Wagner FLEXiO Owner's Manual

Contents

1. Important Safety Information
2. Controls and Functions
3. Material Preparation
4. Assembly
5. Power and Material Controls
6. Spray Pattern Adjustment
7. Proper Spraying Technique
8. Cleanup
9. Reassembly
10. Maintenance
11. Troubleshooting
12. Parts List
13. Warranty

Form No. 0529595B

Questions?

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Important Safety Information

[warning] Indicates a hazardous situation which, if not avoided, could result in death or serious injury.

To reduce the risks of fire or explosion, electrical shock and injury to persons, read and understand all instructions included in this manual. Be familiar with the controls and proper usage of the equipment.

Grounding Instructions

This product must be grounded. In the event of an electrical short circuit, grounding reduces the risk of electric shock by providing an escape wire for the electric current. This product is equipped with a cord having a grounding wire with an appropriate grounding plug. The plug must be plugged into an outlet that is properly installed and grounded in accordance with all local codes and ordinances.

[warning] Improper installation of the grounding plug can result in a risk of electric shock.

If repair or replacement of the cord or plug is necessary, do not connect the green grounding wire to either flat blade terminal. The wire with insulation having a green outer surface with or without yellow stripes is the grounding wire and must be connected to the grounding pin.

Check with a qualified electrician or serviceman if the grounding instructions are not completely understood, or if you are in doubt as to whether the product is properly grounded. Do not modify the plug provided. If the plug will not fit the outlet, have the proper outlet installed by a qualified electrician.

This product is for use on a nominal 120 volt circuit and has a grounding plug that looks like the plug illustrated below. Make sure that the product is connected to an outlet having the same configuration as the plug. No adapter should be used with this product.

Diagram: Illustration of a grounded electrical outlet with a grounding pin, and a grounding pin on an electrical plug. Also shows a cover for a grounded outlet box.

WARNING - To reduce the risk of fire or explosion:

1. Do not spray flammable or combustible materials near an open flame, pilot lights or sources of ignition such as hot objects, cigarettes, motors, electrical equipment and electrical appliances. Avoid creating sparks from connecting and disconnecting power cords.
2. For use with only water-based or mineral spirit-type materials with a minimum flash point of 38°C (100° F). Do not spray or clean with liquids having a flash point of less than 38°C (100° F). Flash point is the temperature at which a fluid can produce enough vapor to ignite.
3. Verify that all containers and collection systems are grounded to prevent static discharge.
4. Connect to a grounded outlet and use grounded extension cords (electric models only). Do not use a 3 to 2 adapter.
5. Keep spray area well ventilated. Keep a good supply of fresh air moving through the area to keep the air within the spray area free from accumulation of flammable vapors.
6. Do not smoke in the spray area.
7. Do not operate light switches, engines, or similar spark producing products in the spray area.
8. Keep area clean and free of paint or solvent containers, rags, and other flammable materials.
9. Know the contents of the paint and solvents being sprayed. Read all Material Safety Data Sheets (MSDS) and container labels provided with the paints and solvents. Follow the paint and solvent manufacturer's safety instructions.
10. Fire extinguisher equipment shall be present and working.

WARNING - To reduce the risk of injury:

1. Always wear appropriate gloves, eye protection, clothing and a respirator or mask when painting. Hazardous vapors – Paints, solvents, insecticides, and other materials can be harmful if inhaled or come in contact with body. Vapors can cause severe nausea, fainting or poisoning.
2. Do not operate or spray near children. Keep children away from equipment at all times.
3. Do not overreach or stand on an unstable support. Keep effective footing and balance at all times.
4. Stay alert and watch what you are doing.
5. Do not operate the unit when fatigued or under the influence of drugs or alcohol.
6. Never aim spray gun at any part of the body.
7. Follow all appropriate local, state, and national codes governing ventilation, fire prevention, and operation.
8. The United States Government Safety Standards have been adopted under the Occupational Safety and Health Act (OSHA). These standards, particularly part 1910 of the General Standards and part 1926 of the Construction Standards should be consulted.
9. Use only manufacturer authorized parts. User assumes all risks and liabilities when using parts that do not meet the minimum specifications and safety devices of the turbine manufacturer.
10. Power cord must be connected to a grounded circuit.
11. Do not spray outdoors on windy days.

