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There are often a number of different causes for the same condition, so be sure to check them all -- even after you have identified the main reason for the problem. Some may be on the verge of developing, while others may develop right after you have fixed the primary cause. So play it safe...CHECK ALL CAUSES!
We recommend that you rely on an experienced professional plumbing and heating contractor for water heater installation and maintenance.

TO FIND SOLUTIONS, CHOOSE FROM THE LIST OF PROBLEMS BELOW:

For more information, view the following Service Manuals:
44943A (Conventional Vent Model)
45960A (Conventional Vent Model)

 

 

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    NO HOT WATER
    REASON
    		 REMEDY
    No power
    		 Check fuses or circuit breaker, replace or reset. Check with utility if necessary
    Wrong wiring connections at heater terminal Correct according to manufacture’s instructions
    Leaks around heating elements (1) Tighten element (2) If necessary, clean and replace with new gasket
    Loose wiring connection Locate loose connections. Clean carefully (remove all oxidation). Reconnect properly
    Lightning Inspect: (1) fuse (or circuit breaker). (2) Heater elements, and (3) thermostat, replace if necessary, see "grounding instructions" below
    High voltage Check utility for correction
    Short Locate short circuit and correct
    Wrong piping connections Reconnect pipes to proper fittings according to manufacture’s instructions
    Undersize service wiring Check with utility co. or electrician
    Improper calibration Replace thermostat
    Faulty thermostat Replace
    Faulty thermal cutout Replace
    Open thermal cutout Reset
    Top heating element burned out Replace

     

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    INSUFFICIENT HOT WATER
    REASON
    		 REMEDY
    Undersized heater Replace heater with one of adequate capacity (for future as well as present needs)
    Wrong wiring connections at heater terminal Correct according to manufacture’s instructions
    Leaking faucets, leaking heater nipples and or leaking tank drain Locate and correct
    Insulation improperly replaced Adjust insulation to original factory condition (add new insulation if necessary)
    Sediment or lime in tank Shut off power. Drain tank. Check to see if water treatment is necessary
    Lime formation on elements Clean elements, (replace if necessary) check to see if water treatment is necessary
    Thermostat not flush to and in contact with tank Position properly. Be sure insulation covers thermostat before replacing access panel
    Loose wiring connection Locate loose connections. Clean carefully (remove all oxidation). Reconnect properly
    Poor ground Install proper ground. See "grounding instructions" below
    Thermostat set too low Turn temperature knob to desired temp. (warm-120°F. normal-140°F hot-160°F.)
    Dip tube in hot water line Remove and replace in cold water inlet
    Wrong piping connections Reconnect pipes to proper fittings according to manufacture’s instructions
    Long runs of exposed piping Insulate piping
    Hot water piping in outside walls Insulate piping
    Faulty thermostat Replace
    Faulty thermal cutout Replace
    Open thermal cutout Reset
    Bottom heating element burned out Replace

     

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    SLOW HOT WATER RECOVERY
    REASON
    		 REMEDY
    Insulation improperly replaced Adjust insulation to original factory condition (add new insulation if necessary)
    Lime formation on elements Clean elements, (replace if necessary) check to see if water treatment is necessary
    Thermostat not flush to and in contact with tank Position properly. Be sure insulation covers thermostat before replacing access panel
    Loose wiring connection Locate loose connections. Clean carefully (remove all oxidation). Reconnect properly
    Poor ground Install proper ground. See "grounding instructions" below
    Thermostat set too low Turn temperature knob to desired temp. (warm-120°F. normal-140°F hot-160°F.)
    Dip tube in hot water line Remove and replace in cold water inlet
    Wrong piping connections Reconnect pipes to proper fittings according to manufacture’s instructions
    Excessive mineral deposits (1) Flush tank thoroughly. (2) Install water filter if necessary. (Tank should be flushed periodically)
    Improper calibration Replace thermostat
    Long runs of exposed piping Insulate piping
    Hot water piping in outside walls Insulate piping
    Faulty thermostat Replace
    Faulty thermal cutout Replace

     

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    OVERHEATED WATER-STEAMING
    REASON
    		 REMEDY
    Wrong wiring connections at heater terminal Correct according to manufacture’s instructions
    No relief valve Install new approved T & P valve (temperature and pressure) relief valve
    Thermostat not flush to and in contact with tank Position properly. Be sure insulation covers thermostat before replacing access panel
    Thermostat and elements not properly insulated Adjust insulation to cover thermostat and element terminal. (Add insulation if necessary)
    Short Locate short circuit and correct
    Thermostat set too high Turn temperature knob to desired temp. (warm-120°F. normal-140°F hot-160°F.)
    Wrong piping connections Reconnect pipes to proper fittings according to manufacture’s instructions
    Improper calibration Replace thermostat
    Faulty thermostat Replace
    Faulty thermal cutout Replace

     

