Looking for opinions from HVAC professionals because I’m trying to determine whether I actually need to replace my furnace or if there’s a way to safely correct the existing setup.
Background:
I recently purchased a roughly 2,050 sq. ft. home in Southeast Texas. We had an HVAC company come out for a routine tune-up and inspection because my kids have been coughing, and I wanted to rule out any air-quality issues.
During the inspection, the technician identified what he considered a serious combustion-air safety concern.
My current setup:
Furnace: Trane XB80, model TUE1B080A9481AD
80,000 BTU/hr input, approximately 80% AFUE
Open-combustion, induced-draft natural gas furnace
Installed horizontally in the attic
Attic roofline was spray-foam insulated in 2019
Furnace has a metal exhaust flue vented through the roof
Existing AC system works fine
What the HVAC technician told me:
Because the attic is encapsulated with spray foam, the furnace may not be receiving enough combustion air. He raised concerns about incomplete combustion, carbon monoxide, and potential backdrafting.
He recommended replacing the furnace with a sealed-combustion unit and specifically told us not to operate the heater until the issue is resolved.
He also mentioned that because his company had already serviced the system, they had liability concerns.
I understand the safety implications, especially with two young children in the house. I’m taking that seriously and keeping the heater off.
However, I haven’t been provided any combustion-analysis readings, draft measurements, combustion-air calculations, or documentation explaining why replacement is the only acceptable solution.
Here’s where things get interesting.
I contacted the previous homeowner, who maintained the house extensively.
He explained that when the attic was spray foamed in 2019, they specifically accounted for the furnace ventilation.
He claims there are TWO separate roof vents:
The existing furnace combustion exhaust.
Another roof vent connected by flexible ductwork to the furnace area, apparently intended to bring in outside air.
He said the system was designed to draw air from outside despite the spray foam insulation.
He also operated the heater every winter without noticing any issues, although I understand that doesn’t rule out carbon monoxide or combustion problems.
What I found in the attic:
While inspecting the furnace, I noticed a separate insulated flexible duct with a round metal opening and a Honeywell motorized damper actuator.
Initially, I thought the duct was disconnected. However, looking closer, I believe the actuator may actually have the damper closed, which would explain why the opening appears blocked.
I don’t know what controls the actuator, when it’s supposed to open, or whether this duct supplies outdoor combustion air, fresh air for the house, or something else entirely.
The previous homeowner specifically mentioned a separate roof vent and flexible duct installed when the attic was spray foamed in 2019.
I’m wondering whether this motorized damper could be part of that original ventilation arrangement.
I’ll attach pictures of the furnace, ductwork, and damper.
What I’m trying to figure out:
I understand that an open-combustion furnace cannot safely rely on an inadequate air supply inside a tightly sealed attic.
But is replacing the entire furnace really necessary?
I’ve been researching several alternatives:
Repairing the existing outside-air intake, assuming the previous owner actually had one installed and it can meet code.
Installing a properly sized outdoor combustion-air duct that supplies air to the furnace area.
Building a separate, sealed mechanical enclosure around the existing furnace, with its own outdoor combustion-air supply, to preserve the rest of the encapsulated attic.
Replacing the furnace with a sealed-combustion model if the other options aren’t feasible.
My other concern is that introducing hot, humid Southeast Texas air directly into my encapsulated attic could undermine the benefits of the spray foam and create moisture or condensation problems.
I’m trying to avoid spending thousands replacing a working furnace if a properly engineered, code-compliant alternative exists.
Questions for HVAC professionals:
Can this particular Trane XB80 operate safely in an encapsulated attic with a dedicated outdoor combustion-air supply?
Does the existing roof intake described by the previous owner sound like a legitimate arrangement?
Could the Honeywell motorized damper be related to combustion air, or is it more likely part of a fresh-air ventilation system?
If that damper is normally closed, how would I determine whether it’s supposed to open when the furnace operates?
Would adding an outdoor-air duct significantly compromise the attic’s humidity control and energy efficiency?
Is building a separate combustion-air enclosure around a horizontal furnace a realistic, code-compliant option?
What specific testing should I request to determine whether the existing furnace is actually unsafe?
Would you recommend repairing the combustion-air arrangement or replacing the furnace?
I’m planning to get an independent combustion-safety inspection with actual CO, draft, spillage, and combustion-air measurements before making any decisions.
I’m not accusing the original HVAC company of dishonesty. I understand their liability concerns, but I’d like objective evidence before agreeing to a potentially $6,000–$10,000 replacement.
If this were your house, what would you do? Is there a reasonable way to keep this furnace safely, or is replacement genuinely the best option?
Any advice from experienced HVAC technicians, installers, or building-science professionals would be appreciated.