Your Complete Source for Powder Coating Supplies

Powder Coating Gun Controler

Operator Manual
for models
ES01 & ES02
Including Complete System Options
with VectorWave™ TECHNOLOGY

— Warning —
This system generates HIGH VOLTAGE. Read and understand
the directions in this manual before using the system.
Electrical shock can occur if improperly used.
READ THIS MANUAL!
 Powder Coating Training is available from
PowderBuyThePound.
These classes will help you to understand and operate your new SpectraCoat™ powder
coating system or the operation of most professional powder coating systems.
Call the office @ 615-776-7600 and ask to schedule your training today!

Our Powder Coating Classes Teach:

 Powder types
 Powder curing
 Powder application
 Applying second and multiple coats
 Heat flocking, or shooting warm/hot
 Surface and part preparation and pretreatment
 Chemical stripping
 Degreasing
 Out-gassing
 Iron phosphate cleansing and conversion
coatings
 Acetone, denatured alcohol
Hands on Instruction includes:
p Powder coating controllers (settings and use)
p Media blasting (ie: sand blasting)
p Pressure hoppers
p Fluidizing hoppers
p Cleaning and ongoing maintenance of your equipment

Learn to avoid and correct:

p Back ionization
p Contamination
p Out gassing

2-Day Class: 4-Day Class:

Includes in-depth instruction Two additional days of creative lab
and hands-on experience and personalized, hands-on training
SKU210801 SKU2148
SpectraCoat System Manual by powderbuythepound.com

1.0
Specifications:
Item Description

Input Power Auto Switching 110-120 / 220-240 VAC

Watts 50 watts at maximum gun output

Gun Output 0-100 Kv — 0-150μA

Air Pressure Maximum input air pressure 80 psi

Fuse 2A

1.1
SpectraCoat™ Systems
Congratulations on purchasing a SpectraCoat™ Powder Coating Gun
Controller! Engineered for professional results with package options
accessible to the beginner who wants professional results from his powder
coating gun and for the industry professional who wants quality equipment
with quick color change features and an affordable price.

4
 Operators Manual — SpectraCoat™ ES01 & ES02

Unpacking your Spectracoat™ System:

Carefully open the box and unpack the contents. Lay out the parts for counting
and inspection. With the checklist provided, confirm the complete shipment of
the system you ordered.

The following pages list precisely what is included

with each of the SpectraCoat™ ES 01 and the
SpectraCoat™ ES02 systems.

ES01-WC
• ES01 Control unit with Wave Board
• ES01-ES02 Manual
• Manual Gun VIII
• Connectivity Pack
 110v Power Cable
 Green Ground Cable, 15 ft
 Quick connect adapter
 Outer nut
 Round spray electrode
 Fan spray electrode

• Hoses – 15’ Red ¼ inch air line

• Pressure Hopper - ½ LB

5
SpectraCoat System Manual

ES01-WP/ES01-WH
• ES01 Control unit with Wave Board

• ES01-ES02 Manual
• Manual Gun VIII
• Connectivity Pack
 110v Power Cable

 Green Ground Cable, 15 ft

 Quick connect adapter

 Outer nut

 Round spray electrode

 Fan spray electrode

• 12 ft of 12mm grounded powder tube

• Hoses
 Red ¼ inch air line, 5’

• Pressure Hopper, 1½ LB

6
 Operators Manual — SpectraCoat™ ES01 & ES02

ES02-WC
• ES02 Control unit with Wave Board

• ES01-ES02 Manual
• Manual Gun VIII
• Connectivity Pack
 110v Power Cable

 Green Ground Cable, 15 ft

 Quick connect adapter

 Outer nut

 Round spray electrode

 Fan spray electrode

• Hoses
 15’ Red ¼ inch air line

• Pressure Hopper, ½ LB

7
SpectraCoat System Manual by powderbuythepound.com

ES02-WP
• ES02 Control unit with Wave Board

• ES01-ES02 Manual
• Manual Gun VIII
• Connectivity Pack
 110v Power Cable
 Green Ground Cable, 15 ft
 Quick connect adapter
 Outer nut
 Round spray electrode
 Fan spray electrode
• 12mm Grounded Powder Tube, 12 ft
• Hoses
15’ Red, ¼ inch air line
• Pressure Hopper, 1½ LB
 “T” quick connector
 5’ of Blue ¼ inch hose
 Regulator with quick connectors

