Will Burt Inflexion Plus 1.8 Operating Instructions Manual
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Will Burt Inflexion Plus 1.8 Operating Instructions Manual

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Inflexion Plus 1.8, 2.3, 3.0, 4.5, 6.0, & 7.5 Operating
Inflexion Plus (721500020)
The Will-Burt Company
401 Collins Blvd
Orrville, OH 44667, USA
Instructions
Inflexion Plus PI-35 ( 720777102)
Phone: +1 330 684 4000
E-Mail: info@willburt.com
Website: www.willburt.com
Authorized Representative:
Will-Burt Germany GmbH & Co. KG
Fischergasse 25
D-91344 Waischenfeld, Germany
Inflexion Plus PI-75 (722515210)
TP-5211901-C, June 2021
© 2021 The Will-Burt Company
Original Instructions

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Summary of Contents for Will Burt Inflexion Plus 1.8

  • Page 1 Inflexion Plus 1.8, 2.3, 3.0, 4.5, 6.0, & 7.5 Operating Instructions Inflexion Plus PI-35 ( 720777102) Inflexion Plus (721500020) Inflexion Plus PI-75 (722515210) The Will-Burt Company Phone: +1 330 684 4000 TP-5211901-C, June 2021 401 Collins Blvd E-Mail: info@willburt.com © 2021 The Will-Burt Company Orrville, OH 44667, USA Website: www.willburt.com...
  • Page 3 INFLEXION PLUS OPERATING INSTRUCTIONS 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;...

  • Page 4: Table Of Contents

    INFLEXION PLUS OPERATING INSTRUCTIONS 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 ......................
  • Page 5 INFLEXION PLUS OPERATING INSTRUCTIONS 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....................
  • Page 6 INFLEXION PLUS OPERATING INSTRUCTIONS PAGE 4 OF 102 TP-5211901-C JUNE 2021...

  • Page 7: Safety Summary

    INFLEXION PLUS OPERATING INSTRUCTIONS 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.
  • Page 8 INFLEXION PLUS OPERATING INSTRUCTIONS 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.
  • Page 9 INFLEXION PLUS OPERATING INSTRUCTIONS 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.
  • Page 10 INFLEXION PLUS OPERATING INSTRUCTIONS 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.
  • Page 11 INFLEXION PLUS OPERATING INSTRUCTIONS 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.
  • Page 12 INFLEXION PLUS OPERATING INSTRUCTIONS 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: •...

  • Page 13: Symbols Used On Product Labels

    INFLEXION PLUS OPERATING INSTRUCTIONS 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.
  • Page 14 INFLEXION PLUS OPERATING INSTRUCTIONS 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. PAGE 12 OF 102 TP-5211901-C JUNE 2021...

  • Page 15: Specification Compliance

    INFLEXION PLUS OPERATING INSTRUCTIONS Specification Compliance 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 CE Declaration of Conformity Refer to the Product page at www.willburt.com for the latest Declaration of Conformity.
  • Page 16 INFLEXION PLUS OPERATING INSTRUCTIONS PAGE 14 OF 102 TP-5211901-C JUNE 2021...

  • Page 17: Introduction

    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) •...

  • Page 18: Additional Documentation

    INFLEXION PLUS OPERATING INSTRUCTIONS 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: •...

  • Page 19: Definitions

    INFLEXION PLUS OPERATING INSTRUCTIONS 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 •...

  • Page 20: Mast Position Definition

    INFLEXION PLUS OPERATING INSTRUCTIONS 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: •...

  • Page 21: Positioner Positions

    INFLEXION PLUS OPERATING INSTRUCTIONS Positioner Positions • Stowed: refers to a factory-set preset position which the positioner moves the payload to the desired pan and tilt position for travel or safe storage. This is set to the Auxiliary Lights button on the HHRC.

