Kaba Mas Auditcon 52R User manual

The installation instructions are the basis for Security Agency Approvals.
The lock installation must be done in accordance to these instructions
in order to maintain the labeled approval level.
Design Parameters for Auditcon 2 Series Locks
1. Bolt dimensions (nominal): .312 inches x 1.000 inches/8 x 25.4mm
2. Bolt movement (nominal) : .465 inches/11.8mm
3. Bolt extension: .465 inches/11.8 mm
4. Maximum load movable by the bolt: 5 lbs. (22N)
Note: Auditcon 2 dead bolt locks may not open if more than 5 lbs.
(22N) of force is applied to the end or side of the bolt.
5. Maximum load against bolt when thrown (all directions): 224.8 lbs. (1kN)
6. The lock can be fitted to safes or vault doors of any material.
Note: As is the case with all mechanical and electronic locking devices,
the container and boltworks must be designed to protect the lock.
Installation Instructions for Auditcon
®
2 Series Locks - Models 52R, 252R, 552R - Round Housing Dead Bolt
Document # 3047.025 Rev. B - 12/06
Figure 1 - Dead Bolt Lock Parts
Dial Assembly
Cable
Cable
Shields (2)
Lock Case
Assembly
Lock Case
Mounting
Screws (4)
Dial
Assembly
Mounting
Screws (2) Spindle &
Tube
Spindle
Mounting
Screw
Keypad
Assembly
with Decal
Part I: Install Lock Case Assembly
WARNING: Do not take the lock case assembly apart. There are
no field servicable parts inside lock case.
1. Insert a cable shield into the deburred spindle hole from the back
side of the container door.
2. Place the protective tube over the
tube retainer on the lock case. (Figure 2)
3. While holding the lock case assembly,
guide the tube through the spindle hole
and place the lock case flush against the
inside of the container door.
4. Mark the tube flush to the outside of
the container door (to within 1/16” or
1.6mm).
5. Remove lock case assembly from door
and cut the tube just inside your mark.
6. Plug one end of the ribbon cable into
the connector on the bottom of the lock
case. (Figure 3)
7. Lay the ribbon cable in the cable
routing path on the lock case and tape
the cable to the outside of the tube with
the insulator tape provided. (Figure 3)
8. Hold the lock case assembly and carefully guide the loose end of
the ribbon cable and the tube through the spindle hole so that they are
accessible outside of the container door.
9. Mount the lock case assembly to the inside of the container door
using the four 1/4-20 (or M6-1) lock case mounting screws. (Torque 25-
30 lbs., 2.8-3.4 N-M)
Note: It is recommended that you use Loctite
®
262 (Red) on the lock
case mounting screws.
10. 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 to extend the bolt and
ensure that the grooves are facing toward the bolt.
11. Mark the spindle shaft 3/8” (9.5mm)
from the outside of the container door
(plus or minus 1/16” or 1.6mm allowed).
(Figure 4)
12. Remove the spindle from the lock
case to prevent damage to the cable
while cutting.
13. Cut the spindle on the mark and
deburr.
14. Re-insert the spindle. Refer to Step 10 for proper positioning.
Figure 4
Basic Tools and Materials Needed
• Medium Phillips head screwdriver (#2)
(recommend magnetized tip)
• 9/64” Allen Wrench
• Fine pitch hacksaw (32 teeth/inch)
• Small flat file
• All-purpose scissors
• Tape measure or ruler
• ESD wrist band
Recommended, but not required:
• Torque screwdriver (30 inch-pounds/3.4
newton-meters capacity)
• Small vise grip
• Loctite®262 (Red) for use on lock case
mounting screws
WARNING: Kaba Mas locks are protected
from 25,000 V Electrostatic Discharge
(ESD) damage when correctly installed.
Follow these precautions to avoid ESD
damage when installing the lock:
• Handle the keypad assembly by the
outer edge only.
• Use an ESD wrist band grounded to the
lock or container during installation.
Prepare for New Installation of the Lock (If Required)
1. Use the template provided to establish the exact locations
(relative to the spindle hole) of the mounting holes for the lock
assembly.
2. The spindle hole diameter can be a minimum of .406” (10.3mm) to
a maximum of .438” (11.1mm). The .406” (10.3mm) diameter is
recommended. Spindle hole must be deburred.
3. The dial assembly mounting screws require drilled and tapped
holes to 3/8” (9.5mm) depth if possible (minimum 1/4” or 6.4mm
depth required.) Drill either the two horizontal mounting holes or the
two vertical holes.
4. When mounting the lock unit (i.e., integrating it in a boltwork),
make sure that the lock bolt has clearance to freely move to its end
positions and that the shifting force works only in the axial direction
(direction of movement). Lateral forces should not be exerted on the
lock.
