DOM Sigma Plus User manual

EDV
-
Nr. 29806
1
/ 0 / gb / 08.09 Rev. D
Assembly Instructions
Key system
Sigma Plus
(Profile 145)

Notes

Sigma Plus Contents
1
Contents
PROD CT DESCRIPTION......................................................................................... 3
YO R SAFETY .......................................................................................................... 4
Important Notes........................................................................................................ 4
SCOPE OF DELIVERY .............................................................................................. 5
PREPARATION.......................................................................................................... 6
Tools ........................................................................................................................ 6
Service box .............................................................................................................. 7
ASSEMBLY................................................................................................................ 8
Preparation of assembly superstructure...................................................................
Filling of cylinder body............................................................................................ 13
Filling of cylinder core............................................................................................. 21
Insertion of the cylinder core into cylinder body ..................................................... 24
Type 333 ................................................................................................................ 25
Type 333H.............................................................................................................. 27
Type 333T .............................................................................................................. 2
Type 333K.............................................................................................................. 31
Type 333KL............................................................................................................ 34
Type 382 ................................................................................................................ 37
Type 555 ................................................................................................................ 3
Type 777 ................................................................................................................ 41
MAINTENANCE ....................................................................................................... 43
STORAGE/MAINTENANCE..................................................................................... 43
DISPOSAL ............................................................................................................... 43
TECHNICAL DATA SIGMA PL S........................................................................... 44

Contents
2
WARRANTY............................................................................................................. 46
WORKSHEET .......................................................................................................... 47

Sigma Plus Product Description
3
Product Description
The Sigma Plus system offers a high degree of flexibility, as many different locking
combinations can be obtained with the 6 sprung locking element pairs.
You can use one key to open everything – from front door to briefcase, from garage
door to window handles. You can also subsequently obtain additional cylinders for
your new Sigma Plus system, which you can open with your Sigma Plus key.
If required, we can also offer the Sigma Plus system in a modular design, to provide
an additional increase in the break-off values and length flexibility.
DOM Sigma Plus is perfectly suited for the use in (general) master key systems or
central lock (master key) systems.

Your Safety/Important Notes
4
Your Safety
Always comply with the instructions and security statements!
In this assembly instructions, several sections are marked by graphical symbols.
Please memorise the graphical symbols and their meanings:
Caution! This symbol marks a danger note and/or refers to an action that
may cause damage to the mechanical cylinder or other objects.
Note! This symbol refers to useful information on assembly or operation.
Important Notes
Caution! Keep the mechanical cylinder and its components away from
small children. They might swallow small parts.
Caution! Material damage caused through incorrect storage. If you store
mechanical cylinders for a longer period of time before assembly, store
all components dry and dust-free in the original packaging.
Caution! Damage caused through inexpert assembly. Please read these
instructions completely and carefully before assembly. Follow the instruc-
tions step by step. The manufacturer accepts no liability for damage re-
sulting from an inexpert assembly.
Caution! Defects caused by untrained personnel! Only extensively
trained personnel are allowed to assemble DOM cylinders. The manufac-
turer disclaims liability for any defects caused by untrained personnel.

Sigma Plus Scope of delivery
5
Scope of delivery
For each Sigma Plus contract you will receive the following documents:
1. Service card / Identification card
2. Client worksheet
3. Encoded worksheet
4. Table of assembly superstructure of the cylinder
5. Supplementary sheet for high-level keys
To fabricate spare cylinder and spare keys please use the coded worksheet, tables
of assembly superstructure of the cylinder and supplementary sheet for high-level
keys.
The principal of the locking system will receive service card and client’s worksheet.
Note! The principal of the locking system shall assure safe storage of the
service card at a place where only authorized persons have access to.

Preparation/ Tools
6
Preparation
To ensure professional assembly you will need the assembly superstructure; the
proper core and body pins and the proper tools.
Caution! Damage caused through inexpert assembly. Please read these
instructions completely and carefully before assembly. Follow the instruc-
tions step by step. The manufacturer accepts no liability for damage re-
sulting from an inexpert assembly.
Caution! Defects caused by untrained personnel! Only extensively
trained personnel are allowed to assemble DOM cylinders. The manufac-
turer disclaims liability for any defects caused by untrained personnel.
Tools
Caution! Defects caused by applying improper tools!
The tool DOM Sicherheitstechnik provides for cylinder assembly is tuned
to all requirements of professional assembly. The manufacturer disclaims
liability for any damages or defective assembly caused by the application
of other tools.
You need the following tools:
123
45
7
8
6
Fig. 1: Tools
1: assembly clam (40026 )
2: loading knife (261674)
3: follower (26600 )
4: assembly clam for type 382
(405634)
5: pliers for cam type KL (265776)
6: Assembly bushing (266674)
7: pliers for extension piece (26166 )
8: pliers for cam (26362 )

