AIAI20-112
AIR INTELLIGENCE AGENCY INSTRUCTION AGENCY 20-112
10 APRIL 1990
HQ AIR INTELLIGENCE AGENCY
Logistics
ELECTROSTATIC DISCHARGE (ESD) CONTROL PROGRAM
This regulation outlines the Electronic Security Command's (ESC) policy and establishes responsibilities for implementing an ESD Control Program. The purpose of the program is to control and minimize the impact of ESD on equipment reliability, operational effectiveness, and life-cycle costs. The program goal is to control and prevent ESD damage to sensitive Air Force cryptologic electronic systems, subsystems, and equipment. This regulation requires compliance with guidelines provided in existing Department of Defense (DOD) standards, DOD handbooks, specifications, Air Force Technical Orders (TO), specifications, ESC Maintenance Bulletins (MB) and specifications. It also defines the requirements of these standards, handbooks, technical orders, MBs, and specifications, and levies additional requirements on ESC organizations. For maximum effectiveness, ESD control should begin with the design of new electronic systems and equipment and continue through manufacture, assembly, deployment, and remain in place throughout the life of the systems at all levels of maintenance, distribution, and utilization. This regulation applies to all ESC organizations involved in the design, manufacture, assembly, testing, acquisition, receiving, storing, shipping, maintenance, or otherwise handling of ESD sensitive (ESDS) electronic equipment. This regulation does not apply to ESC-gained Air National Guard or Air Force Reserve units
Corrected copy of ESC REGULATION 65-5
HQ ESC/LEMM
Mr C. M. Miller
HQ ESC/LEM
Mr Reuben Loeffler
Nada Stenberg
8
F; X: AUL/LDEA (1) (See page 9.)
1. Background:
1.1. The recent technological advances in electronics have resulted in greatly increased sensitivity of components to damage by ESD. The design and construction features of modern microtechnology have resulted in parts and components that can be destroyed or severely damaged by voltages as low as 20 volts. The sudden discharge of static electricity can also cause fires, explosions, and shocks to personnel. The simple act of walking across a room can cause the human body to generate up to 30,000 volts of static electricity. This is more than enough to destroy, in a fraction of a second, most types of static sensitive semiconductors.
1.2. Parts susceptible to ESD include microelectronic devices, metal oxide semiconductor (MOS) devices, thin film resistors, delicate chips and hybrid devices, piezoelectric crystals, discrete semi-conductors, etcetera.
1.3. Protection of the parts can be provided through implementation of relatively low cost controls. The lack of such controls has resulted in premature failures, high repair cost, excessive equipment downtime, and reduced mission effectiveness. Parts have been damaged during assembly, inspection, packaging, storage, and maintenance throughout the life cycle of the equipment. It has been shown that for every catastrophic failure caused by ESD, many other items have had latent damage occur that has caused substandard performance and significantly reduced equipment life. The solution to this problem is timely and effective ESD control.
2. Policy:
2.1. An effective ESD Control Program must be implemented commandwide according to DOD-STD-1686, DOD-HDBK-263, MIL-STD-129, MIL-STD-454, MIL-HDBK-773, TO OO-25-234 (Section VII), and other references listed in paragraph 3 of this regulation. Each unit must designate an office of primary responsibility (OPR) and a point of contact (POC) to standardize its ESD program. To have an effective program, we must:
2.1.1. Establish a physical environment that is not prone to generating static charges and protects ESDS items from electrostatic charges generated outside of the local environment (special clothing, floor covering, etcetera).
2.1.2. Identify all electronic components and assemblies, by special markings, that are ESDS.
2.1.3. Protect ESDS components in all environments (such as, manufacturing, transportation, receiving, storing, operating, and maintenance).
2.1.4. Establish an operating environment in which personnel are aware of ESD problems and perform the required countermeasures.
2.1.5. Utilize the most modern techniques in developing new devices, systems, and equipment with minimized sensitivity without degradation of system performance.
2.1.6. Specify that systems coming into the inventory or undergoing modification have minimal ESD sensitivity for the required performance.
2.1.7. Specify that contractors will follow established ESD control procedures in development of new systems for ESC use.
2.1.8. Establish and maintain a continuous chain of ESD controls from contractor to operating command.
2.1.9. Provide methods to protect equipment from ESD damage. This protection should be according to recommendations of the equipment manufacturer.
2.1.10. Give high visibility attention to the ESD Control Program through use of appropriate posters, POC signs, and training materials. POC signs should be similar in content and purpose to the Reliability and Maintainability (R&M) signs being used. We need good visibility of ESD POCs so that all personnel will know to whom they should report ESD control problems and recommendations.
