Silca Unocode 399 Plus Operating Manual

This manual is written by SILCA S.p.A. All rights reserved. No part of this publication may be reproduced or used in any form or by any means (photocopying, microfilm or other) without the written permission of SILCA S.p.A. Edition: July 2016 Printed in Vittorio Veneto by SILCA S.p.A. via Podgora, 20 (Z.I.) 31029 VITTORIO VENETO (TV) - Italy IMPORTANT NOTE: in compliance with current regulations relating to industrial property, we hereby state that the trade-marks or trade names mentioned in our documentation are the exclusive property of authorized manufacturers of locks and users. Said trade-marks or trade names are nominated only for the purposes of information so that any lock for which our keys are made can be rapidly identified.

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

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

Unocode 399 PLUS Copyright Silca 2016 1 REFERENCE GUIDE This manual has been produced to serve as a guide for users of the UNOCODE 399 PLUS electronic key-cutting machine. Read it carefully; it is essential if you wish to operate your machine safely and efficiently. CONSULTATION The contents of the manual are divided into sections relating to: • Machine description ...................................................................................................Chapter 1 • Transport and installation ...................................................................................................Chapters 2-3 • Regulation and use ...................................................................................................Chapters 4-5-6 • Maintenance ...................................................................................................Chapters 7-8-9 TECHNICAL TERMS Common technical terms are used in this manual. To assist those with little experience of keys and key-cutting, below is an illustration of the terms most frequently used. Fig. 1 1) Head 2) Rim 3) Stop 4) Stem 5) Tip 6) Back 7) Cuts CARD NUMBER: Silca number for cutting by code on Silca electronic machines for flat keys. Fig. 2 2 1 5 3 6 4 1 3 7 5 7 2 NUMERO SCHEDA Card Number FROM SILCA KEY CATALOGUE

Operating manual - English 2 Copyright Silca 2016 GENERAL UNOCODE 399 PLUS has been designed in compliance to the European Community normative (CE). From the design stage, risks for the operator have been eliminated in all areas: transport, regulation, cutting and maintenance. Further risks have been eliminated by means of protective devices. The materials used to manufacture this machine and all its components are not hazardous. USE UNOCODE 399 PLUS is designed for cutting keys of ferrous materials: brass, silver nickel, etc. It must be installed and used according to the instructions indicated by the manufacturer. If the key-cutting machine is used differently or for purposes different from those described in this manual, the customer will forego any rights he may have over Silca S.p.A. Furthermore, unforeseen danger to the operator or any third parties may arise from incorrect use of the machine. INSTRUCTIONS MANUAL The instructions manual provided with the machine is essential to its proper use and to carry out the necessary maintenance. We therefore recommend protecting the manual from damage in a safe sheltered place, easily to hand for quick consultation. INCORRECT USE Operator negligence resulting in improper use of this machine or failure of the operator to observe the instructions written in this manual. The manufacturer may decline all guarantees and responsibilities. It is therefore essential to carefully read this operating manual. FURTHER RISKS No further risks will arise when properly using the UNOCODE 399 PLUS. PROTECTION AND SAFETY PRECAUTIONS FOR THE OPERATOR UNOCODE 399 PLUS is entirely built in compliance to the Machine Directives. The operations for which it has been designed are easily carried out with no risk to the operator. The adoption of general safety precautions and observation of the instructions provided by the manufacturer in this manual eliminate all human error, unless deliberate. UNOCODE 399 PLUS is designed with features which make it completely safe. • Power supply UNOCODE 399 PLUS is supplied with electricity by means of a grounded plug and differential switch. • Pneumatic power With compressed air. • Start-up The machine is turned on by means of a master switch that is located on the Unocode’s lower left back side. • Maintenance The operations to regulate, service, repair and clean the machine are structured in the simplest and safest way possible. Parts that the operator can dismount cannot be incorrectly replaced therefore avoiding any risks.

Unocode 399 PLUS Copyright Silca 2016 3 • Machine identification The machine is provided with an identification label which includes the machine’s serial number (fig. 3). Fig. 3 (*) see chap.8 "DISPOSAL", page 76.

Operating manual - English 4 Copyright Silca 2016 1 MACHINE DESCRIPTION UNOCODE 399 PLUS is an electronic machine operating on two axes (3rd axis optional) with controlled movement. Accurately studied, it adds a high degree of cutting precision to operating speed and ease of use. UNOCODE can be used in different ways: • entering the key code directly by means of the machine keyboard • linking to a PC and Silca software Fig. 4 1.1 MAIN CHARACTERISTICS • Movements Movement of the two axes (X-Y) operates on ball screws activated by step motors, on rectified roller guides. • Clamp Standard four-sided clamp, specially designed to grip most flat keys. • Working tool Consists of a cutter in hard metal carbide, that is easily replaced. Suitable to the type of work and speed rotation needed. • Display Placed on the front of the machine. Its technical features and positioning make it highly practical in use.

Unocode 399 PLUS Copyright Silca 2016 5 1.2 SAFETY • Protective shield The transparent protective shield is designed to cover the working parts as completely as possible, ensuring operator safety. The shield (U) (fig. 5, page 6) must be raised in order to fit keys for cutting or carry out other operations. Raising of the shield is controlled by a microswitch and disactivates the operating and movement functions, including the cutter. A special message appears on the display to warn that the shield is not closed. To re-start the work cycle, place the shield in its original position and press START on the machine’s keyboard. • Emergency stops The red emergency button (N) (fig. 5, page 6) placed on the right-hand side of the machine is used to stop it immediately in the event of faulty operation or danger for the operator. When the cause of the emergency has been eliminated, turn the button 45° clockwise to disactivate it. Note: the operator is responsible for keeping the area around the button clear so that it can be reached as quickly as possible. • Cutter motor protection The cutter motor is protected against overheating by a cut-out switch (located inside the motor) that will automatically stop the motor if it reaches a certain temperature. Should the switch activate: 1) turn the machine off and disconnect the power supply cable. 2) contact Silca’s Technical Assistance Dept.

Operating manual - English 6 Copyright Silca 2016 1.3 MAIN WORKING PARTS Fig. 5 B C D E F H I P O Q S U V Q1 U1 T N R K J

Unocode 399 PLUS Copyright Silca 2016 7 Fig. 6 A - master switch A1 - power socket / fuse tray B - keyboard C - display D - clamp - cutter side E - clamp knob F - key gauge H - cutter I - cutter shield J - STOP button K - START button L - external START/STOP connector L1 - connector for unload sorter (*) L2 - serial receptacle for suction (*) N - emergency button O - 3rd axis P - IN/OUT port (Automatic feeder*) Q - serial port Q1 - USB port R - Y axis connector S - X axis carriage T - Y axis carriage U - protective shield U2 - vacuum system connector V - swarf tray (*) Feeder Kit, Suction Kit and Sorter Kit are optional accessories. A A1 R O P J K Q1 L L2 Q L1

Operating manual - English 8 Copyright Silca 2016 1.4 TECHNICAL DATA Electricity supply: 230V-50Hz Nominal power: 230V: 1,1 Amp. 210 Watt cutter motor: single phase and speed cutter: hard metal Tool speed: 50Hz: 1700 rpm (+/- 10%) Movements: on 2 axes with ball screws activated by step motors, on rectified roller guides. Possibility to add a 3rd axis to activate the optional tilting and rotating clamps. Clamp: universal 4 sided clamp to grip flat, car and cruciform keys Runs: X axis: 57 mm Y axis:: 32 mm Dimensions: width: 500 mm depth: 700 mm height: 700 mm (with raised shield 900 mm) Mass: Kg. 51 Noise level: sound pressure Lp(A) = 80 dB(A) (cutting iron keys) 77 dB(A) (cutting brass keys)

Unocode 399 PLUS Copyright Silca 2016 9 1.5 ACCESSORIES PROVIDED UNOCODE 399 PLUS comes with a set of accessories for its operation and maintenance (tools, hex wrenches, fuses) supplied in a special tool kit comprising: tool kit 10 mm spanner D916657ZR Z1 template (regulating disk) D931090ZR tip stop bar with notch 13 mm spanner Z20 setting template tip stop bar D912423ZR 2 Amp fuse - delayed D916658ZR Z3 template (regulating key) D900754ZR cutter release rod D901185ZR 4 Amp fuse - rapid Z4 serial test connector D931082ZR 2 mm allen key D916568ZR 10 Amp fuse - delayed belt tension plate 2,5 mm allen key D908726ZR 4 Amp fuse - delayed D933777ZR ø 1,7 mm steel pin 3 mm allen key D910652ZR 6,3 Amp fuse - delayed ø 1,2 mm steel pin 4 mm allen key D906963ZR 19 mm socket wrench D909281ZR serial cable 9/9 5 mm allen key D906935ZR slanted brush D929095ZR USB cable 6 mm allen key

Operating manual - English 10 Copyright Silca 2016 2 TRANSPORT The key-cutting machine is easily transported and is not dangerous to handle. The packed machine should be carried by at least two people. 2.1 PACKING The packing for UNOCODE 399 PLUS is designed to ensure safe transportation and to protect the machine and all its parts. It comprises a pallet base (b) to which the machine is attached, and a cardboard box as a cover (a). The machine is fixed to the base of the pallet with screwed down brackets that hold it firm into place. This prevents the machine and its protective shield from any damage. The closed packing is held in place by two straps which hold the cardboard box firmly on the pallet. Symbols are printed on the outside of the cardboard box to give instructions and warnings for transportation. Fig. 7 To prevent any damage to the machine it is advisable to save and use the brackets provided for future transportation. a b Keep dry This side up Handle with care Use no hooks

Unocode 399 PLUS Copyright Silca 2016 11 2.2 UNPACKING To remove the machine from the packing box: 1) cut the straps with scissors and remove 2) raise the top part of the cardboard box 3) loosen the screws, both on the front and back brackets that hold the machine to the pallet 4) use the special spanner (provided in the tool kit), to loosen the nuts on the machine’s feet 5) remove the metal brackets and re-tighten the nuts on the feet. 6) check the contents in the box, that should comprise with the following: 1 UNOCODE 399 PLUS key-cutting machine 1 set of documents, including: an operating manual, a spare parts list and a guarantee 1 power supply cable 1 tool kit Note: we strongly recommend you keep the packing intact for future transportation 2.3 MACHINE HANDLING When the UNOCODE 399 PLUS has been unpacked, place it directly on its workbench; this operation should be carried out by at least two people. Take care to lift the machine firmly holding the base, and no other part. ATTENTION: never lift the machine by holding the keyboard stand (fig. 8). Fig. 8 INCORRECT! CORRECT!

