I have a brand new 2016 unit with a Suburban furnace Model #SF-30FQ that is having a smell and noise issue. With my previously new Roo the furnace had that new smell for the first few minutes upon start up. It never triggered the smoke alarm and was perfect after those initial minutes. This baby is giving me problems unlike the furnace in my Roo.
INITIAL STARTUP AT DEALER
We turned on the furnace and the smoke alarm was triggered. They told me to run for a few min when I got home and it would go away. They turned it off immediately after feeling the heat trigger on. Probably normal thing to do.
A couple of days after getting home I turned it on and the alarm triggered again. The smell also was really intense as I let it run. My eyes were burning from the air too. I left the camper and let the furnace run for an hour. I returned and turned it off thinking it was probably clear. I had left the doors open when it ran.
SECOND USE: LAST NIGHT
So last night I went out and turned it on again. Alarm triggered and I let it run for two hours. The smell was again intense. I tried to stay in the camper but I got a strong headache and nausea so I left the camper. My eyes at least were not burning like the night before. I went out to the camper after that run and the smell had diminished a bit. Improvement.
THIRD USE: THIS MORNING
I turned on the furnace and let it run. The alarm did not trigger. The smell had improved greatly. It was still there but not overpowering. My eyes were not burning. I went back to the unit after two hours and I could actually sit in the camper and not be uncomfortable. I have had it running for 3.5 hours so far. Its still running. Here's the deal now though. I was in the garage (door closed) and I could hear a motor howling. Sounds like bad bearings or a fan blade that is rubbing against something. I went into the camper and sat on the couch. The furnace is under the couch. I could hardly hear my wife talk to me (she was 10 feet away) as the noise was really strong. The smell is getting better all the time.
So I've attached a video of the sound. I have a couple of questions.