8
 Operators Manual — SpectraCoat™ ES01 & ES02

ES02-WF
• ES02 Control unit with Wave Board

• ES01-ES02 Manual
• Manual Gun VIII
• Connectivity Pack
 110v Power Cable
 Green Ground Cable, 15 ft
 Quick connect adapter
 Outer nut
 Round spray electrode
 Fan spray electrode
• 12mm Grounded Powder Tube, 12 ft
• Hoses
 5’ Red ¼ inch air line
 5’ Clear ¼ inch air line

• Powder Pump
• Fluidizing Kit
 “T” quick connector
 5’ of Blue ¼ inch hose
 Regulator with quick connectors
• Gray Fluidizing Bucket Hopper, 2 LB

9
SpectraCoat System Manual by powderbuythepound.com

1.5

Electrical Safety:
p This system must be properly grounded for safe
operation. Do not remove or bypass the ground plug.
This system must be plugged into an AC power source
with a proper earth ground. This is necessary for the safe
operation of the unit and to prevent electrical shock.
p Operate this powder coating system
in a clean and dry work area.
p While spraying, or doing other trigger down KV
and Air Solenoid tests, and/or experiments, avoid
touching the electrode tip of the gun. Doing so can
cause a static shock which could be painful.
p During the coating operation, always maintain
a minimum distance of at least (4”) between
the gun and the part being coated.

VERY IMPORTANT!
Never touch the tip of the gun to a part being coated or any other metal part
grounded or not. Touching the electrode tip of the gun to any metal part to see
if it sparks may void your warranty. Spark suppression is built into the control
unit and gun to minimize the possibility of static sparking.
Evidence of spark testing in returned repair work voids owner’s warranty!
(NO SPARK TESTING ALOWED)

10
 Operators Manual — SpectraCoat™ ES01 & ES02

1.6

General Safety:
p Do not operate the SpectraCoat™ ES System near an
open flame. Powder coating dust can be combustible
given the right circumstances. Back Ionization Sparks in a
dense enough powder can cause the powder to ignite.
 This system utilizes compressed air. Always use proper eye,
ear, and skin protection while operating.
 Operate the SpectraCoat™ ES system in a clean, well
ventilated area or booth with adequate air filtration.
 Always use a respirator, particle filter mask, or a vapor mask
while operating any powder coating spray system.
 The gun handle is the point where the operator is
grounded. Always hold the gun handle with your bare hand.
DO NOT wear a glove on the hand that is holding the gun
unless you know you are grounded to the system through
another means, such as a ground strap or conductive glove.

VERY IMPORTANT!
Keep your unit free from extremes of moisture and dust. Clean dry compressed
air is required in powder coating.
Cleaning dirty or seized regulators and solenoids is not covered under warranty
and evidence of moisture, extreme dusty environments or dirty compressed air
source voids owner’s warranty!
(CLEAN DRY COMPRESSED AIR AND OPERATING ENVIRONMENT ARE REQUIRED)

11
SpectraCoat System Manual by powderbuythepound.com

1.7

Voltage
Input Voltage Selection and Fuse Replacement:
Always unplug the unit from the AC power source before changing the fuse.

Auto Switching Input Voltage Power Supply:

Each Spectracoat system is equipped with an auto switching power supply
that can be used with either 110V or 220V without having to make any
changes for international customers. You may need to supply the correct
power cable or adapter to use in your country.
The actual input range is 100-240VAC. This power supply provides the control
board with stable power and consistent voltage output, with improved Faraday
area coverage performance on second and third coats over older technology.
It is very important that the AC power source for the SpectraCoat™ ES is properly
grounded to the building’s electrical service. Check the electrical wall service for
the powder coating gun controller and make sure the ground is engaged. This
common ground is separate from the green earth ground wire that is provided
for connection to the back of the unit.

