Dell PowerEdge 6800 User manual

www.dell.com | support.dell.com
Dell™ Systems
Tower-to-Rack
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.
© 2005 Dell Inc. All rights reserved.
Reproduction in any manner whatsoever without the written permission of Dell Inc. is strictly forbidden.
Trademarks used in this text: Dell, RapidRails, VersaRails, and the DELL logo are trademarks of Dell Inc.
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 Inc. disclaims any proprietary interest in trademarks and trade names other than its own.
March 2005 P/N C8527 Rev. A01

Contents 3
Contents
Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Installation Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Before You Begin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Installing the Tower-to-Rack Kit. . . . . . . . . . . . . . . . . . . . . . . . . . 7
Tower-to-Rack Kit Contents. . . . . . . . . . . . . . . . . . . . . . . . . . 8
Recommended Tools and Supplies . . . . . . . . . . . . . . . . . . . . . . 8
Conversion Tasks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Removing the Optional Tower Bezel, Metal Feet, and Cover. . . . . . . . . 9
Removing the Control Panel Assembly and Tower Front Panel . . . . . . 11
Installing the Rack Front Panel and Control Panel Assembly . . . . . . . 13
Removing the Trim Panel . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Installing the System in a Rack . . . . . . . . . . . . . . . . . . . . . . . 16
Installing the Optional Rack Bezel . . . . . . . . . . . . . . . . . . . . . 16
Figures
Figure 1-1. Tower-To-Rack Kit Contents . . . . . . . . . . . . . 8
Figure 1-2. Removing the Optional Tower Bezel . . . . . . . . . 9
Figure 1-3. Removing the Metal Feet . . . . . . . . . . . . . . . 10
Figure 1-4. Removing and Installing the Cover . . . . . . . . . . 11
Figure 1-5. Removing and Installing the Control Panel
Assembly and Front Panel . . . . . . . . . . . . . . 12
Figure 1-6. Replacing the Control Panel Assembly
Metal Bracket . . . . . . . . . . . . . . . . . . . . 14
Figure 1-7. Removing the Trim Panel . . . . . . . . . . . . . . . 15
Figure 1-8. Installing the Optional Rack Bezel . . . . . . . . . . 16

4Contents

Tower-to-Rack Conversion Guide 5
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, see your
Product Information Guide . Warranty information might be included within
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: Before installing systems in a rack, install front and side stabilizers on stand-alone (single)
racks or the front stabilizer on racks joined to other racks. Failure to install stabilizers accordingly
before installing systems in a rack could cause the rack to tip over, potentially resulting in bodily injury
under certain circumstances. Therefore, always install the stabilizer(s) 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
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 an approved rack by trained service
technicians. If you install the kit in any other rack, be sure that the rack meets the
specifications.
CAUTION: 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 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.

6Tower-to-Rack Conversion Guide
www.dell.com | support.dell.com
• 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.
Installation Instructions
This installation guide provides instructions for trained service technicians installing one or more
systems in an open-frame relay rack or in a rack cabinet. The Dell™ RapidRails™ rack kit can be
installed in all the manufacturer’s rack cabinets without tools, and the VersaRails™ rack kit can be
installed in most industry-standard rack cabinets. The procedures for installing both RapidRails
and VersaRails rack kits are similar. One rack kit is required for each system installed in the rack.
CAUTION: Do not install rack kit components designed for another system. Use only the rack kit for
your Dell system. Using the rack kit for another system may result in damage to the system and personal
injury.
The RapidRails rack kit can be installed in any Dell rack cabinet and in most industry-standard rack
cabinets.
NOTICE: The VersaRails rack kit is intended to be installed by trained service technicians in a rack that
meets the specifications of American National Standards Institute (ANSI)/Electronic Industries
Association (EIA) standard ANSI/EIA-310-D-92, International Electrotechnical Commission (IEC) 297, and
Deutsche Industrie Norm (DIN) 41494. One rack kit is required for each system that is installed in a rack.
Before You Begin
Before you begin installing your system in the rack, carefully read "Safety Instructions," found
earlier in this guide, as well as the safety instructions found in your
Product Information Guide for
additional information.
CAUTION: When installing multiple systems in a rack, complete all of the procedures for the current
system before attempting to install the next system.
CAUTION: Rack cabinets can be extremely heavy and move easily on the casters. The cabinet has no
brakes. Use extreme caution while moving the rack cabinet. Retract the leveling feet when relocating
the rack cabinet. Avoid long or steep inclines or ramps where loss of cabinet control may occur. Extend
the leveling feet for support and to prevent the cabinet from rolling.

Tower-to-Rack Conversion Guide 7
Important Safety Information
Observe the safety precautions in the following subsections when installing your system in the rack.
CAUTION: You must strictly follow the procedures in this document to protect yourself as well as
others who may be involved. Your system may be very large and heavy, and proper preparation and
planning are important to prevent injury to yourself and to others. This becomes increasingly important
when systems are installed high up in the rack.
Rack Stabilizer Feet
CAUTION: Before installing systems in a rack, install front and side stabilizers on stand-alone (single)
racks or the front stabilizer on racks joined to other racks. Failure to install stabilizers accordingly before
installing systems in a rack could cause the rack to tip over, potentially resulting in bodily injury under
certain circumstances. Therefore, always install the stabilizer(s) before installing components in the rack.
CAUTION: After installing systems in a rack, never pull more than one system out of the rack on its
slide assemblies at one time. The weight of more than one extended system could cause the rack to tip
over and cause injury.
The stabilizer feet help prevent the rack from tipping over when a system or other component is
pulled out of the rack with the slide assemblies fully extended. See the documentation provided
with the rack cabinet for instructions on installing and anchoring the stabilizer feet.
Installing the Tower-to-Rack Kit
CAUTION: The system may weigh up to 49 kilograms (108 pounds) when fully loaded. To prevent
personal injury, do not attempt to move the system by yourself.

8Tower-to-Rack Conversion Guide
www.dell.com | support.dell.com
Tower-to-Rack Kit Contents
The tower-to-rack kit includes the following items (see Figure 1-1):
• One rack front panel with rack handles and thumbscrews
• Twenty-one 6-32 x 0.312-inch black pan-head Torx screws
• Four 6-32 x 0.312-inch black flat-head Phillips screws
• Six shoulder mounting screws
• Replacement rack control-panel bracket
An optional rack bezel, complete with keylock and keys, is available separately.
Figure 1-1. Tower-To-Rack Kit Contents
Recommended Tools and Supplies
• #2 Phillips screwdriver
• 1/4-inch nut driver
• T-10 Torx driver (for removing and installing the front panels)
• T-15 Torx driver (for removing and installing the front panels)
Conversion Tasks
Installing a rack kit involves performing the following tasks:
• Removing the optional tower bezel, feet, and cover
• Removing the control panel assembly and tower front panel
• Installing the rack front panel and control panel assembly
• Removing the trim panel
• Installing the system in the rack
• Installing the optional rack bezel
rack front panel
rack control panel bracket
6-32 x 0.312 Torx
screws (21)
6-32 x 0.312
Torx screws (4)
shoulder mounting
screws (6)

Tower-to-Rack Conversion Guide 9
Removing the Optional Tower Bezel, Metal Feet, and Cover
1 To remove the tower bezel, orient the system as shown in Figure 1-2 and perform the
following steps:
a Unlock the keylock. See Figure 1-2.
b Rotate the keylock end of the bezel away from the front panel.
c Unhook the other end of the bezel and pull the bezel away from the system.
Figure 1-2. Removing the Optional Tower Bezel
bezel
keylock

10 Tower-to-Rack Conversion Guide
www.dell.com | support.dell.com
2 Remove the four metal feet from the system:
a Orient the system so that the metal feet hang over the edge of the table as shown in
Figure 1-3.
b Using a #2 Phillips screwdriver or a 1/4-inch nut driver, remove the screw that secures
each metal foot and pull each foot from the chassis. See Figure 1-3.
Repeat this step for the other three metal feet.
Figure 1-3. Removing the Metal Feet
3 Remove the system cover and set it aside (see Figure 1-4):
a Loosen the two thumbscrews on the front of the system.
b Slide the system cover back and grasp the cover at both ends.
c Carefully lift the cover away from the system and set it aside.
metal feet (4) hex-head Phillips
screws (4)

Tower-to-Rack Conversion Guide 11
Figure 1-4. Removing and Installing the Cover
Removing the Control Panel Assembly and Tower Front Panel
1 Label each hard drive, any optical drives, and devices installed in the media bay with their
location in the chassis.
2 Remove all hard drives, media devices, and filler plates from the drive and media bays.
3 Disconnect any cables from the media bay devices.
cover
thumbscrews (2)

