Installation & Operating manual
The harman dvC-500 Coal Stoker
r18
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.
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 lOCAlAuThOrITY (SuCh AS muNICIPAl buIldINg dEPArTmENT, FIrE dEPArTmENT, FIrE
PrEvENTION burEAu, ETC.) TO dETErmINE ThE NEEd FOr A PErmIT.
dO NOT uSE mAkEShIFT COmPONENTS Or OThEr COmPrOmISES durINg INSTAllATION Or SErvICE.
SAvE ThESE INSTruCTIONS.
#3-90-08311
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Index
Warnings
4
Introduction
Assembly
5
6
Installation
Direct Vent Pipe
7
14
15
17
19
23
25
26
27
30
31
DVC500 Microprocessor Control
Operation
Maintenance
Fuel
Wiring Diagram
Control and Safety Sensors
Parts
Specifications
Troubleshooting
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
3
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warnings
Carbon monoxide (CO) Awareness
Carbonmonoxide,referredtoasCO,isacolorless,
CO detectors are very sensitive and may sound an
odorless gas that is produced during combustion alarm for fumes other than CO or CO from sources
of coal and other fuels. CO fumes are toxic and other than the stove such as car or lawn mower
can be fatal.
exhaust.
The DVC 500 is a closed loop system specially If the alarm sounds
designed to prevent the escape of CO and other 1. Increase ventilation by opening windows or doors.
combustion products from the stove.
Even though this stove is designed to be as safe
2. Make sure the stove doors and hopper lid are
closed and latched.
as possible, it is important that you install a CO 3. Check stove for electrical power and normal
detector. This is true for oil, gas, or wood burning
operation.
products as well.
4. Check for false alarm.
(Never sleep in the same room with any coal burning stove.)
wet Coal
Always Empty hopper
Freshly delivered coal is watered down to
eliminatedustwhenloadingandunloading. Wet
rice coal does not flow as well as damp or dry
coal. We do not recommend burning wet coal;
however, werealizeifit'stheonlycoalyouhave,
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 fire. 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,itwillflowverywellandfeedproperly.
Feed rate will be the same as with dry coal.
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
willvoidthewarrantyonthoseparts. Always
checktoseethatmovingpartsarefreebefore
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.
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.
4
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Introduction
This remarkable design by Harman features the
Verti-flow Direct Vent Stoker System.
This unique, high efficiency unit uses only outside
air for combustion.
Micro-processorcontrolsprovideforanautomatic
widerangeofheatoutputfrom7,000to75,000BTU.
With a big 93 pound hopper capacity, this unit can
burn on high approximately 16 hours or extend for
over 96 hours on low.
ARoomSensorconnectedtothemicro-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 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 buildings 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 build-up.
mobile home installations should be done in
accordancewiththemanufacturedhomeand
Safety Standard (hud), CFr 3280, Part 24.
dAmP COAl ShOuld NOT bE lEFT
IN ThE hOPPEr OF A COld STOvE.
5
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Assembly
1. Install the hopper latch as shown at left.
2. Install 3 firebricks on the cast iron angle be-
hind the grate as shown.
3. Cement in grates as shown below. This may
already be done at the factory.
3 Bricks
Grate
Inserts
fig. 3
6
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viewing glass
The glass in your Harman stove is a special ceramic glass.
• Do not abuse the glass by striking or slamming the door.
• Never burn the appliance if the door glass is cracked or broken.
• Replace only with Harman supplied glass.
Soot and/or fly-ash may accumulate on the viewing glass, and will ocassionally need to be cleaned.
Clean the glass with a soft cloth and mild glass cleaner. Do not spray cleaner on hot glass, and avoid
the use of abrasive cleaners.
Glass replacement
Carefully remove all remaining glass and gasket materials prior to replacing the glass.
Lay the door face down on a flat surface. Remove the glass retainers and screws. Apply the gasket
material to the face of the new glass. Lay the glass into the door, making sure that the glass is contained
within the channels and raised areas of the door itself. Lay the glass retainers into position and install
the screws. Tighten each screw evenly to avoid making any stress points.
HINGE PINS
DOOR
BRASS HANDLE
HANDLE BOLT
PAW BOLT
GLASS
SET SCREW
WOOD HANDLE
GLASS GASKET
4 GLASS
RETAINER
CLIPS
4 GLASS
RETAINER
BOLTS
7
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Installation
Tips On Installation
Before the positioning of the 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 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?
Follow the guidelines to the left regarding
clearances to combustible materials.
Floor Protector
fig. 6
This stove should be placed on a non-combustible floor
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 figure the thickness of the
floor 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 screwdriver)
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)
fig. 7
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 flue pipe section 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.
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
7. Check the exterior of the termination for best fit and
screw to exterior and caulk with high grade exterior
caulking.
8
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Installation
8. Complete any other exterior flue piping necessary,
wArNINg:
dO NOT INSTAll IN mObIlE hOmE
SlEEPINg rOOm
using 4" pellet venting.
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 it against the wall and fasten
it to the wall.
