Technicians hand-book

CIRCUIT DIAGRAM WORKING & WIRING:HPC-1K

The figure 1 shows the relay connection of HPC-1K.Relays A & B are input side of
transformer while relays C & D are on the output side. These relays (A,B,C,D)are all
single change over type. One relay E a double change over type is used for low &
high voltage cut-off. The relays operate as per Relay Truth table given in Table-I
The operation of the relays is manipulated and controlled with the aid of an electric
control circuit shown in figure 3 & 4.
Three DC power supplies are obtained. The supply V2 & V3 are obtained by rectifying the output
of the L.T. winding of main transformer. The third supply Vm is obtained from control transformer
by rectifying its output by a bridge rectifier. A regulated DC output of 7.8 volts is obtained from
Vm with the aid of regulator IC7808.The supplies V2,V3,& Vm change according to the mains
voltage while V3 remains constant. The supply V3 is given to relay coils. The supply Vs is used as
reference.(after obtaining the required voltage level through potentiometer settings of VR1 to
VR6) while Vm & V2 are compared to it V2.Vm & Vs are also used as power for ICs.
Let us consider the operation of relay E-figure 8.Comparator 1 is used for lower cut-off while
comparator 2 is for higher cut-off. The relay E will operate only when both the comparator give
an output simultaneously.
For Comp 1 Vm. VR1 for high output.
For Comp 2 Vm. VR2 for high output.
Both the comparator remain on from 150V to 230V mains voltage. When the voltage exceeds
230V:comp 2 turns off & so does the relay E.
The circuit in dashed position is the delay circuit. When at 150 volts input, both the comparators
turn on ,capacitor C11 starts charging & gets fully charged in two minutes giving a bare to drive
to transistor TR1.Now TR1 switches on and provides a drive for the transistor array IC which
turns the relay E on. For quick start, the capacitor C11 is removed from the ckI by pressing a
switch & stabilizer turns on without any delay.
For relays C & D voltages Vs(adjusted through VR6 & VR5 respectively)& V2 are compared while
for relays A & B voltages Vs(adjusted through VR3 & VR4 respectively) & Vm are compared. The
component layout ,placement & artwork of the PCB for the control ckI are shown in figure
3/11,12.The figures -13 gives complete wiring diagram of the voltage stabilizers HPC-1K.

AUTOMATIC VOLTAGE STABILIZER

RELAY OPERATION TRUTH TABLE
MAINS
INPUT
VOLTAGE
(VOLTS)

RELAY
A

STABILIZER OUTPUT
VOLTAGE
(VOLTS)

145
150
162(-)
162(+)
175(-)
175(+)
190(-)
190(+)
204(-)
204(+)
220(-)
220(+)
240(-)
240(+)
257(-)
257(+)
280(-)
280(+)

0
0
0
0
0
0
0
1
1
1
1
1
1
1
1
1
1
1

0
0
0
0
0
0
0
0
0
0
0
0
0
1
1
1
1
1

0
0
0
1
1
1
1
0
0

0
0
0
0
0
1
1
0
0
0
0
1
1
0
0
1
1
1

0
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
0

0
213
230
213
230
211
230
214
230
214
230
214
230
214
230
211
230
0

1
1
1
1
1
1
1
1

TABLE I

PRICE LIST SAGAR OLD TYPE PCB(WITH 1 IC)

R1
R2
R3
R4
R5
R6
R7
R8
R9
R10
R11
R12
R13
R14
R15
R16
R17
R18
R19
R20
R21
R22
R23
R24
R25
R27

2K2
6KB
4K7
6KB
10K
3KB
4K7
6KB
10K
120K+22K
1K
0K
10K
4K7
10K
10K
220K
3KB
2KB
10K
2K2
120K
4K7
3K3
10K
22K+47K

R 28
R 29
R 30
R 31
R 32

6KB
4K7
22K
10K
100K+0

VR1-VR6
IC-Reg.
IC
T1,T5,T7
T2,T6,T8
T3,T4
D1-D12
D21
C1
C2
C3
C4
C5
C6
C7
C8
C9
C11
C12

2K2
7808
IM339
BC147B
SK100
SL100
IN4004
5V
100F/63V
22F/40V
47F/63V
470F/63V
220F/10V
1000F/10V
22F/40V
22F/40V
22F/40V
22F/40V
22F/40V

10

11

PART LIST SAGAR NEW TYPE PCB(WITH 3 ICs)

R1
R2
R3
R4
R5
R6
R7
R8
R9
R10
R11
R12
R13
R14
R15
R16
R17
R18
R19
R20
R21
R22
R23
R24
R25

2K2
10K
2KB
6KB
10K
2K2
4K7
4K7
10K
100K+10K
2K2
10K
6K8
4K7
10K
4K7
4K7
330K+330K
10K
330K+270K
10K
6KB
6KB
2K2
10K

R 26
R 27
R 28
R 29
R 30
R31
C1
C2
C3
C4
C5
C6
C7
C8
C9
C10
C11
REG.IC
IC1
IC2
IC3
Tr
D1-D7
VR1-VR6
DZ1

12

470K+470K
6KB
6KB
10K
470K+470K
120K
100F/63V
22F/25V
47F/50V
470F/50V
220F/16V
1F/63V
22F/25V
22F/25V
22F/25V
22F/25V
1000F/10V
AN7808
IM339
IM339
ULN2003
BC147B
IN4004
2K2
5V

