Festo SOPA-C series User manual

en Operating
instructions
8078142
2017-09b
[8068125]
Air gap sensor
SOPA-...

SOPA-...
2Festo – SOPA-... – 2017-09b
Original instructions
SOPA-EN
Identification of hazards and instructions on how to prevent them:
Danger
Immediate dangers which can lead to death or serious injuries
Warning
Hazards that can cause death or serious injuries
Caution
Hazards that can cause minor injuries
Other symbols:
Note
Material damage or loss of function
Recommendations, tips, references to other documentation
Essential or useful accessories
Information on environmentally sound usage
Text designations:
 Activities that may be carried out in any order
1. Activities that should be carried out in the order stated
– General lists
èResult of an action/References to more detailed information

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English – Air gap sensor SOPA-...
Table of contents
1 Product description 5.......................................................
1.1 Overview 5................................................................
1.2 Features 7................................................................
1.3 Factory settings 8...........................................................
2 Function and application 9...................................................
2.1 Design 9..................................................................
2.2 Operating statuses 10........................................................
2.3 Function range 11...........................................................
2.3.1 Binary signals and switching signals 11..................................
2.3.2 Graphic distance monitoring 13........................................
2.3.3 Spurious pulse suppression – parameter options 14........................
2.3.4 Switching off the display 14...........................................
2.3.5 Security code 14....................................................
2.3.6 Min/max values 14..................................................
3 Requirements for product use 15...............................................
4 Installation 18..............................................................
4.1 Mechanical system 18........................................................
4.2 Pneumatic system 20.........................................................
4.3 Electrical connection 21.......................................................
5 Commissioning 23...........................................................
5.1 Symbols on the display 23.....................................................
5.2 Bar graph on the display 24....................................................
5.3 Symbols for representing the menu structure 25...................................
5.4 RUN mode 25...............................................................
5.5 INFO/SHOW mode 26........................................................
5.6 Edit mode 28...............................................................
5.6.1 Start EDIT mode 28..................................................
5.6.2 Setting the switching characteristic of binary signals 29.....................
5.6.3 Setting special menu [SPEC] 31........................................
5.7 TEACH mode 32.............................................................

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6 Operation 33...............................................................
6.1 Resetting the sensor module to its factory settings 33...............................
6.2 Using the differential pressure regulator 34.......................................
7 Maintenance and care 34.....................................................
8 Disassembly 35.............................................................
9 Fault clearance 36...........................................................
10 Accessories 37..............................................................
11 Technical data 37............................................................
12 Quick commissioning 43......................................................

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1 Product description
For all available product documentation èwww.festo.com/pk
1.1 Overview
6
123
4
5
78 69
aJ
1Control module (optional)
2Sensor module (max. 4 modules permitted
incombination with control module)
3Plug for electrical connection
4Display
5Fastening slides
6Threaded sleeve (M4)
7Blanking plug (M7)
8Label holder
9Adapter plate for wall mounting
aJ Plug for electrical connection
Fig. 1 Mechanical and electrical connections

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1
23
4
5
6
7
8
9aJaAaB
1Manual LED (green) – Ready indication for
manual override1)
2Pushbutton – Clean (exhaust air)1)
3Pushbutton – Sense (instrumentair)1)
4EDIT button
5B pushbutton
6A pushbutton
7Pneumatic connection for measuring nozzle
(output)
8Supply port for operating pressure
9Vent screw (width across flats 14)
aJ Supply port for supply pressure
aA Status LED (yellow) – Sense(instrument air)
aB Status LED (yellow) – Clean(exhaust air)
1) Only for product variants with manual override (SOPA-C-...-H)
Fig. 2 Operating elements and pneumatic connections

