A. O. Smith Recalls Ultra-Low NOx Water Heaters Due to Fire Hazard

What was recalled

In November 2018, the U.S. Consumer Product Safety Commission (CPSC) announced a significant recall involving specific gas-fired water heaters manufactured by A. O. Smith. This is not a vague or general alert; it targets a precise range of equipment designed to meet strict environmental standards. Specifically, the recall covers Ultra-Low NOx emission gas water heaters with capacities of 30, 40, and 50 gallons. These units were engineered to run on either natural gas or propane and were created primarily to comply with air quality regulations in certain districts within California. As a result, these particular models were sold predominantly in that state, though they may have been distributed elsewhere through various retail channels.

One of the most confusing aspects of any product recall is identifying exactly which of your appliances is affected, especially when multiple brand names are involved. In this instance, the manufacturing was widespread across several well-known household names. Consumers should check their units if they were purchased under the following brand labels: A. O. Smith, American, Kenmore, Reliance, State, U.S. Craftsmaster, and Whirlpool. It is important to note that even though these items carry different badges on the front, they share the same internal components and manufacturing timeline. The production window for these recalled units is quite specific: they were manufactured between April 8, 2011, and August 1, 2016. If your water heater was installed or purchased outside of this five-year window, it is likely not part of this specific safety alert.

The most critical factor in determining if your unit is included is the serial number. The recall does not apply to every model from these brands produced during those years; it is strictly limited by production date codes. You need to locate the data plate on your water heater, which is typically found next to the gas control valve or thermostat. On this plate, look for the first four digits of the serial number. These digits represent the year and week of production. The recall includes only those water heaters where the first four digits fall between 1115 and 1631. For example, a serial number starting with 1201 would indicate the first week of 2012, which falls within the affected range. Conversely, a number starting with 1701 would be outside the scope of this recall.

If you are unsure how to read your serial number or cannot find the data plate, do not guess. The manufacturers have established a dedicated resource to help consumers verify their status safely and accurately. You can visit www.waterheaterrecall.com and input your specific model and serial numbers into their lookup tool. This online system will immediately tell you whether your particular unit is subject to this recall. Until you have confirmed the status of your appliance through official channels, it is wise to treat any water heater matching these general descriptions with caution.

The hazard, explained

To understand why this recall is so serious, it helps to look at the specific mechanical failure that triggers the danger. Inside these Ultra-Low NOx water heaters is a component called the gas burner screen. Think of this screen as a fine mesh filter or shield designed to protect the rest of the unit and ensure the flame burns evenly and safely. Over time, due to manufacturing variations or material fatigue, this screen can develop tears or holes. When that happens, the protective barrier is compromised, allowing the gas burner to operate in an unintended way.

The critical issue arises from what happens next: excess radiant heat. Normally, the water heater’s design keeps heat contained within the combustion chamber where it belongs. However, when the screen is torn, the burner can create excessive radiant heat that escapes its intended path. This isn't just a minor efficiency loss; it is a significant thermal anomaly. The unit begins to emit more intense heat than it was designed to handle in its immediate surroundings.

This becomes a fire hazard specifically under one common installation condition: when the water heater is placed directly on a wood floor or other combustible surface. Standard building codes often allow gas appliances to sit on flooring materials like hardwood, laminate, or engineered wood, assuming the unit generates heat within safe limits. Because of the torn screen, the radiant heat from these specific A. O. Smith models can become hot enough to ignite that flooring over time. It is not an explosion risk in the traditional sense, but rather a slow-burn ignition risk where the floor material beneath the unit gradually reaches its flash point.

The Consumer Product Safety Commission (CPSC) has documented six reported fires linked to this specific failure mode. In every case, the water heater was installed directly on a combustible surface, which allowed the excess heat to do its damage. Fortunately, there have been no reports of injuries associated with these incidents. This suggests that while the potential for property destruction is real and immediate, the risk to personal safety depends heavily on how quickly the fire is detected and extinguished.

