Instruction Manual
Version 2.0
BOD2
3D Construction Printer Generation 21. Contents
1.1. Document Version 4
1. Identification 4
1.1. Supplier information 4
2. Product description 6
2.1. General 6
2.1.1. Function description 6
2.1.2. Machine construction 6
2.1.3. Process description 9
2.1.4. Proper use 9
2.1.5. Improper use 9
2.1.6. Modification 9
2.1.7. Before the commissioning 9
2.1.8. Limits of machinery 9
2.1.8.1. Use limits 9
2.1.8.2. Space limits 10
2.1.8.3. Time limits 11
2.1.8.4. Other limits 11
2.2. Machine information 11
2.3. Safety information 11
2.3.1. general 11
2.3.2. Signs 12
2.3.3. Safety functions 12
3. Definitions 16
3.1. Technical terms and abbreviations 16
3.2. Rererences 16
4. Handling 17
4.1. Transport and storage 17
4.2. Unpacking 17
4.3. Safe disposal of packing material 17
4.4. Installation and assembly of the machine 17
4.5. Storage 35
5. Operating manual 36
5.1. Normal function 36
5.1.1. Connecting printer to a computer 36
5.1.2. Manual operation 38
5.1.3. Automatic operation 40
5.1.4. User interface 41
5.1.4.1. Duet touch panel 41
5.1.4.2. Duet3D web interface 41
5.1.4.3. G-code commands 43
5.1.4.3.1. Map foundation 45
5.1.4.4. COBOD Slice 48
5.1.4.4.1. Settings guidelines 49
5.2. Error situations 51
5.3. Signals to be observed 51
5.4. Accessories 52
5.5. Disposal of waste materials 52
6. Maintenance and cleaning 52
6.1. Precautionary measures 52
6.2. Maintenance made by the operator 52
6.2.2. Inspect pump control cable 53
6.2.3. Check printer for obvious signs of damage 53
6.2.4. Test all emergency stops 53
6.2.5. Test Printhead collision detection 54
6.2.6. Test safety door 54
6.2.7. Inspect extruder screw and hopper 54
6.2.8. Inspect hoses and couplers 54
6.2.9. Inspect cables and E-chains 54
6.2.10. Clean rails 54
6.2.11. Grease tooth rack 54
6.3. Maintenance and cleaning made by cleaning personnel 55
6.3.1. Cleaning all parts of the printhead 55
6.3.2. Cleaning material hose 56
6.3.3. Cleaning material mixer 56
6.3.4. Cleaning material pump 56
6.3.5. Cleaning printing Area 56
6.3.6. Cleaning other equipement 56
6.3.7. Cleaning extruder inner parts 56
6.3.8. Cleaning rails 56
6.3.9. Tooth rack 56
6.3.10. Signal lamp 56
6.3.11. Safety door latch 56
6.4. Errors 57
7. Service 58
7.1. Service intervals 58
7.2. Customer service 58
8. Disposal of the machine 58
9. Logbook 59
1.1. Document Version
Version Description Date of issue
UK03 Third version June 2020
2. Identification
2.1. Supplier information
Manufacturer: COBOD International A/S Address: Dronningens Tværgade 26
DK - 1302 København K
Phone +45 70 60 55 33
E-Mail: [email protected]
2.2. Declaration of Conformity
3. Product description
3.1. General
Before the machine is commissioned, the instruction manual must be thoroughly read an understood!
This warning symbol indicates that special precautionary measures must be taken.
If the safety precautions are not observed, it may lead to hazardous conditions and result in personal injury or damage to property.
This symbol indicates that the following information is important.
3.1.1. Function description
This instruction manual describes the proper use of the machine.
The BOD2 is a modular gantry-based 3D construction printer, which is built from 2.5m modules that can be specified and built to customer requirement.
The BOD2 printer works in 3 dimensions. The printhead moves along the X-axis, where the X-axis moves on the Y-axis, and the whole XY-group moves up and down on the 4 Z-columns. Thereby, the gantry principle allows the printer to access any position within the print envelope, while giving complete freedom of move- ment within the volume.
3.1.2. Machine construction
The BOD2 is designed as a stand-alone unit that consists of several integrated units and components:
• 1 printhead, 2 servomotors, drivers included
(One for turning the nozzle and one for controlling the material flow)
• 1 X-axes, width = up to 12.5m , 1 servomotor, drivers included
• 2 Y-axis, length = up to 30m, 2 servomotors, drivers included
• At least 4 Z-columns (legs), height = up to 10m, 4 servomotors, drivers included
• Control cabinet with supply disconnector, electrical equipment, 3D print controller and safety PLCs
Figure 1: BOD2 3D Printer
1 Z1-Axis 14 Y2-Axis
2 Z1-E-box 15 X-Axis
3 Power connection and circuit breaker 16 X-Carriage E-Box
4 Emergency stop 17 Status and Signal Lamp
5 Z1-Carriage 18 X-Carriage
6 Zn-Axis 19 Printhead Material Hopper
7 Hose management 20 Archimedean Extruder Screw
8 Zn-Carriage 21 Cylinder
9 Zn-Axis 22 U-Axis
10 Zn-Carriage 23 Nozzle
11 Zn-Axis 24 Camera Mount
12 Zn-Carriage 25 Printhead IP Cameras
13 Y1-Axis
3.1.3. Process description
The machine is intended for automated extrusion of concrete materials in layers. The shape of the layers is directed by a predefined digital model.
• Fresh concrete or mortar is fed to the hopper. Either manually or by an external pumping device
• From the hopper, the concrete is extruded through a nozzle, and placed in a predefined layer pattern
• Layers are applied on top continuously until the desired geometry is printed
• The machine can be controlled manually or automatically 3.1.4. Proper use
The machine may only be used under the operating conditions foreseen in this instructions manual.
Any other use beyond such operating conditions is deemed disregardance to the instruction manual, and the manufacturer cannot accept any liability what-so-ever for subsequent loss or damage.
Proper use shall be deemed to include:
• The observance of all references of this instruction manual
• The observance of service intervals and maintenance routines 3.1.5. Improper use
The manufacturer / supplier will not be liable for any subsequent loss or damage resulting from improper use of the machine.
Improper use shall be deemed to include:
• The use of substances that may damage the machine parts. Including substances that may create explosive or poisonous gases posing a risk to personnel or property
• Improper or absent maintenance of the machine
• Improper installation of machine or its sub-components
• Use of the machine for other any other operations than the stated purpose 3.1.6. Modification
Any alterations or additions to the machine must be filed in the technical documentation of the machine.
If necessary, the Declaration of Conformity must be updated and resigned. The responsibility for this rests with the owner of the machine.
3.1.7. Before the commissioning
Before the commissioning of the machine, it must be checked that all parts have been installed according to the documentation and instructions from COBOD International A/S. Therefore, all relevant personnel must be instructed in the documentation of the machine – including the instruction manual, maintenance instruc- tions, diagrams etc.
