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Dell 5200 Service Manual

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Dell Edge Gateway 5200
Service Manual
Regulatory Model: EGW-5200
Regulatory Type: EGW-5200-NA
November 2023
Rev. A01

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Summary of Contents for Dell 5200

  • Page 1 Dell Edge Gateway 5200 Service Manual Regulatory Model: EGW-5200 Regulatory Type: EGW-5200-NA November 2023 Rev. A01...
  • Page 2 A WARNING indicates a potential for property damage, personal injury, or death. © 2022–2023 Dell Inc. or its subsidiaries. All rights reserved. Dell Technologies, Dell, and other trademarks are trademarks of Dell Inc. or its subsidiaries. Other trademarks may be trademarks of their respective owners.

  • Page 3: Table Of Contents

    Contents Preface............................4 Part I: Keep your hard drive......................5 Remove SSD..................................5 Reinstall SSD..................................7 Part II: Installation procedure for 4G expansion module..............11 Part III: Installation procedure for 5G expansion module..............23 Part IV: Installation procedure for 2x isolated COM 422/485 or 232 uFM module......35 Part V: Installation procedure for 2x GbE with PoE uFM module..........45 Part VI: Installation procedure for 2x GbE LAN uFM module............

  • Page 4: Preface

    Preface Table 1. Expansion modules overview  Module Interface details Reference link WiFi Intel WiFi AX210 M.2 2230 https://www.intel.com/content/www/us/en/products/ docs/wireless/wi-fi-6e-ax210-module-brief.html Sierra EM7565 M.2 3042 https://www.sierrawireless.com/iot-solutions/products/ em7565/ Telit Cinterion MV31-W M.2 https://www.telit.com/devices/mv31/ 3042 mPCIe Isolated RS-422 and RS-485 EMP2-X4S2 https://www.innodisk.com/en/products/embedded- peripheral/communication/emp2-x4s2 Isolated RS-232 EMP2-X2S1 https://www.innodisk.com/en/products/embedded- peripheral/communication/emp2-x2s1...

  • Page 5: Part I: Keep Your Hard Drive

    About this task If you need to send the unit back to Dell Technologies for service or replacement, you may choose to keep the SSD to protect data or intellectual property. To do so, remove any drives from the unit, then reinstall them once the unit is returned or replaced.
  • Page 6 Figure 2. Upper SSD bracket screw locations 3. Remove the four screws of the upper SSD holder and remove from the unit. Figure 3. Screws of the upper SSD holder 4. Remove the four screws of the lower SSD bracket, disconnect the assembly, and remove the assembly from the unit. Keep your hard drive...

  • Page 7: Reinstall Ssd

    Figure 4. Lower SSD bracket 5. Remove the four screws that mount the default SSD to the lower SSD bracket. Figure 5. Default SSD mounting screws 6. Reattach the bottom panel. See the screw locations in step 1. Reinstall SSD About this task Once the unit is returned following service or replacement, perform the following steps to reinstall the SSD drive or drives.
  • Page 8 Steps 1. Remove the eight screws from the bottom panel of the EGW-5200, as shown in the following figure, and remove the bottom panel. Figure 6. Bottom panel screw locations NOTE: If 4G or 5G is installed, you must also remove the remaining four screws from the bottom panel.
  • Page 9 Figure 8. Screws of the upper SSD holder 5. If applicable, use four screws to install the second SSD to the upper SSD bracket. Figure 9. Mounting screws of the upper SSD bracket 6. Slide the upper SSD bracket or assembly into place, with the SSD back to the device, and use four screws to secure the bracket in place, as shown in the following figure.
  • Page 10 Figure 10. Upper SSD assembly installation 7. Reattach the bottom panel. See the screw locations in step 1. Keep your hard drive...

