SERVICE INSTRUCTIONS
for fuel-burning heater type
STROCO 35.02 M
Applicable from heater no.
Diesel: 44752
Ethanol: 34762
RME: 31032
STROCO ApS, Viborgvej 50, DK-8450 Hammel, ph. +45 86961066, fax +45 86969647
Technical approval no. SP 555 AD 05
EU directive 42/245:
EU technical approval no. E5 10R-03153
Heating directive E 2001/56:
EU technical approval no. R122 E5 00002
ISO certified
Developed with aid from the Danish Environmental Protection Agency
GB 09/17
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 ...………………………………………………… 12-13
Technical specifications .………………………………………………... 14-15
Explanation of terminology .………………………………………………. 15
Maintenance …………………………………………………………….. 16-18
Description of functionality - operation ………………………………….. 19
Description of functionality ……………………………………………….. 20
Troubleshooting - how? …………………………………………………… 21
Disconnection of combustion chamber …………………………………... 22
Process control diagram …………………………………………………... 23
Alarm functionality ………………………………………………………... 24
Combustion unit …………………………………………………………… 25
Voltage check on electrodes ………………………………………………. 26
Photoelectric sensor ……………………………………………………….. 27
Under-/overvoltage ………………………………………………………… 28
Replacement of fan motor ………………………………………………… 29
Fuel preheater ……………………………………………………………... 30
Fuel pump ………………………………………………………………….. 30
Inspection of fuel pump solenoid valve …………………………………... 30
Control thermostat sensor ………………………………………………… 31
Assembly drawing - part list …………………………………………… 32-35
Electrical diagram ….…………………………………………………… 36-37
STROCO 35.02 M EL .…………………………………………………. 38-42
Warranty conditions ………………………………………………………. 43
Dealers ……………………………………………………………………… 44
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.
Heat
Fuel
Water
Electrical power
Air
+ =
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:Fuel, 2:Filter, 3:Air, 4:Exhaust, 6:Engine, 7:Heating system, 8: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
This guide applies to STROCO fuel-burning heater type 35.02 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.
Fuel hoses located on the outside of the vehicle must be shielded against damage. Electrical cables
must not be run next to fuel hoses.
Uninsulated exhaust pipes/hoses must be located at least 7.5 cm from flammable materials.
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 exhaust system does not damage the heater. Conversely, the vehicle’s components must be protected
against damage from the heater’s exhaust.
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 100 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.
The opening of the exhaust pipe must be placed so that:
1) Combustion is not notably affected by airflow around the vehicle.
2) There is no heat damage to adjacent vehicle components.
3) There is no risk of igniting dry grass etc.
The exhaust pipe must be designed to work with local exhaust ventilation, although not directly
connected, as this can affect combustion.
The vehicle must have safety measures to ensure that no exhaust ends up in rooms where there are
people.
INSTALLATION GUIDE/INSTALLATION PLAN
PAGE 10
The exhaust pipe should be max. 4000 mm in length and should be 90 mm in diameter.
If the heater is installed in a cargo area, that section of the fuel line must be made of steel.
Connections to the vehicle’s fuel supply must be made outside this area.
The heater may not be installed in a driver’s or passengers’ compartment.
The exhaust pipe should be made from a material that resists heat and corrosion
(AISI304 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
hose.
455 mm (with EL-heater)
LIST OF CONNECTIONS
PAGE 11
Water/fuel connection
Pos 1: Intake fuel flow (to heater fuel pump from vehicle fuel tank):
Connection of fuel hose with 1/4 x 1/4 fitting (standard design).
Pos 2: Outlet fuel return (to fuel tank):
Fuel hose with 1/4 x 1/4 fitting (standard design).
Pos 3: Intake return water: Branch for connection of 38 mm frost resisting hose.
Pos 4: Outlet supply water: Branch for connection of 38 mm frost resisting hose.
Pos 5: Exhaust: Outer diameter Ø90 mm.
Pos 6: Connection of electrical immersion heater (optional):
ELECTRICAL CONNECTIONS
PAGE 12
The fuel-burning heater is available in two versions: 12V or 24V. External connections are collected
in a 7 pin plug labelled B and 4 pin plug labelled R. The heater’s internal connections are illustrated
in the diagram on page 36. Always use correct cable dimensions according to applicable standard...
