Fire pot over flowed

You keep saying grill, are you talking the FE Grill? Did you buy it from Danson's?

The firepot on ANY pellet cooker will overflow if the fire goes out.

The first culprit is usually airflow not getting to the fire

Sorry for tyhe confusion but the grill as I call it is a FEC-100. Its rather new, about 1.5 years old w/ IQ controller.
Any suggestions?

It's a smoker, not a grill. Repeat after me.

CS actually does sell a Pellet Grill, that's why we have to know.

You need to watch it to figure out when/what's happening. I tell people time and again, it's not a Set it and Forget it smoker. Can you? Yes. Should you? No.

If this happened when you loaded it with ribs, you'll typically see new smoke then anyway because you opened the door (how long?) and you'll get it dumping pellets to try to bring the heat back up.

A temp drop down to 175 after opening the door isn't unusual, especially if the door was open long.

I'm not sure there was a problem since you say it went back up to normal temp.

Yes it can easily operate 22 hours without emptying the ash, but definitely empty the ash after using it.

The same thing happened to me last week. Call CS they will send you a replacement control panel which I was told had something updated to stop this problem. I put it on in about 30 min and only operated once and had no problem so far.

I did call Cookshask and the sent out a new controller with no questions. Grear customer service as I have always heard! I have not had time to install the new controller yet but it loks better since it's stainless.

You have not given enough information. Do you have an exhaust stack? Some people have not added one and wind blows into the cooker and puts the fire out. The stack does not have to be long just a little higher than the cooker. That fixed my problem.