WPG FLEXR Series User manual

Rev 0.1/3-22 FLEXR(L)8-DC3: #350441
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).
FLEXR(L) SERIES FLAT
LIFTER, DC-VOLTAGE WITH
INTELLI-GRIP® TECHNOLOGY
(Available with REMOTE CONTROL SYSTEM)
Model numbers: FLEXR8HV11DC3 (shown), FLEXRL8HV11DC3
KEEP FOR FUTURE REFERENCE

FLEXR(L)8-DC3: #35044 Rev 0.1/3-222

Rev 0.1/3-22 FLEXR(L)8-DC3: #350441
SPECIFICATIONS .....................................................................................3
SAFETY...................................................................................................6
OPERATING FEATURES............................................................................7
FLEXR8HV11DC3 FEATURES........................................................................7
FLEXRL8HV11DC3 FEATURES ......................................................................7
INTELLI-GRIP® CONTROL UNIT FEATURES .........................................................8
ASSEMBLY..............................................................................................9
TOCHANGE THE PAD FRAME CONFIGURATION ................................................11
Extending/Retracting the Telescoping Pad Arms ..............................................................12
Repositioning the Sliding Pad Arms ..................................................................................13
Repositioning the Sliding Pad Mounts ..............................................................................13
Connecting/Disconnecting Vacuum Hoses .......................................................................14
INTENDED USE .....................................................................................15
LOAD CHARACTERISTICS...............................................................................15
OPERATING ENVIRONMENT..........................................................................16
DISPOSAL OF THE LIFTER .............................................................................16
OPERATION..........................................................................................17
BEFORE USING THE LIFTER...........................................................................17
Taking Safety Precautions .................................................................................................17
Selecting a Screen Language.............................................................................................17
Performing Inspections and Tests .....................................................................................18
Checking the 12-Volt Battery ............................................................................................18
Preparing to Use the Remote Control System ..................................................................19
TOATTACH THE PADS TO ALOAD ..................................................................20
Positioning the Lifter on the Load.....................................................................................20
Powering up the Lifter ......................................................................................................21
Sealing the Pads on the Load............................................................................................21
Reading the Vacuum Gauges ............................................................................................22
TOLIFT AND MOVE THE LOAD......................................................................23
Interpreting the Lift Light..................................................................................................23
Monitoring Vacuum Indicators .........................................................................................23
Controlling the Lifter and Load .........................................................................................24
In Case of a Power Failure.................................................................................................24
TABLE OF CONTENTS

FLEXR(L)8-DC3: #35044 Rev 0.1/3-222
TORELEASE THE PADS FROM THE LOAD .........................................................25
AFTER USING THE LIFTER.............................................................................26
Storing the Lifter ...............................................................................................................26
Transporting the Lifter ......................................................................................................27
INSPECTIONS AND TESTS......................................................................28
INSPECTION SCHEDULE ................................................................................28
TESTING ...................................................................................................29
Lifter/Load Compatibility Test...........................................................................................29
Operational Tests ..............................................................................................................30
Vacuum Test......................................................................................................................30
Rated Load Test.................................................................................................................31
Remote Control System Test .............................................................................................31
MAINTENANCE ....................................................................................32
VACUUM PAD MAINTENANCE.......................................................................32
Pad Inspection ..................................................................................................................32
Pad Cleaning .....................................................................................................................33
12-VOLT BATTERY RECHARGE.......................................................................34
NOTIFICATION BUZZER BATTERY REPLACEMENT ...............................................35
INTELLI-GRIP® DIAGNOSTIC CODES ...............................................................36
REPLACEMENT PARTS...........................................................................40
LIMITED WARRANTY ............................................................................41
TOOBTAIN REPAIRS OR WARRANTY SERVICE...................................................41
TABLE OF CONTENTS

