BOD2 - User Instructions - V3 - 2020 - 06

Instruction Manual
Version 2.0
BOD2
3D Construction Printer
Generation 2
1. Contents
1.1. Document Version 7
1. Identification 7
1.1. Supplier information 7
1.2. Declaration of Conformity 8
2. Product description 9
2.1. General 9
2.1.1. Function description 9
2.1.2. Machine construction 9
2.1.3. Process description 12
2.1.4. Proper use 12
2.1.5. Improper use 12
2.1.6. Modification 12
2.1.7. Before the commissioning 12
2.1.8. Limits of machinery 12
2.1.8.1. Use limits 12
2.1.8.2. Space limits 13
2.1.8.3. Time limits 14
2.1.8.4. Other limits 14
2.2. Machine information 14
2.3. Safety information 14
2.3.1. general 14
2.3.2. Signs 15
2.3.3. Safety functions 15
3. Definitions 19
3.1. Technical terms and abbreviations 19
3.2. Rererences 19
4. Handling 20
4.1. Transport and storage 20
4.2. Unpacking 20
4.3. Safe disposal of packing material 20
4.4. Installation and assembly of the machine 20
4.5. Storage 39
5. Operating manual 40
5.1. Normal function 40
5.1.1. Connecting printer to a computer 40
5.1.2. Manual operation 42
5.1.3. Automatic operation 44
5.1.4. User interface 45
5.1.4.1. Duet touch panel 45
5.1.4.2. Duet3D web interface 45
5.1.4.3. G-code commands 47
5.1.4.3.1. Map foundation 49
5.1.4.4. COBOD Slice 52
5.1.4.4.1. Settings guidelines 53
5.2. Error situations 55
5.3. Signals to be observed 55
5.4. Accessories 56
5.5. Disposal of waste materials 56
6. Maintenance and cleaning 56
6.1. Precautionary measures 56
6.2. Maintenance made by the operator 56
BOD2 Instruction Manual V3 – 06/2020 2

6.2.1. Test axis movement 57
6.2.2. Inspect pump control cable 57
6.2.3. Check printer for obvious signs of damage 57
6.2.4. Test all E-stops 57
6.2.5. Test print head collision detection 58
6.2.6. Test safety door 58
6.2.7. Inspect extruder screw and hopper 58
6.2.8. Inspect hoses and couplers 58
6.2.9. Inspect cables and E-chains 58
6.2.10. Clean rails 58
6.2.11. Grease tooth rack 59
6.3. Maintenance and cleaning made by cleaning personnel 59
6.3.1. Cleaning all parts of the print head 59
6.3.2. Cleaning material hose 60
6.3.3. Cleaning material mixer 60
6.3.4. Cleaning material pump 60
6.3.5. Cleaning printing Area 60
6.3.6. Cleaning other equipement 60
6.3.7. Cleaning extruder inner parts 60
6.3.8. Cleaning rails 60
6.3.9. Tooth rack 60
6.3.10. Signal lamp 61
6.3.11. Safety door latch 61
6.4. Errors 61
7. Service 62
7.1. Service intervals 62
7.2. Customer service 62
8. Disposal of the machine 63
9. Logbook 64

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, this 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. The BOD 2 printer is built from 2.5m mod-
ules and can be built to customer specifications.
The BOD2 printer works in 3 dimensions, with the print head moving on the X-axis, the X-axis bar moving
on the Y-axis and the whole XY-group moving up and down on the 4 Z-columns. The gantry principle allows
the printer to access any position within the print envelope and gives complete freedom of movement within
the volume.
3.1.2. Machine construction
The BOD2 is designed as a stand-alone unit consisting of several integrated units and components:
• At leat four Z-columns (legs), height = up to 10 m, 4 servomotors, drivers included.
• Two Y-axis, length = up to 30 m, 2 servomotors, drivers included.
• One X-axes, width = up to 12.5m , 1 servomotor, drivers included.
• One print head, 2 servomotors, drivers included
(One for turning the nozzle and one for controlling the material flow)
• 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 Main E-box 15 X-axis
3 Power connection and circuit breaker 16 X-carriage E-Box
4 Emergency stop 17 Status lamp
5 Z1-carriage 18 X-carriage
6 Z2-axis 19 Material hopper
7 Hose management 20 Mixing shaft
8 Z2-Carriage 21 PCP
9 Z3-axis 22 U Axis
10 Z3-carriage 23 Nozzle
11 Z4-axis 24 Camera Mount
12 Z4-carriage 25 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 not conform to the instructions manual and the man-
ufacturer 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 machine parts. Including substances that may create explosive or
poisonous gases posing a risk to personnel or property.
• Improper or missing 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 signed again. 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.
Before the commissioning of the machine, all relevant personnel must be instructed in the documentation of
the machine – including instruction manual, maintenance instructions, diagrams etc.
3.1.8. Limits of machinery
3.1.8.1. Use limits
The BOD2 is intended for use on 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 foot print 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 Xp [mm] Xi [mm] Xc [mm]