3.1.8. Limits of machinery 3.1.8.1. Use limits
The BOD2 is intended for use within construction sites, and will be installed inside (typically in a tent).
• 3D print of objects within the dimensions of the machine
• Automatic mode used to move the machine based on G-code
• Manual mode used to operate the machine when not printing
• The machine is operated from a web interface or from a touch panel
• The supply disconnector is installed outside of the operating area of the machine
• Energy supply: see Power Sources
3.1.8.2. Space limits
The footprint of the BOD2 is defined by the machine configuration. All sizes for different module configura- tions can be found in table 1 below
Number of
X modules Xp [mm] Xi [mm] Xc [mm]
1 2077 4947 4487
2 4603 7473 7013
3 7129 9998 9539
4 9654 12524 12064
5 12180 15050 14590
Number of
Y Modules pr. axis Yp [mm] Yi [mm] Yc [mm] Z-Columns axis
1 2112 2558 1950 2
2 4638 5084 3350 2
3 7163 7610 7250 2
4 9689 10135 7250 2
5 12215 12661 7250 2
6 14741 15187 7250 3
7 17267 17713 7250 3
8 19793 20239 7250 3
9 22318 22765 7250 4
10 24844 25290 7250 4
11 27370 27816 7250 4
12 29896 30342 7250 5
13 32422 32868 7250 5
14 34948 35394 7250 5
15 37473 37920 7250 6
16 39999 40445 7250 6
17 42525 42971 7250 6
18 45051 45497 7250 7
19 47577 48023 7250 7
20 50103 50549 7250 7
Number of
Z modules Zp[mm] Zi [mm]
1 565 2566
2 3090 5092
3.1.8.3. Time limits
The service life of the machine is 20 years of a daily 8-hour operation. This is based on the presumption that all service and maintenance are complied and conducted according to the instructions that are described in this instruction manual.
3.1.8.4. Other limits
The BOD2 is intended for use on construction sites and must be installed inside (typically in a tent).
Printing material is a premix of concrete and cement-based mortars.
Temperature limits: 5 °C to +50 °C.
3.2. Machine information
Description Unit Value
Measurements (length x width x
height) [m] See table 1
Weight [kg] 5023
Current [A] 32
Voltage [V] 3x400VAC + PE
Frequency [Hz] 50/60
Short circuit current, Ikmin [A] 500
Short circuit current, Ikmax [A] 1200
Max. speed (X – Axis) [mm/s] 250
Max. speed (Y – Axis) [mm/s] 250
Max. speed (Z – Axis) [mm/s] 50
Sound level [dB(A)] Less than 70
Required bed plate flatness [mm/m] 10
Power consumption
(normal operation) [W] 1000
Power consumption (peak) [W] 8000
Power consumption (idle) [W] 50
3.3. Safety information
3.3.1. general
The owner must ensure that the instructions for assembly and use of the equipment supplied by COBOD are available at all times, and understood by the site personnel.
These instructions can be used as the basis for creating a risk assessment. The risk assessment is complied by the owner. However, these instructions do not replace the risk assessment!
For the application and inspection of the COBOD products, the current safety regulations and valid guide- lines in the respective country must be observed.
Materials and working areas are to be inspected before each use and assembly of the machine, in regard to:
• Signs of damage or wear
• Stability
• Function
Deviations from the standard configurations of the BOD2 are only permitted after the further risk assessment has been carried out by the owner.
Appropiate measures for working and operational safety, as well as stability, are defined on the basis of the risk assessment.
Before and after exceptional occurences that may have an adverse effect on the safety in and around the BOD2 system, the owner must immidiately:
• Create another risk assessment, with appripiate measures being carried out based on the results, tho en- sure the safety of the system installation
• Arrange for an extraordinary inspection to be carried out by a cometent person qualified to do so
• Exceptional occurences can include:
• Accidents
• Longer periods of non-usage
• Natural events, e.g. heavy rainfall, icing, heavy snowfall, storms or earthquakes 3.3.2. Signs
The machine is fitted with several mandatory warning signs.
Protection Description Symbol
Electricity Warning:
Control Cabinets.
Only experienced and skilled personnel may open the control cabinets.
Crushing of hands Warning:
Transmission parts, toothed rack on each axis.
Crushing Warning:
When moving the X-, Y- axis and the printhead downwards, between the printhead and floor.
When the printhead is moving towards one of the two
“end” positions on the X-axis.
3.3.3. Safety functions
Before operating the machine, the operator must seek information about the safety functions and the protec- tive equipment of the machine.
The use and operation of the machine must only be initiated when all safety functions are fully present and in The use and operation of the machine must only be initiated when all safety functions are fully present and in an operable condition!
an operable condition!
Defective safety functions and protection equipment may lead to loss of safety and hazardous situations.
In case of defective safety functions and protective equipment, do the following:
• Stop the machine immediately.
• Make sure the machine cannot restart by disconnecting the supply sources to the machine.
The following safety and protection devices are installed on the machine:
Emergency stop function Emergency stop function
The emergency stop function is a supplementary safety function, which has the purpose of preventing a source of hazard from arising caused by the improper use of the machine. For instance, a source of hazard could result in a personal injury, damage to the machine or ongoing work, or it may arise because another safety function is failing.
After activation and before disengaging the emergency stop devices, the machinery shall be inspected in order to detect the reason for activating the emergency stop.
Components included in the safety function Components included in the safety function
Input part Logical part Output part
The emergency stop push-button is shaped like a red push-button switch with a yellow background.
To induce an emergency stop of the machine, the push-button has to be activated.
The emergency stop push-buttons are located in the following loca- tions of the machine:
- One on each leg (Z-axis) - Three on the printhead - One at the control panel - One on the safety door
Disengagement of the emergency stop push-button:
- Turn the red push-button counter clockwise.
Safety controller.
Intelligent controller monitoring the safety function.
The service life of the safety con- troller is 20 years.
The safety function i.e. the ma- chine must not be used beyond 20 years. The use beyond 20 years is conditional, where relevant com- ponents must be replaced by new components of identical or im- proved properties.
The safety controllers are located in the control cabinets.
Servo drives.
Disconnects the power supply to the moving parts.
- X-axis (front-, backwards) - Y-axes (up-, downwards) - Printhead (sideways) - Mixer in the printhead - Rotation of the printhead
The service life of the servo drives is 20 years.
The servo drives are located in the control cabinet.
Displays and alarms Displays and alarms
When activating the emergency stop, the following status will appear on the operator monitor:
”Emergency stop of the machine is activated”.
Operating conditions Operating conditions
The work of the emergency function is unchanged throughout any operation modes of the machine.
The emergency stop function must be activated and tested before commissioning, and after each installa- tion or reinstallation of the machine.
Test: Activating the emergency stop one at the time, must stop all servo drives.
As a minimum, the emergency stop function must be visually checked, and activated at least every 6 months.
Also see section 7 of this instruction manual.
The safety function complies with EN ISO 13849-1:2015.
The emergency stop function is constructed as a Category 3, PL d.
