SERVICE MANUAL

Model
IP-011

FEBRUARY 2000
CSM-IP011

KONICA BUSINESS TECHNOLOGIES, INC.

 IP-011
SERVICE MANUAL
FEBRUARY 2000

Used on Konica Model

7020
 IMPORTANT NOTICE
Because of the possible hazards to an inexperienced
person servicing this equipment, as well as the risk of
damage to the equipment, Konica Business Technolo-
gies strongly recommends that all servicing be per-
formed by Konica-trained service technicians only.

Changes may have been made to this equipment to

improve its performance after this service manual was
printed. Accordingly, Konica Business Technologies,
Inc., makes no representations or warranties, either
expressed or implied, that the information contained in
this service manual is complete or accurate. It is under-
stood that the user of this manual must assume all risks
or personal injury and/or damage to the equipment while
servicing the equipment for which this service manual
is intended.

Corporate Publications Department

© 2000, KONICA BUSINESS TECHNOLOGIES, INC.

All rights reserved.
Printed in U.S.A.
 Contents

CONTENTS
Safety Precautions............................................................................................ v

1. Overview
■ Product specifications ................................................................................ 1-1
● IP-011 printer controller .................................................................................................. 1-1
■ Product overview ........................................................................................ 1-3
● Capabilities of the IP-011 ................................................................................................ 1-3
● Startup sequence of the 7020 series + IP-011 system ................................................... 1-4
● Data processing of the IP-011 (See data flow.) .............................................................. 1-4
● Data flow ......................................................................................................................... 1-5
■ Option ......................................................................................................... 1-6
● KN-304 network board .................................................................................................... 1-6

2. Disassembly/assmbly
■ Construction ............................................................................................... 2-1
■ Disassembly/assembly procedures ............................................................ 2-2
● Removal/installation of boards ........................................................................................ 2-2
● Expanding the memory ................................................................................................... 2-5

3. Troubleshooting
■ Troubleshooting .......................................................................................... 3-1
● Troubleshooting of the IP-011 and copier ....................................................................... 3-1

4. Appendices
■ Rewriting the firmware ................................................................................ 4-1
● Preparation ..................................................................................................................... 4-1
● Procedure of rewriting the firmware ................................................................................ 4-1
● In case of failure in rewriting the firmware ...................................................................... 4-2
■ Functions of parts mounted on boards ....................................................... 4-3
● LED indications and board status ................................................................................... 4-4
● Push switch ..................................................................................................................... 4-4
● Jumpers .......................................................................................................................... 4-4

iii IP-011 PRINTER CONTROLLER

Blank page
SAFETY PRECAUTIONS
Installation Environment effect may be caused by altering any aspect of the
machine’s design. Such changes have the potential
Safety considerations usually are directed toward of degrading product performance and reducing
machine design and the possibility of human error. In safety margins.
addition, the environment in which a machine is oper-
ated must not be overlooked as a potential safety For these reasons, installation of any modification not
hazard. specifically authorized by Konica Business Machines
U.S.A., Inc., is strictly prohibited.
Most electrical equipment is safe when installed in a
normal environment. However, if the environment is The following list of prohibited actions is not all-inclu-
different from what most people consider to be nor- sive, but demonstrates the intent of this policy.
mal, it is conceivable that the combination of the • Using an extension cord or any unauthorized
machine and the room air could present a hazardous power cord adapter.
combination. This is because heat (such as from
fusing units) and electrical arcs (which can occur • Installing any fuse whose rating and physical size
inside switches) have the ability to ignite flammable differs from that originally installed.
substances, including air. • Using wire, paper clips, solder, etc., to replace or
When installing a machine, check to see if there eliminate any fuse (including temperature fuses).
is anything nearby which suggests that a poten- • Removing (except for replacement) any air filter.
tial hazard might exist. For example, a laboratory
might use organic compounds which, when they • Defeating the operation of relays by any means
evaporate, make the room air volatile. Potentially dan- (such as wedging paper between contacts).
gerous conditions might be seen or smelled. The • Causing the machine to operate in a fashion other
presence of substances such as cleaners, paint thin- than as it was designed.
ners, gasoline, alcohol, solvents, explosives, or simi-
lar items should be cause for concern. • Making any change which might have a chance
of defeating built-in safety features.
If conditions such as these exist, take appropriate
action, such as one of the following suggestions. • Using any unspecified replacement parts.

