Flex 8EX2 System: Radio Control Equipment Instruction Manual

Flex 8EX2 System
Radio Control Equipment

Instruction Manual
Part Number: 191-50800-M000F R01

June 2019
©Copyright 2019 Magnetek Material Handling
Distributed by Ergonomic Partners

[email protected]
www.ErgonomicPartners.com
Tel: (314) 884-8884
Page Intentionally Left Blank
Flex 8EX2 Instruction Manual

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Table of Contents
1 Introduction......................................................................................................................................... 7
2 Radio Controlled Safety ..................................................................................................................... 8
2.1 Critical Installation Considerations ............................................................................................... 9
2.2 General......................................................................................................................................... 9
2.3 Persons Authorized to Operate Radio Controlled Cranes............................................................ 9
2.4 Safety Information and Recommended Training for Radio Controlled Equipment Operators.... 10
2.5 Transmitter Unit.......................................................................................................................... 11
2.6 Pre-Operation Test..................................................................................................................... 11
2.7 Batteries ..................................................................................................................................... 11
3 General System Information............................................................................................................ 12
3.1 Transmitter ................................................................................................................................. 12
3.1.1 External Illustration ................................................................................................................ 12
3.1.2 Internal Illustration ................................................................................................................. 13
3.2 Receiver ..................................................................................................................................... 14
3.2.1 External Illustration ................................................................................................................ 14
3.2.2 Internal Illustration ................................................................................................................. 15
4 Function Settings ............................................................................................................................. 16
4.1 Transmitter ................................................................................................................................. 16
4.1.1 Transmitter Firmware Version ............................................................................................... 16
4.1.2 Display Frequency Band........................................................................................................ 16
4.1.3 Transmitter Channel Settings ................................................................................................ 16
4.1.4 Remote Pairing ...................................................................................................................... 18
4.1.5 I-Chip ..................................................................................................................................... 19
4.1.6 Transmitter Output Power Settings........................................................................................ 19
4.1.7 Transmitter Inactivity Timer Settings .....................................................................................20
4.1.8 Zero-G Sensor Settings ......................................................................................................... 20
4.1.9 Transmitter Start Function Settings .......................................................................................20
4.1.10 Infrared Programming ............................................................................................................ 21
4.1.11 Output Feedback Settings ..................................................................................................... 21
4.1.12 Pushbutton Function Settings ................................................................................................ 21
4.2 Receiver ..................................................................................................................................... 27
4.2.1 Receiver Channel Dipswitch .................................................................................................. 27
4.2.2 Receiver Channel Settings .................................................................................................... 27
4.2.3 Receiver Channel Scanning Function ................................................................................... 28
4.2.4 System Channels Table......................................................................................................... 29
4.2.5 Output Relay Configurations.................................................................................................. 30
4.2.6 Receiver Function Dipswitch Settings ................................................................................... 34
4.2.7 Jumper Settings ..................................................................................................................... 37
4.2.8 Voltage Settings..................................................................................................................... 38
4.2.9 Horn Installation ..................................................................................................................... 38
4.2.10 Other Function Output Relays Settings ................................................................................. 39
5 Receiver Installation......................................................................................................................... 40
5.1 Output Relay Contact Diagrams................................................................................................. 40
5.1.1 Flex 8EX2 (dual speed model) ..............................................................................................40
5.2 Pre-installation Precautions........................................................................................................ 40
5.3 Step-by-Step Installation ............................................................................................................ 41
6 Operating Procedures ...................................................................................................................... 44
6.1 General Operation...................................................................................................................... 44
6.2 Tandem System Operation ........................................................................................................ 45
6.3 A/B Rotary Select Operation (AB Systems Only)....................................................................... 46

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6.4 Changing Batteries..................................................................................................................... 46
6.5 Battery Charging ........................................................................................................................ 46
6.6 System Status Light Indications ................................................................................................. 47
6.6.1 Transmitter Status Indications ............................................................................................... 47
6.6.2 Receiver Status Indications ................................................................................................... 48
6.6.3 Receiver Power Indications ................................................................................................... 48
6.6.4 Receiver COM Indications ..................................................................................................... 48
7 General Specifications ..................................................................................................................... 49

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SERVICE INFORMATION
Your New Radio Remote Control System

Thank you for your purchase of Magnetek’s Flex EX2 Radio Remote Equipment Control. Magnetek has set
a whole new standard in radio remote performance, dependability, and value with this unique new line of
handheld transmitters.
If your product ever needs modification or service, please contact one of our representatives at the
following locations:
U.S. Service Information

For questions regarding service or technical information contact:
1-314-884-8884
Headquarters:
Magnetek, Inc.
N49 W13650 Campbell Drive
Menomonee Falls, WI 53051
Telephone: 314-884-8884
Website: www.ErgonomicPartners.com
E-mail: [email protected]
© 2019 MAGNETEK
All rights reserved. This notice applies to all copyrighted materials included with this product, including, but
not limited to, this manual and software embodied within the product. This manual is intended for the sole
use of the person(s) to whom it was provided, and any unauthorized distribution of the manual or dispersal
of its contents is strictly forbidden. This manual may not be reproduced in whole or in part by any means
whatsoever without the expressed written permission of MAGNETEK.

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PRODUCT MANUAL SAFETY INFORMATION
Magnetek, Inc. (Magnetek) offers a broad range of radio remote control products, control products and
adjustable frequency drives, and industrial braking systems for overhead material handling applications.
This manual has been prepared by Magnetek to provide information and recommendations for the
installation, use, operation and service of Magnetek’s material handling products and systems (Magnetek
Products). Anyone who uses, operates, maintains, services, installs or owns Magnetek Products should
know, understand and follow the instructions and safety recommendations in this manual for Magnetek
Products.
The recommendations in this manual do not take precedence over any of the following requirements
relating to cranes, hoists and lifting devices:
• Instructions, manuals, and safety warnings of the manufacturers of the equipment where the radio
system is used,
• Plant safety rules and procedures of the employers and the owners of facilities where the
Magnetek Products are being used,
• Regulations issued by the Occupational Health and Safety Administration (OSHA),
• Applicable local, state or federal codes, ordinances, standards and requirements, or
• Safety standards and practices for the overhead material handling industry.
This manual does not include or address the specific instructions and safety warnings of these
manufacturers or any of the other requirements listed above. It is the responsibility of the owners, users
and operators of the Magnetek Products to know, understand and follow all of these requirements. It is the
responsibility of the owner of the Magnetek Products to make its employees aware of all of the above listed
requirements and to make certain that all operators are properly trained. No one should use Magnetek
Products prior to becoming familiar with and being trained in these requirements.
WARRANTY INFORMATION
FOR INFORMATION ON MAGNETEK’S PRODUCT WARRANTIES BY PRODUCT TYPE, PLEASE
VISIT WWW.MAGNETEK.COM.

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1 Introduction
The Flex EX2 radio remote control systems are designed for control of industrial equipment and machinery
such as overhead traveling cranes, jib cranes, gantry cranes, tower cranes, electric hoists, winches,
monorails, conveyor belts, mining equipment and other material handling equipment where wireless
control is preferred.
Each Flex EX2 system consists of a transmitter handset and receiver unit. Other standard-equipped
accessories include transmitter waist belt, spare transmitter power key, vinyl pouch, “AA” alkaline batteries,
pushbutton labels, output cable, and instruction manual CD.
List of notable features includes:
• Advanced Controls – the system utilizes dual advanced microprocessor controls with 32bit CRC
and Hamming Code, providing ultra-fast, safe, precise, and error-free encoding and decoding.
• Frequency Hopping RF Transceiver – the system automatically searches and locks onto a free
and uninterrupted channel at every system start-up or during operation when encountering radio
interference. The system is also capable of two-way communication between the transmitter and
receiver as well as receiver-to-receiver with system status and relay output feedbacks.
• Zero-G Sensor Embedded – the transmitter is embedded with a Zero-G sensor to guard against
any unintended control of the crane or equipment when transmitter is thrown or dropped.
• Wireless Remote Pairing Function – system information can be transferred wirelessly between
two transmitters or between a transmitter and a receiver without the hassle of resetting the spares.
• Reliable Pushbuttons – the pushbuttons have gold-plated contacts and are rated for more than
2 million press cycles. The defined snap-action steps provide positive tactile feedback even
through gloves.
• Low Power Consumption – requires only two “AA” alkaline batteries for more than 100 hours of
uninterrupted operation between replacements.
• Durable Nylon and Fiberglass Composite Enclosures – highly resistant to breakage and
deformation even in the most abusive environments. The receiver enclosures and output cables
are UL94-V0 rated. The transmitter and receiver enclosures are IP66 rated.
• Full Compliance – all systems fully comply with the FCC Part: 15 Rules and IC-RSS-210.
• Other Optional Accessories and Features – transmitter belt clip, transmitter lanyard, transmitter
rubber guard, buzzer, charging station, tandem function, multiple receivers function, and many
others.

