Magnetek Flex 8ex2 Radio Remote Control Manual

Flex 8EX2 System
Radio Control Equipment

Instruction Manual
Part Number: 191-50800-M000F R00

November 2017
©Copyright 2017 Magnetek Material Handling
Distributed by Tri-State Equipment Company Inc.
sales@tsoverheadcrane.com
www.tsoverheadcrane.com
Tel: (314) 869-7200
Page Intentionally Left Blank
Flex 8EX2 Instruction Manual

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Table of Contents
Service Information ............................................................................................................................ 5
Product Manual Safety Information .................................................................................................. 6
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 Transmitter Channel Settings ................................................................................................16
4.1.3 Remote Pairing ......................................................................................................................18
4.1.4 I-Chip .....................................................................................................................................19
4.1.5 Transmitter Start Function Settings .......................................................................................20
4.1.6 Transmitter Inactivity Timer Settings .....................................................................................20
4.1.7 Transmitter Output Power Settings........................................................................................21
4.1.8 Infrared Programming ............................................................................................................21
4.1.9 Pushbutton Function Settings ................................................................................................21
4.1.10 Display Frequency Band........................................................................................................26
4.1.11 Output Feedback Settings .....................................................................................................26
4.1.12 Zero-G Sensor Settings .........................................................................................................27
4.1.13 Receiver Select Configurations (RS Systems Only) ..............................................................27
4.2 Receiver .....................................................................................................................................28
4.2.1 Receiver Channel Settings ....................................................................................................28
4.2.2 Output Relay Configurations..................................................................................................29
4.2.3 Dipswitch Settings .................................................................................................................33
4.2.4 Jumper Settings .....................................................................................................................36
4.2.5 Voltage Settings.....................................................................................................................37
4.2.6 Indicator Light and Buzzer Installation ...................................................................................37
4.2.7 Other Function Output Relays Settings .................................................................................38
4.2.8 Receiver Select Setup (RS Systems Only)............................................................................38
4.2.9 System Channels Table.........................................................................................................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

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6.2 Master/Master Tandem Operation (Tandem Systems Only)......................................................45
6.3 Master/Slave Tandem Operation (Tandem Systems Only)........................................................47
6.4 A/B Pushbutton Select Operation...............................................................................................48
6.5 A/B Rotary Select Operation (AB Systems Only).......................................................................48
6.6 Pitch & Catch Operation.............................................................................................................49
6.7 Changing Batteries.....................................................................................................................49
6.8 Battery Charging ........................................................................................................................49
6.9 System Status Light Indications .................................................................................................50
6.9.1 Transmitter Status Indications ...............................................................................................50
6.9.2 Receiver Status Indications ...................................................................................................51
6.9.3 Receiver Power Indications ...................................................................................................51
6.9.4 Receiver COM Indications .....................................................................................................51
7 General Specifications .....................................................................................................................52

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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.
World Headquarters:
Magnetek, Inc.
N49 W13650 Campbell Drive
Menomonee Falls, WI 53051

Tel: (314) 869-7200
© 2017 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.TSOVERHEADCRANE.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 startup 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 European Safety
Standards.
• Other Optional Accessories and Features – transmitter magnet mount, transmitter belt clip,
transmitter lanyard, transmitter rubber guard, miniature indicator light and buzzer, charging station,
tandem function, random access 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
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 Antenna Port (optional) 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 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 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 OFF ( 0 ) position.
4.1.2 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 startup.
NOTE: Pitch and catch, tandem, and receiver select configurations are unable to 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
(+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 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. When transmitter is set to
“channel unassigned” the receiver must also set to “channel unassigned” in order for
the entire system to work.
7. Exit Channel Setting mode by rotating the power switch key to OFF ( 0 ) position.

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B. Assigned Channel Scheme (preset system channel)
Both transmitter and receiver is assigned with a matching preset channel
(channel 01 - 62).
NOTE: Pitch and catch, tandem, and receiver select 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. Channel unassigned is represented by solid orange on the Status LED.
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 START position until the Status LED turns to solid green (transfer
complete). Turn off the transmitter power if constant 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 OFF ( 0 ) position.
NOTE: When selecting a new channel, make sure each button press does not
exceed 3 seconds.
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.

