1. Engineer Training XL1200 Mechanics

2. Engineer Training XL1200 Mechanics Confidential 2 The XL1200 is both a Roll to Roll and a Roll to Sheet Printing Machine MachineXL1200-2mXL1200-3mXL1200-5m Length (total)370 cm470 cm650 cm Depth (total)160 cm Height (total)200 cm Weight (unpacked) 2200 Kg3000 Kg3700 Kg Maximum printing width 220 cm320 cm 520 cm General Mechanic Specs

3. Engineer Training XL1200 Mechanics Confidential 3 Working Concept Overview: The XL1200 is comprised of four rotating axles, which are controlled by the motion control system, and a fifth independent collecting shaft. 1.X Axle – Linear motion along the printing table 2.Y Axle – Media advance 3.Z Axle – Media Tension and forward collection 4.T Axle – Backward collection

6. Engineer Training XL1200 Mechanics Confidential 6 General Mechanic Chassis Structure The XL1200 chassis is constructed from Two Aluminum Side Plates, which are connected together by Aluminum Beams and hold all rotating shafts. The Chassis is reinforced using Metal Brackets.

7. Engineer Training XL1200 Mechanics Confidential 7 In each bottom corner of the chassis are the Leveling Pads\Wheels:  The wheels are to be used only for moving and positioning the machine in its place.  The Leveling Pads are the permanent positioning pads of the machine and assist in the final leveling process. General Mechanic Chassis Structure (Cont.)

8. Engineer Training XL1200 Mechanics Confidential 8 General Mechanic - Leveling 5m machines have an additional support leg located in the middle of the main beams, in the front and in the back of the machine.

9. Engineer Training XL1200 Mechanics Confidential 9 XL1200 Ver B Chassis The Ver B XL1200 has a Metal frame of combined R.H.S Metal Profiles,and Metal Sheet – constructed using the combined method of welding and fastened with screws. Several reinforcements are installed on the Side Plates.

10. Engineer Training XL1200 Mechanics Confidential 10 Leveling Pads Positioning

11. Engineer Training XL1200 Mechanics Confidential 11 Ver B Positioning Pads and Wheels

12. Engineer Training XL1200 Mechanics Confidential 12 Printing Table The Printing Table is constructed of:  5 Printing Table Bases spread evenly along the Printing Table  The Bases are connected to corresponding vertical Frame Beams, and accuratly positioned using the Table Spacers Printing Table Plates Frame Support Beam Backlit Glass

13. Engineer Training XL1200 Mechanics Confidential 13 Printing Table 5 Table Profiles evenly spread from the bottom to top are connected to the Table Bases.  4 Printing Table Plates are inserted between the Profiles. Table Profile

14. Engineer Training XL1200 Mechanics Confidential 14 Mechanics – Printing Table  Along the Media Flow Route, there are two rounded Teflon coated Profiles,which are connected to the Chasis under and above the Printing Table. Upper Profile Lower Profile

15. Engineer Training XL1200 Mechanics Confidential 15 The Linear Unit The Linear Unit in the machine consists of three elements: 1.Head Carriage 2.Linear Profile (Linear Beam) 3.Module X

16. Engineer Training XL1200 Mechanics Confidential 16 Head Carriage The Head Carriage is constructed from four sub elements: 1.The Head Carriage Cover.  Completely covers the Head Carriage,  Protects the electronic parts installed within, includes 2 maintenance doors and ventilation windows.

17. Engineer Training XL1200 Mechanics Confidential 17 Head Carriage 2.Head Carriage Frame: Includes  The Printing Heads Plate  The Printing Heads and Holders  The Ink Secondary Tanks, and  The air valves.

18. Engineer Training XL1200 Mechanics Confidential 18 Head Carriage 3. Cards Plate:  Holds the CCB2 cards, the 5/12 V  P.S., the optic sensor, and the air manifold.

19. Engineer Training XL1200 Mechanics Confidential 19 Head Carriage 4.Head Carriage Base Plate:  Groups all the above sub elements and connects them to Motion Belt and the Linear Bearings.  The Base Plate is connected to the inner bearing using the head box plate support, which is also used for leveling the head carriage. head box plate support

20. Engineer Training XL1200 Mechanics Confidential 20 The Linear Profile The Linear Profile consists of five main elements: 1.The Linear Beam 2.Two Pulleys on each end of the beam 3.Tension Belt 4.Tenacity block, which adjusts the tension of the belt 5.Three Linear Bearings

21. Engineer Training XL1200 Mechanics Confidential 21 The Linear Profile

22. Engineer Training XL1200 Mechanics Confidential 22 The Linear Profile Upper view of Linear Profile Linear Bearings Tenacity Block Linear Bearings

23. Engineer Training XL1200 Mechanics Confidential 23 The Linear Profile The linear profile is laid on top of the machine’s front chassis beam with a set of adapters, which are specially designed to allow the very fine adjustment of the profile’s position (twist and leveling).

