Fogazzo 525 Service manual

®
MODEL 525
INSTALLATION INSTRUCTIONS
&
OWNER’S MANUAL

Fogazzo Wood Fired Ovens and Barbec es, LLC
Manufacturing, import, export, sales, and the distribution of wood fired ovens, barbecues, fireplaces, and, related accessories.
114 E Saint Joseph Street
rcadia C 91106
Toll Free: 1-866-364-2996
www.fogazzo.com
[email protected]
Model 525 Installation Instr ctions © 2001-2014 Fogazzo Wood Fired Ovens and Barbecues LLC, all rights reserved
Images, illustrations, and, text by: Sergio de Paula
Note:
ll 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:
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 ssociation” NFP Classification of a “Prefabricated Fire Chamber ssembly”. It shall be professionally
installed in accordance to these instructions in order to maintain its UL and NFP Compliance.
This product must be installed in accordance to the NFP Standards for Chimneys, Fireplaces, Vents and Solid Fuel Burning ppli-
ances “NFP 211” in addition to all applicable local code requirements.
This kit comes complete with its own chimney. If an extension is used, all chimney systems used in conjunction with this kit must
meet both the NFP and UL Standards and be must be installed in strict accordance to the specific manufacturers instructions.
®
Declaration of Conformity s the manufacturer of this barbecue kit, Fogazzo Wood Fired Ovens & Barbecues
LLC 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 525
Charcoal Fired BBQ Kit
89/106 EEC
Constr ction Prod cts Directive
93/68/EEC
EC Marking Directive
Model 525 Installation Instructions ©2014 Fogazzo Wood Fired Ovens and Barbecues LLC. ll Rights Reserved

Thank you for choosing a Fogazzo Barbecue kit that is Made in the US .
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 BBQ.
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 BBQ 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. ll Fogazzo plans emphasize the efficiency and safety for the
completed installation. Minimal cracking inside and outside is expected and is a char-
acteristic of any cast refractory product.
Following the guidelines contained herein will minimize cracking and insure that your
Fogazzo BBQ will last a lifetime. Upon completion of the bbq 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,
The Fogazzo Team
®

TABLE OF CONTENTS
· Kit Contents 1
· Exploded view 1
· Kit Dimensions, Foundation & Floor Slab 2
· BBQ ssembly, Distance to Combustibles 3, 4
· Interior Finishes 5
· Exterior Finishes 5
· Curing and Initial Firing 6
· Resources 6
· BBQ Basics 7
· Fogazzo Limited Warranty 8
Model 525 Installation Instructions ©2014 Fogazzo Wood Fired Ovens and Barbecues, LLC. ll Rights Reserved

Model 525
Mesquite Fired BBQ Kit
Installation Instructions
Kit Contents
Cap
Chimney
2 Piece Hood
Upper cooking area
Lower cooking area
Firebox surround
Firebox (four pieces)
Firebox floor
Stand (base)
Rotisserie Rack
Rotisseries are optional and
can be found at
www.fogazzo.com
Printed Materials
Installation Instructions &
Owners Manual
Warranty
Installation Instr ctions Toll Free Help Line 1-866-FOGAZZO
Model 525 Installation Instructions ©2014 Fogazzo Wood Fired Ovens and Barbecues, LLC. ll Rights Reserved Page 01
Order Model 525
accessories at
WWW.FOGAZZO.COM
®

Model 525 Installation Instructions ©2014 Fogazzo Wood Fired Ovens and Barbecues, LLC. ll Rights Reserved Page 02
Kit Dimensions
Fo ndation and floor slab
Installation Instr ctions Toll Free Help Line 1-866-FOGAZZO
Fo ndation and floor slab
Dig a 42” 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 your foundation (minimal 12 inches) 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.
®
4”
Min.
Slab on grade
12” min.
12” min.
#4 rebar
Footing
Fig 1
Kit Dimensions

Model 525 Installation Instructions ©2014 Fogazzo Wood Fired Ovens and Barbecues LLC. ll Rights Reserved Page 03
BBQ Assembly
Distance to Comb stibles
Installation Instr ctions Toll Free Help Line 1-866-FOGAZZO
BBQ Parts
ll our BBQs are hand made pre-cast products. s
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, ll pieces are reinforced with pencil
rod inside the casting which will ensure its struc-
tural strength. The assemble parts will be much
stronger than the individual pieces.
Note: small differences can be made up with the
finish materials.
BBQ Assembly
Use Type S masonry mortar to assemble all BBQ
parts except the firebox.
Firebox Assembly
Set firebox pieces using fireproof mortar. Mix mor-
tar as follows:
• 5 Parts fire-clay sand (provided w/ kit)
• 1 Part Portland Cement
Mix using clean water to a peanut butter like consis-
tency.
Do not se add mixes with this mortar.
Distance to comb stibles
If the barbecue is installed in proximity to wood
framed walls, a minimal distance to combustibles
must be maintained. The inner firebox must have a
total distance of no less than 6” to combustibles.
This means that the outer face of all walls of the
barbecue must be 2” to a wood framed wall that is
covered with drywall or 1” to wood framed wall
covered with a cement backer board.
Fig 3
®