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4.1.3 Remote Pairing
A. Transmitter-to-Transmitter Pairing:
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 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:
JP8 Open Method: After the transmitter enters the Remote Pairing mode, output
receiver data by pressing and holding the PAIRING button located on the receiver
cover and receive data by pressing and holding PB3 on the transmitter, both at the
same time. When the transmitter Status LED turns to solid green while both
pushbuttons are still pressed down the pairing is completed.
→ →
Set JP8 to “Open” Output data – receiver Receiving data – transmitter

(press and hold the Pairing button) (press and hold PB3)
JP8 Short Method (press Pairing button not required): After the transmitter
enters the Remote Pairing mode, press and hold PB3 on the transmitter until the
Status LED turns to solid green, indicating the pairing is complete. Make sure the
transmitter and receiver are within 10 meters from one another and that no other
active receivers are nearby during the pairing process. During pairing process the
receiver MAIN relays must be deactivated (relay open). For tandem systems make
sure the receiver is not locked to any of its existing transmitters.
4.1.4 I-Chip
When an I-Chip is inserted into the Flex EX2 transmitter it becomes backwards
compatible with a Flex EX (GEN 1) receiver. Refer to the appropriate Flex EX
(GEN 1) manual for information on configuring the I-Chip or contact Magnetek field
service.
NOTE: A Flex EX (GEN 1) transmitter will NOT work with a Flex EX2 receiver.

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4.1.5 Transmitter Start Function Settings
When transmitter goes into sleep mode the system is temporarily deactivated (MAIN
relays opened). Execute the START command or press any pushbutton to wake up the
system (MAIN relays closed).
Dipswitch
Function
Settings
START
1 xxxxxxxxx0
Reactivation
Any Button
2 xxxxxxxxx1
Reactivation
4.1.6 Transmitter Inactivity Timer Settings

Set how long the system waits to enter the sleep mode when the transmitter is not in
use (pushbutton not pressed). When transmitter goes into sleep mode the receiver
MAIN relays are deactivated.
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)

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4.1.7 Transmitter Output Power Settings
1mW offers the shortest operating range with lowest battery consumption while 10mW
offers the longest operating range with highest battery consumption (manufacture
preset at 1mW).
Dipswitch Dipswitch
Output Power Output Power
Settings Settings
1 000xxxxxxx 1mW 5 100xxxxxxx 5mW

4.1.8 Infrared Programming

Other custom functions and settings not listed in this
manual can be programmed via the infrared IR
programmer unit, such as the system serial number,
frequency range, relay output status feedback, new and
updated functions, and many others. Please contact
Magnetek field service for more details.
4.1.9 Pushbutton Function Settings

2. With the STOP button elevated, press and hold PB3 and
PB4 at the same time.
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 blink.
For example, 1 orange blink followed by 5 red blinks is pushbutton function no.105.
6. Set 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 OFF ( 0 ) position.

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4.1.9.1 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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4.1.9.2 A/B Pushbutton Select with LED Indication – Standard Right/Left
There are 4 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
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
* PB5…PB8 → Pushbutton number.

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

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4.1.9.3 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 4.2.4 on
page 36 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
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.

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4.1.9.4 A/B Pushbutton Select with LED Indication – Inline Top/Bottom
There are 4 different types of A/B selector sequence available. Choose one that is most
suitable for your application. See Section 4.2.4 on page 36 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
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
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

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Function
Number
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

* A/1&2 - D/3&4 → A/B pushbutton select function with designated LED indication.
4.1.10 Display Frequency Band

2. With the STOP button elevated, press and hold PB2 and PB4 at
the same time.
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 433 MHz.
6. Exit Frequency Band Display mode by rotating the power switch key to OFF ( 0 )
position.
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.