  • Page 11: Part Ii: Installation Procedure For 4G Expansion Module

    Installation procedure for 4G expansion module About this task Installation of the 4G expansion module requires an additional heat sink to ensure performance. Use the paddle-style antennas that are included with the expansion kit. The following figure shows the dimensions of the antenna.
  • Page 12 Nut drivers 4.5 mm, 5 mm, 5.5 mm, 8 mm Steps 1. Remove the eight screws from the bottom panel of the EGW-5200, as shown in the following figure, and remove the bottom panel. Figure 12. Bottom panel screw locations 2.
  • Page 13 Figure 13. Bottom panel screw locations 3. Remove the screws and nuts from the side panel, as shown in the following figures. Hold the nuts from inside while unscrewing. Discard these three sets of screws and nuts. Figure 14. Side panel screws Installation procedure for 4G expansion module...
  • Page 14 Figure 15. Side panel nuts 4. Remove the rubber insert from the ANT1, ANT5, and ANT6 antenna holes. Figure 16. ANT1 antenna hole in side panel Installation procedure for 4G expansion module...
  • Page 15 Figure 17. ANT5 and ANT6 antenna holes in back panel and side panel 5. Install the SMA cables into the antenna holes in the back and side panels. Align the flat section of the gold connector tube with the flat section of the antenna hole. Position the SMA cable connector so that the sheet metal of the panel is between the connector nut and the washer.
  • Page 16 Figure 20. 4G cable routing diagram NOTE: The figure shows the M.2 module installed. This is for reference only, as the module will be installed in a later step. Table 5. 4G cable routing  Antenna Function Diagram color Cable length (cm) ANT1 4G Main White...
  • Page 17 Figure 21. SMA cables connected 6. Wire the SMA cables to the M.2 module. Use cable clips to secure the cables. 7. Note the installation location for the M.2 module, as indicated with a red rectangle in the following figure. Figure 22.
  • Page 18 Figure 23. Thermal pad 9. Install the cabled M.2 module, and slide the protection bracket of IPEX connectors into position, as shown in the following figure. Installation procedure for 4G expansion module...
  • Page 19 Figure 24. Protection bracket 10. Install the H7.8 standoff, as shown in the following figure. Figure 25. Standoff installed 11. Assemble the standoffs on the heat sink. Screw the standoffs tightly into position, as shown in the following figures. Installation procedure for 4G expansion module...
  • Page 20 Figure 26. Standoff screw hole locations Figure 27. Standoff screws assembled 12. To apply the heat sink onto the M.2 module, use one M3 x 6L screw to secure the heat sink into position, as shown in the following figure, then use three M3 x 4L screws to secure the heat sink to the side panel. NOTE: Remove the protective film from the thermal pad material before installing.
  • Page 21 Figure 28. Heat sink installation 13. Organize the SMA cables in the chassis to avoid kinks. Figure 29. SMA cable organization 14. Use twelve M3 x 4L screws (eight from step 1, four from the Expansion Module contents) to reattach the bottom panel to the chassis and the heat sink.
  • Page 22 Figure 30. Reattach the bottom panel 15. Two physical USIM card slots are located on the right-hand side of the chassis. Remove the cover and insert the USIM cards. Figure 31. USIM card holder Installation procedure for 4G expansion module...

