klover KL User manual

SICURO TOP SYSTEM BOILERS
MODELS: KL top - KLB top
TRADITIONAL BOILERS
MODELS: KL - KLB
INSTALLATION
USE AND MAINTENANCE
USEFUL ADVICE
User guide
S.R.L.
EN

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Dear Customer,
First of all we would like to thank you for choosing a
“KLOVER” boiler and we hope you will be satisfied with this product.
Read the warranty guarantee carefully, which is found on the last page
of this User guide; fill the attached warranty card in fully and send it
within 10 days from the date of purchase.
We would like to thank you again for trusting KLOVER products and we
also inform you that these models are the result of forty years
experience in the field of construction of solid fuel products (wood,
pellets).
Every single detail that composes the boiler has been realised by
qualified staff, using the most modern equipment.
The manual contains a detailed description of the boiler and its
functioning, instructions for proper installation, basic maintenance and
control points, which must be periodically performed; furthermore it
contains practical advice which helps to obtain maximum performance
from the boiler with minimum fuel consumption.
Enjoy the heat with KLOVER!

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DECLARATION OF CONFORMITY
The Manufacturer KLOVER s.r.l.
With head offices in Via A. Volta, 8
37047 San Bonifacio
Verona –Italy
Declares that the product:
Product name : Boiler
Type : Wood burning boiler
Models : KL top - KLB top
KL - KLB
Has been designed and built in compliance with standards in force
regarding the structure of the boiler, water tightness of the boiler body
and the electric parts.
In particular:
The overall heat output is greater than 75%;
The direct fluid heat output is greater than 45%;
The temperature of flue gas exiting the combustion gas outlet is no
more than 400 °C beyond room temperature;
The temperature of the rear and side external surfaces is no more
than 130 °C beyond room temperature;
The boiler complies with DM 1/12/1975 “Safety standards for
appliances containing hot pressurised liquids”.
We reserve the right to modify the appliance, for technical purposes,
remaining within tolerances foreseen by standards.
Therefore, the installer is excluded from all liability due to boiler faults
that do not derive from incorrect assembly of the same or from the
hydraulic plant that is not built in compliance with all Standards in force.
September 2004
The Sole Administrator
S.R.L.

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SICURO TOP SYSTEM BOILERS
MODELS: KL top - KLB top
TRADITIONAL BOILERS
MODELS: KL - KLB
S.R.L.

6
Copyright
All rights reserved. The reproduction of any part of this manual, in any form,
without the explicit written permission of KLOVER srl is forbidden. The
content of this manual can be modified without forewarning. Although we
have carefully collected and verified the documentation contained in this
manual, KLOVER srl cannot be held liable for how you utilise it.
Copyright © 2004 KLOVER srl
Latest revision: February 2012

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GENERAL INDEX
Introduction…………………………………………………. 9
Important security instructions…………………………......... 9
Some precautions……………………………………………… 10
Conventions used in the manual……………………………… 10
Dimensions and technical data……….……………......... 11
SICURO top wood-burning boilers……….…………............. 11
SERIE 2000wood-burning boilers………….…………………. 12
Technical features of wood-burning boilers…………..……… 13
Air vent…………………………………………………...14
Dimension and position........................................................ 14
Connections……………………………………………….....16
Hydraulic connection (SICURO top models)…….…...……...16
Example of connection (SICURO top models)……………… 17
Hydraulic connection (SERIE 2000 models)….…...……….. 19
Example of connection (SERIE 2000 models)….…...….……20
Electrical connection……………………………………………. 21
Electric control unit…………………………………………...... 22
Draught regulator assembly…………………………………... 27
Flue and connection to the same ……………………………. 28
Chimney……………………………………………………. 30
Commissioning……………………………………..............31
Filling the system.................................…………………........ 31
Filling the boiler (SICURO top models)…....….…...……….. 32
Ignition……………………………………………………........... 33
Anti-freeze protection………………………………………….. 34
Boiling (SICURO top models)...................…….…...………. 34
Boiling (SERIE 2000 models)……….…………….………….. 35
Maintenance…………………………………………………. 36
Cleaning the boiler body…………………………………........ 36
Maintenance of boiler body (SICURO top models)……...…. 37

