MGI JETVARNISH 3DS User manual

Version 6.0
06/06/2017
User Manual
JETVARNISH 3DS
EN
Original instructions

JETVARNISH 3DS
User Manual
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Created by MGI Digital Technology
4, rue de la Méridienne
94260 Fresnes
FRANCE
© 2017 by MGI. All rights reserved.
The copyright protection includes all forms of material content and information subject to all applicable
legal standards of government regulations and relevant laws of judicial court protection. This includes
without exception the contents generated by software and displayed on the screen such as format,
patterns, symbols, screen display, layout.
MGI®, the MGI logo and all MGI products mentioned in this document are trademarks of MGI Digital
Technology, in France (FR) and/or other countries. All brand names and products mentioned are
trademarks of their respective holders and are hereby acknowledged.
This document is not contractual. Subject to change without notice.

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User Manual
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Table of contents
1Revision History ....................................................................................................................................................6
2Security and Safety Rules ....................................................................................................................................7
2.1Safety and important warning safety and important warning items ..............................................................7
2.2 Outline...........................................................................................................................................................7
2.3 Important notice.............................................................................................................................................7
2.4 Description items for danger, warning and caution.......................................................................................7
2.5 Safety and warning items location ..............................................................................................................10
2.6 Emergency stop buttons location................................................................................................................12
2.7 Before doing service work apply security rules when using the JETVARNISH 3DS..................................13
2.8 JETVARNISH 3DS Safety Instructions .......................................................................................................14
3Machine specifications and configurations......................................................................................................16
3.1 Machine specifications................................................................................................................................16
3.2 Expected print speeds.................................................................................................................................18
3.3 Machine configurations ...............................................................................................................................19
3.4Working Conditions .....................................................................................................................................21
4General description.............................................................................................................................................25
4.1 Feeder.........................................................................................................................................................25
4.2 Margin Table................................................................................................................................................25
4.3 Printer..........................................................................................................................................................25
4.4 Dryer............................................................................................................................................................26
4.5 Stacker ........................................................................................................................................................26
4.6 Pilot presentation.........................................................................................................................................26
4.7 JETVARNISH 3DS –Tactile Interface presentation ...................................................................................32
5Periodical Maintenance.......................................................................................................................................34
5.1 Maintenance chart.......................................................................................................................................34
5.2 Cleaning of the cleaning roller.....................................................................................................................34
5.3 Cleaning of the print heads .........................................................................................................................36
5.4 Cleaning of the printing belt.........................................................................................................................37
5.5 Cleaning of the top cells reflectors..............................................................................................................38

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6Installing the Machine Consumables ................................................................................................................40
6.1 Installation of the Cleaning Agent. Waste and Varnish Containers ............................................................40
6.2 Varnish registration procedure....................................................................................................................45
7Start up & Shutdown procedures ......................................................................................................................50
7.1 Procedure details ........................................................................................................................................50
7.2 Start up........................................................................................................................................................51
7.3 Shutdown.....................................................................................................................................................53
8How to use the machine .....................................................................................................................................57
8.1 Feeder.........................................................................................................................................................57
8.2 Cleaning unit................................................................................................................................................68
8.3 Margin table.................................................................................................................................................69
8.4 Stacker ........................................................................................................................................................70
9How to use the 3DSHM .......................................................................................................................................72
9.1 Main menu...................................................................................................................................................72
9.2 Standard printing.........................................................................................................................................75
9.3 Print menu...................................................................................................................................................76
9.4 Printing summary ........................................................................................................................................87
9.5 History .........................................................................................................................................................89
9.6 Supervision menu........................................................................................................................................90
9.7 Settings menu .............................................................................................................................................94
9.8 Information and Cost Calculator..................................................................................................................95
9.9 How to use the MGI Spot Varnish Editor ....................................................................................................97
9.10 Login Management....................................................................................................................................102
9.11 Remote access..........................................................................................................................................103
9.12 Automatic cleaning of the print heads.......................................................................................................104
10 MGI ARC system................................................................................................................................................109
10.1 Substrate...................................................................................................................................................109
10.2 Camera connection...................................................................................................................................109
10.3 Camera setting..........................................................................................................................................110
10.4 Image quality.............................................................................................................................................112
10.5 Model definition .........................................................................................................................................114
10.6 Overall function test...................................................................................................................................122
10.7 3DSHM camera configuration...................................................................................................................124

