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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

..................1 EU Declaration of Incorporation .................... 12 6............................................... 18 7........................................................ 15 7...................3 Ambient Temperature Sensor . 20 8 Customer Supplied Attachments .......1............. 18 7............ 16 7.. 23 9....................................................2........ 15 7...............................4 Flame Proof Engine ....... 23 9..............................................2 Electrical Harness Connectors ..1................1 System Pressure .............. 19 7.................5 Exhaust Gas Cooler ............ 19 7..1 Wiring Requirements .................................1 Battery Circuit Protection ....... 14 7 Customer Requirements ................3 Battery Disconnect .2 Cooling System ...2............................................. 15 7............................... 12 6.....2 Mandatory Venting ..................2 Termination of J1 harness ...........6 Servicing Considerations ..2 EU Declaration of Conformity ................................................. 23 ..................... 18 7. 13 6..................................... 22 9 Engine Documentation ............1 Connecting Service Tools.....................

Additional engine systems. Engine-specific information and data are available from a variety of sources. CATERPILLAR. Materials and specifications are subject to change without notice. CAT. and/or its subsidiaries. ©2011 Caterpillar® All rights reserved. Contact the Application Support Center (ASC) for the latest information on future Hazardous location feature release dates. Information contained in this publication may be considered confidential. and any use except that for which it is loaned is prohibited. The information in this document is the property of Caterpillar Inc. Systems and components described in this guide may not be available or applicable for every engine. components and dynamics are addressed in other sections of this Application and Installation Guide. as well as corporate and product identity used herein. Refer to the Introduction section of this guide for additional references. . any copying. transmission to others. Without written permission. their respective logos and “Caterpillar Yellow”. are trademarks of Caterpillar and may not be used without permission.Foreword This section of the Application and Installation Guide generally describes hazardous location engines for Caterpillar® engines listed on the cover of this section. Discretion is recommended when distributing.

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maintenance and repair are caused by failure to observe basic safety rules or precautions. The meaning of this safety alert symbol is as follows: Attention! Become Alert! Your Safety is Involved. Safety precautions and warnings are provided in this manual and on the product. lubrication. The Safety Alert “WARNING” label is shown below. A person must be alert to potential hazards. If these hazard warnings are not heeded. maintenance or repair of this product can be dangerous and could result in injury or death.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. bodily injury or death could occur to you or to other persons. maintenance or repair on this product. any copying. until you have read and understood the operation. maintenance and repair information. The information in this document is the property of Caterpillar Inc. and/or its subsidiaries. This person should also have the necessary training. Improper operation. transmission to others. The message that appears under the warning explains the hazard and can be either written or pictorially presented. lubrication. An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs. and C32 (EPA Tier 2). Page 1 . Without written permission. The hazards are identified by the “Safety Alert Symbol” and followed by a “Signal Word” such as “DANGER”. Do not operate or perform any lubrication. “WARNING” or “CAUTION”. skills and tools to perform these functions properly. and any use except that for which it is loaned is prohibited. C9. ©2011 Caterpillar® All rights reserved. 2 Important Safety Information Most accidents that involve product operation. Contact the Application Support Center (ASC) for the latest information on future Hazardous location feature release dates.

illustrations. The specifications. The warnings in this publication and on the product are. Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard. torques. work method or operating technique that is not specifically recommended by Caterpillar is used. not all inclusive. therefore. The information. . lubrication. pressures. Caterpillar dealers have the most current information available. measurements. If a tool. maintenance or repair procedures that you choose. and other items can change at any time. and illustrations in this publication are on the basis of information that was available at the time that the publication was written. Page 2 ©2011 Caterpillar® All rights reserved. You should also ensure that the product will not be damaged or be made unsafe by the operation. specifications. These changes can affect the service that is given to the product. procedure. Obtain the complete and most current information before you start any job. you must satisfy yourself that it is safe for you and for others.Hazardous Location Engines Application and Installation Guide Operations that may cause product damage are identified by “NOTICE” labels on the product and in this publication. adjustments.

