® X-07 Troubleshooting Guide
Contents CHAPTER 1 INTRODUCTION ................................................................................... 5 ASSUMPTIONS ....................................................................................................................... 5 CHECKOUT STANDARDS ..................................................................................................... 5 CHAPTER 2 MAJOR SUBASSEMBLIES.................................................................. 6 CASE ASSEMBLY ........................
Continued from previous page SECURITY VIOLATION ............................................................................................................ 14 HUB ASSEMBLY SET SCREWS LOOSE OR GROOVED ON SPINDLE - .......................... 14 DRIVE CAM ASSEMBLY INSERT LOOSE ............................................................................. 14 FAULTY LCD, BAD CONNECTION, OR FLEX CABLES SEVERED .................................. 14 ELECTRONIC CARD FAILURE ..........................................
Continued from previous page CHANGE KEY LOCKED IN CONTAINER ......................................................................... 24 APPENDICES ...........................................................................................26 APPENDIX A - REMOVING THE BACK COVER ASSEMBLY ......................................... 27 APPENDIX B - REMOVING THE X-07 DIAL (CONTAINER OPEN) ................................ 28 APPENDIX C - REMOVING THE X-07 DIAL (CONTAINER IS CLOSED) ......................
CHAPTER 1 INTRODUCTION ASSUMPTIONS The following four assumptions are made to simplify the documentation. 1. All texts pertain only to GSA approved containers. 2. Mounting position of lock All text reference to the X-07 in this document is with the X-07 mounted in the BOLT DOWN position. 3. Thermal relock Unless otherwise noted, this document assumes that the thermal relock is working correctly.
CHAPTER 2 MAJOR SUBASSEMBLIES The X-07 electromechanical lock is comprised of 5 major subassemblies. Each subassembly provides a vital and unique function for the X-07 combination. The following listing is a nomenclature list of each subassembly and the components that make up the subassembly.
Motor Gear (with/without counter weight ball bearing) * Screws (2) DIAL RING Dial Ring Cover Dial Bushing Tube Retainers a. Inner Tube/Cable Retainer (black plastic) b.
CHAPTER 3 X-07 OPERATION A BRIEF DESCRIPTION OF HOW THE LOCK OPERATES: 1 The X-07 cover assembly is comprised of the back cover, generator, and the system electronic card. The electronic card receives pulses from the generator as the dial is turned. These pulses are then rectified and used to charge up a super capacitor. The super capacitor provides the operating voltage for the entire lock. The super capacitor will maintain power on the system card for approximately 90 seconds after dialing has stopped.
d. Check delay between sets of pulses Wrist delay should be at least ¼ second between turns; e. Check delay between direction change Dial turn around should be at least ¼ second between turns. 4. Upon power up, the microprocessor reads and determines the phase relationship for initial dial position. The microprocessor will output a two digit number and an arrow symbol for dial position and direction to the display driver.
f. As the slide moves down, it will allow the lever assembly to move into the proper position to be engaged by the drive cam. g. The lever assembly is attached to the bolt mechanism and when moved in the direction away from the bolt by the drive cam, it will retract the bolt. h. Continuing to turn the dial in the clockwise direction will move the lever assembly and bolt to their full limit of travel (viewed from front of dial). i.
CHAPTER 4 TROUBLESHOOTING X-07 PROBLEMS LIGHTNING BOLT AFTER DIALING COMBINATION Symbol displayed to indicate a software protective security feature has been violated by the user or incorrect combination entered. POSSIBLE CAUSES TO SECURITY FEATURES VIOLATIONS 1. Wrong combination. 2. Dialing the combination in less than 15 seconds. 3. Turning the dial more than 1 and 1/3 revolutions without pausing. 4. Turning dial without pausing for a ¼ second between turns. 5.
TURNING DIAL WITHOUT PAUSING FOR A ¼ SECOND ON A DIRECTION CHANGE Experienced mechanical lock users have a difficult time with this security feature. They dial to the number and reverse direction with the same grip of the dial. You must pause during direction changes for ¼ of a second. BACKUP DIALING This method should always be avoided if experiencing lightning bolts. RECOMMENDATION FOR DIALING 1 .
1. Exceeded maximum error count without getting “OP”. a. Ten (10) errors in succession will cause the X-07 lock to blank out the LCD. The LCD will remain off until the lock has totally powered off. Power off occurs 90 seconds after dialing has stopped. b. If you do not stop dialing for 90 seconds the electronics will remain powered up and the LCD will stay blank. c. Confirm your combination and dialing techniques. HUB ASSEMBLY SET SCREWS LOOSE, OR CAM ASSEMBLY INSERT LOOSE 1 .
1 . Security violation. 2. Hub assembly set screws loose. 3. Drive cam assembly insert loose. 4. Faulty LCD or card failure. SECURITY VIOLATION 1 . Exceeded maximum error count without getting “OP”. a. Ten (10) errors in succession will cause the X-07 lock to blank out the LCD. The LCD will remain off until the lock has totally powered off. Power off occurs 90 seconds after dialing has stopped. b. If you do not stop dialing for 90 seconds the electronic will remain powered up and the LCD will stay blank.
