A common source of furnace noise is the air filter, which collects dirt and debris and gets loud when air flow begins to become obstructed. Turn off the Tempstar DC90 furnace and open the access panel to reach the air filter. Lift the filter up and out and vacuum the filter or wash with warm water. Allow it to air dry before putting the filter back in with the arrows lined up in the air flow direction. The filter should be cleaned on a regular basis.
The blower fan may also get dirty, which makes sound as the blower operates to distribute the warm air from the furnace. When the control panel is open and the power to the furnace disconnected, use a soft brush to carefully clean the blower fan and the blower area. Be careful not to damage the fan or touch the burner.
A rattling sound when the Tempstar furnace is in use might indicate something as simple as loose hardware on the control panel. Check the screws on the cover panel and the mounting on the transformer. Tighten any screws that are loose.
If the furnace is making a whooshing or banging sound, especially when the furnace is igniting, Tempstar should be contacted for service. The gas burner may be short on combustion air or need to be cleaned, the heat exchanger may be damaged, or the gas solenoid valve may need to be replaced. If you see any leaks, rust, corrosion or soot, turn off the furnace and contact Tempstar immediately. The system may be leaking carbon monoxide, and this must be attended to as soon as possible to prevent a potentially fatal problem.