UC199 UC199 Japan Operating Manual Original Instructions D441737XA vers. 2.0

Transcription

1 Japan Operating Manual Original Instructions D441737XA vers. 2.0 EN

2 (c) 2012 SILCA S.p.a. Vittorio Veneto This manual has been drawn up by SILCA S.p.a. All rights reserved. No part of this publication can be reproduced or circulated by any means whatsoever (photocopies, microfilm or other) without the consent of SILCA S.p.a. Edition: May 2013 Printed at Vittorio Veneto by SILCA S.p.a. Via Podgora, 20 (Z.I.) VITTORIO VENETO (TV) Italy The Manufacturer declines any responsibility for possible inaccuracies in this document due to printing or transcription errors. The Manufacturer reserves the right to alter the information without prior notice, except when they affect safety. This document or any of its parts cannot be copied, altered or reproduced without written authorization from the Manufacturer. Keep the manual and look after it for the entire life cycle of the machine. The information has been drawn up by the manufacturer in his own language (Italian) to provide users with the necessary indications to use the key-cutting machine independently, economically and safely. IMPORTANT NOTE: in compliance with current regulations relating to industrial property, we hereby state that the trade-marks or trade names mentioned in our documentation are the exclusive property of authorized manufacturers of locks and users. Said trade-marks or trade names are nominated only for the purposes of information so that any lock for which our keys are made can be rapidly identified.

3 INDICE USE OF THE MANUAL... 1 GENERAL WARNINGS MACHINE DESCRIPTION Main characteristics Safety Main working parts (Standard) Main working parts - with OPTIONAL Loader Unit Technical Data Accessories Provided TRANSPORT Packing Unpacking Machine handling MACHINE INSTALLATION AND PREPARATION Checking for demage Environmental conditions Positioning and installation Description of work station Graphics SET UP AND USE OF THE MACHINE Keyboard and function Use of standard clamp (L100) Cutting cruciform keys (with 3 fins) Use of the automatic clamp - OPTIONAL Use of loader - OPTIONAL Fitting the standard clamp to the machine Application/Removing of loader Unit (automatic clamp + loader) - optional Changing cutting tool OPERATING GUIDE Initial operation [1] Copy from an original [1] Copy from an original [2] Copy with Corrections [2] Copy with Correction QUEUE FROM PC DECODING (only with pc program) [4] Calibrations CLAMPS CALIBRATION Calibrating the L100 standard clamp (1st calibrating) Calibrating the OPTIONAL Automatic clamp L1 (2nd calibrating) CUTTER CALIBRATION ADAPTER CALIBRATION [5] MAINTENANCE Test Machine zeroes OPTIONAL Loader Unit [6] Options...60

4 5.10 Machine message Error message ATTENTION messages Alarm Messages CLEANING MAINTENANCE Trouble shooting Maintenace operations Access to the top compartment Access to the bottom compartment Cutter replacement Belt replacement and tension adjustment Replacement of the jaws on the automatic optional clamp - OPTIONAL Checking and replacing fuses Electronic circuit board replacement Keyboard / display replacement Sensors replacement Replacing the condenser (motor) and/or feeder (lamp) Motor replacement Lamp replacement Master/emergency switch replacement Clock Battery replacement WIN-TRANSFER Program for loading/updating the internal machine program DISPOSING OF MACHINE ASSISTANCE How to request service...89 Appendix 1 - ELECTRICAL DIAGRAMS Appendix 2 - CE DECLARATION

5 USE OF THE MANUAL This manual has been drawn up by the Manufacturer and is an integral part of the machine literature. The manual gives information it is obligatory for the operator to know and which makes it possible to use the machine safely. User s Manual This user s manual is provided because it is essential for proper use and maintenance of the machine. The manual must be kept carefully throughout the life of the machine, including the decommissioning stage. Keep in a dry place close to the machine where it is always to hand for the operator. ATTENTION: IT IS OBLIGATORY to read the manual carefully before using the machine. Readers characteristics This manual must be read and its contents acquired by those who will use it. Manufacturer s ID has an ID plate located on the back of the machine, showing the serial number. Fig. 1 (*) see chap.8 DISPOSING OF MACHINE. How to apply for after-sales service Silca provides purchasers of with After-Sales Service. For the total safety of the operator and machine, any operation not described in the manual must be carried out by the manufacturer or in the special Service Centres recommended by Silca. At the end of the manual there is a list of manufacturers and authorized Service Centre addresses. The warranty card attached to the machine covers free repairs or replacement of faulty parts for 24 months from the date of purchase*. All operations must be agreed by the user with Silca or the Service Centre. * Damage caused by negligence or wrong use of the machine by the user will null the warranty. Copyright Silca

6 TERMINOLOGY For those inexperienced in the subject of keys and key cutting, below is an illustration of the most frequently used terms: Fig. 2 1) Head 3) Stop 5) Tip 7) Cuts 2) Neck 4) Stem 6) Back 8) Diameter GRAPHICS IN THE USER S MANUAL Pay attention Obligation to read the manual GRAPHICS ON THE KEY-CUTTING MACHINE Obligatory use of safety goggles Laser warning labels (ch.1.2) 2 Copyright Silca 2012

7 GENERAL WARNINGS is designed to the principles of European Standards (CE). Right from the design stage solutions have been adopted to eliminate hazards for the operator in all the stages of use: handling, regulation, use and maintenance. The materials used in manufacture and the components employed in using are not dangerous and ensure that the machine complies to current standards. Silca S.p.A. has also experimented and applied numerous technical solutions that allow the key-cutting machine to optimize the quality of the cut keys. To guarantee maintaining these results over time, please follow the instructions below: Observe the procedures described in this manual; Always use Original Silca Tools as they are designed to make the best of and provide quality keycutting; Use Silca key blanks, made with top quality materials; Have the key-cutting machine checked periodically by an authorized Silca After-Sales Service Centre (list at the end of this manual); always use Silca Original Spare Parts. Beware of imitations! NORMAL USE is a key-cutting machine and must be installed and used according to the rules and specifications established by the manufacturer. Any other use different from that indicated in this manual will cause the forfeiture of all customers rights to make claims on Silca S.p.A. and may be an unknown source of hazard for the operator or third parties. ATTENTION: Negligent use or failure by the operator to observe the instructions in this manual are not covered by the warranty and the manufacturer declines any responsibility in such cases. RESIDUAL RISKS No further risks will arise when properly using the. SAFETY REGULATIONS Always disconnect the machine when it is not in use or when performing maintenance operations. Check the electrical wiring periodically; replace any wires that show signs of wear. Always work with dry hands free of grease or oil. Never pull hard on the power lead and make sure it does not come into contract with oil, sharp objects or heat. Never remove the earth wire from the plug. Make sure the earth wire connection is sound. Do not use the machine in dangerous environments (wet or damp). All visitors, especially children, must stay at a safe distance from the machine and must never come into contact with the electric wiring. Copyright Silca

8 1 MACHINE DESCRIPTION is an electronic machine operating on two axes with controlled movement (3rd axis only with OPTIONAL Loader Unit). Accurately studied, it adds a high degree of cutting precision to operating speed and ease of use. can operate by: Reading a key with a laser reader and duplicating it Connecting to a PC and using Silca software is used to cut the following types of keys: Fig. 3 only with JAPAN Fig. 4 ATTENTION: keys with cuts that begin before Stop 0 cannot be cut. Fig. 5 4 Copyright Silca 2012

9 1.1 Main characteristics Movements The 2 axes (X-Y) move on ball screws activated by step motors on rectified roller guides and ball bushes. Clamp Standard four-sided clamp, specially designed to grip most flat keys. Working tools Consists of a cutter in hard metal (carbide), that is easily replaced. Suitable to the type of work and speed rotation needed. Display Rear-illuminated and placed on the front of the machine. Display with 4 rows of 20 characters each. Its technical features and positioning make it highly practical in use. Laser reader Designed to read cuts on keys to be reproduced. Automatic Clamp Only for keys as in Fig. 6. Loader Only for keys as in Fig. 6. LOADER UNIT - OPTIONAL TECHNICAL DATA FOR KEYS TO BE CUT WITH OPTIONAL FEEDER Fig. 6 Key thickness: min.1,8 mm - max.2,6 mm (with jaws A o B) min. 2,0 mm - max.2,8 mm (with jaws A + 2,0 2,8) Max. cutting depth: 3,9 mm (with jaws A); 2,9 mm (with jaws B) Blade height/width: max.10 mm (with jaws A); max.9 mm (with jaws B) Key head width: *max. 28 mm ATTENTION: only for keys with cuts on 1 side and key stop [not keys with plastic heads (except for SWING and SILKY), not cruciform keys or keys with tip stops]. Copyright Silca

10 1.2 Safety is entirely built in compliance to the Machine Directives. The operations for which it has been designed are easily carried out with no risk to the operator. The adoption of general safety precautions and observation of the instructions provided by the manufacturer in this manual eliminate all human error, unless deliberate. is designed with features which make it completely safe. Protective shield The protective shield is designed to cover the working parts as completely as possible, ensuring operator safety. The shield (U) (Fig. 8) must be raised in order to fit keys for cutting or carry out other operations. Raising of the shield is controlled by a microswitch and disactivates the operating and movement functions, including the cutter. A special message appears on the display to warn that the shield is not closed. To re-start the work cycle, place the shield in its original position and press START on the machine s keyboard. Emergency stops The red emergency button (A) (Fig. 8), located on the left of the keyboard is used to stop it immediately in the event of faulty operation or danger for the operator. When the cause of the emergency has been eliminated, turn the button 45 clockwise to disactivate it. NOTE: the operator is responsible for keeping the area around the button clear so that it can be reached as quickly as possible. Laser warning Regulations require that warning labels (supplied - ch.1.6) in the language to be used be attached to the optical reader, as shown in Fig. 7. Fig. 7 Cutter motor protection The cutter motor is protected against overheating by a cut-out switch (located inside the motor) that will automatically stop the motor if it reaches a certain temperature. Should the switch activate: 1) turn the machine off and disconnect the power supply cable. 2) contact Silca s Technical Assistance Dept. 6 Copyright Silca 2012

11 1.3 Main working parts (Standard) Fig. 8 A - master switch / emergency button B - keyboard C - display D - clamp optical reader D2 - clamp cutter side (standard) E - optical reader clamp knob E2 - clamp knob - cutter side F - key gauge - optical reader side F2 - key gauge - cutter side H - cutter I - cutter shield L - optical reader P - power input Q - serial port S - X axis carriage T - Y axis front panel U - protective shield V - swarf tray V1 - swarf tray W - glove compartment Copyright Silca

12 1.4 Main working parts - with OPTIONAL Loader Unit D741756ZB Set Feeder Fig. 9 A - master switch / emergency button B - keyboard C - display D - clamp optical reader D1- clamp cutter side (Automatic) E - optical reader clamp knob F - key gauge optical reader side H - cutter (Fig. 8) I - cutter shield (Fig. 8) L - optical reader P - power input (Fig. 8) Q - serial port (Fig. 8) S - X axis carriage T - Y axis front panel U - protective shield V - keys tray V1- swarf tray V2 - key slide W - glove compartment Z - loader 8 Copyright Silca 2012

13 1.5 Technical Data Electricity supply: 230V - 50Hz 120V - 60Hz 100V - 50/60Hz ( Japan) Maximum absorbed power: 230V: 2,1 Amp. 300 Watt 120V: 3,9 Amp. 300 Watt 100V: 3,3 Amp. 200 Watt Cutter motor: single phase and speed Cutter: hard metal (carbide) Tool speed: 50Hz: 2110 rpm 60Hz: 2530 rpm Movement: on 2 axes with ball screws activated by step motors, on rectified roller guides and ball bushes. Standard clamp : universal 4 sided clamp to grip flat, car and cruciform keys Japan clamp: 4 sided clamp to grip flat, car, cruciform keys and MIWA keys Automatic clamp (with optional Loader Unit) Automatic to grip flat keys (see Fig. 2) Runs: X axis: 74 mm Y axis: 45 mm Dimensions: width: 396 mm (with optional key tray: 458 mm) depth: 543 mm height: 386 mm (with raised shield 590 mm) Mass: Kg. 50 Noise level: sound pressure Lp(A) = 83 db(a) (cutting steel keys) 78 db(a) (cutting brass keys) CLASS 1 LASER READER: Maximum radiation with safety lock excluded: 170 µw Wave length: 785 µm (invisible) Classed to: EN : E.C A1: A2:2001 Copyright Silca