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4.1.12 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 transmitter is thrown or dropped. When
triggered, the receiver MAIN relays are deactivated with the exception of the horn
output that can be assigned to any of the Function output relays (K25, K26 or K30). This
horn output setting requires the infrared IR programmer unit. Please contact Magnetek
field service for more details.
Dipswitch
Function
Settings
1 xxxxxxxx0x Sensor Disabled
2 xxxxxxxx1x Sensor Enabled
4.1.13 Receiver Select Configurations (RS Systems Only)

TYPE B: A/B Receiver Select with Bridge Receiver

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TYPE C: A, B, C, D Receiver Select
NOTE: All settings are preset at the factory.
4.2 Receiver
4.2.1 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 programming. The
system channels table in Section 4.2.9 on page 39
illustrates which dipswitch setting corresponds to which
channel. Once the receiver channel is altered, make sure
to change the transmitter channel as well. The channel
on both transmitter and receiver must be identical in
order for the system to work (see Section 4.1.2 on
page 16, part B). When set to all zeros (000000), the
receiver becomes unassigned channel scheme (see
Section 4.1.2 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 4.2.9 on page 39.

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4.2.2 Output Relay Configurations
4.2.2.1 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.
4.2.2.2 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 4.2.3.1 on page 33 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 4.2.3.1 on page 33 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 4.2.3.1 on page 33 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 4.2.3.1 on page 33 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 4.2.3.1 on
page 33 on how to set to this function.
st nd
↓ ġ ġ ġ ġ ġ ġġ ↓ġġġġġ
Fwd Rev Slow Fast Fwd Rev Slow Fast
4.2.2.3 START + AUX Function

After executing the START command at transmitter
startup the same START position becomes an auxiliary
function with momentary contact connected through K25
Function output relay. There are other types of auxiliary
functions made available for K25, K26 and K30 Function
output relays (see Section 4.2.7 on page 38). Contact
Magnetek field service if your application requires other
types of auxiliary function connected to these Function
output relays.
4.2.2.4 ON/OFF Pushbutton Function

The user can set any of the two adjacent pushbuttons on the
transmitter to behave like a mechanical ON & OFF rocker or
toggle switch. ON output relay closes when ON pushbutton
is pressed (OFF output relay opens) and OFF output relay
closes when OFF pushbutton is pressed (ON output relay
opens). See Section 4.2.3.1 on page 33 on how to set to
this function.
4.2.2.5 Brake Function (Flex 8EX2 only)

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. See Section 4.2.3.1 on page 33 on how to set to this
function.
4.2.2.6 External Warning Function

The user can install an external warning device (rotating lights, horn, etc.) to the K26
Function output relay located inside the receiver. The user can choose which
pushbutton pair (or pairs) triggers the external warning device when pressed. See
Section 4.2.3.1 on page 33 on how to set to this function.

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4.2.2.7 Momentary Contact
When pushbutton is released the corresponding output relay will open or deactivate.
This type of relay action usually applies to external applications such as horn and
buzzer. See Section 4.2.3.2 on page 34 on how to set to this function.
4.2.2.8 Toggled Contact

When pushbutton is released the corresponding output relay will maintain contact or
closure until the user presses the same pushbutton again. This type of relay action
usually applies to external applications such as lights. See Section 4.2.3.2 on
page 34 on how to set to this function.
4.2.2.9 Pitch & Catch Function

This function allows two operators controlling from opposite ends of a crane or
equipment. When set to “Pitch & Catch” make sure the 2nd transmitter is set to the
next highest channel (channel X+1). For example, if the system is set to channel 01
then the newly added 2nd transmitter must be set to channel 02 with identical serial
number. Furthermore, the Channel dipswitch position #7 and #8 on the decoder
board must set to “10” for 2-channel scanning (scans channel 01 and 02). Refer to
Section 4.2.2.9 on page 32 and Section 4.2.3.2 on page 34 on how to set to this
function. Pitch & Catch function must set to assigned channel scheme (see Section
4.1.2 on page 16, part B).
4.2.2.10 Receiver Channel Scanning Function

Receiver channel scanning function is applicable only when a preset channel is
assigned to the system (see Section 4.1.2 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

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(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
2-channel scanning (type 2 above) the receiver will scan only channel 01 and 02.
4.2.3 Dipswitch Settings

4.2.3.1 Interlocked Pushbutton Pair
Interlocked means any pushbutton pair
cannot be pressed simultaneously as
each press will cancel the other out.
Interlocked setting usually applies to
electric motor’s forward and reverse
motion and ON and OFF switches. Each
dipswitch on the decoder board
corresponds to a pushbutton pair.
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.

