Buying guide
Broil King Regal Pellet 500
vs 500 Pro
Cast iron or stainless steel? Put the upgrade where you will use it.
The decision
Make the Pro upgrade about the cooking surface.
The Broil King Regal Pellet 500 and Regal Pellet 500 Pro share the features that make a connected pellet grill appealing: a 625-square-inch main cooking surface, Wi-Fi and Bluetooth control, a 22-pound hopper, two meat probes and a supplied rotisserie kit. The clearest reason to move to Pro is its stainless-steel cooking grids, compared with cast iron on the standard grill.
Choose the Regal Pellet 500 if…
You like cast iron and are happy to keep the grids seasoned. You get the same listed primary cooking area and the connected cooking equipment without paying more simply to obtain an app or rotisserie.
Choose the Regal Pellet 500 Pro if…
You prefer a stainless-steel cooking surface and value the longer grid warranty: five years for stainless compared with three years for cast iron under the pellet warranty. That is a useful ownership difference, particularly if you grill frequently.
Both compared models are freestanding wood-pellet grills. This is a choice within the Regal Pellet range, rather than a comparison with Broil King gas grills or a claim that “Pro” changes the fuel or adds a larger main grate.
At the grate
The part you cook on deserves a closer look.
The standard grill’s cast iron brings a familiar seasoning routine. Broil King instructs owners to coat the grids with a high-smoke-point cooking oil, dry them thoroughly after washing and give cast iron a light seasoning before each use. If you already enjoy that routine, cast iron is a deliberate choice.
The Pro changes the main grid material to stainless steel. It still needs cleaning, and the grease system still needs attention. We would choose it because you prefer that surface and its ownership terms, rather than promising that stainless automatically produces better food or removes maintenance.
Think about your most common meal. If you spend many evenings cooking directly on the main grate, you will encounter this material choice every time. If your usual cook is a roast in a pan or food turning on the spit, the grid upgrade may have less influence on the result you care about.
Compare the two
Same main-grate area. A different surface.
| Decision | Regal Pellet 500 | Regal Pellet 500 Pro |
|---|---|---|
| Main cooking area | 625 sq. in. | 625 sq. in. |
| Main cooking grids | Cast iron | Stainless steel |
| Grid warranty | 3 years, limited | 5 years, limited |
| Connected controls | Wi-Fi and Bluetooth | Wi-Fi and Bluetooth |
| Current configuration | $1,399.00 | $1,699.00 |
Use the main cooking area when comparing how much food sits on the primary grate. The upper warming rack is useful additional space, but it sits at a different level. Compare the shared 625-square-inch main grate when deciding whether Pro holds more food directly on the primary cooking surface.
Both use a substantial 2 mm / 14-gauge steel body and a 22-pound pellet hopper. Hopper capacity is fuel storage, not a promise that either grill will run for a fixed number of hours. Temperature, weather and the cooking session affect consumption.
What they share
Rotisserie night comes with either grill.
A turning roast is one of the more compelling reasons to look at the Regal Pellet platform. The supplied spit, forks and motor make rotisserie cooking part of the package on either model. You do not need to choose Pro just to add that kind of meal to the week.
The two food probes let you follow internal readings alongside the controller’s cooking-temperature setting. They are useful for checking two foods, or two positions in a larger cook, without treating the set temperature of the grill as the temperature inside the food.
Both controller instructions describe quick-set buttons for Smoke at 225°F, Roast at 350°F and Grill at 600°F. Think of a smoked weekend meal, an evening roast and a higher-heat grate cook as different uses of the shared platform. These are grill setpoints, not internal-food targets; use the probes to follow the food itself.
Wi-Fi and Bluetooth are shared too. Check the signal where the grill will stand; the current controller instructions specify 2.4 GHz Wi-Fi. Connectivity helps you follow the cook and use the controller, but it does not replace checking the appliance, fuel and food.
The Hearth Outpost view
Buy the surface you will enjoy using.
