Related Manuals for Full Gauge Controls RCK-862 plus
Summary of Contents for Full Gauge Controls RCK-862 plus
- Page 1 RCK-862 plus OLED Graphic Supervisory Hour meter Alarms Display System Progressive Suction Discharge Floating Recipe Algorithm Control Control Condensation System...
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Page 2: Table Of Contents
1. TABLE OF CONTENTS........................................2 2. DESCRIPTION..........................................3 3. APPLICATIONS..........................................5 4. GLOSSARY............................................5 5. TECHNICAL SPECIFICATIONS......................................6 6. ELECTRICAL PRECAUTIONS......................................6 7. INSTALLING THE RCK-862 plus....................................7 8. DIMENSIONS...........................................7 9. WIRING SCHEMATICS........................................8 10. NAVIGATION KEYS........................................9 11. NAVIGATION KEYS........................................10 12. SUMMARY SCREENS........................................11 12.1 GROUP (S) SUMMARY SCREENS..................................11 12.2 SUCTION SUMMARY SCREENS....................................12... - Page 3 1. TABLE OF CONTENTS 16. AUXILIARY FUNCTIONS......................................31 16.1 PUMP DOWN..........................................31 16.2 COMPRESSOR PROTECTION THERMOSTATS..............................33 16.3 ADIABATIC CONDENSATION....................................33 16.3.1 TEMPERATURE CONTROL...................................33 16.3.1.1 TEMPERATURE CONTROL USING TWO SENSORS (DIFFERENTIAL TBS-TBU).................34 16.3.1.2 TEMPERATURE CONTROL USING A SENSOR (TBS)..........................34 16.3.1.3 TEMPERATURE CONTROL USING TWO SENSORS (TBS-TBU DIFFERENTIAL AND TEMPERATURE LIMIT)........34 16.3.2 CYCLE TIMER MODE....................................34 16.4 FLOATING CONDENSATION....................................34 16.5 INDIVIDUAL PRESSURE SWITCHES..................................35...
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Page 4: Description
The RCK-862 plus is a control module that acts alone or together with expansion modules to increase the number of inputs and outputs in large systems. -
Page 5: Applications
3. APPLICATION - Low and medium power industrial refrigeration - Rack type refrigeration equipment (compressors in parallel) - Compression centers for supermarkets, logistic storage centers or air conditioning systems - Cold storage facilities - Condensing units - Plug-ins 4. GLOSSARY Group: It is a set of suction or discharge lines that have links (same refrigerator circuit). -
Page 6: Technical Specifications
-Installation or maintenance of the product must be performed only by qualified professionals. ACCESSORIES: -Use only Full Gauge Controls original accessories; -In case of doubt, contact technical support. BEING IN CONSTANT DEVELOPMENT, FULL GAUGE CONTROLS RESERVES THE RIGHT TO CHANGE ANY INFORMATION IN THE MANUAL AT ANY TIME, WITHOUT PRIOR NOTICE. -
Page 7: Installing The Rck-862 Plus
To remove the controller from the DIN rail, use a wrench compatible with the size of the lock to make a lever. 8. DIMENSIONS For a better fixation of the RCK-862 plus observe the product dimensions. 135,7 mm [5,34"] 110 mm [4,33'’] 3,21"... -
Page 8: Wiring Schematics
9.CONNECTION SCHEMATICS Charge supply SSRs - Solid Relays Type 1 connector State Relays 24Vac/dc Type 1 connector The C and GND signals are connected internally except Insulated for the isolated RS485-2 port. port RS485-1 RS485-2 Type 2 connector 0-10 Vdc Temperature sensor Type 1 connector... -
Page 9: Navigation Keys
10.NAVIGATION KEYS To toggle between screens, edit parameters, view advanced functions and other features, the RCK-862 plus has 6 navigation keys: MENU INCREASE DECREASE BACK ALARM MENU key: Access the Main Menu and the Control Menu. Control Menu: Press the MENU key. -
Page 10: Navigation Keys
11.NAVIGATION TUTORIAL Gr1 DD/MM HH:MM:SS Suction: The first summary screen is the GROUP 1 screen. You can find #1 100.0 psi information about the controlled #2 100.0 psi system. #3 100.0 psi Discharge: #1 100.0 psi By using the INCREASE and DECREASE keys it is possible to Gr1 DD/MM HH:MM:SS navigate through the other... -
