Will Burt INFLEXION 2.3 Instruction manual

INFLEXIONTM 2.3, 4.5, 6.0 & 7.5
INSTALLATION, OPERATION & MAINTENANCE MANUAL
The Will-Burt Company
169 S. Main Street
Orrville, OH 44667
www.willburt.com
TP-4976401-C, October 2018

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Inflexion™ Warranty
Will-Burt warrants its Inflexion™ masts 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 NON-
INFRINGEMENT 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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Document History
Manual
Version
Date
Remarks
TP-4976401
00
11/12/2013
INITIAL RELEASE
A
12/3/2013
Updated warranty page.
B
01/06/14
Clarify power requirements (section 1.6),
emergency stow procedure (section 3.2)
C
10/1/18
Updated the Cover Image and Figure 1-1

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TABLE OF CONTENTS
SAFETY SUMMARY...............................................................................................................................vii
1. INTRODUCTION 1-1
1.1 Safety Precautions..........................................................................................................................1-1
1.2 Document Introduction....................................................................................................................1-1
1.3 INFLEXION Description..................................................................................................................1-1
1.4 Dimensions .....................................................................................................................................1-2
1.5 Mast Load .......................................................................................................................................1-3
1.6 Power Requirements ......................................................................................................................1-3
2. INSTALLATION 2-4
2.1 Introduction .....................................................................................................................................2-4
2.2 Tools and Materials Required for Installation .................................................................................2-4
2.3 Unpacking.......................................................................................................................................2-5
2.4 Attaching to vehicle.........................................................................................................................2-5
2.5 Connecting DC Power to the Base.................................................................................................2-6
2.6 Pre-operational Check....................................................................................................................2-8
2.7 Functional Test ...............................................................................................................................2-8
3. OPERATING INSTRUCTIONS 3-1
3.1 General Mast Operation..................................................................................................................3-2
3.2 Emergency Stow (Loss of Power): .................................................................................................3-3
4. MAINTENANCE AND SERVICE INSTRUCTIONS 4-5
4.1 Introduction .....................................................................................................................................4-5
4.2 Cleaning the INFLEXION................................................................................................................4-5
4.3 Adjustments ....................................................................................................................................4-5
4.4 Troubleshooting..............................................................................................................................4-7

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LIST OF ILLUSTRATIONS
Figure 1-1 INFLEXION Mast Major Components (INFLEXION 4.5, model 720378040 shown) ..............1-1
Figure 1-2 INFLEXION 4.5 Model Number 722069001 Dimensions........................................................1-3
Figure 2-1 INFLEXION 4.5 Mounting Hole Pattern...................................................................................2-6
Figure 3-1 Hand-held Controller ...............................................................................................................3-2
Figure 3-2 Emergency Stow Allen Screw Location...................................................................................3-3
Figure 4-1 Proximity Switches...................................................................................................................4-5
Figure 4-2 Status LEDs on Base Board....................................................................................................4-9
LIST OF TABLES
Table 2-1 Tools and Materials Required for Installation ...........................................................................2-5
Table 4-1 Troubleshooting Table..............................................................................................................4-9

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SAFETY SUMMARY
SIGNAL WORD DEFINITION
Per the ANSI Z535.4 standard, 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. It is also used to alert against unsafe practices.
GENERAL SAFETY PRECAUTIONS
The following are general safety precautions that are not related to any specific procedures and therefore do not appear
elsewhere in this publication. These are recommended precautions that personnel must understand and apply during many
phases of operation and maintenance.
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. Do not operate mast in lightning. Be certain electrical
cables are undamaged and properly terminated. Always disconnect power before performing service, repair
or test operations.
Safety Instruction - Read Manual! Failure to follow operating instructions could result in death or serious
injury. Read and understand the operator’s manual before using the mast.
Tip Over Hazard! Mast tip over could result in death or serious injury. Do not operate in high winds.
Operate on level ground only. Stand clear of mast and mast payload during operation. Be certain mast is
level and secure before and during installation, operation and maintenance.
Safety Instruction - Trained Personnel Only! Death or serious injury could result if proper inspection,
installation, operation and maintenance procedures are not observed. Installation, operation and
maintenance to be performed by trained and authorized personnel only. Proper eye protection should be
worn when servicing the mast.
Health and Safety Hazard! Solvent used to clean parts is potentially dangerous. Avoid inhalation of fumes
and also prolonged contact to skin.

