AC STAG-300 QMAX BASIC User Manual Download

Page: 1 / 65

within this document, in particular photographs, drawings, illustrations, trademarks, etc.

Controller User Manual

67R-01 4903

110R-00 4904

10R-03 6616

(information contained in this manual is also available

in the diagnostics software help system and at the

www.ac.com.pl

website)

ver. 1.7.9

2017-04-12

Summary of Contents for STAG-300 QMAX BASIC

Page 1: ...n any way all or any part of information contained within this document in particular photographs drawings illustrations trademarks etc Controller User Manual 67R 01 4903 110R 00 4904 10R 03 6616 information contained in this manual is also available in the diagnostics software help system and at the www ac com pl website ver 1 7 9 2017 04 12 ...

Page 2: ...tial control 19 1 9 Full group control 19 1 10 Mounting the controller STAG 4 QBOX QNEXT and STAG 300 QMAX 19 1 11 Selection of pressure regulator 20 1 12 Selection of injector nozzles 20 2 The AC STAG diagnostic program 20 2 1 Controller computer connection 20 2 2 AC STAG version 23 2 3 Main menu 23 2 4 Controller Parameters 25 2 5 Signals ingectors LED switchboard 32 2 6 Auto calibration 34 2 7 ...

Page 3: ...2 25 1 Diagnostics test actuators 56 2 25 2 Service 57 3 STAG 4 QBOX QNEXT STAG 300 QMAX controller programming 57 3 1 Auto calibration 57 3 2 Collection of the petrol injection map with petrol petrol map 58 3 3 Collection of the petrol injection map with LPG LPG map 58 3 4 Checking if maps match verification of deviations 58 3 5 Controller manual setting 58 3 6 LPG temperature correction 59 3 7 I...

Page 4: ...c 4 1 Controller installation To ensure proper and long lasting operations of STAG Autogas systems in vehicles equipped with START STOP engine mode high durability gas valves are recommended to mount The proper valve shall be marked with additional H3 symbols meaning 1 000 000 switching operations endurance according to paragraph 4 7 of Annex 3 of regulation no 67 Revision 4 1 1 Layout diagram STA...

Page 5: ...e and or use in any way all or any part of information contained within this document in particular photographs drawings illustrations trademarks etc 5 1 2 Layout diagram STAG 4 QBOX PLUS Fig 2 STAG 4 QBOX PLUS controller installation layout diagram Fig 3 Wiring diagram for STAG 4 QBOX QNEXT QMAX PLUS connection to OBD interface ...

Page 6: ...en to copy publish distribute make available and or use in any way all or any part of information contained within this document in particular photographs drawings illustrations trademarks etc 6 1 3 Layout STAG 4 QNEXT PLUS Fig 4 STAG 4 QNEXT PLUS controller installation layout diagram ...

Page 7: ...n to copy publish distribute make available and or use in any way all or any part of information contained within this document in particular photographs drawings illustrations trademarks etc 7 1 4 Layout STAG 300 QMAX BASIC Fig 5 STAG 300 QMAX PLUS controller installation layout diagram ...

Page 8: ...n to copy publish distribute make available and or use in any way all or any part of information contained within this document in particular photographs drawings illustrations trademarks etc 8 1 5 Layout STAG 300 QMAX PLUS Fig 6 STAG 300 QMAX PLUS controller installation layout diagram ...

Page 9: ... any way all or any part of information contained within this document in particular photographs drawings illustrations trademarks etc 9 1 6 Wiring diagram for fuel level emulator FLE Fig 7 Wiring diagram for fuel level emulator FLE connection to STAG 4 QBOX PLUS Fig 8 Wiring diagram for fuel level emulator FLE connection to STAG 4 QNEXT PLUS ...

