In the world of professional broadcast and video production, Cobalt Digital Inc. stands out as a well-known manufacturer of openGear modules, encoders, decoders and ancillary equipment. While their gear offers advanced features and reliability, it’s not free from quirks — so we’re diving deep into the most common Cobalt Digital issues, what causes them, and how to resolve or avoid them.
1. Overview: Why Cobalt Digital gear matters
Cobalt Digital supplies cards and frames for high-end video processing — conversion, routing, signal transport, multiviewer, encoding, etc. For example, they upgraded their 9992 encoder/decoder line to support HEVC, frame sync, SRT and other modern workflows. (Sports Video Group)
Given the complexity and mission-critical nature of broadcast infrastructure, even small issues can have major operational impact. So knowing the “gotchas” and best‐practices up front can save headaches.
2. Common Issues Reported for Cobalt Digital Modules
Here are some of the main problem categories reported by users and listed in public release notes:
2.1 Firmware & Software-Related Problems
Cobalt’s release notes list known issues, such as limitations in closed-caption burn-in, timecode formatting, or analog video outputs not supporting certain features. (Cobalt Digital, Inc.)
These typically manifest as:
- Certain overlay or burn-in text showing only in 24-hour format even when 12-hour was selected. (Cobalt Digital, Inc.)
- Analog video outputs limited to certain frame rates, or features disabled because not applicable to that model. (Cobalt Digital, Inc.)
- Remote control or dashboard communication failures after firmware upgrade. (Cobalt Digital, Inc.)
2.2 Hardware & Mechanical Connectivity Issues
Older versions of frames/modules had problems with connector reliability or signal path stability. For example, Cobalt documented that one of their “big issues” was the module interconnect edge connector shearing off in shipping or transport. (The Samtec Blog)
Loose cards, improper seating, thermal stress and vibration are real-world causes of module failures — the owner’s manual explicitly states a check-list around reseating cards, checking power LEDs and cable connections. (Cobalt Digital, Inc.)
2.3 Signal & Workflow Mismatch Problems
In broadcast workflows, mismatches between input formats, wrong frame rates, poorly routed signals, or unrecognised sources often lead to failures. As one article explains:
“Common digital video problems such as blockiness, hiccups, missing frames and jitter can usually be traced to buffering and bandwidth.” (The Broadcast Bridge)
In the case of Cobalt modules:
- If the input signal format isn’t supported, the card may lock up or output black.
- If cascade configurations or multi-card communications are used, older firmware may not support full features (e.g., PIP layouts, cascade mode). (Cobalt Digital, Inc.)
3. Specific Example: Known Issues in 9970-QS/BBG-1070-QS Cards
Digging into the engineering release notes reveals model-specific issues:
- For all 9970-QS and BBG-1070-QS cards, one listed “Known Issue” is that closed captioning ident text burn-in can only be used on PIP 1. (Cobalt Digital, Inc.)
- Another: Timecode burn-in will only appear in 24-hour format regardless of the setting. (Cobalt Digital, Inc.)
- Some controls or menu choices may appear but are non-functional/not applicable for the model. (Cobalt Digital, Inc.)
This kind of detail is important: if you have a system relying on one of the “broken” features (like caption burn-in on PIP 2), you’ll need a workaround or a later firmware/hardware revision.
4. Root Causes Behind the Issues
Understanding why these issues arise helps with preventive strategy:
- Complexity & Density of Design: These modules pack many features into a small form factor; connector stress, thermal loads, signal integrity issues are real. (See the connector problem described by Cobalt) (The Samtec Blog)
- Legacy Feature Support: Some models support both SD/HD/3G/12G, analog and digital; as workflows evolve, not all feature combinations may be tested equally — hence limitations (like analog output only at certain frame rates).
- Firmware vs Hardware Mismatch: New firmware may enable features but hardware may not fully support them (or there may be known issues unresolved). Users sometimes face regressions.
- Installation & Use-Case Mistakes: Even the best hardware can misbehave if wiring, grounding, power supplies, signal cabling or module seating are poor. The manual’s checklist emphasises these. (Cobalt Digital, Inc.)
5. Practical Troubleshooting Steps
If you’re dealing with Cobalt Digital gear showing problems, follow this methodical approach:
- Visual Review – Check connectors, card seating in frame, fans/ventilation, power supply LEDs. Manual emphasises this. (Cobalt Digital, Inc.)
- Check Firmware Version & Release Notes – Compare your version to the latest and review “Known Issues” section in the release notes.
- Review Input/Output Formats – Ensure your source format (frame rate, resolution) matches what the module supports (especially analog/SDI conversions).
- Module Reseat / Replace – If feasible, swap the card into another slot/frame to determine if the issue follows the card or is related to the slot/cabling.
- Consult Support Documentation – Cobalt offers support and publishes engineering release notes. For example: Download “9970-QS release notes” which list issues. (Cobalt Digital, Inc.)
- Escalate to Manufacturer – If the issue is confirmed as “known bug” (e.g., caption burn-in limitation), contact Cobalt for firmware correction, hardware replacement, or workarounds.
6. Preventive Best Practices
To minimise the chance of running into Cobalt Digital issues:
- Use robust, well-regulated power supplies and ensure proper cooling/ventilation of modules.
- Train installation staff to follow the manual’s installation steps (card insertion, cable terminations, frame slots) to avoid mechanical connector stress.
- Keep a firmware-update policy: Track your hardware model and firmware version, subscribe to manufacturer updates/reports.
- Maintain documentation of system configurations, versioning and cabling to aid troubleshooting.
- For mission-critical installs, keep a “known good spare card” on site for quick swap-out and minimise downtime.
7. When the Issue is Not With Cobalt Gear
Sometimes what looks like a Cobalt issue is actually external:
- Faulty cabling or incorrect impedance can cause SDI signal drop-out — some modules may show video corruption though the card is fine.
- Mismatch between software workflows and hardware — e.g., using analog output for features that only work on SDI or digital paths.
- Interference, ground loops, improper grounding can cause random video artefacts rather than a card fault.
- In complex broadcast chains, the “fault” may occur upstream or downstream of the Cobalt module; separation and isolation tests help.
8. Conclusion
While Cobalt Digital gear (openGear modules, encoders, multiviewers and more) is among the higher-end broadcast industry equipment, these devices are sophisticated and can experience issues — from known firmware limitations (like caption burn-in or analog output constraints) to hardware connector stress or installation‐related problems.
By staying informed (through release notes), applying good installation practices, running a methodical troubleshooting approach and keeping firmware up to date, you can mitigate most of the Cobalt Digital issues and ensure your system remains robust and reliable.
If you are currently facing a specific fault with a Cobalt module, feel free to share the model number and symptoms — I can help dig into the particular known issues and possible fixes.
