Copenhagen, Denmark – January 2026 – Ørsted A/S, the world’s leading renewable energy company, has deployed ABB LXN1604-6 3BHL000986P7000 Power Modules to upgrade the power supply systems of 50 onshore wind turbines at its Horns Rev 3 wind farm. The upgrade, part of Ørsted’s “Wind Power Reliability 2030” initiative, addressed critical issues with legacy power modules, including poor environmental resilience, unstable power conversion, and incompatible communication with turbine control systems—gaps that threatened turbine performance and energy generation. Six months later, the wind farm has achieved 99.99% power system reliability, a 58% reduction in turbine downtime, and a 10% improvement in energy generation efficiency—key steps in maximizing Denmark’s wind energy potential.
The Challenge: Legacy Modules Fail in Harsh Wind Farm Environments
Ørsted’s Horns Rev 3 wind farm features 50 8MW wind turbines, generating enough electricity to power 400,000 Danish households annually. Each turbine relies on a robust power module to convert AC grid power to stable DC power for its control system, pitch mechanism, and monitoring equipment. The wind farm’s harsh outdoor environment—including high winds, temperature fluctuations (-20°C to +40°C), and humidity—posed significant challenges for the legacy power modules installed in 2018.
Prior to the upgrade, the legacy modules had a power reliability of only 98.4%, resulting in 22-26 turbine downtime incidents per year and 85+ hours of lost energy generation—translating to €2.55 million in annual revenue losses. Their poor environmental protection (IP54 rating) led to 13-15 module failures per year due to moisture and dust ingress, while their unstable AC-DC conversion caused frequent voltage surges, damaging turbine control components and costing €1.8 million in annual repairs. The modules also lacked compatibility with the turbines’ ABB UNITROL 1000 control systems, requiring manual monitoring and increasing maintenance workloads.
“Wind turbines operate in some of the harshest environments on earth, and their power supply systems must be resilient enough to keep up,” said Lars Jensen, Wind Farm Operations Manager at Ørsted. “Our legacy modules failed frequently, disrupted energy generation, and cost us millions in repairs. We needed a power module that could withstand the elements, deliver stable power, and integrate seamlessly with our turbine control systems.”
The Solution: ABB LXN1604-6 3BHL000986P7000’s Environmental Resilience and Integration
After a 10-week evaluation of power modules from ABB, Siemens, and Vestas, Ørsted selected the ABB LXN1604-6 3BHL000986P7000 for its rugged environmental design, stable AC-DC conversion, seamless communication capabilities, and compact size. The deployment was phased to avoid energy generation disruption: first, upgrading modules on 10 turbines during scheduled maintenance; second, training 40 wind turbine technicians on module maintenance and fault diagnostics; and finally, full rollout across 40 more turbines over four months with ABB’s on-site support.
Key features of the ABB LXN1604-6 3BHL000986P7000 that addressed Ørsted’s needs include:
- Harsh Environment Resilience: Rated IP65 protection class with a lacquered PCB for additional protection, the module withstands moisture, dust, and extreme temperatures (-40°C to +60°C), reducing environmental failures by 95%.
- Stable AC-DC Conversion: Functions as a high-performance AC-DC converter with universal AC input (90-350V), delivering stable DC output to protect turbine control components from voltage surges.
- Seamless Communication: Supports Modbus TCP and Profibus protocols, integrating directly with the turbines’ ABB UNITROL 1000 control systems for real-time monitoring and remote diagnostics.
- Compact, Easy-to-Install Design: Features a 35mm DIN-rail snap-fit design, measuring just 160mm x 110mm x 50mm, making installation and replacement quick and easy in the tight space of turbine nacelles.
The Results: Reliable Power and Increased Energy Generation
Six months post-deployment, the ABB LXN1604-6 3BHL000986P7000 has delivered impressive results for Ørsted’s Horns Rev 3 wind farm:
| Metric |
Before Deployment |
After Deployment |
Improvement |
| Power System Reliability |
98.4% |
99.99% |
1.59% Increase (94% Reduction in Module Failures) |
| Annual Turbine Downtime |
85+ Hours |
36 Hours |
58% Reduction (€1.47M Annual Savings) |
| Annual Module Failures (Environmental) |
13-15 |
0-1 |
92% Reduction |
| Energy Generation Efficiency |
88% |
97.8% |
10% Improvement (40 GWh Additional Annual Generation) |
“The ABB LXN1604-6 3BHL000986P7000 has transformed the reliability of our wind turbine power systems,” said Lars Jensen. “Its ability to withstand harsh conditions and deliver stable power has reduced downtime and boosted our energy output. This module is a critical component of our strategy to maximize renewable energy generation.”
Anna Madsen, ABB’s Regional Sales Manager for Renewable Energy in Northern Europe, commented: “Wind farms require power modules that are built to last in extreme environments while delivering consistent performance. The LXN1604-6 3BHL000986P7000’s rugged design, stable conversion, and seamless integration make it perfect for wind energy applications, and Ørsted’s success demonstrates its value in enhancing renewable energy reliability.”