Product
Description
Designed for use with hoisting equipment, FLEXR(L)8-DC3 lifters support loads in the flat orientation
using vacuum.
Model Number FLEXR8HV11DC3 FLEXRL8HV11DC3 (optional)
Pad Spread
(to outer edges)
Maximum: 48" x 107" [122 cm x 272 cm]
Minimum: 22¼" x 54" [57 cm x 137 cm]
Maximum: 48" x 154¼" [122 cm x 392 cm]
Minimum: 22¼" x 114¼" [57 cm x 290 cm]
Lifter
Weight 215 lbs [98 kg] 245 lbs [111 kg]
Vacuum Pads
(standard rubber1
1...... Available with other rubber compounds for special purposes (see www.wpg.com).
)Eight 10" [25 cm] nominal diameter, lipped (Model HV11)
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”.
Per pad: 200 lbs [91 kg]
Total: 1600 lbs [725 kg]
Power
Source 12 volts DC, 5.5 amps
Battery
Capacity 18 amp-hours
Product
Options
Available with Remote Control System.
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"
Troubleshooting
Guide4
4...... To view this guide, click the link at right. Additionally, you can search for your lifter's Model Number at www.wpg.com and select the “Troubleshooting” link
on the product page.
TST-016_GENERIC_LEAK_TEST_rev_2014-086
Rev 0.1/3-22 FLEXR(L)8-DC3: #350443
SPECIFICATIONS

FLEXR(L)8-DC3: #35044 Rev 0.1/3-224
Note: Dimensions above are shown for a FLEXR8HV11DC3.
SPECIFICATIONS

Rev 0.1/3-22 FLEXR(L)8-DC3: #350445
Note: Dimensions above are shown for an optional FLEXRL8HV11DC3.
SPECIFICATIONS

FLEXR(L)8-DC3: #35044 Rev 0.1/3-226
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.

Rev 0.1/3-22 FLEXR(L)8-DC3: #350447
OPERATING FEATURES
Features shown here are underlined on their first appearance in each section following.
FLEXR8HV11DC3 FEATURES
1 SLIDING PAD ARM CLAMP 2 STROBE LIGHT 3 VACUUM GAUGES
4 VACUUM LIFT LIGHT 5 INTELLI-GRIP® CONTROL UNIT 6 LIFT POINT
7 BATTERY CHARGER 8 VACUUM RESERVE TANK 9 BATTERY
10 SLIDING PAD MOUNT 11 VACUUM PAD 12 SLIDING PAD ARM
13 QUICK CONNECTORS 14 PARKING STANDS 15 AIR FILTERS
16 ADJUSTABLE CONTROL HANDLE 17 PAD FRAME Not shown: NOTIFICATION BUZZER,
VACUUM PUMP
FLEXRL8HV11DC3 FEATURES
1 TELESCOPING PAD ARM 2 PAD ARM LOCKING PIN 3 STROBE LIGHT
4 VACUUM GAUGES 5 VACUUM LIFT LIGHT 6 QUICK CONNECTORS
7 INTELLI-GRIP® CONTROL UNIT 8 LIFT POINT 9 BATTERY CHARGER
10 VACUUM RESERVE TANK 11 BATTERY 12 SLIDING PAD MOUNT
13 VACUUM PAD 14 SLIDING PAD ARM 15 ADJUSTABLE CONTROL HANDLE
16 SLIDING PAD ARM CLAMP 17 ADJUSTABLE CONTROL HANDLE 18 AIR FILTERS
19 PARKING STANDS 20 PAD FRAME Not shown: NOTIFICATION BUZZER,
VACUUM PUMP

