Silca Unocode 399 Plus User manual

®
D437711XA
vers. 1.0
Operating manual
GB

(c) 2010 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:
october 2010
Printed in Vittorio Veneto
by SILCA S.p.A.
via Podgora, 20 (Z.I.)
31029 VITTORIO VENETO (TV) - Italy
IMPORTANT NOTE: in compliance with current regulations relating to industrial property, we hereby state that the
trade-marks or trade names mentioned in our documentation are the exclusive property of authorized
manufacturers of locks and users.
Said trade-marks or trade names are nominated only for the purposes of information so that any lock for which our
keys are made can be rapidly identified.

INDEX
REFERENCE GUIDE .............................................................................................1
GENERAL ...............................................................................................................2
1 MACHINE DESCRIPTION ...............................................................................4
1.1 MAIN CHARACTERISTICS ................................................................................ 4
1.2 SAFETY ........................................................................................................ 5
1.3 MAIN WORKING PARTS .. ................................................................................ 6
1.4 TECHNICAL DATA .......................................................................................... 8
1.5 ACCESSORIES PROVIDED . ............................................................................. 9
2 TRANSPORT .................................................................................................10
2.1 PACKING . ................................................................................................... 10
2.2 UNPACKING ... ............................................................................................. 11
2.3 MACHINE HANDLING .................................................................................... 11
3 MACHINE INSTALLATION AND PREPARATION .......................................12
3.1 CHECKING FOR DAMAGE .. ........................................................................... 12
3.2 ENVIRONMENTAL CONDITIONS .. ................................................................... 12
3.3 POSITIONING AND INSTALLATION .................................................................. 12
3.4 DESCRIPTION OF WORK STATION ................................................................. 13
3.5 GRAPHICS .. ................................................................................................ 13
4 “SET UP” AND USE OF THE MACHINE .....................................................14
4.1 USE OF THE CLAMP . ................................................................................... 14
4.2 FITTING THE CLAMP TO THE MACHINE . ......................................................... 16
4.3 CUTTER .. ................................................................................................... 16
4.4 CHANGING THE CUTTER ... ........................................................................... 16
5 OPERATING GUIDE .....................................................................................17
5.1 ON-BOARD KEYPAD AND FUNCTIONS ........................................................... 17
5.2 PRELIMINARY OPERATIONS . ........................................................................ 18
5.3 COPY BY DATA CARD . ................................................................................ 19
5.3.1 FAVOURITE DATA CARDS ........................................................................24
5.3.2 ACCESSORY FUNCTIONS FOR “COPY BY DATA CARD” ............... 25
5.4 SPECIAL CASES ..................................................................................... 31
5.4.1 CUTS NOT ALLOWED .............. ................................................................ 31
5.4.2 LIMITED ACCESS TO DATA (PROTECTED SYSTEMS) ............ ...................... 32
5.5 PC QUEUE FUNCTION ............................................................................. 33
5.6 CODEMAKER CARD MANAGEMENT ............................................................ 36
5.7 GAUGING ................................................................................................. 40
5.7.1 CALIBRATE STANDARD JAWS ............................................................. 41
5.7.2 CALIBRATE CUTTERS .......................................................................... 43
5.7.3 CALIBRATE ADAPTERS ........................................................................ 43
5.8 MAINTENANCE . ...................................................................................... 44
5.8.1 MOTOR TESTS ................................................................................... 44
5.8.2 DIGITAL INLETS TEST ....................................................................... 44
5.8.3 DIGITAL OUTLETS TESTS ................................................................. 45
5.8.4 KEYPAD TEST .................................................................................... 45
5.8.5 DISPLAY TEST ................................................................................... 45
5.8.6 SERIAL PORT ..................................................................................... 45
5.8.7 MACHINE ZERO POINTS ................................................................... 46
5.8.8 PHOTOCELLS AND SENSORS REGULATION ................................. 49
5.9 OPTIONS . ................................................................................................ 52
5.10 ENABLING .. ............................................................................................. 55
5.11 MESSAGES ................................................................................................. 56
5.11.1 ATTENTION MESSAGES ........... ................................................................ 56
5.11.2 ERROR MESSAGES ................. ................................................................ 58
5.11.3 ALARM MESSAGES ................. ................................................................ 59
5.11.4 CODEMAKER MESSAGES ..................................................................... 60

