1. That Trane system is a very good, high end furnace. Unless there was some defect in manufacturing, not likely the heat exchanger is burned out this soon. That is a high liability item, not something a mfg would want to shortcut. If there is a problem it had a lifetime warranty.
Typical symptoms are the flame dancing above the burners, turbulance in the fire box as soon as the main blower comes on, flame roll out (as in the flame actually coming out the front of the furnace), discolored paint around the vents, CO monitor sounding (serious life threat from CO and fire!).
2. I wouldn't think low gas would cause flame roll out. It can cause the flame to burn at the jet instead of on top of the burner as it should. That will cause sooting, clogged burners, definitely not a good situation. Look for black soot around the jets, inside the air horn of the burners.
3. Lack of combustion air is one of the most likely causes of flame roll out. Also negative pressure around the combustion air intake.
Where is the unit installed? If it's in the attic, certain air drafts, strong wind currents flowing through can cause backdraft down the flue. But, I would think the combustion air flow sensor would catch that and shut down the flame before the roll out sensor over heated. Easy test for the combustion air flow sensor, unplug the hose, it should shut down the gas flow.
If the unit is located in the house or basement, there should be a combustion air duct from the attic or outside feeding air to the closet where it is located. Without that air supply to equalize the pressure, air can be drawn back down causing the backdraft. Possibly the air supply could have been blocked by snow?
If possible, try watching the furnace. Try opening outside doors, one at a time or combinations. The flame should be steady, no leaping or blowing around. Of course a lot depends on the wind direction and speed. If you can, do some detective work, note when the failure occurs, what was the wind doing, any unusual events, certain door opened or closed... Sometimes if there is a return air duct in the same room as the furnace, and the doors are closed to that room, it can cause low pressure and backdraft the heat exchanger.
4 Plugged burner orfice would show as one burner having a much lower flame or no flame at all. Could also cause the same symptom as low pressure, but only on the one that was restricted.
5. Plugged heat exchanger, that would be a possibility. As in the vent pipe not properly routed and collecting condensation, or icing. Anything that could partially block the exhaust vent. Is the vent covered to prevent birds or rodents from nesting or getting in? Wasp nests, dirt daubers?
If there is not enough air flow to handle the expanding combustion gasses, the flame will try to find it's way out, and that's why the roll out sensor is there.
If this unit has been in service for a few years, and just now having this problem, something must have changed. A remote possibility is a faulty roll out sensor, but not likely. If there is roll out, typically you will see sooting or paint discoloration around the area of the sensor.
Hope this helps. Do you have the install manual? It has all the specs for vent size, dip switch settings for fan speeds, etc. Many installers don't bother to customize the settings. It's time consuming, but makes for a better install and efficiency.
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