autogaz AC STAG-50 Assembly instructions

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STAG-50, STAG-100, STAG-150
LAMBDA SENSOR CONTROLLER
INSTALLATION & PROGRAMMING MANUAL
version : V1.77 -V1.79
Manufacturer:
AC Spółka Akcyjna.
15-181 Białystok, ul. 42 Pułku Piechoty 50, Poland
tel. [phone], fax [phone]
www.ac.com.pl, e-mail: [email protected]

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SET COMPONENTS
1. STAG-50 or STAG-100 or STAG-150 - lambda sensor controller
2. Actuator (stepping motor) & base plate
3. A group of wires
4. Installation set:
- control panel
- fastening screws
- temperature sensor
- connectors, screws
5. Programming & operation manual
APPLICATION OF THE CONTROLLER
The STAG-50/100/150 lambda sensor controller has been designed for controlling of
operation of engines adapted for LPG and fitted with a lambda sensor. The control
panel enables manual, automated or emergency switching over working mode
(gasoline / LPG) as well as visual monitoring of LPG quantity.
INJECTOR EMULATOR LPG LEVEL INDICATION
STAG-50 - only LPG reserve indication (1 LED)
STAG-100 single-point emulator full indication (5 x LEDs)
STAG-150 four-point emulator LPG reserve or full indication
CONTROLLER OPERATION
After starting of the engine and reaching of required rpm (in the automatic mode green LED blinks) LPG
supply is switched on (green LED shines constantly). The LPG output is controlled with a actuator and
depends on lambda sensor indications. All STAG-50/100/150 parameters are set with an external tester
or a PC (AcLpgWin software).
CONTROL PANEL FUNCTIONS
The control panel contains:
 working mode switch (gasoline / LPG) - B/G key
 working mode indicator - green LED
 LPG quantity indicator: five LEDs
After switching on the ignition switch (without starting the engine) LPG supply may be switched on in
the normal (automatic) mode or emergency mode (starting up of the engine with LPG). Next functions
are switched on by pressing the working mode selector.
 green LED does not shine - running with gasoline
 green LED blinks - automatic mode (LPG supply begins after starting the engine, reaching
required rpm and, alternatively, reaching the temperature set at the pressure regulator).
 green LED shines constantly - emergency mode (starting up the engine with LPG). The function is
available only with switched ignition switch but without starting up the engine.
The last working mode is stored and recalled automatically during next engine start-up.

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WIRING DIAGRAM AND INSTALLATION MANUAL
The STAG-50/100/150 controller should be mounted within the engine room in the place, which is not
exposed to high temperature, water and fuel.
CAUTION!
It is recommended to install the controller vertically using its mounting eye and a screw, placing
sockets downward to avoid water penetration. Install bundle protecting rubbers carefully to seal the
entire housing.
Electrical connections should be soldered, carefully insulated and protected from humidity to avoid
shorting.
CONTROL PANEL FIXING & INSTALLATION
The control panel should be mounted within the driver's cab in the range of driver's sight.
First check fitting of the lower panel part, then drill two openings Ø 1,8 mm for fastening the panel and
one Ø 5 mm for the bundle. Fix the lower part of the panel (together with a plate) with screws
(installation set) in the chosen place and cover it with panel's upper part. Check the working mode
switch function.
50 100 150 CABLE COLOUR DESCRIPTION
11 15 11 BLACK GND
1 2 1 BLACK-RED +12 V BATTERY
15 13 15 RED +12 V IGNITION SWITCH
19 14 19 BROWN RPM - 5/12 V PULSES
14 1 14 BLUE LPG SWITCH ON
12 8 12 YELLOW-GREEN TPS
18 10 18 WHITE LPG LEVEL SEN SOR
20 9 20 ORANGE TEMPERATURE SENSOR
- 16 - YELLOW EMULATOR RELAY ( SWITCHING OVER )
- 17 - WHITE-GREEN EMULATOR RELAY ( CLOSED )
- 18 - GREEN EMULATOR RELAY ( OPEN )
10 15 10 BLACK SWITCHBOARD LED-100 or LED-50 ( new ) * (GND)
8 6 8 WHITE-RED SWITCHBOARD LED-100 or LED-50 ( new ) *
4 5 4 WHITE-GREEN SWITCHBOARD LED-100 or LED-50 ( new ) *
9 4 9 GREY-BLACK SWITCHBOARD LED-100 or LED-50 ( new ) *
- 3 14* GREEN-RED SWITCHBOARD LED-100 (+12V)
10 - - BLACK SWITCHBOARD LED-50 ( old ) (GND)
8 - - GREEN-RED SWITCHBOARD LED-50 ( old )
4 - - YELLOW SWITCHBOARD LED-50 ( old )
9 - - BROWN SWITCHBOARD LED-50 ( old )
5 12 5 PURPLE LAMBDA SENSOR
13 11 13 GREY CAR COMPUTER ( SIMULATION )
- 7 - option – WHITE-BLACK RESERVED CONNECTION
- 23 option – BLUE-BLACK RESERVED CONNECTION
-
6 19 6 BLUE-BLACK ACTUATOR
7 20 7 WHITE-BLACK ACTUATOR
17 21 17 ORANGE-BLACK ACTUATOR
16 22 16 VIOLET-BLACK ACTUATOR
* STAG-50 only LED-50 , STAG-100 only LED-100 , STAG-150 - LED-50 or LED-100

