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Operating manual

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1. P K Stop Stop 3 example Silca key ref 6 24 87 Copyright Silca 2004 49 IDEA Operating Manual English Cutting in progress Copy 1 of 1 Copy 1 of 1 finished More copies No STOP Yes ENTER DECODE SSN 110 Art Silca 6FT12 ATTENTION for Fichet Sans Soucis P P keys operations only possible when decoding with SSN 110 Decoding Cutting SSN 110 Decode Make gt Fichet Sans Soucis P P Decode SSN 110 Original on right Clamp S100 Stop 0 Adapt E11 START Press START Decoding in progress Bit 1 0790636 6360970 Possible depths 01234567891 8 Press ENTER SSN 110 M1 Brass Clamp 51 K2 Stop 1 Cutter 1 25 Pcs 1 1 START Press START to cut Cutting in progress Copy 1 of 1 Copy 1 of 1 finished More copies No STOP Yes ENTER 50 Copyright Silca 2004 Operating Manual English IDEA 5 12 1 FRENCH REAR STOP KEYS For this type of keys see the information in Chapter 5 12 KEYS WITH REAR STOP Male keys and Female keys page 43 TYPES OF KEYS see page 47 OPERATION FLOW Choose option 0 Copy from Original 0 Copy from Original 1 Decode and Copy 2 Insert cuts 3 Queue from PC gt gt Choose option 8 Rear Stop french SELECT TYPE OF KEY 0 Bit stop male 1 Bit stop female 2 Shou
2. Fig 111 IDEA Copyright Silca 2004 81 IDEA Fig 112 Fig 113 Example Adapter E11 Side reading Adjustments X 00 Y1 00 Y2 00 Save adjustements No STOP Yes ENTER Example Operating Manual English Adapter E15 Side cutting Adjustments X 00 Y1 00 Y2 00 Save adjustements No STOP Yes ENTER 82 Copyright Silca 2004 Operating Manual English IDEA Example Adapter E16 Side reading Adjustments X 00 Y1 00 Y2 00 Save adjustements No STOP Yes ENTER Fig 114 Copyright Silca 2004 83 IDEA 6 MAIN MENU TEST FUNCTIONS TEST 1 Machine zero points 2 Test 1 Optical 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 X axis photocell 10 Y axis photocell 11 T wrench micro 12 Protective shield microsw 13 Electric contact 14 Keypad 15 Display 16 Clamp Code 17 Inlets 18 Outlet 1 19 Outlet 2 20 Outlet 3 21 Outlet 4 22 Serial port Operating Manual English 84 Copyright Silca 2004 Operating Manual English IDEA 6 1 TEST A TEST menu is incorporated in the machine provided for fi
3. Clamp 5100 indicates the clamp S100 into which the key must be fitted and which jaw to use Stop 0 reference or point for positioning the key on the reading clamp 5 5 1 Reading keys with front stop double bit single bit female 1 Press on the grip lever of the fixed clamp A and fit the centring device see table so that it protrudes towards the mobile clamp B Release the grip lever Press on the grip lever on the mobile clamp B and fit the key so that the hole in the stem is up against the centring device Release the grip lever Hold the key head with one hand and the end of the centring device with the other and push the key up against the stop 0 A The ideal position for the mobile clamp B is when there is a distance of 3 mm min and 15 mm max between the bit and inner side of the mobile clamp B see ch 5 5 2 Reading in progress Data processing in progress Please wait Press START to proceed with cutting the key see ch 5 5 2 Fig 30 ATTENTION ATTENTION 5 CENTRING STEM C gt 04 5 mm from 4 mm to 5 mm 0 5 5 mm from 5 mm to 6 mm 0 6 5 mm from 6 mm to 7 mm make sure that the bit is up against the stop 0 A position the key so that the highest tooth is facing left ensuring contact with the stop 0 on the vertical side of the tooth start the reading process which will take the reader along the path i
4. KEY READING Original on right Clamp S100 Stop 0 START Operate as follows Fig 50 1 2 3 4 ATTENTION 5 6 7 Press the grip on the S100 B1 mobile clamp and remove the adapter jaw Install jaw C so that the letter C is facing the operator Open the fixed clamp A and the mobile clamp C by exerting pressure on the jaw lever F and F1 Fit the key into the special groove taking the bit all the way into the fixed clamp A position the key so that the highest tooth is facing left ensuring contact with the stop 0 on the vertical side of the tooth Release the jaw lever Place the mobile clamp C in the best position on the stem between the bit and key head Make sure that there is a distance of min 3 mm and max 15 mm between the bit and inside of the mobile clamp C the square part of the stem should butt against jaw When the reading process starts the carriage will take the key into contact with the laser beam along the path dictated by the Software At the end of the cycle see the message on the display in order to continue Fig 51 Copyright Silca 2004 39 IDEA Operating Manual English READING SPECIAL SQUARE STEMMED FIAM KEY WITH STEP KEY READING Original on right Clamp S100 A C Stop 0 START Operate as follows 1 Press the grips on the S100 B mobile clamp and remove the adapter jaw B fig 52 2 Install jaw
5. Left blank Brass Clamp S1 K1 Stop 0 Cutt 1 25 Pes 1 1 START The key blank to be cut must be positioned according to the parameters given on the display after selecting the program involved the type of key with front stop requires the use of the rotating clamp S1 the K1 tailstock support and the key reference on Stop 0 Please follow the instructions below carefully and observe the order of operations 1 2 7 8 Loosen the knob T1 by turning it anticlockwise until the rotating clamp S1 can be moved to a convenient distance for fitting the key Orient the standard tailstock K1 for male keys in the special seat on the support using the screw V2 to direct it upwards Take the T wrench T4 from its seat and open the rotating clamp jaws by turning the sunk hex screw V1 at the end of the operation leave the T wrench in the screw V1 Fit the key blank into the rotating clamp S1 from the front positioning the square stem over the V on the grips diagonally so that the left hand bit is sloping downwards fig 54 and fig 55 Close the mobile clamp jaws slightly using the T wrench already in the screw V1 without gripping the key stem move the rotating clamp G towards the tailstock keeping a minimum safety distance of 10 mm between the rotating clamp jaws and the rear limit of the bit Secure the rotating clamp in position by means of knob T1 Hold th
6. 57 5 15 POST READING adjustments to make to the key after reading 61 5 15 1 Front rear bit conversion sss 5 15 2 X Specular bit conversion 5 15 3 Correcting bit depth ai SOM Bit constr ction 2 AAT A Parco lA po 5 16 Decode and Ko oN AREE CREUSE T 5 17 Entering he Cuts scott E ATE 5 18 Use Of The Machine With A Personal Computer 2 70 5 19 EESE E E al 72 5 20 Guerin Li 75 5 21 AdapferS nia thi agin abd pog qe Ee ds 76 MAIN MENU TEST FUNCTIONS 2 242424224 000 in 84 6 1 iei ides D ette Bedae Rar tege d alal 85 624515 Machine zeropolntsz neget rn iei a mtd n ep e eun a Rer np de 88 6 2 Options cicci 105 6 21 Serial number e ua 105 6 2 2 Carriage approach SPeOG cte ete eee e tee dad D ede 105 6 2 3 gt Rotating Spod enne n S VON 105 06 2 4 Preferences ees entere ben enda ua c an e ae 106 6 2 5 Language 6 2 6 Keyboard ifiversion e RR ERREUR RADAR DRM 6 2 7 Limited access to Data Protected Systems sss 6 2 7 1 OF ENABLED SYSTEMS ACTIVATED AND REMOVAL OF AN ACTIVATION x 6 28 Bit height ione e ETE ER HEATED DI YID D ION S receive 6 2 9 Reading anne le a
7. Operating manual D429094XA vers 3 0 2004 SILCA S p A Vittorio Veneto This manual is written by SILCA S p A All rights reserved No part of this publication may be reproduced or used in any form or by any means photocopying microfilm or other without the written permission of SILCA S p A Edition february 2005 Printed in Vittorio Veneto by SILCA S p A via Podgora 20 2 1 31029 VITTORIO VENETO TV Italy GUIDE LALA 1 GENERAL ARE ia 5 MACHINE 25205 laica 6 14 1 2 1 3 1 4 Te hinical data oer RE UR Pn UNE 9 1 5 Accessories provided e dein 10 TRANSPORT m 11 2 1 mcd 11 2 2 Unpacklng aci ne til T E RUBIA 11 2 3 Machine handlind iaia lana dia a NANA aes MACHINE INSTALLATION AND PREPARATION 3 1 Checking for damage 3 2 Environmental conditions 3 3 Positioning and installation sisinio Aea edie aa E Naas Iir EENT 3 4 Description of work station 2 00 00000 3 5 EENI lie A E SET UP AND USE OF THE MACHINE 4 1 Keyboard and functions 4 2 Use of the clamp iais te te aaa A a 4 3 Cutting by electric contact nresnain a tremere tea arie d 4 4 Guiter 5 uae ere vn tel ew tasti epi
8. max 12 max 12 max 12 Fig 72 1 Press the grip on the S100 mobile clamp and remove the adapter jaw B 2 Install jaw E so that the letter E is facing the operator 3 Open the fixed clamp A and the mobile clamp E by exerting pressure on the jaw lever F and F1 fig 73 Fig 73 4 Fit the key into the special seat axis X1 taking the bit all the way into the fixed clamp A fig 74 ATTENTION position the key so that the highest tooth is facing left ensuring contact with the stop 0 on the vertical side of the tooth 5 Release the jaw lever 6 Place the mobile clamp E in the best position on the stem between the bit and key head Make sure that there is a distance of min 3 mm 15 mm between the bit and inside of the mobile clamp ig 87 When the reading process starts the carriage will take the key into contact with the laser beam along the path dictated by the Software Fig 74 7 At the end of the cycle see the message on the display in order to continue Fig 75 Reading in progress Data processing in progress Please wait 54 Copyright Silca 2004 Operating Manual English CUTTING small bit or small double bit keys Left blank Brass Clamp S1 K1 Stop 0 Cutt 1 25 Adapt E10 Pes 1 1 START IDEA Clamp S1 K1 indicates which clamp 61 and tailstock K1 to use for gripping the key Stop 0
9. take the worn belt off the pulleys fit the new belt onto the pulleys tighten the 2 screws W3 on the plate W4 Cutter belt remove the motor belt raise the safety shield loosen the screw W5 to remove the brush unit loosen the 2 screws W3 and remove the plate W4 take the motor belt off the pulleys take the worn cutter belt off the pulleys fit the new belt onto the pulleys fitthe motor belt onto the pulleys tighten the 2 screws W3 on the plate W4 5 use the special plate provided and tighten the belt by turning the screw W2 6 tighten the 4 motor fixing screws W 7 replace the back metal panel and bottom plate Copyright Silca 2004 121 IDEA Operating Manual English To tighten the belt s proceed as follows 1 turn the machine off and pull out the plug 2 remove the bottom plate ch 7 9 3 loosen the 4 motor fixing screws W 4 use the special plate provided to tighten the belt by turning the screw W2 5 tighten the 4 motor fixing screws W 6 replace the bottom plate 7 5 CHECKING AND OR 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 elec
10. E9 Chubb RKS E9 Chubb RKS E10 Small Bit E11 Rear Stop R E15 Special Bit F C E16 Special Bit F R parameters Adapter E1 Side cutting Adjustments B 00 X 00 Y1 00 Y2 00 Save adjustments No STOP Yes ENTER Operating Manual English SHIFT arrow Up increases the value within 300 hundredths of a mm or hundredths of a degree axis B X Y1 Y2 20 cent SHIFT arrow Down decreases the value within 300 hundredths of a mm or hundredths of a degree axis X Y1 Y2 20 cent CLEAR to zero the value ENTER in the last field is used to quit the window and show the message requiring the editing to be saved 76 Copyright Silca 2004 Operating Manual English Example Adapter E2 Side cutting Adjustment B 00 X 00 Y1 00 Y2 00 Save adjustment No STOP Yes ENTER IDEA ATTENTION when STOP is pressed the new measurements are not saved the previous gauging values therefore remain valid Fig 102 Example Adapter E3 Side cutting Adjustment B 00 X 00 Y1 00 Y2 00 Save adjustment No STOP Yes ENTER Fig 103 Copyright Silca 2004 77 IDEA Fig 104 Fig 105 Example Adapter E4 Side reading Correzioni X 00 Y1 00 Y2 00 Salvare le correzi
11. E3 Pcs 1 1 START Fit the key blank into the adapter and follow the instructions in the user s manual then press START Cutting in progress Copy 1 of 1 Bit 1 Copy 1 of 1 finished More copies No STOP Yes ENTER Press STOP remove the key and use a centesimal gauge to measure it Y gt Fig 126 98 Copyright Silca 2004 Operating Manual English IDEA Measurement X should be 4 40 mm inch 0 03 mm Measurement 1 should be 2 80 mm inch 0 03 mm Measurement Y should be 9 50 mm inch 0 03mm If this is not the case e g X 4 50 and Y 9 40 proceed as follows 4 Calibration 5 Maintenance 6 Options Choose 4 Calibrations from the main menu and press ENTER 1 Clamps 2 Cutters 3 Adapters Choose 3 Adapters and press ENTER Adapters 1 E1 Mortice 2 E2 Bit Stop Female 3 E3 Pump cutting Choose 3 E3 Pump cutting and press ENTER Adapter E3 Side Cutting Adjustments B 000 X 00 Y1 00 Y2 00 Position the pointer at the side of the parameter to be edited with the arrow keys or ENTER and use the following keys to edit the parameters SHIFT arrow up increases the value within 300 hundredths of a mm or hundredths of a degree axis B 20 cent mm X Y1 Y2 SHIFT arrow down decreases the value within 300 hundredths of a mm or hun
12. ra centi 6 2 10 Machine Messages 6 2 10 1 ALARM MESSAGES 6 2 10 2 ERROR MESSAGES 6 2 10 3 SIGNAL MESSAGES MAINTENANCE ree 7 1 Trouble Shooting eret eger Ed e ERREUR A EE 118 7 2 Maintenance operations 120 7 8 Cutter replacement 120 7 4 Replacing and tightening the 121 7 5 Checking and or replacing 122 7 6 Electronic circuit board replacement 2 123 7 7 Keyboard display replacement sess 124 7 8 Access to back compartment menn 125 7 9 Access to bottom compartment nennen trenes 125 740 Sensor replacement eR E REPE ai 126 7 11 Replacing the photocell sees 128 7 11 1 Machine zero setting after replacing the photocells esses 130 2 Br srreplacement op ER nat 132 7 13 WIN TRANSFER Program for loading updating the internal machine program vast tert reto ent edo 7 14 DIAGNOSTIC FUNCTION errors in Copy from Original on IDEA DISPOSING OF MAGHINE IIa sane 55 5 2 5 aisi 9 1 How to request service c eerte rerit a Anaao Appendix 1 E
13. reference or positioning point on the key cutting clamp Cutter 1 25 thickness of the cutter currently selected press SHIFT ENTER to change thickness Brass Steel material of the key press SHIFT to change material Adapter E10 shows the adapter to fit on the rotating clamp in order to position the key properly ATTENTION always check that the wording corresponds to the material of the key The key blank to be cut must be positioned according to the parameters given on the display after selecting the program involved the type of key small bits with front stop requires the use of adapter E10 and the key reference on Stop 0 Please follow the instructions below carefully and observe the order of operations 1 Loosen the knob T1 by turning it anticlockwise until the rotating clamp S1 can be moved to a convenient distance for fitting the key 2 Orient the standard tailstock K1 for male keys in the special seat on the support using the screw V2 to direct it upwards fig 76 Fig 76 3 Take the T wrench T4 from its seat and fit into the screw V1 fig 76 then loosen until the jaws are fully open At the end of the operation do not remove the T wrench from the screw V1 4 Fit the key blank into the adapter E10 taking care to position it properly fig 77 tighten the P screw ATTENTION For single bit keys the distance between the adapter and the end of
14. so that the letter C is facing the operator fig 52 3 Open the fixed clamp A by pressing on the grip lever F and fit the E6 adapter on the S100 A clamp so that it butts against jaw and the initials E6 are upwards Press on the lever grip F1 and fit the key into its seat so that the bit is up against the fixed clamp E6 fig 53 re 4 ATTENTION position the key so that the highest tooth is facing left ensuring contact with the stop 0 on the vertical side of the tooth Release the jaw lever Press START to proceed When the reading process starts the carriage will take the key into contact with the laser beam along an ideal path At the end of the cycle see the message on the display in order to continue 5 6 7 52 Fig 53 Reading in progress Data processing in progress Please wait 40 Copyright Silca 2004 Operating Manual English CUTTING KEYS CUTTING FIAM KEYS WITH SQUARE STEM CUTTING FIAM KEYS WITH SQUARE ROUND STEM Clamp 51 K1 indicates which clamp S1 and tailstock K1 to use for gripping the key Stop 0 reference or positioning point on the key cutting clamp Cutter 1 25 thickness of the cutter currently selected press SHIFT ENTER to change thickness Brass Steel material of the key press SHIFT to change material ATTENTION always check that the wording corresponds to the material of the key
15. 6 2 9 To cut a STEEL key blank BIT OR DOUBLE BIT the maximum height allowed is1500 15 mm This option is used to alter this value and set a bit height above 1500 Press ENTER the display shows Max bit width for steel keys 1500 1500 2400 If the value of 1500 15 mm is exceeded digited when ENTER is pressed the display will show ATTENTION Recommended value 1500 See operating manual Press ENTER Save adjustment No STOP Yes ENTER STOP Cancel the operation and return to the Options menu ENTER Confirm save the alteration Reading Check Press ENTER the display shows Check reading Enable reading check 1 1 enabled 1 Enables the bit check function at the end of the reading process 0 Disables the bit check function at the end of the reading process Setting 1 function enabled the machine software will check the reading and assess the possibility to make a perfect copy of the key In the event of anomalies the display will show an error message see errors 22 23 ch 6 2 10 2 page 116 Setting 0 function disabled the machine will not check the key reading Keys reproduced in this way could be different and not operational 108 Copyright Silca 2004 Operating Manual English IDEA CUTTING NARROW TEETH When cutting teeth that are narrower than the cutter thickness the display will show 125mm x A Current cutter 1 25
16. Adap E7 START Reading in progress Date processing in progress in corso Follow the instructions on the display Fit the key blank into the clamp see ch 5 9 on page 32 then press START Left blank Brass Clamp S1 K1 Stop 0 Cutt 1 25 Adap E3 Pcs 1 1 START Cutting in progress Copy 1 of 1 100 Copyright Silca 2004 Operating Manual English IDEA Copy 1 of 1 finished More copies No STOP Yes ENTER Press STOP remove the key and use a centesimal gauge to measure it Y Fig 127 Measurement Y should be 4 40 mm inch 0 03 mm Measurement Y1 should be 2 80 mm inch 0 03 mm Measurement X should be 9 50 mm inch 0 03mm If this is not the case e g X 9 40 and Y 4 30 proceed as follows 4 Calibrations 5 Maintenance 6 Options Choose 4 Calibrations from the main menu and press ENTER 1 Clamps 2 Cutters 3 Adapters Choose 3 Adapters and press ENTER 4 E4 Muel cutting 5 E5 Fiam cutting 6 E6 Fiam reading 7 E7 Pump reading Choose 7 E7 Pump reading and press ENTER Adapter E7 Side Cutting Adjustments B 000 X 00 Y1 00 Y2 00 Position the pointer at the side of the parameter to be edited with the arrow keys or ENTER and use the following keys to edit the parameters SHIFT arrow up increases the v
17. DE SQUARE SQUARE ROUND SPECIAL SQUARE stem stem stem Fig 49 WITH OPTIONAL E5 Centring device for FIAM keys E5 ID used in cutting install on the K1 tailstock Special Square Stem E6 Centring device for FIAM keys E6 ID used in reading install on the fixed clamp S100 A Adapter for FIAM keys ID used in reading install on clamp S100 in the place of jaw Square Round Stem and Special Square Stem When the machine requires indicates on display adapter E5 or E6 or C proceed in the way described in the following examples Itis very important to distinguish the type of key to be copied SELECT TYPE OF KEY 0 Bit stop male 1 Bit stop female 2 Shoulder stop Choose option 4 for keys with square stems option 5 for keys with square and round stems option 6 for keys with special square stems step on tip 3 Pump 4 Square square tip 5 Square round tip 6 Square stepped tip Choose option 1 Reading Cutting 1 Reading Copying 2 Cutting only 3 Reading only 4 Post reading adj 38 Copyright Silca 2004 Operating Manual English KEYS READING READING SQUARE STEMMED FIAM KEYS IDEA KEY READING Original on right Clamp S100 A B Stop 0 START Operate as follows See Operating Manual as for keys with front stop M READING SQUARE AND ROUND STEMMED FIAM KEYS
18. K2 clamp see ch 5 12 on page 43 then press START Bit 1 Simm F R 11 11 11 11 Possible depths 123456 8 Cutt 1 25 SSN 110 1 Brass Clamp S1 K1 Stop 1 Pcs 1 1 START Cutting in progress Copy 1 of 1 Bit 1 Cutting in progress Copy 1 of 1 Bit 2 Copy 1 of 1 finished More copies No STOP Yes ENTER Press STOP remove the key and use a centesimal gauge to mesure it 17 30 gt Fig 128 Measurement X should be 17 30 mm inch 0 03 mm Measurement Y Y1 Y2 should be 11 25 mm inch 0 03 mm IDEA Copyright Silca 2004 103 IDEA Operating Manual English If this is not the case e g X 17 40 and Y 11 40 proceed as follows 4 Calibration 5 Maintenance 6 Options Choose 4 Calibrations from the main menu and press ENTER 1 Clamps 2 Cutters 3 Adapters Choose 1 Clamps and press ENTER Clamps 1 S1 Rotating Jaw 2 5100 Reading Jaw Choose 1 S1 Rotating Jaw and press ENTER Clamp S1 K1 gt gt Adjustments B 000 X 10 Y1 15 Y2 00 To calibrate START Clamp S1 K1 unit comprising clamp 51 and interchangeable tailstock K1 Press SHIFT ENTER SHIFT ENTER to go to the other interchangeable tailstock used with clamp S1 if applicable Digit the corrections required for axis X
