Silca Omnia, Omnia W Max, Omnia 650rpm, Omnia Max Operating Manual

Omnia

Omnia 650rpm

Omnia Max

Omnia W Max

Operating Manual

Original Instructions

D442661XA

vers. 3.0

© 2013 SILCA S.p.A - Vittorio Veneto This manual has been drawn up by SILCA S.p.A. All rights reserved. No part of this publication can be reproduced or circulated by any means whatsoever (photocopies, microﬁ lm or other) without the consent of SILCA S.p.A.

Edition: June 2016

Printed at Vittorio Veneto by SILCA S.p.A. Via Podgora, 20 (Z.I.) 31029 VITTORIO VENETO (TV) - Italy

The Manufacturer declines any responsibility for possible inaccuracies in this document due to printing or transcription errors. The Manufacturer reserves the right to alter the information without prior notice, except when they affect safety. This document or any of its parts cannot be copied, altered or reproduced without written authorization from the Manufacturer. Keep the manual and look after it for the entire life cycle of the machine.

The information has been drawn up by the manufacturer in his own language (Italian) to provide users with the necessary indications to use the key-cutting machine independently, economically and safely.

IMPORTANT NOTE: in compliance with current regulations relating to industrial property, we hereby state that the trade-marks or trade names mentioned in our documentation are the exclusive property of authorized manufacturers of locks and users.

Said trade-marks or trade names are nominated only for the purposes of information so that any lock for which our keys are made can be rapidly identiﬁ ed.

INDEX

USE OF THE MANUAL .......................................................................................................................1

TERMINOLOGY ..................................................................................................................................2

GENERAL WARNINGS .......................................................................................................................4

1 MACHINE DESCRIPTION ....................................................................................................................6

1.1 OMNIA / OMNIA 650rpm: main working parts .............................................................................7

1.2 OMNIA MAX / OMNIA W MAX: main working parts .....................................................................8

1.2.1 OMNIA MAX: Clamp carriage for VERTICAL CUTS .........................................................9

1.2.2 OMNIA W MAX: Clamp carriage for VERTICAL CUTS.....................................................9

2 MAIN CHARACTERISTICS ................................................................................................................10

3 ACCESSORIES PROVIDED ..............................................................................................................13

4 Technical Data ....................................................................................................................................14

4.1 Electrical diagram .......................................................................................................................14

5 TRANSPORT ......................................................................................................................................15

5.1 Packing .......................................................................................................................................15

5.2 Pack opening ..............................................................................................................................15

5.3 Unpacking ..................................................................................................................................16

5.4 Removing the stop .....................................................................................................................18

5.5 Separate parts ...........................................................................................................................18

5.5.1 Power cable ....................................................................................................................18

5.5.2 Warning label .................................................................................................................18

5.5.3 Carriage levers ................................................................................................................19

5.5.4 OMNIA/OMNIA 650rpm: standard carriage (bit, double bit and pump keys) ..................19

5.5.5 OMNIA MAX / OMNIA W MAX: carriage for bit, double bit and pump keys ....................20

5.5.6 OMNIA MAX / OMNIA W MAX: clamp carriage for vertical cuts .....................................20

5.5.7 OMNIA MAX / OMNIA W MAX: solution with a SINGLE CARRIAGE .............................21

5.6 Removing the clamp carriage .....................................................................................................22

6 MACHINE INSTALLATION AND PREPARATION ..............................................................................23

6.1 Checking for damage .................................................................................................................23

6.2 Environmental conditions ...........................................................................................................23

6.3 Positioning .................................................................................................................................23

6.4 Description of work station ........................................................................................................23

6.5 Connection to the mains .............................................................................................................23

7 MACHINE REGULATION AND UTILIZATION ....................................................................................24

7.1 Micrometric tracer point ..............................................................................................................24

7.2 Tracer point spring .....................................................................................................................24

7.3 Using the tilting clamp (carriage for bit/double bit and pump keys) ............................................25

7.4 Locking Y axis ............................................................................................................................25