Fuse Replacement:
The fuse is located in the Fuse Drawer of the power entry module.
p Remove the AC power cord.
p Insert the tip of a small flat screw driver into the slot at
the top of the fuse drawer in the power entry module.
p With a gentle prying motion pull out the Fuse Drawer.
p If blown, replace with a new 2 Amp fuse. A blown
fuse commonly looks clouded or has a dark spot. If
you see these symptoms the fuse should be replaced.
You can also test for resistance. Good fuses will have
zero resistance (closed or short circuit). A blown fuse
will give no resistance reading (open circuit).

12
 Operators Manual — SpectraCoat™ ES01 & ES02

1.8

Shop Air
What You Need To Know
Air delivery is an important part of a powder coating operation. The wrong air
pressure or filtration system may result in poor spray performance and ultimately
will damage your powder coating equipment

Consistent Air Pressure!

The SpectraCoat™ systems work best if they are driven by shop
air systems that maintain regulated air pressures of at least 50 up Example:
to 80 PSI and 5 CFM per ES control head. This ensures that there is Two ES control units
enough air volume to properly fluidize the powder in the hopper(s) will run well at 60 to
and run steady supply air to all of the other pressure lines. 80 PSI and 10 CFM.
If you are running more than one SpectraCoat™ or any of the ES Three ES control
control heads together in contractor packs, on the same airline, then units will run well at
make sure your shop air system is showing 60 to 80 PSI and 5 CFM 60 to 80 PSI and 15
constant at the Air Input on the back panel of each control unit in CFM.
series or each stand alone unit.

Use clean dry air only!

Moisture in the shop supplied air will reduce the static
charge to the powder and cause moisture/solvent popping Air pressure over 80 PSI can
or pin holes in the cured film.
press hard enough against the
The ES control unit uses industrial regulators that do not industrial strength springs in
show CFM. The regulators show active PSI usage with the the regulators to open them
trigger engaged. slightly. This will make a hissing
sound. If this happens, turn
Having sufficient and consistent air pressure is required for
down your shop air pressure
ensuring air volume to properly fluidize/condition powder
supply feeding the control unit.
in a hopper(s) while running steady supply air to the other
You can monitor the shop air
pressure lines in your system.
input fitting with a PSI and CFM
The supply air used with all of the SpectraCoat™ systems Regulator/Monitor installed in
must be clean. It must be free of oil and moisture. It is the shop air line input on the
very important that you have an air drying system in line back panel of the ES02.
between your air compressor and any SpectraCoat™ system.

13
SpectraCoat System Manual by powderbuythepound.com

1.9

How it works
Magic!
As with all corona charged powder coating systems, the SpectraCoat™ Gun
Systems, and the parts to be coated must be properly grounded. This is essential
to the operation of a corona generating electro-static powder coating system
and to the quality of the finished coating.
As powder passes through the electro-static corona field emitted from the
electrode tip of the gun, the powder particles become energized with a
negative electrical charge. Parts that are properly grounded attract the negative
ions, drawing them to ground. The charged powder particles within about 4 to
6 inches magnetically attract and adhere to the part.
Without proper grounding, the magnetic field is weak and
does not attract and hold powder.
Industry standards for powder coating mandate that
resistance for an open ground drain be measured at less
The thing in
than 1 Mega Ohm. This is the path for the electrical charge to
your shop that
flow away from the surface of the part, in effect draining the
has the best
ions as fast as they transfer to the substrate.
ground will
attract ionized While spraying and charging powder, even a well grounded
powder the part can eventually fill up with electrostatic negative ions
most. like a bath tub full of water. This negative ion charge pooling
is stored in the part. There are also areas of the part where
Make sure it is
magnetic fields overlap, called a Faraday Cage.
your part! These situations create force-field type repulsion of charged
powder particles. The resulting coatings will be poor,
showing uneven coverage or rejecting powder adhesion.
Always have the best possible ground!
Not all workshops operate in the same environmental conditions. Local
grounding conditions will change without notice as a result of the water table
rising and falling. Know your area and be aware of surrounding weather
conditions.