X modules
1 2077 4947 4487
2 4603 7473 7013
3 7129 9998 9539
4 9654 12524 12064
5 12180 15050 14590
Number of Yp [mm] Yi [mm] Yc [mm] Z-Columns axis
Y Modules pr. 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 Zp[mm] Zi [mm]
Z modules
1 565 2566
2 3090 5092
3 5616 7618
4 8142 10143
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 instructions described in this instruction manual are observed carefully.
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 [m] See table 1
height)
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 [W] 1000
(normal operation)
Power consumption (peak) [W] 8000
Power consumption (idle) [W] 50
3.3. Safety information
3.3.1. general
Theo owner must ensure that the instructions for assembly and use of the equipment supplied by COBOD at
all times are available and understood by the site personnel.
These instructions can be used as the basis for creating a risk assessment. The risk assessment is compiled by
the owner. However, these instructions do not replace the risk assessment!
For the application of and inspection of COBOD products, the current safety regulations and guidelines valid
in the respective country must be observed
Materials and working areas are to be inspected before each use and assembly for
• 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 customer.
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 use
• 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 print head down-
wards, between print head and floor.
When print head is moved 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 protection
equipment of the machine.
The use and operation of the machine must only be initiated when all safety functions are fully present and in
an operable condition!
Defective safety functions and protection equipment may lead to loss of safety and hazardous situations.
In case defective safety functions and protective equipment is found, 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
The emergency stop function is a supplementary safety function, with the purpose of preventing a source
of hazard from arising caused by the improper use of the machine. As an example, a source of hazard could
result in personal injury, damage to the machine or ongoing work, or it may arise because another safety
function is failing.
After actuation and before disengaging the E-stop devices, the machinery shall be inspected in order to
detect the reason for actuation.
Components included in the safety function.
Input part Logical part Output part
Emergency stop push-button Safety controller. Servo drives.
(E-stop) Intelligent controller monitoring Disconnects the power supply to
The emergency stop push-button the safety function. the moving parts.
is shaped like a red push-button The service life of the safety con- - X-axis (front-, back-
switch on a yellow background. troller is 20 years. ward);
Emergency stop of the machine is The safety function i.e. the ma- - Y-axes (up-, down-ward);
induced by activating the emer- chine must not be used beyond - Print head (Side wards);
gency stop push-button. 20 years. The use beyond 20 years - Mixer in the print head.
The emergency stop push-buttons is conditional to the fact that the - Rotation of the print head.
are located at the following places relevant components are replaced The service life of the servo drives
of the machine: by new components of identical is 20 years.
- One on each leg (Z-axis). or improved properties than the The servo drives are located in the
- Three on the print head. original ones. control cabinet.
- One at the control panel. The safety controllers are located
- One on safety door in the control cabinets.
Disengagement of the E-stop push
button:
- Turn the red push button
counter clockwise.
Displays and alarms

When activating an E-stop, the status will appear on the operator monitor:
”Emergency stop of the machine is activated”
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 after each installation or
reinstallation of the machine.
Test: Activating the E-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 Print head (optional)
The speed monitoring of the movement of the X – axis and the print head is a safety function, with the pur-
pose of preventing them 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 also is optional.
If the application requires a speed higher than 250 mm/sec. for the X-axis and print head, the perimeter
guarding together with an interlocked door must be installed. When entering the guarded zone, opening
the interlocked door, the speed of the X-axis and the print head 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.

Input part Logical part Output part
Encoder. Safety controller. Servo drives.
If the speed limit of 250mm/ Intelligent controller monitoring Disconnects the power supply to
sec is exceeded by the X-axis or the safety function. the moving parts.
the print head, the machinery is The service life of the safety con- - Y-axis (Up-, Down wards);
stopped. troller is 20 years. - X-axis (For-, Back- wards);
The encoders are located at/on the The safety function i.e. the ma- - Print head (Sidewards);
drive for the X-axis and on the chine must not be used beyond - Mixer in the print head.
drive for the Print head. 20 years. The use beyond 20 years - Rotation of the print head.
is conditional to the fact that the The service life of the servo drives
relevant components are replaced is 20 years.
by new components of identical The servo drivers are located in
or improved properties than the the control cabinets.
original ones.
The safety controllers are located
in the control cabinets.
Displays and alarms

When the door is open, the status will appear on the operator monitor:
”Door open, running with reduced speed”
Works:
- only together with perimeter guarding and interlocked door;
- in automatic and manual mode when interlocked door is open.
Maintenance and test
The encoders must be tested before commissioning, after each installation or reinstallation of the machine.
Test by opening the door, speed must be reduced to 250 mm/sec. When door is closed, speed is increased.
As a minimum, the encoders function must be visually checked and activated at least every 6 months.

The speed monitoring function is constructed as a Category 3, PL d.

Interlocked door, perimeter guarding (optional, speed > 250mm/sec.)
This safety function is to protect the operator against the hazardous fast moving parts (Speed > 250mm/
sec), the
X-axis and the movement of the print head.
The perimeter guarding is optional and comes together with the speed monitoring, which also is optional.
If the application requires a speed higher than 250 mm/sec. for the X-axis and print head, the perimeter
guarding together with an interlocked door must be installed. When entering the guarded zone, opening
the interlocked door, the speed of the X-axis and the Print head 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.
Components included in the safety function

Innput part Logical part Output part
Interlock. Safety controller. Servo drives.
The Interlock is an electrical safety Intelligent controller monitoring Reduces the speed on the following
device. the safety function. moving parts.
The safety device may be coded to The service life of the safety con- - X-axis (For-, Backwards);
prevent bypassing. troller is 20 years. - Print head (Sidewards);
The safety device is installed on the The safety function i.e. the ma-
doors to the guarded zone: chine must not be used beyond The service life of the servo drives
20 years. The use beyond 20 is 20 years.
years is conditional to the fact The servo drives are located in the
that the relevant components are control cabinet.
replaced by new components of
identical or improved properties
than the original ones.
The safety controllers are located
in the control cabinets.
Displays and alarms

When the door is open, the status will appear on the operator monitor:
”Door open, running with reduced speed”
The safety function operates unchanged in any operating conditions of the machine.
Maintenance and test
The safety function must be activated and tested before commissioning after each installation or reinstalla-
tion of the machine.
Test by opening the door, speed must be reduced to 250 mm/sec. When door is closed, speed is increased
again.
As a minimum, the safety function must be visually checked and activated at least once a day.

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
Print head The device that attached on the carriage, handles
extrusion and deposition of material
Nozzle The small piece that sits on the end of the print head,
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. Where specific personal quali-
fications are required, this will be described.
Installation and dismounting of the machine must be carried out by qualified and trained personnel. To pre-
vent accidents, all safety instructions must be observed.
5.1. Transport and storage

The machine is built 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.
• 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.
5.2. Unpacking
When unpacking the machine, it is to be controlled if damage to the machine has occurred during transport.
Damage affecting the functionality or safety of the machine must be repaired before the machine is put into
operation.
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 law. non reusable items must al-
ways be disposed according to local law.
5.4. Installation and assembly of the machine

To ensure the safe use of the printer, installation must always be performed according to the instructions in
this manual.
Steps for installation:

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)

Locate the specific measurements for your BOD2 If installing in a warehouse or lab:
printer in table 1 Look for Xc and Yc values re- Roughly measure out the center points to assure the
spectively in the sheet corresponding to your size printer is placed as intended. Go to step 2
printer.
If you are installing on site:
Example: It is recommended to have the land surveyor mark
BOD2-562 means that your printer has 5 X mod- the center positions for the columns to assure cor-
ules, 6 Y modules and 2 Z modules. In the table, rect placement. Go to step 8
you will find the values:
Xc = 14590 mm
Yc = 4492 mm
Z1 Z4
Yc
Xc
Z3 Z2
Using the drill guide supplied with the machine, Using a small block or plate, move out until the
place it with its center on the first marked spot (Z1). distance measured on the laser is within 2mm of
your Xc / Yc value from step 1.
Place an angle laser on top of the drill guide cen-
tered, so the 90 degree angle are flush with the angle Mark the point where the angle laser and distance
marked on the drill guide. sensor meet as the correct centerpoint of the next
column (Z3)Do the same for the other column
Ensure, that the two beams are close (<50mm) to (Z4).
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.

Place a new drill guide on the point marked at Z3. Place a new drill guide in Z2.
Place the angle laser on top as in step 3.
Using the angle laser, point back towards the center
Point the laser, so the two beams now are directed point of Z2 and Z3.
towards Z1 and Z2.
If the markings and measurements are good, the
Make sure, that the laser beam towards Z1 is cross- angle laser should cross the center holes of Z2 and
ing exactly in the centerpoint of the Z1 column. Z3. Small deviations can be tolerated (+-3mm).
Repeat the procedure from step 4 to precisely mark If needed, redo the privious steps until the devia-
the new point in Z4. Mark the 4 holes in the drill tions is within the limits.
guide
Mark the 4 holes. Repeat this step for column Z3
If the printer has more than 4 columns, repeat the Remove the drill guides.
process in steps of 2 at a time until the full length is
measured. 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.

