Harman Stove Company DVC500-C User manual

Contact your local authority (such as municipal building
department, fire department, fire prevention bureau, etc.)
to determine the need for a permit.
Contact local building or fire officials about restrictions
and installation inspection requirements in your area.
FOR USE IN THE U.S. AND CANADA
SUITABLE FOR INSTALLATION IN MOBILE HOMES
DVC500-C COALSTOKER MANUAL
Failure to Read
This Manual
Will Cause You
Unnecessary
Problems.
DVC500C-R8
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INDEX
Introduction 5
Warnings 4
Assembly 6
Installation 7
DVC500 Microprocessor Control 14
Operation 14
Maintenance 18
Fuel 22
WiringDiagram 25
ControlandSafetySensors 26
Parts 27
Specifications 28
Troubleshooting 29
From serial # 1157
Please read this entire manual before you install and use your new
room heater. Failure to follow instructions may result in
property damage, bodily injury, or even death.
SUITABLE FOR MOBILE HOME INSTALLATIONS.
SAVE THESE INSTRUCTIONS
Harman Stove Company
352 Mountain House Road
Halifax, PA 17032
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4
Always empty hopper when not
burning for more than a week. When
left standing for long periods with
wet coal, the pusher block will rust
and corrode, causing it to seize. If the
stoker is then turned "on", damage
to the pusher assembly and feed
motor could result. This will be
considered neglect and will void the
warranty on those parts. Always
check to see if moving parts are free
before using if the unit has not been
burned for a period of time. This can
best be determined by watching the
cam block and pusher arm inside the
right rear side door.
Freshly delivered coalis watered down
to eliminate dustwhen loadingand unloading.
Wet rice coaldoes not flow as wellas damp or
dry coal.We do not recommend burning wet
coal; however, we realize if it's the only coal
you have, it is betterto burn it than be cold. If
you must burnwet coal, the feedrate must be
increased in order to get the same size fire. As
the wet coalin the hopper dries out, the feed
rate must be decreased. If you don’t, the feeder
will over-fire the stove and waste coal. Doing
this once or twice a year willnot damage your
stove as long as it is hot and burning. The
damage is caused when the hopper has wet
coal in it when the stove is cold. This will
cause rustand corrosionand it istotally the
operator’s fault. Usually after thecoaldries for
three orfour days,depending on conditions, it
will flow very well and feed properly. Feed
rate will be the same as dry coal.
Wet Coal
WARNINGS
(Never sleep in the same room with any coal burning stove.)
Carbon Monoxide (CO) Awareness
Carbon monoxide referred to as CO, is a
colorless, odorless gas that is produced during
combustion of coal and other fuels.CO fumes
are toxic and can be fatal.
The DVC 500 is a closed loop system
specially designed to prevent the escape of CO
and other combustion products from the stove.
Even though this stove is designed to be as
safe as possible, it is important that youinstall
a CO detector. This is true for oil, gas, or
wood as well.
CO is heavier than air. This causes accu-
mulation to occur at the floor first. Therefore, it
is best to install the detector at table top level or
lower rather than on the ceiling like a smoke
detector.
CO detectors are very sensitive and
may sound an alarm for fumes other than
CO or CO from sources other than the stove
such as car or lawn mower exhaust.
If the alarm sounds
1. In crease ventilatio n b y o pen in g w in dow s
or doors.
2. M ake sure the stove doors and hopper lid
are closed and latched.
3. Check stove for electrical pow er and
norm al operation.
4. C h eck fo r false alarm .
Always Empty Hopper
Never use gasoline, gasoline-type lantern fuel,kerosene, charcoal lighter fluid, or similar
liquids to start or “freshen up” a fire in this heater. Keep all such liquids well away from the
heater while it is in use.
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INTRODUCTION
This all new design by Harman features the
Verti-flow Direct Vent Stoker System.
This unique high efficiency unit uses only
outside air for combustion.
Micro-processor controls provide for an
automatic wide range of heat output from 7,000 to
75,000 BTU .
With a big 93 pound hopper capacity, this
unit can burn on high approximately 16 hours or
extend for over 96 hours on low.
A Room Sensor connected to the micro-
processor automatically adjusts the feed rate to
compensate for changes in temperature.