14 1.6 Accessories Provided comes with a set of accessories for its operation and maintenance (tools, hex wrenches, fuses) supplied in a special tool kit comprising: tools kit 4 mm allen key template Z3 (regulating key) tip stop with notch 5 mm allen key Z4 serial test connector tip stop 6 mm allen key Z19 template for Zero machine Cutter release rod 6.3 Amp fuse - delayed Z20 template 10 mm spanner 4 Amp fuse - delayed ø 1,7 mm steel pin 13 mm spanner 2 Amp fuse - delayed ø 1,2 mm steel pin 14 mm spanner 5 Amp fuse rapid (for 230V) 10 Amp fuse rapid (for 100V-120V) Slanted brush 2 mm allen key 10 Amp fuse - delayed Emergency button release clip 2,5 mm allen key Serial cable 9/9 Laser warning labels 3 mm allen key 3 mm allen key USB serial cable 10 Copyright Silca 2012

15 2 TRANSPORT The key-cutting machine is easily transported and is not dangerous to handle. The packed machine should be carried by at least two people. 2.1 Packing The packing for is designed to ensure safe transportation and to protect the machine and all its parts. It comprises a pallet base (b) to which the machine is attached, and a cardboard box as a cover (a). The machine is fixed to the base of the pallet with screwed down brackets that hold it firm into place. This prevents the machine and its protective shield from any damage. The closed packing is held in place by two straps which hold the cardboard box firmly on the pallet. The symbols on the outside of the cardboard box give indications for transport. Fig. 10 Keep dry Keep dry This side up Use no hooks To prevent any damage to the machine it is advisable to save and use the brackets provided for future transportation. Copyright Silca

16 2.2 Unpacking To remove the machine from the packing box: 1) cut the straps with scissors and remove. 2) raise the top part of the cardboard box. 3) loosen the screws, both on the front and back brackets that hold the machine to the pallet. 4) use the special spanner, to loosen the nuts on the machine s feet. 5) remove the metal brackets and re-tighten the nuts on the feet. 6) check the contents in the box, that should comprise with the following: 1 key-cutting machine 1 set of documents, including: an operating manual, a spare parts list and a guarantee 1 power supply cable 1 serial cable 1 pouch/ tool kit 1 USB serial cable 1 Loader Unit (*) NOTE: we strongly recommend you keep the packing intact for future transportation. 2.3 Machine handling When the has been unpacked, place it directly on its workbench; this operation should be carried out by at least two people. ATTENTION: Take care to lift the machine firmly holding the base, and no other part. Fig Copyright Silca 2012

17 3 MACHINE INSTALLATION AND PREPARATION The key-cutting machine can be installed by the purchaser and does not require any special skills. It is supplied ready for use and does not need any special set up. However, the operator may have to control a few things before operating the machine. 3.1 Checking for demage is solid and compact and will not normally damage if transport, unpacking and installation have all been carried out according to the instructions in this manual. However, it is always advisable to check that the machine has not suffered any damage 3.2 Environmental conditions To ensure that the best use is made of the key-cutting machine, it is important to place it in a well-aired area which is not too damp. The ideal conditions for the machine are: - temperature between 10 C and 40 C; relative humidity: 60% approx. 3.3 Positioning and installation 1) Place the machine on a horizontal surface, solid enough to support the weight of (50 Kg). - to work with ease, we suggest that the workbench be approximately the height of the operator s hip. - it is important to leave clearance of at least 30 cm behind the machine and on each side to ensure proper ventilation. 2) Ensure that the machines voltage is the same as that of the mains power supply, which must be properly earthed and provided with a differential switch. 3) Connect the power supply cable to the power supply socket. Fig. 12 Copyright Silca

18 3.4 Description of work station The machine needs only one operator, who has the following controls at his/her disposal (Fig. 8): general power switch/emergency button located on the front left-hand side of the keyboard key-positioning clamp keyboard display 3.5 Graphics The front panel carries an adhesive warning label (Fig. 14). This label must never be removed. Two laser warning labels must be attached to the optical reader (Fig. 14), (provided - Ch.1.6). Fig. 13 Do not use compressed air for cleaning Fig. 14 Laser warning labels 14 Copyright Silca 2012

19 4 SET UP AND USE OF THE MACHINE 4.1 Keyboard and function The machine s keyboard has 9 function keys. Fig. 15 Function keys STOP: Stop button, particularly when the machine is in motion. Stops the function in progress at any time in the operation. START: Starts the machines operations (only with the shield in its closed position). ENTER: Activation of various functions in the menu. CLEAR: Deletes numerical characters. SHIFT + CLEAR: Combine the SHIFT + CLEAR keys to automatically switch to the Copy from original function from any menu in the internal program (Ch.5.2). SHIFT + STOP: Combine the SHIFT+STOP keys to re-position the carriages accurately (operation from the main menu only, or if the cutting process is interrupted). Regulating the display it is possible to modify the angle of vision (illumination) on the machine s display by following the instructions below. Press the arrow key [Down] to get a better view from below and then press the arrow key [Up], simultaneously keeping the arrow keys both pressed [Up/Down] up until you reach the desired visualization. Press the arrow keys [Up/Down] to get a better view from above and then press the arrow key [Down], simultaneously keeping the arrow keys both pressed [Up/Down] up until you reach the desired angle. Copyright Silca

20 4.2 Use of standard clamp (L100) Cutting Clamp Fig. 16 Reading Clamp The four-sided clamp ensures excellent grip on the keys placed on their back or profile sides (Fig. 17). To copy keys (which may be secured to any of the clamp sides A, B, C or D) the user will choose the most suitable side of the clamp to use (Fig. 17). CLAMP Fig Copyright Silca 2012

21 CLAMP JAPAN Fig. 18 ATTENTION: the position of the clamps (CUTTING and READING) cannot be inverted. KEY STOP POSITIONS Fig Keys with Stop 0 Fig Keys with tip stop To fit keys with tip stops into the clamps, use the bar provided inserted into the special grooves (Fig. 20), or up against the right-hand side of the clamp. ATTENTION: when closing the clamp, do not apply excessive pressure to the knob. Turning the knob approximately 70 (equal to a force of 3Nxm) is sufficient to secure the key (Fig. 21). Fig. 21 Copyright Silca

22 NOTE: before starting the cutting process the L100 clamp (of cutting) key gauge will automatically tilt itself to its rest position. Using the pins (only with standard clamp) For keys with narrow stems the pins must be placed between the bottom of the clamp and the back of the key so that the key protrudes sufficiently out of the clamp and therefore can be properly read and cut. If the key has a narrow stem and is also very thin, 2 pins must be used (Fig. 22). Fig. 22 If the original key is broken, place a suitable sized pin in the groove of the keys stem so that it is properly held in place and therefore can be copied (Fig. 23). NOTE: the diameter of the pin used for the original key must be the same as that of the pin used for the blank key; only in this way will the two keys be locked in the same position. pin Attention: the pin should be placed vertically Fig. 23 ATTENTION: never use pins with the Automatic Clamp. 18 Copyright Silca 2012

23 4.3 Cutting cruciform keys (with 3 fins) Almost all cruciform keys (wiyh the exception of Y and T shapes) can be cut with four-sided Standard clamp (L100). Positioning cruciform keys 1) Leave the gauges in the idle position. 2) Fit the original key into the left-hand clamp: Insert the grooved bar into the notch on the clamp according to the key stop (as shown in Fig Key stop towards the inner part of the clamp, Fig. 25 Key stop DOWN and Fig Key stop UP). Butt the key stop up against the bar. 3) Tighten the knob (F) to secure the key. 4) Remove the bar. 5) Repeat the same procedure on the other clamp holding the key blank to be cut (pay attention to the corresponding fin). 6) Remove the bar. 7) Cut the first fin. 8) Turn the keys in the same direction to cut the other fins. ATTENTION: the cuts on each fin are different. position of key and bar Fig Key stop towards the inner part of the clamp Fig. 25 Key stop DOWN Fig Key stop UP Copyright Silca

24 4.4 Use of the automatic clamp - OPTIONAL Keys are fitted into the clamp automatically by means of a mechanical loader. The keys are positioned on their back and automatically locked. Keys are secured by the clamp jaws, which are powered by a motor incorporated in the clamp. This excludes any operator interference. NOTE: never use pins with the Automatic Clamp. ATTENTION: only for keys with cuts on 1 side and key stop. NO keys with plastic heads (except for SWING and SILKY), no cruciform keys or keys with tip stop. Keys cut on this clamp must be of the types described below: TECHNICAL DATA FOR KEYS TO BE CUT Fig. 27 Key thickness min.1,8 mm - max.2,6 mm (with jaws A or B) min. 2,0 mm - max.2,8 mm (with jaws A + 2,0 2,8) Max. cutting depth: 3,9 mm (with jaws A); 2,9 mm (with jaws B) Blade height/width: max.10 mm (with jaws A); max.9 mm (with jaws B) Key head width: *max. 28 mm 1) Jaws A (standard) (Fig. 28) Automatic Clamp (L1): with jaws A Reading standard Clamp (L100): side A 2) Jaws B (provided) (Fig. 29) Automatic Clamp (L1): with jaws B Reading standard Clamp (L100): side B 3) Jaws A (lower) + 2,0 2,8 (upper - provided) (Fig. 30) Automatic Clamp (L1): A (lower) + 2,0 2,8 (upper) Reading standard Clamp (L100): side A 20 Copyright Silca 2012

25 Fig. 28 Fig. 29 Fig. 30 ATTENTION: always replace both jaws. Mixed jaws may be used only for keys with a thickness of 2.0 mm to 2.8 mm. NO! type: Upper jaw A + Lower jaw B type: Upper jaw B + Lower jaw A type: Upper jaw 2,0 2,8 + Lower jaw B YES type: Upper jaw A + Lower jaw A type: Upper jaw B + Lower jaw B type: Upper jaw 2,0 2,8 + Lower jaw A NOTE: instructions on how to replace the jaws on the Automatic clamp are given in ch.7.7. Copyright Silca

26 4.5 Use of loader - OPTIONAL After installation of the Loader Unit (ch. 4.7), when placing key blanks into the loader, to ensure proper operation of the mechanical parts of the device, remember the parameters highlighted in Fig. 27, and pay attention to: Orientation of the key Stem dimension regulation Head dimension regulation 1) The keys must be placed into the loader with the head to the left and the back to the operator. 2) Adjust the screw (G), place the plate (J2) against the stem of the key, then draw back by about 1 mm. 3) Loosen the screw (G2) adjust the screw (G1), place the magnet plate (J1) against the head of the key. Tighten the screw (G2). Fig Copyright Silca 2012

27 4.6 Fitting the standard clamp to the machine To remove the standard clamp (cutting side): loosen the screw (D2) (Fig. 32) the mechanical loader cannot be used when operating the key-cutting machine with the standard 4 sided clamp.25) and slide the clamp unit out of the dovetail guide. To install the standard calmp unit (cutting side) on the machine: slide the clamp into the dovetail guide, pushing it all the way in, then secure it by tightening the screw (D2). Fig. 32 NOTE: (with the optional Loader Unit) the mechanical loader cannot be used when operating the keycutting machine with the standard 4 sided clamp. Copyright Silca

