Dormakaba PowerPlex 2000 Series Manuel utilisateur

E-Plex 2000 &

PowerPlex 2000

Installation Instructions



Table of Contents

A. Cylindrical Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

B. Mortise Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11

C. Exit Trim Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33

D. Installing Outside Lever on Non-Mechanical Override. . 37

Reversing the Outside Lever for Series Without

Mechanical Override . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

F. Installing Optional K-I-L Key or Best Removable Core

Override and Outside Lever . . . . . . . . . . . . . . . . . . . . . . . . . 38

G. Testing the Operations of the Outside Lever. . . . . . . . . . 40

H. Testing the Mechanical Key Override with Change

Key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

I. Changing Lock Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . .42

J. Changing Best-Type Core . . . . . . . . . . . . . . . . . . . . . . . . . . .43

K. Removing and Reassembling the Outside Lever . . . . . . .43

L. Installing Rubber Bumpers . . . . . . . . . . . . . . . . . . . . . . . . . .44

M. Installing Battery Pack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44

N. Testing the Operation of the

Lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . .45

Warranty card . . . . . . . . . . . . . . . . . . . . . . . . .center of book

For technical assistance, call 1-800-849-TECH (8324) or 336-725-1331

Please read and follow all directions carefully.

These instructions are designed for use by maintenance professionals or

lock installers who are familiar with common safety practices and

competent to perform the steps described. dormakaba is not

responsible for damage or malfunction due to incorrect installation.

Important: Carefully inspect windows, doorframe, door, etc. to ensure

that the recommended procedures will not cause damage. dormakaba

standard warranty does not cover damages caused by installation.

E-PLEX 2000 & POWERPLEX 2000 Installation Guide KD10113-E-1121

A. CYLINDRICAL

CHECKLIST

Parts and Tools List

Each E-Plex/PowerPlex 2xxx lockset includes:

•Outside lock housing

•Inside lock assembly

•Outside lever

•Gasket for outside lock housing (not for PowerPlex 2000 versions)

•Cylindrical latch

•Cylinder drive unit

•Battery holder with 3 AA batteries (not included in PowerPlex 2000

versions)

•Drilling templates

•Hardware bag, includes:

-Square spindle

-Phillips screw (6-32 x 5⁄16") (not for PowerPlex 2000 versions)

-Strike kit

-(3) mounting screws (12-24, 1⁄8" hex head)

-Allen Key 1⁄8" — Allen Key 5⁄64"

-(2) 1" (25 mm) Phillips mounting screws

-(1) extension spring

-(4) pairs of Flat Head screws 10-24

-(3) spacers

•Key Override (Optional)

-(1) cylinder with 2 keys for override (if equipped)

-(1) cylinder plug (if equipped)

-(1) cylinder cap (if equipped)

-(2) adaptors for best-type cylinders (if equipped)

-(1) override shaft tool (if equipped)

Warning: For E-Plex/PowerPlex 2000 locks, the Master Code of this

lock has been factory preset: 1,2,3,4,5,6,7,8. To activate lock functions,

the master combination must be changed at the time of installation.

For E-Plex 24xx locks, you will have to generate an access code using

the web application to test the lock operation.

E-PLEX 2000 & POWERPLEX 2000 Installation Guide KD10113-E-1121

DIAGRAM OF LOCK:

BackFront

(A)

(D)

(B)

(E)

(F)

(G)

(H)

(I)

( )

(C)

TOOLS REQUIRED:

•Safety Glasses

•1⁄2" (13 mm) chisel

•1⁄8" (3 mm) drill bit

•1⁄2" (13 mm) drill bit

•7⁄8" (22 mm) drill bit or hole saw

•1" (25 mm) drill bit or hole saw

•21⁄8" (54 mm) hole saw

•Drill

•Awl or center punch

•Rubber mallet

•Small flat screwdriver (less than 1⁄8")

•Phillips screwdriver (#2)

•Fine steel file

•Router

•Adjustable square

•Tape measure

•Pencil

•Tape

•Cleaning supplies (drop cloth,

vacuum)

•Spanner screwdriver #6

(A) Lock housing

(B) Inside drive hub

(D) Drive tube

(E) Lever catch

(F) Countersink

(G) Outside Lever

(H) Cap (if equipped)

(I) Cylinder (if equipped)

(J) Cylinder plug (if

equipped)

E-PLEX 2000 & POWERPLEX 2000 Installation Guide KD10113-E-1121

A-1. Door Preparation

Note: Drill from both sides of the door to prevent unsightly damage.

