Carrier INDUCED-COMBUSTION GAS FURNACE Installation guide

INDUCED-COMBUSTION
GAS FURNACE
USER: Please read all manuals and
retain manuals for future reference.
WARNING:
Fire or Explosion Hazard. Failure to follow safety
warnings exactly could result in serious injury
death or property damage.
!
Do not use this furnace if any part has been
under water. Immediately call a qualified
service technician to inspect the furnace and
to replace any part of the control system and
gas control which has been under water.
NOTE TO INSTALLER:
THIS MANUAL MUST BE LEFT WITH THE
EQUIPMENT USER.
WeatherMaker
8000TS
— Do not store or use gasoline or other flammable
vapors and liquids in the vicinity of this or any
other appliance.
— WHAT TO DO IF YOU SMELL GAS
• Do not try to light any appliance.
• Do not touch any electrical switch; do not use
any phone in your building.
• Leave the building immediately.
• Immediately call your gas supplier from a
neighbor’s phone. Follow the gas supplier’s
instructions.
• If you cannot reach your gas supplier, call the
fire department.
— Installation and service must be performed by a
qualified installer, service agency or the gas
supplier.
WARNING:
Carbon Monoxide is invisible, odorless, and toxic!
Carrier Corporation recommends a carbon mon-
oxide alarm in your home, even if you do not own
a gas appliance. Locate the carbon monoxide
alarm in the living area of your home and away
from gas appliances and doorways to attached
garages. Follow the alarm manufacturer’s instruc-
tion included with the alarm.
!

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WELCOME TO TODAY’S
GENERATION OF COMFORT
Congratulations!Your new, higher efficiency gas furnace is a
sound investment which will reward you and your family
with years of warm memories winter after winter.
Not only is your new furnace energy efficient, it is also
extremely reliable. Spend just a few minutes with this booklet
to learn about the operation of your new furnace—and the
small amount of maintenance it takes to keep it operating at
peak efficiency.Years went into the development of your new
furnace. Take a little time now to assure its most efficient
operation for years to come.
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(Furnace shown in upflow position; may be used in
downflow or horizontal orientation or applications)
WeatherMaker
8000TS
FURNACE COMPONENTS
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VENT ELBOW
DRAFT
SAFEGUARD
SWITCH
GAS MANIFOLD
GAS BURNER
FLAME SENSOR
BLOWER DOOR
SAFETY SWITCH
BLOWER AND
MOTOR
PRESSURE
SWITCH
FLUE
COLLECTOR
BOX
GAS VALVE
MANUAL RESET
LIMIT SWITCHES
HOT SURFACE
IGNITER
CONTROL
MAIN LIMIT SWITCH
(BEHIND GAS VALVE)
INDUCER MOTOR
ASSEMBLY
RATING PLATE
NOT SHOWN
(LOCATED ON
BLOWER DOOR)
*Elbow may be turned to a different position, depending
on type of installation

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IMPORTANT FACTS (DO’S AND
DON’TS)
•DO: READ AND UNDERSTAND THIS MANUAL.
•DO: Have your furnace and vent system inspected annually
by a qualified service technician.
•DO: Inspect your filter monthly and clean or replace when
needed.
•DO: Provide adequate airflow to the furnace or efficient
combustion and safe ventilation.
•DO: Keep your furnace free and clear of insulating material.
Some materials may be combustible.
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•DO NOT: Enclose your furnace in an airtight room or seal
it behind solid doors.
•DO NOT: Keep combustible materials, gasoline, and other
flammable liquids or vapors around your furnace.
•DO NOT: Cover your furnace in any manner.
•DO NOT: Store anything (including trash or debris) near
your furnace.
•DO NOT: In any way block or restrict airflow around your
furnace.
•DO NOT: In any way block or restrict airflow to your supply
air and return air grills.
•DO NOT: Use your furnace room as a broom closet or a
place to store any kind of chemical or cleaner.
•DO NOT: Contaminate the air used for combustion of your
furnace with any kind of chemical or fumes. This could
also cause heat exchangers, metal vent systems or compo-
nents to deteriorate.
