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n this article we will study the Condor XC-MINI key machine, its accessories, cut a few keys and take by it for a test run. Robert Sieveking The Condor is a remarkable little machine. It weighs in at a hefty 39.68 lbs. There are a few new innovations and twists to the set-up and operation of the machine that I feel you will appreciate. Operation was surprisingly intuitive. This machine will require a relatively short learning curve to become proficient in its operation. Setup, installing and calibrating the cutter and probe took only a few minutes. The new machine requires that the vises be installed and “learned,” which I found interesting. Self-Test, Calibration and vise learning procedures are prompted by the onboard processor. Careful study of the operators’ manual is a must. The machine is relatively quiet, fast and accurate. The finish and component quality is excellent. The Condor XC-MINI Automatic Key Cutting Machine appears to be a solid, well thought out solution for duplicating or creating side-milled and edge-cut automotive keys. Decoding from the original key, on the Condor, and then cutting a new key will produce original specification duplicate Reprinted from THE NATIONAL LOCKSMITH February 2017
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keys. Keys made “To Code,” or from a known bitting are produced using the onboard “Key Data.” Condor also has a “missing bitting” function, which will aid you in completing the unknown bittings for a key when you have an incomplete bitting. Key numbers, in the Key Data, appear to follow the Silca™ numbering convention. The Condor XC-MINI ships with a three year Conditional Warranty, and a one year subscription to the InstaCode code program, that’s a huge bonus. Key Data updates are supplied through online support. Download the software driver to a PC and then connect the Condor using the supplied USB 2.0 cable. Updates can be easily installed from the Internet. Additional Technical Assistance is available by SKYPE. Figure 1, shows a front quarter view of the Condor XC-MINI Automatic Key Cutting Machine. The Condor is a computer controlled 3-Axis key milling machine. It uses a Ball-Screw Transmission to transmit motion to the Key Clamps and Cutter/
Probe carriage. It is designed to cut edge-milled and side-milled internal and external track keys, Dimple Keys and Tibbe keys. The machine is operated by an internal processor controlled by a seven inch Capacitive Touch “Touch Screen Display” mounted at the top of the machine. An Emergency Stop Button controls power to the processor and milling machine. Right rotation of the button turns the machine on. Pressing the button instantly powers down the machine. The tinted plastic Safety Shield protects the operator from flying key chips. Safety shields are fine, but Safety Glasses in the shop are the Rule. Always wear safety glasses when operating any key cutting machinery. The Condor X-C MINI incorporates the welcome addition of Lifting Handles, at the left and right sides of the machine. Always lift by the handles to avoid damage to the case or Lift-Up Safety Shield. With the Safety Shield lifted, the 7” Touch Screen Display Control is fully accessible, as you see in Figure 2. This opens the cutting deck. Multiple LED lights behind the cutter fully illuminate the cutting deck. The Key Clamp is mounted to the moving Clamp Platform, and locked in place by the Clamp Lock. A pull-out chip drawer below the Clamp Platform provides an easy way of removing chips from the machine. A chip brush is provided to remove chips and To subscribe go to www.TheNationalLocksmith.com
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2mm socket head Probe Lock Screw. The Cutter is fixed in the motor spindle by the 2mm socket head Cutter Lock Screw. The machine is supplied with a 2mm Allen Wrench, two 1.0mm Probes (Detection Tools), one 1.5mm Cutter (01.5x06x40L) and one 2.5mm Cutter (02.5x06x40L).
