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.