IP-511 IP-511Type-A: Service Manual

SERVICE MANUAL
IP-511 IP-511Type-A
2003.12 Ver. 3.0
2003 KONICA MINOLTA BUSINESS TECHNOLOGIES, INC. Use of this manual should be strictly supervised to avoid disclosure of confidential information. Printed in Japan MN13RN1230
CONTENTS
CONTENTS
SAFETY AND IMPORTANT WARNING ITEMS .........................................................................S-1
1. Overview

Product Specifications (IP-511) ......................................................................................... 1-1
Print Controller specification .................................................................................................................1-1 Network Interface Card specification .................................................................................................1-3-1
Product Specifications (IP-511Type-A) ..........................................................................1-3-2
Print Controller specification ..............................................................................................................1-3-2 Network Interface Card specification .................................................................................................1-3-4
Overview of the Product .................................................................................................... 1-4
Print Controllers Capabilities ...............................................................................................................1-4 Principle of Operation ............................................................................................................................1-5 Data flow ..................................................................................................................................................1-6
2. Disassembly / Reassembly

Overall Construction .......................................................................................................... 2-1
Tools Required ........................................................................................................................................2-1 Removal / Installation of Print Controller .............................................................................................2-2 Removal / Installation of Hard Disk .......................................................................................................2-3 Removal / Installation of PostScript Protection Chip ..........................................................................2-5 Removal / Installation of Memory ..........................................................................................................2-7 Removal / Installation of CPU ................................................................................................................2-8 Removal / Installation of Network Interface Card ..............................................................................2-10 Removal / Installation of System Board .............................................................................................2-11
Disassembly / Reassembly ............................................................................................... 2-2
3. Field Service

25 Mode ............................................................................................................................... 3-1 Updating Print Controller System Program ..................................................................... 3-4
Checking On the Parallel Port Mode (ECP) ..........................................................................................3-4 How to update IP-511 system software (Ver. before 5.7.x => Ver. 5.7.x) ...........................................3-6 System Software Rewriting Procedure .................................................................................................3-7 How to update IP-511 system software (ver. 5.7.x => ver. 6.0.x) ......................................................3-10 How to update IP-511 system software (Ver. 6.0.x => Ver. 6.2.x) .....................................................3-15 How to update IP-511Type-A system software ..................................................................................3-19 Checking for Successful Update ......................................................................................................... 3-23 Error conditions ....................................................................................................................................3-24
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CONTENTS
Rewriting the Network Interface Card Firmware ............................................................ 3-25
Rewriting by FTP Download ................................................................................................................3-25 Rewriting the firmware via the parallel port .......................................................................................3-29 Overview of the Service Port ...............................................................................................................3-30 Installing and Booting Up Hyper Terminal .........................................................................................3-31 Booting Up Service DOS ...................................................................................................................... 3-35 Memory Test Methods ..........................................................................................................................3-36 Recovery of Print Controller System ..................................................................................................3-38
Service Port ....................................................................................................................... 3-30
4. Troubleshooting

Troubleshooting ................................................................................................................. 4-1
Appendix
Components on the Board ...................................................................................Appendix-1
System Board ........................................................................................................................... Appendix-1 Network Interface Card ............................................................................................................ Appendix-2 Factory Default Settings for Network Interface Card ............................................................ Appendix-3
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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 print controller units as well as the risk of damage to the print controller units, Konica Minolta Business Technologies, Inc. strongly recommends that all servicing be performed only by KMBT-trained service technicians. Changes may have been made to this print controller units to improve its performance after this Service Handbook was printed. Accordingly, KMBT 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," and " CAUTION" is 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 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
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SAFETY WARNINGS
[1] MODIFICATIONS NOT AUTHORIZED BY KONICA MINOLTA BUSINESS TECHNOLOGIES, INC.
Konica Minolta brand 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
PROHIBITED ACTIONS:
Using any cables or power cord not specified by KMBT.
Using any fuse or thermostat not specified by KMBT. Safety will not be
assured, leading to a risk of fire and injury.
Disabling fuse functions or bridging fuse terminals with wire, metal clips,
solder or similar object
Disabling relay functions (such as wedging paper between relay contacts).
Disabling safety functions (interlocks, safety circuits, etc.) Safety will not
be assured, leading to a risk of fire and injury.

Making any modification to the print controller units unless instructed by
KMBT.
Using parts not specified by KMBT.
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[2]
CHECKPOINTS WHEN PERFORMING ON-SITE SERVICE
Print controller units are extensively tested before shipping, to ensure that all applicable safety standards are met, in order to protect the customer and customer engineer (hereafter called the CE) from the risk of injury. However, in daily use, any electrical equipment may be subject to parts wear and eventual failure. In order to maintain safety and reliability, the CE must perform regular safety checks.
1. Power Supply
WARNING: Wall Outlet

Check that mains voltage is as specified. Plug the power cord into the
dedicated wall outlet with a capacity greater than the maximum power consumption. If excessive current flows in the wall outlet, fire may result.
If two or more power cords can be plugged into the wall outlet, the total
kw
load must not exceed the rating of the wall outlet. If excessive current flows in the wall outlet, fire may result.
WARNING: Power Plug and Cord

Make sure the power cord is plugged in the wall outlet securely.
Contact problems may lead to increased resistance, overheating, and the risk of fire.
Check whether the power cord is damaged. Check whether the sheath is
damaged. If the power plug, cord, or sheath is damaged, replace with a new power cord (with plugs on both ends) specified by KMBT. Using the damaged power cord may result in fire or electric shock.
Check whether the power cord is not stepped on or pinched by a table and
so on. Overheating may occur there, leading to a risk of fire.
Do not bundle or tie the power cord.
Overheating may occur there, leading to a risk of fire.
Check whether dust is collected around the power plug and wall outlet.
Using the power plug and wall outlet without removing dust may result in fire.
Do not insert the power plug into the wall outlet with a wet hand.
The risk of electric shock exists.
S-3
WARNING: Power Plug and Cord

When unplugging the power cord, grasp the plug, not the cable.
The cable may be broken, leading to a risk of fire and electric shock.
WARNING: Wiring
Never use multi-plug adapters to plug multiple power cords in the same
outlet. If used, the risk of fire exists.

When an extension cord is required, use a specified one.
Current that can flow in the extension cord is limited, so using a too long extension cord may result in fire. Do not use an extension cable reel with the cable taken up. Fire may result.
WARNING: Ground Lead

Check whether the copier / print controller units are grounded properly.
If current leakage occurs in an ungrounded copier / print controller units, you may suffer electric shock while operating the copier / print controller units. Connect the ground lead to one of the following points: a. Ground terminal of wall outlet b. Ground terminal for which Class D work has been done
Pay attention to the point to which the ground lead is connected.
Connecting the ground lead to an improper point such as the points listed below results in a risk of explosion and electric shock: a.Gas pipe (A risk of explosion or fire exists.) b. Lightning rod (A risk of electric shock or fire exists.) c. Telephone line ground (A risk of electric shock or fire exists in the case of lightning.) d. Water pipe or faucet (It may include a plastic portion.)
CAUTION: Power Supply Voltage Setting

When installing a unit which is equipped to operate on manual setting for
power supply and voltage, make sure certainly that the input voltage selection matches to the line voltage at the installation site. Operating a product on voltages different from the specified one may result in malfunctioning or fire.
S-4

2. Installation Requirements
WARNING: Prohibited Installation Place

Do not place the copier / print controller units near flammable materials
such as curtains or volatile materials that may catch fire. A risk of fire exists.
Do not place the copier / print controller units in a place exposed to water
such as rain water. A risk of fire and electric shock exists.
WARNING: Nonoperational Handling

When the copier / print controller units are not used over an extended
period of time (holidays, etc.), switch it off and unplug the power cord. Dust collected around the power plug and outlet may cause fire.
CAUTION: Temperature and Humidity

Do not place the copier / print controller units in a place exposed to direct
sunlight or near a heat source such as a heater. A risk of degradation in copier / print controller units performance or deformation exists. Do not place the copier / print controller units in a place exposed to cool wind. Recommended temperature and humidity are as follows: Temperature: 10C to 30C Humidity: 10% to 80% (no dew condensation) Avoid other environments as much as possible.
CAUTION: Ventilation
Do not place the copier / print controller units in a place where there is
much dust, cigarette smoke, or ammonia gas. Place the copier / print controller units in a well ventilated place to prevent machine problems and image faults.
The copier generates ozone gas during operation, but it is not sufficient to
be harmful to the human body. If a bad smell of ozone is present in the following cases, ventilate the room. a. When the copier is used in a poorly ventilated room b. When taking a lot of copies c. When using multiple copiers at the same time
S-5
CAUTION: Vibration
When installing the copier / print controller units, read the Installation Guide thoroughly. Be sure to install the copier / print controller units in a
level and sturdy place. Constant vibration will cause problems.

Be sure to lock the caster stoppers of copier / print controller units.
In the case of an earthquake and so on, the copier / print controller units may slide, leading to a injury.
CAUTION: Inspection before Servicing

Before conducting an inspection, read all relevant documentation (service
handbook, technical notices, etc.) and proceed with the inspection following the prescribed procedure, using only the prescribed tools. Do not make any adjustment not described in the documentation. If the prescribed procedure or tool is not used, print controller units may break and a risk of injury or fire exists.
Before conducting an inspection, be sure to disconnect the power plugs from the copier and print controller units.
When the power plug is inserted in the wall outlet, some units are still powered even if the POWER switch is turned OFF. A risk of electric shock exists.
The area around the fixing unit is hot.
You may get burnt.
DANGER: Work Performed with the Copier / Print controller units Powered
Take every care when making adjustments or performing an operation
check with the copier / print controller units powered. If you make adjustments or perform an operation check with the external cover detached, you may touch live or high-voltage parts or you may be caught in moving gears or the timing belt, leading to a risk of injury.
Take every care when servicing with the external cover detached.
High-voltage exists around the drum unit. A risk of electric shock exists.
S-6
WARNING: Safety Checkpoints

Check the exterior and frame for edges, burrs, and other damages.
The user or CE may be injured.

Do not allow any metal parts such as clips, staples, and screws to fall into
the print controller units. They can short internal circuits and cause electric shock or fire.
Check wiring for squeezing and any other damage.
Current can leak, leading to a risk of electric shock or fire.

