STS 300 Series User manual

R6
Read entire manual
before installing
Special Technical Services Inc.
354 US Highway 46 Suite 1C
Hackettstown, NJ 07840 USA
T [phone]
F [phone]
Email [e-mail]
Installation and Operating Instructions
STS 300 Series Electronic Indicating Ground Assembly

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Description
The STS 300 Series Electronic Indicating Ground Assembly consists of an electronic assembly housed in a
cast aluminum enclosure of explosion-proof and dust-ignition-proof design. A 15-100 ft length of flexible cord
with a clamp is attached to the exterior of the device for making a connection to tanker trucks, drums, or other
vessels. A coiled cord is also available for easier cord management. The monitoring ground integrity circuit is
intrinsically safe for Class I, Group D; Class II, Groups E, F, and G hazardous locations.
The STS 300 will indicate a proper ground has been established on a vehicle or drum for the handling of
hazardous materials such as flammable liquids like gasoline or products that generate dust. The ground clamp
will also safely dissipate any unwanted static charge. The STS 300 provides permissive control with pumps
and control circuits to inhibit the transfer of these materials unless a proper earth ground is established.
Model Designation
The STS 300 has many different options, and each system is marked on the front nameplate designating its
specific configuration. The following is an example of how to interpret the model number:
G = STS 300 Series Electronic Indicating Ground Assembly
2 = Voltage (2=120VAC, 4=240VAC, 12=12VDC, 24=24VDC)
L = Indicator Light Type (L=LED, I=Incandescent)
C = Cable Type (C=Coil, S=Straight)
25 = Cable Length (in Feet)
KA = Clamp Style
-XXX = Any additional options or accessories
Installation
The STS 300 Series Electronic Indicating Ground Assembly is fully assembled and tested prior to shipment.
Installation requires mounting, connecting power conductors, and auxiliary control circuits (if used). Installation
of this equipment should be performed by a licensed and qualified person and according to all applicable
requirements and codes of the country of installation.
Mounting
Four 5/16”-18 mounting holes are provided on the back of the enclosure to secure to a Unistrut type support.
The optimal height of the installation is eye-level of the operator, with the indicator lights easily visible to the
operator. A seal fitting (not included) is required immediately before the supply conduit enters the top of the
enclosure. After wiring and testing, the seal fitting is required to be filled with the proper sealing compound.
Failure to do so could result in vapors and liquids being able to enter the enclosure causing damage, explosion,
and bodily harm. The (14) 5/16”-18 bolts that secure the cover should be torqued to 11 ft-lb (1.24 N/m).
Keep cover tightly closed when circuits are energized!
ALWAYS disconnect power and ventilate area before opening enclosure!

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Electrical Connections
The supply voltage should be in accordance with the rating specified on the nameplate on the front cover.
Connect supply voltage to terminals 1 & 2. There are no connections to terminals 3 & 4. Connect Normally
Open (NO) and Normally Closed (NC) contacts to interlocking control contactors to permit the operation of
pumps or valves when a proper ground is detected. Do not connect these contacts directly to motor loads.
An optional power on/off switch rated for the environmental conditions can be installed to disconnect power to
the unit while not in use. This will extend the life of the indicating bulbs.
Model
Connection
Nominal Voltage
Connection
G2
120VAC
N
L
G4
240VAC
L
L
G12
12VDC
-
+
G24
24VDC
-
+
Max Voltage
Min Voltage 102VAC 204VAC 9VDC 18VDC
130VAC 240VAC 15VDC 30VDC
Model
Connection
Nominal Voltage
Connection
G2
120VAC
N
L
G4
240VAC
L
L
G12
12VDC
-
+
G24
24VDC
-
+
Max Voltage
Min Voltage 102VAC 204VAC 9VDC 18VDC
130VAC 240VAC 15VDC 30VDC
12345678910
NC2
NC1
NO2 COM2
NO1 COM1
No Connection No Connection
DRY CONTACTS
10A 250VAC
*NOTE: NO: NORMALLY OPEN CONTACT THAT CLOSES WHEN GROUND IS ESTABLISHED
NC: NORMALLY CLOSED CONTACT THAT OPENS WHEN GROUND IS ESTABLISHED
R
G
Customer Connections
*Note
*Note
Terminal Block
Mounted Inside
Explosion-Proof
Enclosure
5.000in
[127mm]
4.375in
[111.125mm]
3.738in
[85.69mm]
11.125in
[282.575mm]
4.500in
[114.300mm]
(4) 5/16"-18
Threaded Mounting
Holes
1/2" Deep
3/4"-14 NPT
Conduit Opening

