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Feature Article

Fred Tenzer and Gene Felder, Desco Industries, Inc.

ESD Control Program Periodic


Verification
Some practical advice for implementing ESD control
periodic checks

properties of the technical ESD Handbook TR 20.20

W
ant to accomplish something
important? A familiar formula requirements that are incorporated S20.20 has an accompanying ESD
is write a plan, select the into the ESD program plan.” Handbook, TR 20.20, which offers a
specifications, and then periodically comprehensive list of questions (Ref:
test to verify that the plan is being S20.20, paragraph 6.1.3.2., Compliance paragraph 4.3.3, Checklists). However,
implemented according to the test Verification Plan Guidance, states: only general periodic testing frequency
results. This is basically the “In addition to internal audits, advice is offered, as follows:
requirements of an ESD control external audits (organization and Worksurface: “Periodic testing of
program, per the ESD Association supplier of ESDS items) should be worksurfaces is necessary to
standard, ANSI/ESD S20.20. This performed to ensure compliance evaluate functionality. While not
important standard, entitled covered specifically in ESD STM-
with planned requirements.
Development of an Electrostatic 4.1, resistance to ground
Verifications should include routine
Discharge Control Program, covers the measurements verify that the path to
requirements necessary to design, checks of the Technical
Requirements in the Plan. The the equipment grounding conductor
establish, implement, and maintain an is intact. Surface to groundable
ESD control program to protect frequency of verification checks
should be based on the control item point [RTG] or point to point
electrical or electronic parts, assemblies resistance [RTT] measurements
and equipment susceptible to ESD usage, its durability and associated
risk of failure” across the surface are recommended
damage. periodically to ensure that excessive
wear, dirt, or coatings do not
S20.20 is a process document, and The purpose of this article is to add
interfere with worksurface function.
provides ESD control plan guidance; practical advice on dealing with The frequency of periodic testing is
one of its requirements is having a verification checks, otherwise referred normally specified in corporate
“compliance verification plan” as a to as periodic testing. Technical operating procedures. However, a
component of the ESD control plan. requirements and frequency of periodic common guide would be to conduct
Per S20.20, paragraph 6.1.3., testing will depend upon the value of these measurements at least
Compliance Verification Plan: the ESD sensitive product, probability quarterly.”
“A Compliance Verification Plan of failure, and the potential cost of an
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shall be established to ensure the ESD induced failure. We will assume Wrist Strap: “Wrist straps should be
organization’s compliance with the adoption of Table 1 in S20.20, listing tested periodically. The frequency of
requirements of the Plan. Formal the minimum recommended technical testing, however, is driven by the
audits or certifications shall be requirements of ANSI/ESD S20.20, amount of risk exposure that can
conducted in accordance with a and note typical periodic test occur between tests. Because wrist
Compliance Verification Plan that frequencies that are currently being straps have a finite life, it is
identifies the requirements to be practiced in the field. Our advice uses important to develop a test frequency
verified, and the frequency at which system tests that will provide overall that will guarantee integrity of the
those verifications must occur. Test information making periodic testing system. Typical test programs
equipment shall be selected to make more effective and productive. recommend that wrist straps that are
measurements of appropriate used daily should be tested daily.”

20 CONFORMITY ® MARCH 2004


Feature Article

Footwear: “Once products are case of shoes, when the wearer is The types of monitoring and type of
found to meet the existing standards, fitted, the shoe should be tested as equipment are considerations. In
a system test of the footwear in worn at the point of acceptance. This some cases, a simple electrical
combination with the existing or is typically done by a resistance resistance test with a megohmmeter
proposed floor materials in the plant test.” may suffice. In others, a static
should be made to ensure that the charge generation test may be
criteria for the facility are met. Floor: “Another consideration is the required.”
Incoming inspection on a lot monitoring requirement to assure
sampling basis should be performed that the floor material is still Seating: “The recommended
for all static control footwear. In the functioning within specifications. electrical resistance range for

Frequency ESD Protective Item Tests* Specification Tool/Reference*

Daily EPA access controlled Verify that control procedures are being “Access limited to trained or escorted Visual
followed personnel” ANSI/ESD S20.20

