Steps to ensure proper wire connection when you get errors noting a component is disconnected on your AC grill.

Non-WiFIRE Enabled (AC) Grill Wiring

How to Ensure Proper Component Connection

1. Turn off and unplug the grill.
2. Unscrew and carefully pull out the grill controller from the hopper.
3. Disconnect each connector on the back of the controller. Gently pull on and wiggle each plug to disconnect.
   
   
   
4. If the connector is not disconnecting, spray a bit of WD40 on the connector and try again.
5. Reconnect each connector. Follow the chart below to ensure the proper connectors are connected.
   
6. If the component continues not to work after reconnection and ensuring all the connectors are connected to the proper spots, check the wire swap test for each component before determining if a replacement is necessary. See below under Wire Swap Test for more information.

Wire Swap Test

A wire swap test is used to determine whether the grill controller or a specific grill component (fan, hotrod, auger motor) is faulty and requires replacement. The test involves disconnecting the part's wires from the controller and reconnecting to a different port. This method allows us to see if the controller or the part is at fault.

If a wire swap test is required for troubleshooting, the associated section below will direct you to perform the correct wire swap test. 

Hot Rod Test

1. Check the Hot Rod's connection.
   
   1. With the grill still ON and set to Smoke, hold your hand over the firepot without touching it and check if you feel the heat radiating. 
      1. If you can feel the heat - the grill is fine.
      2. If you can not feel the heat - continue troubleshooting. 
   2. Turn OFF the grill and disconnect the fiberglass-wrapped wire's Molex connector from the purple and white Molex connector.
      • Reconnect the Hot Rod's fiberglass-wrapped wire's Molex connector (cream and red colored wires in picture) with the purple and white connector to ensure the connection is secure. 
        
        
        
   3. Turn ON the grill and let it run for 5 minutes to check if it starts working (pellets in the firepot should start to smoke, and heat should radiate from the firepot).
      • If the hot rod does not heat up, shut down the grill and continue troubleshooting.
   4. Follow the hot rod's high heat fabric wire (this is the white, not cream, wire) until you find its connector to the next component connector, the Induction Fan. Next, disconnect the Induction Fan's orange wire connector.
      • Reconnect the wires using the other component's connections (see diagram).
        
        
        
   5. Plug in the grill, turn it on and allow 3 minutes for the hot rod to heat up.
      • If the Induction Fan turns on: Replace the hot rod. The controller is fine; the hot rod is bad.
      • If the hot rod turns on (3+ minutes) and the induction fan does not: Replace the controller. The controller is bad, and the components are fine.
      • If neither component turns on: Replace the controller and the hot rod.

Induction Fan Test

1. Check the Induction Fan's connection.
   
   1. With the grill still ON and set to Smoke, hold your hand over the firepot without touching it and check if you feel the airflow coming from it. 
      1. If you can feel the airflow - the fan is OK.
      2. If you can not feel the airflow - continue troubleshooting. 
   2. Turn OFF the grill and disconnect the double-orange Molex connector from the orange and white connector.
      • Reconnect the Induction Fan's Molex connector (double-orange in the picture) with the orange and white connector to ensure the connection is secure (basically just disconnecting and reconnecting the same connection/wires).
        
        
        
   3. Turn ON the grill and let it run for 5 minutes to check if it starts working. Airflow should be coming from the firepot, and you should be able to hear the fan.
      • If the induction fan still does not work (remember, "slow fan" has been debunked, so the fan either works or doesn't work), shut down the grill and continue troubleshooting.
   4. Follow the Induction Fan's high heat fabric wire (this is the white wire) until you find its connector to the next component connector, the Auger Motor (red wires). Next, disconnect the Induction Fan's orange wire connector. 
      • Reconnect the wires using the other component's connections (see diagram).
        
        
        
   5. Plug in the grill and turn it on and run for 5 minutes.
      
      • If the Induction Fan turns on: Replace the controller. The controller is bad, and the components are fine.
      • If the Auger Motor turns on and the induction fan does not: Replace the induction fan. The controller is fine; the induction fan is bad.
      • If neither component turns on: Replace the controller and the induction fan.
      • If each component turns on: No replacement is needed, and the components are working fine. Confirm original wiring/connections are secure. 

Auger Motor Test

1. Check the Auger Motor's connection.
   1. With the grill OFF, disconnect the red wire's connector for the Auger Motor from the red and white connector.
      • Reconnect the red wire's connector for the Auger Motor with the same red and white connector to ensure the connection is secure (see diagram below).
        
        
        
   2. Turn ON the grill and let it run for 5 minutes to check if it starts working (the auger should turn slowly, and pellets should start flowing into the firepot).
      • If the auger still does not turn, shut down the grill and continue troubleshooting.
   3. Next, follow the Auger Motor's white cord until you find the orange and white connector (for the induction fan); disconnect the orange wire's connector.
   4. Then disconnect the red wire's connector from the red and white connector for the Auger Motor.
      • NOTE: Both the Induction Fan and Auger Motor should now be disconnected, and we will proceed to the wire swap test below. 
   5. Perform a wire swap test by following the steps below: 
      1. Reconnect the Auger Motor by connecting the Auger Motor's red wire's connector to the orange and white (Induction Fan) connector (see diagram below).
      2. Then reconnect the Induction Fan by connecting the Induction Fan's orange wire's connector to the red and white (Auger Motor) Molex connector (see the diagram below). 
         
         
         
   6. Plug in the grill and turn it ON and wait for 5 minutes for the Auger to begin rotating. 
      1. If the Induction Fan turns ON: Replace the Auger Motor. The controller is fine; the Auger Motor is bad.
      2. If the Auger Motor turns ON and the Induction Fan does not: Replace the Controller. The Controller is bad, and the components are fine.
      3. If neither component turns on: Replace the Controller and the Auger Motor.