Royal RGPRO User manual

WOOD PELLET GRILL
OWNER’S MANUAL
www.royallgrills.com 325 South Park Street Reedsburg, WI 53959 Phone [phone]
CAUTION DO NOT USE OR STORE NEAR COMBUSTIBLE MATERIALS
INCLUDING GASOLINE, THINNER, OIL, PAINTS OR FLAMABLE LIQUIDS
DESIGNED FOR RESIDENTIAL OUTDOOR USE ONLY. USE FOOD GRADE WOOD PELLETS.
MODEL: RGPRO (Front Loading Hopper)

Thank you for selecting ROYALL for your wood pellet grill
purchase. Your grill is proudly made in America and is
designed to provide years of grilling enjoyment.
SPECIAL FEATURES
-EXTRA LARGE GRILLING SURFACE
-TALL SMOKE CHAMBER PROFILE WITH EXTENDED GRILL LID
ACCESS
-UNIQUE SMOKE BAFFLE PLATE FOR ENHANCED
CIRCULATION
-SOLID WELD CONSTRUCTION FOR STRENGTH AND
DRUABILITY
-OPTIONAL 2 OPTIONAL GRATE LOCATION AVAILABLE
Your new grill has been shipped with some assembly required.
Follow the simple instructions and you’ll be ready to start
grilling in minutes.
TOOLS REQUIRED:
-7/16 wrenches to secure wheels and support bars to legs
-1/2 wrench to secure legs to grill base
-1/4 wrench to attach inducer fan bracket assembly to
grill base
STEP#1: Carefully remove packaging material and free unit
from shipping skid. (use cardboard or cloth under
the grill base during assembly to prevent scratches)
STEP#2: Check the packaging for the following items
- (4) Legs
- (4) Wheels [2 swivel & 2 locking swivel]
- (1) Hopper Cover Plate
- (1) Hardware Bag
- (1) Grill Grate
- (1) Directional spatter plate
- (1) Combustion Deflector Cover
- (1) Drip Pail

STEP#3: Lay Grill on it’s back. Unwrap COMBUSTION FAN ASSEMBLY
& MOUNTING BRACKET. Locate 4 legs of bracket over 4-1/4” hole in
bottom of auger box. Line up with (4) mounting holes and
secure to base with (4) small self drilling screws. NOTE: check
blade after installation to ensure that it spins without rubbing when
mounted.
STEP#4: Plug combustion fan into receptacle with orange
and white wire coming from the control board wire
harness.
STEP#5: Attach swivel wheels to legs using (2) 1/4-20 screws
and flange nuts for each leg. NOTE: locking swivel
wheels & legs are place on the hopper side of the
grill.
STEP#6: Attach the legs to the grill base using 5/16 bolt, and
washer by sliding washer over bolt, then slid bolt
though the single hole in the leg. Move the leg to
the mounting position and thread the screw into
weld nut on the grill base (only finger tight for now).
(Note: locking wheels should be positioned on the
front lid side of the grill base.) Repeat for each leg.
Locate fan motor
assembly with bracket
over auger box opening

STEP#7: Attach each of the 4 leg supports to the bottom of
the legs using (4) 1/4-20 screws and flange nuts.
Then final tighten with wrench.
STEP#8: Check all the leg connections to ensure all
hardware is tight. Final tighten 4 leg bolts in bottom
of grill. Then use a helper to stand the grill on it’s
legs.
STEP#9: Move the grill and remaining components out
doors near a grounded 110V electrical outlet.
STEP#10: Place the power switch in the off position and plug
in the unit. Inspect the auger tube by looking into
the hopper to see that no foreign objects are
present.
STEP#11: Turn the power switch to the on position. Visually
check to see that the auger is turning.
STEP#12: Check to see that air is blowing around the circular
fire pot.
CAUTION: THE HOT ROD IS WARMING UP AT THIS POINT, DO NOT PUT
FINGERS IN THE FIRE POT.
STEP#13: Visually watch to see that the HOT ROD in the fire
pot glows faintly red after a couple of minutes.
STEP#14: Charge the pellet auger. Add food grade wood
pellets to the hopper and observe fire pot until
pellets appear. (takes approx. 5 minutes)
STEP#14: Turn the power switch to the off position. Then
install the COMBUSTION DEFLECTOR COVER.
STEP#15: Install the DIRECTIONAL SPATTER PLATE with one end
sloping towards the catch drain. NOTE: for easy clean
up, place a layer of aluminum foil over the spatter plate.
STEP#16: Place the GRILL GRATE onto the grill supports.

