24 V DC Over 110 V Ac
24 V DC Over 110 V Ac
24 V DC Over 110 V Ac
David B. Durocher
I. INTRODUCTION
In the past, control devices have required too much
power to make 24 VDC products cost effective or practical.
During the past few years, industrial control product
manufacturers have placed more emphasis on 24 VDC as the
control voltage of choice. Design innovations like increased
microprocessor content and separation of control and power
circuits have reduced control power requirements. The result
has been DC power supplies with improved reliability at
reduced costs. Technology advances in power transistor
ampere ratings have helped reduce the issues of excessive
DC voltage drop over long cable runs. This has led to an
increase in the variety of 24 VDC controlled devices along
with improvements in quality, robustness, features and size.
Electrical devices that have used 24 VDC for some time
include programmable logic controllers (PLC's) and distributed
control systems (DCS) central processing units (CPUs),
human machine interfaces (HMIs) and input/output (I/O)
hardware. Most recently, adjustable frequency drives (AFDs),
solid state reduced voltage starters (SSRVS) and servo drives
have changed to this control voltage. We are seeing a new
generation of contactors, starters, control relays and sensors
that will be dedicated to this control philosophy.
Migration to 24 VDC control is being driven by the need for
safer operating voltages, simplified compliance with safety
standards and more reliable interface with PLCs and DCS.
Presented at the 2002 IEEE IAS Pulp and Paper Industry Conference in Toronto, ON: IEEE 2002 - Personal use of this material is permitted.
Inductive Prox
Sensors
Output Modules
2) Size:
The push to reduce cost has led to the
minimization of control panel and equipment size. This has
led to an increasing demand for smaller and smaller control
devices. Sensors are typically offered in a smaller and wider
variety of sizes in 24 VDC versions. General purpose relays
are typically about the same size. Contactors and starters are
smaller. I/O density is significantly higher for 24 VDC
controls, up to 64 inputs/module, while the maximum for 120
VAC is normally 16.
Input Modules
General
Purpose
Relays
Contactors
0.1
10
100
1000
Speed Factor
1.500
Zero Crossing
1.000
0.500
Alternating Current
0.000
t o 2 ms
10 ms
-0.500
-1.000
-1.500
90
% R etained Voltage
80
70
60
50
40
30
CBEMA Curve
Control Relay
AC Coil Starter
24 VDC Supply
20
10
0
0.1
20ms
10
100
0.5 sec
1000
10 sec
10000 Cycles
Steady Seconds
State
Relay or Contactor
Stop
Start
V. RELIABILITY
1) Control Power Supply Reliability: Reliability requirements
for control power supplies are dependent on the process. If it
can be restarted easily, power supply reliability is not
important unless safety is a concern. But if restart is very
expensive and/or safety is an issue, a reliable power supply is
needed.
Typically for AC control systems a UPS is used. Where
very high reliability is important, two independent UPS are
used. These typically are fed through an automatic transfer
switch with an open transition. One must consider using a
very short transfer time to coordinate with the downstream
control relays to keep them from dropping out during
transition. In most cases, general purpose relays cannot be
coordinated with a high-speed open-transition transfer switch
but heavy duty machine tool relays can.
DC control systems, on the other hand, can be paralleled
and fed from different sources without the need of a transfer
switch. This eliminates the concern for downstream relays
UPS A
UPS B
Power
Panel A
Power
Panel B
DC Power
Supply
DC Power
Supply
DC
Controls
Automatic
Transfer
Switch
AC
Controls
2) Operational
Life:
Devices
that
incorporate
electromechanical switching of hard contacts tend to have a
shorter life than their solid state counterparts. This is due to
contact wear and mechanical failure. Most manufacturers
offer only 24 VDC control for solid state devices, suggesting
that 24 VDC must be more dependable.
In low power applications for 24 VDC control, contact
continuity is an issue that should be addressed. In most
cases, oxidation of the contacts slowly increases contact
resistance until continuity is lost. The rate and degree of
oxidation is due to a number of conditions including contact
design, operating current, switching frequency and operating
environment. Proper selection of the switching device will
reduce or eliminate occurrences of this problem.
Contact material must be reviewed to determine if its
suitable for the application needs. Gold plated contacts
typically provide the lowest contact and highest oxidation
resistance but have the lowest current carrying capability and
mechanical durability.
Other alloys can offer better
performance but also require higher minimum currents to
operate reliably. Mechanical contact design itself can have a
significant impact on contact continuity. Bifurcated and
pentafurcated contact designs can significantly reduce
continuity application issues. Hermetically sealed contacts are
available for applications in extreme environment applications
operating at very low power levels.
Indicator pilot lamps have a very poor life expectancy
compared to other control devices. Published estimated
operating hours for 24 VDC and 120 VAC incandescent lamps
are approximately equal. 24 VDC LED lamps provide the
longest life expectancy.
VI. COSTS
While good design, reliability and safety are key ingredients to
a successful controls system, cost is always an important
criteria in determining if a particular solution is acceptable.
The costs of a control scheme encompasses a variety of
items including engineering, startup, operation and
maintenance.
All of these must be considered when
determining the total lifetime costs.
Photo Sensors
0%
20%
40%
VII. SUMMARY
VIII. RERERENCES
[1] OSHA Regulations (Standards 29 CFR), Part 1910,
Subpart S Electrical General, U.S. Department of Labor,
http://www.osha.gov/OshStd_toc/OSHA_Std_toc.html.
[2] Code Changes 2002. National Electric Code. M Holt,
Consultant, EC&M Magazine, September 2001.
[3] National Electric Code, NFPA 70, National Fire Protection
Association, Quincy, Massachusetts, 1999.
[4] D. Mohla, D. Schouten, J. Tamblingson, Jr., and C.
Wellman, Comparative Issues of 24 V DC vs. 120 V AC
Process Control Systems", IEEE 2001 Petroleum &
Petrochemical Industry Technical Conference Record