Glue the anchor rods in place with HILTI Anchor After the appropriate amount of hardening time,
glue. remove the drill guides. (see Hilti glue instructions)
Place the drill guide on top of the anchors with a Place M30 Nuts and washers on the M30 rods and
couple of spacers below to ensure they are aligned make sure they are close to level.
and verticalFollow instructions from HILTI on the
specific anchor glue.HIT-HY 200A must be glued in You are now ready to install the printer.
dry conditionsHIT-RE 500V3 can be glued in wet
and dry conditions

Z column installation
Tools needed Safety
1 x Crane or telescope forklift Ensure to always follow local safety proce-

(min. 1500 kg at 12 meters) dures and use correct Personal Protective
1 x Appropiate lifting straps Equipment (PPE) when installing the
2 x 24mm wrench machine
32 x Nuts for M30 thread
32 x Washers for M30 bolt
1 x Spirit level

Locate the Z1 column. This is always the column All other columns (Zn) are identical and can be
with the large Ebox and power inlet placed on the placed in any order and position in the system.
back side.
Mount lifting straps in the dedicated hook on top Ensure the tooth rack is oriented towards the
of Z-columns. inside of the printing area
Carefully tilt the column up, until it hangs in the

lifting strap.
Move the Z-column above it’s decided mounting
bolts.

Ad
jus
t
Tight
Loose Ad
jus
t
Slowly lower the Z-column onto the bolts in the Loosen both the top and bottom nut on 1 of the 4
ground while manually steering the foot in place. bolts.
As soon as the Z-column sits on the bottom nuts, The Bolt in the opposite corner of the place will
place 4 washers and nuts on the bolts to secure it in remain tightened.
place.
Adjustment will be done on the two remaining
Remove the lifting straps. bolts.
Repeat for all columns
Tight
Tight
t Tight
gh
Ti
Place a high precision spirit level on one side of the Once the two adjustment bolts are in place and the
truss. column is in spirit, tighten the remaining loose bolt
by switching back and fourth from upper to lower
Adjust the screw corrosponding to that side until nut to avoid forcing the plate down / up.
fully level.
Ensure all bolts are fully tightened.
Move the spirit level to the other side and repeat
Repeat for all columns.

Y axes installation
Tools needed Safety
1 x Crane or telescopic forklift (min. 2000 kg Ensure to always follow local safety proce-
at 6 meters) dures and use correct Personal Protective
1 x 6mm Allen key (or bit) Equipment (PPE) when installing the
16 x M8 bolts + washers machine

Locate the Numbers on the side of the Y-axes. (Y1, Y2)The Y axes are placed according to the above draw-
ing (Y1 is placed on the same side as the main E-box
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.

Place the Y axis centered on top of the Z-carriages. Secure the axis position by attaching the safety
To ensure that the Axis is centered, measure the clamps on top of the Y-axis.
distance from the two ends and in towards the Do not fully tighten the screws. The axis needs to be
column. A small deviation can be tolerated here able to move until the X-axis is mounted.
(2-3mm).
Larger deviations will result in smaller print area
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.

X axis installation
Tools needed Safety
1 x Crane or telescope forklift (min 1000 kg Ensure to always follow local safety proce-
at 6 meters) dures and use correct Personal Protective
2 x 24 mm wrench Equipment (PPE) when installing the
1 x 4 mm Allen key machine
16 x M5x16 bolts and washers
4 x End-pieces
8 x M16x100 bolts, nuts and washers

E-BOX
Before installing the X axis on the machine, Locate the end with 3 electrical sockets on ine
ensure that the orientation is correct. side.
The two ends of the X-axis are different. This end must be mounted on the same side of the
- One end has one electrical socket on both sides printer as the Main E-box.
- The other end has 3 electrical sockets on one side.
If placed wrongly, the sockets will not fit.
Ensure that end gaurds has been removed from

Lift the X-axis by placing lifting straps according to the ends of both Y-axes in the ends where the X-ax-
the drawing. is is mounted from.
Ensure that the print head 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.

Raise the X-axis to the height, so the wheels and Secure the end guards again.
cogs are flush with the Rails on the Y axes.
The straps can now be relaxed, and the X-axis is in
Have 1 man on each side to ensure the correct place.
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
Mount a total of 4 finger guards, one on each side Manually move the X-axis back and fourth on the
of the box on each end of the X-axis 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.

