . . . . . . . . . 1-4
Removing the Cable-Management Arm. . . . . . . . . . . . . . 1-5
Removing the System From the Rack . . . . . . . . . . . . . . 1-6
Removing the Bezel, Cover, and Front Panel . . . . . . . . . . . 1-8
Installing the Trim Panel . . . . . . . . . . . . . . . . . . . . 1-10
Installing the Front Panel . . . . . . . . . . . . . . . . . . . . 1-11
Installing the Cover, Metal Feet, and Bezel . . . . . . . . . . 1-12
Removing the Slide Assemblies . . . . . . . . . . . . . . . . . 1-14
Replacing the Rack Doors . . . . . . . . . . . . . . . . . . . 1-16
Figures
Figure 1-1. Rack-to-Tower Kit Contents. . . . . . . . . . . 1-3
Figure 1-2. Removing the Cable-Management Arm . . . . . 1-5
Figure 1-3. Removing the System From the
Slide Assemblies . . . . . . . . . . . . . . . . 1-7
Figure 1-4. Removing the Front Bezel. . . . . . . . . . . . 1-8

Rack-to-Tower Conversion Guide 1-1
This conversion guide provides instructions for trained service technicians on removing a
system from a rack cabinet and converting the system to a tower version. One rack-to-tower
conversion kit is required for each system to be converted from a rack version system to a
tower version system.
CAUTION: The system is very heavy. To prevent personal injury, do not attempt
to move the system by yourself.
Safety Instructions
Use the following safety guidelines to ensure your own personal safety and to help protect
your server, storage system, or appliance from potential damage. For complete safety and
regulatory information, refer to your System Information Guide. Warranty information may
be included in this document or as a separate document.
Precautions for Rack-Mountable Products
Observe the following precautions for rack stability and safety. Also refer to the rack
installation documentation accompanying the system and the rack for specific warning
and/or caution statements and procedures.
Servers, storage systems, and appliances are considered to be components in a rack. Thus,
"component" refers to any server, storage system, or appliance, as well as to various
peripherals or supporting hardware.
CAUTION: Installing system components in a rack without the front and side
stabilizers installed could cause the rack to tip over, potentially resulting in
bodily injury under certain circumstances. Therefore, always install the
stabilizers before installing components in the rack.
CAUTION: After installing system/components in a rack, never pull more than
one component out of the rack on its slide assemblies at one time. The weight of
more than one extended component could cause the rack to tip over and injure
someone.
NOTE: Your system is safety-certified as a free-standing unit and as a component for
use in a rack cabinet using the customer rack kit when both the rack cabinet and rack
kit were designed for your system. The installation of your system and rack kit in any
other rack cabinet has not been approved by any safety agencies. It is your
responsibility to have the final combination of system and rack kit in a rack cabinet
evaluated for suitability by a certified safety agency. The manufacturer disclaims all
warranties and liability in connection with such combinations.

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• System rack kits are intended to be installed in a rack by trained service technicians. If
you install the kit in any other rack, be sure that the rack meets the specifications.
• Do not move large racks by yourself. Due to the height and weight of the rack, it is
recommended that a minimum of two people to perform this task.
• Before working on the rack, make sure that the stabilizers are secured to the rack,
extend to the floor, and that the full weight of the rack rests on the floor. Install front
and side stabilizers on a single rack or front stabilizers for joined multiple racks before
working on the rack.
• Always load the rack from the bottom up, and load the heaviest item in the rack first.
• Make sure that the rack is level and stable before extending a component from the
rack.
• Use caution when pressing the component rail release latches and sliding a component
into or out of a rack; the slide rails can pinch your fingers.
• After a component is inserted into the rack, carefully extend the rail into a locking
position, and then slide the component into the rack.
• Do not overload the power supply branch circuit that provides power to the rack.
The total rack load should not exceed 80 percent of the branch circuit rating.
• Ensure that proper airflow is provided to components in the rack.
• Do not step on or stand on any system/component when servicing other
systems/components in a rack.
Rack-to-Tower Kit Contents
The rack-to-tower kit includes the following items (see Figure 1-1):
• One tower bezel
• One tower front panel
• One tower trim panel
• Four metal feet
• Ten 6-32 x 0.25-inch hex-head Phillips screws
• Six 6-32 x 0.312-inch black flat-head T-10 Torx screws

Rack-to-Tower Conversion Guide 1-3
Figure 1-1. Rack-to-Tower Kit Contents
Before You Begin
Before you begin removing your system from the rack and converting it to a tower version
system, carefully read "Safety Instructions."
You will reuse the following parts:
• The fourteen 6-32 x 0.312-inch black flat-head T-10 Torx screws that you remove from
the rack version system’s front panel
• The bezel attaching bracket and the four 6-32 x 0.312-inch black flat-head T-10 Torx
screws
• The control panel and one 6-32 x 0.25-inch hex-head Phillips screw that you remove
from the control panel
tower bezel
tower front panel
tower trim panel
6-32 x 0.25-inch hex-
head Phillips screws (10)
6-32 x 0.312-inch black
flathead T-10 Torx screws (6)
metal feet (4)

