Magnetek FLEX EX2 User manual

IR Programmer
Radio Control Equipment
Instruction Manual
Part Number: 191-00424-0002 R5
September 2023
©Copyright 2023 Magnetek

IR Programmer Instruction Manual
September 2023
Page 2 of 84
Page Intentionally Left Blank

IR Programmer Instruction Manual
September 2023
Page 3 of 84
SERVICE INFORMATION
For questions regarding service or technical information contact:
1.866.MAG.SERV
(1.866.624.7378)
International Service
Outside the U.S. and Canada call +1.262.783.3500, press 3.
Columbus McKinnon Corporation Locations
Magnetek
N49 W13650 Campbell Drive
Menomonee Falls, WI 53051
Telephone: [phone]
E-mail: [e-mail]
Fax Numbers:
Main: 800.298.3503
Sales: 262.783.3510
Service: 262.783.3508
Canada
161 Orenda Road
Unit 1
Brampton, Ontario
L6W 1W3 Canada
Telephone: [phone]
Fax: [phone]
416.424.7617 (24/7 Service pager)
Europe
STAHL CraneSystems GmbH
Telephone: [phone]
E-mail: [email protected]m
Website
www.cmco.com/magnetek
© 2023 Columbus McKinnon Corporation
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 the Columbus McKinnon Corporation.
Parts of this product may be covered by one or more of the following patents: 7,190,146, 7,841,583,
8,401,814, 8,669,724, 8,686,670, and 3,017,333 (Canada).

IR Programmer Instruction Manual
September 2023
Page 4 of 84
Table of Contents
1 Introduction.........................................................................................................................................8
1.1 Product Manual Safety Information ..............................................................................................8
1.2 Warnings and Cautions ................................................................................................................9
2 External Illustrations ........................................................................................................................10
3 Power On/Off the Unit ......................................................................................................................11
4 Model Selection ................................................................................................................................12
5 Flex EX Models .................................................................................................................................13
5.1 Programming I-Chip ...................................................................................................................13
5.2 Program Serial Number (TX & RX) ............................................................................................13
5.3 Program System Type (TX & RX) ..............................................................................................14
5.4 Program System Frequency Range (TX) ...................................................................................14
5.5 Program System Channel (TX) ..................................................................................................14
5.6 Program RF Power (TX)............................................................................................................. 15
5.7 Program Transmitter Inactivity Timer (TX) ................................................................................. 15
5.8 Program Password (TX).............................................................................................................15
5.9 Program Pushbutton Functions (TX)..........................................................................................16
5.10 Program Function Relay / K26 Relay (RX).................................................................................16
5.11 Program Brake Functions (RX) ..................................................................................................17
5.12 Program Serial Number (Flex Pro transmitter)...........................................................................17
5.13 Program Project ID (Flex Pro transmitter) ..................................................................................18
5.14 Program CAN ID (Flex Pro transmitter)......................................................................................18
6 Flex EX2 Models ...............................................................................................................................19
6.1 Program IR ................................................................................................................................. 19
6.1.1 Transmitter............................................................................................................................. 19
6.1.2 Receiver................................................................................................................................. 20
6.2 Program Serial Number (TX & RX) ............................................................................................20
6.3 Program System Type (TX & RX) ..............................................................................................21
6.4 Program T-Type Functions (TX & RX) .......................................................................................21
6.5 Program System Frequency Range (TX & RX).......................................................................... 21
6.6 Program System Channel (TX & RX).........................................................................................21
6.7 Program RF Power (TX)............................................................................................................. 22
6.8 Program Pushbutton Functions (TX)..........................................................................................22
6.9 Program Left Rotary Switch Functions (TX)...............................................................................22
6.10 Program Right Rotary Switch Functions (TX) ............................................................................ 22
6.11 Program Transmitter Inactivity Timer (TX) .................................................................................23
6.12 Program LED1 Feedback Function (TX) .................................................................................... 23
6.13 Program LED2 Feedback Function (TX) .................................................................................... 23
6.14 Program LED3 Feedback Function (TX) .................................................................................... 24
6.15 Program LED4 Feedback Function (TX) .................................................................................... 24
6.16 Program Infrared START Function (TX).....................................................................................24
6.17 Program Infrared START ID Code (TX) .....................................................................................25
6.18 Program IRS Time Out (TX)....................................................................................................... 25
6.19 Program DEADMAN PB Function (TX) ......................................................................................25
6.20 Program PB Reset Function (TX)...............................................................................................26
6.21 Program All PB Interlocked (TX) ................................................................................................26
6.22 Program PB Delay Function (TX)...............................................................................................26
6.23 Program Channel Scanning (RX)...............................................................................................27
6.24 Program Function Relay 1 / K25 Relay (RX)..............................................................................27
6.25 Program Function Relay 2 / K26 Relay (RX)..............................................................................28
6.26 Program Function Relay 3 / K30 Relay (RX)..............................................................................29

