GAC IGC700 Series User manual

Governors America Corp. 720 Silver St. Agawam, MA 01001
Tel: [phone] Fax: [phone]
http://www.governors-america.com
E-mail: [e-mail]
E
NGINE
GOVERNING
SYSTEMS
Integrated Engine Governor and Protection Control for
Constant or Variable Speed Applications.
Remote Starting with Battery System Monitor.
Ten Discrete, User Configurable Signal Sensor Inputs.
Three Contacts for Starter Motor, Fuel Valve or Solenoid
Output and Alarm or PreHeat Output.
Small size for In-panel Mounting (96mm * 96mm).
INTRODUCTION
The IGC700 is a highly configurable, compact, panel
mounted module designed for the control and protection of
diesel and spark ignited engines. This integrated speed
control system is a high performance multi-functional
isochronous digital speed control. The governor function can
be used for wide range variable speed (Pumps, Hydraulic
system, Sweepers, etc.) applications or constant speed
Generator Sets. The front panel keypad allows direct settings
and security without need of a laptop or special software.
Customized firmware can also be downloaded into the flash
memory with a laptop or via a Down Load Module (DLM)
available from GAC. Integrated “Start” and “Stop” buttons
provide manual control and shutdown supervision with
additional security. The monitoring and protection capability
of the IGC700 includes inputs for up to 10 sensors, all of
which are setup through the front panel keypad. Oil
Pressure, Engine Coolant Temperature and Charge Level are
dedicated standard inputs, which can be configured for either
digital or analog inputs. The additional inputs can be
configured to accept signals (switch-type, analog, active high
or active low) through GAC’s SmartView software. With
this greater flexibility, conditions like Low Air Pressure, Low
Oil Level, Low Coolant Level and Door Open can be
configured and monitored with the proper sensory devices.
All faults and failures are indicated by bright, multi-colored
LED’s located on the front Annunciator Panel. The IGC700
is designed to take the appropriate action, which is to warn
the operator of the faulty/failed condition and to shutdown
the system if the condition is potentially damaging and/or
dangerous. These actions are taken based on parameters set
at the time of installation. The IGC700 Series has three
normally open 20 Amp relays with outputs that are common
to battery voltage. These are provided for Crank
Termination, Fuel Solenoid (shut down signal) and Glow
Plug Preheating.
DESCRIPTION
Engine speed functions are easily set up through the keypad.
The use of an external potentiometer for trim or wide speed
range setting can also be configured with the keypad. The
general-purpose inputs can also be configured to switch
between fixed speed settings. The internal actuator driver
circuit can deliver enough power to drive most proportional
actuators with a current rating of up to 10 Amps. If levels are
expected to exceed 10 amps or you are unsure of the actuator
compatibility, contact GAC application engineering or a
qualified GAC representative.
The IGC700 provides a simple 2-button control for operation
under normal conditions. Depressing the STOP button will
shut down the engine immediately by cutting the engine’s
fuel supply and turning the actuator power off (if it is in use).
Depressing the START button will begin the crank cycle.
Once the engine is started, the control will govern the engine
and provide protection according to the parameters that were
set during installation.
IGC700 Series
Integral Governor Control

2
Diagram 1

3
INSTALLATION
The electrical connections for the IGC700 are illustrated in
Diagram 1 on the previous page. For specific speed
configuration using Terminals R and S, please see Table 1
below. Actuator and Battery connections to Terminals A, B,
C, D and E should be #14 AWG (18mm) or larger. Long
cables require an increased wire size to minimize voltage
drops. Battery positive (+) inputs at Terminals A and C
should be fused for 15 Amps as illustrated. The Magnetic
Speed Sensor connections to terminals L and M must be
twisted and/or shielded for their entire length. If shielding is
used on the magnetic sensor, then it should be connected to
Terminal B. This is to prevent unwanted signals from being
introduced into the IGC700 causing erratic operation of the
unit.
Terminal Identification & Connectivity
Accessory Wiring
The cables to the Variable Speed Potentiometer can be of any
length up to 5m (15ft). A shielded cable is required for
lengths over 5m. Connect the shield to Terminal B and to
Case Ground as shown in Diagram 1.
Magnetic Pickup
With the engine stopped, adjust the gap between the
magnetic speed pick-up and a ring gear tooth. The gap
should not be any smaller than 0.45 mm (0.020 in.). Please
follow the manufacturer’s instructions when installing the
Magnetic Pickup. Verify proper installation by measuring
the AC voltage output of the pickup while cranking the
engine. This output must be greater than 0.5Vac, while
cranking. Connect the Magnetic Pickup to Terminals L & M.
Battery
The battery can be either 12 or 24 volts. Connect the positive
cable to Terminals A and C (+) and the negative cable to
Terminal B (-).
Actuator
Connect the actuator wires to Terminals D & E. The IGC700
can deliver up to 10 Amps for actuator operation. Check the
actuator literature for more information.
Fuel Solenoid
Connect the Fuel Solenoid to Terminal F. The second wire
of the Fuel Solenoid is connected the negative (-) of the
Battery.
Variable Speed Potentiometer
Although a 2k-10k pot is acceptable, it is recommended that
a 5k pot be used for the Variable Speed pot. Terminals I, J &
K are used to connect the Variable Speed pot. Connect the
wiper terminal of the pot to Terminal I. Use Terminals J & K
for the other two connections to the pot.
Preheat
Terminal G supplies battery voltage to the Preheat Solenoid
with the second wire connected to the negative (-) of the
Battery.
Crank Solenoid
Terminal H supplies battery voltage to the Crank Solenoid.
Connect the other end to the negative (-) of the Battery.
Remote START/STOP
Connect the negative (-) of your Remote Start/Stop switch to
Terminal N. The other side of your Remote Switch is tied to
Battery positive (+).
Alarm Output
Terminal O can sink up to 500mA for use as an audio or
visual annunciator. This output is configured to activate
when Engine Temperature or Oil Pressure exceeds the
parameter previously set by the user. The Alarm Output can
also be configured to work with any or all of the configured
inputs.
Engine Temperature & Oil Pressure
Terminals P & Q are dedicated inputs. These two inputs
require switch type sensors. Connect the Engine
Temperature Sensor to Terminal P and the Oil Pressure
Sensor to Terminal Q. The second wire from each of these
sensors is connected to Battery ground (B-).
User Configurable Inputs
•Terminals R & S can be configured as either
independent, general-purpose inputs or as a pair of
inputs for Fixed Speed Selection.
•Terminal T can be configured as an independent,
general-purpose input. It has no secondary function.
Terminals Selected Selected
R S Speed Droop
No
Connect
No
Connect
Variable Speed Droop
No
Connect
+
Battery
Fixed Speed 1 Droop 1
+
Battery
No
Connect
Fixed Speed 2 Droop 2
+
Battery
+
Battery
Fixed Speed 3 Droop 3
Table 1 – Speed Select Settings

