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APPLICATION AND

INSTALLATION GUIDE

HAZARDOUS LOCATION
ENGINES

Tier 3 Petroleum
C9 C7
Tier 2 Petroleum
C32
Hazardous Location
Engines

Contents
Hazardous Location Engines .................................................. 1
1 Introduction & Purpose ................................................. 1
2 Important Safety Information ........................................ 1
3 Hazardous Location Terms & Compliance ....................... 3
3.1 Caterpillar Hazardous Location Engine Compliance..... 3
3.1.1 Class I Division 2 / Zone 2............................... 3
3.1.1.1 NEC 500 and NEC 505 Gas Groups ............... 5
3.1.1.1.1 NEC 500 ................................................. 5
3.1.1.1.2 NEC 505 ................................................. 5
3.1.2 ATEX Directive Compliance ............................. 5
3.1.2.1 Group II, 3G (Zone 2) Environments ............... 5
3.1.2.2 ATEX Gas Groups ....................................... 6
3.1.2.3 Temperature Classes ................................... 7
4 Engine Markings .......................................................... 8
4.1 ATEX Electrical Markings ....................................... 8
4.2 ATEX Mechanical Markings .................................... 8
4.3 NEC 500 Markings ................................................ 9
4.4 NEC 505 Markings ................................................ 9
4.5 CE Marking ........................................................ 10
5 Ratings .................................................................... 11
5.1 Derated Engine Ratings ........................................ 11
5.2 Non-Derated Engine Ratings ................................. 11

6 Servicing Considerations ............................................ 12


6.1 Connecting Service Tools..................................... 12
6.2 Electrical Harness Connectors ............................... 13
6.3 Battery Disconnect ............................................. 14
7 Customer Requirements ............................................. 15
7.1 Wiring Requirements ........................................... 15
7.1.1 Battery Circuit Protection .............................. 15
7.1.2 Termination of J1 harness ............................. 16
7.2 Cooling System .................................................. 18
7.2.1 System Pressure .......................................... 18
7.2.2 Mandatory Venting ....................................... 18
7.3 Ambient Temperature Sensor ............................... 19
7.4 Flame Proof Engine ............................................. 19
7.5 Exhaust Gas Cooler ............................................. 20
8 Customer Supplied Attachments .................................. 22
9 Engine Documentation ............................................... 23
9.1 EU Declaration of Incorporation ............................ 23
9.2 EU Declaration of Conformity ............................... 23

Foreword
This section of the Application and Installation Guide generally describes
hazardous location engines for Caterpillar engines listed on the cover of this
section. Additional engine systems, components and dynamics are addressed
in other sections of this Application and Installation Guide.
Engine-specific information and data are available from a variety of
sources. Refer to the Introduction section of this guide for additional
references. Contact the Application Support Center (ASC) for the latest
information on future Hazardous location feature release dates.
Systems and components described in this guide may not be available or
applicable for every engine.

Information contained in this publication may be considered confidential.


Discretion is recommended when distributing. Materials and specifications
are subject to change without notice.
The information in this document is the property of Caterpillar Inc. and/or its
subsidiaries. Without written permission, any copying, transmission to
others, and any use except that for which it is loaned is prohibited.
CAT, CATERPILLAR, their respective logos and Caterpillar Yellow, as well
as corporate and product identity used herein, are trademarks of Caterpillar
and may not be used without permission.

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Application and Installation Guide

Hazardous Location Engines

Hazardous Location Engines


1 Introduction & Purpose
This document is intended to provide the necessary information for correct
installation of the following Caterpillar EPA Tier 3 Petroleum Hazardous
Location Engines as used in off-highway applications: C7, C9, and C32 (EPA
Tier 2).
The information in this document is the property of Caterpillar Inc. and/or
its subsidiaries. Without written permission, any copying, transmission to
others, and any use except that for which it is loaned is prohibited.
Contact the Application Support Center (ASC) for the latest information on
future Hazardous location feature release dates.