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Dip # of Relays
Function Descriptions
Settings Used
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*
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 function requires installing an external warning device such as horn or lights to the K26 Function
output relay.
4.2.3.2 Non-Interlocked Pushbutton Pair

Non-interlocked setting allows the pushbutton pair to be pressed simultaneously. It
usually applies to equipment's auxiliary functions such as lights, horn or buzzer.
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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4.2.4 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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4.2.5 Voltage Settings
Prior to installation always check to make sure the voltage setting is correct for your
application.
Position 1 → 110 - 120VAC

Position 2 → 220 - 240VAC or 48VAC* or 24VAC**
Position 3 → 380 - 400VAC or 110 - 120VAC* or
42VAC**
Position 4 → 410 - 460VAC or 220 - 240VAC* or
48VAC** or 9 - 36VDC***
* For system equipped with 48/110 - 120/220 - 240VAC power supply
** 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
4.2.6 Indicator Light and Buzzer Installation

The miniature indicator light and buzzer can
be easily fitted onto the receiver enclosure.
The indicator light or the buzzer works
simultaneously with the receiver MAIN
relays (manufacturer preset). When receiver
MAIN relays are activated the indicator light
or the buzzer is also activated, or vice versa.
Make sure the indicator light or the buzzer is
connected to the K30 Function output relay
CN11 port located on the AC line filter/relay
board inside the receiver. Contact Magnetek
field service if you would like the indicator
light or the buzzer to work differently.

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4.2.7 Other Function Output Relays Settings
Listed below are other types of functions that can be outputted through the three
Function output relays (K25, K26 and K30) via the infrared IR programmer unit.
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 is 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 rotate 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.
4.2.8 Receiver Select Setup (RS Systems Only)

The receiver select systems use the small Flex EX2 receiver. For wiring, refer to the
wiring diagram on the front of the receiver or the Flex 4EX2 manual.
TYPE B: A/B Receiver Select with Bridge Receiver
-8 Button Transmitter (bottom two buttons for A/B Select)
-3 Receivers (A, B, and Bridge)
TYPE C: A, B, C, D Receiver Select
-8 Button Transmitter (bottom four buttons for A, B, C, D Select)
-4 Receivers (A, B, C and D)
Jumper Settings Function
JP4 JP5 Receiver A setting for PB1 through PB4

(Opened) (Opened) (receiver select configuration)
JP4 JP5 Receiver B setting for PB5 through PB8
(Inserted) (Opened) (receiver select configuration)
JP4 JP5 Receiver C setting for PB9 through PB12
(Opened) (Inserted) (receiver select configuration)
NOTE: All settings are preset at the factory.

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4.2.9 System Channels Table
The following dipswitch settings only apply to setting the channel in the receiver when
using the assigned channel scheme (see Section 4.2.1 on page 28). For information
on setting the transmitter channel when assigned channel is used. See Section 4.1.2
on page 16, part B.
Channel Dipswitch Setting Channel Dipswitch Setting

01 000001 32 100000
02 000010 33 100001
03 000011 34 100010
04 000100 35 100011
05 000101 36 100100
06 000110 37 100101
07 000111 38 100110
08 001000 39 100111
09 001001 40 101000
10 001010 41 101001
11 001011 42 101010
12 001100 43 101011
13 001101 44 101100
14 001110 45 101101
15 001111 46 101110
16 010000 47 101111
17 010001 48 110000
18 010010 49 110001
19 010011 50 110010
20 010100 51 110011
21 010101 52 110100
22 010110 53 110101
23 010111 54 110110
24 011000 55 110111
25 011001 56 111000
26 011010 57 111001
27 011011 58 111010
28 011100 59 111011
29 011101 60 111100
30 011110 61 111101
31 011111 62 111110
NOTE: Channel unassigned is represented by “000000” dipswitch setting. See Section 4.1.2
on page 16, part A unassigned channel scheme.

