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1. 0000 take the electronic circuit board off unscrewing the 1 nuts off fig 50 mount the new electronic circuit board and re connect all cables all cable connections are polarised therefore cannot be connected incorrectly re fit the bottom panel and re position the machine on its workbench turn the machine on and launch the WIN TRANSFER program Fig 50 electronic circuit board 58 Copyright Silca 2002 Operating manual English UNOCODE 399 7 7 KEYBOARD DISPLAY REPLACEMENT turn the machine off and unplug it from its power supply cable remove the display s support by unscrewing the 2 B1 fixing screws fig 51 detach the flat cable and ground wire from the keyboard fig 52 unscrew the keyboard s fixing nuts and remove the keyboard from its support fit the new keyboard display repeating the operations described above backwards Fig 51 Fig 52 Copyright Silca 2002 59 399 Operating manual English 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 remove the vacuum system s connector U2 fig 53 3 unscrew the 6 M1 screws that secure the back panel fig 53 thus removing it Fig 53 7 9 ACCESS BOTTOM
2. 4 9 o ANALVWAOASNVAL eILICV aD J3SNVal L 131930 45 1 AJWADASNYAL AYO LYWaO AS VAL aOadV1ILN3A 1 7111 3 3 33ID19 11 LN3A 31591401510 HHGS d 339N3D530 aIDSSh Dd NH1108 A3N3D238W3 vZN3D2333N3 3lNVS Td 331113 D31114 14 341113 3031d022331N1 331114 HOLIMS 041714 4 ZHOS AO 2 Appendix Copyright Silca 2002 Operating manual English UNOCODE 399 2 z a lt ac Eu 10 08 lt v A uj O o m E O a x lt u ra Q cx aua 555 Lorry m m eee ee mA i x y 2D z lt o eo 2 9 RO ROSSO RED ROUGE ROJO ROT GIALLO YELLOW JAUNE AMARILLO GLEB AR ARANCIO ORANGE ORANGE ANARANJADO ORANGE NERO BLACK NOR Mx NEGRO SCHWARZ J7 BROWN 5 BRUN MARRON 24V BRAUN AZZURRO GND BLUE 12 AZUR AZUL BLAU ae G N 00000000 lt 2 5 I 5 zi a an lt gt lt lt 2
3. MAINTENANCE zm 53 7 1 HUE cc 7 2 MAINTENANCE OPERATIONS 7 3 2 7 4 BELT REPLACEMENT AND TENSION ADJUSTMENT eene 56 7 5 CHECKING AND OR REPLACING FUSES 57 7 6 ELECTRONIC CIRCUIT BOARD REPLACEMENT 58 7 7 KEYBOARD DISPLAY REPLACEMENT 5 erepto 7 88 ACCESS BACK COMPARTMENT 7 9 ACCESS TO BOTTOM COMPARTMENT 7 10 SENSOR REPLACEMENT 8 7 11 REPLACEMENT 7 11 1 MACHINE ZERO SETTING AFTER REPLACING THE PHOTOCELLS 72107 BRUSH REPLACEMENT esteso dee etai EAS 7 13 WIN TRANSFER PROGRAM 1 derent eter bete nene te 67 DISPOSING OF MACHINE 68 ASSISTANCE 69 9 0 1 HOW REQUEST SERVICE 69 Appendix 1 ELECTRICAL DIAGRAMS 22 22 l VII Operating manual English UNOCODE 399 Fig 1 REFERENCE GUIDE This manual has been produced to serve as a guide for users of the UNOCODE 399 electronic 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
4. 1 Serial No 2 Cutter material 3 Cutting speed 4 Carriage speed gt gt 5 Min distance 6 Modify keys stop 7 Preference 8 Language 9 Optical reader 10 Invers keyboard 11 Cutting check 12 Protected Systems Ser n 153214523123 Model 399 Keys cut SW Version _ _ _ Cutter Material 0 0 HSS 1 Hard metal See operating manual Cutting speed HSS Hd Met 300 400 100 400 200 700 Recommended speed Hard metal carbide 200 700 Copyright Silca 2002 45 UNOCODE 399 4 CARRIAGE APPROACH SPEED This is the speed at which the carriages move towards the cutting area before starting the cutting cycle We recommend to operate the machine with the Speed that is set 4000 If required the operator can adjust the carriage approach speed from a minimum of 1000 to a maximum of 5000 5 MINIMUM DISTANCE The number shown on the machine s display represents the X axis distance between the key blank shoulder and the beginning of the first cut fig 40 This function is extremely important with keys that require cuts on both sides as it ensures precise positioning on the key 2nd side Fig 40 The set figure is 50 hundredths of a mm which can be varied between 0 max 99 hundredths of a mm ATTENTION settings that are too high may render precise cuts impossible with the following message on th
5. UNOCODE 399 Operating manual D425338XA vers 5 0 2002 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 may 2004 Printed in Vittorio Veneto by SILCA S p A via Podgora 20 2 1 31029 VITTORIO VENETO TV Italy REFERENCE GUIDE 1 GENERAL MACHINE DESCRIPTION 1 1 MAIN CHARACTERISTICS 1 ec ct eet Erbe bee 3 42 led ee AIRE EIER 4 1 3 MAIN WORKING PARTS enn n een e nre nnne nnne nnne 5 1 4 TECHNICAL Mee Ue MERERI RR 6 1 5 ACCESSORIES PROVIDED eedem egomet 7 TRANSPORT 8 24 m ce EE EIE 8 2 2 UNPACKING ve 2 3 MACHINE HANDLING MACHINE INSTALLATION AND PREPARATION 3 1 CHECKING FOR DAMAGE 2 n rennen nnns 10 3 2 ENVIRONMENTAL CONDITIONS 2 2 10 3 3 POSITIONING AND 5 10 3 4 DESCRIPTION OF WORK 5 11 3 5 GRAPHICS T 11 SET UP AND USE OF THE MACHINE 12 4 1 KEYBOARD AND FUNCTIONS 12 4 2 USE OF THE CLAMP 4 3 CUTTING BY ELECTRIC CONTACT
6. open the rear compartment ch 7 8 page 60 unscrew the two brush caps M4 fig 65 remove and fit two new brushes replace the two caps M4 CO close the rear compartment carry out Test 7 to check proper operation ch 5 7 1 page 36 Fig 65 66 Copyright Silca 2002 Operating manual English UNOCODE 399 7 13 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 see ch 7 6 page 58 or loss of the internal machine program 1 replace the board with a new one if necessary 2 install on your personal computer the latest version received of the WinTransfer program and follow the instructions given on the instruction sheet provided with the program 3 read the serial number on the data plate on the back of the machine ch 5 8 page 45 and enter on the machine 4 gauge the machine according to the instructions in the manual as follow
7. 4 4 FITTING THE CLAMP TO THE MACHINE senem 16 4 5 CUTTER ge 16 4 6 CHANGING THE CUTTER U 16 4 7 INVERTING THE PULLEYS 17 OPERATING 2 nennen nenne nnne nn Kaaa 18 5 1 INITIAL OPERATIONS E 5 2 0 FROM AN ORIGINAL 5 3 1 GOPY BY CODE irre 5 31 SPECAL GASES icio ERU UP RR RR RASEN 5 3 2 LIMITED ACCESS DATA PROTECTED SYSTEMS 26 5 4 2 CODES acit 26 5 5 USE OF THE MACHINE WITH A PERSONAL COMPUTER ee 27 5 5 1 3 QUEUE FROM 5 5 2 KEY DECODING u itg Doe e 5 6 4 GALIBRATIONS L as 5 6 1 CALIBRATING THE V100 CLAMP 5 6 2 CALIBRATING THE R100 CLAMP E 5 6 3 CALIBRATING 5 5 6 4 MANUAL ADJUSTMENTS nennen n rnnn nitri n entres sten rennen 5 7 151 MAINTENANCE een tte bete tee bids ESTIS usa au rientro idees 5 7 2 MACHINE ZERO POINTS J ca ec 5 8 OPTIONS O feritate teens 5 9 ERROR MESSAGES idt ie iaa eia eiat edat
8. 4 using the provided belt tension plate and the W2 screw fig 45 adjust the belt s tension by turning the W2 screw 5 tighten the 4 W fig 45 screws back into place securing the motor 6 remount the bottom panel 56 Copyright Silca 2002 Operating manual English UNOCODE 399 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 electrically faulty Fuses must always be replaced with the same amperage and type rapid or delayed as indicated in this manual There are 6 fuses in the UNOCODE 399 2fuses 4 Amps rapid located next to the power socket on the back of the machine next to the main switch fig 47 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 use a flat screwdriver to open the flap covering the socket remove and check the fuses replacing them if necessary 2 Fig 47 4 fuses F1 F2 F4 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 ou
9. act iene di t ch tb te es Chapter 1 Transport and installation Chapters 2 3 s Use tra ee tte en een da Chapters 4 5 6 cett Chapters 7 8 9 TECHNICAL TERMS Common technical terms are used in this manual To assist those with little experience of keys and key cutting below is an illustration of the terms most frequently used Head Rim Stop Stem Tip Back Cuts AR D I I N Copyright Silca 2002 1 399 Operating manual English GENERAL UNOCODE 399 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 UNOCODE 399 is designed for cutting keys of ferrous materials brass silver nickel etc It must be installed and used according to the instructions 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 i
10. py wiring inside the Y axis carriage is not seeded properly or disconnected c defective electronic control board d wear on the brushes ch 7 12 page 66 b the F4 fuse on the electronic control board is faulty Copyright Silca 2002 53 UNOCODE 399 Operating manual English 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 Fig 42 a glass lent on the optical reader is dirty b i i c defective optical reader d defective electronic control board wiring between 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 a fuse on the electronic control
11. CUTTING UNIT READING UNIT CLAMPS CUTTERS Replacement of photocells YES YES NO NO Replacement of YES YES YES YES the electronic board see ch 7 6 58 seech 7 6 page58 see 7 6 58 see ch 7 6 page 58 Replacement of NO YES NO NO the Optical Reader unit Replacement of sensors NO NO NO NO Replacement of the cutter shaft NO NO Replacement of the ball screws NO PRELIMINARY OPERATIONS 1 2 turn the machine off and unplug it from its power supply cable remove the back panel ch 7 8 page 60 loosen the G1 and G2 grub screws that secure the X axis photocell disk fig 32 remove the bottom panel ch 7 9 page 60 disconnect the J1 Y axis cable from the carriage fig 33 unscrew the 3 B5 fixing screws and remove the Y axis protective cover by pulling it in the direction shown in figure 33 loosen the G3 and G4 grub screws that secure the Y axis photocell disk fig 35 pag 41 8 plug the Y axis J1 cable fig 33 and the machine s power supply cable back into place 9 turn the machine on and carry on with the procedures described on page 40 jil 2 III Q Too oo fel Copyright Silca 2002 39 UNOCODE 399 Operating manual English
12. ART GT10P arrow keys WA to scroll the lines SHIFT arrow keys WA to scroll 4 lines at a time SHIFT ENTER keys to show customer data and key item linked to the selected code When the START key is pressed the cursor will automatically position itself on the first key code that indicates the mark Copyright Silca 2002 27 399 Operating manual English 5 5 2 KEY DECODING The decoding function by means of the optical reader can be activated only when using a PC Decode S 50 After the decoding function is launched from the ORIGINAL on right program the machine s display shows the 2 following information 2 100 2 cs S 50 the data card used Side 1 1 insert the key into the R100 optical reader s side clamp 2 press START to begin the operation DECODING IN PROGRESS Side 1 NOTE if the key has 2 or more asymmetrical sides the machine s display will show the Li message waiting for computer data Waiting for Each side of the key to be decoded will m appear computer data Decode 5 50 ORIGINAL right Clamp 100 Pos 0 Side 2 START the Silca Key Program will then display the cutting data decoded from the ma chine Decoding OK See computer ATTENTION if a key decoding reading operation is started and the diameter of the cutting tool exceeds 60 4 mm e g cutter 06 0 64 6 mm the display