28 4.7 Application/Removing of loader Unit (automatic clamp + loader) - optional In the main menu place the pointer on position 5 (Maintenance) and press ENTER, then place the pointer on position 3 (Loader Unit) and press ENTER. Follow the instructions in Ch OPTIONAL Loader Unit. NOTE: it is compulsory to turn off the machine before removing the Loader Unit or any part of it. With Loader Unit installed Remove automatic clamp: loosen the screw (D2) and pull out the clamp to the left. NOTE: If the machine is to be used without the Loader Unit, loosen the screw (D3) with the (long) hex wrench provided, remove the loader and remember to fit the serial protection (S1) into the loader seat. Fit the standard cutting clamp into the special dovetail runner, pushing it to the right until it stops, then tighten the screw (D2). Fit the Automatic Clamp: fit the automatic clamp into the special dovetail runner, pushing it to the right until it stops, then tighten the screw (D2). Fig. 33 Fig Copyright Silca 2012

29 Without Loader Unit Installed Proceed as follows: 1) Remove the standard cutting clamp: loosen the screw (D2) and pull out the clamp to the left (Fig. 32). 2) Fit the loader: Remove the cover/protection (S1) (Fig. 34) on the serial input fitted to the loader seat. Please keep the protection for future use. Fit the loader, pushing it all the way in, then tighten the screw (D3) with the (long) hex wrench provided. 3) Fit the Automatic Clamp: fit the automatic clamp into the special dovetail runner, pushing to the right until it stops, then tighten the screw (D2) (Fig. 36). NOTE: please note that the automatic clamp can be fitted only after the loader has been inserted. NOTE: the mechanical loader cannot be used when operating the key-cutting machine with the standard 4 sided clamp. Fig. 35 Fig. 36 Copyright Silca

30 4.8 Changing cutting tool 1) Zero the carriage movements (from the main menu press SHIFT+STOP). 2) Turn off the power to the key-cutting machine. 3) Raise the safety shield. 4) Loosen the screw (D2) (Fig. 38), pull out the clamp to the left and remove (see Ch. 4.7 for the automatic clamp). 5) Fit the cutter release rod (X) provided into the special hole (if a new cutter is being fitted to replace a worn one, or in order to sharpen the cutting edge (Fig. 37). 6) Use the 14 mm wrench (X1) to loosen the cutter locking nut. ATTENTION: the thread is left-handed. 7) Replace the cutter, tighten the nut and remove the rod from the hole. 8) Fit the clamp unit and push all the way in to the right. Tighten the screw (D2). close open Fig. 37 ATTENTION: if a new cutter is being fitted to replace a worn one, or in order to sharpen the cutting edge, see Ch. 5.7 [4] Calibrations. Fig Copyright Silca 2012

31 5 OPERATING GUIDE Introduction The Operating Guide below gives instructions on how to use the automatic key-cutting machine. All operations are described to facilitate use of the machine. To facilitate describing the operations we have summarised the two possible machine configurations as follows: with Standard configuration: Cutting side standard clamp (L100) Standard optic reader clamp (L100) Fig. 39 with Loader Unit configuration (OPTIONAL): Key blank loader Cutting side automatic clamp (L1) Standard optic reader clamp (L100) Fig. 40 Copyright Silca

32 5.1 INITIAL OPERATION When the key-cutting machine has been placed on its workbench and connected to the mains (Ch. 3.3), proceed as follows: 1) turn on the machine by means of the master switch/emergency button (turn 45 clockwise). 2) to check or alter the parameters for use of the machine, consult the Options [6] (Ch.5.9). When the machine is turned on, for a few seconds the display shows the internal software version and the machine model: Version x.x.xxx Vers. DB xx.xx The display shows (only on fi rst start-up): Select language = 2 1-Italiano 2-English 3-Deutsch 4-Francais 5-Espanol Operational keys: arrow keys [< >] to choose the option, ENTER to confi rm. Save the modifi cation? No=STOP Yes=ENTER The message will appear: Zero the axes! [START] NOTE: This message will appear every time the machine is started. Press START, the machine checks the position of the carriages then goes on to: MAIN MENU 1- Copy from original 2- Copy with adjust. 3- Queue from PC 4- Calibrations >> 5- Maintenance 6- Options Operational keys: use the arrow keys [Up/Down] to move the cursor to the option required and press ENTER. The >> symbol indicates that the menu contains other items which can be reached with the arrow key [Down]. 28 Copyright Silca 2012

33 5.2 [1] Copy from an original - with standard configuration - Operational keys: use the arrow keys [Up/Down] to move the cursor to the option required and press ENTER. 1- Copy from original 2- Copy with adjust. 3- Queue from PC 4- Calibrations >> 5- Maintenance 6- Options Place the pointer on position 1, press ENTER to select the function; the display will show: Original on right Key blank on left Adaptor: Pcs: 1 / 1 [START] - Insert the original key in the right-hand clamp (remember to lower the gauge or remove the stop bar, if applicable). - insert the key blank into the left-hand clamp (remember to remove the stop bar, if applicable. The gauge need not be lowered because it will automatically release itself when the carriage moves). ATTENTION: keys with cuts that begin before Stop 0 cannot be cut. Fig. 41 ATTENTION: use the same side and stop position as the key fitted to the L100 optical reader side clamp. Set the number of keys. Operational keys: press the keys [< >] to enter the quantity of keys to be cut. To increase or decrease the values more quickly, press the keys SHIFT+ [>] or SHIFT+ [<] (the max. value is 255). Close the protective shield. Press START. - if the shield is not lowered, when the START button is pushed the following warning message appears: otherwise: Close shield! Reading & cutting in progress Copyright Silca

34 during the reading stage the key blank is also cut. Copy: 1 of: 1 finished. More copies? No=STOP Yes=ENTER Press ENTER to repeat the cycle and copy more keys. If a number of pieces over 1 (e.g. 3) has been set, the following sequence will occur: Reading & cutting in progress Press STOP to return to the main menu. Install the Key blank on left Adaptor: Pcs: 2 / 3 [START] 5.3 [1] Copy from an original - Configuration with OPTIONAL Loader Unit NOTE: check the parameters of the key to be cut with those given in Fig. 27 page to verify whether to use Side A or B of the standard clamp, and whether the automatic clamp should have jaws A, B or A/2,0 2,8. Operational keys: use the arrow keys [Up/Down] to move the cursor to the option required and press ENTER. 1- Copy from original 2- Copy with adjust. 3- Queue from PC 4- Calibrations >> 5- Maintenance 6- Options 1) With the pointer on position 1, press ENTER to select the function. Original on right Feeder ready Adaptor: Pcs: 1 / 10 [START] 2) place the original key into the R/h clamp. Lower the gauge. 3) the key blank (or blanks) into the loader, with their backs towards the operator. 4) press the arrow keys [< >] keys to set the number of keys to be cut. Press START to see on the display at first: 30 Copyright Silca 2012

35 Reading & cutting in progress ATTENTION: The key depth is not fully cut during reading. CUTTING IN PROGRESS Copy: 1 of: 10 Press CLEAR to stop the cycle When CLEAR is pressed (for about 2 seconds) the cycle is stopped. The cut being made will be completed and then the carriages will stop in their initial position and the following screen will appear: Stopping cycle In progress Feeder ready Adapter: Pcs.: 2 / 10 [START] The machine will continue until the programmed operation is finished. The display will show: Copy: 10 of: 10 Finished. More copies? No=STOP Yes=ENTER Press ENTER to repeat the cycle and copy more keys. Press STOP: Original on right Feeder ready Adapter: Pcs: 1 / 1 [START] Press STOP to return to the main menu. ATTENTION: if a machining cycle is interrupted (intentionally or accidentally), the display will show: ATTENTION Remove key from clamp! [START] IT IS COMPULSORY to remove the key: press START, raise the safety shield and remove the key from the Automatic Clamp. The display will show the message: Zero the axes! [START] Copyright Silca

36 Lower the safety shield and press START to continue. NOTE: in exceptional cases (e.g. machine breakdown) the key can be removed from the automatic clamp manually : 5) raise the safety shield. 6) use a 5 mm hex wrench on the automatic clamp screw (D5) in order to open the jaws. 7) remove the key (blank or cut) and close the jaws with the 5 mm hex wrench. 8) remove the 5 mm hex wrench and lower the safety shield. Fig. 42 NOTE: if the absence of key blanks in the loader is detected during the cycle, the display will show: FEEDER EMPTY Pieces maked: x / y Continue? No=STOP Yes=ENTER Open the guard and insert one or more key BLANKS (according to needs). At the cutting stage it can be used to know how many keys should be added to finish the job. NOTE: press SHIFT + START to continue, even if the key has not been detected (e.g. head bore too big). 32 Copyright Silca 2012

37 5.4 [2] Copy with Corrections - Standard configuration - Function used to correct (on the copy) any imperfections in the depth and/or cutting pitch on the original key (generally used for very worn keys). Operational keys: use the arrow keys [Up/Down] to move the cursor to the option required and press ENTER. 1- Copy from original 2- Copy with adjust. 3- Queue from PC 4- Calibrations >> 5- Maintenance 6- Options 1) With the pointer on position 2, press ENTER to select the function. Original on right [START] ATTENTION: keys with cuts that begin before Stop 0 cannot be cut. Fig. 43 2) Insert the original key in the right-hand clamp (remember to lower the gauge or remove the stop bar, if applicable). Press START to see on the display at first: Reading in progress and then: Key blank on left Depth adj. = +00 Spaces adj. = +00 Pcs: 1 / 1 [START] 3) place the key blank into the L/h clamp (remember to remove the stop bar, if applicable. The gauge may be left up as it will automatically release itself during carriage motion). If a loader unit is used the keys must be inserted with their backs towards the operator. 4) Make the necessary adjustments to copy the key as required. Copyright Silca

38 Data alteration The operator may alter the depth and space parameters. Operational keys: to increase or decrease the parameters use the arrow keys [< >] or combination of the keys SHIFT + [>] or SHIFT + [<]. Depth: (from -30 to +30 hundredths of a mm) - Enter the value (positive or negative) to raise or low er all the cuts. Fig DEPTH ADJUSTMENTS Spaces: (from -30 to +30 hundredths of a mm) - Enter the value (positive or negative) to move all the cuts closer to or farther from the key stop. Fig SPACES ADJUSTMENTS 5) Set the number of keys to be cut. Operational keys: press the keys [< >] to enter the quantity of keys to be cut. Press START to see on the display at first: CUTTING IN PROGRESS Copy: 1 of: 1 Then: Copy: 1 of: 1 Finished. More copies? NO=STOP Yes=ENTER Press STOP to return to the main menu. 34 Copyright Silca 2012

39 5.5 [2] Copy with Correction - Configuration with OPTIONAL Loader Unit Function used to correct (on the copy) any imperfections in the depth and/or cutting pitch on the original key (generally used for very worn keys). 1- Copy from original 2- Copy with adjust. 3- Queue from PC 4- Calibrations >> 5- Maintenance 6- Options 1) with the pointer on position 2, press ENTER to select the function. Operational keys: use the arrow keys [Up/Down] to move the cursor to the option required and press ENTER. Original on right Adaptor: [START] 2) place the original key into the R/h clamp (remember to lower the gauge). 3) place the key blank (or blanks) into the loader, with their backs towards the operator. Press START to see on the display, at first: Reading in progress ATTENTION: The key depth is not fully cut during reading. and then: Feeder ready Depth adj. = +00 Spaces adj. = +00 Pcs: 1 / 1 [START] 4) Make the necessary adjustments to copy the key as required. Data alteration The operator may alter the depth and space parameters. Operational keys: to increase or decrease the parameters use a combination of the keys SHIFT + [arrow Up] or SHIFT + [arrow Down]. Depths: (from -20 to +20 hundredths of a mm) Enter the value (positive or negative) to move all the cuts closer to or farther from the key stop. Fig. 46 DEPTH ADJUSTMENTS Copyright Silca