Page 11: Group (S) Summary Screens
12.1. Group summary screen: Displays the basic status of the lines (Suction and/or Discharge) that make up the group, if configured. By default, the RCK-862 plus is configured with Suction 01 and Discharge 01 in Group 01. If the Group is not configured, access the Main Menu Function Settings Groups. -
Page 12: Suction Summary Screens
: Indication of active alarm Suc1: Suction 1; Suc2: Suction 2; : Percentage of power referring to the active outputs by RCK-862 plus. Suc3: Suction 3. : Percentage of power required by the system for the operating interval Control status indication:... -
Page 13: Discharge Summary Screens
Discharge 3 : Percentage of power referring to the Temp : It is the discharge value, used to active outputs by the RCK-862 plus measure the subcooling : Percentage of power required by the Pres : It is pressure value read by the... -
Page 14: Continuation Of Summary Screens
12.SUMMARY SCREEN 12.4. Continuation of summary screens: For each suction and discharge it has a summary screen where you can see how many outputs are connected and their respective status. After the equal sign, you can see the percentage of the control outputs connected with each compressor and fan that are on. It can even monitor the capacity control status (unloaders valves and inverter output). -
Page 15: Individual Pressure Switches
12.SUMMARY SCREEN 12.5. Invidual pressure switches: The individual pressure switch screens are accessed from the Control Menu. To toggle between the available pressure switches just navigate using the keys Prs1 On Pres:25.3 psi SP 1 SP 2 SP 3 10.0 20.0 30.0 SP 4... -
Page 16: Individual Thermostats
12.SUMMARY SCREEN 12.6. Individual thermostats: The individual thermostat screens are accessed from the Control Menu To toggle between the available pressure switches just navigate using the keys Trm1 On Setpoint: 20.0 °C Temp: 15.4°C Output: Defrost: Thermostat on display: Defrost output status Trm1: Individual thermostat 1 Trm2: Individual thermostat 2 Control output status... -
Page 17: Inputs And Outputs
12.SUMMARY SCREEN 12.7. Inputs and outputs: The input and output menu allows you to view the status of all inputs and outputs of the RCK-862 plus and its configured expansion modules, as well as to check their function. Outputs - Base... -
Page 18: Compressor Protection Thermostats
12.SUMMARY SCREEN 12.8. Compressor protection thermostats: Thermostat information is accessed from the Control Menu. To toggle between the available compressors just navigate using the keys Therm. compressors Suc. 1 Temp: 50.0 °C Comp.1 Out Suc. 1 Temp: 50.0 °C Comp.2 Out Suc. -
Page 19: Control Menu
13.CONTROL MENU key, has settings and commands for easy access to the operations of the RCK-862 plus. The Control Menu is accessible by pressing the Control menu: Access control Control status Resetting alarms Economic setpoint Pump Down Adiabatic Cond. Floating Cond. -
Page 20: Suction Controls
2.Suction. Compressor control is linked with a suction pressure switch. The RCK-862 plus allows the control of up to 3 suction pressure switches with up to 6 compressors each. The digital outputs indicated as O1, O2...O6, are in charge of the on-off control (On/Off) of compressors and unloaders valves, while the analog outputs, indicated as A1 and A2, emit a 0-10V signal for frequency inverters or other devices. -
Page 21: Modulation Of Variable Capacity Compressors (Vcc)
VCC: Starting time (1.2.x.67). The Algorithm present in the RCK-862 plus automatically determines when the auxiliary outputs are to be actuated. If it is of interest to carry out the control of the valves at fixed time intervals, select the desired period in the parameter VCC-Digital: Control period (1.2.x.70). -
Page 22: Control Modes
The Linear control mode, when it has only digital outputs connected, commands the actuation and shutdown of each compressor sequentially and with pressure intervals of the same magnitude (step). The RCK-862 plus uses a setpoint value and pressure hysteresis to control the suction of the compressors. -
Page 23: Linear Mode Linked With A Vcc Compressor In Conjunction With On/Off Compressors
