Kaba PowerLever 1550 User manual

PowerLever®
Door Lock Series
™
INSTALLATION
GUIDE
Models 1550, 4550/4560, PROX 9000

NOTICE: This product may not be transferred or exported into any country or used in any manner prohibited by the
United States Export Administration Act, as amended from time to time (the “ACT”), or any other export laws, restrictions,
or regulations.
Trademarks
iButton is a registered trademark of Dallas Semiconductor.
Ilco is a registered trademark of Ilco Unican Corp.
ASSA is a registered trademark of Aug. Stenman Aktiebolag of Eskilstuna, Sweden.
Abloy is a registered trademark of Abloy Security Ltd OY.
Arrow is a registered trademark of Arrow Lock Manufacturing Company.
Schlage is a registered trademark of Schlage Lock Company.
Primus is a registered trademark of Schlage Lock Company.
Corbin Russwin is a registered trademark of Corbin Russwin, Inc.
Medeco is a registered trademark of Medeco Security Locks, Inc.
Best is a registered trademark of Best Lock Corporation.
Everest is a registered trademark of Schlage Lock Company.
Falcon is a registered trademark of Falcon Lock Co.
KSP is a registered trademark of Killeen Security Products.
Keymark is a registered trademark of Medeco Security Locks, Inc.
Patents
This product is covered by one or more of the following U.S. patents:
4,803,860 5,410,301 5,493,279 5,709,114 5,873,276 D366,822
5,170,431 5,451,934 5,511,401 5,774,058 5,881,589 D388,308
5,265,452 5,488,358 5,590,917 5,774,059 5,893,283 D388,309
5,271,253 5,488,660 5,592,838 5,870,914 5,896,026
NOTICE: The information in this manual is subject to change without notice and does not represent a commitment on the
part of Kaba Ilco. Kaba Ilco shall not be liable for technical or editorial errors or omissions contained herein; nor for
incidental or consequential damages resulting from the furnishing, performance or use of this material.
© 2003-2004 Kaba Mas
All rights reserved.

TABLE OF CONTENTS
INTRODUCTION ................................................................................................................................ 1
Lock Description ................................................................................................................................ 1
Self-Power Operation ......................................................................................................................... 1
Door Handing ..................................................................................................................................... 2
Basic Tools and Materials Needed ..................................................................................................... 2
PARTS CHECK ............................................................................................................................... 3
Illustrated Parts Breakdown ............................................................................................................... 3
INSTALLATION TEMPLATE ................................................................................................................. 6
DOOR PREPARATION ....................................................................................................................... 7
Mark the Door .................................................................................................................................... 7
For non-prepped doors ................................................................................................................ 7
For all doors ................................................................................................................................. 8
Drill the Holes ..................................................................................................................................... 8
For non-prepped doors ................................................................................................................ 8
For all doors ................................................................................................................................. 9
Optional Drill Jig........................................................................................................................... 9
INSTALLATION ................................................................................................................................10
Install the Latchbolt ............................................................................................................................ 10
Adjust the Lockset for the Door Thickness ......................................................................................... 10
Install the Lock Chassis/Outside Case Assembly .............................................................................. 11
Install the Inside Backing Plate/Electronics Assembly ........................................................................ 12
Install the Cables ................................................................................................................................ 14
Install the Inside Case ........................................................................................................................ 15
Attach the Inside Lever ...................................................................................................................... 15
Attach the Outside Lever .................................................................................................................... 16
Conventional (Non-Interchangeable) Key Cylinder ...................................................................... 16
Tailpieces .................................................................................................................................... 17
Interchangeable Key Core ........................................................................................................... 18
Install the Interchangeable Key Core ................................................................................................. 19
Locate and Install the Strike ............................................................................................................... 19
For non-prepped doors ................................................................................................................ 19
For all doors ................................................................................................................................. 19
Test Procedure .................................................................................................................................. 20
SERVICE ....................................................................................................................................... 21
Remove the Outside Lever ................................................................................................................ 21
Conventional (Non-Interchangeable) Key Cylinder ...................................................................... 21
Interchangeable Key Core ........................................................................................................... 21