2 Important Safety Information


Most accidents that involve product operation, maintenance and repair are
caused by failure to observe basic safety rules or precautions. An accident
can often be avoided by recognizing potentially hazardous situations before
an accident occurs. A person must be alert to potential hazards. This person
should also have the necessary training, skills and tools to perform these
functions properly.
Improper operation, lubrication, maintenance or repair of this product can
be dangerous and could result in injury or death.
Do not operate or perform any lubrication, maintenance or repair on this
product, until you have read and understood the operation, lubrication,
maintenance and repair information.
Safety precautions and warnings are provided in this manual and on the
product. If these hazard warnings are not heeded, bodily injury or death
could occur to you or to other persons.
The hazards are identified by the Safety Alert Symbol and followed by a
Signal Word such as DANGER, WARNING or CAUTION. The Safety
Alert WARNING label is shown below.

The meaning of this safety alert symbol is as follows:


Attention! Become Alert! Your Safety is Involved.
The message that appears under the warning explains the hazard and can
be either written or pictorially presented.
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Operations that may cause product damage are identified by NOTICE


labels on the product and in this publication.
Caterpillar cannot anticipate every possible circumstance that might involve
a potential hazard. The warnings in this publication and on the product are,
therefore, not all inclusive. If a tool, procedure, work method or operating
technique that is not specifically recommended by Caterpillar is used, you
must satisfy yourself that it is safe for you and for others. You should also
ensure that the product will not be damaged or be made unsafe by the
operation, lubrication, maintenance or repair procedures that you choose.
The information, specifications, and illustrations in this publication are on
the basis of information that was available at the time that the publication
was written. The specifications, torques, pressures, measurements,
adjustments, illustrations, and other items can change at any time. These
changes can affect the service that is given to the product. Obtain the
complete and most current information before you start any job. Caterpillar
dealers have the most current information available.

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3 Hazardous Location Terms & Compliance


3.1 Caterpillar Hazardous Location Engine Compliance
Caterpillar Tier 3 Petroleum Hazardous Location Engines are certified for
use in Class I Division 2 (NEC 500), Class I Zone 2 (NEC 505), and ATEX
Directive (94/9/EC) Group II, 3G environments (Zone 2) with Gas Group IIA,
and Temperature Class T3.
The electrical system of the aforementioned engines also meets the
following ratings:
Ingress Protection = IP56
Ambient =

-20C < Ta < +45C

Zone =

2 (3G)

Gas Group =

IIC (ATEX and NEC 505); ABCD (NEC 500)

Temperature Class = T3
3.1.1 Class I Division 2 / Zone 2
Class I Division 2 and Class I Zone 2 are in reference to the North
American standard that addresses the engines electrical system only.
Caterpillar Tier 3 Petroleum Hazardous Location Engines are assessed and
certified by Factory Mutual (FM) to meet this standard.
The standard places equipment into three basic categories: Class I, Class II,
and Class III. Class I is for equipment in environments containing flammable
gases, vapors, or liquids. Caterpillar Tier 3 Petroleum Hazardous Location
Engines are Class I. Class II is defined for combustible dusts, and Class III for
combustible fibers. Neither Class II or Class III are covered in this guide.
As defined by standard NEC 500, a Class I Division 2 location is one in
which flammable gases, flammable liquid-produced vapors, or combustible
liquid-produced vapors are handled, processed, or used, but in which the
liquids, vapors, or gases will normally be confined within closed containers or
closed systems from which they can escape only in case of accidental
rupture or breakdown of such containers or systems or in case of abnormal
operation of equipment, or in which such gases or vapors are normally
prevented by positive mechanical ventilation and which might become
hazardous through failure or abnormal operation of the ventilation system, or
that is adjacent to a Class I Division 1 location, and to which ignitable
concentrations of such gases or vapors above their flash points might
occasionally be communicated unless such communication is prevented by
adequate positive-pressure ventilation from a source of clean air and
effective safeguards against ventilation failure are present.
A Class I Division 1 location is defined as a location in which ignitable
concentrations of flammable gases, flammable liquid-produced vapors, or
combustible liquid-produced vapors can exist under normal operating
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conditions, or in which ignitable concentrations of such gases or vapors