The dimensions mentioned are minimum requirements.
Pin B1: Free.
Pin B2: Connect to main switch or timer. The other side of the switch should be connected
via 10A fuse to + (positive).
Pin B3: Connect via 10A fuse if separate operation of the circulation pump is desired.
Pin B4: Signal for field coil open (+) max. load 1A.
Pin B5: Connect to diagnostics lamp. The other side of the diagnostics lamp should be
(positive) connected to + switch. Diagnostics lamp should be an LED. For safety reasons,
make sure that the diagnostics lamp is placed within the driver’s field of vision so
that potential errors can be detected quickly and the heater can be checked.
Pin B6: Connect to - (negative) if low temperature is desired.
Pin B7: Connect to relay for room fan.
Pin R1: Connected via 15A fuse to + (positive). If the fuel used is RME, the fuse must be 20A.
Pin R2: Connected via 10A fuse to + (positive). Please note: Join together the + cables from the
two fuses and route to the vehicle’s battery in a 4 mm² cable.
Pin R3 Free.
Pin R4: Connect to chassis earth (negative). Use at least the same cable thickness as B3 and B4.
PLEASE NOTE: The heater can be set to adjust the temperature within two ranges
(see p. 14-15: High/low temperature). Select the low range by connecting cable B6 to
chassis point M. Select the NORMAL range by NOT connecting B6.
PAGE 13
Plug B Plug R
Front
Back
TECHNICAL SPECIFICATIONS
PAGE 14
Technical data:
STROCO fuel-burning heater
type 35.02 M: Fuel-burning heater with integrated control system and safety
and alarm functionality.
Dimensions L x W x H: 570 x 245 x 234 mm
Weight: 30 kg total. (plus any optional parts).
Connections: The fuel-burning heater connects to the vehicle’s electrical
installation, fuel tank and water/heating system.
Supply voltage: 24 or 12V DC
Fuel: Diesel EN 590 - Ethanol ED 95 - RME EN 14214
Fuel filter: Filter area: 1937 cm²
Degree of filtration: 0.02 mm
Connection: 1/4”RG
Heating output: Emitted: Diesel 30kW - RME 30kW - Ethanol 25kW
Power consumption: 11A at 24V DC diesel. 14A at RME
22A at 12V DC diesel
3A Pre-heater element diesel. 6A at RME
2.5A at 24V DC filter pre-heater - optional
Combustion data: CO2: Diesel 30kW 10% - RME 30kW 10% - Ethanol 25kW 8.5%.
Sooting level: 0-1 Bacharach
Stated values +/-1%
Circulation pump: 6000 l/h at 0.4 bar Power consumption: 6.6A at 24V DC
Fuel pump: Working pressure: RME/Ethanol 10 bar - Diesel 30kW 8 bar
Nozzle: Please see spare part list.
Photo unit: Type LDR
Overtemperature control: Type Therm-o-dise
Disconnect temperature 110°C
Control thermostat: NTC 10 K sensor. Boiler temperature:
High: stop/disconnect approx. 73/80°C
Low: stop/disconnect approx. 55/60°C
Cabin fan: 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).
PAGE 15
Pre-ventilation: For cold start approx. 60 sec.
For restarting approx. 10 sec.
Post-ventilation: Approx. 120 sec.
Undervoltage: In 24V units:
Disconnect/connect approx. 20.5/22V DC
In 12V units:
Disconnect/connect approx. 10.5/11.5V DC
Overvoltage: In 24V units:
Disconnect/connect approx. 30/29.5V DC
In 12V units:
Disconnect/connect approx. 15/14.5V DC
safety period: Max. 15 sec.
Switch load: Max. 10A (cabin fan pin B7)
Electrical connection: 15 pin AMP plug (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 B6 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 B6 if the high temperature range is desired.
Overtemperature 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 16
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
suction 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. Replacement of the nozzle and subsequent check that the nozzle
is centred in the turbolator. Electrodes, nozzle, and turbolator should be clean and undamaged.
Checking of electrode setting as per page 26. Improper combustion can lead to boiler or
combustion pipe being blackened by soot. Inspection of the photoelectric sensor for cracks;
cleaning if necessary. Inspection of the coupling between fan wheel 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 ethanol or RME, 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 17
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.
