Will Burt Inflexion Plus 1.8 User manual

The Will-Burt Company
401 Collins Blvd
Orrville, OH 44667, USA
Phone: [phone]
E-Mail: [e-mail]
Website: www.willburt.com
TP-5211901-C, June 2021
© 2021 The Will-Burt Company
Original Instructions
Authorized Representative:
Will-Burt Germany GmbH & Co. KG
Fischergasse 25
D-91344 Waischenfeld, Germany
Inflexion Plus 1.8, 2.3, 3.0, 4.5, 6.0, & 7.5 Operating
Instructions
Inflexion Plus (721500020)
Inflexion Plus PI-35 ( 720777102)
Inflexion Plus PI-75 (722515210)

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Warranty
Will-Burt warrants its Inflexion Plus to be free from defects in material and workmanship for a
period of two (2) years, with such time period running from the date of shipment by Will-Burt. Will-
Burt shall not be responsible for any damage resulting to or caused by its products by reason of
failure to properly install, maintain or store the product; use of the product in a manner
inconsistent with its design; unauthorized service, alteration of products, neglect, abuse,
accident, or acts of God. This warranty does not extend to any component parts not
manufactured by Will-Burt; provided, however, Will-Burt’s warranty herein shall not limit any
warranties by manufacturers of component parts which extend to the buyer.
THE FOREGOING WARRANTY IS IN LIEU OF ALL OTHER WARRANTIES, AND NO
REPRESENTATIONS, GUARANTEES OR WARRANTIES, EXPRESS OR IMPLIED,
INCLUDING BUT NOT LIMITED TO, A WARRANTY OF MERCHANTABILITY, FITNESS FOR A
PARTICULAR PURPOSE, OR NONINFRINGEMENT ARE MADE BY WILL-BURT IN
CONNECTION WITH THE MANUFACTURE OR SALE OF ITS PRODUCTS. NO EMPLOYEE,
DISTRIBUTOR, OR REPRESENTATIVE IS AUTHORIZED TO CHANGE THIS WARRANTY IN
ANY WAY OR GRANT ANY OTHER WARRANTY ON BEHALF OF WILL-BURT.
Claims for defects in material and workmanship shall be made in writing to Will-Burt within thirty
(30) days of the discovery of defect. Failure to provide notice as required hereby shall be
conclusive evidence that the product was in conformity with the warranty, and Will-Burt shall be
released from any and all liability relating to the product. Will-Burt may either send a service
representative or have the product returned to its factory at Buyer's expense for inspection. If
judged by Will-Burt to be defective in material or workmanship, the product will be replaced or
repaired at the option of Will-Burt, free from all charges except authorized transportation.
THE REMEDIES OF BUYER SET FORTH HEREIN ARE EXCLUSIVE AND ARE IN LIEU OF
ALL OTHER REMEDIES. THE LIABILITY OF WILL-BURT WHETHER IN CONTRACT, TORT,
UNDER ANY WARRANTY, OR OTHERWISE, SHALL NOT EXTEND BEYOND ITS
OBLIGATION TO REPAIR OR REPLACE, AT ITS OPTION, ANY PRODUCT OR PART FOUND
BY WILL-BURT TO BE DEFECTIVE IN MATERIAL OR WORKMANSHIP. WILL-BURT SHALL
NOT BE LIABLE FOR COST OF INSTALLATION AND/OR REMOVAL, OR BE RESPONSIBLE
FOR DIRECT, INDIRECT, SPECIAL OR CONSEQUENTIAL DAMAGES OF ANY NATURE.