7.5 Checking and calibration ............................................................................................................26

7.5.1 Axis calibration - carriage for bit, double bit and pump keys ...........................................26

7.5.2 Axis calibration - clamp carriage for vertical cuts (Omnia MAX / Omnia W MAX) ..........27

7.5.3 Depth calibration - carriage for bit, double bit and pump keys ........................................28

8 CUTTING OPERATIONS ...................................................................................................................30

8.1 Cutting bit and double bit keys ...................................................................................................31

8.1.1 Cutting short keys ...........................................................................................................32

8.2 Cutting double female bit keys ...................................................................................................33

8.3 Cutting keys with centre stop .....................................................................................................34

8.4 Cutting bit keys with rear stop (Omnia MAX / Omnia W MAX) ...................................................35

8.5 Cutting pump keys ......................................................................................................................36

8.6 Cutting keys with vertical cuts (Omnia MAX/Omnia W MAX carriage) .......................................37

9 MAINTENANCE ..................................................................................................................................38

9.1 Replacing the carriage ..............................................................................................................38

9.2 Replacing the tracer point .........................................................................................................38

9.3 Replacing the cutter ...................................................................................................................38

9.4 Replacing the brush ...................................................................................................................39

9.5 Replacing the fuses ....................................................................................................................39

9.6 Accessing the bottom compartment ...........................................................................................40

9.7 Replacing the ON/OFF switch ...................................................................................................40

9.8 Replacing the motor start button ................................................................................................41

9.9 Replacing the reset switch .........................................................................................................41

9.10 Replacing the microswitch ..........................................................................................................42

9.11 Replacing the brush button ........................................................................................................43

9.12 Replacing the plug/socket/ﬁ lter ..................................................................................................44

9.13 Replacing the relay ....................................................................................................................44

9.14 Replacing the lamp power box ...................................................................................................45

9.15 Replacing the motor condenser .................................................................................................45

9.16 Replacing the Plexiglas shield ...................................................................................................46

9.17 Replacing the lamp .....................................................................................................................47

9.18 Replacing and/or tightening the belt ...........................................................................................48

9.19 Replacing the motor ...................................................................................................................49

10 DISPOSAL ..........................................................................................................................................51

11 ASSISTANCE .....................................................................................................................................52

11.1 How to request service ...............................................................................................................52

CE DECLARATION

Operating Manual OMNIA / OMNIA 650rpm / OMNIA MAX / OMNIA W MAX

USE OF THE MANUAL

This manual has been drawn up by the Manufacturer and is an integral part of the machine literature. The manual gives information it is obligatory for the operator to know and which makes it possible to use the machine safely.

User’s Manual

This user’s manual is provided because it is essential for proper use and maintenance of the machine. The manual must be kept carefully throughout the life of the machine, including the decommissioning stage. Keep in a dry place close to the machine where it is always to hand for the operator.

ATTENTION: IT IS OBLIGATORY to read the manual carefully before using the machine.

Readers’ characteristics

This manual must be read and its contents acquired by those who will use it. The OMNIA key-cutting machine is designed for professional use by adults of either gender in full possession of their physical, sensorial or mental capacities.

Manufacturer’s ID

OMNIA has an ID plate located on the back of the machine, showing the serial number.

Fig.1

(*) see chap. 10 DISPOSAL.

How to apply for after-sales service

Silca provides purchasers of OMNIA with After-Sales Service. For the total safety of the operator and machine, any operation not described in the manual must be carried out by the manufacturer or in the special Service Centres recommended by Silca. At the end of the manual there is a list of manufacturers’ and authorized Service Centre addresses; if the manual was downloaded is necessary visit the website to see the contacts (www.silca.biz). The warranty card attached to the machine covers free repairs or replacement of faulty parts for 24 months from the date of purchase*. All operations must be agreed by the user with Silca or the Service Centre.

