Danfoss Combustion Gas Leakage / Incomplete Combustion

Strong fuel or exhaust smell around the furnace during operation

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Safety Warning

This repair may involve working with high voltage components or water connections. Always unplug the appliance before removing any panels.

If you are not confident in your ability to perform this repair safely, we strongly recommend contacting a professional technician.

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Possible Causes

Leaking flue joint, cracked heat exchanger, misaligned burner, incorrect air-fuel ratio, loose oil fittings on Danfoss oil pump

How to Fix / Troubleshooting

Safety first: If you smell gas, evacuate immediately and contact your gas supplier. For oil or exhaust smells, turn off power and fuel and ventilate the area. Do not ignore combustion odors.

Steps:

  • Inspect flue connections: Check all visible flue joints for gaps, corrosion, or soot marks indicating leakage. Tighten clamps and reseal with appropriate high-temperature sealant where allowed.
  • Check burner mounting: Ensure the burner flange is tightly sealed to the combustion chamber with the correct gasket.
  • Oil systems: Inspect oil lines, filter, and Danfoss oil pump for wet spots or drips. Tighten fittings and replace damaged copper lines.
  • Call a professional: A cracked heat exchanger or improper combustion must be diagnosed with test instruments. Do not operate the furnace until inspected by a qualified technician.
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Repair Difficulty

Professional Required 5/5

Required Part

Flue Pipe Assembly
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