Strong burning plastic or electrical smell when smoker is heating

Safety first: If you smell strong burning plastic or see smoke from the control area, unplug the smoker immediately.

• Initial burn‑off (new units): For a new Char‑Broil smoker, run an empty burn‑off cycle at high temperature for 1–2 hours as recommended in the manual. Some odor is normal initially.
• Inspect interior: After cooling, check for any plastic packaging, zip ties, or labels left inside the cabinet or on the element. Remove them.
• Check wiring near element: Remove access panels and inspect wires near the heating element for melted insulation or contact with hot metal. Repair with high‑temperature wire and proper routing.
• Inspect terminal connections: Look for darkened or melted spade connectors at the element and terminal block. Replace any overheated connectors and ensure tight fit.