Powder buy the pound Spectracoat es01 User manual

Powder Coating Gun Controler

Operator Manual

for models

ES01 & ES02

Including Complete System Options

with VectorWave™ TECHNOLOGY

Your Complete Source for Powder Coating Supplies

— 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:

Powder coating controllers (settings and use)

Media blasting (ie: sand blasting)

Pressure hoppers

Fluidizing hoppers

Cleaning and ongoing maintenance of your equipment

Learn to avoid and correct:

Back ionization

Contamination

Out gassing

2-Day Class:

Includes in-depth instruction

and hands-on experience

SKU210801

4-Day Class:

Two additional days of creative lab

and personalized, hands-on training

SKU2148

SpectraCoat System Manual by powderbuythepound.com

Item Description

Input Power

Watts

Gun Output

Air Pressure

Fuse

Auto Switching 110-120 / 220-240 VAC

50 watts at maximum gun output

0-100 Kv — 0-150A

Maximum input air pressure 80 psi

1.0

Speciﬁcations:

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 aordable price.

Operators Manual — SpectraCoat™ ES01 & ES02

•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

ES01-WC

•ES01 Control unit with Wave Board

Unpacking your Spectracoat™ System:

Carefully open the box and unpack the contents. Lay out the parts for counting

and inspection. With the checklist provided, conrm 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.

SpectraCoat System Manual

•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

ES01-WP/ES01-WH

•ES01 Control unit with Wave Board

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

SpectraCoat System Manual by powderbuythepound.com

•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

ES02-WP

•ES02 Control unit with Wave Board

Operators Manual — SpectraCoat™ ES01 & ES02

•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

ES02-WF

•ES02 Control unit with Wave Board

SpectraCoat System Manual by powderbuythepound.com

1.5

Electrical Safety:

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.

Operate this powder coating system

in a clean and dry work area.

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.

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

Operators Manual — SpectraCoat™ ES01 & ES02

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

1.6

General Safety:

Do not operate the

SpectraCoat

™ ES System near an

open ame. 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.

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.

Remove the AC power cord.

Insert the tip of a small at screw driver into the slot at

the top of the fuse drawer in the power entry module.

With a gentle prying motion pull out the Fuse Drawer.

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).

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 ltration 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

to 80 PSI and 5 CFM per ES control head. This ensures that there is

enough air volume to properly fluidize the powder in the hopper(s)

and run steady supply air to all of the other pressure lines.

If you are running more than one

SpectraCoat

™ or any of the ES

control heads together in contractor packs, on the same airline, then

make sure your shop air system is showing 60 to 80 PSI and 5 CFM

constant at the Air Input on the back panel of

each

control unit in

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

or pin holes in the cured lm.

The ES control unit uses industrial regulators that do not

show CFM. The regulators show active PSI usage with the

trigger engaged.

Having sucient and consistent air pressure is required for

ensuring air volume to properly uidize/condition powder

in a hopper(s) while running steady supply air to the other

pressure lines in your system.

The supply air used with all of the

SpectraCoat

™ systems

must be clean. It must be free of oil and moisture. It is

very important that you have an air drying system in line

between your air compressor and any

SpectraCoat

™ system.

Example:

Two ES control units

will run well at 60 to

80 PSI and 10 CFM.

Three ES control

units will run well at

60 to 80 PSI and 15

CFM.

Air pressure over 80 PSI can

press hard enough against the

industrial strength springs in

the regulators to open them

slightly. This will make a hissing

sound. If this happens, turn

down your shop air pressure

supply feeding the control unit.

You can monitor the shop air

input tting with a PSI and CFM

Regulator/Monitor installed in

the shop air line input on the

back panel of the ES02.

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 nished coating.

As powder passes through the electro-static corona eld 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

than 1 Mega Ohm. This is the path for the electrical charge to

ow away from the surface of the part, in eect draining the

ions as fast as they transfer to the substrate.

While spraying and charging powder, even a well grounded

part can eventually ll up with electrostatic negative ions

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

magnetic fields overlap, called a Faraday Cage.

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.

The thing in

your shop that

has the best

ground will

attract ionized

powder the

most.

Make sure it is

your part!

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.

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, ttings and the Gun.

