Dormakaba PowerPlex 2000 Series User manual

E-Plex 2000 &
PowerPlex 2000
Installation Instructions

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Table of Contents
A. Cylindrical Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
B. Mortise Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
C. Exit Trim Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
D. Installing Outside Lever on Non-Mechanical Override. . 37
Reversing the Outside Lever for Series Without
Mechanical Override . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
F. Installing Optional K-I-L Key or Best Removable Core
Override and Outside Lever . . . . . . . . . . . . . . . . . . . . . . . . . 38
G. Testing the Operations of the Outside Lever. . . . . . . . . . 40
H. Testing the Mechanical Key Override with Change
Key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
I. Changing Lock Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . .42
J. Changing Best-Type Core . . . . . . . . . . . . . . . . . . . . . . . . . . .43
K. Removing and Reassembling the Outside Lever . . . . . . .43
L. Installing Rubber Bumpers . . . . . . . . . . . . . . . . . . . . . . . . . .44
M. Installing Battery Pack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44
N. Testing the Operation of the
Lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . .45
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 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. dormakaba
standard warranty does not cover damages caused by installation.
E.
E-PLEX 2000 & POWERPLEX 2000 Installation Guide KD10113-E-1121

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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
•Battery holder with 3 AA batteries (not included in PowerPlex 2000
versions)
•Drilling templates
•Hardware bag, includes:
-Square spindle
-Phillips screw (6-32 x 5⁄16") (not for PowerPlex 2000 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/PowerPlex 2000 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.
E-PLEX 2000 & POWERPLEX 2000 Installation Guide KD10113-E-1121

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DIAGRAM OF LOCK:
BackFront
(A)
(D)
(B)
(E)
(F)
(G)
(H)
(I)
( )
(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
(C) Nylon washer
(D) Drive tube
(E) Lever catch
(F) Countersink
(G) Outside Lever
(H) Cap (if equipped)
(I) Cylinder (if equipped)
(J) Cylinder plug (if
equipped)
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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 3⁄8" [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.
D
Closing Direction
Left Hand Left Hand Reverse Bevel R
LEFT HAND DOOR
Right Hand Right Hand Reverse Bevel
RIGHT HAND DOOR
L
LH Assembly RH Assembly
Cylindrical Drive Unit Position
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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
-1 -
3⁄8"
1 3⁄8" (35 mm) to
1 9⁄16" (40 mm) (10 mm)
-2 -
1⁄2"
Over 1 9⁄16" (40 mm) to
less than 1 11⁄16" (43 mm) (13 mm)
12 -
5⁄8"
1 3⁄4" (44 mm) DOOR
1 11⁄16 (43 mm) to less than 1 7⁄8"(16 mm)
1- 1
5⁄8"
1 7⁄8" (48 mm) to
1 15⁄16" (49 mm) (16 mm)
2- 1
3⁄4"
Over 1 15⁄16" (49 mm) to
less than 2 1⁄8" (54 mm) (19 mm)
- 1 1 3⁄4"
2 1⁄8" (54 mm) to
2 3⁄16" (56 mm) (19 mm)
21 1
7⁄8"
Over 2 3⁄16" (56 mm)
to 2 3⁄8" (60 mm) (22 mm)
--2
7⁄8"
Over 2 3⁄8" (60 mm)
to 2 1⁄2" (64 mm) (22 mm)
Screws
Cylindrical
Unit
Assembly
05
04
02
Spacers
Attachment
Plate
Correct Position of Spacers
See Table 1
E-PLEX 2000 & POWERPLEX 2000 Installation Guide KD10113-E-1121

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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 spac-
ers and screws included in the hardware
bag.
Door Thickness Table 2
Door Spacer Spacer Screw
Thickness 07 08 length
1 3⁄8" (35 mm) to 1 9⁄16" (40 mm) 2-
3⁄8" (10 mm)
1 5⁄8" (41 mm) to 1 11⁄16" (43 mm) 11
1⁄2" (13 mm)
1 3⁄4" (44 mm) to 1 13⁄16" (46 mm) 21
5⁄8" (16 mm)
1 7⁄8" (48 mm) to 1 15⁄16" (49 mm) -2
5⁄8" (16 mm)
2" (51 mm) to 2 1⁄16" (52.5 mm) 12
3⁄4" (19 mm)
2 1⁄8" (54 mm) to 2 3⁄16" (56 mm) 2 2 3⁄4" (19 mm)
2 1⁄4" (57 mm) to 2 5⁄16" (59 mm) -3
7⁄8" (22 mm)
2 3⁄8" (60 mm) to 2 1⁄2" (64 mm) 13
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
E-PLEX 2000 & POWERPLEX 2000 Installation Guide KD10113-E-1121

