Instruction Sheet
C503a 12-2003
Installation Instructions for
Bus PT Module Kit 300-4767
GENERAL INFORMATION
WARNING Incorrect installation or parts re-
placement can result in severe personal injury,
death, and/or equipment damage. Service per-
sonnel must be trained and experienced to per-
form electrical and mechanical service.
This kit can be used in the following situations:
• Upgrade the PowerCommand
Control
(PCC) with the PowerCommand Digital Par-
alleling control. Review the installation in-
structions for each kit to become familiar with
the safety precautions and installation proce-
dures before starting. Begin the modification
with Digital Board EPROM kit 300−4721 (In-
struction Sheet C499), followed by Paralleling
Control kit 300−4883 (Instruction Sheet
C514), and then this Bus PT Module kit and
Rail Mount kit 300−4765 (Instruction Sheet
C501) or 300−4766 (Instruction Sheet C502).
• Upgrade a current paralleling generator set
to include an integrated first start sensor
function.
• Replace a failed Bus PT Module.
The primary function of the Bus PT Module is to pro-
vide a synchronizing reference voltage to the PCC
so that a generator set can be safely paralleled to an
energized system bus. The Bus PT transforms the
primary voltage sensed (up to 600 VAC) to a nomi-
nal 18 VAC level required by the control. Higher volt-
age systems are managed by using a PT to drop the
sensing voltage to a level less than 600V, so that the
Bus PT Module can safely sense it. In these situa-
tions, it is especially important that care be taken to
PowerCommand is a registered trademark of Cummins Inc.
make sure that proper phasing of the sensing leads
is maintained.
PowerCommand paralleling generator sets may in-
corporate a 300−4309 Bus PT Module or the
300−4985 Bus PT Module with First Start Sensor in-
cluded in this kit. The 300−4985 module may be
used in systems with 300−4309 modules, simply by
connecting the 300−4985 in the same way as the
existing 300−4309 modules.
The First Start Sensor system prevents simulta-
neous closing of generator set breakers on to a
dead bus during black start conditions.
Note that there are four distinct versions of Bus PT
Modules. The proper module for each application is
determined by the primary side line-to-neutral volt-
age that the module is designed to support. Select a
module suitable for the operating voltage range
where it will be used. The table below lists the oper-
ating voltage range for the four kits covered by this
instruction sheet.
Kit Volts Line-to-Line
300−4767−01 0 − 300V
300−4767−02 301 − 480V
300−4767−03 600V
300−4767−04 Special
The modules normally sense line-to-line voltages
and are applied in 3-phase/4-wire systems. Howev-
er, if a 3-phase/3-wire system is required, the
neutral wire to the control from the Bus PT Mod-
ule must be disconnected.
Page 1 of 14
 FUNCTION AND INTERCONNECTION OF source for the first start logic of the Bus PT Module
THE BUS PT WITH A FIRST START comes from the genset battery.
SENSOR
Black Start Sequence (summary):
The Bus PT Module receives the ready to load sig- 1. Gensets start – Bus PT Modules receive ready
nal from the PCC. The PCC receives the first start to load signals.
signal from the Bus PT Module if the PCC is to be
the first genset to connect to the dead bus. The Bus 2. Bus PT Modules arbitrate to select which unit to
PT Module has inhibit lines which are daisy chained go on-line first.
between the modules. When the modules receive 3. One genset wins arbitration and provides a first
the “ready to load” signals from their PCC controls, start signal to its PCC; other modules are inhib-
the modules arbitrate, using the inhibit line to deter- ited.
mine which unit is allowed to close its breaker. The 4. The PCC that receives the first start signal
Bus PT Module that wins the arbitration activates its closes the breaker; bus is live.
first start output and inhibits all other first start Bus
PT Modules from performing first start commands. Figure 2 shows the physical layout locations for the
One phase of the bus voltage is used by the first I/O on the first start Bus PT Module. The bus voltage
start logic to inhibit operation of the first start func- inputs and outputs are located in the same spot and
tion when bus voltage is present. use the same terminal block connectors in both Bus
PT Module designs. On the 300−4985 module,
Figure 1 is a block diagram showing the inter-mod- there are 2 new terminal blocks that have four posi-
ule connections for paralleling PCC gensets with tions each to provide connections for the first start
the new first start Bus PT Module. The power sensor inputs and outputs.

START

PCC #1 PCC #2 PCC #N

...

