4210 Rack

Installation 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.
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.

April 2002

P/N 2T165

Rev. A00

Contents

. . . . . . . . . . . . . . . . . . . . . . . .

1-1

. . . . . . . . . . . . . . . . . . . . .

1-2

. . . . . . . . . . . . . . . . . . . . . .

1-2

. . . . . . . . . . . . . . . . . . . . . . . . .

1-2

. . . . . . . . . . . . . . . . . . . . . . .

1-2

Safety Instructions

Installation Instructions
Rack Requirements
Rack Installation

Before You Begin

Important Safety Information.

. . . . . . . . . . . . . .

1-3

. . . . . . . . . . . . . . . . . . .

1-3

. . . . . . . . . . . . . . . . . . . . . . .

1-4

. . . . . . . . . . . . . . .

1-4

. . . . . . . . . . . . . . . . . . . . . . . .

1-4

Rack Stabilizer Feet

Installation Tasks

Recommended Tools and Supplies

Provided Tools .

Removing and Replacing the Rack Doors .

. . . . . . . . . . .

1-4

Removing the Front Door

. . . . . . . . . . . . . . . . . . .

1-5

Replacing the Front Door

. . . . . . . . . . . . . . . . . . .

1-6

. . . . . . . . . . . .

1-6

Replacing the Back Doors

. . . . . . . . . . . . . . . . . . .

1-8

Removing the Side Panels

. . . . . . . . . . . . . . . . . . .

Replacing the Side Panels

. . . . . . . . . . . . . . . . . .

1-10

. . . . . . . . . . . . .

1-10

. . . . . . . . . . . . . .

1-14

Opening and Removing the Back Doors

Reversing the Front Door (optional)

Securing the Rack Leveling Feet .

Installing the Rack Stabilizer Feet .

Routing Cables

1-9

. . . . . . . . . . . . .

1-16

. . . . . . . . . . . . . . . . . . . . . . .

1-19

Coupling Two Racks .

. . . . . . . . . . . . . . . . . . . . . .

1-20

Index

Cont e nt s

Figures

. . . . . . . . . . . .

1-5

. . . . . . . . . . .

1-7

. . . . . . . . . . . .

1-8

. . . . . . . . . . . . .

1-9

Figure 1-1.

Removing the Front Door

Figure 1-2.

Opening the Left Back Door

Figure 1-3.

Removing the Back Doors

Figure 1-4.

Removing a Side Panel

Figure 1-5.

Removing the Front-Door Hinges

Figure 1-6.

Reversing the Top and Bottom Hinges

Figure 1-7.

Rotate Front Door

Figure 1-8.

Adjusting the Leveling Feet

Figure 1-9.

. . . . . . .

1-11

. . . . .

1-12

. . . . . . . . . . . . . . .

1-13

. . . . . . . . . .

1-15

Attaching the Front Stabilizer Foot

. . . . . .

1-17

Figure 1-10.

Attaching the Side Stabilizer Foot .

. . . . . .

1-18

Figure 1-11.

Cable-Routing Options .

. . . . . . . . . . . .

1-19

Figure 1-12.

Rack Coupling Kit

. . . . . . . . . . . . . . .

1-20

Figure 1-13.

Installing the Hexagonal Spacers

. . . . . . .

1-21

Co n t e n t s

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.
CAUTION: For complete safety and regulatory information, refer to your System
Information document.
CAUTION: 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 cabinet
evaluated for suitability by a certified safety agency. The manufacturer disclaims all
warranties and liability in connection with such combinations.
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.

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.

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.

I ns t al l at i on G u i de

1-1

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.

Installation Instructions
This installation guide provides instructions for trained service technicians installing a
42-unit (U) rack. Information includes assembling the rack, coupling two 42-U racks, and
routing cables through the rack. The 42-U rack can be installed using the recommended
tools.

Rack Requirements
NOTICE: The 42-U rack 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.

Rack Installation
Before attempting this installation, you should read through this entire procedure carefully.