2. Follow instructions in Appendix I ELECTRONIC CARD FAILURE 1 . There is not a lot that can be done at this point. If time permits, let the X-07 sit idle for 72 hours to allow the stored power in the super capacitor to discharge to a minimum level, then try to power up with quick half turns of the dial. 2. A sharp blow on the container (at the 5 o’clock position) with a dead blow hammer MAY make a loose connection and allow the X-07 lock to power up. 3. If unsuccessful, see forced entry.
6. Loosen the two screws INSIDE the dial ring, being careful not to damage the flex cables. These screws are in slotted holes to allow centering of LCD display and dial assembly. Once loosened you should be able to turn the dial ring slightly to the left and right on the container. 7. Reinstall the dial assembly, drive cam, and cam screw. Tighten the cam screw. 8. Move dial ring around until dial assembly turns freely. 9. Remove cam screw, drive cam, and dial assembly, tighten the inside dial ring screws.
After executing the combination and with “OP” displayed, the X-07 dial is restricted when turned to the right. When the dial is turned back to the left and “OP” goes out, the dial is free turning. First, a bit of information about the containers and the locking bars. The bars are two equal lengths of hardened steel that extend out of the container drawer head and into the side walls of the container. When extended, the locking bars prevent any movement of the drawer head.
container drawer shut and the handle in the locked position until the dial is successfully turned to the left to reset the stepper motor. Remember that the X-07 bolt is in the open position and its bolt is fully retracted. Therefore, you will experience a block to the right under this condition. The block right is normal and is not the error condition. 1. The X-07 bolt is blocked or binding as it is extended into the gap between the locking bars. a.
1 . Execute combination and open container. 2. Follow instructions in Appendix D. CONTAINER IS CLOSED, NUMBERS CANNOT BE ACCURATELY INTERPRETED 1. Check ribbon cable and splice if possible to open container. See Appendix I. 2. If unable to open the container, follow instructions in Appendix E. BLACK SPOTS ON LCD The display has black spots. First, can the numbers be accurately interpreted, and secondly, is the container open or closed? Container is open. Follow instructions for Appendix D.
4. Stepper motor fails to step. BACK COVER ASSEMBLY (ELECTRONIC CARD) Extremely low probability since the lock did execute the combination properly and “OP” going out indicates that the reed switch is detected. HUB SET SCREW LOOSE OR GROOVED ON SPINDLE 1. May have enough torque to power up the X-07 but not enough to pull the X-07 bolt. Try to determine if you can feel any feedback (rasping) from the generator being turned after “OP” is displayed. 2.
lock to lock. Some have opened right up with a slow speed setting and others at a much faster speed. 4. The hammer drill works even better if you remove the dial (Appendix C) and apply the vibrations to the hardplate. To get directly to the hardplate after removing the dial, drill a ¼ inch hole through the dial ring assembly and the drawer head skin. DO NOT DRILL INTO THE HARDPLATE! The position of the ¼ inch hole should be about 1 ½ inches down and 1 inch to the right of the spindle hole.
Appendix B if the container is open, or Appendix C if the container is closed (to allow for more side play in the spindle). The increased side play may allow the cam magnet to get closer to the reed switch. If the container is open, check the reed switch to make sure it is not tilted to one side. Replace the drive cam with a new one and try the lock. If the container is closed, remove the dial as stated in Appendix C and bias the spindle away from the ribbon cables (opposite the direction shown in Fig. 5).
lever spring is not completely compressed the relocker lever will only be partially lifted. This may result in the slide assembly tab being blocked as the dial is turned to the right. The following is a list of the possible causes for the relocker failure. 1 . Back cover assembly mounting screws are loose. If the back cover assembly mounting screws are loose, you may be able to use a deadblow hammer to open the lock. First you must get a dial block right by dialing the correct combination.
1 . Locate the interlock release, usually located near the locking bolts on the outer perimeter of the drawer head. Different container manufacturers have different interlock releases, so please take the time to locate it and then press, pull, and/or slide the interlock release while moving the locking handle to the locked position. See Figure 12 for some sample locations. 2.
4. Repeat the steps for changing the combination. When PO is displayed, pull out the change key. The display will show CC. You must confirm the new combination by entering it until OP is displayed and the bolt is retracted. At that point the new combination is stored in the microprocessor.
APPENDICES
APPENDIX A REMOVING THE BACK COVER ASSEMBLY 1 Remove the drawer head cover plate. 2. Remove the back drill pate and filler plate. 3. Remove the X-07 back cover assembly. Remove the two screws on perimeter of the back cover assembly. One is on the end of cover assembly and the other is on the side. Both screws are Phillips head screws and require a #2 Phillips screw driver. Lift the cover assembly out perpendicular to the lock assembly.
APPENDIX B REMOVING THE X-07 DIAL (CONTAINER OPEN) 1 Remove the drawer head cover plate. 2. Remove the back drill plate and filler plate. 3. Remove the X-07 back cover assembly. Remove the two screws on perimeter of the cover assembly. One is on the end of cover assembly and the other is on the side. Both screws are Phillips head screws and require a #2 Phillips screw driver. Lift the cover assembly out perpendicular to the lock assembly.
