stag 400 dpi manual

5/24/2018 Stag 400 Dpi Manual

1/44

AC S.A. All rights reserved. Copying, publishing, distribution and any usage of the full or partial data included in the herewith document, particularly pictures, drawings, illustrations, trade marks etc. is

strictly prohibited under the law.

Page 1 of 44

INSTALLATION MANUAL FOR LPG SYSTEMS

DESIGNED FOR DIRECT PETROL INJECTION ENGINES

PROGRAMMING MANUAL FOR STAG 400 DPI CONTROLLER

(also available in the diagnostic software and atwww.ac.com.pl)

ver. 1.3 2012-06-22

Manufacturer:

AC Spka Akcyjna.

15-182 Biaystok, ul. 27 Lipca 64

tel. +48 85 7438117, fax +48 85 653 8649www.ac.com.pl,e-mail:[email protected]
http://www.ac.com.pl/http://www.ac.com.pl/http://www.ac.com.pl/http://www.ac.com.pl/http://www.ac.com.pl/mailto:[email protected]:[email protected]:[email protected]:[email protected]://www.ac.com.pl/http://www.ac.com.pl/


2/44



Page 2 of 44

Table of contents

1 PART ONE installation of the system ..................................................................... 3

1.1 List of standards .............................................................................................................................. 31.2 Description of the LPG STAG 400 DPI system .................................................................................... 3

1.2.1 Scope of use ......................................................... .............................................................. ...................................... 31.2.2 STAG 400 DPIoperation principle ................................................................ ......................................................... 31.2.3 Scheme for connecting STAG 400 DPI system ................................................ ......................................................... 4

1.2.3.1 Scheme for connecting STAG 400.4 DPI controller ......................................................................... ................ 41.2.3.2 Scheme for connecting STAG 400.6 DPI or STAG 400.8 DPI controller ........................................................... 5

1.3 Principles regarding installation of particular elements in a vehicle ................................................... 5

1.3.1 Refuelling valves ...................................................................................................................................................... 61.3.2 Autogas tanks .......................................................................................................................................................... 7

1.3.2.1 Cylindrical tanks .............................................................................................................................................. 71.3.2.2 Toroidal tanks ......................................................... .............................................................. ........................... 8

1.3.3 Tank accessories ....................................................................... ............................................................... ................ 91.3.3.1 Selection of tank accessories........................................................................................................................... 91.3.3.2 Installation of accessories ............................................................................................................................... 9

1.3.4 Installation of gas tubes ............................................................ ............................................................... .............. 111.3.4.1 Installation of copper tubes .......................................................................................................................... 111.3.4.2 Fitting non-metal class 1 tubes ..................................................................................................................... 11

1.3.5 Reducer, volatile phase filter, PS-02 sensor .............................. .............................................................. .............. 121.3.6 Electronic control unit ........................................................................................................................................... 141.3.7 Installation of injection nozzles and manifold absolute pressure nozzles .......................................................... ... 151.3.8 Connecting a fuel rail pressure sensor ............................................................ ....................................................... 161.3.9 Installation of the switchboard ..................................................................................................... ......................... 16

1.4 Approval of a vehicle for installation of an LPG system ................................................................... 17

1.5 The first start-up of the gas injection system .................................................................................. 17

1.6 Installation quality inspection ........................................................................................................ 17

2 PART TWO AC STAG diagnostic software ............................................................ 18

2.1 Description of the diagnostic software ........................................................................................... 18

2.1.1 Connecting the controller to a PC ........................................................ ............................................................... ... 182.1.2 Diagnostic software version................................ ................................................................ ................................... 192.1.3 Main menu ........................................................... .............................................................. .................................... 202.1.4 Controller's parameters ....................................................................... ............................................................. ..... 242.1.5 Maps ......................................................................................... ............................................................... .............. 262.1.6 Auto-calibration .............................................................................................. ....................................................... 30

2.1.7 Errors ..................................................................................................................................................................... 302.1.8 Recorder ................................................................................................................................................................ 322.1.9 Monitor window.......................................................... .............................................................. ......................... 332.1.10 Oscilloscope window.............................................................................................. ............................................ 342.1.11 OBD Monitor window............................................................ ............................................................... .............. 352.1.12 Gas level indicator ................................................................................................................................................. 362.1.13 Controllers update................................................................................................. ............................................... 37

2.2 Programming the controller ........................................................................................................... 38

2.2.1 Auto-calibration .............................................................................................. ....................................................... 382.2.2 Multiplier map correction ......................................................... ............................................................... .............. 39

2.3 Operation of the LED switchboard and sound signals (user's manual) .............................................. 42

2.3.1 LED-400 switchboard ................................................................ ............................................................... .............. 422.4 Sound signals ................................................................................................................................. 44

2.5 Technical specification ................................................................................................................... 44

2.6 Appendices .................................................................................................................................... 44


3/44



Page 3 of 44

1 PART ONEinstallation of the system1.1 List of standards

Regulations applicable to the installation process:

UNECE Regulation No. 115; UNECE Regulation No. 67; installation of systems to be used in Poland consistent with Appendix 9 Additional

requirements applicable to vehicles fitted with an LPG system to the Ordinance by the

Minster of Infrastructure of December 31, 2002 on technical requirements applicable to

vehicles as well as the scope of the necessary equipment; Journal of Laws No. 32 item

262;

other domestic regulations.1.2 Description of the LPG STAG 400 DPI system

1.2.1 Scope of useSTAG 400 DPI supply system has been designed to control injection of autogas in the case

of spark ignition direct petrol injection engines.

1.2.2 STAG 400 DPI operation principleThe system is based on typical elements including a tank along with its accessories, gas

tubes, LPG injectors and reducers. The system prepares fuel to be supplied to the inlet manifold

by vaporisation in the reducer and pressure stabilisation depending on the reducer setting.