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11 Working method with the JETVARNISH 3DS..................................................................................................126
12 Troubleshooting ................................................................................................................................................138
12.1 Error codes................................................................................................................................................138
12.2 Jam procedure ..........................................................................................................................................142
12.3 Emergency stop procedure.......................................................................................................................148
12.4 Power failure procedure............................................................................................................................150
12.5 Paper feeding issue...................................................................................................................................151
12.6 File troubleshooting...................................................................................................................................152
12.7 Varnish image troubleshooting..................................................................................................................153
13 Glossary .............................................................................................................................................................158
14 Appendix ............................................................................................................................................................161
14.1 Pilot tree view............................................................................................................................................161
14.2 3DS Hub Manager tree view.....................................................................................................................167

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1 REVISION HISTORY
The following changes have been made from the original version.
Version
Date
Comments
Version 4.0
12/05/2015
Updates
Version 5.0
02/11/2016
Certified version
Version 5.1
26/01/2017
Mark and safety symbol changes
Version 6.0
06/06/2017
Wording changes and better descriptions
Varnish thicknesses & Cost Calculator
changes
New error message table
New printhead height setting

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2.Security and Safety Rules
Technical Manual
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2 SECURITY AND SAFETY RULES
2.1 Safety and important warning safety and important warning items
Read carefully the Safety and Important Warning Items described below to understand them.
2.2 Outline
Read carefully the Safety and Important Warning Items described below to understand them before doing service
work.
2.3 Important notice
Because of possible hazards to an inexperienced person servicing this product as well as the risk of damage to the
product, MGI Digital Technology (hereafter called MGI) oblige that only an operator trained by MGI or its
distributors can use the machine.
Changes may have been made to this product to improve its performance after this Technical Manual was printed.
Accordingly, MGI does not warrant, either explicitly or implicitly, that the information contained in this Technical
Manual is complete and accurate.
The user of this Technical Manual must assume all risks of personal injury and/or damage to the product while
servicing the product for which this Technical Manual is intended. Therefore, this Technical Manual must be
carefully read before doing service work both in the course of technical training and even after that, for performing
maintenance and control of the product properly. Keep this Technical Manual also for future service.
2.4 Description items for danger, warning and caution
2.4.1 Description in the Technical Manual
In this Technical Manual, each of three expressions «DANGER», «WARNING», and «CAUTION» is defined as
follows together with a symbol mark to be used in a limited meaning. When servicing the product, the relevant
works (disassembling, reassembling, adjustment, repair, maintenance, etc.) need to be conducted with most care.
DANGER
Indicates a hazardous situation that, if not avoided, will
result in death or serious injury*
WARNING
Indicates a hazardous situation that, if not avoided, could
result in death or serious injury*
CAUTION
Indicates a hazardous situation that, if not avoided, could
result in minor or moderate injury*
* using the ANSI Z535.5 definition

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2.4.2 Descriptions for safety and important warning items
When residual risks are present, symbols for safety and important warning items are used as follow:
High Voltage
Caution to be taken against high voltage. Electrification may cause
fatal or serious injury. Handling of the product is allowed only for
the qualified service engineer.
Make sure to open the covers only after disconnecting the
corresponding electric supply line.
Optical Radiation (UV)
Protect your eyes and skin from UV radiation. Exposure to UV
radiation may cause serious eye or skin injury.
High Temperature
Risk of burn when touched. Never remove the safety cover while the
product is in operation.
Maintenance work should be conducted only after confirming the
power supply is cut off and the temperature reaches low and safe
level.
Moving Parts
Risk of injury when hand or finger is caught by the moving parts.
Caution to be taken not to pinch your hand or finger in the moving
parts when working on the product.
Clothing
Caution to be taken so that any part of your clothing is not caught by
the moving parts. It may cause serious injury to the body part
involved.
Eye Protection
Wear eye/face protection such as chemical splash proof UV goggles
or face shield.
Ear Protection
For continuous and all-day use at close proximity of the equipment,
it is recommended to wear ear protection.

