Quick Start Wiring Guide for Certain G3300B Gas Compression Engines {1000, 1408, 1451, 1453} Caterpillar

Gas Engine

G3304B (S/N: A4E1-UP)

G3306B (S/N: R6S1-UP)

Introduction

This Special Instruction provides installation tips for Cat^® G3300B gas compression engines utilizing the A4 ECM and the optional Messenger-based customer interfaces.

The Special Instruction is not intended to provide detailed installation information or replace the expertise and engineering judgment of the system designer. The Special Instruction is, intended to complement, do not replace, the Application and Installation guide information and service manuals. Caterpillar acknowledges that specific project parameters may cause deviations from these guidelines. Exceptions to these guidelines are at the discretion of the manufacturer, operator, and owner of the compression package.

Power Connections

A 24 VDC battery positive and negative must be provided to the engine. The connections are different between electric and air starters, as noted below.

Electric Starter (Non-Canadian Standards Association)

Illustration 1	g03896532
(1) Battery (+) 1/2-13-2A stud (2) Battery (-) 1/2-13-2A stud

Air Starter (Canadian Standards Association)

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Illustration 2	g03896540
(3) Recommended hole locations on the sides of the enclosure

1. Punch a hole in the enclosure.

2. Route the power wires in a Canadian Standards Association (CSA) approved conduit.
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   Illustration 3	g03896541
   (4) TB5 (24V -) (5) TB6 (24V +)

3. Connect the 24 V - to the TB5 (4) and connect 24 V + to the TB6 (5).

   • Terminal blocks 5 and 6 wire range: 20 – 6 AWG

   • The wires must be sized to support a maximum current draw of 4 A

   • Caterpillar recommends that the wires be terminated with ferrules

Air Starter (Non-Canadian Standards Association)

Illustration 4	g03896579
(6) Battery (-) (7) Battery (+)

Use 4C-4075 Crimp Tool for crimping the pins and sockets to the wiring.

Basic Wiring

Engine Interface Connector

The G3300B gas compression engine uses a 47-pin MS (mil spec) connector.

Illustration 5	g03896580
Non-CSA engine connector locations (right-hand side view of engine) (8) Catalyst connector (9) Customer connector

Illustration 6	g03896581
CSA engine connector locations (right-hand side view of engine) (8) Catalyst connector (9) Customer connector (10) Ignition connector (11) Service tool connector

Basic Engine Wiring Without Optional Messenger Panel

If a Cat engine interface was not purchased, the circuits highlighted in bold are required for basic engine operation.

Basic Engine Wiring With Optional Messenger Panel

Messenger Options

The Messenger-based customer interface control is offered in three configurations.

1. Messenger Controller – For this option, the customer can mount the controller in their package control panel. The customer is required to provide E-stop, run-start-stop logic, and remote speed control.

2. Messenger Plate – For this option, the customer can mount the preassembled plate on the face of their package control panel. It comes with the messenger control, run, alarm and shutdown lights, e-stop, run-start-stop switch, remote speed potentiometer, idle rated switch, and customer service connector.

3. Messenger Panel – This option offers the Messenger Plate mounted in an enclosure.

   Reference: Operator's Guide, LEMB3227, "Caterpillar^® Messenger Display" at https://engines.cat.com/.

   Reference: Troubleshooting, SENR5002, "Troubleshooting for Marine Engine Electronic Displays"

User-Defined Shutdown (Formally Driven Equipment Ready)

To enable this feature, the factory installed jumper between terminal blocks T11 and T12 must be removed. Then connect the user-defined shutdown signal wire to terminal block T12. For the engine to run, the circuit must be closed to digital return. This method should be used as an intermediate shutdown, as it bypasses the engine cool-down cycle.

Idle/Rated

The T8 is the Idle/Rated input. When the T8 is closed to digital return, T11, the engine will go to the programmed Idle speed. When the T8 is open to digital return, T11, the engine will go to the desired speed requested by the package.

Speed Control (0V to 5V)

Speed is controlled via the 0V to 5V Potentiometer input at terminal T7. The +5V is available on T18. The 5V reference is available on T19.

Reset

A reset is accomplished by placing the mode switch in the 9 o'clock position. This removes keyswitch from the ECM and clears the active codes.