Page 10: ...way all or any part of information contained within this document in particular photographs drawings illustrations trademarks etc 10 Fig 9 Wiring diagram for fuel level emulator FLE connection to STAG 300 QMAX PLUS 1 7 Wiring diagram for fuel pressure emulator FPE Fig 10 Wiring diagram for fuel pressure emulator FPE connection to STAG 300 QMAX PLUS ...

Page 11: ...r of manufac ture Petrol ECM harness Installation notes Conne ctor Pin No Wire colour Signal 2 5T 2004 2009 B 47 yellow Fuel pump control signal ECM location A 2 green grey Fuel pressure sensor signal 3 0T 2010 2011 B 21 yellow orange Fuel pump control signal ECM location A 71 blue red Fuel pressure sensor signal VOLVO S60 R Engi ne Year of manufac ture Petrol ECM harness Installation notes Conne ...

Page 12: ...ssure sensor signal VOLVO XC60 Engi ne Year of manufac ture Petrol ECM harness Installation notes Conne ctor Pin No Wire colour Signal 3 0T 3 2T 2009 2010 B 21 yellow orange Fuel pump control signal ECM location A 71 blue red Fuel pressure sensor signal VOLVO XC70 Engi ne Year of manufac ture Petrol ECM harness Installation notes Conne ctor Pin No Wire colour Signal 2 5T 2004 2007 B 47 yellow Fuel...

Page 13: ...Signal 2 5T 2004 2011 B 47 yellow Fuel pump control signal ECM location A 2 green grey Fuel pressure sensor signal 3 2 2007 2011 B 21 yellow Fuel pump control signal ECM location A 71 green grey Fuel pressure sensor signal 4 4 2007 2011 B 20 yellow Fuel pump control signal ECM location A 71 blue Fuel pressure sensor signal JAGUAR X TYPE Engi ne Year of manufac ture Petrol ECM harness Installation ...

Page 14: ... Petrol ECM harness Installation notes Conne ctor Pin No Wire colour Signal 2 5 3 0 4 0 4 2 2001 FH1 58 white violet Fuel pump control signal ECM location PI1 49 white green Fuel pressure sensor signal View of the pins in the connector of the petrol controller Engi ne Year of manufact ure Petrol ECM harness Installation notes Pin No Wire colour Signal 2 5 3 0 4 0 4 2 2002 2005 27 white red Fuel pu...

Page 15: ...act ure Petrol ECM harness Installation notes Conn ector Pin No Wire colour Signal 2 5 3 0 4 0 4 2 2006 FH300 020 biało czerwony Fuel pump control signal ECM location PI300 071 niebieski Fuel pressure sensor signal View of the pins in the connector of the petrol controller LAND ROVER SUPERCHARGED Engi ne Year of manufac ture Petrol ECM harness Installation notes Conne ctor Pin No Wire colour Signa...

Page 16: ...contained within this document in particular photographs drawings illustrations trademarks etc 16 FORD KUGA Engi ne Year of manufac ture Petrol ECM harness Installation notes Conne ctor Pin No Wire colour Signal 2 5T 2008 2012 B 21 blue yellow Fuel pump control signal ECM location A 89 white blue Fuel pressure sensor signal View of the pins in the connector of the petrol controller ...

Page 17: ...ol ECM harness Installation notes Conne ctor Pin No Wire colour Signal 5 4 2003 2005 B 62 blue orange Fuel pump control signal ECM location E 32 red pink Fuel pressure sensor signal View of the pins in the connector of the petrol controller FORD EXPLORER IV Engi ne Year of manufac ture Petrol ECM harness Installation notes Conne ctor Pin No Wire colour Signal 4 0 2005 2010 B 12 yellow orange Fuel ...

Page 18: ...ion contained within this document in particular photographs drawings illustrations trademarks etc 18 FORD MUSTANG Engi ne Year of manufac ture Petrol ECM harness Installation notes Conne ctor Pin No Wire colour Signal 4 0 2009 B 12 light blue red Fuel pump control signal ECM location B 3 red Fuel pressure sensor signal View of the pins in the connector of the petrol controller ...

