Technicians hand-book

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 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.

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 AUTOMATIC VOLTAGE STABILIZER

RELAY OPERATION TRUTH TABLE

MAINS RELAY STABILIZER OUTPUT

INPUT VOLTAGE
VOLTAGE A B C D E (VOLTS)
(VOLTS)
145 0 0 0 0 0 0
150 0 0 0 0 1 213
162(-) 0 0 0 0 1 230
162(+) 0 0 1 0 1 213
175(-) 0 0 1 0 1 230
175(+) 0 0 1 1 1 211
190(-) 0 0 1 1 1 230
190(+) 1 0 0 0 1 214
204(-) 1 0 0 0 1 230
204(+) 1 0 0 1 214
220(-) 1 0 1 0 1 230
220(+) 1 0 1 1 1 214
240(-) 1 0 1 1 1 230
240(+) 1 1 1 0 1 214
257(-) 1 1 1 0 1 230
257(+) 1 1 1 1 1 211
280(-) 1 1 1 1 1 230
280(+) 1 1 1 1 0 0

TABLE I

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PRICE LIST SAGAR OLD TYPE PCB(WITH 1 IC)

R1 2K2 R 28 6KB
R2 6KB R 29 4K7
R3 4K7 R 30 22K
R4 6KB R 31 10K
R5 10K R 32 100K+0
R6 3KB
R7 4K7
R8 6KB VR1-VR6 2K2
R9 10K IC-Reg. 7808
R10 120K+22K IC IM339
R11 1K T1,T5,T7 BC147B
R12 0K T2,T6,T8 SK100
R13 10K T3,T4 SL100
R14 4K7 D1-D12 IN4004
R15 10K D21 5V
R16 10K C1 100F/63V
R17 220K C2 22F/40V
R18 3KB C3 47F/63V
R19 2KB C4 470F/63V
R20 10K C5 220F/10V
R21 2K2 C6 1000F/10V
R22 120K C7 22F/40V
R23 4K7 C8 22F/40V
R24 3K3 C9 22F/40V
R25 10K C11 22F/40V
R27 22K+47K C12 22F/40V

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PART LIST SAGAR NEW TYPE PCB(WITH 3 ICs)

R1 2K2 R 26 470K+470K
R2 10K R 27 6KB
R3 2KB R 28 6KB
R4 6KB R 29 10K
R5 10K R 30 470K+470K
R6 2K2 R31 120K
R7 4K7 C1 100F/63V
R8 4K7 C2 22F/25V
R9 10K C3 47F/50V
R10 100K+10K C4 470F/50V
R11 2K2 C5 220F/16V
R12 10K C6 1F/63V
R13 6K8 C7 22F/25V
R14 4K7 C8 22F/25V
R15 10K C9 22F/25V
R16 4K7 C10 22F/25V
R17 4K7 C11 1000F/10V
R18 330K+330K REG.IC AN7808
R19 10K IC1 IM339
R20 330K+270K IC2 IM339
R21 10K IC3 ULN2003
R22 6KB Tr BC147B
R23 6KB D1-D7 IN4004
R24 2K2 VR1-VR6 2K2
R25 10K DZ1 5V

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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.

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 OLD TYPE(1 IC) PCB CONNECTOR CONNECTIONS NEW TYPE(3 IC)
------------------------------------------------------------------------------------------------------
D5 A-------------------------E2 ---------------------------------A D1

T6 B-------------------------Rel. D --------------------------------B IC3 Pin 13

Col.

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 V3+

D6 F-------------------------E3 ------------------------------------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 T1 Base

Base

Cap J-------------------------Quick Start------------------------------J Cap C11+

C6+ sw

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.

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FAULT FINDING:(SAGAR)

Output Check Press Check Check

Voltage Input Quick Voltage at Volume
Condition Voltage Start N/O of pole of
No within
o.k. switch
No connect
No
relay E
specified output of relay
output range o.k. output E Voltage
i.e.150v-
280v

No Input No Voltage Yes

Check Check Check D.C.

Voltage at Voltage at voltage at
Loadster Contact of C coil of relay
& Drelays E

No Voltage Check PCB Yes

Voltage Check delay circuit
Relay E
present at Voltage at try to obtain
coil voltage faulty replace
Loadster but contacts of relay E
not at main relays A & by adjusting
transformer B 11 & 10
presets
keeping
quick start
switch
No Voltage pressed.
Replace Replace PCB
Replace the
Loadster relay that if required
does not
supply
voltage
further

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 FAULT FINDING:(SAGAR)

Output Voltage Vary the input voltage Identify the Check DC

Condition through a variac & Relay not voltage the coil
Low/High output Voltage check relay operations functioning of relay not
as per truth table at its functioning. Try
respective to obtain voltage
Voltage by adjusting
position respective preset
to make relay
functioning

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

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 FAULT FINDING:(SAGAR)