19. No key read In the memory ATTENTION No decodable key See instructions manual ATTENTION Positive X adjustment can damage tailstock Copyright Silca 2004 117 IDEA Operating Manual English 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 IDEA 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 apply to the parts used for electrical contact clamps decoders cutters gauging templates etc Do not contaminate the electronic parts with the oil ATTENTION do not use alcohol to clean plexiglass and plastic parts of the machine 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
20. Operating Manual English IDEA 3 7 60 Fig 125 Measurement X should be 7 60 mm inch 0 03 mm Measurement Y Y1 Y2 should be 20 40 mm inch 0 03 mm If this is not the case e g X 7 50 and Y 20 50 proceed as follows 4 Calibrations 5 Maintenance 6 Options Choose 4 Calibrations from the main menu and press ENTER 1 Clamps 2 Cutters 3 Adapters Choose 1 Clamps and press ENTER Clamps 1 S1 Rotating Jaw 2 5100 Reader Jaw Choose 2 S100 Reader and press ENTER Clamp 5100 Adjustments X 10 Y1 0 5 Y2 0 5 To calibrate START Digit the required corrections for axis X and axis Y bit 1 Y1 bit 2 Y2 Press ENTER Save adjustment No STOP Yes ENTER Press ENTER to confirm the data Copyright Silca 2004 97 IDEA Operating Manual English DIMENSION CHECK CUTTING TEST PUMP KEYS To check the machine s precision proceed as follows 0 Copy from Original 1 Decode and Copy 2 Insert cuts 3 Queue from PC gt gt Choose 2 Insert cuts from the main menu and press ENTER SSN 24 Cut Make MOTTURA MT2 MT3 MT4 Choose SSN 24 and press ENTER Bit 1 Symm F R Possible depths 1234567 1 Enter the depth for bit 1 as in the example Bit 1 Symm F R 4441444 Possible depths 123456 6 Press ENTER SSN 24 M1 Brass Clamp S1 K1 Stop 3 Cutt 1 25 Adapt
21. machine has not suffered any damage 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 approx 60 POSITIONING AND INSTALLATION 1 Place the machine on a horizontal surface solid enough to support the weight of 40 Kg to work with ease we suggest that the workbench be approximately the height of the operator s hip itis 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 100 cm DESCRIPTION OF WORK STATION The machine needs only one operator who has the following controls at his her disposal fig 10 page 8 master switch placed on the back of the machine key positioning clamp keyboard display emergency button Copyright Silca 2004 13 IDEA Operating Manual English 3 5 GRAPHICS The Plexiglass protective shield carries an adhesive warning label fig 15 This label must never be removed Two laser warning labels must be attached to the optical reader fig 15 y LASER OPENING CLASS 1 LASER EQUI
22. the adapter E2 must be properly fitted into its seat and pressed up against the stop point Take the T wrench T4 from its seat and open the rotating clamp jaws by turning the sunk hex screw V1 at the end of the operation leave the T wrench in the screw V1 Fit the key blank into the front side of the rotating clamp G and position it on the groove in the jaws then take the key forward until the adapter E2 goes into the hole in the stem Close the mobile clamp jaws slightly using the T wrench already in the screw V1 without gripping the key stem move the rotating clamp G towards the tailstock keeping a minimum safety distance of 10 mm between the rotating clamp jaws and the rear limit of the bit Secure the rotating clamp in position by means of knob T1 Hold the key head in the left hand and align crosswise making sure that the bit is all the way up against the adapter E2 on the tailstock K1 then close the grips round the key stem using the T wrench T4 already in place on the screw V1 Transfer the T wrench T4 onto the screw V2 of the tailstock and secure the adapter E2 Replace the T wrench in its seat lower the mobile safety shield and begin the process with START To remove the key after cutting carry out the operations described in reverse order Copyright Silca 2004 27 IDEA Operating Manual English Cutting in progress Copy 1 of 1 Copy 1 of 1 finished More copies No STOP Yes EN
23. unscrew the keyboard s fixing nuts and remove the keyboard from its support 5 fit the new keyboard display repeating the operations described above backwards are BI A Fig 137 Fig 138 124 Copyright Silca 2004 Operating Manual English IDEA 7 8 ACCESS TO BACK COMPARTMENT To gain access to the back compartment proceed as follows 1 turn the machine off and unplug it from its power supply cable 2 unscrew the 6 M1 screws that secure the back panel fig 139 thus removing it 53 7 Fig 139 7 9 55 gain access to the bottom compartment proceed as follows 1 turn the machine off and unplug it from its power supply cable 2 turn the machine on its back side 3 remove the machine s bottom panel by unscrewing the 8 L1 screws Fig 140 Copyright Silca 2004 125 7 10 SENSOR REPLACEMENT X AXIS SENSOR REPLACEMENT 1 Oo E O1 za Fig 141 Fig 142 Operating Manual English turn the machine off and unplug it from its power supply cable remove the bottom panel ch 7 9 Access to bottom compartment disconnect the X axis sensor s connector from the electronic circuit board unscrewing the L3 nut Unscrew the sensor from the plate and remove it remove the front cover on the X axis lower carriage fig 142 by unscrewing the 3 B4 screws fit the new sensor in position tightening it until it almost touche
24. 61 Clamps S1 KI Adjustment B 000 X 00 Y1 06 Y2 06 To calibrate START Clamp S1 K1 unit comprising clamp 51 and interchangeable tailstock K1 SHIFT ENTER to go to the other interchangeable tailstock used with clamp S1 if applicable START press START to begin the automatic gauging procedure for the CLAMP TAILSTOCK unit if applicable Place the pointer at the side of the parameter to be edited with the arrows or with ENTER and edit the parameters using the following keys SHIFT arrow Up increases the value within 300 hundredths of a mm or hundredths of a degree axis B 20 cent mm X Y1 Y2 SHIFT arrow Down decreases the value within 300 hundredths of a mm or hundredths of a degree axis B 20 cent mm X Y1 Y2 CLEAR to zero the value ENTER in the last field is used to quit the window and show the message requiring the editing to be saved Save adjustment No STOP Yes ENTER ATTENTION when STOP is pressed the new measurements are not saved the previous gauging values therefore remain valid Select 5100 Clamp S100 Adjustments X 04 Y1 04 Y2 04 FOR K2 TAILSTOCK Clamps S1 K1 gt gt Adjustments B 000 X 00 Y1 00 Y2 00 To calibrate START Press SHIFT ENTER Clamp S1 K1 unit comprising the 51 clamp and K1 interchangeable tailstock gt gt press SHIFT ENTER to go to the other interchangeable tailstocks used with t
25. 95 SPECULAR F R Each bit is specular in the direction FRONT BACK enter half the cuts for each bit to have the full combination REAR FRONT 2 o Fig 96 68 Copyright Silca 2004 Operating Manual English IDEA After entering the cuts for all the bits go on to cutting SSN 9 M1 Brass Clamp S1 K1 Stop 0 Cutter 1 25 Pes 1 1 START M1 bit 1 Clamp 51 K1 indicates which clamp 61 and tailstock K1 to use for gripping the key Stop 0 reference or point for positioning the key in the cutting clamp Cutter 1 25 thickness of the cutter currently selected press SHIFT ENTER to change thickness Brass Steel material of the key press SHIFT to change material Pc 1 1 enter the number of keys required ATTENTION always check that the wording BRASS STEEL corresponds to the material of the key SHIFT ENTER used to change the thickness of the current cutter by pressing ENTER against the cutter thickness required Choose cutter 1 PL 1 25 2 PL 1 00 3 PL 1 50 Press STOP to quit Press START to begin cutting Copyright Silca 2004 69 IDEA Operating Manual English 5 18 USE Or THE MACHINE WITH A PERSONAL COMPUTER In the previous pages the IDEA key cutting machine operations and parts have been presented as a stand alone machine with the data stored in the machine memory It is of interest to examine a very important functio
26. Copyright Silca 2004 Operating Manual English ATTENTION do not touch the X and Y axes carriages and press START 10 press START the machine s zero settings are detected by electric contact when this operation is completed the machine s display will show the measured quotes ATTENTION if the STOP key is pressed the new settings will be lost If so only the previous setting values will remain valid 11 press ENTER to save the settings 12 remove the Z12 and Z13 templates 13 proceed with setting the reading unit READING UNIT 1 Select Reading unit 2 2 press ENTER 3 install the 714 template fig 153 4 lower the protective shield and press START the machine s zero settings are detected by the optical reader when this operation is completed the machine s display will show the measured quotes ATTENTION if the STOP key is pressed the new settings will be lost If so only the previous setting values will remain valid 5 press ENTER 6 remove the Z14 template the new setting has been made IDEA Pos sensors See operating manual START Zero detection in progress Measurements read X 4444 Y 3333 Save data No STOP Yes ENTER 1 Cutting unit 2 Reading unit Install the A amp B clamps 214 template See operating manual START Zero detection in progress Me
27. Left blank Brass Clamp S1 K1 Stop 1 Cutt 1 25 Adap E1 Pcs 1 1 START Clamp 51 K1 indicates which clamp S1 and tailstock K1 to use for gripping the key Stop 0 reference or point for positioning the key in the cutting clamp Cutter 1 25 thickness of the currently selected cutter press SHIFT ENTER to change thickness Adapt E1 special adapter for keys with CENTRE STOP Brass Steel material of the key press SHIFT to change material ATTENTION always check that the wording corresponds to the material of the key The key blank to be cut must positioned according to the parameters given on the display after selecting the program involved the type of key with centre stop requires the use of the E1 adapter and the key reference on Stop 0 Please fallow the instructions below carefully and observe the order of operations 1 Loosen the knob T1 turning it anticlockwise until the rotating clamp S1 be drawn back and secured at the end of its external run mechanical stop 2 Take the T wrench T4 from its seat and fit into the screw V1 then loosen until the jaws are fully open At the end of the operation do not remove the T wrench from the screw V1 3 Fit the key blank into the adapter E1 taking care that it is in the right position fig 33 then tighten the screw V4 4 Fit the adapter E1 with the key blank in the inner side of the rotating clamp S1 take the adapter up ag
28. Operating Manual English 5 13 SMALL BIT DOUBLE BIT KEYS OPTIONAL D727711ZB Adapters Fig 71 The set comprises E10 Adapter for small bit or double bit keys E10 ID initials used for cutting max 12 max 12 max 12 IDEA E Adapter for small bit or double bit keys E ID initials used for reading to fit to the S100 clamp in the place of jaw B When the machine requires indicates on display adapter E10 or E proceed as follows Itis very important to distinguish the type of key to be copied Choose option 9 Small bit Choose option 1 Reading Copying Operate as follows SELECT TYPE OF KEY 0 Bit stop male 1 Bit stop female 2 Shoulder stop 3 Pump 4 Square square tip 5 Square round tip 6 Square stepped tip 7 Rear stop 8 Rear stop french 9 Small bit 10 Special bit female 1 Reading Copying 2 Cutting only 3 Reading only 4 Post Reading KEY READING Original on right Clamp S100 A E Stop 0 START Copyright Silca 2004 53 IDEA Operating Manual English READING small bit or small double bit keys O Si Note 4 Maximum dimensions of keys for Reading from the original Max stem thickness 4 mm Max bit length 18 mm 18 de 18 Max bit height 12 mm If these conditions are not observed the machine will produce the error Key cannot be decoded
29. Serial No 2 Carriage speed 3 Clamp rotation speed 4 Preferences gt gt Place the cursor on the option required and press ENTER 5 Language 6 Keyboard inversion 7 Protected Systems 8 Bit width 9 Check reading 6 2 1 Serial number D 153214523123 The display shows the machine s serial number that 4 Model IDEA should correspond to the one stamped on the date plate K on the back of the machine eys cut SW version 6 2 2 Carriage approach speed ica 1 This is the speed at which the carriages move towards the speed 3000 cutting area before starting the cutting cycle 00 3000 We recommend to operate the machine with the speed that is set If required the operator can adjust the carriage approach speed from a minimum of 1000 to a maximum of 3000 by 6 2 3 Rotating speed This is the speed at which the rotating clamp move towards the cutting area before starting the cutting cycle eis We recommend to operate the machine with the speed Speco that is set If required the operator can adjust the carriage 1000 3000 approach speed from a minimum of 1000 to a maximum of 3000 by Copyright Silca 2004 105 IDEA Operating Manual English 6 2 4 Preferences 1 used to choose the measuring unit used to view dimensions such as parameters adjustments etc 1 Measurement unit 1 INCH or 0
30. 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 Copyright Silca 2004 7 IDEA 1 3 OQO 000 2 9 Fig 10 MAIN WORKING PARTS 4ao0om3ovozr roou T1 T2 T4 wrench U U1 Fixed clamp clamp A U2 Mobile clamp clamp B V Metal chippings tray Master switch Keyboard Display Connector for revolving clamp Cutter Cutter shield Optical reader Emergency button 3rd axis IN OUT port Serial port Y axis connector X axis carriage Rotating clamp Y axis carriage Rotating clamp locking handle Rotating clamp removal screw Protective shield Operating Manual English 4 t e C9 ES Fig 11 Copyright Silca 2004 Operating Manual English IDEA 1 4 TECHNICAL DATA Electricity supply 230V 50Hz Maximum absorbed power 230V 2 Amp 250 Watt Cutter motor single phase and speed Cutter hard metal carbide 100 mm x 1 25 mm Tool speed 50Hz 1150 rpm 10 Movement on 2 axes with ball screws activated by step motors on rectified roller guides Possibility to add a 3rd axis to activate the optional tilting and rotating clamps Clamp revolving Runs X axis 37 mm Y axis 32 mm Dimensions and types of keys The machin
31. and axis Y bit 1 Y1 bit 2 Y2 Example Clamp 51 2 Adjustments B 000 X 10 Y1 15 Y2 00 To calibrate START Position the pointer at the side of the parameter to be edited with the arrow keys or ENTER and use the following keys to edit the parameters SHIFT arrow up increases the value within 300 hundredths of a mm or hundredths of a degree axis B 20 cent mm X Y1 Y2 SHIFT arrow down decreases the value within 300 hundredths of a mm or hundredths of a degree axis B 20 cent mm X Y1 Y2 CLEAR to zero the value ENTER in the last field to quit the window so that the query Save appears for the edited data START press START to begin the automatic gauging procedure or the CLAMP TAILSTOCK unit Press ENTER Save Adjustments No STOP Yes ENTER ATTENTION if STOP is pressed the new measurements are not saved the previous gauging values therefore remain valid Press ENTER to confirm the data 104 Copyright Silca 2004 Operating Manual English IDEA 6 2 OPTIONS Below are described all the steps necessary for choosing options 0 Copy from Original 1 Decode and copy Select the function from the main menu by placing the 2 Insert the Cuts cursor on 6 Options 3 QueuefromPC gt gt Press Y Down arrow key 4 Calibrations 5 Maintenance 6 Options A list of machine OPTIONS will appear 1
32. been launched but the key is not in the reading clamp ERROR 13 Original key not found 114 Copyright Silca 2004 Operating Manual English IDEA Indicates that one of the machine gauging operations has found an adjustment that exceeds tolerance ERROR 14 Possible causes Exceeded settino gauging templates are not properly positioned Tolerance limit repeat the operation more carefully A limit switch sensor is not working properly carry out the sensor test for the axis out of tolerance A machine zero photocell is not working properly carry out the photocell test for the axis out of tolerance One of the carriages has excessive play on it The motor for the axis out of tolerance is not working properly carry out the MOTOR test Indicates that one or more incompatible POST READING adjustments have been made See chapter 5 15 of this ERROR 15 manual Adjustments Incompatibile with Those already made The message indicates that the key installed cannot be decoded ERROR 16 Possible causes Key cannot be The key is bigger than the one on the selected card decoded The key is not properly positioned in the reading clamp The card selected for decoding does not correspond to the key used The message indicates that the adapter fitted to the optic reader or cutting clamp is not properly ERROR 17 positioned Adapter not Possible causes properly installed The adapter is
33. depths B radius and bit angles with controlled movement Accurately studied it adds a high degree of cutting precision to operating speed and ease of use IDEA can be used in 4 different ways entering the key code directly by means of the machine keyboard reading the key with a laser reader and reproducing it linking to a and Silca software decode and copy MAIN CHARACTERISTICS Movements Movement of the two axes X Y operates on ball screws activated by step motors on rectified roller guides e Clamp Motorized rotating clamp to control the revolving movement for the cutting radius to turn over double bit keys and control the third axis B Working tool Consists of a cutter in hard metal carbide optional High Speed Steel that is easily replaced Suitable to the type of work and speed rotation needed Optional hard metal carbide cutter 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 Copyright Silca 2004 Operating Manual English IDEA 1 2 SAFETY Protective shield The transparent protective shield is designed to cover the working parts as completely as possible ensuring operator safety The shield U fig 10 page 8 must be raised in order to fit keys for cutting or carry out other
34. in the centre of the photocell sensors 8 tighten the screws G11 9 replace the lower plate 10 connect the power supply wire and turn on the machine 11 check with the cutter motor Test NO DAWN I I 2 II Fig 149 Fig 150 Copyright Silca 2004 129 IDEA Operating Manual English 7 11 1 Machine zero setting after replacing the photocells CUTTING UNIT 1 enter Maintenance menu 5 4 Calibrations 5 Maintenance 6 Options 2 select Machine zero points 2 1 Test 2 Machine 0 points 1 Cutting unit 3 select Cutting unit 1 2 Reading unit 4 install the 713 template 5 remove the cutter from the machine and install the Z12 Install 212 amp 213 template templates 6 manually move the X and Y axes up until the templates See operating manual make contact ENTER 7 lower the protective shield and press START Move X and Y axis ATTENTION check that both the Z13 and 212 templates make up until contact is made perfect contact If this does not occur the display will See operating manual show an error message START 8 press START ATTENTION do touch the axes carriages and press ERROR 10 START no contact made See operating manual Pos Photocells TZX ON TZY ON See operating manual START 9 press START Fig 151 130
35. is possible to modify the angle of vision on the machine s display by following the instructions below e to incline the angle of the display towards the bottom you must press the NV key and then press the A key simultaneously keeping them both pressed WA up until you reach the desired visualization e to incline the visualization of the display towards the top you must press the key and then press the WV key simultaneously keeping them both pressed AW up until you reach the desired angle Copyright Silca 2004 15 IDEA 4 2 Fig 17 Operating Manual English USE OF THE CLAMP The rotating clamp 51 fig 17 is the fundamental tool of IDEA It has various functions and constitutes the third working axis rotation controlled by the machine The rotating clamp is housed in a mobile support which runs along the X axis spaces and is anchored to the carriage below it by means of a dovetail guide this allows the operator to position the clamp at any point along the key stem ensuring the best grip on the stem LOCKING The rotating clamp is locked in position by means of the handle T1 fig 17 the position along the X axis starts from the resting point for the jaws on the tailstock up to a rear mechanical stop which prevents the mobile support from coming off dovetail support REMOVAL Turn off the machine and pull out the plug If it is necessary to remove the rotating clamp from the guide for cleaning etc turn the k
36. loosen the 2 2 locking screws remove and withdraw the B axis carriage cover disconnect the sensor connector M5 fig 145 loosen the grub screw M6 with the allen wrench provided remove the worn sensor and fit the new one so that it almost touches the bottom fig 147 connect the sensor connector M5 Carry out the B axis sensor Test the state is OFF Use a screwdriver to turn the screw M7 clockwise fig 146 the state changes to ON tighten the grub screw M6 Replace the B axis carriage cover OFF ON Copyright Silca 2004 127 IDEA Operating Manual English 7 11 REPLACING THE PHOTOCELL REPLACING THE X AXIS PHOTOCELL 1 2 turn off the machine and unplug remove the back panel ch 7 8 page 125 raise the safety shield loosen the screw W5 to remove the brush unit loosen the screws W3 to remove the transmission unit loosen the 2 photocell fixing screws G7 and remove disconnect the photocell wire G5 fig 147 connect the wire to the new photocell place the photocell in position and secure with the screws G7 0 1 2 3 4 FW 10 replace the transmission unit 11 replace the brush unit 12 replace the back panel 13 connect the electricity supply wire and turn on the machine 14 proceed with gauging the machine MEN X axis photocell a7 d 24