WARNING - To reduce the risk of electric shock:

1. Always remove turbine before cleaning.
2. Power cord must be connected to a grounded circuit.
3. Never submerge electrical parts.
4. Never expose the equipment to rain. Store indoors.
5. Keep electrical cord plug and spray gun trigger free from paint and other liquids. Never hold the cord at plug connections to support the cord. Failure to observe may result in an electrical shock.

Important Electrical Information

Use only a 3-wire extension cord that has a 3-blade grounding plug and a 3-slot receptacle that will accept the plug on the product. Make sure your extension cord is in good condition. When using an extension cord, be sure to use one heavy enough to carry the current your product will draw. An undersized cord will cause a drop in line voltage resulting in loss of power and overheating. A 14 gauge or 12 gauge cord is recommended. If an extension cord is to be used outdoors, it must be marked with the suffix W-A after the cord type designation. For example, a designation of SJTW-A would indicate that the cord would be appropriate for outdoor use.

IMPORTANT: Household use only. Intended for indoor/outdoor use ONLY with materials having flashpoint above 100°F (38°C).

Thank you for your purchase!

Thank you for purchasing the Wagner FLEXiO sprayer with best-in-class features that are designed for spraying residential paint, un-thinned, indoors or out. Only the FLEXiO sprayers have the power of the X-Boost® turbine and versatility of the iSpray nozzle that will help you finish projects fast and professionally. They are easy to use right out of the box and with low overspray and less clogging you will enjoy the flexibility to tackle all the painting projects on your list. We appreciate your feedback, so please visit our website and write a review on the FLEXiO handheld sprayer so we can continue to learn and improve our products. Just click on www.wagnerspraytech.com

Controls and Functions - Model 570

Diagram: Labels the components of the FLEXiO 570 sprayer: X-Boost Turbine, iSpray® Nozzle (for large projects), Filter housing (both sides), Spray width lever, Adjustment ring, Material flow control, 2-stage Trigger, and 1.5 qt cup. Also shows diagrams of the X-Boost™ Power Dial (2-speed HI/LO) and how the Adjustment Ring creates horizontal and vertical spray patterns.

X-Boost™ Power Dial:

The X-Boost power dial adjusts the level of air power produced by the turbine. The FLEXiO sprayer model 570 is equipped with a 2-speed air power control (HI/LO).

Spray Width Lever:

The spray width lever determines the width of the spray pattern.

Adjustment Ring:

The spray pattern shape is adjusted by turning the adjustment ring to either the vertical or horizontal positions.

Material Flow Control:

The material flow control determines the amount of spray material that is sprayed from the spray gun.

Controls and Functions - Model 590

For descriptions of all components marked with (*), refer to the previous page.

Diagram: Labels the components of the FLEXiO 590 sprayer, including the Detail Finish Nozzle™. It shows the X-Boost™ Power Dial (variable speed 1-9).

X-Boost™ Power Dial:

The X-Boost power dial adjusts the level of air power produced by the turbine. The FLEXiO sprayer model 590 is equipped with a variable speed air power control (1 - 9).

iSpray Nozzle:

FLEXiO sprayer model 570 and 590. Designed to provide a roller-like finish on broad indoor and outdoor surfaces. Sprays un-thinned materials including un-thinned latex.

Detail Finish Nozzle:

FLEXiO sprayer model 590 only. Ideal for detail projects and finer finishes. It is designed for spraying thinner materials, such as oil based stains and paints. The Detail Finish nozzle leaves a smoother finish.

Material Preparation

Note: Material to be sprayed may need to be strained to remove any impurities in the paint which may enter and clog the system. Impurities in the paint will give poor performance and a poor finish.

Note: Only thin the material if absolutely necessary to improve spray performance. Optimal spray performance should be achieved simply by adjusting the various controls on the unit.