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    HIGH OPERATING COSTS
    REASON
    		 REMEDY
    Undersized heater Replace heater with one of adequate capacity (for future as well as present needs)
    Leaking faucets, leaking heater nipples and or leaking tank drain Locate and correct
    Leaks around heating elements (1) Tighten bolts (2) If necessary, clean and replace with new gasket
    Insulation improperly replaced Adjust insulation to original factory condition (add new insulation if necessary)
    Thermostat not flush to and in contact with tank Position properly. Be sure insulation covers thermostat before replacing access panel
    Thermostat and elements not properly insulated Adjust insulation to cover thermostat and element terminal. (Add insulation if necessary)
    Poor ground Install proper ground. See "grounding instructions" below
    Short Locate short circuit and correct
    Thermostat set too high Turn temperature knob to desired temp. (warm-120¾F. normal-140¾ hot-160¾F.)
    Return circulating lines Recommend change to one pipe system
    Improper calibration Replace thermostat
    Long runs of exposed piping Insulate piping
    Hot water piping in outside walls Insulate piping
    Faulty thermostat Replace

     

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    DRIP FROM RELIEF VALVE
    REASON
    		 REMEDY
    Sediment or lime in tank Shut off power. Drain tank. Check to see if water treatment is necessary
    Excessive water pressure Install proper pressure reducing valve and proper pressure relief valve
    Surge from automatic washer solenoid valve Install blind pipe air cushion
    Improper calibration Replace thermostat
    Faulty thermostat Replace

     

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    EXCESSIVE RELIEF VALVE OPERATION
    REASON
    		 REMEDY
    Excessive water pressure Install proper pressure reducing valve and proper pressure relief valve
    Surge from automatic washer solenoid valve Install blind pipe air cushion
    Improper calibration Replace thermostat
    Faulty thermostat Replace

     

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    CONDENSATION
    REASON
    		 REMEDY
    Leaks around heating elements (1) Tighten bolts (2) If necessary, clean and replace with new gasket
    Insulation improperly replaced Adjust insulation to original factory condition (add new insulation if necessary)

     

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    TANK BULGED-REVERSED HEADS
    REASON
    		 REMEDY
    No relief valve Install new approved T & P valve (temperature and pressure) relief valve
    Excessive water pressure Install proper pressure reducing valve and proper pressure relief valve
    Surge from automatic washer solenoid valve Install blind pipe air cushion
    Check valve in water line
    		 Install proper pressure relief valve
    Pressure reducing valve installed in water line Install pressure relief valve or "T & P" (temperature and pressure) relief valve
    Faulty thermostat Replace

     

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    ELEMENT FAILURE
    REASON
    		 REMEDY
    Wrong wiring connections at heater terminal Correct according to manufacture’s instructions
    Loose wiring connection Locate loose connections. Clean carefully (remove all oxidation). Reconnect properly
    Lightning Inspect: (1) fuse (or circuit breaker). (2) Heater elements, and (3) thermostat, replace if necessary, see "grounding instructions" below
    Power surge Inspect: (1) fuse (or circuit breaker). (2) Heater elements, and (3) thermostat, replace if necessary, see "grounding instructions" below
    Low voltage Check utility for correction
    High voltage Check utility for correction
    Short Locate short circuit and correct

     

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    BLOWN FUSE OR CIRCUIT BREAKER CUTOUT
    REASON
    		 REMEDY
    No power
    		 Check fuses or circuit breaker, replace or reset. Check with utility if necessary
    Wrong wiring connections at heater terminal Correct according to manufacture’s instructions
    Loose wiring connection Locate loose connections. Clean carefully (remove all oxidation). Reconnect properly
    Lightning Inspect: (1) fuse (or circuit breaker). (2) Heater elements, and (3) thermostat, replace if necessary, see "grounding instructions" below
    Power surge Inspect: (1) fuse (or circuit breaker). (2) Heater elements, and (3) thermostat, replace if necessary, see "grounding instructions" below
    High voltage Check utility for correction
    Short Locate short circuit and correct
    Undersize service wiring Check with utility co. or electrician

     

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    SERVICE WIRES CHARRED OR HOT
    REASON
    		 REMEDY
    Wrong wiring connections at heater terminal Correct according to manufacture’s instructions
    No relief valve Install new approved T & P valve (temperature and pressure) relief valve
    Poor ground Install proper ground. See "grounding instructions" below
    Lightning Inspect: (1) fuse (or circuit breaker). (2) Heater elements, and (3) thermostat, replace if necessary, see "grounding instructions" below
    Power surge Inspect: (1) fuse (or circuit breaker). (2) Heater elements, and (3) thermostat, replace if necessary, see "grounding instructions" below
    High voltage Check utility for correction
    Short Locate short circuit and correct
    Undersize service wiring Check with utility co. or electrician

     

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    CONTINUOUS OPERATION
    REASON
    		 REMEDY
    Undersized heater Replace heater with one of adequate capacity (for future as well as present needs)
    Thermostat not flush to and in contact with tank Position properly. Be sure insulation covers thermostat before replacing access panel
    Thermostat and elements not properly insulated Adjust insulation to cover thermostat and element terminal. (Add insulation if necessary)
    Thermostat set too low Turn temperature knob to desired temp. (warm-120¾F. normal-140¾ hot-160¾F.)
    Return circulating lines Recommend change to one pipe system
    Improper calibration Replace thermostat
    Faulty thermostat Replace
    Faulty thermal cutout Replace