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STAG-50 installation diagram

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STAG-100 installation diagram
RELAY FUNCTIONS IN STAG-100
Connect wires Cut/Connect Connect
resistor ”Relay” parameter
Emulation of single-
point injector
yellow
white-green
Injector power supply
point ~20Ω Emulation of injections
Emulation of multi-
point injector
yellow
white-green
+12 power supply of
all injectors ~100Ω Emulation of injections
Fuel pump cutoff yellow
white-green
Pump power supply
circuit Emulation of injections
External emulator
controlling
yellow
green
+12V
Emulator
Emulation of injections
Error erasure yellow
green
+12V
Computer Memory erasure

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STAG-150 Installation diagram.
OUTLETS OF STAG 150 EMULATOR WIRE SET
No. WIRE COLOUR DESCRIPTION
1 (option) BLACK FRAME POWER SUPPLY OF EXTERNAL EMULATOR
8 (option) BLUE + 12V POWER SUPPLY OF EXTERNAL EMULATOR
2 YELLOW INJECTOR 1 - POWER SUPPLY
9 YELLOW-BLACK INJECTOR 1 - COMPUTER
3 GREEN INJECTOR 2 - POWER SUPPLY
10 GREEN-BLACK INJECTOR 2 - COMPUTER
4 RED INJECTOR 3 - POWER SUPPLY
11 RED-BLACK INJECTOR 3 - COMPUTER
5 BLUE INJECTOR 4 - POWER SUPPLY
12 BLUE-BLACK INJECTOR 4 - COMPUTER
14 (option) RESERVED CONNECTION
Near the STAG 150 emulator socket, there is an emulator resistance switch. When the switch is not
pressed, the resistance is 100Ω, and when it is pressed the resistance is 50Ω.

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STAG-50/100/150 - PROGRAMMING WITH A PC AND AcLpgWin SOFTWARE
To set STAG-50/100/150 parameters using a PC it is indispensable to connect the PC through a RS socket
and a RS-232 interface to the STAG-50/100/150 programming socket and start the AcLpgWin.exe
software.
During communication appears the screen PARAMETERS and transmission percentage indicator .
If after a few trials the software cannot establish communication with the controller then instead of the
transmission percentage indicator appears the window CONNECT, which should be activated to renew
communication. If there is no communication check RS-232 connection, change the serial port number
or activate auto-search (V1.76 only).
If the communication is established appears the window PARAMETERS, oscilloscope function is on.

