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
[phone] Fax
www.fogazzo.com
[email protected]
Model 515 In tallation In truction © 2001-2005 Fogazzo Wood Fired Ovens and Barbecues LLC, all rights reserved
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 Installation Instructions ©2007 Fogazzo Wood Fired Ovens and Barbecues, LLC. All Rights Reserved

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
Model 515 Installation Instructions ©2007 Fogazzo Wood Fired Ovens and Barbecues, LLC. All Rights Reserved Page 01
Order Model 515
acce orie at
WWW.FOGAZZO.COM
®

Model 515 Installation Instructions ©2007 Fogazzo Wood Fired Ovens and Barbecues, LLC. All Rights Reserved Page 02
Foundation and floor lab
In tallation In truction Toll Free Help Line 1-866-FOGAZZO
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.
12” min.
#4 rebar
Footing
Fig 1
®

Model 515 Installation Instructions ©2007 Fogazzo Wood Fired Ovens and Barbecues, LLC. All Rights Reserved Page 03
BBQ A embly
In tallation In truction Toll Free Help Line 1-866-FOGAZZO
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.

Model 515 Installation Instructions ©2007 Fogazzo Wood Fired Ovens and Barbecues, LLC. All Rights Reserved Page 04
Interior Fini he
Exterior Fini he
Lighting
In tallation In truction Toll Free Help Line 1-866-FOGAZZO
®
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.

Motorized roti erie kit , pit and other acce orie are
available at:
www.fogazzo.com or toll free at [phone]
Model 515 Installation Instructions ©2007 Fogazzo Wood Fired Ovens and Barbecues LLC. All Rights Reserved Page 05
Curing & Initial Firing
Re ource
In tallation In truction Toll Free Help Line 1-866-FOGAZZO
Curing
You must allow the BBQ to cure a minimum of 3 days (72
hours) in order to allow sufficient moisture to evaporate
from tile, brick, mortar, thin set, etc., prior to initial firing.
Initial Firing Procedure
Initial firing is the ingle mo t critical component
in completing a good in tallation. Please follow
these instructions carefully to ensure proper operation of
your BBQ for many years to come.
Using an electric or canister type charcoal starter, light a
small pile of charcoal.
In cold or humid climates it is recommended that the
minimal curing period be extended to a full 7 days.
Re ource
Chimney / Venting product :
Fogazzo
Toll free at (877) FOGAZZO or online at
www.http //www.fogazzo.com
Churra co Barbecue Acce orie
Fogazzo
Toll free at (877) FOGAZZO or online at
www.http //www.fogazzo.com
Charcoal tarter
The Home Depot
Lowe’ Home Center
®
Electric or canister
type charcoal
starters are
available at most
home centers.
Once the charcoal is burning well, spread the lit charcoal and
add more on top. Try to keep the bulk of your fire in the
center of the firebox during the first three times you use your
new barbecue in order to allow the finishes to dry thoroughly.
Under normal operating condition , mall crack will
develop due to the heating and cooling proce .
The e mall crack are normal and will not effect the
performance or durability of your BBQ.

“Even if you own the world greate t e pre o machine, it will not guarantee
that you will get the be t coffee in the world on your fir t try”.
Cooking with real fire takes some getting used to, but don’t be afraid to experiment. Many
recipes need adjustments, but will work well. As a general rule, anything a gas BBQ can do, a
wood fired BBQ will do better.
Alway
• Allow 1 hour or more to bring your BBQ to temperature slowly.
• Use quality mesquite (wood) charcoal or quality firewood (in small amounts).
• Use safety gear to avoid injuries or burns
Never
• Allow cold water to hit a hot BBQ.
• Use tools that can chip or scrape your BBQ firebox walls or floor.
• Add too much charcoal at once.
• Build a large fire inside your BBQ.
• Dispose of hot coals in the trash.
• Use liquid fuels such as gasoline to start the BBQ.
BBQ Ba ic
Model 515 Installation Instructions ©2007 Fogazzo Wood Fired Ovens and Barbecues, LLC. All Rights Reserved Page 06
®
Enjoy your new
Fogazzo BBQ!
Model 525

Fogazzo Limited Warranty
All items that we manufacture are warranted, when properly installed, operated and
maintained, to be free from defects in material and workmanship and to conform to the
specification, if any, listed on the installation instructions. If no specifications are listed, the
items are warranted to conform to our currently published specifications. The warranty period is
one year from the date of installation by the first user of the goods, or eighteen (18) months
from the date of shipment to the first user, whichever occurs first.
No warranty is given for products or components (such as accessories, books, thermostats,
etc.) manufactured by companies not affiliated by ownership with Fogazzo, or for goods which
have been subject to misuse, improper installation, exposure to weather, or which have been
modified or repaired by unauthorized persons.
We must receive written notice of defect within the warranty period.
Our liability is limited to servicing, repairing or adjusting any item as determined by our
engineering department. After evaluating the problem, Fogazzo will determine the course of
action to be taken in order to make necessary repairs or for the damaged or defective item to
be returned to the factory for the purpose or receiving repairs. This may include replacing any
defective parts. Customer must pay packing, crating and transportation costs to and from the
factory. At Customer’s request, we will make reasonable efforts to provide warranty service at
the Customer’s premises, provide that Customer pays our then current rates for field service
and the associated travel and living expenses. If a fault has been caused by improper
installation, maintenance or use, or by abnormal conditions of operation, repairs will be billed at
normal rates. If any fault develops, the following steps should be taken
1. Notify us by giving the item model number, serial number and details of the difficulty.
On receipt of this information, you will be given service data or shipping instructions.
2. On receipt of shipping instructions, forward the item prepaid. If the item or the fault is
not covered by warranty, an estimate of charges will be furnished before work begins.
FOGAZZO WOOD FIRED OVENS AND BARBECUES DISCLAIMS STATUTORY AND IM-
PLIED WARRANTIES, SUCH AS WARRANTIES OF MERCHANTABLITY AND FITNESS
FOR PURPOSE. WE ALSO DISCLAIM ALL WARRANTIES REGARDING ANY ANCILLARY
SERVICES RENDERED.