4
•Terminal W can be configured as an independent,
general-purpose input or it can be configured as a Battle
Short.
Internal / External (Battle Short) enable
When this input is left open, the IGC700 will be in normal
operation. The IGC700 will respond to preset sensory inputs
and take the appropriate action based on these inputs. This
means all shutdown signals are active.
When this input is connected to battery +, the IGC700 will be
in Battle Short mode and will not shutdown for critical faults.
Only Overspeed will be monitored. Remote Shutdown must
be triggered to command a shutdown.
•Terminal X can be configured as an independent,
general-purpose input or it can be configured to use a
Temperature Sensor for PreHeat time.
•Terminals Y & Z can be configured as independent,
general-purpose inputs. Or their alternate functions are
as Voltage and Current inputs, respectively, for Voltage
control applications.
Charge Fail (D+)
When the voltage signal drops below Battery minimum, the
Charge Fail LED will illuminate and the Alarm Output
(Terminal O) will activate. The threshold levels for this input
is dependent on the system battery voltage. See the
following Table for threshold levels.
Driver Output for AUX Control
Terminal V is the output for the AUX button on the front
panel. It can sink up to 500mA and can be used to control
any device based on the following options:
CONFIGURATION
User Interface
Before configuring the IGC700 you should familiarize
yourself with the front panel. The IGC700 allows direct
access from the keypad to the menus and parameters you will
use. Diagrams 2 & 3 on the next two pages offer a graphical
representation of the keypad and examples of how to read
and understand the LED’s on the front panel.
The next few pages provide a detailed description of the
Front Panel of the IGC700. To access the various parameters
available, you must first be in SETUP mode. Once in
SETUP mode, choose which MENU you need access to and
then press the number button on the keypad that corresponds
to the parameter you wish to make changes to.
Accessing SETUP mode
1. To access SETUP mode, press and hold SETUP button
until the RUN/SETUP LED begins to flash. This will
take about two seconds, the flashing RUN/SETUP LED
indicates that you are in SETUP mode and it will
continue to flash as long as you are in SETUP mode.
2. Enter the 4-digit Security Code and then press ENTER
Note: Each time a button is depressed as you are
entering the Security Code, the entire Bar Graph display
will flash (See Flash Code mode, Page 6). The IGC will
System
Battery
Threshold
Level
24 Volts
23.6 Volts
12 Volts
11.4 Volts
AUX Driver Configurations
Option 1
Alternate action On/Off with AUX button
Option 2
Turns ON when engine is running
Option 3
Disables and will never turn ON
Warning
An overspeed shutdown device, independent of the
governor system, should be provided to prevent loss of
engine control, which may cause personal injury or
equipment damage. Do not rely exclusively on the
governor system electric actuator to prevent overspeed. A
secondary shut off device, such as a fuel solenoid, must be
used.
Before starting the engine safely,
The IGC700 must be properly configured.
Important Note
You can access SETUP mode with engine OFF or while the
engine is running.
With the engine OFF, Steps 1 & 2 below describe the
LED activity when accessing setup mode.
If the engine is RUNNING however, you will not see
any LED activity until after you have entered the correct
Security Code. Only then will the Bar Graph begin to
flash the 4-digit software version as stated in step 2.
If an incorrect Security Code is entered while the engine
is running, you will not see any LED activity (the
RUN/SETUP LED remains ON) and the IGC700 will
return to RUN mode.
This is a safety feature that prevents any accidental
tampering with the IGC700.

5
validate that the correct Security Code has been entered.
Once the correct Security Code has been entered, the Bar
Graph will begin to flash the 4-digit software version
number. If not, you must repeat this step (2).
3. In SETUP mode, the parameters listed under each
numeric button can be accessed by pressing the MENU
button and then pressing a Number button (See page 5).
4. Pressing the MENU button repeatedly will cycle through
the menus. Do this until the appropriate LED
illuminates for the menu you want to access. You can
verify which MENU you are in by looking at the LED
Bar Graph on the left side of the front panel. Currently,
there are six MENUS to choose from. These menus
correspond to LED 0, LED 1, LED 2, LED 3, LED 4 and
LED 5 respectively.
5. Next, press the numeric button on the keypad for the
parameter you want to access. For example: pressing the
MENU button twice and then pressing the 5-button will
access the Overspeed parameter.
6. Remember that a flashing RUN/SETUP LED indicates
that you are in SETUP mode. To exit SETUP mode and
save changes to parameters, press and hold the
RUN/SETUP button until the RUN/SETUP LED stops
flashing and stays ON.
GAC recommends that the user take time to fully understand
the following items before attempting to start the engine or
going any further:
1. Understanding the Keypad, Menus and Parameters
(Pages 4, 5 & 6).
2. Understanding the LED Display Modes (Page 5 & 6).
3. Entering SETUP mode & Security Code.
4. Configuring the necessary basic parameters and saving
changes.

6
Bar Graph Display
&
Flash Codes
Code Flash Mode
All IGC values that are flashed out are always 4 digits. The LED’s are labeled as 0, 1, 2,..,10. Code
Flash mode can display any value between 0 and 9999. They would be displayed by flashing 0-0-0-0 thru
9-9-9-9 respectively. Please review the example below of displaying the value 1500.
1
5
0
0
repeat
repeat
Bar Graph Display
The Bar Graph displays the “
approximate” percentage from 0 to 100%. Pressing the +/- arrow buttons,
increases or decreases the value. You may have to press the +/
- button several times to illuminate the next
LED. This is due to the difference in resolution between the LED’s and th
e actual parameter being
adjusted.
EXAMPLE 1 –Bar Graph displaying between 50% and 59%.
EXAMPLE 2 –Code Flash mode displaying the number 1500.
If only LED 0 is on, the
value is between 0%
and 9%.
This indicates the value is
between 50% and 59%.
0
2
1
5
4
6
8
7
9
10
0
2
1
5
4
6
8
7
9
10
0
2
1
5
4
6
8
7
9
10
0
2
1
5
4
6
8
7
9
10
0
2
1
5
4
6
8
7
9
10
0
2
1
5
4
6
8
7
9
10
0
2
1
5
4
6
8
7
9
10
3
3
3
3
3
3
3

7
1
1
1
2
2
2
3
3
3
4
4
4
5
5
5
6
6
6
7
7
7
8
8
8
9
9
9
0
0
0
M
M
ME
E
EN
N
NU
U
U
S
S
SE
E
ET
T
TU
U
UP
P
P
R
R
RU
U
UN
N
N
E
E
EN
N
NT
T
TE
E
ER
R
R
+
+
+
-
-
-
Note: The fault light also comes on
when a menu is active. This is
useful if you are unsure if you’ve
selected a menu.
MADE IN USA
2
OVERNORS
0
MERICA
1
ORP.
8
7
4
3
5
6
STABILITY
DERIVATIVE
10
9
GAIN
TEMP. °C
OIL PRESS.
CHARGE FAIL
ERROR 1
ERROR 2
ERROR 3
ERROR 4
FAULT
ENGINE RUN
RUN / SETUP
IP54
MADE IN USA
2
OVERNORS
0
MERICA
1
ORP.
8
7
4
3
5
6
STABILITY
DERIVATIVE
10
9
GAIN
TEMP. °C
OIL PRESS.
CHARGE FAIL
ERROR 1
ERROR 2
ERROR 3
ERROR 4
FAULT
ENGINE RUN
RUN / SETUP
IP54
MADE IN USA
2
OVERNORS
0
MERICA
1
ORP.
8
7
4
3
5
6
STABILITY
DERIVATIVE
10
9
GAIN
TEMP. °C
OIL PRESS.
CHARGE FAIL
ERROR 1
ERROR 2
ERROR 3
ERROR 4
FAULT
ENGINE RUN
RUN / SETUP
IP54
Gain-Speed Stability-Speed Derivative-Speed Menu 0 = LED 0 ON
Gain-Secondary Stability-Secondary Derivative-Secondary Menu 1 = LED 1
Scale ------ Current Limit Menu 2 = LED 2
------ ------ ------ Menu 3 = LED 3
------ ------ ------ Menu 4 = LED 4
------ ------ ------ Menu 5 = LED 5
Fixed Speed FlyWheel Teeth Start Fuel Ramp Menu 0 = LED 0
Droop Overspeed Start Fuel Begin Point Menu 1 = LED 1
------ Input P Trip Point Input R Trip Point Menu 2 = LED 2 ON
------ Input P Delay Input R Delay Menu 3 = LED 3
------Input Q Trip Point Input S Trip Point Menu 4 = LED 4
------ Input Q Delay Input S Delay Menu 5 = LED 5
Var. Upper Limit Voltage Ref. Speed Ramp UP Menu 0 = LED 0
Var. Lower Limit ------ Speed Ramp Down Menu 1 = LED 1
Crank Term. Input T Trip Point Input Y Trip Point Menu 2 = LED 2
Crank Attempts Input T Delay Input Y Delay Menu 3 = LED 3
Crank Pause Input X Trip Point Input Z Trip Point Menu 4 = LED 4
Crank Time Input X Delay Input Z Delay Menu 5 = LED 5 ON
Front Panel –MENUS, PARAMETERS & LED’S
In Short:
1. Press and hold SETUP until RUN/SETUP LED flashes.
2. Press MENU to access the Menu 1, 2, 3, 4, 5 or 6 (LED 0, 1, 2, 3, 4 or 5).
3. Press NUMERIC button for parameter you want access to.
a. Use the + or – buttons for fine adjustments. The LED Bar Graph will indicate your
change. Remember, the resolution is a scale of approximately 10:1. (press +/- 10 times
for next LED to come on. Do Not press ENTER.
b. You can also use the numeric buttons to make larger changes. Any changes this way
must be made with a 4-digit number (99 becomes 0099). Press ENTER.
4. Press and hold the RUN button until the RUN/SETUP LED becomes steady ON.
Note: ------ = Not currently used

