Silca Idea Operating Manual
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Silca Idea Operating Manual

Key-cutting machine
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Operating manual
D430478XA
6.0
vers.

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Summary of Contents for Silca Idea

  • Page 1 Operating manual D430478XA vers.
  • Page 2 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: January 2009 Printed in Vittorio Veneto by SILCA S.p.A.

  • Page 3: Table Of Contents

    INDEX REFERENCE GUIDE ........................1 GENERAL ............................5 MACHINE DESCRIPTION ......................6 Main characteristics ....................... 6 Safety ............................. 7 Main working parts ......................... 8 Technical data ........................9 Accessories provided ......................10 TRANSPORT ..........................11 Packing ..........................11 Unpacking ..........................11 Machine handling ......................... 12 MACHINE INSTALLATION AND PREPARATION ..............13 Checking for damage ......................
  • Page 4 7.12 Brush replacement ......................133 7.13 WIN-TRANSFER Program for loading/updating the internal machine program ....................... 133 7.14 DIAGNOSTIC FUNCTION – errors in: Copy from Original on IDEA ......... 134 DISPO ....................136 ASSISTANCE ........................137 How to request service ...................... 137 Appendix 1 - ELECTRIC DIAGRAMS...................

  • Page 5: Reference Guide

    Operating Manual - English IDEA REFERENCE GUIDE This manual has been produced to serve as a guide for users of the IDEA key-cutting machine: Read it carefully; it is essential if you wish to operate your machine safely and efficiently. CONSULTATION The contents of the manual are divided into sections relating to: •...
  • Page 6 In addition to the machine's general technical characteristics already described, keys with the following parameters can be cut on the IDEA (fig. 2, fig. 3, fig. 4, fig. 5, fig. 6 and fig. 7). STEM LENGTH: the machine is provided with a headstop and designed to take keys with lengths of up to 150 DIAMETER: the self-centering jaws on the rotating clamp will take stems with diameters from Ø...
  • Page 7 . 4) The minimum and maximum dimensions of this type of key are shown in the diagram below. To cut this type of key on the IDEA is necessary the optional adaptor D726180ZB. This class of keys includes: pump keys with round stems (ø max. 7 mm - min.4 mm)
  • Page 8 . 5) The minimum and maximum dimensions of this type of key are shown in the diagram below. To cut this type of key on the IDEA is necessary the optional adaptor D727711ZB (cap. 5.13 a pag. 53). max 18 mm...

  • Page 9: General

    IDEA is supplied with electricity by means of a grounded plug and differential switch. • Start-up The machine is turned on by means of a master switch that is located on the Idea’s lower left back side. • Maintenance The operations to regulate, service, repair and clean the machine are structured in the simplest and safest way possible.

  • Page 10: Machine Description

    MACHINE DESCRIPTION IDEA is an electronic machine operating on 3 axes (X = spaces, Y = depths, B = radius and bit angles) with controlled movement. Accurately studied, it adds a high degree of cutting precision to operating speed and ease of use.

  • Page 11: Safety

    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. Copyright Silca 2004...

  • Page 12: Main Working Parts

    T1 - Rotating clamp locking handle T2 - Rotating clamp removal screw T4 - ’T’ wrench U - Protective shield U1 - Fixed clamp (clamp A) U2 - Mobile clamp (clamp B) V - Metal chippings tray Fig. 11 Copyright Silca 2004...

  • Page 13: Technical Data

    3 and page 4. Dimensions: width: 500 mm depth: 500 mm height: 420 mm (with raised shield 650 mm) Mass: 45 kg Noise level: sound pressure Lp(A) = 81,5 dB(A) - steel keys / 75,5 dB(A) - brass keys Copyright Silca 2004...

  • Page 14: Accessories Provided

    IDEA Operating Manual - English CCESSORIES PROVIDED IDEA comes with a set of accessories for its operation and maintenance (tools, hex wrenches, fuses) supplied in a special tool kit comprising: tool kit 1,5 mm allen key Z13 template D302434ZZ (regulating disk)

  • Page 15: Transport

    ACKING The packing for IDEA is designed to ensure safe transportation and to protect the machine and all its parts. It comprises a pallet base (b) to which the machine is attached, and a cardboard box as a cover (a).

  • Page 16: Machine Handling

    Operating Manual - English ACHINE HANDLING When the IDEA has been unpacked, place it directly on its workbench; this operation should be carried out by at least two people. Take care to lift the machine firmly holding the base, and no other part.

  • Page 17: Machine Installation And Preparation

    HECKING FOR DAMAGE IDEA is solid and compact and will not normally damage if transport, unpacking and installation have all been carried out according to the instructions in this manual. However, it is always advisable to check that the machine has not suffered any damage.

  • Page 18: Graphics

    The Plexiglass protective shield carries an adhesive warning label (fig. 15). This label must never be removed. • Two laser warning labels must be attached to the optical reader (fig. 15). Do not use compressed air for cleaning Laser warning labels Fig. 15 Copyright Silca 2004...

  • Page 19: "Set Up" And Use Of The Machine

    COPY Combination of SHIFT & CLEAR/COPY enables you to automatically switch to the (0) CLEAR “Copy from original” function from any menu in the Idea internal program. SHIFT COPY Pressed in combination with all the keys of the same colour to enter the number or letter available.