above their flash points may exist frequently because of repair or
maintenance operations or because of leakage, or in which breakdown or
faulty operation of equipment or processes might release ignitable
concentrations of such gases or vapors and might also cause simultaneous
failure of electrical equipment in such a way as to directly cause the
electrical equipment to become a source of ignition.
NOTE: Caterpillar does not offer Class I Division 1 engines or components
on its current Tier 3 Petroleum Hazardous Location platforms.
Class I Zone 2 (NEC 505) terminology is very similar to the Class I Division
2 classification, except that when using the Zone X terminology, Division
1 equipment can be further divided into Zone 0 and Zone 1 equipment. As
such, Class I Division 2 and Class I Zone 2 terminology indicate the same
location classification. See Table 3.1 below.
North American Area Classifications
Class

Division
(NEC 500)

Zone
(NEC 505)

Description

Zone 0

A zone where ignitable


concentrations of
flammable gases,
vapors, or liquids are
present continuously or
for long periods of time
under normal operating
conditions

Zone 1

A zone where ignitable


concentrations of
flammable gases,
vapors, or liquids are
likely to exist under
normal operating
conditions

Zone 2

A zone where ignitable


concentrations of
flammable gases,
vapors, or liquids are
not likely to exist under
normal operating
conditions.

Division 1

Class I

Division 2

Shaded area represents Caterpillar Hazardous Location Engine Compliance.

Table 3.1

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3.1.1.1 NEC 500 and NEC 505 Gas Groups


The NEC 500 and NEC 505 gas groups are divided by the type of explosive
gas, liquid, or vapor that may be present in the environment.
3.1.1.1.1 NEC 500
Caterpillar Tier 3 Petroleum Hazardous Location Engines comply with all of
the NEC 500 gas groups up to T3 temperature class. Below is a description
of each of these gas groups, A, B, C, and D.
Group A:

Atmospheres that contain acetylene.

Group B:

Atmospheres that contain hydrogen.

Group C:

Atmospheres that contain coal gas (lighting gas) or ethylene.

Group D:

Atmospheres that contain Acetone, Ethane, Ethyl ethanoate,


Ammonia, Benzol (pure), Ethanoic acid, Carbon oxide,
Methane, Methanol, Propane, Toluene, Ethanol, i-Amyl
acetate, n-Butane, n-Butyl alcohol, Benzine, Diesel fuel,
Aircraft fuel, Heating oils, n-Hexane.

3.1.1.1.2 NEC 505


Caterpillar Tier 3 Petroleum Hazardous Location Engines comply with all of
the NEC 505 gas groups up to T3 temperature class. Below is a description
of each of these gas groups, IIA, IIB, IIB + Hydrogen, and IIC.
IIA (same as Group D from NEC 500): Atmospheres that contain Acetone,
Ethane, Ethyl ethanoate, Ammonia, Benzol (pure), Ethanoic acid, Carbon
oxide, Methane, Methanol, Propane, Toluene, Ethanol, i-Amyl acetate, nButane, n-Butyl alcohol, Benzine, Diesel fuel, Aircraft fuel, Heating oils, nHexane.
IIB (same as Group C from NEC 500): Atmospheres that contain coal gas
(lighting gas) or ethylene.
IIB + Hydrogen (same as Group B from NEC 500): Atmospheres that
contain ethylene and/or hydrogen.
IIC (same as Group A from NEC 500): Atmospheres that contain acetylene.
3.1.2 ATEX Directive Compliance
The ATEX directive is a European standard that considers both electrical
and mechanical hazards. Caterpillars Tier 3 Petroleum Hazardous Location
Engines are assessed and certified by third parties to meet this directive.
ATEX compliance is comprised of several different categories. Caterpillars
Tier 3 Petroleum Hazardous Location Engines are certified for ATEX Directive
94/9/EC Group II, 3G (Zone 2) environments with Gas Group IIA, and
Temperature Class T3.
3.1.2.1 Group II, 3G (Zone 2) Environments
The ATEX directive is comprised of two machinery groups, Group I and
Group II. Group I is for mining equipment and is not covered in this guide.
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Any hazardous location equipment that is not used for mining (Group I) is
classified under Group II. A description of Group II can be seen in Table 3.2
below.
ATEX Group II
Equipment
Group