FLEXR(L)8-DC3: #35044 Rev 0.1/3-228
INTELLI-GRIP®CONTROL UNIT FEATURES
1 LCD SCREEN with BATTERY GAUGE
2 “POWER” BUTTON
3 “FUNCTION” BUTTON
4 “ATTACH” BUTTON
5 “RELEASE” BUTTON
Note: Although some of the following photos do not show these specific lifters, 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 0.1/3-22 FLEXR(L)8-DC3: #350449
ASSEMBLY
1) Remove all shipping materials and save them with the shipping container for future use.
2)
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.
3)
3A
3B
Attach the hoisting
hook to the lift point
(figs. 3A).
Make sure
hook has
restraining latch
(fig. 3B).
4) Use the hoisting equipment to remove the lifter from the shipping container. Avoid
damaging the vacuum pads.
5) Retract the spring-loaded parking stands:
5.1)
5A 5B
Pull the handle
of a parking
stand (fig. 5A).
5.2) Rotate the
handle 90° in
either direction
(fig. 5B). Then
allow the spring to lock the handle in place.
5.3) Repeat steps 5.1 and 5.2 with the other 3 parking stands.

6A
6B
6C
6D
FLEXR(L)8-DC3: #35044 Rev 0.1/3-2210
6) Connect the electrical connectors (figs. 6A-B and 6C-D).
7)
7A
Remove the pad covers (fig. 7A) and save them for future use.
8) Perform tests as required under “TESTING”.
ASSEMBLY

Rev 0.1/3-22 FLEXR(L)8-DC3: #3504411
TOCHANGE THE PAD FRAME CONFIGURATION
Various pad frame configurations enable the lifter to match different load dimensions and
weights. The illustrations in “SPECIFICATIONS” show the configurations’ maximum and
minimum pad spreads for the standard pad frame (see page 4) and the optional extended-
length pad frame (see page 5).
1)
Make sure pads are arranged
symmetrically, to keep the load
balanced.
Choose the configuration that maximizes
support across the load surface and
minimizes load overhang (see “LOAD
CHARACTERISTICS”).
2) Reposition pad arms (sliding and/or telescoping) and reposition sliding pad mounts as
needed (see following sections):
• To support the maximum load weight, you must connect all 8 vacuum pads (see
“Connecting/Disconnecting Vacuum Hoses”).
• To support larger load dimensions, you must move sliding pad arms outward. If the
lifter is equipped with the optional extended-length pad frame, you must extend
the telescoping pad arms, as well.
•
Disconnecting any
vacuum pad reduces
lifting capacity.
To support smaller dimensions and weights, you
may retract sliding pad arms, reposition sliding pad
mounts and/or disconnect vacuum hoses, provided
the lifter still has sufficient capacity to support the
load in question.1If the lifter is equipped with the optional extended-length pad
frame, retract the telescoping pad arms, as well.
1..... Whenever a quick connector is disconnected, the corresponding vacuum pad does not contribute to the lifting capacity, whether or not the pad
is mounted on the pad frame.
ASSEMBLY

FLEXR(L)8-DC3: #35044 Rev 0.1/3-2212
Extending/Retracting the Telescoping Pad Arms
Note: Only the optional FLEXRL8HV11DC3 features telescoping pad arms.
1) Disengage the spring-loaded pad arm locking pin:
•
1A 1B
Pull the pin directly
upward (fig. 1A):
This allows the pad
arm to slide into or
out of the pad
frame tube until
the pin locks
automatically at
the next position.
• Pull the pin directly upward AND twist the pin (fig. 1B). This allows the pad arm to
slide without locking. Twist the pin again to allow automatic locking.
2)
2A
Slide the pad arm to the desired position
(fig. 2A).
3)
3A
Make sure the locking pin is engaged so the pad arm is
secured in position (fig. 3A).
4) Repeat steps 1-3 to similarly reposition the other pad arm.
Note: Position both telescoping pad arms at an equal distance from the center, to
maximize the lifter’s stability.
ASSEMBLY

