Stag 400 Dpi Manual

AC S.A. All rights reserved.
Copying, publishing, distribution 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.
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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. 1.3 2012-06-22

Manufacturer:
AC Spka Akcyjna.
15-182 Biaystok, ul. 27 Lipca 64
tel. +48 85 7438117, fax +48 85 653 8649
www.ac.com.pl, e-mail: autogaz@ac.com.pl

AC S.A. All rights reserved. Copying, publishing, distribution and any usage of the full or partial data included in the herewith document, particularly pictures, drawings, illustrations, trade marks etc. is
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Table of contents
1 PART 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 controller ......................................................................................... 4
1.2.3.2 Scheme for connecting STAG 400.6 DPI or STAG 400.8 DPI controller ........................................................... 5
1.3 Principles regarding installation of particular elements in a vehicle ................................................... 5
1.3.1 Refuelling valves ...................................................................................................................................................... 6
1.3.2 Autogas tanks .......................................................................................................................................................... 7
1.3.2.1 Cylindrical tanks .............................................................................................................................................. 7
1.3.2.2 Toroidal tanks .................................................................................................................................................. 8
1.3.3 Tank accessories ...................................................................................................................................................... 9
1.3.3.1 Selection of tank accessories........................................................................................................................... 9
1.3.3.2 Installation of accessories ............................................................................................................................... 9
1.3.4 Installation of gas tubes ......................................................................................................................................... 11
1.3.4.1 Installation of copper tubes .......................................................................................................................... 11
1.3.4.2 Fitting non-metal class 1 tubes ..................................................................................................................... 11
1.3.5 Reducer, volatile phase filter, PS-02 sensor .......................................................................................................... 12
1.3.6 Electronic control unit ........................................................................................................................................... 14
1.3.7 Installation of injection nozzles and manifold absolute pressure nozzles ............................................................. 15
1.3.8 Connecting a fuel rail pressure sensor ................................................................................................................... 16
1.3.9 Installation of the switchboard .............................................................................................................................. 16
1.4 Approval of a vehicle for installation of an LPG system ................................................................... 17
1.5 The first start-up of the gas injection system .................................................................................. 17
1.6 Installation quality inspection ........................................................................................................ 17
2 PART TWO AC STAG diagnostic software ............................................................ 18
2.1 Description of the diagnostic software ........................................................................................... 18
2.1.1 Connecting the controller to a PC .......................................................................................................................... 18
2.1.2 Diagnostic software version................................................................................................................................... 19
2.1.3 Main menu ............................................................................................................................................................. 20
2.1.4 Controller's parameters ......................................................................................................................................... 24
2.1.5 Maps ...................................................................................................................................................................... 26
2.1.6 Auto-calibration ..................................................................................................................................................... 30
2.1.7 Errors ..................................................................................................................................................................... 30
2.1.8 Recorder ................................................................................................................................................................ 32
2.1.9 Monitor window ................................................................................................................................................. 33
2.1.10 Oscilloscope window .......................................................................................................................................... 34
2.1.11 OBD Monitor window ......................................................................................................................................... 35
2.1.12 Gas level indicator ................................................................................................................................................. 36
2.1.13 Controllers update ................................................................................................................................................ 37
2.2 Programming the controller ........................................................................................................... 38
2.2.1 Auto-calibration ..................................................................................................................................................... 38
2.2.2 Multiplier map correction ...................................................................................................................................... 39
2.3 Operation of the LED switchboard and sound signals (user's manual) .............................................. 42
2.3.1 LED-400 switchboard ............................................................................................................................................. 42
2.4 Sound signals ................................................................................................................................. 44
2.5 Technical specification ................................................................................................................... 44
2.6 Appendices .................................................................................................................................... 44

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1 PART 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 vehicles 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 controller

(*) dedicated connections have been described in the appendices hereto.

