Viessmann EM-EA1 extension Quick guide

Installation and service instructions
for contractors
VIESMANN
EM-EA1 extension
DIO electronics module
Function extension
EM-EA1 extension
6131087 GB 6/2019 Please keep safe.

2
Please follow these safety instructions closely to
prevent accidents and material losses.
Safety instructions explained
Danger
This symbol warns against the risk of injury.
!Please note
This symbol warns against the risk of material
losses and environmental pollution.
Note
Details identified by the word "Note" contain additional
information.
Target group
These instructions are exclusively intended for quali-
fied contractors.
■Work on gas installations may only be carried out by
a registered gas fitter.
■Work on electrical equipment may only be carried
out by a qualified electrician.
■The system must be commissioned by the system
installer or a qualified person authorised by the
installer.
Regulations to be observed
■National installation regulations
■Statutory regulations for the prevention of accidents
■Statutory regulations for environmental protection
■Codes of practice of the relevant trade associations
■Relevant country-specific safety regulations
Safety instructions for working on the system
Working on the system
■Where gas is used as the fuel, close the main gas
shut-off valve and safeguard it against unintentional
reopening.
■Isolate the system from the power supply, e.g. by
removing the separate fuse or by means of a mains
isolator, and check that it is no longer live.
■Safeguard the system against reconnection.
■Wear suitable personal protective equipment when
carrying out any work.
Danger
Hot surfaces and fluids can lead to burns or
scalding.
■Before maintenance and service work, switch
OFF the appliance and let it cool down.
■Never touch hot surfaces on the boiler, burner,
flue system or pipework.
!Please note
Electronic assemblies can be damaged by elec-
trostatic discharge.
Prior to commencing work, touch earthed
objects such as heating or water pipes to dis-
charge static loads.
Repair work
!Please note
Repairing components that fulfil a safety func-
tion can compromise the safe operation of the
system.
Replace faulty components only with genuine
Viessmann spare parts.
Auxiliary components, spare and wearing parts
!Please note
Spare and wearing parts that have not been tes-
ted together with the system can compromise its
function. Installing non-authorised components
and making non-approved modifications or con-
versions can compromise safety and may inva-
lidate our warranty.
For replacements, use only original spare parts
supplied or approved by Viessmann.
Safety instructions
Safety instructions
6131087

3
Safety instructions for operating the system
If you smell gas
Danger
Escaping gas can lead to explosions which may
result in serious injury.
■Do not smoke. Prevent naked flames and
sparks. Never switch lights or electrical appli-
ances on or off.
■Close the gas shut-off valve.
■Open windows and doors.
■Evacuate any people from the danger zone.
■Notify your gas or electricity supply utility from
outside the building.
■Have the power supply to the building shut off
from a safe place (outside the building).
If you smell flue gas
Danger
Flue gas can lead to life threatening poisoning.
■Shut down the heating system.
■Ventilate the installation site.
■Close doors to living spaces to prevent flue
gases from spreading.
What to do if water escapes from the appliance
Danger
If water escapes from the appliance there is a
risk of electrocution.
Switch OFF the heating system at the external
isolator (e.g. fuse box, domestic distribution
board).
Danger
If water escapes from the appliance there is a
risk of scalding.
Never touch hot heating water.
Condensate
Danger
Contact with condensate can be harmful to
health.
Never let condensate touch your skin or eyes
and do not swallow it.
Flue systems and combustion air
Ensure that flue systems are clear and cannot be
sealed, for instance due to accumulation of conden-
sate or other external causes.
Ensure an adequate supply of combustion air.
Inform system users that subsequent modifications to
the building characteristics are not permissible (e.g.
cable/pipework routing, cladding or partitions).
Danger
Leaking or blocked flue systems, or an inade-
quate supply of combustion air can cause life
threatening poisoning from carbon monoxide in
the flue gas.
Ensure the flue system is in good working order.
Vents for supplying combustion air must be non-
sealable.
Extractors
Operating appliances that exhaust air to the outside
(extractor hoods, extractors, air conditioning units, etc.)
can create negative pressure. If the boiler is operated
at the same time, this can lead to a reverse flow of flue
gas.
Danger
The simultaneous operation of the boiler and
appliances that exhausts air to the outside can
result in life threatening poisoning due to a
reverse flow of flue gas.
Fit an interlock circuit or take suitable steps to
ensure an adequate supply of combustion air.
Safety instructions
Safety instructions (cont.)
6131087

4
1. Information Disposal of packaging ............................................................................ 5
Symbols ................................................................................................. 5
Intended use .......................................................................................... 5
Product information ................................................................................ 6
■System examples ............................................................................... 6
■Spare parts lists .................................................................................. 6
2. Installation sequence Wall mounting ........................................................................................ 7
Overview of electrical connections ........................................................ 7
Electrical connections ............................................................................ 8
Connecting external functions ............................................................... 8
■Connecting external default set flow temperature: 0 - 10 V IN ........... 8
■Connecting an external default output: 0 - 10 V IN ............................. 9
■Connecting the operating mode changeover: DI1 to DI3 ................... 10
■Connecting external demand: fD ....................................................... 10
■Connecting external blocking: fD ....................................................... 11
Connecting the fault message input and fault message output ............. 11
■Connection without system blocking via 230 V fault message input:
fD ....................................................................................................... 11
■Connection with system blocking via 230 V fault message input: fD . 12
■Connection with system blocking via 24 V fault message input: DI1 .. 12
■Connecting only message facility: hH ................................................. 13
Connecting the external LPG valve: fD ................................................. 13
Connecting the external extractor interlock: hH ..................................... 13
Connecting the PlusBus to the heat generator ...................................... 14
Power supply ......................................................................................... 14
■Power supply at heat generator .......................................................... 14
■Separate power supply ....................................................................... 14
3. Commissioning and
adjustment
Rotary switch S1 for subscriber number addressing ............................. 17
Configuring functions ............................................................................. 17
4. Connection and wiring dia-
gram
................................................................................................................ 18
5. Specification ................................................................................................................ 19
6. Disposal Final decommissioning and disposal ..................................................... 20
7. Declaration of Conformity Declaration of conformity ....................................................................... 21
Index
Index
6131087

5
Please dispose of packaging waste in line with statu-
tory regulations.
Symbols
Symbol Meaning
Reference to other document containing
further information
1.
Step in a diagram:
The numbers correspond to the order in
which the steps are carried out.
Warning of material losses and environ-
mental pollution
Live electrical area
Pay particular attention.
■Component must audibly click into place.
or
■Acoustic signal
■Fit new component.
or
■In conjunction with a tool: Clean the sur-
face.
Dispose of component correctly.
Dispose of component at a suitable collec-
tion point. Do not dispose of component in
domestic waste.
Intended use
The appliance is only intended to be installed and
operated in sealed unvented heating systems that
comply with EN 12828, with due attention paid to the
associated installation, service and operating instruc-
tions as well as the details in the datasheet.
It is only designed for the heating up of heating water.
Commercial or industrial usage for a purpose other
than the heating up of heating water shall be deemed
inappropriate.
Intended use presupposes that a fixed installation in
conjunction with permissible components designed for
this purpose has been carried out.
Every other use will be deemed to be inappropriate.
Any resulting losses are excluded from the manufac-
turer's liability.
Any usage beyond this must be approved by the man-
ufacturer for the individual case.
Intended use also includes the adherence to mainte-
nance and inspection intervals.
Information
Disposal of packaging
6131087
Information

6
Maximum 3 EM-EA1 function extensions can be con-
nected to one heat generator.
Only one function can be connected to each EM-EA1
function extension (DIO electronics module).
The functions that can be connected depend on the
settings made at the heat generator.
Heat generator installation and service instruc-
tions
System examples
Available system examples: See www.viessmann-
schemes.com.
Spare parts lists
Information about spare parts can be found on the
Viessmann spare parts app.
Information
Product information
6131087
Information

7
1.
Fig. 1
Overview of electrical connections
jF jF [{][{][{] hH [{] fÖ
1234123456121212?
1??
fD
K1
S1
+-+-
Fig. 2
DI1 Digital input 1
DI2 Digital input 2
DI3 Digital input 3
0 - 10 V IN 0 - 10 V input
0 - 10 V OUT 0 - 10 V output
F4 Fuse 2 A (slow)
PWM1 Control voltage output
S1 Rotary switch for subscriber number
addressing
Z1 fD 230 V relay output, 230 V input
fÖ Power supply
fÖ A Power supply for additional accessories
hH Changeover contact (floating switching
contact) for connecting signalling equip-
ment for fault messages or an extractor
hood
jF PlusBus
Installation sequence
Wall mounting
6131087
Installation

8
Function Page Connections:
DI1 DI2 DI3 PWM1 0 - 10 V hH fD
IN OUT 43-1 43-L
External functions
■External default set flow temperature 8 X X
■External default output 9 X X
■Operating mode changeover 10 X X X
■External demand 10 X
■External blocking 11 X
Fault message input and fault mes-
sage output
■Connection without system blocking 11 X X
■Connection with system blocking,
230 V
12 X X
■Connection with system blocking,
24 V
13 X X
■Connecting only message facility (e.g.
buzzer)
13 X
External LPG valve 13 X
External extractor interlock 13 X
Electrical connections
!Please note
Electronic assemblies can be damaged by elec-
trostatic discharge.
Prior to commencing any work, touch earthed
objects such as heating or water pipes to dis-
charge static loads.
■Apply strain relief to on-site cables.
■Seal any unnecessary apertures with cable grom-
mets (not cut open).
Danger
Incorrect wiring can lead to serious injury from
electrical current and result in appliance dam-
age.
Take the following measures to prevent wires
drifting into the adjacent voltage area:
■Route extra low voltage (ELV) leads < 42 V
separately from cables > 42 V/230 V~/400 V~.
Secure with cable ties.
■Strip as little of the insulation as possible,
directly before the terminals. Bundle the
cables close to the corresponding terminals.
■If 2 components are connected to the same
terminal, press both cores together in a single
wire ferrule.
■When connecting external switching contacts
and on-site components, observe the insula-
tion requirements of IEC/EN 60335-1.
Connecting external functions
Connecting external default set flow temperature: 0 - 10 V IN
Analogue input for connecting the external default set
flow temperature or the external default output
Installation sequence
Overview of electrical connections (cont.)
6131087
Installation

9
hH [{] fÖ
1212?
1??
fD
+-+-
U
+AB
Fig. 3
AEnable signal
BJunction box
When making the connection, ensure correct polarity
of the DC control voltage 0 - 10 V.
Note
No galvanic separation is required between the earth
conductor and the negative pole of the on-site power
source.
The 0 to 10 V hook-up generates the following set flow
temperatures:
< 1 V No default set flow temperature
1 V ≙ 10 °C
10 V ≙ 100 °C or max. set flow temperature in
accordance with factory-set limit for heat gener-
ator
If 230 V voltage is present at digital input 43-1, the
external default set flow temperature is enabled.
Connecting an external default output: 0 - 10 V IN
Analogue input for connecting the external default set
flow temperature or the external default output
hH [{] fÖ
1212?
1??
fD
+-+-
U
+AB
Fig. 4
AEnable signal
BJunction box
When making the connection, ensure correct polarity
of the DC control voltage 0 - 10 V.
Note
No galvanic separation is required between the earth
conductor and the negative pole of the on-site power
source.
The 0 to 10 V hook-up generates the following default
output for the heat generator:
< 1 V ≙ 0 %
1 V ≙ 10 % or lower modulation limit
10 V ≙ 100 %
If 230 V voltage is present at digital input 43-1, the
external default output is enabled.
Installation sequence
Connecting external functions (cont.)
6131087
Installation

10
Connecting the operating mode changeover: DI1 to DI3
jF jF [{][{][{]
DI1 DI2 DI3
1234123456
Fig. 5
■External contacts at DI1, DI2 and DI3 must be poten-
tial-free.
■When making the connection, adhere to the require-
ments of protection class II. That is 5.0 mm air and
creep paths and 2.0 mm insulation thickness against
'live' components.
Weather-compensated operation
As soon as the contact closes, the following demand
becomes active:
■Demand for all installed heating circuits simultane-
ously, with the respective programmed set room tem-
perature of the individual heating circuit:
DI1 Reduced room temperature
DI2 Standard room temperature
DI3 Comfort temperature
Continuous operation or room temperature-
dependent operation
As soon as the contact closes, the following demands
become active:
■Set flow temperature demand for the system
■Demand for all installed heating circuits simultane-
ously, at the respective programmed temperature
level of the individual heating circuit:
DI1 Reduced flow temperature
DI2 Standard flow temperature
DI3 Comfort flow temperature
(Only with continuous operation)
Connecting external demand: fD
? ?
fÖf-]
A
?
1
A B
fD
Fig. 6
ASignal for external demand or external blocking
BJunction box
The demand is active if 230 V voltage is present at dig-
ital input 43-1. A demand is issued to the heat genera-
tor.
The set values for the flow temperature and the speed
of the primary pump are specified with parameters
528.0 and 1100.2.
Installation sequence
Connecting external functions (cont.)
6131087
Installation

11
Connecting external blocking: fD
? ?
fÖf-]
A
?
1
A B
fD
Fig. 7
ASignal for external demand or external blocking
BJunction box
If 230 V voltage is present at digital input 43-1, the
heat generator is blocked.
The message I.57 is shown.
Connecting the fault message input and fault message output
Connection without system blocking via 230 V fault message input: fD
hH [{] fÖ
?
1??
fD
AB
?
N
L
Fig. 8
AFault message facility
BJunction box
■Fault message input 43-1 and conductor L of the
power supply at plug fÖ must be connected in
phase.
■Rated current at floating fault message output hH:
Max. 1 A ~.
The fault message is active if 230 V voltage is present
at digital input 43-1. Floating fault message output hH
is switched over from "Ö" to "S".
Installation sequence
Connecting external functions (cont.)
6131087
Installation

12
Connection with system blocking via 230 V fault message input: fD
hH [{] fÖ
?
1??
fD
AB
?
N
L
Fig. 9
AFault message facility
BJunction box
■Fault message input 43-1 and conductor L of the
power supply at plug fÖ must be connected in
phase.
■Rated current at floating fault message output hH:
Max. 1 A ~.
The fault message is active if 230 V voltage is present
at digital input 43-1. The heat generator is blocked.
Floating fault message output hH is switched over from
"Ö" to "S". Fault message F.104 is shown.
Connection with system blocking via 24 V fault message input: DI1
Example: Connecting a condensate removal pump
[{][{][{] hH
123456121212
+-+-
?
N
L
Fig. 10
Installation sequence
Connecting the fault message input and fault… (cont.)
6131087
Installation

13
■External contacts at DI1 must be potential-free.
When making the connection, adhere to the require-
ments of protection class II. That is 5.0 mm air and
creep paths and 2.0 mm insulation thickness against
'live' components.
■Rated current at fault message output hH:
Max. 1 A ~.
The fault messaging is active if the digital fault mes-
sage input DI1 is closed. The heat generator is
blocked.
Floating fault message output hH is switched over from
"Ö" to "S". Fault message F.104 is shown.
Connecting only message facility: hH
Example: Buzzer with illuminated signal switched in
parallel
? ?
fÖf-]
A
hH
?
1
?
N
L
fD
Fig. 11
Connecting the external LPG valve: fD
[{] fÖ
?
1??
fD
M
1~
Fig. 12
Output 43-L is active as soon as the burner control unit
starts the burner. The external LPG valve opens.
Connecting the external extractor interlock: hH
Example: Extractor hood
? ?
fÖf-]
A
hH
?
1
?
N
L
1~
M
fD
Fig. 13
Installation sequence
Connecting the fault message input and fault… (cont.)
6131087
Installation

14
The floating contact switches from "Ö" to "S" as soon
as the burner control unit starts the burner. The extrac-
tor is switched off.
Connecting the PlusBus to the heat generator
B
74
1 2
A
jF jF
1234
Fig. 14
AExtension (electronics module)
BPlusBus to heat generator
Note
If making the connection to the heat generator with an
external plug for the bus connection, disconnect plug
jF and connect the wires directly.
Heat generator installation and service instruc-
tions
Power supply
Power supply at heat generator
L?NL
?
N
156
LN
A
Fig. 15
AExtension (electronics module)
fÖ Power supply
fÖAPower supply for further accessories
aBH Plug for heat generator accessories power supply
Create the power supply connection.
Route the power cable to the heat generator. Connect
to plug aBH. Observe fuse protection at output, plug
aBH of the heat generator.
If the power supply connection is made to another
accessory, use plug fÖA provided.
Heat generator installation and service instruc-
tions
Danger
Incorrect core assignment can result in serious
injury and damage to the appliance.
Never interchange cores "L" and "N".
Power supply for several accessories
Several EM-EA1 function extensions (DIO electronics
module) or other accessories can be connected to the
heat generator.
Heat generator installation and service instruc-
tions
Separate power supply
If the power supply for the extension is not made at
the heat generator.
Installation sequence
Connecting the external extractor interlock: hH (cont.)
6131087
Installation

