Installation Sheets Manual 121 Energy Conservation and Miscellaneous Kits Section Q Technical Bulletin Q35 Issue Date 0999 Q35 Series Automatic Vent Damper System Figure 1: Q35 Automatic Vent Damper System Application The Q35 energy-saving, high-efficiency, automatic vent damper system retains heat that is normally wasted through the open flue when the appliance is not firing. The Q35 consists of a Y15 damper, M35 actuator, and Y84 wiring harness. The damper section is available in sizes from 102 mm (4 in.) through 305 mm (12 in.) nominal duct diameter. The Q35 damper system can be used with boilers, furnaces, and other gas-fired appliances. Models are available for standing pilot or electronic ignition systems. IMPORTANT: In standing pilot applications, a stack assembly model with a vent hole in the damper blade must be used. 1999 Johnson Controls, Inc. 1 Part No. 24-8711-463, Rev. www.johnsoncontrols.com Code No. LIT-121505
The Y84 wiring harness is used to connect the M35 actuator to the appliance. The Y84 electrically interlocks the damper system to the appliance. Unplugging either end results in a system shutdown. In addition, the Y84 incorporates a circuit that blows a special fuse found in most electronic ignition controls. This is designed to prevent system operation if a bypass plug, supplied with the ignition control, is later used in place of a damper.! CAUTION: This product must be used only in conjunction with redundant gas valves (main burner flow must pass through both valve seats), and must not be used with valves that can be manually opened. Table 1: Specifications Product Voltage Q35 Automatic Vent Damper 24 VAC, 50/60 Hz Nominal Duct Diameter D o (Effectiveness) mm in. Intermittent Ignition Standing Pilot Available 102 4.00 0.006 0.065 Sizes 127 5.00 0.004 0.041 152 6.00 0.002 0.028 178 7.00 0.002 0.021 203 8.00 0.002 0.017 230 9.00 0.069 0.081 255 10.00 0.070 0.079 305 12.00 0.085 0.092 Material Stack/Blade: 430 Stainless Steel Cover/Case: Galvanized Steel Maximum Actuator: 66 C (150 F) Operating Temperature Stack: 274 C (525 F) Y84 Wiring Harness Termination Agency Listing Specification Standards Actuator End: Appliance End: Board Edge Connection (Standard) Molex Receptacle (Optional) Molex Plug (Standard) Bare or Terminals (Optional) Q35 components Y15 and M35 IAS (AGA/CGA) Certificate Number C2154004 ANSI Standard Z21.66 CGA 6.14 The performance specifications are nominal and conform to acceptable industry standards. For application at conditions beyond these specifications, consult the local Johnson Controls office. Johnson Controls, Inc. shall not be liable for damages resulting from misapplication or misuse of its products. Refer to the Q35 Series Product Bulletin (LIT-4350750) for necessary information on operating and performance specification of this product. 2 Q35 Series Automatic Vent Damper System Technical Bulletin
Operation The damper actuator opens and closes the damper blade upon heat demand from the system thermostat. Damper must be in the open position when appliance main burner(s) is operating. A damper blade position indicator and a green light are visible on the front of the actuator (see Figure 2). The light signifies that power from the thermostat has opened the damper and that power is available to the appliance for main burner ignition. AUTOMATIC DAMPER M35BA-1 INPUT 24V 50/60 Hz OPERATING CURRENT: 0.2A CONTACT RATING: 2A STEADY 5A INRUSH POSITION INDICATOR OPEN ROTATION CLOSED INDICATOR LIGHT "ON" - DAMPER OPEN Figure 2: Label Diagnostic Indicators Sequence of Operation The Q35 operates as follows: 1. The damper is in the closed position. 2. The thermostat contacts close on a call for heat. 3. The M35 actuator rotates the damper blade to the open position. Power is available for main burner ignition (green light is on). 4. The system thermostat reaches setpoint and contacts open. 5. The burner circuit is de-energized and the M35 closes the damper. 6. The system is now ready for the next heating cycle. Q35 Series Automatic Vent Damper System Technical Bulletin 3
Installation IMPORTANT: This technical bulletin is intended as a guide for authorized service personnel installing or servicing Johnson Controls products. Carefully follow all instructions in this sheet and all instructions on the appliance. Limit repairs, adjustments, and servicing to the operations listed in this sheet or on the appliance.! WARNING: Fire or Explosion. The system must meet all applicable codes. Improper installation may cause gas leaks, explosions, property damage, and injuries.! WARNING: Shock Hazard. Avoid electrical shock and equipment damage. Disconnect electrical power and turn off the gas before installing the vent damper. All installations must comply with local codes or, in the absence of local codes, with the National Fuel Gas Code, ANSI Z223.1, and the National Electrical Code, ANSI/NFPA 70. 4 Q35 Series Automatic Vent Damper System Technical Bulletin
