wallas xs duo Setup guide

XC Duo
Asennus-, käyttö- ja huolto-ohjeet
fi
en
de Montage-, Bedienungs- und Wartungsanleitung
Installation, operation and service instructions

en
Contents
41 Technical information
41 Supplies and accessories
42 Package contents
43 Stove operation
43 Function as a heater
43 Technical information
44 Installation
44 Things to note when selecting the installation location
44 Things to note when installing pipes, hoses and cables
44 The necessary installation tools
45 Stove installation
46 Fastening the device
47 Connections of the device
47 Things to note about the connections
48 Control panel installation
49 Electrical connections
49 Things to note about the connections
49 The cross-sectional area of the cable
49 Main switch
50 Electrical connections of the device
50 Checking the connection
51 Fuel connections
51 Things to note about the connections
51 Country-specicrequirements
51 Fuel feed
51 Connectiontoaxedtank
51 Connection to a separate tank
51 Wallas fuel tanks
52 Installation instructions for Tank connection 30018
52 Description
52 Getting Started
52 Stages
53 Installation instructions for Tank connection (XC Duo)
54 Tank-externallters
54 Fuellter30014
55 Selecting the fuel
56 Combustion gas connections
56 Locationoftheexhausthead
56 Location in the underframe
57 Location under a window
57 Installing the hoses
57 Installation
58 Removingtheplasticframeoftheexhausthead
58 Fixingthehosesontheexhausthead
59 Installingtheexhausthead
59 Orientationoftheexhausthead
60 Fixingtothevehiclebottom
61 Installingtheplasticframeontheexhausthead
D90220-1-3
- 3 -
XC Duo
490541G

en
Contents
62 Installation and initial start-up
63 Device use
63 Ignition
64 First start-up
64 Normal Use
64 Cooker used as a heater, thermostat use
65 Sun-switch (heating)
65 Manual power adjustment (stove/heating)
65 Shutdown
66 High altitude switch
66 Signal lights
67 Things to note about the use of the cooking plate
67 Cleaning and maintaining the stove top
68 Maintenance
68 Fault signals and releasing the lock
69 Maintenance recommendations
69 Cleaningtheexhausthead
69 Basic maintenance
69 it otherwise behaves abnormally
69 Special recommendations
69 Removal of the water from the tank
70 Winter storage
70 Spare parts
71 Troubleshooting, locking indication
72 Troubleshooting, undervoltage
73 Troubleshooting,indicatingameout/overheat
74 Warranty Terms
D90220-1-3
- 4 -
XC Duo
490541G

4300
4310
4320
1028
1030
4350
30018
367215
1102
4330
368202
1150
2024
2027
XC Duo
12V
10L5L
368202
30018
367215
1030
4330
4300
4m, MAX 8m
4m
3m
4m
1028
Ø 28mm
L= 1-2m
4310
4320
2024 2027
4360
4360
367216
6m
367216
en
Technical information
Exhausthead
Supplies and accessories
ExhausttubeØ28mminox
Heat insulation Ø 30 mm, Fiber glass
Bracket set
Cover plate kit
XC Duo Installation kit
Tanktting,Cu
Tank feed through, diesel, 4 m
Standard delivery Installation accessory Special installation
Fasteningequipmentfortheupperpartofthestove
Extensionkitforbracketset
Plasticcoverforexhausthead
Toasting grill
Fuel tank, 5 l
Fuel tank, 10 l
Accessory
Frame set for stove
Tank feed through, diesel, 6 m
D80131B
- 41 -
XC Duo
490541G

