AC STAG 400 Installation Manual Download

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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 at

www.ac.com.pl

)

ver. 1.8

2021-01-13

Summary of Contents for STAG 400

Page 1: ...ALLATION MANUAL FOR LPG SYSTEMS DESIGNED FOR DIRECT PETROL INJECTION ENGINES PROGRAMMING MANUAL FOR STAG 400 DPI CONTROLLER also available in the diagnostic software and at www ac com pl ver 1 8 2021 01 13 ...

Page 2: ...n of gas tubes 13 1 3 4 1 Installation of copper tubes 13 1 3 4 2 Fitting non metal class 1 tubes 13 1 3 5 Reducer volatile phase filter PS 02 sensor 14 1 3 6 Electronic control unit 16 1 3 7 Installation of injection nozzles and manifold absolute pressure nozzles 17 1 3 8 Connecting a fuel rail pressure sensor 18 1 3 9 Installation of the switchboard 18 1 4 Approval of a vehicle for installation ...

Page 3: ...es 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 use STAG 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 principle The system is based on typical elements includi...

Page 4: ...e full or partial data included in the herewith document particularly pictures drawings illustrations trade marks etc is strictly prohibited under the law Page 4 of 54 1 2 3 Scheme for connecting STAG 400 DPI system 1 2 3 1 Scheme for connecting STAG 400 4 DPI model A1 controller ...

Page 5: ...on 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 5 of 54 1 2 3 2 Scheme for connecting STAG 400 4 DPI model B1 B2 controller ...

Page 6: ...tion 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 6 of 54 1 2 3 3 Scheme for connecting STAG 400 4 DPI model C1 controller ...

Page 7: ...lar elements in a vehicle Prior 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 ...

Page 8: ...ited under the law Page 8 of 54 1 3 1 Refuelling valves Refuelling valves are fitted in the rear bumper or in the petrol inlet bay Picture 1 3 1 An opening in the bumper Picture 1 3 2 Fitting a refuelling valve cover Picture 1 3 3 A refuelling valve from the inside Picture 1 3 4 A refuelling valve from the outside Picture 1 3 5 A refuelling valve fitted next to the petrol inlet Picture 1 3 6 Refue...

Page 9: ...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 ...

Page 10: ... 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 sh...

Page 11: ...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 accordin...

Page 12: ...to the sleeves inside the vehicle Picture 1 3 17 Sleeve 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 18 A mu...

Page 13: ...21 Fitting electrical wires with tie wraps Picture 1 3 22 Fitting 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 ...

Page 14: ...lt to meet the above mentioned requirements 1 3 5 Reducer volatile phase filter PS 02 sensor The reducer is mounted on a support or directly on the element connected to the vehicle s 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 Pictu...

Page 15: ...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 15 of 54 Picture 1 3 29 Suggested diagrams of connection of 2 reducers to the LPG CNG instalation ...

Page 16: ... the vehicle away from the heat sources 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 Picture 1 3 30 PS 02 type sensor 1 3 6 Electronic control unit The controller should be mounted on a support or directly on the element connected to the vehicle s bodywork It is recommended to install the controller...

Page 17: ...ifold 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 t...

Page 18: ...a fuel rail pressure sensor Detailed instructions have been included in the appendices hereto Picture 1 3 36 Fuel 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 37 Exemplary locati...

Page 19: ...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 inspection Verification of completeness of the system Verification of tightness of the system Inspection of performance of the gas system 2 PART TWO AC STAG diagnostic software 2 1 Description of the diagnostic software 2 1 1 Co...

Page 20: ...ny 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 20 of 54 Figure 2 1 1 Controller detection window Figure 2 1 2 Parameters tab Car parameters ...

Page 21: ...sage 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 21 of 54 Figure 2 1 2a Parameters tab Gas controller settings Figure 2 1 2b Parameters tab Car info ...

Page 22: ...warning window and the Port tab in the Menu bar 2 1 2 Diagnostic software version Once 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 4 indicates version 0 22 38 Figure 2 1 4 Main menu bars 2 1 3 Main menu The main menu includes the following options Port enables one to change the communication port establish ...

Page 23: ...ndows restoration of the default settings Update of the controller as well as the LED switchboard has been discussed in item 2 1 14 In order to save settings and the controller s map select the floppy icon located on the right hand side of the Parameters window or select Tools Save parameters from the main menu Figure 2 1 6 Tools tab in the Menu bar Indicate the location on the computer s hard dri...

Page 24: ...ed parameters window Help information on the software and the controller Figure 2 1 8 Gas controller info window The window Gas controller info includes the following parameters o Fuel the total controller operation time on petrol displayed in the following format H hours M minutes a percentage share in the total operation time o Since last connection the time of operation on petrol from the last ...

Page 25: ...displayed 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 1h 50 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 select...

Page 26: ...e and time of compilation of the firmware STAG 400 4 DPI controller s model ver 3 0 0 controller s firmware version number 10 0 5 controller s version number 2017 02 08 11 54 00 date and time of compilation of the controller s 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 p...

Page 27: ...ultiplier map Switch over to gas o Fuel type the 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 Intermediate phase controls the rate of switching individual cylinders to LPG fueling time when LPG and petrol are supplied simultaneously Modification recommended only when problems with smooth switc...

Page 28: ...witches to petrol if the gas pressure value is lower than the minimum value set in the calibration parameters o Min gas temp minimum gas temperature below which the controller switches to petrol Sensors and actuators o Gas injector type settings of the installed gas injector Once the button has been clicked the following window including gas injector settings will be displayed Figure 2 1 10 Gas in...

Page 29: ...llation fitter contact details of the installation of a gas fitter Car info car data which was mounted the gas installation Gas installation general information about the components of the gas installation 2 1 5 Maps This 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 vertica...

