CONQUEST 80 Manuals

Manuals and User Guides for CONQUEST 80. We have 1 CONQUEST 80 manual available for free PDF download: Service Manual

CONQUEST 80 Service Manual (130 pages)

GAS UPFLOW, GAS DOWNFLOW

Brand: CONQUEST | Category: Furnace | Size: 17 MB

Table of Contents
3
Introduction
5
Upflow Low Profile Furnace
5
Upflow/Horizontal Unit
6
Downflow Unit
6
Horizontal Unit
6
Standing Pilot Burner and Hot Surface Igniter
6
Heat Exchanger
7
Lnshot Burner Assembly
7
Induced Draft Blower Motor (IDM)
7
Limit Switches
8
Over Temperature Switches
8
Remote Flame Sensor
8
Cabinet
8
Blowers
8
Pressure Switch
9
Gas Valve
9
Unit Model Number Explanation
10
Unit Serial Number Explanation
11
Heatexchanger
11
Equipment Application
12
Unit Specifications
12
Physical Data
14
Accessories Ano Optional Equipment
23
LP Conversion Kits
23
Combustible Floor Base
23
Return Air Cabinets
23
Return Air Cabinet
23
Conversion Kits
23
Metal Base Plate
24
Plenum Adapters and Coil Plenums
24
Fossil Fuel Kits
24
External Filter Frames
24
Twinning Kits
24
Sidewall Vent Kits
24
Base Plate
24
Installation Requirements
25
Safety Rules Ano Helpful Information
25
Installation Procedures
26
Clearance Accessibility
26
Base Plate Installation
27
Dimensions: Downflow Units
29
Dimensions: Horizontal Only Units and Upflow/Horizontal Units in the Horizontal Position
30
Combustion and Ventilation Air
31
Furnace Located in Unconfined Space Using Indoor Air
32
Furnace Located in Aconfined Space
32
Using Indoor Air for Combustion
32
Using Outdoor Air for Combustion
32
Unconfined Space Dimensions
32
Indoor Air Opening Dimensions
32
Outside Air from Attic/Crawl Space
33
Outside Air Using a Horizontal Inlet & Outlet
33
Vertical Outdoor Air Opening Dimensions
33
Horizontal Outdoor Air Opening Dimensions
33
Venting General Information
34
Induced Draft Blower
34
Furnace Category Information
34
Retrofit Venting Instructions
34
Vent Pipe Material
34
National Fuel Gas Code Book
34
Pre-Drilling Fan Collar
34
Vertical Venting with B-Vent
35
Dedicated Venting through Chimney with B-Vent
35
Vertical Venting
35
Vertical Vent Systems
36
Special Vent System (S.V.s.)
36
Typical Venting with "B-Vent
36
Power Vent Systems
37
Power Venter Installation
37
Gas Supply and Piping
38
Electronic Combustible Gas Detector
38
Gas Pipe Installation
38
Electrical Wiring
40
Electrical Connections
40
Thermostat
40
Heat Anticipator Settings
40
Low Voltage Wiring
40
Isolation Relay
41
Return Air Ducting and Supply
41
Upflow Units
42
Start-Up Proceoure
42
Standing Pilot Models
42
Electronic Ignition Models
43
Pilot Positioning
43
Sequence of Operation
44
Electronic Ignition Gas Valve
44
Furnace Twinning
44
Honeywell Instructions
44
Honeywell Twinning Connections
44
UTEC Instructions
45
UTEC Single Stage Twinning
45
UTEC Two Stage Twinning
45
Electrical Wiring
47
Circuit Protection Sizing
47
Operation
48
Fossil Fuel Kits (Rxpf-E01)
49
Location and Wiring
49
Thermostat Operation
49
Fossil Fuel Kit Plenum Switch
49
Fossil Fuel Kits (Rxpf-F01)
50
Location and Wiring
50
Theromstat Operations
50
Fossil Fuel Kits (Rxpf-F02)
51
Location and Wiring
51
Thermostat Operations
51
Accessory Blower Time Delay Rxmd-Co2
51
Maintenance
52
Filters
52
Upflow Unit Filter Size Adjustment
52
Filter Retaining Rods
53
Horizontal Filter Installation
53
Optional External Filter Racks
54
Lubrication
55
Burner and Heating Components
55
Service and Troubleshooting
56
Introduction
56
Test Equipment
56
Water Heater
57
Installation and Service Checklist
57
High Voltage Circuit
58
Low Voltage Circuit
58
Robertshaw and Honeywell Standing Pilot Fan Control Boards
59
Fan Control Board
59
Blower off Settings - Robertshaw Standing Pilot
