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A852 PRINTER CONTROLLER TYPE 650
SERVICE MANUAL
WARNING
The Service Manual contains information regarding service techniques, procedures, processes and spare parts of office equipment distributed by Ricoh Corporation. Users of this manual should be either service trained or certified by successfully completing a Ricoh Technical Training Program. Untrained and uncertified users utilizing information contained in this service manual to repair or modify Ricoh equipment risk personal injury, damage to property. or loss of warranty protection.
Ricoh Corporation
LEGEND
PRODUCT CODE A852 COMPANY GESTETNER RICOH Printer Controller Type 650 SAVIN
DOCUMENTATION HISTORY
REV. NO. * DATE 3/99 COMMENTS Original Printing
TABLE OF CONTENTS
1. OVERALL MACHINE INFORMATION ........................................ 1-1
1.1 INTRODUCTION ...................................................................................... 1-1 1.2 SPECIFICATIONS .................................................................................... 1-2 1.3 SOFTWARE ............................................................................................. 1-2 1.3.1 PRINTER DRIVERS ........................................................................ 1-2 1.3.2 NETWORK UTILITIES..................................................................... 1-2 1.4 MACHINE CONFIGURATION .................................................................. 1-3 1.5 STRUCTURE............................................................................................ 1-4 1.5.1 BLOCK DIAGRAM ........................................................................... 1-4 1.5.2 DESCRIPTIONS .............................................................................. 1-5
2. DETAILED SECTION DESCRIPTIONS....................................... 2-1
2.1 HARDWARE OVERVIEW ........................................................................ 2-1 2.2 IMAGE PRINTING .................................................................................... 2-3 2.3 IMAGE DATA PROCESSING................................................................... 2-4 2.3.1 EDGE SMOOTHING........................................................................ 2-4 2.3.2 TONER SAVING MODE .................................................................. 2-4 2.4 FEATURES............................................................................................... 2-5 2.4.1 SORTING ........................................................................................ 2-5 2.4.2 DUPLEX PRINTING ........................................................................ 2-5 2.4.3 STAPLING ....................................................................................... 2-6 2.4.4 PUNCHING...................................................................................... 2-6 2.4.5 JAM RECOVERY............................................................................. 2-7 2.4.6 AUTO TRAY SELECT ..................................................................... 2-7 2.4.7 POWER ON SELF DIAGNOSTICS ................................................. 2-7 Test Items ............................................................................................ 2-7 2.4.8 DOCUMENT SERVER .................................................................... 2-8 2.5 HARD DISK .............................................................................................. 2-9 2.5.1 PRINTER HDD ................................................................................ 2-9 2.5.2 ENGINE HDD .................................................................................. 2-9 2.6 PAPER OVERFLOW DETECTION ........................................................ 2-10 2.6.1 BRIDGE UNIT................................................................................ 2-10
3. INSTALLATION PROCEDURE ................................................... 3-1
3.1 PRINTER CONTROLLER......................................................................... 3-1 3.1.1 ACCESSORY CHECK ..................................................................... 3-1 3.1.2 INSTALLATION PROCEDURE........................................................ 3-2 3.2 HARD DISK DRIVE .................................................................................. 3-5 3.2.1 INSTALLATION PROCEDURE........................................................ 3-5 3.3 POSTSCRIPT KIT .................................................................................... 3-8 3.3.1 INSTALLATION PROCEDURE........................................................ 3-8 3.4 NETWORK INTERFACE BOARD ............................................................ 3-9
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3.4.1 INSTALLATION PROCEDURE........................................................ 3-9 3.5 DRAM SIMM........................................................................................... 3-12 3.5.1 REQUIRED SPECIFICATION CHECK .......................................... 3-12 3.5.2 INSTALLATION PROCEDURE...................................................... 3-12 3.6 CONNECTING THE INTERFACE CABLES ........................................... 3-15 3.6.1 PARALLEL INTERFACE ............................................................... 3-15 3.6.2 NETWORK INTERFACE ............................................................... 3-15 3.7 CHECKING THE CONNECTION............................................................ 3-15 3.7.1 CONNECTION BETWEEN PRINTER CONTROLLER (AND RELATED OPTIONS; POSTSCRIPT ROM, DRAM SIMM, HARD DISK DRIVE, NIB) AND ENGINE.................................................. 3-15 3.7.2 CONNECTION BETWEEN MAIN CONTROLLER BOARD AND THE NETWORK INTERFACE BOARD ................................ 3-17 Print the Network Interface Board Status Sheet................................. 3-17
4. SERVICE TABLE ........................................................................ 4-1
