STAG 400 DPI Manual EN Ver.1.6 PDF

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. 1.6 2017-02-16

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 model A1 controller ......................................................................... 4
1.2.3.2 Scheme for connecting STAG 400.4 DPI model B1 controller ......................................................................... 5
Scheme for connecting STAG 400.6 DPI model A1 or STAG 400.8 DPI model A1 controller ........................................... 6
1.3 Principles regarding installation of particular elements in a vehicle ................................................... 6
1.3.1 Refuelling valves ...................................................................................................................................................... 7
1.3.2 Autogas tanks .......................................................................................................................................................... 8
1.3.2.1 Cylindrical tanks .............................................................................................................................................. 8
1.3.2.2 Toroidal tanks .................................................................................................................................................. 9
1.3.3 Tank accessories .................................................................................................................................................... 10
1.3.3.1 Selection of tank accessories......................................................................................................................... 10
1.3.3.2 Installation of accessories ............................................................................................................................. 10
1.3.4 Installation of gas tubes ......................................................................................................................................... 12
1.3.4.1 Installation of copper tubes .......................................................................................................................... 12
1.3.4.2 Fitting non-metal class 1 tubes ..................................................................................................................... 12
1.3.5 Reducer, volatile phase filter, PS-02 sensor .......................................................................................................... 13
1.3.6 Electronic control unit ........................................................................................................................................... 15
1.3.7 Installation of injection nozzles and manifold absolute pressure nozzles ............................................................. 16
1.3.8 Connecting a fuel rail pressure sensor ................................................................................................................... 17
1.3.9 Installation of the switchboard .............................................................................................................................. 17
1.4 Approval of a vehicle for installation of an LPG system ................................................................... 18
1.5 The first start-up of the gas injection system .................................................................................. 18
1.6 Installation quality inspection ........................................................................................................ 18
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................................................................................................................................... 21
2.1.3 Main menu ............................................................................................................................................................. 21
2.1.4 Controller's parameters ......................................................................................................................................... 25
2.1.5 Maps ...................................................................................................................................................................... 28
2.1.6 Auto-calibration ..................................................................................................................................................... 33
2.1.7 Errors ..................................................................................................................................................................... 34
2.1.8 Recorder ................................................................................................................................................................ 37
2.1.9 “Monitor” window ................................................................................................................................................. 38
2.1.10 “Oscilloscope” window .......................................................................................................................................... 39
2.1.11 “OBD reader” window ........................................................................................................................................... 40
2.1.12 Gas level indicator ................................................................................................................................................. 42
2.1.13 Autoadaptation .................................................................................................................................................... 43
2.1.13.1 OBD mode ..................................................................................................................................................... 43
2.1.14 Controller’s update ................................................................................................................................................ 44
2.2 Programming the controller ........................................................................................................... 45
2.2.1 Auto-calibration ..................................................................................................................................................... 45
2.2.2 Multiplier map correction ...................................................................................................................................... 46
2.3 Operation of the LED switchboard and sound signals (user's manual) .............................................. 50
2.3.1 LED-401 switchboard ............................................................................................................................................. 50
2.3.2 LED-500 switchboard ............................................................................................................................................. 51
2.4 Sound signals................................................................................................................................. 53
2.5 Technical specification ................................................................................................................... 53
2.6 Appendices.................................................................................................................................... 53
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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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 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 controller
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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 Picture 1.3.6 Refuelling tube clips
inlet
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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
The tank should be mounted perpendicularly to

Cylindrical tanks are mounted using a mounting
the longitudinal axis of the vehicle. Leave 10 cm
frame and bolt connections.
[1 cm = 0.393 in] between the tank and the
The required connection strength is ensured by
back seat. In the event the tank is mounted in
installation of mounting frames as well as bands,
the boot, which is separated from the back seat
the strength of which is confirmed through
with a division and there is no possibility of
relevant tests conducted by the tank
contact between the tank and the back seat,
manufacturer.
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
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 1.3.12 Mounting elements
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 Picture 1.3.17 Sleeve outlet underneath the vehicle
connected to the sleeves inside 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 Picture 1.3.24 Fitting with metal clamps
valve
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 Picture 1.3.28 LPG volatile phase filter
the cooling system
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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 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 1.3.32 A view of the controller’s mounting

