Konica Minolta IP-421 How to use

IP-421
SERVICE HANDBOOK
March, 2001
Ver.1.1
KONICA MINOLTA BUSINESS TECHNOLOGIES, INC.
TECHNOLOGY SUPPORT CENTER
TOKYO JAPAN
KCSI42110

COPYRIGHT ©2001
KONICA MINOLTA BUSINESS TECHNOLOGIES, INC.
All rights reserved
MF13JA1780

C-1 IP-421 PRINT CONTROLLER
Safety and Important Warning Items
SAFETY AND IMPORTANT WARNING ITEMS
Read carefully the Safety and Important Warning Items described below to understand them before
doing service work.
IMPORTANT NOTICE
Because of possible hazards to an inexperienced person servicing this equipment, as well as the
risk of damage to the equipment, Konica Minolta Business Technologies, INC. , strongly recommends that all servicing be
performed only by Konica-trained service technicians.
Changes may have been made to this equipment to improve its performance after this service
handbook was printed. Accordingly,
Konica Minolta Business Technologies, INC. , makes no representations or warranties,
either expressed or implied, that the information contained in this service handbook is complete or
accurate. It is under-stood that the user of this service handbook must assume all risks or personal
injury and/or damage to the equipment while servicing the equipment for which this service hand-
book is intended.
Therefore, this Service Handbook must be read carefully before doing service work both in the
course of the technicaltraining and evenafter that, forkeeping the correct maintenance andcontrol
of the copying machine. Keep the Service Handbook also for the future service. When it is impos-
sible to read the description about safety and warning (due to contamination or tear), the relevant
page should be re-placed.
DESCRIPTION ITEMS FOR Danger,Warning AND Caution
In this Service Handbook, each of three expressions, “ Danger, Warning and Caution” is
defined as follows together with a symbol mark to be used in a limited meaning.
When servicing, the relevant works (disassembling, assembling, adjustment, repair and mainte-
nance) need to be conducted with utmost care.
Danger: Actions having a high possibility of suffering death or serious
wound
Warning: Actions having a possibility of suffering death or serious wound
Caution: Actions having a possibility of suffering a slight wound, medium
trouble and material damage

C-2 IP-421 PRINT CONTROLLER
Safety and Important Warning Items
SAFETY WARNINGS
●MODIFICATIONS NOT AUTHORIZED BY Konica
Konica copiers are renowned for their high reliability. This reliability is achieved through high-quality
design and a solid service network.
Photocopier 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
ofdegrading performanceand safety.Such modificationsaretherefore strictlyprohibited.The points
listed below are not exhaustive, but they illustrate the reasoning behind this policy.
Prohibited Actions :
(1) Using extension cables or a different power cord than specified by Konica.
(2) Using other fuses than specified by Konica. Safety will not be assured, lead-
ing to a risk of fire and injury.
(3) Disabling fuses or bridging fuse terminals with wire, metal clips, solder or
similar. (This applies also to thermal fuses.)
(4) Removing air filters (except for replacement).
(5) Disabling relay functions (such as wedging paper between relay contacts,
etc.).
(6) Disabling safety functions (interlocks, safety circuits, etc.). Safety will not be
assured, leading to a risk of fire and injury.
(7) Performing actions to copier not described in the instruction manual or the
service handbook.
(8) Using parts other than specified by Konica.
●CHECKPOINTSWHEN PERFORMING ON-SITE SERVICE
Konica copiers are extensively tested before shipping, to ensure that all applicable safety stan-
dards are met, in order to protect the customer and customer engineer from the risk of injury.
However, in daily use, any electrical equipment will be subject to parts wear and eventual failure. In
order to maintain safety and reliability, the customer engineer must perform regular safety checks.
Caution :
(1) Wear clothing that facilitates work and is designed for safety.
(2) Carry out all procedures carefully to prevent injury.
(3) Be sure to disconnect the power cord of the copier and all optional equip-
ment from the AC outlet.
Simply turning off the power switch is not sufficient, because paper feed
units or other electrical equipment may be powered also when the power
switch is turned off.
(4) Proceed with special care when performing operation checks or adjustment
while the unit is powered. When carrying out operation checks or adjust-
ment while external covers are removed, the risk of electrical shock exists
when touching parts which carry high voltage or electrical charge. The risk
of injury exists when touching moving parts such as gears or chains.