Rev 0.1/3-22 FLEXR(L)8-DC3: #3504413
Repositioning the Sliding Pad Arms
1)
2A1A
Loosen a sliding arm
clamp (fig. 1A).
2) Move the sliding pad
arm to the desired
position along the
pad frame (fig. 2A).
3) Tighten the clamp, to
secure the sliding pad arm.
1) Repeat steps 1-3 to similarly reposition the other sliding pad arm.
3A
Note: Position sliding pad arms at an equal
distance from the center (fig. 3A), to
maximize the lifter’s stability.
Repositioning the Sliding Pad Mounts
1)
1B 2B
Loosen the knob on the
side of a sliding pad
mount (fig. 1B).
2) Slide the pad mount to
the desired position along
the sliding pad arm (fig.
2B).
3) Tighten the knob, to secure the pad mount.
4) Repeat steps 1-3 to similarly reposition other pad mounts, as needed.
Note: Position the pad mounts at an equal distance from the center of their pad arm, to
maximize the lifter’s stability.
ASSEMBLY

FLEXR(L)8-DC3: #35044 Rev 0.1/3-2214
Connecting/Disconnecting Vacuum Hoses
Make sure quick connectors seal completely and all vacuum
hoses function correctly (see “Vacuum Test”).
1A 1B
To connect a vacuum hose,
push the male and female
ends of the quick
connector together until
they lock (figs. 1A-B).
1C
Make sure all hoses are connected correctly:
Green hoses to circuit 1 and red hoses to circuit 2
(fig. 1C).
1D
The 2 vacuum gauges are labeled to indicate the
related circuits (fig. 1D).
Note: The gauge face colors do not correspond
with the circuit colors.
1E 1F
To disconnect a hose, move
the release ring on the
female end until the quick
connector separates (figs.
1E-F).
ASSEMBLY

Rev 0.1/3-22 FLEXR(L)8-DC3: #3504415
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.

FLEXR(L)8-DC3: #35044 Rev 0.1/3-2216
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 other unsuitable conditions.
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 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

Rev 0.1/3-22 FLEXR(L)8-DC3: #3504417
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.
Selecting a Screen Language
When the lifter is powered up for the first time, the Intelli-Grip®
control unit prompts the operator to select a language for the LCD
screen. Use the buttons as follows:
•To scroll down, press the “release” button ( ).
•To scroll up, press the “attach” button ( ).
•To select a language, press the “function” button ( ).1
Note: A similar process is used to navigate all menus.
1..... To change the language again, refer to the “INTELLI-GRIP®OPERATOR MENUS” section of the SERVICE MANUAL.

FLEXR(L)8-DC3: #35044 Rev 0.1/3-2218
Performing Inspections and Tests
• Follow the “INSPECTION SCHEDULE”and “TESTING”.
•
Examine air filters regularly
and service when needed.
Service the 2 air filters whenever a bowl contains
liquid or other contaminates, or an element
appears dirty (see “AIR FILTER MAINTENANCE” in
SERVICE MANUAL).
•
Make sure
notification
buzzer can be
heard over noise
at operator
position.
Make sure the notification buzzer is clearly
audible at the maximum distance between the
operator and the lifter, despite any barriers or
obstacles.1, 2
Checking the 12-Volt Battery
Always check battery
energy before every lift.
While the lifter is powered up, a battery gauge on the LCD
screen displays the current energy level.3, 4
• If battery energy is in the red range, discontinue lifter
use and charge the battery (see “12-VOLT BATTERY
RECHARGE”).
• If battery energy continues to decrease and you try to
attach the lifter to a load, the notification buzzer will
sound continuously and the LCD screen will display “Lockout (low 12V battery)”, along
with a diagnostic code (see “INTELLI-GRIP® DIAGNOSTIC CODES”). In this case, you must
charge the battery in order to continue using the lifter.
1..... Maximum buzzer volume is 95 dBA at 2' [60 cm]. If CE or UKCA Standards apply, consult EN 7731 to make sure the notification buzzer is
compliant.
2..... The “Vacuum Test” provides a convenient opportunity to check this.
3..... If the lifter remains in “Power Save” mode for a long time, the pump will run periodically to test the battery.
4..... If the battery charger is connected to an AC power source, the reading on the battery gauge will not be accurate and “Replace 12V battery?”
may appear on the LCD screen, because the system cannot accurately evaluate the battery.
OPERATION