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2 Radio Controlled Safety
WARNINGS and CAUTIONS
Throughout this document WARNING and CAUTION statements have been deliberately placed to
highlight items critical to the protection of personnel and equipment.
WARNING
WARNING indicates a potentially hazardous situation which, if not avoided, could result in death or
serious injury.
CAUTION
CAUTION indicates a potentially hazardous situation which, if not avoided, could result in minor or
moderate injury. It may also be used to alert against unsafe practices.
NOTE: A NOTE statement is used to notify people of installation, operation, programming, or

maintenance information that is important, but not hazard-related.
WARNINGS and CAUTIONS SHOULD NEVER BE DISREGARDED.

The safety rules in this section are not intended to replace any rules or regulations of any applicable local, state, or
federal governing organizations. Always follow your local lockout and tagout procedure when maintaining any radio
equipment. The following information is intended to be used in conjunction with other rules or regulations already in
existence. It is important to read all of the safety information contained in this section before installing or operating the
Radio Control System.

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2.1 Critical Installation Considerations
WARNING
Prior to installation and operation of this equipment, read and develop an understanding of the contents
of this manual and the operation manual of the equipment or device to which this equipment will be
interfaced. Failure to follow this warning could result in serious injury or death and damage to
equipment.
All equipment must have a mainline contactor installed and all tracked cranes, hoists, lifting devices
and similar equipment must have a brake installed. Failure to follow this warning could result in serious
injury or death and damage to equipment.
An audible and/or visual warning means must be provided on all remote controlled equipment as
required by code, regulation, or industry standard. These audible and/or visual warning devices must
meet all governmental requirements. Failure to follow this warning could result in serious injury or
death and damage to equipment.
Follow your local lockout tagout procedure before maintaining any remote controlled equipment.
Always remove all electrical power from the crane, hoist, lifting device or similar equipment before
attempting any installation procedures. De-energize and tagout all sources of electrical power before
touch-testing any equipment. Failure to follow this warning could result in serious injury or death and
damage to equipment.
The direct outputs of this product are not designed to interface directly to two state safety critical
maintained functions, i.e., magnets, vacuum lifts, pumps, emergency equipment, etc. A mechanically
locking intermediate relay system with separate power considerations must be provided. Failure to
follow this warning could result in serious injury or death or damage to equipment.
2.2 General
Radio controlled material handling equipment operates in several directions. Cranes, hoists, lifting devices
and other material handling equipment can be large and can operate at high speeds. The equipment is
often operated in areas where people are working in close proximity to the material handling equipment.
The operator must exercise extreme caution at all times. Workers must constantly be alert to avoid
accidents. The following recommendations have been included to indicate how careful and thoughtful
actions may prevent injuries, prevent damage to equipment, or even save a life.
2.3 Persons Authorized to Operate Radio Controlled

Cranes
Only properly trained persons designated by management should be permitted to operate radio controlled
equipment.
Radio controlled cranes, hoists, lifting devices and other material handling equipment should not be
operated by any person who cannot read or understand signs, notices and operating instructions that
pertain to the equipment.

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Radio controlled equipment should not be operated by any person with insufficient eyesight or hearing or
by any person who may be suffering from a disorder or illness that may cause them to lose control of the
equipment, is taking any medication that may cause loss of equipment control, or is under the influence of
alcohol or drugs.
2.4 Safety Information and Recommended Training for

Radio Controlled Equipment Operators
Anyone being trained to operate radio controlled equipment should possess as a minimum the following
knowledge and skills before using the radio controlled equipment.
The operator should:
• have knowledge of hazards pertaining to equipment operation
• have knowledge of safety rules for radio controlled equipment
• have the ability to judge distance of moving objects
• know how to properly test prior to operation
• be trained in the safe operation of the radio transmitter as it pertains to the crane, hoist, lifting
device or other material handling equipment being operated
• have knowledge of the use of equipment warning lights and alarms
• have knowledge of the proper storage space for a radio control transmitter when not in use
• be trained in transferring a radio control transmitter to another person
• be trained how and when to report unsafe or unusual operating conditions
• test the transmitter emergency stop and all warning devices prior to operation; testing should be
done on each shift, without a load
• be thoroughly trained and knowledgeable in proper and safe operation of the crane, hoist, lifting
device, or other material handling equipment that utilizes the radio control
• know how to keep the operator and other people clear of lifted loads and to avoid “pinch” points
• continuously watch and monitor status of lifted loads
• know and follow cable and hook inspection procedures
• know and follow the local lockout and tagout procedures when servicing radio controlled
equipment
• know and follow all applicable operating and maintenance manuals, safety procedures, regulatory
requirements, and industry standards and codes
The operator shall not:
• lift or move more than the rated load
• operate the material handling equipment if the direction of travel or function engaged does not
agree with what is indicated on the controller
• use the crane, hoist or lifting device to lift, support or transport people
• lift or carry any loads over people
• operate the crane, hoist or lifting device unless all persons, including the operator, are and remain
clear of the supported load and any potential pinch points
• operate a crane, hoist or lifting device when the device is not centered over the load
• operate a crane, hoist or lifting device if the chain or wire rope is not seated properly in the
sprockets, drum or sheave
• operate any damaged or malfunctioning crane, hoist, lifting device or other material handling
equipment
• change any settings or controls without authorization and proper training
• remove or obscure any warning or safety labels or tags
• leave any load unattended while lifted
• leave power on the radio controlled equipment when the equipment is not in operation

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• operate any material handling equipment using a damaged controller because the unit may be
unsafe
• operate manual motions with other than manual power
• operate radio controlled equipment when low battery indicator is on
WARNING
The operator should not attempt to repair any radio controller. If any product performance or safety
concerns are observed, the equipment should immediately be taken out of service and be reported to
the supervisor. Damaged and inoperable radio controller equipment should be returned to Magnetek
for evaluation and repair. Failure to follow this warning could result in serious injury or death and
damage to equipment.
2.5 Transmitter Unit

Transmitter switches should never be mechanically blocked on or off. When not in use, the operator should
turn the transmitter off. A secure storage space should be provided for the transmitter unit, and the
transmitter unit should always be placed there when not in use. This precaution will help prevent
unauthorized people from operating the material handling equipment.
Spare transmitters should be stored in a secure storage space and only removed from the storage space
after the current transmitter in use has been turned off, taken out of the service area and secured.
2.6 Pre-Operation Test

At the start of each work shift, or when a new operator takes control of the crane, operators should
do, as a minimum, the following steps before making lifts with any crane or hoist:
Test all warning devices.
Test all direction and speed controls.
Test the transmitter emergency stop.
2.7 Batteries
WARNING
Know and follow proper battery handling, charging and disposal procedures. Improper battery
procedures can cause batteries to explode or do other serious damage. Failure to follow this warning
could result in serious injury or death and damage to equipment.

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3 General System Information
3.1 Transmitter
3.1.1 External Illustration
1. STOP Button 9. Pushbutton 6 (PB6)
2. Power Key Switch 10. Pushbutton 7 (PB7)
3. Status LED Indicator 11. Pushbutton 8 (PB8)
4. Pushbutton 1 (PB1) 12. Future Feature
5. Pushbutton 2 (PB2) 13. Battery Cover Screw
6. Pushbutton 3 (PB3) 14. System Information
7. Pushbutton 4 (PB4) 15. Lanyard and Waist Belt

Attachment Slot
8. Pushbutton 5 (PB5)
NOTE: Flex 8EX2-AB and 8EX2-T models have the A/B/A+B rotary switch on PB8 slot.