  • Page 22: Mast Component Descriptions

    INFLEXION PLUS OPERATING INSTRUCTIONS Mast Component Descriptions The Inflexion Plus models normally mount to a vehicle roof and consist of a: • Mast • Base • Saddle • Positioner (if applicable) •PositionIt™ PI-35 (P/N: 5467802) •PositionIt™ PI-75 (P/N: 5191201) •PositionIt™ Saddle The exact configuration of the Inflexion Plus may vary.
  • Page 23 INFLEXION PLUS OPERATING INSTRUCTIONS Top Platform Stowed Limit Switch Not Shown 90° Switch Actuator Safety Valve Air Compressor Figure 3-7 Right Side of Models 1.8 and 2.3 (Base Cover Removed) Top Platform Not Shown Magnetic Down Switch Tube Section Collars Mast 90°...
  • Page 24 INFLEXION PLUS OPERATING INSTRUCTIONS Tube Section Collars Top Platform Not Shown Magnetic Down Switch (Hidden) Mast 90° Switch Saddle Rubber Padding Access Holes Base Circuit Board Look-Up Light Air Compressor Figure 3-9 Left Side of Models 3.0, 4.5, 6.0, and 7.5 with Optional Air Compressor (Base Cover Removed) Mast: The mast consists of concentric tube sections that extend as air pressure is applied.
  • Page 25 INFLEXION PLUS OPERATING INSTRUCTIONS Base Board: The PC Board (PCB) contains the system logical controller and provides landing points for customer power supply and vehicle interlock cables. The PCB also distributes DC (and optional AC) power to components in the system. Figure 3-10 Base Board (P/N: 4311701) Wiring/Air Access Panel: The wiring/air access panel provides interface points to attach supply air and power/data cables.
  • Page 26 INFLEXION PLUS OPERATING INSTRUCTIONS Tilt Actuator: This actuator tilts the mast. Actuator Figure 3-11 Right Side of Models 3.0, 4.5, 6.0, and 7.5 (Base Cover Removed) Safety Valve: This valve prevents over-pressurization of the mast system. Air Control Valve Assembly: The air control valve assembly consists of the extend and exhaust valve and factory set regulator to control pressure into the mast.

  • Page 27: Positioners

    INFLEXION PLUS OPERATING INSTRUCTIONS Positioners 3.7.1 PositionIt™ PI-35 (P/N: 5467802) The PositionIt™ PI-35 pan and tilt positioner (Figure 3-12): • Is made of die-cast aluminum casing • Uses stainless steel fasteners • Has weather and dust proofing to an IP68 rating •...

  • Page 28: Positionit™ Pi-75

    INFLEXION PLUS OPERATING INSTRUCTIONS 3.7.2 PositionIt™ PI-75 The PositionIt™ PI-75 pan and tilt positioner (Figure 3-13): • Is made of die-cast aluminum casing • Uses stainless steel fasteners • Has weather and dust proofing to an IP68 rating • Is designed to minimize backlash •...

  • Page 29: Remote Control Options

    INFLEXION PLUS OPERATING INSTRUCTIONS Remote Control Options There are three options for controlling the mast functions. Each option provides full system control. See Figure 3-15 for a picture of each option. 1. Wired Hand-Held Remote Control (HHRC): This option includes a 25 foot (7.6 meters) quick connect coil cord and LED display.
  • Page 30 INFLEXION PLUS OPERATING INSTRUCTIONS PAGE 28 OF 102 TP-5211901-C JUNE 2021...

  • Page 31: Technical Data

    INFLEXION PLUS OPERATING INSTRUCTIONS Technical Data Inflexion Plus Extended Height (ft / m) 5.2 / 1.6 6.6 / 2.0 9 / 2.7 14 / 4.2 19 / 5.8 24 / 7.3 System Weight Range (lb / kg) 63 / 29 66 / 30 105 / 47 113 / 51...
  • Page 32 INFLEXION PLUS OPERATING INSTRUCTIONS PositionIt PI-35 Positioners PositionIt PI-75 Maximum Payload Capacity 35 / 47.4 75 / 101 (ft.-lb. / Nm) Overall Height (in / mm) 9.72 / 246.8 11.32 / 287.7 Overall Width (in / mm) 9.61 / 244.1 9.7 / 246.0 Weight (lb.