5. If other parts of the boltwork are to be connected to the lock unit
(e.g., for activating a blocking device), corresponding adapters can
be fixed with screws (#10-32 or M4) to the front of the lock bolt
(tightening torque for 15mm screwing depth: 200Ncm maximum).
Figure 2
Figure 3
Not Shown in Photo: InsulatorTape

15. Insert the second cable shield into
the spindle hole from the front of the
container with the cable feeding
through the center of it. (Figure 5)
Part II: Install Front Housing Assembly
1. Hold the dial assembly in the
upright position. (Red area on the
dial assembly should be at top of
dial). The lip on the dial should
be positioned to cover the red
area.This is referred to as the
“HOME” position. (See correct dial
position in Figure 6.)
2. Guide the ribbon cable
through the appropriate cable
receiving hole, based on the
orientation of the ribbon cable to
the spindle. (Figure 7).
3. Align the dial assembly with
the mounting holes and spindle,
and position against the outside
of the container door.
Caution: Do not turn the dial at
this time as you could damage
the cable.
4. While holding the dial
assembly in place, attach it to the
container door using the two #8-
32 dial assembly mounting
screws and the 9/64” Allen
wrench. Tighten the screws
(Torque 17-20 lbs., 1.9-2.25 N-M)
and then ensure that the dial
turns smoothly. (Figure 8)
5. While holding the dial in place,
insert the #6-32 spindle mounting
screw through the back of the
lock case and into the end of the
spindle. (Figure 9) Turn the screw
until it is securely attached to the
spindle. (Torque 14-16 lbs., 1.6-
1.8 N-M)
6. Insert the 4-pin generator
cable on the dial assembly into
the 4-pin connector on the back
of the keypad assembly. The
generator cable will only connect
to the keypad assembly in one
orientation. (Figure 10)
7. Insert the keyed Picoflex
connector on the end of the
ribbon cable into the connec-
tion header on the keypad.
(Figure 11)
8. Position the generator cable
and the ribbon cable around
the generator in a counter-
clockwise direction to ensure
that the cables will not be
pinched when you attach the
keypad assembly. (Figure 12).
9. Orient the lip of the dial to the
HOME position.
Caution Next Step: Once the
keypad assembly is snapped into
place, it cannot be easily
removed without performing an
“uninstall” procedure. Do not
snap the keypad assembly into
place when performing the next
step.
10. Align the keypad assembly
in the upright position and
carefully insert the two catches
on the keypad assembly into the
notches on the dial assembly, but
do not snap the keypad
assembly into place. (Figure 13)
11. Test the operation of the
lock before completing the
installation of the keypad
assembly by verifying the
following:
Note: If the keypad is not
oriented correctly, you can
remove the keypad and adjust
the orientation of the dial
assembly.
• Power the lock by turning the
dial back and forth 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 and key in the
Factory Combination. (For a Model 52 or T52, enter “502550”. For a
Model 252 or 552, enter a two-digit number in the range from 01-20,
followed by “502550”.) If the combination is entered successfully, one
green flash displays to indicate the lock is ready to open. To open,
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
retract the bolt within 4-6 seconds.
Figure 8
© 2005-2006 Kaba Mas Corporation. All rights reserved.
Product warranty information can be found at: www.kaba-mas.com
Kaba Mas Corporation
749 W. Short Street, Lexington, KY 40508 USA
Phone: [phone] FAX: [phone]
Customer Service: [phone]
Figure 9
Figure 14
Uninstall Keypad Assembly
1. Remove the decal from
the keypad assembly.
2. Insert a flat head
screwdriver into the slot in
the upper left hand corner of
the keypad to release one of
the two keypad catches.
(Figure 14)
3. Carefully pull the keypad
assembly out from the dial
assembly.
4. Check for pinched or
poorly connected cables.
Figure 12
HOME: Red
portion is not
showing
Figure 6
Figure 7
Figure 11
Figure 10 12. After successfully testing lock operation and verifying that none of
the cables will be pinched, snap the keypad assembly into place.
13. Test the operation of the lock again. If the lock does not operate
properly, refer to the following instructions to “Uninstall Keypad
Assembly”.
14. If your lock includes the Battery Assist option, you should now
mount the battery clip inside the door near the lock and install a fresh
9 Volt Alkaline battery.
Note: To remove any excess
cable or if you choose not to use
the Battery Assist option, wrap
and tie the battery assist cable.
(Figure 14) If you do not ever
plan on using the Battery Assist
option, you can cut the cable
next to the lock case to remove it.
Figure 13
Cable
receiving
holes
Cable
Shield
Figure 5
Tube
Spindle
Ribbon
Cable
Figure 14

The installation instructions are the basis for Security Agency Approv-
als. The lock installation must be done in accordance to these
instructions in order to maintain the labeled approval level.
