Viessmann EM-S1 Quick guide

Installation and service instructions
for contractors
VIESMANN
Solar EM-S1 extension
ADIO electronics module
Function extension for connecting a solar thermal system
Solar EM-S1 extension
5837803 GB 12/2018 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
5837803

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.)
5837803

4
1. Information Disposal of packaging ............................................................................ 5
Symbols ................................................................................................. 5
Intended use .......................................................................................... 5
System examples .................................................................................. 6
2. Installation sequence Wall mounting ........................................................................................ 7
Overview of electrical connections ........................................................ 7
Rotary switch S1 .................................................................................... 8
Connecting the PlusBus to the heat generator ...................................... 8
Power supply ......................................................................................... 9
■Power supply at heat generator .......................................................... 9
■Separate power supply ....................................................................... 9
3. Commissioning Configuring the solar EM-S1 extension ................................................. 11
4. Troubleshooting Faults displayed with a fault code .......................................................... 12
Faults displayed without a fault code ..................................................... 12
Repairs .................................................................................................. 12
■Checking the solar circuit pump at output P1 ..................................... 12
■Checking the temperature sensors ..................................................... 13
5. Parts lists Parts list ................................................................................................. 15
6. Function description ................................................................................................................ 17
7. Specification Specification .......................................................................................... 19
Connection and wiring diagram ............................................................. 19
8. Declaration of Conformity Declaration of conformity ....................................................................... 20
9. Keyword index ................................................................................................................ 21
Index
Index
5837803

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 device serves to control heating systems with
solar DHW heating.
Commercial or industrial use for a purpose other than
heating the solar circuit shall be deemed inappropriate.
Intended use presupposes that a permanent installa-
tion in conjunction with permissible components
designed for this purpose has been carried out.
All other use is deemed inappropriate. Any resulting
losses are excluded from the manufacturer's liability.
Any usage beyond this must be approved by the man-
ufacturer in each individual case.
Intended use also includes adherence to maintenance
and inspection intervals.
Information
Disposal of packaging
5837803
Information

6
For available system examples, see www.viessmann-
schemes.com
Information
System examples
5837803
Information

7
2.
1.
Fig. 1
Overview of electrical connections
?
jF jF [{] [{] [{] [{] fÖ
M
1~
230 V~/50 Hz
? ?
sF
[{{]
&% ?
2
fH
M
1~
1
Fig. 2
Plug 230 V~
P1 sF Solar circuit pump
P3 fH Transfer pump
fÖ Power supply
fÖAPower supply for accessories
Extra low voltage connections
PWM1 Speed control, solar circuit pump
TS1 %Cylinder temperature sensor NTC 10 kΩ
TS2 &Collector temperature sensor NTC 20 kΩ
TS3 No function
jF PlusBus
!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.
Note
Apply strain relief to on-site cables.
Secure individual wires directly to each plug using
cable ties.
Seal any unnecessary apertures with cable grommets
(not cut open).
Installation sequence
Wall mounting
5837803
Installation

8
Fig. 3
Set rotary switch S1 to 0 (factory setting is 1).
Note
The rotary switch can be found on the PCB of the elec-
tronics module.
Connecting the PlusBus to the heat generator
B
74
1 2
A
jF jF
1234
Fig. 4
AExtension
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
Installation sequence
Rotary switch S1
5837803
Installation

9
Power supply at heat generator
L?NL
?
N
156
LN
A
Fig. 5
AExtension
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 and con-
nect to plug aBH. Observe fuse protection at output,
plug aBH of the heat generator.
If power is supplied to a further 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".
Separate power supply
If the power supply for the extension is not made at
the heat generator.
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
■TAR medium voltage VDE-AR-N-4110
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.
Installation sequence
Power supply
5837803
Installation

10
L1
B
FE
D
D
N
C
A
40
Fig. 6
APower supply for extension
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)
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.)
5837803
Installation