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2.Security and Safety Rules
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Skin & Hand Protection
Avoid skin contact. Wear impermeable gloves and suitable
protective clothing. Barrier creams may help to protect the exposed
areas of the skin, they should however not be applied once
exposure has occurred. Use Nitrile rubber gloves. Do not use natural
rubber gloves. Do not wear PVC gloves as PVC absorbs acrylates.
Replace gloves immediately when torn or any change in appearance
(dimension, color, flexibility, etc.) is noticed. When maintaining
varnish or cleaning solution area, replace gloves every 30 minutes.
Use only powder free gloves.
Foreign Materials
Do not introduce foreign materials or leave jigs in the product.
Do not put any weight on this part as it might damage it.
Additional advice
Food, beverages, and tobacco products should not be carried, stored, or consumed where this material
is in use. Before eating, drinking, or smoking, wash face and hand thoroughly with soap and water. End
user must always be present while the machine is running.

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2.5 Safety and warning items location
①UV Radiation
Protect your eyes from UV radiation. Exposure to UV radiation may cause serious eye injury.
②Eye protection
Wear eye/face protection such as chemical splash proof UV goggles or face shield.
③Ignitable Liquid/vapor/gas
Risk of explosion or fire. Never bring heat, spark, and fire close to the area. Make sure sufficient
exhaustion or ventilation.
④High Temperature
Risk of burn when touched. Never remove the safety cover while the product is in operation.
Maintenance work should be conducted only after confirming the power supply is cut off and the
temperature reaches low and safe level.
⑤Moving Parts
Risk of injury when hand or finger is caught by the moving parts. Caution to be taken not to pinch your
hand or finger in the moving parts when working on the product.
⑥High Voltage
Caution to be taken against high voltage. Electrification may cause fatal or serious injury. Handling of the
product is allowed only for the qualified service engineer.
Make sure to open the covers only after disconnecting the corresponding electric supply line.
⑦Skin and Hand Protections
Avoid skin contact. Wear impermeable gloves and suitable protective clothing. Wear eye/face
protection such as chemical splash proof goggles or face shield. Barrier creams may help to protect the
exposed areas of the skin, they should however not be applied once exposure has occurred. Nitrile
rubber gloves. Do not use natural rubber gloves. Do not wear PVC gloves as PVC absorbs acrylates.
Replace gloves immediately when torn or any change in appearance (dimension, color, flexibility, etc.) is
noticed.
⑧Foreign Materials
Do not introduce foreign materials or leave jigs in the product. It may cause damage to the product or
cause fire due to short-circuit occurred on the electric parts.
⑨Moving Parts
Caution to be taken so that any part of your clothing is not caught by the moving parts. It may cause
serious injury to the body part involved.

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Inside ①②③④
Inside ⑤
Inside ①②⑤
Note: red dotted rectangle indicates an internal part of the machine.
Inside ⑦② ⑥
Note: red dotted rectangle
indicates an internal part of
the machine.
Inside ⑦
①②
⑥⑥
Inside ⑥
Inside ⑤

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Inside ⑧
Note: red dotted rectangle indicates
an internal part of the machine.
⑨
⑨⑧
2.6 Emergency stop buttons location

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2.Security and Safety Rules
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To acknowledge an emergency stop or a door opening, release the emergency button or close the door
and press on the Reset button.
To release an emergency button, turn it counter clockwise to lift it:
To reset a stop, press the Reset button to change the state of the JV3DS from RED to GREEN:
2.7 Before doing service work apply security rules when using the JETVARNISH 3DS
2.7.1 General using security rules
For security purposes, always disconnect the main power plug before any maintenance or reparation on the
equipment.
2.7.2 Moving parts
For security purposes, when you see this Logo, take care of moving parts;
disconnect the main power plug before any maintenance or reparation on the
equipment.
RED
GREEN