Picture 1.3.31 A view of an installed controller
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 Picture 1.3.34 Location for installation of nozzles (view
in the manifold (view from the outside) 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)
Figure 2.1.2b “Parameters” tab (Car info)
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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 0.22.38.
Figure 2.1.4 Main menu bars
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
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“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
2.1.14.
In order to save settings and the controller’s 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
Indicate the location on the computer’s 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.
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Figure 2.1.7 “Open saved parameters” window
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 Fuel – 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 controller’s operation time on gas
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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 system’s
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.
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 controller’s
settings;
o Last PC connection – the date, on which the controller was connected to
a PC with the diagnostic software for the last time;
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o Mod. date 1 ÷ Mod. date 5 – the list of modifications in terms of
controller’s 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 controller’s
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 controller’s 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.
2.1.4 Controller's parameters
At the bottom of the screen, the software displays the controller’s firmware version, its model as
well as the date and time of compilation of the firmware:
STAG 400.4 DPI – controller’s model

ver. 3.0.0 – controller’s firmware version number
10.0.5 – controller’s version number
2017-02-08 11:54:00 – date and time of compilation of the controller’s 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 Engine type – engine type, Standard – normally aspireted engine with no
supercharger, Turbo – supercharged engine,
o Source of RPM signal – engine speed signal source:
Ignition Coil: ignition coil (standard option). Set the number of cylinders per one
coil for correct data presentation.
Camshaft: timing belt sensor. This option is very useful in vehicles, in which
cylinders are switched off in the cut-off state and lack of ignition coil pulses might
be interpreted by the controller as zero engine speed.
CAUTION Use that option only with a digital sensor of the timing belt. Define
number of pulses per one engine revolution. Option active while a timing belt digital
sensor feeds engine speed pulses to the controller: specifies the number of pulses
per one engine revolution. Parameter value must be adjusted for correct engine
speed readings in the controller
o Number of cyl. per coil – the number of cylinders per one ignition coil
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o RPM signal – RPM signal source. RPM detection threshold in Volts. Set the
detection threshold to a value ensuring proper revolutions reading from the
controller. E.g. for impulses originating in a petrol engine usually equal app. 5 [V],
set the detection threshold to app. 2,5 [V]. For impulses originating from the
ignition coil, set the threshold to app. 7 [V].
o Number of pulses per rotation – defining the number of signal pulses from the
camshaft position sensor per engine rotation.
o Engine code – factory engine code (selected in autocalibration).
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 Intermediate phase – controls the rate of switching individual cylinders to LPG
fueling (time when LPG and petrol are supplied simultaneously). Modification
recommended only when problems with smooth switching occur.
Very fast – cylinder switching occurs almost instantaneously.
Fast, normal, slow – steps for non-linear adjustment between “Very fast” and
“Very slow” values.
Very slow – the phase with LPG/petrol feeding overlap through 10 cylinder
working cycles.
o Switch-over time – time after starting the engine, when the controller can switch to
LPG
o Reducer filling time – 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
o Hot start – if checked, warm engine may be started directly from LPG. Check that
option also in vehicles equipped with the Start/Stop function, e.g. Mazda. The
option is used if the engine is started with the reducer temperature equal to or
higher than 65°C.
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
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o Intermediate phase – controls the rate of switching individual cylinders to LPG
fueling (time when LPG and petrol are supplied simultaneously). Modification
recommended only when problems with smooth switching occur.
Very fast – cylinder switching occurs almost instantaneously.
Fast, normal, slow – steps for non-linear adjustment between “Very fast” and
“Very slow” values.
Very slow – the phase with LPG/petrol feeding overlap through 10 cylinder
working cycles.
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
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 Lambda sensor 2 – probe 2 type settings, Voltage – standard voltage probe, UEGO –
wide band UEGO probe
o Reducer temperature sensor – pressure regulator temperature sensor type
selection.
o Gas level indicator – gas level indicator configuration (description In section 2.1.12).
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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.
o Interface type – Indicates OBD2/EOBD communication type available in the vehicle.
The default AUTO mode enables scanning and automatic selection of proper OBD
interface. If, despite of AUTO mode selected, no OBD communication can be
established, an appropriate interface type shall be selected individually.
The Car info window lists the following groups of parameters:
Gas installation fitter – contact details of the installation of a gas fitter.