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1.2.3.2 Scheme for connecting STAG 400.6 DPI or STAG 400.8 DPI 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 vehicles 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 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 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 manufacturers 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 vehicles 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

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).

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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 vehicles
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 1.3.31 A view of an installed controller
Picture 1.3.32 A view of the controllers mounting
elements

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1.3.7 Installation of injection nozzles and manifold absolute pressure nozzles

Picture 1.3.33 Location for installation of nozzles
in the manifold (view from the outside)
Picture 1.3.34 Location 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 1.3.35 A 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 1.3.36 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 location for installation of the P/G switchboard

A connection with a pair of 3-pin connectors has been used in order to make it easy to connect the
switchboard to the harness of STAG 400 DPI controller. Having installed the switchboard, place the wires
in the dedicated connection (included) as shown in the Picture 1.3.38 while observing the correct
connection order.

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Picture 1.3.38 The connection and the order of the wires Picture 1.3.39 The P/G switchboard

NOTE! The switchboard must be connected to the harness in the passengers compartment.
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

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2 PART 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.

Figure 2.1.1 Controller detection window

Figure 2.1.2 Parameters tab (Car parameters)

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Figure 2.1.2a Parameters tab (Gas controller settings)

Select another port from the Port menu in the top section of the screen in the event the
application displays NO LPG controller! message.

Figure 2.1.3 System 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 0.9.229.

Figure 2.1.4 Main menu bars

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2.1.3 Main menu
The main menu includes the following options:
Port enables one to change the communication port, establish and terminate
connection with the controller as well as activate the automatic connection detection
mode;
Window selection from among main windows of the application.

Figure 2.1.5 Window tab in the Menu bar

Window menu allows one to restore main windows, in the event they have been
closed. AC STAG enables the user to freely arrange application windows. Use the drag &
drop technique to easily modify location of particular windows. Pressing and holding the
left mouse button on the bar of the selected window allows one to move it. Releasing
the left mouse button causes embedding or extraction of the window depending on the
current position of the cursor.

Language selection of the language version; AC STAG requires restarting once a new
language version has been selected.
Tools update of the controller and the LED switchboard, automatic distribution of
setting windows, restoration of the default settings.
Update of the controller as well as the LED switchboard has been discussed in item
2.1.13.
In order to save settings and the controllers 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

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Indicate the location on the computers hard drive, where the file with the setting is to
be saved, enter the name of the file and click Save. By following the above-mentioned
instructions, the user can save the settings and the maps.
In order to load the settings and the maps, click on the Open button located on the
right-hand side of Parameters window,

or select Tools Open saved parameters from the main menu.
The application will ask the user to indicate the file with the settings (.set extension).
Indicate the file and open it. Subsequently, Open saved parameters window will be
displayed. The user can open just the settings, just the map or both the settings and the
map simultaneously. Tick the desired selection in the window presented below and click
Ok.

Figure 2.1.7 Open saved parameters window

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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 Petrol 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
connection to a PC
o Gas the total controllers operation time on gas
o Since last connections the time of operation on gas from the last connection
to a PC
o Service the set time to inspection. Once the controller's time of operation
on gas exceeds the set time to inspection value, the controller, each time the
ignition is turned off, will inform the user about the need to inspect the
system with the sound signal. The method for setting the time to systems
inspection has been described in the following section. A negative value
denotes the time, which has passed from the first indication of the need to
carry out the inspection.
To set the time to inspection, click on the

button in the window Gas controller info; the following window will be
displayed.

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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 selected, which in this
particular case translates into 200 hours of operation.
Select Inactive in the selection field, in order to delete the inspection. Once
the above-mentioned option has been selected, the controller will not check
the time to inspection any more.