Pressurised volatile LPG is supplied to the gas injectors installed in the vehicles engine, which

inject the fuel into the manifold through the gas tubes.

The injectors are opened by an electric signal generated by the LPG system controller.


4/44



Page 4 of 44

1.2.3 Scheme for connecting STAG 400 DPI system1.2.3.1 Scheme for connecting STAG 400.4 DPI controller

(*)dedicated connections have been described in theappendiceshereto.


5/44



Page 5 of 44

1.2.3.2 Scheme for connecting STAG 400.6 DPI or STAG 400.8 DPI controller

(*)dedicated connections have been described in theappendiceshereto.

1.3 Principles regarding installation of particular elements in a vehiclePrior to commencement of an LPG system installation process, the vehicle must be verified as

suitable. Vehicles displaying engine defects must be restored to a fully operational condition. Particular

attention should be paid to inspection of the ignition system.

With certain engines, it is recommended to replace selected elements of the ignition system just in

case or to warn the customer about the need to replace such elements. Failure to comply with the above-

mentioned recommendations may result in defective operation of an LPG fuelled engine due to reasons

not attributable to the LPG system itself or the installation method.


6/44



Page 6 of 44

1.3.1 Refuelling valvesRefuelling valves are fitted in the rear bumper or in the petrol inlet bay.

Picture 1.3.1An opening in the bumper Picture 1.3.2Fitting a refuelling valve cover

Picture 1.3.3A refuelling valve from the inside Picture 1.3.4A refuelling valve from the outside

Picture 1.3.5A refuelling valve fitted next to the petrol

inlet

Picture 1.3.6Refuelling tube clips


7/44



Page 7 of 44

1.3.2 Autogas tanksSteel tanks are used. When choosing your tank, make sure that the fitting method ensures

fulfilment of the applicable strength requirements. This applies particularly to the vehicles, in the case of

which an LPG tank is mounted on a plastic support.

1.3.2.1 Cylindrical tanks

Picture 1.3.7A frame for a cylindrical LPG tank Picture 1.3.8A fitted LPG tank

Cylindrical tanks are mounted using a mounting

frame and bolt connections.

The required connection strength is ensured by

installation of mounting frames as well as bands,

the strength of which is confirmed through

relevant tests conducted by the tank

manufacturer.

The tank should be mounted perpendicularly to

the longitudinal axis of the vehicle. Leave 10 cm

[1 cm = 0.393 in] between the tank and the

back seat. In the event the tank is mounted in

the boot, which is separated from the back seat

with a division and there is no possibility of

contact between the tank and the back seat,

there is no need to leave the 10 cm space.

Picture 1.3.9In the event a cylindrical tank is mounted along the vehicles longitudinal

axis, an element which prevents movement of the tank forward must be prepared.


8/44



Page 8 of 44

1.3.2.2 Toroidal tanks

Picture 1.3.10A fitted toroidal tank Picture 1.3.11A multi-valve

Picture 1.3.12Mounting elements

Toroidal tanks should be attached to metal elements

of the vehicle using the parts provided with the tank

(Picture 1.3.12).Orifices must be cut out in the

bodywork in order to enable routing of the gas tubes,

ventilation of the gas tight housing (the inside of the

torus) as well as installation of the fitting bolts. A

plastic support should be placed underneath the

tank. Once the tank has been installed, gas tubes are

fitted as well as the wiring harness. All mounted bolts

and screws should be covered with an anti-corrosion

substance (Picture 1.3.13).

Picture 1.3.13The view from underneath of the

vehicle after installation of the tank

Using factory fittings ensures appropriate strength of the elements connecting the tank with the vehicle.


9/44



Page 9 of 44

1.3.3 Tank accessories1.3.3.1 Selection of tank accessories

Accessories should be selected based on the list of the required equipment elements included in

the tank approval certificate.

1.3.3.2 Installation of accessoriesAccessories should be installed in line with the manufacturers requirements.The tubes should be

secured with a gas tight cover and routed outside of the vehicle (Picture 1.3.15).

Picture 1.3.14A fitted multi-valve Picture 1.3.15Gas tight tubes

The tank must be fitted with a suitable combined valve, also referred to as a multi-valve (Picture 1.3.14).Make sure the selected valve can be used with a given tank. Place a gas tight cover element underneath

the valve. The bolts securing the valve should be fitted diagonally. Subsequently, route the gas tubes

through cable conduit protection hoses and connect them to the multi-valve using suitable connections.

Electrical wires should be connected to the multi-valve according to the scheme. Subsequently, mount

the gas tight cover as well as the cable conduit protection hoses. Any leakages from the multi-valve must

be discharged out of the vehicle. For this purpose, the cable conduit protection hoses are tightly attached

to the sleeves installed in the orifices previously cut out in the bodywork (Picture 1.3.16). Such an outlet

must not be cut out in the inner wheel arch or another element, where it could be obstructed with mud

or snow, and must not be pointed to the exhaust (Picture 1.3.17). Vent tubes (cable conduit protection

hoses) should be as short as possible.


10/44



Page 10 of 44

Picture 1.3.16cable conduit protection hoses

connected to the sleeves inside the vehicle

Picture 1.3.17Sleeve outlet underneath the vehicle

A multi-valve must be installed in the case of toroidal tanks (Picture 1.3.18). Subsequently, route the gas

pipe and connect it to the sockets in the body of the multi-valve. Seal the orifice in the metal sheet

(Picture 1.3.20)and connect the solenoid valve and the gas level indicator (Picture 1.3.19).

Picture 1.3.18A multi-valve Picture 1.3.19A connected multi-valve

Picture 1.3.20An orifice for gas tubes in the bodywork


11/44



Page 11 of 44

1.3.4 Installation of gas tubesThe gas tube should be routed in such a manner, as to ensure easy fitting as well as examination of its

technical condition in the future. Make sure there is no risk of damaging the vehicle and do not leave

sharp edges, which could be dangerous to the vehicle users or other individuals. Tubes must not be

connected with one another.

