Because of possible hazards to an inexperienced person servicing this print controller units as well as the risk of damage to the print controller units, Konica Corporation strongly recommends that all servicing be performed only by Konica-trained service technicians. Changes may have been made to this print controller units to improve its performance after this Service Handbook was printed. Accordingly, Konica Corporation does not warrant, either explicitly or implicitly, that the information contained in this Service Handbook is complete and accurate. The user of this Service Handbook must assume all risks of personal injury and/or damage to the controller product while servicing the controller product for which this Service Handbook is intended. Therefore, this Service Handbook must be carefully read before doing service work both in the course of technical training and even after that, for performing maintenance and control of the print controller units properly. Keep this Service Handbook also for future service. When it is impossible to read the description about safety and warning (due to contamination or tear), the relevant page should be replaced.
DANGER, WARNING, AND CAUTION SYMBOLS AND EXPRESSIONS
In this Service Handbook, each of three expressions "DANGER," "WARNING," a n d defined as follows together with a symbol mark to be used in a limited meaning. When servicing the print controller units, the relevant works (disassembling, reassembling, adjustment, repair, maintenance, etc.) need to be conducted with utmost care. DANGER: Action having a high possibility of suffering death or serious injury "CAUTION
WARNING: Action having a possibility of suffering death or serious injury AUTION: Action having a possibility of suffering a slight wound, medium trouble, and property damage
Symbols used for important warning items are defined as follows:

Precaution

General precaution Electric shock Heated surface

Prohibition

General prohibition Do not touch with wet hand Do not disassemble

Direction

General instruction Unplug Ground/Earth

SAFETY WARNINGS

[1] MODIFICATIONS NOT AUTHORIZED BY KONICA
Konica controllers for copier are renowned for their high reliability. This reliability is achieved through high-quality design and a solid service network. Print controller units design is a highly complicated and delicate process where numerous mechanical, physical, and electrical aspects have to be taken into consideration, with the aim of arriving at proper tolerances and safety factors. For this reason, unauthorized modifications involve a high risk of degradation in performance and safety. Such modifications are therefore strictly prohibited. The points listed below are not exhaustive, but they illustrate the reasoning behind this policy

Be sure to use a Konica approved hard disk.

Hold this area and pull.

Do not touch the surface of the disk.
G Removal / Installation of PostScript3 (Protection Chip)
The PostScript3 protection chip is sensitive to static electricity. Handle it with care.
Remove the PostScript3 protection chip using a PLCC pull-out tool.
See the silk on the board, and align the corner of the chip with that of the socket and insert the PostScript3 chip.

PLCC pull-out tool

G Removal / Installation of Memory
Remove 10 screws, and remove the outside cover to the arrow direction.

Rubber Insert

Release the clips on either side of the expansion memory slot.
Make sure that the clips for the expansion memory slot are securely locked.
Remove the memory from the expansion memory slot.
When removing the memory unit, put it in at an angle relative to the expansion memory slot.
I Overall Construction (IP-423)
PostScript3 (protection chip : PS-345) Expansion memory (MU-404/405) Cooling fan motor Hard disk (field option)
Printer I/F board CPU Compact Flash
I Disassembly / Reassembly (IP-423)
Remove 2 screws, and remove the board cover plate /C.
Remove 3 screws, and remove the board cover plate /A.
Refer to "Removal / Installation of PostScript3 (Protection Chip)".
G Removal / Installation of the Cooling Fan Motor
Remove the 9 screws, then remove the board cover.
Remove the 3P connector (CN14) and 4 screws, then remove the cooling fan motor.
Caution: Removal / Installation
Take care not to lose that parts removed at the same time as the cooling fan motor (fan guard and 4 collars). Also, be sure to attach the collars when installing the cooling fan motor.
G Removal / Installation of the CPU

Remove the board cover.

See the procedure in "Removal / Installation of the Cooling Fan Motor",
Remove the 3P connector (CN14) and 2 screws, then remove the cooling fan motor and heat sink.
Radiation Sheet Radiation Sheet CPU

NorthBridge

Be careful not to mislay the (2) radiation sheets, 1 each between the heat sink and CPU and between the heat sink and the North Bridge. Also be sure to apply the radiation sheet when installing the heat sink. There are 2 types of radiation sheet. Be sure to use the correct sheet for each location. Radiation sheet for CPU: 30x30x1mm Radiation sheet for North Bridge: 30x30x2mm When installing the radiation sheets, there is sufficient space to install the sheets then the heat sink. When installing the radiation sheets, install them so that they face each IC board.