C-3 IP-421 PRINT CONTROLLER
Safety and Important Warning Items
The following list is not exhaustive, but it includes actions which must be carried out at every ser-
vice call.
Caution :
(1) Check external covers and the frame for sharp edges, burrs, or nicks.
(2) Check external covers and hinges for loosening or damage.
(3) Check wiring for squeezing or damage.
(4) Checkpower cordfor insulationproblems(conductor mustnot beexposed).
(5) Check that power cord is properly connected.
Warning :
(1) Verify that the copier is properly grounded. If a problem is detected, estab-
lish a proper ground connection.
(2) Connecting the ground lead to an improper point such as listed below re-
sults in a risk of explosion and electric shock.
Unsuitable ground points:
- Gas pipe
- Lightning rod
- Telephone line ground
- Plastic water pipe or water pipe or faucet that has not been approved by
authorities for grounding use
●PRECAUTIONS FOR ON-SITE SERVICE
Caution :
(1) Before performing maintenance work, read all relevant documentation (ser-
vice handbook, technical notices, etc.) and proceed according to the pre-
scribed procedure, using only the prescribed tools. Do not carry out any
adjustments not described in the documentation.
(2) If the power cord is damaged, replace it only with the specified power cord.
If the power cord insulation has been damaged and there are exposed sec-
tions, shortcircuits and overheating may occur, leading to a serious fire risk.
(3) Do not route the power cord so that it can be stepped on or pinched. Other-
wise overheating may occur, leading to a serious fire risk.
(4) When disconnecting any cables, always grasp the connector and not the
cable (especially in the case of AC and high-voltage leads).
(5) Carefully remove all toner remnants from electrical parts, electrodes, etc.
(6) Make sure that wiring cannot come into contact with sharp edges, burrs, or
other pointed parts.
(7) Double-check to make sure that all screws, components, wiring, connec-
tors, etc. that were removed for maintenance have been reinstalled in the
original location. (Pay special attention to forgotten connectors, pinched
cables, forgotten screws, etc.)
(8) When installation and preventive maintenance, verify that the power cord
has been securely plugged into the AC outlet. Contact problems may lead
to increased resistance, overheating, and the risk of fire.
Warning :
(1) Before disassembling or adjusting the optical unit or any parts that use a
laser, make sure that the power cord has been disconnected.

C-4 IP-421 PRINT CONTROLLER
Safety and Important Warning Items
(2) Do not remove the main cover of the write unit. Direct exposure of the eye to
laser beams may lead to blindness.
(3) Do not turn the copier on while the write unit is not installed in its normal
position.
(4) Danger of explosion if battery is incorrectly replaced, replace only with the
same or equivalent recommended by the manufacturer. Discard used bat-
teries according to the manufacture’s instructions.
Vorsicht :
(4) Expiosionsgefahr dei unsachegemäßem Austausch der Battetie. Ersatz nur
durch denselben oder einen vom. Hersteller empfohlenen gleichwertigen Typ.
Entsorgung gebrauchter Batterien nach Angaben des Herstellers.
●HANDLING OF MATERIALS FOR SERVICING
Caution: Drum cleaner (alcohol-based) and roller cleaner (acetone- based) are
highly flammable and must be handled with care.
When using these materials for cleaning of copier parts, observe the
following pre-cautions.
(1) Disconnect the power cord from the AC outlet.
(2) Use only a small amount of cleaner at a time and take care not to spill any
liquid. If this happens, immediately wipe it off.
(3) Performcleaningonly inan environmentwheresufficient ventilationis assured.
Breathing large quantities of organic solvents can lead to discomfort.
(4) Do not replace the cover or turn the unit on before any solvent remnants on
the cleaned parts have fullyevaporated.
Caution: Toner and developer are not harmful sub-stances, but care must be
taken not to breathe excessive amounts or let the substances come
into contact with eyes etc.
If this happens, immediately rinse with eye wash and plenty of water,
and consult a physician.
●MEASURESTOTAKE IN CASE OF AN ACCIDENT
(1) If an accident has occurred, the distributor who has been notified first must
immediately take emergency measures to provide relief to affected persons
and to prevent further damage.
(2) If a report of a serious accident has been received from a customer, an on-
site evaluation must be carried out quickly and Konica Minolta Business Technologies, INC. must be
notified.
(3) To determine the cause of the accident, conditions and materials must be
recorded through direct on-site checks, in accordance with instructions is-
sued by Konica Minolta Business Technologies, INC..
●CONCLUSION
Safety of users and customer engineers has topmost priority, ranking even higher than operability.
Safety depends on a appropriate maintenance work and is maintained by proper daily service work
conducted by customer engineers. When performing service, each copier on the site must be
tested for safety. The customer engineer must verify the safety of parts and ensure appropriate
management of the equipment.