• Determine that the environment is controlled

(such as through the use of an exhaust hood) so General Safety Guidelines
that an offending substance or its fumes cannot This copier has been examined in accordance with
reach the machine. the laws pertaining to various product safety regula-
• Remove the offending substance. tions prior to leaving the manufacturing facility to
protect the operators and service personnel from
• Install the machine in a different location. injury. However, as with any operating device, compo-
The specific remedy will vary from site to site, but the nents will break down through the wear-and-tear of
principles remain the same. To avoid the risk of injury everyday use, as will additional safety discrepancies
or damage, be alert for changes in the environment be discovered. For this reason, it is important that the
when performing subsequent service on any ma- technician periodically performs safety checks on the
chine, and take appropriate action. copier to maintain optimum reliability and safety.
The following checks, not all-inclusive, should be
Unauthorized Modifications made during each service call:

Konica copiers have gained a reputation for being CAUTION: Avoid injury. Ensure that the copier is
reliable products. This has been attained by a combi- disconnected from its power source before continu-
nation of outstanding design and a knowledgeable ing.
service force. • Look for sharp edges, burrs, and damage on all
The design of the copier is extremely important. It is external covers and copier frame.
the design process that determines tolerances and • Inspect all cover hinges for wear (loose or bro-
safety margins for mechanical, electrical, and elec- ken).
tronic aspects. It is not reasonable to expect individu-
als not involved in product engineering to know what • Inspect cables for wear, frays, or pinched areas.

v
• Ensure that the power cord insulation is not dam- Applying Isopropyl Alcohol
aged (no exposed electrical conductors).
Care should be exercised when using isopropyl alco-
• Ensure that the power cord is properly mounted hol, due to its flammability. When using alcohol to
to the frame by cord clamps. clean parts, observe the following precautions:
• Check the continuity from the round lug (GND) of • Remove power from the equipment.
the power cord to the frame of the copier -- ensure
continuity. An improperly grounded machine can • Use alcohol in small quantities to avoid spillage
cause an electrically-charged machine frame. or puddling. Any spillage should be cleaned up
with rags and disposed of properly.

Safeguards During Service Calls • Be sure that there is adequate ventilation.

Confirm that all screws, parts, and wiring which are • Allow a surface which has been in contact with
removed during maintenance are installed in their alcohol to dry for a few minutes to ensure that the
original positions. alcohol has evaporated completely before apply-
ing power or installing covers.
• When disconnecting connectors, do not pull the
wiring, particularly on AC line wiring and high
voltage parts. Summary
• Do not route the power cord where it is likely to It is the responsibility of every technician to use pro-
be stepped on or crushed. fessional skills when servicing Konica products. There
are no short cuts to high-quality service. Each copier
• Carefully remove all toner and dirt adhering to any must be thoroughly inspected with respect to safety
electrical units or electrodes. considerations as part of every routine service call.
• After part replacement or repair work, route the The operability of the copier, and more importantly,
wiring in such a way that it does not contact any the safety of those who operate or service the copier,
burrs or sharp edges. are directly dependent upon the conscientious effort
of each and every technician.
• Do not make any adjustments outside of the
specified range. Remember...when performing service calls, use good
judgement (have a watchful eye) to identify safety
hazards or potential safety hazards that may be pre-
sent, and correct these problem areas as they are
identified -- the safety of those who operate the copier
as well as those who service the copier depend on it!

