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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
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.
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Zone =
2 (3G)
Gas Group =
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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Division
(NEC 500)
Zone
(NEC 505)
Description
Zone 0
Zone 1
Zone 2
Division 1
Class I
Division 2
Table 3.1
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Group B:
Group C:
Group D:
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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
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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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
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.
Ex nA nR IIC T3
II 3G
II:
T3:
nA: Protection concept No arcs, sparks, or hot surfaces (EN/IEC 6007915 standard)
nR:
Ex II 3G
IIA
T3
Ta = XX C
II:
Ta:
T3:
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Non-Incendive:
Ta:
Ratings:
Group IIC:
Ta:
nA:
nR:
Ratings:
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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.
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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.
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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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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Page 13
Figure 6.2
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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
52
53
55
70
61
63
65
69
15 A
Engine
Chassis
Battery
Master Disconnect
Switch
Gas tight seals in the cabling between safe and hazardous zones
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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
Terminal Rail
Non-Incendive
Wiring
Liquid Tight
Conduit
HAZARDOUS AREA
SAFE AREA
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
HAZARDOUS AREA
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Bulkhead plate
bolted to ECM
guard
70 pin
connection
to the ECM
Incendive
Circuits (mainly
battery power)
Fault Current
Wire attached
with tie wraps.
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Figure 7.5
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Oil Level Gauges - The oil gauges also need to be flame proof.
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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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Page 21
Alternators
Starters
Air compressors
Anti-static fans
Solenoids
Messenger Display
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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.
ATEX
Type of Certification
Electrical
Electrical
Mechanical
Certifying Body
SIRA
Pyroban /
Intertek
Table 9.1
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LEBW0003-01
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