January 11, 2022

Looking at 2021 – The Rear View Mirror that Wasn’t

Like many other USA based manufacturers, CPI had many reasons to be optimistic about 2021 back in December of 2020. A COVID vaccine was on the horizon, business was off, but continued at reasonable levels. There was lots of talk about pent up demand and lots of justifiable pride over our decisions to invest in our infrastructure during a time of great uncertainty. Yes, 2021 was going to be the year we put the pandemic in the rear view mirror and moved on to brave new worlds, or at least an extremely welcome status-quo.

And while 2021 was indeed a different and positive year in many ways, it was also more of the same. That rear view mirror remained foggy, and in some cases showed us exactly what we saw last year.

The global business environment remains challenging and despite some effort by governments and individuals, the pandemic remains with us, having gifted us with the omicron variant which made cautionary tales and behavior as necessary this year as last. Early year optimism has been replaced with more caution, and inflationary fears have become part of the conversation again for the first time in a long time. The effects of global warming are accelerating at a breathtaking pace, and cultural shifts in the work force have brought the changing work-life value systems of young workers to the forefront as baby boomers retire.

So where does that leave manufacturers like CPI? While there is no doubt that everyone is affected by global changes in the supply chain, inflation, and trade, we believe the key is to remain nimble and accepting in a fundamentally changing world. In 2021, we became part of discoverIE Group, a synergistic partnership that has proved prescient in the face of global economic changes. With access to a renewed presence throughout Europe and Asia as well as the USA, CPI solidifies its visibility in distribution channels and its resilience against market upheaval. Our centralized, US based manufacturing continues to be a tremendous competitive advantage in terms of responsiveness, with over 95% of our raw material sourced from the USA.

We continue to provide unique solutions to engineering problems through our waterproof switch, thermal switch, and draw wire sensor product lines, and in 2021 we drove hard into the green economy by targeting our sales and marketing efforts on green energy products in the electric vehicle, wind and solar markets — a trend we expect to continue into 2022.

When we look forward to 2022, we are cautiously optimistic about many of the same things we were cautiously optimistic about last year. We are especially thankful for the dedicated employees who come to work every day and take all necessary precautions to protect themselves and their co-workers. We’re thankful for our customers who kept the faith and continue to work with us to discover new and exciting applications for our products.

We’re cleaning off the rear view mirror, again, and we may finally see the things in there we expected to see last year. But regardless of what happens, CPI is looking forward. To learn more about us, please visit our website at: https://www.cpi-nj.com/

Original content published: https://www.cpi-nj.com/looking-at-2021-the-rear-view-mirror-that-wasnt/

October 25, 2021

Fuel Cell Thermal Management by CPI

As we all look forward to a greener, more sustainable energy future, the promise of hydrogen based fuel cells is certainly one of the most exciting energy technologies on the cusp of mainstream acceptance. Fuel cells were a 10 billion dollar industry in 2019 and that is only growing as the technology continues to become more affordable and more efficient. CPI is excited about this promising technology and even more excited that fuel cell manufacturers are choosing CPI thermal switches as key components in their evolving solutions.

What is a Fuel Cell and How does it Work?

Fuel Cell Diagram A fuel cell is an electrochemical device that combines hydrogen fuel and oxygen to produce electricity, heat and water. Fuel cells operate without combustion, so they are virtually pollution free literally producing water as a by-product. Since the fuel is converted directly to electricity and heat, a fuel cell’s total system efficiency can be much higher than internal combustion engines, extracting much more energy from the same amount of fuel. Some modern fuel cells have an overall efficiency of almost 65% compared only 20% of a gas engine. The fuel cell itself has no moving parts, making it a quiet and reliable source of power.

Of course challenges exist with fuel cells because hydrogen is not a naturally occurring element. Hydrogen must be separated from other compounds that contain hydrogen, and breaking these chemical bonds requires energy that is mostly coming from fossil fuel sources. Until renewables provide a much higher percentage of the energy grid, it is fair to say that fuel cells aren’t entirely emissions-free. And of course, in this electrochemical reaction heat is produced along with electricity and water. This heat must be managed carefully as the temperature of the fuel cell is a significant performance changing factor. That’s where CPI comes in.

Managing Thermal Performance of Fuel Cells.