Page 3 . 3G environments (Zone 2) with Gas Group IIA. As defined by standard NEC 500. Class II. Caterpillar Tier 3 Petroleum Hazardous Location Engines are assessed and certified by Factory Mutual (FM) to meet this standard. vapors. and ATEX Directive (94/9/EC) Group II. processed.1 Caterpillar Hazardous Location Engine Compliance Caterpillar Tier 3 Petroleum Hazardous Location Engines are certified for use in Class I Division 2 (NEC 500). 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 used. Neither Class II or Class III are covered in this guide. and Class III.1. or combustible liquid-produced vapors can exist under normal operating ©2011 Caterpillar® All rights reserved. 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. The electrical system of the aforementioned engines also meets the following ratings: Ingress Protection = IP56 Ambient = -20°C < Ta < +45°C Zone = 2 (3G) Gas Group = IIC (ATEX and NEC 505). Class I Zone 2 (NEC 505). a Class I Division 2 location is one in which flammable gases. vapors. 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 combustible liquid-produced vapors are handled. flammable liquid-produced vapors.Application and Installation Guide Hazardous Location Engines 3 Hazardous Location Terms & Compliance 3. or that is adjacent to a Class I Division 1 location. but in which the liquids. or liquids. Class II is defined for combustible dusts. Caterpillar Tier 3 Petroleum Hazardous Location Engines are Class I. ABCD (NEC 500) Temperature Class = T3 3. A Class I Division 1 location is defined as a location in which ignitable concentrations of flammable gases. Class I is for equipment in environments containing flammable gases. The standard places equipment into three basic categories: Class I. flammable liquid-produced vapors.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. and Temperature Class T3. and Class III for combustible fibers.

Division 1 Class I Division 2 Shaded area represents Caterpillar Hazardous Location Engine Compliance. .Hazardous Location Engines Application and Installation Guide conditions. Division 1 equipment can be further divided into Zone 0 and Zone 1 equipment.1 below. North American Area Classifications Class Division (NEC 500) Zone (NEC 505) Description Zone 0 A zone where ignitable concentrations of flammable gases. NOTE: Caterpillar does not offer Class I Division 1 engines or components on its current Tier 3 Petroleum Hazardous Location platforms. 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. or liquids are not likely to exist under normal operating conditions. or liquids are likely to exist under normal operating conditions Zone 2 A zone where ignitable concentrations of flammable gases. vapors. Class I Division 2 and Class I Zone 2 terminology indicate the same location classification.1 Page 4 ©2011 Caterpillar® All rights reserved. Table 3. See Table 3. 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. Class I Zone 2 (NEC 505) terminology is very similar to the Class I Division 2 classification. As such. vapors. except that when using the “Zone X” terminology. 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.

