Controller Problems

[Ken]

Thanks. I don't have one, but it sounds like I should.  That would eliminate a lot of trial and error. 

[old sarge]

They are handy to have for a lot of 'around the house' problems/repairs.

[LarryD]

I'm still kind of brain-storming here and working with the idea that when the unit gets hot for a period of time that there is expansion/movement involved and that is what triggers the issue.  Unfortunately, I've never taken mine apart, so I have no idea what's inside.  I do know there is a big heat-sink on the back of mine.  Have you dug in enough to know what that attaches to?  I'm assuming it's important or it wouldn't exist.  If there is some way that heat sink separates from whatever it's cooling then that might cause it to be flaky.   One could run a fan across the heatsink to help it cool more efficiently to see if that makes any difference.

Have you ever noticed that the problem is better or worse based on the ambient outside temperature?

[old sarge]

The heat sink takes the heat from the solid state relay (SSR). I have not operated on mine so cannot help there.  However, several folks did convert their analog smokers to PID and if you use the search function, you will find some photos of the smoker opened up and the wire set up.  Keep in mind those are analog. I will look tonight when I get home from work. Just a guess but there may be a loose connection on the ssr or maybe the ssr is shot.  Hard to tell. Here is a link describing the ssr:
https://www.auberins.com/index.php?main_page=page&id=10&chapter=0

[Ken]

I just ordered a multi meter and wiring pliers. 

Here are some images of the wiring and basic components, controller and relay.  It's so straight forward that it just adds to the mystery. 

[old sarge]

Ken - Some of this will not apply to your situation.  However, dig into the links - lots of photos of wiring inside the smokers from the days of folks hard wiring an auber into their analog.
https://www.smokinitforums.com/index.php?topic=1287.0
https://www.smokinitforums.com/index.php?topic=1287.0

And here some SSR testing directions:
https://www.electricaltechnology.org/2019/01/solid-state-relay-types-of-ssr-relays.html

[Ken]

When I get the new multimeter and the weather breaks I’ll jump back into this.  I have an outdoor smoker so dry weather is important.

[Ken]

After 4 months I seem to have finally found the problem.   I bought a multimeter after a suggestion from Old Sarge on the forum.  While testing the second wire, another of the connectors just fell off.  This is the third one that just fell off seemingly for no reason.  After replacing it, I performed three almost identical two-hour tests just like the attached screen shot.  I don't know if it just my bad luck with this unit or not, but the wiring seems a bit flimsy.  Just my thoughts for future upgrades and repairs.   

[old sarge]

I hope this solved your problem.

[Ken]

After four months, me too.

[old sarge]

I know the controller wires are small, probably 20 to 24 gauge. And the copper strands fragile. The crimping of the connectors may have damaged the strands to the point of poor transmission as well as breakage. Stripping the insulation back and soldering the wire to the connectors would be stronger.  Not now but in the future should the need arise.

[Ken]

It looks like the wires may be aluminum, not copper for sure.  Maybe an upgrade in the quality should be considered.  Replacement wiring of the same would be nice.  It's an easy install.  It's the wires from the controller to the relay that are light weight. Maybe a new set should be sent with each controller, relay or free with anyone having problems.

[old sarge]

Let Steve know what you found and make the suggestion.  Can't hurt!

[Ken]

He and Auber both know what happened to me.  For now I’m very happy that I can smoke again.

[LarryD]

I hope Steve is throwing some bonus goodies your way as it seems you've really done them a service.

The idea that aluminum wiring would be used is obscene.  I would take my unit apart to see what it has except for fear that then it might not work afterwards.

Very glad to hear you have it figured out and appreciate that you shared the fix and took us on the journey with you.