2.1.11. Provide effective and appropriate ESD training to newly assigned personnel and refresher training to all personnel.
2.2. Parts susceptible to ESD will be identified as ESDS per MIL-HDBK-773; however, any item not specified in that handbook, that contains parts considered susceptible to ESD, should be treated as ESDS. All assemblies containing circuit boards or other ESDS components will be treated as ESDS until the level of assembly is such that it provides a complete electrostatic shield around the circuit boards and components, or the sensitivity of the assembly can be shown to be above 15,000 volts.
2.3. All individuals using ESDS items will use the Materiel Deficiency Reporting (MDR) system (TO OO-35D-54) for identifying, evaluating, reporting, and correcting ESD related problems of lowered reliability, reduced operational effectiveness, high failure rates, and increased system life-cycle costs.
2.4. All ESC organizations that prepare ESC Maintenance Bulletins, Test Maintenance Bulletins, or other maintenance instructions for electronic equipment will make sure all such publications contain identification of all ESD sensitive components.
2.5. The ESD sensitive electronic parts, assemblies, and equipment will not be handled, repaired, assembled, tested, or packaged outside of ESD protective areas.
2.6. When not being worked on, or when being transported outside protected areas, ESD sensitive items will be enclosed in protective packaging or will have shunting that shorts all device contact pins and be within conductive trays or racks for protection against triboelectric charging, direct contact with charged objects, and electrostatic fields.
2.7. Unit packs will be enclosed in an ESD protective pack that will provide protection from electrostatic discharge voltage sources of at least 15,000 volts.
2.8. If a conflict develops regarding ESD control between this regulation and any other ESC regulation, this regulation will take precedence.
3. References:
3.1. DOD-STD-1686, Electrostatic Discharge Control Program for Protection of Electrical and Electronic Parts, Assemblies, and Equipment (excluding Electrically Initiated Explosive Devices).
3.2. DOD-HDBK-263, Electrostatic Discharge Control Handbook for Protection of Electrical and Electronic Parts, Assemblies, and Equipment (excluding Electrically Initiated Explosive Devices).
3.3. MIL-HDBK-773, Electrostatic Discharge Protective Packaging.
3.4. MIL-STD-129, Marking for Shipment and Storage.
3.5. MIL-STD-454, General Requirements for Electronic Equipment.
3.6. MIL-STD-701, List of Semi-Conducting Devices.
3.7. TO 00-35D-54, USAF Materiel Deficiency Reporting and Investigating System.
3.8. TO 00-25-234 (Section VII), General Shop Practice Requirements for the Repair, Maintenance, and Test of Electronic Equipment, Electrostatic Discharge Control.
3.9. ESC Regulation 66-7, Communications-Electronics (C-E) Equipment Maintenance.
3.10. ESC Specification LE 1-1, Preparation of Technical Publications for Use with ESC Antenna and Electronic Equipment.
4. Explanation of Terms:
4.1. Electrostatic Discharge (ESD). A transfer of electrostatic charges between bodies at different electrostatic potentials caused by contact or induced by an electrostatic field.
4.2. Electrostatic Discharge Sensitive (ESDS) Items. Parts or assemblies that are sensitive to ESD damage.
4.3. ESD Protective Material. Material capable of limiting the accumulation of electrostatic charges by safely dissipating electrostatic charges, or by shielding parts from the effects of external electrostatic charges.
4.4. ESD Protective Packaging. Packaging with ESD protective materials to minimize the chance of damage to sensitive items.
4.5. Static Safe Areas. Any area that is capable of controlling static on people and conductive and nonconductive materials.
4.6. Worksite. Area identified, constructed, and equipped with materials for trained personnel to handle ESDS items.
4.7. Workstation. Area centrally located within the worksite, containing the workbench and materials to handle ESDS items.
4.8. Static Dissipative. A material which will rapidly dissipate electrostatic charges over its surface or volume, having a resistivity range between conductive and insulative.
4.9. Conductive. Materials defined as being either surface or volume conductive. Such materials may be either metal or impregnated with metal, carbon particles, or other conductive ingredients or whose surface has been treated with such materials through a process of lacquering, plating, metalizing, or printing.
4.10. Triboelectric Effect. The generation of static electricity caused by rubbing two substances.
4.11. Conformal Coatings. Liquid materials applied directly to printed circuit boards (PCB) and electronic components during final manufacture; once hardened they provide physical, electrical, and environmental protection.
4.12. Protected Areas. An area which is equipped with the necessary ESD protective materials and equipment to limit ESD voltages below their sensitivity level of protection to ESDS items.
