Stroco 35.02 M Operating instructions

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. [phone], fax [phone]
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 function-
ality 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 sur-
rounding 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.
 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 overtempe-
rature 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
1Fan wheel 15 Temperature sensor
2Fan housing 16 Overtemperature control
3Motor 17 Fuel filter
4Control system 18 Circulation pump
5Fuel pump 19 Outer boiler
6Nozzle socket 20 22 mm copper pins
7Nozzle 21 Inner boiler
8Ignition electrode block 22 Plastic cover
9Photoelectric 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