Connection and Programming Manual for controller
Contents
1. L INTERFACE Bluetooth Omit wi m i CL INERFACE RS 232 USB CONNECTORS me 1 7 3 p ose the proper type m of sensor in software VIOLET GREY VIOLET GREY VIOLET VIOLET VIOLET GREY LI 1 L1 8 LPG or CNG INJECTORS 0 2 ud cue u1 lt p BLUE RED pu i LAMBDA LAMBDA Fog 4 GREY YELLOW SENSOR SENSOR 2 SENSOR before for 6 and 8 i wideband catalytic converter cylinders version 1 amp before catalytic converter X VOLTAGE 1 CURRENT 4 Eu MA SS e me es l GREY GREEN P 4 cylinders version 6 cylinders version WHITE GREEN FUSE 25A 8 cylinders version GREY BLACK RED us PETROL LPG or CNG VIRA ATTENTION a BLUE RED SWITCH 2 a a l GREY RED ram gt prog i BATTERY u4 BLUE RED 412v WPG l GREY BLUE gt E MULTI VALVE BLACK Lis lt WHITE qo RED LPG LEVEL SENSOR I E TEMPERATURE WPG H Lt GREY ORANGE SENSOR CT 04 2K ORANGE WATER BLACK N BLACK RS SX z 2 a WHITE supply LPG or CNG GREY VIOLET IIl ORANGE BLACK ELECTRO VALVE W2. 9 2 1 55 45 60 0 snenia SiE nT TEESE hu E env p 9 2 2 A6 6835 SV INCA OV CISION ms SE sd UR SOM Md MI EUN 11 PAS IE TRIS EIU m 11 24 Controller P AGAIN CCUG ose eius sea ioter keep iud viuum M MPH 11 PE COMEPONCE MM Oe ERR D m 15 2 6 OBD adaptation for STAG 300 Premium controller only eene 17 2 7 15 2 AutoAdaptation for STAG 300 ISA2 controller 20 2 8 Matching gas injectors with relevant Bank for STAG 300 Premium controller only 21 2 9 SIgnals InJectors SWIECnDOGSEFQ 22 DVO PUT ORC ANN GAO 23 2 IE CS CMOS CON 24 PA Zs EGU OU See ce sac sce E E A E A E EE 25 2 13 2D NTHRIDIIBI N Deea 26 2 14 3D multiplier calibration map for STAG 4 Plus STAG 300 ISA2 STAG 300 Premium COLO MER Oniy MMMKK 27 2 145 OPON 1 29 2 16 3D petrol injection time map for STAG 300 ISA2 and STAG 300 Premium controller uu e 30 2 17 The status of 3D injection time map acquisition for STAG 300 ISA2 controller only 31 2 18 3D multiplier calibration map d
3. elektronika systemow autogaz Connection and Programming Manual for STAG 200 STAG 4 Plus STAG 300 ISA2 STAG 300 Premium controller also available in the diagnostic software and at www ac com pl 2 6 2011 03 17 Manufacturer AC Spotka Akcyjna 15 182 Biatystok ul 27 Lipca 64 Poland tel 48 85 7438148 fax 48 85 653 8649 www ac com pl e mail autogaz ac com pl Strona 1 740 Table of contents UNUM 4 1 1 STAG 200 Connection Diagram 2 e PY equ ura ee enn row d veau 4 1 2 STAG 4 Plus Connection 4 4 5 1 3 STAG 300 ISA2 Connection Diagram 4 4 1 1 nnus 6 1 4 STAG 300 Premium Connection Diagram esses emere nnns 7 1 5 Wiring Diagram for semi sequential 5 5 5 8 1 6 Connection Diagram for full group 8 1 7 STAG 200 STAG 4 Plus STAG 300 ISA2 STAG 300 Premium ECU Installation Method 8 1 8 Selection of Pressure usi coins ensi aka is 8 1 9 Selection of injector nozzles 9 2 Ac Gas Synchro diagnostic software description
4. BLUE_RED 12V RED GREY BLUE_RED 12V AmacVvusOgNg com BLUE GREY BLUE BLACK Fig 6 Connection Diagram for full group systems 1 7 STAG 200 STAG 4 Plus STAG 300 ISA2 STAG 300 Premium ECU Installation Method During the STAG 200 STAG 4 Plus STAG 300 ISA2 STAG 300 Premium installation it is suggested for the wire set to point downwards Regardless of the type of ECU it is suggested that it is placed in such a way to avoid the negative impact of high temperature and humidity 1 8 Selection of Pressure Regulator Install the system according to the connection diagrams Fig 1 Fig 2 Fig 3 Fig 4 When installing the STAG 200 STAG 4 Plus STAG 300 ISA2 STAG 300 Premium sequence gas injection systems it is important to select the proper pressure regulator for given engine power as well as injector nozzles Improper selection of the pressure regulator in relation to the engine power will result in the pressure regulator inability to ensure nominal LPG pressure i e it will result in pressure drops when the LPG Strona 8 z 40 c delivery is high i e when the throttle is fully open When the LPG pressure drops below the minimum value programmed in the controller the system will switch to petrol 1 9 Selection of injector nozzles The injector nozzles selection should also be based on the engine power The selection of injector nozzles should ensur
5. BATTERY re I I WPG a gt m LPG LEVEL SENSOR WPG H BLACK BLUE WHITE supply ORANGE BLACK WHITE pressure WHITE MAP BLACK afal 2 4 TO INLET MANIFOLD GAS before catalytic converter Chose the proper type of sensor in software VIOLET GREY ATTENTION Description and connection diagram of UEGO sensor is located in the help section of controller configuration program MULTI VALVE LPG or CNG ELECTRO VALVE BLUE RED 12 Bie LPG or CNG FILTER PRESSURE and TEMPERATURE REDUCER OUTPUT GREY WHITE SENSOR Fig 4 STAG 300 Premium Connection Diagram for Vehicle Installation Strona 7 z 40 c 1 5 Wiring Diagram for semi sequential systems 1 5 GAS INJECTORS PI 1 PIG PETROL INJECTORS 7 BLUE_RED 12V YELLOW GREY BLUE_RED 12V GREEN GREY BLUE_RED 12V RED GREY BLUE_RED 12V Amacuvsoqg com BLUE GREY Fig 5 Connection Diagram for semi sequential systems 1 6 Connection Diagram for full group systems 1 5 GAS INJECTORS PI 1 Pl 6 PETROL INJECTORS et 2 RA gt dle BLUE_RED 12V YELLOW GREY BLUE_RED 12V GREEN GREY
6. ECU LAMBDA SENSOR FUSE LPG LEVEL SENSOR GAS OUTPUT WATER INTERFACE Bluetooth 5 pee EP A 4 INERFACE DIAGNOSTIC RS 232 or USB 1 CONNECTORS E ME FUSE 3 LI 1 L16 QS or CNG INJECTORS LI 1 5 5 zt BLUE RED ES 12V GREY YELLOW WHITE GREEN GREY BLACK PETROL LPG E BLUE RED SWITCH 12V GREY GREEN BLACK RED S PRESSURE BW A SENSOR 9 59 lt YELLOW RED 12V o a BUZZER GREY RED PE GI BLACK WHITE kolektor WHITE reduktor WHITE 12 BLUE RED 12V i Cx GREY BLUE A TO INLET MANIFOLDS EN 5 SS BLUE RED gt S5 MEASUREMENT E TEE GREY ORANGE 4 1 TEMPERATURE SENSOR via TUN CT 02 SH BLACK RED E 612V ORANGE BLACK GREY VIOLET Ho k LPG or CNG Fig 1 5 200 Connection Diagram for Vehicle Installation WPGH BLACK BLUE TEMPERATURE SENSOR CT 04 2K REDUCER Strona 4 z 40 ORANGE MULTIVALVE LPG or CNG ELECTRO VALVE 1 2 STAG 4 Plus Connection Diagram BROWN IGNITION COIL RED 6 IGNITION SWITCH PI 1 Pl 8 PETROL INJECTORS 1 1 YELLOW 2 Ah 5 YELLOW BLACK 2 a P SM GREEN E T 5 ix GREEN BLACK R S L A ec RED 4 b RED BLACK E
7. 2 13 2D Multiplier Map The Map window shows the LPG controller 2D maps 434 anasa 1 2 3 4 5 8 9 10 11 12 13 14 15 1B 17 18 18 21 222 23 24 Injection time m Petrol Erase Gas Erase 3D View 4 6 ms v 1 ae Fig 18 2D Controller maps Fig 18 shows 3 maps Multiplier map orange Petrol injection time map with petrol blue Petrol injection time map with LPG green The multiplier map is orange The left axis of the co ordinate system Multiplier and the lower axis Injection time ms relate to the multiplier map The multiplier map is used to set the multiplier for given petrol injection time The yellow points visible at the map are used to set the multiplier Upon auto calibration 2 yellow points appear on the left most and right most positions with 4 additional points in between To move a given point select it by clicking on it The value of a selected point is displayed at the lower right corner of the map To move the points on the map use the following keys lt left arrow moves the point to the left change of the injection time for a given point gt right arrow moves the point to the right change of the injection time for given point J down arrow decreases the multiplier for given injection times up arrow increases the multiplier for given injection times Insert when a point is active or right mouse button add a new po
8. 820 3x E Engine load Active LPG CNG injectors 4 aaananan 280860 565 ty te a lt I lt l O Peto DER 1 49 MAP 0 45 INJECTION ms Petrol 1 Petrol 2 Petrol 3 Petrol 4 Patrol 5 Gas 1 Gas Gas 3 Gas 4 TEMPERATURE Gas Hed VOLTAGE V Lambda 1 4 61 Lambda 0 47 Battery 12 55 RPH rpm RPM w 820 3X E Engine load Active LPG CNG injectors sanaana S I I I 1 amp lI I lt lt cccc5u Ct utUu eum Petrol Strona 10 z 40 c If you get the Controller Error message and No connection appears in the lower left corner of the screen select a different COM port from the Port menu at the top of the screen 2 2 Ac Gas Synchro version When the diagnostic software is open the top title bar shows the version of the software Fig 7 shows the software version 7 0 0 86 2 3 Main menu The main menu consists of the following options Port changing the communication port connecting and disconnecting the controller Window selecting the software windows Language selecting the required software language version Controller update updating the controller firmware Documentation opening a folder with available documentation Help about the software 2 4 Controller Parameters The controller firmware version is shown at the bottom of the
9. Collector pressure KPa RPM rpm areas 85 90 The engine needed for collect the missing of points 100 12 3 5 1 03 sde Hdd dwaj AY dwaj Fig 24 Petrol map acquisition status Strona 31 z 40 c In the course of drive the controller interprets in real time the status of acquisition of map points The engine run areas required for the acquisition of points such that the data acquisition could be regarded complete are displayed as chequered rectangles The vertical line visible on the left side of the view indicates the required RPM range The red part represents the basic range from 1000 through 3500 RPM within which the map has to be acquired for the adaptation to be effective The yellow part designates an extended range of the map necessary to be acquired when the engine is often highly loaded 2 18 3D multiplier calibration map digital for STAG 300 ISA2 STAG 300 Premium controller only Upon pressing the RPM calibration tab a digital multiplier calibration map is displayed in the map window This map is a different method of visualising the 3D map described in 2 14 The digital map offers new possibilities presented below Parameters AutoCalibration Errors Map Settings RPMVIRe a va sa 47 sa sa ea vo 77 va sa reas sl aon