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3.1.2 Internal Illustration
1. RF Transceiver Board 5. Infrared Sensors
2. Encoder Board 6. I-Chip Slot
3. Status LED Indicator 7. Function Dipswitch
4. A/B/C/D LED Indicators 8. Programming Port*
* The programming port is only used for updating the transmitter firmware. It is not used with the IR
Programmer. For more information, contact Magnetek field service.
NOTE: Flex 8EX2-AB and 8EX2-T models have the A/B/A+B rotary switch on PB8 slot.

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3.2 Receiver
3.2.1 External Illustration
1. External RP-TNC Antenna Port 7. Remote Pairing Button
2. COM LED Indicator 8. System Information
3. Status LED Indicator 9. Cord Grip
4. Power LED Indicator 10. Mounting Bracket
5. Output Relay LED Indicators 11. Mounting Bracket Release
6. Infrared Sensors

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3.2.2 Internal Illustration
1. Decoder Board 6. Function Jumpers
2. RF Transceiver Board 7. Channel Dipswitch
3. INT/EXT Antenna Jumpers 8. AC Line Filter/Relay Board
4. Programming Port 9. Power Transformer
5. Function Dipswitches 10. Voltage Selector

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4 Function Settings
4.1 Transmitter
4.1.1 Transmitter Firmware Version
1. Rotate the power switch key to the OFF ( 0 ) position.
2. With the STOP button elevated, press and hold PB1 and PB3
at the same time.
3. Rotate the power switch key to the ON ( I ) position.
4. Release PB1 and PB3 at the same time. The Status LED
displays firmware version with red, green and orange blinks.
5. Exit Firmware Version mode by rotating the power switch key
to the OFF ( 0 ) position.
4.1.2 Display Frequency Band

2. With the STOP button elevated, press and hold PB2 and PB4 at the same time.
4. Release PB2 and PB4 at the same time. The system will enter Frequency Band
Display mode.
5. The Status LED displays the preset transmitter frequency band with orange, green
and red blinks. An orange blink represents the hundreds (+100), a green blink
represents the tens (+010) and a red blink represents the units (+001). For example, 4
orange blinks followed by 3 green blinks and 3 red blinks is 433MHz.
6. Exit Frequency Band Display mode by rotating the power switch key to the OFF ( 0 )
position.
4.1.3 Transmitter Channel Settings

A. Unassigned Channel Scheme (no preset system channel)
When both transmitter and receiver are set to unassigned channel scheme (no
preset channel), the system automatically searches and locks onto a free and
uninterrupted channel at every transmitter start-up.
NOTE: Pitch and catch and multi-receiver configurations MUST NOT be set to the
unassigned channel scheme.
at the same time.
4. Release PB1 and PB2 at the same time. The system will enter
Channel Setting mode. The Status LED displays current
channel setting with red and green blinks. A green blink
represents the tens (+10) and a red blink represents the units
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(+1). For example, 1 green blink followed by 5 red blinks is channel 15. Channel
unassigned is represented by solid orange on the Status LED.
5. Change transmitter channel to “channel unassigned” by pressing PB4 one time
(Status LED displays solid orange).
6. Transfer “channel unassigned” setting to the receiver by rotating and holding the
power switch key at the START position until the Status LED turns to solid green. This
is the indication that the transfer is complete. Turn off the transmitter power if solid
green is not shown on the Status LED after more than 10 seconds. This is the
indication that the transfer was incomplete. The transmitter will then revert to its
previous channel setting. Make sure the receiver power is turned on and the receiver
is within the operating distance during the entire process. When transmitter is set to
“unassigned channel” the receiver must also be set to “unassigned channel” in order
for the entire system to work.
7. Exit Channel Setting mode by rotating the power switch key to the OFF ( 0 ) position.
B. Assigned Channel Scheme (preset system channel)

Both transmitter and receiver are assigned to a matching preset channel.
NOTE: Pitch and catch and multi-receiver configurations MUST be set to the
assigned channel scheme.
at the same time.
Channel Setting mode. The Status LED displays current
channel setting with red and green blinks. A green blink
represents the tens (+10) and a red blink represents the units
(+1). For example, 1 green blink followed by 5 red blinks is
channel 15. If the transmitter has been configured for the “unassigned channel” the
Status LED will show solid orange.
5. Change transmitter channel by pressing PB1 to increment the units (+1) and PB2 to
increment the tens (+10). For example, press PB2 two times and then PB1 four times
for channel 24 (Status LED blinks 2 greens and 4 reds).
6. Transfer the newly selected channel to the receiver by rotating and holding the power
switch key at the START position until the Status LED turns to solid green (transfer
complete). Turn off the transmitter power if solid green is not shown on the Status LED
after more than 10 seconds (transfer incomplete). The transmitter will revert back to its
previous channel setting. Make sure the receiver power is turned on and the receiver
is within the operating distance during the entire process. Skip step 6 if changing
receiver channel is not required.
7. Exit Channel Setting mode by rotating the power switch key to the OFF ( 0 ) position.
NOTE: When selecting a new channel, make sure each button press does not
exceed 3 seconds.

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Important Note:
Step 6 is strictly required if you are intending to change the entire system channel (both
transmitter and receiver). The entire system no longer works if step 6 is skipped
because the transmitter and receiver channels are now different (new vs. old). In this
case you would have to redo steps 1-4 and step 6 to transfer the newly selected
transmitter channel to the receiver.
4.1.4 Remote Pairing

A. Transmitter-to-Transmitter Pairing:
1. Rotate the power switch key on both transmitters to the OFF
( 0 ) position.
at the same time.
Remote Pairing mode. The Status LED displays firmware
version with red, green and orange blinks.
5. Output data (original transmitter) by pressing and holding PB2
(Status LED off).
6. Receive data (new transmitter) by pressing and holding PB1 (Status LED blinks
green).
7. When the Status LED (receiving data end) turns to solid green while both pushbuttons
are still pressed down, the pairing is completed.
8. Exit Remote Pairing mode by rotating the power switch key to the OFF ( 0 ) position.
Output data – original transmitter Receive data – new transmitter

(press and hold PB2) (press and hold PB1)
NOTE: During remote pairing make sure the distance between the two transmitters
is no more than 1 meter.

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B. Receiver-to-Transmitter Pairing:
1. Rotate the power switch key on both transmitters to the OFF ( 0 ) position.
4. Release PB1 and PB3 at the same time. The Status LED will now display the firmware
version with red, green and orange blinks. The transmitter is now in Remote Pairing Mode.
5. Press the Pairing Button on the receiver and PB3 on the transmitter until the Status
LED on the transmitter shows solid green.
NOTE: If you have completed the above procedure and it does not work, cycle
power on the receiver and try the above procedure again.
4.1.5 I-Chip
A Flex EX2 transmitter will enter a legacy mode and become backwards compatible
with Flex EX receivers once an I-Chip is inserted. The serial number and channel are
transferred through the I-Chip. The dipswitch is NOT used to change the channel. If the
channel needs to be changed, refer to the Channel Change via Push Buttons procedure
in a GEN 1 Flex EX manual. The first 8 positions on the EX2 transmitter dipswitch
(positions 9 and 10 are not used) will operate the same as the function dipswitch on the
Flex EX transmitter. Refer to the appropriate GEN 1 Flex EX manual for function
dipswitch settings.
NOTE: All settings in this manual are no longer applicable once an I-Chip is inserted
into a Flex EX2 transmitter. Refer to the appropriate GEN 1 Flex EX manual instead.
NOTE: A Flex EX transmitter will NOT work with a Flex EX2 receiver.
4.1.6 Transmitter Output Power Settings

The transmitter is set to 1mW by default as that is the
maximum allowed due to FCC regulations. If a different
output power is required please contact Magnetek field
service.
Dipswitch
Output Power
Settings
1 000xxxxxxx 1mW