13. Slowly push the Y axis carriage manually from its right all the way to its left checking that the machine s display indicates OFF to ON NOTE if the ON OFF transition is not made contact Silca s Technical Assistance Dept Test 11 B AXIS PHOTOCELL This test can be carried out only when an optional clamp is installed on the machine e Test 12 PROTECTIVE SHIELD MICROSWITCH Lift and lower the protective shield checking that the machine s display indicates OFF to ON NOTE if the ON OFF transition is not made contact Silca s Technical Assistance Dept Test 13 ELECTRIC CONTACT Use any metal conductor to contact clamp to cutter checking that the machine s display indicates OFF to ON NOTE if the ON OFF transition is not made check the brushes or contact Silca s Technical Assistance Dept Test 14 KEYBOARD One at a time press all the keys except STOP checking that an asterisk appears for each key pressed Press the STOP key for last NOTE if the asterisk does not appear contact Silca s Technical Assistance Dept e Test 15 DISPLAY All points on the display should be obscured NOTE if this is not so contact Silca s Technical Assistance Dept e Test 16 CLAMP CODE This test can be carried out only when an optional clamp is installed on the machine Copyright Silca 2002 37 399 Operating manual English Test 17 INLETS This test can be carried out only when an auto
14. U protective shield U2 vacuum systems connector V swarf tray Fig 5 Copyright Silca 2002 5 UNOCODE 399 Operating manual English 1 4 TECHNICAL DATA Electricity supply 230V 50Hz 110V 60Hz 100V 50Hz Maximum absorbed power 230V 2 Amp 250 Watt 110 3 6 Amp 250 Watt cutter motor single phase and speed cutter hard metal carbide optional high speed steel HSS Tool speed 50Hz 1150 rpm 10 60Hz 1100 rpm 10 with pulleys inverted 50Hz 1830 rpm 10 60Hz 2700 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 universal 4 sided clamp to grip flat car and cruciform keys Runs X axis 57 mm Y axis 32 mm Dimensions width 500 mm depth 500 mm height 420 mm with raised shield 650 mm Mass 37 kg Noise level sound pressure Lp A 85 dB A cutting steel keys Copyright Silca 2002 Operating manual English 1 5 tool kit ACCESSORIES PROVIDED UNOCODE 399 UNOCODE 399 comes with a set of accessories for its operation and maintenance tools hex wrenches fuses supplied in a special tool kit comprising 4 mm allen key D300224ZZ Z1 template regulating disk D416657BA Tip stop with notch D402301BA LI o 5 mm allen key 030022572 Z2 template regulating block D41
15. Y axis photocell disk Y axis sensor Fig 33 CUTTING UNIT s 4 Calibrations 1 enter the Maintenance 5 5 Maintenance 6 Options 2 select Machine zero points 2 1 Test 272 2 Machine 0 point Operational keys use the VA keys to move the cursor to the option required and press ENTER or directly press the numbered key corre sponding to the option number 1 Cutting unit 3 select Cutting unit 1 2 Reading unit 4 remove the V100 clamp cutter side from ord E Install Z1 amp Z2 inser e emplate the clamp s bushing and secure them with the clamp s templates knob fig 34 See operating manual 6 remove the cutter ch 4 6 page 16 and insert the Z1 template into place fig 34 7 8 manually move the X and Y axis up until the Z1 and 72 templates make contact Move X and Y AXIS see fig 34 top view up until contact is made See operating manual 9 lower the protective shield and press START ATTENTION check that both the Z2 and Z1 templates TEMPLATE ERROR make perfect contact fig 34 If this does not occur the display will show an error No contact made message See operating manual 40 Copyright Silca 2002 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 i
16. only the previous setting values will remain valid 12 press ENTER to save the settings 13 remove the Z1 and Z2 templates 14 proceed with setting the reading unit READING UNIT 1 Select Reading 2 2 press ENTER 3 remove the R100 clamp optical reader side from its support 4 fit the Z2 template and the clamp s bushing securing it with the clamp s knob fig 64 5 lower the protective shield and press START the machine s zero settings are de tected by the optical reader when this operation is completed the machine s display will show the meas ured quotes ATTENTION if the STOP key is pressed the new settings Fig 64 will be lost If so only the previous setting values will remain valid 6 press ENTER 7 remove the Z2 template the new setting has been made UNOCODE 399 Pos sensors ON ON 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 Z2 template See operating manual START Zero detection in progress Measurements read X 4444 Y 3333 Save data No STOP Yes ENTER clamp s knob clamp s bushing on 22 Copyright Silca 2002 65 399 Operating manual English 7 12 BRUSH REPLACEMENT
17. 1 Cutting unit 2 Reading unit Install the Z2 template See operating manual START Zero detection in progress Measured quotes X 4444 Y 3333 Save measurements No STOP Yes ENTER Fig 39 44 Copyright Silca 2002 Operating manual English 5 8 OPTIONS 6 1 Enter Options menu 6 Operational keys use the W keys to move the cursor to the option required and press ENTER or directly press the numbered key corre sponding to the option number 1 SERIAL NUMBER displays the machine s serial number that should correspond to the serial No that is stamped on the back of the machine Model type of Unocode Keys cut numbers of keys cut SW Version Software version of the program installed on the machine 2 CUTTER MATERIAL The option cutter material shows all the HSS enter 0 or hard metal enter 1 cutters By inverting the pulleys two cutter rotation speeds be obtained low speed for HSS tools high speed for hard metal carbide tools Inversion of the pulleys gives the first or second Speed according to the method described in Ch 4 7 page 17 3 CUTTING SPEED Corresponds to the carriage advancement speed during the key cutting operation On the basis of the cutter material selected Speed can be altered as shown in the table cutter metal UNOCODE 399 4 Calibrations 5 Maintenance 6 Options
18. Copy by code and or List of codes Copyright Silca 2002 47 399 Operating manual English 11 CUTTING CTRL This option is used to enable and disable control of Enable check on the combinations included in the data card by excluded NER IT keys TEM combinations YES efault is Le permanent control of the combinations entered to check compatibility with See operating manual the cutting path The control function follows given rules that prevent the operator from creating keys whose operation is not guaranteed 12 LIST OF ENABLED SYSTEMS ACTIVATED AND REMOVAL OF AN ACTIVATION PROTECTED SYSTEMS To read the list of data cards enabled select menus 6 12 Select the item in menu 1 to see the Machine Identification Number PROTECTED SYSTEMS 1 Machine ID 2 Enabled Systems Select the item in menu 2 to see the list of Enabled Systems ENABLED SYSTEMS 1 CARD 121 2 CARD 234 3 CARD 20 To delete an enabled system place the cursor on the line to be eliminated and press the CLEAR key 48 Copyright Silca 2002 Operating manual English UNOCODE 399 5 9 ERROR MESSAGES The selected data card is for a different clamp from the one installed on the machine Install proper clamp The entered data card number is not available in the machine s data base The entered cuts cannot be carried out see Ch 5 3 1 page 22 Non feasible
19. NO NO Replacement of sensors NO NO NO Replacement of the cutter shaft YES NO NO Replacement of the ball screws YES YES NO NO V100 clamp replacement NO NO YES NO with a new one of the same type V100 clamp replacement NO NO YES NO with a new one of the same type Re sharpening of existing cutter and or NO NO NO YES cutter replacement with a new one of the same type Installation of optional clamps NO NO YES NO if applicable 1 Enter the Calibrations menu 4 4 Calibrations 5 Maintenance 1 Clamps 2 Select Clamps 1 2 Cutters 3 Adaptors 5 6 1 CALIBRATING THE V100 CLAMP Clamps V100 CUTTER SIDE V101 V102 Before starting the clamp calibration make sure that there are no keys and or adapters fitted in the V100 and or R100 clamp V100 SIDE A Operational keys Adjustment SIDE A SHIFT ENTER to select and visualize each side of the clamp X 00 00 where applicable STOP to exit the menu To calibrate START Copyright Silca 2002 29 UNOCODE 399 7 ATTENTION replace the cutter with the Z1 template fig 27 To remove the cutter follow the instructions on page 16 ch 4 6 Changing the cutter insert the Z3 template to the side of the V100 clamp that is shown on the machine s display close the protective shield press START this will automatically start the setting oi the V100 clamp by means of electric contact be
20. THE CLAMP V100 Clamp cutter side Clamp OPTICAL READER side Fig 11 7 The four sided clamp ensures excellent grip on the keys placed on their back or profile sides fig 12 Keys with 1 or 2 cuts to reproduce by code should be fitted mainly on the A and or B side of the clamp When copying with the optical reader the key can be fitted to any side A B C or D of the clamp ATTENTION never invert the clamps For keys to be cut by code the side of the clamp on which to place the key is shown on the machines display For keys to be copied with the D side optical reader the side of the clamp to be used is at the dis cretion of the operator To fit keys with tip stops on the optic reader clamp fit the bar provided into the special grooves fig 13 Fig 12 A side C side TERRE B side Fig 13 key stops Copyright Silca 2002 13 399 Operating manual English ATTENTION whenclosing the clamp do not apply excessive pressure to the knob Turning the knob approximately 70 equal to a force of 3NxM is sufficient to secure the key fig 14 Fig 14 NOTE before starting the cutting process the V100 clamps key gauge will automatically tilt itself to its resi position USING THE PINS Copying with the optical reader For keys with narrow stems the pins must be placed between the bottom of the clamp and the back of the key so t