40 Spaces: (from -20 to +20 centesimi di mm) Enter the value (positive or negative) to move all the cuts closer to or farther from the key stop. Fig SPACES ADJUSTMENTS 5) Set the number of keys to be cut. Operational keys: press the keys [< >] to enter the quantity of keys to be cut. Press START to see on the display, at first: CUTTING IN PROGRESS Copy: 1 of: 1 And then: Press STOP to return to the main menu. Copy: 1 of: 1 Finished. More copies? NO=STOP Yes=ENTER NOTE: if a machining cycle is interrupted (intentionally or accidentally), the display will show: ATTENTION Remove key from clamp! [START] IT IS COMPULSORY to remove the key: press START, raise the safety shield and remove the key from the Automatic Clamp. the display will show the message: Lower the safety shield and press START to continue. Zero the axes! [START] NOTE: in exceptional cases (e.g. machine breakdown) the key can be removed from the automatic clamp manually : 1) raise the safety shield. 2) use a 5 mm hex wrench on the automatic clamp screw (D5) in order to open the jaws. 3) remove the key (blank or cut) and close the jaws with the 5 mm hex wrench. 4) remove the 5 mm hex wrench and lower the safety shield. 36 Copyright Silca 2012

41 Fig. 48 ATTENTION: if the absence of key blanks in the loader is detected during the cycle, the display will show: FEEDER EMPTY Pieces maked: x / y Continue? No=STOP Yes=START Open the guard and insert one or more key BLANKS (according to needs). At the cutting stage it can be used to know how many keys should be added to finish the job. NOTE: press SHIFT + START to continue, even if the key has not been detected (e.g. head bore too big). Copyright Silca

42 5.6 QUEUE FROM PC USING THE MACHINE WITH A PERSONAL COMPUTER The key-cutting machine can be used with the SILCA KEY PROGRAMS program, which can be used to transmit cutting and decoding jobs. Cutting jobs transmitted to the machine by a PC remain in the memory even when the key-cutting machine is turned off. Data received from a PC appear in the form of a list (example in Fig. 49): a - No. of jobs received b - indirect cutting code c - Silca cutting card No d - No. of pieces to be cut e - sign + indicates that the key set up has been cut. f - sign - indicates that none of the keys set up has been cut. Fig. 49 By using the arrow keys (up/down) the user may select the job to be carried out and confirm with ENTER. ATTENTION: job data received from a PC program CANNOT be altered on the machine. Place the cursor on position 3 and press ENTER. Select the job to carry out and press ENTER. 1- Copy from original 2- Copy with adjust. 3- Queue from PC 4- Calibrations >> 5- Maintenance 6- Options IF A STANDARD CLAMP IS INSTALLED: Press START to cut the key. Side: 1 Clamp: L1 / A Pos.: 0 Cutt.: U01W / Pcs.= 1 / 3 [START] 38 Copyright Silca 2012

43 IF THE OPTIONAL FEEDER IS INSTALLED: Press START to start the MANUAL CYCLE 1- [316] Pieces: 1 of: 3 Manual cycle = START 1+ [316] Pieces: 1 of: 1 MAN. CYC. IN PROGRESS Press CLEAR to stop the cycle MANUAL CYCLE The manual cycle is enabled by default: if there are a number of jobs in the PC queue, start the first one; when the job is finished the machine will stop to wait for new orders. Press SHIFT+START to start the AUTOMATIC CYCLE. AUTOMATIC CYCLE The automatic cycle can be enabled: if there are a number of jobs in the PC queue, start the first one; when the job is finished the machine does not wait for new orders but starts the second job immediately. ATTENTION: if there are keys set up in the feeder for several jobs (if the profile is not the same) these must be checked before starting work. When CLEAR is pressed (for about 2 seconds) the cycle stops. The cut being made will be completed and then the carriages will stop in their initial position. Stopping cycle in progress Feeder ready Adaptor: Pcs.:2/3 [START] Copyright Silca

44 5.6.1 DECODING (only with pc program) DECODING is a reading of the cuts on an original key made by the Silca cutting card for the key in question. This operation is used by the program to generate the path of the tool so that it creates a faithful copy of the original key. Start the Silca Key Programs program and enter the Key Cutting menu (1st icon top left-hand corner). Enter the search parameters (Silca art., Code, Cutting card, Manufacturer...). Once in the selected cutting card, click on Decode (top right-hand corner). Fig. 50 The key-cutting machine receives the information for starting the decoding operation from the: DECODE S.327 Original on right Clamp: 100/A Pos.0 Side 1 [START] Fit the key to be decoded (cut) into the right-hand reading clamp, as shown on the machine display. ATTENTION: during decoding THERE MUST BE NO KEY IN THE CUTTING CLAMP OR OPTIONAL LOADER AND AUTOMATIC CLAMP. Press START. The display will show: DECODING IN PROGRESS Side 1 Decoding OK See computer [ENTER] 40 Copyright Silca 2012

45 The result of decoding is shown by Silca Key Programs: Fig Set the number of keys to be cut in the Quantity field. - Click on Transmit to send the job to the key-cutting machine and create a faithful copy of the original key. Copyright Silca

46 5.7 [4] Calibrations The machine leaves the Silca workshops perfectly calibrated and ready for use. If it is necessary to check, bear in mind that: The machine has a partial self-setting system that uses templates (Ch. 1.6) and specific procedures. From the main menu press the SHIFT + STOP keys to zero the axes, then: Operational keys: use the arrow keys [Up/Down] to move the cursor to the option required and press ENTER. 1- Copy from original 2- Copy with adjust. 3- Queue from PC 4- Calibrations >> with the pointer on position 3 press ENTER to see on the display: 1- Cutting clamps 2- Cutter 3- Adaptors CLAMPS CALIBRATION In the circumstances listed below (see events) it may be necessary to re-set one or all calibration. This operation is semi-automatic and requires close attention to the instructions listed below. EVENT MACHINE ZEROES CALIBRATIONS STANDARD CLAMPS AUTMATIC CLAMP Electronic board replacement NO YES YES Replacement of the Optical Reader unit NO YES YES Replacement of sensors YES YES YES Replacement of the cutter shaft (*) YES YES YES Replacement of the ball screws (*) YES YES YES L100 clamp replacement / Cutting (with a new one of the same type) L100 clamp replacement / Reading (with a new one of the same) Re-sharpening of existing cutter and/or cutter replacement (with a new one of the same type) NO YES YES NO YES YES NO YES YES (*) Solo from Silca S.p.A. or Silca Authorized After-Sales Service Centres. Select Cutting clamps and press ENTER. Clamps L100 - Standard L1 - Autom. Feeder 42 Copyright Silca 2012

47 The calibrating sequence (if machine zeroes are not involved) is always: 1) L100 Standard Clamp (Cutting clamp + Reading clamp) 2) L1 Automatic Clamp (optional). After the 1st calibration (ch ) proceed with the 2nd calibration (ch ), special cases excepted (page Calibrating the L100 standard clamp (1st calibrating) - cutter side CLAMP - Before starting the calmp calibration, check that there are no keys (or other) fitted to clamps. ATTENTION: if the machine is with Loader Unit, remove the automatic clamp and loader (see Ch ) before proceeding. ATTENTION: carefully clean the Z20 template, test key Z3 and clamps before gauging. ATTENTION: manual adjustments set are enabled only for job data received from a PC (SKP). Select L100-STANDARD and press ENTER; the display will show: L100-STANDARD S: A Manual adjustment: X=+000 Y=+000 To calibrate [START] Press START; the display will show: ATTENTION Before proceeding read carefully the operating manual. Press START. Fit TEST key blank on Left side. See operating manual. [START] raise the safety shield. place the test key blank Z3 on side A of the standard cutting clamp. close the safety shield. Press START to see on the display, first: TEST key-cutting in progress! And then: Fit cut key on reader clamp to check measurements. [START] Remove the key from the cutting clamp, clean the key and fit to side A of the reading clamp. Copyright Silca

48 Fig. 52 Lower the gauge and press START; the display will show first: TEST key check in progress! And then: To compare detected quotes fit Gauge Z20 on reader clamp. [START] Remove the key from the reading clamp and fit the Z20 template in its place. Fig. 53 ATTENTION: carefully clean the Z20 template, test key Z3 and clamps before gauging. Lower the gauge and press START; the display will show first: Gauge dimensions reading in progress. and then: Adjustements: X =-005 Y= +002 Save data? No=STOP Yes=ENTER The display will show the adjustments relating to the X and Y axes; the correction values are viewed automatically (they are the difference between the value read on the key and the template value) (Fig. 54). Fig. 54 Press ENTER to save the adjustments, which will be applied automatically to the cutting side L100 clamp. ATTENTION: if the STOP key is pressed, the new settings will be lost. If so, only the previous setting values will remain valid. The settings will be accepted only if the tolerances remain within a range between -40/ +40 hundredths of a mm. 44 Copyright Silca 2012

49 The display will show: - OPTICAL READER CLAMP- READER CALIBRATION Install the Z20 template on reading clamp. [START] The Z20 template should be fitted, otherwise: - Raise the safety shield. - Fit the Z20 template on side A of the reading clamp, as if it were a key, and use the gauge as a stop. - Lower the gauge and safety shield. Press START. The display will show: Reading in progress X POSITION READING: X=404 (400) See operatine manual. [START] NOTE: Note: X deviations of +/- 20 hundredths of a mm from the theoretical measurement can be considered insignificant. Press START to confirm gauging without mechanical regulation. The X measurement read should be the same as the theoretical one (value = 400 expressed in brackets). If not, proceed as follows: For X values of less than 400, loosen the grub screw (P1) and use the hex. wrench to loosen the screw (P2). ATTENTION: a quarter turn of the screw (P2) makes a movement of approx. 19 hundredths of a millimetre. For X values of over 400, loosen the grub screw (P1) and use the hex. wrench to tighten the screw (P2). ATTENTION: a quarter turn of the screw (P2) makes a movement of approx. 19 hundredths of a millimetre. Fig. 55 Tighten the grub screw (P1) and press START: Y POSITION READING: Y=502 (500) See operatine manual. To repeat [START] NOTE: Y deviations of +/- 20 hundredths of a mm from the theoretical measurement can be considered insignificant. Press STOP to confirm gauging without mechanical regulation. Copyright Silca

50 The Y measurement read should be the same as the theoretical one (value = 500 expressed in brackets). If not, proceed as follows: For Y values of less than 500, loosen the grub screw (P3) and use the hex. wrench to tighten the screw (P4) ATTENTION: a quarter turn of the screw (P4) makes a movement of approx. 19 hundredths of a millimetre. For Y values of over 500, loosen the grub screw (P3) and use the hex. wrench to tighten the screw (P4). ATTENTION: a quarter turn of the screw (P4) makes a movement of approx. 19 hundredths of a millimetre. Fig. 56 Tighten the grub screw (P3) and press START to repeat the operation until the X and Y values are correct. When the values read for X and Y are the same as the theoretical ones (expressed in brackets), press STOP. The display will show: Confirm you want to quit the gauging procedure? No=STOP Yes=ENTER Press ENTER (*) to confirm. The display will show: Press START to re-start the gauging cycle. Press STOP. L100-STANDARD S: A Manual adjustment: X=+000 Y=+000 To calibrate [START] a MANUAL ADJUSTMENTS When the automatic calibration procedure is finished for clamp L100 (Side: A) adjustments to X (spaces) and Y (depths) can be made manually for sides B - C - D. Fig SPACING ADJUSTMENT (X) Fig DEPTH ADJUSTMENT (Y) Press SHIFT+ENTER to see on the display: L100-STANDARD S: B Manual adjustment : X=+000 Y= Copyright Silca 2012

