Harman DVC-500 Installation instructions

R1
SAFETY NOTICE
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.
FOR USE IN THE U.S. AND CANADA. SUITABLE FOR INSTALLATION IN MOBILE HOMES
IF THIS HARMAN STOVE IS NOT PROPERLY INSTALLED, A HOUSE FIRE MAY RESULT. FOR YOUR SAFETY,
FOLLOW INSTALLATION DIRECTIONS.
CONTACT LOCAL BUILDING OR FIRE OFFICIALS ABOUT RESTRICTIONS AND INSTALLATION INSPECTION
REQUIREMENTS IN YOUR AREA.
CONTACT YOUR LOCAL AUTHORITY (SUCH AS MUNICIPAL BUILDING DEPARTMENT, FIRE DEPARTMENT, FIRE
PREVENTION BUREAU, ETC.) TO DETERMINE THE NEED FOR A PERMIT.
CETTE GUIDE D'UTILISATION EST DISPONIBLE EN FRANCAIS. CHEZ VOTRE CONCESSIONNAIRE DE HARMAN
HOME HEATING.
SAVE THESE INSTRUCTIONS.
The Harman DVC-500 Coal Stoker
Installation & Operating Manual
R13

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This appliance is also approved
for installation into a shop.

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INDEX
Warnings 4
Introduction 5
Assembly 6
Installation 7
DVC500 Microprocessor Control 15
Operation 17
Maintenance 19
Fuel 23
Wiring Diagram 26
Control and Safety Sensors 27
Parts 28
Specications     29
Troubleshooting 30
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 Home Heating
352 Mountain House Road
Halifax, PA 17032
harmanstoves.com

4
Always empty the 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 that 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 coal is watered down to elimi-
nate dust when loading and unloading. Wet rice
coaldoesnotowaswellasdampordrycoal.
We do not recommend burning wet coal; how-
ever, we realize if it's the only coal you have,
it is better to burn it than be cold. If you must
burn wet coal, the feed rate must be increased
inordertogetthesamesizere.Asthewet
coal in the hopper dries out, the feed rate must
be decreased. Loading wet coal once or twice a
year will not 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 rust and corrosion and it is totally
the operator’s fault. Usually after the coal dries
for three or four days, depending on conditions,
itwillowverywellandfeedproperly.Feed
rate will be the same as with 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 spe-
cially 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 you install
a CO detector. This is true for oil, gas, or wood
burning products as well.
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. Increase ventilation by opening windows
or doors.
2. Make sure the stove doors and hopper lid
are closed and latched.
3. Check stove for electrical power and normal
operation.
4. Check for false alarm.
Always Empty Hopper
Never use gasoline, gasoline-type lantern fuel, kerosene, charcoal lighter uid, or similar liq-
uids to start or “freshen up” a re in this heater. Keep all such liquids well away from the heater
while it is in use.

5
INTRODUCTION
This remarkable design by Harman features the
Verti-owDirectVentStokerSystem.
 This unique, high efciency unit uses only
outside air for combustion.
Micro-processor controls provide for an au-
tomatic 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.
ARoom Sensor connected to the micro-proces-
sor 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 ue pipe is:
1. Less than 8 feet from 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 ue
pipe terminates at least 12 inches away from the
side of the building in order to minimize any y
ash build-up.
Mobile home installations 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.

6
Assembly
1. Install the hopper latch as shown at left.
2.Install3rebricksonthecastironanglebehind
the grate as shown.
3. Cement in grates as shown below. This may
already be done at the factory.
4. Install the front door and latch it closed.
3 Bricks
Grate
Inserts
g. 3

7
4 GLASS RE-
TAINER 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 seal-
ing.
* Apply the rope exactly along the edge of the ex-
ternal face of the glass, not overhanging or pressed
too far in from the edge.
* Make sharp 90o turns at the corners.
* Tightly join the ends of the rope at the upper left
or right corner.
Glass Retainer Clips
* Use the glass retainer clips and screws supplied
in the door kit.
* Use a 1/8" Allen wrench to tighten the glass clips
to cast door with 10-24 x 3/8" screws supplied.
Paw Bolt
* The paw bolt should be 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atspotof
the paw bolt).
* The set screw on the brass elbow must be aligned
tocontacttheatspotonthepawbolt,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 it does 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