dust from the Key Clamp and keep the area clean. It is essential that the machine be free of chips and dust to insure accuracy and proper operation. NEVER use compressed air to clean this machine. Brass dust or chips can be blown into the area of the Computer Processor and Ball Screw Transmissions, which will damage the machine. Use the Chip Brush. In Figure 3, we see the cutter assembly. The Cutter Motor is mounted to the “Z-Axis” transport. It moves up and down to control the depth of the cutter into the key. This is a multi-pole “stepping motor” drive, which spins up the three fluted Carbide milling cutter at 9,000rpm. To preserve the cutter
3 and insure the best finish of the milled surface, the cutter produces the profile cuts in the key using two passes. The cutter makes a first pass to“rough the cut profile, and then makes a second pass to complete the cut. The Probe and Cutter heights are fixed on the Z-Axis carriage and move together. The Probe is fixed in the Probe spindle by the Reprinted from THE NATIONAL LOCKSMITH February 2017
Figure 4, details the moving Clamp Platform. The Clamp Platform moves left and right and fore and aft (in and out). The XAxis is left and right. The Y-Axis is fore and aft. The cutter motor moves in the vertical or Z-Axis to advance the cutter down (into the key) and up (away from the key). The Clamp Platform has a Dovetail Socket which accommodates
the clamp-locking lever to the right, to lock the clamp base to the clamp platform. In Figure 5, we have installed Key Clamp M1 onto the Clamp Platform. A colored plastic button identifies the Key Clamps. Index Lines on the Clamp Lock and Key Clamp base are aligned, showing that the clamp is correctly positioned. The Clamp Locking Lever is moved to the right to lock the Key Clamp in position. When the Clamp Locking Lever is unlocked it is loose, and will rest on the Lever Rest at the left of the Clamp Platform. Gauge Lines on the deck of the Key Clamp indicate the various positions of the tip of the key to
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4 the various adaptor Key Clamps (Key Vises). The Locating Stop Pin limits and positions the Key Clamps as they are installed onto the Clamp Platform. The Clamp Lock has a profile foot which engages the dovetail Base of the various Key Clamps. The Clamp Locking Lever is moved to the left to unlock the Clamp Base and to the right to lock the Clamp Base to the Clamp Platform. An Index line on the Clamp Lock insures that select Key Clamps are properly positioned (fully engaged) before locking them in position. That’s a lot of description for a very simple operation. Simply slide the dovetail of the Key Clamp into the dovetail socket of the clamp platform. It will stop as it contacts the locating stop pin. Observe that the index on the clamp lock aligns with the index on the key clamp base and move
be cut or decoded. This machine does not use solid tip stops. The Probe will be moved around the key blade to detect the top surface, tip, left side (at the tip) and right side (at the tip). By learning the position of the key blade every time it is asked to cut a key, it insures that the bitting will be applied to the blank in the correct position. You might think of this as self-gauging. The machine checks the location of the key blade surfaces in all three Axes before it begins any cutting or decoding sequence. In Figure 6, we see the M1 Key Clamp. This clamp is used for all “Outside Milled” keys. The four-track Honda HO01 key (see Figure 20), would be an example. Ford side-milled keys would be an example of a two-track “Outside-Milled” key. To subscribe go to www.TheNationalLocksmith.com
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The Hold Down Bridge is used to hold the key down on the Key Supports. A 2mm socket head Hold Down Screw in the Hold Down Bridge, applies pressure to hold the key blade. The Clamp Knob is rotated clockwise (right) to bring the Clamp Jaws together, further holding the key blade stationary. The Clamping Jaws also square the key blade in the fixture. Laser engraved Gauge Lines on the fixture will be called out in the programming, to indicate the position of the key tip. The Calibration Post is used to allow the machine to locate the fixture (Key Clamp). The Condor will use the Probe to touch (Locate) the top (Z-Axis location), sides (X-Axis location) and front face (Y-Axis location) of the Calibration Post. The locating sequence is repeated to find the location (define) the key blade. This is repeated every time the Condor begins a cutting or decoding operation. You might think of this as the check sequence. It is absolutely necessary to insure accuracy of the cut or decoded keys. In machinist language, this is called “edge finding.” For an NC (Numerically Controlled) mill, it only takes a few seconds. Figure 7, details the M1 Key Clamp fixture. The Front View shows a clear view of the Dovetail Base, common to all of the Key Clamp fixtures used on the Condor XC-MINI. The Top View shows the locations of the Calibration Post, Gauge Lines and Key Support. The 2mm socket head Hold Down Screw is shown in the Hold Down Bridge. In the Side View we see the two Clamp Jaws. As the Locking Knob is rotated right, these jaws Reprinted from THE NATIONAL LOCKSMITH February 2017
