Silca Omnia User manual

Operating Manual
Original Instructions
D442661XA
vers. 3.0
EN
Omnia
Omnia Max
Omnia W Max
Omnia 650rpm

© 2013 SILCA S.p.A - Vittorio Veneto
This manual has been drawn up by SILCA S.p.A.
Allrightsreserved.Nopartofthispublicationcanbereproducedorcirculatedbyanymeanswhatsoever(photocopies,
microfilm or other) without the consent of SILCA S.p.A.
Edition: June 2016
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 machine.
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
identified.

INDEX
USE OF THE MANUAL.......................................................................................................................1
TERMINOLOGY..................................................................................................................................2
GENERAL WARNINGS.......................................................................................................................4
1 MACHINE DESCRIPTION....................................................................................................................6
1.1 OMNIA / OMNIA650rpm: main working parts.............................................................................7
1.2 OMNIA MAX / OMNIA W MAX: main working parts.....................................................................8
1.2.1 OMNIA MAX: Clamp carriage for VERTICAL CUTS.........................................................9
1.2.2 OMNIA W MAX: Clamp carriage for VERTICAL CUTS.....................................................9
2 MAIN CHARACTERISTICS................................................................................................................10
3 ACCESSORIES PROVIDED..............................................................................................................13
4 Technical Data....................................................................................................................................14
4.1 Electrical diagram.......................................................................................................................14
5 TRANSPORT......................................................................................................................................15
5.1 Packing.......................................................................................................................................15
5.2 Pack opening..............................................................................................................................15
5.3 Unpacking ..................................................................................................................................16
5.4 Removing the stop .....................................................................................................................18
5.5 Separate parts ...........................................................................................................................18
5.5.1 Power cable ....................................................................................................................18
5.5.2 Warning label .................................................................................................................18
5.5.3 Carriage levers................................................................................................................19
5.5.4 OMNIA/OMNIA 650rpm: standard carriage (bit, double bit and pump keys) ..................19
5.5.5 OMNIA MAX / OMNIA W MAX: carriage for bit, double bit and pump keys....................20
5.5.6 OMNIA MAX / OMNIA W MAX: clamp carriage for vertical cuts.....................................20
5.5.7 OMNIA MAX / OMNIA W MAX: solution with a SINGLE CARRIAGE.............................21
5.6 Removing the clamp carriage.....................................................................................................22
6 MACHINE INSTALLATION AND PREPARATION ..............................................................................23
6.1 Checking for damage.................................................................................................................23
6.2 Environmental conditions...........................................................................................................23
6.3 Positioning .................................................................................................................................23
6.4 Description of work station ........................................................................................................23
6.5 Connection to the mains.............................................................................................................23
7 MACHINE REGULATION AND UTILIZATION....................................................................................24
7.1 Micrometric tracer point..............................................................................................................24
7.2 Tracer point spring .....................................................................................................................24
7.3 Using the tilting clamp (carriage for bit/double bit and pump keys)............................................25
7.4 Locking Y axis............................................................................................................................25
7.5 Checking and calibration............................................................................................................26
7.5.1 Axis calibration - carriage for bit, double bit and pump keys...........................................26
7.5.2 Axis calibration - clamp carriage for vertical cuts (Omnia MAX / Omnia W MAX) ..........27
7.5.3 Depth calibration - carriage for bit, double bit and pump keys........................................28
8 CUTTING OPERATIONS ...................................................................................................................30
8.1 Cutting bit and double bit keys...................................................................................................31
8.1.1 Cutting short keys ...........................................................................................................32
8.2 Cutting double female bit keys...................................................................................................33
8.3 Cutting keys with centre stop .....................................................................................................34

8.4 Cutting bit keys with rear stop (Omnia MAX / Omnia W MAX)...................................................35
8.5 Cutting pump keys......................................................................................................................36
8.6 Cutting keys with vertical cuts (Omnia MAX/Omnia W MAX carriage).......................................37
9 MAINTENANCE..................................................................................................................................38
9.1 Replacing the carriage ..............................................................................................................38
9.2 Replacing the tracer point .........................................................................................................38
9.3 Replacing the cutter ...................................................................................................................38
9.4 Replacing the brush ...................................................................................................................39
9.5 Replacing the fuses....................................................................................................................39
9.6 Accessing the bottom compartment...........................................................................................40
9.7 Replacing the ON/OFF switch ...................................................................................................40
9.8 Replacing the motor start button................................................................................................41
9.9 Replacing the reset switch .........................................................................................................41
9.10 Replacing the microswitch..........................................................................................................42
9.11 Replacing the brush button ........................................................................................................43
9.12 Replacing the plug/socket/filter ..................................................................................................44
9.13 Replacing the relay ....................................................................................................................44
9.14 Replacing the lamp power box...................................................................................................45
9.15 Replacing the motor condenser .................................................................................................45
9.16 Replacing the Plexiglas shield ...................................................................................................46
9.17 Replacing the lamp.....................................................................................................................47
9.18 Replacing and/or tightening the belt...........................................................................................48
9.19 Replacing the motor...................................................................................................................49
10 DISPOSAL..........................................................................................................................................51
11 ASSISTANCE .....................................................................................................................................52
11.1 How to request service...............................................................................................................52
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.