Equipment
Category

Group II

Zone
Gas
0

Environmental Conditions

Dust
20

Explosive atmospheric
conditions always present, or
present for long periods of time
(Typical >1000 hr/yr)

21

Explosive atmospheric
conditions are likely to occur
during normal operation.
(Typical 10-1000 hr/yr)

22

Explosive atmosphere is not


likely to occur during normal
operation, or will occur
infrequently and for short time
periods. (<10 hr/yr)

Shaded area Applicable to Caterpillar Hazardous Location Engines.

Table 3.2
As is the case in the North American region, equipment Categories (and
Zones) in Europe are divided by how frequently or likely an explosive
atmospheric condition will exist.
The terms 3G and Zone 2 are synonymous. The letter indicates the type of
explosive environment. G indicates a gaseous environment (gases, vapors,
or liquids) and D indicates dust. Using the terminology Zone 2
automatically defines the piece of equipment as Category 3 for environments
with potentially explosive gases, vapors, or liquids.
3.1.2.2 ATEX Gas Groups
Flammable gases, vapors, and liquids are separated into three different
groups. Groups IIA, IIB, and IIC. These groups are defined as follows:
Group IIA: Atmospheres containing acetone, ammonia, ethyl alcohol,
gasoline, methane, propane, or flammable gas, flammable liquidproduced vapor, or combustible liquid-produced vapor mixed
with air that may burn or explode.

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Group IIB: Atmospheres containing acetaldehyde, ethylene, or flammable


gases, liquids, or vapors mixed with air that may burn or
explode.
Group IIC: Atmospheres containing acetylene, hydrogen, or flammable
gases, liquids, or vapors mixed with air that may burn or
explode.
3.1.2.3 Temperature Classes
The temperature class is the maximum temperature any surface of the
piece of equipment can reach. This is an important rating because different
substances have different temperatures at which they become autoignitable.
Table 3.3 below shows the temperature classes of both the North American
and European standards.
Temperature Classes
Class I Division 1, 2

ATEX

Temp. Class

Temp. Limit

Temp. Class

Temp. Limit

T1

450 C

T1

450 C

T2

300 C

T2

300 C

T2A

280 C

N/A

T2B

260 C

N/A

T2C

230 C

N/A

T2D

215 C

N/A

T3

200 C

T3

T3A

180 C

N/A

T3B

165 C

N/A

T3C

160 C

N/A

T4

135 C

T4

T4A

120 C

N/A

T5

100 C

T5

100 C

T6

85 C

T6

85 C

200 C

135 C

Shaded area represents Caterpillar ATEX engine compliance.

Table 3.3

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4 Engine Markings
Each Caterpillar Tier 3 Petroleum Hazardous Location Engine is affixed with
certification plates that indicate the protection concepts and equipment
category of the engine.

4.1 ATEX Electrical Markings


The ATEX electrical certification plate contains the following markings:
Classification:
Equipment Category:

Ex nA nR IIC T3
II 3G

These markings can be defined as:


Ex:

Specific marking to indicate explosion protection (ATEX only)

II:

Equipment group (see section 3.1.2.1)

3G: Equipment category and atmosphere type (see section 3.1.2.1)


IIC:

Gas group compliance (see section 3.1.2.2)

T3:

Temperature rating (see section 3.1.2.3)

nA: Protection concept No arcs, sparks, or hot surfaces (EN/IEC 6007915 standard)
nR:

Protection concept Restricted breathing to control flammable gases


(EN/IEC 60079-15 standard)

4.2 ATEX Mechanical Markings


The ATEX mechanical markings on the engine are:
Equipment Category:
Gas Group:
Temperature Class:
Ambient Capability:

Ex II 3G
IIA
T3
Ta = XX C

These markings can be defined as:


Ex:

Specific marking to indicate explosion protection (ATEX only)