8
Accessing Parameters
When entering large numbers into parameter settings, it is
much easier to enter the number as a 4-digit number. For
example, to enter 125 teeth into the Flywheel Teeth
parameter, it is easier and faster to press 0-1-2-5 and then
press the ENTER button than it is to press to + button one
hundred twenty five times.
For smaller changes and for fine-tuning certain parameters
such as RPM settings, the +/- buttons are more useful.
To access the following parameters, you must be in SETUP
mode.
Flywheel Teeth
1. Press and hold the MENU button until the LED
representing 0 lights up indicating that Menu 0 is
active.
2. Press the 5 button to access the FLYWHEEL TEETH
parameter. The Bar Graph will flash the current value
for this parameter.
3. Enter the correct number of teeth and press the ENTER
button.
4. If you are configuring the IGC700 for the first time or
you have changed the Flywheel Teeth parameter, you
must proceed to the next step, OVERSPEED. If not,
save and exit the setup routine by holding down the
RUN button until the RUN/SETUP LED stops flashing.
Overspeed
1. Press the MENU button illuminating LED 1. When
LED 1 comes on, you will be in MENU 1.
2. Press the 5 button to select the OVERSPEED
parameter. The Bar Graph will flash out the current
RPM value of the OVERSPEED parameter. This value
is based on the Flywheel Teeth parameter you
previously entered. Therefore, you must configure the
OVERSPEED parameter every time you change the
Flywheel Teeth parameter.
3. Using the numeric keypad, enter the 4-digit RPM value of
the desired OVERSPEED setting. If you make a mistake
just re-enter the complete 4-digit number again.
4. Press the ENTER button to apply the new RPM value.
Speed Settings
Connect the SPEED SELECT terminals R & S according to
one of the four settings shown in Table 1 on page 3. If you
have selected Variable Speed mode, then skip over Fixed
Speed Operation and go directly to Variable Speed Operation
below.
Fixed Speed Operation
1. Access Menu 0 (LED 0).
2. Press the 4 button to access the FIXED SPEED
parameter. The Bar Graph will flash out the current
RPM.
3. For small RPM changes, use the +/- buttons to adjust the
current RPM setting of the FIXED SPEED. DO NOT
press Enter.
4. For a large RPM change, use the Numeric keypad Entry
method.
5. Re-configure the SPEED SELECT connections according
to Table 1 to set up additional fixed speed settings and
repeat steps 1 - 5 until all fixed speeds are configured.
Variable Speed Operation
1. Make sure the potentiometer is attached as shown in
Diagram 1 on page 2.
2. Turn the Potentiometer such that maximum voltage is
present on Terminal E. This can be verified by using the
IGC700 Bar Graph Display in the next steps.
3. Access Menu 0. (LED 0).
4. Press the 7 button to gain access to the VARIABLE
UPPER LIMIT parameter. This step also causes the
IGC700 to remember the Potentiometer’s maximum
position. At this point, the Bar Graph display also shows
a representation of the voltage on Terminal I. If this reads
zero then turn the wiper on the pot all the way in the other
direction and repeat steps 3 and 4. If the Bar Graph now
reads higher, then you must swap the wires at terminal J
and K. Repeat steps 3 and 4.
TIP: The value can be directly entered by using the
number buttons on the keypad. All numeric keypad
entries must contain 4 digits. For values of less than 4
digits you must enter zero(s).
Example: pressing 0,1,0,9 and then the ENTER button
will set the FLYWHEEL TEETH parameter to 109.
NOTE: This is a critical parameter because the IGC700
uses it to calculate Speed and Overspeed values. Please
take extreme care when modifying this value.
NOTE: This is also a critical parameter as it is a
necessary safety feature.