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2.8 JETVARNISH 3DS Safety Instructions
General operating rules
For safety reasons, always disconnect power connectors prior to performing
any maintenance or repair operation. Any person authorized to intervene shall
be called for any important setting or repair operations, especially for electrical
repair purposes.
Handling UV varnish and cleaning agent require the following rules to be
complied with in order to prevent any risks to health: Refer to MSDS –
Material Safety Datasheet: Steps 2 - 7 - 8 - 15, delivered together with the
consumables.
Rules related to presence of UV
system
The use of UV systems may entail a few risks. These risks are eliminated
when these systems are used under normal circumstances. The risks to
humans when using UV systems are the following:
Skin and eye exposure to UV radiation.
Contact between skin, eyes and UV varnish.
As regards the environment, two elements have to be taken into account:
UV varnish and UV LED.
UV radiation
Exposure to UV radiation causes skin and eye injury. High doses cause
sunburns. As eyes are the most sensitive to UV radiation, it is recommended
to not directly look at a UV LED. The symptoms are actinic conjunctivitis and
snow blindness. Although such disorders may be very painful, they disappear
without leaving permanent damage. A good UV system features a device
which masks direct radiation of the lamp or reflectors through protective plates
and narrow beam.
UV varnishes and cleaning
agent
UV varnish and the cleaning agent bear a safety sign which warns that eye
and skin irritation may occur upon any contact.
Waste treatment
Residues of UV varnish are chemical residues which shall therefore be
transformed by a specialized company.
Safety - Fire extinguisher
As any machine using elements heating up to more than 70°C, the
JETVARNISH 3DS shall have a fire extinguisher nearby.
Tips and tricks
"Post curing" (that could be termed delayed drying) is a well-known
phenomenon in UV printing processes. It is recognized that, regardless of the
power of the UV LED used for drying, the polymerization reaction is not
complete. It is therefore better to wait for 24 hours prior to performing any
finishing (cutting or scoring) or lamination operation. As regards glossy
varnishes, it is also better to wait for 24 hours before delivery in order to
prevent any fingerprints during handling.
Legislation
Industrial safety legislation concerning control of hazardous materials makes
the user fully responsible for safety during use and application of inks; this
includes by-product treatment and waste disposal. The ink supplier's
responsibility consists in transmitting Safety Datasheets relating to products or
groups of products; the latter contain information in condensed form.
Safety perimeter
For more safety, a 60cm perimeter around the JETVARNISH 3DS is
recommended; as a rule, the freer the direct area around the machine, the
less substantial the risks in terms of both pallet size and chemical products. It
is prohibited to place chemical products inside the machine, except at the
specific locations -replacement of ink container-.
Recommendations
It is highly recommended not to have flammable materials around the
machine; 1 meter clearance all around the machine allows for safe working.
For user convenience, it is recommended to have an air renewal system.
As a matter of fact, the JETVARNISH 3DS operates together with UV LED
which release heat, and the ambient temperature may rise at the end of the
day.