Speed monitoring of the movement of the X–axis and the printhead (optional) Speed monitoring of the movement of the X–axis and the printhead (optional)
The speed monitoring of the movement of the X–axis and the printhead is a safety function, wich has the purpose of preventing them from going faster than 250 mm/sec. If the limit is exceeded, the machine is stopped.
The speed monitoring is optional, and comes together with the perimeter guarding which is also optional.
However, if the application requires a speed higher than 250 mm/sec for the X-axis and the printhead, the perimeter guarding must be installed together with an interlocked door. When entering the guarded zone, by opening the interlocked door, the speed of the X-axis and the printhead is automatically reduced to 250mm/sec, and is then monitored by the speed monitoring as long as the door to the guarded zone is open. As soon as the door is closed, the speed is automatically increased.
See also Interlocked door.
Components included in the safety function Components included in the safety function
Input part Logical part Output part
Encoder.
If the speed limit of 250mm/
sec is exceeded by the X-axis or the printhead, the machinery is stopped.
The encoders are located at/on the drive for the X-axis and on the drive for the printhead.
Safety controller.
Intelligent controller monitoring the safety function.
The service life of the safety con- troller is 20 years.
The safety function i.e. the ma- chine must not be used beyond 20 years. The use beyond 20 years is conditional, where relevant com- ponents must be replaced by new components of identical or im- proved properties.
The safety controllers are located in the control cabinets.
Servo drives.
Disconnects the power supply to the moving parts.
- Y-axis (up-, downwards) - X-axis (for-, backwards) - Printhead (sideways) - Mixer in the Printhead - Rotation of the Printhead
The service life of the servo drives is 20 years.
The servo drivers are located in the control cabinets.
Displays and alarms Displays and alarms
When the door is open, the following status will appear on the operator monitor:
”Door open, running with reduced speed”.
Operating conditions Operating conditions Works:
- Only together with the perimeter guarding and the interlocked door - In automatic and manual mode when the interlocked door is open Maintenance and test
Maintenance and test
The encoders must be tested before commissioning, and after each installation or reinstallation of the ma- chine.
Test: Openening the door, the speed must be reduced to 250 mm/sec. When the door is closed, the speed will increase again. As a minimum, the encoders function must be visually checked and activated at least every 6 months.
Also see section 7 of this instruction manual.
The safety function complies with EN ISO 13849-1:2015.
The speed monitoring function is constructed as a Category 3, PL d.
Interlocked door, perimeter guarding (optional, speed > 250mm/sec.) Interlocked door, perimeter guarding (optional, speed > 250mm/sec.)
This safety function protects the operator against hazardous fast moving parts (speed > 250mm/sec); the X-axis and the movement of the printhead.
The perimeter guarding is optional, and it comes with the speed monitoring which is also optional.
However, if the application requires a speed higher than 250 mm/sec for the X-axis and the printhead, the perimeter guarding must be installed together with an interlocked door. When entering the guarded zone, by opening the interlocked door, the speed of the X-axis and the printhead is automatically reduced to 250mm/sec, and is then monitored by the speed monitoring as long as the door to the guarded zone is open. As soon as the door is closed, the speed increases automatically.
Components included in the safety function Components included in the safety function
Innput part Logical part Output part
Interlock.
The Interlock is an electrical safety device.
The safety device may be coded to prevent bypassing.
The safety device is installed on the doors to the guarded zone.
Safety controller.
Intelligent controller monitoring the safety function.
The service life of the safety con- troller is 20 years.
The safety function i.e. the machine must not be used be- yond 20 years. The use beyond 20 years is conditional, where relevant components must be replaced by new components of identical or improved properties.
The safety controllers are located in the control cabinets.
Servo drives.
Reduces the speed on the following moving parts.
- X-axis (for-, backwards) - Printhead (Sideways)
The service life of the servo drives is 20 years.
The servo drives are located in the control cabinet.
Displays and alarms Displays and alarms
When the door is open, the following status will appear on the operator monitor:
”Door open, running with reduced speed”
Operating conditions Operating conditions
The safety function operates unchanged in any operating condition of the machine.
Maintenance and test Maintenance and test
The safety function must be activated and tested before commissioning, and after each installation or rein- stallation of the machine.
Test: Opening the door, the speed must be reduced to 250 mm/sec. When the door is closed, the speed will increase again. As a minimum, the safety function must be visually checked and activated at least once a day.
Also see section 7 of this instruction manual.
The safety function complies with EN ISO 13849-1:2015.
The speed monitoring function is constructed as a Category 3, PL d.
4. Definitions
4.1. Technical terms and abbreviations
In the following, the technical terms and abbreviations used in this instruction manual are described.
Terms Explanations
Instructed person A person having received the necessary training to carry out a task in a safe and responsible way
3DCP 3D Concrete Printing
Printhead The device that attached on the carriage, handles
extrusion and deposition of material
Nozzle The small piece that sits on the end of the Printhead,
that shapes the final form of the extruded material.
Can be 3D printed or machined.
Origo The starting position of the printer, defined as
[X,Y,Z,E,U] = [0,0,0,0,0]
4.2. Rererences
1. Mixing/pumping equipment M-tec duo mixer. https://m-tec.com
2. Hilti HIT-Z anchors https://www.hilti.dk/medias/sys_master/documents/h1c/h4b/9330166333470/In- struction-for-use-HIT-RE-500-V3-Instruction-for-use-PUB-5307431-000.pdf
3. G-code documentation https://duet3d.dozuki.com/Wiki/G-code
4. Duet3D documentation, firmware updates, maintenance, etc. - https://duet3d.dozuki.com/
5. Handling
This section describes how the machine is to be operated in various situations, and where specific personal qualifications are required.
Installation and dismounting of the machine must be carried out by qualified and trained personnel in order to prevent accidents. Therefore, all safety instructions must be observed.
5.1. Transport and storage
The machine consists of components from various suppliers. Some of these parts are of a size, shape and weight that require special handling. Follow the instruction manual from the manufacturer or supplier on how to apply lifting equipment and the appropriate lifting points.
5.2. Unpacking
When unpacking the machine, it must be controlled to determine if any damages has occurred during trans- port. Damages that could affect the functionality or safety of the machine must be repaired before the ma- chine is operated.
5.3. Safe disposal of packing material
Packing material consists of:
• Specially construction plywood stacking frames (reusable)
• EU pallets (reusable)
• Strappers (reusable)
• polymer strappers (not reusable)
Reusable items, if damaged, must always be disposed of according to local legislation.
Non-reusable items must always be disposed according to local legislation.
5.4.
5.4. Installation and assembly of the machine Installation and assembly of the machine
To ensure a safe use of the printer, the installations must always be performed according to the instructions within this manual.
The following pages entail the different steps for site preparation and installation;
- Site Preparation - Z-Column Installation - Y-Axis Instalation - X-Axis Instalation - Electrical Installation
• Only instructed and certified personnel have the permission to move machine parts using a fork lift truck or crane.