FIRST USE: WE RECOMMEND RUNNING THE GRILL
FOR 20 MINUTES ON HIGH TO SEASON THE GRILL
YOU ARE READY TO START YOUR GRILL !
(always with the lid open)
WHEN YOU TURN THE POWER SWITCH ON, THE HOT ROD WILL
HEAT FOR ABOUT 2 MINUTES AND SHUT OFF. NORMALLY THIS IS
ENOUGH TIME TO IGNITE THE PELLTS. ONCE SMOKE IS STARTING
TO SHOW YOU CAN SELECT THE DESIRED GRILL SETTING. IF IT
DIDN’T START, TURN IT OFF AND ON AGAIN.
OPERATING DO’S and DON’TS
EACH TIME YOU START YOUR GRILL:
CHECK PELLET HOPPER TO ENSURE PELLETS ARE DRY AND
READY TO USE. (Wet pellets can swell and damage the auger
or shear the pin)
Apply a new foil to the spatter plate for easy clean up.
Check for and remove any excessive drippings build up to
avoid flare ups and fires.
If the auger has been previously charged as described
above, you should be able to turn the power switch on with
the cook setting on Medium to ignite the pellets. Smoke
should appear with in 2 minutes. It’s usually good to leave the
grill run for 10 minutes prior to adjusting the control or adding
food.
Always leave lid open until pellets are ignited.
CAUTION: Locate your new grill such that all surfaces are at least 12”
from any combustible material. Also consider winds and proximity to
windows so that exhaust is not directly entering your home.

COOKING MODE SELECTION: Note –always cook with lid closed
HIGH MODE: Allows the auger to run continuously and
creates temperatures of 400 to 500 degrees depending on
outside temperature. Allow grill to run at least 15 minutes to
obtain this temperature. This setting is normally used for short
cooking times of select meats and searing meat surfaces.
MEDIUM MODE: ALLOWS AUGER TO STOP AND START IN 2
MINUTE INTERVALS. Temperature will vary depending type of
pellets and outside air temperature(250 to 350 ). This mode is
normally used following HIGH MODE searing of meat or for
slightly longer cooking times that promote more smoke
flavoring.
LOW / SMOKE MODE: ALLOWS auger to run and stop at a
1 : 3 ratio. (160 to 225) This MODE is normally selected for
longer cooking times of larger cuts of meats. This tends to
promote smoke flavoring and tender servings. It may also be
used to keep faster cooked items warm for a period of time.
GRILL MAINTENANCE
Wipe cool grill exterior down with warm soapy water just as
you would any interior cooking appliance. High quality car
wax can be applied a couple of times a year to maintain the
finish.
Monitor grease build up on the grill interior and drip rail and
remove when any surfaces builds up exceeding 1/8 to 1/4 of
an inch to avoid grease fires.
Before lighting the grill, occasionally check ash build up in and
around the fire pot. Excessive ash can get distributed to food
and can reduce the efficiency of the fire pot. To remove ash,
use a shop vacuum on dry ash and brush with soapy water
where grease has helped to stick it to the surface.
Cover the grill with a water proof cover when not in use. Or
store under roof. Controls should not be exposed to the
elements for long periods

TROUBLE SHOOTING
GROUND FAULT ON OUTLET TRIPS:
-Turning the unit off and back on while cooking will restart
the hot rod timer and may provide too much resistance
to the circuit causing a fault. (avoid returning to the off
position while cooking). Hot rods need to be installed
with at least 1.25 inches protruding out the rear of the
lock collar on the fire pot. This tends to minimize
resistance to the system if the control is accidently
turned to off and back on during cooking.
PELLETS DID NOT IGNITE:
-CHECK to make sure pellets are dry and being delivered
to the burn pot
oIf pellets are not being delivered, make sure hopper
is full and auger is not jammed (is turning)
DANGER: DO NOT STICK FINGERS INTO MOVING AUGER