21. board faulty b short circuit on inlets or outlets To find which inlet or outlet is causing the error message discon nect the J4 5 7 8 12 14 15 20 connectors one at a time and check each time whether the alarm disappears 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 4 fig 43 C cutter motor wiring disconnected d internal fault on the electronic control board Fig 43 54 Copyright Silca 2002 Operating manual English UNOCODE 399 7 2 MAINTENANCE OPERATIONS Cutter replacement Beltreplacement and tension adjustment Fuse check and replacement Electronic 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 44 4 loosen the cutter
22. combination This message appears when the cutter must be changed with one that is compatible to the type of cuts required for ATTENTION the entered data card number Install cutter 001 This clamp is not available in the machine s data base Clamp not available This cutter is not available in the machine s data base Cutter not available This adapter is not available in the machine s data base entered data card number requires a type of cut that is not available in the machine s data base minimum distance from the key stop position overlaps the first cut on the key Ch 5 8 page 45 This message appears when the cutter is unable to identify the keys measurements when cutting by means of electric contact During the cutting cycle one or more depth exceeded the maximum limit These depths ATTENTION are automatically aligned to the maximum Depth limit permitted depth exceeded Data card not compatible with clamp installed Data card not available Adaptor not available Type of cut not available MIN Parameter of DISTANCE FROM STOP is incompatible with selected card POSITION ERROR Key not properly installed Copyright Silca 2002 49 UNOCODE 399 During the reading or decoding cycle the machine s optical reader verified that the key gauge had not been lowered The automatic setting revealed a variation that exceeded
23. cycles disposed off or to be disposed off 68 Copyright Silca 2002 Operating manual English UNOCODE 399 9 9 1 ASSISTANCE Silca provides full service to purchasers of the UNOCODE 399 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 How TO REQUEST SERVICE The guarantee attached to the 399 UNOCODE 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 Copyright Silca 2002 69 Operating manual English UNOCODE 399 Appendix 1 ELECTRICAL DIAGRAMS The following pages contain the electrical diagrams for the UNOCODE 399 key cutting machine described in this manual Copyright Silca 2002 Appendix 1 UNOCODE 399 Operating manual English UNOCODE 399 ELECTRICAL DIAGRAMS 1 0 J 25222 f 5 8159 7 5 1 Em 298642 19 J 4234 in o9 mo an FA 10 man F4 2 le D F2 63A Jf 4 2 9 amp S e DL2 5 5 5 3 2 1 26 Daaa aal
24. for keys without a shoulder stop from 0 to 9 99 mm To insert the Dist distance quote you must first enter the Pos stop position from 1 to 4 The entered Pos stop position cannot be stop 0 Pos must be 1 2 3 or 4 Example with tip stop 2 the cuts must start to be read at least 2 mm before the normal starting posi tion stop 0 Fig 22 Operational keys numerical keys to enter the distance in the Dist field SHIFT arrow key chooses the clamp from those availa ble for the reading unit with R prefix the clamp sides and stop are automatically set up Important the last reading clamp set ting remains until another one is selected 3 Place the key to be cut in the V100 cutter side clamp ATTENTION use the same side and stop position as the key fitted to the R100 optical reader side clamp during the reading process the key is partially cut it will be completed only at the end of the reading process 4 Close the protective shield if the shield is not lowered when the START button is pushed the following warning message appears UNOCODE 399 0 Copy from original 1 Copy by code 2 List of codes 3 Queue from PC Original on right Clamp R100 _ ABCD Pos 0 0 4 Dist 000 START READING IN PROGRESS Close shield Copyright Silca 2002 19 UNOCODE 399 Data alteration The opera
25. in the Options menu can in any case be disabled ch 5 8 Copyright Silca 2002 23 UNOCODE 399 Types of cut Operating manual English All the data cards provided by Silca have the type of cut pre set according to the original parameters The types of cut possible with UNOCODE 399 are Normal Flat Laser and Vertical bow EXAMPLE OF HOW TO CHANGE THE TYPE OF CUT NORMAL For conventional car and door keys FLAT Mainly used for car keys where the cut edges are rounded to facilitate the movement of the blades when the key is put into the lock LASER Conjunction of the cutting angles is determined automatically by the machine allowing cuts to be made with variable angles this facilitates the smooth entry of the key into the lock prolonging the working life of the key VERTICAL Necessary for special keys with small bits Silca art FO19P FO21P where a special cutter is required When this cutting method is used a special angled cutter is needed Enter card number All the technical data regarding the types of STANDARD 50 cuts stored in the machine s memory can be USER 0 changed according to the user s requirements ver DB 1 1 enter data card number e g nr 50 2 before entering the cuts press combination of keys SHIFT ENTER the Side 1 x2 5 50 Possible depths 1234 3 enter the L type cut by pressing the SHIFT L keys to set the laser typ
26. locking nut turning it clockwise with the19 mm 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 Fig 44 WARNING when replacing a worn cutter with a new one or with a re sharpened cutter consult ch 5 6 4 Calibrations page 29 Copyright Silca 2002 55 UNOCODE 399 7 4 Operating manual English BELT REPLACEMENT AND TENSION ADJUSTMENT To replace the belt proceed as follows turn the machine off and unplug it remove the back panel Ch 7 8 page 60 remove the bottom panel Ch 7 9 page 60 loosen the 4 screws W securing the motor fig 45 remove the worn belt from the pulleys fit the new belt onto the pulleys making sure that the direction of rotation is correct using the provided belt tension plate and the W2 screw fig 45 adjust the belt s tension by turning the W2 screw tighten the 4 W fig 45 screws back into place securing the motor remount the back and bottom panel W Ne TK AN N Fig 45 Fig 46 To adjust belt tension proceed as follows 1 turn the machine off and unplug it 2 remove the bottom panel Ch 7 9 page 60 3 loosen the 4 screws W securing the motor fig 45
27. 00 clamp see fig 28 turn the V100 clamp to side D insert the Z3 template into the clamp and proceed with the settings following the same procedure described for side A make sure that the Z3 template is properly inserted into side D of the V100 clamp see fig 28 Operational keys SHIFT ENTER to select and visualize each side of the clamp START to begin the setting procedure STOP to interrupt the setting procedure ATTENTION Fig 28 after calibrating all sides of the V100 clamp remove the Z3 template from the V100 clamp remove the Z1 template from the cutter shaft replacing it with a cutter 73 side C side D UNOCODE 399 V100 SIDE B Adjustment SIDE B X 00 Y 00 To calibrate START V100 SIDE C Adjustment SIDE C 00 00 calibrate START V100 SIDE D Adjustment SIDE D X 00 00 To calibrate START Copyright Silca 2002 31 UNOCODE 399 5 6 2 CALIBRATING THE R100 CLAMP OPTICAL READER Before starting the clamp setting make sure that there is no key and or adapter fitted in the V100 cutter side clamp 1 enter the Options menu and select option 1 Clamps The symbol indicates that the selected clamp has more than one side Operational keys SHIFT ENTER to select and visualize each side of the clamp where applicable STOP to exit the menu 2 fit the
28. 2 A oon OF ED Lo FOTOCELULA EJE X FOTOZELLE ACHSE X Copyright Silca 2002 Appendix IV Operating manual English RO AR GIALLO YELLOW JAUNE AMARLLO AZ MARRONE BROWN BRUN MARR N RO ROSSO G e gt o VE VERDE AZ AZZURRO Bl BIANCO WHITE BLANC BLANCO WEISS FOTOCELLULA ASSE Y PHOTOCELL AXIS Y CELLULE PHOTOELECTRIQUE AXE Y FOTOCELULA EJE Y FOTOZELLE ACHSE Y JA2 UNOCODE 399 E MT trc 1 M SY UR Y INS c3 2 x GND co SENSOR Y x m Lo lt lt lt LJ lt Copyright Silca 2002 Appendix V Operating manual English UNOCODE 399 2 5 9 22 TAN Ro 5 _ 225 853626 Usa 6 1 00 1 or 2 071 op ALIMENTATORE AUTOMATICO AUTOMATIC FEEDER ne ALIMENTATEUR AUTOMATIQUE ALIMENTADOR AUTOMATICO AUTOMATISCHE ZUFUHRER SY BONONSRARARS N01 1 NO GND vec 13 GND 12 13 veo n GND 10 VLED 9 SER DIN 8 SER DIN 7 SER RES 6 SER RES 5 4 3 2 1 du D SOOO IG PIC Coup CO SER DOUT SER DOUT SER CLK SER CLK VI Appendix Copyrig
29. 6660BA Tip stop D402302BA Cutter release rod D400754BA 13 mm spanner 10 mm spanner 030030877 F 202 030278877 030118577 6 mm allen key 030022672 2 Amp luse delayed 031242327 4 Amp fuse rapid 10 Amp fuse delayed 031656877 Z3 template regulating key D416658LR Z4 serial test connector 041666177 n LJ Belt tension plate D416552BA 020244377 Anti tilting device 050869977 1 5 mm allen key 030243477 IN 4 Amp fuse delayed 030872677 Slanted brush D306935ZZ 2 mm allen key 030022177 2 5 mm allen key 030022277 3 mm allen key 03002232727 6 3 Amp fuse delayed 031065277 19 mm socket wrench D306963ZZ laser CLASS 1 LASER EQUIPMENT warning labels D416816XA D416817XA ES LASER OPENING 9 1 7 mm steel pin 040122577 9 1 2 mm steel 040122477 T 3 s WIN TRANSFER program disk Copyright Silca 2002 399 Operating manual English 2 2 1 Fig 6 TRANSPORT The key cutting machine is easily transported and is not dangerous to handle The packed machine should be carried by at least two people PACKING The packing for UNOCODE 399 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 m
30. 7 4 page 56 8 remount the back and bottom metal panel 9 enter the cutter material function in ch 5 8 Options 6 page 45 and alter the speed OE Oo MS Aui motor shaft for HSS cutter for carbide cutter Fig 21 Copyright Silca 2002 17 399 Operating manual English 5 OPERATING GUIDE Introduction The Operating Guide below explains how to use the UNOCODE 399 without a Personal Computer All operations to manually use the key cutting machine are explained step by step The programs available for Personal Computers connected to the key cutting machine are able to transmit data for cutting reading or decoding keys Programs for Personal Computer eliminate manual procedures of certain functions once the data has been transmitted to the machine it bypasses some of the operating guides screens When the UNOCODE 399 is used with a Personal Computer the operating guide does not change its displays logic with the exception of all the screens that are rendered unnecessary 5 1 INITIAL OPERATIONS When the key cutting machine has been placed on its workbench and connected to the mains Ch 3 3 page 10 proceed as follows 1 make sure that the emergency button is not turned on 2 turn the machine on by means of the main switch that is located on the back of the machine 3 to chec