It is important to note that this hazard is not present in all gas water heaters. It is specific to the tear in the burner screen of these particular Ultra-Low NOx models. If your unit’s screen is intact, it is functioning as designed. However, because the tear can develop unpredictably and may not be visible without close inspection, the only safe course of action is to assume the defect exists until verified otherwise by the manufacturer.

Who is most at risk

When discussing who is most vulnerable in this specific recall, we need to look at the intersection of where these water heaters were sold and how they were installed. The primary group at risk consists of homeowners in California who purchased natural gas or propane-fired Ultra-Low NOx emission water heaters between April 8, 2011, and August 1, 2016. These units were manufactured specifically to meet air quality regulations in certain districts within the state, meaning that if you live outside of those specific California zones, it is highly unlikely you own one of these affected models unless you purchased it secondhand.

The danger is not inherent to every owner of an A. O. Smith, Kenmore, Reliance, State, U.S. Craftsmaster, American, or Whirlpool water heater from that era. It is strictly tied to the installation method. The most at-risk individuals are those who installed their unit directly on a wood floor or other combustible surface without proper protection. If your water heater is sitting on a concrete slab, a metal stand, or a non-combustible pad, the risk of this specific fire hazard is effectively neutralized because the excess radiant heat from the torn burner screen has no fuel source to ignite.

In terms of physical vulnerability, while no injuries have been reported in the six known incidents, any household with residents who may have slower evacuation times is at greater theoretical risk. This includes elderly family members or individuals with mobility challenges. A fire starting directly beneath a large tank can spread rapidly, potentially blocking exits or creating intense heat that rises quickly in a room. Children are also at higher risk due to their lower height; they would be exposed to the radiant heat and potential smoke inhalation sooner than an adult standing upright.

Furthermore, renters are often at a disadvantage here because they may not know where the data plate is located or might hesitate to inspect their landlord’s equipment. The brand name on these units varies widely, which adds a layer of confusion. A renter using a "Kenmore" branded unit might assume it is safe if they do not recognize the A. O. Smith manufacturing connection. Similarly, homeowners who bought refurbished units from local hardware stores or online marketplaces may have lost the original documentation that would have alerted them to the recall. These groups are particularly at risk because they may be unaware that their specific serial number falls within the dangerous range of 1115 to 1631.

Ultimately, the people most at risk are those who have ignored the warning signs or are unaware that their unit is part of this specific batch. The hazard develops over time as the gas burner screen tears. If you have owned your water heater for several years and have never had it inspected for this specific defect, you fall into the category of individuals who need to act immediately. The risk is not just about owning the appliance; it is about owning an unaddressed defect in a high-heat environment within your home.

How to tell if you have the recalled item

Before you take any action, it is crucial to confirm whether your specific water heater is part of this recall. Because these units were sold under several different brand names and manufactured over a five-year period, simply knowing the brand isn't enough. You need to verify the model number, the serial number, and the production date range. The brands involved in this recall include American, A. O. Smith, Kenmore, Reliance, State, U.S. Craftsmaster, and Whirlpool. If your water heater does not carry one of these specific brand names, it is likely not affected by this particular safety notice.

The most reliable way to identify your unit is by looking at the data plate. This metal or plastic tag is typically located on the front of the water heater, right next to the gas control valve and thermostat. On this plate, you will find three critical pieces of information: the brand name, the model number, and the serial number. The brand name is usually printed near the top of the unit, but the data plate holds the precise details needed for verification.

You are only concerned with natural or propane gas-fired Ultra-Low NOx emission water heaters that hold 30, 40, or 50 gallons. These units were designed to meet strict air quality regulations in certain California districts and were sold primarily within that state. The key identifier for inclusion in this recall is the serial number. Specifically, look for a four-digit serial number where the first two digits represent the year of production and the next two represent the week. Your unit is included in this recall if it was manufactured between April 8, 2011, and August 1, 2016. In terms of the serial number format, this corresponds to units with first four-digit serial numbers ranging between 1115 and 1631.

