Silca Omnia Operating Manual

Omnia 650rpm

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, microfi lm 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 identifi ed.

TERMINOLOGY ..................................................................................................................................2 GENERAL WARNINGS .......................................................................................................................4 1 MACHINE DESCRIPTION ....................................................................................................................6 1.1 OMNIA / OMNIA 650rpm: 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

8.5 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/fi lter ..................................................................................................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

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 Copyright Silca 2014 1

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 Operating Manual OMNIA / OMNIA 650rpm / OMNIA MAX / OMNIA W MAX Copyright Silca 2014 2

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 OMNIA key-cutting machine and see the continuously evol- ving range of optional accessories. Operating Manual OMNIA / OMNIA 650rpm / OMNIA MAX / OMNIA W MAX Copyright Silca 2014 3

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 OMNIA is a key-cutting machine (see chap.1) and must be installed and used according to the rules and specifi cations 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. Operating Manual OMNIA / OMNIA 650rpm / OMNIA MAX / OMNIA W MAX Copyright Silca 2014 4

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 Copyright Silca 2014 5

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 Operating Manual OMNIA / OMNIA 650rpm / OMNIA MAX / OMNIA W MAX Copyright Silca 2014 6

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 - fi xed clamp for bit, double bit and pump keys M1 - mobile clamp for bit, double bit and pump keys P - fi xed 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 Operating Manual OMNIA / OMNIA 650rpm / OMNIA MAX / OMNIA W MAX Copyright Silca 2014 7

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 - fi xed clamp for bit, double bit and pump keys M1 - mobile clamp for bit, double bit and pump keys P - fi xed 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 Operating Manual OMNIA / OMNIA 650rpm / OMNIA MAX / OMNIA W MAX Copyright Silca 2014 8

Fig.9 1.2.2 OMNIA W MAX: Clamp carriage for VERTICAL CUTS Fig.10 J - fi xed clamp for vertical cuts J1 - mobile clamp for vertical cuts K - fi xed clamp knob K1 - mobile clamp knob N - mobile clamp lever Operating Manual OMNIA / OMNIA 650rpm / OMNIA MAX / OMNIA W MAX Copyright Silca 2014 9

• 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 fi xed 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 Copyright Silca 2014 10

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 Copyright Silca 2014 11

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 OMNIA MAX / OMNIA W MAX: solution with a SINGLE CARRIAGE). Operating Manual OMNIA / OMNIA 650rpm / OMNIA MAX / OMNIA W MAX Copyright Silca 2014 12

OMNIA comes 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 Copyright Silca 2014 13

Electricity supply: 230V - 50Hz Max. absorbed power: 230V: 1 Amp. 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 Copyright Silca 2014 14

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 fi xed, and a cardboard cover (a). • The machine is fi xed 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 fi x 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 Copyright Silca 2014 15

carriages on Omnia MAX and Omnia W MAX): OMNIA / OMNIA 650rpm OMNIA MAX / OMNIA W MAX Fig.17 Fig.18 1 1 2 2 3 3 Operating Manual OMNIA / OMNIA 650rpm / OMNIA MAX / OMNIA W MAX Copyright Silca 2014 16

Fig.19 NOTE: the complete packing (cardboard, pallet, brackets and screws) should be kept for use whenever the machine is moved. ATTENTION: lift the machine by gripping the external rib on the base (Fig.20). Never lift it by holding the clamps, levers or other parts. When the key-cutting machine has been removed from its packing, place it directly on a worktop; this should be done by at least 2 persons. Fig.20 4 5 Operating Manual OMNIA / OMNIA 650rpm / OMNIA MAX / OMNIA W MAX Copyright Silca 2014 17

1) Loosen and remove the screw (E1). 2) Insert the stopper (E3) provided - chap.3) into the hole on the carriage. Fig.21 5.5 Separate parts The parts separate from the machine and separately packed must be installed by the operator as follows: 5.5.1 Power cable Connect power cable to the key-cutting machine (Fig.22). Fig.22 5.5.2 Warning label Place the adhesive label in the appropriate language in position as shown in Fig.23. Provided (chap.3) Fig.23 Operating Manual OMNIA / OMNIA 650rpm / OMNIA MAX / OMNIA W MAX Copyright Silca 2014 18

OMNIA / OMNIA 650rpm OMNIA MAX / OMNIA W MAX Standard carriage (bit, double bit and pump keys) Carriage for bit, double bit and pump keys Fig.24 Clamp carriage for vertical cuts Fig.25 5.5.4 OMNIA/OMNIA 650rpm: standard carriage (bit, double bit and pump keys) 1) Insert the carriage from right to left in the special groove and take to the end of its . 2) Lock the carriage with the handle (F). Fig.26 Operating Manual OMNIA / OMNIA 650rpm / OMNIA MAX / OMNIA W MAX Copyright Silca 2014 19

1) Insert the carriage from left to right in the special groove and take to the end of its run. 2) Lock the carriage with the handle (F). Fig.27 5.5.6 OMNIA MAX / OMNIA W MAX: clamp carriage for vertical cuts 1) Insert the carriage from right to left in the special groove and take to the end of its run. 2) Lock the carriage with the handle (F). Fig.28 Operating Manual OMNIA / OMNIA 650rpm / OMNIA MAX / OMNIA W MAX Copyright Silca 2014 20

Use the connecting plate and screw set provided with the key-cutting machine and follow the instructions below: 1 2 3 4 5 Operating Manual OMNIA / OMNIA 650rpm / OMNIA MAX / OMNIA W MAX Copyright Silca 2014 21

