Viessmann EA1 Extension Module Installation Instructions

EA1 Extension Module

This document provides installation instructions for the EA1 Extension Module, designed for programmable inputs and outputs.

Important: Read and save these instructions for future reference. Product may not be exactly as shown.

Certified as a component part for Viessmann boilers.

Safety, Installation and Warranty Requirements

Please ensure these instructions are read and understood before commencing installation. Failure to comply with the instructions can cause product/property damage, severe personal injury, and/or loss of life.

Product Documentation

Read all applicable documentation before commencing installation. Store documentation near the boiler in an accessible location for reference by service personnel. Refer to the section "Important Regulatory and Safety Requirements" for a listing of applicable literature.

Licensed Professional Heating Contractor

The installation, adjustment, service, and maintenance of this equipment must be performed by a licensed professional heating contractor.

Advice to Owner

Upon completion of installation, the heating contractor must familiarize the system operator/owner with all equipment, safety precautions, shutdown procedures, and the need for annual professional service before the heating season begins.

Warranty

Information contained in this and related product documentation must be read and followed. Failure to do so renders the warranty null and void.

Important Precautions

Important Regulatory and Installation Requirements

Approvals

Viessmann boilers, burners, and controls are approved for sale in North America by CSA International.

Codes

Installation must comply with local codes. In the absence of local codes, use CSA C22.1 Part 1 and/or local codes in Canada, and the National Electrical Code ANSI/NFPA 70 in the U.S. Always use the 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.

Working on the Equipment

Installation, adjustment, service, and maintenance must be performed by a licensed professional heating contractor. There are no user-serviceable parts.

Power Supply

Install power supply according to the authorities having jurisdiction or National Codes. Viessmann recommends a disconnect switch for the 120V power supply outside the boiler room. Ensure main power supply to the equipment and heating system is deactivated. Close main oil or gas supply valve. Take precautions to avoid accidental activation of power during service.

WARNING: Turn off electric power supply before servicing. Contact with live electric components can cause shock or loss of life.

Please carefully read this manual prior to installation. Any warranty is null and void if instructions are not followed.

For information on other Viessmann System Technology components, refer to their respective product documentation. Viessmann offers installation and service seminars; please inquire.

Verify the completeness and functionality of field-supplied electrical controls and components, including low water cut-offs, flow switches, staging controls, pumps, motorized valves, air vents, and thermostats.

General Information

About these Installation Instructions

Take note of all symbols and notations intended to draw attention to potential hazards or important product information.

WARNING: Indicates an imminently hazardous situation which, if not avoided, could result in death, serious injury, or substantial product/property damage.

CAUTION: Indicates an imminently hazardous situation which, if not avoided, may result in minor injury or product/property damage.

IMPORTANT: Helpful hints for installation, operation, or maintenance.

[Info Symbol]: Indicates to note additional information.

[Reference Symbol]: Indicates that other instructions must be referenced.

Installation

Mounting the Extension Kit

Extension kit for installation on a wall:

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.

Components:

• EA1 extension module
• KM BUS plug 145
• Power cord pre-wired to plug 40
• Digital inputs DE1, DE2 and DE3 plugs
• 0-10VDC input plug
• Programmable output plug 157
• Accessory power plug 40 A

Connections

Overview of Electrical Connections

Legend:

• DE1: Digital input 1
• DE2: Digital input 2
• DE3: Digital input 3
• 0-10V: 0-10 V input
• 40: Power supply
• 40 A: Power supply for additional accessories
• 157: Programmable output
• 145: KM BUS to the control unit
• A: Extension EA1
• F1: Fuse

CAUTION: The electronic modules are static sensitive. To avoid damage caused by static discharge, follow Electro-Static Discharge safety procedures.

Note: Apply strain relief to all on-site cables. Close any unnecessary knock-outs with cable entries.