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Operation and Care
Attach the grounding clamp at the end of the ground cable to the metal frame of vehicle, vessel, railcar, barge,
etc. The red light should turn off, and the green light should turn on when a proper ground connection is made.
At the same time, all auxiliary contacts will change state, allowing pump, blower, etc. to operate.
The indicator lights operate the following during normal conditions:
Red
Green
Status
ON
OFF
A good ground connection is not verified, and the controller is in a non-permissive state, do
not begin operation
OFF
ON
A good ground connection is verified, and the controller is in permissive state, operation may
begin
OFF
OFF
No power to the grounding system, controller is in the non-permissive state, do not begin
operation
Both ground cables should be inspected regularly to ensure there is no damage to the insulation. Damaged
insulation may impair the proper operation of the grounding device. All hardware should also be inspected to
ensure proper tightness. Please refer to the Maintenance Schedule on page 6 for all recommended
maintenance and servicing.
LOCKOUT
(RED)
PERMISSIVE
(GREEN)
WHITE WIRE
CASE GROUND
10-32 3/8" SCREW
GROUND ROD
FOR REMOTE
LOCATIONS
TO
GROUND CLAMP
OR
DEADMAN
CONTROL
INTEGRITY GROUND (IG)
CONNECTION STUD
WHITE WIRE
10-32 3/8" SCREW
CASE GROUND AND IG STUD WIRES
MUST BE CONNECTED SEPARATELY
AT GROUND ROD UNDER SEPARATE
ACORN CLAMPS *NOT INCLUDED
GROUND
BUS
*PROTECTIVE
BOOT NOT
SHOWN
CASE GROUND AND IG STUD WIRES
MUST BE CONNECTED SEPARATELY
AT GROUND BUS
INSTALL WITH
RED AND GREEN
LIGHTS ON TOP