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4.1.7 Transmitter Inactivity Timer Settings
After 5 minutes (default) of the transmitter pushbuttons not being pressed, the system
will go into sleep mode and the receiver MAIN relays will be deactivated.
NOTE: If an A/B pushbutton function is set, then the transmitter may not go idle
and, therefore, may not timeout.
Dipswitch Dipswitch
Time Time
Settings Settings
1 xxx000xxxx 1 minute 5 xxx100xxxx 10 minutes
2 xxx001xxxx 20 seconds 6 xxx101xxxx 30 minutes
3 xxx010xxxx 3 minutes 7 xxx110xxxx 60 minutes
Constant On (sleep
4 xxx011xxxx 5 minutes 8 xxx111xxxx
mode disabled)
4.1.8 Zero-G Sensor Settings

The transmitter is embedded with a Zero-G sensor to guard against any unintended
control of the crane or equipment when the transmitter experiences a Zero-G instance.
By default, the sensor is disabled. When the sensor is enabled and a Zero-G instance is
detected, the receiver MAIN relays will be deactivated. Please contact Magnetek field
service for more details.
Dipswitch
Function
Settings
1 xxxxxxxx0x Sensor Disabled
2 xxxxxxxx1x Sensor Enabled
4.1.9 Transmitter Start Function Settings

When the transmitter goes idle and the receiver MAIN relays are deactivated, execute
the START command (default) or press any pushbutton to reactivate the MAIN relays.
Dipswitch
Function
Settings
START
1 xxxxxxxxx0
Reactivation
Any Button
2 xxxxxxxxx1
Reactivation

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4.1.10 Infrared Programming
Other custom functions and settings not listed in this
manual can be programmed via the infrared IR
programmer unit. Refer to the IR Programmer manual or
contact Magnetek field service for more details.
4.1.11 Output Feedback Settings

Up to 4 assignable relay outputs can be programmed into
the system and feedback to the transmitter LED indicators
during operation. These settings require using the infrared
IR programmer unit. Please contact Magnetek field service for more details.
4.1.12 Pushbutton Function Settings

Only one function value can be active at a time. The following steps show the function
value and the corresponding result from the transmitter's operation.
4. Release PB3 and PB4 at the same time. The system will enter Pushbutton Function
mode.
5. The Status LED displays current pushbutton function setting with orange, green and
red blinks. An orange blink represents the hundreds (+100), a green blink represents
the tens (+010) and a red blink represents the units (+001). For example, 1 orange
blink followed by 2 green blinks and 5 red blinks is pushbutton function no. 125.
Pushbutton function number with "0" is represented by no orange, green or red blinks.
For example, 1 orange blink followed by 5 red blinks is pushbutton function no. 105.
6. Set the pushbutton function number by pressing PB3 to increment the hundreds
(+100), PB2 to increment the tens (+010), PB1 to increment the units (+001), and PB4
to reset (000 - solid orange). For example, press PB3 one time, PB2 four times, and
PB1 six times for pushbutton function no. 146 (Status LED blinks 1 orange, 4 greens
and 6 reds).
7. Exit Pushbutton Function mode by rotating the power switch key to the OFF ( 0 )
position.

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4.1.12.1 Toggled Pushbutton with LED Indication - Standard Right/Left
Pushbutton Configuration
Set pushbutton toggled function (latching output relay) with
LED indications. LED 1 - 4 shown inside the shaded box
illustrates which LED on the transmitter lights up when the
designated pushbutton is pressed.
Function
Display Type PB1 PB2 PB3 PB4
Number
1 1 Red Normal Normal Normal LED 4
2 2 Reds Normal Normal LED 3 LED 4
3 3 Reds Normal LED 2 LED 3 LED 4
4 4 Reds LED 1 LED 2 LED 3 LED 4
Function
Number
5 5 Reds Normal Normal Normal LED 4
6 6 Reds Normal Normal LED 3 LED 4
7 7 Reds Normal LED 2 LED 3 LED 4
8 8 Reds LED 1 LED 2 LED 3 LED 4
* PB1...PB8 → Pushbutton number.

* Normal → Normal momentary contact.
* LED 1 - LED 4 → Pushbutton toggled function with designated LED indication.

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4.1.12.2 A/B Pushbutton Select with LED Indication – Standard Right/Left
There are 5 different types of A/B selector sequence available. Choose one that is most
suitable for your application. See Section 5.1 on page 40 for output relay contact
diagrams.
Type-A selector sequence: A → B
Type-B selector sequence: Off → A → B
Type-C selector sequence: A → B → A+B
Type-D selector sequence: Off → A → B → A+B
Type-E selector sequence: A+B → A → B
Function
Number
47 4 Greens + 7 Reds Normal Normal A/1&2 Normal
48 4 Greens + 8 Reds Normal Normal B/1&2 Normal
49 4 Greens + 9 Reds Normal Normal C/1&2 Normal
50 5 Greens Normal Normal D/1&2 Normal
51 5 Greens + 1 Red Normal Normal Normal A/3&4
52 5 Greens + 2 Reds Normal Normal Normal B/3&4
53 5 Greens + 3 Reds Normal Normal Normal C/3&4
54 5 Greens + 4 Reds Normal Normal Normal D/3&4
55 5 Greens + 5 Reds Normal Normal A/1&2 A/3&4
56 5 Greens + 6 Reds Normal Normal A/1&2 B/3&4
57 5 Greens + 7 Reds Normal Normal A/1&2 C/3&4
58 5 Greens + 8 Reds Normal Normal A/1&2 D/3&4
59 5 Greens + 9 Reds Normal Normal B/1&2 B/3&4
60 6 Greens Normal Normal B/1&2 C/3&4
61 6 Greens + 1 Red Normal Normal B/1&2 D/3&4
62 6 Greens + 2 Reds Normal Normal C/1&2 C/3&4
63 6 Greens + 3 Reds Normal Normal C/1&2 D/3&4
64 6 Greens + 4 Reds Normal Normal D/1&2 D/3&4
2 Orange + 6 Greens +
262 Normal Normal E/1&2 Normal
2 Reds
263 Normal Normal Normal E/3&4
3 Reds

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Function
Number
264 Normal Normal E/1&2 E/3&4
4 Reds
265 Normal Normal E/1&2 B/3&4
5 Reds
266 Normal Normal E/1&2 C/3&4
6 Reds
267 Normal Normal E/1&2 D/3&4
7 Reds
* PB5…PB8 → Pushbutton number.

* A/1&2 - E/3&4 → A/B pushbutton select function with designated LED indication.
4.1.12.3 Toggled Pushbutton with LED Indication – Inline Top/Bottom

Set pushbutton toggled function (latching output relay) with
LED indications. LED 1 - 4 shown inside the shaded box
illustrates which LED on the transmitter lights up when the
designated pushbutton is pressed. See Section 4.2.7 on
page 37 for jumper settings.
Function
Number
1 1 Red Normal Normal Normal LED 4
17 1 Green + 7 Reds Normal Normal LED 3 LED 4
18 1 Green + 8 Reds Normal LED 2 LED 3 LED 4
19 1 Green + 9 Reds LED 1 LED 2 LED 3 LED 4

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Function
Number
5 5 Reds Normal Normal Normal LED 4
20 2 Greens Normal Normal LED 3 LED 4
21 2 Greens + 1 Red Normal LED 2 LED 3 LED 4
22 2 Greens + 2 Reds LED 1 LED 2 LED 3 LED 4

* LED 1 - LED 4 → Pushbutton toggled function with designated LED indication.
4.1.12.4 A/B Pushbutton Select with LED Indication – Inline Top/Bottom

There are 5 different types of A/B selector sequence available. Choose one that is most
suitable for your application. See Section 4.2.7 on page 37 for jumper settings and
Section 5.1 on page 40 for output relay contact diagrams.
Type-A selector sequence: A → B
Type-B selector sequence: Off → A → B
Type-C selector sequence: A → B → A+B
Type-D selector sequence: Off → A → B → A+B
Type-E selector sequence: A+B → A → B
Function
Number
1 Orange + 1 Green
115 Normal Normal A/1&2 Normal
+ 5 Reds
1 Orange + 1 Green
116 Normal Normal B/1&2 Normal
+ 6 Reds
1 Orange + 1 Green
117 Normal Normal C/1&2 Normal
+ 7 Reds
1 Orange + 1 Green
118 Normal Normal D/1&2 Normal
+ 8 Reds
51 5 Greens + 1 Red Normal Normal Normal A/3&4
52 5 Greens + 2 Reds Normal Normal Normal B/3&4
53 5 Greens + 3 Reds Normal Normal Normal C/3&4
54 5 Greens + 4 Reds Normal Normal Normal D/3&4