OMNIA / OMNIA 650rpm: 1) Turn off the machine. 2) Loosen the handle (F) and pull out the clamp carriage to the right. 3) To fi t the clamp carriage see chap. 5.5.4. OMNIA MAX / OMNIA W MAX: 1) Turn off the machine. With clamp carriage for bit, double bit and pump keys: 1) Loosen the handle (F) and pull out the clamp carriage to the left. 2) To fi t the standard clamp carriage see chap. 5.5.5. With clamp carriage for vertical cuts: 1) Loosen the handle (F) and pull out the clamp carriage to the right. 2) To fi t the vertical cuts clamp carriage see chap.5.5.6. With double carriage: 1) Loosen the handle (F) and move the carriage (double) slightly to the right. 2) Loosen and remove the screw (E2) 3) Pull out the clamp carriage to the left. 4) To fi t the double clamp carriage see chap.5.5.7. 6 7 Operating Manual OMNIA / OMNIA 650rpm / OMNIA MAX / OMNIA W MAX Copyright Silca 2014 22

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. 6.1 Checking for damage OMNIA 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. 6.2 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. 6.3 Pos itioning 1) Place the machine on a horizontal surface, solid enough to support the weight (32 Kg). - to work with ease, we suggest that the workbench be approximately the height of the operator’s hip. - we recommend leaving a clearance of at least 10 cm behind the machine and 30 cm on each side to ensure good ventilation and facilitate handling (Fig. 29). 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. 29 6.4 Description of work station The machine needs only one operator, who has all the controls at his/her disposal (see chap.1.1 OMNIA / OMNIA 650rpm: main working parts, chap.1.2 OMNIA MAX / OMNIA W MAX: main working parts and chap.1.2.1): 6.5 Connection to the mains For the safety of the operator and the machine it is important to ensure that the machine is connected to the proper mains voltage by means of an earthed differential switch. Operating Manual OMNIA / OMNIA 650rpm / OMNIA MAX / OMNIA W MAX Copyright Silca 2014 23

To get the most out of your key-cutting machine, check gauging periodically. ATTENTION: before regulating the machine, turn it off and remove the plug. 7.1 Micrometric tracer point The use of a micrometric tracer point on a machine for cutting bit and pump keys not only provides perfect fast readings, but also rapidly resolves all those small depth variations needed when worn keys are involved. NOTE: every notch on the micrometric ring nut corresponds to a movement of 0,05 mm. Fig.30 - Omnia / Omnia 650rpm / Omnia MAX Fig.31 - Omnia W MAX 7.2 Tracer point spring The spring function facilitates the search for spaces with the tracer point before the cutter makes the cuts. • To enable the tracer point spring: Turn the cam (D1) to the left (Fig.32). • To disable the tracer point spring: Turn the cam (D1) to the right (Fig.33). Fig.32 - spring ENABLED Fig.33 - spring DISABLED Operating Manual OMNIA / OMNIA 650rpm / OMNIA MAX / OMNIA W MAX Copyright Silca 2014 24

Fig.34 Use the lever (Q) to lock the right-hand clamp (M1) in the horizontal position for calibration and cutting operations on pump keys and those with a centre stop. Lower the lever (Q) to release the right-hand clamp (M1), which activates oscillation to cut bit/double bit keys (rounding cuts off). 7.4 Locking Y axis The Y axis locking function is useful when positioning certain bit and double bit keys (especially short ones). It is also used to operate successfully on heavy duty cuts using the carriage for vertical cuts (chap.8.6). To lock or release the Y axis, turn the knob (G) clockwise or anticlockwise. Fig.35 Operating Manual OMNIA / OMNIA 650rpm / OMNIA MAX / OMNIA W MAX Copyright Silca 2014 25

The cutting tool on the machine is the part used to cut the key blanks and should be periodically checked and replaced, if necessary. Every time the cutting tool is changed, and during periodical operational tests, check calibration. The OMNIA key-cutting machine requires two types of calibration: AXIS and DEPTH. Fig.36 7.5.1 Axis calibration - carriage for bit, double bit and pump keys Axis calibration is used to adjust the cutting space on the key. Axis calibration is fi xed and established when the key-cutting machine is being assembled. Axis calibration control: 1) Turn off the machine and unplug. 2) Use lever (Q) to lock the right-hand clamp in the horizontal position. 3) Close the 2 clamps with their handles (P) and (P1). 4) Disable the tracer point spring by turning the cam (D1) (chap.7.2). 5) Use the lever (L) to take the stops (Y) against the right-hand side of the tracer point and cutter. The ideal condition is achieved when the internal part of the left-hand stop is up against the right-hand side of the tracer point and the internal part of the right-hand stop is in contact with the right-hand side of the cutter. If this condition is not achieved, contact Silca After-Sales Service. Fig.37 Operating Manual OMNIA / OMNIA 650rpm / OMNIA MAX / OMNIA W MAX Copyright Silca 2014 26

If a clamp is replaced or has imperfections the clamp inter-axis for vertical cuts can be adjusted. 1) Turn off the machine and unplug. 2) Loosen the clamp knobs, push the clamps forward and insert the calibration pin into the key shaft groove (to the right or left of each clamp.) 3) With the machine off take the carriage up to the cutter and tracer point so that it rests against the 2 calibration pins (sideways). 4) When the tracer point is in contact with the side of the calibration pin the cutter should skim the side of the corresponding pin. If not: - loosen the 2 upper screws (J2) fi xing the fi xed clamp and the 2 rear screws (J3). - regulate the grub screw (K3) to achieve the optimum condition. - tighten the 2 screws (J2) and the 2 screws (J3). Fig.38 Fig.39 Fig.40 Operating Manual OMNIA / OMNIA 650rpm / OMNIA MAX / OMNIA W MAX Copyright Silca 2014 27

