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One of my customers has now asked for the size of the single key
to be increased is it possible on a live site to increase the key size
and keep all the Keyboard setting as they were.

No.
If you want to increase the single key size from 3 x 8 to 4 x 8, the
Free key Settings will be deleted, all the other program data will
remain.

Is it possible to have a Master Back-Up  Configuration on a 2 Till
System.

Yes, The bit that is sometimes missed out is that the Master
machine must have a Recovery declaration carried out before
operation begins.

See Guide..

See Guide..

When trying to download Program data from the Master to Slaves
the error message “NON-RESET” appears.

This is because there is sales data in the Slave machine usually
you will have to Reset the General,PLU and Hourly Report.

I have performed the Memory clear in Service Mode but the EJ has
not been cleared down.

That’s normal.
The EJ will not be cleared by the Memory Clear, You will have to
clear it by Data Clear in PGM Mode.