WPG FLEXR Series User manual

Rev 5.1/4-21 FLEXR(L)-HV11DC: #350371
INTENDED FOR USE BY SKILLED
PROFESSIONALS • READ AND
UNDERSTAND BEFORE OPERATING
OPERATING
INSTRUCTIONS 908 W. Main • P.O. Box 368
Laurel, MT USA 59044
800-548-7341 (phone)
406-628-8231 (phone)
406-628-8354 (fax)
www.WPG.com
KEEP FOR FUTURE REFERENCE
FLEXR(L) SERIES FLAT LIFTER,
DC-VOLTAGE
Model numbers: FLEXR4HV11DC, FLEXR6HV11DC (shown), FLEXRL6HV11DC
Serial number: ___________________________ (to locate, see serial label on the product)

FLEXR(L)-HV11DC: #35037 Rev 5.1/4-212

Rev 5.1/4-21 FLEXR(L)-HV11DC: #350371
SPECIFICATIONS .....................................................................................3
SAFETY...................................................................................................5
OPERATING FEATURES............................................................................6
ASSEMBLY..............................................................................................7
INTENDED USE .......................................................................................8
LOAD CHARACTERISTICS.................................................................................8
OPERATING ENVIRONMENT............................................................................9
DISPOSAL OF THE LIFTER ...............................................................................9
OPERATION..........................................................................................10
BEFORE USING THE LIFTER...........................................................................10
Taking Safety Precautions .................................................................................................10
Performing Inspections and Tests .....................................................................................10
Checking the Battery.........................................................................................................11
TOUSE THE OPTIONAL PAD SHUTOFFS ..........................................................12
TOADJUST PAD POSITIONS..........................................................................13
Positioning Pad Arms ........................................................................................................13
Positioning Pad Mounts ....................................................................................................14
TOADJUST THE CONTROL HANDLES ..............................................................14
TOATTACH THE PADS TO ALOAD ..................................................................15
Powering up the Lifter ......................................................................................................15
Positioning the Lifter on the Load.....................................................................................15
Sealing the Pads on the Load............................................................................................16
Reading the Vacuum Gauge..............................................................................................17
TOLIFT AND MOVE THE LOAD......................................................................18
Interpreting the Warning Light .........................................................................................18
Watching Vacuum Indicators ............................................................................................18
Controlling the Lifter and Load .........................................................................................19
In Case of a Power Failure.................................................................................................19
TORELEASE THE PADS FROM THE LOAD .........................................................20
About Stand-By Mode.......................................................................................................20
AFTER USING THE LIFTER.............................................................................20
Storing the Lifter ...............................................................................................................21
Transporting the Lifter ......................................................................................................21
TABLE OF CONTENTS

FLEXR(L)-HV11DC: #35037 Rev 5.1/4-212
INSPECTIONS AND TESTS.....................................................................22
INSPECTION SCHEDULE ................................................................................22
TESTING ...................................................................................................23
Lifter/Load Compatibility Test...........................................................................................23
Operational Tests ..............................................................................................................24
Vacuum Test......................................................................................................................24
Rated Load Test.................................................................................................................25
MAINTENANCE ....................................................................................26
VACUUM PAD MAINTENANCE.......................................................................26
Pad Inspection ..................................................................................................................26
Pad Cleaning .....................................................................................................................27
BATTERY RECHARGE....................................................................................28
REPLACEMENT PARTS...........................................................................29
LIMITED WARRANTY ............................................................................30
TOOBTAIN REPAIRS OR WARRANTY SERVICE...................................................30
TABLE OF CONTENTS

