Konica ip302 Service Manual
Model
IP-302
IMAGE PROCESSOR
with Parts Catalog
(For use with 7060 Service Manual)
CSM-IP302
FEBRUARY 1998
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IP-302
SERVICE MANUAL
FEBRUARY 1998
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 Machines
U.S.A., Inc., strongly recommends that all servicing be
performed 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 Machines
U.S.A., Inc., makes no representations or warranties,
either expressed or implied, that the information contained in this service manual is complete or accurate. It
is understood 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
© 1998, KONICA BUSINESS MACHINES U.S.A., INC.
All rights reserved.
Printed in U.S.A.
CONTENTS
CONTENTS
SAFETY PRECAUTIONS
Installation Environment ....................................... v
Unauthorized Modifications ...................................... v
General Safety Guidelines....................................... v
Safeguards During Service Calls .............................. vi
Applying Isopropyl Alcohol ...................................... vi
Summary............................................................... vi
INTRODUCTION
Introduction ............................................................ 1-1
Start-up Process..................................................... 1-2
Data Flow Chart ...................................................... 1-3
INSTALLATION
Video Interface Kit ................................................2-1
Printer Installation .................................................2-2
Adjustment and Confirmation................................2-4
IP-302 Installation .................................................2-6
IP-302 Driver/Software Installation........................2-7
KN-101 Installation ...............................................2-8
KN-201 Installation ...............................................2-8
DISASSEMBLY AND REASSEMBLY
Tools .................................................................... 3-1
Removing the Covers.............................................. 3-2
Removing/Installing the Floppy/Hard Drive ................ 3-2
Removing/Installing the Power Supply ...................... 3-3
Removing/Installing the Motherboard ........................ 3-3
Removing/Installing the Memory (SIMM)............... 3-4
TROUBLESHOOTING
Tools ....................................................................4-1
Table ....................................................................4-1
APPENDIX
IP-302 Software Installation Guide........................ 5-1
CMOS Setup Program .......................................... 5-2
P5TXBpro Board Jumper Settings ........................ 5-4
POST and BOOT Error Messages......................... 5-5
BEEP Codes ......................................................... 5-6
Copier Codes ....................................................... 5-7
Limitations ............................................................ 5-7
25 Mode and P Function....................................... 5-8
Block Diagram ...................................................... 5-9
Motherboard Do's and Don'ts................................ 5-10
Special Tools ........................................................ 5-11
INDEX
PARTS CATALOG
iii
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SAFETY PRECAUTIONS
[1] Installation Environment
Safety considerations usually are directed toward machine design and the possibility of human error. In
addition, the environment in which a machine is operated must not be overlooked as a potential safety
hazard.
Most electrical equipment is safe when installed in a
normal environment. However, if the environment is
different from what most people consider to be normal,
it is conceivable that the combination of the machine
and the room air could present a hazardous combination. This is because heat (such as from fusing units)
and electrical arcs (which can occur inside switches)
have the ability to ignite flammable substances, including air.
When installing a machine, check to see if there is
anything nearby which suggests that a potential
hazard might exist. For example, a laboratory might
use organic compounds which, when they evaporate,
make the room air volatile. Potentially dangerous conditions might be seen or smelled. The presence of
substances such as cleaners, paint thinners, gasoline,
alcohol, solvents, explosives, or similar items should
be cause for concern.
If conditions such as these exist, take appropriate
action, such as one of the following suggestions.
• Determine that the environment is controlled
(such as through the use of an exhaust hood) so
that an offending substance or its fumes cannot
reach the machine.
• Remove the offending substance.
• Install the machine in a different location.
The specific remedy will vary from site to site, but the
principles remain the same. To avoid the risk of injury
or damage, be alert for changes in the environment
when performing subsequent service on any machine,
and take appropriate action.
[2] Unauthorized Modifications
Konica has gained a reputation for manufacturing
reliable products. This has been attained by the combination of outstanding design and knowledgeable
service forces.
The design of the equipment is extremely important. It
is the design process that determines tolerances and
safety margins for mechanical, electrical, and electronic aspects. It is not reasonable to expect individuals not involved in product engineering to know what
effect may be caused by altering any aspect of the
machine’s design. Such changes have the potential of
degrading product performance and reducing safety
margins.
For these reasons, installation of any modification not
specifically authorized by Konica Business Machines
U.S.A., Inc., is strictly prohibited.
The following list of prohibited actions is not all-inclusive, but demonstrates the intent of this policy.
• Using an extension cord or any unauthorized
power cord adapter.
• Installing any fuse whose rating and physical
size differs from that originally installed.
• Using wire, paper clips, solder, etc., to replace
or eliminate any fuse (including temperature
fuses).
• Removing (except for replacement) any air filter.
• Defeating the operation of relays by any means
(such as wedging paper between contacts).
• Causing the machine to operate in a fashion
other than as it was designed.
• Making any change which might have a chance
of defeating built-in safety features.
• Using any unspecified replacement parts.
[3] General Safety Guidelines
This machine has been examined in accordance with
the laws pertaining to various product safety regulations prior to leaving the manufacturing facility to protect the operators and service personnel from injury.
However, as with any operating device, components
will break down through the wear-and-tear of everyday
use, as will additional safety discrepancies be discovered. For this reason, it is important that the technician
periodically performs safety checks on the machine to
maintain optimum reliability and safety.
The following checks, not all-inclusive, should be
made during each service call:
CAUTION: Avoid injury. Ensure that the machine is
disconnected from its power source before continuing.
v
• Look for sharp edges, burrs, and damage on all
external covers and the machine frame.
• Inspect all cover hinges for wear (loose or bro-
ken).