10. acquisition of the 3D petrol map In the course of petrol driving a buzzer will be emitting sounds guiding to the demanded RPM range facilitating the 3D petrol map acquisition Petrol map capture state graphical indicator It can take on the following colours Grey it means that the model map is not acquired and switching to gas is not possible provided that ISA2 adaptation and map acquisition assistant are active The petrol map shall be acquired Yellow partially acquired map Gas drive is possible but at higher RPM ranges an automatic switching to petrol may occur in order to acquire the missing parts of the map Strona 20 z 40 Green fully acquired map i e its required range has already been acquired When the Show button is pressed the model petrol map acquisition status is displayed Sounds the buttons are used to hear the sounds which are generated by the map acquisition assistant buzzer sounds When a sound button is pressed a short description of this particular audible sound shall be displayed explaining its role in the system 2 8 Matching gas injectors with relevant Bank for STAG 300 Premium controller only In the case of V or boxer engines the controller may have 2 banks Bank 1 and Bank 2 The trim value STFT B2 and LTFT B2 are different from zero In this case an individual gas injector must be set to the relevant Bank In order to do that Press Gas injecto
11. o fisz eoa zrs fessos T sao o fo 23309 00 PON 006000 0 fo o o EN 0 0 9 0 0 0 0 0 0 908 0 0 0 0 0 0 98 0 0 0 0 0 o o o o sco o fo 0 Changing value change neighbour too v Show values Erase Fig 25 Digital multiplier calibration map view Thanks to the digital multiplier calibration map shown above it is possible to modify the multiplier according to rpm in the same mann
12. shows current LPG level in the tank 4 green LEDs indicate a full tank a red LED indicates reserve The LED shows current operating status off the engine runs on petrol Slow blinking once per second awaiting engine temperature reading normal blinking twice per second the controller is in the auto mode waiting for required rpm before switching to LPG fast blinking 4 times per second controller error no LPG in the tank On the engine runs on LPG Push button for switching from one fuel type to another The controller remembers the last fuel type setting before switching the ignition switch off In order to start the engine on LPG e g when the petrol pump is damaged press in and hold the button on the LED switchboard while turning the ignition on The LED should come on When the engine revolutions are detected the controller turns the solenoid valves on and the engine starts on LPG In this mode it is not possible to turn back to petrol Turn the ignition off to turn this special mode off 4 2 Acoustic signals The controller generates the following acoustic signals Three acoustic signals when switching from LPG to petrol because of low LPG level in the tank Three short acoustic signals followed by a long one when a controller error occurs Strona 39 z 40 c When switching the ignition off two short signals followed by a long one indicate a scheduled service vi
13. 0 0 0 0 0 0 0 ODO Changing value change neighbour too Show values Erase Fig 26 Disabling of 3D map area ISA2 AutoAdaptation process Strona 33 z 40 2 20 Gas temperature calibration map The Gas calibration map opens in the Map window after selecting the Temperature calibration tab Correction 95 30 25 20 15 10 5 5 10 15 20 25 30 35 40 45 50 55 B5 70 75 80 85 80 35 Temperature C X 30 C 10 Fig 27 Gas temperature calibration map view The controller has the gas temperature multiplier calibration value permanently set The gas temperature calibration map enables percentage adjustments of this calibration value Editing the gas calibration map is analogous to the same function performed in the case of the multiplier map 2 21 Controller update To update the controller connect it to the diagnostic software and turn the engine off Select Controller update from the main menu and select STAG 200 STAG 4 Plus STAG 300 ISA2 STAG 300 Premium depending on the connected controller type The Controller update window will pop up The Controller Parameters window shows the information on current controller firmware version The Available actualizations window includes a list of updates available for the connected controller Loading an update not included in the program directory requires clicking Load update and selecting the update file Loaded update shoul
14. After clicking on the 3D view button a 3D multiplier calibration map will open in the Map window fo 20 ms 4500 rpm 0 TIT Fi s 4 a i La ee a i PH 1 4 u E E 7 2 T ROS Sey 4 T D 3 7 3 4 rc oe n Erase Petrol Erase Gas X Erase 2D View X 12 0 ms Y 0 70 Fig 19 3D map view The 3D map shows the multiplier map described in point 2 13 The multiplier map makes up a plane One axis of the plane represents the petrol injection time ms while the other represents engine revolutions rom The map makes it possible to calibrate the multiplier depending on engine revolutions This is shown In Fig 19 It is possible to enrich weaken the mixture for a defined petrol injection time and revolutions by means of calibrating the multiplier on the 3D map A yellow square marker seen in the diagram shows where on the plane the engine currently is The marker position depends on the current rom value and of the petrol injection time Strona 27 z 40 The following working modes are available when using the 3D map m Multiplier change This mode is used to change the multiplier characteristics plane by following steps analogous to those in the case of the 2D map Editing in this mode is analogous to the same function in the 2D map The mode is activated by means of clicking with the left mouse button beyond the plane marked out by the multiplier map or by means of pressing the TAB key switch from th
15. auto mode The currently used fuel type information is shown under the switchboard There are 5 LEDs at the top of the switchboard showing current LPG CNG level in the tank Click on one of the four LEDs to enter the LED threshold settings LED threshold settings O gt 06 gt 1 2 gt 18 gt 24 LPG level 378 V Sensor type 50 kOhm growing Fig 16 LED threshold settings Use this window to set the voltage which will turn on a given LED The LPG level sensor type is also set here as well as the LPG level voltage When the LED threshold settings window is active changing the LPG level on the sensor results in immediate change of LEDs status This is used to check the proper activity of the full tank sensor and the LED bar When this window is closed normal activity the LED level change on the sensor is shown on the LED bar after a very long period of time 2 10 Auto calibration The auto calibration window is used to calibrate the engine at idle run Start the calibration after the engine is turned on and the lambda probe begins to work During the auto calibration the engine should work at idle run Switch off air conditioning and lights and do not turn the steering wheel During the calibration the controller will automatically switch from petrol to LPG The controller will be automatically switching on selected LPG cylinders Once the auto calibration is complete the controller displays a message
16. informing the auto calibration has finished successfully The following messages may appear during the calibration Strona 23 z 40 Engine rpm too low rpm engine rpm are too low please check the Num of cyl for coil setting No injection at the injector no signal at the petrol injector check the connection of the emulator s bundle Collector pressure bar incorrect the collector pressure may be incorrect check the collector s pressure sensor settings Available calibration options All injectors together in the case of standard calibration All injectors together option is switched off the controller switches one cylinder to LPG first and then switches the remaining cylinders one by one If the All injectors together option is switched on the controller will switch on all injectors at the same time This option can be very useful in the case of some full group injection systems for which it is not possible to separate individual petrol injectors and 4 injectors form a single primed module with two terminals This option should be switched on as well if fuel strip pressure emulators or Renix emulators are used If this option is selected the Cylinder switchover parameter will be automatically set to O 2 11 Oscilloscope 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180 190 200 Fig 17 Oscilloscope view When the auto calibration or map tab is selected the oscillosc
