Silca UC 199 User manual

Operating Manual
Original Instructions
D441737XA
vers. 1.0
EN
UC199
UC199
UC199 Japan
UC199 Japan

(c) 2012 SILCA S.p.a. – Vittorio Veneto
This manual has been drawn up by SILCA S.p.a.
All rights reserved. No part of this publication can be reproduced or circulated by any means whatsoever (photocopies, microlm or other) without
the consent of SILCA S.p.a.
Edition: October 2012
Printed at Vittorio Veneto
by SILCA S.p.a.
Via Podgora, 20 (Z.I.)
31029 VITTORIO VENETO (TV) – Italy
The Manufacturer declines any responsibility for possible inaccuracies in this document due to printing or transcription errors. The Manufacturer
reserves the right to alter the information without prior notice, except when they affect safety. This document or any of its parts cannot be copied,
altered or reproduced without written authorization from the Manufacturer. Keep the manual and look after it for the entire life cycle of the machi-
ne.
The information has been drawn up by the manufacturer in his own language (Italian) to provide users with the necessary indications to use the
key-cutting machine independently, economically and safely.
IMPORTANT NOTE: in compliance with current regulations relating to industrial property, we hereby state that the trade-marks or trade names
mentioned in our documentation are the exclusive property of authorized manufacturers of locks and users.
Said trade-marks or trade names are nominated only for the purposes of information so that any lock for which our keys are made can be rapidly
identied.

INDICE
USE OF THE MANUAL.......................................................................................................................1
GENERAL WARNINGS.......................................................................................................................3
1 MACHINE DESCRIPTION....................................................................................................................4
1.1 Main characteristics ...................................................................................................................5
1.2 Safety..........................................................................................................................................6
1.3 Main working parts (Standard)....................................................................................................7
1.4 Main working parts - with OPTIONAL “Loader Unit” ..................................................................8
1.5 Technical Data ............................................................................................................................9
1.6 Accessories Provided ...............................................................................................................10
2TRANSPORT......................................................................................................................................11
2.1 Packing.....................................................................................................................................11
2.2 Unpacking.................................................................................................................................12
2.3 Machine handling......................................................................................................................12
3MACHINE INSTALLATION AND PREPARATION ..............................................................................13
3.1 Checking for demage................................................................................................................13
3.2 Environmental conditions..........................................................................................................13
3.3 Positioning and installation .......................................................................................................13
3.4 Description of work station........................................................................................................14
3.5 Graphics....................................................................................................................................14
4“SET UP”AND USE OF THE MACHINE............................................................................................15
4.1 Keyboard and function..............................................................................................................15
4.2 Use of standard clamp (L100)...................................................................................................16
4.3 Cuttingcruciformkeys(with3ns) ...........................................................................................19
4.4 Use of the automatic clamp - OPTIONAL.................................................................................20
4.5 Use of loader - OPTIONAL.......................................................................................................22
4.6 Fitting the standard clamp to the machine................................................................................23
4.7 Application/Removing of loader Unit (automatic clamp + loader) - optional.............................24
4.8 Changing cutting tool................................................................................................................26
5OPERATING GUIDE ..........................................................................................................................27
5.1 Initial operation..........................................................................................................................28
5.2 [1] Copy from an original ..........................................................................................................29
5.3 [1] Copy from an original ..........................................................................................................30
5.4 [2] Copy with Corrections..........................................................................................................33
5.5 [2] Copy with Correction............................................................................................................35
5.6 QUEUE FROM PC....................................................................................................................38
5.6.1 DECODING (only with pc program)......................................................................................40
5.7 [4] Calibrations ........................................................................................................................42
5.7.1 CLAMPS CALIBRATION ......................................................................................................42
5.7.1.1 Calibrating the L100 standard clamp (1st calibrating)....................................................43
5.7.1.2 Calibrating the OPTIONALAutomatic clamp L1 (2nd calibrating)..................................47
5.7.2 CUTTER CALIBRATION .....................................................................................................49
5.7.3 ADAPTER CALIBRATION ...................................................................................................49
5.8 [5] MAINTENANCE ................................................................................................................51
5.8.1 Test.......................................................................................................................................51
5.8.2 Machine zeroes ....................................................................................................................56
5.8.3 OPTIONAL Loader Unit........................................................................................................58
5.9 [6] Options.................................................................................................................................60