To Prepare the Material:

1. Stir the spraying material thoroughly.
2. Unscrew the cup from the nozzle.
3. After the material has been properly thinned and strained, fill the container to desired level.

Thinning the material:

For certain spraying situations or desired finishes, thinning the material may be desired. It is not necessary for most materials when used with the iSpray nozzle. For use with the Detail Finish nozzle thinning may be needed to achieve a finer finish. Make sure you adjust the X-Boost™ and Material flow settings for your specific material needs.

If thinning is necessary, use the proper solvent as specified by the material manufacturer. Never exceed the thinning advice given by the coating manufacturer.

[warning] Do not thin with materials that have a flashpoint below 100°F (38°C). The material flashpoint should be shown on the material container.

Diagrams: Three illustrations show material preparation: 1. Stirring paint with a stick. 2. Unscrewing the paint cup from the nozzle assembly. 3. Filling the paint container to a desired level.

Assembly

[warning] NEVER point the spray gun at any part of the body.

To Assemble:

IMPORTANT: Make sure the power cord is unplugged.

1. Insert the suction tube into the intake opening.
2. Align the suction tube:
   a. If spraying downward, the angled end of the suction tube should point toward the front of the gun.
   b. If spraying upward, the angled end of the suction tube should point toward the rear of the gun.

Note: Make sure the suction tube is inserted as far as it will go to ensure a tight fit.

IMPORTANT: Never tip the sprayer at more than a 45° angle. Material could get into the turbine and damage the sprayer.

3. Carefully screw the cup back onto the nozzle assembly. Tighten firmly.
4. Align the arrow on the nozzle with the “unlock” symbol on the turbine.
5. Insert and twist the nozzle into the turbine toward the “lock” symbol on the turbine. The tab below the trigger will lock the two pieces into place.

Diagrams: Illustrations show assembly steps: 1. Inserting the suction tube. 2a. Aligning the suction tube for downward spraying. 2b. Aligning the suction tube for upward spraying. 3. Screwing the cup onto the nozzle assembly. 4. Aligning the nozzle with the "unlock" symbol. 5. Inserting and twisting the nozzle to the "lock" symbol.

Power and Material Controls

Spray performance depends on material thickness, air power, spray pattern, and material flow. Testing different control settings helps achieve desired results. Refer to descriptions and the suggested Power and Material Settings Guide.

X-Boost™ Power Dial

The X-Boost™ power dial adjusts the level of air pressure produced by the turbine. It is factory-set at maximum.

• A high air power level results in faster coverage and a smoother finish with thicker materials.
• Lowering air power results in larger drops of material and a slightly rougher finish.

Tip: Thicker material requires higher turbine power.

Tip: For fine finishes with thinner materials, decrease air power. Spraying thin material at high air power causes overspray.

2-Speed Air Power Control

The FLEXiO model 570 has a 2-speed air power control (high/low).

Variable Air Power Control

The FLEXiO model 590 has a variable air power control (1-9).

Material Flow Control

The material flow control determines the amount of spray material. It is set by the red knob on the trigger.

• For thicker materials, start with the highest flow setting and gradually decrease.
• For thinner materials, start with a low flow setting and gradually increase.
• Higher flow settings require quicker work to avoid drips and sags.

Tips: Control set too high results in runs/sags; too low results in poor coverage. Test spray patterns on a poster or scrap material.

Power and Material Settings Guide

Table: Lists recommended Material Flow and Air Power settings for various coatings (Transparent/semi-transparent stains, Lacquers, Solid stains, Polyurethane, Oil enamels, Latex paints, Oil/latex primers) for both iSpray Nozzle (570/590) and Detail Finish Nozzle (590).

Spray Pattern Adjustment

Adjust Spray Shape - both nozzles

The spray pattern shape is adjusted by turning the adjustment ring (iSpray) or air cap ears (Detail Finish) to vertical, horizontal, or diagonal positions. Test each pattern for suitability.

[warning] NEVER trigger the gun while adjusting the ears on the air cap. NEVER point the spray gun at any part of the body.

Adjust Spray Width - iSpray only

The spray width lever on the iSpray nozzle determines the width of the spray pattern.

