Abstract: An overload protection and control circuit and methods for electrocoat painting systems is disclosed. A resistive shunt is utilized to generate a voltage proportional to the level of current flow to electrodes in the electrocoat painting system. After amplification, the generated voltage is compared with a reference voltage. If the current exceeds a predetermined level, indicative of an overcurrent condition, a comparator causes a control circuit to disable current flow. A timer is provided to delay re-enabling of current flow for a predetermined delay interval. The control circuit may receive inputs from a control PLC or computer. The control PLC or computer may receive inputs from sensors such as a pH sensor or a membrane monitor. The control PLC or computer may selectively control the control circuit to various electrodes so as to more appropriately operate the electrocoat painting system.