WPG P1HV1102DC3 User manual

Rev 2.2/12-21 P1-02DC3: #351221
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).
2-PAD CHANNEL
LIFTER, DC-VOLTAGE
WITH INTELLI-GRIP®
TECHNOLOGY
(Available with REMOTE CONTROL SYSTEM)
Model numbers: P1HV1102DC3 (shown),
P110T02DC3, P110C02DC3, P111L02DC3,
KEEP FOR FUTURE REFERENCE
INTENDED FOR USE BY SKILLED
PROFESSIONALS • READ AND
UNDERSTAND BEFORE OPERATING

P1-02DC3: #35122 Rev 2.2/12-212

Rev 2.2/12-21 P1-02DC3: #351221
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
Selecting a Screen Language.............................................................................................11
Performing Inspections and Tests .....................................................................................12
Checking the 12-Volt Battery ............................................................................................12
Preparing to Use the Remote Control System ..................................................................13
TOATTACH THE PADS TO ALOAD ..................................................................14
Positioning the Lifter on the Load.....................................................................................14
Powering up the Lifter ......................................................................................................15
Sealing the Pads on the Load............................................................................................15
Reading the Vacuum Gauges ............................................................................................16
TOLIFT AND MOVE THE LOAD .....................................................................17
Interpreting the Lift Light..................................................................................................17
Monitoring Vacuum Indicators .........................................................................................17
Controlling the Lifter and Load .........................................................................................18
In Case of a Power Failure.................................................................................................18
TOROTATE THE LOAD .................................................................................19
TOTILT THE LOAD ......................................................................................20
TORELEASE THE PADS FROM THE LOAD .........................................................21
AFTER USING THE LIFTER.............................................................................22
Storing the Lifter ...............................................................................................................23
Transporting the Lifter ......................................................................................................23
INSPECTIONS AND TESTS......................................................................24
INSPECTION SCHEDULE ................................................................................24
TABLE OF CONTENTS

P1-02DC3: #35122 Rev 2.2/12-212
TESTING ...................................................................................................25
Lifter/Load Compatibility Test...........................................................................................25
Operational Tests ..............................................................................................................26
Vacuum Test......................................................................................................................26
Rated Load Test.................................................................................................................27
Remote Control System Test .............................................................................................27
MAINTENANCE ....................................................................................28
VACUUM PAD MAINTENANCE.......................................................................28
Pad-to-Load Friction Coefficient .......................................................................................28
Pad Inspection ..................................................................................................................28
Pad Cleaning .....................................................................................................................29
TOREPLACE SEALING RING IN VPFS10T PADS ...............................................30
12-VOLT BATTERY RECHARGE.......................................................................31
NOTIFICATION BUZZER BATTERY REPLACEMENT ...............................................32
INTELLI-GRIP® DIAGNOSTIC CODES ...............................................................33
REPLACEMENT PARTS...........................................................................37
LIMITED WARRANTY ............................................................................38
TOOBTAIN REPAIRS OR WARRANTY SERVICE...................................................38
TABLE OF CONTENTS