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The wood to burn…………………………………………… 38
Troubleshooting…………………………………………..... 41
Useful advice……………………………………………...... 43
Notes……………………………………………………..…… 44
Warranty certificate………………………………………… 46

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INTRODUCTION
Important security instructions
Read these instructions before installing and using the
product.
Wood-burning boiler installation and commissioning must be
performed by skilled staff aware of the importance of
respecting the Safety Standards in force. They will be
responsible for the definitive installation of the machinery
and its consequent proper functioning.
KLOVER srl will not be held responsible if these precautions
are not respected.
During installation of the appliance all local regulations,
included those referring to National and European Standards,
must be followed.
Connect the product flue gas outlet to a flue that has the features
given in the Connections section in this user guide.
The appliance is not suitable for the installation on a shared flue
system.
If the flue should catch fire, you must be provided with
appropriate systems for damping down the fire or call the fire
service.
Connect the product to sockets with earth. Avoid using sockets
controlled by switches or automatic timers.
Do not use a damaged or worn power supply cable.
If a multiple socket is used, make sure that the total voltage of the
connected devices does not exceed that supported by the socket.
Furthermore make sure that the total voltage of all these devices
connected to the socket does not exceed the maximum level
accepted.
Do not use flammable substances to clean the appliance and its
elements.
Do not leave containers and flammable substance in the place
where the wood-burning boiler is installed.

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Do not use the appliance as incinerator or in any other way
different from that for which it has been designed.
Do not use fuels different to those which are recommended
Do not use liquid fuels
External surfaces of the appliance reach high temperatures when
it is running; operate with caution in order to avoid burns.
Only use original spare parts recommended by the manufacturer.
Do not perform any unauthorised modification to the appliance.
Some Precautions
Do not touch the hot components of the boiler (wood loading door,
flue gas exhaust outlet) during normal functioning.
Use the appropriate luminous button to switch the electrical panel
off. Do not disconnect the power cable while the boiler is running.
Keep children away from the boiler when it is running since they
could get burned by touching its hot components.
Children and inexperienced people are not allowed to use the
appliance
Conventions used in the manual
Danger due to boiler functionality
General danger for personal safety.
Danger for people and objects due to materials at high
temperatures.
Danger for people and objects due to electric power.
Burns hazard for people due to hot liquids.

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DIMENSIONS AND TECHNICAL DATA
Here below are the three fundamental views of the boiler useful to
check clearance and detailed dimensions.
SICURO top wood-burning boilers
mod. KL top - KLB top
MODEL
H
L
P
FLUE GAS
EXHAUST
h1
h2
p1
p2
WEIGHT
Kg
KL 29 top
1.500
650
650
160
1.300
1.000
1040
240
280
KL 40 top
1.500
650
650
180
1.300
1.000
1040
240
290
KLB 29 top
1.500
650
650
160
1.300
1.000
1040
240
290
KLB 40 top
1.500
650
650
180
1.300
1.000
1040
240
305
N.B.: measurements expressed in millimetres. KLOVER s.r.l. declines all liability for possible errors or
omissions.
1= SYSTEM FLOW 1” M GAS
2= DOMESTIC HOT WATER OUTLET (only mod. KLB top) 3/4” M GAS
3= BOILER LOADING 1/2” M GAS
4= DOMESTIC COLD WATER INLET (only mod. KLB top) 3/4” M GAS
5= SYSTEM RETURN 1” M GAS
6= BOILING EXHAUST 1” M GAS
7= BOILER EXHAUST 3/4” F GAS
LOADING INLET SIZE H x L 280 x 320 mm
COMBUSTION CHAMBER SIZE H x L x D 440 x 490 x 450 mm
H
Pp2
p1
h1
1 2 3 4 5 6
7
h2
SCARICOFUMI
F
L
H
Pp2
p1
h1
1 2 3 4 5 6
7
h2
SCARICOFUMI
F
L