1.3.4.1 Installation of copper tubes

Picture 1.3.21Fitting electrical wires with tie-wraps Picture 1.3.22Fitting with metal clamps

Use exclusively clamps and tubes with anti-corrosion protection designed for use with LPG systems. The

distance between tie-wraps/metal clamps must not exceed 70 cm (Picture 1.3.22). When routing the

tubes, make sure the radius of curvature prevents bending. Use compensation loops at connections with

the elements of the gas system. Do not make additional connections, which are not necessary for the

purpose of connection of particular elements.

1.3.4.2 Fitting non-metal class 1 tubes

Picture 1.3.23Connecting the tubes to the solenoid

valve

Picture 1.3.24Fitting with metal clamps

Place the tubes in cable conduit protection hoses. Use exclusively terminals approved for use with the

tube. The distance between particular fitting elements must not exceed 40 cm (Picture 1.3.24). The


12/44



Page 12 of 44

minimum distance from hot elements is 30 cm. Avoid crossing elements of the exhaust system. Use a

copper tube in the event it is difficult to meet the above-mentioned requirements.

1.3.5 Reducer, volatile phase filter, PS-02 sensorThe reducer is mounted on a support or directly on the element connected to the vehicles bodywork

(Picture 1.3.25). Mount the reducer close to the engine in order to limit the length of the gas tubes

connecting the reducer and the injectors, in the place where it will not be exposed to high temperatures.

Picture 1.3.25Fitting of the reducer Picture 1.3.26Connection of the reducer

Picture 1.3.27Connection between the reducer and

the cooling systemPicture 1.3.28LPG volatile phase filter


13/44



Page 13 of 44

Picture 1.3.29Suggested diagrams of connection of 2 reducers to the LPG/CNG instalation

The reducer should be connected to the cooling system with metal tees incorporated into to the

vehicle's heater system (Picture 1.3.27).

The volatile phase filter should be attached to non-moving parts of the vehicle, away from the heatsources (Picture 1.3.28).

The PS-02 pressure sensor should be fitted on the gas tube between the volatile phase filter and the

gas injectors (Picture 1.3.30).


14/44



Page 14 of 44

Picture 1.3.30PS-02 type sensor

1.3.6 Electronic control unitThe controller should be mounted on a support or directly on the element connected to the vehicles

bodywork. It is recommended to install the controller near the engine, were the device will not be

exposed to water or high temperatures. The engine compartment is a typical installation location.

Picture 1.3.31A view of an installed controllerPicture 1.3.32A view of the controllers mounting

elements


15/44



Page 15 of 44

1.3.7 Installation of injection nozzles and manifold absolute pressure nozzles

Picture 1.3.33Location for installation of nozzles

in the manifold (view from the outside)Picture 1.3.34Location for installation of nozzles (view

from the inside of the manifold conduit)

In certain cases (see the appendices), it is necessary to remove the inlet manifold. Orifices should be

drilled as close to the engine head as possible. Mount nipples in such a manner, as to makes sure they

point to the suction valves, and secure them against unscrewing. Connect injection tubes to the nipples

and secure them with a metal clamp.

Mount the injector on supports and connect it to the injection tubes. Subsequently, fit the supply tube

as well as the pressure measuring tube. Connect the wiring harness to the injectors, while observing the

order specified in thescheme.

NOTE! Nozzle sizes for particular types of engines have been specified in the appendiceshereto.

The manifold absolute pressure nozzle should be installed in the shared part of the inlet manifold

(downstream the throttle).

Picture 1.3.35A manifold absolute pressure nozzle fitted in the manifold


16/44



Page 16 of 44

1.3.8 Connecting a fuel rail pressure sensorA gas system compatible with direct injection engines must include a fuel rail pressure sensor. Detailed

instructions have been included in theappendiceshereto.

Picture 1.3.36Fuel rail pressure sensor

1.3.9 Installation of the switchboard

The switchboard must be installed in a location visible

to the driver. Additionally, the location of the

switchboard must be accessible and using the

switchboard must not hinder driving the vehicle.

Picture 1.3.37Exemplary location for installation of the P/G switchboard

A connection with a pair of 3-pin connectors has been used in order to make it easy to connect the

switchboard to the harness of STAG 400 DPI controller. Having installed the switchboard, place the wires

in the dedicated connection (included) as shown in the Picture 1.3.38 while observing the correct

connection order.


17/44



Page 17 of 44

Picture 1.3.38The connection and the order of the wires Picture 1.3.39The P/G switchboard

NOTE! The switchboard must be connected to the harness in the passengers compartment.

1.4Approval of a vehicle for installation of an LPG systemMake sure the vehicle's engine is included in the list of supported engine types (subsectionAppendicesof this manual). Do not proceed with the installation process if the engine is not of the

supported type.

Perform technical inspection of the vehicle's engine. In the event the engine is worn out or displays

defects, restore the engine to a fully operational condition prior to proceeding with the installation

process.

1.5 The first start-up of the gas injection systemRefuel the vehicle and inspect tightness of particular elements of the system.

Inspect connections between the controller and the LPG system.

Perform auto-calibration and setting adjustment while driving the vehicle.

1.6 Installation quality inspectionVerification of completeness of the system

Verification of tightness of the system

Inspection of performance of the gas system


18/44



Page 18 of 44

2 PART TWOAC STAG diagnostic software2.1 Description of the diagnostic software

2.1.1 Connecting the controller to a PCHaving completed the installation process, connect a computer with AC STAG software to STAG

400 DPI controller using AC S.A. RS 232 or USB interface. Prior to launching the software, turn

the key in the vehicle ignition in order to supply voltage "through the ignition" and activate the

controller in order to enable communication. Once the software has been launched, AC STAG

will automatically make an attempt to make the connection through the COM port, to which the

interface has been connected to. A status window in the left-hand bottom corner of the

application notifies the user about correctness of the connection.