31. 99 9 Y axis sensor oy N Ke SEA bottom view ATTENTION if itis necessary to work close 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 Fig 37 Fig 38 Copyright Silca 2002 43 UNOCODE 399 READING UNIT Operational keys use the VA keys to move the cursor to the option required and press ENTER or directly press the numbered key corresponding to the option number 1 enter the Maintenance menu 5 2 select Machine zero points 2 3 select Reading unit 2 4 remove R100 clamp optical reader side from its support 5 install the 72 template the clamp s bushing and secure them with the clamp s knob fig 39 6 lower the protective shield and press START the machine s zero settings are detected by the optical reader when this operation is completed the ma chine 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 Operating manual English 4 Calibrations 5 Maintenance 6 Options 1 Test 2 Machine 0 point
32. COMPARTMENT To gain access to the bottom compartment proceed as follows 1 turn the machine off and unplug it from its power supply cable remove the vacuum system s connector U2 fig 53 turn the machine on its back side remove the machine s bottom panel by unscrewing the 8 L1 screws Fig 54 60 Copyright Silca 2002 Operating manual English UNOCODE 399 7 1 SENSOR REPLACEMENT X AXIS SENSOR REPLACEMENT 1 turn the machine off and unplug it from its power supply cable remove the bottom panel chap 7 9 Access to bottom compartment disconnect the X axis sensor s connector from the electronic circuit board fig 55 4 loosen the L3 nut Unscrew the sensor from the plate and remove it fig 56 remove the front cover on the X axis lower carriage fig 57 by unscrewing the 3 B4 screws fit the new sensor in position tightening it until it almost touches the L2 screw fig 56 thus securing it with the L3 nut 7 connect the sensor s connector to the electronic circuit board 8 remount the bottom panel and front cover Fig 55 2 SI Hcc 0 1 0 4 mm A Z N Fig 56 Fig 57 Copyright Silca 2002 61 399 Operating manual English Y AXIS SENSOR REPLACEMENT 1 turn the machine off and unplug it from its power supply cable raise the protecti
33. ECTION ALARM Turn the machine off CUTTER MOTOR ALARM Check fuse F1 50 Copyright Silca 2002 Operating manual English UNOCODE 399 Indicates fault on the electronic control board CUTTER MOTOR ALARM Fault on motor circuit The Machine ID has not been set In such cases access cannot be gained to Protected Systems ERROR until the Machine ID is set Select menu 6 12 1 Machine ID and check that the Machine ID is different from not defined 0 To set Machine ID ask for a Software update valid for your machine machine internal program version higher than or the same as 2 0 078 and install with the SILCA WinTransfer Program or SILCA Code Program See operating manual Copyright Silca 2002 51 399 Operating manual English 6 CLEANING keep the operational parts of the machine as clean as possible by brushing away the chippings in areas where they accumulate during cutting operations under no circumstances must compressed air be used to clear the work zone of chippings as this will blow them onto the moving parts Never use oily products or thinners for cleaning painted surfaces clamps electrical or electronic connections 52 Copyright Silca 2002 Operating manual English UNOCODE 399 7 MAINTENANCE ATTENTION for repairs or replacement of parts for maintenance the mark is guaranteed only if original spare parts provided by the manufacturer a
34. 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 DATA CARD If the key cutting card is protected access is denied Gain access to protected data in the following way request the maker s authorization communicate to Silca The 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 No 11 When card 11 is selected from menu 1 the following appears on the screen PROTECTED CARD Mach ID 12345 Code 5 5 00011 Password 0 When authorization has been received from the maker apply to Silca for a password providing 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 12 1 on the machine ACTIVATION Code 5 5 00011 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 the password shows No STOP Yes ENTER The password can be saved so that it need not be entered whenever the p
35. Z3 template to side of clamp R100 fig 29 ATTENTION lower the key gauge 3 press START to proceed with automatic setting of side A during this operation the settings are read by the optical reader 4 press ENTER to save data ATTENTION if the STOP key is pressed the new settings will be lost If so only the previous setting values will remain valid NOTE the settings will be accepted only if the tolerances remain within a range between 40 40 hundredths of a mm if the tolerances exceed the acceptea range the machine s display will show an error message carefully follow the instructions ana repeat the procedure Operating manual English 1 Clamps 2 Cutters 3 Adaptors 5 R100 R100 Adjustment SIDE A gt gt 00 Y 00 To calibrate START R100 Install the Z3 template See operating manual START R100 SIDE A Detection in progress R100 SIDE A X 023 009 Save data No STOP Yes ENTER Exceeded setting tolerance limit X 450 y 1 See operating manual ones 32 Copyright Silca 2002 Operating manual English ATTENTION ATTENTION Fig 29 the operational sequence will continue and the display will show the settings for sides B C D turn the R100 clamp to side B insert the Z3 template into the clamp and proceed with the settings following the
36. achine 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 oes 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 Copyright Silca 2002 Operating manual English UNOCODE 399 2 2 2 3 UNPACKING To remove the machine from the packing box 1 cutthe 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 use the special spanner provided in 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 1 UNOCODE 399 key cutting machine 1 set of documents including an operating manual a spare parts list and a guarantee 1 power supply cable 1 tool kit NOTE we strongly recommend you keep the packing intact for future transportation MACHINE HANDLING When the UNOCODE 399 has been unpacked place it direc
37. bration Copyright Silca 2002 35 399 Operating manual English 5 7 5 MAINTENANCE 4 Calibrations 1 enter the Maintenance menu 5 5 Maintenance Operational keys 6 Options use the VA keys to move the cursor to the option required and press ENTER or directly press the numbered key corre sponding to the option number 5 7 1 TESTS There is an on board TEST menu that should be 1 Test used to verify the cause of any breakdown that na na may occur to the machine 2 Machine 0 point 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 if the OFF ON transition is not made contact Silca s Technical Assistance Dept Test2 X AXIS MOTOR Carefully follow the instructions on the machine s display Check that the X axis carriage moves ATTENTION during this test function all end of run controls are disactivated avoid moving the carriage up against its mechanical stops NOTE if the motor does not start contact Silca s Technical Assistance Dept Test 3 Y AXIS MOTOR Carefully follow the instructions on the machine s display Check that the Y axis carriage moves ATTENTION during this test function all end of run controls are disactivated avoid moving the carriage up against its mechanical stops NOTE if the motor does not start contact Silca s Technical As
38. ce 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 Machine identification The machine is provided with an identification label which includes the machine s serial number fig 2 SILCA SpA Manufacturer s e PODGORA 20 2 1 identity 31029 VITTORIO V TO TV ITALY lt Tel 0438 9136 Fax 0438 913800 e mail info silca it TIPO Type of machine TYPE pos Working MATRICOLA Serial No voltage gt uz w A Absorbed current CE mark S lt MADE ITALY Year of Working N Absorbed manufacture frequency N power Fig 2 2 Copyright Silca 2002 Operating manual English UNOCODE 399 Fig 3 1 1 MACHINE DESCRIPTION UNOCODE 399 is an electronic machine operating on two axes with controlled movement Accurately studied it adds a high degree of cutting precision to operating speed and ease of use UNOCODE can be used in 3 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 PC and Silca software MAIN CHARACTERISTICS Movements Movement of the two axes X Y operates on ball screws activated by step motors on rectified roller guides Clamp Standard fo
39. ckwise to disactivate it NOTE the operator is responsible for keeping the area around the button clear so that it can be reached as quickly as possible Laser warning Regulations require that warning labels in the language to be used be attached to the laser reader as shown in fig 4 LLLA APERTURA LASER LASER OPENING ao CLASS 1 LASER EQUIPMENT Fig 4 laser warning Cutter motor protection The cutter motor is protected against overheating by a cut out switch located inside the motor that will automatically stop the motor if it reaches a certain temperature Should the switch activate 1 turn the machine off and disconnect the power supply cable 2 contact Silca s Technical Assistance Dept 4 Copyright Silca 2002 Operating manual English UNOCODE 399 1 3 MAIN WORKING PARTS OS EO A master switch B keyboard C display D clamp cutter side D1 clamp optical reader E clamp knob 1 optical reader clamp knob F key gauge cutter side F1 key gauge optical reader side H cutter cutter shield L optical reader N emergency button O 3rd axis P IN OUT port Q serial port R Y axis connector S X axis carriage T Y axis carriage
40. d to any side of the clamp when the data card is enabled for electric contact Operating keys SHIFT START changes the cutting procedure standard or by electric contact and starts cutting START begins the cutting process ATTENTION the alternative selected with the SHIFT START keys standard or by electric contact is maintained as long as the chosen data card is in use When the procedure has been selected simply press START for successive cutting operations Copyright Silca 2002 15 UNOCODE 399 Operating manual English 4 4 FITTING THE CLAMP TO THE MACHINE To remove the clamp unit loosen the grub screw 02 fig 18 and slide the clamp out of the dovetail guide To install the clamp unit on the machine Slide the clamp into the dovetail guide pushing it all the way in then secure it by tightening the grub screw D2 These instructions refer exclusively to the standard clamp V100 For the use of optional clamps please refer to the instructions provided along with them pr n cio Fig 18 4 5 CUTTER The majority of keys utilize the standard cutter 001 for code cutting Only in certain cases some special keys with particular type cuts require different cutters To change the cutter see chapter 4 6 4 6 CHANGING THE CUTTER 1 raise the protective shield 2 remove the cutter protective shield i by loosening the screw i2 3 Mes the cutter release rod X into the h
