Kroll Kozy manual 

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Kroll Kozy
Instruction Handbook
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Kroll Kozy
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Contents
Contents............................................................................................................................................ 2
Major Components............................................................................................................................ 3
Assembly of Your Kozy....................................................................................................................... 4
Installation ........................................................................................................................................ 4
Space Heating Principles ................................................................................................................ 4
Fitting The Flue .............................................................................................................................. 5
Operation & Starting ......................................................................................................................... 7
If using light oil eg: diesel [warning] ............................................................................................... 8
Turning off......................................................................................................................................... 8
Cleaning & Maintenance ................................................................................................................... 9
Exploded View & Part Breakdown ................................................................................................... 13
Components ................................................................................................................................ 14
Kozy Circuit Schematic ................................................................................................................. 16
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MajorComponents
Tip:
ThismanualwasNOTwrittenbyadeskboundtechnician.Itisin“plainEnglish”andeasyto
follow.
Pleasedon’tfileitwithallyourotherowner’smanualsand“onlyreaditwhenallelsefails”.
Pleasereaditrightthroughbeforeevencommencinginstallation.Takeadvantageofour
experienceandyou’llgetthebestoutofyourKrollKozy. Start by looking at the major components
below?



Kroll Kozy
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AssemblyofYourKozy
Removethesepartsfrominsidetheheater:Oiltank,pilotring,baffle,liftingrod,andvapourising
pans.Inthetankyouwillfindtheoilstrainer,auniversal“pickup”tool,theoilfeedline,a
masonrydrill,thealuminumcup,andattachedtothismanual,thefibrewasherthatgoes
betweentheoilfeedlineandthepump(plusaspare)
Theheatermustbeonalevelsurface.Thebottomoftheheatergetshotenoughtoscorcha
woodenfloor,soyoumustplacethedriptrayonapadofbricks,orsimilar,insuchacase.
Sittheheaterinthedrippan,sothewideendofthepanisundertheoiltank,orwhatwemight
callthebackoftheheater.Hangthestainlesssteelbaffleinsidetheheater,onthelipabovethe
flueoutlet.Hangthetankintotheslitsontherearpanel.(Atthebottomitshouldrestagainst
thesmallledge,notsitonit).Screwthepearfittingatthelowerendoftheoilfeedlineontothe
oilinletpipe,andtheupperend,usingthefibrewasher,tothepumpoutletunderthecontrol
box.Plugthefivepinterminalintothesocketatthebackofthecontrolbox.Makesurethe
waterdraincockisclosedandthatthealuminiumcupissittingfreelyinitsseat.Whenyoupress
itdownandup,youshouldhearthe“clickclack”ofthemicroswitchunderneathit.
Installation
SpaceHeatingPrinciples
Theprincipleofspaceheatingisthatyou“fill”yourbuildingwithabodyofwarmair.AsyourKroll
blowerfan“pulls”theheatoffthefurnaceandpushesitout,thehotairnaturallywantstorise.So
whilstthereissomeextrawarmthifyou’restandingsay3or4metresinfrontoftheblowerfan,
mostoftheheatisrisingbythen.
Asitbuildsupundertheroof,thewarmthgraduallyreachesbacktofloorlevel.
Inhighroofedbuildings,aslowturningceilingfanwhichpushesthewarmairdownwardscan
makeatremendousdifference.
MostIndustrialbuildingsarenotperfectlysealed,andyourKrollcancopewiththis.But,ifyou
havelargeventilatorssuckingtheairoutoranopenridgeintheroof,thentheheatwilleasily
escapeasquicklyasit’sgenerated.Ifyouwanttogetthebestfromyourheater,thenyou’llneed
toreducethisuncheckedheatloss.
ChooseaSafeLocation
BecauseoftheradiantheatgivenofffromthesidesandfrontofyourKOZY,itmustnotbelocated
withinonemetreofcombustiblematerial,suchaswoodenwallstuds.Attherearoftheheater,
thereisconsiderablylessradiantheat,so500mmclearanceisadequate.However,youwillneed
accesstothebacktofillthetank,andforroutinemaintenancefromtimetotime,sothiswillneed
tobetakenintoconsideration.
Certainly,highlyflammablematerialsuchaspetrol,thinners,paint,cardboardboxesandpacking
materialmustnotbestoredwithin3metresoftheheater.

