GAC EEG7500 User manual

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Governors America Corp. © 2021 Copyright All Rights Reserved
EEG7500 Enhanced Electric Governor 8-2021-A8 PIB5115
EEG7500
Enhanced Electronic Governor
1INTRODUCTION
GAC’s EEG7500 enhanced electronic governor is designed to regulate engine speed
on diesel and gaseous fueled engines. When paired with a GAC actuator the EEG is
a suitable upgrade for any mechanical governor system that needs exibility, preci-
sion, or accurate control of governed speed. The EEG7500 is designed for industrial
engine applications from generator sets, mechanical drives, pumps, and compressors
to o󰀨-road mobile equipment. Conguring is easy with GAC’s free GACong Tool
software. The EEG7500 supports:
Flexible actuator compatibility including bidirectional actuators with or without
actuator position feedback signal, bi-directional torque motors, and Bosch-style
throttle bodies.
Fully congurable digital and analog inputs and outputs
Inputs: 5 analog, 2 digital
Outputs: 1 analog, 3 digital
0 - 5 V DC, 4 - 20 mA, 0 - 10 V DC, or ±3 V DC input ranges
Speed Sync using CAN bus
Virtual Input/Output Routing
Feedback Speed Control Mode
Variable Speed Capability
Fuel Curve Shaping
EEG7500 supports three operating modes:
Non-Feedback Speed Control (NFSC) provides standard PID governing function for use with proportional actuators. No position
feedback sensor is required. PID (Proportional, Integral, Derivative) governor functions are optimized for best response and control
of the requested engine revolutions per minute (rpm).
Feedback Speed Control (FSC) combines NFSC and PM modes for use with proportional or bidirectional (torque motor) actuators. A
position feedback sensor is required. The Speed PID position request is the input to the Positioner loop, the Position PID optimizes
response and control of the requested actuator position.
Positioner Control (PC) (uncommon) provides actuator positioning control and is used with proportional actuators or bidirectional
(torque motor) actuators with a feedback sensor (required).
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PERFORMANCE
Isochronous Operation ± 0.25 %
Governed Speed /
Sensor Frequency Range 100 Hz - 12 kHz
Droop Range Up to 25 % regulation
COMPLIANCE / STANDARDS
Agency CE and RoHS Requirements
Communications USB, RS-232-C, SAE J1939
PHYSICAL
Dimension See Section 3, Controller Installation
Weight 18.4 oz [0.52 kgf]
Mounting Any position, vertical preferred
RELIABILITY
Vibration 10 - 2000 Hz @ 7 g, per SAE J1455
Shock 20 g, 11 ms per SAE J1455
Testing 100 % Functional Testing
LED
Solid Green Ready. Controller is powered on.
Blinking Green Warning. Engine service due, or other. Dis-
played in GACong Tool System Status.
Unlit No power.
INPUT / OUTPUT
Supply 12 - 24 V DC Battery systems
(6.5 to 32 V DC)
Polarity Negative Ground (Case Isolated)
Power Consumption 200 mA continuous plus actuator current
400 mA with excitation at MAX load current
Speed Sensor Signal Input 1.0 - 60.0 V RMS
Actuator Output 10 A Continuous
Load Share /
Synchronizer Input
0 - 10 V DC (5 V Nominal, Selectable
Polarity, 145 Hz / V Sensitivity)
or 0 V ± 3 V DC
Reverse Power Protection Protected to -40 V DC
Transient Voltage Protection 60 V DC
Digital Switch Output(s) Rated to 2 A DC
ENVIRONMENTAL
Ambient Temperature -40 to 180 °F [-40 to 85 °C]
Relative Humidity up to 90 % Non-Condensing
at 38 °C [100 °F] (per SAE J1455)
Salt Spray ASTM B117
All Surface Finishes Fungus Proof and Corrosion Resistant
EEG7500 SPECIFICATIONS

