GAC EEG7500 User manual

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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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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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5EEG7500 WIRING DIAGRAMS (CONTINUED)
WIRING FOR FEEDBACK SPEED CONTROL AND NON-FEEDBACK SPEED CONTROL MODE

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5EEG7500 WIRING DIAGRAMS (CONTINUED)
WIRING FOR POSITION CONTROL

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• 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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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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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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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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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

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8
ENGINE TUNING
Engine Tuning is the basic menu to store your engine startup and tuning information.
●System Status includes basic engine speed settings and actuator settings.
● System Setup for the actuator and engine with Control Mode (Type of actuator): non-feedback (default) feedback, or position ,
H-Bridge Mode and required setting Flywheel teeth, overspeed, fuel limit
● Speed Conguration including:
• Fixed speeds
• Variable speed settings
● Tuning (Gain, Stability, Deadtime, Lead circuit, Light force Governing, Speed anticipation), Feedback Speed Control (FSC) Fuel
Limit, and Start-Up / Ramp Control for the Actuator Start Fuel rate, Fuel ramp rate, starter cuto󰀨, acceleration and deceleration
POSITION CONTROL TUNING
Actuators with feedback sensors can be ne tuned using Position control. Position Control must be set to a minimum calibration before
using a feedback actuator.
Fixed position
Variable position
Position Speed Settings
Position Feedback Setup
Position Control Table
GAConfig TOOL SETTINGS (CONTINUED)

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I/O CONFIGURATION
I / O Conguration maps physical input and output connections between the EEG7500 controller, the engine, and other hardware.
Physical Input Mapping allows you to choose from 15 options to relate that terminal to a hardware device. For example:
A potentiometer is wired at Terminal 7 (Analog In) on the EEG7500 controller to support Variable Speed
In the GACong Tool
• Set I/O Conguration Analog Input Mode AI 1 to 0 - 5 V DC
• Set Physical Input Mapping Variable Speed Input to Analog Input 1
 connects to data points outside the system, such as speed switches and position switches, setting a digital output
mode mapping the output source to a specic event. Physical output mapping sets a specic output to a specic function. such as shut-
ting down the actuators, changing speed.
ADVANCED CONFIGURATION
QUICK CONFIGURATION
The advanced conguration menu lets you set
up aux and load sharing, droop and trim as well
as congure J1939 settings and general system
information:
• Auxiliary settings, Droop, Speed Trim
• J1939 message display, mapping, and control
settings
• See overall system and software information
like engine runtime and last fault time
The Quick Conguration menu includes all
the menu settings for the EEG7500 available
in the GACong Tool in one menu area.
Use this menu with its multiple tabs to update
parameter settings directly.
8GAConfig TOOL SETTINGS (CONTINUED)

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9INITIAL SYSTEM SETUP
1. Complete wiring between the engine, EEG7500 controller, and actuator before starting the
engine. The following are the minimum wiring requirements:
• Connect actuator to EEG7500 (Terminals A and B)
• Connect magnetic pickups to EEG7500 (Terminals 1 and 2)
• Connect EEG7500 to battery (Terminal C and D)
• Connect USB from EEG7500 to PC
2.  and connect the PC to the EEG7500 and the EEG7500
to the engine.
The EEG7500 can be set up and used out of the box, with an actuator attached, using default settings. Default settings are shown in
section 17, Default Conguration.
This section details the initial installation and setup using the default settings. Wiring between the engine and the EEG7500 is required,
and reviewing this document and default settings is advised.
There are two sets of parameters to work with: basic engine performance and engine tuning. Getting Started gets your engine started.
Engine Tuning improves performance.
3. Set the minimum settings in the GACong Tool:
 Your actuator’s Control Mode
• Overspeed
• Number of engine ywheel teeth
• Fuel Limit
• Acceleration and Deceleration
• Actuator Ramp Rate
• Starter Cuto󰀨
• Fixed Speed Settings
COMPLETING MINIMUM SETUP

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Actuator Type
Proportional Motor
Control Mode
Non-Feedback
Speed Control
Default Mode
Feedback Speed
Control
Positioner
Settings in GACong Tool must match the actuator type. Actuators use one of three operating control modes: non-feedback speed con-
trol, feedback speed control, or positioner. These feedback modes are further divided into half and full(2) bridge modes.
1. Actuators are connected Terminals A and B as
shown on the control mode wiring diagrams. An
actuator with a position feedback sensor is required
to use the GACong Tool settings feedback speed
control or positioner mode.
2. If control mode is changed, cycle power to the
EEG7500 controller for the change to take e󰀨ect.
The default setting is Non-Feedback Speed Control
(NFSC). No other parameter settings need to have
the power cycled.
3. Positioner Mode is further dened in Section 14 of
this manual.
(1) Half-bridge connects an output pin to either VCC (voltage
common collector), ground, or disconnects. Use half-bridge
to turn a DC motor on or o󰀨, or apply braking. Do not use it to
reverse the motor. Half bridge mode requires an actuator with a
spring to return to the original setting.
(2) Full bridge control drives the actuator both ways and does not
require a spring in the actuator.
If H-Bridge Mode is set to Half Bridge, but the actuator does not support half bridge(1), attempting to run the engine may harm
the engine or actuator. The information in the Initial Setup is based on using a Non-Feedback Speed Control actuator.
SELECTING ACTUATOR CONTROL MODE
9INITIAL SYSTEM SETUP (CONTINUED)
DEFAULT I / O DEVICE MAPPING
The EEG7500 controller pairs device input mapping of signals physically connected to the EEG with various input and output parame-
ters. The controller supports 5 analog and 2 digital inputs, and 1 analog and 3 digital outputs. Physical inputs are mapped to the param-
eter settings in the GACong Tool.
Each physical connection made to the controller terminals must be mapped using the I/O Conguration screen of the GACong Tool.
The Controller Wiring table shows the terminal to input/output mapping. The following details the GACong Tools corresponding map-
pings.
The Physical Input Mapping block in the I/O Conguration menu of the GACong Tool allows you to map each hardware device to a spe-
cic use, assigning analog or digital signals to a specic input or output. The tool o󰀨ers the exibility to assign di󰀨erent input parameters
for various applications. Review the default I/O Conguration parameters and note the following:
• Actuator is wired to Terminals A and B
• Speed A and Speed B defaults are set to be wired as Digital Input 1 and Digital Input 2 (Terminals 3 and 4)
• Variable Speed Input is mapped to Analog Input 1 (Terminal 7)
• This input combination sets Selected Speed Mode as 1 (shown in Quick Access). Speed Mode 1 = idle.

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DEFAULT I / O DEVICE MAPPING
The Physical Input Mapping links settings between the terminal a
device is attached to and its assigned use. For example, Terminal
16 could be physically connected to a speed switch. Therefore
Digital Output 1 Source should be set to Speed Switch 1 as shown
in the Output Mapping.
Check the Override box to set the physical input to On or O󰀨.
By combining settings you can map signals to specic uses. See
more on Mapping Physical Inputs in section 8.
Output Mapping lets you assign external signals such as J1939 to
specic outbound locations. It is also useful for setting external de-
vices to complete tasks based on overspeed or another event.
9INITIAL SYSTEM SETUP (CONTINUED)
MAPPING TERMINALS TO SOFTWARE SETTINGS

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Once the parameter settings are reviewed and updated as required, start your engine.
1. Crank the engine with DC power applied to the governor system.
2. Set the engine at operating speed with no load.
3. The actuator/ fuel to the engine will be positioned to the level set by the Actuator Start Fuel parameter (default is MAX fuel). Actua-
tor Ramp Rate controls the rate at which fuel is increased to start the engine. Set it 10 % by default.
4. If the engine is unstable after starting, open the GACong Tool and adjust Gain, Stability, and Deadtime in the Engine Tuning menu
in the PID Tuning block, until the engine is relatively stable.
5. Once the engine is stable you can connect additional devices and further optimization.
Use an overspeed shutdown device, independent of the governor system, to prevent loss of engine control which may cause
personal injury or equipment damage. 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.
PARAMETER RANGE DEFAULT DEFINITION
Control Mode
Operating Mode NFSC, FSC,
or PC NFSC Operating mode of the actuator. Requires restart of the EEG7500 for changes to take
󰀨.
H-Bridge Mode Bridge Half Bridge
SET-UP
Flywheel Teeth 60 - 250 120 Number of teeth on the engine ywheel. This should be set prior to starting the engine.
Overspeed 600 - 6000 1800
rpm set to cause automatic engine shut down. Set this value low enough to prevent mechan-
ical damage but high enough to allow realistic load rejection speeds without stopping the
engine.
Fuel Limit 0 - 100 100 % Maximum fuel output.
START-UP
Actuator Start Fuel 1 - 100 % 100 % Initial actuator position at start of crank.
Actuator Ramp Rate 1 - 100 % 10 % The rate of change for the actuator start from the throttle begin point to 100%, during the start/
crank cycle (% / s)
Starter Cuto󰀨 100 - 1000 400 The rpm at which governor switches from starting to governing. Also known as crank termina-
tion.
Acceleration 25 - 2000 300 Rate of acceleration controlled by the governor when a command to increase rpm is received.
Deceleration 25 - 2000 300 Rate of deceleration controlled by the governor when a command to decrease rpm is received.
Once the control mode for your actuator is selected, the following minimum parameters must be set, or the default settings used, before
starting the engine. GAC suggests using the default settings to rst ensure the engine runs smoothly before adding additional devices.
However, you may want to update default settings and additional parameter value depending on the engine, before starting the engine.
OTHER DEFAULT SETTINGS
PARAMETER DEFAULT PARAMETER DEFAULT
Speed 1 1500 Gain 1, 2, and 3 50
Speed 2 1500 Stability 50
Speed 3 1500 Deadtime High
Variable Speed Minimum 1500 Lead Circuit On
Variable Speed 1500 Light Force Governor Enable O󰀨
Variable Speed Gain 50 Variable Speed End Gain 50
Analog Input 1 0 - 5 V DC Input MIN 0 %
Speed Minimum 1500 Input MAX 100 %
Variable Speed Start Gain 50 Input Actual 0
Speed Maximum 1500
9INITIAL SYSTEM SETUP (CONTINUED)
START YOUR ENGINE
I/O CONFIGURATION DEFAULT SETTINGS

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1. For basic potentiometer connection, connect the EEG7500 to the potentiometer as follows:
Terminal 11 to potentiometer terminal 1
Terminal 6 to potentiometer terminal 3
Terminal 7 to potentiometer terminal 2
2. Set the potentiometer to the application you want to use it for. For example, if using the
potentiometer for variable speed, in Physical Input mapping set the following:
a. At Speed Select A, select Override and select On.
b. At Speed Select B, select Override and select On.
c. Quick Access to the far right now says Selected Speed: Variable.
3. To calibrate the potentiometer:
a. Open Engine Tuning  Variable Speed.
b. Set the potentiometer to the full CCW position and click the Calibrate Minimum.
c. Turn the potentiometer CW all the way and click Calibrate Maximum.
d. Note the input actual
When using a potentiometer, the following wiring and GACong Tool settings are required. See the GAC potentiometer manual for
additional information on GAC potentiometers and the Wiring section in this manual.
Terminals
Potentiometer EEG7500
111
2 7
36
ADDING A POTENTIOMETER
The shutdown STOP button available on the GACong tool shuts down fuel to the actuator, but does not directly shutdown the engine. To
shut down the engine automatically at a set speed use the GACong Tool and a solenoid or other relay switch and complete the following
set up.
1. Connect a shutdown solenoid between the engine and an EEG7500 digital terminal.
2. From the GACong Tool, open the I/O Conguration menu and set the following:
a. Map the solenoid switch location to the Digital Output. In this example the switch is attached to the Digital Output 1 (Terminal 16).
In the Physical Output mapping block, set Digital Output 1 Source to Speed Switch 1.
b. At the Speed Switches SSW1 Limit/Threshold set the rpm. This example shows 2600. Overspeed on the Engine Tuning menu
should be set above the engine shutdown switch speed.
c. Set the Select SSW1 Latch. This causes the latching relay to maintain its position after the switch has been released.
d. At Digital Output Mode, set Digital Output 1 to Normally Closed.
3. When the rpm shutdown is reached, the switch engages the solenoid, shutting down the engine.
NOTE Default settings include setting the Digital Output Mode to Normally Open, setting the switch to stay open.
SETTING UP ENGINE OVERSPEED SHUTDOWN
9INITIAL SYSTEM SETUP (CONTINUED)

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To improve basic performance at no engine load:
1. Open the GACong Tool open the Engine Tuning menu, and at the PID Tuning block, perform the following:
a. Increase the Gain parameter by entering new parameter settings until instability develops. Gradually decrease the Gain until
stability returns. Decrease the adjustment one count further to ensure stable performance.
b. Increase Stability parameter on the until instability develops. Gradually decrease the Stability until stability returns. Decrease
the parameter by one to ensure it is stable. If there is no instability leave set at 50.
c. Set the DEADTIME to Low. If instability persists, change DEADTIME to High.
Once the engine is running at operating speed, with no load, use the GACong Tool to adjust the parameter settings to increase engine
stability. Each speed parameter, 1 through 3, has a separate Gain setting. The speed selection number and active Gain are shown in
the PID Tuning section.
Stability is achieved by balancing PID: Gain (P), Stability (I), and Deadtime (D).
Gain (Proportional) changes the initial response of the governor. Increasing gain makes the engine more responsive to load
changes while decreasing gain makes it less responsive to load changes. Avoid engine instability due to high gain when adjusting
this parameter.
Stability (Integral) changes the steady state response of the engine. Increasing stability allows the system to come to steady
state speed faster, while decreasing the stability results in a more gradual transition to steady state speed.
Deadtime (Derivative) sets the transient response of the engine to high or low and a󰀨ects the stability parameter during transient
load changes. Increasing deadtime decreases the percent of overshoot and settling time during a transient load change while
decreasing deadtime increases them. Note that setting Deadtime to High can cause random speed instability during steady state
since small speed errors are amplied by this parameter.
Additional adjustments may be required after engine load is applied. Normally adjustments made at no load achieves satisfactory perfor-
mance.
10 TUNING WITH THE EEG7500
ADJUSTING FOR BASIC STABILITY WITH FIXED SPEED

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10 TUNING WITH THE EEG7500 (CONTINUED)
1. Review Analog Input Mode settings in the I/O Conguration menu.
Select the analog voltage settings that map to the voltage of the actuator
you are using. In this case the Analog Input 1 maps to the 0 - 5 V DC
potentiometer.
2. Set Selected Speed to Variable by completing the following:
a. In Physical Input Mapping  Speed Select A, select Override and
select On.
b. At Speed Select B, select Override and select On.
3. The Quick Access view on the far right should now show Selected Speed
Mode: Variable. Recheck Input Mapping for the potentiometer and
related wiring if Selected Speed Mode is not Variable.
4. If using resistive input, set the potentiometer to the full clockwise
position.
5. Set Variable Position Input Minimum and Input Maximum by either
manually adding settings or use the automatic calibration buttons.
a. To set calibration automatically:
• Turn potentiometer fully CCW and click Calibrate Minimum.
• Turn potentiometer fully CW and click Calibrate Maximum.
b. To set each manually:
• Set Input Minimum to between 0 to 75 %
• Set Input Maximum to at least 25 % greater than the Minimum
value. Values entered which are not 25 % di󰀨erent are
automatically reset to the closest accepted value by the GACong
Tool.
Variable Position Input Position shows the potentiometer value
when a potentiometer is used.
NOTE
Using the single remote speed adjustment potentiometer to adjust the engine speed continuously over a specic speed range. Other
variable speed input devices include other controllers as well as J1939 data. Potentiometer wiring is shown in the Wiring section of this
manual and in the previous section Adding a Potentiometer.
Use the Tuning menu to adjust gain and to set each endpoint of
the speed range to add additional stability.
Gain (P), Stability (I), Deadtime (D), and Lead Circuit are shared
across the entire speed range. For each xed speed create sepa-
rate gain settings to create shared stability.
To maintain engine stability at the minimum speed setting, add a
small amount of droop, available in the Advanced Conguration
menu. At the maximum speed setting the governor performance
will be near isochronous, regardless of the droop adjustment
setting.
1. Open Engine Tuning Variable Speed
2. For each variable speed:
• Set Gain
• Set Speed Maximum and Variable Speed End Gain
• Set Stability
SETTING VARIABLE SPEED WITH A POTENTIOMETER
ADJUSTING VARIABLE SPEED STABILITY

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10 TUNING WITH THE EEG7500 (CONTINUED)
The EEG7500 supports three xed speeds and one variable speed de-
vice. The variable speed can also be used as an additional xed speed
by setting speed minimum and speed maximum to the same value.
By default, upon initial installation, the Selected Speed Mode input is set
to 1 (Idle).
A simple drop down on Engine Tuning  Speed Conguration Speed
Mode allows you to choose your speed mode. Using these selections
also changes the I/O Conguration Physical Input Mapping.
1. Open the GACong Tool Physical Input mapping menu. Note the
default settings:
• Speed Select A = Digital 1
• Speed Select B = Digital 2
• Variable Speed Input = Analog Input 1
• Auxiliary Input = Analog Input 2
• Selected Speed Mode = 1 in the Quick Access view
2. In the Physical Input mapping box, for Speed Select A, check the
Override and then check the O󰀨 selection. At Speed Select B,
check Override and then check On.
3. Note the Select Speed Mode is now 2 in Quick Access.
4. Review the chart below for information on how the EEG7500 uses
Speed Select A and B input to determine speed settings based on
the state of switch inputs.
Speed Setting Override Speed Select A Speed Select B
Speed 1 (Idle) Checked O󰀨 O󰀨
Speed 2 Checked O󰀨 On
Speed 3 Checked On O󰀨
Variable Speed (4) Checked On On
5. Open the Engine Tuning menu and set the desired settings that map
the Selected Speed Input Mode 2. For each Selected Speed Mode
you can set the desired tuning parameter settings using the Engine
Tuning menu.
Instead of using physical inputs, you can also check the Override box,
and manually set the On or O󰀨 state of the selected physical input. The
On/O󰀨 state stays set even after the EEG7500 is disconnected from PC
software.
 On equals a closed state
 󰀨 is the open state.
MAPPING PHYSICAL INPUTS TO SPECIFIC SPEED MODE
In this example the following is true:
• Speed Mode is 2
• The device mapped to Speed Mode 2:
»Fixed Speed = 1900
»Gain 2 = 100
Engine Status on the Engine Tuning screen and
Selected Speed Mode will be 2.