-CHECK to see if hot rod glows red after a couple minutes
oIf hot rod does not glow. Unplug grill, and check
fuse on back of control board. NOTE: a spare is
wire tied to the functioning fuse at the connection
point
oIf fuse is ok and rod does not get hot, a new HOT
ROD will be needed. Manual lighting of pellets can
be done at owner’s discretion.
GRILL FIRE GOES OUT:
-CHECK that supply of pellets has not been interrupted.
-CHECK that pellets are dry and designed for grilling
applications
-CHECK that excessive wind is not affecting burning.
-CHECK Visually verify that auger is turning properly
oAuger not turning: set to high mode and visually
recheck that auger is not turning. If not, unplug grill
and check motor connector plug to see that it is
properly connected (connector with RED wire). If
connections are tight, a new auger drive motor will
be needed.
oCheck fan to see if it’s spinning. If not, unplug grill
and check fan connector with ORANGE wire to
ensure that it has not come loose. If connection is
tight, turn power back on and check fan. NOT
turning indicates a new fan motor will be needed.

• Three Digit Temperature Display
• Front Panel Cook Control
• Eight Cook Temperature Settings (180 through 375 degrees)
• “High” Cook Temperature Setting
• Front Panel Smoke Control
• Sixteen Smoke Settings (P0 Warmest - P15 Coldest)
• Ignition Indicator
• Smoke Setting Indicator
• Cook Idle Fuel Rate Indicator
• Low Temperature Indicator
• Inadvertent Start Protection
• Over Temperature Protection
How It Works
Cook Mode In Cook Mode, the temperature of the grill is
constantly monitored and a microprocessor operates the draft
fan and fuel feed auger to maintain a constant grill temperature.
Smoke Mode In Smoke Mode, the fuel feed rate is set manually by the operator.
The grill operates at low temperature to provide maximum smoke.
SMOKE CONTROL
COOK CONTROL
DIGITAL DISPLAY
RG-DIGITAL CONTROL MAJOR FEATURES
RG-Digital Control comes standard in the following Royall Grills:
RG5000VSRGPRO RG2000 RG3000
RG-Three Speed comes standard in the following Royall Grills:
RG1000
RGTAILGATER

LED Readout
Displays grill temperature, smoke settings, idle fuel feed settings, igniter status, low temperature status, and error messages.
Cook Control Switch
Selects o, smoke mode, or one of nine cook mode grill temperatures.
Smoke Control Switch
Selects one of sixteen smoke/idle fuel feed rates.
Cook Mode
Maintains the selected cook temperature.
Smoke Mode
Produces maximum smoke at a low grill temperature.
Microprocessor Control
In cook mode, the temperature of the grill is constantly monitored and a microprocessor operates the draft fan and
fuel feed auger to maintain a constant grill temperature.
Manual Control
In smoke mode, the fuel feed rate is set manually by the operator. The grill operates at low temperature to provide
maximum smoke.
RG-DIGITAL CONTROL OPERATION OVERVIEW
SMOKE CONTROL
COOK CONTROL
DIGITAL DISPLAY

Numbers
When the grill is connected to AC power, the model number
and software version of the control are displayed momentarily.
Temperature
In cook mode and smoke mode, the grill temperature is
displayed in 5 degree (Fahrenheit) increments.
Flashing Temperature
In cook mode, the displayed temperature ashes if the grill
temperature is below 150 degrees.
In smoke mode, the displayed temperature ashes if the grill
temperature is below 110 degrees.
Flashing Dots
The igniter is on.
“P0” - “P15”
When the cook control switch is set to the smoke position,
the smoke setting is displayed for 3 seconds.
If you adjust the smoke control switch while in smoke
mode, the smoke setting is displayed for 3 seconds.
If you adjust the smoke control switch while in the cook
mode, the idle fuel feed rate setting is displayed for 3 seconds.
Flashing “ErH”
The grill temperature exceeded 615 degrees.
Flashing “ErP”
The cook control switch was not in the o position when
the grill was connected to AC power.
RG-DIGITAL CONTROL UNDERSTANDING THE DISPLAY

