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 1/2020 Please keep safe.

2
Please follow these safety instruc-
tions 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 environmen-
tal pollution.
Note
Details identified by the word "Note"
contain additional information.
Target group
These instructions are exclusively inten-
ded for qualified 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 per-
son 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 regu-
lations
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 safe-
guard it against unintentional reopen-
ing.
■Isolate the system from the power sup-
ply, 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 recon-
nection.
■Wear suitable personal protective
equipment when carrying out any work.
Safety instructions
Safety instructions
6131087

3
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 pipe-
work.
!Please note
Electronic assemblies can be dam-
aged by electrostatic discharge.
Prior to commencing work, touch
earthed objects such as heating or
water pipes to discharge static
loads.
Repair work
!Please note
Repairing components that fulfil a
safety function 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 tested together with the
system can compromise its func-
tion. Installing non-authorised com-
ponents and making non-approved
modifications or conversions can
compromise safety and may invalid-
ate our warranty.
For replacements, use only original
spare parts supplied or approved by
Viessmann.
Safety instructions
Safety instructions (cont.)
6131087

4
Safety instructions for operating the system
If you smell gas
Danger
Escaping gas can lead to explo-
sions which may result in serious
injury.
■Do not smoke. Prevent naked
flames and sparks. Never switch
lights or electrical appliances 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 sup-
ply 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 spread-
ing.
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 condensate or other
external causes.
Ensure an adequate supply of combus-
tion air.
Inform system users that subsequent
modifications to the building characteris-
tics are not permissible (e.g. cable/pipe-
work routing, cladding or partitions).
Danger
Leaking or blocked flue systems, or
an inadequate supply of combus-
tion 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-seala-
ble.
Extractors
Operating appliances that exhaust air to
the outside (extractor hoods, extractors,
air conditioning units, etc.) can create
negative pressure. If the boiler is oper-
ated at the same time, this can lead to a
reverse flow of flue gas.
Safety instructions
Safety instructions (cont.)
6131087

5
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 suita-
ble steps to ensure an adequate
supply of combustion air.
Safety instructions
Safety instructions (cont.)
6131087

6
1. Information Disposal of packaging ............................................................................ 7
Symbols ................................................................................................. 7
Intended use .......................................................................................... 7
Product information ................................................................................ 8
■System examples ............................................................................... 8
■Spare parts lists .................................................................................. 8
2. Installation sequence Wall mounting ........................................................................................ 9
Overview of electrical connections ........................................................ 9
Electrical connections ............................................................................ 10
Connecting external functions ............................................................... 11
■Connecting external set flow temperature 0 to 10 V: 0 - 10 V IN ....... 11
■Connecting external set value for heat generator modulation 0 to
10 V: 0 - 10 V IN ................................................................................. 11
■Connecting the operating mode changeover: DI1 to DI3 ................... 12
■Connecting external heating circuit hook-up: ..................................... 12
■Connecting external demand: fD ....................................................... 13
■Connecting external blocking: fD ....................................................... 13
Connecting the fault message input and fault message output ............. 14
■Fault message input 230 V (without system blocking): fD ................. 14
■Fault message input 230 V and system blocking: fD ......................... 14
■Fault message input 24 V and system blocking: DI1 .......................... 15
■Connecting only message facility: hH ................................................. 15
Connecting an (external) LPG valve: fD ............................................... 16
Connecting an extractor hood (external extractor interlock): hH ............ 16
Connecting the PlusBus to the heat generator ...................................... 16
Power supply ......................................................................................... 17
■Power supply at heat generator .......................................................... 17
■Separate power supply ....................................................................... 17
Connecting several accessories ............................................................ 19
■Power supply and PlusBus connection .............................................. 19
3. Commissioning and
adjustment
Rotary switch S1 for subscriber number addressing ............................. 20
Configuring functions ............................................................................. 20
4. Connection and wiring dia-
gram
................................................................................................................ 21
5. Specification ................................................................................................................ 22
6. Disposal Final decommissioning and disposal ..................................................... 23
7. Declaration of Conformity Declaration of conformity ....................................................................... 24
Index
Index
6131087

7
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

8
Depending on the heat generator, a maximum of
3 EM-EA1 function extensions can be connected.
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 at
www.viessmann.com/etapp or in the Viessmann
spare part app.
Information
Product information
6131087
Information

9
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 to 10 V input
0 - 10 V OUT 0 to 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

10
Function Page Connections:
DI1 DI2 DI3 PWM1 0 - 10 V hH fD
IN OUT 43-1 43-L
External functions
■External set flow temperature
0 to 10 V
11 X X
■External set value for heat generator
modulation 0 to 10 V
11 X X
■Operating mode changeover 12 X X X
■External heating circuit hook-up 12 X X X
■External demand 13 X
■External blocking 13 X
Fault message input and fault mes-
sage output
■Fault message input 230 V (without
system blocking)
14 X X
■Fault message input 230 V and sys-
tem blocking
14 X X
■Fault message input 24 V and system
blocking
15 X X
■Connecting only message facility (e.g.
buzzer)
15 X
LPG valve (external) 16 X
Extractor hood (external extractor in-
terlock)
16 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.
Installation sequence
Overview of electrical connections (cont.)
6131087
Installation

11
Connecting external set flow temperature 0 to 10 V: 0 - 10 V IN
Analogue input for connecting the externally specified
set flow temperature
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 external set value for heat generator modulation 0 to 10 V: 0 - 10 V IN
Analogue input for connecting the external output
specification
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.
Installation sequence
Connecting external functions
6131087
Installation