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Contents
1 Safety Summary................................................................................................... 5
1.1 Signal Word Definitions............................................................................................. 5
1.2 Safety Instructions .................................................................................................... 5
1.3 Symbols Used on Product Labels........................................................................... 11
2 Specification Compliance ................................................................................. 13
2.1 NFPA 1901-2016 .................................................................................................... 13
2.2 CE Declaration of Conformity ................................................................................. 13
3 Introduction........................................................................................................ 15
3.1 Additional Documentation ....................................................................................... 16
3.2 Power Requirements .............................................................................................. 16
3.3 Intended Use........................................................................................................... 16
3.4 Definitions ............................................................................................................... 17
3.4.1 Mast Position Definition ................................................................................ 18
3.5 Positioner Positions ................................................................................................ 19
3.5.1 Positioner Orientations.................................................................................. 19
3.6 Mast Component Descriptions................................................................................ 20
3.7 Positioners .............................................................................................................. 25
3.7.1 PositionIt™ PI-35 (P/N: 5467802)................................................................. 25
3.7.2 PositionIt™ PI-75 .......................................................................................... 26
3.7.3 PositionIt™ Saddle ....................................................................................... 26
3.8 Remote Control Options ......................................................................................... 27
4 Technical Data.................................................................................................... 29
5 Installation.......................................................................................................... 31
5.1 Mounting Location Requirements ........................................................................... 31
5.2 Recommended Installation Tools............................................................................ 32
5.3 Unpacking & Handling ............................................................................................ 32
5.4 Attaching to Mounting Location............................................................................... 34
5.4.1 Positioner Mounting ...................................................................................... 35
5.5 Attaching the Air Connections................................................................................. 36
5.6 Installing Remote Control........................................................................................ 37
5.6.1 Wired Hand Held Remote Control (HHRC)................................................... 37
5.6.2 Panel Mount Remote Control (PMRC).......................................................... 39
5.6.3 Wireless Hand-Held Remote Control (WHHRC)........................................... 40
5.7 Electrical Installation ............................................................................................... 41
5.7.1 Wiring Remote Control Cable to the Base Board ......................................... 42
5.7.2 Wiring DC Source Power to the Mast Control Circuit ................................... 43
5.7.3 Wiring Vehicle Safety Interconnect Circuit.................................................... 44
5.7.4 Wiring Optional Enable Circuit ...................................................................... 44
5.7.5 Secure Wiring and Attach Cover................................................................... 45
5.8 Mounting the Payload ............................................................................................. 45
5.9 Test the Installation................................................................................................. 47
6 Operation............................................................................................................ 49
6.1 Pre-Operation Check .............................................................................................. 49
6.2 Operation Tools ...................................................................................................... 49
6.3 Remote Control Functions ...................................................................................... 50
6.3.1 Presets.......................................................................................................... 50
6.4 Operating the Positioner ......................................................................................... 52

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6.5 Quick Operation Summary...................................................................................... 53
6.6 Initiating (Power-Up) ............................................................................................... 54
6.7 Raising the Mast to 90°........................................................................................... 54
6.7.1 Using the Auto-Up Feature ........................................................................... 55
6.7.2 Using the Mast Up Button ............................................................................. 55
6.8 Extending the Mast ................................................................................................. 55
6.9 Lowering the Mast................................................................................................... 56
6.10 Stowing the Mast .................................................................................................. 56
6.10.1 Using the Auto Stow® Feature ................................................................... 57
6.10.2 Using the Mast Down Button ...................................................................... 57
6.10.3 Emergency Stow with Power ...................................................................... 58
6.10.4 Emergency Stow without Power ................................................................. 59
7 Maintenance, Adjustments and Disposal ........................................................ 61
7.1 Pre-Maintenance Check ......................................................................................... 61
7.2 Maintenance Tools.................................................................................................. 61
7.3 Power Isolating Procedure...................................................................................... 62
7.4 Cleaning and Lubricating the System ..................................................................... 62
7.5 Positioner Routine Maintenance ............................................................................. 64
7.6 Spare Parts ............................................................................................................. 64
7.7 Periodic Inspections................................................................................................ 65
7.8 Adjusting the 90° and Mast Stowed Limit Switches ................................................ 66
7.8.1 Diagnostic LEDs on the Base PC Board....................................................... 67
7.8.2 Adjusting the mast 90° Limit Switch.............................................................. 68
7.8.3 Adjusting the Mast Stowed Limit Switch ....................................................... 70
7.8.4 Adjusting the Mast Magnetic Down Switch ................................................... 71
7.9 System Disposal ..................................................................................................... 72
8 Reference Information....................................................................................... 73
8.1 DIP Switch Definitions............................................................................................. 73
8.2 D-TEC® Sensor ...................................................................................................... 73
8.2.1 D-TEC® Sensor Location ............................................................................. 73
8.2.2 D-TEC® Functionality ................................................................................... 74
8.3 Nycoil® (Optional)................................................................................................... 76
8.4 The Will-Burt Company Mast Oil Safety Data Sheet .............................................. 77
9 Troubleshooting................................................................................................. 81
9.1 Troubleshooting Electrical....................................................................................... 81
9.2 Troubleshooting Mechanical Symptoms ................................................................. 89
9.3 Positioner Troubleshooting ..................................................................................... 91
10 Document History............................................................................................ 93
11 Appendix........................................................................................................... 95
11.1 Installing a Wired HHRC with J-Box ..................................................................... 95
11.2 System Wiring Diagram ........................................................................................ 95
11.2.1 Inflexion Plus............................................................................................... 96
11.2.2 PositionIt™ PI-35 ...................................................................................... 100
11.2.3 PositionIt™ PI-75 ..................................................................................... 102