When disconnecting connectors, grasp the connector, not the cable.
(Specifically, connectors of the AC line and high-voltage parts) Current can leak, leading to a risk of electric shock or fire.
Carefully remove dust from electrical parts.
Current can leak, leading to a risk of print controller units trouble or fire.
Check cables and sheaths for any damage.
Current can leak, leading to a risk of electric shock or fire.
When replacing a lithium battery, replace it with a new lithium battery
specified in the Parts Guide Manual. Dispose of the used lithium battery using the method specified by local authority. Improper replacement can cause explosion.
Make sure the wiring cannot come into contact with sharp edges, burrs, or
other pointed parts. Current can leak, leading to a risk of electric shock or fire.
Make sure that all screws, components, wiring, connectors, etc. that were
removed for safety check and maintenance have been reinstalled in the original location. (Pay special attention to forgotten connectors, pinched cables, forgotten screws, etc.) A risk of print controller units trouble, electric shock, and fire exists.
Xpcs?
CAUTION: Safety Checkpoints

When transporting or storing electrical boards or electrical parts, be sure
to contain them in an anti-static packaging. Otherwise, there is a risk that error conditions may occur.
S-7
CAUTION: Safety Checkpoints

Discharge static electricity from your body by touching metallic parts of
appropriate fixtures before starting to carry out work on a carpet or at a location where the human body is likely to be charged with static electricity. Otherwise, there is a risk that electrical parts can be damaged. (It is recommended that you wear an anti-static wrist strap.)
Use a dedicated PLCC pull-out tool when removing IC parts such as PS
chips or other chips. Using other tools may result in damaging the chip socket or the chip itself.
Never touch the terminal of electrical parts with hands.
To do so may result in a poor electrical conductivity. In extreme cases, error conditions may occur.
When inserting boars/parts into slots in electrical boards (like the PCI, ISA,
or Memory slots, for example), do so carefully and firmly. A careless insertion may be responsible for a poor electrical conductivity. In extreme cases, error conditions may occur.
S-8
[3]
MEASURES TO TAKE IN CASE OF AN ACCIDENT

emergency measures to provide relief to affected persons and to prevent further damage.
1. If an accident has occurred, the distributor who has been notified first must immediately take 2. If a report of a serious accident has been received from a customer, an on-site evaluation must be carried out quickly and KMBT 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 issued by KMBT. 4. For reports and measures concerning serious accidents, follow the regulations given in "Serious Accident Report/Follow-up Procedures."
[4]
CONCLUSION
tration. Therefore, safety can be maintained by the appropriate daily service work conducted by the customer engineer.
1. Safety of users and customer engineers depends highly on accurate maintenance and adminis-
2. When performing service, each print controller units on the site must be tested for safety. The customer engineer must verify the safety of parts and ensure appropriate management of the equipment.
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1
Overview
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Chapter 1 Overview
Product Specifications (IP-511)

Print Controller specification
Type: Paper: Built-in box type for the KONICA Printer/Copier 5.5X8.5 / 8.5x11 / 8.5x14 / 11x17 / A3 / A4 / A5 / A6 / B4 / B5 / B6 / F4 / 8K / 16K / 5.5X8.5W / 8.5x11W / 11x17W / A3W / A4W / A5W / B4W / B5W Same as the copier Same as the copier The dual operation of the copier and the printer is available (5 jobs, including scanning jobs, can be processed at the maximum.) Offset, Staple Function, Combination, Punch Function, Fold and Stitch Function, Wait Mode Function, Image Shift Function, Password Printing, Chapter, Image Storage, Form Overlay Function, Front/Back Cover Function, etc. Portrait and Landscape Printing System: 600 x 600 dpi Scanning System: 200 dpi / 300 dpi / 400 dpi / 600 dpi 1 bit 1 to 9999 65 ppm (A4, 8.5 x 11) / (with KONICA 7165: 600 x 600 dpi) *1 55 ppm (A4, 8.5 x 11) / (with KONICA 7155: 600 x 600 dpi) *1 Standard: Top and bottom Margins: 4.0 mm Right and Left Margins: 4.0 mm Wide Size: Margin is 0 mm as compared to the standard size. Max. Printable Area: 298 x 458 mm
Paper Feeding and Amount of Feeding Paper: Load Output Paper: Mode:
Special Printing:
Orientation: Resolution: Gradation: No. of Print: Continuous print speed: Printable Area:
Warm-up time: Basic Configuration: CPU: System Memory:
Same as the copier
Intel Celeron 566 MHz 64 MB SD-RAM (Standard), Expandable up to 192 MB (Option: MU-404 / MU-405) Parallel port Centronics (IEEE 1284 / amphenol 36 pin male connector) Ethernet (100BaseTX / 10 BaseT) 2 GB PCL5e Adobe PS3 (optional PS3 kit required)
Host Interface: Network Interface: Hard disk drive: Printer Description Language:
Built-in fonts:
Agfa Microtype fonts
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Chapter 1 Overview
Compliant OS: Windows 95/98/Me Windows NT 4.0 (NT Service Pack 3 or more) Windows 2000/XP Mac OS 7.x - 9.x (optional PS3 kit required) Printer driver for Windows 95/98/Me/NT 4.0/2000/XP PS printer driver for Windows (optional PS3 kit required) PS printer driver for Macintosh (optional PS3 kit required) A Windows-based computer Macintosh (optional PS3 kit required) PS-351 (PostScript Option) memory: MU404 (64 MB) / MU-405 (128 MB) 190 mm(W) x 240 mm(D) x 35 mm(H) 7.5" (W) x 9.5" (D) x 1.4" (H) Approx. 2.3 kg Approx. 5.0 pounds Suplied from the copier Temperature: 10 degree C to 30 degree C 50 degree F to 86 degree F Humidity: 10 % to 80 %RH (non-condensing)
Printer Driver:
Compliant Host Computer: Option: Dimension: Weight: Power: Working Environment:
Restrictive Conditions Although the Weekly Timer function of the main body printer 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. *1Numbers in the case of continuous printing following the storage of all pages in E-RDH memory, or numbers in the case of printing the same image on multiple papers.
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Chapter 1 Overview
Network Interface Card specification
CPU: Memory Frame Type: Ethernet Connection: Network Connector: Protocols: Compliant OS (NOS):
NCC NET+ARM Processor 2 MB RAM IEEE 802.2/802.3/Ethernet II/IEEE 802.3 SNMP 10Base-T/100Base-TX RJ-45 TCP/IP (BOOTP, ARP, RARP, ICMP, DHCP, SNMP, HTTP, SMTP, FTP, IPP), IPX/SPX, AppleTalk (EtherTalk) Novell NetWare (3.x, 4.x), Microsoft Windows 95/98/Me, Microsoft Windows NT 4.0, Microsoft Windows 2000/XP, UNIX, MAC OS 7.x - 9.x Automatic selection Peer-to-Peer (TCP/IP for Windows 95/98/Me), Pserver (IPX/SPX), LPD/LPR (TCP/IP for Windows NT 4.0/2000/XP), lpd/lpr (TCP/IP for UNIX), AppleTalk (EtherTalk) IP-P2P, IPX-P2P, MAP (Management Access Program), NWSetup, UNIX-TCP/IP Programs Web Browser (Netscape Navigator, Internet Explorer) 0 to 50 degrees Centigrade, 5% to 80% RH Green LED, Yellow (amber) LED (one each) Stored in nonvolatile memory
Multiple Protocols: Printing Method:
Dedicated Utilities: Standard Utilities: Operating Conditions: Status Indicators: Settings:
Note: Specifications are subject to change without notice.
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METHOD REPLACEMENT
Chapter 1 Overview
Product Specifications (IP-511Type-A)

Print Controller specification
Type: Paper: Built-in box type for the KONICA Printer/Copier 5.5X8.5 / 8.5x11 / 8.5x14 / 11x17 / A3 / A4 / A5 / A6 / B4 / B5 / B6 / F4 / 8K / 16K / 5.5X8.5W / 8.5x11W / 11x17W / A3W / A4W / A5W / B4W / B5W Same as the copier Same as the copier The dual operation of the copier and the printer is available (5 jobs, including scanning jobs, can be processed at the maximum.) Offset, Staple Function, Combination, Punch Function, Fold and Stitch Function, Wait Mode Function, Image Shift Function, Password Printing, Chapter, Image Storage, Form Overlay Function, Front/Back Cover Function, etc. Portrait and Landscape Printing System: 600 x 600 dpi Scanning System: 200 dpi / 300 dpi / 400 dpi / 600 dpi 1 bit 1 to 9999 72 ppm (A4, 8.5 x 11) / (with KONICA 7272: 600 x 600 dpi) *1 55 ppm (A4, 8.5 x 11) / (with KONICA 7255: 600 x 600 dpi) *1 Standard: Top and bottom Margins: 4.0 mm Right and Left Margins: 4.0 mm Wide Size: Margin is 0 mm as compared to the standard size. Max. Printable Area: 298 x 458 mm
Paper Feeding and Amount of Feeding Paper: Load Output Paper: Mode:
Special Printing:
Orientation: Resolution: Gradation: No. of Print: Continuous print speed: Printable Area:
Warm-up time: Basic Configuration: CPU: System Memory:
Same as the copier
Intel Celeron 566 MHz 64 MB SD-RAM (Standard), Expandable up to 192 MB (Option: MU-404 / MU-405) Parallel port Centronics (IEEE 1284 / amphenol 36 pin male connector) Ethernet (100BaseTX / 10 BaseT) 2 GB PCL5e Adobe PS3 (optional PS3 kit required)
Host Interface: Network Interface: Hard disk drive: Printer Description Language:
Built-in fonts:
Agfa Microtype fonts
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METHOD ADDITION
Chapter 1 Overview
Compliant OS: Windows 95/98/Me Windows NT 4.0 (NT Service Pack 3 or more) Windows 2000/XP Mac OS 8.x - 9.x (optional PS3 kit required) Mac OS X v10.2 (optional PS3 kit required) Printer driver for Windows 95/98/Me/NT 4.0/2000/XP PS printer driver for Windows (optional PS3 kit required) PS printer driver for Macintosh (optional PS3 kit required) A Windows-based computer Macintosh (optional PS3 kit required) PS-351Type-A (PostScript Option) memory: MU404 (64 MB) / MU-405 (128 MB) 190 mm(W) x 240 mm(D) x 35 mm(H) 7.5" (W) x 9.5" (D) x 1.4" (H) Approx. 2.3 kg Approx. 5.0 pounds Suplied from the copier Temperature: 10 degree C to 30 degree C 50 degree F to 86 degree F Humidity: 10 % to 80 %RH (non-condensing)
Printer Driver:
Compliant Host Computer: Option: Dimension: Weight: Power: Working Environment:
Restrictive Conditions Although the Weekly Timer function of the main body printer 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. *1Numbers in the case of continuous printing following the storage of all pages in E-RDH memory, or numbers in the case of printing the same image on multiple papers.
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METHOD ADDITION
Chapter 1 Overview
Network Interface Card specification
CPU: Memory Frame Type: Ethernet Connection: Network Connector: Protocols: Compliant OS (NOS):
NCC NET+ARM Processor 2 MB RAM IEEE 802.2/802.3/Ethernet II/IEEE 802.3 SNMP 10Base-T/100Base-TX RJ-45 TCP/IP (BOOTP, ARP, RARP, ICMP, DHCP, SNMP, HTTP, SMTP, FTP, IPP), IPX/SPX, AppleTalk (EtherTalk) Novell NetWare (4.x-6.x), Microsoft Windows 95/98/Me, Microsoft Windows NT 4.0, Microsoft Windows 2000/XP, UNIX, MAC OS 8.x - 9.x, Mac OS X v10.2 Automatic selection Peer-to-Peer (TCP/IP for Windows 95/98/Me), Pserver (IPX/SPX), LPD/LPR (TCP/IP for Windows NT 4.0/2000/XP), lpd/lpr (TCP/IP for UNIX), AppleTalk (EtherTalk) IP-P2P, IPX-P2P, MAP (Management Access Program), NWSetup, UNIX-TCP/IP Programs Web Browser (Netscape Navigator, Internet Explorer) 0 to 50 degrees Centigrade, 5% to 80% RH Green LED, Yellow (amber) LED (one each) Stored in nonvolatile memory
Multiple Protocols: Printing Method:
Dedicated Utilities: Standard Utilities: Operating Conditions: Status Indicators: Settings:
Note: Specifications are subject to change without notice.
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Chapter 1 Overview
Overview of the Product

