SCS is excited to announce a brand new video series discussing real-life ESD problems and solutions. This is a great educational resource for anybody new to ESD or just wanting to learn more about best practices.
Each episode will focus on one issue commonly found in an ESD Protected Area – at the same time we will present solutions so you know how to tackle the problem should you ever face it in your own factory.
A new episode will be published each week so make sure you subscribe to our YouTube channel to get notified when a new video is available. Episodes 1 and 2 are now live so don’t waste a second longer and catch-up now:
The best way to keep electrostatic
sensitive devices (ESDs) from damage is to ground all conductive objects and
remove insulators from your ESD Protected Area (EPA). This is not always
possible because some insulators are “process-essential” and are necessary to
build or assemble the finished product. The only way to control charges on
these necessary non-conductive items is the use of ionization systems.
However, if an ionizer is out of balance,
instead of neutralizing charges, it will produce primarily positive or negative
ions. This results in placing an electrostatic charge on items that are not
grounded, potentially discharging and causing ESD damage to nearby sensitive
It is therefore essential to regularly
clean your ionizers and verify they function correctly. Below we have put
together a list of tasks you need to perform with your ionizers on a regular
ionization devices will require periodic maintenance for proper operation.
Maintenance intervals for ionizers vary widely depending on the type of
ionization equipment and use environment. Critical clean room uses will
generally require more frequent attention. It is important to set-up a routine
schedule for ionizer service. Routine service is typically required to meet
quality audit requirements.” (ESD Handbook TR20.20 section 184.108.40.206
Maintenance / Cleaning)
EIA-625, recommends checking ionizers every
6 months, but this may not be suitable for many programs particularly since an
out-of-balance may exist for months before it is checked again. ANSI/ESD S20.20
section 220.127.116.11 Compliance Verification Plan Requirement states: “Test equipment shall be selected to make
measurements of appropriate properties of the technical requirements that are
incorporated into the ESD program plan.”
Under normal conditions, an ionizer will
attract dirt and dust (especially on the emitter points). To maintain optimum
neutralization efficiency and operation, cleaning should be performed on a
Wipe the case with a soft cloth and
deionized water. Fully squeeze the wiping cloth or sponge to remove any excess
liquid. If a stronger cleaning solution is required, dab a soft cloth with
mixture of isopropyl alcohol and deionized water (70% IPA and 30% DI water).
2. Emitter Points
The emitter points should be cleaned using
specific emitter point cleaners or a swab dampened with Isopropyl alcohol.
Below are general instructions on how to clean emitter points. However, each
unit is slightly different so always refer to the ionizer’s manual.
Turn the unit OFF and unplug the power cord.
Open the top screen by loosening the screw and swinging the grill to one side.
Clean the emitter points using the an emitter point cleaner or a swab dampened with Isopropyl alcohol.
Re-attach the top screen.
Plug in the power cord and turn the unit ON.
Verify the performance of the ionizer by using a charged plate monitor or ionization test kit (see below).
With normal handling, the emitter points
should not require replacement during the life of the unit.
Per ESD TR53 section 18.104.22.168.1 “The best practice is to measure the offset
voltage and discharge times, clean the unit, including emitter points and air
filters if present, offset voltage to zero (if adjustable), and then repeat
offset voltage and discharge time testing. If the unit does not meet offset
voltage specifications or minimum established discharge time limits, further
service is indicated. Manufacturers should provide details on service
procedures and typical service intervals.”
Most companies will assign a number or
otherwise identify each ionizer and setup a Compliance Verification /
Maintenance / Calibration schedule. If the ionizers all test good, the data can
justify lengthening the calibration period. If ionizers require adjustment, the
calibration period should be shortened. Although ESD TR53 does not advise a
test frequency, JESDD625-A (Revision of EIA-625) recommends ionizers be tested semi-annually,
noting to use “S3.1 except the number of
measurement points and locations may be selected based on the application.”
Verification should be performed in
accordance with the ESD Association ionization standard ANSI/ESD STM3.1.
Below are general instructions on how to
verify your ionizer’s offset voltage and discharge time. Always refer to the
User Guide accompanying your Charge Plate Monitor or Ionization Test Kit for
proper operation and setup.
1. Testing Ionizer Offset Voltage:
The required limit per ANSI/ ESD S20.20 is
less than ± 35 volts. Check your ionizer’s operating manual or consult with the
ionizer manufacturer to determine what the offset voltage should be for your
Charge Plate Monitor (CPM)
Position the ionizer and charge plate monitor as shown below.
Set the CPM to Decay/Offset mode.
Set the CPM to decay and offset voltage mode with a starting charge at either + or – 1 KV and a stopping charge at either + or -100 Volts.
Start the decay/offset test sequence on the CPM. This will take a few seconds.