Electrical installation
Tools needed Safety
1 x large flat head screwdriver 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

Locate all Electrical sockets and connectors on the Using a phillips flat head screwdriver, tighten all
machine. the plugs in its fitting socket
- 1 on main Ebox (should be connected always)
- 3 on Z1 carriage (same column as Ebox)
- 3 on Y1 carriage
- 2 on Y2 carriage
- 2 on all other Z carriages.
The Connectors cannot be connected wrongly. If

they fit, they are placed correctly.
Locate the power socket on the bottom of the Turn on the power circuit breaker and do follow-
Main Ebox. ing checks:
Ensure the circuit breaker on the side of the E box 1. The lamp on top of the print head is blinking
is turned off (0). red/orange.
2. Press the green button on the main Ebox. A loud
Inser the CEE power cable and ensure it is tight. beeping should sound and all motors are engaged
3. Lamp on print head is blinking either green or
orange/
If above is not the case, contact support.

Startup tests

In the interface, go to the “Machine Control” tab. Check all E-stops:
In the right side of the screen under “macros”. Press Press the Emergency stop button located next to the
1. Set Origo circuit breaker on the main Ebox.
2. Set U Zero Ensure the lamp shifts from green to red and that
the movement of the printer is no longer possible.
In turn, move the X, Y and Z-axis 20mm
forward / backwards and observe the machine is Release the Estop and turn the machine on again by
moving accordingly. pressing the green “start” button on the Ebox
Move the U axis 50 deg and observe the rotation of Repeat for all Estops.
the nozzle
E-stop positions:
Move the Extruder and observe the rotation of the - 1 on each Z column
axle inside the hopper. - 1 on operators desk
- 3 on print head
Test print head collision safety. The BOD2 3D printer is now installed correctly
and ready to print
Grab the bottom of the print head, and yank it hard
to any side. The printer should turn off immidiately.
Turn on the machine and repeat from 4 different

angles.
If the printer does not turn off in 1 or more cases,

contact support immidiately, before proceeding.

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 Z 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 Z and Y 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
In the following it is described how the machine is operated in an appropriate and safe way. The safety in-
structions 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
Direct connection to PC: Go to the search panel on the PC and type

“network connection”
Insert a LAN cable into the connector socket locat-
ed on the bottom of the Ebox. Connect the other Chose the “view network connections” folder.
end to your PC.
Right click on the ethernet connection and select
Connection through a router / wifi: “Properties”
Connect to the router with cable or wifi and skip

step 2-4.

In the pop-up window, double click the “Internet In the new pop-up window, check “Use the fol-
Protocol Version 4 (TCP/IPv4)” lowing IP address” and put the following configu-
ration:
IP Address: 192.168.0.50
Subnet mask: 255.255.255.0
Leave the remaining fields blank
Press “OK” and then close the previous window.

Your PC is now set to static IP.
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.
Open any browser Connect to print head monitor cameras:

(Chrome, Internet explorer, firefox etc)
To Access the cameras, open two new browser win-
In the browser address line, input: dows. And enter the addresses below
192.168.0.250
Camera 1: 192.168.0.200
Press “ctrl+D” to bookmark this address. Camera 2: 192.168.0.201
The web control interface should appear and you Username: admin
can now control the machine. Multiple pc’s / tablets Password: cobod2019
or smart phones can be connected at the same time
if necessary

6.1.2. Manual operation
The machine can be controlled manually using the Duet web interface.
The print head 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.
1000 mm
Z-axis movement:
• Positive direction upwards.
• Distance is in millimeter
1000 mm
U-axis movement:
• The U axis is the rotational movement on the printhead.
• Distance in degrees
1000 mm

Extruder movement
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.
• 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.

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)
WARNING: REMOVE MIXING SHAFT FROM HOPPER

BEFORE PERFORMING THE NEXT STEP
• 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.
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.
• Clean machine thoroughly after printing

• See section 7.3.

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 main 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.
G1 X400 Y600 Z1200 E150 F15000
Go to Position X=400mm, Y=600mm, Z=1200mm, Extrude 150 units of material, at speed 15000 mm/min
G1 X400 Y600
Go to position X=400, Y=600 at default speed without extruding.
G92 X0 Y0 Z0 U0
Defines current position as Origo (X=0mm, Y=0mm, Z=0mm, U=0mm)
G92 X0 Y0 Z0 U0
Defines current X/Y position to be X=200 Y=200

G90
Use absolute positioning
G91
Use relative positioning
M220 Snnn: Set speed override percentage to nnn % of defined speed

M220 S150
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

M221 S150
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

6.1.4.3.1. Map foundation
Home X, Y and Z axis Locate the “Map foundation” macro under macros
menu.
In turn, press “home X” and “Home Y” buttons, and
wait for the printer to move to the homed postion. Change the size of mapping area and number of
points to fit your foundation size.
Move the print head down manually, so it is less
than 300 mm from the foundation. Example:
Press “home Z” button and wait until the printer is M557 X0:2500 Y0:2500 P8:8Map an area of:
idle again. X=0 to X = 2500mm
Y= 0 to Y = 2500mm
8 points on X axis and 8 Points on Y axis
Change the compensation taper value to the de- Save the macro, and run it. Compensation will
sired height for when the printer has adjusted for take more time, the more detailed the mapping.
the foundation deviations.
A 11x11 point map will take roughly 20 minutes to
Example: complete.
H376 H500 The map is now stored in the printer, and will auto-
Set compensation height to 500mm. The value matically be activated.
should not be smaller than layer height*30
To deactivate the map, run the macro “Disable
height compensation”

