ABB Magne 3 Series User manual

2TLC172315M0201 Rev.M3 ORIGINAL INSTRUCTIONS abb.com/lowvoltage
—
SAFETY PRODUCTS
Magne 3 and Magne 4 Electromagnetic
Process Lock
Product Manual

2TLC172315M0201 Rev.M3 2
Read and understand this document
Please read and understand this document before using the products. Please consult your
ABB Electrification Sweden representative if you have any questions or comments.
Suitablity for use
ABB shall not be responsible for conformity with any standards, codes, or regulations that
apply to the combination of products in the customer’s application or use of the product.
Third party certificates for the products are available at https://new.abb.com/low-
voltage/products/safety-products. This information by itself is not sufficient for a complete
determination of the suitability of the products in combination with the end product,
machine, system, or other application or use.
The following are some examples of applications for which particular attention must be
given. This is not intended to be an exhaustive list of all possible uses of the products, nor is
it intended to imply that the uses listed may be suitable for the products:
•Outdoor use, uses involving potential chemical contamination or electrical
interference, or conditions or uses not described in this document.
•Nuclear energy control systems, combustion systems, railroad systems, aviation
systems, medical equipment, amusement machines, vehicles, and installations
subject to separate industry or government regulations.
•Systems, machines, and equipment that could present a risk to life or property.
Please know and observe all prohibitions of use applicable to the products.
NEVER USE THE PRODUCTS FOR AN APPLICATION INVOLVING SERIOUS RISK TO LIFE OR
PROPERTY WITHOUT ENSURING THAT THE SYSTEM AS A WHOLE HAS BEEN DESIGNED TO
ADDRESS THE RISKS, AND THAT THE ABB PRODUCT IS PROPERLY RATED AND INSTALLED FOR
THE INTENDED USE WITHIN THE OVERALL EQUIPMENT OR SYSTEM.
Descriptions and examples show how the product works and can be used. It does not mean
that it fulfills the requirements for all types of machines and processes. The buyer/user is
responsible for installing and using the product according to applicable standards and
regulations. We reserve the right to make changes to the product and the documentation
without prior notice.

2TLC172315M0201 Rev.M3 3
Table of Contents
1Introduction ................................................................................................................................5
1.1 Purpose of document .................................................................................................................5
1.2 Audience ........................................................................................................................................5
1.3 Reading prerequisites.................................................................................................................5
1.4 Special notes.................................................................................................................................5
2Safety .......................................................................................................................................... 6
2.1 Safety precautions ..................................................................................................................... 6
3Product description....................................................................................................................7
3.1 Magne 3..........................................................................................................................................7
3.2 Magne 4..........................................................................................................................................7
3.3 Accessories and parts................................................................................................................ 8
4Installation...................................................................................................................................9
4.1 Installation precautions ............................................................................................................ 9
4.2 Minimum safety distance.........................................................................................................10
4.3 Installation instructions...........................................................................................................10
4.3.1Mounting kits............................................................................................................ 11
4.3.2 Installation on sliding door....................................................................................12
4.3.3 Installation on hinged door ...................................................................................12
4.3.4 Installation Anchor plate ........................................................................................13
4.3.5 Positioning and orientation of Eva with Magne 4............................................14
5Connections ..............................................................................................................................16
5.1 Safety signal................................................................................................................................16
5.2 Magne 3X ..................................................................................................................................... 17
5.3 Magne 4X DYN............................................................................................................................18
5.4 Magne 4 DYN-Info......................................................................................................................19
5.5 Magne 4 DYN-2Info................................................................................................................... 20
5.6 Magne 4 OSSD-Info ...................................................................................................................21
6Serial connections ....................................................................................................................22
6.1 Magne 4 DYN-Info and Pluto ...................................................................................................22
6.2Magne 4 DYN-2Info and Pluto.................................................................................................23
6.3 Magne 4 OSSD-Info and Pluto.................................................................................................23
6.4 Magne 4X DYN, Pluto and M12-3S ......................................................................................... 24
6.5 Magne 4 OSSD-info and Sentry ............................................................................................. 25
6.6 Magne 4 OSSD-Info, Sentry and M12-3G ............................................................................. 25
7Functions ...................................................................................................................................26
7.1 Locking function ....................................................................................................................... 26
7.2 Interlocking function................................................................................................................ 26
7.3 LED Indications ......................................................................................................................... 26
8Maintenance ..............................................................................................................................27
8.1 Maintenance precautions ........................................................................................................27
9Troubleshooting ...................................................................................................................... 28
9.1 LED indications ......................................................................................................................... 28
9.2 Sensing distance Eva and Adam ........................................................................................... 28
9.3 Low or no holding force........................................................................................................... 29
9.4 Testing safety function ........................................................................................................... 29
9.5 Replacing Eva unit .................................................................................................................... 29