CAuTION:
10. Replace the side door / rear cover assembly with 6
black screws.
ThE STruCTurAl INTEgrITY OF ThE
mObIlE hOmE FlOOr, wAll, ANd
CEIlINg/rOOF muST bE mAINTAINEd.
11. Complete the unit assembly and test.
Standard Wall Termination
Wall Trim Plate
Wall
Termiation
Gasket
Wall Trim Plate
Open
fig. 8
fig. 9
9
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Installation
10
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Installation
basement Installation
Wall Termination
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 fittings. Refer to Page 14 for all
of the sections available.
Tee with cover plate
Straight sections
Joint covers
Never use venting other than harman dvC
venting inside the building. It is the only
vent certified for this appliance.
Refer to page 12 & 14 to calculate which sections
will be needed for your installation.
Corner Installation
A corner 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.
fig. 10
Tee with cover plate
D
fig. 11
11
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Installation
12
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Installation
13
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vent Pipe
harman direct vent Coal Flue Pipe venting System
1" Clearance to Combustibles
Exterior Termination for wall
thickness up to 8 inches
9-5/8"
Gasket
8-3/4"
45°
"T"
12"
1-10-08314
1-10-08313
3-44-06256
1-10-08310
13"
9"
6"
1-10-08315
1-10-08317
1-10-08321
8"
12"
1-10-08316
47"
1-10-08320
37"
11"
1-10-08326
27"
1-10-08319
10"
1-10-08323
1-10-08324
1-10-08322
1-10-08318
Exterior Termination for wall
thickness up to 12 inches
Exterior Termination for wall
thickness up to 16 inches
Spacer 3/16"
20"
16"
1-10-08325
1-10-08312
1-10-08311
Maximum Horizontal Run is 48 Inches - (4 ft.)
14
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ESP Control
Feed Adjuster
Sets the maximum feed
rate, 1 to 5
Power Light
Indicates power is "on"
to the control.
Test
Runs all motors at full
speed for two minutes
to check operation.
After two minutes the
feeder stops and the
distribution blower
alternates from high to
low every four seconds
to remind you that you
are still in "Test Mode".
Status Light
Will be lit in either Stove
or Room Temp Mode
when pointer is not
within"off"positionband
exceptafternormalshut
down. Blinks to indicate
errors listed below.
Indicates power to
Distribution Blower
Ash Removal
position
See page 19
Indicates power to
Combustion Blower
Distribution Blower
speed adjustment
range.
Indicates power to the
Feed Motor.
Indicates power to the
Draft Motor.
fig. 12
Mode Selector
Temp Dial
DDM Port
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.
Allows you to adjust the room temperature Allows service technician to
in Room Temp Mode using the outer scale attach diagnostic meter when
marked in degrees Fahrenheit. It also allows troubleshootingorverifyingproper
you to adjust the stove temperature while operation.
in Stove Temp Mode using the inner scale
marked from 1 to 7.
Status light Error messages
2Blinks:Indicatesthatthereisinsufficientnegativepressure
in the firebox. This begins a shut-down process described in
more detail on Page 31.
4 Blinks: Can occur only in Room Temp Mode and indicates
Room Sensing Probe has failed or is not installed. If a
Room Sensing Probe is then installed, the status light will
automatically reset.
The most common cause of the 2 blink status is leaving the
ashdooropenwithoutturningtheFeedAdjusterto"AshOut".
For other causes of a 2 blink status see Page 32.
5 Blinks: Indicates a lack of communication between the
circuit board and theTCP(Temperature Control Probe).This
requires a manual reset*.
This requires a Manual Reset*.
* Manual Reset: Disconnect power cord for a few seconds
and reconnect. If error still occurs call your Dealer.
3 Blinks: Indicates that the ESP(Exhaust Sensing Probe) has
gone out of range a specified number of times. If the stove
seems to be performing normally, perform a Manual Reset*.
15
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Hopper Lid Latch
ESP Control
Glass Door
Latch Handle
Side Panel Latch
Ash Door
Latch Handle
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Operation
Testing Operation:
Turn the Feed Adjuster to "Test" mode, (fig. 13.)
Thiswillcauseallmotorstorun100%for2minutes.
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.
fig. 13
Starting Fire:
1. Fill the hopper with dry coal. NOTE: remove
all coal from hopper ledge. (fig 17)
Test Position
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 back to 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.
fig. 14
#3FeedAdjustmentsetting
7. Turn the Temp Dial to the desired setting.
8. Light the 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.
5
Shutdown Procedure:
1
2
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 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
ofcoaltoshutitdownratherthanusethe"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:
All ash and partially burned coal must be cleaned
out from behind grates down under firebrick until
freshcoalisseen. Follow"StartingFire"procedure
above.
Fig. 15
17
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Operation
Fig. 16
Keep coal off
ledges
Fig 17
when to use "Stove Temp mode"
In "Stove Temp Mode" the control will regulate
the fire to match a constant exhaust temperature,
based on the #1 thru 7 settings on the inner portion
of the temp dial. 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 can be varied according
to the position of the mode selector, between "low"
and "high", fig. 16.