9
5. The current maximum RPM setting for this parameter
will be flashed by the LED’s.
6. Use the +/- buttons or 4-digit keypad numerical entry
method to set a new RPM value for the VARIABLE
UPPER LIMIT.
7. Turn the Potentiometer such that the minimum voltage
is present on Terminal F.
8. Access Menu 1 (LED 1).
9. Press the 7 button to access the VARIABLE LOWER
LIMIT parameter. This step also causes the IGC700 to
remember the potentiometer’s minimum position. At
this point the Bar Graph should display a lower RPM
than it did for the maximum position.
10. The current minimum RPM setting will be flashed by
the Bar Graph.
11. Use the +/- buttons or 4-digit keypad entry numerical
entry method to enter a new value for the VARIABLE
LOWER LIMIT.
Crank Termination Setting
This parameter must be set higher than the maximum
cranking speed (RPM). This helps the IGC700 to determine
if the engine is cranking or running. Otherwise the IGC700
will invoke its Speed Control algorithms instead of its
Starting Fuel algorithms during the starting cycle. When the
IGC700 is in the RUN mode (the SETUP LED will be
steady on), the LED labeled ‘DERIVATIVE’ illuminates as
an indicator to notify you that the IGC700 is in the Start
cycle. Once the engine is running, the LED labeled ‘GAIN’
illuminates indicating the IGC700 is in the Engine Running
mode and is therefore invoking the Speed Control
algorithms. If you are attempting to start the engine and you
notice the Gain LED lighting you may need to increase the
Crank Termination Setting. To increase the Crank
Termination Setting:
1. Gain access to MENU 2 (Press and release the MENU
button until Menu 2 is active).
2. Press the 7 button to select the CRANK
TERMINATION parameter. The Bar Graph will flash
the present RPM value for this parameter.
3. Enter the desired RPM value as a four-digit number.
For example, 275 RPM would be entered as 0,2,7,5 and
press ENTER. After pressing the Enter button, the Bar
Graph will flash the new setting for CRANK
TERMINATION.
Saving IGC700 Settings
Press and Hold the RUN button until the RUN/SETUP LED
stops flashing. This causes the IGC700 to save all settings
into permanent memory. Without doing this all settings will
be lost when the IGC700 is turned off. The IGC700 will now
be in RUN mode, which is verified by a steady RUN/SETUP
LED.
Advanced Configuration
Additionally, there is a group of Advanced Configurations that
do not necessarily need to be preset for basic engine operation.
These are listed below. (Their factory default states should
not hamper basic operation.)
1. Staring Fuel Inhibitor control. (SFI is disabled per factory
configuration.)
2. Speed Ramping for acceleration and deceleration rates.
3. Droop settings (All Droop settings are preset to 0%).
Starting Fuel Inhibit Control
This parameter gradually increases the amount of fuel during
the engine start cycle, which eliminates unnecessary smoke.
The higher the setting the more time it takes to reach full fuel.
1. Enter SETUP mode.
2. Enter the START FUEL RAMP parameter. (Press and
release the MENU button until MENU 0 is active, then
press the 6 button).
3. Use the +/- buttons to adjust the Bar Graph.
Starting Fuel Preset Point
This parameter determines how much fuel to begin with
before fuel ramping engages.
1. You must be in SETUP mode.
2. Enter the START FUEL BEGIN POINT parameter.
(Press and release the MENU button until MENU 1 is
active then press the 6 button).
Tip: The Engine should start more quickly as this value is
decreased. Therefore a value of zero will not restrict any
fuel.
Tip: You may have to press the + or - button several times
before you will see any change in Bar Graph LED’s. This
is due to the fine-tune resolution between LED indicators.

10
3. Use the +/- buttons to adjust the Bar Graph indicating
what percentage of fuel the cranking cycle will begin
with.
Speed Ramping Control
Speed Ramping Control provides acceleration and
deceleration ramping during RPM input changes.
Acceleration Ramp
1. Enter SPEED RAMPING ACCELERATION
parameter. (Press and release the MENU button until
Menu 0 is active then press the 9 button).
2. Use the +/- buttons to set a new Acceleration Ramp
rate.
Deceleration Ramp
1. Enter SPEED RAMPING DECELERATION
parameter. (Press and release the MENU button until
Menu 1 is active then press the 9 button).
2. Use the +/- buttons to set a new Deceleration Ramp
rate.
Droop Setting
Each of the four speed settings also has a corresponding
droop setting. When the IGC700 ramps from Fixed Speed 1
to Fixed Speed 2, the Droop value also ramps from Droop 1
to Droop 2. This type of operation provides maximum
stability performance.
1. The Droop value is automatically selected based on
which Speed is selected by terminals Q and R (Table
1).
2. Enter the DROOP parameter. (Press and release the
MENU button until Menu 1 is active then press the 4
button.
3. Use the +/- buttons to select desired Droop amount in
percent.
Saving IGC700 Settings
Press and Hold the RUN button until the RUN/SETUP LED
stops flashing. This causes the IGC700 to save all settings
into permanent memory. Without doing this, all settings will
be lost when the IGC700 is turned off. The IGC700 will now
be in the RUN mode indicated by the RUN/SETUP LED
being steady ON.
OPERATING AND TUNING
Verify Settings
Before starting the engine with the IGC700 connected please
follow the steps listed below:
1. Apply power but do not start the engine.
2. Enter SETUP mode and verify that all parameters are set
to what you expected. Pay particular attention to
Flywheel Teeth, Overspeed, Speed configuration and
Crank Termination.
3. Once you are satisfied that ALL parameters are correctly
set, press and hold the RUN button to exit SETUP mode.
4. Now you are ready to start the engine.
Starting the Engine
Press and release the green START button. This will initiate
the startup sequence based on the parameters you have
installed.
Once the engine has started, you must set the Gain, Stability
and Derivative (PID) parameters in order to obtain peak
engine performance. The following section will assist you in
adjusting these parameters.
Tuning Engine (adjusting PID)
Starting Fuel Diagram –FIGURE 2
Time [t]
Fuel
Maximum Fuel
Cranking Begins
Zero Fuel
Starting Fuel Inhibit set to 10%
*****Important Note*****
When the engine is running and you enter the SETUP mode,
there will be no LED activity until after you have entered the
correct Security Code. Once the correct Security Code is
entered the Bar Graph will display the software version
number. If the wrong code is entered, nothing will happen.
The engine will continue to run and you will have to attempt to
enter SETUP mode again.
The key here is to press and hold the RUN/SETUP button for
2-3 seconds, then enter the 4-digit Security Code and press the
ENTER button. If done correctly, the Bar Graph will flash the
software version number.