One CPI thermal switch already seeing use in fuel cells is our AD173 bimetallic thermal switch. This switch is a small form factor switch that can detect temperatures from –18C to 148C with tolerances as tight as 2.8C. The under-clamp mounting tab makes this switch perfect for pipe or exhaust mounting and the small size and custom lead lengths mean it can fit into a tight space. Another feature of the AD series appropriate for fuel cells is the fact that it is hermetically sealed and can be deployed inside or exposed to the elements without issue. The switch is also impervious to shock and vibration for vehicle mounted cells and will not fail even under highly challenging environmental conditions.

Controlling the temperature of fuel cell reactions is critical to the overall efficiency of its operation and the AD series of thermal switches has been used for both high and low temperature detection in fuel cells for different monitoring applications.

Low Temperature Fuel Cell Detection & Prevention

Given that water is such an important part of fuel cell operation, careful precautions must be take to ensure that the water in a cell is not allowed to freeze. For this our AD series turns out to be a perfect solution as well. Deployed at a 35F set point, our AD series switches have been used to initiate anti-freeze protection extending the useful temperature range of outdoor fuel cells.

Our AD series also offers flexible off the shelf mounting options as well as customizable lead lengths. And for those who need something more, our engineering team is able to handle custom features.

Please call our team today for a consultation on your Fuel Cell Application.

Original content published: https://www.cpi-nj.com/fuel-cell-thermal-management-by-cpi/

September 21, 2021

CPI Thermal Switches, Tried and True for Aviation Applications

Power requirements in your average helicopter represent a few uncommon challenges. Consider the startup power required to get those turbines spinning. Then the instantaneous braking force necessary to respond to the pilots commands in real-time as he dips and rises to navigate safely.

All of that requires a pretty powerful engine, and that engine is lubricated by a whole lot of oil. Over a long trip or in hot/dusty conditions, that oil gets hot, too hot to be a very effective lubricant or coolant for the engine. If it remains too hot for too long, even specialized lubricants can break down and so oil temperature control has become a key safety subsystem in many high power, high rpm engines and motors on many kinds of military and industrial vehicles, boats and planes.

CPI Thermals are Helping the Next Generation of Helicopters Fly

The road to a world filled non-polluting electric vehicles doesn’t stop with cars. Manufacturers like Kopter helicopters of Switzerland already have their eyes on the prize. Per CEO Gian Piero Cutillo, of Leonardo who recently acquired Kopter, “… (Kopter) will act as a competence center for new light helicopters, developing future advanced technologies, especially in the areas of hybrid/electrical propulsion”.

Key to the success of this future roadmap is their new AW09 light helicopter. This is the first all new single engine helicopter design in over 4 decades, reimagined to be a design that could someday represents the world’s first hybrid chopper.

The powerful Honeywell HTS 900 turbine engine with 1020 hp is of particular interest to operators who wish to avail themselves of hot and high altitude performance. But a critical single engine design requires a critical, fail-safe cooling system.

“For Kopter we actually created a custom version of our AD series SnapStat Thermal Switch with a MIL STD connector”, notes John Crozier of CPI. “The thermal switch is installed in an oil cooler heat exchanger for the helicopter”. As is common to many CPI thermal switches used in this application, the switch activates when the oil temperature is above the thermal activation temperature (pre-programmed set point). The signal is used to switch a cooling fan on or off depending on the oil temperature.

Several Characteristics Make CPI Thermals Perfect for Heat Exchangers

According to Crozier, CPI’s SnapStat line of Thermals are finding their way into more and more heat exchanger designs for a number of reasons.

Small Form Factor – AD series thermal switches like the AD197 can fit in tight spots with a surface mount footprint of less than 0.75 square inches.
Extreme Durability – The basic SnapStat design is a double snap action design making them extremely resistant to vibration, shock and other modes of field failure. In almost every case, our switches will outlive your equipment.
Standalone Operations – CPI Thermal Switch closures do not require external power or interpretation by central control circuitry. Thermocouple based closure/opening is guaranteed to happen based on set point every time, making them the ultimate fail-safe solution.
Temperature Range – CPI’s SnapStat Switches have an operating temperature range of between 0F to 300F, easily covering the breakdown temperature limits of almost any modern lubricants.
Readily Available Customizations – With CPI’s engineering ready to provide parts with your exact customizations you can fit our parts more easily into your manufacturing process and specific mounting requirements. Customer connectors, lead lengths, hermetic sealing, and double pole double throw options are all available.