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1 Safety Summary
This section describes safety instructions for the Inflexion Plus that personnel must understand
and apply throughout all product activities such as transportation, handling, installation,
operation, maintenance, storage, disposal and troubleshooting. Read and understand this entire
document, and contact The Will-Burt Company with any questions, before performing any
procedure outlined in this document. Keep this document during the entire duration of use of the
device. Pass this document along to trained and qualified end users.
1.1 Signal Word Definitions
The following signal words and definitions are used to indicate hazardous situations:
DANGER indicates an imminently hazardous situation that, if not avoided, will result in death or
serious injury.
WARNING indicates a potentially hazardous situation that, if not avoided, could result in death or
serious injury.
CAUTION indicates a potentially hazardous situation that, if not avoided, may result in minor or
moderate injury or equipment damage. It is also used to alert against unsafe practices.
1.2 Safety Instructions
Electrocution Hazard! Contact with high voltage will result in death or serious injury. Observe
general safety precautions for handling equipment using high voltage. Do not locate or operate
mast near electrical lines, cables or other unwanted sources of electricity. Allow sufficient
clearance on all sides of mast to allow for side sway. Do not operate mast during an electrical
storm. Be certain electrical cables are undamaged and properly terminated. Do not touch live
wires. Follow OSHA or other national safety regulations when working near energized power
lines. Personnel working with or near high voltages should be familiar with methods of
resuscitation.
Disconnect Power for Service! Always disconnect all power sources following proper lock-out
tag-out procedures before performing service, repair or test operations. Remove the tethered
hand held control where applicable for added protection during maintenance.
Mast Tip Over Hazard! Mast tip over could result in death or serious injury. Before operation, be
certain mounting structure is capable of resisting forces generated from all loading and

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environmental conditions, including, but not limited to, mast size and weight, payload and cable
size and weight, payload sail area, wind speed, guy line arrangement, support bracket or roof
line location, and base plate assembly. Do not operate in wind speed conditions exceeding the
maximum rated wind speed. Do not operate on slopes exceeding the maximum deployment
angle. Do not install a payload that exceeds the maximum payload lifting capacity of mast. Do not
install a payload with the center of gravity offset from mast centerline exceeding the maximum
allowed offset. Stand clear of mast and mast payload during operation. Be certain mast is level
and secure before and during installation, operation, and maintenance.
Falling Objects from Mast Hazard! Wear a protective hard hat when working on mast or
situated near mast operating area while mast is extending, retracting or deployed in any position
above the nested position. Improperly secured payload or mast components, ice formations, etc.
could be dislodged from mast and fall. Be sure the payload is properly installed and secured.
Relocation/Driving Hazard! Do not relocate the system during operation or while mast is
extended to any height above the nested position or powered up. Do not move vehicle until mast
has been securely nested and isolated from power. Power-up and operate mast only if the
vehicle is stationary and securely parked with the parking brake properly applied. Do not put
mast in service or operate without the vehicle interlock warning circuit or magnetic warning kit
installed to provide confirmation mast is nested prior to moving the vehicle. Contact The Will-Burt
Company Engineering for special on-the-move situations for military only use on specialized
products.
Burst Hazard! For pneumatically operated masts, do not operate without the over-pressure
safety valve installed. Keep personnel clear of safety valve exhaust direction. Do not exceed the
maximum rated pressure of mast. If the mast air pressure is not fully discharged prior to
removing air hoses, a rapid release of air pressure will occur requiring hearing and eye
protection.
Payload Lifting Hazard - Intended Use! The mast is intended to lift a specific payload for
lighting, surveillance or communication use only. Any other use without written consent is
prohibited and could cause death or serious injury. Do not use mast to lift personnel. Do not
exceed specified payload capacity. Large payload wind sail areas can reduce payload capacity.
Consult The Will-Burt Company engineering.
Read Operating Instructions! Read and observe the operating instructions. Non-observance of
the instructions, operation which is not in accordance with use as prescribed in the instructions,
wrong installation or incorrect handling can seriously affect the safety of operators and
machinery. Adhere to the safety instructions when carrying out any activity relating to the
Inflexion Plus.
Trained Personnel Only! This product is intended for use by trained professionals only. It is not
intended for general use by the public or untrained personnel. Handling, installation, operation