4.1 GENERAL CAUTION................................................................................ 4-1 4.2 SERVICE PROGRAM MODE................................................................... 4-1 4.2.1 SERVICE PROGRAM ACCESS PROCEDURE .............................. 4-1 Entering SP mode ................................................................................ 4-1 Exiting SP mode................................................................................... 4-1 4.2.2 SERVICE PROGRAM MODE TABLES ........................................... 4-1 4.3 DOWNLOADING NEW FIRMWARE ........................................................ 4-2 4.3.1 FIRMWARE UPDATE USING A FLASH MEMORY CARD (SP02 AND 04)................................................................................. 4-2 4.3.2 FIRMWARE UPDATE FROM PARALLEL PORT ............................ 4-3 4.3.3 FORMATING THE HARD DISK....................................................... 4-3 4.3.4 COPY FLASH ROM......................................................................... 4-4 Download from ROM DIMM to printer controller .................................. 4-4 Download from the controller to ROM DIMM........................................ 4-5 4.3.5 PARALLEL LOOP BACK TEST (SP11)........................................... 4-5 4.4 USER PROGRAM MODE......................................................................... 4-6 4.4.1 UP MODE TABLE (PRINTER FEATURES)..................................... 4-6 4.5 DIP SWITCHES/JUMPER PINS/LEDS..................................................... 4-7 4.5.1 DIP SWITCHES ............................................................................... 4-7 4.5.2 JUMPER PINS................................................................................. 4-7 4.5.3 LEDS ............................................................................................... 4-7
5. REPLACEMENT AND ADJUSTMENT........................................ 5-1
5.1 PRINTER CONTROLLER BOARD........................................................... 5-1 5.2 HARD DISK .............................................................................................. 5-4 5.3 NETWORK INTERFACE BOARD ............................................................ 5-4 5.3.1 POSTSCRIPT ROM BOARD AND DRAM SIMM............................. 5-5
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6. TROUBLESHOOTING................................................................. 6-1
6.1 ERROR MESSAGES................................................................................ 6-1 Service call (SC) codes........................................................................ 6-1 Other messages................................................................................... 6-2 6.2 LEDS ........................................................................................................ 6-3 6.2.1 LOCATION....................................................................................... 6-3 6.2.2 LED CODE TABLE .......................................................................... 6-3 Self diagnostic...................................................................................... 6-3 Controller Firmware Copy/Download ................................................... 6-4
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OVERALL MACHINE INFORMATION
TAB POSITION 8
TAB POSITION 7
TAB POSITION 6
TROUBLESHOOTING
TAB POSITION 5
REPLACEMENT AND ADJUSTMENT
TAB POSITION 4
SERVICE TABLE
TAB POSITION 3
INSTALLATION
TAB POSITION 2
DETAILED DESCRIPTIONS
TAB POSITION 1
OVERALL MACHINE INFORMATION
INTRODUCTION
1.1 INTRODUCTION
The A229 base engine contains an interface for the A852 multi-function controller. The A852 multi-function controller adds printer function. Printer function can operate independently and simultaneously with other functions in the background, and their output will be interleaved with the copy mode output. The printer supports the PCL6, and PostScript level 3. PostScript language support is an optional function. Host printer data can be received via the standard parallel port or the optional Network Interface Board (NIB). The parallel port supports bi-directional Command and Status feed back communication with the host machines. An optional IDE hard disk drive provides font download, macro download, and other functions. Additional DRAM SIMMs can be installed to boost the printer performance. Images can be rasterized at 300, 400, or 600 dpi in the controller but printed at 400 or 600 dpi. For 300 dpi printing, the 300 dpi data from the controller is simulated in the base engine by printing the same pixel twice and the same line twice at 600 dpi. The A229 (65ppm) engine can print 65 pages per minute at both 400 and 600 dpi. On the other hand, the A229 (55ppm) engine can print 55 pages per minute at both 400 and 600 dpi.
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Overall Information
1. OVERALL MACHINE INFORMATION
SPECIFICATIONS
1.2 SPECIFICATIONS
Resolution: 600 x 600 dpi 400 x 400 dpi (available when the PostScript option is installed) 300 x 300 dpi (simulated by doubling pixel width and height at 600 dpi resolution) Gray Scale: Printing Speed: Printing Emulation: Printer Font: 256 levels A229 65 ppm A229 55 ppm Main Controller Board: PCL5e and PCL6 Optional PS Board: PostScript Level 3 45 scaleable typefaces in 14 typeface families (35 Intellifont and 10 TrueType format fonts) 6 bitmapped typefaces in the Line Printer typeface family Printer Interface: Bi-directional Parallel x 1 (Standard) Network Interface x 1 (Option) Ethernet (100 base-TX/10 base-T for TCP/IP, IPX/SPX, EtherTalk) DRAM Capacity: 8 MB (Standard) 2 DRAM SIMM slots (up to 64 MB) Maximum Total: Up to 72 MB
1.3 SOFTWARE
1.3.1 PRINTER DRIVERS
The following printer drivers are enclosed in the printer manual/driver kit · PCL5e Printer Driver for Windows 3.1/95/98/NT · PCL6 Printer Driver for Windows 3.1/95/98/NT · PS3 Printer Driver for Windows 3.1/95/98/NT and Macintosh
1.3.2 NETWORK UTILITIES
The network utilities are enclosed in the Network Interface Board option. Refer to the A855 NIB manual for details.
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MACHINE CONFIGURATION
4 3 2
5 6
7
1
A852V500.WMF
Item Printer Controller PostScript Kit Hard Disk Network Interface Board Mailbox Mailbox Bridge Unit RAM SIMM Printer Manual/Driver Kit
Machine Code A852 A866 A853 A855 G909 G912 --A868
No. 7 3 5 6 1 2 4 ---
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Overall Information
1.4 MACHINE CONFIGURATION
STRUCTURE
1.5 STRUCTURE
1.5.1 BLOCK DIAGRAM
Hard Disk
(Controller)
PS Kit Printer Controller DRAM SIMM
MB
SBICU
Network Interface Board
Hard Disk
: Printer's Options (Main Frame)
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STRUCTURE
1. Printer Controller The printer controller handles the following functions: · Printer host interface · Printing functions · Interface and control of additional controller options (HDD, PS kit, DRAM SIMM, and network interface board) 2. Hard Disk (option) This HDD stores the additional soft fonts and macros (both PCL and PS fonts).
3. PS Kit (option) This is to add the PostScript level 3 feature.
4. Network Interface Board (option) The network interface board is an additional printer interface to allow the printer to be used on a network.
5. DRAM SIMM (option) There are two DRAM SIMM slots. This is used for an additional printer processing memory area. 8, 16, or 32 Mbyte standard SIMM modules can be installed. As a result, up to 72 Mbytes of RAM are installable (8 Mbytes on board plus 64 Mbytes (32 X 2) of optional SIMM).
