vertical lock
Transcription
vertical lock
INSTALLATION GUIDE VERTICAL LOCK TABLE OF CONTENTS INTRODUCTION .....................................................................1 Design Parameters for Auditcon & 52 Series Locks .................... 1 Prepare for New Installation of the Lock ...................................... 1 SPINDLED INSTALLATION (DEAD BOLT) ....................................2 Basic Tools and Materials Needed .............................................. 2 Table of Recommended Torques for Lock Screws ....................... 2 Template ..................................................................................... 2 PowerStar (Self Powered) Lock Parts for Installation ................... 3 PowerSaver (Battery Powered) Lock Parts for Installation ........... 4 Install the Lock ............................................................................ 5 NON-SPINDLED INSTALLATION (SLIDE BOLT) ..........................14 Basic Tools and Materials Needed ............................................ 14 Table of Recommended Torques for Lock Screws ..................... 14 Template ................................................................................... 14 PowerStar (Self Powered) Lock Parts for Installation ................. 15 Install the Lock .......................................................................... 16 WARNING: Kaba Mas locks are well protected from Electrostatic Discharge (ESD) damage once they are installed, but can be damaged during the installation process if proper precautions are not observed. Follow these precautions to avoid ESD damage when installing the lock: • Do Not Touch the end of the flex cable. • Handle the keypad assembly by the outer edge only. • For the best protection, use an ESD wrist band grounded to the lock or container during installation. The lock is protected to greater than 25,000 V ESD when correctly installed. INTRODUCTION You should read all instructions carefully before you install and use your Auditcon or 52 Series Lock with Vertical Housing. This will help you avoid unnecessary costs and concerns resulting from improper installation. These installation instructions apply to all Vertical Housing models for Auditcon Series & 52 Series locks. Within the Vertical Housing there can be two different types of Installation, one for a Spindled Installation (Dead Bolt) and one for a Non-Spindled Installation (Slide Bolt). Installation will also vary somewhat depending on whether you have a PowerStarTM (Self Powered) or PowerSaverTM (Battery Powered) lock. Design Parameters for Locks 1. Bolt dimensions (nominal): .312 inches X 1.000 inches / 8 X 25,4 mm 2. Bolt movement (nominal) : .465 inches /11,8 mm 3. Maximum load movable by the bolt: 0,23 N 4. Maximum load against bolt when thrown (all directions): 1kN (maximum) 5. The lock can be fitted to safes or vault doors of any material. Prepare for New Installation of the Lock 1. Use the template to establish the exact locations (relative to the spindle hole) of the mounting holes for the lock assembly. 2. The lock case mounting screws (1/4-20) require drilled and tapped holes to 3/8” depth if possible (minimum 1/4” depth required). 3. The spindle hole diameter for spindled installation must be a minimum of 3/8” (9.525mm). The maximum spindle hole diameter of 13/32 inch (10.32mm) is also the recommended diameter. 4. Deburr the spindle hole, ensuring that there are no sharp edges that could cut the cable. 5. The keypad/base assembly mounting screws (8-32) require drilled and tapped holes to 3/8” depth if possible (minimum 1/4” depth required). 1 SPINDLED INSTALLATION (DEAD BOLT) Basic Tools and Materials Needed • Medium Phillips head screwdriver (#2) (magnetized tip recommended) • Fine pitch hacksaw (32 teeth/inch) • Small flat file • All-purpose scissors • Tape measure or ruler Recommended, but not required: • Torque screwdriver (30 inch-pounds/3.4 newton-meters capacity) • Small vise grip • Needle-nosed pliers • Loctite® 262 (Red) for use on lock case mounting screws Table 1 - Recommended Torques for Lock Screws Application Screw P/N Screw Size Torque in Lbs Torque N-M Front cover mounting screws 205056 6-32 14 to 16 1.6 to 1.8 Spindle screw 105030 6-32 14 to 16 1.6 to 1.8 Base assembly mounting screws 315019 8-32 17 to 20 1.9 to 2.25 1/4-20 25 to 30 2.8 to 3.4 Lock case mounting screws 305026 Template A template is provided as an aid for locating, drilling, and tapping the lock mounting screw holes relative to the spindle hole. Since the lock is designed to fit most industry standard container lock mounting screw hole patterns, the need to use this template should be minimal. 