A customer of mine has a persistent issue that seems hard to diagnose. It seems that every time that there is a significant time interval between the last call and the current call for heat or hot water, the boiler fails to restart and throws the code E003 (Ignition Failure). The usual suspects have all been checked: power is on, gas line is on, flame rod ignitor has been replaced, water pressure is good.
Navien tech support has obviously been called and after going over all the options, one suggestion was to manually "choke" the air inlet. Interestingly, this works consistently at restarting the boiler but the problem might resurface again the next day. Apparently, this has to be done on a frequent basis by the customer now that winter is upon us.
Effectively, this solution is a stop-gap measure as the customer cannot take vacations as the boiler might not restart and the house will freeze over, burst pipes, you get the idea. The house is located at 500 ft altitude, and the boiler dip switch settings are appropriate (Front panel DIP Switch set of 10: 4-OFF, 5-OFF). The boiler runs on propane and the dip switch is set right (Front panel DIP switch set of 2: 2-ON). Boiler was installed in Dec 2014 and ran error free until Jan 2019. This problem has persisted since Jan 2019.
So my question is: What can be done to correct the air-fuel ratio for a cold start?
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