Carrier Weathermaker Furnace Manual

The Carrier Weathermaker Furnace is a high-efficiency gas furnace designed for residential heating applications. It features advanced combustion technology, multiple heating stages, variable-speed blower motor, electronic ignition, built-in diagnostic system, safety controls, and compatibility with various thermostat systems. Below are key sections for safety, features, installation, setup, operation, maintenance, and troubleshooting.

1. Features at a Glance 2. Installation 3. First-Time Setup 4. Specifications 5. Controls and Settings 6. Connecting Thermostat 7. Operation 8. Maintenance 9. Care & Cleaning 10. Regulatory Information 11. Troubleshooting

Features at a Glance

Key components: Heat exchanger, burners, blower assembly, gas valve, ignition system, pressure switches, limit switches, diagnostic LED.

Feature	Description
Heat exchanger	Stainless steel primary and secondary heat exchangers
Burners	Multi-port inshot burners for efficient combustion
Blower assembly	Variable-speed ECM motor for quiet operation
Gas valve	Modulating gas valve for precise temperature control
Ignition system	Hot surface ignition for reliable startup
Pressure switches	Safety switches to verify proper venting
Limit switches	High-temperature safety cutoffs
Diagnostic LED	Flashing code indicator for troubleshooting
Filter access	Easy-access filter compartment
Drain connections	Condensate drain ports for high-efficiency models

Installation

Unpack and inspect contents. Verify proper location with adequate clearance.

Gas connection: Use approved gas piping; pressure test for leaks.
Electrical connection: Connect to 120V AC power supply with proper grounding.
Vent system: Install PVC vent pipes according to local codes.
Drain system: Connect condensate drain line to proper disposal.
Ductwork: Connect supply and return ducts securely.

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

First-Time Setup

Power on furnace; follow startup procedure.

Verify gas supply: Ensure gas valve is open and pressure is correct.
Check electrical: Confirm proper voltage at unit.
Test ignition: Initiate heating cycle to verify proper operation.
Set thermostat: Configure thermostat for desired temperature settings.
Check airflow: Verify proper airflow through all registers.

CAUTION! Never bypass safety controls. Ensure proper ventilation during initial startup.

Specifications

Heating Capacity: 40,000 to 120,000 BTU/hr
Efficiency: Up to 98% AFUE
Stages: Single-stage, two-stage, or modulating
Blower Type: Variable-speed ECM
Ignition: Hot surface ignition
Voltage: 120V AC, 60Hz
Gas Type: Natural gas or propane
Vent Material: PVC, CPVC, or ABS
Sound Level: As low as 65 dB
Warranty: Limited lifetime heat exchanger warranty

Controls and Settings

Access control board via front panel. Integrated control module with diagnostic capabilities.

Thermostat Connections: R (24V power), W (Heat), G (Fan), C (Common), Y (Cooling)

Operating Modes: HEAT, COOL, FAN ONLY, OFF. Blower Settings: Continuous fan, auto fan. Temperature Control: Single-stage or multi-stage operation. Diagnostic Codes: LED flash patterns indicate specific error conditions.

Connecting Thermostat

Compatible with most 24V thermostat systems including programmable and smart thermostats.

Turn off power to furnace at circuit breaker.
Remove existing thermostat and note wire connections.
Connect wires to new thermostat according to wiring diagram.
Mount thermostat and restore power.
Configure thermostat settings for furnace operation.

Tip: Use thermostat compatible with furnace staging for optimal performance.

Operation

Normal heating cycle operation.

Thermostat calls for heat: Sends signal to control board.
Inducer motor starts: Creates draft through heat exchanger.
Pressure switch verification: Confirms proper venting.
Ignition sequence: Hot surface igniter glows, gas valve opens.
Burner ignition: Flame sensed by flame sensor.
Blower activation: Delays until heat exchanger warms.
Cycle completion: Thermostat satisfied, gas valve closes.

WARNING! Never operate furnace with access panels removed. Keep combustible materials away from unit.

Maintenance

Regular maintenance ensures optimal performance and safety.

Monthly: Check and replace air filter as needed
Seasonal: Inspect vent system for obstructions
Annual: Professional inspection and cleaning
As needed: Clean flame sensor and burners

Care & Cleaning

Turn off power before cleaning. Use soft brush and vacuum for dust removal.

CAUTION! Do not use water or chemical cleaners on electrical components. Keep burners and heat exchanger dry.

Regulatory Information

UL listed and ANSI certified. Complies with ASHRAE standards. Manufactured to meet or exceed industry safety standards. For technical support, contact Carrier at 1-800-CARRIER or visit www.carrier.com. Installation must comply with local building codes and NFPA standards.

Troubleshooting

Symptom	Possible Cause	Corrective Action
Furnace won't start	Power, thermostat, switch	Check circuit breaker; verify thermostat setting; ensure door switch engaged.
No heat	Gas supply, ignition	Verify gas valve open; check for ignition lockout; inspect flame sensor.
Short cycling	Filter, airflow, sensor	Replace dirty filter; check for blocked vents; clean flame sensor.
Blower not working	Motor, capacitor, control	Check for loose wires; test capacitor; verify control board output.
Unusual noises	Motor, bearings, ducts	Lubricate motor if required; tighten loose panels; check ductwork.

Reset: Turn power off for 30 seconds, then restore.

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