Redi Controls RuptureSeal RS-2 Troubleshooting guide

RuptureSeal™
Model
RS-2
Rupture Disk
Backup
Relief Valve.....
PatentNumbers5,577,389 & 5,644,930
.....forLowPressure Centrifugal Chillers
R-11 R-113 R-123
Manufactured inaccordance with
ASHRAE Guideline 3-1990 Sec. 4.6
Flow Tested per ASMEStandards
Redi Controls, Inc.
Installation Operation &Maintenance Manual
FileLiteratureNo. 1028-04

2
RevisedTechnicallyas of April 15, 1996
This Copywas Printed as of February 4, 2005
©1994 INDIANAPOLISSPECIALTY VALVE, INC., IND’PLS, IN
This product is marketed andsoldbyRediControls, Inc.,
under licensefrom Indianapolis SpecialtyValve, Inc.

3
Table of Contents
............................................................................................................................................Page
GENERALINFORMATION........................................................................................................4
Specifications.............................................................................................................................5
GeneralOverview.......................................................................................................................5
Installation Kit.............................................................................................................................6
Field Provided Items...................................................................................................................6
INSTALLATION .........................................................................................................................7
Figure 1. - Typical Installation.....................................................................................................8
Figure 2 - Hook-up to Vent Pipe.................................................................................................8
Figure 3 - Cutaway View ............................................................................................................9
Pressure Gauge and Auxiliary Alarm .........................................................................................9
SupplementalMounting Support ................................................................................................9
Double Check Pressure Equalizing Valve................................................................................10
Chillers utilizing R-123 (special piping instructions) .................................................................10
Leak Testing Procedure ...........................................................................................................10
MAINTENANCE .......................................................................................................................11
Following a Rupture .................................................................................................................11
Annual ......................................................................................................................................11
Servicing and Replacing O-Rings ............................................................................................12
Appendix“A”(Table fordetermining size of vessel RS-2 can be installed on) .........................13
Appendix“B”(Excerpt fromGuideline BSR/ASHRAE 15-1992R) ............................................14
Appendix“C”(Non-typical installations and theireffect on valve’s operation)..........................15
Parts List ..................................................................................................................................17
Warranty.................................................................................................................... Back Page

4
GENERALINFORMATION
YOU AREURGEDTOREAD THISMANUALCOMPLETELY BEFORE
INSTALLINGTHISVALVE
Upon Receiving YourUnit
Inspectthe unitforpossibledamage caused during shipping.Contact Equipment Servicing
before attemptingto use a damagedunit. [phone].
Warningsand Cautions
NOTE: Warnings and Cautions appearinhighlighted boxesasillustrated belowatappropriate
pointsthroughout thismanual. Givespecialattention totheseitems.
Warnings:areprovidedto alertyouto potential hazardsthatcouldresultinserious
personal injuryanddamageto your equipment.Warningsmayappearinthis manual
oronthe equipment. Heedall Warnings.
Cautions:aredesignedto alert youto situationsthatmayresultindamageto your
equipment.
Personalsafety and the properoperation of yourequipment requirestrict observance of
these precautions.
THIS VALVE SHOULDBE INSTALLEDONLYBY
QUALIFIEDPERSONNEL
Warning: Certainservicingprocedures mayexpose youto harmfulmaterials and
dangerousconditions. Tominimize thepossibilityof injury,followsafetyprocedures
andinstructions describedinthis manual, onproductlabels andinmaterial safetydata
sheets provided.
NOTE: The manufacturerhasacontinuousequipmentimprovementpolicy and reservesthe rightto
change specificationsand design of itsproductswithout notice.

