ABB ACS800 TIM foil IGBT

ABB ACS800 EconOPACK+IGBT Module TIM Thermal Foil Application and Spare Parts Replacement Guide

In the maintenance of ACS800 frequency converter power module, the thermal interface material between IGBT and heat sink directly affects the device junction temperature, cyclic load life, and consistency of on-site maintenance. In the continuous improvement process of the ACS800 product family, TIM foil, commonly known as TIM thermal conductive foil or graphite sheet, has been introduced for modules using EconOPACK+IGBT to replace traditional thermal conductive silicone grease. For engineers in the "search solution" stage, what they really need to master is not just "having this material", but where it is suitable, whether it can be mixed, how to identify spare parts, what to check during installation, and how to avoid procurement and maintenance deviations during the 2024 spare parts switching period.

The core function of TIM thermal conductive foil is to transfer the heat generated by IGBT to the heat sink. Compared with thermal conductive silicone grease, the advantages of TIM foil are mainly reflected in its easier installation, more durable long-term thermal conductivity, and particularly significant durability improvement in cyclic load applications. Thermal conductive silicone grease has a high dependence on construction quality in terms of long-term thermal cycling, pumping effect, and pollution control; TIM foil uses pre formed materials to reduce coating differences, making maintenance consistency easier to control. However, it should be emphasized that TIM foil is not a simple consumable that can be simply installed. The final thermal resistance is still determined by the cleaning of the installation surface, protective film treatment, clamping force, and screw sequence.

Scope of application and principle of mixed use

TIM thermal conductive foil is used for the thermal conduction path from IGBT to heat sink. The complete installation instructions should be provided with the TIM IGBT spare parts kit, and priority should be given to following the instructions provided with the kit on site. In engineering, it is allowed to mix IGBTs with thermal grease and IGBTs with TIM foil in the same equipment; In the R8i modules connected in parallel, it is also allowed to mix modules using TIM foil and modules using thermal conductive silicone grease. This is important for the maintenance of existing equipment: there is no need to force a complete replacement on site because some modules are still using the silicone grease solution, but it is necessary to ensure that the interface material between each IGBT and the heat sink is correct and complete. Silicon grease and TIM foil cannot be stacked on the same thermal interface, and old foil cannot be reused.

The premise of mixing is' each is correct '. For parallel R8i modules, maintenance records should clearly indicate the type of thermal interface material currently used, spare parts batch, and replacement date for each module. If there are both TIM foil modules and silicone grease modules in the same group, it is important to check the compression status, radiator cleanliness, and temperature performance of each module to avoid uneven heat distribution caused by poor installation of individual modules. Mixing is an allowed maintenance strategy, not a reason to lower installation standards.

Spare parts switching and timeline

The ACS800 EconoPACK+module maintenance strategy has transitioned to the TIM foil solution. TIM foil is used in related repairs, and the spare IGBT kit has also been updated to the TIM foil version, with the thermal grease removed. It should be noted that this is a Running Change, planned to be launched in the second quarter of 2024; Early IGBT kits containing thermal conductive silicone grease will consume inventory first. Therefore, procurement and maintenance personnel may encounter both old kits containing silicone grease and new kits containing TIM foil during the transition period. When receiving the goods, the package label, accompanying instructions, and thermal interface material form should be checked, and cannot be judged solely based on old spare part numbers.

For maintenance sites, it is recommended to add a "hot interface material type" check item in the material requisition process: whether the kit contains TIM foil or silicone grease, with accompanying instructions on whether it matches, whether the TIM foil has independent packaging and spare part numbers. For old inventory containing silicone grease kits, they can be used according to the accompanying instructions; For new repairs and purchases, priority should be given to implementing the TIM foil plan and refreshing the recommended spare parts information to avoid using expired lists.

IGBT module kit and TIM foil spare parts identification

The following table is organized by kit model and spare part number for quick verification during maintenance and material requisition. The spare part numbers for TIM foil in the table are listed as 3AXD50000948185 according to the kit information; The actual shipment is subject to the kit label and recommended spare parts.