59
Blower off Settings - Honeywell Standing Pilot
59
Standing Pilot Troubleshooting Guide
60
Accessory Board
61
Accessory (Baby) Board
61
Fan Control Board Responses
62
Integrated Furnace Control (Ifc)
62
United Technologies (Utec)
63
Lock out Status
63
Soft Lock out Causes
63
Hard Lock out Causes
63
Self Healing
63
UTEC Integrated Circuit Board
63
Heat Assisted Limit Control (HALC)
63
Low Thermostat Anticipation
64
Control Board Characteristics
64
Twinning Jumper Plug
64
Control Responses
65
Honeywell Circuit Board
65
Voltage Spikes
65
Honeywell
66
Lock out Status
66
Soft Lock out Causes
66
Hard Lock out Causes
66
Control Board Characteristics
66
Control Responses
66
Setting Blower off Controls
67
Blower off Setting - Honeywell Integrated Circuit
67
Blower off Setting - UTEC Integrated Circuit
67
Blower Wiring Connections
68
Field Installed Accessories
68
Flame Sensing Current Switch Box Assembly
68
Switch Box Operation
68
Equipment Test Connections
68
Switch Box
68
Reasons for Burner Lockout
69
Remote Flame Sensor Kit Installation
69
Kit Components and Tools Needed
69
Sensor Mounting
70
Sensor Bracket Mounting
70
Flame Sensor Mounting
70
Sensor Splicing
71
Measure Voltage at 2-Pin Molexcap for 110-120 Volts
71
Measure Voltage from First Pin to Chassis Ground
71
Measure Voltage from Second Pin to Chassis Ground
71
Location of Wire Splice
72
Measure Flame Sense Current Using Flame Sensing Current Switch Box
72
Remote Flame Sensing Rod
73
Flame Sensor
73
Factory Installed Flame Sensor
73
Reasons for Burner Lockout
74
Integrated Furnace Control Board Replacement Kit
74
Normal Installations
74
Remote Flame Sensor Installation
75
Twinned Installations
75
Fossil Fuel Kits
76
Twinned Units with Fossil Fuel Kits
76
Present Control Descriptions and Troubleshooting
76
Integrated Furnace Controls Used on Current Low Profile Gas Furnaces
76
UTEC and Honeywell Controls
76
Setting the Blower off Timings
77
UTEC Led's
77
Honeywell Led's
77
UTEC-920/920A Blower off Timings
77
Honeywell E2001 Blowerofftimings
77
Flash Code
78
UTEC 1012-925 Controls
79
UTEC 1012-925 Furnace Control
79
Motor Wire Connections
80
Troubleshooting
80
Indicator Lights
80
UTEC 1012-925 Blower off Timings
80
Integrated Furnace Controls Used on Current Low Profile Gas Furnaces
81
UTEC 1028-927 DSI Furnace Control
81
DSI Output Transformer
82
IFC Troubleshooting Guide
83
Control Responses
89
Main Power "J" Box
90
Blower Door Switch
90
Controls
90
Negative Pressure Switch
90
Pressure Switch Settings
90
High Limit Control
91
High Limit Settings
91
Heat Assisted Limit Control (Halc)
92
Over Temperature Switch
92
Heat Assisted Limit Switch Setting Temperatures
92
Vent Safety Switch
93
Over Temperature Switch
93
Induced Draft Blower Vent Safety Switch Location
93
Induced Draft Blower
93
Transformer
94
Blower Motor
94
Induced Draft Blower Assembly
94
Blower Dimensions
94
Standing Pilot Control Board
95
Standing Pilot 9-Pin Plug
95
HSI Control 6-Pin Plug
95
Furnace Gas Train
96
Gas Valve
96
Adjusting Gas Pressure
96
Induced Draft Blower
96
LP Conversion Kit
96
Checking Line Gas Pressure
97
Furnace Orifice Sizing
98
Checking Furnace Input
98
Orifice Sizes
98
Hot Surface Igniters
99
Direct Spark Igniters
99
Hot Surface Igniter
99
Direct Spark Igniter
99
HSI Igniter
99
Standing Pilot Burner
100
Air Flow
100
Pilot Hood Location
100
Making Temperature Rise Check
100
Co and Co2 Levels in Flue Gases
101
Flue Gas Temperature Range
101
Checking Flue Temperature
101
Wiring Diagrams
102
Service Analyzer Charts
119
Remote Flame Sensor
119
Review Questions
123
Index
125
Index of Figures
127
Index Oftables
128

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