I’ve Googled this without any real answers. I have a four-burner propane grill. I get my propane tanks filled at Costco. For some reason, my current tank delivers noticeably less heat than prior tanks. Now, for clarity, I’m using the same physical tank, it just gets refilled.
As an example of what I mean by “less heat,” I typically cook steaks in a cast iron skillet on the grill. I let the skillet get screaming hot before dropping the steak. Usually this results in an even sear and a satisfying sizzle as soon as the meat hits the surface. The first time using this tank there wasn’t any sizzle and the steak was still grey (although cooking) after 5 minutes. The skillet was hot to the touch (or hover) but not doing the job. I eventually took off my cooked, but not well-seared beef and ate it without enthusiasm.
Last night the kids wanted smash burgers. I have a cast iron griddle I use in the same way as I make the steaks. The burgers are smashed very thin on the hot griddle and usually only take a minute or two per side. Nope. Same deal. I eventually moved them to the open grill and they cooked fine.
So what gives? Can one propane tank deliver less heat (or whatever the proper term may be)? The one thing I did notice is that when opening the valve it turns more easily than I recall. I did a leak test and didn’t see any bubbles.
You need to try a different tank to makes sure that’s the problem. Could be the regulator, could be the venturi/burner manifold, could be the fuel control valves. When did you last use it before getting the current tank filled?
Good points. I have a second tank. Costco isn’t super close so I usually try to refill one after I swap in the other. So I was using the other tank within a few weeks ago and didn’t notice any issue. I will swap them and see if the issue persists.
I’m not sure how it could be the tank. If you open the tank valve fully, the gas should be exiting the tank at the same relative pressure as it did before. I’m stumped.
If this problem is new to this grilling season, and the grill sat idle over the winter months, check everywhere for possible insect lairs/nests. I’ve had that happen not only with propane grills, but the propane generator on my camper (although a shade different) - there’'s a small vent tube on the propane “carburetor” that small insects love to plug up, and it will starve the generator enough to keep from running.
ETA: Swapping tanks will tell you if that’s not the problem - if the other tank works fine, you’ve got your answer. But if the new tank doesn’t work, I’d check for blockages before buying a new regulator. Regulators aren’t terribly expensive, but no sense spending it if you don’t have to.
Could be the hose (!).
We couldn’t get the grill working in the camper, and I thought it had to be the regulator, but it turned out to be the hose - the check valve in the connection to the propane tank got plugged somehow, and blowing it out fixed the probelm.
My tests were inconclusive. I definitely saw a temp difference with the two tanks, but my infrared thermometer was pretty varied even with multiple reads on the same tank.
I heated an empty carbon steel skillet with the problematic tank for fifteen minutes. The readings ranged from 245 to 310. At the same time, the “flavor bar” that sits over the gas jets was reading 450 to “Hi.”
After letting the pan cool completely I swapped tanks and let it heat for fifteen minutes again. The new tank gave higher readings, ranging from 350 - 425, which is significant, but still not as hot as I would have expected.
I had this happen to me on an old grill. It came with a note that said watch out for spiders nesting in the venturi tube. I scoffed. The next spring the grill wouldn’t light. It would just pop when I hit the igniter. Guess what was wrong?
It has no problem with ignition. All 4 burners (and the side burner) light right away. One day this week I will make a steak using the tank I swapped in to see if there is any difference.