5
Specifications
Flowcapacity:940 SCFM
Setpressure:15 psig
Reseals“bubbletight”within 3psiofset
pressure
Refrigerantcompatibility:R-11
R-113 &R-123
Weight:17 pounds
Dimensions(approximate):Length13
inches;height13 inches;width6inches
Inlet - 2-inchmaleNPTpipethreads
Outlet - 2-inchfemaleNPTpipethreads
IntegralsupportBoss - 3/4-inchpipe
O-Ring seat - sealsbubbletight
VALVE CONSTRUCTEDOFSTAINLESS
STEEL
Tell-talepressuregauge 30”Hg -0- 30 psig
Doublecheck pressureequalizing valve
(included)
Everyvalve100%testedfor pressure
setting and leakage
O-Ringsserviceablewithoutdisturbing
pressurereliefcalibration
Carbon fragmentcollection trapwith
speciallyformulatednon-toxic, non-
corrosivetack compound
Directspring acting
Pivotedspring action correctsmis-
alignmentand compensatesfor spring
sidethrust
Calibration isfactorysealedtoprevent
inadvertenttampering or dis-assembly
High capacityfull nozzledesign
Instantaneous“pop open” action
BACK PRESSURE COMPENSATED
General Overview
The RuptureSeal™rupturedisk backup reliefvalve, withits exclusivecarbon fragment collection trap,
isdesigned specificallyforinstallation inserieswithexisting carbon type fragmenting rupturedisks
used on lowpressure(15 psiorbelow) centrifugalchillers.
The primaryfunction ofthe RuptureSeal™isto minimizerefrigerantloss tothe atmosphereinthe
eventofaburstrupturedisk.The RuptureSeal™accomplishesthisvitalfunction byautomatically
closing off the ventpath,thusre-sealing the chilleroncepressurereturnstonormal.Inthe eventof a
burst rupturedisk, the RuptureSeal™alsoservesasthe interim primaryrelief.
NOTE: The RuptureSeal™ modelnumberdesignatesthe sizeofcarbon fragmenting rupturedisk it is
designed tobe used with(i.e., the “RS-2”isdesigned tobe used withatwo (2”) inchcarbon
fragmenting rupturedisk designed forcentrifugalchillers)..TheRS-2hasaflowcapacityof940
SCFM,however(perASHRAEguidelines),thiscapacitymustbede-rated10%wheninstalledin
serieswitharupturedisk.Whenfitting theRS-2 toachiller,theinstallermustdetermineifthe
de-ratedflowcapacityisadequatefor thatchiller.INCLUDEDFORYOURCONVENIENCEAS
Appendix“A”ISATABLEOFVARIOUSVESSELDIMENSIONSCOVEREDBYTHEMODELRS-2
RuptureSeal™ AFTER10%DE-RATING based on computationsusing the formulaprovided bythe
Guideline BSR/ASHRAE 15-1992R. Appendix“B”ofthismanualcontainsthe excerptfromthe
Guideline BSR/ASHRAE 15-1992Rwhich can be used todetermine the minimumflowcapacity
requirement forapressure-relief deviceasapplied toalowpressurecentrifugalchiller.

6
Installation Kit
Kitincludes:
Warning: Removal of thewiredscrews andleadseal (16) fromthe valve body (7) will
destroythepressurereliefcalibrationandvoidthewarranty!Ifservice to thevalve
assemblyeffectingcalibrationis required,itmustbereturnedto manufacturerfor
service.
FieldProvidedItems
Itemstobe supplied byinstaller:
(see Figure2on page 8)
Pipe & FlexibleMetalConnection (33)
Pipe Fittings
Dripleg (31) withDrainPort (38)
¼” line (37) toconnect ValveBodywater
drainhole (24) toDripLeg (31)
A twoinch (2”) FemaleNPTPipe Union (12)
(see Figure2on page 8)
Materialsforproviding supplementalsupport of
valve(3/4”iron pipe)
Typical Installation
One (1)Pre-assembled RS-2 RuptureSeal™
whichincludes:
3O-rings (1),(2) &(3)
Eight (8)1/4”Stainless SteelCap Screws (4)
One (1)Collection Trap ChamberCover (5)
One (1)Carbon Fragment Collection Trap CanisterInsert
withSpecialTack Compound (6)
One (1)Tee Connection (14) withplug
One (1)Tell-TalePressureGauge 30”Hg - 0-30 psig (21)
One (1)DoubleCheck PressureEqualizing valve (22) withFilter/Vent (34)
One (1)Installation Operation & MaintenanceManual
NOTE:
See Figure
3on Page9
for location
ofpartson
assembled
unit.
Chiller