Operating manual - English 12 Copyright Silca 2016 3 MACHINE INSTALLATION AND PREPARATION The key-cutting machine can be installed by the purchaser and does not require any special skills. It is supplied ready for use and does not need any special set up. However, the operator may have to control a few things before operating the machine. 3.1 CHECKING FOR DAMAGE UNOCODE 399 PLUS is solid and compact and will not normally damage if transport, unpacking and installation have all been carried out according to the instructions in this manual. However, it is always advisable to check that the machine has not suffered any damage. 3.2 ENVIRONMENTAL CONDITIONS To ensure that the best use is made of the key-cutting machine, it is important to place it in a well-aired area which is not too damp. The ideal conditions for the machine are: temperature between 10°C and 40°C; relative humidity: approx 60% 3.3 POSITIONING AND INSTALLATION 1) Place the machine on a horizontal surface, solid enough to support the weight of 51 Kg. - to work with ease, we suggest that the workbench be approximately the height of the operator’s hip. - it is important to leave clearance of at least 30 cm behind the machine and on each side to ensure proper ventilation. 2) Ensure that the machines voltage is the same as that of the mains power supply, which must be properly earthed and provided with a differential switch. 3) Connect the power supply cable to the power supply socket. Fig. 9 30 cm 30 cm 30 cm 100 cm

Unocode 399 PLUS Copyright Silca 2016 13 3.4 DESCRIPTION OF WORK STATION The machine needs only one operator, who has the following controls at his/her disposal (fig. 5, page 6): • master switch placed on the back of the machine • key-positioning clamp • keyboard • display • emergency button 3.5 GRAPHICS • There is a prohibition warning label on the front side of the machine (fig. 10). This label must never be removed. Fig. 10 Do not use compressed air for cleaning

Operating manual - English 14 Copyright Silca 2016 4 “SET UP” AND USE OF THE MACHINE 4.1 USE OF THE CLAMP The four-sided clamp ensures excellent grip on the keys placed on their back or profile sides (fig. 12). • Keys with 1 or 2 cuts should be fitted mainly on the A and/or B side of the clamp. Fig. 11 - The side of the clamp on which to place the key is shown on the machines display. Fig. 12 Fig. 13 - key stops Clamp V100 1 2 3 4 2 C 4 3 2 3 4 1 4 D B A 2 1 1 3 D side C side B side A side 1 2 3 4 0 B 4 3 1 C D 4 3 1 A 4 3 2 1 6

Unocode 399 PLUS Copyright Silca 2016 15 ATTENTION: the knob is gauged so that it do not exert too much pressure for closing (if pressure is too high it only idles), which would damage the key and the parts of the clamp (including the knob). To turn the clamps: With loosened handle (E) a light rotation of the clamp is sufficient (gripping by the 2 jaws) to turn it to the required side. Alignment is automatic and guaranteed by the mobile pressure device (D5) (fig. 14). Fig. 14 Note: before starting to cut a key the V100 clamp gauge goes automatically to the idle position so there is no need to lower it. USING PINS Pins must be used in the case of keys with special profiles, to stop the keys from moving and vibrating. Fig. 15 Fig. 16 D5 E Attention: the pin should be placed vertically 2 C 4 3 2 3 4 1 4 D B A 2 1 1 3 pin

Operating manual - English 16 Copyright Silca 2016 4.2 FITTING THE CLAMP TO THE MACHINE To remove the clamp unit: - loosen the grub screw (D2) (fig. 17) and slide the clamp out of the dovetail guide. To install the clamp unit on the machine: - slide the clamp into the dovetail guide, pushing it all the way in, then secure it by tightening the grub screw (D2). These instructions refer exclusively to the standard clamp (V100). For the use of optional clamps please refer to the instructions provided along with them. Fig. 17 4.3 CUTTER The majority of keys utilize the standard cutter for code cutting. Only in certain cases some special keys with particular type cuts require different cutters. To change the cutter see chapter 4.4. 4.4 CHANGING THE CUTTER 1) raise the protective shield. 2) remove the cutter protective shield (i) by loosening the screw (i2). 3) slide the cutter release rod (X) into the hole located on the left side of the machines cutter shaft chassis (fig. 18). 4) loosen the cutter locking nut (turning it clockwise) with the19 mm socket wrench (X1) provided with the machine. ATTENTION: the thread is left-handed. 5) replace the cutter, then tighten the nut (turning it anticlockwise) and remove the rod from its hole. 6) place the cutters protective shield (i) back into position securing it with the screw (i2). Fig. 18 ATTENTION: when replacing a worn cutter with a new one or with a re-sharpened cutter consult chap.5.7 "GAUGING", page 40. D2 X1 X i2 i loosen tighten

Unocode 399 PLUS Copyright Silca 2016 17 5 OPERATING GUIDE Introduction The Operating Guide below explains how to use the UNOCODE 399 PLUS without a Personal Computer. All operations to manually use the key-cutting machine are explained step by step. The programs available for Personal Computers connected to the key-cutting machine are able to transmit data for cutting. Programs for Personal Computer eliminate manual procedures of certain functions, once the data has been transmitted to the machine it bypasses some of the operating guides screens. If UNOCODE 399 PLUS is used with a PC, exclude the manual mode pages when consulting the operator’s handbook. 5.1 ON-BOARD KEYPAD AND FUNCTIONS Fig. 19 The MENU key is used to view the list of main functions: MENU key: is always active from any of the windows. Function keys: select the on-screen options Arrow keys: used to move the pointer (navigation) in the on-screen fields CLEAR: used to delete a single character SHIFT+ CLEAR: pressed together to delete an entire row SHIFT+ ENTER: pressed together to insert a digit space START: starts the procedure STOP: cancels the operation and/or returns to the previous menu.

Operating manual - English 18 Copyright Silca 2016 5.2 PRELIMINARY OPERATIONS 1) place the key-cutting machine on the work top. 2) connect the power lead to the mains (cap.3.3, page 12). 3) make sure that the emergency button (N, fig. 5, page 6) is not turned on. 4) turn the machine on by means of the main switch (A, fig. 5, page 6) that is located on the back of the machine. - to check or edit the parameters for using the machine, access the OPTIONS menu (chap.5.9, page 52). - set the required measuring unit (default is MILLIMETRES) 5) When the machine is turned on the display shows the following screen: The main screen will show: • Main functions • Name of the key-cutting machine • Serial number of the key-cutting machine • SW version: machine program version • DB version: version of the cutting card Database on board the machine • Date • Time • MENU word (flashing) Fig. 20 MAIN MENU FUNCTIONS • Copy from Original (FUNCTION NOT ON THIS MACHINE) • Copy card • PC queue • CODEMAKER • Gauging • Maintenance • Options • Enabling Press the MENU key to view the list of icons relating to the main functions of the machine program.

Unocode 399 PLUS Copyright Silca 2016 19 5.3 COPY BY DATA CARD The Copy by Data Card function is used to cut a key using the “original” parameters memorized by Silca or the operator (USER data card and CODEMAKER data card). Part of the machine memory is used for storing data cards. A data card is a database of “Spaces”, “Depths”, “Cutting angles” and “Flares” for all the keys taken into consideration by Silca. Figura 21 From the initial screen press F2 to use the function and then: • Key F1 to access the SILCA and USER data cards. • Key F2 to access the CODEMAKER data cards. • SILCA data cards References to “SILCA data cards” are found in: - Silca paper catalogues - Silca electronic catalogue - Silca Key Programs SILCA data cards can be edited for certain parameters only. Variations CANNOT BE SAVED in the machine memory. The number of SILCA data cards increases periodically, with “Silca Code Program” updates that the user can purchase separately. Through the Silca Code Program the user can update the program and the on-board machine data. • USER data cards This is a data card customized by the user with Silca Key Programs on a PC and sent to the machine. It may be: - created by the SKP Code Maker - a Silca SKP data card with certain parameters edited. USER data cards can be edited for certain parameters only. Variations CAN BE SAVED in the machine memory. • Press F3 to view the list of USER data cards. cutting angle cutting space flare (base of the cut) depth F1 F3

Operating manual - English 20 Copyright Silca 2016 • CODEMAKER data card: Data card customized by the user, created with the CODEMAKER function on the machine (see cap.5.6, page 36). • From the initial screen “Copy by data card” press F2 • Enter the CODEMAKER data card number or press F3 to see the list of CodeMaker data cards (chap.5.6, page 36). F2 F3 F2 Nr. Scheda CodeMaker Description

Unocode 399 PLUS Copyright Silca 2016 21 “Copy by data Card” procedure 1) Digit the card number (e.g.: 50): 2) Press ENTER: Fig. 22 Fig. 23 (*) Adapter on certain data cards provided by Silca the parameter “Adapt: B...” indicates the type of accessory needed to cut a key. 3) Digit the cuts. In the cut entry field: - The dots shown represent possible cuts. The same card can be used for a number of keys with a different number of cuts. - If the key needs fewer cuts than the dots on display, just enter the partial combination (from left to right). - in the case of double asymmetrical cuts, enter the cuts for both fields involved. 4) Press ENTER. Card No Number of cuts per side for current key cut entry field Symbols associated to cutting depths symbols allowed for data Adapter* (if required) Clamp to use Side 1: single cut Side 1x2: double symmetrical cuts Side 1 / Side 2: double asymmetrical cuts Key Stop Side 1 Side 1 x 2 Side 1 / Side 2 Single cut Double symmetrical cuts Double asymmetrical cuts

Operating manual - English 22 Copyright Silca 2016 5) Enter the quantity of keys to be cut (max.999) Fig. 24 6) Press ENTER. Fig. 25 • Check that the clamp is the right one (e.g. V100 Side A) • Install the key blank with the required reference (e.g. Stop 0). • Check that the installed cutter is the right one (e.g. U01W - standard). Cutters: some data cards available in the machine memory require the use of tools different from the standard universal cutter U01W (e.g. key FO21P). To replace the cutter follow the instructions given in chap.7.3, page 65. number of pieces a b c d e F4 Accessory functions (chap.5.3.2, page 25) to cut Press F4 to view all the functions cutter to use key stop: Stop 0 f g h clamp to use Accessory functions (chap.5.3.2, page 25)

Unocode 399 PLUS Copyright Silca 2016 23 7) Press START. TO CUT ON BOTH SIDES: - Turn the key and cut the second side if the key is symmetrical, as in this case. Press START. 8) Press STOP and remove the key. TO CUT ON ONE SIDE: - Press STOP and remove the key.

