BQT Solutions COBALT-mini YD39M User manual

YD30M COBALT-mini
INSTALLATION AND OPERATING INSTRUCTIONS

© BQT Solutions (SEA) Pte Limited Page
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CONTENTS
1. DESCRIPTION
2. PRODUCT UNBOXED
3. DIMENSIONS
o3.1. Lock
o3.2. Strike Plate
o3.3. Fitting Tab
o3.4. Housing
o3.5. Dress Plate
4. PRE - INSTALLATION ASSESMENT
o4.1. Mechanical
o4.2. Electrical
5. INSTALLATION
o5.1. Mortise Installation
o5.2. Surface installation
6. WIRING
o6.1. Fail Safe connection
o6.2. Fail Secure connection
o6.3. Jumper position
7. OPERATION
o7.1. Fail Safe Operation
o7.2. Fail Secure Operation
8. SPECIFICATIONS
9. MAINTENANCE
10. WARRANTY
11. UPGRADE
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1. DESCRIPTION
The COBALT-mini is a motor driven low voltage electric lock designed to secure commercial and residential doors.
It is supplied with a matching strike plate and due to its small size it is perfect for installing into a mortise for a
concealed solution. The COBALT-mini offers two unique features not commonly found in this style of lock;
1. The ability to ‘pull’ a door in tight against a seal.
2. The ability to release when requested even if there is excessive load on the door.
The bolt pin of the COBALT-mini operates on a cam action which enables the bolt pin to pull a door into place. In
practice as the door closes it may come to rest in a position that is not fully closed, especially if it closing against a
door seal of some type. The COBALT-mini senses when the door is within 8mm of being fully closed and activates
the bolt pin. The bolt pin then rotates out and pulls the door from its resting position to the closed and sealed
position.
With the door secured and locked the COBALT-mini can be given an unlock signal and it will instantly unlock. If the
door is loaded (pre-load) when the unlock signal is given the COBALT-mini will still unlock, even with loads in
excess of 100Kg on the door. Critically the ability of the COBALT-mini to instantly release with excessive pre-load
on the door even occurs in the event of a power failure if the lock is configured as fail safe.
Additional features of the COBALT-mini are;
Multi-voltage input (12-24VDC)
Very low current consumption
Door position and Bolt position monitors
High physical strength –10,000N holding force
Fail safe / fail secure on site conversion with the re-positioning of a single jumper
2. PRODUCT UNBOXED
Along with the COBALT-mini and matching strike there are also 10G
Self Tapping and M5 Machine Screws supplied. Four fitting tabs are
also enclosed and can be used in conjunction with the M5 screws for
recessing the lock or strike plate to metal doors and frames.
The 7 way wire loom supplied is used to ease installation as the wiring
can be done without the lock being installed until the very end.
Wire Loom
Mounting Screws Fitting Tabs Strike Plate Lock

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3. DIMENSIONS
3.1 Lock
3.2 Strike Plate
3.3 Fitting Tab
3.4 Housing
Available separately
3.5 Dress Plate
Available separately

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4. PRE - INSTALLATION ASSESMENT
4.1 Mechanical
The COBALT-mini is designed for mortise installations as this offers a discrete solution as the lock and strike plate
can be embedded into the door and frame. In some instances however mortise installation is not possible so by
utilizing the YD30M housing, surface installation of the COBALT-mini is possible. Whichever installation method is
chosen it is important that the lock and strike plate are aligned correctly. The strike plate has an opening to accept
the bolt pin and centring this opening with the bolt pin will ensure correct operation.
The COBALT-mini can be installed vertically or horizontally but is not designed to be mounted in a floor
cavity firing upwards or in a wet environment.
When installing the COBALT-mini vertically, take note of which way the door is closing from. It the door is
approaching form the left the bolt pin is at the top, if the door is approaching from the right then the bolt pin is at the
bottom, as indicated below:
4.2 Electrical
The first consideration is to establish where to run the wires and decide on what feedback is required from the lock.
There are a total of seven available connections; three are compulsory power connections whilst the remaining four
provide optional door and bolt position feedback. These optional connections can be integrated into access control
or alarm systems to provide full monitoring.
The correct gauge of wire needs to be chosen as voltage drop across the power wires (+ and -) can limit the locks
operation. For all the remaining connections, a lower gauge wire can be used as these are only signal wires. The
following chart shows the maximum distance that the power supply can be away from the lock, assuming the power
supplies output 12VDC or 24VDC:
AWG
AREA (mm2)
MAXIMUM DISTANCE (m)
12VDC
24VDC
24
0.20
7
20
22
0.33
11
32
20
0.52
17
51
18
0.82
27
82
16
1.31
43
130
14
2.08
69
206
Door closing
from the right,
the lock is
installed with
the bolt pin at
the bottom.
Door closing
from the left,
the lock is
installed with
the bolt pin at
the top.

