I hired an established 20 year American Standard authorized "Customer Care" Dealer size and install an AUY080 variable speed 2 stage high efficiency natural gas furnace in my house last fall. It replaced a 30+ year furnace. Over the past two months we've had a number of nights that fell to around -8 to -11 F, about as low as it ever gets for this area. During this time, the furnace has never needed the second stage at all. In fact, the only time the second stage goes on is when the 2 stage thermostat is manually increased more than 2 degrees.
There are return ducts in almost every room upstairs. The return air flow is very noisy (to my taste), even in the rooms farthest from the middle of the house, where the furnace is located. The supply ducts are not noisy at all. When the second stage is on, the increased airflow is very loud in my opinion. This wouldn't be a problem for the heating season, but full fan is used for cooling.
I'm ready to give the contractor a call and ask him about this. But I'd like to get more informed first. How much (if ever) should second stage be needed? Is it normal to put up with a constant rumbling of air in return ducts? The opening in the (upflow) furnace side between the side return duct and the furnace is smaller than the blower, leaving me to wonder if this is at least part of the return noise problem. How long should the on cycle times be, for a 30F degree day, for example?
My house is a split level, about 1700 sq ft, 1350 "livable" and is in eastern Massachusetts.
Thanks!