17. screen Fig 7 ver is followed by the firmware version where STAG 300 8 ISA2 controller model 7 2 controller firmware version number 4 0 0 controller version number 2011 02 23 08 36 51 date and time of the firmware compilation Clicking the E button in the upper right corner will bring up the Controller Info window A detailed description of the Controller Info window is presented later in this manual The Parameters window lists a number of parameters which need to be set individually for each vehicle The Car parameters group contains Number of cylinders number of engine cylinders Num of cyl for coil the number of cylinders for each ignition coil Camshaft RPM the source of RPM revolutions per minute signal This option shall be marked if the distribution shaft position sensor is the source of RPM signal This option is very useful in case of the cars in which cylinders are stopped and pulses on the ignition coil disappear in the cut off status In such cases if the coil was the source of rotation pulses the controller would be reading either lower or no rotation NOTE the rotation RPM measurement input shall be connected only to a digital distribution shaft position sensor Pulses per revolution the option is active when the source of rotation signal is the digital sensor of the distribution shaft position This sensor measures the Strona 11 z 40 number of pulses per one en
18. sequential controlling It can be easily noticed by observing the LPG CNG injection time indicator on the 2D map When the petrol controller alters from the sequential into semi sequential controlling at the same load the petrol injection time is reduced by approximately 50 The vertical axis indicator for constant load changes its injection time value position e g from 8 ms to 4 ms In the case of such a controlling type in the LPG mode jerking can occur resulting from the fact that the mixture is too rich for the semi sequential mode In order to eliminate the above mentioned problems Mazda leading TM function should be used The weakening coefficient should be properly set According to the research its value should be approximately 17 However the value can be different depending on the engine NOTE setting this parameter at zero value in such engines may preclude proper operation of ISA2 AutoAdaptation described in another part of these Instructions The LPG Controller Settings window lists the following groups of parameters Switchover to gas parameters related to switching from petrol to LPG Switchover temp LPG pressure regulator temperature required for the controller to switch to LPG Switchover threshold engine rpm required for the controller to switch to LPG For rpm set to 700 the controller switches to LPG at idle run Switchover time time after starting the engine when the contro
19. situation the LPG Strona 13 z 40 c controller can only open LPG injectors permanently as well However corrections e g resulting from changes in the LPG pressure will be no longer possible The moment when petrol injectors are fully open corresponds to the load value of 100 96 If petrol injectors become fully open the Max LPG load parameter should be set to approximately 95 96 This will result in the controller switching to petrol before full opening of LPG injectors Calibration parameters parameters related to controller calibration Gas temp at Calib LPG temperature at which the controller was calibrated Pressure Operational LPG pressure at which the controller was calibrated This setting can be altered manually However each change of the operational LPG pressure requires multiplier map calibration Minimum when the pressure is lower than minimum the controller will switch to petrol if the duration of min pressure exceeds the Pressure Error Time Remaining parameters in the LPG Controller Settings group Fuel Type type of fuel in the LPG system Gas level indicator LED thresholds setting This button is used to set the low LPG LED on off threshold settings as well as to select the LPG level sensor this is explained in more details later in the manual Pressure release in the course of driving when gas injectors are not controlled e g in the cut off status gas pressure in
20. the gas controller may rise If this option is on when pressure exceeds the set value Switch over threshold the controller will start a procedure to bring it down The procedure is switched off when the pressure drops down to 1 5 bar ntensity parameter controlls the frequency of the injectors opening Injector Type type of the LPG injector Changing the injector type requires re auto calibration or multiplier map calibration Gas Injectors Settings calibration of particular LGP injectors Injectors heating enabling this option results in starting the procedure of heating LPG injectors after a longer stopover Activation of the procedure is indicated in the oscilloscope diagram with a red line and flashing active LPG injectors Extra injection switch off threshold petrol injection impulses below the set value will be ignored by the controller meaning that the controller will not generate the LPG injection impulse if the petrol injection impulse is below the set value Permissible number of start ups in emergency mode a limitation of the number of emergency start ups which are available for the end user When the number is exceeded then the engine will always start either in the petrol or automatic mode The number of emergency start ups is always reset during software update It can also be manually cancelled by the Cancel button Strona 14 z 40 Clicking the Gas Injectors Settings button will open up the following win
21. the multiplier map The second left point is the point of engine operation at idle run i e the point of operation during auto calibration The multiplier s value for this point should be between 1 1 and 1 6 if the value is greater than 1 6 longer times of petrol injection i e greater load and high rpm may cause overlapping of injection times i e one LPG injection will begin before the previous one ends looped injections In such a case the controller will display the Too long injection time error message However in such a case check the operation of the lambda probe if it is in the rich mode and the vehicle drives without problems the error can be ignored Strona 35 z 40 3 2 Collection of the petrol injection map with petrol petrol map Having finished the auto calibration switch over to petrol and drive the vehicle for app 4 km to collect the petrol map During the collection of the map try to drive without changing gears e g at the gear a way making the lambda probe work changing its mode from weak to rich Blue points should appear during the collection of the map To collect the map quicker adjust vehicle load in such a way causing new points to be collected in places which are still empty Collection of maps is performed without participation of the diagnostic software thus can be done with the PC disconnected However collecting the map while the PC is connected and the diagnostic so
22. 4 S S i BLUE U e l 5i re BLUE BLACK INTERFACE Bluetooth a DIAGNOSTIC pc a g A A Em INERFACE I RS 232 or USB LI 1 LI 8 LPG or CNG INJECTORS BLUE RED 12V GREY YELLOW BLUE RED 12V l GREY GREEN BLUE RED 121 GREY RED BLUE RED 2 GREY BLUE Fig 2 CONNECTORS a LI tle WHITE GREEN GREY BLACK PETROLILPG orCNG WIFE RED SWITCH BLACK CP BUZZER TEMPERATURE SENSOR CT 04 2K WATER ORANGE BLACK GAS WATER OUTPUT REDUCER LPG CNG INJECTION CONTROLLER Es 67R 01 4903 110R 00 4904 www ac com p U 12V 7 w Chose the proper type of sensor in software VIOLET GREY VIOLET GREY VIOLET VIOLET VIOLET VIOLET GREY 6 leo i ECU ECU ECU LAMBDA LAMBDA rs SENSOR SENSOR 2 SENSOR before for 6 and 8 It wideband catalytic converter cylinders version ra before catalytic converter VOLTAGE 1 ot CURRENT SENSORS SENSO
23. HITE pressure WHITE MAP _ _ Q BLACK Li 7 Dust eer 12V 77 TO INLET 4 GREY BLACK ey MANIFOLD may MANIFOLD GAS WATER 1 OUTPUT gt LPG or CNG ec 9 us 3 80 BLUE RED REDUCER FILTER CD OUTPUT gt PRESSURE and TEMPERATURE l GREY WHITE SENSOR A Eq STR 01 4289 ALB 110R 00 4534 STAG 300 8 ISAE e Fig 3 STAG 300 ISA2 Connection Diagram for Vehicle Installation Strona 6 z 40 Description and connection diagram of UEGO sensor Is located the help section of controller configuration 1 4 STAG 300 Premium Connection Diagram OBD connector 1 8 9 16 e 2 elektronika system w autogaz STAG OBD Adapter v BROWN IGNITION COIL IGNITION SWITCH PI 1 8 PETROL INJECTORS PI1 SS Sa L YELLOW A Kae 7 5 YELLOW BLACK 2 E 4 GREEN E Xx 1 5 GREEN BLACK S RED RED BLACK PI4 S E 9 SS So BLUE LY 9 u c 4 CYLINDERS BL
24. R po WD i IR ee am Na ee ine an Spee NR 2 et E i EE FUSE 15A RED BROWN ATTENTION Description and connection diagram of UEGO sensor is located in the help were 2 ii section of controller configuration gt program YELLOW T BATTERY I NO CONNECT NO CONNECT E E MULTI VALVE BLACK WHITE Hen LPG LEVEL SENSOR WPG H WP BLACK WHITE supply BLUE WHITE pressure LPG or CNG WHITE ELECTRO VALVE BLACK TO INLET MANIFOLD GAS a LPG or CNG OUTPUT FILTER PRESSURE and TEMPERATURE SENSO STAG 4 Plus Connection Diagram for Vehicle Installation Strona 5 z 40 1 3 STAG 300 ISA2 Connection Diagram 9 4 CYLINDERS VERSION 6 CYLINDERS VERSION 8 CYLINDERS VERSION N BROWN At IGNITION COIL O Y IGNITION SWITCH PI 1 8 PETROL INJECTORS PI1 3 iB YELLOW 7 lt lt lt 5 1 YELLOW BLACK PI2 r H GREEN S ac GREEN BLACK I a RED LY Kiar 6 RED BLACK e y E BLUE Av Ki BLUE BLACK E ORANGE 5 ORANGE BLACK VIOLET VIOLET BLACK BROWN BROWN BLACK GREY GREY BLACK
25. UE BLACK VERSION e T mmm SN E ORANGE A Kan 5 ORANGE BLACK 6 t Ih 6 N VIOLET AY Kae 6 CYLINDERS ViOLET BLACK VERSION BROWN BROWN BLACK 8 CYLINDERS GREY BLACK VERSION a LI 1 L1 8 INTERFACE Bluetooth I Omer 4 a 1 INERFACE RS 232 or USB DIAGNOSTIC 1 CONNECTORS LPG or CNG INJECTORS BLUE RED 12 GREY YELLOW BLUE RED 112v GREY GREEN BLUE RED 112V GREY RED BLUE RED 2V GREY BLUE WHITE GREEN GREY BLACK GREEN RED PETROL LPG or CNG SWITCH LE BUZZER BLUE RED 12V GREY ORANGE BLUE RED 12V GREY VIOLET BLUE RED 12V GREY BLACK TEMPERATURE SENSOR 04 2 ORANGE BLACK WATER GAS WATER OUTPUT o OLEI STAG 300 8 LPG 4 CNG TINITECTION CONTROLLER VIOLET GREY VIOLET GREY VIOLET VIOLET LAMBDA SENSOR 2 for 6 and 8 cylinders version LAMBDA SENSOR before catalytic converter i VOLTAGE SENSORS i ee 15A 4 cylinders version 20A 6 cylinders version 25A 8 cylinders version