• Only appropriate and certified equipment must be used for the lifting of machine parts.
Site Preparation
Tools needed
16 x Hilti HIT-Z anchors M30x240 1 x Laser measuring device
1 x Angular laser 1 x Marker Pen
1 x Hammer Drill (tripod mounted) 1 x M8 Concrete drill bit
1 x M35 core drill bit 1 x wooden drill guide
1 x small guide box (cardboard or similar)
Using a small block or plate, move out until the distance measured on the laser is within 2mm of your Xc / Yc value from step 1.
Mark the point where the angle laser and distance sensor meet as the correct centerpoint of the next column (Z3)Do the same for the other column (Z4).
Using the drill guide supplied with the machine, place it with its center on the first marked spot (Z1).
Place an angle laser on top of the drill guide cen- tered, so the 90 degree angle are flush with the angle marked on the drill guide.
Ensure, that the two beams are close (<50mm) to the rough points marked in step 2. Mark the outline and the 4 holes of the drill guide and leave the guide in place with the angle laser on top.
Place the laser measurer so the backside flush with the angler laser beam. Point it towards the next center point.
If installing in a warehouse or lab:
Roughly measure out the center points to assure the printer is placed as intended. Go to step 2.
If you are installing on site:
It is recommended to have the land surveyor mark the center positions for the columns to assure cor- rect placement. Go to step 8.
Locate the specific measurements for your BOD2 printer in Table 1. Look for Xc and Yc values re- spectively in the sheet corresponding to your size printer.
Example:
BOD2-562 means that your printer has 5 X mod- ules, 6 Y modules and 2 Z modules. In the table, you will find the values:
Xc = 14590 mm Yc = 4492 mm
Z1
Z3
Z4
Z2
Yc
Xc
Remove the drill guides.
Using an Ø=35mm core drill (tripod mounted), drill out all the marked holes in the foundation.
Make sure to drill to a depth of 250mm and remove all debris from the holes.
If the printer has more than 4 columns, repeat the process in steps of 2 at a time until the full length is measured.
Place a new drill guide in Z2.
Using the angle laser, point back towards the center point of Z2 and Z3.
If the markings and measurements are good, the angle laser should cross the center holes of Z2 and Z3. Small deviations can be tolerated (+-3mm).
If needed, redo the privious steps until the devia- tions is within the limits.
Mark the 4 holes. Repeat this step for column Z3 Place a new drill guide on the point marked at Z3.
Place the angle laser on top as in step 3.
Point the laser, so the two beams now are directed towards Z1 and Z2.
Make sure, that the laser beam towards Z1 is cross- ing exactly in the centerpoint of the Z1 column.
Repeat the procedure from step 4 to precisely mark the new point in Z4. Mark the 4 holes in the drill guide
After the appropriate amount of hardening time, remove the drill guides (see Hilti glue instructions).
Place M30 Nuts and washers on the M30 rods and make sure they are close to level.
You are now ready to install the printer.
Glue the anchor rods in place with HILTI Anchor glue.
Place the drill guide on top of the anchors with a couple of spacers below to ensure they are aligned and verticalFollow instructions from HILTI on the specific anchor glue. HIT-HY 200A must be glued in dry conditionsHIT-RE 500V3 can be glued in wet and dry conditions
Z-column Installation
Tools needed
1 x Crane or telescope forklift (min. 1500 kg at 12 meters) 1 x Appropiate lifting straps 2 x 24mm wrench
32 x Nuts for M30 thread 32 x Washers for M30 bolt 1 x Spirit level
1 x Laser measuring device
Safety
Ensure to always follow local safety proce- dures and use correct Personal Protective Equipment (PPE) when installing the machine
Ensure the tooth rack is oriented towards the inside of the printing area
Mount lifting straps in the dedicated hook on top of Z-columns.
Carefully tilt the column up, until it hangs in the lifting strap.
Move the Z-column above it’s decided mounting bolts.
All other columns (Zn) are identical and can be placed in any order and position in the system.
Locate the Z1 column. This is always the column with the large Ebox and power inlet placed on the back side.
Once the two adjustment bolts are in place and the column is in spirit, tighten the remaining loose bolt by switching back and fourth from upper to lower nut to avoid forcing the plate down / up.
Ensure all bolts are fully tightened.
Repeat for all columns.
Place a high precision spirit level on one side of the truss.
Adjust the screw corrosponding to that side until fully level.
Move the spirit level to the other side and repeat
Loosen both the top and bottom nut on 1 of the 4 bolts.
The bolt in the opposite corner of the place will remain tightened.
Adjustment will be done on the two remaining bolts.
Slowly lower the Z-column onto the bolts in the ground while manually steering the foot in place.
As soon as the Z-column sits on the bottom nuts, place 4 washers and nuts on the bolts to secure it in place.
Remove the lifting straps.
Repeat for all columns.
Tight Tight
Tight Tight
Tight
Loose Ad
just Adjust
WARNING! DO NOT CLIMB ON THE COLUMNS AS IT COULD RESULT IN PERSONNEL INJURIES OR DAMAGES TO THE MACHINE
Y-axes Installation
Tools needed
1 x Crane or telescopic forklift (min. 2000 kg at 6 meters)
1 x 6mm Allen key (or bit) 16 x M8 bolts + washers 1 x Laser measuring device
Safety
Ensure to always follow local safety proce- dures and use correct Personal Protective Equipment (PPE) when installing the machine
Lift the Y-axis by placing lifting straps according to the drawing.
Ensure that the weight is evenly distributed, so the axis is horizontal when lifting.
If the axis is tilting, lower it down and move the straps slightly towards the lower side.
Locate the Numbers on the side of the Y-axes. (Y1, Y)The Y-axes are placed according to the drawing above (Y1 is placed on the same side as the Z1-E-box).
Repeat for the other Y-axis. When done, ensure that on one side, the mechanical endstop plate is removed to allow for the X-axis to be placed.
Secure the axis position by attaching the safety clamps on top of the Y-axis.
Do not fully tighten the screws. The axis needs to be able to move until the X-axis is mounted.
Place the Y-axis centered on top of the X-Carriag- es. To ensure that the axis is centered, measure the distance from the two ends and in towards the column. A small deviation can be tolerated here (2-3mm).
X-axis Installation
Tools needed
1 x Crane or telescope forklift (min 1000 kg at 6 meters)
2 x 24 mm wrench 1 x 4 mm Allen key
16 x M5x16 bolts and washers 4 x End-pieces
8 x M16x100 bolts, nuts and washers
Safety
Ensure to always follow local safety proce- dures and use correct Personal Protective Equipment (PPE) when installing the machine
Ensure that end gaurds has been removed from the ends of both Y-axes in the ends, where the X-axis is mounted from.
Lift the X-axis by placing lifting straps according to the drawing.
Ensure that the Printhead is secured in the middle of the axis and cannot move during installation.
Ensure that the weight is evenly distributed, so the axis is horizontal when lifting. If the axis is tilting, lower it down and move the straps slightly towards the lower side.