Car info – car data, which was mounted the gas installation.
Gas installation – general information about the components of the gas installation.
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
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simultaneously, to delete columns. Highlight the desired points prior to any deletion operation.
Extreme values of columns and lines cannot be deleted.
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.
Figure 2.1.14 The multiplier line; full view
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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.
Reducer temperature correction map
Reducer temperature map calibration allows for additional percentage matching of the
multiplier. Adjustment of the reducer temperature map calibration is similar to the multiplier
map. Modification of the correction line of the regulator temperature can be used in vehicles
where petrol fuel dosing strongly depends on the degree of the engine temperature.
Figure 2.1.16 Reducer temperature correction map view
Gas pressure correction map
The controller is provided with automatic gas injection time correction based on gas pressure.
The “Gas pressure correction map” allows the user to enter manually an additional percentage
correction based on gas pressure. Entering modifications is just like on the multiplier.
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Figure 2.1.17 Gas pressure correction map view
MAP correction map (autoadaptation map)
Autoadaptation systems available in STAG 400 DPI controllers are provided with dedicated maps
of correction with rpm and load (MAP negative pressure) axes to make the corrections more
natural and precise. The map view can be accessed through the “MAP correction Bx” tab. If
autoadaptation is inactive, the map can be used for additional, manual corrections of gas fuel
dosing.
Figure 2.1.18 MAP correction map
If autoadaptation is active but it is not desired in certain ranges of engine operation, it is possible
to deactivate such ranges in the autoadaptation process. Select an area of the map with a mouse
and click the right button after selection. A context menu with “Autoadaptation lock” and
“Autoadaptation unlock” commands is displayed. Locked areas are marked with grey correction
values.
Controllers offer two MAP correction maps, one for each bank. The maps can be switched only
with B1/B2 buttons under the map clearing button .
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Petrol portion map
The “Petrol portion” map offers configuration of the petrol post-injection with simultaneous gas
injector control. Configuration of petrol post-injection is made on a two-dimensional map with
an RPM and petrol injection time axes.
Figure 2.1.19 Petrol portion map
Map values specify the percentage of petrol while running on gas in a given operating curve
point. The actual petrol post-injection time is based on the map values related to the petrol
injection time in a given operating curve point.
Like on the RPM correction map, the cursor shows the engine operation curve point. Navigation
on the petrol portion map is identical as on the RPM correction map, i.e. cursor keys (← ,↑,→,
↓), SHIFT and CTRL keys can be used to select map areas and modify their values.
After modification of the petrol portion map, verify if the mixture is correct in
areas allowing petrol extra-injection.
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.
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Figure 2.1.20 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 2.1.21 The view of Errors tab. OBD faults
“Auto clear list” button allows configuration and activation of automatic clearing of OBD2/EOBD
errors. The configuration window is split into two panels. The left one contains a list of all errors
that can be cleared. In order to activate the automatic clearing function, move the selected
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errors to the right panel by using the Select button. Errors from the right panel can be removed
only with the “Clear selected” button.
The errors will be cleared when the ignition is put to the ignition switch, on the condition that
there are recorded errors displayed in the right panel of the automatic clearing configuration
window.
Figure 2.1.22 The view of the OBD error clearing configuration window.
If there are other errors recorded for the vehicle, besides those configured in the auto
clearing tool, clearing will not be executed for safety reasons. Additionally, when engine
startup is too fast, automatic clearing may fail due to the fact that not all vehicles allow
error clearing when the engine is running.
Figure 2.1.23 "Errors" window.
Figure 2.1.23 presents a window used to set the maximum limit for cancellations of a single
error, some petrol controllers will be blocked when a specific error is cancelled more than 255
times (examples includePeugeot 508, 3008 1.6 THP).
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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 logger’s
firmware version as well as the current date will be displayed too. From this moment on, the
user can view the logger’s files.
Figure 2.1.24 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 2.1.24), 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 2.1.25 “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 [ºC] – temperature of the
injected gas, reducer temperature and
temperature inside the controller
Voltage [V] – voltage values for lambda
probes as well as the car’s battery
RPM [obr./min.] – engine rpm value
Figure 2.1.26 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.
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The user can adjust the number of displayed parameters by clicking on the button on the
parameter category bar, which collapses the parameters.
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 injector’s symbol. This option allows detecting mechanical damage to an LPG injector.
Figure 2.1.27 “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 window’s 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 2.1.28 “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.
Display oscilloscope file information (data logging start/stop, total number of stored
samples, application version, controller version, controller serial number).
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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
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 2.1.29 „File info” window
2.1.11 “OBD reader” window
The OBD reader window becomes visible by selecting Window → OBD reader from the main
menu.
Figure 2.1.30 “OBD reader” window
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Figure 2.1.31 OBD2/EOBD reader configuration.
The reader window can display maximum 7 parameters at the same time. Navigation is realized
with buttons , which are used to scroll through the parameters read via OBDII/EOBD. For
showing or hiding the parameters of OBD reader on the oscilloscope in the application use the
button .
The button opens the parameters configuration window (Figure 2.1.31), which allows creating
any sets of displayed parameters thanks to which it is possible to display a set including only
parameters that are required for system calibration (such as fuel loop status, STFT and LTFT
trims, results of a wide-band oxygen sensor). The window displays a set of 96 parameters
available in OBDII/EOBD standard. Parameters unavailable in a given vehicle are grey. In order
to add or remove a parameter from the reader, select it or deselect it in the field on the left side,
next to its description.
If it is necessary to diagnose the vehicle with an external scanner, when