This setting will produce medium heat with the
Distribution Blower on "low".
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
stovewillincreaseoutput.WhentheRoomSensing
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. If the temperature in the room exceeds
the set point, the stove will idle on a low burn until
more heat is needed.
This setting will produce a room temperature of 70 degrees
with the Distribution Blower at "medium" speed.
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 fire.
In "Room Temp Mode" fuel consumption is
sacrificedforexactroomtemperature.Therefore,as
itgetscolder,morecoalwillbeburnedautomatically.
The distribution blower speed can be varied
according to the position of the mode selector.
This setting will produce continuous maximum heat output
with the Distribution Blower at full speed.
18
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daily maintenance
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
blockedgrateandthefirewillnotburnproperly.
Remember, the ashpan will be hot, so always wear
protective gloves.
Fig. 18
Ash Out Position
Ash removal Setting:
The "Ash Out" position on the feed adjuster knob
is for ash removal (fig. 18). This position stops the
Combustion Blower, the Feeder Motor, and slows
theDistributionBlowersothedoorscanbeopened.
This is to limit exhaust fumes from leaving the unit.
don't forget to turn knob back to previous feed
numbersettingaftercompletionofashremoval.
If the feed adjuster is left in the "Ash Out"
position the fire will burn out.
removing Ash while unit Is burning:
wArNINg
OPENINg ThE vIEwINg dOOr Or ASh
dOOr wIThOuT TurNINg ThE FEEd Ad-
juSTErTOThE"AShOuT"POSITION mAY
CAuSE COmbuSTION gASES ANd FlY
ASh TO ESCAPE.
CAuTION: ASh PAN 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 finished 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
removaltakesmorethan4minutes,theDistribution
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
returntheFeedAdjustertoitsprevioussettingwhen
completed. If left in the "Ash Out" position, the
fire will burn 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
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.
fig. 19
19
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weekly maintenance
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 FinesTray Cover, fig# 20. Next,
turn the cover 90 degrees and slide out the Tray as
shown. If the Tray has over- flowed, 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 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 FeedAdjuster is set, fig 14. Turn FeedAdjuster
knobto"AshOut".(Thisistheashremovalsetting.)
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. If further
cleaning is necessary, the window can now be
cleaned with liquid cleaner and a non synthetic
cloth. CAuTION: do not spray cleaner directly
on hot glass. If the cleaning takes more than 4
minutes,theDistributionBlowerwillstarttocycleup
and down to indicate the Feed Adjuster knob was
left in the "Ash Out" (ash removal setting). This is
not a problem, just remember to return the Feed
Adjuster to its previous setting when completed.
FINES TRAY COVER
FINES TRAY
Fig 20
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
fluegases. Incompletecombustion,suchasoccurs
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.
Fig 21
20
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maintenance Every 3 months:
A3-month cleaning will give you a base line as
Never Block Air Outlets on top of stove, above door.
to how often your dvC500 needs to be cleaned.
Cleaningintervalswilldifferineachinstallation
because of the ash and moisture content of the
coal and the amount of coal burned.
NOTE: unitshouldbeoff&cooleddownenough
to perform these maintenance items:
1. RemoveAsh Pan then remove ash shield behind
Ash Pan, fig.22. Lift the shield up and forward
in order to remove it from the stove. This will
expose the Blower Cover and Latch, fig.23.
Tabs
Ash Shield
2. Rotate the Latch counterclockwise to the vertical
position as shown in fig. 24.
3. Remove the Blower Cover by tilting the left side
slightly forward. Next, slide the Cover left and
out of the slot that holds the right side in place.
The Cover can now be removed to expose the
Draft Blower Wheel and Exhaust Outlet, fig. 25.
Fig 22
4. The blower wheel, blower housing, and exhaust
outlet can now be cleaned with a brush and
vacuum cleaner. NOTE: The ESP probe is
located at the rear of the exhaust outlet shown
in fig 28. be careful not to damage the probe
when cleaning.
5. Open the Fines Cover on the bottom of the
feeder under the grates and clean, see fig.26.
ATTENTION:mAkESurECOvErISClOSEd
ANd TIghTENEd bEFOrE rElIghTINg
uNIT. uNIT wIll NOT OPErATE PrOPErlY
wITh ClEAN OuT COvEr lEAkAgE.
Latch
Blower Cover
Fig 23
6. Check the flue pipe for excess buildup of fly ash
and clean if necessary.
7. Clean the glass thoroughly, use a safety razor
to scrape the sulfur buildup from the surface
of glass. Then clean with standard window
cleaning fluid, fig.21.
8. Inspect all gaskets for damage and turn the
control to "test", for motor test before relighting
a fire.
Fig 24
Rotate Latch
21
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End of heating Season maintenance:
The End Of Season Shut down list.
1. Allow the stove to run out of coal in order to
extinguish the fire. This saves having to remove
the coal from the hopper manually and most
importantly, drives the moisture out of the stove
that may be present in the coal.
2. Perform all the steps of the 3 month maintenance
list.