IR Programmer Instruction Manual
September 2023
Page 5 of 84
6.27 Program Brake Functions (RX) ..................................................................................................30
6.28 Program MRX Micro Receiver PB type (MRX)...........................................................................30
6.29 Program Function Relay 1 (K10 and CN5) (MRX) .....................................................................31
7 Flex MINI Models...............................................................................................................................32
7.1 Program Direct ...........................................................................................................................32
7.2 Program Serial Number (TX & RX) ............................................................................................32
7.3 Program Keypad Type (TX & RX) .............................................................................................. 33
7.4 Program System Frequency Range (TX & RX).......................................................................... 33
7.5 Program System Channel (TX & RX).........................................................................................34
7.6 Program RF Power (TX)............................................................................................................. 34
7.7 Program Transmitter Inactivity/Sleep Timer (TX) ....................................................................... 34
7.8 Program Output Relay 1 & 2 (PB1 & PB2) (RX) ........................................................................ 35
7.9 Program Output Relay 3 & 4 (PB3 & PB4) (RX) ........................................................................ 35
7.10 Program Output Relay 5 & 6 (PB5 & PB6) (RX) ........................................................................ 36
7.11 Program Output Relay 7 & 8 (PB7 & PB8) (RX) ........................................................................ 36
8 Flex BASE & DUO Models................................................................................................................37
8.1 Program IR ................................................................................................................................. 37
8.1.1 Transmitter............................................................................................................................. 37
8.1.2 Receiver................................................................................................................................. 37
8.2 Program Serial Number (TX & RX) ............................................................................................38
8.3 Program System Type (TX & RX) ..............................................................................................38
8.4 Program T-Type Function (TX & RX) .........................................................................................39
8.5 Program System Frequency Range (TX & RX).......................................................................... 39
8.6 Program System Channel (TX & RX).........................................................................................39
8.7 Program RF Power (TX)............................................................................................................. 39
8.8 Program Pushbutton Functions (TX)..........................................................................................40
8.9 Program Transmitter Inactivity Timer (TX) ................................................................................. 40
8.10 Program Channel Scanning (RX)...............................................................................................41
8.11 Program Function Relay 1 / K25 Relay (RX)..............................................................................41
8.12 Program Function Relay 2 / K26 Relay (RX)..............................................................................42
8.13 Program Function Relay 3 / K30 Relay (RX)..............................................................................43
8.14 Program Brake Functions (RX) ..................................................................................................44
8.15 Program MRX Micro Receiver PB type (MRX)...........................................................................44
8.16 Program Function Relay 1 (K10 and CN5) (MRX) .....................................................................45
9 Transmitter Access Card (TAC) ......................................................................................................46
10 Flex EX Models ................................................................................................................................. 48
10.1 Install Software........................................................................................................................... 48
10.1.1 Install the provided software ..................................................................................................48
10.2 Firmware Update........................................................................................................................49
10.2.1 Set dipswitch position #1 to “1” or “up” position..................................................................... 49
10.2.2 Plug in the USB cable (not provided).....................................................................................49
10.2.3 Please try the following if device cannot be found when plugged in by USB into the
computer................................................................................................................................50
10.2.4 Open Flip 3.4.7 ......................................................................................................................51
10.2.5 Select a target device ............................................................................................................52
10.2.6 Select ATxmega256A3U .......................................................................................................52
10.2.7 Select a communication medium........................................................................................... 53
10.2.8 Select USB ............................................................................................................................53
10.2.9 Open USB.............................................................................................................................. 54
10.2.10 Load HEX file.........................................................................................................................54
10.2.11 Select HEX file (downloaded from ARC website) .................................................................. 55
10.2.12 Program target device memory .............................................................................................55
10.2.13 Download and Complete .......................................................................................................56
10.2.14 Unplug the USB cable and set dipswitch position #1 back to “0” or “down” position ............. 56