SAGAR SETTING PROCEDURES FOR POTENTIOMETERS

(Common for both old and new type PCBS)
1.Turn variac to 0' output.
2.Turn all variable resistors(VR) to their centre points.
3. Connect the stabilizer to variac output.
4. Increase input voltage slowly to 150 V keeping time-delay bypass switch pressed
adjust VR1 to operate relay 'E'.
NOTE: After performing each of the following steps 5 to 12,observe output voltage
which should be within 210-230V
5. Increase input slowly to 162V,adjust VR6 to operate Rel.C.
6.Increase input to 175V,adjust VR5 to operate Rel B, shall remain operational.
7.Increase input to 190V,adjust VR3 to operate Rel.A(C & D shall drop now)
8.Increase input to 204V,Rel C should operate again.
9.Increase input to 220V,Rel D.should also operate now.
10.Increase input to 240V,adjust VR4 to operate Rel.B(Rel.A remains operated,
Rel.C & D shall drop)but Rel.C may not drop also, which will not make any
difference.
11.Increase input to 257V,Rel.D shall operate(observe Rel.ABC also remain
operated)
12.Increase input to above 280V(say 285 V),adjust VR2 to drop Rel.E.
13.Now reduce input slowly to slightly below 280V and press by-pass switch to
operate Rel.E. again.
14.Now,slowly go on reducing the input voltage and observe that output remains
within the specified level of 209 to 231 volts.At input below 150V,Rel.E.should drop
again.

13

OLD TYPE(1 IC)

PCB CONNECTOR CONNECTIONS NEW TYPE(3 IC)

-----------------------------------------------------------------------------------------------------D5

A-------------------------E2

---------------------------------A

T6
Col.

B-------------------------Rel. D --------------------------------B

IC3 Pin 13

T8
Col.

C-------------------------Rel. C---------------------------------C

IC3 Pin 14

T2
Col.

D-------------------------Rel. E---------------------------------D

IC3 Pin 16

V3+ E-------Rel.A&B--------------------Rel.A,B,C,D,E-----------E
D6

F-------------------------E3

D1

V3+

------------------------------------F D2

T4 G------------------------Rel. B-----------------------------------G IC3 Pin 14

Col.
T3 H------------------------Rel. A-----------------------------------H IC3 Pin 15
Col.
T1 I-------------------------Rel. E(NC)-------------------------------I
Base

T1 Base

Cap J-------------------------Quick Start------------------------------J

C6+
sw

Cap C11+

Cam K------------------------Rel: C,D,E-------------------------------K

Camman Vo

Bridge I-----------------------Cont.TXFR------------------------------L
Rect
M--------------------------------------------------M
N Blank---------------------------------------- N Blank
IMPORTANT NOTE:
For fitting New Type of PCB (with 3 ICs)
In place of Old Type PCB(with 1 IC)
1.Disconnect wire coming to common of C,D & E relays at relay end.
2.Connect common of C,D & E relay to common of A & B relays.

14

FAULT FINDING:(SAGAR)
Output
Voltage
Condition

No
output

Check
Input
Voltage
within
specified
range
i.e.150v280v

No

o.k.

Press
Quick
Start
switch
output
o.k.

No
output

Input

Check
Voltage at
Loadster

No Voltage

Check
Voltage at
contacts of
relays A &
B

No
Replace
Loadster

Voltage

Replace the
relay that
does not
supply
voltage
further

15

Check
Volume
of pole of
relay E

No
Voltage

Yes

Check
Voltage at
Contact of C
& Drelays

No Voltage
Voltage
present at
Loadster but
not at main
transformer

Check
Voltage at
N/O
connect
of relay
E

Check D.C.
voltage at
coil of relay
E

Check PCB
delay circuit
try to obtain
coil voltage
by adjusting
11 & 10
presets
keeping
quick start
switch
pressed.
Replace PCB
if required

Yes
Relay E
faulty replace
relay E

FAULT FINDING:(SAGAR)

Output Voltage
Condition
Low/High output Voltage

Vary the input voltage

through a variac &
check relay operations
as per truth table

Identify the
Relay not
functioning
at its
respective
Voltage
position

Check DC
voltage the coil
of relay not
functioning. Try
to obtain voltage
by adjusting
respective preset
to make relay
functioning

NO
Replace PCB &
adjust output
voltage with help
of respective
preset

16

FAULT FINDING:(SAGAR)

Output Voltage
Condition
Voltmeter not Reading

Check voltage at
Voltmeter
Terminals

Check voltage
between on/off
switch &
input/output switch

Check voltage
between on/off
switch &
input/output switch

Yes
Voltmeter defective
replace

Check for loose

connection or
broken wire
between voltmeter

Check function of
input/output and
on/off switch

Replace if defective

17

Yes

Voltmeter
available

FAULT FINDING: (SAGAR)

Output Voltage
Condition
No Switching delay

Check relay E if it is
permanently on i.e.There
is no DC voltage at coil
but AC voltage available
on N/O contact.