In order to maintain VdS Class 2/EN 1300 Class B lock approval levels
in a container where multiple locks are required, special considerations
must be observed. The Auditcon 2 Series lock must be the first one
secured by the boltworks. Check the locked status of the container with
the handle of the boltworks.
Design Parameters for Auditcon 2 Series Locks
1. Bolt dimensions (nominal): .312 inches x 1.000 inches/8 x 25.4mm
2. Bolt movement (nominal) : .465 inches/11.8mm
3. Bolt extension: • Square Nose Slide Bolt is .465 inches/11.8mm
• Roller Slide Bolt is .495 inches/12.6mm
4. Maximum load movable by the bolt: None
Note: Auditcon 2 slide bolt locks will not open if force is applied to the
end or side of the bolt.
5. Maximum load against bolt when thrown (all directions): 224.8 lbs.(1kN)
6. The lock can be fitted to safes or vault doors of any material.
Note: As is the case with all mechanical and electronic locking devices,
the container and boltworks must be designed to protect the lock.
Installation Instructions for Auditcon
®
2 Series Locks - Models 52R, 252R, 552R - Round Housing Slide Bolt
Figure 4
.136 MIN. CLEARANCE
.458
.216 CORRECT LOCATION FOR BOLT WORKS
.062 MIN. CLEARANCE.
.465
STRIKE
STRIKE OPENING
SUFFICIENT
TO CLEAR A 1 INCH BOLT
.136 in. MIN. CLEARANCE
.062 in. MIN. CLEARANCE
RADIUS
STRIKE
REVERSE
ANGLE
STRIKE
CONTACT POINT
IS NOT ALLOWED
TO BE BEHIND
ROLLER CENTER LINE
FORWARD
ANGLE
STRIKE
STRAIGHT
STRIKE
.300 in. REFERENCE
CASE TO CENTER LINE
0.000 TO .080 in. MAX
RECOMMENDED
STRIKE
CONTACT POINT
STRIKE
CONTACT POINT
BEHIND ROLLER
CENTER LINE
ALLOWED
ROLLER CENTER LINE
NOT ALLOWED
ROLLER CENTER LINE
STRIKE
CONTACT
POINT
STRIKE
CONTACT
POINT
15° MAX
.495
STRIKE
Figure 3 - Roller Slide Bolt Clearances, StrikeTypes & Contact Points
Basic Tools and Materials Needed
• Medium Phillips head screwdriver
(#2) (recommend magnetized tip)
• 9/64” Allen Wrench
• ESD wrist band
Recommended, but not required:
• Torque screwdriver (30 inch-
pounds/3.4 newton-meters
capacity)
• Loctite®262 (Red) for use on lock
case mounting screws
WARNING: Kaba Mas locks are
protected from 25,000 V
Electrostatic Discharge (ESD)
damage when correctly installed.
Follow these precautions to
avoid ESD damage when
installing the lock:
• Handle the keypad assembly
by the outer edge only.
• Use an ESD wrist band
grounded to the lock or container
during installation.
Figure 2 - Square Nose Slide Bolt Clearances and Positioning
Document # 3048.025 Rev. B - 12/06
Dial Assembly
Cable
Lock Case
Assembly
Lock Case
Mounting
Screws (3)
Dial
Assembly
Mounting
Screws (2)
Keypad
Assembly
with Decal
Figure 1 - Slide Bolt Lock Parts
Prepare for New Installation of the Lock
(If Required)
1. Using the lock parts along with the template
provided, establish the exact location for the drilled
and tapped holes.
Caution: The lock case must be mounted exactly
according to the template if mounted over the cable
routing hole. Otherwise, the lock case must be mounted
so that no part of the case covers the cable routing
hole.
2. The spindle hole diameter can be a minimum of
.406” (10.3mm) to a maximum of .438” (11.1mm).
The .406” (10.3mm) diameter is recommended.
Spindle hole must be deburred.
3. The dial assembly mounting screws require
drilled and tapped holes to 3/8” (9.5mm) depth if
possible (minimum 1/4” or 6.4mm depth required.)
Drill either the two horizontal mounting holes or the
two vertical holes.
4. When mounting the lock unit (i.e., integrating it
in a boltwork), make sure that the lock bolt has
clearance to freely move to its end positions and
that the shifting force works only in the axial
direction (direction of movement). Lateral forces
should not be exerted on the lock. A minimum
clearance of 1/16” (1.6mm) is required between the
bolt roller/nose and the inside edge of the strike.
Refer to Figures 2 and 3.

