SERVICE INSTRUCTIONS
for fuel-burning heater type
STROCO 15.00 M
Applicable from heater no.
12V: 238
24V: 405
STROCO ApS, Viborgvej 50, Voldby, DK-8450 Hammel, ph. +45 86961066, fax +45 86969647
Technical approval no. SP 555 AD 06
EU directive 42/245:
EU technical approval no. E5 10R-03152
Heating directive E 2001/56:
EU technical approval no. R122 E5 00002
ISO certified
Developed with aid from the Danish Environmental Protection Agency
GB 04/18
This manual is also available at www.stroco.dk
IMPORTANT
PAGE 3
The minimum conditions below must be met in order to
maintain the right to claims under the warranty.
1. Installation must be carried out as described in this manual.
2. Service and maintenance must be performed in a proper
professional manner. Maintenance/service must be
performed within the established schedule.
3. Only original spare parts may be used.
4. The heater may only be used for the type of fuel stated on
the model plate.
5. The heater may only be used with the voltage stated on the
model plate.
The heater must not be used in service stations.
The heater must not be used where there is risk of ignition of
flammable vapours and/or materials. Nor where there is risk
of accumulation of toxic gasses, e.g. in closed spaces.
The heater must not be used if the heater or its exhaust
opening is near flammable materials, e.g. dry grass.
IMPORTANT
PAGE 4
CONTENTS
PAGE 5
PAGE:
Description ………………………………………………………………… 6-7
Schematic diagram of fuel-burning heater ………………………………... 7
Built-in dimensions …………………………………………………………. 8
Installation guide/installation plan ...…………………………………... 9-10
List of connections .………………………………………………………… 11
Electrical connections ....…………………………………………………... 12
Technical specifications ………………………………………………... 13-14
Explanation of terminology ..……………………………………………… 14
Maintenance …………………………………………………………….. 15-16
Description of functionality - operation ..………………………………… 17
Description of functionality ..……………………………………………… 18
Troubleshooting - how? …………………………………………………… 19
Dismounting burner and combustion chamber ..………………………... 20
Process control diagram ....………………………………………………... 21
Alarm functionality ....……………………………………………………... 22
Combustion unit .…………………………………………………………... 23
Voltage control of electrodes .……………………………………………... 24
Photoelectric sensor ...……………………………………………………... 25
Under/overvoltage ..………………………………………………………... 26
Replacing the fan motor …………………………………………………... 27
Checking the fuel pump solenoid valve …………………………………... 28
Operating thermostat sensor .……………………………………………... 29
Assembly drawing - parts list ..………………………………………… 30-31
Electrical diagram ……………………………………………………… 32-33
Installation in boats ..…………………………………………………… 34-36
Warranty conditions .……………………………………………………… 37
Dealers .……………………………………………………………………... 38
DESCRIPTION
PAGE 6
It is important to read and understand this manual before using the STROCO heater to ensure
optimum utility and safety. Please mail the warranty card to STROCO ApS.
The presence of the above-mentioned basic elements, in the right quantities and correct mixtures, is
essential to the heat production of the STROCO heater.
In case of failure or unsatisfactory operation, make sure to check these basic elements first.
The STROCO heater is independent of the operation of the vehicle’s engine, and vice versa. This
means that interruptions in one system do not affect the operation of the other. However, lack of
electrical power or fuel will affect both systems, if both engine and heater are connected to the same
battery and fuel tank.
The fuel-burning heater’s job is to heat the water in the heating system. It does this by burning fuel
at a high temperature in the combustion chamber. This heat is transferred to the water in the boiler
section of the heater, and the water is pumped into the heat exchanger units in a continual process,
where the hot water acts as a transfer agent between heat production (the heater) and heat
exchangers.
The heart of the heater is the combustion section. Fuel is pumped to here and vaporized by a nozzle.
This fuel vapour ignites, establishing a flame (combustion). One of the factors that ensure correct
combustion of the fuel vapour is regulation of air intake. The combustion process and other functionality of the heater is controlled by the brain of the system: the electronic control and monitoring unit.
This automatic system ensures that the process follows predetermined routines. If the process should
deviate from these routines, or if the combustion process fails or becomes deficient due to poor
supply of the basic elements - fuel, water, and air - the system shuts down the process. In theory, the
presence of the basic elements alone should ensure the combustion process, but since we require the
process to be highly efficient and reliable, it must run in a controlled manner. This manual will help
you to keep the heater running satisfactorily at all times. What to do if the heater is not working, or
performs inadequately?
The section Alarm Functionality can help you to locate the source of an error and analyse the
symptoms.
The section Error Remedy Instructions in the Description of Functionality explains and illustrates
remedial actions.
Fuel
Water
Electrical power
Air
Heat
+ =
PAGE 7
Precautionary measures are always better than repairs, and there are a number of Maintenance
Procedures that should be undertaken regularly to ensure the continued working order of the heater.
Please consult the maintenance section. Section 1 in the manual deals with the installation of the
heater, i.e. the actual fitting. The other sections deal with servicing and maintenance exclusively.
Schematic diagram of fuel-burning heater
1: Supply, diesel fuel, 2: Return, diesel fuel, 3: Filter, 4: Exhaust, 5: Engine, 6:Heating system,
7:Control panel
BUILT-IN DIMENSIONS
PAGE 8
All measurements +/- 2 mm.
