Thanks for the reply.
I've attached a couple photos.
CabinetDuct4a.jpg is looking towards the rear of the unit towards the crawlspace. Instead of removing the standard 16"x13" cover --- he cut a hole and installed a round flange. CabinetDucta.jpg is a close up looking through the round flange and shows my existing rectangular ductwork. In other words, he installed a round flange - on the supply and return sides - but did not connect anything to the flanges??? Instead of utilizing the entire 16x13 areas he restricted them to smaller round openings???
Thanks for the info --- i'm gathering the data you suggested and will continue tomorrow.
With thermostat set at 74:
Temp at hallway return filter: 74
Temp at floor register: 59
The blower also makes a pulsating sound at a rate of once per second. Sounds like it is struggling?
There are jumpers on the control board and the contractor has previously set the cool blower to the max speed. I have 2ea 16x20 filters for a return filter area of 640sq in -- but there is very little suction when I change them.
I actually measured run times last nite:
Cooling for 22 min, off for 5 min.
Cooling for 16 min, off for 7 min.
Cooling for 16 min, off for 8 min.
Cooling for 17 min, off for 7 min.
The outside temp was approx 82 degrees.
Remember we're talking about a package unit --- there is no inside unit.
The basic model # of the unit is R6GF 3ton , 2 stage cooling, 2 stage heat.
The round duct in the photo have NOTHING attached to them.
I know this sounds crazy but it is like you take a package unit, install round flanges on the supply and return as if you were installing in a mobile home, but instead you connect the existing rectangular ducts to the side of the unit.
The pictures might help me explain it.
At any rate - I highly suspect these round flanges are restricting the airflow.
Thanks for the input. I've filed an official complaint with the state hvac board. They will perform an inspection. If problems are found then I'll get estimates for repair, and the original contractor is supposed to pay for them. I hope this will happen in the next few days and will let you know what happens.
Also - there has always been a pulsating sound when cooling. Of a whim, I replaced the thermostat (RTH8320) with the previous honeywell single stage thermostat. The pulsating sound stopped. I then reinstalled the RTH8320 and the pulsating sound started again. Is it possible that the thermostat is pulseing the unit? I'm thinking of putting an osciliscope on the cool and fan terminals to verify. Your thoughts?