SPECIFICATIONS ............................................................................................................................. 22
Electronic Specifications .................................................................................................................... 22
Hardware Specifications .................................................................................................................... 22
TROUBLESHOOTING ......................................................................................................................... 22

Document Number 481.093 Rev. A - 06/04 1
Introduction
INTRODUCTION
Lock Description
The PowerLever®Door Lock is an advanced design electronic lock that operates using inter-
nally-generated power, “PowerStarTM technology”, and includes a microprocessor and a cylindri-
cal lock mechanism. Installation of the following lock models is covered in this manual:
· PowerLever 1550
· PowerLever 4550/4560
· PowerLever PROX 9000
Note: Various lock models will be shown throughout the Installation Guide.
The lock consists of the following major assemblies:
· Outside cover assembly - includes a keypad for entry of control data, a pair of LEDs (red
and green) for visual feedback, a beeper for audio feedback, and the outside lever with a
return of 1/2” (12.7mm) to the door (unassembled). Depending on which PowerLever lock
model you are installing, the cover assembly may also include a Smart Key* reader (Model
45xx only) or a PROX card reader, along with a communication port for a handheld PDA
(Personal Digital Assistant).
* iButtonTM memory device manufactured by Dallas Semiconductor.
· Inside cover hardware - includes system electronics and the inside lever with a return of
1/2” (12.7mm) to the door (unassembled).
· Cylindrical lock hardware - includes a Grade 1 lock mechanism with free-wheeling system
and stainless steel retractor, a 6-pin standard key cylinder with tailpiece and two keys
(unless prepared for interchangeable core), a 9/16” (14.3mm) throw latchbolt with adjustable
bevel, and either a 2-3/4” (70mm) T-strike with box or a 4-7/8” (124mm) ASA strike, and a
screw pack.
Self-Power Operation
The PowerLever lock is designed to operate using internally-generated power. The self-con-
tained PowerStar generator is triggered by depressing the outside lever. Each 67-degree open
and 67-degree restore rotation of the lever constitutes a charging cycle. A door open operation
will require only one charging cycle if the period of door lever inactivity does not exceed a
weekend (approximately 65 hours) when operating at normal room temperature. Periods of non-
use beyond a weekend will require two charging cycles for a door open operation. One simulta-
neous flash of the green and red LEDs accompanied by a low volume beep indicates that the
lock is powered. Extended operations such as audit data downloads will require a charging cycle
approximately every 15 seconds. When lock power drops below a sufficient level for operation,
the lock will continually beep and flash the red LED, prompting the user to depress the outside
lever to provide additional power.

Document Number 481.093 Rev. A - 06/04
2
Introduction
Door Handing
The PowerLever Door Lock can be installed as Right Hand Reverse or Left Hand Reverse.
Basic Tools and Materials Needed
Before beginning installation, be certain that you have the following tools readily available:
• Measuring tape
• Combination square
• Tape
• Center punch
• Electric hand drill
• 1/8” (3mm) drill bit
• 11/32” (9mm) drill bit
• 1” (25mm) hole saw
• 2 1/8” (54mm) hole saw
• File
• Wood chisel
• Hammer
• 1/4” or smaller slotted head screwdriver
• #1 Phillips head screwdriver
• #3 Phillips head screwdriver
• 1/4” hex driver handle
• T-15 security Torx bit
• Safety glasses
• Electrostatic Discharge (ESD) wrist band
• C-clamp (if using optional Drill Jig)
WARNING: PowerLever locks are well protected from Electrostatic Discharge
(ESD) damage once they are installed, but can be damaged during the
installation process if proper precautions are not observed. Follow
these precautions to avoid ESD damage when installing the lock:
• Do not remove the metal shield covering the system card on the
inside backing plate.
• For the best protection, the use of a grounded ESD wrist band
during installation is strongly recommended. The lock is protected
to greater than 25,000 V when correctly installed.