Page 19: ... this document in particular photographs drawings illustrations trademarks etc 19 1 8 Semi sequential control Fig 11 Semi sequential control layout diagram 1 9 Full group control Fig 12 Full group control layout diagram 1 10 Mounting the controller STAG 4 QBOX QNEXT and STAG 300 QMAX STAG 4 QBOX QNEXT STAG 300 QMAX controller must not be installed in a place exposed to high temperatures and or dam...

Page 20: ...ducer pressure 1 bar Power per cylinder range KM 1 7 1 8 11 16 1 9 2 2 17 28 2 3 2 5 29 34 2 6 2 8 35 40 2 9 3 0 41 48 3 1 3 2 49 55 The above rough values may in some cases not correspond to actual values 2 The AC STAG diagnostic program 2 1 Controller computer connection Using a RS USB or Bluetooth NEXT link connect the vehicle installed STAG 4 QBOX BASIC QNEXT STAG 300 QMAX controller with a PC...

Page 21: ...den to copy publish distribute make available and or use in any way all or any part of information contained within this document in particular photographs drawings illustrations trademarks etc 21 Fig 13 Parameters window Car parameters Fig 14 Parameters window Gas controller settings ...

Page 22: ...forbidden to copy publish distribute make available and or use in any way all or any part of information contained within this document in particular photographs drawings illustrations trademarks etc 22 Fig 15 Parameters window Advanced settings Fig 16 Parameters window Car info ...

Page 23: ...der OBD digital recorder if they have been closed Language options may be used to select user interface language version Tools option may be used to update hardware devices setup program settings load store settings store modified settings restore default factory settings Help options may be used to display info on the program the controller and documentation including this manual To bring up the ...

Page 24: ...ration to the nearest inspection An alternative method of inspection set up is an option of inspection by date where the date of scheduled inspection is specified instead of a mileage limit To clear the service schedule select Inactive in which case the controller will not monitor the service schedule Selecting the option LPG CNG lock prevent driving on the gas beyond the set time of the review Be...

Page 25: ...s the engine speed brown wires need not to be connected since the controller can calculate current speed from injection pulses When RPM readings are disrupted RPM changes significantly but the engine operation is stable specify the minimum injection pulse time to ensure filtering the extra injection pulses and stabilize the RPM readings RPM signal RPM signal source RPM detection threshold in Volts...

Page 26: ...troller switches to LPG at idle run Switch over time time after starting the engine when the controller can switch to LPG Reducer filling time delay between opening solenoid valve and gas injectors The function used to pre fill the system with gas Switch over temp time after starting the engine when the controller can switch to LPG Cylinder switch over time elapsing between the switching of subseq...

Page 27: ...jectors permanently as well However corrections e g resulting from changes in the LPG pressure will be no longer possible The moment when petrol injectors are fully open corresponds to the load value of 100 If petrol injectors become fully open the Max load on gas parameter should be set to approximately 95 This will result in the controller switching to petrol before full opening of LPG injectors...

Page 28: ...f gas air mixture injected by gas injectors to each engine cylinder Test automatic testing of the flow on individual gas injectors Injector opening correction the window allows configuration of very precise absolute correction of gas injector Unlike the percentage correction it is constant and not dependent on time It is ideal for compensating differences in performance of injection rails resultin...

Page 29: ...unters should be reset after injector replacement They are used for information purposes only Reducer temperature sensor pressure regulator temperature sensor type selection Gas temp sensor gas temperature sensor type selection Extra injection off threshold petrol injection pulses shorter than the set value will be ignored by the controller gas injection pulses will not be generated for them Intel...

Page 30: ... close to the engine temperature at which jerking stops NOTE Engine temperature threshold influences the time of function operation Always note if the ratio represents a rich fuel mixture for the warmed engine under high load Failure to follow this note may result in engine damage Max rpm threshold should be set by experience so that there is no power drop under maximum acceleration at higher rpm ...