Weekly ESD protective versions of Check areas for presence of non-essential “All nonessential insulators ..must be Visual
Insulators items, particularly insulators removed” Static Field Meter
Measure charge or RTG of ESD protective ANSI/ESD S20.20
product versions

Quarterly Signs EPA has sufficient identification signage “Posted and clearly visible to Visual
EPA boundary marked with aisle tape personnel prior to entry” ANSI/ESD S20.20
Workstations have identification signage

Quarterly - For personnel safety, verify that GFCI are “Ground fault circuit interrupters Visual
installed & personal grounding items not should be considered wherever ANSI/ESD S20.20
used if exposure to over 250 VAC is personnel might come into contact
possible with electrical sources.”

Quarterly Electrical Ground Verify correct wiring of 3-wire electrical “Receptacle wiring should be checked AC Outlet Analyzer
outlet to verify correct wiring configuration” TR 20.20

Quarterly Worksurface Measure RTG to equipment ground 10E6 to 10E8 ohms Megohmmeter Test Kit
ESD S4.1 (Work Surfaces)

Quarterly Seating Measure RTG to equipment ground Less than 1 x 10E9 ohms Megohmmeter Test Kit ESD-STM12.1
(Seating)

Quarterly Shelves Measure RTG to equipment ground Less than 1 x 10E9 ohms Megohmmeter Test Kit
(Mobile or Stationary) ANSI/ESD S20.20 (Table 1)

Quarterly Flooring-Footwear System Measure RTG through ESD footwear & Less than 3.5E7 ohms Megohmmeter Test Kit ESD STM 97.1
person to equipment ground (Resistance Measurement in
Combination with a Person)

Quarterly Flooring-Footwear System Approximate voltage on person wearing Less than 100 volts Charged Plate Analyzer
ESD footwear walking on ESD floor ESD STM 97.1 (Floor Materials and
Footwear-Voltage Measurement in
Combination with a Person)

Quarterly Garment Check for ESD Protective Symbol 10E5 to 10E10 ohms Visual
Measure Sleeve to Sleeve RTT Megohmmeter Test Kit ESD STM2.1
(Garments)

Quarterly Ionizers Measure Offset Voltage (Balance) Less than +/- 50 volts Ionization Test Kit
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Measure Charge Decay Time 1,000 to 100 volts (< 6 seconds is ESD SP3.3 (Periodic Verification
typically used) of Air Ionizers)

Semi-Annual Wrist Strap Measure Breakaway Force (Para. 5.4) >1<5 pounds Force Gage & Fixtures
Measure Resistance Interior Cuff to plug 0.8E6 to 1.2E6 ohms ESD S1.1 (Wrist Straps)
Run Cord Bending Life Test (Para. 5.7) >16,000 cycles

Semi-Annual Continuous Monitor Follow manufacturer’s instructions “Constant monitoring devices should Manufacturer Calibration or Verification
be functionally checked periodically to Unit
ensure that they are operating as ANSI/ESD S20.20
designed.”

* Using modified test methods in accordance with concepts outlined in ESD Association standards
Table 1: Typical ESD control plan document
22 CONFORMITY ® MARCH 2004
seating is less than 1 x 10E9 ohms as audit, and the consequences of failing
tested in accordance with ESD STM such an audit can be drastic.
12.1. This value should be during
acceptance testing, installation and Typical Periodic Testing Practice
periodically thereafter.” Depending upon the situation, one might
test each item or conduct nonrandom
Garments: “To maintain process sampling looking for worst case
control, it is imperative that the conditions. Where a variety of ESD
garment be tested per ESD STM 2.1. protective products are being used, the
The point to point and sleeve to user should measure at least one product
sleeve resistance test should be representative of each type.
made.”
Many companies claim that the major
Goals benefit to an ESD control program is
Verification checks or periodic testing improving discipline on the shop floor.
should be done with the goal that the See our Daily Check Form (Table 2),
ESD control system is functioning which can be used to remind workers to
properly, so as to provide the company control their area and check access,
with improved productivity, quality, and ground at their ESD protected
customer satisfaction. Keenly important workstation, removal of non-essential
to the ESD coordinator is that these items particularly insulators, ESD
daily, weekly, monthly, quarterly, and protective worksurface, ionizers,
semi-annual checks will ensure that the handling of ESD sensitive part handling
annual ESD audit will be passed with , packaging, and that products are used
flying colors. This is particularly products properly. These checks are in
important if a major customer’s contract addition to at least daily testing of wrist
is dependent upon passing the annual straps and ESD footwear while worn.