NOTE: These chemicals or fumes are present in many prod-
ucts around the home, such as: water softener salts, any type
of household cleaning product, any type of laundry product,
adhesives, paints, varnishes, paint strippers, waxes and
plastics, etc.
During remodeling be sure the combustion air is fresh and
uncontaminated. If these compounds are burned in your
furnace, the heat exchangers and metal vent system may
deteriorate.
•DO NOT: Use your furnace if any part has been under-
water. Call a qualified service technician to inspect your
furnace.
NOTE: The qualified installer or agency must use only
factory-authorized replacement parts, kits, and accessories
when modifying this product.
This furnace contains safety devices which must be manu-
ally reset. If the furnace is left unattended for an extended
period of time, have it checked periodically for proper oper-
ation. This precaution will prevent problems associated
with no heat, such as frozen water pipes, etc. See “Before
You Request a Service Call’’ section in this manual.
SAFETY CONSIDERATIONS
Installing and servicing heating equipment can be hazard-
ous due to gas and electrical components. Only trained and
qualified personnel should install, repair, or service heating
equipment.
Untrained personnel can perform basic maintenance func-
tions such as cleaning or replacing air filters. All other
operations must be performed by trained service person-
nel. Observe safety precautions in this manual, on tags, and
on labels attached to the furnace, and other safety precautions
that may apply.
Recognize safety information. This is the safety-alert sym-
bol . When you see this symbol on the furnace and in
instructions or manuals, be alert to the potential for personal
injury.
Understand the signal words DANGER, WARNING, and
CAUTION. These words are used with the safety-alert sym-
bol. DANGER identifies the most serious hazards which
will result in severe personal injury or death. WARNING
signifies hazards which
could result in personal injury or
death. CAUTION is used to identify unsafe practices which
would result in minor personal injury or product and prop-
erty damage. NOTE is used to highlight suggestions which
will result in enhanced installation, reliability or operation.
STARTING YOUR FURNACE
Your furnace uses an automatic hot surface ignition system
to light the burners each time the thermostat signals the fur-
nace to start.
Follow these important safeguards:
• Never attempt to manually light the burners with a match
or other source of flame.
• Read and follow the operating instructions on the furnace,
especially the item that reads as follows:
“Wait 5 minutes to clear out any gas. Then smell for gas,
including near the floor. If you smell gas,
STOP! Follow “B’’
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in the safety information above on this label. If you don’t
smell gas, go to the next step.”
• If a suspected malfunction occurs with your gas control
system, such as the burners do not light when they should,
refer to the shutdown procedures on the furnace, or in the
next section, to turn off your system, then call your dealer as
soon as possible.
•
Check Air Filter: Before attempting to start your furnace,
be sure the furnace filter is clean and in place. (See the main-
tenance section of this manual.) Do not run the furnace with-
out a filter in place. Then proceed as follows:
STEPS FOR STARTING YOUR
FURNACE
1. Set your room thermostat to the lowest temperature set-
ting. (See Fig. 5.)
2.
Close the external manual gas valve. (See Fig. 6.)
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3. Turn OFF electrical supply to the furnace. (See Fig. 7.)
4.
Remove the outer door by loosing the thumbscrew and
pulling the door forward. (See Fig. 8.)
5. Turn the control switch to
OFF and wiat 5 minutes to
clear out any gas. (See Fig. 9)
6. After waiting 5 minutes if you still smell gas,
STOP! Fol-
low the safety information on the cover of this manual. If
you do not smell gas, go to the next step.
7. Turn the control switch to
ON (See Fig. 10.)
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9
10
11
WARNING
Should overheating occur or the gas valves fail to
shut off the gas supply, turn off the manual gas
valve (See Fig. 6.) to the furnace BEFORE turning
off the electrical supply. A failure to follow this
warning could result in a fire or explosion, and
personal injury or death.
!
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8. Replace the outer door and tighten the thumbscrew. (See
Fig. 11.)
9. Turn
ON the electrical supply to the furnace. (See
Fig. 12.)
