Dormakaba PowerPlex 2000 Series Installation Instructions Manual
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Dormakaba PowerPlex 2000 Series Installation Instructions Manual

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E-Plex 2000 &
PowerPlex 2000
Installation Instructions

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  • Page 1 E-Plex 2000 & PowerPlex 2000 Installation Instructions...
  • Page 2                                 ...

  • Page 3: Table Of Contents

    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.
  • Page 4 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 •...
  • Page 5 TOOLS REQUIRED: • Safety Glasses • Phillips screwdriver (#2) • ⁄ " (13 mm) chisel • Fine steel file • ⁄ " (3 mm) drill bit • Router • ⁄ " (13 mm) drill bit • Adjustable square • ⁄ "...

  • Page 6: Cylindrical Installation

    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 ⁄ " [60 mm] Backset or the 2 ⁄ " [70 mm] Backset). 2.
  • Page 7 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 ⁄ " assembled in the factory. Note: It is very important to assemble the spacers in the position shown.
  • Page 8 2. LOCK WITH 2 DIFFERENT SPACERS Correct Position of The cylindrical unit and plate assembly Spacers See Table 2 is shipped assembled in factory for 1 ⁄ " (44 mm) door thickness up to 1 ⁄ " [46 mm] with 2 spacers "07"; 1 spacer "08" and 2 flat head screws ⁄...
  • Page 9 A-4. INSTALLING LOCK HOUSINGS Square Spindle Position 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. correct incorrect (The spindle can be removed by pulling on it, if oriented incorrectly.)
  • Page 10 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"...
  • Page 11 B. MORTISE Checklist and Exploded Views (Mortise Only) Each E2x00 Mortise lockset includes: Outside lever handle (or) Parts for Mechanical override model only: ) Outside lever handle ) Outside housing ) Cylinder plug ) Cylinder (for locks with KIL option) ) Cylinder cap ) Instruction sheet “How to attach lever on lock”...
  • Page 12 Tools Required: • Safety Glasses • 1/2” (13mm) chisel • 1/8” (3mm) drill bit • 1/2” (13mm) drill bit • 1” (25mm) drill bit or hole saw • Drill • Awl or center punch • Hammer Rubber mallet • Small flat screwdriver •...