8
Tips On Installation
Before the positioning of the unit can be de-
cided 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yashaffecttheexteriorofthe
structure or surrounding structures?
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 electrical outlet?
Floor Protector
This stove should be placed on a non-combus-
tibleoorprotectorextending16inchestothefront,
8 inches to the sides, and 1 inch to the rear.
Straight Through Wall
1. When positioning of the unit has been decided,
use measurements on Page 10 for cutting the hole
throughthewall.Don’tforgettogurethethick-
nessoftheoorprotectorused.
2. Cut at least a 9" x 9" hole through the wall.
3. Remove the side doors / rear cover assembly
(6 black screws, 5/16" socket or straight screw-
driver)
4. Place the unit in front of the hole approximately
1/2" closer to the wall than the length of the wall
termination. (From outside of wall to back of unit
where termination bolts up)
5. Take the wall termination outside and slide it into
the hole until it mates to the rear of the unit. Go
inside and install the bolts and tighten, making
surethegasketisinplaceandtheuepipesec-
tion is level.
6. Reposition the unit inward until the stainless steel
intake section comes against the outside wall
surface. NOTE: If the wall is over 8" thick you
will need a longer wall termination. The standard
termination will provide 3" of wall clearance
behind the stove, with a 8" wall. Therefore, with
a 5" thick wall, it will provide 6" of clearance
behind the stove.
INSTALLATION
DO NOT INSTALL A FLUE DAMPER IN THE
EXHAUST VENTING SYSTEM OF THIS UNIT
DO NOT CONNECT THIS UNIT TO A CHIM-
NEY FLUE SERVING ANOTHER APPLIANCE.
INSTALL VENT AT CLEARANCES SPEC-
IFIED BY THE MANUFACTURER
g. 6
g. 7

9
7.Checktheexterioroftheterminationforbestt
and screw to exterior and caulk with high grade
exterior caulking.
8.Completeanyotherexterioruepipingneces-
sary, using 4" pellet venting.
9. Back inside, place the 2 halves of the interior
walltrimplateoveruepipe.Usingtheblack
pop rivets, fasten together, then slide it against
the wall and fasten it to the wall.
10. Replace the side door / rear cover assembly
with 6 black screws.
11. Complete the unit assembly and test.
Wall Trim Plate
Wall Trim Plate
Gasket
Wall
Termiation
Installation
Open
CAUTION:
THE STRUCTURAL INTEGRITY OF THE
MOBILE HOME FLOOR, WALL, AND
CEILING/ROOF MUST BE MAINTAINED.
WARNING:
DO NOT INSTALL IN MOBILE
HOME SLEEPING ROOM
Standard Wall
Termination
g. 9
g. 8

10
Installation

11
Basement Installation
To install a DVC 500 in a basement you will
need additional DVC vent sections. These sections
are made with a 316-grade 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ttings.RefertoPage14forallofthesec-
tions available.
Never use venting other than Harman DVC
venting inside the building. It is the only vent
certied for this appliance.
Refer to page 12 & 14 to calculate which sec-
tions will be needed for your installation.
Corner Installation
Acorner installation requires a 45 degree section
in addition to the standard wall termination.
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 13.
Wall Termination
Tee with cover plate
Straight sections
Joint covers
Tee with cover plate
Installation
g. 10
g. 11
D

12
Installation

13
Installation

14
Installation
Harman Direct Vent Coal Flue Pipe Venting System
1" Clearance to Combustibles
Exterior Termination for wall
thickness up to 8 inches
1-10-08310
Exterior Termination for wall
thickness up to 16 inches
Exterior Termination for wall
thickness up to 12 inches
3-44-06256 1-10-08313
1-10-08314
1-10-08321
1-10-08317
1-10-08315
1-10-08316
1-10-08320
1-10-08319
1-10-083181-10-08322
1-10-08323
1-10-08324
1-10-08326
1-10-083111-10-08312
Gasket
Spacer 3/16"
1-10-08325
12" 45° "T"
6"
9" 13"
8"
12"
11"
10"
16"
27"
20"
37"
47"
9-5/8"
8-3/4"
Joint Cover
Maximum Horizontal Run is 48 Inches - (4 ft.)

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 stove
will go to minimum
burn and the blowers
will alternate from
high to low every two
minutes to remind
you that you are still
in "Test Mode".
Distribution Blower
speed adjustment range.
2 Blinks:Indicatesthatthenegativepressureinthere-
box has been too low for at least 68 seconds. This begins
a three stage shut-down process described in detail on
Page 30.
The most common cause of the 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 30.
This requires a Manual Reset*.
3 Blinks: Indicates that the ESP (Exhaust Sensing Probe)
has gone out of range a specied number of times. If
the stove seems to be performing normally, perform a
Manual Reset*.
4 Blinks: Can occur only in Room Temp Mode and indi-
cates Room Sensing Probe has failed or is not installed.
If a Room Sensing Probe is then installed, the status light
will automatically reset.
5 Blinks: Indicates a lack of communication between the
circuit board and the TCP (Temperature Control Probe).
This requires a manual reset*.
* Manual Reset:Disconnectpowercordfora fewseconds
and reconnect. If error still occurs call your Dealer.
Temp Dial
Allows you to adjust the room temperature
in Room Temp Mode using the outer scale
marked in degrees Fahrenheit. It also allows
you to adjust the stove temperature while
in Stove Temp Mode using the inner scale
marked from 1 to 7.
Mode Selector
Allows you to choose between Room Temp
Mode, Stove Temp Mode, or OFF. Also
allows you to vary the Distribution Blower
speed by turning the knob to the "high" or
"low" side of each mode.
Power Light
Indicates power is "on" to
the control.
Indicates power to
Distribution Blower
Indicates power to the
Feed Motor.
Indicates power to
Combustion Blower
Status Light
Will be lit in either Stove
or Room Temp Mode when
pointer is not within "off"
position band except after
normal shut down. Blinks
to indicate errors listed
below.
Ash Removal position
See page 19
Operation
Indicates power to the
Draft Motor.
Status Light Error Messages:
g. 12