Operating manual - English 24 Copyright Silca 2016 5.3.1 FAVOURITE DATA CARDS Frequently used data cards (SILCA, USER or CODEMAKER data cards), saved in the Favourites menu (chap.5.3.2 "ACCESSORY FUNCTIONS FOR “COPY BY DATA CARD”", page 25). From the initial screen “Copy by data card”, press F4 to view the list of Favourite data cards. Enter the number of the required data card to start the “Copy by Data Card” function. F4

Unocode 399 PLUS Copyright Silca 2016 25 5.3.2 ACCESSORY FUNCTIONS FOR “COPY BY DATA CARD” a) Data Card Decoding FUNCTION NOT AVAILABLE ON THIS MACHINE b) Manual Adjustments • Press F2 to set manual adjustment to cutting depths and spaces. Figura 26 • Press F1 to obtain positive values (+). • Press F2 to obtain negative values (-). • Press F3 to cancel the settings. Y depth adjustment (from -30 to +30 hundredths of a mm): - Y positive value: raise the cuts - Y negative value: lower the cuts X space adjustment (from -30 to +30 hundredths of a mm): - X positive value: move cuts to the right of the stop - X negative value: move cuts to the left of the stop This symbol appears in Copy by Data Card when manual adjustments have been made. F1 F2 cutting angle cutting spaces flare (base of the cut) cutting depths F3 F2 F1

Operating manual - English 26 Copyright Silca 2016 c) Save Data Cards in the Favourites menu Press F3 to save in the Favourites Menu: - a SILCA data card - a USER data card - a CODEMAKER data card From the keyboard digit a number from 1 to 0 to assign a position to the data card to be saved. If all the numbers are taken, re-use an existing position • Enter the data card description. • Press ENTER, which takes you back to the initial screen “Copy by Data Card”. F3

Unocode 399 PLUS Copyright Silca 2016 27 d) Data Card Parameters Function used to view the technical data relating to the data card. • Press F4. • Press F1. • Press STOP to exit. (*) With the measuring unit set on millimetres the highlighted measurements are expressed in hundredths of a millimetre. F1 F4 Key blank measurements * Cutting angle Symbols associated to cutting depths * Cutting spaces * Base of the cuts * Key stop Measuring unit

Operating manual - English 28 Copyright Silca 2016 e) Copy SILCA Data Card in CODEMAKER Function used to copy a SILCA data card into CODEMAKER and edit some of the parameters. • Press F4. • Press F2. ATTENTION:not all SILCA data cards can be copied into CODEMAKER. If there is no icon shown the data card in question cannot be copied (due to non- compatible data). • Press ENTER. • Press ENTER. • Enter a description of the data card. • Press ENTER. The “Copy SILCA Data Card” function can also be used in CODEMAKER through the CODEMAKER function. F2 F4 F2

Unocode 399 PLUS Copyright Silca 2016 29 f) Edit the Cutting Method • Type of Cut The machine can run several types of cut: NORMALE, PIANO, LASER, VERTICALE. If provided for on the data card, the user can edit the type set by default. NORMAL For conventional car and door keys. FLAT Mainly used for car keys where the cut edges are rounded to facilitate the movement of the blades when the key is put into the lock. LASER Conjunction of the cutting angles is determined automatically by the machine, allowing cuts to be made with variable angles; this facilitates the smooth entry of the key into the lock, prolonging the working life of the key. VERTICAL Necessary for special keys with small bits (Silca art. FO19P, FO21P...) where a special cutter is required. When this cutting method is used a special angled cutter is needed. • Press F1 to view the type of cut set by Silca for the data card and the possible alternatives (if applicable). Edit the set type of cut with one of the alternatives given. The type of cut is active throughout the time the machine is in use. When the machine is turned off the function returns automatically to the original setting for the type of cut. ATTENTION: for certain cutting methods the standard cutter U01W must be replaced with a specific cutter. N P L V V F1 Current cut type Cut type set by Silca as original Feasible and selectable options for the selected card

Operating manual - English 30 Copyright Silca 2016 g) Electric Contact FUNCTION NOT AVAILABLE ON THIS MACHINE h) Key Blank Measurement Function used to edit the key blank measurement. The key blank figure in the database refers to a key produced by Silca. Figura 27 1) Press F3 to vary the set measurement for the key blank to be cut. 2) Enter the required measurement and press ENTER to save. 3) Press STOP to quit. F2 Key Blank measurement F3

Unocode 399 PLUS Copyright Silca 2016 31 5.4 SPECIAL CASES 5.4.1 CUTS NOT ALLOWED When the machine is used manually with certain data cards, it may not be possible to carry out certain entered combinations. This happens when the cutting depths are not compatible in the order the user entered the possible cuts. Example: 1) Enter data card number 2) Press ENTER 3) Enter the cut 4) Press ENTER The Silca software calculates the validity of the data entered. If they are not congruous the following message will appear: This message is explained below. The reason for the conflict between certain cuts is explained simply in the case shown. With regard to the cut that originated the message it can be seen that between the two deep cuts (8) and the constant angle (100°) the intermediate cut (0) would be removed. This happens when the cutting angle N (Normal) is not made variable by means of the type of cut L (Laser). Fig. 28 The new drawing of the key shows how for the same cutting process (80846) the cutting angles are automatically calculated by the conjunction of the cutting base with a straight line. This aspect, admissible with certain car keys, is more commonly known as ‘the ideal cutting line’. ATTENTION: in this example it can be seen that the ß angle is less than 45°. This could cause serious problems with a lock, making it difficult or impossible to place the key into the cylinder or remove it. Fig. 29 Control of the combinations in the Options menu can in any case be disabled (Cutting check - cap.5.9). NON-FEASIBLE COMBINATION     8 8 6 0 4 ?  8 8 6 0 4     

Operating manual - English 32 Copyright Silca 2016 5.4.2 LIMITED ACCESS TO DATA (PROTECTED SYSTEMS) Silca has limited access to some of the data in the Database in agreement with certain manufacturers. Limitations are applied to: - DATA CARD, if the key-cutting card is protected, access is denied. To access protected data: a) apply to the manufacturer for authorization. b) communicate to Silca: - cutting machine SERIAL NUMBER - cutting machine ID - the ACTIVATION CODE Silca will issue a Password to enter in order to enable cutting of the protected system. When a protected data card is selected from the F1 menu (e.g.: 2211) the following screen will appear: When the manufacturer’s authorization has been given, contact SILCA to be issued a password, providing the following information: - Machine serial No XXXXXXXXXXXXX Read the serial number on the ID plate located on the back of the key-cutting machine or on the initial display. - Machine ID XXXXX Can be seen in the box used to apply for the password. - ACTIVATION Code XXXXXXXXXX ONLY shown when access is tried to protected data. Enter the password issued by Silca into the relevant field. If the password entered is correct, the following screen will appear: • The password can be saved (with ENTER) so that it will not be necessary to enter it again when using the protected data card. • Press STOP if you don’t want to save the password in the machine memory. In any case the choice made is enabled for the operation in progress. The password will be required again for future ac- cess to the data card. PROTECTED DATA CARD ENABLING PROCEDURE 1) Enter the data card number. 2) Press ENTER. 3) Enter the Password. 4) Press ENTER. 5) Press ENTER again to confirm.

Unocode 399 PLUS Copyright Silca 2016 33 5.5 PC QUEUE FUNCTION USING THE MACHINE WITH A PC The “Silca Code Program” is used to make various searches by cutting code and store them in a special job queue (or file). This special function is designed to assist operators who wish to work with a number of simultaneous searches. After making the required searches by code, just file them in this special job queue then transfer them all together onto UNOCODE 399 PLUS. The information transmitted by the PC is read only files and cannot be edited manually (except for “Key blank measurement”). Each line transmitted corresponds to a cutting stage for one or more keys. For each cut transmitted the number of pieces to produce is set. When the set number of pieces has been completed, a “+” sign will indicate that the cycle is finished. Should a work queue be interrupted, turn off the UNOCODE 399 PLUS. When the machine is turned on again and the is called up, the list reappears, starting from the first line. To enable the function press F3 from the initial screen. • PC queue The data received from the PC are given in the form of a list, e.g: - Number of jobs received - Indirect cutting code - Number of Silca data card used - Number of pieces to cut Use F1 to view the data relating to the job selected. PROCEDURE: 1) Select the job to be done and press ENTER. • A “+” sign indicates that the job HAS BEEN COMPLETED. • A “-” sign indicates that the job HAS NOT BEEN COMPLETED. The job data received from the PC program CANNOT be edited manually (except for “Key blank measurement”). For example, the following will appear on the display: • Press F2 to view any manual adjustments set by the PC program. 2) Press ENTER to continue: Card No. Pieces No. jobs received Indirect codes F1 F2

Operating manual - English 34 Copyright Silca 2016 “CUTTING METHOD” Accessory Function • Press F1 to view the CUTTING METHOD set by Silca for the data card involved. “KEY BLANK MEASUREMENT” Accessory Function • Press F3 to alter the setting for the measurement of the key blank to be cut. 3) Insert the key blank in the clamp on the cutter side. 4) Press START. Cutting starts and the display will show: When the first side has been cut, the display will show: F1 F3

Unocode 399 PLUS Copyright Silca 2016 35 5) Position the second side of the key to be cut. 6) Press START, the display will show: When the second side has been cut, the display will show: • Press STOP to finish the job. • Press ENTER to continue cutting other keys with the same cuts as the key just finished.