* Damage caused by negligence or wrong use of the machine by the user will null the warranty.

Operating Manual OMNIA / OMNIA 650rpm / OMNIA MAX / OMNIA W MAX

TERMINOLOGY

For those inexperienced in the subject of keys and key cutting, below is an illustration of the most frequently used terms:

1) Head

2) Stem

3) Tip

4) Bit

Fig.2

5) Stop

6) Side

Keys with rear stops

and keys with vertical cuts:

STANDARD with

OMNIA MAX and OMNIA W MAX

7) Cuts

8) Vertical cuts

Operating Manual OMNIA / OMNIA 650rpm / OMNIA MAX / OMNIA W MAX

GRAPHICS IN THE USER’S MANUAL

Pay attention

Obligation to read

the manual

Using ear protection QR Code *

GRAPHICS ON THE OMNIA KEY-CUTTING MACHINES

Obligatory use of

safety goggles

Omnia

Omnia MAX

Omnia 650rpm Omnia W MAX

Obligation to read

the manual

Motor start

push button symbol

Brush button

symbol

QR Code *

Adhesive label

Mass - RPM - Fusibles

Adhesive label DANGEROUS MOBILE PARTS

(provided - chap.3)

(*) A QR code is a two dimensional bar code used to memorize information to be read by means of a mobile phone or smart phone. Read the QR code on the machine to connect to useful and constantly updated information relating to key-cutting machine maintenance, useful tips for your OMNIA key-cutting machine and see the continuously evolving range of optional accessories.

Operating Manual OMNIA / OMNIA 650rpm / OMNIA MAX / OMNIA W MAX

GENERAL WARNINGS

OMNIA is designed to the principles of European Standards (CE). Right from the design stage solutions have been adopted to eliminate hazards for the operator in all the stages of use: handling, regulation, use and maintenance. The materials used in manufacture and the components employed in using OMNIA are not dangerous and ensure that the machine complies to current standards. Silca S.p.A. has also experimented and applied numerous technical solutions that allow the key-cutting machine to optimize the quality of the cut keys. To guarantee maintaining these results over time, please follow the instructions below:

• Observe the procedures described in this manual;

• Always use Original Silca Tools as they are designed to make the best of OMNIA and provide quality key-cutting;

• Use Silca key blanks, made with top quality materials;

• Have the key-cutting machine checked periodically by an authorized Silca After-Sales Service Centre (list at the end of this manual);

• Always use Silca Original Spare Parts. Beware of imitations!

ATTENTION: in the event of prolonged use, cutting extra thick bits or keys in hard materials (iron, steel) we recommend using individual ear protection devices.

NORMAL USE

OMNIA is a key-cutting machine (see chap.1) and must be installed and used according to the rules and speciﬁ cations established by the manufacturer. The OMNIA key-cutting machine is designed for use on business or industrial premises (e.g. hardware shops, key cutting centres, etc...). Any other use different from that indicated in this manual will cause the forfeiture of all customers’ rights to make claims on Silca S.p.A. and may be an unknown source of hazard for the operator or third parties.

ATTENTION: Negligent use or failure by the operator to observe the instructions in this manual are not covered by the warranty and the manufacturer declines any responsibility in such cases.

SAFETY

The key-cutting machine is built entirely to standards. The operations for which it has been designed are easily carried out at no risk to the operator. The adoption of general safety precautions (wearing protective goggles) and observation of the instructions provided by the manufacturer in this manual eliminate all human error, unless deliberate. The key-cutting machine is designed with features which make it completely safe in all its parts.

• CUTTER MOTOR PROTECTION

ATTENTION: the cutter motor is protected from overheating by a device (inside the motor) that stops it whenit reaches a dangerous temperature.

This condition can occur when the machine motor is left on continuously (protection will cut in after approximately 40 minutes), with high ambient temperatures or in severe working conditions (considering an average work cycle

- duty cycle 85% - protection will cut in after approximately 1 hr 40 minutes). If the cutter motor overheats it cuts

outautomatically. In such cases proceed as follows: a) turn off the master switch (A). b) let the motor cool for at least 2 hours then use the machine normally.