Engine Operation

Starting the Package

• Prepare to Start - Verify that the Driven Equipment Starter Interlock Diagnostic is not active. (Determined from User-Defined Shutdown wiring).

• Start - Place the Engine Operating control switch to RUN. The engine will go through purge cycle, then open the GSOV and start the engine to achieve desired speed.

Stopping the Package

• Normal Stop – Place the Engine Operating switch to the STOP state. Engine will change to the Cooldown cycle and shutdown after the Cooldown cycle is complete by closing the Gas Shutoff Valve.

• User-Defined Shutdown - (Determined from User-Defined Shutdown wiring) Engine bypasses Cool-down cycle, and goes immediately to stopping state. GSOV closes immediately.

• Emergency Stop - SHOULD BE USED IN EMERGENCY SITUATIONS ONLY to prevent damage to the engine and connected components. Gas Shutoff Valve and Fuel/Throttle valves close. Ignition is disabled.

PL641 Environmental Information

Elite-System

When the Elite system is added to the G3306, a Gen 2 Radio and PLE Network Manager are placed on the engine to transmit diagnostic codes, event codes, engine parameters, GPS location, and Compressor data to the back office. The hardware consists of a Gen 2 Radio, Radio Harness, A5N2 ECM, Radio and ECM Bracket, and mounting hardware. Refer to REHS8850 for additional installation information.

Illustration 7	g06093865
(1) A-C19

For the G3306 (Non-CSA), the Elite harness plugs into the Product Link Connection (A-C19) off the main engine harness.

Illustration 8	g06093873
(2) Product Link Connector

For the G3306 (CSA), the Elite harness plugs into the Product Link Connector on the ECM box.

There are several connection points off the Elite harness shown below:

Illustration 9	g06093878
(3) Service Tool Connector (4) Radio Disable Switch Connector (5) TCP/IP Modbus Interface Connector (6) RS485/RS232 Modbus Interface Connector (7) Power Interconnect Connector

Illustration 10	g03402798
425-6889 Cable As (Optional service tool)

• The service connector is used if the Network Manager needs updated with the latest firmware. Cat^® Electronic Technician (Cat ET) has to be used in combination with the service cable, 425-6889 Cable As, to complete the flashing of the Network Manager.

Illustration 11	g03261220
353-4515 Toggle Switch (Radio disable switch)

• The radio disable connector can be used if the customer requires the radio to be disabled during certain operating conditions. The harness is shipped with a jumper installed, but a switch can be ordered to plug into this connection. This switch will remove Battery Power from the Radio.

Illustration 12	g06093903

Illustration 13	g06093955

• The Power Interconnect Connection contained in the Radio harness provides a means of connecting a separate battery source up to the Radio so it doesn’t drain the battery used for the engine. As shipped from the factory, 24 volt battery is pulled from the engine harness along with the 24 volt key switch input. To supply an additional power supply input to the radio, disconnect the two connectors from each other and leave the engine side connector unconnected while supplying a new connector with power feeds into the radio side.

Illustration 14	g06093959

• The TCP/IP Modbus Interface Connector provides a way for connecting to customer controls through Modbus. This connection provides translated Modbus data from the engine to the compressor controls and also from compressor controls back to the product link module for display in the back office. Refer to REHS9763 for additional information for configuring Modbus.

Illustration 15	g06093965

• The RS485/RS232 Modbus Interface Connector provides a way for connecting to customer controls through Modbus. This connection provides translated Modbus data from the engine to the compressor controls and also from compressor controls back to the product link module for display in the back office. Refer to , REHS9763 for additional information for configuring Modbus.

Illustration 16	g03582550
443-8463 Antenna As (Adhesive mount external antenna for cellular and satellite radios)

Note: Installations of the adhesive mount external antenna will have difficulty acquiring the proper adhesive properties when both the antenna and the mounting surface are below certain temperatures. For installations on a metal surface, temperatures under −6.67° C (20° F) will cause improper adhesion. For installations on a non-metallic surface, temperatures under −1.11° C (30° F) will cause improper adhesion. It is necessary to increase the temperature of the adhesive mount external antenna, and the mounting surface prior to installation. Apply direct force until the adhesive mount antenna can hold on its own. Full adhesion can take over 24 hours in colder climate.

1. When using thePL641 radio with an external antenna, the antenna must be located more than 200 mm (7.87 inch) from the machine operator to comply with FCC regulations for RF human body safety. If the PL631 Satellite antenna radio is used the distance from the machine operator increases to 500 mm.