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IfyouareusingyourKOZYwithouttheblowerfan,thentheradiantheatoutputishigherandALL
theaboveclearancesshouldbedoubled,tobeonthesafeside.
FittingTheFlue
Theheatermustbeconnectedtoa150mm(6”)diameterstainlesssteelflue,ofatleastfour
metresinheight.Itisimportant,becauseitcreatesadraughtwhichallowstheheatertoburn
properly,enablingsmokelesscombustion.
TheflueconsistsofaTpiece(whichtrapsanycondensationorrainwaterthatcomesdownthe
flue),somestraightsectionsandacowled“Chinaman’shat”ontop.Thetopoftheflueshouldbe
infreeair.Thecowledhatensuresthatthedraughtislessaffectedbystrongwinds.Thetopofthe
flueshouldextendatleastonemetrethroughtheroof.Ifit’sneartheridge,halfametrewilldo.
Wheninstallingtheflue,itispreferabletomaintainagoodupwardsslope,butifyoumusthavea
horizontalsection,itmustnotexceedonethirdofthetotalfluelength.
BecauseyourKozyisnotatemperamentalheater,youcanbendtheseguidelinesabit,butit’sbest
toadheretothemwherepossible.Ifindoubt,consultyourdealer.
Ifthelengthofyourflueismorethan5or6metres,it’spossiblethatthedraughtwillbetoo
high.Thismeanstoomuchheatmaybe“sucked”outofyourKOZY,andlostuptheflue.Thiscan
beeasilyfixedbyfittingasimpledraughtcontroldevice
Werecommendthattheoverlaponthefluesectionconnectionsissuchthatanymoisturefrom
condensationrunningdowntheinsideofthefluedoesnotleaktotheoutside,becauseitwill
causeunsightlystreaks.Iftheappearancedoesn’tbotheryou,suityourself.Airtightflue
connectionsarenotcritical.Forjoinsoutsidetheroof–usesilastictostopwaterenteringtheflue
atthejoint.Theheatandupwardsmovementofthefluegasmeansthepressureintheflueis
slightlylowerthanthepressureoutside,sofluegasdoesn’tleakout.Butyoushouldn’thavebig
gaps,ortheairwillbedrawninandaffectyourdraught.
Thefluegetsveryhot.Ifyou’regoing
throughaceiling,youmustusea
doubleskinnedflueforthatsection.
Ifyourflueislikelytobetouchedby
thegeneralpublic(kidsinparticular),
westronglyadviseaheatshield.In
fact,werecommenditforalmostall
installations.
Foraweatherproofsealwherethe
fluegoesthroughtheroof,we
recommendaDEKTITEDFS160220
RE“rubber”roofcollar.We
recommendtheSILICONERED
dektite,ratherthattheblackone,as
ithasabetterheatandUV

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resistance.
Youshouldstraporsecureyourfluetosupporttheverticalweight,soit’snotbeingsupportedby
theheater.Notonlydoesthistaketheloadofftheoutletspigot(whichcouldotherwiseeventually
distort),butitenablesyoutotakeyourheaterawayinSummerandjustleaveallorpartoftheflue
hangingthere,ifyouwish.