For more information about any of CPI’s Thermal Switches contact John Crozier of CPI’s Application engineering team today to discuss your application.

Original content published: https://www.cpi-nj.com/cpi-thermal-switches-tried-and-true-for-aviation-applications/

January 11, 2021

CPI Plugstat Thermal Switches – Getting There Slowly

For engineers looking to solve demanding temperature switching applications, robust, standalone thermal switches are surprisingly hard to come by. A quick google search yields hundreds of parts in a confused presentation of thermals, with every shape and size represented, sold everywhere from Alibaba to Amazon. But for the endurance focused designer, there might as well be 0 results.

Sometimes Slow is Good…

In the world of thermal switches, bimetallic switches generally belong to one of two categories:

Snap Action Switches – As the name implies this group of switches has a quick make/break switching action, ideal when there is a fairly large differential between the opening and closing temperatures of activation.
Slow make/break or “Creep Action” devices – These are excellent in temperature control or high limit control applications. They are designed for a narrow temperature differential between opening and closing temperatures where slower cycling characteristics provide some immunity from chattering in precision thermal sensing. This is the CPI Plugstat thermal switch line.

Accurate, and Durable Standalone Thermal Detection and Switching

The primary difference between CPI’s Plugstat Thermal Switches and others is their high endurance design. The PlugStat Series of close tolerance, bimetal thermal switches serve as a robust and accurate temperature control switch at temperature ratings from 17C (0F) to 343C (650F). This slow make and break thermal switch, open-on-rise device is hermetically sealed, with 1/2-20UNF-3A thread mounting or other custom mountings available.

Electrically, our switch handles up to 2A at 28V off the shelf, but custom values are possible. No matter what variation you get, the quality of this thermal is in keeping with the quality of the parts that make it.

Stainless Steel type 304
Stainless Steel type 321
Inconel Alloy 600
Stycast type 2651
Platinum Contacts

Hey, it was Good Enough for NASA…

Despite NASA’s stringent material and electrical requirements for the International Space Station, CPI’s off-the-shelf Plugstat model M1102 met their need for a reliable, space deployable, thermal safety switch solution. In this application, CPI’s switch was used to sense the temperature of a highly specialized liquid to prevent it from turning into a toxic gas during heating. Additionally CPI provided all applicable CoC’s, Material Test Reports, and Chemical Analysis’ required to meet NASA’s stringent quality control. The application is fascinating and can be read about here.

CPI Plugstat switches have been used on tanks and planes both military and commercial for oil overtempt, and hydraulic fluid temperature sensing where designers wanted a reliable, long lasting, standalone thermal sensor in places not so easy to service. These kinds of applications are really made for the CPI M-series Plugstat switches.

Also available in hermetically glass sealed version.

Contact CPI Thermal engineers today to discuss your application or visit https://cpi-nj.com

Originally posted: https://www.cpi-nj.com/blog/cpi-plugstat-thermal-switches-getting-there-slowly/

September 21, 2020

CPI Thermals Pick up Slack in Aerospace Aftermarket

Thermal switches for aircraft and avionics systems

While most companies are riding out the pandemic with some degree of production and sales, one area that has seen disruption across the board is related to supply chain dynamics. Remember how hard it was to get toilet paper for a while? Well toilet paper availability has largely returned (thank goodness..) but inventory and demand remain out of sync for all kinds of manufactured goods needed for all kinds of production. Add to this, the uncertainty of the trade and tariff situation with respect to China where so many cheap offshore parts and subassemblies are made, and we understand why lead times, and radical price increases have become all too common.

Nowhere has this been more true than in aviation, where manufacturers are finding that their offshore components either aren’t available or are now going to cost 2 or 3 times what they used to. CPI has seen the trend affect our thermal switch line, albeit in a good way as many avionics manufacturers have come to us for thermal switch replacements for various avionic subsystems. Our thermal switches were always of higher performance than what they were using but the irony is that now in many cases they are price competitive in quantity, with formerly less expensive solutions. One advantage of our Made in the USA manufacturing is that our costs and distribution models are largely unaffected by the pandemic since we’re sourcing and building everything locally.

Who’s using CPI thermal Switches and for What?