11
Gain
Press and release the MENU button until Menu 0 is active,
then press the 1 button. The LED labeled GAIN will
illuminate and the Bar Graph will display the current setting
of Gain. Use the +/- buttons to adjust the Gain parameter.
Stability
Press and release the MENU button until Menu 0 is active,
then press 2 button. The LED labeled STABILITY will
illuminate and the Bar Graph will display the current setting
of Stability. Use the +/- buttons to adjust the Stability
parameter.
Derivative
Press and release the MENU button until Menu 0 is active,
then press the 3 button. The LED labeled DERIVATIVE
will illuminate and the Bar Graph will display the current
setting of Derivative. Use the +/- buttons to adjust the
Derivative parameter.
Range Setting
This function will double or triple the Gain and Stability
parameter ranges by reducing the resolution. This is useful
when large amounts of gain and stability are needed. This
function basically multiplies the Gain and Stability
parameters by 1, 2 or 3. The normal setting for the Range is
1. By changing it to 2 or 3, the values are doubled or
tripled. To access Range adjustment press and release the
MENU button until Menu 2 is active, then press the 1
button. The current Range parameter setting will be flashed
on the Bar Graph as either 0,0,0,1 or 0,0,0,2 or 0,0,0,3. Use
the +/- buttons to adjust the Range. Again, do not press
ENTER.
Saving Values (While Engine is Running)
When all tuning and engine configuration is complete, press
and hold the RUN button to save all changes.
TIP: The longer you hold the + or - button down, the
faster the value will change.

12
SPECIFICATIONS
PERFORMANCE
Isochronous Operation & Steady State Stability………………………………………±0.25% or better
Speed Range/Governor……………………………………………………………………400 – 10KHz
Speed Drift with Temperature………………………………………………………< ±1% Maximum
Idle Adjust………………………………………………………………………Full Range of set speed
Droop Range………………………………………………………………………1 – 17% Regulation
Speed Trim Range………………………………………………………………±5% of Running Speed
ENVIROMENTAL
Ambient Operating Temperature Range……………………………………………………-40oto 85oC
…………………………………………………(-40°to +180°F)
Relative Humidity……………………………………………………………………………Up to 95%
All Surface Finishes……………………………………………Fungus Proof and Corrosion Resistant
INPUT / OUTPUT PARAMETERS
Supply……………………………………………………………………12 or 24Vdc Battery Systems
………………………………………………………………………(6.5Vdc to 33Vdc Nominal)
Polarity………………………………………………………………Negative Ground (Case Isolated)
Power Consumption……………………………………70mA max. continuous plus actuator current
Actuator Current Range@ 25oC (77°F) – (Inductive Load) ………………Max. 10 Amps continuous
Speed Sensor Signal………………………………………………………………0.5-120 Volts RMS
Discrete Outputs (Alarm/AUX………………………………………………Sink up to 500mA@25ºC
CONFIGURATION PARAMETERS
Flywheel Teeth…………………………………………………………………………………50 – 250
Range (Gain and Stability Multiplier) ……………………………………………………………1,2,3
Fixed Speed settings………………………………………………………………………0-Max RPM*
Variable Speed settings……………………………………………………………………0-Max RPM*
Overspeed Setting…………………………………………………………………………0-Max RPM*
Starting Fuel Preset…………………………………………………………………………0-Max Fuel
RELIABILITY
Vibration…………………………………………………………………………………7G@20-100Hz.
Testing………………………………………………………………………100% Functionally Tested
PHYSICAL
Dimensions………………………………………………………………………9.6cm x 9.6cm x 3.7cm
……………………………………………………………………(3.765 x 5.55 x 1.44 inches)
Weight……………………………………………………………………………………0.64kg (1.41lbs)
Mounting………………………………………………………………Panel Mounted, vertical preferred
Sealing………………………………………………………………………IP 54, using optional gasket
*Note: -Max RPM is based on the Flywheel Teeth.
-RPM=Frequency*60/FlywheelTeeth.
-Maximum frequency is 10,000 Hz.

13
TROUBLESHOOTING
Troubleshooting Guide 1
Engine Will Not Start
Checklist - After You Stop Cranking
With Power
applied to
IGC,
Is Fault LED
on?
Indicates the Overspeed limit was exceeded during
starting. Recheck Flywheel Teeth, Overspeed, and
Speed settings. Cycling the power on the IGC will
remove the Overspeed Fault Condition. Try
Restarting.
Is RUN/SETUP
LED Blinking
IGC is in SETUP Mode. Press and hold the RUN
Button to exit Setup mode. The Fault LED should
turn off. If it doesn’t, that means the Overspeed limit
was exceeded during starting. Recheck Flywheel
Teeth, Overspeed, and Speed settings. Cycling the
power on the IGC will remove the Overspeed Fault
Condition. Try Restarting.
Is RUN/SETUP LED
Blinking
N
Y
N
N
N
N
N
Y
Y
Y
Y
Y
Is the battery (+) connected to Terminals A & C? Is
Battery (
-
) connected to Terminal B? Verify polarity.
Are any LED’s on
Measure Voltage across
Terminals A(+) and B(
-
) to
verify sufficient Voltage (12V
or 24V). Cycle Power. If still
no LED’s turn on, then
controller needs to be
replaced.
Connect
Battery
Is RUN/ SETUP
LED steady On
Go To Next Section Labeled
“WHILE CRANKING the ENGINE”