  • Page 23: Part Iii: Installation Procedure For 5G Expansion Module

    Installation procedure for 5G expansion module About this task Installation of the 5G expansion module requires an additional heat sink to ensure performance. Use the paddle-style antennas that are included with the expansion kit. The following figure shows the dimensions of the antenna.
  • Page 24 Nut drivers 4.5 mm, 5 mm, 5.5 mm, 8 mm Steps 1. Remove the eight screws from the bottom panel of the EGW-5200, as shown in the following figure, and remove the bottom panel. Figure 33. Bottom panel screw locations 2.
  • Page 25 Figure 34. Bottom panel screw locations 3. Remove the screws and nuts from the side panel, as shown in the following figures. Hold the nuts from inside while unscrewing. Discard these three sets of screws and nuts. Figure 35. Side panel screws Installation procedure for 5G expansion module...
  • Page 26 Figure 36. Side panel nuts 4. Remove the rubber insert from the ANT1, ANT4, ANT5, and ANT6 antenna holes. Figure 37. ANT1 antenna hole in side panel Figure 38. ANT4, ANT5, and ANT6 antenna holes in back panel and side panel 5.
  • Page 27 the connector nut and the washer. Use an 8 mm nut driver to torque the SMA cable outer nut to 8 kgf.cm. See the following figures and tables for cabling details. Figure 39. Align SMA cable with antenna hole Figure 40. Position sheet metal (A) between washer (B) and cable connector nut (C) Installation procedure for 5G expansion module...
  • Page 28 Figure 41. 5G cable routing diagram NOTE: The figure shows the M.2 module installed. This is for reference only, as the module will be installed in a later step. Table 8. 5G cable routing  Antenna Function Diagram color Cable length (cm) ANT1 5G FR1 TX/RX White...
  • Page 29 Figure 42. SMA cables connected 6. Wire the SMA cables to the M.2 module, as shown in the following figure. Use cable clips to secure the cables. Figure 43. 5G M.2 module wiring 7. Note the installation location for the M.2 module, as indicated with a red rectangle in the following figure. Installation procedure for 5G expansion module...
  • Page 30 Figure 44. M.2 module location 8. Apply the thermal pad, as shown in the following figure. Figure 45. Thermal pad 9. Install the cabled M.2 module, and slide the protection bracket of IPEX connectors into position, as shown in the following figure.
  • Page 31 Figure 46. Protection bracket 10. Install the H7.8 standoff, as shown in the following figure. Figure 47. Standoff installed 11. Assemble the standoffs on the heat sink. Screw the standoffs tightly into position, as shown in the following figures. Installation procedure for 5G expansion module...
  • Page 32 Figure 48. Standoff screw hole locations Figure 49. Standoff screws assembled 12. To apply the heat sink onto the M.2 module, use one M3 x 6L screw to secure the heat sink into position, as shown in the following figure, then use three M3 x 4L screws to secure the heat sink to the side panel. NOTE: Remove the protective film from the thermal pad material before installing.
  • Page 33 Figure 50. Heat sink installation 13. Organize the SMA cables in the chassis to avoid kinks. Figure 51. SMA cable organization 14. Use twelve M3 x 4L screws (eight from step 1, four from the Expansion Module contents) to reattach the bottom panel to the chassis and the heat sink.
  • Page 34 Figure 52. Reattach the bottom panel 15. Two physical USIM card slots are located on the right-hand side of the chassis. Remove the cover and insert the USIM cards. Figure 53. USIM card holder Installation procedure for 5G expansion module...

  • Page 35: Part Iv: Installation Procedure For 2X Isolated Com 422/485 Or 232 Ufm Module