  • Page 13: Mortise Installation

    American Standard Mortise illustrated E-PLEX 2000 & POWERPLEX 2000 Installation Guide KD10113-E-1121...
  • Page 14 B-1. Installation of Standard ASM Models 1. Check the Mortise Handing a. Compare the mortise with the diagram below. If the mortise is the correct handing for the door, continue with step 2. Note: Refer to B-2 to change the handing of a field-reversible mortise. E-PLEX 2000 &...
  • Page 15 2. Install the Strike a. Align the paper template on the door frame at the desired handle height, and along the vertical center line of the mortise (CL), which is also the center line of the door edge, allowing for any bumpers on the door frame.
  • Page 16 e. Remove material from within the strike outline so that the strike will be flush with the doorframes. For ASM, install the dust box (optional for wood door frames, required for metal door frames), and check the strike handing on the template.
  • Page 17 B-2. Reversing the Mortise Handing 1. Reversible ASM a. Remove the mortise faceplate. Place the mortise on a flat surface for the following steps. b. Partially extend the deadbolt: For normal ASM, rotate hub (H) using a screwdriver, until the deadbolt (D) extends approximately 1/4”.
  • Page 18 For Autodeadbolt ASM, rotate hub (H) until the deadbolt (D) is fully retracted. The deadbolt will extend approx. 1/16” from the mortise case. 1/16” Hold deadbolt (D) gently. Press and release the auxiliary latch (X). You should feel the deadbolt trigger and begin to extend under the force of the spring.
  • Page 19 1. Reversible ASM (continued) c. Push in the latch bolt (L) to the middle of its stroke, and hold it there.(Continue Step 1 and 2) Lock Position Unlock Position Push in the latchbolt to the Use a small screwdriver end of the stroke, and hold to lift unlock mechanism.
  • Page 20 d. Pull out the latch bolt (L), until it just clears the front plate. (Note: If you remove the bolt completely, you must turn it 90° to re-insert it.) 180° Rotate the latch bolt (L) 180°. Re-insert it to the end of its stroke. Holding tool (S) in place, re-engage tailpiece (T) with latch bolt (L) (slide tailpiece down).
  • Page 21 e. Release the latch bolt (L). Position the latch bolt so that the bottom tooth of the anti-friction latch (F) remains inside the mortise case as shown. Note: If the tooth of (F) is outside the mortise, you will not be able to re-assemble the faceplate on the mortise.
  • Page 22 B-3. Additional steps for Autodeadbolt ASM inside trim assembly If not already installed at the factory, put the thumbturn in the vertical position and install all four (4) parts (M) as shown, on the inside trim assembly. Turn the thumbturn all the way to the right for a RH installation (arrow on M2 points UP), or all the way to the left for a LH installation (arrow on M2 points DOWN).
  • Page 23 Place 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"...
  • Page 24 PowerPlex 2xxx SERIES ® LIMITED WARRANTY dormakaba warrants this product to be free from defects in material and workmanship under normal use and service for a period of three (3) years. dormakaba will repair or replace, at our discretion, 2xxx Series Locks found by dormakaba analysis to be defective during this period.
  • Page 27 B-4. Install the Mortise (CL) 1. Mark the handle height on the edge of the Door door, as determined directly from the Strike strike. For ASM, the axis of rotation of the handle is level with the bottom lip of the Strike strike.
  • Page 28 4. Prepare the cut-outs for the mortise in the edge of the door using a mortising machine, router and chisel (for dimensions, refer to template). Ensure clearance is provided for moving latch parts as indicated on the template. (ASM shown) LH/RHR RH/LHR (ASM shown)
  • Page 29 B-5. Install the Outside Housing and Inside Trim Assembly for 2000 Series without Key Override (for E2000 Series Key Override, see Section F) 1. Install the gasket (N) (if required) on the outside housing prior to assembly, aligning the notch in the gasket with the battery compartment.
  • Page 30 5. 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 handle (H) and the post (P). Note: For Autodeadbolt ASM, Office and Storeroom models, refer to section B-3 6.
  • Page 31 8. Three AA batteries should already be installed in the battery holder (C). Insert the battery holder into the outside housing and secure it using the supplied 6-32 x 5/16" (7.9mm) Phillips screw (H). Note: If the lock makes a continuous buzzing noise or the red LED lights continuously, reset the electronics by removing the battery holder for ten seconds then reinsert it.
  • Page 32 B-9.Testing (E-2400 Series ONLY) Caution! Perform the following procedures in order, with the door OPEN unless otherwise indicated. Inside Lever: Turn the inside lever downward. The latch bolt retracts fully. If the lever or the thumbturn feels tight (hard to turn or does not return easily to its horizontal position), check the alignment of the lock assemblies.
  • Page 33 Programming Program the Lock with at least one user with the Privacy/Deadbolt Override privilege, and one user without this privilege, using the Oracode Maintenance Unit. Generate valid codes for these 2 users. (Recommendation: generate codes that starts a day before today and finishes at least one day after current date, in order to avoid check-in/check-out time periods) Code entry and access With the Deadbolt/Privacy deactivated, enter the first code to validate...
  • Page 34 Operating the Override Operating the Key Override, See Section H. Note: If the lock will not respond to any code, there are three options that should be attempted to open the door. In order, they are: 1. Verify the batteries, and replace them if they are providing less than 4 Volts total.

  • Page 35: Exit Trim Installation

    C. EXIT TRIM C-1. CHECKLIST FOR PRECISION EXIT DEVICES 21/22/FL21/FL22 VON DUPRIN 98/99EO- F/9827 /9927 EO- F/9875/9975/9847 /9947 ** DETEX 10/F10/20/F20 DORMA F9300 YALE 7100/7160/7170 Mechanical Override Models ONLY (Not for PowerPlex 2000 Versions) (Not for PowerPlex 2000 Versions) ** Detex 10 & 20 Series are Panic Hardware only. (Not fire rated) Detex F10 &...
  • Page 36 C-2. PREPARE THE DOOR FOR THE APPROPRIATE EXIT DEVICE Choose the drilling template of the lock for the exit device to be assembled on the door. Mark the desired handle height on the edge of the door. (see Fig.1) Mark the backset vertical line on each side of the door. Consult the exit device manufacturer’s instructions for the correct backset.
  • Page 37 C-3. INSTALL THE LOCK AND EXIT DEVICE Install the Mortise (if applicable) For mortise exit devices, install the mortise according to the manufacturer’s instructions Install the Outside Lever Access Hole A. Assemble the lever on the outside B. The lever is field reversible. housing, in the horizontal rest position If the handling is incorrect, insert a small pick or flat...
  • Page 38 Install Lock & Exit Device on the door a. Choose the required SPINDLE BAG from the spindle chart in the Hardware bag depending ON THE TYPE OF EXIT DEVICE AND THE DOOR THICKNESS b. Insert the slotted end of the spindle (D) into the outside housing until it locks, at the correct position for the exit device (see Fig.4).