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
PAGE 18
Circulation pump
The circulation pump transports water around the heating system.
The pump runs constantly when the main switch/starting clock is activated and the heating unit is
operational.
The pump is activated via the circulation pump relay. The relay receives a control current from the
control system through plug A, pin 7.
When the relay is active, the pump receives its working power via the relay from main plug R, pin 2
(see page 36).
During operation, plug V, pin 1 should read out 24V (12V).
DESCRIPTION OF FUNCTIONALITY - OPERATION
PAGE 19
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 21.5V 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 20
1 Fan wheel 15 Temperature sensor
2 Fan housing 16 Overtemperature control
3 Motor 17 Fuel filter
4 Control system 18 Circulation pump
5 Fuel pump 19 Outer boiler
6 Nozzle socket 20 22 mm copper pins
7 Nozzle 21 Inner boiler
8 Ignition electrode block 22 Plastic cover
9 Photoelectric sensor 23 Exhaust
10 Fuel pipe 24 Fuel hose
11 Lock bolt for ignition electrode block 25 Connection for immersion heater
12 Air plate 26 Air intake
13 Combustion unit 27 Flue gas conduit
14 Combustion pipe
TROUBLESHOOTING - HOW?
PAGE 21
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 (R pin 1, 2, and 4) (see page 36).
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 B6? (see page 36)
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.
DISCONNECTION OF COMBUSTION CHAMBER
PAGE 22
Detach overtemperature control plug, control thermostat, circulation pump, and main plug(s).
Detach fuel lines.
Gain access to the combustion chamber by removing tow M8 nuts (pos. 1) The combustion head an
now be detached to reveal the combustion pipe (pos. 2).
PROCESS CONTROL DIAGRAM
PAGE 23
PERIOD Pre-vent. Safety time Operation Post-vent.
TIME 60 (10) seconds 15 seconds heating 120 seconds
CONTROL PANEL
Main switch (clock)
Operation lamp
Error lamp
CONTROL BOX
Low voltage relay
Thermostat
Photoelec. sensor
Overtemp. control
Timer
FUNCTIONALITY
Circulation pump/relay
Fan/fuel pump motor
Ignition
Preheating
Solenoid valve/fuel pump
PROCESS
Ventilation
Combustion
Please note: When cold starting the heater, the pre-ventilation time is
60 seconds. When starting during normal operation, the pre-ventilation
time is 10 seconds.
Pre-heating is not used in ethanol heaters.
: Signal for activation or deactivation
: Activation
: Deactivation
Please note: THE HEATER MUST NOT BE USED IN GARAGES, SERVICE STATIONS, OR OTHER
LOCATIONS WHERE THE USE OF OPEN FIRE IS PROHIBITED!
ALARM FUNCTIONALITY
PAGE 24
IMPORTANT !
Heater with LED indicator:
Black areas mean red light. White areas mean no light. Dotted areas mean blinking light.
Page 25 Page 26 Page 27 Page 28 Page 28 Page 29 Page 30 Page 31
Page 31
(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 25
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 26.
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 main switch on the dashboard for approx. 5 seconds and then switching it on again. The heater
should then start up normally.
VOLTAGE CHECK ON ELECTRODES
PAGE 26
Perform when inspection ignition and oscillator. Detach overtemperature control plug, control
thermostat sensor, and solenoid valve. When inspecting the ignition, short-circuit the overtemperature control plug to keep the ignition functioning.
For access to the combustion unit, please see the section ”Disconnection of combustion chamber”,
page 22.
The discharge by the electrodes can now be inspected as described.
The ignition system receives power for the ignition oscillator and coil from the control system via
plug A pin 2 (see page 36).
The ignition oscillator and coil are interconnected and will not function separately.
The ignition oscillator changes the negative operating current into impulses, which are transformed
by the ignition coil into high voltage and discharged in the form of a spark between the ignition
electrodes.
Discharge failure may be caused by:
1. A defective ignition cable.
2. Electrode settings.
3. Dirt on the electrodes.
4. Defective ceramic coating on the electrode unit.
5. Ignition coil, oscillator, control system.
Adjust the electrodes using the illustration below.