The ash pan is large enough to hold the ash
from one hopper full of coal at any setting.
The DVC 500 is the most advanced coal
stove ever put into production. However, there
are places where it should not be installed. If
the end of the flue pipe is:
1. Less than 8 feet of an air intake.
2. On the side of the house where a window is
left open for sleeping.
3. Less than 5 feet from a door.
4. Less than 7 feet above and 3 feet away from
a public walkway.
5. Less than 3 feet above ground level.
6. Between two building less than 10 feet apart.
It is recommended that the end of the flue
pipe terminates at least 12 inches away from
the side of the building in order to minimize
any fly ash residue build-up.
Mobile home installation should be
done in accordance with the
Manufactured Home and Safety
Standard (HUD), CFR 3280, Part 24.
DAMP COAL SHOULD NOT BE LEFT IN THE HOPPER OF A COLD STOVE.
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Assembly
1. Install hopper latch as shown at left.
2. Install 3 firebricks on angle behind grate as
shown.
3. Cement in grates as shown below. This may
already be done at the factory.
4. Install door and latch on stove.
3 Bricks
GrateInserts
fig. 3
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4 GLASS
RETAINER
CLIPS 4 GLASS
RETAINER
BOLTS
GLASS
GLASS GASKET
DOOR
HINGE PINS
BRASS HANDLE
HANDLE
BOLT
WOOD HANDLE
PAW BOLT
SET SCREW
Door Glass
* Rope the glass carefully to insure proper
sealing.
* Applythe rope exactlyalongthe edge of the
external face of the glass, not overhanging or
pressed too far in from the edge.
* Make sharp 90o turns at the corners.
* Overlapthe endsof the ropeat theupperleft
or right corners.
Glass Retainer Clips
* Use the glass retainer clips and screws
supplied in the door kit.
* Use a1/8"Allen wrench to tighten the glass
clips to cast door with 10-24 x 3/8" screws
supplied.
Paw Bolt
* The paw boltshouldbe turned into the door
from the inside approximately 14 turns.
* With the set screw removed, turn the brass
elbow onto the paw bolt approximately 5
turns, or until a 1/16" clearance is achieved
between the elbow and the door face (make
sure to stop on the flat spot of the paw bolt).
* The set screw on the brass elbow must be
aligned tocontact the flat spoton the pawbolt,
then tighten using a 5/32" Allen wrench.
* After attaching the door handle, close and
latch the door by turning the handle to the six
o'clock position. During this process observe
to see that the door rope is being compressed
properly.
* If itdoes not compress,loosen the set screw
and turn the paw bolt one additional turn into
the door. Repeat as required to insure a tight
seal.
Door Assembly/Installation Tips
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Tips On Installation
Before the position of unit can be decided a
few questions should be considered?
1. Can the unit be vented properly and installed
safely?
2. Will exhaust be vented where fumes can build
up or be drawn into lower levels of the structure
3. Will fumes and fly ash affect the exterior of the
structure or someone else’s?
4. Are there any local regulations governing the
use and placement of the unit?
5. Are there any structural reasons why the unit
cannot be placed where you want?
6. How close is the electric outlet?
Floor Protector
This stove should be placed on a non-com-
bustible floor protector extending 16 inches to the
front, 8 inches to the sides, and 1 inch to the rear.
Straight Through Wall
1. When position of unit has been decided, use
measurements on Page 9. In this manual for the
hole through wall. Don’t forget the thickness of
floor protector used.
2. Cut at least a 9" x 9" hole through wall.
3. Remove side doors and rear cover assembly (6
black screws, 5/16" socket or straight screw-
driver)
4. Place unit in front of the hole approximately
1/2" closer to the wall then the length of the
wall termination. (From outside of wall to back
of unit where termination bolts up)
5. Take wall terminators outside and slide into
hole until it mates to rear of unit. Go inside and
install bolts and tighten, making sure the gasket
is in place and the flue pipe section is level.
6. Reposition unit inward until the stainless steel
intake section comes against the outside surface.
NOTE: If the wall is over 8" thick you will need
a longer wall termination. The standard termina-
tion will provide 3" of wall clearance behind the
stove. Therefore a 5" thick wall will provide 6"
of clearance.