CPI Thermal Switches have a long history of use in both military and commercial avionics system that continues today. We have three lines of Thermal Switches covering temperatures from 0F to 1750F, a range very few manufactures worldwide can even produce. All boast highly accurate, factory programmable set-points, and the robust endurance parameters the world has come to know from CPI.

Whatever Application you’re flying with, CPI thermal switches were actually designed for aviation applications. Here’s just a few ways they’ve been used

Fire Detection – In every application from galley fire detection, to engine and avionics bay temperature detection, in planes from Ebaraer’s Novaer Training, to large military aircraft where their exact usages are classified, fire detection is a mainstay of CPI thermal use because of their high temperature capability.

Over Temperature Detection – The list of over-temperature detection applications in aviation is long. It includes such applications as engine over-temp, generator over-temp, APU backup temperature monitoring, environmental control system fail-safe, gear box OT on rotary wing aircraft, hydraulic fluid OT, and much more. Because our switches operate standalone and do not require an external computer to initiate close/open, they are preferred in applications that are critical for fail safe operation.

Freeze Detection – Most think of thermals checking when things get too hot, but our switches are one of the few in the world that can check when things get too cold! In a weapons system, this can be used to ensure that internal heaters are activated that prevent the electronics from failing due to freezing conditions.

Custom Solutions – CPI has a long history of making custom thermal switch solutions for clients, that meet their requirements without compromise. For more information on whether we can make the right solution for you, call our engineering team directly

CPI Thermals are Right for Aviation, Pandemic or Not.

For more information on CPI Thermal Switch lines and their unique capabilities, please visit our website or contact an application engineer today.

Originally posted: https://www.cpi-nj.com/blog/cpi-thermals-pick-up-slack-in-aerospace-aftermarket/

October 5, 2018

Aircraft Fire Detection – Spot Fire detection Systems

Hondajet uses CPI M2 Plugstat Thermal Switch

CPI’s X1 thermal switch is being increasingly used by both American and European avionics manufacturers and integrators as their thermal switch of choice for spot detection of overtemperature conditions in systems throughout the aircraft. Recent integrations include FAA approval as a Fenwal replacement on Gulfstream jets, use in the De Havilland “Twin Otter” aircraft, and use by specialty aircraft manufacturer Diamond Aircraft in Europe to name a few of the most recent.

But actually, CPI’s thermal switches have been flying around the world in commercial aircraft for decades. The recent uptick in design-ins may have something to do with manufacturers realizing that in addition to superior thermal performance, vibration resistance, and electro-mechanical endurance, our switches are just a whole lot less expensive than Fenwal, and other solutions commonly used.

Thermal Switch Uses in Modern Aircraft

All modern aircraft employ a number of thermal sensing elements for aircraft systems. So called Spot Fire Detection Systems refer to systems where overheat conditions are monitored at a specific point in a compartment or LRU bay. In order to receive FAA approval, these systems must demonstrate superior detection performance and have the proven ruggedness to survive in the harsh thermal and vibrational environment of modern aircraft.

Typical zones on aircraft that employ spot fire detection include:

Auxiliary power unit (APU)
Engine compartments
Cargo and baggage compartments
Lavatories on transport aircraft
Electronic bays
Wheel wells

Several detectors, or sensing devices, are available to solve these detection challenges, encompassing a number of different technologies. Many modern aircraft have some type of thermal switch system or thermocouple system. A thermal switch system has one or more indicator lights or audible alarms that trip when a thermal limit is reached.

They are sometimes connected in parallel with each other but in series with the indicator lights. If the temperature rises above a set value in any one section of the circuit, the thermal switch closes, completing the light circuit to indicate a fire or overheat condition. No set number of thermal switches is required; the exact number is usually determined by the aircraft manufacturer. On some installations, all the thermal detectors are connected to one light; on others, there may be one thermal switch for each indicator light.

CPI Rod & Tube Series Thermal Switches for Avionics Applications

Recently CPI thermal switches like our X1 have seen increasing use as replacements for other thermals owing to their extreme mechanical endurance, setpoint precision, and much lower unit cost making them extremely good choices in spares and retrofit applications. In a recent retrofit application undertaken for a Gulfstream, the CPI X1 thermal switch was qualified to replace the equivalent Fenwal Switch for almost half the cost. The CPI X1 Thermal Switch has 100% equivalent functionality and accuracy with arguably superior electromechanical endurance.

