Smart Combustion Motherboard & Cover Replacement Instructions

1. Remove the hopper side service panel.

2. Remove 6 screws (2 located on top of the access panel, 2 below the hopper side rail, and 2 on the bottom of the access panel).
3. Remove the smart combustion cover by unscrewing the 4 screws securing it in place.
4. Unplug the AUGER, FAN, SMART COMB/GREASE, PELLET, and AC IGN connections.
    
5. The SMART connection is siliconed into place to prevent strain on the cable. Follow the blue and brown wires and disconnect the connections to the Lid Light and the Auxiliary Fan.
   
6. Unscrew the plastic bottom smart combustion housing from the side of the hopper.
7. Replace the Smart Combustion Wire Harness that comes with Motherboard replacement.
8. Fasten the new bottom of the smart combustion housing assembly (with motherboards) to the side of the hopper.
9. Connect all the harnesses based on the given diagram. See Wire Harness.
10. Reattach the smart combustion cover and reattach the hopper side service panel.

 See Wiring Harnesses for visuals of the wiring diagram, and images of the individual harnesses.

 Before You Start

1. Make sure the grill is turned off and unplugged.
2. Remove the grease and ash keg from the grill (located inside the grill cabinet/ underside of the grill).
3. Remove Hopper Side Service Panel
   • Use a manual impact driver to remove 6 screws:
     • 2 on top
     • 2 below the hopper side rail
     • 2 on the bottom

1. Access the Smart Combustion Wire Harness

1. Under the grease and ash keg opening, remove the metal plate (2 screws).
2. Cut the zip tie holding the wire in place.

2. Disconnect the Smart Combustion Wire Harness from the Flame Sensor Wire Harness

1. Located inside the grill cabinet.
2. Remove the igniter access panel by unscrewing the four screws. Be cautious of falling ash and pellet debris.
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3. Disconnect the Smart Combustion Wire Harness from the Flame Sensor Wire Harness
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4. Tape the new Smart Combustion Wire Harness to the old wiring (shown in image above) that goes towards the motherboard to help guide it during removal
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5. Connect the flame sensor harness to its connector on the new Smart Combustion Wire Harness.
   

3.  Pull the Flame Sensor Wire

1. Inside the hopper assembly, find the original Smart Combustion Wire Harness.
2. Gently pull the wire toward the motherboard.
3. Optional: For easier access, remove the induction fan. This helps you feed and pull wires under the grill from the hopper side.

4. Disconnect the Old Wire Harness

Follow minutes 0:00-1:03 of the video below for visual on accessing the motherboard and replacing the Smart Combustion Wire Harness.                                 

To access and disconnect the Smart Combustion Wire Harness, follow these steps:

1. Open the hopper lid.
2. Inside the hopper, locate the front interior panel. You’ll see 4 screws holding it in place.
   1. Start by removing the bottom-left screw. This screw holds the pellet safety guard.
3. Remove the pellet safety guard.
4. Unscrew the remaining 3 screws.
5. Carefully pull the front interior panel away from the hopper to expose the internal wires and the back side of the lid sensor/light.

6. Locate and disconnect the wire harness connectors to the Smart Combustion Wire Harness (seen in time stamp 1:01 in video above).
7. Plug in the lid sensor to new Smart Combustion Wire Harness (the shortest wire in the harness).
8. Inside the hopper assembly, find the original Smart Combustion Wire Harness. It has green, black, red, and yellow wires.
9. Disconnect the old harness from Motherboard.
10. Connect new Smart Combustion Wire Harness to Motherboard

5. Reconnect and Test

1. Plug the grill back in.
2. Turn on the power.
3. Run a Self-Test & Diagnostic Test to confirm everything works.
4. Reassemble grill.