Well I added a KBQ to my arsenal and while it was running I fired up the Yoder 640 and tripped the GFCI once i clicked the START button. From this point forward I would trip the GFCI JUST BY PLUGGING IN THE YODER. So I had ground fault somewhere but so many years on I decided to by the upgraded board. I already had a ceramic starter I wanted to install so here is my story. I bought them online at ATBBQ and began the journey which involves removing the end piece,--- disconnecting everything including the old controller... then removing the hopper. You will be removing a lot of 5/16" self tapping screws so a socket set and drill helps. One of them (inside the hopper near the bottom on the opposite side of the firebox) is snug enough I used a scredriver to turn the box end of a 5/16 socket. The two inside the firebox area also tricky. With the hopper removed --- With the hopper removed you install some new insulation and make a few wiring additions (wifi connector -- ignoter in the new controller). most of the action comes with the hopper reinstalled. You replace the old interior fan and then start reattaching everything. I had the old style temp probe so I had some easy holes to drill to mount the new one. On the other hand drilling the 1.125" hole (and a 7/16" above it) wasn't as simple but necessary for the 2 new meat probes. Everything fired up and ran nicely. I replaced the high temp silicone just above the firebox as well. The Fireboard software and controller works nicely. Probe accuracy is as good as my thermoworks. All in all it seemed to be money well spent and I didn't have to track down where the other problem was (just glad it wasn't the auger or exteior fan-- the only electronics thst dont get replaced)
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Regarding the GFI, have you replaced it? They do go bad. Even newer ones can have issues in high humidity or wet areas. If they get weak, they might work for a radio, but if you put an appliance on them, they trip often.
I’m not an electrician, but my brother is (retired). He sure had a lot of service calls for outside GFI outlets. I have replaced 2 of 4 in my outside kitchen. They were new 5 years ago. After you turn off the breaker, takes about 5-10 minutes to put a new one in. -
GFCI tripping is almost always the ignitor on a pellet grill. Hope you enjoy your refreshed smoker! Plus you can give a solid review on old vs new!Last edited by ItsAllGoneToTheDogs; November 27, 2025, 08:20 AM.Comment
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Johnny Booth I went down the rabbit hole of upgrading my GFCI because I had just got a new ignitor because the GFCI was tripping. Old ignitor had got a nick in the wire. Well, it turned out the new ignitor had a hairline crack that was only visible when there was humidity/moisture which ended up being the source, not the GFCI. After diving down the rabbit hole for other grill models and ignitor types, it seems it's very rarely the GFCI and usually the ignitor if the grill worked fine previously.
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Nice and you got the parts in time. I did that conversion too. What I have changed is putting a threaded stud in that fire box where the fan attaches. Now I can easily remove the fan and never have to take that sealed fire box out. The nuts are now on the outside of the fan. I have replaced a few fans since I use it quite a bit plus in the winter those fans scream a bit on start-up when it's very cold out.Comment
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