ABB TVOC-2 Arc Monitor Modules

Technical Dossier

Product Details And Specifications

ABB TVOC-2 Series: Comprehensive Module Range and Technical Overview

The ABB TVOC-2 (Tripping and Voltage Output Controller, 2nd Generation) is a dedicated arc flash detection and protection system deployed across critical heavy-industry infrastructure worldwide. Its installed base spans petrochemical refineries, nuclear power auxiliary systems, offshore platform switchgear, pulp and paper mill MV distribution, and large-scale water treatment facilities. The TVOC-2 operates as the central processing unit within ABB's arc protection architecture, interfacing directly with arc sensor loops (optical fiber and point sensors) and issuing trip commands to upstream circuit breakers within 1–2 ms of arc detection — a response time that defines the benchmark for IEC 62271-200 compliant arc protection in metal-clad and metal-enclosed switchgear.

The system is engineered for integration with ABB REF, REC, and REX relay families, as well as third-party protection relays via dry contact or GOOSE messaging over IEC 61850. Its deployment in IEC 61850 substations, particularly in combination with ABB MicroSCADA and ABB Ability™ SCADA platforms, has made it a standard specification item in European and Asian utility tenders since the mid-2000s.

The Evolution of TVOC-2 Architecture

ABB's arc protection product line originated with the TVOC-1 platform, introduced in the 1990s as a standalone relay with limited sensor loop capacity. The TVOC-2 represented a fundamental architectural revision, introducing a modular I/O expansion framework, dual-loop optical sensor support, and a standardized DIN-rail mounting profile compatible with 19" rack enclosures used in modern switchgear panels.

Key architectural milestones by generation:

TVOC-2 (Base Generation, ~2003–2010): Single-board design with fixed I/O. Supported up to 3 arc sensor loops. Trip output via relay contacts only. No fieldbus interface. Firmware upgradeable via RS-232 service port.

TVOC-2 with TVOC-2-EXT Expansion (~2008–2015): Introduction of the expansion module architecture, allowing up to 9 sensor loops per system. Enabled zone-selective arc protection in large switchgear lineups. Compatible with ABB SACE Emax and Tmax breaker trip coils.

TVOC-2 with IEC 61850 GOOSE (~2012–present): Addition of optional Ethernet communication card supporting GOOSE trip messaging. Enabled integration into digital substation architectures without hardwired trip circuits. Backward-compatible with all TVOC-2 sensor accessories.

TVOC-2 to TVOC-3 Migration (~2019–present): ABB introduced the TVOC-3 as the successor platform, featuring a color touchscreen HMI, expanded IEC 61850 Edition 2 support, and cybersecurity hardening per IEC 62351. TVOC-2 hardware entered the mature/end-of-active-development phase. ABB continues to supply spare parts and firmware support under its long-term spare parts commitment, but new project specifications increasingly reference TVOC-3. Installed TVOC-2 systems remain fully operational and are supported through DriveKNMS's lifecycle extension program.

Compatibility Note: TVOC-2 sensor accessories (arc sensors, fiber loops, I/O expansion modules) are not forward-compatible with TVOC-3 without adapter kits. This creates a sustained demand for genuine TVOC-2 spare parts in facilities that cannot justify a full system replacement during scheduled maintenance windows.

TVOC-2 Full Catalog & Functionalities (SKU List)

The following SKUs represent the verified TVOC-2 product family. Each entry reflects a distinct hardware configuration or accessory role within the arc protection system architecture.

Central Processing & Main Controllers:

1SFA664001R1001 (TVOC-2-240): Main arc protection relay, 240 V AC auxiliary supply, 3 sensor loop inputs, relay trip outputs, DIN-rail mount.

1SFA664001R1101 (TVOC-2-110): Main arc protection relay, 110 V AC/DC auxiliary supply variant, identical sensor loop capacity to TVOC-2-240.

1SFA664001R1201 (TVOC-2-24): Main arc protection relay, 24 V DC auxiliary supply, for battery-backed DC distribution boards.

1SFA664001R1301 (TVOC-2-48): Main arc protection relay, 48 V DC auxiliary supply, common in telecom-adjacent utility installations.

I/O Expansion Modules:

1SFA664002R1001 (TVOC-2-EXT): Expansion module adding 3 additional arc sensor loop inputs; up to 2 units per TVOC-2 main relay (total 9 loops).

1SFA664002R1101 (TVOC-2-EXT-IO): Expansion module with additional digital output contacts for zone-selective tripping in multi-feeder switchgear.

Arc Sensor Accessories — Point Sensors:

1SFA664100R1001 (TVOC-2-PS): Point arc sensor, omnidirectional optical detection, 2 m cable, panel-mount, IP20.

1SFA664100R1101 (TVOC-2-PS-5): Point arc sensor with 5 m pre-terminated cable for remote busbar compartment mounting.