XC Duo
4350
en
Technical information
Package contents
ScrewforironfastenerM6x12
FasteningscrewM6x30
Locking nut M6
Hose clamp 20 - 32 mm
Plastic holder, 15 mm
4 pcs
4 pcs
4 pcs
2 pcs
1 pcs
Stove XC Duo
Accessory bag 17735
Power cable with connector and integrated fuse 15 A (4m)
Steel fastener
1 pcs
1 pcs
2 pcs
1 pcs
Cover plug4 pcs
Installation, operation and maintenance instructions1 pcs
Control panel cable, 3 m
Control panel
Controlpanelfasteningscrews3,5x20mm(black)TX10
Control panel package 361070
Plasticcoverforexhausthead368202
1 pcs
1 pcs
Exhausthead
FasteningscrewM5x10
Exhausthead4300
Locking nut M5
Washer M5
1 pcs
1 pcs
4 pcs
2 pcs
2 pcs
1 pcs
4 pcs
1 pcs
Extensioncollar1 pcs
Controlpanelfasteningscrews3,5x40mm(black)TX104 pcs
L-shapeprole1 pcs
Hose clamp 20 - 32 mm2 pcs
Bracket set 43101 pcs
Mounting bracket2 pcs
Bracketprole2 pcs
Exhaustheadbracket2 pcs
FasteningscrewM5x108 pcs
Locking nut M58 pcs
Sheetmetalscrew4,8x138 pcs
Cover plate kit 43201 pcs
Cover plate2 pcs
Sheetmetalscrew4,8x134 pcs
Fasteningscrew3,9x161 pcs
Heat insulation Ø 30 mm, Fiber glass, 1,5 m 10301 pcs
ExhausttubeØ28mminox,2m10282 pcs
D80141A
- 42 -
XC Duo
490541G

12 V DC
0,09 - 0,18 l/h
900 - 1800 W
456x343x208mm
8 m
100 cm2
2 m
4300
~ 12 kg
en
Technical information
Stove operation
The XC Duoisasafedieselstovewithnoopename.Thestoveisequippedwith
a single burner which burns either diesel oil or light furnace oil (diesel heating oil).
The stove takes the air needed for the burning process from outside of the vehicle
withacombustionairbloweranddischargestheresultantexhaustoutsideofthe
vehicle.
The fuel pump in the stove dispenses fuel, and the electronics control the combus-
tionairandtheamountoffuelautomaticallytokeeptheameoftheburnerclean.
Whenthestoveisrstswitchedon,theglowplugintheburnerignitesthefuelthat
has been pumped into the burner. The glow time begins and ends automatically.
TheheatsensorinthestovedetectstheheatoftheameandlightstheredLED
lighttosignalthattheamehasbeenignited.
The heat which is released as the fuel burns is transferred into the ceramic stove
top. The left side of the stove top is hotter, as the burner is located under it. The
power of the stove can be adjusted steplessly. The control adjusts both sides of the
stove simultaneously.
When the stove is switched off, a cool down cycle begins. The cooling function ven-
tilatestheburneranddischargestheexhaustgasesgeneratedduringcooldown
outside the vehicle.
Thestovelendsitselfextremelywelltocookingandheatingallkindsoffoods.
It has been manufactured entirely from stainless and aluminium materials.
Function as a heater
By lowering the blower lid to the horizontal position, the stove works as a cabin
heater.
Adjustment of heat control works either manually or with the help of control panel
built-in thermostat.
Fuel Diesel oil, light furnace oil (diesel heating oil)
0,55...0.85 A (when ignited ca. 5-10 min. 8 - 10 A)
Operating voltage
Consumption
Heating power
Power consumption
Measurements
Weight
Max.permissiblelengthoftheuegas
pipe
Max. permissible length of the fuel hose
Minimum size of the replacement air
opening
Suitableuegaslead-throughs
Technical information
D80121B
- 43 -
XC Duo
490541G

7 mm
8mmx2
10 mm
12 mm
Ø 43 mm
Ø 2 mm
Ø 5 / Ø 6 mm
6,5 mm TX 10
5 mm
en
Installation
Things to note when selecting the installation location
When installing the device, bear in mind that the device must be detached for
maintenance. Therefore, it is advisable to make the connections easy to open and
disconnect.
Thestoveshouldbeinstalledlevel.Theinclinationshouldnotexceed5°withthe
standing level. While the device may not be damaged if it is temporarily tilted to a
steep angle while running (even for some hours), the burner will not yield optimal
performance while inclined.
The control panel should be installed in a vertical surface, away from sources
of heat or cold (for thermostatic function) and within the 3 meter control harness
length.
The stove should not be installed on top of a refrigerator. The stove will heat its sur-
roundings and thus decrease the power of the refrigerator.
We recommend that the device be installed by an authorised Wallas Dealer.
Things to note when installing pipes, hoses and cables
Power cables and fuel hoses must be protected in locations where they are sus-
ceptible to mechanical damage due to sharp edges or heat.
The necessary installation tools
If possible, install the control panel on a vertical surface.
D10361B
- 44 -
XC Duo
490541G



