Modernization of the Induction Generator REL30Tr - A New Era of Efficiency

At the DACPOL SERVICE, an induction generator upgrade was conducted on the REL30Tr, which has been in operation for over three decades at the Institute of Molecular Physics in Poznań. The generator, manufactured in 1990 by ELCAL, underwent a comprehensive transformation to meet modern efficiency and safety standards. In this article, we will look at the details of the upgrade and the benefits it has brought.

Condition of the REL30Tr Generator Before the Upgrade

Before the upgrade, the REL30Tr generator operated based on a relay control system. The picture below shows a cabinet with a thyristor controller PRW 210/440, which was the central element controlling the operation of the device.

The disadvantage of the previous system was that each heating cycle required the complete activation and deactivation of the high-power circuit, which strained the system and could lead to its quicker wear and tear. Relays and contactors were responsible for initiating the heating process, as shown in the photo below.

The filament transformer powered the cathode of the T26-W triode produced by LAMINA, but the lack of "soft start" caused multiple exceedances of the nominal current of the cathode, which could lead to its damage. The picture below shows this transformer.

Upgrade of the REL30Tr Generator

The goal of the upgrade was to increase the efficiency and safety of the generator's operation. Several key changes were introduced:

1. Modernization of the RD35ZM Triode Cathode Power Supply:

• Introduced the ERPA1-440-F controller, which enables a "soft start" of the filament voltage, significantly reducing the initial load on the cathode.
• Added a heater resistor, which prevents a rapid increase in cathode current. The triode cathode power supply system is shown in the photo below.

2. Improvement of the Oscillator Circuit:

• Application of an additional feedback transformer in the modified Meissner circuit. This allowed independent adjustment of the triode excitation current from the generator load. The generator chamber (oscillator) is shown in the photo below.

3. Integration of an Additional Control Panel:

• Separation of the activation of the high voltage transformer from the activation of the TPR-3SL160H thyristor controller. This ensures that in standby mode, the three-phase power path is activated, and heating power is only supplied after unlocking the thyristors. The additional power control panel of the generator is shown in the photo below.

Results of the Upgrade

The upgrade of the REL30Tr generator brought significant benefits, such as:

• Increased reliability: The introduction of "soft start" reduced the load on the cathode and extended its lifespan.
• Better control: New control systems allow for more precise management of heating power and the safety of generator operation.
• Higher efficiency: Changes in the oscillator circuit enable better energy utilization, resulting in savings and increased efficiency.

The upgrade of the REL30Tr generator demonstrates how technology can evolve to meet contemporary demands, providing greater efficiency and safety. It is an investment that will undoubtedly bring benefits in the long term.