1

Technicians hand-book
2

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 VR 1 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 .
3
4
AUTOMATIC VOLTAGE STABILIZER
RELAY OPERATION TRUTH TABLE
MAINS RELAY
INPUT
VOLTAGE
(VOLTS)
ABCDE
STABILIZER OUTPUT
VOLTAGE
(VOLTS)
145 0 0 0 0 0 0
150 0 0 0 0 1 213
162(-)
162(+)
0
0
0
0
0
1
0
0
1
1
230
213
175(-)
175(+)
0
0
0
0
1

1
0
1
1
1
230
211
190(-)
190(+)
0
1
0
0
1
0
1
0
1
1
230
214
204(-)
204(+)
1
1
0
0
0
0
0
1
1
230
214
220(-)
220(+)
1
1
0

0
1
1
0
1
1
1
230
214
240(-)
240(+)
1
1
0
1
1
1
1
0
1
1
230
214
257(-)
257(+)
1
1
1
1
1
1
0
1
1
1
230
211
280(-)
280(+)

1
1
1
1
1
1
1
1
1
0
230
0
TABLE I
5
6
7
8
9
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
10
11
12
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)
No o.k. No No
output output Voltage
No Input No Voltage Yes
No Voltage Yes
No Voltage
Output
Voltage
Condition
Check
Input
Voltage
within
specified
range
i.e.150v280v
Press
Quick
Start
switch
output
o.k.
Check
Voltage at
N/O
connect
of relay
E
Check
Volume
of pole of
relay E
Check
Voltage at
Loadster
Voltage
present at
Loadster but
not at main

transformer
Replace
Loadster
Check
Voltage at
Contact of C
& Drelays
Check
Voltage at
contacts of
relays A &
B
Replace the
relay that
does not
supply
voltage
further
Check D.C.
voltage at
coil of relay
E
Relay E
faulty replace
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

16
FAULT FINDING:(SAGAR)
NO
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
Replace PCB &
adjust output
voltage with help
of respective
preset

17
FAULT FINDING:(SAGAR)
Yes
Yes

Output Voltage
Condition
Voltmeter not Reading
Check voltage at
Voltmeter
Terminals
Check voltage
between on/of
switch &
input/output switch
Check voltage
between on/of
switch &
input/output switch
Voltmeter defective
replace
Check for loose
connection or
broken wire
between voltmeter
Voltmeter
available
Check function of
input/output and
on/of switch
Replace if defective

18
FAULT FINDING: (SAGAR)
No No
Yes
No No
Yes

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.
Check any dry
soldering on

capacitor
C6.resolder C6
and check
delay
Replace PCB
& adjust
output
Replace Relay
Check Quick Start
Switch.if
permanently
pressed
Replace /
Release Switch

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PCB SAGAR NEW TYPE (3 IC) TEST VOLTAGES
INPUT
VOLTS
Vm
(C1)
Vs
(Reg)
V2
(C3)
V3
(C4)
Voltages 9(w.r.t. ve,i.e. K)
(E.of )
145
12.5 7.9 18.4 20.1 ICI/4
2.3
ICI/ 5-6
2.2
ICI/ 7
4.9
ICI/ 1-2
0
T1
8-0
E-5.2
C-0
IC3/1
0
IC3/
16
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
T1
8-2.8
E-5.0
C-2.2
IC3/1
1.8
IC3/
16
*0.8
(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
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 of)
195
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
(A,C on)

210
20.1 7.9 21.5
2.2
IC2/7
3.5
IC2/1
4.9
IC3/5
7.6
IC3/12
(A,C,D) on
225
21.7 7.9 23.1
2.2
IC2/5
3.9
IC2/2
4.9
IC3/4
7.6
IC3/1
(A,B) on
245 of
23.8 7.9 21.4
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
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
2.2
IC1/5.6
5.1
IC1/7
4.9
IC1/1-2

21.1 IC1/6

21.3 IC2/4

20.5 IC1/10

21.2 IC2/4

23.9 IC1/4

0
T1
B-0
E-5.2
C-0
IC3/1
0
IC3/
16
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,
T1
SAGARHPC-1K
V/S
0602 Control
Transformer
(Aux)T2
SAGARHPC-1K
V/S
0603 Control PCB
Complete
SAGARHPC-1K
V/S
0604 Relays(single
Chg 10A)24V,
750 ohms
10 A OEN 4R1-24
(Spl)
SAGARHPC-1K
V/S
0605 Relays(single
Chg 10A)24V,
DC
750 ohms
10 A PLA HCC

1C-24
SAGARHPC-1K
V/S
0606 Relays(Double
Chan 10A),
ge over 24V
750 ohms
10 A OEN 4R2-24
(Spl)
SAGARHPC-1K
V/S
0607 Relays(Double
Chan 10A ge
Over,24V,
750 ohms
10 A PLA HCC
2C-24
SAGARHPC-1K
V/S
0608 Time delay
by-pass NC
switch
NC SAGARHPC-1K
V/S
0609 Miniature circuit
5A breaker,
1-pole
5 A SAGARHPC-1K
V/S
0610 Voltmeter,Class
1.5
0-300V SAGARHPC-1K
V/S
0611 Jewel lamp
Complete 230V
SAGARHPC-1K
V/S
0612 Output Terminal
Strip ,6 way

SAGARHPC-1K
V/S
0613 Input/Output
Selector switch
for Vmtr 230V
230 V SAGARHPC-1K
V/S
0614 ON/OFF switch
for Voltmeter
230V
230 V SAGARHPC-1K
V/S
0615 PCB Connector
strip
SAGARHPC-1K
V/S