15
Danger
Incorrect electrical installations can lead to seri-
ous injury from electrical current and result in
appliance damage.
Connect the power supply and implement all
safety measures (e.g. RCD circuit) in accord-
ance with the following regulations:
■IEC 60364-4-41
■VDE regulations
■Connection conditions of the local grid opera-
tor
Danger
The absence of system component earthing can
lead to serious injury from electric current if an
electrical fault occurs.
The appliance and pipework must be connected
to the equipotential bonding of the building.
Isolators for non-earthed conductors
■The mains isolator (if installed) must simultaneously
isolate all non-earthed conductors from the mains
with a minimum contact separation of 3 mm.
■If no mains isolator is installed, all non-earthed con-
ductors must be isolated from the power supply by
the upstream circuit breaker with a minimum contact
separation of 3 mm.
L1
B
FE
D
D
N
C
[{] fÖ
??
A
Fig. 16
APower supply, extension (electronics module)
BPower supply for heat generator
CPower supply 1/N/PE, 230 V/50 Hz
DFuse (max. 16 A)
EMains isolator, 2-pole, on site
FJunction box (on site)
Installation sequence
Power supply (cont.)
6131087
Installation

16
Connect the power supply in accordance with the dia-
gram.
If the power supply to the appliance is connected with
a flexible cable, ensure that the live conductors are
pulled taut before the earth conductor in the event of
strain relief failure. The length of the earth conductor
wire will depend on the design.
Danger
Incorrect core assignment can result in serious
injury and damage to the appliance.
Never interchange cores "L" and "N".
!Please note
Incorrect phase sequence can cause damage to
the appliance.
Ensure phase equality with the heat generator
power supply.
Colour coding to IEC 60757
BN Brown
BU Blue
GNYE Green/yellow
Installation sequence
Power supply (cont.)
6131087
Installation

17
Fig. 17
Set rotary switch S1 to a consecutive numbers as
shown in the example below:
■1st EM-EA1 extension: Rotary switch to 1
■2nd EM-EA1 extension: Rotary switch to 2
■3rd EM-EA1 extension: Rotary switch to 3
Note
These settings are independent of the settings made
at other extensions, such as EM-MX (mixer). If an
EM-EA1 extension (DIO electronics module) has the
setting 1, an EM-MX, EM-M1 or EM-P1 extension
(ADIO electronics module) can also have the setting 1.
Configuring functions
Set the connected function during commissioning of
the heat generator.
Commissioning assistant
Heat generator installation and service instruc-
tions
Setting for the connected function in the commissioning assistant:
Function Setting
External functions
■External default set flow temperature "External set flow temperature 0 to 10 V"
■External default output "External default output 0 to 10 V"
■Operating mode changeover "Operating mode changeover"
■External demand "External demand"
■External blocking "External blocking"
Fault message input and fault message output
■Connection without system blocking "Fault message input 230 V and fault message out-
put"
■Connection with system blocking, 230 V "Fault message input 230 V and block system"
■Connection with system blocking, 24 V "Fault message input 24 V and block system"
■Connecting only message facility (e.g. buzzer) "Fault message output 230 V"
External LPG valve "LPG valve"
External extractor interlock "Cooker hood"
Commissioning and adjustment
Rotary switch S1 for subscriber number addressing
6131087
Commissioning

18
Fig. 18
DI1 Digital input 1
DI2 Digital input 2
DI3 Digital input 3
0 - 10 V IN Input 0 to 10 V
0 - 10 V OUT Output 0 to 10 V
F4 Fuse 2 A (slow)
PWM1 Control voltage output
S1 Rotary switch
Z1 fD 230 V relay output, 230 V input
fÖ Power supply
fÖAPower supply for additional accessories
hH Floating switching contact (changeover
contact) for connecting a fault message
facility or extractor hood
jF PlusBus
Connection and wiring diagram
Connection and wiring diagram
6131087
Appendix

19
Rated voltage 230 V∼
Rated frequency 50 Hz
Rated current 2 A
Power consumption – electronics 2.8 W
Power consumption 12 mA
Permissible ambient temperature
■Operation 0 to +40 °C
■Storage and transport –20 to +60 °C
Output for rated breaking capacity hH (floating) 1 A, 230 V~
Rated breaking capacity of output Z1 fD 1 A, 230 V~
Specification
Specification
6131087
Appendix

20
Viessmann products can be recycled. Components
and substances from the system are not part of ordi-
nary household waste.
For decommissioning the system, isolate the system
from the power supply and allow components to cool
down where appropriate.
All components must be disposed of correctly.
Disposal
Final decommissioning and disposal
6131087
Appendix