uptime increase

Fix problems before they cost you money.

Preventive maintenance keeps your machines running. Certify your crew, keep them current on the latest recommendations, and build routine checks into every shift, so printing never stops.

MAINTENANCE INTELLIGENCE

BOD2 Printers

01

Consumables

DEFINITION

Items that are used up and depleted through normal operation and must be regularly replenished (like water or oil).

Download here – COBOD BOD2 Consumables

02

Wearables

DEFINITION

Parts that gradually degrade through friction, contact, or mechanical stress during operation and need periodic replacement once worn beyond their limit (like tires in a car).

Download here – COBOD BOD2 Wearables

03

Most recommended spare parts

DEFINITION

Parts the manufacturer advises keeping in stock so they are on hand when needed, minimizing downtime that may arise from shipping logistics, customs or other situations.

Download here – COBOD BOD2 Recommended Spare Parts

04

Printer Maintenance – Hourly Tracker

DEFINITION

Information on how to retrieve operational hours from your COBOD Printer.

Download here – COBOD BOD2 Hourly Tracker

MAINTENANCE INTELLIGENCE

BOD3 Printers

01

Consumables

DEFINITION

Items that are used up and depleted through normal operation and must be regularly replenished (like water or oil).

Download here – COBOD BOD3 Consumables

02

Wearables

DEFINITION

Parts that gradually degrade through friction, contact, or mechanical stress during operation and need periodic replacement once worn beyond their limit (like tires in a car).

Download here – COBOD BOD3 Wearables

03

Most recommended spare parts

DEFINITION

Parts the manufacturer advises keeping in stock so they are on hand when needed, minimizing downtime that may arise from shipping logistics, customs or other situations.

Download here – COBOD BOD3 Recommended Spare Parts

04

Printer Maintenance – Hourly Tracker

DEFINITION

Information on how to retrieve operational hours from your COBOD Printer.

Download here – COBOD BOD3 Hourly Tracker

MAINTENANCE INTELLIGENCE

Batch Plant and Silo

01

Consumables

DEFINITION

Items that are used up and depleted through normal operation and must be regularly replenished (like water or oil).

Download here – COBOD Batch Plant Consumables

02

Wearables

DEFINITION

Parts that gradually degrade through friction, contact, or mechanical stress during operation and need periodic replacement once worn beyond their limit (like tires in a car).

Download here – COBOD Batch Plant Wearables

03

Most Recommended Spare Parts

DEFINITION

Parts the manufacturer advises keeping in stock so they are on hand when needed, minimizing downtime that may arise from shipping logistics, customs or other situations.

Download here – COBOD Batch Plant Recommended Spare Parts

04

Batch Plant Maintenance – Hourly Tracker

DEFINITION

Information on how to retrieve operational hours from your COBOD MDS.

Download here – COBOD Batch Plant Hourly Tracker

MAINTENANCE INTELLIGENCE

Pistons Pump

01

Consumables

DEFINITION

Items that are used up and depleted through normal operation and must be regularly replenished (like water or oil).

Download here – COBOD Piston Pump Consumables

02

Wearables

DEFINITION

Parts that gradually degrade through friction, contact, or mechanical stress during operation and need periodic replacement once worn beyond their limit (like tires in a car).

Download here – COBOD Piston Pump Wearables

03

Most recommended spare parts

DEFINITION

Parts the manufacturer advises keeping in stock so they are on hand when needed, minimizing downtime that may arise from shipping logistics, customs or other situations.

Download here – COBOD Piston Pump Recommended Spare Parts

04

Hourly Tracker

DEFINITION

Information on how to retrieve operational hours from your COBOD MDS.

Download here – Piston Pump Hourly Tracker

MAINTENANCE INTELLIGENCE

Warranty Information

01

Warranty Claim Form

DEFINITION

To process any warranty claim, please make sure the attached warranty claim form is filled in and submitted to TechSupport via the ticket system in a timely manner. Claims received without a completed form may be treated as invalid, so completing it in full protects your coverage.

TROUBLESHOOTING

Printer

16 procedures

01

The signal lamp is not on

Symptom

Printer signal lamp light is not on.

Likely cause

The printer has not been initiated.

Steps to resolve

  1. Plug in the operator module and turn on the printer.
  2. Insert and turn the key on the operator module.

02

Discrepancy error

Symptom

Printer signal lamp lights are red. The printer does not respond to movement commands

Likely cause

The system is either in an error state or not activated/turned on properly

Steps to resolve

  1. Check Estops – Go to the main E-box and observe the screen for any E-stops triggered. Remember to check the E-stop on the Operator Panel. A triggered E-stop will show a stop symbol. Release any triggered E-stops.
  2. Check print head collision – Check if the printhead has collided with any objects.

