Practical Guide
Gema ClassicLine Manual Booths: Selection, Guidelines & Workflow for Stable Extraction
From small series to high-volume parts: How to get reproducible quality out of ClassicStandard / ClassicOpen and the matching exhaust unit – with fast cleaning and predictable maintenance.
ATEX-compliant components
Extraction: 4000 / 6600 Nm³/h
Cartridge filter + Jet cleaning
Example: Exhaust unit kit – relevant for stable vacuum control & a clean workspace.
Why ClassicLine? (Practical benefits in 30 seconds)
ClassicLine manual booths are designed for manual powder coating (including plastic and metallic powders) and protect the process through vacuum/inward flow – this ensures the powder stays in the booth and not in your environment. At the same time, filter cartridges and color changes are designed so that cleaning and replacement remain predictable. (See below for guidelines & details)
KPI 1
4000 / 6600 Nm³/h
Extraction volume (nominal) – suitable for smaller tasks vs. large objects.
KPI 2
30 / 60 m²
Filter area depending on version – important for stable suction & service life.
KPI 3
< 78 dB(A)
Noise level (without external sources / without cleaning pulses).
Product Overview: Variants, Applications, Advantages
| Variant | Typical Use | Extraction (nominal) | Filter / Area | Practical Advantage |
|---|---|---|---|---|
| ClassicStandard 2 | Small series, individual parts, repairs | 4000 Nm³/h | 2 Cartridges / 30 m² | Compact, space-saving, quick routine tasks |
| ClassicStandard 4 | Higher throughput, larger parts | 6600 Nm³/h | 4 Cartridges / 60 m² | More filter area for stable performance with higher powder volume |
| ClassicOpen | Recoating, voluminous workpieces | 6600 Nm³/h | 4 Cartridges / 60 m² | Open design – ideal when parts need "more room" |
Note: Values are derived from the provided documentation and are considered guidelines depending on the version/options.
Practical Tip (yellow box): Keep filters clean – but don't "over-clean"
Jet filter cleaning is effective, but should be used sparingly in everyday operations: As a guideline, trigger no more than 1–2 times per shift. If the fault message for high filter resistance recurs despite correct cleaning, a complete cartridge set replacement is usually more sustainable than constant re-cleaning.
CTA: Matching Exhaust Unit Kits for your ClassicLine
Choose the kit based on the number of cartridges and handling (Tray / Collection container / Fluid container). For most applications, these two "quick starters" are particularly popular:
Tip: If you frequently change colors or have a lot of overspray, the variant with more filter area (4 cartridges) is usually worth it – this stabilizes the suction effect with higher powder accumulation.
Recommended Basic Settings (as guidelines)
These guidelines help with a "clean start". If the system/options differ, please validate on-site.
| Parameter | Guideline | Why important |
|---|---|---|
| Compressed Air Inlet Pressure | min. 6 bar / recommended 7 bar | Ensures stable supply (esp. cleaning). |
| Booth Pressure Regulator | do not set above 6 bar | Protects pressure tank/components from overpressure events. |
| Cleaning Pressure (Pressure Tank) | 5 bar recommended (max. 6 bar) | Enough pulse energy for jet cleaning without unnecessary stress. |
| Pulse Time (Jet) | 10–30 ms, factory setting 20 ms | Affects how "hard" the cartridge is blown off. |
| Pause Time between Pulses | Factory setting 10 s | Stable cycle without unnecessarily disturbing the airflow. |
| Trigger Cleaning | max. 1–2 times per shift | Excessive cycles often yield less than a planned cartridge change. |
Note: Cycle times should typically only be adjusted if a fault due to high filter resistance is repeatedly displayed – and then structured (check cause, evaluate cartridge condition).
Professional Workflow (5–7 steps)
- Before shift start: Correctly attach collection container/handling part, check connections, visual check of filters/filter mats.
- Release compressed air: Ensure inlet pressure (guideline min. 6 bar), booth regulator not above 6 bar.
- Start booth: Main switch on, check fan operation, only then release ES device.
- Coating: With constant movements, focus on intake into the workspace (vacuum helps bind overspray).
- If necessary: Manually trigger filter cleaning (sparingly, not "rapid fire").
- Color change: Clean booth & collection container, clean injector/hose/gun separately, consistently swap cartridges during color changes.
- End of shift: Rough cleaning, check/empty collection container, documentation (faults/cleaning/changes).
Troubleshooting (4 typical cases)
1) System shuts down / Motor protection triggered
- Main switch off, let motor cool down, reset motor protection (according to circuit diagram).
- If it repeats: Systematically check the cause (fan, contamination, bearings) and involve the manufacturer representative.
2) ES device is switched off (minimum exhaust air volume not reached)
- Clean filter cartridges (one planned cycle instead of multiple short pulses).
- If alarm recurs: Cartridges at end of life → change the complete cartridge set.
3) Powder visible on filter mats (clean air side)
- Suspected leaking/defective filter cartridge: replace affected cartridge or entire set.
- Check and clean clean air chamber, then check again.
4) Filter cartridge is not being cleaned
- Check solenoid valve/coil or cable (defect/cable break) and replace.
- If valves are OK: check control relay/module as cause (specialist personnel).
Maintenance (5 points that really count)
- Daily/per shift: Blow through powder hose, clean gun exterior, check wear parts.
- Daily/per shift: Roughly clean booth and check collection container for impurities.
- Weekly: Check filter cartridges for visible damage; check filter mats at discharge openings (powder deposit = warning signal).
- Weekly: Completely clean booth (no wet cleaning) + empty collection container/tray.
- Semi-annually: Check exhaust fan (motor/impeller) for dust and powder deposits.
FAQ (practice-relevant)
1) Which ClassicLine version fits large workpieces?
For particularly voluminous parts, the open version (ClassicOpen) is typically the appropriate choice – alternatively ClassicStandard 4, if the workspace is sufficient.
2) 4000 or 6600 Nm³/h – when do I need which?
4000 Nm³/h is usually suitable for smaller coating tasks, 6600 Nm³/h for larger objects or higher powder volumes. Decisive factors are part size, overspray amount, and desired vacuum stability.
3) How often should I trigger filter cleaning?
As a guideline, no more than 1–2 times per shift. If a fault due to high filter resistance occurs frequently, the cause must be checked (filter condition, leaks, powder accumulation) – replace cartridge set if necessary.
4) May I "blow off" filter cartridges with compressed air?
During booth cleaning, it is explicitly important not to blow off filter cartridges with a compressed air gun – a jet that is too strong can damage the structure. Use the jet cleaning as intended.
5) Why does the ES device sometimes switch off?
If the minimum exhaust air volume is not reached (e.g., due to clogged filters), the ES device is switched off. Cleaning or cartridge replacement are the typical measures.
Status of guidelines: dependent on version/options and filter condition. Changes/deviations in practice possible.
Would you like us to select the appropriate configuration (2 vs. 4 cartridges, container/tray/fluid) based on your part size & color change frequency? Then briefly write us your requirements.