37. mm or hundredths of a degree axis B 20 cent mm 1 2 SHIFT arrow down decreases the value within 300 hundredths of a mm or hundredths of a degree axis B 20 cent mm X Y1 Y2 CLEAR to zero the value ENTER in the last field to quit the window so that the query Save appears for the edited data Save adjustments No STOP Yes ENTER ATTENTION if STOP is pressed the new measurements are not saved the previous gauging values therefore remain valid OPERATION FLOW Choose option 0 Copy from Original 0 Copy from Original 1 Decode and Copy 2 Insert cuts 3 Queue from PC Choose option 7 Rear Stop SELECT TYPE OF KEY 0 Bit stop male 1 Bit stop female 2 Shoulder stop 3 Pump 4 Square square tip 5 Square round tip 6 Square stepped tip 7 Rear stop 8 Rear stop french 9 Small bit 10 Special bit female Choose option 1 Reading Cutting 1 Reading Cutting gt Select JAWS 2 Cutting only A E 3 Reading only A F 4 Post Reading adj A G KEY READING Original on right 5100 A E Stop 0 Adapt E11 START To select jaws see diagram ch TYPE OF KEYS and Choosing an adapter for READING page 47 Copyright Silca 2004 45 IDEA Operating Manual English Jaws A E READING DECODING SSN110 1 Remove the mobile unit B from the 100 clamp 2 Fitthe E11 mobile adapte
38. the Maintenance menu 5 1 Test 2 Machine 0 point 2 select Machine zero points 2 1 Cutting unit 2 Reading unit 3 select Reading unit 2 giani Install A amp B clamps 4 install the Z14 template and Z14 template install A and B clamps S100 See operating manual START 92 Copyright Silca 2004 Operating Manual English IDEA Fig 122 5 lower the protective shield and press START the machine s zero settings are detected by the optical reader when this operation is completed the machine s display will show the measured quotes ATTENTION if the STOP key is pressed the new settings will be lost If so only the previous setting values will remain valid Zero detection in progress Measured quotes X 4444 Y 3333 Save measurements No STOP Yes ENTER Copyright Silca 2004 93 IDEA DIMENSION CHECK CUTTING TEST To check the machine s precision proceed as follows 0 Copy from Original 1 Decode and Copy 2 Insert cuts 3 Queue from PC gt gt Choose 2 Insert cuts from the main menu and press ENTER Choose SSN 10 and press E SSN 10 Cut Make CISA CSL CSLC 5CS1 5CS2 NTER Bit 1 2 Symm F R Possible depths 123456 1 Enter the depth for bit 1 as in the example Press ENTER Bit 1 2 Symm F R 111 66666 111 Possible depths Ent
39. the bit should be at least 2 3 mm fig 77 For double bit keys the distance between the adapter and the end of the bit should be at least 8 mm fig 77 If these measurements are not observed the display will show an error ERROR 17 Adapter not properly fitted Fig 77 min 8mm Copyright Silca 2004 55 IDEA 5 Fit the E10 adapter with the key blank in the rotating clamp S1 from the inside take the adapter up to the side of the self centring jaws fig 78 and slightly close the grips on the rotating clamp with the T wrench 4 6 Move the rotating clamp S1 so that the key fits into the tailstock K1 with the bit all the way in fig 79 N _ Tighten the knob T1 Use the T wrench T4 to tighten the screw 1 first then the screw V2 fig 80 Replace the wrench T4 into its seat lower the mobile safety shield and begin the process with START Fig 78 Cutting in progress Copy 1 of 1 Copy 1 of 1 finished More copies No STOP Yes ENTER To make further copies of the key you can now press ENTER Fig 79 Fig 80 Operating Manual English 56 Copyright Silca 2004 Operating Manual English 5 14 SPECIAL BIT FEMALE KEYS OPTIONAL D728717ZB Adapters E15 E16 Fig 81 The set comprises E15 Adapter Centring device E15 ID code used for cutting install on the K1 tailstock E16 Ad
40. the machine s display indicates ON to OFF NOTE ifthe OFF ON transition is not made contact Silca s Technical Assistance Dept Test 10 Y AXIS PHOTOCELL Slowly push the Y axis carriage manually from its right all the way to its left checking that the machine s display indicates ON to OFF NOTE ifthe OFF ON transition is not made contact Silca s Technical Assistance Dept Test 11 T WRENCH MICRO Carefully follow the instructions that are on the machine s display Check that the status changes from OFF to ON NOTE ifthe OFF ON transition is not made contact Silca s Technical Assistance Dept Test 12 PROTECTIVE SHIELD MICROSWITCH Raise and lower the protective shield checking that the machine display shows first OFF then ON Test 13 ELECTRIC CONTACT Use any metal conductor to create a connection between the cutter and the clamp checking that the machine display shows first OFF then ON Test 14 KEYBOARD One at time press all the keys except STOP checking that an asterisk appears for each key pressed Press the STOP key for last Test 15 DISPLAY All points on the display should be obscured Test 16 CLAMP CODE Check on the display that 0 is code 1 Test 17 INLETS To use the test properly consult the literature provided with the specific optional accessories 86 Copyright Silca 2004 Operating Manual English Test 18 OUTLET 1 To use the test properly consult the literature provided with the s
41. 04 IV Appendix Operating manual English IDEA BIANCO WHITE BLANC I GI 7 E FOTOCELLULA ASSE Y PHOTOCELL AXIS Y CELLULE PHOTDELECTRIQUE AXE Y FOTOCELULA EJE Y FOTOZELLE ACHSE Y ROSSO RED ROUGE ROJO ROT GIALLO YELLOW JAUNE AMARILLO G s OO000000 jode meu a 2 wxx IO lt 4 OU FOTOCELLULA VELOCITA MOTORE SENSORE GREVOLE ame Copyright Silca 2004 Appendix V Operating manual English 10 J2 26 25 24 OUT 525 J4 OUT 2 22 121 out 0 20 GND 18 GND 17 GND 16 GND 15 NB 14 13 24V 12 24V 11 24 10 24y 9 N78 N67 N56 NAS N34 N23 N12 NOT GND 14 vec 13 GND 12 13 vec GND IDEA GND 252 RTS RS 232 no nanuuo 8 13 25 12 QUT 3 24007 2 4 our f 25 0uT 0 fo 22 GND 9 GND 21 GND ALIMENTATORE AUTOMATICO 8 GND AUTOMATIC FEEDER 2048 ALIMENTATEUR AUTOMATIQUE ALIMENTADOR AUTOMATICO 6 247 AUTOMATISCHE ZUFUHRER 18 24 8 24 17N 7 ANS 165 3N4 15 iN 5 2 N2 14141 No VLED SER DIN SER DIN SER RES SER RES SER DOUT SER DOUT SER CLK SER CLK OOOO 89858 696506269 630000 V
42. 1 J I OARA 175 Tum 2 N x G5 97 3 I di NY ER NB Yi CP E Fig 147 REPLACING THE Y AXIS PHOTOCELL 1 turn the machine off and unplug it from its power supply cable 2 disconnect the J1 Y axis cable from the carriage fig 116 page 89 3 remove the Y axis carriage cover by unscrewing the 3 B5 locking screws and pull the cover in the direction shown in fig 116 4 disconnect the J2 photocell cable and J sensor cable fig 148 5 unscrew the 2 K screws that hold the photocell card and remove it from the carriage 6 place the new photocell card in the carriage and tighten the 2 K supporting screws 7 reconnect both the photocell and sensor cables 8 remount the Y axis protective cover 9 connect the J1 Y axis cable back on the carriage 10 plug the machine back in and turn it on 11 proceed with machine settings Y axis photocell Fig 148 128 Copyright Silca 2004 Operating Manual English IDEA REPLACING CUTTER MOTOR PHOTOCELL turn the machine off and pull out the plug remove the lower plate see ch 7 9 Access to bottom compartment page 125 loosen the 2 screws G11 disconnect the photocell wire G8 fig 149 loosen the 2 screws G9 fixing the photocell and remove it connect the wire to the new photocell position the photocell and secure with the screws G9 so that the disk G10 is
43. 9 pin serial port and electronic circuit board not seeded properly or disconnected wiring between optical reader and the electronic control board is not seeded properly b check that the fan on the back of the key cutting machine is working serial cable between key cutting machine and computer is faulty computer serial port is not functional defective electronic control board Not working a fan faulty b electronic control board faulty electronic control board faulty fuse F4 on the electronic control board faulty a b short circuit on inlets or outlets To find which inlet or outlet is causing the error message disconnect the J4 5 7 8 12 14 15 20 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 D4 fig 130 cutter motor wiring disconnected d internal fault on the electronic control board Fig 130 Copyright Silca 2004 119 IDEA Operating Manual English 7 2 MAINTENANCE OPERATIONS Cutter replacement Belt replacement and tension adjustment Fuse check and replacement Elect
44. D3 fig 130 closed but the display reads close shield b the F4 fuse on the electronic control board is faulty Keyboard not working a the keyboard connector is not properly connected to the interface board fig 129 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 Electric contact not a wiring between the J14 connector on the electronic control board and cutter shaft is loose or working during disconnected calibrating or cutting b wiring inside the Y axis carriage is not seeded properly or disconnected defective electronic control board d wear on the brushes ch 7 12 page 132 118 Copyright Silca 2004 Operating Manual English IDEA FAULT PROBABLE CAUSE Optical reader working Key cutting machine fails to communicate with computer The display shows the message TEMPERATURE ALARM turn machine off the The display shows the message 1 0 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 Fig 129 a glass lent on the optical reader is dirty b i i defective optical reader d defective electronic control board a wiring between
45. 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 defective display cutter motor not a the closed protective shield is not making proper contact with the safety microswitch the F1 fuse the electronic control board is faulty 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 axes motors None of the a fuse F2 on the electronic control board faulty are not working motors working b the wiring between the transformer and electronic control board is loose or the connector is not seeded properly defective electronic control board Only one motor a the connection wires between the motor and the electronic control board are is not working loose or the connector is not seeded properly b defective electronic control board Protective shield is a the closed protective shield is not making proper contact with the microswitch
46. G Stop 2 Raise the positioning plate P and fit the key blank into the rotating clamp S1 from the front placing the stem into the V on the jaws of the K2 tailstock Take care to keep the bit in the horizontal position and the key stop up against the stop STOP 2 achieved by fitting the plate P into its seat and securing the key by tightening the jaw screw W2 with the T4 wrench fig 66 Replace the T4 key in its seat Fig 66 CUTTING Stop 3 Raise the positioning plate P e and fit the key blank into the rotating clamp S1 from the front placing the stem into the V on the jaws of the K2 tailstock Take care to keep the bit in the horizontal position and the key stop up against the stop STOP 3 achieved by fitting the plate P into its seat and securing the key by tightening the jaw screw W2 with the T4 wrench fig 67 Replace the T4 wrench into its seat Fig 67 Important the key can be fitted into the S1 K2 clamp from the front or from the back according to the type of key 48 Copyright Silca 2004 Operating Manual English IDEA Choosing a STOP for CUTTING 1 place the original key on the drawing using the stop as a reference 2 in this position the bit should enter the 43 mm zone eee se SS Uu eS E Stop 1 example Silca key ref 6FT12 Stop 2 example Silca key ref 6 14
47. I Appendix Copyright Silca 2004 Operating manual English J5 jme E GND 9 9 10 Gi X J 14 END J 20 a Vcc IDEA ELETTROVALVOLA ASPIRAZIONE SUCTION SOLENOID VALVE ELECTROVANNE ASPIRATION ELECROVALVULA ASPIRADOR ELECTROVENTIL SPANEABSAUGANL AGE CONTATTO ELETTRICO CHIAVE ELECTRIC CONTACT CONTACT ELECTRIQUE CONTACTO ELECTRICO ELEKTRISCH KONTAKT MICROINTERRUTTORE CHIAVE MICROINTERRUPTEUR MICROINTERRUPTOR MIKRISCHAL TER MICROINTERRUTTORE CARTER MICROSWITCH SHIELD MICROINTERRUPTEUR ECRAN MICROINTERRUPTOR SCHUTZ GND ENA CHARGE COMP1 COMP2 LETTORE OTTICO OPTIC READER LECTERU OPTIQUE LECTOR OPTICO LESER Copyright Silca 2004 Appendix VII Operating manual English IDEA VIII Appendix Copyright Silca 2004 SILCA S p A Via Podgora 20 2 1 31029 VITTORIO VENETO Tel 0438 9136 Fax 0438 913800 www silca it Member of the Kaba Group DO iy d
48. ICAL DIAGRAMS The following pages contain the electrical diagrams for the IDEA key cutting machine described in this manual Copyright Silca 2004 Appendix IDEA IDEA ELECTRICAL DIAGRAMS Ver 1 0 25252119 17 1515197551 69 63 neo o 9 TOO lt COM UNILVWADISNVAL aoc VWADASNYUL YNILVWADASNVAL ASNVal Sao LVWalC JS ValL UDIVITINIA agay LN3A ANALY TT LN3A NWA 38IDILLV TI LN3A pm T 2159190152103 1 30 ZJINIDIN A 41055709 NOLLA AIN3DIIMI 925304343 I3INWS TINA 12345 DL e 4 a a lt tr eus E ax OH in e DL2 J7 381215 8311114 S31 WHOIS DILIIA elbd eel31NI 341111 UNILANINILNI 2317114 HOLIMS 051715 dIOLINAHIINI J4 0 654321 WGI 34 26 24 22 2018 16 1412108 6 4 2 10 9 7 5 3 1 1 1 9 7 5 5 1 t 2 Operating manual English 1 N GND ZHOS A0 2 Appendix III Copyright Silca 2004 IDEA Operating manual English Ji ZLOHIS s3171HOSDebL IW Nv323 INILANFNZINIONZIIN 871 8 H2LIASDSOIN SILVI 3D E LOIS LN amp 1 VS38i 351943 SOLOW 7001 DNILINI 5341 38010W X 3SHOV 31320104 X 355 v7 T3908 X 51 T13201DHd Copyright Silca 20
49. IDEA Version X X XXX Vers DB xx xx Version this refers to the version of internal software that runs the machine functions The figure changes at every upgrade Vers DB this refers to the version of the data relating to the Systems Locks entered You may ask SILCA to upgrade your machine database with any of the new systems on the market The figure changes at every upgrade The WinTransfer program see ch 7 13 page 132 or the Silca Key Programs can be used to update the machine program and data by means of a PC and serial port The first operation is to set the language for machine messages Select language 2 1 Italiano 2 English 3 Deutsch 4 Fran ais 5 Espa ol The main menu for the machine program then appears OPERATING KEYS Use the arrow keys Up Down to position the pointer and choose the option by pressing the ENTER key or enter directly the key relating to the option number The symbol gt gt indicates the other items in the menu that can be accessed with the arrow key Down 0 Copy from original 1 Decode and Copy 2 Insert the Cuts 3 Queue from PC 4 Calibrations 5 Maintenance 6 Options Copyright Silca 2004 IDEA Operating Manual English 5 3 0 COPY FROM ORIGINAL READING PROCESS The laser reader is used to find the measurements and cuts on original keys so that they can be copied onto the keyblanks ATTENTION before undergoi
50. IDEA has never been configured on SKP do it by clicking with the mouse on the New button Click with the mouse on the Sw upgrade button Wintransfer will be opened automatically Click with the mouse on the Connection test button if the connection is OK the Bit download for after sales service button will be enabled Click with the mouse on the Bit download for after sales service button Select the path e g disk C and give a name to the file to be saved Click with the mouse on the Save button The bit will be downloaded from IDEA approx 1 minute and at the end of the operation the monitor will show a saved message 10 Send the file to Silca the file will have the extension map via e mail to the address service silca it SW Version of key cutting machine complete with the following information Description of problem The last tooth of bit 1 is missing Errors on machine display INTERNAL ERROR n 11 or part of the bit has been cut on the stem How to download a bit from IDEA with Wintransfer 1 2 3 ia 5 Launch the Wintransfer program Select the Idea machine and click with the mouse on the Select button Click with the mouse on the Connection test button if the connection is OK the Bit download for after sales service button will be enabled Click with the mouse on the Bit download for after sales service button Select the path e g di
51. ISPOSING OF MACHINE To dispose the machine it must be rendered unusable by carrying out the operations listed below e deactivation of the electricity supply separation of the plastic and metal parts 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 IDEA 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 t
52. IT DOUBLE BIT KEYS SPECIAL BIT FEMALE KEYS 6 KEYS WITH REAR STOP BIT STOP KEYS Fic 2 The minimum and maximum dimensions of this type of key are shown in the diagram below This class of key includes mortice and bit and double bit keys male and female keys a gt Stop 0 15 7 mm mm max 15 mm max 7 mm Fig 2 Copyright Silca 2004 Operating Manual English IDEA SHOULDER STOP KEYS ENGLISH TYPE FIG 3 The minimum and maximum dimensions of this type of key are shown in the diagram below This class of key includes Single bit keys with rim close to the bit double bit keys with rim close to the bit Stop v max 26 mm max 20 mm max 6 mm Fig 3 PUMP KEYS FIG 4 The minimum and maximum dimensions of this type of key are shown in the diagram below To cut this type of key on the IDEA is necessary the optional adaptor D726180ZB This class of keys includes pump keys with round stems 0 max 7 mm min 4 mm pump keys with flat stems 7 mm Stop 3 max 55 mm N V max 22 mm N 12mm 19mm Fig 4 Copyright Silca 2004 IDEA Operating Manual English SMALL BIT DOUBLE BIT KEYS FIG 5 The minimum and maximum dimensions of this type of key are shown in the diagram below To cut this type of key on the IDEA is necessary
53. K2 Note before starting any operation for keys with rear stops the K1 tailstock must be removed Simply loosen the screw W with the wrench T4 fig 59 and push the K1 tailstock to the left in order to remove it from its seat If this is not done an alarm will appear even in the case of a simple reading operation ALARM 17 ALARM 17 Key origin not found See operating manual Fig 59 To install K2 tailstock 1 Loosen the knob T1 by turning it anticlockwise until the rotating clamp S1 can be moved to the end of run towards the operator then use the T4 wrench to tighten the rotating clamp screw V1 in order to close the self centring jaws Fit the K2 tailstock into its seat slightly inclined to the left with the fixing cam C fig 60 aligned with the slide runners and secure by tightening the screw W1 fig 67 page 48 with the T4 wrench Take the S1 rotating clamp towards the K2 tailstock so that T fit together perfectly then secure by tightening the knob m Note use the T4 wrench to loosen the screw V1 in order to open the jaws of the S1 rotating clamp exerting normal pressure to secure the K2 tailstock firmly to the S1 rotating clamp Fig 60 Poceed with GAUGING Copyright Silca 2004 43 IDEA Operating Manual English Use the arrow keys up down to scroll 1 Clamps 2 Cutter 3 Adapter Clamps 1 S1 R
54. LECTRIC 5 VIII Operating Manual English REFERENCE GUIDE IDEA This manual has been produced to serve as a guide for users of the IDEA key cutting machine Read it carefully it is essential if you wish to operate your machine safely and efficiently CONSULTATION The contents of the manual are divided into sections relating to Machine description 2 Chapter Transport and Chapters Regulation and Chapters Maintenance ee Ite rere ret bett eerta Dese ta eins Chapters TECHNICAL TERMS Common technical terms are used in this manual 2 3 4 5 6 7 8 9 To assist those with little experience of keys and key cutting below is an illustration of the terms most frequently used 1 Head 2 Stem 3 Bit WITH OPTIONAL ADAPTERS Fig 1 Copyright Silca 2004 IDEA Operating Manual English CHARACTERISTICS OF KEYS FOR READING AND DECODING The IDEA electronic key cutting machine is designed to take a number of different types of mortice and bit double bit pump keys etc The following are the general key characteristics and conformations for which the machine has been designed or for which special adapters can be fitted in order to develop specific cutting systems In addition to the machine s general technical characteristics already described keys w
55. Max trimming 25 Continue No STOP Yes START When START is pressed the cutter will trim a portion of material totalling 25 100 mm from the right and left hand sides of the tooth drawing 1 imm For Max trim bear in mind the 3 situations describedbeloW 2 1 1 Negative tooth not the first tooth with base less that the cutter The cutter trims a portion of material from the right and left hand sides of the tooth totalling 25 100 mm drawing 1 max 0 4 mm 2 First negative tooth front stop M height greater than the safety measurement for the K1 tailstock When START is pressed the cutter trims a portion of material drawing 2 3 First negative tooth front stop M height below the safety measurement for the K1 tailstock When START is pressed the cutter trims a portion of material totalling 25 100 mm drawing 3 ATTENTION if the max thickness value of the cutter to be selected is less than that forseen on the machine the key cannot be cut see ERROR 12 Press STOP ERROR 12 Select the cutter with max thickness 1 01 mm ENTER drawing 2 Press ENTER and select a cutter with a thickness the same as or less than that indicated change the cutter Press STOP to quit cutter selection and START to begin cutting ATTENTION if the max thickness value of the cutter to be selected is less than th