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1.2 Features
Feature Order
code
Type
Air gap sensor SOPA Air gap sensor for contact and distance monitoring with LCD
Modules CM1- Control module with one sensor module
CM2- Control module with two sensor modules, pneumatically
interlinked
CM3- Control module with three sensor modules, pneumatically
interlinked
CM4- Control module with four sensor modules, pneumatically
interlinked
M1- Single sensor module 1)
Manual override of
control module
H- Control module with electrically activatable manual override
Sensing range R1- 20…200 µm
Type of mounting HH-rail mounting/through-hole
WAdditional wall mounting
Pneumatic connection Q6- Push-in connector 6 mm
Electrical inputs/
outputs
2P- 2x PNP
2N- 2x NPN
Electrical connection M12- Plug connector; M12x1, 4-pin; A-coded
Electrical accessories E1 Connecting cable with straight socket, cablelength 2.5 m2)
E2 Connecting cable with straight socket, cablelength 5 m2)
E3 Connecting cable with angled socket, cablelength 2.5 m2)
E4 Connecting cable with angled socket, cablelength 5 m2)
1) Optional manual override not selectable
2) Number of connecting cables dependent on the number of modules
Tab. 1 Overview of variants

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1.3 Factory settings
Settings Menu option Value/function
[SPEC]
Spurious pulse suppression [Option] Off
Signal assignment Out x to Pin 2 [P 2] c
Display timeout [di.] ON
Security code [lock] OFF
[OutA]
Switching point [SP] 100
Hysteresis [Hy] 5
Switching characteristic NO (normally open contact)
[OutB]
Switching point [SP] 150
Hysteresis [Hy] 5
Switching characteristic NO (normally open contact)
[OutC]
Lower switching point [SP min] 0.6 bar (60 kPa)
Upper switching point [SP max] 1.8 bar (180 kPa)
Switching characteristic NO (normally open contact)
Tab. 2

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2 Function and application
The air gap sensor SOPA-... is intended for distance monitoring in a range of 20...200 μm. The distance
measurement is performed using a non-contact pneumatic measuring process. This enables it to be
used in harsh ambient conditions.
2.1 Design
The system consists of two sub-components. The control module provides acompressed air
preparation that is adapted to the supply pressure of the sensor module, as well as the functionality for
switching measuring and exhaust air. Up to 4 sensor modules contain the sensory functions. The sensor
modules can be operated both individually and in combination with the control module.
123 45
6
7
8
9aJ
13/2-way valve (instrument air)
2Pressure regulator
33/2-way valve (exhaust air)
4Supply pressure
5Sensor modules (pneumaticallylinked)
6Object (example)
7Measuring nozzles
(1 per sensor module)
8Air gap
9Vent screw
aJ Supply port for operating pressure
Fig. 3 Configuration – with a control module and two sensor modules here
The compressed air flows from the sensor modules to the measuring nozzles. If the object is very close
to a measuring nozzle, the air gap is very small and only a small amount of air flows through. As the
object gets further away, the air gap becomes larger and more air flows through. The change in flow
rate is detected by the sensor modules, converted into a distance-correlated value and displayed
(speed measuring method with ejector).

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2.2 Operating statuses
INFO mode EDIT mode TEACH mode
SHOW mode
RUN mode
Fig. 4 Overview of the SOPA operating statuses
Operating status Function
RUN mode – Basic status after the operating voltage is applied
– Numerical and graphical display of distance-correlated values (bar graph)
– Display of measured values for supply pressure (in bar)
– Display of signal statuses for binary signals Out A, Out B, Out C
INFO mode – Display of input variables in the display.
– Switching of the display by pressing the A and/or B pushbutton.
SHOW mode – Display of current settings for the binary signals,
– Display and reset of the min/max values for the distance-correlated value
and supply pressure.
EDIT mode – Setting or alteration of the parameters for the air gap sensor
(switchingoutputs, display).
TEACH mode – Teaching-in of the switching points for the distance-correlated values
(transfer of the current value as the trigger level).
Tab. 3 SOPA operating statuses