INSTALLATION
DO NOT INSTALL A FLUE
DAMPER IN THE EXHAUST
VENTING SYSTEM OF THIS UNIT
DO NOT CONNECT THIS UNIT
TO A CHIMNEY FLUE SERVING
ANOTHER APPLIANCE.
INSTALL VENT AT
CLEARANCES SPECIFIED BY
THE MANUFACTURER
fig. 6
fig. 7
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7. Checkexterioroftermination forbest fit and screw
to exteriorand caulkwith highgradeexterior
caulking.
8. Complete any other exterior flue piping neces-
sary.
9. Back inside, place the 2 halves of the interior
wall trim plate over flue pipe. Using the black
pop rivets, fasten together, then slide against
wall and fasten to wall.
10. Replace door assembly with 6 black screws.
11. Complete unit assembly and test.
Wall TrimPlate
Wall TrimPlate
Gasket
Wall
Termiation
Installation
Open
WARNING:
CAUTION:
THE STRUCTURAL INTEGRITY
OF THE MOBILE HOME FLOOR,
WALL, AND CEILING/ROOF
MUST BE MAINTAINED.
DO NOT INSTALL IN
MOLBILE HOME
SLEEPING ROOM
Standard Wall
Termination
fig. 9
fig. 8
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Installation
Open
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Basement Installation
To install a DVC 500 in a basement you will
need additional DVC vent sections. These sections
are made with a 316 stainless steel liner and a 20
gauge galvaneeled outer shell. Each joint is sealed
with a gasket and is bolted together with 4 bolts.
In order to maintain the best seal, there are no
adjustable sections. There are straight, 45 degree,
and Tee fittings. Refer to Page 13 for all the
sections available.
Never use venting other than Harman
DVC venting inside the building. It is the
only vent certified for this application.
Refer to page 11 to calculate which section
will be needed for your installation.
Corner Installation
A corner installation requires a 45 degree
section in addition to the standard wall termina-
tion. In order to cut a hole in the wall that will
allow the stove to be placed an equal distance to
each wall, refer to Page 12.
Wall Termination
Tee with cover plate
Straight sections
Joint covers
Tee with cover plate
Installation
fig. 10
fig. 11
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12
Installation
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13
Installation
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14
Installation
Harman Direct Vent Coal Flue Pipe Venting System
1" Clearance to Combustibles
1-00-08326
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15
ESP CONTROL Feed Adjuster
Sets the maximum feed
rate, 1 to 5
Test
Runs all motors at
full speed for two
minutes to check
operation. After two
minutes the stovewill
go tominimum burn
and the blowers will
alternatefromhigh
to low every two
minutesto remind
you that you are still
in "Test Mode".
Distribution Blower
speedadjustmentrange.
1 Blink:Indicates controlboard selfdiagnostic
failure. This requires a Manual Reset*.
2 Blinks:Indicates thatthe negativepressure in the
firebox has been too low for at least 68 seconds.
This begins a threestage shut-down process de-
scribed in detailon Page 30.
The most common cause ofthe 2 blink status is
leaving the ash door open for more than 3 to 5
minutes without turning the Feed Adjuster to "Ash
Out". For other causes of a 2 blink status see Page
29.
This requires a ManualReset*.
3 Blinks:Indicates ESP (ExhaustSensingProbe)
failure. This requires a Manual Reset*.
4 Blinks: Can occur only in Room Temp Mode
and indicates Room Sensing Probe failed or not
installed. If a Room Sensing Probe is then in-
stalled the status light will automatically reset.
NOTE: Only after unit has warmed up.
5 Blinks: Indicates TCP (Temperature Control
Probe) failure. This requires a manual reset*.
* Manual Reset:Disconnect power cord for a few
seconds and reconnect. If error still occurs call
your Dealer.
Temp Dial
Allows you to adjust the roomtemperaturein
Room Temp Mode using the outerscale
marked in degreesFahrenheit. Italso allows
you to adjust the stovetemperaturewhile in
StoveTemp Modeusing the inner scale
marked from 1 to 7.
Mode Selector
Allows you to choosebetween Room Temp
Mode, StoveTemp Mode, orOFF. Also
allowsyou tovarytheDistribution
Blowerspeed by turning theknob to the
"high" or "low" side of each mode.
