Initial Start Up and Burn in Process for a Pellet Smoker

The Z Grills Initial Startup and Burn-in Process

The initial startup and burn-in process must be performed before your first cook on your new pellet smoker. Like any pellet smoker, your grill needs to be seasoned before use. The entire process takes about an hour, and you’ll need enough wood pellets to run the grill on HIGH for at least 45 minutes. Be sure to perform this outside or in a well-ventilated area.

If reading isn’t your forte, here’s a helpful video!

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Step-by-Step Guide

1. Remove Everything

  • Open the hopper and grill lids.
  • Remove the grill racks, grease tray, and baffle plate that sits over the fire-pot.

2. Turn the Grill ON

  • Ensure the controller dial is in the Shut Down Cycle position.
  • Turn the switch ON.
  • If you see "Er2" on the display, the grill is not in the Shut Down Cycle mode.

3. Set to SMOKE

  • Turn the controller dial to Smoke.
  • Listen for the fan to start running.

4. Check Auger Operation

  • Confirm that the auger is slowly rotating. You should hear a faint "whirring" sound.
  • The auger will rotate for a few seconds, then pause for 30-40 seconds. Over the next 5 minutes, it will turn on and off periodically.

5. Check the Fire-pot

  • Hold your hand above the fire-pot to feel for air movement, confirming the fan is working.
  • You should hear the fan running when the controller is on Smoke.
  • Observe the ignition rod at the bottom of the fire-pot—it should turn a dull red color within 4 minutes. Do not touch it!
  • Some smoke may appear as surface oil burns off; this is normal.

Once you’ve confirmed that:
✅ The auger is rotating periodically
✅ The fan is blowing
✅ The ignition rod is heating up

Proceed to the next step.

6. Add Wood Pellets

  • Pour about 4 lbs of wood pellets into the hopper—just enough to reach the safety grate.
  • Close the hopper lid.
  • Only add a full hopper of pellets if planning a long cook. Always store pellets in a sealed container to prevent moisture absorption.

7. Turn to HIGH

  • Turn the controller dial to High to feed pellets from the hopper through the auger tube into the fire-pot.

8. Wait for Pellet Drop

  • About 7-8 minutes after adding pellets, they should start dropping into the fire-pot.
  • As soon as you see pellets dropping, move to the next step.

9. Ignite the Fire

  • Turn the controller to Shut Down Cycle, then immediately back to Smoke to activate the ignition rod.

10. Fire Up Your Grill!

  • After 3-5 minutes, you should see lots of smoke, followed by a flame.
  • Congratulations! Your grill is officially running.
  • Reinstall the baffle plate, grease tray (no foil), and grill racks.
  • Close the grill lid.

11. Burn-in Process

  • Turn the controller to High and let the grill run at maximum temperature. This burns off any remaining manufacturing oils.
  • The smell may be unpleasant, so avoid doing this near an open window.
  • After 10-15 minutes, the smell will disappear.
  • Keep the grill on High for at least 45 minutes, then:
    • Turn to Smoke for 10 minutes to let the fire die down.
    • Switch to Shut Down Cycle (leave the power on).
  • The fan will run for 10 minutes before automatically shutting off.

Once the grill has turned itself off, you can unplug it—or start cooking!

12. Time to Cook!

  • Once the grill has shut down, open the lid and wipe the grill racks with a damp cloth.
  • Cover the grease tray with heavy-duty aluminum foil.
  • Start the grill by turning it to Smoke with the lid open.
  • After 4-5 minutes, you should see lots of smoke. Wait until you hear a roaring fire and see less smoke before closing the lid and setting your desired temperature.
  • Let the grill reach the target temperature before placing your food inside.


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