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Table 2: Daily ESD check form Go to www.conformity.com/INFODIRECT


Input #13
MARCH 2004 CONFORMITY ® 23
Feature Article

Testing is typically performed using a Protected Area.” This is often grounding system is dependent upon
wrist strap/ ESD footwear combo tester accomplished by equipping the the electrical outlets being wired
located at the entrance to the ESD entrance to an ESD Protected Area properly. This can be easily checked
Protected Area, and results should be with a wrist strap / ESD footwear with an AC outlet analyzer. A typical
logged. combo tester, where test results are company would verify their electrical
logged (Ref: S20.20, paragraph receptacles quarterly.
ESD Control Prerequisites 6.2.2.2). This daily visual verification
The prerequisites of ESD control are: check should verify that controlled
1) identifying the ESD Protected Area; access procedures are being followed.
2) identifying all ESD sensitive items;
and 3) providing ESD control training. ESD Control Basics
The basics of ESD control are:
Signs ● Ground all conductors
A typical periodic ● Remove all non-essential insulators,
testing program or convert to ESD protective versions,
would include a & neutralize essential insulators with
quarterly check that ionizers if the electrostatic charge is
the ESD Protected considered a threat
Area is clearly ● Use low charging and dissipative
identified using signs packaging including static discharge Figure 4: ESD workstation
(see Figure 1) & aisle Figure 1: ESD shielding property to store or
tape. (Ref: S20.20, protected area transport ESD susceptible items
Paragraph 6.2.3.1) warning sign
outside the ESD protected area Worksurface / Floors / Seating /
Shelves
ESD Susceptible Items Clearly Identified Grounding The ESD Association standards,
ESD Susceptible Items should be
Equipment Ground primarily used for test lab qualification
clearly identified and handled only in
The most important element of ESD testing, details RTT and RTG tests
an ESD Protected
control is to ground all conductors, where the RTG test is to the mat’s
Area. The ESD
including people. Personal grounding groundable snap. Steve Halperin of
susceptibility symbol
devices used to ground human beings Stephen Halperin & Associates advises
(see Figure 2) exists to
should be checked daily while being using a three-wire extension cord and
do this (Ref: S20.20,
worn. In addition, there are ESD measuring RTG to equipment ground.
Paragraphs 6.2.3.1 &
protective product dissipative or The electrical outlet and the extension
6.2.5.1). However, Figure 2: The ESD
conductive versions of common cord should be checked to ensure that
many companies find susceptibility
production supplies such as mats, they are properly wired. Using a
that it is more cost symbol
flooring, garments, gloves, chairs, surface resistance megohmmeter with
effective to consider
packaging, etc. For example, one 5# electrode, the sensing lead can
all electronic components and
dissipative loose-leaf binders or be plugged into the extension cord
sub-assemblies containing electronic
document holders can have charges (equipment ground), and then one can
components as ESD sensitive, requiring
removed from them when handled by move the 5# electrode on many
that ESD precautions be followed when
grounded personnel or when in contact surfaces and quickly take many
handling. In addition, employees are to
with a properly grounded ESD measurements. We refer to this test as
be grounded and follow all ESD
worksurface. Since “the third wire using modified test methods in
control procedures while working at an
(green) AC equipment ground is the accordance with concepts outlined in
ESD-protected workstation, regardless
preferred choice for ground,” the ESD S4.1.
of what they are working on (even nuts
& bolts!). If running different systems
dependent upon identifying ESD sus-
ceptible items, then periodic verification
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of this should occur at least quarterly.