Restart after printer failure

If, during printing or normal operation, the safety Home the printer to the excact same position as
circuit has been activated the printer will have lost was initially used. It is alway recommended to use
its positioning. This can happen if: the Machines inbuilt homing functions. Simply
press “Home X”, followed by “Home Y” and finally
- An E-stop is pressed “Home Z”.
- A power failure on the grid occours
- Print head crashes into an object or into the Move the print-head to the position where you
ground want to recover the printing from.
- Any of the internal safety monitoring has been
activated.
Read out the coordinates from the Web interface.
To reset the printer, and continue printing, follow
these guidelines
In COBOD Slice: Click “Generate gcode” and save it as a new file.

Upload the new .gcode file to the printer.
Open the ongoing project, and ensure the settings
are the same as before. Move the printhead slightly to the side, and preex-
trude a small amount of material to ensure material
Click “Compute Toolpath” to generate the path. has not changed consistency.
Under “Edit toolpath” tick the option “Start from Start the new print file.
recovery point”.
Insert the X, Y and Z values recorded in the previ-

ous step here

6.1.4.4. COBOD Slice
COBOD Slice is a software used to prepare 3D models from various CAD software to print with 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
3
• .OCC
1
2
4
1. Main settings and statistics
See 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.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. model must desribe the center surfaces 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
gcode 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 print head 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 print head 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 is start-
ed.
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 print head
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 print head above the foundation for the first layer.
28. Last layer Z: The position of the print head 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, try waiting 1-2 minutes. During which try
to refresh duet3D interface web page (press f5 on keyboard). Printer can also be controlled via Touch panel
located on E-box meanwhile. If error doesn’t resolve on its own, try restarting your browser and reconnect to
the machine.
6.3. Signals to be observed
Signal Lamp
Signal Description Possible causes Solutions
Red / Orange 1. Motors and drivers are 1. Printer is not turned on 1. Turn on the printer using the green button on
not activated 2. One or more Estops are engaged the Ebox
Blinking 3. Machine has surpassed the speed 2. Disengage all estops and turn on the printer
limit 3. Slow the printer down to the speed limit
4. No connection to U-motor 4. Make sure that the cable between print head
5. Print head collided with object in Ebox and U-motor is connected.
its path 5. Ensure the printers path is clear of obstructions.
6. One or more cables in the ma- 6. Check all cable connections for loose cables.
chines are disconnected 7. Contact support
7. Internal error in the machine
Green / Orange Material level in hopper 1. Manual pumping mode: The sup- 1. Turn on the pump or fill the material hopper
is low ply of material to the printer is too manually
Blinking slow, or the pump has been turned 2a. Check cable connection betwen printer and
If in automatic mode, and off too long pump
pump is turned on: no 2. Automatic pumping mode and 2b. click the “Output on extrude” macro to activate
issues pump is not turned on, possible the pump.
signal error from printer to 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 Interna-
tional does not develop, produce or supply any concrete or mortar materials. For disposal of waste materials,
please refer to supplier documentation and local law.
7. Maintenance and cleaning

The daily maintenance and cleaning of the machine and its surroundings is made by the operator or specially
trained cleaning staff. During this work, the same requirements for the use of tools and personal protective
equipment apply as for the operational work.
7.1. Precautionary measures

Before the work is initiated, this instruction manual must be read and understood by the personnel.
In case specific tasks require the use of personal protective equipment, this requirement is to be observed by
all occupational groups.
7.2. Maintenance made by the operator

Tasks to be made by the operator are described in this section. The instructions are meant as minimum re-
quirements to be carried out according to the following plan.
The operator must have read and understood this instruction manual before the maintenance of the machine
is initiated.
When specific tasks require the use of personal protective equipment, this requirement must be complied
with.
For the documentation purpose of the maintenance and cleaning tasks, the keeping of a logbook or similar is
recommended. If the regular maintenance and cleaning of the machine cannot be demonstrated, the manu-
facturer’s warranty may lapse.
Special precautionary measures to be taken during a maintenance and cleaning task will be described under
each single task. For general maintenance and cleaning tasks, the general guide lines are followed for the safe
work at the machine. This includes the use of personal protective equipment, that machinery and compo-
nents are put in a safe condition before the task is initiated, and that the manufacturer instructions are com-
plied with.