6 CLEANING ....................................................................................................62
7 MAINTENANCE .............................................................................................63
7.1 TROUBLE SHOOTING ... ................................................................................ 63
7.2 MAINTENANCE OPERATIONS .. ...................................................................... 65
7.3 CUTTER REPLACEMENT ............................................................................... 65
7.4 BELT REPLACEMENT AND TENSION ADJUSTMENT . ......................................... 66
7.5 CHECKING AND/OR REPLACING FUSES ... ...................................................... 67
7.6 ELECTRONIC CIRCUIT BOARD REPLACEMENT .. .............................................. 68
7.7 KEYBOARD/DISPLAY REPLACEMENT .. ........................................................... 69
7.8 ACCESS TO BACK COMPARTMENT . .............................................................. 70
7.9 ACCESS TO BOTTOM COMPARTMENT .. ......................................................... 70
7.10 SENSOR REPLACEMENT ... ........................................................................... 71
7.11 PHOTOCELL REPLACEMENT . ........................................................................ 73
7.12 BATTERY REPLACEMENT .. ........................................................................... 74
7.13 WIN-TRANSFER PROGRAM ..................................................................... 75
8 DISPOSING OF MACHINE ...........................................................................76
9 ASSISTANCE ................................................................................................77
9.1 HOW TO REQUEST SERVICE .. ...................................................................... 77
Appendix 1 - ELECTRICAL DIAGRAM ............................................................ I - XI
Appendix 2 - DECLARATION COMPLIANCE

Operating manual - English Unocode 399 PLUS
Copyright S ilca 2010 1
REFERENCE GUIDE
This manual has been produced to serve as a guide for users of the UNOCODE 399 PLUS electronic key-
cutting machine. Read it carefully; it is essential if you wish to operate your machine safely and efficiently
.
C ONSULTATION
The contents of the manual are divided into sections relating to :
• Machine description ................................................................................. Chapter 1
• Transport and installation ........................................................................... Chapters 2-3
• Regulation and use ................................................................................. Chapters 4-5-6
• Maintenance ... .............................................................................. Chapters 7-8-9
T ECHNICAL 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
.
Fig. 1
1) Head
2) Rim
3) Stop
4) Stem
5) Tip
6) Back
7) Cuts
CARD NUMBER:
Silca nu mber f or cu tting b y c ode on Si lca e lectronic
machines for flat keys.
Fig. 2
2
1
5
3
6
4
1
3
7
5
7
2
NUMERO SCHEDA
Card Number
FROM SILCA KEY CATALOGUE

Unocode 399 PLUS Operating manual - English
2 Copyright S ilca 2010
GENERAL
UNOCODE 399 PLUS 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
.
U SE
UNOCODE 399 PLUS 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 incorrect use of the machine .
I NSTRUCTIONS MANUAL
The instructions manual provided with the machine is essential to its proper use and to carry out the
necessary maintenance.
We therefore re commend pro tecting the ma nual from da mage in a safe sheltered p lace, easil y to
hand for quick consultation.
I NCORRECT USE
Operator neglige nce resulting in improper use o f 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 .
F URTHER RISKS
No further risks will arise when properly using the UNOCODE 399 PLUS.
P ROTECTION AND SAFETY PRECAUTIONS FOR THE OPERATOR
UNOCODE 399 PLUS is entirely built in compliance to the Machine Directives. The operations for which
it has been designed are easily carried out with no risk to the operator
.
The ado ption of general safety pr ecautions and observation of the instructions prov ided by the
manufacturer in this manual eliminate all human error, unless deliberate
.
UNOCODE 399 PLUS
is designed with features which make it completely safe .
• Power supply
UNOCODE 399 PLUS 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 .
• Maintenance
The operations to regulate, service, repair and clean the machine are structured in the simplest and safest
way possible. Parts that the operator can dismount cannot be incorrectly replaced therefore avoiding any
risks .

Operating manual - English Unocode 399 PLUS
Copyright S ilca 2010 3
• Machine identification
The machine is provided with an identification label which includes the machine’s serial number (fig. 3).
Fig. 3
(*) see chap.8 "DISPOSING OF MACHINE", page 76.

Unocode 399 PLUS Operating manual - English
4 Copyright S ilca 2010
1 MACHINE DESCRIPTION
UNOCODE 399 PLUS i s an electronic machin e o perating on two a xes (3rd axis op tional) 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 different ways :
• entering the key code directly by means of the machine keyboard
• linking to a PC and Silca software
Fig. 4
1.1 MAIN CHARACTERISTICS
• Movements
Movement of the two axes (X-Y) operates on ball screws activated by step motors, on rectified roller guides .
•Clamp
Standard four-sided clamp, specially designed to grip most flat keys .
• Working tool
Consists of a cutter in hard metal carbide , that is easily replaced.
Suitable to the type of work and speed rotation needed
.
•Display
Placed on the front of the machine .
Its technical features and positioning make it highly practical in use .

