Hitzer 503 Owner's manual

INTRODUCTION TO HITZER STOVES
INSTALLATION AND OPERATION
Welcome to our proud team of HITZER heater owners. Your HITZER heater has
the finest in Swiss craftsmanship and quality material to assure you that safety is the
number one priority at HITZER.
We must now depend on you, our valued customer, to continue this safety in
installation and operations, at the same time obtaining the maximum heat for comfortable
living. Therefore, please read the entire manual before you install and use your new
Hitzer heater.
SAFETY NOTICE: IF THIS HITZER HEATER IS NOT PROPERLY
INSTALLED A HOUSE FIRE MAY RESULT. FOR YOUR SAFETY
AND TO REDUCE THE RISK OF FIRE FOLLOW THE INSTALLATION
INSTRUCTIONS CAREFULLY. FAILURE TO FOLLOW THESE
INSTRUCTIONS MAY RESULT IN PROPERTY DAMAGE, BODILY
INJURY OR EVEN DEATH. INSTALLATION OF SMOKE DETECTORS
IS ALWAYS A GOOD IDEA. CONTACT YOUR LOCAL BUILDING
INSPECTOR OR FIRE OFFICIALS ABOUT THE NEED FOR A PERMIT,
RESTRICTIONS, OR INSTALLATION INSPECTION REQUIRED IN
YOUR AREA. SAVE THESE INSTRUCTIONS FOR FUTURE
REFERENCE.
CAUTION: THIS UNIT IS HOT WHEN IN OPERATION. DO NOT TOUCH.
KEEP CHILDREN, CLOTHING, AND ANY COMBUSTIBLES A SAFE
DISTANCE AWAY. CONTACT MAY CAUSE SKIN BURNING. SEE
NAMEPLATE AND INSTRUCTION SHEET FOR SAFETY. CONTACT YOUR
LOCAL BUILDING INSPECTOR, OR FIRE MARSHAL FOR SAFETY
REGULATIONS IN YOUR AREA. FOLLOW THE MANUAL VERY CLOSELY.
NOTE: THIS UNIT IS NOT APPROVED FOR MOBILE HOME USE.
“OUR STOVES MAKE WARM FRIENDS”
Keep warm and enjoy comfortable living with your Hitzer heater.
For more information contact: Hitzer Inc.
269 East Main Street
Berne, Indiana 46711
260-569-8536
260-589-3538 Fax
www.hitzer.com
[e-mail] e-mail

INSTALLATION AND OPERATION INSTRUCTIONS 503 EZ FLO INSERT
This unit must be installed in a fireplace with either a listed type HT (2100°F)
chimney per UL 103 or ULC S629 or a code approved masonry chimney with flue liner.
The chimney size should not be less than or more than 3 times greater than the cross
sectional area of the flue. Fireplace must accommodate this insert. No bricks or mortar
may be removed to make the insert fit. All openings between the masonry of the fireplace
and the facing masonry must be permanently sealed with mortar.
NOTE: For installations in Canada this insert must be installed with a continuous
chimney liner with a diameter of 6” extending from the fireplace insert to the top of the
chimney. The liner must conform to the Class 3 requirements of chimney liner standards
CAN/ULC-S635 or CAN/ULC- S640.
CAUTION: DO NOT CONNECT THIS UNIT TO A CHIMNEY SERVING
ANOTHER APPLIANCE. Inspection and cleaning are a prerequisite before installing
your insert. Your fireplace and chimney system must be free of all soot and creosote.
Inspect for deterioration of mortar joints and cracked liners for the safety of your unit and
your home. If chimney is damaged or if local regulations or insurance companies require
chimney lining for safety, install liner or reline the chimney following all of the liner
manufacturer’s instructions.
Installation in a masonry fireplace (see Fig 1)
Remove your damper from your
fireplace or block open permanently
to prevent it from accidentally
closing and causing smoke in your
room. A 6 inch chimney connector
must be connected from your insert
up through the damper area to the first
flue liner This connector should be
stainless steel chimney liner material.