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Replacement Parts List
Part Number Voltage
Grounding System Options Part Number Length ft (m) Cord Type Clamp or Switch
CH-12 None CA-15SK 15 (4.57) Straight K78160A
CH-12DM Deadman C A-25 None
CH-24 None CA-25DBGP Dual Ball Plug
CH-24DM Deadman C A-25GATIP GATIP
CH-120 None C A-25K K78160A
CH-120DM Deadman CA-25KSRS K78160A SRS Strain Release
CH-240 None CA-25DMS14 DMS-14 Deadman Switch
CH-240DM Deadman CA-25DMS15 DMS-15 Deadman Switch
CA-25S None
CA-25SDBGP Dual Ball Plug
Part Number Voltage Type Color CA-25SK K78160A
BI-12 12 VDC CA-25SKSRS K78160A SRS Strain Release
BI-24 24 VDC CA-25SDMS14 DMS-14 Deadman Switch
BI-120 120 VAC CA-25SDMS15 DMS-15 Deadman Switch
BI-240 240 VAC CA-35 None
BL-120G Green CA-35K K78160A
BL-120R Red C A-35S None
BL-DC 12/24 VDC White CA-35SDBGP Dual Ball Plug
CA-35SK K78160A
CA-35SKSRS K78160A SRS Strain Release
Part Number Voltage CA-50 None
RL-12 12 VDC CA-50K K78160A
RL-24 24 VDC CA-50DMS14 DMS-14 Deadman Switch
RL-120 120 VAC C A-50DMS15 DMS-15 Deadman Switch
RL-240 240 VAC C A-50S None
CA-50SDBGP Dual Ball Plug
CA-50SK K78160A
Part Number Color CA-50SKSRS K78160A SRS Strain Release
ST-1-GA Green CA-50SDMS14 DMS-14 Deadman Switch
ST-1-GC Green CA-50SDMS15 DMS-15 Deadman Switch
ST-1-RA Red
ST-1-RC Red
Part Number Description
K78160A Aluminum Ground C lamp with Isolated Points
Part Number K78160ASRS Aluminum Ground C lamp w/strain relief and release
FU-1 CP-1 #1 C ontactor Plug, Dual Ball
FU-5 REB Aluminum Ground C lamp
REB-IP Aluminum Ground C lamp with Isolated Points
VUD-IP Aluminum Ground C lamp with Isolated Points
Part Number GAT-IP Aluminum GAT C lamp with Isolated Points
DMS-14 G40-IP Bronze Ground C lamp with Isolated Points
DMS-15
Part Number Description
Part Number Duty K7817512 K7817512 1/2" Nylon Strap
AW-7-25K Standard K7817538 K7817538 3/8" Nylon Strap
AW-7-50K Standard KH-1 Handle for K C lamp (isolated point side)
GW-7-25K Heavy KH-2 Handle for K Clamp (2 point side)
GW-7-50K Heavy RK-1 Repair Kit for K78160A C lamp
GW-7-100K Heavy 100 ft C able with K78160A C lamp RK-2 Repair Kit for K78160ASRS C lamp
IP Kit IP Kit consists of 2 washers/1 tube
Part Number Description
K78166 Phenolic Stud, Phenolic Bushing Ring, Brass Bolt and Nut
IN-NT Brass Insulator Nut
IN-ST Phenolic Insulator Stud Bushing
N18660 Rubber Protection Boot for C able Stud
EP-0416 Clamp Stowage Plate
LED
Miscellaneous
Description
25 ft C able with K78160A C lamp
50 ft C able with K78160A C lamp
25 ft C able with K78160A C lamp
50 ft C able with K78160A C lamp
Replacement Ground Clamps
Clamp Replacement Parts
Fuse 1 Amp
Fuse 5 Amp
Deadman Switch
Description
Complete Lamp Assembly
Lens C over Only
Complete Lamp Assembly
Lens C over Only
Replacement Fuses
Description
G24
G2
G4
Replacement Lamps
Retractable Cable Reel
STS RD14 Deadman Switch,Standard
STS RD15 Deadman Switch,C ast Aluminum
Incandescent
Clear
35 (10.67)
Coil
Description
120 VAC
Straight
50 (15.24)
Coil
Control Relay
Grounding System
G12
Straight
Circuit Board
Replacement Cords
12 DC
G12
25 (7.62)
Coil
24 VDC
G24
120 VAC
G2
240 AC
G4
Straight
Replacement Light Bulbs

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Maintenance Schedule
TASKS TO BE PERFORMED
Daily
Weekly
Monthly
Annually
External Assembly
Check enclosure for damage
X
Check enclosure cover bolts are free from excessive corrosion
X
Verify breather is installed and undamaged
X
Verify red lens cap is not cracked or damaged
X
Verify green lens cap is not cracked or damaged
X
Verify neoprene boots are installed properly on both sides of the enclosure
X
Verify neoprene boots are not damaged or cracked on the enclosure
X
Check Ground Cable insulation is free from damage
X
Check Ground Cable is properly connected to stud and case
X
Check Clamp Cable insulation is free from damage
X
Check Clamp Cable is properly connected to stud and enclosure
X
Check Clamp Cable is properly secured to the enclosure by white strap
X
Check Clamp Cable is correctly terminated at the clamp
X
Check Clamp Cable is correctly secured at clamp with white strap and zip ties
X
Check Clamp Points are not worn and are free from corrosion
X
Check Clamp Point insulators are not damaged
X
Check Clamp Strain Release is secured to the cable at proper length (if applicable)
X
Check Clamp Cable wire terminals are crimped and secured at the clamp
X
Check Clamp Brass Screw is free from corrosion
X
Internal Assembly
Check PCB mounting screws are properly installed
X
Verify wiring from PCB to stud connected to Clamp Cable
X
Verify wiring from PCB to stud connected to Ground Cable
X
Check PCB is free from corrosion or water damage
X
Operational Test
Verify the red lamp (ON) when source voltage is applied
X
Verify the green lamp (OFF) when source voltage is applied
X
Measure dry NC contacts resistance in a de-energized state
X
Verify green lamp (ON) when ground connection is made
X
Verify red lamp (OFF) when ground connection is made
X
Measure dry NO contacts resistance in an energized state
X