PAGE 9
INSTALLATION GUIDE/INSTALLATION PLAN
In general: Installation must be performed in accordance with the ECE 2001/56 standard
These instructions apply to STROCO fuel-burning heater, type 15.00 M.
Material and design of fuel hoses/pipes: TA max. -40°C/+120°C.
In case of replacement of hoses, use ONLY hoses from STROCO ApS, or hoses approved by
STROCO ApS. The heater’s warranty will be void if any other hoses are used. Leaky hoses and
joints lead to increased risk of fire.
Non-insulated exhaust pipes/hoses must have at least 7.5 cm to flammable material.
Fuel hoses placed on the outside of the vehicle must be screened to prevent any damage. Electric
cables may not be placed next to fuel hoses.
The fuel-burning heater should be mounted where it is protected from water and spatter from the
vehicle’s wheels, and from impact or other damaging effects. It is very important to clean the surrounding area thoroughly when servicing the unit, and to check all electrical connections and
plugs, greasing with acid-free grease. The area should be kept free of damp. Covers, casings etc.,
must not be removed.
The heater must be positioned in an way that does not impede maintenance work on the heater and
the vehicle’s other components. If necessary, the heater must be placed in a separate box.
Installation must be performed in such a way that heat impact from the vehicle’s engine and ex-
haust system does not damage the heater. Conversely, the vehicle’s components must be protected
against damage from the heater’s exhaust.
Electrical installations for the heater must comply with SEN 3607111 ”Electric installations for
motor vehicles” or similar.
The water system which the heater will be connected to must be fitted with a pressure control valve
for safety.
The heater should be installed in as low a position as possible relative to the vehicle’s cooling/
heating system.
If the heater is installed inside a casing, this must have an air intake opening of at least 75 cm².
(The air intake must not be blocked off). The casing must be made from a non-flammable material.
Intake air for the heater must not come from rooms where there are people. The placement of the
intake must be such that exhaust gas from the vehicle does not mix with the intake air.
The air intake must be placed and designed to avoid clogging by snow or dirt. The air intake must
be placed to keep the airflow around the vehicle from interfering with the pressure in the system.
Place the orifice of the exhaust pipe so that the combustion is not materially affevted by airflows
around the vehicle to prevent heating damage on adjacent vehicle components, and to prevent igni-
tion of grass, etc.
The exhaust pipe must be designed to work with local exhaust ventilation, although not directly
connected, as this can affect combustion.
INSTALLATION GUIDE/INSTALLATION PLAN
PAGE 10
The vehicle must have safety measures to ensure that no exhaust ends up in rooms where there are
people.
The exhaust pipe should be max. 4000 mm in length and should be 65 mm in diameter.
If the heater is mounted in driver, passenger or storage room, this part of the fuel line must be
made from solid-drawn pipe steel. Connection to the fuel supply of the vehicle must be established
outside these rooms.
If the heater is mounted in driver or passenger rooms, the air inlet must be led to fresh air.
The exhaust pipe should be made from a material that resists heat and corrosion
(AISI 304 SS 2333 alloy steel resistant to max. 800°C with at least 0.75 mm wall thickness).
Connections to the exhaust system must be tight and secured with brackets.
If the heater is installed in a cargo area, the exhaust must be made from an unbroken steel pipe.
After installation, the model plate must be accessible and readable.
THE EXHAUST MUST BE ROUTED OUTSIDE OF THE VEHICLE IN HOSE OR PIPE.
There should be adequate room at the combustion end of the heater to remove the combustion unit
and combustion pipe. Minimum distances are shown in the illustration. We recommend mounting the
heater unit on vibration dampers. In this case, the heater connections should be made with flexible
hoses.
LIST OF CONNECTIONS
PAGE 11
Water/fuel connection
Pos 1: Exit for supply water:
3/4” thread
Pos 2: Inlet for fuel supply (to the fuel pump of the heater from the fuel tank):
Connection of fuel hose with 1/4 x 1/4 mm nipple.
Pos 3: Exit for return fuel (to fuel tank):
Fuel hose with 1/4 x 1/4 nipple.
Pos 4: Electric connecteion, 8- and 2-pin connectors.
Pos 5: Inlet for return water:
3/4” thread.
Pos 6: Exhaust:
External dimensions Ø65 mm.
ELECTRICAL CONNECTIONS
PAGE 12
The heater is available in two versions that can be used only for either 24V DC or 12V DC. The
external connections are gathered in 8-pin connectors A and B. The internal connectors of the heater
appears on a separate diagram, see page 32. Connect connectors as follows:
Connector A: Connected to the circulation pump.
Pin B1: Connected to the diagnostic lamp. The other end of the diagnostic lamp is connected
to + (positive) contact. The diagnostic lamp must be a LED.
Pin B2: Connect to - for a low temperature.
Pin B3: Connect through a 10A (at 24V) and 8A (at 12V) fuse to + (positive).
Pin B5: Connect to the room fan relay.
Pin B7: Connect to the main switch or timer. Connect the other end of the switch through an
8A fuse to + (positive).
Pin B8: Connect to frame (negative).
NOTE: The Heater can be set to adjust the temperature within two ranges (see
page 8-9: high/low temperature). Select the low range by connecting wire B2 to frame
point M. Select the NORMAL range by NOT connecting B2.
TECHNICAL SPECIFICATIONS
PAGE 13
Technical data:
STROCO Fuel-burning
heater type 15.00 M: Fuel-burning heater unit with integrated automatic controls and alarm
functions.