Turn the Grill O
Set the cook control switch to the o position.
Plug the Grill In
Connect the grill to AC power. The control displays its model number and software version.
If you see“ErP”
If the cook control switch is in the smoke position or any temperature setting when the grill is plugged in, the control
will display “ErP” indicating an inadvertent start error. The standard ignition sequence is halted. This feature prevents
an inadvertent start. For example, if the grill is stored in the garage, the grill will not ignite if plugged in inadvertently.
To clear the error, set the cook control switch to o.
Cook Control
To ignite the grill, set the cook control switch to the smoke position or any temperature setting.
Ignition Sequence
- The draft fan turns on.
- The igniter turns on.
- The fuel feed auger turns on and delivers fuel continuously for two minutes.
- The grill temperature is displayed along with three ashing dots signifying that the igniter is on.
The igniter will turn o when one of the following three conditions is met:
- The igniter has been on for four minutes and the grill temperature has increased by 30 degrees.
- The igniter has been on for four minutes and the grill temperature is greater than 150 degrees.
- The igniter has been on for ve minutes.
Once the igniter turns o, if the cook control switch is set to the Smoke position, the grill operates in smoke mode.
If the cook control switch is set to a temperature setting, the grill operates in cook mode. The ashing dots are turned o.
CONNECTING THE GRILL TO AC POWER
IGNITING THE GRILL
Cook Control
Set the cook control switch to the desired temperature. The control displays the grill’s current temperature.
Cook sequence once the ignition sequence is complete and the igniter turns o, the auger feeds fuel into the re pot
to maintain the set temperature.
COOKING

Temperature Settings
180 180 degrees
225 225 degrees
250 250 degrees
275 275 degrees
300 300 degrees
325 325 degrees
350 350 degrees
375 375 degrees
High 450 degrees or Maximum Temperature
High Temperature Setting
If the cook control switch is set to high, the grill operates at 450 degrees. If the grill is unable to attain 450 degrees
due to ambient temperature and humidity, fuel type and quality, and/or thermal characteristics of the grill, the auger
feeds fuel continuously allowing the grill to operate at its maximum temperature.
On Fuel Feed Rate
The on fuel feed rate is the rate the auger delivers fuel while the grill is under the set temperature. In cook mode, the
on fuel feed rate is designed to drive the grill’s temperature upward to the set temperature and limit temperature
overshoot. The on fuel feed rates are preprogrammed into the control and are not adjustable.
Temperature
Setting Auger On Auger O
180 15 seconds 15 seconds
225 always on 0
250 always on 0
275 always on 0
300 always on 0
325 always on 0
350 always on 0
375 always on 0
High always on 0
Idle Fuel Feed Rate
The idle fuel feed rate is the rate the auger delivers fuel while the grill is idling at or above the set temperature.
In cook mode, you can manually adjust the idle fuel feed rate using the Smoke Control switch. See “Understanding
Idle Fuel Feed Rate and Smoke Settings”for more information.
Low Temperature
If the grill temperature is less than 150 degrees, the displayed temperature ashes, indicating a low temperature.
This is not an error condition and does not aect the operation of the grill. The ashing display is designed to alert the
operator that there is some risk of the re going out.
High Temperature
If the grill temperature is greater than 615 degrees, a ashing “ErH”is displayed indicating a high limit error and
the grill shuts down. Refer to the “Error Modes and Messages” section for details.

Smoke Control
Set the cook control switch to smoke. Use the smoke control switch to manually select the auger fuel feed rate.
The control displays the grill’s current temperature.
Smoke sequence once the ignition sequence is complete and the igniter turns o, the auger delivers fuel at a
constant rate determined by the smoke setting (P0 - P15).
Smoke Setting
The smoke fuel feed rate is the rate the auger delivers fuel while the grill is operating in the smoke mode. In smoke
mode, manually adjust the fuel feed rate using the smoke control switch to establish the desired temperature
and/or smoke output See “Understanding Idle Fuel Feed Rate and Smoke Settings” for more information.
Low Temperature
If the grill temperature is less than 110 degrees, the displayed temperature ashes, indicating a low temperature.
This is not an error condition and does not aect the operation of the grill. The ashing display is designed to
alert the operator that there is some risk of the re going out.
High Temperature
If the grill temperature is greater than 615 degrees, a ashing “ErH”is displayed indicating a high limit error and the
grill shuts down. Refer to the “Error Modes and Messages” section for details.
Smoke Control Switch
The smoke control switch sets the fuel feed rate (the amount of fuel delivered in a given period of time) when the grill
is operating in smoke mode and when the grill is idling in cook mode.
During cook idle or smoke mode, the auger turns on, delivers fuel for 15 seconds, then turns o. The o time is set by
the smoke control switch.
SMOKING
UNDERSTANDING IDLE FUEL FEED RATE & SMOKE SETTINGS