2TLC172315M0201 Rev.M3 4
10 Model overview .........................................................................................................................31
10.1 Magne models ............................................................................................................................31
10.2 Accessories and spare parts ...................................................................................................31
11 Dimensions................................................................................................................................33
12 Technical data ...........................................................................................................................35
13 EC Declaration of conformity..................................................................................................38

2TLC172315M0201 Rev.M3 5
1Introduction
1.1 Purpose of document
The purpose of this document is to describe the functions and to provide instructions for
installation, operation, maintenance and troubleshooting of the product.
1.2 Audience
This document is intended for authorized personnel.
1.3 Reading prerequisites
It is assumed that the reader of this document has knowledge of the following:
•Basic knowledge of ABB safety products
•Knowledge of machine safety
•Knowledge of safety devices and process locks
1.4 Special notes
Pay attention to special notes in the document:
Warning!
Danger of severe personal injury!
An instruction or procedure which, if not carried out correctly, may result in
injury to the technician or other personnel.
Caution!
Danger of damage to the equipment!
An instruction or procedure
which, if not carried out correctly, may damage
the equipment.
Note!
Important or explanatory information.

2TLC172315M0201 Rev.M3 6
2Safety
2.1 Safety precautions
The safety precautions must be followed during installation, operation, maintenance and
troubleshooting.
It is the responsibility of the user to ensure the correct overall functionality of its systems
and machines.
Warning!
Carefully read through the entire product manual before using the device.
Warning!
The devices
shall be installed by authorized personnel following the Safety
regulations, standards and the Machinery directive.
Warning!
Failure to comply with instructions, operation that is not in accordance with
the use prescribed in the instructions, improper insta
llation or handling of
the device can affect the safety of people and the plant.
Warning!
For installation and prescribed use of the product, the special notes in the
instructions must be carefully observed and the technical standards relevant
to the application must be considered.
Warning!
In case of failure to comply with the instructions or standards, especially
when tampering with and/or modifying the product, any liability is excluded.

2TLC172315M0201 Rev.M3 7
3Product description
Magne is an electromagnetic process lock that locks a door or a hatch and is intended for
applications that are sensitive to unintentional or unnecessary interruptions.
Magne has a holding force of up to 1500 N.
Magne uses a M12 connector for power and connection with other safety devices.
There are several different Magne models. All of them must be used with an anchor plate.
Magne 4 models also require an Eva actuator.
Magne can be installed on a door, preferably using an ABB mounting kit, available for sliding
doors or hinged (conventional) doors. See chapter ‘Mounting kits’.
3.1 Magne 3
Magne 3 keeps a door locked. If used in safety applications, Magne 3 needs to be
complemented with an external interlocking device.
3.2 Magne 4
Magne 4 keeps a door locked with integrated interlocking.
Magne 4 has an integrated Adam sensor which provides an interlocking function together
with an Eva actuator.
The Eva actuator is ordered and installed separately. Eva is available with a general or a
unique code.
Magne 4 is available with integrated Adam DYN (DYNlink signal) or Adam OSSD (OSSD signal)
using M12 5-pole or M12 8-pole connector.