Locate the end with 3 electrical sockets on one side.
This end must be mounted on the same side of the printer as the Z1-E-box.
If placed wrongly, the sockets will not fit.
Before installing the X-axis on the machine, ensure that the orientation is correct.
The two ends of the X-axis are different.
- One end has one electrical socket on both sides - The other end has 3 electrical sockets on one side.
E-BOX
Manually move the X-axis back and fourth on the Y-axes, to ensure free and clean movement.
If movement in some places are tight, use a crow- bar to slightly adjust the placement of the Y-axes.
Mount a total of 4 finger guards, one on each side of the box on each end of the X-axis
Secure the end guards again.
The straps can now be relaxed, and the X-axis is in place.
Raise the X-axis to the height, so the wheels and cogs are flush with the Rails on the Y-axes.
Have 1 man on each side to ensure the correct height.
Slowly guide the X-axis into the rails, and move it until it sits directly next to the 2 closest columns.
Don’t remove the lifting straps yet
Electrical Installation
Tools needed
1 x Large flat head screwdriver
Safety
Ensure to always follow local safety proce- dures and use correct Personal Protective Equipment (PPE) when installing the machine.
Ensure, that the power outlet is supplying:
- 380 V AC (3 phases + N + PE) - Min 32 A
- min 300 mA leakage current
Use a phillips flat head screwdriver to tighten all the plugs in its fitting socket.
Turn on the power circuit breaker and do follow- ing checks:
1. The lamp on top of the Printhead is blinking red/
orange
2. Press the green button on the Z1-E-box. A loud beeping should sound and all motors are engaged 3. Lamp on Printhead is blinking either green or orange
If above is not the case, contact support.
Locate the power socket on the bottom of the Z1- E-box.
Ensure the circuit breaker on the side of the E box is turned off (0).
Inser the CEE power cable and ensure it is tight.
Locate all Electrical sockets and connectors on the machine.
- 1 on Z1-E-Box (should be connected always) - 3 on Z1-carriage (same column as the E-box) - 3 on the Y1-Carriage
- 2 on the Y2-Carriage - 2 on all other X-Carriages.
The connectors cannot be connected wrongly. If they fit, they are placed correctly.
Start-up Tests
The BOD2 3D printer is now installed correctly and ready to print.
Test printhead collision safety.
Grab the bottom of the printhead, and yank it hard to any side. The printer should turn off immidiately.
Turn on the machine, and repeat the movement from 4 different angles.
If the printer does not turn off in 1 or more cases, contact support immidiately, before proceeding any further.
Check all emergency stops:
Press the Emergency stop push-button, located next to the circuit breaker in the Z1-E-box.
Ensure the lamp shifts from green to red, and that the movement of the printer is no longer possible.
Release the emergency stop, and turn the machine on again by pressing the green “start” button on the Ebox
Repeat for all emergency stops.
Emergency stop positions:
- 1 on each Z-column - 1 on operators desk In the interface, go to the “Machine Control” tab.
In the right side of the screen under “macros”.
Press:
1. Set Origo 2. Set U-Zero
In turn, move the X-, Y- and Z-axis 20mm
forward / backwards, while observing that the ma- chine is moving accordingly.
Move the U-axis 50 deg and observe the rotation of the nozzle.
Move the Extruder and observe the rotation of the axle inside the hopper.
5.5. Storage
Before storage, the printer must be disassembled into separate parts:
• 1 X-beam (including X- and Y-Carriages)
• 2 Y-beams
• Z-beams (Including X-Carriages and E-box)
• Printhead (including cables)
Parts must be stored assembled in modules and raised from ground (with i.e.: pallets or joists) in such a manner that it is possible to access under using fork lift or wrap lifting strap around. Printhead can be stored on a regular EU-pallet or similar. All cable ends must be covered and tied to the beams to avoid damage. All accessories must be stored on pallets and protected from weather.
Packing of Y- and Z-beams:
Packing of X-axis:
Cable trays should always face upwards or to the side to avoid damages while transporting/handling. Cable connector ends must be stored inside trusses.
Correct placement of beams and columns:
6. Operating manual
The following section describes how the machine is operated in an appropriate, and safe manner. Therefore, the safety instructions described in this instruction manual must be observed.
6.1. Normal function
Operation of the machine can be either in a warehouse or on a construction site. Operator should always be located next to the machine, outside the printing area by a desk with full view of the machine.
If installed on a building site, the machine must be protected from rain and wind in order to achieve the best printing results.
6.1.1. Connecting printer to a computer
Go to the search panel on the PC and type “network connection”.
Select the “view network connections” folder.
Right click on the ethernet connection and select
“Properties”
Direct connection to PC:
Insert a LAN cable into the connector socket locat- ed on the bottom of the E-box. Connect the other end to your PC.
Connection through a router / wifi:
Connect to the router with cable or wifi and skip step 2-4.
Connect to Printhead monitor cameras:
To access the cameras, open two new browser win- dows, and enter the addresses below:
Camera 1: 192.168.0.200 Camera 2: 192.168.0.201 Username: admin Password: cobod2019 Open any browser
(Chrome, Internet explorer, firefox etc) In the browser address line, input:
192.168.0.250
Press “ctrl+D” to bookmark this address.
The web control interface should appear and you can now control the machine.
Multiple pc’s / tablets or smart phones can be con- nected at the same time if necessary.
In the new pop-up window, check:
“Use the following IP address”
Insert the following configuration:
IP Address: 192.168.0.50 Subnet mask: 255.255.255.0 Leave the remaining fields blank.
Press “OK”, and close the previous window.
Your PC is now set to static IP.
NOTE! At any point you can revert this setting by going back to this menu and select “Obtain an IP Address Automatically”. This will disable your connection to the printer.
In the pop-up window, double-click:
“Internet Protocol Version 4 (TCP/IPv4)”.
6.1.2. Manual operation
The machine can be controlled manually using the Duet web interface.
The printhead and axes can be moved manually using the buttons under the “machine control” panel in the web interface.
X-axis movement:
• Positive direction to the right, when standing in front of the machine.
• Distance is in millimeter.
• To change the amount on a button, right click on the button and insert a new value, i.e. 200 mm, 500 mm 1000 mm
Y-axis movement:
• Positive direction moving backwards (away), when standing in front of the machine.
• Distance is in millimeter.
• To change the amount on a button, right click on the button and insert a new value, i.e. 200 mm, 500 mm 1000 mm
Z-axis movement:
• Positive direction upwards.
• Distance is in millimeter
• To change the amount on a button, right click on the button and insert a new value, i.e. 200 mm, 500 mm 1000 mm
U-axis movement:
• The U axis is the rotational movement on the printhead.
• Distance in degrees
• To change the amount on a button, right click on the button and insert a new value, i.e. 200 mm, 500 mm 1000 mm
Extruder movement
• Feed amount is the amount of material being extruded by clicking the button once.
• Feedrate is the speed of extrusion.