Print Controllers Capabilities
The print controller is a print controller to serve as a printer or as a network scanner when used in combination with the copier that may be connected to computers or to networks. This print controller gets files from computers or over networks and resolves their contents into image data for the copier to be able to print out. Still more, an integrated network interface card lets the copier work as a network scanner, thus making it possible to send images scanned into the copier to e-mail recipients as an attachment, or to store those scanned images on the hard disk in the print controller and import them into Adobe Acrobat or other TWAINcompliant applications. This service handbook offers information on components, assembly/disassembly procedures, the rewriting of system software, service port, troubleshooting, and jumper settings and so on.
Copier
For use as a network printer
Print Controller
For use as a local printer
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Chapter 1 Overview
Principle of Operation
The print controller includes a 566-MHz Intel Celeron CPU to do high-speed image processing (rasterization). It also includes a 64 MB memory as standard so as to be capable of, while transferring a rasterized image data of the current page to the print engine, rasterizing at the same time the image data of the next page, and this memory is expandable to 192 MB to accommodate extremely complex print data processing requirements. This design enables the print controller to produce outputs at high speed without causing the print engine to stop in the process even when processing a large number of pages. The print controller system software runs on VxWorks from Wind River and is included on the standard hard disk. This hard disk is also used to store data scanned by the copier. The scanned data is sent to PCs via the standard Ethernet Network Interface. The transmission and reception of scanned data between the print controller and the print engine is a task of a built-in engine interface (video interface). As well, the serial interface gives access to the system in the print controller and is used when restoring the system software for example.
Network Interface Card
System Board
Memory (Optional)
Network Control ROM
Network Memory
PS Protection Chip
CPU
Memory (Standard)
BIOS (Flash ROM)
North Bridge
ISA Bus
PCI Bus
South Bridge
Network I/F
Network Control CPU
Network Control ROM (Flash ROM)
Serial I/F
HDD
Rasterization Parallel I/O
Engine I/F
Ethernet Network
Service Port Parallel Port Engine
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METHOD REPLACEMENT
Chapter 1 Overview
Data flow
Computer
Application Print Commands Printer Driver Spooler Browser HTML
Parallel I/F ( IEEE 1284 )
Ethernet Network I/F

( TCP/IP, IPX/SPX, AppleTalk )
Interface
Print Controller
Parallel I/F Input Buffer
ISA bus
Hard Disk
PDL Processing ( Rasterization ) / Interpreter
Page Memory
Main body printer
PCI bus E-RDH memory
Print Engine ( Print )
PDL command
Rasterized image data
Printer status
1-6
2
Disassembly / Reassembly
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Chapter 2 Disassembly / Reassembly
Overall Construction
Hard Disk Overall Cooling Fan PostScript Protection Chip Network Interface Card CPU Cooling Fan Heat Sink CPU System Board Expanded Memory
Cover Hard Disk
Board Cover
CPU Cooling Fan Heat Sink
Overall Cooling Fan PostScript Protection Chip Network Interface Card
CPU Expanded Memory
System Board
Tools Required
Standard screwdriver Spanner or needle-nose pliers PLCC pull-out tool
Caution
Be sure to unplug the power cable, not only to turn the copier off, before attempting to make servicing. Avoid making servicing the copier with the print controller outfitted.
Caution
Before engaging in Disassembly/Reassembly, check to make sure that all the cables are unplugged from the print controller. Use in-magnetized tools in Disassembly/Reassembly to prevent the hard disk being affected. There are occasions when boards are damaged if no appropriate grounding measures are taken. Wear a wrist strap or others during servicing. Disassembly/Reassembly should be made on cushioning materials.
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Disassembly / Reassembly
Caution: Installation
Assembly should be made in reverse order of disassembly unless otherwise noted.
Removal / Installation of Print Controller
1. 2. 3.
Press the copier's main power switch off, and unplug the power cord from the AC outlet. Unplug the network cable and the parallel cable from the print controller. Remove four screws from the copier, and remove the plastic cover.
Caution: Removal
In removing the plastic cover, care should be taken not to damage the parallel cable holding levers.
Screw
Plastic Cover
4.
Remove six screws, and remove the print controller from the copier.
Caution: Removal Installation

In removing the print controller, pull it horizontally. In assembly, align the print controller to the lower two pins in the copier.
Upper hook
Screw Pin
Screw
2-2
Removal / Installation of Hard Disk

The hard disk contains the system software for operating the print controller. The hard disk needs to be replaced when the copier does not start up at all and the recovery/rewriting procedure is of no avail. In replacing the hard disk, be sure to use a hard disk specifically designed for the print controller. The use of any other hard disks is not allowed.
1.
Remove three screws, and open the cover as shown.
Caution: Removal
In opening the cover, you should be aware that the hard disk is mounted to the back of the cover and is attached to a connector.
Screw
Cover
2.
Turn the cover over, and disconnect the connector from the hard disk.
Connector
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DATE Dec 2003
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2-3
METHOD REPLACEMENT
3.
Remove four screws, and remove the hard disk unit from the cover.
Screw
4.
Remove four screws, and remove the earth plates and hard disk mounting brackets.
You don't need to remove the rubber insert from the hard disk mounting bracket at replacement. Rubber Insert Rubber Insert Earth Plate Hard Disk Mounting Bracket
Rubber Insert
Rubber Insert
Earth Plate
Screw
Hard disk Mounting Bracket
Screw
Hard Disk Mounting Bracket
Install new hard disk in reverse order of removal. When mounting the hard disk mounting brackets to the hard disk, use
the tightening torque T of from 0.4 to 0.5 (Nm) and also check for deformation or distortion. You should be aware of the orientation of the connector for the hard disk and the orientation of the label (this should be up).
Label Connector Joint Red line
2-4
Removal / Installation of PostScript Protection Chip

The PostScript protection chip is mounted only in a print controller equipped with PostScript option, a PostScript option. Normally, there is no need to remove/reinstall the PostScript protection chip. However, it should be removed and reinstalled when replacing the network interface card. To remove the PostScript protective chip, you need to remove the Overall cooling fan or there is no space in which to manipulate your PLCC pull-out tool.
Caution
The PostScript protection chip is sensitive to static electricity. Handle it with care.
1. 2.
Remove three screws, open the cover to the back of which the hard disk is mounted, and remove the hard disk.
Refer to "Removal / Installation of Hard Disk."
Remove sixteen screws, and remove the board cover.

Screw Screw Board Cover
Screw
Screw
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METHOD REPLACEMENT
3.
Remove the overall cooling fan, remove four screws from the cooling fan mounting plate, then remove the cooling fan mounting plate.
Screw Cooling Fan Mounting Plate DC Connector for the Overall Cooling Fan
Network Interface Card DC Connector for the Overall Cooling Fan Cooling Fan Mounting Plate
Screw
4.
Remove the PostScript protection chip using a PLCC pull-out tool such as shown below.
In installing the chip, fit the corners into the socket.
PostScript Protection Chip
PLCC pull-out Tool
2-6
Removal / Installation of Memory

Memory Slot
1. 2. 3.
Remove three screws, open the cover to the back of which the hard disk is mounted, and unplug the hard disk connector.

Refer to "Removal / Installation of PostScript Protection Chip."
Remove the memory unit by pushing the levers outwards with both hands as if to open them.
Memory Slot Lever
tor.
In installing the memory unit, push it in obliquely relative to the connec-
Slot for Memory
Memory Unit
Push down the upper end of the memory unit, and fasten it in place
with the levers.
2-7
Removal / Installation of CPU
1. 2. 3.
Remove three screws, and open the cover to the back of which the hard disk is mounted.

Remove the DC connector for the CPU cooling fan from the system board.
DC Connector for CPU Cooling Fan Mounting Bracket A
Mounting Bracket A Mounting Bracket B
Mounting Bracket B
4.
Push down and remove heat sink Mounting bracket A that hangs on a lever in the CPU socket.
Caution
Great care is needed so that the bracket does not touch and damage the circuit pattern on the board.
Mounting Bracket A
2-8
5.
Tilt the heat sink to one side and remove Mounting bracket B.
Caution
Great care is needed so that the bracket does not touch and damage the circuit pattern on the board.
Mounting Bracket B
6. 7.
Slowly pull up and remove the heat sink. Lift up the lock lever that holds the CPU in the socket and take the CPU out of the socket.
CPU
Lock Lever
Installation should be made in reverse order of removal. In installing the heat sink, first fasten it with Mounting bracket B then
with bracket A.
In installing the CPU, be aware of the guide pin that prevents you from
installing it way round.
When replacing the CPU, the heat sink also needs to be replaced.
2-9
Removal / Installation of Network Interface Card
1. 2. 3.
Remove three screws, open the cover to the back of which the hard disk is fastened, and remove the hard disk.