56. PMENT Do not use compressed air for cleaning Laser warning labels Fig 15 14 Copyright Silca 2004 Operating Manual English IDEA Fig 16 SET UP AND USE OF THE MACHINE KEYBOARD AND FUNCTIONS The machine s keyboard has 19 alphanumeric and 6 function keys The alphanumeric keys are used for entering the data card number and the cutting data numbers and or letters according to the code on the card in use Each of the 19 alphanumeric keys contains two characters the main character white which is directly active and an alternate character red which can be activated by simultaneously pressing the SHIFT key E g pressed directly produces 1 Pressed simultaneously produce H EE 00000 o BF 9 9 Cw Ex Cy C2 function keys alphanumeric keys FUNCTION KEYS Stop button particularly when the machine is in motion Stops the function in progress at any time in the operation Starts the machines operations only with the shield in its closed position Activation of various functions in the menu CLEAR deletes numerical characters Copy from original function from any menu in the Idea internal program Combination of SHIFT amp CLEAR COPY enables you to automatically switch to the 0 Pressed in combination with all the keys of the same colour to enter the number or letter available e e 6 REGULATING THE DISPLAY It
57. START ATTENTION check that both the 213 and 212 templates make perfect contact If this does not occur the display will show an error message 4 Calibrations 5 Maintenance 6 Options 1 Test 2 Machine 0 point 1 Cutting unit 2 Reading unit Install 212 amp 213 templates See operating manual ENTER Move axis up until contact is made See operating manual START ERROR 10 No contact made See operating manual Copyright Silca 2004 89 IDEA Fig 117 Operating Manual English the machine will take the X and Y axes to a predefined position the operator must manually rotate the X and Y photocell disks up until the cut in the disks face the photocells card Y axis photocell manually turn the Y axis disk fig 118 up until the display s description changes from OFF to ON use the provided allen key to tighten the G3 grub screw fig 118 X axis photocell manually turn the X axis disk fig 115 page 88 up until the display s description changes from OFF to ON use the provided allen key to tighten the G1 grub screw fig 115 lower the protective shield press START the machine goes on to a new position and is ready for regulating the sensors C Pos Photocell TZX OFF TZY OFF See operating manual START Pos Photocell TZX OFF TZY ON See operating manual START Pos Phot
58. See operating manual The tailstock is not in the machine archive ERROR 2 Tailstock not defined See operating manual The type of key associated to the cutting card has not been defined ERROR 2 Type of key not defined See operating manual When gauging the Machine Zeros lack of contact is detected between the two templates used ch 6 1 1 page ERROR 10 88 Template no contact made See operating manual The message signals a reader malfunction or an obstacle before starting the reading cycle ERROR 11 Possible causes Optical reader the reader is not working proceed with the Reader Test is off in the Maintenance menu gt Test See operating manual Check that there is no material on the laser slide located on the bottom of the reader bracket the key used is too big or exceeds the dimensions allowed for the type of key an accessory or adapter has been fitted not required by the selected operation The message indicates that the chosen cutter is not suitable for cutting or copying the key as its thickness is ERRORE 12 greater than the minimum width of the teeth to be cut Select the cutter As current cutter select a cutter from those available in the with max thickness x xx mm cutter archive with a thickness less than or the same as ENTER that given in the message with an overall tolerance of 25 hundredths Indicates that the reading of an ORIGINAL key has
59. TER You can now press ENTER in order to make further copies of the previously read original key 5 6 Copy FROM ORIGINAL FoR CENTRE STOP Original on right Clamp S100 A B Stop 0 START Clamp 5100 indicates the clamp S100 into which the key must be fitted and which jaws to use Stop 0 reference or point for positioning the key in the reading clamp 5 6 1 Reading keys with centre stop English type E Fig 32 1 Open the fixed clamp A and the mobile clamp B by pressing on the grip lever 2 Fitthe key into the special groove axis X1 taking the bit up against the fixed clamp A ATTENTION position the key so that the highest tooth is facing left ensuring contact with the stop 0 on the vertical side of the tooth 3 Release the grip lever 4 Place the mobile clamp B in position on the key stem at a minimum distance of 3 mm from the end of the collar 5 When the reading process is started the carriage takes the key into contact with the laser beam along the path and in the direction indicated by the broken line 6 Atthe end of the cycle see the message on the display in order to continue see ch 5 6 2 28 Copyright Silca 2004 Operating Manual English IDEA 5 6 2 Reading in progress Data processing in progress Please wait Press START to proceed with cutting the key see ch 5 6 2 Cutting keys with centre stop English type
60. adjustment has been made to X on the circuit board by means of the SILCA KEY PROGRAMS program N 15 The SKP program version transmitting the data to the ALARM 15 machine is incompatible with the SW version of the Incopatible data machine program format Solution See operating manual update the SKP program with a compatible version N 16 The cutter is working under pressure and the motor ALARM 16 cannot guarantee the minimum number of revs The Strain on cutter machine has made unsuccessful attempts to reduce too high cutting speed during cutting Possible causes the key material has not been selected properly this parameter is important for setting the correct cutting speed the cutter is worn the bit is too thick the key material is very resistant N 17 The message indicates that the procedure for detecting ALARM 17 the beginning of the bit for a FEMALE FRONT STOP key Key origin has been unsuccessful Not found Possible causes See operating manual the key is not properly positioned The E2 adapter centring device for female keys is not fitted properly electrical contact by the cutter is not working the tailstock is not the one expected N 18 The message indicates that the height of the key bit ALARM 18 exceeds the maximum dimension allowed Bit too high See this manual at page 1 GUIDE TO CONSULTATION See instructions for the maximum key dimensions allowed for all types of manual keys 112 Co
61. adjustments No STOP Yes ENTER Stop to quit Enter to continue confirmation Copyright Silca 2004 65 IDEA 5 16 Operating Manual English DECODE AND COPY Make a search for the SSN by entering the number corresponding to the system and confirm with ENTER SSN 9 Decode MFG gt CISA 5 5 55 Decode CISA gt CISA 04 List ENTER press the key Right hand arrow to place the pointer next to the Make field It is enough to enter the first letters of the name the name of the MAKE closest in alphabetical order appears automatically the arrows can be used to scroll the sequence of previous and successive MAKES in alphabetical order use the key CLEAR to delete the text entered the last line of the window indicates the result of the search 04 List ENTER 4 SSN have been found press ENTER to see the list CISA 04 1 5CS6P 5CS8P 2 CS CSC 3 CSL CSLC 5CS1 5CS2 gt gt the symbol gt gt indicates that there are other systems locks press arrow Down to scroll the list and highlight the one required view further information relating to the SSN listed hold down the key Right hand arrow After selecting the SSN you will see DECODE SSN 9 Original on right Clamp S100 A B Stop 0 START Clamp 5100 indicates the clamp 8100 into which the key must be fitted and which jaws
62. ainst the face of the self centring jaw and use the T wrench T4 to slightly close the jaws on the rotating clamp 5 Move the rotating clamp S1 so that the adapter E1 enters the tailstock K1 6 Tighten the knob T1 Use the T wrench T4 to tighten the screw V1 first then the screw V2 Replace the wrench 4 into its seat lower the mobile safety shield and begin the process with START To remove the key after cutting carry out the same operations in reverse order Copyright Silca 2004 29 IDEA Operating Manual English Cutting in progress Copy 1 of 1 1 of 1 finished More copies No STOP Yes ENTER You can now press ENTER in order to make further copies of the key 5 7 FAS 309 PLASTIC STEM ONLY DECODE AND COPY Reading decoding Cutting p Fig 34 OPTIONAL OPTIONAL OPTIONAL L D727713ZB D711802ZB D727058ZB Adapter D Spacer Adapter 1 Fig 35 30 Copyright Silca 2004 Operating Manual English IDEA 5 8 ADAPTER FOR CUTTING CHUBB KEYS WITH SQUARE SECTION STEMS The Chubb adapter set is required for the code cutting of Chubb keys CHUBB RKS with square section stems fig 36 It comprises 2 identical adapters A for the optic reader clamp and the swivel clamp 1 Fit adapter A1 into the groove on the optic reader clamp take it up against the stop X1 2 Place the key to be decoded in its place on the adapter which must but
63. alue within 300 hundredths of a mm or hundredths of a degree axis B 20 cent mm X Y1 Y2 SHIFT arrow down decreases the value within 300 hundredths of a mm or hundredths of a degree axis B 20 cent mm X Y1 Y2 CLEAR to zero the value Copyright Silca 2004 101 IDEA Operating Manual English Example Adapter E7 Side Reading Adjustments B 000 X 10 Y1 10 Y2 00 ENTER in the last field to quit the window so that the query Save appears for the edited data START press START to begin the automatic gauging procedure or the CLAMP TAILSTOCK unit Digit the corrections required for axis X and axis Y Press ENTER Save adjustment No STOP Yes ENTER ATTENTION if STOP is pressed the new measurements are not saved the previous gauging values therefore remain valid Press ENTER to confirm the data 102 Copyright Silca 2004 Operating Manual English DIMENSIONAL CHECK CUTTING TEST FoR REAR STOP To check the machine s precision proceed as follows 0 Copy from Original 1 Decode and Copy 2 Insert cuts 3 Queue from PC gt gt Choose 2 Insert cuts from the main menu and press ENTER Marca FICHET Sans Soucis P P SSN 110 Cut Choose SSN 110 and press ENTER Bit 1 Simm F R Possible depths 0123456789 Enter the depth for bit 1 as in the example Press ENTER Fit the key blank into the S1
64. apter Centring device E16 ID code used for reading install on the S100 A clamp When the machine requires indicates on display adapter E15 or E16 proceed as follows max 31 mm Itis very important to distinguish the type of key to be copied Choose option 10 Special Bit Female Choose option 1 Reading Copying max 7 mm a PES max 15 mm SELECT TYPE OF KEY 0 Bit stop male 1 Bit stop female 2 Shoulder stop 3 Pump 4 Square square tip 5 Square round tip 6 Square stepped tip 7 Rear stop 8 Rear stop french 9 Small bit 10 Special bit female 1 Reading Copying 2 Cutting only 3 Reading only 4 Post Reading adj KEY READING Original on right Clamp S100 Stop 0 Adapt E16 START Is adaptor E16 installed No STOP Yes START IDEA Copyright Silca 2004 57 IDEA Reading Operating Manual English KEY READING Original on right Clamp 5100 A B Stop 0 Adapt E16 START Is adaptor E16 i max 7 mm installed No STOP 5 max 31 mm max 15 mm Note Maximum dimensions of keys for Reading from the original Max stem thickness 7 mm Max bit length 31 mm Max bit height 15 mm If these conditions are not observed the machine will produce the error Key cannot be decoded Press on the grip lever of the
65. asurements read X 4444 Y 3333 Save data No STOP Yes ENTER Fig 152 Copyright Silca 2004 131 IDEA 7 12 Fig 153 7 13 Operating Manual English BRUSH REPLACEMENT open the rear compartment ch 7 8 unscrew the two brush caps M4 fig 153 remove and fit two new brushes replace the two caps M4 close the rear compartment carry out TEST 13 to check proper operation Sr N 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 For further details on installation and use of the program follow the instructions given on the instruction sheet provided with the disks or CD ROM Replacement of the electronic board 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 and enter on the machine 4 gauge the machine according to the in
66. at forseen on the machine the key cannot be cut Press STOP drawing 3 Copyright Silca 2004 109 IDEA 6 2 10 6 2 10 1 Machine Messages ALARM MESSAGES N 1 This message indicates that during advancement the cutter or tracer point has encountered an unexpected obstacle For example a foreign body has been left on the clamp the key has not been positioned properly vertical instead of horizontal or does not correspond to the one required by the selected SSN clamp has been installed different from the one required for the job decoding in progress the wrong adapter has been fitted or is not required for the job decoding in progress 2 The message indicates that the clamp required by the program flow for cutting or decoding has not been gauged Carry out the CLAMP GAUGING instructions given N 3 The permitted temperature has been exceeded on the electronic control board Check the cooling fan see ch 7 1 Trouble shooting 4 Signals that the fuse has cut out due to a short circuit in one of the inputs or outputs see ch 7 1 Trouble shooting N 5 Signals a short circuit on port P IN OUT see ch 7 1 Trouble shooting N 6 Signals that fuse F1 has probably cut out see ch 7 1 Trouble shooting N 7 Signals a fault on the electronic circuit board Operating Manual English ALARM 1 Faulty contact made Press START to move a
67. be carried out only when the S1 clamp is installed on the machine Copyright Silca 2004 85 IDEA Operating Manual English Test 5 CUTTER MOTOR Carefully follow the instructions on the display and check that the cutter motor works test is if speed is approximately 2880 If the cutter is turning and the display shows a speed of 0 the motor photocell is faulty and must be replaced NOTE if the cutter motor does not start contact Silca s Technical Assistance Dept Test 6 X AXIS SENSOR the machine s display should show ON when the carriage is drawn away from the machine towards the operator the machine s display should show OFF when the carriage is pushed all the way in towards the machine NOTE if the OFF ON transition is not made contact Silca s Technical Assistance Dept Test 7 Y AXIS SENSOR the machine s display should show OFF when the carriage is moved all the way to the right the machine s display should show ON when the carriage is moved all the way to the left NOTE if the OFF ON transition is not made contact Silca s Technical Assistance Dept Test 8 B AXIS SENSOR rotating with rotation in the standard position the display shows OFF using a screwdriver to turn screw M7 fig 145 page 127 clockwise the display goes to ON Test 9 X AXIS PHOTOCELL Slowly push the X axis carriage manually towards the machine s chassis checking that
68. cal and horizontal faces of the teeth are regulated over the size of the tooth at its base on the stem 6 Steps with a thickness of less than 0 75 mm are regulated over the prevailing measurement of the adjacent tooth Copyright Silca 2004 61 IDEA Operating Manual English 5 15 1 Front rear bit conversion The FRONT REAR BIT CONVERSION function makes it possible to make a supplementary correction to the data read from a key which has symmetrical cuts on the bit The operator may activate this function when part of the bit is more worn than its corresponding part e g wear on the side of the key which operates only on the outside of the lock or a tooth is missing or broken which was identical to the one symmetrically placed on the opposite side of the bit fig 88 Fig 88 Applicate Front Rear bit conversion No STOP Yes ENTER The software program which converts the bit divides it symmetrically into two parts front and rear attributing each tooth with the deepest cut of the two teeth symmetrically opposed Stop to quit Enter to continue confirmation 5 15 2 X Specular bit conversion The X SPECULAR BIT CONVERSION function makes it possible to make a supplementary correction to the data read from a key which has diagonally symmetrical cuts on the bit The operator may activate this function when part of the bit is more worn than its corresponding part e g wear on the side of
69. ce or point for positioning the key on the cutting clamp Cutter 1 25 thickness of the currently selected cutter press SHIFT ENTER to change thickness Brass Steel material of the key press SHIFT to change material Adapier E15 adapter centring device to position the tip of the key female properly Fit into the K1 tailstock ATTENTION always check that the wording corresponds to the material of the key The key blank to be cut must be positioned according to the parameters given on the display after selecting the program involved the type of key with front stop requires the use of the rotating clamp S1 the K1 tailstock the E15 adapter and the key reference on Stop 0 Please follow the instructions below carefully and observe the order of operations 1 Loosen the knob T1 by turning it anticlockwise until the rotating clamp S1 can be moved to a convenient distance for fitting the key 2 Fit the adapter E15 into the tailstock K1 up against the mechanical stop fig 85 3 Use the T wrench T4 to tighten the screw V2 on the tailstock and secure the E15 adapter Attention the adapter E15 must be properly fitted into its seat and pressed up against the stop point Fig 84 4 Take the T wrench T4 from its seat and open the rotating clamp jaws by turning the sunk hex screw V1 at the end of the operation leave the T wrench in the screw V1 5 Fit the key blank into the front sid
70. construction of the key read ERROR 23 Possible causes Key cannot be cut of the teeth on the key are extremely deformed due to reading error or badly broken there is dirt on the key that deforms the image of the reconstructed bit grease swarf threads of cloth Solution clean the key carefully with a metal brush and repeat the reading operation NOTE If the error is repeated consult ch 7 14 DIAGNOSTIC FUNCTION errors in Copy from Original on IDEA page 133 and or contact Silca After Sales Service A POST READING adjustment has been incorrectly made to a key read from an original The error code ERROR 24 distinguishes the following situations Error in 1 An X conversion has been applied to a single bit key post reading adj reading An X conversion can be applied only to double Code bit keys 2 A FRONT BACK adjustment has been applied but the reading algorithm is unable to identify the number of teeth 116 Copyright Silca 2004 Operating Manual English 6 2 10 3 SIGNAL MESSAGES This message is an example and refers to the use of the Standard cutter PL 1 25 The message indicates that the key to be cut has a tooth with a minimum width of 1 00 mm and the Standard cutter is installed In this case the difference between the width of the cutter and the tooth is within the maximum tolerance of 0 25 mm The machine allows the operator to proceed and when START is pressed t
71. d to a convenient distance for fitting the key 2 Take the wrench T4 from its seat and fit into the screw V1 then loosen until the jaws are fully open At the end of the operation do not remove the T wrench from the screw fig 47 Fig 46 3 Fit the key blank into the adapter E4 so that the bit stops butt against the E4 adapter stops P7 fig 46 tighten the screw 4 Fit the E4 adapter with the key blank in the rotating clamp S1 from the inside take the adapter up to the side of the self centring jaws and slightly close the grips on the rotating clamp with the T wrench T4 5 Move the rotating clamp S1 so that the adapter E4 enters the tailstock K1 6 Tighten the knob T1 Use the T wrench T4 to tighten the screw V1 first then the screw V2 fig 46 Replace the T wrench T4 into its seat lower the mobile safety shield and begin the process with START To remove the key at the end of the cutting operation loosen the grub screw P and remove the key or carry out the operations described above in reverse order Fig 47 Cutting in progress Copy 1 of 1 Bit 1 Copy 1 of 1 finished More copies NO Stop YES Enter You can now press ENTER in order to make further copies of the key Select STOP to quit Fig 48 Copyright Silca 2004 37 IDEA Operating Manual English 5 11 FIAM KEYS OPTIONAL D726462ZB Adapters LE LEED
72. dredths of a degree axis B 20 cent mm X Y1 Y2 CLEAR to zero the value Esempio Adapter E3 Side Cutting Adjustments B 000 X 10 Y1 10 Y2 00 ENTER in the last field to quit the window so that the query Save appears for the edited data START press START to begin the automatic gauging procedure Press ENTER Digit the corrections required for axis X and axis Y Press ENTER Save adjustment No STOP Yes ENTER ATTENTION if STOP is pressed the new measurements are not saved the previous gauging values therefore remain valid Press ENTER to confirm the data Copyright Silca 2004 99 IDEA DIMENSION CHECK WITH COPY FROM ORIGINAL after making the Cutting Test After carrying out the Cutting Test proceed as follows Choose 0 Copy from Original from the main menu and press ENTER Operating Manual English 0 Copy from Original 1 Decode and Copy 2 Insert cuts 3 Queue from PC SELECT TYPE OF KEY 0 Bit stop male 1 Bit stop female 2 Shoulder stop 3 Pump 4 Square square tip 5 Square round tip 6 Square stepped tip Choose 3 Pompa and press ENTER 1 Reading Cutting 2 Cutting only 3 Reading only 4 Post Reading Choose 1 Reading Cutting and press ENTER Follow the instructions on the display Press START KEY READING Original on right Clamp S100 Stop 3