14
 Operators Manual — SpectraCoat™ ES01 & ES02

Important Grounding Note:

The included green grounding wire runs from

the ground lug on the back of your control
unit to an 8’ copper earth ground rod

NOT to the part being sprayed!

Your part will need a separate grounding
wire running from it to the 8’ Grounding
Rod. A 12 gauge or larger stranded
grounding wire is a REQUIRED minimum for
powder coating safety.

15
SpectraCoat System Manual by powderbuythepound.com

2.0

Setup the SpectraCoat™ ES01

Before you start operating the SpectraCoat™ ES01, take a minute to examine the
front and back panels. Familiarize yourself with the controls, fittings and the Gun.

•5
• 12

•7 • 10 • 11
•1 • • • •6 •8 •9
2 3 4
• 13
Front Panel Back Panel
• (1) Feed air regulator • (7) Spray gun cable connector
• (2) Feed air guage • (8) Serial number
• (3) Voltage (KV) adjustment • (9) Ground lug with wing nut
knob, adjusts the level of kilovolt
output at the gun electrode tip
• (10) 110 volt input
• (4) Gun voltage (KV) and • (11) ¼” hose (red)*
current (Amps) output • (12) Supply air fitting ( / ”) .
38

indicator - active when the Use no more than 80 PSI

trigger is pulled on the gun • (13) 2 amp glass fuse
• (5) Main power switch and
power on indicator

• (6) Faraday VectorWave™

*Special note: regulators indicate
controlled pressure only when the
activation switch (optional) trigger is pulled. Dial them down before
you start spraying to avoid wasting
powder

16
 Operators Manual — SpectraCoat™ ES01 & ES02

ES01 General Setup:

Connect the AC power source last, after all other connections have been made.

• Unscrew the gray nose cone from the gun and insert the desired white electrode nozzle into
the gun. Round tip nozzle is recommended for beginners. Reinstall the nose cone until snug.

• Insert and twist the gun cable end to the gun cable connector on the back panel.
• Unscrew and remove the wing nut from the ground lug (leave the hex nut, and
confirm that it remains tight for proper grounding). Put the open eye of the green
ground cable onto the ground lug. Tighten only finger tight - No wrench needed.

• Install your shop air disconnect into the threaded end of the quick connect adapter.
• Insert the tube end of the quick connect adapter into the
main air fitting on the back of your control unit.

Configuration:

ES01-C & WC ES01-P & WP

• Insert one end of the red ¼” • Insert the red ¼” hopper pressure
pressure hopper hose into the hose into the ¼” hopper feed fitting
¼” connector labelled “feed” on on the back of the control unit.
the back of the control unit. • Insert the other end of the 15’ red
• Insert the other end of the 15’ red ¼”air line into the ¼” elbow fitting
¼”air line into the ¼” elbow fitting on the 1½lb powder hopper.
on the ½lb powder hopper. • Attach the white elbow barb on the
• Attach the white barb on the .5lb powder 1½lb powder hopper cup
lid to the black powder barb at the
hopper cup lid to the black powder in
barb at the base of the gun handle with base of the gun handle using the
the short ½” X 3” powder hose jumper. ½” grounded powder hose.

• Insert the 1/4” tube end of the ES01 quick • After completing all of the above
connect adapter into the main air fitting steps, connect your AC power cord.
on the back of your ES01 control unit.

• After completing all of the above

steps, connect your AC power cord.

See the video setup of the

ES01 and ES02 on

YouTube.com/user/powdercoat101

17
SpectraCoat System Manual by powderbuythepound.com

3.0

Setup the SpectraCoat™ ES02

Before you start operating the SpectraCoat™ ES02, take a minute to examine the
front and back panels. Familiarize yourself with the controls, fittings and the Gun.