1. Determine which template fits your E-Plex 2xxx installation (either

the 2 3⁄8" [60 mm] Backset or the 2 3⁄4" [70 mm] Backset).

2. Place appropriate paper template (supplied) onto door and mark

for holes. Drill the three 1⁄2" (13 mm) holes first. Next drill the 2

1⁄8" (54 mm) cross bore hole. Drill the 1" (25 mm) hole last.

3. Mortise door edge for latch unit faceplate 3⁄16" (5 mm)

deep to dimensions shown. Insert latch unit into the

1" (25 mm) hole, making certain that the latch bolt

bevel faces direction of closing door.

4. Secure the latch to the door using two 1" (25 mm)

Phillips Mounting screws supplied. Latch unit

faceplate must be flush with door (for doors with

1" diameter hole, use sleeve on latch).

A-2. LOCK HANDING

The E-Plex 2xxx is a non-handed lock

that is preassembled for left-hand

door installations.

1. Determine the hand of your door. For Left Hand doors, proceed to

Section C. For Right Hand doors, follow steps below.

2. Remove the two connecting screws from the

cylindrical drive unit. Rotate cylindrical

drive unit 180º. Reposition spacer(s) as

found before disassembly. Remount drive

unit with the two connecting screws.

Closing Direction

Left Hand Left Hand Reverse Bevel R

LEFT HAND DOOR

Right Hand Right Hand Reverse Bevel

RIGHT HAND DOOR

LH Assembly RH Assembly

Cylindrical Drive Unit Position

E-PLEX 2000 & POWERPLEX 2000 Installation Guide KD10113-E-1121

A-3. DOOR THICKNESS

Depending on the kind of spacers shipped with the lock, choose Table

1 or Table 2 to prepare the attachment plate and cylindrical drive unit

for door thickness different than 1 3⁄4" assembled in the factory.

Note: It is very important to assemble the spacers in the position

shown.

1. LOCK WITH 3 DIFFERENT SPACERS

The cylindrical unit and plate assembly

is shipped assembled in factory for 1

3⁄4" (44 mm) door thickness (1 11⁄16" [43

mm] to less than 1 7⁄8" [48 mm]) with 2

spac-ers "04"; 1 spacer "02" and 2 flat

head screws 5⁄8" (16 mm) LG. For other

door thicknesses, use Door Thickness

Table 1 for appropriate spacers and

screws included in the hardware bag.

Prepare attachment plate and

cylindrical drive unit for door

thicknesses less than 1 11⁄16"

(43 mm) or 1 7⁄8" (48 mm) and

above according to the

Door Thickness Table 1.

Door Thickness Table 1

Door Spacer Spacer Spacer Screw

Thickness 02 04 05 length

-1 -

3⁄8"

1 3⁄8" (35 mm) to

1 9⁄16" (40 mm) (10 mm)

-2 -

1⁄2"

Over 1 9⁄16" (40 mm) to

less than 1 11⁄16" (43 mm) (13 mm)

12 -

5⁄8"

1 3⁄4" (44 mm) DOOR

1 11⁄16 (43 mm) to less than 1 7⁄8"(16 mm)

1- 1

5⁄8"

1 7⁄8" (48 mm) to

1 15⁄16" (49 mm) (16 mm)

2- 1

3⁄4"

Over 1 15⁄16" (49 mm) to

less than 2 1⁄8" (54 mm) (19 mm)

- 1 1 3⁄4"

2 1⁄8" (54 mm) to

2 3⁄16" (56 mm) (19 mm)

21 1

7⁄8"

Over 2 3⁄16" (56 mm)

to 2 3⁄8" (60 mm) (22 mm)

--2

7⁄8"

Over 2 3⁄8" (60 mm)

to 2 1⁄2" (64 mm) (22 mm)

Screws

Cylindrical

Unit

Assembly

Spacers

Attachment

Plate

Correct Position of Spacers

See Table 1

E-PLEX 2000 & POWERPLEX 2000 Installation Guide KD10113-E-1121

2. LOCK WITH 2 DIFFERENT SPACERS

The cylindrical unit and plate assembly

is shipped assembled in factory for 1 3⁄4"

(44 mm) door thickness up to 1 13⁄16" [46

mm] with 2 spacers "07"; 1 spacer "08"

and 2 flat head screws 5⁄8" (16 mm) long.