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and maintenance to be performed by trained and authorized personnel only. Only a properly
trained and qualified certified electrician should perform electric installations and service.
Erratic Mast Operation Impact Hazard! The mast should operate smoothly during extension
and retraction. If erratic mast motion is observed during extension or retraction that results in
impact loading between the tube and the tube collar (mechanical travel stop), cease use of the
mast and contact The Will-Burt Company service department. Repeated operation with impact
loading can damage tubes and lead to mast separation.
Over-current Protection! Over-current protection or power switching by the installer on mast
incoming power supply as specified in this document should be a type suitable to allow lock-out
tag-out procedures for power disconnect.
Safety Instruction - Explosion! For outdoor use only. Do not use in explosive areas or areas
that have been classified as hazardous as defined in Article 500 of the National Electric Code or
equivalent national standards. Do not use in the presence of flammable gases or liquids such as
paint, gasoline or solvents. Do not use in areas of limited ventilation or where high ambient
temperatures are present.
Safety Equipment (PPE)! Proper personal protective equipment (PPE) like hard hats, gloves,
and safety shoes shall be properly worn while working on mast or near the deployment area of
mast. In addition, eye protection shall be worn during maintenance procedures. Follow national
PPE guidelines in your area of operation.
Pinch Point Hazard! Keep clear of all moving parts like mast collars nesting. Be sure to stay
clear of system during operation. Moving parts can crush and cut resulting in serious injury. The
mast shall be mounted out of reach of the operator during operation.
Crush Hazard - Mast Failure! Do not stand directly beneath mast or its payload. Be certain the
payload is properly installed and secured.
Entanglement Hazard! Tangled cables can cause equipment damage. Ensure payload cables,
Nycoil®, trip lines, guy lines or other cables are not tangled and are free to pay out as mast is
deployed. Cables that get tangled or snagged on mast or other objects can cause mast tubes to
lurch upward suddenly when the cable is freed. This can cause damage to mast and lead to mast
separation if repeatedly allowed to continue.
Health and Safety Hazard while Cleaning! Solvent used to clean parts is potentially
dangerous. Avoid inhalation of fumes and prolonged contact to skin.

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Fire Hazard Solvent! Cleaning solvent, used for maintenance, is flammable and can be
explosive. Do not smoke near solvent. Use cleaning solvent in a well-ventilated area. Keep
cleaning solvent away from ignition sources. Always store cleaning solvent in the proper marked
container and in a proper location.
Bright Light Radiation Hazard! For systems equipped with scene lighting or look-up lights, do
not look directly into lights when they are illuminated. Temporary impairment or permanent vision
damage could occur.
Personnel Freezing/Burn Hazard! Make sure the lights are completely cool before attempting
to clean the lens, replace bulbs or perform maintenance. Wear gloves to protect from contact
with exposed metal that may be at extremes of hot and cold temperatures from sun or cold
outdoor exposure.
Mast Extension Hazard - Obstruction! Extending mast into obstructions could result in death or
serious injury and could render mast inoperable and partially extended. Before applying power
and operating mast, be certain there is sufficient clearance above and to all sides of the expected
location of the fully extended mast and payload. Keep all persons clear of mast and mast
extension. Do not lean directly over mast. Locate the operator station such that the operator has
a clear view of the operating space of mast and payload prior to deployment to avoid contact with
overhead objects.
Manual Retraction! For powered masts, make sure all power sources have been disconnected
from the system prior to manually lowering mast to avoid unexpected start-up motion and/or
damage to mast.
Mast Lifting/Handling! Use extreme caution while lifting mast System and when mast System is
suspended to avoid injury and equipment damage. Be certain mast is properly secured using at
least two sling points at the center of gravity label. All operators should be aware of and follow
the applicable local, regional, and national standards and codes of practice for slinging and
transporting equipment. Never lift Mast System over people. Ensure lifting equipment including,
but not limited to, lifting straps and hoist, are capable of handling the forces generated from lifting
the system. Observe manufacturer instructions on lifting equipment.
Remove Payload! For mast systems shipped with no payload (customer installed payloads),
remove payload before performing maintenance on mast system. The Will-Burt Company
installed devices can remain installed.
Equipment Damage - Submerged! Do not submerge mast in liquid or operate the vehicle in a
fording situation that would result in a submerged mast.