  • Page 20: Use Of The Clamp

    SE OF THE CLAMP The rotating clamp (S1) (fig. 17) is the fundamental tool of IDEA. It has various functions and constitutes the third working axis (rotation) controlled by the machine. The rotating clamp is housed in a mobile support which runs along the X axis (spaces) and is anchored to the carriage below it by means of a dovetail guide;...

  • Page 21: Cutting By Electric Contact

    IDEA UTTING BY ELECTRIC CONTACT The IDEA key-cutting machine is equipped with a low voltage electrical contact device which permits the cutter to individualize the key blank as it approaches the cutter during the cutting phase. Electrical contact is guaranteed for keys in steel, brass, silver nickel, Zamak or iron (with or without nickel- plating).

  • Page 22: User's Guide

    Personal computer programs eliminate the need to carry out certain functions manually and skip some of the screens in the User’s Guide once the data have been transmitted. When IDEA is used with a Personal Computer, the User’s Guide does not change its viewing logic, except for the screens that are not required.
  • Page 23 Version = this refers to the version of internal software that runs the machine functions. The figure changes at every upgrade. Vers DB = this refers to the version of the data relating to the Systems/Locks entered. You may ask SILCA to upgrade your machine database with any of the new systems on the market.

  • Page 24: 0] Copy From Original

    If all the teeth are thicker than the cutting tool, the program will indicate the difference and the number of times the cutting tool needs to pass to reproduce the cuts correctly. Fig. 21 Copyright Silca 2004...
  • Page 25 +180° -60° Fig. 24 Copyright Silca 2004...
  • Page 26 Ø max. Ø min. Fig. 26 It is now very important to distinguish the type of key to be copied. Copyright Silca 2004...
  • Page 27 3) Reading only: the key is read; in this way the cuts read can be edited before cutting the key. 4) Editing of key read: the original key read can be edited in order to adjust any defects or broken parts (see ch. 5.15, page 61). Copyright Silca 2004...

  • Page 28: Copy From Original For Front Stop - Male

    Stop 0 = reference or positioning point on the key cutting clamp. Cutter: 1.25 = thickness of the cutter currently selected (press SHIFT+ENTER to change thickness) Brass/Steel = material of the key (press SHIFT+ ? to change material) Copyright Silca 2004...
  • Page 29 Fig. 29 Cutting in progress Copy: 1 of: 1 Copy: 1 of: 1 finished More copies ? No=STOP Yes =ENTER You can now press ENTER in order to make further copies of the previously read original key. Copyright Silca 2004...

  • Page 30: Copy From Original For Front Stop - Female

    5) start the reading process, which will take the reader along the path indicated by the broken line. At the end of the cycle see the message on the display in order to continue. Copyright Silca 2004...

  • Page 31: Cutting Front Stop Keys (Double Bit, Single Bit - Female)

    7) Transfer the T wrench (T4) onto the screw (V2) of the tailstock and secure the adapter E2. 8) Replace the T wrench in its seat, lower the mobile safety shield and begin the process with START. To remove the key after cutting, carry out the operations described, in reverse order. Copyright Silca 2004...

  • Page 32: Copy From Original For Centre Stop

    5) When the reading process is started the carriage takes the key into contact with the laser beam along the path and in the direction indicated by the broken line. 6) At the end of the cycle see the message on the display in order to continue (see ch.5.6.2). Copyright Silca 2004...

  • Page 33: Cutting Keys With Centre Stop (English Type)

    Use the T wrench (T4) to tighten the screw (V1) first, then the screw (V2). Replace the T wrench (T4) into its seat, lower the mobile safety shield and begin the process with START. To remove the key after cutting, carry out the same operations, in reverse order. Copyright Silca 2004...

  • Page 34: Fas 309 Plastic Stem

    You can now press ENTER in order to make further copies of the key. FAS 309 P LASTIC ONLY DECODE AND COPY Reading / decoding Cutting Fig. 34 OPTIONAL OPTIONAL OPTIONAL D727713ZB D711802ZB D727058ZB Adapter D Spacer Adapter E1 Fig. 35 Copyright Silca 2004...

  • Page 35: Adapter For Cutting Chubb Keys With Square Section Stems

    4) Place the key to be cut into its seat on the adapter, which must butt up against the key rim (Y2); take the rotating clamp up to the stem and secure the key. 5) Proceed with the cutting operation. OPTIONAL D716544ZB Adapters E9 Fig. 36 Copyright Silca 2004...

  • Page 36: Pump Keys

    Choose option 1 - Reading + Copy 1 - Reading + Copying 2 - Cutting only 3 - Reading only 4 - Post-reading adj. READING PUMP KEYS KEY READING Original on right Clamp: S100 A Stop: 0 Adapt: E7 [START] Copyright Silca 2004...
  • Page 37 Fig. 38 2-3 mm Adapter E7 Fig. 39 At the end of the cycle see the message on the display in order to continue. Reading in progress… Data processing in progress Please wait… Copyright Silca 2004...
  • Page 38 Fig. 42 Cutting in progress Copy: 1 of: 1 Copy: 1 of: 1 finished More copies ? No=STOP Yes=ENTER You can now press ENTER in order to make further copies of the key. Select STOP to quit. Copyright Silca 2004...