73. duce the backwards and forwards movement of the cutting tool limiting its excursion to within a new safety measurement of 2 mm beyond the edge of the bit thereby accelerating the cutting process Fig 22 CUTTING On taking the key up to the cutting tool the rotating clamp imposes an anticlockwise angle of 30 to the transversal axis of the bit thus facilitating cutting by providing a single direction 60 clockwise for the cutting radius after the depth for the tooth being cut has been reached Fig 23 Atthe end of the cutting operation on the left hand bit the cutting tool trims the bit up to the stem diameter read from the original key thereby rectifying the diameter of the stem as the key turns simultaneously together with the removal of any portion of bit which exceeds the length of the original Fig 24 Copyright Silca 2004 21 IDEA Operating Manual English With square stemmed keys the program applies a special bit trimming process which does not remove the edges of the stem The key is positioned on the horizontal axis at a distance of 2 mm from the end of the stem the cutting tool then enters tangentially on the vertical side of the stem so that any portion of the bit which exceeds the original measurement can be removed Fig 25 The speed ratio is selected from a scale of diameters sub div
74. e is designed for cutting keys with the minimum maximum dimensions described on page 2 page 3 and page 4 Dimensions width 500 mm depth 500 mm height 420 mm with raised shield 650 mm Mass 45 kg Noise level sound pressure Lp A 81 5 dB A steel keys 75 5 dB A brass keys Copyright Silca 2004 9 IDEA 1 5 ACCESSORIES PROVIDED Operating Manual English IDEA comes with a set of accessories for its operation and maintenance tools hex wrenches fuses supplied in a special tool kit comprising tool kit 1 5 mm allen key 030243427 Cutter release 2 mm allen key D400754BA P d 030022177 2 Amp fuse delayed 2 5 mm allen key 031242372 030022227 4 Amp fuse delayed 3 mm allen key 030872677 030022377 213 template regulating disk D416657BA Laser reading template caliper 214 212 template regulating block D426037BA Z4 serial test connector D416661ZZ O Slanted brush D306935ZZ Belt tension plate D416552BA lt S 020244377 laser warning APPARECCHIO LASER labels D416816XA ee D41 681 APERTURA LASER 6 3 Amp fuse delayed 4 mm allen key D310652ZZ 030022427 10 Amp fuse delayed 5 mm allen key 031656822 030022577 4 Amp fuse rapid 6 mm allen key 030118572 030022677 A 10 mm spanner 13 mm spanner 030030877 3 030278877 x centering pin 045mm 05 5 for female keys for key stem for key st
75. e key head with the left hand and push towards the tailstock making sure that the bits butt up against the grips on the tailstock K1 simultaneously transfer the T wrench T4 onto the tailstock screw V2 and secure the key tip fig 56 Transfer the wrench T4 onto the screw V1 and tighten the grips on the key stem Replace the T wrench in its seat lower the mobile safety shield and begin the process with START To remove the key after cutting carry out the operations described in reverse order IDEA Fig 54 Fig 55 Fig 56 Copyright Silca 2004 41 IDEA Operating Manual English CUTTING SPECIAL SQUARE STEMMED FIAM KEY WITH STEP Left blank Brass Clamp S1 K1 Stop 3 Cutter 1 25 Adap E5 Pes 1 1 START Clamp 51 K1 indicates which clamp S1 and tailstock K1 to use for gripping the key Stop 0 reference or positioning point on the key cutting clamp Cutter 1 25 thickness of the cutter currently selected press SHIFT ENTER to change thickness Brass Steel material of the key press SHIFT to change material E5 Adapter indicates the adapter to fit into the K1 tailstock in order to position the key properly ATTENTION always check that the wording corresponds to the material of the key The key blank to be cut must be positioned according to the parameters given on the display after selecting the program involved the type of key with f
76. e of the rotating clamp S1 and position it on the groove in the jaws then take the key forward until the adapter E15 goes into the hole in the stem fig 86 Fig 85 Copyright Silca 2004 59 IDEA Operating Manual English Close the mobile clamp jaws slightly using the T wrench T4 already in the screw V1 without gripping the key stem move the rotating clamp S1 towards the tailstock until the adapter E15 goes into the hole in the stem keeping a minimum safety distance of 10 mm between the rotating clamp jaws and the rear limit of the bit Secure the rotating clamp in position by means of knob T1 Hold the key head in the left hand and align crosswise making sure that the bit is all the way up against the adapter E15 on the tailstock K1 then close the grips round the key stem using the T wrench T4 already in place on the screw V1 Replace the T wrench T4 in its seat lower the mobile safety shield and begin the process with START To remove the key after cutting carry out the operations described in reverse order Fig 86 Pressing Start shows Reading in progress When the reading process starts the carriage will take the key into contact with the laser beam along the path dictated by the Software at the end of the cycle To make further copies of the key you can see the message on the display Data processing in progress Please wait C
77. e screw G 1 on the S100 clamp 2 Pull out the mobile clamp unit B 3 Fit the E7 adapter into the S100 clamp then tighten the screw 4 Fit the original key into the E7 adapter so that the key stem rectangular or round fits perfectly into its seat The key head will protrude from the side marked E7 whereas the bit will fit inside the adapter not in contact with the stop but at approx 2 3 mm fig 39 When this condition is reached tighten the grub screw C to secure the key 5 Push the E7 adapter until the side Y is butting against the fixed part of the S100 Aclamp 6 Press the START key to continue 7 When the reading process starts the carriage will take the key into contact with the laser beam along an ideal path Fig 38 i mm Adapter E7 Fig 39 Atthe end of the cycle see the message on the display in order to continue Reading in progress Data processing in progress Please wait Copyright Silca 2004 33 IDEA CUTTING PUMP KEYS Left blank Brass Clamp S1 K1 Stop 3 Cutt 1 25 Adapt E3 Pes 1 1 START Operate as follows Clamp S1 K1 indicates which clamp S1 and tailstock K1 to use for gripping the key Stop 0 reference or positioning point on the key cutting clamp Cutter 1 25 thickness of the cutter currently selected press SHIFT ENTER to change thickness Adatt E3 special ada
78. eave the T wrench in the screw V1 Fit the key blank into the rotating clamp S1 from the front placing the stem in position on the jaw groove then place the key tip into the tailstock K1 Close the mobile clamp jaws slightly using the T wrench already in the screw V1 without gripping the key stem move the rotating clamp G towards the tailstock keeping a minimum safety distance of 10 mm between the rotating clamp jaws and the rear limit of the bit Secure the rotating clamp in position by means of knob T1 Hold the key head in the left hand and align crosswise making sure that the bits are all the way up against the grips on the tailstock K1 at the same time close the grips round the key stem using the T wrench T4 already in place on the screw V1 Transfer the T wrench T4 onto the screw V2 of the tailstock and secure the tip of the key Replace the T wrench in its seat lower the mobile safety shield and begin the process with START To remove the key after cutting carry out the operations described in reverse order Cutting in progress Copy 1 of 1 Copy 1 of 1 finished More copies No STOP Yes You can now press ENTER in order to make further copies of the previously read original key Copyright Silca 2004 25 IDEA Operating Manual English 5 5 Copy FROM ORIGINAL FRONT STOP FEMALE KEY READING Original on right Clamp S100 A B Stop 0 START
79. em 4mm 5mm 5mm 6mm adapter E2 centering for AM female keys 7 oy 6 5 mm for key stem 6mm 7mm 10 Copyright Silca 2004 Operating Manual English IDEA 2 TRANSPORT ATTENTION the key cutting machine is easily transported and is not dangerous to handle The packed 2 1 Fig 12 2 2 machine should be carried by at least two people PACKING The packing for IDEA 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 Symbols are printed on the outside of the cardboard box to give instructions and warnings for transportation Keep dry Handle with care 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 UNPACKING To remove the machine from the packing box 1 cut the straps with scissors and remove raise the top part of the cardboard box loosen the screws both on the front and back brackets that hold the machine to the pallet gt use the special span
80. er the depth for bit 2 the same as bit 1 as in the example Press ENTER 123456 8 Bit 2 2 Symm F R Possible depths 123456 1 Bit 2 2 Symm F R 111 66666 111 Possible depths 123456 8 SSN 10 M1 Brass Clamp S1 K1 Stop 0 Cutter 1 25 2 1 1 START Fit the key blank into the clamp S1 then press START Cutting in progress Copy 1 of 1 Bit 1 Cutting in progress Copy 1 of 1 Bit 2 Copy 1 of 1 finished More copies No STOP Yes ENTER Operating Manual English 94 Copyright Silca 2004 Operating Manual English IDEA Press STOP remove the key and use a centesimal gauge to measure it e SE amp 7 60 gt Fig 123 Measurement X should be 7 60 mm inch 0 03 mm Measurement Y Y1 Y2 should be 20 40 mm inch 0 03 mm If this is not the case e g X 7 70 and Y 20 30 proceed as follows 4 Calibrations 5 Maintenance 6 Options Choose 4 Calibrations from the main menu and press ENTER 1 Clamps 2 Cutters 3 Adapters Choose 1 Clamps and press ENTER Clamps 1 S1 Rotating Jaw 2 S100 Reader Jaw Choose 1 51 Rotating and press ENTER Clamp S1 K1 Adjustments B 00 10 Y1 0 5 2 0 5 To calibrate START Digit the corrections required for axis X and axis Y bit 1 Y1 b
81. essing in progress Please wait Fig 28 5 4 2 Cutting keys with front stop double bit single bit male Left blank Brass Clamp S1 K1 Stop 0 Cutt 1 25 Pes 1 1 START Clamp 51 K1 indicates which clamp S1 and tailstock K1 to use for gripping the key Stop 0 reference or positioning point on the key cutting clamp Cutter 1 25 thickness of the cutter currently selected press SHIFT ENTER to change thickness Brass Steel material of the key press SHIFT to change material 24 Copyright Silca 2004 Operating Manual English IDEA ATTENTION always check that the wording corresponds to the material of the key The key blank to be cut must be positioned according to the parameters given on the display after selecting the program involved the type of key with front stop requires the use of the rotating clamp S1 the K1 tailstock support and the key reference on Stop 0 Please follow the instructions below carefully and observe the order of operations Fig 29 1 Loosen the knob T1 by turning it anticlockwise until the rotating clamp S1 can be moved to a convenient distance for fitting the key Orient the standard tailstock K1 for male keys in the special seat on the support using the screw V2 to direct it upwards fig 29 Take the T wrench T4 from its seat and open the rotating clamp jaws by turning the sunk hex screw V1 at the end of the operation l
82. fixed clamp A and fit the centring device E16 so that it protrudes towards the mobile clamp B fig 82 Release the grip lever Press on the grip lever on the mobile clamp B and fit the key so that the hole in the stem is up against the centring device E16 fig 83 Release the grip lever Hold the key head with one hand and the end of the centring device with the other and push the key up against the stop 0 A The ideal position for the mobile clamp B is when there is a distance of 3 mm min and 15 mm max between the bit and inner side of the mobile clamp B Clamp 100 A B indicates the clamp S100 into which the key must be fitted and which jaw to use Stop 0 reference or point for positioning the key on the reading clamp Adapt E16 adapter for positioning the key female from the tip only for reading ATTENTION make sure that the bit is up against the Stop 0 A Fig 82 Pressing Start shows Left blank Brass Clamp S1 K1 Stop 0 Cutt 1 25 Adptt E15 pcs 1 1 START Is adaptor E15 installed No STOP Yes START Fig 83 58 Copyright Silca 2004 Operating Manual English IDEA Cutting Left blank Brass Clamp S1 K1 Stop 0 Cutt 1 25 Adapt E16 1 1 START Is adaptor E15 installed No STOP Yes START Clamp S1 K1 indicates which clamp S1 and tailstock K1 to use for gripping the key Stop 0 referen
83. 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 clockwise 122 Copyright Silca 2004 Operating Manual English 7 6 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 9 3 disconnect all cable connectors from the electronic circuit board Fig 135 4 take the electronic circuit board off by unscrewing the Y1 nuts off fig 136 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 turn the machine on and launch the WIN TRANSFER program Fig 136 IDEA g uu electronic circuit board Copyright Silca 2004 123 IDEA Operating Manual English 7 7 KEYBOARD DISPLAY REPLACEMENT 1 turn the machine off and unplug it from its power supply cable 2 remove the display s support by unscrewing the 2 B1 fixing screws fig 137 3 detach the flat cable and ground wire from the keyboard fig 138 4
84. g the following information Key cutting machine serial No 1170145634567 Read the serial number on the ID plate fixed to the back of the machine Machine ID 12345 Visible in the password application box or by selecting menus 6 7 1 on the machine ACTIVATION Code SPWSC00011 Shown ONLY when access to protected data is attempted Once obtained enter the password on the Password line as shown in the example given above CORRECT PASSWORD If the correct password has been entered the screen Save shows Password No STOP Yes ENTER The password can be saved so that it need not be entered whenever the protected data card is used or not saved so that access is limited only to the person in possession of the password LIST OF ENABLED SYSTEMS ACTIVATED AND REMOVAL OF AN ACTIVATION To consult the list of enabled DATA data card series or table select menus 6 7 Select the item in menu 1 to see the Machine Identification Number PROTECTED SYSTEMS Select the item in menu 2 to see the list of Enabled 1 Machine ID Systems 2 Enabled Systems Enabled Systems 1 SSN121 SC 2 SSN234 SC Use the Right hand arrow key to view the description associated to the lock system To delete an enabled system place the cursor on the line to be eliminated and press the CLEAR key Copyright Silca 2004 107 IDEA 6 2 8 Operating Manual English Bit height ATTENTION Only if the material setting is STEEL
85. he 1 00 mm tooth will be cut with the PL 1 25 cutter and therefore widened equally on the left and right as per drawing 1 on page 109 The message indicates that the combination relating to the cutting operation must be completed no cuts can be skipped The lock system number entered is not in the archive Indicates a machine function not yet available Indicates that the machine should ALWAYS be turned off in order to remove or fit the ROTATING clamp otherwise the electronic circuit board could be damaged The message requires the T wrench to be inserted into its housing or pocket to avoid damaging the machine or cutting process if it is out of place The message indicates that a type of key is being reproduced without first having read the original Note the machine is able to hold only the last key read in its memory The message indicates that the characteristics of the key will not allow decoding by card The message indicates that with S1 K1 manual adjustments if a value of X is set the K1 tailstock could be damaged first tooth in proximity of the tailstock has a height value of less than 4 5 mm IDEA Current cutter 1 25 Max trimming 1 00 Continue No STOP Yes START ATTENTION Incomplete cutting data Code not found ATTENTION No feasible function ATTENTION Turn off machine And fit clamp Place The T wrench Into holder ATTENTION
86. he S1 clamp if applicable Clamp 51 K2 unit comprising the 51 clamp and K2 interchangeable tailstock Copyright Silca 2004 73 IDEA Operating Manual English Clamps S1 K2 Adjustments B 000 00 Y1 00 Y2 00 To calibrate START START press START to begin the automatic gauging procedure for the CLAMP TAILSTOCK unit Clamps S1 K2 Install 215 and 713 See operating manual START Template 213 fit in place of the cutter fig 100 Template 715 fit on the S1 K2 clamp as if it were a key fig 100 Use the plate P as a point of reference in position 2 with the second pin on the template up against it Tighten the screw W2 with the T4 wrench Replace the T4 wrench in its seat Fig 100 Press START Clamps S1 K2 Detection In progress Clamps S1 K2 Adjustments B 000 X 02 Y1 02 Y2 04 To calibrate START Position the pointer at the side of the parameter to be edited with the arrow keys or ENTER and use the following keys to edit the parameters SHIFT arrow up increases the value within 300 hundredths of a mm or hundredths of a degree axis B 20 cent mm X Y1 Y2 SHIFT arrow down decreases the value within 300 hundredths of a mm or hundredths of a degree axis B 20 cent mm X Y1 Y2 CLEAR to zero the value ENTER in the last field to quit the window so that the query Save appears for the edited data Save ad
87. ided proportionally between a minimum diameter of 3 6 mm and a maximum diameter of 7 mm in effect the thicker the key the slower the advancing speed of the cutting tool advancing speed of the tool over the bit not to be confused with the speed of cutting or tool operation which depends on whether the material is brass or steel is automatically adopted by the program according to the diameter of the stem read from the original key Fig 26 It is now very important to distinguish the type of key to be copied 22 Copyright Silca 2004 Operating Manual English IDEA SELECT TYPE OF KEY 0 Bit stop male 1 Bit stop female 2 Shoulder stop 3 Pump 4 Square square tip 5 Square round tip 6 Square stepped tip 7 Rear stop 8 Rear stop french 9 Small bit 10 Special bit female Bit stop Bit stop SHOULDER PUMP MUEL PUMP SQUARE MALE FEMALE stop keys keys tip SQUARE ROUND SQUARE tip STEPPED tip Special Small BIT FEMALE BIT REAR STOP Fig 27 Select the operation to be carried out on the selected key 1 Reading Copying 2 Cutting only 3 Reading only 4 Post Reading adj Reading Cutting the key and cutting data are read without interruption Cutting only the previously read key is cut 3 Reading only the key is read in this way the cuts read can be edited before cutting the
88. ight cutting speed the cutter is worn the bit is too thick the key material is too resistant the cutter motor rev control device may be faulty N 13 The message indicates that the axis indicated X Y or B is not working properly due to an obstacle preventing the axis from moving freely and complete its run the limit switch sensor is not working carry out the sensor TEST the photocell if applicable is not working carry out the photocell TEST the motor that moves the axis is faulty carry out the motor TEST the motor control on the electronic circuit board is faulty carry out the motor TEST ALARM 8 The bit to be cut is too high See operating manual ALARM 9 Depth limit overrun See operating manual ALARM 11 An X movement exceeds safety limit ALARM 12 CUTTER MOTOR Minimum speed is Not ottained ALARM 13 X Y B axis movement not completely zeroed IDEA Copyright Silca 2004 111 IDEA Operating Manual English N 14 The message indicates that the key cutting machine is ALARM 14 unable to complete an X movement because it goes The bit to be cut is beyond the limits set for the X axis too long Possible causes See operating manual a key with too long a bit has been used anegative MANUAL adjustment has been made to X on the clamp or adapter used to grip the key anegative MANUAL
89. ist ENTER 4 SSN have been found press ENTER to see the list CISA 04 2 5CS6P 5CS8P 3 CS CSC 4 CSL CSLC 5CS1 5CS2 the symbol gt gt indicates that there are other systems locks press Down arrow to scroll the list and highlight the item required e to view further information relating to the SSN listed hold down the key Right hand arrow After selecting the SSN you will see Bit 1 1 dai Possible depths 12345 7 or in the case of a double bit Bit 1 2 Possible depths 12345 7 indicates a fixed tooth and cannot be edited 123 the depth symbols admitted for the selected data card SHIFT produces the special character that indicates a depth the same as that of the STEM arrow Down goes from one bit to the other CLEAR deletes the symbols ONLY from the box relating to BIT 1 with SHIFT arrow Up to define one of the following characteristics of the key Copyright Silca 2004 67 IDEA Operating Manual English SYMMETRICAL Bits 1 and 2 are the same when the combination of bit 1 is entered that for BIT 2 is entered automatically missing tooth Fig 94 SPECULAR X Bits 1 and 2 are specular to X when the combination of bit 1 is entered that for BIT 2 is entered automatically missing tooth Fig