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Function
Number
1 Orange + 1 Green
119 Normal Normal A/1&2 A/3&4
+ 9 Reds
120 1 Orange + 2 Greens Normal Normal A/1&2 B/3&4
1 Orange + 2 Greens
121 Normal Normal A/1&2 C/3&4
+ 1 Red
1 Orange + 2 Greens
122 Normal Normal A/1&2 D/3&4
+ 2 Reds
1 Orange + 2 Greens
123 Normal Normal B/1&2 B/3&4
+ 3 Reds
1 Orange + 2 Greens
124 Normal Normal B/1&2 C/3&4
+ 4 Reds
1 Orange + 2 Greens
125 Normal Normal B/1&2 D/3&4
+ 5 Reds
1 Orange + 2 Greens
126 Normal Normal C/1&2 C/3&4
+ 6 Reds
1 Orange + 2 Greens
127 Normal Normal C/1&2 D/3&4
+ 7 Reds
1 Orange + 2 Greens
128 Normal Normal D/1&2 D/3&4
+ 8 Reds
285 Normal Normal E/1&2 Normal
6 Reds
263 Normal Normal Normal E/3&4
3 Reds
286 Normal Normal E/1&2 E/3&4
6 Reds
287 Normal Normal E/1&2 B/3&4
7 Reds
288 Normal Normal E/1&2 C/3&4
8 Reds
289 Normal Normal E/1&2 D/3&4
9 Reds

* A/1&2 - E/3&4 → A/B pushbutton select function with designated LED indication.

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4.2 Receiver
4.2.1 Receiver Channel Dipswitch
The Flex EX2 receiver has its decoder board mounted to
the inside of the front half of the enclosure. The dipswitch
on the bottom right of the decoder board label “S7” is the
channel dipswitch (pictured to the right).
4.2.2 Receiver Channel Settings

Set the receiver channel by configuring the channel
dipswitch located on the decoder board. Only the first 6
dip positions are used for channel selection. The system
channels table in Section 4.2.4 on page 29 illustrates
which dipswitch setting corresponds to which channel.
If the receiver channel is altered, make sure to change the transmitter channel as well.
The channel on both the transmitter and the receiver must be identical in order for the
system to work (see Section 4.1.3 on page 17, part B).
When set to all zeros (000000), the receiver utilizes the unassigned channel scheme
(see Section 4.1.3 on page 16, part A).
Example:
Top position → “1”

Bottom position → “0”
1 2 3 4 5 6 7 8
The above dipswitch setting “1 0 0 1 0 0” corresponds to “channel 36” in the system

channels table in Section 4.2.4 on page 29.

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4.2.3 Receiver Channel Scanning Function
Receiver channel scanning function is applicable only when a preset channel is
assigned to the system (see Section 4.1.3 on page 16, part B).
(1) → “00” manufacturer preset (channel X)*

1 2 3 4 5 6 7 8
(2) → “01” scans 2 channels (channel X and channel X+1)

1 2 3 4 5 6 7 8
(3) → “10” scans 3 channels (channel X… channel X+2)

1 2 3 4 5 6 7 8
(4) → “11” scans 4 channels (channel X… channel X+3)**

1 2 3 4 5 6 7 8
* Channel X → channel set on the Channel dipswitch.

** Contact Magnetek field service if your application requires
scanning more than 4 channels.
Example: If the first 6 dipswitch positions are set to channel 01 (000001), when set to
two-channel scanning (type 2 above) the receiver will scan only channel 01 and
02.

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4.2.4 System Channels Table
The Flex EX2 system makes use of 124 channels. The first set of 62 channels
comprises the lower-end channels that can be selected through dipswitch configuration
in the receiver and pushbutton configuration in the transmitter.
There is a second set of 62 channels that comprises the upper-end channels that
cannot be selected through dipswitch or pushbutton configurations. They are only used
when the lower-end channel experiences interference. In this case, the system will
automatically switch to its accompanying upper-end channel. If both the lower- and
upper-end channel experience interference, then it is recommended that the transmitter
be power-cycled to reestablish a clean channel again. The upper-end channels are
listed below for the purpose of frequency management only.
Channel Channel
Dipswitch Dipswitch Upper End Channel
CH Frequency CH Frequency
Setting Setting Frequency (MHz)
(MHz) (MHz)
01 000001 433.050 32 100000 434.600 436.550 438.100
02 000010 433.100 33 100001 434.650 436.600 438.150
03 000011 433.150 34 100010 434.700 436.650 438.200
04 000100 433.200 35 100011 434.750 436.700 438.250
05 000101 433.250 36 100100 434.800 436.750 438.300
06 000110 433.300 37 100101 434.850 436.800 438.350
07 000111 433.350 38 100110 434.900 436.850 438.400
08 001000 433.400 39 100111 434.950 436.900 438.450
09 001001 433.450 40 101000 435.000 436.950 438.500
10 001010 433.500 41 101001 435.050 437.000 438.550
11 001011 433.550 42 101010 435.100 437.050 438.600
12 001100 433.600 43 101011 435.150 437.100 438.650
13 001101 433.650 44 101100 435.200 437.150 438.700
14 001110 433.700 45 101101 435.250 437.200 438.750
15 001111 433.750 46 101110 435.300 437.250 438.800
16 010000 433.800 47 101111 435.350 437.300 438.850
17 010001 433.850 48 110000 435.400 437.350 438.900
18 010010 433.900 49 110001 435.450 437.400 438.950
19 010011 433.950 50 110010 435.500 437.450 439.000
20 010100 434.000 51 110011 435.550 437.500 439.050
21 010101 434.050 52 110100 435.600 437.550 439.100
22 010110 434.100 53 110101 435.650 437.600 439.150
23 010111 434.150 54 110110 435.700 437.650 439.200
24 011000 434.200 55 110111 435.750 437.700 439.250
25 011001 434.250 56 111000 435.800 437.750 439.300
26 011010 434.300 57 111001 435.850 437.800 439.350
27 011011 434.350 58 111010 435.900 437.850 439.400
28 011100 434.400 59 111011 435.950 437.900 439.450
29 011101 434.450 60 111100 436.000 437.950 439.500
30 011110 434.500 61 111101 436.050 438.000 439.550
31 011111 434.550 62 111110 436.100 438.050 439.600
NOTE: Channel unassigned is represented by “000000” dipswitch setting in the receiver. See
Section 4.1.3 on page 16, part A unassigned channel scheme.

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4.2.5 Output Relay Configurations
4.2.5.1 Output Relay Types
1. 3 output relays per motion – shared 2nd speed output relay
Output relays with Forward 1st speed (F1), Reverse 1st speed (R1) and Forward/
Reverse 2nd speed (F/R2). Forward and Reverse 2nd speed (F/R2) share the same
output relay.
2. 4 output relays per motion – separate 1st and 2nd speed output relays
Output relays with Forward 1st speed (F1), Reverse 1st speed (R1), Forward 2nd
speed (F2) and Reverse 2nd speed (R2). Forward and Reverse 2nd speed are
separate output relays.
4.2.5.2 Output Relay Actions at 2nd Speed (Flex 8EX2 only)

1. 3 output relays configuration with Closed/Closed contact at 2nd speed
F1 (or R1) output relay closed at 1st speed and F1 + F/R2 (or R1 + F/R2) output
relays closed at 2nd speed. See Section 4.2.6.1 on page 34 on how to set to this
function.
st nd
Forward 1 speed pushbutton pressed Forward 2 speed pushbutton pressed
↓ ↓
F1 R1 F/R2 F1 R1 F/R2

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2. 4 output relays configuration with Opened/Closed contact at 2nd speed
F1 (or R1) output relay closed at 1st speed and F2 (or R2) output relay closed at 2nd
speed. See Section 4.2.6.1 on page 34 on how to set to this function.
st nd
↓ ↓
F1 R1 F2 R2 F1 R1 F2 R2
3. 4 output relays configuration with Closed/Closed contact at 2nd speed

