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Effective coolant management is critical across a wide range of industries, from high-performance data center cooling distribution units (CDUs) to heavy construction vehicles, power generators, and semiconductor manufacturing. Proper coolant levels help regulate temperature, prevent overheating, and extend equipment lifespan. The ULS-200 solid-state level sensor from Gems Sensors is designed to provide highly accurate and reliable monitoring of aqueous (water-based) coolants, making it the ideal choice for demanding applications where precision matters.
Coolants and Their Role in Critical Systems
Coolants are used to dissipate heat, prevent corrosion, and ensure efficient system operation in liquid-cooled applications. The most common coolants include:
- Ethylene Glycol-Water Mix (EGW) – Common in data centers, power generation, and OHV applications, with typical ratios of 50:50 or 60:40 (water to coolant) to balance freeze protection and heat transfer.
- Propylene Glycol-Water Mix (PGW) – Used in environmentally sensitive applications, such as pharmaceutical processing and some industrial cooling systems.
- Deionized (DI) Water – Used in semiconductor manufacturing and sensitive electronics cooling to prevent electrical conductivity issues.
- Dielectric Fluids – Non-conductive coolants used in direct-to-chip and immersion cooling for high-performance computing and electrical insulation in transformers.
Regardless of the coolant type, accurate level sensing is essential to prevent costly failures, reduce downtime, and maintain system efficiency.
Why the ULS-200 Excels in Coolant Applications
The ULS-200 Advanced Level Sensor is uniquely engineered to provide accurate measurement of aqueous (water-based) coolants. Unlike traditional float sensors that stick, the ULS-200 operates using a solid-state open collector output with capacitive technology, which measures changes in the dielectric constant of the fluid to determine liquid levels with precision.
Key Features & Benefits of the ULS-200
- Designed for Water-Based Coolants – Engineered specifically for aqueous coolants, ensuring highly accurate and repeatable measurements.
- Reliable in Harsh Conditions – Performs in vibrating, high-temperature, and high-contaminant environments where mechanical floats may fail.
- Compact & Durable – A rugged, low-profile sensor for easy integration into tight spaces within CDUs, engines, and cooling tanks.
- Solid-state Switching – No moving parts means less maintenance and a longer lifespan.
- Customizable Configurations – Available in multiple mounting and output options, wet or dry signal, and built-in time delays to match specific application requirements.
Applications for the ULS-200 in Coolant Monitoring
Data Center CDUs (Coolant Distribution Units)
CDUs manage liquid cooling in rack-based and row-based liquid-cooled data centers. The ULS-200 ensures the coolant remains at optimal levels to prevent air pockets, system failure, or overheating, helping maintain peak thermal performance in high-density IT environments.
Heavy Construction Vehicles
Equipment like excavators, loaders, and mining trucks rely on cooling systems to protect engines and hydraulic systems from excessive heat. The ULS-200 ensures proper coolant levels, reducing downtime and overheating risks in extreme work environments.
Power Generators
Standby and prime power generators require efficient cooling to prevent overheating and ensure continuous operation. The ULS-200 helps monitor coolant levels in engine cooling reservoirs, providing early alerts for low fluid conditions and reducing unexpected failures.
Semiconductor Manufacturing
Semiconductor fabs use precision liquid cooling for process equipment, lasers, and wafer etching tools. The ULS-200's high accuracy and reliability make it ideal for monitoring DI water and other critical cooling fluids, ensuring stable thermal conditions for production.
Industrial and HVAC Cooling Systems
Large-scale HVAC chillers, industrial cooling loops, and refrigeration systems depend on water-based coolants. The ULS-200 provides real-time level monitoring, preventing compressor damage, pump cavitation, and system inefficiencies.
Gems Sensors: Your Expert Partner in Coolant Level Sensing
With decades of expertise in fluid sensing technology, Gems Sensors provides more than just products—we deliver custom-engineered solutions tailored to your exact application needs. Our team of experts can assist with:
- Application-specific sensor selection
- Customization for unique cooling system requirements
- Integration support for seamless deployment