Task Task Before After After Monthly When
No. printing printing instal- required
lation
1 Test axis movement x x
2 Inspect pump control cable x x
3 Check printer for obvious signs of x x x
damage
4 Test all E-stops x x
5 Test print head 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 main Ebox
7.2.4. Test all E-stops
While machine is in operational mode (signal lamp is green):
One at a time – for each E-stop button located on the machine (1 on each Z axis, 3 on printhead, 1 in control
room, 1 on safety door (if connected).
1. Push the button, observe that signal lamp turns RED.
2. When lamp is red, unlatch the E-stop button by turning it Clockwise.
3. Press the green “start” button on the main E-box to reset. Lamp should turn GREEN.

If one or more E-stops fails the test, immidiately stop all operation of the machine and contact technical sup-
port.
7.2.5. Test print head collision detection
Grab the bottom of the print head, and yank it hard to any side. The printer should turn off immidiately.
Turn on the machine and repeat 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 door.
9. Turn key counter-clockwise 90 deg. Machine should still move slow. Turn key 90 deg. clockwise again
10. Close 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 or visible damage.
Visually inspect material hopper for clogged / hardened concrete and visible damage.
Clean if necessary
7.2.8. Inspect hoses and couplers
Inspect material feeder hoses for visible wear and tear and for clogged material
Inspect material hose couplers for wear and tear and check to ensure gaskets are in place in all couplings
7.2.9. Inspect cables and E-chains
Inspect all electrical cables for damage or wear.

Carefully inspect cables around mounting places and at hook points
Inspect 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, add grease on all racks. Run the printer back and fourt a couple
of times to spread the grease.
7.3. Maintenance and cleaning made by cleaning personnel

Cleaning tasks to be made by the cleaning personnel is described in this section. The instructions are meant
as a minimum requirement and are to be carried out according to the plan below.
The cleaning personnel must have read and understood this instruction manual before any maintenance and
cleaning of the machine is commenced.
If specific tasks require the use of personal protective equipment, this must be complied with.
For the documentation purpose of maintenance and cleaning tasks, the keeping of a logbook or similar is
recommended. If the regular maintenance and cleaning of the machine cannot be demonstrated, the manu-
facturer warranty may lapse.
Special precautionary measures to be taken during a maintenance and cleaning task, is described under each
single task. For regular maintenance and cleaning tasks, the general instructions for the safe work at the
machine are to be followed. This includes the use of personal protective equipment, and that machines and
components are put into a safe condition before the task is initiated and that the manufacturer instructions
are complied with.
Task No Task After Monthly As

printing required
1 All parts of the print head x
2 Material hose x
3 Material mixer x
4 Material pump x
5 Printing area x
6 Other equipment x
7 Extruder inner parts x
8 Rails x
9 Tooth rack x
10 Signal lamp x
11 Safety door latch x
7.3.1. Cleaning all parts of the print head
After all operation involving fresh concrete (not for dry-runs etc.).
Thoroughly clean using high pressure water or similar:

• Material hopper (inside and outside): Use the excess valve located on bottom.
• Extruder pump: run clean water through pump until outlet water is clean.
• Nozzle and Nozzle clamp: Dismount and clean separately.

• Extruder outlet: Spray from underneath while pump is running.
• Mixing shaft: Take out mixing shaft and clean separately
7.3.2. Cleaning material hose
Thoroughly clean material hose, using specified foam balls and high-pressure water outlet. See specific in-
struction in user manual from hose supplier
7.3.3. Cleaning material mixer
Thoroughly clean the material mixer following the specific guidelines from the mixer supplier
7.3.4. Cleaning material pump
Thoroughly clean the material pump following the specific guidelines from the pump supplier
7.3.5. Cleaning printing Area
• Remove all equipment from the printing area

• Removing all excess materials from floor / ground and dispose of it according to local regulation
• Make sure that the printing area is drained from excess water
7.3.6. Cleaning other equipement
• Empty and clean all equipment that has been in contact with concrete (buckets, shovels etc)
7.3.7. Cleaning extruder inner parts
• Dismount the bottom part of the print head (below material hopper)
• Disassemble rotational nozzle parts.
• Check for material buildup / hardened concrete and clean if necessary
• Check state of bearings and clean / replace if necessary.
• Check state of rubber belt and replace if necessary.
• Check the state of sealings and O-rings and replace if necessary
7.3.8. Cleaning rails
Remove all dust / oil / dirt gathered using high pressure water hose or similar.
7.3.9. Tooth rack
Clean tooth racks with a steel brush or with pressurized water

7.3.10. Signal lamp
Clean signal lamp with pressurized water or a wet cloth
7.3.11. Safety door latch
Inspect safety door latch

Using pressurized air, clean out all dust / dirt gathered. Lubricate latch if necessary.
7.4. Errors
Error No Symptom Procedure