Depth calibration is used to adjust the depths of cuts. Depth calibration should be checked periodically to ensure perfect machine effi ciency, and whenever the cutter or tracer point is replaced. Depth calibration control: 1) Turn off the machine and unplug. 2) Use the lever (Q) to lock the right-hand clamp in the horizontal position. 3) Place the calibration pins (provided) in place on the clamps. 4) Disable the tracer point spring with cam (D1) (chap.7.2). 5) Move the carriage and take the calibration pins into contact with the tracer point and cutter. 6) Fit a hex key into the brush screw (Fig. 41). Turn the brush clockwise manually and check that the cutter skims the calibration pin in a number of points. 7) If necessary, use the tracer point to adjust cutting depths as follows: - turn the ring nut (D2) clockwise to move the tracer point forward (less deep cut) (Fig.43). - turn the ring nut (D2) anticlockwise to move the tracer point back (deeper cut) (Fig.44). 8) Repeat these operations until the cutter skims the calibration pin in a number of points. NOTE: every notch corresponds to a movement of 0.05 mm. Fig. 41 Fig.42 Operating Manual OMNIA / OMNIA 650rpm / OMNIA MAX / OMNIA W MAX Copyright Silca 2014 28

Result: LESS DEEP CUTS. Fig.44 Turning the right nut to the LEFT (anticlockwise) moves the tracer point forward. Result: DEEPER CUTS. Operating Manual OMNIA / OMNIA 650rpm / OMNIA MAX / OMNIA W MAX Copyright Silca 2014 29

ATTENTION: for complete safety during the cutting operations, take the following precautions: • Start the motor only after completing the operations on the carriage (securing the keys, etc..).. • Always work with dry hands. • Check that the machine is properly earthed. • Wear protective goggles even if the machine has a protective shield. • Keep hands away from the cutting tool in motion. ATTENTION: the machine is protected from inadvertent motor start. When the carriage is all the way back towards the operator a microswitch turns off the motor. If the carriage is inadvertently moved towards the cutter the motor does not start. ATTENTION: the Y axis lock function is useful to facilitate positioning certain bit/double bit keys and cutting with the vertical cuts clamp. Turn the knob (G) clockwise or anticlockwise to lock or release the Y axis (chap.7.4). 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. Operating Manual OMNIA / OMNIA 650rpm / OMNIA MAX / OMNIA W MAX Copyright Silca 2014 30

1) Use the lever (Q) to lock the right-hand clamp in the horizontal position. 2) Fit the keys into the clamps (original key in the left-hand clamp and key blank in the right-hand clamp) with the bit up against the stop (Y). 3) Close the clamps making sure that the key shafts are in the V groove and check that the key bits are perpendicular to the tracer point and cutter (Fig.47). 4) Lower the lever (Q) to release the right-hand clamp. 5) Turn on the machine with the ON/OFF switch (A). 6) Use the lever (L) to slowly take the carriage towards the cutter and press the button (B) to start the motor. 7) Hold the lever (R) slightly raised with the key facing downwards. 8) Take the cut closest to the original key tip against the tracer point and lower the lever (R) to round off the cut. 9) Take the carriage back to come out of the cut. Move the carriage sideways and enter the next cut (Fig.48).Do not move sideways once into the cut. 10) Complete all the bits in the same way and remove any excess material at the end of the cutting operation (towards the head). 11) Take the carriage all the way back (the motor will stop automatically). 12) For double bit keys, turn both keys over and repeat the operations described above. 13) When the cutting operation is fi nished, take the carriage all the way back (the motor will stop automatically) and remove the keys. Fig.45 Fig.46 Fig.47 Fig.48 Operating Manual OMNIA / OMNIA 650rpm / OMNIA MAX / OMNIA W MAX Copyright Silca 2014 31

If the keys to be cut are very short and do not touch the stop (Y) proceed as follows, observing the illustration. 1) Use the lever (Q) to lock the right-hand clamp in the horizontal position. 2) Lock the key blank into the right-hand clamp (M1) (as shown) (Fig.45). 3) Raise the carriage and place the right-hand side of the bit against the cutter. Lock the carriage in this position with the knob (G). 4) Lock the original key into the left-hand clamp (M) (as shown), with the right-hand side of the bit up against the tracer point. In this way the two keys will be perfectly aligned (Fig.45). 5) Release the knob (G) and take the carriage all the way back. 6) Lower the lever (Q) to release the right-hand clamp. 7) Turn on the machine with the ON/OFF switch (A). 8) Use the lever (L) to slowly take the carriage towards the cutter and press the button (B) to start the motor. 9) Hold the lever (R) slightly raised with the key facing downwards. 10) Take the cut closest to the original key tip against the tracer point (do not apply force, remember that the key tip is not held) and lower the lever (R) to round off the cut. 11) Take the carriage back to come out of the cut. Move the carriage sideways and enter the next cut. Do not move sideways once into the cut. 12) Complete all the bits in the same way and remove any excess material at the end of the cutting operation (towards the head). 13) Take the carriage all the way back (the motor will stop automatically). 14) For double bit keys, turn both keys over and repeat the operations described above. 15) When the cutting operation is fi nished, take the carriage all the way back (the motor will stop automatically) and remove the keys. Fig.49 Operating Manual OMNIA / OMNIA 650rpm / OMNIA MAX / OMNIA W MAX Copyright Silca 2014 32