41. e V100 clamp 4 close the shield and proceed with setting the cutter by pressing START the display shows the differences from the theoretical values NOTE the setting will be accepted only if the tolerance of the cutter s diameter remains within a range between 10 100 hundredths of a mm if the tolerances exceed the accepted range the machine s display will show an error message carefully follow the instructions and re peat the procedure ATTENTION once this operation is completed the Z3 template must be discharged of contact with the cutter skims the surface of the template therefore it would cause errors if used for future settings Operating manual English 1 Clamps 2 Cutters 3 Adaptors Cutters 00 U01 01 01 02 02 00 001 Adjustment Y 00 To calibrate START 00 001 Install the Z3 template See operating manual START 00 001 Detection in progress 00 001 Adjustment 002 Save data No Stop Yes ENTER Exceeded setting tolerance limit 110 See operating manual res 34 Copyright Silca 2002 Operating manual English UNOCODE 399 The operator may carry out manual adjustments by entering new X and Y parameter values 5 6 4 MANUAL ADJUSTMENTS CLAMPS CUTTERS ADAPTERS ATTENTION where applicable Adjustments be mad
42. e cut the letter in brackets L indicates the type of cut recommended by Silca S 50 001 NOTE for certain cutting methods the standard Cut type L L cutter U01 must be replaced with a Alternative N P V specific cutter ch 4 6 Changing the cutter page 16 4 enter the combination and proceed with the operations described in ch 5 3 page 21 Side 1 x2 S 50 112233 Possible depths 1234 24 Copyright Silca 2002 Operating manual English e Changing the cutter UNOCODE 399 Some of the data cards stored in the machine s memory require a different cutter from the standard UO1 cutter EXAMPLE WITH FO21P key Replace the cutter according to the instructions in ch 4 6 Changing the cutter page 16 Adapters Some of the data cards provided by Silca may show a new parameter Adapt 7 which indicates the type of accessory that is needed to cut the key in question See the Unocode Adapters leaflet included with the Unocode 399 machine Enter card number STANDARD 0 USER 0 ver DB 1 220 Side1 x4 Possible depths 1234 S 220 ATTENTION Install cutter 05 1 cutter 05 installed No STOP 5 ENTER Side 1 Clamp 100 A Pos 0 Cutter 001 Adapt 7 Pcs 1 1 START Copyright Silca 2002 25 399 Operating manual English 5 3 2 5 4 LIMITED ACCESS TO DATA
43. e display 6 MODIFY KEYS STOP Normally the machine does not require key shoulder stop adjustment If required it is possible to modify the key s shoulder according to the modification made to the key shoulder fig 41 If the operation is confirmed with SHIFT 4 items are required thickness X measurement of the shoulder stop to be cut is expressed in hundredths of a mm 0 max 99 height Y height of the shoulder read on the key using a calliper expressed in hundredths of a mm E g 3 300 hundredths depth H depth of the part to be removed expressed in hundredths referred to the measurement of the key blank length L movement of the cutter axis referred to X Operating manual English Carriage approach speed 4000 1000 5000 Min distance of cut from key stop 50 0 90 Min Parameter of DISTANCE FROM STOP is incompatible with selected card Modify key stop Enabled YES Thickness X 0 Height Y 300 Depth 100 Length L 50 X L Y a H gt Fig 41 Copyright Silca 2002 Operating manual English 7 PREFERENCES work parameters are chosen from this menu Inches or millimetres choose the measurements you intend to work with __ mm millimetres inch inches Start up menu choose the function in the Main menu that you would like to appear first when the machine
44. e within a range between 30 and 30 hundredths of a mm To adjust clamps and adapters the positive values of X will give the result shown in fig 30 Fig 30 For adjustments to cutters clamps adapters the positive values of Y will give the result shown in fig 31 Fig 31 The symbol indicates that the selected clamp has more than one side Operational keys place the cursor next to the parameter and enter the adjustment figure using the SHIFT arrow keys CLEAR to zero out adjustments ENTER or W to move the cursor from the X to the Y axis settings ENTER press in the final entry field to quit the menu STOP to exit the menu SHIFT ENTER to go from one side of the clamp to another when making manual adjustments ATTENTION if the STOP key is pressed the new settings will be lost If so only the previous setting values will remain valid such adjustments should be made only when the automatic setting has already been carried out 4 Calibrations 5 Maintenance 6 Options 1 Clamps 2 Cutters 3 Adaptors Clamps R100 Adjustment SIDE A gt gt X 00 Y 00 To calibrate START Q Cutters 00 001 Adjustments Y 00 calibrate START Q Adaptors B1 Adjustments X 00 Y 00 Save adjustments No STOP Yes ENTER Press START only if you intend to proceed with automatic cali
45. hat the key protrudes sufficiently out of the clamp and therefore can be properly read and cut If the key has narrow stem is also very thin 2 pins must be used see fig 15 Fig 15 If the original key is broken place a suitable sized pin in the groove of the keys stem so that it is properly held in place and therefore can be copied fig 16 NOTE the diameter of the pin used for the original key must be the same as that of the pin used for the blank key only in this way will the two keys be locked in the same position Attention the pin should be placed vertically Fig 16 14 Copyright Silca 2002 Operating manual English UNOCODE 399 4 3 Fig 17 CUTTING BY ELECTRIC CONTACT The UNOCODE 399 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 fig 17 This technical solution permits the operator to secure the key to the more appropriate side of the 4 faced clamp A B C or D therefore improving the grip on the key and eliminating the need of pins and or adaptors With the electrical contact card enabled depth calibration is automatically calculated when the cutter touches the keys profile during the cutting process Electrical contact is guaranteed for keys in
46. herefore can be re used if intact or if dismantled used as combustible materials Warning Take great care when dismantling the packing as it contains nails which could cause injuries We recommend to bend the nails downwards into the wood with a hammer or to completely remove the nails disposing them in authorized metal recycling centres The packing is considered solid urban waste and must not be thrown into the environment but placed in special cardboard collection bins Waste deriving from key cutting The waste deriving from key cutting is classified special waste but is still classified as solid urban waste as metal wool Such waste must be disposed of in special collection centres according to the classification assigned to them by the current EEC law The circumstances which transform metal residue from solid urban waste into contaminated or toxic noxious waste are listed in the appendices to the current European Union regulations regarding disposal of such waste 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 12 01 01 Paper and 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
47. ht Silca 2002 Operating manual English UNOCODE 399 5 ELETTROVALVOLA ASPIRAZIONE 244 154 SUCTION SOLENOID VALVE GND 2 o P ELECTROVANNE ASPIRATION ELECROVALVULA ASPIRADOR ELECTROVENTIL SPANEABSAUGANLAGE JA INPKEY ELETTRICU CHIAVE GND P ELECTRIC LECTRIQUE CONTACTO ELECTRICO ELEKTRISCH KONTAKT ND GND a MICRUINTERRUTTORE CARTER m MICROSWITCH SHIELD MICROINTERRUPTEUR CRAN MICROINTERRUPTOR MIKROSCHALTER SCHUTZ Co GND ENA CHARGE COMPA COMP2 2 LASER r3 LETTURE READER LECTERU OPTIQUE LECTOR UPTICHER LESER Copyright Silca 2002 Appendix VII Operating manual English UNOCODE 399 VIII Appendix Copyright Silca 2002 SILCA S p A Via Podgora 20 2 1 31029 VITTORIO VENETO TV Tel 0438 9136 Fax 0438 913800 wwWW silca it Member of the Kaba Group DO iy d
48. ing and secure them with the clamp s knob fig 63 6 remove the cutter from the machine Ch 4 6 page 16 and install the Z1 template fig 63 manually move the X and Y axes up until the templates make contact fig 63 top view 8 lower the protective shield and press START ATTENTION check that both the Z2 and Z1 templates make perfect contact If this does not occur the display will show an error message lt press START ATTENTION do not touch the X and Y axes carriages and press START 10 press START clamp s knob clamp s bushing Fig 63 4 Calibrations 5 Maintenance 6 Options 1 Test 2 Machine 0 points 1 Cutting unit 2 Reading unit Install Z1 amp Z2 templates See operating manual ENTER Move X and Y axis up until contact is made See operating manual START TEMPLATE ERROR no contact made See operating manual Pos Photocells TZX ON TZY See operating manual top view 64 Copyright Silca 2002 Operating manual English ATTENTION do not touch the X and Y axes carriages and press START 11 press START the machine s zero settings are de tected by electric contact when this operation is completed the machine s display will show the meas ured quotes ATTENTION if the STOP key is pressed the new settings will be lost If so
49. is turned on Main menu 0 Copy from original 1 Copy by code 2 List of codes 3 Queue from PC Attention press the CLEAR COPY key to void any selection made and to select the main menu function Quick menu when enabled 21 some operational functions will be skipped if admissible e g when 0 is selected in the Start Menu the display will show the following when the machine is turned on 8 LANGUAGE enter the number that corresponds to the language you intend to work with 9 OPTICAL READER the recommended reading speed is 350 if required the operator can adjust the setting min 100 max 350 10 KEYBOARD INVERSION This function inverts the alphanumerical keyboard numbers to letters fig 10 pag 12 With Inversion keyboard disactivated 0 e to digit number 1 press B to digit the letter H press SHIFT cp With Inversion keyboard enabled 1 10 digit number 1 press SHIFT to digit the letter H press Cy L mm 0 Start Menu UNOCODE 399 Quick Menu 0 ORIGINAL on right Clamp R100 _ ABCD Pos 0 0 4 Dist 000 START Select language 2 1 Italiano 2 English 3 Deutsch 4 Francais 5 Espa ol Reading Speed 350 100 350 Inversion keyboard function 0 1 enabled see Operating manual NOTE this function can be carried out from the main menu
