Congratulations for purchasing Fastbind Casematic hard cover maker

Making high quality hard covers with the Fastbind Casematic is easy. This manual provides you a step by step guide. After making a few covers you can do it by heart, but you can always refer to the manual for specific questions.

Casematic is an on-demand hard cover maker for high quality book covers. It is optimized to work with Fastbind FotoMount photobook makers and perfect binding machines, allowing you to produce high quality hard covers in a variety of formats. This versatile case maker features registration marks for thicker and thinner cover boards and quick-change spacers for spine guides. In Pro models, Casematic also integrates a user-friendly edge-folding unit adjustable for different cover board thicknesses.

Casematic features a built-in light table and a suction assistance for easy and exact positioning and registration. The unique support rail cardboard positioning method makes the placing of cardboards quick and consistent. A robust edge folding unit (in Pro models only) wraps and folds the covers precisely.

There are three accessories available: Fastbind Corner Cutter Ha10, for cutting the sheet corners and separate magnetic side/rear guides for tacking sheet positioning, when not using registration marks on the printed tacking sheet.

Main steps in cover production

Each standard package* contains:

1. Design, print, laminate and cut the cover tacking sheet

1 hard cover making unit 1 power cord 2 spacers for 8 mm (0.3”) gap 1 allen key (hex key) 1 wrench (13mm)

2. Cut the cardboards and spine stick
3. Adjust the spine guides, place the spacers
4. Position the tacking sheet
5. Place the cardboards

• This user’s manual

6. Cut the corners

• Definition of a standard package may vary in different countries

7. Fold the edges and mount

H32 and H32 Pro

Max finished book cover size * (WxLxH):

492x490x40mm / 9.4 x 19.3 x 1.5“

Max finished case size (A x B):

700x330mm / 27.5 x 13˝

1040x490mm / 42.5 x 20.8”

Max tacking sheet size (C x D):

740x370mm / 29.1 x 14.5˝

1080x530mm/ 41 x 19.3”

Max thickness of the cardboards:

5 mm / 0.2˝

5 mm / 0.2˝

• An example, for 40 mm spine. With less page width you can have more spine width (thicker book) and vice versa.

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2. MAIN PARTS AND CONTROLS

Casematic H32 AND H32 Pro

FRONT

Support rail Spine guides, 3 mm (0.12”) gap Thumb screws Spacers* Handle Edge folding unit** Folding pressure adjustment** Suction area Light table with positioning line and registration marks

10. Suction switch
11. Light switch

Optional accessories:

12. Side guide
13. Rear guide
14. Corner cutter

CD covers and ringbinders are done with the 3 mm spine guides, the spacers are used for hard cover books In Pro models only

BACK

14. Mains socket
15. Fuse: 220-240V models; 4A(T) 110-120V models; 4A(T)
16. Type plate with serial number

Thumb screws Corner guide Cutting handle Finger guard Counter blade Installation screws

CORNER CUTTER (Optional accessory)

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2. MAIN PARTS AND CONTROLS

Casematic H46 Pro

FRONT

Support rail Spine guides, 3 mm (0.12”) gap Thumb screws Spacers* Handle Edge folding unit Folding pressure adjustment Suction area Light table with positioning line and registration marks

10. Suction switch on the left side
11. Light switch

Optional accessories:

12. Side guide
13. Rear guide
14. Corner cutter

CD covers and ringbinders are done with the 3 mm spine guides, the spacers are used for hard cover books

BACK

14. Mains socket
15. Fuse: 220-240V models; 4A(T) 110-120V models; 4A(T)
16. Type plate with serial number

CORNER CUTTER (Optional accessory)

Thumb screws Corner guide Cutting handle Finger guard Counter blade Installation screws

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3. SAFETY

Before installing and operating Casematic, please do read this User’s Manual carefully to ensure proper handling and safety! Store this document within easy reach of personnel operating or maintaining the unit. All of the machine covers, panels and safety labels must be in place when operating the machine. Do not attempt to alter or modify the machine. It contains high voltage components and unexpected faults or electric shock might occur. Modification will invalidate the warranty.