2 PowerStarTM (Self Powered) Lock Parts for Installation 1. Front cover and keypad/base assembly (no grounding wire on 52 Series) 2. Lock case assembly 3. Dial 4. Spindle with protective tube 5. Spindle mounting clip (1) 6. Lock case mounting screws (4) 7. Spindle mounting screw (1) 8. Front cover mounting screws (3) 9. Keypad/base assembly mounting screws (2) 10. Dial Label 11. Insulator tape (not pictured) 12. Lubricant (not pictured) 13. Cable Shields (2) (not pictured) 2 1 3 4 5 9 10 8 7 6 Fig. 1 - Spindled PowerStar Lock Parts for Installation 3 PowerSaverTM (Battery Powered) Lock Parts for Installation 1. Dial 2. Lock case assembly 3. Front cover and keypad/base assembly (no grounding wire on 52 Series) 4. Spindle with protective tube 5. Lock case mounting screws (4) 6. Keypad/base assembly mounting screws (2) 7. Spindle mounting screw (1) 8. Front cover mounting screws (3) 9. Spindle mounting clip (1) 10. Battery compartment cover 11. Dial Label (not pictured) 12. Insulator tape (not pictured) 13. Lubricant (not pictured) 14. Cable Shields (2) (not pictured) Fig. 2 - Spindled PowerSaver Lock Parts for Installation 4 Install the Lock Warning: Do not take the lock case assembly apart. There are no field servicable parts inside lock case. Complete the following steps to install the lock: 1. Insert a cable shield into the spindle hole from the back side of the container door. 2. Place the protective tube on the tube retainer over the spindle hole on the lock case. Make sure that the flex cable is positioned on the outside of the tube (Figure 3). Fig. 3 - Place tube on tube retainer Caution: Do not touch the silver leads on the flex cable. This could cause ESD damage. 3. While holding the lock case assembly, carefully guide the end of the flex cable and the tube through the container so that they are easily accessible at the outside of the container. 4. Hold the lock case assembly tightly against the inside of the container and mark the tube flush (to within 1/16”) with the outside of the container door for cutting. 5. Guide the end of the cable and the tube back through the inside of the container. 6. Remove the tube from the tube retainer on the lock case and use scissors to cut the tube just inside your mark. Keep the cut as straight as possible. Place the tube back on the tube retainer on the lock case and tape the flex cable to the outside of the tube with the insulator tape provided. 7. While holding the lock case assembly, again carefully guide the end of the flex cable and the tube through the inside of the container so that they are easily accessible at the outside of the container. 8. Mount the lock case assembly to the inside of the container door in the proper orientation using the four lock case mounting screws. Note: It is recommended that you use Loctite® 262 (Red) on the lock case mounting screws. 5 9. Insert the end of the spindle with the screw hole into the lock case assembly until the spindle is properly seated. The grooved side of the spindle should be oriented so that the grooves in the spindle align with the grooves in the drive cam. Turn the spindle so that the grooves are facing toward the bolt, if they are not already oriented in that direction (Figure 4). 10. Mark the spindle shaft 1 1/4” from the outside of the container door for cutting (plus or minus 1/8” allowed) (Figure 5). Fig. 4 - Insert screw hole side of spindle into spindle hole 11. Remove the spindle from the lock case to prevent damage to the cable while cutting. 12. Use the hacksaw to cut the spindle on the mark. You may want to use a small vise to secure the spindle when cutting. 13. Use a small, flat file to deburr the spindle after cutting. 14. Insert the spindle through the outside of the container into the lock case. Refer to Step 9 for proper insertion. Fig. 5 - Mark spindle for cutting 15. While holding the spindle, insert the spindle mounting screw through the back of the lock case and into the end of the spindle (Figure 6). Turn the screw until it is securely attached to the spindle. Verify that the spindle grooves are still facing toward the bolt and that the bolt is still extended. 