Dimensions L x W x H: 409 x 178 x 307 mm
Weight: 17.5 kg
Connections: The fuel-burning heater is connected to the electrical installation, fuel
tank and water/heating system of the vehicle.
Supply voltage: 24 or 12V DC
Fuel: Diesel EN 590
Fuel consumption: approx. 1.25 kg/h
Fuel filter: Filter area: 1937 cm2
Filter degree: 0.02 mm
Connection: 1/4”RG
Heating effect: Output approx. 13 kW
Power consumption: approx. 5A at 24V DC (incl. circulation pump)
9A at 12V DC (incl. circulation pump)
Combustion data: CO2: approx. 10%, Soot figure: 0-1 Bacharach
Circulation pump: approx. 22.5 l/min.
Fuel pump: Operating pressure: 8 bar (kg/cm2)
Nozzle: 1.46 kg/h (0.40 Usgal/h 80°S)
Photo unit: Type LDR
Over boiling protection: Type Therm-o-disce
Breaking temperature 110°C
Control thermostat: NTC 10 K sensor. Boiler temperature:
High: making/breaking approx. 73/80°C
Low: making/breaking approx. 55/60°C
Cab ventilation: Start approx. 50°C/Stop approx. 45°C.
MAX. AMBIENT
TEMPERATURE: 80°C
IMPORTANT! THE HEATER SYSTEM MUST BE FILLED WITH AN ANTI-CORROSIVE
ADDITIVE (E.G. 40-60% ANTI-FREEZE) (SEE ENGINE SPECIFICATIONS).
TECHNICAL SPECIFICATIONS
PAGE 14
Pre-ventilation period: At first start approx. 60 sec.
At restart approx. 10 sec.
Post-ventilation period: approx. 120 sec.
Under voltage: At 24V system:
Connection or disconnection approx. 20.5/22 VDC
At 12V system:
Connection or disconnection approx. 10.5/11.5 VDC
Over voltage: At 24V system:
Connection or disconnection approx. 30/29.5 VDC
At 12V system:
Connection or disconnection approx. 15/14.5 VDC
Safety time: Max. 15 sec.
Contact load: Max. 10 Amp (cabin fan pin B5)
Electrical connection: 15 pin AMP connector (A in electrical diagram)
Explanation of terminology
Low temperature boiler supply water
At low supply water temperatures, the control thermostat cuts out at approx. 60°C and cuts in at
approx. 55°C. This is referred to as the low range in this text.
Please note: Connect cable B2 if the low temperature range is desired.
High temperature boiler supply water
At high supply water temperatures, the control thermostat cuts out at approx. 80°C and cuts in at
approx. 73°C. This is referred to as the high range in this text. This is the temperature range most
commonly used.
Please note: Do not connect cable B2 if the high temperature range is desired.
Overheating protection (max. temperature)
Excessive heating of the boiler water is prevented by means of a circuit breaker in the overtemperature thermostat, which is activated at approx. 110°C. If the circuit is tripped, disconnecting the
electrical system, it must be reactivated manually by pressing the black button on the thermostat.
The system does not restart automatically, even if the water has cooled down again.
Safety period in case of flame failure
If no flame is established, the safety relay switches on the ignition to attempt a restart. If there is still
no flame within the relay’s safety period of 15 seconds, the relay cuts out and the systems starts to
post-ventilate. If the safety relay cuts out, the error lamp comes on.
Pre-ventilation
The heater starts up with a pre-ventilation period of 60 seconds. This period is reduced to 10 seconds
once the heater is in regular operation where start and stop is controlled by the thermostat.
MAINTENANCE
PAGE 15
To ensure reliable operation of the fuel-burning heater, perform the following maintenance
inspections at least once per year, at the end of the heating season, or well ahead of the start of
the season.
General servicing:
Replacement of the fuel filter.
Replacement of the nozzle.
Inspection of motor carbon brushes.
Inspection of pipes and hoses for any leaks. It is particularly important that the heater’s fuel suc-
tion hose has absolutely no leaks. All fuel hoses should be replaced every 2 years. Use only hoses
sourced from STROCO, or hoses approved by STROCO. The heater’s warranty will be void if it is
fitted with hoses not approved by STROCO, or if there is no documentation of replacement of fuel
hoses with 2 year intervals.
Inspection of the boiler and combustion pipe. Removal of any soot or incrustation from the boiler.
Replacement of the combustion pipe if damaged.
Inspection of the combustion unit.
Electrodes, nozzle, and turbolator should be clean and undamaged.
Replacement of the nozzle and subsequent check that the nozzle is centred in the turbolator.
Checking of electrode setting as per page 24.
Improper combustion can lead to boiler or combustion pipe being blackened by soot.
The nozzle service life is limited. Do not attempt to clean or repair the nozzle, but replace it with a
new one.
Inspection of the photoelectric sensor for cracks; cleaning if necessary.
Inspection of the coupling between fan motor and fuel pump; replacement of the coupling if the
contact surfaces are worn.
When the combustion unit is fitted back on the boiler, adjust the fuel pressure to the correct value
and then adjust the air setting to comply with relevant combustion data.
Inspection of all cables and electrical connections for possible damage or corrosion.
Outside the heating season, run the heater for at least 15 min. per week.
IMPORTANT!
When using biofuel, the fuel pump must be replaced every 2 years.