Product
Description
Designed for use with hoisting equipment, the FLEXR(L)-HV11DC lifters support loads in the flat
orientation using vacuum.
Model
Number
FLEXR4HV11DC
(w/4 Vacuum Pads)
FLEXR6HV11DC
(w/6 Vacuum Pads)
FLEXRL6HV11DC
(w/6 Vacuum Pads)
Maximum Load
Capacity1
1...... The Maximum Load Capacity is rated at a vacuum of 16" Hg [-54 kPa] on clean, smooth, nonporous flat surfaces with a friction coefficient of 1. Pad
compound, load rigidity, strength, surface conditions, overhang, angle, center of gravity and temperature can also affect the lifting capacity. A
“qualified person” should evaluate the effective lifting capacity for each use (see definition under “Rated Load Test”).
Per pad: 300 lbs [136.5 kg]
Total: 1200 lbs [545 kg]
Per pad: 300 lbs [136.5 kg]
Total: 1500 lbs [680 kg]
Per pad: 200 lbs [91 kg]
Total: 1200 lbs [545 kg]
Pad Spread ----------------------------- (to outer edges) -----------------------------
Maximum 41" x 70¼" [104 cm x 178 cm] 41" x 70¼" [104 cm x 178 cm] 41" x 105" [104 cm x 267 cm]
Minimum 23" x 54¼" [58 cm x 138 cm] 23" x 54¼" [58 cm x 138 cm] 23" x 61" [58 cm x 155 cm]
Lifter
Weight 160 lbs [73 kg] 185 lbs [84 kg] 205 lbs [93 kg]
Vacuum
Pads 10" [25 cm] nominal diameter, lipped (Model HV11), standard rubber2
2...... Available with other rubber compounds for special purposes (see www.wpg.com).
Power
Source 12 volts DC, 28 amps
Battery
Capacity 26 amp-hours
Product
Options
Available with Individual Pad Shutoffs.
Available with Spring-Shaft Pad Mounts.
See separate instructions about other options.
Operating
Elevation Up to 6,000' [1,828 m]
Operating
Temperatures 32° — 104° F [0° — 40° C]
Service Life 20,000 lifting cycles, when used and maintained as intended3
3...... Vacuum pads, filter elements and other wear-out items are excluded.
ASME Standard
BTH-1 Design Category "B", Service Class "0" (see www.wpg.com for more information)
Troubleshooting
Guide4
4...... To view this guide, click the link above.
TST-016_GENERIC_LEAK_TEST_rev_2014-086
Rev 5.1/4-21 FLEXR(L)-HV11DC: #350373
!!–CE–!! This symbol appears only when a CE Standard is different from other applicable standards. CE requirements are mandatory
in the European Union, but may be optional elsewhere.
SPECIFICATIONS

FLEXR(L)-HV11DC: #35037 Rev 5.1/4-214
Note: A standard FLEXR6HV11DC is shown.
SPECIFICATIONS

Rev 5.1/4-21 FLEXR(L)-HV11DC: #350375
SAFETY
Wear personal protective
equipment that is appropriate for
the load material. Follow trade
association guidelines.
Do not remove or obscure safety
labels.
Do not make any modifications to
the lifter (see “LIMITED
WARRANTY”).
Use the lifter only in an approved
“OPERATING ENVIRONMENT”(see
“INTENDED USE”).
Do not use a lifter that is damaged,
malfunctioning, or missing parts.
Do not use a lifter if the sealing
edge of any vacuum pad is cut or
otherwise damaged.
Do not use a lifter to lift cracked or
broken glass.
Do not exceed the Maximum
Load Capacity or lift loads the
lifter is not designed for (see
“INTENDED USE”).
Do not use a lifter if the
Maximum Load Capacity or
any safety label appears to be
missing or obscured.
Make sure the contact surfaces of
the load and vacuum padsare clean
before attaching the lifter (see
“MAINTENANCE”).
Position the vacuum pads correctly
on the load before lifting (see
“OPERATION: Positioning the Lifter
on the Load”).
Do not lift a load if any vacuum
indicator shows inadequate
vacuum.
Keep unauthorized personnel away
from the lifter, to avoid injury in
case of an unintended load release.
Do not touch the vacuum release
controls during a lift.
Do not allow people to ride on the
lifter or the load.
Do not lift a load higher than
necessary or leave suspended loads
unattended.
Do not position a loaded or
unloaded lifter over people.
Before servicing a powered lifter,
place the power control in the
inactive position and, when
possible, disconnect the power source.

FLEXR(L)-HV11DC: #35037 Rev 5.1/4-216
Features shown here are underlined on their first appearance in each section following.
1 LIFT POINT 2 CONTROL HANDLE 3 PADFRAME
4SLIDINGPADARM 5 VACUUM PAD 6 AIR FILTER
7 BATTERY TEST BUTTON 8 BATTERY GAUGE 9 LOW VACUUM WARNING LIGHT
10 Enclosure with VACUUM SWITCH 11 POWER SWITCH 12 VACUUM GAUGE
13 VACUUM CONTROL VALVE 14 VACUUM RESERVE TANK 15 Enclosure with BATTERY
16 BATTERY CHARGER 17 MOVABLE PAD MOUNT 18 VACUUM PUMP
Note: A standard FLEXR6HV11DC is shown. Although some of the following photos do not show
this specific lifter, they all illustrate how this kind of lifter functions.
For information about specific parts, see “REPLACEMENT PARTS” and/or any separate
instructions for Product Options.
OPERATING FEATURES