vi
 1
Overview
 Chapter 1 Overview

■ Product specifications
● IP-011 printer controller
Type: Built in Konica 7020 series copy machine
Paper size: A3R, A4, A4R, A5R, B4R, B5, B5R, B6R, 11"X17", 8.5"x14"R,
8.5"x11", 8.5"x11"R, 5.5"x8.5"R
Paper feeding: Same as copier
Output stack capacity: Same as copier
Mode: Possible dual mode of copy machine/printer (up to 5 jobs)
Next job reservation: Next copy job can be reserved during print job.
Special printing features: Printing on both faces, choice of paper type, zoom
function, choice of paper tray, choice of output tray,
choice of print quality, Alternate function, sort/
group function, staple function, layout function,
front/back cover intersheet function, booklet func-
tion, smoothing function, page protection function,
watermark function
Direction of printing: portrait, landscape
Resolution: 600 dpi
Gradation: 2
Number of output pages: 1-999
Warm-up: Same as copier
CPU: Power PC 401GF
Memory: 16MB (standard), expandable up to 80MB (option:MU-403/MU-404)
Cards: Controller board x1
PCI intermediate board x1
KN-304 network board (option)

1-1 IP-011 PRINTER CONTROLLER

Chapter 1 Overview

Interface: Parallel port

Centronics (IEEE 1284)/Amphenol male 36pin connector
Network interface: (option)
KN-304 network board
Network: Ethernet (100BaseT/10BaseT)
Protocols: IPX/SPX (NetWare), LPD/LPR (TCP/IP),
peer-to-peer (TCP/IP)
Compliant OS:
Windows 95/98
Windows NT 4.0
Windows 2000 (to be supported)
Printer Language:
Destiny: WinStyler Nozomi Ver 2.0
Printer drivers:
Windows 95/98 printer driver
Windows NT printer driver
Host computer: A Windows based computer
Finisher: FS-107
Size: 240 mm(W) x 160 mm(H) x 37 mm(D)
Weight: Approx. 1.1 kg
Power source: 5 V, 2 A or less (supplied from copier)
Operating conditions:temperature: 5-55˚C,
humidity: 5-95%RH (condensation not allowed)
Restrictive Conditions:
• In the Printer mode, the ECK (Electric Key Counter) of the Konica
7020 series is not available.
• Although the Weekly Timer function of the Konica 7020 series is
available in the Printer mode, the power is not turned Off until
the data output is finished when print data remains in the E-RDH
Notice: Specifications are subject to change for improvements without no-
tice.

1-2 IP-011 PRINTER CONTROLLER

 Chapter 1 Overview

■ Product overview
● Capabilities of the IP-011
The Konica IP-011 printer controller allows you to use the Konica 7020 series copying machine as
a printer connected to computers and a network. It receives print jobs from computers and network
and converts them into image data (video data) that the Konica 7020 series copying machine prints
out.

The IP-011 printer controller is characterized as follows.

• Built in the Konica 7020 series copying machine.

• Host-base printer of Windows only.

• Printer status can be monitored and several settings can be changed from the
status monitor/Control Panel through parallel line.

• The drivers interfacing with Windows 95/98 and NT allow use of the functions
of the Konica 7020 series copying machine.

• The KN-304 network board allows use of the IP-011 as a network printer.

• Use of flash memory enables to upgrade the system software through the par-
allel port.

This Service Handbook describes hardware construction, disassembly and assembly procedures,
troubleshooting, and appendixes (upgrading firmware, error messages, etc).

KN-304
(OPTION)

IP-011

1-3 IP-011 PRINTER CONTROLLER

Chapter 1 Overview

● Startup sequence of the 7020 series + IP-011 system

As the IP-011 is built in the 7020 series, supplying power to the IP-011 and its initialization starts as
soon as you turn on the copier. The startup sequence is as follows.

1. You turn on the copier.

Supplying power to start the IP-011 starts. Its CPU works to test the system memory
and the system program starts running.

2. The IP-011 performs system check.

3. On completion of system check, the controller’s icon appears on the copier LCD screen.

If printer mode is selected, a message “Ready to print” appears.

● Data processing of the IP-011 (See data flow.)
When you attempt to print a document data from a computer connected the IP-011, processing will
be made as follows.