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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 4.1.9.2 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 drive 300 mm
and electric motor 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 (not provided with the system) 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 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 6.9.1 Transmitter Status Indications on
page 50). 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 4.2.2.3 START + AUX Function on page 31).
Pressing any pushbutton before executing the START command at system startup 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 when the transmitter is turned on or after every STOP
button reset.
6. After 5 or 30 minutes of inactivity (pushbutton not pressed) the receiver MAIN relays are
temporarily disconnected (see Section 4.1.6 Transmitter Inactivity Timer Settings on
page 20). The Status LED blinks 3 reds and then shuts off. Press any pushbutton or
execute the START command to resume operation (see Section 4.1.5 Transmitter Start
Function Settings on page 20).

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7. Turn off the transmitter power by rotating the power switch key counterclockwise to 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 Master/Master Tandem Operation (Tandem Systems

Only)
1. To gain control of one or both receivers, first Receiver Receiver
rotate the selector switch to either A, B or A+B A B
position and then execute the START command

to activate the receiver MAIN relays inside
receiver A, receiver B, or both receivers
(depending on the selector switch position). In
order to gain control of a receiver, the PITCH
pushbutton on the other transmitter must be
pressed prior to your takeover. For example, in
order for transmitter-A to gain control of receiver-
B, transmitter-B must first release its control of
receiver-B by first rotating the selector switch to
B position and then pressing the PITCH
pushbutton for up to 2 seconds. This action
releases transmitter-B control of receiver-B. A
B
A
Transmitter-A is then able to take control of

receiver-B by first rotating the selector switch to Transmitter Transmitter
A B
B position and then executing the START
command. Make sure the START command is
executed 2 seconds after transmitter-B presses the PITCH pushbutton (refer to the
following diagram).

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Master Transmitter-A Takeover Procedure
Press PITCH Rotate to B position Rotate to START
→ →
(After 2 seconds)
Transmitter-B Transmitter-A Transmitter-A
Master Transmitter-B Takeover Procedure
Press PITCH Rotate to A position Rotate to START
→ →
(After 2 seconds)
Transmitter-A Transmitter-B Transmitter-B
2. Once the transmitter is locked on to both receivers, rotate the selector switch to either A,
B, or A+B position for independent or simultaneous operation.
3. At the beginning of each shift prior to turning on the transmitter power, always check to
see if the selector switch is correctly positioned for the intended receiver or receivers.
4. For safety, there is a 2-second grace period after executing the PITCH command. This
means that after PITCH pushbutton is pressed, executing the START command on the
other transmitter within this 2-second grace period has no effect. To gain control of the
other receiver, you must first wait for up to 2 seconds after the PITCH pushbutton is
pressed on the other transmitter and then execute the START command.

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6.3 Master/Slave Tandem Operation (Tandem Systems
Only)
1. To gain control of one or both receivers, first Receiver Receiver
rotate the selector switch to either A, B or A+B A B
position and then execute the START command

to activate the receiver MAIN relays inside
receiver A, receiver B, or both receivers
(depending on the selector switch position). In
order to gain control of a receiver, the PITCH
pushbutton on the other transmitter must be
pressed prior to your takeover. For example, in
order for Master transmitter to gain control of the
Slave receiver (receiver-B), Slave transmitter
must first release control of its receiver (receiver-
B) by pressing the PITCH pushbutton for up to
2.0 seconds. This action releases Slave
transmitter control from its receiver (receiver-B). A
Master transmitter is then able to take control of

the Slave receiver (receiver-B) by first rotating Master Slave
Transmitter Transmitter
the selector switch to B position and then
executing the START command. Make sure the
START command is executed 2 seconds after the PITCH pushbutton is pressed on the
Slave transmitter (refer to the following diagram).
Master Transmitter Takeover Procedure
Press PITCH Rotate to B position Rotate to START
→ →
(After 2 seconds)
Slave transmitter Master transmitter Master transmitter