10. Open the external manual gas valve. (See Fig. 13.)
11. Set the room thermostat to a temperature slightly
above the room temperature. This will automatically
signal the furnace to start. The inducer motor will start,
and the hot surface ignitor will energize. When hot, the
ignitor will have an orange glow.
12. After about 32 seconds, the gas valve permits gas to flow
to the main burners where it is ignited. Hot flames begin
to warm the furnace’s heat exchanger. After a time
delay of approximately 25-45 sec the furnace blower is
switched on.
NOTE: If the main burners fail to ignite, the furnace control
system will go through 3 more ignition cycles. Then, if burn-
ers fail to ignite, the system will lockout. If lockout occurs,
or the blower does not come on—shut down your furnace and
call your dealer for service.
13. Set your thermostat to the temperature that satisfies
your comfort requirements. SUGGESTION: Setting
the thermostat back a few degrees—and compensating
for the difference with warmer clothing—can make a big
difference in your fuel consumption on extremely cold
days. The few degrees at the top of your thermostat “com-
fort level’’ are the most costly degrees to obtain.
When the room temperature drops below the temperature
selected on the thermostat, the furnace will switch on auto-
matically. When the room temperature reaches the setting
selected on the thermostat, the furnace will be automatically
switched off.
Continuous Fan Operation -Some thermostats have a “FAN’’
switch with 2 selections: AUTO and ON. When thermostat is
set on AUTO, the furnace blower cycles on and off, controlled
by the thermostat. In ON position, the furnace blower runs con-
tinuously except for a 42-62 sec delay at the “call for heat.’’
This keeps the temperature level in your home more evenly
balanced. It also continuously filters the indoor air.
Comfort Fan™ -On all but the 58STA or 58STX, the blow-
er speed can be increased or decreased if desired due to
change of seasons, large gatherings in your home, etc. Sim-
ple change your “FAN” switch from “on” to “off” (or “auto”
depending on your thermostat), and then return to “on.”
The blower will switch to the next highest speed. There
are at least 3 speeds to choose from. If the blower is run-
ning on its highest speed, a request to change will direct
the blower to return to its lowest speed.
SHUTTING DOWN YOUR FURNACE
Should you ever suspect a malfunction in your furnace, you
will need to turn the furnace off. The following procedures
must be followed:
1. Set your room thermostat to the lowest temperature
setting. (See Fig. 14.)
2.
Close the external manual gas valve (See Fig. 6 on page 4.)
3. Turn
OFF electrical power to your furnace. (See Fig. 15.)
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4. Remove the outer door on your furnace. (See Fig. 8.)
5. Turn the switch on the gas valve to the
OFF position. (See
Fig. 16.)
6.
Replace the outer door. (See Fig 11.)
7. If the furnace is being shut down because of a malfunc-
tion,
call your dealer as soon as possible.
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PERFORMING ROUTINE
MAINTENANCE
With proper maintenance and care, your furnace will operate
economically and dependably. Basic maintenance, which can
easily be accomplished by someone who follows the directions,
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is found on this and the following pages. However, before begin-
ning maintenance, follow these safety precautions:
FILTERING OUT TROUBLE
A dirty filter will cause excessive stress on the furnace, heat
exchanger, and blower motor and can cause it to overheat
and automatically shut down. The furnace filter should be
checked every 4 weeks or so and cleaned or replaced if
necessary.
If installed with factory specified disposable media filter,
check or replace filter before each heating and cooling
season. Replace disposable media filter at least twice
a year.
If your furnace filter needs replacing, be sure to use the
same size and type of filter that was originally specified.
The air filter for the furnace may be located in a filter cabinet
attached to the side or bottom of the furnace. If air filter has
been installed in another location, contact your dealer for
instructions. To inspect, clean and/or replace the air filter(s),
follow these steps:
1. Turn off the electrical supply to the furnace. (See
Fig. 7.)
2. Remove filter cabinet door (See Fig. 18 and 19.)
NOTE: It may be necessary to remove 1 thumbscrew.
3. Slide air filter out of filter cabinet. Keep dirty side up (if
dirty) to avoid spilling dirt. (See Fig. 20 and 21.)
