Troubleshooting

Resolving InstaStart™ Ignition Performance Issues

Burners Troubleshooting

Problem Identifying the cause
Burner will not light
(with igniter or match)
  1. Low or out of propane
  2. Cylinder or the gas supply valve is turned off
  3. Positive connection has NOT been made between the tank and the regulator. Regulator will not allow fuel in the line.
  4. The Flow Limiting Device in the regulator has been activated
  5. Manifold valve assembly is damaged
Fire at control knob and control panel = Flash Fire
  1. Burner port holes and/or Venturi tubes are blocked
  2. Burner is improperly seated on valve gas jet
Yellow smoky flames
  1. Blocked Venturi tubes
  2. Excess cooking salts on burner
Flame blows out on LOW
  1. Flow Limiting Device has been activated
  2. High Wind condition – Adjust the placement of Barbecue to shield from wind
  3. Propane is running low
  4. Burner improperly seated on valve gas jet
  5. Heat Distribution plates are not in position
  6. NATURAL GAS MODELS: Installation issues related to incorrect size supply line installed and /or Water Column supply is not adequate for a Barbecue BTU rating of this grill. Do not use a longer Natural Gas hose than is supplied with your grill.
Burner does not get hot enough
  1. Barbecue needs to be preheated for 5 to 10 minutes with a closed lid. Outside temperatures will affect the amount of preheat time required.
  2. Flow limiting device in regulator has been activated and requires resetting
  3. NATURAL GAS MODELS: Installation issues related to incorrect size supply line installed and /or Water Column supply is not adequate for a Barbecue BTU rating of this grill. Do not use a longer Natural Gas hose than is supplied with your grill.
Low or incomplete flame (assuming burners and Venturi tubes are free and clear of blockages)
  1. Proper start up and shut down procedure not followed
  2. Flow limiting device in regulator has been activated and requires resetting
  3. Flame Tamers (heat plates) are missing or not in position
  4. NATURAL GAS MODELS: Installation issues related to incorrect size supply line installed and /or Water Column supply is not adequate for a Barbecue BTU rating of this grill. Do not use a longer Natural Gas hose than is supplied with your grill.
Too much heat/ Excessive flare up
  1. Excessive fat in meat
  2. Grease drain plugged
  3. Cooking system including flame tamers and cooking grates have a build up of grease that must be removed
  4. Lower casting of the Barbecue is clogged with grease
  5. Cooking on lower temperature setting. Reduce temperatures according to type of foods being cooked.
Problem Identifying the cause
Controller will not turn "ON"
Led display does not light up.
  • Selection dial not pressed correctly.
  • Power supply issue.
  • 5-AMP fuse may be blown.
  • Power cord wire unplugged or has a loose connection to the controller.
  • Faulty controller.
Grill will not ignite – Igniter not working
Fan can be heard and auger can be heard.
  • Too much ash buildup in the burner pot.
  • Igniter is unplugged or has a loose connection to the controller.
  • Faulty igniter.
  • See the Manual Lighting Instructions in your Safety & Care manual, to use your pellet grill without the igniter.
Grill will not ignite – Igniter is working
Igniter is working and is glowing red (Maybe difficult to see in daylight). Fan can be heard at start up.
  • Auger jammed.
  • Auger motor unplugged or has a loose connection to the controller.
Grill will not ignite – Igniter is working
Igniter is working and is glowing red (Maybe difficult to see in daylight). Auger is working. Fan is "OFF".
  • Fan blades may be dusty and dirty and need to be cleaned.
  • Fan wire unplugged or has a loose connection to the controller.
Difficulty getting to "SET" temperature and/ or maintaining "SET" temperature.
  • Controller tolerance +/- 20°F is normal.
  • Controller "P" setting – Only applicable on the "SMOKE" setting.
  • Too much ash. Insufficient air flow through burner pot.
  • Fan may be dirty. The fan should be heard from start to finish.
  • Cooking with the lid open.
  • Weather conditions.
  • Low fuel.
  • Damp pellets clumping together and sticking to the walls of the hopper.
  • Sensor probe is dirty.
  • Sensor probe loose or disconnected from the controller.
Hopper Fire
  • Too much ash buildup.
  • Hopper lid left open during cooking.
  • Too many pellets in the burner pot.
  • Too many old and clumping pellets loading the auger at a time.
  • Fan may be dirty or working intermittently because it is dirty.
  • Grill not on a level surface.
  • Grease Fire caused by a combination of high cooking temperatures and grease and ash build up within the firebox.
Grill temperature on "SMOKE" setting is too hot.
  • "P" Setting is too LOW.
  • Overfiring/ too many pellets in the burner pot.
Grill produces excess smoke or dark smoke.
  • Too much ash/ grease buildup in the burner pot and firebox.
  • Old or damp wood pellets. Incorrect pellets (Do not use heating pellets).
Not Enough Smoke
  • Your Cookout™ Pellet Grill produces a superior thin blue smoke that provides a cleaner, smoke flavor. Often, the smoke is so thin it only appears as heat waves coming off the grill. You will be able to see the smoke rings on your meat and taste the difference. If you require even more smoke, you can add the Coleman Smoke Generator (85-2343-0) to your grill.
Frequent Flare-ups
  • Grill Maintenance required.
  • Cooking temperatures are too high. Grease does have a flash point, keep the temperature under 350°F when cooking highly greasy food.
Controller temperature is changing rapidly from "HIGH" to "LOW" temperatures in a nonsequential order or ERL, ERR, or ERH Error codes are possible depending on the cause.
  • Clean the sensor.
  • The sensor connection to the controller may be loose or unplugged.
  • Not following proper lighting procedure with the lid open.
  • Flame burned out in the burner pot, but the auger continues to feed. At re-ignition extreme temperature swings can be found.
  • Incorrectly filling fuel when you have run out. You MUST always shut down before reloading the hopper assembly.
  • Fan may be dirty or working intermittently because it is dirty.
  • Controller malfunction.
Grease Fire / Over-Firing (too many pellets) / "ERH" - Error code
High temperature alert when the temperature is higher than 615°F.
  • Maintenance required.
  • Too many pellets in the burner pot.
  • Old and clumping pellets loading the auger too many at a time.
  • If the grill is "not" hot and you still have this ERH error, the sensor may be dirty and require maintenance or the connection to the controller may be loose.
  • Pellets are tunneling (stuck to the side of the hopper) before dropping suddenly into the auger or out of fuel procedure was not followed.
"ERR" – Error code in operation indicates an auger, fan or ignition error (Icons may be flashing).
  • Low fuel.
  • Fuel is stuck on the sides of the hopper.
  • ERR code during start-up. Press and hold the selection dial to shut down and disconnect the power cord for 1 minute. Reconnect power cord, wait 30 seconds before trying to start-up again.
"ERL"- Error Code
Low Temperature alert
  • The Sensor connection to the controller may be loose or disconnected.
  • Sensor is dirty and requires cleaning
  • Igniter issue. Pellets are not successfully lighting in the burner pot.
  • Hopper out of fuel - Check hopper to ensure fuel is not stuck to the sides.
  • Fuel blockage in auger.
  • Ash blockage obstructing air flow in the burner pot.
  • Auger/auger motor not functioning correctly.
  • Fan may be dirty or working intermittently. Make sure it is clean and that it is plugged in correctly.
"ERP" - Error Code
Power Alert
  • Power cord not plugged in correctly or an issue with the GFCI outlet.