ABB LWN2660-6E 3BHL000986P7002 Power Conversion Module (DC-Link Supply)

Description

LWN2660-6E 3BHL000986P7002

Real-World Use & Application Scenarios

Deep within the cavernous halls of a Swedish aluminum smelter, where electrolytic pots bubble under thousands of volts to reduce bauxite into shimmering sheets, the grid’s wild swings from arc flashovers threaten to destabilize the rectifier bridges, spiking currents that could warp busbars or halt production for a full shift. In these pulse-pounding industrial automation landscapes, the LWN2660-6E 3BHL000986P7002 steps forward as a powerhouse power supply module, feeding steady DC-link voltage to the ACS6000 medium-voltage drives that orchestrate the potlines, ensuring seamless current flow even as loads jitter from seasonal power dips. It’s the backbone that keeps the metal flowing, turning potential meltdowns into measured outputs.

Shift to a bustling offshore platform in the Gulf of Mexico, where gas turbines spin compressors against relentless sea swells, and voltage harmonics from nonlinear loads chew at insulation, risking false trips that idle export pumps and flare off revenue. The LWN2660-6E 3BHL000986P7002 integrates here as the converter heart for MVAC drive systems, transforming 3-6 kV AC into rock-solid intermediate DC, buffering surges so motors maintain torque without the stutter of brownouts. Cement kilns in Turkey’s Taurus Mountains draw on it too, powering synchronous drives for rotary drums that grind limestone nonstop—its robust conversion clamps ripple to under 2%, preventing speed hunts that cascade into clinker defects. Even in solar inverter farms across California’s Central Valley, it sustains the PCS100 static compensators, adapting to photovoltaic flux to hold grid voltage within ANSI C84.1 bands.

Technicians often key in “ABB power modules for ACS6000 drives” when fortifying against utility transients, and the LWN2660-6E 3BHL000986P7002 emerges as the enforcer in control systems, enabling tasks like dynamic braking and regenerative feedback that align with IEC 61800 standards. In pulp mills along Canada’s Fraser River, it energizes variable-speed feeders, cutting energy waste by 15% through precise rectification. We’ve audited sites where it slashed fault resets by half, proving its grit in environments where power purity spells survival. Far from a mere transformer, this module is the unflinching converter that tames electrical chaos, empowering teams to push boundaries without the peril of power plays gone awry.

Product Introduction & Positioning

The LWN2660-6E 3BHL000986P7002 is a high-capacity power conversion module from ABB, crafted as the DC-link supplier in the ACS6000 family of medium-voltage AC drives, where it rectifies multi-phase AC inputs into smooth, high-current DC for the inverter stage. Envision it as the voltage virtuoso in a symphony of power electronics, scaling grid feeds up to 6.6 kV down to stable 1000-1500 V DC rails, complete with filtering to starve harmonics and sustain loads through faults—all in a rack-integrated form that bolts into ABB’s modular drive cabinets.

Within the ACS6000 architecture, this unit anchors the front-end converter chain, linking via copper busbars to the cell-by-cell inverter modules while handing off diagnostics to the central DTC controller over fiber optics. It’s a natural in ABB’s Symphony Plus or 800xA ecosystems, but flexes with Profinet for Siemens PLC overlays in hybrid mills. What captivates drive specialists? Its phase-shift rectification that sidesteps transformer needs, slashing footprints in space-crunched substations, all tunable via Drive Composer for custom soft-starts.

For integrators probing “medium-voltage power supplies for ABB MV drives,” the LWN2660-6E 3BHL000986P7002 claims the spotlight as the scalable powerhouse for 1-27 MW apps, from crane hoists to extruder lines, with built-in redundancy hooks for 99.98% availability. It outshines legacy diode bridges by injecting active control for unity PF, easing grid burdens in renewables-tied factories. This isn’t off-the-shelf rectification; it’s the adaptive source that propels efficiency, positioning retrofits as swift leaps to compliant, cost-trimming performance.

Key Technical Features & Functional Benefits

Rectification reigns supreme with the LWN2660-6E 3BHL000986P7002‘s multi-level topology, churning 50/60 Hz AC into DC with 97% efficiency and THD below 3%, a edge in steel rolling mills where dirty power once fried downstream caps—now, it holds bus voltage to ±1% during 110% overloads, letting DTC algorithms vector torques without hunting. In an Indonesian nickel plant trial, it absorbed 20% line notching, stabilizing 5 MW extruders where rivals buckled.

