WPG FL1HV11DC User manual

Rev 6.0/11-20 FL1-DC: #350261
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
Record serial number in blank space above (to locate, see serial
label on the product).
FLAT LIFTER 300,
DC-VOLTAGE
Model number: FL1HV11DC
KEEP FOR FUTURE REFERENCE

FL1-DC: #35026 Rev 6.0/11-202

Rev 6.0/11-20 FL1-DC: #350261
SPECIFICATIONS .....................................................................................3
SAFETY...................................................................................................5
OPERATING FEATURES............................................................................6
ASSEMBLY..............................................................................................7
INTENDED USE .......................................................................................9
LOAD CHARACTERISTICS.................................................................................9
OPERATING ENVIRONMENT..........................................................................10
DISPOSAL OF THE LIFTER .............................................................................10
OPERATION..........................................................................................11
BEFORE USING THE LIFTER...........................................................................11
Taking Safety Precautions .................................................................................................11
Performing Inspections and Tests .....................................................................................11
Checking the Battery.........................................................................................................12
TOATTACH THE PAD TO ALOAD ...................................................................13
Positioning the Lifter on the Load.....................................................................................13
Sealing the Pad on the Load .............................................................................................14
Reading the Vacuum Gauge..............................................................................................14
TOLIFT AND MOVE THE LOAD......................................................................15
Interpreting the Warning Light and Optional Warning Buzzer .........................................15
Watching Vacuum Indicators ............................................................................................15
Controlling the Lifter and Load .........................................................................................16
In Case of a Power Failure.................................................................................................16
TORELEASE THE PAD FROM THE LOAD...........................................................17
AFTER USING THE LIFTER.............................................................................17
Storing the Lifter ...............................................................................................................18
INSPECTIONS AND TESTS.....................................................................19
INSPECTION SCHEDULE ................................................................................19
TESTING ...................................................................................................20
Lifter/Load Compatibility Test...........................................................................................20
Operational Tests ..............................................................................................................21
Vacuum Test......................................................................................................................21
Rated Load Test.................................................................................................................22
MAINTENANCE ....................................................................................23
TABLE OF CONTENTS

FL1-DC: #35026 Rev 6.0/11-202
VACUUM PAD MAINTENANCE.......................................................................23
Pad-to-Load Friction Coefficient .......................................................................................23
Pad Inspection ..................................................................................................................23
Pad Cleaning .....................................................................................................................24
BATTERY RECHARGE....................................................................................25
REPLACEMENT PARTS...........................................................................26
LIMITED WARRANTY ............................................................................27
TOOBTAIN REPAIRS OR WARRANTY SERVICE...................................................27
TABLE OF CONTENTS

Product
Description
Designed for use with hoisting equipment, the FL1-DC lifter supports loads using vacuum for lifting in
the flat orientation.
Model
Number FL1HV11DC
Vacuum Pad
(standard rubber1
1...... Available with other rubber compounds for oily surfaces and other special purposes (see www.wpg.com).
)10" [25 cm] nominal diameter, lipped (Model HV11)
Pad Spread 11" x 11" [28 cm x 28 cm] to outer edges
Maximum
Load Capacity2
2...... 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”).
300 lbs [135 kg]
Lifter
Weight 45 lbs [21 kg]
Power
Source 12 volts DC, 3.5 amps
Battery
Capacity 7 amp-hours
Product
Options See separate instructions about optional features.
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 intended.3
3...... Vacuum pads, filter elements and other wear-out items are excluded.
!!–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.
ASME Standard
BTH-1 Design Category "B", Service Class "0" (see www.wpg.com for more information)
Rev 6.0/11-20 FL1-DC: #350263
SPECIFICATIONS

FL1-DC: #35026 Rev 6.0/11-204
SPECIFICATIONS

Rev 6.0/11-20 FL1-DC: #350265
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 pad are clean
before attaching the lifter (see
“MAINTENANCE”).
Position the vacuum pad 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.

