CONQUEST 80 - User Manual

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CONQUEST 80®

SERVICE GUIDE

CONQUEST CONQUEST

GASUPFLOW GAS DOWNFLOW

GAS

FURNACE

BO+

Main Page

Table of Contents3
Introduction5
Upflow Low Profile Furnace5
Upflow/Horizontal Unit6
Downflow Unit6
Horizontal Unit6
Standing Pilot Burner and Hot Surface Igniter6
Heat Exchanger7
Lnshot Burner Assembly7
Induced Draft Blower Motor (IDM)7
Limit Switches8
Over Temperature Switches8
Remote Flame Sensor8
Cabinet8
Blowers8
Pressure Switch9
Gas Valve9
Unit Model Number Explanation10
Unit Serial Number Explanation11
Heatexchanger11
Equipment Application12
Unit Specifications12
Physical Data14
Accessories Ano Optional Equipment23
LP Conversion Kits23
Combustible Floor Base23
Return Air Cabinets23
Return Air Cabinet23
Conversion Kits23
Metal Base Plate24
Plenum Adapters and Coil Plenums24
Fossil Fuel Kits24
External Filter Frames24
Twinning Kits24
Sidewall Vent Kits24
Base Plate24
Installation Requirements25
Safety Rules Ano Helpful Information25
Installation Procedures26
Clearance Accessibility26
Base Plate Installation27
Dimensions: Downflow Units29
Dimensions: Horizontal Only Units and Upflow/Horizontal Units in the Horizontal Position30
Combustion and Ventilation Air31
Furnace Located in Unconfined Space Using Indoor Air32
Furnace Located in Aconfined Space32
Using Indoor Air for Combustion32
Using Outdoor Air for Combustion32
Unconfined Space Dimensions32
Indoor Air Opening Dimensions32
Outside Air from Attic/Crawl Space33
Outside Air Using a Horizontal Inlet & Outlet33
Vertical Outdoor Air Opening Dimensions33
Horizontal Outdoor Air Opening Dimensions33
Venting General Information34
Induced Draft Blower34
Furnace Category Information34
Retrofit Venting Instructions34
Vent Pipe Material34
National Fuel Gas Code Book34
Pre-Drilling Fan Collar34
Vertical Venting with B-Vent35
Dedicated Venting through Chimney with B-Vent35
Vertical Venting35
Vertical Vent Systems36
Special Vent System (S.V.s.)36
Typical Venting with "B-Vent36
Power Vent Systems37
Power Venter Installation37
Gas Supply and Piping38
Electronic Combustible Gas Detector38
Gas Pipe Installation38
Electrical Wiring40
Electrical Connections40
Thermostat40
Heat Anticipator Settings40
Low Voltage Wiring40
Isolation Relay41
Return Air Ducting and Supply41
Upflow Units42
Start-Up Proceoure42
Standing Pilot Models42
Electronic Ignition Models43
Pilot Positioning43
Sequence of Operation44
Electronic Ignition Gas Valve44
Furnace Twinning44
Honeywell Instructions44
Honeywell Twinning Connections44
UTEC Instructions45
UTEC Single Stage Twinning45
UTEC Two Stage Twinning45
Electrical Wiring47
Circuit Protection Sizing47
Operation48
Fossil Fuel Kits (Rxpf-E01)49
Location and Wiring49
Thermostat Operation49
Fossil Fuel Kit Plenum Switch49
Fossil Fuel Kits (Rxpf-F01)50
Location and Wiring50
Theromstat Operations50
Fossil Fuel Kits (Rxpf-F02)51
Location and Wiring51
Thermostat Operations51
Accessory Blower Time Delay Rxmd-Co251
Maintenance52
Filters52
Upflow Unit Filter Size Adjustment52
Filter Retaining Rods53
Horizontal Filter Installation53
Optional External Filter Racks54
Lubrication55
Burner and Heating Components55
Service and Troubleshooting56
Introduction56
Test Equipment56
Water Heater57
Installation and Service Checklist57
High Voltage Circuit58
Low Voltage Circuit58
Robertshaw and Honeywell Standing Pilot Fan Control Boards59
Fan Control Board59
Blower off Settings - Robertshaw Standing Pilot59
Blower off Settings - Honeywell Standing Pilot59
Standing Pilot Troubleshooting Guide60
Accessory Board61