2. When installing a cellular radio with external antenna, ensure the external antenna, is mounted a minimum of 250 mm (9.84 inch) away from any metal structures that extend above the mounting plane. Any metal obstruction for the radio will create diminished cellular and GPS connectivity.

3. When using the PL641 radio with external antenna, the external antenna must be mounted in a horizontal orientation on a flat surface.

4. The radio or antenna needs to have a clear line of sight of the sky. Usually, the canopy/container roof will provide an optimal view of the sky with minimal blockages.

5. To utilize the GPS Signal, the cellular radio or antenna may be mounted under a non-metallic cover, but not a metallic one.

6. Do not mount the radio or antenna in an area that will expose the radio or antenna to extreme conditions of heat. Exposure to high heat may make the radio or antenna inoperable. Refer to Table 5.

7. Locate the radio and antenna so that the radio and antenna connectors are not exposed to high-pressure spray or underwater immersion. Exposure to high-pressure spray or underwater immersion may compromise the connector seals and lead to connection failure.

8. Mount the antennas more than 1000 mm (39.370 inch) from radiation sources of similar frequencies and more than 250 mm (9.84 inch) from radiation sources of other parts of the spectrum. The lists of radio antennas to maintain a distance from include the citizen band radio, data radio, and commercial communication radios.

9. Keep in mind the routing of the radio and antenna cable. Route the cable such that the cable is not subject to abrasion or pinching. Do not route the cable near any source of extreme heat (exhaust). Do not mount the cable so that the limitations of temperature −40° C (−40.00° F) and 85° C (185.00° F) are exceeded.

10. The coax leads between the Product Link radio and the external antenna should not exceed 4.5 m (14.76 ft).

11. Route the coax antenna cable with a minimum bend radius of 49.5 mm (1.94 inch). Bend radius depends on the type of cable used. Do not bend the radius any less than ten times the diameter of the cable. The Antenna and extension coax should not be bundled with or routed right next to any power cable lengths having any Beacon, HID, or other noisy electrical source.

12. Locate a clean dry location where the external antenna can be mounted horizontally with clear line of site to the sky.

    Note: Ensure that the cable length of the external antenna is long enough to reach to the mounted location of the PL641 cellular radio.

13. Install the antenna.

    • Remove the adhesive cover tab on the back of the 443-8463 Antenna As. This will expose the adhesive mounting surface of the external antenna. Apply the adhesive surface to the previously chosen clean dry surface.

    Note: For antennas requiring an isolation mount refer to "Isolated Hard Mount Antenna Installation".

14. Connect the coax cables to the external antenna and the PL641 cellular radio.

15. When using a dual-mode external antenna, that has cellular and satellite connections, it is possible to connect the antenna backwards. Ensure that the coax cable with the image of the cellular tower is connected to the cellular radio. The coax wire color will be brown for cellular and white for satellite. If the external antenna is hooked up incorrectly, an event will become active.

Illustration 17	g03356592

Install the warning film in a location such as the dash or control panel. Ensure that the warning film is clearly visible to the operator during the normal operation of the equipment.

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This equipment is equipped with a Cat® Product Link communication device. When electric detonators are being used for blasting operations, radio frequency devices can cause interference with electric detonators for blasting operations which can result in serious injury or death. The Product Link communication device should be deactivated within the distance mandated under all applicable national or local regulatory requirements. In the absence of any regulatory requirements Caterpillar recommends the end user perform their own risk assessment to determine safe operating distance.

The blast site is defined as the area that handles explosive material during loading. Included is the perimeter that is formed by the loaded blast holes.

If required, the following are suggested methods to disable the Caterpillar Product Link communication device:

• Turn the Product Link radio disable switch to the "OFF" position.

• Disconnect the Caterpillar Product Link communication device from the main power source. This action is performed by disconnecting the wiring harness at the Product Link radio.

Note: If no radio disable switch is installed and the equipment will be operating near a blast zone, a radio disable switch may be installed. The switch will allow the Caterpillar Product Link communication device to be shut off by the operator from the equipment control panel. Refer to Special Instruction, REHS7339, Special Instruction, REHS8850, Special Instruction, REHS9111, and Special Instruction, REHS9757 for more details and installation instructions.