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A-4. INSTALLING LOCK HOUSINGS
1. 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.
(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
PowerPlex 2000 versions)
3. Place the outside housing (a) and
cylindrical plate assembly on the
door so that it engages the latch
as shown.
4.
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
a
(outside)
cylindrical
unit
latch
h
p
l
Gasket (not for
PowerPlex 2000
version)
Assembly
Cylindrical Plate
aa
E-PLEX 2000 & POWERPLEX 2000 Installation Guide KD10113-E-1121

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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.
E-PLEX 2000 & POWERPLEX 2000 Installation Guide KD10113-E-1121

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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
(C) Battery holder with 3 AA batteries (not for PowerPlex 2000 versions)
(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 PowerPlex 2000 versions)
Parts inside hardware bag:
(F) Thumbturn (hex) spindle
(G) Square spindle
(H) Phillips screw (6-32X 5/16”) (not for PowerPlex 2000 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”
E-PLEX 2000 & POWERPLEX 2000 Installation Guide KD10113-E-1121

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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
•Philips screwdriver (#2)
•Fine steel file
•Mortising machine
•Router
•Mortise faceplate router template
•Adjustable square
•Tape measure
•Pencil
•Tape
•Cleaning supplies (drop cloth, vacuum)
E-PLEX 2000 & POWERPLEX 2000 Installation Guide KD10113-E-1121

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American Standard Mortise illustrated
A
C
H
B
N
F
D
S
G
J
J
L
I
E
K
B1
D1
C1
A1
E1
E-PLEX 2000 & POWERPLEX 2000 Installation Guide KD10113-E-1121

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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 & POWERPLEX 2000 Installation Guide KD10113-E-1121

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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.
Note: Respect applicable building codes regarding handle height.
b. Mark the locations of the dust box cutout and mounting screws
for the strike.
c. Mortise the door frame to receive the dust box, and drill the pilot
holes for the mounting screws (dimensions and depths marked
on template).
d. Position the strike against the doorframe and align it with the
mounting screw holes. Trace the outline of the strike.
(CL)
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e. Remove material from within the strike outline so that the strike will
be flush with the doorframes.
f. For ASM, install the dust box (optional for wood door frames,
required for metal door frames), and check the strike handing on
the template. Install the strike using the screws provided. Use
wood screws for wood frame and machined screws for steel
frames.
Note: When strike is installed on wood frames under one inch thick,
wood screws supplied are not adequate. Use screws of efficient
length to engage the structural stud behind the frame. Use only
the strike and dust box supplied. Use of non-approved parts may
void the warranty.
E-PLEX 2000 & POWERPLEX 2000 Installation Guide KD10113-E-1121

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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”.
Proceed to step c.
1/4”
H
D
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For Autodeadbolt ASM, rotate hub (H) until the deadbolt (D) is fully
retracted. The deadbolt will extend approx. 1/16” from the mortise case.
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.
Release the deadbolt (D) gently. It should extend to 5/16” approx. and
stop. If the deadbolt extends past this point, gently press it in until it
locks at 5/16” throw, or start step b again.
D (hold gently)
X (press nd rele se)
D
5/16”
D
1/16”
H
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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)
Hold the latch (L) inside the mortise, and insert the tailpiece
retaining tool (S, part #027-510382 or #041-513342 available
separately) so that the tailpiece (T) will not drop inside the mortise
case. Hold the tool and the latch with one hand, and slide up the
tailpiece using a small screwdriver.
Continue to hold tool (S). Release the latch bolt (L) and keep the
anti-friction latch (F) toward the flat side of the latch bolt so
that the bolt extends fully.

12
Use a small screwdriver
to lift unlock mechanism.
Unlock PositionLock Position
Push in the latchbolt to the
end of the stroke, and hold
it there.
LL

L
T
S
(part #027-510382)

L
F
S
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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.)
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). There may be some play required to
align the parts. Remove the tool (S).
Release the latch to the middle of the stroke and hold it there.
Use a small screwdriver to push the lock mechanism back on
lock position (see step 1 and 2) .
Note: The lock mechanism has to be horizontal on lock position

L
180°

L

L
T
S
E-PLEX 2000 & POWERPLEX 2000 Installation Guide KD10113-E-1121