` Connection and Programming Manual for Stag-4
Contents
1. 0 Changing value change neighbour too Show values Erase Fig 14 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 manner 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 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 14 the second interval operates from 300 to 500 rpm2. 13 2 7 iloig io MR Ncc 16 2 8 OSEIIOSCODB iaar tee T A aE TEE 16 2 9 ENTOT IM sadasi aieiaa KE SEa E E AEE Eaa ak t 17 2 10 2D M ltiplier 18 2 11 3D multiplier calibration map for Stag 300 Plus controller only 19 2 12 OPUONS MON T cleats we 21 2 13 3D multiplier calibration map digital for Stag 300 Plus controller only 22 2 14 LPG temperature calibration map eese eene 23 2 15 Controller ipie 23 3 Stag 4 Stag 300 Plus controller programming essere 24 3 1 Auto calibratiO E 24 3 2 Collection of the petrol injection map with petrol petrol map 24 3 3 Collection of the petrol injection map with LPG LPG 25 3 4 Checking if maps match verification of 25 3 5 Controller manual Setting ic serre pucr agro ai 25 3 6 Multiplier map calibration 3D map for Stag 300 Plus only 26 3 7 LPG temperature correction for Stag 300 Plus 26 4 LED switchboard operation and acoustic signals User Manual
3. 27 4 1 LED switchboard t 27 4 2 Acoustic signals ccccecessccecececessesssaeeeceeeesceesesaeeceeecsseeseuaeseeeeeesssesesasaeeeseeesesenaees 27 Mee 28 b Limited warranty eie oc dici i ro bed e ce evi aul guck ri e ded 28 Strona 2 z 28 1 Set up 1 1 Stag 4 Connection Diagram IGNITION COIL IGNITION SWITCH RED PI 1 PI 8 PETROL I INJECTORS YELLOW YELLOW BLACK GREEN GREEN BLACK RED RED BLACK BLUE BLUE BLACK INERFACE RS 232 or USB INTERFACE Bluetooth ea z LI 1 L18 LPG or CNG INJECTORS ui S EM u2 S et BLUE RED 12V GREY YELLOW BLUE RED 12V GREY GREEN BLUE RED 12V GREY RED BLUE RED 2V GREY BLUE Fig 1 E DIAGNOSTIC 1 CONNECTORS 2 ff WHITE GREEN GREY BLACK PETROLILPG orCNG SWITCH VOme RED YELLOW PRESSURE SENSOR TEE NO CONNECT D BUZZER BLACK WHITE MAP WHITE pressure WHITE supply TO INLET MANIFOLD GAS TEMPERATURE SENSOR CT 02 BLACK l ORANGE BLACK OUTPUT LPG or CNG FILTER 25
4. 2 elektronika systemow autogaz Connection and Programming Manual for Stag 4 Stag 300 plus controller also available in the diagnostic software and at www ac com pl 2 2 2009 04 14 Strona 1 z 28 Table of contents Ss S 3 1 1 Stag 4 Connection Diagram nennen 3 1 2 Stag 300 plus Connection Diagram 2 oorr tme n cue ropa cop ke SR Uc a du CERE 4 1 3 Wiring Diagram for semi sequential 5 1 4 Connection Diagram for full group 5 1 5 Stag 4 Stag 300 plus ECU Installation 5 1 6 Selection of Pressure Regulator eene eene nennen eene 5 1 7 Selection of injector nozzles tpe oam env dapi vue Rp pud 6 2 Ac Gas Synchro diagnostic software GESCIIPtiON ccssccccsssseeecesssneeeeessseeeesseeneees 6 2 1 Controller PG COnPBEElOR siisii rito a e reu cd un nep bat dnb i nnd 6 2 2 Gas Synhro version 7 2 3 EIN nitenan naea 7 24 Controller Parametbls a 8 2 5 Controller dne 12 2 6 Signals injectors switchboard ee hax
5. Chose the proper type of sensor in software VIOLET GREY VIOLET GREY VIOLET VIOLET pe ete ee 1 i oy 1 l E i LAMBDA LAMBDA E UEGO 1 SENSOR SENSOR 2 bg SENSOR 1 before for 6 and 8 pog wideband 1 catalytic converter cylinders version F4 VOLTAGE D before catalytic converter CURREN SENSORS SENSOR BROWN ATTENTION Description and connection diagram of UEGO sensor is located in the help section of controller configuration program BATTERY COMI 1 E LPG LEVEL SENSOR dr WPG H 2 ORANGE BLACK m BLUE LPG or CNG Z TEMPERATURE ELECTRO VALVE SENSOR CT 04 2K Neos REDUCER water Stag 4 Connection Diagram for Vehicle Installation Strona 3 2 28 1 2 Stag 300 plus Connection Diagram T INTERFACE v BROWN Bluetooth B m 1 IGNITION COIL INERFACE DIAGNOSTIC RS 232 or USB 4 CONNECTORS p RED IGNITION SWITCH PI 1 PI 8 LI 1 118 PETROL INJECTORS LPG or CNG INJECTORS 1 YELLOW uy ini BLUE RED M2 A Kis 4 VELLOWSLACK GREVXELLOW A
6. Controller update from the main menu 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 should 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 100 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 Strona 23 z28 e 3 Stag 4 Stag 300 Plus controller programming There are two ways to program the Stag 4 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 4 controller Collection of the petrol injection times with petrol petrol map Collection of the petrol injection times with LPG LPG map Making sure both maps match and checking deviations 3 1