CPI’s X1 Series thermal can maintain a setpoint anywhere from 0 to 850F, with a +/- 5F tolerance standard. Tighter tolerances are available. CPI thermal switches are made entirely in the USA at our manufacturing facility in East Hanover New Jersey.

FEATURES	TECHNICAL SPECS	APPROVALS/CERTIFICATIONS
· Factory Adjustable Set Point	Temperature Range 0F -850F (-17C to 454C)	FAA, IPV-67, MIL-S-24236
· Highly Vibration Resistant	Response time max 5s
· Stainless-steel and inconel construction	Different Probe lengths from 2.25” to 5.00”
· Rapid Response Time and high tolerance versions available	Available in close-on-fall, open-on-fall, close-on-rise, open-on-rise configurations

Consider CPI Thermal Switches for your Next Spares Order

It makes good economic sense to consider CPI thermal switches for your next retrofit program, or as a design-in when your current thermals are too scarce or too expensive, or both! CPI’s USA made thermal switches are readily available through distribution, or directly from the factory for special configurations.

For more information, Contact your CPI Solutions team today.

Original content posted on https://www.cpi-nj.com/blog/aircraft-fire-detection-spot-fire-detection-systems/

April 13, 2018

CPI Thermal Switches – Keeping Astronauts Safe on the ISS

ISS-CPI-Thermals2-1000x288

The International Space Station (ISS) may be one of the most underappreciated technological (and geopolitical) marvels on, or off the planet. While it has been under development since the 1990’s it is actually the joint effort of five different space agencies representing 15 countries, all of whom contributed technology and resources to the ISS, especially the United States and Russia. It is a shining example of what scientists across borders can do together when focused on a common technological challenge.

The space station is the largest structure ever assembled in space. Orbiting at about 248 miles above the earth it is so large that it is often visible at night to the naked eye. It is longer than a football field (including the end zones) and can sleep 7 astronauts. It has habitable space often compared to that on a 747 jumbo jet, or about the size of a 5 bedroom house.

Astronaut Peggy Whitson aboard ISS

The ISS has been populated by astronauts since November of 2000 and has been populated non-stop for the almost 18 years since. Its useful accomplishments range over almost the entire spectrum of scientific discovery. For instance, scientists were able to grow proteins in space with a near-perfect crystalline structure. These proteins have unique properties that prove useful in the development of new drugs. Also the detection of “dark matter” long predicted by physicists, was accomplished using the Alpha Magnetic Spectrometer, deployed on the space station. This discovery sent shock waves through the scientific community, a moment as pivotal as Einstein’s E=MC². These achievements and many more were only possible over a long period in the pure gravity free environment afforded by the ISS.

Technology and Experiments Aboard the ISS

Needless to say, the ISS houses some of the most sophisticated technology and experiments that NASA and other space agencies can think of. Safety of the astronauts and “space tourists” that visit and reside there is of paramount importance. The stringent testing and documentation required by vendors and space agencies providing parts and subsystems to NASA, is well known to every subcontractor.

One of the experiments headed for the ISS from NASA is called the Flow Boiling and Condensation Experiment (FBCE), a joint effort between the Purdue University Boiling and Two-Phase Flow Laboratory (BTPFL) and the NASA Glenn Research Center. The experiment will fly aboard the International Space Station sometime in 2020 for two years or longer. The purpose of the FBCE project is to develop an integrated two-phase flow boiling and condensation experiment for the ISS to serve as a primary platform for obtaining two-phase flow and heat transfer data in microgravity.

Technicians at work preparing the FBCE for launch in 2020.

One of the key safety concerns of the FBCE experiment involves preventing the formation of a highly dangerous gas during the boiling phase of the experiment. The system uses a special fluid called perfluorohexane as the primary boiling/condensation substance, however when this substance exceeds 200C it can degrade into a highly toxic gas called Perfluoroisobutene (PFIB). PFIB when inhaled can cause pulmonary edema and other heart disorders. The goal is to have thermal switching in place at setpoints well below the 200C to prevent such an occurrence.

CPI’s Thermal Safety Solution for the FBCE.

