ABB ACS355 vs ACS580

Overview

Variable Frequency Drives (VFDs) are the backbone of modern industrial automation, controlling motor speed, torque, and energy consumption. Within the ABB low-voltage AC drive portfolio, two product families stand out as industry standards: the ABB ACS355 Machinery Drive and the ABB ACS580 General-Purpose Drive. While both belong to ABB’s reputable drives family, they are engineered for fundamentally different application envelopes, machine architectures, and lifecycle expectations.

The ACS355 is a micro-machinery drive designed specifically for system integrators, cabinet builders, and Original Equipment Manufacturers (OEMs). Engineered for rapid installation, space-constrained enclosures, and high-volume machine production, it excels in applications requiring high dynamic response, integrated sequence programming, and compact dimensions.

The ACS580, part of ABB’s "all-compatible" drive portfolio, is a versatile, component-built, general-purpose drive. It is designed to control a broad spectrum of industrial applications with minimal commissioning effort. Featuring integrated harmomic mitigation technology, advanced software assistants, and a wide power range, the ACS580 is optimized for pumps, fans, conveyors, mixers, and general process automation.

Understanding the core architectural differences, electrical specifications, and functional limitations between these two drives is essential for choosing the optimal VFD for your specific application.

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Key Differences at a Glance

The table below outlines the primary distinctions in design, features, and target applications between the ACS355 and ACS580 product series.

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Specifications Comparison

This specifications matrix details the exact operating envelopes, electrical characteristics, and hardware differences between the ACS355 and ACS580 drive lines.

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Performance & Capabilities

When evaluating the performance differences between these two drives, standard motor output ratings do not tell the whole story. The control loop topology, motor compatibility, and dynamic responsiveness of each drive series must be analyzed.

Vector Control & Speed Feedback

The ACS355 punches above its weight class by supporting closed-loop vector control. By integrating the optional MTAC-01 pulse encoder interface module, users can configure closed-loop speed and torque control. This makes the ACS355 highly effective for dynamic positioning, winders, tension control, and materials-handling systems that require high torque at zero speed.

Conversely, the ACS580 is designed as a sensorless, open-loop vector control drive. While it lacks standard encoder-feedback options for full closed-loop positioning, its advanced sensorless vector control algorithm provides superb speed accuracy and high starting torque. It features optimized energy-saving algorithms and native support for highly efficient Synchronous Reluctance (SynRM) motors, a feature not supported by the ACS355's control firmware.

Harmonics and Power Quality

The physical design of the ACS580 emphasizes power quality. Every ACS580 drive incorporates ABB’s patented swinging choke technology. This variable-impedance DC choke adjusts its inductance dynamically based on motor load, significantly reducing Total Harmonic Distortion (THD) under partial load conditions compared to typical fixed-inductance reactors.

[Partial Load] ---> AC Drive without Choke ---> High THD (up to 80%)
[Partial Load] ---> ACS580 with Swinging Choke ---> Low THD (under 40%)

The ACS355 has no internal DC choke or swinging choke due to its ultra-compact micro footprint. System designers using the ACS355 must size and install external line reactors to meet IEEE 519 harmonic requirements in environments sensitive to electrical noise.

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Programming & Software

Programming paradigms between these two series illustrate the transition from traditional fieldbus parameter configuration to the modern ABB "all-compatible" user interface.

ACS355 Programming Architecture

To commission an ACS355, users typically rely on the DriveWindow Light 2 software or the MFDT-01 FlashDrop tool. The FlashDrop tool is highly favored by OEMs: it allows parameters to be uploaded to or downloaded from a drive in less than three seconds without connecting main power to the drive.

Furthermore, the ACS355 features built-in Sequence Programming. This allows the programmer to define up to 8 sequence states, utilizing internal timers, inputs, and limit parameters to execute complex logic operations without a separate PLC.

ACS580 Programming Architecture

The ACS580 utilizes the modern Drive Composer PC tool (available in Entry and Pro variants). Connection to the PC software is made through a standard USB mini-B port on the face of the standard Assistant Control Panel.

The ACS580 supports Adaptive Programming (AP). This visual, block-diagram-based programming environment is embedded within the Drive Composer software. It operates on soft-PLC logic, allowing users to build custom control functions, state machines, and mathematical equations directly inside the drive using standard logic gates, timers, and arithmetic operators.

+-----------------------------------------------------------+
| Drive Composer (Adaptive Programming Block Diagram)       |
|                                                           |
|  [ DI1 ] ---                                             |
|              [ AND Gate ] ---> [ Timer ] ---> [ Relay 1 ] |
|  [ AI1 > 5V ]/                                            |
|                                                           |
+-----------------------------------------------------------+

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Communication & Networking

Modern industrial automation relies on robust communication profiles to report diagnostic information, energy consumption, and status words to central controllers.

ACS355 Communication Options

The ACS355 requires external, form-factor-specific, plug-in fieldbus adapters to communicate with industrial networks. It features Modbus RTU via an EIA-485 interface as standard. For higher-level networks, users must install specific modules under the dynamic front cover:

• FPBA-01 for PROFIBUS-DP
• FCAN-01 for CANopen
• FDNA-01 for DeviceNet
• FMBA-01 for Modbus RTU (alternative configurations)
• FEIP-21 or MFEA-01 for high-speed industrial Ethernet protocols

ACS580 Compact Communication

The ACS580 is equipped with standard Modbus RTU embedded on-board via field terminals. For Ethernet networks, the drive features a dedicated slot for high-performance F-series fieldbus adapters, which fit seamlessly inside the chassis:

• FENA-21 (2-port Ethernet/IP, Modbus TCP, and PROFINET IO adapter)
• FPBA-01 (PROFIBUS DP)
• FCAN-01 (CANopen)

The dual-port design of the FENA-21 adapter in the ACS580 facilitates linear or ring topologies (such as Device Level Ring - DLR), eliminating the need for external network switches inside control panels.

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Pricing & Lifecycle

Analyzing the purchase price versus long-term Total Cost of Ownership (TCO) reveals distinct roles for each drive.

• Acquisition Cost: On a simple dollar-per-horsepower basis at lower power levels (under 22 kW / 30 hp), the ACS355 possesses a significantly lower initial price point. It is optimized as a cost-effective, bulk-ordered component for machine builders.
• System Integration Complexity: When integrating a drive into larger facilities, the ACS580 reduces overall system cost. Standard built-in features (swinging choke, EMC C2 filter, Assistant control panel, and USB programming) eliminate the hidden costs of purchasing, panel-mounting, and wiring external components.
• Lifecycle Phase: The ACS355 is in the "Classic" phase of the ABB lifecycle. While still manufactured and widely available as spare parts, it has been succeeded in new designs by the ACS380 machinery drive. The ACS580 is in the "Active" phase of its lifecycle, assuring users of ongoing product enhancements, software updates, and active technical support for years to come.

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When to Choose Each

Choose the ABB ACS355 when:

1. Space is extremely limited: The ACS355 features a compact, side-by-side book mounting design that reduces panel space.
2. You require closed-loop motor control: The application involves precise positioning, tensioning, or high torque requirements at very low RPMs requiring an encoder.
3. High-volume OEM manufacturing: Your machines are built repetitively, and you can leverage the unpowered FlashDrop configuration tool for mass programming.
4. Integrated logic is required: You can utilize the 8-state sequence programming to eliminate a low-level PLC from your machine architecture.

Choose the ABB ACS580 when:

1. You are operating in the ~22 kW to 500 kW range: Your industrial motor application exceeds the high-end power limitations (22 kW) of the ACS355.
2. Harmonic mitigation is critical: The drive will be deployed in a facility with strict power quality requirements or sensitive electronics.
3. You are driving modern SynRM motors: The highest possible motor and drive efficiency class is required to meet environmental standards (IE4 or IE5).
4. Commissioning must be fast and intuitive: Maintenance staff require an Assistant keypad with text-based diagnostics, troubleshooting help screens, and native USB connectivity.

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Migration & Upgrade Path

For installations currently running the declining ACS355, planning a migration or upgrade path is an important lifecycle task.

       [ Legacy ACS355 ] 
               |
               | (For Machine Builders / High-Performance Space)
               +---> Migrate to: [ ACS380 Machinery Drive ]
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               | (For General Industry / Infrastructure / Higher Power)
               +---> Migrate to: [ ACS580 General-Purpose Drive ]

• Upgrading from ACS355 to ACS380: For specialized machinery, the direct modern successor to the ACS355 is the ACS380 Machinery Drive. It preserves the compact footprint, dynamic control modes, and OEM-focused design while integrating the all-compatible platform features, improved processing power, and native functional safety protocols.
• Migrating from ACS355 to ACS580: If your application is a pump, fan, or simple conveyor and you no longer require closed-loop encoder feedback or sub-compact spatial configurations, transitioning your machinery to the ACS580 family offers superior diagnostic feedback, an easier programming layout, and extended product availability.

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Frequently Asked Questions

1. Can I use the ABB ACS580 for closed-loop vector control?

No. The ACS580 is an open-loop vector control drive. It features sensorless vector control optimized for high starting torque and precise speed control down to low frequencies, but it does not support connection to encoder speed-feedback modules. If you require closed-loop control in this drive class, safety demands, or power rating, you must step up to the ACS880 Industrial Drive series or use the ACS355 (for smaller applications).

2. Is a line reactor necessary for the ACS580?

In most standard industrial environments, an external line reactor is not necessary for the ACS580. The drive features an integrated, variable-impedance swinging DC choke that mitigates harmonics to levels comparable to or better than a standard 3% line reactor.

3. How does sequencing programming on the ACS355 differ from Adaptive Programming on the ACS580?

The ACS355's Sequence Programming is a state-based programming configuration where transitions between 8 states are predefined by logic inputs or parameters. The ACS580's Adaptive Programming is a graphical block programming environment where you can wire together up to 20 or 30 (depending on firmware version) logic or arithmetic function blocks (such as AND, OR, ADD, SUB, Timer, SR Latches) to develop complex custom application logic.

4. Can both drives control Permanent Magnet (PM) synchronous motors?

Yes, both the ACS355 and the ACS580 can run PM motors. However, the ACS580 is better optimized for ultra-high-efficiency motor technologies, offering dedicated control algorithms for both PM synchronous motors and ABB SynRM (Synchronous Reluctance) motors without the need for additional firmware modules.

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Related Articles

• ABB ACS380 vs ACS580: Micro Machinery vs General Purpose VFDs
• How to Program an ABB VFD Using Drive Composer
• Understanding Harmonic Distortion and Swing Choke Technology in Industrial VFDs