1. Engineer Training XL1500 Mechanics

2. Engineer Training XL1500 Mechanics Confidential 2 The XL1500 is both a Roll to Roll and a Roll to Sheet Printing Machine MachineXL1500-2mXL1500-3mXL1500-5m Length (total)400 cm501 cm680 cm Depth (total)182 cm Height (total)238 cm Weight (unpacked) 2700 Kg3500 Kg4400 Kg Maximum printing width 220 cm320 cm 520 cm General Mechanic Specs

3. Engineer Training XL1500 Mechanics Confidential 3 Working Concept Overview  The XL1500 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

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6. Engineer Training XL1500 Mechanics Confidential 6 XL1500 Ver B Chassis-Current form The Ver B XL1500 has a Metal frame of combined R.H.S Metal Profiles, and a Metal Sheet – constructed using the combined method of welding and fastened with screws. Several reinforcements are installed on the Side Plates.

7. Engineer Training XL1500 Mechanics Confidential 7 General Mechanic Chassis Structure The XL1500 chassis is constructed from Two Aluminum Side Plates, which are connected together by metal beams and hold all rotating shafts. The Chassis is reinforced using Metal Brackets.

8. Engineer Training XL1500 Mechanics Confidential 8 General Mechanic Chassis Structure In each bottom corner of the chassis are the Leveling Pads and wheels: The wheels are 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.

9. Engineer Training XL1500 Mechanics Confidential 9 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.

10. Engineer Training XL1500 Mechanics Confidential 10 Leveling Pads Positioning

11. Engineer Training XL1500 Mechanics Confidential 11 Leveling Pads Position –5m machine Leveling pads and wheels position Additional support legs

12. Engineer Training XL1500 Mechanics Confidential 12 Ver B Positioning Pads and Wheels

13. Engineer Training XL1500 Mechanics Confidential 13 Printing Table  The printing table is used for leading the Media between the Y and Z shafts.  From the Printing table the media goes to the Dryer.  The printing table is adjusted while the machine is in integration stages – therefore there is no need to adjust it during installation.

14. Engineer Training XL1500 Mechanics Confidential 14 Printing Table-Construction 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

15. Engineer Training XL1500 Mechanics Confidential 15 Printing Table  5 Table Profiles spread evenly from bottom to top connected to the Table Bases.  4 Printing Table Plates are inserted between the Profiles.  On top of the printing table base, the front roller is located.

16. Engineer Training XL1500 Mechanics Confidential 16 Printing table base Printing table profile Printing table front roller Printing Table (Cont.)

17. Engineer Training XL1500 Mechanics Confidential 17 Mechanics – Printing Table  Under the printing table there is a rounded Teflon coated Profile, which is connected to the Chasis.  Above the printing table there is a roller which is connected to the chassis as well. Roller Rounded profile

18. Engineer Training XL1500 Mechanics Confidential 18 The Linear Unit The Linear Unit in the machine consists of three elements: 1.Head Carriage 2.Linear Profile (Linear Beam) 3.Module X

19. Engineer Training XL1500 Mechanics Confidential 19 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, and includes 2 maintenance doors and ventilation windows.

20. Engineer Training XL1500 Mechanics Confidential 20 Head Carriage (Cont.) 2.Head Carriage Frame:  Includes the Printing Heads Plate, the Printing Heads and Holders, the Ink Secondary Tanks, and the air valves.

21. Engineer Training XL1500 Mechanics Confidential 21 XL1500 Head carriage frame was replaced by a newer version. The new version allows the option of lowering all secondary tanks (especially the Yellow secondary tank). The bottom of the head carriage frame is open, yellow secondary tanks can go down.

22. Engineer Training XL1500 Mechanics Confidential 22 Head Carriage 3.Cards Plate:  Holds the CCB2 cards, the 5/12 V P.S., the optic sensor, and the air manifold.

23. Engineer Training XL1500 Mechanics Confidential 23 Head Carriage (Cont.) Head Carriage Base Plate:  Groups all the above sub elements and connect 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

24. Engineer Training XL1500 Mechanics Confidential 24 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

25. Engineer Training XL1500 Mechanics Confidential 25 The Linear Profile (Cont.)

26. Engineer Training XL1500 Mechanics Confidential 26 Upper view of Linear Profile Linear Bearings Tenacity Block Linear Bearings The Linear Profile (Cont.)

27. Engineer Training XL1500 Mechanics Confidential 27 The Linear Profile (Cont.) The linear profile is laid on top of the machine’s front chassis beam with a set of adapters, which are specially design to allow the very fine adjustment of the profile’s position (twist and leveling).

28. Engineer Training XL1500 Mechanics Confidential 28 1 1 4 3 2 2 54 5 6 The Linear Profile (Cont.) Operation (acc’ to screw number): 1.Y axis pulling screw down 2.Y axis direction locking screws 3.X axis direction locking screws 4.X axis Pushing backwards screws 5.Locking screws 6.Y axis pushing up screws

29. Engineer Training XL1500 Mechanics Confidential 29 The Linear Profile (Cont.)

30. Engineer Training XL1500 Mechanics Confidential 30 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

31. Engineer Training XL1500 Mechanics Confidential 31 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

32. Engineer Training XL1500 Mechanics Confidential 32 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

33. Engineer Training XL1500 Mechanics Confidential 33 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

34. Engineer Training XL1500 Mechanics Confidential 34 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 that 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.

35. Engineer Training XL1500 Mechanics Confidential 35 Installation of Module Y (Cont.) 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.

36. Engineer Training XL1500 Mechanics Confidential 36 New Y Coupling

37. Engineer Training XL1500 Mechanics Confidential 37 Z AXIS Z axle is comprised of two shafts:  Z rubber shaft  Teflon pressure shaft When using the Roll to Roll printing mode, the substrate will be taped to the rubber shaft, which is the end of the media path.  Z Rubber Shaft  Teflon Pressure Shaft

38. Engineer Training XL1500 Mechanics Confidential 38 Z AXIS (Cont.) When using a Roll to Sheet printing mode 1.The substrate will flow 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.

39. Engineer Training XL1500 Mechanics Confidential 39 Z AXIS (Cont.) 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

40. Engineer Training XL1500 Mechanics Confidential 40 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. Z AXIS (Cont.)

41. Engineer Training XL1500 Mechanics Confidential 41 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

42. Engineer Training XL1500 Mechanics Confidential 42 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

43. Engineer Training XL1500 Mechanics Confidential 43 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 the following: 1.Roller Tube 1

44. Engineer Training XL1500 Mechanics Confidential 44 Teflon Pressure Shaft – for Y axle (Cont.) 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

45. Engineer Training XL1500 Mechanics Confidential 45 Teflon Pressure Shaft – for Y axle (Cont.) 3.Pneumatic Piston  The Pistons are supplied with 2.5 Bar air pressure.  Connection to the air tube is via 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.

46. Engineer Training XL1500 Mechanics Confidential 46 3 Pneumatic Cylinders – for Y axle

47. Engineer Training XL1500 Mechanics Confidential 47 Media Plates and Tube

48. Engineer Training XL1500 Mechanics Confidential 48 Media Support Rollers

49. Engineer Training XL1500 Mechanics Confidential 49 Media Support Rollers

50. Engineer Training XL1500 Mechanics Confidential 50 New Head Carriage 4.Head Carriage Base Plate:  Heads Carriage Base is designed to allow the adjustment in two axes:  Around the parallel axis to the Linear Profile.  Around the perpendicular axis to the Linear Profile and the Printing Table