Mi primer trabajo de ingeniero fue instalar y configurar un PLC. Mi jefe, que no sabía mucho de este tema, SE le compró a un representante de una prestigiosa marca. El vendedor tampoco conocía mucho acerca del tema. El trabajo consistía en reemplazar un controlador obsoleto por otro de nueva generación. Todos los sensores y actuadores del sistema original se mantenían.
Cuando se estaba haciendo el reemplazo, notamos que los sensores instalados en campo eran de 24 Vdc NPN o sumidero y las módulos que se habían adquirido también. El mismo trabajo se iba a repetir en doce máquinas y cada máquina usaba 3 módulos de entradas DC. Un total de 36 módulos que se compraron con una especificación errada. Mi jefe no iba a durar mucho en su puesto, afortunadamente para él, el problema se resolvió con muy poco dinero.
Conexión del sensor NPN
La mayoría de los sensores NPN, cuando se activan conectan su salida al negativo de la fuente de 24 Vdc, activando la entrada a la que están conectados.
Cuando el sensor se desactiva, la salida queda en un estado de alta impedancia. Esto se conoce en electrónica como el tercer estado. Esta característica fue la usamos en nuestro provecho, en esta condición el flujo de corriente es igual a cero y la entrada del módulo, donde está conectado el sensor, se desactiva.
Conexión de un sensor NPN a una entrada NPN.
Solución
Cuando se conecta el sensor NPN a una tarjeta NPN no hay forma que haya conducción. La solución a esto es colocar una resistencia de pull-up, como se muestra en la siguiente figura. Se puede observar que cuando el sensor está activado su transistor de salida hace un corto circuito en la entrada. La corriente que entra al módulo es igual a cero, lo que hace que la entrada esté desactivada.
Cuando el sensor está desactivado, el transistor está abierto y la fuente alimenta la entrada a través de la resistencia de pull-up. Esto hace que la entrada esté activa.
Conexión del pull-up
Si miramos con detenimiento, el funcionamiento de la entrada se invierte. En el sistema original si el sensor está activo, la entrada está activa y viceversa. En el sistema con pull-up cuando el sensor está activo la entrada esta desactivada y viceversa. Esto se corrige cambiando el contacto asignado a la entrada donde está conectado el sensor en el programa. Si la entrada tiene asignado un contacto abierto (–] [–), este se cambia por uno cerrado (–]\[–), y viceversa.
¿Cómo calcular la resistencia?
Pero ¿de cuánto es el valor de la resistencia de pull-up? Si a resistencia de pull-up es muy grande la corriente que suministraría la fuente a el módulo de entrada puede que no sea suficiente para activa la entrada en el módulo. Si la resistencia es muy pequeña se puede dañar el transistor de salida del sensor. Así que necesitamos saber la corriente mínima de activación de la entrada, la impedancia de entrada de la entrada y la máxima corriente que puede drenar el sensor.
El valor mínimo de la resistencia de pull up viene dado por la siguiente ecuación:
Rpmin = Vdc/Ismax
Donde Ismax es valor más grande de corriente que el sensor puede drenar. Y el valor máximo de la resistencia de pull-up viene dado por la siguiente ecuación.
Rpmax = Vdc/Iemin – Ree
Donde Iemin es la corriente mínima de activación de la entrada y Ree es la resistencia de entrada de la entrada en la que está conectado el sensor. Para los siguientes datos de operación Vdc =24V, Ree= 3,1 KΩ, Iemin = 2 mA e Ismax = 100 mA. El valor de la resistencia de pull-up estaría en el rango de 240 a 8.900 Ω. Lo aconsejable es ir hacia el valor más alto, para proteger el sensor y exigirle menos potencia a la fuente de poder. Un valor comercial puede ser 8,2 KΩ de 1/4w. En la medida que nos acercamos al valor inferior de la resistencia de pull-up la cantidad de potencia que debe disipar es mayor, una resistencia de 240Ω consumirá 2,4 vatios cuando el sensor este activo. Recuerda que la potencia disipada es i2R.
Si el sensor y la entrada son PNP
Un análisis similar se puede hacer para un sensor PNP conectado a una entrada PNP. Por supuesto que este tipo de conexión no es recomendable de forma permanente. La solución definitiva fue cambiar los sensores por sensores tipo PNP, pero este tipo de conexión nos permitió continuar la producción mientras llegaban los nuevos sensores.