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Safety Instruction-Do not look at lights! Do not look directly into lights when they are illuminated.
Temporary impairment or permanent vision damage could occur.
SPECIFIC SAFETY PRECAUTIONS
The following are safety precautions that are related to specific procedures and therefore appear elsewhere in this
publication for emphasis. These are recommended precautions that personnel must understand and apply during
specific phases of installation, operation and maintenance.
Safety Instruction-Operation! For outdoor use only. Do not use in areas that have been classified as
hazardous as defined in Article 500 of the National Electric Code.
Crush Hazard! Death or serious injury could result if mast fails suddenly. Do not stand directly
beneath the mast or its payload. Be certain payload is properly installed and secured.
Burst Hazard! Over pressurizing mast will trip safety valve and could result in death or serious injury.
Do not exceed maximum operating pressure of 20 psi (138 kPa) for Standard Duty masts. Keep
personnel clear of safety valve exhaust direction.
Fire Hazard! Cleaning solvent, used for maintenance, is flammable and can be explosive resulting in
death or serious injury. Do not smoke. Use cleaning solvent in a well-ventilated area. Keep cleaning
solvent away from ignition sources. Always store cleaning solvent in the proper marked container.
Relocation Hazard! Relocating the mast during operation or after being raised could result in death or
serious injury. Do not relocate the mast during operation or while raised. This applies especially to
masts mounted to vehicles. Operate the mast only if the vehicle is stationary and the vehicle engine is
off.
Mounting Structure Hazard! Mounting mast into a structure unable to resist the forces generated
from customer-specific loading scenario could result in death or serious injury and could damage the
mast. Before operation, be certain mounting structure is capable of resisting forces generated from all
loading and environmental conditions, including, but not limited to, mast size and weight, payload size
and weight, sail size, wind speed, guy line arrangement, support bracket or roof line location and base
plate assembly.
Electrocution Hazard! Do not touch live wires. Death or serious injury could result.
Safety Instruction –Operation! Make sure all power has been disconnected prior performing
maintenance.

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Safety Instruction -Trained Personnel Only! Only trained and qualified personnel should perform
installation, adjustments, and servicing. Only a properly trained and qualified certified electrician should
perform electric installations and service.
When relamping an installed fixture, make sure all power to fixture is off and that the fixture is cool
Safety Instruction –Operation! At all times prior to mast operation, insure that:
1.) The mast area is free of personnel and mechanical obstruction;
2.) All electrical cables are undamaged and properly terminated;
3.) The operator must have full view of the mast during use;
4.) Any transit tie-downs on the payload have been removed;
5.) The vehicle is not moving;
6.) The area above the mast is free of mechanical obstructions.
Safety Instruction-Operation! Lamps are extremely hot and should not come into contact with people
or combustible and/or explosive materials. Do not operate if breakage occurs or unit is knocked over.
Entanglement Hazard! Tangled cables can cause equipment damage. Ensure control cables are not
tangled and are free to pay out as mast is raised.
Safety Instruction –Operation! Do not operate the mast during an electrical storm.
Lifting Hazard! Manually lifting over 55 lb (25kg) 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.
Safety Instruction –Operation! All operators must read the Operation section of this manual and be
properly trained.

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CHAPTER 1
INTRODUCTION
1.1 SAFETY PRECAUTIONS
Refer to the Safety Summary for precautions to be observed while operating or servicing this equipment.
1.2 DOCUMENT INTRODUCTION
This document covers installation, operation, maintenance, and troubleshooting for the INFLEXION masts. The manual
should be reviewed in its entirety. Contact the Will-Burt factory with any questions before performing any procedures
outlined in this manual. The INFLEXIONTM 1.5, 2.3, 4.5, 6.0, and 7.5 masts will be referred to as the “INFLEXION” mast
in this manual.
1.3 INFLEXION DESCRIPTION
The INFLEXION mast is a transportable platform elevation system which serves as a platform for communications
antennae, camera, and other payloads. The unit is designed for installation on any vehicle for the purpose of providing
temporary communications, or surveillance. See Figure 1-1 for identification of the major components of the
INFLEXION mast.
Figure 1-1 INFLEXION Mast Major Components (INFLEXION 4.5, model 720378040 shown)
Mast
Optional Nycoil
Saddle
Platform
Base Covers (base board
and actuator inside)
Unit DC
Power In
Compressor
DC Power In

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1.4 DIMENSIONS
Dimensions and mounting hole locations for INFLEXION are shown. Please refer to product literature or
www.willburt.com for additional information including length, width and height information.
MODEL
DIM "X"
inch [mm]
4.5 METER
66 5/8 [1692.3]
6.0 METER
79 7/8 [2028.8]
7.5 METER
94 3/8 [2397.1]

