What are the typical applications for a solistat?

What are the typical applications for a solistat?

The typical customer are manufacturers and integrators who make diesel powered equipment that is subject to EU or EPA (US) emissions requirements and whose equipment gets used when temperatures fall below 0˚ C.


[caption id="attachment_4734" align="alignnone" width="205"]closed crankcase ventilator closed crankcase ventilator[/caption]

Take a look at the attached picture.  The black thing is a CCV (closed crankcase ventilator) filter housing, sometimes called an oil separator, or a coalescer.  This is used as part of the emissions control scheme in about half of all diesel engines that require emissions restrictions.  The input to this is exhaust blowby (partially combusted diesel fuel that has leaked past—or blown by—the piston rings, plus some oil mist, plus some water vapor, plus some metal particles and dirt), the filter should remove everything so that the output should be only partially combusted fuel vapors that get routed back into the combustion path, and what drains out the bottom should be pure oil but it will typically have some water mixed in with it.  Typically, once a system is started and running, these won’t cause problems unless it’s very cold (for instance -30 and below), because the engine heat will keep the water from freezing.  However, when the machine is shut down for the night or the weekend, the water vapor that is trapped in the filter freezes solid as does any water that is running down the drain line.  Then the next morning, when they try to start the equipment, the equipment won’t start (or, in some of the older engines, head-gaskets will blow out).


The IntelliThaw™ jackets were designed to cost effectively heat objects such as the CCV filter housing (and, of course, the actual filter inside) in a short period of time.  We have been working on designs for a couple of different sizes of one manufacturer’s CCV filter housings, and we are capable of raising the temperature of the internal filter from -50˚C to approximately +10˚C in less than five minutes while consuming relatively little power from the battery.  If the customer wants to keep the parts just above freezing while the engine is off (thus drawing power strictly from the battery) this is possible depending on the length of time required and the capacity of the customer’s battery.


The other place where we’ve done these is for a PCV filter (Positive Crankcase Ventilator)—it’s similar to the CCV filter, but it doesn’t recycle anything back into the combustion path.  One jacket we made is shown on the PCV filter  in the ThermEvolve flyer I   That one is on a 6.2 litre Ford diesel engine that is used in a generator set.


Our products are more cost effective and prototypes can be delivered quickly.  In one example, we know that a solution from competitors were priced at USD 1300 and there were no discounts at any quantity.  In addition, the lead time for a first sample would have been 12 weeks.  Our solution was way cheaper USD 500 at 200 piece deliveries and we were able to deliver a functional model within three weeks and first articles from the tool within six weeks from order.


[caption id="attachment_4736" align="alignnone" width="595"]intellihose intellihose[/caption]

With regard to IntelliHose™ heated hoses, our intent is to be able to supply heated hoses in the smallest quantities and configurations .  In many cases, customers who have freezing PCV and CCV filters also have freezing drain or inlet lines where an IntelliHose will fix the problem.  We developed the IntelliHose concept to be able to quickly and cost-effectively provide small quantities of temperature-controlled heated hose.  for instance we do 200 pieces per year of a 6’ long (a little less than 2 m) 5/8” (about 16mm) hose for a PCV drain line.    In this case we procure a 1000’ spool of the customer’s specified hose and build as required…usually 25 at a time.  If the annual usage of hose would be much smaller, and if the customer purchases large quantities of the hose anyway, we can quote an IntelliHose using customer supplied material (the hose).


Also, there’s the issue of Diesel Exhaust Fluid (DEF).  This stuff freezes solid at -12˚ C.  The standard hose diameter for equipment use is 6mm.  The problem is that in the market there are only a couple of standard lengths (for the large LKW type machines and for pickup trucks here in the States); if your application requires a heated hose that is longer, you are out of luck.  That’s where we come in.  We can make odd lengths of DEF hose for surprisingly reasonable prices, and if a customer only needs one or two that’s usually not a problem.  In addition, we can thaw a frozen DEF hose more quickly than anyone else…the secret is our ThermEvolve™ technology.



One other application that comes to mind is keeping pneumatic valves from freezing—typical when the compressed air isn’t thoroughly dry and temperatures are below 0˚ C.  We have a SoliStat application with a company that makes small rail engines that are used for pushing train cars around in factories and switching yards.  We sell them a SoliStat and a heater and they install them on the valve and add their own insulation—I imagine this is a large pain in the ass, and that life would be much easier for them with a one-piece heating jacket.