F1 (or R1) output relay closed at 1st speed and F1 + F2 (or R1 + R2) output relays
closed at 2nd speed. See Section 4.2.6.1 on page 34 on how to set to this function.
st nd
↓ ↓
F1 R1 F2 R2 F1 R1 F2 R2
4. 4 output relays configuration with Slow and Fast output relays (Type A)
Fwd (or Rev) + Slow output relays closed at 1st speed and Fwd (or Rev) + Fast output
relays closed at 2nd speed. See Section 4.2.6.1 on page 34 on how to set to this
function.
st nd
↓ ↓
Fwd Rev Slow Fast Fwd Rev Slow Fast

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5. 4 output relays configuration with Slow and Fast output relays (Type B)
Fwd + Slow (or Rev + Slow) output relays closed at 1st speed and Fwd + Slow + Fast
(or Rev + Slow + Fast) output relays closed at 2nd speed. See Section 4.2.6.1 on
page 34 on how to set to this function.
st nd
↓ ġ ġ ġ ġ ġ ġġ ↓ġġġġġ
Fwd Rev Slow Fast Fwd Rev Slow Fast
4.2.5.3 START + AUX Function

After executing the START command at transmitter
start-up the same START position becomes an auxiliary
function with momentary contact connected through the
K25 Function output relay.
4.2.5.4 ON/OFF Pushbutton Function

Any of the two adjacent pushbuttons on the transmitter can
be set to behave like a mechanical ON & OFF rocker or
toggle switch. The ON output relay closes when the ON
pushbutton is pressed (OFF output relay opens) and the
OFF output relay closes when the OFF pushbutton is
pressed (ON output relay opens).
4.2.5.5 Brake Function

When the transmitter pushbutton is released from 2nd speed up to 1st speed, both
1st and 2nd speed output relays will open for up to 1 second and then with 1st speed
output relay closed thereafter.
4.2.5.6 External Warning Function

An external warning device (rotating lights, horn, etc.) can be installed to a function
output relay on the receiver. The user can choose which pushbutton pair (or pairs)
triggers the external warning device when pressed.
4.2.5.7 Momentary Contact

When a pushbutton is released the corresponding output relay will open or
deactivate. This type of relay action usually applies to external applications such as
a horn.

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4.2.5.8 Toggled Contact
When a pushbutton is released the corresponding output relay will maintain contact
closure until next time the user presses the same pushbutton again which will open
the relay’s contact. This type of relay action usually applies to external applications
such as a warning light.
4.2.5.9 Pitch & Catch Function

This function allows one transmitter to retain control of a receiver, even if it is
powered off, until the “Pitch” command is sent from the transmitter to the receiver
and is locked onto and received by the receiver.
Whichever transmitter gains control of the receiver, the receiver locks on to that
transmitter’s channel. This lock remains in place even if the transmitter is turned off
or goes out of range. This will prevent the other transmitter from being able to start
the receiver. This lock remains in place until the correct transmitter sends the Pitch
command allowing the receiver to go back into channel scanning.
When set to “Pitch & Catch” make sure the 2nd transmitter is set to one channel
higher (channel X+1) than the 1st transmitter (channel X). The receiver must be set
to the same channel as the 1st transmitter (channel X) and be set to two-channel
scanning per Section 4.2.3 on page 28. The Pitch & Catch function will not work if
the unassigned channel scheme is used.
Example: If the system is set to channel 01 then the 2nd transmitter must be set to channel
02 with identical serial number. Furthermore, on the Channel dipswitch on the
decoder board, positions #7 and #8 must set to “01” for two-channel scanning
(scans channel 01 and 02). Refer to Section 4.2.6.2 on page 35 on how to set
the Pitch & Catch function.

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4.2.6 Receiver Function Dipswitch Settings
Located on the receiver decoder board are
dipswitches that control how the receiver
responds to commands from the transmitter.
Each pair of buttons has a dipswitch
associated with them and is labeled on the
board to identify it.
Dipswitch S1 is for pushbuttons 1 & 2
4.2.6.1 Interlocked Pushbutton Pair

Interlocked means that when a pushbutton pair are pressed simultaneously, they will
cancel each other out and result in no relay output. The interlocked setting usually
applies to electric motor’s forward & reverse motion and On & Off switches.
Dip # of Relays
Function Descriptions
Settings Used
00000000 Single speed only 2
4 output relays Closed/Closed relay action at 2nd speed

00000010 4
(separate 2nd speed output relays)
3 output relays Closed/Closed relay action at 2nd speed

00000100 3
(shared 2nd speed output relay)
4 output relays Opened/Closed relay action at 2nd speed

00000110 4
(separate 2nd speed output relays)
Forward (or Reverse) + Fast output relays engaged at

00001000 4
2nd speed
Forward (or Reverse) + Slow + Fast output relays

00001010 4
engaged at 2nd speed
00001100 On (right button) & Off (left button) 2
On + Start/Off + Start - For added safety, you must first

rotate and hold the power switch key at START position
00010010 2
and then press the On or Off pushbutton to activate the
output relay.
00010100 FWD/REV toggled (latching) 2
00100000 Single speed + External warning* 2
4 output relays Closed/Closed relay action + External

00100010 4
warning*
3 output relays Closed/Closed relay action + External

00100100 3
warning*

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Dip # of Relays
Function Descriptions
Settings Used
4 output relays Opened/Closed relay action + External

00100110 4
warning*
01000010 4 output relays Closed/Closed relay action + Brake 4
01000100 3 output relays Closed/Closed relay action + Brake 3
01000110 4 output relays Opened/Closed relay action + Brake 4
4 output relays Closed/Closed relay action + Brake +

01100010 4
External warning*
3 output relays Closed/Closed relay action + Brake +

01100100 3
External warning*
4 output relays Opened/Closed relay action + Brake +

01100110 4
External warning*
* External warning function requires installing an external warning device such as horn and lights to the
K26 Function output relay.
4.2.6.2 Non-Interlocked Pushbutton Pair

The non-interlocked setting allows the receiver to activate relays when a pushbutton
pair are pressed simultaneously. It usually applies to equipment’s auxiliary functions
such as a horn or light. Each dipswitch on the decoder board corresponds to a
pushbutton pair. Only the first 7 dipswitch positions are used (counting from left to
right), the 8th dipswitch position (far right) is not used.
1 2 3 4 5 6 7 8

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Dip Dip Position
Function
Position #2 - #4 (left button) and Function Description
Code
#1 #5 - #7 (right button)
A 1 000 Normal momentary contact
Toggled/latching contact
B 1 001
(type A)
Toggled/latching contact
(type B)
Output relay disconnects
C 1 011
when STOP button is
pressed or transmitter
power is off
Normal + Start function

For added safety, first rotate
and hold the power switch
D 1 100 key at the START position
and then press the intended
pushbutton to activate the
output relay
E 1 110 Pitch & Catch (type A)
Pitch & Catch (type B)

Receiver MAIN relays
F 1 101
maintain closure
during switchovers
2 steps with Closed/Closed

G 1 111
relay action
Example #1: Left button (set to function code A) / right button (set to function code B) → 1 000 001
Example #2: Left button (set to function code C) / right button (set to function code D) → 1 011 100

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4.2.7 Jumper Settings
Jumper setting applies to functions such as the standard
or reversed logic A/B selector sequence, transmitter
inline pushbutton configurations, firmware version,
system testing and remote pairing methods.
Jumper Settings Function
Standard A/B selector sequence – Output

JP3
relay A activated at A position, output relay B activated at
(Opened)
B position, both relays activated at A+B position
Reversed logic A/B selector sequence – Output

JP3
relay B activated at A position, output relay A activated at
(Inserted)
B position, both relays deactivated at A+B position
JP4 JP5
Standard right/left pushbutton configuration
(Opened) (Opened)
JP4 JP5
Inline top/bottom pushbutton configuration for PB1 to PB8
(Inserted) (Opened)
JP4 JP5
(Opened) (Inserted)
JP4 JP5
(Inserted) (Inserted)
JP6
System firmware version
(Inserted)
JP7
For system testing only (receiver MAIN relays disabled)
(Inserted)
JP8 Receiver-to-transmitter remote pairing

(Opened) (pressing the Pairing button required)
JP8 Receiver-to-transmitter remote pairing

(Inserted) (pressing the Pairing button not required)

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4.2.8 Voltage Settings
Prior to installation always check that the voltage setting is correct for your application.
In each receiver are black, vertically mounted fuse holders. Fuses F1 & F2 are for the
control voltage to power the receiver and all other fuses are for the control voltage feeds
to the output relays.
Position 1 → 110 - 120VAC

Position 2 → 220 - 240VAC or 24VAC*
Position 3 → 380 - 400VAC or 42VAC*
Position 4 → 410 - 460VAC or 48VAC* or 9 - 36VDC**
* For system equipped with 24/42/48VAC power
supply
** For system equipped with 9 - 36VDC power supply
42 &
FUSE # 110 - 120VAC 220 - 240VAC 380 - 400VAC 410 - 460VAC 24VAC 9 - 36VDC
48VAC
F3 - F10 5.0A 5.0A 5.0A 5.0A 5.0A 5.0A 5.0A
F1 - F2 1.0A 1.0A 1.0A 0.5A 3.0A 2.0A 3.0A
4.2.9 Horn Installation

A horn can be easily fitted onto the receiver enclosure.
When installed at the factory, the horn is wired into the
K25 (FUNC 1) output relay and will function as described
in Section 4.2.5.3 on page 32. Please contact Magnetek
field service if you would like the horn to work differently.

