Use and Care Manual

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CAUTION: The burner chamber is a sealed area.
If the burner access door is removed, the burner
access door gasket must be replaced. This should
only be done by a qualified service technician.
1. INSPECT SHIPMENT:
Inspect contents for possible missing or damaged
components. See Figure 1. This kit includes:
1 - Burner Access Door Gasket
4 - Speed Clips
4 - T20 Torx Head Screws
1 - Thermocouple
2. ADDITIONAL INSTRUCTIONS REQUIRED:
Refer to the Use and Care Manual supplied with the water
heater for complete information on the installation, lighting
instructions, operation and maintenance of the water heater.
3. SHUT OFF THE GAS SUPPLY:
Turn the temperature dial “counter clockwise”  to the lowest
setting. Shut off the gas supply to the water heater by
turning the gas cock knob “clockwise”  to the “OFF”
position. Turn off the gas supply at the main gas line.
Refer to the label located above the gas valve for additional
information on shutting off the gas supply.
5. REMOVE THE JACKET DOOR:
Remove the jacket door by grasping the round center of the
door and pushing inward and to the left or right to release
one side then release the opposite side and remove the
jacket door from the water heater.
6. REMOVAL OF CONNECTIONS TO GAS VALVE:
Unscrew the pilot supply tube, the thermocouple, the
burner supply tube, and unplug the ignitor wire from the
bottom of the piezo ignitor striker. See Figure 2.
7. REMOVAL OF T20 TORX HEAD SCREWS:
Remove the four T20 Torx head screws at the corners of the
Burner Access Door and discard.
You will need a #20 size TORX head tool.
8. REMOVAL OF BURNER ACCESS DOOR:
Remove the Burner Access Door Assembly. If removal is
difficult you can insert a flat head screw driver between
the door and the burner chamber and pry the two apart all
around the outside area of the burner access door.
Grasp the Burner Supply Tube and remove the burner
access door assembly from the burner chamber.
9. REMOVING THE THERMOCOUPLE:
Remove the thermocouple from the burner assembly by
cutting the wire with wire cutters and pulling it through the
orange grommet from the front side of the door.
Remove the remainder of the thermocouple from the
bracket by pulling firmly on the thermocouple. Then pull
the old thermocouple and remaining wire through from the
back of the burner access door assembly.
10. REPLACING THE THERMOCOUPLE:
Install the new thermocouple by pushing the metal tip of the
thermocouple thru the orange grommet as shown in Figure 3.
Take care not to damage the grommet or push it out as you
push the thermocouple through it.
Push the thermocouple into the thermocouple bracket until
it seats all the way into the bracket.
Do not bend the thermocouple within 1” of tip when
installing, as this may damage the thermocouple. See
Figure 4.
INSTALLATION INSTRUCTIONS
(FVIR) System Thermocouple Assembly Replacement Kit
Read these instructions thoroughly and understand all steps and procedures before
proceeding with the installation.
AP13277-1 (12/12)
1
Burner Access
Door Gasket
Thermocouple
T20 Torx Head Screws
Speed Clips
Figure 1
Figure 3
Push the thermocouple
through the hole in the
grommet where you pulled
the old thermocouple out.
Pilot Supply Tube
Piezo Ignitor
Wire
Thermocouple
Burner Supply Tube
Figure 2