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Operation&Starting
1 Plugitin(240V).
2 .Usingtheliftingrod,loweracleanvapourisingpanintothe
burnerbasin,pasttheoilinletpipe.Rotateit90or180°and
placeasshownindiagramtotheright.Theinletpipemustnot
beoverthepan’s‘V’notch,sothattheoildrippingfromthepipe
landsonthepansurfaceNOTthebottomoftheburnerbasin!
. 
3 Makesurethatthewaterdraincockisclosed,putoilinthetank(alwaysthroughthestrainer)
andopenthemainstopcock[fig2,overleaf]atleast2or3fullturns.Keepinmindthatreally
thinoilcanseepthroughthegearpumpevenifit’snotrunning,somakesurethatyouclosethe
stopcockwhenyouswitchtheheateroff.

4 Pour1/3ofalitre[2coffeemugsapproximately]ofstartingfluidintothepan.Useasuitable
container,andreachdownintotheheatersoitdoesn’tsplashoverthesideofthepan.For
startingfuel,youcanusestraightkerosene,dieselorheatingoilor,anyoneofthese,mixedwith
wasteoilalsoworkswell.Makeupabatchofit,soyoudonothavetodoiteveryday.
5 Usingthehalfcircleontheliftingrod,seatthepilotringontheindentedledgeintheburner
basin.(Ifyoupictureitasaplate,itgoesinupsidedown)
6 Thegearpumpinthemotormount[fig1,below]mustbeseton‘LO’forstarting.Toensure
properengagement,youmayneedtoreachunderthecontrolboxhousingandturnthe
pump/motorconnectionalittle,untilyoufeeltheleverdropintoplace.

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7 Putasmallpieceofrag(about100mmx100mm)inthejawsofthesuppliedpickuptool,dipit
inthepan,lightit,anddropitbackintothepan.Youwillgetalittlebitofsmokefromthis,but
notforlong.
8 Placethecastironlidontop.
9 Switchtheon/offswitchtoON.[Pushthe
switch‘1’positiondown]
10 Afterabout10minutes,thestartingfuelwill
generateenoughheatforthethermostatto
switchontheoilpump,theblowerfanand
theindicatorlightonthecontrolbox.When
startingyourKOZYforthefirsttimeonly,
you’llgetsomesmokefromthenewpaint,
butitwon’tlastlong.Whentheheaterisup
andrunning,youcanpeekthroughthehole
inthelidandseethefingersofflame
burning,likegasjetsaroundtherimofthe
burnerbasin.
11 LeavetheKozyonLOfor20minutes.ThenyoucanswitchittoHIifdesired.Whenchanging
betweenHI&LO[highandlow]whileheaterisrunningholdtheleverstraightandfirmly,and
sortof“feel”yourwayup,acrossanddown,toensureproperengagement.(Ifyoudon’tyou
won’trealizethepumpisnotworkinguntilthefiregoesoutabout15minuteslater).
Ifusinglightoileg:diesel[warning]
Ifrunningonstraightheatingoilordiesel,useonlyontheLOsetting.Becausethisoilissothin
comparedtowasteoil,itwillflowthroughtheoilpumpatafasterrate.Thiscancauseyour
KOZYtorunmuchtoohotandshortenitslife.Ifyouwouldliketousedieselfuelorheatingoilin
yourKOZY,wehavetworecommendations.

� Proptheblowerfanlidopenabout150mmwithanoncombustibleprop,(suchasapieceof
steel)toenablethefantodrawinsomecoolerair.

� Thestopcockisnotusuallyusedasameteringdevice.Itisusuallyfullyopenorfullyclosed.
However,youcanrestricttheflowbyfindingapartialopeningpointwherethepumpis
deliveringabout2litresanhour.UseLOWonly.
Turningoff

Runonthe‘LO’settingfor20minutesbeforeturningoff.Toturntheheateroff,puttheswitchin
theOFFpositionandclosethemainstopcock.Afterabout15minutes,theflamewillgooutand
theheaterwillgraduallycooldown.Whenitdoes,thethermostatwhichswitchedtheblowerfan
on,willswitchitoff.