Insert this liner in chimney now and
support up in chimney until your
insert is in place. Now position your
insert on the hearth (Note: First you
will want to place a thin sheet of metal
or cardboard on your hearth for
protection from chipping or
scratching your hearth.) With
your insert positioned on the hearth,
you are now ready to fasten the
shroud on the sides of your insert Fig 1
with 2 screws on each side. Determine the depth of the insert in the fireplace and adjust
the shroud sides accordingly to line the flues up as close as possible. The sides are
adjustable and should be tightened to the insert at this time. The shroud should overlap
the face of the fireplace a minimum of 2 inches. This is necessary to hold the insulation
in place and insure a good airtight seal around fireplace. Contact your dealer if a custom
sized shroud is required. Pull chimney connector down into flue collar of the insert and

fasten to insert with screws. Fasten the shroud top panel to the two shroud side panels
with 2 bolts at each end. The optional brass trim for around the shroud, if ordered, should
be fastened, now by cutting and fitting the sides, then the top and corner, drill holes and
fasten with screws provided. Place the insulation that is provided behind the shroud on
sides and top to assure a good seal on the face of your fireplace. Now push your insert the
remainder of the distance into your fireplace until shroud panel seals top and sides. If
your fireplace has deep mortar joints or if your fireplace is rough stone make sure all
joints and cavities are sealed. More insulation may have to be added. This is regular
unfaced fiberglass building insulation. Slightly lift your unit and remove the metal or
cardboard that is protecting your hearth
Installation in a factory built fireplace (see fig 1)
Install only in a factory built fireplace that is listed per UL 127 (US) or ULC S610
(CANADA) and is approved for insert installations. Alterations to the fireplace in any
manner are not permitted with two exceptions. The first is the chimney damper may be
removed to install the liner. The second is any external trim pieces not effecting the
operation of the fireplace may be removed provided they can be stored on or within the
fireplace for reassembly if the insert is removed. Attach the metal plate provided with
these instructions to the rear of your fireplace. This states that the fireplace must be
returned to its original condition for safe use if the insert is removed. Installation must
include a full length 6 inch listed chimney liner meeting type HT requirements (2100°F)
per UL 1777 (US) or ULC S635 or ULC S640 (CANADA). Liner must be securely
attached to the chimney top and also the flue collar of the insert. Remove your damper
from your fireplace or block open permanently to prevent it from accidentally closing and
causing smoke in your room. Run liner down chimney and support at top of fireplace.
Now position your insert on the hearth. First you may want to place a thin sheet of metal
or cardboard on your hearth for protection from chipping or scratching your hearth. With
your insert positioned on the hearth, you are now ready to fasten the shroud on the sides
of your insert with 2 screws on each side. Determine the depth of the insert in the
fireplace and adjust the shroud sides accordingly to line the flues up as close as possible.
The sides are adjustable and should be tightened to the insert at this time. The shroud
should overlap the face of the fireplace a minimum of 2”. This is necessary to hold the
insulation in place and insure a good airtight seal around fireplace. This seal is necessary
to prevent room air from entering the chimney area. This may also be accomplished by
sealing around the flue liner in the damper area. This must be done with ceramic wool
insulation or equivalents that will not burn or melt.
CAUTION: WHEN POSITIONING SHROUD IT MUST NEVER ALTER OR
RESTRICT AIR FLOW WITHIN OR AROUND FIREPLACE BY BLOCKING
ANY LOUVERS OR COOLING AIR INLET OR OUTLET PORTS.
CIRCULATING AIR CHAMBERS AROUND FIREPLACE ALSO SHALL NOT
BE BLOCKED.
Different sized custom shrouds are available to felicitate this. Contact your dealer or
Hitzer Inc to order. Pull chimney liner down into flue collar of the insert and fasten to
insert with screws. Fasten the shroud top panel to the two shroud side panels with 2

bolts at each end. The optional brass trim for around the shroud, if ordered, should be
fastened, now by cutting and fitting the sides, then the top and corners, drill holes and
fasten with screws provided. Place the insulation that is provided behind the shroud on
sides and top to assure a good seal on the face of your fireplace. Now push your insert the
remainder of the distance into your fireplace until shroud panel seals top and sides. If
your fireplace has deep mortar joints or if your fireplace is rough stone make sure all
joints and cavities are sealed. More insulation may have to be added. This is regular
unfaced fiberglass building insulation. If the floor of the fireplace is raised above the
hearth support is needed under the front of the insert. Contact your dealer or Hitzer Inc
for these support structures. Please have the height of the rise and also the distance the
insert protrudes from the front of the fireplace when you call. Slightly lift your unit and
remove the metal or cardboard that is protecting your hearth.