Controlled Access to An ESD Protected


Area
Access to an ESD Protected Area is to
be controlled. Per S20.20, Paragraph
6.2.3.1, “access to the Protected Area
shall be limited to personnel who have
completed appropriate ESD training.
Trained personnel shall escort Figure 5: Surface resistance meter
untrained individuals while in a Figure 3: Data logger

24 CONFORMITY ® MARCH 2004


Feature Article

Periodic testing would typically not be If the measurement is high, cleaner and letting the surface dry
performed on every item. Non-random troubleshooting would include completely. Ground snaps, common
sampling should be used, for example, measuring each component separately point grounds, and ground cords can be
particularly with worn or dirty to determine which item is out of spec. checked for less than 1 ohm resistance
worksurfaces, and at least one each of The first troubleshooting measurement using a multimeter. If the ground cord
different types should be tested. If the would typically be RTT of the surface, includes a 1 Megohm resistor, the
following elements are part of the ESD which can measure high if dirty (as dirt measurement should be 1E6 ohms.
control program, measuring RTG to is typically insulative), or coated with
equipment ground would include: silicone from non-ESD cleaners. If Flooring-Footwear System Resistance
● Worksurfaces 1 x 10E6 – surface RTT measures high, it should in Combination with a Person
less than 1 x 10E9 ohms be re-tested after cleaning with an ESD The above noted RTG to equipment
● Floors – less than 1 x 10E9 ohms
● Chairs – less than 1 x 10E9 ohms
● Shelves – less than 1 x 10E9 ohms
● Carts – less than 1 x 10E9 ohms

Ideally, particularly if unpackaged ESD


sensitive items are placed upon the
surface, it should be dissipative with
RTG of 1 x 10E6 to less than 1 x 10E9
ohms. Per ESD S4.1, paragraph 8,
Resistance Guidelines, “Resistance-to-
groundable point 1 x 10E6 to 1 x 10E9
ohms. These guidelines represent a
range of resistance that has generally
been proven to provide protection in
the manufacturing environment.”

ESD Handbook, TR20.20, paragraph


5.3.1.7, Electrical Considerations,
states:
“[RTG is] the most important
functional consideration for
worksurfaces. This establishes the
resistance of the primary path to
ground for items, placed on the
surface. When worksurface materials
are being selected, consideration
should be given to possible Charged
Device Model (CDM) damage to
ESD sensitive products. If CDM
damage is a concern then setting a
lower resistance limit for the
worksurface should be considered.
Typically, the lower limit for these
types of worksurfaces is 1 X10E6
ohms.”

Resistance Troubleshooting
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If the overall resistance RTG to


equipment ground measurement is
good, this system method provides the
information that all the components are
good:
● RTT of the surface material
● Snap or other conductor connections
to surface material
● Ground cord or other path-to-ground
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MARCH 2004 CONFORMITY ® 25


Feature Article

ground systems test provides overall information, making walking pattern is suggested Figure 1 in the standard.
periodic testing more effective and productive. Instead of However, per Appendix A, “the user of this test method
testing program components, it verifies that they are working should choose a step pattern typical of the majority of the
together properly. Another such systems test is in accordance workers.” This test can be approximated using a charged plate
with ESD STM 97.1, Floor Materials and Footwear - analyzer where the electrostatic charge on the person is
Resistance Measurement in Combination with a Person, transferred to the conductive plate clipping worn wrist strap
which measured the path-to-ground of the ESD floor and cord to the plate. The charged plate analyzer will measure the
ESD footwear and the person together not separately. charge on a person wearing ESD footwear walking upon ESD
Floor taking a few normal steps.
Per S20.20, paragraph 6.2.2.2, Personnel Grounding
Guidance, “ESD protective flooring, used with approved ESD Protective Product Version of Insulators
footwear, may be used as an alternative to the wrist strap ESD workstations should be checked to verify that all non-
system for standing operations.” That is, both ESD floor and essential insulators are removed. Ideally, all ESD protective
ESD footwear need to be used together. Personnel will likely items are marked or identified. A grounded static field meter
be testing their ESD footwear daily, but doing so standing on should be used to measure the ability of questionable items to
a metal plate. As part of a quarterly periodic verification plan, generate a charge. Per S20.20, “all nonessential insulators,
we suggest using a Megohmmeter with one lead attached to such as those made of plastics and paper (e.g. coffee cups,
equipment ground and electrode held by person wearing ESD food wrappers and personal items) must be removed from the
footwear standing on factory’s ESD protective floor measured workstation.” Instead of removing them altogether, many
at 10 volts. RTG should be less than 3.5E7 ohms. insulative items are replaced with ESD protective versions
which will be low charging, conductive/dissipative, or both.
Flooring-Footwear System Voltage Measurement in These include ESD protective packaging, material handling
Combination with a Person containers, tape, document holders, loose leaf binders, etc.
Alternatively, the proper functioning of the flooring-footwear The worksurface RTG test can be repeated with the 5#
system can be verified by measuring less than 100 Volts on electrode placed upon the dissipative ESD protective item,
the person in accordance with ESD STM 97.2, where voltage verifying a path-to-ground.
on the person is measured using a charged plate analyzer. A
Per ESD Handbook, TR 20.20, paragraph 2.4:
“It should be understood that any object, item, material or
person could be a source of static electricity in the work
environment. Removal of unnecessary nonconductors,
replacing nonconductive materials with dissipative or
conductive materials and grounding all conductors are the
principle methods of controlling static electricity in the
workplace, regardless of the activity.”