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5. INSTALLATION
Two installation examples are detailed on the following pages; mortise and surface, however any combination of
the two can be achieved. Whichever installation method is chosen it is vital to ensure that the lock face plate
and the strike plate align correctly and the gap between the lock face plate and strike plate does not
exceed 8mm when the door is closed.
5.1 Mortise Installation
A typical mortise installation is described with the lock fitted into the door frame and the strike plate secured into the
door. It is possible to install the lock into the door and the strike plate into the frame however with this method
running wiring to the lock requires additional work.
5.1.1 Cutting the mortises
Referring to the dimension drawings in Section 3;
mortises are cut into the door and door frame
suitable to fit the strike plate and lock. Wooden
doors and frames require full mortises where metal
doors and frames, being hollow, often only require
a single rectangle cut-out to accommodate the lock
face plate or strike plate. For these installations the
supplied fitting tabs can be used to secure the lock
and strike plate in place.
The mortise behind the lock body needs to have
enough space to accommodate the wiring.
5.1.2 Wiring the lock
Wires are run from the power supply to the lock. A
hole needs to be drilled in the back of the mortise
to bring the wires out and a connection can be
made to the supplied wire loom which in turn plugs
into the lock. The jumper needs to be positioned
for fail safe / fail secure configuration as per the
instructions on the lock cover.
The Red, Black and Blue wires are essential
connections whilst the Violet and White are
optional. Detailed wiring instructions are found in
Section 6.
5.1.3 Fitting the lock and strike plate
The lock is slid back into the mortise, making sure
that the wiring integrity is maintained and secure in
place with the supplied 10G self-tapping screws.
Before the strike plate is installed the fitting tabs
are secured in behind the cut-out using the
supplied M5 machine screws. The strike plate is
then placed into the cut out and the remaining M5
screws are used to secure it.
Strike plate
installed in
the door using
the fitting tabs.
Lock secured
directly into
the door frame.
Cut-out in a
wooden door
frame to
accommodate
the lock.
Cut-out in a
metal door to
accommodate
the strike plate.

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5.1.4 Checking the operation
With the lock and strike installed and wiring
complete the door is closed to check the alignment
and operation. The key area for alignment is the
bolt pin; the pin is designed to touch the leading
edge of the strike plate hole to pull the door in, but
it cannot be allowed to touch the sides of the hole
as this will limit its unlocking ability. If its rubs or
touches the side of the strike plate hole, either the
lock or strike plate needs to be re-positioned.
5.2 Surface Installation
By using a YD30M housing, the lock and or strike plate can be surface mounted to the door or door frame
eliminating the need for cutting mortises. Housings are available with adhesive tape supplied for easy application to
glass doors in addition to having screw hole mounting points for wood and metal doors.
5.2.1 Securing the lock housing to wood
Before fitting the housing, determine exactly where
the wiring will enter the housing and drill one or two
8mm holes through the housing wall. Ensure the
holes are on the housing face that goes against
the wooden frame. Push the supplied grommet(s)
into the drilled hole(s). The two 10G Hex head self-
tapping screws supplied with the housing can then
be screwed into the wood but not tightened. The
two keyhole shaped cut outs in the housing fit over
these screw heads which are tightened with a ring
spanner once the housing is in place.
5.2.2 Wiring the lock
Wires are run from the power supply to the lock
through the drilled hole(s) in the housing. A
connection can be made to the supplied wire loom
which in turn plugs into the lock. The jumper needs
to be positioned for fail safe / fail secure
configuration as per the instructions on the lock
cover.
The Red, Black and Blue wires are essential
connections whilst the Violet and White are
optional. Detailed wiring instructions can be found
in Section 6.
Clearance
Bolt pin
Clearance
The bolt pin touches the leading edge of
the strike plate hole but there needs to be
clearance around the sides of the hole.

