Controller Replacement Instructions for Non-WiFi Grills

What's in This Article?

In this article you'll learn how to replace and install a non-WiFi controller on your Traeger pellet grill in just a few, easy steps. There are several variations of Traeger controllers without WiFIRE technology (sometimes referred to as "AC" grills); we'll walk through how to remove and install each variation here. The ease of the plug-and-play type connections on our AC controllers, will have you back to grilling in no time.

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The instructions outlined in this article apply to the following controller part numbers:

  • BAC236
  • BAC331
  • BAC365
  • BAC390
  • KIT0185
  • KIT0277
  • KIT00278
  • KIT0330
  • KIT0352
  • KIT0390
  • KIT0569
  • KIT0576
  • KIT0746
  • KIT0747

 

What kind of controller does my grill have?

You can identify a non-WiFi grill by the controller and the side of the grill the hopper is on. If your controller looks similar to one of the ones below and your hopper is on the left-hand side of the grill (when facing the grill), you have a non-WiFi AC grill. 

traeger-arc-controller-studio.png
digital-thermostat-kit-meat-probe.png
digital-thermostat-kit.png
Arc Controller Pro-Style Controller

 

 

Replacing & Installing a Pro-Style Controller

Pro-style controllers come in one of three styles, shown below, each featuring a dial temperature control. Follow the steps here to replace and install any of these variations on your Traeger pellet grill.

  • Elite Digital Controller
  • Pro AGL Controller
  • Pro Controller w/ P Setting
  Controller Front Controller Back
Elite Digital Controller different_1.png Elite Controller.png
Pro AGL Controller different_3.png Pro AGL Controller back.png
Pro Controller w/ P Setting controller_with_p_2.png Pro Controller w_P setting back.png

 

Tools Needed

  • Phillips Screwdriver
  • Replacement Zip Ties (Optional)

Replacement Steps

  1. Power off and unplug your grill.
  2. Remove bottom hopper panel (If applicable. Not all hoppers have a bottom panel).
  3. Go underneath the hopper and locate the 4 Molex (Plastic) connectors.
  4. Unplug the connectors. 
    • Each wire is color coordinated (Except the wire that connects to the Hot Rod) to assist in reconnection once new controller is installed.
      ac grill shutdown.jpeg
  5. At the front of the hopper, remove the 2 screws that hold your controller in place using a Phillips head screwdriver.
  6. Gently pull controller away from the hopper and locate the 2 white wires, at the back of the controller, that connect to the RTD probe.
  7. Unscrew the 2 white wires from the green terminal box.
  8. Pull out defective controller.
  9. Connect white RTD wires to the green terminal on new controller.
  10. Reinsert the 2 screws that hold the controller in place.
  11. Plug all corresponding plastic Molex connectors under the hopper.
  12. Make sure cables are not in the way of the fan, zip ties will be helpful.
  13. Replace hopper panel (If applicable)
  14. Plug in your grill and turn it on

 

Replacing an ARC Controller

Follow these steps to replace an ARC controller on a non-WiFI Traeger pellet grill.

different_5.png arc controller back.jpg
Arc Controller, front Arc Controller, back

Tools Needed

  • Phillips Screwdriver
  • Zip Ties (Optional)

Replacement Steps

  1. Power off and unplug your grill.
  2. If the grill has one, unscrew and remove your grill's bottom hopper cover. 
  3. Unscrew and carefully pull your grill's current controller away from the hopper to expose the back wires. 
    • If the replacement controller did not include screws, use these screws to install the new one. 
  4. Disconnect all wires connected to the back of the controller.
  5. Connect the cables to the new controller, referring to the wire color coding below:
    • Red, White, White (Auger Motor)
    • Orange, White, White (Induction Fan)
    • Black, White, White (Power Cord)
    • Black, Black (Switch)
    • Purple, White (Hot Rod)
    • Metal loop - Ground Wire
  6. Connect the RTD wires to the back of the controller.
    7.png
    • NOTE: Loosen the two screws of the terminal block, then insert the RTD wire ends (the customer can install cables in either combination). Tighten the screws to secure the wires.
  7. Connect the ground screws
  8. Feed cables into the hopper.
  9. Screw the controller back into place.
  10. Install the cable ties. 
    NOTE: Use the cable ties to bundle the wiring away from moving components.
  11. Reattach the hopper bottom cover (if the grill has one and it was removed).