We can also use the instructions for cutting very short bit or double bit keys to cut some bit or double bit (female) keys, taking care to observe and check some dimensional and operational characteristics: Dimensional: - Maximum height of bit against stem axis = 15 mm (max) - Maximum length of bit to be cut = 17 mm (max) Operational: • Between the end of the bit (towards the key head) and the left-hand internal side of the clamp there must be a space of 2 mm (max) and no less than 1,5 mm (cutter thickness). • During cutting (especially for iron keys) do not exert too much pressure when pushing the key towards the cutter, as the key tip has nothing to butt against. NOTE: the precision of keys cut in this way will refer to the external stem diameter rather than the centre of the internal hole in the tip. Any imprecision between the hole axis and the stem is additional to the normal tolerance for manual cutting. Fig.50 It is advisable to use optional accessories for female bit and double bit keys (see OMNIA, OMNIA 650rpm, OMNIA MAX and OMNIA W MAX Specialist Guide). Operating Manual OMNIA / OMNIA 650rpm / OMNIA MAX / OMNIA W MAX Copyright Silca 2014 33

1) Use the lever (Q) to lock the right-hand clamp in the horizontal position. 2) Loosen the clamp handles slightly to be able to fi t the keys. 3) Fit the original key into the left-hand clamp with the centre stop up against the clamp and the bit parallel to the clamp (perpendicular to the tracer point); secure the key with the handle (P). 4) Fit the key blank into the right-hand clamp with the centre stop up against the clamp and the bit parallel to the clamp (perpendicular to the cutter); secure the key with the handle (P1). Cutting: 1) Turn on the machine with the ON/OFF switch (A). 2) Use the lever (L) to slowly take the carriage towards the cutter and press the button (B) to start the motor. 3) Take the cut closest to the original key tip against the tracer point (if required release the lever (Q) and lower the lever (R) to round off the cut). 4) Take the carriage back to come out of the cut. Move the carriage sideways and enter the next cut. Do not move sideways once into the cut. 5) Complete the bit in this way and check the sides of the bit if necessary. 6) When the cutting operation is fi nished, take the carriage all the way back (the motor will stop automatically) and remove the keys. Fig.51 Operating Manual OMNIA / OMNIA 650rpm / OMNIA MAX / OMNIA W MAX Copyright Silca 2014 34

The Omnia MAX and Omnia W MAX clamp carriage for bit/double bit keys has a pin/gauge set (Z) on the left-hand part of each clamp for positioning keys with rear stops. The pin can change position by moving from right to left, or vice versa. The length of the pin has small grooves along it to provide the operator with the following indications: • sound, when the ball presser enters one of these positions/ grooves (a click is heard); • visual, to position the keys on the same notch. The 2 pins- gauges (Z) must show the same number of clicks/grooves. 1) Use the lever (Q) to lock the right-hand clamp in the horizontal position. 2) Fit the keys into the clamps, moving them to the right until the rear stop goes up against the (Z) (Fig.53). The spacing on the gauge set (Z) must be the same for both clamps ( a = b ). Fig. 52 3) Secure the keys with the handles (P) and P1). 4) Lower the lever (Q) to release the right-hand clamp. 5) Turn the machine on with the ON/OFF switch . 6) Use the lever (L) to slowly take the carriage towards the cutter and press the button (B) to start the motor. 7) Hold the lever (R) slightly raised with the key facing downwards. 8) Take the cut closest to the original key tip against the tracer point and lower the lever (R) to round off the cut. 9) Take the carriage back to come out of the cut. Move the carriage sideways and enter the next cut. Do not move sideways once into the cut. 10) Complete the bit in this way and remove any excess material at the end of the operation (towards the head). 11) Take the carriage all the way back (the motor will stop automatically). Fig.53 Operating Manual OMNIA / OMNIA 650rpm / OMNIA MAX / OMNIA W MAX Copyright Silca 2014 35

1) Use the lever (Q) to lock the right-hand clamp in the horizontal position. 2) Fit the original key into the left-hand clamp (M) with the bit up against the lower jaw of the clamp (Fig.55). 3) Use the special seats for pump keys: for keys with round shafts and Mottura type keys with square shafts (Fig.54). 4) Fit the key blank into the right-hand clamp (M1) in the same way. NOTE: we recommend using the tracer point spring function (chap.7.2). 5) Turn on the machine with the ON/OFF switch. 6) Use the lever (L) to slowly take the carriage towards the cutter and press the button (B) to start the motor. 7) Take the fi rst cut on the right of the original key against the tracer point and push the carriage all the way. 8) Take the carriage back to come out of the cut. Move the carriage sideways and enter the next cut. Do not move sideways once into the cut. 9) Complete all the bits in the same way and if necessary check the sides of the bits. 10) When the cutting operation is fi nished, take the carriage all the way back (the motor will stop automatically) and remove the keys. Fig.54 Fig.55 Operating Manual OMNIA / OMNIA 650rpm / OMNIA MAX / OMNIA W MAX Copyright Silca 2014 36