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Safety Instruction - Potential Air Contaminants! If internally mounted in a vehicle, air from
mast and any accumulated water will discharge into the vehicle. Install appropriate drainage and
venting.
Fastener Vibration Hazard! Mast system and payload mounting hardware must include proper
means to resist vibration loosening such as thread-locking compound, locking hardware, or
equivalent. Use specified assembly torques appropriate for the fastener size.
Frozen Water Hazard! Water freezing inside mast may render mast inoperable and cause major
equipment damage such as tube deformation. Ensure water is free to exit at the base of mast.
Safety Instruction - Guy Anchors! For masts using Guy Lines, verify the Guy Anchor point
strength is adequate to support the Guy Line forces.
Lubrication! Do not lubricate the exterior of mast moving tubes. The lubricant will attract dust
and other environmental contaminants into mast.
Equipment Damage - Forces! Before unloading the system, be certain the unloading region is
capable of resisting forces generated from unloading the system including but not limited to
system weight. Ensure the unloading region is level and has sufficient room and strength to hold
the system. If the unloading region is incapable of meeting the requirements of the system,
damage to the system and/or unloading region could occur.
Equipment Damage - Support Bracket! For masts using an upper support bracket, do not
over-tighten mast support bracket. Over-tightening may damage the Base Tube causing mast
tubes to stick.
Mast and Payload Access! The operator must provide safe means to access mast and payload
during installation, removal and maintenance.
Tripping Hazard! Cables, trip lines, guy lines and guy anchors can be hard to see during and
after installation. Any equipment posing trip hazards should be clearly marked.
Lifting Hazard! Manually lifting over 55 lb. (25 kg) is prohibited. In the UK, all lifting equipment
must be thoroughly examined annually by a competent person according to the Lifting
Operations and Lift Equipment Regulations 1998. Equivalent regulations exist in other EU states.

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Safety Instruction – Roof Access! If the mast will be mounted to a vehicle, the operator must
provide a safe means to access the roof of the vehicle during installation.
Safety Instruction – Hose Installation! At all times while using hose during installation:
• Hose should be routed, mounted, and restrained to protect from damage
• Second-hand hose should not be used for installation
• Hose should not be bent at a radius less than specified by the manufacturer
• Hose should be marked to avoid hazards from incorrect connections
• The exhaust should be fitted with a silencer and directed away from personnel
• Hose should be routed and installed in such a way as to minimize torsion on the joints
• Hose mounting should be accomplished only by the use of tools to prevent readily
disconnecting hose from the mast
Emergency Stow! Using the emergency stow button causes the actuator to lower mast without
regard to any faults, switches, or system interlocks. It is totally up to the operator to ensure safe
operation during an emergency stow attempt. When using the emergency stow button, normal
operation switches are disabled. The mast can be overdriven into saddle and cause damage to
the unit. Disengage the emergency stow button when the payload reaches the saddle and is
tight. Do not drive mast beyond this position.
Pressurized Device Hazard! Completely lower the mast, depressurize, and shut down power
before disassembly. Mast disassembly prior to depressurization may release pressurized air jet.
Safety Instruction – Remote Control! The equipment is subject to remote control and may be
operated at any time. Persons working on the equipment should take appropriate precautions to
ensure that any unexpected movement does not occur as this could lead to injury.
Equipment Damage! Each positioner contains a 1.85 amp self-resetting circuit breaker to
protect the PC board. Do not disassemble the positioner side plates, or separate from the
pedestal. Doing so will break the environmental seal and potentially cause improper stop limit
settings. This will void the warranty.
Safety Instruction – Lightning! Lightning protection is not part of this system. A proper means
of electrical grounding should be provided. Failure to observe this warning could result in death
or serious injury.
Safety Instruction – High Pressure Spray! Do not expose the positioner to high pressure
spray. Equipment damage may occur.

