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.



Kroll Kozy
Page 9
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.

Kroll Kozy
Page 10
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!