603406
Markku


33.4 g
date author inspectedand approved code
ratio version
drawing no.
name
material
Arkki A3
finishing mass
Description
Rev author & date Productm ust fulfil the RoHS-directive
(Directive2002/95/EY)requirements.
24.10.07




 

    
    
      


442 mm (17 13/32”)
295 mm (11 5/8”)
XC Duo
431 mm (16 31/32”)
309 mm (12 5/32”)
Installation en
Stove installation
Saw a cut-out (see picture) for the stove and the control panel in your chosen loca-
tion.
The length of the control panel cable is 3 m.
2 Ensure that there is sufcient space under
the stove for cables and
hoses.
3 The control panel should be installed on
a vertical surface.
Note! The unit
dissipates heat to its sur-
roundings, and the control
panel thermostat and Sun
Switch. will not operate
as planned if installed too
close to the unit.
Select the location for the
control panel to suit the
intended use.
You can also fabricate a
detachable panel to go in
front of the stove. This will
facilitate installation and
maintenance.
Measurements of the stove installation cut-out.
5 Glue the L-shape pro- le to the edge of hole.
1 The stove requires a replacement air opening of at least 100 cm2.
Ensure that the air circulation under the
stove is sufcient.
When the replacement air open-
ing is at oor level, the heat will
be better transferred to the oor
level.
Please pay atten-
tion to all numbered
items!
4 Ensure that there is sufcient space between the stove and the vertical
surface to facilitate installing and detach-
ing the device.
D10361B
- 45 -
XC Duo
490541G

3
1
5
4
2
1
Fastening the device
Place the stove in the installation cut-out and attach the steel fasteners (1) with the
screws M6x12(2) to the rivet nuts at the ends. After this, install the cover plug (3)
on the end of the screw and tighten the steel fasteners against the table with the
screw M6x30(4). Remember the locking nuts M6 (5).
Attach the steel fasteners to the stove (1) with screws (2).
The steel fasteners can be installed in two ways depending on the thickness of the table board.
Push the cover plug (3) on the screw.
Tighten the screw (4) rmly against the table board and then tighten the locking nut (5).
Thin table Thick table
Installation en
Always use original Wallas accessories and parts with Wallas equip-
ment.
Thesurfacethattheunitistobefastedtomustbeperfectlyat.
D10361B
- 46 -
XC Duo
490541G

K00114
Installation en
Connections of the device
Things to note about the connections
In installation, to make the mounting and demounting for service easier, it is recom-
mendedtoleavesomeextralengthofloosecablesandfuellinebycreatingacoil.
If the installation location is cramped, it is recommend to connect the cabels and
the fuel line to the device before mounting the unit to bracket. This will help the
installation of device.
Power cable
Install the combustion gas ex-
hausthosetothishosetting
Control panel
Install the combustion air in-
takehosetothishosetting
D10361B
- 47 -
XC Duo
490541G