3. Clean the glass as shown in fig.21.
4. Empty the fines tray and inspect the area for
rust and corrosion
5. Make sure the hopper is empty. Wet or damp
coal in the hopper will promote rust.
6. Remove the FSS Tube from the rear of the
firebox (fig.27) and clean the brass fitting going
into the firebox with a pipe cleaner. Reconnect
tube.
Exhaust Outlet
Blower Wheel
Fig. 25
Blower Cover
7. The FSS line filter can be changed annually
to insure proper flow, however, it may only be
necessary if the filter is discolored.
8. Remember to cover the flue pipe over the
summer to block out rodents and birds. Place a
note inside the unit to remind yourself or others
not to forget to uncover the flue pipe before
lighting a fire.
Prevent rust
Summertime moisture and high humidity are your
stove's enemy. Aclean stove will have less fly ash
and fines to absorb moisture and cause rust and
corrosion.Allowingwetcoaltoremaininthehopper
of a cold stove will promote the formation of rust
and corrosion. Some owners choose to spray a
light coating of oil on all internal workings and the
firebox as a rust inhibitor.
Fig. 26
GRATE CLEAN-OUT COVER
Annual Service
FSS Tube
It is recommended that your DVC500 is serviced
annually by your trained Harman dealer. The best
time for this service is during a non-use period.You
may choose to combine this service with the end of
season maintenance.
FSS Line
Filter
Fig. 27
22
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motors
Feed Motor
3-20-60906
Combustion
Blower
1-10-08332
Distribution
Blower
3-21-22647
Draft Motor
3-21-08639
ESP Probe
3-20-00744
Fig. 28
Fuel
If you buy in bulk, try to have the coal delivered
before temperatures reach the freezing level. This is
because salt may be added to the coal to keep it from
freezing on the truck. This will not affect burning
but will promote rust and corrosion.
Some Coal Companies wash their coal better than
others to remove fines and dirt. This makes air flow
through the coal better and produces less fly ash.
Whether bagged or in bulk, the coal must be dry
before loading it into the stove. At a minimum,
open bags a few days in advance to allow drying.
Buy your bulk coal mid summer to allow plenty of
time for drying.
The DVC500 is designed to burn Anthracite Rice
Coal, which is approximately 3/8" long and wide
by 3/16 thick. Anthracite coal is considered either
White Ash or Red Ash.
White Ash Coal will have 13 to 14,000 btu's per
lb. White ash coal usually has less ash and will burn
longer.
Red Ash coal is usually about 12,000 btu's per lb.
and is higher in volatiles. Higher volatiles makes the
coaleasiertolightandproducesamoreyellowflame.
At a very low burn rate the TCP (Temperature
Control Probe) may be activated with RedAsh coal,
especially if the hopper lid is open or leaking. The
TCP senses the temperature of the feeder and feeds
coal if the temperature rises too much.This prevents
the fire from reaching the coal in the hopper. Red
Ash Coal may form klinkers (fused together ash)
which may cause grate blockage in severe cases.
AnthraciteCoalcanbepurchasedinbagsorinbulk.
Good, clean, White Ash Coal is the fuel of choice,
"however" Red Ash Coal will also burn well. As
long as it is Anthracite.
23
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grate System Assembly Or replacement
The DVC500 grate system is composed of four
grate insert
pieces: the grate holder, (2)-63 hole grate inserts,
and grate angle. The grate angle is bolted to the
grate holder with (2) 3/8 x 1 1/4 bolts. Before
installing the grate holder, 3/8" round gasket must
be checked in the groove on the bottom side of the
grate holder, as shown in Fig 31. Check to be sure
the gasket has not been damaged.
Fig. 29
grate angle
The grate holder must be installed through the top
door opening after the feeder has been installed.
Locate the flange at the rear of the grate holder
into the slot on the feeder as shown below. Bolt the
front end down with the 1/4 x 20 allen bolt and nut
provided. The rear end will be locked in place by
the flange. Before tightening the bolt, be sure the
grateholderisbackasfaraspossibleandcentered
side to side on the feeder opening.
grate holder
Fig.30
Install grate inserts as shown at left. Seal joints
with high temp furnace cement caulking as shown
in Fig 30. Insert first grate and squeeze into
caulking. Caulk other grate insert, Fig 29, on edge
that joins grate already in place. Insert caulked
grate in remaining space and squeeze together to
make middle joint as tight as possible. Clean any
caulking that has pushed out from the joints on top
of grates. Let caulking cure before firing.
bottom groove
Fig.31
Install firebricks
as shown
Fig.32
gasket
Fig.33
IMPORTANT
Be sure the grate holder is centered and back
as far as possible.