For other door thicknesses, use Door

Thickness Table 2 for appropriate spac-

ers and screws included in the hardware

bag.

Door Thickness Table 2

Door Spacer Spacer Screw

Thickness 07 08 length

1 3⁄8" (35 mm) to 1 9⁄16" (40 mm) 2-

3⁄8" (10 mm)

1 5⁄8" (41 mm) to 1 11⁄16" (43 mm) 11

1⁄2" (13 mm)

1 3⁄4" (44 mm) to 1 13⁄16" (46 mm) 21

5⁄8" (16 mm)

1 7⁄8" (48 mm) to 1 15⁄16" (49 mm) -2

5⁄8" (16 mm)

2" (51 mm) to 2 1⁄16" (52.5 mm) 12

3⁄4" (19 mm)

2 1⁄8" (54 mm) to 2 3⁄16" (56 mm) 2 2 3⁄4" (19 mm)

2 1⁄4" (57 mm) to 2 5⁄16" (59 mm) -3

7⁄8" (22 mm)

2 3⁄8" (60 mm) to 2 1⁄2" (64 mm) 13

7⁄8" (22 mm)

Screw Length Full Scale

Length 3

⁄

"(10 mm)

Length 1

⁄

"(13 mm)

Length 5

⁄

"(16 mm)

Length 3

⁄

"(19 mm)

Length 7

⁄

"(22 mm)

Correct Position of

Spacers See Table 2

E-PLEX 2000 & POWERPLEX 2000 Installation Guide KD10113-E-1121

A-4. INSTALLING LOCK HOUSINGS

1. Remove the cylindrical plate assembly from

the outside housing (a). Insert the slotted

end of the square spindle into the outside

housing lever hub until it locks, at an angle

of 45º.

(The spindle can be removed by pulling on

it, if oriented incorrectly.)

2. Assemble gasket onto the outside

housing (a). Assemble cylindrical

plate assembly onto the outside

lock hous-ing. (Not required for

PowerPlex 2000 versions)

3. Place the outside housing (a) and

cylindrical plate assembly on the

door so that it engages the latch

as shown.

On the inside trim assembly, turn the

lever to the correct horizontal rest

position for the handing of the

door. Install the tension spring (l)

between the stop plate (h) and

the post (p).

Square Spindle Position

correct incorrect

(outside)

cylindrical

unit

latch

Gasket (not for

PowerPlex 2000

version)

Assembly

Cylindrical Plate

E-PLEX 2000 & POWERPLEX 2000 Installation Guide KD10113-E-1121

A-5. INSTALLING THE STRIKE

Note: Use only the strike and strike box supplied.

The use of non-approved parts will result in a

functionality problem and may void the warranty.

1. Mark location of strike on the door frame,

making certain that the strike opening is

aligned with latch bolt.

2. Mortise doorframe for strike 3⁄32" (3 mm)

deep minimum to dimensions shown. Make

cut out for dust box. Secure strike to the

door frame using two 1" (25 mm)

combination screws.

Caution: Check the operation of the latch by making sure that the

deadlatch stops against the strike as shown and does not slide into the

strike opening when the door is closed. If that situation occurs, then a

total lockout may occur. This will void our warranty of the complete

lock mechanism. If necessary, correct the door over-travel by using the

rubber bumpers as described in Section P (Installing Rubber Bumpers).

5. Put the thumbturn (T) in a vertical

position. Assemble 3 spacers (S) on

the door (for recent models only).

Place the inside trim assembly on

the door so that the upper and

lower spindles (F) and (G) engage

the thumbturn and the inside lever.

Fasten to the outside housing using

the three 1/8" hex drive mounting

screws (I). Install the screws

without tightening. Verify the

inside lever and thumbturn

operates smootly. If not move the

inside and outside housings slightly.

Then tighten the screws.

E-PLEX 2000 & POWERPLEX 2000 Installation Guide KD10113-E-1121

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