Fogazzo 515 Service manual

MODEL 515

WOOD CHARCOAL FIRED BBQ

KIT

INSTALLATION INSTRUCTIONS

OWNER’S MANUAL

“ F I R E W I T H S T Y L E ”

Fogazzo Wood Fired Oven and Barbecue LLC

Manufacturing, import, export, sales, and the distribution of wood fired ovens, barbecues, fireplaces and related accessories.

USA Headquarters

114 E Saint Joseph Street

Arcadia CA 91106

Toll Free 1-866-364-2996

(626) 799-8110 Fax

www.fogazzo.com

[email protected]

Images by Christina Mortimer, Sergio de Paula and Ricardo Forte

Text by Christina Mortimer and Sergio de Paula

Illustrations by Sergio de Paula and Santiago de Tezanos

Note:

All text, illustrations, specifications, etc, are based on information available at the time of publication. Fogazzo Wood Fired Ovens

and Barbecues LLC reserves the right to make changes at any time without notice.

Important:

Check with the local building authority and or fire department having jurisdiction over your project for all construction and permit

requirements and or use approvals prior to the start of your installation.

Warranty:

A copy of the Fogazzo Limited Warranty is found on the last page of this manual and is also posted on the world wide web at

http //www.fogazzo.com/waranty.html

UL and NFPA Compliance

This product has been tested to comply with the “Underwriters Laboratory”

UL 737 Standard

for “Fireplace Stoves” and, meets the

“National Fire Protection Association”

NFPA Classification

of a “Prefabricated Fire Chamber Assembly”. It shall be professionally

installed in accordance to these instructions in order to maintain its

UL and NFPA Compliance.

This product must be installed in accordance to the

NFPA Standards

for Chimneys, Fireplaces, Vents and Solid Fuel Burning Appli-

ances

“NFPA 211”

in addition to all applicable local code requirements.

Declaration of Conformity As the sole manufacturer of this charcoal fired barbecue kit, Fogazzo

hereby declares that this product is in conformity with the following standards and directives of the EEC.

The construction files for this product are held by Fogazzo (the manufacturer)

and would be available for inspection by a national authority, upon request.

Signed by Sergio de Paula 21st May 2001

For Fogazzo Wood Fired Ovens and Barbecues LLC

Fogazzo Model 515

Charcoal Fired Barbecue Kit

89/106 EEC

Con truction Product Directive

93/68/EEC

EC Marking Directive

Thank you for choosing a Fogazzo Charcoal Barbecue.

Because of the assembly requirements and unique features of this product, we have

developed this Installation Instructions and Owner’s Manual to assist you. It contains

valuable information on how to properly install, operate and maintain your new oven.

Please read all instructions carefully and plan your installation well ahead of time to

ensure the timely completion of your project. This installation system is designed for

professionals with full knowledge of construction practices and is not recommended

for amateurs or do-it-yourselfers. If you are unsure of any aspect of this installation,

please consult Fogazzo or a qualified local contractor.

Every barbecue installation is unique because generally, the architectural elements

of the home will dictate the style and types of finishes to be used.

The aim of these plans is to convey known practices that are considered essential for

a good installation. All Fogazzo plans emphasize the efficiency and safety for the

completed installation. A properly installed barbecue will look great and perform well

to produce amazing cooking results. Minimal cracking inside the barbecue is ex-

pected and is a characteristic of any cast refractory product.

Following the guidelines contained herein will minimize cracking and insure that your

Fogazzo Barbecue will last a lifetime. Upon completion of the installation, it is critical

to follow the initial firing guidelines to aid in the proper curing of your installation.

Please follow the directions carefully and be patient. Your patience will be rewarded.

Cheers,

Sergio de Paula

President

Fogazzo Wood Fired Ovens and Barbecues LLC

TABLE OF CONTENTS

· Kit Contents 1

· Exploded view 1

· Foundation & Floor Slab 2

· BBQ Assembly 3

· Interior Finishes 3

· Exterior Finishes 3

· Curing and Initial Firing 4

· Resources 3

· Fogazzo Limited Warranty 5

· BBQ Basics 6

Model 515

Mesquite Fired BBQ Kit

Installation Instructions

Kit Content

Barbecue

1. Flue

2. Upper BBQ area

3. Lower BBQ area

4. Firebox surround

5. Firebox floor with firebrick

6. Stand

7. Chimney and chimney cap

Mortar Mix

1 bucket refractory sand for mortar mix

Printed Material

1 Ea. Installation Instructions &

Owners Manual

In tallation In truction Toll Free Help Line 1-866-FOGAZZO

Order Model 515

acce orie at

WWW.FOGAZZO.COM

Foundation and floor lab

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Foundation and floor lab

Dig a 33” wide by 24“ front to back hole to a depth

of at least 12 inches. Set forms around the perime-

ter using 2x4 or 2x6 material held by stakes. Place

rebar grid using #4 rebar at 12 inches on center in

both directions.

