AC STAG-4 QBOX BASIC User manual

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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

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within this document, in particular photographs, drawings, illustrations, trademarks, etc
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Table of contents:
1. Controller installation............................................................................................................4
1.1. Layout diagram STAG-4 QBOX BASIC.............................................................................................................4
1.2. Layout diagram STAG-4 QBOX PLUS..............................................................................................................5
1.3. Layout STAG-4 QNEXT PLUS..........................................................................................................................6
1.4. Layout STAG-300 QMAX BASIC ......................................................................................................................7
1.5. Layout STAG-300 QMAX PLUS........................................................................................................................8
1.6. Wiring diagram for fuel level emulator FLE .......................................................................................................9
1.7. Wiring diagram for fuel pressure emulator FPE ..............................................................................................10
1.8. Semi-sequential 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. Oscilloscope ....................................................................................................................................................34
2.8. Errors...............................................................................................................................................................35
2.8.1. Errors of the gas controller .....................................................................................................................35
2.8.2. Gas controller message..........................................................................................................................37
2.8.3. Errors the ECU........................................................................................................................................38
2.9. Multiplier map ..................................................................................................................................................39
2.9.1. Multiplier matching..................................................................................................................................41
2.10. RPM correction map......................................................................................................................................43
2.11. Petrol portion map .........................................................................................................................................44
2.12. Gas temperature correction map...................................................................................................................45
2.13. Reducer temperature correction map............................................................................................................45
2.14. Gas pressure correction map ........................................................................................................................46
2.15. Petrol map „B”................................................................................................................................................46
2.16. Petrol map „G” ...............................................................................................................................................47
2.17. Map acquisition state.....................................................................................................................................47

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2.18. Injection time deviation map..........................................................................................................................49
2.19. MAP correction map (autoadaptation map)...................................................................................................49
2.20. OBDII/EOBD reader ......................................................................................................................................50
2.21. Digital recorder ..............................................................................................................................................52
2.22. Assignment of gas injectors to banks............................................................................................................52
2.23. Autoadaptacion..............................................................................................................................................53
2.23.1. ISA3 mode ..............................................................................................................................................54
2.23.2. OBD mode ..............................................................................................................................................55
2.24. Controller update ...........................................................................................................................................56
2.25. Diagnostics and service.................................................................................................................................56
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. Intelligent gas level indicator............................................................................................................................59
4. LED switchboard operation and acoustic signals (User Manual)....................................61
4.1. LED-300 switchboard ......................................................................................................................................61
4.2. LED-300/401B and LED-401 switchboard.......................................................................................................62
4.3. Automatic calibration of LPG level indicator....................................................................................................62
4.4. Acoustic signals...............................................................................................................................................63
4.5. Emergency start on gas...................................................................................................................................63
5. Bluetooth communication interface...................................................................................63
6. Technical specifications......................................................................................................65
7. Warranty, restrictions, exclusions......................................................................................65

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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 STAG-4 QBOX BASIC
Fig. 1 STAG-4 QBOX BASIC controller installation layout diagram

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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.

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1.3. Layout STAG-4 QNEXT PLUS
Fig. 4 STAG-4 QNEXT PLUS controller installation layout diagram.

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1.4. Layout STAG-300 QMAX BASIC
Fig. 5 STAG-300 QMAX PLUS controller installation layout diagram.

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1.5. Layout STAG-300 QMAX PLUS
Fig. 6 STAG-300 QMAX PLUS controller installation layout diagram.

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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.

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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.

