Conquest FAQs

Why is the Valve-M icon flashing on the Temptrac Control when the unit appears to be operating properly?

When the TempTrac Control is energized, internal Digital Inputs 1 and 2 are activated. Digital input 1 establishes a specified firing rate for the burner, and Digital Input 2 is the alarm function. When Digital Input 1 is active, the Valve/M icon illuminates and flashes on the display screen.When the gas valve is energized the Burner ON light illuminates. After a 10 second delay, Digital Input 1 is de-activated and the flashing Valve/M icon shuts off and is replaced by a steady Valve icon. When the call-for-heat is satisfied, the Burner On and Call-for-Heat lights shut off. Digital Input 1 is then reactivated and the Valve/M icon will illuminate and flash.

Is a trap required on the condensate drain?

The Conquest water heater produces a significant amount of condensate. The condensate drain is under slightly positive flue pressure, so the provided 3/4” PVC condensate trap must always be used. This trap is sized and designed to fill with the proper amount of condensate to create a liquid barrier to prevent flue gases escaping through the condensate drain into the installed space. See product I&M for proper installation instructions.

Where do I tie in remote connections for a Building Management System (BMS), Building Automation System (BAS), remote alarm or other proving devices?

For Conquest BTU inputs of 199 to 299 Mbtu, the terminal strip for remote connections is located at the top of the unit under the top access cover. For Conquest BTU inputs of 399 to 800 Mbtu the terminal strip for remote connections is located behind the bottom control panel door and is accessed by removing the four thumb screws and lifting the hinged door. IMPORTANT: Do not use single strand bell wire for remote field connections to terminals R1-R2 and C1-C2. Use only multi-strand copper wire. See table in I&M manual for terminal functions, wire length and gauge.

If there is a BMS connection either by Modbus or gateway, how will the BMS read the alarm? Does the specific alarm get sent or just an alarm notification and the code must be read from the Temptrac Controller?

The Temptrac control does not send out information. BMS systems continually communicate or poll the control to obtain the alarm status and other information. This typically occurs several times per minute.

What happens if you exceed 10.5” w.c. gas supply pressure as noted on the unit’s rating plate? Does this void the warranty?

The inlet gas supply pressure of 10.5 inches w.c. is the increased gas supply pressure that was used in the ETL testing and certification of the product. The individual gas valves, regulators and pressure switches are rated by the component manufacturer to withstand a maximum supply pressure of 14 inches w.c. As long as the maximum incoming gas supply pressure does not exceed the 14 inches w.c. or ½ psi of pressure, you will not void the unit’s warranty.

My gas pressure is within the required range while the unit is not firing. Why does the gas pressure drop too low when the unit attempts to fire?

A drop in gas supply pressure indicates excessive pressure drop in the gas supply piping system. This pressure drop may be caused by frictional losses from excessive length of pipe or an excessive number of fittings in the pipe system. Pressure drop can also be caused by regulators or gas meters that are marginally or improperly sized to deliver the volume of gas required to allow the unit to fire at full rate manifold pressure.

Are referenced gas valves more forgiving when it comes to gas pressure or volume? If so, approximately how much?

A referenced gas valve allows the gas output from the regulator to vary as the output of the combustion air fan varies. Many conditions such as voltage, draft, wind, equipment room pressures, etc. can change the output pressure of the combustion air fan. A referenced gas valve will automatically vary the gas supply to balance the changes in combustion air. This ensures a reliable clean combustion process and eliminates nuisances flame failure problems due to job site related conditions.

What advantage do “biased” gas valves serve, and what exactly are they?

A biased gas valve references the gas manifold pressure to the outlet pressure of the combustion air fan. When ever there is a variation in the fan output, the gas output from the biased gas valve responds accordingly to prevent nuisance flame failure or operational problems.

I have 14” of supply gas pressure? Will this damage the unit?

The individual gas valves, regulators and pressure switches are rated by the component manufacturer to withstand a maximum supply pressure of 14 inches w.c. or ½ psi gas pressure. As long as the maximum incoming gas supply pressure does not exceed the 14 inches w.c. of pressure, you will not damage the internal components of the gas train.

Why does the drop in gas pressure cause the unit to stop running?

PVI units designed for fan assisted combustion, delivers air in a fixed volume. When the required volume of gas is decreased it can lean the combustion process where the flame can not be sensed by the ignition control. This results in a flame failure condition. Many times you may experience a flame failure but the movement of the gas manometer indicates that the gas pressure only reached the minimum required for operation. This is because the movement of the water column in the manometer has a lag between the actual drop in pressure and the time that it takes to show the indicated change. The change in pressure is not sustained for an extended period of time and the manometer will not give an instantaneous indication of the change in pressure. A properly calibrated magnahelic will usually show these quick response changes in gas supply pressure more readily than a basic manometer. This is seen by the extreme swings in the indicating needle on the pressure scale.

Why is your maximum gas pressure lower than other manufacturers on some products? Why do you only go to 10.5” w.c. on natural gas?