Garments
ESD garments are not required by S20.20, but can be an
effective means of complying with Paragraph 6.2.3.2,
Protected Areas Guidance. “All process essential insulators
that have electrostatic fields that exceed 2,000 volts should be
kept at a minimum distance of 12 inches from ESDS items,”
since worker clothing may charge to that level and beyond.

An ESD garment is manufactured from a number of panels,


which must have electrical continuity. Garments whose
electrical continuity wears out over time can do more harm
than good. Per ESD Handbook, TR 20.20, paragraph
5.3.13.2.6, Proper Use, “the garment should be electrically
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bonded to the grounding system of the wearer so as not to act


as a floating [conductor].” If not grounded or if a conductive
panel is electrically isolated, the garment can become an
isolated charged conductor that can discharge to ESD
sensitive items.

To verify point-to-point RTT of 10E5 to 10E10 ohms, the


garment should be placed on an insulative test surface. Place
a 5# electrode on each sleeve, and measure resistance using a
Megohmmeter. The sleeve to sleeve resistance test can be
made using a “banker’s clip” on each sleeve and isolating the
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26 CONFORMITY MARCH 2004
®
Feature Article

garment by hanging it in air (a wooden airflow to measure the balance (offset should be performed periodically,
hanger can also be used). Connect voltage). Just place a 1,000 volt charge perhaps semi-annually; the “breakaway
Megohmmeter leads to banker’s clip via on its isolated plate and place the force” test and the “bending life” test.
alligator clip or bulldog clip. This ionization test kit on a worksurface.
verification should be done quarterly. Count or use a stopwatch to measure For ESD control, to prevent accidental
charge decay time until the charge is disconnects, a strain gage or torque
Ionizers reduced to 100 volts. This should be meter can be used to verify the ESD S.1
Ionizers are pieces of equipment that done with both a positive and a negative breakaway force requirement of greater
can also do more harm than good if not 1,000 charge on the isolated plate. A six than one pound. The less than five
properly maintained. Insulators cannot second charge decay time requirement pound requirement can be an important
be grounded (non-conductors by is not unusual, and the S20.20- safety issue.
definition). Ionizers neutralize recommended technical requirement
electrostatic charges with fans that blow range is < +/- 50 volts voltage offset. Per ESD Handbook, TR 20.20,
large quantities of negatively and Many users perform this periodic test paragraph 5.3.2.2.1.1, Cuffs:
positively charged ions. The quantity of quarterly and/or whenever the ionizer “Wrist strap cuffs may have a quick
negative and positive ions cannot be emitter pins are cleaned. parting electrical-mechanical
exactly the same. Measured in volts, the connector that mates with a
difference is referred to as balance or Wrist Straps corresponding connector on the head
offset voltage. If significantly out-of- Most companies will have workers test of the ground cord. This connector
balance, the ionizer can place a their wrist straps while being worn serves two purposes. First, it is a
significant charge on items instead of daily. Per ESD-S1.1, paragraph 6.1.3, physical connection for attaching the
neutralizing charges. Frequency of Functional Testing, “the ground cord. Second, it is the
wrist strap system should be tested groundable point on the cuff. Quick
Per ANSI/ESD S20.20, Paragraph daily to ensure proper electrical value.” release is an important feature of the
6.2.3.1, Protected Areas Requirement, However, two important wrist strap test connector. The breakaway force
“ionization or other charge mitigating should be low enough to allow easy
techniques shall be used at the release, but high enough to prevent
workstation to neutralize electrostatic unintentional disconnection. If the
fields on all process essential breakaway force is too light, the
insulators if the electrostatic field is ground connection could be lost
considered a threat.” without the knowledge of the
wearer.”
An ionization test kit, in accordance
with ESD SP3.3, Periodic Verification Per ESD Handbook, TR20.20,
of Air Ionizers, can very quickly verify paragraph 5.3.2.2.2, Wrist Strap
the proper functioning of an ionizer. Ground Cord:
The ionization test kit should be “At first glance, the ground cord
grounded and placed in the ionizer Figure 6: ESD mat with test kit appears to be a relatively simple