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Tab. 1 Table of versions
VOLVO S40 / V50 / C30 / C70
Engi
ne
Year of
manufac
ture
Petrol ECM harness
Installation notes
Conne
ctor
Pin
No.
Wire colour
Signal
2.5T
2005
B
20
white-black
Fuel pump control signal
ECM location
A
91
white-blue
Fuel pressure sensor signal
2006
÷
2011
B
21
white-black
Fuel pump control signal
A
89
white-blue
Fuel pressure sensor signal
VOLVO S60
Engi
ne
Year 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
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
VOLVO S80
Engi
ne
Year of
manufac
ture
Petrol ECM harness
Installation notes
Conne
ctor
Pin
No.
Wire colour
Signal
2.5T
2004
÷
2006
B
47
yellow
Fuel pump control signal
ECM location
A
2
green-grey
Fuel pressure sensor signal
2007
÷
2011
B
21
yellow-orange
Fuel pump control signal
A
89
blue-brown
Fuel pressure sensor signal

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within this document, in particular photographs, drawings, illustrations, trademarks, etc
12
VOLVO V70
Engi
ne
Year of
manufac
ture
Petrol ECM harness
Installation notes
Conne
ctor
Pin
No.
Wire colour
Signal
2.5T
2007
÷
2011
B
21
yellow-orange
Fuel pump control signal
ECM location
A
89
blue-brown
Fuel pressure 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 pump control signal
ECM location
A
2
green-grey
Fuel pressure sensor signal
2007
÷
2011
B
21
yellow-orange
Fuel pump control signal
A
89
blue-brown
Fuel pressure sensor signal
3.0T
3.2T
2008
÷
2011
B
21
yellow-orange
Fuel pump control signal
ECM location
A
71
blue-red
Fuel pressure sensor signal

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within this document, in particular photographs, drawings, illustrations, trademarks, etc
13
VOLVO XC90
Engi
ne
Year of
manufac
ture
Petrol ECM harness
Installation notes
Conne
ctor
Pin
No.
Wire colour
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 notes
Pin No.
Wire colour
Signal
2.5
3.0
2003
÷
2004
27
brown
Fuel pump control signal
ECM location
73
blue
Fuel pressure sensor signal
View of the pins in the connector of the petrol controller.

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within this document, in particular photographs, drawings, illustrations, trademarks, etc
14
JAGUAR S-TYPE
Engi
ne
Year of
manufact
ure
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 pump control signal
ECM location
73
blue
Fuel pressure sensor signal
View of the pins in the connector of the petrol controller.

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within this document, in particular photographs, drawings, illustrations, trademarks, etc
15
Engi
ne
Year of
manufact
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
Signal
4.2
2007
B
20
green-orange
Fuel pump control signal
ECM location
A
71
blue
Fuel pressure sensor signal

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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.

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within this document, in particular photographs, drawings, illustrations, trademarks, etc
17
FORD EXPEDITION II
Engi
ne
Year of
manufac
ture
Petrol 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 pump control signal
ECM location
E
32
blue-brown
Fuel pressure sensor signal
View of the pins in the connector of the petrol controller.

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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.

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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 damp.

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1.11. Selection of pressure regulator
Install the controller according to the layout show in Fig. 1 to Fig. 6. In a sequential injection system,
pay attention to select a pressure regulator properly matched to the given car engine power and
injector nozzles. A pressure regulator that is poorly matched to the car engine power will not be able to
provide sufficient supply of gas at large demand (fully open throttle) and to maintain nominal gas
pressure within the system. Should gas pressure drop below some preset low threshold, the controller
will automatically switch to petrol.
1.12. Selection of injector nozzles
Injector nozzles diameter must also be matched to the given car engine power, see the table below.
Power per cylinder is engine power divided by number of cylinders in the engine.
Nozzle diameter [mm]
reducer 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 computer on which the Ac Stag diagnostic
program is to be run. Turn the vehicle ignition switch ON to supply the controller with power before
launching the program. This step is required since no communication with the controller is possible
while it is in sleep mode into which it is automatically turned about 10 minutes after its power is
disconnected. As soon as the program is started, the controller links with it (provided the correct COM
serial port is selected). Successful communication is confirmed by the „Status: No ignition switch”,
„Status: Waiting for gas”, „Status: Petrol” or „Status: Gas” message displayed at the bottom left corner
of the program screen. Parameters window and tabs are presented on figures 13 ÷ 16.
If you get the “Controller Error” message and “No connection” appears in the lower left corner of
the screen, select a different COM port from the Port menu at the top of the screen.