  • Page 39: Installing Outside Lever On Non-Mechanical Override

    D. INSTALLING OUTSIDE LEVER ON NON-MECHANICAL OVERRIDE Assemble the lever on the outside housing in the hori- zontal rest position appropriate to the handing of the door. Simply push the lever onto the tube until it clicks in place. If more force is required, use a rubber mallet. Test the attachment of the handle by pulling on it to make sure it is securely fastened.

  • Page 40: Installing Optional K-I-L Key Or Best Removable Core

    F. INSTALLING OPTIONAL K-I-L KEY OR BEST REMOVABLE CORE OVERRIDE AND OUTSIDE LEVER F-1 Upon unpacking, the lock housing with mechanical override should look like the diagram below with: • The small indents (i) on the cross of the override shaft (m) in line horizontally •...
  • Page 41 For Optional K-I-L Key F-8 Put the cylinder plug (k) into the lever (h). Making sure that the cylinder plug (k) does not fall out, insert the key into the cylinder (j). The key will be horizontal. Caution: The position of the key is very important. If the lever is not assembled with the key in the correct position before placing the lever on the housing, the inside mechanism of the lock could be damaged if the lever is rotated and forced.

  • Page 42: Testing The Operations Of The Outside Lever

    F-13 Remove the key. The lock will look as shown at right. Right-Handed lock F-14 Gently check the rotation of the lever handle. It should easily rotate approximately 45º. Troubleshooting: If you have assembled the lever and housing with the key in the wrong position, the key will get stuck.

  • Page 43: Testing The Mechanical Key Override With Change

    Test the Movement of the Lever (without the key in cylinder) a. Turn the lever (h) clockwise for a Right-Handed lock or counter-clockwise for a Left-Handed lock b. Release the lever slowly. It should return freely to its horizontal position. H.

  • Page 44: Changing Lock Cylinders

    H-4 Install cap (i) to cover key hole. The cap has a Top snap small groove on one edge (to allow ease of (Second) removal). This should be facing down. Insert bottom snap of cap in lever hole below the cylinder.

  • Page 45: Changing Best-Type Core

    J. CHANGING BEST-TYPE CORE Use the control key to remove the removable core from the lever Remove the adapter from the removable core and reassemble it on the new removable core. Note: It is important that the new removable core has the same number of pins (6 or 7) as the dismounted one.

  • Page 46: Installing Rubber Bumpers

    INSTALLING RUBBER BUMPERS L -1 Close the door and apply pressure making sure the deadlatch (a) rests on the strike plate (b) as shown. Standing on the frame (door stop) side of the door, check for gaps between the door and the frame on the three sides of the frame (left, right, and top).

  • Page 47: Testing The Operation Of The

    TESTING THE OPERATION OF THE LOCK Rotate inside lever and hold. Ensure that the latch is fully retracted and flush with the latch faceplate. Release the inside lever; the latch should be fully extended. N-2 For PowerPlex 2000 you need to activate the outside lever 3 to 4 times to power the lock prior N-3 Enter the factory-set combination: 1,2,3,4,5,6,7,8.
  • Page 48 USA Inc. 6161 E. 75th Street Indianapolis, IN 46250 USA T: 855-365-2707 dormakaba Canada Inc. 7301 Decarie Blvd Montreal QC Canada H4P 2G7 T: 888-539-7226 www.dormakaba.us...

This manual is also suitable for:

E-plex 2000Powerplex 2000Powerplex p2031ll

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