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Pinch and Crush Hazard! The Inflexion Plus with PositionIt PI-35 has automatic payload
management features which cause the positioner to shift up to 5° up from the saddle when power
is applied to the system. Use care to keep clear of moving parts during system operation. Moving
parts can crush and cut resulting in serious injury.
Manual Tilt! If manually tilting mast, make sure all power has been disconnected from the
system prior to manually lowering mast to avoid unexpected motion and/or damaging mast
components.
Safety Instruction - Motion on Power Interruption or Emergency Stop! Mast uses a normally
open air control valve. If power is lost or turned off or the emergency stop is activated while mast
is extended, mast will begin releasing air pressure and retracting at a controlled rate until power
is restored or mast fully retracts. Masts that fold down will not initiate any tilt motion.
1.3 Symbols Used on Product Labels
The following symbols are displayed on the product. The symbol meanings are as follows:
This symbol indicates an electrocution hazard or hazardous voltage hazard.
There is voltage present inside mast and control box. Do not operate mast
near electrical lines or during electrical storms. Contact with high voltage will
result in death or serious injury.
This symbol indicates a pinch point hazard. Keep fingers and hands clear of
moving parts.
This symbol indicates a tip-over hazard. The mast must be properly
supported during transport, handling, installation, maintenance, operation and
decommissioning. System tip-over could result in death or serious injury.
This symbol indicates a general warning. In this unit, this symbol indicates a
frozen water hazard. Water must be permitted to exit mast to avoid ice
damage to mast.
This symbol is used to remind users to read and understand the operator's
manual before operating the mast system. Failure to follow operating
instructions could result in death or serious injury. Read and understand
operating instructions before handling, installing, operating, or maintaining
the mast system.

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This symbol indicates an electrical ground connection point.
This symbol is used to indicate the center of gravity (COG) of a fully nested
mast in a horizontal transport position.

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2 Specification Compliance
2.1 NFPA 1901-2016
The mast systems are designed to be compliant with the following sections of National Fire
Protection Agency NPFA-1901-2016 Edition:
22.14 Powered Operated Light Masts
23.13 Power Operated Masts
2.2 CE Declaration of Conformity
Refer to the Product page at www.willburt.com for the latest Declaration of Conformity.

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3 Introduction
Thank you for selecting The Will-Burt Company for your critical payload elevation needs. These
operating instructions describe transporting, handling, installing, operating, maintaining, storing,
and troubleshooting procedures for the Inflexion Plus, Inflexion Plus with PositionIt™ PI-35, and
the Inflexion Plus with PositionIt™ PI-75. These procedures assume the use of standard mast
systems. Procedures and characteristics for mast systems customized to meet customer-specific
needs may vary.
These operating instructions are intended for professionals who are qualified by their appropriate
training and experience to perform the procedures. Review this document in its entirety. Contact
The Will-Burt Company with any questions before performing any procedure outlined in this
manual.
The views depicted in this manual are provided for clarification and are subject to change without
notice. Views are not to scale.
The Inflexion Plus, Inflexion Plus with PositionIt™ PI-35, and Inflexion Plus with PositionIt™ PI-
75 mast systems are roof-mounted, fold-down telescoping masts designed for smaller payloads,
like broadcast devices. They are created for installation on any vehicle. The different mast
models tilt to vertical and extend upwards for usage and retract and fold down for transport. Air
pressure required to extend the mast is provided by the vehicle air system or an optional
compressor unit.
The following models are covered in these operating instructions:
• Inflexion Plus 1.8
• Inflexion Plus 2.3 (available with PositionIt™ PI-35)
• Inflexion Plus 3.0 (available with PositionIt™ PI-35 and PositionIt™ PI-75)
• Inflexion Plus 4.5 (available with PositionIt™ PI-35 and PositionIt™ PI-75)
• Inflexion Plus 6.0 (available with PositionIt™ PI-35 and PositionIt™ PI-75)
• Inflexion Plus 7.5 (available with PositionIt™ PI-35)
The Inflexion Plus masts are available with many options installed by The Will-Burt Company,
including the option to come with a positioner, which can be integrated into an Inflexion Plus mast
to remotely position a suitable payload. The PositionIt™ PI-35 can go on the 2.3, 3.0, 4.5, 6.0,
and 7.5 Inflexion Plus models. The PositionIt™ PI-75 can go on the 3.0, 4.5, and 6.0 Inflexion
Plus models.

