Technical Manual 

STACK Charcoal Oven 

Ritual. Precision. Versatility. 

Contents

1. Introduction

WARNING: Failure to adhere strictly to the guidelines provided in this manual may lead to a fire, resulting in extensive property destruction, serious physical injury, or loss of life. It is strictly prohibited to store or operate equipment using gasoline, or any other combustible liquids and vapors, in the area surrounding this appliance or any other similar device.

WARNING: Incorrect setup, modification, adjustment, or inadequate servicing and maintenance may lead to property loss, severe bodily harm, or fatality. It is essential to conduct a comprehensive review of the installation, operation, and maintenance manuals prior to the initial setup or any subsequent repair of this equipment.

This manual provides critical guidance essential for the correct construction and secure operation of this equipment. You must read and comply with every warning and instruction prior to the assembly or use of the unit. Ensure that all safety protocols and directions are strictly followed during operation. Retain this documentation in a safe place for future consultation.

2. General Safety Advice 

The STACK Charcoal Oven reaches exceptionally high temperatures and must never be operated by children. Keep children away from the unit during use and throughout the cooling process, as the device retains significant heat for several hours after operation.

2.1 Operational Restrictions & Safety Placement

• Location Constraints: Do not operate the oven beneath balconies or decks of apartments or condominiums.

• Restricted Environments: This unit is not designed for use on boats, within recreational vehicles, or in any other enclosed or confined spaces.

• Outdoor Use Only: Use only in well-ventilated outdoor areas; indoor operation is strictly prohibited.

• Proximity to Flammables: Maintain a minimum distance of 8 meters from any combustible liquids.

• Surface Stability: Ensure the oven is positioned on a solid, level, flat surface.

2.2 Usage Protocols

• Supervision: Never leave the appliance unattended while in use.

• Prohibited Uses: This device is intended solely for cooking and must never be used as a space heater.

• Physical Handling: Do not attempt to move the unit while it is functioning.

• Water Hazard: Never pour water into the oven during operation. This can lead to structural warping or cause dangerous reactions with hot oils and grease.

2.3 User Safety & Attire

• Authorised Assembly: Setup and operation should only be performed by a competent individual.

• Impairment: The use of alcohol or medication (prescription or otherwise) may hinder the ability to safely assemble or manage the device.

• Clothing: Avoid wearing loose-fitting, flammable garments or long sleeves when near the oven.

• Protective Gear: Always wear heat-resistant gloves during use.

Technical & Material Precautions

• Utensil Safety: Do not utilise plastic or glass tools with this appliance.

• Capacity Limits: Do not force items into the oven that exceed the physical dimensions of the opening.

• Manufacturer Seals: Users are strictly forbidden from tampering with or altering any components sealed by the manufacturer.

• Residual Heat: Be aware that heated liquids can maintain scalding temperatures long after cooking has finished.

3. Product Overview & Technical Details  

4. Operation & Installation

This section details the correct operation and installation of The STACK. 

4.1 SAFETY CONSIDERATIONS

Critical Safety Alerts

• Extreme Temperatures: This unit reaches very high heat levels; do not attempt to relocate it while it is in use.

• Vulnerable Groups: Ensure children and pets are kept at a safe distance at all times.

• Physical Hazards: The product may feature sharp edges; handle all components with care during assembly and use.

Environment & Stability

• Secure Base: This appliance must be installed on a secure, level, non combustible base able to support the oven's weight or the STACK Oven Cabinet prior to use.

• Ventilation Requirements: Operation in confined or enclosed spaces is prohibited. The unit must always be used in a well-ventilated area.

• Weather Conditions: Do not use the appliance during periods of high wind.

• Mobile Restrictions: This oven is not designed for, and must not be installed within, any recreational vehicle (RV) or trailer.

• Surface Placement: The unit must remain stationary and attended for the duration of its use.

Equipment & Maintenance

• Internal Utensils: Avoid the use of glass or plastic tools inside the oven dome.

• Liquid Hazards: Do not pour or splash water into the cooking chamber. This is hazardous and may result in the permanent deformation of the oven structure.

• Assembly Integrity: All fittings must be securely tightened according to the provided manual.

• No Unauthorized Changes: Do not modify the appliance in any way. Any components or settings sealed by the manufacturer are not to be adjusted or tampered with by the user.

4.2 FIRE

The accumulation of grease is the primary cause of most fires. In the event of an ignition, immediately ensure that all individuals and pets are evacuated to a safe distance.

If a fire occurs, prioritise the use of a fire extinguisher. If water is the only available means of suppression, thoroughly drench the area surrounding the unit. When applying water to the STACK itself, avoid using a high-pressure jet; a concentrated stream can cause flaming grease to splash, potentially spreading the fire further.

4.3 CARBON MONOXIDE

Inadequate ventilation during operation can lead to the production of Carbon Monoxide (CO), a highly toxic and lethal gas. To prevent this, the STACK should always be operated in a well-ventilated exterior space, positioned away from direct, heavy gusts of wind.