• Extrude will move pump Counter Clockwise (seen from top) and push material out using the chosen parameters for feed amount / feedrate.
• Retract will move the pump Clockwise (seen from top) and pull material back.
• To change a number, right click on the button, and insert the updated value.
WARNING!
TO AVOID DAMAGE TO THE EXTRUDER PUMP, NEVER RUN THE EXTRUDER IN A DRY STATE I.E. WITHOUT CONCRETE, OIL OR WATER IN THE HOPPER.
6.1.3. Automatic operation
Automatic operational procedure:
1. Prepare 3D model:
• Prepare a model in any CAD/CAM software. Model must consist of center line surfaces
• Export model as STP or IGS file format
• Import STP or IGS to COBOD slice, set parameters and output G-code (see section 6.1.4.4).
2. Prepare printer
Make sure printer is on, without errors and homed to the desired position (see section 6.1.4.2) Perform a “dry-run” (test print without material).
• In Duet Web Interface (when connected to printer), select “upload and print” on home screen.
• Locate the sliced G-code file from step 1.c. and select this.
• The printer will upload and immediately start printing (without material)
• Observe the first 2-3 layers, that the printer is performing as expected 3. Prepare material
• Use either a manual mixer, a cyclone mixer or a mixing pump (i.e. m-tec Duomix 2000)
• Ensure that the material has the right consistency and water amount before adding it to the pump 4. Print model
• Re-insert the drive-axle into the hopper
• Fill mixed material into pump and extrude a small amount manually using the “extrude” button in the control panel to ensure that nozzle is primed, and material has the right consistency.
• Start print
• Ensure that hopper always has enough material if in manual mode. In automatic mode (using m-tec mix- er-pump), this is controlled automatically.
• Clean machine thoroughly after printing
• See section 7.3.
WARNING: REMOVE MIXING SHAFT FROM HOPPER BEFORE PERFORMING THE NEXT STEP
IF UNEXPECTED HALT HAS CAUSED PRINT TO STOP, ENSURE MATERIAL DOES NOT CLOG THE HOSE OR PUMP UNITS BY BOTH PUMPING AND EXTRUDING MATERIAL FOR 5-10 SECONDS EVERY 2 MINUTES DURING MACHINE STOPS.
6.1.4. User interface
The BOD2 printer has two options for controlling the machine.
1. Using the touch panel mounted on the E-box 2. Using a web interface controller
For all operations it is recommended to use a laptop or tablet with the web-interface to control the machine.
Small movements and adjustments can be performed on the touch panel.
6.1.4.1. Duet touch panel
The touch panel is mounted on front of the Z1-E-box. Use the touch panel to manually move the machine, find the IP of the machine to connect, and access and print files from the local file storage. For any printing operations it is strongly recommended to use the Duet web interface
6.1.4.2. Duet3D web interface
Duet web interface is the preferred control option for BOD2. In this section you will find a short description of the control interface. A full documentation of the interface can be found at:
https://duet3d.dozuki.com/Wiki/Duet_Web_Control_Manual
1. Browser address field. Enter IP address here (see section 6.1.1) 2. Input field for manual G-code commands. (See section 6.1.4.3)
3. Upload and Print. Choose G-code file to be uploaded to printer. Print starts immediately after upload.
4. Status bar indicating state of machine – idle, printing, busy.
5. Emergency Stop – stops machine and restarts control board in the middle of any operation.
6. Machine statistics – displays current machine coordinates in relation to defined Origo.
7. Main menu of Duet to access tabs such as Print Status, G-code Console, Settings and other.
8. Head Movement contains buttons to move printhead in positive or negative X,Y,Z direction. Right click over particular button to change values on buttons.
9. Additional Axes is used to control “U Axis” – rotation and orientation of nozzle.
10. Extruder Control allows you to manually extrude material from the material hopper. Do not use if hop- per is empty – it will result in fast wear of the PCP unit.
11. User-Defined Macros Lists all macros created under the tab “Macros” under main menu of Duet (7).
Macros can be run at any time during operation.
1. Status bar indicating current print-job file as well as percentage of completion.
2. Print Control lets you pause the print. CAUTION: Pausing is not immediate – printer will carry out pre-buffered G-code command before full stop. After pausing, Duet retains all coordinates and print pro- gression. After pausing, “Pause” button becomes “Resume” button.
3. Layer Statistics will gather data related to current print-job and plot it in the graph.
4. Speed Factor and Extrusion Factor allows to change speed and extrusion rates while printing.
5. Z Baby Stepping controls offset along Z-axis (height of the print).
6. File Information displays data Duet can read from the G-code file currently uploaded.
7. Collected Data shows information of Layer Time and Print Duration of the current print-job.
8. Estimations uses current print speed to assess file progress and estimated time remaining until comple- tion.
1. Subsetting tabs – User interface, System Editor, tools, Machine properties, List items 2. Software and firmware information
3. Button to upload firmware, control files, etc.
4. Settings related to communication and reconnecting rules.
5. Apply made changes or reset to factory Defaults.
6.1.4.3. G-code commands
G-code is the industry standard for CNC equipment, and the specific flavor of G-code for BOD2 is similar, with some special additions. Below is a shortlist of usable G-code commands. A full G-code reference docu- mentation can be found at: https://duet3d.dozuki.com/Wiki/G-code.
Move and positioning commands
G1 Xnnn Ynnn Znnn Ennn Fnnn: Move to position Xnnx,Ynnn,Znnn while extruding Ennn amount of ma- terial at Fnnn speed. Can be used partly or with all parameters. G0 can be used for move commands without extrusion.
Go to Position X=400mm, Y=600mm, Z=1200mm, Extrude 150 units of material, at speed 15000 mm/min
Go to position X=400, Y=600 at default speed without extruding.
Defines current position as Origo (X=0mm, Y=0mm, Z=0mm, U=0mm)
Defines current X/Y position to be X=200 Y=200
G1 X400 Y600 Z1200 E150 F15000
G1 X400 Y600
G92 X0 Y0 Z0 U0
G92 X0 Y0 Z0 U0
Use absolute positioning
Use relative positioning
M220 Snnn: Set speed override percentage to nnn % of defined speed
Set speed to 150 % of normal speed (defined by print file). All axes including extruder will increase the speed by 50%.
M221 Snnn: Set extrusion override percentage to nnn % of defined speed
Extrude at 150% of normal extrusion (defined by print file). This will not affect other axes.
Z probing commands
G30: Probe a single point.
This is used, if printing on a small platform, or an even underlayer. Using the ultrasonic distance probe in the printhead, the printer will move down to the correct distance to the floor and reset the Z-homing position to this coordinate.
G29: Probe printing area
Using a predefined mesh-grid, the printer will move around the printing area and probe the distances in a grid.
This grid is used as a transformation matrix to all prints performed after probing, and the printer will auto- matically adjust for uneven surfaces in the foundation or on the floor. See next page for instruction on how to use this function to map a foundation before printing
G90
G91
M220 S150
M221 S150
Save the macro, and run it. Compensation will take more time, the more detailed the mapping.