The section below the time of operation values in the window Gas controller
info includes the following events recorded by the controller:
o First PC connection the date, on which the controller was connected to
a PC with the diagnostic software for the first time;
o First change of settings the first modification of the controllers
settings;
o Last PC connection the date, on which the controller was connected to
a PC with the diagnostic software for the last time;
o Mod. date 1 Mod. date 5 the list of modifications in terms of
controllers settings. From the most recent ones to the earliest ones;
o Clear errors a recorded event from the most recent deletion of errors
of the gas controller;
o Unknown change of settings the event is displayed, if controllers
settings are modified with a date preceding the date of the most recent
modification.
A code is assigned to each event, which identifies the PC, which was used to
modify the settings. With the modification date as well as the code, which
identifies the PC, which was used to introduce the change, the user can
determine whether or not the controllers settings were modified by third
parties.

The following additional information can be found in the bottom section of
the window:
o ECU S/N
o Your PC code the code assigned to the PC, on which AC STAG
diagnostic software is currently running.

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2.1.4 Controller's parameters
At the bottom of the screen, the software displays the controllers firmware version, its model as
well as the date and time of compilation of the firmware:

STAG 400.8 DPI controllers model
ver. 0.46 controllers firmware version number
12.0.0 controllers version number
2012-06-22 09:34:14 date and time of compilation of the controllers 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 parameters' windows
by dragging with the left mouse button and dropping in the desired location. The user can also
collapse the windows:
Engine parameters:
o Number of cylinders the number of cylinders in the vehicle
o Number of cyl. per coil the number of cylinders per one ignition coil
o Engine code factory engine code
Calibration parameters:
o Operational pressure gas pressure value at which the controller was calibrated.
Manual modification of the operating pressure is possible, yet each modification
requires correction of the multiplier map.
o Minimum pressure gas pressure value, below which the controller switches to
petrol.
o Gas temp. gas temperature at which the controller was calibrated. Manual
modification of the temperature value is possible, yet each modification requires
correction of the multiplier 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 Switch-over time time after starting the engine, when the controller can switch to
LPG
o Reducer filling delay the time between activation of the LPG/CNG solenoid valve
and activation of the gas injectors
o Switch-over temp. reducer temperature required for the controller to switch to
LPG
o Cylinder switch-over time elapsing between activation of subsequent gas injectors
Petrol switch-over:
o Min gas RPM engine rpm threshold value, below which the controller switches to
petrol
o Max gas RPM engine rpm threshold value, above which the controller switches to
petrol
o Pressure error delay time, after which the controller switches 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

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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 injectors settings window

The window enables the user to set the correction rate individually for each section
of the injector as well as assign a given injector to a particular vehicle's Bank.

o Lambda sensor 1 probe 1 type settings, Voltage standard voltage probe, UEGO
wide band UEGO probe
o External sensor additional sensor settings.
Voltage sensor (lambda) a standard voltage probe.
UEGO sensor (lambda) a wide band UEGO probe.
Sensor emulation the setting used in the case of dedicated connections
of the controller's wiring harness (see the description in the appendices
hereto).
Advanced settings:
o Extra inj. correction additional injections will be indicated by a yellow backlight of
the Inj. dose window in Monitor window. This is the ECU mode of operation,
which is characterised by an additional fuel injection. The slide control setting
impacts response of STAG controller to additional injections. Set the correction
value for additional injections by the trial and error method, while observing STFT
correction indications, when they occur. We recommend the setting, which would
result in STFT correction around 0%. STFT correction reading with OBD Monitor
window or an SXC 1011 diagnostic scanner.

OBD:
o Configuration OBD communication enabled/disabled STAG 400 controller detects
connection of the diagnostic scanner and does not interrupt the transmission, thus
enabling operation with the scanner connected. The communication feature should
be disabled in the event diagnostic scanners are used, in the case of which issues
related to connection to the ECU controller occur.