The information supplied on the unit’s rating plate is specified by the ANSI Standard. The 10.5 inches maximum is the maximum supply pressure that the unit was tested to per the ANSI Standard for natural gas. The individual components that are used in the gas train are rated for a maximum inlet pressure of 14 inches w.c or ½ psi of gas. As long as gas supply pressures do not exceed the 14 inches w.c or ½ psi there will be no damage to the gas train components.

What happens if my gas supply pressure is too high?

Excessive gas supply pressure can either lock the gas valve or regulator in a closed position or, in the case of extremely high gas pressure; it may override the gas valve, damage the diaphragm and allow unrestricted gas flow to the burners. Extremely high gas pressure can result in a catastrophic failure of the equipment.

How do I measure draft?

A draft gauge must be used. A small ¼” hole should be placed in the stack approximately 3 to 4 feet above the unit’s flue outlet and below any installed barometric dampers. Insert the tube from the draft gauge just into the flue and measure the draft on the scale as the unit is firing.

Why do the Conquest heaters have a LWCO test button and reset button? Is this code?

Some jurisdictions require a functional test of all safety controls. The LWCO test button provides a practical way to simulate a loss of liquid level in the tank by opening the circuit between the electrode in the tank and the control. Note - There is a three-second time delay before the control de-energizes. The LWCO is a manual reset type.

Does the water heater need to be firing in order to perform the LWCO test?

The water heater does not need to fire to functionally test the LWCO control. The control is energized when the liquid rises to the electrode in the tank and the reset button is pushed. The LWCO control is de-energized when the test button is pushed (LED will not be lit).

Under normal operation, how many degrees from set point does the water temp fall before activating the call for heat?

The differential from the Temptrac set point is -5 degrees.

Some jurisdictions require you to test a LWCO device. How do I perform this test?

Push the LWCO Test Button for three seconds to de-energize the control (the LED on the control should go out). Push the LWCO Reset pushbutton to re-energize the LWCO control.

When the water heater goes off on LWCO (and during the test), why doesn’t this condition activate an alarm? It didn’t, should an alarm have been activated?

The Alarm on Any Failure feature is active only during a Call-For-Heat cycle. If any safety device or proving interlock prevents the burner from firing during a call-for-heat cycle within an allotted time period (3 minutes), the Temptrac will initiate an alarm notification. The LWCO test of the alarm feature must occur while the unit is operating, and remains de-energized for three minutes.

What is the fault code AL2?

All Conquest commercial water heaters are equipped with an Alarm On Any Failure (AL2) functionality. An “AL2” fault on the Temptrac Controller indicates that an ignition did not occur in the time required for the ignition trial. An alarm is sounded and the Temptrac Controller must be reset to resume operation. An AL2 fault should occur if any of the following conditions exists:
− A temperature limit condition is exceeded
− The air flow proving switch fails to close during the time required for ignition
− Flame is not successfully established during the time required for ignition
− A high or low gas pressure condition has occurred
− A field interlock remained open during the time required for ignition
− A low water control or low water condition exists
− A DPDT relay in the alarm circuit is faulty

How should the AL2 alarm be reset?

To reset the TempTrac once the alarm is activated, attempt to determine the safety device which caused the condition and correct the condition. Once the condition is corrected the TempTrac can be reset by pressing any button. If the lockout is caused by the ignition control, power must be re-cycled in order to reset the ignition module.

I still have a AL2 alarm and none of the fault conditions exist. What do I do?

If none of the fault conditions has occurred during an AL2 alarm, it is reasonable to conclude that one or more of the DPDT relays in the alarm circuit are faulty. This is a nuisance shut-down problem and is not a dangerous or hazardous issue. If the DPDT alarm relay is defective and no other problem is detected, switching the power switch OFF and then ON following and alarm should restart the water heater until the relay can be replaced.

Is there anything I can do to keep the heater running until I can replace the alarm relay?

If you have confirmed that that the alarm is not resulting from any other fault condition, cycling power should restart the water heater until the relay can be replaced. If the frequency to recycle the water heater becomes a nuisance or if a replacement relay is not immediately available, the alarm timing function can be extended temporarily to eliminate shut downs until the relay is replaced.
To temporarily extend the TempTrac alarm timing function:
1. First Enter the password protected programming menu by pressing the SET then DOWN buttons together for more than 3 seconds. The name of the parameter is on the upper display and its value is on the lower display.
2. Press the UP button to select parameter”PR2” in the upper display. Its value “PAS” is shown in the lower display.
3. Now press the SET button. The value “0_ _“ is displayed and flashes.
4. Use the UP or DOWN buttons to input the passkey 3-2-1 in the flashing value. Push the SET button after each entry.
5. Now use the UP or DOWN buttons to scroll to the“i2d”parameter.
6. Press the SET button and the value in the lower display will start blinking.
7. Use the UP button to change the i2d parameter value from 3 minutes to 250 minutes.
8. Press SET to store the new value. Note that the next parameter and value is now displayed.
9. To exit press the SET then UP buttons together, or wait 30 seconds without pressing a button to return to the home screen.
Important: Remember to return the “i2d” value to 3 minutes when the defective relay is replaced.

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