  • Page 33: Installation

    INFLEXION PLUS OPERATING INSTRUCTIONS Installation This section describes the physical and electrical installation of the Inflexion Plus and provides the general procedures that must be followed to ensure a successful installation. Be sure to read and understand the entire installation procedure and the Safety Summary (Section 1) before beginning installation.

  • Page 34: Recommended Installation Tools

    INFLEXION PLUS OPERATING INSTRUCTIONS Recommended Installation Tools Table 5-1 lists recommended tools and materials for installation. Table 5-1 Recommended Installation Tools & Materials Tools and Materials Safety Glasses Safety Gloves Safety Shoes Hard Hat or Helmet Hearing Protection Crimping Tool or Solder Set Wrenches Screwdrivers Multimeter (to verify power is turned off)
  • Page 35 INFLEXION PLUS OPERATING INSTRUCTIONS 3. Ensure all components are included and that the required tools are readily available. The components in the system shipment are shown in Table 5-2. Table 5-2 Components in the System Ship Base Assembly DC Board Power Exhaust Hose Controller (Selected Cable...

  • Page 36: Attaching To Mounting Location

    INFLEXION PLUS OPERATING INSTRUCTIONS Attaching to Mounting Location Physically attach the system as follows: 1. Reference Figure 5-3 for standard mounting hole locations. These locations will vary based on which system you are using. Measure the hole locations to confirm or use the unit as a template to mark before drilling.

  • Page 37: Positioner Mounting

    INFLEXION PLUS OPERATING INSTRUCTIONS 5.4.1 Positioner Mounting The PositionIt™ saddle ships assembled to the base. It may be necessary to remove the two bolts that secure the PositionIt™ saddle to the base in order to mount the system to the vehicle. When installing, the mast should be tilted to the vertical position.

  • Page 38: Attaching The Air Connections

    INFLEXION PLUS OPERATING INSTRUCTIONS Attaching the Air Connections This section describes how to make the air connections for 3.0, 4.5, 6.0, and 7.5 models. Two barbed fittings are provided for connecting the air-lines required to pressurize and exhaust the system (see Figure 5-4). Air may be supplied externally by a compressor or other source of clean, dry air with a maximum pressure of 100 psi (6.9 bar).

  • Page 39: Installing Remote Control

    INFLEXION PLUS OPERATING INSTRUCTIONS Installing Remote Control This section provides information to install the remote control. Several options are available. Follow the instructions appropriate for your system. 5.6.1 Wired Hand Held Remote Control (HHRC) Go to section 5.6.2 to if you are installing the Panel Mount Remote Control (PMRC) or section 5.6.3 for the wireless control option.
  • Page 40 INFLEXION PLUS OPERATING INSTRUCTIONS Figure 5-5 HHRC Bulkhead Bracket Installation Dimensions The HHRC comes with a holder (see Figure 5-6) to hang the HHRC. Attach the HHRC holder at a convenient location to hang the HHRC in a dry, protected environment. To install the holder: 1.

  • Page 41: Panel Mount Remote Control (Pmrc)

    INFLEXION PLUS OPERATING INSTRUCTIONS Figure 5-6 HHRC Holder 5.6.2 Panel Mount Remote Control (PMRC) If your system was not ordered with the optional PMRC, go to section 5.7. The PMRC should be located where the operator has line-of-sight to the mast operating space. The PMRC should be located in a protected, dry location (the PMRC is IP54).

  • Page 42: Wireless Hand-Held Remote Control (Whhrc)

    INFLEXION PLUS OPERATING INSTRUCTIONS Figure 5-7 PMRC Panel Cutout Dimensions A loose wiring connector is shipped with the PMRC to allow cable routing in the vehicle. Once the cable is routed, wire the connector and attach the connector to the back of the PMRC. To wire the PMRC connector: 1.