PHOTOELECTRIC SENSOR
PAGE 27
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 36).
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 36).
UNDER/OVERVOLTAGE
PAGE 28
Undervoltage
The undervoltage alert is activated if the system voltage drops below 22/11.5V (in step 0) and below
20.5/10.5V during pre-ventilation, operation, and post-ventilation. The alarm can only be reset with
the switch off and the voltage above 22/11.5V.
Overvoltage
The alarm is activated if the voltage is above 30/15V and reset below 29.5/14.5V.
REPLACEMENT OF FAN MOTOR
PAGE 29
Replace the motor by detaching the fan housing from flange no. 1 and then disassembling the
housing. Detach the fan wheel and remove the two M4 screws holding the motor in place. When
replacing the fan motor, make sure that the bearing can rotate freely, even when the new fan motor
is mounted completely.
To maximise airflow, install the fan wheel with the shortest distance possible to the fan housing air
intake - approx. 2 mm. This will ensure optimum contact area for the fuel pump coupling.
Setting the air volume
Adjust the air volume for combustion by loosening screw no. 2 and 3 and turning air valve no. 4 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 page 14.
SERVICING
PAGE 30
Fuel pre-heater
The pre-heater is located in the nozzle holder, which it heats. It is activated upon start-up of the
heater unit, but remains inactive during regular operation.
The pre-heater ensures flame establishment when cold starting.
The automatic system controls the pre-heater, which is powered via plug F, approx. 3A for diesel and
6A for RME. (see page 36) The pre-heater functionality is not present in ethanol heater models.
Fuel pump
- The fuel pump is attached to the fan housing with two 6 mm set screws.
- The pump is installed in a two-pipe system with automatic ventilation through the return pipe.
- The pump solenoid valve is activated by the control system via plug L (see page 36).
- The pump’s working pressure value can be found on page 14. Adjust the pressure using screw
P1 (see page 17).
- The pump is operational while the fan motor is running, but fuel is not supplied to the nozzle
for vaporisation until the solenoid valve is activated.
- The pump’s intake must be absolutely free of leaks and fitted with a fuel filter (see spare parts
list for filter types).
Inspection of fuel pump solenoid valve
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:
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 23).
If the voltage is correct in plug L, pin 2 (see page 36), 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.
SERVICING
PAGE 31
Control thermostat sensor
The control thermostat sensor connects to the control system via plug C (see page 36).
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. 55/60°C
Please note: This temperature range can be selected by connecting cable B6 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 B6 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 36) and unscrewing the sensor from its socket.
Overtemperature 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
PAGE 32
73
PARTS LIST
PAGE 33
Pos. Description Part number
Diesel Ethanol RME
1 Boiler 35.541 35.541 35.541
2 Circulation pump Highflow 24V 35.470 35.470 35.470
3+4 Installation kit 11.039 11.039 11.039
3+4+6 Fuel filter cpl. 11.038 11.038-1 11.038-1
5 Bracket for fuel filter 35.015 35.015 35.015
6 Fuel filter cartridge 11.037 11.037-1 11.037-1
7 Nipple 1/4 x 1/4 thread 30.395 30.395 30.395
8 Clip 71-95 35.581 35.581 35.581
9 Clip 32-44 35.021 35.021 35.021
10 Rubber hose 35.022 35.022 35.022
12 Fuel hose 300 mm 35.179 35.179 35.179