STAG 400 DPI and an active OBD interface is available, switch the system to
petrol fueling, switch off and switch on the ignition. OBD connection will not be
active in petrol fueling mode.
Activation of autoadaptation OBD results in automatic configuration of

OBD2/EOBD reader parameters.
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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 2.1.32 “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.
Auto brightness adjust.
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 Autoadaptation
STAG 400 DPI controllers are provided with a mechanism that corrects gas dosing in real time,
during driving. Activation, selection of autoadaptation mode and configuration is performed in
the Autoadaptation window accessed through the Window menu. There are one mode available:
 OBD – Correction of gas dosage is based on the readings of parameters from the
on-board diagnostic interface compliant with the OBD2/EOBD standard.
2.1.13.1 OBD mode
With OBD selected, the following settings and parameters can be configured and viewed:
Figure 2.1.33 Configuration of OBD adaptation
 The map of OBD target corrections – Press the Open button to display the
configuration window, in which the resulting OBD corrections for each bank are
displayed as a map with rpm and negative pressure axes. Map content is also
automatically refreshed during controller autocalibration.
 The minimum engine temperature – Engine temperature threshold (read through
OBD2/EOBD or emulated by the controller), above which it is allowed to correct the
gas dose.
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Figure 2.1.34 OBD target correction map
 Switch on threshold – A value that extends the range of acceptable resultant target
correction. For example, a threshold of 4% with target correction of 0% (on the map)
means the range of -4% +4% of the OBD resulting correction, within which the
adaptation procedure will not correct gas doses.
 LTFT max. – a limit, maximum trim value that the OBD autoadaptation can make.
 Acquire OBD correction map – Activation results in automatic filling of target
correction maps when driving on petrol.
 Adaptation in OL – OBD correction values are used if the engine open loop control is
applied. Activation of the option allows additional adaptation, adjusted to the status
of the open loop. In order for the function to be activated by the controller, a Lambda
probe must be connected or Lambda value must be read by the OBD2/EOBD reader.
Limitation of the OBD autoadaptation depending on engine rpm is implemented with the
“Adaptation lock” option accessible through the context menu on the MAP correction
map tab (see 2.1.5).
2.1.14 Controller’s update
Turn the key in the ignition in order to supply the controller and enable update of the
controller’s firmware. Select Tools → Devices update in the main menu.
Figure 2.1.35 “Tools” tab in the main menu
A window (Figure 2.1.36) 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.
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Select the controller (e.g. STAG 400 DPI model A1) 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 2.1.36 “Devices update” window
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.
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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
2.2.2 Multiplier map correction
Figure 2.2.3 Multiplier map view
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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 controller’s 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.
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
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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.
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.
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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 (1D button in Maps tab) is
insufficient for the entire rpm range, use the 2D map (2D button in Maps tab).
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.
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2.3 Operation of the LED switchboard and sound signals (user's manual)
2.3.1 LED-401 switchboard
Figure 2.3.1 LED-401 switchboard view
LED-401 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.
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 – controller’s 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 functionalities are accessible, when LED-401 switchboard is connected to STAG 400
controller:
Sound level adjustment for the buzzer installed inside the switch (4 selectable sound
levels);
Brightness adjustment for the LEDs (4 selectable brightness levels) – the function is
inactive when „Auto brightness adjust.” is ON;
LED switchboard orientation adjustment in order to ensure correct visualisation of the
LPG level indication, the buzzer installation location being the reference point;
Selectable activation of automatic adjustment of switch LEDs brightness depending on
the ambient light;
Automatic identification of the type of connected LED switchboard; a connected LED-401
switchboard is recognised by the application as LED-401.
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Figure 2.3.2 LED-401 set-up window
The controller remembers the most recent fuel settings applicable prior to cutting off the
supply voltage with the key.
2.3.2 LED-500 switchboard
Figure 2.3.3 LED-500 switchboard view
LED-500 switchboard features the following elements:
 LED line – shows current LPG level in the tank. Four green LEDs indicate a full tank; a red
LED indicates “reserve”,
 Touch-button (recess in the center of the switch) – enables fuel switchover,
 STAG logo (status LED) – 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;
backlit in white – the vehicle is running on LPG;
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 Autogas system fault LED – indication of a failure In the autogas system. After a fault, the
LED is kept ON (amber light). The LED can be also used for information purposes (pulsing
with the buzzer sounds).
The following functionalities are accessible, when LED-500 switchboard is connected to STAG 400
controller:
Sound level adjustment for the buzzer installed inside the switch (4 selectable sound
levels);
Brightness adjustment for the LEDs (4 selectable brightness levels) – the function is
inactive when "Auto-adjustment of brightness" is ON;
Brightness adjustment for the status LED with the STAG logo (4 selectable brightness
levels) – the function is inactive when "Auto-adjustment of brightness" is ON;
Selectable activation of automatic adjustment of switch LEDs brightness depending on
the ambient light;
Selectable illumination of the status LED with the STAG logo in the petrol-fueling mode;
Selectable activation of the error LED working in an informative mode (visual information
according to the sounds generated by the switch). When the "Buzzer" option is selected,
the error LED will pulse according to the sequence of buzzer sounds – the function assists
users with impaired hearing;
Sensitivity adjustment for the touch-button (5 selectable sensitivity levels);
Automatic identification of the type of connected LED switchboard; a connected LED-500
switchboard is recognised by the application as LED-500.
Figure 2.3.4 LED-500 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 controller’s 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
Emission compliance 1
Emission [g/km] Result Euro 6

