Manufacturing tailored length loop sensor for an arc protection system - Arc protection - Auto synchronization - Bay control and measurement - Merging unit - Transformer protection - 2 winding - Feeder protection - Voltage regulation - Capacitor bank protection - Petersen Coil control - Grid automation - Busbar differential protection (high impedance) - Back-up protection - Motor protection - Busbar protection (voltage and frequency) - Transformer protection - 3 winding - Interconnection protection - Generator protection - Power management/Load shedding - Installation Manual - REX640 Protection and control - PCL4 - IEC - ANSI - 16.02.2023

REX640 Installation Manual

These instructions are for manufacturing tailored length arc loop sensors using

  1. 400 μm V-System® Termination Kit DT03732-34 by OFS Fitel, LLC to be purchased from local distributor, not in ABB’s offering.
  2. Bulk glass core arc sensor fiber, offered in REA accessories as three alternative lengths:
    • 1MSC 380018.100  ARC sensor fiber, delivery length 100 m
    • 1MSC 380018.300 ARC sensor fiber, delivery length 300 m
    • 1MSC 380018.500 ARC sensor fiber, delivery length 500 m
  3. Connector items, offered in REX640 accessories as:
    • 2RCA056821  ARC fiber spacer sleeve, 25 pcs
    • SJG BP05226-02  ARC sensor fiber V-pin connector, 25 pcs

Two spacer sleeves and two V-pin connectors are needed per each arc loop sensor.

Figure 1. Arc loop sensor parts

Figure 2. Contents of the termination tool kit
image/svg+xmlFiber StripperBrushProng ToolScissorsCrimp ToolCable StripperDiamond CleaveTool

Cable Stripper tool is not needed as the naked fiber 1MSC 380018.x00 has no jacket to be stripped.

Step by step procedure:

  1. Cut with scissors required length of the fiber, note that allowed maximum arc loop sensor length with REX640 is 60 meters.
  2. Install spacer sleeve and then crimp ring.
    Figure 3. Spacer sleeve

    Figure 4. Crimp ring

    1. Spacer sleeves are used to increase the unjacketed fiber diameter to fit the size of crimp ring.
    2. Feed fiber through spacer sleeve and crimp ring, large diameter first. Slide the spacer along the fiber until it is 63 mm (2½ inch) from the end of the fiber. Bottom out the crimp ring on the spacer sleeve using a clockwise turning motion (i.e. screw the crimp ring onto the spacer if necessary).
      Figure 5. Attaching the crimp ring to the spacer sleeve

    3. Holding cable, crimp ring and spacer in left hand and crimp tool in right, insert small end of crimp ring completely into the front die nest of the crimp tool.
      Figure 6. Using the crimp tool

    4. Squeeze crimp tool handles together until it clicks, then releases.
  3. Strip Fiber Buffer
    Note: Make sure to use the appropriate strip tool insert for the buffer removal process: ROYAL BLUE.
    Note: Be careful while handling the FIBER STRIPPER. Handle as a precision device and do not strike on hard surfaces or drop.
    Note: Be sure to clean blades frequently using small bristle brush supplied.
    Note: IMPORTANT: Pull straight when stripping the fiber buffer. The HCS fiber cladding can be damaged if fiber is not pulled straight.
    1. Insert the fiber through the guide tube of the fiber stripper until the cable spacer sleeve bottoms out in the tube.
      Figure 7. Using fiber stripper

    2. Holding cable securely, squeeze handles to cut buffer and PULL straight to remove buffer.
    3. Release the buffer strip tool handles.
    4. Inspect HCS cladding for damage from improper buffer stripping (i.e. white dusty stripes).
      Figure 8. Correct HCS cladding

      Tip: If unable to insert buffered fiber through guide tube, trim tip of the fiber using scissors.
      Tip: Be careful not to touch the HCS fiber coating with bare fingers. Use of disposable nitrile powder free examination gloves is recommended. Once the fiber has been stripped, the coating will retain finger oils, which can transfer to and damage gripper pads in the cleaver during the last step 4 in the termination process.
      Tip: If damage is visible, cut off the damaged fiber and repeat the procedure from step 2 with a new spacer and crimp ring.
  4. Install V-Pin Connector ferrule.
    1. Slide the ferrule onto the fiber, large diameter first, and push completely into the outer flange of the crimp ring.
      Figure 9. Sliding the ferrule onto the fiber

      Figure 10. Ferrule in place

    2. Insert the crimp ring completely into the rear die nest of the crimp tool. Be sure the ferrule flange is flush against the edge of the die nest.
      Figure 11. Inserting the crimp ring into the crimp tool

    3. Squeeze crimp tool handles together until it clicks, then releases.
      Tip: Be careful not to touch the HCS fiber coating. Once the fiber has been stripped, the coating will retain finger oils, which can transfer to and damage gripper pads in the cleaver.
  5. Cleave Fiber.
    Note: Make sure the appropriate cleave tool positioner plate is being used: V-Pin.
    Note: Make sure the appropriate colored tension spring is being used: Black.
    Note: Careful while handling the Cleave Tool. Handle as a precision device and do not strike on hard surfaces or drop.
    Note: Keep the cleave tool clean and free from oils, including naturally occurring finger oils. Gripper pads, diamond blade and anvil should be cleaned after every 50 cleaves. Use the OFS Cleave Tool Cleaning Kit — Part #P16247, available separately.
    Note: Do not use alcohol to clean the diamond blade or the gripper pads. Alcohol will chemically react with the gripper pads and ruin them.
    Note: Do not insert metal tools near the diamond blade, as it is fragile and may chip.
    1. Holding the cleave tool in a horizontal position, grip the handle while leaving your index finger free to actuate trigger.
    2. Place the ferrule into the hole of the positioner plate until it is fully inserted.
      Figure 12. Placing the ferrule into the cleave tool

      Tip: It is critical to fully insert the connector into the positioner plate. Failure to do so, may cause poor cleave quality and/or damage to the diamond blade.
      Tip: Do not hold onto the connector during the cleave process. Doing so may cause poor cleave quality.
      Tip: Always follow termination kit manufacturers recommendation for cleave tool service and maintenance.
    3. Release the connector in the tool.
    4. Using index finger, slowly and gently depress trigger to perform the cleave process. The cleave process is complete when the fiber snaps away from the connector. Do not release the trigger!
    5. Before releasing the trigger, remove the connector from the cleave tool and grasp the top of the scrap fiber while releasing the trigger. Gently remove the scrap fiber while keeping it away from the diamond blade.
    6. Dispose of scrap fiber safely in a hard-sided container.
  6. Repeat these procedure steps 2-5 to the other end of the arc sensor fiber and then the arc loop sensor is ready.
    Figure 13. Finished termination of arc loop sensor

    1. Cover ready connectors in both ends with dust caps.