14 Temperature sensor 35.010 35.010 35.010
15 Overtemperature control 35.030 35.030 35.030
16 Cable for overtemperature control 35.031 35.031 35.031
17 Support bolt 8 mm 35.023 35.023 35.023
18 Bracket for circulation pump 35470 35.459 35.459 35.459
19 Gasket ring 35.028 35.028 35.028
20 Combustion pipe 35.042 35.042 35.042
21 Combustion unit 35.041 35.041 35.041
22 Screw 4 mm 35.024 35.024 35.024
58
Angle 1/4 x 1/4”RG / Nipple 1/4”RG + 14 x 1.50 mm
30.390/35.019 30.390/35.019 30.390/35.019
59 Plug for overtemp. 35.013 35.013 35.013
73 Filter pre-heater (optional) 11.046 11.046 11.046
ASSEMBLY DRAWING
PAGE 34
PARTS LIST
PAGE 35
Pos. Description Part number
Diesel Ethanol RME
23 Nozzle 35.071 35.070 35.071
24 Air plate 35.080 35.081 35.082
24A Plate for nozzle socket 35.123 35.123 35.123
25 Pre-heater element 31.142 Not in use 31.143
26 Oil pressure pipe cpl. 35.250 35.250 35.250
27 Nozzle socket 30.130 30.130 30.130
30 Photoelectric sensor 31.160 35.161 31.160
31 Ignition oscillator 35.510-1 35.510-1 35.510-1
32 8 mm nut 35.026 35.026 35.026
33 Relay for circulation pump 31.190 31.190 31.190
33A Bracket for relay holder and chassis
connection clamp 35.033 35.033 35.033
33B Chassis connection clamp 31.380 31.380 31.380
34 Control system 24/12V 35.520-1/35.522-1 35.520-1/35.522-1 35.520-1/35.522-1
35 Flange 35.036 35.036 35.036
36+57 Ignition cable 35.170-1 35.170-1 35.170-1
37 Ignition coil 12V (24V heater) 30.490 30.490 30.490
39 Fan motor 24/12V 35.340-1/35.342-1 35.340-1/35.342-1 35.340-1/35.342-1
40 Fan housing, motor section 35.037 35.037 35.037
41 Fan wheel 35.270 35.270 35.270
42 Coupling cpl. 35.360 35.360 35.360
43 Fan housing, intake 35.032 35.038 35.032
44 Air valve 35.300 35.300 35.300
45+46 Fuel pump cpl. 31.370-2 31.370-2 31.370-2
46 Solenoid valve 24/12V 31.376/31.373 31.376/31.373 31.376/31.373
47 Plastic nut for photoelectric sensor 35.140 35.140 35.140
48 Plastic cover 35.034-1 35.034-1 35.034-1
49 Fuse for fan motor 35.575 35.575 35.575
50 Wiring harness cpl. 35.570-1 35.570-1 35.570-1
51 Electrode block 35.101 35.101 35.101
52 Nut 35.035 35.035 35.035
53 Fuel line return 35.018 35.018 35.018
54 Fuel line supply 35.016 35.016 35.016
55 Nipple 4 x 1/8 straight 35.127 35.127 35.127
56 Rahjan coupling 35.188 35.188 35.188
ELECTRICAL DIAGRAM
PAGE 36
TIME SWITCH SEPARATE OPERATION OF CIRCULATION PUMP OUTLET FIELD COIL MAX. 1A DIAGNOSTICS LAMP + TIME SWITCH LOW-POWER RELAY FOR ROOM FAN
ELECTRICAL DIAGRAM
PAGE 37
Keys to abbreviations
Color codes
A
Control system plug
bl blue
B
Main plug signal cables
br brown
BM
Fan motor
ge yellow
C
Control thermostat plug
gn green
D
Photoelectric sensor plug
gr grey
E
Ignition electrodes
or orange
F
Nozzle pre
-heater plug
rt red
H
Overtemperature control plug
sw black
L
Field coil plug
ws white
LDR
Photoelectric sensor
vl violet
ST
Overtemperature control
N
Fan motor plug
R
Main plug power supply
FØ
Control thermostat sensor
RVP
Circulation pump relay
T
Ignition coil
TO
Ignition oscillator
V
Circulation pump plug
VP
Circulation pump
DV
Nozzle pre
-heater
MS
Field coil
I
Fuse
J
Accumulator
K
Main switch
LABELS STROCO 35.02 M EL
PAGE 38
The heater is labelled with a model plate and warning label, as shown below.
DESCARIPTION/TECHNICAL SPECIFIC. STROCO 35.02 M EL
PAGE 39
Description
The Stroco 35.02 M EL is an electrical heater designed primarily for heating vehicles in unheated
garages or in places where fuel-burning heaters cannot be used. STROCO 35.02 M EL is fitted to the
vehicle’s existing heating system and can therefore heat both the vehicle’s engine and cabin.
STROCO 35.02 M EL has integrated heating elements, control thermostat, and safety thermostat.