001 Signal lamp is red, printer will not move 1. Check all E-stops are disengaged. Press
start button on E-box
2. Check that material hopper is installed
and closed. Correct, and press start Button on
E-box.
3. Check that printhead is not loaded with
any external weight, or driven into the ground
002 Printhead has crashed into the ground, Sig- To reset printer position:
nal lamp is red 1. Turn off printer using the Circuit Break-
er on main E-box.
2. Insert “override” key in key-hole located
above circuit breaker on main E-box.
3. Turn key clockwise 90 deg. to override
safety.
4. Turn on machine.
5. Manually move Z-axis upwards (Z+200)
using web control.
6. Turn off machine
7. Turn key Counter Clockwise 90 deg and
remove it from keyhole
8. Turn on printer and press green “start”
button on main E-box.
003 Material does not feed from extruder 1. Check material consistency in material
hopper. Add a little water to material, until con-
sistency is more fluid. Manually extrude until
material is coming out of the nozzle.
2. Extruder pump is not connected to
extruder motor. Insert the mixing shaft and try
again.

Error No Symptom Procedure
004 Can’t connect to printer (web control) 1. Check, that ethernet cable is correctly
inserted into both printer and computer
2. On duet touch-panel, press “console” to
see the IP of the machine. Check that you are
connecting to the correct IP.
3. Check ethernet settings. If connected
directly through an ethernet cable, IP should be
set to static, within the same address space as
printer.
4. Turn printer off, wait 10 seconds, and
turn it on again. Try to reconnect.
005 Extruder is clogged, printer goes into error Material is too hard, or has hardened inside
mode when trying to extrude material the pump unit. Immidiately clean the material
hopper, while shifting between extrude and
retract, until pump unit has loosened and mate-
rial comes out. F printer goes into error mode,
restart on green “start” buttom every time.
8. Service
8.1. Service intervals

The servicing of the machine must be carried out by trained personnel only. Various tasks may require var-
ious skills and training. The instructions of this section are meant as a minimum requirement and must be
carried out according to the below plan.
The maintenance staff must have read and understood this instruction manual before the maintenance of the
machine is commenced. If specific tasks require the use of personal protective equipment, the requirement
must be complied with by all occupational groups.
For the documentation purpose of maintenance tasks, the keeping of a logbook or similar is recommended.
If the regular maintenance of the machine cannot be demonstrated, the manufacturer’s warranty may lapse.
Special precautionary measures to be taken during a maintenance task will be described under each single
task. For general maintenance and cleaning tasks, the general guide lines are followed for the safe work at the
machine. This includes the use of personal protective equipment, and that machines and components are put
into a safe condition before the task is initiated and that the manufacturer instructions are complied with.
A service visit should be performed twice yearly.
8.2. Customer service

Manufacturer: COBOD International A/S
Address: Dronningens Tværgade 26
DK - 1302 København K
Phone +45 70 60 55 33
E-Mail: [email protected]

9. Disposal of the machine
Oil and other liquids must be drained off the machine and treated separately according to local regulation.
Switchboards, motors, cables and other electronics must be demounted and treated separately according to
the local regulations.
Metal parts are disposed of as scrap iron.

10. Logbook

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Instruction Manual

BOD2 Instruction Manual V3 – 06/2020 2

BOD2 Instruction Manual V3 – 06/2020 3

2.1. Supplier information

Address: Dronningens Tværgade 26

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3.1.1. Function description

This instruction manual describes the proper use of the machine.

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3.1.4. Proper use

3.1.5. Improper use

3.1.8.1. Use limits

The BOD2 is intended for use on construction sites and will be

BOD2 Instruction Manual V3 – 06/2020 9

Number of Xp [mm] Xi [mm] Xc [mm]

3.2. Machine information

Description Unit Value

3.3. Safety information

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The machine is fitted with several mandatory warning signs.

Protection Description Symbol

Crushing of hands Warning:

3.3.3. Safety functions

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Displays and alarms

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Components included in the safety function.

Displays and alarms

The safety function complies with EN ISO 13849-1:2015.

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Components included in the safety function

Displays and alarms

The safety function complies with EN ISO 13849-1:2015.

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4.1. Technical terms and abbreviations

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5.1. Transport and storage

• Only instructed and certified personnel have the permission

5.3. Safe disposal of packing material

• Specially construction plywood stacking frames (reusable)

5.4. Installation and assembly of the machine

Steps for installation:

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16 x Hilti HIT-Z anchors M30x240

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Place the laser measurer so the backside flush with

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Make sure to drill to a depth of 250mm and remove

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Tools needed Safety

1 x Crane or telescope forklift Ensure to always follow local safety proce-

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Carefully tilt the column up, until it hangs in the

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Tools needed Safety

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Lift the Y-axis by placing lifting straps according to the drawing.