Changing Components - Baxi Boston 2 80 RS Installation And Servicing Instructions

Changing Components – page 12
When changing components ensure that electrical and gas
supplies are isolated.
Before changing any components please read the
Important Information section on page 3.
THERMOCOUPLE
1) Remove the outer case front panel by pulling forwards at
the top and lifting upwards.
2) Turn off the gas supply at the service tap or at the ON/OFF
button on the gas valve.
3) Release the thermocouple nut at the side of the gas valve
(Fig. 15).
4) Release the thermocouple nut at the pilot bracket.
5) Re-assemble in reverse order of dismantling.
THERMOCOUPLE RE-ROUTE DEVICE
1) Remove the burner and controls assembly as described in
steps 1 to 6 - Servicing the Unit.
2) Remove valve heat shield.
3) Release thermocouple nut at the valve.
4) Disconnect the re-route nut.
5) Remove terminal cover and re-route device.
6) Re-assemble in reverse order of dismantling.
INJECTOR
1) Remove the burner and controls assembly.
2) Remove the burner securing screws and remove the
burner.
3) Unscrew the injector from the feed pipe.
4) Re-assemble in reverse order.
BURNER
1) Remove the burner and controls assembly.
2) Remove the burner securing screws and remove the
burner.
3) Re-assemble in reverse order.
BOILER THERMOSTAT
1) Remove the outer case front panel by pulling forwards at
the top and lifting upwards.
2) Remove the outer case top panel by pulling upwards.
3) Remove the two facia retaining screws (Fig 8) taking care
not to lose the two spacer washers and allow the facia to
swing forwards on its hinges.
4) Release the thermostat capillary from behind its retaining
clip and remove the thermostat phial from the boiler
(Fig 8).
5) Remove the screws securing the thermostat cover to the
facia.
6) Disconnect the three spade electrical terminals from the
thermostat.
7) Pull off the thermostat knob and remove the locknut
securing the thermostat to the facia panel.
8) Re-assemble in reverse order of dismantling ensuring that
the thermostat phial is replaced into the thermostat pocket.
GAS VALVE (Fig 15)
1) Remove the burner and controls assembly as described in
steps 1 to 6 - Servicing the Unit.
2) Disconnect the thermocouple nuts at the valve and at the
pilot bracket.
3) Disconnect the pilot feed pipe at the valve and at the pilot
bracket ensuring that the pilot injector is not misplaced.
4) Disconnect the electrode lead and remove the piezo unit.
5) Remove the screw securing the electrical terminal cover to
the gas valve. Disconnect the electrical connections.
6) Remove the valve complete with the heat shield and inlet
pipe by disconnecting the flanged burner feed pipe (Fig 7).
7) Disconnect the flanged inlet pipe. Retain the O rings for re-
assembly but replace if damaged.
8) Remove the heat shield by undoing the retaining screws.
9) Release the thermocouple re-route nut and remove the re-
route.
10) Individual sub components of the valve may be replaced
as outlined by Honeywell instructions.
11) Re-assemble in reverse order of dismantling:
INSULATION IN COMBUSTION BOX
1) Remove the burner and controls assembly as described in
steps 1 to 6 - Servicing the Unit.
2) Release the 2 screws securing the front insulation
assembly and remove the assembly (Fig 9).
3) Remove the two screws and air guides securing the two
side insulation panels (Fig 16) and carefully remove
diagonally through the door opening.
4) Remove the two screws and washers securing the back
panel insulation (Fig 16).
5) Remove the ceramic insulation pad from the front
insulation assembly by bending the securing tabs.
6) 50, 40 RS only - Remove the two sloping panels of
insulation adjacent to the heat exchanger by removing four
screws and washers. Ease out the bottom edge of the
insulation panel and slide down (Fig 16).
7) Replace insulation as necessary and bend down securing
tabs where applicable.
8) Re-assemble in reverse order of dismantling taking care
not to damage the new insulation.
PIEZO UNIT (Fig 15)
1) Remove the burner and controls assembly as described in
steps 1 to 6 - Servicing the Unit.
2) Disconnect the electrode lead at the piezo unit.
3) Remove the nut securing the piezo unit to the heat shield
and remove the piezo unit.
4) Re-assemble in reverse order of dismantling:
SPARK ELECTRODE (Fig 15)
1) Remove the burner and controls assembly as described in
steps 1 to 6 - Servicing the Unit.
2) Disconnect the electrode lead at the electrode.
3) Remove the nut securing the electrode and remove the
electrode.
4) Re-assemble in reverse order of dismantling.