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.

12 I EN
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

EN I 13
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

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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.
It is possible to control up to 5 ventilation devices together. To control more than one, use the LA3
connector on DIN rail relay.
5.8 Installation of the ventilation device DIN rail relay U
1. Let the DIN rail relay to be installed by authorized company to your electrical switchboard.
2. Connect the ventilation DIN rail relay and control unit with the cable (socket LA2).
3. The authorised company connects the phase of the power cord of the ventilation device (230 V) to the inlet (A) of DIN rail relay.
4. Diode (B) indicates the status of ventilation device: diode on – ventilation device is powered / diode off – ventilation is not powered.
5.9 Installation of the chimney clamp ø150-250 mm with holder of silicone hose
and temperature sensor U
1. Remove the pressure measuring tube (A) from the buckle.
2. Place the clamp in the desired position on the chimney.
3. Mark the entry point for the pressure measuring tube or for the temperature sensor (when installed).
4. Take off the clamp.
5. Drill a hole with a diameter of 6 mm for the pressure measuring tube.
6. When installing high temperature sensor, drill also 8 mm diameter hole.
7. Reattach the clamp and secure it with a tensioner (B).
8. Place the pressure measuring tube (A) in such a way, that the output is facing upwards.
9. Cut the hose in a length needed to connect the output with the control unit.
10. Push the hose upwards (D) through the spring (C) and place it on the input on the clamp in such a way, that it faces at least the
first 10 cm vertically upwards (this will prevent the condensate from getting into the electronics). At the same time, ensure the hose
not to be squeezed or break.
11. Put the second end of the silicone hose in the control unit (input marked as DK).
12. If you are also installing a high temperature sensor, mount it into the inlet (E).
LA2
B
A
LA3
Fig. 12 / Connection of the switch to the DIN bar for air-conditioning equipment

EN I 15
When installing, make sure the silicone hose is not deformed in any way. Otherwise, the correct
function of the device will not be ensured!
When installing, make sure the silicone hose is not deformed in any way. Otherwise, the correct
function of the device will not be ensured!
5.10 Installation of silicone hose for room pressure measurement U
1. Cut the appropriate length of the hose needed to measure the pressure. This must be long enough to reach from the control unit
to the room when the appliance is installed.
2. Plug the end of the hose to the control unit input (marked DR).
3. Install the end of the hose freely in the area where the is installed (for example, make a hole in the enclosure and place the end of
the hose in there.
A
A
B
B
E
E
C
C
D
D
≥ 10 cm
≥ 10 cm
45°
45°
Fig. 13 / Installation of the buckle on the vertical flue
Fig. 14 / Installation of the buckle on the horizontal flue

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S1 AT TK T1 T2 T3
DR DK
KP1 LA1
MODULE A
MODULE W
MODULE U
5.11 Description of the connectors and the control unit AWU
1. Connect all installed components with the control unit (see Fig. 15).
2. Components can be plugged in in any order.
3. Connect the control unit (with the provided power adapter) into the 230 V power supply (see Fig. 16).
4. HOS electronic control has now been installed and you can move to the SET-UP phase.
5. The prerequisite for the proper functioning of HOS is the correct connection and proper operation of all connected components.
S1 - air inlet flap
AT - high temperature sensor
TK - door sensor
KP1 - circulation pump switch
T1 - PT1000 fireplace heat
exchanger heat sensor
T2 - PT1000 top accumulation tank
heat sensor
T3 - PT1000 bottom accumulation tank
heat sensor green connector
3 pins
green connector
2 pins
blue
connector
orange connector
green
connector
yellow
connector
red
connector
white
connector
blue
connector
black
connector
LA1 - switch of
ventilation device
DK - chimney clamp with
pressure measuring input
DR - hose for measuring
room pressure
Fig. 15 / Face 1 of HOS regulation and connection diagram of components

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Abb. 16 / Face 2 of HOS regulation and connection diagram, description of HOS signalling
Green
indicates:
normal function
of module U
Orange
indicates:
ventilation device
temporarily switched off
Red
indicates:
ventilation device permanently
switched off / module U
malfunction (error number
onthe display)
Green
indicates: normal function
of modules A and W
Orange
indicates: door opened
Red
indicates: malfunction ofmodule
A or W (error number on
thedisplay), air supply flap is
opened, ciruclation pump is on
MODULE U
MODULE A (+ W)
Button for module U
restart
Button for pairing with
wireless display and for
restart (modules A and W)
Power adaptor of
control unit (24V)
Sensor for
pairing with
wireless display

18 I EN
6. Set-up
6.1 Wireless display and control unit pairing AWU
1. Make sure all the components are properly connected to the control unit and that the diodes on its back does not indicate any error.
In case of any error message, solve the error first.
2. Open the battery cover on the back of the wireless display, insert two AAA-sized alkaline batteries (included) and close the battery
cover.
3. The pairing symbol appears on the wireless display.
4. Bring the wireless display closer to the pairing sensor on the back of the control unit (max. 15 cm).
5. Press the SYS button on the back of the control unit.
6. The start of the pairing process is accompanied by a slight vibration of the wireless display.
7. Successful pairing is confirmed by a short beep.
8. The controller has now been paired with the control unit.
≤ 15 cm
Fig. 17 / Pairing the wireless display with the control unit

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6.2 Settings of the control unit parameters – menu SETTINGS AWU
1. Wake up the wireless display from stand-by mode by moving it (take it in your hand).
2. Enter the SETTINGS menu by long pressing (2 s) of the OK button .
3. Use the arrow keys in the menu to confirm the choice by short pressing OK.
·MODULE A – setting the values of the „electronic combustion control module“
·MODULE W – setting the values of „primary water cycle control“
·MODULE U – setting the values of „underpressure watcher“
·TEST – test the basic functions of each connected device
·RESET – factory settings of all modules
6.3 Settings of the combustion control parameters (MODULE A) A
1. Choose MODULE A in the HOS main menu to open the combustion control settings
2. After entering the MODULE A, use the arrows to select:
·T-START temperature setting after which the combustion control process starts
·EP setting the burn-out phase, when the air flap is fully closed
3. T-START is set to 180 °C by default. Use the arrows to edit the temperature in a range 80–250 °C. Press OK to confirm. Choose
the temperature depending on the position of the high temperature sensor. If the temperature T-START is not reached, the
control process will not start!
4. EP is set to 0 by default. Use the arrows to edit the EP in a range of -6 to +6. Changing these values affects the start of the phase
when the combustion control completely closes the air supply flap (switches to phase Po5, see Fig.18).
MODULE A
MODULE W
MODULE U
TEST
RESET
MODULE A
T-START
EP
T-START
Po1 Po2 Po3 Po4 Po5 Time
Temperature
Only purchased modules are available in the main menu. The TEST module is displayed only when the
fireplace insert is out of order (not burning).
Fig. 18 / / Burn curve with a picture of the individual combustion phases

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If the flap closes too early, select positive values to extend the glowing phase.
If the flap closes too late, select negative values to shorten the glowing phase
5. Confirm the selected value by pressing OK button.
6. Select and confirm with the OK button to return to the main menu.
6.4 Settings of the circulation pump parameters (MODULE W) W
1. Choose MODULE W in the HOS main menu to open the circulation pump settings.
2. In the MODULE W menu, select:
· KP-START temperature setting (fireplace heat exchanger) of the start of the circulation pump.
· KP-STOP temperature setting (fireplace heat exchanger) of the stop of the circulation pump.
· WT-DIFF the difference between the water temperature in the heat exchanger and the average water temperature in the
accumulation tank. The circulation pump starts when the temperature in the heat exchanger is higher (of set difference) than the
average temperature in the accumulation tank.
· FT setting of the limit temperature in the fire chamber to start/stop the circulation pump.
· ALARM setting of the percentage value (accumulation tank charge). When value reached, sound notification starts.
· KPA regular start of the circulation pump function (off-season).
3. KP-START default set to 65 °C. Use the arrows to edit the temperature in a range 60–75 °C. Press OK to confirm.
4. KP-STOP default set to 60 °C. Use the arrows to edit the temperature in a range 50–70 °C. Press OK to confirm. (The device
does not allow setting the KP-STOP value higher than KP-START value).
5. WT-DIFF default set to 5. Use the arrows to edit the value in a range 0–10. Press OK to confirm.
6. FT default set to 65 °C. Use the arrows to edit the temperature in a range 60–100 °C. Press OK to confirm.
7. ALARM default set to 80 %. Use the arrows to change it in the range of 75–90 %. Press OK to confirm.
8. KPA default set to ON. Use the arrows to turn it OFF. If this parameter is active, the circulation pump starts once every 14 days for
3 minutes. After each restart of the device, the pump starts for 3 minutes as well.
9. Select and confirm with the OK button to return to the main menu.
MODULE W
KP-START
KP-STOP
WT-DIFF
FT
ALARM
KPA
6.5 Settings of the underpressure watcher parameters (MODULE U) U
1. Choose MODULE U in the HOS main menu to open the circulation pump settings.
2. In the MODULE U menu, select:
The KP START temperature value must always be at least 5°C higher than the KP STOP value. If you
set KP START or KP STOP out of this range, the second (not chosen) temperature will be updated
automatically in order to meet this condition.

EN I 21
· DELTA p setting the pressure difference between the pressure in the flue gas path and the pressure in the room. If the pressure
lower than DELTA p is reached for the time period defined by parameter LAV, the air ventilation is temporarily disconnected. If
the pressure higher than DELTA p is reached for the time period defined by parameter LAV, the air ventilation is put back into
operation.
· LAV setting the time delay to switch off and turn on the ventilation device if the condition DELTA p is met
3. DELTA p – default set to 4 Pa. Use the arrows to change it in the range of 4–20 Pa. Press OK to confirm.
4. LAV default set to 40 s. Use the arrows to change it in the range of 10–180 s. Press OK to confirm.
5. Select and confirm with the OK button to return to the main menu.
6.6 Functionality test AWU
1. Choose TEST in the HOS main menu to open the test settings. The TEST menu is only available when no other module is
activated and the temperature in the fireplace unit is lower than 35 °C.
2. In the TEST menu, select:
· KLAPPE air inlet flap testing.
· KP testing of the circulation pump switch.
· LA testing of the ventilation device switch.
3. KLAPPE by selecting this option, the air flap is tested by moving the damper.
4. KP by selecting ON/OFF the circulation pump is turned ON/OFF.
5. LA by selecting ON/OFF the ventilation device is turned ON/OFF.
6. Select and confirm with the OK button to return to the main menu.
7. After leaving the TEST menu, all parameters are returned to the original values set before entering the TEST menu.
8. If the remote control is in TEST mode, it will never be put into the standby mode.
6.7 Factory settings AWU
1. In the RESET menu, you can return all modules to factory settings.
2. Confirm the option with the OK button and your changes will be irreversibly deleted and you will be return to the main settings
menu.
3. Select and confirm with the OK button to return to the main menu.
TEST
KLAPPE
KP
LA
By returning to factory settings, your changes will be irreversibly deleted and you will return to the
main settings menu.
MODULE U
DELTA p
LAV

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7. Operating
7.1 Wireless display AWU
The wireless display consists of two parts, the upper (information) and the lower (control). Device status is displayed in the upper part
of the display. The bottom of the display is touch-sensitive and is used to change the displayed information.
To turn the wireless display on, take it in your hands (motion control). When not used for 7 seconds, the display gets in the standby
mode.
00:30
OK
Po 3
Control zone
Ventilation status
Notifications and alarms
Burning time
Basic information menu
Pump status
Fig. 19 / Wireless display

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7.2 Displayed information
Circulation pump status
Pump status W
If the symbol is on, the hot water circulation pump is in operation.
Basic information menu
During standard operation, the display shows the following information. Use the arrow keys to switch the information.
150 °C
Temperature in the fire chamber A
Value of the current temperature in the burning chamber measured by a high temperature sensor.
Po 3
Flap position A
Shows the current position of the air inlet flap. The damper can be in any position between Po1 (fully open air supply) and Po5
(closed air supply). The burning curve is not fixed, but is dynamic and individually evaluated for each burning process based on
the maximum achieved temperature (T-MAX) in phase Po2.
·Po1 – first position. This phase begins when the fire chamber door is opened and closed and ends when the starting
temperature T-START is reached. The starting temperature depends on the program that is set-up.
·Po2 – second position. The second phase begins when the starting temperature T-START is reached and lasts at least
15 minutes after closing the door. The maximum temperature T-MAX is reached in this phase.
·Po3 – third position. This is the phase of active burning.
·Po4 – fourth position. Phase of active burning where the air flap lets the smallest amount of air in the combustion chamber.
·Po5 – fifth position. Phase of glowing coals without access of combustion air. The air flap is fully closed.
·Po0 – position zero – inactive phase where the air flap is closed. The temperature in the combustion chamber is below 50°C.
T-START
Po1 Po2 Po3 Po4 Po5 Time
Temperature T-MAX
Fig. 20 / Burn curve with a picture of the individual combustion phases