A 11x11 point map will take roughly 20 minutes to complete.
The map is now stored in the printer, and will auto- matically be activated.
To deactivate the map, run the macro “Disable height compensation”.
Change the compensation taper value to the de- sired height for when the printer has adjusted for the foundation deviations.
Example:
H376 H500
Set compensation height to 500mm.
The value should not be smaller than layer height*30.
Locate the “Map foundation” macro under the macros menu.
Change the size of the mapping area, and number of points to fit your foundation size.
Example:
M557 X0:2500 Y0:2500 P8:8Map an area of:
X=0 to X = 2500mm Y= 0 to Y = 2500mm
8 points on X axis and 8 Points on Y axis Home X-, Y- and Z-axis
In turn, press “home X” and “Home Y” buttons, and wait for the printer to move to the homed postion.
Move the Printhead down manually, so it is less than 300 mm from the foundation.
Press “home Z” button and wait until the printer is idle again.
6.1.4.3.1. Map foundation
Restart after printer failure
Click “Generate gcode” and save it as a new file.
Upload the new .gcode file to the printer.
Move the printhead slightly to the side, and preex- trude a small amount of material to ensure material has not changed consistency.
Start the new print file.
In COBOD Slice:
Open the ongoing project, and ensure the settings are the same as before.
Click “Compute Toolpath” to generate the path.
Under “Edit toolpath” tick the option “Start from recovery point”.
Insert the X, Y and Z values recorded in the previ- ous step here
Home the printer to the excact same position as initially used.
It is alway recommended to use the Machines inbuilt homing functions. Simply press “Home X”, followed by “Home Y” and finally “Home Z”.
Move the printhead to the position where you want to recover the printing from.
Read out the coordinates from the Web interface.
If, during printing or normal operation, the safety circuit has been activated, the printer will have lost its positioning. This can happen if:
- An emergency stop push-button is pressed - A power failure on the grid occours
- The printhead crashes into an object or into the ground
- Any of the internal safety monitoring has been activated.
To reset the printer, and continue printing, follow these guidelines.
6.1.4.4. COBOD Slice
COBOD Slice is a software used to prepare 3D models from various CAD software to print with the BOD2 printer. It generates G-code files which can be read, and interpreted by the printer’s web interface and control board.
Supported import file types:
• .STEP / .STP
• .IGES / IGS
• .BREP
• .OCC
•
1. Main settings and statistics See the page below
2. 3D View port
- 3D view of the drawing on a 1x1 meter grid
- Objects should always be placed in positive space according to the coordinate system.
- Red arrow indicates X-direction - Green arrow indicates Y-direction - Blue arrow indicates Z-direction 3. View options
- Choose the desired view of the model 4. Print preview and simulation
- Simulates the print in real time or in accelerated time. Shows the print direction, material placement and buildup as well as nozzle rotation. Useful for debugging issues in a print model.
1 2
3
4
1.Import Centerlines
2. Layer height
3. Max linear move length 4. Compute toolpath
5. Apply vase mode 6. Start from recovery point 7. Recovery point
8. Start Randomization 9. Nozzle offset
10. Edit toolpath Orientation 11. Edit toolpath order
12. Nozzle width 13. Z-lift
14. Lower head extrusion 15. Use fixed layer time 16. Layer time
17. Print speed 18. Move speed 19. Lift speed 20. Generate G-code
21. Total length 22. Print length 23. Rapid length 24. Estimated duration 25. Estimated concrete volume 26. Layer count
27. First layer Z 28. Last layer Z
29. Single layer statistics
6.1.4.4.1. Settings guidelines
1. Import Centerlines: Import your file in a supported file format. The model must describe the center sur- faces of the desired print
2. Layer height: The actual height of each layer in the print. Normally between 10 and 50mm
3. Max Linear Move length: The size of the subdivision of lines that happens before export. Larger numbers make less smooth curves, while smaller numbers might decrease printing speed
4. Compute toolpath: Generates the toolpath from the 3D model input file using the two parameters above 5. Apply vase mode: Used applied to fully closed contours. In this mode, the printer will print a spiral up-
wards instead of printing layer by layer. This eliminates the small blod of material each layer
6. Start from recovery point: Toggle Yes/No. Used after a printing failure to start from an earlier point of the print
7. Recovery point: The actual coordinate of the print where it should start from. The slicer will generate a G-code starting at this point, and continuing to the full height of the model
8. Start randomization: Used in order to randomly shift the starting point of each layer to avoid having a single seam through the print
9. Nozzle offset: Offsets the nozzle a given distance in X and Y direction throughout the print
10. Edit toolpath orientation: Choose which way the Printhead should be moving on a wall. Click on a wall piece to flip the direction, and check if the direction is correct in the print preview
11. Edit toolpath order: Change the order your components are built in. Only appliccable if there is one or more seperate components in the drawing. Either edit the list, or choose interactively
12. Nozzle width: The actual width of the nozzle being used for this print
13. Z-lift: When the printer moves from one position to another without printing (i.e. between two seperate building components) the Printhead raises this distance to avoid collision with the exsisting print. If flaps are being used, this value should be minimum the length of the flaps +5 mm
14. Lower head extrusion: The amount of material that is pre-extruded right before a new print path starts 15. Use fixed layer time: Optional, instead of setting the print speed, the slicer will use a predefined layer
time, and automatically adjust the speed individually for each layer to time it to the given time. This set- ting will override the speed settings
16. Layer time: Set the desired layer time when using fixed layer time
17. Print speed: Set the desired speed (in X/Y direction) of the printer when printing 18. Move speed: Set the desired speed (in X/Y direction) of the printer when moving 19. Lift Speed: Set the desired speed (in Z direction) for lifting and lowering the printhead 20. Generate G-code: Generate the G-code for the printer, and save it in a chosen directory 21. Total length: Total distance the printer will print + move during the print
22. Print length: Total distance of the printed path of the full print 23. Rapid length: Total distance of the non printing path in the full print
24. Estimated duration: Estimated time it will take to complete the full print. This value is still in some cases 10-15% off compared to actual printing time. For project evaluation add 15% to this time to get a more realistic estimate
25. Estimated concrete volume: The total amount of concrete used for the entire print. This value depends somewhat on the material characteristics, and can be off by 2-5% when using flaps, and up to 50% when not using flaps
26. Layer count: Total number of layers in the print
27. First Layer Z: The position of the printhead above the foundation for the first layer 28. Last layer Z: The position of the printhead above the foundation for the last layer 29. Print layer statistics: Various statistics on each layer of the printed material
6.2. Error situations
Duet3D web interface – Connection Error.
If you received this error while printing, and the print did not stop - then try waiting 1-2 minutes. During which you try to refresh duet3D interface webpage (press f5 on keyboard). The printer can also be controlled via the Touch panel located on the E-box. If the error does not resolve on its own, then try restarting your browser and reconnect to the machine.