7
INSTALLATION
Installation ofthe RuptureSeal™shouldbe performed onlybyqualified personnel.The following
installation instructionsshouldbe thoroughlyread and understood beforeattempting installation.
Minoralterationstothe existing rupturedisk ventpiping arenecessarytoinstall the RuptureSeal™
valve. The installershoulddetermine inadvancewhat toolsand materialswill be needed.
Warning:Wheneverpossible, theRS-2 shouldbeconnecteddirectlyto thechiller’s
outerrupturedisk flangeto assurethat,ifthereis arupture, ALL of thecarbon
fragmentsof thedisk will be projectedstraightinto the RuptureSeal™ carbonfragment
collectiontrap. Ifthis is not possible, see Appendix “C” forfurtherinformation.
Also,ifthereis arestrictionorconstrictionintheventpipeafterthe
RuptureSeal™ valve, orifa numberof chillerreliefs are ventedinto one inappropriately
sizedpipe, theoverall flowrateof thesystemmaybenegativelyaffected.Each
installationmusthavesuchfactorstakeninto consideration.(Forreference, see
ASHRAE Guidelines relatingto pipingaftera rupture device.)
Warning: DO NOTinstall anRS-2 RuptureSeal™ ona3” rupturedisk. Likewise,
DO NOTinstall anRS-3 RuptureSeal™ ona2” rupturedisk. Theratedflowcapacities
of theRuptureSeal™ reliefvalveare accurateonlywhentheappropriateModel is used
onanappropriatesizedrupturedisk. MISMATCHING MAYCAUSE THEVALVE NOTTO
OPEN, HENCEFLOW CAPACITYMAYBE(0)ZERO.
Installation Steps1thru 7 - (see below)
Warning: DO NOTattempt to install a damagedvalve!
NOTE: ITIS NOTNECESSARYTOREMOVE THECHILLER’S RUPTUREDISKTOINSTALL THE
RuptureSeal™.The valve’s2”carbon fragmentcollection trap inlet (13) (see Figure3on page 9for
location) shouldbe screwed directlyintothe chiller’souterrupturedisk flange (see Figure1on Page
8).If thisisnotpossible,see Appendix“C” forotherinstallation possibilities.If the installerwantsto
avoidputting stress on the rupturedisk assembly, astraight, 2inchIDflexiblecoupling can be used
between the rupture disk flange and the RuptureSeal™.