Operating manual - English 36 Copyright Silca 2016 5.6 CODEMAKER CARD MANAGEMENT The CODEMAKER function is used to create a new data card with user definable cutting parameters. To enable the function press F4 from the initial screen. A display will appear with the list of user created data cards (if the machine is new the display is blank). The list of functions included with CODEMAKER is represented by icons on the left. • Create new data card (F1) • Edit a data card (F2) • Delete a data card (F3) • Copy a data card (F4 then F1) • Copy a SILCA data card (F4 then F2) NOTE: creating of new cards is allowed for two key types: - SINGLE side - DOUBLE SYMMETRICAL side • Creating new data Card Step 1 Assign a name (description) to the new data card. All the data on the card, except the card number, can be edited. Once the values have been entered press F1 to continue. The display will show: Step 2 This display screen can be used to edit: • Type of cut (see chap. 5.4) • Cutter (set automatically in relation to the type of cut) • Angle (can be set for types of cut different from “V”) When editing is complete, press F1 to continue. Press F2 to go back to the previous screen. ATTENTION: if error messages appear, see chap.5.11.4 "CODEMAKER messages", page 60. F4 F3 F2 F1 F2 F1 F2 F1 Head Tip Reference F2 F1

Unocode 399 PLUS Copyright Silca 2016 37 Step 3 • Insert the depth symbol (number or letter). Press ENTER. • Enter the depth measurement associated to the symbol. Press ENTER. Repeat the operation to the last depth. All measurements are expressed in hundredths of millimetres or inches, according to the setting in machine Options (chap.5.9, page 52) When the operation is finished, press F1 to continue. Fig. 30 Step 4 • Enter the figure for the cutting space from the key stop to the centre of the first cut and press ENTER. • Enter the figure for flare related to the set cut and press ENTER. • Enter the figure for the cutting space from the centre of the first cut to the centre of the second cut and press ENTER. • Enter the figure for flare related to the set cut and press ENTER. • Repeat the operation to the last cut. When the operation is complete, press F1 to save and continue. The display will show: • Press ENTER to save the data. • Press STOP to go back to the previous menu without saving the data. F2 F1 number of depths symbols associated with depths depths entered cutting angle cutting spaces flare (base of the cut) cutting depths HEAD stop TIP stop

Operating manual - English 38 Copyright Silca 2016 • Edit Data Card This function is used to edit a card previously created by CODEMAKER. • Select the data card from the list and press F2. • Follow the procedure described in “Create a new Data Card” and edit the required parameters. ATTENTION: if error messages appear, see chap.5.11.4 "CODEMAKER messages", page 60. • Delete Data Card This function is used to eliminate a data card previously created by CODEMAKER. • Select the data card and press F3. ATTENTION: when a card is deleted the number of that card cannot be reused. • Copy Data Card This function is used to copy a data card previously created by CODEMAKER and edit its parameters. • Select the data card. • Press F4 then F1. • Press ENTER. • Enter a description of the data card. • Follow the procedure described in “Create a new data card” and edit the required parameters. F2 F3 F1

Unocode 399 PLUS Copyright Silca 2016 39 • Import SILCA Card This function is used to copy an original SILCA data card and edit its parameters. • Press F4 then F2. • Enter the number of the SILCA data card to be copied. • Press ENTER. • Follow the procedure described in “Create a new data card” and edit the required parameters. Note: not all SILCA data cards can be imported. F4 F2

Operating manual - English 40 Copyright Silca 2016 5.7 GAUGING The following components on the machine have a specific ‘self-setting’ procedure with the use of regulating templates (chap.1.5 "Accessories provided", page 9): - CLAMPS - CUTTERS - ADAPTERS CUTTERS do not need an automatic calibration system. ADAPTERS provided as optionals do not require calibrating. However, if necessary adjustments can be made to the cutting data, according to the procedures described in chap.5.3.2 "ACCESSORY FUNCTIONS FOR “COPY BY DATA CARD”", page 25. In the circumstances listed below (see events) it may be necessary to re-set one or all of the clamps and/or cutters that the user has in possession. This operation is semi-automatic and requires close attention to the instructions listed below. From the initial screen press MENU then F1 to enable the function. • Clamps  • Cutters  • Adapters  EVENT MACHINE ZEROES CALIBRATION CLAMP CUTTERS Replacement of photocells YES YES NO Electronic board replacement YES YES NO Replacement of sensors YES YES NO Replacement of the cutter shaft YES YES NO Replacement of the ball screws YES YES NO Clamp V100 replacement (with a new one of the same type) NO NO NO Re-sharpening of existing cutter and/or cutter replacement (with a new one of the same type) NO YES YES Installation of optional clamps NO YES (if applicable) NO F1

Unocode 399 PLUS Copyright Silca 2016 41 5.7.1 CALIBRATE STANDARD JAWS 1) Press F1 to access the list of clamps. 2) Select standard clamp V100, then press ENTER. 3) Press START to proceed with automatic calibration; the display will show: 4) Press ENTER, the display will show: 5) Make sure the U01W standard prismatic cutter is installed. ATTENTION:if the original Silca U01W cutter is replaced with one that is NOT original or has been sharpened, it will be necessary to repeat clamp calibration and also gauge all the optional cutters. 6) Press ENTER, the display will show: 7) Fit the test key blank (Z3 template) into side A of the clamp (Stop 0). Fig. 31 8) Press START. 9) Clean the previously cut test key (template Z3) and measure measurements A and B with a centesimal gauge. Fig. 32 10) Press ENTER. F1 Z3 Z3 A B

Operating manual - English 42 Copyright Silca 2016 11) Enter the values for A and B, expressed in hundredths of a millimetre, into the special fields. Nota bene: values are accepted if they are the same or differ by +/- 40 hundredths of a millimetre from the theoretical value. A: min. 960 max. 1040 B: min. 410 max. 490 12) Press ENTER to save the data. Press STOP to quit without saving. 13) Press START. The operation is confirmed and the program goes back to the Calibration menu for the V100 standard clamp. Note: besides automatic gauging, the operator can make manual adjustments by entering the values in the X and Y parameters. ATTENTION:such adjustments (if necessary) are to be entered only after automatic gauging, if applicable. Adjustments can be made within a range of +30 and -30 hundredths of a mm. Adjusting CLAMPS and ADAPTERS Adjust depth Y (-30 to +30 hundredths of a mm): - Y positive value: raise cut - Y negative value: lower cut Adjusting CUTTERS, CLAMPS and ADAPTERS Adjust spaces X (-30 to +30 hundredths of a mm): - X positive value: move cut to the right of the stop - X negative value: move cut to the left of the stop 14) Press STOP to go back to the main menu.

Unocode 399 PLUS Copyright Silca 2016 43 5.7.2 CALIBRATE CUTTERS From the Gauging menu press F2 to enable the cutter gauging function. Select the U01W standard cutter and press ENTER. The display will show: • Press F1 to get positive values (+). • Press F2 to get negative values (-). • Press F3 to cancel the set adjustments. Adjust depth Y (-30 to +30 hundredths of a mm): - Y positive value: raise the cut - Y negative value: lower the cut ATTENTION:if the original Silca U01W cutter is replaced with one that is NOT original or has been sharpened, it will be necessary to repeat clamp calibration and also gauge all the optional cutters. 5.7.3 CALIBRATE ADAPTERS From the Gauging menu press F3 to enable the Adapter gauging function. Select the adapter to be calibrated and press ENTER. The display will show: • Press F1 to get positive values (+). • Press F2 to get negative values (-). • Press F3 to cancel the set adjustments. Adjust depth Y (-30 to +30 hundredths of a mm): - Y positive value: raise the cut - Y negative value: lower the cut Adjust spaces X (-30 to +30 hundredths of a mm): - X positive value: move cut to the right of the stop - X negative value: move cut to the left of the stop F2 F3 F2 F1 F3 F3 F2 F1

Operating manual - English 44 Copyright Silca 2016 5.8 MAINTENANCE From the initial screen press MENU then F2 to enable the function. Use the up/down arrow keys to select the option and press ENTER, or directly press the key relating to the option number. 5.8.1 MOTOR TESTS Read the instructions on the display carefully and check that the carriage (or optional clamp in the case of B) for the axis involved moves. ATTENTION: during this test function all end of run controls are disactivated; avoid moving the carriage up against its mechanical stops. 5.8.2 DIGITAL INLETS TEST - Lift and lower the protective shield checking that the ma- chine’s display indicates OFF (with shield raised) to ON (with shield lowered). Note: if the ON/OFF transition is not made, contact Silca’s Technical Assistance Dept. Jaw acknowledgement: operational only with electrically connected device. This test can be carried out only when an automatic feeder (or other optional component) is installed on the machine.

Unocode 399 PLUS Copyright Silca 2016 45 5.8.3 DIGITAL OUTLETS TESTS Use the up/down arrow keys to move onto the required field, lower the safety shield and press START; it will go from OFF to ON. - In the case of the cutter, the motor will also start. - In the case of the cutting side or reading lamp, the one in ques- tion will illuminate momentarily. Note: if this is not so, contact Silca’s Technical Assistance Dept. This test (Exit...) can be carried out only when an automatic feeder (or other optional component) is installed on the machine. 5.8.4 KEYPAD TEST Press all keys (except STOP) one at time and verify that for every key pressed the display shows the same key circled. Press STOP at the end of the operation to quit the test. Note: if this is not so, contact Silca’s Technical Assistance Dept. 5.8.5 DISPLAY TEST Press ENTER repeatedly to verify changes in the background colour. Note: if no changes are noticed, contact Silca’s technical assistance department. Press STOP to exit Test. 5.8.6 SERIAL PORT Check that the machine’s display indicates OFF. Fit the special (Z4) serial test connector (accessories provided) to the machine’s serial port. Press START and check that the machine’s display indicates OFF to ON. Note: if the ON/OFF transition is not made, contact Silca’s Technical Assistance Dept. Fig. 33 Z4

Operating manual - English 46 Copyright Silca 2016 5.8.7 MACHINE ZERO POINTS With the use of regulating templates (chap.1.5 "Accessories provided", page 9) the machine provides a ‘self-setting’ procedure. These procedures must be carefully carried out following the descriptions and illustrations indicated below. The table below indicates the situations where the Machine Zeroes function must be activated. Fit the template (Z1) in the place of the cutter; (to remove the cutter read the instructions in chap.7.3). EVENT MACHINE ZEROES CALIBRATING CLAMPS CUTTERS Replacement of photocells YES YES NO Replacement of the electronic board YES YES NO Replacement of sensors YES YES NO Replacement of the cutter shaft YES YES NO Replacement of the ball screws YES YES NO

Unocode 399 PLUS Copyright Silca 2016 47 Press ENTER to continue, the display shows: Read the instructions on the display and fit the Z20 template into the cutter side of the clamp, with Stop 0 as the reference. Fig. 34 Lower the gauge and press ENTER to continue. The display shows: Read the instructions on the display, move the carriages manually so that the Z20 template is taken into contact with the Z1 template (fig. 35) in the vertical zone after the stop, up against the front and up against the stem. Fig. 35 When the given position is reached, lower the safety shield and press START. First the display will show: “Positioning” (**) And then:

Operating manual - English 48 Copyright Silca 2016 Press START, the display will show: Press ENTER to confirm, only if the previous parameters were ON (***). Press STOP to cancel the operation and not confirm the adjustments made (if there is one value or more on OFF). The previous values remain valid (already in the machine’s memory). ATTENTION: if the STOP key is pressed, the new settings will be lost. If so, only the previous setting values will remain valid. (**) If the templates have not been properly positioned the following ERROR message appears: (***) If one or both the photocells or one or both the sensors are OFF, repeat the operation following the procedure described in chap. 5.8.8, page 49.