Sigma Plus Preparation/ Service box
7
Service box
DOM Sicherheitstechnik has compiled an service box for system Sigma Plus that
contains all necessary sorts of pins (body pins, core pins) as well as masterkey wa-
fers. You may order this service box directly via DOM Sicherheitstechnik. Thus you
are always well equipped with all tools and necessary pins.
Note! This service box also exists for other systems, e.g. for ix 6 KG,
Diamant, etc..
Core pins
N
N
N
N
No. 0
No. 1
No. 2
No. 3
4,85 mm
5,25 mm
5,65 mm
6,05 mm
509254 112
509255 112
509256 112
509257 112
AB
AB
AB
AB
No. 4
No. 5
No. 6
No. 7
6,45 mm
6,85 mm
7,25 mm
7,65 mm
509259 112
509260 112
509261 112
509262 112
Cam
End piece
Cam
Cam
Coupling
Coupling
half
half
standard
double entry
standard
double entry
new design
218426 008
204217
218228 008
235855 008
502154
235860
Body pins
N
N
FB
FB
No. 0, 1, 2, 3
No. 4, 5, 6, 7
No. 0, 1, 2, 3
No. 4, 5, 6, 7
5,5 mm
4,5 mm
5,5 mm
4,5 mm
509264 112
509265 112
509268 112
509269 112
H
H
H
H
No. 0, 1
No. 2, 3
No. 4, 5
No. 6, 7
5,6 mm
4,6 mm
3,6 mm
3,1 mm
509271
509272
509273
509274
Masterkey
Masterkey
Masterkey
Profile pin
Spring
Spring
Security ring
wafers
wafers
wafers
RD 2,7 x 14
V2A
0,8 mm
1,6 mm
2,4 mm
V2A
382, 393
1,0 mm
509250
509251
509252
509276
333, 555, 777
243515
202335F
242172
The box contains single compartments where you can sort in pins. The following fig-
ure shows how the wrapped pins are sorted in the service box ex works.
Note! A list of contents is part of the service box. You may make use of
the sequence of pins according to the list of contents to avoid confusion.
Note! The assembly tools may be delivered together with the service box
on your explicit order.

Assembly
8
Assembly
Please follow the stated order and pay attention to the notes and figures.
Caution! For assembly please use only the special tool that is described
in the assembly steps. Manufacturer disclaims liability for any defects
caused by application of inappropriate tools.
Note! Please use a soft pad for assembly, such as a foam rubber. Thus
you ensure that no pins drop out of the cylinder core when placing the
core into the body.
Note! All material numbers for common spare parts are specified to-
gether with the respective step of assembly.
At first all common steps of assembly that apply for all types of cylinders will be de-
scribed in the assembly instructions. So at first basic handling of the assembly su-
perstructure, body filling, core filling and core fitting into body are specified. Subse-
quently each step of assembly will be described. These apply for the respective type
of cylinder only.

Sigma Plus Assembly /Assembly without/with masterkey wavers
Preparation of assembly superstructure
For each Sigma Plus contract you receive a sheet with tables of assembly super-
structures of the cylinders. If positions of core and body pins are not stated in the ta-
ble ex works please enter the pins in the table.
The following shall apply:
The FB body pins may only be assembled at the first five positions, maximally 2
at each side of the cylinder.
FB body pins are assemble to the positions with the lowest values. In case of su-
perstructures (master key system), the lowest value including the superstructure is
considered.
Only N pins are available as core pins for the lengths of 0, 1, 2, 3, and for the
lengths 4, 5, 6, 7 only AB pins are available. There is no restriction of the positions
for core pins. The core pins are applied at positions P1 – P6 depending on their
lengths.
Assembly without masterkey wafers
Body pins
4 5 1 2 3 5
FB FB
P1 P2 P3 P4 P5 P6
4 5 1 2 3 5
N N FB FB N N
P1 P2 P3 P4 P5 P6
1.) At first the two FB-body pins are inserted at
the positions P1 – P5 with the lowest val-
ues.
(here: position P3=value 1 and P4=value 2)
2.) N-pins are inserted at the remaining posi-
tions.

