Replacing an ABB ACS150 with an ACS180 – Complete Comparison Guide
The ABB ACS150 is obsolete and has been succeeded by the ACS180. This guide is intended to assist maintenance engineers, machine builders, OEMs and electricians who are replacing an existing ABB ACS150 with the newer ACS180.
Introduction
Although the ABB ACS180 succeeds the ACS150, several important differences must be considered before installation. This guide compares the two drives side-by-side, including electrical rating, dimensions, control terminals, parameter differences and hardware features, making it easier to select and commission the correct replacement.
Throughout this guide we use a traffic light system to highlight the significant differences between the two products:
🟢 No significant change – generally compatible
🟡 Minor difference – check before installation
🔴 Important difference – may require modification or affect operation
Quick Summary
| Question |
Answer |
| Are the ratings the same? |
The ACS180 is dual-rated, which may offer a different drive selection for fan and pump applications. The range also extends up to 22 kW. |
| Are the units the same size? |
Dimensions and frame sizes differ. Some replacement units are smaller, while one constant-torque selection uses a larger frame. |
| Is the performance the same? |
The ACS180 includes sensorless vector control, which can improve low-speed torque performance when selected. |
| The keypad and keys are different, am I losing any functions? |
The graphical keypad retains the main functions, but there is no front-mounted potentiometer; arrow keys are provided instead. |
| Can I DIN mount the ACS180? |
Yes, with an optional DIN mounting kit |
| Are the control terminal references the same? |
No. The ACS180 offers additional functions, and the terminal references differ. |
| Are the parameters the same? |
No. The parameters use different references and groupings, which are easy to navigate on the graphical keypad. |
| Why have these changes been made? |
The ACS180 is more closely aligned with other ABB ACS drive ranges and includes Safe Torque Off (STO), a useful safety feature in many applications. |
Image Comparison
Below are examples of the ACS150 and ACS180 frame size R1. The images highlight several design changes and enhancements.
kW Rating, Current Ratings and Frame Size
It is always important when replacing any AC inverter that the continuous output current is sufficient for the motor rated current. Current ratings can vary between product ranges and manufacturers. If the exact amp rating does not exist in the AC inverter range then the next largest unit should be selected. In all AC VSDs, the motor current value should be programmed during commissioning to ensure that the motor is thermally protected.
The ACS150 has one kW rating and the ACS180 has two kW ratings. The ACS180 is dual rated: it has a constant torque rating (150% overload) and a variable torque rating (110% overload). This means that product selection is now based not just on kW rating but overload rating too. This adds a selection step but may allow a lower-rated drive to be selected for centrifugal loads such as fans and pumps which do not require a high overload capability.
To select the correct replacement, identify the supply voltage, the application’s overload requirement and the motor rating. The part number (if known) will be repeated for both overloads. If the required overload rating is unknown, use the 150% overload tables as the starting point and confirm suitability before ordering.
- Voltage – information is split between 230 Vac single-phase and 400 Vac three-phase supplies.
- Overload – each voltage range is divided into 150% overload (typically constant-torque loads) and 110% overload (typically variable-torque loads, such as centrifugal fans and pumps).
- kW rating – each overload category is subdivided by available drive power ratings.
230 Vac Single-Phase VSDs (200-240Vac)
Select a linked kW rating to view the product listing, price and availability. ACS150 links are provided for reference only because the range is obsolete.
