Contents Page
1.0 User Instructions ............................................................................................................................................................ 2
1.1 Goldbird Models ................................................................................................................................................. 2
1.2 Bluebird, Kabin Pak and Whitebird Models ........................................................................................................ 2
1.3 Servicing ............................................................................................................................................................ 2
1.4 Components 50/70, 70/90, 90/120, 120/150, 150/200, 200/250 ........................................................................ 2
1.5 System Boiler ..................................................................................................................................................... 3
1.6 Components 50/90 Front Servicing Boiler
1.7 Components 300, 400 & 500 Industrial Boilers .................................................................................................. 4
1.8 Baffles ................................................................................................................................................................ 5
2.0 Introduction..................................................................................................................................................................... 6
2.1 General Requirements ....................................................................................................................................... 6
3.0 Dimensions ..................................................................................................................................................................... 7
3.1 Goldbird & Whitebird Models ............................................................................................................................. 7
3.2 Bluebird Models ................................................................................................................................................. 7
3.3 Industrial Bluebird Models .................................................................................................................................. 8
3.4 Kabin Pak ........................................................................................................................................................... 8
3.5 Kabin Pak Back Outlet ....................................................................................................................................... 9
3.6 Slimline Kabin Pak ............................................................................................................................................. 9
3.7 Flue Options ..................................................................................................................................................... 10
4.0 Installation..................................................................................................................................................................... 12
4.1 Service Access ................................................................................................................................................. 12
4.2 Hearth .............................................................................................................................................................. 12
4.3 Heating System ................................................................................................................................................ 12
4.4 Sealed System ................................................................................................................................................. 12
4.5 Air Vents ........................................................................................................................................................... 13
4.6 Drain Cock ....................................................................................................................................................... 13
4.7 Expansion Vessels ........................................................................................................................................... 13
4.8 System Filling ................................................................................................................................................... 13
4.9 System Pressure .............................................................................................................................................. 13
5.0 Electricity Supply ......................................................................................................................................................... 14
5.1 Dual Thermostat ............................................................................................................................................... 14
5.2 RDB Control Box .............................................................................................................................................. 14
5.3 Control Panel Wiring (Goldbirds) ..................................................................................................................... 15
5.4 R40 Control Box ............................................................................................................................................... 16
5.5 Installation of Optional Programmer ................................................................................................................. 16
5.6 System Wiring Diagrams (Goldbirds) ............................................................................................................... 17
6.0 Technical Data............................................................................................................................................................... 19
6.1 Goldbird, Whitebird & Bluebird ......................................................................................................................... 19
6.2 Industrial Bluebirds ........................................................................................................................................... 21
7.0 Air Supply ...................................................................................................................................................................... 22
7.1 Open Flue Boilers ............................................................................................................................................ 22
7.2 Balanced Flue Boilers ...................................................................................................................................... 22
8.0 Flues ......................................................................................................................................................................... 23
8.1 Conventional Flues .......................................................................................................................................... 23
8.2 Low Level Flues ............................................................................................................................................... 23
8.3 Installation of Flues .......................................................................................................................................... 25
9.0 Installation of Boilers ................................................................................................................................................... 27
9.1 120/150 & 150/200 White Casings................................................................................................................... 27
9.2 Industrial Bluebird Casings .............................................................................................................................. 27
9.3 Industrial Firebrick ............................................................................................................................................ 27
9.4 Kabin Pak Installations ..................................................................................................................................... 29
9.5 Standard Kabin Paks ....................................................................................................................................... 30
9.6 Kabin Pak Vertical Flue Adaptor....................................................................................................................... 30
9.7 Slimline Kabin Pak ........................................................................................................................................... 31
9.8 Slimline Kabin Pak Vertical Flue Adaptor ......................................................................................................... 31
10.0 Oil Supply ...................................................................................................................................................................... 32
10.1 One Pipe System ............................................................................................................................................. 32
10.2 Two Pipe System ............................................................................................................................................. 33
10.3 Deaerator System ............................................................................................................................................ 33
10.4 One Pipe Lift .................................................................................................................................................... 34
11.0 Burners ......................................................................................................................................................................... 35
11.1 RDB Burner ...................................................................................................................................................... 35
11.2 G10 Burner....................................................................................................................................................... 35
11.3 G20S Burner .................................................................................................................................................... 36
11.4 Oil Supply ......................................................................................................................................................... 36
11.5 Air Damper Adjustment .................................................................................................................................... 37
11.6 Electrode Setting .............................................................................................................................................. 37
11.7 Burner Start-up Cycle ....................................................................................................................................... 37
12.0 Servicing & Commissioning ........................................................................................................................................ 38
12.1 Commissioning................................................................................................................................................. 38
12.2 Servicing .......................................................................................................................................................... 38
13.0 User Instructions – Horstmann 626 Internal Programmer ........................................................................................ 39
14.0 Fault Finding ................................................................................................................................................................. 44
15.0 Spares ......................................................................................................................................................................... 45
15.1 RDB Burners 1 & 2 ........................................................................................................................................... 45
15.2 RDB 3 & 4 Burners ........................................................................................................................................... 46
15.3 R40 G10 Burner ............................................................................................................................................... 47
15.4 R40 G20S Burner............................................................................................................................................. 48
15.5 Boiler Parts List ................................................................................................................................................ 49
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