Yes
Check Quick
NoStart
Switch.if
permanently
pressed

No

Replace Relay

Yes

Replace /
Release Switch

18

No

Check any dry

soldering on
capacitor
C6.resolder C6
and check
delay

No

Replace PCB
& adjust
output

PCB SAGAR NEW TYPE (3 IC) TEST VOLTAGES

INPUT
VOLTS

Vm
(C1)
12.5

Vs
V2
(Reg) (C3)
7.9
18.4

V3
(C4)
20.1 ICI/4
2.3

ICI/ 5-6
2.2

ICI/ 7
4.9

ICI/ 1-2
0

(E.on )
155

18.8

7.9

20.0

20.8 ICI/4
2.3

ICI/ 5-6
2.2

ICI/ 7
4.9

ICI/ 1-2
7.6

(Con)
165

15.0

7.9

21.4

21.7 ICI/6
3.5

IC2/ 7
3.9

IC2/1
2.9

IC3/5
2.9

T1
8-0
E-5.2
C-0
T1
8-2.8
E-5.0
C-2.2
IC3/12
0.7

(C.D. on)

16.7

7.9

20.3

22.9 IC2/4
3.8

IC2/ 5
4.2

IC2/2
2.9

IC3/4
2.9

IC3/13
0.7

(A on,C
,D off)

18.1

7.9

19.6

19.9 IC1/8
2.9

IC1/9
3.3

IC1/14
2.9

IC3/2
3.9

IC3/15

195
(A,C on)
20.1
210

7.9

21.5

21.1 IC1/6
2.2

IC2/7
3.5

IC2/1
4.9

IC3/5
7.6

IC3/12

(A,C,D) on 21.7
225

7.9

23.1

21.3 IC2/4
2.2

IC2/5
3.9

IC2/2
4.9

IC3/4
7.6

IC3/1

(A,B) on
23.8
245 off

7.9

21.4

20.5 IC1/10
3.8

IC2/11
4.3

IC3/3
2.9

IC3/13
0.7

(A,B,C,D)
On
26

25.7

7.9

22.8

21.2 IC2/4
2.2

IC2/5
4.6

IC2/2
4.9

IC3/4
7.6

IC3/13
0.7

(A,B,C,D)
On

28.3

7.9

25.0

23.9 IC1/4
2.2

IC1/5.6
5.1

IC1/7
4.9

IC1/1-2
0

T1
B-0
E-5.2
C-0

(E.off )
145

Voltages 9(w.r.t. ve,i.e. K)

* Voltages 0.7 or 0.8 V may show '0' in analog meters with higher range.

19

IC3/1
0

IC3/
16
0

IC3/1
1.8

IC3/
16
*0.8

IC3/1
0

IC3/
16
0

20

21

22

SPARE PARTS FOR SAGAR HPC-1K VOLTAGE STABILIZERS

Code
0601
0602

0603
0604

0605

0606

0607

0608

0609

0610
0611
0612
0613

0614

0615

Commodity
Rating
Main Auto Transformer,
T1
Control
Transformer
(Aux)T2
Control PCB
Complete
Relays(single
10 A
Chg 10A)24V,
750 ohms
Relays(single
10 A
Chg 10A)24V,
DC
750 ohms
Relays(Double
10 A
Chan 10A),
ge over 24V
750 ohms
Relays(Double
10 A
Chan 10A ge
Over,24V,
750 ohms
Time delay
NC
by-pass NC
switch
Miniature circuit
5A
5A breaker,
1-pole
Voltmeter,Class
0-300V
1.5
Jewel lamp
Complete 230V
Output Terminal
Strip ,6 way
Input/Output
230 V
Selector switch
for Vmtr 230V
ON/OFF switch
230 V
for Voltmeter
230V
PCB Connector
strip

Part No.

Spare of Item
SAGARHPC-1K
V/S
SAGARHPC-1K
V/S

OEN 4R1-24
(Spl)

SAGARHPC-1K
V/S
SAGARHPC-1K
V/S

PLA HCC
1C-24

SAGARHPC-1K
V/S

OEN 4R2-24
(Spl)

SAGARHPC-1K
V/S

PLA HCC
2C-24

SAGARHPC-1K
V/S

SAGARHPC-1K
V/S
SAGARHPC-1K
V/S
SAGARHPC-1K
V/S
SAGARHPC-1K
V/S
SAGARHPC-1K
V/S
SAGARHPC-1K
V/S
SAGARHPC-1K
V/S
SAGARHPC-1K
V/S

23