8
INSTALLATION(continued)
1.Determine the bestmounting arrangementforthe RuptureSeal™inrelation to
the chiller’sexisting rupturedisk, vent piping, and the recommended supplemental
support. The bestarrangementisone thatplacesthe RuptureSeal™asclose
aspossibletothe rupturedisk.The valvebody (7) can be rotated toorientthe
“outlettoventpipe” (8) inanyhorizontaldirection bylooseningthe three (3)valve
bodylocking screws (9) (forillustration,see the firstrowof Appendix“C” on page
16).Onceinposition,be suretore-tighten the three (3)valvebodylocking
screws (9).
2The RuptureSeal™“valve”shouldbe mounted inthe verticalposition withthe
carbon fragmentcollection trap chamber (10) inthe horizontalposition (see
Figure1 - TypicalInstallation).The RS-2can be mounted inotherpositions
(exceptupside down),however,the valveiscalibrated forthe verticalposition and
itshouldbe mounted inaposition otherthan verticalonlyif absolutelynecessary.
READWARNING BELOW.
Warning: YOU MUSTREADAppendix “C” ifmountinginpositionsotherthanas
illustratedinFigure 1.
Warning: Regardless of RS-2’s position, the Double Check Pressure EqualizingValve
(22) MUSTbemountedverticallywiththefilter/vent (34) pointingup(é).Anyposition
otherthanwiththe filter/ventendpointingupwill create a serious safetyhazard.
3. Determine howmuchofthe existingrupturedisk vent piping will havetobe removed to
accommodatethe RuptureSeal™. Cut out and removethissection ofpiping.
4.Itisrecommended thatyou utilizeaflexiblemetalconnection (33) tomakethe installation easier.
You must usea2”NPTunion (12) forfutureservicing.
5.The installershall determine the bestwaytoplumbthe exhaust
ventline using the hook-up toventpipe illustration inFigure2as
aguide.
6.Applythread sealantcompound tothreadson the valve’s2”
carbon fragmentcollection trap inlet (13) and install (see Caution
below.)Thisshould be screwed DIRECTLY intothe existing
rupturedisk flange wheneverpossible.Inno eventshouldthe
valvebe installed withan extension pipe morethan 14 inches
fromthe rupturedisk.(See Appendix“C” on Page 17 for
illustrationsifextension mustbe used.)IFANEXTENSIONPIPE
ISUSED,ITMUSTBESTRAIGHT(NO45ºor 90ºELBOWS)
and havea2”inside diameter.[Ifthevalveisnotverticalafter
tightening intotherupturediskflange,itmaybenecessaryto
install a2”pipeunion betweenthevalveand theouter
rupturediskflange.]
Caution: Be surethereis agasketbetweenthecarbonrupturedisk andtheouter
flange. Ifthere is not, one mustbe installed.
Figure1.
Typical Installation
(See Appendix“C”for
other installations)
Chiller
(33)FlexibleMetal Connection
(31)DripLeg
(38)Capped
DrainPort
(11)VentPipe
(8)OutlettoVentPipe
(12)2" NPTUnion
(24)Valve
Bodywater
drainhole
(37)Valve
Bodywater
drainhole
connection
toDrip
Leg
Figure2.
Hook-up to Vent Pipe

9
INSTALLATION(continued)
7.Determine best method forconnecting dripleg (31) tothe “outlet tothe vent pipe” (8) (see figure2
on page 8).Again, the “outlet tovent pipe” (8) can be adjusted topoint inanyhorizontaldirection
byloosening the 3valvebodylocking screws (9) and turning the valvebody (7) (see firstrowof
Appendix“C” on page 16 forillustration).Run a¼” line (37) fromthe ValveBodywaterdrain
hole (24) tothe DripLeg (31). (Don’t forget tore-tighten the 3valvebodylocking screws (9).)
(10 )Carbon fragment
collection trap chamber
(26 )Tension bar
(29 )Spring tension adjusting
mechanism and isolation
chamber upper part
(17 )Pin holefor spring locking
when servicing O-rings
(15 )3/4"non-threaded Boss
(18 )Collection
chamber
flange
(3)Collection chamber
flangeO-Ring
(4)Eight1/4"
SS cover
screws
(35 )Alarmport
with plug
(5)Collection trap
chamber cover
(14 )1/8"NPT Tee
(34 )Filter/vent
(22 )
Double
check
pressure
equalizing
valve
(6)Carbon fragment
collection trap
canister insert
with tack compound
(replaceable)
(21 )
Pressure
gauge
(8)Outlet to ventpipe
(23 )Water drain holein
isolation chamber
(1)Valve seat O-ring
(2)Valve bodyO-ring
(32 )Valve neck
(25 )Pull Ring
(30 )Spring
(39) Stem Seal
(9)Three valve body
locking screws
at 120 degrees apart
(28) Isolation Chamber
lower part
(13 )2"carbon fragment
collection trap inlet
(7)Valve body
(24) Valve Body
water drain hole
(16 )Calibration locking
screws and seal
Figure3 - Cutaway View
PressureGaugeand AuxiliaryAlarm
The pressuregauge (21) between the rupturedisk and the seating mechanismofthe valveisused to
letthe operatorknowifarupturedisk hasburstorisseeping.Apressureorvacuumreading other
than “0”psigindicatesaproblemwiththe rupturedisk.The doublecheck pressureequalizing valve
(22) isprovided topreventapressurebuild-up between the RuptureSeal™valveand the rupture
disk,usuallyresulting fromaseeping rupturedisk.Thisspecialdoublecheck pressureequalizing
valveallowslowpressurebuild-up tobleed-off,butre-sealsitself athigh pressuresorvacuum.IFAN
ALARMIS DESIRED tosupplementthe pressuregauge (ITIS HIGHLYRECOMMENDED)tosignal
when the rupturedisk hasruptured,itcan be installed inthe plugged alarm port (35) ofTee (14).
The ALARMshouldbe settoactivatebetween 4and 10 psig.Contactequipmentservicing for
information on the optional RediControlsAlarm™.
Supplemental Mounting Support
Itisrecommended thatasupplementalmounting supportbe provided forthe RuptureSeal™valveto
relieveanystress itmayputon the rupturedisk assembly(see Figure1on page 8).Asupport
mounting coupling (15) hasbeen provided forthispurpose.The coupling will accommodate3/4”
non-threaded pipe. The installershall determine the best waytoprovide the supplementalsupport.