•5
• 12

•7 • 10 • 11
•1 • 2 • 3 • 4 • 6 •8 •9 • 13 • 14

Front Panel Back Panel

• (1) Feed air regulator • (7) Spray gun cable connector
and guage
• (8) Serial number
• (2) Auxiliary air • (9) Ground lug with wing nut
regulator and guage

• (3) Voltage (KV) adjustment • (10) 110 volt input

knob, adjusts the level • (11) ¼” hose (red)
of kilovolt output at the
gun electrode tip
• (12) Supply air fitting ( / ”) .
38

Use no more than 80 PSI

• (4) Gun voltage (KV) and • (13) 2 amp glass fuse
current (amps) output
indicator - active when the • (14) ¼” hose (clear)
trigger is pulled on the gun

• (5) Main power switch

and power on indicator

• (6) Faraday VectorWave™

*Special note: regulators indicate
controlled pressure only when the
activation switch (optional) trigger is pulled. Dial them down before
you start spraying to avoid wasting
powder

18
 Operators Manual — SpectraCoat™ ES01 & ES02

ES02 General Setup:

Connect the AC power source last, after all other connections have been made.

• Unscrew the gray nose cone from the gun and insert the desired white electrode nozzle into
the gun. Round tip nozzle is recommended for beginners. Reinstall the nose cone until snug.

• Insert and twist the gun cable end to the gun cable connector on the back panel.
• Unscrew and remove the wing nut from the ground lug (leave the hex nut, and
confirm that it remains tight for proper grounding). Put the open eye of the green
ground cable onto the ground lug. Tighten only finger tight - No wrench needed.

• Install your shop air disconnect into the threaded end of the quick connect adapter.
• Insert the tube end of the quick connect adapter into the
main air fitting on the back of your control unit.

Configuration:
ES02-P & WP, ES02-C &WC ES02-F & WF
• Insert the ¼” red hose into the ¼” • Connect one end of the ½”
feed pressure fitting on the back grounded powder feed hose
panel. Insert the other end of the to the ½” barb fitting on the
same ¼” red hose into the ¼” hose front of the venturi pump.
fitting on the cup hopper lid.
• Insert the other end of the ¼”
• Insert one end of the ¼”black or clear black or clear auxiliary air hose
auxiliary air hose into the ¼” auxiliary into the ¼” dosage air fitting on
air fitting on the back of the ES02. the top front of the powder pump.
Connect the other end of the same
hose to the chrome ¼” rinse air nipple • Insert one end of the ¼” red
hopper feed hose into the ¼” feed
on the bottom of the gun handle.
air fitting on the back (top) of the
• Connect the powder hopper to the powder pump. The powder pump
black barb at the base of the gun sits on (top) the SpectraCoat™
handle using the ½” powder hose. constant fluidizing hopper.
[For ES02-P & WP models, use the 12’ of
½” grounded powder hose to connect • Connect one end of the ½”
grounded powder hose to
to the 1.5 LB pressure hopper lid.]
the black ½” nozzle barb
• After completing all of the above on the front of the powder
steps, connect your AC power cord. pump atop the SpectraCoat™
• Squeeze the trigger to set the PSI on constant fluidizing hopper.
the aux regulator at 4 to 5 PSI, and • Squeeze the trigger to set the PSI
the feed regulator at 8 to 10 PSI on the feed air regulator at 8 to
10 PSI. Note for Starting out: Your
Feed Air should be about twice the
pressure of your aux/dose air PSI.

19
SpectraCoat System Manual by powderbuythepound.com

Powder Buy The Pound

VectorWave™ TECHNOLOGY
(Available on the SpectraCoat™ ES-01, ES-02, and ES-03 systems only)
With the optional Faraday VectorWave™ feature engaged you could easily coat
those previously challenging recessed, concave, inside angles, outside corners,
and other areas that would normally present a Faraday cage effect.
With our optional VectorWave™ feature engaged and the gun trigger pulled,
you will see the Red and Green LED meter bridge cycle/sweep back and forth
within your selected KV range. You can control the KV range that the unit cycles/
sweeps through, by adjusting the KV Knob.
Below is an example of normal and favorable operating settings.
Always start with a higher KV setting, such as 80 KV. This allows you to drop
20 KV each time you return to apply multiple coats.
For the second coat, set the KV knob at 40-60 KV then press the VectorWave™
button. If you are planning a third coat then leave the VectorWave™ off until it is
time to apply the third or final coat.
Before applying the third coat, set the KV knob at somewhere between
20-40KV. If this is your final coat then turn on the SpectraCoat™ systems
VectorWave™ TECHNOLOGY™.
Example ~ First coat 80 KV, 2nd coat 60 KV, 3rd coat 40 KV, 4th coat 20 KV
These procedures are anticipated starting points for the operation of all semi-
pro and commercial SpectraCoat™ systems.