The model designations 6 kW and 9 kW describe the heating output in kW. The heater is connected
to the mains supply via a EURO socket fitted to the vehicle. To provide water circulation, a circulation pump should be installed with electrical connection from the heater. The direction of the water
circulation should follow the existing flow. An arrow on the circulation pump indicates the pump
flow direction.
STROCO 35.02 M EL should be fitted so that the cover on the electrical unit
may be removed.
Technical specifications
Type: STROCO 35.02 M EL type 6 kW and 9 kW
Heating output: 6 or 9 kW
Electrical connection: 3 x 400 V via 5 pin EURO plug (incl. neutral and earth).
Control thermostat: adjustable 5-85°C
Safety thermostat: 110°C, push-button reset
Circulation pump: Overall length 130 mm:
Electrical connection 1 x 230 V
Output 30-80 W, three step adjustable
Capacity 38 l/min at 2 m/vs
The pump must be fitted with the axle in horizontal position
PAGE 40
Pos. Description Part no.
1 Electrical immersion heater 9kW w/ ext. coupl. housing 750 mm 11.925
2 Thermostat EGO 30-85°C/110 11.926
3 Tag block 8 pin 4q wago 11.913
4 Circulation pump 11.812-1
The circulation pump must always be installed with horizontal motor shaft. no other installation is
allowed!
4
ELECTRICAL INSTALLATION OG SETTING
PAGE 41
The following is a description of the electrical installation. Please refer to the diagram on the
nextpage.
1. Internal wiring
The wiring between the three parts of the system: heater, pump, and EURO plug must be
established using at least 1 mm² regular plastic sheath cable HO7 N-F. Cables can be inserted
In the heater tag block by pressing down with a small screwdriver at L. The wiring must be
protected by flexible 3/8” armoured hose with metal inserts (e.g. STROCO no. UDG 11.865).
The armoured hose must have PG11 threaded joints at the ends with clamping ring fittings to
relieve the weight on the hose (e.g. STROCO no. UDG 11.867). Where the hose may be subject to
vibrations it must be further secured with cable clips. Check that the thermostat is set to the
desired temperature. NOTE! Turn up the thermostat and press the overheat button before
start-up.
2. EURO sockets
Connect to the mains grid only with a permanently fitted 5 pin EURO socket (E.g. STROCO
no. UDG 11.861). The socket should be fitted to the vehicle in a location that is sheltered from
water and dirt. The opening should be down-facing to allow condensation water to escape.
All plugs should be greased liberally with acid-free grease. The accompanying label reading
”Only to be used with an earthed socket” must be placed clearly visibly on or next to the socket.
3. Chassis earth connections
Earth connections may only be established as shown in the diagram on the following page.
Earth connections between individual parts must always be enclosed in the armoured hoses.
The earth connections from H to K, leading to the vehicle chassis, must be established using 4 mm²
wire. Clear off paint and rust thoroughly at the vehicle chassis point. Use at least a Ø3.5 mm
self-tapping or threading screw with a toothed washer. Do not remove chassis earth connection G
to the cover of the heater.
4. Thermostats
The control thermostat D may be adjusted continuously from 5°C to 85°C. The thermostat has an
integrated 12 K hysteresis, meaning that there are 12°C between activation and deactivation.
The operating temperature can be set using a screwdriver at D. The safety thermostat E is
triggered if the temperature exceeds 110°C. The thermostat can be re-activated by pressing the
button E.
Please note: Remove mains plugs before setting or re-activating thermostats.
5. Circulation pump
The circulation pump C has 3 speed settings, 1, 2, and 3, which can be selected using the button F.
If the return line to the heat exchanger feel hot to the touch, select a slower speed.
DIAGRAM
PAGE 42
A Heat exchanger B Circulation pump C EURO socket D Control thermostat E Safety thermostat F Circulation pump adjustment G Earth connection to cover
H Outer earth connection
K Earth connection to chassis L Tag block M Heating elements N Capillary tube sensors
bl blue
ge yellow gn green sw black
PAGE 43
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 44
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 MUICON 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
SCHWEIZ, Switzer land:
AUTOKÜHLER AG Tlf. 44 840 65 00
Wiesackerstrasse Fax 44 840 60 80
CH-8105 Regensdorf
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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