Information on preventing damage to electronic components due to electrostatic discharge - AH54.00-P-0001-01A

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Electrostatic charge 

Every contact and each physical separation of materials or any movement of solid substances, fluids or particulate loaded gases can generate electrostatic charges. Plastics generally produce the highest electrostatic charge.

We come across electrostatic charge or discharge in lots of everyday situations, e.g. with:

• Combs
• Walking on carpets or plastic floors
• Putting on and removing textiles made with synthetic fiber
• Disembarking from the vehicle
• Contact between various electrostatically chargeable packaging materials in shelves or in the transport container

The following electrostatic discharge (E  lectro S  tatic D  ischarge (ESD)) can be so strong that a small electric shock is detected. Even the smallest discharges which people cannot detect can cause lasting damage to electronic components and control units.

Effects and consequences of ESD 

Electronic components and control units are very sensitive to ESD. The damage is often not immediately obvious, but becomes apparent some time later. In order to avoid failures and damage due to ESD in vehicle electronics, various procedures and safety precautions must be taken into account and followed.

Risks of damage occur during transport, handling, testing, removal and installation of electronic components in production as well as during repair work.

The following electronic components listed as an example can be damaged by ESD:

• Airbag components
• Control units, in particular their bus connections (Control Area Network (data bus/CAN bus) (CAN), local interconnect network (LIN) etc.)
• Sensors
• Mechatronic components (actuators etc.)
• Antenna amplifier
• Receivers and displays (Radio, TV, GPS, telephone etc.)

Modes of behavior and safety precautions 

• Electrostatic discharge from the fitter (e.g. due to brief contact with the vehicle body).
• Suitable clothing, e.g. made of cotton.
• Wear ESD safety shoes with conductive soles.
• Keep workplace clean, remove unnecessary objects such as common plastics.
• Special anti-static seat cushion protectors must be used when performing repair work inside a vehicle.
• Leave replacement parts in the original packaging for as long as possible, Do not cut open seals, but cut open carefully.
• The ESD workplace must conform to the ESD guidelines. ESD protection

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• Before unpacking, discharge ESD protective packaging at the ESD workplace.
• Avoidance of contact with electrostatic chargeable materials such as PE, PVC, styrofoam.
• Use only original packaging or specially labeled and defined packaging and transport materials.
• Electronic components which have been removed must be put down on an ESD workplace.
• Touch connectors on electronic components and in the wiring harness on the housing only. Do not touch the pins and contacts!
• Electronic components must be installed before they are connected so that potential equalization with the body can take place.
• Shelves and worktables must stand directly on the floor, there must not be any insulating materials between the base of the shelves/feet and the floor. If the above mentioned insulators cannot be removed, the shelves and work tables must be grounded (e.g. low-resistance electrical connection/line from metal shelf to a heating pipe).
• Put down conductive transport container/box in a non insulated manner

  (e.g. on a wooden pallet), otherwise no potential equalization takes place.

• Do not place control units and electronic components removed from the vehicle on electrostatically chargeable materials, such as PE, PVC, styrofoam. The electrostatic charge is transferred to the control unit or electronic component. An ESD service kit or a connected ESD table mat must be used.

Training 

We strongly advise that each company should appoint a trained ESD officer in accordance with DIN EN 61340-5-1.

The ESD officer can hold employee training courses.

The objective of the training course measures is to familiarize the employees with the essential difficulties and effects of ESD:

• Creation of discharging
• Reasoning behind safety precautions
• Effects and consequences of ESD
• ESD rules of conduct and safety precautions

Returning electronic components in warranty and goodwill cases 

When returning electronic components it is absolutely essential to observe the procedure and safety precautions listed. Electrostatic charge or discharge mean the original fault can be falsified or overlaid.

This can lead to distorted fault symptoms in the case of the fault analysis of the component concerned.