Unocode 399 PLUS Copyright Silca 2016 49 5.8.8 PHOTOCELLS AND SENSORS REGULATION PRELIMINARY OPERATIONS 1) turn the machine off and unplug it from its power supply cable. 2) remove the back panel (chap.7.8). 3) loosen the (G1) and (G2) grub screws that secure the X axis photocell disk (fig. 36). 4) remove the bottom panel (chap.). 5) disconnect the (J1) Y axis cable from the carriage (fig. 37). 7) unscrew the 3 (B5) fixing screws and remove the Y axis protective cover by pulling it in the direction shown in fig. 38. 8) plug the Y axis (J1) cable. 9) turn the machine on and carry on with the procedures described on page 50 . Fig. 36 Fig. 37 - the machine will take the X and Y axes to a predefined position. - the operator must manually rotate the X and Y photocell disks up until the cut in the disks face the photocells card. G1 G2 X axis X axis photocell disk photocell X axis photocell disk X axis photocell card Y axis photocell Y axis sensor Y axis photocell disk B5 J1

Operating manual - English 50 Copyright Silca 2016 Y axis photocell: • manually turn the Y axis disk (fig. 38) up until the display’s description changes from OFF to ON. • use the provided allen key to tighten the (G3) grub screw. X axis photocell: • manually turn the X axis disk (fig. 36) up until the display’s description changes from OFF to ON. • use the provided allen key to tighten the (G1) grub screw (fig. 36). 9) lower the protective shield. 10) press START. - the machine goes on to a new position and is ready for regulating the sensors. Fig. 38 Regulating the Y axis sensor: • raise the protective shield. • use the provided allen key to loosen the (C1) grub screw; manually rotate the (C2) rod in both directions up until the changeover point from OFF to ON is found. • tighten the (C1) grub screw to secure the rod. Regulating the X axis sensor: • carefully tip the machine over. • remove the bottom panel by unscrewing all 8 securing screws. • loosen the (C3) screw that secures the sensor support plate. Manually move the sensor support plate up until the display’s description goes from OFF to ON. • tighten the (C3) screw to secure the plate back into place. • re-position the machine back on its workbench and lower the protective shield. • press START. G3 G4 Y axis photocell Y axis sensor

Unocode 399 PLUS Copyright Silca 2016 51 Figura 39 Figura 40 Fig. 41 C2 C1 Y axis sensor C2 bottomview ATTENTION: if it is necessary to work close to this area with the machine turned on (e.g. to regulate the X axis sensor) take great care not to touch any components on the machine’s electronic boards as it is connected to 230 Volts. C3 X axis sensor C3

Operating manual - English 52 Copyright Silca 2016 5.9 OPTIONS From the initial screen, press MENU then F3 to enable the function. There are 4 machine option windows that are selected by pressing F4. ATTENTION: Hold down F4 to take the machine back to its initial state (with the original parameters set by Silca). Machine Parameters/Options that can be forced from the original factory setting: Rapid speed: 4000 Cutting speed: 400 Reading speed: 350 Minimum distance from stop: 50 Stop adjustment enabling: 0 --> Disabled Parameter X stop adjustment: 0 Parameter Y stop adjustment: 300 Parameter H stop adjustment: 370 Parameter L stop adjustment: 0 Measuring unit: 0 Date format: 0 --> GG/MM/AA Time format: 0 --> 0-24 Keyboard Inversion: 0 --> Disabled Cutting check: 1 --> Enabled Rapid menu for PC queue: 0 --> Disabled Machine Options [page 1/4] The display shows: Preferences Current language: use the arrow keys (rh/lh) to select the measuring unit required (mm = millimetres, inches) then press ENTER to confirm. Measuring unit: use the arrow keys (rh/lh) to select the measuring unit required (mm = millimetres, inches) then press ENTER to confirm. Key pad inversion: this function is normally disabled. Use the arrow keys (rh/ lh) to select enabled or disabled then press ENTER to confirm. The operation is used to invert the function of the alphanumerical keys. With “Key pad inversion” disabled: • To digit number 3 press 3/K • To digit the letter K: press SHIFT + 3/K With “Key pad inversion” enabled: • To digit number 3: press SHIFT + 3/K • To digit the letter K: press 3/K Cutting check: This option is used to enable and disable control of the combinations entered on the cutting card, by pressing SHIFT + [up arrow]. Default is enabled, i.e. there is constant control that the combination entered is compatible with the cutting path. Such control has certain rules that prevent the operator from creating keys which are not guaranteed to work.

Unocode 399 PLUS Copyright Silca 2016 53 Machine options [page 2/4] the display shows: Machine data Model: machine model. Serial No: the serial number corresponding to that on the ID plate located on the back of the machine. Keys cut: cutting completed. Operating System Version: version of the machine operating system. Carriage speed Fast speed: the speed at which the carriages approach the cutting zone before cutting is started. The set speed is that for ideal conditions, but the operator can change it from a minimum of 1000 to a maximum of 5000. Cutting speed: corresponds to the speed at which the carriage advances during key-cutting. The set speed (400) is that for ideal conditions, but the operator can change it from a minimum of 200 to a maximum of 700. Reading speed: Recommended reading speed is 350; the operator can change from a minimum of 100 to a maximum of 350. Machine options [page 3/4] The display shows: Head stop processing Min. cut distance: The number shown on the machine’s display represents the X axis distance between the key blank shoulder and the beginning of the first cut (fig. 42). This function is extremely important with keys that require cuts on both sides as it ensures precise positioning on the key 2nd side. The set figure is 50 hundredths of a mm, which can be varied between min.0 - max. 90 hundredths of a mm. ATTENTION: settings that are too high may render precise cuts impossible, with the following message on the display: Fig. 42 Rectify Key Stop: The machine does not normally allow for key stop rectification. However, it is possible, when necessary, to rectify the stop by removing a part of it, and arrange cutting according to the new key stop created. If the operation is enabled, 4 items are required: Rectification thickness X: thickness of the part to be removed, quantified in hundredths of a mm (min. 0 - max.90) Key stop height Y: height of the stop read by a gauge on the key, quantified in hundredths of a mm. E.g.: Y = 3 mm = 300 hundredths of a mm (min.100 - max.999). Depth H: depth of the part to be removed, quantified in hundredths of a mm, relating to the key blank measurements (min.0 - max.600). Length L: distance in hundredths of a mm of the axis from the cutter, relating to X (min.0 - max.4000). MIN. Parameter of DISTANCE FROM STOP is incompatible with selected card!

Operating manual - English 54 Copyright Silca 2016 Machine options [page 4/4] The display shows: Clock management Date and time format: use the arrow keys (rh/lh) to select the DATE format (DD/ MM/YY by default, or MM/DD/YY or YY/MM/DD) and TIME format (0 - 24 by default or am - pm) required, then press ENTER to confirm. Setup date and time: use the up/down arrow keys to enter the field to be edited and use the arrow keys (rh/lh) to go to the item to be edited. Edit with the numerical keys and press ENTER to confirm each item. Press F4 for overall validation of the edited string. The same preset data will also be shown along the bottom. Battery status: CHARGED Automatically reads whether the battery is charged or flat. The battery is used exclusively for the date function.

Unocode 399 PLUS Copyright Silca 2016 55 5.10 ENABLING From the screen, press MENU and/or F4 to enable the function. This display shows all the protected systems enabled and allows them to be protected again, if necessary. E.g.: In this case a single protected card has been previously enabled. As explained on the display, use the arrow keys (up and down) to select the enabled protected system. Press F1 to make it protected again. The display shows a further message requiring confirmation of removal. Press STOP to quit the operation without making alterations, press F1 to protect the selected card. Press ENTER, the display will show:

Operating manual - English 56 Copyright Silca 2016 5.11 MESSAGES 5.11.1 ATTENTION MESSAGES • The entered data card number is not available in the machine’s data base. • The entered cuts cannot be carried out (see chap.5.4, page 31). • This message appears when the cutter must be changed with one that is compatible to the type of cuts required for the entered data card number. • This clamp is not available in the machine’s data base. • This cutter is not available in the machine’s data base. • This adapter is not available in the machine’s data base. • The entered data card number requires a type of cut that is not available in the machine’s data base. • The minimum distance from the key stop position overlaps the first cut on the key (chap.5.9, page 52). Data card not available! Non-feasible combination! ATTENTION!! Install cutter: U01W Clamp not available! Cutter not available! Adaptor not available! Type of cut not available! MIN. Parameter of DISTANCE FROM STOP is incompatible with selected card!

Unocode 399 PLUS Copyright Silca 2016 57 • During the cutting cycle one or more depth exceeded the maximum limit. These depths are automatically aligned to the maximum permitted depth. • Indicates that the entered function is not yet available. • This message appears when the calibration data are not on the machine. • This message appears when the data are not compatible with the data structure. • This message appears when axis clearance has not been successful. • Indicates that the adjustments inserted can only be applied to the two cases and not to Copy from original. • This message appears if you wish to reset the machine on the initial settings, i.e. with the default parameters set up by Silca (see chap.5.9, page 52). ATTENTION Depth limit exceeded! Non-feasible function ! Jaw not calibrated ! Data format not compatible! See operating manual Zero point axis Movement not completed! Modifications are only applied to COPY BY CARD and COPY WITH ADJUSTMENTS Resetting of original machine data Con- firm operation? No=STOP Yes=ENTER

Operating manual - English 58 Copyright Silca 2016 5.11.2 ERROR MESSAGES • The automatic setting revealed a variation that exceeded the permitted nominal figure setting reference. Carefully repeat the setting procedure. • During the setting of the “machine’s zero points” there is a contact failure between the two templates (see chap.5.8.7, page 46). • This message indicates that during the reading cycle an anomalous form has been revealed that cannot be reproduced with the cutters provided. • The Machine ID has not been set. In such cases access cannot be gained to Protected Systems until the Machine ID is set. Select menu 5.10 "ENABLING"and check that the Machine ID is different from 0. To set Machine ID ask for a Software update valid for your machine and install with the SILCA WinTransfer Program or SILCA Code Program. ERROR 3 Exceeded setting tolerance limit See operating manual ERROR 4 No template contact made. See operating manual ERROR 5 Key cannot be copied ERROR 6 Machine ID not defined See operating manual

Unocode 399 PLUS Copyright Silca 2016 59 5.11.3 ALARM MESSAGES • The electronic control board has exceeded the maximum permitted temperature. Check the cooling fan (SEE chap.7.1 "Trouble shooting", page 63). • Indicates that the fuse has blown due to a short circuit in an inlet or outlet (see chap.7.1 "Trouble shooting", page 63). • Indicates a short circuit in port P (IN/OUT) (see chap.7.1 "Trouble shooting", page 63). • Indicates that the fuse has probably blown (see chap.7.1 "Trouble shooting", page 63). • Indicates a fault on the electronic control board. • This message appears when the machine detects an unexpected contact. • This message appears when gauging a clamp that requires the previous gauging of the standard V100 clamp. ALARM 2 TEMPERATURE ALARM Turn the machine off! ALARM 3 I/O POWER ALARM Check fuse F4! ALARM 4 DIGITAL OUTLET PROTECTION ALARM Turn the machine off! ALARM 5 CUTTER MOTOR ALARM Check fuse F1! ALARM 6 CUTTER MOTOR Fault on motor circuit! Faulty contact made! Press START to move axis at zero point. Before calibrating the jaw: V... it's necessary to have calibrated the V100 jaw

Operating manual - English 60 Copyright Silca 2016 5.11.4 CODEMAKER MESSAGES • Appears when the depth value exceeds the key blank measurement assigned to the key. • Appears when the set angle is higher or lower than the limit allowed by the cutter in use. • Appears when the set depth is higher or lower than the limit for the clamp in use. • Appears when the value of a set space is not within the limit. • Appears when the value of a set flare is not within the limits. • The set combination of spaces and flares exceeds the maximum run allowed for the space axis. • Appears when the value of a set flare would overlay a previous flare. • Appears when the value of a space is altered in such a way as to cause the flare to overlay the previous one. Key Blank dimension out of range! Limit values: Cutting angle out of range! Limit values: Cutting Depth out of range! Limit values: Spacing value out of range! Base of cut out of range! Limit values: Cutting process exceeds X axis carriage range ! See operating manual. Overlapping base of cut! Spacing values are not compatible with base of cuts! The cut depth is not compatible with cutting edge of the cutter. See operating manual.