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The parameters for the solar EM-S1 extension are set
at the heat generator control unit.
Heat generator installation and service instruc-
tions
Commissioning
Configuring the solar EM-S1 extension
5837803
Commissioning

12
Fault codes
Heat generator installation and service instruc-
tions
Faults displayed without a fault code
Fault Cause Remedy
Solar yield too low Temperature sensors inter-
changed.
Check temperature sensor connections.
Air in the solar circuit Vent the solar circuit. Check flow rate.
Inadequate flow rate ■Check flow rate.
■Check connection of output sF (see
page 19).
■Check hydraulic connections.
■Ensure check valves are operating correctly.
Incorrect circulation Check the system characteristics.
Solar circuit pump not running
or runs constantly.
Temperature sensors inter-
changed.
Check temperature sensor connections.
Solar circuit pump faulty or in-
correctly connected
Check solar circuit pump connection (see
page 19).
Carry out an actuator test.
Solar control unit switched off Fuse F1 has responded. Check fuse F1. See page 19.
Disconnect consumers. Connect again in se-
quence. While doing so, observe the behaviour
of fuse F1.
Repairs
Check the function of the connected components by
means of an actuator test:
Heat generator installation and service instruc-
tions
Checking the solar circuit pump at output P1
Characteristics of the circulation pump (see also the
following chapter):
■Pump always off:
–High limit safety cut-out has responded. Reset the
high limit safety cut-out.
–Output P1 faulty
Replace extension.
–Solar circuit pump faulty
Replace solar circuit pump.
■Pump always on:
–PWM connection faulty
–Output P1 always live.
Replace extension.
Multi stage circulation pump
The multi stage circulation pump is switched on and off
via output P1.
Variable speed circulation pump with PWM control
Whenever a demand is present, a voltage of 230 V∼
must always be applied to output P1. The pump speed
is governed by means of a control signal via PWM
connection.
If the PWM connection is interrupted, the circulation
pump must be switched off. If the circulation pump
runs at maximum speed when the PWM connection is
interrupted, an incorrect circulation pump has been
installed.
Troubleshooting
Faults displayed with a fault code
5837803
Diagnosis

13
Checking the temperature sensors
jF jF [{] [{] [{] [{{]
&%
Fig. 7
1. Disconnect the plug from the relevant temperature
sensor and check the resistance.
2. Compare the sensor resistance with the curve (see
the following diagram).
3. In the event of severe deviation, replace the sen-
sor.
0.1
1
10
100
0 20 40 60 80 100 120 140
Temperature in °C
Resistance in kΩ
A
B
25
Fig. 8
ACollector temperature sensor & (sensor type:
NTC 20 kΩ)
BCylinder temperature sensor % (sensor type:
NTC 10 kΩ)
Troubleshooting
Repairs (cont.)
5837803
Diagnosis

14
Troubleshooting
Repairs (cont.)
5837803
Diagnosis

15
The following details are required when ordering
parts:
■Manufacturing information (see type plate)
■Position number of the individual part within the
assembly (from this parts list)
0001 0006
0013
0005000400030002
0015
0014
Fig. 9
Parts lists
Parts list
5837803
Components

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Pos. Part
0001 ADIO electronics module
0002 Collector temperature sensor NTC
0003 Temperature sensor NTC 10 kΩ
0004 Connecting cable 40
0005 PlusBus cable with plug 74
0006 ADIO/M2IO plug set
0013 Strain relief fittings
0014 Fuse, 2.0 A (slow) 250 V (10 pce)
0015 Installation and service instructions
Parts lists
Parts list (cont.)
5837803
Components