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Troubleshooting
Condition
Possible Cause
No lights ON
•No power to control unit
•Blown bulb
•Input fuse F2 blown
•Fault or damage in controller wiring or PCB
Green light ON when the
system is not attached to
vehicle or drum
•Incorrect installation of lens caps (Red on the left, Green on the right)
•The isolating washer on clamp is missing or damaged
•Stainless steel points are set at improper depth and are touching
•Fault or damage in controller wiring
Red light ON when the
system is attached to
vehicle or drum
•High resistance between vehicle/drum and ground
•Stainless steel points are not making contact with the metallic surface
•Integrity ground cable not connected to a valid grounding point
•Damage to any wiring outside of the explosion-proof enclosure
•Fault or damage of K1 relay
•Input fuse F1 blown
Call or email us for additional support
Additional Accessories
Accessory
Description
Retracting Reel
Standard Duty
Our standard duty retractable reel is built from cast aluminum, which is
lighter and smaller than our heavy-duty reel. Easy to install and easy to
operate, this can use cable lengths from 25 ft. to 50 ft. Our standard duty
reels have ratchet controlled spring rewind for precise distances. Built to
meet a NEMA 4 rating, this style reel is best for areas where there is slight
protection from physical damage, such as on the ceiling or behind a
concrete barricade.
Heavy Duty
Built entirely out of steel, the heavy-duty retractable reel is optimal for
harsh environments where excessive wear and tear may occur. Easy to
install and easy to operate, this can use cable lengths from 25 ft. to 100 ft.
The reels have either fully automatic or ratchet controlled spring rewind.
This rugged and watertight design is best for applications such as
mounted to trucks or not protected by a roof.
Deadman Feature
Standard
Our standard Deadman Control option requires the handle to be activated
in addition to an acceptable ground to enable the permissive interlock
circuits in the ground monitoring system. As soon as an operator
depresses the handle, the system will open all contacts and indicate a red
light.
Timing
The enhanced Deadman option is to also have an integrated timer to
ensure the operator has not defeated the Deadman control by tampering
with the handle. After an adjustable time delay (15 seconds to 10 minutes)
the operator must reactivate the handle to continue.
Clamp Stowage Plate
Protect your equipment by having a designated location to store the
grounding cable and clamp. The clamp stowage plate is made of a durable
chemical-resistant plastic to endure prolonged use in hazardous areas.

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Technical Specifications
Monitoring System
Power Supply
(marked on nameplate)
120VAC Model: 102-130VAC, 50/60Hz
240VAC Model: 204-240VAC, 50/60Hz
12VDC Model: 9-15VDC
24VDC Model: 18-30VDC
Power Rating
5 Watts
Temperature range
-40°F to 130°F (-40°C to 55°C)
Fused Protection
5 Amps
Enclosure Type
NEMA 7, 8, & 9
Weight
22 lbs. (10 kg)
Certification/Approvals
UL 913 & UL 1203 Standards
Class I, Division I, Group D
Class II, Division I, Groups E, F, G
Monitoring Circuit
Intrinsically Safe
Loop Resistance of Clamp to Grounding Point
≤ 5 Ohms (continuously monitored)
Output Relay Contact Rating
2 Voltage Free (dry) Form C contacts (DPDT)
Maximum contact rating:
10A, 277VAC
15A, 120VAC
15A, 30VDC
Integrity Lights
Status Indicator Lights:
Red: Non-permissive
Green: Permissive
Integrity Ground Cable
Type
Service Grade
Conductors
2 x 14 AWG Stranded Copper
Length
8ft
Operator Cable
Coil Cable
Type
Service Grade
Conductors
3 x 16 AWG Stranded Copper
Length
25 ft. or 50 ft.
Straight Cable
Type
Service Grade
Conductors
2 x 14 AWG Stranded Copper
Length
10ft. to 100 ft.
Grounding Clamp
Clamp Contacts
Stainless Steel
Clamp Body
Aluminum or Bronze