Replacing an ARC Controller on a Portable Grill

Use caution around metal edges and wear gloves when working around the fiberglass insulation.

  1. Turn the grill off and unplug from power.
  2. Remove the grease bucket, grill grate, and drip tray.
  3. Empty the pellets.
  4. Remove five Phillips screws using a Phillips screwdriver (three holding the HBA, two holding the RTD).
    portable grill ARC.png
  5. Carefully pull the HBA up with the handle that says 'Caution Hot'
    • Older Ranger/Scout models may not have this handle. Instead, pull from the hopper and firepot.
      portable grill ARC 2.png
  6. Cut the zip ties holding the wire bundle together. Be careful not to cut the actual wires.
    portable grill ARC 3.png
  7. Unplug the two black wires from the power switch on the back of the grill (Ranger only).
    portable grill ARC 4.png
  8. Remove two Phillips screws from the controller and carefully pull the controller out.
    portable grill ARC 5.png
  9. Replace the controller.
  10. Reverse steps to reassemble the grill. 

 

Controller "Upgrades"

Some grill models are compatible with multiple controllers. Depending on your model, you may be able to purchase a different controller to an "upgraded" style (e.g. Your controller doesn't have jacks for meat probes, and you want to install a controller that does).

Contact Traeger Customer Support to determine if your model is compatible with additional controllers.

Upgrading a Pro Controller to a Different Pro Controller

The steps to upgrade your Pro controller to a different Pro-style controller are just as easy as the steps to replace it with the same style.

  1. Power off and unplug your grill.
  2. Remove bottom hopper panel (If applicable. Not all hoppers have a bottom panel).
  3. Go underneath the hopper and locate the 4 Molex (Plastic) connectors.
  4. Unplug the connectors. 
    • Each wire is color coordinated (Except the wire that connects to the Hot Rod). Keep this in mind when reconnecting replacement controller.
  5. At the front of the hopper, remove the 2 screws that hold your controller in place using a Phillips head screwdriver.
  6. Gently pull controller away from the hopper and locate the 2 white wires that connect to the RTD probe.
  7. Unscrew the 2 white wires from the green terminal box.
  8. Pull out old controller.
  9. Connect white RTD wires to the green terminal on controller upgrade.
  10. Reinsert the 2 screws that hold the controller in place.
  11. Plug all corresponding plastic Molex connectors under the hopper.
  12. Make sure cables are not in the way of the fan, zip ties will be helpful.
  13. Replace hopper panel (If applicable)
  14. Plug in your grill and turn it on

Upgrading a Pro Controller to an ARC Controller

  1. Turn your grill's power off (O) and disconnect your grill. 
    ARC controller-install-1 power off.png
  2. Unscrew your grill's bottom hopper cover (if installed). 
    2.png
  3. Unscrew and carefully pull out your grill's current controller and disconnect any cables. 
    NOTE: You can reuse the screws from your old controller. 
    3.png
  4. Screw on the top screw on the plate and thread the cables. 
    4.png
  5. Connect the cables to the new controller, referring to the wiring diagram color coding in step 6.
    5.png
  6. Cable Diagram
    6.png
    • Red, White, White (Auger Motor)
    • Orange, White, White (Fan)
    • Black, White, White (Power Cord)
    • Black, Black (Switch)
    • Purple, White (Hot Rod)
    • Metal loop - Ground Wire
  7. Connect the RTD wires to the back of the controller.
    7.png
    • NOTE: Loosen the two screws of the terminal block, then insert the RTD wire ends (the customer can install cables in either combination). Tighten the screws to secure the wires.
  8. Connect the ground screw
    8.png
  9. Feed cables into the hopper.
    9.png
  10. Hook the top of the controller onto the plate and snap the bottom. 
    NOTE: Install screw #2 into the bottom of the cover.
    10.png
  11. Install the cable ties
    NOTE: Use the cable ties to bundle the wiring away from moving components.
    11.png
  12. Reattach the hopper bottom cover (if the grill has one and it was removed).
    12.png

 

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