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Overall Information
1.5.2 DESCRIPTIONS
DETAILED DESCRIPTIONS
HARDWARE OVERVIEW
2. DETAILED SECTION DESCRIPTIONS
2.1 HARDWARE OVERVIEW
Flash ROM
NVRAM
Flash Memory Card I/F
ROM & I/O Bus
EIDE Disk Interface
HDD
CPU
DRAM Bus
CPU Bus
CoProcessor
NIB Interface Network Interface Board
DRAM
Printer Controller
Mother Board
DRAM SIMM
DRAM SIMM
SBICU
PC/AT Compatible via Parallel Port
A852D500.WMF
The above block diagram shows the major components of the printer controller. The main features of the controller are as follows. 1. CPU An IBM PPC603 processor is used. A 33 MHz oscillator is used as the clock source for both this CPU and the coprocessor. 2. Co-processor This performs the following functions. · ROM control · I/O control · DRAM control · Printer video interface · Printer communication interface · IEEE 1284 compliant bi-directional parallel port interface · Interrupt control
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Detailed Descriptions
HARDWARE OVERVIEW
3. ROM memory 1) Flash ROM (4 Mbytes) This flash ROM includes boot code, operation system code, PCL5e codes, PCL6 code, and font data for both PCL languages (resident fonts). 2) ROM SIMM (4 Mbytes for the PostScript option) This ROM SIMM includes the PostScript code and PostScript font data. 4. NVRAM (8 Kbytes) This Non-Volatile Random Access Memory contains the printer settings, job record data, and error record data. 5. Network Interface Board Interface The NIB Interface controls the optional network interface board, and printer MIB is provided to support the network operations. 6. Hard Disk Drive Interface (Enhanced IDE) This HDD interface is provided to support storage of fonts and macros downloaded from a PC. 7. Flash Memory Card Interface The flash memory card used for updating the controller and PostScript firmware, is connected to this flash memory card slot. 8. Power-on Self Diagnostic When the controller is turned on, the controller performs a self diagnostic test.
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IMAGE PRINTING
2.2 IMAGE PRINTING
Parallel Interface, from PC Printer Controller CPU Co-processor Resident RAM DRAM SIMM NIB
LD Unit GAVD FCI SBICU
IPU
GA1
HDD
A852D502.WMF
Printer Controller
Resident RAM Co-processor NIB Buffer Parallel Intelligent Personality Selection PCL-5e PCL-6 Post script Image Data Generation
Base Engine
HDD
SBICU
IPU
LD
DRAM SIMM
A852D503.WMF
The printer controller receives the print data from the computer through the parallel or network interface port. The co-processor handles the image data but only creates raster images. All image processing, such as edge smoothing and toner saving, are done in the base engine. The image data from a PC goes to the buffer in the resident RAM. Then, it goes to the co-processor. The co-processor selects the printer language automatically, then the co-processor generates the print data to match the selected printer language. After generating the print data, the co-processor sends it to the LD unit through the IPU on the SBICU board. At that time, the data is also sent to the hard disk for multiple printing and sorting, as well as backup in case of paper jams.
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Detailed Descriptions
IMAGE DATA PROCESSING
2.3 IMAGE DATA PROCESSING
The FCI (Fine Character Image) in the LD unit is responsible for edge smoothing and toner saving functions. The edge smoothing and toner saving modes can be switched on or off using the appropriate printer user tool or when configuring the printer driver functions.
2.3.1 EDGE SMOOTHING
A850D504.WMF
Usually, binary picture processing generates jagged edge on characters as shown in Figure A. The FCI reduces the edges of characters using edge smoothing. (See Figure B above.) Whether or not the object pixel undergoes smoothing depends on the surrounding image data. Smoothing for the object pixel is done by changing the laser pulse position.
2.3.2 TONER SAVING MODE
Toner saving is done by reducing the number of black dots printed, not by varying the development bias. In toner saving mode, the image data is processed through a matrix filter. As a result of passing through the filter, less toner is used to create the latent image on the drum, and black areas print as gray.
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FEATURES
2.4 FEATURES
2.4.1 SORTING
If "Collate" is turned on and a multicopy job is printed, the first copy of the job will be printed directly. At the same time, the image data for the copy job is stored in the hard disk of the main machine. The next copy and additional copies will be printed from the hard disk. If the finisher is not installed, the rotate sort feature can be used. The image is rotated by the SBICU, in the same manner as image rotation for the copier.
2.4.2 DUPLEX PRINTING
Duplex printing is available with all output bin options but not all paper sizes (refer to the specifications section of the copier manual). If a job specifies duplex but the paper size to be used is not usable in the duplex unit, the job will be printed simplex. Duplex printing is available in two binding methods: Short-edge binding and Longedge binding. In short-edge binding, when printing the second side of a page, the image may require rotation. The image is rotated by the co-processor in the printer controller. The co-processor corrects the image printing order for duplexing as follows. · Larger than A4 lengthwise/LT lengthwise (example 8 pages) 1st page 3rd page 2nd page 5th page 4th page 7th page 6th page 8th page · Up to A4 lengthwise/LT lengthwise (example 14 pages) 1st page 3rd page 5th page 2nd page 7th page 4th page 9th page 6th page 11th page 8th page 13th page 10th page 12th page 14th page
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Detailed Descriptions
FEATURES
2.4.3 STAPLING
Stapling is only available when the finisher is installed. The finishers have the following stapling positions. 1) Upper left, diagonal 2) Left, two staples 3) Top, two staples 4) Upper left, horizontal 5) Upper left, vertical Depending on the paper orientation, the image may have to be rotated. This image rotation is done by the co-processor in the printer controller. There is a limit for the number of sheets which can be stapled by finisher. If a job that specifies stapling has more than this number of sheets, it will not be stapled.
2.4.4 PUNCHING
Punching is only available when the punch unit is installed with the 3000 sheet finisher. The punching unit has only one available position, so the relationship between the punching position and the printed image depends on the paper feeding orientation and imaging.
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FEATURES
2.4.5 JAM RECOVERY
If the jam recovery feature is on and a paper jam occurs, the controller will reprint all pages for which a feed-out indication has not been received from the main machine. In usual cases, all image data from the controller will be sent to the hard disk on the main machine, When a jam occurs, the recovery data will be sent from the hard disk on the main machine.
2.4.6 AUTO TRAY SELECT
When "Auto Select" is selected with the printer driver, the printer searches for a tray that contains the specified size of normal plain paper. The search starts from the LCT, and when a tray that contains the specified size of paper is found, the printer starts printing and feeds paper from that tray. The search sequence is as follows. LCT 1st tray 2nd tray 3rd tray LCT The default setting for the current tray is LCT. If the LCT is not installed, the default tray is then the 1st tray.
