Kelvin Cozy User manual

Kelvin System, Inc.
Cozy Installation Guide

Table of Contents
Tools.......................................................................................................................................
Personal Protection Equipment..........................................................................
The Cozy – Metal Enclosure..................................................................................
The Cozy – Electronics Kit (e-Kit)......................................................................
The Cozy – Cables & Sensors..............................................................................
The Cozy – Installation.............................................................................................
Installation – Sensor & Cables............................................................................
Installation – Prepping the Cozy........................................................................
Installation – Lifting & Placing the Cozy........................................................
Installation – Electronics Testing.......................................................................
Installation – Installing the Electronics Kit...................................................
1
1
2
3
4
5
6
8
10
12
13

1
PPE Needed:
Gloves (Heat Resistant &
Insulation Safe)
Face Mask
Protective Glasses
•
•
•
Tools
Heat-resistant tape
Power Drill (with phillips and
Torx head bits)
Screwdriver (with phillips
and Torx head bits)
Self-Tapping screws (to
Secure to Wall)
L-Bracket Screws (to Secure
to Enclosure)
Electronics-Kit screws
1.
2.
3.
4.
5.
6.
x4 per Cozy
x4 per Cozy
x6 per Cozy
Cozy Installation GuideKelvin Systems, Inc.

2
Figure 2: Cozy (Front Isometric) Figure 3: Cozy (Rear Isometric)
A metal cover that fits over the radiator (figures 1, 2, 3 below)
An Electronics Kit (e-Kit) that fits into the metal cover and
connects to a power outlet (figures 4, 5, and 6 on
following page)
1.
2.
Figure 1: Cozy (Front View)
Cozy Installation GuideKelvin Systems, Inc.
The Cozy – Metal Enclosure
The Cozy is comprised of two main
components:

3
A metal cover that fits over the radiator (figures 1, 2 and 3 on
previous page)
An Electronics Kit (e-Kit) that fits into the metal cover and
connects to a power outlet (figures 4, 5, and 6 below)
1.
2.
Figure 4 E-Kit – Front View
Figure 5 E-Kit – Top View
Figure 6 E-Kit (Rear View)
The Cozy – Electronics Kit (e-Kit)
The Cozy is comprised of two main
components:
Cozy Installation GuideKelvin Systems, Inc.

4
Power cable (and Power Brick) (figure 7)
Barrel Jack Extender (essentially an internal extension cord)
(figure 8)
Radiator Sensor (figure 9)
Steam Trap Sensor (if applicable) (figure 10)
3.
4.
5.
6.
Figure 7
Power Cable & Brick
Figure 9 Radiator Sensor (Copper
Sensor on one end, plastic connector
on other)
Figure 10 Steam Trap Sensor (Plastic
Connector on one end, two copper
sensors on the other)
Figure 8 Barrel Jack Extender (Power
Extension cable)
Cozy Installation GuideKelvin Systems, Inc.
The Cozy – Cables & Sensors
There are four cables in the Cozy:

5
Attach all sensors
Install the metal enclosure over the radiator
Test and install the electronics kit (e-Kit)
1.
2.
3.
Figure 11
Radiator before Cozy Installation Figure 12 Radiator after Cozy Installation
The Cozy – Installation
Cozy installation consists of three primary steps:
Cozy Installation GuideKelvin Systems, Inc.

6
Radiator Sensor:
Ziptie the Radiator Sensor to radiator pipe
just below copper sensor (Figure 13, 14)
For additional security, tape the copper
sensor directly to the pipe (Figure 15)
1.
Installation – Sensor & Cables
Select a Cable Bundle and separate out the three cables. Each
bundle should have a Radiator Sensor, Power Cable, and Steam
Trap Sensor cable. The first step is to attach the Radiator and
Steam Trap sensors
Figure 13
Figure 14 Figure 15
Cozy Installation GuideKelvin Systems, Inc.

7
Steam Trap Sensor:
Ziptie the Steam Trap sensors to either side of the steam
trap (Figure 16 & 17)
For additional security, tape each sensor directly to
the pipe (Figure 18)
2.
Figure 16
Figure 19
Figure 17
Figure 18
Power Cable:
Route the power cable
starting from over the top
of the radiator, between
the radiator and the wall,
to the closest power outlet.
Keep the three cords close
together (figure 19)
3.
Cozy Installation GuideKelvin Systems, Inc.