II:

Equipment group (see section 3.1.2.1)

3G: Equipment category and atmosphere type (see section 3.1.2.1)


IIA:

Gas group compliance (see section 3.1.2.2)

Ta:

Ambient capability of mechanical certification (see engine specific


documentation)

T3:

Temperature rating (see section 3.1.2.3)

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4.3 NEC 500 Markings


The NEC 500 markings are as follows:
Classification:
Protection Method:
Ambient Capability:
Ratings:

Class I Division 2 Groups ABCD


Non-Incendive Field Wiring (NIFW)
Ta = 45C
12/24 Vdc @ 15 Amperes

These markings can be defined as:


Class I Division 2: Equipment classification (see section 3.1.1)
Groups ABCD:

NEC 500 Gas Groups (see section 3.1.1.1)

Non-Incendive:

Non-incendive wiring protection (FM 3611 standard)

Ta:

Ambient temperature rating for electrical system

Ratings:

12/24 Vdc @ 15 Amperes: Electrical system power


rating

4.4 NEC 505 Markings


The NEC 505 markings are as follows:
Classification:
Protection Method:
Ambient Capability:
Ratings:

Class I Zone 2 Group IIC


nA nR
Ta = 45C
12/24 Vdc @ 15 Amperes

These markings can be defined as:


Class I Zone 2:

Equipment classification (see section 3.1.1)

Group IIC:

NEC 505 Gas group compliance (see section 3.1.1.1.2)

Ta:

Ambient temperature rating for electrical system

nA:

Protection Concept No arcs, sparks, or hot surfaces

nR:

Protection Concept Restricted breathing

Ratings:

12/24 Vdc @ 15 Amperes: Electrical system power


rating

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4.5 CE Marking
The CE mark is required per the ATEX directive 94/9/EC as part of the
conformity assessment procedures for products placed in the European
Union (EU). The mark indicates the product conforms to the provisions of
the relevant Directives i.e. ATEX and Electromagnetic Compatibility. The
marking will typically be found in the vicinity of the engine information
labels. The CE marking will appear as depicted in Figure 4.1.

Figure 4.1

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5 Ratings
Currently, there are two types of ratings for Caterpillar Petroleum Tier 3
Hazardous Location Engines: Derated and Non-Derated.

5.1 Derated Engine Ratings


A derated hazardous location engine will automatically derate maximum
available engine power based on ambient conditions. Derating engine power
is necessary to maintain skin temperature and/or charge air temperature
below the T3 temperature classification.
Derate curves of available power at increasing ambient temperatures are
available in TMI for each derated rating. Maximum ambient temperature
compliance for each engine can be found on PowerNet in the pricelist, and
on the engine certification plate.
NOTE: Derated engine ratings require the customer to install an ambient
temperature sensor. More information and installation considerations are
found in section 7.3 of this guide.

5.2 Non-Derated Engine Ratings


A non-derated engine always follows the standard published performance
curve found in TMI. These engines will only maintain skin temperature and
charge air temperature compliance up to a specified maximum ambient
temperature that will be lower than that of the derated engine. Maximum
ambient temperature capabilities can be found on PowerNet in the pricelist,
and on the engine certification plate.
For applications that require the full power of a non-derated engine but are
required to operate at a higher ambient than the rating is capable of, it is
possible to work with a 3rd party packager to increase the ambient capability
by installing additional components and/or technology.

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6 Servicing Considerations

All servicing of hazardous location engines must be done by a


qualified technician familiar with hazardous locations. Failure to
heed this warning can lead to premature failures, product
damage, personal injury or death.

Exact part numbers must be used when servicing. Not utilizing


exact part numbers bears the risk of voiding hazardous location
certifications. Failure to heed this warning can lead to premature
failures, product damage, personal injury or death.

6.1 Connecting Service Tools


Service tools need to be connected by using a Y connector or a T
harness and never by probing.