Fuel hoses must be replaced every 2 years regardless of fuel type. Fuel hoses must be replaced with
original STROCO fuel hoses, or approved hoses that meet the same minimum specifications.
It is important that hoses, seals etc. be inspected for leaks continually. Leaky fuel lines present a
serious safety hazard. The warranty on the STROCO fuel-burning heater will be void in case of
deficient or improper servicing.
PAGE 16
Inspection of pump suction
Is there fuel in the tank?
Check vacuum, max. -0.4 bar, connect to port ”V” and check with vacuum gauge
STROCO part no. 13.909.
Are the fuel filter, intake line, or any taps clogged or closed?
Is the fuel very cold and viscous?
Inspection of pump pressure
Check fuel pressure; connect gauge to port ”P”.
Adjust the pressure at port ”P1”; check with pressure gauge STROCO part no. 13.902.
Unsteady gauge readings are a sign of air in the intake line.
For fuel pressure, please consult the technical specifications.
Fuel filter
The filter is located on the fuel intake line between the fuel pump and the fuel tank.
Install the filter so that the arrows correspond to the flow direction.
On replacement, inspect the filter and joints for any leaks.
Circulation pump
The circulation pump transports water in the heating system.
The pump is running continuously while the main switch/start clock is connected and the oil burner
system is running.
The pump is connected to connector A.
Pressure regulation
Intake line G 1/4
Return line G 1/4
Nozzel attachment left G 1/8 (alternatively right)
Pressure gaugeattachment front G 1/8 (alternatively
left)
Vacuum gauge attachment G 1/8
Cartridge filter
DESCRIPTION OF FUNCTIONALITY - OPERATION
PAGE 17
The heater can be started using the main switch on the dashboard. Alternatively, a stating clock can
function as main switch.
The start-up process connects control current from the installation (12V or 24V battery).
The main power supply is connected directly to the heater’s control system, which controls the power
supply to the heater.
The pump relay is activated immediately on start-up to start the circulation pump. The pump runs
constantly when the main switch is activated.
The control thermostat sends a signal to start up the combustion unit when the boiler temperature
drops below the set value.
During the pre-ventilation period, the ignition electrodes (sparks) receive current, the fan motor runs,
and the nozzle pre-heater is engaged.
The fuel pump solenoid valve is switched on approx. 60 seconds after system start-up to release fuel
to be vaporised in the nozzle. The safety timer is engaged at the same time.
Once the flame is established, the nozzle pre-heater and ignition are disengaged. The starting
sequence is now complete, and the combustion unit remains operational until the control thermostat
cuts it off and the ventilation period begins.
When the control thermostat completes the circuit again, the starting sequence repeats with a
pre-ventilation period of 10 seconds.
The control system’s monitoring is focused primarily on the combustion process.
If the fuel does not ignite on start-up, the safety relay remains active. After approx. 10 seconds, the
safety relay disconnects, and post-ventilation begins.
If the flame goes out during operation, the safety relay switches on the ignition to attempt a restart. If
the fuel does not ignite, the safety relay disconnects, the fuel supply stops, and the alarm is activated.
If the fuel does ignite successfully, the combustion process continues until the control thermostat cuts
it off.
The electronic circuit is controlled automatically, so fuel supply stops in case of component failure in
photoelectric or engine circuits. In case of abnormal operating conditions, such as flame failure
during operation or false light during pre-ventilation, the automatic safety system stops the heater
and activates Alarm functions. It is therefore important to install the LED lamp that displays this
alarm from the system within the driver’s field of vision so that potential errors can be detected
quickly.
The control system has an integrated motor voltage regulator, which maintains a constant approx.
21V/11.8V on the fan motor.
The heater’s pre- and post-ventilation and low voltage logic is also controlled by the automatic system.
DESCRIPTION OF FUNCTIONALITY
PAGE 18
1 Nozzle 18 Operation thermostat
2 Nozzle retainer 19 Exit water 3/4“RG
3 Nozzle retainer plate 20 Outer boiler
4 Photo 21 Inner boiler
5 Igniters 22 Copper pins
6 Flange 23 Burner pipes
7 Air shutter 24 Entry water 3/4“RG
8 Fan Wheel 25 Chimney
9 Fan motor 26 Burner
10 Automatic controls 27 Foot
11 Coupling 28 Foot
12 Fuel pump 29 Oli pipes
13 Fuel hose 30 Gasket
14 Fuel hose 31 End cover
15 Ignition coil 32 Plastic cover ABS
16 Ignition oscillator 33 Spiral
17 Over boiling protection
TROUBLESHOOTING - HOW?
PAGE 19
If you initiate troubleshooting because the heater is not working correctly, be sure to note the state
and condition of the unit before and after the fault, if possible, in order identify the problem prior to
repairs.
Is the main switch or starting clock inactive?
Is the operation/diagnostics lamp on?
Does the operation/diagnostics lamp show an error in case of alarm functions?
Have any irregularities with the heater been observed prior to the fault? Any unusual smells,
sounds, of visible changes?
Is there fuel in the tank?
Is there water in the system?
Is the power supply to the heater okay? 24V plug B pin 3, 4, and 7 (see page 32).
Is the air intake unobstructed?
Are the fuses in the electrical circuit intact?
Has the overtemperature control been tripped?
Has the desired temperature range been selected correctly using cable A13? (see page 32)
Before further troubleshooting, note the automatic control of the heater in various sequences.