Model 525 Installation Instructions ©2014 Fogazzo Wood Fired Ovens and Barbecues LLC. ll Rights Reserved Page 04
BBQ Assembly
Installation Instr ctions Toll Free Help Line 1-866-FOGAZZO
®
1) Anchor the base to
footing using angles and
concrete anchors.
2) Set firebox floor using
type S mortar.
3) Set firebox surround
using type S mortar
4) Set the firebox using
fireproof mortar. A small
gap of up to 1” to the sur-
round is normal.
5) Set the lower cooking
area section using type
S mortar.
6) Set the upper cooking
area section using type
S mortar.
7) Set the 2 piece hood
using type S mortar.
9) Now set the chimney
section using Type S
mortar.
10) Set the chimney cap
using type S mortar.
11) Install metal corners
on each corner using
screws or nails (pre-drill)
and lath over the entire
barbecue. Place stucco,
tile, or stone as you like
over the entire structure.

Model 525 Installation Instructions ©2014 Fogazzo Wood Fired Ovens and Barbecues LLC. ll Rights Reserved Page 05
Interior Finishes
Exterior Finishes
Lighting
Installation Instr ctions Toll Free Help Line 1-866-FOGAZZO
®
light fixture can be easily added inside the BBQ. You must use a low profile,
s rface mo nted metal electrical box, a ceramic fixture, fire proof wire and
a 25 to 40 watt appliance 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.
The firebox can be surrounded by regular bricks
that are cut to fit as shown above or using a
stone such as slate or granite or even glazed
ceramic tile as shown on the unit to the right.
The Model 525 BBQ above is shown with an
optional Model 2006 Rotisserie Kit that has a
motor and, two levels for spits that will hold up
to a total of 12 spits. The Model 525 on the right
is shown with an optional Model 1006 Non-
motorized Rotisserie Kit, with three levels that
can hold up to a total of 18 spits. Both rotisseries
can use an optional top rack or grill (both are
shown on the image to the right).
Exterior surfaces can be finished with tile, brick,
brick veneer, stone, slate, stucco or any other
non-flammable exterior finish.
Interior sides and back of BBQ area should be
finished using glazed ceramic tile, natural stone,
or quarry tile. Most types of tile will resist heat
well. ll natural stone will loose its polish over
time, and eventually will show stains. Glazed tile
as shown on the image below will last a lifetime
and is a better low maintenance option than
most natural stones.

Model 525 Installation Instructions ©2014 Fogazzo Wood Fired Ovens and Barbecues LLC. ll Rights Reserved Page 06
C ring & Initial Firing
Reso rces
Installation Instr ctions Toll Free Help Line 1-866-FOGAZZO
C ring
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 Proced res
Initial firing is the single most critical component
in completing a good installation. 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.
Reso rces
Chimney / Venting prod cts:
Fogazzo
Toll free at (877) FOG ZZO or online at:
www.http://www.fogazzo.com
Ch rrasco Barbec e Accessories
Fogazzo
Toll free at (877) FOG ZZO or online at:
www.http://www.fogazzo.com
Charcoal starters
The Home Depot
Lowe’s Home Centers
®
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.

“Even if yo own the worlds greatest espresso machine, it will not g arantee
that yo will get the best coffee in the world on yo r first try”.
Cooking with real fire takes some getting used to, but don’t be afraid to experiment.
Always
• llow 2 hours or more to bring your BBQ to temperature slowly.
• Use quality mesquite charcoal.
• Use safety gear to avoid injuries or burns
Never
• llow cold water to hit a hot BBQ.
• Use tools that can chip or scrape your BBQ firebox walls or floor.
• dd 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 Basics
Model 525 Installation Instructions ©2014 Fogazzo Wood Fired Ovens and Barbecues LLC. ll Rights Reserved Page 7
®

Fogazzo Limited Warranty
ll 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. fter 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. t 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 IMPLIED WARRANTIES, SUCH AS WARRANTIES OF MERCHANTABLITY
AND OF FITNESS FOR PURPOSE. WE ALSO DISCLAIM ALL WARRANTIES
REGARDING ANY AND ALL ANCILLARY SERVICES RENDERED.