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SERIE 2000 wood-burning boilers…Mod. KL - KLB
MODEL
H
L
P
F
h1
h2
h3
P1
WEIGHT
Kg
KL 29
1.250
650
650
160
1170
1000
270
840
265
KL 40
1.250
650
650
180
1170
1000
270
840
275
KLB 29
1.250
650
650
160
1170
1000
270
840
275
KLB 40
1.250
650
650
180
1170
1000
270
840
290
N.B.: measurements expressed in millimetres. KLOVER s.r.l. declines all liability for possible errors or
omissions.
1= OPEN VESSEL VENT VALVE 1” F GAS
2= SYSTEM FLOW (mod. KL 29, KL 40, KLB 29, KLB 40) 1 1/4” F GAS
3= DOMESTIC HOT WATER OUTLET (only models KLB SERIE 2000) 3/4” M GAS
4= DOMESTIC COLD WATER INLET (only mod. KLB SERIE 2000) 3/4” M GAS
5= SYSTEM RETURN (mod. KL 29, KL 40, KLB 29, KLB 40) 1 1/4” F GAS
6= BOILER EXHAUST 1/2” F GAS
LOADING INLET SIZE H x L 280 x 320 mm
COMBUSTION CHAMBER SIZE H x L x D 440 x 490 x 450 mm

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Technical features of wood-burning boilers
mod. KL top –KLB top –KL –KLB
*With boiler at 85°C
** BEECH WOOD fuel with NCV = 3,800 Kcal/Kg
*** With house insulated according to law 10/91. Heat requirement of 45 Kcal/m3
SICURO top LINE
SERIE 2000 LINE
KL
29
top
KL
40
top
KLB
29
top
KLB
40
top
KL
29
KL
40
KLB
29
KLB
40
NOMINAL HEAT
INPUT
KCal/h
KW
29.900
34,7
40.000
46,5
29.900
34,7
40.000
46,5
29.900
34,7
40.000
46,5
29.900
34,7
40.000
46,5
NOMINAL HEAT
OUTPUT
KCal/h
KW
24.800
28,8
33.200
38,6
24.800
28,8
33.200
38,6
24.800
28,8
33.200
38,6
24.800
28,8
33.200
38,6
OVERALL EFFICIENCY
%
83
83
83
83
83
83
83
83
WATER CONTENT
L
130
140
125
135
110
120
105
115
DOMESTIC HOT WATER
PRODUCTION *
Δt=25°C
/
/
18
L/min
20
L/min
/
/
18
L/min
20
L/min
RECOMMENDED
AMOUNT OF WOOD **
Kg/h
3 ÷ 10
3 ÷ 13
3 ÷ 10
3 ÷ 13
3 ÷ 10
3 ÷ 13
3 ÷ 10
3 ÷ 13
VOLUME HEATED ***
m3
550
735
550
735
550
735
550
735
COMBUSTION CHAMBER
VOLUME
dm3
97
97
97
97
97
97
97
97

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AIR VENT
Dimension and position
Modern houses are all equipped with hermetic fittings,
which do not allow any air to pass.
To burn one Kg of wood, approximately 15 m3 of air are
required (in closed hearth boilers).
If the combustion of the wood inside the combustion
chamber is perfect, the amount of carbon dioxide (CO2)
produced will be equal to that absorbed by a living plant
via the “chlorophyll photosynthesis” process.
The lack of oxygen leads to bad and incomplete
combustion, which only makes partial use of the wood's
energy and instead of developing carbon dioxide (CO2)
causes the formation of carbon monoxide (CO), a highly
toxic substance. Consequently it heats less and pollutes
more.
This is why an external air vent is absolutely necessary.
IMPORTANT:
Make an external air vent respecting the following
minimum passages:
Boilers up to 40,000 Kcal/h:
MINIMUM PASSAGE 600 cm2(DIAMETER 28 cm)