Page 31: ...ocedure press the Start button and start the engine that has been warmed up earlier The calibration is an automatic process and takes about 3 minutes Correct calibration will end with the Completed successfully message Fig 23 Calibration of the fuel pressure emulator AUX output configuration3 enables operating mode to be selected for universal control output This output can provide voltage close t...

Page 32: ... pressure bar pressure inside the suction collector absolute pressure value 3 Injection time ms petrol injection time P1 P8 Petrol injection time for Injector 1 8 4 Gas injection dose ms Gas injection time G1 G8 Gas injection time for Injector 1 8 5 Gas temperature C LPG temperature at the pressure regulator output 6 Reducer temperature C liquid temperature at the reducer 7 Internal temperature C ...

Page 33: ...line of 5 diodes while LED 300 401B and LED 401 indicate it with 4 diodes arranged around the button The minimum level low fuel alarm is indicated by a red LED diode in LED 300 switches In LED 300 401B and LED 401 switches the status is indicated by illuminating the button in red After right clicking on the LED witch view its settings window is displayed Figure 26 Alternatively use the Gas level i...

Page 34: ...ensor starts operating start the auto calibration During the auto calibration the engine should work at idle run Switch off air conditioning and lights and do not turn the steering wheel During the calibration the controller will automatically switch from petrol to LPG The controller will be automatically switching on selected LPG cylinders Once the auto calibration is complete the controller disp...

Page 35: ...ber of stored samples application version controller version controller serial number Continuous green line is displayed at top of the oscilloscope screen while the controller operates in the LPG mode red line indicates operation of the injectors heating function The oscilloscope is an excellent tool to analyze vehicle working conditions Recorded parameters can be saved and reviewed In order to ma...

Page 36: ...ed circuit of the gas temperature sensor Reducer temperature sensor missing Disconnected or disrupted circuit of the reducer temperature sensor Gas temperature sensor circuit shorted Gas temperature sensor shorted to vehicle grounding Reducer temperature sensor circuit shorted Reducer temperature sensor shorted to vehicle grounding Injector supply circuit failure Controller s circuit for injectors...

Page 37: ...figuration Unlike the errors message prompts are displayed in blue The controller can generate the following messages Description in AC STAG application Meaning Gas injectors fully open Check the Lambda sensor at maximum load Looping of gas injection i e one gas injection pulse is overlapped by another pulse If the Lambda sensor during the message display works in a rich mode the error can be igno...

Page 38: ...ed emulator circuits No rotation The controller can see the impulses of petrol injection but does not see RPM signal No petrol injection pulses channel n Despite running engine controller has not registered petrol injection pulses on the specific channel 2 8 3 Errors the ECU The controllers equipped with a OBD adapter STAG 4 QBOX QNEXT PLUS STAG 300 QMAX PLUS are capable of continuous monitoring o...

Page 39: ...played in the right panel of the automatic clearing configuration window Fig 31 The view of the OBD error clearing configuration window If there are other errors recorded for the vehicle besides those configured in the auto clearing tool clearing will not be executed for safety reasons Additionally when engine startup is too fast automatic clearing may fail due to the fact that not all vehicles al...

Page 40: ...When no point is selected the arrows move the entire map Apart from the multiplier map there are two other maps in the window The blue map represents the petrol injection times with petrol The right axis Collector pressure Bar and the lower axis Injection Time ms relate to this map The map consists of blue points After collecting the data the controller turns these points into a continuous line Th...

Page 41: ...ig 34 Multiplier map Suggested area of gas map acquisition 2 9 1 Multiplier matching When 2 3 of the suggested area on gas and petrol map is acquired button for multiplier matching function is activated The operation modifies the multiplier based on a deviation between the recorded maps for petrol and gas injection If map differences are minor the multiplier is not modified It is recommended to ac...

Page 42: ...t is forbidden to copy publish distribute make available and or use in any way all or any part of information contained within this document in particular photographs drawings illustrations trademarks etc 42 Fig 35 Multiplier map Operation of the multiplier matching function ...

