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Semiconductor Cooling

Madison Company • July 31, 2024

Maintain Optimal Efficiency in High Pressure Applications with the Madison FS8000 Flow Sensor



Integral parts of an overall control system


Flow Sensors in cooling towers for semiconductor wafer manufacturing are not standalone components.


Understanding Integration


Sensor Placement: Flow sensors are strategically placed within the cooling tower system. Common locations include the water inlet, outlet, and recirculation lines.


Signal Output: Flow sensors generate an electrical signal (usually a voltage or current) proportional to the flow rate. This signal is transmitted to the control system.


Controller Input: The control system (often a PLC or DCS) receives the flow sensor’s signal. It processes this data to determine the actual flow rate.


Setpoints and Alarms: Setpoints are configured based on desired flow rates. Alarms are triggered if the actual flow deviates from these setpoints (e.g., due to clogs or leaks).


Feedback Loop: Based on flow sensor feedback, the control system adjusts cooling tower parameters (fan speed, chemical dosing, or water makeup). For example: If flow decreases, the system may increase fan speed to compensate. If flow exceeds a threshold, chemical dosing may be adjusted. Flow sensors are not just about maintaining the right flow rate. They also contribute significantly to safety. In the event of a significant drop in flow, indicating a malfunction, the control system can promptly shut down the cooling tower, preventing any potential damage. This safety feature is a key aspect of flow sensors.


Integration with Supervisory Control and Data Acquisition (SCADA): In more extensive facilities, flow sensor data is often integrated into a SCADA system. Operators monitor and control cooling tower performance remotely.


MADISON’s Flow Sensors precisely measure the volume of liquids or gases flowing through a tube or pipe to maintain a specified flow rate. When the flow rate deviates from the required range, the sensor alerts the equipment or operator to act or disrupt the operation of the equipment (auto shut down) to prevent a potential issue or damage.


The robust FS8000 inline flow switch is the pinnacle of reliability and performance in high-pressure applications. Engineered to resist clogging and deliver reliable, consistent switching, the FS8000 showcases innovation through its one-piece magnetic Ryton® piston.


Tailored for high-pressure industrial cleaning equipment and cooling systems applications, it embodies the perfect synergy of straightforward design and unwavering operational dependability for discerning engineers. Low-pressure drop over the sensing range makes this the ideal solution for most applications.


Key FS8000 Attributes


Wetted Materials

  • Housing/Body: 316 Stainless Steel
  • Piston: Ryton R4
  • Spring: 302 Stainless Steel
  • O-Ring: Viton
  • Epoxy


FS8000 Specifications

  • Fitting type: 3/8” NPT or 3/8” Compression
  • Flow Switch Points: 0.10 - 3.0 GPM
  • Set Point Accuracy: +/- 10%
  • Operating temperature: -20° to 275°F
  • Max. pressure: 1500 psi
  • Switch rating: 20-watt SPST, 120VAC/VDC, N.O.
  • Recommended Filtration: 100 micron
  • Approvals: UL recognition


See the FS8000 Flow Switch

Optimizing Liquid Cooling in Data Centers

By Madison Company • February 14, 2025
Liquid cooling is transforming data center efficiency, reducing energy costs, and improving thermal management. Explore innovative techniques for better cooling performance.