16. Insert the second cable shield into the spindle hole from the front of the container with the cable feeding through the center of it. (See Figure 7.) Cable Shield Spindle Flex Cable Fig. 6 - Insert spindle mounting screw 6 Fig. 7 - Insert cable shield into spindle hole 17. Remove the front cover from the keypad/base assembly (Figure 8). Caution: During the next series of steps in the installation, you will be handling the front cover and the cables . It is very important that you take measures to observe ESD protection while handling the front cover and flex cable and when plugging in connectors. Do not touch the silver leads on the flex cable and do not touch the metal pins in the connectors. Fig. 8 - Remove front cover from keypad/base assembly 18. Hold the keypad/ base assembly in the upright position (i.e., the keypad is positioned at the top) and hold the keypad in place. There are four available cable receiving holes on the keypad/ base assembly Fig. 9 - Keypad/assembly dial bushing (Figure 9). Guide the flex cable through the appropriate cable receiving hole on the back of the keypad/base assembly based on the orientation of the flex cable to the spindle. For example, if the flex cable comes out below the spindle, the cable should be guided through the bottom cable receiving hole (Figure 10). 19. Align the keypad/base assembly so that the dial bushing on the keypad/base assembly is centered over the spindle and position the keypad/base assembly so that it rests firmly against the container door. Fig. 10 - Guide flex cable through cable receiving hole 7 20. If you are installing an Auditcon Series lock, there will be a grounding wire on the keypad/base assembly that will have one end already attached. For a self powered lock, the grounding wire will be attached to the generator. On a battery powered lock it is attached to the keypad. (There will be no grounding wire or keypad ESD shield present on a 52 Series lock.) The terminal on the other end of the wire needs to be attached to the keypad/ base assembly using one of the two keypad/base assembly mounting screws. (See Figure 11a.) While holding the keypad/base assembly in place, attach it to the container door using the two keypad/base assembly mounting screws. (Make sure that you attach the grounding wire at this time). Use either the two horizontal mounting holes or the two vertical holes, depending on the orientation in which you are mounting the lock. (See Figure 9.) 21. Visually center the dial bushing (Figure 9) on the keypad/base assembly with the center of the spindle hole and tighten the screws (Figure 11a for PowerStar - Self Powered, Figure 11b for PowerSaver- Battery Powered). Fig. 11a - Attach PowerStar keypad/base assembly Fig. 11b - Attach PowerSaver keypad/base assembly 22. Route the flex cable appropriately as indicated, dependant on whether you have a PowerStar (Self Powered) or PowerSaver (Battery Powered) version of the lock. Cable Rcv Hole PowerStar Method (Generator): 8 Route the flex cable toward the generator so that the cable is positioned in between the upper generator mounting stud and the generator. Gently lift the keypad board assembly and guide the cable up through the cable receiving hole in the keypad/base assembly keeping the silver leads facing away from the container. (See Figure 12.) Upper Generator Stud Fig. 12 - PowerStar - Route cable toward generator PowerSaver Method (Battery): Route the flex cable upward toward the keypad so that the cable enters the cutout in the upper left side of the keypad housing. Gently lift the keypad board assembly and guide the cable across to the ZIF (Zero Insertion Force) connector keeping the silver leads facing away from the container (See Figure 13.) Fig. 13 - PowerSaver - Route cable toward keypad 23. If the ZIF connector on the keypad assembly is not already open, pull the release on the ZIF connector outward to its open position. (See Figure 14.) 24. Insert the flex cable into the ZIF connector with the silver leads facing away from the container. Close the ZIF connector to lock the flex cable in place. Ensure that both sides of the connector are snapped in place and that the flex cable is squared to the connector. (See Figure 15.) Fig. 14 - Pull release on ZIF connector outward Fig. 15 - Insert flex cable into ZIF connector and close ZIF connector 25. Fold the excess cable accordian style and position the cable under the keypad assembly so that it will not be pinched when the keypad cover assembly is snapped into place. 26. If this is a self powered lock, apply a small amount of lubricant to the gear on the generator. 27. If the bolt is not extended at this time, turn the spindle and cam so that the grooves in the spindle are facing toward the bolt. This should cause the bolt to be extended. 9 28. While holding the dial, orient the lip of the dial in the upright position once it is placed onto the spindle (Figures 17 and 18). This is referred to as the “Home” position. Place the dial onto the spindle and seat into the dial bushing. For the self powered version of the lock, push gently to place the dial so that the gear on the generator seats properly into the gear teeth on the dial. 29. If this is a battery powered version of the lock, the battery must be installed before you can test the operation of the lock. Complete the following step: • Connect a fresh 9 volt Alkaline battery to the battery connector that is attached to the base assembly. 