2.4.7 POWER ON SELF DIAGNOSTICS
When the controller is turned on, it performs a self diagnostic sequence of tests automatically. If any errors were detected, an error message will be displayed on the operation panel.
Test Items
Devices always tested · Co-processor · Flash ROM · Resident RAM · NVRAM · Engine I/F Devices tested when they are installed · DRAM SIMM · PS DIMM I/F · HDD I/F · Network interface board I/F
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Detailed Descriptions
FEATURES
2.4.8 DOCUMENT SERVER
The Document Server enables the operator to save documents in the mainframe memory (HDD), which can be edited and printed as the operator wants. There are two ways to save documents. · Sending data from the computer · Scanning originals from the document feeder (ADF), or the exposure glass of the machine There are three features. · Prepare the documents that the operator wants to save. · Save the documents. The documents are saved in the mainframe memory. · Print the documents. Operator can print any of the saved documents with any desired settings at any time.
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HARD DISK
2.5 HARD DISK
Two hard disks are used for the printer functions. One is connected to the printer controller (Printer HDD). The other is in the main machine (Engine HDD).
After installation only the machine asks you to format the hard disk in the printer mode. If you press the "Continue" button, the machine formats the hard disk. At this time, two partitions will be made on the hard disk. One is for PCL storage and the other is for PostScript (fonts and macros only) storage. If you press the "Cancel" button, the machine determines that there is no optional printer hard disk.
2.5.2 ENGINE HDD
The hard disk in the main machine is used for copy, printer and document server functions. Therefore, the hard disk has three partitions: copier, printer, and document server (one of the copier features). The size of the partitions depend on the setting of "System Settings Count Manager Memory Allocation", as shown in the chart below.
Copy Priority (Default) OMB Document Server Priority Printer Priority Min. Memory for Copier Max. Memory for Copier Max. Mem. for Doc. Server
Copier 650 MB Copier 1050 MB
Copier 650 MB
Copier 450 MB
Copier 450 MB
Printer 200 MB Printer 600 MB Printer 200 MB Document Server 800 MB Document Server 400 MB 1650 MB Document Server 400 MB
Printer 400 MB
Printer 200 MB Copier 1450 MB
Document Server 800 MB
Document Server 100 MB Document Server 100 MB
Document Server 1000 MB
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Detailed Descriptions
2.5.1 PRINTER HDD
PAPER OVERFLOW DETECTION
2.6 PAPER OVERFLOW DETECTION
2.6.1 BRIDGE UNIT
The bridge unit has a paper sensor [A] to detect paper on the bridge unit. This is monitored to ensure that the bridge unit does not contain more than 250 sheets. If a print job of more than 250 sheets is executed, the machine will print up to 250 pages, then the print job is stopped. Once the output stack is removed, the printing job automatically continues. [A]
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INSTALLATION
PRINTER CONTROLLER
3. INSTALLATION PROCEDURE
3.1 PRINTER CONTROLLER
3.1.1 ACCESSORY CHECK
Check the accessories in the box against the following list.
No. 1 2 3 4 5 6 7 Description Controller Box Cover Cable Clamp Key Top - Copy/Printer/Document Server Tapping Screw M4 x 8 Tapping Screw M3 x 6 Ferrite Core Installation Procedure Q'ty 1 1 1 3 6 1 1
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Installation
PRINTER CONTROLLER
3.1.2 INSTALLATION PROCEDURE
[A]
[B] [D]
[C]
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[F]
[G]
[E]
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CAUTION
Unplug the copier power cord before starting the following procedure. 1. Disconnect the ADF connector [A]. 2. Remove the upper rear cover [B] (2 screws [C]). 3. Remove the bracket [D] (2 screws). 4. Remove the cable folder [E] (1 screw). 5. Stretch the flat cable [F]. 6. Thread the flat cable through the ferrite core [G]. NOTE: The ferrite core drops easily, so bend the end of cable as shown in the diagram on the next page.
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PRINTER CONTROLLER
[B] [C] [B]
[G]
[F] [A] [D]
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[E] [J] [I]
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[H]
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7. Install the controller box [A] (3 screws). 8. Attach the flat cable [B] to the ferrite core [C]. 9. Connect the flat cable [D] as shown (1 connector). 10. Connect the cable [E] and attach the clamp [F] (1 connector and 1 screw) 11. Install the cover [G] (5 screws). 12. Remove the key top cover [H] of the operation panel. 13. Install the key top [I] and the key top cover [J] on the operation panel as shown.
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Installation
PRINTER CONTROLLER
14. Make sure that the parallel cable is not connected to the controller and turn the machine on, then check the setting of the following copier SP mode. · SP5-907: Plug & Play Brand Name and Production Name Setting select the correct one. · SP5-811: Machine Serial Number-make sure that this is stored. 15. If the customer wishes to expand the hard disk space in the main machine for use by the printer, change the setting of "Memory Allocation" (User Tools System Settings Count. Manager Memory Allocation) to "Printer Priority". 16. Print the Printer Configuration Page (User Tools Printer Features Test Print Configuration page) to check the printer controller connection. 17. If the parallel cable is going to be connected, turn off the machine first and connect the parallel cable, then turn the machine back on again. NOTE: If the Plug & Play Brand Name setting is changed, perform the power on cycle twice to create a valid new Brand Name, prior to connecting the printer cable to the PC.
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HARD DISK DRIVE
3.2 HARD DISK DRIVE
3.2.1 INSTALLATION PROCEDURE
[B]
[A]
Installation
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[C]
[D]
[E]
A853I503.WMF
CAUTION
Unplug the copier power cord before starting the following procedure. NOTE: When this hard disk drive and the printer controller (A852) are installed at the same time, skip step 1 to 6. 1. Disconnect the ADF connector [A]. 2. Remove the upper rear cover [B] (2 screws [C]). 3. Remove the cover [D] (5 screws). 4. Disconnect the cable [E] (1 connector, 1 clamp).
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HARD DISK DRIVE
[F]
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[G] [H]
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5. Remove the controller box [F] (3 screws, 1 connector, 1 ferrite core). NOTE: The ferrite core drops off the cable easily. 6. Remove the controller cover [G] (12 screws). 7. Remove the controller board [H] (7 screws).