24
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maintenance Schedule
It is recommended that End of Season Cleaning and the Annual Service are coordinated to happen at
the same time for best results.
wiring diagram
ESP PROBE
(RED TWISTED)
HARMAN DIRECT VENT COAL STOKER( DVC 500 C ) WIRING DIAGRAM
ESP
CONTROL
TCP PROBE
BOARD
TO ROOM SENSOR
(RED TWISTED)
ROOM
SENSOR
YELLOW TAPE ON ENDS
SPLICE
1
BLACK
3
4
5
6
8
WHITE
7
POWER CORD
9
10
11
GREEN
FEEDER MOTOR
BLUE&BLACK
YELLOW&WHITE
FSS 1-10-163
FIREBOX STATIC
SENSOR
TCP
X
DISTRIBUTION BLOWER
BLACK
BLACK
MALE / FEMALE
WIRE CONNECTORS
18-3 RUBBER CORD
DRAFT MOTOR
18-3 RUBBER CORD
COMBUSTION BLOWER
300 WATTS -- 2.5 A. --
120 VOLTS A.C. 60 HZ.
PART NO. 3-89-08193 Rev A
25
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Control and Safety Sensors
Control and Safety Sensors
ESP
TheESP(ExhaustSensingProbe)isatemperature
sensing probe located in the exhaust outlet. The
ESP works with the Control to perform all burn
rate functions as well as high and low limit control.
room Sensor
The Room Sensor is a small temperature sensor
placedwhereyouwouldnormallyputathermostat.
The Room Sensor is extended to the stove with
normal thermostat wire. The Room Sensor works
with the ESP and the Control to provide the right
size fire.
ESP
FSS
FSS 1-10-163
FIREBOX STATIC
SENSOR
The FSS (Firebox Static Sensor) is an electronic
pressure sensor reading the firebox pressure. The
FSS works with the ESP Control to adjust the draft
blowerspeedtocompensateforwindandchanging
house pressures.
TCP
TCP
X
The TCP (Temperature Control Probe) is located
on the left side of the feeder. The TCP works with
the Control to reduce the feeder temperature if the
temperature begins to rise.
This sensor is located in the control box
behind the control board. It is preset and is
non-adjustable.
TCP
26
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Service Parts
dvC-500
beginning manufacturing date: N/A
Ending manufacturing date: Active
direct vent Coal Stoker
Active--1-90-08600-1 (black w/door)
Ending manufacturing date june 2011--1-70-08600-1 (black)
1
2
3
4
5
6
7
8
9
14
10
13
11
12
Part number list on following page.
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Service Parts
dvC-500
beginning manufacturing date: N/A
Ending manufacturing date: Active
IMPORTANT: THIS IS DATED INFORMATION. When requesting service or replacement
parts for your appliance please provide model number and serial number. All parts listed
in this manual may be ordered from an authorized dealer.
Stocked
at depot
ITEm
dESCrIPTION
COmmENTS
PArT NumbEr
1
2
Hopper Lid Swell Latch
Hopper Lid Assembly
3-31-191410
1-10-08212A
1-00-06308
Y
Lid Catch W/Hardware
Door Kit Assembly
Classic Black
1-00-08600-1
Y
3
Door Kit Assembly (Gold)
Glass, Rect 12-7/16” X 17-5/8”
Grate Holder Assembly
Grate Inserts
No longer available 1-00-08600-4
3-40-08214
Y
Y
4
5
6
7
1-10-01000
Qty. 2 Req.
4-00-08307D
1-00-00122
1-10-08205A
1-00-38223
Wooden Handle with screws
Ash Door Assembly
Y
Y
Ash door Latch Hardware
Control Box Assembly - W/Board & Pressure Switch
Control Box
8
1-10-06486
1-00-05889
1-00-163
Circuit Board (Requires D-Shaft Knobs)
Pressure Switch
Y
Y
9
Hopper Assembly
1-10-08207A
1-10-70219720
3-21-08639
3-21-33647
3-20-11744
3-20-00844
3-20-60906
3-30-6007-25
3-43-4722386
1-10-08177
2-00-06423B
1-00-939639
3-40-00121
1-00-00382
1-10-08552W
3-44-06417
1-10-08553S
10
11
12
Combustion Blower - W/Flange
Draft Motor
Y
Y
Y
Y
Y
Y
Y
Distribution Blower
Pre 008065076
Post 008065076
13
14
Thermister Probe
Feed Motor - 4 rpm
1/4"-20 x 2 1/2" Phillips Round Head Zinc Pltd Machine Screw
Ash Lip Trim
Pkg of 25
Ash Pan
Y
Y
Y
Ash Shield
Airwash O-Rings
Pkg of 10
Brass Elbow
Brick Set
Y
Combustion Blower Inlet Cover
Combustion Blower Seal
Combustion Inlet Cover Retainer Assembly
Door (frame only) (Gold)
Door (frame only)
Y
Y
No longer available 1-10-05165
Cast
4-00-05165
3-20-502222
3-20-502221
1-10-08197A
1-10-00102A
3-40-35125
Double Paddle Fan Blade 4-3/4” (old tilt out draft motor)
Double Paddle Fan Blade 5” (new style draft motor)
Feeder Assembly
Y
Y
Feeder Cam Block Assembly
Filter, In line for DVC
Y
Additional service part numbers appear on following page.