IGBT module kit model kit spare part number

FS450R12KE3/AGDR-61C S64635875

FS300R17KE3/AGDR-66C S64717839

FS300R12KE3/AGDR-62C S64717812

FS450R17KE3/AGDR-61C S64783831

FS225R12KE3/AGDR-71C S68569303

FS300R12KE3/AGDR-72C S68569541

FS450R12KE3/AGDR-71C S68569354

FS225R17KE3/AGDR-76C S68569583

FS300R17KE3/AGDR-76C S68569362

FS450R17KE3/AGDR-71C S68569591

FS450R17KE3/ADGR-72C S68569427

FS300R12KE3/AGDR-71C S68569346

FS450R17OE4/AGDR-71C S (check according to kit label)

TIM foil can also be ordered separately: 3AXD50000724666 for ACS800-104 (LC) R7i and R8i. The spare part number for TIM foil in the kit is 3AXD50000948185. The correct selection should refer to the recommended spare parts section of Drives Installed Base and refresh the spare parts page to obtain the latest recommendations. Before installing the TIM foil on the R8i radiator, the size, hole position, and edge condition of the foil should be confirmed to avoid bending, scratching, and contamination.

Key points for pre installation inspection and cleaning

Before installation, power-off, DC bus discharge, and anti-static preparation must be completed. Check if the installation surface of the radiator is flat, clean, free of old silicone grease residue, metal shavings, and dust. Old silicone grease should be removed using a non damaging cleaning method to avoid scratching the radiator with hard tools. TIM foil should be flat, without creases, damage, or contamination; It is recommended to wear powder free gloves when retrieving to avoid finger grease affecting the interface. If the foil has a protective film, it should be removed in the correct steps according to the kit instructions to avoid premature tearing of the film that may cause contamination or misalignment.

During installation, positioning should be done first, and then the screws should be gradually tightened in diagonal order to ensure that the foil is not squeezed or displaced. Torque and sequence should be executed according to the kit instructions, and it is not recommended to increase torque based on experience. After completion, check whether the edges of the foil are evenly exposed, whether there are curled edges, and whether there are foreign objects trapped. For mixed modules, the type of thermal interface material should be identified in the casing or maintenance records for subsequent maintenance and judgment.

R8i Parallel Module and Maintenance Strategy

The R8i parallel module allows for the mixing of TIM foil modules and silicone grease modules, but the "thermal interface material consistency management" should be included in the records during maintenance. Suggest recording the module location, kit spare part number, TIM foil spare part number, installation date, and torque verification results. When there is a high temperature or alarm, first check the dust accumulation in the fan, air duct, radiator, and the temperature inside the cabinet, and then check whether the TIM foil is misaligned, contaminated, or insufficiently compressed. Do not "compensate" for TIM foil installation issues by adding silicone grease, and do not stack silicone grease on TIM foil.

In cyclic load applications, the durability advantage of TIM foil is more worthy of attention, but the prerequisite is stable installation quality. Spare parts storage should avoid high temperature, humidity, heavy pressure, and bending; TIM foil should be kept in its original packaging until installation. For transitional inventory, it is necessary to distinguish between old silicone grease containing kits and new TIM foil kits, with a first in first out policy but without mixing labels.

Common Problems and Suggestions for Handling

Q: Can we mix silicone grease IGBT and TIM foil IGBT? Okay. Parallel R8i modules can also be mixed with TIM foil modules and silicone grease modules, but each interface must be constructed correctly according to its own material.

Q: Can we apply silicone grease on TIM foil again? Not recommended. It should be used according to the kit instructions to avoid interface stacking that may cause thermal resistance and compression abnormalities.

Q: Can old TIM foil be reused? Not recommended. The disassembled foil is prone to deformation and contamination, and repeated use may pose a risk of thermal resistance.

Q: What should we pay attention to during the transition period procurement? Check the kit label and accompanying instructions to confirm whether it is an old kit containing silicone grease or a new kit made of TIM foil; Refresh recommended spare parts and verify the applicability of 3AXD50000724666 and 3AXD50000948185 when ordering separately.

Overall, the ACS800 EconOPACK+IGBT module using TIM thermal conductive foil is an improvement aimed at long-term durability and maintenance consistency. Engineers should grasp three points in maintenance: allowing reasonable mixing but not allowing erroneous stacking; During the transition period in the second quarter of 2024, it is necessary to verify the type of kit; The installation quality determines whether the advantages of TIM foil can be fully utilized. To ensure the stable implementation of the TIM foil solution in R7i, R8i, and parallel module maintenance, it is necessary to follow the kit instructions for construction, clean and record, and refresh recommended spare parts.