• Note that the machine is heavy! When handling the machine, two persons should always be used.
• Install the machine on a stable horizontal surface, close to a power outlet.
• This machine is designed for indoor use only. Avoid moist and dusty environment. For normal operation, the ambient temperature range should be +15 to +35 °C (59 – 86 F).
• Avoid inserting anything in the suction holes on the positioning table. This might damage the machine or result in personal injury.
• Make sure not to drop any extra material such as cardboard pieces, staples etc. in to the folding units groove, as this might damage the unit and reduce the quality of the folding results.
• Do not handle liquids near this machine to avoid electrical shock.
• Disconnect the power plug before cleaning the machine or changing the lamp
• No user servisable parts inside.
• Before using the machine, check that the operating voltage and other specifications indicated on machine’s identity plate match with the specifications of the power source. This plate is located at the rear of the machine.
• This unit may be connected only to a properly grounded power outlet.

4. SETTING UP

Open the thumb screws. Align the left spine guide’s right edge with the guide line on the light table, so that the edge is exactly on top of the line.

Put a properly cut spine stick between the spine guides so that one end lays on top of the support rail. See chapter 5 for instructions for the spine stick size.

Secure the position by tightening the thumb screw. The spine guide and support rail should be in a perfect 90° angle.

Move the right spine guide to touch lightly the right edge of the spine stick. Ensure that spine guides and support rail are in 90° angle, and the left edge of the spine stick is aligned with the guide line on the light table.

Tip! You can use a grey board as a help when aligning the spine guide. Make sure that the grey board is cut right (90° angles). Note that the standard spine guides can be used for all cover sizes.

Secure the position by tightening the blue thumb screw of the right spine guide. Put the removable plastic spacers in place.

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5a. THE COVER GRAY BOARD AND SPINE STICK SIZES

Cover gray board and spine stick size, for Perfect Binding or FotoMount

Cover boards for books in Perfect Binding:

Cover board in FotoMount:

Depending on the required offset of the cover. The gray board width can be calculated as follows:

Depending on the required offset of the cover. The gray board width can be calculated as follows:

The width of your book block (A) + offset + spine stick thickness (SST)

• gap

The width of your book block (A) + offset + spine stick thickness (SST)

• gap

Example:

• Hard cover book with 8 mm (0.31”) gap (standard with books)
• 3 mm (0.12”) offset in width and height
• SST thickness 0.7 mm (0.03”) as recommended in perfect binding > both front and back gray boards are 6 mm (0.24”) higher and 4 mm (0.16”) narrower than the book block (A).

The spine stick for books in Perfect Binding:

The spine stick width is calculated as follows:

The thickness of your book block (content pages & end papers) + 2 times the cover board thickness (CBT)

In FotoMount binding the gap is usually 8 mm (0.31”). Spine stick thickness (SST) in FotoMount books is the same as the gray boards.

Example:

• FotoMount cover with 4 mm (0.16”) offset in all three sides
• SST thickness 2 mm (0.08”) > the cover boards are 2 mm (0.08”) narrower and 8 mm (0.31”) higher than the book block.

Spine stick in FotoMount:

The spine stick width is calculated as follows:

The thickness of your mounted book block + 2 times the cover board thickness (CBT)

For a 3 mm (0.12”) offset in all sides, the spine stick is 6 mm (0.24”) higher than the book block height.

For a 4 mm (0.16”) offset in all three sides, the spine stick is 8 mm (0.31”) higher than the book block height.

Cover boards for CD/DVD cases:

For CD/DVD covers the coverboard and spine stick sizes are calculated with the same formula as for books. Now, however, the spine stick thickness (SST) is the same as the cover board and the gap is 3 mm (0.12”).