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Do not let the machine operate alone
When operating, the JETVARNISH 3DS uses heating elements - up to more
than 70°C - even though sensors are present to prevent all risks, it is
prohibited to leave the JETVARNISH 3DS in unattended operation.
Wearing protective gloves and
safety goggles
Varnish is an irritating product - see MSDS attached to each product - and
cleaning agent dry skin. It is mandatory to observe the usual precautions:
Wear appropriate protections such as gloves, goggles and gown before
handling.
Avoid skin contact. - Use synthetic material gloves
Change any contaminated clothing.
In case of skin contact, immediately wash with water and soap.
Never use UV cleaning agent to clean hands!
Should there be any risk of varnish or cleaning solution splashes into eyes,
wear protective goggles.
In case of contact with eyes, immediately wash with plenty of water, and
seek medical advice.
Use a hand barrier cream.
In case of varnish splashes, immediately clean.
Dispose of all cleaning materials in containers provided for this purpose.
Machine precautions
Hold the printing unit doors closed. The varnish was specially developed for
the JETVARNISH 3DS; it can harden through the action of UV LED;
nevertheless, varnish left in the open may polymerize under the effect of solar
radiation or neon tubes. Holding the printing system as far away as possible
from direct light guarantees longevity of the components in contact with
varnish.
Caution relating to products
Any product having started a polymerization phase cannot be used as severe
damage to the JETVARNISH 3DS may occur, thus jamming the print heads. It
is mandatory to dispose of any product having suspicious looks.
Dust and environment
The room where the JETVARNISH 3DS is located shall be as clean as
possible as any dust deposited on sheets before varnish drying is
"encapsulated"
Varnish and cleaning agent storage
Preserve inks and varnish in the original containers and cartons closed and
sealed, away from light. - See MSDS Step No. 7
Store in a cool and dry place.
Varnish shelf lives
MGI varnish has a shelf life of 1 year.
The storage place temperature shall be between 15°C and 35°C.

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3 MACHINE SPECIFICATIONS AND CONFIGURATIONS
3.1 Machine specifications
Printing technology
MGI’s exclusive inkjet engine technology
Drop-on-Demand (DoD) technology
Piezoelectric print heads
Single pass printing
Flexible & scalable printing architecture
Coating thicknesses
Depending on your file, the printed material, the CYMK printing technology
and/or finishing technology used, the coating thickness can vary from 21 µm up
to 121 µm for 3D raised effects and a tactile finish (and 42µm to 242µm when
the twin bar option is installed) - new data as of June 2017
30-35 µm required on toner (such as Bizhub C1070/C1060, C1100/C1085 and
Meteor DP8700+) in order to have optimum printing quality
Production speeds
Up to 2,298 A3 per hour at 21** µm
Up to 1,624 A3 per hour at 43** µm
Up to 513 A3 per hour at 116** µm
**new data as of June 2017
NOTA: Printing speeds are given to indicative information and may vary
according to printing substrate, number of drop set on the data file and under
full operator responsibility. See the above table showing the production speeds
per drop.
Registration
Fully motorized and automatic left side lay guide
New feature of automated registration using MGI ARC System with optical
detection of printed crop marks. Overall registration of ± 200 µm
Formats
Min: 21.0x29.7 cm / 8 x 11.8” (in portrait mode i.e. long side first)
Max: 36.4x102.0 cm / 14.33x40.15”
Max. print width
35.3 cm or 353 mm - new data as of September 2016
Substrate thickness
Min: 135 gsm and not less than 150 µm/6 mil before printing & lamination
Max: 450 gsm and not more than 450 µm/18 mil before printing & lamination
Motorized height-adjustment print heads
Substrates
Printing on most matte or glossy laminated surfaces, with or without aqueous
coating, layered paper, plastic, PVC and other coated materials
Printing directly on most digital prints (i.e. Bizhub C1070/C1060, C1100/C1085
or Meteor DP8700+) with no lamination or coating required
UV coating container capacity
10 liters/2.6 US gal. tank capacity
High capacity automatic feeder
Feeder able to handle a paper pile up to 30 cm / 11.86” high
Approximately 2,500 sheets at 135 gsm
High pile output stacker
Stacker able to handle a paper pile up to 30 cm / 11.86” high
Approximately 2,500 sheets at 135 gsm
Paper path
100% flat paper path
Vacuum feed system
Air feed system
Automatic double sheet detection

