AC STAG 400 User manual
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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.
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1.3.3 Tank accessories
1.3.3.1 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 accessories
Accessories should be installed in line with the manufacturer’s requirements. The tubes should be
secured with a gas tight cover and routed outside of the vehicle (Picture 1.3.15).
Picture 1.3.14 A fitted multi-valve
Picture 1.3.15 Gas 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.
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Picture 1.3.16 cable conduit protection hoses
connected 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 multi-valve Picture 1.3.19 A connected multi-valve
Picture 1.3.20 An orifice for gas tubes in the bodywork
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1.3.4 Installation of gas tubes
The 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 1.3.21 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 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 1.3.23 Connecting the tubes to the solenoid
valve
Picture 1.3.24 Fitting 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
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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 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.
Picture 1.3.25 Fitting of the reducer Picture 1.3.26 Connection of the reducer
Picture 1.3.27 Connection between the reducer and
the cooling system
Picture 1.3.28 LPG volatile phase filter
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Picture 1.3.29 Suggested diagrams of connection of 2 reducers to the LPG/CNG instalation
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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 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 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 controller
Picture 1.3.32A view of the controller’s mounting
elements
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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 the scheme.
NOTE! Nozzle sizes for particular types of engines have been specified in the appendices hereto.
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
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1.3.8 Connecting a fuel rail pressure sensor
A gas system compatible with direct injection engines must include a fuel rail pressure sensor. Detailed
instructions have been included in the appendices hereto.
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
Picture 1.3.38The P/G switchboard
NOTE! The switchboard must be connected to the harness in the passengers’ compartment.
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1.4 Approval of a vehicle for installation of an LPG system
•Make sure the vehicle's engine is included in the list of supported engine types (subsection
Appendices of 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 system
•Refuel 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 inspection
•Verification of completeness of the system
•Verification of tightness of the system
•Inspection of performance of the gas system
2PART TWO – AC STAG diagnostic software
2.1 Description of the diagnostic software
2.1.1 Connecting the controller to a PC
Having 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.
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Figure 2.1.1 Controller detection window
Figure 2.1.2 “Parameters” tab (Car parameters)
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