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8 move together to clamp the key blade. Both jaws move to center the key blade in the fixture. The rear Key Support and locating Index are seen at the center of the fixture. In Figure 8, the M2 Key Clamp has been installed on the Clamp Platform. The M2 Key Clamp is used for all “Channel-Milled” track keys. Toyota Lexus fourtrack inside-milled keys would be an example. Audi, BMW (late), GM and VW side-milled keys are examples of Channel-Milled track keys. There is no Index on this Key Clamp. Slide the fixture into the dovetail socket against the stop pin to locate it. Move the Clamp Locking Lever to the right to lock the fixture in place. The Clamping Knob is rotated clockwise (right) to close the jaws and clamp the key blade. The key is seated in the Key Well for clamping. The Calibration Post is used by the Condor to define and locate the fixture. The Condor uses a 4-Way Vise to accommodate a variety of key blades. This photo shows Vise Jaw “A” in position. Vise Jaw designators are laser engraved on each of the four jaws. To index the vise jaw, rotate it as you see in Figure 9. The Clamp Base will disengage and re-engage when the next vise jaw is in position. There are four unique vise jaw configurations lettered: A, B, C and D. The correct vise jaw for the key being made will be called out in the display by the Key Data program. The Condor will detect the position of the Calibration Post, on
9 the Key Vise. This insures that the correct Key Vise is being used for the key being cut. This is another self-check by the machine. Figure 10, details the M2 Clamp for Channel or Track keys. The Front View clearly shows the Dovetail Base. The Top View shows the position of the Calibration Post. (Note that it is even with the rear edge of the fixture.) Lines on the Clamp Jaws indicate the desired position of the key tip, as indicated in the set-up procedures of the Key Data step-by-step tutorial. In the Side View we see the “B” Jaw (out of position). Note the position of the Calibration Post. It is about an eighth of an inch back from the edge of the jaw. In Figure 11, we see the Identification Label. This is a Model: Master Series XC-Mini. Manufactured for: Xhorse Electronics Co., Limited, by: Ningbo Yongyuan CNC Machine Company, Limited. The Patent Number and country of origin is also listed on this label. Figure 12, shows a rear view of the Condor machine. There is an SD Slot for a memory card and a USB Connection. The USB 2.0 connection is used to connect the Condor to a PC Computer for upTo subscribe go to www.TheNationalLocksmith.com
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11 dates and diagnostic services. The Power Label Defines the required input power and power supply output voltages. The Fused Power Socket accommodates a removable power cord. In Figure 13, we see the Power Supply information. This unit uses a Model: CP-2 power supply. Input power of 90 to 264VAC, and from 47 to 63HZ is required. North American Power is nominally 120VAC at 60HZ, which is well within the required input voltage and frequency parameters. The Power Supply produces 24VDC for the CNC processor and electro-mechanical key cutter. It appears that the Condor operates on a total of less than 200W of power. In Figure 14, we see the Power Socket and removable Fuse Carrier. The Power Socket accommodates a removable power cord. The Fuse Carrier fits into the Fuse Socket at the left of the cord socket. Pull the Fuse Carrier to replace the line fuse. The installed fuse was a F15AL250V mini fuse. Figure 15, shows the seveninch Capacitive Touch Screen and Operation Buttons. There are eight Operation Buttons, four on each side of the screen. These are used to select the operations to be performed by the processor. This is the Welcome or home screen. Available functions are: Self Test, Cutting Setting, System Setting, History, Key Database, Key Duplication, Cut by Bitting and Find Bitting. This screen also shows the Date and time, Serial Number of the Reprinted from THE NATIONAL LOCKSMITH February 2017
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machine and the Software Version. The serial number is shown: KM03239062. The Software Version is: 3.0.1. The date and time is shown: 2016-12-21 07:02:01 In Figure 16, the screen shows the self-test parameters. These are “offsets” for the X, Y and Z Axes, which were discovered in the self-test procedure. They refer to Clamp Jaws M1, M2A, M2B and etc. From here, we can advance to setting the Height Level of the cutter and probe if we change a cutter. Clamp Calibration is also accessed from this menu. Simply touch one of the Operation Buttons at the edge of the screen to advance to the next screen. The button at the top left side of this screen will return us to the main menu. In Figure 17, we see the cutter height adjustment screen. This adjustment must be made any time a cutter or probe is changed. Verbiage below the illustrations fully explains the step-by-step procedure of what you are to do to complete this procedure. Press the Continue button, to advance to the next screen. Each screen has step-by-step instructions for actions and checks that should be made.