Slowly lift the lever up in the direction of the arrow to release the CPU. Remove the CPU.
Be sure to install the CPU correctly.
G Removal / Installation of the Printer I/F Board

Removal Procedure

Remove the 6 screws, then remove the electrical locking plate.
Push the locking levers for the parallel connector to the inside, and remove the 2 screws. Loosen the 7 screws, then remove board attachment /C.
Remove the 6 screws, then slowly lift out the printer I/F board.
The printer I/F board is connected to the printer controller board by the connector (CN1) in the center of the board. Be careful not to damage the connector during removal/installation.

Installation Procedure

Attach the printer I/F board with the 6 screws.
Align the 6 holes on the printer I/F board with the 6 holes on printer controller and place the printer I/F board on the attachment area, then insert the relay connector into the "CONNECTOR" socket in the center of the printer I/F board.
For the remaining steps, reverse the procedure for removal.
G Connecting via Service Port (Serial Port)
Remove the 2 screws, then remove board cover /B. Attach the serial cable.

Chapter 3 Field Service

I 25 Mode
The copier has a settings feature for service, [25 mode]. This service handbook describes only settings for the print controller. For details of the 25 mode, refer to the copier's Service Handbook.

G Accessing the Settings

1. 2. 3.
Press the copier's sub power switch OFF. While pressing copy quantity setting buttons [2] and [5] on the copier operation panel, press the copier's sub power switch ON. From the memory setting mode screen, select [1. Software SW].
The [Memory setting mode] screen appears on the operation panel.

G Definable Settings

The framed items are the default settings.
Operation when key counter is removed (DIPSW 01-0)

Service Port Operating Environment
The following is required to use the service port: Computers running on Windows HyperTerminal (terminal communications program)

Setting requirements

Bits/sec.: Data bit: Parity: Stop bit: Flow control: 9600 bits/sec.(fixed) 8 bits None 1 None
RS-232C serial cable (terminated in a female 9-pin D-Sub connector on both ends)

Pin assignment

1 DCD 2 TxD 3 RxD 4 DTR 5 GND 6 DSR 7 RTS 8 CTS 9 RI
9-pin D-SUB Connector (female)
Turn the copier's main power switch OFF.
Connect an RS-232C serial cable between the PC and the print controller.
When connecting IP-423 via serial cable, see "Connecting via Service Port (Serial Port)".

Run HyperTerminal.

Turn the copier's main power switch ON (i.e., boot up the print controller).
Now you can access various functions from HyperTerminal.
For how to install and use the HyperTerminal, refer to the manual for your Windows, as well as the later corresponding section of this manual.
G Installing and Booting Up HyperTerminal
HyperTerminal is a terminal communications program with which Windows95/98/Me/NT4.0/2000/XP comes as standard. If it is not installed in your Windows, it is necessary that it should be installed.
To install HyperTerminal, you need the installer CD for the Windows PC in use. The procedure for setting up HyperTerminal varies according to the version of Windows being used.

Installing HyperTerminal

In the following, we use the Windows 98 as an example.

1. 2. 3. 4.

Insert the installer CD for the version of Windows you are using. Select [Start]-[Settings]-[Control Panel].
A [Control Panel] window will appear.
Double-click [Add/Remove Programs].
An [Add/Remove Programs Properties] window will appear.
Click the [Windows Setup] tab, and check the [Communications] check box under [Components].
Click the [Details] button.
[Communications] window will appear.
Check the [HyperTerminal] check box, and click the [OK] button. When the [Add/Remove Programs Properties] window reopens, click the [OK] button.
The necessary files are copied and the installation is completed.

Booting Up HyperTerminal

Select [Start]-[Programs]-[Accessories]-[Communications]-[HyperTerminal].
[HyperTerminal] window will appear.