2TLC172315M0201 Rev.M3 8
3.3 Accessories and parts
A standard Magne installation includes a Magne, an anchor plate and, with Magne 4, an Eva
actuator. Anchor plate and Eva actuator are ordered separately. Several accessories are
available. See chapter ‘Model overview’ for ordering codes and further details.
Anchor plate must be ordered with every Magne.
Anchor plates are delivered with a cellular rubber. Anchor plate 32E has an integrated
permanent magnet. It holds the door closed with a force of approximately 30 N when the
power to Magne is disconnected. Anchor plate 32D is without a magnet.
Eva actuator must be ordered with every Magne 4.
Eva units with general code all have the same code and fulfill the requirement for a low-level
coded interlocking device according to EN ISO 14119:2013.
Eva units with unique code all have a different unique code and fulfill the requirements for a
high-level coded interlocking device according to EN ISO 14119:2013.
Accessories for connection in series
Y-connectors and other accessories are available to facilitate connection in series.
Anchor plate Cellular rubber
Eva actuator
Y-connector

2TLC172315M0201 Rev.M3 9
4Installation
Installation shall be done in accordance with a risk assessment for the individual application.
Installation shall be carried out by authorized personnel and in accordance with instructions
in this document.
Please read and understand Magne and Eden product manuals before starting.
4.1 Installation precautions
Warning!
All safety functions
shall be tested before starting up the system.
Warning!
Follow the instructions carefully to avoid personal injury or damage to the
device.
Warning!
Do not defeat, tamper or bypass the safety function. Failure can result in
death or serious injury.
Warning!
The M12 connector shall be connected
after Magne has been installed on the
intended surface.
Caution!
It is important that Eva is correctly positioned and oriented in relation to the
integrated
Adam sensor in Magne 4. See chapter ‘Positioning and
orientation of Eva with Magne 4’.
Caution!
Magne shall be installed as close to the door handle as possible. The
distance between the lock and the handle creates a lever effect, reducing the
holding force. The bigger the distance, the greater the risk of the anchor
plate not being parallel and aligned with the electromagnet, which
significantly reduces the holding force.
Caution!
Magne
4 shall be connected to the power supply after the door is closed and
when
Eva is within sensing distance of Adam.
Caution!
After installation, check
the locking function and that the surfaces of the
magnet and the anchor plate are parallel,
i.e. that full contact is obtained
when the door is closed.
If the anchor plate tilts, the holding force of the lock
can be significantly reduced
or eliminated.

2TLC172315M0201 Rev.M3 10
4.2 Minimum safety distance
When using interlocking guards without guard locking to safeguard a hazard zone, the
minimum allowed safety distance between the guarded opening and the hazardous machine
must be calculated.
In order to ensure that the hazardous machine motion will be stopped before it can be
reached, the minimum safety distance is calculated according to EN ISO 13855: 2010
(“Positioning of safeguards with respect to the approach speeds of parts of the human
body”).
The minimum safety distance is calculated according to the formula:
S = (K x T) + C
Where:
S= minimum safety distance (mm)
K= approach speed of a human body (1600 mm/s)
T= the total time from opening of the guard until the hazardous machine movement has
stopped, including control system reaction times and other delays (seconds)
C= a safety distance (mm) taken from Table 4 or Table 5 of EN ISO 13857:2008; if it is
possible to push fingers or a hand through the opening towards the hazard before a stop
signal is generated.
Note!
In some cases, T might be reduced by the opening time of the guard until the
opening size permits access of the relevant parts of the body. Refer to EN
ISO
13855:2010 for further details and EN ISO 13857:2008 for specified values.
4.3 Installation instructions
1. Install Magne and accessories as close to the door handle as possible. Use relevant
mounting kit and follow the installation guide included in the kit (see chapter ‘Mounting
kits’).
2. Calibrate the position of the anchor plate with Magne according to chapter ‘Anchor plate
installation’.
3. Make sure Eva is correctly positioned and oriented in relation to the integrated Adam
sensor in Magne 4 (see chapter ‘Positioning and orientation of Eva with Magne 4’).
4. Connect the pin out according to chapter ‘Connections’.
5. Connect the M12 connector to Magne.
Note!
M
ake sure no power supply is connected when cable is fitted to the Magne
M12 pin out.
6. Close the door to put Eva within sensing distance of Adam.
7. Connect Magne to the power supply and turn power on.
Note!
Only connect Magne to power supply when Eva is within sensing distance. The
integrated Adam sensor in Magne 4 needs to learn the Eva code.
For Magne 3 the blue LED will illuminate with a solid light when connected.
For Magne 4 the green LED will illuminate with a solid light. The blue LED will illuminate
with a solid light when the locking signal is activated.
8. After installation, check the locking function.

