the 'lo' pellet warning comes on way before my hopper is actually empty, is my sensor broken?

Diagnosis

The "LO" pellet warning on the Pit Boss Pro Series 1150 is triggered by a mechanical paddle switch located at the base of the hopper. This switch acts as a simple binary trigger: when pellets push the paddle down, the circuit is closed; when the paddle swings upward due to a lack of pellets, the circuit opens and triggers the alert. If you see this warning while the hopper still looks full, you are likely experiencing "bridging." This occurs when pellets clump together in a dome shape, leaving a void of air directly around the sensor paddle even though there are pounds of fuel remaining above the gap.

Alternatively, the issue may be mechanical interference. Small fragments of sawdust, broken pellet shards, or moisture-swollen pellets can wedge themselves between the paddle arm and the hopper wall. This prevents the paddle from returning to its "full" position or causes it to flutter, sending inconsistent signals to the control board. You can confirm this by looking closely at the paddle; if it isn't resting flat against the side of the hopper when pellets are present, the sensor is obstructed.

How to Fix It

To resolve a false "LO" reading, you must clear the bridge and ensure the mechanical arm has a full range of motion. Follow these steps precisely:

1. Power down the grill and unplug it from the wall outlet to prevent any accidental auger activation while your hand is in the hopper.
2. Remove the hopper lid and use a long, thin wooden dowel or a sturdy coat hanger. Gently poke the pellets starting from the center and moving outward toward the edges to break any bridges or "domes" of pellets.
3. Locate the black plastic paddle switch near the bottom of the hopper. Reach in and manually push the paddle arm up and down several times. It should snap back into place with a distinct mechanical feel.
4. Inspect the area around the pivot point of the paddle. If you see any "pellet dust" or clumps of sawdust, use a vacuum or compressed air to clear the debris from the hinge.
5. Refill the hopper with fresh, high-quality pellets and shake the hopper slightly to ensure the fuel settles evenly around the sensor.
6. Plug the grill back in and power it on. The "LO" warning should disappear immediately once the pellets weigh down the paddle.

If That Didn't Work

• Check for Wire Chafing: The wiring harness leading from the paddle switch to the main control board can sometimes rub against the metal frame of the Pro Series 1150. Inspect the wires for any exposed copper or pinch points. If the wire is frayed, the circuit may be breaking intermittently, triggering the "LO" light regardless of pellet levels. Use electrical tape or heat-shrink tubing to seal any nicks.
• Clean the Sensor Contact: If you have used pellets with high oil content or have experienced moisture ingress, a film of grime can build up on the switch. Use a contact cleaner spray (like QD Electronic Cleaner) directly into the pivot mechanism of the paddle to remove oxidation and debris.
• Test the Control Board Logic: Perform a hard reset of the electronics. Unplug the unit for 10 full minutes to drain the capacitors on the control board. This clears any "ghost" errors in the memory that might be keeping the "LO" warning active even after the physical sensor has been fixed.
• Replace the Paddle Assembly: If the internal spring of the paddle switch has snapped or the plastic arm is warped, the sensor will fail to trigger. You will need to remove the hopper assembly and replace the pellet level sensor switch. Ensure the replacement part matches the Pro Series 1150 specifications to avoid voltage mismatches.

Heads Up

• Avoid "Over-Packing": Do not force pellets down into the hopper with a tool. Over-compressing the fuel can lead to severe bridging or, worse, put too much pressure on the auger motor, causing it to overheat.
• Storage is Key: Always store your pellets in a sealed, airtight container. Pellets that absorb moisture expand and become "sticky," which is the primary cause of paddle sensors getting stuck.
• Regular Stirring: Every few long cooks, give the hopper a gentle shake or stir the top layer of pellets to prevent the formation of bridges before they trigger the sensor.
• Vacuum the Base: Periodically vacuum out the bottom of the hopper where the auger meets the pellet bin. Accumulated sawdust here can interfere with the sensor's movement.