  • Page 43: Electrical Installation

    INFLEXION PLUS OPERATING INSTRUCTIONS Electrical Installation Refer to the wiring diagrams in the Appendix section for electrical connections. These diagrams are also available at www.willburt.com. Be sure to follow the torque requirements shown on the wiring diagram. See 5.7.1 for wiring access panel. To electrically connect the mast system, proceed as follows: 1.

  • Page 44: Wiring Remote Control Cable To The Base Board

    INFLEXION PLUS OPERATING INSTRUCTIONS 5.7.1 Wiring Remote Control Cable to the Base Board The Bulkhead Cable (or PMRC Control Cable) connects the bulkhead, Remote Control, and Base Board. 3. Connect the wires from the Bulkhead Cable (or PMRC Control Cable) to the green J4 connector located on the top left of the Base Board ensuring the wires match the color strip on the J4 connector (Figure 5-10).

  • Page 45: Wiring Dc Source Power To The Mast Control Circuit

    INFLEXION PLUS OPERATING INSTRUCTIONS 5.7.2 Wiring DC Source Power to the Mast Control Circuit The mast control system requires DC power. Source DC power is provided by the installer from the vehicle battery. The mast system will operate with 12VDC or 24VDC source power. The power supply must be capable of supplying 15 Amps to the mast at 12VDC (or 10 Amps at 24VDC).

  • Page 46: Wiring Vehicle Safety Interconnect Circuit

    INFLEXION PLUS OPERATING INSTRUCTIONS 5.7.3 Wiring Vehicle Safety Interconnect Circuit The mast provides an isolated relay contact output to enhance integration into vehicle safety circuitry. This output indicates whether or not the mast is stowed to indicate it is safe to move the vehicle.

  • Page 47: Secure Wiring And Attach Cover

    INFLEXION PLUS OPERATING INSTRUCTIONS 5.7.5 Secure Wiring and Attach Cover 5. Secure all loose wires with wire ties. 6. Attach the 0.709 inch (18 mm) inside diameter ferrite (shipped loose with the mast) around the Control/DC cable as it enters the base. This ferrite provides EMI (electromagnetic interference) filtering.
  • Page 48 INFLEXION PLUS OPERATING INSTRUCTIONS Figure 5-13 PositionIt™ PI-75 Payload Mounting Hole Pattern PAGE 46 OF 102 TP-5211901-C JUNE 2021...

  • Page 49: Test The Installation

    INFLEXION PLUS OPERATING INSTRUCTIONS Test the Installation Review the Operation Section 6 and Safety Summary Section 1 and observe all safety dangers, warnings, and cautions before proceeding to test the installation. If any part of the testing fails, check the LEDs on the controller and Base Board. To test the installation, proceed as follows: 1.
  • Page 50 INFLEXION PLUS OPERATING INSTRUCTIONS PAGE 48 OF 102 TP-5211901-C JUNE 2021...

  • Page 51: Operation

    INFLEXION PLUS OPERATING INSTRUCTIONS Operation This section describes the operation of the system. Be sure to read and understand the entire operation procedure and the Safety Summary (Section 1) before beginning operation. Pre-Operation Check Before operating the system: 1. Ensure that there are no overhead obstructions. The system location should be no closer than a horizontal distance equal to the extended height of the mast away from power lines.

  • Page 52: Remote Control Functions

    INFLEXION PLUS OPERATING INSTRUCTIONS Remote Control Functions Using the Remote Control, the operator can perform an emergency stop and move the mast up and down. The following are the Remote Control buttons: 6.3.1 Presets The system is capable of having two preset positions as follows: •...
  • Page 53 INFLEXION PLUS OPERATING INSTRUCTIONS The customer can program an optional unstow preset position for the positioner to go to once at 90° or extended. To program the unstowed position: 1. Raise the mast to 90°. 2. Pan and tilt the positioner to the desired position. 3.