PowerLight
Indicatespower is"on" to
thecontrol.
Indicates power to the
Feed Motor.
Indicates power to
CombustionBlower
StatusLight
Will be lit in either Stove
or Room Temp Mode
when pointeris not within
"off"position bandexcept
afternormal shutdown.
Blinks toindicate errors
listedbelow.
Indicatespower to
DistributionBlower.
Ash Removal
position
See page 16
Operation:
Indicates power to the
DraftMotor.
Status LightErrorMessages:
fig. 12
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16
ESP Control
HopperLid
Latch
Ash Door Latch
Handle
GlassDoor
Latch Handle
Side Panel Latch
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Testing Operation:
Turn the Feed Adjuster to "Test" mode, fig. 13.
This willcause allmotors to run100% for2 minutes.
The lights on the control panel will be lit for each
motor.It willalso turn thepowerlight into atest light
which will indicate when the low draft switch is
making contact. To check this switch, open the top
door and the power light should go "off". Close the
door and it should come back "on" etc.
Starting Fire:
1. Fill hopper with dry coal. NOTE: Remove all
coal from hopper ledge, fig 17.
2. Fill burn-grate area from firebrick to front of
grate with about one inch of (DRY) coal.
3. Plug into 120 volt AC outlet and turn control to
"OFF".Turning to "OFF" and then backto the
desired mode resets the control.
4.Turn Feed Adjuster to the # 3 position, fig. 14.
5. Make a valley in the coal at the top of the burn
grate. Fill valley with fire starting material
(coal starter, crushed charcoal, wood pellets).
6.Turn Mode Selector to Room Temp or Stove
Temp as desired.
7. Turn the Temp Dial to the desired setting.
8. Light fire and make sure that all doors and the
hopper lid are closed. As the ESP senses the
correct temperature, the Feed Motor will start.
Shutdown Procedure:
To kill the fire or stop burning the stove, turn
the Mode Selector knob to the "OFF" position. This
will stop the feeder and the fire willburn out. When
the stove cools to about 95 degrees Fahrenheit, all
motors will stop. The unit can then be unplugged.
NOTE: It is always best to let the stove run out of
coal to shut it down rather than use the "OFF"
position.This is because there is nomoisture left
in the hopper from the coal. Always run the stove
outofcoaltoshutitdownwhentheheatingseason
is over or the stove will not be used for several
days.
Restarting Fire After Shutdown:
Allash and partially burnt coalmustbe cleaned
out from behind grates down under firebrick until
fresh coal is seen. Follow "Starting Fire" procedure
above.
2
5
1
Operation:
Test Position
#3 Feed Adjustment setting
fig. 13
fig. 14
fig. 15
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This setting will producemedium heat with the
Distribution Bloweron"low".
This setting will producea room temperatureof 70
degreeswith the Distribution Blower at "medium" speed.
This setting will producecontinuous maximum heat output
with the Distribution Blower at full speed.
Fig. 16
When to use "Stove Temp Mode"
In "Stove Temp Mode" the Stove Temp Dial
determines the temperature of the stove. Heat
output and fuel consumption will remain constant.
This makes it possible to tell how long a hopper
full of coal will last. The distribution blower speed
will vary according to the position of the mode
selector, between "low" and "high", fig. 16.
When to use "Room Temp Mode"
In "Room Temp Mode" heat output is con-
trolled automatically by the Room Sensing Probe.
When the Room Sensing Probe calls for heat, the
stove will increase output. When the Room Sens-
ing Probe is getting close to the set temperature,
the stove will begin to level off output and keep
the fire burning at just the right temperature to
maintain that setting.
High output is determined by the Feed Rate.
The maximum Feed Rate should be set for 11/2" to
2" of ash in front of fire.
In "Room Temp Mode" fuel consumption is
sacrificed for exact room temperature. Therefore,
as it gets colder, more coal will be burned auto-
matically.
The distribution blower speed will vary
according to the position of the mode selector.
Operation:
Keep coal off
ledges
Fig 17
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19
WARNING
OPENING THE VIEWING DOOR
OR ASH DOOR WITHOUT TURN-
INGTHE FEED ADJUSTER TO THE
"ASHOUT"POSITION MAYCAUSE
COMBUSTION GASES AND FLY
ASH TO ESCAPE.