CPI was approached by NASA to consider the use of a thermal switch solution based on our M1102 “PlugStat” series of thermal switches. The PlugStat Series of close tolerance, bimetal thermal switches act as a robust and accurate temperature control switch in a wide variety of thermal control systems at temperature ratings from 17C (0F) to 343C (650F). This is a slow make and break, open-on-rise device that is hermetically sealed, with 1/2-20UNF-3A thread mounting.

Despite NASA’s stringent material and electrical requirements, CPI’s off-the-shelf M1102 met their need for a reliable, space deployable, thermal safety switch solution.

Our switch uses:

Stainless Steel type 304
Stainless Steel type 321
Inconel Alloy 600
Stycast type 2651
Platinum Contacts

Our standard electrical rating of 2A at 28V was able to meet the electrical needs of NASA in the application. Additionally CPI provided all applicable CoC’s, Material Test Reports, and Chemical Analysis’ required to meet NASA’s stringent quality control.

CPI Thermal Switches – Good for the International Space Station…Good For You Too.

Sometimes a robust thermal switch is what you need, remote sensors and controls systems have their place, but in tough applications, they have their limits too.

The chances are that the team at CPI can fit our thermals into whatever application you have, without expensive customization.

Call the thermal switch engineering team today to discuss your application!

Original content posted on https://www.cpi-nj.com/blog/cpi-thermal-switches-keeping-astronauts-safe-on-the-iss/

March 10, 2018

CPI Thermal Switches Are Heating Up

The vast majority of thermal switch applications we get have to do with keeping things from getting too hot. Just a few examples of this include:

Gally fire detection
Avionics Bay Over Temperature
Brake over temperature warnings
Hydraulic fluid temperature monitoring
Engine oil over temperature monitoring
Gun barrel temperature monitoring for heavy duty weapons.
APU temperature monitor…

The list continues but most of these applications are essentially safety systems where our high temperature thermal switch products are uniquely capable and reliable. They detect a high temperature and then close or open to activate a cooling system, an alarm, or a slowdown of the machinery to restore acceptable thermal limits.

The Navy’s Phalanx Gun Firing System

In an interesting twist on our normal thermal switch applications, one of our SnapStat series, flange mount thermal switches, is being used to heat things up!

The Phalanx system is part of a family of military defenses referred to as “Close-in Weapon Systems” (CIWS ) They are designed to engage anti-ship cruise missiles and fixed-wing aircraft at short range. Phalanx is the most heavily deployed CIWS with thousands of these guns mounted on US naval vessels and exported to allies around the world. Like other close-in weapon systems, Phalanx provides ships with a terminal defense against anti-ship missiles that have penetrated other fleet defenses. Phalanx is unique in that it combines search, detection, threat evaluation, acquisition, track, firing, target destruction, kill assessment and cease fire into a single, small deck footprint, mounting.

The electronics on Phalanx are complicated and actually work most reliably at a higher operating temperature. In this application our AD006-501 will trigger when ambient temperature in the electronics bay drops below 70F. This activation triggers heaters built into the gun to keep circuit boards in the bay from getting too cold!

In this application, our AD006, part of our SnapStat line of thermal switches (0 – 300F) switches almost 10 amps of resistive power. It is set to close-on-fall at 70F but our thermal switches are available in all varients (close on rise, open on fall, etc…)

CPI Thermal Switches for Military Applications

CPI is certainly a well seasoned supplier of military grade, thermal control components, having produced parts for the US military for over 70 years. We maintain these designs through the years, supporting the military’s upgrade and obsolescence programs, providing drop in replacements when older thermal switches from other manufactures cannot be produced any more.

Whether you’re trying to keep it hot or cold in your application. CPI’s thermal switches get the job done. Call our engineering team today!

https://www.cpi-nj.com

Original content posted on https://www.cpi-nj.com/blog/cpi-thermal-switches-are-heating-up/

February 9, 2018

New MSHA Specification Requires Compressor Thermal Monitoring.

If you’re a manufacturer of high pressure, high horsepower industrial air compressors, like the kind that might be used in large drilling or mining operations, you need to know that the Mine Safety and Health Administration has new safety requirements affecting high horsepower, recirculating type air compressors.

The issue is related to the fact that an overstressed compressor can get extremely hot. So hot in fact that it can approach the flashpoint of the compressor’s lubricating oil. Indeed this is a common concern in machinery generally, where normal operating temperatures are driven to extremes by deployment in hot ambient environments, or extended non-stop usage, or even equipment failure.