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or -control panel - working mode change (mouse click )
- open help file
- window layout
- open gauges window
- controller parameters readout
- grid on
- start / stop oscilloscope
- oscilloscope time base change
- save visualisation file
- open visualisation file
- oscilloscope on / off; graph colour change
- save controller configuration file
- open controller configuration file
- restore manufacturer’s parameters

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On the oscilloscope you can see basic STAG controller signals:
lambda sensor, lambda simulation, TPS and actuator positions .
Below the graph, there is a signal table.
You can enable each graph and select its colour in the “Graph” column.
Apart from the oscilloscope, signal values are displayed in the “Values” column and visualised as line
graphs.
Gauge windows – display signals, it is possible to change
their position, size and shape ([-][+][O] buttons)
Additionally, in V1.77 version the windows of additional gauges are also accessible. They are displayed
by clicking a list below the “Gauges” button or by double-clicking relevant line in the signal table. It is
possible, separately for each such window, to change its position (using left mouse button), size ([-] [+]
buttons), shape ([O] button) and close ([X] button).
KEYBOARD SHORTCUTS
F1 - full function switch names / abbreviations
F2 - screen SETTINGS
F3 - screen PARAMETERS
F4 - screen CONFIGURATION
F6 - screen VERSION
F7 - parameter table activation for the screen PARAMETERS
F8 - working mode change GASOLINE / AUTO / LPG
NOTE: working mode change is possible also with mouse
F9 - font change
F10 - start of communication with the controller
QUICK CHANGE OF PARAMETERS
To change parameters and their values it is possible to use mouse buttons through
clicking on selected parameter as well as keyboard keys:
UP / DOWN - parameter change
RIGHT / LEFT - parameter value change

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STAG-50/100/150 ADJUSTMENT PARAMETERS
IGNITION COIL - according to the connection of rpm pulse and ignition type it is indispensable to
choose such type of coil to obtain the same rpm indication at the tachometer and
software window. In certain vehicles it is indispensable to use an ignition pulse adder.
COIL SIGNAL – change of the rpm detection voltage threshold. Set suitable detection level
depending on rpm pulses voltage value.
TPS - after connection of a throttle opening sensor choose its type and voltage range.
TPS THRESHOLD – voltage level, which causes switching over from idle operation to operation
with load
ADJUSTMENT FROM TPS - adjustment from TPS on / off
TPS HISTERESIS - removal of voltage noise from the TPS sensor
ENRICHMENT - number of actuator steps proportional to accelerator's pressing
WEAKENING - number of actuator steps proportional to accelerator's loosing
ACTUATOR SPEED - actuator speed during enrichment / weakening
OPEN - additional opening of actuator after reaching of TPS level
TPS LEVEL - TPS voltage level causing mixture enrichment – additional opening of the actuator
ACTUATOR AT THE POSITION - number of actuator steps during additional opening
ACTUATOR SPEED - actuator speed during opening
CUT OFF - additional closing of actuator during accelerator's loosing and reaching TPS level
downward. This function works if rpm falls to the set level.
RPM LEVEL - rpm level activating CUT OFF function
ACTUATOR AT THE POSITION - number of actuator's steps during CUT OFF execution
ACTUATOR SPEED - actuator speed during CUT OFF
LAMBDA SENSOR TYPE - lambda sensor operation range
LAMBDA SENSOR - lambda sensor type:
STANDARD – zirconium
RESISTIVE (-) – load from the frame
RESISTIVE (+) – load from the positive pole (+)