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In-line UV dryer
“On-the-fly” drying & curing via integrated LED
Spot Coated sheets can be immediately finished or handled, no additional
drying time required
Front end system
Dedicated PC; CPU + touch-screen + keyboard/mouse
Ethernet connection 10/100/1000 BT (RJ 45)
Built-in application software
Comprehensive job queue management
Predictive printing cost calculator (coating consumption)
Dedicated image editor to do local and fast image editing prior to production
Maintenance & remote
technical support
Daily maintenance completed in less than 10 minutes
Majority of procedures are automated
Automatic cleaning system
From cold start to production in less than 10 minutes
Remote troubleshooting & support via included video/web camera
(high speed internet connection required)
Operator panel
Integrated user-friendly LCD touch-screen
Options
Variable data package: Barcode 1D and 2D camera reader to spot varnish
on-the-fly
Twin bar: Increase the maximum thickness up to 200/232 µm and double the
print speed in most of the situations
iFOIL S: inline hot foiling module
Dimensions (L x W x H)
& weight
4.26 (5.47*) x 1.14 x 1.80 meter
1 meter / 3.3’ clearance required on all 4 sides
± 1,100 kg / ± 2,425 lbs
Electrical requirements
7.5 kW (32 A) at 220-240 Volts - 2 plugs CEE/IP44 32A (1P+N+E)
Operating environment
Temperature: 18 to 30 °C / 64 to 86 °F
Relative humidity: between 35 and 55 % (no condensation)
Optimum 22°C, 40% humidity
*with the longest paper extensions installed

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3.2 Expected print speeds
Since the release of the 3D Hub Manager V1.6, the method to compute, both the varnish consumption and the
varnish thicknesses, has evolved. Therefore, the expected JETVARNISH 3DS print speeds are now the following:
JETVARNISH 3DS with 1 printhead bar (standard configuration)
Varnish
thickness
(in µm)
Droplet
number
Speed (in meter per sec.)
Standard varnish
coverage < 50%
High varnish
coverage ≥ 50%
21
3
0.3
0.15
29
4
0.28
0.14
36
5
0.24
0.12
43
6
0.212
0.106
51
7
0.182
0.091
58
8
0.159
0.0795
65
9
0.141
0.0705
73
10
0.127
0.0635
80
11
0.116
0.058
87
12
0.106
0.053
94
13
0.098
0.05
102
14
0.091
0.05
109
15
0.085
0.05
116
16
0.079
0.05
JETVARNISH 3DS with 2 printhead bars (with the optional twin bar)
Varnish
thickness
(in µm)
Droplet
number
Speed (in meter per sec.)
Standard varnish
coverage < 50%
High varnish
coverage ≥ 50%
42
6
0.3
0.15
58
8
0.25
0.125
72
10
0.2
0.1
86
12
0.17
0.085
102
14
0.164
0.082
116
16
0.158
0.079
130
18
0.141
0.0705
146
20
0.127
0.0635
160
22
0.116
0.058
174
24
0.106
0.053
188
26
0.098
0.05
204
28
0.091
0.05
218
30
0.085
0.05
232
32
0.079
0.05

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NOTA: Printing speeds are given to indicative information and may vary according to printing substrate,
number of drop set on the data file and under full operator responsibility.
You will notice that JETVARNISH has two technical limits. The upper limit where the JETVARNISH cannot
go faster than 0.3 meter per second. The lower limitation where the JETVARNISH 3DS cannot go slower
than 0.05 meter per second.
It is not possible to print in less than 3 droplets, equivalent to 21µm of thickness.
3.3 Machine configurations
JETVARNISH 3DS:
- Paper Feeder
- Main body with the IJ Print
Engine
- Computer with the 3DS Hub
Manager
- Banner extensions
-AIS SmartScanner (might be
optional and not represented on
this picture)
Variable data option:
1D and 2D barcode reader
(camera 3) with
-JETVARNISH 3DS RIP1 (standard
VDP performances)
or
-JETVARNISH 3DS RIP2 (high VDP
performances)
Hot Foiling Option:
Inline iFOIL S module
Twin bar option:
Increase the maximum thickness
up to 200/232 µm (depending on
the 3DS Hub Manager version)

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AIS SmartScanner:
Artificial Intelligence SmartScanner
for an automated registration and
make ready. Replace totally the
ARC System (XY cameras)
Refer to the “AIS Scanner
User” manual