6.3. Signals to be observed
Signal Lamp
Signal Description Possible causes Solutions
Red / Orange Blinking
1. Motors and drivers are
not activated 1. Printer is not turned on
2. One or more emergency stops are engaged
3. Machine has surpassed the speed limit
4. No connection to the U-motor 5. Printhead collided with object in its path
6. One or more cables in the ma- chines are disconnected 7. Internal error in the machine
1. Turn on the printer using the green button on the E-box
2. Disengage all emergency stops and turn on the printer
3. Slow the printer down to the speed limit 4. Make sure that the cable between the printhead E-box and the U-motor is connected.
5. Ensure that the printers path is clear of obstruc- tions.
6. Check all cable connections for loose cables.
7. Contact support
Green / Orange Blinking
Material level in hopper is low
If in automatic mode, and the pump is turned on:
No issues
1. Manual pumping mode: The sup- ply of material to the printer is too slow, or the pump has been turned off too long
2. Automatic pumping mode and the pump is not turned on, possible signal error from printer to pump
1. Turn on the pump or fill the material hopper manually
2a. Check the cable connection betwen the printer and the pump
2b. Click the “Output on extrude” macro to activate the pump.
Green Printer is active: No issues
6.4. Accessories
• Concrete pump (optional, third party product)
• Print nozzles
• Ethernet cable – CAT5e 20 meter
• Material silo (optional)
• Safety fence with safe interlocking system (optional)
• Material supply hose (optional)
• Pump controller cable (optional)
• Printer maintenance kit (optional)
• Printer installation kit (optional)
• Printing kit (optional)
6.5. Disposal of waste materials
The BOD2 printer is open to all materials with compatible aggregate sizes and consistency.
COBOD International does not develop, produce or supply any concrete or mortar materials.
For disposal of waste materials, please refer to supplier documentation and local legislation.
7. Maintenance and cleaning
The daily maintenance and cleaning of the machine, and its surroundings, is made by the operator or the spe- cially trained cleaning staff. During this work, the same requirements applies for the use of tools and personal protective equipment in regard to the operational work.
7.1. Precautionary measures
Before the work is initiated, this instruction manual must be read and understood by the personnel.
This is due to some specific tasks having requirements such as the use of personal protective equipment. In these cases, the requirements are to be observed by all occupational groups.
7.2. Maintenance made by the operator
Tasks to be made by the operator are described within this section, where the instructions are meant as minimum requirements to be carried out according to the following plan. Therefore, the operator must have read and understood this instruction manual before any maintenance of the machine is initiated. In addition, when specific tasks require the use of personal protective equipment, this requirement must be complied with.
In regard to maintenance and cleaning tasks, it is recommended that this is documented in form of logbooks or similar documentation in order to record machine’s maintenance. If regular maintenance and cleaning of the machine cannot be demonstrated, the warranty of the manufacturer may not be guaranteed.
Furthermore, there are some special precautionary measures to be taken during maintenance and cleaning.
These will be described under each individual task. However, for the overall maintenance and cleaning tasks, the general instructions for safe conduct with and around the machine are to be followed. This includes the use of personal protective equipment, that machines and components are brought into a safe state before a certain task is initiated, and that the instructions of the manufacturer are complied with.
Task
No. Task Before
printing After
printing After instal- lation
Monthly When required
1 Test axis movement x x
2 Inspect pump control cable x x
3 Check printer for obvious signs of
damage x x x
4 Test all the emergency stops x x
5 Test Printhead collision detection x x
6 Test safety door x x
7 Inspect extruder Screw and hopper x x x
8 Inspect hoses and couplers x x
9 Inspect cables x x
10 Clean rails x x
11 Grease tooth-rack x
12 Check nozzle mount x x x
7.2.1. Test axis movement
Use the Web interface “Machine Control” Panel (see section 6.1.2).
1. Move X-axis Left / Right. Repeat for Y-axis Forward / Backward 2. Move Z-axis Up / Down
3. Move extruder axle (Extrude / Retract)
4. Rotate U-axis (rotational nozzle) Clockwise / Counter-clockwise Observe that all axes are moving the expected direction and length.
7.2.2. Inspect pump control cable
Inspect the cable connecting the printer to the pump for signs of damage or wear. Replace if nessesary.
7.2.3. Check printer for obvious signs of damage
Inspect the printer thoroughly for signs of damage that could cause failure. Damage can include, but is not limited to:
1. Damage to Rails, tooth racks or cog wheels 2. Damage to truss or steel components 3. Damage to carriages
4. Damage to Z1-E-box
7.2.4. Test all emergency stops
While the machine is in operational mode (the signal lamp is green):
One at a time – for each emergency stop push-button located on the machine (1 on each Z-axis, 3 on the printhead, 1 in the control room, 1 on the safety door (if connected).
1. Push the button, observe that signal lamp turns RED
2. When the lamp is red, unlatch the emergency stop button by turning it Clockwise 3. Press the green “start” button on the Z1-E-box to reset. Lamp should turn GREEN
If one or more emergency stop fails the test, immidiately stop all operation of the machine and contact tech- nical support.
7.2.5. Test Printhead collision detection
Grab the bottom of the printhead, and yank it hard to any side. The printer should turn off immidiately.
Turn on the machine and repeat the movement from 4 different angles.
If the printer does not turn off in 1 or more cases, contact support immidiately, before proceeding.
7.2.6. Test safety door
While printer is in operational mode (signal lamp is green) 1. Ensure, that print area is clear of personnel
2. Ensure that door is connected, closed and lock is engaged
3. Ensure that printer has at least 3x3 meters of clearance and is homed 4. Using Web Control, locate file “safety door test” in G-code file library 5. Start printing “safety door test”. The printhead should move 1000 mm/s 6. On safety door, turn the key clockwise 90 deg
7. Printhead movement should immediately slow down to 250 mm/s and door lock should disengage 8. Open the door
9. Turn key counter-clockwise 90 deg. Machine should still move slow. Turn key 90 deg. clockwise again 10. Close the door
11. Turn key 90 deg counter-clockwise. Lock should re-engage, and printhead speed should accelerate to 1000 mm/s
7.2.7. Inspect extruder screw and hopper
Visually inspect the extruder screw for clogged / hardened concrete and visible damage.
Visually inspect material hopper for clogged / hardened concrete and visible damage.
Clean if necessary.
7.2.8. Inspect hoses and couplers
Inspect the material feeder hoses for visible wear and tear and for clogged material.
Inspect the material hose couplers for wear and tear, and check to ensure the gaskets are in place in all the couplings.
7.2.9. Inspect cables and E-chains
Inspect all the electrical cables for damage or wear.
Carefully inspect cables around the mounting places and at hook points Inspect the E-chains for wear.
7.2.10. Clean rails
Ensure that all rails are clean and free of concrete lumps and dust. If necessary, clean with pressurized air or water.
7.2.11. Grease tooth rack
Using regular mechanical grease and a brush, and add grease on all the racks.
Run the printer back and fourt a couple of times to spread the grease.