IR Programmer Instruction Manual
September 2023
Page 6 of 84
11 Pushbutton Function Table .............................................................................................................57
A. Flex EX Models ..........................................................................................................................57
A. Transmitter Toggle Functions (Standard) .............................................................................. 57
B. Transmitter Toggle Functions (Inline) ....................................................................................58
C. A/B Pushbutton Select Functions (Standard) ........................................................................59
D. A/B Pushbutton Select Functions (Inline) .............................................................................. 62
E. Transmitter Toggle + A/B Pushbutton Select Functions (Standard) ...................................... 65
F. Transmitter Toggle + A/B Pushbutton Select Functions (Inline) ............................................ 67
B. Flex EX2 Models ........................................................................................................................69
A. Transmitter Toggle Functions (Standard) .............................................................................. 69
B. Transmitter Toggle Functions (Inline) ....................................................................................70
C. A/B Pushbutton Select Functions (Standard) ........................................................................71
D. A/B Pushbutton Select Functions (Inline) .............................................................................. 74
E. Transmitter Toggle + A/B Pushbutton Select Functions (Standard) ...................................... 77
F. Transmitter Toggle + A/B Pushbutton Select Functions (Inline) ............................................ 79
C. Flex BASE Models ..................................................................................................................... 81
A. Transmitter Toggle Functions (Standard) .............................................................................. 81
B. Transmitter Toggle Functions (Inline) ....................................................................................81
C. A/B Pushbutton Select Functions (Standard) ........................................................................82
D. A/B Pushbutton Select Functions (Inline) .............................................................................. 83

IR Programmer Instruction Manual
September 2023
Page 7 of 84

IR Programmer Instruction Manual
September 2023
Page 8 of 84
1 Introduction
Thank you for your purchase of a Magnetek®IR Programmer.
These instructions are to be used as a reference for personnel operating the IR Programmer and the
equipment that it is controlling.
The user of these instructions should have basic knowledge in the handling of electronic equipment.
1.1 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 proper equipment operation:
• Instructions, manuals, and safety warnings from 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
• Safety standards and practices for the specific 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 and the
instructions and safety recommendations in this manual.
WARRANTY INFORMATION
For information on Magnetek’s product warranties by product type, please visit
www.cmco.com/magnetek.

IR Programmer Instruction Manual
September 2023
Page 9 of 84
1.2 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.
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.
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.

IR Programmer Instruction Manual
September 2023
Page 10 of 84
2 External Illustrations
1. Infrared Sensors 8. “WRITE” Button
2. LCD Screen 9. Programming Port
3. “↑” Button 10. Mini USB Port (for firmware update)
4. “↓” Button 11. I-Chip Port
5. “BACK” Button 12. I-Chip Programming Board Connector
6. “→” Button 13. Connector to Programming Port
7. “READ” Button 14. Connector to I-Chip Programming Board
(TX & RX) →Programming for both transmitter and receiver
(TX) →Programming for transmitter only
(RX) →Programming for receiver only