Your solution started out as bearable (5V at 100mA) but ended up completely unacceptable at 500 mA. You say that your "wall wart" is rated at 300 mA. When you supply a voltage using a linear regulator the current in is the same as the current out - the regulator drops the difference in voltage. So here if you draw 500 mA at 5V you must supply 500 mA at 12V or 24V. The transformer will be overloaded in either case.
If the ratings are as you say then a potentially acceptable solution is to use a switching regulator (SR) operating from 24V in. \$5V \times 500 mA = 2.5 W\$.
\$24V \times 5 W =~ 210 mA\$. If the SR is 80% efficient (easily achieved) that rises to 260 mA. As that is liable to be an occasional requirement the total current at 24V will probably be acceptable with a 300 mA supply - depending on how many solenoids you wish to maintain on.
If you switch only one solenoid on at once the current drain with N activated is \$20 \times N + 20 mA\$. The surge current is essentially immaterial.
If you wanted more than 3 or 4 solenoids then current drain at 5V may need to be limited.
e.g.
- 10 solenoids at 20 mA = \$200 mA\$
- Balance = \$300mA-200mA = 100 mA\$
- Available current at 5V at 80 % efficient = \$ 100 mA \times \frac{24}{5} \times 0.8 = 384 mA\$, say \$400 mA\$.
Note that when a switching regulator is used, using a higher input voltage will result in less input current drain. Hence it is better here to use the full 24V supply.
Note also that if the transformer is a genuine 24 VAC then the rectified DC will be about \$24 VAC \times 1.414 - 1.5V - \$ "a bit" \$~= 30 VDC \$
Because:
\$VDC_{peak} = VAC_{RMS} \times \sqrt{2} ~= VAC \times 1.414 ~= 34 V\$.
A full bridge rectifier will drop about 1.5V.
34 VDC is peak voltage and available DC will be slightly lower - depends on load. There will be "a bit" of ripple and wiring loss and transformer droop and ...
At 80% efficiency this gives a 24VAC to 5V DC current boost of \$ \frac{30}{5} \times 0.8 = 4.8:1 \$
e.g.
- for 48 mA at 5V you need 10 mA at 30V.
- for 480 mA at 5V you need 100 mA at 30V.
So you about get 10 solenoids plus almost 500 mA at 5V DC :-)
One solution of many:
There are many SR IC's and designs. Here a simple buck regulator will suffice.
You can buy commercial units or "roll your own". There are many modern ICs but if cost is at a premium you could look at ye olde MC34063. About the cheapest switching regulator IC available and able to handle essentially any topology. It would handle this task with no external semiconductors and a minimum of other components.
MC34063. $US0.62 from Digikey in 1's. I pay about 10 cents each in 10,000 qauntity in China (about half Digikey's price).
Figure 8 in the datasheet referenced below happens to be a "perfect match" to your requirement. Here 25 VDC in, 5V at 500 mA out. 83% efficient.
3 x R, 3 x C, diode, inductor. It would work without alteration at 30 VDC in.
Datasheet - http://focus.ti.com/lit/ds/symlink/mc33063a.pdf
Prices - http://search.digikey.com/scripts/DkSearch/dksus.dll?Detail&name=296-17766-5-ND
Figure 8 in the LM34063 datasheet shows ALL component values except for the inductor design (inductance only is given). We can spec the inductor for you from Digikey (see below) or wherever and/or help you design it. Basically it's a 200 uH inducor designed for general power switching use with a saturation current of say 750 mA or more. Things like resonant frequency, resistance etc matter BUT are liable to be fine in any part that meets the basic spec. OR you can wind your own for very little on eg a Micrometals core. Design software on their site.
From Digikey $US0.62/1. In stock. Bourns (ie good).
Price:
http://search.digikey.com/scripts/DkSearch/dksus.dll?Detail&name=SDR1005-221KLCT-ND
Datasheet:
http://www.bourns.com/data/global/pdfs/SDR1005.pdf
Slightly better spec
This isn't too hard to implement. I can see the box and controller getting out of sync, but if the controller hits the zone twice and it doesn't matter what order the two sub-zones come on in, then that seems fine.
You are right in that you need some kind of memory. Since the unit will have no power to it between uses, that memory needs to be non-volatile. A microcontroller with built in EEPROM would do fine. EEPROMs are only good for a finite number of writes, but that's 100s of 1000s at least so no issue there.
When the power to the switch box turns on, all it really does is run the micro. The micro then turns on one of N relays to route the power to one of the sub-zones. It also writes the new state to its EEPROM so that it will power the next sub-zone in sequence next time.
A tiny micro running at slow clock speed can easily handle this. The 5V current will be small so a linear regulator will do well enough and be simple. Get relays that can run directly from the full wave rectified AC so there are no power conversion issues. 24V AC after full wave bridge with filter cap should be around 30-32 Volts. "24V" DC relays would work but get a little warm. Genuine 30V relays may be harder to find, so you could get 24V relays and put a resistor in series with the coil. A reverse catch diode accross the coil and a NPN transistor with base resistor to the micro is all you need per sub-zone output.
Another thing to consider is that the micro needs to see one power up each time the main controller turns on the zone. This should be as simple as putting a little low pass filtering on the micro's reset input so that it doesn't start running until a 100 ms or so after power is applied. By that time glitches and switching transients should be over.
The main controller also needs to leave some off time between powering this zone so that it toggles to the next sub-zone. It will take some time for the voltage to drop before the micro loses power or is shut down by the reset circuit. It could be a second or two depending on what values are chosen.
The more I think about it, the more I'm realizing the trickiest part of this is the reset circuit. You want to make sure the micro runs cleanly once per power up, and that it goes into reset cleanly once on power down and not too long after power down. This is all quite doable, but something that needs to be considered.
Best Answer
Question 1: The difference is because worldwide some power distribution systems are 50Hz, and some are 60Hz. The coil in the valve reacts differently for the different supply frequencies.
Question 2: That 1000mA rating is the maximum the power supply can deliver. The actual valve will only use what it needs to; you won't damage it in any way by using a higher capacity (current wise) supply as long as the applied voltage is proper.