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CATERPILLAR ZoneII Installation
CATERPILLAR ZoneII Installation
HAZARDOUS LOCATION
ENGINES
Tier 3 Petroleum
C9 • C7
Tier 2 Petroleum
C32
Hazardous Location
Engines
Contents
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.
©2011 Caterpillar®
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Application and Installation Guide Hazardous Location Engines
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Hazardous Location Engines Application and Installation Guide
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Application and Installation Guide Hazardous Location Engines
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Hazardous Location Engines Application and Installation Guide
Table 3.1
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Application and Installation Guide Hazardous Location Engines
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Hazardous Location Engines Application and Installation Guide
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
Table 3.2
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Application and Installation Guide Hazardous Location Engines
Table 3.3
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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.
Classification: Ex nA nR IIC T3
Equipment Category: II 3G
Equipment Category: Ex II 3G
Gas Group: IIA
Temperature Class: T3
Ambient Capability: Ta = XX C
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Application and Installation Guide Hazardous Location Engines
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Hazardous Location Engines Application and Installation Guide
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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Application and Installation Guide Hazardous Location Engines
5 Ratings
Currently, there are two types of ratings for Caterpillar Petroleum Tier 3
Hazardous Location Engines: Derated and Non-Derated.
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Hazardous Location Engines Application and Installation Guide
6 Servicing Considerations
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.
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Application and Installation Guide Hazardous Location Engines
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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Hazardous Location Engines Application and Installation Guide
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.
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Application and Installation Guide Hazardous Location Engines
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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Hazardous Location Engines Application and Installation Guide
P1/J1 ECU
15 A
Engine
Chassis
Master Disconnect
Battery Switch
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Application and Installation Guide Hazardous Location Engines
Customer Interface
Engine Chassis Connection
Packager Supplied
Junction Box:
Liquid Tight
Connectors
Terminal Rail –
Incendive Wiring
Control Harness
Connection
Isolation Shield
ECM
Terminal Rail –
Non-Incendive
Wiring
Gas Tight Seal Required
Liquid Tight
Conduit Gas Tight Seal Required
Customer Interface
Engine Chassis Connection
Packager Supplied
Junction Box
Terminal Rail –
HAZARDOUS AREA
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Hazardous Location Engines Application and Installation Guide
Bulkhead plate
70 pin bolted to ECM
connection guard
to the ECM
1-1/4” liquid-
tight conduit
Non-incendive Fault Current
Circuits Wire attached
(monitoring & with tie wraps.
diagnostics)
Incendive
Supplied in Interface Kit: Circuits (mainly
battery power) Gas Tight Seal
• Harness (25 foot)
• Conduit Gas Tight Seal
• Fittings
• Fault Wire
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Application and Installation Guide Hazardous Location Engines
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Hazardous Location Engines Application and Installation Guide
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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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Hazardous Location Engines Application and Installation Guide
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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.
Pyroban /
Certifying Body Factory Mutual (FM) SIRA
Intertek
Table 9.1
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