ABB ACS355 Replacement Guide

Overview

The ABB ACS355 micro drive has been a reliable choice for machine builders, OEMs, and system builders requiring high-performance speed and torque control in a compact package. However, as industrial automation transitions toward the ABB "all-compatible" platform, system integrators and maintenance personnel must transition legacy systems to modern hardware. The direct, manufacturer-supported successor to the ACS355 is the ABB ACS380 machinery drive.

While both series are engineered for demanding machinery applications, moving from the ACS355 to the ACS380 requires careful attention to physical mounting profiles, control terminal configurations, programming tool changes, and communication protocols. This technical guide outlines the exact parameters, physical dimensions, and operational differences encountered when migrating your system.

Legacy Product Information

The ABB ACS355 range covers power ratings from 0.37 to 22 kW (0.5 to 30 hp) across voltage ranges of 100V, 200V, and 400V. It features a scalar and vector sensorless/closed-loop induction motor control capability, along with support for Permanent Magnet (PM) synchronous motors.

Key features of the legacy ACS355 include:

• Frame Sizes: R0, R1, R2, R3, and R4.
• Control Capabilities: Built-in Safe Torque Off (STO) to SIL3, dynamic braking chopper, and standard sequence programming.
• Configuration Interface: Driven by DriveWindow Light 2 software using the OPMP-01 or panel port interface.
• Standard Communication: Serial Modbus RTU via an RJ45 port or using optional F-series fieldbus adapters (e.g., FENA-11, FMBA-01) mounted directly beneath the front cover.

Recommended Replacements

ABB recommends the ACS380 machinery drive as the primary replacement for the ACS355. For simple fan/pump or general-purpose conveyor systems that do not require high overload capacities or advanced machinery programming, the ACS480 general-purpose drive serves as an alternative secondary option.

Below is a comparison of equivalent frame capacities and configurations:

When ordering a replacement ACS380, match the nominal output current rating rather than the horsepower rating, particularly if you are running the legacy drive at high overload schedules (150% overload for 1 minute every 10 minutes).

Compatibility Considerations

Footprint and Mounting Dimensions

The physical dimensions of ACS355 and ACS380 do not match exactly across all frame sizes. Both drives offer a uniform, zero-clearance side-by-side mounting design, but depth adjustments may be necessary for shallow control cabinets.

• Standard Height: The ACS380 is taller in most configurations due to integrated EMC filters and fieldbus modules.
• Depth Changes: The legacy ACS355 R1 frame depth is 161 mm. The corresponding ACS380 R1 frame measures 174 mm in depth. Confirm your cabinet clearances before installation.
• DIN Rail Mounting: Both drives support 35 mm DIN rail mounting for frames R0 through R2, though screw mounting directly to the subpanel is recommended for high-vibration applications.

Terminal Connections and Power Wiring

• Line and Motor Terminals: The terminal configuration of the ACS380 isolates line power input at the top of the drive and motor power output at the bottom of the drive. The ACS355 utilized a different layout with relay/control terminals layered closely to the mains connections. Ensure field power cables have sufficient slack to reach the relocated terminal blocks.
• STO Terminals: The ACS355 utilizes a single physical terminal header for Safe Torque Off (STO). The ACS380 features a distinct terminal block configuration requiring dual-channel wirings. If upgrading, you must translate the safety circuit wiring to meet the modern SIL3 / PL e dual-channel architecture.

I/O and Fieldbus Mapping

The ACS355 features a fixed, layout-specific control board with an option slot for F-series fieldbus adapters (such as the FENA-11 EtherNet/IP or PROFINET module). The ACS380 series uses pre-configured internal fieldbus interfaces tailored at order entry (e.g., standard Modbus RTU variant ACS380-04XS vs. specialized Ethernet variant ACS380-040C). Review the suffix of your replacement's part number to ensure compatibility with your network.

Upgrade Benefits

Transitioning from the ACS355 to the ACS380 offers several significant operational and performance advantages:

• Enhanced Motor Control: Superior vector control performance capable of running Induction Motors, Permanent Magnet (PM) Motors, and Synchronous Reluctance Motors (SynRM) without system instability.
• Adaptive Programming: Unlike legacy sequence programming on the ACS355, the ACS380 features an integrated IEC 61131-3 compliant programming environment (Adaptive Programming) built directly into the free Drive Composer software. This allows custom logic blocks to run without needing an external PLC.
• Streamlined Connectivity: Integrated functional safety and fieldbus modules eliminate the need to buy and mount optional external communication modules.
• Improved Diagnostics: The modern control panel supports multi-line text displays and USB-to-PC connections for rapid debugging and parameter downloads.

Common Migration Challenges

Parameter Transposition

You cannot upload a database file using DriveWindow Light from an ACS355 and directly download it to an ACS380 via Drive Composer. Parameters must be mapped and input manually or converted. Key differences exist in group structures; for example, the motor setup parameters in Group 99 of the ACS355 are mapped differently inside the unified Group 99 parameters of the ACS380.

Communication Protocol Mapping

When substituting an ACS355 using an FPBA-01 PROFIBUS or FENA-21 PROFINET module with an integrated PROFINET-based ACS380 (ACS380-040C), the logical GSDML/EDS configuration files in the master PLC (such as TIA Portal or Studio 5000) must be updated. Hardware identifiers and memory maps do not map 1:1.

FAQ

Q: Can I use my old ACS355 parameter hex keys or control panels with the new ACS380?

No. The ACS355 parameter upload/download tools, such as the FlashDrop tool (MFDT-01) and legacy assistant control panels (ACS-CP-A), are mechanically and digitally incompatible with the ACS380 series. The ACS380 uses Drive Composer software over a mini-USB connection or the modern BMUM-01 Bluetooth control panel.

Q: Do the dual-channel STO circuits of the ACS355 map directly to the ACS380?

Yes, although the physical terminal designations differ. The ACS355 uses standard multi-connection interfaces for safety, and the ACS380 uses dual-channel terminal loops (OUT1, SGND, IN1, IN2). You must consult the manual's wiring schematic to map legacy loops to the corresponding inputs.

Q: Is there an automated software tool to convert ACS355 parameters to ACS380?

No. ABB does not provide an automated file converter. You must extract the parameter set of your ACS355 through a printout or file viewer and key the parameters into Drive Composer while connected to the test/commissioning run of the new ACS380 drive.

Q: Can I replace an ACS355 with an ACS480 instead?

Yes. If your application does not require high starter torque overload limits or customized adaptive logic, the ACS480 is a cost-effective alternative. However, the ACS380 remains the direct engineering equivalent for machinery applications requiring dynamic performance.