50. itted over to the machine As the memory can be rewritten the Personal Computer updates the data cards automatically STANDARD data card S comprises the spaces and depths database as de scribed in the introduction to 5 OPERATING GUIDE page 18 The source of this information can be the SILCA Car Book Silca Code Program catalogues and other documents available from Silca USER data card U personalized data cards be created by means ol a function available in the Silca Code Program Cards be stored from the PC to the memory and the operator may recall them at any time 1 enter the data card No e g STANDARD 50 2 enter the cutting data ver DB 1 gives the number of the Silca board database ver sion installed on the machine the dots on the display represent the maximum number of cuts that are permitted The same data card can be used for a number of keys with different numbers of cuts If a key is used with fewer cuts than the dots shown on the display simply enter a partial combination 3 Press ENTER Clamp V100 The special symbol asterisk means that the cuts will be made by electric contact Ch 4 3 page 15 therefore it is unnecessary to select the clamp side Pos 0 Place the key to be cut into the V100 clamp cutter side using the stop that is shown Cutter U01 Recommended cutter Pieces enter the quantit
51. k or alter the parameters for use of the machine consult the Options 6 menu ch 5 8 page 45 When the machine is turned on for a few seconds the display shows the internal software version and the machine model UNOCODE 399 version 1 0 023 MAIN MENU Operational keys 0 Copy from original use the W keys to move the cursor to the option required 1 Copy by code and press ENTER or directly press the numbered key corre 2 List of codes sponding to the option number The gt gt symbol indicates that the menu contains other items which can be reached with the arrow key 3 Queue from PC gt gt 4 Calibrations 5 Maintenance 6 Options 18 Copyright Silca 2002 Operating manual English 5 2 0 Copy FROM AN ORIGINAL WITH THE OPTICAL READER 1 select the function Operational keys use the arrow keys VA to move the cursor to the option re quired and press ENTER or directly press the numbered key corresponding to the option number 2 insert the original key into the R100 optical reader side clamp Clamp R100 According to the type of key to be copied establish which side of the clamp the key must be inserted Enter A B C or D in the clamp sides fiela Ch 4 2 page 13 Pos 0 Key gauge stop by default the program always shows the 0 stop Ch 4 2 page 13 For keys without a shoulder stop enter the tip stop position 1 2 3 4 Dist 000 To be used only
52. l by unscrewing all 8 securing screws loosen the C3 screw fig 37 pag 43 that secures the sensor support plate Manually move the sensor support plate up until the display s description goes from OFF to ON tighten the C3 screw fig 37 pag 43 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 de tected by electric contact 12 when the operation has been completed the display will show the measured quotes 13 manually turn the Y axis disk to get access to the G4 grub screw fig 35 pag 41 14 manually turn the X axis disk to get access to the G2 grub screw fig 32 pag 39 15 use the provided allen key to tighten and lock ATTENTION the grub screws if the STOP key is pressed the new settings will be lost If so only the previous setting values will remain valid Operating manual English Pos sensors ICX OFF ICY OFF See operating manual START Pos sensors ICX OFF ICY See operating manual START Pos sensors ICX OFF ICY OFF See operating manual START Pos sensors ICX ON ICY ON See operating manual START o Zero detection in progress Measured quotes X 2 4444 Y 3333 Save measurements No STOP Yes ENTER 42 Copyright Silca 2002 Operating manual English UNOCODE 3
53. matic feeder or other optional component is installed on the machine Test 18 OUTLET 1 This test can be carried out only when an automatic feeder or other optional component is installed on the machine Test 19 OUTLET2 This test can be carried out only when an automatic feeder or other optional component is installed on the machine Test20 OUTLET 3 This test can be carried out only when an automatic feeder or other optional component is installed on the machine Test21 OUTLET 4 This test can be carried out only when an automatic feeder or other optional component is installed on the machine e Test 22 VACUUM SYSTEM This test can be carried out only when a vacuum system is installed on the machine Test23 SERIAL PORT Check that the machine s display indicates OFF Fit the special Z4 serial test connector accessories provided to the machine s serial port checking that the machine s display indicates OFF to ON NOTE if the ON OFF transition is not made contact Silca s Technical Assistance Dept 38 Copyright Silca 2002 Operating manual English UNOCODE 399 5 7 2 Fig 32 MACHINE ZERO POINTS With the use of regulating templates ch 1 5 Accessories provided page 7 the machine provides a self setting procedure These procedures must be carefully carried out following the descriptions and illustrations indicated below MACHINE ZEROES CALIBRATING Ch 5 6 page 29
54. n the disks face the photocells card Y axis photocell manually turn the Y axis disk fig 35 up until the displays description changes from OFF to ON use the provided allen key to tighten the G3 grub screw fig 35 X axis photocell manually turn the X axis disk fig 32 pag 39 up until the display s description changes from OFF to ON use the provided allen key to tighten the G1 grub screw fig 32 pag 39 10 lower the protective shield 11 press START the machine goes on to a new posi tion and is ready for regulating the Sensors clamp s knob clamp s bushing Fig 34 UNOCODE 399 Pos Photocell TZX OFF TZY OFF See operating manual START Pos Photocell TZX OFF TZY ON See operating manual START Pos Photocell TZX OFF TZY OFF See operating manual START Pos Photocell TZX ON TZY ON See operating manual START X 21 z2 top view Copyright Silca 2002 41 UNOCODE 399 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 36 in both directions up until the changeover point from OFF to ON is found tighten the C1 grub screw fig 36 to secure the rod Regulating the X axis sensor carefully tip the machine over remove the bottom pane
55. ncorrect use of the machine 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 CAUTION itis not permitted to cut ultralite anodized aluminium 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 FURTHER RISKS No further risks will arise when properly using the UNOCODE 399 PROTECTION AND SAFETY PRECAUTIONS FOR THE OPERATOR UNOCODE 399 is entirely built in compliance to the Machine Directives The operations for which it has been designed are easily carried out with no risk to the operator The adoption of general safety precautions and observation of the instructions provided by the manufacturer in this manual eliminate all human error unless deliberate UNOCODE 399 is designed with features which make it completely safe Power supply UNOCODE 399 is supplied with electricity by means of a grounded plug and differential switch Pneumatic power with compressed air Start up The machine is turned on by means of a master switch that is located on the Unocode s lower left back side Maintenan
56. ocess transmitted the number of pieces to be cut is set a sign shows when the cycle is finished The sign warns the operator that the last cutting operation has been carried out Should a work queue be interrupted turn off the UNOCODE 399 When the machine is turned on again and the PC queue is called up the list reappears starting from the first line 3 QUEUE FROM PC The data received from the PC are presented in one form only quantity of keys in queue transmitted key code 71 card number quantity of each code transmitted the mark indicates that all three keys or N 6 CODES RECEIVED more have been cut 100 234 3 the mark indicates that the total quantity 22 baal of keys referring to its code have not been cut 4 2315 122 5 5 1251 122 5 6 W109 567 5 Pressing the ENTER key takes us to the Copying by code procedure From this point on the operational functions are the same as those described in ch 5 3 page 21 C data card from PC Side 1 C 234 1234 Possible depths 1234 When the SHIFT ENTER keys are pressed additional data referring to the choosen code u can be visualized such as Customer s name Key blank Operational keys To quickly go to the next key to be cut strike the GIUSEPPE VERDI arrow key VV Doing so the operator starts from where she or he stopped the previous operation
57. ole located on the left side of the machines cutter shaft chassis fig 19 4 loosen the cutter locking nut turning it clockwise with the19 mm socket wrench X1 provided with the machine ATTENTION the thread is left handed 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 Fig 19 WARNING when replacing a worn cutter with a new one or with a re sharpened cutter consult ch 5 6 4 Calibrations page 29 16 Copyright Silca 2002 Operating manual English UNOCODE 399 4 7 INVERTING THE PULLEYS This operation must be carried out when the operator intends to use a high speed steel HSS cutter optional in order to adapt the cutter speed to the new characteristics of the cutter s material Fig 20 turn the machine off and disconnect the power supply cable remove the back and bottom metal panel ch 7 8 and ch 7 9 page 60 loosen the 4 motor locking screws W fig 20 and remove the belt loosen the 2 grub screws securing the pulley and remove it from the motor shaft fit the cutter shaft locking rod and use the allen key provided to loosen the screw A1 and grub screws A2 on the pulley fig 21 6 invertthe pulleys and secure them by tightening the grub screws fit the screw and washer on the cutter shaft 7 remount the belt and adjust its tension ch