Certain functionality, e.g. pre-ventilation and ignition, only runs in limited periods.
If the heater stops automatically due to errors, the post-ventilation will run for approx. 120 seconds,
and the diagnostics lamp will come on (see page 23).
Servicing and repairs may only be performed by qualified personnel. Unauthorised tampering
presents a serious safety hazard. The warranty may be void if repairs are attempted by unauthorised
persons.
DISMOUNTING BURNER AND COMBUSTION CHAMBER
PAGE 20
Access to the burner and combustion chamber is obtained by dismounting the end cover
(pos. 31) at the three 6 mm nuts (pos. 29) and the three 6 mm stay bolts (pos. 32).
Dismount the oil pipe (pos. 48) and the connectors (pos. 38).
Remove the burner (pos. 34), and the combustion chamber (pos. 47) is free.
PROCESS CONTROL DIAGRAM
PAGE 21
PERIOD Pre-vent. Safety time Operating Post-ventilation
TIME INTERVAL 60 (10) seconds 15 seconds heating time 120 seconds
CONTROL PANEL
Main Switch/clock
Operating lamp
Defect light
AUTOMATIC BOX
Low voltage relay
Thermostat
Photocell
Safety thermostat
Timer
FUNCTION
Circ.pump/relay
Fan/oil pump motor
Ignition
Pre-heating
Magnetic valve/oil pump
PROCESS
Ventilation
Combustion
Note: When starting first time the pre-ventilation time is 60 seconds.
When starting during the operating period the pre-ventilation time is 10
seconds
: Signal for either connection or disconnection
: Connection
: Disconnection
Please note: THE HEATER MUST NOT BE USED IN GARAGES, SERVICE STATIONS, OR OTHER
LOCATIONS WHEREVER THE USE OF OPEN FIRE IS PROHIBITED!
ALARM FUNCTIONALITY
PAGE 22
IMPORTANT !
Heater with LED indicator:
Black areas mean red light. White areas mean no light. Dotted areas mean blinking light.
Page 23 Page 24 Page 25 Page 26 Page 26 Page 27 Page 28 Page 29
Page 29
(reset at operaon and light)
Remedy
Display
indicator
With LED indicator
(seconds)
Type of defect
0 Normal operaon 1 Safety me exceeded 2 Ignion electrode defecve 3 Photodetector defecve 4 Undervoltage 5 Overvoltage 6 Fan defecve 7 Solenoid valve defecve 8 Sensor defecve 9 Too many start aempts 10(A) Overtemperature alarm
COMBUSTION UNIT
PAGE 23
The combustion unit is the heart of the combustion process. It mixes air with fuel vapour, which is
ignited by a spark from the coil.
The flame is registered by the photoelectric sensor.
Correct setting of the combustion unit is important to ensure efficient combustion:
Please observe the following: Electrode settings, as per page 24.
Proper centring of the nozzle in the turbolator.
In case of flame failure
Possible reasons:
- The fuel tank is empty.
- The intake line is leaky.
- Air collecting in the intake line.
- The fuel pump is not drawing fuel.
- The fuel pump is not rotating, due to defective coupling.
- The fuel pump pressure is low.
- The pump solenoid valve is not supplying fuel to the nozzle.
- Dirt from the fuel tank is blocking the nozzle.
- The fuel is very cold and viscous.
- The intake and return fuel lines have been switched around.
- No spark due to defective coil/oscillator or ignition cable.
- No spark due to short-circuited electrodes or carbon deposits on the ceramic insulator.
Manual re-activation
If the control system has been deactivated by the safety relay, it can be re-activated by switching off
the mainswitch on the dashboard for approx. 5 seconds and then switching it on again. The heater
should then start up normally.
VOLTAGE CONTROL OF ELECTRODES
PAGE 24
Carried out when checking the ignition coil and ignition oscillator.
During ignition control, the solenoid coil connector must be disconnected.
Access to the burner unit is obtained by removing the end flange of the burner, unscrewing the three
6 mm nuts, and removing the burner.
Remove and cover the photocell to prevent it from being exposed to light.
Start the burner. Voltage discharges at the electrodes can now be observed. The automatic controls
provide power to the ignition oscillator and ignition coil of the ignition system via connector A, pin 2
(see page 32).
The ignition coil and oscillator are mutually connected and do not work separately.
The ignition oscillator picks the minus of the operating current apart, and these pulses are then
transformed by the ignition coil to high voltage, discharged as a spark between the igniters.
If no charge occurs, the causes may be:
1. Defective ignition cable.
2. Electrode settings.
3. Dirt on the electrodes.
4. Defective ceramic coating on the electrode unit.
5. Ignition coil, oscillator, automatic controls.
PHOTOELECTRIC SENSOR
PAGE 25
The photoelectric sensor must not be exposed to light during the pre-ventilation; this will cause an
error indication.
When the pre-ventilation period ends and the fuel supply begins, the sensor should pick up light.
Otherwise the safety relay will shut down the process.
The photoelectric sensor connects to the control system via plug D (see page 32).
Adjustment and remedial action
If the light-sensitive LDR in the photoelectric sensor is shortcircuited or defective, the control system
will not allow the heater to start.
If the sensor does not detect enough light while the flame burns, the system will also shut down. This
may be caused by dirt on the sensor or incorrect placement in the combustion unit. Troubleshoot the
photoelectric sensor using STROCO testing device part no. 35.960. The sensor voltage should be 4.9V
when the combustion unit is off. When the heater is operational, the voltage should be 0V.
For 12V system, check the voltage at the photoelectric sensor, plug D. See electrical diagram.
The photoelectric sensor can be disconnected in plug D (see page 32).
UNDER/OVERVOLTAGE
PAGE 26
Undervoltage
If the voltage is below 22/11.5V (in step 0) and below 20.5/10.5V during pre-ventilation, operating
and post-ventilation, the undervoltage alarm will be activated. The alarm can be reset only with the
off switch and a voltage exceeding 22/11.5V.
Overvoltage
If the voltage exceeds 29.5/15V, the alarm will be activated, and the alarm will be reset below
29/14.5V.
Setting the air volume
The air volume for the combustion is regulated by turning pos. 21 (see page 27) + and - . The air setting influences the complete combustion of the fuel, i.e. too little air (soots up, black smoke) or excessive air (blue smoke).
The correct setting is measured form the smoke:
The CO2 (carbon dioxide) content of the smoke must be 10-11%, and the soot figure close to 0-1
Bacharach.
Fuel pre-heater
The preheater is mounted on the nozzle retainer, which it heats.
The preheater operates when the heater is started, but is disconnected during operating.
The preheater is to ensure that a flame is established during cold starts.
The automatic system controls the pre-heater, which is powered through connector F, approx. 3 Amp
(see page 32).
Fuel pump
The fuel pump is mounted on the motor engine bracket with two 6 mm tailstock screws.
The pump is mounted in a two-wire system where ventilation occurs automatically through the return line.
The solenoid valve of the pump is activated by the automatic controls through connector L (see page
32).
The operating pressure of the pump must be 8 bars (kg/cm2). The pressure can be set on screw P (see
page 16).
The pump is running when the fan motor is running, but fuel is not released for atomisation in the
nozzle until the solenoid valve is activated.
It is important that the suction line of the pump is completely tight, and that a fuel filter (Stroco type
2000) has been mounted in the suction line.
REPLACING THE FAN MOTOR
PAGE 27
The fan motor is replaced according to the chart below referring to the position numbers on the
illustration.
Setting the air volume
Adjust the air volume for combustion by loosening and turning air valve no. 21 to + or -.
The air setting affects the fuel combustion. Black smoke = not enough air, blue/grey smoke = too
much air.
Check the correct air setting using STROCO soot gauge part no. 13.982 or STROCO flue gas tester
part no. 13.983
For combustion data, please see technical specifications.
Sequence Action
1 Turn off the power and check that the heater is dead before any replacement work
is commenced
2 Loosen knurled screws pos. 1 and remove casing pos. 2
3 Loosen nut pos. 15
4 Remove nuts and washers pos. 15 and 16
5 Remove end casing pos. 17
6 Remove ignition coil pos. 13 by removing nuts pos. 14
7 Removes pressure pipe pos. 12
8 Removes hoses pos. 3 and 4 and wire for solenoid valve pos. 10 on fuel pump pos. 9
9 Loosen screws pos. 11 and remove the fuel pump
10 Remove fan wheel pos. 5
11 Loosen tensioning band pos. 6 and remove fan motor pos. 7
12 Mounted in the opposite sequence
CHECKING THE FUEL PUMP SOLENOID VALVE
PAGE 28
The simplest way to check the field coil is using a STROCO test device part no. 35.960. The field coil
should draw 0.2A-0.4A power. An audible click from the solenoid valve indicates that the field coil is
activated. Field coil and solenoid valve can be checked manually (12V system):
Take a reading of the coil voltage before checking the solenoid valve. The voltage should be approx.
24V (12V) in plug L pin 2 (se page 36).
Please note: The plug has no electrical power until after the pre-ventilation period, and the power is cut
off again after approx. 10 seconds, if the photoresistor does not register combustion. (see the diagram for
normal operation, page 21).
If the voltage is correct in plug L, pin 2 (see page 32), proceed to check the field coil’s magnetic force.
The core of the coil become magnetised when an electrical current is applied. (E.g. use a screwdriver).
If the photoelectric sensor registers light during pre-ventilation, this is interpreted as a malfunction in
the solenoid valve. The error message can only be reset with the switch in the ”off” position.
OPERATING THERMOSTAT SENSOR
PAGE 29
Control thermostat sensor
The control thermostat sensor connects to the control system via plug C (see page 32).
The sensor reads the temperature in the boiler from its position screwed into a socket on the side of
the boiler.
The thermostat may be set to two different operational ranges:
1: Cut in/cut-off: approx. 50/70°C
Please note: This temperature range can be selected by connecting cable B2 to chassis earth.
2: Cut in/cut-off: approx. 73/80°C (The normal range).
Please note: This temperature range can be selected by not connecting cable B2 to chassis earth.
The simplest way to check the temperature sensor is using STROCO testing device part no. 35.960.
Activate the heater and raise the operating temperature to 22-85°C. The sensor is functional if the
test device displays a temperature reading. If the test device display is blinking, the temperature
sensor is defective. If in doubt, you can check the sensor manually:
A defective temperature sensor is evident by the heating process continuing beyond the pre-set range,
and finally being shut down by the overtemperature control.
Voltage readings on a working temperature sensor should show the following:
A decrease in voltage as the temperature rises. Once the sensor voltage falls to 1.2V, the thermostat
should disconnect (for the normal temperature range). An increase in voltage as the temperature
falls. At 3.6V, the thermostat should connect (for the normal temperature range).