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ADJUSTMENT FROM LAMDBA SENSOR - adjustment from sensor on / off
LAMDBA SENSOR THRESHOLD - a voltage causing mixture weakening
ACTUATOR SPEED ABOVE TPS THRESHOLD- actuator speed during LPG – air mixture
adjustment set by the sensor during idle operation
ACTUATOR SPEED BELOW TPS THRESHOLD- actuator speed during LPG – air mixture
adjustment set by the sensor during idle operation
LAMDBA SENSOR COLD - theoretical time of sensor heating. At each switching of LPG supply the
controller ignores sensor indications maximally for the set time period
and awaits sensor's proper operation. Until the parameters become
stable, the controller uses internal map.
SIMULATION - during running with LPG vehicle's computer receives simulated signal with adjustable
parameters instead of lambda sensor signal
TYPICAL - square wave 08 / 08 s.
AUTO - simulation of the sensor regarding petrol engine characteristics
FRAME - vehicle's computer input connected to the frame
USER - square wave adjusted freely
TIME HI - duration of simulation pulse upper course
TIME LO - duration of simulation pulse lower course
TIME OFF - total time of pauses between pulses' groups, 0 = no pause
PULSE NUMBER - number of pulses within a group, 0 = no groups
DISCONNECTED - vehicle's computer input disconnected from the sensor
RELAY – switchover of additional relay function, which can operate as a injection emulator or switch
off of car computer (erase car computer errors)
CAUTION! Function available only for STAG – 100
SWITCH-OVER TIME – time of fuel “overlapping” during switching on the LPG (function RELAY –
emulator)
SWITCH OFF TIME – time of relay switch off after the ignition switch is off (function RELAY –
memory erase)
SWITCH-OVER TYPE - LPG supply switch on according to rpm
RPM UP - LPG supply on during rpm increase
RPM DOWN - LPG supply on during rpm decrease
RPM + TPS - additional TPS voltage check at rpm (driver opens / closes throttle)
SWITCH OVER RPM - rpm causing LPG supply on
SWITCH OVER POSITION – position of controller actuator during switching on the LPG
SWITCH OVER TEMPERATURE - temperature causing LPG supply on if the pressure regulator
temperature sensor is connected
MAX rpm for LPG - rpm level causing switchover to gasoline. Rpm decrease causes switchover to LPG.

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ACTUATOR MAX LEVEL - number of steps for max. actuator opening.
3000 RPM LEVEL - number of steps of actuator at 3000 rpm (sensor cold or off).
900 RPM LEVEL - number of steps of actuator at 900 rpm (sensor cold, off or damaged).
ACTUATOR MIN LEVEL - number of steps for min. actuator opening.
LEAKAGE – actuator opening just after switching on the ignition switch (while working with gasoline)
LPG LEVEL SENSOR – depending on LPG level sensor, voltage thresholds for activation of relevant LEDs
indicating LPG level
FAULTS DETECTED BY THE STAG-50/100/150 CONTROLLER
VOLTAGE SUPPLY FAULT - to big voltage drop or disconnection of battery, which causes controller's
reset
DATA FAULT - faults within controller's memory (damage or improper assembly)
LAMBDA SENSOR FAULT - long-lasting lack of voltage from the sensor
TPS FAULT - long-lasting lack of TPS voltage change

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CONFIGURATION
To match controller parameters to the individual vehicle type choose CONFIGURATION menu; software
detects petrol engine parameters and automatically adjusts LPG mode parameters.
CONFIGURATION is activated with the key GASOLINE.
Dialog windows shows commands to execute to configure the controller for a LPGpowered vehicle.
During check of gasoline mode parameters individual parameters will be displayed within a table; during
LPG mode configuration revolutions of actuator will be added for individual rpms.
CONFIGURATION – GASOLINE
Start controller configuration for gasoline with the key GASOLINE.
According to dialog window commands proceed as follows:
 start the engine
 set working mode GASOLINE (control panel key or mouse)
 keep idle rpm - gasoline mode parameters will be checked
 increase rpm to 3000 - gasoline mode parameters will be checked once again
At this moment all parameters indispensable for LPG controller operation will be stored to the
parameter table - match them to the engine type.
NOTE: sensor type (standard / resistive +, -) is not recognised automatically. Insert sensor parameters
manually to the window PARAMETERS after CONFIGURATION (e.g. OPEL OMEGA, lambda sensor
5 V, resistive +).

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Finish the gasoline configuration pressing one of following keys:
NEXT - LPG mode configuration
OK - save gasoline mode settings
SKIP - skip settings
CONFIGURATION – LPG
NOTE: LPG MODE CONFIGURATION SHOULD BE MADE AFTER PRELIMINARY PRESSURE REGULATOR
ADJUSTMENT! (SEE QUICK START P. 12)
LPG mode configuration may be activated with LPG or NEXT - if gasoline configuration has been
performed previously.
According to dialog window commands proceed as follows:
 set AUTO working mode (control panel key or mouse)
 increase rpm to ca. 2000 to switch over to LPG
 leave idle rpm - actuator position will be adjusted
 increase to 3000 rpm - actuator position will be adjusted