26. User Manual 30 aT LED WIDDO IA tuat NIMM EU 30 2 A COUSHC E 39 Terzo NN 40 6 Limited warranty 5 40 Strona 3 740 1 Set up 1 1 STAG 200 Connection Diagram IGNITION COIL IGNITION SWITCH BROWN RED PI 1 Pl 6 PETROL INJECTORS YELLOW com YELLOW BLACK VIOLET VIOLET BLACK P12 B a4 0 77 lt 7 j GREEN BLACK i5 77 lt lt die RED BLACK 5 4 Sa gt 5 BLUE A f ae BLUE BLACK PI5 E oj 4 0 771 2 lt i cle ome ORANGE BLACK elektronika system w autogaz KONTROLER WTRYSKU GAZU STAG 200 6 67R 01 3912 110R 00 4533 www ac com pl ORANGE WATER VIOLET
27. age standard voltage probe Two voltage probes can be connected simultaneously UEGO gt voltage wide band UEGO lambda current The controller shows on an oscilloscope values from the probe in the same form as for a voltage probe Only 1 wide band lambda can be connected at any given time UEGO gt full range wide band UEGO lambda current The controller shows on an oscilloscope values in Volts This makes it possible to watch the entire working range of the UEGO probe i e from lean to rich mixtures Only 1 broad band probe can be connected at any given time Do not select UEGO probe for a voltage probe as this may damage the probe Refer to the Connection Diagram Type of Injection type of injection used in the car Standard standard indirect injection petrol injectors with no current limit Renix indirect injection system petrol injectors with Renix current limit Type of petrol Inj type of petrol injectors control Sequential each petrol injector is controlled from a separate channel in the petrol controller Semi sequential petrol injectors are controlled in pairs i e 2 injectors are controlled from a single channel in the petrol controller FullGroup petrol injectors are controlled from a single channel the petrol controller Strona 12 z 40 Mazda leaning TM in some types of Mazda the petrol controller can in some conditions alter from sequential into semi
28. al adaptation tailored to the open loop status Adaptation on threshold value expanding the range of resultant correction Possible values 0 396 OBD RPM threshold the adaptation shall be active only when engine s RPM are above the set value Desired resultant correction B1 B2 Desired resultant correction is calculated automatically during calibration Accepted correction range B1 B2 destined range value of desired resultant corrections of bank 1 and 2 Depending on desired resultant correction B1 B2 and adaptation activation threshold Example Adaptation on threshold equals 1 with desired resultant correction B1 at 3 gives accepted correction range B1 between 2 4 If in given configuration resultant correction B1 petrol ECU remains within above range adaptation will be stopped because it has reached its target In case the resultant correction B1 petrol ECU again reaches over the above given range the adaptation will resume A window showing connection status with OBD is presented below Grey icon and text No connection with OBD means that at the moment the connection with OBD is not possible no ignition no OBD adapter Yellow icon and text Connecting to OBD means that the controller is connecting with OBD Flashing red icon and text Connected OBD means that the controller has been connected to OBD Strona 19 z 40 c In order to switch on adaptation the process of auto cali
29. bration must be performed first see chapter 3 1 Auto calibration After completing auto calibration the programming process must be implemented see chapter 3 STAG 200 STAG 4 plus STAG 300 ISA2 STAG 300 Premium controller programming WARNING OBD Adaptation is recommended for cars made after 2002 2 7 ISA2 AutoAdaptation for STAG 300 ISA2 controller only In STAG 300 ISA2 controllers without OBD support when the AutoAdaptation button is pressed in the right upper corner of the program a window is displayed with data associated with the AutoAdaptation function following the ISA2 injection times ISA2 AutoAdaptation restart shall be possible only after autocalibration AutoAdaptation AutoAdaptation a ISA Adaptation STAG 300 2 STFT 23 4 Momentary deflection 12 4 Adaptation enable threshold 0 s Adaptation assistant Fetrol map tulfillment state Fig 13 ISA2 AutoAdaptation window Description of parameters STFT short term correction of gas injection time period Distortion proportion of the actual petrol injection time deviation vs the injection time on model map Adaptation threshold the acceptable value of the actual fuel injection time deviation and the injection time indicated on model map YES NO adaptation assistant activation deactivation of the map collection assistant If the assistant is on switching to gas shall be possible only after
30. can be modified to 500 800 rpm The blue square which can be seen in the map changes its position within the horizontal axis depending on the actual petrol injection time value and within the vertical axis depending on the actual rpm value 2 19 Automatic change of 3D multiplier correction for STAG 300 ISA2 controller only Long term ISA2 correction is demonstrated as an automatic change of field values on the 3D multiplier correction map It also enables matching of both controller maps petrol and gas providing for optimal engine performance If the automatic modification of multiplier correction map in certain run stages undesirable then these stages can be switched off from the AutoAdaptation process In order to achieve it encircle a selected map area with a mouse and click with the right button with the cursor on the area A concise menu will open with the following options Turn ON AutoaAdaptation and Turn OFF AutoAdaptation Correction values in the disabled areas shall be displayed in grey colour It should be kept in mind that if the Show values option is marked off then the disabled areas will not be distinctive either 7 2 n S 2 10 7 5 O0 0O O0 O nit Im 3 n T 2 10 3 b 3 3 0 O0 1 UU O 1 UU O O 300 0 2 n n n n mg 0 O 0 i 0 OD 01
31. d date 1 Mod date 5 a list of controller settings modifications From the most recent ones till the oldest Unknown settings mod This happens when the controller s settings modification is performed with a date earlier than a previously performed modification Each event is also accompanied by a code linked to the PC on which the modification was made Thus knowing the modification date as well as the PC code it is easy to determine whether any modifications have been performed by anyone else The bottom of this window shows additional information S N gas ECU the serial number of the controller Not available for older versions of controllers Your PC code The code of the PC on which the AcGasSynchro software is currently used 2 6 OBD adaptation for STAG 300 Premium controller only In the upper right corner of the screen AutoAdaptation button is located when pressed a window is displayed with OBD related information This window will be displayed automatically once the connection with OBD in the car is established AutoAdaptation AutoAdaptation i OBD Adaptation 5 300 premium B1 LTFT B1 Be B OBD Il EOBD Humber af trouble codes Show Closed loop Hl LTFT H1 Resultant correction B1 B2 LTFT Be Resultant correction B2 Engine RPM 5 C Connected to OBD Fig 11 OBD window Strona 17 z 40 OBD Adaptation STAG 300 p
32. d be included in the list of available updates Click Update once the update file has been selected from the list When the progress bar reaches 10096 the controller will disconnect and then re connect The new version number should appear at the bottom of the screen and should reflect the version number of the update file Should the update go wrong the update window will be opened automatically upon connecting with the controller Perform the update procedure again 2 22 Update of STAG OBD Adapter In order to update a controller connect it to a diagnostics program turn the ignition on Select option Controller update from the main menu and select STAG OBD Adapter Next select an update from the list and press Update button After successful completion of the update an appropriate confirmation window should be displayed If not repeat the update process Next turn off the engine and restart after approximately 30 seconds a connection with OBD should be established Strona 34 z 40 c 3 STAG 200 STAG 4 Plus STAG 300 ISA2 STAG 300 Premium controller programming There are two ways to program the STAG controller Programming with the petrol and LPG maps See 3 1 to 3 4 Manual programming of the controller See 3 5 Programming with the petrol and LPG maps consists of the following stages Auto calibration of the STAG controller Collection of the petrol injection times with petrol petrol map C