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HARD DISK DRIVE
[B] [C]
[A]
Installation
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8. Attach the HDD brackets [A] to the hard disk drive [B] as shown (2 screws each). 9. Connect the cable [C] to the hard disk drive. 10. Attach the hard disk drive to the printer controller (4 screws, 1 connector). 11. Install the printer controller board in the controller box. 12. Install the controller box in the main machine (refer to the Printer Controller Installation Procedure). 13. After turning on the main switch and pressing the printer key, the machine asks you to format the hard disk drive.
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POSTSCRIPT KIT
3.3 POSTSCRIPT KIT
3.3.1 INSTALLATION PROCEDURE
[B]
[A] [E]
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[C]
[D]
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[F]
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CAUTION
Unplug the copier power cord before starting the following procedure. NOTE: When the hard disk and the printer controller (A852) are installed at the same time, skip steps 1 to 3. 1. Disconnect the ADF connector [A]. 2. Remove the upper rear cover [B] (2 screws [C]). 3. Remove the cover [D] (5 screws). 4. Install the PostScript board [E] into the slot marked "PS SIMM". 5. Attach the PostScript decal [F] to the front cover as shown.
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NETWORK INTERFACE BOARD
3.4 NETWORK INTERFACE BOARD
3.4.1 INSTALLATION PROCEDURE
[B] [A]
Installation
[C] [D]
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[E]
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CAUTION
Unplug the copier power cord before starting the following procedure. NOTE: When the network interface board and the printer controller (A852) are installed at the same time, skip step 1 to 6. 1. Disconnect the ADF connector [A]. 2. Remove the upper rear cover [B] (2 screws [C]). 3. Remove the cover [D] (5 screws). 4. Disconnect the cable [E] (1 connector, 1 clamp).
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NETWORK INTERFACE BOARD
[F]
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[G] [H]
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5. Remove the controller box [F] (3 screws, 1 connector, 1 ferrite core). NOTE: The ferrite core drops off the cable easily. 6. Remove the controller cover [G] (12 screws). 7. Remove the controller board [H] (7 screws).
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NETWORK INTERFACE BOARD
[E] [A] [G] [C]
[B] [F]
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[D]
[I]
[H]
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8. Attach two spacers [A] to the printer controller board [B] (1 screw each). 9. Remove the cover bracket [C] (2 screws). 10. Install the network interface board [D] as shown (2 screws [E] in the accessory box, 2 screws [F] were used for the cover bracket [C]). 11. Connect the cable [G] to both the network interface board and printer controller as shown. 12. Install the printer controller board in the controller box. 13. Install the controller box in the main machine (refer to the Printer Controller Installation Procedure). 14. Attach the ferrite core [H] to the Shielded Twisted Pair (STP) cable [I] as shown.
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Installation
DRAM SIMM
3.5 DRAM SIMM
3.5.1 REQUIRED SPECIFICATION CHECK
Before installing the DRAM SIMM, check that it satisfies the requirements below.
Type Number of bins Access speed Capacity Parity PC Compatible 72 pins 60 ns or faster 8, 16, or 32 MB Any OK
3.5.2 INSTALLATION PROCEDURE
[B]
[A]
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[C]
CAUTION
Unplug the copier power cord before starting the following procedure. 1. Disconnect the ADF connector [A]. 2. Remove the upper rear cover [B] (2 screws [C]).
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DRAM SIMM
[F] [D]
Installation
[E]
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[G]
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3. Remove the cover [D] (5 screws). 4. Disconnect the cable [E] (1 connector, 1 clamp). 5. Disconnect the flat cable [F] (1 connector, 1 ferrite core). NOTE: The ferrite core drops off the cable easily. 6. Remove the controller cover [G] (12 screws).
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DRAM SIMM
[E]
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7. Install the DRAM [H], as shown. NOTE: Make sure that DRAM SIMM is installed properly.
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CONNECTING THE INTERFACE CABLES
3.6 CONNECTING THE INTERFACE CABLES
3.6.1 PARALLEL INTERFACE
An IEEE1284 compatible bi-directional printer cable is required to connect the printer controller to a host PC parallel port.
3.6.2 NETWORK INTERFACE
A STP (Shielded Twisted Pair) cable with RJ45 connectors is required to connect the Network Interface Board to the computer network. (The cable should be Category/Type 5 or better.) After hardware setup, the network setup should be done by the user. The setup procedure is described in the NIB manual.
3.7 CHECKING THE CONNECTION
3.7.1 CONNECTION BETWEEN PRINTER CONTROLLER (and related options; PostScript ROM, DRAM SIMM, Hard Disk Drive, NIB) AND ENGINE.
1. Plug in the power cord and turn on the main and operation switches. 2. Enter the printer user mode. 1) Press the User Tool key. 2) Press the Printer Features button. 3. Print out the printer configuration page. 1) Select the List Print tab. 2) Press the Configuration Page button to print the configuration page. The machine prints the printer configuration page automatically. NOTE: For more detailed information about the operation panel settings, refer to the operation manual. The printer configuration page is similar to that shown on the next page.