  • Page 39: Muel Pump Keys

    - Choose option 1 - “Decode and Copy” - Choose the SN required (SN328 / SN329 / SN352...) and proceed. To read Muel keys, proceed as follow: READING MUEL PUMP KEYS DECODE SSN 328 Original on right Clamp: S100 Stop: 4 Adapt: E8 [START] Copyright Silca 2004...
  • Page 40 8)At the end of the cycle see the message on the display in order to continue. Decoding in progress… Bit 1 Bit 1 5 3 1 0 2 5 4 3 2 4 Possible depths: 0 1 2 3 4 5 [10] Copyright Silca 2004...
  • Page 41 Copy: 1 of: 1 Bit 1 Copy 1 of 1 finished More copies ? NO=Stop YES =Enter - You can now press ENTER in order to make further copies of the key. - Select STOP to quit. Fig. 48 Copyright Silca 2004...

  • Page 42: Fiam Keys

    3 - Pump 4 - Square-square tip 5 - Square-round tip 6 - Square-stepped tip Choose option 1 - Reading + Cutting 1 - Reading + Copying 2 - Cutting only 3 - Reading only 4 - Post-reading adj. Copyright Silca 2004...
  • Page 43 7) When the reading process starts the carriage will take the key into contact with the laser beam along the path dictated by the Software. At the end of the cycle see the message on the display in order to continue. Fig. 51 Copyright Silca 2004...
  • Page 44 7) When the reading process starts the carriage will take the key into contact with the laser beam along an ideal path. At the end of the cycle see the message on the display in order to continue. Fig. 52 Fig. 53 Reading in progress… Data processing in progress Please wait… Copyright Silca 2004...
  • Page 45 8) Replace the ‘T’ wrench in its seat, lower the mobile safety shield and begin the process with START. To remove the key after cutting, carry out the operations described, in reverse order. Fig. 56 Copyright Silca 2004...
  • Page 46 Cutting in progress Copy: 1 of: 1 Copy: 1 of 1 finished More copies ? No=STOP Yes=ENTER You can now press ENTER in order to make further copies of the key. Copyright Silca 2004...

  • Page 47: Keys With Rear Stop (Male Keys And Female Keys)

    Note: use the (T4) wrench to loosen the screw (V1), in order to open the jaws of the (S1) rotating clamp, exerting normal pressure to secure the K2 tailstock firmly to the (S1) rotating clamp. Fig. 60 Poceed with GAUGING. Copyright Silca 2004...
  • Page 48 2 with the second pin on the template up against it. Tighten the screw (W2) with the (T4) wrench. Replace the (T4) wrench in its seat. Fig. 61 Press START Clamp: S1 - K2 Detection In progress Copyright Silca 2004...
  • Page 49 A - F 4 - Post-Reading adj. A - G KEY READING Original on right Clamp.:S100 A-E Stop:0 Adapt.: E11 [START] To select jaws see diagram ch. "TYPE OF KEYS" and "Choosing an adapter for READING", page 47. Copyright Silca 2004...
  • Page 50 7) On starting the reading operation the carriage will take the key into contact with the laser beam along the path dictated by the software. 8) In the case of female keys, use one of the standard centring devices (according to stem diameter) on the S100-A clamp (see ch. 5.14 "SPECIAL BIT FEMALE KEYS", page 57). Copyright Silca 2004...
  • Page 51 Place the original key on the drawing, using the Rear Stop as a reference; the bit should enter the highlighted zone. Jaws A - E Max. 65 Adapter E Rear Stop (example: Silca key ref. 6FT12) Jaws A - F Max. 75 Adapter F Rear Stop (example: Silca key ref.
  • Page 52 (W2) with the (T4) wrench (fig. 67). Replace the (T4) wrench into its seat. Fig. 67 (*) Important:the key can be fitted into the S1-K2 clamp from the front or from the back, according to the type of key. Copyright Silca 2004...
  • Page 53 1) place the original key on the drawing, using the stop as a reference. 2) in this position the bit should enter the 43 mm zone. Stop 1 (example: Silca key ref. 6FT12) Stop Stop 2 (example: Silca key ref. 6M14)
  • Page 54 Copy 1 of 1 finished More copies ? No=STOP Yes=ENTER DECODE SSN 110 Art. Silca 6FT12 ATTENTION: for Fichet Sans-Soucis P.P. keys operations only possible when decoding with SSN 110. Decoding + Cutting SSN 110 (Decode) Make = => Fichet Sans-Soucis P.

  • Page 55: French Rear Stop Keys

    [START] NOTE: Jaws F or G could also be used (see JAWS A-E / A-F / A-G on page 46. The rear stop is not necessarily up against the side of the jaw (fig. 68). Fig. 68 Copyright Silca 2004...
  • Page 56 Replace the plate (P) in position in seat 2 or 3. Replace the (T4) wrench in its seat. Stop 0 Fig. 69 NOTE: the key can be fitted into the S1-K2 clamp from the front or from the back, according to the type of key Fig. 70 Copyright Silca 2004...