Because Carbon Monoxide is both colorless and odorless, it is impossible to detect without specialized equipment. Exposure may manifest through the following physical symptoms:

• Initial Signs: Tightness across the forehead and persistent headaches.

• Physical Weakness: General lethargy, dizziness, or feelings of nausea.

• Advanced Symptoms: Vomiting, intermittent convulsions, or falling into a coma.

• Critical Failure: Slowed breathing and depressed heart function.

Severe exposure to Carbon Monoxide can be fatal. You must adhere to all local safety regulations and, where applicable, install a CO alarm to ensure early detection.

4.4 Moving The Oven

Relocating the STACK requires strict adherence to safety protocols to prevent injury or equipment damage.

Preparation for Transport

• Cooling Period: Do not attempt to move the unit while it is operating or before it has completely cooled down after use.

• Component Removal: Before transport, remove all detachable parts, including the chimney and ash pan.

• Internal Clearance: Entirely empty the oven’s interior, including the firebox and cooking racks.

• Secure the Unit: Ensure the oven door is shifted to the closed and locked position.

Safe Lifting Techniques

• Team Lift Required: Never attempt to move the oven alone. A minimum of two people is required for any relocation.

• Proper Grip: Lift the unit from the base with one hand while using the other hand to stabilise the top.

• Cooking Chamber: Under no circumstances should the internal cooking chamber be used as a handle or lifting point.

Logistics and Placement

• Route Planning: Scout your intended path beforehand. Clear all obstacles and verify that the oven can pass through all openings safely.

• Destination Compliance: Confirm that the new location meets all site requirements and safety guidelines outlined on the following page of this manual.

4.5 Oven Placement

When selecting a location for your STACK, ensure the site is spacious enough to allow for a 5cm perimeter around the oven's base. This gap is vital for air intake; any restriction to the airflow at the bottom of the unit will negatively impact its performance.

WARNING: Fire Safety Clearances

To prevent fire hazards, you must maintain the following minimum distances from any combustible construction:

• Sides and Rear: 60cm clearance.

• Front: 2-meter clearance.

• Vertical Restrictions: The oven must never be positioned underneath or on top of any combustible structure.

Always ensure the surrounding area is kept free of combustible materials, gasoline, and any other flammable liquids or vapors.

Surface Requirements

The mounting surface must be:

1. Perfectly Level: To ensure operational stability.

2. Structurally Sound: Capable of safely supporting the oven’s total weight (104kg with cabinet).

WARNING: Wind and Orientation

Environmental conditions must be considered for safe operation:

• High Winds: Never operate the appliance during strong winds.

• Strategic Positioning: Avoid locations where the wind blows directly into the cooking chamber.

• Directional Placement: Position the oven so that the opening of the cooking chamber faces away from the prevailing wind direction.

4.6 Flue Assembly

For shipping purposes, the chimney is detached and must be properly installed prior to using the oven.

Chimney Installation Instructions

1. Unpacking: Completely remove all protective packaging materials from both the chimney and the oven body.

2. Alignment: Place the chimney into the designated opening on the top of the oven. Ensure that the mounting holes on the chimney base are perfectly aligned with the corresponding holes on the oven roof.

3. Securing the Bolts: Carefully thread the provided bolts through the holes to anchor the chimney to the roof.

4. Important Torque Warning: Do not overtighten the bolts, as excessive force can cause the oven roof to warp or deform.

5. Torque Guidance: Stop tightening as soon as the bolt head sits flush against the chimney flange. The goal is to secure the component without applying significant downward pressure onto the chimney or the oven roof.

4.7 Ash Tray

Before firing the oven, make sure you have removed the ash tray and disposed of any packaging. The ash tray should always be inserted into its slot and in its closed position when the oven is in use.

5. First Firing: The Seasoning Process 

For the initial firing of the oven, it is vital to increase the temperature gradually. This seasoning process tempers the unit and protects it against thermal shock, which can lead to irreversible structural warping.

5.1 Charcoal Safety Protocols

WARNING: Prior to ignition, confirm that all safety guidelines in this manual have been followed. If you have any doubts, do not operate the oven and reach out to support@stack-online.com.

• Prohibited Accelerants: Never use flammable liquids such as gasoline, petrol, or barbecue lighter fluid to start or intensify the fire. All such substances must be kept far from the unit during operation.

• Approved Fuels Only: Use only authorised fuel types. Placing charcoal directly against the side or rear walls of the oven is prohibited and may void your warranty.

• Liquid Damage Warning: Do not spray or pour any liquids into the oven interior or onto the cooking chamber walls. Doing so can cause damage and may invalidate your warranty.

• Safe Ash Disposal: Exercise caution when removing ash debris. Embers can remain dangerously hot long after the oven has cooled.

