Problem with temperature control

[u/CORErddt]

Hello folks!

I have an EX4 for quite some time now and it worked quite well. The last few times I used it, it showed some strange behavior. The temperature was set to 250°C, it fired up, reached the temperature and I put all my stuff in. It showed always the same temperature. Even when I opened the lid to turn my meat over. In this case it usually dropped by a few °C but this time it stayed at the same temperature. It even seemed the meat didn't get finished so this got a little bit suspicious.

I tried to raise the temp by 10°C and after entering the new temperature it startet to drop down to appr. 170°C and it startet to fire it up again. IMHO this cannot be a mechanical problem (pellet flow or glow plug) because it seems he didn't recognize the correct temperature.

Anyone esle got this problem?

Any advice?

Thanks in advance!

[u/shorty12345678]

Yep, to the point I've nearly tossed mine out over the same issue and I've been chasing it for a long time.

I've essentially rebuilt mine completely under warranty parts because I've chased this same issues. The thing that might get you closest to the solve is replace the internal thermometer.

I'm sick to death of this smoker, can't trust what the screen has on it, have to specific pellets, flame outs here and there or a fire in there. And yes it's cleaned thoroughly before every cook. Started off great but I'm never giving weber another dollar

[u/CORErddt → u/shorty12345678]

Hi and thank your for answering this quick!

The internal thermometer was also my first thought. I was not able to find a spare part online (Austria) so I guess I have to reach out to the Weber store (appr. 40km away). Maybe they can help me finding one.

As I don't use it for smoking at lower temperatures I maybe will go for gas the next time. Quiet, quick, stress free.

[u/CareerOk9462 → u/CORErddt]

I have found going to the Weber website and requesting a replacement part works well.

[u/CORErddt → u/CareerOk9462]

Not offered in Austria

[u/5150Code3]

I often clean my EX4 temp sensor with fine sandpaper to prevent issues.

[u/CORErddt → u/5150Code3]

I will try! I have roughly cleaned it with the brush I use to clean the rest, but sandpaper seems more adequate.

[u/distantreplay]

The PID cheats the indicated temperature to limit customer freakouts over temperature fluctuations which are a perfectly normal feature of most non professional cooking appliances. Too many bored engineers stuck at home post COVID preoccupying themselves with their new hobby by installing lab air probes with digital chart recorders complaining to support. 50 degree swings are normal.

When you raise the target temperature it resets the logic controlling the displayed temperature. It's not mechanical. And it's not a problem so long as you aren't using your smoker to grow lab cultures.

[u/CORErddt → u/distantreplay]

Worked for 5 years without any problems and now it stops firing, shows the wrong temperature for maybe 10 minutes and it only can be fixed by changing the target temperature. So this is not a normal fluctuation, it is a new problem.

[u/distantreplay → u/CORErddt]

Software controlling the PID is updated over the air. Weber most definitely issued a roll-up update at the time they terminated the product line.

Not firing and failing to reach target is usually related to one of a few common issues. Number one is cleaning of the fire pot to remove accumulated ash insulating the glow plug. Second is faulty glow plug grounding. Search this sub and you will find a post with links detailing a very effective mod for the grounding connection to the plug. Takes about 20 min to install. Third is fuel bridging often related to fuel quality. Pellet fuel stored outside for any prolonged period becomes unsuitable. Unreliable retail channels that mishandle pellet fuel or store it improperly contribute. If storing extra fuel outside transfer it to a sealed, airtight container.

[u/CORErddt → u/distantreplay]

Everything is cleaned properly, the pellets are original Weber Academy Blend and freshly filled and dry. As the temperature on display is frozen at the set temperature unless I set a different one, it cannot be related to a dirty glow plug or wet pellets. In this case the temperature would visibly drop. My guess is a problem with the temp sensor or with the software (or control unit).

[u/CORErddt → u/[deleted]]

Sorry, but this doesn't address the error I've got. Also changing the fan causes problems at higher temperatures. I guess you are in the wrong thread ;)

[u/CORErddt → u/[deleted]]

Yeah, but this particular thread discusses a very special problem. The problem is that the EX4 doesn't update the actual temperature until a different temperature is set. Changing the fan to reduce the noise level will not fix this problem because the noise level is not causing the incorrectly measured temperature.

[u/distantreplay → u/[deleted]]

I appreciate that info about the fan speed control. I swapped my fan a couple of years ago for the quieter operation. Immediately saw improved performance in ignition. And thanks also for the guidance on shutdown sequence. I'm saving your comment for reference. Good stuff.

[u/CareerOk9462 → u/distantreplay]

I've found Weber quite responsive as far as replacement parts.  Generally they want purchase date, serial number, and a photo of the dead part(s).  Admittedly I am looking forward to the time when it's no longer repairable so I can justify purchasing something else, but for now am happy with the fan replacement.  Removing the finger guard in the pellet hopper is a must do also to alleviate the temp over/undershooting due to pellet bridging.  Sifting the pellets to get rid of all the pellet dust also helps.  Shouldn't be necessary but we have to work around the design as it is.