C-5 IP-421 PRINT CONTROLLER
Contents
CONTENTS
SAFETY AND IMPORTANT WARNING ITEMS ............................................ C-1
1. Overview
■Product specifications ................................................................................ 1-1
●IP-421 print controller ..................................................................................................... 1-1
■Product overview ........................................................................................ 1-3
●Capabilities of the IP-421 ................................................................................................ 1-3
●Startup sequence of the 7020 series + IP-421 system ................................................... 1-4
●Data processing of the IP-421 (See data flow) ............................................................... 1-4
●Data flow ......................................................................................................................... 1-5
■Option ......................................................................................................... 1-6
●KN-303 Network card ..................................................................................................... 1-6
● Hard Disk (HD-103) ........................................................................................................ 1-6
● Post Script 3 (PS-341) .................................................................................................... 1-6
2. Disassembly/Assembly
■Construction ............................................................................................... 2-1
■Disassembly / Assembly procedures.......................................................... 2-2
●Removal/Installation of boards........................................................................................ 2-2
●Expanding the memory (MU-403/MU-404/MU-405) ....................................................... 2-5
●Installation / Removal of HD-103 .................................................................................... 2-7
●Installation / Removal of PostScript 3 option (PS-341) ................................................... 2-9
3. Troubleshooting
■Troubleshooting .......................................................................................... 3-1
●Troubleshooting of the IP-421 and copier ....................................................................... 3-1
4. Appendices
■Upgrading Firmware ................................................................................... 4-1
●Rewriting the Flash ROM (via Parallel Port) ................................................................... 4-1
●Rewriting the Flash ROM (by removing it) ...................................................................... 4-4
●Comfirming Update ......................................................................................................... 4-2
●Replacing ROM .............................................................................................................. 4-6
■Functions of parts mounted on boards ....................................................... 4-7
●Connector ....................................................................................................................... 4-8
●Switch ............................................................................................................................. 4-8
●Jumpers .......................................................................................................................... 4-8
●Individual ICs’ functions .................................................................................................. 4-8
INDEX ..................................................................................................... Index-1

Overview
1

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1-1 IP-421 PRINT CONTROLLER
Chapter 1 Overview
■Product specifications
●IP-421 print controller
Type: Built in Konica 7020 series copy machine
Paper size: A3, A4, A5, B4, B5, B6, 11"X17", 8.5"x14", 8.5"x11", 5.5"x8.5"
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.
Specialprinting features:Printing on bothfaces, choice of papertype, zoom
function,choiceof papertray, choiceofoutput 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 protectionfunction,
watermark function
Direction of printing: portrait, landscape
Resolution: 600 dpi
Scan Resolution: 600 dpi/400 dpi/300 dpi/200 dpi
Gradation: 2
Number of output pages: 1-999
Warm-up: Same as copier
CPU: Pentium MMX-166Mhz
Memory: 32MB (standard), expandable up to 160MB (option:MU-403 / MU-
404 / MU-405)
Cards: Controller board x1
PCI relay board x1
KN-303 Network card (option)
Option:Harddisk Drive (HD-103)
PS option (PS-341)

1-2 IP-421 PRINT CONTROLLER
Chapter 1 Overview
Interface: Parallel port
Basedon Centronics(IEEE1284)/Amphenolmale 36pinconnector
Network interface: (option)
KN-303 Network card
Network: Ethernet (100BaseTX/10BaseT)
Protocols: IPX/SPX (NetWare),
TCP/IP (LPD/LPR, peer-to-peer)
AppleTalk (EtherTalk)
Compliant OS:
Windows 95/98
Windows NT4.0/2000
Macintosh
Unix
Printer Language:
PCL
PostScript3 (option)
Printer drivers:
Windows 95/98 printer driver
Windows NT4.0/2000 printer driver
Host computer: A Windows based computer
Macintosh
Unix
Finisher: FS-107
paper tray unit: DB-209,DB-409
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: 10-30˚C,
humidity: 20-80%RH (condensation not allowed)
Restrictive Conditions:
• In the Printermode, the EKC(Electric KeyCounter) of theKonica
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
thedata output isfinished when printdata remainsin theE-RDH.
Notice: Specifications are subject to change for improvements without no-
tice.