Rev 5.1/4-21 FLEXR(L)-HV11DC: #350377
ASSEMBLY
1) Remove all shipping materials and save them with the shipping container for future use.
2) Suspend the lifter from appropriate hoisting equipment:
2.1)
Select a crane and/or hoist rated for the Maximum Load Capacity plus the
Lifter Weight.
Note: Any lifter use must comply with all statutory or regulatory standards for
hoisting equipment in your region.
2.2)
2A 2B
Attach the hoisting hook to the lift
point (figs. 2A-B).
Make sure hook has
restraining latch (see arrow).
2.3) Use the hoisting equipment to remove the lifter from the shipping container. Avoid
damaging the vacuum pads.
2C
Note: The hoist control pendant can be attached to the lifter by
inserting it into the lifter’s pendant holder (fig. 2C).
3)
3A 3B 3C
Connect the electrical connectors (figs. 3A-
C).
4)
4A
Remove the pad covers (fig. 4A) and save them for future use.
5) Perform tests as required under “TESTING”.

FLEXR(L)-HV11DC: #35037 Rev 5.1/4-218
INTENDED USE
LOAD CHARACTERISTICS
Do NOT lift explosives, radioactive
substances or other hazardous materials.
Make sure the vacuum lifter is intended
to handle each load according to these
requirements:
• The load weight must not exceed the Maximum Load Capacity.
• The load must be a single piece of relatively nonporous material with a flat and
relatively smooth contact surface.1, 2To determine whether the load is too porous or
rough, perform a “Lifter/Load Compatibility Test”.
• The load's surface temperature must not exceed the Operating Temperatures.3
• The load's minimum length and width are determined by the current Pad Spread
(see “SPECIFICATIONS”).
• The load's maximum length and width are determined by its allowable overhang.4
Note: Standard vacuum pads can stain or deform load surfaces with light colors or soft coatings.
Test such surfaces for damaging effects before using the lifter on them.5
1..... Although concave vacuum pads can also attach to some curved loads, curvature can reduce lifting capacity. Contact WPG for more information.
2..... A “single piece” of material includes curtainwall assemblies, unitized glazing systems and similar construction units.
3..... Vacuum pads made from a heat-resistant rubber compound can enable you to lift loads with higher surface temperatures. Contact WPG or an
authorized dealer for more information.
4..... The allowable overhang is the amount of load material that can extend sideways beyond the vacuum pads without breaking or otherwise being
damaged. This depends on the load material, its thickness, and the angle of handling (if any). Since every material has different physical
properties, the allowable overhang must be evaluated separately for each load type. Contact WPG or an authorized dealer for more
information.
5..... Alternative rubber compounds are available for these purposes. Contact WPG or an authorized dealer for more information.

Rev 5.1/4-21 FLEXR(L)-HV11DC: #350379
OPERATING ENVIRONMENT
Make sure the vacuum lifter is intended for use in each work environment, given the following
restrictions:
•
Never use lifter
in dangerous
environments.
This lifter is not intended for any environment that is
dangerous to the operator or damaging to the lifter. Avoid
environments containing explosives, caustic chemicals and
other dangerous substances.
Metal particles and similar environmental contaminants could result in
vacuum pump failure.
• The work environment is limited by the Operating Elevation and Operating
Temperatures.1, 2
• The lifter is not designed to be watertight.
Moisture can result in
reduced lifting capacity.
Do not
use it in rain or otherunsuitable conditions.
!!–CE–!! A secondary positive holding device is required to lift loads on construction sites.
DISPOSAL OF THE LIFTER
After the Service Life of the vacuum lifter has ended (see “SPECIFICATIONS”), dispose of it in
compliance with all local codes and applicable regulatory standards.
1..... Although lifter use may be possible at higher elevation, lifting capacity is reduced whenever the lifter is unable to attain vacuum in the green
range on the vacuum gauge. Contact WPG for more information.
2..... Special provisions may allow the lifter to operate outside the specified temperature range. Contact WPG for more information.
INTENDED USE

FLEXR(L)-HV11DC: #35037 Rev 5.1/4-2110
OPERATION
BEFORE USING THE LIFTER
Determine whether the vacuum lifter is capable of each intended task (see “SPECIFICATIONS”
and “INTENDED USE”). Then complete the following preparations:
Taking Safety Precautions
•
Read all directions and safety rules before using
lifter.
Always wear appropriate personal protective
equipment.
Be trained in all industry
and regulatory standards
for lifter operation in your
region.
• Follow trade association
guidelines about precautions needed for each load material.
Performing Inspections and Tests
• Follow the “INSPECTION SCHEDULE”and “TESTING”.
•
Examine air filter regularly
and service when needed.
Examine the air filter and service whenever its
bowl contains liquid or other contaminates, or its
element appears dirty (see “AIR FILTER
MAINTENANCE”in SERVICE MANUAL).