  • Page 54: Operating The Positioner

    INFLEXION PLUS OPERATING INSTRUCTIONS Operating the Positioner The positioner can be operated when the mast is in the 90° position, partially extended, or fully extended. To pan and tilt the positioner: • Press the Pan Right button to pan the positioner to the right. •...

  • Page 55: Quick Operation Summary

    INFLEXION PLUS OPERATING INSTRUCTIONS Quick Operation Summary Following is a quick summary of the operation of the system. Detailed steps follow the quick summary. If an emergency stop (E-Stop) is required at any time, press the “E-Stop” button. This will disconnect the unit from power and cause all air to be exhausted from the mast.

  • Page 56: Initiating (Power-Up)

    INFLEXION PLUS OPERATING INSTRUCTIONS Initiating (Power-Up) Perform the following to power up the system: 1. If the “E-Stop” was activated during prior use, it must be reset by turning to enable the system to power-up. Do not reset the “E-Stop” until the cause of the event is corrected. Turn the red “E-Stop”...

  • Page 57: Using The Auto-Up Feature

    INFLEXION PLUS OPERATING INSTRUCTIONS Two common operator errors can occur when the operator does not use the Auto-Up feature: 1. On uneven ground, an operator may believe the mast has reached 90° and release the "Mast Up" button too early. This could cause an error when the operator wants to use certain controller functions since the mast must be at 90°...

  • Page 58: Lowering The Mast

    INFLEXION PLUS OPERATING INSTRUCTIONS Lowering the Mast Once the mast has been extended, pressing "Mast Down" will lower the mast. Continue to press "Mast Down" until the mast reaches the desired height and then release the button. 6.10 Stowing the Mast The "stowed"...

  • Page 59: Using The Auto Stow® Feature

    INFLEXION PLUS OPERATING INSTRUCTIONS 6.10.1 Using the Auto Stow® Feature ® Using the Auto Stow feature does not require the operator to stop the mast exactly in the saddle. The mast can be auto-stowed from any position including 90°, partially extended, or fully ®...

  • Page 60: Emergency Stow With Power

    INFLEXION PLUS OPERATING INSTRUCTIONS 6.10.3 Emergency Stow with Power If the mast cannot be stowed using the Auto Stow® feature or "Mast Down" button, the emergency stow button (S4) on the Base Board can be used to stow the mast if the following are both true: •...

  • Page 61: Emergency Stow Without Power

    INFLEXION PLUS OPERATING INSTRUCTIONS 6.10.4 Emergency Stow without Power If power is lost or an unrecoverable error occurs, the mast will automatically exhaust all air and lower to its nested height. However, the mast will not return to its fully stowed, horizontal position. Since there is no power to run the actuator, the emergency stow button cannot be used and the mast must be stowed manually.
  • Page 62 INFLEXION PLUS OPERATING INSTRUCTIONS PAGE 60 OF 102 TP-5211901-C JUNE 2021...

  • Page 63: Maintenance, Adjustments And Disposal

    INFLEXION PLUS OPERATING INSTRUCTIONS Maintenance, Adjustments and Disposal This section describes the routine maintenance and adjustment procedures required to keep the system operational. Be sure to read and understand the entire operation procedure and the Safety Summary (Section 1) before beginning any maintenance or adjustment procedure. Pre-Maintenance Check Before performing maintenance procedures, ensure: •...

  • Page 64: Power Isolating Procedure

    INFLEXION PLUS OPERATING INSTRUCTIONS Power Isolating Procedure Remove all power sources from the mast system including mast controls and auxiliary device power before performing any maintenance operation on the mast system other than optional cleaning and lubricating. Use proper lock-out tag-out procedures. To isolate power to the mast system: 1.
  • Page 65 INFLEXION PLUS OPERATING INSTRUCTIONS To clean and lubricate the mast: 1. While at the 90° position, have one person press the "Mast Up" button to slowly pressurize the mast just enough to extend the desired mast section. A second person may have to hold down the larger mast section collars to ensure the desired tube extends.