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Cleaning&Maintenance
Whenyouburnwasteoilinyourkroll,thereisnosmokeorfumes,butyouwillgetanaccumulation
ofashinthevapourisingpan.Theamountofashyougetdependsuponhow“dirty”yourwasteoilis
–eg.Verythick,blackoilfromolddieselenginesleaveslotsofash.Usedtransmissionoilleavesvery
little.

Onatypicalday,beforestartingyourheater,youwilltakeout“yesterday’span”andputintheclean
one.Atsomeconvenienttime,youcancleanyesterday’span,readyfortomorrow.

Ifyouarefindingsomeoftheashisdifficulttoremove,youcan,afterscrapingoutthe“easy”stuff,
placeyesterday’spanbackintheheater,onitsside,ontheledge.Theheatturnsthatstubborn
carbonintoawhitishpowderwhichiseasytoremove.

TheprincipleofoperationofyourKOZYisthatwasteoiltricklesontotheveryhotcastironpanand
vapourises.Ifthereisathicklayerofashandsolidcarboncoveringmostofthesurface,thentheoil
willnotvapouriseproperlyandyouwillgetincompletecombustion,wetoil,smokeandamess
insideyourburnerbasin.

So,it’simportantthatyoucleanthepansproperly.

Youalsoneedtoworkouthowmuchashaccumulatesinthepaneachday.Ifthepanistoofulland
thereisabitofwetoilpresent,youmayneedtoswitchitoffearliereachdayand/orrunitonLOW
only.Iftheburnerbasinneedstobecleaned,becauseofexcessivebuildupinthebottomandonthe
wall,thebestwayistotakeitoutoftheheater.Thisisnotadifficulttaskifyoufollowthesesteps:
1. Unplugthepoweratthepowerpointanddisconnectthefivepinterminal.
2. Removetheoilfeedline,takingcarenottolosethefibrewasher.
3. Removethealuminiumoverflowcup.
4. Removethepanitsitsin,butplaceitaside
carefully,becauseitisstillattachedtothe
combustionfan.
5. Removetheoilinletpipeandgasket,which
isheldtothebackoftheburnerbasinby
two6mmnuts(10mmsocketrequired).
6. Removethethreephilipsorhexhead
screwsaroundtherimoftheburnerbasin,
andliftitstraightup.It’spossiblethatthe
threescrews(twoontherim,andoneon
thesmallrectangularplate),have
deterioratedintheheat,andyoumayhave
todrillthemout.

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Whenrefittingtheburnerbasinitisveryimportantthatitisscreweddownagainandsealsfairly
wellaroundtherim.
Thecombustionairthatisbeinginducedintothecavityaroundtheburnerbasinmustgo
throughtheholesintheburnerbasin
to
ensuregoodcombustion.Ifthis
combustionaircanfindaneasierpath
aroundtherim,yourKOZYwillnot
burncleanly.

This“major”cleaningoftheburner
basinshouldnotbenecessarymore
thanonceortwiceeachwinter.

Also,dependingonyourwasteoil,
youmayneedtoreamouttheoilinlet
pipeusingthemasonrydrillsupplied.
Carbonwillbuildupinside,starting
withthehotend,eventuallyblocking
itcompletely.Toreducethisbuildup,
eachtimeyou’retakingoutthepan,poketheendoftheliftingrodintothepipe,andjiggleit
aroundabit.

OnceortwiceeachWinter,itwillprobablybenecessarytoremovethebignut,andrunthe
masonrydrillthroughfromtheoutside.

Youshouldalsopokeastiffpieceofwirethroughtheoverflowpipeoccasionally,tomakesure
it’snotblocked.Ifyoursilveroverflowcuphasanyoilinit[duetoacrackedpanforexample]
youmustalsocleartheoverflowpipe.Theoverflow pipeisthesmallerpipejustabovetheoil
inletpipeandthepipeMUSTBECLEARtofunctioncorrectly!


