what's the story on the silver duct at the back of the unit which has tape over it?
Agree with all the others, there is something wrong with air flow, or gas nozzles. Propane and nat gas burn amazingly clean. They have to burn well and not produce significant free carbon deposits like that. Get someone who's got a cert in HVAC so they can do all the right baro pressure tests as it's installed, or when the new one is installed.
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