Front Panel

•(1) Feed air regulator

•(2) Feed air guage

•(3) Voltage (KV) adjustment

knob, adjusts the level of kilovolt

output at the gun electrode tip

•(4) Gun voltage (KV) and

current (Amps) output

indicator - active when the

trigger is pulled on the gun

•(5) Main power switch and

power on indicator

•(6) Faraday

VectorWave

™

activation switch (optional)

Back Panel

•(7) Spray gun cable connector

•(8) Serial number

•(9) Ground lug with wing nut

•(10) 110 volt input

•(11) ¼” hose (red)*

•(12) Supply air fitting (3

8”) .

Use no more than 80 PSI

•(13) 2 amp glass fuse

*Special note: regulators indicate

controlled pressure only when the

trigger is pulled. Dial them down before

you start spraying to avoid wasting

powder

•1•2•3•4•6

•12

•11

•10

•13

•9

•8

•7

•5

Operators Manual — SpectraCoat™ ES01 & ES02

ES01-C & WC

•Insert one end of the red ¼”

pressure hopper hose into the

¼” connector labelled “feed” on

the back of the control unit.

•Insert the other end of the 15’ red

¼”air line into the ¼” elbow tting

on the ½lb powder hopper.

•Attach the white barb on the .5lb powder

hopper cup lid to the black powder in

barb at the base of the gun handle with

the short ½” X 3” powder hose jumper.

•Insert the 1/4” tube end of the ES01 quick

connect adapter into the main air tting

on the back of your ES01 control unit.

•After completing all of the above

steps, connect your AC power cord.

ES01-P& WP

•Insert the red ¼” hopper pressure

hose into the ¼” hopper feed fitting

on the back of the control unit.

•Insert the other end of the 15’ red

¼”air line into the ¼” elbow fitting

on the 1½lb powder hopper.

•Attach the white elbow barb on the

1½lb powder hopper cup

lid to the black powder barb at the

base of the gun handle using the

½” grounded powder hose.

•After completing all of the above

steps, connect your AC power cord.

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

conrm that it remains tight for proper grounding). Put the open eye of the green

ground cable onto the ground lug. Tighten only nger 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 tting on the back of your control unit.

Conﬁguration:

See the video setup of the

ES01 and ES02 on

YouTube.com/user/powdercoat101

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, ttings and the Gun.

Front Panel

•(1) Feed air regulator

and guage

•(2) Auxiliary air

regulator and guage

•(3) Voltage (KV) adjustment

knob, adjusts the level

of kilovolt output at the

gun electrode tip

•(4) Gun voltage (KV) and

current (amps) output

indicator - active when the

trigger is pulled on the gun

•(5) Main power switch

and power on indicator

•(6) Faraday

VectorWave

™

activation switch (optional)

Back Panel

•(7) Spray gun cable connector

•(8) Serial number

•(9) Ground lug with wing nut

•(10) 110 volt input

•(11) ¼” hose (red)

•(12) Supply air fitting (3

8”) .

Use no more than 80 PSI

•(13) 2 amp glass fuse

•(14) ¼” hose (clear)

*Special note: regulators indicate

controlled pressure only when the

trigger is pulled. Dial them down before

you start spraying to avoid wasting

powder

•1•2•3•4•6

•12

•11

•14

•10

•13

•9

•8

•7

•5

Operators Manual — SpectraCoat™ ES01 & ES02

ES02-P & WP, ES02-C &WC

•Insert the ¼” red hose into the ¼”

feed pressure tting on the back

panel. Insert the other end of the

same ¼” red hose into the ¼” hose

tting on the cup hopper lid.

•Insert one end of the ¼”black or clear

auxiliary air hose into the ¼” auxiliary

air tting on the back of the ES02.

Connect the other end of the same

hose to the chrome ¼” rinse air nipple

on the bottom of the gun handle.

•Connect the powder hopper to the

black barb at the base of the gun

handle using the ½” powder hose.

[For ES02-P & WP models, use the 12’ of

½” grounded powder hose to connect

to the 1.5 LB pressure hopper lid.]

•After completing all of the above

steps, connect your AC power cord.

•Squeeze the trigger to set the PSI on

the aux regulator at 4 to 5 PSI, and

the feed regulator at 8 to 10 PSI

ES02 General Setup: