hoxter HOS A User manual

HOS

EN I 5
Content
1. Introduction 5
2. Package content 5
3. Description of the device 4
4. Components description 8
5. Installation 10
6. Set-up 18
7. Operating 22
8. Troubleshooting 26
9. Wiring diagrams of HOS versions 28
10. Warranty 34
1. Introduction
We would like to thank you for purchasing electronic combustion system HOS.
· The installation of this product must be carried out by a specialist - stove maker - only.
· Before you start using the device we would like to invite you to read this manual and follow the instruction inside.
· The prerequisite for the proper functioning of HOS is the correct installation and proper functionality of all its
subcomponents.
2. Package content
* socket switch version supplied as standard, at the customer‘s request the DIN rail version available
HOS A
no display
HOS A HOS AW HOS AWU HOS AU HOS U
control unit (power supply including)
wireless display
contactless door sensor
air inlet flap
high temperature sensor
3 x heat sensor PT1000
sump for heat sensor PT1000
socket switch for boiler pump * *
socket switch for ventilation device * * *
silicone hose
chimney clamp

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3. Description of the device
Electronic combustion control HOS is a device containing some of the following modules or their combination:
· Module A – electronic combustion control - chapters related with this module are marked A
· Module W – primary water cycle control - chapters related with this module are marked W
· Module U – Underpressure watcher - chapters related with this module are marked U
· The chapters related to electronic combustion control without a display are marked
This manual is common to all available versions. Please, consider your own version during
theinstallation and set-up.
3.1 Description of the function of electronic combustion control – Module A A
Module A controls the burning process by dosing the optimal amount of air for combustion. The contactless door sensor (2) transmits
information about the status of the door to the control unit. When they are opened and then closed, the control unit initiates the
combustion control process. The high temperature sensor (3) measures the current temperature in the fire chamber or flue gas path.
Based on this value, the control unit sets the position of the flap (1) to ensure the supply of the optimal amount of air.
If you have a version with a wireless display (4), the display shows the temperature measured by the high temperature sensor, the
burning phase and the burning time.
Fig. 1 / HOS connection – Module A
3.2 Description of the function of primary water cycle control – Module W W
Module W regulates the circulation pump depending on the temperature values measured by the heat sensors. The switching of the
circulation pump (A) by the switch (7) is controlled on the basis of ratio of values measured by heat sensors in the heat exchanger (4)
and in the accumulation tank (5) and (6). The wireless display (8) shows the value of the water temperature in the exchanger (4), the
percentage charge of the accumulation tank and the status of the circulation pump (A). Module W can only be used in combination
with module A.
1
2
3
4
HOS
A

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Fig. 2 / HOS connection – Module AW
Fig. 3 / HOS connection – Module U
1
2
3
4
A
7
8
5
6
HOS
AW
3.3 Description of the function of underpressure watcher – Module U U
Module U allows, based on the difference between underpressure values in the flue gas path and pressure in the room, short-term
disconnecting of the ventilation systems (kitchen hood, recuperation or other ventilation equipment in the house) from operation. High
temperature sensor (1) activates the measurement of underpressure in the chimney (2) and room pressure (B). If the safe value of the
difference between these pressures is not ensured, the switch (3) will temporarily disable the ventilation unit (A). Once the safety time
limit has expired and the difference between the pressures is safe, the unit is put back into operation.
Only two consecutive disconnections of the ventilation system are allowed. If the ventilation system is disconnected for the third time
within 24 hours, it will not be put back into operation. The device can only be turned on again by manual restart. Within 24 hours, such
restarts can be performed thrice through the wireless display, the fourth restart must be performed physically on the control unit of
the device (4) shows the current difference between the room pressure (B), and the pressure in the flue gas path (2) as well as the
status of the ventilation unit (A).
1
2
3
A
4
HOS
U
B

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4. Components description AWU
4.1 HOS Electronic combustion control unit
· Powered by 24 V adapter
· Heat resistance max. 50°C
4.2 Power supply adapter AWU
· Input 110–230 V
· Output 24V DC
· Heat resistance: 40 °C
· Cable length: 3,3 m
4.3 Wireless display AWU
· The wireless display shows information from the control unit
· Power supply: 1,5 V AAA (2 alkaline batteries)
· Heat resistance: 50 °C
· More about using the display in the chapter „Operating“
4.4 Contactless door sensor AW
· Sensor with connecting cable (length 4 m)
· Cable heat resistance: 180 °C
· Magnetic counterpart
· Metal holder (only compatible with Hoxter products)
· M4 x 6 screws to attach the door sensor holder and the magnetic counterpart
4.5 Air inlet flap AW
· Heat resistance of the stainless steel flap and its components: 50 °C
· Cable heat resistance: 180 °C
· Cable length: 5 m
· Available flap diameters: Ø125 mm, Ø150 mm, Ø180 mm
· The air flap motor is equipped with a return spring, which automatically opens the air flap in case of a power failure.
4.6 High temperature sensor with ceramic housing AWU
· Range 0–1200 °C
· Temperature sensor and the ceramic housing heat resistance max 1200 °C
· Cable heat resistance 400 °C
· Cable length 4 m
· Assembly length of the sensor is 155 mm
4.7 3x Heat sensor PT1000 W
· Range 0–150 °C
· Heat temperature resistance: 180 °C
· Cable heat resistance: 105 °C
· Cable length 8 m
· Optimal depth of the sensor in the sump: 60 mm
·

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4.8 Sump for heat sensor PT1000 W
· Heat resistance: 450 °C
· Fitting G 1/2“ (M20 x 1,5)
· Sump length including fitting: 60 mm
· Sump diameter: 8 mm
4.9 Socket switch for circulation pump 1 W
· Heat resistance: 50 °C
· Power supply: 24 V DC
· Connection cable length 8 m (Type LIYY 2 x 0,34 mm2)
4.10 DIN rail relay for circulation pump 1 W
· Heat resistance: 50 °C
· Power supply: 24 V DC
· Connection cable length 8 m (Type LIYY 2 x 0,34 mm2)
4.11 Socket switch for ventilation device 1U
· Heat resistance: 50 °C
· Power supply: 24 V DC
· Connection cable length 8 m (Type LIYY 2 x 0,34 mm2)
4.12 DIN rail relay for ventilation device 1 U
· Heat resistance: 50 °C
· Power supply: 24 V DC
· Connection cable length 8 m (Type LIYY 2 x 0,34 mm2)
4.13 Chimney clamp U
· Flue diameter: 150–250 mm
· Inlets for high temperature sensor and pressure measurement hose
4.14 Silicone hose U
· Heat resistance: 200 °C
· Length: 8 m (can be shortened as needed)
· The hose is intended for measuring the pressure in the room and in the flue gas path
1socket switch version supplied as standard, at the customer‘s request the DIN rail version available

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5. Installation
The prerequisite for the proper functioning of HOS is the correct installation and proper functionality
of all its subcomponents.
5.1 Installation of contactless door sensor AW
If the door sensor was not already mounted on the product, follow these instructions:
1. Break out the indicated opening in the sensor holder (B), pull the door sensor through this hole (A) and fasten with the distance
barrel (C) and a nut (D).
2. Attach the door sensor with the holder using the supplied screws to the designed place on the doorframe (E).
3. Attach the magnetic counterpart on the bottom edge of the doors.
4. Both the door sensor and the magnetic counterpart must be placed in a common axis. The distance between those parts must be
2-12 mm / (F) In case the distance between these part is too large, underlay the magnetic counterpart with the distance barrel.
5. The magnetic counterpart is strong enough to stay in place. For the fixation use the supplied screws (G).
Fig. 4 / Door sensor installation
If you need to install second door contact (double faced fireplace inserts or products with rear feeding), follow these instructions:
1. Remove the green connectors from the door sensors.
2. Put the blue cable of one door sensor and brown cable of second sensor together to one connector.
3. Connect two remaining cables (blue and brown) with connection piece contained in the package of second door sensor.
Fig. 5 / Wiring diagram of two door sensors
B
A
E
F
G
C
D
2–12 mm
brown cable
blue cable