17
Solar DHW heating
Note
Set or alter the functions described below in the
parameters in the "Solar" group.
The solar circuit pump is switched on according to the
following criteria, resulting in the DHW being heated:
■The temperature differential between the cylinder
temperature and the collector temperature is greater
than the start temperature differential set in parame-
ter 1492.0.
■The minimum collector temperature set in parameter
1126.0 is exceeded.
The solar circuit pump is switched off if one of the fol-
lowing criteria is met:
■The temperature differential between the cylinder
temperature and the collector temperature is smaller
than the stop temperature differential set in parame-
ter 1492.1.
■The maximum cylinder temperature (set DHW tem-
perature) set in parameter 1125.0 is exceeded.
■The maximum collector temperature set in parameter
1126.1 is exceeded.
■The temperature set at the high limit safety cut-out (if
installed) is exceeded.
Suppression of DHW cylinder reheating by the boiler
Reheating is suppressed in 2 stages:
■Reheating of the DHW cylinder by the boiler is sup-
pressed as soon as the DHW cylinder is heated by
the collectors. For this, the set DHW temperature for
reheating by the boiler is reduced. Suppression
remains active for a certain time after the solar circuit
pump has stopped.
■When the collectors provide continuous heating
(> 2 h):
The DHW cylinder will only be heated by the boiler if
the third set DHW temperature is not achieved by the
solar thermal system.
The third set DHW temperature is specified by
parameter 1394.0 in the "Solar" group. This value
must be below the first set DHW temperature.
Maximum collector temperature
If the maximum collector temperature set in parameter
1126.1 is exceeded, the solar circuit pump is switched
off to protect the system components (emergency col-
lector shutdown).
The solar circuit pump will restart when the collector
temperature falls to 20 K below the set value.
Minimum collector temperature limit
The solar circuit pump is started when the minimum
collector temperature set in parameter 1126.0 is
exceeded.
Reduction of stagnation time
If there is an excess of solar energy, the speed of the
solar circuit pump is reduced before the maximum cyl-
inder temperature is reached (parameter 1125.0). This
causes an increase in the differential between collector
temperature and cylinder temperature. The heat trans-
fer to the DHW cylinder is reduced, which delays stag-
nation.
The temperature differential for reducing the stagna-
tion time can be adjusted in parameter 1505.
This function can only be implemented in systems with
a variable speed solar circuit pump.
Function description
Function description
5837803
Appendix

18
Collector frost protection
Viessmann collectors are filled with Viessmann heat
transfer medium. Consequently, this function does not
need to be enabled.
Only enable it if water is used as the heat transfer
medium.
To prevent damage to the collectors, the solar circuit
pump is switched on if the collector temperature falls
below +5 °C. The pump is switched off when +7 °C is
reached.
Note parameter 1127.0.
Relay kick
To prevent the pumps and valves from seizing up, they
are started for about 10 s every 24 h.
Function description
Function description (cont.)
5837803
Appendix

19
Rated voltage 230 V∼
Rated frequency 50 Hz
Rated current 2 A
Power consumption – electronics 1.5 W
Power consumption 7 mA
Permissible ambient temperature
■Operation 0 to +40 °C
■Storage and transport –20 to +65 °C
Rated relay output breaking capacity
■P1 (solar circuit pump) 1 A 230 V~
■P3 (transfer pump) 1 A 230 V~
Connection and wiring diagram
Fig. 10
Plug 230 V~
P1sF Solar circuit pump
P3 fH Transfer pump
fÖ Power supply
fÖAPower supply for accessories
Extra low voltage connections
PWM1 Speed control, solar circuit pump
TS1 %Cylinder temperature sensor NTC 10 kΩ
TS2 &Collector temperature sensor NTC 20 kΩ
TS3 No function
jF PlusBus
Specification
Specification
5837803
Appendix

20
Declaration of Conformity
We, Viessmann Werke GmbH & Co. KG, D-35107
Allendorf, declare as sole responsible body that the
named product complies with the European directives
and supplementary national requirements in terms of
its design and operational characteristics.
Conformity has been verified with the CE designation.
Using the serial number, the full Declaration of Con-
formity can be found on the following website:
www.viessmann.co.uk/eu-conformity
Declaration of Conformity
Declaration of conformity
5837803
Appendix