4 3 2 1 4 3 2 1 4 3 2 1 4 3 2 1 4 3 2 1 4 3 2 1
INHB INHB INHB INHB RDY 1ST B+ GND INHB INHB INHB INHB RDY 1ST B+ GND INHB INHB INHB INHB RDY 1ST B+ GND
GND GND TO ST GND GND TO ST GND GND TO ST
TB13 LD TB14 TB13 LD TB14 TB13 LD TB14
C− 1 C− 1 C− 1
A39 A39 A39
C+ 2 C+ 2 C+ 2
BUS PT/ BUS PT/ BUS PT/
B− 3 1st START B− 3 1st START B−
1st START 3
MODULE PCC B+ MODULE MODULE
PCC PCC
300−4985 4 300− 4985 B+ 4 300− 4985 B+ 4
A− 5 MODULE #2 A− A−
MODULE #1 5 MODULE #N 5
A+ 6 A+ 6 A+
BUS BUS 6
BUS
A B C N A B C N A B C N
TB2 TB2 TB2
1 2 3 4 1 2 3 4 1 2 3 4
TB1 TB1 TB1

LOAD

FIGURE 1. BLOCK DIAGRAM FOR PARALLELING PCC GENSETS USING BUS PT MODULES WITH FIRST
START SENSOR
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 4 3 2 1 4 3 2 1
If a single module is used and a First Start pulse is
required (i.e. one unit in utility single mode), the
INHB INHB INHB INHB RDY 1ST B+ GND
GND GND TO ST module can be made to generate a First Start pulse
TB13 LD TB14 by connecting a 10k 1/2 watt resistor from TB 14-2
RUNNING
C− 1 to TB13-2 (see Figure ).
CONNECTOR C+ 2
J1 When the genset is in utility single mode, the first
1ST START
B− 3
start input is used for sync enable. In this case,
PCC since the Bus PT Module is not connected to any
B+ 4 other modules, it will never provide a first start sig-
A− 5
nal and shouldn’t interfere with an external sync en-
able signal.
BUS A+ 6
A B C N TB2
TB1 1 2 3 4 10k
RESISTOR
BUS PT/FIRST START MODULE 300−4985
TB13 TB14

FIGURE 2. FIRST START BUS PT MODULE PCB

LAYOUT B+ B+

The Bus PT Module with First Start Sensor also has 4 3 2 1 4 3 2 1

a J1 connector located in the center of the board.
This connector duplicates the connections going to
TB2 and TB14. These are the connections that go
to the control. If the proper connector is in the en-
gine harness, no connections need to be made to
these terminal blocks. Although current production
does not include a harness that can connect to the FIRST START
J1 connector, this connector can be used to simplify MODULE 300−4985
installation with future gensets.

The maximum number of gensets that can be paral-

leled is limited by the Bus PT Module to 24. This limit
is due to the LED current ratings of the opto couplers. TB2
Note that there may be a lower maximum number of
paralleled units allowed if components, other than
the Bus PT Module, are the limiting factor.

There must be at least two powered Bus PT Mod- TB1

ules wired together at the inhibit connections before
one of the Bus PT Modules will produce a first start
signal. If only one Bus PT Module is operational, the FIGURE 3. CONNECTION FOR FIRST START
first start signal will never occur. PULSE USING A SINGLE MODULE

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 INSTALLATION
CAUTION Always disconnect a battery char-
ger from its AC source before disconnecting the
battery cables. Otherwise, disconnecting the
cables can result in voltage spikes high enough
to damage the DC control circuits of the set.
WARNING Accidental starting of the generator
set while working on it can cause severe per-
sonal injury or death. Prevent accidental start-
ing by disconnecting the starting battery cables
(negative [−] first).
Make certain the battery area has been well-ven-
tilated before servicing a battery. Arcing can ig-
nite explosive hydrogen gas given off by batter-
ies, causing severe personal injury. Arcing can
occur when a cable is removed or re-attached,
or when the negative (−) battery cable is con-
nected and a tool used to connect or disconnect
the positive (+) battery cable touches the frame
or other grounded metal part of the set. Always
remove the negative (−) cable first, and recon-
nect it last. Make certain hydrogen from the bat-
tery, engine fuel, and other explosive fumes are
fully dissipated. This is especially important if a
battery has been connected to a battery char-
ger.
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DANGER Hazardous voltage will cause se-
vere personal injury or death. Disconnect all
electrical supply sources before opening the
generator output box, control panels, or per-
forming any service work.
1. Place the genset Start/Stop/Remote switch to
the Stop position.
2. Disconnect the power supply to the battery
charger (if applicable). Remove all electrical
supply sources.
3. Disconnect the generator set starting battery
cable(s). disconnect the negative (−) cable(s)
first to reduce the risk of arcing.
4. Verify that the paralleling breaker is open, and
prevented from closing.
5. Verify that the parallel bus that is the source of
voltage to the Bus PT Module is de-energized,
or the Bus PT Module is effectively isolated.
6. Secure the Bus PT Module to the back of the
accessory box with the four screws provided,
as shown in Figures 4, 5, or 6.
7. Complete the Rail Mount kit (C501 [HC4/5] or
C502 [HC6/7]).
8. Refer to the wiring instructions in C501 or C502
and the customer connection wiring diagrams
at the end of this instruction sheet to complete
the installation.
 BUS PT
MODULE
(A39)