03

Duplicate slave-node addresses

Symptom

Printer signal lamp does not light up. The printer does not respond to movement commands. The printer initiation key does not activate the system.

Likely cause

Some nodes in the printer are duplicated.

Steps to resolve

  1. Contact COBOD/Distributer tech support to ensure that the node numbering is correct.

04

Signal lamp Red – FSOE Slave address error

Symptom

Signal lamp red – troubleshooter: FSoE Slave address error.

Likely cause

The safety system is not validated and needs to be validated.

Steps to resolve

  1. Contact COBOD/Distributer tech support to validate the safety system.

05

Slave application error

Symptom

Printer signal lamp does not light up. The printer does not respond to movement commands. The printer initiation key does not activate the system.

Likely cause

The PLC system does not recognize the setup of the printer or the “slave nodes” are not configured correctly.

Steps to resolve

  1. Make sure that the installation of the printer is correct and make sure that the wiring of the printer is correct and that all plugs have been inserted firmly. (The U-axis is an exception).
  2. Make sure that no ethernet cables are damaged, (Green cables in the echains or loose cables).
  3. Contact COBOD/Distibuter tech support to ensure that the node numbering is correct.

06

Material hopper runs out of material

Symptom

Material hopper running out of material, but the signal lamp is solid green, and pump is not pumping material.

Likely cause

Printer is not outputting pump signal.

Steps to resolve

  1. Go to the “Materials” tab on the HMI and check if your level setting is set too low. Readjust level settings.
  2. Go to the “Materials” tab on the HMI and if it indicates that the hopper is full then safely clean the level sensor on the printhead.

07

Encoder communication disconnected

Symptom

The light is green, but the troubleshooter is stating a “Encoder Communications Disconnection Error”.

Likely cause

A motor with an encoder has been disconnected. This is very common if the printhead is not attached and the system can move around (except the U-axis).

Steps to resolve

  1. Move the printer up and attach the printhead mechanically.
  2. Turn the main power switch to off and connect the U-axis motor.
  3. Reset all errors in the troubleshooter.

08

Motion control – Axis 18

Symptom

The printer is unable to turn the U-axis.

Likely cause

The U-axis cable is not connected.

Steps to resolve

  1. Move the printer up and attach the printhead mechanically.
  2. Turn the main power switch to off and connect the U-axis motor.
  3. Reset all errors in the troubleshooter.

09

Printer stops and drops 5–10 mm

Symptom

Printer stops and drops 5-10mm

Likely cause

An emergency stop has been triggered while the printer is doing a Z – movement

Steps to resolve

  1. Identify the reason that an emergency stop was triggered. Fix and restart the printer.
  2. As positioning will be wrong use the “Realign Z” and “Realign Y” on the HMI to restore accurate positioning.

10

Emergency/collision detection does not work

Symptom

The safety system does not engage.

Likely cause

The safety override has been activated.

Steps to resolve

  1. Insert and turn the safety-override key to the left position.
  2. Pull out the safety-override key.

11

The U-axis stops turning

Symptom

The U-axs stops working suddenly. Troubleshooter stating motor overload.

Likely cause

The U-axis motor has either stalled or got disconnected.

Steps to resolve

  1. Check the troubleshooter to see if the motor has stalled.
  2. Check if it is possible to move the U-axis by hand.
  3. If the U-axis is tight when rotating or the troubleshooter is indicating a motor stall. Check the mechanical assembly for concrete and rusted parts.
  4. If the U-axis moves freely, reset the error, and move the U-axis through the PLC.
  5. If the issue persists, do a “soft reboot” and reset the errors in the troubleshooter.
  6. Contact COBOD/Distributer tech support for further assistance.

12

Motor overload error

Symptom

The motor has stalled, and the signal lamp turns red.

Likely cause

The motor has overloaded due to too much resistance.

Steps to resolve

  1. Set the printer to “PLC mode” in SoftNA.
  2. Reset all errors in the troubleshooter.

13

Signal Lamp red – Ethercat frame not received

Symptom

Printer signal lamp lights red. The printer does not turn on high power

Likely cause

There is a fault on the EtherCAT and/or a EtherCAT cable has been damaged.

Steps to resolve

  1. Isolate the damaged cable or plug.
  2. Repair the damaged plug or cable according to specifications of technician.

14

Pump is turning on – then reversing

Symptom

The pump is turning on and then suddenly reversing.

Likely cause

There is a bad connection in your pump remote.

Steps to resolve

  1. Disconnect the pump remote and check the inside.
  2. If there has been some water sneaking in, dry it out, and reseal it.