Application and Installation Guide Hazardous Location Engines 3.2. nButane. Group I is for mining equipment and is not covered in this guide. 3. Ethane. Below is a description of each of these gas groups.1. Aircraft fuel. A. Methanol. Diesel fuel. Aircraft fuel. n-Hexane. Ethyl ethanoate. Propane. and IIC.1. Below is a description of each of these gas groups. Benzol (pure). C. 3. n-Butyl alcohol. i-Amyl acetate. Group B: Atmospheres that contain hydrogen. IIA. Diesel fuel.2 ATEX Directive Compliance The ATEX directive is a European standard that considers both electrical and mechanical hazards. and D. Caterpillar’s Tier 3 Petroleum Hazardous Location Engines are assessed and certified by third parties to meet this directive. Benzine. IIB + Hydrogen. Toluene. liquid. Ammonia. and Temperature Class T3. IIB. Toluene. Page 5 . 3. IIB (same as Group C from NEC 500): Atmospheres that contain coal gas (lighting gas) or ethylene. Group I and Group II. IIB + Hydrogen (same as Group B from NEC 500): Atmospheres that contain ethylene and/or hydrogen. Group C: Atmospheres that contain coal gas (lighting gas) or ethylene. nHexane. Heating oils.1. Benzine. Methane. Ethanol. ©2011 Caterpillar® All rights reserved.1. Ethanoic acid. Ethanoic acid. IIC (same as Group A from NEC 500): Atmospheres that contain acetylene. Heating oils. 3G (Zone 2) environments with Gas Group IIA. Methane. Propane.2 NEC 505 Caterpillar Tier 3 Petroleum Hazardous Location Engines comply with all of the NEC 505 gas groups up to T3 temperature class. Ammonia. ATEX compliance is comprised of several different categories. Caterpillar’s Tier 3 Petroleum Hazardous Location Engines are certified for ATEX Directive 94/9/EC Group II. Ethyl ethanoate. Group D: Atmospheres that contain Acetone. Methanol. i-Amyl acetate. Group A: Atmospheres that contain acetylene.1.1. Benzol (pure).1. Carbon oxide.1 NEC 500 Caterpillar Tier 3 Petroleum Hazardous Location Engines comply with all of the NEC 500 gas groups up to T3 temperature class.1 NEC 500 and NEC 505 Gas Groups The NEC 500 and NEC 505 gas groups are divided by the type of explosive gas.1. n-Butane. Carbon oxide. IIA (same as Group D from NEC 500): Atmospheres that contain Acetone. or vapor that may be present in the environment. 3.1. Ethanol. Ethane.1 Group II. n-Butyl alcohol. B. 3G (Zone 2) Environments The ATEX directive is comprised of two machinery groups.1.

. Page 6 ©2011 Caterpillar® All rights reserved. ATEX Group II Equipment Group Equipment Category 1 Group II 2 3 Zone Gas 0 1 2 Environmental Conditions Dust 20 Explosive atmospheric conditions always present. (Typical 10-1000 hr/yr) 22 Explosive atmosphere is not likely to occur during normal operation. 3. These groups are defined as follows: Group IIA: Atmospheres containing acetone. vapors. The terms 3G and Zone 2 are synonymous. (<10 hr/yr) Shaded area Applicable to Caterpillar Hazardous Location Engines. propane. or combustible liquid-produced vapor mixed with air that may burn or explode.1.2 As is the case in the North American region. A description of Group II can be seen in Table 3. The letter indicates the type of explosive environment. or flammable gas. ammonia. and liquids are separated into three different groups.2. equipment Categories (and Zones) in Europe are divided by how frequently or likely an explosive atmospheric condition will exist. Using the terminology Zone 2 automatically defines the piece of equipment as Category 3 for environments with potentially explosive gases. methane. gasoline. vapors. ethyl alcohol. or will occur infrequently and for short time periods.2 ATEX Gas Groups Flammable gases. Groups IIA.Hazardous Location Engines Application and Installation Guide Any hazardous location equipment that is not used for mining (Group I) is classified under Group II. or present for long periods of time (Typical >1000 hr/yr) 21 Explosive atmospheric conditions are likely to occur during normal operation. vapors. Table 3.2 below. or liquids) and “D” indicates dust. IIB. “G” indicates a gaseous environment (gases. or liquids. flammable liquidproduced vapor. and IIC.

Table 3. Page 7 . liquids.2. ethylene. 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. hydrogen. 3. This is an important rating because different substances have different temperatures at which they become autoignitable.Application and Installation Guide Hazardous Location Engines Group IIB: Atmospheres containing acetaldehyde. liquids.1. 2 ATEX Temp. or flammable gases. or vapors mixed with air that may burn or explode.3 below shows the temperature classes of both the North American and European standards. Group IIC: Atmospheres containing acetylene.3 Temperature Classes The temperature class is the maximum temperature any surface of the piece of equipment can reach.3 ©2011 Caterpillar® All rights reserved. Table 3. Temperature Classes Class I Division 1. or vapors mixed with air that may burn or explode. Class Temp. Limit Temp. Class Temp. or flammable gases.