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SludgeBuildUpInTank
Dependinguponthequalityofyouroil,youmaygetagradualbuildupofsludgeinthebottom
ofyourKroll’soiltank.Werecommendthatattheendoftheseason,yourunthetankempty,
removeitfromit’smount,andflushoutthesludgewithabitofkerosene.Leaveitemptyover
Summer.
InspectPansRegularly
Thecastironvaporisingpansshouldlast2or3Wintersdependingonusage.Harshtreatmentor
droppingthemcanshortentheirlife.DONOTUSECRACKEDORBADLYDISTORTEDPANS.
AFEWTIPSONOILQUALITY
YourKrollKozywillburnjustaboutanykindofoil,butthebetteritis,thelessmaintenanceyou
havetodoonyourheater.
Thebestwasteoilistransmissionoil.Theworstisfromdieselenginesthatdoalotofwork
betweenoilchanges.OilfromdieselsisOKifit’sbeenchangedregularly,butifit’svery,very
dirty,thenitwillleavealotofash.Buteventheworstoilcanbeused,ifit’smixedwithbetter
wasteoil,orsay10to1withnewdieselfuelorheatingoil.Alternatively,ifit’sallowedtosettle
for6weeksorso,thetophalfbecomesquitegoodanditgetsprogressivelyworseasyougo
down.SowesuggeststoringyourwasteoiloverSummer,soitsettles,andthendiscardingthe
last10%orso,ofeachdrum.Thisgetsridofexcessivewateralso.
YourKrollisfairlytolerantofabitofwaterintheoil,butit’sbesttocheckanddrainitoff
throughthewaterdraincock,onaregularbasis.
Italsopaystocheckboththefansforbuildupofdirtandlintontheblades,andcleanthemif
necessary.
Malfunctions
#1Heaterwon’t“cutin”beforethestartingfluidburnsout.
Theoverflowcupmayhavesomeoilinit,causingittopressdownonthemicroswitch.Oilcan
accumulategraduallyinthecupfrom“splashing”insidethefurnace,orifspillageoccursdown
thebackoftheheaterwhilefillingthetank.
� HeaternotswitchedonatPowerPoint,orattheON/OFFswitch.
� Notenoughstartingmixture.
� Faultythermostat.Thisismostunusual,butitcanhappen.
#2theHeater“cutsin”,butthefiresdiesoutsoonafter.

� Mainstopcockstillclosed.
� Toomuchwaterinthebottomoftheoiltank.
� TankEmpty.
 

Kroll Kozy
Page 12
� 
� High/lowselectornotengagedproperly.Youcancheckifthepumpisturningbyfeeling
underthecontrolboxwithyourfinger,afterthethermostathasstartedthemotor.
� Gritinpump.Thishappensquiterarely,becauseanythingthatwillgothroughthetank
strainerwillgothroughthepump.Butifabitofoilslopsinoverthesideofthestrainer,
it’spossiblesomegritcanjamthepump.Usuallyyourattentionisdrawntothisbecause
itmakesagraunchingnoise.Sometimesyoucanfreeitupbyswitchingitoff,then
turningthepumpbackandforthbyhand.
� d)Blockedoilinletpipe.Seethe“Cleaningandmaintenance”.Ifyoususpectthatthisis
theproblem,takecarewhenunscrewingtheoilfeedline,becauseitmaycontainhotoil
underslightpressure.
#3Heaterwasrunningokbutgoesout.

� TankEmpty.
� OilinoverflowcupSee1(a).
� Gritinpump–See2(a)
� Toomuchwaterinoil.Unevenburningandahissingsoundaresignsofwater.

#4Oilisgettingunderthevapourisingpanand/ortheashinthepaniswetandtarlike
insteadofdryandcrusty.