“P” Settings
The fuel feed rate setting is displayed momentarily whenever the cook control switch is set to the smoke position.
It is also displayed whenever the smoke control switch is adjusted. The setting is designated with the letter“P”and
a number. The greater the“P” setting number the greater the auger o time.
Setting Auger On Auger O
P 0 15 seconds 45 seconds
P 1 15 55
P 2 15 65
P 3 15 75
P 4 15 85
P 5 15 95
P 6 15 105
P 7 15 115
P 8 15 125
P 9 15 135
P10 15 140
P11 15 145
P12 15 150
P13 15 155
P14 15 160
P15 15 165
Dual Function
The selected “P” setting controls both the smoke mode fuel feed rate and the cook mode idle fuel feed rate.
They are one and the same.
For example, if “P3” is selected using the smoke control switch, the auger delivers fuel for 15 seconds, turns o for
75 seconds, and repeats in smoke mode. It also delivers fuel for 15 seconds, turns o for 75 seconds and repeats while
idling in cook mode.
Cook Mode
The idle fuel feed rate is the rate of fuel delivery that dle fuel feed rate maintains the re in the re pot without
raising the grill’s temperature.
In cook mode, whenever the grill temperature is at or above the set temperature, the auger runs at the idle fuel feed
rate. If the grill temperature is below the set temperature, the auger operates per the on fuel feed rate.
We recommend the“P2” setting as the default idle fuel feed rate while in cook mode.
For the experienced operator, the auger idle fuel feed rate can be adjusted to improve the grill’s performance.
For example, to optimize temperature stability at a high temperature setting, select “P1” or “P0” to increase the
auger idle fuel feed rate or, if due to ambient conditions the grill is unable to cool down enough to reach a low
temperature setting such as 180 degrees, select “P3”, “P4”, or higher to decrease the idle fuel feed rate.
High Temperature Idle Fuel Feed Rate
In cook mode, the idle fuel feed rate for the high temperature setting is preprogrammed into the control. The idle fuel
feed auger timing at high is 15 seconds on / 15 seconds o and is independent of the smoke control switch“P”setting.
The preprogrammed fuel feed rate helps maintain the elevated cooking temperature at the high setting.

Smoke Mode Fuel Feed Rate
In smoke mode, increasing the “P” setting decreases the fuel feed rate, lowering the grill temperature. Start at setting
“P2”, adjust the “P” setting manually for the desiredtemperature and/or smoke output.
Inadvertent Start Error (ErP)
If the cook control switch is set to Smoke or to a temperature setting at the time the grill is plugged in, the control will
display “ErP” indicating an inadvertent start error. The standard ignition sequence is halted.
This feature prevents an inadvertent start. For example, if the grill is stored in the garage, the grill will not ignite if
plugged in inadvertently.
To clear the error, set the cook control switch to the o position
High Temperature Limit Error (ErH)
If the grill temperature exceeds 615 degrees, the control limit error (ErH) displays “ErH”indicating a high
temperature limit error.
The fuel feed auger is turned o, the igniter is turned o, and the draft fan is turned o.
To clear the error, set the cook control switch to the o position. If the error will not clear, your temperature
detector is not functioning normally See“Display is Flashing‘ErH’” in the “Troubleshooting”section.
Flashing In cook mode, the displayed temperature ashes if the grill temperature is below 150 degrees.
This is not an error condition and does not aect the operation of the grill. The ashing display is designed to alert the
operator that there is some risk of the re going out.
In smoke mode, the displayed temperature ashes if the grill temperature is below 110 degrees.
This is not an error condition and does not aect the operation of the grill. The ashing display is designed to alert the
operator that there is some risk of the re going out.
Flashing Dots
The igniter is on.
This is not an error condition and does not aect the operation of the grill. The ashing dots are designed to alert the
operator that the igniter is on.
ERROR MODES AND MESSAGES