90. it 2 Y2 Press ENTER 1 E gt 4 y lt X M2 Fig 124 Save adjustment No STOP Yes Press ENTER to confirm the data Copyright Silca 2004 95 IDEA Operating Manual English DIMENSION CHECK WITH COPY FROM ORIGINAL after the Cutting Test After carrying out the Cutting Test proceed as follows Choose 0 Copy from Original from the main menu and press ENTER 0 Copy from Original 1 Decode and Copy 2 Insert cuts 3 Queue from PC gt gt Choose 0 Bit stop M and press ENTER SELECT TYPE OF KEY 0 Bit stop male 1 Bit stop female 2 Shoulder stop Choose 1 Reading Cutting and press ENTER 1 Reading Cutting 2 Cutting only 3 Reading only 4 Post Reading Follow the instructions on the display KEY READING Original on right Clamp S100 A B Stop 0 START Press START Reading in progress Date processing in progress Please wait Follow the instructions on the display Fit the key blank into the clamp S1 then press START Left blank Brass Clamp 51 1 Stop 0 Cutt 1 25 Pes 1 1 START Press ENTER Cutting in progress Copy 1 of 1 Copy 1 of 1 finished More copies No STOP Yes ENTER Press STOP remove the key and use a centesimal gauge to measure it 96 Copyright Silca 2004
91. ite 4 5 Changing tho CUtter e EE Le e mr e as SER S GUIDE nen iade EI 5 1 SymbokLand terminology 5 rerit ret b rst reet 5 2 Initial Operations x ete eise ne Saad 5 8 0 Copy from original 5 4 from ORIGINAL for FRONT STOP MALE 5 4 1 Reading keys with front stop double bit single bit male 5 4 2 Cutting keys with front stop double bit single bit male 5 5 Copy from ORIGINAL for FRONT STOP FEMALE 5 5 1 Reading keys with front stop double bit single bit female 26 5 5 2 Cutting front stop keys double bit single bit female 2 27 5 6 Copy from ORIGINAL for CENTRE STOP ui 5 6 1 Reading keys with centre stop English type 5 6 2 Cutting keys with centre stop English type 5 7 FAS 309 Plastic Stet eer oe ri Aiino 5 8 Adapter for cutting CHUBB keys with square section stems 31 5 9 PUMPR KEY Sinni ai re ehe re ter nia yb ou eere qu 5 10 MUEL PUMP KEYS bill FIAM KEYS I ELEM 5 12 KEYS WITH REAR STOP Male keys and Female keys 43 52 1 FRENCH HEAR STOP KEYS eeu a ete e d Re RE ere IR EM Eee eec 51 5 13 BIT DOUBLE BIT KEYS enr retener Re tn 53 5 14 SPECIAL BIT FEMALE KEYS reae eet tree ete tere
92. ith the following parameters can be cut on the IDEA fig 2 fig 3 fig 4 fig 5 fig 6 and fig 7 STEM LENGTH the machine is provided with a headstop and designed to take keys with lengths of up to 150 mm DIAMETER the self centering jaws on the rotating clamp will take stems with diameters from 0 3 6 7 mm HOLLOW STEMS female keys are gripped normally by the jaws and a special tailstock is provided for self centering grip on the hole at the tip with diameters from 22 5 mm by centring HEAD WIDTH the grip for the head of a bit or double bit key is the means for visual alignment of the key BIT THICKNESS maximum 7 mm for brass keys max 4 mm for steel keys MATERIAL IDEA is provided with a single phase motor and single cutter speed These are the characteristics and variables common to all types of keys It is now necessary to distinguish clearly between at least 3 families of keys which condition a series of functions on the machine such as a tools to use b necessary controls In the following pages the families of keys are illustrated so that the dimensions of any key to be cut can be compared and the reference elements found These elements are 1 BIT STOP keys mortice and bit double bit round or square stem mainly for Italian German Spanish markets 2 SHOULDER STOP keys with stop on rim close to the bit mainly for English and Swedish markets PUMP KEYS with round and flat stems SMALL B
93. justment No STOP Yes ENTER ATTENTION if STOP is pressed the new measurements are not saved the previous gauging values therefore remain valid 74 Copyright Silca 2004 Operating Manual English IDEA 5 20 CUTTERS Scroll with the arrows Cutter 0 492 0 393 0 590 PL 1 25 0 669 PL 1 00 PL 1 50 PL 1 70 PL 1 90 6 PL 2 00 ENTER to view the cutter parameters SHIFT ENTER to set the current cutter shows the cutter currently selected AJO N 0 748 0 787 ziale 01 PL 1 25 Thickness 125 Diameter 10000 Adjust Diam 00 SHIFT arrow Up increases the diameter within 20 hundredths of amm SHIFT arrow Down decreases the diameter within 20 hundredths of a mm CLEAR to zero the value ENTER in the last field is used to quit the window and show the message requiring the editing to be saved Save adjustments No STOP Yes ENTER ATTENTION when STOP is pressed the new measurements are not saved the previous gauging values therefore remain valid Copyright Silca 2004 75 5 21 Fig 101 ADAPTERS Scroll with the arrows ENTER to view the adapter Adapters E1 Mortice E2 Bit Stop Female E3 Pump cutting E4 Muel Cutting E5 Fiam cutting E6 Fiam reading E7 Pump reading NODI E8 Muel reading
94. key Editing of key read the original key read can be edited in order to adjust any defects or broken parts see ch 5 15 page 61 Copyright Silca 2004 23 IDEA 5 4 5 4 1 Operating Manual English Copy FROM ORIGINAL FoR FRONT STOP MALE KEY READING Original on right Clamp S100 A B Stop 0 START Clamp S100 A B indicates the clamp S100 into which the key must be fitted and which jaw to use Stop 0 reference or positioning point on the key reading clamp Reading keys with front stop double bit single bit male 1 open the fixed clamp A and the mobile clamp B by exerting pressure on the jaw lever 2 fit the key into the special V shaped groove axis X1 taking the bit all the way into the fixed clamp ATTENTION position the key so that the highest tooth is facing left ensuring contact with the stop 0 on the vertical side of the tooth 3 release the jaw lever 4 place the mobile clamp B in the ideal position for the stem between the bit and head making sure that between the bit and internal side of the mobile clamp B there is a distance of min mm and max 10 mm 5 when the reading process is started the carriage takes the key into contact with the laser beam along the path and in the direction indicated by the broken line 6 atthe end of the cycle see the message on the display in order to continue see ch 5 4 2 Reading in progress Data proc
95. key has only one bit the stem of the key CUTTING PROCESS Cutting begins on the bit on the left hand side of the stem starting from the tip and going towards the head The second bit the one on the right is cut in reverse i e from the head to the tip Y Fig 20 cutting path is automatically calculated by the program on the basis of the reading from the original key The thicknesses of all the teeth positive and negative are compared with the thickness of the cutting tool stored in the memory can be read on the machine display by means of the F2 function If the thickness of any of the teeth is less than that of the cutting tool standard cutting tool 1 25 mm the program will indicate the maximum thickness needed to make an identical copy of the key If all the teeth are thicker than the cutting tool the program will indicate the difference and the number of times the cutting tool needs to pass to reproduce the cuts correctly 22 3 Y 4 SEI gt c Sm a t F d Fig 21 20 Copyright Silca 2004 Operating Manual English IDEA The cutting tool is brought into contact with the bit at reduced speed to determine the size then the tool withdraws to the safety distance before beginning the next cut The purpose of the entire procedure is to re
96. lder stop 3 Pump 4 Square square tip 5 Square round tip 6 Square stepped tip 7 Rear stop 8 Rear stop french 9 Small bit 10 Special bit female Choose option 1 Reading Cutting 1 Reading Cutting 2 Cutting only 3 Reading only 4 Post Reading KEY READING Original on right Clamp 5100 A E Stop 0 Adapt E11 START NOTE Jaws F or G could also be used see JAWS A E A F on page 46 The rear stop is not necessarily up against the side of the jaw fig 68 Fig 68 Copyright Silca 2004 51 IDEA Operating Manual English CUTTING Left blank Brass Clamp S1 K2 Stop 0 Cutt 1 25 Pcsz 1 1 START e CUTTING Stop 0 Raise the positioning plate P and fit the key blank into the rotating clamp S1 from the front end Place the stem into the V on the jaws of the 2 tailstock taking care to keep the bit horizontal and the key stop up against the stop STOP 0 obtained by fitting the plate P up against the front end of the 2 tailstock Secure the key by tightening the jaw screw W2 with the wrench T4 fig 67 Replace the plate P in position in seat 2 or 3 Replace the T4 wrench in its seat Fig 69 NOTE the key can be fitted into the S1 K2 clamp from the front or from the back according to the type of key Fig 70 52 Copyright Silca 2004
97. millimetres 2 Start menu 3 Preferred MFG 4 Quick menu Measurement unit 0 Millimetres 1 2 used to select from the main menu the function you wish to appear on the screen when the machine is turned 0 Copy from original on 1 Decode and Copy Place the cursor on the item to be selected and press 2 Insert the Cuts ENTER An asterisk will appear to highlight the 3 Queue from PC selection made 3 searches by code must be filtered by selecting the makes in which you are interested This reduces the Select MFG 63 number of SSNs involved in the search 0 All MFG Place the cursor on the item to be selected and press 1 AGA ENTER An asterisk will appear to highlight the 2 AGB selection made Press CLEAR COPY to null the selection 63 total number of makes The STANDARD setting of the machine enables searches through all makes select the item 0 makes as soon as one of the makes is selected the asterisk disappears from the item 0 All makes and ONLY the MAKES selected are involved 4 if enabled 1 is used to skip some steps or windows when applicable in heavy operating flows in order to Quick menu 0 0 1 speed up the procedure required by the operator 6 2 5 Language Enter the number that corresponds to the language you intend to work with Lang select 2 1 Italiano 2 English 3 Deutsch 4 Francais 5 Espanol 6 2 6 Keyboard inversion This operation is used to invert
98. n regarding connection to a PC so that the machine can receive data directly The Silca Keys Program makes it possible to interface with the IDEA and transmit the cutting data required and selected through the powerful program made available It is also possible to store the selected keys in a special work queue or file so that they can be transmitted to the machine as soon as it is available Each combination sent to the IDEA corresponds to a step in the cutting process for the number of keys entered on the PC When the cutting operation is finished for the number of keys set a sign shows the end of the cycle When the IDEA is turned off in the middle of a work queue the machine stores the status of the work done in its memory When the machine is turned on again the unfinished cutting operations will be easily found with the number of keys still to be cut NOTE the key combinations transmitted by the Personal Computer cannot be altered by the operator QUEUE FROM PC 3 Choose the function from the main menu by placing the 0 Copy from Original cursor on 3 Queue from PC 1 Decode and Copy 2 Insert the Cuts 3 Queue from PC gt gt ENTER 001 Codes received 1 10 1 2 AH100 45 2 3 456 67 3 Analysing the first line in the window above 1 Progression for codes received shows that the 3 keys set have not all been cut shows that the 3 keys set have all been cut 10 SSN 1 Number of pieces
99. ndicated by the broken line At the end of the cycle see the message on the display in order to continue 26 Copyright Silca 2004 Operating Manual English IDEA 5 5 2 Cutting front stop keys double bit single bit female Left blank Brass Clamp S1 K1 Stop 0 Cutt 1 25 Adap E2 Pes 1 1 START Clamp 51 K1 indicates which clamp 61 and tailstock K1 to use for gripping the key Stop 0 reference or point for positioning the key on the cutting clamp Cutter 1 25 thickness of the currently selected cutter press SHIFT ENTER to change thickness Brass Steel material of the key press SHIFT to change material Adapt E2 adapter for positioning the key female from the tip ATTENTION always check that the wording corresponds to the material of the key The key blank to be cut must be positioned according to the parameters given on the display after selecting the program involved the type of key with front stop requires the use of the rotating clamp S1 the K1 tailstock the E2 adapter and the key reference on Stop 0 Please follow the instructions below carefully and observe the order of operations Fig 31 2 ATTENTION 3 6 7 8 E2 Loosen the knob T1 by turning it anticlockwise until the rotating clamp S1 can be moved to a convenient distance for fitting the key Fit the adapter E2 into the tailstock K1 up against the mechanical stop T
100. nding faults and making checks 1 Machine zero points 2 Test ATTENTION this Test chapter serves as a check on any errors anomalies that could occur on the machine ch 7 1 page 118 From the main menu choose the function by placing the pointer on 5 Maintenance 0 Copy from Original 1 Decode and copy 2 Insert the Cuts 3 Queue from PC gt gt 4 Calibrations 5 Maintenance 6 Options Select 2 Test 1 Machine zero points 2 Test 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 NOTE ifthe OFF ON transition is not made contact Silca s Technical Assistance Dept e Test2 X AXIS MOTOR Carefully follow the instructions on the display and check that the X axis carriage moves ATTENTION during this test all the end of run controls are disabled avoid moving the carriage up against its mechanical stops NOTE if the motor does not start contact Silca s Technical Assistance Dept e Test3 Y AXIS MOTOR Carefully follow the instructions on the display and check that the Y axis carriage moves ATTENTION during this test all the end of run controls are disabled avoid moving the carriage up against its mechanical stops NOTE if the motor does not start contact Silca s Technical Assistance Dept e Test4 B AXIS MOTOR This Test can
101. ner provided the tool kit to loosen the nuts on the machine s feet remove the metal brackets and re tighten the nuts on the feet check the contents in the box that should comprise with the following IDEA key cutting machine set of documents including an operating manual a spare parts list and a guarantee power supply cable tool kit O1 NOTE we strongly recommend you keep the packing intact for future transportation Copyright Silca 2004 11 IDEA Operating Manual English 2 3 MACHINE HANDLING When the IDEA has been unpacked place it directly on its workbench this operation should be carried out by at least two people Take care to lift the machine firmly holding the base and no other part ATTENTION never lift the machine by holding the keyboard stand fig 13 Fig 13 12 Copyright Silca 2004 Operating Manual English IDEA 3 1 3 2 3 3 Fig 14 3 4 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 CHECKING FOR DAMAGE IDEA 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
102. ng laser reading the original key must always be cleaned to remove any accumulated impurities at the base of the negative teeth or frazed parts on the key profile use the teflon brush ensure that the positive teeth are not so bent as to obstruct the entry of the beam into the adjacent spaces with all keys ensure that the stem is not bent between the tip held by the fixed clamp A and the part of the stem held in the mobile clamp B position the key so that the transversal axis of the bit s is as horizontal as possible The reading process is started when the program has been selected from the display and the key has been placed in position on the clamps according to the instructions in the special diagrams for each type of key for example fig 28 fig 30 fig 32 Excursion during the reading process is limited by the lower jaw of the mobile clamp B and the transversal run is determined both by the type of key and the size of the bit The laser reader is programmed to circumscribe the bit s on the key starting from the contact on the lower jaw of the mobile clamp B to read the diameter of the part of the stem between the mobile clamp B and the bit and to recognise the type of key and its correct positioning according to the selected program It reads the first side of the bit following the cuts up to a limit of 0 5 mm from Stop 0 up against on the fixed clamp A then goes on the second side to follow the second bit or if the
103. nob T1 to release the underlying mechanical stop Loosen the screw T2 fig 10 page 8 and pull out the rotating clamp After replacing the rotating clamp into the guide turn the knob T1 to activate the stop Tighten the screw T2 Before removing the clamp remember to disconnect the coupling for the rotating clamp connector extension B1 from the Y axis carriage then to connect it again when the clamp has been replaced GRIPPERS The grippers G1 are opened and closed by means of the countersunk hexagonal screw V1 activated by the T wrench T4 housed on the machine The grippers G1 ensure that the key stem is centred on its axis within the set dimensions min 3 6 mm max 7 mm the mobile jaws adapt to the diameter of both straight and conical stems The universal tailstock support K1 is designed and set to align the rotating clamp along the axis of the key stem parallel to the movement of the carriage X spaces so that it remains flat under the cutter this ensures perfect concentricity between the axis and the key stem with any radial position FUNCTIONS The rotating clamp provides rotation for the keyblank this serves two main purposes 1 to provide the cutting radius concentrical to the axis of the key stem during the cutting operation with a tolerance of 30 2 to turn double bit keys 180 By means of a PC function it also provides interpolation of the movements between the Y axis depth and
104. not properly positioned all the way in as described in the instructions booket This message indicates that the height detected by electrical contact is greater than the setting see Options ERROR 20 Bit height cap 6 2 8 a pag 108 Max bit height for steel keys is xx xx mm This message relates to the cutting of keys with rear stop and warns that a STOP number 1 2 3 has been set that ERROR 21 is not compatible with the length of the key read by the STOP Position optic reader not compatibile with Solution key length Select the right STOP Copyright Silca 2004 115 IDEA Operating Manual English The key may not be perfect due to a slight error in the reconstruction of the key read ERROR 22 Possible causes Key reading some of the teeth on the key are deformed or crooked is not optimal there is dirt on the key that deforms the image of the ENTER to continue reconstructed bit grease swarf threads of cloth Solution clean the key carefully with a metal brush and repeat the reading operation NOTE any case the key can be cut by pressing ENTER There is no guarantee that the reproduction will be an exact copy of the original key NOTE If the error is repeated or the key is not properly reproduced consult ch 7 14 DIAGNOSTIC FUNCTION errors in Copy from Original on IDEA page 133 and or contact Silca After Sales Service The key cannot be copied due to a SERIOUS error in the re
105. ocell TZX OFF TZY OFF See operating manual START Pos Photocell TZX ON TZY ON See operating manual START 90 Copyright Silca 2004 Operating Manual English Regulating the Y axis sensor raise the protective shield use the provided allen key to loosen the C1 grub screw manually rotate the C2 rod fig 119 in both directions up until the changeover point from OFF to ON is found tighten the C1 grub screw to secure the rod Regulating the X axis sensor carefully tip the machine over remove the bottom panel by unscrewing all 8 securing screws loosen the C3 screw fig 120 that secures the sensor support plate Manually move the sensor up until the display s description goes from OFF to ON tighten the C3 screw to secure the plate back into place re position the machine back on its workbench and lower the protective shield press START the machine s zero settings are detected by electric contact 10 when the operation has been completed the display will show the measured quotes 11 press ENTER to save 12 manually turn the Y axis disk to get access to the G4 grub screw fig 118 13 manually turn the X axis disk to get access to the G2 grub screw fig 118 ATTENTION if the STOP key is pressed the new settings will be Fig 119 lost If so only the previous setting values will remain valid Y axis sensor IDEA Pos
106. oni No STOP Si ENTER Operating Manual English Y Example Adapter E5 Side cutting Adjustment B 00 X 00 Y1 00 Y2 00 Save adjustment No STOP Yes ENTER 78 Copyright Silca 2004 Operating Manual English Example Adapter E6 Side reading Adjustment X 00 Y1 00 Y2 00 Save adjustement NosSTOP Yes ENTER Fig 106 Example Adapter E7 Side reading Adjustments X 00 Y1 00 Y2 00 Save adjustment No STOP Yes ENTER Fig 107 IDEA Copyright Silca 2004 79 IDEA Fig 108 Fig 109 Example Adapter 8 Side reading Correzioni X 00 Y1 00 Y2 00 Salvare le correzioni No STOP Operating Manual English Example Adapter E9 Side cutting Adjustment B 00 X 00 Y1 00 Y2 00 Save adjustment No STOP Yes ENTER 80 Copyright Silca 2004 Operating Manual English Example Adapter 9 Side reading Adjustments X 00 Y1 00 Y2 00 Save adjustements No STOP Yes ENTER Fig 110 Example Adapter E10 Side cutting Adjustments X 00 Y1 00 Y2 00 Save adjustements No STOP Yes ENTER