Unplug the connector from the overall cooling fan, remove four screws from the cooling fan board, and remove the cooling fan mounting plate.
Screw Cooling Fan Mounting Plate DC Connector for the Overall Cooling Fan
Screw
4.
Remove four hexagonal nuts from the network interface card, and remove the network interface card.
Caution: Removal
In removing the network interface card, care should be taken not to damage the network connector and LEDs.
Network Interface Card Hexagonal Nut
Jumper
Hexagonal Nut
JP7 JP6 JP5 JP4 JP3 JP2 JP1
Jumper
Install the network interface card in reverse order of removal.
2-10
Removal / Installation of System Board
1. 2.
Remove the hard disk, board cover, and network interface card.
Refer to "Removal / Installation of Network Interface Card."
Remove five screws and four hexagonal nuts from the system board, and remove the connector fastening pieces (two screws and two hexagonal nuts), then remove the system board.
Caution: Removal
In removing the system board, care should be taken not to damage any boards and connectors.
Connector section fastening screws
Screw
Hexagonal Nut
System Board Hexagonal Nut Screw
Hexagonal Nut Screw
Install the system board in reverse order of removal.
2-11
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3
Field Service
Blank Page
Chapter 3 Field Service
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.
A. 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 25 mode menu screen, select [Software DIPSW Settings].
The 25 mode menu screen appears on the operation panel.
B. Definable Settings
Printer PWM clip value (08-0, 08-1)
Set up this item when changing the PWM clip value in the printer mode.
PWM clip value DIPSW No. 08-0 08-1 Normal (235) Darker Lighter Supper Light
(default)
0 0
(255)
1 0
(175)
0 1
(150)
1 1
Operation when key counter is removed (09-1)

This setting determines what action a copier equipped with a key counter takes when the key counter dislodges from its position.
DIPSW No. 09-1 Operation when key counter is removed Ignore (default) 0 Same as in copier mode 1
NOTE:
The action taken when DIPSW is set to [1] depends on the setting for "DIPSW 09-0 Action in the case where the key counter dislodges (in copier mode)". For more information about this, refer to the copier's service handbook.
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METHOD REPLACEMENT

Reserved Memory Size (10-0, 10-1)
Set this setting to reserve a space for data extension in the memory mounted in the copier. Be sure to set this setting when connecting print controller.
DIPSW No. 10-0 10-1 Reserved memory size 0 MB (default) 0 0 32 MB 1 0 64 MB 0 1
NOTE:
Set the reserved memory size setting to 32 MB when the standard memory (64 MB) is used in the copier. If, with this setting, a memory extension error turns up, expand the copier's memory. If the memory is expanded to 128 MB or more and a memory extension error persists, set the reserved memory size setting to 64 MB.
Setting of duplex print shift from Adobe PS driver (10-3)

When the "Image Shift" function is used for the duplex print from the Adobe PS driver, printing is made with the set value for the "application function - margin" of the copier. 0: 1: Front shift set to the copier is reflected to the shift on both the front and back sides of the printer output. Shift on the front and back sides set to the copier is reflected to the front and back sides of the printer output.
Setting of print shift on both sides DIPSW No. Simultaneous shift on front and back 0 Simultaneous shift on front and back 1
10-3
Default Dmax Value (15-6)

Set this setting, exclusively in printer mode, to increase print density or inversely reduce toner consumption.
DIPSW No. 15-6 Dmax value in printer mode 1.43 (default) 0 1.35 1
C(K) Count in Printer Mode (16-3)

This setting determines whether or not the number of output sheets of paper is counted when a copier equipped with a key counter is used in printer mode.
DIPSW No. 16-3 C(K) count in printer mode Not counted (default) 0 Count 1
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METHOD REPLACEMENT

Default Scanning Resolution (19-6, 19-7)
This setting determines a default value for scanning resolution.
DIPSW No. 19-6 19-7 Default scanning resolution option 400 dpi (default) 0 0 600 dpi 1 0 200 dpi 0 1 300 dpi 1 1
Disable Staple with Mixed Original (21-0)

The default produces a print output (in real time) each time data whose size corresponds to one sheet of print is stored in the copier's E-RDH. With this default setting, printing stops if staple and mixed original are both set. To make the print job be output, you can change this setting.
Disable staple with mixed original DIPSW No. Enable (real time output) (default) 0 Disable (loading print data in a group) 1
21-0
NOTE:
Selecting loading print data in a group does not make staple effective with mixed size documents: The staple is cancelled and a ordinary printing is performed. In addition, since multiple pieces of print data are read in in a group before producing printouts, it is likely that a memory extension error occured in E-RDH when you try to get a file of large size printed out.
Scanner mode using 600dpi/400dpi (21-7)

Set up this item when not using 600dpi/400dpi for the reading resolution in the scanner mode.
DIPSW No. 21-7 Scanner mode using 600dpi/400dpi Enable (default) 0 Disable 1
Action upon Entry of Unidentifiable User ID (23-1)

This setting determines what action a copier with the EKC feature switched ON takes in printer mode when an unidentifiable User ID is entered. Here, "Unidentifiable User ID" includes "No User ID".
Action upon entry of unidentifiable User ID DIPSW No. Print out seeing the job as from EKC or other authorized user (default) 0 Terminate without printing out 1
23-1
NOTE:
When selecting "Terminate without printing out", a print job is registered on the Non Complete Job List when it is requested with an unidentifiable User ID.
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METHOD REPLACEMENT

Face-up Output with Thick Paper2 + Subtray Selected (23-7)
Set this setting to let thick sheet 2 be output face-up of the subtray.
DIPSW No. 23-7 Face -up output with thick sheet 2 + subtray selected No (default) 0 Yes 1
IP scanner image format (25-0) (IP-511 only)

Select the scanner image storage format.
IP scanner image format DIPSW No. TIFF only. 0 Either TIFF or PDF can be selected from the control panel. 1
25-0
Rotation control for mixplex print (25-2)

Select the image rotating direction control method on the back side in mixplex printing. Determine the image direction fixedly for each unit of job. Determine the image rotating direction according to the information (size or image direction) for each page.
DIPSW No. 25-2 Mixplex print rotating control In the unit of job 0 In the unit of page 1
Selection of sub machine shifting method for tandem print (25-6)

Select the data on the image shifting size used for the sub-machine in tandem printing.
Sub machine shifting method for tandem printing DIPSW No. Use of data for master machine 0 Use of data for sub machine 1
25-6
PROOF PRINT/Wait Mode for tandem print (25-7)

Set whether or not to activate the PROOF PRINT/Wait Mode function for the tandem printing. When this function is activated for the sub-machine also, DIPSW21-5 (assignment recovery of tandem printing) should be set to 1 (No).
DIPSW No. 25-7 PROOF PRINT/Wait Mode for tandem printing No 0 Yes 1
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MixPlex-compatible (28-0)
Set up this item when using MixPlex in the printer mode. Be sure to set up this item when using a printer driver compatible with MixPlex. Default IP-511 :0 IP-511Type-A :1
DIPSW No. 28-0 Compatibility with MixPlex No 0 Yes 1
Disabling the scanner mode (28-1) (IP-511 only)

Set up this item when disabling the scanner.
DIPSW No. 28-1 Able/disable scanner mode Able (default) 0 Disable 1
IP scanner registration name in Japanese (28-7) (IP-511 only) (Japan only)

Select whether to enable the scanner name registration in Japanese from the WEB utility.
DIPSW No. 28-7 IP scanner registered name in Japanese Yes 0 No 1
Prevention of memory overflow in printing job (29-1, 29-2)

Setting to prevent PC timeout due to memory overflow when the engine stops because of paper shortage or so when printing data from the printer controller. When residual memory of E-RDH reaches the specified value, data transfer speed from the print controller is reduced to prevent overflow.
Prevention of memory overflow in printing job DIPSW No. No 0 0 Residual memory 10% 1 0 Residual memory 20% 0 1 Residual memory 30% 1 1
29-1 29-2
Default selection of IP scanner function (29-5, 29-6)

When specifying the IP scanner function, set the function to be selected as default.
DIPSW No. 29-5 29-6 Prevention of memory overflow in printing job E-mail 0 0 HDD 1 0 FTP 0 1 E-mail 1 1
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METHOD ADDITION
Updating Print Controller System Program

By rewriting the firmware (system software), you can update the version without having to replace the board.
Caution
There is no way of newly installing the system program in the formatted hard disk. Limitations: The updating of the print controller system software under the following conditions is not guaranteed to be completed successfully. There are occasions when the system software is not correctly rewritten and, as a result, you cannot let the print controller start. The machine is operating or there are certain jobs left uncompleted. Modes are enabled such as 25/36/47, Key Operator, Service and Interruption. An E or F error or a paper jam is not removed.
Checking On the Parallel Port Mode (ECP)