Once the connection has been established, the connection settings are stored with an icon. You can name this icon in step 3, below. If an icon has already been created (i.e., if the copier connection settings have already been stored in memory), there is no need for you to complete the following steps because the connection with HyperTerminal is established by double-clicking that icon.
Double-click [Hypertrm.exe].
[Connection Description] window will appear.

3. 4. 5.

Enter a name, and click the [OK] button. Select [Direct to COM (1 - 4)] under [Connect using], then click the [OK] button.
[COMx Properties] window will appear.
Set the Port Settings as follows, and click the [OK] button.
Use the Windows default settings for all the settings except [Bits per second] and [Flow control].
Bits per second: 9600 Data bits: Parity: Stop bits: Flow control: 8 None 1 None
Here you cannot change the serial port settings on the print controller.
G POST (Power On Self Test)
POST is hardware diagnostic test run by BIOS when the copier's main power switch is turned ON. It checks the memory, timer settings, hard disk and other function required for the system to run. It is output to the service port and HyperTerminal can be used to view the startup status of the print controller, by connecting a computer to the copier.
Details of the Service Port Output
The details of the status output from when the print controller starts until the system (VxWorks) starts is described below.

IP-422:

===Power On self Test=== Init CPU Reg. (Initialize Device Information) Disable NMI & RTC Ints. (Disable NMI and RTC interrupts) Reset Coprocessor. (Reset the Coprocessor) Wait. (Pause to ensure system stability) Reset Boot Flag P92. (Clear the reset flag) Disable Shadow. (Disable Shadow) Init CMOS Memory. (Initialize the CMOS memory settings) Test Timers. (Test the system timer) Start Refresh DRAM. (Refresh DRAM) Check Memory Amount. (Check the amount of memory) Test Base 64KB Memory. (Test memory below 64KB) Clear Base 64KB Memory. (Clear the area of memory below 64 KB) Enable L1 Cache. (Enable the use of L1 cache) Init BIOS Data Area. (Initialize the BIOS data area and memory controller) Init Interrupt Controller. (Initialize and mask the interrupt controller) Init Interrupt Vector Table. (Initialize the Interrupt Vector Table) Init Extended ROM Area. (Initialize the extended ROM area) Init Timers. (Initialize RTC and timer settings, and clear the interrupt mask) Init Com Port. (Initialize the serial port) Init PCI. (Configure PCI devices) Enable Shadow. (Enable Shadow)

Press the key until the "Low Memory Test (Low Memory Passed)" count starts. As long as it is an ordinary key, any key (e.g. "z", "6") can be pressed.
The detailed memory test is conducted.
Make certain that all memory tests found no problems ("Memory Passed" is then displayed).
When all memory is OK, the copier is able to normally start up. If any test results are unacceptable (The value after the occurrence of "Ext Memory Passed" is less than the amount expanded memory.), remove the added memory and run the memory test from the beginning since the memory may be defective.
Unplug the serial cable. Turn the copier's main power switch back ON to check if it behaves normally.

G Service DOS

The print controller stores DOS (Embedded DOS) along with the BIOS program in flash ROM memory. This can be used to perform a file system check and surface check on the optional hard disk. For more information about this, refer to "Diagnostics for the Hard Disk" The printer controller BIOS and DOS data are stored in Flash ROM memory. The DOS program stored in flash ROM can be run from a computer connected to the service port (RS-232C Serial port).

Booting Up Service DOS

Refer to "Booting Up HyperTerminal"
Type in [k], followed by [a] while "Ext Memory Test" is running. The DOS is boot up.
When the message "Enter new data (mm-dd-yy):" appears, enter the current date (ex: 08-24-2001) and press the Enter key. When the message "Enter new time (hh:mm:ss):" appears, enter the current time (ex: 18:14:20) and press the Enter key.
Now DOS commands are available for use.
Although the printer system (VxWorks) acquires time information from the copier, the service DOS has no way of communicating with the copier: it is necessary that you should enter the current date and time.
Using DOS Commands Caution
Although you can enter commands for the service DOS much the same as for MS-DOS, the system used by the print controller (VxWorks) handles files differently and entering commands without consideration for this may render the print controller inoperable. You can use the following types of commands: Commands that check the file system of (field optional) hard disk. (chkdsk) Commands that check the surface of the (field optional) hard disk. (chdd)

I List of Warning (error) codes
If there are problems with the print controller, look at the error code displayed on the copier's operation panel. This list only listed the error codes that are displayed when the print controller is attached to the copier.
Warning Code E52-06 Cause Abnormal cooling fan motor in print controller. Abnormal system board. Operation in case of warning occurrence Copier stops immediately. Estimated abnormal parts Print controller Measures 1. Recycle the main power. 2. Check on the connection between the print controller and the copier. 3. Replace the system board.