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4.2.10 Other Function Output Relays Settings
Listed below are other types of functions that can be outputted through the K25 and
K26 Function output relays via the IR programmer unit. Please contact Magnetek field
service for more details.
LV → Function relay closes when receiver voltage is low.
ID → Function relay works simultaneously with all motion
commands.
NORMAL → START function + AUX with normal
momentary output.
TOGGLE → START function + AUX with toggled/latching
output.
TOG&E → START function + AUX with toggled/latching
output. The relay opens when STOP button is pressed
down and transmitter power off.
S/P → Function relay closes when START command is executed and opens only when
transmitter power is turned off.
EXT → Function relay works simultaneously with the receiver MAIN relays.
TDM A+B → Function relay closes when selector switch is rotated to the A+B position
and opens when rotated to A or B positions (tandem monitoring output).
HORN → Function relay closes for up to 3 seconds when START command is executed
at transmitter power on and then becomes a normal momentary output thereafter.
G SENSOR → Function relay closes when Zero-G sensor is triggered (receiver MAIN
relays deactivated) and opens when receiver MAIN relays are reactivated.

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5 Receiver Installation
5.1 Output Relay Contact Diagrams

5.1.1 Flex 8EX2 (dual speed model)
• For 9 - 36VDC power supply, wire #1 corresponds to the negative charge (-), wire #3 corresponds to the
positive charge (+), and wire #2 is for GROUND.
• If PB7 (or PB8) is set to A/B pushbutton select or A/B rotary switch select function (AB models), connect
output A to K13 relay (or K14) and output B to K15 relay (or K16). See Section 4.1.12.2 on page 23 on
how to set to this function.
• Due to the possibility of voltage spikes on the contactors, suppressors are required on contactors being
driven by Flex relays.
5.2 Pre-installation Precautions

1. Make sure the transmitter and receiver have the same serial numbers and are set to the
same channel.
2. Make sure the receiver is not set to the same channel as any other systems in use in the
surrounding area.
3. Make sure the crane or equipment is working properly prior to installation.
4. Make sure the power source to the receiver is set correctly.
5. Switch off the main power source to the crane or equipment prior to installation.

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5.3 Step-by-Step Installation
Mounting Bracket Type 1
Mounting Bracket Type 2

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1. For best reception the location of the receiver should be visible
to the operator at all time.
2. The location selected should not be exposed to high levels of
electric noise. Mounting the receiver next to an unshielded
variable frequency drive may cause radio interference. Always
locate the receiver as far away from variable frequency drives 300 mm
and electric motors as possible.

3. Ensure the selected location has adequate space to Control
Panel
accommodate the receiver. If an external antenna is used, to
avoid the possibility of antenna damage always locate the
receiver where the antenna is free from any obstructions.
4. When installing an external antenna make sure the MCX jack
located on the decoder board inside the receiver is connected
and jumper set to “EXT” position.
5. For better reception, make sure the receiver is in an upright position.

6. Drill four holes for mounting bracket type 1 and two holes for mounting bracket type 2 on
the control panel, wall or location where the receiver is to be installed.
7. Make sure the screws, bolts or shock absorbers are tightened after installation.
8. Install suppressor on all contactors being driven by Flex relays. This is due to the
possibility of voltage spike on the contractors.
Mounting Bracket Type 1 Mounting Bracket Type 2
9. Slide down the receiver along the guided track to secure the receiver to the mounting
bracket.
10. Remove the receiver by pressing down the bracket release and pulling the receiver
upward until it clears the guided track.

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Install
Remove

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6 Operating Procedures
6.1 General Operation

1. Reset the STOP button located on the top left-hand corner of the transmitter by rotating it
clockwise or counterclockwise; the button will pop up. Turn on the transmitter power by
inserting the power switch key and rotating to the ON ( I ) position.
2. After turning on the transmitter power, check the Status LED on the transmitter for any
sign of system irregularities (see Section 6.6.1 Transmitter Status Indications on
page 47). If the transmitter is in good working order the Status LED will display solid green
for up to 2 seconds at power on (no faults detected).
3. Rotate the power switch key further to the START position and hold it there for up to 2
seconds (Status LED solid green). When the receiver MAIN relays are activated the Status
LED will change from solid green to solid orange (system on). The power switch key will
retract back to the ON ( I ) position when released. The same START position becomes an
auxiliary function thereafter (see Section 4.2.5.3 START + AUX Function on page 32).
Pressing any pushbutton before executing the START command at system start-up will
result in no signals transmitted (Status LED blinks orange).
4. Press any pushbutton on the transmitter to begin operation. During transmitter inactivity
(pushbuttons not pressed), the transmitter will automatically switch to standby mode, with
an orange blink on the Status LED at 4-second intervals. Always turn off the transmitter
power when not in use to save battery power.
5. In case of an emergency, press down the STOP button to disconnect the receiver MAIN
relays (Status LED blinks 3 reds and then shuts off). To resume operation, rotate the
STOP button clockwise or counterclockwise; the button will pop up. Then execute the
START command to reconnect the receiver MAIN relays. For safety, executing the START
command is required every time the transmitter is turned on or after every STOP button
reset.
NOTE: Pushing the STOP button does not turn off the transmitter power and it will
continue to draw battery power

June 2019
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6. After 5 minutes of inactivity (pushbutton not pressed) the receiver MAIN relays are
temporarily disconnected (see Section 4.1.7 Transmitter Inactivity Timer Settings on
page 20). The Status LED blinks 3 reds and then shuts off. Execute the START command
to resume operation (see Section 4.1.9 Transmitter Start Function Settings on
page 20).
7. Turn off the transmitter power by rotating the power switch key counterclockwise to the
OFF ( 0 ) position; it will disconnect the transmitter power and the receiver MAIN relays
altogether. Turn it further counterclockwise to release the key.
6.2 Tandem System Operation

1. Before initial start-up, rotate the selector switch on one of the master transmitters to either
the A, B, or A+B position. Then, execute the START command to activate the MAIN relays
in receiver A, receiver B, or both receivers (depending on the selector switch position).
2. Once the MAIN relays are active in both receivers, rotate the selector switch to either the
A, B, or A+B position for independent or simultaneous operation. The A/B output relays
(K14/K16) will also activate based on the selector switch position.
• Selector switch is on A → The A relay (K14) will be active on receiver A.
• Selector switch is on B → The B relay (K16) will be active on receiver B.
• Selector switch is on A+B → The A relay (K14) will be active on receiver A and the B
relay (K16) will be active on receiver B.
3. For safety, always check if the selector switch is correctly positioned for the intended
receiver or receivers prior to turning on the transmitter power. After the MAIN relays are
active in both receivers, turning the master transmitter off or pushing the STOP button will
disconnect the MAIN relays in both receivers (regardless of the selector switch position).
Master/Master Operation Master/Dedicated Operation
Receiver Receiver Receiver Receiver