4.13. Static Shielding. Containers or packages capable of protecting against static discharges as well as static fields.
4.14. Antistatic Tote Tray. Conductive containers ideal for static-safe storage, kitting, and in-process handling and transporting of static-sensitive assemblies or devices.
4.15. Additional Information on Terms. The publications listed in paragraph 3 contain additional information.
5. Responsibilities:
5.1. HQ ESC/Deputy Chief of Staff for Logistics and Engineering, Directorate of Maintenance and Plant Engineering (HQ ESC/LEM), is designated as the ESC OPR and command POC for the overall ESD program. This office will:
5.1.1. Formulate command ESD policy, in coordination with other ESC offices, and provide guidance to all interested ESC offices and units.
5.1.2. Coordinate with HQ USAF, other commands, and agencies, as appropriate, to ensure an effective ESD program.
5.1.3. Maintain a listing of ESD POCs for other offices and field units.
5.1.4. Make sure adequate ESD control emphasis is applied commandwide, by management, at all times.
5.1.5. Provide training material, sources of training materials, and technical information for ESD to the ESC field units.
5.1.6. Assist the units in developing their ESD training program.
5.1.7. Recommend appropriate changes to TO 00-25-234, Section VII, and other applicable technical publications.
5.1.8. Monitor new acquisitions of C-E mission equipment, evaluate the ESD coverage, and recommend appropriate changes thereto.
5.2. HQ ESC/Directorate of Contracting (HQ ESC/LEC) will:
5.2.1. Appoint an ESD POC and advise HQ ESC/LEM accordingly.
5.2.2. Make sure ESD control is addressed on all ESC contracts involving acquisition of C-E equipment by verifying that the requirements of DOD-STD-1686 or DOD-STD-1686A are specified.
5.2.3. Make sure requirements organizations specify that proper ESD controls (packaging, handling, shipping, etcetera) are required (as identified in DOD STD-1686) when requesting ESDS items and equipment (as identified in DOD-HDBK-263).
5.3. HQ ESC/Acquisition Assistance and Policy Office (HQ ESC/LEA) will:
5.3.1. Appoint an ESD POC and advise HQ ESC/LEM accordingly.
5.3.2. Make sure the acquisition policy for new C-E systems and equipment includes a requirement for application of ESC control principles by specifying DOD-STD-1686 or DOD-STD-1686A.
5.4. HQ ESC/Directorate of Logistics Plans (HQ ESC/LEX) will:
5.4.1. Appoint an ESD POC and advise HQ ESC/LEM accordingly.
5.4.2. Monitor all new acquisitions for C-E systems and equipment, regardless of the acquisition agency, and make sure ESD control is addressed by specifying DOD-STD-1686 or DOD-STD-1686A.
5.4.3. Make sure ESD considerations are properly addressed in the Integrated Logistics Support Plans for all new systems acquired for ESC use.
5.5. HQ ESC/Directorate of Supply and Transportation (HQ ESC/LES) will:
5.5.1. Appoint an ESD POC and advise HQ ESC/LEM accordingly.
5.5.2. Take action to amend existing supply directives and develop new directives, as required, to ensure proper handling of ESD sensitive components throughout the supply system from acquisition to disposal.
5.5.3. Make sure the ESD control items listed in the references of paragraph 3 of this regulation are kept current to include identification and national stock numbers (NSN).
5.5.4. Make sure ESD requirements are fully addressed in all new contractor-prepared technical manuals for ESC use.
5.6. HQ ESC/Directorate of Systems (HQ ESC/XPZ) will:
5.6.1. Identify an ESD POC and advise HQ ESC/LEM accordingly.
5.6.2. Establish policies and procedures to make sure ESD control policies and design considerations are included in all acquisition programs for new C-E mission equipment for ESC use by specifying DOD-STD-1686 or DOD-STD-1686A.
5.6.3. Make sure the technical publications requirements for new ESC systems include a requirement to identify and classify all ESD sensitive assemblies and components.
5.6.4. When no existing ESD test data is available for new components, direct the contractors to test item ESD sensitivity according to DOD-STD-1686 or other accepted standards.
5.6.5. When requested, assist in determining ESD sensitivity of items currently in the Air Force inventories that have not been identified as ESDS.
5.7. Air Force Cryptologic Support Center/Directorate of Maintenance (AFCSC/MA) will:
5.7.1. Identify an ESD monitor and POC and advise HQ ESC/LEM accordingly.
5.7.2. Evaluate all applicable ESD directives identified herein and develop internal directives and procedures to make sure effective ESD control procedures are practiced throughout the directorate.
5.7.3. Establish a specific training program for ESD control and make sure all affected personnel receive the appropriate training.