E87-02/03

The warning code is an error code which is displayed on the LCD display on the copier operation panel. For other warning codes, refer to the Service Handbook for the copier. Numbers shown in the Measures column indicate priorities. Before attempting to replace component units or parts, be sure to turn the copier's main power switch OFF and unplug the power cord.
I Troubleshooting Network Hardware

G LED Status Indicator

The network controller has two LED status indicators: amber and green. The amber LED generally indicates job activity; it flashes when a print job is being communicated to the Network Controller; it is off when no activity is occurring. The green LED indicates the operating condition of the network controller when it is powered on during normal operation. The following table provides the conditions that these LEDs indicate.
LED status Green lit Printer status Immediately after main power switched ON Waiting print job Green LED flashes three times Lights up Amber flashing Amber lit up Amber off Green flashing rapidly Green LED flashes four times rapidly Goes out Amber LED flashes about 10 seconds Goes out Green LED continues flashing Green LED flashing slowly Self-diagnostics completed Waiting print job Print job waiting/processing Waiting print job Self-diagnostics executing Self-diagnostics executing Flash memory self-diagnostics executing Network controller status Self-diagnostics executing Normal operation Network setting list print Receiving print job Normal operation No print jobs RAM chip defect detected Operating status Normal Normal Normal Normal Normal Normal Error None None None None None None Replace the system board Check the network again Execute flash update Action

Ethernet hardware self-diag- Error nostics failure Did not pass the check-sum test Error
Power on completed, then print job waiting
Printer interface error NetWare connection to file server not possible Has been reset to factory defaults

Error Error Error

Replace the system board Check NetWare settings Reset the settings as described in "Resetting the network controller to Factory Default".
Green LED flashing rap- Print job waiting idly Green LED alternately blinks with amber indicator Finished power-on sequence
G Resetting the network controller to Factory Default
You can reset all the parameters in the settings for the network controller to the factory default settings. This can be used when the print controller is moved to a different operating environment (using NetWare file server, IP subnet, etc.). The setting can be reset to the factory defaults using the web utility or from the LCD operation panel on the copier.
Resetting the settings to the factory default setting means that all information in the existing settings, such as printer server names and IP addresses, will be lost. However, the serial number and MAC address are hardwired on the print controller and are not lost.
Normally, all settings for the network controller can easily be reset to their factory defaults from the print controller by resetting them from the network settings menu in the LCD display on the copier's operation panel. If the settings cannot be reset this way for some reason, they can be reset using the slider switch*. *: The SW No. for slide switch (reset switch) varies depending on the type of printer controller. IP-422 : SW3 (System Board) IP-423 : SW1 (Printer I/F Board)
If grounding is not made securely, the board can be damaged during work. Make sure to ground your body securely by using a wrist strap before starting to work. Do not change except reset switch.
After turning the copier's main power switch OFF, remove the print controller from the copier.
For more information, refer to the print controller Installation Procedure.
Set the reset switch as illustrated below, connect the print controller to the copier, then turn the copier's main power switch ON.
The settings for the network controller will be reset to their factory defaults in about 5 minutes.
When the settings for the network controller are reset to their factory defaults, two LEDs blink alternately on the network controller.
Again, turn the copier's main power switch OFF, remove the print controller, and replace the reset switch to its original position.
Connect the print controller to the copier and turn the copier's main power switch back ON.

To check that the network protocols are correctly installed and setup, refer to the "G NIC Status Page (NIC Config.)" or the relevant chapter in the User's Manual.

6. 7. 8.