The keys can be placed with the bit on the left or right, according to the position of the groove to be turned towards the tracer point and cutter. 1) Loosen the knob (K) and push forward to fi t the original key (with the head upwards) into its seat on the fi xed clamp (J). Take the bit up against the clamp stop and secure the key with the knob (K). 2) Loosen the knob (K1) and push forward to fi t the key blank (with the head upwards) into its seat on the mobile clamp (J1). Take the bit up against the clamp stop and secure the key with the knob (K1). NOTE: we recommend using the tracer point spring function (chap.7.2). NOTE: we recommend using the Y axis carriage lock function (chap.7.4) for very thick keys or keys in particularly hard material. 3) Turn on the machine with the ON/OFF switch (A). 4) Use the lever (L) to slowly take the carriage towards the cutter and press the button (B) to start the motor. 5) Enter the vertical cut/groove on the original key with the tracer point (press fi rmly against the tracer point). 6) Use the lever (N) to move the mobile clamp (J1) from bottom to top. Take the carriage back to come out of the cut. Move the carriage sideways and, if applicable, enter the next groove to complete cutting the key. Do not move sideways once into the cut. 7) When the cutting operation is fi nished, take the carriage all the way back (the motor will stop automatically) and remove the keys. Fig.56 Fig.57 Fig.58 Operating Manual OMNIA / OMNIA 650rpm / OMNIA MAX / OMNIA W MAX Copyright Silca 2014 37

if original spare parts provided by the manufacturer are used. Although the key-cutting machine does not require special maintenance, it is advisable to check and, if necessary, replace the parts subject to wear, such as: the belt, cutting tool, brush, tracer point. Replacement is simple and can be carried out by the operator. CLEANING Keep the carriage and clamps free of chippings from the cutting operations by cleaning with a dry brush. ATTENTION: do not use compressed air! ATTENTION: to keep the machine well maintained we recommend using protective oil, e.g. WD40 or similar, applied to the burnished mechanical parts. This prevents oxidation of the parts in question (clamps, guides, carriages...). Before starting any type of maintenance (checks or replacements), read the instructions below: • Never carry out maintenance or servicing with the machine switched on. • Always remove the mains plug. • Follow all the instructions in the manual to the letter. • Use original spare parts. • Always check that any screws or nuts removed when replacing a piece are properly tightened. 9.1 Replacing the carriage ATTENTION: turn off the machine and unplug. To remove and install the carriage see the instructions in chap.5.6 and chapters 5.5.4, 5.5.5, 5.5.6 and 5.5.7. 1) Fit the new carriage into the dovetail seat and slide all the way up to the limit switch. Secure by tightening the handle (F). 2) Check machine calibration (chap.7.5). 9.2 Replacing the tracer point Proceed as follows to replace the tracer point (D): ATTENTION: turn off the machine and unplug. 1) Enable the tracer point spring function (chap.7.2). 2) Loosen the screw (D3). 3) Remove the worn tracer point. 4) Fit the new tracer point, pushing all the way in. 5) Tighten the screw (D3). 6) Check depth calibration as described in chap.7.5.3. Fig. 59 Operating Manual OMNIA / OMNIA 650rpm / OMNIA MAX / OMNIA W MAX Copyright Silca 2014 38

ATTENTION: turn off the machine and unplug. 1) Remove the carriage (chap.5.6). 2) Slot the locking rod (provided) into the hole of the cutter shaft (Fig.60 and Fig.61). 3) Use the spanner provided to loosen the cutter locking nut. ATTENTION: the thread is left-handed. 1) Remove the worn cutter. 2) Carefully clean the new cutter and its seat. 3) Install the new cutting tool and tighten the nut. ATTENTION: the tool rotates clockwise. 4) Remove the locking rod. 5) Re-position the carriage and check depth calibration as described in chap.7.5.3. Fig.60 Fig.61 9.4 Replacing the brush ATTENTION: turn off the machine and unplug. 1) Remove or move the carriage (chap.5.6). 2) Slot the locking rod (provided) into the hole of the cutting tool shaft (Fig.60). 3) Use the Allen key to loosen the screw (U2) and remove the brush (Fig. 62). 4) Replace the brush and tighten the screw (U2) with the Allen key. Fig. 62 Operating Manual OMNIA / OMNIA 650rpm / OMNIA MAX / OMNIA W MAX Copyright Silca 2014 39

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. The OMNIA key-cutting machine has 2 fuses placed in the inlet socket to protect the key-cutting machine from sudden changes in voltage or short circuits. 1) Turn the machine off and unplug it from its power supply cable. 2) Use a screwdriver to open the fuse plate in the power socket. ATTENTION: fuses must always be replaced with others of the same type (delayed) and with the same Amps (1,6 Ampere). Fig.63 9.6 Accessing the bottom compartment ATTENTION: turn off the machine and unplug. 1) Remove the swarf tray (V) (Fig.64). 2) Remove the clamp carriage (chap.5.6). 3) Remove the mat and any objects on the upper cover. 4) Place the machine on its left-hand side. 5) Loosen and remove the 4 feet (V1). 6) Loosen the 2 screws (X1) and remove the bottom cover (X). Fig.64 Fig.65 Operating Manual OMNIA / OMNIA 650rpm / OMNIA MAX / OMNIA W MAX Copyright Silca 2014 40

ATTENTION: turn off the machine and unplug. 1) Gain access to the bottom compartment (chap.9.6). 2) Disconnect the 4 connectors (A5) (A6) from the switch, observing their position carefully (Fig.67). 3) Press the fi xing tabs on the switch so that it can be pulled out. 4) Fit the new switch into its seat. 5) Re-connect the 4 connectors (A5) (A6). 6) Put the bottom cover (X) in place and secure with the screws (X1); screw in the 4 feet (V1) (Fig.65). 7) Place the machine upright on the worktop and insert the swarf tray (V) (Fig.64). Fig.66 Fig.67 9.8 Replacing the motor start button ATTENTION: turn off the machine and unplug. 1) Gain access to the bottom compartment (chap.9.6). 2) Loosen the ring nut (A3) and remove the motor start button (B). 3) Remove the push button and ring nut. 4) Fit the new push button and tighten the ring nut (A3). Fig.68 Operating Manual OMNIA / OMNIA 650rpm / OMNIA MAX / OMNIA W MAX Copyright Silca 2014 41