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EEG7500 Enhanced Electric Governor 8-2021-A8 PIB5115
4EEG7500 CONTROLLER INSTALLATION
The following connectors are required when using the EEG7500.
ITEM NO. PART NUMBER DESCRIPTION NOTE
1EC02-01-0097 PLUG, 4 POS Included
2EC02-01-0094 PLUG, 11 POS, Included
3 EC12-04-0016 USB COVER Included
4 EC02-01-0098 PLUG, 12 POS Included
Mount in a
cabinet, engine
enclosure, or
sealed metal box.
Ensure adequate
ventilation for
cooling.
Do not mount
directly on engine.
Vertical
orientation
allows for
draining of
uids in moist
environments.
Avoid extreme
heat. Do not
mount next to tur-
bocharger, exhaust
manifold, or other
high temperature
equipment.
Dimensions [mm] in
Use an overspeed shutdown device, independent of the governor system, to prevent loss of engine control.
Do not rely exclusively on the governor system electronic actuator to prevent overspeed. A secondary shuto󰀨 device, such as a fuel
solenoid must be used. GACong Tool shuts down fuel to the actuator, but does not directly shutdown the engine.
EEG7500 CONNECTORS
3BEFORE YOU BEGIN
This manual is divided into hardware controller installation instructions, software installation and overview, and system conguration with
software, and system troubleshooting. Read the entire document before starting installation. You will need internet access to manage
your software settings. Determine what hardware devices are involved in the installation and ensure you know where each device is
mapped on this speed controller.
The GACong Tool can be set up in standalone or congured mode. You can make and save preliminary conguration settings in the soft-
ware prior to connecting to the engine and supporting hardware devices.

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EEG7500 Enhanced Electric Governor 8-2021-A8 PIB5115
5EEG7500 WIRING DIAGRAMS
TERMINAL(1) DEFINITION CONNECTION GAUGE FIXED SPEED VARIABLE SPEED POSITION
CONTROL
AActuator (+) Actuator 16 REQUIRED REQUIRED REQUIRED
BActuator (-) 16 REQUIRED REQUIRED REQUIRED
C (2) Battery Ground (-) 12 or 24 V DC Battery 16 REQUIRED REQUIRED REQUIRED
D (2) Battery Power (+) 16 REQUIRED REQUIRED REQUIRED
1Magnetic Pick-up (+) Mag Pick-up speed sensor
input is not polarity sensi-
tive (3)
20 REQUIRED REQUIRED
2Magnetic Pick-up (-) 20 REQUIRED REQUIRED
3
Digital Input 1 Switch or jumper wire to
Terminal 5
20 REQUIRED with
more than 2 speed
settings
REQUIRED with Idle
speed setting used
REQUIRED with
position select
4
Digital Input 2 Switch or jumper wire to
Terminal 5
20 REQUIRED with
3 speed settings
REQUIRED when
using additional xed
settings
REQUIRED when
using additional
positions
5Digital Ground
(GND)
20 REQUIRED with
Terminals 3 and 4
REQUIRED with
Terminals 3 and 4
REQUIRED with
Terminals 3 and 4
6Analog Ground
(GND)
20 REQUIRED REQUIRED
7
Analog Input 1 0 - 5 V DC, potentiometer
or 4-20 mA (200 Ω resistor
required)
20 REQUIRED REQUIRED IF using
Position Control
(Position 4)
8
Analog Input 2 AUX
0 - 10 V DC (5 V Nominal)
OR ±3 V DC (0 V Nominal).
Selectable polarity.
20
9 Analog Input 3 4 - 20 mA 20
10 Analog Input 4
0 - 5 V DC (4 - 20 mA with
200 Ω external resistor)
20
11
+ 5 V Excitation 20 REQUIRED with
potentiometer on
Terminal 7
REQUIRED with
potentiometer on
Terminal 7
12 + 5 V Excitation Actuator Position
Feedback Sensor
20 REQUIRED with
Position Control
REQUIRED with
Position Control
REQUIRED
13 Analog Input 5 REQUIRED
14 Analog Reference
Ground
REQUIRED
15 Analog Output 0 - 5 V DC
(25 mA MAX)
20
16 Digital Switch
Output 1
Switch output 2 A MAX 20
17 Digital Switch
Output 2
Switch output 2 A MAX 20
18 Digital Switch
Output 3
Switch output 2 A MAX 20
19 CAN Low J1939 BUS, Non Terminat-
ed (3)
20
20 CAN High 20
21 RS232 (2)
Ground Reference
20
22 RS232 TX 20
23 RS232 RX 20
RECOMMENDATIONS
1. Use shielded cable on all external connections. Ground one end of each shield, including speed sensor shield, to a single point on the EEG case.
2. Ground controller case to battery (-)
3. For magnetic pickups and CAN bus, use twisted wires at 14 turns per foot in wire length.
Wire the EEG7500 for either speed control or position control, detailed in this sections following gures. Items highlighted in the following
table are the minimum connections required before starting. Read this entire manual before starting. Determine what hardware devices
will be involved in the installation and ensure you know where they are being mapped to on this speed controller. Document your wiring
setup to make setup easier with the GACong Tool.