2TLC172315M0201 Rev.M3 11
4.3.1 Mounting kits
To achieve proper fitting, it is recommended to use available mounting kits on installation.
The mounting kits include a separate installation guide and screws and nuts necessary to
install Magne on ABB Quick-Guard © fencing system.
Note!
Magne, Eva, anchor plate and cellular rubber are not included in the mounting kits
and need to
be ordered separately. See chapter ‘Model overview’.
Read and follow the separate instructions included in each mounting kit package:
•JSM D23C: Mounting kit for Magne on sliding door.
•JSM D28: Aluminum profile used as door handle for Magne on hinged door.
•JSM D21C: Mounting kit for Magne on hinged door.
•JSM D24: Mounting kit for Eva on hinged door. Often used with JSM D21C.
JSM D23C JSM D28
JSM D21CJSM D24

2TLC172315M0201 Rev.M3 12
4.3.2 Installation on sliding door
JSM D23C Mounting kit is recommended for use on sliding doors. Designed for use on both
right and left opened doors.
Installation tolerances for Magne and JSM D23C on a sliding door:
Ref
Part
Ref
Distance
A
Magne
X
60 mm
B
Anchor plate
Y
69 mm ±5
C
Cellular rubber
Z
18 mm ±5
D
Sliding door
E
Fence
4.3.3 Installation on hinged door
JSM D28 is a handle profile in aluminum for Magne 3 and Magne 4 to be used on hinged
doors. Designed for doors with a minimum opening radius of 200 mm.
JSM D21C and JSM D24 mounting kits are designed for hinged doors with 5-15 mm door gap.
Holding force at door handle
The Magne unit can support a holding force of up to 1500 N depending on installation.
When the Magne unit is mounted on a hinged door, the force needed at the handle to open
the door might be reduced. The possible reduction of the holding force is depending on the
offset between the Magne unit and the door handle, according to graph below.

2TLC172315M0201 Rev.M3 13
Axle
Holding force at door handle
Y
Holding force (kN)
X
Offset between Magne unit and door handle (m)
4.3.4 Installation Anchor plate
Anchor plate (B) is installed with cellular rubber (C) between the anchor plate and the bracket
(G) mounted on the door. The cellular rubber is attached to the anchor plate with adhesive
tape and enables the anchor plate to adjust to Magne.
Use suitable M8 screw (F). Leave enough room for the cellular rubber to ensure movement of
the anchor plate.
Recommended tightening torque is 7 Nm ±2.
Note!
Do not compress the cellular rubber to a thickness less than 8 mm
.
Do
not overtighten the screw. This can deform the anchor plate, causing reduced
or no holding force. A deformed anchor plate must be replaced
.