ATTENTION: turn off the machine and unplug. 1) Gain access to the bottom compartment (chap.9.6). 2) Loosen the ring nut (A3) and remove the motor start button (B) (Fig.68). 3) Disconnect the 4 connectors (A4) on the switch, observing their position carefully (Fig.69). 4) Press the fi xing tabs on the switch so that it can be pulled out towards the operator. Observe its position carefully. 5) Fit the new switch, taking care to position it properly. 6) Re-connect the 4 connectors (A4). 7) Place the bottom cover (X) in position, secure with the screws (X1) and screw in the 4 feet (V1) (Fig.65). 8) Place the machine upright on the worktop and insert the swarf tray (V). Fig.69 9.10 Replacing the microswitch ATTENTION: turn off the machine and unplug. 1) Gain access to the bottom compartment (chap.9.6). 2) Disconnect the 3 connectors (c) (nc) (no) (Fig.70). 3) Loosen the 2 support plate screws (P3) and remove. 4) Loosen the 2 screws (R3) and 2 nuts (R4) so that the microswitch can be removed (Fig.71). 5) Attach the new microswitch to the plate with the 2 screws (R3) and nuts (R4). 6) Replace the plate and secure with the 2 screws (P3). When the carriage is idle (fully back towards the operator) the microswitch lever must be down. 7) Place the bottom cover (X) in position, secure with the screws (X1) and screw in the 4 feet (V1) (Fig.65). 8) Place the machine upright on the worktop and insert the swarf tray (V). Operating Manual OMNIA / OMNIA 650rpm / OMNIA MAX / OMNIA W MAX Copyright Silca 2014 42

ATTENTION: turn off the machine and unplug. 1) Gain access to the bottom compartment (chap.9.6). 2) Disconnect the 2 push button connectors (U1), observing their position carefully (Fig.72). 3) Press the fi xing tabs on the switch so it can be pulled outwards. 4) Fit the new push button into its seat. 5) Re-connect the connectors. 6) Place the bottom cover (X) in position, secure with the screws (X1) and screw in the 4 feet (V1) (Fig.65). 7) Place the machine upright on the worktop and insert the swarf tray. Fig.72 Operating Manual OMNIA / OMNIA 650rpm / OMNIA MAX / OMNIA W MAX Copyright Silca 2014 43

ATTENTION: turn off the machine and unplug. 1) Loosen the 2 screws (A2). 2) Gain access to the bottom compartment (chap.9.6). 3) Disconnect the 2 connectors (A5) from the ON/OFF switch, loosen the nuts (X3) and (X4) in order to remove the earth wire, and remove the plug (Fig.74). 4) Place the new socket in its seat with the fuse box at the bottom and secure with the 2 screws (A2). 5) Connect the 2 connectors (A5) on the new plug to the ON/OFF switch, re-connect the earth wire and tighten the nuts (X3) and (X4). 6) Place the bottom cover (X) in position, secure with the screws (X1) and screw in the 4 feet (V1) (Fig.65). 7) Place the machine upright on the worktop and insert the swarf tray (V). Fig.73 Fig.74 9.13 Replacing the relay ATTENTION: turn off the machine and unplug. 1) Gain access to the bottom compartment (chap.9.6). 2) Release the 2 engaging levers (B2) from the relay (B3). 3) Remove the relay from its holder. 4) Fit the new relay to its support and engage the 2 levers (B2). 5) Place the bottom cover (X) in position, secure with the screws (X1) and screw in the 4 feet (V1) (Fig.65). 6) Place the machine upright on the worktop and insert the swarf tray (V). Fig.75 Operating Manual OMNIA / OMNIA 650rpm / OMNIA MAX / OMNIA W MAX Copyright Silca 2014 44

ATTENTION: turn off the machine and unplug. 1) Gain access to the bottom compartment (chap.9.6). 2) Loosen the 4 low voltage (35V) wire fi xing screws (K5), observing their position carefully. 3) Loosen the 2 power lead fi xing screws (K6) (one wire in position 0 and one in the position of the voltage involved 230V). 4) Loosen the 4 power box fi xing screws (K7) and remove. 5) Install and secure the new power box with the 4 screws (K7). 6) Use the screws (K5) to fi x the 4 low voltage wires into the 35V connectors on the transformer, observing their position carefully. 7) Use the screws (K6) to fi x the 2 power leads into the connectors on the power box (one wire in position 0 and one in the position of the voltage involved 230V). ATTENTION: observe the position of the wires according to the voltage (Fig.76). 8) Place the bottom cover (X) in position, secure with the screws (X1) and screw in the 4 feet (V1) (Fig.65). 9) Place the machine upright on the worktop and insert the swarf tray (V). Fig.76 Fig.77 9.15 Replacing the motor condenser ATTENTION: turn off the machine and unplug. 1) Gain access to the bottom compartment (chap.9.6). 2) Remove the condenser cap and disconnect the 2 connectors (C4) (Fig.78) observing their position carefully. 3) Loosen and remove the old condenser from the machine body, and replace with a new one. 4) Connect the 2 connectors (C4), observing their position carefully, and replace the cap on the new condenser. 5) Place the bottom cover (X) in position, secure with the screws (X1) and screw in the 4 feet (V1) (Fig.65). 6) Place the machine upright on the worktop and insert the swarf tray (V). Operating Manual OMNIA / OMNIA 650rpm / OMNIA MAX / OMNIA W MAX Copyright Silca 2014 45