Before You Begin

CAUTION: Before you begin installing your rack, carefully read "Important
Safety Information," as well as the safety instructions found in your systems
System Information document 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.

1-2

I n s t a l l at i o n G u i de

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.
CAUTION: Do not attempt to move your rack with components installed.. If you
move a fully loaded rack on a slightly uneven floor surface, the rack may become
unstable and tip over.

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: Installing systems in a rack without the front and side stabilizer feet
installed could cause the rack to tip over, potentially resulting in bodily injury
under certain circumstances. Therefore, always install the stabilizer feet 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 injur y.

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.

I ns t al l at i on G u i de

1-3

Installation Tasks
Installing a rack cabinet involves performing the following tasks:
1

Removing and replacing the rack doors

Removing and replacing the side panels

Reversing the front door and badge (optional)

Securing the leveling feet

Installing the stabilizer feet

Routing cables through the rack

Coupling two racks (optional)

Recommended Tools and Supplies

You may need the following tools and supplies to install the rack:

#1 Phillips screwdriver

#2 Phillips screwdriver

12-mm wrench

Needle-nose pliers

4-mm Allen wrench (if you want to reverse the direction that the front door opens)

6-mm Allen wrench

Provided Tools
The following tool is provided: 4-mm Allen wrench.

Removing and Replacing the Rack Doors

CAUTION: Because of the size and weight of the rack cabinet doors, never
attempt to remove or install them by yourself.
CAUTION: Store the doors where they will not injure someone if the doors
accidently fall over.

1-4

I n s t a l l at i o n G u i de

Removing the Front Door

1

Open the front door all the way (see Figure 1-1).
NOTE: The front door, right back door, and side panels all have the same type of
door latch.

While holding the door, pull the top hinge pin upward so that it clears the doors
hinge-pin housing (see Figure 1-1).
The hinge pins retention clip prevents the hinge from being pulled out of the hinge
body.

Figur e 1-1.

Removing the Front Door

front door-latch button

hinge pin

hinge body

hinge-pin
housing

I ns t al l at i on G u i de

1-5

While holding the hinge pin out of the doors hinge-pin housing, pull the door slightly
away from the rack so that the door clears the hinge body.

Release the hinge pin.

Lift the door upward so that the door clears the bottom hinge post.
CAUTION: Due to the size and weight of the door, it is recommended that you lay
the removed door flat with its outer surface facing upward.

Lay the panel in a safe location with the panels outer surface facing upward.
Laying the door flat with the outer surface facing upward will help prevent damage to
the doors cosmetic coating.

Replacing the Front Door

To replace the front door, perform the steps for removal in reverse.

Opening and Removing the Back Doors

CAUTION: Because of the size and weight of the rack cabinet doors, never
attempt to remove or install them by yourself.
NOTE: The front door, right back door, and side panels all have the same type of door
latch.
1

1-6

Open the back doors.

a

Press the door-latch button to release the right door handle (see Figure 1-1).

Open the right door.

Press the left doors thumb latch until the left door is released (see Figure 1-2).

Open the left door.

I n s t a l l at i o n G u i de

Figur e 1-2.

Opening the Left Back Door

thumb latch

Remove the right door.

a

While supporting the door, pull the pin for the top hinge out of the doors hingepin housing (see Figure 1-3).
You will hear a click as you pull the pin out of the doors hinge-pin housing. The
hinge pins are designed to prevent them from being pulled out of the hinge body.

Repeat step a for the bottom hinge.

Pull the door away from the rack.

I ns t al l at i on G u i de

1-7

Figur e 1-3.

Removing the Back Door s

hinge pin

hinge-pin housing

hinge body

CAUTION: Due to the size and weight of the door, it is recommended that you lay
the removed door flat with its outer surface facing upward.
d

Lay the door in a safe location with the doors outer surface facing upward.
Laying the door flat with the outer surface facing upward will help prevent damage
to its cosmetic coating.

Repeat steps a through d for the left door.

Replacing the Back Doors

To replace the back doors, perform the steps for removal in reverse.