     

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    SINGING ELEMENTS PRODUCING NOISE
    REASON
    		 REMEDY
    Lime formation on elements Clean elements, (replace if necessary) check to see if water treatment is necessary

     

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    SINGING THERMOSTAT PRODUCING NOISE
    REASON
    		 REMEDY
    Thermostat not flush to and in contact with tank Position properly. Be sure insulation covers thermostat before replacing access panel
    Loose wiring connection Locate loose connections. Clean carefully (remove all oxidation). Reconnect properly

     

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    WET INSULATION
    REASON
    		 REMEDY
    Leaking faucets, leaking heater nipples and or leaking tank drain Locate and correct
    Leaks around heating elements (1) Tighten bolts (2) If necessary, clean and replace with new gasket

     

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    THERMOSTAT FAILURE
    REASON
    		 REMEDY
    No power
    		 Check fuses or circuit breaker, replace or reset. Check with utility if necessary
    Loose wiring connection Locate loose connections. Clean carefully (remove all oxidation). Reconnect properly
    Lightning Inspect: (1) fuse (or circuit breaker). (2) Heater elements, and (3) thermostat, replace if necessary, see "grounding instructions" below
    Power surge Inspect: (1) fuse (or circuit breaker). (2) Heater elements, and (3) thermostat, replace if necessary, see "grounding instructions" below
    Low voltage Check utility for correction
    High voltage Check utility for correction
    Short Locate short circuit and correct

     

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    SMOKING WIRING
    REASON
    		 REMEDY
    Lightning Inspect: (1) fuse (or circuit breaker). (2) Heater elements, and (3) thermostat, replace if necessary, see "grounding instructions" below
    Power surge Inspect: (1) fuse (or circuit breaker). (2) Heater elements, and (3) thermostat, replace if necessary, see "grounding instructions" below
    Low voltage Check utility for correction
    High voltage Check utility for correction
    Variable voltage Check utility for correction
    Undersize service wiring Check with utility co. or electrician

     

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    ODOR AND/OR TASTE IN WATER
    REASON
    		 REMEDY
    Gas from magnesium anode rod Replace with aluminum anode rod

     

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    FLUCTUATING TEMPERATURE
    REASON
    		 REMEDY
    Undersized heater Replace heater with one of adequate capacity (for future as well as present needs)
    Insulation improperly replaced Adjust insulation to original factory condition (add new insulation if necessary)
    Thermostat not flush to and in contact with tank Position properly. Be sure insulation covers thermostat before replacing access panel
    Thermostat and elements not properly insulated Adjust insulation to cover thermostat and element terminal. (Add insulation if necessary)
    Loose wiring connection Locate loose connections. Clean carefully (remove all oxidation). Reconnect properly
    Dip tube in hot water line Remove and replace in cold water inlet
    Wrong piping connections Reconnect pipes to proper fittings according to manufacture’s instructions
    Long runs of exposed piping Insulate piping
    Hot water piping in outside walls Insulate piping
    Faulty thermostat Replace
    Faulty thermal cutout Replace

     

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    RUSTY OR DISCOLORED WATER
    REASON
    		 REMEDY
    Sediment or lime in tank Shut off power. Drain tank. Check to see if water treatment is necessary
    Lime formation on elements Clean elements, (replace if necessary) check to see if water treatment is necessary
    Rusted supply lines (1) Thoroughly clean and flush entire system. (2) Replace rusted lines if necessary
    Water too soft Install (or replace) anode rod to protect tank
    Excessive mineral deposits (1) Flush tank thoroughly. (2) Install water filter if necessary. (Tank should be flushed periodically)
    Air trap in water system Locate and eliminate
    Dissipated anode rod Replace
    Faulty tank Contact your water softening supplier

     

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    RUMBLING OR POUNDING WATER HEATER
    REASON
    		 REMEDY
    Sediment or lime in tank Shut off power. Drain tank. Check to see if water treatment is necessary
    Lime formation on elements Clean elements, (replace if necessary) check to see if water treatment is necessary
    Return circulating lines Recommend change to one pipe system
    Excessive water pressure Install proper pressure reducing valve and proper pressure relief valve
    Gas from magnesium anode rod Replace with aluminum anode rod
    Surge from automatic washer solenoid valve Install blind pipe air cushion
    Check valve in water line
    		 Install proper pressure relief valve
    Pressure reducing valve installed in water line Install pressure relief valve or "T & P" (temperature and pressure) relief valve
    Wrong piping connections Reconnect pipes to proper fittings according to manufacture’s instructions
    Air trap in water system Locate and eliminate
    Dissipated anode rod Replace
    Faulty thermostat Replace
    Faulty thermal cutout Replace
    Spirits Kidding

    For more information, view the following Service Manuals:
    44943A (Conventional Vent Model)
    45960A (Conventional Vent Model)

    GROUNDING INSTRUCTIONS
    National electrical code requires two grounds: (1) to water system. and (2) to metal stake driven in ground. Be sure all wiring is sufficiently heavy. Connections are clean and secure. There is no excuse for poor grounding: Better to be safe than sorry.
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