  • Page 66: Positioner Routine Maintenance

    INFLEXION PLUS OPERATING INSTRUCTIONS Positioner Routine Maintenance Maintain the positioner as follows: • Visually inspect to ensure the positioner is kept clean. • Visually inspect for damage. If damage is apparent, do not use the positioner and have it serviced prior to use. •...

  • Page 67: Periodic Inspections

    INFLEXION PLUS OPERATING INSTRUCTIONS Periodic Inspections This section describes the systematic care and inspection of equipment to keep it in safe operating condition and to prevent breakdowns. If the system does not perform as required, see Section 9 for troubleshooting. If anything looks wrong and cannot be diagnosed and/or fixed, contact The Will-Burt Company.

  • Page 68: Adjusting The 90° And Mast Stowed Limit Switches

    INFLEXION PLUS OPERATING INSTRUCTIONS Table 7-2 Periodic Inspections (Continued) Frequency Inspection Action Every 6 Months With the mast fully stowed, carefully If mechanical play is observed, lift up on the RCP housing (do not lift adjust the mast stowed limit switch by the light fixtures).

  • Page 69: Diagnostic Leds On The Base Pc Board

    INFLEXION PLUS OPERATING INSTRUCTIONS 7.8.1 Diagnostic LEDs on the Base PC Board The PC Board mounted at the mast Base has LED indicator lights useful for diagnostics for circuits. Table 7-3 charts the colors of the relevant diagnostic LEDs for the various mast positions.

  • Page 70: Adjusting The Mast 90° Limit Switch

    INFLEXION PLUS OPERATING INSTRUCTIONS 7.8.2 Adjusting the mast 90° Limit Switch The 90° Switch (Figure 7-2 and Figure 7-3) senses when the mast is at 90° by checking the position of the actuator. There is a magnet mounted to the actuator arm that triggers the limit switch.
  • Page 71 INFLEXION PLUS OPERATING INSTRUCTIONS 9. Replace the base cover. Mast Stowed Switch 90° Mast Switch Figure 7-2 Models 1.8 and 2.3 Mast Stowed and 90° Switch Mast 90° Switch Mast Stowed Switch Figure 7-3 Models 3.0, 4.5, 6.0, and 7.5 Mast Stowed and Mast 90° Limit Switch Locations (Cover Removed) TP-5211901-C PAGE 69 OF 102...

  • Page 72: Adjusting The Mast Stowed Limit Switch

    INFLEXION PLUS OPERATING INSTRUCTIONS 7.8.3 Adjusting the Mast Stowed Limit Switch The Mast Stowed (near 0°) Switch (Figure 7-2 and Figure 7-3) senses that the mast is in the saddle upon power-up, and when the mast is nearing the saddle during stowing. The circuit then looks for a pre-determined current rise (for a maximum of 0.5 seconds) to indicate a solid nesting before shutting off.

  • Page 73: Adjusting The Mast Magnetic Down Switch

    INFLEXION PLUS OPERATING INSTRUCTIONS 7.8.4 Adjusting the Mast Magnetic Down Switch The Mast Magnetic Down Switch tells the control system the mast is fully retracted and allows the mast to tilt back to the stowed position. The Magnetic Down Switch is band-clamped to the base tube.

  • Page 74: System Disposal

    INFLEXION PLUS OPERATING INSTRUCTIONS System Disposal Dispose of the Mast in accordance with the national environmental regulations. PAGE 72 OF 102 TP-5211901-C JUNE 2021...

  • Page 75: Reference Information

    INFLEXION PLUS OPERATING INSTRUCTIONS Reference Information This section describes reference information for your system including some optional equipment. DIP Switch Definitions DIP Switches on the Base Board and the RCP PC board are set at the factory and normally do not have to be changed.