1 2
69 mm (2 23/32’’)
104 mm (4 3/32’’) 3
4
100 mm (3 15/16’’)
65 mm (2 9/16’’)
17,5 mm
(11/16’’)
17,5 mm
(11/16’’)
ø 2 mm (3/32’’)
56,1 mm (2 13/64’’)
4,5 mm (11/64’’)
47 mm (1 27/32’’)
en
Installation
Control panel installation
Cut a suitable installation hole for the control panel in the selected location. Try to
install the panel in a vertical surface in a location that will remain dry and in dis-
tance from splash water.
Measurements of the control panel installation cut-out.
If necessary, predrill holes for the ø 2 mm ( 3/32”) screws.
You can utilize the sample of the box when drawing the lines of the
installation hole.
Connect the control panel cable from
the device to the control panel (1).
Use the fastening screws to install the
control panel to the installation cut-out
(2).
An extension collar (3) is used when control
panel is surface mounted.
The box of the panel includes 4 pcs screws 3,5
x 40mm (black) TX10 (4).
The thermostat sensor is in the panel face, so select the location
with thermostatic operation/regulation in mind. Do not install close
to heat source or close to a window or door. Avoid locations that
might be contacted by direct sunlight. The length of the control
panel cable is 3 m.
D10301A
- 48 -
XC Duo
490541G

0 - 4
4 - 6
6 - 10
4 (11 or 10 AWG)
6 (9 or 8 AWG)
10 (7 or 6 AWG)
en
Installation
Electrical connections
Things to note about the connections
The device uses 12 V (nominal) direct current voltage. To minimize current losses,
make the power cable as short as possible and avoid joining. The cross-sectional
area of the cable is dependent on the length of the power cord. The cross-sectional
area of the cable must be consistent all the way from the stove to the battery. The
maximumlengthofthepowercordis10m,basedon6AWGcable.
Total length of the power cord (m) Cross-sectional area of the cable in square mm
(US Gauge)
Ifathickercableisrequired,makeaseparatejointinthepowercord.Seepicture
onthenextpage.
Main switch
A main switch must be installed on the device’s “positive (Red)” cord. Always cut
the power at the main switch (after cooling has completed), if the device is going to
be left unused for a long period of time.
Recommended main switch should be 20 V DC / 20 A DC minimum.
Never use the main switch to cut the power before the cooling phase
is completed.
The cross-sectional area of the cable
D10021B
- 49 -
XC Duo
490541G

Electrical connections of the device
12 V direct current system
Connect the red wire of the power cord to the plus terminal of the battery and the
black or blue wire to the minus terminal. A 15 A main fuse must be installed near
the battery on the red plus wire of the power cord. See picture.
24 V direct current system
If the device is to receive power from a 24 V system, always connect a charg-
ing voltage reducer and a 12 V battery before connecting the device. Without the
battery the voltage reducer will not be enough on its own as it cannot generate the
largeamountofcurrenttheglowplugrequires.Afterthe12Vbattery,theconnec-
tion is the same as in a 12 V system.
24 V direct current system
Device’s quick
coupling
Jointing
A jointing should only be made in long
power cords, if necessary, in which case
the cord must be replaced with a thicker
one. The jointing should be less than 1
meter from the device.
Main switch Main fuse
Power cord
Checking the connection
The device consumes most power when it is started up (glowing). At this point volt-
age losses are also at their highest. During the glowing phase, the voltage must be
atleast11,5Vmeasuredatthequickcoupling.Seepicture.Ifthevoltageislower
than this, the device may not start.
The unit should be connected to a battery used for purposes other than
starting the engine, if possible.
Installation en
D10021B
- 50 -
XC Duo
490541G

5 l 2024
10 l
30 l
130 l
2027
4030
4130
200x300x130mm
380x195x210mm
590x200x300mm
800x400x600mm
en
Installation
Fuel connections
Things to note about the connections
Thestandardlengthofthefuelhoseis4m(max8m).Cutthefuelhosetoalength
suitable for installation.
The lift height of the pump should be less than 2 m; preferably 0.5 – 1 m.
ThefuelpipemustalwayshaveaWallaslter.Thefuelltercanbeinstalled
either near the device, near the tank, or in another location where it can be easily
checked and replaced, when necessary.
Dieselenginefuelltersand/orseparatorsarenotapprovedforuse.Allsoftcon-
nections should be made with rubber or silicone hose which is resistant to diesel.
Country-specicrequirements
Thestandardfuelhoseisplastic.Pleaseobservecountry-specicrequirements
withregardtothematerialofthefuelhose/pipeandthefuellter.Theinnerdiam-
eterofanewreplacementhoseshouldbeequaltotheinnerdiameteroftheplastic
hose. Copper pipe 300692andmetallters30016 are available as accessories.
Fuel feed
Iftheliftheightexceeds2m,thefuelfeedmustbecheckedand,ifnecessary,ad-
justed. The fuel feed must also always be checked, if parts of the fuel system, such
as the pump or the electronics card, have been replaced.
Fuelsystemadjustmentsaredevicespecic.Theseadjustmentsshouldonlybe
carried out by an authorized service shop.
Connectiontoaxedtank
Thedevicemusthaveadedicatedconnectionwithafuellteroutsidethetank.
Please note that installation of such fuel intake pipe to the original tank of the
vehiclemayaltertheoriginalcerticationofthevehicle.Certiedinstallationmay
requireaseparateapprovalofthefuelintakeconnection.Ifthevehiclehasalready
a tube end where you can connect the fuel tube of XC Duo, you do not need any
separate approval.
Connection to a separate tank
Caprun-throughsandsinteredltersareusedonplastictanks.
The fuel tank should be mounted securely.
Thefuelconnectionsmustbetightenedrmlysothattheaircannot
leak into the hose. Always check the cleanliness of the connection
surfaces before tightening. Air leaks in the fuel system will cause the
device to malfunction.
(accessory)
(accessory)
(accessory)
(accessory)
Volume length x height x width Order code
Wallas fuel tanks
D10451A
- 51 -
XC Duo
490541G

en
Installation
Installation instructions for Tank connection 30018
Description
Einon®(30018) is a leak-proof intake fuel line.
Getting Started
Parts needed in installation are put in right order and are connected together with
a wire. You shall never cut the installation wire , you’ll need it when installing the
intake pipe. (Installation without the wire is not possible).
Stages
• Make sure that the fuel tank is empty enough.
• Searchabout4cmatsectionfromthefueltankwhereyoucandrilla13
mm diameter hole.
• Clean the selected area of protection grease and clean also other pos-
sible dirt.
• Drill a hole.
• Remove the burr from hole (inside and outside).
• Figure out without installing for Einon®(30018) suitable bending and
length.
• Cut the pipe end diagonally and remove burrs.
• Install the cut and bent intake pipe through the drilled hole into the tank.
• Push through the hole into the tank all the other interior parts (up to the
mark), keep the order of parts as they are mounted to the wire.
• Pull from the wire until the Einon®(30018) threaded part is outside of the
tank.
• Turn the Einon®(30018)tothecorrectpositionandtightenthetankexter-
nal part (nut).
• Attach the fuel line to the Einon®(30018).
MARK
INSIDE TANK PARTS EXTERIOR
D10381C
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XC Duo
490541G

en
Installation
Barrel nut
Sinter bronze lter
Cap seal
Protection spiral
Washer
Seal
Screw cap
Vent hose
Installation instructions for Tank connection (XC Duo)
If the fuel will be taken from a separate tank, you must install a tank connection
367215 (4 m) / 367216 (6 m).
• Disconnectthefuellinewhichisleadingfromthefuelltertodevice.Replaceit
with fuel line of tank connection fuel set.
• Install the tank connection in the Wallas tank.
Attach the hose of the tank
connection here
Do not use these parts
D10401A
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XC Duo
490541G

en
Installation
Tank-externallters
Nearthedevice(0.5m)isafactory-mountedfuellter,30015.
Checkregularlythelterandreplaceitifnecessary.
Filters can be installed in a ø 5 or ø 6 mm plastic. Ensure that the fuel pipes are
cleanbeforeinstallingthelter.Theremustbenodebrisorimpuritiesbetweenthe
pumpandthelterastheywillclogthepump.Theltertypemustbeselectedac-
cordingtotheoperatingconditionsandcountry-specicrequirements.
Fuellter30014
(accessory)
Thislterisintendedforcoldconditions.
Theltercanbeinstalledbetweentwoø5mmfuelhoseswithø5mmbarrelnut,
ø 5 mm olive and ø 2 mm support sleeve.
For connecting a 30011 /
30018 tank connection.
Do not use these parts
For connecting a ø 5 mm
fuel hose.
For connecting a ø 5 mm
fuel hose.
D10 411
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XC Duo
490541G

en
Installation
Selecting the fuel
When selecting the fuel type, take note of the temperature limits of each particular
fuel.Thelimitvaluesprovidedherearetobetreatedasguidelines.Conrmthe
actual temperature limits from the fuel supplier.
• diesel, summer grade, temperature must not fall below –5 °C.
• diesel, winter grade, temperature must not fall below –24 °C.
• diesel, arctic winter grade, temperature must not fall below –40 °C.
Ifthetemperaturedropslowerthantheminimumlevel,parafnmayforminthe
fuel.Thismayresultinthefuellterandpumpbeingclogged.Theclogwilldissolve
only if the fuel temperature rises clearly over 0 °C.
The less aromatic substances the fuel contains, the less deposits will be formed.
Normal furnace oils contain 35–40 % of aromatic substances. In city diesels and
green furnace oils (green diesel heating oil) the concentration is 20 %.
Conrmtheactualtemperaturelimitsforthefuelyouareusingfrom
the fuel supplier.
Dieselqualitiesanddenitionsvarybycountry.Alwayscheckthe
right fuel from your importer / dealer
D10461
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XC Duo
490541G

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=
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min. 300 mm min. 1 m
WALLAS
en
Installation
Combustion gas connections
Location of the exhaust head
Location in the underframe
When selecting the location for installing the 4300exhausthead,theinternallayout
of the vehicle and routing of the combustion gas and intake air hoses should be
taken into account. Try to keep the hoses as short as possible. Also keep in mind
that the combustion gas hose becomes hot.
Afreeowofairpasttheexhaustheadmustbeensuredatalltimes.Installthe
exhaustheadonastraightsurface,ushwiththevehicle’ssideline.Avoidcorners
and cavities where wind pressure may disturb the unit’s operation. Also bear in
mindthatwheninstalledinthemiddleofthevehicle,theexhaustheadwillreduce
ground clearance the most.
Theminimumdistanceoftheexhaustheadfromthefueltank’sllerholeis400
mm (16”).
Thefrontedgeoftheexhaustheadmustalwaysbeinstalledushwiththevehi-
cle’s side line, in a slight downward inclination (at least 5°); the head must not be
under the vehicle. The minimum distance from the rear tyre of the vehicle is 0.3
metres,whiletheminimumdistancefromthefronttyreisonemetre.Theexhaust
head must not be installed at the rear end of the vehicle.
A good place for the exhaust head
A possible place for the exhaust head
The exhaust head must not be installed here
DOOR
DOOR
reduces ground clearance
reduces ground clearance
reduces ground clearance
The minimum ground
clearance shall not be
exceeded.
Make sure that there is
open way to the point
of jack up.
D10341D
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XC Duo
490541G

min. 300 mm
min. 300 mm
min. 400 mm
F
U
E
L
1030
4320
1028
Ø 43 mm
62 mm
Installation en
Location under a window
Theexhausthead4300 shall not be installed under an opening window or closer
than300mmtothewindow’sedges.Iftheexhaustheadhastobeinstallednear
anopeningwindow,thewindowmustbepreventedfromopeningorttedwitha
switch that prevents the hob from being used when the window is open.
Installing the hoses
Installation
When you have chosen the location for the 4300exhausthead,youshouldndthe
best place to lead the combustion gas and intake air hoses through the bottom of
the vehicle.
DrilltwoholesofapproximatelyØ43mmforthehoses,asillustrated.Theholes
must be 62 mm apart. Install the 4320 bottom penetration cover plate set. Insulate
the combustion gas pipe with the 1030breglasssleeve.Iftheoorstructureof
the vehicle at the location of the combustion gas hose is not heat resistant, remove
part of the insulation and replace it with heat-resistant material.
Vehicleoorstructure
D10341D
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XC Duo
490541G