Operating Manual OMNIA / OMNIA 650rpm / OMNIA MAX / OMNIA W MAX

• MOTOR START PUSH BUTTON

The machine is protected from untimely machine start. When the carriage is all the way back towards the operator a safety microswitch turns off the motor. If the carriage is inadvertently moved towards the cutter the motor does not start. To start the motor (with the machine on) move the carriage slightly towards the cutter and press the motor start button (B).

RESIDUAL RISKS

No further risks will arise when properly using the OMNIA, OMNIA 650rpm, OMNIA MAX and OMNIA W MAX machines.

SAFETY REGULATIONS

• Always disconnect the machine when it is not in use or when performing maintenance operations.

• Check the electrical wiring periodically; replace any wires that show signs of wear.

• Always work with dry hands free of grease or oil.

• Never tug on the electricity supply lead and make sure it is not in contact with oil or other liquids, sharp objects or heat. Never remove the earthing pin from the plug. Check that the earthing wire is connected properly.

• Do not use the machine in dangerous environments (wet or damp).

• All visitors, especially children, must stay at a safe distance from the machine and must never come into contact with the electric wiring.

• Place the adhesive label provided “DANGEROUS MOBILE PARTS” as shown in chap.5.5.2.

Operating Manual OMNIA / OMNIA 650rpm / OMNIA MAX / OMNIA W MAX

1 MACHINE DESCRIPTION

OMNIA and OMNIA 650rpm are professional key-cutting machines for bit, male and female* double bit, and pump

keys.

OMNIA - OMNIA 650rpm

STANDARD

(*) It is advisable to use optional accessories for female bit and double bit keys.

Fig.3

OMNIA MAX and OMNIA W MAX are professional key-cutting machines for bit, male and female* double bit keys and pump keys with vertical cuts.

OMNIA MAX - OMNIA W MAX

STANDARD

with carriage for bit, double bit and pump keys

(*) It is advisable to use optional accessories for female bit and double bit keys.

Fig.4

STANDARD

with carriage

for vertical cuts

Operating Manual OMNIA / OMNIA 650rpm / OMNIA MAX / OMNIA W MAX

1.1 OMNIA / OMNIA 650rpm: main working parts

A - ON/OFF switch A1 - power supply socket with fuses B - motor start button C - cutter D - tracer point D1 - tracer point spring cam D2 - micrometric ring nut for tracer point regulation E - clamp carriage F - clamp carriage locking handle G - Y axis locking knob H - motor L - translation lever M - ﬁ xed clamp for bit, double bit and pump keys M1 - mobile clamp for bit, double bit and pump keys P - ﬁ xed clamp tightening handle P1 - mobile clamp tightening handle Q - mobile clamp locking lever R - mobile clamp rotation lever S - plexiglas safety shield S1 - cover T - lamps U - brush U1 - brush push button V - swarf tray

Fig.5

Fig.6

Operating Manual OMNIA / OMNIA 650rpm / OMNIA MAX / OMNIA W MAX

1.2 OMNIA MAX / OMNIA W MAX: main working parts

A - ON/OFF switch A1 - power supply socket with fuses B - motor start button C - cutter D - tracer point D1 - tracer point spring cam D2 - micrometric ring nut for tracer point regulation E - clamp carriage F - clamp carriage locking handle G - Y axis locking knob H - motor L - translation lever M - ﬁ xed clamp for bit, double bit and pump keys M1 - mobile clamp for bit, double bit and pump keys P - ﬁ xed clamp tightening handle P1 - mobile clamp tightening handle Q - mobile clamp locking lever R - mobile clamp rotation lever S - Plexiglas safety shield S1 - cover T - lamps U - brush U1 - brush push button V - swarf tray Z - pin/gauge for keys with rear stop