Operating manual - English Unocode 399 PLUS
Copyright S ilca 2010 5
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 6) must be raised in ord er to fit keys for cu tting or carry ou t other
operations.
Raising of th e shield is controll ed by a micros witch and disactivates t he operating and movemen t
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 6) placed on the right-hand side of the machine is used to
stop it immediately in the event of faulty operation or danger for the operator.
When the cause of the emergency has been eliminated, turn the button 45° clockwise to disactivate it.
Note: the operator is responsible for keeping the area around the button clear so that it can be reached
as quickly as possible.
• Cutter motor protection
The cutter motor is pr otected against overheating by a cut-out switch (located insi de 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.

Unocode 399 PLUS Operating manual - English
6 Copyright S ilca 2010
1.3 MAIN WORKING PARTS
Fig. 5
BC
D
E
F
H
I
P
O
Q
S
U
V
Q1
U1
T N
R
KJ

Operating manual - English Unocode 399 PLUS
Copyright S ilca 2010 7
Fig. 6
A - master switch
A1 - power socket / fuse tray
B- keyboard
C - display
D - clamp - cutter side
E - clamp knob
F - key gauge
H-cutter
I - cutter shield
J - STOP button
K - START button
L - external START/STOP connector
L1 - connector for unload sorter (*)
L2 - serial receptacle for suction (*)
N - emergency button
O - 3rd axis
P - IN/OUT port (Automatic feeder*)
Q - serial port
Q1- USB port
R - Y axis connector
S - X axis carriage
T - Y axis carriage
U - protective shield
U2 - vacuum system connector
V - swarf tray
(*) Feeder Kit, Suction Kit and Sorter Kit are optional accessories.
AA1 ROPJ K
Q1
L
L2
Q
L1

Unocode 399 PLUS Operating manual - English
8 Copyright S ilca 2010
1.4 TECHNICAL DATA
Electricity supply :
230V-50Hz
Nominal power :
230V: 1,1 Amp. 210 Watt
cutter motor :
single phase and speed
cutter :
hard metal
Tool speed :
• 50Hz: 2370 rpm (+/- 10%)
Movement s:
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 : 700 mm height : 700 mm ( with raised shield 900 mm)
Mass :
Kg. 51
Noise level :
sound pressure Lp(A) = 80 dB(A) ( cutting iron keys )
77 dB(A) (
cutting brass keys )

Operating manual - English Unocode 399 PLUS
Copyright S ilca 2010 9
1.5 ACCESSORIES PROVIDED
UNOCODE 399 PLUS comes with a set of acce ssories for its oper ation and maintenance ( tools, hex
wrenches, fuses) supplied in a special tool kit comprising
:
tool kit
10 mm spanner D916657ZR
Z1 template
(regulating disk)
D931090ZR
tip stop bar with notch
13 mm spanner Z20 setting template
tip stop bar D912423ZR
2 Amp fuse
- delayed
D916658ZR
Z3 template
(regulating key)
D900754ZR
cutter release
rod
D901185ZR
4 Amp fuse
- rapid
Z4 serial test connector
D931082ZR
2 mm allen key
D916568ZR
10 Amp fuse
- delayed
belt tension
plate
2,5 mm allen key
D908726ZR
4 Amp fuse
- delayed
D933777ZR
ø 1,7 mm steel pin
3 mm allen key
D910652ZR
6,3 Amp fuse
- delayed
ø 1,2 mm steel pin
4 mm allen key D906963ZR
19 mm
socket wrench
D909281ZR
serial cable 9/9
5 mm allen key D906935ZR
slanted
brush
D929095ZR
USB cable
6 mm allen
key

Unocode 399 PLUS Operating manual - English
10 Copyright S ilca 2010
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 UNOCOD E 399 PLUS is design ed to ensure safe tr ansportation and to protect the
machine and all its parts
.
It comprises a pallet base (b) to which the machine is attached, and a cardboard box as a cover (a).
The machine is fixed to the base of the pallet with screwed down brackets that hold it firm into place. This
prevents the machine and its protective shield from any damage
.
The closed packing is held in place by two straps which hold the cardboard box firmly on the pallet .
Symbols are printed on the outside of the cardboard box to give instructions and warnings for
transportation
.
Fig. 7
To prevent any damage to the mac hine it is advisable to save and use the brackets provided for future
transportation
.
a
b
Keep dry This side up
Handle with care Use no hooks

Operating manual - English Unocode 399 PLUS
Copyright S ilca 2010 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 (provided in the tool kit), 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 UNOCODE 399 PLUS 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
2.3 MACHINE HANDLING
When the UNOCODE 399 PLUS has been unpacked, place it directly on its workbench; this operation
should be carried out by at least two people.
Take care to lift the machine firmly holding the base, and no other part.
ATTENTION: never lift the machine by holding the keyboard stand (fig. 8).
Fig. 8
INCORRECT! CORRECT !

