Kaba E-PLEX 2000 User manual

E-PLEX®2000 and 2400 Series

E-PLEX®PowerStar 2000 and 2400 Series

INSTALLATION INSTRUCTIONS

TABLE OF CONTENTS

A. Cylindrical Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3

B. Mortise Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10

C. Exit Trim Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32

D. Installing Outside Lever on Non-Mechanical Override . . . . . . . . . . . . . . . . .36

E. Reversing the Outside Lever for Series Without Mechanical Override . . .36

F. Installing Optional K-I-L Key or Best Removable Core . . . . . . . . . . . . . . . . .37

Override and Outside Lever

G. Testing the Operations of the Outside Lever . . . . . . . . . . . . . . . . . . . . . . . . .39

H. Testing the Mechanical Key Override with Change Key . . . . . . . . . . . . . . . .40

I. Changing Lock Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41

J. Changing Best-Type Core . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42

K. Removing and Reassembling the Outside Lever . . . . . . . . . . . . . . . . . . . . . .42

L. Installing Rubber Bumpers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43

M. Installing Battery Pack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43

N. Testing the Operation of the Lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44

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 per-

form the steps described. Kaba Access Control 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. Kaba Access Control stan-

dard warranty does not cover damages caused by installation.

A. CYLINDRICAL

CHECKLIST

Parts and Tools List

Each E-Plex 2xxx lockset includes:

• Outside lock housing

• Inside lock assembly

• Outside lever

• Gasket for outside lock housing (not for PowerStar versions)

• Cylindrical latch

• Cylinder drive unit

• Battery holder with 3 AA batteries (not included in PowerStar versions)

• Drilling templates

• Hardware bag, includes:

- Square spindle

- Phillips screw (6-32 x 5⁄16") (not for PowerStar 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 20xx 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.

DIAGRAM OF LOCK:

BackFront

(A)

(D)

(B)

(E)

(F)

(G)

(H)

(I)

(J)

(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)

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

23⁄8" [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

LEFT HAND DOOR

Right Hand Right Hand Reverse Bevel

RIGHT HAND DOOR

LH Assembly RH Assembly

Cylindrical Drive Unit Position

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

13⁄8" (35 mm) to - 1 - 3⁄8"

19⁄16" (40 mm) (10 mm)

Over 1 9⁄16" (40 mm) to - 2 - 1⁄2"

less than 1 11⁄16" (43 mm) (13 mm)

13⁄4" (44 mm) DOOR 1 2 - 5⁄8"

111⁄16 (43 mm) to less than 1 7⁄8" (16 mm)

17⁄8" (48 mm) to 1 - 1 5⁄8"

115⁄16" (49 mm) (16 mm)

Over 1 15⁄16" (49 mm) to 2 - 1 3⁄4"

less than 2 1⁄8" (54 mm) (19 mm)

21⁄8" (54 mm) to - 1 1 3⁄4"

23⁄16" (56 mm) (19 mm)

Over 2 3⁄16" (56 mm) to 2 1 1 7⁄8"

23⁄8" (60 mm) (22 mm)

Over 2 3⁄8" (60 mm) to - - 2 7⁄8"

21⁄2" (64 mm) (22 mm)

Screws

Cylindrical

Unit

Assembly

Spacers

Attachment

Plate

Correct Position of Spacers

See Table 1

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 spacers

and screws included in the hardware bag.

Door Thickness Table 2

Door Spacer Spacer Screw

Thickness 07 08 length

13⁄8" (35 mm) to 1 9⁄16" (40 mm) 2 - 3⁄8" (10 mm)

15⁄8" (41 mm) to 1 11⁄16" (43 mm) 1 1 1⁄2" (13 mm)

13⁄4" (44 mm) to 1 13⁄16" (46 mm) 2 1

5⁄8" (16 mm)

17⁄8" (48 mm) to 1 15⁄16" (49 mm) - 2 5⁄8" (16 mm)

2" (51 mm) to 2 1⁄16" (52.5 mm) 1 2 3⁄4" (19 mm)

21⁄8" (54 mm) to 2 3⁄16" (56 mm) 2 2 3⁄4" (19 mm)

21⁄4" (57 mm) to 2 5⁄16" (59 mm) - 3 7⁄8" (22 mm)

23⁄8" (60 mm) to 2 1⁄2" (64 mm) 1 3 7⁄8" (22 mm)

Screw Length Full Scale

Length 3⁄8"(10 mm)

Length 1⁄2"(13 mm)

Length 5⁄8"(16 mm)

Length 3⁄4"(19 mm)

Length 7⁄8"(22 mm)

Correct Position of Spacers

See Table 2

A-4. INSTALLING LOCK HOUSINGS

1. Insert the slotted end of the square spindle

into the outside 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 PowerStar ver-

sions)

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

Cylindrical Plate

Assembly

(outside)

cylindrical

unit

latch

Gasket

(not for PowerStar versions

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.

B. MORTISE

Checklist and Exploded Views (Mortise Only)

Each E2x00 Mortise lockset includes:

(A) Outside lever handle

(or)

Parts for Mechanical override model only:

(A1) Outside lever handle

(B1) Outside housing

(C1) Cylinder plug

(D1) Cylinder (for locks with KIL option)

(E1) Cylinder cap

(E2) Instruction sheet “How to attach lever on lock”

(B) Outside housing

(D) Mortise (ASM only shipped assembled with faceplate and 2 x 8-32 x 1/4”

screws)

(E) Inside trim assembly, details depend on lock model

(E3) Drilling template

(N) Outdoor Gasket (not for PowerStar versions)

Parts inside hardware bag:

(F) Thumbturn (hex) spindle

(G) Square spindle

(H) Phillips screw (6-32X 5/16”) (not for PowerStar versions)

(I) 3 x mounting screws (12-24, 1/8” Hex Head)

(J) 2 Machined screws (12-24X 1/2” Philips) & 2 wood screws (#12 X 1” Philips)

(K) Strike kit (screws, strike and dustbox)

(L) 1 extension spring

(R2) 1 Cylinder with 2 keys for E2x00 with override

(S) 3 spacers for recent Models only

(T) Allen Key 1/8”

(U) Allen Key 5/64”

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