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Figure 1-2 INFLEXION 4.5 Model Number 722069001 Dimensions
1.5 MAST LOAD
It is important that the mast be securely mounted to a sturdy platform, which will not overturn during operational loading
of the mast. Following is the loading information for the mast, which can be expected during operation:
75 lb at saddle of mast (Inflexion 1.5 and 2.3) or 120 lb saddle of mast (Inflexion 3.0, 4.5, 6.0, and 7.5)
200 lb at the front of the base cover
575 lb at rear of base cover (mast pivot)
1.6 POWER REQUIREMENTS
DC power for the INFLEXION is supplied by the vehicle and customer-wired to the mast base board. The INFLEXION
operates at 12 VDC, but will accept 24 VDC with the optional 24/12 converter. The DC cables should be 12 gauge (for
12V) and 16 gauge (for 24V). Long runs of cable can introduce power loss. There is a 35-40 amp inrush to the motor
(depending on the length and gauge of the wires) that drops to 6-7 amps in 300mS. For long runs, it may be necessary
to increase the wire gauge of the cables. If required, the vehicle-integrator is responsible for installing an ON/OFF switch
to disconnect power from the unit. This switch should be in line with the positive power cable (from battery source). If
using a separate power supply, it should have a 10 amp minimum.

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CHAPTER 2
INSTALLATION
Safety Instruction -Trained Personnel Only! Only trained and qualified personnel should perform installation,
adjustments, and servicing. Only a properly trained and qualified certified electrician should perform electric
installations and service.
Safety Instruction -Trained Personnel Only! Only trained and qualified personnel should perform installation,
adjustments, and servicing. Only a properly trained and qualified certified electrician should perform electric
installations and service.
Lifting Hazard! Manually lifting over 55 lb (25kg) 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.
Safety Instruction –Installation! The INFLEXION should be installed on a location that is out of reach from
unauthorized personnel.
2.1 INTRODUCTION
The INFLEXION has been designed to provide for ease of installation. This section of the manual provides the
procedures that must be followed to ensure a successful installation. Be sure to read and understand the entire
installation procedure before you begin.
2.2 TOOLS AND MATERIALS REQUIRED FOR INSTALLATION
Table 2-1 provides a list of tools and materials required to install and test the INFLEXION.
Wrenches
Crimping tool or Solder set
Screwdrivers
Wire cutter/stripper
½ inch or M12 Mounting Hardware (6 each)
Multimeter (to verify power is turned OFF)
Torque wrench
Clean Shop Rags
Drill

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Hoist (minimum 250 lb capacity)
Table 2-1 Tools and Materials Required for Installation
2.3 UNPACKING
Unpack the INFLEXION as follows:
1. Carefully open and remove all parts from shipping container.
2. Lift the unit from the shipping container by the base tube at the center of gravity of the mast shown by the
symbol.
3. Inspect for any shipping damage. If damage has occurred, notify carrier.
4. Be sure that all components are included and that the required tools are readily available.
2.4 ATTACHING TO VEHICLE
If the INFLEXION is mounted in a well on a vehicle, be certain that adequate drainage is provided. A minimum of (4)
drain holes (one per corner) at least half inch in diameter is recommended to be drilled in the well around the unit so
that water drains out of the well. While the unit has been designed to withstand adverse environmental conditions, it
cannot be submerged.
9/16” bolt holes will be needed to mount mast (Figure 2-1) to the vehicle. It is important that the surface be flat such
that the saddle and base plate are in the same plane. The areas to which the unit is mounted must be reinforced to
withstand operating loading. Torque all hardware as appropriate for its material and size. There are (3) unplugged
strain relief holes in the side of the base for cable entry.

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Figure 2-1
INFLEXION 4.5 Mounting Hole Pattern Shown
See section 1.4 for other hole patterns.
2.5 CONNECTING DC POWER TO THE BASE
1. From the customer supplied 12 VDC power supply, run the red and black 12V DC power wires through one
of the strain reliefs in the side of the base. Ensure the cables are at least AWG 12 and no longer than 50ft
from the power supply to the base board.
2. Locate terminal block TB3.