Mounting! WARNING: Asphyxiation Hazard. Do not install the stainless steel plug in the damper blade hole or use a model without a hole on standing pilot applications. Mount the damper as close to the draft hood outlet as possible. Vertical mounting of the damper stack section is preferred. If a diagonal or horizontal installation is the only option, mount the damper so that the actuator is not more than 30 above or below the horizontal (see Figure 3). This will protect the actuator from overheating if mounted above the horizontal, and from dripping condensate if mounted below the horizontal. Normal Position 30º Maximum 30º Maximum Optional Position Permitted Figure 3: Typical Mounting Positions! WARNING: Asphyxiation Hazard. If more than one appliance is served by a common vent, the damper must be installed only in the branch of the appliance to which it is wired. Mount the damper as follows: 1. Shut off power to the appliance. 2. Turn off gas at the manual shutoff valve adjacent to the appliance. 3. Install the damper assembly in the vent pipe with the flow arrow pointed away from the appliance. The damper assembly must be installed downstream of the appliance draft hood, as close to the hood as practicable, and without modification of the draft hood. If the hood is oval, an adapter section of pipe must be used. Secure with sheet metal screws. Ensure that the damper assembly is mounted at least 152 mm (6 in.) from combustible materials. Q35 Series Automatic Vent Damper System Technical Bulletin 5
Wiring The M35 actuator is powered with 24V, 50/60 Hz supplied through the wiring harness. Install the wiring harness between the actuator and the appliance s ignition circuit in accordance with the appliance manufacturer s instruction. In the absence of specific instructions, use the following procedure. Figure 4 illustrates a typical connection diagram. Note: If the wiring connection is inconvenient with the damper mounted, the actuator can be rotated 180. Remove the actuator cover and remove the two mounting screws holding it to the damper. Rotate the actuator 180 and refasten it to the damper. Pilot Burner Assembly Flame Sensor Q35 Vent Damper System BVSS Connector Spill Switch Main Burner Ground Pilot Gas Supply M35 Actuator AUTOMATIC DAMPER M35BA-1 INPUT 24V 50/60 Hz OPERATING CURRENT: 0.2A CONTACT RATING: 2A STEADY 5A INRUSH POSITION INDICATOR OPEN ROTATION CLOSED INDICATOR LIGHT "ON" - DAMPER OPEN Edge Connector GROUND PLUG 5 24 V LED THS 2 PV 1 MV 3 SENSE 4 G770, G775, G776 Ignition Control P.V. M.V. 1 2 1 Pilot Valve 2 Main Valve Thermostat Limits in Thermostat Line Only Y84 Wiring harness Transformer Power Supply Figure 4: Typical System Connection 6 Q35 Series Automatic Vent Damper System Technical Bulletin
1. Route the wiring harness inside the appliance jacket when possible. Use conduit openings or provide holes. Use clamps or bushings to protect wiring from sharp edges. Where wiring runs outside the jacket, secure it to the surface with cable clamps. Plug the end of the wiring harness securely into the M35 actuator connector. Slide the U-shaped strain relief bracket to the actuator and clip it into the slots in the end of the case. Note that the round edges of the bracket face the back of the actuator (see Figure 5). Figure 5: U-shaped Strain Relief Bracket Connection 2. Connect the appliance end of the wiring harness to the appropriate mating receptacle or terminals as specified by the appliance manufacturer. 3. Neatly stow excess wiring inside the appliance jacket, away from open flame, hot surfaces, and high voltage spark cables. 4. If the actuator is intended for direct interface with a Blocked Vent Shutoff System (BVSS), make sure the connection is secure and the wires are not in contact with hot surfaces. 5. Carefully check the entire installation to ensure it is in compliance with instructions and codes. Q35 Series Automatic Vent Damper System Technical Bulletin 7