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Service Parts
dvC-500
beginning manufacturing date: N/A
Ending manufacturing date: Active
IMPORTANT: THIS IS DATED INFORMATION. When requesting service or replacement
parts for your appliance please provide model number and serial number. All parts listed
in this manual may be ordered from an authorized dealer.
Stocked
at depot
ITEm
dESCrIPTION
COmmENTS
PArT NumbEr
2-00-06387S
Fine Tray
Gasket, Flue Pipe
Pkg of 3
15 Ft
3-44-06256-3
1-00-2312
Y
Y
Y
Y
Y
Y
Y
Gasket, Glass, 1/4” Round
Gasket, Hinge Seal
2-00-06416
3-44-06415
1-00-1086204
2-00-05202-4
3-30-3011-100
3-43-08157
1-00-08176
3-42-08308
4-31-08055
3-31-06238
3-50-06438
3-20-00906
3-44-08551
1-00-5113574
3-44-08215
3-20-08272
Gasket, Hopper Lid
Gasket, Round 1/2” (Load Door)
Glass Clip
20 Ft
Pkg of 4
Pkg of 100
#10-24 x 3/8” Alloy Steel Black Oxide Button Head Cap Screw
Gold Air Grill Trim
Handle Assembly
Y
Hercules Grate Cement
Paw Bolt
12 oz. Tube
Y
Y
Y
Y
Y
Y
Y
Y
Y
Pillow block Bearing
Pusher Block, Aluminum
Room Sensor
Silicone foam 1/16” - grey (hopper lid)
Silicone Tubing For In Line Filter
Silicone, Red Sponge W/PSA (Old Units)
Pre 008065076
TCP Probe (Yellow Thermister Probe)
Post 008065076 3-20-00844
Termination Trim Collar
Tile frame assembly 12 X 6
Tilit Draft Motor
Qty. 2 Req.
2-00-06326
1-00-08617
3-21-42940
No longer available
No longer available
Tile Pack
Brushed Stainless Steel Plate 12 X 6
Deer
1-00-06732-2
3-43-120601
3-43-120602
3-43-120603
3-43-120604
3-43-120605
3-43-120606
3-43-120607
3-43-120608
3-43-120609
3-43-120610
3-43-06731-11
3-43-06731-12
3-43-06731-2
3-43-06731-9
Pheasants
Deer
Mallards
Old Mill
Cottage
Eagle
Ceramic Tile 12 X 6 (No longer available)
Bridge
Bear
Lighthouse
Trout
Floral
Horse Riders
Deer
Slate Tile 12 X 6
Lighthouse
07/12
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Specifications
Weight
500 Pounds
BTU Output Range
Heating Capacity
Fuel
7000 to 75,000
2200 Square Feet
Anthracite Rice Coal
93 Pounds
Hopper Capacity
Distribution Blower Size
Flue
135 cfm
4" Harman DVC Vent
295 Watts
Wattage
Control
ESP with Micro-processor
25 3/4"
Width
Height
403/4"
Depth
29"
30
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2 blink Status details
dvC 500-C
Stage 2:
Firebox Static Pressure
Safety Protocol
If Stage 1 has already begun and the negative
pressure is lost:
The status light will start to blink ( 2 blinks ).
The combustion blower and feeder motor will shut
off.Thesemotorswillremainofffora5minutecool-
down period.After five minutes, those components
will restart at a reduced feed rate ( 30 seconds
max.) for 72 minutes.
After72minutes,ifthesafetyswitchhasnotsensed
another pressure loss, the unit will automatically
go back up to Stage 1.
The status light will continue to blink (2 blinks)
throughout Stage 1 and Stage 2.
If the safety switch senses a loss of negative
pressure anytime during the Stage 2 Protocol, the
unit automatically goes to the Stage 3 Protocol.
The DVC-500 operates with a negative pressure
fireboxasasafetyfeature.Thecontrolcontinuously
adjusts the draft motor speed to maintain a safe
firebox negative static.
NOTE:ObservetheintensityoftheDraftMotorlight
on the control panel in comparison with the Feed
Motor light when it is on. When the appliance and
ventingsystemareclean,theindicatorlightismuch
dimmer than the others. This is because there is
lower voltage flowing to the draft motor. As ashes
build up, the light will get brighter because the draft
motor needs to run faster in order to maintain the
negativepressureinthefirebox.Whentheindicator
light for the draft motor appears as bright as the
rest of the lights, it is a good indication that it's time
to clean the appliance and the venting.
Stage 3:
Duringstage2,ifanotherlossofnegativepressure
is sensed;
If the circuit board is flowing full line voltage to the
DraftMotor,andthenegativepressureinthefirebox
is too low, the following safety protocol will begin.
The status light will continue to blink 2 blinks.
The Distribution Blower will be cycling "high" to
"low" as an audible warning.
Stage 1
The Combustion Blower and Feeder Motor will
shut off.
When the unit reaches Stage 3 these motors will
not restart.
When the safety switch senses a loss of negative
pressure in the firebox for more than 68 seconds
the following happens:
The Draft Motor will continue to run at maximum
voltage, but the fire will go out.
The combustion blower will reduce in speed.