Figure 2.1.1 Controller detection window

Figure 2.1.2 Parameters tab(Car parameters)


19/44



Page 19 of 44

Figure 2.1.2a Parameters tab(Gas controller settings)

Select another port from the Port menu in the top section of the screen in the event the

application displays NO LPG controller! message.

Figure 2.1.3 System warningwindow and the Port tab in the Menu bar

2.1.2 Diagnostic software versionOnce the diagnostic software has been started, AC STAG version will be visible on the bar located

in the top section of the screen.Figure 2.1.4indicates version 0.9.229.

Figure 2.1.4 Main menu bars


20/44



Page 20 of 44

2.1.3 Main menuThe main menu includes the following options:

Port enables one to change the communication port, establish and terminate

connection with the controller as well as activate the automatic connection detectionmode;

Window selection from among main windows of the application.

Figure 2.1.5 Window tab in the Menu bar

Window menu allows one to restore main windows, in the event they have been

closed. AC STAG enables the user to freely arrange application windows. Use the drag &

drop technique to easily modify location of particular windows. Pressing and holding the

left mouse button on the bar of the selected window allows one to move it. Releasing

the left mouse button causes embedding or extraction of the window depending on thecurrent position of the cursor.

Language selection of the language version; AC STAG requires restarting once a new

language version has been selected.

Tools update of the controller and the LED switchboard, automatic distribution of

setting windows, restoration of the default settings.

Update of the controller as well as the LED switchboard has been discussed in item

2.1.13.

In order to save settings and the controllers map, select the floppy icon located on the

right-hand side of the Parameterswindow,

or select Tools Save parameters from the main menu.

Figure 2.1.6Tools tab in the Menu bar


21/44



Page 21 of 44

Indicate the location on the computers hard drive, where the file with the setting is to

be saved, enter the name of the file and click Save.By following the above-mentioned

instructions, the user can save the settings and the maps.

In order to load the settings and the maps, click on the Open button located on the

right-hand side of Parameterswindow,

or select Tools Open saved parameters from the main menu.

The application will ask the user to indicate the file with the settings (.set extension).

Indicate the file and open it. Subsequently, Open saved parameters window will be

displayed.The user can open just the settings, just the map or both the settings and the

map simultaneously. Tick the desired selection in the window presented below and click

Ok.

Figure 2.1.7 Open saved parameters window


22/44



Page 22 of 44

Help information on the software and the controller

Figure 2.1.8Gas controller info window

ThewindowGas controller infoincludes the following parameters:

o Petrol the total controller operation time on petrol displayed in thefollowing format: Hhours, Mminutes, %a percentage share in the total

operation time

o Since last connection the time of operation on petrol from the lastconnection to a PC

o Gas the total controllers operation time on gaso Since last connectionsthe time of operation on gas from the last connection

to a PC

o Service the set time to inspection. Once the controller's time of operationon gas exceeds the set time to inspection value, the controller, each time the

ignition is turned off, will inform the user about the need to inspect the

system with the sound signal. The method for setting the time to systems

inspection has been described in the following section. A negative value

denotes the time, which has passed from the first indication of the need to

carry out the inspection.

To set the time to inspection, click on the

button in the window Gas controller info; the following window will be

displayed.


23/44



Page 23 of 44

Figure 2.1.9 Service set window

The desired time to inspection is calculated based on the selected mileage,

after which the inspection is to be carried out. A default conversion rate of

1h50 km is used with calculating the time to inspection value; yet, the value

of the conversion rate can be modified. In the above-mentioned window, an

inspection after 10,000 km [1 km = 0.62 mile] has been selected, which in this

particular case translates into 200 hours of operation.Select Inactive in the selection field, in order to delete the inspection. Once

the above-mentioned option has been selected, the controller will not check

the time to inspection any more.

The section below the time of operation values in the windowGas controller

infoincludes the following events recorded by the controller:

o First PC connection the date, on which the controller was connected toa PC with the diagnostic software for the first time;

o First change of settings the first modification of the controllerssettings;

o Last PC connection the date, on which the controller was connected toa PC with the diagnostic software for the last time;

o Mod. date 1 Mod. date 5 the list of modifications in terms ofcontrollers settings.From the most recent ones to the earliest ones;

o Clear errors a recorded event from the most recent deletion of errorsof the gas controller;

o Unknown change of settings the event is displayed, if controllerssettings are modified with a date preceding the date of the most recent

modification.

A code is assigned to each event, which identifies the PC, which was used tomodify the settings. With the modification date as well as the code, which

identifies the PC, which was used to introduce the change, the user can

determine whether or not the controllers settings were modified by third

parties.

The following additional information can be found in the bottom section of

the window:

o ECU S/No

Your PC code the code assigned to the PC, on which AC STAGdiagnostic software is currently running.


24/44



Page 24 of 44

2.1.4 Controller's parametersAt the bottom of the screen, the software displays the controllers firmware version, its model as

well as the date and time of compilation of the firmware:

STAG 400.8 DPI controllers model

ver. 0.46controllers firmware version number

12.0.0controllers version number

2012-06-22 09:34:14date and time of compilation of the controllers firmware

Parameters group has been divided into subgroups, which allow the user to set parameters

individually for each vehicle. Additionally, the user can freely arrange the parameters' windows

by dragging with the left mouse button and dropping in the desired location. The user can also

collapse the windows:

Engine parameters:o Number of cylindersthe number of cylinders in the vehicleo Number of cyl. per coilthe number of cylinders per one ignition coilo Engine codefactory engine code

Calibration parameters:

o Operational pressure gas pressure value at which the controller was calibrated.Manual modification of the operating pressure is possible, yet each modification

requires correction of the multiplier map.

o Minimum pressure gas pressure value, below which the controller switches topetrol.

o Gas temp. gas temperature at which the controller was calibrated. Manualmodification of the temperature value is possible, yet each modification requires

correction of the multiplier map.