7. 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 Below the signals Fig 5 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 8 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 off petrol on LPG CNG blinking 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 LE
8. u A S GREEN BLUERED a Ui GREEN BLACK A GREY GREEN WHITE GREEN GREY BLACK GREEN RED is E PETROLILPG or CNG WATERED RED BLUE RED SWITCH 12v RED BLACK idi GREY RED fe BLUE BLUERED ea 4 CYLINDERS BLUE BLACK y GREY BLUE BUZZER VERSION us ORANGE BLUERED 12v TEMPERATURE E SENSOR ORANGESLACK GREVORANGE eR ER ORANGE BLACK Y S us oa VIOLET BLUERED 6 CYLINDERS VIOLET BLACK 4 GREY VIOLET VERSION ur A XK A GREV BLACK GAS WATER ihm REDUCER GREY us BLUE RED d 12V 8 CYLINDERS a GREY BLACK 4 GREY WHITE VERSION 2 Chose the proper type of sensor in software A VIOLET GREY VIOLET GREY VIOLET VIOLET LAMBDA SENSOR for i i 1 i i i t s before catalytic converter VOLTAGE SENSORS 1 15A 4 cylinders exp 20A 6 cylinders FUSE 810 25 8 cylinders LPG LEVEL SENSOR WPG LPG LEVEL SENSOR WPG H tata EWE WHITE supply Eo rM WHITE pressure Brack m Eon El 1 s LPG or CNG OUTPUT FILTER PRESSURE and TEMPERATURE SENSOR Fig 2 Stag 300 plus Connection Diagram for Vehicle Installation 1 1 LAMBDA SENS
9. Bas injectors settings Pressure error time 300 aj ms iniestors setings Switch off at the first error Yes V Readout Save Manufacturer settings Connected Stag 300 4 Plus ver 4 0 3 0 0 2009 04 06 08 52 42 ocoocf fh fh ecececec e IC No Engine load x lv Fig 5 Parameters window 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 5 shows the software version 4 0 0 39 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 Strona 7 z 28 e 2 4 Controller Parameters The controller firmware version is shown at the bottom of the screen Fig 5 ver is followed by the firmware version where Stag 300 4 plus controller model 4 0 controller firmware version number 3 0 0 controller version number 2009 04 06 08 52 42
10. Since last connection Inspection 2003 0510 07 19 07 14F5 4E5E 2009 05 10 07 19 14 14F5 4EBE 2009 05 10 08 19 37 14F5 4E5E 2009 05 11 07 19 56 14F5 4E5E 2009 05 10 08 19 26 14F5 4E5E 2008 05 11 07 20 12 14F6 4E5E S N gas ECU Your PC code 14F6 4E5E Fig 6 Gas controller info window The Gas controller info window Fig 6 shows the following parameters ECU working time Petrol total working time of the controller using petrol listed in the following format H hours M 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 last connection working time of the controller using LPG since its last connection with a PC jnspection 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 7 Set inspection Inspect after gt km 1h 50 km Inspection time 20H OM OS Set Fig 7 Set inspection window Strona 12 2 28 Ac The next service visit time is calculated on the basis of mileage The default setting is 1 h 50 km yet it i
11. 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 Strona 25 z 28 e 3 6 Multiplier map calibration 3D map for Stag 300 Plus 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 11 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 differences 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 300 Plus 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 14 However it must be rem
12. 4 Fig 11 2D Controller maps Fig 11 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 a 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 left arrow moves the point to the left change of the injection time for a given point right arrow moves the point to the right change of the injection time for a given point 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 point Delete delete a point from the map Page Up move the map up Page Down move the map down lt Ctrl gt change the active point move to the next one When the Shift key is pressed in the map movement spee
13. controller 25 A LPG injectors 1 O Current input in the standby mode 10 mA Operating temperature 40 110 Protection class IP54 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 28 z 28
14. date and time of the firmware compilation Clicking the 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 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 the case of American cars 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