Record the decay time, and offset voltage as displayed on the CPM.
your Charge Plate Monitor for Overhead and Benchtop Ionizers
Ionization Test Kit
Zero the charge plate by touching it with a grounded object. This
can either be the finger of a grounded person or some other item which is
connected to electrical ground. In either case, zeroing the charge plate should
make the display on the field meter read zero.
Hold the meter approximately one foot (30.5 cm) in front of the
Monitor the display. The value displayed is the offset balance of
the ionizer, which is the difference between the number of positive and
negative ions being emitted.
2. Testing Ionizer Discharge Time:
The required limit per ANSI/ESD S20.20 is
“user defined”. Please refer to the ionizer’s operating manual or consult with
the ionizer manufacturer to determine what this discharge time should be.
Charge Plate Monitor (CPM)
Set the CPM to Decay/Offset mode.
Set the CPM to decay and offset voltage mode with a starting charge
at either + or – 1 KV and a stopping charge at either + or -100 Volts.
Start the decay/offset test sequence on the CPM. This will take a
Record the decay time, and offset voltage as displayed on the CPM.
Ionization Test Kit
After charging the plate of the ionization test kit, hold the field
meter approximately one foot (30.5 cm) away from the ionizer.
Monitor the display of the meter to see how quickly the 1.1 kV
charge is dissipated to 0.1 kV.
The speed at which this occurs (the discharge time) indicates how
well the ionizer is operating.
Repeat this procedure for both a positively and a negatively charged
Some ionizers offer adjustment options
(e.g. trim pots) which allow modification of the offset voltage.
However, if your ionizer is out of balance
(and cannot be adjusted) or if the discharge time is out of specification, the
ionizer will require service/repair by an authorized company.
Ionization is one of the best methods of
removing charges from insulators and as a result plays an important role in
Remember though: ionizers require periodic
cleaning of emitter pins and verifying of the offset voltage and discharge
time. Otherwise, instead of neutralizing charges, the ionizer will primarily produce
positive or negative ions. The ionizer will therefore place an electrostatic
charge on items that are not grounded, potentially discharging and causing ESD
damage to nearby sensitive items.
Setting up an ESD-safe workstation is often
more challenging than it first appears. There are many methods of controlling
ElectroStatic Discharge (ESD), and typically, it requires a combination of
these to curb all static problems. Unfortunately, there is no single method
that will fill all requirements.
Wrist straps and work surface mats are probably the most familiar to everyone, draining charges from operators as well as from the product being worked on. But what if the static charge in question is on an insulator? Electronic products, by nature, will normally consist of conductors and insulators. Insulators at the workstation can be found on the product itself, tools being used, tapes for masking, even circuit boards. A static charge on an insulator cannot be drained by grounding, as you could with a conductive material.
To effectively remove charges from insulators, we need to make the surrounding air more conductive. We have all seen a balloon cling to a wall because of a static charge, and we know that, after a period of time, it will drop. That is because the air is somewhat conductive and the charge eventually drains off. The problem with this concept is that it takes too long. The more conductive the air is, the faster the charge will be neutralized.
The method most frequently used to increase
the conductivity of the air is ionization.
Ionizers are useful in preventing
electrostatic charge generation, ElectroStatic Discharge, ElectroStatic
Attraction, as well as preventing equipment latch-up. Per ANSI/ESD S20.20
section 22.214.171.124. Protected Areas Requirement states: “Ionization or other
charge mitigating techniques shall be used at the workstation to neutralize
electrostatic fields on all process essential insulators if the electrostatic
field is considered a threat.”
do Ionizers work?
Most ESD workstations will have some
insulators (e.g. product plastic housing) or isolated conductors (e.g. PCB
board components not in contact with ESD worksurface) that cannot be removed or
replaced. These should be controlled using ionization.
Ionizers create great numbers of positively
and negatively charged ions. Fans help the ions flow over the work area. If
there is a static charge present on an item in the work area, it will be
reduced and neutralized by attracting opposite polarity charges from the air.
Ionization can neutralize static charges on
an insulator in a matter of seconds, thereby reducing their potential to cause
The charged ions created by an ionizer
neutralize charges on process
neutralize charges on non-
neutralize isolated conductors
does Ionization fit into an ESD Control Program?
Ionization is just one component of your
ESD Control Program. Before utilizing ionization, you should follow the
fundamental principles of ESD Control:
Ground all conductors
(including people) using conventional grounding methods (e.g. wrist straps or
Remove all insulators, e.g.
coffee cups, food wrappers etc.
“Air ionization is not a replacement for
grounding methods. It is one component of a complete static control program.
Ionizers are used when it is not possible to properly ground everything and as
backup to other static control methods. In clean rooms, air ionization may be
one of the few methods of static control available.” (ESD Handbook ESD TR20.20
Ionization, section 126.96.36.199 Introduction and Purpose / General Information)
Ionizers can be critical to
reduce induction charging caused by process necessary insulators
Ionizers can be critical in
eliminating charges on isolated conductors like devices on PCBs
Ionization can reduce
ElectroStatic Attraction (ESA) and charged particles clinging and contaminating
It is recommended to use ionizers with feedback mechanisms, so you’re notified if the offset voltage is out of balance.
Ionizers should be pieces of equipment that
have serial numbers and are included in the company’s maintenance and
calibration schedules. This is particularly critical to ensure that the offset
voltage or balance is within acceptable limits. Otherwise, instead of
neutralizing charges the out of balance ionizer will charge insulators and
isolated conductors. The user, depending on the value and function of their
products, must determine the appropriate frequency of maintenance and
The best way to keep electrostatic
sensitive devices (ESDs) from damage is to ground all conductive objects and
remove insulators. This is not always possible because some insulators are
“process-essential” and are necessary to build or assemble the finished product.
The only way to control charges on these necessary non-conductive items is the
use of ionization systems. Applications include:
eliminating charges on process
neutralizing workstations where
ESDS are handled,
removing charged particulates
to create a static free work area.
In today’s connected world, we are surrounded by home monitoring networks, fitness trackers and other smart systems. They all use an IoT platform to keep us up to-date with the current temperature in our house or the number of steps we have taken in a day. There are many different applications of IoT: Consumer, Commercial, Industrial, and Infrastructure, but is there a way to use this incredibly smart technology to improve ESD Control? Let’s take a look!
What Is The Internet of Things (IoT)?
The Internet of Things (IoT) is used everywhere today – from medical devices, to vehicles, to homes and more! Simply put, IoT:
Connects “things” in the physical world to the internet using sensors.
Collects data for these “things” via sensors.
Analyses the collected data and provides a deeper insight into the “things”.
Another broad definition provided for IoT is:
“The Internet of Things (IoT) is the network of physical devices, vehicles, home appliances, and other items embedded with electronics, software, sensors, actuators, and connectivity which enables these things to connect and exchange data, creating opportunities for more direct integration of the physical world into computer-based systems, resulting in efficiency improvements, economic benefits, and reduced human exertions.” [Source]
As mentioned previously, there are many different applications for IoT, but The Industrial Internet of Things (IIoT) applies specifically to manufacturing and industrial processes.
It has slightly different requirements compared to consumer IoT products but the principle is the same: smart machines (incorporating various sensors) accurately and consistently capture and analyze real-time data allowing companies to pick-up problems as soon as (or even before) they appear.
Internet of Things (IoT) and Industry 4.0
IoT helped push the 3rd industrial revolution (machine automation) one step further. “Cyber Physical Systems (CPS) dominate the manufacturing floor, linking real objects with information processing, and virtual objects via the internet. The goal is to converge Operational Technology (OT) and Information Technology (IT).” [Source]
The 4th industrial revolution is also referred to as “Industry 4.0”. “At the very core Industry 4.0 includes the (partial) transfer of autonomy and autonomous decisions to cyber-physical systems and machines, leveraging information systems”. [Source]
Industry 4.0 as fourth industrial revolution [Source]
So, how can companies use the power of IoT and create accessible, real-time feedback on the status of their ESD Control Protected Area (EPA) and ESD control items?
Industry 4.0 IoT Platforms in ESD Control
ESD damages can be extremely costly – especially when it comes to latent defects that are not detected until the damaged component is installed in a customer’s system. Conventional ESD control programs incorporate periodic verification checks of ESD control products to detect any issues that could result in ESD events and ESD damage. The problem is that ESD control products (and the EPA as a whole) are not constantly monitored.
Take an ionizer for example: if a company uses ionization to handle process-essential insulators, the ionizers need to be fully reliable at all times. If an ionizer passes one check but is found to be out of balance at the next, the company faces a huge problem: nobody knows WHEN exactly the ionizer failed or if contributed to a charged insulator potentially causing ESD damage.
The Industry 4.0 IoT platform will be a game changer when it comes to creating a reliable and dependable ESD control program. Sensors collecting vital ESD information like field voltage, Electromagnetic Interference (EMI), temperature, humidity etc. in an EPA will help detect potential threats in real-time allowing supervisors to act even before an ESD threat occurs.
Advantages of Internet of Things (IoT) in ESD Control
Here is a (by no means exhaustive) list of advantages, IoT can bring to ESD Control:
The day in an EPA can be busy. Taking the time to capture and record measurements of ionizers, wrist straps, work surfaces, automated processes etc. can be disruptive and is prone to errors. IoT allows data to be collected automatically without any input from users. This helps to increase the accuracy of data and allows operators and supervisors more time focusing on their actual jobs.
Supervisors have all the essential data in one place right in front of them and can make informed decisions; they can provide feedback and give suggestions in case of an ESD emergency. IoT allows to pinpoint areas of concern and prevent ESD events.
IoT continuously monitors processes and provides a real-time picture of them – no manual checks required. If a potential threat is detected, warnings will show-up immediately. There is no need to worry about potentially damaging sensitive devices because the next scheduled check of ionizers, wrist straps etc. has not been completed yet.
The number one reason for adapting an ESD control program is to reduce costs by:
Enhancing quality and productivity,
Improving customer satisfaction,
Lowering repair, rework and field service costs and
Reducing material, labor and overhead costs.
Reduced Workload and Increased Productivity
IoT pushes all the above even further with the additional benefits of:
Reduced workload for operators: Data is collected remotely without any input from users. Operators are not disrupted in their day-to-day activities.
Reduced workload for supervisors: Supervisors don’t have to collect and analyze data from personnel testers, field meters, monitors etc. The system does it for them and will highlight any issues.
Further increases in productivity and cost reductions: An ESD program can be managed better and with fewer resources.
Static Management Program (SMP): the next generation of ESD Process Control – more information
IoT will no doubt change ESD control and the way EPAs are monitored. Quantifiable data allows companies to see trends, become more proactive and improve the efficiency of their ESD process control system. IoT will support organizations’ efforts to make more dependable products, improve yields, increase automation and provide a measurable return on investment. Not only will this benefit users and supervisors, but the company as a whole.
SCS Static Management Program (SMP) is the only smart ESD system on the market that continuously monitors your entire ESD process control system throughout all stages of manufacturing. SMP captures data from SCS workstation, equipment and ESD event continuous monitors and provides a real-time picture of critical manufacturing processes.
For more information on how to continuously monitor your ESD control program and/or improve an existing program, request a free ESD/EOS Assessment or SMP demo at your facility by one of our knowledgeable local representatives to evaluate your ESD program and answer any ESD questions!
Have you ever walked across a car park on a bright cold winter’s day only to get zapped by your car’s door handle? It’s commonly known that these ‘zaps’ are much more common in cold dry weather. It begs the question: if there are less ‘zap, will using air humidifiers in a manufacturing environment prevent ESD damage of sensitive components? Let’s find out!
Humidity describes the amount of water vapor in the air. There are 3 main measurements of humidity with the most common one being the relative humidity (RH). It is expressed in percent and describes “how much humidity there is in the air, compared to how much there could be. Meteorologists often use the relative humidity as a measurement to describe the weather at various places.” [Source]
At 0% the air is completely dry; at 100% it is so moist that mist or dew can form. The optimum relative humidity level is somewhere between 40% and 60%:
A lower relative humidity increases charge generation as the environment is drier.
If the humidity level is too high, condensation can form on surfaces.
Charge Generation and ElectroStatic Discharge (ESD)
The simple separation of two surfaces generates an ElectroStatic charge. Examples:
Unwinding a roll of tape
Gas or liquid moving through a hose or pipe
A person walking across a floor with heels and soles contacting and separating from the floor
The amount of static electricity generated varies and is affected by materials, friction, area of contact and the relative humidity of the environment. A higher charge is generated at low humidity or in a dry environment.
Once an item has generated a charge, it will want to come into balance. If it is in close enough proximity to a second item, there can be a rapid, spontaneous transfer of electrostatic charge. This is called discharge or ElectroStatic Discharge (ESD).
Going back to our earlier example of getting a zap from your car’s door handle:
Charge generation: you walk across the car park with your soles contacting and separating from the floor. A charge is built-up on you.
ElectroStatic Discharge (ESD): you touch the door handle. Charges move from your body to your car until both are balanced out.
Impact of relative humidity on ESD
Many people will notice a difference in the ability to generate static electricity when the air gets dryer (relative humidity decreases). Relative humidity (RH) directly affects the ability of a surface to store an electrostatic charge. “With a humidity level of 40% RH, surface resistance is lowered on floors, carpets, table mats and other areas. …the moisture in the air forms a thin protective “film” on surfaces that serves as a natural conductor to dissipate electric charges. When humidity drops below 40% RH, this protection disappears, and normal employee activities lead to objects being charged with static electricity.” [Source]
In an electronics manufacturing environment lower humidity may result in lower output from production due to an increase in ESD events during manufacturing processes.
Air Humidification and ESD
Air humidifiers are used to add moisture to the air and are commonly used in drier environments to keep humidity at a constant (optimum) level. Given that a lower humidity level increases the risk of ESD events, the obvious questions are:
Can air humidifiers replace normal ESD Control measures?
Are air humidifiers required for complete ESD protection?
Let’s address both questions:
Let’s be very clear about one thing here: air humidifiers cannot replace ESD Control measures.
As explained further above, ESD is caused by two items that are at a different electrostatic equipotential and want to equalize their charges. Adding moisture to the air using humidifiers will not stop this discharge from happening. The only thing you may achieve is a reduction in the number of ESD events. BUT: they will still happen; just walking across a carpet will generate a charge on an operator. If they then touch an ESD sensitive component, discharge will still occur and may damage the component. No humidifier will prevent this.
The only way to control electrostatic charges on a person or object is through ESD grounding – this will ensure any charges generated dissipate to earth:
For more information on how to create a ESD workstation and how to correctly ground all elements, have a look at this post.
Low air humidity can increase the number of ESD events so it may make sense to keep a factory at a higher humidity level. However, there are many other factors that come into play when choosing the ‘right’ humidity for a manufacturing environment. The recommended humidity range is usually determined by the specifications of the devices and components being assembled. Increasing the humidity in an electronics manufacturing facility can help to reduce ESD events but increased humidity can lead to other unwanted quality issues in an electronics manufacturing environment such as corrosion, soldering defects and the popcorn effect on moisture sensitive devices.
A normal range for humidity in electronics manufacturing is between 30% RH and 70% RH. Some facilities try to maintain a constant moderate RH (~50%), whereas other environments may want lower % RH due to corrosion susceptibility to humidity sensitive parts.
And remember: you will not eliminate ESD by using humidifiers and keeping humidity levels at a higher level. You need an ESD Control Program in place to avoid ESD and associated damages.
Air humidification can help reduce the number of ESD events in an electronics manufacturing environment but at the same time there are other factors (e.g. moisture sensitivity of components) that need to be considered.
A lower relative humidity level increases charge generation as the environment is drier. This will result in more ESD events which can potentially damage sensitive components. The only way to protect sensitive components from ESD damage is by having proper ESD control measures in place and connecting operators, objects and surfaces to ground. This will ensure each element is kept at the same electrical potential and any electrostatic discharge is being removed to ground.
For more information on how to get your ESD control program off the ground or improve an existing program, request a free ESD/EOS Assessment at your facility by one of our knowledgeable local representatives to evaluate your ESD program and answer any ESD questions!
When referring to an “ESD Protected Area” or “EPA”, a lot of people imagine rooms or even whole factory floors with numerous workstations. This very common misconception leads to nervousness and even fear when it comes to implementing an ESD Control Program. There is a concern regarding the cost and time implications when establishing an EPA. However, most often, a simple ESD workstation is completely sufficient to fulfill a company’s needs to protect their ESD sensitive products. Today’s post will provide a step-by-step guide on:
How to create an EPA at an existing workstation,
What ESD control products are required
How to correctly set up ESD control products
What is an “ESD Protected Area” or “EPA”?
An EPA is an area that has been established to effectively control Electrostatic Discharge (ESD) and its purpose is therefore to avoid all problems resulting from ESD damage, e.g. catastrophic failures or latent defects. It is a defined space within which all surfaces, objects, people and ESD Sensitive Devices (ESDs) are kept at the same electrical potential. This is achieved by simply using only ‘groundable’ materials for covering of surfaces and for the manufacture of containers and tools. All surfaces, products and people are grounded to Ground.
What is Grounding?
Grounding means linking, usually through a resistance of between 1 and 10 megohms. Movable items (such as containers and tools) are grounded by virtue of lying on a grounded surface or being held by a grounded person. Everything that does not readily dissipate a charge must be excluded from the EPA.
How big does an EPA need to be?
An EPA can be just one workstation, or it could be a room containing several different workstations. “The definition of an EPA depends somewhat on the user environment. An EPA may be a permanent workstation within a room or an entire factory floor encompassing thousands of workstations. An EPA may also be portable as used in a field service situation.” [Handbook ESD TR20.20-2016 Clause 9.0 ESD Protected Areas]
What is needed to convert a Workstation into an EPA?
Creating an EPA at an existing workstation does not need to be complicated or expensive. There are just a few things that are required:
A wristband that is worn comfortably around the wrist and
A coiled cord that connects the band to Ground or a Wrist Strap Grounding System as explained in #4.
2. Wrist Strap Grounding System
These have been designed to be installed underneath bench tops where they are easily accessible to operators and where they are unlikely to be knocked and damaged or hinder the operator. The grounding cord of the Grounding System needs to be connected to a suitable Ground.
ESD worksurfaces, such as mats, are typically an integral part of the ESD workstation, particularly in areas where hand assembly occurs. The purpose of the ESD worksurface is two-fold:
To provide a surface with little to no charge on it.
To provide a surface that will remove ElectroStatic charges from conductors (including ESDs) that are placed on the surface.
4. Worksurface Mat Grounding Cord
An ESD worksurface needs to be grounded using a ground cord. A ground wire from the surface should connect to Ground. Best practice is that ground connections use firm fitting connecting devices such as metallic crimps, snaps and banana plugs to connect to designated ground points. The use of alligator clips is not recommended.
Where sitting personnel will be grounded via a wrist strap, this method is not feasible for operators moving around in an ESD Protected Area. In those situations, a flooring / footwear system is required.
5. Foot Grounders
Foot grounders are designed to reliably contact grounded ESD flooring and provide a continuous path-to-ground by removing electrostatic charges from personnel. They are easy to install and can be used on standard shoes by placing the grounding tab in the shoe under the foot.
Foot grounders must be worn on both feet to maintain the integrity of the body-to-ground connection Wearing a foot grounder on each foot ensures contact with Ground via the ESD floor even when one foot is lifted off the floor.
6. Floor Mat
Floor matting is an essential component in the flooring / footwear system when grounding moving or standing personnel. The path to Ground from operators via heel grounders to Ground is maintained by using dissipative or conductive flooring.
Floor mats don’t just ground personnel; they are also used to ground ESD control items (e.g. mobile carts or workstations).
7. Floor Mat Grounding Cord
Just like worksurface matting, floor matting needs to be connected to Ground. This ensures that any charges on the operator are dissipated through their heel grounders and the floor matting to Ground. A floor mat grounding cord is used to link the floor mat to Ground.
Alternatively, matting can be grounded via a strip of copper foil.
Installing an ESD Workstation
To install the ESD workstation, it is necessary to ground the worksurface and operator with the following steps:
Lay the worksurface mat flat on the workbench with the stud(s) facing upwards.
Connect the worksurface mat grounding cord to the worksurface mat.
Connect the other end of the worksurface mat grounding cord to Ground.
Place the wristband on the wrist.
Connect the coiled cord to the wristband.
Attach the Wrist Strap Grounding System to the bench. Remember that it needs to be connected to a suitable Ground.
Connect the other end of the coiled cord to the Wrist Strap Grounding System and verify personnel is properly grounded.
If your operators are standing or mobile and grounding via a wrist strap is not feasible, ground the worksurface, and the ESD flooring:
Ground the worksurface mat by following steps #1 to #4 above
Lay the floor mat flat on the floor with the stud(s) facing upwards.
Connect the floor mat grounding cord to the floor mat.
Connect the other end of the floor mat grounding cord to Ground.
Place the foot grounders on the feet and verify personnel is properly grounded.
An EPA can be created at an existing workstation in a facility. To establish an EPA it is important to:
Ground all conductors (including people),
Remove all insulators (or substituting with ESD protective versions) or
Neutralize process essential insulators with an ionizer.
With a few simple steps, you can convert your existing workstation into an ESD workstation. You will need:
Worksurface Mat Grounding Cord
Wrist Strap Grounding System
Floor Mat Grounding Cord
We hope this article has introduced the basics of an ESD Protected Area (EPA), and the steps needed to create an ESD Workstation.
For more information on how to get your ESD control program off the ground, Request a free ESD/EOS Assessment at your facility by one of our knowledgeable local representatives to evaluate your ESD program and answer any ESD questions!
Electronic devices and systems can be damaged by exposure to high electric fields as well as by direct electrostatic discharges. A good circuit layout and on-board protection may reduce the risk of damage by such events, but the only safe action at present is to ensure that devices are not exposed to levels of static electricity above the critical threshold.
This can only be achieved by introducing a static control program which usually involves setting up an ESD Protected Area (EPA) in which personnel are correctly grounded and all meet the ESD Standard. However, setting up an EPA does not of itself guarantee a low static environment. Production procedures may change, new materials may be introduced, the performance of older materials may degrade and so on.
Measuring Effectiveness of an ESD Control Program
To ensure the effectiveness of any static control program it is important that regular measurements are carried out:
to determine the sensitivity to ESD of devices being produced or handled.
to confirm that static levels are lower than the critical level, and that new or modified work practices have not introduced high static levels.
to ensure that both new and existing materials in the EPA meet the necessary requirements.
Only after an ‘operational baseline’ has been established by regular auditing will it become possible to identify the origin of unexpected problems arising from the presence of static.
1. Determining the sensitivity of ESD sensitive Devices
It is important to understand the sensitivity of ESD sensitive devices before an action plan can be created. Once you know the sensitivity of the items you are handling, can you work towards ensuring you’re not exceeding those levels.
Part of every ESD control plan is to identify items in your company that are sensitive to ESD. At the same time, you need to recognize the level of their sensitivity. As explained by the ESD Association, how susceptible to ESD a product is depends on the item’s ability to either:
dissipate the discharge energy or
withstand the levels of current.
2. Measurements to prove the effectiveness of an ESD Control Program
Measuring electrostatic quantities poses special problems because electrostatic systems are generally characterized by high resistances and small amounts of electrical charge. Consequently, conventional electronic instrumentation cannot normally be used.
Measuring Electrical Field
Wherever electrostatic charges accumulate, they can be detected by the presence of an associated electric field. The magnitude of this field is determined by many factors, e. g. the magnitude and distribution of the charge, the geometry and location of grounded surfaces and the medium in which the charge is located.
“The current general view of experts is that the main source of ESD risk may occur where ESDS can reach high induced voltage due to external fields from the clothing, and subsequently experience a field induced CDM type discharge.” [CLC TR 61340-5-2 User guide Garments clause 188.8.131.52 Introductory remarks]
A static field meter is often used for ESD testing of static fields. It indicates surface voltage and polarity on objects and is therefore an effective problem-solving tool used to identify items that are able to be charged.
A field meter can be used to:
verify that automated processes (like auto insertion, tape and reel, etc.) are not generating charges above acceptable limits.
measure charges generated by causing contact and separation with other materials.
demonstrate shielding by measuring a charged object and then covering the charged item with an ESD lab coat or shielding bag. Being shielded the measured charge should be greatly reduced.
Measuring ESD Events
ESD events can damage ESD sensitive items and can cause tool lock-ups, erratic behavior and parametric errors. An ESD Event Detector like the EM Eye ESD Event Meter will help detect most ESD events. It detects the magnitude of events and using filters built into the unit, it can provide approximate values for some ESD events for models (CDM, MM, HBM) using proprietary algorithms.
Solving ESD problems requires data. A tool counting ESD events will help carry out a before-and-after analysis and will prove the effectiveness of implementing ESD control measures.
3. Checking Materials in your EPA
When talking about material properties, the measurement you will most frequently come across is “Surface Resistance”. It expresses the ability of a material to conduct electricity and is related to current and voltage. The surface resistance of a material is the ratio of the voltage and current that’s flowing between two pre-defined electrodes.
It is important to remember that the surface resistance of a material is dependent on the electrodes used (shape as well as distance). If your company implements an ESD control program compliant to the ESD Standard ANSI/ESD S20.20, it is therefore vital to carry out surface resistance measurements as described in the Standard itself. For more information on the definition of resistance measurements used in ESD control, check out this post.
Surface resistance testers can be used to perform these tests in accordance with ANSI/ESD S20.20 and its test method ANSI/ESD S4.1; if these measurements are within acceptable ranges, the surface and its connections are good. For more information on checking your ESD control products, catch-up with this. It goes into depth as to what products you should be checking in your EPA and how they should be checked.
Measurements form an integral part of any ESD control program. Measuring devices help identify the sensitivity of ESD devices that ESD programs are based on, and also are used to verify the effectiveness of ESD control programs set in place. High quality instruments are available commercially for measuring all the parameters necessary for quantifying the extent of a static problem.
We hope the list above has introduced the techniques most commonly used. For more information on how to get your ESD control program off the ground, Request a free ESD/EOS Assessment at your facility by one of our knowledgeable local representatives to evaluate your ESD program and answer any ESD questions!
The best-equipped service bench in your shop can be a real money-maker when set up properly. It can also be a source of frustration and lost revenue if the threat of ElectroStatic Discharge (ESD) is ignored.
A typical scenario might be where an electronic product is brought in for service, properly diagnosed and repaired, only to find a new symptom requiring additional repair. Unless the technician understands the ESD problem and has developed methods to keep it in check damage from static electricity cannot be ruled out as a potential source of the new problem.
Static electricity is nothing new; it’s all around us and always has been. What has changed is the spread of semiconductors in almost every consumer product we buy. As device complexity increases, often its static sensitivity increases as well. Some semiconductor devices may be damaged by as little as 20-30 volts!
It is important to note that this post is addressing the issue of ESD in terms of control, and not elimination. The potential for an ESD event to occur cannot be completely eliminated outside of a laboratory environment, but we can greatly reduce the risk with proper training and equipment. By implementing a good static control program and developing some simple habits, ESD can be effectively controlled.
The Source of the Problem
Static is all around us. We occasionally will see or feel it by walking on carpet, touching something or someone and feeling the “zap” of a static discharge. The perception level varies but static charge is typically 2000-3000 volts before we can feel it. ESD sensitivity of some parts is under 100 volts – well below the level that we would be able to detect.
Even though carpet may not be used around the service bench, there are many other static “generators” may not be obvious and frequently found around or on a service bench. The innocent-looking Styrofoam coffee cup can be a tremendous source of static. The simple act of pulling several inches of adhesive tape from a roll can generate several thousand volts of static! Many insulative materials will develop a charge by rubbing them or separating them from another material. This phenomenon is known as “tribocharging” and it occurs often where there are insulative materials present.
People are often a major factor in generation of static charges. Studies have shown that personnel in a manufacturing environment frequently develop 5000 volts or more just by walking across the floor. Again, this is “tribocharging” produced by the separation of their shoes and the flooring as they walk.
A technician seated at a non-ESD workbench could easily have a 400-500 volt charge on his or her body caused not only by friction or tribocharging, but additionally by the constant change in body capacitance that occurs from natural movements. The simple act of lifting both feet off the floor can raise the measured voltage on a person as much as 500-1000 volts.