The OMNIA key-cutting machine is designed for professional use by adults of either gender in full possession of
their physical, sensorial or mental capacities.
Manufacturer’s ID
OMNIA has an ID plate located on the back of the machine, showing the serial number.
Fig.1
(*) see chap. 10 DISPOSAL.
How to apply for after-sales service
Silca provides purchasers of OMNIA 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; if the manual
was downloaded is necessary visit the website to see the contacts (www.silca.biz).
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 OMNIA / OMNIA 650rpm / OMNIA MAX / OMNIA W MAX
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TERMINOLOGY
For those inexperienced in the subject of keys and key cutting, below is an illustration of the most frequently used
terms:
Keys with rear stops
and keys with vertical cuts:
STANDARD with
OMNIA MAX and OMNIA W MAX
Fig.2
1) Head
2) Stem 3) Tip 4) Bit 5) Stop 6) Side 7) Cuts 8) Vertical cuts
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GRAPHICS IN THE USER’S MANUAL
Pay attention Obligation to read
the manual Using ear protection QR Code *
GRAPHICS ON THE OMNIA KEY-CUTTING MACHINES
Obligatory use of
safety goggles Obligation to read the manual Motor start
push button symbol Brush button
symbol QR Code *
Omnia
Omnia MAX
Omnia 650rpm
Omnia W MAX
Adhesive label
Mass - RPM - Fusibles Adhesive label DANGEROUS MOBILE PARTS (provided - chap.3)
(*) A QR code is a two dimensional bar code used to memorize information to be read by means of a mobile phone
or smart phone. Read the QR code on the machine to connect to useful and constantly updated information relating
to key-cutting machine maintenance, useful tips for your OMNIAkey-cutting machine and see the continuously evol-
ving range of optional accessories.
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GENERAL WARNINGS
OMNIA 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 OMNIA 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 OMNIA 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!
ATTENTION: in the event of prolonged use, cutting extra thick bits or
keys in hard materials (iron, steel) we recommend using individual ear
protection devices.
NORMAL USE
OMNIAisakey-cuttingmachine(seechap.1)andmustbeinstalledandusedaccordingtotherulesandspecifications
established by the manufacturer.
The OMNIA key-cutting machine is designed for use on business or industrial premises (e.g. hardware shops, key
cutting centres, etc...).
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.
SAFETY
The key-cutting machine is built entirely to standards. The operations for which it has been designed are
easily carried out at no risk to the operator.
The adoption of general safety precautions (wearing protective goggles) and observation of the instructions
provided by the manufacturer in this manual eliminate all human error, unless deliberate.
The key-cutting machine is designed with features which make it completely safe in all its parts.
• CUTTER MOTOR PROTECTION
ATTENTION: the cutter motor is protected from overheating by a device (inside the motor) that
stops it whenit reaches a dangerous temperature.
This condition can occur when the machine motor is left on continuously (protection will cut in after approximately
40 minutes), with high ambient temperatures or in severe working conditions (considering an average work cycle
- duty cycle 85% - protection will cut in after approximately 1 hr 40 minutes). If the cutter motor overheats it cuts
outautomatically. In such cases proceed as follows:
a) turn off the master switch (A).
b) let the motor cool for at least 2 hours then use the machine normally.
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• MOTOR START PUSH BUTTON
The machine is protected from untimely machine start. When the carriage is all the way back towards the operator
a safety microswitch turns off the motor. If the carriage is inadvertently moved towards the cutter the motor does
not start.