1-3 IP-421 PRINT CONTROLLER
Chapter 1 Overview
■Product overview
●Capabilities of the IP-421
The Konica IP-421 print 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-421 print controller is characterized as follows.
•Built in the Konica 7020 series copying machine.
•The drivers interfacing with Windows 95/98 and NT4.0/2000 allow use of the
functions of the Konica 7020 series copying machine.
•The KN-303 Network card allows use of the IP-421 as a network printer.
•A system can be upgraded by the renewal of the flash memory.
This Service Handbook describes hardware construction, disassembly and assembly procedures,
troubleshooting, and appendixes (upgrading firmware, error messages, etc).
IP-421
KN-303
(OPTION)

1-4 IP-421 PRINT CONTROLLER
Chapter 1 Overview
●Startup sequence of the 7020 series + IP-421 system
As the IP-421 is built in the 7020 series, supplying power to the IP-421 and its initialization starts as
soon as you turn on the copier. The startup sequence is as follows.
1. Turn on the copier.
Supplying power to start the IP-421 starts. Its CPU works to test the system memory
and the system program starts running.
2. The IP-421 performs system check.
3. On completion of system check, the controller is waiting print job.
If printer mode is selected, a message “Ready to print”appears.
●Data processing of the IP-421 (See data flow)
When you attempt to print a document data from a computer connected the IP-421, 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-303 is used).
2. The CPU, mounted on IP-421, 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.

1-5 IP-421 PRINT CONTROLLER
Chapter 1 Overview
●Data flow
Interface
Computer
Printer Engine
Parallel I / F
Print Controller
Browser
HTML
Printer Driver
Spooler
Parallel I / F(IEEE1284) Ethernet I/F
(TCP/IP,IPX/SPX)
Network Card KN-303
(Option)
Application
PCI bus
Input Buffer
Harddisk HD-103
(Option)
PCI bus
E-RDH memory
Engine(Print)
Print Commands
Graphic memory
PDL Processing (Rasterization)
PDL command
Rasterized graphic data
Printer status
IP-421

1-6 IP-421 PRINT CONTROLLER
Chapter 1 Overview
■Option
●KN-303 Network card
If the IP-421 is fitted with the KN-303 Network card, the 7020 series can be used as a remote printer
from any computer belonging to a network (NetWare/Windows).
●Hard Disk (HD-103)
By installing this optional hard disk to the IP-421, you can use the 7020 series copier as a scanner.
The scanned data can be read into your PC via an optional Network Interface Card.
●Post Script 3 (PS-341)
By installing this optional PostScript and the standard compact flash for PostScript to the IP-421,
you can use the 7020 series copier as a PostScript printer.

Disassembly / Assembly
2

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2-1 IP-421 PRINT CONTROLLER
Chapter 2 Disassembly / Assembly
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-421 is provided with a “flash memory”, no tool is needed to replace ROM
for upgrading the firmware.
■Construction
PDL compact flash slot
PCI relay
board Parallel port connector
(CN502)
Printer reray board
Expansion memory slot
Controller Board
CPU cooling fan
PS compact flash slot
HD-103 connector
PS-341 slot

2-2 IP-421 PRINT CONTROLLER
Chapter 2 Disassembly / Assembly
■Disassembly/Assembly procedures
●Removal/Installation of boards
1. Remove the sliding cover. (2 screws)
Sliding cover
2. Remove the Board cover. (11 screws)
Board cover
3. Remove the side cover of the parallel connector side. (5 screws)
Side cover

2-3 IP-421 PRINT CONTROLLER
Chapter 2 Disassembly / Assembly
4. Remove the printer relay board. (5 screws)
5. Remove the Board cover fixtures. (6 screws)
Board cover fixtures
Board cover fixtures
6. Remove the controller board unit and the side cover of the copying machine side all to-
gether.(9 screws)