Dell PowerEdge 6600 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 and the DELL logo 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.
March 2002 P/N 4N568 Rev. A00

Contents 3
Contents
Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Rack-to-Tower Kit Contents. . . . . . . . . . . . . . . . . . . . 1-2
Before You Begin . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Recommended Tools . . . . . . . . . . . . . . . . . . . . . . 1-4
Conversion Tasks . . . . . . . . . . . . . . . . . . . . . . . 1-4
Removing the Rack Doors. . . . . . . . . . . . . . . . . . . . . 1-5
Removing the Cable-Management Arm. . . . . . . . . . . . . . 1-5
Removing the System From the Rack . . . . . . . . . . . . . . 1-7
Removing the Bezel, Cover, and Front Panel . . . . . . . . . . . 1-9
Installing the Front Panel . . . . . . . . . . . . . . . . . . . . 1-11
Installing the Cover, Pedestal, and Bezel. . . . . . . . . . . . 1-13
Removing the Slide Assemblies . . . . . . . . . . . . . . . . . 1-15
Replacing the Rack Doors . . . . . . . . . . . . . . . . . . . 1-17
Figures
Figure 1-1. Rack-to-Tower Kit Contents. . . . . . . . . . . 1-3
Figure 1-2. Removing the Cable-Management Arm . . . . . 1-6
Figure 1-3. Removing the System From the
Slide Assemblies . . . . . . . . . . . . . . . . 1-8
Figure 1-4. Removing the Front Bezel. . . . . . . . . . . . 1-9
Figure 1-5. Removing the System Cover. . . . . . . . . . 1-10
Figure 1-6. Installing the Tower Front Panel . . . . . . . 1-11

4Contents
Figure 1-7. Installing the Right-Side Trim Panel . . . . . . 1-13
Figure 1-8. Attaching Casters to the Pedestal . . . . . . . 1-14
Figure 1-9. Installing the Tower Front Bezel . . . . . . . . 1-15
Figure 1-10. Removing the Slide Assemblies (RapidRails and
VersaRails Slide Assemblies Shown) . . . . . . 1-16

Rack-to-Tower Conversion Guide 1-1
This conversion guide provides instructions for trained service technicians in 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 document. Warranty information
may or may not be included in this 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.
• 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.

1-2 Rack-to-Tower Conversion Guide
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• 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 with keylock and keys
• One tower front panel
• One tower right-side trim panel
• One pedestal
•Sixcasters
• Four plastic feet
• Four #6 plastite screws
• One ball stud
• Nine 6-32 x 0.25-inch hex-head Phillips screws
• Twenty-four 8-32 nuts with attached external star washers

Rack-to-Tower Conversion Guide 1-3
Figure 1-1. Rack-to-Tower Kit Contents
tower bezel
tower front panel
metal casters (6)
ball stud (1)
tower right-side
trim panel
pedestal
8-32 x 0.25-inch nuts
with attached external
star washer (24)
6-32 x 0.25-inch hex-
head Phillips screws (9)
#6 plastite screws (4)
feet (4)

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Before You Begin
Before you begin removing your system from the rack and converting it to a tower version
system, carefully read “Safety Instructions.”
Recommended Tools
The following tools are required to perform the conversion:
• #2 Phillips screwdriver
• 1/4-inch nut driver
• Flat-tipped screwdriver
• Torx T-15 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 tower front panel
• Installing the trim panel
• Installing the pedestal
• Installing the tower front bezel
• Removing the slide assemblies
• Replacing the rack doors

Rack-to-Tower Conversion Guide 1-5
Removing the Rack Doors
For instructions on removing the rack doors, refer to the procedures in the documentation
provided with the rack cabinet.
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 the arm’s 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).
4Remove the captive thumbscrew and bracket that secure the back end of the cable-
management arm to the back vertical rail (see Figure 1-2).

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Figure 1-2. Removing the Cable-Management Arm
cable-management arm
back of
system
Velcro
strap
captive thumbscrew
release tab

Rack-to-Tower Conversion Guide 1-7
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, power supplies, and the microprocessor tray (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 latch locks at the fully
extended position.
3Press up on the yellow system release latch and pull the system forward to the farthest
position on the slide assemblies.
4Using from two to four people, grasp the system by the handles and lift the system up
and out of the slide asssemblies (see Figure 1-3).
If you have difficulty, ensure that the front shoulder screws are lifted out of their slots
on the slide assembly before the back shoulder screws.
5Place the system on a smooth work surface.

