Schneider Altivar 320 ATV320 Replacement

Overview

The Schneider Electric Altivar Machine ATV320 is a variable speed drive (VSD) designed for variable and constant-torque motor control in industrial machinery. Spanning a power range of 0.18 kW to 15 kW (0.25 hp to 20 hp), the ATV320 is commonly deployed in material handling, packaging, textiles, hoisting, and mechanical actuators.

Industrial facilities must periodically replace these drives due to wear-and-tear component failures (such as dried DC bus capacitors, degraded IGBT gates, or internal cooling fan failures), or during systematic modernization programs targeting the migration of legacy Altivar 312 (ATV312) and Altivar 32 (ATV32) units. This technical guide outlines the precise steps, specifications, and hardware profiles required to execute a seamless ATV320 replacement and maintain machine uptime.

Legacy Product Information (catalog/part number, specs, lifecycle status)

The Altivar 320 succeeds older Altivar lines but also contains two distinct, co-existing physical formats: the "Book" format and the "Compact" format. Identifying the exact model code is crucial because these formats have totally different footprints, terminal layouts, and cooling arrangements.

Part Number Nomenclature Breakdown

An example part number is ATV320U15N4B:

• ATV320: Series name (Altivar Machine 320)
• U15: Power rating (e.g., U02 = 0.18 kW, U15 = 1.5 kW, D11 = 11 kW)
• N4: Input voltage code (M2 = 200–240V Single-Phase, M3 = 200–240V Three-Phase, N4 = 380–500V Three-Phase, S6 = 500–600V Three-Phase)
• B: Physical Form Factor Suffix (B = Book format; C = Compact format)

+------------------+-------------------+-----------------+--------------------+
| Voltage Code     | Phase Input       | Voltage Range   | Power Range (kW)   |
+------------------+-------------------+-----------------+--------------------+
| M2               | 1-Phase           | 200 - 240 VAC   | 0.18 to 2.2 kW     |
| M3               | 3-Phase           | 200 - 240 VAC   | 0.18 to 15 kW      |
| N4               | 3-Phase           | 380 - 500 VAC   | 0.37 to 15 kW      |
| S6               | 3-Phase           | 525 - 600 VAC   | 0.75 to 15 kW      |
+------------------+-------------------+-----------------+--------------------+

Lifecycle Status

The Altivar 320 is currently an active, critical product line in Schneider Electric’s catalog. However, older revisions (specifically older firmware versions V1.x or initial hardware builds from its launch around 2016) frequently require substitution. Furthermore, facilities running older, obsolete legacy drives like the ATV31, ATV312, and ATV32 must utilize the ATV320 as their designated modern replacement pathway.

Recommended Replacements

When exchanging an ATV320 or replacing a legacy Altivar drive with an ATV320, several hardware routes can be taken, depending on structural limits and application requirements.

Compatibility Considerations

Before replacing an existing drive, evaluate these mechanical, electrical, and control interfaces:

• Book versus Compact Formats: The B (Book) format is highly vertical (45mm to 180mm wide depending on rating) and allows zero-clearance side-by-side mounting. The C (Compact) format is squarer, with a shallower depth but wider chassis. You cannot mount a Compact drive in a slot wired and drilled for a Book drive without significant backplate drilling and wire rerouting.
• Terminal Interface and Wiring: Book format drives feature pluggable, spring-loaded terminal blocks of a push-in type. Compact format drives typically feature fixed, screw-clamp terminal blocks. If you are substituting standard modules, you must prepare the wiring lugs accordingly.
• Safety Integration: The ATV320 incorporates embedded SIL3-rated Safe Torque Off (STO) across two designated terminals (STOA and STOB) powered by an internal or external 24 VDC source. Ensure your safety circuit dual-channel contactors or safety relays are compatible with the default sinking/sourcing logic (active high-impedance state) of the replacement drive.
• Communication Option Modules (Cassettes): The ATV320 has Modbus RTU and CANopen ports natively integrated. For Ethernet/IP, Modbus TCP, Profinet, Profibus DP, or DeviceNet, the drive requires an option card (e.g., VW3A3627 for Profinet, VW3A3620 for EtherNet/IP). These option cards plug directly into the drive's dedicated communication port. Ensure you order the matching communication module alongside the replacement block.