DO NOT CONNECT TO ANY AIR DISTRIBUTION DUCT OR SYSTEM
CLEARANCE:
Proper clearance from combustibles is a must to prevent fires. See figure for
proper clearances that must be maintained. This is a must to prevent fires and damage to
your home. Listed solid fuel burning fireplace inserts require noncombustible floor
protection 16 inches beyond the front and 8 inches beyond the side of the fuel loading
and ash removal openings.
Minimum clearances to combustible materials:
Unit to sidewall: A- 10”
Unit to right side facing: B- 9”
Unit to left side facing: B- 9”
Unit to top facing: C- 25”
Unit to mantle: D- 30”
Floor protection in front E- 16”
of door
Floor protection each side F- 8”
of door
OPERATION:
CAUTION: USE ONLY THE TYPE OF FUEL SPECIFIED HERE AND ON
THE HEATER
Type of fuel for use in these units is either anthracite or bituminous coal. Nut size
or pea size are the recommended size of anthracite to use in this unit. Caution should be
used when burning pea coal as shaking the grates too far can cause the small coal to be
dumped into the ash pan thus wasting your coal. Kindling and small pieces of wood are
required to use for igniting your coal when starting your fire.

CAUTION: DO NOT USE CHEMICALS OR FLUIDS TO START FIRE.
NEVER USE GASOLINE OR KEROSENE OR ANY OTHER FLAMMABLE
FLUID WHEN STARTING OR REFRESHING YOUR FIRE. DO NOT BURN
GARBAGE OR FLAMMABLE FLUIDS.
NOTE: When your first fire your heater, the exterior paint will go through a curing
process. This may emit some smoke or odor. The first few fires should be small and
slow, this allows the paint to cure and the steel to temper. Adequate room ventilation
should be used in case of smoking.
NOTE: Keep ash door, glass fuel door, and hopper lid closed and sealed during
operation. Keeping any door open during operation may cause your appliance to over
heat and possibly result in damage to your appliance or a house fire. Operating this
appliance with doors open can result in carbon monoxide entering the house. Adequate
room ventilation is also necessary for the chimney to operate correctly. Room air
starvation can be caused by well-sealed vapor barrier and tight windows, exhaust fans, or
other chimney ventilated appliances. Room air starvation can cause your appliance to not
draw steadily, smoke rollout to occur, fuel to burn poorly, or back-drafts to occur whether
or not there is combustion present. It can also result in carbon monoxide not venting
properly or entering the house. Outside combustion air may be required. It is a very good
idea to install a carbon monoxide detector no matter what type of fuel you burn and what
type of appliance you burn it in. Carbon monoxide is produced when burning gas, oil,
wood, coal, and anything else that burns and any venting problems can cause it to back
up into the house. Carbon monoxide is extremely dangerous and can result in serious
injury or even death
Starting your fire with anthracite coal:
First open the draft slide in the ash door to full open position. This is your
primary air control. Also slide open the sliding flue damper by pulling handle directly
above glass door all the way out.
CAUTION: BUILD FIRE ONLY ON INTEGRAL GRATE. DO NOT RAISE
FIRE BY ADDING ANOTHER GRATE.
Place crumpled paper and kindling wood on grate and ignite with a match or lighter.
Watch your fire very closely. When kindling wood is burning well add approximately 2”
of coal over the entire grate area. As the coal starts burning and glowing red another
layer of coal can be added. Keep adding layers of coal waiting between layers for each to
start burning until coal level reaches almost the hopper bottom. Now fill your hopper and
close hopper lid.
CAUTION: MAKE SURE THERE IS NO COAL OR OTHER DERBIES ON
LEDGE WHERE HOPPER LID SEALS. IF HOPPER LID DOES NOT SEAL
STOVE MAY OVER HEAT AND POSSIBLY DAMAGE THE STOVE OR
CAUSE A HOUSE FIRE.