10
INSTALLATION(continued)
Double Check Pressure Equalizing Valve
The doublecheck pressure equalizing valve (22) isprovided topreventapressurebuild-up between
the RuptureSeal™valveand the rupturedisk,usuallyresulting fromaseeping rupturedisk.This
specialdoublecheck pressureequalizing valveallowslowpressurebuild-up tobleed-off,butre-seals
itselfat high pressuresorvacuum.
Warning: DO NOTobstructrelief of Double Check Pressure EqualizingValve (22).
Chillers Utilizing R-123 (special piping instructions)
Warning: WheninstallingtheRuptureSeal™ onachillerutilizingR-123, itis advised
thatyoupipetheoutputof theDouble Check PressureEqualizing Valve (22) [after
removal of thefilter/vent (34)]into thelinerunningfromtheValveBodywaterdrain
hole (24) to theDripLeg (31).Ifthere’s arupture, this will preventseepageof R-123
into theequipmentroom.(See illustrationatbottomright cornerof Appendix “C” on
page 17.)
Leak Testing Procedure
Caution:DO NOTuse this procedureifchilleris atapressurelowerthan15” Hg.
Otherwise, accidental burstingof therupturedisk couldoccur byimplodingthe
rupture disk into the chiller!
1. Removepipe plug (oralarm, ifthe optional RediControlsAlarm™isused)fromalarm port (35)
ofTee (14).
2. Utilizing a1/8”NPTx1/4”Flair halfunion, connect arefrigeration manifoldset (lowside hose)to
the alarm port (35) ofTee (14).
3. Carefullyraisethe pressurelevelto NO MORE THAN5PSIMAXIMUM, and test forleaks using
standardleaktesting procedures.
Warning: Duringtesting,to maintainpressureatsuchalowpsi, youmayhaveto
removethefilter/vent (34) andholdyour fingerovertheoutletof theDouble Check
PressureEqualizingValve. DO NOTuse apluginoutletof theDouble Check Pressure
EqualizingValve. Ifthe plugwere not removed, itwouldcreate a serious safetyhazard.
4. At conclusion ofLeaktest procedure, releasepressureand removehoseat fitting fromTee (14).
Re-install the alarm orplug inthe alarm port (35) ofTee (14) and securetightly. DO NOT
reinstall pipe plug oralarm inanyposition otherthan the alarm port (35) ofTee (14).