APPENDIX C REMOVING THE X-07 DIAL (CONTAINER CLOSED) 1 To remove the dial, cut off the knob close to the dial. (See Fig. 10) 2. Make a continuous vertical cut around the knob and parallel to the dial. 3. Pull the knob off with vise grips. 4. Loosen hub set screws. 5. Remove hub and dial. Note: Hub assembly may be placed back on spindle with set screws tightened to turn spindle.
APPENDIX D REPLACEMENT OF THE LCD (CONTAINER OPEN) 1. Pull out the drawer, release the interlock, and extend the locking bars to the locked position. 2. Remove the drawer head cover plate. 3. Remove the back drill plate and filler plate. 4. Remove the X-07 cover assembly (backplate). Remove the two screws on perimeter of the cover assembly. One is on the end of cover assembly and the other is on the side. Both screws are Phillips head screws and require a #2 Phillips screw driver.
APPENDIX E REPLACEMENT OF THE LCD (CONTAINER CLOSED) 1. To remove the dial, cut off the knob close to the dial. (See Fig. 10) 2. Make a continuous vertical cut around the knob and parallel to the dial. 3. Pull the knob off with vise grips. 4. Loosen hub set screws. 5. Remove hub and dial. (Hub to be reinstalled later to open lock). 6. Remove the dial ring cover and the inner tube retainer by removing the Phillips head screws. 7.
APPENDIX F DRIVE CAM INSERT LOOSE (CONTAINER CLOSED) 1 To remove the dial, cut off the knob close to the dial. 2. Make a continuous vertical cut around the knob and parallel to the dial. 3. Pull the knob off with vise grips. 4. Loosen hub set screws. 5. Remove hub and dial. 6. Remove the dial ring cover. 7. Remove the black plastic inner tube retainer. 8. Caution, the flex cables are exposed to damage from here on out. 9.
APPENDIX G REMOVING/INSTALLING STEPPER MOTOR AND CAM (CONTAINER OPEN) 1. Pull out the drawer, release the interlock, and extend the locking bolts to the locked position. 2. Turn the X-07 dial to the left until the bolt is fully extended. 3. Remove the drawer head cover plate. 4. Remove the back drill plate and filler plate. 5. Remove the X-07 cover assembly (backplate). Remove the two screws on perimeter of the cover assembly. One is on the end of cover assembly and the other is on the side.
12. Install stepper motor using two new Torx screws. 13. Install cam on the spindle and turn the dial in both directions to insure no binding before replacing the back cover assembly. Please Note: If replacing an old style motor with a new style motor you must replace the drive cam with a new style drive cam. To determine which cam you have, compare your cam to the drawings in (Fig. 1, 2, 3, or 4). The new style cam has two (2) extra teeth. The cams shown in Fig. 1 and Fig. 3 are the new style cams. Fig.
APPENDIX H FORCED ENTRY The method used is often determined by answering the following two questions. Urgency to gain entry. Tools available. Naval Facilities Engineering Service Center at Port Hueneme, California, has published a Technical Data Sheet for Neutralizing lockouts of GSA Security Container using a heavy duty 7-1/4 builder circular saw with a 6” x 1/8” abrasive cutoff blade.
and high speed will get you through. Note: Some hardplates are work hardening. This means that when they start to cool, they will be harder than before you started drilling or sawing. If you are drilling for the lever fence or the lever screw: If you are using a magnetic drill and are drilling with a diamond core bit the procedure is very different. You will want to drill at a steady speed of 500-550 RPM with a light steady pressure. You won’t see any chips when drilling with a diamond core drill.
APPENDIX I TEMPORARY SPLICING OF RIBBON CABLE Missing segments on the X-07 LCD are generally caused by a cut ribbon cable. If the segments can not be interpreted, you may be able to splice the cables well enough to get the lock open. First you will need to remove the dial and dial ring assembly. Remove the inner and outer tubes if possible to prevent further damage to the cables. If the cables are cut anywhere on the outside of the container, you can spice the cables if you are careful and patient.
APPENDIX J ILLUSTRATIONS
1 The stepper motor has ten 36 degree steps in one complete revolution of the motor. Each step has a magnetic detent position. The X-07 uses only one of the ten 36 degree steps in the operation of the lock. And any time the stepper motor is removed or replaced this step must be selected and set in the proper position for the lock to work correctly. In other words, the stepper motor gear must be timed to a home position. 2. To time the stepper motor gear to the home position, do the following: a.
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Document Number 041.018 Rev. B 01/98 Converted to Acrobat 08/00 Notice: The information in this manual is subject to change without notice and does not represent a commitment on the part of Mas-Hamilton Group (MHG). MHG shall not be liable for technical errors or omissions contained herein; not for incidental or consequential damages resulting from the furnishing, performance or use of this material. © 1997, 1998, 2000 Mas-Hamilton Group® All rights reserved www.mas-hamilton.