33. damage to the car The correction window may be opened regardless of the selected tab i e the map tab may be opened and the correction window on top of it There are 3 buttons at the bottom of the Settings tab used to perform the following actions Read read the controller settings from file Save save the controller settings to a file Default restore default controller settings 2 5 Controller Info To bring up the About gas ECU window click the button in the upper right corner of the screen or select Gas controller info in the Help menu Strona 15 740 Gas controller info ECU working time Petrol 90 Since last connection Gas 10 Since last connection 2011 03 09 T233 14F6 4E5E 2011 03 09 13 46 03 14F6 4E5E 2011 03 10 12 17 45 14F6 4E5E 2011 03 10 12 20 48 14F6 4E5E Mod date 2 2011 03 09 14 07 05 14F6 4E5E Mod date 3 Mod date 4 Mod date 5 Unknown settings mod 2011 03 01 12 21 55 14F6 4E5E S N gas ECU 0208091117950002 Your PC code 14F6 4E5E Fig 9 Gas controller info window The Gas controller info window Fig 9 shows the following parameters ECU working time Petrol total working time of the controller using petrol listed in the following format H hours minutes S seconds Since last connection working time of the controller using petrol since its last connection with a PC Gas total working time of the controller using LPG Since
34. dow in which the LPG injectors can be calibrated Gas injectors settings Gas injectors corrections H o 1 2 0 our 0 Sf Fig 8 Gas injectors settings window Use this window to calibrate in the LPG injectors These settings enable a correction of the fuel mixture for each cylinder This is used e g to correct the injection time variations present in a V type engine cylinders To calibrate the injectors use the following procedure Upon auto calibration check the petrol injection times for each cylinder when using petrol Turn the LPG injectors on one at a time and observe if there are any differences in the injection times after switching from petrol to LPG Adjust the settings only when necessary for each injector so that switching to LPG one injector at a time will not result in changing the petrol injection times WARNING Use this option as a last resort i e when sure that the installation was performed properly all mechanical issues have been eliminated and injection times variations for given injectors are still present when using LPG Do not ever use injection strip collector pipes of different lengths and then the injectors calibration to accommodate this difference Also never use this option when the system is not in a perfect working condition or when some of its elements have worn out Using this option in a manner not consistent with the above instructions may result in
35. e previous mode Multiplier calibration change in adjacent fields of the petrol injection time In order to calibrate the multiplier the area which is to be calibrated must be selected by moving the mouse with the left button pressed over this area Another method is to press the SHIFT key and while holding it to select the appropriate area by pressing arrow keys gt lt Left arrow gt Up arrow gt Right arrow gt J Down arrow Having marked the area which is to be calibrated specified actions can be performed by using the combination of the CTRL key and one of the keys below gt Arrow up higher calibration richer mixture gt X Arrow down lower calibration leaner mixture Pressing the SHIFT key in the course of the multiplier calibration will multiply the required step by 10 The mode is activated by means of pressing the TAB key switch from the previous mode Multiplier calibration no change in adjacent fields This mode is used to calibrate the multiplier for a given range of engine revolutions and of the petrol injection time This mode functions in a way analogous to Multiplier calibration change in adjacent fields The difference is that only the marked area undergoes changes while adjacent fields remain unchanged The mode is activated by means of pressing the TAB key switch from the previous mode Rotating the diagram Strona 28 z 40 c This mode is used rota
36. e that at high engine loads and high rpm the multiplier for a given injection time should be close to 1 For the majority of engines the injection times equal roughly 15 ms The table below presents the nozzles diameters depending on the engine power per 1 cylinder To select the right diameter of nozzles the engine power needs to be divided by the number of its cylinders Nozzle diameter mm Reducer pressure 1 bar Engine power per cylinder KM 12 17 2 1 2 3 18 24 2 4 2 6 25 32 2 2 9 33 40 41 48 Note the above values are estimates only and do not necessarily always reflect the reality This can occur e g in vehicles with semi sequential or full group all injectors activated simultaneously injection In such cases the nozzles diameters will be smaller than those presented in the table above as in these systems the amount of supplied LPG is higher than in full sequence systems two times higher for semi sequential injectors and four times higher for full group injectors In the event Injection control mode parameter is set to depending on the vehicle type semi sequential or full group diameter values of injector nozzles should correspond to those indicated in the chart 2 Ac Gas Synchro diagnostic software description 2 1 Controller PC connection Upon installing the STAG 200 STAG 4 Plus STAG 300 ISA2 STAG 300 Premium controller in the vehicle connect it to a PC with the AcGasSynchro software install
37. ed via an RS or USB interface manufactured by AC SA Prior to starting the software turn the ignition on in order to supply voltage to the controller this is necessary as the controller switches to sleep mode when it will not communicate with the PC after app 10 minutes without power supply After starting the software provided the COM port is selected properly the controller will establish connection with the diagnostic software and Connected will appear in the lower left corner of the screen Fig 7 and Fig 7a shows the Parameters window Strona 9 740 AC GAS SYNCHRO 7 0 0 80 Port Window Language Controller update Options Documentation Help Parameters AutoCalibration Errors Map Data recorder Gas controller settings Car parameters 4 cylinders single Hol E 25 M Hol Standard Hol Hol Voltage MAZDA leaning 0 Number of cylinders Petrol injector driven by Hum of cyl for coil Lambda type RPH from camshaft sensor Type of injection Type of petrol inj RPH signal RPH signal filter Engine type Wankel engine Headout Dave Manufacturer settings Connected STAG 300 8 1542 wer 4 0 0 2011 02 25 05 36 57 Fig 7 Parameters window Car parameters AC GAS SYNCHRO 7 0 0 86 Port Window Language Controller update Options Documentation Help Parameters AutoCalibration Errors Map Data recorder Car parameters Gas controlle
38. er as in the case of a graphic 3D map also as regards the method of operating it by means of a keyboard All changes to the graphic map will be represented in the digital map and vice versa because physically there is only one map in the controller memory only the method of presentation is different A far as map modifications are concerned the following additional options are also available Changing value change neighbour too if selected in the case of modifying the selected area the neighbouring fields are modified as well Show values if selected the controller displays calibration values in per cent In this display mode the Erase button can be seen By pressing this button all map settings can be deleted the map can be reset Strona 32 z 40 c The vertical axis shows rpm values for individual intervals on the map The red border marks the boundary between the first and the second rpm interval If intervals are set as presented in Fig 25 the second interval operates from 300 to 500 rpm while the third interval operates from 500 to 600 rpm The boundaries between individual intervals can be regulated by clicking on the correct field and entering a new interval boundary value Thanks to this option it is possible to adjust the mixture composition to precisely defined rpm range and injection time The user is not limited by preset intervals For example the operating range of the third interval
39. es must be calibrated by means of enriching weakening using the 3D map The rule is the same as in the case of setting the multiplier i e if the injection time value is bigger after switching from petrol to LPG it means that the mixture is too lean at a given point within the map the petrol computer lengthens the petrol injection time Thus the mixture must be enriched for this point using the 3D map In a reverse situation i e when the petrol injection time is shorter after switching from petrol to LPG the mixture must be weakened 3 7 LPG temperature correction for STAG 4 Plus STAG 300 ISA2 STAG 300 Premium controller only If the petrol injection time changes when the LPG temperature is changed in the LPG mode the LPG temperature calibration must be corrected The correction may be made by means of the LPG temperature calibration map see 2 20 However it must be remembered that this operation may be performed if the auto calibration and the multiplier setting while driving have been carried out correctly In order to make the correction in a proper way the car must be started with a cold engine Then beginning with the temperature of switching to LPG the petrol injection time must be checked and after switching to LPG the petrol injection time should be compared If the petrol injection time value is bigger after switching to LPG the positive correction must be made for this LPG temperature value the LPG temperature calibration