15

Motor replacement detected

Symptom

The troubleshooter is stating “Motor Replacement Detected”.

Likely cause

A motor has been replaced and needs to be verified in the PLC system.

Steps to resolve

  1. Contact COBOD/Distributer tech support to reset the motor errors.

16

Brake interlock error

Symptom

The Printer moves up/down on the Z-axis and when stopping, the printer goes into error mode and the signal lamp turns red.

Likely cause

The printer has a bad connection to one of the braking resistors on for the motor Z-carriage. Sudden stop of Z carriages motor due to failing braking system.

Related to this error message: “Power Module error”

Steps to resolve

  1. If possible, move the printer up, until there is room to work inside the Z-carriages.
  2. Open the Z-carriages that has the issue. (Check the Node number). If in doubt, go through all of them.
  3. Turn the main power switch to off and check the wires going from the braking resistor to the driver. If in doubt, contact COBOD/Distributer tech supprot for further assistance.

System area

Batch plant and silo

5 procedures

17

Mixer gate not closing

Symptom

Mixer gate not closing fully.

Likely cause

Gate not cleaned preoperly.

Steps to resolve

  1. Clean the material outlet gate thoroughly.

18

Mixer gate leaking

Symptom

Mixer gate leaking.

Likely cause

Wear on rubber seal.

Steps to resolve

  1. Replace rubber seal.

19

Dosing tolerance is off

Symptom

Less or more material than indended being dosed.

Likely cause

Settings for silo afterrun are off.

Steps to resolve

  1. Increase or decrease the afterrun value (guide in Batch Plant SOP).

20

Added weight to mixer chamber while dosing

Symptom

Added weight to mixer chamber while dosing.

Likely cause

An item or person was placed/stood on the mixer chamber during dosing.

Steps to resolve

  1. Remove any items/move away from the mixer chamber and restart dosing.

21

Cement hardened in silo

Symptom

Cement hardened in silo.

Likely cause

Cement exposed to moistore (environmental conditions).

Steps to resolve

  1. Empty silo
  2. Clean out hardened cement
  3. Locate and resolve cause of issue

System area

Pump operation

5 procedures

22

Piston pressure (K1) rises above 200 bar

Symptom

Piston pressure (k1) too high – rising above 200 bar – and concrete extrusion stops.

Description 1: Blockage in the hose – LOW k1 pumping pressure on reverse pumping

Description 1: S-valve not switching – HIGH k1 pressure on reverse pumping

Steps to resolve

  1. Follow procedure in hose troubleshooting section in Piston Pump SOP – can be found under User Guidelines
  2. Remove ad clean S-valve flange as seen in maintenance section in Piston Pump SOP – can be found under User Guidelines

23

Control board does not switch on

Symptom

Control board does not switch on, when powering up pump

Description 1: No electric power supply

Steps to resolve:

Description 2: Circuit board breakdown

Steps to resolve

  1. Check main fuse, the direction switch on power box should be on 1, ON/OFF switch on power box.
  2. Contact COBOD at techsupport@cobod.com – you can find a direct contact form under the Tech Support tab

24

Pump motor does not start

Symptom

Pump motor does not start

Likely cause

Pump hopper grid is either open or disconnected

Steps to resolve:

Steps to resolve

  1. Make sure the hopper grid on the pump is both closed and connected properly.

25

Pump stops

Symptom

Pump stops during operation

Likely cause

Multiple reasons for error:

Steps to resolve (match numbers above):

Steps to resolve

  1. Mixer grid is open
  2. Insufficient hydraulic oil level
  3. Hydraulic oil level too high
  4. Breakdown of one of the the control electrovalves of the S-valve and/or the pumping pistons control
  5. Make sure the hopper grid on the pump is closed – if not, close it
  6. Top up the hydraulic oil tank.
  7. Check the hydraulic oil level and clean the hydraulic oil radiato – wait for oil to cool down with diesel engine running
  8. Check the electric wiring

26

Agitators do not turn

Symptom

Agitators does not turn / not turning

Likely cause

Multiple reasons for error:

Steps to resolve (match numbers above):

Steps to resolve

  1. Grid on pump hopper is open.
  2. Function not active on the control panel.
  3. Presence of a foreign body that blocks the agitators. Check the pressure on the manometer (k2).
  4. Breakdown of the agitator control electrovalve. Check switch-on of the relative LED.
  5. Make sure the hopper grid on the pump is closed – if not, close it.
  6. Press the button (e1) on the control panel.
  7. Remove the foreign body.
  8. Check agitator electrovalve wiring and relative relay (see wiring diagram in Piston Pump SOP – can be found under User Guidelines).