5.10 Machine message.................................................................................................................65
5.10.1 Error message.................................................................................................................65
5.10.2 ATTENTION messages...................................................................................................65
5.10.3 Alarm Messages .............................................................................................................67
6CLEANING .........................................................................................................................................69
7MAINTENANCE..................................................................................................................................70
7.1 Trouble shooting.......................................................................................................................70
7.2 Maintenace operations..............................................................................................................72
7.3 Access to the top compartment ................................................................................................72
7.4 Access to the bottom compartment ..........................................................................................73
7.5 Cutter replacement ...................................................................................................................73
7.6 Belt replacement and tension adjustment.................................................................................74
7.7 Replacement of the jaws on the automatic optional clamp - OPTIONAL ................................75
7.8 Checking and replacing fuses...................................................................................................76
7.9 Electronic circuit board replacement.........................................................................................78
7.10Keyboard / display replacement................................................................................................79
7.11 Sensors replacement................................................................................................................80
7.12Replacing the condenser (motor) and/or feeder (lamp)............................................................83
7.13Motor replacement....................................................................................................................84
7.14Lamp replacement....................................................................................................................85
7.15Master/emergency switch replacement ....................................................................................85
7.16Clock Battery replacement........................................................................................................86
7.17WIN-TRANSFER Program for loading/updating the internal machine program.......................87
8DISPOSING OF MACHINE................................................................................................................88
9ASSISTANCE .....................................................................................................................................89
9.1 How to request service .............................................................................................................89
Appendix 1 - ELECTRICAL DIAGRAMS...........................................................................................91
Appendix 2 - CE DECLARATION

USE OF THE MANUAL
This manual has been drawn up by the Manufacturer and is an integral part of the machine literature.
The manual gives information it is obligatory for the operator to know and which makes it possible to use the
machine safely.
User’s Manual
This user’s manual is provided because it is essential for proper use and maintenance of the machine.
The manual must be kept carefully throughout the life of the machine, including the decommissioning stage. Keep
in a dry place close to the machine where it is always to hand for the operator.
ATTENTION: IT IS OBLIGATORY to read the manual carefully before using the
machine.
Readers’ characteristics
This manual must be read and its contents acquired by those who will use it.
Manufacturer’s ID
UC199 has an ID plate located on the back of the machine, showing the serial number.
Fig. 1
(*) see chap.8 DISPOSING OF MACHINE.
How to apply for after-sales service
Silca provides purchasers of UC199 with After-Sales Service.
For the total safety of the operator and machine, any operation not described in the manual must be carried out
by the manufacturer or in the special Service Centres recommended by Silca.
At the end of the manual there is a list of manufacturers’ and authorized Service Centre addresses.
The warranty card attached to the machine covers free repairs or replacement of faulty parts for 24 months from
the date of purchase*. All operations must be agreed by the user with Silca or the Service Centre.
* Damage caused by negligence or wrong use of the machine by the user will null the warranty.
Operating Manual UC199
Copyright Silca 2012 1

TERMINOLOGY
For those inexperienced in the subject of keys and key cutting, below is an illustration of the most frequently used
terms:
Fig. 2
1) Head
2) Neck
3) Stop
4) Stem
5) Tip
6) Back
7) Cuts
8) Diameter
GRAPHICS IN THE USER’S MANUAL
Pay attention Obligation to read
the manual
GRAPHICS ON THE UC199 KEY-CUTTING MACHINE
Obligatory use of
safety goggles Laser warning labels (ch.1.2)
Operating Manual UC199
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GENERAL WARNINGS
UC199 is designed to the principles of European Standards (CE).
Right from the design stage solutions have been adopted to eliminate hazards for the operator in all the stages
of use: handling, regulation, use and maintenance.
The materials used in manufacture and the components employed in using UC199 are not dangerous and ensure
that the machine complies to current standards.
Silca S.p.A. has also experimented and applied numerous technical solutions that allow the key-cutting machine
to optimize the quality of the cut keys.
To guarantee maintaining these results over time, please follow the instructions below:
• Observe the procedures described in this manual;
• Always use Original Silca Tools as they are designed to make the best of UC199 and provide quality key-
cutting;
• Use Silca key blanks, made with top quality materials;
• Have the key-cutting machine checked periodically by an authorized Silca After-Sales Service Centre (list at
the end of this manual); always use Silca Original Spare Parts. Beware of imitations!
NORMAL USE
UC199 is a key-cutting machine and must be installed and used according to the rules and specications
established by the manufacturer.
Any other use different from that indicated in this manual will cause the forfeiture of all customers’ rights to make
claims on Silca S.p.A. and may be an unknown source of hazard for the operator or third parties.
ATTENTION: Negligent use or failure by the operator to observe the instructions in this
manual are not covered by the warranty and the manufacturer declines any responsibility in
such cases.
RESIDUAL RISKS
No further risks will arise when properly using the UC199.
SAFETY REGULATIONS
• Always disconnect the machine when it is not in use or when performing maintenance operations.
• Check the electrical wiring periodically; replace any wires that show signs of wear.
• Always work with dry hands free of grease or oil.
• Never pull hard on the power lead and make sure it does not come into contract with oil, sharp objects
or heat. Never remove the earth wire from the plug. Make sure the earth wire connection is sound.
• Do not use the machine in dangerous environments (wet or damp).
• All visitors, especially children, must stay at a safe distance from the machine and must never come
into contact with the electric wiring.
Operating Manual UC199
Copyright Silca 2012 3

1 MACHINE DESCRIPTION
UC199 is an electronic machine operating on two axes with controlled
movement (3rd axis only with OPTIONAL Loader Unit).Accurately studied,
it adds a high degree of cutting precision to operating speed and ease of
use.
UC199 can operate by:
• Reading a key with a laser reader and duplicating it
• Connecting to a PC and using Silca software
Fig. 3
UC199 is used to cut the following types of keys:
only with
UC199 JAPAN
Fig. 4
ATTENTION: keys with cuts that
begin before Stop 0 cannot be cut.
Fig. 5
Operating Manual UC199
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1.1 MAIN CHARACTERISTICS
• Movements
The2axes(X-Y)moveonballscrewsactivatedbystepmotorsonrectiedrollerguidesandballbushes.
• Clamp
Standardfour-sidedclamp,speciallydesignedtogripmostatkeys.
• Working tools
Consists of a cutter in hard metal (carbide), that is easily replaced. Suitable to the type of work and speed rotation
needed.
• Display
Rear-illuminated and placed on the front of the machine.
Display with 4 rows of 20 characters each.
Its technical features and positioning make it highly practical in use.
• Laser reader
Designed to read cuts on keys to be reproduced.
LOADER UNIT - OPTIONAL
• Automatic Clamp
Only for keys as in Fig. 6.
• Loader
Only for keys as in Fig. 6.
TECHNICAL DATA FOR KEYS TO BE CUT WITH OPTIONAL FEEDER
Fig. 6
Key thickness: min.1,8 mm - max.2,6 mm (with jaws A o B)
min. 2,0 mm - max.2,8 mm (with jaws A + 2,0÷2,8)
Max. cutting depth: 3,9 mm (with jaws A); 2,9 mm (with jaws B)
Blade height/width: max.10 mm (with jaws A); max.9 mm (with jaws B)
Key head width: *max. 28 mm
ATTENTION: only for keys with cuts on 1 side and key stop [not keys with plastic heads
(except for SWING and SILKY), not cruciform keys or keys with tip stops].
Operating Manual UC199
Copyright Silca 2012 5