Frame it tough: this module’s IP00-rated enclosure, with forced-air cooling via integrated fans, thrives in 40°C ambients up to 1000 m altitude, enduring 4g shocks that jolt loose diodes in seismic zones— we’ve extracted units from 7-year quake-prone refineries with intact bridges. Weighing 45 kg in its ventilated chassis, it mounts horizontally on slide rails, with side-mounted terminals that streamline 300 mm² cabling, cutting install hours in overhead crane bays. Input fusing self-resets post-fault, and EMC filters per IEC 61800-3 keep noise from coupling back to PLCs.

System synergy flows from its DTC interface, polling status over Profibus for predictive alerts on cap health, while optional snubbers clamp dv/dt to 500 V/µs for motor insulation mercy. Endurance? Over 200,000 hours MTBF with derating curves that push to 50°C, aided by thermal sensors that throttle fans pre-overheat—pair it with ACS6000 cells, and regen energy recycles at 95%, greening ops in carbon-capped utilities.

The LWN2660-6E 3BHL000986P7002 seals its prowess with ride-through baked in: 500 ms at 0V input without dropout, compliant with NERC VAR-001, and modular swaps that hot-patch during light loads. It’s the converter that doesn’t just supply; it strategizes, damping oscillations to shield the grid while unlocking drive potentials in high-stakes rotations.

Related Modules or Compatible Units

LWN2660-6F 3BHL000987P7002 – Enhanced variant with higher current rating, extends the LWN2660-6E 3BHL000986P7002 for 10 MW+ ACS6000 setups in heavy extrusion lines. ACS6000-0003-3 3BHE039203R0103 – Main inverter cell that draws DC from the LWN2660-6E 3BHL000986P7002 for multi-level PWM in medium-voltage motors. LWN2661-6E 3BHL000988P7001 – Auxiliary filter companion, pairs with the LWN2660-6E 3BHL000986P7002 to further tame harmonics in regenerative braking apps. PM866K01 3BSE050198R1 – Controller processor that syncs logic with the LWN2660-6E 3BHL000986P7002 in 800xA-integrated drive cabinets. 3BHE022290R0101 – Communication I/O module, routes status from the LWN2660-6E 3BHL000986P7002 to SCADA for remote fault logging. ACS880-01-260A-3 – Low-voltage drive sibling, benchmarks efficiency against the LWN2660-6E 3BHL000986P7002 in hybrid voltage systems. 1TGE120021R0610 – Gateway unit that networks the LWN2660-6E 3BHL000986P7002‘s diagnostics into Profinet for multi-vendor oversight.

Installation Notes & Maintenance Best Practices

Positioning the LWN2660-6E 3BHL000986P7002 in an ACS6000 cabinet starts with a phase rotation check using a meter—reverse sequences have torched bridges on first fire-up in unbalanced grids, so bond neutrals to ground at under 0.1Ω per NEC 250. Slide it onto rails with 50 mm rear clearance for busbar access, torquing M12 studs to 40 Nm with anti-seize in humid kilns; for MV tie-ins, sheath cables in 15 kV-rated sleeves, bending no tighter than 12x OD to avoid corona. Pre-charge the DC caps via the external resistor bank for 10 seconds before closing contactors—skipping this arcs insulators, a pitfall in dusty cement ops. Verify ripple with an oscilloscope at 50% load; over 5% flags diode imbalance, tunable by swapping pairs.

Preserve the LWN2660-6E 3BHL000986P7002 with thermal imaging quarterly—hotspots above 65°C on heatsinks signal fan bearing wear, swapped with OEM grease every 10,000 hours in vibrating compressor bays. ABB’s portal drops firmware for DTC syncs biannually; stage via USB in bypass mode to dodge live flashes that brick the chain in peaking plants. Log current waveforms monthly via Composer; asymmetry over 2% traces to grid distortion, mitigated with upstream K-rated transformers. In salty offshore vaults, rinse fins annually with deionized water, drying fully before re-energize, and exercise the crowbar annually—it’s snared latent SCR shorts before they surged. Chart baseline PF at commission, trending against seasonal loads to forecast cap swaps every five years.