Switch-over to gas:

o Fuel typethe type of fuel used for conversion purposes (LPG or CNG)o Switch-over threshold engine rpm threshold value required for the controller to

switch to LPG

o Switch-over timetime after starting the engine, when the controller can switch toLPG

o Reducer filling delaythe time between activation of the LPG/CNG solenoid valveand activation of the gas injectors

o Switch-over temp. reducer temperature required for the controller to switch toLPG

o Cylinder switch-overtime elapsing between activation of subsequent gas injectorsPetrol switch-over:

o Min gas RPMengine rpm threshold value, below which the controller switches topetrol

o Max gas RPMengine rpm threshold value, above which the controller switches topetrol

o Pressure error delaytime, after which the controller switches to petrol, if the gaspressure value is lower than the minimum value set in the calibration parameters

o Min. gas temp.minimum gas temperature, below which the controller switches topetrol


25/44



Page 25 of 44

Sensors and actuators:

o Gas injector type settings of the installed gas injectorOnce the

button has been clicked, the following window, including gas injector settings, will

be displayed:

Figure 2.1.10 Gas injectors settings window

The window enables the user to set the correction rate individually for each section

of the injector as well as assign a given injector to a particular vehicle's Bank.

o Lambda sensor 1 probe 1 type settings, Voltagestandard voltage probe, UEGOwide band UEGO probe

o External sensor additional sensor settings.Voltage sensor (lambda) a standard voltage probe.

UEGO sensor (lambda) a wide band UEGO probe.

Sensor emulationthe setting used in the case of dedicated connections

of the controller's wiring harness (see the description in the appendices

hereto).

Advanced settings:

o Extra inj. correctionadditional injections will be indicated by a yellow backlight ofthe Inj. dose window in Monitor window. This is the ECU mode of operation,

which is characterised by an additional fuel injection. The slide control setting

impacts response of STAG controller to additional injections. Set the correction

value for additional injections by the trial and error method, while observing STFT

correction indications, when they occur. We recommend the setting, which would

result in STFT correction around 0%. STFT correction reading with OBD Monitor

window or an SXC 1011 diagnostic scanner.

OBD:

o ConfigurationOBD communication enabled/disabled STAG 400 controller detectsconnection of the diagnostic scanner and does not interrupt the transmission, thus

enabling operation with the scanner connected. The communication feature should

be disabled in the event diagnostic scanners are used, in the case of which issues

related to connection to the ECU controller occur.


26/44



Page 26 of 44

There are the following five buttons on the right-hand side of Parameterswindow:

Load settings and map file

Save settings and map file

Automatic arrangement of the parameter windows

Return to controllers default settings

Return to the previous size of Parameterswindow

Resize Parameterswindowif the user clicks on this button, the oscilloscope will not

be displayed in the window any more, in order to facilitate window arrangement.

2.1.5 MapsThis window includes 3D maps of the gas controller. Three map views are available.

2D view

The multiplier value can be changed with this map. Engine rpm value is displayed on the vertical

axis. The displayed rpm values can be modified by clicking on the desired value with the left

mouse button and entering a new value. Petrol doses are displayed along the horizontal axis.

Injection times can be modified by clicking on them with the left mouse button and entering new

values. Additionally, rpm and dose values displayed along the axes can be modified by the

following key combinations: CTRL + ALT and SHIFT + , , , . The multiplier

values displayed on the map are percentage values, which are additionally colour mapped

depending on how rich/weak the mixture is. Columns and lines can be added, by clicking with

the right mouse button on the map area. The multiplier can be modified by highlighting with the

left mouse button and pressing the ENTER key. Modification is introduced via the following key

combinations: CTRL and or as well as +,-.In the event the Shift key is pressed

and held and the above-mentioned combination is used, the multiplier will be changed

incrementally by 10%. Pressing the space-bar results in highlighting the point closest to the

engine operation point. By pressing and holding the space-bar while driving, one can easily

correct the multiplier value at the intersection of the closest petrol dose and the engine rpm

value. It is also possible to highlight a larger area for edition. What is more, columns and linescan be deleted. Press simultaneously Shift + Delete to delete lines and "Alt" + "Delete", also

simultaneously, to delete columns. Highlight the desired points prior to any deletion operation.

Extreme values of columns and lines cannot be deleted.


27/44



Page 27 of 44

Figure 2.1.112D maps; classic view

Figure 2.1.122D map; extended view

Various methods for displaying a 2D map as well as the multiplier line view can be selected. To

select the desired display method, select Tools Program settings in the main menu. A window

will be displayed, which includes two groups of options pertaining to the map display method.

Map type group determines the method of arrangement of map points:

Classic map option arranges points evenly regardless of the dose and rpm value;

Expanded map option arranges points proportionately to the values along the

dose and rpm axes.

Map view group determines the visible scope of the displayed map:

Full map option displays the entire available scope of the dose (u p to 25 ms) as

well as the rpm values (up to 10,000 rpm);


28/44



Page 28 of 44

3D view

The 3D view is a graphical representation of the 2D view. It is the same map displayed in 3

dimensions.

Figure 2.1.13 3D map view

Multiplier line view

This view also enables adjustment of the gas system; yet, one must remember that setting the

multiplier in a given spot results in a change throughout the whole rpm range. Therefore, it is

recommended to finally adjust the system with the 2D view map in the event it is impossible to

adjust a given area for a particular rpm value exclusively with the classic multiplier line view. The

horizontal axis represents the petrol dose, and the vertical axis represents the multiplier value.

Adjusting the multiplier is based on highlighting the spot with the left mouse button and setting

the desired multiplier position using or .Press and hold Shiftto change the multiplier

incrementally by 10 steps. Additionally, the entire multiplier line can be elevated by clicking themouse button on the diagram and pressing or .In this case, the Shiftkey function also

applies, which allows adjusting the line incrementally.