Setting up a “Static Safe” Program
Perhaps the most important factor in a successful static control program is developing an awareness of the “unseen” problem. One of the best ways to demonstrate the ESD hazard is by using a “static field meter”. The visual impact of locating and measuring static charges of more than 1000 volts will get the attention of skeptical individuals.
Education of Personnel
ESD education and awareness are essential basic ingredients in any effective static control program. A high level of static awareness must be created and maintained in and around the protected area. Once personnel understand the potential problem, reinforce the understanding by hanging up static control posters in strategic locations. The technician doesn’t need an unaware and/or unprotected person wandering over and touching things on the service bench.
To minimize the threat of an ESD event, we need to bring all components of the system to the same relative potential and maintain that potential. Workstations can be grounded with the following options:
Establish an ESD Common Grounding Point, an electrical junction where all ESD grounds are connected to. Usually, a common ground point is connected to ground, preferably equipment ground.
The Service Bench Surface should be covered with a dissipative material. This can be either an ESD-type high-pressure laminate formed as the benchtop surface, or it may be one of the many types of dissipative mats placed upon the benchtop surface. The mats are available in different colors, with different surface textures, and with various cushioning effects. Whichever type is chosen, look for a material with surface resistivity of 1 x 109 or less, as these materials are sufficiently conductive to discharge objects in less than one second. The ESD laminate or mat must be grounded to the ESD common grounding point to work properly. Frequently, a one Megohm current limiting safety resistor is used in series with the work surface ground. This blog post will provide more information on how to choose and install your ESD working surface.
A Dissipative Floor Mat may also be used, especially if the technician intends to wear foot-grounding devices. The selection of the floor mat should take into consideration several factors. If anything is to roll on the mat, then a soft, cushion-type mat will probably not work well. If the tech does a lot of standing, then the soft, anti-fatigue type will be much appreciated. Again, the mat should be grounded to the common ground point, with or without the safety resistor as desired.
Workstation Tools and Supplies should be selected with ESD in mind. Avoid insulators and plastics where possible on and around the bench. Poly bags and normal adhesive tapes can generate substantial charges, as can plastic cups and glasses. If charge-generating plastics and the like cannot be eliminated, consider using one of the small, low cost air ionizers It can usually be mounted off the bench to conserve work area, and then aimed at the area where most of the work is being done. The ionizer does not eliminate the need for grounding the working surface or the operator, but it does drain static charges from insulators, which do not lend themselves to grounding.
People are great static generators. Simple movements at the bench can easily build up charges as high as 500-1000 volts. Therefore, controlling this charge build-up on the technician is essential. The two best known methods for draining the charge on a person are wrist straps with ground cords and foot or heel grounders. Personnel can be grounded through:
Wrist Straps are probably the most common item used for personnel grounding. They are comprised of a conductive band or strap that fits snugly on the wrist. The wrist strap is frequently made of an elastic material with a conductive inner surface, or it may be a metallic expandable band similar to that found on a watch. For more information on wrist straps, check out this post.
Ground Cords are typically made of a highly flexible wire and often are made retractable for additional freedom of movement. There are two safety features that are usually built into the cord, and the user should not attempt to bypass them. The first, and most important, is a current limiting resistor (typically 1 Megohm) which prevents hazardous current from flowing through the cord in the event the wearer inadvertently contacts line voltage. The line voltage may find another path to ground, but the cord is designed to neither increase or reduce shock hazard for voltages under 250 volts. The second safety feature built into most cords is a breakaway connection to allow the user to exit rapidly in an emergency. This is usually accomplished by using a snap connector at the wrist strap end.
Foot or Heel Grounders are frequently used where the technician needs more freedom of movement than the wrist strap and cord allow. The heel grounder is often made of a conductive rubber or vinyl and is worn over a standard shoe. It usually has a strap that passes under the heel for good contact and a strap of some type that is laid inside the shoe for contact to the wearer. Heel grounders must be used with some type of conductive or dissipative floor surface to be effective and should be worn on both feet to insure continuous contact with the floor. Obviously, lifting both feet from the floor while sitting will cause protection to be lost.Don’t forget to regularly check and verify your personnel grounding items:
An effective static control program doesn’t have to be expensive or complex. The main concept is to minimize generation of static and to drain it away when it does occur, thereby lessening the chance for an ESD event to happen. The ingredients for an effective ESD program are:
Education: to ensure that everyone understands the problem and the proper handling of sensitive devices.
Workstation Grounding: use a dissipative working surface material and dissipative flooring materials as required.
Personnel Grounding: using wrist straps with ground cords and/or foot-grounding devices.
Follow-up to ensure Compliance: all elements of the program should be checked frequently to determine that they are working effectively.
The ESD “threat” is not likely to go away soon, and it is very likely to become an even greater hazard, as electronic devices continue to increase in complexity and decrease in size. By implementing a static control program now, you will be prepared for the more sensitive products that will be coming.