12
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.
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
Contact open: Normal operation
Contact closed:
■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
Contact open: Normal operation according to set time
program
Contact closed:
■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 heating circuit hook-up:
Only in conjunction with weather-compensated opera-
tion.
External heating circuit hook-up is only possible on the
extension kit with rotary switch setting 1; see
page 20.
No additional parameter settings on the heat generator
are required.
jF jF [{][{][{]
DI1 DI2 DI3
1234123456
Fig. 6
Configuration of at least 2 heating circuits with the fol-
lowing mode of operation:
■Contact closed: External demand active. Heating cir-
cuit is supplied with heat.
■Contact open: External demand not active. Heating
circuit is not supplied with heat. Independent of the
current set room temperature or time program. There
is no frost protection for the heating circuit.
The following status messages are displayed on the
heat generator control unit:
–Heating circuit 1: S.94
–Heating circuit 2: S.95
–Heating circuit 3: S.96
Assignment:
DI1 Heating circuit 1
DI2 Heating circuit 2
DI3 Heating circuit 3
Installation sequence
Connecting external functions (cont.)
6131087
Installation

13
Connecting external demand: fD
? ?
fÖf-]
A
?
1
A B
fD
Fig. 7
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 at the control unit of
the heat generator with parameters 528.0 and 1100.2.
Message I.56 is displayed.
Connecting external blocking: fD
? ?
fÖf-]
A
?
1
A B
fD
Fig. 8
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.
Message I.57 is reported.
Installation sequence
Connecting external functions (cont.)
6131087
Installation

14
Fault message input 230 V (without system blocking): 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. Floating fault message output hH
is switched over from "Ö" to "S".
Fault message F.104 is displayed on the heat genera-
tor control unit.
Fault message input 230 V and system blocking: fD
hH [{] fÖ
?
1??
fD
AB
?
N
L
Fig. 10
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".
Installation sequence
Connecting the fault message input and fault message output
6131087
Installation

15
Fault message F.104 and message I.57 are displayed
on the control unit of the heat generator.
Fault message input 24 V and system blocking: DI1
Example: Connecting a condensate removal pump
[{][{][{] hH
123456121212
+-+-
?
N
L
Fig. 11
■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 and message I.57 are displayed
on the control unit of the heat generator.
Connecting only message facility: hH
Example: Buzzer with illuminated signal switched in
parallel
For this mode of operation, one of the fault message
functions must be selected on the control of the heat
generator, e.g. fault message input 24 V. See
page 20.
Heat generator installation and service instruc-
tions
? ?
fÖf-]
A
hH
?
1
?
N
L
fD
Fig. 12
Installation sequence
Connecting the fault message input and fault… (cont.)
6131087
Installation

16
[{] fÖ
?
1??
fD
M
1~
Fig. 13
Output 43-L is active as soon as the burner control unit
starts the burner. The external LPG valve opens.
Connecting an extractor hood (external extractor interlock): hH
Example: Extractor hood
? ?
fÖf-]
A
hH
?
1
?
N
L
1~
M
fD
Fig. 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. 15
AExtension (electronics module)
BPlusBus to heat generator
For connection to heat generators with external
plug, luster terminals or spring-loaded terminals:
For the bus connection, disconnect plug jF. Connect
the wires directly. The wires are interchangeable.
Heat generator installation and service instruc-
tions
Installation sequence
Connecting an (external) LPG valve: fD
6131087
Installation

17
Power supply at heat generator
L?NL
?
N
156
LN
A
Fig. 16 Example: Power supply with plug aBH
AExtension (electronics module)
fÖ Power supply
fÖAPower supply for further accessories
aBH Plug for heat generator accessories power supply
Connect the power cable to the extension.
Route the power cable to the heat generator and con-
nect to plug aBH. Observe the fuse protection of the
contact (output) on the heat generator.
If the power supply is connected 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".
If there is no plug aBH at the heat generator:
■Use a separate power supply. See the following
chapter.
Or
■Heat generator installation and service instruc-
tions
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
■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.
Installation sequence
Power supply
6131087
Installation

18
L1
B
FE
D
D
N
C
A
40
Fig. 17
APower supply for 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)
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

19
Power supply and PlusBus connection
Power supply to all accessories via heat generator control unit
74 74 40A 40 74 74 40A 40
B C
74 40 96/156
A
74 74 40A 40
D
E
Fig. 18
Some accessories with direct power supply
74 74 40A 40 74 74 40A 40
B C
74 40 96/156
A
74 74 40A 40
D
E
Fig. 19
AHeat generator control unit
BMixer extension kit for heating circuit with
mixer M2 (electronics module)
CMixer extension kit for heating circuit with
mixer M3 (electronics module)
DFurther accessories
EON/OFF switch
fÖ (A) Power supply
jF PlusBus
lH/aBH Power supply to accessories in the heat gen-
erator control unit
■In the following circumstances, use the contact (out-
put) of the accessories only to switch an on-site
relay:
An actuator with a higher power demand than the
fuse rating required for the accessories, e.g. a circu-
lation pump, is connected to the contact (output) of
the accessories.
■In the following circumstances, connect one or more
accessories directly to the mains supply via an
ON/OFF switch:
The max. permissible total current of the heat gener-
ator control unit is exceeded.
Note
In this event, the accessories concerned cannot be
isolated with the ON/OFF switch on the control unit.
Installation sequence
Connecting several accessories
6131087
Installation

20
Fig. 20
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
■External heating circuit hook-up is only possible on
the extension kit with rotary switch setting 1.
■These settings are independent of the settings made
at other extensions, such as EM-MX (mixer). If an
EM-EA1 extension is set to 1, an EM-MX, EM-M1 or
EM-P1 extension can also be set to 1.
Configuring functions
To configure the connected functions, carry out com-
missioning on the control unit of the heat generator.
Commissioning assistant
Heat generator installation and service instruc-
tions
Commissioning and adjustment
Rotary switch S1 for subscriber number addressing
6131087
Commissioning