Unocode 399 PLUS Copyright Silca 2016 61 • Appears when the cutting depth would not allow the cutter to move sideways. • The depth exceeds the limits established for the clamp side in use. • Cutting cannot be done for the type of stop set. • Appears when the key blank measurement is altered and the depths exceed such measurement. The cut depth exceeds the safety limit of the selected jaw side! See operating manual. The cutting process is incompatible with the STOP position ! See operating manual. The depth values can't be greater than the Key Blank Dimension See operating manual.

Operating manual - English 62 Copyright Silca 2016 6 CLEANING • keep the operational parts of the machine as clean as possible by brushing away the chippings in areas where they accumulate during cutting operations. • under no circumstances must compressed air be used to clear the work zone of chippings as this will blow them onto the moving parts. • Never use oil-based products or solvents to clean painted surfaces, jaws, electric or electronic connections, display and/or safety screens. • Do not use alcohol to clean plexiglass carters and display.

Unocode 399 PLUS Copyright Silca 2016 63 7 MAINTENANCE ATTENTION: for repairs or replacement of parts for maintenance, the ‘CE’ mark is guaranteed only if original spare parts provided by the manufacturer are used. Although the UNOCODE 399 PLUS key-cutting machine does not require special maintenance, it is advisable to check and, if necessary, replace the parts subject to wear and electric/electronic parts (fuses, circuit boards, etc.) in the event of faulty operation. ATTENTION: for normal servicing of the burnished mechanical parts, we recommend using lubricants or protective oil, e.g. WD40 or similar. Do not contaminate the electronic parts with the oil. Replacement is simple and can be carried out by the operator consulting the instructions. Before starting any type of maintenance (controls or replacements), read the instructions below: • never carry out maintenance with the machine switched on • always remove the main power supply cable • strictly follow all the instructions in the manual • use original spare parts (see Spare Parts sheet provided). 7.1 TROUBLE SHOOTING FAULT PROBABLE CAUSE Machine is on, with no message on its display: check to see if the back fan is working Not working a) emergency button activated b) general fuses in the power socket are faulty Working a) fuse F3 on electronic control board is faulty b) connection wire between display and electronic circuit board loose c) defective display cutter motor not working: a) the closed protective shield is not making proper contact with the safety microswitch (fig. 44). b) the F1 fuse on the electronic control board is faulty c) motor wire not properly attached to the connector d) defective electronic control board e) motor cut-off WARNING: this may derive from inappropriate or heavy use of the key-cutting machine or a fault with the motor itself. DO NOT USE THE MACHINE and call Technical Silca Dept. to determing the cause of activation of the cut-off. X, Y and B axes motors are not working None of the motors working: a) fuse F2 on the electronic control board faulty b) the wiring between the transformer and electronic control board is loose or the connec- tor is not seeded properly. c) defective electronic control board Only one motor is not working: a) the connection wires between the motor and the electronic control board are loose or the connector is not seeded properly b) defective electronic control board Protective shield is closed but the display reads “‘close shield” a) the closed protective shield is not making proper contact with the microswitch (D3) (fig. 44) b) the F4 fuse on the electronic control board is faulty Keyboard not working (partially or completely) a) the keyboard connector is not properly connected to the interface board (fig. ) b) the wiring between the keyboard/display unit and electronic control board is not properly attached to the relative con- nectors c) defective keyboard d) defective electronic control board Key-cutting machine fails to communicate with computer a) wiring between 9-pin serial port and electronic circuit board not seeded properly or disconnected b) serial cable between key-cutting machine and computer is faulty c) computer serial port is not functional d) defective electronic control board

Operating manual - English 64 Copyright Silca 2016 Fig. 43 Fig. 44 The display shows the message: ‘TEMPERATURE ALARM - turn the machine off’. check that the fan on the back of the key-cutting machine is working: Not working: a) fan faulty b) electronic control board faulty Working: electronic control board faulty The display shows the message: ‘I/O POWER ALARM – check fuse F4”. a) fuse F4 on the electronic control board faulty. b) short circuit on inlets or outlets. To find which inlet or outlet is causing the error message, disconnect the J4-5-7-8- 12-14-15-20 connectors one at a time and check each time whether the alarm disappears. The display shows the message: ‘DIGITAL OUTLET PROTECTION ALARM - turn the machine off’. a) short circuit on the outlets. To find which outlet is causing the error message, disconnect the J4-5 connectors one at a time and check each time whether the alarm disappears. b) internal fault on the electronic control board. The display shows the message: ‘CUTTER MOTOR ALARM - check fuse F1’. a) fuse F1 on the electronic control board faulty. b) cutter microswitch on protective cover triggered or disconnected (D4) (fig. 44). c) cutter motor wiring disconnected. d) internal fault on the electronic control board. FAULT PROBABLE CAUSE D3 D4

Unocode 399 PLUS Copyright Silca 2016 65 7.2 MAINTENANCE OPERATIONS • Cutter replacement • Belt replacement and tension adjustment • Fuse check and replacement • Electronic circuit board replacement • Keyboard/display replacement • Access to back compartment • Access to bottom compartment • Sensor replacement • Photocell replacement • Battery replacement • WIN-TRANSFER program for loading/updating the machine program SAFETY MEASURES TO TAKE WHEN MANAGING ELECTRICAL / ELECTRONIC PARTS ATTENTION: these operations must be carried out by trained qualified personnel. Special care must always be taken in replacing electronic components. Observe closely the instructions below. • Read the instructions carefully before proceeding with replacement. • Work in an environment with a temperature of 10° to 40° C and relative humidity of approximately 60%. • The workbench must be clean, free of foreign bodies and covered in shockproof material. • Do not use compressed air. • Do not work with wet or greasy hands. • Ensure there are no static charges. 7.3 CUTTER REPLACEMENT 1) turn the machine off and unplug it. 2) remove the cutter protective shield (i) by loosening the screw (i2). 3) slide the cutter release rod (X) into the hole located on the left side of the machines cutter shaft chassis (fig. 45). 4) loosen the cutter locking nut (turning it clockwise) with the19 mm socket wrench (X1) provided with the machine. ATTENTION: the thread is left-handed (reversed. 5) replace the cutter, then tighten the nut (turning it counter-clockwise) and remove the rod from its hole. 6) place the cutters protective shield (i) back into position securing it with the screw (i2). Fig. 45 ATTENTION: when replacing a worn cutter with a new one or with a re-sharpened cutter consult 5.7 "GAUGING". X1 X i2 i

Operating manual - English 66 Copyright Silca 2016 7.4 BELT REPLACEMENT AND TENSION ADJUSTMENT To replace the belt, proceed as follows: 1) turn the machine off and unplug it. 2) remove the back panel (chap.7.8, page 70). 3) remove the bottom panel (chap., page 70). 4) loosen the 4 screws (W) securing the motor (fig. 46). 5) remove the worn belt from the pulleys. 6) fit the new belt onto the pulleys, making sure that the direction of rotation is correct. 7) using the provided belt tension plate and the (W2) screw adjust the belt’s tension by turning the (W2) screw. 8) tighten the 4 (W) screws back into place, securing the motor. 9) remount the back and bottom panel. Fig. 46 Fig. 47 To adjust belt tension proceed as follows: 1) turn the machine off and unplug it. 2) remove the bottom panel (chap., page 70). 3) loosen the 4 screws (W) securing the motor (fig. 46). 4) using the provided belt tension plate and the (W2) screw adjust the belt’s tension by turning the (W2) screw. 5) tighten the 4 (W) screws back into place, securing the motor. 6) remount the bottom panel. W W2 W2

Unocode 399 PLUS Copyright Silca 2016 67 7.5 CHECKING AND/OR REPLACING FUSES Fuses should be checked with a tester (ohmmeter, multimeter, etc.) as they may appear to be in good condition even when they are electrically faulty. Fuses must always be replaced with the same amperage and type (rapid or delayed), as indicated in this manual. There are 6 fuses in the UNOCODE 399 PLUS. • 2 fuses: 4 Amps rapid (230V) located next to the power socket on the back of the machine, next to the main switch (fig. 48). These fuses protect the machine from power surges and/or spikes in the electricity supply. To check and/or replace the fuses proceed as follows: 1) turn the machine off and unplug it from its power supply cable. 2) use a flat screwdriver to open the flap covering the socket, remove and check the fuses, replacing them if necessary. Fig. 48 • 4 fuses: F1, F2, F3 e F4 F1: 10 Amps delayed - protects the cutter motor and its electronic controls (230V a.c.) F2: 6,3 Amps delayed - protects the step motors and their electronic controls (+32V d.c.) F3: 4 Amps delayed - protects the logic control circuits on the microprocessor board (+5V d.c.) F4: 2 Amps delayed - protects the digital output circuits for the low voltage controls and the sensor inlets (+24V d.c.) Situated on the electronic circuit board inside the base of the machine (fig. 49), protecting the board from short circuits. To check and/or replace the fuses proceed as follows: 1) turn the machine off and unplug it from its power supply cable. 2) remove the bottom panel (chap., page 70). 3) check and, if necessary, replace the fuses in the way described below: to remove the fuse: - press the fuse cap with your fingers and turn it counter clockwise. To fit the new fuse: - carefully position the fuse back into place, then gently press the fuse cap downwards turning it clockwise. Fig. 49 F1 10A F4 2A 6.3A F3 4A F2 F4 F3 F1 F2 to open to close electronic circuit board