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Recommended Tools
The following tools are required to perform the conversion:
• #2 Phillips screwdriver
• 1/4-inch nut driver
• Flat-tipped screwdriver
• Torx T-10 driver (for removing and installing the front panels)
Conversion Tasks
Removing a system from the rack and removing the rack mounting hardware from the rack
cabinet includes the following tasks:
• Removing the rack doors
• Removing the cable-management arm
• Removing the system from the rack
• Removing the bezel, cover, and front panel
• Installing the trim panel
• Installing the tower front panel
• Installing the metal feet
• Installing the tower front bezel
• Removing the slide assemblies
• Replacing the rack doors
Removing the Rack Doors
For instructions on removing the rack doors, refer to the procedures in the documentation
provided with the rack cabinet.

Rack-to-Tower Conversion Guide 1-5
Removing the Cable-Management Arm
1Shut down and turn off the system you are converting as well as all peripherals
attached to this system.
2At the back of the rack cabinet, disconnect and remove the AC power cable and all
other cables connected to the back of the system and secured to the cable-
management arm with Velcro straps.
3Squeeze the release tab that secures the front of the cable-management arm to the
back of the system (see Figure 1-2).
Figure 1-2. Removing the Cable-Management Arm
cable-management arm
back of system
Velcro strap
captive thumbscrew
screws (5)
cable tray

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4Pull the cable-management arm away from the cable tray.
5Remove the captive thumbscrew and bracket that secure the back end of the cable-
management arm to the back vertical rail (see Figure 1-2).
6Remove the five 6-32 x 0.25-inch hex-head Phillips that secure the cable tray to the
back of the system (see Figure 1-2).
7Remove the cable tray from the back of the system.
Removing the System From the Rack
CAUTION: If you are removing more than one system from the rack cabinet,
remove the highest of the systems to be removed first. Complete the removal of
the first system from the rack before starting the second. Never extend more
than one system from the rack at a time. Removing a system from a position high
up in the rack cabinet may require up to four people and may require a sturdy,
elevated platform to stand on. A mechanical lifting platform or similar
equipment of the proper capacity may also be useful. If you attempt to remove
and lower the system without enough people to safely perform the task, you risk
personal injury to yourself and to others and damage to the system.
NOTICE: You will be moving the system chassis several times while you perform this
procedure. You may wish to make the system chassis lighter by labeling and removing
the hard drives and power supplies (for instructions, see the
Installation and
Troubleshooting Guide ).
1Loosen the thumbscrews that secure the system to the front vertical rails (at the front
of the rack cabinet).
2Pull the system out of the rack until the green slide release latches lock at the fully
extended position.
3Press up on the yellow system release latches and pull the system forward to the
farthest position on the slide assemblies (see Figure 1-3).
4Using two to four people, grasp the system at each corner and lift the system up and
out of the slide asssemblies (see Figure 1-3).
If you have difficulty, ensure that the shoulder screws in the slide assemblies are
aligned with the openings on the top of the slide assemblies.
5Place the system on a smooth work surface.

Rack-to-Tower Conversion Guide 1-7
Figure 1-3. Removing the System From the Slide Assemblies
slide release latch
(green)
system release
latch (yellow)

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Removing the Bezel, Cover, and Front Panel
This procedure is best performed with the system positioned as if it were in the rack (see
Figure 1-4).
1Remove the bezel and set it aside:
aUsing the system key, unlock the front bezel, if applicable.
bPivot the bezel away from the system until it is perpendicular to the system (see
Figure 1-4).
Figure 1-4. Removing the Front Bezel
cSqueeze the retaining pins and rotate them into their grooves to release the bezel.
dPull the bezel away and set it aside.
retaining pins

Rack-to-Tower Conversion Guide 1-9
2Remove the system cover and set it aside (see Figure 1-5):
aLoosen the three thumbscrews on the front of the system (see Figure 1-5).
bSlide the system cover back and grasp the cover at both ends (see Figure 1-5).
cCarefully lift the cover away from the system and set it aside.
Figure 1-5. Removing the System Cover
3Remove the front panel:
aLabel and remove all hard drives (see your Installation and Troubleshooting
Guide).
bRemove all power supplies (see your Installation and Troubleshooting Guide).
cRemove the peripheral bay (see your Installation and Troubleshooting Guide).
dRemove the bezel connector cable from the center of the control-panel board.
eRemove the control panel’s interface cable.
fRemove the four T-10 Torx screws that secure the bezel attaching bracket to the
front panel.
gRemove the 14 remaining T-10 Torx screws that secure the rack front panel to the
chassis.
thumbscrews (3)