If the voltage reading is constant and does not follow changes in temperature, the sensor is defective
and the thermostat will not function.
Replace the sensor by detaching plug C (see page 32) and unscrewing the sensor from its socket.
Overheating control (max. temp.)
This device ensures that the water in the boiler is not heated beyond 110°C. The overtemperature
control is screwed into a socket on the side of the boiler next to the temperature sensor. If the control
cuts out in case of overtemperature, the error lamp will come on.
The device cannot be re-activated by attempting to re-start via the main switch; this must be done
manually by depressing the overtemperature device’s black button. Re-activation will not take place
until the boiler temperature has dropped.
It is a good idea to investigate the reason for the cut-out before and after re-activation.
1 Is there water in the system?
2 Is there sufficient circulation?
3 Has the system been bled properly for air?
4 Is the thermostat functioning properly?
ASSEMBLY DRAWING - PARTS LIST
SIDE 30
Pos. Description Part number
1 Nut for plastic cover 35.035
2 Plastic cover 15.034
3 Fuel hose 500 mm with 90° angle, biodiesel 35.178
4 Fuel hose 500 mm with 90° angle, biodiesel 35.178
5 Fan wheel 15.270
6 Fan motor 24/12V 15.340/15.342
7 Clip 15.017
8 Coupling, complete 35.360
9 Pointed screw 15.002
10 Circulation pump 24/12V 11.700/11.702
12+13 Fuel pump, complete 31.370-2
13 Solenoid valve 24/12V 31.376/31.373
14 Screw 4x16 15.003
15 Earth connector 31.380
16 Automatic system 24/12V 35.520-1/35.522-1
17 Screw 4x25 15.005
18 Temperature sensor 15.010
19 Rubber lead-in 15.006
20 Ignition oscillator 15.510
21 Cable harness 15.570
22 Nut 4 mm 15.007
23 Oil pressure pipe, complete 15.250
24 Overboiling device 35.030
25 Ignition coil 12V (24V-fyr) 30.490
26 Holder ignition coil 15.008
27 Nut 6 mm 15.009
28 Washer 6 mm 15.011
29 Top nut 15.012
30 Washer 6 mm 15.013
31 End cover 15.014
32 Stay bolt 15.015
33 Bolt 6 x 10 mm 15.018
34 Screw 35 x 4 mm 15.120
35 Nozzle retainer 30.130
36 Photocell LDR 31.160
37 Preheater element 24/12V 15.142/15.143
38 Electrodes 15.100
39 Flexible washer 30.110
40 Nut 4 mm 15.007
41 Washer 4 mm 30.111
42 Nozzle 15.071
43 Electrode fitting 15.090
44 Nipple 30.210
45 Electrode rubber 30.112
46 Nozzle retainer, complete 15.121
47 Combustion unit 15.041
48 Gasket 15.028
49 Combustion pipe 15.040
50 Boiler 15.540
ASSEMBLY DRAWING - PARTS LIST
PAGE 31
ELECTRICAL DIAGRAM
PAGE 32
ELECTRICAL DIAGRAM
PAGE 33
Key to abbreviations
Colour codes
A
Connectors for automatic system
bl
blue
Automatic system: Elektron. Control unit
br
brown
B
Main connector
ge
yellow
BM
Fan motor
gn
green
C
Connector for operating thermostat
gr
grey
D
Connector for photocell
or
orange
E
Igniters
rt
red
F
Connector for nozzle preheater
sw
black
H
Connector for overboiling device
ws
white
L
Connector for solenoid valve
vl
violet
LDR
photocell
ST
Overboiling device
N
Connector for fan motor
FØ
Sensor for operating thermostat
RVP
Relay for circulation pump
T
Ignition coil
TO
Ignition oscillator
V
Connector for circulation pump
VP
Circulation pump
DV
Nozzle preheater
MS
Solenoid valve
I
Fuse 8A
J
Accumulator
K
Main switch
INSTALLATION IN BOATS
PAGE 34
Fuel lines, fuel filter, melt-fuse valves, etc.
Fuel lines must be made of either steel or copper, be permanently laid up and protected from mechanical loads. Soft soldering is not allowed for any pipe joints.
A fuse-melt valve must be inserted in the fuel line as close to the combustion chamber of the device as
possible to disconnect the fuel flow if the outside temperature exceeds 80°C. If the return line is connected to the tank in a manner that allows the tank to be drained through it, it must also be equipped
with a fuse-melt valve. A short, approved (type approved by the directorate) hose may be used in the
pipe between the fuse-melt valve and heater. If the filter is located in the same room as the heater, it
must be located between the fuse-melt valve and heater. The suction line must be connected to the top
af the tank if the volume exceeds 10 l.
Expansion vessels in general
Every central heating system must be equipped with one or more expansion vessels, the total value of
which is sufficient to take up the thermal expansion of the water during normal operating conditions.
Open expansion vessels
Open expansion vessels must be made from sheet steel. Vessels must be fixed and equipped with terminating pipes with an aperture of least 25 mm.
Expansion vessels with diaphragms
These are system intended for a maximum heat output of no more than 50 Mcal/h and a resulting
boiler pressure below 5.5 bar and with expansion vessels with a static pressure height below 15m VS.
Electrical system
It must be possible to disconnect the heater outside the room in which it is located. This does not,
however, apply to hot water circulation pumps.
