Project Report

On

Digital (PIC Micro-controller 16F72 based ) Stabilizer

Submitted by:

Balram Sharma (BEL-04-2K19)

Sudhir Yadav (BEL-17-2K19)

Under the Guidance of:

Dr. Poonam Singhal

J.C Bose University of Science and Technology, YMCA

Faridabad, Haryana - INDIA

 Table of Contents
[Link] Topic Page no.
1. Introduction 2
2. Circuit Diagram 3
3. Working Methodology 4
4. Schematic Diagram - control card 5
5. Control Card Working 6
6. Working model 8
7. Bill of Material 9

1
 Introduction

Digital stabilizer presents an improved method of controlling AC Voltage within a specified band,
with low/ High cut-off and over-current protection.

Applications of Digital stabilizer are:

1. Domestic Refrigerators
2. Air-conditioners
3. Mains Input of small houses
4. Electronic Equipment

Merits of the Digital Stabilizer include: -

1. Fully automatic.
2. Requires no user attention.
3. Wide input range 140-280V
4. Output Voltage 220+/-10%
5. 7 Segment scrolling LED display of Input Voltage, Output Voltage, Load current and TDR
(Time delay relay) mode
6. Display for Low, High, Over-load, TDR.
7. Low/ High Voltage Intelligent Cut-off
8. Smart Over-current protection.
9. Intelligent TDR (Time delay relay)
10. Low loss toroidal transformer
11. Easy to install, operate and service.
12. Takes no space on floor, wall mounted type.

Limitations of the Digital Stabilizer include:

1. Step control of voltage through relays.
2. Relays make little noise and interference during changer-over.
3. Auto-transformers are bulky and consume power.
4. Digital circuit prone to failure during very high spike/ surges.

2
 Circuit Diagram

Fig1: Circuit Diagram of Digital Stabilizer

The main constituents of Digital Stabilizer are:

1. Control card (Including Micro-controller and 7 Segment LED Display)

2. 4KVA Toroidal Auto-transformer 0-200, 242, 282, 290V and 17V
3. 40A- 12V SPDT Electromagnetic relay- 2nos
4. 20-30A, 12V SPDT Electromagnetic relay- 1nos
5. Low Cost CT (Current Transformer)
6. Input Cord
7. Output Terminal block

3
 Working Methodology

The Working methodology provides a description and explains the working of Main Components of
the circuit.

1. Control Card: - Control card is the heart of this Digital Stabilizer, which controls all the
functions of this stabilizer through 8-bit PIC micro-controller 16F72, manufactured by
Microchip Inc. USA. 16F72 micro-controller has 3 I/O (Input output) ports. (Port A, B, C). In
present application Port A, which has inbuilt analog to digital conversion facility has been used
to sense various inputs, like input voltage, output voltage, load current and time interval. Port
C, which is a digital only I/O port has been used to drive various relays and cathode of 7
segment displays in multiplexing. Port B, which is also a digital only I/O port has been used to
drive anodes of 7 segment LED display. The working principle and detailed description of
Control card has been covered separately.

2. Toroidal Auto-transformer: - An auto-transformer of 4kVA rating having windings of 0-200,

242, 282, 290V taps with an isolated winding of 17V is used to control the output voltage
within a range of 220V+/-10% when the input voltage varies between 140-280V. 17V AC
voltage is full-wave bridge rectified to feed the coil of relays and further regulated to 5V to
energize the control card.

3. 40A 1CO- 12V electromagnetic relays: - Two electro-magnetic relays are used to control the
voltage within the specified range. One relay is put on the input side to feed the transformer at
appropriate tap and one relay is used to receive the output voltage from suitable tap.

4. 20-30A, 12V electromagnetic relay: - This relay is PCB mounted type and is used to switch on
the output when output voltage is within range. This relay also switches off the output in Low,
High, Overcurrent and supply interruption of less than 3 minutes, conditions.

5. Low Cost Current Transformer (CT): - A low cost CT has been manufactured using very small
17No. (0.5” Tongue) X 0.5” stack with few turns of thick wire working as primary and few
hundred turns of thin wire working as secondary. This CT is used to generate a proportional
voltage signal of load current needed to send current signal to microcontroller in the form of
voltage to a maximum value of 5V DC.

6. Input Cord: - A suitable 3 core PVC flexible copper cable has been used to give input to the
stabilizer.

[Link] Block: - A 30A 500V 3-way terminal block is used to take output from the stabilizer.

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Schematic Diagram - control card

Fig 2: Schematic Diagram of Control Card

5
 Control Card Working

The Working methodology provides a description and explains the working of the Control
Card.

1. Power Supply Section: - In Power Supply section, the input AC voltage of 17V received from
auxiliary winding of auto-transformer is rectified using 4 nos. bridge connected IN4007 diodes
and filtered by 470uF and 0.1uF Capacitor. The rectified and filtered supply is used to power
all the relay and is further filtered and regulated at 5V using LM7805. This 5V is used to power
the entire control card.

2. Input Voltage Sensing: - The input AC is half wave rectified, filtered and reduced to a
maximum voltage of 5.6V DC (5V DC=317V AC) using divider network and Zener
diode which is safe for microcontroller to handle and read. This variable voltage is given to pin
2 of the microcontroller. Pin 2 is AN0 pin of port A, which has Analog to Digital conversion
capability. The microcontroller keeps reading this voltage and decides the relay operation
according to input voltage. This input voltage is also displayed on 7 segment LED display after
INP.