29/44



Page 29 of 44

Figure 2.1.14 The multiplier line; full view

Temperature correction view

Figure 2.1.15 Gas temperature correction

KT tab enables one to set the dose correction depending on the gas temperature. The correction

is applied by highlighting a given spot with the left mouse button and setting the desired

correction value by pressing or .Use the right mouse button to increase the number of

spots by clicking in the desired location.


30/44



Page 30 of 44

2.1.6 Auto-calibrationOnce the parameters have been set in Parameters window, one can proceed with auto-

calibration on the system. The mechanical components must be fitted correctly, the gas injector

nozzles must be of the correct size and the reducer operating pressure value must be

appropriate. The auto-calibration procedure has been described in detail in chapter2.2.

Figure 2.1.16 Auto-calibration window

2.1.7 ErrorsErrors tab informs the user about errors of the STAG 400 DPI controller as well as errors of the

ECU petrol controller, if communication with the OBD adapter has been established. In both

cases, it is possible to read and delete errors.

Figure 2.1.17 Errors tab


31/44



Page 31 of 44

List of STAG errors

Error description Error No.

Parameters error, check parameters 32769

Map error, check map 32770

No switchboard connection 256

Lost connection with switchboard 257

No reducer temperature sensor 512

No gas temperature sensor 513

Short circuit in reducer temperature sensor circuit 514

Short circuit in gas temperature sensor circuit 515

Low gas pressure 772

No injection pulses - petrol injector 1 1024


No injection pulses - petrol injector 3 1026No injection pulses - petrol injector 4 1027





Failure of gas injector 1 1792




Failure of gas injector 5 1796Failure of gas injector 6 1797



No gas injector 1 1800






No gas injector 7 1806No gas injector 8 1807

Failure of peripherals supply circuit 2048

Failure of selenoid valves supply circuit 2050

No selenoid valve 2051

Low power supply voltage 2052

High power supply voltage 2053

Data bus communication circuit fault (switch to ground) 2305


32/44



Page 32 of 44

2.1.8 RecorderRecorder window enables the user to browse through the files of the STAG parameters logger,

which was fitted in the vehicle and connected to the diagnostic connection of the STAG

controller. Connecting AC STAG software with the LPG controller is not required in order to

browse the logger files. Once the logger has been connected to a PC using an USB interface, it is

automatically detected and the recorded files are displayed in the window.

The logger window will display the following message Status: Recorder available.The loggers

firmware version as well as the current date will be displayed too. From this moment on, the

user can view the loggers files.

Figure 2.1.18Recorded files

Double click with the left mouse button on a given file to load it or use the "Open" button. In the

event a file with a set marker is loaded (Figure 2.1.18), an oscilloscope file will be displayed with

the cursor set on the event. This means that the user pressed the logger button while the

vehicle's engine was working. The monitor window will display the recorded parameters.

Figure 2.1.19 Recorder tab

Click on "Clear" button in order to delete the logger's files. The time needed to perform the

above-mentioned operation may be substantial as it depends on the number of recorded files.


33/44



Page 33 of 44

2.1.9 Monitor windowMonitorwindow displays current system's parameters:

LED switchboard with the switch click on the

switchboard to switch between LPG and petrol

Pressure[bar] LPG pressure and pressure in the MAP

inlet manifold

Inj. dose [ms] calculated petrol injection time for the

petrol injectors

Gas Inj. dose[ms] injection time for the LPG injectors

Temperature [C] temperature of the injected gas,

reducer temperature and temperature inside the

controllerVoltage [V] voltage values for lambda probes as well

as the cars battery

RPM [obr./min.] engine rpm value

Figure 2.1.20 Monitor window

All the parameters displayed in the monitor window, are also visible on the oscilloscope. A

particular signal can be switched off in order for the oscilloscope not to record it. To do so,

uncheck a given signal in the window by the name. Click on the name field of a given parameterdisplayed in the monitor window to enable its colour change.

The user can adjust the number of displayed parameters by clicking on the button on the

parameter category bar, which collapses the parameters.


34/44



Page 34 of 44

Additionally, by the indication of the wide band lambda probe (Lam. 1WR), there is the

symbol which, when pressed, changes the method for displaying the probe signal on the

oscilloscopethe signal becomes amplified.

Gas Inj. Dose window enables the user to switch off particular LPG injectors by clicking on the

given injectors symbol.This option allows detecting mechanical damage to an LPG injector.

Figure 2.1.21Gas Inj. Dose window

What is more, Monitorwindow offers the auto-hide option, which can be activated by clicking on

the symbol on the windows bar.A hidden window will be displayed as a bar only. A hidden

window automatically drops down, if the mouse cursor is pointed on its bar.

2.1.10Oscilloscope windowTo make Oscilloscope window visible, select Window Oscilloscope from the main menu.

Figure 2.1.22 Oscilloscope window

Oscilloscope window displays all the signals visible in the "Monitor" and OBD Monitor"

windows.All the control buttons have the following functions, starting from the left-hand side:

Start the oscilloscope;

Stop the oscilloscope;

Record the current oscilloscope;

Load the oscilloscope from a file saved on the hard drive;

Reduce the diagram scale;

Increase the diagram scale.

By pointing the cursor to a given event, while viewing the oscilloscope files, the user can view the

values underneath the cursor in the Monitorwindow.The user can move the oscilloscope with


35/44



Page 35 of 44

the slide control at the bottom of the screen or by pointing the cursor to the edge of the diagram

and holding the left mouse button.

Figure2.1.23 File info window

2.1.11OBD Monitor windowThe OBD Monitorwindow becomes visible by selecting Window OBD Monitor from the main

menu.

Figure 2.1.24 OBD Monitor window

The OBD Monitorwindow displays the following parameters:

Fuel system status CL closed loop (STFT and LTFT corrections are on), OT insufficient

engine temperature (heating), OF open loop due to the ECU controllers error, N/A status not available

STFT B1 short term fuel trim Bank I

STFT B1 long term fuel trim Bank I


36/44



Page 36 of 44

STFT B2 short term fuel trim Bank II

LTFT B2 long term fuel trim Bank II

Additionally, STFT and LTFT values are graphically represented on the above-mentioned

indicators.