Document Number 481.093 Rev. A - 06/04 3
Figure 1
Parts Check
PARTS CHECK
Illustrated Parts Breakdown

Document Number 481.093 Rev. A - 06/04
4
Parts Check
Item Description
1Screw packet for latchbolt assembly and strikes containing:
1A • 2 - #8 x 3/4” Phillips head combination screws
1B • 2 - #8 x 3/4” Phillips head combination screws
1C • 2 - #12 x 3/4” Phillips head combination screws
2Trim mounting packet for 1 3/8” - 2” door, containing:
2A • Cylinder insert for door thickness greater than 1 1/2” (wide stop)
2B • Cylinder insert for door thickness less than or equal to 1 1/2” (narrow stop)
2C • Lever release tool
2D • 1/4-28 x 2 1/2” Phillips round head screws (4)
Model 1550 or 45xx:
2E • 8-32 x 1” Torx security screws (4)
2F • 8-32 x 1 1/2” Torx security screws (2)
Model PROX 9000:
2E • 8-32 x 1” Phillips round head screws (4)
• 8-32 x 1 1/2” Phillips round head screws (2)
• 8-32 x 1” Torx security screws (2)
2G • 7/16” diameter x 5/8” long spacers for 1 3/8” door thickness (2)
2H • 7/16” diameter x 1/4” long spacers for 1 3/4” door thickness (2)
2I • 1/4” lock washers (4)
2J • Tailpiece for IC key core for door thickness less than or equal to 1 1/2”
2K • Tailpiece for IC key core for door thickness greater than 1 1/2”
3Outside Levers
3A • Lever to accept conventional key cylinder
OR
3B • Lever to accept interchangeable key core
4Inside Levers
• Lever
5Key Cylinders
5A • Conventional 6-pin
OR
5B • Interchangeable 6-pin core (not furnished with lock assembly)
5C • Interchangeable 7-pin core (not furnished with lock assembly)
6
6A Model 1550 Outside lock case assembly
6B Model 45xx Outside lock case assembly
6C Model PROX 9000 Outside lock case assembly

Document Number 481.093 Rev. A - 06/04 5
Parts Check
Item Description
7
7A Chassis assembly for levers using conventional (non-interchangeable) key cylinder
7B Chassis assembly for levers using interchangeable key core
8Inside case assembly
9
9A Inside backing plate/Electronics assembly - Model 1550
9B Inside backing plate/Electronics assembly - Model 45xx
9B Inside backing plate/Electronics assembly - Model 9000
10 Latchbolt assemblies
10A • 9/16” (14.3mm) throw dead locking latchbolt
11 Strikes
11A • 2 3/4” (70mm) T-strike (strike box included)
OR
11B • 4 7/8” (124mm) ASA-strike (strike box not included)
12 Strike Boxes
12A • Strike box for 2 3/4” (70mm) T-strike (included with strike; refer to 11A)
12B • Strike box for 4 7/8” (124mm) ASA strike (order separately)

Document Number 481.093 Rev. A - 06/04
6
INSTALLATION TEMPLATE
Caution:The following installation template is not to scale and is meant to be used for refer-
ence only. It is not meant to be used for actual installation of the lock.
PowerLever
®
Door Lock
Series
INSTALLATION
TEMPLATE
P/N 482.093
NOT TO SCALE
Installation Template

Document Number 481.093 Rev. A - 06/04 7
Figure 2
Figure 3
DOOR PREPARATION
Mark the Door
Note: Accurate door preparation, including drilling throughbolt holes, is essential for proper
operation. The hand and bevel of the door affect template use. For doors already
prepped, make sure the preparation correctly matches the templates provided before
drilling throughbolt holes. If the door preparation does not match the template, redrill
the door to match the template.
To mark the door, complete the following
steps:
1. Locate and mark the horizontal and
vertical centerlines on the door at the
desired height above the floor.
2. Fold the template on the dashed line
as indicated on the template. It is
critical that the template be folded
correctly on the proper dashed
line to ensure proper hole align-
ment. Place the fold on the edge of
the door. Refer to Figure 2. The
horizontal and vertical centerlines on
the door should be clearly visible and
aligned with the centerlines provided
on the template.
For non-prepped doors:
3. Locate and mark the centerline for
the 1” (25.4mm) diameter latchbolt
hole on the door edge based upon the
door thickness and the desired height
above the floor.
4. Locate and mark the centerline for the
2 1/8” (54mm) diameter hole at the
height marked for the centerline of the
latchbolt. Refer to Figure 2.
5. Locate and mark the centerline for the
1” (25.4mm) diameter strike hole on
the door jamb at the same height as
the latchbolt hole. Refer to Figure 3.
Door Preparation

