Conquest 80 Furnace Parts Manual

The Conquest 80 Furnace is a high-efficiency gas furnace with 80% AFUE rating, featuring a durable heat exchanger, electronic ignition system, multi-speed blower motor, and comprehensive safety controls. This manual provides detailed parts identification, replacement procedures, maintenance guidelines, and troubleshooting information for HVAC technicians and qualified service personnel.

1. Parts Overview 2. Component Identification 3. Replacement Procedures 4. Technical Specifications 5. Maintenance Schedule 6. Electrical Components 7. Gas System Parts 8. Blower Assembly 9. Heat Exchanger 10. Safety Information 11. Troubleshooting Guide

Parts Overview

Key components: Heat exchanger assembly, blower motor and wheel, gas valve, igniter, flame sensor, pressure switches, control board, limit switches, transformer, and inducer motor assembly.

Component	Description
Heat Exchanger	Primary and secondary heat exchanger assembly
Blower Assembly	Multi-speed motor with blower wheel and housing
Gas Valve	24V automatic gas valve with pressure regulation
Hot Surface Igniter	Silicon carbide igniter for direct spark ignition
Flame Sensor	Rod-type flame sensing device
Control Board	Integrated furnace controller with diagnostic LEDs
Inducer Motor	Combustion air inducer assembly
Pressure Switches	Diaphragm-type pressure sensing switches
Limit Switches	High temperature safety cut-off switches
Transformer	24V step-down transformer for control circuit

Component Identification

Detailed identification of all furnace components with part numbers and locations.

Remove front access panel to view internal components.
Identify control board location near blower compartment.
Locate gas valve assembly on burner compartment.
Identify heat exchanger access panels.
Note inducer motor position in combustion area.

WARNING! Always disconnect power and gas supply before accessing internal components. Use proper personal protective equipment.

Replacement Procedures

Step-by-step procedures for common part replacements.

Blower Motor: Disconnect power, remove blower access panel, disconnect wiring, remove mounting bolts, replace motor.
Igniter: Disconnect power, remove igniter access cover, disconnect wires, remove mounting bracket, install new igniter.
Flame Sensor: Disconnect power, remove sensor retaining screw, clean or replace sensor, reinstall.
Gas Valve: Shut off gas supply, disconnect power, remove gas line connections, disconnect wiring, replace valve.

CAUTION! Always verify gas connections for leaks using bubble solution after replacement.

Technical Specifications

Model Series: Conquest 80
AFUE Rating: 80%
Input BTU/H: 40,000 - 120,000 (varies by model)
Electrical: 115V/60Hz/1Ph
Gas Type: Natural Gas or LP (with conversion kit)
Blower Motor: Multi-speed PSC motor
Control Voltage: 24V AC
Venting: Category I venting required
Dimensions: Varies by model capacity

Maintenance Schedule

Recommended maintenance intervals and procedures for optimal performance.

Monthly: Visual inspection of vent system, check air filter

Annual: Complete system inspection by qualified technician

Maintenance Tasks: Clean blower assembly, inspect heat exchanger, check gas pressure, verify safety controls, clean flame sensor, lubricate motor (if required), check electrical connections.

Electrical Components

Detailed electrical parts including control board, transformers, motors, and safety devices.

Control Board: Main furnace controller with diagnostic capabilities
Transformer: 120V to 24V step-down transformer
Blower Motor: Permanent split capacitor motor with multiple speed taps
Inducer Motor: Combustion blower motor assembly
Limit Switches: Manual reset high temperature limits

Tip: Always verify voltage readings before replacing electrical components.

Gas System Parts

Gas valve assemblies, manifolds, burners, and related components.

Shut off gas supply at unit and main valve before servicing.
Gas Valve: Combination gas control valve with pressure regulator
Manifold: Gas distribution manifold with orifice holders
Burners: Inshot burners with precise air/gas mixture
Pilot Assembly: Standing pilot or electronic ignition system

WARNING! Gas work must be performed by qualified technicians only. Always check for gas leaks after service.

Blower Assembly

Complete blower assembly components and replacement guidelines.

Blower Housing: Sheet metal housing containing blower wheel
Blower Wheel: Squirrel cage type blower wheel
Motor: PSC multi-speed motor with mounting brackets
Capacitor: Run capacitor for motor operation
Mounting Hardware: Bolts, brackets, and vibration isolators

WARNING! Ensure proper wheel alignment and clearance during reassembly to prevent vibration and noise.

Heat Exchanger

Heat exchanger inspection, cleaning, and replacement procedures.

Primary Heat Exchanger: Clamshell design for efficient heat transfer. Secondary Heat Exchanger: Condensing section for additional efficiency. Inspection: Check for cracks, corrosion, or damage during annual maintenance. Replacement: Requires complete disassembly of furnace cabinet.

Safety Information

Critical safety procedures and warnings for furnace service.

CAUTION! Always disconnect electrical power and shut off gas supply before servicing. Use carbon monoxide detectors when testing furnace operation. Follow all local codes and manufacturer specifications.

Troubleshooting Guide

Symptom	Possible Cause	Corrective Action
No heat	Thermostat, power, gas supply	Check thermostat setting, circuit breaker, gas valve position
Blower not running	Motor, capacitor, control board	Test motor windings, check capacitor, verify control signal
Furnace locks out	Flame sensor, pressure switch	Clean flame sensor, check pressure switch tubing
Gas valve not opening	Control board, wiring, valve	Check 24V to valve, test valve operation, inspect wiring
Limit switch open	Airflow restriction, high temp	Check filter, blower operation, verify ductwork clear

Diagnostic Codes: Refer to control board LED flash codes for specific error identification.

Technical Support: 1-800-555-HEAT; www.conquestfurnace.com