2TLC172315M0201 Rev.M3 14
Make sure the surfaces of the electromagnet (A) and the anchor plate (B) are completely
parallel, i.e. that full contact is obtained when the door is closed. If ABB mounting accessories
are not used, make sure the anchor plate cannot rotate. If the anchor plate tilts, the holding
force of the lock can be significantly reduced or eliminated.
Installation tolerances between Magne and anchor plate:
Ref
Part
Ref
Distance
A
Magne electromagnet
X
±3 mm sideways
B
Anchor plate
Y
±5 mm lengthways
Note!
To achieve maximum holding force the anchor plate must be installed completely
parallel to Magne.
4.3.5 Positioning and orientation of Eva with Magne 4
The safety functionality of Magne 4 is based on the integrated Adam sensor and the Eva
actuator.
Eva unit (A) must be correctly positioned above the yellow cover on Magne/Adam (B) when
the door is closed.
Note!
For the sensor to work as intended it is very important that the units are correctly
positioned and that the safety functions are tested.
Positioning tolerances for Eva and integrated Adam in Magne 4:
Ref
Part
Ref
Distance
A
Eva
X
±5 mm sideways
B
Adam
Y
±5 mm lengthways
Z
2-7 mm
X
Y

2TLC172315M0201 Rev.M3 15
To decrease distance Z, install distance plate (DA 1B) between the Eva unit and the bracket
holding Eva.

2TLC172315M0201 Rev.M3 16
5Connections
Connection diagrams with pin outs for different Magne models.
Warning!
Always use shielded cables to connect the uni
t to the rest of the safety circuit.
5.1 Safety signal
DYNlink signal – one channel
Magne DYN models use the ABB DYNlink signal as safety signal and must be used with ABB
Vital safety controller and/or ABB Pluto safety PLC.
All products using the DYNlink signal can be mixed and connected in series. Up to 30 DYNlink
devices with a Vital and up to 10 DYNlink devices per Pluto input can be connected while
maintaining PL e (EN ISO 13849-1:2015).
OSSD signal – two channels
Magne OSSD (Output Signal Switching Devices) models can be used with any safety control
module that can handle OSSD signals. Up to 30 Magne OSSD can be connected in series while
maintaining PL e (EN ISO 13849-1:2015).
200 µs
95 ms
190 ms

2TLC172315M0201 Rev.M3 17
5.2 Magne 3X
Male and female M12 5-pole connectors seen from cable side.
M12 5-pole connector
1
Brown
Locking signal +24 VDC
2
White
Not used
3
Blue
0 V
4
Black
Not used
5
Grey
Info output, locked
Warning!
The info
output is non-failsafe and shall never be used to control a safety
application.
Note!
Several Magne 3X
units can be connected using a M12-3A Y-connector, but the
info-signal will not be available.

2TLC172315M0201 Rev.M3 18
5.3 Magne 4X DYN
Male and female M12 5-pole connectors seen from cable side.
M12 5-pole connector
1
Brown
+24 VDC
2
White
DYNlink signal in
3
Blue
0 V
4
Black
DYNlink signal out
5
Grey
Locking signal +24 VDC
Warning!
The DYNlink signal is used to control the safety application.
Note!
Several Magne 4X DYN units can be connected using a M12-3S Y-connector.

2TLC172315M0201 Rev.M3 19
5.4 Magne 4 DYN-Info
Male and female M12 8-pole connectors seen from cable side.
M12 8-pole connector
1
White
DYNlink signal in
2
Brown
+24 VDC
3
Green
Locking signal +24 VDC
4
Yellow
0 V
5
Grey
Info output (Adam and Eva closed & Magne locked)
6
Pink
DYNlink signal out
7
Blue
0 V
8
Red
Not used
Warning!
Warning!
The info
output is non-failsafe and shall never be used to control a safety
application.
The
DYNlink signal is used to control the safety application.

2TLC172315M0201 Rev.M3 20
5.5 Magne 4 DYN-2Info
Male and female M12 8-pole connectors seen from cable side.
M12 8-pole connector
1
White
DYNlink signal in
2
Brown
+24 VDC
3
Green
Locking signal +24 VDC
4
Yellow
0 V
5
Grey
Info output (Adam and Eva closed)
6
Pink
DYNlink signal out
7
Blue
0 V
8
Red
Info output (Locked)
Warning!
The info output is non-failsafe and shall never be used to control a safety
application.
Warning!
The
DYNlink signal is used to control the safety application.