150% Overload (Constant Torque) - 230Vac single-phase
ACS150 (ACS150-01E-xxAx-2)
|
ACS180 (ACS180-04S-xxAx-1)
|
| kW Rating |
Output Amps (Continuous) |
Frame Reference |
Part Ref |
kW Rating |
Output Amps (Continuous) |
Frame Reference |
Part Ref |
| - |
- |
- |
- |
0.25 kW 🆕 |
1.8 A |
R0 |
02A4 |
| 0.37 kW |
2.4 A |
R0 |
02A4 |
0.37 kW |
2.4 A |
R0 |
03A7 |
| - |
- |
- |
- |
0.55 kW 🆕 |
3.7 A |
R0 |
04A8 |
| 0.75 kW |
4.7 A |
R1 |
04A7 |
0.75 kW |
4.5 A |
R1 |
06A9 |
| 1.1 kW |
6.7 A |
R1 |
06A7 |
1.1 kW |
6.6 A |
R1 |
07A8 |
| 1.5 kW |
7.5 A |
R2 |
07A5 |
1.5 kW |
7.4 A |
R1 🟡 |
09A8 |
| 2.2 kW |
9.8 A |
R2 |
09A8 |
2.2 kW |
9.8 A |
R2 |
12A2 |
110% Overload (Variable Torque - Fan and Pump loads) - 230Vac single-phase
ACS150* (ACS150-01E-xxAx-2)
|
ACS180 (ACS180-04S-xxAx-1)
|
| kW |
Output Current (Continuous) |
Frame Size |
Part Ref |
kW |
Output Current (Continuous) |
Frame Size |
Part Ref |
| 0.37 kW |
2.4 A |
R0 |
02A4 |
0.37 kW |
2.3 A |
R0 |
02A4 |
| - |
- |
- |
- |
0.55 kW 🆕 |
3.5 A |
R0 |
03A7 |
| 0.75 kW |
4.7 A |
R1 |
04A7 |
0.75 kW |
4.6 A |
R0 🟡 |
04A8 |
| 1.1 kW |
6.7 A |
R1 |
06A7 |
1.1 kW |
6.6 A |
R1 |
06A9 |
| 1.5 kW |
7.5 A |
R2 |
07A5 |
1.5 kW |
7.4 A |
R1 🟡 |
07A8 |
| 2.2 kW |
9.8 A |
R2 |
09A8 |
2.2 kW |
9.3 A |
R1 🟡 |
09A8 |
| - |
- |
- |
- |
3 kW 🆕 |
11.6 A |
R2 |
12A2 |
*The ACS150 has a 150% overload rating only. Drive selection must be based on the motor nameplate current and the application’s overload requirements.
400 Vac Three-Phase VSDs (380 Vac - 480 Vac)
Select a linked kW rating to view the product listing, price and availability. ACS150 links are provided for reference only because the range is obsolete.
150% Overload (Constant Torque) - 400Vac three-phase
ACS150 (ACS150-03E-xxAx-4)
|
ACS180 (ACS180-04S-xxAx-4)
|
| Power Rating |
Output Current (Continuous) |
Frame Size |
Part Ref |
Power Rating |
Output Current (Continuous) |
Frame Size |
Part Ref |
| 0.37 kW |
1.2 A |
R0 |
01A2 |
0.37 kW |
1.2 A |
R0 |
01A8 |
| 0.55 kW |
1.9 A |
R0 |
01A9 |
0.55 kW |
1.8 A |
R0 |
02A6 |
| 0.75 kW |
2.4 A |
R1 |
02A4 |
0.75 kW |
2.4 A |
R0 🟡 |
03A3 |
| 1.1 kW |
3.3 A |
R1 |
03A3 |
1.1 kW |
3.3 A |
R1 |
04A0 |
| 1.5 kW |
4.1 A |
R1 |
04A1 |
1.5 kW |
4 A |
R1 |
05A6 |
| 2.2 kW |
5.6 A |
R1 |
05A6 |
2.2 kW |
5.6 A |
R1 |
07A2 |
| 3 kW |
7.3 A |
R1 |
07A3 |
3 kW |
7.2 A |
R1 |
09A4 |
| 4 kW |
8.8 A |
R1 |
08A8 |
4 kW |
9.4 A |
R2 🔴 |
12A6 |
| Not Available |
- |
- |
|
5.5 kW 🆕 |
12.6 A |
R2 |
17A0 |
110% Overload (Variable Torque - Fan and Pump loads) - 400Vac three-phase
ACS150* (ACS150-03E-xxAx-4)
|
ACS180 (ACS180-04S-xxAx-4)
|
| Power Rating |
Output Current (Continuous) |
Frame Size |
Part Ref |
Power Rating |
Output Current (Continuous) |
Frame Size |
Part Ref |
| 0.37 kW |
1.2 A |
R0 |
01A2 |
0.55 kW |
1.7 A |
R0 |
01A8 |
| 0.55 kW |
1.9 A |
R0 |
01A9 |
0.55 kW |
1.7 A |
R0 |
01A8 |
| 0.75 kW |
2.4 A |
R1 |
02A4 |
0.75 kW |
2.5 A |
R0 🟡 |
02A6 |
| 1.1 kW |
3.3 A |
R1 |
03A3 |
1.1 kW |
3.1 A |
R0 🟡 |
03A3 |
| 1.5 kW |
4.1 A |
R1 |
04A1 |
1.5 kW |
3.8 A |
R1 |
04A0 |
| 2.2 kW |
5.6 A |
R1 |
05A6 |
2.2 kW |
5.3 A |
R1 |
05A6 |
| 3 kW |
7.3 A |
R1 |
07A3 |
3 kW |
6.8 A |
R1 |
07A2 |
| 4 kW |
8.8 A |
R1 |
08A8 |
4 kW |
8.9 A |
R1 |
09A4 |
| Not Available |
- |
- |
- |
5.5 kW 🆕 |
12 A |
R2 |
12A6 |
*The ACS150 has a 150% overload rating only. Drive selection must be based on the motor nameplate current and the application’s overload requirements.