Page 30: ...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 ...

Page 31: ...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 s...

Page 32: ...f spots by clicking in the desired location Reducer temperature correction map Reducer temperature map calibration allows for additional percentage matching of the multiplier Adjustment of the reducer temperature map calibration is similar to the multiplier map Modification of the correction line of the regulator temperature can be used in vehicles where petrol fuel dosing strongly depends on the ...

Page 33: ... precise The map view can be accessed through the MAP correction Bx tab If autoadaptation is inactive the map can be used for additional manual corrections of gas fuel dosing Figure 2 1 18 MAP correction map If autoadaptation is active but it is not desired in certain ranges of engine operation it is possible to deactivate such ranges in the autoadaptation process Select an area of the map with a ...

Page 34: ...jection time is based on the map values related to the petrol injection time in a given operating curve point 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 After modification of the petrol porti...

Page 35: ... 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 21 The view of Errors tab OBD faults Auto clear list button allows configuration and activation of automatic clearing of OBD2 EOBD errors The configuration window is split into two panels T...

Page 36: ...ed in the right panel of the automatic clearing configuration window Figure 2 1 22 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...

Page 37: ...ction pulses petrol injector 3 1026 No injection pulses petrol injector 4 1027 No injection pulses petrol injector 5 1028 No injection pulses petrol injector 6 1029 No injection pulses petrol injector 7 1030 No injection pulses petrol injector 8 1031 Failure of gas injector 1 1792 Failure of gas injector 2 1793 Failure of gas injector 3 1794 Failure of gas injector 4 1795 Failure of gas injector 5...

Page 38: ...orded files are displayed in the window The logger window will display the following message Status Recorder available The logger s firmware version as well as the current date will be displayed too From this moment on the user can view the logger s files Figure 2 1 24 Recorded 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 ...

Page 39: ...ms calculated petrol injection time for the petrol injectors Gas Inj dose ms injection time for the LPG injectors Temperature ºC temperature of the injected gas reducer temperature and temperature inside the controller Voltage V voltage values for lambda probes as well as the car s battery RPM obr min engine rpm value Figure 2 1 26 Monitor window All the parameters displayed in the monitor window ...

Page 40: ...n LPG injector Figure 2 1 27 Gas Inj Dose window What is more Monitor window offers the auto hide option which can be activated by clicking on the symbol on the window s 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 10 Oscilloscope window To make Oscilloscope window visible select Window Oscilloscope from ...

Page 41: ... a given event while viewing the oscilloscope files the user can view the values underneath the cursor in the Monitor window The user can move the oscilloscope with 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 Figure 2 1 29 File info window 2 1 11 OBD reader window The OBD reader window becomes visible by selec...

Page 42: ...eating any sets of displayed parameters thanks to which it is possible to display a set including only parameters that are required for system calibration such as fuel loop status STFT and LTFT trims results of a wide band oxygen sensor The window displays a set of 96 parameters available in OBDII EOBD standard Parameters unavailable in a given vehicle are grey In order to add or remove a paramete...

Page 43: ...rom 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 level LED brightness setting for the level indication Buzzer position once LED400 has been installed the user must select the location of the speaker to ensure correct vis...

Page 44: ...le OBD Correction of gas dosage is based on the readings of parameters from the on board diagnostic interface compliant with the OBD2 EOBD standard 2 1 13 1 OBD mode With OBD selected the following settings and parameters can be configured and viewed Figure 2 1 33 Configuration of OBD adaptation The map of OBD target corrections Press the Open button to display the configuration window in which th...

Page 45: ...ues are used if the engine open loop control is applied Activation of the option allows additional adaptation adjusted to the status of the open loop In order for the function to be activated by the controller a Lambda probe must be connected or Lambda value must be read by the OBD2 EOBD reader Limitation of the OBD autoadaptation depending on engine rpm is implemented with the Adaptation lock opt...

Page 46: ...sion click on Update button Wait until the update process has been completed The update process progress is reflected by the progress bar The engine must be turned off during the update Figure 2 1 36 Devices update window 2 2 Programming the controller 2 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 ...

Page 47: ...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...

Page 48: ...on the multiplier map on a constant level while driving on petrol Calibration assistant will 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 Start button...

Page 49: ... 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 veri...

Page 50: ...pplicable to petrol usually around 0 Figure 2 2 7 Advanced 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 1D button in Maps tab is insufficient for the entire rpm range use the 2D map 2D button in Maps ta...

Page 51: ...als 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 controller s error e g shutdown due to an empty LPG tank backlit in white the vehicle is running on LPG backlit in red the vehicle is running on LPG but the LPG tank is almost empty The following functionalities are acce...

Page 52: ...atures the following elements LED line shows current LPG level in the tank Four green LEDs indicate a full tank a red LED indicates reserve Touch button recess in the center of the switch enables fuel switchover STAG logo status LED indicates the current mode of operation darkened the vehicle is running on petrol flashes slowly once per second the engine is running on petrol once the set parameter...

Page 53: ...tment for the status LED with the STAG logo 4 selectable brightness levels the function is inactive when Auto adjustment of brightness is ON Selectable activation of automatic adjustment of switch LEDs brightness depending on the ambient light Selectable illumination of the status LED with the STAG logo in the petrol fueling mode Selectable activation of the error LED working in an informative mod...

Page 54: ...rder to inspect the system 2 5 Technical specification Supply 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 Emission compliance 0F 1 Emission g km AC Euro 6 CO 0 13 1 HC 0 02 0 1 NOx 0 04 0 06 PM 0 004 0 005 2 6 Appendices This manual includes appendices with guidelines ...

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