sparks.1. 4.2.2.2.2.2) T3: Temperature rating (see section 3.2.1) 3G: Equipment category and atmosphere type (see section 3.1) IIA: Gas group compliance (see section 3.2 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. .3) Page 8 ©2011 Caterpillar® All rights reserved.1.3) nA: Protection concept – No arcs.1.2.1.Hazardous Location Engines Application and Installation Guide 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.1.1.1.2) Ta: Ambient capability of mechanical certification (see engine specific documentation) T3: Temperature rating (see section 3.1) IIC: Gas group compliance (see section 3.1) 3G: Equipment category and atmosphere type (see section 3.2.2. or hot surfaces (EN/IEC 6007915 standard) nR: Protection concept – Restricted breathing to control flammable gases (EN/IEC 60079-15 standard) 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.

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. sparks. Page 9 .1) Groups ABCD: NEC 500 Gas Groups (see section 3. or hot surfaces nR: Protection Concept – Restricted breathing Ratings: 12/24 Vdc @ 15 Amperes: Electrical system power rating ©2011 Caterpillar® All rights reserved.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 3.3 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.Application and Installation Guide Hazardous Location Engines 4.1.1.1.1.2) Ta: Ambient temperature rating for electrical system nA: Protection Concept – No arcs.1) Group IIC: NEC 505 Gas group compliance (see section 3.

The CE marking will appear as depicted in Figure 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).Hazardous Location Engines Application and Installation Guide 4. ATEX and Electromagnetic Compatibility. Figure 4.e. The marking will typically be found in the vicinity of the engine information labels.1. .1 Page 10 ©2011 Caterpillar® All rights reserved. The mark indicates the product conforms to the provisions of the relevant Directives i.

Derating engine power is necessary to maintain skin temperature and/or charge air temperature below the T3 temperature classification. 5. Maximum ambient temperature capabilities can be found on PowerNet in the pricelist.Application and Installation Guide Hazardous Location Engines 5 Ratings Currently. 5. More information and installation considerations are found in section 7. it is possible to work with a 3rd party packager to increase the ambient capability by installing additional components and/or technology. Page 11 . NOTE: Derated engine ratings require the customer to install an ambient temperature sensor. and on the engine certification plate.1 Derated Engine Ratings A derated hazardous location engine will automatically derate maximum available engine power based on ambient conditions.3 of this guide. Derate curves of available power at increasing ambient temperatures are available in TMI for each derated rating. 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. Maximum ambient temperature compliance for each engine can be found on PowerNet in the pricelist.2 Non-Derated Engine Ratings A non-derated engine always follows the standard published performance curve found in TMI. ©2011 Caterpillar® All rights reserved. and on the engine certification plate. there are two types of ratings for Caterpillar Petroleum Tier 3 Hazardous Location Engines: Derated and Non-Derated. 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.

Hazardous Location Engines Application and Installation Guide 6 Servicing Considerations All servicing of hazardous location engines must be done by a qualified technician familiar with hazardous locations.1 Connecting Service Tools Service tools need to be connected by using a “Y” connector or a “T” harness and never by probing. Warranty claims associated to harness probing are not honored. . personal injury or death. Not utilizing exact part numbers bears the risk of voiding hazardous location certifications. product damage. 6. personal injury or death. Failure to heed this warning can lead to premature failures. personal injury or death. product damage. Probing into the harness renders it non-compliant to Hazardous Location directives and also reduces the ingress protection – creating a potential hazard. Failure to heed this warning can lead to premature failures. Failure to heed this warning can lead to premature failures. product damage. 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 Page 12 ©2011 Caterpillar® All rights reserved. Exact part numbers must be used when servicing. Probing into the harness is NOT allowed.