1. The print job comes from the computer (or network) to the parallel port (or Ethernet port if
the KN-304 is used).

2. The CPU, mounted on IP-011, generates the bit map image of one page to another in the
image memory.

3. The bit map image is transferred in the form of video signals from the image memory to the
copier and printed.

1-4 IP-011 PRINTER CONTROLLER

 Chapter 1 Overview

● Data flow

Computer
Application Printer Tools

Status Monitor Browser

Control Panel HTML

Printer Driver

Spooler

Interface

IEEE1284 Network
IEEE1284
Network (TCP/IP,IPX/SPX) (TCP/IP,IPX/SPX)

NIC

Printer Controller

IEEE1284

Intermediate Language Interpreter

Memory

IP-011

Command for Printing

Image Data Engine Status

Printer Engine
PCI Bus

E-RDH Memory

Engine

1-5 IP-011 PRINTER CONTROLLER

Chapter 1 Overview

■ Option
● KN-304 network board
If the IP-011 is fitted with the KN-304 network board, the 7020 series can be used as a remote
printer from any computer belonging to a network (NetWare/Windows).

1-6 IP-011 PRINTER CONTROLLER

 2
Assembly / Disassembly
 Chapter 2 Disassembly / assembly

■ Construction

Connector for Connector (CN501) for

Controller board SW1 KN-304 Jumper

PCI Intermediate board

Controller board SO-DIMM slot Parallel port connector

(CN502)

Caution:

If grounding is not made securely, the cards can be damaged during work. Make
sure to ground your body securely by using a wrist strap before starting to work.

Tool

• Use a phillips head screwdriver.

Reference information:

As the IP-011 is provided with a “flash memory”, no tool is needed to replace ROM
for upgrading the firmware.

2-1 IP-011 PRINTER CONTROLLER

Chapter 2 Disassembly / assembly

■ Disassembly/assembly procedures
● Removal/installation of boards

1. Remove the sliding cover. (2 screws)

Sliding cover

2. Remove the main cover. (11 screws)

main cover

3. Remove the side cover of the parallel connector side. (5 screws)

Side cover

2-2 IP-011 PRINTER CONTROLLER

 Chapter 2 Disassembly / assembly

4. Remove the top panel fixtures. (4 screws)

Top panel fixtures

5. Remove the board unit and the side cover of the copying machine side all together.
(7 screws)

• When installing, push

the plate spring to the
inside.

6. Pull off the controller board at the connector (CN2) on the PCI Intermediate board fitted to
the side cover.

CN2

2-3 IP-011 PRINTER CONTROLLER

Chapter 2 Disassembly / assembly

7. Remove the PCI Intermediate board. (4 screws)

8. To install, reverse the removal procedure.

2-4 IP-011 PRINTER CONTROLLER

 Chapter 2 Disassembly / assembly

● Expanding the memory (MU-403/MU-404)

The IP-011 is provided with 16MB memory (standard specification). You can expand the memory
capacity up to 80MB by installing a SO-DIMM card additionally into a slot on the controller board.

Caution:

• With the memory expanded, the IP-011 can rasterise more pages during waiting
previous print job than before expansion.

• If memory overflow occurs, expand the memory.

• When adding a DIMM card, they must be all of the same type, with or without
parity.

• The memory card slot is prepared for expansion of 32MB or 64MB.

Installing DIMM

1. Insert the connector of DIMM obliquely.

2-5 IP-011 PRINTER CONTROLLER

Chapter 2 Disassembly / assembly

2. Push the end of the DIMM and lock it with levers provided on both sides of the socket.

Caution:

The DIMM card can fit into the socket only in such a direction that the notch pro-
vided on the bottom of DIMM matches with the one on the socket.

Removing DIMM

1. Release the lock levers provided on both sides of the socket. Take out the DIMM in the
upper oblique direction.

2-6 IP-011 PRINTER CONTROLLER

 3
Troubleshooting
 Chapter 3 Troubleshooting

■ Troubleshooting
This section offers a summary of information on troubleshooting that technicians could refer to
easily and would minimize the time of interruption of work.

● Troubleshooting of the IP-011 and copier

Symptoms Causes Actions

The printer icon does not ap- No power supply to IP-011. Check if the IP-011 is connected
pear on the copier’s display in with the copier properly.
about 2 minutes after power-on.

“Warming up” does not disap- Copier is in trouble. Locate the cause of trouble of
pear. the copier.

“Initialization ” does not disap- The IP-011J has not started prop- See the column of “IP-011 does
pear on the copier screen. erly. not start”.