To start the motor (with the machine on) move the carriage slightly towards the cutter and press the motor start
button (B).
RESIDUAL RISKS
No further risks will arise when properly using the OMNIA, OMNIA 650rpm, OMNIA MAX and OMNIA W MAX
machines.
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 tug on the electricity supply lead and make sure it is not in contact with oil or other liquids,
sharp objects or heat. Never remove the earthing pin from the plug. Check that the earthing wire is
connected properly.
• 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.
• Place the adhesive label provided “DANGEROUS MOBILE PARTS” as shown in chap.5.5.2.
Operating Manual OMNIA / OMNIA 650rpm / OMNIA MAX / OMNIA W MAX
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1 MACHINE DESCRIPTION
OMNIA and OMNIA 650rpm are professional key-cutting machines for bit, male and female* double bit, and pump
keys.
OMNIA - OMNIA 650rpm
STANDARD
(*) It is advisable to use optional accessories for female bit and double bit keys.
Fig.3
OMNIA MAX and OMNIA W MAX are professional key-cutting machines for bit, male and female* double bit keys
and pump keys with vertical cuts.
OMNIA MAX - OMNIA W MAX
STANDARD
with carriage for bit, double bit and pump keys
(*) It is advisable to use optional accessories for female bit and double bit keys.
STANDARD
with carriage
for vertical cuts
Fig.4
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1.1 OMNIA / OMNIA 650rpm: main working parts
Fig.5
A - ON/OFF switch
A1 - power supply socket with fuses
B - motor start button
C - cutter
D - tracer point
D1 - tracer point spring cam
D2 - micrometric ring nut for tracer point regulation
E - clamp carriage
F - clamp carriage locking handle
G - Y axis locking knob
H - motor
L - translation lever
M - fixed clamp for bit, double bit and pump keys
M1- mobile clamp for bit, double bit and pump keys
P - fixed clamp tightening handle
P1 - mobile clamp tightening handle
Q - mobile clamp locking lever
R - mobile clamp rotation lever
S - plexiglas safety shield
S1 - cover
T - lamps
U - brush
U1 - brush push button
V - swarf tray
Fig.6
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1.2 OMNIA MAX / OMNIA W MAX: main working parts
Fig.7
A - ON/OFF switch
A1 - power supply socket with fuses
B - motor start button
C - cutter
D - tracer point
D1 - tracer point spring cam
D2 - micrometric ring nut for tracer point regulation
E - clamp carriage
F - clamp carriage locking handle
G - Y axis locking knob
H - motor
L - translation lever
M - fixed clamp for bit, double bit and pump keys
M1- mobile clamp for bit, double bit and pump keys
P - fixed clamp tightening handle
P1 - mobile clamp tightening handle
Q - mobile clamp locking lever
R - mobile clamp rotation lever
S - Plexiglas safety shield
S1 - cover
T - lamps
U - brush
U1 - brush push button
V - swarf tray
Z - pin/gauge for keys with rear stop
Fig.8
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1.2.1 OMNIA MAX: Clamp carriage for VERTICAL CUTS
Fig.9
1.2.2 OMNIA W MAX: Clamp carriage for VERTICAL CUTS
Fig.10
J - fixed clamp for vertical cuts
J1 - mobile clamp for vertical cuts
K - fixed clamp knob
K1 - mobile clamp knob
N - mobile clamp lever
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2 MAIN CHARACTERISTICS
• ON/OFF SWITCH
The key-cutting machine is connected to a power supply socket with a differential switch; when the machine is
turned on with the switch (A) located on the right-hand side, the lamps (T) illuminate to indicate that the machine
is live.
ATTENTION: switch (A) is electromagnetic and if there is a power failure it goes off automatically.
When power returns it must be reset manually to supply the machine with electricity.
• MOTOR START BUTTON
The push button (B) for starting the motor is located on the front of the machine.
To start the motor (with the machine on) move the carriage slightly towards the cutter and press the motor start
button (B).
The machine is protected from untimely machine start. When the carriage is all the way back towards the operator
a safety microswitch turns off the motor. If the carriage is inadvertently moved towards the cutter the motor does
not start.
• BRUSH PUSH BUTTON
The push button (U1) for activating the brush is located on the front of the machine.