� Thisindicatesincompletecombustion,whichcanbecausedby:
� Insufficientdraught.Istheflueingoodconditionandbreathingfreely?Verystrong
windscansometimescauseadowndraught.Aspecialantidowndraughthatmaybe
requiredinextremecases
� Combustionfanfaulty.Isitspinningnormally?Doesitneedcleaning?It’ssurprisinghow
lintanddirtcanbuildup.Removefanforthoroughcleaning.
� Noncombustiblewasteoil.It’srarebutsomemodernsyntheticoils,don’tburnwell.A
goodtestistodrainthetankandtryagainwitha“known”batchorwasteoil.
� Crackinpan.Inspectclosely.Evenaveryfinecrackwillopenupathightemperatures.
Crackedordamagedpansmustnotbeused.
� Holesinburnerbasinblockedpreventingadequateflowofcombustionair.
� Splitor“burnedaway”burnerbasin,allowingexcessiveandunevencombustionair.
� Toomuchashinpan.It’ssimplyoverflowing.SeeMAINTENANCE.Youmayneedto
reducetherunningtimebetweenswappingpansand/orrunonlyonLOW.
� Somecontaminantsinwasteoilcancausetheashto“frothup”wheretheoilhitsthe
pan.Thisashcanspillovertheedge,eventhoughthepanisnotfull.Toovercomethis,
� putabitofsteelorsomesuitablepackingofabout3mmthickness,underthepansoit’s
slopingawayslightlyfromtheinletpipe.

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ExplodedView&PartBreakdown

Kroll Kozy
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Components
Componentparts AustralianKrollPart#GermanPart#
1 Blower Fan assembly 000062
2 Cover right 001465
3 Cover left 001466
4 Fan assembly complete K11 005319
5 Bearing stocktaking K16 005524
6 Ballbearing K15 005338
7 Turbine K13 005384
8 Capacitor 2 µF K14 005385
9 Seal 005523
10 Coupling (8 mm) 005315
11 Blower Fan Motor K12 005382
12 Compression spring 005381
13 Connecting strip 022255
14 Cable K20 006451-01
15 Cover K30 001856
16 Cover plate 001823
17 Pilot ring K02 011641
18 Burner basin K01 011639
19 Oil chamber K03 001455
20 Cover plate for oil chamber 001824
21 Baffle K42 001822
22 Combustion chamber cpl. 001457
23 Perforated plate right 001810
24 Perforated plate left 001812
25 Cable channel 047208
26 Perforated plate left 001811-01
27 Fan insulating K08 011649
28 Combustion air fan K07 001837
29 Gasket for #28 K04 005386
30 Oil inlet pre assembled K31 000720
31 Fiber seal K06 049594
32 Oil feed line K19 000954
33 Drip pan 001813
34 Cover 001825
35 Tank complete assembled 000716-01
36 Adjusting knob K28 036504
37 Connecting rod 000956
38 Tank cover 0001827-01
39 Strainer K22 001460
40 Tank 000950-01
40a
Water drainage cock 005251
41a
Overflow protection cpl. 000719

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Page 15
Componentparts AustralianKrollPart# GermanPart#
41 Overflow protection cpl. K23 000718
42 Aluminium cup K10 005252
43 Strip terminal 006488
44 Thermostat 005439
45 Microswitch 025317
46 Spacer 006556
47 Holder for overflow protection 001461-01
48 Cable strain relief 006463
49 Cable strain relief 006464
50 Power cord with plug 006453
51 Motor mount complete K26 000952
52 Cable strain relief 006464
53 Motor mount chassis 000952
54 Indicator light yellow K40 006502
55 Rocker switch K29 006529
56 Motor/Gearbox for #51 K27 005351
57 Clutch disk slit 006339
58 Clutch disk with peg 006340
59 Lower adapter K05 011647
60 Gear pump K25 005513
61 Upper adapter K32 011646
62 O - ring K45 003370
63 Power cord with plug 06448
64 Jack 5-pol. K35 006404
65 Jack 3-pol. K36 006402
66 Pickup tool K33 000949
Slag solvent 000721

Kroll Kozy
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KozyCircuitSchematic

Kroll Kozy
Page 18