Digital Old Smokey electric smoker overheats rapidly; display shows E2 and shuts off or cycles erratically.

Safety first: Unplug the smoker and let it cool completely. Do not operate the smoker if it is overheating.

Steps to diagnose E2 overheating fault:

• 1. Inspect the temperature sensor location: Open the lid and locate the internal temperature sensor. Check if it is touching the heating element, a hot metal surface, or has been bent out of position.
• 2. Look for melted insulation: Follow the sensor wires from the probe into the cabinet. Look for melted, brittle, or fused insulation that could allow the wires to short together or to the smoker body.
• 3. Test sensor resistance: With the smoker unplugged, disconnect the sensor from the control board. Measure resistance across the sensor leads at room temperature. A reading near 0 Ω indicates a shorted sensor. Replace if shorted.
• 4. Check for wire-to-chassis shorts: With one meter lead on a sensor wire and the other on the smoker chassis, verify there is no continuity. If there is, the wire insulation is compromised and the sensor harness should be replaced.
• 5. Replace the sensor assembly: If the sensor is shorted or damaged, install a new OEM Old Smokey temperature sensor/thermistor assembly. Ensure it is mounted in free air inside the chamber, not touching metal surfaces.
• 6. Inspect the control board: If a known-good sensor still triggers E2, the control board's sensor circuit may be faulty. Visually inspect for burnt components or corrosion. Replacement of the control module is typically required.
• 7. Test operation: Reassemble, plug in, and set a moderate temperature. Monitor the temperature rise with an oven thermometer to ensure the smoker no longer overheats and the E2 code is cleared.

Warning: Persistent overheating can be a fire hazard. If you cannot verify stable temperature control after these steps, discontinue use and consult a professional.