    Installation procedure for 2x isolated COM 422/485 or 232 uFM module About this task Installation requires the removal of WiFi, as well as COM3 and COM4 ports. The four-port COM cable must be replaced with a dual-port COM cable (included). Table 9.
  • Page 36 4.5 mm, 5 mm, 5.5 mm Steps 1. Remove the eight screws from the bottom panel of the EGW-5200, as shown in the following figure, and remove the bottom panel. Installation procedure for 2x isolated COM 422/485 or 232 uFM module...
  • Page 37 Figure 54. Bottom panel screw locations NOTE: If 4G or 5G is installed, you must also remove the remaining four screws from the bottom panel. 2. To access the mPCIe assembly beneath, remove the heat sink. Remove the screws of the heat sink to the side panel and motherboard, as shown in the following figures.
  • Page 38 Figure 56. Motherboard standoffs and WiFi cable connectors 4. Disconnect the four-port COM cable from the motherboard header and from the front I/O panel, and cut the cable tie, as shown in the following figure. Figure 57. Disconnect COM port cable 5.
  • Page 39 Figure 59. Install screws and nuts on side panel Figure 60. Install screws and nuts on bottom panel NOTE: M3 x 4L screws and M3 nuts are included in the Expansion Module contents. 7. Remove the screws and standoffs of the front I/O panel, as shown in the following figure. Remove the four-port COM cable from the front I/O panel.
  • Page 40 Figure 61. I/O panel screw and standoff locations 8. Install the new dual-port COM cable (included). Connect to the front I/O panel with the port labeled A to COM1 and B to COM2, use four H4 standoffs to secure the ports to the to the front panel, then connect the other end of the cable to the motherboard header.
  • Page 41 Figure 63. Connect dual-port COM cable to motherboard header 9. Use four H4 standoffs to secure the Isolated COM ports to the Isolated COM I/O panel, as shown in the following figure. Figure 64. COM ports installed on Isolated COM I/O panel Use the following table to configure the Isolated COM ports.
  • Page 42 Figure 65. Isolated COM I/O panel installed on front I/O panel 11. Install the Isolated COM mPCIe module on the motherboard. Use the two M2.5 x 6L screws in the corners of the module, as shown in the following figure. Figure 66.
  • Page 43 Figure 67. Isolated COM 232 mPCIe installed on motherboard 12. Connect the cables from the Isolated COM ports to the Isolated COM mPCIe module. Use a cable tie, as shown with a red circle in the following figure. Figure 68. Cables from ports to Isolated COM 422/485 mPCIe module with cable tie Installation procedure for 2x isolated COM 422/485 or 232 uFM module...
  • Page 44 Figure 69. Cables from ports to Isolated COM 232 mPCIe module with cable tie (COM A > CN1, COM B > CN2) 13. Use the screws to reattach the bottom panel. See the screw locations in step 1. 14. Insert the rubber caps into the antenna holes, as shown in the following figure. Figure 70.

  • Page 45: Part V: Installation Procedure For 2X Gbe With Poe Ufm Module

    4.5 mm, 5 mm, 5.5 mm, 10 mm Steps 1. Remove the eight screws from the bottom panel of the EGW-5200, as shown in the following figure, and remove the bottom panel. Installation procedure for 2x GbE with PoE uFM module...
  • Page 46 Figure 71. Bottom panel screw locations NOTE: If 4G or 5G is installed, you must also remove the remaining four screws from the bottom panel. 2. To access the mPCIe assembly beneath, remove the heat sink. Remove the screws of the heat sink to the side panel and motherboard, as shown in the following figures.
  • Page 47 Figure 73. Motherboard standoffs and WiFi cable connectors 4. Disconnect the four-port COM cable from the motherboard header and from the front I/O panel, and cut the cable tie, as shown in the following figure. Figure 74. Disconnect COM port cable 5.
  • Page 48 Figure 76. Install screws and nuts on side panel Figure 77. Install screws and nuts on bottom panel NOTE: M3 x 4L screws and M3 nuts are included in the Expansion Module contents. 7. Remove the screws and standoffs of the front I/O panel, as shown in the following figure. Remove the four-port COM cable from the front I/O panel.
  • Page 49 Figure 78. I/O panel screw and standoff locations 8. Install the new dual-port COM cable (included). Connect to the front I/O panel with the port labeled A to COM1 and B to COM2, secure the ports to the front panel with four H4 standoffs, then connect the other end of the cable to the motherboard header.
  • Page 50 Figure 80. Connect dual-port COM cable to motherboard header 9. Apply the thermal pad to the uFM module, and use a 10 mm nut driver to remove the nut and washer from the DC IN jack, as shown in the following figure. Figure 81.
  • Page 51 Figure 83. GbE with PoE uFM module with I/O panel 11. Secure the bracket to the motherboard using four screws, as shown in the following figure. Figure 84. Bracket secured to motherboard 12. Use two M3 x 6L screws to secure the uFM module to the bracket, and secure the GbE with PoE I/O panel to the front I/O panel, as shown in the following figures.
  • Page 52 Figure 85. uFM module secured to bracket and chassis Figure 86. GbE with PoE I/O panel secured to front I/O panel 13. Use one M3 x L5 screw to install the cable clip to the bracket, as shown in the following figure. Figure 87.
  • Page 53 Figure 88. mPCIe LAN board secured to motherboard 15. Connect the LAN cables from the GbE with PoE module to the mPCIe LAN board. Use cable ties, as shown with red circles in the following figure. Figure 89. LAN cables from GbE with PoE module to mPCIe LAN board with cable ties 16.
  • Page 54 Figure 90. Antenna hole caps Installation procedure for 2x GbE with PoE uFM module...