1.2 SAFETY
UC199 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.
UC199 is designed with features which make it completely safe.
• Protective shield
The protective shield is designed to cover the working parts as completely as possible, ensuring operator safety.
Theshield(U)(Fig.8)mustberaisedinordertotkeysforcuttingorcarryoutotheroperations.
Raising of the shield is controlled by a microswitch and disactivates the operating and movement functions,
including the cutter. A special message appears on the display to warn that the shield is not closed.
To re-start the work cycle, place the shield in its original position and press START on the machine’s keyboard.
• Emergency stops
The red emergency button (A) (Fig. 8), located on the left of the keyboard is used to stop it immediately in the
event of faulty operation or danger for the operator.
When the cause of the emergency has been eliminated, turn the button 45° clockwise to disactivate it.
NOTE: the operator is responsible for keeping the area around the button clear so that it can be
reached as quickly as possible.
• Laser warning
Regulations require that warning labels (supplied - ch.1.6) in the language to be used be attached to the optical
reader, as shown in Fig. 7.
Fig. 7
• Cutter motor protection
The cutter motor is protected against overheating by a cut-out switch (located inside the motor) that will
automatically stop the motor if it reaches a certain temperature. Should the switch activate:
1) turn the machine off and disconnect the power supply cable.
2) contact Silca’s Technical Assistance Dept.
Operating Manual UC199
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1.3 MAIN WORKING PARTS (STANDARD)
Fig. 8
A - master switch / emergency button
B- keyboard
C- display
D- clamp optical reader
D2 - clamp cutter side (standard)
E- optical reader clamp knob
E2 - clamp knob - cutter side
F - key gauge - optical reader side
F2 - key gauge - cutter side
H- cutter
I- cutter shield
L- optical reader
P- power input
Q- serial port
S- X axis carriage
T- Y axis front panel
U- protective shield
V- swarf tray
V1 - swarf tray
W - glove compartment
Operating Manual UC199
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1.4 MAIN WORKING PARTS - WITH OPTIONAL “LOADER UNIT”
Fig. 9
A - master switch / emergency button
B- keyboard
C- display
D - clamp optical reader
D1- clamp cutter side (Automatic)
E- optical reader clamp knob
F- key gauge – optical reader side
H- cutter (Fig. 8)
I- cutter shield (Fig. 8)
L- optical reader
P- power input (Fig. 8)
Q - serial port (Fig. 8)
S- X axis carriage
T- Y axis front panel
U- protective shield
V- keys tray
V1- swarf tray
V2 - key slide
W - glove compartment
Z-loader
D741756ZB
Set Feeder
Operating Manual UC199
Copyright Silca 2012
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1.5 TECHNICAL DATA
Electricity supply:
230V - 50Hz
100V - 50/60Hz (UC199 Japan)
Maximum absorbed power:
230V: 2,1 Amp. 300 Watt
100V: 3,3 Amp. 200W
Cutter motor:
single phase and speed
Cutter:
hard metal (carbide)
Tool speed:
50Hz: 2110 rpm
60Hz: 2530 rpm
Movement:
on2axeswithballscrewsactivatedbystepmotors,onrectiedrollerguidesandballbushes.
Standard clamp UC199:
universal4sidedclamptogripat,carandcruciformkeys
UC199 Japan clamp:
4sidedclamptogripat,car,cruciformkeysandMIWAkeys
Automatic clamp (with optional Loader Unit)
Automatictogripatkeys(seeFig.2)
Runs:
X axis: 74 mm Y axis: 45 mm
Dimensions:
width: 396 mm (with optional key tray: 458 mm) depth: 543 mm height: 386 mm (with raised shield 590 mm)
Mass:
Kg. 50
Noise level:
sound pressure Lp(A) = 83 dB(A) (cutting steel keys)
78 dB(A) (cutting brass keys)
CLASS 1 LASER READER:
• Maximum radiation with safety lock excluded: 170 µW
• Wave length: 785 µm (invisible)
• Classed to: EN 60825-1:1994 + E.C.1995 + A1:2002 + A2:2001
Operating Manual UC199
Copyright Silca 2012 9

1.6 ACCESSORIES PROVIDED
UC199 comes with a set of accessories for its operation and maintenance (tools, hex wrenches, fuses) supplied
in a special tool kit comprising:
tools kit 4 mm allen key
template Z3 (regulating key)
tip stop with notch 5 mm allen key Z4 serial test connector
tip stop 6 mm allen key Z19 template for Zero machine
Cutter release rod 6.3 Amp fuse - delayed Z20 template
10 mm spanner 4 Amp fuse - delayed ø 1,7 mm steel pin
13 mm spanner 2 Amp fuse - delayed ø 1,2 mm steel pin
14 mm spanner 5 Amp fuse rapid (for 230V)
10 Amp fuse rapid (for 100V) Slanted brush
2 mm allen key 10 Amp fuse - delayed Emergency button release clip
2,5 mm allen key Serial cable 9/9 Laser warning labels
3 mm allen key 3 mm allen key USB serial cable
Operating Manual UC199
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2 TRANSPORT
The key-cutting machine is easily transported and is not dangerous to handle.
The packed machine should be carried by at least two people.
2.1 PACKING
• The packing for UC199 is designed to ensure safe transportation and to protect the machine and all its parts.
• It comprises a pallet base (b) to which the machine is attached, and a cardboard box as a cover (a).
• Themachineisxedtothebaseofthepalletwithscreweddownbracketsthatholditrm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rmlyonthepallet.
• The symbols on the outside of the cardboard box give indications for transport.
Fig. 10
Keep dry Keep dry This side up Use no hooks
To prevent any damage to the machine it is advisable to save and use the brackets provided for future
transportation.
Operating Manual UC199
Copyright Silca 2012 11