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There are the following five buttons on the right-hand side of Parameters window:
Load settings and map file
Save settings and map file
Automatic arrangement of the parameter windows
Return to controllers default settings
Return to the previous size of Parameters window
Resize Parameters window if the user clicks on this button, the oscilloscope will not
be displayed in the window any more, in order to facilitate window arrangement.
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 vertical
axis. The displayed rpm values can be modified by clicking on the desired value with the left
mouse button and entering a new value. Petrol doses are displayed along the horizontal axis.
Injection times can be modified by clicking on them with the left mouse button and entering new
values. Additionally, rpm and dose values displayed along the axes can be modified by the
following key combinations: CTRL + ALT and SHIFT + , , , . The multiplier
values displayed on the map are percentage values, which are additionally colour mapped
depending on how rich/weak the mixture is. Columns and lines can be added, by clicking with
the right mouse button on the map area. The multiplier can be modified by highlighting with the
left mouse button and pressing the ENTER key. Modification is introduced via the following key
combinations: CTRL and or as well as +,-. In the event the Shift key is pressed
and held and the above-mentioned combination is used, the multiplier will be changed
incrementally by 10%. Pressing the space-bar results in highlighting the point closest to the
engine operation point. By pressing and holding the space-bar while driving, one can easily
correct the multiplier value at the intersection of the closest petrol dose and the engine rpm
value. It is also possible to highlight a larger area for edition. What is more, columns and lines
can be deleted. Press simultaneously Shift + Delete to delete lines and "Alt" + "Delete", also
simultaneously, to delete columns. Highlight the desired points prior to any deletion operation.
Extreme values of columns and lines cannot be deleted.

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Figure 2.1.11 2D maps; classic view

Figure 2.1.12 2D map; extended view
Various methods 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 value;
Expanded map option arranges points proportionately to the values along the
dose and rpm axes.
Map view group determines the visible scope of the displayed map:
Full map option displays the entire available scope of the dose (up to 25 ms) as
well as the rpm values (up to 10,000 rpm);

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3D view

The 3D view is a graphical representation of the 2D view. It is the same map displayed in 3
dimensions.

Figure 2.1.13 3D map view

Multiplier line view

This view also enables adjustment of the gas system; yet, one must remember that setting the
multiplier in a given spot results in a change throughout the whole rpm range. 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 setting
the desired multiplier position using or . Press and hold Shift to change the multiplier
incrementally by 10 steps. Additionally, the entire multiplier line can be elevated by clicking the
mouse button on the diagram and pressing or . In this case, the Shift key function also
applies, which allows adjusting the line incrementally.

Page 29 of 44

Figure 2.1.14 The multiplier line; full view

Temperature correction view

Figure 2.1.15 Gas temperature correction

KT tab enables one to set the dose correction depending on the gas temperature. The correction
is applied by highlighting a given spot with the left mouse button and setting the desired
correction value by pressing or . Use the right mouse button to increase the number of
spots by clicking in the desired location.

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2.1.6 Auto-calibration

Once the parameters have been set in Parameters window, one can proceed with auto-
calibration on the system. The mechanical components must be fitted correctly, the gas injector
nozzles must be of the correct size and the reducer operating pressure value must be
appropriate. The auto-calibration procedure has been described in detail in chapter 2.2.

Figure 2.1.16 Auto-calibration window
2.1.7 Errors

Errors tab informs the user about 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 2.1.17 Errors tab

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List of STAG errors
Error description Error No.
Parameters error, check parameters 32769
Map error, check map 32770
No switchboard connection 256
Lost connection with switchboard 257
No reducer temperature sensor 512
No gas temperature sensor 513
Short circuit in reducer temperature sensor circuit 514
Short circuit in gas temperature sensor circuit 515
Low gas pressure 772
No injection pulses - petrol injector 1 1024
Failure of gas injector 1 1792
No gas injector 1 1800
Failure of peripherals supply circuit 2048
Failure of selenoid valves supply circuit 2050
No selenoid valve 2051
Low power supply voltage 2052
High power supply voltage 2053
Data bus communication circuit fault (switch to ground) 2305

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2.1.8 Recorder

Recorder window enables the user to browse through the files of the STAG parameters logger,
which was fitted in the vehicle and connected to the diagnostic connection of the STAG
controller. Connecting AC STAG software with the LPG controller is not required in order to
browse the logger files. Once the logger has been connected to a PC using an USB interface, it is
automatically detected and the recorded files are displayed in the window.
The logger window will display the following message Status: Recorder available. The loggers
firmware version as well as the current date will be displayed too. From this moment on, the
user can view the loggers files.