CO 0,13 1
HC 0,02 0,1
NOx 0,04 0,06
PM 0,004 0,005
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.
1
Emission results obtained by AC S.A. with LPG sequential system based on STAG-400.4 DPI controller mounted in Skoda
Rapid 1,2l (2016). Tests had been performed at Motor Transport Institute. For comparison reason, the results are
summarized with the Euro 6 requirements.
Page 53 of 53

STAG 400 DPI Manual EN Ver.1.6 PDF

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STAG 400 DPI Manual EN Ver.1.6 PDF

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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. 1.6 2017-02-16

 UNECE Regulation No. 115;

 UNECE Regulation No. 67;

 installation of systems to be used in Poland consistent with Appendix 9 “Additional

 other domestic regulations.

1.2 Description of the LPG STAG 400 DPI system

1.2.2 STAG 400 DPI – operation principle

1.2.3.1 Scheme for connecting STAG 400.4 DPI model A1 controller

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

1.3 Principles regarding installation of particular elements in a vehicle

1.3.2.1 Cylindrical tanks

The tank should be mounted perpendicularly to

Picture 1.3.10 A fitted toroidal tank Picture 1.3.11 A multi-valve

Toroidal tanks should be attached to metal elements

Picture 1.3.13 The view from underneath of the

1.3.3.1 Selection of tank accessories

1.3.3.2 Installation of accessories

Picture 1.3.14 A fitted multi-valve Picture 1.3.15 Gas tight tubes

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

1.3.4.1 Installation of copper tubes

1.3.4.2 Fitting non-metal class 1 tubes

1.3.5 Reducer, volatile phase filter, PS-02 sensor

1.3.6 Electronic control unit

Picture 1.3.32 A view of the controller’s mounting

Picture 1.3.35 A manifold absolute pressure nozzle fitted in the manifold

Picture 1.3.36 Fuel rail pressure sensor

1.3.9 Installation of the switchboard

The switchboard must be installed in a location visible

Picture 1.3.37 Exemplary location for installation of the P/G switchboard

1.4 Approval of a vehicle for installation of an LPG system

1.5 The first start-up of the gas injection 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 tightness of the system

Inspection of performance of the gas system

2.1 Description of the diagnostic software

Figure 2.1.1 Controller detection window

Figure 2.1.2 “Parameters” tab (Car parameters)

Figure 2.1.2b “Parameters” tab (Car info)

2.1.2 Diagnostic software version

Figure 2.1.4 Main menu bars

2.1.3 Main menu

Figure 2.1.5 “Window” tab in the Menu bar

or select Tools → Save parameters from the main menu.

Figure 2.1.6 “Tools” tab in the Menu bar

or select Tools → Open saved parameters from the main menu.

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:

Figure 2.1.9 “Service set” window

The desired time to inspection is calculated based on the selected mileage,

The following additional information can be found in the bottom section of

2.1.4 Controller's parameters

STAG 400.4 DPI – controller’s model

Sensors and actuators:

Figure 2.1.10 “Gas injectors settings” window

The Car info window lists the following groups of parameters: