Immergas ZEUS Superior Series User manual

Technical documentation Technical documentation
STZS ed 06/03
1
ZEUS SUPERIOR
ZEUS Superior
Manual service centrala termica
murala Immergas zeus superior cu
boiler
ZEUS 21 Superior
ZEUS 24 Superior
ZEUS 27 Superior
- GENERAL FEATURES
ZEUS Superior is a wall-hung room sealed fan-assisted boiler featuring a "Gaudium Magnum" device for
fully exploiting the characteristics of this 54 l boiler in AISI 316L stainless steel.
The appliance is regulated and controlled by means of a printed microprocessor control board which,
through a display, shows the state of boiler operation (temperature, safety devices, etc.) and enables it to
be connected (optional) to the Remote Friend Control, to the zones unit and to the Multisystem Water
Disconnector.(D.I.M.)
The range includes three electronic-ignition versions with heat outputs of 24.4 kW (21,000 kcal/h), 27.9
kW (24,000 kcal/h) and 31.4 kW (27,000 kcal/h).
The hydraulic circuit features a high-head copper water-gas exchanger, an electric 3-way valve, a 2 l
d.h.w. expansion vessel, an adjustable system by-pass and a device that permits to increase the
maximum available flow of the domestic hot water (Gaudium Magnum).
Combustion air flow into the sealed chamber and flue extraction are ensured by a fan, the correct
operation of which is controlled by a differential pressure switch.
- MAIN DIMENSIONS AND CONNECTIONS
DIMENSIONS (mm)
HEIGHT WIDTH DEPTH
ZEUS 21/24/27 900 600 450
ATTACCHI
GAS SYSTEM DOMESTIC
WATER
G R M U E
ZEUS 21/24/27 1/2 “ 3/4 “ 3/4 “ 1/2 “ 1/2 “
V - electric connection
G - gas supply
R - system return
M - system delivery
S - recirculation (optional )
U - domestic hot water outlet
E - domestic cold water inlet

Technical documentation Technical documentation
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ZEUS SUPERIOR
ZEUS 21-24 Superior MAIN COMPONENTS
1 - Intake points (A=air) (F=flue)
2 - Flue safety pressure switch
3 - Adjustment and limit NTC probe
4 - Primary heat exchanger
5 - Combustion chamber
6 - Burner
7 - Pump
8 - Gas valve
9 - Motorized 3-way valve
10 - System filling valve
11- Sealed room
12- Automatic air vent
13- Flue hood
14- Expansion vessel
15- Ignition and detection electrodes
16- Domestic hot water NTC probe
17- Overheating safety thermostat
18- 316L stainless steel storage tank
19- 3 bar safety valve (system)
20- Pump pressure switch
21- 8 bar safety valve (domestic hot water)
22- Gaudium Magnum device
23- Storage tank drain valve
24- Fan
25- Positive signal pressure point
26- Negative signal pressure point
27- System drain valve
28- Adjustable system by-pass
29- Domestic hot water expansion vessel
30- Max d.h.w. flow limit thermostat

Technical documentation Technical documentation
STZSC ed 06/03
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ZEUS SUPERIOR
ZEUS 27 Superior MAIN COMPONENTS
1 - Intake points (A=air) (F=flue)
2 - Flue safety pressure switch
3 - Adjustment and limit NTC probe
4 - Primary heat exchanger
5 - Combustion chamber
6 - Burner
7 - Pump
8 - Gas valve
9 - Motorised 3-way valve
10- System filling valve
11- Sealed room
12- Automatic air vent
13- Flue hood
14- Expansion vessel
15- Ignition and detection electrodes
16- Domestic hot water. NTC probe
17- Overheating safety thermostat
18- 316L stainless steel storage tank
19- 3 bar safety valve (system)
20- Pump pressure switch
21- 8 bar safety valve (d.h.w.)
22- Gaudium Magnum device
23- Storage tank drain valve
24- Fan
25- Positive signal pressure point
26- Negative signal pressure pointr
27- System drain valve
28- Adjustable system by-pass
29- Domestic hot water expansion vessel
30- Max d.h.w flow limit thermostat

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ZEUS SUPERIOR
CONTROL PANEL
1 - Green heating operating indicator
2 - Heating temperature selector
3 - Domestic hot water temperature selector
4 - Green domestic hot water operation indicator
5 - 0/SUMMER and CAR/WINTER switch
6 - Gaudium Magnum operation switch
7 - Green Gaudium Magnum operating indicator
8 - Storage tank thermometer
9 - Boiler pressure gauge
10- Reset
11- Temperatures and diagnostics display
12- Yellow burner operation indicator

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ZEUS SUPERIOR
HYDRAULIC CIRCUIT
1 - Storage tank drain valve
2 - One way valve
3 - Coil
4 - Gas valve
5 - Magnesium anode
6 - Storage tank
7 - Pump
8 - Burner
9 - Combustion chamber
10- Primary heat exchanger
11- Flue hood
12- Fan
13- Flue safety pressure switch
14- Sealed room
15- Adjustment and limit NTC probe
16- Automatic air vent
17- Expansion vessel
18- Overheating safety thermostat
19- Pump pressure switch
20- Pump pressure meter
21- Domestic hot water. NTC probe
22- System drain valve.
23- Motorised 3-way valve
24- System filling valve
25- Adjustable system by-pass
26- 3 bar safety valve
27- D.h.w. expansion vessel
28- 8 bar d.h.w. safety valve
29- Gaudium Magnum device
30- Cold water inlet filter
31- Max flow limit thermostat
G – Gas supply
U – Domestic hot water outlet
E – Domestic cold water inlet
R – System return
M – System delivery
The hot water for the heating system and for the domestic circuit is produced by a primary circuit
and a secondary (domestic) circuit that are activated according to demand.
PRIMARY CIRCUIT (BOILER CIRCUIT)
The primary circuit with the relative control and safety devices is activated with each heating or
domestic circuit demand for water.
- OPERATION
The copper blades of the water-gas exchanger (10) absorb the heat contained in the flue gas
produced by combustion.
Those blades then transfer the heat to the water being circulated inside by the boiler pump (7).
The water is introduced directly into the plant or can be deviated inside the cylinder coil (3).
This depends on the position of the electric 3-way valve (23) which, depending on the demand,
allows water to flow through the plant delivery (M) and return (R) pipes or deviates it to the coil (3).

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ZEUS SUPERIOR
- CIRCULATOR
This operates on the primary circuit return and is
located on the brass header assembly of the electric
three ways valve.
It is connected to the monobloc and exchanger by
means of threaded connecting pipes.
The pumps used differ according to boiler output (see
head - flow graph).
The body is equipped with a threaded fitting which
on the21 and 24 versions is used for the connection of
the expansion vessel and of the automatic vent valve,
while on the 27 version is used for the directly
connection of the automatic air vent.
.
21 and 24 versions 27 version
- FLOW HEAD GRAPH
The curve that represents the relation between the
flow rate and the available head depends on system
bypass adjustment which, depending on its position,
gives the system greater or less head.
The graphs are refereed to the pump operating at top
speed with:
- A = Bypass disconnected (screw fully tightened)
- B = Standard bypass adjustment (screw tightened
by 4.5 turns with respect to fully-tightened position)
- C = Bypass open (screw fully loose)
ZEUS 21 Superior
ZEUS 24 Superior ZEUS 27 Superior
- PRIMARY HEAT EXCHANGER
This is a water-gas blade type exchanger with copper pipes
and fins at the outlet of which an NTC heating probe (5) is
located.
The size differs according to boiler heat output.
The four pipes passing through the exchanger are connected
in parallel (1) two by two, to reduce flow resistance to the
utmost and provide a greater available head.
It is connected to the pump flow and to the primary circuit
flow by means of coupling pipes (2) with O.R. seal (4).
These are secured by means of special forks (3).

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- SAFETY DEVICES AND CONTROLS
System by-pass (6)
This ensures water circulation in the primary circuit
(between flow and return) even when this is prevented
by the high resistance of the system.
It is mounted on the delivery manifold and can be
adjusted by means of a screw accessible from the
bottom part of the valve plate.
System filling valve (5)
This valve is installed between the boiler circuit and the
domestic circuit cold water inlet is used to pressurize the
heating system.
Downstream of the cock, an one way valve is fitted (nr 2
of hydraulic circuit) that prevents accidental flow of
water from the primary circuit to the water network
(d.h.w. circuit).
Its seat is located in the lower part of the monobloc where
it is screwed on.
Pump pressure meter (2)
This detects the difference in pressure at pump
extremities.
Its housing is in the delivery manifold and is coupled to
a micro-switch (3) that prevents burner operation in the
event of pump blockage or no water in the boiler circuit.
Prevents primary exchanger overheating.
3-bar safety valve (4)
Prevents safety pressure (3 bar) being exceeded in the
circuit.
On the versions 21 and 24 is fitted to the rear part of the
delivery manifold group, while on the version 27 is
fastened in its front part by means of a socket head screw.
When this trips, water exits from the flow pipe.
Automatic air vent (7)
Automatically expels any gaseous substances in the
boiler circuit.
On the versions 21 and 24 , the valve is screwed on the water
side of the expansion vessel.
On the version 27 is mounted on the pump body.
Expansion vessel (8)
Compensates changes in volume following heating of water
and permits reducing pressure changes.
It has a pre-load pressure of 0.8 bar and a capacity of 8 l
on the versions 21-24 and 10 l on the version 27.
It is located in front of the storage tank .
21 and 24 versions
27 version
21-24versions 27 version

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HYDRAULIC CIRCUIT
SECONDARY CIRCUIT (D.H.W. CIRCUIT)
The domestic hot water circuit is engaged every time the water contained in the storage tank and
measured by means of the d.h.w. NTC sensor (4) has to be restored to the desired temperature.
This occurs when domestic hot water is used and to restore the losses due to thermal dispersion.
- OPERATION
Following a d.h.w. request, the modulation board starts the boiler pump (7) and powers the
motor of the electric 3-way valve (8).
The consequent movement of the valve to domestic hot water position (see 3-way electric valve
operation), closes the system return pipe (R) and, at the same time, opens the return pipe of the
storage tank coil (4).
This way, circulation is allowed in the coil (4) which, through its walls, enables the cold
domestic water to absorb the heat contained in the primary circuit water.
In this phase, the central heating function is disconnected as the production of d.h.w. has
priority.

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- STORAGE TANK
This AISI 316L STAINLESS STEEL storage tank has a useful capacity of 60 l.
It consists of an external sleeve enclosed at the bottom by a flange fixed by 12 screws.
A STAINLESS STEEL cylindrical pipe with a concentric spiral shape (coil) is inserted inside and is coiled
along all the height of the storage tank.
Heat is exchanged between the hot water in the primary circuit and the water contained in the cylinder
through the walls of the coil.
This keeps the water in the cylinder at a constant temperature and guarantees instant availability of domestic
hot water on demand (21.000, 24.000 e 27.000 kcal/h according to the versions).
If necessary, the coil can be removed from the storage tank after taking off the lower inspection flange.
The following devices ensure that it operates correctly and is maintained in good condition:
Anode (1)
It is inserted in the storage tank and protects it against the
action of galvanic currents.
It is screwed onto the external sleeve at the bottom of the
storage tank.
Polyphosphate metering unit (optional)
This prevents any limestone deposits from accumulating on
the walls of the coil.
The special kit is mounted on the domestic cold water circuit
inlet.
Gaudium Magnum (6)
(see description and operation Gaudium Magnum)
Recirculation kit (optional)
This is used to connect the pipes of any recirculation system
of the domestic hot water circuit.
It consists of a pipe that is inserted into the tank after having
removed the anode with relative plug.
When the kit is installed, the anode must be screwed to the end
of the pipe.
Domestic hot water NTC sensor (NB) (9)
This allows the printed control board to detect the temperature
of the water contained in the storage tank.
It is attached to the external wall of the storage and inserted
inside an immersion trap.
Maximum flow d.h.w limit temperature thermostat (3)
It is a clicson thermostat which supplies the solenoid valve of
the Gaudium Magnum device.
It is fitted on the external wall of the storage tank.
Safety valve unit (13)
This unit is located in the lower part of the cylinder near the
domestic circuit cold water inlet.
In addition to an 8-bar valve (10) that prevents the safety
pressure from being exceeded inside the storage, it also
includes:
- a filter, a cylinder drain valve with hose fitting (12) and a
one-way valve (“5” domestic circuit) to prevent a pressure
increase following heating of the domestic circuit hot water
from causing water to return toward the water mains.
Domestic hot water circuit expansion vessel (11)
It compensates for volume variations following heating of the
water contained in the cylinder.
It is connected to the safety valve unit and has a capacity of 2 l
at a pre-load pressure of 3.5 bar.

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- GAUDIUM MAGNUM (6)
This device is fitted between the cold
water inlet (inlet) and the safety valve
group (outlet).
Inside it works an electrovalve that in
stand-by condition allows the water
passage through a flow limiter (1) (10
l/min for versions 21 and 27, 12 l/min for
version 24)
When the electrovalve (3) is supplied the
water flows trough a supplementary
passage through a 6 l/min flow limiter (2)
- Operation
The valve is electrically enabled (230 VAC) setting the switch “Gaudium Magnum”, located on
the control panel, on position .
It starts to work when the limit thermostat of max flow (3), fitted on the storage tank, detects a
temperature upper 50 °C.
When the temperature gets down under 41 °C, the limit thermostat of max flow (3)
automatically deactivates the valve (3).
When the storage tank temperature is high, this system permits to have an high domestic hot
water flow rate.
Instead when the temperature gets down, the hot water flow rate is limited in order to restore
rapidly the hot water temperature.
Re-setting Gaudium Magnum switch on “0” position, the valve (3) is always deactivates.
N.B.: in order to activate the “Gaudium Magnum” operation, the adjustment knob of domestic hot water
temperature must be adjusted from 6 to 9.
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