Forno Bravo Calore2G75 Installation and operating instructions

Forno Bravo, LLC
Calore2G Series Modular Fireplace Kit, Including:
Calore2G75 (SKUCC2G75)
Calore2G90 (SKUCC2G90)
Calore2G105 (SKUCC2G105)
Calore2G120 (SKUCC2G120)
Assembly and Operation Manual
OUTDOOR USE ONLY.
Forno Bravo, LLC
744 Neeson Road
Marina, CA 93933
[phone]
[email protected]
http://www.fornobravo.com
Calore2G Modular Fireplace Kit
Installation and Operation Manual
© Forno Bravo, LLC 2010. All Rights Served. Ver. 1.0 1

WARNING
READ ALL INSTRUCTIONS BEFORE INSTALLING AND USING THE APPLIANCE. FAILURE TO FOLLOW
INSTRUCTIONS MAY RESULT IN PROPERTY DAMAGE, BODILY INJURY, OR EVEN DEATH.
HOT WHILE IN OPERATION. KEEP CHILDREN, CLOTHING AND FURNITURE AWAY. CONTACT MAY CAUSE SKIN
BURNS.
ALWAYS OBTAIN THE PROPER PERMITS FROM YOUR LOCAL BUILDING AND FIRE SAFETY
AUTHORITIES WHEN INSTALLING THIS PRODUCT. ALWAYS COMPLY WITH ALL LOCAL BUILDING
CODES.
This product is designed to burn wood or gas. Use solid wood, or plumbed propane (LP) or Natural Gas
only.
Any gas log used with this product must be approved for outdoor use.
Do not use a fireplace insert with this product.
This Product is Not Approved for Indoor Installation.
Use Only Non-Combustible Building Materials When Installing the Calore2G Fireplace,
and Follow All Relevant Building and Fireplace Codes for Setbacks to Combustibles
from the Fireplace Opening and Chimney.
SAVE THESE INSTRUCTIONS
Calore2G Modular Fireplace Kit
Installation and Operation Manual
© Forno Bravo, LLC 2010. All Rights Served. Ver. 1.0 2

Limited Warranty
Forno Bravo, LLC Pizza Ovens and Fireplaces
THE WARRANTY
Forno Bravo, LLC, an importer and producer of pizza ovens
and fireplaces, warrants it ovens and fireplaces (herein
referred to as Product) to be free from defects in materials
and workmanship for a period of (1) one year from the date
of shipment.
QUALIFICATIONS TO THE WARRANTY
The complete Product Warranty outlined above does not
apply under the following circumstances:
(1) The Product was not installed in accordance with Forno
Bravo installation instructions and local building codes.
(2)The Product has been subjected to non-standard use,
including burning fuels with abnormal burning
characteristics including, driftwood, coal, plywood and wood
products using a binder that may burn at excessive
temperatures and cause damage to the Product.
(3) This Warranty does not apply to normal wear and tear.
(4) This Warranty does not apply to any cracking caused by
over-firing or the failure to follow a proper curing schedule.
(5) In the event that the Listing plate has been removed,
altered or obliterated.
(6) On parts that would be normally worn or replaced under
normal conditions.
(7) Normal cracking due to expansion and contraction
stress relief in either the dome or floor blocks.
LIMITATION ON LIABILITY
It is expressly agreed and understood that Forno Bravo's
sole obligation and purchaser's exclusive remedy under this
Warranty, under any other warranty, expressed or implied,
otherwise, shall be limited to replacement, repair, or refund,
as specified above, and such liability shall not include, and
purchaser specifically renounces any rights to recover,
special, incidental, consequential or other damages of any
kind whatsoever, including, but not limited to, injuries to
persons or damage to property, loss of profits or anticipated
profits, or loss of use of the product.
In no event shall Forno Bravo be responsible for any
incidental or consequential damages caused by defects in
its products, whether such damage occurs or is discovered
before or after replacement or repair, and whether or not
such damage is caused by Forno Bravo’s negligence.
Some states do not allow the exclusion or limitation of
incidental or consequential damages, so the above
limitation or exclusion may not apply to you. The duration of
any implied warranty with respect to this Product is limited
to the duration of the foregoing warranty. Some states do
not allow limitations on how long an implied warranty lasts,
so the above may not apply to you.
INVESTIGATION OF CLAIMS AGAINST
WARRANTY
Forno Bravo reserves the right to investigate any and all
claims against this Warranty and to decide upon method of
settlement.
DEALERS HAVE NO AUTHORITY TO ALTER THIS
WARRANTY
Forno Bravo's employees and dealers have no authority to
make any warranties nor to authorize any remedies in
addition to or inconsistent with those stated above.
HOW TO REGISTER A CLAIM AGAINST
WARRANTY
In order for any claim under this Warranty to be valid, Forno
Bravo must be notified of the claimed defect in writing or by
telephone to Forno Bravo, 744 Neeson Road, Marina, CA,
93933. Claims against this Warranty in writing should
include the date of installation, and a description of the
defect.
Calore2G Modular Fireplace Kit
Installation and Operation Manual
© Forno Bravo, LLC 2010. All Rights Served. Ver. 1.0 3