58. r 001 Pcs 1 1 START When the machine is used manually with certain data cards it may not be possible to carry out certain entered combinations This happens when the cutting depths are not compatible in the order the user entered the possible cuts Example Enter card number STANDARD 174 USER 0 ver DB 1 5 0174 Possible depths 012345678 08213 non feasible combination 22 Copyright Silca 2002 Operating manual English UNOCODE 399 The reason for the conflict between certain cuts is explained simply in the case shown With regard to the cut that originated the message inadmissible combination it can be seen that between the two deep cuts 8 and the constant angle 1007 the intermediate cut 0 would be removed This happens when the cutting angle N Normal is not made variable by means of the type of cut L Laser page 24 Fig 25 The new drawing of the key shows how for the same cutting process 80846 the cutting angles are automatically calculated by the conjunction of the cutting base with a straight line This aspect admissible with certain car keys is more commonly known as the ideal cutting line ATTENTION in this example it can be seen that the angle is less than 45 This could cause serious problems with a lock making it difficult or impossible to place the key into the cylinder or remove it Fig 26 Control of the combinations
59. r 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 YandBaxesmotors 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 C 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 D3 fig 43 closed but the display reads close shield Keyboard not working a the keyboard connector is not properly connected to the interface board fig 42 b the wiring between the keyboard display unit and electronic control board is not properly attached to the relative connectors defective keyboard defective electronic control board Electric contact not wiring between the J14 connector on the electronic control board and cutter shaft is loose or dis working during connected calibrating or cutting
60. re used Although the UNOCODE 399 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 Replacement is simple and can be carried out by the operator consulting the instructions Before starting any type of maintenance controls or replacements read the instructions below never carry out maintenance with the machine switched on always remove the main power supply cable Strictly follow all the instructions in the manual use original spare parts see Spare Parts sheet provided 7 1 TROUBLE SHOOTING FAULT PROBABLE CAUSE Machine is on with no check to see if the back fan is working message its display Not working emergency button activated as fuses in the Socket connection wire between display and electronic circuit board loose cutter motor not a the closed shield is not making proper contact with the safety microswitch fig 43 working b the F1 fuse on the electronic control board is faulty moto
61. rotected data card is used or not saved so that access is limited only to the person in possession of the password 2 Lisr coDES ATTENTION function currently not available for future use 26 Copyright Silca 2002 Operating manual English UNOCODE 399 5 5 5 5 1 USE OF THE MACHINE WITH A PERSONAL COMPUTER In the previous pages the UNOCODE 399 key cutting machine has been analysed in all its parts from the point of view of manual use i e operating from the keyboard incorporated in the machine to cut keys by code It is now necessary to examine the very important facility with which it is possible to connect up to a PC in order to receive data directly from the computer Taken for granted that the user is in possession of some Silca software the following are the possibilities available The Silca Code Program makes it possible to carry out searches by code for cutting data and to store the information in a special work queue or file This is a special function which has been created to help those users who wish to work with a number of simultaneous searches After having carried out a code search the information is simply filed in the special work queue then everything is transferred to the UNOCODE 399 The information transmitted by the Personal Computer cannot be altered manually Each line transmitted corresponds to a stage in the cutting process for one or more keys As described above for each cutting pr
62. s gauge as explained in chapter 5 7 2 Machine zero points Cutting Unit and Reading Unit in the user s manual first gauge the V100 clamp ch 5 6 1 page 29 then the R100 clamp ch 5 6 2 page 32 At this point the machine is set up and ready for operation e SILCA 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 e Loading of customized key data cards provided 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 Copyright Silca 2002 67 399 Operating manual English 8 DISPOSING OF MACHINE To dispose the machine it must be rendered unusable by carrying out the operations listed below deactivation of the electricity supply Separation of the plastic and metal parts 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 399 UNOCODE 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 t
63. same procedure described for side A turn the R100 clamp to side C insert the Z3 template into the clamp and proceed with the settings following the same procedure described for side A make sure that the Z3 template is properly into side C of the R100 clamp fig turn the R100 clamp to side D insert the Z3 template into the clamp and proceed with the settings following the same procedure described for side A make sure that the Z3 template is properly a into side D of the R100 clamp fig UNOCODE 399 R100 SIDE B Adjustment SIDE B X 00 Y 00 To calibrate START R100 SIDE C Adjustment SIDE C X 00 Y 00 calibrate START R100 SIDE D Adjustment SIDE D X 00 Y 00 To calibrate START Copyright Silca 2002 33 UNOCODE 399 5 6 3 CALIBRATING CUTTERS For this procedure always use side A of the V100 clamp According to the cutter speed determined by fitting the pulleys in the way described in ch 4 7 page 17 and material chosen from the Options cutter material menu on page 45 the list will show all the HSS or hard metal carbide cutters distinguished by the suffix W 1 enter the cutters menu 2 Operational keys use the arrow keys YA to move the cursor to select the re quired cutter and press ENTER 2 fit the selected cutter to the machine 3 fita brand new Z3 template on side A of th
64. sistance Dept Test 4 B AXIS MOTOR This test can be carried out only when an optional clamp is installed on the machine e Test5 CUTTER MOTOR Carefully follow the instructions on the machine s display Check that the cutter motor is working NOTE if the cutter motor does not turn contact Silca s Technical Assistance Dept e 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 ma chine NOTE if the ON OFF transition is not made contact Silca s Technical Assistance Dept 36 Copyright Silca 2002 Operating manual English UNOCODE 399 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 towards the cutter NOTE if the ON OFF transition is not made contact Silca s Technical Assistance Dept Test8 B AXIS SENSOR This test can be carried out only when an optional clamp is installed on the machine Test9 X AXIS PHOTOCELL Slowly push the X axis carriage manually towards the machine s chassis checking that the machine s display indicates OFF to ON NOTE if the ON OFF transition is not made contact Silca s Technical Assistance Dept e Test 10 Y AXIS PHOTOCELL
65. steel brass silver nickel Zamak or iron with or without nickel plating Improper use of electric contact itis not permitted to cut ultralite anodized aluminium keys plastic keys or any keys with materials that do not have electrical conductivity by means of electric contact Attention for these types of materials insert standard cutting cuts cannot be repeated on the same side of the key when electric contact cutting is used data cards provided by Silca are in the machine s memory The cards are enabled or disabled for code cutting by electric contact at Silca s discretion The data cards are divided into 3 types which are distinguished by special symbols shown on the display asterisk and Side 1 1 Clamp 100 A START 100 Pos 0 data card with standard cutting press START 21 001 Adapt 0 Pieces START 2 100 8 START Side 1 data card with standard cutting press START Clamp 100 B Pos 0 alternative electric contact cutting press SHIFT START Cutter 001 Adapt 0 Pieces 3 START 3 100 START Side 1 data card with electric contact cutting press START Clamp 100 Pos 0 alternative standard cutting press SHIFT START Cutter 001 Adapt 0 Pieces 3 START A B indicate the side of the clamp indicates the alternative activated with the SHIFT START keys indicates that the key can be clampe
66. ter 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 display __ N function keys alphanumeric keys Fig 10 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 Combination of SHIFT amp CLEAR COPY enables you to automatically switch to the 0 e Copy from original function from any menu in the Unocodes internal program Ch 5 2 page 19 Pressed in combination with all the keys of the same colour to enter the number or letter available regulating the display itis possible to modify the angle of vision on the machine s display by following the instructions below incline the angle of the display towards the bottom you must press the W key and then press the key simultaneously keeping them both pressed WA until you reach the desired visualization to incline the visualization of the display towards the top you must press the key and then press the W key simultaneously keeping them both pressed A WV up until you reach the desired angle 12 Copyright Silca 2002 Operating manual English UNOCODE 399 4 2 USE OF
67. the permitted nominal figure setting reference Carefully repeat the setting procedure This message indicates that there is a fault in the optical reader or that something is obstructing its laser beam before starting the reading or decoding cycle During the setting of the machine s zero points there is a contact failure between the two templates see ch 5 7 2 page 39 This message indicates that during the reading cycle an anomalous form has been revealed that cannot be reproduced with the cutters provided Indicates that the entered function is not yet available The electronic control board has exceeded the maximum permitted temperature Check the cooling fan ch 7 1 Trouble shooting page 53 Indicates that the fuse has blown due to a short circuit in an inlet or outlet ch 7 1 Trouble shooting page 53 Indicates a short circuit in port P IN OUT ch 7 1 Trouble shooting page 53 Indicates that the fuse has probably blown ch 7 1 Trouble shooting page 53 Operating manual English KEY GAUGE ERROR key gauge out of place Exceeded setting tolerance limit See operating manual OPTICAL READER ERROR See operating manual TEMPLATE ERROR no contact made See operating manual READING ERROR Key cannot be copied Non feasible function TEMPERATURE ALARM Turn the machine off POWER ALARM Check fuse F4 DIGITAL OUTLET PROT