All cables must be permanently fixed.
The electrical system must be implemented as a two-conductor system, i.e. where + on the heater
must be returned to the battery -.
For other specifications, see the section on electrical connections and the section Technical specifications.
Air inlet
If the heater is to be used at same time as the boat engine, the heater must be equipped with a sepa-
rate air inlet. The requirement applies only, however, if the engine performance exceeds 450 HK. A
ventilation hose may be used with a diameter of at least Ø70 mm and a length of maximum 4m.
INSTALLATION IN BOATS
PAGE 35
The sections below concern conditions to be given special consideration in connection with installation in boats.
General information
In boats, the heater must be located as low as possible, and the exhaust must be outside. In all types
of installation, the supplied circulation pump must be installed in the return line (cold). In the example below, the radiators have been located in a two-wire system, but one-wire systems can, of course,
also be used just as both free expansion and pressure expansion may be used.
Fig. 1 shows a basic plan for a two-wire system.
INSTALLATION IN BOATS
PAGE 36
Rooms in which fuel-burner heater are installed must be equipped with ventilation in addition to the
air required for combustion. All ventilation pipes from the heater must be led separately to a free
deck, and the outlet must be kept free of superstructures, ect. The upper part of pipe must be able to
take up heat expansion. The inner cross section of the pipe must always exceed the connection branch
of the unit, Ø65 mm, and the pipe must be equipped with cleanout doors to enable complete cleaning.
The maximum length of the exhaust pipe is 4 meter. Ventilation pipes must be made from stainless
steel pipes or stainless steel hoses approved for a minimum temperature of 600°C. All joints must be
ensured by pipe clamps, clips or the like..
Fig. 2 shows a basic plan for the installation of ventilation pipes.
If there is combustible material within a distance of 7.5 cm from the unit or ventilation pipe, it must
be shielded with incombustible material.
In boiler rooms, the unit must be placed in an fuel-proof tray with an edge of at least 50mm. The tray
must have a discharge pipe with at least the same inner diameter as the delivery pipe, never below
15mm. The pipe must be led to a drain tank (vessel).
Systems with water circulation must have frost protection in periods where temperatures below 0°C
can be expected.
PAGE 37
Warranty conditions for STROCO fuel-burning heaters
A full service history with the heater’s number must be available to STROCO in order to settle
warranty claims. The warranty may be void if the warranty card has not been properly filled in and
returned to STROCO.
STROCO fuel-burning heaters and parts are covered by a 12 month warranty from time of
installation (maximum 2 years from date of delivery).
The warranty covers manufacturing and/or material defects.
The warranty may be void if the unit is altered, or if the unit is not installed in accordance with our
instructions.
During the warranty period, STROCO is obligated to repair units or parts that we determine to be
defective. Repairs may also be performed at our service shops.
Nozzles and wear parts are not covered by the warranty.
Labour costs in connection with disassembly and installation of defective parts
are not covered
If you observe defects in the system during the warranty period, the defective parts should be sent
postage paid to STROCO with information about the defect and delivery date/heater no.
STROCO’s assessment of the defect, and whether it is covered by the warranty, will always be final
and binding for the customer.
STROCO will only accept warranty claims that have been approved beforehand. STROCO can only
accept warranty claims if the owner/user can present written documentation to show that all service
and safety instructions have been followed. All warranties will be void if the installation guide and
other instructions in this manual have not been followed. The same applies if installation and
maintenance has not been performed in a proper professional manner, or if unoriginal parts have
been used for servicing or repairs.
Consequential losses
STROCO assumes no liability for personal injury, damage to property, or operating losses resulting
from failure of the unit, no matter the cause (including manufacturing defects).
DEALERS
PAGE 38
DANMARK, Denmar k:
STROCO ApS Tlf. +45 86 96 10 66
Viborgvej 50, Voldby Fax +45 86 96 96 47
DK-8450 Hammel
ENGLAND:
GRAYSON THERMAL SYSTEMS Tlf. 0121 708 4000
257 Wharfdale Road Fax 0121 706 1886
Tyseley
GB-Birmingham B11 2DP
FINLAND:
EL-CAR OY Tlf. 09 389 4995 MUI CON OY Tlf. 844 2134 131
Jukka Eerola Fax 09 389 4807 Marko Muikko
Mittatie 26A Hakekatu 4
SF-01260 Vantaa SF-70800 Kuopio
FÆRØERNE, the Faroe Islands:
Care on Sea Spf Tlf. 74 88 55
Úti vio Neyst 11
FO-430 Hvalvik
NORGE, Norway:
VEST SERVICE AS Tlf. 90 85 60 00
Visnesvegen 9A
N-6783 Stryn
POLEN, Poland:
MULTITECH sp. z o.o. Tlf. 12 638 06 63
Dabrowa Szlachecka 238 Fax 12 638 06 63
PL-32-070 Czernichóv
PORTUGAL:
PROJECTIVA Tlf. 249 819 240
Zona Industrial Fax 249 819 249
Apartado 175
P-2354-909 Torres Novas
SVERIGE, Sweden:
TK BUSSKLIMAT AB Tlf. 31 44 52 00
Järnringen 2 Fax 31 44 52 65
S-433 30 Partille
ØSTRIG, Austria:
FA. ING. HUBERT KNITTEL Tlf. 1 804 15 23 00
Lastbergstrasse 41 Fax 1 804 15 23 48
A-3031 Pressbaum
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