Assembly /Preparation of assembly superstructures
10
Assembly with masterkey wafers
Body pins
4 5 1 2 3 5
3 4 5
6 7
P1 P2 P3 P4 P5 P6
4 5 1 2 3 5
3 4 5
6 7
FB N FB N N N
P1 P2 P3 P4 P5 P6
4 5 1 2 3 5
3 4 5
6 7
FB N FB N N N
P1 P2 P3 P4 P5 P6
For assembly superstructures with masterkey
wafers the highest plate structure determines the
body pin as stated in the lower cells of the re-
spective columns.
1.) At first the two FB-body pins are inserted at
the positions P1 – P5 with the lowest val-
ues in the lowest cells.
(here: position P1=value 4 and P3=value 3)
2.) N-pins are inserted at the remaining posi-
tions P2, P4, P5 and P6.

Sigma Plus Assembly /Assembly without/with masterkey wavers
11
Assembly without masterkey wafers
Note! Only N pins are available as core pins for the lengths of 0, 1, 2, 3,
and for the lengths 4, 5, 6, 7 only AB pins are available.
Core pins
AB AB N N N AB
4 5 1 2 3 5
P1 P2 P3 P4 P5 P6
The core pins are applied at positions P1 – P6
depending on their lengths.
here: Position P1, P2 and P6: AB-pin;
Position P3, P4 and P5: N-pin
Assembly with masterkey wafers
Core pins
AB AB N N N AB
4 5 1 2 3 5
3 4 5
6 7
P1 P2 P3 P4 P5 P6
For assembly superstructures with masterkey
wafers the values of core pins are shown in the
upper cells. Assignment of pins is done similar
to assembly superstructures without masterkey
wafers. (see above)

Sample lockings
12
Sample lockings without masterkey wafers
core
N AB N N N AB
0 4 1 2 2 6
FB N FB N N N
P1 P2 P3 P4 P5 P6
body
There is no restriction of the positions for core
pins. Therefore, an AB pin is applied at position
P6 depending on length.
Sample lockings with masterkey wafers
core
N AB AB AB AB N
3 4 7 5 6 3
5
FB FB N N N N
P1 P2 P3 P4 P5 P6
body
If two values of the body pins are equal (here:
length 5 on pos. P1 and P4), the FB body pin
must be inserted at the first possible position.
(here at pos. P1)

Sigma Plus Assembly / Filling of cylinder body
13
Filling of cylinder body
Note! Depending on the length of the locking sides, two different core
lengths are applied: core 0 (50 425) and core 5 (50 426). Compared
with core 0, core 5 is 5 mm longer. In case of a cylinder which deviates
from the standard sizes, you must insert a core extension piece with cyl-
inder pin, if necessary.
Double cylinder (standard)
A
B
A
B
A
B
30 30 0 0 --- ---
35 30 5 0 --- ---
40 30 0 0 203643 ---
45 30 0 0 203644 ---
50 30 0 0 203645E ---
55 30 0 0 203643+44 ---
60 30 0 0 203643+45E ---
65 30 0 0 203644+45E ---
70 30 0 0 203647E ---
35 35 5 5 --- ---
40 35 0 5 203643 ---
45 35 0 5 203644 ---
50 35 0 5 203645E ---
55 35 0 5 203643+44 ---
60 35 0 5 203643+45E ---
65 35 0 5 203644+45E ---
40 40 0 0 203643 203643
45 40 0 0 203644 203643
50 40 0 0 203645E 203643
55 40 0 0 203643+44 203643
60 40 0 0 203643+45E 203643
45 45 0 0 203644 203644
50 45 0 0 203645E 203644
55 45 0 0 203643+44 203644
50
50
0
0
203645E
203645E
2115 0 2115 0
2115 0 21158
2115 1 21158
2115 2 211588
21158 21158
2115 0 211588
2115 1 211588
2115 3 211587
211588
21158 211588
2115 0 211587
211587
2115 2 211587
211587 211587
211587
21158 211587
Cylinder pin
standard
A B
--- ---
211587 ---
211588
21158
2115 0
2115 3
211588
2115 1
211588
Lock side Core
(mm)
Core extention
2115 1
2115 2
---
---
---
---
---
---
2115 4 ---

Assembly / Filling of cylinder body
14
Double cylinder (double entry)
A
B
A
B
A
B
30 30 0 0 --- ---
35 30 5 0 --- ---
40 30 0 0 203643 ---
45 30 0 0 203644 ---
50 30 0 0 203645E ---
55 30 0 0 203643+44 ---
60 30 0 0 203643+45E ---
65 30 0 0 203644+45E ---
70 30 0 0 203647E ---
35 35 5 5 --- ---
40 35 0 5 203643 ---
45 35 0 5 203644 ---
50 35 0 5 203645E ---
55 35 0 5 203643+44 ---
60 35 0 5 203643+45E ---
65 35 0 5 203644+45E ---
40 40 0 0 203643 203643
45 40 0 0 203644 203643
50 40 0 0 203645E 203643
55 40 0 0 203643+44 203643
60 40 0 0 203643+45E 203643
45 45 0 0 203644 203644
50 45 0 0 203645E 203644
55 45 0 0 203643+44 203644
50
50
0
0
203645E
203645E
Halve cylinder
511242 + 24 75
511242 + 24 75
511242 + 24 75
511242 + 2462 1
511243
511243
511243
511243
511242
511242
511242
511243
511242
511242
511242
511242
511242 + 2462 1
---
---
---
---
---
---
---
---
---
511242 + 2462 3
511242 + 24 75
511242 + 2462 1
511242 + 2462 2
511243
511242 + 24 75
511242 + 2462 1
511242 + 2462 2
511242 + 2462 1
511242 + 2462 2
511242 + 2462 3
511242 + 2462 4
511242 + 2462 5
511242
511243
511242 + 24 75
511242 + 2462 1
511242 + 2462 2
511242 + 2462 3
511242 + 2462 4
---
511242
511243
511242 + 24 75
A B
Cylinder pin
double entry
50 0 203645E
45 0 203644
40 0 203643
35 5 ---
30 0 ---
Length Core Core extention
(mm)
(mm)
Lock side Core Core extention

Sigma Plus Assembly / Filling of cylinder body
15
Fig. 2: Insert extension piece
1. If necessary please insert a core
extension piece with the appropriate
cylinder pin.
Note! Please hold the table of assembly superstructure ready. The body
pins are always stated in the last cell of a column. The following table of
assembly superstructure shows the body pins highlighted in grey.
Body pins
0 3 1 4 1 6
2 5
4 5
6
Example
N N FB
FB
N N
P1 P2 P3 P4 P5 P6
Type 382
H H H H H H
Body pin N:
0 – 3: 50 264 112 = 5,5 mm
4 – 7: 50 265 112 = 4,5 mm
Body pin FB:
0 – 3: 50 268 112 = 5,5 mm
4 – 7: 50 26 112 = 4,5 mm
Body pin H:
0: 50 271 = 5,6 mm
1: 50 271 = 5,6 mm
2: 50 272 = 4,6 mm
3: 50 272 = 4,6 mm
4: 50 273 = 4,1 mm
5: 50 273 = 4,1 mm
6: 50 274 = 3,1 mm
7: 50 274 = 3,1 mm
Note! When using hollow body pins (type 382) the corresponding N and
FB-body pins are inapplicable.

Assembly / Filling of cylinder body
16
Caution! Position and number of pin types are prescribed:
FB-body pins: On each lock side two FB-body pins are inserted. FB-
pins may only be assembled at positions P1 – P5. The FB-body pins
have to be inserted on the positions with the lowest values (here P3
and P4).
N-body pin: On each lock side at least four N-body pins are inserted.
Note! The pins mentioned in the table, read from left to right, have to be
inserted on the follower from inside to outside.
inside
6
N
5
N
1
FB
4
FB
5
NN
6
outside
Fig. 3: Cylinder assembly superstructure
body pins
2. Please select the necessary body
pins.
Fig. 4: Filling of follower
3. Please insert the body pins into
follower correspondingly to the de-
fined position.
4. Please apply compression springs
(242172) on the pins.
5. Using the loading knife, insert the
springs into the follower to such an
extent until the knife provides flush
fit with the follower.

Sigma Plus Assembly / Filling of cylinder body
17
Caution! Material defects caused by improper insertion of the follower! If
the follower is inserted too far/not far enough into the cylinder body the
compression springs might be damaged.
Note! When mounting type KL you must assemble the long side,first.
Fig. 5: Insert follower together with
loading knife into the cylinder body
6. Please insert the follower incl.
loading knife carefully into the cyl-
inder body to such an extent until
the front edge of the follower pro-
vides approx. flush fit with the in-
ternal body edge (base length 30
mm) or the retainer ring device (ex-
tended version).
Springs and pins overlap the boring in
the cylinder body a little.
180°
Fig. 6: Turning follower together with load-
ing knife
7. Please turn follower incl. knife to
such an extent until the mounting
is positioned over the borings in
the cylinder body.

Assembly / Filling of cylinder body
18
Fig. 7: Pulling out loading knife
8. Please pull out the loading knife.
. Please turn follower carefully back
and forth until body pins are in-
serted into the respective core bor-
ings.
Fig. 8: Reinsertion of loading knife above
the pins
10. Please reinsert loading knife care-
fully above the pins.