• Inspect cables for wear, frays, or pinched areas.
• Ensure that the power cord insulation is not
damaged (no exposed electrical conductors).
• Ensure that the power cord is properly mounted
to the frame by cord clamps.
• Check the continuity from the round lug (GND)
of the power cord to the frame of the machine -ensure continuity. An improperly grounded machine can cause an electrically-charged machine frame.
[4] Safeguards During Service Calls
Confirm that all screws, parts, and wiring which are
removed during maintenance are installed in their
original positions.
• When disconnecting connectors, do not pull the
wiring, particularly on AC line wiring and high
voltage parts.
• Do not route the power cord where it is likely to
be stepped on or crushed.
• Carefully remove all toner and dirt adhering to
any electrical units or electrodes.
• After part replacement or repair work, route the
wiring in such a way that it does not contact any
burrs or sharp edges.
[5] Applying Isopropyl Alcohol
Care should be exercised when using isopropyl alcohol, due to its flammability. When using alcohol to clean
parts, observe the following precautions:
• Remove power from the equipment.
• Use alcohol in small quantities to avoid spillage
or puddling. Any spillage should be cleaned up
with rags and disposed of properly.
• Be sure that there is adequate ventilation.
• Allow a surface which has been in contact with
alcohol to dry for a few minutes to ensure that
the alcohol has evaporated completely before
applying power or installing covers.
[6] Summary
It is the responsibility of every technician to use professional skills when servicing Konica products. There
are no short cuts to high-quality service. Each machine
must be thoroughly inspected with respect to safety
considerations as part of every routine service call.
The operability of the machine, and more importantly,
the safety of those who operate or service the machine, are directly dependent upon the conscientious
effort of each and every technician.
Remember...when performing service calls, use good
judgement (have a watchful eye) to identify safety
hazards or potential safety hazards that may be present, 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!
• Do not make any adjustments outside of the
specified range.
vi
INTRODUCTION
INTRODUCTION
The IP-302 is an image processor that connects the model
7060 copier to a computer or computer network, allowing
it to be used as a printer. The image processor receives files
from the computer or network and translates them into
images to be printed on the copier/printer. Features and
specifications are given in the introduction section of the
controller's User’s Manual.
A video interface kit must be installed to connect the IP-302
to the 7060. Detailed instructions are given in the installation section of this manual. This section also provides
instructions for installing the optional PostScript® upgrade
kit and the network interface cards available for the IP-302.
Other information included in this manual are: product
configuration; disassembly and assembly procedures;
troubleshooting tips; and an appendix section that includes
software installation and CMOS setup instructions,
motherboard jumper settings for setup verification, and
various tables containing error messages, beep codes,
and copier codes to assit the technician while troubleshooting. This manual is to be used as a supplement to the 7060
Service Manual.
Note: The IP-302, KN-101/KN-201 User's Manuals are not
included in this publication.
Pentium 200 MHz
DOS, Floppy Drive,
540 MB Hard Drive,
Serial & Parallel
IP-302
PostScript®
& PCL-5E
Interpreters
16 - 128 MB Image
and Processing
Memory
7060 Copier Interface
Card (CIC)*
(Image Transfer,
Operation Panel,
Status Information)
Optional Ethernet
Network Interface
Card
* The copier interface card (CIC) has also been referred to as
the printer control board (PCB) in other text.
1 - 1
INTRODUCTION
Start-up Process
When powering up these units, the initialization can be
made in either sequence: turning ON the IP-302 first or
turning ON the 7060 copier/printer first. The start-up process
is as follows (in this case, turning ON the IP-302 first):
1. Turn the IP-302 ON. The CIC (copier interface card), which
interfaces with the printer, starts up. The CIC indicates to
the printer that it is running and then waits for the printer
to power up. The CPU in the IP-302 tests the system
memory and then boots up.
2. Turn the copier ON. It sees that the IP-302 is connected
and running, and goes into the printer mode.
3. The CIC and the printer establish a link. The CIC initiates
transfer of configuration information.
4. After the system memory is tested (this will take a few
minutes), DOS boots up and then the system software
loads.
5. When the system is fully configured, READY is displayed. Printing may begin.
When a document is sent to be printed, the following
process takes place (see the diagram on page 1-3):
Data enters the IP-302 through the Ethernet card or one of
the I/O ports. The I/O controller software evaluates and
spools the data to either the PCL-5E interpreter or the
PostScript® interpreter. The interpreter then generates an
image into memory in bitmat form, which then travels
through the CIC to the printer.
1 - 2
Data Flow Diagram
INTRODUCTION
Ethernet Card Serial Port
PCL-5E Interpreter
Parallel Port
I/O Controller Software
(with spooler)
PostScript
Interpreter
Image Memory
7060 Copier
Interface Card (CIC)
1 - 3
To 7060
INTRODUCTION
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1 - 4
INSTALLATION
[1] Video Interface Kit (p/n: PC/UA 950–791)
INSTALLATION
CONTENTS
PART NAME QTY
Printer I/F board
[12ST-9010]
Wiring 1
[12ST90160]
Printer wiring
[12ST90190]
Board support
spacer
[12ST73970]
Board ground
plate
[12ST73980]
CONTENTS
1
1
1
2
2
PART NAME QTY
Main control
EPROM 2 (C2)
[12ST-9160]
Filter support
plate
[25AA73221]
Cleaner cooling
filter
[25AA73230]
TP screw (M3x4)
[00Z193041]
TP screw (M4x6)
[00Z194141]
1
1
1
4
1
Main control
EPROM 1 (C1)
[123G-9210]
1
2 - 1
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