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If it is not possible to implement the air vent near the
boiler, make a hole in a perimeter wall where the boiler is
installed.
If it not possible to make the external air vent in the same
room where the boiler is installed, this hole can be made
in an adjoining room as long as this room communicates
permanently, by means of a transit hole the same
diameter as the air vent.
The UNI 10683 Standard PROHIBITS the withdrawal of
combustion air from garages, combustible material
warehouses, or from businesses where there is a fire
hazard.
If there are other heating or suction appliances in the
room, air vents must guarantee an air volume
necessary for the proper functioning of all devices.
Only sealed appliances (e.g. C type gas appliances,
according to the UNI 7129 Standard) or appliances
that do not cause a lower pressure compared with the
external environment can pre-exist or be installed in
the place where the boiler must be installed.
Extractor fan can cause operation problems to the boiler when
they are installed in the same room or space where the
appliance is found.

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CONNECTIONS
Hydraulic connection (SICURO top models)
The hydraulic connections must be made in a rational way using
the connections on the boiler template. To facilitate connection of
the pipes, we have prepared all hydraulic connections of the
heating and domestic hot water system on the rear.
The boiler can be coupled to any other boiler already installed in the
system; naturally it is indispensable to insert the due safety devices
and shut-offs according to the system used.
IF IT IS INSTALLED AS THE ONLY SOURCE OF HEATING, IN
ALL CASES IT IS DEEMED NECESSARY THAT THE SYSTEM IS
SUPPLIED WITH: CLOSED EXPANSION VESSEL, FILLING
UNIT, SYSTEM SAFETY VALVE (2.5 BAR). THE DOMESTIC
HOT WATER SYSTEM MUST BE EQUIPPED WITH A SAFETY
VALVE CALIBRATED AT 6 BAR.
N.B.: THE SYSTEM MUST BE DIMENSIONED WITH AVERAGE
FLOW TEMPERATURE OF 55°C.
THE BOILER MUST BE INSTALLED EXCLUSIVELY BY
QUALIFIED STAFF. SCRUPULOUSLY COMPLY WITH
THAT STATED IN THIS GUIDE;
ALL LIABILITY IS DECLINED FOR DAMAGE CAUSED BY
INCORRECT ASSEMBLY.
DO NOT PASS ELECTRIC CABLES IN THE IMMEDIATE
VICINITY OF THE FLUE GAS PIPE, UNLESS THEY ARE
INSULATED WITH SUITABLE MATERIALS.
IN THE CASE OF WATER WITH FIXED RESIDUE AT 180°C
THAT EXCEEDS 300 MG/L IT IS INDISPENSABLE TO
INSTALL A WATER SOFTENER UPSTREAM THE BOILER
INLET.

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ENTRATA ACQUA
FREDDA SANITARIA
SCARICO
EBOLLIZIONE
COLLETTORE
DI RITORNO
COLLETTORI
DI MANDATA
CALDAIA A GAS
Legenda: MANDATA IMPIANTO RITORNO IMPIANTO ACQUA FREDDA SANITARIA ACQUA CALDA SANITARIA VALVOLA DI ZONA VALVOLA MOTORIZZATA A 3 VIE VALVOLA DI RITEGNO VALVOLA A SFERA POMPA DI CIRCOLAZIONE
ZONA
1
ZONA
2
ZONA
3
CARICO CAMINO
TRAMITE GALLEGGIANTE
SFIATO
S.R.L.
S.R.L.
USCITA ACQUA
CALDA SANITARIA
ESEMPIO DI COLLEGAMENTO CALDAIA A LEGNA SICURO TOP - CALDAIA
E' NECESSARIO INSTALLARE SULL'IMPIANTO IDRAULICO DI RISCALDAMENTO UNGRUPPO DI CARICAMENTO, UN VASO DI ESPANSIONE CHIUSO ADEGUATO ALL'IMPIANTO E LE OPPORTUNE VALVOLE DI SICUREZZA. L'IMPIANTO SANITARIO DEVE AVERE UNA VALVOLA DI SICUREZZA TARATA A 6 BAR. (Se ritenuto opportuno si possono sfruttare i sopracitati componenti presenti nellacaldaia murale). Questo schema è puramente indiativo e non costituisce impegno o responsabilità alcuna daparte di KLOVER s.r.l. e dei suoi collaboratori. La progettazione esecutiva e la conseguente messa in opera dovranno essere realizzate nel rigoroso rispetto delle norme vigenti.