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2.3 Function range
2.3.1 Binary signals and switching signals
1
Out A
Distance
Supply
pressure
In B
In C
In A
Out B
OUT C
2345
Pin 4
Pin 2
1Sensing variable
2Input signal
3Controller in sensor module
4Binary signal
5Switching signal at sensor module plug
Fig. 5 Binary signals and switching signals
Switching output at Pin 4 (Out A):
The switching output at Pin 4 is assigned to the binary signal OUT A and the distance input variable.
Switching output at Pin 2 (Out B or Out C):
The switching output at Pin 2 can be assigned alternatively to one of the following input variables via
the special SPEC menu (Edit mode):
– to binary signal Out C for monitoring the correct supply pressure input variable (delivery status),
– to binary signal Out B for monitoring an additional distance threshold value.
The allocation of Pin 2 to Out B makes it possible to set two independent binary signals for distance
monitoring over the entire measuring range.
The binary signal Out C for monitoring the supply pressure always acts as an enable signal for the
binary signals Out A and Out B. If the supply pressure is outside the switching window of Out C, SUP.P
appears in the display. The sensor module is then unable to conduct a correct distance monitoring
procedure. It is not possible to teach the binary signals in this case.
Binary signals and switching function
The binary signals Out A and Out B can be configured independently of one another. The threshold
value switching function is assigned to the binary signal OUT A and OUT B (distance input variable).
Thewindow comparator switching function is assigned to the binary signal OUT C (supply pressure
input variable).
– The switching element function normally closed contact (NC) or normally open contact (NO) can be
assigned to each binary signal.
– The switching point (SP) and hysteresis (HY) can be set for the binary signals Out A and Out B.
Onlythe switching points can be adjusted for Out C.

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In: Distance In: Supply pressure
Threshold value comparator Out: Window comparator
Switching
element
function NO
(normally open
contact)
Switching
element
function NC
(normally
closed contact)
Tab. 4 Switching point (SP) and hysteresis (HY) of the binary signals
Hysteresis serves to suppress switching signals in the event of fluctuations around the switching point.
The reset points function as long as the value is within the hysteresis range.
– Upper reset point = switching point + hysteresis
– Lower reset point = switching point – hysteresis
12
3
4
1Range in which switching signals are
suppressed in the event of fluctuations
around the switching point (SP)
2Object
3Sensing distance
4Measuring nozzle
SP Switching point
HY Hysteresis
Fig. 6 Sensing range with switching points

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2.3.2 Graphic distance monitoring
Function of the bar graph in RUN mode
The “distance” input variable is assigned to the two bar graphs. These show the current position of the
object proportional to the value of the respective switching point.
– Object outside the measuring range: All segments illuminate (maximum distance).
– Object approaches the switching point: The red segments switch off one after the other.
– Object has reached the switching point: All red segments are switched off, all green segments are
illuminated.
– Object approaches the measuring nozzle: The green segments switch off one after the other.
Note
Both sets of bars are only active if the switching output at Pin 2 is assigned to the binary
signal Out B.
The bars run synchronously if Out A and Out B have the same switching point. If
different switching points have been set, the bars are asynchronous to one another.
No. Bar graph Switches off if Position of the object
In A In B
9Display
red
Distance < 1.6 x switching point Object outside the specified
switching range1)
8Distance < 1.4 x switching point
7Distance < 1.2 x switching point
6Distance < 1.0 x switching point
5Display
green
Distance < 0.8 x switching point Object within the specified
switching range1)
4Distance < 0.6 x switching point
3Distance < 0.4 x switching point
2Distance < 0.2 x switching point
1Is always lit up Status indicator
1) The switching point of Out A and Out B is between segment 5 and 6
Tab. 5 Bar graph in the RUN mode