Printout is defective, or nothing The controller board or some Put the 7020 in 36 mode and
can be printed. boards of the copier are defec- perform test. If it operates prop-
tive. erly, controller board may be
failure.

IP-011 does not start. The controller board is inactive. Check the connector of the con-
troller board. Replace the con-
troller board as necessary.

Software of the IP-011 is de- Reinstall the IP-011’s firmware.

stroyed.

Test print can be produced but The parallel port has something Check the cables (internal/ex-
not from the parallel port. wrong or the cable is wrong ternal). Perform test using a
or, the problem is on the com- data generator or a well-proven
puter side. PC/I/O cable. Replace the con-
troller board as necessary.

3-1 IP-011 PRINTER CONTROLLER

Chapter 3 Troubleshooting

Symptom Possible causes Actions

Test print can be produced but The network board is inactive or Examine the network card. Check
not from the network port. not installed properly. all connectors. Replace the net-
work board as necessary.

Test print can be produced and Some software error has hap- IP-011’s software or application
all ports are good, but user jobs pened. program has something wrong.
cannot be printed. Save the file, which failed to be
printed, in the disk and analyze
the problem by suitable means.

3-2 IP-011 PRINTER CONTROLLER

 4
Appendices
 Chapter 4 Appendices

■ Rewriting the firmware

The IP-011 is equipped with flash ROM and the firmware can be upgraded via the parallel port.

● Preparation

• Connect the IP-011 through a parallel cable to the computer that is used to upgrade the
firmware.

• Prepare the replacing firmware in the hard disk of the computer or in the form of CD-ROM.

• Turn on the copier’s main and auxiliary powers.

● Procedure of rewriting the firmware

1. On the monitor screen of the computer, click the Start button. Click and select [MS-DOS
Prompt] from [Program].

The [MS-DOS prompt] appears.

2. Responding to the [MS-DOS prompt], designate the folder where the firmware is held.
Execute a COPY command and press the Enter key.

<Example> C:\copy filename.xxx lpt1 /b

3. On completion of file transfer from the computer, a message indicating the completion of
transfer appears on the copier LCD control panel. Press the OK button.

Now rewriting the firmware starts.

4-1 IP-011 PRINTER CONTROLLER

Chapter 4 Appendices

A message indicates that the firmware is being rewritten.

4. On completion of firmware renewal, a message indicating the completion appears. Then

turn off and on the Main SW of the copier.

● In case of failure in rewriting the firmware

If rewriting the firmware fails for some reason, it may be possible to redo the rewriting procedure
when the error happened in file transfer from the computer. Turn off and on the Main SW of the
copier and try the procedure again.

4-2 IP-011 PRINTER CONTROLLER

 Chapter 4 Appendices

■ Functions of parts mounted on boards

SW1

CN501
CN503
CN504

IC1 JP2
D8401
POWER PC

CN502 JP1
LED2

LED1

4-3 IP-011 PRINTER CONTROLLER

Chapter 4 Appendices

● LED indications and board status

The board status can be known from the indications of the LEDs mounted on the controller board.

LED1 (green) lights: Power is being supplied.

LED (red) lights: Ready for data transfer.

● Push switch
No need to operate the switch.

SW1: Resets system. (only for development purpose)

● Jumpers
No need to use the jumpers.

JP1: Not installed (no function)

JP2: For production purpose

4-4 IP-011 PRINTER CONTROLLER

 IP-011 PARTS

Ref. Ref
Part No. Description Part No. Description
No. No.

1 13FM73191 Auxiliary spring 10 13FM73090 Cover plate/1

2 13FM73131 Slide part/lower 11 13FM73110 Spring hold plate

3 13FM73200 Electricity seal 12 13FM73170 Ground spring/2

4 13FM73140 Slide part/upper 13 450011270 Screw

5 13FM-9021 Printer relay board assembly/1 14 13FM73030 Board mount plate/C

6 13FM73040 Board cover plate/A a 00Z670306

7 13FM73100 Board support plate/E b 00Z113065

8 13FM-9011 Printer control board assembly c 00Z193041

9 13FM73180 Ground spring/3 d 00Z183042