  • Page 57: Small Bit / Double Bit Keys

    Choose option 1 - Reading + Copying: 1 - Reading + Copying 2 - Cutting only 3 - Reading only 4 - Post-Reading adj. KEY READING Original on right Clamp: S100 A - E Stop: 0 [START] Operate as follows: Copyright Silca 2004...
  • Page 58 Software. Fig. 74 7) At the end of the cycle see the message on the display in order to continue. Fig. 75 Reading in progress… min. 3 mm max. 15 mm Data processing in progress Please wait… Copyright Silca 2004...
  • Page 59 8 mm (fig. 77). If these measurements are not observed the display will show an error: “ERROR 17 Adapter not properly fitted”. Fig. 77 min. 3mm min. 8mm Copyright Silca 2004...
  • Page 60 START. Fig. 78 Cutting in progress… Copy: 1 of: 1 Copy 1 of 1 finished More copies ? No=STOP Yes=ENTER To make further copies of the key, you can now press ENTER. Fig. 79 Fig. 80 Copyright Silca 2004...

  • Page 61: Special Bit Female Keys

    1 - Reading + Copying 2 - Cutting only 3 - Reading only 4 - Post-Reading adj. KEY READING Original on right Clamp: S100 A - B Stop:0 Adapt. E16 [START] Is adaptor E16 installed ? No=STOP Yes=START Copyright Silca 2004...
  • Page 62 ATTENTION: make sure that the bit is up against the Stop 0 (A). Fig. 82 Pressing Start shows: Left blank Brass Clamp: S1-K1 Stop:0 Cutt: 1.25 Adptt: E15 pcs. = 1/1 [START] Is adaptor E15 installed ? No=STOP Yes=START Fig. 83 Copyright Silca 2004...
  • Page 63 5) Fit the key blank into the front side of the rotating clamp (S1) and position it on the groove in the jaws, then take the key forward until the adapter E15 goes into the hole in the stem (fig. 86). Fig. 85 Copyright Silca 2004...
  • Page 64 Software, at the end of the cycle see the message on the display in order to continue. Data processing in progress Please wait… Cutting in progress… Copy: 1 of: 1 Copy 1 of 1 finished More copies ? No=STOP Yes=ENTER To make further copies of the key, you can now press ENTER. Copyright Silca 2004...

  • Page 65: Post-Reading Adjustments To Make To The Key After Reading

    5) Scratches, wear or warping read on both the vertical and horizontal faces of the teeth are regulated over the size of the tooth at its base on the stem. 6) Steps with a thickness of less than 0.75 mm are regulated over the prevailing measurement of the adjacent tooth. Copyright Silca 2004...

  • Page 66: Front-Rear Bit Conversion

    (fig. 89). missing tooth Fig. 89 Copyright Silca 2004...

  • Page 67: Correcting Bit Depth

    Bit 1 = +00 Bit 2 = +00 [ENTER] = CONFIRM Use SHIFT + [arrow Up] key for higher values (bit is cut less) Use SHIFT + [arrow Down] key for lower values (bit is cut more) Copyright Silca 2004...

  • Page 68: Bit Construction

    From: 180 to: 360 Height: 1500 Up Down [ENTER} Go on to the next tooth by pressing the [arrow Down]. Press STOP to quit. Bit: 2 Tooth: 1 From: 1920 to: 2100 Height: 1350 Up Down [ENTER] Copyright Silca 2004...
  • Page 69 ELETE EDITING When a new key is read or the item “0-Delete editing” is selected, all the POST-READING adjustments previously selected can be eliminated. Delete post-reading adjustments ? No=STOP Yes=ENTER Stop: to quit Enter: to continue (confirmation) Copyright Silca 2004...

  • Page 70: Decode And Copy

    [arrow Down] = goes from one bit to the other CLEAR = delete symbols It is in any case possible to edit the symbols for the combination before proceeding with the cutting operation. NOTE: see the next Chapter for the cutting sequence. Copyright Silca 2004...

  • Page 71: Entering The Cuts

    [arrow Down] = goes from one bit to the other CLEAR = deletes the symbols [ ------- ] = ONLY from the box relating to BIT 1 with SHIFT + [arrow Up] to define one of the following characteristics of the key: Copyright Silca 2004...
  • Page 72 Bits 1 and 2 are specular to X: when the combination of bit 1 is entered, that for BIT 2 is entered automatically. missing tooth Fig. 95 SPECULAR F-R Each bit is specular in the direction FRONT-BACK: enter half the cuts for each bit to have the full combination. REAR FRONT Fig. 96 Copyright Silca 2004...
  • Page 73 SHIFT+ENTER = used to change the thickness of the current cutter by pressing ENTER against the cutter thickness required: Choose cutter 1*: PL 1.25 2: PL 1.00 3: PL 1.50 Press STOP to quit. Press START to begin cutting. Copyright Silca 2004...

  • Page 74: Use Of The Machine With A Personal Computer

    When the cutting operation is finished for the number of keys set, a ‘+’ sign shows the end of the cycle. When the IDEA is turned off in the middle of a work queue, the machine stores the status of the work done in its memory.
  • Page 75 With the use of a PC, i. and. with a much more complete collection of data, keys can be decoded as well as cut. (Important: pay attention to the note for fitting the key). SSN. 10 After launching the Silca Keys Program the decoding Waiting for function for SSN 10, appears on the machine display for a...