Determine whether the parallel port is set to [ECP] mode in the LPT1 settings as follows: In the following, we use the Windows 98 as an example.
1. 2. 3.
Click the Windows [Start] button, and select [Settings]-[Printers]. Click the printer icon selected by default, and right-click [Properties]. Click [Details], and check to see that [LPT1: (ECP Printer Port)] is selected in [Print to the following port].
Caution
When the ECP mode is not selected, it is possible that the PC may not support the ECP mode or that ECP may not be selected in the BIOS settings. If the PC supports the ECP mode, set the parallel port to the [ECP] mode in the BIOS settings. How to set the BIOS settings differs from PC to PC.
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METHOD REPLACEMENT
4.
In the [Properties] dialog box, click [Port Settings] to check to see that the followings are selected:
[Spool MS-DOS print jobs] [Check port state before printing]
5.
Click [Apply] then [OK].
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How to update IP-511 system software (Ver. before 5.7.x => Ver. 5.7.x)
To upgrade, you need the following:
IBM PC/AT-compatible PC OS: Windows 95/98/Me/NT4.0/2000 With parallel interface equipped Parallel cable Anphe.36 pins - D-sub 25 pins (Length 2m or less, IEEE1284 compatible) Data file to be updated
Preparation
Acquire or print all of the required scanner data and password print data in advance. Make a Caution of the controller setting and other required setting information Set the parallel port mode to "ECP" by the computer BIOS setting. (For the parallel port mode, refer to p. 3-4.) Make sure that the print controller vanner page setting is OFF (default).
Caution
IP-511 update file must be installed before installation of Ver. 5.7.0 of Print controller firmware. If you install the Print controller firmware Ver. 5.7.0 first, IP-511 does not startup. In this case, it is necessary to restore the print controller system by starting up DOS for service after connecting the IP-511 with PC via service port. Please see "Recovery of Print Controller System"(p. 3-38) for the print controller system restoring procedure. Network interface card (NIC) firmware must be rewritten to [Ver. 6.28D] or later before installing print controller firmware Ver. 5.7.0. If the print controller firmware Ver. 5.7.0 is installed first, NIC firmware cannot be rewritten. In this case, re-install the IP-511 firmware ver. 5.5.5a or earlier then rewrite the NIC firmware.
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3-6
METHOD REPLACEMENT
System Software Rewriting Procedure
1.
Connect a parallel cable between the PC and the Print Controller.
2. 3.
Turn the copier's main power on. Press the mode switching button on the operation panel to switch the screen to Printer Mode Basic screen.
A printer menu screen will appear.
4.
Select [YES] in [Network Setup] - [Print on Startup].
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METHOD REPLACEMENT
5. When the icon gets [IDLE], open a DOS prompt, input the following
command then install the IP-511 update file.
Command: C:\>copy ip511update.pkg lpt1 /b The message [Updating print controller F/W] will appear on the LCD panel.
Caution
Avoid operating the PC and the copier as long as the message [Updating print controller F/W] is displayed on the copier's LCD panel. The print controller may be damaged if you turn the copier's main power off while this message is displayed.
6.
Upon completion of the updating process, the message [Update Successful] is displayed, then turn the copier OFF and turn ON again after 10 seconds.
7.
After approx. 4 minutes, NIC config page is automatically printed. Then, check the network interface card firmware version on it.
There is chance an error occured the updating process is not completed in about 15 minutes. If this is the case, turn the copier's main power off, then turn it back on, before letting the updating process start from the beginning. (Remember, however, the time it takes for the updating process to be completed depends on the computer performance.) If an error occured the updating process, the software is not updated and the old version remains in effect.
8.
Rewrite the Network interface card firmware to Ver. 6.28D with FTP Download (Refer to "Rewriting by FTP Download"(p. 3-25)).
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3-8
METHOD REPLACEMENT
9. 10.
When you see the FTP download screen, [Do not reset this unit during the next 4 minutes], click [OK] and leave the machine 4 minutes. After approx. 4 minutes, NIC config page is automatically printed. Then, Check the network interface card firmware version is Ver. 6.28D.
Caution
After rewriting Network interface card firmware to Ver. 6.28D, do not turn OFF/ON the power switch of the main body. If the power switch is turned OFF/ON, the LCD shows that IP511 is [INITIAL]. This is only display problem due to mismatching between print controller firmware Ver. 5.5.5a or earlier and Ver. 6.28D. When the Status page is printed as usually that means IP is started up normally. Please continue next step.
11. 12.
Install IP-511 firmware (filename.pkg) by following the firmware installation procedure (Step 1-5). After installation, follow the instruction on LCD and turn OFF the main power switch of main body then turn ON again after 10 seconds.
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METHOD REPLACEMENT
How to update IP-511 system software (ver. 5.7.x => ver. 6.0.x)
Caution
This upgrading procedure is for the IP-511 of system software Ver. 5.7x. For the system software of Ver. 5.6 or before, perform upgrading of the system software to Ver. 5.7.x before this upgrading procedure. Upgrading from the Ver. 5.6.x or before may destruct the system software in same cases. To upgrade the system software from Ver. 5.7.x to Ver. 6.0x, follow the procedure below. You need to use Tera Term Pro Ver. 2.3, a terminal emulator (communication program) of free software, for this upgrading.
Download Tera Term Pro Ver. 2.3 from the site below and install it into the personal computer in advance to use it for the upgrading: http://hp.vector.co.jp/authors/VA002416/teraterm.html
Summary of system software upgrading procedure

Send the file to be upgraded to the controller and upgrade the firmware. Start up the Tera Term Macro IP511UG.ttl. Turn off the main power switch of the copier and then on again to restart the copier. Upgrading is automatically performed in the print controller (taking about 30 minutes). After the message,"UPDATE DONE!", is indicated on the Tera Term, turn off the copier and then on again to restart. Confirm that the upgrading is completed.
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METHOD REPLACEMENT

IBM PC/AT-compatible PC OS: Windows 95/98/Me/NT4.0/2000/XP With parallel interface equipped Parallel cable Anphe.36 pins - D-sub 25 pins (Length 2m or less, IEEE1284 compatible) Data file to be updated Tera Term Pro Ver. 2.3 (terminal communication program) Setting conditions Pit/sec. : 9600 (fixed) Data bit Parity Stop bit :8 : None :1
Flow control : None RS-232C serial cable (terminated in a female 9-pin D-Sub connector on both ends) Upgrade package Macro for TeraTerm
Preparation
Acquire or print all of the required scanner data and password print data in advance. Make a Caution of the controller setting and other required setting information Set the parallel port mode to "ECP" by the computer BIOS setting. (For the parallel port mode, refer to p. 3-4.) Make sure that the print controller vanner page setting is OFF (default).
Caution
By the upgrading process, all of the setting information, scanner data and password print data are deleted. Though the download font is copied, its operation cannot be assured.
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METHOD REPLACEMENT
System software upgrading procedure
1. 2. 3. 4.
Press the copier's main power switch OFF. Connect an RS-232C serial cable and parallel cable between the PC and the print controller. Run the Tera Term. Select [Serial] from [New Connection], select the port of the computer to which the serial cable is connected and click the [OK] button.
5.
Select [Setup] - [Serial port...], set up the port as shown below, and click the [OK] button.
You can leave all the settings at their default except [Baud rate] and [Flow control].
6.
Press the copier's power switch ON.

Start-up of the print controller is displayed on the Tera Term screen. If not displayed, check the cable connection, Tera Term setting, and turn off and on the copier to check the display.
7.
Press the mode switching button on the operation panel and return to the printer mode basic screen.
The Printer menu screen appears.
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METHOD REPLACEMENT
8.
When the icon gets [IDLE], double-click the"filename.bat" file, which should have been prepared in advance, and the follow the instructions on the screen. The message, "Updating Firmware", appears on the copier LCD panel.
Caution
Avoid operating the PC and the copier as long as the message [Updating Firmware] is displayed on the copier's LCD panel. The print controller may be damaged if you turn the copier's main power off while this message is displayed.
9.
Upon completion of the file transfer, the message, "Upgrading Successful" is displayed. Then select [Control] - [Macro] of Tera Term without turning OFF the copier, select [IP511UG.ttl] in [TeraTerm_macro] folder and click the [Open] button.
If you have turned OFF the copier by mistake, turn ON the copier again and perform the Tera Term Macro.
10.
Turn OFF the copier and then turn ON again after 10 seconds.
After the copier is restarted, upgrading process will automatically take place.
The upgrading process requires about 30 minutes. If an error occurs during the upgrading process, check the error condition and take proper corrective steps.
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METHOD REPLACEMENT
11.
Upon completion of the upgrading process, the message, "UPDATE DONE!", appears on the Tera Term screen. Turn OFF the copier and then turn ON again after 10 seconds.
Caution
If the copier is turned off and on again before the message, "UPDATE DONE!", appears, the print controller will go dead. Never turn off the copier before the message "UPGRADE DONE!" appears.
12.
After restarting the system, output [Config. Data] from test print and ensure the system software is upgraded.
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DATE Dec 2003
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3-14
METHOD REPLACEMENT
How to update IP-511 system software (Ver. 6.0.x => Ver. 6.2.x)
Caution
This document explains about the upgrade from version 6.0.X of IP-511 system software. To upgrade 5.7.x or earlier version, perform upgrading the software to version 6.0.x in advance. Otherwise, the software may be damaged. Following is the upgrade procedure from system software Ver6.0.x to Ver6.2.0. Tera Term ver. 2.3, a free software terminal emulator (communication program), is used for upgrading.
Caution
Tera Term Pro ver. 2.3 is available from the following site. Download the file and install it in the PC you want to use for upgrade in advance. http://www.vector.co.jp/authors/VA002416/

IBM PC/AT compatible PC OS: Windows 95/98/Me/NT4.0/2000/XP With parallel interface equipped Parallel cable Anphe.36 pins - D-sub 25 pins (Length 2m or less, IEEE1284 compatible) Tera Term Pro ver. 2.3 (terminal communication program) RS-232C serial cable (Cross cable of D-Sub 9 pins female<=> D-Sub 9 pins female) Upgrade package Macro for Tera Term
Preparation
Print out necessary password print data and hold job and get the all KRDS data. Write down controller setting and other configuration information as needed. Set parallel mode to [ECP] in the BIOS setting on PC. ("Checking On the Parallel Port Mode (ECP)"(p. 3-4)) Ensure that the print controller banner page is set to OFF. (Default: OFF)
Caution
By the upgrade, configuration information, password print data, hold job and KRDS are all deleted.Scan data and download font are preserved.
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METHOD REPLACEMENT
System software upgrade procedures
1. 2. 3. 4.
Turn OFF the main power switch of the copier. Connect computer and print controller with RS-232C serial cable and parallel cable. Startup Tera Term. On [New Connection], select [Serial] then port of computer where the serial cable is connected. Then click [OK] button.
5.
Select [Setup]-[Serial port...] and set the port setting as in the following figure. Then, click [OK] button. (Except [Baud rate] and [Flow control], use Windows default setting)
6.
Startup embedded DOS.
1. 2. 3. 4.
Turn ON main power switch of the copier. While "Ext Memory Test" is performed on Tera Term, press "k" => "a" keys.
=> Embedded DOS starts.
When "Enter new date (mm-dd-yy):" is displayed, input numeric in order of "month-date-year" (ex: To enter [December 1, 2003], input [12-01-2003]) then press enter key. When "Enter new time(hh:mm:ss):" is displayed, input numeric in order of "hour:minute:second" (ex:18:14:20) then press Enter key.
=> DOS command input is enabled.
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METHOD REPLACEMENT
7.
Restore system.
1. 2.
Type DOS command "d:recovery" and press Enter key. Check system recovery progress on Terra Term window.
When the restoring successfully completes, message "RECOVERY DONE" is displayed.
Caution
"EB43DBG:" may be displayed instead of "RECOVERY DONE" message. In this case, turn OFF/ON the main switch of the copier and retype "d:recovery" in embedded DOS again.
"SC49-01" may be displayed on the copier operation panel during system restoring. This means the copier cannot recognize print controller. However, it does not affect the restoring operation. Disregard the message.
3.
Turn OFF main power switch of the copier then turn ON it after 10 seconds.
8. 9.
On copier, touch the mode switching button on the operation panel to switch the screen to the print mode basic screen. Print menu screen is displayed. When the icon turns ready, double click on the "filename.bat" file for upgrading and follow the screen instructions on the PC.
On the copier LCD, "Upgrading firmware" is displayed.
Caution
While the message "Upgrading firmware" is displayed on the copier LCD panel, do not touch PC and copier. If the main switch of the copier is turned OFF in the meantime, print controller may get damaged.
10. 11.
When the transmission completes, the message "Updating Successful!" appear on the LCD panel of the copier. Then, turn OFF the main switch of the copier. On Tera Term, select [Control]-[Macro] then select [IP511_Upd.ttl] in the " TeraMacro_6th" folder and click [Open] button.
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12.
Turn ON the main switch of the copier.