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2.3.3 Spurious pulse suppression – parameter options
If measuring or exhaust air is switched on and off during operation, spurious pulses are generated
(excessive fluctuations in supply pressure). Normally, such spurious pulses must be suppressed by
programming the higher-order controller.
Spurious pulses can be suppressed in the air gap sensor SOPA by adjusting the parameters [Options].
Option Meaning
Off Spurious pulse suppression switched off (factory setting).
Setting optimised for short response times (spurious pulse suppression can be
implemented using a higher-order controller).
1Spurious pulse suppression when using the instrument air on/off function with
deactivated exhaust air.
2Spurious pulse suppression with use of the function exhaust air on/off and with
instrument air switched off.
Tab. 6 Options for spurious pulse suppression
2.3.4 Switching off the display
The numerical (7-segment) display for the distance-correlated value can be switched off permanently or
for a defined time delay. Both switch-off modes allow the usage of the INFO mode and the SHOW mode
for a limited time.
2.3.5 Security code
The settings can be protected from unauthorised access by setting a numerical code which is up to
4digits in length. The security code must be entered each time a setting is changed (EDIT mode and
TEACH mode).
2.3.6 Min/max values
The min/max values for supply pressure monitoring and distance monitoring can be displayed and reset
in the SHOW mode èChapter 5.5.
Note
Switching off the supply voltage resets the min/max values.

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3 Requirements for product use
Warning
Depending on the functioning of the machine/system, manipulation of signal statuses
may cause serious personal injury.
 Note that if the switching characteristics of the outputs are modified in Edit mode,
the new characteristics will become effective immediately.
 Enable the password protection option (security code) to prevent accidental
alteration by an unauthorised third party èChapter 5.6.3, section “Setting the
security code”.
Note
Improper handling can result in malfunctions.
 Make sure that the specifications shown below are always observed.
 Observe the limit values (e.g. operating medium, pressures, forces, torques, temperatures, loads,
speeds, operating voltages, flow rates).
 Take the ambient conditions at the location of use into consideration.
 Comply with the regulations of the workers’ compensation trade association, the German Technical
Control Board (TÜV), of the VDE or relevant national regulations.
 Remove all transport packing, such as protective wax, foils (polyamide), caps (polyethylene),
cardboard boxes (except for the sealing elements of the pneumatic connections).
The material used in the packaging has been specifically chosen for its recyclability (exception:
oiled paper = residual waste).
 Use the product in its original status. Unauthorised modification is not permitted.
Measuring nozzle geometry
Caution
Damage from ingress of foreign matter!
In the event of an inappropriate measuring nozzle configuration or inappropriate routing
of the compressed air lines, foreign matter can enter the sensor modules and cause
amalfunction or damage to the device.
 Take the ambient conditions at the location of use into consideration by means of
suitable design measures – for example a suitable arrangement of the measuring
nozzles.

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1
1Measuring nozzle (diameter 1.5 mm/2.0 mm (nominal diameter)/2.5 mm)
Fig. 7 Measuring nozzle geometry
 Take into consideration the necessary measuring nozzle geometry.
 Execute the outlet of the nozzle with sharp edges. Angled edges at the outlet opening are not
permissible.
Measuring nozzle configuration
 Safeguard air discharge.
In the event of gap distance queries of <30 μm, it may be necessary to reset the outlet openings of
the nozzles by 30 … 60 μm after the bearing surface in order to permit air discharge.
The bearing surface, in which the measuring nozzles are mounted, must be provided with ducts that
permit exhaust to the outside (èFig. 8).
 Observe the permissible tube lengths between the sensor module and measuring nozzle
(èTechnical Data, Chapter 11).
Recessed measuring nozzle Exhaust Invalid
d
1
2
1
2
1Air duct (example)
2Measuring nozzle
d Distance 30 … 60 μm
Fig. 8 Measuring nozzle configuration