68. tly 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 7 Fig 7 INCORRECT CORRECT Copyright Silca 2002 9 399 Operating manual English 3 3 1 3 2 3 3 Fig 8 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 UNOCODE 399 is solid and compact and will not normally damage if transport unpacking and installation have all been carried out according to the instructions in this manual However it is always advisable to check that the machine has not suffered any damage 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 37 Kg to work with ease we suggest that the workbench be approximately the height of the operator s hip itis important
69. 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 10 Copyright Silca 2002 Operating manual English UNOCODE 399 3 4 DESCRIPTION OF WORK STATION The machine needs only one operator who has the following controls at his her disposal fig 5 page 5 master switch placed on the back of the machine key positioning clamp keyboard display emergency button 3 5 GRAPHICS The Plexiglass protective shield carries an adhesive warning label fig 9 This label must never be removed Two laser warning labels must be attached to the optical reader ch 1 2 page 4 T EE ER LASER OPENING d CLASS 1 LASER EQUIPMENT Do not use compressed air for cleaning laser warning labels Fig 9 Copyright Silca 2002 11 399 Operating manual English 4 SET UP AND USE OF THE MACHINE 4 1 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 charac
70. tor may alter the depth and space parameters Operational keys to increase or decrease the parameters use a combination of the SHIFT or SHIFT Depth from 99 to 99 hundredths of a Enter the figure positive or negative to raise or low er all the cuts Fig 23 depth adjustments Spaces from 99 to 99 hundredths of a mm Enter the figure positive or negative to move all the cuts closer to or farther from the key stop Fig 24 spaces adjustments Pieces enter the number required max 255 5 Carry out the same procedure to cut the remaining keys Operating manual English Adjustments Depth 00 Spaces 00 START Example Adjustments Depth 0 03 Spaces 0 02 START e Key blank on left 100 ABCD Dist 000 START Pos 0 Pcs 1 8 CUTTING IN PROGRESS Copy 1 of 3 Copy 3 of 3 Finished More copies No STOP Yes ENTER 20 Copyright Silca 2002 Operating manual English 5 3 1 Copy Bv CODE UNOCODE 399 One part of the machine s memory is used for the data cards A data card is a database of cutting spaces depths and angles for all the keys in the machines data base The number of data cards is increased periodically when the Silca Code Program is updated The updates can be bought separately and easily installed to a P C then transm
71. tput 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 48 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 page 60 3 check and if necessary replace the fuses in the way described below to remove the fuse press the fuse cap with your fingers and turn it counter clockwise To fit the new fuse carefully position the fuse back into place then gently press the fuse cap downwards turning it clock wise e r e F4 to close fuse cap electronic circuit board Copyright Silca 2002 57 UNOCODE 399 7 6 Fig 49 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 page 60 3 disconnect all cable connectors from the electronic circuit board fig 49 D Operating manual English
72. tween the two templates the display shows the differences from the theoretical values to save the data press ENTER if the STOP key is pressed the new settings will be lost If so only the previous setting values will remain valid NOTE the settings will be accepted only if the Fig 27 tolerances remain within a range between 40 40 hundredths of a mm if the tolerances exceed the acceptea range the machine s display will show an error message carefully follow the instructions ana repeat the procedure Operating manual English V100 SIDE A Install Z1 amp Z3 temp See operating manual START Detection in progress V100 SIDE A V100 4002 Save data SIDE A Y 004 No STOP Yes ENTER Exceeded setting tolerance limit 50 2 See operating manual 30 Copyright Silca 2002 Operating manual English ATTENTION ATTENTION the operational sequence will continue and the display will show the settings for sides B C and D turn the V100 clamp to side B insert the Z3 template into the clamp and proceed with the settings following the same procedure described for side A turn the V100 clamp to side C insert the Z3 template into the clamp and proceed with the settings following the same procedure described for side A make sure that the Z3 template is properly inserted into side C of the V1
73. ur sided clamp specially designed to grip most flat keys 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 2002 3 399 Operating manual English 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 5 page 5 must be raised in order to fit keys for cutting or carry out other operations Raising of the shield is controlled by a microswitch and disactivates the operating and movement functions including the cutter A special message appears on the display to warn that the shield is not closed To re start the work cycle place the shield in its original position and press START on the machine s keyboard Emergency stops The red emergency button N fig 5 page 5 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 clo
74. ve shield disconnect the J1 Y axis cable from the carriage fig 58 remove the Y axis carriage cover by unscrewing the 3 B5 locking screws and pull the cover in the direction shown in fig 58 disconnect the sensor s connector fig 59 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 60 Tighten the M2 grub screw to lock the sensor into place 8 connect the M3 sensor s connector 9 replace the Y axis carriage cover 10 connect the J1 Y axis connecting wire to the carriage S Sig m Sa Fig 58 Y axis sensor Fig 59 Y axis sensor d gt Fig 60 62 Copyright Silca 2002 Operating manual English UNOCODE 399 7 11 Fig 61 Fig 62 PHOTOCELL REPLACEMENT REPLACING THE X AXIS PHOTOCELL 1 turn the machine off and unplug it from its power supply cable remove the back panel Ch 7 8 Access to back compartment unscrew the 2 G screws that secure the photocell card and remove disconnect the G5 photocell cable fig 61 connect the photocell cable to the new photocell card replace the photocell in position securing it with the G screws fig 61 remount the back panel plug the machine back in and turn it on proceed
75. will show the following message ATTENTION Install cutter 01 Replace the cutter according to the instructions in ch 4 6 Changing the cutter page 16 Is cutter 01 installed No STOP Yes ENTER 28 Copyright Silca 2002 Operating manual English UNOCODE 399 5 6 Operational keys use the arrow keys WA to move the cursor to the option re quired and press ENTER or directly press the numbered key 6 Options corresponding to the option number 4 CALIBRATIONS The following components on the machine have a specific self setting procedure with the use of regulating templates ch 1 5 Accessories provided page 7 CLAMPS CUTTERS ADAPTERS provided as optionals do not require calibrating However if necessary adjustments can be made to the cutting data according to the procedures described in ch 5 6 4 Manual adjustments page 35 In the circumstances listed below see events it may be necessary to re set or all of the clamps or cutters that the user has in possession This operation is semi automatic and requires close attention to the instructions listed below EVENT ZERI MACCHINA CALIBRATION ch 5 6 page 29 CUTTING UNIT READING UNIT CLAMPS CUTTERS Replacement of photocells YES YES NO NO Electronic board replacement YES YES YES YES ch 7 6 page 58 ch 7 6 page 58 ch 7 6 page 58 ch 7 6 page 58 Replacement of the Optical Reader unit NO YES
76. with machine settings Ch 7 11 1 page 64 X axis photocell 2 1 1 LS j REPLACING THE Y AXIS PHOTOCELL N Ya NOOO co 1 1 8 0 1 turn the machine off and unplug it from its power supply cable disconnect the J1 Y axis cable from the carriage fig 62 remove the Y axis carriage cover by unscrewing the 3 B5 locking screws and pull the cover in the direction shown in fig 62 disconnect the J2 photocell cable and J sensor cable fig 62 unscrew the 2 K screws that hold the photocell card and remove it from the carriage place the new photocell card in the carriage and tighten the 2 K supporting screws reconnect both the photocell and sensor cables remount the Y axis protective cover connect the J1 Y axis cable back on the carriage fig 62 plug the machine back in and turn it on proceed with machine settings Ch 7 11 1 page 64 Y axis photocell Copyright Silca 2002 63 UNOCODE 399 7 11 1 Operating manual English MACHINE ZERO SETTING AFTER REPLACING THE PHOTOCELLS CUTTING UNIT 1 enter Maintenance menu 5 select zero points 2 e select Cutting unit 1 remove the V100 clamp cutter side from the machine install the Z2 template clamp s bush
77. y of keys to be cut max 255 4 proceed with cutting the first side by pressing the START key 5 turn the key over and cut the second side Operating keys SHIFT START changes the cutting procedure standard or by electric contact and starts cutting START begins the cutting operation SHIFT down arrow key selects the side of the key to be cut When the last side of the last key has been cut the screen shows Enter card number STANDARD 50 USER 0 1 Side 1 2 S 50 Possible depths 1234 2213442 Side 1 Clamp 100 Pos 0 Cutter UO1 Pcs 1 2 START CUTTING IN PROGRESS Copy 1 of 2 Side 1 Side 2 Clamp 100 Pos 0 Cutter 001 START C CUTTING IN PROGRESS 1 of 2 Side 2 Copy 2 of 2 finished More copies No STOP Yes ENTER Copyright Silca 2002 21 UNOCODE 399 5 3 1 SPECIAL CASES e Cutting a key with two asymmetrical sides Operational keys use the WA keys to be able to visualize both sides of the keys possible cuts on the machines display Proceed with the cutting process Inadmissible cutting Operating manual English Enter card number STANDARD 115 USER 0 ver DB 1 5 115 Possible depths 4321 1112213331 Side 2 5 115 Possible depths 4321 1121123313 Side 1 Clamp 100 A Pos 0 Cutte

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