Flow Switches: The Silent Guardians of Data Center Cooling

By Madison Company • January 30, 2025
Data centers are the beating heart of our digital world, but they generate an immense amount of heat. Maintaining optimal temperatures is crucial to prevent equipment failure and ensure uninterrupted operation. In this delicate balancing act, flow switches play a critical role as the silent guardians of data center cooling systems. The Importance of Consistent Coolant Flow Data centers rely on sophisticated cooling systems, often utilizing chilled water or specialized coolants, to dissipate heat generated by servers and other equipment. Consistent coolant flow is essential to maintain the right temperature and prevent overheating. Any disruption in this flow can have disastrous consequences, leading to: Equipment Failure: Overheating can cause servers and other critical components to malfunction or fail completely, resulting in costly downtime and data loss. Reduced Lifespan: Operating equipment at elevated temperatures can significantly shorten its lifespan, leading to premature replacements and increased expenses. Performance Degradation: Overheating can cause performance issues, slowing down processing speeds and impacting overall efficiency. Flow Switches: Ensuring Cooling System Integrity Flow switches act as vigilant monitors within the cooling system, ensuring that the coolant is flowing as expected. These compact devices are strategically placed in pipes and cooling loops to detect any anomalies in the flow rate. Here's how they work: Continuous Monitoring: Flow switches constantly measure the flow of coolant, detecting any changes that could indicate a problem. Real-time Alerts: If the flow rate drops below a predetermined threshold, the flow switch triggers an alarm, notifying data center operators of a potential issue. Automated Response: In some cases, flow switches can be configured to automatically shut down equipment or activate backup cooling systems to prevent overheating. Benefits of Flow Switches in Data Center Cooling Prevent Overheating: By ensuring consistent coolant flow, flow switches prevent overheating and protect valuable equipment. Minimize Downtime: Early detection of flow issues allows for prompt intervention, minimizing downtime and preventing costly disruptions. Prolong Equipment Lifespan: Maintaining optimal temperatures helps extend the lifespan of data center equipment, reducing replacement costs. Optimize Cooling Efficiency: Flow switches help ensure that cooling systems are operating at peak efficiency, minimizing energy consumption and reducing operating costs. Enhance Data Center Reliability: By providing an additional layer of protection, flow switches contribute to the overall reliability and resilience of data center operations. Flow Switches: A Small Investment with Big Returns The cost of implementing flow switches is minimal compared to the potential losses associated with equipment failure and downtime. By investing in these critical components, data center operators can ensure the continuous operation of their facilities and protect their valuable assets. Don't leave the health of your data center to chance. Ensure optimal cooling and prevent costly downtime with the reliable protection of flow switches.

The Flow Switch: How Media Affects Material and Sensor Choice

By Madison Company • October 30, 2024
A Deep Dive into the World of Flow Switches As a leading flow switch manufacturer, we often get questions about the different types of flow switches and which ones are best suited for specific applications. The truth is there's no one-size-fits-all answer. One of the most crucial factors to consider when selecting a flow switch is the media that will be flowing through it. Why Media Matters The media, or the substance being monitored, can significantly impact both the material composition of the flow switch and the type of sensor used. Here's why: Chemical Compatibility: Different media have varying levels of corrosiveness. Using a flow switch made from incompatible materials can lead to corrosion, leaks, and ultimately, failure. For example, a stainless steel flow switch might be suitable for water but not for acidic liquids. Fluid Viscosity: The thickness of the media affects the flow characteristics and the force exerted on the sensor. Highly viscous fluids might require a more robust sensor or a different sensing mechanism altogether. Pressure and Temperature: The operating conditions also play a role. High pressure or extreme temperatures can limit material choices and necessitate specialized sensors. Particulate Matter: Some media contain suspended particles or debris that can damage or clog certain sensor types. In such cases, a flow switch with a larger opening or a non-invasive sensor might be necessary. Material Selection Choosing the right materials is essential for ensuring the longevity and reliability of a flow switch. Here are some common materials and their typical applications: Brass: A cost-effective option for water and other non-corrosive fluids. Stainless Steel: Offers excellent corrosion resistance and is suitable for a wide range of applications. PVC: A lightweight and affordable choice for use with mild chemicals. Polypropylene: Highly resistant to many chemicals and solvents. PVDF: Offers superior chemical resistance and can withstand high temperatures. Sensor Types The type of sensor used in a flow switch determines how it detects flow. Here are some common sensor types and their suitability for different media: Paddle/Vane: Simple and reliable, suitable for clean liquids with moderate flow rates. Piston: Can handle higher pressures and flow rates, suitable for viscous fluids. Thermal Dispersion: Measures the cooling effect of the flowing media, suitable for gases and liquids. Ultrasonic: Non-invasive and can be used with a wide range of media, including those with suspended solids. Electromagnetic: Measures the flow rate of conductive liquids. Finding the Perfect Match Selecting the right flow switch for your application requires careful consideration of the media and operating conditions. By understanding the impact of media on material composition and sensor type, you can make an informed decision that ensures optimal performance and longevity. Need help choosing the right flow switch? Our team of experts is here to help you find the perfect flow switch for your specific needs. Contact us today for a consultation!
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