  • Page 76: Use Of The Machine With Optika Via Pc

    In addition to the possibility to produce a copy of a key starting from a reading made by the IDEA optic reader, it is also possible to produce a copy of a key starting from a reading made by OPTIKA using the Key Reader Program or Silca key Program.

  • Page 77: Gauging

    NOTE: MANUAL adjustments to the clamp are not considered when there is an ADAPTER fitted. Use arrows [up, down] to scroll. 1 - Clamps 2 - Cutter 3 - Adapter Clamps 1: S1 - Rotating Jaw 2: S100 - Reader Jaw Copyright Silca 2004...
  • Page 78 Clamp: S1 - K1 = unit comprising the S1 clamp and K1 interchangeable tailstock. >> = press [SHIFT+ENTER] to go to the other interchangeable tailstocks used with the S1 clamp, if applicable. Clamp: S1 - K2 = unit comprising the S1 clamp and K2 interchangeable tailstock Copyright Silca 2004...
  • Page 79 [ENTER]:in the last field to quit the window so that the query Save? appears for the edited data: Save adjustment ? No=STOP Yes=ENTER ATTENTION: if [STOP] is pressed the new measurements are not saved; the previous gauging values therefore remain valid. Copyright Silca 2004...

  • Page 80: Cutters

    [ENTER] in the last field is used to quit the window and show the message requiring the editing to be saved: Save adjustments ? No=STOP Yes=ENTER ATTENTION: when [STOP] is pressed the new measurements are not saved; the previous gauging values therefore remain valid. Copyright Silca 2004...

  • Page 81: Adapters

    - 300 hundredths of a mm or hundredths of a degree (axis B) X/Y1/Y2 = - 20 cent. CLEAR to zero the value [ENTER] in the last field is used to quit the window and show the message requiring the editing to be saved: Copyright Silca 2004...
  • Page 82 ATTENTION: when [STOP] is pressed the new measurements are not saved; the previous gauging values therefore remain valid. Fig. 102 Example: Adapter E3 Side: cutting Adjustment: B=+00 X=+00 Y1=+00 Y2=+00 Save adjustment ? No=STOP Yes=ENTER Fig. 103 Copyright Silca 2004...
  • Page 83 Operating Manual - English IDEA Example: Adapter E4 Side: reading Correzioni: X=+00 Y1=+00 Y2=+00 Salvare le correzioni ? No=STOP Si=ENTER Fig. 104 Example: Adapter E5 Side: cutting Adjustment: B=+00 X=+00 Y1=+00 Y2=+00 Save adjustment ? No=STOP Yes=ENTER Fig. 105 Copyright Silca 2004...
  • Page 84 IDEA Operating Manual - English Example: Adapter E6 Side: reading Adjustment: X=+00 Y1=+00 Y2=+00 Save adjustement ? No=STOP Yes=ENTER Fig. 106 Example: Adapter E7 Side: reading Adjustments: X=+00 Y1=+00 Y2=+00 Save adjustment ? No=STOP Yes=ENTER Fig. 107 Copyright Silca 2004...
  • Page 85 Operating Manual - English IDEA Example: Adapter E8 Side: reading Correzioni: X=+00 Y1=+00 Y2=+00 Salvare le correzioni ? No=STOP Si=ENTER Fig. 108 Example: Adapter E9 Side: cutting Adjustment: B=+00 X=+00 Y1=+00 Y2=+00 Save adjustment ? No=STOP Yes=ENTER Fig. 109 Copyright Silca 2004...
  • Page 86 IDEA Operating Manual - English Example: Adapter E9 Side: reading Adjustments: X=+00 Y1=+00 Y2=+00 Save adjustements ? No=STOP Yes=ENTER Fig. 110 Example: Adapter E10 Side: cutting Adjustments: X=+00 Y1=+00 Y2=+00 Save adjustements ? No=STOP Yes=ENTER Fig. 111 Copyright Silca 2004...
  • Page 87 Operating Manual - English IDEA Example: Adapter E11 Side: reading Adjustments: X=+00 Y1=+00 Y2=+00 Save adjustements ? No=STOP Yes=ENTER Fig. 112 Example: Adapter E15 Side: cutting Adjustments: X=+00 Y1=+00 Y2=+00 Save adjustements ? No=STOP Yes=ENTER Fig. 113 Copyright Silca 2004...
  • Page 88 IDEA Operating Manual - English Example: Adapter E16 Side: reading Adjustments: X=+00 Y1=+00 Y2=+00 Save adjustements ? No=STOP Yes=ENTER Fig. 114 Copyright Silca 2004...

  • Page 89: Main Menu Test Functions

    13 - Electric contact 14 - Keypad 15 - Display 16 - Clamp Code 17 - Inlets 18 - Outlet 1 19 - Outlet 2 20 - Outlet 3 21 - Outlet 4 22 - Serial port Copyright Silca 2004...

  • Page 90: Test

    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. • Test 2: X AXIS MOTOR Carefully follow the instructions on the display and check that the X axis carriage moves.
  • Page 91 If the cutter is turning and the display shows a speed of “0”, the motor photocell is faulty and must be replaced. NOTE: if the cutter motor does not start, contact Silca’s Technical Assistance Dept. • Test 6: X AXIS SENSOR the machine’s display should show ON when the carriage is drawn away from the machine (towards the...
  • Page 92 To use the test properly, consult the literature provided with the specific optional accessories. • Test 22: SERIAL PORT Check that the machine display shows OFF. Fit the special serial test connector (Z4) provided to the machine serial port, checking that the display shows first OFF then ON. Copyright Silca 2004...