Check the status LEDs on the network controller.
Refer to "G LED Status Indicator".
Check if other users can print to the print controller.
If other users cannot print, and are using the same NOS, refer to the NOS User's Guide.
None of the steps above solved the problem.
Refer to "G Basic Printer Checklist".
G Basic Printer Checklist
Check the following to diagnose and solve network related printer problems.
Troubleshooting Network Hardware Connections
For 100Base-TX or 10Base-T, check that the network connector is plugged into the RJ45 connector on the network controller. Try another cable to make sure you do not use a defective cable.
Troubleshooting MAP Problems
If the MAP cannot defect a target network controller, check the following: Are the network settings on the network controller correctly made? Did you correctly select the MAP settings? Are the protocol used by the computer on which the MAP to run correctly set up? Are the Web browser used by the computer on which the MAP to run correctly set up? If nothing irregular is found, turn the copier's main power switch OFF, then turn it back ON, Wait about several minutes and try running the MAP again.
Troubleshooting NetWare Protocol
NetWare should be setup and the parameters checked and set from the LCD operation panel on the copier. If the problem cannot be solved using the operation panel, proceed to check the items in this checklist.

NetWare Checklist

Is the print server name registered correctly? The factory default setting is "KCA_serial number". The serial number is printed on the system board. Is the print queue assigned to the print controller? We recommend that the network controller be used to assign print queues for one printer. If the print queue for the printer on the network controller is assigned to other network printers, the print job may be sent to a different network printer. Has the print controller type been set as Remote Other/Unknown? If the PCONSOLE or NWADMIN settings are correct, the connection between the print controller and the network may have been cut. Turn the copier's main power switch OFF, then use PCONSOLE or NWADMIN and wait for the message "Not Connected" to be displayed. Turn the copier's main power switch back ON again, and the status should change to "Waiting".

File Server Checklist

Is there enough disk space on the file server and is it running? Is the correct file server associated with the print controller? Use PCONSOLE or NWADMIN to check this. Did you have the proper rights to configure the printer? (supervisor or administrator) Are the file server and the network connected? To check the connection, run the NetWare COMCHECK utility from a workstation. Are there enough user positions on the File Server? The Print Server function logs on as a user.

Workstation Checklist

Are workstation mounted on the network? For details information, refer to the NetWare manual. Is the application set up to print to the print controller? For instance, are you using the correct printer driver? Is the workstation connected to the correct print queue? Print a file and verify that the file goes to the queue. Is the print queue assigned to the copier on the network controller assigned to another printer as well? If it is, the print job may be printed on the other printer. From PCONSOLE or NWADMIN, enter a sample print job directly into an assigned queue. Does the job become Active? Is job printed? Is AUTO ENDCAP enabled? Auto Endcap lets you send data to a network printer. Use PRINTCON to check. If not, enable it.
Network Controller Configuration Checklist
If all your hardware connections are correct, check the following: Use MAP to check the status of the network controller. The Unit Status screen shows the status for the selected network controller. This report includes a status of file servers and queues assigned to a print controller along with a description of any problems. The print controller may not be assigned to the correct print queues. Use PCONSOLE or NWADMIN to direct print jobs to the correct queues, then check to see if the print job is in the queue. If devices were added or changed, use PCONSOLE or NWADMIN to make sure you configured the new devices correctly. Check that the entry for the print server is "KCA_serial number". If you changed the name with MAP, you must also change the name in PCONSOLE or NWADMIN before you can print. Use PCONSOLE or NWADMIN to check the print controller status. Make sure it is not stopped. To adjust the settings for the network controller, version 1.0 or later of PCONSOLE or NWADMIN are required. Connect Novell corp. for an upgrade.

A PC that can be connected to the LAN OS : Windows95/98/Me/NT 4.0/2000/XP LAN cable : 10Base-T/100Base-TX interface cross-over cable
Make sure that TCP/IP is enabled in the network setting for the print controller, and that an IP address has been assigned to the network controller. Make sure that the PC and print controller are connected with a cross-over cable.
If the print controller being used to capture files is connected to the LAN, disconnect the cable, and use the cross-over cable to connect it directly to the PC. If the print controller is connected via the parallel port, leave the parallel cable as it is, and connect the print controller and PC by plugging the cross-over cable into the network connectors.
Boot up MS-DOS on the PC.
Click [Start], then select [Programs]-[MS-DOS Prompt].
Boot FTP from the DOS prompt.
Enter "ftp (IP address of the print controller)" after the "C:\" prompt.
The example above uses the IP address 10.11.32.133.