15. 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 can be modified to 500 800 rpm Strona 22 z 28 e 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 14 Gas temperature calibration map The Gas calibration map opens in the Map window after selecting the Temperature calibration tab Correction 95 es ees uonaanuo23 dua Uonoepeg sdejy 30 25 20 15 10 5 OF 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 Temperature C x 30 C Y 10 Fig 15 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 15 Controller update To update the controller connect it to the diagnostic software and turn the engine off Select
16. 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 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
17. 700 the controller switches to LPG at idle run Switchover time time after starting the engine when the controller 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 Strona 9 z 28 e the switching time to 0 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 engine load on gas the maximum load value in the LPG
18. 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 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 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 3 2 Collection of the petrol injection map with petrol petrol map Having finished the auto calibration sw
19. Ds to enter the LED threshold settings Strona 14 z 28 LED threshold settings E3 O e e oe gt 0 6 gt 1 2 18 gt 24 M LPG level 3 78 V Sensor type 50 kOhm growing m Fig 9 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 Strona15 z28 e 2 7 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 informing the auto calibration has finished successfully The following messages may appear during the calibration Engine rpm too low rpm engine rpm are t
20. OR 2 1 before catalytic converter SENSOR 6and8 wideband inders version RED ATTENTION Description and connection diagram of UEGO sensor is located in the help section of controller configuration program BATTERY MULTI VALVE LPG or CNG ELECTRO VALVE Strona 4 2 28 1 3 Wiring Diagram for semi sequential systems YELLOW RED 12V PI 1 Pl 6 GI 1 GI 5 PETROL INJECTORS GAS INJECTORS AS 611 Ss b YELLOW E YELLOW GREY YELLOW BLACK B E G2 AS c 6 eS 2 5 YELLOW RED U amp 120 B a GREEN GREY E GREEN BLACK AS K h YELLOW RED 121 RED GREY M P U Gl4 X A 2 6 YELLOW RED E 12 R BLUE GREY BLUE BLACK Fig 3 Connection Diagram for semi sequential systems 1 4 Connection Diagram for full group systems PI 1 Pl 6 GI 1 GI 5 PETROL INJECTORS GAS INJECTORS Pit ARR XR Ss b YELLOW 2 16 YELLOW RED 12V 5 SN YELLOW GREY i YELLOW_RED 012V A E E GREEN GREY 07 R T YELLOW_RED 127 MX RED GREY 2 15 YELLOW RED 12V s AgmHacuszoo com BLUE GREY Fig 4 Connection Diagr
21. am for full group systems 1 5 Stag 4 Stag 300 plus ECU Installation Method During the Stag 4 Stag 300 plus 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 6 Selection of Pressure Regulator Install the system according to the connection diagrams Fig 1 Fig 2 When installing the Stag 4 Stag 300 plus 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 delivery is high i e when the throttle is Strona5 z28 fully open When the LPG pressure drops below the minimum value programmed in the controller the system will switch to petrol 1 7 Selection of injector nozzles The injector nozzles selection should also be based on the engine power The selection of injector nozzles should ensure 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 no
22. ata 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 There is a Delete button at the bottom of the screen used to delete all registered errors Strona 17 z 28 2 10 2D Multiplier Map The Map window shows the LPG controller 2D maps aunssaud opalo a a 10 11 12 1 14 15 46 i7 19 21 2 23 24 25 Injection time ms Petol Erase Lock LPG Erase P 4 6 ms 1
23. d is multiplied by 10 fast movement When no point is selected the T arrows move the entire map Strona 18 z 28 Ac 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 11 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 The Lock button situated next to it is used to block the petrol map once it is collected by the controller i e the controller will not modify the petrol map once it is collected drawn with a continuous line 2 11 3D multiplier calibration map for Stag 300 Plus controller only After clicking on the 3D view button a 3D multiplier calibration map will op