Thermal runaway monitoring is a common problem in industrial compressors, generators, pumps, essentially anything that uses a motor and oil.

It is a problem that CPI thermal switches were designed to solve.

CPI Snap Stat Thermal Safety Switches – A brief Primer.

The key engineering concerns of designers looking for thermal safety in industrial applications are typically the robustness of the thermal switch, and the accuracy of the set point. In most thermal safety applications temperature set points are well known, being driven by the flash point of lubricants, with a wide safety margin, typically 50F or more. Upon reaching the flash point safety point, the thermal switch will trip, shutting down the compressor, generator, or motor. It can also be used to put the machine in a lower rpm state for critical systems.

Below is an image of the internal construction of our Snap-Stat switches

The CPI SnapStat Switch is designed for durability and reliability above all things. With a temperature range from 0 to 300F they cover most of the flash point settings common to high power machinery lubricants. Set points are built in at the factory and remain fixed and reliable for the life of the switch.

CPI’s SnapStat thermal switches have a bimetal snap disc that actuates a miniature microswitch . This double snap action makes these switches virtually immune to shock and vibration. Epoxy sealing or glass to metal hermetic sealing makes them ideal for demanding industrial or military applications.

Example of SnapStat use on a Commercial Compressor

One of the most common mounting options chosen by equipment manufacturers is exemplified by our AD-173, a pipe clamp mount version that integrates easily to existing designs.

Our client, a large compressor manufacturer for reciprocating type air compressors, uses our sensor on the compressor discharge line to monitor temperature. Locations and setpoints for the sensor may vary depending on whether you are designing in, or retrofitting into your compressor.

Other options include surface mount, thread mount, flange mount, and custom configurations.

CPI Thermal Switches are Problem Solvers For Machine Safety.

We’ve been creatively solving thermal safety problems for equipment manufacturers for over 60 years. Whatever your application, chances are we’ve got a robust, off the shelf solution for you.

Give CPI a call today to discuss your Thermal Switch Applicatiion.

Original content posted on https://www.cpi-nj.com/blog/new-msha-specification-requires-compressor-thermal-monitoring/

September 24, 2017

Monitoring Equipment Temperature is a SnapStat with CPI Switches

Almost every large commercial machine with an engine or motor of some sort has a system for monitoring temperature. Critical systems that are thermally controlled can be designed to shut down or throttle operation to prevent system failure or deliver cooling fluids that bring operation back into nominal ranges. In every case these switches must be trusted to prevent compromised safety situations which can cause damage to both man and machines.

Depending on the operating temperatures involved, CPI’s Thermal switch products are a go-to solution for hundreds of thermal monitoring applications around the world. Our line has evolved over 50 years to include three distinct thermal switch technologies that can accurately switch at precise setpoints from -20F to 1750F.

SnapStat Thermal Switch Applications for Harsh Environments

For operating conditions in the 0 to 300^o F degree range, CPI has a product line known as “SnapStat” which has been used in hundreds of harsh duty thermal monitoring environments.

Just some of these include:

Galley Fire Detection – our switch has been used to detect the conditions on a ship galley’s which could cause fire and activate warning lights or sirens.
Avionics equipment bay temperature Monitor – In this application our switch makes sure the overall temperature of the LRU bay stays in acceptable limits.
Food Processing Equipment – Items like Fryers and portable ovens have used our switches to monitor critical thermal limits in commercial cooking equipment.
Engine Oil Over Temperature – In equipment from Jets to Generators, CPI SnapStat thermal switches have been used to monitor oil temperature and activate safety systems prior to engine overheating.

A Versatile, Affordable solution to Over-Temperature Monitoring

The SnapStat switch is a close tolerance, bimetal type thermal switch made from all stainless steel and an option for a hermetically sealed design. The nature of the bimetal design makes it extremely resistant to high vibration, extremely accurate and the option for glass sealed, pre-soldered wiring of any length, makes it easy to integrate into your application.

Mounting options are equally flexible

We can even custom design a custom mounting for your application.

For over 50 years CPI has been providing robust thermal switching solutions into robust thermal applications. Give us a call today to discuss your design.

Control Products, INC

Providing creative & reliable control solutions

Thermal switches