8
Position the Cozy so that it’s back is to the
radiator and the ekit-Cavity is facing out.
(Figure 20)
1.
Route the Radiator Sensor Wire, Power
Cable and Steam Trap Sensor Cable
through the back of the eKit-Cavity and out
through the right side of the duct, letting
them dangle down the front of the Cozy.
(Figure 21)
2.
Note the location of the side piping and cut
the rigid insulation accordingly, so that the
insulation sits snug against the pipe.
(Figure 22)
3.
Installation – Prepping the Cozy
Now the metal enclosure can be placed over the
radiator:
Cozy Installation GuideKelvin Systems, Inc.

9
Figure 20
Position the Cozy with the
e-Kit cavity facing front.
Adjust the levelers on the
bottom so that the top of
the Cozy sits just above
the top of the Radiator.
Figure 21
Route the three cables
through the back of the
e-Kit cavity and through
the right side of the duct
Figure 22
Note the location of the
side piping
and cut the rigid insulation
accordingly, so that the
insulation sits snug
against the pipe
Cozy Installation GuideKelvin Systems, Inc.

Lift the Cozy and set it in place over the
radiator (see figure 23 on the following
page) with the side brackets against the
wall. Adjust the feet levelers so the Cozy is
not resting on the top of the radaitor.
Note: If the Cozy is not flush against the
wall, the radiator may have to be shifted
closer to the wall.
2.
10
Unfurl the soft insulation affixed to the rear
of the Cozy and tuck it between the rear of
the radiator and the wall. (Figure 23)
1.
Secure the L-Bracket to the side of the Cozy
using the L-Bracket Screws and secure the
L-Bracket to the wall using self-tapping
screws. (Figure 24-25 on following page)
3.
Using the white insulation tape, tape over
the cut in the rigid insulation to leave a
snug and clean-looking fit against the
radiator pipe.
4.
Installation – Lifting & Placing the Cozy
Now the metal enclosure can be placed over the
radiator:
Cozy Installation GuideKelvin Systems, Inc.

11
Installation – Lifting & Placing the Cozy
Now the metal enclosure can be placed over the
radiator:
Figure 23
Unfurl the soft insulation
affixed to the rear of the
Cozy and tuck it between
the rear of the radiator and
the wall. Place the Cozy
over the radiator. Note: If
the Cozy is not flush against
the wall, the radiator may
need to be pushed back
against the wall.
Figure 24
Secure the L-Bracket to
the side of the Cozy.
Figure 25
Secure the L-Bracket to
the wall.
Cozy Installation GuideKelvin Systems, Inc.

12
Installation – Electronics Testing
Before installation, the pre-assembled Electronics Kit
(e-Kit) must be tested:
Once plugged in, the fan should begin to spool up and the
LED display should show green, yellow, and red bars. Once the
front button blinks GREEN (see figure 26 below), the electron-
ics kit has been successfully tested.
Note: If it blinks blue or orange, swap the kit out for a differ-
ent one and mark the malfunctioning e-Kit for return to
Radiator Labs.
3.
Locate the three cables running from the e-Kit. The gray cable
is the radiator sensor, the white cable is the power cord, and
the four-pronged colorful cable is the Steam Trap Sensor.
1.
Connect all three cables to the correct cable that is affixed to
the radiator (for the sensors) and power brick (for the power
cable). The power cable must be connected last.
2.
Ensure the buttons do not stick when you push them.4.
Fig. 26
After you connect
the cables and the
LED light bar starts
up, wait until you see
a green light blink,
indicating a
successful test
Cozy Installation GuideKelvin Systems, Inc.

13
Installation – Installing the Electronics Kit
And finally, install the Electronics Kit:
Connect all three cables to the correct cable that is affixed to
the radiator (for the sensors) and power brick (for the power
cable). The power cable must be connected last. (figure 27).
Note: If the e-Kit successfully passed testing, then the
cables should already be plugged in.
1.
Secure the e-Kit with six screws in the front plate (figure 28). If
using a power drill, torque setting must be set to 3 or 4 ONLY.
Use manual ideally.
Note: ONLY use the security screws provided when installing the
e-Kit. Any other screws will damage the kit and void warranty.
3.
Insert the e-Kit into the cavity, ensuring the wires are not
pinched between the interior duct and the e-Kit.
2.
Plug in the Cozy!4.
Pair the Cozy via the MAC Address barcode on the outside of
the e-kit and the Pairing Form on the Device Magic App on
your smartphone.
5.
Fig. 27
Locate and attach the two cables.
Insert e-Kit into cavity
Fig. 28
Secure the e-Kit with six security screws
and plug in the Cozy!
Cozy Installation GuideKelvin Systems, Inc.