Upgrade Benefits

Upgrading legacy platforms (such as the ATV312 or ATV32) or standardizing older machine controls onto the modern ATV320 brings major technical advantages:

• Advanced Functional Safety: Beyond simple STO, the ATV320 supports comprehensive safety functions—including Safely Limited Speed (SLS), Safe Stop 1 (SS1), Safe Maximum Speed (SMS), and Guard Door Locking (GDL)—simplifying compliance with the Machinery Directive (EN ISO 13849-1).
• Optimized Engine Control: The ATV320 drives not only standard induction asynchronous motors but also permanent magnet synchronous motors (PM motors) in open-loop vector control, delivering higher efficiency and lower thermal output.
• Environmental Resilience: All ATV320 circuit boards are coated to meet IEC 60721-3-3 class 3C3 (for corrosive gases) and 3S2 (for conductive dust) standards as a standard default, unlike older modules where coating was an optional addition.

Common Migration Challenges

• Mechanical Retrofit Footprints: When converting older ATV312 units to ATV320 Compact units, the mounting holes will not line up. Technical technicians must use Schneider’s transition plate mounting kits (such as the VW3A9x series plates) to map the new drive onto the legacy drill footprint.
• Parameter Translation: Simply copying parameter files compiled for older firmware versions into a new ATV320 can raise "CFI" (Configuration Fault) errors. Use SoMove configuration software to open the legacy configuration (.scfg file) and perform an official conversion to match the exact firmware release of the replacement drive.
• Logic State Control Profiles: Standard factory profile settings on the ATV28/31/312 series used standard Drive State control. The ATV320 utilizes the CiA402 device profile standard for Modbus and CANopen control. This changes command structures (Register 8501 versus typical Control Word structures) and may require updates to PLC driver blocks.

Step-by-Step Replacement Procedure

Follow these technical procedures to replace an ATV320 drive:

Step 1: Safety & Isolation

1. Disconnect all primary power supplies from the incoming line terminals (L1, L2, L3).
2. Lock out and tag out (LOTO) the circuit breakers feeding the drive.
3. Wait at least 15 minutes for the internal DC bus capacitors to discharge to a safe level (< 50 VDC). Use a digital multimeter to measure voltage across the PA/+ and PC/- terminals on the power terminal strip before proceeding.

Step 2: Backup Existing Drive Configuration

• If the old drive is functional: Connect a PC running Schneider SoMove software using the USB-to-RJ45 cable (TCSMCNAM3M002P) to the Modbus port of the drive. Upload and save the .scfg file. Alternatively, transfer the parameters directly to a Graphic Display Terminal (VW3A1111) or a Multi-Loader tool (VW3A8121).
• If the old drive is dead: Retrieve the original electrical schematic and mechanical parametrizations (motor nameplate rating, FLA, RPM, control scheme).

Step 3: Physical Disassembly

1. Label all cables to ensure correct re-termination.
2. Unplug the control terminal blocks (for Book format) or unscrew individual wires from the control terminals (for Compact format).
3. Disconnect power terminal wiring: Line input (L1/L2/L3), Motor output (U/V/W), Braking Resistor lines (change to DB+ / DB- if applicable), and protective earth (PE) grounding conductors.
4. Remove the communication option cassette if equipped.
5. Unscrew mounting fasteners and remove the old drive unit.

Step 4: Mount and Install the New Drive

1. Verify clearance zones around the drive. For Book drives, ensure standard top/bottom space is left open for heatsink fan convection.
2. Affix the new drive block to the backplate. Torques should be configured to 1.5 N·m (13 lb-in) for standard mounting screws.
3. Slot the communication option cassette into the new drive, ensuring the grounding tab/screw makes solid connection with the drive's chassis.

Step 5: Power and Control Re-wiring

1. Connect the incoming line power cables to L1, L2, L3 and torque to the manufacturer specifications listed on the side label.
2. Wire the motor phases to U, V, W. Caution: Do not swap phases to change direction if the drive logic relies on specific vector rotation; instead, configure rotation in the drive options.
3. Securely terminate the ground (PE) conductor.
4. Insert control and safety wiring inputs (DI1-DI6, AI1-AI3, STO). If using external 24V source, set the sink-source switch to the match the design setup (PLC sourcing vs PLC sinking).