Document Number 481.093 Rev. A - 06/04
8
For all doors:
6. Locate and mark the center for the
four 11/32” (8.7mm) diameter
throughbolt clearance holes. Refer to
Figure 4.
7. Locate and mark the center for the 1”
(25.4mm) diameter thru-hole for the
system cable.
8. Center punch all hole positions onto
the door.
Drill the Holes
Refer to Figure 5 for summary drilling
dimensions. An optional Drill Jig is avail-
able. Refer to Figure 6 on the following
page.
Note: Make sure the holes are drilled level and straight. When drilling through the door, be
careful not to damage the door finish. It is recommended that safety glasses be worn
during the drilling process.
For non-prepped doors:
1. Drill a 1/8” (3mm) diameter pilot straight through the door where you marked for the
centerline of the 2 1/8” (54mm) diameter hole.
2. Using the pilot hole, drill a
2 1/8” (54mm) diameter hole
straight through the door.
Note: The 2 1/8” (54mm) diam-
eter hole in a labeled door
shall be drilled under li-
censed procedure.
3. Drill a 1/8” (3mm) diameter pilot
hole straight through the door
edge where you marked for the
centerline of the 1” (25.4mm)
diameter hole for the latchbolt
into the edge of the door. Make
sure the latchbolt hole is level
and perpendicular to the 2 1/8”
(54mm) diameter hole.
Figure 4
Figure 5
Door Preparation

Document Number 481.093 Rev. A - 06/04 9
Figure 6
4. Using the pilot hole, drill a 1” (25.4mm) diameter hole for the latchbolt into the edge of the
door. Make sure the latchbolt hole is level and perpendicular to the 2 1/8” (54mm) diameter
hole.
5. Mortise the edge of the door 1 1/8” x 2 1/4” x 5/32” (29mm x 57mm x 4mm) for the latch front.
For all doors:
1. Drill four 11/32” (8.7mm) diameter holes straight through the door.
2. Drill a 1/8” (3mm) diameter pilot hole straight through the door where you marked for the
centerline of the 1” (25.4mm) diameter hole for the system cable.
3. Using the pilot hole, drill the 1” (25.4mm) diameter hole for the system cable.
Note: Remove any burrs from the inside and outside edges of the 1” (25.4 mm) diameter
hole to prevent cutting of the system cable.
Optional Drill Jig:
An optional Drill Jig, Part Number 404044, is
available to ensure accurate locating and
drilling of the four 11/32” (8.7mm) diameter
mounting holes, and the 1” (25.4mm) diam-
eter system cable hole.
1. For the best results, align the jig to the
door with a combination square and
clamp to the door before drilling. Refer to
Figure 6.
Door Preparation

Document Number 481.093 Rev. A - 06/04
10
INSTALLATION
Install the Latchbolt
1. Check the door swing and orient the
latchbolt to the hand of the door.
Refer to Figure 7.
2. Insert the latchbolt into the hole in
the door as shown in Figure 7.
Using the latchbolt front as a tem-
plate, centerpunch and drill two (2)
1/8” (3mm) mounting holes.
3. Using the #1 Phillips head screw-
driver, secure the latchbolt with the
two #8 combination screws pro-
vided.
Adjust the Lockset for the Door Thickness
1. Screw the lock chassis assembly in or
out of the outside case assembly to
obtain dimension “A” as shown in Figure
8. The dimension “A” equals one-half of
the door thickness as shown in the
following chart.
Door Thickness Dimension “A”
1 3/8” (35mm) 11/16” (17.5mm)
1 3/4” (44mm) 7/8” (22mm)
2” (51mm) 1” (25.5mm)
Using a tape measure, set/check dimen-
sion “A”. This adjustment should result in
the retractor being centered in the door.
Note: This measurement should be made
from the back plate of the lock case.
Figure 7
Figure 8
Installation