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Tengo un sensor optico NPN el cual cuando detecta algun objeto me manda señal a mi plc y asi puedo controlar el paro de un motor, el problema es que ya van dos sensores que cambio por que despues de un tiempo de trabajo, mi señal se mantiene activa, a pesar que el led de indicacion de señal activa este apagado, cuando quito el sensor me marca continuidad con el multimetro de positivo a señal, no encuentro el porque, no se si me puedan ayudar.
Saludos.
Hola Andres, es algo extraño eso que te sucede, por lo que describes pareceiera que la salida se puso en corto, esto normamente sucede cuando le exiges más corriente de la que puede dar el sensor. Lo extraño es que la tarjetas de entradas tienen una impedancia de entrada muy alta y es poco probale que la salida se dañe, con la freceuncia que describes, yo te acosenjaria dos cosas, revisa bien el cableado, y revisa la marca del sensor, puede que no sea de buena calidad. Anexo va mi correo me puedes escribir por alli si requieres más detalles. Saludos
Hola compañero, una curiosidad. Se puede conectar una salida PNP a una entrada NPN, o viceversa?
Hola Alberto, lo que preguntas es lo correcto, un dispositivo con salida npn debe conectarse a otro con entrada pnp y viceversa
Estimado, a mi me paso algo similar y quiero saber si al hacer esto, es posible que el sensor se queme o al menos produsca un mal olor ?
Gari. El sensor debe trabajar sin problemas, siempre y cuando tenga una salida de colector abierto como muestra la figura y además hayas calculado la resistencia como se muestra en el articulo. Si tienes problemas como los que describes podría ser que la resistencia de pull up es muy pequeña o estés alimentando con un voltaje mayor del voltaje de alimentación del sensor.
Estimado, según veo que parece que hay error en especificar si es NPN o PNP, en las imágenes. Incluso el titulo esta de NPN a NPN (se supone que la conexión es directa entre sensores y entradas con misma lógica).
Puede hacer confundir a principiantes de electronica.
Debe ser claro en que la conexión es de un Sensor NPN a un modulo PNP (en todo su contenido), pero gracias por su clara explicaion en detalle.
Hola Noe. Gracias por tu comentario. En la automatización, cuando hablamos de dispositivos de entrada, como los sensores y su conexión con los equipos de control, medición registradores entre otros, o cuando hablamos de la conexión de las salidas a los dispositivos de salidas, los dispositivos no pueden tener la misma lógica, en otras palabras un sensor npn (también llamado sumidero o sink) se debe conectar con una entrada pnp (también llamado fuente o source), esa es la forma correcta ya que de otra manera no funcionaría. Los dispositivos npn no necesariamente se llaman así por que tienen un transistor npn a la salida, es posible que por allí venga tu confusión. Son llamados npn por que ellos reciben la corriente del dispositivo fuente (pnp). Dos dispositivos npn conectados simplemente no funcionaría, ¿quien suministraría la potencia de funcionamiento?
puedes encontrar más información al respecto en el siguiente link: http://controlreal.com/es/entradas-salidas-discretos/
Me parece muy loable de tu parte que quieras evitar la confusión en los principiantes, esa, pienso debe ser la actitud, pero este no es el caso.
Me parece un buen artículo, pero estoy de acuerdo con Noe.
En la automatización, cuando hablamos de dispositivos de entrada PNP nos referimos a módulos que esperan un sensor tipo PNP. Un sensor PNP entregará positivo en estado excitado.
Creo que hay un error tanto en tu artículo como en el que citas.
Gracias por el comentario, esa confusión que tienes es muy común sobretodo en los estudiantes de ingeniería electrónica o eléctrica. Pero no tienen que creerme a mi, basta con revisar cualquier manual de sensores de alguna marca conocida como Siemens o Allen Bradley entre otros, para que aclaren la confusión.
PD: Y un comentario, en la última frase: «…permitió continuar la producción llegaban los nuevos sensores.»
Faltó la palabra «mientras», para decir «…mientras llegaban los nuevos sensores.»
Gracias Fidel por tus comentarios y aportes. En relación con los diagramas puedes revisar los siguientes links
http://controlreal.com/es/entradas-salidas-discretos/
http://controlreal.com/es/sensores-tipo-de-salidas/
Interesante experiencia, no se me habría ocurrido una solución de ese tipo, pero ya la tendré en cuenta para cualquier posible uso.
Sin embargo, tengo una duda con el funcionamiento de los módulos, ¿Tiene algún diagrama de la conexión con un módulo PNP?.
Saludos