Diagrams: Show how to adjust spray pattern shape using the adjustment ring or air cap ears for horizontal, vertical, and diagonal patterns. An illustration shows the spray width lever. Arrows indicate achieving wide or narrow spray patterns by adjusting air power and material flow.

Tips:

1. Start with a fan pattern for trim work (1-5" width) and larger surfaces (>5" width).
2. Adjust Material & Air Flow settings based on coating, fan pattern width, and nozzle.
3. Fine-tune Material and Air Power settings for best results.
4. Pull trigger slightly to start the turbine before spraying.
5. Use narrow pattern for detailed work, touch up.
6. Recommended settings may change if coating is thinned.

IMPORTANT: When changing the spray pattern, ensure the black retaining ring is not loosened.

Note: The air cap can be set diagonally on the Detail Finish nozzle only. For a round pattern with the iSpray nozzle, see the “Adjust Spray Width” section.

Proper Spraying Technique

Ensure the spray area is properly masked to prevent overspray. Practice on scrap material or water if new to spray systems.

Spray Poster

A spray poster is included for practice. Follow its guidelines.

Surface Preparation

All objects to be sprayed should be thoroughly cleaned. Mask or cover areas not to be sprayed.

Spray Area Preparation

The spray area must be clean and dust-free.

How to Spray Properly

[stop] Keep arm moving whenever the gun is triggered. Pausing too long causes excessive material application.

[stop] Partially pulling the trigger starts the turbine; full pull sprays material. It's recommended to pull partially first.

• Position the spray gun perpendicular to and 6-8 inches from the spray surface, depending on pattern size. Closer distance with reduced flow/power.
• Spray parallel to the surface with smooth, consistent speed passes to avoid runs and sags.

Diagrams: Illustrate correct spraying motion (smooth strokes, even speed, 6-8 inches distance) and incorrect wrist flex. Also shows comparisons of light vs. heavy coats.

[stop] During a project, periodically wipe the nozzle tip with a cloth to remove dried paint.

Note: When quitting spraying for a period, unplug the sprayer. Restart by wiping the nozzle with a damp cloth.

Proper Spraying Technique (Continued)

Pattern Examples

Use images and guidelines to achieve desired spray patterns. These are starting points; slight modifications may be needed.

Note: It is recommended to pull the trigger partially to start the turbine before a spray pass.

[stop] During a project, periodically wipe the nozzle tip with a cloth to remove any dried paint.

Small Surface Projects

Generally require low material flow and air power. Reduce power, material flow, and switch to a narrow width (iSpray). The Detail Finish Nozzle provides an even narrower pattern for fine finishing. Moving closer narrows the fan; moving farther away widens it.

Large Surface Projects

Generally require high material flow and air power. The iSpray nozzle is ideal for broad coverage on horizontal or vertical surfaces.

Diagrams: Show pattern examples for small and large surfaces, illustrating spray gun movement and air cap position.

• If material is too thin, increase material flow.
• If material is too thick, decrease material flow or move the spray gun further away.

Note: If performance is unsatisfactory, refer to the 'Troubleshooting' section.

Other factors: Distance from object (too far = thin material), Material thickness (runs/splotchy may need thinning), Spray gun movement (too fast = thin/overspray; too slow = coarse/thick).

Cleanup

Flushing the unit

Before you begin: Use appropriate cleaning solution (warm, soapy water for latex; mineral spirits for oil-based). IMPORTANT: Never clean air cap or air holes with sharp metal objects. Do not use solvents or lubricants containing silicone.

Special cleanup instructions for flammable solvents (flashpoint > 100°F): Always flush outside, ensure area is free of flammable vapors, well-ventilated. Do not submerge turbine!

To Flush the Unit:

1. Unplug power cord. Loosen material container by 1/2 turn to relieve pressure. Pull trigger to drain material back into container.
2. Unscrew container, remove, and empty remaining material.
3. Pour a small amount of cleaning solution into the cup (Water=1/2 full; Mineral spirits=1/4 full).
4. Attach cup to nozzle, plug in sprayer.
5. Spray cleaning solution into a safe area. Gently shake gun during spraying to agitate material.
6. Unplug power cord. Loosen container by 1/2 turn and drain material back into container.