AC Auger
The grill is equipped with an AC auger. AC augers operate at a single speed and deliver fuel at a constant rate while
on The fuel feed rate (amount of fuel delivered in a given period of time) is adjusted by varying the on and o
time intervals.
Duty Cycle The ratio of time the auger is on is sometimes referred to as the duty cycle and is expressed as a percent-
age For example, if the auger is always on, its duty cycle is 100 percent If the auger is on half the time, its duty cycle is
50 percent, etc.
Idle and Smoke Fuel Feed Rates and“P” Settings
When the TR-100 is in smoke mode or idling in cook mode, the AC auger is turned on and delivers fuel continuously
for 15 seconds and is then turned o. The smoke control switch sets the auger o time. The smoke mode/cook mode
idle fuel feed rates are as follows:
Setting Auger On Auger O Duty Cycle
P 0 15 seconds 45 seconds 25.0 percent
P 1 15 55 21.4
P 2 15 65 18.8
P 3 15 75 16.7
P 4 15 85 15.0
P 5 15 95 13.6
P 6 15 105 12.5
P 7 15 115 11.5
P 8 15 125 10.7
P 9 15 135 10.0
P10 15 140 9.7
P11 15 145 9.4
P12 15 150 9.1
P13 15 155 8.8
P14 15 160 8.6
P15 15 165 8.3
AC AUGER THEORY OF OPERATION

Always disconnect the grill from AC power before accessing the control for service
or working under the grill.
Removing the control from the grill, installing the control into the grill, or working under the grill while
the grill is connected to AC power could result in shock or could damage the control.
Digital Control Display is Blank
cook control switch is set to the o position. Set cook control switch to the smoke position or any temperature setting.
Circuit breaker on AC outlet is tripped. Reset wall power outlet circuit breaker.
Control is disconnected from grill AC power. Verify control wiring harness plug with black wire is connected to AC
power.
Digital Control Display is Blank
Control AC line fuse is blown. Replace control’s fuse F1 with provided spare fuse or a replacement fuse.
A blown AC line fuse may be caused by several conditions including shorted
grill component lead wires, a jammed auger, or a failing igniter. Inspect the
grill’s components and component lead wires if replacement fuses are
continually blown.
Grill Will Not Ignite
No fuel in repot. Fill hopper with good, dry fuel. Verify auger is properly
connected to control. Clear auger if jammed. Replace auger and/or auger
motor if defective.
No draft air ow
Verify draft fan is properly connected to control and
operating normally. Replace draft fan if defective.
No ignition heat source
Verify igniter is properly connected to control and operating
normally.
Replace igniter if defective
Control is defective
Contact Royall Grills technical support.
RG-DIGITAL CONTROL TROUBLESHOOTING
Fuse
Warning

Fire Goes Out
Set cook control switch to the o position and allow grill to cool.
No fuel in hopper
Fill hopper with good, dry fuel.
No fuel in repot
Verify the control is properly connected to auger. Clear auger if jammed. Replace auger and/or auger motor if defective.
Unburned fuel in repot
Adjust smoke control switch (decrease the “P” setting) to increase auger idle fuel feed rate.
No draft air ow
Verify the control is properly connected to draft fan and operating normally. Replace draft fan if defective.
Control is defective
Contact Royall Grills technical support.
Grill Temperature at the 180 Degree Cook Setting is too High
Auger idle fuel feed rate is too high. Adjust smoke control switch (increase the“P”setting) to decrease idle fuel
feed rate.
Probe is defective
Replace probe
Control is defective
Contact Royall Grills technical support.
Grill Temperature at the High Cook Setting is too Low
At the high temperature setting, the auger runs continually until the grill temperature reaches 450 degrees.
Grill lid is open
Close grill lid. Grill is designed to operate with grill lid closed.
Insucient amount of fuel in re pot
Clear auger if jammed. Tighten auger connection to auger motor shaft if slipping. Replace auger and/or auger motor
if defective.
Damp fuel source
Replace damp fuel with good dry fuel.
Adverse operating conditions
Shield grill from cold wind and/or rain. Grill may not be able to attain 450 degrees in an extremely cold operating
environment.