© BQT Solutions (SEA) Pte Limited Page
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5.2.3 Fitting the lock into the housing
Once wired, the lock is slid into the housing and
secured in place with the supplied M5 machine
screws. Make sure that the wiring integrity is
maintained as the lock is screwed in place.
5.2.4 Fitting the strike plate housing to glass
For simple application to glass the YD30M housing
is supplied with self-adhesive tape. With the
backing removed the housing can be applied
directly to the glass. A flat stainless steel dress
plate is fitted on the opposite side of the glass to
give a clean finish. The protective coating on the
dress plate can be removed once it is in place.
5.2.5 Fitting the strike plate into the housing
The strike plate is placed into the housing and
secured in place with the supplied M5 machine
screws.
5.2.6 Checking the operation
With the lock and strike installed and wiring
complete the door is closed to check the alignment
and operation. The key area for alignment is the
bolt pin; the pin is designed to touch the leading
edge of the strike plate hole to pull the door in, but
it cannot be allowed to touch the sides of the hole
as this will limit its unlocking ability. If its rubs or
touches the side of the strike plate hole, either the
lock or strike plate needs to be re-positioned.

© BQT Solutions (SEA) Pte Limited Page
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6. WIRING
The COBALT-mini is supplied with a 7-way wire loom that plugs directly into the lock. The wires are colour coded
with three being essential connections and four optional. Control of the lock is achieved by using the three power
wires, whilst door and bolt position monitoring are available when desired. Connect the COBALT-mini as per the
chart:
RED
POS
Positive connection to DC power supply (12–24V)
Power
BLACK
NEG
Negative connection to DC power supply (12–24V)
BLUE
CTRL
Switched positive control input
VIOLET
NO
Contacts closed when bolt pins are extended, and
contacts open when bolt pins are retracted
Bolt Position Switch
VIOLET
COM
WHITE
NO
Contacts closed when door is aligned, and contacts
open when door is open
Door Position Switch
WHITE
COM
6.1 Fail Safe Connection
When wiring the COBALT-mini, the positive voltage is connected to RED, negative is connected to BLACK and a
switched positive voltage wire connected to BLUE. In Fail Safe configuration applying voltage to the COBALT-mini
signals it to lock. The lock signal in Fail Safe configuration is active high.
6.2 Fail Secure Connection
When wiring the COBALT-mini, the positive voltage is connected to RED, negative is connected to BLACK and a
switched positive voltage wire connected to BLUE. In Fail Secure configuration applying voltage to the COBALT-
mini signals it to unlock. The lock signal in Fail Secure configuration is active low. .
DC Power Supply
NO - Locked
NC - Unlocked
-
+
WHITE
WHITE
VIOLET
VIOLET
BLUE
BLACK
RED
Wire loom from lock
Bolt Position Switch
Door Position Switch
DC Power Supply
NC - Unlocked
NO - Locked
-
+
WHITE
WHITE
VIOLET
VIOLET
BLUE
BLACK
RED
Wire loom from lock
Bolt Position Switch
Door Position Switch