After restarting of the copier, the system software is automatically updated.
Upgrading takes approximately 10 minutes. "SC49-01" may be displayed on the copier operation panel during system upgrading. This means copy cannot recognize print controller. However, it does not affect the upgrading operation. Disregard the message.
13.
When the upgrading completes, the message "UPDATE DONE!" is displayed on the Tera Term window. Turn OFF the main power switch of the copier then turn ON it after 10 seconds.
Caution
If the switch of the copier is turned OFF/ON before "UPDATE DONE!" is displayed, print controller is completely destroyed. Never turn OFF the switch of the copier until "UPDATE DONE!"
14.
If system software does not start for some reasons, restoring by the embedded DOS may be effective to restore the system. At the restoring, by typing the following command, the system software version you want to restore can be specified.
1. Restore to Ver. 6.0.0 d:recovery ver600 2. Restore to Ver. 6.2.0 d:recovery ver620
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How to update IP-511Type-A system software

Caution
This document explains about the upgrade IP-511Type-A system software. To upgrade the system software, you need the following procedures: Tera Term ver. 2.3, a free software terminal emulator (communication program), is used for upgrading.
Tera Term Pro ver. 2.3 is available from the following site. Download the file and install it in the PC you want to use for upgrade in advance. http://www.vector.co.jp/authors/VA002416/

IBM PC/AT compatible PC OS: Windows 95/98/Me/NT4.0/2000/XP With parallel interface equipped Parallel cable Anphe.36 pins - D-sub 25 pins (Length 2m or less, IEEE1284 compatible) Tera Term Pro ver. 2.3 (terminal communication program) RS-232C serial cable (Cross cable of D-Sub 9 pins female <=> D-Sub 9 pins female) Upgrade package Macro for Tera Term
Preparation
Print out necessary password print data and hold job and get the all KRDS data. Write down controller setting and other configuration information as needed. Set parallel mode to [ECP] in the BIOS setting on PC. ("Checking On the Parallel Port Mode (ECP)"(p. 3-4)) Ensure that the print controller banner page is set to OFF. (Default: OFF)
Caution
By the upgrade, configuration information, password print data, hold job and KRDS are all deleted. Scan data and download font are preserved.
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System software upgrade procedures.
1. 2. 3. 4.
Turn OFF the main power switch of the copier. Connect computer and print controller with RS-232C serial cable and parallel cable. Startup Tera Term. On [New Connection], select [Serial] then port of computer where the serial cable is connected. Then click [OK] button.
5.
Select [Setup]-[Serial port...] and set the port setting as in the following figure. Then, click [OK] button. (Except [Baud rate] and [Flow control], use Windows default setting)
6.
Startup embedded DOS.
1. 2. 3. 4.
Turn ON main power switch of the copier. While "Ext Memory Test" is performed on Tera Term, press "k" => "a" keys.
=> Embedded DOS starts.
When "Enter new date (mm-dd-yy):" is displayed, input numeric in order of "month-date-year" (ex: To enter [December 1, 2003], input [12-01-2003]) then press enter key. When "Enter new time(hh:mm:ss):" is displayed, input numeric in order of "hour:minute:second" (ex: 18:14:20) then press Enter key.
=> DOS command input is enabled.
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7.
Restore system.
1. 2.
Type DOS command "d:recovery" and press Enter key. Check system recovery progress on Terra Term window.
When the restoring successfully completes, message "RECOVERY DONE" is displayed.
Caution
"EB43DBG:" may be displayed instead of "RECOVERY DONE" message. In this case, turn OFF/ON the main switch of the copier and retype "d:recovery" in embedded DOS again.
"SC49-01" may be displayed on the copier operation panel during system restoring. This means the copier cannot recognize print controller. However, it does not affect the restoring operation. Disregard the message.
3.
Turn OFF main power switch of the copier then turn ON it after 10 seconds.
8. 9.
On copier, touch the mode switching button on the operation panel to switch the screen to the print mode basic screen. Print menu screen is displayed. When the icon turns ready, double click on the "filename.bat" file for upgrading and follow the screen instructions on the PC.
On the copier LCD, "Upgrading firmware" is displayed.
Caution
While the message "Upgrading firmware" is displayed on the copier LCD panel, do not touch PC and copier. If the main switch of the copier is turned OFF in the meantime, print controller may get damaged.
10. 11.
When the transmission completes, the message "Updating Successful!" appear on the LCD panel of the copier. Then, turn OFF the main switch of the copier. On Tera Term, select [Control]-[Macro] then select [IP511_xxx.ttl] in the " TeraMacro" folder and click [Open] button.
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12.
Turn ON the main switch of the copier.

After restarting of the copier, the system software is automatically updated.
Upgrading takes approximately 10 minutes. "SC49-01" may be displayed on the copier operation panel during system upgrading. This means copy cannot recognize print controller. However, it does not affect the upgrading operation. Disregard the message.
13.
When the upgrading completes, the message "UPDATE DONE!" is displayed on the Tera Term window. Turn OFF the main power switch of the copier then turn ON it after 10 seconds.
Caution
If the switch of the copier is turned OFF/ON before "UPDATE DONE!" is displayed, print controller is completely destroyed. Never turn OFF the switch of the copier until "UPDATE DONE!"
14.
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Checking for Successful Update

You can print out information on the configuration to determine whether the software has been successfully updated.
1.
Press the [Settings] key to let the printer menu screen appear, then press the [Test Print Menu] tab, and press the [OK] key.
2. 3.
Press [Config. Data], then press the [OK] key.

A configuration data list is printed out.
Look the system software version number in the list to determine whether the software is updated or not.
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Error conditions
Error No. Error condition and correction HDD capacity is not enough so that upgrading cannot be done.
0
1
Error caused when hard disk partition was operated.

Turn off and on the main power switch of the copier and repeat from step 6.
Error caused when the hard disk partition was operated. Turn off and on the main power switch of the copier and repeat from step 6. (This error was caused after the backup space was deleted and therefore system cannot be recovered using the backup space without performing the upgrading process.)
System cannot be started.

Since the error was caused after the system space was deleted, hard disk of the controller should be replaced.
If an error No. 0 - 2 occurred, upgrading process was repeated, but still the same error is caused, the controller hard disk should be replaced.
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Rewriting the Network Interface Card Firmware

The built-in network interface card utilizes a flash ROM and it is possible to rewrite the firmware. Firmware can be rewritten by two of following methods. Rewriting through the network by FTP Download (for TCP/IP) Rewriting the firmware via a parallel port (recommended) (Possible only when the print controller system version is v5.7.0 or later)
Rewriting by FTP Download

IBM PC/AT-compatible Windows PC equipped with network interface card Data file to be updated FTP Download
For the FTP Download version and the OS (Windows) version, check with the Readme file.
Preparation
PCs that utilize the network interface card and FTP Download need to be connected to the same network segment and the TCP/IP setting to be correctly set. Jot down the IP address of the network interface card. FTP Download needs to be installed.
Installing FTP Download
Be sure to read the Readme file for FTP Download in advance. If an earlier version of FTP Download is installed, uninstall it before installing a new one.
1. 2.
Get the latest install program, and run the installation. Follow the on-screen instructions.
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Procedure of Upgrading Network Interface Card Firmware

Caution
Observe the following during the upgrading process: Do not let the printer perform a print job. Do not access the network interface card with a browser or via Telnet. Do not turn the copier's power off. Do not operate the copier.
1. 2. 3.
Connect the PC in which FTP Download is previously installed and a target Network interface card in the same TCP/IP network segment, and store the image file (data file) to be downloaded in any folder on the PC. Run FTP Download from the Windows [Start]-[Programs]. Select [Download] from the File menu.
4.
Select the data file with a "*.upd" extension in the Select dialog box, then click [Open].
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5.
Enter the IP address of the network interface card in the IP Address field, then click [OK].
6.
Type in "sysadm" in the Password field and click [OK].
"sysadm" is the default password. If a password different from "sysadm" has been set up, check it with the administrator and enter that password. The screen shown below appears when communications with the network interface card cannot be established and therefore the rewriting of firmware cannot be performed. If this is the case, chances are the PC is not correctly connected to the network or the TCP/IP setting is not correctly set.
7.
A Download Status popup appears which displays updating progress.

Uploading Unit:xxx.xxx.xxx.xxx Downloading NIC Update Program (BIN) to NIC. xx% complete
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8.
Upon appearance of the message [Do not reset this unit during the next 4 minutes], click [OK] and leave things alone for 4 minutes.
9.
When 4 minutes is up, the updating of the firmware is completed.

Upon completion of the updating process, the network interface card restarts automatically. As the network interface card starts up, the built-in PDL (Page Description Language) outputs a Status Page list.
10. 11.
After the updating process has been completed, enter the URL of the network interface card (example: http://192.168.0.10/) in your browser to check on the firmware version using Web Utilities. After checking on the firmware version, turn OFF the main power switch of the copier then turn ON it after 10 seconds.
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Rewriting the firmware via the parallel port

Caution
When the print controller system version is before v5.7.0, firmware cannot be rewritten through the parallel port. In such a case, use the FTP Download utility.

IBM PC/AT-compatible PC OS : Windows 95/98/Me/NT4.0/2000/XP equipped with parallel port interface Parallel cable Anphe.36 pins - D-sub 25 pins (Length 2m or less, IEEE1284 compatible) Data file to be updated
Procedure of Upgrading Network Interface Card Firmware
1. 2. 3. 4.
With the copier switched off, remove the network cable, connect a parallel cable between the computer and the print controller. Turn the copiers main power on, output the Status Page and make sure of the current firmware version. Press the mode switching button on the operation panel to switch to Printer Mode Basic screen. Double-click the "filename.bat" as arranged previously and follow the instructions shown on the screen.
A message describing that the firmware is being rewritten is indicated on the LCD panel.
Caution
Never turn off the copying machine while updating is going on.
5. 6.
A message describing that the rewriting of firmware has completed is indicated on the LCD panel, turn off the copier and wait for 10 seconds, then restart it. Output the Status Page to make sure that the firmware has been successfully rewritten.
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METHOD ADDITION
Service Port
Overview of the Service Port
The service port is a serial port for use in connecting from a PC to the print controller via an RS-232C serial cable to control the print controller using Hyper Terminal, a terminal communications program. This print controller supports for input/output operations of Hyper Terminal from when the printer system BIOS boots up, thus making it possible to control the progress in initialization and system test (or POST: Power On Self Test) by BIOS, which, when an error develops at the system start time, assists you in determining where error conditions may exist. You can also let the BIOS check memory or boot up a service DOS from Hyper Terminal.
Service Port Operating Environment

The following is required to use the service port: Computers running on Windows Hyper Terminal (terminal communications program)
Setting requirements
Bits/sec.: 9600 bits/sec.(fixed) Data bit: 8 bits Parity: None Stop bit: 1 Flow control: None RS-232C serial cable (terminated in a female 9-pin D-Sub connector on both ends)
Pin assignment
PC
1 DCD 2 TxD 3 RxD 4 DTR 5 GND 6 DSR 7 RTS 8 CTS 9 RI
Print Controller
1 DCD 2 TxD 3 RxD 4 DTR 5 GND 6 DSR 7 RTS 8 CTS 9 RI
5 9
4 8
3 7
2 6
9-pin D-SUB Connector (female)
Preparation
1. 2. 3. 4.
Press the copier's main power switch OFF. Connect an RS-232C serial cable between the PC and the print controller. Run Hyper Terminal. Press the copier's main power switch ON (i.e., boot up the print controller).
Now you can access various functions from hyper terminal.
For how to install and use the Hyper Terminal, refer to the manual for your Windows, as well as the later corresponding section of this manual.
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METHOD ADDITION
Installing and Booting Up Hyper Terminal

Hyper Terminal 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 Hyper Terminal, you need the system program CD for the Windows PC in use. The procedure of setting up and booting up Hyper Terminal depends on the Windows version.
In the following, we use the Windows 98 as an example.
To install Hyper Terminal
1. 2. 3. 4.
Insert the CD containing OS of the Windows PC in use into the CD drive. 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 [Connection] check box under [Components].
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5.
Click the [Details] button.

A [Communication] window will appear.
6. 7.
Check the [Hyper Terminal] check box, and click the [OK] button. When the [Add/Remove Programs] window reopens, click the [OK] button.
The necessary files are copied and the installation is completed.
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To Boot Up Hyper Terminal
1.
Select [Start]-[Programs]-[Accessories]-[Communication]-[Hyper Terminal].

A [Hyper Terminal] window will appear.
Once the connection with Hyper Terminal is established, its 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 Hyper Terminal is established by double-clicking that icon.
2.
Double-click [Connection Description].

A [Connection Settings] window will appear.
3. 4.
Enter a name, and click the [OK] button. Select [Directly to COM (1-3)] under [Connect using], then click the [OK] button.
A [Port Settings] window will appear.
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METHOD ADDITION
5.
Set the Port Settings as follows, and click the [OK] button.
You can leave all the settings at their defaults except [Bits per second] and [Flow control].
Here you cannot change the serial port settings on the copier.
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METHOD ADDITION
Booting Up Service DOS

The print controller carries DOS (Embedded DOS) along with the BIOS program on a flash ROM. This DOS lets you recover the print controller system. For how to do, refer to "Recovery of Print Controller System."
1. 2. 3.
Boot up Hyper Terminal.

Refer to "To Boot Up Hyper Terminal."
Type in "k", followed by "a" while "Ext. Memory Test" is running. The DOS is boot up.
4. 5.
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.
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METHOD ADDITION
Memory Test Methods

The memory test needs to be conducted if, after you have added memory, an unstable operation is observed or a fault develops due to memory size. The memory test includes a normal memory test and a detailed memory test. The normal memory test is a test conducted upon normal powering up.
The normal memory test includes the following:

In memory area of lower than 640 KB: In memory area of higher than 640 KB: Data read/write test, address test, and data test over the entire memory area. Data read/write test in 64 KB units.
The detailed memory test is a test conducted over the entire memory area as controlled from the service port.
The detailed memory test includes the following:

In memory area of lower than 640 KB: In memory area of higher than 640 KB: Data read/write test, address test, and data test over the entire memory area. Data read/write test over the entire memory area.
Memory Test Procedure
1. 2.
Boot up the service terminal.

Refer to "Booting Up Service DOS."
After the service terminal has started running, input any character between the interval from the moment "Test Base 64KB Memory" appears to the moment "Low Memory Test" starts running.
You can press any general character key (example: "z", "6").
3.
The detailed memory test is conducted.
4.
Make certain that all memory tests found no problems ("Memory Passed" is then displayed).
When all memory is OK, the Print Controller is able to normally start up.
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METHOD ADDITION
5. 6. 7. 8.
Press the copier's main power switch OFF. Unplug the serial cable. Turn the copier back on to check if it behaves normally. If any test results are unacceptable (The message "Critical Error" is displayed. Or, the value after the occurrence of "Ext. Memory Passed" is less than the expanded memory capacity.), remove the added memory, and run the memory test from the beginning.
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METHOD ADDITION
Recovery of Print Controller System

Overview
The system software of the print controller is contained in the hard disk. A compressed backup of the system software is held in a separate partition on the same hard disk in case the system software is damaged at the software level. When an error condition occures, you can use this backed up system data to recover the print controller. The hard disk in the print controller is divided into drive C, which holds the system software, and drive D, in which backed-up images are stored, as shown below. Ver6.x and after are equipped with E drive for data storage. To do so, the DOS in a flash ROM is used. For how to boot up the DOS, refer to "Booting Up Service DOS."
IP-511 Ver 6.x and after / IP-511Type-A
IP-511 Ver 5.x and before
Recoverry
Recoverry Drive C (2 GB) System Software (Primary Partition)
Drive C (1 GB) System Software (Primary Partition) Drive D (100 MB) Area for backup (Primary Partition)
Drive D (100 MB) Area for backup (Extended Partition) Area for future use
Drive E (residual space) Data storage area
(Primary Partition)
Drive Configuration in Print Controller

Drive A
Embedded DOS is stored in a flash ROM. The Embedded DOS is a compatibility DOS (FAT16 only) from General Software. After booting this DOS, DOS commands are available for use.
Drive C
VxWorks (realtime OS) and the print controller system, a conventional system file, are stored in a primary partition on the hard disk. Used for data storage also with IP-511 of version 5.x or before.
Drive D
A self-decompressing print controller system compressed file and a batch file, both for recovering the print controller system, are stored.
Drive E (IP-511 Ver. 6.x and after / IP-511Type-A)

Data storage area contains setting information, download font, scanner data, password print data, print spool data, etc.
Drives A and C are switchable at boot-up in BIOS POST (Refer to "Booting Up Service DOS").
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METHOD ADDITION

Steps for Recovering Print Controller System
Complete the following steps to recover the print controller system.
Caution
As a result of completing the following steps, downloaded fonts, password print data and scanned image data are lost, then the settings for the print controller are reset to defaults. If the system software has already been updated, there are occasions where it is downgraded as a result of the recovery process. After recovery, check on the system software version and, if necessary, perform the rewriting of system software.
Completing the following steps makes communications between the print controller and the copier impossible. Therefore, a error code is displayed on the copier's operation panel.
1. 2.
Boot up the service DOS.

Refer to "Booting Up Service DOS."
Execute the command for recovering the print controller system.

The print controller system is automatically recovered using a batch file. In case of IP-511 Ver. 5.x and before Type in "d:install" and press the Enter key. In case of IP-511 Ver. 6.x and after / IP-511Type-A Type in "d:recovery" and press the Enter key.
3.
Check if the process was successful.

In case of IP-511 Ver. 5.x and before The process was successful if "Install Complete!" is displayed. In case of IP-511 Ver. 6.x and after / IP-511Type-A The process was successful if "RECOVERY DONE" is displayed.
4. 5. 6.
Turn the copier off. Unplug the serial cable. Turn the copier back on to check if it behaves normally.
If the process was not successful (when completion of recovery is not displayed), try again from step 1. If you walk through the steps for a second time and the system is still not recovered, then you need to replace the hard disk.
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METHOD ADDITION
Blank Page
4
Troubleshooting
Blank Page
Chapter 4 Troubleshooting
Chapter 4 Troubleshooting
Troubleshooting
If the print controller produces trouble, look through the following, as well as the section on Troubleshooting in the User's Guide.
Warning Code/ Symptom E49-01
Cause
Operation in case of warning occurrence If the copier detects error conditions during printing, it stops feeding sheets of paper and at the same time releases the one that was on the way into the output tray, thereafter the print controller/copier system stops.
Estimated abnormal parts System Board
Measures
The copier recognizes the connected print controller, but is not working as it should. Defective communications between the print controller and the copier
1. Recycle the main power. 2. Check on the connection between the print controller and the copier. 3. Replace the system board.
E49-02
System Board
1. Recycle the main power. 2. Check on the connection between the print controller and the copier. 3. Replace the system board.
E49-03
Trouble in DMA controller Trouble in IP-HDD
System Board
1. Recycle the main power. 2. Replace the system board.
E49-04
System Board
1. Recycle the main power. 2. Check on the connection of the print controller hard disk. 3. Replace the hard disk.
E49-05
Overall cooling fan or CPU cooling fan is stuck.
System Board CPU cooling fan Overall cooling fan Printable only with PCL. PostScript Protection Chip Network Interface Card
1. Recycle the main power. 2. Check on the connection of the fan. 3. Replace the fan. 1. Take out and reinsert the PostScript protection chip. 2. Replace the PostScript protection chip.
With the standard printer language PCL, correct outputs are produced, but with PostScript even PS Demo Page cannot be printed out at all.
PostScript Protection Chip not correctly installed, or trouble in the Network Interface Card.
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 off and unplug the power cord.
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METHOD REPLACEMENT
Blank Page
Appendix
Blank Page
Appendix
Appendix
Components on the Board

