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STS 300 Series Electronic Indicating Ground Assembly

Installation and Operating Instructions

Special Technical Services Inc.

295 US Highway 46 Suite A
Budd Lake, NJ 07828 USA
T +1 609-259-2626
F +1 609-259-0044
Email [email protected]

R7
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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.

Keep cover tightly closed when circuits are energized!

ALWAYS disconnect power and ventilate area before opening enclosure!

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).

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(4) 5/16"-18
Threaded Mounting 4.500in
Holes [114.300mm]
1/2" Deep

3/4"-14 NPT
Conduit Opening
11.125in
[282.575mm]

4.375in
[111.125mm]

5.000in
[127mm]

3.738in
[85.69mm]

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.

Customer Connections Model G2 G4 G12 G24

*Note Nominal Voltage 120VAC 240VAC 12VDC 24VDC
Min Voltage 102VAC 204VAC 9VDC 18VDC
COM2

No Connection

No Connection
NO2
NC2

Max Voltage 130VAC 240VAC 15VDC 30VDC

*Note Connection N L - -
Connection L L + +
COM1
NO1
NC1

Terminal Block
Mounted Inside 10 9 8 7 6 5 4 3 2 1
Explosion-Proof
Enclosure
G
R
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

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GROUND LOCKOUT PERMISSIVE

BUS (RED) (GREEN)

INSTALL WITH
CASE GROUND AND IG STUD WIRES
RED AND GREEN
MUST BE CONNECTED SEPARATELY
LIGHTS ON TOP
AT GROUND BUS

GROUND ROD
FOR REMOTE
LOCATIONS

CASE GROUND AND IG STUD WIRES WHITE WIRE

MUST BE CONNECTED SEPARATELY 10-32 3/8" SCREW
AT GROUND ROD UNDER SEPARATE *PROTECTIVE
BOOT NOT
ACORN CLAMPS *NOT INCLUDED SHOWN

WHITE WIRE
CASE GROUND
10-32 3/8" SCREW

INTEGRITY GROUND (IG)

CONNECTION STUD
TO
GROUND CLAMP
OR
DEADMAN
CONTROL

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.

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Replacement Parts List

Circuit Board Replacement Cords

Part Number Voltage Grounding System Options Part Number Length ft (m) Cord Type Clamp or Switch
C H-12 None C A-15SK 15 (4.57) Straight K78160A
12 DC G12
C H-12DM Deadman C A-25 None
C H-24 None C A-25DBGP Dual Ball Plug
24 VDC G24
C H-24DM Deadman C A-25GATIP GATIP
C H-120 None C A-25K C oil K78160A
120 VAC G2
C H-120DM Deadman C A-25KSRS K78160A SRS Strain Release
C H-240 None C A-25DMS14 DMS-14 Deadman Switch
240 AC G4
C H-240DM Deadman C A-25DMS15 25 (7.62) DMS-15 Deadman Switch
C A-25S None
Replacement Light Bulbs C A-25SDBGP Dual Ball Plug
Part Number Voltage Type Color C A-25SK K78160A
Straight
BI-12 12 VDC C A-25SKSRS K78160A SRS Strain Release
BI-24 24 VDC C A-25SDMS14 DMS-14 Deadman Switch
Incandescent C lear
BI-120 120 VAC C A-25SDMS15 DMS-15 Deadman Switch
BI-240 240 VAC C A-35 None
C oil
BL-120G Green C A-35K K78160A
120 VAC
BL-120R LED Red C A-35S None
35 (10.67)
BL-DC 12/24 VDC White C A-35SDBGP Dual Ball Plug
Straight
C A-35SK K78160A
Control Relay C A-35SKSRS K78160A SRS Strain Release
Part Number Voltage Grounding System C A-50 None
RL-12 12 VDC G12 C A-50K K78160A
C oil
RL-24 24 VDC G24 C A-50DMS14 DMS-14 Deadman Switch
RL-120 120 VAC G2 C A-50DMS15 DMS-15 Deadman Switch
RL-240 240 VAC G4 C A-50S None
50 (15.24)
C A-50SDBGP Dual Ball Plug
Replacement Lamps C A-50SK K78160A
Straight
Part Number Description Color C A-50SKSRS K78160A SRS Strain Release
ST-1-GA C omplete Lamp Assembly Green C A-50SDMS14 DMS-14 Deadman Switch
ST-1-GC Lens C over Only Green C A-50SDMS15 DMS-15 Deadman Switch
ST-1-RA C omplete Lamp Assembly Red
ST-1-RC Lens C over Only Red Replacement Ground Clamps
Part Number Description
Replacement Fuses K78160A Aluminum Ground C lamp with Isolated Points
Part Number Description K78160ASRS Aluminum Ground C lamp w/strain relief and release
FU-1 Fuse 1 Amp C P-1 #1 C ontactor Plug, Dual Ball
FU-5 Fuse 5 Amp REB Aluminum Ground C lamp
REB-IP Aluminum Ground C lamp with Isolated Points
Deadman Switch VUD-IP Aluminum Ground C lamp with Isolated Points
Part Number Description GAT-IP Aluminum GAT C lamp with Isolated Points
DMS-14 STS RD14 Deadman Switch,Standard G40-IP Bronze Ground C lamp with Isolated Points
DMS-15 STS RD15 Deadman Switch,C ast Aluminum
Clamp Replacement Parts
Retractable Cable Reel Part Number Description
Part Number Duty Description K7817512 K7817512 1/2" Nylon Strap
AW-7-25K Standard 25 ft C able with K78160A C lamp K7817538 K7817538 3/8" Nylon Strap
AW-7-50K Standard 50 ft C able with K78160A C lamp KH-1 Handle for K C lamp (isolated point side)
GW-7-25K Heavy 25 ft C able with K78160A C lamp KH-2 Handle for K C lamp (2 point side)
GW-7-50K Heavy 50 ft C able with K78160A C lamp 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

Miscellaneous
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 C lamp Stowage Plate

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 Page |6

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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 Page |7

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 • Incorrect installation of lens caps (Red on the left, Green on the right)
system is not attached to • The isolating washer on clamp is missing or damaged
vehicle or drum • Stainless steel points are set at improper depth and are touching
• Fault or damage in controller wiring
Red light ON when the • High resistance between vehicle/drum and ground
system is attached to • Stainless steel points are not making contact with the metallic surface
vehicle or drum • 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
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
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
Retracting Reel concrete barricade.
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.
Heavy Duty
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.
Our standard Deadman Control option requires the handle to be activated
in addition to an acceptable ground to enable the permissive interlock
Standard circuits in the ground monitoring system. As soon as an operator
depresses the handle, the system will open all contacts and indicate a red
Deadman Feature light.
The enhanced Deadman option is to also have an integrated timer to
ensure the operator has not defeated the Deadman control by tampering
Timing
with the handle. After an adjustable time delay (15 seconds to 10 minutes)
the operator must reactivate the handle to continue.
Protect your equipment by having a designated location to store the
Clamp Stowage Plate 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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 Page |8

Technical Specifications
Monitoring System
Power Supply 120VAC Model: 102-130VAC, 50/60Hz
(marked on nameplate) 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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