Figure 2.1.18 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 a set marker is loaded (Figure 2.1.18), an oscilloscope file will be displayed with
the cursor set on the event. This means that the user pressed the logger button while the
vehicle's engine was working. The monitor window will display the recorded parameters.

Figure 2.1.19 Recorder tab

Click on "Clear" button in order to delete the logger's files. The time needed to perform the
above-mentioned operation may be substantial as it depends on the number of recorded files.

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2.1.9 Monitor window

Monitor window displays current system's parameters:

LED switchboard with the switch click on the
switchboard to switch between LPG and petrol
Pressure [bar] LPG pressure and pressure in the MAP
inlet manifold
Inj. dose [ms] calculated petrol injection time for the
petrol injectors
Gas Inj. dose [ms] injection time for the LPG injectors
Temperature [C] temperature of the injected gas,
reducer temperature and temperature inside the
controller
Voltage [V] voltage values for lambda probes as well
as the cars battery
RPM [obr./min.] engine rpm value

Figure 2.1.20 Monitor window

All the parameters displayed in the monitor window, are also visible on the oscilloscope. A
particular signal can be switched off in order for the oscilloscope not to record it. To do so,
uncheck a given signal in the window by the name. Click on the name field of a given parameter
displayed in the monitor window to enable its colour change.
The user can adjust the number of displayed parameters by clicking on the button on the
parameter category bar, which collapses the parameters.

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Additionally, by the indication of the wide band lambda probe (Lam. 1WR), there is the
symbol which, when pressed, changes the method for displaying the probe signal on the
oscilloscope the signal becomes amplified.

Gas Inj. Dose window enables the user to switch off particular LPG injectors by clicking on the
given injectors symbol. This option allows detecting mechanical damage to an LPG injector.

Figure 2.1.21 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 windows 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 the main menu.

Figure 2.1.22 Oscilloscope window

Oscilloscope window displays all the signals visible in the "Monitor" and OBD Monitor"
windows. All the control buttons have the following functions, starting from the left-hand side:

Start the oscilloscope;
Stop the oscilloscope;
Record the current oscilloscope;
Load the oscilloscope from a file saved on the hard drive;
Reduce the diagram scale;
Increase the diagram scale.

By pointing the cursor to 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

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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 2.1.23 File info window

2.1.11 OBD Monitor window

The OBD Monitor window becomes visible by selecting Window OBD Monitor from the main
menu.

Figure 2.1.24 OBD Monitor window

The OBD Monitor window displays the following parameters:
Fuel system status CL closed loop (STFT and LTFT corrections are on), OT insufficient
engine temperature (heating), OF open loop due to the ECU controllers error, N/A
status not available
STFT B1 short term fuel trim Bank I
STFT B1 long term fuel trim Bank I

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STFT B2 short term fuel trim Bank II
LTFT B2 long term fuel trim Bank II

Additionally, STFT and LTFT values are graphically represented on the above-mentioned
indicators.
OBD Monitor window is a tool, which facilitates setting the vehicle, provided that the STAG
controller is connected to the vehicles OBD connection. A correct connection is indicated by a
flashing light in the left-hand bottom corner of the window.
2.1.12 Gas level indicator

Click the right mouse button on the switchboard in order to edit settings of the Gas level
indicator. A setting window will be displayed, which enables selection of threshold voltage
values for the indicator.