  • Page 93: Machine Zero Points

    7) loosen the (G3) and (G4) grub screws that secure the Y axis photocell disk (fig. 118, page 91). 8) plug the Y axis (J1) cable (fig. 116) and the machine’s power supply cable back into place. 9) turn the machine on and carry on with the procedures described on page 90. Fig. 115 Copyright Silca 2004...
  • Page 94 7) lower the protective shield and press START. START ATTENTION: check that both the (Z13) and (Z12) templates make ERROR 10 perfect contact. If this does not occur the display will show an error message. No contact made. See operating manual. Copyright Silca 2004...
  • Page 95 8) lower the protective shield. Pos. Photocell. 9) press START. TZX=ON TZY=ON See operating manual. the machine goes on to a new position and is ready for regulating the sensors. [START] START Y axis sensor Y axis photocell Fig. 118 Copyright Silca 2004...
  • Page 96 13) manually turn the X axis disk to get access to the (G2) No=STOP Yes=ENTER grub screw (fig. 118). ENTER ATTENTION: if the STOP key is pressed, the new settings will be lost. If so, only the previous setting values will remain valid. Y axis sensor Fig. 119 Copyright Silca 2004...
  • Page 97 2) select ‘Machine zero points” #2. 1 - Cutting unit 2 - Reading unit 3) select ‘Reading unit’ #2. Install A & B clamps and Z14 template 4) install the (Z14) template. See operating manual. install A and B clamps (S100) [START] Copyright Silca 2004...
  • Page 98 Measured quotes: X=4444 Y=3333 ATTENTION: if the STOP key is pressed, the new settings will be Save measurements? lost. If so, only the previous setting values will remain No=STOP Yes=ENTER valid. ENTER Copyright Silca 2004...
  • Page 99 Fit the key blank into the clamp S1, then press START. Cutting in progress Copy: 1 of: 1 Bit 1 Cutting in progress Copy: 1 of: 1 Bit 2 Copy 1 of 1 finished More copies ? No=STOP Yes=ENTER Copyright Silca 2004...
  • Page 100 To calibrate (START) Digit the corrections required for axis X and axis Y (bit 1 = Y1 / bit 2 = Y2). Press ENTER. Fig. 124 Save adjustment? No=STOP Yes =ENTER Press ENTER to confirm the data. Copyright Silca 2004...
  • Page 101 Cutt.: 1.25 Pcs = 1/1 (START) Press ENTER Cutting in progress Copy: 1 of: 1 Copy 1 of 1 finished More copies? No=STOP Yes=ENTER Press STOP, remove the key and use a centesimal gauge to measure it. Copyright Silca 2004...
  • Page 102 Y1= -0,5 Y2= -0,5 To calibrate (START) Digit the required corrections for axis X and axis Y (bit 1 = Y1 / bit 2 = Y2). Press ENTER. Save adjustment? No=STOP Yes =ENTER Press ENTER to confirm the data. Copyright Silca 2004...
  • Page 103 Fit the key blank into the E3 adapter and follow the instructions in the user’s manual, then press START. Cutting in progress Copy: 1 of: 1 Bit 1 Copy 1 of 1 finished More copies? No=STOP Yes=ENTER Press STOP, remove the key and use a centesimal gauge to measure it. 9,50 mm Fig. 126 Copyright Silca 2004...
  • Page 104 Digit the corrections required for axis X and axis Y. Press [ENTER] Save adjustment ? No=STOP Yes=ENTER ATTENTION: if [STOP] is pressed the new measurements are not saved; the previous gauging values therefore remain valid. Press ENTER to confirm the data. Copyright Silca 2004...
  • Page 105 Left blank Brass Clamp: S1-K1 Stop: 0 Cutt: 1.25 Adap. E3 Pcs = 1/1 (START) Fit the key blank into the clamp (see ch. 5.9 on page 32), then press START. Cutting in progress Copy: 1 of: 1 Copyright Silca 2004...
  • Page 106 + 20 cent. mm X/Y1/Y2 SHIFT + [arrow down]: decreases the value within - 300 hundredths of a mm or hundredths of a degree (axis B) - 20 cent. mm X/Y1/Y2 CLEAR = to zero the value. Copyright Silca 2004...
  • Page 107 Digit the corrections required for axis X and axis Y. Press ENTER. Save adjustment ? No=STOP Yes=ENTER ATTENTION: if [STOP] is pressed the new measurements are not saved; the previous gauging values therefore remain valid. Press ENTER to confirm the data. Copyright Silca 2004...
  • Page 108 Press STOP, remove the key and use a centesimal gauge to mesure it. 17,30 11,25 Fig. 128 Measurement X should be 17,30 mm (….inch), +/- 0,03 mm Measurement Y (Y1+Y2) should be 11,25 mm (…inch) +/- 0,03 mm Copyright Silca 2004...
  • Page 109 [START] = press START to begin the automatic gauging procedure or the CLAMP-TAILSTOCK unit. Press ENTER Save Adjustments? No=STOP Yes=ENTER ATTENTION: if [STOP] is pressed the new measurements are not saved; the previous gauging values therefore remain valid. Press ENTER to confirm the data. Copyright Silca 2004...