40. ftware running is quicker and enables the operator to see what is actually happening to the vehicle When the controller collects sufficient number of points the map will be drawn with a continuous line and the petrol map collection is finished 3 3 Collection of the petrol injection map with LPG LPG map Having collected the petrol map switch to LPG and collect the LPG map in the same way the petrol map was collected The LPG map should be collected in the same road conditions and with similar loads as the petrol map The LPG map is drawn with green points Having collected sufficient number of green points the map will be drawn with a continuous green line If the controller is set properly the multiplier characteristics selected properly the petrol and the LPG maps should match If the maps do not match the multiplier characteristic should be corrected at the points where the maps do not match the lower axis of co ordinates for injection times If the LPG map is collected with the PC connected and the diagnostic software running it is possible to immediately correct the multiplier characteristics when the collected green points do not match with the petrol map It is even strongly recommended to use the PC in this way as if the multiplier characteristics differ strongly from the required ones the controller starts to switch over and in the extreme case can activate the check signal lamp When correcting the multiplier characte
41. gine s revolution This value shall appropriately be selected for proper reading of the engine s RPM by the controller 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 Nissan Micra is an exception Its computer ignition impulses equal app 1 4 V in which case the detection threshold needs to be set at app 1 0 V For some Renault Megan models the detection setting needs to be set at app 10 V RPM signal filter Switching on YES and switching off NO of RPM signal filtration In case of cars from the U S A correct reading of RPM value can be difficult so this option should be switched on In other cases it should be switched off Engine type engine type Standard normally aspirated engine with no supercharger Turbo supercharged engine Wankl engine this option shall be marked when fuel petrol injectors stopped in a car with a Wankl engine Petrol Injector driven by injection signals reading in systems where signals are positive i e grounding is the common signal for all injectors and the controlling signals are up to 12 V Lambda type type of the installed lambda probe volt
42. igital for STAG 300 ISA2 STAG 300 Premium COn TOSK ONY E leat 32 2 19 Automatic change of 3D multiplier correction for STAG 300 ISA2 controller only 33 2 20 Gas temperature susci esa skcke wea wa esed ov ana DM 34 2 21 CODtroll st update 34 2 22 Update of STAG OOBD AOSDEOE eee onines peg tuns deste Svo Hx da aeie UR Susi 34 3 STAG 200 STAG 4 Plus STAG 300 15 2 STAG 300 Premium controller programming 35 PIERII EIU INN MIN GM E CMM 35 3 2 Collection of the petrol injection map with petrol petrol Map 36 3 3 Collection of the petrol injection map with LPG LPG 36 3 4 Checking if maps match verification of 5 36 So controller manual 36 3 6 Multiplier map calibration 3D map for STAG 4 Plus STAG 300 ISA2 STAG 300 Premiumcontroler Only 37 3 7 LPG temperature correction for STAG 4 Plus STAG 300 ISA2 STAG 300 Premium COR COMED OMY NRI Tm mm 37 Strona 2 740 c 3 8 Model petrol map acquisition for STAG 300 ISA2 controller only 38 4 LED switchboard operation and acoustic signals
43. incorrect auto adaptation function which may lead to engine damage The above described procedure need not be implemented in the engines with controller and 1 as all gas injectors are by default matched with 1 Bank 2 9 Signals injectors switchboard On the right side of the window Fig 7 there are the Signals and Injectors windows The Signals window shows the following signals measured by the controller Gas pressure bar LPG CNG pressure value the difference in the pressure regulator pressure and the suction collector pressure pressure bar pressure inside the suction collector absolute pressure value Injection time ms petrol injection time Petrol 1 Petrol injection time for Injector 1 Petrol 2 Petrol injection time for Injector 2 Petrol 3 Petrol injection time for Injector 3 Petrol 4 Petrol injection time for Injector 4 Petrol 5 Petrol injection time for Injector 5 Petrol 6 Petrol injection time for Injector 6 Petrol 7 Petrol injection time for Injector 7 Petrol 8 Petrol injection time for Injector 8 Injection time ms Gas injection time Gas 1 Gas injection time for Injector 1 Gas 2 Gas injection time for Injector 2 Gas 3 Gas injection time for Injector 3 Gas 4 Gas injection time for Injector 4 Gas 5 Gas injection time for Injector 5 Gas 6 Gas injection time for Injector 6 Gas 7 Gas in
44. int Delete delete a point from the map Page Up move the map up Page Down move the map down Ctrl lt or Ctrl gt change the active point move to the next one When the Shift key is pressed in the map movement speed is multiplied by 10 fast movement When no point is selected the T J arrows move the entire map Strona 26 z 40 c Apart from the multiplier map there are two other maps in the window The blue map represents the petrol injection times with petrol The right axis Collector pressure Kpa and the lower axis Injection Time ms relate to this map The map consists of blue points After collecting the data the controller turns these points into a continuous line The same applies to the so called LPG map i e the map of petrol injection times with LPG which is green After the controller collects both maps i e the petrol and LPG maps the Deflection tab becomes active where a red line shows the difference between petrol and LPG The map window in Fig 18 shows a blue square marker its position changes vertically depending on the collector pressure and horizontally depending on the petrol injection times It is very useful during map collection as it shows the load and injection times of the engine The Erase button is used to delete the petrol and LPG maps 2 14 3D multiplier calibration map for STAG 4 Plus STAG 300 ISA2 STAG 300 Premium controller only
45. jection time for Injector 7 Gas 8 Gas injection time for Injector 8 Gas temperature C LPG temperature at the pressure regulator output Red Temperature C liquid temperature at the reducer Lambda 1 voltage V voltage at the lambda probe 1 Lambda 2 voltage V voltage at the lambda probe 2 Battery V voltage at the controller s power supply RPM rpm engine revolutions Engine load current engine load value expressed in per cent All the above described signals are also visible on the oscilloscope To turn off a given signal on the oscilloscope click on it By clicking on the name of a given signal you can change its colour on the oscilloscope Strona 22 z 40 Ac Below the signals Fig 7 there is a field with active LPG CNG injectors This is used to turn off selected LPG injectors E g in a 4 cylinder engine normally 4 LPG injectors are active green To turn off a selected injector click on it and the corresponding petrol injector will be turned on This is useful in diagnosing a mechanical damage on an injector When the power is switched off with the ignition key all LPG injectors are turned on There is a LED switchboard under the Signals and Injectors windows Fig 15 LED switchboard There is a button on the LED switchboard for changing the fuel type The LED next to the switch Signals the controller status petrol on LPG CNG blinking
46. last connection working time of the controller using LPG since its last connection with a PC Inspection Service Schedule When the controller reaches the working time using LPG set in this field every time the ignition key is switched off the controller will produce an acoustic signal reminding of the inspection Clearing the Inspection Schedule is explained below To set the Service Schedule click the Set button in the About gas ECU window The following window will pop up Fig 10 Set inspection Inspect after km Th 50 km Inspection time 20H OM 0S Fig 10 Set inspection window The next service visit time is calculated on the basis of mileage The default setting is 1h 50 km yet it is configurable The above window shows the next service visit set to 1000 km which in this case equals 20 hours of work To clear the service schedule select Disabled in which case the controller will not monitor the service schedule Strona 16 z 40 c Below the working times the Controller Info lists the following types of registered events First connection to PC date of the first controller PC connection First settings modification first modification of the controller settings If these fields do not show dates but instead the symbols it means an error occurred in the Controller Info Time information has been lost and the controller will start counting the times from the beginning Mo
47. ller can switch to LPG Cylinder Switchover time elapsing between the switching of subsequent cylinders E g with the setting at 200 ms for a 4 cylinder engine the switching from petrol to LPG or LPG to petrol will take 4 200 ms This works regardless of whether the petrol injection system is the so called full sequence or not Setting the switching time to O will result in the switching from petrol to LPG or vice versa and turning on and off of the solenoid valves without any delay Switchover to petrol parameters related to switching from LPG to petrol Min gas temp min LPG temperature when lower the controller will switch over to petrol Min gas RPM min rpm when lower the controller will switch over to petrol Max gas RPM engine rpm when higher the controller will switch to petrol Pressure error time amount of time with the LPG pressure lower than minimal before the controller switches to petrol and reports LPG pressure too low Switch off at the first error with this option selected the controller will switch to petrol when the LPG pressure drop is detected When unselected the controller will switch some cylinders to petrol when the LPG pressure is detected to lower LPG usage Max engine load on gas the maximum load value in the LPG mode above which the controller switches to petrol This option is very useful for the engines in the case of which petrol injectors can be fully opened In such a
