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IMPROVING OPERATIONAL RELIABILITY OF EVERY ELECTRONIC EQUIPMENT/DEVICES FOR MISSION CRITICAL APPLICATIONS BY PROTECTION OF ELECTRONIC EQUIPMENT FROM ELECTROSTATIC DISCHARGE (ESD)

Kishori Sharan Mathur Research Scholar, Shri JJT University, Jhunjhunu 333001, Rajasthan, India kishorimathur@hotmail.com

1. INTRODUCTION Electrostatic damage of Electronic equipment and components by operating personnel is one of the most significant problems, which directly affects the reliability, and operational maintainability of electronic equipment. With advances in manufacturing technologies of semi-conductor devices e.g. LSI, VLSI, ULSI technology of ICs resulting in higher circuit densities with higher unit performance but quite often-higher static susceptibility. Such devices, which can be easily damaged by static discharge, are called Static Sensitive Devices (SSD). Increase in package density and reduction in dimensions (for example the channel thickness in MOS devices has reduced from 0.15 micron to 0.02 microns) makes almost every type of semiconductor devices extremely susceptible to high voltage regardless of its manufacturing technology. Table 1: Shows the voltage ranges at which these devices, manufactured by various technologies get damaged.

2 TABLE 1 REPORTED SUCEPTIBILITY OF VARIOUS DEVICES EXPOSED TO ELECTROSTATIC DISCHARGE SL NO. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. DEVICE TYPE MOS FET Ga As FET EPROM JFET SAW (Surface Acoustic Wave) Op-Amp CMOS Schottky diodes Film Resistors (Thick, Thin) Bipolar Transistors ECL SCR Schottky TTL RANGE OF ESD SUSCEPTIBILITY (volts) 100 V- 200 V 100 V- 300 V 100 V 140 V- 7000 V 150 V- 500 V 190 V- 250 V 250 V- 3000 V 300 V- 2500 V 300 V- 3000 V 380 V- 7000 V 500 V- 1500 V 680 V- 1000 V 1000 V- 2500 V

Table also shows that if the voltages in working environment can be maintained to less than 100Volts then damage to Static Sensitive Devices (SSDs) should not exist due to Electro Static Discharge (ESD). 2. HUMAN BODY AS A CHARGE CARRIER During normal body movements like walking across a carpet, we generate static charge on our body by the sole of the shoes, which come into direct frictional contact of the floor e.g. a carpet. The amount of tribo electric charging depends on the molecular structure of the shoes, and the carpet. Every time a person walks, some charges will be generated on shoe and an opposing charge will be generated on each footprint on the Carpet. Also the charge on shoe sole will tend to become progressively greater with each step. 3. ELECTROSTATIC DISCHARGE PHENOMENON: When a charged human body comes in contact with an electronic component or electronic equipment it discharges through an available discharge path. This discharge is called Electrostatic discharge. Even if a charged person doesnt touch the SSD, the electro static field generated will induce static charges on the device which can also result in damage to the SSD.

3 This direct injection of charge in an SSD device can damage the molecular structure of the device resulting in permanent failure or partial damage to the device.

4.

ELECTROSTATIC EQUIPMENT

DISCHARGE

EFFECTS

IN

ELECTRONIC

The ESD phenomenon can result in failure of electronic equipment in field and can be a prime reason during handling or repair of electronic equipment. Human beings can hold charges up to 20 KV but unfortunately, people cant feel fields or discharges less than a few thousands volts, so they are not at all aware of the damage they are doing to the electronic equipment unknowingly. 5. COMBATING ELECTRO STATIC DISCHARGE:

Installations of Electronic equipment even for well-designed product, the majority of actual ESD damage will often be done during installation of Electronic equipment. Unfortunately there is a tendency for operating personnel to assume that ESD failures are at very rare occasions. But this is not always true as per one of the survey 28% SSDs are damaged by operating personnel. It is quite common for a component (typically an IC) to be damaged, but not destroyed. A component with such a latent failure can then fail under the stress of continues operation at the site. There is also a tendency for personnel to assume that ESD IS NOT PRESENT IF THEY CANT FEEL IT. This is not always true. Normally, people cant feel ESD levels below 2 to 3 KV, but 3 KV is certainly sufficient to damage many items. Whats more, there need not to be a spark to destroy components. The electrostatic field it self can cause dielectric break down, even if the arc never occurs. Because of the effect of latent failure, one cant wait for problems to occur before implementing ESD protecting measures. Static protection must be continuously maintained.