30. Test the operation of the lock before completing the installation of the front cover by verifying the following: • Ensure that the dial turns freely without scraping. • If you are testing a self powered lock, power the lock by turning the dial briskly in any direction until simultaneous green and red flashes display and two beeps sound to indicate that the lock is powered. Position the lock dial to the HOME position (i.e., the lip of the dial will be in the upright position and will cover the red bar) and key in the Factory Combination. (For a Model 50, D50, 52, or T52, enter “502550”. For a Model 100, 200, 400, 500, enter any pair of numbers except “00”, followed by “502550”.) If the combination is entered successfully, one green flash displays to indicate that the lock is ready to open. To open the lock, turn the dial right (clockwise) until the lock bolt is retracted. Then turn the dial back to the left to return the bolt to the extended position. Note: After correctly entering a valid combination, you must turn the lock dial to the right within ten seconds. Once you have turned the lock dial, you must retract the bolt within four seconds (by continuing to turn the dial to the right). If you do not turn the lock dial to the right or retract the bolt within the allotted time periods, you will need to re-enter the factory combination to open the lock.You might also need to power the lock again. If the lock does not operate successfully, carefully remove the dial, check flex cable connection and spindle orientation (grooves toward the bolt with bolt extended), and verify that all mounting screws are securely tightened. If this is a PowerSaver lock, also check the battery and connections. 31. After you have successfully tested the lock operation, ensure that the bolt is extended and remove the dial from the spindle. Also, if you have a battery powered lock, disconnect the battery. 10 32. Position and insert the keypad assembly into the locating posts on the base assembly. 33. Center the front cover over the spindle and insert the catches on the top of the front cover into the keypad/base assembly. 34. Mount the front cover to the keypad/ base assembly using the round mounting holes on the cover and the three mounting screws. (See Figure 16.) 35. Apply a small amount of lubricant to the bearing surface of the dial, (the portion that fits into the dial bushing of the base assembly) as well as the teeth around the edge of the dial, prior to final dial installation. Fig. 16 - Mount front cover to keypad/base assembly 36. In preparation for the final installation of the dial, once again ensure that the grooves in the spindles are facing the bolt and the bolt is extended. While holding the dial, orient the lip of the dial in the upright position so that it will cover the red bar on the front cover once placed onto the spindle (Figures 17 and 18). Place the dial onto the spindle and seat into the dial bushing. Push gently to place the dial so that the gear on the generator seats properly into the gear teeth on the dial. Red portion is showing Fig. 17 - Incorrect position Red portion is not showing Fig. 18 - Correct position 11 37. Position the spindle mounting clip (Figure 19) over the spindle in the center of the front of the dial. The raised tabs should be facing upwards (the concave side of the clip should be facing downward). Slide the clip down the spindle until the clip stops against the center portion of the dial. Check to make sure the outward dial movement (away from the lock) has been held to a minimum. Raised Tabs Fig. 19 - Spindle mounting clip with raised tabs facing upwards 38. If you have a battery powered lock, ensure that the battery leads and the battery pull cord are not pinched and are accessible through the battery compartment. At this time, you should install the battery by completing the following steps: • Connect a fresh 9 volt Alkaline battery to the battery connector. • Hold the battery with the leads from the connector facing up, and form the leads at a sharp right angle at the connector so that they lie horizontally. • Insert the battery straight into the battery compartment, making sure that the white extractor ribbon is routed along the outer side of the battery. Ensure that the extractor ribbon is routed correctly so that the battery can be easily withdrawn from the battery compart ment for future battery replacement. • Place the battery cover over the battery compartment. Locate the fasteners in their respective holes, and press down on the fasteners until the cover is fully in place. 39. Test the operation of the lock again. 