• BRUSH
The brush (U) is in accident-proof material and its purpose is to eliminate the burrs from the key after cutting. Press
push button (U1) to activate the brush.
• Y AXIS LOCKING KNOB
The Y axis locking knob (G) is located on the front of the machine (see chap.7.4).
• MACHINE CARRIAGE MOVEMENT LEVER
The lever (L) has an ergonomic grip and moves on ball joints that allow smooth movement of the carriage, which
has ball bearing guides.
• ILLUMINATION
The work area is perfectly illuminated by two fixed lamps (LED) (T) turned on by the master switch.
• MICROMETRIC TRACER POINT (SPRUNG)
The tracer point (D) used for reading the cuts on keys to be copied is located on the left-hand side of the machine.
Depth is easily adjusted by means of the micrometric ring nut (D2) (chap.7.1).
The spring function is activated/deactivated by turning the special cam (D1) (chap.7.2).
• CUTTER
The cutter (C) used for cutting key blanks is protected by a safety shield (S).
On Omnia and Omnia MAX: cutter in TiN coated Super Rapid steel.
On Omnia W MAX: hard metal cutter (carbide).
• SWARF TRAY
The tray (V) located on the left is easily removable so that all the swarf can be cleared away.
• MOTOR AND TRANSMISSION UNIT
The motor has belt transmission. The transmission shaft that moves the cutter (C) and brush (U) is located on the
right of the motor.
• CLAMP HANDLES AND KNOBS
Anatomical handles and knobs ensure perfect easy hold on the keys in the clamps even with just light pressure
when closing them.
Clamps for vertical cuts Omnia W MAX: the knobs are gauged so that they do not exert too much pressure for
closing (if pressure is toohigh they only idle), which would damage the key and the parts of the clamp (including
the knob).
Operating Manual OMNIA / OMNIA 650rpm / OMNIA MAX / OMNIA W MAX
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• CLAMP CARRIAGES
OMNIA / OMNIA 650rpm
Clamps for bit/double bit and pump keys
The clamps (M) (M1) comprise two self-centring jaws which ensure perfect hold on the shafts of bit/double bit and
pump keys (Fig.3).
Fig.11
The carriage is found in the machine packing as a separate item (see chap.5.2 and chap.5.5).
Operating Manual OMNIA / OMNIA 650rpm / OMNIA MAX / OMNIA W MAX
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OMNIA MAX / OMNIA W MAX
Clamps for bit/double bit and pump keys
The clamps (M) (M1) comprise two self-centring jaws which ensure perfect hold on the shafts of bit/double bit and
pump keys (Fig.4).
Fig.12
The carriage is found in the machine packing as a separate item (see chap.5.2 and chap.5.5).
NOTE: the Omnia MAX/Omnia W MAX carriage for double bit keys can be used alone or connected to
the Omnia MAX/Omnia W MAX carriages for vertical cuts (see chap.5.5.7 OMNIA MAX / OMNIA W MAX:
solution with a SINGLE CARRIAGE).
Clamps for vertical cuts (only Omnia MAX and Omnia W MAX)
The clamps (J) (J1) are designed to ensure perfect hold on the shafts of bit keys with vertical cuts.
Fig.13 - Clamps for vertical cuts Omnia MAX Fig.14 - Clamps for vertical cuts Omnia W MAX
Clamps for vertical cuts Omnia W MAX: the knobs are gauged so that they do not exert too much pressure for
closing (if pressure is toohigh they only idle), which would damage the key and the parts of the clamp (including
the knob).
The carriage is found in the machine packing as a separate item (see chap.5.2 and chap.5.5).
NOTE: the Omnia MAX and Omnia W MAX carriages for vertical cuts can be used alone or connected to
the carriage for bit keys (see chap.5.5.7 OMNIAMAX / OMNIAW MAX: solution with a SINGLE CARRIAGE).