During this cool down period the feeder is allowed
to opreate. If needed, the feeder can opreate for
up to 3 minutes.
After72minutes,ifthesafetyswitchhasnotsensed
another pressure loss, the unit will automatically
go back to the control board setting.
[At any time, the 2 blink status can be reset by
disconnecting the power to the unit for a few
seconds.]
If the safety switch senses a loss of negative
pressureanytimeduringtheSTAGE1Protocol,the
unit automatically goes to the STAGE 2 Protocol
CAuTION
Resettinga2BlinkStatuslikelyindicates
that service is required.
Clean the appliance and the venting
system thoroughly. If the error persists,
contact your dealer for more advanced
service.
31
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dvC-500 Firebox Static Pressure Safety Protocol
CausesAnd/OrreasonsFor(2-blink)Shutdown:
11. Fines tray cover not closed properly, fig. 20.
The DVC-500 operates with a negative pressure
fireboxasasafetyfeature.Anylossofthisnegative
pressure will start the safety protocol, (Atwo blink
status warning )
12.Poororimproperfluetermination,otherthan
those shown in the owners manual.
13.Toohighofnegativepressureintheareabeing
heated. This is usually caused by the area being
too tight and using many exhausting appliances
( range hood, clothing dryer. exhaust fans, etc.).
Often this condition can be caused by heavy and
gustingwindshittingtheoutside,creatinganegative
pressure inside. This internal to external pressure
difference may cause the unit to go in and out of
Stage 1.
The following list of potential reasons for warnings
is in order of most likely to least likely to occur:
1. Opening the viewing door or the ash door
for long periods of time without turning the feed
adjuster knob to the "ASH OUT" position.
2. blocked or partially blocked flue pipe. This is
generally a slow buildup and may only cause the
unit to go in and out of Stage 1. Although as the
condition worsens, the unit will continue to step
down until it goes out.
14.Faultycomputercircuitordisconnectedwiring
between control board and safety switch.
15. Faulty safety switch (not field adjustable).
3. draft motor fan blades dirty. This is generally
a slow buildup and may only cause the unit to go
in and out of Stage 1. Although as the condition
worsens, the unit will Continue to step down until
it goes out.
16. draft motor failure - there is electricity to the
motor but it will not turn.
[At any time, the 2 blink status can be reset by
disconnecting the power to the unit for a few
seconds.]
4. draft motor fan cover plate not installed or not
in proper position. (Behind ash pan)
5. gasketing problems with the viewing or ash
removal door.
6. grate clean-out cover not closed properly,
Fig.26.
7. grate inserts are extremely loose or out of
alignment, fig. 30.
8. Coal ash building up behind the ash pan to a
point where the ash door is sprung and not sealing
when latched.
9. Transparent tubing from firebox to sensing
switch is off or blocked with fly ash.
10.Poorsealonthehopperlid(usuallycausedby
coal under hopper lid edge gasketing after fueling).
32
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Hearth & Home Technologies Inc.
LIMITED LIFETIME WARRANTY
Hearth & Home Technologies Inc., on behalf of its hearth brands (”HHT”), extends the following warranty for
HHT gas, wood, pellet, coal and electric hearth appliances that are purchased from an HHT authorized dealer.
WARRANTY COVERAGE:
HHT warrants to the original owner of the HHT appliance at the site of installation, and to any transferee taking ownership
of the appliance at the site of installation within two years following the date of original purchase, that the HHT appliance
will be free from defects in materials and workmanship at the time of manufacture. After installation, if covered compo-
nents manufactured by HHT are found to be defective in materials or workmanship during the applicable warranty period,
HHT will, at its option, repair or replace the covered components. HHT, at its own discretion, may fully discharge all of its
obligations under such warranties by replacing the product itself or refunding the verified purchase price of the product
itself. The maximum amount recoverable under this warranty is limited to the purchase price of the product. This warranty
is subject to conditions, exclusions and limitations as described below.
WARRANTY PERIOD:
Warranty coverage begins on the date of original purchase. In the case of new home construction, warranty coverage
begins on the date of first occupancy of the dwelling or six months after the sale of the product by an independent,
authorized HHT dealer/ distributor, whichever occurs earlier. The warranty shall commence no later than 24 months
following the date of product shipment from HHT, regardless of the installation or occupancy date. The warranty period for
parts and labor for covered components is produced in the following table.
The term “Limited Lifetime” in the table below is defined as: 20 years from the beginning date of warranty coverage for
gas appliances, and 10 years from the beginning date of warranty coverage for wood, pellet, and coal appliances. These
time periods reflect the minimum expected useful lives of the designated components under normal operating conditions.