October 2017
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Slave Transmitter Takeover Procedure
Rotate to B position Press PITCH Rotate to START
→ →
(After 2 seconds)
Master transmitter Master transmitter Slave transmitter
2. Once the transmitter is locked on to both receivers, rotate the selector switch to either A,
B, or A+B position for independent or simultaneous operation.
3. At the beginning of each shift prior to turning on the transmitter power, always check to
see if the selector switch is correctly positioned for the intended receiver or receivers.
4. For safety, there is a 2-second grace period after executing the PITCH command. This
means that when PITCH pushbutton is pressed, executing the START command on the
other transmitter within this 2-second grace period has no effect. To gain control of the
other receiver, you must first wait for up to 2 seconds after the PITCH pushbutton is
pressed on the other transmitter and then execute the START command.
6.4 A/B Pushbutton Select Operation

Pressing the “A/B” pushbutton repeatedly toggles between output relay A, B and A+B,
respectively. There are 4 different types of Select A/B sequences available (See Section
4.1.9.2 on page 23).
Standard – Output relay A activated at A position, output relay B
activated at B position, both output relays activated at A+B position.
Reversed logic – Output relay A activated at B position, output relay B
activated at A position, both output relays deactivated at A+B position.
See Section 4.2.4 on page 36 for JP3 jumper settings.
6.5 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 4.2.4 on page 36 for JP3
jumper setting.

October 2017
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6.6 Pitch & Catch Operation
Press the “PITCH” pushbutton for up to 2 seconds to release control of
the receiver. After 2-second grace period, rotate the power switch key to
START position for up to 2 seconds to gain control of the receiver. The
2nd operator is unable to take control of the receiver unless the 1st
operator presses the “PITCH” pushbutton. See Section 4.2.2.10 on
page 32 and Section 4.2.3.2 on page 34 on how to set to this function.
6.7 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.
6.8 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. Do not use any
rechargeable lithium ion batteries as they will damage both
the transmitter and the charging station.

October 2017
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6.9 System Status Light Indications
6.9.1 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 startup

October 2017
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6.9.2 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
6.9.3 Receiver Power Indications
Type Display Type (Red) Indication
1 On Power to receiver
2 Off No power to receiver
6.9.4 Receiver COM Indications
Type Display Type (Red) Indication
1 On Power to relay board

2 Off No power to relay board

October 2017
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7 General Specifications
Frequency Range: 433.050MHz - 439.600MHz
Number of Channels: 62 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)

Tel: (314) 869-7200

October 2017
Page 52 of 52

Magnetek Flex 8ex2 Radio Remote Control Manual

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Flex 8EX2 System

Radio Control Equipment

Part Number: 191-50800-M000F R00

Flex 8EX2 Instruction Manual

Flex 8EX2 Instruction Manual

Flex 8EX2 Instruction Manual

Your New Radio Remote Control System

Distributed by Tri-State Equipment Company Inc.

Flex 8EX2 Instruction Manual

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)

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

4. Pushbutton 1 (PB1) 12. Future Feature

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 Antenna Port (optional) 7. Remote Pairing Button

2. COM LED Indicator 8. System Information

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

Flex 8EX2 Instruction Manual

4.1.2 Transmitter Channel Settings

Flex 8EX2 Instruction Manual

Flex 8EX2 Instruction Manual

Output data – original transmitter Receive data – new transmitter

Flex 8EX2 Instruction Manual

Set JP8 to “Open” Output data – receiver Receiving data – transmitter

Flex 8EX2 Instruction Manual

4.1.6 Transmitter Inactivity Timer Settings

1 xxx000xxxx 1 minute 5 xxx100xxxx 10 minutes

3 xxx010xxxx 3 minutes 7 xxx110xxxx 60 minutes

Flex 8EX2 Instruction Manual

1 000xxxxxxx 1mW 5 100xxxxxxx 5mW

2 001xxxxxxx 2mW 6 101xxxxxxx 6mW

4 011xxxxxxx 4mW 8 111xxxxxxx 10mW

4.1.8 Infrared Programming

4.1.9 Pushbutton Function Settings

Flex 8EX2 Instruction Manual