14.SUCTION CONTROLS Example: Linear control linked with digital outputs from compressors with unloaders On/Off compressors with unloaders. In the compressors that use the unloader capacity regulation valve, the logic for actuating and shutting down the main relays and auxiliary unloader valves is chosen according to parameters 1.2.x.34 - Sequence of actuations and 1.2.x.35 - Sequencing of shutdowns. -
Page 24: Linear Mode Linked With A Vcc-Analog Compressor
14.SUCTION CONTROLS 14.4.1.3 Linear mode connected to a VCC-Analog compressor: The VCC-Analog is used to drive frequency inverters or modules to control compressors that receive a signal between 0-10V. The control uses the parameters of the setpoint value and the hysteresis of the VCC compressor. It is also possible to connect a digital input for the Start-stop output of the VCC compressor. -
Page 25: Rotation Mode
14.SUCTION CONTROLS 14.4.2 Rotation Mode: This mode operates in a similar way to the Linear Mode, however, making a time rotation to start and stop the compressor according to the recording of the hours in operation of each compressor. When the control recognizes the need to start a compressor, the preference is to start the compressor with the lowest number of hours of operation. -
Page 26: Progressive Algorithm Mode
14.SUCTION CONTROLS 14.4.5 Progressive algorithm mode: The Progressive Algorithm is an ideal control mode for systems that use compressors of different capacities for suction. The Progressive Algorithm considers the capacities of each compressor to supply the thermal demand of the system, seeking to optimize the use of unloader valves, minimizing the number of compressors starts and shutdowns. -
Page 27: Integral Action
14.SUCTION CONTROLS 14.4.6 Integral action: In some systems, the control of compressors with only proportional action (Setpoint and hysteresis) tends to present an error in steady state (not reaching the setpoint) or to show oscillatory behavior (excessive pressure variation around the setpoint and high number of compressor start). In these cases, the use of integral action together with proportional control has the objective of keeping the control pressure stable, converging to values close to the setpoint. -
Page 28: Discharge Controls
(step). The RCK-862 plus uses a setpoint value and pressure or temperature hysteresis (depending on the type of control) to control the discharge. Actuation Pressure value of the ‘’N’’ Output Actuation = Setpoint + (N x Step) Shutdown Pressure value of the output ‘’N’’... -
Page 29: Rotation
15.DISCHARGE CONTROL 15.2.1.3 Linear mode using a fan (inverter) together with fans linked with digital outputs: Fan 1 of each discharge line can be controlled proportionally and linked with a proportional 0-10V analog output for its control. To do this, select the modulation of fan 1 as an inverter and assign an analog output (1.3.x.26). -
Page 30: Integral Action
15.DISCHARGE CONTROL 15.2.5 Integral Action: In some systems the control of fans with only proportional action (Setpoint and hysteresis) tends to present an error in steady state (not reaching the setpoint) or to show oscillatory behavior (excessive pressure variation around the setpoint and high number of fan activations). In theses cases, the use of integral action together with proportional control has the objective of keeping the control pressure stable, converging to values close to the setpoint. -
Page 31: Auxiliary Functions
16.AUXILIARY FUNCTIONS The RCK-862 plus allows configuring some complementary functions to control the Rack system. The Pump Down and Compressor protection thermostat logic apply to suctions. The logic of adiabatic condensation and floating condensation apply to discharges and aims to adjust the Rack to work with less energy consumption. - Page 32 16.AUXILIARY FUNCTIONS Example: Suction 1 operating with 2 compressors, 2 external thermostats and 1 individual thermostat: Suction 1: 1.2.x.2 Pressure setpoint: 50,0 psi 1.2.x.4 On / Off compressor hysteresis: 10 psi 1.2.x.15 Number of compressors: 2 1.2.x.22 Modulation of compressor 1: On/Off 1.2.x.23 Modulation of compressor 2: On/Off 1.2.x.37 Compressor 1 main output: O1 1.2.x.38 Compressor 2 main output: O2...