ATTENTION: turn off the machine and unplug. 1) Remove the top mat. 2) Loosen the 4 screws (S2), remove the 2 screws (S3) and remove the top cover (S1) (Fig.79). 3) Loosen the 3 screws (S4) and remove the Plexiglas shield (S) (Fig.80). 4) Place the new shield (S) in position and secure with the screws (S4). 5) Secure the top cover with the 4 screws (S2) and the 2 screws (S3); replace the mat. Fig.79 Operating Manual OMNIA / OMNIA 650rpm / OMNIA MAX / OMNIA W MAX Copyright Silca 2014 46

ATTENTION: turn off the machine and unplug. 1) Remove the top mat. 2) Loosen the 4 screws (S2), remove the 2 screws (S3) and remove the top cover (S1) (Fig.79). 3) Loosen the 2 screws (T1) on the lamp support (Fig.81). 4) Detach the connector (T3) from the lamp to be replaced. 5) Loosen the lamp fi xing screws (T4) and remove (Fig.82). 6) Place the new lamp in position and secure with the screws (T4). 7) Place the lamp support in position and secure with the screws (T1). 8) Secure the top cover with the 4 screws (S2) and the 2 screws (S3); replace the mat. Fig.81 Fig.82 Operating Manual OMNIA / OMNIA 650rpm / OMNIA MAX / OMNIA W MAX Copyright Silca 2014 47

ATTENTION: turn off the machine and unplug. 1) Remove the top mat. 2) Loosen the 4 screws (S2), remove the 2 screws (S3) and remove the top cover (S1) (Fig.79). 3) Gain access to the bottom compartment (chap.9.6). • To TIGHTEN: 4) Loosen the 4 nuts (H1) (Fig.83), push the motor towards the back of the machine and then tighten the 4 nuts (H1). • To REPLACE: 5) Loosen the 4 nuts (H1) and move the motor forward towards the machine . 6) Loosen the 3 screws (S4) and remove the Plexiglas shield (Fig.80). 7) Remove the brush (chap.9.4). 8) Loosen the 3 screws (H6) and remove the belt protection (H7) (Fig.84). 9) Remove the belt (H8) and fi t a new belt into the two pulleys (Fig.85). 10) Replace the belt protection (H7) and secure with the screws (H6). 11) Replace the brush. 12) Re-fi t the Plexiglas shield. 13) Push the motor towards the back of the machine and tighten the 4 nuts (H1). 14) Place the bottom cover (X) in position, secure with the screws (X1) and screw in the 4 feet (V1) (Fig.65). 15) Place the machine upright on the worktop and insert the swarf tray (V). 16) Secure the top cover with the screws (S2) and (S3) (Fig.79); replace the mat. Fig.83 Operating Manual OMNIA / OMNIA 650rpm / OMNIA MAX / OMNIA W MAX Copyright Silca 2014 48

ATTENTION: turn off the machine and unplug. 1) Remove the top mat. 2) Loosen the 4 screws (S2), remove the 2 screws (S3) and remove the top cover (S1) (Fig.79). 3) Loosen but do not remove the 2 grub screws (H5) fi xing the motor (Fig.86). 4) Gain access to the bottom compartment (chap.9.6). 5) Raise the condenser cap and remove the 2 connectors (C4) (Fig.87). 6) Loosen the nut (X3) and remove the earthing wire. 7) Remove the fasteners on the motor wiring. 8) Loosen the screws (1, 2, 7, 8) and disconnect the wiring from the relay (observe the right position carefully) (Fig.88). 9) Loosen and remove the 4 nuts (H1) fi xing the motor (Fig.83). TAKE CARE not to drop the motor. 10) Move the motor towards the front of the machine and remove the belt from the motor pulley. 11) Slide out the motor (upwards) and remove the 4 screws (H2) (Fig.86). 12) Remove the pulley from the old motor and fi t onto the new one, securing with the two grub screws (H5). 13) Place the new motor in position with the 4 screws (H2) and tighten the 4 nuts (H1) without locking them. 14) Take the motor wiring through the special hole and connect the 2 connectors (C4) to the condenser. 15) Insert the belt into the motor pulley, push the motor towards the back of the machine and lock the 4 nuts (H1). 16) Re-connect the connectors (1, 2, 7, 8) to the relay (observe the right position carefully). 17) Re-connect the earthing wire with the nut (X3). 18) Place the bottom cover (X) in position, secure with the screws (X1) and screw in the 4 feet (V1) (Fig.65). 19) Place the machine upright on the worktop and insert the swarf tray (V). 20) Secure the top cover with the screws (S2) and (S3) (Fig.79); replace the mat. Operating Manual OMNIA / OMNIA 650rpm / OMNIA MAX / OMNIA W MAX Copyright Silca 2014 49

Copyright Silca 2014 50

INFORMATION FOR USERS OF PROFESSIONAL EQUIPMENT From “Actuation of Directive 2012/19/EU regarding Waste Electrical and Electronic Equipment (WEEE)” The symbol of a crossed waste bin found on equipment or its packing indicates that at the end of the product’s useful life it must be collected separately from other waste so that it can be properly treated and recycled. In particular, separate collection of this professional equipment when no longer in use is organised and managed: a) directly by the user when the equipment was placed on the market before 31 December 2010 and the user personally decides to eliminate it without replacing it with new equivalent equipment designed for the same use; b) by the manufacturer, that is to say the subject which was the fi rst to introduce and market new equipment that replaces previous equipment, when the user decides to eliminate equipment placed on the market before 31 December 2010 at the end of its useful life and replace it with an equivalent product designed for the same use. In this latter case the user may ask the manufacturer to collect the existing equipment; c) by the manufacturer, that is to say the subject which was the fi rst to introduce and market new equipment that replaces previous equipment, if it was placed on the market after 31 December 2010; Suitable separate collection for the purpose of forwarding discarded equipment for recycling, treatment or disposal in an environmentally friendly way helps to avoid possible negative effects on the environment and human health and encourages re-use and/or recycling of the materials making up the equipment. The sanctions currently provided for by law shall apply to users who dispose of products in unauthorised ways. Operating Manual OMNIA / OMNIA 650rpm / OMNIA MAX / OMNIA W MAX Copyright Silca 2014 51

any job not specifi ed in this manual should 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). 11.1 How to request service The guarantee attached to the key-cutting machines ensures free repairs or replacements of faulty parts within 24 months of purchase. All other service calls must be arranged by the customer with Silca or with a Silca service centre. Operating Manual OMNIA / OMNIA 650rpm / OMNIA MAX / OMNIA W MAX Copyright Silca 2014 52