Probing into the harness is NOT allowed. Probing into the harness
renders it non-compliant to Hazardous Location directives and
also reduces the ingress protection creating a potential hazard.
Warranty claims associated to harness probing are not honored.
Failure to heed this warning can lead to premature failures,
product damage, personal injury or death.
Any of the following T harness assemblies are acceptable in lieu of
probing into the harness:

125-3662

208-0059

224-9282

257-8718

326-4904

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NOTE: Ensure all maintenance is performed under a suitable permit to work


scheme and/or other locally accepted hazardous location safety practices.
NOTE: Caterpillar service tools and the above harness assemblies are NOT
compliant to hazardous location directives. Appropriate precautions should
be taken when servicing with any non-hazardous location certified diagnostic
equipment while in a hazardous area.

6.2 Electrical Harness Connectors


The electrical connectors on hazardous location engines are specially
designed to meet ATEX directives by requiring the use of a tool to break the
connection.
In order to disconnect electrical connectors, a tool is required to insert into
the release hole. See Figure 6.1 below.

Figure 6.1
NOTE: Any tool that fits into the hole on this connector is suitable to use;
however, a tool without a sharp tip is recommended so as to not damage the
connector.
To disconnect electrical connections (Figure 6.2):
1) Push connectors together to release internal latching forces.
2) Insert tool into latch release hole.
3) Pull connector apart.

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Figure 6.2

6.3 Battery Disconnect


A battery power disconnect should be incorporated to cut all battery power
before performing any service operations on the engine.

No harnesses or electrical connections should be connected OR


disconnected prior to cutting all battery power. Failure to heed
this warning can lead to premature failures, product damage,
personal injury or death.

See section 4.6 of the Electronics Application and Installation Guide,


LEBH4623, for specifics on the installation of a battery disconnect switch.

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7 Customer Requirements
7.1 Wiring Requirements
Caterpillar Petroleum Hazardous Location Engines have several additional
wiring requirements in order to comply with current hazardous location
standards. These are items that will be required by the customer in any
hazardous location installation.
The wiring harness and associated parts must be installed on the engine to
minimize mechanical and thermal stresses. These parts have been designed
to withstand normal engine lubricants and fuels. Special care must be taken
by the end user to ensure the harness and associated parts are not subject to
attack by aggressive substances on the non-metallic parts that could
possibly compromise their integrity.
7.1.1 Battery Circuit Protection
Hazardous location engines require additional circuit protection in addition
to the Caterpillar recommendation for non-hazardous location engines. An
additional 15A breaker for all un-switched battery (+) must be used in
addition to the 10A breaker on each individual input. See Figure 7.1 below, a
modified diagram from the Electronics A&I Guide (LEBH4623) which shows
the 15A circuit breaker addition.

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P1/J1
10 A
10 A
10 A
10 A

Key Switch

ECU

48

Un-switched Battery (+)

52

Un-switched Battery (+)

53

Un-switched Battery (+)

55

Un-switched Battery (+)

70

Switched Battery (+)

61

Un-switched Battery (-)

63

Un-switched Battery (-)

65

Un-switched Battery (-)

69

Un-switched Battery (-)

15 A
Engine
Chassis
Battery

Master Disconnect
Switch

Wiring and Circuit Protection for Hazardous Location Engines


Figure 7.1
7.1.2 Termination of J1 harness
The hazardous location certification provided by Caterpillar for the electrical
system ends prior to the required customer supplied junction box. The J1
harness, supplied by Caterpillar, does not include gas tight seals which may
be required at each conduit end for a given application. It is the customers
responsibility to properly terminate the pigtailed wiring at the customer end
of the J1 harness. Steps must be taken to ensure the wiring installation
meets the sites local hazardous location directives and is appropriate for the
application.
Wiring considerations include, but are not limited to (see Figure 7.2, Figure
7.3, and Figure 7.4):

Gas tight seals in the cabling between safe and hazardous zones

Liquid tight conduits between safe and hazardous zones

Approved junction box

Separation of incendive and non-incendive circuits

Fault current wire

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Customer Interface
Connection

Engine Chassis

Liquid Tight
Connectors

Packager Supplied
Junction Box:

Terminal Rail
Incendive Wiring

Control Harness
Connection

Isolation Shield
ECM

Gas Tight Seal Required

Terminal Rail
Non-Incendive
Wiring
Liquid Tight
Conduit

Gas Tight Seal Required

Liquid Tight Conduit

HAZARDOUS AREA

SAFE AREA

Customer Interface Wiring Zone 2 and Safe Zone


Figure 7.2
Customer Interface
Connection

Engine Chassis

Packager Supplied
Junction Box

Terminal Rail
Incendive Wiring

Control Harness
Connection

Isolation Shield
ECM

Terminal Rail
Non-Incendive Wiring
Liquid Tight
Conduit

Liquid Tight
Connectors

Liquid Tight Conduit

HAZARDOUS AREA

Customer Interface Wiring Zone 2 Only


Figure 7.3

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Bulkhead plate
bolted to ECM
guard

70 pin
connection
to the ECM

1-1/4 liquidtight conduit


Non-incendive
Circuits
(monitoring &
diagnostics)

Incendive
Circuits (mainly
battery power)

Supplied in Interface Kit:

Harness (25 foot)


Conduit
Fittings
Fault Wire

Fault Current
Wire attached
with tie wraps.

Gas Tight Seal

Gas Tight Seal

Customer Interface Kit


Figure 7.4

7.2 Cooling System


7.2.1 System Pressure
Caterpillar Hazardous Location Engine cooling systems require a system
pressure of 20 psi. This requires the customer to use a 20 psi radiator and/or
expansion tank cap.
7.2.2 Mandatory Venting
For Tier 3 C7 and C9 Hazardous Location engines, a vent line must be
installed by the customer that leads from the port at the top of the
turbocharger with a gradual upward slope to a higher point in the system.
Consideration should be taken so that there are no high points in the line to
potentially trap air. An additional port is provided in the T fitting at the top
of the turbocharger for this vent line installation.
NOTE: It is important that this line vents to a pressurized location (20 psi
cap) in order to sustain localized pressure at the top port of the turbocharger.
It is recommended to vent to the radiator top tank.
NOTE: A 0.25 inch inner diameter vent line should be used.
NOTE: Additional venting does not need to be installed on the turbo of the
C32 Hazardous Location engine.

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Application and Installation Guide

Hazardous Location Engines

7.3 Ambient Temperature Sensor


For a derated hazardous location engine, an additional ambient temperature
sensor must be installed for the software to function properly. This sensor is
a ship-loose item with every derated engine.
The sensor must be installed in the intake system between the air cleaner
and turbocharger compressor inlet (Figure 7.5). The bushing used should
have a minimum thread engagement of 10 mm with a maximum boss height
of no more than 15 mm. This is to ensure the sensor is fully immersed into
the intake air flow.
NOTE: A STOR port size of 3/8-24 is required for the ambient temperature
sensor provided by Caterpillar.

Ambient Temperature Sensor Recommendation

7.4 Flame Proof Engine

Figure 7.5

Improper installation of this engine into a package may result in


personal injury or death due to the hazardous environment in
which it is installed. It is ultimately the responsibility of the
packager to ensure that the complete intake system, exhaust
system and all peripherals meet EN 1834-1 and any other
applicable standards for an ATEX compliant installation. Failure
to heed this warning can lead to premature failures, product
damage, personal injury or death.
Such peripherals include but are not limited to:

Flameproof Intake System - The packager is responsible for installing


a Certified intake flame arrestor. The packager must ensure that any
intake system components downstream of the flame arrestor are

2011 Caterpillar
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Hazardous Location Engines

Application and Installation Guide

compliant with EN 1834-1. These components could include the


turbocharger, charge air piping, and charge air cooler.

Flameproof Exhaust System - The packager is responsible for


installing a Certified exhaust flame arrestor. The packager must
ensure that any exhaust system components upstream of the
exhaust flame arrestor are compliant with EN 1834-1. These
components could include the exhaust manifold and turbocharger.

Breather System - The breather system on Caterpillar Petroleum


Hazardous Location Engines is an open system (crankcase to
atmosphere). Flame proofing (flame arrestor) and fume venting is
required.