51 Adjustments for X and Y can be made manually. Press SHIFT+ENTER to see on the display: L100-STANDARD S: C Manual adjustment: X=+000 Y=+000 Adjustments for X and Y can be made manually. Press SHIFT+ENTER to see on the display: L100-STANDARD S: D Manual adjustment: X=+000 Y=+000 NOTE: (*) Note: if you are confirming a measurement with a deviation of over +/-30 hundredths of a millimetre the display will show: Repeat the gauging procedure. ATTENTION X/Y gauged beyond the advisable tolerance range! Calibrating the OPTIONAL Automatic clamp L1 (2nd calibrating) ATTENTION: for possessors of the optional feeder unit and only after having calibrated the standard clamp (1st calibration). ATTENTION: manual adjustments set are enabled only for job data received from a PC (SKP). - cutter side CLAMP- Before starting the calmp calibration, check that there are no keys (or other) fitted to clamps. NOTE: check that the loader and automatic clamp are properly fitted (see Ch ). Select L1-AUTOMATIC and press ENTER; the display will show: L1-AUTOMATIC S: A Manual adjustment: X=+000 Y=+000 To calibrate [START] NOTE: the Automatic clamp must have two jaws A. Press START, the display will show: Fit key blank on loader See operating manual. [START] - raise the safety shield. - fit at least 1 test key blank Z3 into the loader, with its back towards the operator. - close the safety shield. - press START to see on the display, first: Copyright Silca

52 TEST key-cutting in progress! and then: Fit cut key on reader clamp to check measurements [START] Fig. 59 Raise the safety shield and place the key/template Z3 made in this way in the clamp on the reader side, using the gauge as a reference point. Lower the gauge and safety shield. Press START to see on the display, first: And then: TEST key check in progress Adjustements: X=+003 Y=+006 Save data? No=STOP Yes=ENTER The adjustment values are automatically shown. Press ENTER to confirm, the display will show: L1-AUTOMATIC S: A Manual adjustment: X= +000 Y= +000 To calibrate [START] Press STOP (once) to end the operation and twice again to return to the main menu. Press SHIFT+ENTER to see on the display: L1-AUTOMATIC S: B Manual adjustment: X=+000 Y= a MANUAL ADJUSTMENTS ATTENTION: manual adjustments set are enabled only for job data received from a PC (SKP). Adjustments to X (spaces) and Y (depths) can be made manually. Fig SPACING ADJUSTMENT (X) Fig DEPTH ADJUSTMENT (Y) 48 Copyright Silca 2012

53 5.7.2 CUTTER CALIBRATION This operation is necessary if existing cutters are sharpened and/or replaced with a tool of the same type. NOTE: if the original Silca U01W cutter is replaced with another Silca original, it is not necessary to repeat clamp calibration. Select Cutter and press ENTER. 1- Cutting clamps 2- Cutter 3- Adaptors Cutter 00 - U01/U01W >> P41 Operating keys: arrow keys [< >] to set the adjustment value (positive or negative). Adjustments can be made within an interval of +10 to -99 hundredths of a millimetre ADAPTER CALIBRATION The special ADAPTERS provided are high precision and do not need an automatic calibration system; however, if the user wishes adjustments can be made to the cutting values using the procedures illustrated. 1- Cutting clamps 2- Cutter 3- Adaptors Adapters B2 - Ford Tibbe B6 - Simplex (SX9) B15- Esety Omega Example: B6 - Simplex (SX9) B6 - Simplex (SX9) Manual adjustment: X=+00 Y=+00 Operating keys: arrow keys [< >] to increase or decrease the adjustment value. Arrow keys (Up/Down) to move from one field to another. Adjustments can be made within an interval of +30 to -30 hundredths of a millimetre. Copyright Silca

54 SPECIAL CASES: Customer check on gauging (in the event of worn cutter) Do 1st gauging operation: - if within tolerance press STOP - if gauging is upgraded and adjustments are made, do the 2nd gauging operations as well (only with the optional feeder unit). Cutter replacement Do 1st gauging operation: - if within tolerance press STOP - if gauging is upgraded and adjustments are made, do the 2nd gauging operations as well.(only with the optional feeder unit). Sensor replacement Do 1st gauging operation: - if within tolerance press STOP - if gauging is upgraded and adjustments are made, do the 2nd gauging operations as well.(only with the optional feeder unit). Basic PCB replacement Do all gauging operations again Loader PCB replacement No gauging operations to carry out Optic reader replacement Do 2^ gauging operation (only with the optional feeder unit). Cutting side clamp replacement Do 1st gauging operation: - if within tolerance press STOP - if gauging is upgraded and adjustments are made, do the 2nd gauging operations as well. Reading side clamp replacement Do 2nd gauging operation (only with the optional feeder unit). Optional Automatic clamp replacement Do 2nd gauging operation Ball screw replacement Do 1st gauging operation: - if within tolerance press STOP - if gauging is upgraded and adjustments are made, do the 2nd gauging operations as well (only with the optional feeder unit). Cutter shaft replacement Do 1st gauging operation: - if within tolerance press STOP - if gauging is upgraded and adjustments are made, do the 2nd gauging operations as well (only with the optional feeder unit). 50 Copyright Silca 2012

55 5.8 [5] MAINTENANCE 1) Enter the Maintenance menu 5. Operational keys: use the arrow keys [Up/Down] to move the cursor to the option required and press ENTER. 1- Copy from original 2- Copy with adjust. 3- Queue from PC 4- Calibrations >> 5- Maintenance 6- Options The display will show: 1- Test 2- Machine 0 point 3- Loader unit Test There is an on board TEST menu that should be used to verify the cause of any breakdown that may occur to the machine. Pointer on position 1 - press ENTER, the display will show: 1- Optic reader 2- X axis motor 3- Y axis motor 4- B axis motor >> 5- Cutter motor 6- X axis sensor 7- Y axis sensor 8- B axis sensor 9- Shield micro 10- Automatic clamp 11- Key sensor 12- Magnet 13- Keyboard 14- Display 15- Serial port 16- Battery status Operational keys: use the arrow keys [Up/Down] to move the cursor to the option required and press ENTER. TEST 1: OPTICAL READER Carefully follow the instructions that are on the machine s display. Check that the optical reader s status changes from OFF to ON. 1 OPTIC READER Close shield and press START. Status:OFF NOTE: if the OFF/ON transition is not made, contact Silca s Technical Assistance Dept. Copyright Silca

56 Test 2: X AXIS MOTOR 2 MOTOR X Arrows keys to move axis. Carefully follow the instructions on the machine s display. Check that the X axis carriage moves, (use the [< >] keys). ATTENTION: during this test function all end of run controls are disactivated; avoid moving the carriage up against its mechanical stops. NOTE: if the motor does not start, contact Silca s Technical Assistance Dept. Test 3: Y AXIS MOTOR 3 MOTOR Y Arrows keys to move axis. Carefully follow the instructions on the machine s display. Check that the Y axis carriage moves, (use the arrow keys [Up/Down]). ATTENTION: during this test function all end of run controls are disactivated; avoid moving the carriage up against its mechanical stops. NOTE: if the motor does not start, contact Silca s Technical Assistance Dept. Test 4: B AXIS MOTOR This test can be carried out only when an automatic clamp (optional) is installed on the machine. 4 MOTOR B Arrows keys to move axis. Use the arrow keys [up/down] to check movement of the jaws on the automatic clamp. NOTE: if the motor does not start, contact Silca s Technical Assistance Dept. Test 5: CUTTER MOTOR Carefully follow the instructions on the machine s display. Check that the cutter motor is working. 5 CUTTER MOTOR START key to activate motor. NOTE: if the cutter motor does not turn, contact Silca s Technical Assistance Dept. 52 Copyright Silca 2012

57 Test 6: X AXIS SENSOR 6 SENSOR X Press arrows keys to move axis. Status:OFF Use the [< >] keys. Move the carriage to the left to reach ON status. NOTE: if the ON/OFF transition is not made, contact Silca s Technical Assistance Dept. Test 7: Y AXIS SENSOR 7 SENSOR Y Press arrows keys to move axis. Status:OFF Use the arrow keys [Up/Down]. Move the cutter support downwards to reach ON status NOTE: if the ON/OFF transition is not made, contact Silca s Technical Assistance Dept. Test 8: B AXIS SENSOR This test can be carried out only when an automatic clamp (optional) is installed on the machine. Use the arrow keys [Up/Down]. 8 SENSOR B Press arrows keys to move axis. Status:OFF NOTE: if the ON/OFF transition is not made, contact Silca s Technical Assistance Dept. Test 9: PROTECTIVE SHIELD MICROSWITCH 9 SHIELD MICRO Open & close shield Status:ON Lift and lower the protective shield checking that the machine s display indicates OFF to ON. NOTE: if the ON/OFF transition is not made, contact Silca s Technical Assistance Dept. Test 10: AUTOMATIC CLAMP - OPTIONAL 10 AUTOMATIC CLAMP DETECTED <INSTALLED> Indicates whether the automatic clamp (optional) is fitted or not. ATTENTION: turn the key-cutting machine off before fitting or removing the automatic clamp. Copyright Silca

58 NOTE: if the right message does not appear (e.g.: FITTED when the automatic clamp is on the machine, or vice versa) contact Silca After-Sales Service. Test 11: KEYS SENSOR (WITH OPTIONAL FEEDER UNIT) 11 KEY PRESENCE Cover the sensor on the loader Status:OFF Use a key stem or other metallic object to make contact with the sensor situated on the key loader and check on the display that the indication goes from OFF to ON. NOTE: if the ON/OFF transition is not made, contact Silca s Technical Assistance Dept. Test 12: MAGNET (WITH OPTIONAL FEEDER UNIT) 12 MAGNET CONTROL Press START to activate. Status:OFF Press START to make the magnet on the key loader trigger as if it were pushing a key and check on the display that the indication goes from OFF to ON (instantly). NOTE: if the ON/OFF transition is not made, contact Silca s Technical Assistance Dept. Test 13: KEYBOARD 13 KEYBOARD Press 0 keys One at a time, press all the keys (except STOP) checking that an asterisk (*) appears for each key pressed. Press the STOP key for last. NOTE: if the asterisk does not appear, contact Silca s Technical Assistance Dept. Test 14: DISPLAY 14 DISPLAY START to activate. All points on the display should be obscured. Press the arrow keys [Up/Down], the first line will appear with the words DISPLAY. NOTE: if this is not so, contact Silca s Technical Assistance Dept. 54 Copyright Silca 2012

59 Test 15: SERIAL PORT 15 SERIAL PORT Install special connector Z4. Status: OFF Check that the machine s display indicates OFF. Fit the special (Z4) serial test connector (accessories provided) to the machine s serial port, checking that the machine s display indicates OFF to ON. NOTE: if the ON/OFF transition is not made, contact Silca s Technical Assistance Dept. Test 16: BATTERY STATE 16 BATTERY STATUS < CHARGED > Check that the display shows <Charged >. If the display shows <Flat> replace the battery (see Ch. 7.16). NOTE: the machine also works with a flat battery (the battery is used only for the function: Options > Set Clock). Copyright Silca

60 5.8.2 Machine zeroes The machine is pre-arranged for a partial self-setting system by means of templates provided (Ch. 1.6) and specific procedures. These procedures must be carefully carried out following the descriptions and illustrations indicated below. EVENT MACHINE ZEROES STANDARD CLAMPS CALIBRATIONS AUTMATIC CLAMP Electronic board replacement NO YES YES Replacement of the Optical Reader unit NO YES YES Replacement sensors YES YES YES Replacement of the cutter shaft (*) YES YES YES Replacement of the ball screws (*) YES YES YES (*) Only from Silca S.p.A. or Silca Authorized After-Sales Service Centres. 2 Machine zeroes NOTE: this operation is possible only with standard 4 sided clamps. NOTE: If the machine has an optional feeder unit installed, proceed as follows (see Ch ): 1) Remove the Automatic Clamp: loosen the screw (D2) and pull out the clamp to the left. 2) Remove the Loader: possible only after having removed the automatic clamp; loosen the screw (D3) and pull out the loader. NOTE: the machine is used without the loader unit, remember to insert the serial protection (S1) into the special loader seat, then fit the standard cutting clamp into the special dovetail runner and push all the way in to the right. Tighten the screw (D2). With the pointer on position 2 - press ENTER Install Z19 template cutting side See operating manual. [ENTER] cutter - fit the template Z19 on side A into the L100 Standard clamp (cutting side). - press ENTER, the display will show: Move axis up until contact is made. See operating manual. [ENTER] Move the X and Y carriages by hand, to take the template Z19 up against the cutter to make contact with the side and front (Fig. 62). clamp cutter side Fig Copyright Silca 2012

