STS 300 Series User manual

Read entire manual

before installing

Special Technical Services Inc.

354 US Highway 46 Suite 1C

Hackettstown, NJ 07840 USA

T +1 609-259-2626

F +1 609-259-0044

Email info@specialtechnicalservices.com

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

120VAC

240VAC

G12

12VDC

G24

24VDC

Max Voltage

Min Voltage 102VAC 204VAC 9VDC 18VDC

130VAC 240VAC 15VDC 30VDC

Model

Connection

Nominal Voltage

Connection

120VAC

240VAC

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

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

Customer Connections

*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

OFF

A good ground connection is not verified, and the controller is in a non-permissive state, do

not begin operation

OFF

A good ground connection is verified, and the controller is in permissive state, operation may

begin

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

GROUND CLAMP

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

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

240 AC

Straight

Replacement Light Bulbs

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Maintenance Schedule

TASKS TO BE PERFORMED

Daily

Weekly

Monthly

Annually

External Assembly

Check enclosure for damage

Check enclosure cover bolts are free from excessive corrosion

Verify breather is installed and undamaged

Verify red lens cap is not cracked or damaged

Verify green lens cap is not cracked or damaged

Verify neoprene boots are installed properly on both sides of the enclosure

Verify neoprene boots are not damaged or cracked on the enclosure

Check Ground Cable insulation is free from damage

Check Ground Cable is properly connected to stud and case

Check Clamp Cable insulation is free from damage

Check Clamp Cable is properly connected to stud and enclosure

Check Clamp Cable is properly secured to the enclosure by white strap

Check Clamp Cable is correctly terminated at the clamp

Check Clamp Cable is correctly secured at clamp with white strap and zip ties

Check Clamp Points are not worn and are free from corrosion

Check Clamp Point insulators are not damaged

Check Clamp Strain Release is secured to the cable at proper length (if applicable)

Check Clamp Cable wire terminals are crimped and secured at the clamp

Check Clamp Brass Screw is free from corrosion

Internal Assembly

Check PCB mounting screws are properly installed

Verify wiring from PCB to stud connected to Clamp Cable

Verify wiring from PCB to stud connected to Ground Cable

Check PCB is free from corrosion or water damage

Operational Test

Verify the red lamp (ON) when source voltage is applied

Verify the green lamp (OFF) when source voltage is applied

Measure dry NC contacts resistance in a de-energized state

Verify green lamp (ON) when ground connection is made

Verify red lamp (OFF) when ground connection is made

Measure dry NO contacts resistance in an energized state

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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

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