14
When Cranking Engine, Are any
IGC LED’s on
This indicates either the Crank Termination or the Fuel Limit Setting is too low.
Typically the Crank Termination value should be at least 50RPM higher than the max.
cranking speed of the engine. If possible measure the cranking RPM of the engine.
Enter Setup mode and configure the Crank Termination Setting (MENU 3, Button 7)
to a higher value. You can try 100RPM increments. If Engine appears to start and the
Stability LED illuminates, this indicates the Fuel Limit Setting may be too low. Enter
the Fuel Limit Function (SETUP mode) then (MENU 2, Button 3). The Bar Graph
displays the Fuel Limit setting. Use the + button to set the FUEL LIMIT to 100%
which disables it.
Is the Gain LED
Turning on?
N
N
N
N
Y
Y
Y
This indicates the IGC700 is seeing the Pickup Sensor and is invoking the Starting Algorithm.
Make sure the actuator is connected to Terminals D and E. Measure the voltage across these terminals while the
engine is cranking. This voltage should be at no less than 2Vdc lower than supplied Battery Voltage during
cranking. Other things to check are the setting
s for Flywheel Teeth and Speed Setting (Fixed or Variable).
Another possibility for not starting may be due to an extremely long fuel ramp. This can be disabled by
Entering Setup mode and accessing the Starting Fuel Function (Menu 0, Button 6). Next enter 0,0,0,0 and press
ENTER. This enters zero into the Starting Fuel Inhibit Control Ramp. This is verified by the Bar Graph
displaying 0%.
Measure Voltage across Terminals A(+) & B(-) while engine is
cranking. Verify sufficient voltage of approximately 8V. If not, then
make sure the battery is charged.
Is the Derivative
LED Turning on?
If neither the Derivative nor the Gain LED’s are turning ON during
cranking, this indicates the IGC700 is not seeing the pickup signal.
Verify the pickup sensor is connected to Terminals L & M. If
possible measure the pickup signal while the engine is cranking. The
voltage must be a minimum of 0.5Vrms while engine is cranking and
greater than 5.0Vrms while engine is running..
Does the Bar Graph
Display show more
than 0% while
cranking?
This indicates the Starting Fuel Function is engaged. This can be
remedied by entering the Starting Fuel Inhibit Function and setting the
fuel ramp to 0000. Enter Setup mode and access the Starting Fuel
Function (Menu 0, Button 6). Then press 0,0,0,0 and press the
ENTER button.. This enters zero into the Starting Fuel Inhibit
Control Ramp. This is verified by the Bar Graph dis
playing 0%.
Y
Engine Will Not Start
Checklist - While Cranking the Engine
Troubleshooting Guide 2

15
Bar Graph flashing when power is applied to IGC700
This indicates the IGC700 configuration is corrupt. It is
recommended to reconfigure the unit before attempting to
start the engine.
Discrete Output Not Working
This terminal sinks current. The typical amount of sink
current is 20mA. This means the device being controlled with
this terminal must be tied to a positive voltage and must not
require more than 20mA to operate. This terminal turns on
when the IGC700 is running under normal conditions. If the
IGC700 overspeeds then this terminal switches to an open
circuit.
Engine Not Running at correct Fixed Speed.
1. Are Terminals R and S properly configured? If nothing
is connected to these terminals the IGC700 is configured
for Variable Speed. Please refer to TABLE 1 on page 3.
2. Make sure the correct number of flywheel teeth has been
configured. This function is accessed in the SETUP
mode under MENU 0, button 5. The IGC700 will flash
out the current number of teeth as a 4-digit code. If this
number is not correct then enter the correct number of
teeth as a 4-digit number followed by the ENTER button.
3. Make sure the Fixed Speed is correctly set. Access
SETUP mode and select MENU 0, Button 4. The
IGC700 will flash out the present RPM speed. If this is
not correct, enter the 4-digit speed in RPM and press
ENTER. The IGC700 will then flash the updated RPM
Speed.
Engine Not Running at Correct Variable Speed.
Make sure potentiometer is connected properly to
terminals I, J and K. Refer to the configuration section in
this manual to setup the potentiometer. When
configuring the potentiometer verify the RPM value
entered for MAXIMUM RPM SPEED (MENU 0, Button
7) is greater than the RPM entered for MINIMUM RPM
SPEED (MENU 1, Button 7). When doing this you
should also verify the Bar Graph displays a higher
reading for MAX. RPM SPD than for MIN. RPM SPD.
Make sure the FLYWHEEL TEETH parameter is correct.
This function is accessed in the SETUP mode (MENU 0,
Button 5). The IGC700 will flash out the current number
of teeth as a 4-digit code. If this number is not correct
then enter the correct number of teeth as a 4-digit number
followed by the ENTER button.
Overspeed During Starting (Tripping Fault LED)
This condition is caused by the OVERSPEED parameter
being too low, the IGC700 not properly tuned for the
application or the CRANK TERMINATION parameter being
set too high. Recheck these parameters.
Overspeeding During Load Transient (Tripping Fault
LED)
OVERSPEED parameter is set too low or IGC700 not
properly tuned for the application. Recheck the
OVERSPEED setting and try retuning the engine.
Overspeeding During Speed Changes (Tripping Fault
LED)
OVERSPEED parameter is set too low or the SPEED RAMP
ACCELERATION parameter is set too low. You can
increase the Speed Ramp Value in SETUP mode (MENU 0,
Button 9). The Bar Graph will display the current Speed
Ramp setting. Press the + button to increase this value. This
causes the engine to accelerate more slowly reducing the
overshoot.
SETUP mode is not accessible
Press and hold the SETUP button until the RUN/LED lamp
starts to flash. Now you must enter the valid 4-digit Security
Code [1] [2] [3] [4] followed by the ENTER button. Each
unit has a specific Security Code. If you forgot the code you
must contact your GAC distributor from where the IGC700
was purchased.
Note: The maximum RPM speed is based on the number of
teeth selected. Typically, the maximum RPM speed is 5000
to 6000 RPM.
Note: Each time one of these parameters is selected, you
must enter a 4-digit value.
Note: Once you’ve entered the proper code the IGC700 will
flash of the Software Version Number.