If you are unsure how to read these codes or want to be absolutely certain, do not guess. Visit www.waterheaterrecall.com and input your model and serial number into their lookup tool. This free online service will immediately tell you if your specific water heater is subject to this recall. Once confirmed, follow the instructions on that page or call the appropriate toll-free number for your brand to arrange for a free repair. Do not attempt to ignore the potential risk; verifying your unit is the first step toward keeping your home safe.

What to do — step by step

Your refund, repair, or replacement options

When you discover that your water heater is part of this recall, the most important thing to understand is that the manufacturer has provided a clear path to resolve the issue at no cost to you. A. O. Smith has committed to addressing the problem through repairs rather than offering immediate refunds or full replacements for every unit. This approach is standard for mechanical defects where a component can be safely updated, but it requires your active participation to initiate the process. The remedy outlined in the recall notice specifically mentions that consumers should contact A. O. Smith to determine if a free repair is necessary. This phrasing is crucial because not every recalled unit may require physical work; however, the determination of whether a repair is needed must come directly from the manufacturer after they verify your specific model and serial number.

To access these options, you cannot simply wait for a mail-in kit or a scheduled technician visit. You must take the first step by visiting the official recall website at www.waterheaterrecall.com. This portal is designed to help you input your model and serial number to confirm whether your unit is subject to this recall. Once you have confirmed that your water heater is included, you will use this same site to complete a form that initiates the claim process. By completing this form, you are essentially telling A. O. Smith that you own a affected unit and are requesting their assistance in making it safe. The company will then evaluate your specific situation to determine if a free repair is necessary and what that repair entails.

If you prefer to speak with a representative directly rather than using the online form, phone support is available, but it is vital that you call the correct number based on the brand of your water heater. The recall notice distinguishes between two groups of brands for customer service purposes. If your water heater was sold under the Whirlpool, U.S. Craftmaster, or American Water Heater brand names, you should call toll-free at 866-854-2793. Their support team is available from 8 a.m. to 10 p.m. Eastern Time Monday through Friday, and from 9 a.m. to 6 p.m. on Saturday and Sunday.

For owners of Reliance, State, A. O. Smith, or Kenmore brand water heaters, a different customer service line is provided. You should call toll-free at 866-880-4661 for more information and to arrange for your remedy. These representatives are available from 8 a.m. to 8 p.m. Eastern Time Monday through Friday, and from 9 a.m. to 6 p.m. on Saturday only. When you contact either of these numbers, be prepared to provide the brand name, model number, and serial number found on your data plate. This information allows them to quickly locate your records and explain exactly what free repair steps will be taken to replace or fix the gas burner screen that poses the fire hazard.

It is worth noting that the recall details do not explicitly mention cash refunds or full unit replacements as standard remedies for all cases. The focus is on determining if a free repair is necessary. This suggests that the goal is to correct the defect in place rather than remove the entire appliance. However, by following the steps above—whether through the website or phone—you ensure that you are covered under the manufacturer’s promise to fix the issue. Do not attempt to fix the burner screen yourself, as this involves gas lines and electrical components that require professional handling to maintain safety and compliance with air quality regulations.

What can happen if you ignore it

Ignoring a product recall is rarely a harmless oversight; in the case of these A. O. Smith Ultra-Low NOx water heaters, it transforms a manageable maintenance issue into a potentially catastrophic home safety crisis. The core danger lies in the specific way this hazard develops. The recalled units suffer from a degradation of the gas burner screen, which eventually leads to tears or holes in that protective mesh. When this screen fails, the burner no longer operates as designed. Instead of a controlled, even flame, the malfunctioning burner generates excess radiant heat. This is not just a minor efficiency loss; it is a significant thermal anomaly that places extreme stress on the immediate surroundings of the appliance.