Page 43: ... possible to enrich weaken the mixture for a defined petrol injection time and revolutions In order to calibrate the multiplier the area which is to be calibrated must be selected by moving the mouse with the left button pressed over this area Another method is to press the SHIFT key and while holding it to select the appropriate area by pressing arrow keys Left arrow Up arrow Right arrow Down arr...

Page 44: ...ctor control Configuration of petrol post injection is made on a two dimensional map with an RPM and petrol injection time axes Like on the RPM correction map the cursor shows the engine operation curve point Navigation on the petrol portion map is identical as on the RPM correction map i e cursor keys SHIFT and CTRL keys can be used to select map areas and modify their values Fig 38 Petrol portio...

Page 45: ...tion map allows the user to enter manually an additional percentage correction based on gas temperature Entering modifications is just like on the multiplier Fig 39 Gas temperature correction map view 2 13 Reducer temperature correction map Reducer temperature map calibration allows for additional percentage matching of the multiplier Adjustment of the reducer temperature map calibration is simila...

Page 46: ... The Gas pressure correction map allows the user to enter manually an additional percentage correction based on gas pressure Entering modifications is just like on the multiplier Fig 41 Gas pressure correction map view 2 15 Petrol map B Two dimensional gas and petrol injection time maps are displayed on the multiplier tab based on actual 3D maps acquired versus RPM and MAP pressure Fig 42 Petrol m...

Page 47: ...quired during driving on LPG The two perpendicular yellow lines form a cursor that indicates the current operational point rpm and suction negative pressure of the engine You can rotate the 3D map dragging it with the right mouse button Fig 43 Petrol map G view 2 17 Map acquisition state In order to monitor the process of map data acquisition the application has been provided with a special petrol...

Page 48: ... is forbidden to copy publish distribute make available and or use in any way all or any part of information contained within this document in particular photographs drawings illustrations trademarks etc 48 Fig 44 Petrol map acquisition state Fig 45 Gas map acquisition state ...

Page 49: ...are shorter on the gas map than on the reference petrol map Conversely negative values indicate leaning It should be noted that particularly within the low load and short petrol pulse range it is not recommended to seek deviations close to zero due to the natural distribution of petrol injection pulses as a result of the ECU control 2 19 MAP correction map autoadaptation map Autoadaptation systems...

Page 50: ...rated reader of parameters and faults based on the OBDII EOBD interface It is not necessary to connect an external adapter all required circuits are integrated with the controller board The tool supports the following standards ISO 15765 ext std 250 500Kbits commonly referred to as CAN ISO 14230 5Baud Fast init ISO 9141 commonly referred to as K line The reader is initiated by selecting the OBD re...

Page 51: ... add or remove a parameter from the reader select it or deselect it in the field on the left side next to its description Fig 49 OBD2 EOBD reader configuration If it is necessary to diagnose the vehicle with an external scanner when STAG 4 QBOX QNEXT PLUS STAG 300 QMAX PLUS and an active OBD interface is available switch the system to petrol fueling switch off and switch on the ignition OBD connec...

Page 52: ...tion records the real pulsing of petrol injectors gas injectors or rpm signals vs time like in advanced measuring tools e g an oscilloscope Fig 50 Digital recorder window 2 22 Assignment of gas injectors to banks In V engines and boxer engines the controller can include 2 banks Bank 1 and Bank 2 correction values for OBD STFT B2 and LTFT B2 are other than zero In such case gas injectors should be ...

Page 53: ...assign the respective injector to the bank 4 Set the injector correction value to 0 After this STFT and LTFT trims should restore the initial values observed before stage 1 Repeat the described procedure steps 1 to 4 for the remaining gas injectors in the system After the assignment of gas injectors to the bank activate autoadaptation if necessary set the initial gas correction values In control s...