Operating Manual OMNIA / OMNIA 650rpm / OMNIA MAX / OMNIA W MAX
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3 ACCESSORIES PROVIDED
OMNIAcomes with a set of accessories for its operation and maintenance (tools, hex wrenches, fuses) supplied in
a special tool kit comprising:
allen key 2 mm spanner 13 mm
allen key 2,5 mm spanner 19 mm
allen key 3 mm cutter release rod
allen key 4 mm fuses 1,6 Amp delayed (230V)
allen key 5 mm setting pins
allen key 6 mm stop pins for FIAM keys
adhesive label “DANGEROUS MOBILE PARTS”
(chap.5.5.2)
connection plate+screws for the carriages (chap.5.5.7)
(only Omnia MAX/Omnia W MAX)
carriage stopper (chap.5.4)
Operating Manual OMNIA / OMNIA 650rpm / OMNIA MAX / OMNIA W MAX
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4 TECHNICAL DATA
Electricity supply: 230V - 50Hz
Max. absorbed power: 230V: 1Amp. 235 Watt
Cutter motor: single phase and speed
Movements: by ball guides (carriage) and ball socket joint (lever)
Cutter: Omnia/Omnia MAX: 80x1,5x22 in TiN coated Super Rapid Steel
Omnia W MAX: 80x1,5x22 in hard metal (carbide)
Omnia 650rpm: 80x1,5x22 in Super Rapid Steel HSS
Tool speed: Omnia/Omnia MAX: 386 rpm
Omnia W MAX: 650 rpm
Runs carriages: 53 mm X axis - 42 mm Y axis (50 mm Z axis for vertical cuts carriage only)
Dimensions: width: 395 mm - depth: 550 mm - height: 320 mm
Mass: Kg.32 Omnia/Omnia 650rpm - Kg.33,5 Omnia MAX/Omnia W MAX with 2 carriages
Noise level: sound pressure Lp(A) = brass 83,7 dB(A) - iron 91,7 dB(A)
sound power Lw(A) = iron keys 92,1 dB(A)
4.1 Electrical diagram
The main parts of the electrical circuit on the OMNIA key-cutting machine are listed below:
1) Power socket with fuses
2) ON/OFF switch
3) Lamp power
4) LED lamps
5) Carriage microswitch
6) Brush push button
7) Electromagnetic switch (reset)
8) 12.5 mF condenser
9) 230V-50Hz motor
10) Relay
Fig.15
Operating Manual OMNIA / OMNIA 650rpm / OMNIA MAX / OMNIA W MAX
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5 TRANSPORT
The key-cutting machine transports easily and there are no particular hazards involved in handling it.
The packed machine must be carried manually by 2 (or more) people or with a transpallet truck.
5.1 Packing
• The packing used for the OMNIA machines guarantees protection for the machine and all its parts during
transport.
• The packing comprises a pallet base (b), to which the machine is fixed, and a cardboard cover (a).
• The machine is fixed to the base with screwed brackets that stop it from moving during transport.
• Once the packing case is closed it is taped with two straps which secure the cardboard cover to the pallet.
• Warnings to observe during transport are shown by symbols on the outside of the cardboard cover.
Fig.16
Keep dry Handle with care This side up Use no hooks
To avoid knocks which could damage the machine, it is advisable to use the original packing and fix the machine
with the special brackets every time it is transported.
5.2 Pack opening
1) Cut the straps with scissors and remove.
2) Raise the cardboard .
3) Check the contents of the box, which should comprise:
OMNIA / OMNIA 650rpm OMNIA MAX / OMNIA W MAX
1 Omnia / Omnia 650rpm key-cutting machine 1 Omnia MAX / Omnia W MAX key-cutting machine
1 set of documents, including: operating manual,
quick guide, spare parts list and guarantee 1 set of documents, including: operating manual, quick guide, spare parts list and guarantee
1 power cable 1 power cable
1 tool set 1 tool set
1 Omnia standard carriage 1 Omnia MAX / Omnia W MAX carriage for bit/double
bit keys
1 lever 1 Omnia MAX / Omnia W MAX vertical cuts carriage
2 levers
NOTE: the complete packing (cardboard, pallet, brackets and screws) should be kept for use whenever
the machine is moved.
Operating Manual OMNIA / OMNIA 650rpm / OMNIA MAX / OMNIA W MAX
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5.3 Unpacking
1) Follow the instructions illustrated to remove the carriage fixing brackets and the carriage from the pallet (2
carriages on Omnia MAX and Omnia W MAX):
OMNIA / OMNIA 650rpm OMNIA MAX / OMNIA W MAX
Fig.17 Fig.18
11
22
33
Operating Manual OMNIA / OMNIA 650rpm / OMNIA MAX / OMNIA W MAX
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