IMPORTANT: If using mineral spirits, repeat steps 1-6 using warm, soapy water.

Diagrams: Six illustrations detail the flushing process: 1. Loosening container and draining. 2. Emptying container. 3. Pouring solution. 4. Spraying solution. 5. Shaking gun. 6. Draining solution.

Cleaning the Nozzle

To Clean the Nozzle:

1. Ensure power cord is unplugged. Push tab below trigger, twist, and separate nozzle from turbine. Wipe exterior clean.
2. iSpray nozzle only: Remove adjustment ring (a) from connecting nut (b). Loosen connecting nut. Remove parts, clean with brush and solution. Reassemble per next page instructions.
3. Detail Finish nozzle only: Unscrew nut, remove air cap and nozzle. Remove parts, clean with brush and solution. Reassemble all parts.
4. Clean air vent (c) on suction tube with a soft brush.
5. Clean rear of nozzle (d). Lubricate O-ring (e) with petroleum jelly.

Diagrams: Illustrations detail cleaning the nozzle: 1. Separating nozzle. 2a. Disassembling iSpray parts. 2b. Cleaning iSpray parts. 3a. Disassembling Detail Finish parts. 4. Cleaning air vent. 5. Cleaning rear of nozzle and lubricating O-ring.

Note on Nozzle Seal (Detail Finish nozzle only): The seal may be stuck; ensure it is pulled out. It is important to reinstall the seal correctly, cup side (with groove) facing out, to prevent leakage and turbine damage.

Reassembly

To Reassemble:

1. Insert nozzle (1), aligning groove (a) and notch (b) with nozzle opening and needle. Note: Ensure red nozzle seal is in place (cup side facing out).
2. Place air screen (d) in air cap (e). Attach both (2) to nozzle (1) and secure with connecting nut (3). Note: Easier if iSpray nozzle faces up.
3. Snap adjustment ring (4) into connecting nut (3), positioning adjustment lever (f) on peg (g) in air cap. Note: Ensure adjustment ring recesses engage air cap tabs.
4. Reattach nozzle to turbine. Note: Ensure air valve tube is clean and securely attached at both ends.

Diagrams: Four illustrations show reassembly steps: 1. Inserting nozzle. 2. Attaching air screen and cap. 3. Snapping adjustment ring. 4. Reattaching nozzle to turbine.

Maintenance

Cleaning the Filters:

IMPORTANT: Before each use, inspect air filters for dirt. Replace if dirty. IMPORTANT: Never operate unit without air filters.

1. Unplug spray gun. Remove turbine covers by pushing snap levers (a). Replace dirty filters with new ones (smooth side toward turbine). Secure covers.

Diagram: Illustration shows how to remove turbine covers (labeled 'a') to access filters.

Cleaning the Air Valve Tube:

Note: If paint entered the air tube, proceed as follows.

1. Pull air tube (a) from nozzle. Screw off valve cover (b). Remove valve seal (c). Clean parts. IMPORTANT: Air tube and valve seal (c) have limited solvent resistance; wipe only, do not immerse.
2. Place valve seal (c) in valve cover (b) with pin facing into tube. Note: Inverting valve cover makes installation easier.
3. Turn nozzle upside down and screw on valve cover (with seal inside) from underneath. Note: This prevents seal from falling out.
4. Place air tube on valve cover and nozzle nipple.

Diagrams: Illustrations show cleaning the air valve tube: 1. Disassembly of air tube, valve cover, and seal. 2. Placing seal in cover. 3. Reassembling cover onto nozzle. 4. Attaching air tube.

Troubleshooting

PROBLEM

CAUSE

SOLUTION

Problem A: Little or no material flow

Causes: Nozzle clogged, suction tube clogged, air vent blocked, low material flow setting, loose suction tube, no pressure, air valve tube not functioning, missing nozzle seal, clogged air filter, material too thick.