[Mains Supply] -> [Breaker/Fuses] -> [Line Terminals: L1, L2, L3]
                                         |
                                  [Altivar ATV320] -> [Safe Torque Off / Relay Circuit]
                                         |
[Motor Cable]  -> [PE (Ground)]    -> [Motor Terminals: U, V, W] -> [AC Motor]

Step 6: Parameter Loading & Commissioning

1. Power up the drive with control line voltage initially, leaving primary 3-phase line isolated if possible (or perform standard commissioning with all power up).
2. Connect the laptop with SoMove. Open the stored configuration, map/convert it to the exact firmware version of the replacement drive, and download the data blocks.
3. Set critical parameter limits:
   • bFr (Standard motor frequency: 50Hz or 60Hz)
   • nPr (Nominal motor power)
   • UnS (Nominal motor voltage)
   • nCr (Nominal motor current - FLA)
   • FrS (Nominal motor frequency)
   • nSp (Nominal motor speed)
   • tUn (Auto-tuning): Conduct a cold auto-tune (tUn -> YES) to optimize the vector loop with the motor cold and inactive. Ensure the motor does not rotate during this quick electrical check.

Step 7: System Operational Tests

1. Test command inputs via local terminal, terminal block switch paths, or fieldbus networks.
2. Confirm the correct motor rotation direction at minimal speed.
3. Check the Dual-channel Safe Torque Off (STO) loop. Verify that removing either safe path triggers the drive fault "PrF" (Power Removal Fault) and disables the output IGBTs immediately.

Frequently Asked Questions

Can I replace an Altivar 32 (ATV32) directly with an Altivar 320 (ATV320)?

Yes. The ATV320 Book format is a form, fit, and functional replacement for the original legacy ATV32 Book series. They feature identical physical widths, mounting patterns, control block configurations, and terminal layout.

Why do I get a "CFI" fault code on my new ATV320 after transferring settings?

A "CFI" (Configuration Fault) error occurs when there is an invalid parameter mapping or an incompatible configuration transfer, often caused by running older firmware parameter maps on a newer firmware system. Resolve this by opening the parameter map file in SoMove, converting it to target the new firmware version, resolving any mismatched settings, and downloading the revised file.

What is the purpose of the sink/source switch on the ATV320 control board?

The sink/source switch (located near the control terminals) configures the binary digital inputs. "Source" is standard for 24V active-high PLC outputs (where 24V logic level triggers the channel), while "Sink" is used for active-low schemes. Setting this switch incorrectly will cause the drive to ignore PLC command inputs or register false-trigger safety conditions.

Can I run a permanent magnet motor on the ATV320?

Yes. The ATV320 supports vector motor tuning parameters for both asynchronous induction motors and PM (Permanent Magnet) synchronous motors in open-loop modes. Change parameter Ctt (Motor Control Type) to match your specific PM motor requirements.

Related Products & Families

• Altivar Machine 340 (ATV340): Advanced machine drive used for high-end hoisting, multi-axis synchronization, and servo-like performance.
• Altivar Process series (ATV630, ATV930): Industrial floor-standing and wall-mount drives engineered for severe duty on pumps, fans, and heavy process equipment.
• SoMove Configuration Tool: The vital software package used to configure, commission, monitor, and back up files across all Schneider Altivar series.
• Power / Control Accessories: Line chokes, output filters, dynamic braking resistors (VW3A7700 series), and Graphic Display terminals (VW3A1111).

Need Help?

Whether you require an exact matching legacy power block or need to verify cross-compatibility specifications during an active downtime situation, Palm Parts Solution can assist. Palm Parts Solution supplies a reliable inventory of brand-new, premium reconditioned, and tested surplus Schneider Altivar 320 drives, option cards, and legacy Altivar modules. All inventory components are backed by a complete warranty to ensure your operations resume with maximum reliability. For immediate stock availability or configuration support, contact the system specialists at Palm Parts Solution.