18
ENTRATA ACQUA
FREDDA SANITARIA
COLLETTORE
DI RITORNO
Legenda: MANDATA IMPIANTO RITORNO IMPIANTO ACQUA FREDDA SANITARIA ACQUA CALDA SANITARIA VALVOLA DI ZONA VASO D'ESPANSIONE CHIUSO VALVOLA DI SICUREZZA GRUPPO DI RIEMPIMENTO POMPA DI CIRCOLAZIONE VALVOLA A SFERA
ZONA
1
ZONA
2
ZONA
3
COLLETTORI DI
MANDATA
2,5 BAR
6 BAR
SFIATO
SCARICO
EBOLLIZIONE
CARICO CAMINO
TRAMITE GALLEGGIANTE
S.R.L.
S.R.L.
USCITA ACQUA
CALDA SANITARIA
Questo schema è puramente indiativo e non costituisce impegno o responsabilità alcuna daparte di KLOVER s.r.l. e dei suoi collaboratori. La progettazione esecutiva e la conseguente messa in opera dovranno essere realizzate nel rigoroso rispetto delle norme vigenti.
ESEMPIO DI COLLEGAMENTO CALDAIA SICURO TOP

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Hydraulic connection (SERIE 2000 models)
The boiler can be coupled to any other boiler already installed in the
system; naturally it is indispensable to insert the due safety devices
and shut-offs according to the system used.
SERIE 2000 MODELS MUST BE INSTALLED WITH AN OPEN
EXPANSION VESSEL.
THE SYSTEM MUST BE EQUIPPED WITH A SAFETY VALVE
CALIBRATED AT 6 BAR.
THE BOILER MUST BE INSTALLED EXCLUSIVELY BY
QUALIFIED STAFF. SCRUPULOUSLY COMPLY WITH
THAT STATED IN THIS GUIDE;
ALL LIABILITY IS DECLINED FOR DAMAGE CAUSED BY
INCORRECT ASSEMBLY.
THE NETWORK WATER INLET PRESSURE MUST NEVER
EXCEED 3 BAR; RECOMMENDED WORK PRESSURE: 1.2
BAR.
DO NOT PASS ELECTRIC CABLES IN THE IMMEDIATE
VICINITY OF THE FLUE GAS PIPE, UNLESS THEY ARE
INSULATED WITH SUITABLE MATERIALS.
IN THE CASE OF WATER WITH FIXED RESIDUE AT 180°C
THAT EXCEEDS 300 MG/L IT IS INDISPENSABLE TO
INSTALL A WATER SOFTENER UPSTREAM THE BOILER
INLET.

20
ENTRATA ACQUA
FREDDA SANITARIA
COLLETTORE
DI RITORNO
COLLETTORI
DI MANDATA
USCITA ACQUA
CALDA SANITARIA
Legenda: MANDATA IMPIANTO RITORNO IMPIANTO ACQUA FREDDA SANITARIA ACQUA CALDA SANITARIA VALVOLA DI ZONA VALVOLA DI RITEGNO VALVOLA A SFERA POMPA DI CIRCOLAZIONE
ZONA
1
ZONA
2
ZONA
3
SCARICO
VASO D'ESPANSIONE APERTO
CON GALLEGGIANTE
SFIATO
CALDAIA A GAS
S.R.L.
S.R.L.
Questo schema è puramente indiativo e non costituisce impegno o responsabilità alcuna daparte di KLOVER s.r.l. e dei suoi collaboratori. La progettazione esecutiva e la conseguente messa in opera dovranno essere realizzate nel rigoroso rispetto delle norme vigenti.
ESEMPIO DI COLLEGAMENTO CALDAIA A LEGNA SERIE 2000