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hLay the front panel on a smooth work surface with the outside surface facing
down.
iRemove the two 6-32 x 0.25-inch hex-head Phillips screws that secure the control
panel board to the back of the front panel.
Set the control panel and screws aside for installation on the tower front panel.
Installing the Trim Panel
To install the tower trim panel on the chassis, perform the following steps.
NOTE: You may find it convenient to leave the chassis in the rack position (as shown
in Figure 1-6) while installing the trim panel.
1Hold the tower trim panel in position with the sides facing up as shown in Figure 1-6.
NOTICE: You will need two to four persons to lift the system into position above the
trim panel. One additional person may be needed to separate the trim panel from
chassis obstructions.
2Using two or four persons, lift the system chassis.
3Lower the system chassis into the trim panel (see Figure 1-6).
4After the chassis is lowered into place, align the three holes in the trim panel with the
three holes in the chassis.
5Secure the right side of the trim panel with three 6-32 x 0.25-inch hex-head Phillips
screws (see Figure 1-6).
6Secure the back of the trim panel with three 6-32 x 0.25-inch hex-head Phillips screws.

Rack-to-Tower Conversion Guide 1-11
Figure 1-6. Installing the Trim Panel
Installing the Front Panel
To install the tower front panel (provided with the kit) to the chassis, perform the following
steps:
1Install the peripheral bay by attaching it to the hard-drive bay with the peripheral bay
handle pointing away from the front fan assembly.
2Secure the tower front panel to the chassis and trim panel with the 20 T-10 Torx
screws (see Figure 1-7).
Use the 14 T-10 Torx screws that you removed from the rack version’s front panel and
the six T-10 Torx screws provided with the kit.
trim panel
6-32 x 0.25-inch
hex-head Phillips
screws (3)

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Figure 1-7. Installing the Tower Front Panel
3Secure the bezel attaching bracket to the front panel using the four T-10 Torx screws
that you removed with the bracket.
4Remove the 6-32 x 0.25-inch hex-head Phillips screw from the control panel bracket
that is closest to the power supply opening in the front panel.
5Install the control panel on the tower front panel and secure it with two
6-32 x 0.25-inch hex-head Phillips screws.
Reuse one of the screws that you removed when removing the control panel from the
rack front panel and the screw that you removed in step 4.
6Reconnect the control panel cable.
7Connect the bezel connector cable to the control panel.
Installing the Cover, Metal Feet, and Bezel
1Position the system as shown in Figure 1-8.
2Replace the system cover.

Rack-to-Tower Conversion Guide 1-13
3Install the four metal feet:
aInsert the two tabs of the metal feet into the slots on the chassis and trim panel
(see Figure 1-8).
bSecure the metal feet to the chassis and trim panel with four 6-32 x 0.25-inch
hex-head Phillips screws (see Figure 1-8).
Figure 1-8. Attaching the Metal Feet
4Position the tower bezel so that it is perpendicular to the system (see Figure 1-9).
5Retract and lock the retaining pins in the bezel’s hinge halves.
6Rotate the retaining pins in their grooves to release the pins into their mating hinge
halves.
7Reinstall the hard drives in their labeled slots in the drive bay (see your Installation
and Troubleshooting Guide for instructions).
8Reinstall the power supplies (see your Installation and Troubleshooting Guide for
instructions).
9Close the bezel.
metal feet (4)
6-32 x 0.25-inch
hex-head Phillips
screws (4)
tabs (2)

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Figure 1-9. Installing the Tower Front Bezel
Removing the Slide Assemblies
This procedure includes information on removing RapidRails™ and VersaRails™ slide
assemblies.
NOTE: If screws are not used to secure the slide assemblies in the rack, continue with
step 1. If screws are used to secure the slide assemblies to the front and back vertical
rails, go to step 4.
1At the front of the rack cabinet, locate the blue release push button on one of the slide
assembly’s mounting-bracket flanges (see Figure 1-10).
2From the front of the rack cabinet, press in on the blue release push button, lift up,
and push the slide assembly approximately 2.54 cm (1 inch) back from the front
vertical rail until the mounting-bracket flange and its mounting hooks disengage from
the square holes in the front vertical rail (see Figure 1-10).

Rack-to-Tower Conversion Guide 1-15
Figure 1-10. Removing the Slide Assemblies (RapidRails and
VersaRails Slide Assemblies Shown)
slide-assembly
mounting-bracket
flange
blue release push button
front of rack slide assemblies (2)
mounting
hooks
mounting
screws
slide-assembly
mounting-bracket
flange

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3Repeat step 2 at the back of the cabinet for this slide assembly.
4If the slide assemblies are secured with screws, remove the screws that secure the front
and back mounting-bracket flanges to the vertical rails.
5Repeat steps 1 through 3 (or step 4 if screws secure the slide assemblies) for the
remaining slide assembly on the other side of the rack.
6Place the cable-management arm, slide assemblies, and all fastener hardware in a box.
Label the box as a rack installation kit for the system you removed from the rack.
Replacing the Rack Doors
Refer to the procedures for replacing the rack doors in the documentation provided with
your rack cabinets.