ABB Emax 2 Ekip Hi-Touch Protection Functions and Settings Guide
What is the ABB Emax 2 Ekip Hi-Touch? The ABB Emax 2 Ekip Hi-Touch is an advanced electronic trip unit for Emax 2 air circuit breakers rated up to 6300 A under IEC 60947-2, offering a full LSIG overcurrent stack plus voltage, frequency, reactive power, and residual-current protection functions configurable via touchscreen. Misconfigured pickup thresholds, incorrect time-current coordination between L, S, and I functions, or overlooked voltage-protection bands can produce nuisance tripping, undetected ground faults, or cascading busbar failures during commissioning. This guide covers core L/S/I/G overcurrent functions, voltage and frequency protections (OV, UV, OF, UF, RP), specialized Rc/Rv/OQ/UQ settings, a practical commissioning workflow, the long-time pickup calculator methodology, and a direct comparison of Ekip Dip LI, LSI, and Hi-Touch LSIG trip units.
In our experience commissioning data centers and pharmaceutical plants across the EU and Gulf region, customers often order a Dip LI variant for cost reasons and then come back six months later asking for selectivity studies they cannot run because the unit lacks short-time delay (S) and ground-fault (G) functions. If you anticipate any of: zone selective interlocking (ZSI), Modbus or IEC 61850 SCADA reporting, harmonic logging, or load shedding logic — you want Hi-Touch from day one.
Hi-Touch versus Dip and Touch — when does the upgrade pay off?
The ABB 1SDA070741R1 E1.2B 800 with Ekip Dip LI handles long-time and instantaneous protection only — adequate for a simple feeder where upstream selectivity is handled by the transformer LV protection. Step up to the E1.2B 1000 LSI variant (1SDA070782R1) and you add short-time discrimination, which matters the moment you have a downstream MCCB feeder you don't want to trip the incomer. Hi-Touch adds everything else: voltage protections, residual current, reverse power, and the metering accuracy needed for ISO 50001 energy monitoring.
Core Overcurrent Functions: L, S, I and G Explained
Every ABB Emax 2 Hi-Touch unit ships with the four classic overcurrent functions defined in IEC 60947-2 Clause 4.7. Each has independent thresholds (I-set) and time delays (t-set), and each can be enabled or disabled independently — something engineers often overlook when copy-pasting settings between projects.
Function L — Long-Time Protection Against Overload
Function L protects cables and busbars against thermal damage. The threshold I1 is set as a multiple of the breaker's rated uninterrupted current Iu, typically between 0.4 and 1.0 × Iu in 0.01 steps. The trip curve is inverse-time, following the I²t = constant law per IEC 60947-2 §8.3.3.1.4.
Formula: Long-Time Trip Time — Source: IEC 60947-2 §8.3.3.1.4
tL = (9 × I1²) / (I² − I1²) × t1
| Symbol | Description | Unit |
|---|---|---|
| tL | Trip time at fault current I | s |
| I1 | L threshold (set as fraction of Iu) | A |
| I | Actual fault current (true RMS) | A |
| t1 | L time delay at 6 × I1 | s |
In practice, t1 is set between 3 s and 144 s. A common mistake is leaving t1 at its factory default (typically 18 s at 6×I1) — for a motor-heavy industrial bus with frequent inrush, that default will trip on every cold start of a 400 kW pump bank. Push t1 to 36 s or 72 s and the same bus runs without nuisance trips. We sized this exact scenario recently for a wastewater plant using an E1.2B 1600 (1SDA070861R1); for the calculator-based sizing methodology, see our step-by-step Emax 2 sizing guide.
Function S — Short-Time Protection (Selective)
Function S is the heart of selectivity. It defines a current threshold I2 (typically 1 to 10 × In) and an intentional delay t2 (0.05 to 0.8 s) so that downstream MCCBs clear faults first while the upstream Emax 2 holds in. Hi-Touch supports two S curves: definite-time (t = constant) and inverse-time (I²t = constant). The latter is preferred when coordinating with downstream thermal-magnetic devices because the curves overlap more naturally.
Function I — Instantaneous Protection
Function I has no intentional time delay (typical operating time 25–35 ms including breaker mechanical opening). The I3 threshold ranges from 1.5 to 15 × In. Engineers often set I3 too low "to be safe" — but a setting of 2 × In on a transformer incomer will trip on every magnetizing inrush. Calculate the worst-case asymmetric inrush (typically 8–12 × In for distribution transformers) and add a 20% margin.
Function G — Ground-Fault Protection
Hi-Touch supports both internal G (residual sum of three phase currents plus neutral) and external G (via a dedicated toroidal CT on the neutral-earth bond). I4 threshold ranges from 0.2 to 1.0 × In, t4 from 0.1 to 0.8 s. Per IEEE 242 (Buff Book) Chapter 8, ground-fault pickup should be set at 20–40% of available ground-fault current to ensure detection of arcing faults.
For complete technical specifications and protection function details of the ABB Emax 2 platform, refer to ABB's official SACE Emax 2 product documentation.
Voltage and Frequency Protections: U, OV, UV, OF, UF, RP
This is where Hi-Touch earns its premium on the ABB Emax 2 platform. None of these functions exist on Dip or basic Touch units. They require the integrated voltage measurement module (VT inputs on terminals K1-K4) and they're essential for any installation with on-site generation, UPS bypass, or sensitive process loads.
Voltage unbalance (U)
Function U trips when the phase voltage unbalance exceeds a programmable percentage (typically 2–10% of nominal). Per NEMA MG-1 Section 14.36, motor derating starts at 1% unbalance and becomes severe above 5%. We typically set U at 5% with a 5-second delay on motor-dominant buses — fast enough to protect motor windings, slow enough to ride through utility transients.
Over/undervoltage (OV/UV)
OV trips on sustained voltage above the U8 threshold (default 1.05 × Un). UV trips below U9 (default 0.9 × Un). Both have programmable delays (0.1 to 5 s). For grid-tied installations in regions with weak distribution networks (parts of South Asia, sub-Saharan Africa), UV is the single most useful function on a Hi-Touch — it prevents motors from operating in the brownout zone where they draw 1.5× rated current and cook their windings.
Reverse power (RP)
RP is critical on generator-paralleled buses. It detects active power flowing from the bus into the generator (motoring) and trips before the prime mover is damaged. Set RP at 5–10% of generator rated kW with a 1–2 second delay per IEEE C37.102. On a recent biomass cogeneration project we configured RP at −8% × 1500 kW = −120 kW with t = 1.5 s on the generator incomer Emax 2 frame — caught a fuel pressure drop incident the very first month.
Specialized Protections: Rc, Rv, OQ, UQ, OP, UP
Hi-Touch on the ABB Emax 2 carries a second tier of functions that most engineers never enable but that solve very specific real-world problems.
Rc — residual current: external toroidal CT input, settings from 30 mA to 30 A, time delays 0.06–5 s. Used for fire protection (per IEC 60364-4-42, Rc set at 300 mA) on installations where standard ground-fault protection is too coarse. Note: this is not a personal-protection RCD — for that you still need devices from our Residual Current Device collection.
Rv — residual voltage: detects neutral displacement on isolated (IT) systems. Critical in hospitals and process plants where you need to alarm on a first earth fault without tripping.
OQ/UQ — over/under reactive power: useful on capacitor banks and for power factor enforcement. Set OQ at 110% of bank rating to detect resonance conditions.
OP/UP — over/under active power: load shedding logic. Hi-Touch can output a contact closure when active power exceeds a threshold, signaling a downstream non-essential breaker to open. We've used this with the E2.2B 2000 (1SDA071021R1) as a tie breaker between two transformers on an automotive plant.
Setting Strategy: A Real Commissioning Workflow
Settings on paper are one thing. Settings that survive a real plant are another. Here is the workflow we use on every ABB Emax 2 commissioning, distilled from roughly 80 projects between 2018 and.
Step 1 — Document the source impedance
Get the transformer nameplate (kVA, %Z, vector group), the upstream MV protection settings, and the cable length/cross-section between transformer and Emax 2. Calculate prospective short-circuit current Ik" at the breaker terminals. For an E2.2B with 42 kA Icu, you need Ik" ≤ 42 kA at 415 V.
Step 2 — Set L based on cable ampacity, not breaker rating
I1 should match the cable ampacity at the installation conditions, not the breaker In. If you have a 1600A breaker feeding 2× 630 mm² Cu cables in a hot ambient with 0.85 derating, your effective ampacity is around 1380 A — set I1 = 0.87 × 1600 = 1392 A, not 1.0 × In.
Step 3 — Coordinate S with downstream
Pull the trip curves of every downstream device. Add 100 ms margin to the slowest downstream operating time, then set t2 to that value. For a typical 250A MCCB clearing in 80 ms at 5 kA, set the upstream Emax 2 t2 at 0.2 s.
Step 4 — Verify with primary injection
Per IEC 60947-2 Annex M, primary injection at 1.5 × I1 should trip within the calculated curve tolerance (±20%). We've found roughly 3% of new Hi-Touch units ship with a CT calibration drift outside spec — always test, never assume.
Hi-Touch Settings Calculator: Long-Time Pickup
Comparison: Ekip Dip LI vs Dip LSI vs Hi-Touch LSIG
| Criteria | Ekip Dip LI | Ekip Dip LSI | Ekip Hi-Touch LSIG |
|---|---|---|---|
| Overcurrent functions | L, I | L, S, I | L, S, I, G + 15 more |
| Voltage protection | No | No | Yes (OV, UV, U, RV) |
| Frequency protection | No | No | Yes (OF, UF) |
| Reverse power (RP) | No | No | Yes |
| Display | LED only | LED only | 4.3" color touchscreen |
| Communication | Optional Modbus | Optional Modbus | Modbus + IEC 61850 + Profibus |
| Energy metering accuracy | N/A | N/A | Class 1 (IEC 61557-12) |
| ZSI support | No | Yes | Yes (in + out) |
| Typical use | Simple feeder | Selective feeder | Main incomer, generator, tie |
| Relative price | 1.0× | 1.15× | 1.6× |
Looking at this table, the obvious question is: when does Hi-Touch's 60% premium on an ABB Emax 2 pay back? In our analysis, it pays back within 18 months whenever any of the following apply: (a) the breaker connects to a generator, (b) energy reporting is required for ISO 50001 or LEED, (c) the installation has a UPS bypass, or (d) IEC 61850 SCADA integration is mandated. For everything else, the E1.2B 1000 Dip LI (1SDA070781R1) or E1.2B 1250 (1SDA070821R1) remains a strong value choice.
Communication, Logging and SCADA Integration
Hi-Touch units on the ABB Emax 2 expose every protection function and every measured value over a built-in Ekip Link bus, with optional plug-in modules for Modbus RTU/TCP, Profibus DP, Profinet, EtherNet/IP, Devicenet and IEC 61850 (the last being mandatory for substation automation in most utility specifications post-2015).
The internal data logger stores up to 200 trip events with full waveform capture (8 channels × 8 cycles pre-trigger, 16 cycles post-trigger) at 4.8 kHz sampling. That has saved us countless arguments with installers blaming "the breaker tripped for no reason" — we pull the COMTRADE file via Ekip Connect, open it in any IED analyzer, and the cause is usually visible in the first 40 ms.
For a deep-dive into how this matters in mission-critical installations, our piece on Emax 2 in data center MDB design walks through exactly how the Hi-Touch's IEC 61850 GOOSE messaging integrates with BMS and DCIM platforms.
Common Mistakes and How to Avoid Them
After a few hundred Hi-Touch commissionings on ABB Emax 2 frames, certain mistakes show up over and over.
Mistake 1: Leaving function I active on the main incomer. If you're using ZSI between the incomer and feeder breakers, function I (instantaneous, no delay) on the incomer will always trip first because the restraint signal cannot reach it in time. Disable I on the incomer and rely on S with a short t2 (0.05 s with ZSI active). The downstream feeder gets its restraint signal, the incomer only trips if the feeder fails to clear. This is fundamental but we still find it wrong on roughly 1 in 5 sites we audit.
Mistake 2: Setting voltage protections on the same set as overcurrent. Hi-Touch supports three setting groups (Set A, B, C) selectable via digital input or schedule. A common pattern is: Set A = grid mode (UV active, RP disabled), Set B = generator mode (UV relaxed, RP active, frequency window wider). Run everything in Set A and you'll either nuisance-trip during generator startup or fail to protect during grid operation.
Mistake 3: Ignoring the THD alarm. Hi-Touch reports voltage and current THD continuously. Some engineers argue it's just nice-to-have data, but in our experience a slow climb in current THD (from 4% to 12% over six months) is the single most reliable predictor of variable frequency drive (VFD) DC bus capacitor degradation downstream. Configure THD as an alarm, not just a measurement, and you'll catch failures before they happen.
Mistake 4: Wrong CT polarity on external G or Rc. If the external toroidal CT is wired with reversed polarity, ground-fault detection still works for symmetrical faults but fails for the asymmetric arcing faults that matter most. Always verify with primary injection at commissioning — a $200 test set catches an issue that could cost a fire.
For a deeper diagnostic walkthrough when these mistakes manifest as recurring trips, see our companion article on Emax 2 nuisance tripping root causes and fixes.
Practical Setting Examples for Three Real Installations
Example 1: 1600 A main incomer, 2 MVA transformer, mixed load
Breaker: ABB Emax 2 E2.2B 1600 Hi-Touch (similar frame to 1SDA070981R1). Settings used:
L: I1 = 0.95 (1520 A), t1 = 36 s at 6×I1. S: I2 = 4 × In (6400 A), t2 = 0.3 s, I²t curve. I: disabled (ZSI active to downstream feeders). G: I4 = 0.4 × In (640 A), t4 = 0.4 s, internal sum. UV: U9 = 0.85 × Un, t = 3 s. OV: U8 = 1.1 × Un, t = 1 s. U (unbalance): 5%, t = 5 s.
Example 2: 2000 A generator incomer, 1.6 MW diesel set
Breaker: E2.2B 2000 with Hi-Touch. Set B (generator mode) settings: L: I1 = 0.9 (1800 A), t1 = 72 s — long delay because generator overload behavior differs from transformer. S: I2 = 3 × In, t2 = 0.4 s. RP: −8% × Pn = −128 kW, t = 1.5 s. UF: 47.5 Hz, t = 2 s. OF: 51.5 Hz, t = 0.5 s. Reverse rotation alarm enabled.
Example 3: 800 A motor control center incomer
Breaker: E1.2B 800 (1SDA070741R1) upgraded to Hi-Touch. L: I1 = 0.85 (680 A), t1 set higher than usual — 96 s — because the bus feeds three 200 kW pumps with sequential start. S: disabled (using I only because no critical downstream selectivity). I: I3 = 6 × In (4800 A) — above worst-case motor inrush of approximately 4500 A. U: 4%, t = 10 s — tighter than typical because motor windings are the asset to protect.
What's striking across these three examples is how different the settings are despite all being Emax 2 platforms with Hi-Touch. There is no universal "good" setting — there is only the setting that matches your specific source impedance, load behavior, and selectivity requirements. For the underlying ratings that constrain these choices, our reference on Emax 2 technical specifications, ratings and dimensions is the source of truth.
Hi-Touch in the Wider ABB and Competitor Context
The Hi-Touch on the ABB Emax 2 is roughly equivalent in capability to the Schneider MicroLogic 6.0 X / 7.0 X on the MasterPact MTZ platform, and to the Siemens 3WL ETU76B. They each have quirks. Schneider's MicroLogic has slightly more granular logging but a clunkier menu structure. Siemens has the best HMI ergonomics but fewer programmable logic blocks. ABB Hi-Touch sits in the middle on UI, leads on communication protocol breadth, and ties or leads on logging depth depending on firmware version.
For a side-by-side breakdown including price points and lead times, see our analysis on ABB Emax 2 vs Schneider MasterPact MTZ. And if you're new to the platform itself, start with what the ABB SACE Emax 2 is and why it exists.
One detail worth flagging: Hi-Touch firmware versions matter. Versions before 2.1.0 had a known issue with IEC 61850 GOOSE message timing that could cause spurious ZSI restraint signals on multi-frame configurations. Always check the firmware revision on a new unit and update via Ekip Connect before commissioning. ABB publishes the changelog freely on their library portal.
Maintenance and Verification Schedule
Hi-Touch units are largely maintenance-free electronically, but the protection chain depends on more than just the trip unit. We recommend the following schedule, aligned with IEC 60364-6 and IEEE 3007.2:
Annually: visual inspection, verify display and LEDs, download event log, verify setting integrity against documented design. Every 3 years: secondary injection test of all enabled functions through the test connector. Every 6 years (or after any short-circuit interruption ≥ 50% Icu): primary injection test, verify CT integrity, contact wear inspection. Every 10 years: full overhaul including arc chute inspection — for the broader maintenance methodology, see our Emax 2 engineering guide.
One nuance: Hi-Touch's self-diagnostic catches roughly 90% of internal hardware faults but cannot test the breaker's mechanical interruption capability. Mechanical wear on the operating mechanism (specifically the closing spring and the latch system on E2.2 and larger frames) is what eventually fails — usually well before the electronics. Don't let a good Hi-Touch self-test convince you the breaker is healthy without mechanical operation testing.
Related Reading
- What Is the ABB SACE Emax 2? Features, Models and Key Benefits
- ABB Emax 2 Full Technical Specifications: Current Ratings, Breaking Capacity and Dimensions
- How to Size ABB Emax 2: Step-by-Step Calculator for LV Distribution Panels
- ABB Emax 2 Nuisance Tripping: Root Causes, Diagnostic Steps and Fixes
For complementary protection devices that work alongside Emax 2 in a complete LV distribution scheme, browse the Air Circuit Breakers collection, downstream Miniature Circuit Breakers for final-circuit protection, and auxiliary Relay components for tripping and signaling logic.
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Frequently Asked Questions
Can I retrofit a Hi-Touch trip unit onto an existing Emax 2 breaker that originally shipped with Ekip Dip?
Yes, the Ekip family is designed as a swappable platform within the same frame. The trip unit unplugs from the breaker via a multi-pin connector, and you can install a Hi-Touch unit of equal or higher capability. You will, however, need the additional voltage measurement module and a compatible communication module for full functionality. Always verify the breaker frame compatibility with ABB's Ekip migration guide before ordering — there are minor differences between first-generation and current Emax 2 frames.
What's the difference between internal G and external G on the Hi-Touch?
Internal G calculates ground-fault current as the vector sum of the three phase currents (and neutral current on 4-pole units), using the breaker's own metering CTs. External G uses a separate toroidal CT typically installed around the neutral-earth bond. Internal G is simpler and adequate for most distribution applications. External G is more accurate at low fault currents (below 0.3 × In) and is required for sensitive applications like fire protection or for systems where the neutral is grounded remotely from the breaker location.
How accurate is the Hi-Touch energy metering compared to a dedicated power meter?
Hi-Touch achieves Class 1 accuracy per IEC 61557-12 for active energy and Class 2 for reactive energy. That's adequate for sub-billing and ISO 50001 energy management, but not for revenue billing where Class 0.5 or 0.2 is typically required. If you need revenue-grade metering, install a dedicated meter downstream and use Hi-Touch for monitoring and protection only. For sizing the breaker correctly to support accurate metering, our Emax 2 sizing calculator guide explains the CT considerations.
Does Hi-Touch support arc flash mitigation through ZSI or maintenance-mode settings?
Yes. Hi-Touch supports both. ZSI reduces clearing time for downstream faults to roughly 50–80 ms regardless of the t2 setting, significantly reducing incident energy. Additionally, Hi-Touch includes a "maintenance mode" (also called RELT — Reduced Energy Let-Through) that, when activated by a key switch or remote command, reduces I3 to a minimum value with no intentional delay during maintenance work. This can drop arc flash incident energy by 60–80% per IEEE 1584 calculations. Both features should be specified at design time, not retrofitted.
Can Hi-Touch settings be changed remotely via SCADA, or only locally?
Settings can be changed remotely via Modbus, IEC 61850 or Profibus, but doing so is generally discouraged in protection engineering practice and explicitly prohibited by some utility specifications. Hi-Touch supports a "remote settings lock" that allows monitoring and event retrieval over the network while requiring physical presence (or a hardware key input) to change protection thresholds. We recommend enabling this lock on every installation — it preserves the auditability of protection changes and prevents accidental modifications from a SCADA HMI.
Is Hi-Touch suitable for IT (isolated neutral) systems?
Yes, Hi-Touch is one of the few trip units that natively supports IT system protection through its residual voltage (Rv) function. On an IT system you cannot use conventional ground-fault tripping because a single ground fault doesn't produce significant return current. Instead, Rv detects the neutral-point voltage shift that indicates the first earth fault, and can be configured to alarm only (recommended) or trip after a programmable delay. Combined with an insulation monitoring device (IMD), this provides full IT system protection per IEC 60364-4-41.
Conclusion
The Ekip Hi-Touch trip unit transforms the ABB SACE Emax 2 from a high-quality circuit breaker into a true protection and measurement platform. The 19+ protection functions, three-tier setting groups, IEC 61850 communication and embedded waveform logger justify the price premium any time the breaker sits at a critical node — main incomer, generator paralleling, UPS bypass, or any installation requiring SCADA integration. For simple downstream feeders, the Dip LI or LSI variants on breakers like the E1.2B 630 (1SDA070701R1) or E1.2B 1600 (1SDA070861R1) remain the right economic choice.
What separates a successful Hi-Touch deployment from a troubled one is rarely the choice of the unit itself — it's the discipline around settings: documenting them, verifying them with primary injection, backing them up before firmware updates, and revisiting them whenever the load profile changes. Treat the Hi-Touch as a protection IED with the same rigor you'd apply to a substation relay, and it will quietly do its job for two decades.
For the complete selection, application and maintenance methodology that places Hi-Touch in the wider Emax 2 lifecycle, our ABB SACE Emax 2 Air Circuit Breaker engineering guide remains the master reference, and our broader air circuit breaker engineering guide covers the underlying principles that apply across manufacturers and frame sizes.
