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A process controller like the PMA KS98-2 or KS98-Rail is ideal for managing complex systems such as Coolant Distribution Units (CDUs) in modern liquid-cooled data centers. These controllers excel in multi-variable monitoring and control, providing precise regulation of flow, pressure, and level, while also offering communication flexibility for integration into a facility’s broader infrastructure. Here’s how the KS98 family enables smarter, more connected cooling.

1. Flow Rate Control with Real-Time Adjustments

• Integration with Flow Sensors: The KS98-2 interfaces seamlessly with Gems’ high-accuracy flow sensors, continuously monitoring coolant flow in the CDU and adjusting to the thermal loads of specific server racks or zones.
• Dynamic Setpoint Management: Inputs from temperature sensors placed on cold plates or server inlets allow the controller to dynamically adjust flow rates to meet demand, ensuring targeted and efficient cooling.
• Proportional Control: PID control loops enable smooth modulation of pump speed and valve position, minimizing energy waste and maintaining optimal flow without overshooting.

2. Pressure Monitoring and Management

• Pressure Sensor Integration: Connected to Gems’ and Setra’s robust pressure transducers, the controller actively monitors system pressure in both supply and return lines, maintaining balance across the loop.
• Adaptive Pump Control: If pressure deviates from target ranges, the KS98-2 adjusts pump operation or triggers relief mechanisms to protect the system.
• Alarming & Shutdowns: Integrated alarm logic ensures that pressure deviations initiate alerts or automated system responses to safeguard uptime.

3. Level Monitoring in CDUs

• Reservoir Management: The KS98-2 can interface with Gems level sensors, such as continuous transmitters or point-level switches, to monitor fluid levels in expansion tanks, manifolds, or coolant reservoirs.
• Low-Level Protection: It maintains safe pump operation by shutting down or alerting operators in low-level conditions.
• Redundant Sensor Support: Dual-sensor configurations can be used for redundancy or tiered alert thresholds, especially in critical systems.

4. Temperature and Humidity Monitoring for Optimal Environmental Conditions

• Temperature & Humidity Sensors Integration: While primarily controlling the liquid circuit, the KS98-2 can monitor ambient humidity using auxiliary sensors to assess condensation risk around equipment.
• Condensation Prevention: By adjusting CDU outlet temperatures or triggering local dehumidifiers, the controller helps prevent moisture buildup near sensitive electronics.
• Data Logging: Historical data collection enables trend analysis for predictive maintenance and long-term thermal management.

5. Multi-Variable Control and Coordination

• Simultaneous Monitoring: The KS98-2 handles multiple simultaneous inputs: temperature, flow, pressure, humidity, and level offering full visibility into CDU performance.
• Logic Programming: Built-in logic tools allow customized routines, such as:
• Boosting flow during load spikes while staying within pressure limits.
• Adjusting flow based on level sensor inputs in reservoir tanks to avoid pump cavitation or dry-run conditions.

6. Data Communication and System Integration

• Flexible Protocol Support: The KS98-2 supports standard protocols including Modbus, PROFIBUS, and Ethernet.
• BMS Integration: When BACnet is required, Modbus-to-BACnet gateways allow seamless communication with Building Management Systems, bridging operational technology with facility infrastructure.
• Remote Interface: Operators can access real-time data remotely through graphical dashboards, allowing faster response and system optimization.

7. Energy and Operational Efficiency

• Optimized Pump Usage: Fine-tuned flow control helps reduce pump load and energy consumption, increasing overall efficiency.
• Predictive Maintenance: The controller’s trend logging and threshold monitoring help identify signs of fouling, clogging, or degradation before failure occurs.

8. Flexibility and Scalability

• Modular I/O: The KS98 platform supports customizable input/output configurations, adapting easily to expanding or changing CDU systems.
• Multi-Zone Management: Multiple CDUs or zones can be controlled independently within a single system, streamlining scale-out deployment in high-density data halls.

9. Integrated Solutions from Gems Setra Featuring Trusted PMA Control Technology

• Unified Architecture: As part of the Gems Setra family, PMA controllers like the KS98-2 and KS98-Rail are designed for tight integration with Gems’ and Setra’s trusted sensing technologies.
• Sensor Coverage: Gems Setra provides an end-to-end portfolio of flow, gauge pressure, differential pressure, temperature & humidity, solenoid valves, and level sensors each tuned for the demands of liquid cooling or hybrid cooling applications.
• Custom Solutions: Gems Setra also engineers fluidic manifolds and assemblies incorporating these sensors, simplifying CDU assembly and improving field reliability.

The PMA KS98-2 and KS98-Rail controllers bring a new level of intelligence and flexibility to CDUs in liquid-cooled data centers. By pairing sophisticated logic and control with the precision of Gems Setra’s sensing technologies, and by enabling integration into BMS systems, data centers gain a reliable, scalable, and energy-efficient cooling solution. Together, these technologies empower smarter, safer, and more sustainable liquid cooling infrastructure, ready to support the rapidly rising densities of next-generation data centers.