1-8

I n s t a l l at i o n G u i de

Removing the Side Panels

CAUTION: Because of the size and weight of the rack cabinet side panels, never
attempt to remove or install them by yourself.
NOTE: You must remove the side panels in order to install the side stabilizer feet.
Also, although removing the side panels is not mandatory for installing systems in a
rack, having the sides open makes it easier to install slide assemblies and support
rails and to reverse the direction that the front door opens.
1

Press the latch buttons to release the left and right handles.
The latches on the side panels are identical to the ones on the front door and the right
back door.

Allow the side panel to swing outward slightly from the bottom.

Grasp the panel firmly on each side.

Lift the panel upward until it clears the top of the rack (see Figure 1-4).

Figur e 1-4.

Removing a Side Panel

side panel (2)

I ns t al l at i on G u i de

1-9

Pull the side panel away from the rack.

CAUTION: Because of the size and weight of the rack cabinet side panels, never
attempt to remove or install them by yourself.

Place the panel in a safe location with the panels outer surface facing upward.
Placing the panel with the outer surface facing upward helps prevent damage to its
cosmetic coating.

Repeat steps 16 for the other side panel.

Replacing the Side Panels

CAUTION: Because of the size and weight of the rack cabinet side panels, never
attempt to remove or install them by yourself.

To replace the side panels, perform the removal steps in reverse.

Reversing the Front Door (optional)

NOTE: Use the 4-mm Allen wrench provided with the rack to remove the front-door
hinge bodies from the rack and reinstall them on the side opposite their original
positions. You might need a stepladder in order to access the Allen bolt that secures
the top hinge body to the rack.

To reverse the direction that the front door opens, complete the following steps:

1-10

Remove the front door. For instructions, see "Removing the Front Door."

Remove the side panels. For instructions, see "Removing the Side Panels."

Reverse the top hinge body.

a

Pull the hinge pin upward slightly so that you can access the retention clip (see
Figure 1-5).

Using the needle-nose pliers, remove the retention clip, and slide the hinge pin
out of the hinge body.

I n s t a l l at i o n G u i de

Figur e 1-5.

Removing the Front-Door Hinges

hinge pin

spring
top hinge body

retention clip

hinge post

bottom hinge body

Remove the hinge spring from the hinge body.

Place the hinge pin, retention clip, and spring in a safe location.

Using the 4-mm Allen wrench, remove the Allen bolt that secures the hinge body
to the rack, and place the bolt with the hinge pin, retention clip, and spring.

Rotate the hinge body 180 degrees so that the hinge-pin holes are now on the right
side of the hinge body (see Figure 1-6).

I ns t al l at i on G u i de

1-11

Figur e 1-6.

R e v e r s i n g t h e To p a n d B o t t o m H i n g e s

hinge pin

top hinge body

spring

retention clip

hinge post

bottom hinge body

Locate the top bolt hole in the right side of the rack, and fasten the hinge body to
the right side of the rack with the Allen bolt.

Insert the spring between the top and bottom hinge-pin holes in the hinge body.

Slide the hinge pin into the hinge body.

Insert the retention clip through the hinge so that the retention clip is below the
spring.

Reverse the bottom hinge body.

a

1-12

Remove the Allen bolt that secures the hinge body to the rack, and place the bolt
in a safe location.

I n s t a l l at i o n G u i de

Rotate the hinge body 180 degrees so that the hinge posts are now on the right
side of the hinge body (see Figure 1-6).

Locate the bottom bolt hole in the right side of the rack, and use the Allen bolt to
fasten the hinge body to the right side of the rack.

Rotate the front door 180 degrees so that its hinge-pin housings are on the right side
(see Figure 1-7).

Figur e 1-7.

Rotate Front Door

Rehang the front door by reversing the steps in "Removing the Front Door."

Reverse the lock catch.

a

Use the #1 Phillips screwdriver to remove the two #1 Phillips screws that hold the
lock catch to the middle horizontal frame member.

Remove the lock catch and rotate it 180 degrees.