  • Page 76: D-Tec® Functionality

    INFLEXION PLUS OPERATING INSTRUCTIONS The cable used to connect the Sensor unit to the positioner should be connected to the bottom of the Sensor unit and wired into the base PC board. Consult The Will-Burt Company’s engineering for electrically connecting the D-TEC® Sensor. 8.2.2 D-TEC®...
  • Page 77 INFLEXION PLUS OPERATING INSTRUCTIONS The D-TEC® Sensor is not serviceable, so most issues will end with returning the sensor to The Will-Burt Company for repair. The following table shows D-TEC® error code meanings: Table 8-2 D-TEC® Sensor Error Codes Message Meaning Root Issue Potential Cause...

  • Page 78: Nycoil® (Optional)

    INFLEXION PLUS OPERATING INSTRUCTIONS Table 8-2 D-TEC® Sensor Error Codes (Continued) Message Meaning Root Issue Potential Cause 5,16 Supply Voltage The power Check power connections, voltage level Fault supply section of and induced noise on power source. the D-TEC® sensor is outside proper operational limits.

  • Page 79: The Will-Burt Company Mast Oil Safety Data Sheet

    INFLEXION PLUS OPERATING INSTRUCTIONS The Will-Burt Company Mast Oil Safety Data Sheet TP-5211901-C PAGE 77 OF 102 JUNE 2021...
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  • Page 81 INFLEXION PLUS OPERATING INSTRUCTIONS TP-5211901-C PAGE 79 OF 102 JUNE 2021...
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  • Page 83: Troubleshooting

    INFLEXION PLUS OPERATING INSTRUCTIONS Troubleshooting This section describes system troubleshooting information. Please contact The Will-Burt Company if these guides do not solve the issue. Be sure to read and understand the entire operation procedure and the Safety Summary (Section 1) beginning any maintenance or troubleshooting procedure.
  • Page 84 INFLEXION PLUS OPERATING INSTRUCTIONS Table 9-1 Error and Warning Codes for Base Board (Continued) Message Meaning Root Issue Potential Cause 1,01 Mast Down (mag switch) This is only checked at 1. The magnetic sensor - Sensor State Error power up, if stowed. is not being energized or Sensor outputs are O.K., is defective...
  • Page 85 INFLEXION PLUS OPERATING INSTRUCTIONS Table 9-1 Error and Warning Codes for Base Board (Continued) Message Meaning Root Issue Potential Cause 1,06 Well Open (vertical with Switch outputs are O.K., Well cover open or well cover) - Switch but show wrong polarity wiring error.
  • Page 86 INFLEXION PLUS OPERATING INSTRUCTIONS Table 9-1 Error and Warning Codes for Base Board (Continued) Message Meaning Root Issue Potential Cause 1,12 Sensor Output Error Sensor outputs are bad Wiring error, faulty sensor Roof-mount - Actuator at 90° magnetic sensor (Vertical only) mag switch positioning.
  • Page 87 INFLEXION PLUS OPERATING INSTRUCTIONS Table 9-1 Error and Warning Codes for Base Board (Continued) Message Meaning Root Issue Potential Cause 1,19 Both Near 0° and 90° - Both the Nested LS and Both sensors indicate Sensor State Error the 90° LS have been proximity, one may be detected active at the same time.
  • Page 88 INFLEXION PLUS OPERATING INSTRUCTIONS Table 9-2 Error and Warning Codes for RCP (Continued) Message Meaning Root Issue Potential Cause WRN 2,06 Pan Stuck Checked only when Something is preventing moving out of a limit movement of pan position. mechanism, the motor is defective, or the RCP board is defective The software indicates...
  • Page 89 INFLEXION PLUS OPERATING INSTRUCTIONS Table 9-2 Error and Warning Codes for RCP (Continued) Message Meaning Root Issue Potential Cause 2,11 Right Tilt Up wrap The software indicates 1. The flag that around the same photosensor interrupts the light may was made before the need to be adjusted to opposite limit go deeper into the...
  • Page 90 INFLEXION PLUS OPERATING INSTRUCTIONS Table 9-3 Error and Warning Codes for HHRC (Continued) Message Meaning Root Issue Potential Cause WRN 3.07 Unrecoverable The display board in the Defective HHRC or Communication Error HHRC or PMRC has defective base board. power, but the Base Bad or improper Board is not connection in...