40. If the lock does not operate properly, hold the dial and carefully remove the spindle mounting screw. Carefully pull out the dial assembly and then pull out the spindle. Repeat steps 14-39. (You will not need to perform step 35 again.) At this time you could re-adjust the keypad/base assembly mounting screws, the position of the spindle, or could replace the spindle if necessary. Note: The lock will not open if excessive force is applied to the end or side of the bolt. The installer should check for these conditions during installation. 41. If the lock operates properly, orient the lip of the dial so that it covers the red bar on the front cover. 12 Caution: To meet the requirements of certain approval agencies, a tamper evident dial label may have been included with your lock. It is important that the next step of the installation be completed very carefully, allowing the dial label to be applied correctly on the first attempt. If the tamper evident dial label is removed after initial application, a part of the label will stay on the dial. A new label would then be required for reapplication. 42. Apply the dial label to the dial. The Kaba Mas logo should be aligned horizontally (Figure 20). Fig. 20 - Apply dial label to dial 13 NON-SPINDLED INSTALLATION (SLIDE BOLT) You should read all instructions carefully before you install and use your Auditcon or 52 Series lock. This will help you avoid unnecessary costs and concerns resulting from improper installation. Basic Tools and Materials Needed • Medium Phillips head screwdriver (#2) (magnetized tip recommended) Recommended, but not required: • Torque screwdriver (30 inch-pounds/3.4 newton-meters capacity) • Loctite® 262 (Red) for use on lock case mounting screws Table 1 - Recommended Torques for Lock Screws Application Screw P/N Screw Size Torque in Lbs Torque N-M Front cover mounting screws 205056 6-32 14 to 16 1.6 to 1.8 Base assembly mounting screws 315019 8-32 17 to 20 1.9 to 2.25 1/4-20 25 to 30 2.8 to 3.4 Lock case mounting screws 305026 Template A template is provided as an aid for locating, drilling, and tapping the lock mounting screw holes. 14 PowerStarTM (Self Powered) Lock Parts for Installation 1. Keypad/base assembly 2. Lock case assembly 3. Lock cable 4. Spindle 5. Front cover mounting screws (3) 6. Nylon dial spacer 7. Metal dial mounting washer 8. Lock case mounting screws (3) 9. Dial mounting screw (1) 10. Keypad/base mounting screws (2) 11. Dial 12. Lubricant (not pictured) 13. Dial Label (not pictured) 2 1 3 4 11 9 7 10 5 8 6 Fig. 1 - Non-Spindled PowerStar Lock Installation Parts 15 Install the Lock Warning: Do not take the lock case assembly apart. The lock will not operate if the back cover has been removed. Complete the following steps to install the lock: 1. Mount the lock case assembly in the desired position relative to the container locking bar. Allow 1/32” minimum clearance between the lock bolt roller and the container locking bar (Figure 2). Note: The lock case assembly can be mounted in bolt roller up position or bolt roller down Fig. 2 - Lock case mounting bolt roller up position for all mounting locations. It is recommended that you use Loctite® 262 (Red) on the lock case mounting screws. 2. . Route the cable through the cable routing hole in the door of the container as shown in Figure 3. Fig. 3 - Cable through door 3. Remove the front cover from the keypad/base assembly (Figure 4). Fig. 4 - Remove front cover from keypad/base assembly 16 4. Hold the keypad/base assembly in the upright position (i.e., the keypad is positioned at the top) and hold the keypad in place. Guide the cable through the cable receiving hole on the back of the keypad/base assembly (Figure 5). 5. 6. Insert the spindle from the back of the keypad/ base assembly (Figure 6). Back of Keypad Spindle Position the keypad/base assembly so that it rests firmly against the container door. Fig. 5 - Cable through keypad base assembly 7. 8. If you are installing an Auditcon Series lock, there will be a grounding wire on the keypad/base assembly that will have one end already attached. For a self powered lock, it will be attached to the generator. (There will be no grounding wire or ESD shield present on a 52 Series lock.) The terminal on the other end of the wire needs to be attached to the keypad/base assembly using one of the two keypad/base assembly mounting screws. (See Figure 7.) While holding the keypad/base assembly in place, attach it to the container door using the two keypad/base assembly mounting screws. (Make sure that you attach the grounding wire at this time). Use either the two horizontal mounting holes or the two vertical holes, depending on the orientation in which you are mounting the lock. Route the cable toward the generator. (See Figure 8.) Gently lift the keypad board assembly and guide the cable up through the cable receiving hole in the keypad assembly. (See Figure 9.) Fig. 6 - Insert spindle from back of keypad/base assembly Fig. 7 - Attach PowerStar keypad/base assembly Figure 8 - Cable routing to keypad 17 9. Plug the cable into the connector on the back of the keypad (Figure 9). 