  • Page 55: Part Vi: Installation Procedure For 2X Gbe Lan Ufm Module

    Nut driver 4.5 mm, 5 mm, 5.5 mm Steps 1. Remove the eight screws from the bottom panel of the EGW-5200, as shown in the following figure, and remove the bottom panel. Installation procedure for 2x GbE LAN uFM module...
  • Page 56 Figure 91. Bottom panel screw locations NOTE: If 4G or 5G is installed, you must also remove the remaining four screws from the bottom panel. 2. To access the mPCIe assembly beneath, remove the heat sink. Remove the screws of the heat sink to the side panel and motherboard, as shown in the following figures.
  • Page 57 Figure 93. Motherboard standoffs and WiFi cable connectors 4. Disconnect the four-port COM cable from the motherboard header and from the front I/O panel, and cut the cable tie, as shown in the following figure. Figure 94. Disconnect COM port cable 5.
  • Page 58 Figure 96. Install screws and nuts on side panel Figure 97. Install screws and nuts on bottom panel NOTE: M3 x 4L screws and M3 nuts are included in the Expansion Module contents. 7. Remove the screws and standoffs of the front I/O panel, as shown in the following figure. Remove the four-port COM cable from the front I/O panel.
  • Page 59 Figure 98. I/O panel screw and standoff locations 8. Install the new dual-port COM cable (included). Connect to the front I/O panel with the port labeled A to COM1 and B to COM2, use four H4 standoffs to secure the ports to the front panel, then connect the other end of the cable to the motherboard header.
  • Page 60 Figure 100. Connect dual-port COM cable to motherboard header 9. Secure the GbE LAN uFM module to the GbE LAN I/O panel. Use the two screws on the panel, as shown in the following figure. Figure 101. GbE LAN ports installed on GbE LAN I/O panel 10.
  • Page 61 Figure 102. Bracket installed 11. Secure the GbE LAN I/O panel to the front I/O panel. Use the two screws to the sides of the GbE LAN I/O panel and the two screws on the bottom edge of the chassis. Use two M3 x 6L screws to secure the module to the bracket, as shown in the following figure.
  • Page 62 Figure 104. GbE LAN mPCIe installed on motherboard 13. Use one M3 x 5L screw to secure the cable clip to the bracket, as shown in the following figure. Figure 105. Cable clip attached 14. Connect the LAN cables from the uFM module to the mPCIe module. Use a cable tie, as shown with red circles in the following figure.
  • Page 63 Figure 106. Cables from uFM to mPCIe module with cable ties 15. Use the screws to reattach the bottom panel. See the screw locations in step 1. 16. Insert the rubber caps into the antenna holes, as shown in the following figure. Figure 107.