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3. Connect the positive, red, 12 VDC cable to 7 PWR and connect the negative, black, cable to 8 COM.
4. Upon receipt of the INFLEXION, the hand-held controller should already be wired to the green base board
connector.
Terminal Block TB3

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2.6 PRE-OPERATIONAL CHECK
Before beginning installation, make certain that the area is free of overhead power lines and other
unwanted sources of electricity. Follow OSHA safety regulations when working near energized power
lines. Be sure to allow sufficient clearance on all sides of mast to allow for side sway.
This mast is for outdoor use only. Do not use in areas that have been classified as hazardous as
defined in Article 500 of the National Electric Code.
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. Contact with
combustible materials can cause ignition resulting in fire or explosion.
Before operating the INFLEXION, be sure that there are no overhead obstructions and that there are no power lines
within 20 feet of the mast. Visually inspect the unit for any damage. If damage is apparent, do not use the mast. Have
it serviced prior to use. Check for any objects which might obstruct motion of the mast or cause binding. Remove any
material that may hinder mast function.
2.7 FUNCTIONAL TESTS
To test the installation, proceed as follows. If any part of the testing fails, check the LEDs on the base
board as described in Section 4.4:
1. Check for proper clearance above the mast.
2. Press and hold the “Mast Up” button until the mast is fully deployed. The mast should raise to 90o
then go fully deployed. There is no Auto-up feature.
3. Release the “Mast Up” button. Press and hold the “Mast Down” button. The mast should lower
to 90othen stow and turn power off. There is no Auto-stow feature.

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CHAPTER 3
OPERATING INSTRUCTIONS
All operators must read the Operation section of this manual and be properly trained.
Keep personnel clear of mast while during operation.
For outdoor use only. Do not use in areas that have been classified as hazardous as defined in Article
500 of the National Electric Code.
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. Contact with
combustible materials can cause ignition resulting in fire or explosion.
Before operating, make certain that the area is free of overhead power lines and other unwanted
sources of electricity. Be sure to allow sufficient clearance on all sides of mast to allow for side sway.
Do not move vehicle until mast has been securely stowed.

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3.1 GENERAL MAST OPERATION
The mast hand-held controller (Figure 3-1).has a momentary toggle switch and a cord that is wired into the baseboard.
When the “Mast Up” button is pressed and held, the INFLEXION operates the DC powered actuator and drives the mast
from the stowed position to the 90oposition. Releasing the “Mast Up’ switch at any time stops mast motion. Note there
is no Auto-up feature to automatically raise the mast to 90o. When at 90o, the 90oproximity switch detects the magnet
in the actuator arm and stops further driving of the actuator. Pressing and holding the “Mast Up” switch will raise the
mast until the mast is fully deployed and the mast up switch is sensed. When the mast up switch is sensed, air into the
mast is stopped and the mast is left fully deployed.
To stow the mast, you must first ensure the payload is positioned to be stowed. There are no controls on the hand held
remote to pan or tilt the payload. The payload may have to be manually positioned for stowing.
When the “Mast Down” button is pressed and held, the INFLEXION releases air from the mast and the mast lowers to
the 90oposition. Once the 90osensor is reached and the “Mast Down” switch is held down, the electric actuator lowers
the mast to the stowed position in the saddle. When the stow switch is sensed, the actuator stops. The INFLEXION
remains powered until manually turned off.
Figure 3-1 Hand-held Controller
UP Position
Down Position
Momentary Toggle Switch

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3.2 EMERGENCY STOW (LOSS OF POWER):
Make sure all power has been disconnected from the INFLEXION prior to manually lowering mast.
In the event of power loss, the INFLEXION mast will vent and lower automatically but the mast will not return to its fully
stowed horizontal position. If possible, this must be accomplished manually and must be done with extreme caution. It
may be necessary to manually pan the payload so that when it is manually stowed, the payload does not make contact
with the mounting surface or the saddle. Consult payload manufacturer to determine if best way to move the payload
without power.
To emergency stow the mast, proceed as follows:
1. Remove the base access cover.
2. Make sure all power has been disconnected from the system by turning all breakers to the OFF position.
3. Ensure your payload is secure and may by safely lowered.
4. Remove the base cover.
5. Remove the 6mm Allen (set screw) on the end of the actuator cover (Figure 3-2 Emergency Stow Allen
Screw Location).
6. Place a long 6mm Allen wrench into the hole to reach the 6mm Allen-head drive screw. A socket Allen
wrench may be used but care must be taken not to damage the adjacent air compressor.
7. Turn the socket Allen wrench clockwise to lower the mast. Lower the mast until it seats firmly in the
saddle.
8. Replace the 6mm Allen set screw.
9. Replace the right side base cover.
Figure 3-2 Emergency Stow Allen Screw Location
Set Screw

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