Carrier Furnace Weathermaker Parts Manual

The Carrier Weathermaker furnace is a high-efficiency residential heating system designed for reliable performance and energy savings. This manual covers the Weathermaker series models including installation guidelines, component identification, maintenance procedures, troubleshooting, and replacement parts information. Below are key sections for safety, features, installation, operation, maintenance, and parts replacement.

1. Features at a Glance 2. Installation Guidelines 3. Component Identification 4. Specifications 5. Controls and Operation 6. Maintenance Procedures 7. Parts Replacement 8. Safety Features 9. Care & Cleaning 10. Regulatory Information 11. Troubleshooting

Features at a Glance

Key components: Heat exchanger, blower motor, gas valve, igniter, flame sensor, pressure switch, control board, air filter, venting system.

Feature	Description
Heat exchanger	Stainless steel primary and secondary heat exchangers
Blower motor	Variable speed ECM motor for efficient airflow
Gas valve	Modulating gas valve for precise temperature control
Igniter	Hot surface igniter for reliable ignition
Flame sensor	Safety device to detect flame presence
Pressure switch	Ensures proper venting operation
Control board	Main system controller with diagnostic LEDs
Air filter	Standard 1-inch or 4-inch media filter
Venting system	PVC pipe venting for high-efficiency operation
Thermostat connection	Compatible with standard 24V thermostats

Installation Guidelines

Proper installation is critical for safe and efficient operation.

Location: Install in dry, well-ventilated area with adequate clearance for service.
Venting: Use approved PVC pipe for intake and exhaust venting.
Gas connection: Use proper pipe size and thread sealant approved for natural gas.
Electrical: Connect to dedicated 120V circuit with proper grounding.
Ductwork: Ensure proper sizing and sealing of supply and return ducts.

WARNING! Installation must be performed by qualified HVAC technician. Gas leaks can cause explosion or fire.

Component Identification

Understanding furnace components for proper maintenance and troubleshooting.

Front access panel: Removable for filter replacement and basic service.
Blower compartment: Contains blower motor and wheel assembly.
Burner compartment: Houses burners, igniter, and flame sensor.
Heat exchanger section: Primary and secondary heat exchangers.
Control board: Located in blower compartment with diagnostic LEDs.
Gas valve: Regulates gas flow to burners.
Pressure switches: Monitor venting system pressure.
Inducer motor: Creates draft for combustion gases.

CAUTION! Always disconnect power before servicing internal components.

Specifications

Model Series: Weathermaker 8000, 9000, S9X1
Input Capacity: 40,000 to 120,000 BTU/hr
Efficiency: 80% to 98% AFUE
Gas Type: Natural gas or propane (conversion kit required)
Electrical: 120V, 60Hz, 15A circuit
Airflow: 600 to 2000 CFM depending on model
Static Pressure: Maximum 0.8 inches water column
Venting: 2-inch or 3-inch PVC pipe
Dimensions: Varies by model (typically 21"W x 21"D x 45"H)
Warranty: 20-year heat exchanger, 5-year parts

Controls and Operation

Understanding furnace controls and proper operation sequence.

Control Board: LED status lights indicate system operation and fault codes. Thermostat calls for heat, control board initiates inducer motor, pressure switch closes, igniter heats, gas valve opens, flame sensor confirms ignition, blower starts after heat exchanger warms.

Operating Modes: HEAT, COOL (with AC), FAN ON, FAN AUTO. Diagnostic Codes: Flash patterns indicate specific faults (1 flash = pressure switch, 2 flashes = igniter failure, etc.).

Maintenance Procedures

Regular maintenance ensures optimal performance and longevity.

Monthly: Check and replace air filter as needed.
Seasonal: Inspect burners for proper flame pattern.
Annual: Professional inspection and cleaning recommended.
Blower maintenance: Clean blower wheel and housing annually.
Heat exchanger: Visual inspection for cracks or corrosion.
Venting: Check for obstructions and proper slope.
Drain system: Clear condensate drain line and trap.

Tip: Keep area around furnace clear of combustible materials.

Parts Replacement

Common replacement parts and procedures.

Air filter: Slide out old filter, insert new one with arrow pointing toward blower.
Igniter: Disconnect power, remove wires, slide out old igniter, install new one.
Flame sensor: Remove single screw, pull out sensor, clean or replace.
Pressure switch: Disconnect tubing and wires, remove mounting screw, replace.
Blower motor: Remove blower access panel, disconnect electrical, remove mounting bolts.
Control board: Document wire locations, disconnect all connections, remove mounting screws.
Gas valve: Shut off gas supply, disconnect gas line and electrical, remove mounting nuts.

WARNING! Gas components should only be serviced by qualified technicians.

Safety Features

Multiple safety systems protect against hazardous conditions.

Flame Rollout Switches: Detect improper burner operation. High Limit Switches: Prevent overheating. Pressure Switches: Ensure proper venting. Gas Valve: Automatic shutoff if ignition fails. Control Board: Monitors all safety circuits and provides diagnostic information.

Care & Cleaning

Proper cleaning maintains efficiency and reliability.

Exterior: Wipe with damp cloth. Burners: Clean with soft brush only. Heat Exchanger: Professional cleaning recommended. Blower: Vacuum accessible surfaces. Drain System: Flush with clean water. Filter: Replace regularly based on usage.

CAUTION! Never use water or cleaning chemicals on electrical components.

Regulatory Information

UL listed and ANSI certified for safety. Complies with ASHRAE standards for residential furnace performance. Manufactured to meet DOE energy efficiency requirements. For technical support, contact Carrier at 1-800-CARRIER or visit www.carrier.com. Copyright © Carrier Corporation. All rights reserved.

Troubleshooting

Symptom	Possible Cause	Corrective Action
Furnace won't start	Power, thermostat, door switch	Check circuit breaker, thermostat setting, ensure door properly closed.
No heat	Gas supply, igniter, flame sensor	Verify gas valve on, check for igniter glow, clean flame sensor.
Short cycling	Dirty filter, airflow restriction	Replace filter, check for blocked vents or returns.
Blower runs continuously	Thermostat setting, control board	Check thermostat fan setting, inspect control board.
Unusual noises	Blower, inducer motor, ductwork	Inspect blower wheel, inducer assembly, check for loose panels.
Error codes flashing	Various system faults	Count flash pattern and refer to diagnostic chart in manual.

Reset: Turn power off for 30 seconds, then restore power to reset control board.

Service: 1-800-CARRIER; www.carrier.com