Conquest 90 Furnace Manual

The Conquest 90 Furnace is a high-efficiency gas furnace with 90% AFUE rating, featuring advanced combustion technology, electronic ignition, variable-speed blower motor, multi-speed operation, built-in diagnostics, safety controls, and compatibility with standard thermostat systems. Designed for residential use with natural gas or propane capability. Below are key sections for safety, features, installation, setup, operation, maintenance, and troubleshooting.

1. Features at a Glance 2. Installation Requirements 3. First-Time Setup 4. Technical Specifications 5. Controls and Settings 6. Operating Instructions 7. Maintenance Procedures 8. Safety Features 9. Care & Cleaning 10. Regulatory Information 11. Troubleshooting

Features at a Glance

Key components: High-efficiency heat exchanger, electronic ignition system, variable-speed blower, integrated control board, gas valve, pressure switches, flame sensor, and diagnostic LED.

Feature	Description
AFUE Rating	90% Annual Fuel Utilization Efficiency
Ignition System	Electronic hot surface ignition
Blower Motor	Variable-speed ECM motor
Heat Exchanger	Stainless steel primary and secondary
Gas Type	Natural gas or propane (conversion kit required)
Venting	PVC pipe compatible
Control Board	Microprocessor-based with diagnostics
Safety Controls	Flame rollout, limit switches, pressure switches
Thermostat Compatibility	Standard 24V single-stage and two-stage
Dimensions	Standard cabinet size for easy replacement

Installation Requirements

Professional installation required. Ensure proper clearances and venting.

Location: Install in approved areas with proper combustion air and clearances.
Venting: Use approved PVC pipe for intake and exhaust; maintain proper slope.
Gas Connection: Use approved pipe and fittings; pressure test required.
Electrical: 120V AC power supply with proper grounding.
Drainage: Condensate drain line with proper trap and routing.

WARNING! Gas appliances can be hazardous; installation must comply with local codes and be performed by qualified technician.

First-Time Setup

Initial startup must be performed by qualified technician.

System Check: Verify all connections, clearances, and venting.
Gas Pressure: Set manifold pressure to specifications (3.5" WC natural gas).
Electrical: Verify proper voltage and grounding.
Startup Sequence: Follow control board initialization procedure.
Operation Test: Verify heating cycle, blower operation, and safety controls.

CAUTION! Never attempt to adjust gas pressure or electrical connections without proper training and equipment.

Technical Specifications

AFUE Rating: 90%
Input BTU/H: 40,000 to 120,000 (model dependent)
Output BTU/H: 36,000 to 108,000 (model dependent)
Gas Type: Natural gas or LP (with conversion)
Electrical: 120V AC, 60Hz, 5-8 amps
Blower Motor: Variable-speed ECM
Airflow: 600-1600 CFM
Venting: 2" PVC intake and exhaust
Sound Level: < 65 dBA
Warranty: 20-year heat exchanger, 5-year parts

Controls and Settings

Integrated control board with diagnostic LED and DIP switch settings.

Control Board: LED status light indicates system operation and fault codes. DIP switches for blower speeds, thermostat type, and accessory configuration.

Thermostat Settings: Compatible with single-stage and two-stage thermostats. Heat anticipator settings for optimal cycling. Blower Settings: Adjustable delays for fan-on and fan-off. Multi-speed capability for different duct configurations. Diagnostic Codes: LED flash patterns indicate specific fault conditions for troubleshooting.

Operating Instructions

Normal operation controlled by thermostat. System includes automatic safety checks.

Thermostat Call: Set thermostat to desired temperature above room temp.
Ignition Sequence: Control board initiates pre-purge, ignition trial, and flame verification.
Heating Cycle: Gas valve opens, burner ignites, blower activates after heat exchanger warms.
Cycle Completion: Thermostat satisfied, gas valve closes, blower continues for post-purge.
Safety Monitoring: Continuous monitoring of flame, temperature, and pressure conditions.

Tip: Maintain consistent thermostat settings for optimal efficiency and comfort.

Maintenance Procedures

Regular maintenance required for optimal performance and safety.

Monthly: Check air filter; replace when dirty (typically 1-3 months).
Seasonal: Inspect vent pipes for obstructions or damage.
Annual: Professional inspection of heat exchanger, burners, and safety controls.
Biannual: Clean blower assembly and check motor operation.
As Needed: Clean flame sensor and inspect ignition system.

WARNING! Always turn off power and gas supply before performing any maintenance. Professional service recommended.

Safety Features

Multiple safety systems protect against hazardous conditions.

Safety Feature	Function
Flame Rollout Switch	Detects burner flame outside combustion chamber
High Limit Switch	Prevents overheating of heat exchanger
Pressure Switches	Verify proper venting and draft conditions
Flame Sensor	Confirms burner ignition within safety time
Ignition Control	Limits ignition attempts to prevent gas buildup
Gas Valve	Automatic shutoff during power loss or fault

Care & Cleaning

Regular cleaning maintains efficiency and extends equipment life.

Air Filter: Replace regularly to maintain airflow and indoor air quality. Burners: Clean annually to ensure proper flame pattern. Heat Exchanger: Professional inspection for cracks or corrosion. Blower: Clean wheel and housing to maintain airflow. Condensate System: Flush drain lines and check trap for proper operation.

CAUTION! Never operate furnace without filter. Keep combustion air intake clear of debris.

Regulatory Information

UL listed and ANSI certified. Complies with ASHRAE standards for residential gas furnaces. Manufactured to meet or exceed Department of Energy efficiency requirements. Natural gas conversion must be performed by qualified technician using approved conversion kit. For technical support, contact Conquest Heating Systems at 1-800-555-HEAT or visit www.conquestheating.com.

Troubleshooting

Symptom	Possible Cause	Corrective Action
Furnace won't start	Power, thermostat, safety lockout	Check circuit breaker, thermostat settings, reset power
No heat	Gas supply, ignition, filter	Verify gas valve on, check filter, observe ignition sequence
Short cycling	Filter, limit switch, airflow	Replace filter, check vents, verify proper airflow
Blower doesn't run	Motor, capacitor, control board	Check power to motor, inspect capacitor, verify control signal
Unusual noises	Blower, burners, ductwork	Inspect blower wheel, clean burners, check duct connections
Error codes	Various system faults	Refer to diagnostic chart in service manual

Reset Procedure: Turn off power for 30 seconds, then restore. If problem persists, contact professional service.

Service: 1-800-555-HEAT; www.conquestheating.com