ALTERNATOR
FRAME SIZE
HC4/HC5
ACCESSORY BOX
WRAPPER
(COVER NOT SHOWN)

BUS PT
MODULE

ALTERNATOR
FRAME SIZE
HC6/HC7

FIGURE 4. TYPICAL PCC 3100 ACCESSORY BOX ASSEMBLY

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 BUS PT
MODULE

FIGURE 5. TYPICAL PCC 3200 ACCESSORY BOX ASSEMBLY (8 SLOT CARD CAGE)

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 BUS PT
MODULE

FIGURE 6. TYPICAL PCC 3200 ACCESSORY BOX ASSEMBLY (4 SLOT CARD CAGE)

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 THIS PAGE LEFT INTENTIONALLY BLANK

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 THIS IS A TYPICAL SCHEMATIC/WIRING DIA-
GRAM. FOR WIRING, REFER TO THE SCHE-
MATIC AND WIRING DIAGRAM PACKAGE THAT
WAS SHIPPED WITH YOUR GENERATOR SET.

No. 612-6675 Sh 3 of 3
Rev. D Sys: HP
Modified 8/1997

FIGURE 7. PCC 3100 CUSTOMER WIRING CONNECTIONS

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 THIS IS A TYPICAL SCHEMATIC/WIRING DIA-
GRAM. FOR WIRING, REFER TO THE SCHE-
MATIC AND WIRING DIAGRAM PACKAGE THAT
WAS SHIPPED WITH YOUR GENERATOR SET.

No. 612-6751 Sh 6 of 7
Rev. B Sys: Pro-E
Modified 7/2002

FIGURE 8. PCC 3200 CUSTOMER WIRING CONNECTIONS − 8 SLOT CARD CAGE (SHEET 1 OF 2)
C503a
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 THIS IS A TYPICAL SCHEMATIC/WIRING DIA-
GRAM. FOR WIRING, REFER TO THE SCHE-
MATIC AND WIRING DIAGRAM PACKAGE THAT
WAS SHIPPED WITH YOUR GENERATOR SET.

No. 612-6751 Sh 7 of 7
Rev. B Sys: Pro-E
Modified 7/2002

FIGURE 9. PCC 3200 CUSTOMER WIRING CONNECTIONS − 8 SLOT CARD CAGE (SHEET 2 OF 2)

C503a
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 THIS IS A TYPICAL SCHEMATIC/WIRING DIA-
GRAM. FOR WIRING, REFER TO THE SCHE-
MATIC AND WIRING DIAGRAM PACKAGE THAT
WAS SHIPPED WITH YOUR GENERATOR SET.

No. 630-2592 Sh 5 of 10
Rev. C Sys: Pro-E
Modified 9/2003

FIGURE 10. PCC 3200 CUSTOMER WIRING CONNECTIONS − 4 SLOT CARD CAGE (SHEET 1 OF 3)
C503a
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 THIS IS A TYPICAL SCHEMATIC/WIRING DIA-
GRAM. FOR WIRING, REFER TO THE SCHE-
MATIC AND WIRING DIAGRAM PACKAGE THAT
WAS SHIPPED WITH YOUR GENERATOR SET.

No. 630-2592 Sh 6 of 10
Rev. C Sys: Pro-E
Modified 9/2003

FIGURE 11. PCC 3200 CUSTOMER WIRING CONNECTIONS − 4 SLOT CARD CAGE (SHEET 2 OF 3)

C503a
Page 13 of 14
 THIS IS A TYPICAL SCHEMATIC/WIRING DIA-
GRAM. FOR WIRING, REFER TO THE SCHE-
MATIC AND WIRING DIAGRAM PACKAGE THAT
WAS SHIPPED WITH YOUR GENERATOR SET.

No. 630-2592 Sh 7 of 10
Rev. C Sys: Pro-E
Modified 9/2003

FIGURE 12. PCC 3200 CUSTOMER WIRING CONNECTIONS − 4 SLOT CARD CAGE (SHEET 3 OF 3)
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