48. map must be brought up If the petrol injection time value is lower after switching to LPG the calibration map for a given LPG temperature value must be brought down The calibration map must be set in such a way as to ensure that the petrol injection time remains the same after switching from petrol to LPG In order to set the LPG temperature calibration map correctly the procedure described above must be repeated for the full range of LPG temperature values in 5 C steps Strona 37 z 40 3 8 Model petrol map acquisition for STAG 300 ISA2 controller only Proper ISA2 AutoAdaptation performance requires correct model petrol map acquisition When the map is missing no switching to gas shall be possible see the appropriate messages displayed in the AC Gas Synchro application The term correctly acquired map shall be understood as map acquired in the course of normal engine operation conditions heated engine no defects reported by the engine s ECU engine control unit Map acquisition consists in recording injection times for various engine operation parameters RPM and overload The so called map acquisition assistant has been designed to facilitate the task The tool by means of sound signals from a buzzer prompts the fitter to appropriate engine RPM range and informs when the engine runs at required point of operation Completed map acquisition is also sound signalled Taking into account driving style differences am
49. ollection of the petrol injection times with LPG LPG map Making sure both maps match and checking deviations STAG 300 ISA2 and STAG 300 premium controllers are provided with mechanisms automatically adapting blend contents depending on current engine operation conditions Having these functions in the system allows improvement of gas driving parameters with simultaneous considerable facilitation of controller calibration process by the fitter OBD AutoAdaptation STAG 300 Premium controls gas injection time following the data from the vehicle s petrol controller SA2 AutoAdaptation STAG 300 ISA2 controls gas injection time following the recorded engine operation characteristics in the petrol mode It requires the model petrol map to be recorded See section 3 8 3 1 Auto calibration Prior to starting the auto calibration start the engine and wait until the lambda probe begins to work During the auto calibration the engine should work at idle run do not increase rpm switch off air conditioning and lights and do not turn the steering wheel as this may cause errors during the auto calibration During the auto calibration watch carefully petrol and LPG injection times If LPG injection times are shorter than petrol injection times the injector nozzles may be too large and should be replaced with smaller diameter ones When the auto calibration is complete 2 extreme yellow points and 4 additional points in between will show up on
50. ona 36 z 40 c switch the car to LPG and watch the blue marker for variations in injection times when compared with the earlier petrol injection times If the injection times decreased the marker moved to the left it means that for the selected injection times the multiplier is too high the mixture is too rich In this case lower the multiplier value for the 5 ms injection time in our case If upon switching to LPG the blue marker moves to the right it means the mixture is not reach enough and the multiplier needs to be brought up for given injection times The procedure described above should be performed for a few different injection times starting at the calibration point all the way until heavy load injections You can check the multiplier map e g every 2 ms starting at the calibration point If necessary add a point at the multiplier map to set it more precisely Once the manual setting is complete both maps petrol and LPG should match 3 6 Multiplier map calibration 3D map for STAG 4 Plus STAG 300 ISA2 STAG 300 Premium controller only Having performed auto calibration and having set the multiplier map while driving additional calibration of the multiplier depending on the engine revolutions can be performed using the 3D map see 2 14 If there are any differences in injection times for a given range of the petrol injection time and the engine revolutions after switching from petrol to LPG such differenc
51. ong individual drivers the map has been divided into two sub ranges the first range covers 1000 3500 RPM the red vertical line in the petrol map acquisition view and is absolutely required to switch car driving into gas the second range covers RPM gt 3500 the vertical yellow line in the petrol map acquisition view If in the course of driving the engine operation point moves into the not acquired part of the map and stays there for approximately 3 seconds the car will automatically switch to petrol in order to acquire a model map for this point the sound assistant is also activated A return of the engine operation point to the acquired map area will cause a switch to gas drive again with some delay of approximately 10 seconds A short drive in full rotation and load ranges to determine engine run characteristics is recommended as the first step in model map recording The model petrol map is always acquired during petrol driver when certain conditions are fulfilled including among others gas reducer temperature gt 50 C however the map acquisition assistant is active only when the controller is in the automatic mode No sounds will be generated in the oetrol mode Strona 38 z 40 4 LED switchboard operation and acoustic signals User Manual 4 1 LED switchboard The LED switchboard consists of LED line indicating LPG level the LED indicating type of fuel button LED line
52. ope is visible The oscilloscope shows all the signals described in point 2 5 The control buttons have the following functions from left to right Start the oscilloscope Stop the oscilloscope Save current oscilloscope display Load saved oscilloscope display Decrease the number of displayed points only for loaded graphs Increase the number of displayed points only for loaded graphs When the controller works with LPG a continuous line appears at the top of the oscilloscope its colour corresponding to the LPG ignition time In case of enforced petrol drive caused by the ISA2 AutoAdaptation mechanism the line will turn yellow Strona 24 z 40 c 2 12 Errors The Error window shows the following field Continuous acoustic signal for errors if selected acoustic signals will inform of an error until manually turned off by the user If unselected the acoustic signals will remain on only for a set amount of time The Actual Errors window shows current errors recorded by the controller and the Saved Errors window shows errors recorded during the controller s operation The following errors may appear during operation Injector No Error no LPG injector No or injector damage Voltage Error voltage at the controller s power supply lower than 9 V LPG pressure too high the LPG pressure has been two times higher than operational pressure for 60 seconds a reducer problem LPG pressure
53. ps as functions of the collector pressure and RPM Selected view activating buttons are grouped in the upper left corner of 3D view Collector pressure KPa RPM rpm WY uoraanoa dwaj uanaajpjar m 2 5 P n m n m 2 Gas Erase 2 View X 1i b ms 1 32 Fig 22 3D injection time map gas Strona 30 z 40 The differences between 3D maps of injection times recorded available through the deviation view Petral Erase Gas Erase 20 View during petrol and gas drive are Deflection 25 ae Collector pressure KPa RPM rpm Fig 23 Deviation of 3D injection time maps 2 17 The status of 3D injection time map acquisition for STAG 300 ISA2 controller only The 3D injection time map recorded during petrol drive is a model petrol map for the ISA2 AutoAdaptation mechanism The AutoAdaptation process is carried out via continuous comparing of the engine s run at definite parameters load and RPM with acquired model map An additional task shall comprise its correct acquisition In order to monitor the map data acquisition process the application has been provided with a special view of the petrol map acquisition status available via the State button M P State G D 1 15 20 25 30 35 40 45 50 55 65 70 Petral Erase Gas Erase 2D View jection time ms
54. r settings Switch o er to gas Fuel type LPG Calibration parameters 30 C CNG 600 rpm 200 ms 0 o ilm 16000 rpm 100 X 300 ms Yes v Gas temp at calib 30 1 00 level indicator 0 60 Switch o er temp Switch over threshold Pressure bar Switch over time Operational Cylinder switch over Minimum Switch o er to petrol Pressure release gas temp Switch ov er threshold Hin gas gas RPH a Ear s WALTEK IG 17 A Hol Extra injection switch off threshold 10 0 ms Gaz injectors settings Sensors CT 04 2K included i CT 02 2K included i Intensity Injector type engine load on gaz _ _ Injectors heating Pressure error time Switch off at the first error Emergency starts Allowed 24 o Heducer temperature sens Performed Gas temperature sens Readout cuve Manufacturer settings STAG SU0 51S42 Z2 4 0 0 2011 02 23 05 36 51 Connected Fig 7a Parameters window Gas controller settings caer B AutoAdaptation d Ga at AutoAdaptation 4 Ga at Elk 1 49 MAP 0 45 INJECTION TIME ms Petrol 1 Petrol 2 Petrol 3 Petrol 4 Botral 5 Gas 1 Gas Gas 3 Gas 4 TEMPERATURE Gas Hed VOLTAGE Vv Lambda 1 0 45 Lambda 4 61 Battery gt 12 55 HPH rpm HPM