I ns t al l at i on G u i de

1-13

On the horizontal frame member that held the lock catch, reinstall one #1
Phillips screw in the bottom hole to maintain structural integrity.

On the other side of the rack, locate the new horizontal frame member and
remove the #1 Phillips screw.
NOTE: On the new horizontal frame member there are two types of screws: a #1
Phillips screw and a Tor x screw. Do not remove the Tor x screw.

Reinstall the lock catch on the new horizontal frame member by aligning the holes
of the catch with the holes of the frame member and then reinserting the two #1
Phillips screws.

Reverse the two logo badges on the front door.

a

Open the front door.

Remove the retention screw on the top logo badge with a #2 Phillips screwdriver.

Remove the logo badge.

Repeat steps b and c for the bottom logo badge.

Switch the logo badges and turn the text logo badge 180 degrees so that it will
read correctly when reinstalled.

Place the text logo badge into the top circular depression so that the three tabs on
the badge align with the slots near the edge of the depression.

Using the screws removed in step b, install the text logo badge.

Install the blank badge in the bottom circular depression.

Securing the Rack Leveling Feet

CAUTION: Read all statements below before you adjust the leveling feet.

Your rack includes four leveling feet, which are mounted on the corners of the rack. The
leveling feet are designed to align the rack in an upright, level position when the rack is
situated on a slightly uneven floor surface. Before you install your systems in the rack,
deploy and adjust the leveling feet. When you level your rack, follow these guidelines.
CAUTION: When you adjust the leveling feet, ensure that the casters on each
corner of the rack do not rise more than 9.5 mm (3/8 inch) above the floor. If you
exceed 9.5 mm of clearance between the floor and the casters as you adjust the
leveling feet, slowly retract the leveling feet, and then move the rack to another
location that requires minimal adjustments to the leveling feet.

1-14

I n s t a l l at i o n G u i de

CAUTION: Adjust the leveling feet until each leveling foot rests firmly on the
floor. Proper contact with the floor ensures that each leveling foot is supporting
the weight of the rack and prevents the rack from swaying in any direction. If
the leveling feet are not all in firm contact with the floor, the rack can become
unstable and tip over.
CAUTION: Do not attempt to move your rack with the leveling feet deployed.
Always retract the leveling feet before moving the rack. Having the leveling feet
deployed when you move the rack may cause the rack to tip over.
CAUTION: Always level the rack and install the stabilizing feet before you install
your systems. A fully loaded rack may tip over if your rack is resting on an
uneven floor surface and the leveling and stabilizing feet are not supporting the
weight of the rack.
NOTE: If the rack is not leveled properly, you might not be able to install the
stabilizer feet, which are necessary to prevent the rack from tipping over.
1

Using a screwdriver, lower the leveling foot until it rests on the floor.

If you need to lower the foot further, tighten the hex nut clockwise with a 12-mm
wrench (see Figure 1-8).

Repeat steps 1 and 2 for the remaining leveling feet.

Ensure that the rack is level.

I ns t al l at i on G u i de

1-15

Figur e 1-8.

A dj u st i n g t he Le vel i ng Fee t

leveling foot stem

hex nut

leveling pad

Installing the Rack Stabilizer Feet

CAUTION: Installing systems in a rack without the front and side stabilizer feet
installed could cause the rack to tip over, potentially resulting in bodily injury
under certain circumstances. Therefore, always install the stabilizer feet before
installing components in the rack.

Install stabilizer feet on the rack as follows:

Install front and side stabilizer feet on a standalone rack.

Install front stabilizer feet on all racks in a suite, and install a left or right stabilizer
foot on the racks at each end of a suite.

To install a front stabilizer foot, perform the following steps:

1-16

Open the front door.

Position the front stabilizer foot against the base of the rack frame and align its holes
with the corresponding holes in the frame.

I n s t a l l at i o n G u i de

Use a 6-mm Allen wrench and the provided Allen bolts and washers to secure the front
stabilizer foot to the rack as shown in Figure 1-9.

Figur e 1-9.