Ash Out
Position
Fig.18
Removing Ash While Unit Is Burning:
CAUTION: Ashpan handle will be hot,
wear gloves.
Make note of the position of the Feed Ad-
juster knob so it can be returned to the same
position when you are finished removing the
ashes.
Turn Feed Adjuster knob to "Ash Out", this is
the ash removal setting, Fig 18. This setting turns
off the Combustion Blower and Feeder Motor but
does not turn off Draft Motor. Now the ash door
can be opened with minimal exhaust leakage. If
ash removal takes more than 4 minutes, the Distri-
bution Blower will start to cycle up and down to
indicate the Feed Adjuster knob was left in the
"Ash Out" position. This is not a problem if you
remember to return the Feed Adjuster to its previ-
ous setting when completed. If left in the "Ash
Out" position,the fire will burn out.
If the feed adjuster is
left in the "Ash Out"
position the fire will
burn out.
DAILYMAINTENANCE:
Ash Removal
With each hopper of coal that is burned,
approximately one ashpan full of ashes must be
removed, fig. 19. It may take from one to four
days for the ash pan to get full, depending on the
burn rate.
Failure to remove the ashes will result in a
blocked-up grate and the fire will not burn
properly. Remember, the ashpan will be hot, so
always wear protective gloves.
Ash Removal Setting:
The "Ash Out" position on Feed Adjuster
knob is for ash removal, fig. 18. This position
stops the Combustion Blower, the Feeder Motor,
and slows the Distribution Blower so the doors can
be opened. This is to limit exhaust fumes from
leaving the unit.
Don't forget to turn knob back to previous feed
number setting after completion of ash re-
moval.
fig. 19
Ashes should be placed in a metal container with a tight
fittinglid.Theclosedcontainerofashesshouldbeplaced on
anoncombustiblefloororontheground, wellawayfromall
combustiblematerials, pendingfinaldisposal.If ashesare
disposedofbyburialin soilorotherwiselocallydispersed,
they should be retained in the closed container until all
cindershavethoroughlycooled.
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WEEKLY MAINTENANCE:
FINESTRAYCOVER
Empty Fines Tray
The small Fines Tray in the side of the stoker
should be removed and emptied
To remove the Fines Tray, first open the door
on the left rear of the stove. Next, loosen the
thumb screws holding the Fines Tray Cover, fig#
20. Next, turn the Cover up 90 degrees and slide
out the Tray as shown. If the Tray has over-
flowed, use a vaccuum cleaner to reach into the
opening and remove the excess material.
Cleaning Glass While Unit Is Burning:
Caution: The glass and door frame will
still be hot, gloves must be worn.
Turn the temperature control to lowest setting
and allow the stove to cool down. Have all clean-
ing supplies ready and close by. Take note at
which # the Feed Adjuster is set, fig 14. Turn
Feed Adjuster knob to "Ash Out". (This is the ash
removal setting.) This setting turns "off" the
Combustion Blower and Feeder Motor but does
not turn "off" the Draft Motor. Now the viewing
door can be opened with minimal exhaust leakage.
Use a safety razor in handle and scrape the inside
of the glass with the blade almost flat to the
surface, Fig 21. The window can now be cleaned
with liquid cleaner and a non synthetic cloth.
CAUTION: HOT GLASS MAY CAUSE
CLEANER TO BOIL. If you take more than 4
minutes, the Distributor Blower will start to cycle
up and down to indicate the Feed Adjuster knob
was left in the "Ash Out" (ash removal setting).
This is not a problem if you remember to return
the Feed Adjuster to its previous setting when
completed.
FINESTRAY
Fig 20
Fig 21
Soot and Fly Ash
The products of combustion will contain
small particles of fly ash. The fly ash will collect
in the exhaust venting system and restrict the flow
of the flue gases. Incomplete combustion, such as
occurs during startup, shutdown, or incorrect
operation of the room heater, will lead to some
soot formation which will collect in the exhaust
venting system. The exhaust venting system
should be inspected at least once every year to
determine if cleaning is necessary.
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