61 Press ENTER, the display will show: Pos. sensors ICX=ON ICY=ON See operating manual. [ENTER] If this does not occur and the status of one or both is OFF, taking due care (the machine is live), proceed as follows: Regulation of the Y axis sensor: 1) Without disconnecting the power lead, gain access to the bottom compartment (Ch. 7.4). 2) Loosen the screw (S2) and move the sensor support by hand until the point at which OFF goes to ON is found. 3) Lock the sensor support in place by tightening the screw (S2) (Ch. 7.11). 4) Secure the bottom plate with the 8 screws (V1) then re-position the machine on the work bench (Ch. 7.4). Fig. 63 Regulation of the X axis sensor: 1) Without disconnecting the power lead, gain access to the bottom compartment (Ch. 7.4). 2) Loosen the sensor support plate screws (W1) (Fig. 64) and move the plate by hand until the description on the display goes from OFF to ON. 3) Secure the plate by tightening the screws (W1) (Ch. 7.11). 4) Secure the bottom plate with the 8 screws (U3) then re-position the machine on the work bench (Ch. 7.4). 5) When regulation of one or both the axes is completed, press ENTER. Fig. 64 Copyright Silca

62 5.8.3 OPTIONAL Loader Unit NOTE: the screen shows different information according to whether there is a Loader Unit (optional) or not. Pointer on 3 - press ENTER; the display will show: WITH STANDARD 4 SIDED CLAMPS: INSTALLATION LOADER UNIT Press [START] to proceed INSTALLATION LOADER UNIT Positioning In progress! INSTALLATION LOADER Turn off the machine and fit the loader unit. ATTENTION: it is compulsory to turn off the machine before fitting the Loader Unit or part of it. Proceed as follows: 1) Remove the Standard cutting Clamp: Loosen the screw (D2) and pull out the clamp to the left. 2) Fit the Loader: remove the cover/protection (S1) on the serial outlet located in the loader seat. Please keep the protection for future use. Insert the loader and push all the way in then tighten the screw (D3) using the (long) hex wrench provided. 3) Fit the Automatic Clamp: the automatic clamp into the special dovetail runner, pushing all the way in to the right, then tighten the screw (D2) (Fig. 68). Fig. 65 Fig Copyright Silca 2012

63 WITH OPTIONAL LOADER UNIT INSTALLED: REMOVE LOADER UNIT Press [START] to proceed Press START to remove the loader; the carriages will automatically find a position which allows the operation to be carried out. The display will show first: REMOVE LOADER UNIT Positioning in progress! then: REMOVE LOADER UNIT Turn off the machine and fit the loader unit ATTENTION: it is compulsory to turn off the machine before removing the Loader Unit or part of it. Proceed as follows: 1) Turn off the machine with push button (A). 2) Remove the Automatic Clamp: loosen the screw (D2) and pull out the clamp to the left. 3) Remove the Loader: possible only after having removed the automatic clamp; loosen the screw (D3) and pull out the loader. NOTE: If the machine is to be used without a Loader Unit, remember to fit the serial protection (S1) into the special seat for the loader (Fig. 65). Fit the standard cutting clamp into the dovetail runner and push all the way in, then tighten the screw (D2). Fig. 67 Fig. 68 Copyright Silca

64 5.9 [6] Options MAIN MENU: 4) Enter Option menu 6. The display will show: 1- Copy from original 2- Copy with adjust. 3- Queue from PC 4- Calibrations >> 5- Maintenance 6- Options 1- Machine data 2- Cutter material 3- Cutting speed 4- Carriage speed >> 5- Preference 6- Language 7- Set clock 8- Min. distance 9- Cutting check 10- Activation time Operational keys: use the arrow keys [Up/Down] to move the cursor to the option required and press ENTER. 1 Machine data: Ser.n: Model: Keys cut: 212 SW Version: x.x.xxx Serial Number: displays the machine s serial number that should correspond to the serial No that is stamped on the back of the machine (if absent, enter the 13 numbers in the serial number, using the arrow keys. Press ENTER to confirm the number). Model: type of. Keys cut: number of keys cut. (To reset the value, hold down the SHIFT+CLEAR+START keys for approx. 2 seconds). SW Version: Software version of the program installed on the machine. 2 Cutter material: Cutter material = 1 (0 = HSS) (1 = Hard metal) See operating manual. This option is used to view/set the type of cutters to be used, in HSS (enter 0) or hard metal (enter 1). The key-cutting machine uses hard metal cutters. To set a different cutter material invert the pulleys (*): - low speed for HSS tools - high speed for hard metal carbide tools 60 Copyright Silca 2012

65 ATTENTION: always set 1 with. (*) pulleys cannot be inverted on Japan (100V-50/60Hz). 3 Cutting spped: Cutting speed HSS Hd. Met ( ) ( ) Corresponds to the carriage advancement speed during the key cutting operation: On the basis of the cutter material selected, speed can be altered as shown in the table. Cutter metal Recommended speed Speed range HSS Hard metal (carbide) Operating keys: arrow keys [Up/Down] to go from one field to another (HSS or hard metal). Arrow keys [< >] to increase or decrease the speed value. Confirm with ENTER. 4 - Carriage speed: Carriage approach speed = 4000 ( ) This is the speed at which the carriages move towards the cutting area, before starting the cutting cycle. We recommend to operate the machine with the speed that is set (4000). If required, the operator can adjust the carriage approach speed from a minimum of 1000 to a maximum of Arrow keys [< >] to increase or decrease the speed value. 5 - Preferences: work parameters are chosen from this menu. 1- Measurement unit 2- Start menu 3- Quick menu 4- Adjusted copy 1 / Measurement (inches or millimetres): choose the viewing method for measurement values (mm = millimetres, inch. = inches). Measurement unit = 0 ( 0=Millimetres ) ( 1=Inch ) 2 / Start-up menu choose the function in the Main menu that you would like to appear first when the machine is turned on. Copyright Silca

66 * = Main menu 1 = Copy from original 2 = Copy with corrections 3 = Queue from PC Select start menu: Main menu 1- Copy from original 2- Copy with adjust. 3- Queue from PC ATTENTION: press the CLEAR key to void any selection made and to select the main (*) menu function. 3 / Quick menu: Unavailable function. Non-feasible function! 4 / Correction of copy: if enabled (=1) used to maintain the adjusted value with the function: Copy with adjustments. 4- Copy with adjust. Keep the adjustement = 0 (1=Enabled) Operational keys: arrow keys [> <] to choose the option, ENTER to confirm. 6 - Language: This menu is used to choose the required language. Select language = 2 1-Italian 2-English 3-Deutsch 4-Francais 5-Espanol Operational keys: arrow keys [><] to choose the option, ENTER to confirm. 7 Clock: This menu is used to set the values for Date and Time. DATE-TIME SETTING Date: 00/00/00 Time: 00:00:00 Press the arrow keys (Up/Down) to change the sector to be edited, then use the arrow keys [< >] to set the exact figure. Press ENTER to confirm. STOP to exit. 62 Copyright Silca 2012

67 8 - MINIMUM DISTANCE The number shown on the machine s displayrepresents the X axis distance between the key blankshoulder and the beginning of the first cut. Minimum distance of cut from key stop = 50 ( 0-90 ) This function is extremely important with keys thatrequire cuts on both sides as it ensures precisepositioning on the key 2nd side. The set figure is 50 hundredths of a mm, which can bevaried between min.0 - max. 90 hundredths of a mm: Fig. 69 ATTENTION: settings that are too high may renderprecise cuts impossible, with the following messageon the display: MIN. parameter of DISTANCE FROM STOP is incompatible with selected card! 9 - CUTTING CHECK Enable check on excluded combinations: YES See operating manual Operating keys: Arrow keys [< >] to select YES or NO. ENTER to confirm. Example: with the function Check on excluded combinations enabled (YES) when the machine receives a job from the PC (through Silca Key Programs) it checks the path the tool must take to cut a key. In the event of incongruity, press ENTER and the following message will appear: Non-feasible combination Copyright Silca

68 The cuts illustrated on the right cannot coexist. With regard to the cut that originated the message<non-feasible COMBINATION> it can be seenthat between the two deep cuts (8) and the constantangle (100 ) the intermediate cut (0) would beremoved. This happens when the cutting angle N (Normal) is notmade variable by means of the type of cut L (Laser), parameter that can be selected from a PC program. Fig. 70 The new drawing of the key shows how for the samecutting process (80846) the cutting angles areautomatically calculated by the conjunction of thecutting base with a straight line. This aspect, admissible with certain car keys, is morecommonly known as the ideal cutting line. ATTENTION: in this example it can be seen that the ßangle is less than 45. This could cause seriousproblems with a lock, making it difficult or impossibleto place the key into the cylinder or remove it. Fig ACTIVATION TIME If the key-cutting machine is used with the limited promotional version of the Silca Key Programs program this particular counter function starts counting from the first transmission by SKP to (PC queue). At the end of the promotional period, the key-cutting machine can no longer communicate with the program. ELAPSED TIME FROM FIRST ACTIVACTION Days: 64 Copyright Silca 2012

69 5.10 Machine message Error message ERROR 1 Key gauge out of place! During the reading or decoding cycle the machine s optical reader verified that the key gauge had not been lowered ERROR 2 Optical reader not activated! See operating manual. This message indicates that there is a fault in the optical reader or that something is obstructing its laser beam before starting the reading or decoding cycle. ERROR 3 Key cannot be copied! The key cannot be cut by during the reading stage and at this point ATTENTION messages ATTENTION Depth limit exceeded! During the cutting cycle one or more depth exceeded the maximum limit. These depths are automatically aligned to the maximum permitted depth. ATTENTION Turn off machine and fit clamp: L1 A gauging operation that requires the Loader Unit (L1=Automatic clamp) is about to take place but the unit is not detected. Remedy with: Maintenance (5) > Loader Unit (3) (see Ch. 5.8). ATTENTION Turn off machine and fit clamp: L100 A gauging operation that requires the standard cutting clamp (L100=Standard clamp) is about to take place but the clamp is not detected. Remedy with: Maintenance (5) > Loader Unit (3) (see Ch. 5.8). Copyright Silca

70 ATTENTION Install clamp: L100 [ENTER] A Machine Zeroes operation that requires the standard cutting clamp (L100=Standard clamp) is about to take place but the clamp is not detected. ATTENTION Clamp L100 not calibrated! ATTENTION Clamp L1 not calibrated! The gauging values are missing. Proceed with Gauging menu (see Ch. 5.7). FEEDER EMPTY Pieces maked: x/y Continue? No=STOP Yes=ENTER A gauging or CUTTING operation with Loader Unit is about to take place. No key blanks are detected in the loader. Lift the safety shield and insert one or more KEY BLANKS (according to needs). NOTE: press SHIFT + START to continue, even if the key has not been read (e.g. head punch too big). Press SHIFT + START to exclude the sensor control. The exclusion is valid until the machine is turned off for the first time. ATTENTION Before proceeding read carefully the operating manual. Consult the manual (for the operation required) and press ENTER to continue. ATTENTION Remove key from clamp! [START] Press START, raise the safety shield and remove the key from the clamp. This done, press START to continue. Zero the axes! [START] Operation required on start-up or when a procedure has been interrupted. Press START to continue. ATTENTION X/Y gauged beyond the advisable tolerance range! Gauging values exceeded max. tolerance allowed (+/- 30 hundredths of a mm). Repeat the gauging procedure. 66 Copyright Silca 2012