Table of Contents
...........................................................................................................................................1. About Your Fireplace 5
..................................................................................................................................2. Provided with the Product 6
...........................................................................................................................................................3. Clearances 7
............................................................................................................................................................4. Ventilation 8
..............................................................................................................................................................5. Assembly 9
.............................................................................................................................6. Operation and Maintenance 11
......................................................................................................................................Appendix 1: Dimensions 12
Calore2G Modular Fireplace Kit
Installation and Operation Manual
© Forno Bravo, LLC 2010. All Rights Served. Ver. 1.0 4

1. About Your Fireplace
The Calore2G is a modular fireplace kit designed for
outdoor use. It consistent of a number of interlocking
refractory components that are assembled to construct the
basic fire box, fireplace throat, smoke box and chimney.
The inside of the fire box is finished with firebrick splits for
an authentic brick fireplace appearance, while the outside
of the fireplace kit can either be finished with a non-
combustible decorative materials, such as stucco, brick or
stone, or it can be built into a decorative enclosure, but
using either Concrete Masonry Units (CMU) or metal studs
and backer board.
The fireplace kit can be assembled on a concrete slab
poured at ground level, or it can be raised up with a CMU
stand and a concrete slab.
Calore2G Modular Fireplace Kit
Installation and Operation Manual
© Forno Bravo, LLC 2010. All Rights Served. Ver. 1.0 5

2. Provided with the Product
Part #
Description
30”
36”
42”
48”
1
Base
1
1
1
1
2
Fire box back wall
1
2
2
2
3
Fire box angled back wall
1
1
1
1
4
Fire box side wall
4
6
6
6
5
Throat angled front wall
1
1
1
1
6
Throat back wall
1
1
1
1
7
Throat side wall
2
2
2
2
8
Smoke box front/back wall
2
2
2
2
9
Smoke box side walls
2
2
2
2
10
12” smoke box top
1
1
10
14” smoke box top
1
1
11
12” chimney section
4
4
11
14” chimney section
4
4
Owner Supplied Installation Materials
High Temperature, waterproof mortar
Firebrick splits (9”x4.5”x1.25” or 9”x2.5”x1.25”)
Optional Owner Supplied Installation Materials
Concrete Masonry Units (CMU)
Metal studs and backer board (Hardibacker) panels
Stucco, brick, decorative stone
Calore2G Modular Fireplace Kit
Installation and Operation Manual
© Forno Bravo, LLC 2010. All Rights Served. Ver. 1.0 6

3. Clearances
The Calore2G is designed for outdoor use. It can be
installed as a free standing fireplace, or it can be built into
a larger decorative enclosure. It must be installed on a
non-combustible platform; typically a reinforce concrete
slab on the ground, or raised with Concrete Masonry Units
(CMU).
All installation building materials must be non-combustible,
such as CMUs or metal stud framing and backer board
(Hardibacker) panels. There are no air-space or clearance
requirements between the Calore2G fireplace and the
non-combustible building materials.
Do not use insulation with the Calore2G fireplace kit. In
the event that your building enclosure does have air-space
between the fireplace kit and the building materials, do not
pack insulation or any other material in the opening.
Drywall, plywood, and wood framing are all combustible
building materials and cannot be used when installing this
product.
Hearth Extension
The Calore2G fireplace kit does not provide a hearth
extension product or building material. If you want to build
a hearth extension, use non-combustible building
materials.
The minimum floor hearth extension areas from the
fireplace opening to combustible floors are as follows:
•8” on each side of the fireplace opening
•24” in front of the fireplace opening
Additional Clearances
Clearance from the fireplace opening to a combustible
sidewall is 28”
Mantel Requirements
A decorative mantel can be attached above the fireplace,
and must be a minimum of 12” above the fireplace
opening.
Calore2G Modular Fireplace Kit
Installation and Operation Manual
© Forno Bravo, LLC 2010. All Rights Served. Ver. 1.0 7