Rev 5.1/4-21 FLEXR(L)-HV11DC: #3503711
Checking the Battery
Always check battery energy before
every lift.
Use the battery gauge to determine whether the battery needs to be charged (see “BATTERY
RECHARGE”).1Never use the lifter unless battery energy appears in the green range.
• While the power switch is in the “on” position ( ), the battery gauge automatically
shows battery energy.2
• While the power switch is in the “off”
position ( ), use the battery test
button (circled) to check the battery
energy.3
1..... If the vacuum pump is running or the battery charger is connected to an AC power source, the reading on the battery gauge will not be
accurate.
2..... After the pump stops running, the battery gauge requires a few moments to stabilize before it shows an accurate energy level.
3..... If the lifter has not been used since the battery was charged, the battery gauge may falsely show a high energy level. This “surface charge”
dissipates after the pump runs for about 1 minute, allowing the gauge to show accurate energy.
OPERATION

FLEXR(L)-HV11DC: #35037 Rev 5.1/4-2112
TOUSE THE OPTIONAL PAD SHUTOFFS
Each pad shutoff on the pad frame controls the vacuum line to the adjacent vacuum pad.
Activating or deactivating the airflow at specific pads enables the lifter to handle loads with
different weights and dimensions (see “SPECIFICATIONS”) or to avoid holes in the load surface.
Closing any pad shutoff
reduces lifting capacity.
To support the maximum load weight and larger load
dimensions, all pads must be activated; for smaller weights
and dimensions, some pads may be deactivated, provided
that the lifter still has sufficient capacity to support the
load (see “LOAD CHARACTERISTICS”).
1A 1B
To activate a pad,
place the valve
lever parallel with
the vacuum line
(ie, valve open —
fig. 1A).
To deactivate a
pad, place the
valve lever
perpendicular to
vacuum line (ie,
valve closed —
fig. 1B).
To calculate the lifting capacity when some pads are deactivated, consult the Per-Pad Load
Capacity and multiply by the number of pads currently activated. Always activate pads in
a symmetrical configuration and use as many pads as possible for each load being lifted, to
maximize lifting capacity and to minimize load overhang.
OPERATION

Rev 5.1/4-21 FLEXR(L)-HV11DC: #3503713
TOADJUST PAD POSITIONS
Position vacuum hoses
as needed to prevent
damage to them during lifter
operation.
To reposition the vacuum pads on the pad frame for
handling various load dimensions (see “OPERATING
FEATURES”), move the sliding pad arms and movable pad
mounts as needed to provide optimal load support and to
minimize load overhang.
Note: The pads must be arranged symmetrically, to keep the load balanced.
Positioning Pad Arms
1)
1A
2A
Remove the cotterless hitch
pin from the mount for the
sliding pad arm on one end
of the pad frame (fig. 1A).
2) Slide the pad arm to a
suitable position where the
pin holes align (fig. 2A).
3) Reinsert the pin.
4) Repeat these steps to
position the opposite pad
arm at an equal distance
from the center of the lifter.
OPERATION

FLEXR(L)-HV11DC: #35037 Rev 5.1/4-2114
Positioning Pad Mounts
1)
1A 2A
3A 4A
Remove the
cotterless
hitch pin
from one
movable pad
mount (fig.
1A).
2) Move the
pad mount
to a suitable
position
where the
pin holes
align (fig.
2A).
3) Reinsert the
pin (fig. 3A).
4) Reposition the other pad mount on the same arm at an equal distance from the main
beam of the pad frame (fig. 4A).
5) Repeat these steps for other pad mounts as needed.
TOADJUST THE CONTROL HANDLES
1)
1B 3B
Remove the
cotterless hitch pin
from one
adjustable control
handle (fig. 1B).
2) Move the handle to
a suitable position
where the pin holes align.
3) Reinsert the pin (fig. 3B).
4) Repeat these steps for other adjustable control handle, if desired.
OPERATION