Accessory (Baby) Board61
Fan Control Board Responses62
Integrated Furnace Control (Ifc)62
United Technologies (Utec)63
Lock out Status63
Soft Lock out Causes63
Hard Lock out Causes63
Self Healing63
UTEC Integrated Circuit Board63
Heat Assisted Limit Control (HALC)63
Low Thermostat Anticipation64
Control Board Characteristics64
Twinning Jumper Plug64
Control Responses65
Honeywell Circuit Board65
Voltage Spikes65
Honeywell66
Lock out Status66
Soft Lock out Causes66
Hard Lock out Causes66
Control Board Characteristics66
Control Responses66
Setting Blower off Controls67
Blower off Setting - Honeywell Integrated Circuit67
Blower off Setting - UTEC Integrated Circuit67
Blower Wiring Connections68
Field Installed Accessories68
Flame Sensing Current Switch Box Assembly68
Switch Box Operation68
Equipment Test Connections68
Switch Box68
Reasons for Burner Lockout69
Remote Flame Sensor Kit Installation69
Kit Components and Tools Needed69
Sensor Mounting70
Sensor Bracket Mounting70
Flame Sensor Mounting70
Sensor Splicing71
Measure Voltage at 2-Pin Molexcap for 110-120 Volts71
Measure Voltage from First Pin to Chassis Ground71
Measure Voltage from Second Pin to Chassis Ground71
Location of Wire Splice72
Measure Flame Sense Current Using Flame Sensing Current Switch Box72
Remote Flame Sensing Rod73
Flame Sensor73
Factory Installed Flame Sensor73
Reasons for Burner Lockout74
Integrated Furnace Control Board Replacement Kit74
Normal Installations74
Remote Flame Sensor Installation75
Twinned Installations75
Fossil Fuel Kits76
Twinned Units with Fossil Fuel Kits76
Present Control Descriptions and Troubleshooting76
Integrated Furnace Controls Used on Current Low Profile Gas Furnaces76
UTEC and Honeywell Controls76
Setting the Blower off Timings77
UTEC Led's77
Honeywell Led's77
UTEC-920/920A Blower off Timings77
Honeywell E2001 Blowerofftimings77
Flash Code78
UTEC 1012-925 Controls79
UTEC 1012-925 Furnace Control79
Motor Wire Connections80
Troubleshooting80
Indicator Lights80
UTEC 1012-925 Blower off Timings80
Integrated Furnace Controls Used on Current Low Profile Gas Furnaces81
UTEC 1028-927 DSI Furnace Control81
DSI Output Transformer82
IFC Troubleshooting Guide83
Control Responses89
Main Power "J" Box90
Blower Door Switch90
Controls90
Negative Pressure Switch90
Pressure Switch Settings90
High Limit Control91
High Limit Settings91
Heat Assisted Limit Control (Halc)92
Over Temperature Switch92
Heat Assisted Limit Switch Setting Temperatures92
Vent Safety Switch93
Over Temperature Switch93
Induced Draft Blower Vent Safety Switch Location93
Induced Draft Blower93
Transformer94
Blower Motor94
Induced Draft Blower Assembly94
Blower Dimensions94
Standing Pilot Control Board95
Standing Pilot 9-Pin Plug95
HSI Control 6-Pin Plug95
Furnace Gas Train96
Gas Valve96
Adjusting Gas Pressure96
Induced Draft Blower96
LP Conversion Kit96
Checking Line Gas Pressure97
Furnace Orifice Sizing98
Checking Furnace Input98
Orifice Sizes98
Hot Surface Igniters99
Direct Spark Igniters99
Hot Surface Igniter99
Direct Spark Igniter99
HSI Igniter99
Standing Pilot Burner100
Air Flow100
Pilot Hood Location100
Making Temperature Rise Check100
Co and Co2 Levels in Flue Gases101
Flue Gas Temperature Range101
Checking Flue Temperature101
Wiring Diagrams102
Service Analyzer Charts119
Remote Flame Sensor119
Review Questions123
Index125
Index of Figures127
Index Oftables128

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CONQUEST 80 Specifications

General

Brand	CONQUEST
Model	80
Category	Furnace
Language	English

CONQUEST 80 - User Manual

Table of Contents

CONQUEST 80 Specifications