Operating manual - English 68 Copyright Silca 2016 7.6 ELECTRONIC CIRCUIT BOARD REPLACEMENT Proceed as follows: 1) turn the machine off and unplug it from its power supply cable. 2) remove the bottom panel (ch., page 70). 3) disconnect all cable connectors from the electronic circuit board (fig. 50). Fig. 50 4) take the electronic circuit board off by unscrewing the (Y1) nuts off (fig. 51). 5) mount the new electronic circuit board and re-connect all cables (all cable connections are polarised therefore cannot be connected incorrectly). 6) re-fit the bottom panel and re-position the machine on its workbench. 7) turn the machine on and launch the WIN-TRANSFER program (chap.7.13, page 75). Fig. 51 F1 10A F4 2A 6.3A F3 4A F2 electronic circuit board Y1

Unocode 399 PLUS Copyright Silca 2016 69 7.7 KEYBOARD/DISPLAY REPLACEMENT 1) turn the machine off and unplug it from its power supply ca- ble. 2) loosen the 4 screws (W4) and remove the support (W3). 3) remove the display’s support, by unscrewing the 2 (B1) fixing screws (fig. 53 and fig. 54). 4) detach the flat cable and ground wire from the keyboard (fig. 55). 5) unscrew the keyboard’s fixing nuts and remove the keyboard from its support. 6) fit the new keyboard/display, repeating the operations described above, backwards. Fig. 52 Fig. 53 Fig. 54 Fig. 55 W4 W3 B1

Operating manual - English 70 Copyright Silca 2016 7.8 ACCESS TO BACK COMPARTMENT To gain access to the back compartment, proceed as follows: 1) turn the machine off and unplug it from its power supply cable. 2) remove the vacuum system’s connector (U2) (fig. 7.9). 3) unscrew the 6 (M1) screws that secure the back panel (fig. 7.9) thus removing it. Fig. 56 7.9 ACCESS TO BOTTOM COMPARTMENT To gain access to the bottom compartment, proceed as follows: 1) turn the machine off and unplug it from its power supply cable. 2) remove the vacuum system’s connector (U2) (fig. 7.9). 3) turn the machine on its back side. 4) remove the machine’s bottom panel by unscrewing the 8 (L1) screws. Fig. 57 M1 U2 L1

Unocode 399 PLUS Copyright Silca 2016 71 7.10 SENSOR REPLACEMENT X AXIS SENSOR REPLACEMENT 1) turn the machine off and unplug it from its power supply cable. 2) remove the bottom panel (chap. "To gain access to the bottom compartment, proceed as follows:"). 3) disconnect the X axis sensor’s connector from the electronic circuit board (fig. 58). 4) loosen the (L3) nut. Unscrew the sensor from the plate and remove (fig. 59). 5) remove the front cover on the (X axis) lower carriage by unscrewing the 3 (B4) screws (fig. 60). 6) fit the new sensor in position, tightening it until it almost touches the (L2) screw (fig. 59) thus securing it with the (L3) nut. 7) connect the sensor’s connector to the electronic circuit board. 8) remount the bottom panel and front cover. Fig. 58 Fig. 59 Fig. 60 C3 0,1 - 0,4 mm L2 X axis sensor L3 B4

Operating manual - English 72 Copyright Silca 2016 Y AXIS SENSOR REPLACEMENT 1) turn the machine off and unplug it from its power supply cable. 2) raise the protective shield. 3) disconnect the (J1) Y axis cable from the carriage (fig. ). 4) remove the Y axis carriage cover by unscrewing the 3 (B5) locking screws and pull the cover in the direction shown in fig. . 5) disconnect the (M3) sensor’s connector (fig. 62). 6) slightly loosen the (M2) grub screw with the provided allen key. 7) remove the faulty sensor and replace it with a new one. Screw it in until it almost touches the underlying rod (fig. 63). Tighten the (M2) grub screw to lock the sensor into place. Fig. 61 8) connect the (M3) sensor’s connector. 9) replace the Y axis carriage cover. 10) connect the (J1) Y axis connecting wire to the carriage. Fig. 62 Fig. 63 B5 J1 M3 M2 Y axis sensor Y axis sensor 0,1 - 0,4 mm

Unocode 399 PLUS Copyright Silca 2016 73 7.11 PHOTOCELL REPLACEMENT REPLACING THE X AXIS PHOTOCELL 1) turn the machine off and unplug it from its power supply cable. 2) remove the back panel (chap.7.8 "Access to back Compartment"). 3) unscrew the 2 (G) screws that secure the photocell card and remove. 4) disconnect the (G5) photocell cable (fig. 64). 5) connect the photocell cable to the new photocell card. 6) replace the photocell in position securing it with the (G) screws. 7) remount the back panel. 8) plug the machine back in and turn it on. 9) proceed with machine settings (chap.5.8.7 "MACHINE ZERO POINTS", page 46). Fig. 64 REPLACING THE Y AXIS PHOTOCELL 1) turn the machine off and unplug it from its power supply cable. 2) disconnect the (J1) Y axis cable from the carriage (fig. 65). 3) remove the Y axis carriage cover by unscrewing the 3 (B5) locking screws and pull the cover in the direction shown in fig. 65. 4) disconnect the (J2) photocell cable and (J) sensor cable (fig. 65). 5) unscrew the 2 (K) screws that hold the photocell card and remove it from the carriage. 6) place the new photocell card in the carriage and tighten the 2 (K) supporting screws. 7) reconnect both the photocell and sensor cables. 8) remount the Y axis protective cover. 9) connect the (J1) Y axis cable back on the carriage. 10) plug the machine back in and turn it on. 11) proceed with machine settings (chap.5.8.7 "MACHINE ZERO POINTS", page 46). Fig. 65 X axis photocell card G G5 K M2 J J2 Y axis photocell card B5 J1

Operating manual - English 74 Copyright Silca 2016 7.12 BATTERY REPLACEMENT Replacing the battery is a simple operation but must be carried out with care. 1) Disconnect the power lead from the key-cutting machine. 2) Gain access to the bottom compartment. 3) Use pliers with insulated tips to grip the battery and pull it out, taking care to push towards the pressure tab to remove from its shaped housing. 4) Use the pliers with insulated tips to introduce the new battery, inclining it and pushing against the tab to help it enter the shaped housing. 5) Close up the machine and connect to the mains. 6) Reconfigure the date and time on the machine (chap.5.9, page 52). ATTENTION:RISK OF EXPLOSION IF BATTERY IS REPLACED BY AN INCORRECT TYPE. DISPOSE OF USED BATTERIES ACCORDING TO THE INSTRUCTIONS (chap.8 "DISPOSAL", page 76). Fig. 66 insulated points with adhesive tape

Unocode 399 PLUS Copyright Silca 2016 75 7.13 WIN-TRANSFER PROGRAM FOR LOADING/UPDATING THE INTERNAL MACHINE PROGRAM The machine is supplied with an internal program already loaded and tested in our workshops. The user therefore does not need to carry out any operations. Only in the situations described below can the WIN-TRANSFER program be used to re-start the machine. The following is a list of situations where the use of the WIN-TRANSFER program is required. • Replacement of the electronic board (see chap. 7.6, page 68) or loss of the internal machine program. 1) replace the board with a new one, if necessary. 2) install on your personal computer the latest version received of the WinTransfer program. 3) read the serial number on the data plate on the back of the machine (ch.5.9, page 52) and enter on the machine. 4) gauge the machine according to the instructions in the manual, as follows: - gauge as explained in chapter 5.8.7 "MACHINE ZERO POINTS" and chap.5.7.1 "Calibrate STANDARD JAWS"” in the user’s manual. - first gauge the V100 clamp (chap. 5.7.1, page 41). - continue with the gauging of remaining jaws used. At this point the machine is set up and ready for operation. • SILCA update for the program or machine data 1) Install the WinTransfer Program update on your personal computer, following the instructions in the program.

Operating manual - English 76 Copyright Silca 2016 8 DISPOSAL For correct disposal please refer to current standards. INFORMATION FOR USERS OF PROFESSIONAL EQUIPMENT From "Actuation of Directive 2012/19/EU regarding Waste Electricaland 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 first to introduce and market new equip- ment 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 first to introduce and market new equip- ment that replaces previous equipment, if it was placed on the market after 31 December 2010; With reference to portable batteries/accumulators, when such products are no longer in use the user shall take them to suitable authorised waste treatment facilities. Suitable separate collection for the purpose of forwarding discarded equipment and batteries/ accumulators 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. To remove batteries/accumulators, consult the manufacturer’s specific instructions: (see relevant chapter in the users’ manual) The sanctions currently provided for by law shall apply to users who dispose of equipment, batteries and accumulators in unauthorised ways. .

Unocode 399 PLUS Copyright Silca 2016 77 9 ASSISTANCE Silca provides full service to purchasers of the UNOCODE 399 PLUS key-cutting machine. To ensure complete safety to the operator and machine, any job not specified in this manual should only be carried out by the manufacturer or recommended Silca Service Centres. On the back cover of this manual is a list of the manufacturer’s addresses; listed below are the addresses of specialized service centres. 9.1 HOW TO REQUEST SERVICE The guarantee attached to the UNOCODE 399 PLUS ensures free repairs or replacements of faulty parts within 24 months of the date of purchase. All other service calls must be arranged by the customer with Silca or specialized Silca service centres.