  • Page 110: Options

    6.2.1 Serial number Ser. n.: 153214523123 The display shows the machine’s serial number, that Model: IDEA should correspond to the one stamped on the date plate Keys cut: _ _ _ on the back of the machine. SW version. : _. _._ 6.2.2...

  • Page 111: Preferences

    With Keypad inversion enabled (1): • to digit number 1: press SHIFT + [1/H] key. • to digit letter H: press [1/H] key. NOTE: this function is operative with “Insert the Cuts”, “Decode and Copy” and in from the main menu. Copyright Silca 2004...

  • Page 112: Limited Access To Data (Protected Systems)

    Operating Manual - English 6.2.7 Limited access to Data (Protected Systems) Silca has predisposed limited access to some of the data in the Database, in compliance with agreements with some makers. Limitations apply to: SERIES: No access to codes or data cards [SR]...

  • Page 113: Bit Height

    In the event of anomalies the display will show an error message (see errors 22-23, ch. 6.2.10.2, page 117) Setting 0 = function disabled, the machine will not check the key reading. Keys reproduced in this way could be different and not operational. Copyright Silca 2004...
  • Page 114 Press STOP to quit cutter selection and START to begin cutting. ATTENTION: if the max. thickness value of the cutter to be selected is less than that forseen on the machine, the key cannot be cut. Press STOP. 4,30 mm 4,50 mm drawing 3 Copyright Silca 2004...

  • Page 115: Machine Messages

    Nº 6 ALARM 6 Signals that fuse F1 has probably cut out (see ch.7.1 "Trouble shooting"). CUTTER MOTOR Check fuse F1! Nº 7 Signals a fault on the electronic circuit board. ALARM 7 CUTTER MOTOR Motor circuit anomaly! Copyright Silca 2004...
  • Page 116 • a negative manual adjustment of Y has been made to See operating manual. the clamp or adapter used to grip the key. • a negative MANUAL adjustment of Y has been made to the circuit board by means of the SILCA KEY PROGRAMS program. Nº 11 ALARM 11...
  • Page 117 • a negative MANUAL adjustment has been made to X on the clamp or adapter used to grip the key. • a negative MANUAL adjustment has been made to X on the circuit board by means of the SILCA KEY PROGRAMS program. Nº 15...

  • Page 118: Error Messages

    The messages listed below appear when there has been a problem during or after updating the program in the machine. Try updating or re-loading the machine internal software using the WINTRANSFER Program or the SILCA KEY PROGRAMS. • The ISO cutting function has not been found.
  • Page 119 +25 hundredths. Indicates that the reading of an ORIGINAL key has been ERROR 13 launched but the key is not in the reading clamp. Original key not found Copyright Silca 2004...
  • Page 120 STOP number (1, 2, 3) has been set that is not compatible with the length of the key read by the STOP Position optic reader. not compatibile with Solution: key length. • select the right STOP. Copyright Silca 2004...
  • Page 121 NOTE: If the error is repeated or the key is not properly reproduced, consult ch.7.14 "DIAGNOSTIC FUNCTION – errors in: Copy from Original on IDEA", page 134, and/or contact Silca After-Sales Service.

  • Page 122: Signal Messages

    X =+... is set the K1 tailstock Positive X could be damaged. (first tooth in proximity of the tailstock adjustment can has a height value of less than 4.5 mm). damage tailstock Copyright Silca 2004...

  • Page 123: Maintenance

    Although the IDEA key-cutting machine does not require special maintenance, it is advisable to check and, if necessary, replace the parts subject to wear and electric/electronic parts (fuses, circuit boards, etc.) in the event of faulty operation.
  • Page 124 ‘CUTTER b) cutter microswitch on protective cover triggered or disconnected (D4) ( fig. 130 MOTOR ALARM - c) cutter motor wiring disconnected. check fuse F1’. d) internal fault on the electronic control board. Fig. 129 Fig. 130 Copyright Silca 2004...

  • Page 125: Maintenance Operations

    6) place the cutters protective shield (i) back into position securing it with the screw (i2). Fig. 131 ATTENTION: when replacing a worn cutter with a new one or with a re-sharpened cutter consult ch.5.20 "Gauging", page 73. Copyright Silca 2004...

  • Page 126: Replacing And Tightening The Belts

    2 screws (W3) on the plate (W4). 5) use the special plate (provided) and tighten the belt by turning the screw (W2). 6) tighten the 4 motor fixing screws (W). 7) replace the back metal panel and bottom plate. Fig. 132 Copyright Silca 2004...

  • Page 127: 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 IDEA. • 2 fuses: 4 Amps rapid located next to the power socket on the back of the machine, next to the main switch (fig.

  • Page 128: Electronic Circuit Board Replacement

    5) mount the new electronic circuit board and re-connect all cables (all cable connections are polarised therefore cannot be connected incorrectly). 6) re-fit the bottom panel and re-position the machine on its workbench. 7) turn the machine on and launch the WIN-TRANSFER program. Fig. 136 Copyright Silca 2004...