4. Ventilation
The height of the chimney sections provided with the
Calore2G fireplace kit represent the minimum height
necessary to provide adequate air draw. Additional
chimney sections can be purchased to increase the height
of the chimney to either improve air draw and for design
reasons.
The Calore2G fireplace kit can also be vented using a pre-
fabricated, Listed UL103 steel chimney system. Available
from a number of manufacturers, these systems offer an
anchor plate, chimney pipe, spark arrestor, and various
angles and straps. Always use the correct anchor plate to
attach the chimney system to the Calore2G fireplace, and
follow the manufacturer’s installation instructions.
A UL103 Listed chimney system can be used to extend
the chimney sections provided with the Calore2G fireplace
kit, or it can be attached to the smoke box top.
Fireplace Size
Chimney
Diameter
Minimum
Chimney
Height
30”
12”
24”
36”
12”
24”
42”
14”
24”
48”
14”
36”
Chimney termination must be a minimum of 24” above any
combustible structure within 10’.
Calore2G Modular Fireplace Kit
Installation and Operation Manual
© Forno Bravo, LLC 2010. All Rights Served. Ver. 1.0 8

5. Assembly
The Calore2G fireplace kit is assembled using high
temperature, waterproof mortar. Here are some tips to
make your assembly fast and accurate.
•Take a few minutes to “dry stack” your Calore2G
fireplace kit without using mortar. That will show you
how the pieces fit together;
•Know that this is a two-man job. Have a helper;
•Use a level to make sure that all of your fireplace
components are level and plumb;
•Be sure to calculate the thickness of the firebrick floor
and mortar to determine the finished height of the
fireplace and the height of the foundation and/or CMU
stand that holds the fireplace kit;
•Use a trowel to place a 1/4” bead of mortar between
each touching fireplace component face;
•Line the assembled fire box (component numbers 1,
2, 3 and 4)with firebrick splits before you assemble
the fireplace throat (component numbers 5, 6 and 7).
Assembly Steps
1. Set the fireplace base.
The fireplace base (1) is not designed to span a gap
between CMU walls. If you are raising your fireplace on a
CMU stand, be sure to frame and pour a 3 1/2” rebar
reinforced concrete slab to hold the fireplace base.
Make sure the fireplace base is level and that it “faces” in
the right direction. You will not be able to move it later.
2. Set the firebox.
Mortar one level of the firebox sides (4) and back wall (2)
together and to the fireplace base. Check for level and
continue with the next level. Mortar the fire box angled
back wall (3) and the fire box sides and complete the fire
box. Check that it is level and plumb. At this point, you can
line the fire box walls and floor with firebrick splits.
3. Set the fireplace throat.
Place the angled throat front (5) and the straight throat
back (6)across the opening at the top of the fire box.
Note: the hearth extension is not provided with the
Calore2G kit.
Calore2G Modular Fireplace Kit
Installation and Operation Manual
© Forno Bravo, LLC 2010. All Rights Served. Ver. 1.0 9

Assembly (continued)
Place the throat side pieces (7) into the interlocking joints
with the throat front (5) and back (6).
4. Set the smoke box
Place the smoke box front and back (8) across the
fireplace throat.
Place the smoke box sides (9) into the interlocking joints
with the smoke box front and back (8).
5. Set the smoke box top
Place the smoke box top (10) over the smoke box
opening.
6. Set the chimney pieces.
Place the chimney pieces (11) over the smoke box top.
7. Line the fire box with firebrick splits.
Notes
You can enclose the Calore2G in a decorative enclosure
using CMUs or metal studs and backer board. You can
also attach non-combustible finish materials, including
stucco, brick or stone directly to the fireplace kits. You can
use brick ties with the Calore2G kit.
Do not worry if one of your fireplace components has a
hairline crack. The structure of the fireplace holds each
component tightly in place, and small cracks are not a
problem. If one of your components is cracked in one
place from improper handling, you can mortar the piece
together and continue with assembly.
If you receive a shipment which has been handled
improperly and a component is broken in more one place,
contact Forno Bravo to receive a replacement component.
Calore2G Modular Fireplace Kit
Installation and Operation Manual
© Forno Bravo, LLC 2010. All Rights Served. Ver. 1.0 10