CE DECLARATION OF MACHINE COMPLIANCE SILCA S.p.A. - VIA PODGORA 20 ( Z.I.) 31029 VITTORIO VENETO (TV) - (ITALY) TEL. 0438 9136 - FAX. 0438 913800 Declares under its own responsibility that the Key-cutting machine model OMNIA complies with the requirements of the following European Directives: European Union DIRECTIVE 2006/42/CE (Machines) and with the EN 12100 – 1 :2010 Standards European Union DIRECTIVE 2004/108/CE (Electromagnetic Compatibility) and with the EN 55022 : 2010 / EN 55024 : 2010 EN 61000 – 3 – 2 : 2006 + A1 + A2 : 2009 EN 61000 – 3 – 3 : 2008 Standards European Union DIRECTIVE 2006/95/CE (Low Voltage) | 13 | and with the EN 60950 – 1 : 2006 + A11 : 2009 + A1 : 2010 + A12 : 2011 EN 62233 : 2008 Standards Claudio Tomasella of the Silca S.p.A. Research & Development Division is authorized to create a Technical File. General Manager Basic Production Center

CE DECLARATION OF MACHINE COMPLIANCE SILCA S.p.A. - VIA PODGORA 20 ( Z.I.) 31029 VITTORIO VENETO (TV) - (ITALY) TEL. 0438 9136 - FAX. 0438 913800 Declares under its own responsibility that the Key-cutting machine model OMNIA MAX complies with the requirements of the following European Directives: European Union DIRECTIVE 2006/42/CE (Machines) and with the EN 12100 – 1 :2010 Standards European Union DIRECTIVE 2004/108/CE (Electromagnetic Compatibility) and with the EN 55022 : 2010 / EN 55024 : 2010 EN 61000 – 3 – 2 : 2006 + A1 + A2 : 2009 EN 61000 – 3 – 3 : 2008 Standards European Union DIRECTIVE 2006/95/CE (Low Voltage) | 13 | and with the EN 60950 – 1 : 2006 + A11 : 2009 + A1 : 2010 + A12 : 2011 EN 62233 : 2008 Standards Claudio Tomasella of the Silca S.p.A. Research & Development Division is authorized to create a Technical File. General Manager Basic Production Center

31029 VITTORIO VENETO (TV) Phone: +39 0438 9136 Fax +39 0438 913800 E-mail: [email protected] www.silca.biz United Kingdom SILCA Ltd. Unit 6 Lloyds Court - Manor Royal CRAWLEY RH10 9QU Phone: +44 1293 531134 Fax +44 1293 531108 E-mail: [email protected] www.silcaltd.co.uk India MINDA SILCA Engineering Ltd. Plot no.37, Toy City, GREATER NOIDA (U.P.) - 201308 Phone: +91 9871397630/31 Fax: +91 120 2351301 E-mail: [email protected] www.mindasilca.in France SILCA S.A.S. 12, Rue de Rouen Z.I. de Limay - Porcheville 78440 PORCHEVILLE Phone: +33 1 30983500 Fax +33 1 30983501 E-mail: [email protected] www.silca.fr North America U.S.A., Canada, Caribbean Islands KABA Ilco Corp. 400 Jeffreys Road Rocky Mount, NC 27804 USA Phone: 1 800 334 1381 / 1 252 446 3321 Fax: 1 252 446 4702 E-mail: [email protected] www.ilco.us Germany SILCA GmbH Siemensstrasse, 33 42551 VELBERT Phone: +49 2051 2710 Fax +49 2051 271172 E-mail: [email protected] www.silca.de Central America Mexico, Guatemala, Belize, El Salvador, Honduras, Nicaragua, Costa Rica, Panama Corporación Cerraiera Alba S.A. de C.V. Kaba Mexico Prolongación avenida independencia 14, Bodega 5, Col.Los reyes, Tultitlán, Estado de México C.P. 54915 Phone: 01 55 5366 7200 E-mail: [email protected] www.kabamexico.com Spain SILCA KEY SYSTEMS S.A. C/Santander 73A 08020 BARCELONA Phone: +34 93 4981400 Fax +34 93 2788004 E-mail: [email protected] www.silca.es Brazil KABA DO BRASIL Ltda Rua Guilherme Asbahr Neto, 510 São Paulo, SP 04646-001 Phone: +55 11 55454520 / 29 E-mail: [email protected] www.silcachaves.com.br Netherlands H. CILLEKENS B.V. Metaalweg, 4 6045 JB ROERMOND Phone: +31 475 325147 Fax +31 475 323640 E-mail: [email protected] www.hcillekens.nl Colombia SILCA SOUTH AMERICA S.A. Km 1.5 Via Briceño-Zipaquira Parque Ind. Trafalgar Bodega 3 Tocancipa-Cundinamarca Phone: +57 1 7366480 Fax +57 1 7366490 www.fl exonsilca.co