we are an authorized distributor for the solistat products



thermevolve arctic diesel engine protection

thermevolve arctic diesel engine protection

The New Standard in Performance
Since 2011, engenity has shipped thousands of
SoliStat™ industrial thermostats. SoliStat, the one-of-a
-kind control for D.C. powered heating and cooling
applications, has been successfully deployed in many
applications where durability, resilience to a wide range
of environmental conditions, and reliability— greater
than 5M cycles MTBF—are of the utmost importance. also for arctic diesel engine protection!
In the time since SoliStat’s market introduction, we
have spoken with hundreds of system designers and
engineers who have successfully used SoliStat to
control heaters, chillers, and fans in a variety of
applications. One thing we have heard those customers
tell us over and over is that they would like complete,
engineered thermal management systems that could
be easily field-installed, rather than having to piece the
components together themselves.
Well, when our customers talk, we listen. Introducing
engenity’s patent pending IntelliThaw™ heating jackets
and IntelliHose™ heated hoses featuring ThermEvolve
IntelliThaw and IntelliHose products are applicationspecific,
engineered heating systems that can be
economically produced in small quantities for short-run
projects or one-offs. While originally conceived to
meet the needs of manufacturers of off-road diesel and
gas turbine powered equipment, IntelliThaw and
IntelliHose systems can be designed for any application
where D.C. operation is required.
Unlike other solutions, all IntelliThaw and IntelliHose
products are guaranteed to
• Maintain the designed setpoint
temperature all the way down to –40°C, so good for arctic diesel engine protection.
• Heat from –40°C to the setpoint faster
than any other available solution
• Consume less power at any ambient
temperature than any other available
Durable, Controlled, and Contained Heat
IntelliThaw heating jackets are designed to withstand
the rigors of use encountered by components in heavy
equipment. All IntelliThaw heating jackets consist of:
• A form-fitting insulator made of polyamide foam
• A heating element suitably sized to the application
• A SoliStat-based temperature control
The polyamide foam used in IntelliThaw heating jackets
is non-reactive with a wide range of industrial and automotive
chemicals, and offers a maximum continuous
operating temperature of 190˚C (374˚F). Setpoints for
the temperature control are determined based on customer
© 2015 engenity, LLC
ThermEvolve Flyer, Rev. A 1/2
ThermEvolve™ Technology
Patent Pending
IntelliThaw Heating Jacket on a
PCV Filter in a diesel engine
Heated Hoses—6mm and Larger
IntelliHose heated hoses are built with virtually any hose
specified by the customer:
• Inside diameters down to 6mm
• Length from 0.3m (1’) to 10m (33’)
All IntelliHose heated hoses consist of:
• High Temperature 150˚C (302˚F) EPDM insulation
• A heating element suitably sized to the application
• A SoliStat-based temperature control
An optional outer abrasion prevention layer is available
on request.
5/8” IntelliHose used
as a CCV drain line

ThermEvolve Flyer, Rev. A 2/2
IntelliThaw and IntelliHose Application Information
Made in the U.S.A.
SoliStat controls are not protected against long-term accidental reverse polarity connection to the power supply. Please
consult your local representative or the factory if you require reverse polarity protection!
engenity, LLC
739 Kasota Avenue Southeast
Minneapolis, Minnesota 55414-2842
+1 (612) 767-9590
Configured for Your Design
Every IntelliThaw heating jacket and IntelliHose heated hose is designed specifically for your application. Below is
the information we will need to get started designing and quoting yours.
• Component dimensions and geometry (SolidWorks files preferred, step files acceptable)
• Desired component maintenance temperature
• Minimum ambient temperature
• Operating voltage—6 VDC— 24 VDC standard, voltages up to 100V DC available on request
• Allowable maximum current consumption
• Desired rise time from minimum ambient temperature to maintenance temperature
• Additional pertinent information—lead wire length, system bypass/shutdown requirement, et al
• Estimated annual usage
Within three business days we will let you know whether your application is feasible. If it is, you will receive a quote
at that time. Once you have accepted the quote, we will then need a sample of the hose or component to be
heated—especially important if the component is mostly plastic. At this point we will build and test a prototype in
our lab.
After you have approved the prototype, we go to tooling for IntelliThaw heating jackets then to a pre-production
run, or for IntelliHose heated hoses we go straight to pre-production.
Lead time from quote initiation to receipt of first articles for IntelliThaw heating jackets ranges from six to eight
weeks, and three to four weeks for IntelliHose heated hoses.

New Freeze Prevention Products for Engine Systems Components

New Freeze Prevention Products for Engine Systems Components

engenity, LLC, the Minneapolis, MN-based manufacturer of SoliStat™—the only compact, rugged, one-piece industrial thermostat for D.C- powered temperature control applications—announces the launch of two new product lines for preventing the performance problems associated with frozen diesel-engine components such as CCV filters, PCV filters, fuel filters, and DEF lines among others.  The patent-pending products, IntelliHose™ temperature-controlled heated hoses and IntelliThaw™ heating jackets, both utilize the company’s ThermEvolve™ temperature control technology, which enables the new products to safely thaw frozen components faster than any other available solution.  ThermEvolve temperature control technology also makes it possible for the new products to prevent freeze-ups while consuming less power than other available solutions.

engenity has delivered thousands of SoliStat controls into a wide variety of applications since the product’s introduction in 2011.  “Although our customers have been highly satisfied with SoliStat,”   says engenity’s President, Rick Garber, “many potential customers have told us that what they want are complete temperature control solutions incorporating heater, temperature controller, and insulator in a single package that is easily installed in the field or factory.  IntelliThaw heating jackets and IntelliHose heated hoses meet that requirement.”

IntelliHose heated hoses can be economically implemented with hose diameters as small as 6mm, hose lengths from 0.3m to 10m, and in quantities from one to thousands.  “We are well aware that there are heated hose solutions readily available for high-volume users who are implementing very specific applications such as thawing DEF lines,” says engenity’s Garber.  “However, IntelliHose is intended for the systems integrators and machine builders who might have multiple projects in a given year, each of which requires, in small quantities, a different non-standard heated hose.”  Each IntelliHose incorporates virtually any customer-specified hose, a resistive heater that engenity guarantees is suitable to the customer’s application requirements, EPDM closed-cell foam insulation that is suitable for use up to 150˚C, and a SoliStat-based control that ensures safe, fast-acting temperature control.

As with IntelliHose, engenity’s IntelliThaw heating jackets are customer- and application-specific products that eliminate cold-weather-related problems associated with a number of components used in diesel-powered systems.  Each IntelliThaw heating jacket consists of:  a guaranteed-suitable-to-task electric heating element; a SoliStat-based control incorporating ThermEvolve technology; and, a form-fitted, closed-cell polyamide foam insulator that is capable of sustaining working temperatures up to 190˚C.

Can we receive a printed catalogue?