Server Rack and Flight Case 101

This guide goes through the build process for a server rack or flight case for installations and events.

Required tools and components

Screwdriver set (preferably an IFIXIT kit.)
Cage nuts

(Avoid using power tools.)

The Basics

Servers Rack

A server rack is a metal frame that contains rack mounting rails. These a typically used for static installations.

Flight Case Rack

A flight case rack combines the ruggedness of a flight case with the mounting layout of a server rack. These are typically used for touring installations or events.

Cage Nut

U

A U is a standard unit of measurement for designating the height of the mounting rails within computer enclosures and server rack cabinets. Rack units are typically abbreviated to U with a number prefix. A racked Dell server has a height of 4U, a drawer in our case typically has a height of 2U and a HDBT matrix like the Blustream C66 has U value of 1.

Server racks or flight cases will have a maximum U value. A 16U rack can only accommodate four 4U Enclosures.

1U = 1.75”

1U = 3 Holes in the rail

Building the rack out

Whilst there is a process, the main prevailing trait required here is good common sense.

To start with, ask the PM for the system diagram, as these typically contain a rack elevation drawing which will illustrate where the system architect intended each item to go.

If an article of tech has changed, or there isn’t a rack evaluation drawing, you’ll need to build it out yourself.

Firstly, you will want to get all the rack mounted tech out of their boxes and attach the ears.

The ears are typically L shaped brackets that attach to the sides of rack mountable hardware.

The process differs from product to product, if you are unsure, consult the manual that came with the device.

Next fit the Dell ears, consult this video guide on fitment:

(83) Dell Precision 5820 and 7820: Convert to Rack Mount - YouTube

Now fit the Dell rails, they click in on the front and back.

(Make sure to fit them close to the bottom on freestanding/mobile racks. A high centre of gravity could cause the rack to tip over.)

It’s important to note that you need to attach them on the U rather in the middle of a U.

If you fit the Dell rails incorrectly, they will not clip in properly. This is because the spacing between the holes on the rack rails isn’t uniform.

Now lower the Dell into the catches on the fully extended rails. This can be done by one person, but if you are unsure, get someone to help you.

If you need to remove the Dell rails, pull the blue tab on the face of the rail mount.

If you need to retract them, push the blue tab on the outside of the extended rail.

Before fitting the remaining items, consider the following:

Airflow. Do you need to leave a 1U gab above and below the item you’re installing for adequate cooling ?
Try to keep the centre of gravity as low as possible in freestanding/mobile racks.
What is the item I’m fitting doing ? Does it need to be closer to any of the other components being installed ? E.G. A Blustream C66 is usually located closer to the media server as the signal output from the server is going directly to it.
Is the rack being shipped to site ? Some items like the Blustream HDBT converters (C66,C88) have low quality mounting ears, which lend themselves to bending during transit. So consider attaching the ears but shipping them in the box they came in.
The rack mounted power gang usually goes on the back rail.

It’s recommended that you keep all the extra pieces that came with the components you unpacked in a cardboard box and that it is sent to site with the rack.

If you have any questions feel free to ask Stu, Bill, Lawrence, Dean or Clive.