Adjust draft slide in the ash door for the amount of heat desired. Sliding knob on ash
door to the right opens the air holes producing more heat. Sliding it to the left closes the
holes producing less heat. Burn stove at the lowest setting to produce the heat you need.
This will increase the life of the stove and make your coal last longer. Close the sliding

flue damper as far as you can and keep the insert burning good. In most cases this will be
completely pushed in. Even with damper all the way closed the flue is not completely
blocked. If insert seams sluggish or smoke backs up into the room the damper must be
pulled out till the problem is eliminated. For most efficient operation burn with damper as
far closed as possible. Air wash draft under glass door may be adjusted to add air on top
of fire and across glass. This operates the same as the ash door slide. Slide handle to the
right to open draft holes and to the left to close the draft holes. This helps burn coal gas
and also keeps combustion by- products away from glass keeping it cleaner.
Starting your fire with bituminous coal:
To burn bituminous coal you must first remove the lower portion of the hopper.
CAUTION: DO NOT PUT BITUMINOUS COAL IN THE HOPPER AS IT WILL
BURN UP INTO THE HOPPER AND POSSIBLY OVERHEAT THE STOVE.
BUILD FIRE ONLY ON INTEGRAL GRATE. DO NOT RAISE FIRE BY
ADDING ANOTHER GRATE.
Bituminous coal is started in much the same manner however it is not necessary to cover
the entire grate with the coal. The opening of the air wash is more important with
bituminous coal as there is much more soot that can cloud the glass.
Adding fuel and removing ashes: Anthracite coal
When it is time to add coal slide flue damper all the way out to the full open
position. Open the ash door and place shaker handle on the end of grate. Shake
vigorously until you see red coals dropping into the ash pan. Caution should be used
when burning pea coal as shaking the grates too far can cause the small coal to be
dumped into the ash pan thus wasting your coal. Remove shaker from grate and attach to
other grate. Shake until you see red coals again. Now you can refill the hopper with
fresh coal. Remove hopper lid and fill hopper with coal. For best results push coal with
poker or small shovel to fill the back of the hopper. Replace hopper lid making sure it
seals and reset your flue damper.
CAUTION: MAKE SURE THERE IS NO COAL OR OTHER DERBIES ON
LEDGE WHERE HOPPER LID SEALS. IF HOPPER LID DOES NOT SEAL
STOVE MAY OVER HEAT AND POSSIBLY DAMAGE THE STOVE OR
CAUSE A HOUSE FIRE.
How often you do this will depend on how hard you are burning the stove. Once or
twice a day should be enough in most cases. Remove and empty ash pan each time and
make sure ash in pan does not contact bottom of grates as this can cause the grate to
warp. If fire seems sluggish or is going out then not enough ash has been shaken out.
Ashes should be placed in a metal container with a tight fitting lid. The closed container
of ashes should be placed on a noncombustible floor or on the ground, well away from all
combustible materials, pending final disposal. If the ashes are disposed of by burial in
soil or otherwise locally dispersed, they should be retained in the closed container until
all cinders have thoroughly cooled.

Adding fuel and removing ashes: Bituminous coal
When it is time to add coal slide flue damper all the way out to the full open
position. Open the ash door and place shaker handle on the end of grate. Shake
vigorously until you see red coals dropping into the ash pan. Remove shaker from grate
and attach to other grate. Shake until you see red coals again.
With bituminous coal clinkers can form and it may be necessary to break these up to get
them to fall into the ash pan. They may also be removed through the main glass door
with metal tongs and placed in ash receptacle. Next add fresh coal to the firebox as
needed and reset your flue damper. How often you do this will depend on how hard you
are burning the stove. Once or twice a day should be enough in most cases. Remove and
empty ash pan each time and make sure ash in pan does not contact bottom of grates as
this can cause the grate to warp. If fire seems sluggish or is going out then not enough ash
has been shaken out. Ashes should be placed in a metal container with a tight fitting lid.