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In Figure 18, we see the Key Clamp Calibration initial screen. Touch the button beside the desired Key Clamp to advance to the calibration screen. When all checks have been successfully completed, the last screen will indicate “Success.” In the screen, shown in Figure 19, we are being instructed to insert a Honda Hon66 blank into Key Clamp M1 (Single/Double Sided Clamp). We are shown the position of the tip of the key. The key tip aligns with the first Gauge Line as you see in the Detail inset. In the instruction, we are reminded, “Before using this function, please confirm that “Height Level Adjustment of Cutter” is completed. Press the “Continue” Button, to advance to the next screen and initiate the test. In Figure 20, we see two cutkeys. The Test Key is the result of the cutter calibration test. The machine has cut a small bit from the Left side, Right side and Tip of the HO01 service key. The Condor located the tip of the key, and then cut a test cut on each surface. The machine continued to use the probe to gauge each of the completed cuts. By this, it To subscribe go to www.TheNationalLocksmith.com
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20 was able to define the necessary offsets in memory, to produce a perfect key to code or by the bitting. An enlarged detail of the key tip is shown to see the small test cuts made in the cutter calibration procedure. A key was made to the code: K325 (Master). This key is shown in the photo. The bitting is: 1 4 3 3 5 1 – 2 5 1 1 3 1. The key was de-burred and reversed in the vise to cut the opposite side. Measurements made, showed this to be an accurate rendition of this code. Surface finish of the key-cuts was very good. The “Web” dimension was within tolerance.
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All in all, the machine performed quite well and would make a great addition to any locksmith business. I believe in the long run this will be a very accurate and dependable machine. It did everything we asked it to do without a problem and performed flawlessly. The intuitive interface insures success, while the self-check functions and on-screen prompts help to avoid mistakes.
American Key Supply is one of the major product distributors of the Condor XC-Mini for North America. For more information contact them at: Phone: Within the US: 1.800.692.1898 Phone: Outside the US: 1.650.360.0804 Web: www.americankeysupply.com
With a MSRP of $3000, the Condor XC-Mini is packing a Mike Tyson punch to the competition and should definitely be on your list of key machines to check out. I don’t think you will be disappointed.
To subscribe go to www.TheNationalLocksmith.com
VVDI MB Machine
BGA Mercedes Key Programmer The latest and best key programmer for Mercedes Benz. Program new keys without the need for desoldering/ resoldering. Features frequent online updates, supports Mercedes Benz keys, reading password and preparing a new key via IR. Mainly used for key reading and writing, EIS tools, password calculation, key file preparing, ESL tools, ECU/Gearbox renewal, and much more.
$1890.00 VVDI2 Commander
BUNDLE
Condor XC Mini Cutter + VVDI MB Programmer
LOADED (BMW/ VW/Porsche) The VVDI2 Commander is the latest key programmer for modern European vehicles. It will allow you to program new keys to your customer's VW, Audi, Porsche, BMW, and others, usually without the need for any desoldering/resoldering.
Save when buying together!
$2189.00
$4800.00
Condor XC Mini Tibbe Jaw
Remote Control Tester
Used for tibbe keys like Jaguar & Ford. 6-cut tibbe keys only.
Infrared (iR) and radio frequency (RF) 300-320 MHz, 434 MHz, & 868 MHZ 9V Battery Operated
$189.00
$35.00
1-800-692-1898
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americankeysupply.com
CONDOR XC MINI
High Security Key Cutting Machine • Cuts all types of automotive keys (edge-cut, high security, and tibbe*) • Compact, quiet, and fast • Starts up in 1 second! • Extremely easy to use • InstaCode built in and fully integrated • Includes FREE one year of InstaCode LIVE (a $240 value!) • Includes free support and a 3 year warranty
$2995.00 1-800-692-1898
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americankeysupply.com
*purchase of M3 Jaw is needed for cutting tibbe keys (6-cut only, 8-cut not supported)
N I W O N ! K C O T S