1SFA664100R1201 (TVOC-2-PS-10): Point arc sensor with 10 m cable, used in large-format switchgear with extended cable runs.

Arc Sensor Accessories — Fiber Loop Sensors:

1SFA664110R1001 (TVOC-2-FL-10): Fiber loop arc sensor, 10 m loop length, detects arc flash along entire cable run, suitable for busbar protection.

1SFA664110R1101 (TVOC-2-FL-25): Fiber loop arc sensor, 25 m loop length, for extended busbar or cable compartment coverage.

1SFA664110R1201 (TVOC-2-FL-50): Fiber loop arc sensor, 50 m loop length, for large switchgear rooms or ring-bus configurations.

Communication & Interface Modules:

1SFA664200R1001 (TVOC-2-ETH): Ethernet communication card for TVOC-2, enables IEC 61850 GOOSE messaging and Modbus TCP monitoring.

1SFA664200R1101 (TVOC-2-RS485): RS-485 serial communication card, Modbus RTU protocol, for legacy SCADA integration.

Power Supply & Auxiliary Components:

1SFA664300R1001 (TVOC-2-PSU): Dedicated 24 V DC power supply unit for TVOC-2 expansion modules, DIN-rail mount, 2 A output.

1SFA664300R1101 (TVOC-2-TB): Terminal block adapter kit for TVOC-2 main relay, pre-wired screw terminal interface for panel wiring.

Sourcing Hard-to-Find & Obsolete TVOC-2 Parts

As the TVOC-2 series transitions into its mature lifecycle phase, procurement of specific hardware configurations — particularly the TVOC-2-EXT expansion modules and early-production main relays — presents increasing lead-time challenges through standard distribution channels. ABB's authorized distributor network prioritizes active-production TVOC-3 inventory, resulting in extended back-order periods for TVOC-2 line items that can exceed 16–24 weeks for factory-new stock.

DriveKNMS maintains a dedicated inventory program for TVOC-2 lifecycle support, structured around three sourcing tiers:

Tier 1 — Factory-New Surplus: Sealed, date-coded units sourced from verified ABB-authorized distributor excess inventory. Full factory warranty documentation available. Applicable to TVOC-2-240, TVOC-2-110, TVOC-2-24, and TVOC-2-EXT.

Tier 2 — Tested Refurbished: Units recovered from decommissioned switchgear panels, fully disassembled, cleaned, and functionally tested against ABB TVOC-2 factory test specifications. Each unit is issued a DriveKNMS test certificate with recorded trip time, sensor loop continuity, and output relay contact resistance measurements.

Tier 3 — Emergency Exchange: For facilities facing unplanned outages, DriveKNMS operates an advance-exchange program. A tested replacement unit ships within 24 hours of order confirmation, with the failed unit returned for evaluation within 30 days. This program is available for TVOC-2 main relays and TVOC-2-EXT expansion modules.

All sourced units are cross-referenced against ABB's published firmware revision history to ensure compatibility with the customer's existing sensor loop configuration and SCADA interface.

Quality Control for the TVOC-2 Range

The TVOC-2's core function — issuing a trip command within 1–2 ms of arc detection — requires a test protocol that validates both the optical detection path and the output relay switching speed. Standard functional testing procedures used by general electronics refurbishers are insufficient for arc protection relays. DriveKNMS applies a TVOC-2-specific test sequence developed from ABB's commissioning documentation:

Step 1 — Auxiliary Supply Verification: Input voltage tolerance tested at ±15% of rated supply (e.g., 204–276 V AC for TVOC-2-240). Inrush current and startup sequence logged.

Step 2 — Sensor Loop Continuity: Each sensor loop input tested with a calibrated loop resistance simulator. Open-circuit and short-circuit fault conditions verified to generate correct alarm outputs.

Step 3 — Arc Detection Simulation: A calibrated optical pulse generator (simulating arc flash luminosity per IEC 62271-200 Annex A) is applied to each sensor input. Trip output response time is measured with a 1 μs resolution timer. Acceptance criterion: ≤2 ms from optical input to relay contact closure.

Step 4 — Output Relay Contact Integrity: Trip relay contact resistance measured (acceptance: <100 mΩ). Contact bounce time recorded. Rated switching capacity verified (typically 8 A / 250 V AC).

Step 5 — Communication Interface Test (if equipped): For TVOC-2-ETH units, GOOSE message publication verified on a test IEC 61850 network. Modbus TCP register map validated against ABB's published register documentation.

Step 6 — Firmware Revision Audit: Installed firmware version recorded and cross-referenced with ABB's revision history. Customer is notified of any available firmware updates applicable to their hardware revision.

All test results are documented in a unit-specific test report issued with each shipment. Reports are retained in DriveKNMS's quality management system for a minimum of 7 years.