107. ont of the bit and establishing the measurements of the cuts height from the stem axis It is possible to reconstruct up to a maximum of 6 teeth on each bit side fig 91 NOTE always calculate the position of the tooth from STOP 0 missing S tooth i ela Sul 85 1st side S i I S 2 5 E 2nd side missing 9 B o tooth 2 5 Fig 91 BIT CORRECTION Select the bit 1 Bit 1 2 Bit 2 Select BIT 1 for example Bit 1 Tooth 1 From 0 to 180 Height 1200 Up Down 7 ENTER Enter the position from to and height of the tooth and press ENTER to confirm Bit 1 Tooth 2 From 180 to 360 Height 1500 Up Down T ENTER Go on to the next tooth by pressing the arrow Down Press STOP to quit Bit 2 Tooth 1 From 1920 to 2100 Height 1350 Up Down T ENTER 64 Copyright Silca 2004 Operating Manual English IDEA Examples Pump keys Stop 3 p to calculate tooth construction Fig 92 Square stemmed keys Stop 1 to calculate tooth construction Fig 93 0 DELETE EDITING When a new key is read or the item 0 Delete editing is selected all the POST READING adjustments previously selected can be eliminated Delete post reading
108. 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 e Emergency stops The red emergency button N fig 10 page 8 placed on the right hand side of the machine 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 T WRENCH HOLDER The special holder for the wrench T4 on the front of the machine below keyboard fig 10 prevents damage to the machine caused by inadvertently leaving the wrench on the rotating clamp or the tailstock It is therefore essential that the wrench T4 is placed into its holder after use If the wrench T4 is not in its holder the machine will not begin the cutting cycle and the display will show the message T WRENCH INTO HOLDER Laser warning Regulations require that warning labels in the language to be used be attached to the laser reader as shown in fig 15 page 14 Cutter motor protection The cutter motor is protected against overheating by
109. otating Jaw 2 8100 Reading Jaw Clamp S1 K1 gt gt Adjustments B 000 X 00 Y1 00 Y2 00 To calibrate START Press SHIFT ENTER Clamp S1 K1 unit comprising the 51 clamp 1 interchangeable tailstock gt gt press SHIFT ENTER to go to the other interchangeable tailstocks used with the S1 clamp if applicable Clamp S1 K2 unit comprising the 51 clamp and K2 interchangeable tailstock Clamp S1 K2 Adjustments 000 00 Y1 00 Y2 00 To calibrate START START press START to begin the automatic gauging procedure for the CLAMP TAILSTOCK unit Clamp S1 K2 Install Z15 and Z13 See operating manual START Template Z13 fit in place of the cutter fig 61 Template Z15 fit on the S1 K2 clamp as if it were a key fig 61 Use the plate P as a point of reference in position 2 with the second pin on the template up against it Tighten the screw W2 with the T4 wrench Replace the T4 wrench in its seat Fig 61 Press START Clamp S1 K2 Detection In progress 44 Copyright Silca 2004 Operating Manual English IDEA Clamp S1 K2 Adjustments B 000 02 Y1 02 Y2 04 To calibrate START Position the pointer at the side of the parameter to be edited with the arrow keys or ENTER and use the following keys to edit the parameters SHIFT arrow up increases the value within 300 hundredths of a
110. oxic noxious waste are listed in the appendices to the current European Union regulations regarding disposal of such waste To facilitate disposal of the waste generated by the machine during its operation and of the machine itself at the end of its useful life refer to identification of the main types of waste by the relative European CER code CER code Electronic circuit boards 16 02 16 Iron filings and swarf 120101 Paper cardboard packaging 15 01 01 Wooden packaging 15 01 03 Plastic packaging 15 01 02 9 Waste is any substance or object deriving from human activity or natural cycles disposed off or to be disposed off Copyright Silca 2004 135 IDEA Operating Manual English 9 ASSISTANCE Silca provides full service to purchasers of the IDEA 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 IDEA ensures free repairs or replacements of faulty parts within 12 months of the date of purchase All other service calls must be arranged by the customer with Silca or specialized Silca service centres 136 Copyright Silca 2004 Operating manual English IDEA Appendix 1 ELECTR
111. p then tighten the screw G 4 Fit the original key into the adapter E8 so that the stops on the bit butt against the stops P6 on the adapter E8 and the cuts are directed upwards From this condition turn the knob P5 to turn the pin cam securing the key 5 Push the E8 adapter until the side Y is butting against the fixed part of the S100 A clamp tighten the grub screw B9 6 Press the START key to continue 7 When the decode process starts the carriage will take the key into contact with the laser beam along an ideal path Adapter 8 Operating Manual English Adapter 8 Fig 45 8 At the end of the cycle see the message on the display in order to continue Decoding in progress Bit 1 5310254324 Possible depths 012345 10 36 Copyright Silca 2004 Operating Manual English IDEA To cut Muel keys proceed as follow CUTTING MUEL PUMP KEYS SSN 328 1 Brass Clamp S1 K1 Stop 0 Cutt 1 25 Adapt E4 Pes 1 1 The key blank to be cut must be positioned according to the parameters given on the display after selecting the program involved the type of Muel pump keys requires the use of the E4 adapter and the key reference on Stop 0 Please follow the instructions below carefully and observe the order of operations Adapter E4 1 Loosen the knob T1 by turning it anticlockwise until the rotating clamp S1 can be move
112. p and the rear end of the bit Secure the rotating clamp by tightening the knob T1 9 Hold the key head with the left hand and push the key making sure that the bits butt up against the adapter E5 installed on the tailstock K1 simultaneously close the grips on the key stem by means of the wrench T4 already on the screw Fig 58 Replace the T wrench in its seat lower the mobile safety shield and begin the process with START To remove the key after cutting carry out the operations described in reverse order Cutting in progress Copy 1 of 1 Copy 1 of 1 finished More copies No STOP Yes ENTER You can now press ENTER in order to make further copies of the key 42 Copyright Silca 2004 Operating Manual English IDEA 5 12 KEYS WITH REAR STOP MALE KEYS AND FEMALE KEYS OPTIONAL D727498ZB Set for keys with rear stop The set comprises K2 Tailstock for keys with rear stop E11 Adapter for reading install on S100 clamp in place of S100 B mobile clamp E Adapter E ID initial used for reading some types of keys install on S100 E11mobile clamp see diagram TYPE OF KEYS page 47 F G Adapter F or G ID initial used for reading some types of keys install on S100 E11 mobile clamp according to the type of key see diagram TYPE OF KEYS page 47 215 Template for gauging the cutting unit with K2 tailstock Gauging Cutting unit Clamp S1
113. panel ch 7 8 page 125 3 loosen the G1 and G2 grub screws that secure the X axis photocell disk fig 115 4 remove the bottom panel ch 7 9 page 125 5 disconnect the J1 Y axis cable from the carriage fig 116 6 unscrew the 3 B5 fixing screws and remove the Y axis protective cover by pulling it in the direction shown in fig 116 7 loosen the G3 and G4 grub screws that secure the Y axis photocell disk fig 118 page 90 8 plug the Y axis J1 cable fig 116 and the machine s power supply cable back into place 9 turn the machine on and carry on with the procedures described on page 89 FEE r uu G1 G2 I 72 J LI 5 TE 9i n LI H _ x gt MO E y4 SS Fig 115 88 Copyright Silca 2004 Operating Manual English IDEA Y axis sensor Y axis photocell disk Fig 116 CUTTING UNIT 1 enter the Maintenance 5 2 select Machine zero points 2 Operational keys use the WA arrow keys to move the cursor to the option required and press ENTER or directly press the numbered key corresponding to the option number 3 select Cutting unit 1 4 insert the 712 template fig 99 page 73 5 remove the cutter and insert the Z13 template into place fig 99 6 manually move the and Y axis up until the 712 and Z13 templates make contact fig 117 7 lower the protective shield and press
114. pecific optional accessories Test 19 OUTLET 2 To use the test properly consult the literature provided with the specific optional accessories e Test 20 OUTLET 3 To use the test properly consult the literature provided with the specific optional accessories Test 21 OUTLET 4 To use the test properly consult the literature provided with the specific optional accessories e Test 22 SERIAL PORT Check that the machine display shows OFF IDEA Fit the special serial test connector Z4 provided to the machine serial port checking that the display shows first OFF then ON Copyright Silca 2004 87 Operating Manual English IDEA 6 1 1 Machine zero points With the use of regulating templates ch 1 5 page 10 the machine provides a self setting procedure These procedures must be carefully carried out following the descriptions and illustrations indicated below MACHINE ZEROES CALIBRATING EVENT CUTTING UNIT dn e CLAMPS CUTTERS Replacement of photocells NO Replacement of YES the electronic board Replacement of NO the Optical Reader unit Replacement of sensors YES Replacement of the cutter NO shaft Replacement of the NO Screws PRELIMINARY OPERATIONS 1 turn the machine off and unplug it from its power supply cable 2 remove the back
115. pter for cutting PUMP keys Brass Steel material of the key press SHIFT to change material ATTENTION always check that the wording corresponds to the material of the key The key blank to be cut must be positioned according to the parameters given on the display after selecting the program involved the type of pump keys requires the use of the E3 adapter and the key reference on Stop 3 Please follow the instructions below carefully and observe the order of operations 1 2 Loosen the knob T1 by turning it anticlockwise until the rotating clamp S1 can be moved to a convenient distance for fitting the key Take the wrench T4 from its seat and fit into the screw V1 then loosen until the jaws are fully open At the end of the operation do not remove the T wrench from the screw fig 41 Fit the key blank into the E3 adapter paying attention to its position fig then tighten the screw P Fit the E3 adapter with the key blank in the rotating clamp S1 from the inside take the adapter up to the side of the self centring jaws and slightly close the grips on the rotating clamp with the T wrench T4 Move the rotating clamp S1 so that the adapter E3 enters the tailstock K1 Tighten the knob T1 Use the T wrench T4 to tighten the screw V1 first then the screw V2 fig 42 Replace the T wrench T4 into its seat lower the mobile safety shield and begin the process
116. ption of general safety precautions and observation of the instructions provided by the manufacturer in this manual eliminate all human error unless deliberate IDEA is designed with features which make it completely safe Power supply IDEA is supplied with electricity by means of a grounded plug and differential switch Start up The machine is turned on by means of a master switch that is located on the Idea s lower left back side Maintenance The operations to regulate service repair and clean the machine are structured in the simplest and safest way possible Parts that the operator can dismount cannot be incorrectly replaced therefore avoiding any risks e Machine identification The machine is provided with an identification label which includes the machine s serial number fig 8 SILCA S p A Via Podgora 20 2 1 M anufacturer s 31029 VITTORIO VENETO TV ITALY identity Tel 0438 9136 lt Telefax 0438 913800 Telex 410579 SILCA I TIPO Type of machine TYPE ac 4 N MATRICOLA Serial No Working SERIAL No E voltage VOLT Hz A WATT lat Absorbed power CE mark A 14 aa CE MADE IN ITALY Year of y Working Absorbed manufacture frequency current Copyright Silca 2004 5 IDEA Fig 9 1 1 Operating Manual English MACHINE DESCRIPTION IDEA is an electronic machine operating on 3 axes X spaces Y
117. pyright Silca 2004 Operating Manual English IDEA 6 2 10 2 ERROR MESSAGES These errors may occur when the machine gauging procedure has not been successful ERROR 1 Possible causes X AXIS no contact The 213 gauging disk has not been properly fitted made The Z12 gauging template has not been properly fitted ERROR 1 Y AXIS no contact made ERROR 1 B AXIS no contact made The messages listed below appear when there has been a problem during or after updating the program in the machine Try updating or re loading the machine internal software using the WINTRANSFER Program or the SILCA KEY PROGRAMS The ISO cutting function has not been found ERROR 2 ISO Function not defined See operating manual Machine ID has not been programmed ERROR 2 MACHINE ID not defined See operating manual The card uses a type of cut not run on the machine ERROR 2 Type of cut not available See operating manual The clamp is not in the machine archive ERROR 2 Clamp not available See operating manual The cutter is not in the machine archive ERROR 2 Cutter not available See operating manual The adapter is not in the machine archive ERROR 2 Adaptor not available See operating manual Copyright Silca 2004 113 IDEA Operating Manual English The clamp is not in the machine archive ERROR 2 Undefined Clamp
118. r on the S100 clamp 3 Fit the jaw E with the letter facing the operator into the E11 adapter 4 Open the fixed clamp A and mobile clamp E by pressing on the gripper lever 5 Place the key into its seat and take the bit up against the fixed clamp A Fig 62 ATTENTION position the key so that the first tooth is facing to the left ensuring contact with the stop 0 on the vertical face of the tooth fig 62 6 Release the gripper lever ATTENTION the rear stop must butt against the face of jaw E fig 62 7 On starting the reading operation the carriage will take the key into contact with the laser beam along the path dictated by the software 8 In the case of female keys use one of the standard centring devices according to stem diameter on the S100 A clamp see ch 5 14 SPECIAL BIT FEMALE KEYS page 57 Jaws A F READING 1 Remove the mobile unit B from the S100 clamp 2 Fit the E11 mobile adapter on the S100 clamp 3 Fit the jaw F with the letter towards the operator on the E11 adapter 4 Open the fixed clamp A and mobile clamp F by pressing on the gripper lever 5 Fitthe key into its seat and take the bit up against the fixed clamp A Fig 63 ATTENTION position the key so that the first tooth is facing to the left ensuring contact with the stop 0 on the vertical face of the tooth fig 63 6 Release the gripper lever ATTENTION the rear stop must butt against
119. ronic circuit board replacement Keyboard display replacement Access to back compartment Access to bottom compartment Sensor replacement Photocell replacement Brush replacement WIN TRANSFER program for loading updating the machine program 7 3 CUTTER REPLACEMENT 1 turn the machine off and unplug it 2 remove the cutter protective shield i by loosening the screw i2 3 slide the cutter release rod X into the hole located on the left side of the machines cutter shaft chassis fig 131 4 loosen the cutter locking nut turning it clockwise with the socket wrench X1 provided with the machine ATTENTION the thread is left handed reversed 5 replace the cutter then tighten the nut turning it counter clockwise and remove the rod from its hole 6 place the cutters protective shield i back into position securing it with the screw i2 ifs e Nee N f E A XL Fig 131 ATTENTION when replacing a worn cutter with a new one or with a re sharpened cutter consult ch 5 19 Gauging page 72 120 Copyright Silca 2004 Operating Manual English IDEA 7 4 Fig 132 REPLACING AND TIGHTENING THE BELTS To replace the belt proceed as follows 1 turn off the machine and pull out the plug 2 remove the back metal panel ch 7 8 page 125 3 remove the bottom plate ch 7 9 page 125 4 loosen the 4 motor fixing screws W Motor belt loosen the 2 screws W3 and remove the plate W4
120. ront stop requires the use of the rotating clamp S1 the K1 tailstock support and the key reference on Stop 0 Please follow the instructions below carefully and observe the order of operations 1 Loosen the knob T1 by turning it anticlockwise until the rotating clamp S1 can be moved to a convenient distance for fitting the key 2 Orient the standard tailstock K1 for male keys in the special seat on the support using the screw V2 to direct it upwards 3 Take the T wrench T4 from its seat and use on the screw V2 to open the K1 tailstock grips 4 Fitthe adapter E5 into the K1 tailstock so that the initials E5 are facing upwards and the adapter is butting well up against the K1 tailstock grips fig 57 5 Tighten the screw V2 with the T4 wrench 6 Take the T wrench T4 from its seat and open the rotating clamp jaws by turning the sunk hex screw V1 at the end of the operation leave the T wrench in the screw V1 Fig 57 7 Fit the key blank into the rotating clamp S1 from the front positioning the square stem over the V on the grips diagonally so that the left hand bit is sloping downwards fig 54 and fig 55 8 Use the T wrench already on the screw V1 to slightly tighten the grips on the rotating clamp without exerting pressure on the key stem move the rotating clamp G towards the tailstock keeping a minimum safety distance of 10 mm between the grips on the rotating clam
121. ructions indicated by the manufacturer If the key cutting machine is used differently or for purposes different from those described in this manual the customer will forego any rights he may have over Silca S p A Furthermore unforeseen danger to the operator or any third parties may arise from incorrect use of the machine INCORRECT USE Operator negligence resulting in improper use of this machine or failure of the operator to observe the instructions written in this manual The manufacturer may decline all guarantees and responsibilities It is therefore essential to carefully read this operating manual IMPROPER USE OF ELECTRIC CONTACT itis not permitted to cut anodized keys plastic keys or any keys with materials that do not have electrical conductivity by means of electric contact cuts cannot be repeated on the same side of the key when electric contact cutting is used INSTRUCTIONS MANUAL The instructions manual provided with the machine is essential to its proper use and to carry out the necessary maintenance We therefore recommend protecting the manual from damage in a safe sheltered place easily to hand for quick consultation FURTHER RISKS No further risks will arise when properly using the IDEA PROTECTION AND SAFETY PRECAUTIONS FOR THE OPERATOR IDEA 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 ado
122. s the L2 screw fig 141 thus securing it with the L4 nut connect the sensor s connector to the electronic circuit board see ch 6 1 1 Machine zero points page 88 remount the bottom panel and front cover X axis sensor 12 2 v 0 1 0 4 mm L3 Y AXIS SENSOR REPLACEMENT 1 turn the machine off and unplug it from its power supply cable raise the protective shield disconnect the J1 Y axis cable from the carriage remove the Y axis carriage cover by unscrewing the 3 B5 locking screws and pull the cover in the direction shown in fig 116 disconnect the M3 sensors connector fig 143 slightly loosen the M2 grub screw with the provided allen key remove the faulty sensor and replace it with a new one Screw it in until it almost touches the underlying rod fig 143 Tighten the M2 grub screw to lock the sensor into place connect the M3 sensor s connector replace the Y axis carriage cover 10 connect the J1 Y axis connecting wire to the carriage Y axis sensor Fig 143 126 Copyright Silca 2004 Operating Manual English IDEA Fig 144 Y axis sensor n REPLACING THE AXIS SENSOR 1 2 NO C 9 Fig 145 Fig 146 turn off the machine and unplug raise the safety shield
123. sensors ICX OFF ICY OFF See operating manual START Pos sensors ICX OFF ICY ON See operating manual START Pos sensors ICX OFF ICY OFF See operating manual START Pos sensors ICX ON ICY ON See operating manual START Zero detection in progress Measured quotes X 4444 Y 3333 Save measurements No STOP Yes ENTER Copyright Silca 2004 91 IDEA Operating Manual English bottom view ATTENTION H if it is necessary to work close 9 to this area with the machine turned on e g to regulate the X axis sensor take great care not to touch any components on the machine s electronic boards as it is connected to 230 110 Volts 7 rn DDDLETTTITTI Fig 120 Fig 121 READING UNIT Operational keys 4 Calibrations use the WA keys to move the cursor to the option required 5 Maintenance and press ENTER or directly press the numbered key 6 Options corresponding to the option number 1 enter
124. sk C and give a name to the file to be saved Click with the mouse on the Save button The bit will be downloaded from IDEA approx 1 minute and at the end of the operation the monitor will show a saved message Send the file to Silca the file will have the extension map via e mail to the address service silca it complete with the following information SW Version of key cutting machine Description of problem The last tooth of bit 1 is missing or part of the bit has been cut on the stem Errors on machine display INTERNAL ERROR n 11 Copyright Silca 2004 133 IDEA Operating Manual English REDUCTION OF UPGRADING TIMES FoR INTERNAL MACHINE SOFTWARE The new Wintransfer program allows you to reduce data transfer times to the machine during upgrading when part of the key cutting machine data are already updated The choice of data transfer procedure complete or fast is at the user s discretion IMPROVEMENTS TO THE USE OF THE QUEUE FROM PC FUNCTION Enable the RAPID MENU on the machine in the way described below 1 Select OPTIONS 2 Select FAVOURITES 3 Select RAPID MENU 4 Set the value 1 In QUEUE FROM PC when the key has been cut the message below will no longer appear Copy 1 of 1 finished More copies NO STOP YES ENTER and the next operation will start automatically 134 Copyright Silca 2004 Operating Manual English IDEA 8 D