Frame Size Comparison
All Units - 230 Vac and 400 Vac
| ACS150 |
ACS180 |
| Frame Reference |
H (H2*) x W x D (Overall) |
h x w (Fixing) |
Fixings |
Mains Cable Entry |
Frame Reference |
H (H2*) x W x D (Overall) 🟡 |
h x w (Fixing) 🟡 |
Fixing Holes 🟡 |
Mains Cable Entry |
| R0 |
169 (239) x 70 x 144 |
201 x 50 mm |
4 x 5mm or DIN |
Bottom |
R0 |
174 mm (209) x 70 mm x 143 mm |
164 mm x 60 mm |
3 x 5.5mm |
Top 🔴 |
| R1 |
169 (239) x 70 x 144 |
201 x 50 mm |
4 x 5mm or DIN |
Bottom |
R1 |
190 mm (220) x 70 mm x 143 mm |
180 mm x 60 mm |
2 x 5.5mm |
Top 🔴 |
| R2 |
170 (239) x 105 x 144 |
191 x 85 mm |
4 x 5mm or DIN |
Bottom |
R2 |
202 mm (230) x 120 mm x 143 mm |
190 mm x 106 mm |
4 x 5.5 mm |
Bottom |
*H2 includes the earth clamp and fixings as well as the main body of the VSD. H is the main body of the VSD only.
⚠️ Traffic lights have only been added to show key differences between the frame references and are not related to the kW rating and overload. Use the Ratings tables to determine any Frame Size difference. ⚠️
Useful Notes:
- DIN Mounting is included in the ACS150 but is optional for the ACS180. DIN kits are available for frames R0 to R2 (same frame range as the ACS150)
- Mains cable entry is at the top of the ACS180 for frames R0 and R1 and may require consideration depending on cable routing
- Frame-size boundaries have changed, so some replacement drives are smaller and others are larger. Larger frame sizes have been highlighted with a red indicator
Key Hardware Differences
Internal Brake Chopper (DBr)
Part references can be used to compare. Part references are given above for all ratings and all overloads.
230Vac single-phase
ACS150
|
ACS180
|
| Power Rating |
Part Ref |
Frame |
DBr Included |
Resistance |
kW Rating |
Part Ref |
Frame |
DBr Included |
Resistance |
| - |
- |
- |
- |
- |
0.25 kW / 0.37 kW |
02A4 |
R0 |
❌ |
- |
| 0.37 kW |
02A4 |
R0 |
✅ |
70Ω-390Ω |
0.37 kW / 0.55 kW |
03A7 |
R0 |
❌ |
- |
| - |
- |
- |
- |
- |
0.55 kW / 0.75 kW |
04A8 |
R0 |
❌ |
- |
| 0.75 kW |
04A7 |
R1 |
✅ |
40Ω-200Ω |
0.75 kW / 1.1 kW |
06A9 |
R1 |
❌ |
- |
| 1.1 kW |
06A7 |
R1 |
✅ |
40Ω-130Ω |
1.1 kW / 1.5 kW |
07A8 |
R1 |
❌ |
- |
| 1.5 kW |
07A5 |
R2 |
✅ |
30Ω-100Ω |
1.5 kW / 2.2 kW |
09A8 |
R1 |
❌ |
- |
| 2.2 kW |
09A8 |
R2 |
✅ |
30Ω-70Ω |
2.2 kW / 3 kW |
12A2 |
R2 |
✅ |
19.5Ω - 47Ω |
400 Vac three-phase
| ACS150 |
ACS180 |
| Power Rating |
Part Ref |
Frame |
DBr Included |
Resistance |
kW Rating |
Part Ref |
Frame |
DBr Included |
Resistance |
| 0.37 kW |
01A2 |
R0 |
✅ |
200 - 1180 Ω |
0.37 kW / 0.55 kW |
01A8 |
R0 |
❌ |
- |
| 0.55 kW |
01A9 |
R0 |
✅ |
175 - 800 Ω |
0.55 kW / 0.75 kW |
02A6 |
R0 |
❌ |
- |
| 0.75 kW |
02A4 |
R1 |
✅ |
165 - 590 Ω |
0.75 kW / 1.1 kW |
03A3 |
R0 |
❌ |
- |
| 1.1 kW |
03A3 |
R1 |
✅ |
150 - 400 Ω |
1.1 kW / 1.5 kW |
04A0 |
R1 |
❌ |
- |
| 1.5 kW |
04A1 |
R1 |
✅ |
130 - 300 Ω |
1.5 kW / 2.2 kW |
05A6 |
R1 |
❌ |
- |
| 2.2 kW |
05A6 |
R1 |
✅ |
100 - 200 Ω |
2.2 kW / 3 kW |
07A2 |
R1 |
❌ |
- |
| 3 kW |
07A3 |
R1 |
✅ |
70 - 150 Ω |
3 kW / 4 kW |
09A4 |
R1 |
❌ |
- |
| 4 kW |
08A8 |
R1 |
✅ |
70 - 110 Ω |
4 kW / 5.5kW |
12A6 |
R2 |
✅ |
32 - 75 Ω |
Useful Notes:
- If braking is required but is not available in the kW rating, selecting a larger unit may be an option.