A B A B
A
A A
B
B B
Transmitter Transmitter Master Dedicated

A B Transmitter Transmitter

June 2019
Page 45 of 49
6.3 A/B Rotary Select Operation (AB Systems Only)
Standard – Rotating to A position activates output relay A, rotating to B
position activates output relay B, rotating to A+B position activates both
output relays.
Reversed logic – Rotating to A position activates output relay B,
rotating to B position activates output relay A, rotating to A+B position
deactivates both output relays. See Section 4.2.7 on page 37 for JP3
jumper setting.
6.4 Changing Batteries

Change transmitter batteries (“AA” alkaline battery x 2) by unscrewing the battery cover
located on the backside of the transmitter. During battery installation make sure the batteries
are installed correctly, with “+” to “+” charge and “-” to “-” charge. Also make sure the screw is
tightened after battery installation to avoid water, moisture, dirt, grease, and other liquid
penetration.
6.5 Battery Charging

The transmitter is designed to accept any off-the-shelf NiMH
rechargeable batteries. When charging both transmitter and
individual batteries at the same time the priority always goes
to the transmitter charging. The individual battery charging
begins only after the transmitter charging is completed.
Depending on the battery capacity the average charging time
is approximately 3 hours from completely drained to fully
charged. Solid red on the LED represents charging in
progress, solid green represents batteries fully charged, and
LED off represents no batteries detected.
NOTE: Do not use any rechargeable lithium ion batteries, as
they will damage both the transmitter and the charging station.

June 2019
Page 46 of 49
6.6 System Status Light Indications
6.6.1 Transmitter Status Indications
Type Display Type Indication
Voltage below 1.8V at initial

1 Solid red
power on or during operation
Voltage below 1.75V during

2 3 red blinks and then off operation
(receiver MAIN relays shut off)
Voltage below 1.85V during

1 red blink followed by a
3 operation (changing batteries is
2-second pause
recommended)
2 red blinks followed by a Defective or jammed pushbutton

4A
2-second pause detected at initial power on
When defective pushbutton

condition occurs (2 red blinks,
type 4A above), find out which
pushbutton is defective by
pressing all of them one at a
4B No light displayed
time. If the pushbutton is in good
working order when pressed, the
Status LED is off. If the Status
LED maintained 2 red blinks
then the pushbutton is defective.
4 red blinks followed by a 2-second Transmitter is unable to lock

5
pause onto the assigned channel
Transmitter power on with no

6 Solid green for up to 2 seconds
faults detected
7 Blinking green Transmission in progress
Pressing any pushbutton prior to

8 Blinking orange executing the START command
at power on
2 orange blinks followed by a 2-second Receiver MAIN relays jammed

9
pause or defective
3 orange blinks followed by a 2-second

10 Decoding processors defective
pause
11 3 slow red blinks STOP button pressed down
Solid orange when the power switch key

12 is rotated and hold at the START position Receiver MAIN relays activated
at initial system start-up

June 2019
Page 47 of 49
6.6.2 Receiver Status Indications
Type Display Type (Green & Red) Indication
1 Fast green blinks Decoding in process
2 Slow green blinks Decoding on standby
Receiver MAIN relays jammed

3 2 red blinks
or defective
4 3 red blinks Decoding processors defective
5 4 red blinks Receiving RF board defective
Incorrect transmitter serial

6 Fast red blinks
number
7 Solid red Receiver low voltage
8 No light displayed Decoding processors defective
3 slow red blinks followed by

9 STOP button pressed down
slow green blinks
6.6.3 Receiver Power Indications
Type Display Type (Red) Indication
1 On Power to receiver
2 Off No power to receiver
6.6.4 Receiver COM Indications
Type Display Type (Red) Indication
1 On Power to relay board
2 Off No power to relay board

June 2019
Page 48 of 49
7 General Specifications
Frequency Range: 433.050MHz - 439.600MHz
Number of Channels: 124 channels
Channel Spacing: 50 KHz
Modulation: Digital Frequency Modulation based on Manchester Code,
20-bit address, 32-bit CRC and Hamming Code.
Encoder & Decoder: Microprocessor-controlled
Transmitting Range: >100 meters (300 feet)
Hamming Distance: >6
Frequency Control: Synthesized PLL
Receiver Type: Frequency Auto Scanning
Receiver Sensitivity: -116 dBm
Spurious Emission: -50 dB
Antenna Impedance: 50 ohms
Responding Time: 40 mS (average)
Transmitting Power: 1.0 mW
Enclosure Type: NEMA4
Enclosure Rating: IP66
Output Contact Rating: 250V @ 8 Amps
Transmitter Operating Voltage: 3.0VDC
Receiver Power Consumption: 22VA (max)
Available Receiver Voltages: 9 - 36VDC
24VAC
42VAC
48VAC
110 - 120VAC
220 - 240VAC
380 - 400VAC
410 - 460VAC
Operating Temperature: -25°C - 75°C / -13°F - 167°F
Transmitter Dimension: 198 mm (L) x 70 mm (W) x 44 mm (H)
Receiver Dimension: 260 mm (L) x 204 mm (W) x 83 mm (H)
Transmitter Weight: 292 g / 10.3 oz (include batteries)
Receiver Weight: 2.75 kg / 6.1 lb (include output cable)
Distributed by Ergonomic Partners

[email protected]
www.ErgonomicPartners.com
Tel: (314) 884-8884

June 2019
Page 49 of 49

Flex 8EX2 System: Radio Control Equipment Instruction Manual

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Flex 8EX2 System

Radio Control Equipment

Part Number: 191-50800-M000F R01

Distributed by Ergonomic Partners

Flex 8EX2 Instruction Manual

Flex 8EX2 Instruction Manual

Flex 8EX2 Instruction Manual

Your New Radio Remote Control System

U.S. Service Information

Flex 8EX2 Instruction Manual

• Regulations issued by the Occupational Health and Safety Administration (OSHA),

• Applicable local, state or federal codes, ordinances, standards and requirements, or

Flex 8EX2 Instruction Manual

Flex 8EX2 Instruction Manual

NOTE: A NOTE statement is used to notify people of installation, operation, programming, or

WARNINGS and CAUTIONS SHOULD NEVER BE DISREGARDED.

Flex 8EX2 Instruction Manual

2.3 Persons Authorized to Operate Radio Controlled

Flex 8EX2 Instruction Manual

2.4 Safety Information and Recommended Training for

Flex 8EX2 Instruction Manual

2.5 Transmitter Unit

2.6 Pre-Operation Test

Flex 8EX2 Instruction Manual

1. STOP Button 9. Pushbutton 6 (PB6)

2. Power Key Switch 10. Pushbutton 7 (PB7)

3. Status LED Indicator 11. Pushbutton 8 (PB8)

4. Pushbutton 1 (PB1) 12. Future Feature

5. Pushbutton 2 (PB2) 13. Battery Cover Screw

6. Pushbutton 3 (PB3) 14. System Information

7. Pushbutton 4 (PB4) 15. Lanyard and Waist Belt

Flex 8EX2 Instruction Manual

1. RF Transceiver Board 5. Infrared Sensors

2. Encoder Board 6. I-Chip Slot

3. Status LED Indicator 7. Function Dipswitch

4. A/B/C/D LED Indicators 8. Programming Port*

Flex 8EX2 Instruction Manual

1. External RP-TNC Antenna Port 7. Remote Pairing Button

2. COM LED Indicator 8. System Information

3. Status LED Indicator 9. Cord Grip

4. Power LED Indicator 10. Mounting Bracket

5. Output Relay LED Indicators 11. Mounting Bracket Release

Flex 8EX2 Instruction Manual

1. Decoder Board 6. Function Jumpers

2. RF Transceiver Board 7. Channel Dipswitch

3. INT/EXT Antenna Jumpers 8. AC Line Filter/Relay Board

4. Programming Port 9. Power Transformer

5. Function Dipswitches 10. Voltage Selector

Flex 8EX2 Instruction Manual

4.1.2 Display Frequency Band

4.1.3 Transmitter Channel Settings

B. Assigned Channel Scheme (preset system channel)

Flex 8EX2 Instruction Manual

4.1.4 Remote Pairing

Output data – original transmitter Receive data – new transmitter

Flex 8EX2 Instruction Manual

4.1.6 Transmitter Output Power Settings

Flex 8EX2 Instruction Manual

1 xxx000xxxx 1 minute 5 xxx100xxxx 10 minutes