Installation Sheets Manual
Energy Conservation and Misc. Kits Section
Technical Bulletin
Issue Date
121
Q
Q135
0300
Q135 Automatic Flue Damper System
Figure 1: Q135 Automatic Flue Damper System
Application
This energy-saving, high-efficiency, automatic flue damper system retains
heat that is normally wasted through the open flue when the appliance is
not firing. It consists of a Y15 damper and an M35 actuator.
The system is for use with certified gas fired appliances. It can be used
with both standing pilot and electronic ignition systems.
A wiring harness electrically interlocks the damper system to the
appliance. Unplugging either end results in a system shut down.
The output of the Q135 is safety relevant and must be supervised by the
appliance throughout main burner operation. A position check during
burner startup is not sufficient.
IMPORTANT:
© 2000 Johnson Controls, Inc.
Part No. 24-8143-529, Rev. B
Code No. LIT-121530
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.
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Table 1: Specifications
Product
Q135 Automatic Flue Damper
Voltage
24 VAC, 50/60 Hz
Operating Current
0.2 Ampere
Output Contact
Rating
5 Amperes Inrush
2 Amperes Steady
Available Sizes
127 mm (5 in.) through 254 mm (10 in.) diameter
Stack Material
Cover/Case
Stainless Steel
Galvanized Steel
Operating
Temperature Range
Actuator:
Stack:
0 to 65°C (32 to 150°F)
0 to 385°C (32 to 725°F)
Y184 Terminations
Actuator End:
Appliance End:
Molex Receptacle
Molex Plug (Standard)
Bare or Terminals (Optional)
Open Position
Standard:
± 3° From Full Open
Agency Listing
Approved as part of the appliance.
Specification
Standards
ANSI Standard Z21.10.3
prA2, EN 89
Enclosure Degree of
Protection
IP10
IMPORTANT: For applications that require EN certification, the damper
flow characteristics test per prA2, EN 89 must be
conducted as part of the approval testing of the
application appliance.
IMPORTANT: For applications that require EN certification, the 24V
transformer must be a safety insulating transformer tested
to EN60742 or equivalent, and it must be installed and
protected according to the manufacturer’s specifications.
IMPORTANT: The output of the Q135 is safety relevant and must be
supervised by the appliance throughout main burner
operation. A position check during burner startup is not
sufficient.
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 Q135 Series Product Bulletin (LIT-4350760) for necessary information on operating and
performance specifications of this product.
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Q—Q135 Automatic Flue Damper System Technical Bulletin
Operation
The damper actuator opens and closes the damper blade upon demand of
the system thermostat.
The damper must be in the open position before the main burner circuit is
energized. It will remain open while the main burner is operating.
Visible on the front label of the actuator are a damper blade position
indicator and a green light. The light signifies that power from the
thermostat has opened the damper and that power is available to the
appliance for main burner ignition. See Figure 2.
Figure 2: Diagnostic Indicators
The blade and the actuator are designed to rotate in only one direction and
must not be turned manually except as described in the Emergency
Operation Procedure section.
The direction of rotation is clearly marked on the flue duct and the
actuator. Any attempt to turn the blade in the opposite direction will cause
damage to the unit and possible unsafe operation.
!
CAUTION: Equipment Damage Hazard. Forcing the shaft in the
wrong direction will damage the switches and cause
unsafe operation.
Q—Q135 Automatic Flue Damper System Technical Bulletin
3
Sequence of
Operation
The Q135 operates in the following manner:
1.
Damper is in the closed position.
2.
Thermostat contacts close on a call for heat.
3.
M35 actuator rotates the damper blade to the open position. Power is
available for main burner ignition (green light is on).
4.
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.
Installation
!
WARNING: Shock Hazard. Avoid electrical shock and
equipment damage. Disconnect electrical power and
turn off gas before wiring control into circuit.
All installations must comply with local codes or, in the absence of local
codes, with the National Fuel Gas Code (ANSI Z223.1) and National
Electrical Code (ANSI/NFPA 70), or European National standards.
Mounting
!
WARNING: Asphyxiation Hazard. Do not install the stainless
steel plug in the damper blade hole or use a model
without a hole on a standing pilot application.