Product
Description
Designed for use with hoisting equipment, P1-02DC3 lifters support loads using vacuum and manipulate
loads using manual 180° rotation and manual 90° motions.
Model Number P110C02DC3 P110T02DC3 P1HV1102DC3 P111L02DC3 P11216L02DC3
Vacuum Pads:1
1...... Available with other rubber compounds for special purposes (see www.wpg.com).
(2 each, standard rubber)
10" [25 cm]
nom. diameter,
concave
(Model G0750)
10" [25 cm]
nom. diameter,
w/replaceable ring
(Model VPFS10T2
2...... Standard with replaceable sealing rings for rough or textured surfaces (see “REPLACEMENT PARTS”).
)
10" [25 cm]
nom. diameter,
lipped
(Model HV11)
11" [28 cm]
nom. diameter,
lipped
(Model G3370)
12" x 16"
[31 cm x 41 cm]
nom. diimensions,
lipped
(Model RF1216)
Pad Spread:
(to outer edges)
23" x 10"
[59 cm x 25 cm]
25" x 11¾"
[64 cm x 30 cm]
24" x 11"
[61 cm x 28 cm]
25" x 12"
[64 cm x 30 cm]
25½" x 16½"
[65 cm x 42cm]
Maximum Load
Capacity3
3...... The Maximum Load Capacity is rated at a vacuumof 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”).
-------------------------------------- (standard and European ratings) -------------------------------------------
Standard Rating — Per-Pad 150 lbs [68 kg] 150 lbs [68 kg] 150 lbs [68 kg] 175 lbs [80 kg] N/A
Standard Rating — Total 300 lbs [135 kg] 300 lbs [135 kg] 300 lbs [135 kg] 350 lbs [160 kg] N/A
150 lbs [68 kg]
300 lbs [135 kg]
Lifter
Weight -------------------------------------- 85 lbs [39 kg] ------------------------------------------- 95 lbs [43 kg]
Power System 12 volts DC, 5.5 amps
Battery Capacity 7 amp-hours
Rotation
Capability Manual, 180°, with latching at each ¼ turn (when required)
Tilt
Capability Manual, 90°, with automatic locking in vertical position
Product
Options
Available with Remote Control System – FCC, CE and ICC certified.
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 intended4
4...... Vacuum pads, filter elements and other wear-out items are excluded.
Software Version Intelli-Grip®7.6
ASME Standard BTH-1 Design Category "B", Service Class "0"
Troubleshooting Guide5
5...... 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-021_DC3_REV_2018-023
Rev 2.2/12-21 P1-02DC3: #351223
SPECIFICATIONS
On construction sites, a secondary positive holding device(eg, load sling)
is required to achieve theStandard Ratings for thelifters above.
h< Rating — Per-Pad
h< Rating — Total

P1-02DC3: #35122 Rev 2.2/12-214
Note: A standard P1HV1102DC3 is shown.
SPECIFICATIONS

Rev 2.2/12-21 P1-02DC3: #351225
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.

P1-02DC3: #35122 Rev 2.2/12-216
Features shown here are underlined on their first appearance in each section following.
1 LIFT POINT 2 BUZZER BATTERY HOLDER 3 COVER for VACUUM PUMP, VACUUM
SENSORS and AIR FILTERS
4 Windows for AIR FILTERS 5 VACUUM GAUGES 6 VACUUM LIFT LIGHT
7 NOTIFICATION BUZZER 8 STROBE LIGHT 9 INTELLI-GRIP® CONTROL UNIT
9a LCD SCREEN with BATTERY GAUGE 9b “FUNCTION” BUTTON 9c “ATTACH” BUTTON
9d “RELEASE” BUTTON 9e POWER BUTTON 10 LIFT BAR
11 PAD FRAME 12 VACUUM PAD 13 CONTROL HANDLES
14 ROTATION RELEASE LEVER 15 TILT RELEASE LEVER 16 BATTERY
17 BATTERY CHARGER 18 VACUUM RESERVE TANKS Not shown: INSTRUCTIONS CANISTER
Note: A standard P1HV1102DC3 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 2.2/12-21 P1-02DC3: #351227
1) Remove all shipping materials and save them with the shipping container for future use.
2)
2A
Adjust the lift point to optimize the lifter's
hang angle:
2.1) Remove the retaining bolt and loosen
the pivot bolt (fig. 2A).
2.2) Move the lift point to the appropriate
position.1
2.3) Reinstall the retaining bolt and tighten
both bolts securely.
3) Suspend the lifter from appropriate
hoisting equipment:
3.1) 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.
3A 3B 3C
3.2) Disengage the tilt latch and raise the lift bar (fig. 3A-C).
1..... Moving the lift point forward (away from operator) helps keep the hang angle vertical while the lifter is loaded; moving the lift point rearward
(towards operator) helps keep the hang angle vertical while the lifter is unloaded.
ASSEMBLY