System Board
Added Memory CPU Slot for Memory Extension
Standard Memory
Parallel Port North Bridge
Clock Driver
Serial Port (for servicing) Flash ROM
Gate Array 1 (KPC01) Engine I/F Connector

JP2
South Bridge Super I/O
Gate Array 2 (PPBC2000) Fuse
Network Interface Card I/F Connector
EIDE Hard Disk Connector
South Bridge:Hard Disk Controller ISA I/F North Bridge:CPU Local Bus I/F Memory Controller PCI I/F Super I/O:Serial I/F Controller
Jumpers
Normally, no need to change jumper settings. JP2: For production purpose
Appendix-1
Appendix

Flash ROM for Network Green LED Yellow LED
Network Control Memory
RJ-45 Ethernet Network Port
EEPROM Connector for the System Board PAL Clock Chip Buffer Chip Network Control CPU Network Control Chip
JP7 JP6 JP5 JP4 JP3 JP2 JP1
PostScript Protection Chip
EEPROM: Network Configuration Data maintenance
Appendix-2
Appendix
Factory Default Settings for Network Interface Card

Normally, all settings for the network interface card can easily be reset to their defaults from the printer setting menu, without having to disassemble the print controller. And yet if this resetting is of no avail, you can surely get around this simply by changing a jumper position. This jumper switch is situated next to the PostScript protection chip.
Caution 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 jumper positions except JP2.
1. 2.
After turning the copier off, remove the print controller from the copier.
Refer to "Removal / Installation of Network Interface Card."
Set the JP2 jumper as illustrated below, connect the print controller to the copier, then turn the copier on.
The settings for the network interface card will be reset to their factory defaults in about 5 minutes.
When the settings for the network interface card are reset to their factory defaults, two LEDs blink alternately on the network interface card.
JP1
JP2
JP3
JP4
JP5
JP6
JP7
3.
Again, turn the copier off, remove the print controller, and replace the JP2 jumper to its original position.
JP1
JP2
JP3
JP4
JP5
JP6
JP7
4.
Connect the print controller to the copier and turn the copier back on.
Now the copier is available for use.
Appendix-3
Blank Page
Index
Index
Numerics
25 Mode ...................................................................3-1
G
Gradation ..................................................... 1-1, 1-3-2
A
Add/Remove Programs .........................................3-31
H
Hard Disk ................................................................ 2-1 Hard disk drive ............................................. 1-1, 1-3-2 hard disk mounting brackets ................................... 2-4 Heat Sink ................................................................. 2-1 Host Interface ............................................... 1-1, 1-3-2
B
Bits per second ......................................................3-34 Booting Up Service DOS .......................................3-35
C
C(K) Count in Printer Mode .....................................3-2 Communication window .........................................3-32 Compliant OS ...............................................1-2, 1-3-3 Continuous print speed .................................1-1, 1-3-2 Cooling Fan Mounting Plate ....................................2-6 CPU ................................1-1, 1-3-1, 1-3-2, 1-3-4, 2-9 CPU Cooling Fan .....................................................2-1 Critical Error ...........................................................3-37
I
Install Complete! ................................................... 3-39 Installing and Booting Up Hyper Terminal ............. 3-31
J
JP2 ............................................................ Appendix-3 Jumper .................................................................. 2-10
L
lock lever ................................................................. 2-9
D
Data flow ..................................................................1-6 DC Connector for the Overall Cooling Fan ..............2-6 Dedicated Utilities ..................................... 1-3-1, 1-3-4 Default Dmax Value .................................................3-2 default password ....................................................3-27 Default Scanning Resolution ............................... 3-3-1 Dimension .....................................................1-2, 1-3-3 Disable Staple with Mixed Original ...................... 3-3-1 Disassembly / Reassembly ......................................2-2 DOS prompt .............................................................3-8 Download Status popup .........................................3-27 Drive A ...................................................................3-38 Drive C ...................................................................3-38 Drive Configuration ................................................3-38 Drive D ...................................................................3-38
M
Memory .................................. 1-1, 1-3-1, 1-3-2, 1-3-4 Memory Slot ............................................................ 2-7 Memory Test ......................................................... 3-36 Mounting Bracket A ................................................. 2-8 Mounting Bracket B ................................................. 2-8
N
Network Interface ......................................... 1-1, 1-3-2 Network Interface Card ................................... 2-1, 2-6 No. of Print ................................................... 1-1, 1-3-2 North Bridge ............................................... Appendix-1 NOS .......................................................... 1-3-1, 1-3-4
O
Operation when key counter is removed ................. 3-1 Option ........................................................... 1-2, 1-3-3 Orientation .................................................... 1-1, 1-3-2 Overall Construction ................................................ 2-1 Overall Cooling Fan ................................................ 2-1 Overview of the Product .......................................... 1-4
E
earth plates ..............................................................2-4 ECP .........................................................................3-4 EEPROM ....................................................Appendix-2 Embedded DOS .....................................................3-35 Ethernet Connection ................................. 1-3-1, 1-3-4 Expanded Memory ...................................................2-1 Ext. Memory Passed ..............................................3-37
P
Parallel Port Mode ................................................... 3-4 Pin assignment ...................................................... 3-30 plastic cover ............................................................ 2-2 PLCC pull-out tool ................................................... 2-6 Port Settings .......................................................... 3-34 POST .................................................................... 3-30 PostScript Protection Chip ...................................... 2-1 Power ........................................................... 1-2, 1-3-3 Printable Area .............................................. 1-1, 1-3-2 Printer Description Language ....................... 1-1, 1-3-2 Printer Drive ................................................. 1-2, 1-3-3 Printer Mode Basic screen ...................................... 3-7
F
Face-up Output with Thick Paper2 + Subtray Selected ......................... 3-3-2 Factory Default Settings for Network Interface Card ......................Appendix-3 Flow control ...........................................................3-34 Frame Type .............................................. 1-3-1, 1-3-4 FTP Download .......................................................3-25
REVISION EDITION
2
DATE Dec 2003
PAGE
Index-1
METHOD REPLACEMENT
Index
Printing Method ......................................... 1-3-1, 1-3-4 Product Specifications ..................................1-1, 1-3-2 Protocols ................................................... 1-3-1, 1-3-4
R
Recovery of Print Controller System ......................3-38 Removal / Installation of CPU ..................................2-8 Removal / Installation of Memory ............................2-7 Removal / Installation of Network Interface Card .................................2-10 Removal/Installation of Hard Disk ............................2-3 Removal/Installation of PostScript Protection Chip ................................................2-5 Removal/Installation of Print Controller ...................2-2 Removal/Installation of System Board ...................2-11 Reserved Memory Size ...........................................3-2 Resolution .....................................................1-1, 1-3-2 RS-232C ................................................................3-30 Rubber Insert ...........................................................2-4
S
serial cable .............................................................3-30 service DOS ...........................................................3-30 Service Port ...........................................................3-30 South Bridge ...............................................Appendix-1 Special Printing .............................................1-1, 1-3-2 Standard Utilities ....................................... 1-3-1, 1-3-4 sysadm ..................................................................3-27 System Board .....................................2-1, Appendix-1
T
terminal communications program .........................3-30 Trouble in DMA controller ........................................4-1 Trouble in IP-HDD ...................................................4-1 Troubleshooting .......................................................4-1
U
User ID ................................................................. 3-3-1
W
Warm-up time ...............................................1-1, 1-3-2 Warning Code ..........................................................4-1 Weight ...........................................................1-2, 1-3-3
REVISION EDITION
2
DATE Dec 2003
PAGE
Index-2
METHOD REPLACEMENT

IP-511 IP-511Type-A: Service Manual

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IP-511 IP-511Type-A: Service Manual

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SERVICE MANUAL

2003.12 Ver. 3.0

Print Controller specification .................................................................................................................1-1 Network Interface Card specification .................................................................................................1-3-1

Product Specifications (IP-511Type-A) ..........................................................................1-3-2

Print Controller specification ..............................................................................................................1-3-2 Network Interface Card specification .................................................................................................1-3-4

Overview of the Product .................................................................................................... 1-4

Disassembly / Reassembly ............................................................................................... 2-2

DATE Dec 2003

Rewriting the Network Interface Card Firmware ............................................................ 3-25

Service Port ....................................................................................................................... 3-30

DATE Dec 2003

SAFETY AND IMPORTANT WARNING ITEMS

SAFETY AND IMPORTANT WARNING ITEMS

DANGER, WARNING, AND CAUTION SYMBOLS AND EXPRESSIONS

Symbols used for important warning items are defined as follows:

DATE Dec 2003

SAFETY AND IMPORTANT WARNING ITEMS

assured, leading to a risk of fire and injury.

solder or similar object

Disabling relay functions (such as wedging paper between relay contacts).

be assured, leading to a risk of fire and injury.

Using parts not specified by KMBT.

DATE Dec 2003

SAFETY AND IMPORTANT WARNING ITEMS

CHECKPOINTS WHEN PERFORMING ON-SITE SERVICE

WARNING: Wall Outlet

WARNING: Power Plug and Cord

so on. Overheating may occur there, leading to a risk of fire.

Do not bundle or tie the power cord.

Overheating may occur there, leading to a risk of fire.

The risk of electric shock exists.

SAFETY AND IMPORTANT WARNING ITEMS

WARNING: Power Plug and Cord

outlet. If used, the risk of fire exists.

WARNING: Ground Lead

CAUTION: Power Supply Voltage Setting

SAFETY AND IMPORTANT WARNING ITEMS

WARNING: Prohibited Installation Place

such as rain water. A risk of fire and electric shock exists.

WARNING: Nonoperational Handling

CAUTION: Temperature and Humidity

SAFETY AND IMPORTANT WARNING ITEMS

level and sturdy place. Constant vibration will cause problems.

CAUTION: Inspection before Servicing

The area around the fixing unit is hot.

You may get burnt.

SAFETY AND IMPORTANT WARNING ITEMS

WARNING: Safety Checkpoints

The user or CE may be injured.

Current can leak, leading to a risk of electric shock or fire.

Check cables and sheaths for any damage.

Current can leak, leading to a risk of electric shock or fire.

When replacing a lithium battery, replace it with a new lithium battery

CAUTION: Safety Checkpoints

SAFETY AND IMPORTANT WARNING ITEMS

CAUTION: Safety Checkpoints

SAFETY AND IMPORTANT WARNING ITEMS

MEASURES TO TAKE IN CASE OF AN ACCIDENT

DATE Dec 2003

Product Specifications (IP-511)

Warm-up time: Basic Configuration: CPU: System Memory:

Same as the copier