71 ATTENTION Install cutter U01W A hard metal cutter is required. Press ENTER to continue Alarm Messages ALARM 1 Key not properly installed! Key blank not properly fitted in the loader, or not properly loaded onto the automatic clamp. ALARM 2 Movement axis not completely zeroed! The message indicates that there is a fault on the axis referred to (X, Y or B) due to: - an obstacle impeding free movement of the axis to complete its run - a fault on the limit switch (do the sensor TEST) - a fault on the motor that moves the axis (do the motor TEST) - break down of motor control on the electronic board (do the motor TEST) ALARM 3 HIGH TEMPERATURE Turn the machine off! The electronic control board has exceeded the maximum permitted temperature. Check the cooling fan (see Ch. 7.1 Trouble shooting). ALARM 4 I/O POWER Check fuse F4! Indicates that the fuse has blown due to a short circuit in an inlet or outlet (Ch.7.8). ALARM 5 DIGITAL OUTLET Turn the machine off! Indicates a short circuit in port P (IN/OUT) (see Ch. 7.1 Trouble shooting) ALARM 6 CUTTER MOTOR Check fuse F1! Indicates that the fuse has probably blown (see Ch. 7.8). Copyright Silca

72 Indicates a fault on the electronic control board. ALARM 7 CUTTER MOTOR Fault on motor circuit! ALARM 8 Data format not compatible! See operating manual. The PC program version that transmits data to the machine is not compatible with the SW version of the machine program. Solution: Upgrade the PC program with a compatible version. 68 Copyright Silca 2012

73 6 CLEANING Keep the operational parts of the machine as clean as possible by brushing away the chippings in areas where they accumulate during cutting operations. Under no circumstances must compressed air be used to clear the work zone of chippings as this will blow them onto the moving parts. Never use oily products or thinners for cleaning painted surfaces, clamps, electrical or electronic connections. Copyright Silca

74 7 MAINTENANCE ATTENTION: for repairs or replacement of parts for maintenance, the CE mark is guaranteed only if original spare parts provided by the manufacturer are used. Although the key-cutting machine does not require special maintenance, it is advisable to check and, if necessary, replace the parts subject to wear and electric/electronic parts (fuses, circuit boards, etc.) in the event of faulty operation. ATTENTION: for normal servicing of the burnished mechanical parts, we recommend using lubricants or protective oil, e.g. WD40 or similar. Do not contaminate the electronic parts with the oil. Replacement is simple and can be carried out by the operator consulting the instructions. Before starting any type of maintenance (controls or replacements), read the instructions below: never carry out maintenance with the machine switched on always remove the main power supply cable strictly follow all the instructions in the manual use original spare parts (see Spare Parts sheet provided). 7.1 Trouble shooting FAULT PROBABLE CAUSE Machine is on, with no check to see if the back fan is working: message on its display: Not working a) emergency button activated b) general fuses in the power socket are faulty Working a) fuse F3 on electronic control board is faulty b) connection wire between display and electronic circuit board loose c) defective display cutter motor not working: a) the closed protective shield is not making proper contact with the safety microswitch b) the F1 fuse on the electronic control board is faulty c) motor wire not properly attached to the connector d) defective electronic control board e) motor cut-off WARNING: this may derive from inappropriate or heavy use of the key-cutting machine or a fault with the motor itself. DO NOT USE THE MACHINE and call Technical Silca Dept. to determing the cause of activation of the cut-off X, Y and B axes motors are not working None of the motors working: a) fuse F2 on the electronic control board faulty b) the wiring between the transformer and electronic control board is loose or the connector is not seeded properly c) defective electronic control board Protective shield is closed but the display reads close shield Only one motor is not working: a) the connection wires between the motor and the electronic control board are loose or the connector is not seeded properly b) defective electronic control board a) the closed protective shield is not making proper contact with the microswitch (Fig. 72) b) the F4 fuse on the electronic control board is faulty 70 Copyright Silca 2012

75 Keyboard not working (partially or completely) Optical reader not working Key-cutting machine fails to communicate with computer The display shows the message: TEMPERA- TURE ALARM - turn the machine off The display shows the message: I/O POWER ALARM check fuse F4 The display shows the message: DIGITAL OUTLET PROTECTION ALARM - turn the machine off The display shows the message: CUTTER MOTOR ALARM - check fuse F1 a) the keyboard connector is not properly connected to the interface board (Fig. 73) b) the wiring between the keyboard/display unit and electronic control board is not properly attached to the relative connectors c) defective keyboard d) defective electronic control board a) glass lent on the optical reader is dirty b) wiring between optical reader and the electronic control board is not seeded properly c) defective optical reader d) defective electronic control board a) wiring between 9-pin serial port and electronic circuit board not seeded properly or disconnected b) serial cable between key-cutting machine and computer is faulty c) computer serial port is not functional d) defective electronic control board Check that the fan on the back of the key-cutting machine is working: Not working: a) fan fault b) electronic control board faulty Working: electronic control board fau a) fuse F4 on the electronic control board faulty b) short circuit on inlets or outlets. To find which inlet or outlet is causing the error message, disconnect the J connectors one at a time and check each time whether the alarm disappears a) short circuit on the outlets. To find which outlet is causing the error message, disconnect the J4-5 connectors one at a time and check each time whether the alarm disappears b) internal fault on the electronic control board a) fuse F1 on the electronic control board faulty b) cutter microswitch on protective cover triggered or disconnected (Fig. 72) c) cutter motor wiring disconnected d) internal fault on the electronic control board Fig. 72 Fig. 73 Copyright Silca

76 7.2 Maintenace operations Access to the top compartment Access to bottom compartment Cutter replacement Belt replacement and tension adjustment Replacement of the set of jaws on the Automatic clamp (Optional) Fuse check and replacement Electronic circuit board replacement Keyboard/display replacement Sensor replacement Motor replacement Lamp replacement Condenser (motor) and/or feeder (lamp) replacement Master/emergency switch replacement Clock battery replacement Win-Transfer program for loading/updating the machine program 7.3 Access to the top compartment To gain access to the top compartment, proceed as follows: 1) turn off the machine and disconnect from the power supply. 2) loosen the 4 screws (U2) securing the top cover, then lift the cover off (Fig. 74). Fig Copyright Silca 2012

77 7.4 Access to the bottom compartment To gain access to the bottom compartment, proceed as follows: 1) turn off the master switch and detach all the connection wires to the machine. 2) remove the 2 swarf collection trays. 3) turn the machine over onto its right-hand side. 4) loosen the 8 fixing screws (U3) on the bottom plate and remove. Fig Cutter replacement 1) Zero the carriage movements (from the main menu press SHIFT+STOP) 2) Disconnect the key-cutting machine from the power supply. 3) Raise the safety shield. 4) Loosen the screw (D2) and pull out the clamp to the left (Ch. 4.6); (if it is an automatic clamp, see Ch. 4.7). 5) Fit the cutter release rod (X) provided, into the special hole (Fig. 76). 6) Loosen the cutter locking nut using the 14 mm wrench (X1). ATTENTION: the thread is left-handed. 7) Replace the cutter; lock the nut and remove the rod. 8) Put back the clamp unit, pushing all the way in to the right. Tighten the screw (D2). ATTENTION: when replacing a worn cutter with a new one or with a re-sharpened cutter consult the Ch. 5.7 [4] Calibrations. close open Fig. 76 Copyright Silca

78 7.6 Belt replacement and tension adjustment To replace the belt proceed as follows: 1) Turn off the machine and disconnect it from the power supply. 2) Access the top compartment (Ch.7.3). 3) Loosen the 2 belt tightening screws (H3) and the 4 screws (H4) on the motor support plate. to replace: 4) pull the worn belt off the pulleys. 5) fit the new belt onto the pulleys. to adjust tension: 6) Adjust belt tension by tightening the 2 belt tightening screws (H3). 7) Tighten the 4 motor support plate screws (H4). 8) Put back the top cover and secure with the 4 screws (U2) (Ch. 7.3). Fig Copyright Silca 2012

79 7.7 Replacement of the jaws on the automatic optional clamp - OPTIONAL To replace the jaws procede as follows: 1) Enter the Maintenance / Feeder Unit menu and press START. 2) Turn off the machine and unplug from the mains. 3) Raise the safety shield, loosen the screw (D2) and remove the automatic clamp by pulling it out to the left (Fig. 38). 4) Loosen the 2 screws (V2) (Fig. 78) and remove the set of jaws installed. 5) If the jaws are mixed ( A), replace the upper one. 6) Fit the new set of jaws, ensuring that they are buttino against the lower seat (Fig. 79) and centred on the rear seat. 7) Tighten teh 2 screws (V2) to secure the jaws. NOTE: jaws B can be used only when the standard clamp (reading) is placed on Side B. Fig. 78 Fig. 79 ATTENTION: the jaws are usually replaced in pairs. Mixed jaws can be used only with 2.0 mm to 2.8 mm thick keys. type: Upper jaw A + Lower jaw B type: Upper jaw A + Lower jaw A NO! type: Upper jaw B + Lower jaw A YES type: Upper jaw B + Lower jaw B type: Upper jaw 2,0 2,8 + Lower jaw B type: Upper jaw 2,0 2,8 + Lower jaw A Fig. 80 Copyright Silca

80 7.8 Checking and replacing fuses Fuses should be checked with a tester (ohmmeter, multimeter, etc.) as they may appear to be in good condition even when they are electrically faulty. Fuses must always be replaced with the same amperage and type (rapid or delayed), as indicated in this manual. There are 6 fuses in the. 2 fuses: 5 Amps rapid (230V) - 10 Amps rapid (100V-120V) Located next to the power socket on the back of the machine (Fig. 81). These fuses protect the machine from power surges and/or spikes in the electricity supply. To check and/or replace the fuses proceed as follows: 1) turn the machine off and unplug it from its power supply cable. 2) use a flat screwdriver to open the flap covering the socket, remove and check the fuses, replacing them if necessary. 4 fuses: F1, F2, F3 and F4 Fig. 81 F1: 10 Amps delayed protects the cutter motor and its electronic controls (230V a.c.) F2: 6,3 Amps delayed protects the step motors and their electronic controls (+32V d.c.) F3: 4 Amps delayed protects the logic control circuits on the microprocessor board (+5V d.c.) F4: 2 Amps delayed protects the digital output circuits for the low voltage controls and the sensor inlets (+24V d.c.) Situated on the electronic circuit board inside the base of the machine (Fig. 82), protecting the board from short circuits. To check and/or replace the fuses proceed as follows: 3) turn the machine off and unplug it from its power supply cable. 4) remove the bottom panel (Ch. 7.4). 5) check and, if necessary, replace the fuses in the way described below: to remove the fuse: press the fuse cap with your fingers and turn it counter clockwise. To fit the new fuse: carefully position the fuse back into place, then gently press the fuse cap downwards turning it clock wise. 76 Copyright Silca 2012

81 Fig. 82 Fig. 83 Copyright Silca

82 7.9 Electronic circuit board replacement Proceed as follows: 1) turn the machine off and unplug it from its power supply cable. 2) remove the bottom panel (Ch. 7.4). 3) disconnect all cable (connectors) from the electronic circuit board (Fig. 84). 4) take the electronic circuit board off by unscrewing the 6 nuts (Y1) (Fig. 85). 5) mount the new electronic circuit board and re-connect all cables (all cable connections are polarised therefore cannot be connected incorrectly). 6) re-fit the bottom panel and re-position the machine on its workbench. 7) to transmit the software, turn on the machine and launch the WIN-TRANSFER program from the PC. Fig. 84 Fig Copyright Silca 2012