Rev 5.1/4-21 FLEXR(L)-HV11DC: #3503715
TOATTACH THE PADS TO ALOAD
Powering up the Lifter
1)
1A
Make sure the lever on the vacuum control
valve is in the center position (fig. 1A).
2)
2A
Place the power switch in the “on” position ( in fig 2A).1
Do not place power switch in “off” position ()
while operating lifter.
Placing the power switch in the “off” position ( ) during lifter
operation could result in a load release and personal injury (see “In Case of a Power
Failure”).2
Positioning the Lifter on the Load
1)
1B
Make sure the contact surfaces of the load and vacuum pads are
clean (fig. 1B; see “Pad Cleaning”).
1..... Although the low vacuum warning light and the vacuum pump may turn off, this does not mean the lifter is ready to lift a load.
2..... If any powered component fails to function while the power switch is in the “on” position, examine the circuit breaker (next to power switch) to
determine whether it has interrupted the electrical circuit to the component. Although you can reset the circuit breaker, the power interruption
may indicate an electrical problem that requires attention. Any fault must be corrected before resuming normal operation of the lifter.
OPERATION

2B
FLEXR(L)-HV11DC: #35037 Rev 5.1/4-2116
2)
Always center pad
frame on load.
Center the pad frame on the load (fig. 2B).1Off-center
loading could result in unexpected load movement, release
or personal injury.
3) Make sure all vacuum pads will fit on the load and will be loaded evenly (fig. 3B).
Consult the Per-Pad Load Capacity.
4) Place the vacuum pads in contact with the load surface.
Sealing the Pads on the Load
1)
1A
Place the lever on the vacuum control valve in the
“attach” position ( — fig. 1A). 2
Keep valve lever in “attach” position
throughout lift.
Any interruption of airflow during lifter operation
could cause a load release and personal injury.
2) Make sure the vacuum pads seal completely
against the load.3
1..... The lifter is designed to handle the maximum load weight when the load’s center of gravity is positioned within 2" [5 cm] of the pad frame’s
center point.
2..... Do not place the valve lever in the “attach” position until the pads are contacting the load.
3..... Although a vacuum pad may become distorted during shipping or storage, this condition should correct itself with continued use.
OPERATION

Rev 5.1/4-21 FLEXR(L)-HV11DC: #3503717
Reading the Vacuum Gauge
A vacuum gauge shows the current vacuum level in positive inches of Hg and negative kPa:
•
1B 1C
Green range (>16" Hg [-54 kPa]): Vacuum
level is sufficient to lift the maximum load
weight (fig. 1B).
•Red range (<16" Hg [-54 kPa]): Vacuum level
is not sufficient to lift the maximum load
weight (fig. 1C).
If it takes more than 5 seconds for the vacuum
level to reach 5" Hg [-17 kPa], press on any
vacuum pad that has not yet sealed.
Once the pads have sealed, the lifter should be able to maintain sufficient vacuum for lifting,
except when used above the maximum Operating Elevation.1If it does not:
• Make sure the vacuum switch is adjusted correctly (see SERVICE MANUAL).
• Perform the “Vacuum Test”.
1..... If the lifter is used above the maximum Operating Elevation (see “SPECIFICATIONS”), it may not be able to maintain sufficient vacuum for lifting.
Contact WPG for more information.
OPERATION

FLEXR(L)-HV11DC: #35037 Rev 5.1/4-2118
TOLIFT AND MOVE THE LOAD
Interpreting the Warning Light
Never lift load unless warning devices turn off, because
this could result in load release and personal injury.
When vacuum is
sufficient to lift the
Maximum Load Capacity,
the vacuum pump and the low vacuum warning light turn off temporarily, to conserve battery
energy.
When air leaks into the vacuum system, the vacuum pump turns on and off (along with the
warning light) as necessary to maintain sufficient vacuum for lifting.
Watching Vacuum Indicators
1A
Watch the low vacuum warning light and the vacuum
gauge (fig. 1A) throughout the entire lift.
Make sure vacuum indicators remain
completely visible.
If the warning light turns on and the vacuum gauge
shows a level less than 16" Hg [-54 kPa]:
1) Keep everyone away from a suspended load until
it can be safely lowered to a stable support.
Stay clear of any suspended load while
indicators warn of low vacuum.
2) Stop using the lifter until the cause of the vacuum loss can be identified: Conduct the
“Pad Inspection” and perform the “Vacuum Test”.
3) Correct any faults before resuming normal operation of the lifter.
OPERATION