This instruction sheet is intended as a guide for qualified personnel
installing or servicing Johnson Controls Q135 flue damper. To mount
the Q135:
1.
Install the damper assembly vertically on the flue collar with the flow
arrow pointed away from the appliance (see Figure 3). Secure
according to the manufacturer’s recommendations.
The damper assembly must be installed upstream of the appliance
draft hood.
2.
Mount the damper assembly with clearance not less than 6 inches
from combustible materials.
Install vertically on the
flue collar with the
flow arrow pointed
away from the appliance.
Figure 3: Mounting Position
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Q—Q135 Automatic Flue Damper System Technical Bulletin
Wiring
!
WARNING: Asphyxiation Hazard. Do not negate the action of
any existing safety or operational control.
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 ignition circuit in accordance with the appliance manufacturer’s
instructions.
Carefully check the entire installation to be sure it is in compliance with
instructions and codes.
Note: For applications that require EN certification, the 24V transformer
must be a safety insulating transformer tested to EN60742 or
equivalent, and it must be installed and protected according to the
manufacturer’s specifications.
Connection
Diagram
Figure 4 illustrates the general connection diagram of the Q135 system and
the connections of the Q135 actuator.
Note: The Q135 provides power to the output when the damper is in the
open position.
Common
24 VAC
Output
Thermostat
Fuse*
24 VAC
Com
Thermostat
Q135
Ignition
Control
Y184 Wiring Harness
Gas
Valve
* The fuse electrical rating should be determined by the
application requirements to provide proper protection.
Figure 4: Connection Diagram
Q—Q135 Automatic Flue Damper System Technical Bulletin
5
Checkout
Procedure
Repairs and
Replacement
Turn on the electrical power and gas supply to the appliance.
Before leaving the installation, observe three complete operating cycles as
follows:
1.
Turn the system thermostat to a high setting (call for heat).
2.
Observe that the damper rotates open and that the ignition circuit is
fully energized only after the damper is fully open, as shown by the
position indicator and the green light on the actuator.
3.
Turn the thermostat to a low setting. The ignition circuit should be
immediately de-energized (the green light goes off), and the damper
should rotate and stop in the closed position.
4.
Return the thermostat to the normal setting.
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
appliance ignition circuit (valves, pilot, electronic ignition, 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 wiring harness are not the problem. If it appears
that the actuator has failed and a replacement Q135 is not readily
available, the appliance may temporarily be returned to service by using
the Emergency Operation Procedure detailed below.
Emergency
Operation
Procedure
6
To temporarily return the appliance to service after an actuator failure,
follow these steps:
1.
Move the manual switch, located on the side of the actuator to the On
position.
2.
If the green light illuminates, the appliance is operational.
3.
If the green light does not illuminate, it will be necessary to manually
rotate the damper blade to the open position; refer to the Manual
Opening section.
Q—Q135 Automatic Flue Damper System Technical Bulletin
Manual Opening
!
CAUTION:
Equipment Damage Hazard. Forcing the shaft in
the wrong direction will damage the switches and
cause unsafe operation.
To manually open the damper blade, use a small wrench or pliers placed
on the square indicator protruding through the cover of the actuator
(see Figure 5).
Slowly and gently turn the square indicator, only in the direction
indicated by the rotational arrows on the cover of the actuator, until the
green light comes on.
If the light comes on and goes off, this indicates you have turned the blade
too far. Do not reverse the direction of rotation but continue rotating the
blade another 180 degrees. Repeat this procedure until the light remains
on.
Figure 5: Manual Rotation
The flue damper will now remain in the open position and supply power to
the ignition circuit on demand of the system thermostat. However, the flue
damper will not provide energy savings until a replacement Q135 is
obtained from the original equipment manufacturer.
Field repairs, other than the procedure above, must not be made.
Q—Q135 Automatic Flue Damper System Technical Bulletin
7
Notes
Controls Group
507 E. Michigan Street
P.O. Box 423
Milwaukee, WI 53201
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Q—Q135 Automatic Flue Damper System Technical Bulletin
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Installation Sheets Manual
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