my daniel boone prime plus just shows 'ERR' on the display and won't do anything, what is that?

Diagnosis

The "ERR" message on the Daniel Boone Prime Plus is a general fault indicator triggered when the controller board detects a reading that falls outside of the expected electrical range. In 95% of cases, this is caused by a failure in the RTD (Resistance Temperature Detector) probe, which is the internal temperature sensor. The controller monitors the resistance of this probe to determine the grill temperature; if the circuit is broken (open) or shorted, the system cannot safely operate the auger or fan, triggering the error to prevent a grease fire or overheating.

This failure typically happens due to thermal fatigue—the constant expansion and contraction of the probe's internal wiring—or physical damage to the wiring harness where it enters the cook chamber. You can confirm this by observing if the error appears immediately upon power-up or only after the grill reaches a certain temperature. If it's instant, the probe is likely completely dead. If it happens mid-cook, the probe is likely "drifting" or intermittently failing as it heats up.

How to Fix It

To resolve this, you must test the probe's resistance and replace the sensor if it is out of spec. You will need a digital multimeter set to the Ohms (Ω) setting.

1. Completely disconnect the grill from the 120V power source to avoid damaging the controller board.
2. Remove the controller housing from the grill frame by unscrewing the mounting bolts. Carefully pull the controller forward to expose the wiring harness.
3. Locate the RTD probe connector—this is the two-wire plug leading from the cook chamber into the main control board. Unplug this connector from the board.
4. Set your multimeter to the 2k Ohm range. Place the probes on the two pins of the RTD sensor plug (not the board side).
5. Check the reading at room temperature (approximately 70°F). A functioning probe should read between 1080 and 1120 ohms.
6. If the multimeter displays "OL" (Open Loop) or "0.00" (Short Circuit), the probe has failed.
7. Order a replacement RTD probe specific to the Daniel Boone Prime Plus model.
8. Thread the new probe through the existing mounting hole in the cook chamber, ensuring the sensor tip is properly seated and not touching the metal walls of the grill.
9. Plug the new sensor into the controller board, secure the housing, and power on the grill to verify the "ERR" code is gone.

If That Didn't Work

• Inspect the Wiring Harness: Check the entire length of the wire from the probe to the controller. Look for pinch points, melted insulation, or rodent chew marks. A partial break in the wire can cause an intermittent "ERR" code that a static multimeter test might miss. Use a continuity test while gently wiggling the wire.
• Check the Controller Board Pins: Inspect the pins on the control board where the RTD plugs in. If there is corrosion or a bent pin, the connection will be unstable. Clean the contacts with a small amount of isopropyl alcohol and a cotton swab.
• Power Cycle and Hard Reset: Occasionally, the logic board can glitch. Unplug the grill for at least 10 minutes to allow the capacitors to discharge fully. While unplugged, hold the power button for 10 seconds, then plug it back in.
• Replace the Controller Board: If a brand new RTD probe still triggers the "ERR" code, the fault lies within the analog-to-digital converter on the main control board. The board will need to be replaced entirely as these are integrated circuits and cannot be repaired manually.

Heads Up

• Avoid High-Pressure Washers: Never use a pressure washer near the RTD probe entry point; moisture intrusion into the sensor housing is a leading cause of probe failure.
• Probe Positioning: Ensure the probe is not touching the side of the grill barrel. If it touches the metal, you will get inaccurate temperature readings or "false" ERR codes due to rapid heat transfer.
• Avoid Chemical Cleaners: Do not use caustic oven cleaners on the internal probe sensor, as these chemicals can eat through the protective sheath and short the internal elements.
• Tighten Connections: Periodically check that the controller housing is tight; vibrations from the auger motor can occasionally loosen the wiring harnesses over several seasons of use.