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6.3 Jumper position
The fail mode of the COBALT-mini is factory set as Fail Safe, i.e. in the event of a power cut the COBALT-mini will
unlock. Before the lock is installed this can be changed to Fail Secure by repositioning the jumper located next to
the 7-way plug on the end of the lock. Select the desired jumper location as indicated:
7. OPERATION
7.1 Fail Safe Operation
Assume the lock is installed and wired, the door is open and there is voltage applied to the BLUE wire. As the door
closes the COBALT-mini senses the door approaching and activates the appropriate bolt pin to pull the door into
centre alignment. Once the first bolt pin has fully extended, the second bolt pin activates and drives to its full
extension. If the door closes to a centre aligned position quickly then both bolt pins activate at the same time rather
than one leading the other. The Bolt Position and Door Position monitors will have changed state as the door is
moved into place and secured.
To unlock the door, voltage is removed from the BLUE wire. The COBALT-mini will immediately release and will do
so even when significant load is being applied to the door. With the door now open the Bolt Position and Door
Position monitors change state again. The COBALT-mini will remain unlocked as long as the door is open but will
instantly re-lock when voltage is applied to the BLUE wire and the door is closed.
In the event of a power failure, voltage is removed from the BLUE wire and the COBALT-mini unlocks.
7.2 Fail Secure Operation
Assume the lock is installed and wired, the door is open and voltage is removed from the BLUE wire. As the door
closes the COBALT-mini senses the door approaching and activates the appropriate bolt pin to pull the door into
centre alignment. Once the first bolt pin has fully extended, the second bolt pin activates and drives to its full
extension. If the door closes to a centre aligned position quickly then both bolt pins activate at the same time rather
than one leading the other. The Bolt Position and Door Position monitors will have changed state as the door is
moved into place and secured.
To unlock the door, voltage is applied to the BLUE wire. The COBALT-mini will immediately release and will do so
even when significant load is being applied to the door. With the door now open the Bolt Position and Door Position
monitors change state again. The COBALT-mini will remain unlocked as long as the door is open but will instantly
re-lock when voltage is removed from the BLUE wire and the door is closed.
In the event of a power failure, voltage is removed from the BLUE wire and the COBALT-mini locks if the door is
closed.
Fail Safe
= Fail Unlocked
= Power To Lock
= PTL
Fail Secure
= Fail Locked
= Power To Open
= PTO
Jumper in Fail Safe position.
Jumper in Fail Secure position.

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8. SPECIFICATIONS
MATERIALS
Bolt Pin
SS17-4PH, 10mm Thick, 13mm extension
Strike Plate
SS304, 3mm Thick
Lock Face Plate
SS304, 3mm Thick
MECHANICAL
Cycle life
> 300,000
Strike Gap
< 7mm
Holding Force
> 10,000N (1000kg)
Side Load Release
> 1,000N (100kg)
Door Misalignment
Up to 8mm
ELECTRICAL
Voltage at Lock
12 –24VDC ±15%
Current Usage
Holding Current
< 50mA@12V
< 30mA@24V
Operating Current
< 250mA@12V
< 200mA@24V
Initial Power Up*
< 1800mA@12V
< 600mA@24V
Monitor Switches
Bolt position –30VDC, 0.1A
Door position –100VDC, 0.5A
CERTIFICATIONS
Patent
Pending PCT/IB2013/053737
FCC
Part 15 Subparts A & B –Unintentional Radiators
CE
EN 61000-6-1: 2007, EMC Directive 2001/108/EC Immunity
EN 61000-6-3: 2007, EMC Directive 2001/108/EC Emissions
*Initial power up of the lock requires up to 1800mA@12VDC and up to 600mA@24VDC for up to 6 seconds but only occurs
when the power has been completely removed for an extended period then re-applied, for example after a power outage.
Normal Operating Current after initial power up is <250mA@12VDC and <200mA@24VDC.
9. MAINTENANCE
The COBALT-mini has been lubricated at assembly and applying any other type of lubricant may void the warranty.
Removing the lock cover may void the warranty. A dry cloth can be used to polish the stainless steel face plate and
strike plate as required.
10. WARRANTY
The COBALT-mini is covered with a manufacturers 12month warranty against faulty or malfunctioning parts,
components or product. At the manufacturer’s discretion, either a replacement lock or affected part will be supplied
to remedy the fault or the lock can be returned at the customer’s expense to the manufacturer for repair.
Mistreatment or ill-use of the lock may void the warranty. COBALT-mini is a trademark of BQT Solutions (SEA) Pte
Limited. BQT Solutions (SEA) Pte Limited will not be liable for any direct, indirect, incidental or consequential loss
or damage in any way related to this product.
11. UPGRADE
The COBALT-mini is designed by BQT Solutions (SEA) Pte Limited and manufactured by BQT Solutions (NZ)
Limited. BQT Solutions (SEA) Pte Limited reserves the right to upgrade or change this product without prior notice.
For more information visit www.bqtsolutions.com

© BQT Solutions (SEA) Pte Limited Page
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NOTES
Version 3.0