Viessmann EA1 Operation and maintenance manual

Please file in Service Binder
5774 470 - 02 03/2015
EA1
Extension Module
Installation Instructions
for use by heating contractor
EA1 Extension Module
for programmable inputs and outputs
Product may not be exactly as shown
Read and save these instructions
for future reference.
IMPORTANT
Certified as a component
part for Viessmann boilers

2
EA1 Extension Module Installation
5774 470 - 02
Safety, Installation and Warranty Requirements
Please ensure that these instructions are read and understood before commencing installation. Failure to comply with
the instructions listed below and details printed in this manual can cause product/property damage, severe personal
injury, and/or loss of life. Ensure all requirements below are understood and fulfilled (including detailed information
found in manual subsections).
Product documentation
Read all applicable documentation before commencing
installation. Store documentation near boiler in a
readily accessible location for reference in the future
by service personnel.
For a listing of applicable literature,
please see section entitled “Important
Regulatory and Safety Requirements”.
Licensed professional heating contractor
The installation, adjustment, service and maintenance
of this equipment must be performed by a licensed
professional heating contractor.
Please see section entitled Safety and
“Important Regulatory and Installation
Requirements”.
Advice to owner
Once the installation work is complete, the heating
contractor must familiarize the system operator/
ultimate owner with all equipment, as well as safety
precautions/requirements, shutdown procedure, and
the need for professional service annually before the
heating season begins.
Safety
Warranty
Information contained in this and
related product documentation must
be read and followed. Failure to do
so renders the warranty null and void.
2
Safety, Installation and Warranty Requirements

3
5774 470 - 02
EA1 Extension Module Installation
3
Safety
Important Precautions
General Information
Installation
Connections
Additional Information
Safety, Installation and Warranty Requirements..............2
Product documentation...........................................2
Licensed professional heating contractor...................2
Advice to owner....................................................2
Warranty...............................................................2
Important Regulatory and Installation Requirements........4
Approvals.............................................................4
Codes..................................................................4
Working on the equipment......................................4
Power supply........................................................4
About these Installation Instructions..............................5
Mounting the Extension Kit............................................6
Extension kit for installation on a wall......................6
Overview of Electrical Connections...............................7
Connecting Digital Inputs.............................................8
Connecting the Analog Input 0-10V............................10
Connecting the KM Bus to the Boiler Control Unit.........10
Connecting the Circulation Pump or a
Fault Message Facility...............................................11
Power Supply..........................................................12
Connection and Wiring Diagram.................................14
Specifications..........................................................15
Page
Table of Contents
Page

4
5774 470 - 02
EA1 Extension Module Installation
Important Precautions
Important Regulatory and Installation Requirements
Approvals
Viessmann boilers, burners and controls are approved for
sale in North America by CSA International.
Codes
The installation of this unit shall be in accordance with
local codes. In the absence of local codes, use:
- CSA C22.1 Part 1 and/or local codes in Canada
- National Electrical Code ANSI/NFPA 70 in the U.S.
Always use latest editions of codes.
The heating contractor must comply with the Standard
for Controls and Safety Devices for Automatically Fired
Boilers, ANSI/ASME CSD-1 where required by the
authority having jurisdiction.
Working on the equipment
The installation, adjustment, service, and maintenance
of this product must be done by a licensed professional
heating contractor who is qualified and experienced in the
installation, service, and maintenance of hot water boilers.
There are no user serviceable parts on the boiler, burner,
or control.
Power supply
Install power supply in accordance with the regulations
of the authorities having jurisdiction or, in absence of
such requirements, in accordance with National Codes.
Viessmann recommends the installation of a disconnect
switch to the 120V power supply outside of the boiler
room.
Ensure main power supply to equipment, the heating
system, and all external controls have been deactivated.
Close main oil or gas supply valve. Take precautions in
both instances to avoid accidental activation of power
during service work.
Please carefully read this manual prior to attempting
installation. Any warranty is null and void if these
instructions are not followed.
For information regarding other Viessmann System
Technology componentry, please reference
documentation of the respective product.
We offer frequent installation and service seminars
to familiarize our partners with our products. Please
inquire.
The completeness and functionality of field supplied
electrical controls and components must be verified
by the heating contractor. These include low water
cut-offs, flow switches (if used), staging controls,
pumps, motorized valves, air vents, thermostats, etc.
WARNING
Turn off electric power supply before
servicing. Contact with live electric
components can cause shock or loss
of life.

5
5774 470 - 02
EA1 Extension Module Installation
About these Installation Instructions
General Information
Take note of all symbols and notations intended to draw attention to potential hazards or important
product information.
CAUTION
Cautions draw your attention to the presence of potential
hazards or important product information.
WARNING
Warnings draw your attention to the presence of potential
hazards or important product information.

IMPORTANT
Indicates an imminently hazardous situation which,
if not avoided, could result in death, serious injury or
substantial product/property damage.
Indicates an imminently hazardous situation which,
if not avoided, may result in minor injury or product /
property damage.
Helpful hints for installation, operation or maintenance
which pertain to the product.
This symbol indicates to note additional information
This symbol indicates that other instructions must be
referenced.

6
5774 470 - 02
Installation Instructions Extension EA1
Installation
Extension kit for installation on a wall
Components:
HEA1 extension module
HKM BUS plug aVG
HPower cord pre-wired to plug fÖ
HDigital inputs DE1, DE2 and DE3 plugs
H0-10VDC input plug
HProgrammable output plug aBJ
HAccessory power plug fÖA
Mounting the Extension Kit
1. Loosen the retaining screws from the extension kit
encloser (do not remove) .
2. Remove cover and set aside.
3. Mount the extension module enclosure to the wall
using the supplied hardware.
4. Install the cover.

7
5774 470 - 02
EA1 Extension Module Installation
Legend
DE1 Digital input 1
DE2 Digital input 2
DE3 Digital input 3
0-10V 0-10V input
fÖ Power supply
fÖA Power supply for additional accessories
aBJ Programmable output
aVG KM BUS to the control unit
A Extension EA1
F1 Fuse
Note: Apply strain relief to all on-site cables.
Close any unnecessary knock-outs with cable
entries (not cut open).
Connections
Overview of Electrical Connections
CAUTION
The electronic modules are static
sensitive. To avoid damage caused by
static discharge, follow Electro-Static
Discharge safety procedures.
A

8
5774 470 - 02
EA1 Extension Module Installation
Connecting Digital Inputs
The following functions can be connected alternatively:
HExternal heating program changeover for each heating
circuit
HExternal blocking
HExternal blocking with central fault message
HExternal demand with set flow temperature
HCentral fault message
HBrief operation of the DHW circulation pump
The hooked-up contacts must correspond to protection
class II.
Coding
address
Control unit
Vitotronic, type H... Vitotronic, type G...
Input DE1 3A 5d
Input DE2 3b 5E
Input DE3 3C 5F
Function assignment of inputs DE1 to DE3
Select the input functions by means of the codes on the
boiler control unit.
Complete description of the coding addresses:
Subject to function and digital input selected for the
respective function, the following codes need to be
changed at the boiler control unit:
Function Setting
Code 3A, 3b, 3C
(Vitotronic, type H ... )
Code 5d, 5E, 5F
(Vitotronic, type G ...)
No function 0
Heating program
changeover
1
External demand with set
flow temperature
2
External blocking 3
External blocking with fault
message input
4
Fault message input 5
Brief operation, DHW
circulation pump
6
Service instructions for boiler
or control unit
Connections

9
5774 470 - 02
EA1 Extension Module Installation
Assigning the heating program changeover function to the
heating circuits
Assign the heating program changeover function for the
respective heating circuit via code d8 at the boiler control
unit:
HChangeover via input DE1: Code d8:1
HChangeover via input DE2: Code d8:2
HChangeover via input DE3: Code d8:3
HSelect the effect of the heating program changeover
via code d5
HSet the duration of the changeover via code F2
Effect of the external blocking function on the pumps
HSelect the effect on the internal boiler circulation pump
(Vitotronic, type H ...) with code 3E
HSelect the effect on the respective heating circuit pump
with code d6
HSelect the effect on the circulation pump for DHW tank
heating (Vitotronic, type H ...) with code 5E
Effect of the external demand function on the pumps
HSelect the effect on the internal boiler circulation pump
(Vitotronic, type H ...) with code 3F
HSelect the effect on the respective heating circuit pump
with code d7
HSelect the effect on the circulation pump for DHW tank
heating (Vitotronic, type H ...) with code 5F
Set flow temperature for external demand
HThe set flow temperature can be selected with code 9b
Runtime of the DHW recirculation pump
Set the runtime:
HVitotronic, type H ...: Code 3d
HVitotronic, type G ...: Code 12
Refer to the boiler Service Instructions
Connecting Digital Inputs (continued)
Connections

10
5774 470 - 02
EA1 Extension Module Installation
Connecting the Analog Input 0-10V
The 0 - 10V hook-up provides an additional set boiler
water temperature:
0 - 1V seen as “no default set boiler water temperature”
1V set value 50°F (10°C)
10V set value 212°F (100°C)
On the Vitotronic, type G ... the range of the set value
default can be changed with code 1E:
1V set value 86°F (30°C)
10V set value 248°F (120°C)
Connections
Connecting the KM BUS to the Boiler Control Unit
Legend
A Extension EA1
B Connection area of boiler control unit
Boiler control unit installation
and service instructions

11
5774 470 - 02
EA1 Extension Module Installation
Connecting the KM BUS to the Extension Modules
Legend
A Boiler control unit
B Extension kit for heating circuit with mixing valve M2
C Extension kit for heating circuit with mixing valve M3
D Extension AM1, EA1 and/or solar control module,
type SM1

12
5774 470 - 02
EA1 Extension Module Installation
The following components can be connected to plug aBJ:
HPump speed reduction function
or
HDHW re-circulation pump
or
HFault message facility
Rated voltage (max): 120V
Rated current (max): 2 A~
Connecting a Circulation Pump or a Fault Message Facility
Function assignment
Select the function of output aBJ:
HVitotronic, type H ...: Code 36
HVitotronic, type G ...: Code 5C
If a digital input is used as fault message input, the
connected fault message facility is switched on when
a fault occurs.
If the relay of output aBJ is switched, contact P-Ö
is open.
If a fault occurs at extension EA1 or communication
is interrupted, contact P-Ö is closed.
Note: If a fault message facility is connected, this will
be activated briefly when the system starts.
Legend
A Circulation pump or fault message facility
Refer to the boiler Service Instructions
Connections

13
5774 470 - 02
EA1 Extension Module Installation
Power Supply (continued)
WARNING
The absence of component grounding in the system can
lead to serious injury from electrical current if an electrical
fault occurs. Connect the appliance and pipework to the
equipotential bonding of the building in question.
WARNING
Incorrect core allocation can result in serious injury and
damage to the appliance.
Never interchange cores “L” and “N”.
WARNING
Incorrectly executed electrical installations can result in
injuries from electrical current and in equipment damage.
Direct power supply
Isolators for non-grounded conductors
HThe mains isolator (if installed) must simultaneously
isolate all non-grounded conductors from the mains
with a minimum contact separation of 3 mm.
HIf no mains isolator is installed, all nongrounded
conductors must be isolated from the mains by the
upstream circuit breaker with a minimum contact
separation of 3 mm.
CAUTION
An incorrect phase sequence can cause damage
to the appliance. Check for phase equality with
the power supply connection of the control unit.
Connections
Legend
A Extension EA1
Connect the power supply (see page 2) and implement
all grounding measures (e.g. RCD circuit) in accordance
with the following regulations:
HIn Canada all electrical wiring is to be done in
accordance with the latest edition of CSA C22.1 Part 1
and/or local codes. In the U.S. use the National
Electrical Code ANSI/NFPA 70. The heating contractor
must also comply with both the Standard for Controls
and Safety Devices for Automatically Fired Boilers,
ANSI/ASME CSD-1, and the Installation Code for
Hydronic Heating Systems, CSA B214-01, where
required by the authority having jurisdiction.
HConnection requirements specified by your local power
supply utility
HProtect the power cable with max. 15A

14
5774 470 - 02
EA1 Extension Module Installation
Connections
Legend
DE1 Digital input 1
DE2 Digital input 2
DE3 Digital input 3
0-10V 0-10V input
A Extension EA1
Connection and Wiring Diagram
fÖ Power supply
fÖA Power supply for additional accessories
aBJ Fault message facility/Feed pump/DHW circulation
pump (floating)
aVG KM BUS to the control unit

15
5774 470 - 02
EA1 Extension Module Installation Additional Information
Rated voltage 120 V~
Rated frequency 60 Hz
Rated current 2A
Power consumption 1.5W
Protection class I
Specifications
Permissible ambient temperature
HDuring operation 32 to 104°F (0 to 40°C)
HDuring storage
and transport -4 to +149°F (–20 to +65°C)
Rated breaking capacity,
floating output aBJ 2A 120V~

5774 470 - 02 Technical information subject to change without notice. Printed on environmentally friendly
(recycled and recyclable) paper.
Installation Instructions Extension EA1
Scan for
digital copy
of this
document