Page 54: ...o stop checking the option will result in automatic blocking of engine operating curve points on MAP correction map when the specified deviation limit is reached see Adaptation enable threshold Active autoadaptation On Off STFT bank 1 current correction of injection time implemented by the autoadaptation Temp dev Bank 1 Momentary percentage value of petrol injection time deviation when driving on ...

Page 55: ...read through OBD2 EOBD or emulated by the controller above which it is allowed to correct the gas dose Fig 54 OBD target correction map Próg włączenia Wartość poszerzająca zakres akceptowanej docelowej korekcji Switch on threshold A value that extends the range of acceptable resultant target correction For example a threshold of 4 with target correction of 0 on the map means the range of 4 4 of th...

Page 56: ...Controller update To update the controller connect it to the diagnostic software and turn the engine off Select Tools Devices update from the main menu All available devices are automatically found The Devices update window will pop up The Devices Parameters window shows the information on current controller firmware version The Available updates window includes a list of updates available for the...

Page 57: ...g 56 Gas firing progress window 3 STAG 4 QBOX QNEXT STAG 300 QMAX controller programming The controller may be programmed using the acquired petrol map and the gas map The procedure Auto calibrate the controller Acquire petrol map B Acquire petrol map G Check deviations between both maps 3 1 Auto calibration Prior to starting the auto calibration start the engine and wait until the lambda probe be...

Page 58: ...axis of co ordinates for injection times If the LPG map is collected with the PC connected and the diagnostic software running it is possible to immediately correct the multiplier characteristics when the collected green points do not match with the petrol map It is even strongly recommended to use the PC in this way as if the multiplier characteristics differ strongly from the required ones the c...

Page 59: ... be compared If the petrol injection time value is bigger after switching to LPG the positive correction must be made for this LPG temperature value the LPG temperature calibration map must be brought up If the petrol injection time value is lower after switching to LPG the calibration map for a given LPG temperature value must be brought down The calibration map must be set in such a way as to en...

Page 60: ...WPGH version is required Learning process stage 1 after the WPGH indicator autocalibration the function waits until the driver uses all gas in the tank and fills up to full Learning process stage 2 the function waits until the driver uses all gas in the tank again and fills up to full Waiting to refuel the function was not able to detect the initial level of gas this is why it s on hold until the ...

Page 61: ...LED 300 switchboard The LED switchboard consists of Przycisk LED line indicating LPG level the LED indicating type of fuel button LED line shows current LPG level in the tank 4 green LEDs indicate a full tank a red LED indicates reserve The LED shows current operating status Off the engine runs on petrol Slow blinking once per second the engine is started on petrol and switches to autogas when the...

Page 62: ...roller settings Fast blinking 4 times per second with acoustic signals EMERGENCY mode system error prevents gas fueling e g empty gas tank LPG installation fault the engine runs on petrol Continuous light in white GAS mode the engine is supplied with autogas Continuous light in red operation on gas low fuel level If the controller is connected to the LED 401 switch additional functions are availab...

Page 63: ...witch has just been turned on is a warning that the system needs to be inspected Three long beeps repeated every minute is a reminder that the engine is operating in emergency mode 4 5 Emergency start on gas In order to start the engine on gas emergency mode e g when the fuel pump fails position the key in ignition mode then press and hold the button on the switch The LED will be switched on in a ...

Page 64: ...n five times Programming mode is automatically deactivated after 30 seconds After changing the pairing code it is required to re pair the BT interface in the system Every successful change in the interface configuration is confirmed with three long sounds If you forget the pairing code saved previously it is possible to restore the bt default code This is possible within 60 seconds after powering ...

Page 65: ...mended layout diagram in particular from hooking signal cables up to other terminals than those specified in installation guidelines 2 Damage resulting from installing the controller in places incompatible with installation guidelines or from exposition to water high temperatures vehicle battery vapours 3 Devices tampered with repaired without proper authorisation 4 Mechanical damage through Custo...

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