Document Number 481.093 Rev. A - 06/04 11
Install the Lock Chassis/Outside Case Assembly
If you are installing a Model 45xx lock or a PowerLever PROX
9000 lock, the outside case assembly includes a communication
cable that exits the outside case assembly at the same location
as the system cable (as shown in the photo.) The communication
cable is a 6-conductor ribbon cable that carries communication
signals from the RJ-12 connector on the outside case assembly
through the door to the system card.
1. If your lock includes outdoor gaskets (P/N 405054 - Inside
Gasket and P/N 405056 - Outside Gasket), you should at
this time install the Outside Gasket.
Warning: For outdoor applications, you must install the
gaskets. Otherwise, the product warranty will be voided.
Gaskets are not for use on fire doors.
Refer to Figure 9 and identify the Lock Chassis/Outside Case
Assembly and Outside Gasket (four holes at top and bottom).
Remove the paper backing sheet from the adhesive on the
Outside Gasket.
Slide the gasket down over the Chassis
Assembly and the cables, with the
adhesive side toward the Case Assem-
bly. Center gasket over Outside Case
Assembly. Ensure the gasket is cen-
tered in all directions so that an equal
amount of cover is visible around the
perimeter of the gasket. Once the
proper position of the gasket is verified,
press the gasket firmly into place.
2.Refer to Figure 10. Make sure that the latch holder
slot in the chassis assembly faces the front edge of
the door.
Caution:Handle the electrical wiring harness with
care. Do not pinch the wires.
Figure 9 - Model 1550 shown
Exit 1/3 way
down from
top
Communication
Cable
System
Cable
Solenoid
Cable
Figure 10 - Model 45xx shown
Installation

Document Number 481.093 Rev. A - 06/04
12
3. From the outside of the door, feed the solenoid cable through the 2 1/8” (54mm) hole.
Caution:Ensure that the solenoid cable does not get tangled in the latchbolt mechanism.
4. From the outside of the door, feed the system cable and
communication cable (if applicable) through the 1”
(25.4mm) hole.
5. Insert the chassis assembly into the hole. Be sure that
the chassis assembly engages the latch prongs and that
the latch tail engages the retractor as shown in Figure
11.
Caution:Ensure that the solenoid cable does not get tangled
in the latchbolt mechanism.
Install the Inside Backing Plate/Electronics Assembly
1. If your lock includes outdoor gaskets, you should
at this time install the Inside Gasket. Refer to
Figure 12 and identify the Inside Backing Plate/
Electronics Assembly and Inside Gasket. Re-
move the paper backing sheet from the adhesive
on the Inside Gasket. Position the gasket, with
the adhesive side toward the inside backing plate,
so that the large hole in the gasket is centered
over the four protrusions on the backing plate.
Ensure that the four corner holes in the gasket
are aligned with the matching four corner holes in
the backing plate. When properly installed, the
gasket will overhang the backing plate an equal
amount on all four sides. Once the proper position
of the gasket is verified, press the gasket firmly
into place.
2. Guide the solenoid cable through the hole in the backing
plate. Refer to Figure 13.
Note:The phantom cable indicated in the drawing is the
routing path of the solenoid cable for opposite handing.
3. Guide the system cable (and communication cable if
applicable) through the rectangular hole in the backing
plate.
Figure 11
Figure 12
Figure 13
Installation

Document Number 481.093 Rev. A - 06/04 13
4. Refer to Figure 14. Install
the two top 1/4-28 x 2 1/2”
Phillips round head screws
with the appropriate spac-
ers to compensate for the
door thickness, and with
the lockwashers (Refer to
note below). Do not tighten
yet.
Note:Use the two 7/16” dia.
x 1/4” (short spacers) for a
1 3/4” door. Use the 7/16”
dia. x 5/8” (long spacers) for
a 1 3/8” door. No spacers
are required for a 2” door.
5. Install the two bottom 1/4-
28 x 2 1/2” Phillips round
head screws with the
lockwashers.
6. Tighten all four screws.
Figure 14
Installation