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5.2 Installation of high temperature sensor AWU
Place the high temperature sensor in the specified input in the product and tighten it (in the case of Hoxter products). If the appliance
does not have such an input or it is not possible to install the high temperature sensor in it, put it in the flue gas path.
5.3 Air inlet flap installation AW
1. Connect the air inlet flap by aluminium flexible pipe (not included) with the fireplace insert or stove doors. The connection between
the air inlet flap and the product must be air-tight.
2. When installing into closed-in build, the air inlet flap must be placed outside the environment with high temperature. The heat
resistance of the air inlet flap is max 50 °C.
If you want to control the fireplace using electronic combustion control only and if you want to disassemble manual air control, follow
these instructions:
5.4 Installation of heat sensors PT1000 and sensor sump W
1. Module W contains 3 pieces of heat sensors PT1000 with different coloured connectors and 1 piece of sump for heat sensor.
2. Install the heat sensor sump in the heat exchanger of Hoxter water heating fireplace insert (follow the instructions attached
tothe product).
3. Mount the heat sensor PT1000 marked yellow in the sump in the heat exchanger of the fireplace insert. Put the sensor at least
60mm deep.
Option A (flat air control lever)
1. Set the air control to opened position (maximum air).
2. Remove the air control lever (dotted).
3. As an accessory, it is possible to order a hole cover, which
can be mounted instead of the lever.
Option B (round air control lever)
1. Set the lever to opened position (maximum air).
2. Remove the air control lever (dotted).
3. Turn the hole in the cap not to be visible from the front.
Install the high temperature sensor at least 20 mm deep into the hot zone. For proper functionality,
always install high temperature sensor before the attached accumulation mass (if available).
For the proper function of the electronic combustion control, it is always necessary to open the
manual air control to the maximum.
≥ 20 mm
Fig. 6 / Position of the high temperature sensor
Fig. 7 / Disassembly of the manual air control lever on the fireplace insert
To ensure correct measurement the high
temperature sensor must be calibrated
every2 years.

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4. Mount the heat sensor PT1000 marked red in the top of the accumulation tank. Put the sensor at least 60 mm deep.
5. Mount the heat sensor PT1000 marked white in the bottom of the accumulation tank. Put the sensor at least 60 mm deep.
5.5 Installation of the circulation pump socket switch W
1. Plug the socket switch (A) of the circulation pump into the 230 V power supply.
2. Connect the pump socket switch and control unit with the cable (socket KP2).
3. Plug the circulation pump power cord (230 V) into the socket switch socket (C).
4. Diode (B) indicates the status of circulation pump: diode on – circulation pump is powered / diode off – pump is not powered.
5.6 Installation of the circulation pump DIN rail relay W
1. Let the DIN rail relay to be installed by authorized company to your electrical switchboard.
2. Connect the pump DIN rail relay and control unit with the cable (socket KP2).
3. The authorised company connects the phase of the power cord of the circulation pump (230 V) to the inlet (A) of DIN rail relay.
4. Diode (B) indicates the status of circulation pump: diode on – circulation pump is powered / diode off – pump is not powered.
≥ 60 mm
The total length of cables for switches is max. 30 meters.
Fig. 8 / Position of heat sensor PT1000
Fig. 9 / Connection of the circulation pump socket switch
B
KP2
A
C

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Contact an authorized company with the appropriate certification for electric installations.
The total length of cables for switches is max. 30 meters.
5.7 Installation of the ventilation device socket switch U
1. Plug the socket switch (A) of the ventilation device into the 230 V power supply.
2. Connect the ventilation device socket switch and control unit with the cable (socket LA2).
3. Plug the ventilation device power cord (230 V) into the socket switch socket (C).
4. Diode (B) indicates the status of ventilation device: diode on – ventilation device is powered / diode off – ventilation is not powered.
The total length of cables for switches is max. 30 meters.
It is possible to control up to 5 ventilation devices together. To control more than one, use the LA3
connector on socket switch.
Fig. 10 / Connection of the switch to the DIN bar for the boiler circuit pump
Fig. 11 / Connection of the socket switch of the ventilation device
B
LA2
KP2
A
B
A
C
LA3