10. Apply a small amount of lubricant to the gear on the generator. Be careful not to apply too much lubricant. 11. Center the dial over the spindle and slide the dial onto the spindle until it is properly seated. The lip of the dial should be in the upright position. Fig. 9 - Plug cable into back of keypad 12. Plug the cable into the lock case being careful to route the cable so it will not get caught in the boltworks of the container. 13. Test the operation of the lock before completing the installation of the front cover by verifying the following: • Ensure that the dial turns freely without scraping. • Power the lock by turning the dial briskly in any direction until simultaneous green and red flashes display and two beeps sound to indicate that the lock is powered. Key in the Factory Combination. (For a Model 50, D50, 52, or T52, enter “502550”. For a Model 100, 200, 400, 500, enter any pair of numbers except “00”, followed by “502550”.) If the combination is entered successfully, one green flash displays to indicate that the lock is ready to open. To unlock the container, engage the boltworks by turning the handle on the container. This will automatically retract the lock bolt and open the door. Note: After correctly entering a valid combination, you must engage the boltworks within 6-8 seconds. If you do not cause the bolt to be retracted within the allotted time period, you will need to re-enter the factory combination to open the lock.You might also need to power the lock again. If the lock does not operate successfully, carefully remove the dial, check the cable connection, and verify that all mounting screws are securely tightened. 14. After you have successfully tested the lock operation, remove the dial from the spindle. 15. Position and insert the keypad assembly into the locating posts on the base assembly. 16. Center the front cover over the spindle and insert the catches on the top of the front cover into the keypad/base assembly. 18 17. Mount the front cover to the keypad/ base assembly using the round mounting holes on the cover and the three mounting screws (Figure 10). 18. Place the nylon dial spacer over the spindle. 19. Apply a small amount of lubricant to the bearing surface of the dial, (the portion that fits into the dial bushing of the base assembly) as well as the teeth around the edge of the dial, prior to final dial installation. 20. Place the dial onto the spindle and seat into the dial bushing. Push gently to place the dial so that the gears on the generator seat properly into the gear teeth on the dial. Fig. 10 - Mount front cover to keypad/base assembly 21. Test the operation of the lock again. 22. If the lock does not operate successfully, carefully remove the dial, check the cable connection, and verify that all mounting screws are securely tightened. Note: The lock will not open if excessive force is applied to the end or side of the bolt. The installer should check for these conditions during installation. 23. If the lock operates properly, insert the dial mounting screw through the metal dial mounting washer. Then insert the dial mounting screw/washer assembly into the spindle and tighten the dial mounting screw. Caution: To meet the requirements of certain approval agencies, a tamper evident dial label may have been included with your lock. It is important that the next step of the installation be completed very carefully, allowing the dial label to be applied correctly on the first attempt. If the tamper evident dial label is removed after initial application, a part of the label will stay on the dial. A new label would then be required for reapplication. 19 24. Apply the dial label to the dial. The Kaba Mas logo should be aligned horizontally. (See Figure 11.) Fig. 11 - Apply dial label to dial 20 Document Number 301.047 Rev. G - 09/02 Notice: The information in this manual is subject to change without notice and does not represent a commitment on the part of Kaba Mas. Kaba Mas shall not be liable for technical or editorial errors or omissions contained herein; nor for incidental or consequential damages resulting from the furnishing, performance or use of this material. © 1997-2002 Kaba® Mas All rights reserved Kaba® Mas Corporation 749 W. Short Street, Lexington, KY 40508 USA Phone: (859) 253-4744 FAX: (859) 255-2655 Technical Support: (800) 950-4744 www.kaba-mas.com