The consequences of leaving this defect unaddressed are most severe when the water heater is installed directly on a combustible floor, such as wood, plywood, or other flammable materials. Under normal circumstances, these units are engineered to dissipate heat safely. However, with the torn burner screen creating hotspots, that excess heat can easily ignite the flooring beneath or immediately adjacent to the unit. This does not require an open flame to escape the appliance; radiant heat alone is sufficient to reach the ignition temperature of wood and other common building materials. Once the floor ignites, a fire can spread rapidly through the subflooring and into the walls, potentially trapping residents and causing extensive structural damage before it is detected.

While the official reports from A. O. Smith and the CPSC currently list six fires associated with this defect, relying on that number as a "safe" threshold is dangerous. Incident reporting often lags behind actual occurrences, and many small fires may be extinguished by residents before they are documented in national databases. More importantly, the potential for injury or loss of life increases dramatically with every day the recalled unit remains in service. A fire originating from a water heater can produce thick, toxic smoke and spread with terrifying speed, leaving little time for evacuation. Even if no injuries have been officially reported to date, the risk is not zero—it is actively growing with each passing hour the defect persists.

Beyond the immediate threat of structural fire, ignoring the recall also means you are forfeiting your right to a free repair. The manufacturer has committed to addressing this issue at no cost to you, but that offer will not last forever. By delaying action, you risk being stuck with an appliance that is both unsafe and expensive to fix out of pocket. The peace of mind that comes from knowing your home’s heating system is safe cannot be replaced by short-term convenience. The steps to verify your unit and schedule a repair are straightforward, but the cost of inaction—whether measured in dollars or safety—is far too high to ignore.

Staying safe: broader tips

While specific product recalls address immediate dangers in manufactured goods, the broader landscape of home safety requires a proactive and layered approach. Gas-fired appliances, including water heaters, are powerful tools that provide essential comfort but also demand respect due to their inherent risks. One of the most critical steps you can take is to ensure your living space is equipped with working carbon monoxide (CO) detectors. Carbon monoxide is an odorless, colorless gas that can be produced by incomplete combustion in gas appliances. Even when a unit is functioning correctly, minor malfunctions or ventilation issues can lead to dangerous buildup. Place CO alarms on every level of your home, especially near sleeping areas, and test them monthly. Replace the batteries at least once a year, or whenever the alarm chirps, and replace the entire unit according to the manufacturer’s lifespan recommendations—typically five to seven years—to ensure reliable protection.

Proper installation is another cornerstone of preventing fire hazards associated with gas water heaters. Many incidents occur because units are placed directly on combustible surfaces like wood flooring without a proper protective barrier. Building codes in many jurisdictions now require non-combustible floors, such as concrete or tile, beneath these units to prevent radiant heat from igniting the substrate. If your home has wooden floors, consult a licensed plumber or contractor to install an approved fire-resistant pad that meets current safety standards. This simple physical barrier can stop a potential fire before it starts, even if internal components of the heater begin to degrade over time.

Maintenance and vigilance are equally important. Regularly inspect your gas water heater for signs of wear, such as rust, corrosion, or leaks around the connections. If you notice a smell resembling rotten eggs near the appliance, leave the house immediately and call your gas company from a safe distance. Do not attempt to fix gas leaks yourself. Additionally, consider scheduling annual professional inspections. A qualified technician can check the burner assembly, venting system, and pressure relief valve to ensure everything is operating within safe parameters. Over time, sediment buildup in the tank can reduce efficiency and increase stress on the unit, so draining the tank annually can extend its life and maintain safety.

Finally, stay informed about product safety through official channels. Sign up for recall alerts from the Consumer Product Safety Commission (CPSC) or subscribe to email notifications from appliance manufacturers. This allows you to act quickly if a new hazard is identified in your home. By combining regular maintenance, proper installation practices, and awareness of broader safety resources, you create a resilient environment that protects your family far beyond the scope of any single recall.