83 7.10 Keyboard / display replacement 1) turn off the machine and disconnect from the power supply. 2) gain access to the bottom compartment (Ch. 7.4). 3) use the special utensil (T1) to detach the emergency button terminal strip, remove the connector (C1) and loosen the nut (C2) in order to remove the earthing wire from the keyboard (Fig. 86). 4) loosen the keyboard fixing nuts (C5) and remove the keyboard from its support. 5) disconnect the connector (C4). 6) loosen the ring nut (C3) on the emergency button and remove. 7) to fit the new keyboard/display carry out the operations described above, in reverse order. Fig. 86 Fig. 87 Copyright Silca

84 7.11 Sensors replacement X axis sensor replacement (carriage sensor) 1) turn off the machine and disconnect from the power supply. 2) gain access to the bottom compartment (Ch. 7.4). 3) use the pliers to disconnect the X axis sensor connector (Q1) from the board (Fig. 88). 4) cut the 2 wiring clips (Q2). 5) loosen the nut (W), loosen the 2 screws (W1) and remove together with the sensor and its support (Fig. 89). 6) remove the faulty sensor from its support and screw in the new one, then secure the support with the new sensor by tightening the 2 screws (W1). 7) place the new sensor in position by screwing it down until it almost touches the bracket (W2) (Fig. 89) then secure with the nut (W) and lock nut. 8) connect the sensor connection (Q1) to the board and secure the sensor wiring with a new clip. 9) proceed to Maintenance > Machine zeroes (Ch ). 10) replace the bottom plate. Fig. 88 Fig. 89 Fig Copyright Silca 2012

85 Y axis sensor replacement (front panel sensor) 1) turn off the machine and disconnect from the power supply. 2) gain access to the top compartment (Ch. 7.3). 3) gain access to the bottom compartment (Ch. 7.4). 4) use pliers to disconnect the Y axis sensor connection (K) from the board. 5) loosen the screw (S2) and remove together with the sensor and its support (S3). Remove the worn sensor and replace with a new one. Fit the support with the new sensor, regulating it until it almost touches the upper bracket (Fig. 93). 6) securing the nut (K1) 7) connect the sensor connector (K). 8) proceed to Maintenance > Machine zeroes (Ch ). 9) replace the bottom plate. 10) turn the machine upright, place the top cover in position and secure with the 4 screws (U2) (Ch. 7.3). Fig. 91 Fig. 92 Copyright Silca

86 Fig Copyright Silca 2012

87 7.12 Replacing the condenser (motor) and/or feeder (lamp) 1) turn off the machine and disconnect from the power supply. 2) gain access to the bottom compartment (Ch. 7.4). CONDENSER (Motor) 3) Loosen the nut (N1) and remove the washer and condenser (Fig. 94). 4) Fit the new condenser and fix with the washer and nut. 5) Remove the cap (N2) from the new condenser. 6) Remove the cap from the old condenser and detach the connectors (a) and (b) from the old condenser to connect them to the new one, paying attention to their positions. 7) Replace the cap (N2) on the new condenser. 8) Replace the bottom safety plate, fix with the 8 screws (U3) (Ch. 7.4,). Fig. 94 FEEDER (Lamp) 1) Loosen the 2 screws (H1) and remove the reactor (Fig. 96). 2) Use the tip of a small screwdriver to enter the slits (H2) and detach the 2 wires (c) and (d). 3) Fit the 2 wires (c) and (d) into the special connections on the new reactor. 4) Place the new reactor in its seat and secure with the 2 screws (H1). 5) Replace the bottom safety plate and fix with the 8 screws (U3). (Ch. 7.4). Fig. 95 Copyright Silca

88 7.13 Motor replacement 1) turn the machine off and disconnect from the power supply. 2) gain access to the top compartment (Ch. 7.3). 3) gain access to the bottom compartment (Ch. 7.4). 4) disconnect the 4 wires (1, 2, 3, 4) on the motor from their connections (Fig. 97). 5) loosen the nut (M1) and remove the earthing wire. 6) place the key-cutting machine in position on the work bench. 7) loosen the wiring clip (M2) (Fig. 96). 8) loosen the 2 belt tightening screws (H3). 9) loosen the 4 screws (H4) on the motor support plate and remove the unit. 10) loosen the 4 motor fixing screws (M3) and remove the motor, taking care when pulling the wire through the wiring clip. 11) loosen the 2 motor pulley grub screws. Remove the pulley and fit to the new motor. Secure by tightening the 2 grub screws. 12) fit the new motor onto its plate and secure with the 4 screws (M3). 13) fit the motor plate into its seat and tighten the 4 screws (H4) without locking them. 14) fit the belt. 15) tighten the 2 screws (H3) until the belt is properly tightened then lock the 4 screws (H4) on the motor support plate. 16) carefully take the motor wires through the wiring clip, then tighten. 17) place the machine on its right-hand side. 18) Connect the 4 motor wires (1, 2, 3, 4) and earthing wire. 19) repeat the above operations in reverse order to gain access to the bottom compartment. 20) repeat the above operations in reverse order to gain access to the top compartment. Fig. 96 Fig Copyright Silca 2012

89 7.14 Lamp replacement 1) turn off the machine and disconnect from the power supply. 2) gain access to the top compartment (Ch ) loosen the 2 lamp fixing screws (L2) (Fig. 98). 4) remove the light bulb taking care not to use pointed utensils for this operation. 5) insert the new light bulb. 6) secure the lamp by tightening the 2 screws (L2). Fig Master/emergency switch replacement 1) turn off the machine and disconnect from the power supply. 2) gain access to the bottom compartment (Ch. 7.4). 3) insert the special utensil provided (T1) into the slit on the terminal strip in order to detach it from the switch (Fig. 99). 4) loosen the ring nut (C3) in order to remove the faulty push button/switch. 5) fit the new push button/switch and secure by tightening the ring nut (C3). 6) in order to remove the wiring from the switch/push button, eliminate any wiring clips, disconnect the wires from the 6 terminal board connectors ( ), from the 2 connections (R3) to the power input and loosen the 2 earthing wire fixing nuts (M1) and (C2) (Fig. 87). 7) to fix the new wiring, repeat the operations described above, in reverse order. 8) connect the switch/push button terminal strip to the switch. 9) repeat the above operations in reverse order to gain access to the bottom compartment. Fig. 99 Fig. 100 Copyright Silca

90 Fig Clock Battery replacement 1) turn off the machine and disconnect from the power supply. 2) gain access to the bottom compartment (Ch. 7.4). 3) loosen the 6 board fixing nuts (Y1) di in order to reach the battery (Ch. 7.9). 4) use insulated long-nosed pliers to remove the flat battery (Fig. 102), or push out from the back. 5) use insulated long-nosed pliers to insert the new battery into its seat, paying attention to the poles (Fig. 103). 6) secure the board by tightening the 4 nuts. 7) repeat the above operations in reverse order to gain access to the bottom compartment. Fig. 102 insulated points with adhesive tape Fig Copyright Silca 2012

91 7.17 WIN-TRANSFER Program for loading/updating the internal machine program The machine is supplied with an internal program already loaded and tested in our workshops. The user therefore does not need to carry out any operations. Only in the situations described below can the WIN-TRANSFER program be used to re-start the machine. The following is a list of situations where the use of the WIN-TRANSFER program is required. Replacement of the electronic board (see Ch. 7.9) or loss of the internal machine program. 1) replace the board with a new one, if necessary. 2) install on your personal computer the latest version received of the WinTransfer program and follow the instructions given on the instruction sheet provided with the program. 3) read the serial number on the data plate on the back of the machine (Ch.5.9) and enter on the machine. 4) gauge the machine according to the instructions in the manual, as follows: - gauge as explained in chapters Machine zeroes and 5.7 [4] Calibrations in the Operating Manual. At this point the machine is set up and ready for operation. SILCA update for the program or machine data 5) install on your personal computer the latest version of the WinTransfer program and follow the instructions. Copyright Silca

92 8 DISPOSING OF MACHINE To dispose the machine, it must be rendered unusable by carrying out the operations listed below: Deactivation of the electricity supply; Separation of the plastic and metal parts; Remove the lithium battery from the electronic board. ATTENTION: the lithium battery must be disposed of in the special containers. When these operations have been carried out, the machine can be disposed of according to the current regulations in the country of use. Waste disposal CEE standards state special regulations for waste disposal (**). Machine The, is made up of recyclable parts. Recycling is ecologically recommended. Packing The packing in which the machine is transported is made of cardboard and wood therefore can be re-used if intact or if dismantled used as combustible materials. Warning! Take great care when dismantling the packing as it contains nails, which could cause injuries. We recommend to bend the nails downwards into the wood with a hammer or to completely remove the nails disposing them in authorized metal recycling centres. The packing is considered solid urban waste and must not be thrown into the environment but placed in special cardboard collection bins. Waste deriving from key cutting The waste deriving from key cutting is classified special waste, but is still classified as solid urban waste, as metal wool. Such waste must be disposed of in special collection centres according to the classification assigned to them by the current EEC law. The circumstances which transform metal residue from solid urban waste into contaminated or toxic noxious waste are listed in the appendices to the current European Union regulations regarding disposal of such waste. InformaTion FOR USeRS as per art. 10 of Directive 2002/96/CE of 27/01/2003 regarding waste from electric and electronic appliances (RAEE), The symbol illustrated above, also found on the machine, indicates that it has been placed on the market and must be included in separate rubbish collection when the user wishes to dispose of it (including all components, sub-assemblies and consumables that are integrated in the product). For information about the collection system for such appliances please contact SILCA S.p.A. or another subject registered in the various National Rolls for other countries in the European Union. Household waste (or of similar origin) can be included in the separate collection system for urban waste. On purchasing a new appliance of equivalent type, the old one can be consigned to the dealer. The dealer will then contact whoever is responsible for collecting the appliance. Suitable separate collection of the unused appliance and its dispatch for treatment, recovery and environmentally compatible disposal, makes it possible to avoid potential negative effects on the environment and human health, and aids recycling and the recovery of the materials used. Unauthorised disposal of the product by users involves the application of the sanctions provided for in received Directives 91/156/CE and 91/689/CE. (**) Waste is any substance or object deriving from human activity or natural cycles, disposed off or to be disposed off. 88 Copyright Silca 2012

93 9 ASSISTANCE Silca provides full service to purchasers of the key-cutting machine. To ensure complete safety to the operator and machine, any job not specified in this manual should only be carried out by the manufacturer or recommended Silca Service Centres. On the back cover of this manual is a list of the manufacturer s addresses; listed below are the addresses of specialized service centres. 9.1 How to request service The guarantee attached to the ensures free repairs or replacements of faulty parts within 24 months of the date of purchase. All other service calls must be arranged by the customer with Silca or specialized Silca service centres. Copyright Silca

94 90 Copyright Silca 2012

95 Appendix 1 - ELECTRICAL DIAGRAMS The following pages contain the electrical diagrams for the key-cutting machine described in this manual. Copyright Silca

96 ELECTRICAL DIAGRAMS 92 Copyright Silca 2012

97 Copyright Silca

98 94 Copyright Silca 2012

99 Copyright Silca

100 96 Copyright Silca 2012

101 Terminal board connection Copyright Silca

102 KEY-CUTTING MACHINE - OPTIONAL LOADER UNIT 98 Copyright Silca 2012

103 Copyright Silca

104 VITTORIO VENETO 10/10/2012 CE DECLARATION OF MACHINE COMPLIANCE SILCA S.p.A. - VIA PODGORA 20 ( Z.I.) VITTORIO VENETO (TV) - (ITALY) TEL FAX Declares under its own responsibility that the Key-cutting machine model UNOCODE 199 complies with the requirements of the following European Directives: European Union DIRECTIVE 2006/42/CE (Machines) and with the EN 292/1 EN 292/2 Standards European Union DIRECTIVE 2004/108/CE (Electromagnetic Compatibility) and with the EN : A1 : EN : 1998 EN : 2000 EN : A1 : 2001 Standards European Union DIRECTIVE 2006/95/CE (Low Voltage) 12 and with the EN ( sections ) Standards Claudio Tomasella of the Silca S.p.A. Research & Development Division is authorized to create a Technical File. Operations Director