  • Page 129: Keyboard/Display Replacement

    3) detach the flat cable and ground wire from the keyboard (fig. 138). 4) unscrew the keyboard’s fixing nuts and remove the keyboard from its support. 5) fit the new keyboard/display, repeating the operations described above, backwards. Fig. 137 Fig. 138 Copyright Silca 2004...

  • Page 130: Access To Back Compartment

    To gain access to the bottom compartment, proceed as follows: 1) turn the machine off and unplug it from its power supply cable. 2) turn the machine on its back side. 3) remove the machine’s bottom panel by unscrewing the 8 (L1) screws. Fig. 140 Copyright Silca 2004...

  • Page 131: Sensor Replacement

    (fig. 143). Tighten the (M2) grub screw to lock the sensor into place. 8) connect the (M3) sensor’s connector. Y axis sensor 9) replace the Y axis carriage cover. 10) connect the (J1) Y axis connecting wire to the carriage. Fig. 143 Copyright Silca 2004...
  • Page 132 7) connect the sensor connector (M5). Carry out the B axis sensor Test: the state is OFF. 8) Use a screwdriver to turn the screw (M7) clockwise (fig. 146), the state changes to ON, tighten the grub screw (M6). 9) Replace the B axis carriage cover. Fig. 145 Fig. 146 Copyright Silca 2004...

  • Page 133: Replacing The Photocell

    8) remount the Y axis protective cover. 9) connect the (J1) Y axis cable back on the carriage. 10) plug the machine back in and turn it on. 11) proceed with machine settings. Y axis photocell Fig. 148 Copyright Silca 2004...
  • Page 134 7) position the photocell and secure with the screws (G9) so that the disk (G10) is in the centre of the photocell sensors. 8) tighten the screws (G11). 9) replace the lower plate. 10) connect the power supply wire and turn on the machine. 11) check with the cutter motor Test. Fig. 149 Fig. 150 Copyright Silca 2004...

  • Page 135: Machine Zero Setting After Replacing The Photocells

    START ATTENTION: do not touch the X and Y axes carriages and press ERROR 10 START. no contact made. See operating manual START Pos. Photocells. TZX=ON TZY=ON See operating manual. [START] 9) press START START Fig. 151 Copyright Silca 2004...
  • Page 136 If so, only the previous setting values will remain valid. Measurements read: X=4444 Y=3333 Save data ? 5) press ENTER No=STOP Yes=ENTER 6) remove the (Z14) template. the new setting has been made. ENTER Fig. 152 Copyright Silca 2004...

  • Page 137: Brush Replacement

    At this point the machine is set up and ready for operation. • SILCA update for the program or machine data install on your personal computer the latest version received of the WinTransfer program and follow the instructions in the program.

  • Page 138: Diagnostic Function - Errors In: Copy From Original On Idea

    7) Select the path (e.g. disk C:\) and give a name to the file to be saved. 8) Click with the mouse on the "Save" button. 9) The bit will be downloaded from IDEA (approx. 1 minute) and at the end of the operation the monitor will show a ‘saved’ message.
  • Page 139 4) Set the value : 1 In QUEUE FROM PC, when the key has been cut, the message below will no longer appear: Copy: 1 of: 1 finished More copies ? NO=STOP YES=ENTER and the next operation will start automatically. Copyright Silca 2004...

  • Page 140: Dispo

    The sanctions currently provided for by law shall apply to users who dispose of products in unauthorised ways. Copyright Silca 2004...

  • Page 141: Assistance

    The guarantee attached to the IDEA ensures free repairs or replacements of faulty parts within 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 2004...
  • Page 142 IDEA Operating Manual - English Copyright Silca 2004...

  • Page 143: Appendix 1 - Electric Diagrams

    Operating manual - English IDEA 1 - ELECTRICAL DIAGRAMS Appendix The following pages contain the electrical diagrams for the IDEA key-cutting machine described in this manual. Copyright Silca 2004 Appendix - I...
  • Page 145 Operating manual - English IDEA IDEA ELECTRICAL DIAGRAMS Copyright Silca 2004 Appendix - III...
  • Page 146 Operating manual - English IDEA IV - Appendix Copyright Silca 2004...
  • Page 147 Operating manual - English IDEA Copyright Silca 2004 Appendix - V...
  • Page 148 Operating manual - English IDEA GND 12 V LED SER DIN+ SER DIN- SER / RES+ SER / RES- SER DOUT+ SER DOUT- SER CLK+ SER CLK- VI - Appendix Copyright Silca 2004...
  • Page 149 Operating manual - English IDEA Copyright Silca 2004 Appendix - VII...
  • Page 150 European Union DIRECTIVE 2006/95/CE (Low Voltage) and with the EN 60204-1 ( sections 20.2 – 20.3 – 20.4 ) Standards Claudio Tomasella of the Silca S.p.A. Research & Development Division is authorized to create a Technical File. General Manager Basic Production Center...
  • Page 152 Phone: +39 0438 9136 Fax +39 0438 913800 E-mail: silca@silca.it www.silca.biz India United Kingdom MINDA SILCA Engineering Ltd. SILCA Ltd. Plot no.37, Toy City, Unit 6 Lloyds Court - Manor Royal GREATER NOIDA (U.P.) - 201308 CRAWLEY RH10 9QU Phone: +91 9871397630/31...

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