Complete Guide to Replacing Heating Elements in Aaon Units

      

Heating elements are essential to the performance of Aaon HVAC units, delivering consistent heating in commercial and industrial applications. Over time, these components can deteriorate due to heavy use, electrical issues, or harsh environmental conditions. When heating elements fail, efficiency drops, operating costs rise, and system reliability suffers. Understanding how to recognize early warning signs, prepare with the right tools, and replace faulty elements using genuine Aaon parts and Aaon replacement parts is key to ensuring long-term performance. This guide outlines common failure symptoms, preparation steps, replacement procedures, and mistakes to avoid when servicing heating elements in Aaon units.

Signs Your Aaon Heating Element Needs Replacement

Early detection of a failing heating element in Aaon units is crucial. Inconsistent heating, unusual odors, or tripped breakers often indicate the element needs inspection or replacement promptly.

1. Inconsistent Heating Output

One of the first signs of a failing heating element is inconsistent temperature output. You may notice certain zones are warmer or cooler than others, or the system struggles to maintain the set temperature. Uneven heating can indicate that one or more elements are partially burned out or failing to operate at full capacity. Over time, this inconsistency increases strain on other Aaon HVAC parts and reduces overall system efficiency.

2. Extended Heating Cycles

A functional heating element should bring the space to the desired temperature within a predictable timeframe. If your system takes longer than usual to heat, it may indicate the element is not producing sufficient heat. Extended heating cycles not only consume more energy but also signal that replacement may be needed to restore optimal performance.

3. No Heat Production

In severe cases, a heating element failure may result in the unit blowing cold air. While electrical issues could also cause this problem, a completely burnt-out element is a common reason for total heat loss. Inspecting the element and replacing it with genuine Aaon replacement parts ensures the unit resumes normal operation.

4. Visible Damage or Discoloration

During routine inspection, physical signs like cracks, burn marks, or discoloration on the heating element indicate wear and imminent failure. Such damage can compromise efficiency and, if ignored, may lead to further electrical or mechanical issues within the unit.

5. Unusual Odors

A deteriorating heating element may emit unusual smells, often due to overheating or insulation breakdown. Detecting burning or metallic odors should prompt immediate inspection, as continued operation under these conditions can pose safety risks.

6. Tripped Circuit Breakers

Faulty heating elements may draw excessive electrical current, causing breakers to trip frequently. This not only interrupts operations but also indicates potential hazards. Replacing the defective element with authentic Aaon parts resolves the issue and safeguards the system.

7. Error Codes on Control Panels

Modern Aaon units are equipped with diagnostic systems. Error codes related to heating circuits often indicate element malfunction. Always refer to the unit’s manual for accurate interpretation and act promptly to replace the affected element.

Tools and Preparation Before Replacing Aaon Heating Elements

Proper preparation is crucial before replacing heating elements in Aaon HVAC units. Using the right tools, safety gear, and genuine Aaon parts ensures a safe, efficient, and damage-free replacement process.

Essential Tools

  1. Screwdrivers and Nut Drivers: Required for removing access panels and securing heating element brackets.

  2. Multimeter: Used to verify the unit is de-energized and to test the heating element for continuity.

  3. Wrenches and Pliers: Helpful for loosening and tightening electrical connections and mounting hardware.

  4. Insulated Gloves and Safety Glasses: Protect the technician from electrical shocks and debris.

  5. Flashlight or Headlamp: Ensures visibility in low-light areas inside the unit.

Preparation Steps

  1. Review the Service Manual: Each Aaon unit may have unique configurations. Confirm specific instructions for your model.

  2. Shut Down and Isolate Power: Disconnect the unit at the main breaker and follow LOTO procedures. Verify the unit is fully de-energized with a multimeter.

  3. Allow the System to Cool: Heating elements can retain heat even after shutdown. Wait until components are safe to handle.

  4. Inspect Surrounding Components: Check for worn or damaged Aaon parts such as wiring, brackets, and insulation that may need replacement during the process.

  5. Organize Workspace and Parts: Keep tools, fasteners, and new components organized to streamline installation and protect delicate Aaon parts from damage.

Steps to Replace Heating Elements in Aaon Units

Replacing a heating element in an Aaon HVAC unit requires safety, the right tools, and genuine Aaon parts. Following proper steps ensures efficient operation, protects components, and minimizes downtime.

Step 1: Power Down and Ensure Safety

Before starting work, turn off the unit at the main breaker and follow lockout/tagout (LOTO) procedures. Confirm it’s de-energized with a multimeter, wear safety gear, and let the heating element cool to protect the technician and Aaon parts.