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Installation
CHECKING THE CONNECTION
Printer Configuration Page
PCL MENU ORIENTATION = PORTRAIT FORM LENGTH = 60 LINES FONT SOURCE = INTERNAL FONT NUMBER = 0 POINT SIZE = 12.00 PITCH = 10.00 SYMBOL SET = ROMAN-8 POSTSCRIPT MENU PRINT ERRORS = OFF FEEDER MENU PAGE SIZE = LETTER PAPER TRAY = AUTO AUTO TRAY CHANGE = ON BYPASS PAPER TYPE = DUPLEX = OFF BINDING = LONG SEPARATION = OFF STAPLE = OFF PUNCH = OFF PARALLEL MENU EMULATION = AUTO BIDIRECTION = ON I/O TIMOUT = 30 CONFIGURATION MENU RESOLUTION = 600 AUTO CONTINUE = ON SMOOTHING = ON AUTOCONT TIMEOUT = 30 NETWORK MENU I/O TIMEOUT = 30 TCP/IP SETTING IP ADDRESS = 131.100.100.111 SUBNET MASK = 255.255.255.0 GATEWAY ADDRESS = 131.100.100.1 PRINTER DETAILS MODEL: MANUFACTURER: MACHINE S/N: 00000010200 SERVICE PHONE: 00-0000-0000 FIRMWARE LEVELS: Controller 1.15 PeerlessPrint5-E V 1.4.10 98/05/06 PeerlessPrintXL V 1.1.10 98/05/06 PS 1.05 PRINTER OPTIONS Printer Hard Disk Drive Adobe Postscript Network Interface Board PAPER HANDLING OPTIONS MSU Installed Tandem Tray 1 Standard Tray 2 Internal LCT Tray 3 Manual Paper Tray Large Capacity Tray Duplex Unit 9 Bin Mailbox Unit Finisher 3000 Punch Unit, 2 Hole TOTAL MEMORY = 72 MB
[C]
[D]
[A]
Peerless Print is a trademark of Peerless System Corporation. Adobe, PostScript, the Adobe logo and the Postscript logo are the trademarks of Adobe System Incorporated.
A852I509.WMF
[B]
A852I510.WMF
Check the following: · For the printer controller board, confirm that the machine prints the printer configuration page. · For the hard disk drive and PS kit, confirm that the configuration page includes them in the "Printer Options" section [A]. · For DRAM SIMM, confirm that "Total Memory" [B] printed on the configuration page shows the correct amount of memory in the machine (including the 8 MB on board and the SIMM). · For the NIB, confirm that the configuration page includes the "Network Menu" section [C] and includes the network interface board in the "Printer Options" section [A]. · For the firmware version, check "Firmware Levels" [D]. If any problem occurs with the above checks, reinstall the printer controller and other options. Then set up the machine again and redo the test.
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CHECKING THE CONNECTION
3.7.2 CONNECTION BETWEEN MAIN CONTROLLER BOARD AND THE NETWORK INTERFACE BOARD
There are two ways to check the connection between the main controller board and the network interface board. 1. To check "Network Menu" on the configuration page. 2. To check the Network Interface Board Status Sheet with the network information that is printed automatically after power on.
Print the Network Interface Board Status Sheet
Whenever the main switch is turned on, the machine prints the network interface board status sheet automatically. NOTE: If the machine does not print the status sheet, check the Network menu in the printer user tools. If any problem occurs with the above check, reinstall the printer controller and other options. Then set up the machine again and redo the test.
Installation
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SERVICE TABLES
GENERAL CAUTION
4. SERVICE TABLE
4.1 GENERAL CAUTION
Do not turn off the machine or switch the controller off-line when the data LED is blinking or is lit, or the data which has been sent to the controller will be lost. If you need to do this, ask the customer for consent.
4.2 SERVICE PROGRAM MODE
4.2.1 SERVICE PROGRAM ACCESS PROCEDURE
The service program access procedure, such as "Entering Service Program (SP) Mode" and "Exiting SP Mode" is the same procedure as for copier, as follows.
Entering SP mode
# . - 4 $ (depress for more than 3 seconds.)
Exiting SP mode
Press the "Back" and "Exit" keys until the standby mode display appears.
4.2.2 SERVICE PROGRAM MODE TABLES
No. 01 02 03 04 05 06 07 08 09 10 11 Description Flash System From Parallel Flash System From PCMCIA Flash Postscript From Parallel Flash Postscript From PCMCIA Copy Flash ROM Format Disk Print Job Log Data Print Error Log Data Clear Job Log Counter Clear Error Log Data Parallel Loop Back Test Function Downloads the printer controller firmware from a PC through the parallel port. Downloads the printer controller firmware using an IC card through the PCMCIA port. Downloads the PostScript firmware from a PC through the parallel port. Downloads the PostScript firmware using an IC card through the PCMCIA port. Copies the printer controller firmware between ROM DIMM and printer controller Formats the hard disk drive Prints the print/job count log page Prints the printer error log page Clears the print/job counter Clears the error log counter Performs the parallel loop back test
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Service Tables
DOWNLOADING NEW FIRMWARE
4.3 DOWNLOADING NEW FIRMWARE
New firmware for the printer controller and PostScript can be downloaded from a PC through the parallel cable and from a flash memory card through the PCMCIA port.
4.3.1 FIRMWARE UPDATE USING A FLASH MEMORY CARD (SP02 AND 04)
1. Prepare a flash memory card that has been programmed with the latest firmware. NOTE: When you program a flash memory card with a firmware file, use the following parameter settings. · Start Address 000000h · Length 3FFFFFh 2. Turn off the machine, remove the cover [A], and insert the flash memory card [B] into the slot so that the "A" side of the card faces the rear of the machine.
[A]
[B]
A852M501.WMF
3. Turn on the machine and enter the printer SP mode. 4. Select the Flash tab. 5. Press "Flash System From PCMCIA" button or "Flash PostScript From PCMCIA" button depending on the firmware type. 6. Press "Yes" in reply to the confirmation message. Firmware download will take several minutes. 7. After new firmware has been downloaded successfully, turn off the machine, remove the card from the slot, and turn the machine back on. 8. Print the "Printer Configuration Page" to check the new firmware version ([User Tools] [Printer Features] [List Print tab] [Configuration Page]). The firmware version number is printed in the "Printer Details" section of the configuration page.
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DOWNLOADING NEW FIRMWARE
4.3.2 FIRMWARE UPDATE FROM PARALLEL PORT
1. Prepare the latest firmware file and Fcopy.exe on a host computer. 2. Turn off the machine, connect the host computer using a parallel cable, and turn the machine back on. 3. Enter the printer SP mode. 4. Select the Flash tab. 5. Press "Flash System from Parallel" button or "Flash Postscript From Parallel" button depending on the firmware type. 6. Press "Yes" in reply to the confirmation message. 7. On the host computer, start MS-DOS Prompt and type the following command. Either C:\> FCOPY path\filename
Service Tables
or C:\> COPY /b path\filename port CAUTION: Do not turn off the machine while "Downloading New System Software" is displayed on the LCD, even if FCOPY has finished in the MS-DOS Prompt. 8. After the new firmware has been downloaded successfully, turn off the machine, disconnect the printer cable if necessary, and turn the machine back on. 9. Print the "Printer Configuration Page" to check the new firmware version ([User Tools] [Printer] [List Print] [Configuration Page]). The firmware version number is printed in the "Printer Details" section of the configuration page.