55. remium sao 2 Hl soo 2 B2 ooo LTFT B Inversed OBD trim No Adaptation in open loop Yes iv OBD adaptation enable threshold 0 841 threshold for adaptation 0 rom Desired resultant correction H1 0 1 Desired resultant correction B 0 2 Accepted correction range B1 0 O 55 Accepted correction range B 0 575 Reset adaptation Connected to D BD Fig 11a OBD window OBD window displays the following data OBD II EOBD Data available from fuel ECU via the OBD interface Number of trouble codes Number of recorded OBD troubles Closed Open loop the fuel system status STFT B1 Short term fuel trim Bank 1 ECU fuel LTFT B1 Long term fuel trim Bank 1 ECU fuel Resultant trim B1 Resultant trim Bank 1 ECU fuel STFT B2 Short term fuel trim Bank 2 ECU fuel B2 Long term fuel trim Bank 2 ECU fuel Resultant trim B2 Resultant trim Bank 2 ECU fuel Engine RPM Engine rpm value Additionally after pressing button Show a window containing information on stored trouble codes ECU fuel and pending trouble codes ECU fuel will be displayed Stored trouble codes Pending trouble codes Erase Refresh Fig 12 Window ECU fuel trouble codes read from OBD Strona 18 z 40 c STAG 300 Premium Data related to OBD adaptation In the basic view onl
56. ristics make the points on the LPG map match with the petrol map Once both maps match the characteristics are properly set 3 4 Checking if maps match verification of deviations Having collected the petrol and LPG maps both maps drawn with continuous lines check the deviation between them In the Map window there is the Deflection button located on the right Press it to see the deviation graph drawn with a red line If the deviation fits within 10 the controller is programmed properly otherwise the multiplier characteristics should be corrected at points where maps do not match 3 5 Controller manual setting The controller may also be set up manually which provided sufficient experience has been gained may prove quicker than the above described procedure Start with the auto calibration in the same way as described above this is necessary to ensure the controller works properly see 3 1 If the auto calibration finishes properly and the multiplier values are correct for the calibration point switch the engine to petrol and take it for a ride The multiplier characteristics need to be set in the following way Drive the car with a constant load i e the petrol injection times should be stable Adjust the engine loads so that the injection times equal e g app 5 ms The blue marker will help determine the injection times as it is location on the horizontal axis is determined by the injection times Next Str
57. rs settings button in the Parameters bookmark The window Gas injectors settings will be displayed Gas injectors settings Gas injectors corrections Bank1 Bank2 0 ee we re re 3 Fig 14 Gas injectors settings window STAG 300 Premium Start the engine wait for the controller to establish connection with OBD The engine should operate at low rotation speed with adaptation off Set correction value for all gas injectors to zero Remember the correction value STFT and LTFT for Bank 1 and Bank 2 Next perform the following procedure starting from gas injector 1 1 In the window Gas injectors settings change the correction value of the gas injector from 0 to 25 2 Observe for which of 2 Banks STFT LTFT corrections change towards lower values 3 After identifying for which Bank corrections change match a given gas injector with the corresponding Bank 4 Change the value of gas injector correction to O After that the STFT and LTFT should return to the initial values priori to point 1 Repeat the procedures described in steps 1 to 4 as many times as there are gas injectors in the system After matching gas injectors with banks turn auto adaptation on if necessary and set gas injectors corrections to the initial value Strona 21 z 40 c In the case of controllers with 2 Banks improper realisation of the above described procedure will result in
58. sit Visit a service station to have your system checked Three long signals repeated every minute the car started in the emergency mode 5 Specification Power supply voltage 12 V 20 30 Maximum power supply current value for 8 cylinder controller 25 A LPG injectors 1 Q Current input in the standby mode lt 10 mA Operating temperature 40 110 C Protection class 54 6 Limited warranty exclusions The warranty shall not cover the following 1 Damage resulting from installing the unit inconsistently with applicable installation diagram in particular damage resulting from connecting signal wires to other connections than those indicated in the installation manual 2 Damage resulting from installing the unit in locations inconsistent with the installation manual as well as locations in which the unit may be affected by water high temperature or car battery vapour 3 Systems modified or repaired by unauthorised parties 4 Mechanical damage resulting from the customer s fault in particular connections damage connections damage resulting from application of chemical cleaning substances casing damage PCB damage 5 Systems damaged electrically due to connecting communication interfaces other than those recommended in the installation manual Strona 40 z 40
59. te the 3D diagram In order to rotate the diagram press the right mouse button and move the mouse so that the desired result is achieved Another method is to rotate the diagram by pressing the following arrow keys gt lt Left arrow gt T Uparrow gt Right arrow gt XL Down arrow 2 15 Options menu The Options menu can be accessed from the upper menu Thanks to the Options menu the user can define their own 3D map window view corresponding to their requirements Options Display chart cursor position Display mouse cursor position Show legend Themes Fig 20 Options menu view The menu presented above makes it possible for the user to adjust the 3D map display mode The following 5 display modes are available Classic Classic with grid lines Classic grey Black Full black VN VN N The following additional options are also available Display chart cursor position rpm and injection time values are displayed for the actual engine status Display mouse cursor position rpm and injection time values corresponding to the actual mouse position are displayed Show legend the legend on the 3D map is shown hidden Strona 29 z 40 Ac 2 16 3D petrol injection time map for STAG 300 ISA2 and STAG 300 Premium controller only The 3D view of the map besides the insight into the multiplier correction map makes also available the views of petrol injection time ma
60. too low the LPG pressure has dropped under the min pressure value for a set amount of time No petrol injection the controller has detected a lack of petrol injector signal for one or more petrol injectors Data error check settings the controller has detected a settings error check all controller settings Power supply voltage too low for LPG CNG the controller power supply is too low to work with LPG Working time error Controller Info has been damaged and automatically deleted In this case the First PC Connection and First Settings Modifications info will not be shown The following warnings may appear in the Warnings window LPG injectors fully open Check the lambda probe at full engine load LPG injection loop i e an LPG injection s started before the previous LPG injection ended If the lambda probe is rich at the time of this message this warning may be ignored Otherwise replace the injectors nozzles with higher diameter ones to decrease the multiplier Inspection of Gas system required The installation requires a periodical service visit To delete this message go to the Controller Info settings click Set Inspection and either set the next service visit in kilometres or select Off in which case the service reminder will be inactive Car runs in emergency mode on LPG CNG There is a Delete button at the bottom of the screen used to delete all registered errors Strona 25 z 40
61. y short and long term corrections shall be displayed calculated by the adaptation process In order to display and change AutoAdaptation parameters press the wide button which is below the displayed corrections The window will unwind covering the OBD on board diagnostics data For return to the previous view press the same button again STFT B1 Short term fuel trim Bank 1 STAG 300 Premium LTFT B1 Long term fuel trim Bank 1 STAG 300 Premium STFT B2 Short term fuel trim Bank 2 STAG 300 Premium LTFT B2 Long term fuel trim Bank 2 STAG 300 Premium Adaptation on Switching on off of OBD adaptation In the case of engines with two Banks control systems e g V type or boxer engines one has to define which bank a particular gas injector is located Detailed information in the chapter 2 8 Matching gas injectors with relevant Bank for STAG 300 Premium controller only OBD inversed trim in classical fuel dose control systems OBD correction values become positive in the case of a poor blend and negative in the opposite instance This option shall be on in the vehicles with a reversed relationship between the blend status and OBD correction sign NOTE wrong option setting will lead to rapid gas injection correction which will disable vehicle drive Adaptation at open loop OBD correction values shall be applicable when the engine runs in closed loop Switching on the option shall enable an addition
Download Pdf Manuals
Related Search