Checkout Procedure A qualified service agency should conduct an annual inspection of the flue product carrying areas, the vent system, and the damper device for deterioration from corrosion, and for safe operation by performing the Checkout Procedure in these instructions. More frequent inspections by the home owner for corrosion and safe operation of the damper device in accordance with the checkout procedure are recommended. 1. Turn on the electrical power and gas supply to the appliance. 2. Turn the system thermostat to a high setting (call for heat). 3. Observe that the damper rotates open and that the ignition circuit is energized only after the damper is fully open, as shown by the position indicator and green light on the actuator. 4. If the actuator is directly interfaced with a BVSS, unplug the BVSS cable momentarily to ensure that the ignition circuit becomes de-energized. 5. Turn the thermostat to a low setting. The ignition circuit should immediately de-energize (the green light goes off), and the damper should rotate and stop in the closed position. 6. Return the thermostat to its normal setting. Adjust the thermostat s heat anticipator if necessary (see Figure 6). 7. Before leaving the installation, observe at least three complete operating cycles. 8 Q35 Series Automatic Vent Damper System Technical Bulletin
Thermostat Heat Anticipator The anticipator setting is normally equal to the ignition system current draw, plus that of the pilot and main valve. Due to variations in wiring and valve options, it is advisable to measure the actual current draw of the heating system at the thermostat location. Measuring this current can be accomplished by opening the thermostat contacts (lowering the setpoint) and installing an AC ammeter across the terminal, or by using a clamp-on ammeter with a 10-turn multiplier attached to the terminals (see Figure 6). To Heating System W R AC Ammeter Low Scale Setting To Heating System W R Ten Turns Clamp-on Ammeter (Divide reading by ten.) Figure 6: Measuring the Thermostat Current Q35 Series Automatic Vent Damper System Technical Bulletin 9
Emergency Operation If the ignition circuit is not operating when the system thermostat is calling for heat and the damper is open with the green light on, check the following. BVSS appliance ignition circuit (valves, pilot, ignition control, etc.) If the damper is not in the open position (with the green light on) when the system thermostat is calling for heat, verify that the transformer, thermostat, limits, and Y84 wiring harness are not the problem. If it appears that the actuator has failed and a replacement is not readily available, the appliance may temporarily be returned to service by manually turning the damper to the open position. To manually open the damper: 1. Turn off the electrical power to the appliance at the disconnect switch. 2. Remove the M35 actuator cover. 3. Remove the motor wire from Terminal A and reconnect it to Terminal B (see Figure 7). This disables the motor. Remove wire from here. Place it here. Figure 7: Moving Motor Lead Wire 4. Turn on the power at the disconnect switch and turn the system thermostat to a high setting. 10 Q35 Series Automatic Vent Damper System Technical Bulletin
! CAUTION: Equipment Damage. Forcing the shaft in the wrong direction could damage the switches and cause unsafe operation. 5. Locate the section of flat shaft between the actuator and the damper. Using a small wrench or pliers, gently turn the shaft only in the direction indicated by the rotational arrows (as shown on the actuator cover) until the green light comes on (see Figure 8). Figure 8: Manual Rotation 6. Replace the actuator cover and return the system thermostat to its normal setting. The damper will now remain in the open position and supply power to the ignition circuit on demand of the system thermostat; however, the damper will not provide energy savings until a replacement actuator is obtained. Q35 Series Automatic Vent Damper System Technical Bulletin 11
Accessories Repairs and Replacement Johnson Controls offers a complete line of G750 Hot Surface Ignition, G76x Direct Spark Ignition, and G77x Intermittent Pilot Ignition controls that are compatible with the Q35 vent damper system. G Series redundant gas valves, J Series pilot burners, and Y75 sensing probes are also available. Consult Johnson Controls for more information. The Q35 vent dampers are not field repairable, other than the emergency operation procedure. Do not attempt field repairs. For a replacement M35 actuator or any of the products listed in the Accessories section, contact the original equipment manufacturer or the nearest Johnson Controls distributor. Controls Group www.johnsoncontrols.com 507 E. Michigan Street FAN 121 P.O. Box 423 Installation Sheets Manual Milwaukee, WI 53201 Printed in U.S.A. 12 Q35 Series Automatic Vent Damper System Technical Bulletin