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MARCH 2004 CONFORMITY ® 27


Feature Article

assembly. However, the design requirements are Most companies will check their continuous monitors semi-
considerable, given the wide range of user applications annually. Following manufacturer’s instructions, this can be
and the durability requirements of constant tugging, accomplished within a minute without removing the monitor
flexing, and dragging over the edge of workstation tops from the workbench.
and equipment chassis.”
Conclusion
To ensure reliable circuit connections, the bending life test
found in paragraph 5.7 applies, using the apparatus described An ESD control program should be treated as an on-going
in ESD S1.1. Many companies consider the 16,000 cycles process, like any good quality control system. As such, it
figure found in ESD S.1 totally inadequate as most good should never be treated as an event. The ESD control plan
quality wrist strap cords will operate a million cycles or many compliance verification plan must include ongoing and
times that. Instead of part of their periodic testing, some effective periodic or verification checks. Issues will be
companies require the breakaway force and bending life test identified which can be corrected, greatly improving the
wrist strap test information to be provided by their suppliers. probability of passing annual audits.

Continuous Monitors ESD control programs must be comprehensive and ESD


If used, continuous monitor functions can be quickly verified protective products must be checked periodically to verify
at the workstation as leading manufacturers have calibration that they are working properly. If used effectively, companies
or verification units available. Frequency of the periodic test can turn ESD control programs into a competitive advantage -
might be done semi-annually. Continuous monitors are a strategic tool focused on quality, productivity, and customer
becoming increasing important as a cost effective means to satisfaction improvement. 
verify on an ongoing basis that operator and worksurface
ESD controls are functioning properly. Per the ESD About The Authors
Handbook, “if the products that are being produced are of Gene Felder is the corporate product manager at
such value that knowledge of a continuous, reliable ground is Desco Industries, and can be reached by e-mail at
needed, and then continuous monitoring should be considered gene.felder@desco.com.
or even required.” (Ref: TR 20.20, paragraph 5.3.2.4.4.)
Fred Tenzer is the Midwest Regional Sales Manager for
Desco and can be reached by e-mail at
fred.tenzer@desco.com

References
1. ANSI/ESD S20.20, Protection of Electrical and Electronic
Parts, Assemblies and Equipment (Excluding Electrically
Initiated Explosive Devices), ESD Association, 1999.
2. ESD TR 20.20, Handbook for the Development of an
Electrostatic Discharge Control Program for the Protection
of Electronic Parts, Assemblies and Equipment
3. ANSI/ESD S1.1: Wrist Straps.
4. ANSI/ESD STM2.1: Garments
5. ESD SP3.3: Periodic Verification of Air Ionizers.
6. ANSI/ESD S4.1: Worksurfaces – Resistance Measurements
7. ESD STM7.1: Resistive Characterization of Materials —
Floor Materials
8. ANSI/ESD STM12.1: Seating - Resistive Measurement
9. ANSI/ESD STM97.1: Floor Materials and Footwear –
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Resistance Measurement in Combination with a Person.


10. ANSI/ESD STM97.2: Floor Materials and Footwear –
Voltage Measurement in Combination with a Person.

Reproduced with Permission,


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28 CONFORMITY ® MARCH 2004

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