12 Tower-to-Rack Conversion Guide
www.dell.com | support.dell.com
4 Remove the control panel assembly:
a Orient the system so that the front panel hangs over the edge of the table as shown in
Figure 1-5.
b Disconnect the interface cables from the control panel assembly.
c Using a #2 Phillips screwdriver, remove the three screws that secure the control panel
assembly to the tower front panel.
d Slide the control panel assembly back away from the front panel and remove the assembly
from the chassis.
Figure 1-5. Removing and Installing the Control Panel Assembly and Front Panel
control panel assembly
screws (3)
pan-head T-15 Torx
screws (21)
front panel
interface cables (2)
flat-head T-10 Torx screws (4)

Tower-to-Rack Conversion Guide 13
5 Remove the tower front panel:
a Using a T-10 Torx driver, remove the 4 flat-head screws located between the drive bays on
the tower front panel. See Figure 1-5.
b Using a T-15 Torx driver, remove the 21 pan-head screws that secure the tower front panel
to the drive tray.
Installing the Rack Front Panel and Control Panel Assembly
1 Install the rack front panel:
a Orient the system so that the front of the system hangs over the edge of the table as
shown in Figure 1-5.
b Using a T-15 Torx driver, install the 21 pan-head screws (supplied in the conversion kit)
that secure the rack front panel to the drive tray.
c Using a T-10 Torx driver, install the additional 4 flat-head screws (supplied in the
conversion kit) into the screw holes located between the drive bays on the rack front
panel.
NOTE: The control panel assembly’s LCD board and the I/O board are the same for both the tower and
rack systems. Only the metal carrier bracket is different and must be replaced when converting your
tower system to a rack system.
2 Replace the metal bracket in the control panel assembly. See Figure 1-6.
a Using a #2 Phillips screwdriver, remove the screw that secures the I/O board to the
existing control panel bracket.
b Using a #2 Phillips screwdriver, remove the two screws that secure the LCD board to the
bracket.
c Detach the control-panel front plate from the bracket by releasing the three tabs on the
inside of the plate.
d Snap the front plate onto the front of the new bracket included in your conversion kit.
e Align the I/O board on the replacement bracket.
f Using a #2 Phillips screwdriver, install the screw that secures the I/O board to the
replacement bracket.
g Align the LCD board on the replacement bracket.

14 Tower-to-Rack Conversion Guide
www.dell.com | support.dell.com
NOTICE: The system identification switch is very fragile. When aligning the LCD board on the rack
carrier, be careful not to damage the system identification switch. See
Figure 1-6.
h
Using a #2 Phillips screwdriver, install the two screws that secure the LCD board to the
replacement bracket.
Figure 1-6. Replacing the Control Panel Assembly Metal Bracket
3 Install the control panel assembly:
a Connect the interface cables to the control panel assembly.
b Position the control panel assembly with the panel cutouts on the back of the rack front
panel.
c Using a #2 Phillips screwdriver, install the three screws (that came with your kit).
4 Connect any cables to the devices previously removed from the media bay.
5 Reinstall the media bay devices, hard drives, and filler plates into the system.
NOTE: Ensure that the hard drives, any optical drives, and devices are reinstalled into the same
positions that they were removed from. The devices should be labeled appropriately.
6 Install the top cover. See Figure 1-4.
control panel bracket
screws (3)
front plate
I/O board
LCD board
tabs (3)
system identification switch

Tower-to-Rack Conversion Guide 15
Removing the Trim Panel
1 Lay the system on its cover as shown in Figure 1-7.
Figure 1-7. Removing the Trim Panel
2 Using a #2 Phillips screwdriver or 1/4-inch nut driver, remove the three screws from the side
of the trim panel. See Figure 1-7.
3 Using a #2 Phillips screwdriver or 1/4-inch nut driver, remove the three screws from the back
of the system.
4 Slide the trim panel backward and then remove the trim panel from the chassis.
5 If not already present on the system, install the six shoulder screws included with the kit,
attaching three screws to each side. See Figure 1-7.
NOTE: The shoulder screws must be tightened firmly enough (10.8 to 13.2 in-lbs of torque) to
support the weight of the system in the rack and to prevent loosening.
The system is ready to install in the rack.
hex-head Phillips screws (6)
shoulder mounting
screws (6)

16 Tower-to-Rack Conversion Guide
www.dell.com | support.dell.com
Installing the System in a Rack
For information on installing the system in a rack, including installing the cable-management arm
and routing the system cables, see the system
Rack Installation Guide .
Installing the Optional Rack Bezel
To install the rack bezel, hook the right end of the bezel onto the chassis, then fit the free end of
the bezel onto the system. Secure the bezel with the keylock. See Figure 1-8.
Figure 1-8. Installing the Optional Rack Bezel
rack bezel
keylock