4. Inspect the filter. If torn, replace it.
NOTE: If a washable filter has been replaced with:
a) Factory specified disposable media filter – Do not clean.
If dirty, replace only with media filter having the same
part number and size. Install with airflow direction arrow
pointing towards blower.
b) Electronic air cleaner (EAC) – Refer to EAC Owner’s
Manual for maintenance information.
5. Wash filter (if dirty) in sink, bathtub, or outside with a gar-
den hose. Always use cold tap water. A mild liquid deter-
gent may be used if necessary. Spray water through filter
in the opposite direction of airflow. Allow filter to dry.
6. Reinstall clean air filter
7. Replace filter cabinet door. (See Fig. 22 and 23.)
8. Turn on electrical supply to furnace (See Fig 12).
NOTE: If side return ducts are used, 2 filters may be required
in some models.The procedure listed above may be used to
remove side filters.
* Recommended ** Some furnaces may have 2 filters
Filters may be field modified by cutting filter material and support rods (3)
in filters. Alternate sizes and additional filters may be ordered from your
dealer.
COMBUSTION AREA AND
VENT SYSTEM
Inspect the combustion area and vent system before each
heating season. An accumulation of dirt, soot, or rust can
mean a loss of efficiency and improper performance. Build-
ups on the main burners can cause faulty firing. This “delayed
ignition’’ is characterized by an alarmingly loud sound. If
your furnace makes a loud noise when the main burners are
ignited, shut down the furnace and call your servicing dealer.
Use your flashlight and follow these steps for inspecting the
combustion area and vent system of your furnace:
1. Turn off electrical supply to the furnace and remove
the access door. (See Fig. 7 and 8.)
2. Carefully inspect the gas burner for dirt, rust, or scale
(See Fig. 17.) Inspect the elbow, flue connection
area, and the vent pipe for rust.
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NOTE: If dirt, rust, soot, or scale accumulations are found, call
your servicing dealer. DO NOT OPERATE THE FURNACE.
WARNING
Turn off electrical power supply to your furnace
before removing the access doors to service or
perform maintenance. A failure to follow this
warning could result in personal injury or death.
CAUTION
Although special care has been taken to minimize
sharp edges, be extremely careful when handling
parts or reaching into the furnace.
CAUTION
Never operate your furnace without a filter in place.
Doing so may damage the furnace blower motor.
An accumulation of dust and lint on internal parts
of your furnace can cause a loss of efficiency.
!
!
!
FURNACE CAS-
ING WIDTH
FILTER QUANTITY
AND SIZE **
FILTER TYPE *
SIDE
RETURN BOTTOM RETURN
14-1/2 (1) 16 x 25 (1) 14 x 25 1” thick cleanable
or 4-5/16” thick
media-type
17-1/2 (1) 16 x 25 (1) 16 x 25 1” thick cleanable
or 4-5/16” thick
media-type
21 (1) 16 x 25 (1) 20 x 25 1” thick cleanable
or 4-5/16” thick
media-type
24 (1) 16 x 25 (1) 24 x 25 1” thick cleanable
or 4-5/16” thick
media-type
CAUTION
Use care when cutting support rods in filters to
protect against flying pieces and sharp rod ends.
Wear safety glasses, gloves, and appropriate pro-
tective clothing. Failure to follow this caution
could result in personal injury.
!

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18
19
20
21
22
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3. Inspect the vent pipe for a sag, holes, or a disconnection.
A horizontal vent pipe must slope upward away from fur-
nace. If rusty joints or seams, or signs of water leakages
are found, call your dealer for service.
4. Restore electrical power to the furnace. (See Fig. 12.)
5. Start the furnace and observe its operation. If possible,
watch the burner flames. Are they burning bright blue?
If not or if you suspect some other malfunction, call
your servicing dealer.
6. Replace the access door. (See Fig. 11.)
BEFORE YOU REQUEST A
“SERVICE CALL’’
Before you call for service, check for several
easily solved problems:
• Check for sufficient airflow. Check the air filter for dirt.