Figure 2.1.25 Gas level indicator window

The window enables access to the following settings:

Gas level sensor type the user can select from 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 visualisation of the LPG level indication.

The voltage boxes can be edited in order to ensure correct level indication. Once the sensor type
has been selected, set the extreme values for en empty and a full tank, by setting the voltage
values, including a margin, to ensure correct indication for the Empty and Full reading. Enter
intermediate values, in appropriate proportions, in both of the middle boxes.

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2.1.13 Controllers update

Turn the key in the ignition in order to supply the controller and enable update of the
controllers firmware. Select Tools Devices update in the main menu.

Figure 2.1.26 Tools tab in the main menu

A window (Figure 2.1.27) indicating the current version of the controller's firmware as well as the
available updates will be displayed. Parameters window includes a list of devices, for which an
update is available. Firmware updates for STAG 400 DPI controller and LED switchboard are
available.
Select the controller (e.g. STAG 400 DPI) or LED switchboard (LED-400) in Devices parameters
window, to proceed with the firmware update. Connect the logger and use Find Recorder button
in order to update the firmware of the Stag Parameter Logger. Subsequently, select the desired
firmware version from Available updates window. In the event the list of available updates is not
displayed, click on Read Update button and select the desired file from the computer's hard
drive. Having selected the desired firmware version, 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 2.1.27 Devices update window

Page 38 of 44

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 lambda probe starts working before proceeding with the auto-
calibration procedure. Appropriate LTFT and STFT corrections are important when running on
petrol. Usually correction values should oscillate around 0%. When performing auto-calibration,
the engine should work at idle run. Do not rev up the engine, AC and the lights should be turned
off. Do not move the steering wheel, as this might result in an incorrect course of the calibration
procedure. Once Auto-calibration window has been selected and Start button clicked, the
Choose engine code window will be displayed.

Figure 2.2.1 Choose engine code window

Note! A valid engine code list can be found in the list of appendices.

Once the engine 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 injectors have been adjusted, the auto-calibration process is
complete.

Figure 2.2.2 Auto-calibration window

Page 39 of 44
2.2.2 Multiplier map correction

Figure 2.2.3 Multiplier map view

Once the auto-calibration has been performed, the user can proceed with setting the vehicle in
road conditions using the multiplier map. Select Maps tab to do so and subsequently choose the
desired view option. We recommend the following controllers map adjustment methods:

Adjustment based on the injection times keep injection times as well as the load on
the points visible 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, while running on petrol in order to activate
the assistant.

Page 40 of 44
Petrol injection time (the red line) as well as automatic switchover to LPG will be saved in
Calibration assistant window at stable driving conditions.

Figure 2.2.5 Calibration assistant window

Following the switchover, the green line indicates the current petrol injection time.
Correct the multiplier in such a manner as to make sure the green line corresponds with
the red one following the switchover. In order to facilitate the task, the assistant window
displays the rpm as well as the manifold pressure values saved while running on petrol
(marked with blue colour on the dials). In the event the saved rpm and manifold pressure
values are exceeded, the dials will become backlit in yellow. Lower the multiplier in the
calibrated point, in the event the green injection time indicator, following the switchover,
is situated on the left-hand side of the red indicator (the mixture too rich). Similarly, in
the event the mixture is too weak, the green indicator is situated on the right-hand side.
Increase the multiplier value in such a case. STFT and STFT (red colour) correction values
are frozen in the assistant window following the switchover in order to facilitate the task.
This represents the correction value, which applied in the calibration point just prior to
switchover to LPG. Additionally, following switchover to LPG, on the left-hand side of the
assistant window, an arrow is displayed, which informs the user about the recommended
multiplier correction direction. Following the switchover to LPG by the assistant,
depending on which map is being configured (LM or 2D), the nearest calibration area
point is activated. Pressing or causes immediate correction of the same. In
order to verify the multiplier, switchover to petrol and move back to the calibration point.
If necessary, it is possible to add calibration points by clicking the right mouse button on
the multiplier line. The second point along the multiplier line is calculated during the
auto-calibration procedure, while the engine is working at idle run. Having 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 verify correctness of the setting.
Press STOP button to discontinue operation of the assistant.