1 below. 6. however. 3) Pull connector apart. NOTE: Caterpillar service tools and the above harness assemblies are NOT compliant to hazardous location directives. a tool without a sharp tip is recommended so as to not damage the connector. a tool is required to insert into the release hole. Appropriate precautions should be taken when servicing with any non-hazardous location certified diagnostic equipment while in a hazardous area. 2) Insert tool into latch release hole. See Figure 6.2): 1) Push connectors together to release internal latching forces.Application and Installation Guide Hazardous Location Engines NOTE: Ensure all maintenance is performed under a suitable permit to work scheme and/or other locally accepted hazardous location safety practices.1 NOTE: Any tool that fits into the hole on this connector is suitable to use.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. Figure 6. To disconnect electrical connections (Figure 6. In order to disconnect electrical connectors. Page 13 . ©2011 Caterpillar® All rights reserved.

No harnesses or electrical connections should be connected OR disconnected prior to cutting all battery power.6 of the Electronics Application and Installation Guide. Failure to heed this warning can lead to premature failures. Page 14 ©2011 Caterpillar® All rights reserved. for specifics on the installation of a battery disconnect switch. . product damage. See section 4.2 6. LEBH4623.Hazardous Location Engines Application and Installation Guide Figure 6.3 Battery Disconnect A battery power disconnect should be incorporated to cut all battery power before performing any service operations on the engine. personal injury or death.

An additional 15A breaker for all un-switched battery (+) must be used in addition to the 10A breaker on each individual input. 7.1 Wiring Requirements Caterpillar Petroleum Hazardous Location Engines have several additional wiring requirements in order to comply with current hazardous location standards.1 below. 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. These parts have been designed to withstand normal engine lubricants and fuels.1. These are items that will be required by the customer in any hazardous location installation. ©2011 Caterpillar® All rights reserved. The wiring harness and associated parts must be installed on the engine to minimize mechanical and thermal stresses. See Figure 7.Application and Installation Guide Hazardous Location Engines 7 Customer Requirements 7.1 Battery Circuit Protection Hazardous location engines require additional circuit protection in addition to the Caterpillar recommendation for non-hazardous location engines. a modified diagram from the Electronics A&I Guide (LEBH4623) which shows the 15A circuit breaker addition. Page 15 .

and Figure 7.2 Termination of J1 harness The hazardous location certification provided by Caterpillar for the electrical system ends prior to the required customer supplied junction box.1 7. does not include gas tight seals which may be required at each conduit end for a given application.1. Steps must be taken to ensure the wiring installation meets the site’s local hazardous location directives and is appropriate for the application. Figure 7.3. The J1 harness. but are not limited to (see Figure 7. . It is the customer’s responsibility to properly terminate the pigtailed wiring at the customer end of the J1 harness.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 Page 16 ©2011 Caterpillar® All rights reserved. Wiring considerations include.2. supplied by Caterpillar.Hazardous Location Engines Application and Installation Guide 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.

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.Application and Installation Guide Hazardous Location Engines 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 7.3 ©2011 Caterpillar® All rights reserved. Page 17 .

2 Cooling System 7.25 inch inner diameter vent line should be used.2.1 System Pressure Caterpillar Hazardous Location Engine cooling systems require a system pressure of 20 psi.2 Mandatory Venting For Tier 3 C7 and C9 Hazardous Location engines. Gas Tight Seal Gas Tight Seal Customer Interface Kit Figure 7. This requires the customer to use a 20 psi radiator and/or expansion tank cap. 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. NOTE: A 0. 7. It is recommended to vent to the radiator top tank.Hazardous Location Engines Application and Installation Guide 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. 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.2. NOTE: Additional venting does not need to be installed on the turbo of the C32 Hazardous Location engine. 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.4 7. . Page 18 ©2011 Caterpillar® All rights reserved.