Unocode 399 PLUS Operating manual - English
12 Copyright S ilca 2010
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 DAMAGE
UNOCODE 399 PLUS is solid and compact and will not normally damage if transpor t, unpacking and
installation hav e all been carried out acco rding to the instructions in th is 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-c utting 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%
3.3 POSITIONING AND INSTALLATION
1) Place the machine on a horizontal surface, solid enough to support the weight of 51 Kg.
- to work with ease, we suggest that the workbench be approximately the height of the operator’s
hip
.
-
it is im portant to leave clearance of at least 30 cm behind the machine and on each side to
ensure proper ventilation
.
2) Ensure th at the machines voltage is the same as that of the main s 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. 9
30 cm
30 cm
30 cm
100 cm

Operating manual - English Unocode 399 PLUS
Copyright S ilca 2010 13
3.4 DESCRIPTION OF WORK STATION
The machine needs only one operator, who has the following controls at his/her disposal (fig. 5, page 6):
• master switch placed on the back of the machine
• key-positioning clamp
• keyboard
• display
• emergency button
3.5 GRAPHICS
• There is a prohibition warning label on the front side of the machine (fig. 10). This label must never
be removed.
Fig. 10
Do not use compressed air
for cleaning

Unocode 399 PLUS Operating manual - English
14 Copyright S ilca 2010
4 “SET UP” AND USE OF THE MACHINE
4.1 USE OF THE CLAMP
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 should be fitted mainly on the A and/or
B side of the clamp.
Fig. 11
- The side of the clamp on
which to plac e the key is
shown on the mac hines
display.
Fig. 12
Fig. 13 - key stops
Clamp
V100
1
2
3
4
2
C
4
3
2
3
4
1
4
D
B
A
2
1
1
3
D side
C side
B side
A side
1
2
3
4
0
B
4
3
1
C
D
4
3
1
A
4
3
2
1
6

Operating manual - English Unocode 399 PLUS
Copyright S ilca 2010 15
ATTENTION: the knob is gauged so that it do not exert too
much pressure for closing (if pressure is too high it only idles),
which would damage the key and the parts of the clamp
(including the knob).
To turn the clamps:
With loosened handle (E) a light rotation of the clamp is
sufficient (gripping by the 2 jaws) to turn it to the required
side. Alignment is automatic and guaranteed by the mobile
pressure device (D5) (fig. 14).
Fig. 14
Note: before starting to cut a key the V100 clamp gauge goes automatically to the idle position so there
is no need to lower it.
U SING PINS
Pins must be used in the case of keys with special profiles, to stop the keys
from moving and vibrating.
Fig. 15
Fig. 16
D5
E
Attention: the pin
should be placed
vertically
2
C
4
3
2
3
4
1 4
D
B
A
2
1
1
3
pin

Unocode 399 PLUS Operating manual - English
16 Copyright S ilca 2010
4.2 FITTING THE CLAMP TO THE MACHINE
To remove the clamp unit:
- loosen the grub s crew (D2) ( fig. 17) and s lide the
clamp out of the dovetail guide.
To install the clamp unit on the machine:
- slide the clamp into the do vetail guide, pushing it all
the way in, then secure it by tightening the grub screw
(D2).
These instruction s refer exclu sively to th e stan dard
clamp (V1 00). For the use of option al cl amps please
refer to the instructions provided along with them.
Fig. 17
4.3 CUTTER
The majority of keys utilize the standard cutter for code cutting. Only in certain cases some special
keys with particular type cuts require different cutters.
To change the cutter see chapter 4.4.
4.4 CHANGING THE CUTTER
1) raise the protective shield.
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. 18).
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 anticlockwise) and remove the rod from its hole.
6) place the cutters protective shield (i) back into position securing it with the screw (i2).
Fig. 18
ATTENTION: when replacing a worn cutter with a new one or with a re-sharpened cutter consult
chap.5.7 "GAUGING", page 40.
D2
X1
X
i2
i
loosen
tighten