Pour foundation and floor slab (minimal 4 inches) as

a monolith, using 1500 lbs. or higher concrete mix

with 3/4” rock. Varieties of pre-mixed concrete are

readily available at local home centers with cured

strength ratings as high as 5000 lbs. Follow mixing

instructions on bag.

Very important:

The Model 515 Barbecue i normally lower

than the height of a tandard outdoor kitchen

countertop. If you wi h to rai e the working

height of the BBQ, you mu t elevate the ba e.

You can accompli h thi by increa ing the

thickne of the tab on grade or the footing

a needed up to a maximum recommended

height of 18 inche , making the ba e for the

barbecue to it on 4 to 6 inche above fini h

floor. Thi elevated ba e will increa e the

cooking height elevation to a comfortable

working height.

4”

Min.

Slab on grade

12” min.

#4 rebar

Footing

Fig 1

BBQ A embly

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BBQ Part

All our BBQs are hand made pre-cast products. As

such, small imperfections are a known characteristic

including small (hairline) shrinkage cracks that often

appear as the parts dry after casting. These small

cracks are visible on the various pieces specially

near corners, All pieces are reinforced with pencil

rod inside the casting which will ensure its struc-

tural strength. The assembled parts will be much

stronger than the individual pieces.

Note: mall difference can be made up with

the fini h material .

BBQ A embly

Starting with the base, and using Type S ma onry

mortar, assemble all BBQ parts except the firebox.

Firebox A embly

Set firebox pieces using fireproof mortar. Mix the

mortar as follows

• 1 Part fire-clay sand (provided w/ kit)

• 1 Part Type S Mortar

Mix using clean water to a peanut butter like consis-

tency.

Do not u e add mixe with thi mortar.

Place a 2 inch bead of mortar along the perimeter

of the firebox. Set the sides, front and rear firebox

walls over mortar, and trowel joints clean.

Stucco fini h (fini hing option)

Various sizes and styles of stucco beads, corners

and stops are available in both vinyl or metal. We

obviously do not recommend vinyl due to the heat

factor, therefore use metal only for this application.

A one part stucco at 3/8” is adequate for this appli-

cation. Using a suitable construction adhesive, at-

tach the 3/8” beads and stops to the BBQ as

needed. Once all the beads and stops have cured

sufficiently, mix and apply a one part stucco over all

the exterior surfaces. Trowel evenly with the beads

and stops using a Darby or other suitable tool.

After as little as one hour the stucco base can be

ready for a finish coat, with or without a color mix.

Apply the finish per the manufacturers instructions.

Fig 3

A embled

Model 515

ready for

fini h.

Rapid Set Brand Mortar Mix

This plastering material can be

applied as a one part stucco. It is

ready for a finish coat in as little as

one hour. It is a low shrinkage,

high strength mortar, that is well

suited for this application.

Rapid Set products are available at

Lowe’s and Home Depot!

Note the Rapid Set Mortar Mix has a very short working time.

Mix only as much as you can apply in 15 minutes.

Interior Fini he

Exterior Fini he

Lighting

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The firebox can be surrounded by regular

bricks that are cut to fit as shown here or

stone such as slate or granite. Do not use tile

in this area.

Interior sides and back of BBQ

area should be finished using

ceramic or quarry tile. Most

types of tile will resist heat well.

Exterior surfaces can be finished

with tile, brick, brick veneer,

stone, slate, stucco or any other

non-flammable exterior finish

A light fixture can be easily added inside the BBQ. You must use a low profile,

urface mounted metal electrical box, a ceramic fixture, fire proof wire and

a 25 to 40 watt oven light bulb.

You must use heat proof non-metallic washers between the ceramic light

fixture and the electrical box. Do not over tighten the fixture or it will crack

with expansion and contraction.

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