24. ectors 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 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 Strona 10 2 28 e amp 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 Clicking the Gas Injectors Settings button will open up the following window in which the LPG injectors can be calibrated Gas injectors settings Gas injectors corrections 0 zi 12 0 13 0 14 0 E un Use this window to calibrate in 96 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 injecti
25. embered 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 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 26 z 28 4 LED switchboard operation and acoustic signals User Manual 4 1 LED switchboard The LED switchboard consists of line indicating LPG level the LED indicating type of fuel button LED line 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 run
26. en in the Map window sdeyy uonaano02 duia Uu 4 4 5 R 7 Petrol Erase Lock Gas Erase 2D View 12 0 Y 0 70 Fig 12 3D map view The 3D map shows the multiplier map described in point 2 10 The multiplier map makes up a plane One axis of the plane represents the petrol injection time ms while the other represents engine revolutions rpm The map makes it possible to calibrate the multiplier depending on engine revolutions This is shown In Fig 12 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 Strona 19 z 28 e A yellow square marker seen in the diagram shows where on the plane the engine currently is The marker position depends on the current rpm value and of the petrol injection time The following working modes are available when using the 3D map 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 the previous mode Multiplier calibration change in adjacent fields FRA This mode is used to calibrate the multip
27. 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 voltage standard voltage probe Two voltage probes can be connected simultaneously UEGO gt voltage wide band UEGO lambda current Strona 8 z 28 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 co
28. f 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 characteristics 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 1096 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
29. ftware is currently used 2 6 Signals injectors switchboard On the right side of the window Fig 5 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 MAP 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 Strona 13 z 28 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 injection time for Injector 7 Gas 8 Gas injection time for Injector 8 Gas temperature C LPG temperature at the pressure regulator output Red Temperature
30. he 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 Left arrow gt Uparrow gt gt Right arrow gt J Down arrow 2 12 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 SEE Display chart cursor position Display mouse cursor position Show legend Themes Classic with grid Classic grey Fig 13 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 VVVV WV 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 21 z 28 e 2 13 3D multiplier calibration map digital for Stag 300 Plus 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 vi
31. itch 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 4 gear and in a way making the lambda probe to work i e 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 software 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 Strona 24 z 28 e 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 I
32. lier for a given range of engine revolutions and 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 Left arrow gt T Uparrow gt Right arrow gt 4 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 T Arrow up higher calibration richer mixture gt J 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 7 Multiplier calibration no change in adjacent fields This mode is used to calibrate the multiplier for a given range of engine revolutions 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 Strona 20 z 28 Rotating the diagram This mode is used rotate the 3D diagram In order to rotate t
33. lowing 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 Strona 16 z 28 e When the controller works with LPG a continuous line appears at the top of the oscilloscope its colour corresponding to the LPG ignition time Increase the number of displayed points only for loaded graphs 2 9 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 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 D