Tip: Fastbind Designer software calculates all measurements automatically and adds the registration marks to the printing file. It’s an easy to use tool for accurate design of photobook covers and content pages

Example:

• Hard cover for a CD/DVD with 3 mm (0.12”) gap
• 3 mm (0.12”) offset in width and height
• CBT 2 mm (0.08”)
• SST 2 mm (0.08”) - the same as the cover board thickness > both front and back coverboards are 6 mm (0.24”) higher and 1 mm (0.04”) wider than the CD tray.

> For a 3 mm (0.12”) offset in all sides, the spine stick is 6 mm (0.24”) higher than the book block height.

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5b. TACKING SHEET DESIGN & POSITIONING

How to design the printable tacking sheet for a hard cover

Margins for folding:

18 mm (0.7”) margins on all sides recommended, 9 mm (0.4”) is the minimum for a lasting result. Note that when using A4 size pages the top and bottom margins are max 13.5 mm (0.53”) on Fastbind’s printable tacking sheets due to the tacking sheet size.

Crop marks:

Registration marks with cover boards up to 2.5 mm (0.1”):

Registration marks with cover boards thicker than 2.5 mm (0.1”):

The upper registration marks horizontal line should be 15 mm (0.6˝) from the top of the cover boards and you use the upper horizontal guide line on the light table (Fig. b and b2). The lower mark - the straight vertical line |, should be placed 15 mm (0.6˝) from the bottom of the cover boards, in line with the spine stick front edge, and positioned on the vertical guide line of the light table.

Corner cutting:

The upper registration mark on the tacking sheet should be a ┴ shape. The horizontal line should be 7 mm (0.3˝) above the top of the cover boards. When positioning the tacking sheet on the Casematic, use the lower horizontal guide line on the light table (Fig. a and a2). Place the vertical line in line with the vertical guides right side. This saves time later on.

The lower mark on your printed sheet should be a straight vertical line |, placed 7 mm (0.3˝) from the bottom of the cover boards, in line with the spine stick front edge. On the Casematic it should be positioned on the vertical guide line of the light table.

Use the corner cutter (accessory) to cut the corners or cut the corners with scissors leaving a margin 1mm (0.04”) more than the gray board thickness.

Paper slips to the gaps:

To prevent unnecessary tacking noises when opening the final book, it is recommended to insert paper slips in to the gaps on both sides of the spine stick.

Cut the paper slips 1 mm (0.04”) thinner than the gap with the same height as the visible gap in your folded cover. Press them gently in to the gaps as the last step in cover production.

Up to 2.5 mm (0.1”) gray boards

More than 2.5 mm (0.1”) gray boards

Fig. a) The recommended registration mark placing for max 2,5 mm (0.1”) grey board.

Fig. b) The recommended registration mark placing for grey board thicknesses more than 2.5 mm (0.1”).

18 mm (0.7”) margins on all sides of the tacking sheet

Fig. a2) Light table position using grey board thickness max 2,5 mm (0.1”)

18 mm (0.7”) margins on all sides of the tacking sheet

Fig. b2) Light table position using grey board thickness more than 2,5 mm (0.1”)

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6. MAKING THE COVER STEP BY STEP

Turn the support rail up. Remove the silicon paper and place the tacking sheet on the light table, adhesive side up.

Use your fingertips to position the tacking sheet so that the registration marks of the tacking sheet are aligned with the guide lines on the light table.

Make sure that the alignment is correct. Red lines represent the registration marks in the printed tacking sheet and black lines the guide lines on the light table.

See also chapters 5b and 12.

Lower the support rail on the tacking sheet.

Place the spine stick’s top on the support rail and slowly lower it towards the bottom of the sheet, aligning it to the vertical registration line of the light board.

SLI

Place the right cover board on the support rail at least a few centimeters (1”) to the right of the spine guide. Then slide it left to meet the right spacer.