Oil Level Gauges - The oil gauges also need to be flame proof.

Oil Fillers All oil fillers also need to be flame proof.

Air Shut-offs - Air shut-offs function to protect the engine from


running away - a condition where combustible gasses are ingested
by the engine and can cause an overspeed event even when fuel to
the cylinders has been shut off.

Flame Arrestors - Use of flame arrestors in the intake and breather


systems prevents a possible ignition source initiating from the
engine.

Spark Arrestors - Spark arresting mufflers are used to prevent an


ignition source condition from forming at the exhaust outlet of the
engine.

Separate Circuit Aftercooler Condensation Drain The SCAC


condensation drain that comes standard on SCAC hazardous location
engines, is not certified to be flameproof.

Consultation with a third party packager that specializes in hazardous


location installations is recommended when addressing the above
recommendations.

7.5 Exhaust Gas Cooler


Exhaust gas coolers are yet another mandatory installation requirement per
EN1834.
It is allowable to divert coolant from the jacket water circuit for a gas
cooler. Care must be taken that the cooling system is sized adequately as to
never exceed the max top tank temperature advertised for the engine.
Consideration must also be made for the additional restriction caused by
diverting coolant for a gas cooler. The entire jacket water cooling system
restriction, external to the engine, must lie within the limits of the published
jacket water pump flow curve in order to maintain an adequate flow rate.

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Application and Installation Guide

Hazardous Location Engines

For engines that utilize separate circuit aftercoolers (SCAC), coolant from
this circuit can also be diverted for the gas cooler as long as the aftercooler
coolant inlet design temp is maintained. The external restriction of this circuit
must also lie within the limits of the published SCAC pump curve so as to
maintain adequate flow.

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8 Customer Supplied Attachments


In addition to the components offered by Caterpillar on hazardous location
engines, additional attachments may be required by customers in order to
meet the needs of their application. These attachments could include:

Alternators

Coolant level sensors

Starters

Air compressors

Anti-static belts (see PowerNet for a list of currently available belts


that are certified to ISO 1813 for electrical conductivity of anti-static
belts)

Anti-static fans

Air Shutoffs (see PowerNet for a list of currently available air


shutoffs that are certified to EN 1834-1)

Solenoids

Turbocharger Exhaust Outlet Adapters

Mufflers and other exhaust system components

Throttle positioning sensors/controls

Messenger Display

The customer must ensure that any attachments added to a Caterpillar


Hazardous Location Engine are certified to meet the applicable hazardous
location standards.

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Application and Installation Guide

Hazardous Location Engines

9 Engine Documentation
9.1 EU Declaration of Incorporation
The Declaration of Incorporation (DOI) is available via PowerNet for every
Caterpillar Tier 3 Petroleum Hazardous Location Engine. This document is
required for engines shipped to or within the EU for free movement of goods,
or as requested by a customer order, per the applicable Machinery Safety
Directive, 98/37/EC or 2006/42/EC after December 29, 2009.
NOTE: Machinery Safety compliance is self-assessed by Caterpillar.

9.2 EU Declaration of Conformity


The Declaration of Conformity (DOC) is another document that is available
via PowerNet for every Caterpillar Tier 3 Petroleum Hazardous Location
Engine. This document states compliance to the EU Explosive Atmosphere
(ATEX) Directive 94/9/EC and Electro Magnetic Compatibility Directive (EMC)
2004/108/EC of engine installations into a larger, more complex pieces of
machinery.
NOTE: EMC is self-assessed by Caterpillar.
The ATEX certification for Caterpillar Petroleum Tier 3 Hazardous Location
Engines is 3rd party evaluated and certified. 3rd party certificates are
available for each engine. See Table 9.1 for the applicable 3rd party
certification depending on the region in which the engine will operate.
Certification Bodies by Type and Region
Class I Division 2 / Zone 2
(North America)

ATEX

Type of Certification

Electrical

Electrical

Mechanical

Certifying Body

Factory Mutual (FM)

SIRA

Pyroban /
Intertek

Table 9.1

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