We would start with the standard Regal Pellet 500 for someone who wants the full connected pellet-and-rotisserie setup and likes cooking on cast iron. There is a lot of shared equipment here. Paying more for Pro makes less sense if the feature you really want is already included on the standard grill.
The Regal Pellet 500 Pro makes a clearer case for someone who specifically wants stainless grids. The longer grid term is another positive, although a warranty is coverage for qualifying defects, not a prediction of when a part will wear out. Compare the current prices below and put the difference against how often you cook directly on the grate.
The current standard product information includes a low-pellet warning as well, so we would not pay for Pro on the assumption that fuel sensing is exclusive. Put your attention on the grid material, the complete package and the care you are comfortable doing.
The everyday routine
Good access matters on both.
Leave working space around the shelves, hopper and cleanup points. These are freestanding grills, so plan the actual standing area, outdoor clearances, grounded electrical supply and route for moving the grill before choosing its permanent spot. A wheeled cart does not make a heavy grill a portable camping appliance.
The burn-pot agitator and removable ash tray make ash accessible, while the grease-management system handles drippings. They are convenient features when used as part of a routine; they do not mean the firebox takes care of itself. Empty ash only when fully cool and follow the manual’s disposal instructions.
Finish the session through the controller’s shutdown process. The manual describes a 15-minute shutdown cycle. Keep fuel dry and remove unused pellets through the hopper cleanout as instructed, rather than leaving damp fuel to affect the next cook.
Add the appropriate cover, cooking pellets and any optional griddle or pizza accessory to your complete package only after confirming compatibility. The grill price should not be read as a complete outdoor-kitchen or accessory bundle.
Shop the ranges
Continue with the exact configuration.
Compare the exact standard and Pro configurations. Both include the rotisserie and two meat probes.
Broil King
Broil King Regal Pellet 500
$1,399.00 $1,599.00
Cast iron cooking grids, connected controller, two meat probes and rotisserie kit. Freestanding configuration.
Broil King
Broil King Regal Pellet 500 Pro
$1,699.00 $1,899.00
Stainless-steel cooking grids, connected controller, two meat probes and rotisserie kit. Freestanding configuration.
Warranty and documents
Five years on the cookbox.
Regal Pellet 500
The high-heat-coated cookbox has five-year limited coverage. Cast iron grids have three-year coverage, as do the digital controller, components, remaining parts and paint.
- Cookbox
- 5 years
- Cast iron grids
- 3 years
- Controls
- 3 years
Regal Pellet 500 Pro
The high-heat-coated cookbox and stainless-steel grids have five-year limited coverage. The controller, components, remaining parts and paint retain the three-year term.
- Cookbox
- 5 years
- Stainless grids
- 5 years
- Controls
- 3 years
Coverage is for the original retail purchaser under normal domestic use in the country of purchase, subject to the complete terms. The warranty provides repair or replacement of qualifying defective parts; transportation, service labor, removal and reinstallation costs are excluded. Keep proof of purchase and the exact model and serial number.
Before ordering
Choose for your next hundred dinners.
Let’s match the Regal to your routine.
Tell us whether you cook mostly on the grate, enjoy turning roasts or want to settle into weekend smoking. We can help you compare the two Broil King packages and choose the equipment you will use.
Speak to an Expert
Good questions
What does Pro actually change?
Do I need Pro for Wi-Fi and Bluetooth?
No. Both compared configurations have Wi-Fi and Bluetooth-enabled digital controls.
Is the rotisserie extra on the standard grill?
The Regal Pellet 500 and Regal Pellet 500 Pro compared here both include a rotisserie kit and two electronic meat probes.
Does Pro give me a larger main grate?
Both list 625 square inches of primary cooking surface. The meaningful main-grate distinction is material: cast iron on standard, stainless steel on Pro.
Is the Pro warranty longer on every part?
No. The stainless-grid term is five years compared with three for cast iron. Cookbox and controller terms are otherwise the same categories described above.