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EEG7500 Enhanced Electric Governor 8-2021-A8 PIB5115
5EEG7500 WIRING DIAGRAMS (CONTINUED)
WIRING FOR FEEDBACK SPEED CONTROL AND NON-FEEDBACK SPEED CONTROL MODE

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EEG7500 Enhanced Electric Governor 8-2021-A8 PIB5115
5EEG7500 WIRING DIAGRAMS (CONTINUED)
WIRING FOR POSITION CONTROL

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Governors America Corp. © 2021 Copyright All Rights Reserved
EEG7500 Enhanced Electric Governor 8-2021-A8 PIB5115
• Wires must be twisted and/or shielded for their entire length (14 turns per foot).
• Gap between speed sensor and gear teeth should be > 0.02 in [0.51 mm].
• Speed sensor voltage should be at least 1 V AC RMS during crank.
If the EEG7500 detects no input from the magnetic (mag) pickup, the EEG will set the actuator to 0 V DC and set the speed
to 0 rpm.
Terminals A and B are dedicated to actuator usage. They provide input for bidirectional devices such as torque motors which require
specic polarity settings.
Proportional actuators are not polarity sensitive. See your specic actuator manual for details.
Connect the engine battery to the Terminals C and D.
Terminals 3 and 4 are digital inputs used to support incoming digital, analog, or virtual (J1939) signals. An external switch can also be
used between Terminals 3 and 4 (Ground to Terminal 5) to select assigned xed speed settings.
From the GACong Tool set I/O Conguration  Physical Input Mapping Run/Stop Input - set to Digital Input 1 or 2 to match the
external switch wiring.
6EEG7500 WIRING DETAILS
A 15 A fuse and power switch must be installed on the positive battery lead going to Terminal D.
Actuator Connection: Connector 1 - Terminals A and B
Digital Input 1 and 2 - Speed Input Routing: Connector 2 - Terminals 3 and 4
Magnetic Speed Pickup Signal: Connector 2 - Terminals 1 and 2: Speed In / Speed Ref
Battery Connection: Connector 1 - Terminals C and D
The EEG7500 provides broad conguration capabilities. The wiring provides a dedicated actuator and mag pickup input as well as
congurable analog and digital inputs to support direct communications like CAN (J1939) using the GACong Tool software.
The EEG7500 supports analog and digital input connections and electrical connections to the EEG terminals. These connections
are then mapped to specic locations in the GACong Tool software where you add expected settings including speed and all related
engine tuning setups in various speed modes (congurations).
The output mapping is done for both input connections and for specic output results, for example meeting a specic speed might
output a warning or shut down or engage a particular piece of hardware.
For example, with an actuator installed, create a variable speed setup with GACong Tool. Setting the output of the actuator and the
Speed Switch 1 output to a J1939 source such as the engine Electronic Control Unit (ECU) enables speed settings or vehicle miles to
be monitored, sends warnings for things like past due oil changes, or shuts down the engine.
Terminal 5 provides a digital ground. Terminal 6 provides the internal ground for use with external trim or variable speed potentiometers.
An external switch can be added between Terminals 3 and 4 with ground to Terminal 5 to select assigned xed speed settings using the
GACong Tool
Digital and Analog Ground Reference: Connector 2 - Terminals 5 and 6:
Terminal 7 is the analog input from external trim or variable speed potentiometer.
Speed trim uses a potentiometer to vary the engine speed remotely.
The GACong Tool Speed Trim parameter lets you adjust speed trim ±10 % based
on the minimum and maximum voltage congured for the variable speed input. Trim
speed logic is used with xed speed settings.
Analog Input: Connector 2 - Terminal 7

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EEG7500 Enhanced Electric Governor 8-2021-A8 PIB5115
The auxiliary (AUX) terminal accepts input signals from load sharing units, auto
synchronizers, and other governor system accessories. The AUX input enables or
disables the load sync input. GAC accessories connect directly to this terminal.
The AUX function decreases engine speed in response to increased input voltage.
Use the Auxiliary Polarity shift function to choose to increase engine speed as
input voltage increases:
• To decrease speed set above 5 V DC.
• To Increase speed set below 5 V DC. The AUX input is a 0 - 10 V DC reverse
polarity signal used to parallel to the mains, or load share multiple generators.
The AUX input also enables or disables the load sync input.
To use the AUX input at AI4, using the GACong Tool select Advanced
Conguration  Aux / Load Sharing  Auxiliary Enable checkbox.
Select the desired Auxiliary Polarity (Decreasing Speed or Increasing Speed) from
the drop down box. Polarity must be matched for all auxiliary products used with
the EEG7500.
Auxiliary Input - Analog Input 2: Connector 2 - Terminal 8
Terminal 9, Analog Input 3, provides dedicated 4 - 20 mA input signal.
Terminal 10, Analog Input 4, provides dedicated 0 - 5 V DC input signal, or 4 - 20 mA with external 200 Ω resistor.
• Terminal 11 provides +5 V DC excitation, power to potentiometers or other equipment requiring power.
• Terminal 6 is ground.
• Terminal 7 provides Analog Input. Terminal 7 input must be equated to the GACong Tool  Physical
Input Mapping  Variable Speed Input Analog Input setting
Section 8 o󰀨ers details on using the potentiometer with the EEG7500. For information on available
potentiometers see the GAC Potentiometers list on the GAC website.
Potentiometer Terminal EEG7500 Terminal Location
111 +5 V (power)
2 7 Analog Input
36 Ground
The potentiometers outer legs are used for power and ground while the middle is used for analog input. This
means that the value coming out of the third leg will change depending on how far the knob is turned.
+5 Volt Power Supply: Connector 2 - Terminals 6, 7, and 11
4 - 20 mA Input and 0 - 5 V DC Input: Connector 2 - Terminals 9 and 10
6EEG7500 WIRING DETAILS (CONTINUED)

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EEG7500 Enhanced Electric Governor 8-2021-A8 PIB5115
Supports CAN SAE J1939 Protocol or RS-232 communication.
The CAN bus must be terminated at both ends by a 120 Ω resistor.
Termination resistance should be set in parallel (60 Ω), 2 X 120 Ω.
• Terminal 19 = CAN Low
• Terminal 20 = CAN High
• Terminals 21 - 23 = RS232
6EEG7500 WIRING DETAILS (CONTINUED)
Terminals 16 - 18 support 3 digital output sources including engine speed, load,
actuator position, switches, alarms, or J1939 inputs.
Using the GACong Tool I/O Conguration  Output Configuration and Physical
Output Mapping:
• Map input sources to output actions
• Set speed or position switch limits, with and without latch
• Assign an output to be normally open (NO) or normally closed (NC)
Terminal 15 supports one 0 - 5 V DC analog output and can be assigned to any analog output source including engine speed, load, actuator
position, switches, alarms, or J1939 inputs.
Use the GACong Tool I/O Conguration  Physical Output Mapping to set the output destination.
0 - 5 V Analog Output: Connector 3 - Terminal 15
Digital Output 1, 2, and 3: Connector 3 - Terminals 16, 17 and 18
CAN and RS232: Connector 3 - Terminals 19 - 20 and Terminals 21 - 23
An actuator position feedback sensor is required for the Control Mode Feedback
Speed Control and Position Control, but not for Non-Feedback Speed Control
mode.
Terminal 12: 5 V Supply to Position Feedback Sensor
Terminal 13: 0 - 5 V DC Actuator Position Signal
Terminal 14: Position Sensor Ground Ref
Position control is not intended for use in gaseous fuel control. Contact your
GAC representative for more details.
Position Feedback Sensor: Connector 3 - Terminals 12, 13 and 14
7THE GAConfig TOOL
EEG7500 controller uses the GACong Tool to update parameter values, map physical
connections, adjust performance settings, and view results. This PC software provides
a menu-driven user-friendly interface to update settings, and speed diagnostics and
troubleshooting. The tool also allows you to set up multiple scenarios and save them
for use later or for sharing with other sites-solutions using the EEG7500.
The GACong Tool is downloaded from GAC’s website. The following is required to run
the software:
• A PC with at least Windows 7 or higher and at least one USB port
• An internet connection
A secondary shuto󰀨 device, such as a fuel solenoid must be used. GACong tool shuts down fuel to the actuator, but does not
directly shutdown the engine.

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EEG7500 Enhanced Electric Governor 8-2021-A8 PIB5115
7THE GAConfig TOOL (CONTINUED)
1. Download the EEG7500 GACong Tool .zip le from the GAC Download
page. Depending on your workplace the download installer may request
additional information. After the software is installed the PC must be re-
started.
2. The zip le is saved in the PCs default download area, unless you tell it
otherwise. Once downloaded, double-click the le name to start the instal-
lation. You may need to double click again on the EEG7500 IT setup.exe
le to actually begin the installation.
3. The Welcome screen displays. Click Next. Note the default installation is
in the Governors America Corp program les area.
4. Click Next. Allow the installation to create a desktop icon. You can also
create a quick Launch icon. Click Next.
5. Click Next. The installation will create a Governors America Corp folder
location on your PC. Click Next. Click Install.
6. Click Finish when complete. The GACong icon is placed on the
desktop.
7. Connect the EEG7500 to the PC using a USB-A port and connect the
USB-B port on the EEG7500. Power for the controller comes from the
engine battery. Ensure the system is powered, a green LED displays on
the EEG7500.
8. Do not start the engine.
9. Double-click the GACong Tool icon on your desktop. On rst use, when
prompted, select EEG7500 from the drop-down list.
10. Connect the GACong Tool to the EEG7500 by clicking on the Connect
icon on the top left of the GACong window.
11. A pop-up dialogue window displays a drop-down list of available comm
ports. Select the appropriate port and click OK. If you are unsure of the
comm port, use the Windows Device manager to locate what device is
plugged in to which USB port.
12. The Connection Status indicator on the lower left corner of GACong Tool
ashes yellow then turns green as the connection is completed. The status
bar displays Connected.
If the connection does not complete, a red Disconnected
message displays. Check your connections and note
any error messages on the PC and try again.
INSTALLING GAC TOOL AND CONNECTING TO EEG7500
Power for the EEG7500 comes from the engine battery.
REMINDERREMINDER
If you already have the GACong Tool
software on your system, an automatic
upgrade with the latest version will
be o󰀨ered. Remember to save your
congurations prior to installing any
upgrades.

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EEG7500 Enhanced Electric Governor 8-2021-A8 PIB5115
8GAConfig TOOL SETTINGS
EEG7500 controller uses the GACong Tool software to enter
parameter values, adjust performance settings, and view results.
Parameters are grouped by functionality at the main menu. The tool
allows you to change controller parameters on the y.
The initial view shows this Dashboard.
Initial setup is completed from Engine Tuning menu without the engine
running, but powering the GACong Tool using engine voltage.
TOOL BAR
The tool bar provides access to connect to your EEG7500,
use imported and exported conguration les, create and
save data plots, view setting history, view error logs, or
reset your current settings. From the tool bar you can:
• Connect software to the EEG7500 controller
• Export and import settings
• View history of parameter settings
• Create and save data plots
Some quick tips when using the GACong Tool:
• Use the Tab key to jump to the next parameter.
• Update parameter values by double-clicking the existing value next to a parameter name. Type in the new value and use the key-
board Enter key to save the change. If you are outside the acceptable parameter settings an error message displays.
• For a short description of a parameter, hover the cursor over the parameter name and a description briey displays, or reference
the item in the Quick Conguration menu where a short description is available in its associated menu tab.
• Parameter setting errors may display when you change a value. Read all RED warning boxes error information, yellow cautions,
and other pop-up information. Setting some parameter values impact other parameter values, often displaying a caution. One
common message indicates the selected Control Mode does not support the parameter changed.
• The GACong Tool windows automatically re-sizes its window.
• Some settings require a restart of the GACong Tool to take a󰀨ect. A reset or power cycle is required after changing the following
settings. The tool will automatically reset the unit for the user.
• While using the tool, note the far right Quick Access bar, showing engine and setup status. This quick access area is very useful.
• Each physical input is mapped to one physical input device (terminal). Each output device (terminal) can be mapped to multiple
output destinations.
• Quick Access STOP sets the engine speed to 0 rpm and shuts down the actuator. STOP does not directly shut down the engine.
TIPS
The main menu provides access to parameter settings and information. The Quick Access panel details the current engine status. The
menus are:
• The Dashboard gives a quick view of the engine status.
• Engine Tuning includes basic setup of initial and system safety settings including control mode (based on actuator type) overspeed,
ywheel teeth, fuel settings, and acceleration rates. Engine Tuning also includes xed speed settings, Gain, Stability, Deadtime, and
Variable Speed setup. A fuel limiting table can also be built here.
• Position Control Tuning sets xed and variable positioner settings, and allows a positioner table to be built.
• I/O Conguration assigns analog and digital devices to the wiring.
• Advanced Conguration sets Droop, Auxiliary sharing, Trim and congures and displays diagnostic messaging for TSC1/J1939.
• Quick Conguration puts all the parameter settings on one place.
MAIN MENU