4.3.3 FORMATING THE HARD DISK
This function is used to format the printer hard disk. If the hard disk is formatted, the stored data (downloaded fonts and macros) will be erased. So, when performing this function, ask the customer for consent. After this operation, advise the customer to restore their data, if necessary. 1. Enter the printer SP mode. 2. Select the Flash tab. 3. Press "Format Disk" button. 4. Press "Yes" in reply to the confirmation message. Hard disk formatting will take several minutes. 5. After confirming that formatting was successful, turn the machine off and back on again.
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DOWNLOADING NEW FIRMWARE
4.3.4 COPY FLASH ROM
There are two functions; one is to copy the printer controller firmware from the ROM DIMM to the printer controller, the other is to copy code to the ROM DIMM from the printer controller.
Download from ROM DIMM to printer controller
When downloading printer controller firmware from either the flash memory card or a PC, and the operation was not successful and the printer controller does not start up, the controller firmware code cannot be downloaded from the flash memory card or a PC to recover the machine. However, the firmware can be downloaded from ROM DIMM, using the following procedure. [A]
CS0 TB1 CS1 CS0 TB1 CS1 CS1 TB1 CS0 CS1 TB1 CS0
[B]
TB1 IC9 IC10
Printer Controller
IC41
ROM DIMM
A850M500.WMF
1. Remove the printer controller. 2. Change the position of the TB1 jumper [A] on the controller from CS0 to CS1. 3. Change the position of the TB1 jumper [B] on the ROM DIMM that contains the controller firmware from CS1 to CS0. 4. Install the ROM DIMM on the controller. CAUTION: Make sure to install the correct ROM DIMM in the PostScript SIMM. 5. Install the printer controller and turn on the machine. 6. Enter the printer SP mode and press "Copy Flash ROM" button. 7. Press "Yes" in reply to the confirmation message. 8. After downloading is successful, turn off the machine and remove the printer controller then remove the ROM DIMM as well. 9. Reposition the jumpers on the printer controller and ROM DIMM. 10. Reinstall the printer controller then turn on the machine. 11. Check that the printer controller starts up.
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TB2
CN1
TB1
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DOWNLOADING NEW FIRMWARE
Download from the controller to ROM DIMM
CAUTION: Never perform this function if the PostScript ROM SIMM is installed on the controller. Otherwise, the controller firmware will be copied to the PostScript kit. Take out the PostScript ROM SIMM and install a blank ROM DIMM. 1. Remove the printer controller. 2. Install the ROM DIMM on the controller. 3. Install the printer controller and turn on the machine. 4. Enter the printer SP mode and press "Copy Flash ROM" button. 5. Press "Yes" in reply to the confirmation message. 6. After downloading is successful, turn off the machine and remove the printer controller then remove the ROM DIMM as well. 7. Reinstall the printer controller then turn on the machine.
Service Tables
BUSY PE SELECT /AUTOFD NC GND GND PLH GND GND GND GND GND GND GND GND GND GND GND GND /INIT /FAULT NC NC NC /SELECTION
4.3.5 PARALLEL LOOP BACK TEST (SP11)
1. Plug the loop back connector into the parallel port of the printer. 2. Enter the printer SP mode then press "Parallel Loop Back Test" button. 3. Press "Yes" in reply to the confirmation message. The result of the test will be displayed on the operation panel.
Pin No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 Signal Name /STROBE DATA_1 DATA_2 DATA_3 DATA_4 DATA_5 DATA_6 DATA_7 DATA_8 /ACK
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USER PROGRAM MODE
4.4 USER PROGRAM MODE
A user program (UP) mode is available for printer features as well as for copy and fax. Press the User Tool button to access it.
4.4.1 UP MODE TABLE (PRINTER FEATURES)
NOTE: The function of each UP mode is explained in the Printer Reference section of the operating instructions.
1. PCL 1. Orientation 2. Form Length 3. Font Source 4. Font Number 5. Font Size 6. Font Pitch 7. Symbol Set 1. Print Errors 1. Input
2. Postscript 3. Paper Feed
2. Output
1. Paper Size 2. Tray Priority 3. Auto Tray Switching 4. Bypass Paper Type 1. Duplex 2. Sort 3. Staple 4. Punch
4. Parallel
5. Network
6. Configuration
7. List Print
8. Reset Select
1. Printer Language 2. Bi-direction 3. I/O Timeout 1. I/O Timeout 2. IP Address 3. Subnet Mask 4. Gateway Address 1. Resolution 2. Auto Continue 3. Edge Smoothing 4. Continue Timeout 1. PS Font List 2. PCL Font List 3. PS Demo Page 4. PCL Demo Page 5. Configuration Page 1. Job Reset 2. Menu Reset 3. System Reset
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DIP SWITCHES/JUMPER PINS/LEDS
4.5 DIP SWITCHES/JUMPER PINS/LEDS
4.5.1 DIP SWITCHES
SW2:
No. 1 2 3 Function Destination for firmware downloading Source for firmware downloading On To flash ROM OFF To ROM SIMM
4
Operation mode
(No.2, 3) On, On: From Host PC On, Off: From flash memory card Off, On: From ROM SIMM Off, Off: From flash ROM Normal operation Programming firmware
NOTE: The functions of DIP switches no.1, 2, and 3 are enabled when changing the setting of no.4 to the off position. However, do not change the default settings (keep them all on). Always do the firmware downloading using SP mode.
4.5.2 JUMPER PINS
TB1:
Function Bank setting for resident flash ROM CS0 Bank setting for flash ROM is "0". CS1 Bank setting for flash ROM is "1".
TB2
Function Not used UN-PROT PROT Do not change this setting. Keep at "UN-PROT".
