Protherm
Overheating Components / Electrical Overload
Burning smell or hot plastic odor when furnace runs
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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
Dust burning off heat exchanger on first use, Overheating blower motor, Loose electrical connection on Protherm PCB, Melted insulation near flue
How to Fix / Troubleshooting
Safety first: If you see smoke or flames, shut off power and gas immediately and call emergency services.
- Step 1 – New or seasonal use: A light burning smell for the first few cycles after long inactivity can be normal as dust burns off. It should dissipate quickly.
- Step 2 – Inspect wiring: With power off, inspect wiring near the heat exchanger, blower, and PCB for discoloration or melted insulation. Repair or replace damaged wiring.
- Step 3 – Motor temperature: Check if the blower or fan motor is excessively hot. If so, the motor may be failing or overloaded and should be replaced.
- Step 4 – Flue clearance: Ensure no plastic or combustible materials are touching the flue pipe.
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Repair Difficulty
Medium
3/5
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