FL1-DC: #35026 Rev 6.0/11-206
Features shown here are underlined on their first appearance in each section following.
1 LIFT POINT 2 LIFT BAR 3 BATTERY
4 BATTERY CHARGER 5 VACIUUM PAD and PAD FRAME 6 CONTROL HANDLES
7 LOW VACUUM WARNING BUZZER (optional) 8 BATTERY GAUGE 9 VACUUM RESERVE TANK
10 BATTERY TEST BUTTON 11 LOW VACUUM WARNING LIGHT 12 Enclosure with VACUUM PUMP
13 VACUUM GAUGE 14 AIR FILTER and VACUUM SWITCH
15 VALVE HANDLE
Note: 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”, the corresponding SERVICE
MANUAL and/or engineering drawings.
OPERATING FEATURES

Rev 6.0/11-20 FL1-DC: #350267
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.
2A 2B 2C
Make
sure
hook has
restraining
latch
(circled).
2.2)
Only use rigging rated for Maximum Load Capacity
plus Lifter Weight.
Attach the hoisting
hook to the lift
point (figs. 2A-B).
Use rigging as
needed (fig. 2C) to make sure the hook does not interfere with the load.
2.3) Use the hoisting equipment to remove the lifter from the shipping container. Avoid
damaging the vacuum pad.
ASSEMBLY

3A 3B
FL1-DC: #35026 Rev 6.0/11-208
3)
3C 3D
Connect the
electrical
connectors
(figs. 3A-B and
figs. 3C-D).
4)
4A
Remove the
pad cover (fig. 4A) and save it for future use.
5) Perform tests as required under “TESTING”.
ASSEMBLY

Rev 6.0/11-20 FL1-DC: #350269
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 mustnot 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, 2Todetermine 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 pad 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.

FL1-DC: #35026 Rev 6.0/11-2010
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.
Metal particles and similar
environmental contaminates
could result in vacuum pump failure.
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.
• 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 other unsuitable 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.
Note: Special disposal regulations may apply to the battery.
1..... Although lifter use may be possible at higher elevations, 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

Rev 6.0/11-20 FL1-DC: #3502611
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).
•
1A
If the lifter has a low vacuum warning buzzer (fig. 1A), make sure it is
clearly audible at the maximum distance between the operator and
the lifter, despite any barriers or obstacles.1, 2
Make sure warning buzzer can be heard over noise at
operator position.
1..... Maximum alarm volume is 103 dBA at 2' [60 cm]. If CE Standards apply, consult EN 7731 to make sure the warning buzzer is compliant.
2..... The “Vacuum Test” provides a convenient opportunity to check this.

FL1-DC: #35026 Rev 6.0/11-2012
Checking the Battery
Always check battery energy before
every lift.
Use the battery gauge todetermine whether the battery needs to be charged (see “BATTERY
RECHARGE”).1Never use the lifter unless battery energy appears in the green range.
• While the valve handle is in the “attach” position ( / power on), the battery gauge
automatically shows battery energy.2
•While the valve handle is in the
“release” position ( / power off),
use the battery test button (circled)
to check the battery energy.3
1..... If the 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 vacuum 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

Rev 6.0/11-20 FL1-DC: #3502613
1) Center the pad frame on the
load, to avoid unexpected
load movement or
release.1
Always center pad
on load.
Off-center loading could
result in personal injury, as
well as damage to the lifter
or load.
2) Make sure the vacuum pad
will fit on the load.
3) Place the vacuum pad in
contact with the load
surface.
1..... The lifter is designed to handle the maximum load weight when the load’s center of gravity is positioned within 3" [7.5 cm] of the pad frame’s
center point.
OPERATION
TOATTACH THE PAD TO ALOAD
Make sure the contact surfaces of the load and vacuum pad are clean
(see “Pad Cleaning”).
Positioning the Lifter on the Load