personal injury or death. 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. NOTE: A STOR port size of 3/8-24 is required for the ambient temperature sensor provided by Caterpillar. Such peripherals include but are not limited to:  Flameproof Intake System . The bushing used should have a minimum thread engagement of 10 mm with a maximum boss height of no more than 15 mm. The sensor must be installed in the intake system between the air cleaner and turbocharger compressor inlet (Figure 7. This is to ensure the sensor is fully immersed into the intake air flow. Page 19 . Ambient Temperature Sensor Recommendation 7. 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 packager must ensure that any intake system components downstream of the flame arrestor are ©2011 Caterpillar® All rights reserved.Application and Installation Guide Hazardous Location Engines 7.4 Flame Proof Engine Figure 7. It is ultimately the responsibility of the packager to ensure that the complete intake system. product damage.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.3 Ambient Temperature Sensor For a derated hazardous location engine.5).The packager is responsible for installing a Certified intake flame arrestor.

Hazardous Location Engines Application and Installation Guide compliant with EN 1834-1.  Oil Fillers – All oil fillers also need to be flame proof.Use of flame arrestors in the intake and breather systems prevents a possible ignition source initiating from the engine. external to the engine.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. is not certified to be flameproof. Consideration must also be made for the additional restriction caused by diverting coolant for a gas cooler. These components could include the turbocharger.Air shut-offs function to protect the engine from “running away” .The oil gauges also need to be flame proof. and charge air cooler.  Flameproof Exhaust System .  Air Shut-offs . The entire jacket water cooling system restriction. 7. Care must be taken that the cooling system is sized adequately as to never exceed the max top tank temperature advertised for the engine. It is allowable to divert coolant from the jacket water circuit for a gas cooler. The packager must ensure that any exhaust system components upstream of the exhaust flame arrestor are compliant with EN 1834-1.  Separate Circuit Aftercooler Condensation Drain – The SCAC condensation drain that comes standard on SCAC hazardous location engines. Page 20 ©2011 Caterpillar® All rights reserved. Consultation with a third party packager that specializes in hazardous location installations is recommended when addressing the above recommendations. must lie within the limits of the published jacket water pump flow curve in order to maintain an adequate flow rate.  Oil Level Gauges . Flame proofing (flame arrestor) and fume venting is required.5 Exhaust Gas Cooler Exhaust gas coolers are yet another mandatory installation requirement per EN1834.  Breather System . These components could include the exhaust manifold and turbocharger.Spark arresting mufflers are used to prevent an ignition source condition from forming at the exhaust outlet of the engine. .  Flame Arrestors . charge air piping.The packager is responsible for installing a Certified exhaust flame arrestor.  Spark Arrestors .The breather system on Caterpillar Petroleum Hazardous Location Engines is an open system (crankcase to atmosphere).

The external restriction of this circuit must also lie within the limits of the published SCAC pump curve so as to maintain adequate flow. ©2011 Caterpillar® All rights reserved.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. Page 21 .

. additional attachments may be required by customers in order to meet the needs of their application.Hazardous Location Engines Application and Installation Guide 8 Customer Supplied Attachments In addition to the components offered by Caterpillar on hazardous location engines. 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. Page 22 ©2011 Caterpillar® All rights reserved.

per the applicable Machinery Safety Directive. This document is required for engines shipped to or within the EU for free movement of goods.1 for the applicable 3rd party certification depending on the region in which the engine will operate. NOTE: Machinery Safety compliance is self-assessed by Caterpillar. more complex pieces of machinery. 3rd party certificates are available for each engine. 98/37/EC or 2006/42/EC after December 29.2 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. or as requested by a customer order. NOTE: EMC is self-assessed by Caterpillar.Application and Installation Guide Hazardous Location Engines 9 Engine Documentation 9. 2009.1 EU Declaration of Incorporation The Declaration of Incorporation (DOI) is available via PowerNet for every Caterpillar Tier 3 Petroleum Hazardous Location Engine. 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. Page 23 .1 ©2011 Caterpillar® All rights reserved. The ATEX certification for Caterpillar Petroleum Tier 3 Hazardous Location Engines is 3rd party evaluated and certified. See Table 9. 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. 9.

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A. .S.LEBW0003-01 ©2011 Caterpillar® Printed in U. All rights reserved.