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Page 33: Compressor Protection Thermostats
16.AUXILIARY FUNCTIONS 16.2 Compressor protection thermostats: A protection thermostat can be configured for each of the 6 compressors on the 3 suction lines. Each thermostat has a sensor for measuring the compressor temperature, a digital output for activating a cooling device and a shutdown alarm. The output is activated, and the high temperature alarm only occurs when the compressor is on. -
Page 34: Temperature Control Using Two Sensors (Differential Tbs-Tbu)
(1.7.3.x.4) and Differential for shutdown (1.7.3.x.5), the control is done by both modes (temperature differential and temperature limits). Whenever ate least one of the two modes have an actuation condition, the RCK-862 plus activates the control output of the adiabatic condensation. -
Page 35: Floating Condensation
16.5 Individual pressure switches: The RCK-862 plus allows configuring up to 3 individual pressure switches disconnected from the Rack’s main control. On each pressure switch, it is possible to associated a pressure sensor and up to 6 digital outputs with setpoint and independent hysteresis. -
Page 36: Individual Thermostats
16.6 Individual thermostats: The RCK-862 plus allows you to configure up to 6 individual thermostats unrelated to the Rack’s main control. Each thermostat can be configured to work in heating or cooling mode. In heating mode, the output is activated if the temperature value is lower than the (setpoint-hysteresis) and shuts off if the temperature value is higher than the setpoint. -
Page 37: Alarms
17.ALARMS The RCK-862 plus controller has an alarm system in which it is possible to configure protection or display-only alarms. All alarm settings are linked to the suction and discharge pressure switches. In the event of an alarm, an audible warning will sound and remain active until one of the following conditions occurs: - The alarm condition no longer occurs, and the alarm is not in a manual reset condition. -
Page 38: Automatic Resets
(1.4.4.1), the intervals between attempts and a period within which attempts will be made. If the number of attempts is set to the minimum ‘’Off’’ value, the reset must be manual only. If the maximum value ‘’Always’’ is set, the RCK-862 plus does not limit the number of reset attempts, it only respects the times. -
Page 39: Alarm Tables
AL0004 (Contact Full Gauge Controls) The RCK-862 plus can control up to 3 suction pressure switches. The address of each pressure switch in the alarm 17.4.2 Suction alarms: nomenclature is represented by the letter ‘’x’’. Where ‘’x’’ can be 1, 2 or 3 and represents suction pressure switches 1, 2 or 3, respectively. -
Page 40: Discharge Alarm
External fault 10 switch. Ignores the time between shutdown The RCK-862 plus can control up to 3 discharge pressure switches. The address of each pressure switch in the alarm 17.4.3 Discharge alarms: nomenclature is represented by the letter ‘’x’’. Where ‘’x’’ can be 4, 5 or 6 and represents discharge pressure switches 1,2 or 3, respectively. - Page 41 17.ALARMS Description Alarm Effect Backup temperature sensor fault Actuates according to the configuration of menu 1.5 AL0x12 Actuates according to the configuration of menu 1.5 External temperature sensor / dry bulb fault Floating and adiabatic condensation logic will be AL0x13 disabled Actuates according to the configuration of menu 1.5 Wet bulb temperature sensor fault...
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Page 42: Individual Pressure Switches Alarms
ALxx03 17.4.6 Rotating output alarms : The RCK-862 plus can control up to 3 sets of rotating outptus. The address of each set of rotating outputs in the alarm nomenclature is represented by the letter ‘’x’’. Where ‘’x’’ can be 16, 17 and 18, representing sets of outputs 1, 2 or 3, respectively. -
Page 43: Main Menu
18.MAIN MENU The Main Menu is accessible by pressing the key for at least 3 seconds when using the Groups, Suction or Discharge keys. 1 Main Menu: 1.1 Settings: 1 Functions settings 1 Groups 2 System 2 Suction settings 3 Communication 3 Discharge settings 4 Alarms... -
Page 44: System Settings
Note: If the pressure read by the sensor is equivalent to a region outside the sub-critical, the message ‘’PC’’ is displayed, indicating that the value is above the critical point. 18.3 Communication settings: The RCK-862 plus has two independently configurable RS-485 communication ports for communication with the Sitrad software or supervisory ones that use the MODBUS protocol.ie Feature... -
Page 45: Communication With Sitrad
18.4 Expansions: The RCK-862 plus has the possibility to expand the number of inputs and outputs using expansion modules. This feature allows you to control more complex systems, increasing the number of controlled devices and expanding the possibilities for monitoring and protecting the system. - Page 46 On the RCK-862 plus the module model used at each address must be selected. To do this, access the menu 4.x, where x represents the address from 1 to 10, and select the corresponding model.