Warranty Period
Parts Labor
HHT Manufactured Appliances and Venting
EPA
Components Covered
Gas
X
Wood Pellet
Coal Electric Venting
Wood
All parts and material except as
covered by Conditions,
Exclusions, and Limitations
listed
1 Year
X
X
X
X
X
X
Igniters, electronic components,
and glass
X
X
X
X
X
X
2 years
X
X
X
Factory-installed blowers
Molded refractory panels
3 years
X
X
Firepots and burnpots
Castings and baffles
5 years 1 year
X
X
Manifold tubes,
HHT chimney and termination
7 years 3 years
X
X
10
1 year
years
X
X
X
Burners, logs and refractory
Firebox and heat exchanger
Limited
3 years
Lifetime
X
X
X
X
X
X
X
X
All replacement parts
beyond warranty period
90 Days
X
X
See conditions, exclusions, and limitations on next page.
4021-645C 12-29-10
Page 1 of 2
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WARRANTY CONDITIONS:
•
This warranty only covers HHT appliances that are purchased through an HHT authorized dealer or distributor. A list of
HHT authorized dealers is available on the HHT branded websites.
•
•
This warranty is only valid while the HHT appliance remains at the site of original installation.
Contact your installing dealer for warranty service. If the installing dealer is unable to provide necessary parts, contact
the nearest HHT authorized dealer or supplier. Additional service fees may apply if you are seeking warranty service
from a dealer other than the dealer from whom you originally purchased the product.
•
Check with your dealer in advance for any costs to you when arranging a warranty call. Travel and shipping charges
for parts are not covered by this warranty.
WARRANTY EXCLUSIONS:
This warranty does not cover the following:
•
•
•
Changes in surface finishes as a result of normal use. As a heating appliance, some changes in color of interior and
exterior surface finishes may occur. This is not a flaw and is not covered under warranty.
Damage to printed, plated, or enameled surfaces caused by fingerprints, accidents, misuse, scratches, melted items,
or other external sources and residues left on the plated surfaces from the use of abrasive cleaners or polishes.
Repair or replacement of parts that are subject to normal wear and tear during the warranty period. These parts
include: paint, wood, pellet and coal gaskets, firebricks, grates, flame guides, light bulbs, batteries and the discolor-
ation of glass.
•
•
Minor expansion, contraction, or movement of certain parts causing noise. These conditions are normal and com-
plaints related to this noise are not covered by this warranty.
Damages resulting from: (1) failure to install, operate, or maintain the appliance in accordance with the installation
instructions, operating instructions, and listing agent identification label furnished with the appliance; (2) failure to
install the appliance in accordance with local building codes; (3) shipping or improper handling; (4) improper opera-
tion, abuse, misuse, continued operation with damaged, corroded or failed components, accident, or improperly/
incorrectly performed repairs; (5) environmental conditions, inadequate ventilation, negative pressure, or drafting
caused by tightly sealed constructions, insufficient make-up air supply, or handling devices such as exhaust fans or
forced air furnaces or other such causes; (6) use of fuels other than those specified in the operating instructions; (7)
installation or use of components not supplied with the appliance or any other components not expressly authorized
and approved by HHT; (8) modification of the appliance not expressly authorized and approved by HHT in writing;
and/or (9) interruptions or fluctuations of electrical power supply to the appliance.
•
•
•
Non-HHT venting components, hearth components or other accessories used in conjunction with the appliance.
Any part of a pre-existing fireplace system in which an insert or a decorative gas appliance is installed.
HHT’s obligation under this warranty does not extend to the appliance’s capability to heat the desired space. Informa-
tion is provided to assist the consumer and the dealer in selecting the proper appliance for the application. Consider-
ation must be given to appliance location and configuration, environmental conditions, insulation and air tightness of
the structure.
This warranty is void if:
•
The appliance has been over-fired or operated in atmospheres contaminated by chlorine, fluorine, or other damaging
chemicals. Over-firing can be identified by, but not limited to, warped plates or tubes, rust colored cast iron, bubbling,
cracking and discoloration of steel or enamel finishes.
•
•
The appliance is subjected to prolonged periods of dampness or condensation.
There is any damage to the appliance or other components due to water or weather damage which is the result of, but
not limited to, improper chimney or venting installation.
LIMITATIONS OF LIABILITY:
•
The owner’s exclusive remedy and HHT’s sole obligation under this warranty, under any other warranty, express or
implied, or in contract, tort or otherwise, shall be limited to replacement, repair, or refund, as specified above. In no
event will HHT be liable for any incidental or consequential damages caused by defects in the appliance. Some states
do not allow exclusions or limitation of incidental or consequential damages, so these limitations may not apply to you.
This warranty gives you specific rights; you may also have other rights, which vary from state to state. EXCEPT TO
THE EXTENT PROVIDED BY LAW, HHT MAKES NO EXPRESS WARRANTIES OTHER THAN THE WARRANTY
SPECIFIED HEREIN. THE DURATION OF ANY IMPLIED WARRANTY IS LIMITED TO DURATION OF THE
EXPRESSED WARRANTY SPECIFIED ABOVE.
4021-645C 12-29-10
Page 2 of 2
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Service & maintenance log
Date Of Service
Performed By
Description Of Service
35
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At Harman, we build each product to a standard, not a price.
(Signature of Boxer)
Your premium quality hearth product designed and assembled
by the experienced and skilled members at Harman in Halifax,
PA, USA.
Proudly Printed On 100% Recycled Paper
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