I think I solved the chip burning problem. To recap, I would start the unit and when it got up to temp then I would put about a half of a cup of chips in the chip loader. Vent half open. Within a minute or two I would get a flash and the chips would be on fire. You could actually see the flames! When I started to look at the pan the chips would fall into, it was about an 1/8th of an inch above the heating element. What was happening was the chip pan was getting very hot to the point that when I put the chips in it was like putting dry chips on a hot fire. They flashed! So what did I do? First I left the spent chips in the chip pan. The dust from the previous burn acted as an insulator between the hot pan an the new chips. The next thing was I put the chips in at the same time I started the unit so the chips heated gradually with the pan. I repeated this test 5 times. At about 100f I started to get nice heavy smoke and no fire. For kicks I added chips when the unit hit 150f. Still no flames. A long story....but a great lesson learned. So simple...I feel stupid for no thinking of it sooner!