Fig.7

Fig.8

Operating Manual OMNIA / OMNIA 650rpm / OMNIA MAX / OMNIA W MAX

1.2.1 OMNIA MAX: Clamp carriage for VERTICAL CUTS

Fig.9

1.2.2 OMNIA W MAX: Clamp carriage for VERTICAL CUTS

J - ﬁ xed clamp for vertical cuts J1 - mobile clamp for vertical cuts K - ﬁ xed clamp knob K1 - mobile clamp knob N - mobile clamp lever

Fig.10

Operating Manual OMNIA / OMNIA 650rpm / OMNIA MAX / OMNIA W MAX

2 MAIN CHARACTERISTICS

• ON/OFF SWITCH

The key-cutting machine is connected to a power supply socket with a differential switch; when the machine is turned on with the switch (A) located on the right-hand side, the lamps (T) illuminate to indicate that the machine is live.

A TTENTION: switch (A) is electromagnetic and if there is a power failure it goes off automatically. When power returns it must be reset manually to supply the machine with electricity.

• MOTOR START BUTTON

The push button (B) for starting the motor is located on the front of the machine. To start the motor (with the machine on) move the carriage slightly towards the cutter and press the motor start button (B). The machine is protected from untimely machine start. When the carriage is all the way back towards the operator a safety microswitch turns off the motor. If the carriage is inadvertently moved towards the cutter the motor does not start.

• BRUSH PUSH BUTTON

The push button (U1) for activating the brush is located on the front of the machine.

• BRUSH

The brush (U) is in accident-proof material and its purpose is to eliminate the burrs from the key after cutting. Press push button (U1) to activate the brush.

• Y AXIS LOCKING KNOB

The Y axis locking knob (G) is located on the front of the machine (see chap.7.4).

• MACHINE CARRIAGE MOVEMENT LEVER

The lever (L) has an ergonomic grip and moves on ball joints that allow smooth movement of the carriage, which has ball bearing guides.

• ILLUMINATION

The work area is perfectly illuminated by two ﬁ xed lamps (LED) (T) turned on by the master switch.

• MICROMETRIC TRACER POINT (SPRUNG)

The tracer point (D) used for reading the cuts on keys to be copied is located on the left-hand side of the machine. Depth is easily adjusted by means of the micrometric ring nut (D2) (chap.7.1). The spring function is activated/deactivated by turning the special cam (D1) (chap.7.2).

• CUTTER

The cutter (C) used for cutting key blanks is protected by a safety shield (S). On Omnia and Omnia MAX: cutter in TiN coated Super Rapid steel. On Omnia W MAX: hard metal cutter (carbide).

• SWARF TRAY

The tray (V) located on the left is easily removable so that all the swarf can be cleared away.

• MOTOR AND TRANSMISSION UNIT

The motor has belt transmission. The transmission shaft that moves the cutter (C) and brush (U) is located on the right of the motor.

• CLAMP HANDLES AND KNOBS

Anatomical handles and knobs ensure perfect easy hold on the keys in the clamps even with just light pressure when closing them.

Clamps for vertical cuts Omnia W MAX: the knobs are gauged so that they do not exert too much pressure for

closing (if pressure is toohigh they only idle), which would damage the key and the parts of the clamp (including the knob).

Operating Manual OMNIA / OMNIA 650rpm / OMNIA MAX / OMNIA W MAX

• CLAMP CARRIAGES

OMNIA / OMNIA 650rpm

Clamps for bit/double bit and pump keys

The clamps (M) (M1) comprise two self-centring jaws which ensure perfect hold on the shafts of bit/double bit and pump keys (Fig.3).

Fig.11

The carriage is found in the machine packing as a separate item (see chap.5.2 and chap.5.5).

Operating Manual OMNIA / OMNIA 650rpm / OMNIA MAX / OMNIA W MAX

OMNIA MAX / OMNIA W MAX

Clamps for bit/double bit and pump keys

The clamps (M) (M1) comprise two self-centring jaws which ensure perfect hold on the shafts of bit/double bit and pump keys (Fig.4).