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Page 47: Data Management
18.MAIN MENU 18.5 Data management: The RCK-862 plus has a USB port with support for communication via pen drive, where it is possible to manage recipes and update the controller firmware. Access path: Main Menu Data manager. RCK-862 plus 18.5.1 Export recipe Pendrive (5.1):... -
Page 48: Parameter Table
19.PARAMETER TABLE 1.1 Groups: Settings menu related to groups. A group is a set of suction or discharge lines that have links (same refrigerator circuit). Example: A Rack-type refrigeration system with two suction lines, one for frozen and one for colds, sharing the same discharge line forms a group composed of three pressure switches. - Page 49 Defines the amount of suction pressure switches that are controlled by the RCK-862 plus. 1.1.3 Number of discharge pressure switches: Defines the amount of discharge pressure switches that will be controlled by the RCK-862 plus. 1.1.4 to 1.1.6 Suction group x: The suction pressure switches are linked with the control groups.
- Page 50 19.PARAMETER TABLE Description Feature Minimum Maximum Standard Unit Compressor 2 - Modulation 1.2.x.23 Compressor 3 - Modulation 1.2.x.24 Compressor 4 - Modulation 1.2.x.25 Compressor 5 - Modulation 1.2.x.26 Compressor 6 - Modulation 1.2.x.27 Compressor 1 - Activation mode 1.2.x.28 Compressor 2 - Activation mode 1.2.x.29 Compressor 3 - Activation mode 1.2.x.30...
- Page 51 19.PARAMETER TABLE 1.2.x.1 Control mode: Selection of compressor control mode. Available modes: 0 = Linear 1 = Rotation Note: More information on the control modes in item 14.4. 2 = Dead zone 3 = Dead zone with rotation 4 = Progressive Algorithm (compressors of differente capacity) 1.2.x.2 Pressure setpoint: Pressure value for suction control where the system shuts down all compressors.
- Page 52 19.PARAMETER TABLE 1.2.x.22 to 1.2.x.27 Compressor x modulation: Configures the type of compressor actuation. On/Off: On-off compressor that uses only one digital output (relay) for its actuation. On/Off 50 I 100: Compressor that used two digital outputs (relay) for its actuation. The main output, and an auxiliary output in which each output corresponds to 50% of the compressor capacity.
- Page 53 19.PARAMETER TABLE 1.2.x.37, 41, 45, 49, 53, 57 Compressor 01-06 main output: Digital output Compressor xx digital output address. address: 0 = Not configured 1.2.x.38, 42, 46, 50 , 54, 58 Compressor 01-06 auxiliary output 01: 1 = Base - O1 Compressor xx auxiliary output 01 address.
- Page 54 19.PARAMETER TABLE 1.3 Discharge: Opens the list of discharge pressure switches. 1.3.x Discharge x: List of parameters related to the control of the discharge pressure switch ‘’x’’. Where x represents discharges 1, 2 or 3. Feature Standard Description Minimum Maximum Unit Control mode 1.3.x.1...
- Page 55 19.PARAMETER TABLE 1.3.x.2 Control type: The discharge control can be carried out by pressure or temperature. In pressure control, the pressure sensor, pressure setpoint and pressure hysteresis will be considered. Temperature control will consider the temperature sensor, temperature setpoint and temperature hysteresis Note: Calculation of the subcooling only available when the control type is by pressure.
- Page 56 19.PARAMETER TABLE 1.3.x.19 Discharge pressure sensor: Sensor options: Specifies the pressure sensor used to contro the discharge. 0 = Not configured 1 = Base - S1 1.3.x.20 Backup pressure sensor: 2 = Base - S2 Specifies the backup pressure sensor used to control the discharge. 3 = Base - S3 When configured, this sensor automatically takes the discharge pressure reading.
- Page 57 19.PARAMETER TABLE 1.3.x.37 Analog output starting time: It is the time that the analog output remains at the starting value. If the control calculates a demand greater than the starting value, the required value will be applied. 1.3.x.38 Analog output validation time: This time is a validation of the need to actuate or shutdown a next ventilation stage and avoid unnecessary fan actuation or shutdown.
- Page 58 19.PARAMETER TABLE 1.4.2.x.7 Hysteresis of temperature alarms: It is the temperature variation necessary to get out of the alarm situation. 1.4.3 Discharge alarms: 1.4.3.x Discharge alarms - discharge 1 to 3 The letter x represents discharges 1, 2 and 3. Feature Description Maximum...