  • Page 91: Troubleshooting Mechanical Symptoms

    INFLEXION PLUS OPERATING INSTRUCTIONS Table 9-4 Error and Warning Codes for Wireless HHRC (Continued) Message Meaning Root Issue Potential Cause 8,10 Memory Error Memory Error 8,11 HHRC power up Unit could not establish Wireless HHRC is not negotiation failed communication with any plugged in during power- HHRC (wired or wireless) when the NS...
  • Page 92 INFLEXION PLUS OPERATING INSTRUCTIONS Table 9-5 Mechanical Symptoms and Troubleshooting Sequence (Continued) Symptom Root Issue Troubleshooting Sequence Mast leaks down Air leak in mast or valve/ Use a soapy water solution to pinpoint when extended compressor assembly the leak. If the mast is leaking, it will require new seals.

  • Page 93: Positioner Troubleshooting

    INFLEXION PLUS OPERATING INSTRUCTIONS Positioner Troubleshooting Do not open the positioner. Opening the positioner breaks the environmental seal and potentially causes improper stop limit settings. This voids the warranty. Table 9-6 describes troubleshooting of the positioner. Table 9-6 Troubleshooting the Positioner Symptoms Possible Cause Remedy...
  • Page 94 INFLEXION PLUS OPERATING INSTRUCTIONS PAGE 92 OF 102 TP-5211901-C JUNE 2021...

  • Page 95: 10 Document History

    INFLEXION PLUS OPERATING INSTRUCTIONS 10 Document History Table 10-1 Document History Changes Backward Document Compatible Date Change Details Revision with Previous Manual Version TP-5211901- May 2015 Initial Release TP-5211901-A Apr. 2016 General Update TP-5211901-B Nov. 2016 Updated Section 4.5.1 Updated to CE format. Added information TP-5211901-C June 2021 about the PositionIt PI-35 and the...
  • Page 96 INFLEXION PLUS OPERATING INSTRUCTIONS PAGE 94 OF 102 TP-5211901-C JUNE 2021...

  • Page 97: 11 Appendix

    INFLEXION PLUS OPERATING INSTRUCTIONS 11 Appendix This section contains the appendixes for the system. 11.1 Installing a Wired HHRC with J-Box To electrically connect a wired HHRC with a J-Box, follow the instructions in Section 5 for Wiring the Base Board, and use the following schematic (Figure 11-1). Figure 11-1 Alternate Wiring Using J-Boxes 11.2 System Wiring Diagram The system wiring diagrams are as follows:...

  • Page 98: Inflexion Plus

    INFLEXION PLUS OPERATING INSTRUCTIONS 11.2.1 Inflexion Plus FORCED STOW PAGE 96 OF 102 TP-5211901-C JUNE 2021...
  • Page 99 INFLEXION PLUS OPERATING INSTRUCTIONS TP-5211901-C PAGE 97 OF 102 JUNE 2021...
  • Page 100 INFLEXION PLUS OPERATING INSTRUCTIONS PAGE 98 OF 102 TP-5211901-C JUNE 2021...
  • Page 101 INFLEXION PLUS OPERATING INSTRUCTIONS TP-5211901-C PAGE 99 OF 102 JUNE 2021...

  • Page 102: Positionit™ Pi-35

    INFLEXION PLUS OPERATING INSTRUCTIONS 11.2.2 PositionIt™ PI-35 PAGE 100 OF 102 TP-5211901-C JUNE 2021...
  • Page 103 INFLEXION PLUS OPERATING INSTRUCTIONS TP-5211901-C PAGE 101 OF 102 JUNE 2021...

  • Page 104: Positionit™ Pi-75

    INFLEXION PLUS OPERATING INSTRUCTIONS 11.2.3 PositionIt™ PI-75 PAGE 102 OF 102 TP-5211901-C JUNE 2021...

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