Appendix-4

Enter the user name.
Enter "capture" after the "User ID 10.11.32.133:(none):" prompt.
The user name is "capture".

Enter the password.

Enter "sysadm" after the "Password:" prompt.
The password is "sysadm".
Display the list of captured files.
Enter the "dir" command to display the list.

Appendix-5

Copy the desired capture file(s).
Enter the "bin" command to set the transfer mode to binary mode, and then enter the "get" command to copy the captured file.
Remote file: Enter the name of the file from the list of captured file displayed after running the "dir" command. Local file: Enter the destination and file name for saving the captured file selected as the remote file. Deleting Capture Files To delete capture files on the hard disk, use the "del" command to delete the desired files.

End the FTP session.

Enter the "bye" command.
G Using Captured Files to Analyze Problems
The data in the captured files is the raw data created by printer driver on the computer for print jobs sent from a computer to the print controller. By comparing the print job data with the captured files, it possible to analyze problems with the I/O signals. In addition, you can use the "copy/lpr" commend to send the file to the print controller to recreate a problem. You can also extract the print job parameters from captured files.

Appendix-6

I Components on the System Board

G Parts Side

IP-422
Flash ROM for Network CN12 (for Fan) EEPROM Standard Memory Network Control Memory SW3 CPU Standard Memory Network Control CPU Network Control Chip Clock Chip for Network Control Slot for Memory Extension Slot for Memory Extension RJ-45 Ethernet Network Port Green LED Amber LED Parallel Port Serial Port (for Service)

System Clock

PCMCIA Slot
Clock Chip for Network Control CPU
Serial No. Printing Position ISA/HDD Control IC

Power Supply

PCI Control IC

Gate Arrey 1 (KPC01) SW2

Gate Arrey 2 (PPBC2000)

Engine I/F Connector

EEPROM: Network Configuration DATA maintenance

Slide Switch Functions

Normally, no need to change switch settings. SW2: For Production purpose SW3: Reset to factory default setting

IP-423

Serial Port (for Service) Power Supply Standard Memory CN14 (for Fan) Power Supply Standard Memory Standard Memory Standard Memory Serial No. Printing Position SW2 PCMCIA Slot Clock Driver

North Bridge

PPBC-XP
South Bridge Postscript Protection Chip
Normally, no need to change switch settings. SW2: For Production purpose

Appendix-7

G Pattern side
Postscript Protection Chip
Flash ROM Slot for Compact Flash

Relay Connector

Flash ROM

Slot for Compact Flash

Appendix-8
I Components on the Printer I/F Board (IP-423)

EEPROM

Gate Arrey 2

Flash ROM for Network

Gate Arrey 1 (KPC01)

Network Control Memory

Green LED Amber LED
Clock Chip for Network Control
Network Control CPU Clock Chip for Network Control CPU

G Pattern Side

RJ-45 Ethernet Network Port
Relay Connector Parallel Port
Normally, no need to change switch settings. SW1: Reset to factory default setting
I Initializing the (field optional) Hard Disk
If the hard disk does not operate correctly, format the disk. You can format the hard disk from the [Main Menu] in the LCD display on the copier. For more information, refer to the print controller User's Manual.
When the hard disk is formatted any scan data, confidential data, PC-Fax reception data stored on the disk will be erased. In addition, the printer setting and controller settings will be reset the factory default settings. If the PostScript3 option has been installed, the font stored on the hard disk will also be erased.

Appendix-9

Appendix-10

IP-422 PARTS

Ref. No. 5
Part No. 13SP-9010 13SP13FM73191 13FM73170
Description Printer control board assembly Cooling fan Screw Auxiliary spring Ground spring/2

Ref No. 6 a b c d

Part No. 13FM73110 00Z183042 00Z193041 00Z193121 00Z670306
Description Spring hold plate

IP-423 PARTS

Part No. 13RN80520 13WJ-13FM73191 13WJ-9020
Description Cooling fan/M Printer control board assembly Table knob screw Auxiliary spring Printer I/O board assembly

Ref No. a b c d e f

Part No. 00Z183041 00Z193041 00Z163061 00Z183201 00Z670306 00Z610401

Description