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3.1 Additional Documentation
In addition to this manual, the system ships with top-level drawings. These drawings can be
referenced during the installation process.
If more information is needed for the positioners, additional information can be found in the
following:
•PositionIt PI-35 (P/N: 5467801) Operator’s Manual (TP-5406201)
•PositionIt PI-150 (P/N: 5061001) and PI-75 (P/N: 5191201) Operator’s Manual (TP-
5129001).
To obtain these documents, contact The Will-Burt Company.
3.2 Power Requirements
All electrical devices on the system are nominal 12 volt DC devices, except for the PositionIt™
PI-35 which receives 24 volts DC from the board. The boards driving them monitor and chop the
battery voltage at 300 Hz adjusting the duty cycle to deliver 12 volts. During mast incline at 13.8
volts the system may draw up to 13 amps. During mast incline at 28.8 volts the system may draw
up to 9 amps.
Power must be supplied to the Inflexion Plus at 12 or 24 VDC.
If a high output compressor is used, 12 VDC power must be supplied separately to the
compressor. The source must be protected at 50 amps.
3.3 Intended Use
The Inflexion Plus, Inflexion Plus with PositionIt™ PI-35, and Inflexion Plus with PositionIt™ PI-
75 are intended for use by professionals in the fire/rescue/first responder/security industries. It is
not intended for use by non-professionals. Do not use the mast to lift personnel. The mast
systems are intended to be installed on the roof or in a roof well of fire/rescue/first responder
vehicles with the vehicle interconnect safety circuit installed and operational.
The Inflexion Plus, Inflexion Plus with PositionIt™ PI-35, and Inflexion Plus with PositionIt™ PI-
75 are intended to be used only when the vehicle is stationary and the vehicle parking brake is
properly applied. Do not supply input supply voltage or operate the mast system when the
vehicle is in motion. The mast shall remain in the powered-down, nested position during vehicle
motion.

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3.4 Definitions
General Terms:
•System: refers to the entire mast system, controller, and other optional accessories like the
optional Nycoil and optional D-TEC II system
•Positioner: refers to either the PositionIt™ PI-35 or PositionIt™ PI-75
•Hand-Held Remote Controller (HHRC): refers to the controller used to operate the mast
•Payload: refers to the object or equipment being extended by the mast to an operational
height
Figure 3-1 System Orientations (Inflexion Plus 4.5 Shown)
Figure 3-2 System Orientations (Inflexion Plus 4.5 with PositionIt™ Shown)
Top
Look-Up
Light
(Hidden)
Bottom
Front
Right
Left
Look-Up
Light
Rear
Side View from Left Side Overhead View from Rear
MIL Connector Top
Look-Up Light
Bottom
Front
Left Right
Look-Up Light
Rear
Side View from Left Side Overhead View from Rear

PAGE 18 OF 102
INFLEXION PLUS
OPERATING INSTRUCTIONS
TP-5211901-C
JUNE 2021
3.4.1 Mast Position Definition
An actuator electrically tilts the mast from the stowed position to the 90° position. The mast is
then pneumatically moved by air pressure to the extended position. The following positions (see
Figure 3-3) are used throughout this manual:
•Stowed: is the horizontal position in which the mast is firmly seated in the saddle. This
position is sometimes referred to as the nested position.
•90°: is the position that the mast electrically goes to from the stowed position. At 90°, the
mast has angled up, but no mast sections have risen. The mast remains retracted.
•Extended: is the partial or full raised position that the mast pneumatically goes after the 90°
position. In the extended position, some or all of the mast sections have risen.
Figure 3-3 Mast Positions (Night Scan Mast Shown)