AC STAG 400 User manual

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

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Table of contents
1PART ONE – installation of the system .......................................................................................... 3
1.1 List of standards............................................................................................................................................... 3
1.2 Description of the LPG STAG 400 DPI system .................................................................................................... 3
1.2.1 Scope of use............................................................................................................................................................. 3
1.2.2 STAG 400 DPI – operation principle......................................................................................................................... 3
1.2.3 Scheme for connecting STAG 400 DPI system .........................................................................................................4
1.2.3.1 Scheme for connecting STAG 400.4 DPI model A1 controller.........................................................................4
1.2.3.2 Scheme for connecting STAG 400.4 DPI model B1/B2 controller ...................................................................5
1.2.3.3 Scheme for connecting STAG 400.4 DPI model C1 controller .........................................................................6
1.2.3.4 Scheme for connecting STAG 400.6 DPI model A1 or STAG 400.8 DPI model A1 controller ..........................7
1.3 Principles regarding installation of particular elements in a vehicle .................................................................. 7
1.3.1 Refuelling valves ...................................................................................................................................................... 8
1.3.2 Autogas tanks ..........................................................................................................................................................9
1.3.2.1 Cylindrical tanks ..............................................................................................................................................9
1.3.2.2 Toroidal tanks................................................................................................................................................ 10
1.3.3 Tank accessories ....................................................................................................................................................11
1.3.3.1 Selection of tank accessories.........................................................................................................................11
1.3.3.2 Installation of accessories .............................................................................................................................11
1.3.4 Installation 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 of an LPG system ................................................................................... 19
1.5 The first start-up of the gas injection system .................................................................................................. 19
1.6 Installation quality inspection ........................................................................................................................ 19
2 PART TWO – AC STAG diagnostic software.................................................................................. 19
2.1 Description of the diagnostic software ........................................................................................................... 19
2.1.1 Connecting the controller to a PC..........................................................................................................................19
2.1.2 Diagnostic software version ..................................................................................................................................22
2.1.3 Main menu............................................................................................................................................................. 22
2.1.4 Controller's parameters.........................................................................................................................................26
2.1.5 Maps ...................................................................................................................................................................... 29
2.1.6 Auto-calibration .....................................................................................................................................................34
2.1.7 Errors ..................................................................................................................................................................... 35
2.1.8 Recorder ................................................................................................................................................................38
2.1.9 “Monitor” window.................................................................................................................................................39
2.1.10 “Oscilloscope” window .......................................................................................................................................... 40
2.1.11 “OBD reader” window ...........................................................................................................................................41
2.1.12 Gas level indicator ................................................................................................................................................. 43
2.1.13 Autoadaptation ....................................................................................................................................................44
2.1.13.1 OBD mode ..................................................................................................................................................... 44
2.1.14 Controller’s update................................................................................................................................................45
2.2 Programming the controller ........................................................................................................................... 46
2.2.1 Auto-calibration .....................................................................................................................................................46
2.2.2 Multiplier map correction...................................................................................................................................... 47
2.3 Operation of the LED switchboard and sound signals (user's manual) ............................................................. 51
2.3.1 LED-401 switchboard .............................................................................................................................................51
2.3.2 LED-500 switchboard .............................................................................................................................................52
2.4 Sound signals ................................................................................................................................................. 54
2.5 Technical specification ................................................................................................................................... 54
2.6 Appendices .................................................................................................................................................... 54

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1PART ONE – installation of the system
1.1 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 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 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 vehicle’s 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.

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1.2.3 Scheme for connecting STAG 400 DPI system
1.2.3.1 Scheme for connecting STAG 400.4 DPI model A1 controller

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1.2.3.2 Scheme for connecting STAG 400.4 DPI model B1/B2 controller

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1.2.3.3 Scheme for connecting STAG 400.4 DPI model C1 controller

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1.2.3.4 Scheme for connecting STAG 400.6 DPI model A1 or STAG 400.8 DPI model A1
controller
(*) – dedicated connections have been described in the appendices hereto.
1.3 Principles regarding installation of particular 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 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.

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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 Refuelling tube clips

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1.3.2 Autogas tanks
Steel 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 1.3.7 A frame for a cylindrical LPG tank
Picture 1.3.8 A 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 1.3.9 In the event a cylindrical tank is mounted along the vehicle’s longitudinal
axis, an element which prevents movement of the tank forward must be prepared.

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1.3.2.2 Toroidal tanks
Picture 1.3.10 A fitted toroidal tank
Picture 1.3.11 A multi-valve
Picture 1.3.12 Mounting 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 ou
t 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 1.3.13 The 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.