3. Output Voltage Sensing: - The Output AC is half wave rectified, filtered and reduced to a
maximum voltage of 5.6V DC using divider network and Zener diode which is safe for
microcontroller to handle and read. This variable voltage is given to pin 3 of the
microcontroller. Pin 3 is AN1 pin of port A, which has Analog to Digital conversion capability.
The microcontroller keeps reading this voltage and decides the operation of low/ high cut off,
TDR relay operation according to output voltage. This output voltage is also displayed on 7
segment LED display after OUT.

4. Load current Sensing: - The output AC voltage from current transformer is full wave rectified,
filtered and reduced to a maximum voltage of 5.6V DC (5V DC=25.5A AC) using divider
network and Zener diode which is safe for microcontroller to handle and read. This variable
voltage is given to pin 5 of the microcontroller. Pin 5 is AN3 pin of port A, which has Analog
to Digital conversion capability. The microcontroller keeps reading this voltage and decides the
high current tripping of the TDR relay operation according to load current. This current is also
displayed on the 7 segment LED display after CUR.

5. Instant Start: - Instant start switch is configured at pin 4 of the microcontroller, which is pulled
up using a 10K resistor to 5V. If switch is pressed, ground appears on this pin and
microcontroller switches on the TDR relay ignoring the power supply failure time. This
function is not provided in current stabilizer as intelligent TDR function is enabled.

6
6. Intelligent TDR: - Intelligent TDR function is configured on pin 6 of the microcontroller,
which is pin AN4 of port A having Analog to digital conversion facility. 100uF capacitor C5
gets charged up to 5V when stabilizer is in function through 1.2Mohm resistor R24. The
microcontroller reads this voltage by switching on transistor Q1 by sending high signal from
pin 12, RC1 (Port C) if this voltage is less than 2.5V, the microcontroller knows that it is more
than 3 minutes the stabilizer was off and starts the TDR relay in next cycle if output voltage
condition is healthy.

7. Clock: - Clock signal is needed by microcontroller to execute the instructions stored in

Program memory. For this application a 4MHz crystal is used on Pin 9-10, executing one
instruction in 1Micro-second.

8. Low/High cut off, TDR, Overcurrent protection Relay control: -This relay is controlled
through pin 13 of the microcontroller, pin RC2 of port C, which is a digital I/O port. The
decision to operate this relay is based on various input received and conditions written in
software.

9. Input relay control: - Input relay is operated from pin 14 of the microcontroller, pin RC3 of
port C. The decision to operate this relay is based on input voltage and conditions written in the
software to operate this relay.

10. Output relay Control: - Output relay is operated from pin 15 of the microcontroller, pin RC4 of
port C. The decision to operate this relay is based on input voltage and conditions written in the
software to operate this relay.

11. Digital Display Control: - 7 segment LED display is controlled through multiplexing
technique. Port B (Pin21-28) supplies the anodes of various LED simultaneously through a
560-ohm resistor on each pin, but the display glow is controlled by the transistors controlling
the cathodes of 7 segment display. Only the segment having positive voltage at anode and
ground at cathode through controlling transistor glows at a time, but we see permanently
glowing display due to persistence of vision, as the LED’s are switched on and off at a very
fast pace, not noticeable by human eye.

7
Working model :

8
 Bill of Material
MATERIAL
REQUIRE
D FOR 4KVA, 1-PHASE, 3-
QTY STEP STABILIZER
1 DATE : 25/09/2019

[Link]. ITEM [Link]. DESCRIPTION UNIT LEGEND

1 28PIN IC (CHIP) 1 IC NO - PIC16F72 PCS U5

2 IC BASE 1 28 PIN PCS

3 REGULATOR - 1 LM7805/T0220 PCS U6

4 RESISTANCE 4 150KΩ - 1W PCS R 1,2,7,8

5 RESISTANCE 4 27K - 1/4W PCS R -3,5,9,18

6 RESISTANCE 7 10K - 1/4W PCS R -4,10,11,17,15,21,25,

7 RESISTANCE 1 3K3-1/4W PCS R - 16,

8 RESISTANCE 4 2K2-1/4W PCS R-23,38,39,40

9 RESISTANCE 1 1M2-1/4W PCS R-24

10 RESISTANCE 8 560E-1/4W PCS R-26,27,28,29,30,31,32,34

11 RESISTANCE 3 4K7-1/4W PCS R-35,36,37

12 RESISTANCE 1 1K-1/4W PCS R-19,22

13 VERTICAL PRESET 3 5K PCS R-13,14,20

14 DIODE 10 IN 4007 PCS D - 1,2,3,4,5,6,7,8,9,10

15 DIODE 3 IN 1183A PCS D - 11,12,13

16 ZENER DIODE , 1N3348A 3 1K , 5V6 PCS Z-1,2,3

17 CRYSTAL 1 4 MHz PCS Y-1

18 TRANSISTOR 4 BC 547B PCS Q-1,2,3,4

19 TRANSISTOR 3 CD 100 PCS Q-5,6,7

9
 SEVEN SEGMENT LED
20 3 PCS
DISPLAY

BASE FOR SEVEN

21 2 8PIN PCS
SEGMENT LED DISPLAY

22 CAPACITOR 1 33uF / 25V PCS C - 1,

23 CAPACITOR 1 47uF / 25V PCS C - 2,

24 CAPACITOR 1 220uF / 16V PCS C - 3,

25 CAPACITOR 1 100uF / 16V PCS C - 5,

26 CAPACITOR 1 470uF / 63V PCS C - 9,

27 CAPACITOR 1 0.1uF / 63V PCS C - 10,13

28 CAPACITOR 1 220uF / 16V PCS C - 12,

29 CAPACITOR 1 10uF / 16V PCS C - 4,

30 CAPACITOR 1 22pF / 16V PCS C - 6,7

31 PCB CONNECTOR 1 5PIN PCS CN1

32 PCB CONNECTOR 1 6PIN PCS CN2

10