FL1-DC: #35026 Rev 6.0/11-2014
Sealing the Pad on the Load
1A
Pull the valve handle outward until it latches (circled
in fig. 1A) in the “attach” position ( ).
Keep valve handle in “attach” position
throughout lift.
The vacuum pump will turn on, the low vacuum
warning light will remain lit and the low vacuum warning buzzer, if present, will sound until the
vacuum pad seals. This is normal.
Press the lifter firmly against the load to help the pad begin to seal.1
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 pad has sealed, the lifter should be able to maintain sufficient vacuum for lifting,
except when used above the maximum Operating Elevation.2If it does not:
• Make sure the vacuum switch is adjusted correctly (see SERVICE MANUAL).
•When necessary, perform the “Vacuum Test”.
1..... Although a vacuum pad may become distorted during shipping or storage, this condition should correct itself with continued use.
2..... If the lifter is used above the maximum Operating Elevation (see “SPECIFICATIONS”), itmay not beable to maintain sufficient vacuum
for lifting. Contact WPG for more information.
OPERATION

Rev 6.0/11-20 FL1-DC: #3502615
TOLIFT AND MOVE THE LOAD
Interpreting the Warning Light and Optional Warning Buzzer
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. Note: The low vacuum
warning buzzer, if present, turns on and off together with the warning light.
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

FL1-DC: #35026 Rev 6.0/11-2016
Controlling the Lifter and Load
1A
When the lifter is ready, use the hoisting equipment to raise
the lifter and load as needed.
Use the control handle (circled in fig. 1A) to keep the lifter
and load in the required position.
Once there is enough clearance, you may move the load as
required.
In Case of a Power Failure
A vacuum reserve tank helps maintain vacuum temporarily in the event of a battery failure or
electrical system failure. Although the lifter is designed to support the load for at least 5
minutes without power,this depends on many factors, including the “LOAD CHARACTERISTICS”
and the condition of the vacuum pad (see “VACUUM PAD MAINTENANCE”).
Stay clear of any suspended
load during power failure.
If a power failure occurs, keep everyone away from a
suspended load until it can be safely lowered to a stable
support. Correct any faults before resuming normal
operation of the lifter.
OPERATION

Rev 6.0/11-20 FL1-DC: #3502617
TORELEASE THE PAD FROM THE LOAD
Make sure load is at rest and fully supported before
releasing vacuum pad.
1A
1) Press the lever to release the latch and push the valve
handle inward (fig. 1A) to the “release” position ( ).
Do not move lifter until pad releases completely, because such movement could
result in load damage or personal injury.
2) Before you lift another load, perform the Every-Lift Inspection (see “INSPECTION
SCHEDULE”).
AFTER USING THE LIFTER
1) Leave the valve handle in the “release” position ( / power off).
2) Charge the battery after each workday as needed (see “BATTERY RECHARGE”).1
3) Use the hoisting equipment to lower the vacuum lifter gently onto a stable support. Then
detach the hoisting hook from the lift point.
Caution: Do not set the lifter on surfaces that could soil or damage vacuum pad.
1..... To maximize battery life, charge it promptly after each use.
OPERATION

FL1-DC: #35026 Rev 6.0/11-2018
4) To transport the lifter, secure it in the original shipping containers with the original
shipping materials or equivalent.
Storing the Lifter
1)
1B
Use the pad cover supplied (fig. 1B) to keep the vacuum pad
clean.
!!–CE–!! To prevent the lifter from tipping over on relatively horizontal surfaces, place the
vacuum pad facedown on a clean, smooth, flat surface.
2) Charge the battery completely and repeat every 6 months (see “BATTERYRECHARGE”).
3A 3B
3C 3D 3E
3) Disconnect the electrical connectors (figs. 3A-B and figs. 3C-E), to prevent battery
discharge.
4) Store the lifter in a clean, dry location. Store the battery between 32° and 70° F [0-21° C].
Avoid storage above 100° F [38° C.]
OPERATION