The closed container of ashes should be placed on a noncombustible floor or on the
ground, well away from all combustible materials, pending final disposal. If the ashes
are disposed of by burial in soil or otherwise locally dispersed, they should be retained in
the closed container until all cinders have thoroughly cooled.
MAINTENANCE
NOTE: Failure to maintain or properly use this appliance may cause a house fire.
At the beginning of each heating season this appliance, the connector pipe, and chimney
should be inspected to see that it is in good working condition.
Removal of your 503 insert for chimney and insert inspection:
You may have to remove your insert for cleaning and inspection. The first thing you
want to do is lift insert slightly and slide cardboard or sheet metal under it to protect your
hearth from scratching. Begin sliding insert out of fireplace until you can reach the two
bolts on either side of the insert that attach the shroud. Remove these bolts and lift shroud
off of the insert. You now have access to the flue. With a long screwdriver or nut driver
remove screw holding liner pipe into flue exit collar. Work pipe out of collar. You can
now remove insert from fireplace. Be careful as you slide insert out to make sure your
hearth protection stays under the insert. The hearth can be damaged by the weight of the
insert sliding on it with out the protection. You may also reduce the weight of the insert
by removing the firebricks, grates, and doors.
Prevent Soot and Creosote Fires:
When coal is burned, the products of combustion combine with moisture to form a
soot residue, which accumulates on the flue lining. When ignited, this soot makes an
extremely hot fire. When wood is burned it produces tar and other organic vapors, which
combine with expelled moisture to form creosote. The creosote vapors condense in the
relatively cool chimney flue of a slow-burning fire. As a result, creosote residue
accumulates on the flue lining. When ignited this creosote makes an extremely hot fire.
Chimney connector and chimney should be inspected at least once every two months
during operation to determine if a build up has occurred. If buildup has occurred it must
be removed with chimney cleaning chemicals and a chimney brush or contact a local
chimney sweep.

Fans:
Your unit is equipped with dual fans, which may run continually or may be
operated automatically. When your switch is on manual your fans will run continually.
You may want your switch on automatic and your fans will start when the unit heat is up
to 110°and will stop if unit cools down to 90°. Fans should be cleaned of dust and dirt
periodically. Replace only with original fan available from your Hitzer dealer.
CAUTION: ALWAYS DISCONNECT UNIT FROM POWER SOURCE BEFORE
ATTEMPTING TO SERVICE OR REPLACE ANY ELECTRICAL SYSTEM
COMPONENTS
Care and replacement of glass:
Never strike the glass or slam door shut as such abuse can damage the glass and
cause it to fail. Never operate your appliance with broken glass. Never attempt to clean
glass when hot. Never clean glass with harsh abrasives. Replace glass only with ROBAX
CERAMIC glass (5mm x 7 ½” x 13 ½”) available from your Hitzer dealer. Use of any
other type of glass can cause glass to fail creating a fire hazard
Should you be required to replace the glass first remove door from your stove and
lay face down on a smooth solid surface. You will want to pad the surface especially if
you have the optional gold plated door so as not to scratch the finish. Remove and save
the glass retainers and screws. Carefully remove all broken glass and sealing gasket
material. Install new glass using new sealing gasket material and reinstall all glass
retainers and screws.
Optional gold plating;
The gold plating option is real gold. Gold is very soft. Any abrasive type cleaner or
polish will destroy the finish. It is best to use a clean, soft, damp cloth or a clean, soft
cloth and window cleaner.
Fuel storage:
Coal does not absorb moisture as much as wood so coal can be easily stored outside.
It is a good idea to build a bin, in your garage, basement, shed, or even outside if you are
getting your coal in bulk. This will keep coal contained and not spread out all over the
floor. If stored outside it is a good idea to cover your bin with a tarp to keep out a lot of
snow. A estimate on size is a bin 4 feet wide by 8 feet long by 4 feet high will hold 3 ton
or a little more of nut size anthracite coal. Bagged coal can be stored anywhere inside or
out.
Other information needed may be received by contacting your Hitzer dealer or
Hitzer Inc.
269 E. Main St
Berne Indiana 46711
Phone- 260-589-8536
Fax- 260-589-3538
E-mail - [email protected]
www.hitzer.com