Fig.12

The carriage is found in the machine packing as a separate item (see chap.5.2 and chap.5.5).

NOTE: the Omnia MAX/Omnia W MAX carriage for double bit keys can be used alone or connected to the Omnia MAX/Omnia W MAX carriages for vertical cuts (see chap.5.5.7 OMNIA MAX / OMNIA W MAX: solution with a SINGLE CARRIAGE).

Clamps for vertical cuts (only Omnia MAX and Omnia W MAX)

The clamps (J) (J1) are designed to ensure perfect hold on the shafts of bit keys with vertical cuts.

Fig.13 - Clamps for vertical cuts Omnia MAX Fig.14 - Clamps for vertical cuts Omnia W MAX

Clamps

for vertical cuts Omnia W MAX: the knobs are gauged so that they do not exert too much pressure for

closing (if pressure is toohigh they only idle), which would damage the key and the parts of the clamp (including the knob).

The carriage is found in the machine packing as a separate item (see chap.5.2 and chap.5.5).

NOTE: the Omnia MAX and Omnia W MAX carriages for vertical cuts can be used alone or connected to the carriage for bit keys (see chap.5.5.7 OMNIA MAX / OMNIA W MAX: solution with a SINGLE CARRIAGE).

Operating Manual OMNIA / OMNIA 650rpm / OMNIA MAX / OMNIA W MAX

3 ACCESSORIES PROVIDED

OMNIA comes with a set of accessories for its operation and maintenance (tools, hex wrenches, fuses) supplied in a special tool kit comprising:

allen key 2 mm spanner 13 mm

allen key 2,5 mm spanner 19 mm

allen key 3 mm cutter release rod

allen key 4 mm

allen key 5 mm setting pins

allen key 6 mm stop pins for FIAM keys

adhesive label “DANGEROUS MOBILE PARTS” (chap.5.5.2)

carriage stopper (chap.5.4)

fuses 1,6 Amp delayed (230V)

connection plate+screws for the carriages (chap.5.5.7) (only Omnia MAX/Omnia W MAX)

Operating Manual OMNIA / OMNIA 650rpm / OMNIA MAX / OMNIA W MAX

4 TECHNICAL DATA

Electricity supply: 230V - 50Hz Max. absorbed power: 230V: 1 Amp. 235 Watt Cutter motor: single phase and speed Movements: by ball guides (carriage) and ball socket joint (lever) Cutter: Omnia/Omnia MAX: 80x1,5x22 in TiN coated Super Rapid Steel

Omnia W MAX: 80x1,5x22 in hard metal (carbide) Omnia 650rpm: 80x1,5x22 in Super Rapid Steel HSS

Tool speed: Omnia/Omnia MAX: 386 rpm Omnia W MAX: 650 rpm

Runs carriages: 53 mm X axis - 42 mm Y axis (50 mm Z axis for vertical cuts carriage only) Dimensions: width: 395 mm - depth: 550 mm - height: 320 mm Mass: Kg.32 Omnia/Omnia 650rpm - Kg.33,5 Omnia MAX/Omnia W MAX with 2 carriages Noise level: sound pressure Lp(A) = brass 83,7 dB(A) - iron 91,7 dB(A)

sound power Lw(A) = iron keys 92,1 dB(A)

4.1 Electrical diagram

The main parts of the electrical circuit on the OMNIA key-cutting machine are listed below:

1) Power socket with fuses

2) ON/OFF switch

3) Lamp power

4) LED lamps

5) Carriage microswitch

6) Brush push button

7) Electromagnetic switch (reset)

8) 12.5 mF condenser

9) 230V-50Hz motor

10) Relay

Fig.15

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Silca Omnia, Omnia W Max, Omnia 650rpm, Omnia Max Operating Manual

Specifications and Main Features

Frequently Asked Questions

User Manual