Part I: Install Front Housing Assembly
1. Route the end of the lock
cable with the Picoflex connector
from the back of the container
door through the cable routing
hole so that approx. 6 1/2”
(165.1mm) of the cable is
available from the front. (Figure
4)
2. Hold the dial assembly in the
upright position. (The generator
cable should be positioned at
approximately one o’clock.)
(Figure 5)
3. Guide the ribbon cable
through the cable receiving hole.
(Figure 6).
4. Align the dial assembly with
the mounting holes, and position
against the outside of the
container door, ensuring that 6
1/2” (165.1mm) of cable is still
available from the front.
5. While holding the dial
assembly in place, attach it to
the container door using the two
#8-32 dial assembly mounting
screws and the 9/64” Allen
wrench. Tighten the screws
(Torque 17-20 lbs., 1.9-2.25 N-M)
and then ensure that the dial
turns smoothly. (Figure 7)
6. Insert the 4-pin generator
cable on the dial assembly into
the 4-pin connector on the back
of the keypad assembly. The
generator cable will only connect
to the keypad assembly in one
orientation. (Figure 8)
7. Insert the keyed Picoflex
connector on the end of the
ribbon cable into the connection
header on the keypad. (Figure 9)
8. Position the generator cable
and the ribbon cable around the
generator in a counter-clockwise
direction to ensure that the
cables will not be pinched when
you attach the keypad assembly.
(Figure 10)
Caution Next Step: Once the
keypad assembly is snapped into
place, it cannot be easily
removed without performing an
“uninstall” procedure. Do not
snap the keypad assembly into
place when performing the next
step.
9. Align the keypad assembly in
the upright position and
carefully insert the two catches
on the keypad assembly into the
notches on the dial assembly, but
do not snap the keypad
assembly into place. (Figure 11)
10. Plug the RJ11 end of the cable into the lock case in order to test
the lock.
11. Test the operation of the lock before completing the installation
of the keypad assembly by verifying the following:
Note: If the keypad is not oriented correctly, you can remove the
keypad and adjust the orientation of the dial assembly.
• Power the lock by turning the dial back and forth 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 52
or T52, enter “502550”. For a Model 252 or 552, enter a two-digit
number in the range from 01-20, followed by “502550”.) If the
combination is entered successfully, continuous green flashes display
to indicate that the lock is ready to open. Rotate the container handle
to unlock. Then rotate the handle back to the locked position.
Note: After correctly entering a valid combination, you must
retract the bolt within 4-6 seconds.
12. Unplug the RJ11 end of the cable from the lock case and lay the
case aside.
13. After successfully testing lock operation and verifying that none
of the cables will be pinched, snap the keypad assembly into place.
Part II: Install Lock Case Assembly
WARNING: Do not take the lock case assembly apart. The lock
will not operate if the back cover has been removed.
1. Ensure that the cable lays in the cable channel as you mount the
lock case assembly to the inside of the container door using the three
1/4-20 (or M6-1) screws (Torque 25-30 lbs., 2.8-3.4 N-M), allowing 1/16”
(1.6mm) clearance between the lock bolt and the container locking bar.
(See Figure 2 for proper clearances and positioning when installing a
square nose slide bolt. See Figure 3 for proper clearances, strike types
and contact points when installing a roller slide bolt.)
Note: The lock case
assembly can be mounted
in bolt roller up position or
bolt roller down position
(Figure 12) for all mounting
locations. It is recommended
that you use Loctite
®
262
(Red) on the lock case
mounting screws.
2. Test the operation of the
lock again. If the lock does
not operate properly, refer to the following instructions to “Uninstall
Keypad Assembly”.
3. If your lock includes the Battery Assist option, you should now
mount the battery clip inside the door near the lock and install a fresh
9 Volt Alkaline battery.
Note: To remove any excess
cable or if you choose not to use
the Battery Assist option, wrap
and tie the battery assist cable.
(Figure 14) If you do not ever
plan on using the Battery Assist
option, you can cut the cable
next to the lock case to remove it.
© 2005-2006 Kaba Mas Corporation. All rights reserved.
Product warranty information can be found at: www.kaba-mas.com
Kaba Mas Corporation
749 W. Short Street, Lexington, KY 40508 USA
Phone: [phone] FAX: [phone]
Customer Service: [phone]
Figure 4
Figure 6
Figure 7
Figure 13
Uninstall Keypad Assembly
1. Remove the decal from
the keypad assembly.
2. Insert a flat head
screwdriver into the slot in
the upper left hand corner of
the keypad to release one of
the two keypad catches.
(Figure 13)
3. Carefully pull the keypad
assembly out from the dial
assembly.
4. Check for pinched or
detached cables.
Figure 10
Figure 11
Figure 8 Figure 9
Figure 12
Figure 5
Generator cable
is at one o’clock
6 1/2” of Cable
Figure 14