Thanks for the input.
Pulled heat exchanger out of the 530. Applied about 1psi to it and soaped it all down. No leaks at the relief gasket or any of the welds or joints but there was some bubbles coming from around the peep window gasket. I dialed up the Px and the relief plate started to "buzz" and still no leaks elsewhere.
So I replaced all 3 gaskets, peep, relief and lower exchanger gaskets. Ran it on the bench in the Toyo guys big shop (1000sq-ft?) So I am confident all is well.
Toyo warrantied the gaskets and the Toyo guys time so that was good.
I will check those things suggested if it continues to smell. Its not the installation due to the fact I installed it ..... and yes, I am that good.

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