• Overloading Hazard: Excessive fuel creates dangerous conditions, including surplus smoke and uncontrolled flames. If flames begin to exit the cooking chamber, retreat to a safe distance and allow the fire to subside naturally.

5.2 Ignition Procedures

1. Fuel Selection: Use high-quality lumpwood charcoal. To ensure the flavour of your food is not compromised, avoid using treated charcoal or chemical firelighters.

2. Placement: Distribute the charcoal onto the fire grates. 

3. Ignition: Use natural firelighters tucked into the coals or ignite using a blow torch.

4. Airflow: Set both the upper and lower air vents to the fully open position.

5. Close The Door: After 2 to 3 minutes, shut the oven door and ensure it is securely locked.

6. Preheating: Allow approximately 15 minutes for the temperature gauge to reach a range between 100°C and 350°C.

7. Regulation: Adjust the air vents to modulate the oxygen flow and reach your specific target temperature.

5.3 Seasoning Process

Performing an initial seasoning of your STACK is a mandatory step. This process mitigates the risk of thermal shock, establishes a natural non-stick coating, and eliminates any residual manufacturing oils or contaminants. 

WARNING: The oven should be heated to 300°C degrees for at least 40 minutes prior to the first cooking session.

Pre-Seasoning Preparation

1. Grid Maintenance: Wash the cooking grid with water and dry it thoroughly.

2. Interior Cleaning: Use a damp cloth and water to wipe down all internal surfaces.

3. Oil Application: Coat the grid and all interior surfaces with a thin layer of peanut or vegetable oil. Use a paper towel to remove any excess oil.

The Seasoning Process

• Initial Ignition: Light approximately 2kg (or four large handfuls) of charcoal.

• Airflow: Keep air controls fully open until the temperature reaches 200°C.

• Temperature Staging: Follow the schedule below, adjusting the air vents to the "hold" position to maintain each temperature for the specified duration:

Cooling and Post-Seasoning

Once the final 10-minute window is complete, shut both the top and bottom air vents, close the door, and allow the unit to cool down entirely.

Observations:

• Successful seasoning is indicated by the full expansion of the oven chamber and a change in the color of the stainless steel grid. This change in colour is a normal sign that the non-stick surface is developing.

Ongoing Maintenance:

• Frequency: To preserve the non-stick properties, repeat the seasoning process every 3 months.

• Re-activation: If the oven has been dormant for an extended period, treat the next use as if it were a first-time firing by following the gradual temperature stages outlined above.

6. Temperature Control Settings 

7. General Operation

7.1 Door Handling

To open the unit, pull the door lever toward you. To close it, push the door into position and press the lever downward to lock it. The mechanism is designed for ease of use; do not slam the door.

7.2 Drip Management

It is recommended to position the plancha rack on a lower shelf to serve as a drip tray. Before sliding out any cooking grids above, extend the plancha rack by 50% to ensure it captures any falling grease or liquids.

7.3 Ash Disposal and Safety

Residual heat in ashes can persist for up to 24 hours post-use. When clearing debris, strictly adhere to these safety measures:

• Equipment: Use only non-combustible tools, such as a metal ash shovel, for extraction.

• Storage: Immediately place ashes into a metal container featuring a tight-fitting lid.

• Cooling: Keep the sealed metal container in a safe, fire-proof location until the contents have completely cooled before final disposal.

8. General Maintenance

8.1 Internal Cleaning

The most effective method for cleaning the interior of The STACK is through high-heat combustion. When the oven operates at temperatures exceeding 300°C, it initiates a self-cleaning process. Over a period of three hours, food residue and soot will naturally incinerate.

For any remaining debris:

• Manual Removal: Once the oven has completely cooled, use a soft-bristled brush to gently dislodge soot. Avoid applying heavy pressure to protect the oven's internal structure.

• Vacuuming: Use a shop vacuum equipped with a plastic attachment to safely extract the loose particles. Only do so when the oven and any residual material has fully cooled. 

8.2 External Cleaning

To maintain the oven’s exterior, apply a non-caustic, bleach-free cleaning spray to dirty areas. Wipe the surface using warm, soapy water and a sponge or non-abrasive cloth, then dry thoroughly with paper towels.

Storage Protection:

• When not in operation, the oven should be stored under a protective cover to shield it from rain.

• Important: Ensure the unit has cooled down entirely before applying any direct cover.

8.3 Chamber Sweep

During the cooking process, ash will accumulate on the plate situated beneath the fire grates. Every three uses (or more frequently if necessary), perform the following maintenance:

1. Ensure the oven and all ashes are completely cool.

2. Remove the fire grates and fire box. 

3. Open the bottom air vent to its maximum setting.

4. Sweep the accumulated ash down into the ash pan for disposal.

8.4 Tightening of Fixings

The mechanical vibrations and heat cycles may cause bolted components such as the door latch, hinge brackets, and flue to loosen over time. Conduct a safety check every 3 months and use the provided Allen keys to ensure all fixings remain securely tightened.