20
 Operators Manual — SpectraCoat™ ES01 & ES02

Color Change and Cleaning

Color changing and cleaning are pretty much the same operation. It is always
a good idea to keep the SpectraCoat™ gun clean between jobs, as with other
systems.

Do yourself a favor and clean the system when you are done for the day/night.
Any powder left in the hopper, feed lines, or gun can be very difficult to
clean out later or forgotten altogether. This can potentially create frustrating
contamination issues. For this procedure, you will need an air nozzle on a
shop airline to blow any residual powder from the system hoses and nozle.
An air pressure level of 80-100PSI is recommended for the cleaning process.

Wiping system parts with Micro Fiber Towels and Denatured

Alcohol is also a very good idea. The Alcohol in the Micro Fiber
Towel helps lift out very small particles that cannot be
removed by air alone. Only use clean, lint free microfiber
towels!

21
SpectraCoat System Manual by powderbuythepound.com

6.0

Warranty & Repair Info

When you decide your system is not functioning properly and you need help or want to
send in a tool for testing, warranty, or repair, please follow these simple steps to expedite
your service.
1. Before sending your coating system, call our technical department for assistance!
Many repairs can be made with replacement parts right in your shop, and some require
additional tools and training available only at PowderBuyThePound.
Dirty Regulators and Solenoids are not covered under this warranty. We can replace
regulators and solenoids that have been damaged.
2. After determining that a system or part needs to be repaired by our trained technicians,
we will assign an RMA number to each item to be sent to us. Please complete an
information sheet provided with your RMA number and pack it in a box along with
adequate protective packaging and your item for repair. Keep a copy of this information
for your records.
p Name of the purchaser for this product (name used in the
original invoice is required for warranty service!)
p Return shipping address
p Contact phone AND e-mail address
p Serial number of the product and/or original invoice number
p Note any circumstances or problems surrounding your device:, such as:
- controller is leaking air;
- gun spits powder;
- system was caught in a flood;
Standard shop rates apply for non-warranty repair labor and parts.
Shipping of warranty items to PowderBuyThePound is paid by the customer, and return
shipping to the customer will be paid by PowderBuyThePound.
Gun system warranties extend 1 year from the original owners purchase date on invoice.
The warranty is not transferable to new owners. Models included are ES01, ES02, ES03,
and the related accessories included with these systems.
Oven frames, walls, floors, ceilings, door seal, hinges, door latches, building hardware,
heating elements, wiring, control panel including control box internal parts and switches,
are warranted for 6 months from delivery date on the original owners shipping invoice.
An extended warranty is available at the time of purchase. Please inquire with our sales
team regarding the purchase of extended warranty products.

22
 RELIABLE ACCESSORIES & REPLACEMENT PARTS,
OVENS, BOOTHS, STARTUP PACKAGES
& HANDS-ON TRAINING
are all available
through our website at

PowderBuyThePound.com
See you there!

2011 Johnson Industrial Blvd. Nolensville, TN 37135

Phone 615-776-7600
Fax 615-776-2963

PowderBuyThePound.com

Copyright © 2019 Providing System Solutions, Inc.

All rights reserved. No portion of this training manual or any of the artwork
herein may be reproduced or distributed in any way shape or form.
Please read and understand this manual thoroughly before attempting to operate
SpectraCoatTM ES Powder Coating Systems and accessories.
Due to ongoing research, development, and quality control, SpectraCoatTM Systems specifications,
design parameters, and operations training are subject to change at the manufacturer’s sole discretion.
This book in no way claims to contain all information available regarding powder coating technology,
equipment and practice, but represent a standard of instruction for most powder coating operators.