6. ANTISTATIC MEASURES: In fact static charges, which are responsible for damaging the components, are generated by quite casual movements like walking, raising a hand or a foot, getting up from a chair etc. Such movements are not avoidable. Hence, our anti-static measures must take care of such charge generating mechanisms. So, to protect the devices, we must ensure that the electrostatic charges do not build up. We must also ensure that whatever small charges do build up despite the precautions is dissipated safely. It must be clearly understood, that the static-sensitive devices remain staticsensitive throughout their working life: they are not free of danger when mounted in a

6 PCB or a module. Therefore, all assemblies containing SSDs are to be treated as if they are static sensitive themselves. The various methods to combat ESD are described below: 7. STATIC SAFE FACILITIES 7.1. THE PROTECTED AREA. 7.1.1. Materials: The use of materials, which are major static charge generators (Table-2), must be prohibited.

TABLE 2 MAJOR CHARGE GENERATORS OBJECT OR PROGRESS Work surfaces MATERIAL OR ACTIVITY Waxes, painted or varnished surfaces. Common vinyl or plastics. Sealed Concrete. Waxes/finished wood Common vinyl tile or sheeting. Synthetic garments. Non-conductive shoes. Virgin cotton (Below 30% RH). Finished wood. Vinyl. Fiberglass.

Floors

Clothes

Chairs

Packing, Handling & stores -

Common plastic-bag, wraps, envelop. Common bubble pack, foam. Common plastic trays, plastic tote boxes. Spray cleaners. Common plastic solder suckers. Soldering irons with ungrounded tips.

Assembly, cleaning, Test & Repair Area.

7.1.2. Flooring:

7 For maximum protection, the floor of the work area should be conductive. Conductive floor tiles and floor mats are commercially available. Conductive footwear offers further protection. 7.1.3. Access: Access to a work area where SSDs are stored or handled must be restricted to personnel not trained in SSD protective procedures. 7.1.4. Signs/Symbols: Warning signs can be displayed such as ESD PROTECTED AREAAUTHORISED PERSONNEL ONLY. One of the prominent symbols used for instantly identifying Static Sensitive Device (SSD) is shown in Figure 5.

Figure 5 Environment: 7.1.5.1. Humidity: The relative humidity should be controlled between 40 and 60 percent. Where this cannot be achieved, the use of ionized air is required (Figure6)

Figure 6

7.1.5.2. Ionized Air: Ionized air dissipates electrostatic charges. There are two types of ionized air generators: nuclear activated and corona discharge. (Some corona discharge unit can generate excessive amounts of ozone. The maximum level allowed by OSHA standards is 0.1 ppm for 9 hrs exposures) (Figure 6) 8. THE WORK STATION: The conductive work-surface (Table-top) and the floor mats are grounded through a resistor having a value between 0.5 mega ohms and 100 mega ohms to limit the discharge current. (This ensures operator safety. Limiting the discharge current also protects a charged device) Figure 7 and 8.

Figure 7

Figure 8

9. WORKER PROVISIONS: 9.1. Conductive Wrist Strap: A conductive wrist-strap in both the hands must be provided to ensure that the worker is at the ground potential. A one-mega ohm resistor is required between the strap and the Antistatic Earth to limit the discharge current 9.2. Heel Grounders: Conductive footwear (or a conductive strap on conventional foot wear) offers additional protection. 9.3. Conductive Garments: Some fabrics can generate static electricity. Practically, workers should wear over-garments that dissipate charges. Few general fabrics, which are presently available. a) b) c) d) Cotton. Polyester. Cotton Polyester Blends Cotton Polyester Blend with additional stainless steel threads.

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9.4. STORAGE AND TRANSPORT: 9.4.1. Cabinets: Cabinet should be conductive (e.g. steel) and should be grounded through a onemega ohm resistor. 9.4.2. Device-carrying containers: Containers used to store or transport SSDs must be made out of conductive material. Treated cardboard and plastic are acceptable. Containers holding SSDs should be stored only on conductive, grounded surfaces (Figure 11& 12). 9.4.3. Trolleys: Trolleys should be conductive. A conductive strap (or brush) fixed to the trolley, which is in constant contact with the conductive floor (even when the trolley is moving), provides additional protection.

9.4.4. Packing Material: The packing material described in section (Packaging options only should be allowed in the work area). See figure 13 & 14 9.4.5. Equipment: All electrical equipment should be grounded to Electrical Earth. (It may be noted that the Electrical Earth and the Antistatic Earth are not the same point). Plastic surfaces such as CRT covers and terminals, should be treated with a topical antistat at regular intervals.