24. Engineer Training XL1200 Mechanics Confidential 24 The Linear Profile (Cont.)

25. Engineer Training XL1200 Mechanics Confidential 25 Module X Module X consists of four main elements: 1.Coupling 2.Gear Adapter 3.Gear, decreases the speed of the motor at a ratio of 1:5 4.Electric Servo Motor, which powers the X axis 4 3 2 1

26. Engineer Training XL1200 Mechanics Confidential 26 Y Axis The Y-axis consists of five basic parts: 1.Rubber Shaft, which grips the substrate and determines its advance. 2.Two Bearing Holders, holding the rubber shaft in place. One bearing holder allows free axial movement. 3.Two Bearings 4.Coupling 5.Module Y

27. Engineer Training XL1200 Mechanics Confidential 27 Y Coupling The Coupling consists of two basic elements: 1.Torsionsstefie Kuppling, bridge element between the Gear output shaft and the rubber shaft. 2.Two Clampex, one for the output shaft from the gear (2a), and one for the rubber shaft (2b). 1 2b 2a

28. Engineer Training XL1200 Mechanics Confidential 28 Module Y The Module Y consists of four parts : 1.The Gear output shaft 2.Gear Adapter 3.Gear with a ratio of 1:91 4.Electric Servo Motor 4 3 2 1

29. Engineer Training XL1200 Mechanics Confidential 29 Installation of Module Y The installation of the Y Module is as follows: 1.Mount the Torsionsstefie Kuppling on the Clampex.  The Allen screws on the Clampex should be facing the inside of the Torsionsstefie Kuppling, and tighten just enough for the two parts to attach together.  Note: The two parts should be flushed on the outside. 2.Mount the Sub Assy on the rubber shaft and tighten the Allen screws.  Note: Make sure the coupling rotates around its axis smoothly without deviation. In order to achieve this, tighten opposing positioned screws; check the alignment of the coupling by rotating the Y shaft for a few rounds.

30. Engineer Training XL1200 Mechanics Confidential 30 Installation of Module Y 3.Mount the second Clampex on the Gear Shaft and lock the shaft with a circlips.  Note: Screw tops should be facing inwards 4.Install the Module in the Side Plate, assuring that the Clampex is inserted into the Torsionsstefie Kuppling and that the faces are flushed. 5.Tighten screws crosswise.

31. Engineer Training XL1200 Mechanics Confidential 31 New Y Coupling

32. Engineer Training XL1200 Mechanics Confidential 32 Z AXIS The Z axle is comprised of two shafts:  Z rubber shaft  Teflon pressure shaft When using the Roll to Roll printing mode, the substrate is taped to the rubber shaft, which is the end of the media path. Z Rubber Shaft Teflon Pressure Shaft

33. Engineer Training XL1200 Mechanics Confidential 33 Z AXIS 1.When using a Roll to Sheet printing mode, the substrate flows around the rubber shaft scope to the Teflon pressure shaft, creating an S shape in the substrate flow route. 2.The rubber shaft is then lowered to press the pressure shaft. 3.The pressure created between the rubber shaft and the Teflon pressure shaft, plus the friction between the substrate and the rubber shaft ensures the grip of the substrate and the tension needed for the printing process. Note: When the standard Printing mode is selected, the Z shaft is pushed upwards by the two Pistons located at both sides of the shaft and than secured into position by the Free Fall Bracket Pin. Media Z –Shaft Teflon Pressure Shaft

34. Engineer Training XL1200 Mechanics Confidential 34 Z AXIS An Indicator Clock is mounted on each Free Fall Arm to assist in the adjustment of the Z-Rubber Shaft’s Parallelism and for each media type used in the Free Fall mode.

35. Engineer Training XL1200 Mechanics Confidential 35 Module Z The Module Z is constructed from four main parts: 1.Aluminum Coupling 2.Gear Adapter 3.Gear with a ratio of 1:50 4.Electric Servo Motor 4 3 2 1

36. Engineer Training XL1200 Mechanics Confidential 36 4 3 2 1 Module T The Module T is constructed from four main parts: 1.Aluminum Coupling 2.Gear Adaptor 3.Gear with a ratio of 1:50 4.Electric Servo Motor

37. Engineer Training XL1200 Mechanics Confidential 37 Teflon Pressure Shaft – for Y axle  The Teflon Pressure Shaft provides the initial pressure needed for traction between the substrate and the Y rubber shaft  It’s product tree name is Substrate Pressure Sub Assy and it is constructed from: 1.Roller Tube 1

38. Engineer Training XL1200 Mechanics Confidential 38 Teflon Pressure Shaft – for Y axle 2.Support Arm on which the the Roller Tube is laid. It is connected to the machine frame and to the pistons  On the two ends of the tube the Arm is connected to the Tube, but not to the pistons. 2

39. Engineer Training XL1200 Mechanics Confidential 39 Teflon Pressure Shaft – for Y axle 3.Pneumatic Piston  The Pistons are supplied with 2.5 Bar air pressure.  The connection of the air tube is with a Quick Connection.  The Quick Connection is also mounted to a flow valve which can increase and decrease the speed at which the piston is coming out or going in.

40. Engineer Training XL1200 Mechanics Confidential 40 3 Pneumatic Cylinders – for Y axle

41. Engineer Training XL1200 Mechanics Confidential 41 Media Plates and Tube

42. Engineer Training XL1200 Mechanics Confidential 42 Media Support Rollers

43. Engineer Training XL1200 Mechanics Confidential 43 Media Support Rollers

44. Engineer Training XL1200 Mechanics Confidential 44 New Head Carriage 5.Head Carriage Base Plate:  Heads Carriage Base is designed to allow the adjustment of two axes:  Around the parallel axis to the Linear Profile.  Around the perpendicular axis to the Linear Profile and the Printing Table.