Stroco 35.02 M LE HYBRID Service Instructions Manual
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Stroco 35.02 M LE HYBRID Service Instructions Manual

Fuel-burning heater
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SERVICE INSTRUCTIONS
for fuel-burning heater type
STROCO 35.02 M LE HYBRID
Applicable from heater no.
Diesel/HVO: 44969
RME:
31032
STROCO ApS, Banealle 8H, DK-8450 Hammel, ph. +45 86961066
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 07/20
This manual is also available at www.stroco.dk

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Summary of Contents for Stroco 35.02 M LE HYBRID

  • Page 1 STROCO 35.02 M LE HYBRID Applicable from heater no. Diesel/HVO: 44969 RME: 31032 STROCO ApS, Banealle 8H, DK-8450 Hammel, ph. +45 86961066 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.
  • Page 2 This manual covers many different version of STROCO 35.02 M - Please check label on top of the heater to identify correct version. Example of label:...
  • Page 3 IMPORTANT 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.
  • Page 4 IMPORTANT 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.

  • Page 5: Table Of Contents

    CONTENTS 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 …………………………………..

  • Page 6: Description

    DESCRIPTION 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. Fuel Water Heat Electrical power 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.

  • Page 7: Schematic Diagram Of Fuel-Burning Heater

    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.

  • Page 8: Built-In Dimensions

    BUILT-IN DIMENSIONS All measurements +/- 2 mm PAGE 8...

  • Page 9: Installation Guide/Installation Plan

    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.
  • Page 10 INSTALLATION GUIDE/INSTALLATION PLAN  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. ...

  • Page 11: List Of Connections

    LIST OF CONNECTIONS 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.

  • Page 12: Electrical Connections

    ELECTRICAL CONNECTIONS 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.
  • Page 13 Plug B Plug R Front Back PAGE 13...

  • Page 14: Technical Specifications

    TECHNICAL SPECIFICATIONS Technical data: STROCO fuel-burning heater type 35.02 M LE HYBRID: Fuel-burning heater with integrated control system and safety and alarm functionality. Dimensions L x W x H: 613 x 245 x 234 mm Weight: 30 kg total. (plus any optional parts).

  • Page 15: Explanation Of Terminology

    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.

  • Page 16: Maintenance

    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.
  • Page 17 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.
  • 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.

  • Page 19: Description Of Functionality - Operation

    DESCRIPTION OF FUNCTIONALITY - OPERATION 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.

  • Page 20: Description Of Functionality

    DESCRIPTION OF FUNCTIONALITY 1 Fan wheel Temperature sensor 2 Fan housing Overtemperature control 3 Motor Fuel filter 4 Control system Circulation pump 5 Fuel pump Outer boiler 6 Nozzle socket 22 mm copper pins 7 Nozzle Inner boiler 8 Ignition electrode block Plastic cover 9 Photoelectric sensor Exhaust...

  • Page 21: Troubleshooting - How

    TROUBLESHOOTING - HOW? 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? ...

  • Page 22: Disconnection Of Combustion Chamber

    DISCONNECTION OF COMBUSTION CHAMBER 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 can now be detached to reveal the combustion pipe (pos. 2). PAGE 22...

  • Page 23: Process Control Diagram

    PROCESS CONTROL DIAGRAM 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...

  • Page 24: Alarm Functionality

    ALARM FUNCTIONALITY PAGE 24...

  • Page 25: Combustion Unit

    COMBUSTION UNIT 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.

  • Page 26: Voltage Check On Electrodes

    VOLTAGE CHECK ON ELECTRODES Perform when inspection ignition and oscillator. Detach overtemperature control plug, control thermostat sensor, and solenoid valve. When inspecting the ignition, short-circuit the overtempera- ture control plug to keep the ignition functioning. For access to the combustion unit, please see the section ”Disconnection of combustion chamber”, page 22.

  • Page 27: Photoelectric Sensor

    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.

  • Page 28: Under/Overvoltage

    UNDER/OVERVOLTAGE 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.

  • Page 29: Replacement Of Fan Motor

    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.

  • Page 30: Fuel Preheater

    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.

  • Page 31: Control Thermostat Sensor

    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.

  • Page 32: Assembly Drawing - Part List

    ASSEMBLY DRAWING PAGE 32...
  • Page 33 PARTS LIST Pos. Description Part number Diesel Boiler 35.541 35.541 Circulation pump Highflow 24V 35.470 35.470 Installation kit 11.039 11.039 3+4+6 Fuel filter cpl. 11.038 11.038-1 Bracket for fuel filter 35.015 35.015 Fuel filter cartridge 11.037 11.037-1 Nipple 1/4 x 1/4 thread 30.395 30.395 Clip 71-95...
  • Page 34 ASSEMBLY DRAWING PAGE 34...
  • Page 35 PARTS LIST Pos. Description Part number Diesel Nozzle for 23 kW (LE) 35.073 Nozzle for 30 kW (LE) 35.072 35.072 Air plate 35.080 35.082 Plate for nozzle socket 35.123 35.123 Pre-heater element 31.142 31.143 Oil pressure pipe cpl. 35.250 35.250 Nozzle socket 30.130 30.130...

  • Page 36: Electrical Diagram

    ELECTRICAL DIAGRAM PAGE 36...
  • Page 37 ELECTRICAL DIAGRAM PAGE 37...

  • Page 38: Technical Specification For Electrical Heating

    TECHNICAL SPECIFICATION FOR ELECTRICAL HEATING Description STROCO LE HYBRID is used to heat the vehicle during parking and day to day travel on hybrid or all-electric vehicles. STROCO Electrical heater is mounted in the vehicle's existing heating system and can heat the driver's area, passenger space and engine. STROCO Electrical heater has built-in heating elements operating thermostat and safety thermostat.
  • Page 39 Pos. Description Part no. El-heater 7,5 kW 672V DC w/ext. coupl. housing 750 mm cpl. 11.927 El-heater 15 kW 672V DC w/ ext. coupl. housing 750 mm cpl. 11.936 Thermostat EGO 30-85°C/110 11.926 Connection Block 11.915 Optional El-heater 7,5 kW 620V DC w/ext. coupl. housing 1000 mm cpl. 11.932 El-heater 12,5 kW 620V DC w/ext.
  • Page 40 LABELS STROCO 35.02 M EL-HEATING The El-heater is labelled with a model plate and warning label, as shown below. PAGE 40...
  • Page 41 Switch of the vehicle. 3 Level sensor for low water level of heating circuit. Level sensor shall be used to block activation of heating elements when water level is low to prevent damage on the heating elements. (Not supplied by Stroco). PAGE 41...
  • Page 42 COUPLING SCHEME FOR 7,5KW AND 15KW 672V DC 24V DC 24V DC PAGE 42...
  • Page 43 CONNECTIONS PAGE 43...

  • Page 44: Warranty Conditions

    STROCO heaters and parts are covered by 24 months warranty. The warranty is valid from the date of installation. However, the warranty only covers if the following guidelines are followed: The STROCO heater is properly mounted according to manual Warranty card correctly completed with serial number and returned to STROCO The warranty covers manufacturing defects and material defects.

  • Page 45: Dealers

    DEALERS DANMARK, Denmar k: STROCO ApS Tel. +45 86 96 10 66 Banealle 8H E-mail DK-8450 Hammel info@stroco.dk ENGLAND: GRAYSON THERMAL SYSTEMS 0121 708 4000 257 Wharfdale Road E-mail Tyseley info@graysonts.com GB-Birmingham B11 2DP FINLAND: EL-CAR OY Tel. 09 389 4995 MUICON OY Tel.

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