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Figure 9(I)

Figure 9 (II)

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Figure 10

Figure 11

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Figure 12

Figure 13

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Figure 14

10. STATIC SAFE HANDLING The following general guidelines should be followed: 10.1. Operations, which require human, handling, should be minimized. 10.2 While maintaining static sensitive equipment in a place where ground straps cannot be used, the maintenance personnel should ground themselves prior to removing sensitive items from protective packaging. 10.3 Tools and test equipment used in protected areas should be properly grounded. If possible, hand tools should not have insulation on the handles. (If plastic handled tools must be used, they should be treated with a topical antistat).

10.4 Ensure that all containers, tools, test equipment and fixtures used in protected areas are grounded before (and during) use; either directly or by contact with a grounded surface. Grounding of electrical equipment should be via a grounded plug, not through the conductive surface of the grounded workstation. 10.5 Work instructions (method-sheets), test equipment and fixtures used in protected area should not be covered in common plastic sheeting or containers. 10.6 Workers clothing should never make contact with the device, and workers should avoid friction-producing activities in the vicinity of the workstation. 10.7 Workers should avoid touching leads of the devices (or contacts, in case of the surface-mounted devices). 10.8 When devices are removed from their protective containers, they should be kept only in the following manner: a) Pin-side down, on a conductive surface; or b) In a conductive container, with pins in contact with the conductive surface. 10.9 Keep dielectric materials to a minimum such as floors, chairs, stools, personnel clothing and shoes should be limited to poor charge generator such as cotton and leather (Not polyester and rubber).

15 10.10 Periodic continuity and resistivity measurement should be performed. The test should include. a) b) c) d) Worker ground straps. Work surfaces. Floor mats. Other ground connections.

10.11 Caution should be observed in using solvents (such as acetones and alcohol or other cleaning agents) for cleaning ESD-protective materials. The use of such solvents can reduce the effectiveness of some protective materials, especially those employing detergent type antistat. 10.12 When moving sensitive devices from one work station to another, the operators should first ground themselves before moving or placing any devices on a grounded work station. This will safely discharge any charge, which is developed during transportation.

11 PACKAGING OPTIONS: 11.1 Product to be shipped must be packed in one of the following: a) Conductive foam. b) Conductive Tubes. c) Antistatic Carriers. d) Formed Antistatic Plastic. e) Fluted Cardboard. Figure 15 & 16 shows packing options and antistatic bench to be used by logistics. 11.2 All radial leaded components should be packaged with a layer of conductive foam, thus creating a faraday cage. 11.3 Dual-in-line package should be packed in conductive tubes. Antistatic stoppers to be placed at each end to cushion the product. Pins will also be inserted in each end of the tube to prevent sliding movement within the tube. 11.4 Those Dual-in-line packages, which are not possible to pack in a conductive tube, to be packed in conductive foam. 11.5 SSD devices should have an ESD warning, stamp or label, affixed to each box or tube. 11.6 All leadless chip carriers be packed in conductive tubes, with and ESD warning stamp or label on each tube.

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11.7 Certain products, due to their uniqueness or the fact that optimum packaging is still under development, may still be packaged in non-conductive or non-antistatic containers. These will be sealed in conductive bags (used as first level). 11.8 All PCBs should be packed in conductive bags. 11.9 All modules be packed in conductive bags, or wrapped in antistatic layer. 11.10 In general if there is any doubt regarding the exact type of packaging to be used, a conductive bag should be used. 12. UTILIZATION OF ANTISTATIC TEST EQUIPMENTS WILL FURTHER IMPROVE REQUIRED PRECAUTIONS (Figure 9).

Figure 15

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Figure 16

CONCLUSION Practically in todays world all aircrafts, space vehicles and missiles have ICs and other semiconductor devices (SSDs) as the electronic system. With every day advancing technology of electronics now the emphasis is not only on small size and weight of airborne equipment components but also reliability of electronic equipment is of prime concern. To improve the reliability of an electronic system one of the major areas of protection is ESD protection of electronic equipment/component. This ESD protection can certainly improve the reliability of an electronic system. This will also result in high maintainability of the electronic equipment, which in turn fulfills the operational requirement and mission critical requirement of electronic equipment. Not only will this but it may also result in savings in foreign exchange for those countries who are not able to manufacture SSDs at their home land since spares (SSDs components) requirement will be comparatively less due to implementing ESD protection for SSDs.

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