Check for blocked return-air or supply-air grilles. Be sure
WARNING
If holes are found or if the vent pipe is obstructed
or is not connected, toxic fumes can escape into
your home. DO NOT OPERATE YOUR FURNACE.
Call your dealer for service. A failure to follow this
warning could result in personal injury or death.
!

TO OBTAIN INFORMATION ON PARTS: Consult your installing dealer or the classified section of your local telephone directory under the
“Heating Equipment’’ or “Air Conditioning Contractors & Systems’’ heading for dealer listing by brand name.
Have available the Model No., Series Letter, & Serial No. of your equipment to ensure correct replacement part.
Carrier Corporation 7310 West Morris St. Indianapolis, IN 46231
Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations .
Copyright 2002 Carrier Corporation Form: OM58-102 Replaces OM58-101 Printed in the U.S.A. a6-02 PC 101 Catalog No. 535-80080
8
they are open and unobstructed. If this isn’t the cause of the
problem, call your servicing dealer.
If your furnace isn’t operating at all, check the following list
for easily solved problems:
• Is your thermostat set above room temperature? Is the
HEAT mode selected?
• Is the electrical power supply switch on? Is the blower
access door firmly in place? Are any fuses blown? (There is a
fuse on the furnace control.) Has a circuit breaker tripped?
• Is the manual shut-off valve in the gas supply pipe leading
to the furnace open? Does the lever point in the same direction
that the pipe runs (open)? Or is it at a right angle to the pipe
(closed)?
NOTE: Before proceeding with the next checks, turn off the
electrical power supply to the furnace. Remove access door.
• Is the switch on the gas valve turned to the ON position? If
this or the preceding check shows an interruption in the gas
supply, make sure the gas has not been shut off for safety rea-
sons. If nothing else seems to be wrong, follow the startup pro-
cedures found on pages 4 and 5 of this booklet.
• If for some reason the vent is blocked, the blocked vent safe-
guard switch will shut off the furnace. (See page 2 or 3 for
switch location.) The switch will automatically reset after the
furnace cools off.
• Check the manual reset limit switches located on the end of
the burners. If the furnace has experienced a high-temperature
condition due to inadequate combustion air, these switches will
shut off the furnace. Reset the switches by pushing the button
on the switch. If the switch trips a second time, turn off the
furnace and call for service.
• If your furnace still fails to operate, call your servicing deal-
er for troubleshooting and repairs. Tell your dealer the model
and serial numbers for your furnace. (You should have them
recorded on page 8 of this booklet.) By knowing exactly which
furnace you have, the dealer may be able to offer suggestions
over the phone or save valuable time through knowledgeable
preparation for the service call.
Regular dealer maintenance
In addition to the type of routine maintenance you might be
willing to do, your furnace should be inspected regularly by a
properly trained service technician. A semiannual inspection
(or annual inspection, at least) should include the following:
1. Inspection of all flue gas passages including the burners,
heat exchanger, inducer, elbow, and vent pipe.
2. Inspection of all combustion and ventilation air
passages and openings.
3. Close check of all gas pipes leading to and inside of your
furnace.
4. Inspection and cleaning of the blower motor and wheel.
5. Routine inspection and cleaning/replacement of the air filter.
6. Inspection of all supply- and return-air ducts for obstruc-
tions, air leaks, and insulation. Any problems found should
be resolved at this time.
7. Inspection of furnace installation for proper support and any
obvious deterioration of the furnace. The support must be
sound and without sags, gaps, cracks, etc., around the fur-
nace base so as to provide an air seal between the return-air
duct and furnace.
8. A check for loose connections attaching individual compo-
nents. Inspection of all electrical wiring and their connections.
9. Operational check of the furnace itself to determine working
condition. Repair or adjustment should be made at this time.
Ask your servicing dealer for further details about an econom-
ical service contract that covers seasonal inspections.
INSTALLATION DATA
Date Installed
Dealer Name
Address
City
State/Province Zip/Postal Code
Telephone
FURNACE
Product No.
Model No.
Serial No.
AIR CONDITIONER OR HEAT PUMP
Product No.
Model No.
Serial No.
INDOOR COIL:
Product No.
Model No.
Serial No.