Step 2: Access the Heating Element

Remove the access panels carefully using screwdrivers or nut drivers. The heating element is typically located near the blower assembly or heat exchanger. Document the wiring configuration or take a photo for reference during reinstallation. Ensuring a clear, well-lit workspace prevents accidental damage to surrounding Aaon parts and allows for precise handling of the heating element.

Step 3: Disconnect Electrical Connections

Identify and carefully disconnect the wires from the heating element terminals. Label each wire to avoid confusion during reconnection. Inspect the wiring for signs of wear, corrosion, or damage. Replace any compromised wires with compatible Aaon HVAC parts to maintain proper operation and prevent future electrical issues.

Step 4: Remove the Faulty Heating Element

Loosen the mounting brackets or screws securing the heating element. Gently remove it from its housing, taking care not to damage adjacent components. Inspect the area for debris, mineral buildup, or corrosion. Cleaning the surrounding area ensures that other Aaon parts in the unit continue to function reliably after installation.

Step 5: Install the New Heating Element

Position the new, genuine Aaon replacement part in the same location as the old element. Secure it with the mounting brackets or screws without overtightening. Reconnect all electrical connections according to the earlier documentation. Ensure all wiring is tight, insulated, and properly routed to prevent shorts or loose contacts. Using authentic Aaon parts guarantees compatibility and long-term reliability.

Step 6: Reassemble the Unit

Reinstall the access panels and verify that all fasteners, brackets, and wiring are secure. Ensure no tools or debris remain inside the unit, as these could interfere with operation or damage other Aaon parts.

Step 7: Test the Heating Element

Restore power to the unit and monitor the startup sequence. Confirm that the element heats properly and that the unit reaches the desired temperature. Use a multimeter to verify that amperage draw matches manufacturer specifications. Observe for unusual noises, odors, or vibrations, which may indicate improper installation.

Step 8: Perform a Final Inspection

Ensure unobstructed airflow and consistent heating output. Inspect for leaks or loose connections and record the replacement in maintenance logs, including the part number and date. Regular inspections help protect all connected Aaon parts and maintain optimal system performance.

Common Mistakes to Avoid During Heating Element Replacement

Even experienced technicians can make mistakes when servicing Aaon HVAC parts. Avoiding these errors can prevent costly damage, extended downtime, or safety risks.

  1. Skipping Safety Protocols: Failing to shut off power or neglecting LOTO procedures can result in serious injury. Always verify that the unit is de-energized.

  2. Using Non-Genuine Parts: Installing off-brand heating elements may lead to compatibility issues, reduced efficiency, and premature failure. Always opt for genuine Aaon replacement parts for best results.

  3. Incorrect Wiring Connections: Miswiring the heating element can cause short circuits or damage to the control board. Carefully label and reconnect wires exactly as found.

  4. Overtightening or Undertightening Fasteners: Excess force can damage the element or mounting brackets, while loose fasteners may lead to vibrations and poor connections. Apply balanced torque when securing components.

  5. Ignoring Related Issues: Replacing the heating element without inspecting relays, contactors, or wiring can leave hidden issues unresolved. Always assess surrounding Aaon HVAC parts during the repair.

  6. Failing to Test the System Properly: Some technicians skip post-installation checks, but testing ensures the repair was successful. Always verify amperage, airflow, and heating output before declaring the job complete.

  7. Poor Recordkeeping: Neglecting to update maintenance logs can create confusion later. Recording the repair helps track service intervals and ensures future maintenance is timely.

By avoiding these mistakes, technicians can extend the lifespan of Aaon heating elements and ensure systems run safely and efficiently.

Replacing heating elements in Aaon HVAC units is essential for maintaining efficient, reliable heating in commercial and industrial settings. Recognizing early signs of failure, preparing with the right tools, and following a structured replacement process ensures optimal performance while protecting other Aaon parts. Using genuine Aaon replacement parts guarantees compatibility, safety, and long-term system reliability. Regular inspection and preventive maintenance of heating elements and related Aaon HVAC parts can extend the life of your unit, reduce energy costs, and prevent unexpected downtime. Proper care keeps your Aaon system running efficiently for years to come.

Find high-quality HVAC parts for heating, cooling, and ventilation systems at PartsHnC with fast delivery to keep your equipment running smoothly.

FAQ’s

1. What is the lifespan of an AAON HVAC unit?

AAON devices have an average life expectancy of 17 years when properly maintained and serviced.

2. How to know if a heating element is bad?

A defective heating element can be identified by watching the appliance's performance, such as insufficient heating, uneven cooking, or no heat at all, as well as conducting a physical inspection for visible damage such as cracks or scorching.

3. How to check HVAC heating element?

To check an HVAC heating element, turn off power, access the element, and test it with a multimeter for continuity. No continuity usually means the element is faulty.


Location: Chicago, IL, USA

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