Solutions: Clean components, increase material flow, tighten connections, tighten container, ensure tube connections and seal are in place, replace nozzle, change filter, thin material.

Problem B: Material leaking

Causes: Loose nozzle, worn nozzle, missing/worn nozzle seal, material build-up on air cap/nozzle.

Solutions: Tighten, replace nozzle, clean.

Problem C: Spray pattern too thick, runs and sags

Causes: High material flow, low air power, applying too much material, clogged nozzle, clogged air filter, low pressure, material too thick.

Solutions: Decrease material flow, increase air power, adjust flow/movement, clean, change filter, tighten container, thin material.

Problem D: Spray jet pulsates

Causes: Material running out, clogged air filter, disconnected air valve tube.

Solutions: Refill, change filter, reconnect air tube.

Problem E: Too much overspray

Causes: Gun too far from object, high air power setting.

Solutions: Reduce distance (6"-8" ideal), decrease air power setting.

Problem F: Pattern is very light and splotchy

Causes: Gun moving too fast, low material flow, high air power.

Solutions: Adjust material flow or decrease movement, increase material flow, decrease air power.

Note: Material generally only needs thinning for Detail Finish nozzle. Thin as a last resort. Optimal performance from control adjustments.

General Note: This unit contains no serviceable electrical parts. Do not attempt to service yourself. Store indoors with the cord wrapped around the turbine handle.

For further assistance, contact Wagner Technical Service at 1-800-328-8251 or visit www.wagnerspraytech.com.

Parts List

X-Boost™ Turbine

Diagram: Exploded view of the X-Boost Turbine with numbered parts (1-4) corresponding to the parts list.

iSpray Nozzle

Diagram: Exploded view of the iSpray Nozzle assembly with numbered parts (1-8) corresponding to the parts list.

Detail Finish Nozzle™ (590 only)

Diagram: Exploded view of the Detail Finish Nozzle assembly with numbered parts (1-9) corresponding to the parts list.

Accessories

Notes

Blank page for notes.

Limited Warranty

HVLP paint spray equipment

This product, manufactured by Wagner Spray Tech Corporation (Wagner), is warranted against defects in material and work-manship for one year following date of purchase if operated in accordance with Wagner's printed recommendations and instructions. This warranty does not cover damage resulting from improper use, accidents, user's negligence or normal wear. This warranty does not cover any defects or damages caused by service or repair performed by anyone other than a Wagner Authorized Service Center.

ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE IS LIMITED TO one year FOLLOWING DATE OF PURCHASE. WAGNER SHALL NOT IN ANY EVENT BE LIABLE FOR ANY INCIDENTAL OR CONSEQUENTIAL DAMAGES OF ANY KIND, WHETHER FOR BREACH OF THIS WARRANTY OR ANY OTHER REASON. THIS WARRANTY DOES NOT APPLY TO ACCESSORIES.

THIS PRODUCT IS DESIGNED FOR HOME USAGE ONLY. IF USED FOR COMMERCIAL OR RENTAL PURPOSES, THIS WARRANTY APPLIES ONLY FOR 30 DAYS FROM DATE OF PURCHASE.

If any product is defective in material and/or workmanship during the applicable warranty period, return it with proof of purchase, transportation prepaid to any Wagner Authorized Service Center. Wagner's Authorized Service Center will either repair or replace the product (at Wagner's option) and return it to you, postage prepaid.

SOME STATES DO NOT ALLOW LIMITATIONS ON HOW LONG AN IMPLIED WARRANTY LASTS OR THE EXCLUSION OF INCIDENTAL OR CONSEQUENTIAL DAMAGES, SO THE ABOVE LIMITATION AND EXCLUSION MAY NOT APPLY TO YOU. THIS WARRANTY GIVES YOU SPECIFIC LEGAL RIGHTS, AND YOU MAY ALSO HAVE OTHER RIGHTS WHICH VARY FROM STATE TO STATE.

Questions?

Call Wagner Technical Service at: 1-800-328-8251

See www.wagnerspraytech.com in the "Contact Us" section for Technical Service hours.

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