- The Flux Braking feature may be a suitable alternative if the motor is stopped or decelerated occasionally and the braking load is light. In this instance any excess energy is transferred to the motor as heat which needs to be considered.
Keypad Differences
The multi-line graphical LCD Keypad is a significant improvement. Both keypads are fixed; however, the ACS180 now has optional keypads available for panel mounting and Bluetooth connectivity.
Front Mounted Keypad Summary
Door Mounted Keypad
The ACS150 could not have an external keypad fitted. The ACS180 has external keypad capability. See the ACS180 keypad options here.
Control Terminal Differences
The terminal references are different and therefore any existing control wires must be identified and connected to the appropriate ACS180 terminals. To assist with this, we have given a wiring diagram below with the function of the inputs in addition to the terminal reference.
| |
Analogue Input |
Analogue Output |
Digital Input |
Digital Output |
Relay |
Comms |
| ACS150 |
1 |
0 |
5 |
0 |
1 x Change-over |
None |
| ACS180 |
2* |
1 |
5* |
1 |
1 x Change-over |
Modbus RTU |
Additional Useful Notes
- ACS180 control terminals are spring-loaded for ease of installation.
- STO is fitted to all ACS180 units with the Safety inputs linked out (disabled).
- *On the ACS180 Analogue Input 1 and Digital Input 5 share the same terminal (either, or - not both)
Default Wiring
Terminal references differ, but the basic control functions shown are comparable.
Parameter Differences
Default operation is slightly different in the ACS180. Below is a list of parameters that you may come across during the most basic set-up that need reviewing.
| Function |
ACS150 |
ACS180 |
Difference or possible consequence with ACS180 fitted |
| Stopping Mode |
Coast to stop (default) |
Ramp to stop (default) |
Default stopping mode is controlled rather than uncontrolled |
| Deceleration time |
5 seconds (default) |
3 seconds (default) |
A quicker deceleration time can lead to over-voltage trips on high inertia loads |
| Acceleration time |
Value set by Parameter 2202 |
Set by Parameter 28.72 (V/F) or 23.12 (SVC) |
Ramp rate needs to be set for specific control mode |
| Deceleration time |
Value set by Parameter 2203 |
Set by Parameter 28.73 (V/F) or 23.13 (SVC) |
Ramp rate needs to be set for specific control mode |
Common Mistakes
- ACS180 is only suitable for panel mounting. Units can no longer be wall mounted as the wall mounting adapter kit is no longer available
- ACS180 is not fitted with a braking switch (DBr) in the smaller frame sizes.
- DIN rail mounting kits are now optional on ACS180 R0 and R1 frame sizes.
- Acceleration and deceleration rates are set by different parameters depending on the control type (V/F or Sensorless Vector). Ensure the correct rates are set - refer to our ACS180 Easy Start Guide
- Removing the factory STO links without connecting an appropriate safety circuit.
What’s New in the ACS180 - Top 5
- Sensorless Vector Control for improved torque performance
- STO (Safe Torque Off) dual-channel input for suitable safety circuit
- Easy-to-read graphical keypad and optional door-mounted keypads
- More I/O: Additional analogue and digital I/O options
- Modbus RTU
Conclusion
The ACS180 is a well-featured entry-level product with an easy-to-use graphical keypad. It is not an identical replacement but the enhancements such as sensorless vector control and STO will suit many users. The lack of an internal braking on frames R0 and R1 needs to be highlighted but is infrequently used at these power ratings. Those familiar with the ACS380, ACS480 and ACS580 will be familiar with the parameter sets, which are now more aligned with the ABB product family. The additional external keypads are a welcome addition enabling Bluetooth programming and parameter storage. The extension of the power ratings and dual rating also make the ACS180 a good alternative for the ACS310 which is also in its retirement phase.
Useful Additional Information
ACS180 Easy Start Guide
ACS150 Easy Start Guide (coming soon)
ACS180 Product Overview
Images and content created by Inverter Drive Supermarket. Last revised October 2026