2.2 UNPACKING
To remove the machine from the packing box:
1) cut the straps with scissors and remove.
2) raise the top part of the cardboard box.
3) loosen the screws, both on the front and back brackets that hold the machine to the pallet.
4) use the special spanner, to loosen the nuts on the machine’s feet.
5) remove the metal brackets and re-tighten the nuts on the feet.
6) check the contents in the box, that should comprise with the following:
1 UC199 key-cutting machine
1 set of documents, including: an operating manual, a spare parts list and a guarantee
1 power supply cable
1 serial cable
1
pouch/ tool kit
1 USB serial cable
1 Loader Unit (*)
NOTE: we strongly recommend you keep the packing intact for future transportation.
2.3 MACHINE HANDLING
When the UC199 has been unpacked, place it directly on its workbench; this operation should be carried out by
at least two people.
ATTENTION: Takecaretoliftthemachinermlyholdingthebase,andnootherpart.
Fig. 11
Operating Manual UC199
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3 MACHINE INSTALLATION AND PREPARATION
The key-cutting machine can be installed by the purchaser and does not require any special skills.
It is supplied ready for use and does not need any special set up. However, the operator may have to control a
few things before operating the machine.
3.1 CHECKING FOR DEMAGE
UC199 is solid and compact and will not normally damage if transport, unpacking and installation have all been
carried out according to the instructions in this manual. However, it is always advisable to check that the machine
has not suffered any damage
3.2 ENVIRONMENTAL CONDITIONS
To ensure that the best use is made of the key-cutting machine, it is important to place it in a well-aired area which
is not too damp.
The ideal conditions for the machine are:
- temperature between 10°C and 40°C; relative humidity: 60% approx.
3.3 POSITIONING AND INSTALLATION
1) Place the machine on a horizontal surface, solid enough to support the weight of (50 Kg).
- to work with ease, we suggest that the workbench be approximately the height of the operator’s hip.
- it is important to leave clearance of at least 30 cm behind the machine and on each side to ensure proper
ventilation.
2) Ensure that the machines voltage is the same as that of the mains power supply, which must be properly
earthed and provided with a differential switch.
3) Connect the power supply cable to the power supply socket.
Fig. 12
Operating Manual UC199
Copyright Silca 2012 13

3.4 DESCRIPTION OF WORK STATION
The machine needs only one operator, who has the following controls at his/her disposal (Fig. 8):
• general power switch/emergency button located on the front left-hand side of the keyboard
• key-positioning clamp
• keyboard
• display
3.5 GRAPHICS
• The front panel carries an adhesive warning label (Fig. 14). This label must never be removed.
• Two laser warning labels must be attached to the optical reader (Fig. 14), (provided - Ch.1.6).
Fig. 13
Do not use compressed air for cleaning Laser warning labels
Fig. 14
Operating Manual UC199
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4 “SET UP” AND USE OF THE MACHINE
4.1 KEYBOARD AND FUNCTION
The machine’s keyboard has 9 function keys.
Fig. 15
FUNCTION KEYS
STOP: Stop button, particularly when the machine is in motion.
Stops the function in progress at any time in the operation.
START: Starts the machines operations (only with the shield in its closed position).
ENTER: Activation of various functions in the menu.
CLEAR: Deletes numerical characters.
SHIFT + CLEAR: Combine the SHIFT + CLEAR keys to automatically switch to the “Copy from original” function
from any menu in the UC199 internal program (Ch.5.2).
SHIFT + STOP: Combine the SHIFT+STOP keys to re-position the carriages accurately (operation from the main
menu only, or if the cutting process is interrupted).
REGULATING THE DISPLAY
it is possible to modify the angle of vision (illumination) on the machine’s display by following the instructions
below.
• Press the arrow key [Down] to get a better view from below and then press the arrow key [Up], simultaneously
keeping the arrow keys both pressed [Up/Down] up until you reach the desired visualization.
• Press the arrow keys [Up/Down] to get a better view from above and then press the arrow key [Down],
simultaneously keeping the arrow keys both pressed [Up/Down] up until you reach the desired angle.
Operating Manual UC199
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4.2 USE OF STANDARD CLAMP (L100)
Cutting Clamp Reading Clamp
Fig. 16
Thefour-sidedclampensuresexcellentgriponthekeysplacedontheirbackorprolesides(Fig.17).
• To copy keys (which may be secured to any of the clamp sides A, B, C or D) the user will choose the most
suitable side of the clamp to use (Fig. 17).
CLAMP UC199
Fig. 17
Operating Manual UC199
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