6. Operation and Maintenance
Operation
DO NOT OVER FIRE
Burn solid, well seasoned wood only.
To maximize wood burning efficiency, use a log grate.
Use firewood for burning only. DO NOT use charcoal,
pressure treated lumber, sappy wood such as pine,
laminated wood or any material other than dry medium or
hard firewood.
DO NOT USE liquid fuel (firelighter fluid, gasoline, lantern
oil, kerosene or similar liquids) to start or maintain a fire.
Fire starters (smokeless, odorless, non-toxic lighter cubes)
are recommended.
Dispose of ashes using a metal shovel and place in a
metal bin with a tightly fitting lid. The container should be
stored on a non-combustible surface, away from all
combustible materials. Ensure ashes are completely cold
before disposing of them appropriately.
BEWARE of flying sparks from mouth of fireplace. Ensure
that no combustible materials are within range of fireplace
at any time.
DO NOT use water to dampen or extinguish fire in the
fireplace.
Contact your local building department for clarification on
any restrictions on installation of this fireplace in your area.
Maintenance
Have your chimney cleaned by a professional chimney
sweep if you have doubts about your ability to clean it.
Use a plastic, wood, or steel brush. If you have installed a
UL103 chimney system, do not use a brush that will
scratch the stainless steel liner of your chimney. Scrub the
spark arrestor with a wire brush.
Creosote – Formation and need for removal. When wood
is burned slowly, it produces tar and other organic vapors
that combine with expelled moisture to form creosote. The
creosote vapors condense in a relatively cook oven flue
and exhaust hood of a slow burning fire. As a result,
creosote residue accumulates on the flue lining and
exhaust hood. When ignited, this creosote makes an
extremely hot fire.
The oven flue should be inspected at least twice a year to
determine when creosote buildup has occurred.
When creosote has accumulated, it should be removed to
reduce risk of fire.
Calore2G Modular Fireplace Kit
Installation and Operation Manual
© Forno Bravo, LLC 2010. All Rights Served. Ver. 1.0 11

Appendix 1: Dimensions
27"
22"
30"
10 1/2"
21"
24"
9"
24"
20"
27"
10 1/2"
21"
24"
9"
24"
20"
12"
5"
12"
Calore2G75
30" Modular Fireplace Kit
v1.0, 09/10
Copyright Forno Bravo, LLC 2010
744 Neeson Road
Marina, CA 93933
[phone]
3"
3"
15"
6"
6"
3"
38"
26"
5
8
10
11
1
11
11
11
2
3
11
11
11
11
2
3
1
10
4
4
4
9
8
8
32 1/2"
38"
75"
51"
99
56
4
4
4
4
4"
22"
777
Calore2G Modular Fireplace Kit
Installation and Operation Manual
© Forno Bravo, LLC 2010. All Rights Served. Ver. 1.0 12

27"
22"
36"
10 1/2"
31 1/2"
24"
9"
24"
20"
27"
10 1/2"
31 1/2"
24"
9"
24"
20"
12"
5"
12"
Calore2G90
36" Modular Fireplace Kit
v1.4, 09/10
Copyright Forno Bravo, LLC 2010
744 Neeson Road
Marina, CA 93933
[phone]
3"
3"
15"
6"
6"
3"
44"
26"
2
5
8
10
11
1
11
11
11
2
3
11
11
11
11
2
2
3
1
10
4
4
4
9
8
8
38 1/2"
44"
86"
62"
99
56
4
4
4
4
4
4
4"
22"
77 7
Calore2G Modular Fireplace Kit
Installation and Operation Manual
© Forno Bravo, LLC 2010. All Rights Served. Ver. 1.0 13

27"
22"
42"
10 1/2"
31 1/2"
24"
9"
24"
22"
27"
10 1/2"
31 1/2"
24"
9"
24"
22"
14"
5"
14"
Calore2G105
42" Modular Fireplace Kit
v1.0, 09/10
Copyright Forno Bravo, LLC 2010
744 Neeson Road
Marina, CA 93933
[phone]
3"
3"
15"
6"
6"
3"
50"
26"
2
5
8
10
11
1
11
11
11
2
3
11
11
11
11
2
2
3
1
10
4
4
4
9
8
8
44 1/2"
50"
86"
62"
99
56
4
4
4
4
4
4
4"
22"
777
Calore2G Modular Fireplace Kit
Installation and Operation Manual
© Forno Bravo, LLC 2010. All Rights Served. Ver. 1.0 14

27"
22"
48"
10 1/2"
31 1/2"
24"
9"
24"
22"
27"
10 1/2"
31 1/2"
24"
9"
24"
22"
14"
5"
14"
Calore2G120
48" Modular Fireplace Kit
v1.0, 09/10
Copyright Forno Bravo, LLC 2010
744 Neeson Road
Marina, CA 93933
[phone]
3"
3"
15"
6"
6"
3"
56"
26"
2
5
8
10
11
1
11
11
11
2
3
11
11
11
11
2
2
3
1
10
4
4
4
9
8
8
50 1/2"
56"
86"
62"
99
56
4
4
4
4
4
4
4"
22"
777
Calore2G Modular Fireplace Kit
Installation and Operation Manual
© Forno Bravo, LLC 2010. All Rights Served. Ver. 1.0 15