Finish the configuration with:
OK - save LPG mode settings
SKIP - skip settings
Other controller settings as e.g. sensor simulation, LPG mode on level etc. may be adjusted with menu
PARAMETERS.
QUICK START, FIRST PRESSURE REGULATOR ADJUSTMENT
First pressure regulator adjustment must be done before use of CONFIGURATION -LPG function.
Adjustment should be done using menu PARAMETERS.
 start the engine in gasoline mode and wait for proper lambda sensor operation
 set the controller for GASOLINE mode.
 Check lambda sensor operation for idle and 3000 rpm (sensor indications should be between
upper and lower voltage value).
 Set the controller for AUTO
 Increase rpm to ca. 2000 to switch over to LPG
 Watching lambda sensor graph at the oscilloscope adjust LPG output (with an adjustment screw
located on the pressure regulator) so that the actuator works in the range 50 - 100 steps (idle
engine rpm)
 Check sensor balancing at 3000 rpm
 If the sensor shows long return time to balancing during rpm change check pressure regulator
membrane tension and adjust it with a screw, if necessary.
NOTE: if during pressure regulator adjustment it is impossible to obtain sensor
balance at high rpm and the mixture is weak, it means that the system pressure
regulator - mixer does not work properly, thus before adjustment of electronics some
mechanical components must be adjusted. If the pressure regulator has been
adjusted and works properly, proceed with LPG CONFIGURATION.

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CALIBRATION OF LPG LEVEL INDICATOR
LPG level indicator calibration should be performed with ignition switch on without starting the engine.
Displayed voltage will be quickly responding to changes in float position.
VERSION
The STAG-50/100/150 controller from the version 1.60 on is provided with the option of user-made
software modification.
After connecting the controller to a PC the new window VERSION appears.
If the folder containing the program AcLpgWin.exe includes also a batch program of the STAG
50/100/150 controller marked with the wildcard .img, the batch program will be also displayed after
activation of the VERSION window; this enables controllers software exchange.
Click with the mouse on the program, which should be copied into the controller software
Click the button Write
When the question “Start software installation?” appears, press OK.

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wait until the installation progress bar reaches 100%
when the message “Programming finished successfully” appears, press OK.
The controller performs restart and begins to work with the new version of the
software.
If the programming process is interrupted or there are some errors, diagnostic software will display the
“Software error ...” message. Press OK and repeat the controller programming procedure.

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TECHNICAL DATA
Operation voltage 12V ( +30% - 25% )
Max current consumption 0,3 A
Max current supplied to LPG control system 6,5 A
Max injection emulator current 5 A
Ignition pulse input voltage 3 – 12 V
PROGRAMMABLE FUNCTIONS
Number of cylinders and ignition type…………………3, 4, 5,6, 8 cylinders, single or double coil
Type of throttle position sensor………………………………..0-5 V, 5-0V linear, switch 0-12/12-0 V
Lambda sensor type…………………………………..0-1V, 0-5V, 5-0V, 0.8-1.6V, standard or resistive
Lambda sensor emulation………………………………………………square wave, disconnected, frame
Type of changeover gasoline / LPG……………………………………….rpm up, rpm down, rpm + TPS
Time of simultaneous operation gasoline + LPG…………………………………………………..0 - 1,020 s
Temperature of switchover gasoline / LPG…………………………………………………………..60 - 185°C
Switchover rpm………………………………………………………………………………………..1000 - 10000 rpm
Max rpm for LPG mode…………………………………………………………………………….5000 - 10000 rpm
Fuel level sensor STAG-100/150………………………………………..0-90 Ω, 90-0 Ω, 0-50 kΩ, 50-0 kΩ
Actuator operation range…………………………………………………………………………………0 - 255 steps
Actuator speed………………………………………………………………………………………………………….0 - 255
Option of automated actuator opening during acceleration…………………………………….on / off
Option of additional actuator opening during acceleration………………………………………on / off
Option CUT OFF………………………………………………………………………………………………………..on / off
Emulator relay operation mode STAG-100…………………………1 point emulator / erase vehicle
computer memory
Default parameters option …………………………………………………………………………………………….yes
Fault recognition…………………………………………………power supply (reset), TPS, lambda sensor