PRESS

PULL

Lower the cover board to touch the tacking sheet so that the upper part of the cardboard still rests on the rail. Leave it in place. Don’t move the tacking sheet.

SLI

Lower the cover board to touch the tacking sheet so that the upper part of the cardboard still rests on the rail. Leave it in place. Don’t move the tacking sheet.

LOWER

Press the spine stick lightly down to the tacking sheet to ensure the whole length is attached.

LOWER

Place the left cover board on the support rail at least a few centimeters (1”) to the left of the spine guide. Then slide it right to meet the left spacer.

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Press the cover board down firmly to attach them well to the tacking sheet.

Pull the tacking sheet and cover board towards yourself so that they slide away from the support rail. Then press gently the pre cut paper slips in to both gaps (see chapter 5b).

7. CORNER CUTTING

Cut all four corners of the tacking sheet using the optional corner cutter for quick and accurate results.

You can also use scissors. Cut in a 45° angle. The distance from the corner of the cardboard to the cut should be 1 mm (0.04”) more than the thickness of your cover board.

With thicker cover board, increase the cutting distance and reduce it with thinner. See chapter 10 for installing and adjusting the corner cutter.

8.a FOLDING THE EDGES WITH THE EDGE FOLDING UNIT (Pro model)

LIFT AND SLIDE

TO FOLD

Hold the cover with both hands and place the long edge on the roll of the folding unit.

Make sure that the cover boards are aligned with the roll.

Lift your end of the cover up so that the tacking sheet starts to fold over the cover boards on the roll. Note that the edge must be in contact with the roll all the time during this phase.

PRESS

Lift your end of the cover up until the cover is in an upright position (90° angle).

After folding the long edges, put the cover on top of the casematic. Then pinch the corners with your fingernail so that the tacking sheet is sharply bent against the edge of the cover board.

Press the cover straight down until it touches the bottom of the groove (you can feel when it stops).

Repeat pinching with all corners

PULL

Pull the cover up from the edge folding unit keeping it still in vertical position.

Repeat steps 1 to 6 with the other long edge.

After pinching, place a short edge on the roll of the edge folding unit and repeat phases 1 to 6 with the short edges to fold them.

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8.b FOLDING THE EDGES MANUALLY

Hold the cover from the long edge further from you and lift it to start folding the tacking sheet edge as shown above.

Make sure that the cover boards are aligned with the top of the Casematic and continue the lifting and folding motion. Press the edge down all the time.

Turn the cover all the way. Remember to keep pressure on the folded edge all the time.

After reaching vertical position, place one hand on the top side of the cover and press down to prevent the folding edge of the tacking sheet from slipping.

Move your other hand also to the center of the folded edge. Press the edge down all the time.

Slide your hands along the folded edge while pressing it down. This attaches the folded part of the tacking sheet to the grey boards. Repeat steps 1 to 6 with the other long edge.

After pinching, place a short edge on top of the Casematic and repeat phases 1 to 6 with both short edges.

Before mounting, insert paper slips into the gaps (1 mm / 0.04” thinner than the gap).

After folding the long edges, pinch all four corners with your fingernail so that the tacking sheet is sharply bent against the edge of the cover board.

9. MOUNTING THE COVER

It is a good practice to mount the cover to remove excess air between the tacking sheet and the cover boards. Manually, do this by pressing the tacking sheet tightly to the cover boards by hands.

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Some roll and pouch laminating machines can be used for mounting (pressure only). Check the specifications of your laminating machine to see its applicability.

Your deluxe hard cover is now ready to be used in applications ranging from FotoMount photobooks or CD/DVD covers to ring binders and perfect bound books.

After mounting, press with your forefinger and thumb along the spine to make a neat fold when the case is opened.

10. INSTALLING AND ADJUSTING THE CORNER CUTTER

Place the cutter on the right side of the machine. There are two holes for the screws marking the right spot.

Support the cutter with one hand and tighten the first securing screw with the included hex head wrench (Allen wrench). Use only machine screw DIN912 M4x12.

Tighten the second screw and the unit is ready to be used.

The corner guide on top of the corner cutter defines how far from the cover gray board the tacking sheet corner will be cut. Suggested distance with 2-2,5 mm board is 3 mm.

Release the thumb screws and adjust the corner guide to set the distance. Thicker board requires more distance (move inwards) and thinner board less (move outwards).

Then tighten the screws. Be careful not to overtighten them - do not use tools for tightening. Test the cutting before production use. Tip! You can insert a piece of the grey board you are using, between the corner guide and finger guard, then adjust to it, and get automatically the right distance.

11. CLEANING THE CORNER CUTTER

For cleaning or changing the blade, you don’t have to detach the cutter from the Casemaker. Be careful, the knife is sharp. First, loosen the thumb screws.

Remove the thumb screws to release the corner guide and remove it.

Lift and turn the fingerguard clockwise out of the way.

The blade is attached to the cutting handle. It can be wiped clean with a non toxic solvent and soft cloth.

When ready, re-assemble following these instructions in reverse order.

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12. OPTIONAL SIDE AND REAR GUIDES

Side and rear guides are available as accessories, to make it easier to register the cover materials accurately (especially opaque materials).

REAR GUIDE

SIDE GUIDE

Place your tacking sheet on the Casematic. Don’t remove the protective silicon paper. Put the cover boards in place and center the tacking sheet. With opaque materials you have to do this face up to see the graphics and spine text, and to position them correctly.

Put the side guide to touch lightly the edge of the cover sheet, aligned with it. Do the same with the rear guide.

Remove the materials from top of the Casematic and remove the protective silicon paper. Put the cover sheet on the Casematic aligning it with the side and rear guides. Make the cover as explained in chapter 6.

13. ADJUSTING THE EDGE FOLDING UNIT FOR DIFFERENT THICKNESSES

Using different cover board thicknesses may require adjusting the pressure of the edge folding unit. With thicker cover boards, you should increase the gap between the roll and pressure bar. With thinner material, it should be decreased.

To adjust the pressure, remove the end caps at both right and left end of the edge folding unit. Use a regular 10 mm wrench for the locking nut (collar) and a 4 mm Allen wrench (hex wrench) for the screw. Loosen the collar first. Then turn the screw counter clockwise to decrease the gap or clockwise to increase it.

Check that the gap is equal on both sides. Use a piece of your grey board to check the adjustment. Put it in the gap and move it slightly. When the resistance is equal on both ends, and the roll and pressure bar are aligned, the gap is properly aligned. You can then tighten the locking nut (collar) and put the end caps back.

14. CHANGING THE LAMP

Remove the light table cover by lifting from the finger-notch.

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Carefully pull the lamp towards yourself and then up to detach it.

Remove the lamp and replace with a new lamp of the same type. For H32 and H32 Pro Osram Dulux L 24W/840. For H46 Pro Osram Dulux L36W/840.

15. TROUBLESHOOTING

Check that the machine is connected to a functioning power outlet.

The light or the suction area is

Check that the light and suction are switched on.

Check the fuse and change it if necessary. Switch off the machine prior changing it!

Check that the suction holes are clean and free of any obstructing obstacles.

Change the fluorescent lamp if necessary. Switch off the machine before changing it!

Check that the pressure of the folding unit is set according to the thickness of your cover material.

The folding result is not satisfactory

If the cover does not fit in the groove when folding, decrease the pressure of the folding unit. See chapter 13 for more instructions.

If the folded sheet does not attach to the grey board when using the folding unit, increase the pressure of the folding unit. See chapter 13 for more instructions.

Check that the tube is not damaged.

Check that the groove is clean and there are no obstructing obstacles.

If you are folding the edges manually, please refer to chapter 8b.

16. TECHNICAL SPECIFICATIONS

CASEMATIC H32 and H32 Pro

Max print size (WxH) 740 x 370 mm

Thickness of the cardboard

Up to 5 mm

Voltage 220 - 240V

Max. folding length 700 mm

Frequency / Max Current 50/60Hz / 1A

Machine size H32 (WxDxH) 830 x 470 x 200 mm

Machine size H32 Pro (WxDxH) 840 x 550 x 200 mm

Net/Gross weight H32 23 / 28 kg

51 / 62 lbs

Net/Gross weight H32 Pro 29,7 / 34 kg

66 / 75 lbs

Fuse 4 A (T)

Max print size (WxH) 1080 x 530 mm

Thickness of the cardboard

Up to 5 mm

Voltage 220 - 240V

Frequency / Max Current 50/60 Hz / 1A

50/60 Hz / 1A

Machine size H46 Pro (WxDxH) 1130 x 685 x 200 mm

Net/Gross weight H32 Pro 45 / 58 kg

Fuse 4 A (T)

99 lbs / 128 lbs

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17. COPYRIGHT, TRADEMARKS AND WARRANTY

© 2008 Copyright Maping Co. Reproduction, adaptation or translation without prior written permission is prohibited, except as allowed under the copyright laws. The information contained herein is subject to change without notice.

Fastbind, Casematic, FotoMount, PhotoBook end sheet, PhotoBook mounting sheet, Mountinglift, Secura, Elite, Ultra and Optima are trademarks of Maping Co. Fastbind Casematic H32, H32 Pro and H46 Pro are inventions of Maping Co (patents pending).

One year limited warranty

Maping Co warrants this product against defects in material or workmanship as follows:

For the period of twelve months from the date of purchase, repair or replace free of charge, for the original purchaser, any part or parts found by inspection to be defective by our factory authorized service outlet or by the manufacturer at Espoo, Finland. All transportation charges on parts submitted for repair or replacement under this warranty shall be paid for by the purchaser.

All service under this warranty will be furnished and performed by factory authorized service stations or by the manufacturer. Warranty service does not extend the warranty period.

This warranty is limited to the value of the product and it does not cover damage caused by:

• Normal wear and tear
• Neglected or improper maintenance

The warranty will be voided if machine’s type plate has been wholly or partially removed or erased.

Maping Co is not responsible for any damages, including but not limited to direct, indirect or consequential damages, loss of material, profit or interruption of business. Maping Co may at any time discharge its warranty by refunding the purchase price and taking back the product.

The crossed-out wheeled-bin symbol on your product, literature, or packaging reminds you that in the European Union all electrical and electronic products, batteries, and accumulators must be taken to separate collection at the end of their working life. Do not dispose of these products as unsorted municipal waste.

Return the products to collection to prevent possible harm to the environment or human health from uncontrolled waste disposal and to promote the sustainable reuse of material resources. Collection information is available from the product retailer, local waste authorities or national producer responsibility organizations.

Kuusiniemi 10, FIN-02710 Espoo, FINLAND

Tel. +358 9 562 6022, Fax +358 9 562 6215

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18. DECLARATION OF CONFORMITY

We, Maping Company, hereby declare that following products:

Casematic H32 Pro, H32 Casematic H46 Pro

2811 - Casematic H32, 110V 2821 - Casematic H32 Pro, 110V 2911 - Casematic H46 Pro, 110V 2812 - Casematic H32, 230V 2822 - Casematic H32 Pro 230V 2912 - Casematic H46 Pro 230V

The products fulfill the essential safety requirements for CE conformity marking according to the Low Voltage Directive (2006/95/EC) and EMC Directive 2004/108/EC.

EN 60950 - 1:2001 (safety) EN 61000 - 6-3:2001 (EMC emission) EN 61000 - 6-1:2001 (EMC immunity)

Kuusiniemi 10, FIN-02710 Espoo, FINLAND

Tel. +358 9 562 6022 Fax: +358 9 562 6215

Lauri Huotari, Managing Director

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