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Adjustment based on observation of STFT correction while driving, when conditions
are stable and the cursor is on the selected point of the map, switchover to LPG and
observe STFT correction indications (using OBD Monitor window or SXC 1011 diagnostic
scanner). Set the multiplier point in such a manner as to make sure the correction
oscillates around 0%. In the case of a positive STFT value, elevate the multiplier point,
otherwise lower it. Continue until the required correction is achieved. Once the selected
map point has been set, increase the load to move to the next point (without switching
over) and repeat the above-mentioned actions.

Having initially set up the multiplier map, verify nozzle selection at the maximum load. Check
STFT correction at the maximum petrol injection times recorded, when pulling out with the full
load (the accelerator pedal pushed to the floor). Usually, the correction value should oscillate
around zero. In the event changing the multiplier has no effect and STFT correction remains
positive at all times or the lambda probe works in the weak mixture range, it means that the size
of LPG injector nozzles is too small and larger nozzles should be installed instead. Repeat the
calibration procedure, once the nozzles have been replaced.

Verify additional injections settings once the vehicle has been set up. In Parameters Advanced
settings Extra inj. correction tab, there is a slide control, which is used to set LPG injectors'
correction in the event additional injections occur. Additional injections are signalled with a
yellow backlit of the Gas Inj. Dose window in the Monitor window.

Figure 2.2.6 Inj. dose window

Such a situation usually accompanies dynamic engine performance, such as acceleration. In the
event additional injections are observed, watch STFT correction and if the mixture is too weak or
too rich, use the slide control to adjust the correction value as to make sure STFT indication is
identical with the one applicable 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 (LM button in Maps tab) is
insufficient for the entire rpm range, use the 2D map (2D button in Maps tab).

Page 42 of 44

Figure 2.2.8 2D map view

In order to modify the multiplier value in the calibration area, highlight the area and edit the
multiplier value by pressing Enter and entering the desired value.

Figure 2.2.9 Changing the multiplier value in the 2D map view

You can also use + and - or and keys, while holding CTRL, to change the multiplier value.
Apply a 10% incremental change by holding the Shift key.

2.3 Operation of the LED switchboard and sound signals (user's manual)
2.3.1 LED-400 switchboard

Figure 2.3.1 LED-400 switchboard view

LED-400 switchboard features the following elements:

LED circle four LEDs in the form of a circle, which indicate the current LPG level in the tank.
Four green LEDs indicate a full tank.

Page 43 of 44

AC logo button enables fuel switchover and 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
parameters have been achieved, the system will automatically switchover to LPG;
flashes normally (twice per second) with no sound signals 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 controllers 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 additional functionalities are accessible, when LED-400 switchboard is connected
to STAG 400 controller:
LED brightness level adjustment (4 LED brightness levels to choose from);
LED switchboard buzzer volume control;
LED switchboard orientation adjustment in order to ensure correct visualisation of the
LPG level indication, the buzzer installation location being the reference point;
automatic identification of the type of connected LED switchboard; a connected LED-400
switchboard is recognised by the application as LED-400.

Figure 2.3.2 LED-400 set-up window

The controller remembers the most recent fuel settings applicable prior to cutting off the
supply voltage with the key.

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2.4 Sound signals

The controller emits the following sound signals:

three sound signals a switchover to petrol due to insufficient LPG volume in the tank;
three short sound signals and one long signal a controllers error after turning off the
ignition;
two short signals and one long signal required system inspection missing. Go to a
service station in order 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

2.6 Appendices
This manual includes appendices with guidelines regarding installation of STAG 400 DPI
controller in vehicles equipped with various engine types.
The appendices are also available here.

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