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Range of application and certifications
In combination with the UL mark on the product, the information included in this section is also
applicable for compliance with the certification requirements of Underwriters Laboratories Inc. (UL)
forUSA and Canada. Observe the following English-language remarks from UL:
This device is intended to be used with a Class 2 power source or Class 2 transformer in accordance
with UL1310 or UL1585.
As an alternative a LV/C (Limited Voltage/Current) power source with one of the following properties
can be used:
– This device shall be used with a suitable isolating source such that the maximum open circuit
voltage potential available to the product is not more than 30 V DC and the current is limited to
avalue not exceeding 8 amperes measured after 1 minute of operation.
– This device shall be used with a suitable isolating source in conjunction with a fuse in accordance
with UL248. The fuse shall be rated max. 3.3 A and be installed in the 30 V DC power supply to the
device in order to limit the available current.
Note that, when more than one power supply or isolating device is used, connection in parallel is not
permitted.
UL approval information
Product category code NRNT2 (USA) or
NRNT8 (Canada)
File number E253738
Considered standards UL 508, 17th edition,
C22.2 No. 14-2005
UL mark
Tab. 7 UL approval information

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4 Installation
4.1 Mechanical system
Fitting sensor modules (a maximum of 4 with a control block)
1
2
1. Remove the blanking plug 1by using an
internal hexagon socket spanner size AF 3 mm.
2. Make sure the sealing ring on the sensor
module to be mounted is seated properly.
3. Press on the sensor module lightly and tighten
the threaded sleeves 2by using an internal
hexagon socket spanner size AF 2.5 mm;
max.tightening torque 0.7 Nm.
4. Tighten the blanking plug 1on the last sensor
module (max. 4) so it is hand-tight – spanner
size AF 3 mm. Make sure the seal is seated
properly.
Fig. 9 Mounting the sensor module
Attaching the sensor module
Caution
Material damage caused by fluid in the sensor module.
If the sensor module is located below the measuring nozzles, condensed water or other
fluids can enter the module via the nozzles.
 Always position the sensor module so it is above the measuring nozzles.
Placing the sensor module
 Above the measuring nozzles èFig. 3.
 According to the specified tube lengths (0.5…8 m).
H-rail mounting:
 Hang the SOPA on the H-rail and press it until
the mounting tabs engage in place.
Fig. 10 H-rail mounting

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Plate mounting:
1. Create 4 x M5 threaded holes.
Hole patterns and dimensions èFig. 23.
2. Tighten the screws with a tightening torque
of0.8 Nm. Use washers.
Fig. 11 Plate mounting
Wall mounting:
1. Mount 2 adapter plates (e.g. 2 x M3).
Holepatterns and dimensions èFig. 23.
2. Hang the SOPA on the mounting plates and
press it until the mounting tabs engage in
place.
Fig. 12 Wall mounting
Attaching the sensor module without a control module
Use a suitable pressure regulator to guarantee the required supply pressure for all pneumatically
linked sensor modules (èTechnical Data, Chapter 11).
1
2
The supply pressure can be fed from the left
and/or right-hand side.
1. Mount the threaded M7 fitting onto the supply
pressure connection 1or 2.
Max. thread length: 5.5 mm.
2. Seal the opposite connection with the M7
blanking plug.
Spanner size AF 3 mm, tighten by hand.
Fig. 13 Attaching sensor modules

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4.2 Pneumatic system
122
1Control module
2Sensor modules
Fig. 14 Pneumatic arrangement
1. Insert the tube (outside diameter: 6 mm) into the push-in fittings.
2. Connect the supply port for the measuring nozzle to the corresponding measuring nozzle (èFig. 3).
3. For operation with a control module: Connect the supply port for the operating pressure to the
compressed air source.
For operation without a control module: Connect the supply port for the supply pressure to the
precision pressure regulator.
4. Ensure adequate exhaust at the vent screw connection (èFig. 2) (via vent screw or differential
pressure regulator (LRLL-1/8-QS-6).
Avoiding contamination of the measuring nozzles during downtimes
The vent screw (èFig. 2) can be removed and this connection used with a deactivated main air supply
and power supply, if necessary, to feed purge air.