  • Page 64: Part Vii: Installation Procedure For 2X Canbus Ufm Module

    — Nut drivers 4.5 mm, 5 mm, 5.5 mm Steps 1. Remove the eight screws from the bottom panel of the EGW-5200, as shown in the following figure, and remove the bottom panel. Installation procedure for 2x Canbus uFM module...
  • Page 65 Figure 108. Bottom panel screw locations NOTE: If 4G or 5G is installed, you must also remove the remaining four screws from the bottom panel. 2. To access the mPCIe assembly beneath, remove the heat sink. Remove the screws of the heat sink to the side panel and motherboard, as shown in the following figures.
  • Page 66 Figure 110. Motherboard standoffs and WiFi cable connectors 4. Disconnect the four-port COM cable from the motherboard header and from the front I/O panel, and cut the cable tie, as shown in the following figure. Figure 111. Disconnect COM port cable 5.
  • Page 67 Figure 113. Install screws and nuts on side panel Figure 114. Install screws and nuts on bottom panel NOTE: M3 x L4 screws and M3 nuts are included in the Expansion Module contents. 7. Remove the screws and standoffs of the front I/O panel, as shown in the following figure. Remove the four-port COM cable from the front I/O panel.
  • Page 68 Figure 115. I/O panel screw and standoff locations 8. Install the new dual-port COM cable (included). Connect to the front I/O panel with the port labeled A to COM1 and B to COM2, use four H4 standoffs to secure the ports to the front panel, then connect the other end of the cable to the motherboard header.
  • Page 69 Figure 117. Connect dual-port COM cable to motherboard header 9. Use four H4 standoffs to secure the Canbus ports to the Canbus I/O panel, as shown in the following figure. Figure 118. Canbus ports installed on Canbus I/O panel 10. Secure the Canbus I/O panel to the front I/O panel. Use the two screws to the sides of the Canbus I/O panel and the two screws on the bottom edge of the chassis, as shown in the following figure.
  • Page 70 Figure 119. Canbus I/O panel installed on front I/O panel 11. Install the Canbus mPCIe module on the motherboard. Use the two M2.5 x 6L screws in the corners of the module, as shown in the following figure. Figure 120. Canbus mPCIe installed on motherboard 12.
  • Page 71 Figure 121. Cables from ports to Canbus mPCIe module with cable tie 13. Use the screws to reattach the bottom panel. See the screw locations in step 1. 14. Insert the rubber caps into the antenna holes, as shown in the following figure. Figure 122.

  • Page 72: Part Viii: Installation Procedure For 8X Di/O Ufm Module

    VIII Installation procedure for 8x DI/O uFM module About this task Pin mappings for the DI/O connector are shown in the following figure and table. Figure 123. DI/O connector pin locations Table 23. Digital I/O uFM module pin definitions  Signal Signal Signal DI0_L...
  • Page 73 Small size Nut driver 5 mm Steps 1. Remove the eight screws from the bottom panel of the EGW-5200, as shown in the following figure, and remove the bottom panel. Figure 124. Bottom panel screw locations NOTE: If 4G or 5G is installed, you must also remove the remaining four screws from the bottom panel.
  • Page 74 2. Remove the screws and standoffs of the front I/O panel, as shown in the following figure. Figure 125. I/O panel screw and standoff locations 3. Disconnect the four-port COM cable from the motherboard header and from the front I/O panel, and cut the cable tie, as shown in the following figure.
  • Page 75 Figure 127. Connect new COM ports to I/O panel Figure 128. Connect dual-port COM cable to motherboard header 5. Use two H4 standoffs to secure the DI/O uFM module to the DI/O front panel, as shown in the following figure. Figure 129.
  • Page 76 Figure 130. Bracket installed 7. Install two H7 standoffs on the bracket, as shown in the following figure. Figure 131. Standoffs installed on bracket 8. Secure the DI/O front panel to the main I/O panel. Use the two screws to the sides of the DI/O front panel and the two screws on the bottom edge of the chassis.
  • Page 77 Figure 132. DI/O module installed 9. Connect the DI/O cable. Use a cable tie, as shown with a red circle in the following figure. Figure 133. DI/O cable with cable tie 10. Use the screws to reattach the bottom panel. See the screw locations in step 1. Installation procedure for 8x DI/O uFM module...

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