UNOCODE 399 PLUS Copyright Silca 2016 Appendix - I UNOCODE 399 PLUS ELECTRICAL DIAGRAMS F2 6.3A F3 4A F1 10A F4 2A PULSANTE EMERGENZA EMERGENCY BUTTON POUSSOIR DURGENCE' PULSADOR DE EMERGENCIA NOTSTOPTASTE 230V-50Hz INTERRUTTORE + FILTRO SWITCH + FILTER INTERRUPTEUR + FILTRE INTERRUPTOR + FILTRO SCHALTER + FILTER F 4A L GND N 1 24 Vac VENTILATORE FAN VENTILATEUR VENTILADOR VENTILATOR TRASFORMATORE TRANSFORMER TRANSFORMATEUR TRANSFORMADOR TRANSFORMATEUR GND 3 5 4 2 GND 18 Vac 18 Vac 24 Vac L1 J 16 GND N1

UNOCODE 399 PLUS Appendix - II Copyright Silca 2016 SCHWARZ 2 ORANGE J17 - BLAU BLUE BRAUN BROWN CELLULE PHOTOELECTRIQUE AXE X PHOTOCELL AXIS X FOTOZELLE ACHSE X + FOTOCELLULA ASSE X 6 MA 5 BI MA NERO BLANC ROUGE ORANGE AR AZUR OUT GND INFX B- INSX 2 - NEGRO BI MX BRUN +12V SENSOR X 1 GI 1 NE MA 3 BLACK WHITE ROJO WEISS PP AZUL MARRONE SENSEUR X SENSORE X DETECTOR X 3 - B+ A+ 4 RO ROSSO RED 4 2 AZ +24V NE 1 +12V NOIR BIANCO BLANCO ANARANJADO ARANCIO M AZ JA1 SENSOR X 3 2 JA1 INFX GND RO - 7 - AZ 5 ROT ORANGE J7 NE 4 3 GND AZZURRO MARRON 4 FOTOCELULA EJE X 1 GND A- RO 8 6 MOTORE FRESA CUTTING TOOL MOTOR MOTEUR FRAISE MOTOR FRESA MOTOR FRASER 8 uF M 1 2 GND L1 N1 1 2 2 1 J1 MIKROSCHALTER SCHUTZ MICROINTERRUPTOR MICROINTERRUPTEUR ECRAN MICROSWITCH SHIELD MICROINTERRUTTORE CARTER

UNOCODE 399 PLUS Copyright Silca 2016 Appendix - III BLANC NERO GLEB GRUN SCHWARZ ANARANJADO AZ - ARANCIO INFY ROJO VERT 2 MARRONE 8 AZ BI ROSSO YELLOW A+ 2 SENSOR Y BLANC 1 ORANGE AZUL AZZURRO FOTOZELLE ACHSE Y BRUN GLEB GRUN 8 GREEN +24V 4 10 AZZURRO MARRONE ORANGE GND INSY BI 2 PP AZUR INFB AZUR WEISS GRIS 3 GND 7 AR 15 5 8 5 GND GND FOTOCELULA EJE Y 1 AMARILLO 1 - AR 9 15 8 BLAU 1 BI RO 4 12 GND JAUNE GND GIALLO RO 2 BIANCO AXIS B NE VERDE 7 2 RO BLUE NEGRO AZUR B+ 3 YELLOW 4 - WHITE VE GRUN ANARANJADO VE 15 - RO RED 4 1 GI J19 AZ AZZURRO 11 13 6 13 9 NE SCHWARZ ROJO MARRON BIANCO INSY 2 GI JAUNE 5 JA3 3 +12V BLACK 7 GREEN +24V VE BLANCO BLACK GRAU 4 J8 MA 1 VE VERDE 2 OUT INS AXE B BRUN 1 9 VE 5 CELLULE PHOTOELECTRIQUE AXE Y 3 - J12 MA BRAUN +12V 11 INSB RO 4 2 J18 GND ROSSO AZ 3 ORANGE 14 1 9 MA - 5 NE WEISS 6 ORANGE AZ BLUE MA 2 B- ROUGE B- 4 ACHSE B VERDE 14 12 ORANGE VERDE 3 1 MY BLANCO MA - +12V 3 GRIS 9 NE VERT 1 5 6 15 4 BI GIALLO GRIGIO - SENSORE Y ARANCIO 2 8 NE BRAUN NE ROT 4 12 VERT 8 10 AZUL A- INFY 6 3 GR NE VE INFB AZ +12V BI B+ M DETECTOR Y 10 NERO 4 5 15 8 JA2 ROT ORANGE GI SENSEUR Y SENSOR Y 15 JA3 6 BROWN NE VE J15 9 PHOTOCELL AXIS Y 3 GREY +12V AZUL NE + MARRON ASSE B 5 1 6 +24V 7 BI 4 AMARILLO A- NOIR 1 1 RO 8 BLAU NOIR GND BLAU - NEGRO 4 JA2 9 1 3 11 ROUGE BROWN WHITE A+ RO RED VERDE 3 8 BI 5 6 RO RO FOTOCELLULA ASSE Y BLUE GI AR 2 VERDE 6 GND EJE B 1 GREEN 7 GND INSB

UNOCODE 399 PLUS Appendix - IV Copyright Silca 2016 ALIMENTATORE AUTOMATICO AUTOMATIC FEEDER ALIMENTATEUR AUTOMATIQUE ALIMENTADOR AUTOMATICO AUTOMATISCHE ZUFUHRER .. 8 - ELETTROVALVOLA 1 12 OUT 3 11 OUT 1 7 OUT AUX 1 5 - 4 - +24V 12 +24V 9 21 - 8 25 SENSORE E OUT AUX 1 13 IN AUX 2 24 OUT AUX 0 19 14 23 ELETTROVALVOLA 4 7 ELETTROVALVOLA 3 9 5 ELETTROVALVOLA 5 15 SENSORE F 8 GND 25 IN AUX 2 13 IN AUX 1 3 SENSORE D IN 0 1 IN 5 6 13 - 7 - IN 8 14 IN AUX 1 25 OUT 0 20 14 SENSORE C 10 12 SENSORE B 14 IN 1 23 OUT 0 4 IN6 6 - IN 7 8 IN 3 4 10 ELETTROVALVOLA 2 1 13 1 16 SENSORE B OUT 2 22 8 2 +24 4 ELETTROVALVOLA 2 6 ELETTROVALVOLA 4 9 GND 21 GND 22 GND 3 IN 4 1 - IN 1 2 IN 2 3 12 ELETTROVALVOLA 3 25 OUT 3 23 3 GND 3 24 ELETTROVALVOLA 5 14 13 15 9 GND 11 SENSORE D 13 SENSORE E 6 +24V 18 +24V 17 IN 7 1 IN 0 19 +24 +24V 11 IN 6 7 22 - GND 18 GND 16 OUT 1 21 1 - SENSORE G 24 OUT 2 15 IN 3 10 OUT AUX 0 19 +24V 2 SENSORE G 15 SENSORE C +24V 10 20 - 11 ELETTROVALVOLA 1 GND 15 IN AUX 3 26 14 2 IN 2 5 +24V 20 IN 8 16 IN 5 18 - 17 SENSORE F IN 4 5 9 GND 25 GND 17 J4 1 8 15 7 14 6 13 5 12 4 11 3 10 2 9 1

UNOCODE 399 PLUS Copyright Silca 2016 Appendix - V SCHEDA RSR232/USB FICHE RSR232/USB J2 CARD RSR232/USB FICHA RSR232/USB J3 KARTE RSR232/USB 1 20 20 1

UNOCODE 399 PLUS Appendix - VI Copyright Silca 2016 CONTATTO ELETTRICO CHIAVE 4 (IN8) 2 RO 3 MIKROSCHALTER SCHUTZ MICROINTERRUPTEUR ECRAN CONTACTO ELETRICO ELEKTRISCH KONTAKT GND 1 2 2 J5 1 (IN7) ELETTROVALVOLA ASPIRAZIONE 1 SUCTION SOLENOID VALVE 8 ELECTROVANNE ASPIRATION 1 GND 9 ELECTROVALVULA ASPIRADOR 15 ELECTROVENTIL SPANEABSAUGANLAGE 9 ELECTRIC CONTACT INPKEY GND MICROSWITCH SHIELD GND J20 10 MICROINTERRUTTORE CARTER NE 24V/1.5A J14 CONTACT ELECTRIQUE MICROINTERRUPTOR NOT ENABLE ON THIS MACHINE LAMPE LED LAMPARA LED J24 LAMPADA LED LAMPE LED LED LAMP Stacker solenoid valve - - - - OUT-AUX3 POLARIZZATORE - - STOP +24 GND 1 8 J23 START 3 2 1 4 1 3 4 J22 1 8 GND GND POLARIZZATORE IN-AUX0 IN-AUX1 IN-AUX2 IN-AUX3 +24 Input AUX3 tray filling sensor Auxiliary output 4

UNOCODE 399 PLUS Copyright Silca 2016 Appendix - VII 15 8 9 1 POS. 8 POS. 4 POS. 7 POS. 3 POS. 6 POS. 5 POS. 15 POS. 14 POS. 13 POS. 9 POS. 12 POS. 11 POS. 2 POS. 1 POS. 10 libero CLAMP OPEN/CLOSE SOLENOID VALVE KEY GUIDE PLATE ADVANCEMENT SOLENOID VALVE KEY GUIDE PLATE BACK SOLENOID VALVE KEY BACK LIMIT SWITCH D SENSOR KEY EJECTOR GUIDE PLATE CYLINDER SOLENOID VALVE GAUGE OPEN/CLOSE SOLENOID VALVE 1 2 3 4 5 RED BLACK BLACK RED RED BLACK BROWN BLACK BLUE BLACK RED RED BLACK 3 OUT 2 4 1 GND + SENSORE X SENSOR X SENSEUR X DETECTOR X SENSOR X VISTA VALVOLE PER CONNESIONE CABLAGGIO 4 3 1 2 5 BROWN F BLUE BLUE BROWN C BLUE BROWN E BLUE BROWN B BLUE BROWN D KEY GUIDE PLATE LIMIT SWITCH E SENSOR INTERMEDIATE SENSOR B KEY GUIDE PLATE LIMIT SWITCH E SENSOR KEY ADVANCEMENT LIMIT SWITCH C SENSOR KEY GUIDE PLATE LIMIT SWITCH F SENSOR OUTPUT 2 AUXILIARY OUTPUT 1 OUTPUT 4 OUTPUT 1 OUTPUT 3

UNOCODE 399 PLUS Appendix - VIII Copyright Silca 2016 PENUMATIC DIAGRAMS MARCA CAVO 5 4 PNEUMATIC DIAGRAM AUTOMATIC FEEDER - UNOCODE 399 PLUS Air inlet 4 2 Gauge 3 2 4 8 3 4 Clamps sensors 4 3 2 5 1 Key guide plate / Ejector 2 1 3 4 3 14 Key feeder 14 5 1 2 at 5/6 atm 5 12 14 5 3 5 6 1 sensors 7 1 14 1 2

UNOCODE 399 PLUS Copyright Silca 2016 Appendix - IX at 5/6 atm Air inlet CLOSED OPEN CLAMP PNEUMATIC DIAGRAM AIR INLET KEY SORTER PNEUMATIC DIAGRAM at 5/6 atm Aitr inlet 1 14 4 3 5 2 2 4

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 UNOCODE 399 EVO complies with the requirements of the following European Directives: European Union DIRECTIVE 2006/42/CE (Machines) and with the EN 12100 – 1 / EN 12100 – 2 Standards European Union DIRECTIVE 2004/108/CE (Electromagnetic Compatibility) and with the EN 55022 / EN 55024 EN 61000 – 3 – 2 / EN 61000 – 3 – 3 / EN 62233 : 2008 Standards European Union DIRECTIVE 2006/95/CE (Low Voltage) | 08 | and with the EN 60950 – 1 / EN 60825 – 1 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