34. 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 situation the LPG 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 Injector Type of the LPG injector Changing the injector type requires re auto calibration or multiplier map calibration Gas Injectors Settings calibration of particular LGP inj
35. ntrolled from a single channel in the petrol controller FullGroup petrol injectors are controlled from a single channel in the petrol controller Mazda leaning in some types of Mazda the petrol controller can in some conditions alter from sequential into semi 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 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 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
36. on 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 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 a file Save save the controller settings to a file Default restore default controller settings Strona 11 z 28 2 5 Controller Info To bring up the About gas ECU window click the Ed button in the upper right corner of the screen or select Gas controller info in the Help menu Gas controller info working time Petrol Since last connection Gas
37. oo 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 0 2 8 Oscilloscope Wykres sygnat w T NE iii iial TT EE TE TT TTT O 10 20 30 40 50 60 70 80 90 100 110120 130 140 150 160 170 180 190 20 Fig 10 Oscilloscope view When the auto calibration or map tab is selected the oscilloscope is visible The oscilloscope shows all the signals described in point 2 5 The control buttons have the fol
38. r will establish connection with the diagnostic software and Connected will appear in the lower left corner of the screen Fig 5 shows the Parameters window Strona 6 z 28 GAS SYNCHRO 4 0 0 39 Port Window Language Controller update Options Documentation Help PRESSURE B Parameters AutoCalibration Errors Map Settings eae v Car parameters m INJECTION TIME ms Number of cylinders 4 cylinders Petrol injector driven Nof Petrol 1 Num of cyl for coil single coil Lambda type Voltage z Petrol 2 X Petrol RPM signal 2 5 H Iv Type of injection Standard Petrol 4 RPM signal filter Nol Type of petrol inj Sequential Petrol 5 Engine type Standard v MAZDA leaning 0 Petrol 6 LPG controller settings Switchover to gas Calibration parameters Fuel type Switchover temp 30 zi Gas temp calib 13 eu CNG Gas 1 us Switchover threshold 660 rpm Pressure bar EEUU 12 5 n indicat CR Ur nee 3 0 Is Operational 0 90 E as level indicator ped c 66 Cylinder switchover 0 al ms Minimum 0 54 1 Sensors Lambda 1 M 0 20 Lambda 2 4 74 Switchover to petrol Battery iv 13 58 Mn tenp 30 VALTEK Z RAIL 640 Min gas RPM 0 rpm Injectors heating Max gas RPM 6000 zi rpm s CEP REN oo ms xtra injection switch off threshol j ims i ini Mas nne landmass ino 00 21 a Active LPG CNG injectors
39. s 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 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 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 serial number of the controller Not available for older versions of controllers Your PC code The code of the PC on which the AcGasSynchro so
40. s 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 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 27 z 28 e When switching the ignition off two short signals followed by a long one indicate a scheduled service visit Visit a service station to have your system checked 5 Specification Power supply voltage 12 V 20 30 Maximum power supply current value for 8 cylinder
41. sualising the 3D map described in 2 11 The digital map offers new possibilities presented below Parameters AutoCalibration Errors Settings RPM ms 0 0 1 8 47 5 1 5 6 amp 2 6 9 21 84 9 3 111 12 0 12 3 1 s eo 120 v2 20 3 21 5 228 s 25 0 6000 4600 0 0 0 0 0 4000 3400 2800 2300 1700 1300 900 600 o ot se o o o o o o o o o o o o 0 0 300
42. zzles 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 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 4 Stag 300 plus controller in the vehicle connect it to a PC with the AcGasSynchro software installed 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 controlle
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