OBD Monitor window is a tool, which facilitates setting the vehicle, provided that the STAG

controller is connected to the vehicles OBD connection. A correct connection is indicated by a

flashing light in the left-hand bottom corner of the window.

2.1.12Gas level indicatorClick the right mouse button on the switchboard in order to edit settings of the Gas level

indicator. A setting window will be displayed, which enables selection of threshold voltage

values for the indicator.

Figure 2.1.25 Gas level indicator window

The window enables access to the following settings:

Gas level sensor type the user can select from among the following LPG level sensors:

WPGH Hall sensor (3-wire), 50 [kOhm], 90 [Ohm] resistance sensors (2-wire)

Characteristics sensor signal increment method: decreasing or increasing

Sound level buzzer volume, 4 levels

LED brightness levelLED brightness setting for the level indication

Buzzer positiononce LED400 has been installed, the user must select the location of the

speaker, to ensure correct visualisation of the LPG level indication.

The voltage boxes can be edited in order to ensure correct level indication. Once the sensor type

has been selected, set the extreme values for en empty and a full tank, by setting the voltage

values, including a margin, to ensure correct indication for the Empty and Full reading. Enterintermediate values, in appropriate proportions, in both of the middle boxes.


37/44



Page 37 of 44

2.1.13Controllers updateTurn the key in the ignition in order to supply the controller and enable update of the

controllers firmware. Select Tools Devices updatein the main menu.

Figure 2.1.26 Tools tab in the main menu

A window (Figure 2.1.27)indicating the current version of the controller's firmware as well as theavailable updates will be displayed. Parameterswindow includes a list of devices, for which an

update is available. Firmware updates for STAG 400 DPI controller and LED switchboard are

available.

Select the controller (e.g. STAG 400 DPI) or LED switchboard (LED-400) in Devices parameters

window, to proceed with the firmware update. Connect the logger and use Find Recorderbutton

in order to update the firmware of the Stag Parameter Logger. Subsequently, select the desired

firmware version fromAvailable updateswindow. In the event the list of available updates is not

displayed, click on Read Update button and select the desired file from the computer's hard

drive. Having selected the desired firmware version, click on Update button. Wait until the

update process has been completed. The update process progress is reflected by the progressbar. The engine must be turned off during the update.

Figure 2.1.27Devices update window


38/44



Page 38 of 44

2.2 Programming the controller2.2.1 Auto-calibration

Auto-calibration is possible once the reducer temperature has reached the level of 60 C.Start

the engine and wait until the lambda probe starts working before proceeding with the auto-

calibration procedure. Appropriate LTFT and STFT corrections are important when running on

petrol. Usually correction values should oscillate around 0%. When performing auto-calibration,

the engine should work at idle run. Do not rev up the engine, AC and the lights should be turned

off. Do not move the steering wheel, as this might result in an incorrect course of the calibration

procedure. Once Auto-calibration window has been selected and Start button clicked, the

Choose engine code window will be displayed.

Figure 2.2.1Choose engine code window

Note! A valid engine code list can be found in the list of appendices.

Once the engine type has been selected, the auto-calibration procedure commences.

NOTE! In the event the engine code is selected incorrectly, the engine will malfunction and the

vehicle may become immobilised.

The progress bar informs the user about the state of the calibration procedure. During the

calibration process, the user can observe petrol injection times and switching on of subsequent

LPG injectors. Once all the injectors have been adjusted, the auto-calibration process is

complete.

Figure 2.2.2 Auto-calibration window


39/44



Page 39 of 44

2.2.2 Multiplier map correction

Figure 2.2.3 Multiplier map view

Once the auto-calibration has been performed, the user can proceed with setting the vehicle in

road conditions using the multiplier map. Select Mapstab to do so and subsequently choose the

desired view option.We recommend the following controllers map adjustment methods:

Adjustment based on the injection timeskeep injection times as well as the load onthe points visible on the multiplier map on a constant level while driving on petrol.

Calibration assistantwill help you do this. The tool is represented by a window, which

displays a blown-up multiplier line to facilitate monitoring at the injection time.

Figure 2.2.4 Calibration assistant window

Calibration assistant can be accessed through the main menu, by selecting Window

Calibration assistant. Click on Startbutton, while running on petrol in order to activate

the assistant.


40/44



Page 40 of 44

Petrol injection time (the red line) as well as automatic switchover to LPG will be saved in

Calibration assistantwindow at stable driving conditions.

Figure 2.2.5 Calibration assistant window

Following the switchover, the green line indicates the current petrol injection time.

Correct the multiplier in such a manner as to make sure the green line corresponds with

the red one following the switchover. In order to facilitate the task, the assistant window

displays the rpm as well as the manifold pressure values saved while running on petrol

(marked with blue colour on the dials). In the event the saved rpm and manifold pressure

values are exceeded, the dials will become backlit in yellow. Lower the multiplier in the

calibrated point, in the event the green injection time indicator, following the switchover,

is situated on the left-hand side of the red indicator (the mixture too rich). Similarly, in

the event the mixture is too weak, the green indicator is situated on the right-hand side.

Increase the multiplier value in such a case. STFT and STFT (red colour) correction values

are frozen in the assistant window following the switchover in order to facilitate the task.

This represents the correction value, which applied in the calibration point just prior to

switchover to LPG. Additionally, following switchover to LPG, on the left-hand side of the

assistant window, an arrow is displayed, which informs the user about the recommended

multiplier correction direction. Following the switchover to LPG by the assistant,

depending on which map is being configured (LM or 2D), the nearest calibration area

point is activated. Pressing or causes immediate correction of the same. In

order to verify the multiplier, switchover to petrol and move back to the calibration point.