16
ESP Control
Hopper Lid Latch
Ash Door
Latch Handle
Glass Door
Latch Handle
Side Panel Latch

17
Testing Operation:
Turn the FeedAdjuster to "Test" mode, (g.
13.) This will cause all motors to run 100% for 2
minutes. The lights on the control panel will be lit
for each motor. If you leave it on "test" the blowers
will cycle as an audible reminder.
Starting Fire:
1. Fill the hopper with dry coal. NOTE: Remove
all coal from hopper ledge. (g 17)
2.Fillburn-grateareafromrebrick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 back to the
desired mode resets the control.
4.TurnFeedAdjustertothe#3position,g.14.
5. Make a valley in the coal at the top of the burn
grate.Fillvalleywithre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there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reorstopburningthestove,turn
the Mode Selector knob to the "OFF" position. This
willstopthefeederandtherewillburn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 no moisture
left in the hopper from the coal. Always run the
stove out of coal to shut it down when the heating
season is over or if the stove will not be used for
several days.
Restarting Fire After Shutdown:
Allash andpartiallyburned coalmustbe cleaned
outfrombehindgratesdownunderrebrickuntil
fresh coal is seen. Follow "Starting Fire" procedure
above.
Operation
Test Position
#3 Feed Adjustment setting
g. 13
g. 14
g. 15
2
1
5

18
This setting will produce medium heat with the Dis-
tribution Blower on "low".
This setting will produce a room temperature of 70 de-
grees with the Distribution Blower at "medium" speed.
This setting will produce continuous maximum heat output
with the Distribution Blower at full speed.
Fig. 16
When to use "Stove Temp Mode"
In "Stove Temp Mode" the Temp Dial deter-
mines 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.Thedistributionblowerspeedwillvaryaccording
to the position of the mode selector, between "low"
and"high",g.16.
When to use "Room Temp Mode"
In "Room Temp Mode" heat output is controlled
automatically by use of 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
reburningatjusttherighttemperaturetomaintain
that setting. If the temperature in the room exceeds
the set point, the stove will idle on a low burn until
more heat is needed.
High output is determined by the Feed Rate.
The maximum Feed Rate should be set for 1 1/2" to
2"ofashinfrontofthere.
In "Room Temp Mode" fuel consumption is
sacriced for exact room temperature. Therefore,
as it gets colder, more coal will be burned automati-
cally.
The distribution blower speed will vary accord-
ing to the position of the mode selector.
Operation
Keep coal off
ledges
Fig 17

19
WARNING
OPENING THE VIEWING DOOR OR
ASH DOOR WITHOUT TURNING THE
FEED ADJUSTER TO THE "ASH OUT"
POSITION MAY CAUSE 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 Adjuster
knob so it can be returned to the same position when
youarenishedremovingtheashes.
Turn the 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 Distribution
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 previous setting when
completed. If left in the "Ash Out" position, the
re will burn out.
If the feed adjuster is left in
the "Ash Out" position the
re will burn out.
DAILY MAINTENANCE
Ash Removal
With each hopper of coal that is burned, approxi-
mately one ashpan full of ashes must be removed.
(g.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 grate and the re will not burn properly.
Remember, the ashpan will be hot, so always wear
protective gloves.
Ash Removal Setting:
The"AshOut"positionon thefeedadjusterknob
isforashremoval(g.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 removal.
Ashes should be placed in a metal container with a tight t-
ting lid. The closed container of ashes should be placed on a
noncombustible oor or on the ground, well away from all
combustible materials, pending nal disposal. If 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.
g. 19

20
WEEKLY MAINTENANCE
FINES TRAY COVER
Empty Fines Tray
The small Fines Tray in the side of the stoker
should be removed and emptied
ToremovetheFinesTray,rstopenthedoor
on the left rear of the stove. Next, loosen the thumb
screwsholdingtheFinesTrayCover,g#20.Next,
turn the Cover up 90 degrees and slide out the Tray
asshown.IftheTrayhasover-owed,useavacuum
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 cleaning
supplies ready and close by. Take note at which #
theFeedAdjusterisset,g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
at 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 Distribution 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.
FINES TRAY
Fig 20
Fig 21
Soot and Fly Ash
The products of combustion will contain small
particlesofyash.Theyashwillcollectinthe
exhaustventingsystemandrestricttheowofthe
ue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.