Output Voltage Check voltage at Check voltage Check voltage

Condition Voltmeter between on/off between on/off
Voltmeter not Reading Terminals switch & switch &
input/output switch input/output switch

Yes

Voltmeter defective Check for loose Voltmeter

replace connection or Yes available
broken wire
between voltmeter

Check function of
input/output and
on/off switch

Replace if defective

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FAULT FINDING: (SAGAR)

Output Voltage
Condition Check relay E if it is Check any dry Replace PCB
No Switching delay permanently on i.e.There soldering on & adjust
is no DC voltage at coil No capacitor No output
but AC voltage available C6.resolder C6
on N/O contact. and check
delay

Yes

Check Quick
NoStart No
Switch.if Replace Relay
permanently
pressed

Yes

Replace /
Release Switch

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 PCB SAGAR NEW TYPE (3 IC) TEST VOLTAGES

INPUT
VOLTS Vm Vs V2 V3 Voltages 9(w.r.t. ve,i.e. K)
(C1) (Reg) (C3) (C4)
(E.off ) 12.5 7.9 18.4 20.1 ICI/4 ICI/ 5-6 ICI/ 7 ICI/ 1-2 T1 IC3/1 IC3/
145 2.3 2.2 4.9 0 8-0 0 16
E-5.2 0
C-0
(E.on ) 18.8 7.9 20.0 20.8 ICI/4 ICI/ 5-6 ICI/ 7 ICI/ 1-2 T1 IC3/1 IC3/
155 2.3 2.2 4.9 7.6 8-2.8 1.8 16
E-5.0 *0.8
C-2.2
(Con) 15.0 7.9 21.4 21.7 ICI/6 IC2/ 7 IC2/1 IC3/5 IC3/12
165 3.5 3.9 2.9 2.9 0.7

(C.D. on) 16.7 7.9 20.3 22.9 IC2/4 IC2/ 5 IC2/2 IC3/4 IC3/13
3.8 4.2 2.9 2.9 0.7

(A on,C 18.1 7.9 19.6 19.9 IC1/8 IC1/9 IC1/14 IC3/2 IC3/15
,D off) 2.9 3.3 2.9 3.9
195
(A,C on) 20.1 7.9 21.5 21.1 IC1/6 IC2/7 IC2/1 IC3/5 IC3/12
210 2.2 3.5 4.9 7.6

(A,C,D) on 21.7 7.9 23.1 21.3 IC2/4 IC2/5 IC2/2 IC3/4 IC3/1
225 2.2 3.9 4.9 7.6

(A,B) on 23.8 7.9 21.4 20.5 IC1/10 IC2/11 IC3/3 IC3/13

245 off 3.8 4.3 2.9 0.7

(A,B,C,D) 25.7 7.9 22.8 21.2 IC2/4 IC2/5 IC2/2 IC3/4 IC3/13
On 26 2.2 4.6 4.9 7.6 0.7

(A,B,C,D) 28.3 7.9 25.0 23.9 IC1/4 IC1/5.6 IC1/7 IC1/1-2 T1 IC3/1 IC3/
On 2.2 5.1 4.9 0 B-0 0 16
E-5.2 0
C-0

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

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 SPARE PARTS FOR SAGAR HPC-1K VOLTAGE STABILIZERS

Code Commodity Rating Part No. Spare of Item

0601 Main Auto Transformer, SAGARHPC-1K
T1 V/S
0602 Control SAGARHPC-1K
Transformer V/S
(Aux)T2
0603 Control PCB SAGARHPC-1K
Complete V/S
0604 Relays(single 10 A OEN 4R1-24 SAGARHPC-1K
Chg 10A)24V, (Spl) V/S
750 ohms
0605 Relays(single 10 A PLA HCC SAGARHPC-1K
Chg 10A)24V, 1C-24 V/S
DC
750 ohms
0606 Relays(Double 10 A OEN 4R2-24 SAGARHPC-1K
Chan 10A), (Spl) V/S
ge over 24V
750 ohms
0607 Relays(Double 10 A PLA HCC SAGARHPC-1K
Chan 10A ge 2C-24 V/S
Over,24V,
750 ohms
0608 Time delay NC SAGARHPC-1K
by-pass NC V/S
switch
0609 Miniature circuit 5A SAGARHPC-1K
5A breaker, V/S
1-pole
0610 Voltmeter,Class 0-300V SAGARHPC-1K
1.5 V/S
0611 Jewel lamp SAGARHPC-1K
Complete 230V V/S
0612 Output Terminal SAGARHPC-1K
Strip ,6 way V/S
0613 Input/Output 230 V SAGARHPC-1K
Selector switch V/S
for Vmtr 230V
0614 ON/OFF switch 230 V SAGARHPC-1K
for Voltmeter V/S
230V
0615 PCB Connector SAGARHPC-1K
strip V/S

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