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Figure 1-3. Removing the System From the Slide Assemblies
slide release latch
(green)
system release latch
(yellow)

Rack-to-Tower Conversion Guide 1-9
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 by pulling it away from the system front panel and set it aside.
Figure 1-4. Removing the Front Bezel
2Remove the back cover:
aUsing the system key, unlock the back cover, if it is locked.
bLoosen the thumbscrew that secures the back cover to the chassis (see Figure 1-5).
cSlide the system cover backward and grasp the cover at both ends.
dCarefully lift the cover away from the system.
back cover key lock

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Figure 1-5. Removing the System Cover
3Remove the front system cover:
aSlide the front cover backward and grasp the cover at both ends (see Figure 1-5).
bCarefully lift the cover away from the system and set it aside.
4Label each hard drive with its location in the chassis.
5Remove the hard drives from the system.
6Remove the four T-15 Torx screws that secure the control panel to the front panel.
7On the back of the control panel, disconnect the cable leading to the peripheral I/O
card (CONTROL PANEL connector).
8On the back of the control panel, disconnect the cable leading to the square LED
connector.
9Remove the square LED connector by squeezing the left- and right-side release
latches and pushing it back, through the front panel.
10 Remove the eight T-15 Torx screws that secure the rack front panel to the chassis.
11 Lift the rack front panel away from the chassis and set it aside.
back cover
front cover thumbscrew
system key

Rack-to-Tower Conversion Guide 1-11
Installing the Front Panel
To install the tower front panel (provided with the kit) to the chassis, perform the following
steps:
1Secure the tower front panel to the chassis with the eight T-15 Torx screws that you
removed from the original front panel (see Figure 1-6).
2Install the LCD control panel on the front of the tower front panel and secure it with
the four T-15 Torx screws that you removed with the control panel.
3Secure the control panel cable from the CONTROL PANEL connector (on the top
front corner of the peripheral I/O board) to the back of the control panel.
4Using a 1/4-inch nut driver, install a ball stud nut onto the threaded stud in the top
right corner of the front panel (see Figure 1-6).
The ball stud is used to latch the bezel to the tower front panel.
5Install the square LED connector by aligning the connector with the square hole and
seating it into the front panel.
The square LED connector clicks when properly installed.
6Reconnect the cable from the LED connector to the back of the control panel.
Figure 1-6. Installing the Tower Front Panel
hole for ball
stud

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Installing the Trim Panel
To install the tower right-side 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 1-7) while installing the right-side trim panel.
1Hold the tower right-side trim panel in position with the sides facing up as shown in
Figure 1-7.
NOTE: You will need two to four persons to lift the system into position just above
the right-side 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 using the four handles on the sides.
3Check to see that the slots in the inner surfaces of the trim panel are aligned directly
below the shoulder screws on the side of the system chassis (see Figure 1-7).
4Lower the system chassis into the right-side trim panel, with the shoulder screws
entering the slots on the inner surfaces of the trim panel.
5After the chassis is lowered into place, move the trim panel forward until it is flush
with the front panel.
6Secure the right-side of the trim panel with three 6-32 x 0.25-inch hex-head Phillips
screws from the inside of the system chassis (see Figure 1-7).

Rack-to-Tower Conversion Guide 1-13
Figure 1-7. Installing the Right-Side Trim Panel
Installing the Cover, Pedestal, and Bezel
1Position the system as shown in Figure 1-8.
2Replace the system front and back covers.
3Install six casters on the bottom of the pedestal and secure them using 8-32 nuts with
attached external star washers.
4Install four plastic feet and secure each with a #6 plastite screw (see Figure 1-8).
5Secure the pedestal to the bottom of the system with six 6-32 x 0.25-inch hex-head
Phillips screws (see Figure 1-8).
tower front panel
right-side trim panel
6-32 x 0.25-inc
h
hex-head Phillips
screws (3)

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Figure 1-8. Attaching Casters to the Pedestal
6Position the bezel so that its hinged mounting bracket thumbscrews are aligned with
the holes in the system front panel (see Figure 1-9).
7Secure the thumbscrews to the front panel with a Phillips screwdriver.
8Reinstall the hard drives in their slots in the drive bay, if they were removed to lighten
the chassis (see your Installation and Troubleshooting Guide for instructions).
9Install the power supplies and the microprocessor tray, if they were removed to lighten
the chassis.
10 Close the bezel.
casters (6)
6-32 x 0.25-inch
hex-head Phillips
screws (6)
8-32 studs (24)
8-32 nuts (24)
plastic foot (4)
#6 plastite screw (4)

Rack-to-Tower Conversion Guide 1-15
Figure 1-9. Installing the Tower Front Bezel
Removing the Slide Assemblies
NOTE: If no screws are used to secure the slide assemblies in the rack, continue with
step 1. If the slide assemblies are secured to the front and back vertical rails with
screws, 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).
thumbscrews
keylock

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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