ABB ACS580-01-096A-4 Variable Frequency Drive 45kW 400V | Replacement, Equivalent & Selection Guide
The ABB ACS580-01-096A-4 is a general-purpose AC variable frequency drive (VFD) rated at 45 kW / 96 A, 380–480 V three-phase, part of ABB’s ACS580 all-compatible drive series. Designed for pump, fan, compressor, and conveyor applications, it delivers precise motor control with built-in EMC filtering and a real-time clock. This page provides full technical specifications, compatible replacement models, system compatibility notes, and a structured selection guide to help engineers and procurement teams make the right sourcing decision.
Technical Specifications
- Part Number: ACS580-01-096A-4
- Brand / Manufacturer: ABB
- Series: ACS580 (All-Compatible Drive)
- Power Rating: 45 kW (60 HP)
- Output Current: 96 A (continuous)
- Input Voltage: 380–480 V AC, 3-phase, 50/60 Hz
- Output Voltage: 0–480 V AC, 3-phase
- Control Mode: Scalar (V/Hz) & Direct Torque Control (DTC)
- Protection Class: IP21 (UL Type 1)
- Ambient Temperature: -15 °C to +40 °C (operating)
- Altitude: Up to 1000 m without derating
- Communication: Modbus RTU (built-in); optional PROFIBUS, PROFINET, EtherNet/IP via fieldbus adapter
- Built-in EMC Filter: Class C2 (EN 61800-3)
- Braking: Internal brake chopper (external resistor required)
- Weight: ~38 kg
- Dimensions (H×W×D): 520 × 237 × 237 mm (approx.)
- Standards: CE, UL, cUL, RoHS
Compatible Replacement & Equivalent Models
The table below lists verified compatible replacements and functional equivalents for the ACS580-01-096A-4. Always confirm voltage class, current rating, and control interface before substitution.
| Model | Brand | Power | Voltage | Notes |
|---|---|---|---|---|
| ACS580-01-106A-4 | ABB | 55 kW | 400 V | Next-size-up within same series; upward compatible |
| ACS580-01-072A-4 | ABB | 37 kW | 400 V | Lower-power sibling; same form factor |
| ACS480-04-096A-4 | ABB | 45 kW | 400 V | Compact successor; check mounting dimensions |
| FR-A840-03250-2-60 | Mitsubishi | 45 kW | 400 V | Cross-brand equivalent; different fieldbus ecosystem |
| 6SL3210-1PE28-8UL0 | Siemens SINAMICS G120 | 45 kW | 400 V | Modular design; requires CU240 control unit |
| ATV630D45N4 | Schneider Electric | 45 kW | 400 V | Altivar 630 series; compatible I/O mapping needed |
| GD350-045G/055P-4 | INVT | 45 kW | 400 V | Cost-effective alternative; verify EMC compliance |
Note: Cross-brand replacements require parameter re-commissioning and may need different fieldbus adapters.
Why Choose the Original Model
- ABB Direct Torque Control (DTC): Industry-leading torque response without encoder feedback — ideal for demanding pump and fan loads.
- All-Compatible Design: Single drive platform supports multiple motor types (induction, PM, SynRM) without hardware changes.
- Built-in Safety: STO (Safe Torque Off) SIL 2 / PLd certified as standard — no external safety relay required.
- Integrated EMC Filter: Class C2 filter reduces installation cost and cabinet space.
- Energy Optimizer: Automatic energy-saving algorithm reduces motor losses in partial-load conditions.
- Long-term Support: ABB ACS580 series has a confirmed production lifecycle with global spare-parts availability.
Typical Applications
- Centrifugal pumps and water treatment systems
- HVAC fans and air handling units (AHU)
- Compressors and blowers in industrial plants
- Conveyor and material handling systems
- Mixers and agitators in process industries
- Building automation and energy management systems
System Compatibility
- PLC Integration: Compatible with Siemens S7, Allen-Bradley ControlLogix/CompactLogix, Mitsubishi MELSEC, and Omron NJ/NX via optional fieldbus adapters (FENA-21 for EtherNet/IP, FPBA-01 for PROFIBUS DP).
- Motor Types: Standard induction motors (IE2/IE3/IE4), permanent magnet (PM) motors, synchronous reluctance motors (SynRM).
- DCS Compatibility: Integrates with ABB System 800xA, Emerson DeltaV, Honeywell Experion via HART or fieldbus.
- Panel Builder: Supports ABB DriveAP and Drive Composer PC tools for commissioning and diagnostics.
- Bypass / Redundancy: Compatible with ABB bypass modules for critical applications requiring uninterrupted operation.
Selection Guide
Use the following criteria to confirm the ACS580-01-096A-4 is the correct model for your application:
- Step 1 — Motor Power: Confirm motor nameplate power ≤ 45 kW and rated current ≤ 96 A.
- Step 2 — Supply Voltage: Verify 3-phase supply is within 380–480 V ±10%.
- Step 3 — Load Type: Identify load profile — constant torque (CT) or variable torque (VT/pump-fan). ACS580-01-096A-4 is rated for both.
- Step 4 — Environment: Check ambient temperature and altitude. Above 40 °C or 1000 m requires derating — consult ABB derating tables.
- Step 5 — Protection Class: IP21 suits indoor, clean environments. For outdoor or dusty locations, consider IP55 variant (ACS580-01-096A-4+B055).
- Step 6 — Communication: Confirm fieldbus protocol. Built-in Modbus RTU is standard; order appropriate FENA/FPBA adapter for Ethernet or PROFIBUS.
- Step 7 — Braking: If dynamic braking is required, confirm external braking resistor sizing per ABB application guide.
Quality Assurance & Sourcing
- All units sourced through authorized ABB distribution channels or verified surplus with full traceability documentation.
- Each unit undergoes incoming inspection: visual check, label verification, and functional power-on test where applicable.
- Counterfeit-risk screening applied to all non-factory-sealed units.
- Certificates of conformity and test reports available upon request.
- Warranty: 12 months from shipment date (new units); 90 days (tested surplus units).
How to Order
- Part Number: ACS580-01-096A-4
- Minimum Order Quantity: 1 unit
- Lead Time: In-stock units ship within 3–5 business days; ex-factory orders 6–12 weeks.
- Shipping: DHL Express / FedEx International Priority; sea freight available for bulk orders.
- Payment: T/T, PayPal, credit card (via Shopify Payments).
- Request a Quote: Contact support@konmask.com for volume pricing, OEM projects, or urgent requirements.
Replacement & Compatibility FAQ
Q: Can I replace ACS580-01-096A-4 with ACS480-04-096A-4?
A: Yes, functionally equivalent in power and current. The ACS480 is more compact — verify panel cutout dimensions and cable entry positions before installation.
Q: Is the ACS580-01-096A-4 compatible with IE4 ultra-premium efficiency motors?
A: Yes. ABB ACS580 natively supports IE4 synchronous reluctance (SynRM) motors with the correct motor model selection in parameters.
Q: Can I use a Siemens G120 as a drop-in replacement?
A: Not a drop-in — different terminal layout, parameter structure, and fieldbus adapters. Requires full re-commissioning and possible wiring changes.
Q: Does the ACS580-01-096A-4 include a built-in bypass?
A: No. Bypass functionality requires an external bypass module. ABB offers dedicated bypass panels for this drive size.
Q: What is the difference between ACS580-01-096A-4 and ACS580-01-096A-4+B055?
A: The +B055 option adds an IP55 enclosure for use in dusty or humid environments. All electrical specifications are identical.
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