16
MADE IN USA
2
OVERNORS
0
MERICA
1
ORP.
8
7
4
3
5
6
STABILITY
DERIVATIVE
10
9
GAIN
TEMP. °C
OIL PRESS.
CHARGE FAIL
ERROR 1
ERROR 2
ERROR 3
ERROR 4
FAULT
ENGINE RUN
RUN / SETUP
IP54
L1
L8
L6
L9
L5
L7
L2
L3
L4
B8
B7
B6
B5
B4
B3
B2
B1
Diagram 2 – See Tables 2 & 3
for Description of Front Panel Buttons and LED’s
Table 3 - Description of Front Panel LED’s
LED LED Label Description
L1 Run/Setup
Steady ON = IGC is operating;
Flashing = SETUP mode.
L2 Engine Run
ON = Engine speed has exceeded
Crank Termination setting.
L3 Engine
Temperature ON= Engine temperature has exceeded Temperature setting.
L4 Oil Pressure
ON = Engine oil pressure has
exceeded Oil Pressure setting.
L5 Charge Fail
ON = Batteries has failed to charge
(failed alternator, broken belt, etc.).
L6 Error
1,2,3 & 4
User Configurable. Use with any
of the configurable inputs.
(R, S, T, W, X, Y & Z)
L7 Bar Graph
During Crank Cycle the graph will
sequence from 1 to 10 (0-100%)
indicating preheat time and pause
between crank time. In SETUP
mode, shows 0 to 100% of the
parameter value and depending on
the parameter will flash a 4-digit
code to show exact value of that
parameter.
L8 Gain, Stability
& Derivative
These LED’s will come on
individually when their respective
parameters are being accessed for
adjustment. The Derivative LED
also lights during the Cranking
Cycle.
L9 Fault
ON = Overspeed has been tripped -
OR - IGC Self-test failed (bad
checksum or invalid configuration
parameter) - OR - IGC stopped by
local Stop button when Remote
Start/Stop is latched on.
Table 2 - Description of Front Panel Buttons
Button Button Label Description
B1 Stop
Stops the engine. Will also stop any
start cycle.
B2 AUX
Turns AUX Driver on or off.
B3 Fault
Clears all faults in the IGC.
B4 Start
Initiates Crank Cycle. Pressing and
holding this button will bypass Crank
Cycle and begin cranking.
B5 Enter
Used to enter any 4-digit number.
DO NOT use with +/- buttons.
B6 Run
Pressing and Holding until Run/Setup
LED stops flashing saves changes.
B7 Setup
Press and Hold this button until
Run/Setup LED starts to flash. Enter
4
-digit access code and press Enter
button. Note: IF IGC is running the
Run/Setup LED will not flash. You
can however proceed
B8 Menu
Press this button sequentially to access
the p
arameter you want to adjust.
Each time you depress this button, the
next LED will come on indicating that
you are in menu selection mode. Also,
the Fault LED will come on indicating
menu selection mode. .

17
Table 4 – Accessing Menus
Button # Menu 0 Menu 1 Menu 2 Menu 3 Menu 4 Menu 5
1 Gain Speed Gain
Secondary Scale Not Used Not Used Not Used
2
Stability Speed
Stability
Secondary Not Used Not Used Not Used Not Used
3 Derivative
Speed Derivative Secondary Current Limit Not Used Not Used Not Used
4 Fixed Speed Droop Not Used Not Used Not Used Not Used
5 Flywheel
Teeth Overspeed Input 'P' Trip Point Input 'P' Delay Input 'Q' Trip Point Input 'Q' Delay
6 Start Fuel
Ramp Start Fuel Begin Point Input 'R' Trip Point Input 'R' Delay Input 'S' Trip Point Input 'S' Delay
7 Variable
Upper Limit Variable Lower Limit Crank Termination Crank Attempts
Crank Pause
Crank Time
8 Voltage
Reference Not Used Input 'T' Trip Point Input 'T' Delay Input 'X' Trip Point Input 'X' Delay
9 Speed Ramp
Up Speed Ramp Down Input 'Y' Trip Point Input 'Y' Delay Input 'Z’ Trip Point Input 'Z' Delay

18
December 2003
PTI1061
Rev XA
Preliminary