Document Number 481.093 Rev. A - 06/04
14
Install the Cables
Warning: Do not remove the shield. This
could cause damage to the system
card.
Warning: Ensure that the solenoid cable is
routed to the inside of the PEM nuts
used for mounting the inside case. The
solenoid cable will exit either the left or
right hole in the backing plate depend-
ing on the latchbolt position.
Note: Refer to Figure 15.
1. Plug the system cable into the system
card.
2. Route the solenoid cable through the
cable clip.
3. Plug the solenoid cable into the 2-pin
connector on the system card.
4. If installing a Model 45xx or PowerLever
PROX 9000 lock, you must also connect
the communication cable to the system
card. Plug the communication cable into
the appropriate connector on the bottom
edge of the system card, as shown in the
photo.
Figure 15
Communication
Cable Connector
System Cable
Connector
SW2 - Factory
Reset Switch
Solenoid Cable
Connector
Installation

Document Number 481.093 Rev. A - 06/04 15
Install the Inside Case
Note: Refer to Figure 16.
1. Slightly wiggle and push the inside
case assembly over the lock
cylinder assembly, past the lever
catch and against the door.
Note: Ensure that the solenoid cable
is not pinched and is routed
through the cable clip.
2. Install the two top long mounting
screws.
3. Install the four bottom short mount-
ing screws.
Note: A Torx security screwdriver bit
can be ordered as part number
404050. A Torx security
screwdriver bit is supplied with
the optional Drill Guide Jig,
part number 404044.
Attach the Inside Lever
Note: Refer to Figure 17.
1. Push the inside lever onto the lock tube.
Slightly wiggle and push the inside lever until
the lever engages the lever catch.
2. If the door thickness is greater than 1 1/2”
(38mm), the attachment of the inside lever is
complete and you can proceed to the “Attach
the Outside Lever” section. If the door thick-
ness is 1 1/2” (38mm) or less, go to Step 3.
3. Insert the lever release tool into the lever hole
closest to the door. Push in the lever release
tool.
4. While pushing in the lever, allow the lever to
move to engage the lever catch. This second
catch point ensures that the end of the lever is
less than 1/2” (13mm) away from the door as
required by many building codes.
Figure 16
Figure 17
LONG MOUNTING
SCREWS
SHORT MOUNTING
SCREWS
Installation

Document Number 481.093 Rev. A - 06/04
16
Attach the Outside Lever
Conventional (Non-Interchangeable) Key Cylinder
1. Refer to Figure 18. Make sure the
cylinder tailpiece is aligned in the same
direction as the cylinder bible. Slide the
cylinder all the way into the lever.
2. Select the appropriate cylinder insert.
Refer to Figure 19. If the door thick-
ness is 1 1/2” (38mm) or less, use the
cylinder insert with the narrow stop. If
the door thickness is greater than
1 1/2” (38mm), use the cylinder insert
with the wide stop.
3. Align and position the cylinder insert in
the lever shank with the prongs facing toward
the cylinder. Press the cylinder insert firmly
into the lever shank securing the cylinder.
Note: Refer to Figure 20.
4. Ensure that the outside lock tube is oriented
such that the lever catch is facing the same
direction as the latchbolt.
5. With the key inserted in the cylinder, slide the
outside lever onto the lock tube until the lever
stops against the lever catch.
6. Turn the key 45 degrees clockwise.
7. Push the lever until it engages with the
lever catch.
8. If the door thickness is greater than 1 1/2”
(38mm), the lever installation is complete.
If the door thickness is 1 1/2” (38mm) or
less, complete the following steps.
9. With the key still turned 45 degrees, insert
the lever release tool into the lever hole to
depress the lever catch.
10. Push the lever further onto the lock tube
until the lever engages the lever catch at
the second catch position. This second
catch point ensures that the end of the
lever is less than 1/2” (13mm) away from
the door as required by many building
codes.
OUTSIDE COVER
OUTSIDE
LOCK TUBE
OUTSIDE
LEVER
LEVER RELEASE
TOOL
LEVER
CATCH
KEY
Figure 20 - Model 9000 shown
Figure 18
Figure 19
Installation