P1-02DC3: #35122 Rev 2.2/12-218
3.3)
3D 3E
Make sure
hook has
restraining latch
(circled).
Attach the hoisting
hook to the lift point
(fig. 3D).
Use rigging (fig. 3E)
as needed to make
sure the hook does
not interfere with the
load.
Only use rigging rated for Maximum Load Capacity
plus Lifter Weight.
3.4) Use the hoisting equipment to remove the lifter from the shipping container. Avoid
damaging the vacuum pads.
4B4A
4)
4C 4D
Connect the electrical
connectors (figs. 4A-B
and figs. 4C-D).
Install the 9-volt battery
for the notification buzzer
as directed in “NOTIFICATION BUZZER BATTERY REPLACEMENT”.
5)
5A
Remove the pad covers (fig. 5A) and save them for future use.
6) Perform tests as required under “TESTING”.
ASSEMBLY

Rev 2.2/12-21 P1-02DC3: #351229
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 the “Lifter/Load Compatibility Test”.
• The load's contact surface must be able to obtain a friction coefficient of 1 with the lifter's
vacuum pads(see “Pad-to-Load Friction Coefficient”). Otherwise, the capacity should be
derated appropriately.
• 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
• 1" [2.5 cm] is the allowable thickness at Maximum Load Capacity.5
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.6
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..... However, the allowable thickness increases as load weight decreases. Contact WPG for more information.
6..... Alternative rubber compounds are available for these purposes. Contact WPG or an authorized dealer for more information.

P1-02DC3: #35122 Rev 2.2/12-2110
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.
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 2.2/12-21 P1-02DC3: #3512211
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.

P1-02DC3: #35122 Rev 2.2/12-2112
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

Rev 2.2/12-21 P1-02DC3: #3512213
Preparing to Use the Remote Control System
1 EMERGENCY DISCONNECT BUTTON
2 TRANSMISSION INDICATOR LIGHT
3 “RELEASE” BUTTON
4 “ATTACH” BUTTON
5 POWER/“FUNCTION” BUTTON
1A
The optional radio transmitter (fig. 1A) and radio
receiver enable you to activate the lifter's “attach”
and “release” functions at distances up to 250' [76 m],
provided you have a clear and direct view of the lifter and
its status indicators.
To operate a lifter remotely, follow these safety rules:
• Visually verify the status of the lifter and load prior
to lifting.
Make sure nearby personnel are aware
of intended remote control actions.
• Monitor the lifter at all times to make sure it is
functioning as intended.1
• Be sure the load is lowered and supported correctly
before releasing it (see following sections).
Note: To prevent any radio transmission, press the
emergency disconnect button.2
1..... The Remote Control System is designed to prevent multiple lifters from responding. Nevertheless, radio-controlled lifters should be tested to
make sure each transmitter controls only one lifter.
2..... To reset the emergency disconnect button, twist the button clockwise and allow it to spring outward to its original position.
OPERATION

P1-02DC3: #35122 Rev 2.2/12-2114
TOATTACH THE PADS TO ALOAD
Make sure the contact surfaces of the load and vacuum pads are clean (see
“Pad Cleaning”).
Positioning the Lifter on the Load
1) Center the pad frame on the load.1
2) Make sure all vacuum pads will fit on
the load and will be loaded evenly.
Consult the Per-Pad Load
Capacity.
3) Place the vacuum pads 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 2" [5 cm] of the lifter’s rotation
axis. Uncentered loads may rotate or tilt unexpectedly.
OPERATION

Rev 2.2/12-21 P1-02DC3: #3512215
Powering up the Lifter
1A
Press the lifter's power button ( — fig. 1A). The
vacuum pump will run for a few seconds, as a
normal function of the Intelli-Grip®self-diagnostics.
The lifter automatically tests the 9-volt battery for
the notification buzzer each time the lifter is
powered up. When this battery runs down, the
LCD screen displays “Replace 9V battery?” and the
buzzer chirps once per minute. Replace the battery
as needed (see “NOTIFICATION BUZZER BATTERY
REPLACEMENT”).
1B
To use the optional Remote Control System, briefly hold the
power button ( — fig. 1B) on the radio transmitter to
activate it.1
1C
Note: When you hold any button on the transmitter, the
transmission indicator light flashes green if the transmitter is
activated.
Sealing the Pads on the Load
Press the lifter’s “attach” button ( — fig. 1 C ).
Keep “attach” function
activated throughout lift.
1..... The radio transmitter turns off automatically after a period of inactivity.
OPERATION

2B
P1-02DC3: #35122 Rev 2.2/12-2116
To use the optional Remote Control System, press the “attach”
button ( — fig. 1D) on the radio transmitter.
The vacuum pump will run until the vacuum pads seal completely. If the lifter takes too long to
attach, the notification buzzer chirps and the LCD screen displays “Vacuum not increasing
normally”, along with a diagnostic code (see “INTELLI-GRIP® DIAGNOSTIC CODES”). In this case, press
the lifter firmly against the load to help the pads begin to seal.1
Reading the Vacuum Gauges
The 2 vacuum gauges of the dual vacuum system show the current vacuum level in positive
inches of Hg and negative kPa:
•
1A 1B
Green range (>16" Hg [-54
kPa]): Vacuum level is sufficient
to lift the maximum load weight
(fig. 1A).
• Red range (< 16" Hg [-54 kPa]):
Vacuum level is not sufficient to
lift the maximum load weight
(fig. 1B).2
If it takes more than 5 seconds for the
vacuum level to reach 5" Hg [-17 kPa]
on either vacuum gauge, 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.3If it does not, 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..... The gauge face colors do not correspond with the circuit colors.
3..... 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

Rev 2.2/12-21 P1-02DC3: #3512217
TOLIFT AND MOVE THE LOAD
Lift bar must be vertical to lift
load.
Interpreting the Lift Light
Never lift load unless lift
light is illuminated,
because premature lifting could
result in load release and
personal injury.
When vacuum is sufficient to lift the
Maximum Load Capacity, the vacuum
lift light turns on automatically and the
vacuum pump turns off temporarily, to
conserve battery energy.
Monitoring Vacuum Indicators
1A
Monitor the vacuum lift light and both vacuum
gauges throughout the entire lift (fig. 1A).
Make sure all vacuum indicators remain
completely visible.
The vacuum pump turns on and off to overcome any
leakage. However, if the leak rate is greater than
normal, the notification buzzer chirps and the LCD
screen displays the message “Vacuum decrease on
circuit #”, along with a diagnostic code (see “INTELLI-
GRIP® DIAGNOSTIC CODES”).1Such leaks can cause the
battery to be discharged more quickly.
If the vacuum pump is unable to overcome leakage, the notification buzzer sounds
continuously, the lift light turns off, and the LCD screen displays the message “INSUFFICIENT
VACUUM!”, along with a diagnostic code (see “INTELLI-GRIP® DIAGNOSTIC CODES”). If this happens:
1) Stay clear of any suspended load while
indicators warn of low vacuum.
Keep everyone away from a
suspended load until it can be safely
lowered to a stable support.
1..... Automatic leak detection is not a substitute for performing the “Vacuum Test”, required by the “INSPECTION SCHEDULE”and “TESTING”. Sensitivity
of leak detection can be adjusted (see “INTELLI-GRIP® OPERATOR MENUS” in SERVICE MANUAL).
OPERATION

P1-02DC3: #35122 Rev 2.2/12-2118
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.
Controlling the Lifter and Load
1A
When the lifter is ready, use the hoisting
equipment to raise the lifter and load as
needed.
Use a 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
In the event of a battery failure or electrical system failure, the notification buzzer will sound
continuously.
Although the vacuum reserve tanks are 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 vacuum pads (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 lowered safely to a stable
support. Correct any faults before resuming normal
operation of the lifter.
OPERATION