If necessary, it is possible to add calibration points by clicking the right mouse button on

the multiplier line. The second point along the multiplier line is calculated during the

auto-calibration procedure, while the engine is working at idle run. Having set all the

points in road conditions, also check the point calculated during calibration. Once the

vehicle has stopped, verify its settings and make adjustments, if necessary.

When setting the vehicle based on the injection times, it is a good practice to observe

STFT and LTFT correction indications using the OBD Monitor and Calibration assistant

windows or SXC 1011 diagnostic scanner, in order to verify correctness of the setting.Press STOP button to discontinue operation of the assistant.


41/44



Page 41 of 44

Adjustment based on observation of STFT correctionwhile driving, when conditions

are stable and the cursor is on the selected point of the map, switchover to LPG and

observe STFT correction indications (using OBD Monitorwindow or SXC 1011 diagnostic

scanner). Set the multiplier point in such a manner as to make sure the correction

oscillates around 0%. In the case of a positive STFT value, elevate the multiplier point,

otherwise lower it. Continue until the required correction is achieved. Once the selected

map point has been set, increase the load to move to the next point (without switching

over) and repeat the above-mentioned actions.

Having initially set up the multiplier map, verify nozzle selection at the maximum load. Check

STFT correction at the maximum petrol injection times recorded, when pulling out with the full

load (the accelerator pedal pushed to the floor). Usually, the correction value should oscillate

around zero. In the event changing the multiplier has no effect and STFT correction remains

positive at all times or the lambda probe works in the weak mixture range, it means that the size

of LPG injector nozzles is too small and larger nozzles should be installed instead. Repeat the

calibration procedure, once the nozzles have been replaced.

Verify additional injections settings once the vehicle has been set up. In Parameters Advanced

settings Extra inj. correction tab, there is a slide control, which is used to set LPG injectors'

correction in the event additional injections occur. Additional injections are signalled with a

yellow backlit of the Gas Inj. Dose window in the Monitor window.

Figure 2.2.6 Inj. dose window

Such a situation usually accompanies dynamic engine performance, such as acceleration. In the

event additional injections are observed, watch STFT correction and if the mixture is too weak or

too rich, use the slide control to adjust the correction value as to make sure STFT indication isidentical with the one applicable to petrol (usually around 0%).

Figure 2.2.7Advanced settings window

Shifting the slide control to the right makes additional LPG injections richer, while shifting the

slide control to the left makes additional LPG injections weaker.

In the event setting the multiplier through the multiplier line (LM button in Maps tab) is

insufficient for the entire rpm range, use the 2D map (2D button in Mapstab).


42/44



Page 42 of 44

Figure 2.2.82D map view

In order to modify the multiplier value in the calibration area, highlight the area and edit the

multiplier value by pressingEnterand entering the desired value.

Figure 2.2.9 Changing the multiplier value in the 2D map view

You can also use + and - or and keys, while holding CTRL, to change the multiplier value.

Apply a 10% incremental change by holding theShiftkey.

2.3

Operation of the LED switchboard and sound signals (user's manual)2.3.1 LED-400 switchboard

Figure 2.3.1 LED-400 switchboard view

LED-400 switchboard features the following elements:

LED circle four LEDs in the form of a circle, which indicate the current LPG level in the tank.

Four green LEDs indicate a full tank.


43/44



Page 43 of 44

AC logo buttonenables fuel switchover and indicates the current mode of operation:

darkenedthe vehicle is running on petrol;

flashes slowly (once per second) the engine is running on petrol, once the set

parameters have been achieved, the system will automatically switchover to LPG;

flashes normally (twice per second) with no sound signals the system is switching over

to LPG; this can last up to 10 seconds depending on the current parameters of the

engine;

flashes rapidly (4 times per second) and emits sound signals controllers error (e.g.

shutdown due to an empty LPG tank);

backlit in whitethe vehicle is running on LPG;

backlit in redthe vehicle is running on LPG, but the LPG tank is almost empty.

The following additional functionalities are accessible, when LED-400 switchboard is connected

to STAG 400 controller:

LED brightness level adjustment (4 LED brightness levels to choose from);

LED switchboard buzzer volume control;

LED switchboard orientation adjustment in order to ensure correct visualisation of the

LPG level indication, the buzzer installation location being the reference point;

automatic identification of the type of connected LED switchboard; a connected LED-400

switchboard is recognised by the application as LED-400.

Figure 2.3.2LED-400 set-up window

The controller remembers the most recent fuel settings applicable prior to cutting off the

supply voltage with the key.


44/44



Page 44 of 44

2.4 Sound signalsThe controller emits the following sound signals:

three sound signalsa switchover to petrol due to insufficient LPG volume in the tank;three short sound signals and one long signal a controllers error after turning off the

ignition;

two short signals and one long signal required system inspection missing. Go to a

service station in order to inspect the system.

2.5 Technical specificationSupply voltage 12[V] (-20% +30%)

Maximum current draw of the controller (1 ohm LPG injectors) 25 [A]

Current drawn when in sleep mode < 10 [mA]Operating temperature -40 - 125 [C]

Protection class IP54

2.6AppendicesThis manual includes appendices with guidelines regarding installation of STAG 400 DPI

controller in vehicles equipped with various engine types.

The appendices are also availablehere.
http://localhost/var/www/apps/conversion/tmp/scratch_4/Table_of_appendices.pdfhttp://localhost/var/www/apps/conversion/tmp/scratch_4/Table_of_appendices.pdfhttp://localhost/var/www/apps/conversion/tmp/scratch_4/Table_of_appendices.pdfhttp://localhost/var/www/apps/conversion/tmp/scratch_4/Table_of_appendices.pdf

stag 400 dpi manual

Documents

lpg stag

installation manual

trade marks

partial data

autogas tanks

cylindrical tanks

toroidal tanks

ac spka akcyjna