A t t ac hi n g t h e Fr o n t S t abi l i z er Fo o t

front stabilizer foot

I ns t al l at i on G u i de

1-17

To install a side stabilizer foot, perform the following steps:

1

Remove the side panel.

On the side of the rack frames bottom rail, locate the three threaded holes (see
Figure 1-10).

Slide the top lip of the side stabilizer foot under the rack, and then align its holes with
the corresponding holes in the frame.

Figur e 1-10.

At t ach i ng t he Si d e S t ab i l i z er Fo o t

lip of stabilizer foot

Use the 6-mm Allen wrench, the provided washers, and the Allen bolts to secure the
side stabilizer foot to the rack frame.
NOTE: Unless you need to couple two or more racks, you may now install systems into
the rack. Use the white numbered labels on the front and back of the rack mounting
rails to help install products in the rack.

1-18

I n s t a l l at i o n G u i de

Routing Cables
The 42-U rack offers several features that simplify cable routing (see Figure 1-11).

Four cable-routing channels in each rack flange allow you to route power distribution
unit (PDU) power cables to the systems mounted in the rack.

Cable clips mounted on the frame uprights keep cables out of the way and help
prevent cords from becoming tangled.

Figur e 1-11.

Cable-Routing Opt ions

cable raceway

cable-routing
channels (4)

cable clips

cable exit route

I ns t al l at i on G u i de

1-19

You can route cables out of the rack in two ways:

Through the space under the back right door (see Figure 1-11)

Upward through the four rack ceiling holes into a cable raceway (see Figure 1-11)
NOTE: To protect cables from abrasion, ensure that the plastic grommets are
installed in the rack ceiling holes before routing cables to a cable raceway.

Coupling Two Racks

CAUTION: Because of the size and weight of the rack cabinets, never attempt to
couple two rack cabinets by yourself.
1

Unpack and set up both racks.

Unpack the coupling kit, shown in Figure 1-12.

The contents of the rack coupling kit include:

Four gasket strips

Four hexagonal spacers

Eight Allen screws

A stamped-metal crescent wrench

A T-handle Allen wrench

Figur e 1-12.

Ra ck C o up l i ng Ki t

Allen screw (8)

gasket strip (4)

hexagonal spacer (4)

stamped-metal crescent wrench

1-20

I n s t a l l at i o n G u i de

T-handle Allen wrench

Remove the doors and side panels from both racks. See "Removing the Front Door,"
"Opening and Removing the Back Doors," and "Removing the Side Panels."

Place the gasket strips, with their protective backing removed, on one of the racks
adjacent to the four locations where the hexagonal spacers will be inserted into the
racks (see Figure 1-13).
NOTE: Do not cover the square holes in the rack frame with the gasket strips. It
does not matter on which rack you place the gasket strips, as long as the strips
protect each rack from getting scratched.

Figur e 1-13.

Installing t he Hexagonal Spacers

Allen screw (8)

hexagonal spacer (4)

gasket strip (4)

I ns t al l at i on G u i de

1-21

1-22

Install the hexagonal spacers.

a

Position the two racks side-by-side.

Adjust the leveling feet on both racks so that the racks are parallel and in the same
horizontal plane. For instructions, see "Adjusting the Leveling Feet."

Install the four hexagonal spacers on the front and back of the racks with the
provided Allen screws, as shown in Figure 1-13.

Use the stamped metal crescent wrench to hold each hexagonal spacer in turn and
tighten the coupling bolts.

I n s t a l l at i o n G u i de

Index
B

back door
opening, 1-6
removing, 1-7

rack mount precautions, 1-2

C
cables
routing, 1-19
coupling two racks, 1-20

rack stabilizer feet, 1-3, 1-16

routing cables, 1-19

S
safety instructions, 1-1
side panels
removing, 1-9, 1-10

doors
removing, 1-4

stabilizer feet
installing front-stabilizer
foot, 1-16
installing side-stabilizer
foot, 1-18

front door
removing, 1-5, 1-6

tools and supplies, 1-4

L
leveling feet, 1-14

I ndex

I n de x

I n de x