Connecting Digital Inputs

The following functions can be connected alternatively:

• External heating program changeover for each heating circuit
• External blocking
• External blocking with central fault message
• External demand with set flow temperature
• Central fault message
• Brief operation of the DHW circulation pump

The hooked-up contacts must correspond to protection class II.

Function assignment of inputs DE1 to DE3

Select the input functions by means of the codes on the boiler control unit. Refer to the service instructions for the boiler or control unit for a complete description of the coding addresses.

Subject to function and digital input selected, the following codes need to be changed at the boiler control unit:

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:

• Changeover via input DE1: Code d8:1
• Changeover via input DE2: Code d8:2
• Changeover via input DE3: Code d8:3
• Select the effect of the heating program changeover via code d5
• Set the duration of the changeover via code F2

Effect of the external blocking function on the pumps

• Select the effect on the internal boiler circulation pump (Vitotronic, type H...) with code 3E
• Select the effect on the respective heating circuit pump with code d6
• Select 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

• Select the effect on the internal boiler circulation pump (Vitotronic, type H...) with code 3F
• Select the effect on the respective heating circuit pump with code d7
• Select the effect on the circulation pump for DHW tank heating (Vitotronic, type H...) with code 5F

Set flow temperature for external demand

The set flow temperature can be selected with code 9b.

Runtime of the DHW recirculation pump

Set the runtime:

• Vitotronic, type H...: Code 3d
• Vitotronic, type G...: Code 12

Refer to the boiler Service Instructions.

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 [Arrow Symbol] set value 50°F (10°C)
• 10V [Arrow Symbol] 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 [Arrow Symbol] set value 86°F (30°C)
• 10V [Arrow Symbol] set value 248°F (120°C)

Connecting the KM BUS to the Boiler Control Unit

Legend:

• A: Extension EA1
• B: Connection area of boiler control unit

Refer to the boiler control unit installation and service instructions.

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

Connecting a Circulation Pump or a Fault Message Facility

The following components can be connected to plug 157:

• Pump speed reduction function
• DHW re-circulation pump
• Fault message facility

Rated voltage (max): 120V

Rated current (max): 2A

Function assignment

Select the function of output 157:

• Vitotronic, type H...: Code 36
• Vitotronic, 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.

Refer to the boiler Service Instructions.

If the relay of output 157 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.

Additional Information

Power Supply (continued)

Direct power supply

WARNING: Incorrectly executed electrical installations can result in injuries from electrical current and in equipment damage.

Connect the power supply and implement all grounding measures (e.g., RCD circuit) in accordance with the following regulations:

• In Canada, all electrical wiring must 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 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.
• Connection requirements specified by your local power supply utility.
• Protect the power cable with max. 15A.

WARNING: The absence of component grounding 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.

Isolators for non-grounded conductors:

• The mains isolator (if installed) must simultaneously isolate all non-grounded conductors from the mains with a minimum contact separation of 3 mm.
• If no mains isolator is installed, all non-grounded conductors must be isolated from the mains by the upstream circuit breaker with a minimum contact separation of 3 mm.

WARNING: Incorrect core allocation can result in serious injury and damage to the appliance. Never interchange cores “L” and “N”.

CAUTION: An incorrect phase sequence can cause damage to the appliance. Check for phase equality with the power supply connection of the control unit.

Legend:

• A: Extension EA1

Connection and Wiring Diagram

Legend:

• DE1: Digital input 1
• DE2: Digital input 2
• DE3: Digital input 3
• 0-10V: 0-10V input
• A: Extension EA1
• 40: Power supply
• 40 A: Power supply for additional accessories
• 157: Fault message facility/Feed pump/DHW circulation pump (floating)
• 145: KM BUS to the control unit

Specifications

• Rated voltage: 120 V~
• Rated frequency: 60 Hz
• Rated current: 2A
• Power consumption: 1.5W
• Protection class: I
• Permissible ambient temperature:
• During operation: 32 to 104°F (0 to 40°C)
• During storage and transport: -4 to +149°F (-20 to +65°C)
• Rated breaking capacity, floating output 157: 2A 120V~