5.7.4. Make sure ESD control procedures are required in all maintenance, repair, and service contracts that involve electronic equipment and components by specifying DOD-STD-1686 or DOD-STD-1686A.
5.8. AFCSC/Directorate of Materiel Management (AFCSC/MM) will:
5.8.1. Identify an ESD POC and advise HQ ESC/LEM accordingly.
5.8.2. Make sure ESD control is fully covered in all maintenance bulletins developed or revised by AFCSC. This should include the identification of all ESD sensitive assemblies and components used in the equipment and specific precautions and handling instructions to prevent any damage from ESD.
5.8.3. Update specific product MBs and engineering drawings with appropriate warnings, caution notices, and instructions when an unacceptable level of system reliability, due to insufficient ESD controls, is experienced on those items. This can be done by simply adding a brief appendix to the product MB.
5.9. AFCSC/Directorate of Distribution (AFCSC/DS) will:
5.9.1. Identify an ESD monitor and POC and advise HQ ESC/LEM accordingly.
5.9.2. Establish a package of information that will ensure proper storage and handling of ESDS items and components throughout the distribution from acquisition to disposal.
5.9.3. Make sure all personnel handling ESDS material receive the appropriate training.
5.9.4. Perform inspections as necessary on ESDS items in storage to ensure the integrity of the ESD control packaging.
5.10. The 6966 Engineering Systems Flight (6966 ESF) will:
5.10.1. Identify an ESD POC and advise HQ ESC/LEM accordingly.
5.10.2. Apply the most modern ESD techniques and engineering concepts during the design and fabrication of new ESC systems and equipment to minimize ESD sensitivity.
5.10.3. Make sure all maintenance publications (Test Maintenance Bulletins) they develop for new systems contain identification, precautions, and specific handling instructions for all ESD sensitive assemblies and components contained in the systems.
5.11. HQ ESC/Directorate of Programs and Acquisition (HQ ESC/SCA) will:
5.11.1. Appoint an ESD POC and advise HQ ESC/LEM accordingly.
5.11.2. Establish policies and procedures to make sure ESD control policies and design considerations are included in all acquisition programs for new communications computer systems for ESC use by specifying DOD-STD-1686 or DOD-STD-1686A.
5.11.3. Make sure technical publications requirements for new communications computer systems include a requirement to identify all ESD sensitive assemblies and components and specific ESC control and handling procedures for those items.
5.12. ESC field organizations (including the Air Force Electronic Warfare Center (AFEWC)) will:
5.12.1. Appoint an ESD POC and advise HQ ESC/LEM accordingly.
5.12.2. Develop and maintain an effective unit ESD Control Program according to this regulation, DOD-STD-1686, DOD-HDBK-263, MIL-HDBK-773, MIL-STD-129, and TO 00-25-234, Section VII.
5.12.3. Provide ESD training for initiating new workers, annual refresher training for all personnel, and make sure adequate ESD controls are applied in all unit facilities.
5.12.4. Develop and publish a unit directive to formalize the unit ESD program.
5.12.5. Take action to obtain copies and future changes of all documents referenced in paragraph 5l(2) of this regulation; acquire and utilize the ESD materials identified therein.
5.12.6. Submit proposed changes to this regulation and all documents referenced herein as appropriate.
5.12.7. Work with local civil engineers to obtain conductive floor tile and an effective ground for the clean rooms and workbenches.
DOUGLASS COUTO
Lt Col, USAF
Director of Information Management
DISTRIBUTION
HQ ESC/LE 1
LEA 1
LEC 1
LEE 1
LEMM 10
LES 1
LEX 1
SCA 1
XPZ 1
CESD/LG 1
EESD/LG 1
PESD/LG 1
690 ESW/RM 1
691 ESW/RM 1
693 ESW/RM 1
694 ESW/RM 1
695 ESW/RM 1
6903 ESS/LG 1
6906 ESS/LG 1
6911 ESS/LG 1
6913 ESS/LG 1
6914 ESS/LG 1
6916 ESS/LG 1
6917 ESS/LG 1
6920 ESS/LG 1
6922 ESS/LG 1
6924 ESS/LG 1
6931 ESS/LG 1
6933 ESS/LG 1
6940 ESW 1
6947 ESS 1
6948 ESS 1
6949 ESS 1
6950 ESG 1
6952 ESS 1
6960 ESSG/LG 1
6981 ESS/LG 1
6985 ESS/LG 1
6988 ESS/LG 1
6990 ESS/LG 1
6993 ESS/LG 1
6994 ESS/LG 1
AFCSC/MA 1
AFCSC/MM 1
AFCSC/DS 1
AFEWC/RML 1
DET 3, 395 ESW 1
6968 AIS/EII 1
6966 ESF 1