125. structions in the manual as follows gauge as explained in chapter Machine zero points Cutting Unit and Reading Unit in the user s manual At this point the machine is set up and ready for operation e update for the program or machine data 1 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 Loading of customized key data cards provided by SILCA on Customer s request 1 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 132 Copyright Silca 2004 Operating Manual English IDEA 7 14 DIAGNOSTIC FUNCTION ERRORS IN COPY FROM ORIGINAL ON IDEA On IDEA key cutting machines the new upgrade of SKP and Wintransfer can be used to notify Silca S p a of any anomalies by simply sending a file If a key is not properly reproduced after reading it with the Copy from Original function before carrying out other operations especially the reading of other original keys proceed as follows Connect the PC to the key cutting machine IDEA KEY CUTTING MACHINE How to download a bit from IDEA with SKP 6 ON Launch the SKP program Go to the list of machines Select the Idea machine and click with the mouse on the Edit button if an
126. t against the key rim Y1 NOTE place the key so that the bit is as horizontal as possible 3 Place the second adapter A2 into the standard tailstock and tighten the grub screw G fig 36 4 Place the key to be cut into its seat on the adapter which must butt up against the key rim Y2 take the rotating clamp up to the stem and secure the key 5 Proceed with the cutting operation OPTIONAL D716544ZB Adapters E9 Fig 36 Copyright Silca 2004 31 IDEA Operating Manual English 5 9 PUMP KEYS OPTIONAL D726180ZB Adapters Fig 37 E3 Adapter for pump keys ID used for cutting install between the rotating 51 and K1 tailstock E7 Adapter for pump keys E7 ID used for reading install in the place of the S100 B mobile clamp When the machine requires indicates on display adapter E3 or E7 proceed in the way described in the following examples Itis very important to distinguish the type of key to be copied Choose option 3 Pump SELECT TYPE OF KEY 0 Bit stop male 1 Bit stop female 2 Shoulder stop 3 Pump Choose option 1 Reading Copy 1 Reading Copying 2 Cutting only 3 Reading only 4 Post reading adj READING PUMP KEYS KEY READING Original on right Clamp S100 Stop 0 Adapt E7 START 32 Copyright Silca 2004 Operating Manual English IDEA Operate as follows 1 Loosen th
127. t length in reading max 40 mm Bit height max 17mm 19 5 mm Distance from stop to bit min 6mm Head width max 30 mm Choosing an adapter for READING Place the original key on the drawing using the Rear Stop as a reference the bit should enter the highlighted zone Jaws A E 6 LO E gt 65 Adapter E example Silca key ref 6FT12 24 Jaws A F x 75 Adapter F Rear Stop example Silca key 6 14 24 Jaws A G ie 19 5 lt lt A Rear Stop Adapter G example Silca key ref 6M24 Copyright Silca 2004 47 IDEA Operating Manual English CUTTING Left blank Brass Clamp S1 K2 Stop Cutt 1 25 Pes 1 1 START ATTENTION the cutting STOP is not presented automatically by the machine The operator must identify it from the diagram on page 49 and enter it from the keyboard when the display requires it CUTTING Stop 1 DECODING SSN 110 Remove the plate P in order to fit the key blank into the rotating clamp S1 from the front placing the stem into the V on the jaws of the K2 tailstock Take care to keep the bit in the horizontal position and the key stop up against the stop STOP 1 Secure the key by tightening the jaw screw W2 with the T4 wrench fig 65 Replace the T4 wrench in its seat Fig 65 CUTTIN
128. the face of jaw F fig 63 7 On starting the reading operation the carriage will take the key into contact with the laser beam along the path dictated by the software 8 In the case of female keys use one of the standard centring devices according to stem diameter on the 5100 clamp see ch 5 14 SPECIAL BIT FEMALE KEYS page 57 Jaws READING 1 Remove the mobile unit B from the S100 clamp 2 Fitthe E11 mobile adapter on the S100 clamp 3 Fit jaw G with the letter towards the operator into the E11 adapter 4 Open the fixed clamp A and the mobile clamp G by pressing on the gripper lever 5 Fit the key into its seat and take the bit up against the fixed clamp A Fig 64 ATTENTION position the key so that the first tooth is facing left ensuring contact with the stop 0 on the vertical face of the tooth fig 64 6 Release the gripper lever ATTENTION the rear stop must butt against the face of jaw G fig 64 7 On starting the reading operation the carriage will take the key into contact with the laser beam along the path dictated by the software 8 In the case of female keys use one of the standard centring devices according to stem diameter on the S100 A clamp see ch 5 14 SPECIAL BIT FEMALE KEYS page 57 46 Copyright Silca 2004 Operating Manual English IDEA TYPE OF KEYS Stem diameter min 5 mm max 7mm Collar diameter max 9mm Bi
129. the function of the alphanumeric keys Inversion keyboard With Keypad inversion disabled 0 function 0 to digit number 1 press 1 H key 1 Enabled to digit letter press SHIFT 1 H key See operating manual With Keypad inversion enabled 1 e to digit number 1 press SHIFT 1 H key to digit letter press 1 H key NOTE this function is operative with Insert the Cuts Decode and Copy and in from the main menu 106 Copyright Silca 2004 Operating Manual English IDEA 6 2 7 6 2 7 1 Limited access to Data Protected Systems Silca has predisposed limited access to some of the data in the Database in compliance with agreements with some makers Limitations apply to SERIES No access to codes or data cards SR TABLE No access to codes TB DATA CARD No access to data card SC Gain access to protected data in the following way request the maker s authorization communicate to Silca key cutting machine SERIAL NUMBER The ACTIVATION CODE Key cutting machine ID Silca will issue a Password to enter in order to enable key cutting of the protected system Example Silca provides a protected data card for SSN No yyy When SSN yyy is selected from menu 0 1 or 2 the following appears on the screen PROTECTED DATA CARD Machine 10 12345 Code SPWSC00011 Password 0 When authorization has been received from the maker apply to Silca for a password providin
130. the key which operates only on the outside of the lock or a tooth is broken or missing which was identical to the one specularly placed on the opposite side of the bit fig 89 missing tooth Fig 89 62 Copyright Silca 2004 Operating Manual English 5 15 3 Stop to quit Enter to continue confirmation Correcting bit depth Applicate X specular bit conversion No STOP Yes ENTER Bit Depth Bit 1 00 Bit 2 00 ENTER CONFIRM IDEA With the CORRECTING BIT DEPTH function a number of alterations can be made to measurements for the cuts on all the teeth on sides 1 and 2 for double bit keys within the limits of min 0 50 mm and max 0 50 mm MEASUREMENT A READ 1st BIT i 2 Fig 90 Correcting Bit Depth Bit 1 00 Bit 2 00 ENTER CONFIRM Use SHIFT arrow Up key for higher values bit is cut less Use SHIFT arrow Down key for lower values bit is cut more Copyright Silca 2004 63 IDEA Operating Manual English 5 15 4 Bit construction The BIT CONSTRUCTION function is useful when a positive tooth the high part between two lows has broken off As the program cannot formulate hypothetical compensation because it is not possible to read the missing part of the bit the operator must reconstruct the tooth involved determining its position from the fr
131. the optional adaptor D727711ZB cap 5 13 a pag 53 max 18 mm max 4 mm max 12 mm max 12 mm Fig 5 SPECIAL BIT FEMALE KEYS FIG 6 The minimum and maximum dimensions of this type of key are shown in the diagram below To cut this type of key on the IDEA is necessary the optional adaptor D728717ZB cap 5 14 a pag 57 E E N 8 15 Fig 6 KEYS WITH REAR STOP 7 The maximum dimensions of this type of keys are described in the table below To cut this type of key on the IDEA is necessary the optional adaptor D727498ZB cap 5 12 a pag 43 TYPE OF KEYS Stem diameter min 5 mm max 7 mm Collar diameter max 9 mm Bit length in reading max 40 mm Bit height max 17 mm 19 5 mm Distance from stop to bit min 6 mm Head width max 30 mm Fig 7 4 Copyright Silca 2004 Operating Manual English IDEA Fig 8 GENERAL IDEA has been designed in compliance to the European Community normative CE From the design stage risks for the operator have been eliminated in all areas transport regulation cutting and maintenance Further risks have been eliminated by means of protective devices The materials used to manufacture this machine and all its components are not hazardous USE IDEA is designed for cutting keys of ferrous materials brass silver nickel etc It must be installed and used according to the inst
132. the rotation axis B enabling radial cuts with set measurements INSERTING THE KEY The rotating clamp makes it possible to insert keys from either the front or the back according to the length of the key 16 Copyright Silca 2004 Operating Manual English IDEA 4 3 4 4 4 5 CUTTING BY ELECTRIC CONTACT The IDEA key cutting machine is equipped with a low voltage electrical contact device which permits the cutter to individualize the key blank as it approaches the cutter during the cutting phase Electrical contact is guaranteed for keys in steel brass silver nickel Zamak or iron with or without nickel plating IMPROPER USE OF ELECTRIC CONTACT It is not permitted to cut anodized keys plastic keys or any keys with materials that do not have electrical conductivity by means of electric contact CUTTER The majority of keys utilize the standard cutter for code cutting Only in certain cases some special keys with particular type cuts require different cutters CHANGING THE CUTTER 1 raise the protective shield 2 remove the cutter protective shield by loosening the screw i2 3 slide the cutter release rod X into the hole located on the left side of the machines cutter shaft chassis fig 18 4 loosen the cutter locking nut turning it clockwise with the allen wrench X1 provided with the machine ATTENTION the thread is left handed Fig 18 5 replace the cutter then tighten the nut
133. then DECODE SSN 10 Original on right Clamp S100 Dist 0 START Press START Decoding in progress Bit 1 Decoding in progress Bit 2 The data relating to key depth are transmitted to the PC for processing only at the end of the decoding cycle Decoding OK See computer Copyright Silca 2004 71 IDEA Operating Manual English 5 19 GAUGING DEFINITIONS The direction of compensation always refers to the key of whatever type or the device to which the compensations are fitted The reference axes for the direction of compensation are the key axis and stop 0 tip Positive compensations cause moving away from the reference zeroes highest teeth and or closest to the tip negative compensations cause moving towards them lowest teeth and or farthest from the tip Below is described a case of single or double bit keys A cut more P Y Ri 7 Cut less Fig 97 Fig 98 NOTE Adjustments to a key held by an adapter are the sum of automatic adjustments to the clamp manual adjustments to the adapter NOTE MANUAL adjustments to the clamp are not considered when there is an ADAPTER fitted Use arrows up down to scroll 1 Clamps 2 Cutter 3 Adapter Clamps 1 S1 Rotating Jaw 2 S100 Reader Jaw 72 Copyright Silca 2004 Operating Manual English IDEA Select
134. to cut Press the SHIFT ENTER keys to see the Data received list for each code transmitted which gives other data sent by the PC such as Customer s name Name of the customer assigned by the PC program in the HISTORIC archive Art Key article Each key received by the PC has a set quantity or number of pieces The machine program decreases the number with every key cut and stores the count in its memory even when the machine is turned off For this purpose a START key has been added in order to search for the first code in the list with a number of cut keys lower than that set Operational keys Arrow keys to scroll the lines DN AN SHIFT X 8 V arrows Up Down to scroll 4 lines at a time SHIFT ENTER m keys to view customer data and key article for the code selected 70 Copyright Silca 2004 Operating Manual English IDEA Press ENTER Bit 1 2 121 21212 121 Possible depths 123456 A R Bit 2 2 212 21212 212 Possible depths 123456 A R SSN 10 M1 Brass Clamp S1 K1 Stop 0 Cutter 1 25 Pcs 1 1 START KEY DECODING BY PC With the use of a PC i and with a much more complete collection of data keys can be decoded as well as cut Important pay attention to the note for fitting the key SSN 10 After launching the Silca Keys Program the decoding function for SSN 10 appears on the machine display for a Waiting for few seconds computer data
135. to use Stop 0 reference or point for positioning the key in the reading clamp Pressing START begins a quick process that reads only the cuts close to the teeth Decoding in progress Bit 1 At the end a window appears showing the various cuts deduced from the depths read Bit 1 2 123 456 Possible depths 12345 7 a fixed tooth 123 the symbol for the depth read arrow Down goes from one bit to the other CLEAR delete symbols It is in any case possible to edit the symbols for the combination before proceeding with the cutting operation NOTE see the next Chapter for the cutting sequence 66 Copyright Silca 2004 Operating Manual English IDEA 5 17 ENTERING THE CUTS Make a search for the SSN by entering the number corresponding to the system required and confirm with ENTER SSN 9 Cut MFG gt CISA 5 5 55 Cut MFG CISA gt CISA 03 List ENTER press the key Right hand arrow to place the pointer next to the Make field It is enough to enter the first letters of the name the name of the MAKE closest in alphabetical order appears automatically the arrows can be used to scroll the sequence of previous and successive MAKES in alphabetical order use the key CLEAR to delete the text entered the last line of the window indicates the result of the search 04 L
136. trically 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 IDEA 2fuses 4 Amps rapid located next to the power socket on the back of the machine next to the main switch fig 133 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 Fig 133 4fuses F1 F2 FA F1 10 Amps delayed protects the cutter motor and its electronic controls 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 134 protecting the board from short circuits To check and or replace the fuses proceed as follows 1 turn the machine off and unplug it from its power supply cable 2 remove the bottom panel ch 7 9 to close fuse cap n 3 check and if necessary replace the fuses in the way described below Fig 134 to remove the fuse press the
137. turning it counter clockwise and remove the rod from its hole 6 place the cutters protective shield i back into position securing it with the screws i2 ATTENTION when replacing a worn cutter with a new one or with a re sharpened cutter consult ch 5 19 Gauging page 72 Copyright Silca 2004 17 IDEA 5 1 Fig 19 5 2 Operating Manual English USER S GUIDE INTRODUCTION The Users Guide provided below explains how to use the IDEA key cutting machine without a Personal Computer All the operations are explained step by step so that the machine can be used in the manual mode The personal computer programs available that can be connected to the key cutting machine are used to transmit data for the cutting and decoding of keys Personal computer programs eliminate the need to carry out certain functions manually and skip some of the screens in the User s Guide once the data have been transmitted When IDEA is used with a Personal Computer the User s Guide does not change its viewing logic except for the screens that are not required SYMBOL AND TERMINOLOGY For the sake of clarity below is a glossary of the commonly used symbols and terms connected with keys or key cutting machines These symbols and terms will be quoted in the text with a reference to this page but it will facilitate your reading if you go through them first Cutter 1 25 0 492 indicates the thickness in mm or inches of the c
138. urrently selected cutter B1 indicates the left hand bit of the key B2 indicates the right hand bit of the key Stem Head 1 initials to identify a key clamp rotating 100 initials to identify a key clamp reader K1 initials to identify a tailstock for gripping the key stem from the front E1 initials to identify a special adapter used for fitting certain types of keys fig 3 STOP 0 reference for fitting the key into the clamp or tailstock Y1 00 DEPTH OF BIT 1 Y2 00 DEPTH OF BIT 2 Silca Serial Number SSN serial number assigned by Silca to each system lock They are listed in Silca key catalogues or Silca software programs Make is the make of the lock related to the key to be cut Brass Steel indicates the material of the key to be cut to use the key cutting machine properly always check that the wording corresponds to the material of the key INITIAL OPERATIONS After positioning the key cutting machine on the worktop and connecting the power supply wire to the machine proceed as follows 1 make sure that the emergency push button is off 2 turn on the machine by means of the switch on the back 3 to check or edit the working parameters on the machine go to the Options 6 menu page 105 18 Copyright Silca 2004 Operating Manual English IDEA When the machine is turned on for a few seconds the display shows the internal software version and the machine model
139. utting in progress Copy 1 of 1 Copy 1 of 1 finished More copies No STOP Yes ENTER now press ENTER in order to continue 60 Copyright Silca 2004 Operating Manual English IDEA 5 15 POST READING ADJUSTMENTS TO MAKE TO THE KEY AFTER READING To correct any defects found on the original key proceed as follows ADJ POST READING 0 Delete adjustments 1 Front Rear conv 2 X specular conv 3 Cut depth correction 4 Bit correction Use the arrows Up Down to scroll NOTE asterisk next to one or more of the choices listed indicates that the relative adjustment has been made min LASER F 0 3mm 0 3 Fig 87 1 Bent teeth re aligned vertically over the projection of the support base The minimum distance between the edges must be at least 0 3 mm 2 Worn edges on the top part of positive teeth are squared over the projection of the maximum width and height read from the tooth 3 Ifthe base of negative teeth is worn depth is corrected up to the highest measurement for the side edges less worn as leverage is normally exercised on the centre 4 Steps read on very wide parts of the bit cutting close to the lock tooth identical adjacent cuts etc are aligned on the highest measurement if the difference is no more than 0 15 mm 5 Scratches wear or warping read on both the verti
140. with START To remove the key at the end of the cutting process carry out the same operations in reverse order Operating Manual English Adapter E3 Copy 1 of 1 Cutting in progress More copies Copy 1 of 1 finished No STOP Yes ENTER Fig 41 You can now press ENTER in order to make further copies of the key Select STOP to quit 34 Copyright Silca 2004 Operating Manual English IDEA 5 10 MUEL PUMP KEYS OPTIONAL Fig 43 THE SET COMPRISES E4 Adapter for Muel pump keys E4 ID used for cutting install between the rotating 51 and 1 tailstock 8 Adapter for Muel pump keys E8 ID used for reading install the place of the S100 B mobile clamp Note operations allowed only when decoding using SN 328 SN 329 SN 352 When the machine requires indicates on display adapter E4 or E8 proceed as in the example 0 Copy from original 1 Decode and Copy 2 Insert the cuts 3 Queue from PC Choose option 1 Decode and Copy Choose the SN required SN328 SN329 SN352 and proceed To read Muel keys proceed as follow READING MUEL PUMP KEYS DECODE SSN 328 Original on right Clamp S100 Stop 4 Adapt E8 START Copyright Silca 2004 35 IDEA 1 Loosen the screw G 1 on the S100 camp 2 Pull out the mobile clamp unit B 3 Fit the E8 adapter into the S100 clam
141. xis at zero point ALARM 2 Clamp not calibrated ALARM 3 HIGH TEMPERATURE Turn machine off ALARM 4 POWER Check fuse F4 ALARM 5 DIGITAL OUTLET Turn the machine off ALARM 6 CUTTER MOTOR Check fuse F1 ALARM 7 CUTTER MOTOR Motor circuit anomaly 110 Copyright Silca 2004 Operating Manual English N 8 The height of the bit read by electrical contact is too big Use a key blank with a lower bit height N 9 Indicates that a movement has taken place exceeding the depth limit for the cutting job in progress Possible causes a negative manual adjustment of Y has been made to the clamp or adapter used to grip the key anegative MANUAL adjustment of Y has been made to the circuit board by means of the SILCA KEY PROGRAMS program N 11 The message indicates that the key cutting machine cannot complete an X movement because it exceeds the limits set for the X axis Possible causes a positive MANUAL adjustment has been made to X on the clamp or adapter used to grip the key a positive MANUAL adjustment has been made on the circuit board by means of the SILCA KEY PROGRAMS program a cutter that is too thick has been used N 12 The cutter is working under pressure and the motor cannot guarantee the minimum number of revs Possible causes the key material has not been selected properly this parameter is important for setting the r

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