- Page 59 1.4.5.x Output x: The RCK-862 plus has up to six configurable alarm outputs. For each output, a specific alarm on the control lines can be linked and the output can be configured to cycle on and off or only on in the event of an alarm.
- Page 60 19. PARAMETER TABLE 1.4.5.x.6 Digital output: Digital output address for alarm. 0 = Not configured 1 = Base - O1 2 = Base - O2 3 = Base - O3 4 = Base - O4 5 = Base - O5 6 = Base - O6 Note: If a sensor already in use is selected, it will be replaced.
- Page 61 19.PARAMETER TABLE 1.6.x.1 Use Link: Links input x with a pressure switch, group, or auxiliary function according to: 4 = Discharge 1 8 = Group 1 suction 12 = Group 3 suction 16 = Rotation outputs 3 0 = Off 13 = All pressure switches 5 = Discharge 2 9 = Group 2...
- Page 62 19.PARAMETER TABLE 1.6.x.3 Contact type NO-NC: Actuation status at the input. NO is actuated via a normally open contact and NC is actuatead via a normally closed contact. 1.6.x.4 Address of the digital input: Links the address of the physical digital input with input x. 0 = Not configured 5 = Base - I2 Note: The inputs present in the expansion modules will be listed in...
- Page 63 19.PARAMETER TABLE 1.7.2.x Compressor protection thermostat: The letter x represents compressors 1 to 6 for each suction line Suction 1: x between 1 and 6. Suction 2: x between 7 and 12. Suction 3: x between 13 and 18. Feature Description Minimum Maximum...
- Page 64 19.PARAMETER TABLE 1.7.3.x.2 Temperature for actuation: Temperature of the dry bulb sensor to actuate the output. 1.7.3.x.3 Temperature for shutdown: Temperature of the external temperature sensor (TBS) for shutting down the output. 1.7.3.x.4 Differential for actuation: Value of the difference between dry and wet bulb temperatures for actuating the output. 1.7.3.x.5 Differential for shutdown: Value of the difference between dry and wet bulb temperatures for shutting down the output.
- Page 65 19.PARAMETER TABLE 1.7.4.x.3 Safety sub-cooling: Minimum subcooling value. At this point, the setpoint reduction is stopped. 1.7.4.x.4 Start time: Logic operating start time. Note: If parameters 1.7.4.x.4 and 1.7.4.x.5 are set to OFF, adiabatic condensation will remain active. 1.7.4.x.5 End time: Logic operating end time.
- Page 66 19.PARAMETER TABLE 1.7.5.x.15 to 1.7.5.x.20 Address of digital output 01-06: Digital output address 01-06 linked to the individual pressure switch. 1.7.5.x.21 Low pressure alarm: Enables the alarm indication when the pressure is lower than the configured value. 1.7.5.x.22 High pressure alarm: Enables the alarm indication when the pressure is higher than the configured value.
- Page 67 19.PARAMETER TABLE 1.7.6.x.6 Alarm hysteresis: Hysteresis of temperature alarms. 1.7.6.x.7 Linked pressure switch: Allows you to link the thermostat to a suction pressure switch. 0 = Suction 1 1 = Suction 2 2 = Suction 3 1.7.6.x.8 Temperature sensor: Specifies the temperature sensor. 1.7.6.x.9 Main output address: Output address linked to the individual thermostat.
- Page 68 19.PARAMETER TABLE 1.7.8 Control status output: Feature Description Standard Minimum Maximum Unit Digital output address 1.7.8.1 1.7.8.1 Digital output address: Digital output that indicates that the controller is operating. 1.8 Maintenance time: Time setting for maintenance of compressors and fans. 1.8.x Suction / Discharge: The letter x represents suctions (x between 1 and 3) and discharges (x between 4 and 6).
- Page 69 19.PARAMETER TABLE 1.10.x.1 Operating range of the analog output: Defines the operating range of the output voltage. The minimum voltage value corresponds to 0% and the maximum value corresponds to 100% capacity of the linked compressor or fan. 0 = 0-10V 1 = 0-5V 2 = 1-5V 0-10V...
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Page 70: Important
After this year with resellers, the warranty will continue to be effective if the instrument is sent directly to Full Gauge Controls. This period is valid for the Brazilian market. Other countries have a 2 (two) year warranty. The products are guaranteed in case of manufacturing failure that makes them improper or unsuitable for the applications for which they are intended.