4.5.3 LEDS
Symbol PWR LED2 LED3 LED4 LED5 Function This LED turns on when +5 V is supplied to the printer controller. Refer to section 6.2 (LEDs) for more detail.
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Service Tables
DIP SWITCHES/JUMPER PINS/LEDS
4.5.4 SPECIAL TOOLS
Part Number Description Q'ty
A8545120 G0219350
ROM DIMM Loop Back Connector
1 1
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REPLACEMENT AND ADJUSTMENT
PRINTER CONTROLLER BOARD
5. REPLACEMENT AND ADJUSTMENT
CAUTION
Turn off the main power switch and unplug the machine before attempting any of the procedures in this section.
5.1 PRINTER CONTROLLER BOARD
[B]
[A]
A853I501.WMF
[C]
[D]
[E]
A853I503.WMF
1. Disconnect the ADF connector [A]. 2. Remove the upper rear cover [B] (2 screws [C]). 3. Remove the cover [D] (5 screws). 4. Disconnect the cable [E] (1 connector, 1 clamp).
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Replacement Adjustment
PRINTER CONTROLLER BOARD
[F]
A853I504.WMF
[G] [H]
A853I505.WMF
5. Remove the controller box [F] (3 screws, 1 connector, 1 ferrite core). NOTE: The ferrite core drops off the cable easily. 6. Remove the controller cover [G] (12 screws). 7. Remove the controller board [H] (7 screws).
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PRINTER CONTROLLER BOARD
[I]
A850R506.WMF
8. Remove the optional hard disk, network interface board, PS kit, and DRAM SIMMs if they are installed (See their replacement procedures). 9. Remove the NVRAM [I] from the old printer controller and install it on the new printer controller.
Replacement Adjustment
10. Install the options on the new printer controller.
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HARD DISK
5.2 HARD DISK
[B]
[C]
[A]
A850R504.WMF
1. Remove the printer controller (see Printer Controller). 2. Dismount the hard disk [A] with bracket and IDE cable from the printer controller (4 screws). 3. Remove the brackets [B] (2 screws each). 4. Disconnect the IDE cable [C].
5.3 NETWORK INTERFACE BOARD
[A]
[B]
A850R503.WMF
1. Remove the printer controller (see Printer Controller). 2. Disconnect the cable [A] from the printer controller and network interface board. 3. Remove the network interface board [B] (4 screws).
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NETWORK INTERFACE BOARD
5.3.1 POSTSCRIPT ROM BOARD AND DRAM SIMM
[B]
[A]
A850R505.WMF
1. Remove the printer controller (see Printer Controller). 2. Remove the PS ROM board [A]. 3. Remove the DRAM SIMMs [B].
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Replacement Adjustment
TROUBLESHOOTING
ERROR MESSAGES
6. TROUBLESHOOTING
6.1 ERROR MESSAGES
If an error occurred, the error LED lights (red light with the printer key) and an error message is displayed on the LCD.
Copy
Document Server
Printer
A852T501.WMF
Service call (SC) codes
SC No. SC2000 Description / Definition Functional problems (Self diagnostic error) Possible Cause Printer controller board defective.
A diagnostic error occurred at power on. The controller has a hardware problem. Functional problems (Debug trap error) An error has occurred in the controller. The controller has a software problem. Functional problems (Exception error) An error has occurred in the controller. The controller has a software or hardware problem.
SC2001
The controller software has a problem.
SC2002
Printer controller board defective.
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Troubleshooting
ERROR MESSAGES
Other messages
The following errors might need assistance from service.
Error Message Printer HDD Error. Press Reset to cancel current job. Parallel Communication Error. Please set up communication parameters in parallel menu. Press Reset to cancel current job. Print overrun. Press Reset to cancel current job, or press Continue to print. Condition A hard disk error was detected during downloading the macro or fonts. Parallel communication error occurred during a print job via the parallel port. · · · · · This error occurred when a file was being printed in banding mode. A complex page may not have enough time to image a band while the engine is printing the previous page. This error occurred during printing. The language has sent a file that is too complex to interpret in the available memory. Possible Cause Printer HDD defective Printer controller defective An item in the parallel menu was set incorrectly Parallel cable defective Printer controller defective
Memory overflow. Press Reset to cancel current job.
· Insufficient memory · A complex page is printed · The DRAM SIMM board is defective · The controller is defective · Insufficient memory · A complex page is printed · The DRAM SIMM is board defective · The controller is defective
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LEDS
6.2 LEDS
6.2.1 LOCATION
Four LEDs (LED2 to LED5) are located near SW2 on the printer controller. They indicate the progress of the self test, errors and status conditions.
TB2 LED2 LED3 LED4 LED5 PWR
SW2
A850T500.WMF
6.2.2 LED CODE TABLE
Self diagnostic
The following LED table is for the self diagnostic function. When an error occurs during the self diagnostic test, all four LEDs blink then indicate the error as shown in the following table. e.g.) RAM error: All LEDs on (1 s) off (1 s) on (1 s) off (1 s) LED4 on (5 s) return to the beginning. 1 = LED is lit,
LED2 0 0 0 0 0
Troubleshooting
0 = LED is off
LED5 1 0 1 1 0 Description ROM error RAM (resident, SIMM) error: note 1) NVRAM error: note 1) Fatal error Debug trap error: note 2)
LEDs LED3 LED4 0 0 0 1 0 1 1 0 1 1
NOTE: 1) SC2000 is also displayed. 2) SC2002 is also displayed.
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LEDS
Controller Firmware Copy/Download
During controller firmware copying and downloading, the following LED status will be indicated. 1 = LED is lit,
LED2 1 0 1/0 0 1 1 1 1 1 1
0 = LED is off,
LED5 0 0 0 1 1 0 1 0 1 1
1/0 = LED is blinking
Description Data downloading Erasing Programming Verifying Insufficient RAM error Verify failure Download failure (check sum error) Erase failure Download failure (other error) Copy/download success
LEDs LED3 LED4 0 0 1/0 0 1/0 1 0 0 0 0 0 1 0 1 1 0 1 0 1 1
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