Critical Sensing for Harsh Environments
A comprehensive guide to robust and highly accurate sensing technologies from Gems Sensors & Controls and Setra Systems, backed by Davis Controls expertise across Canada.
What You’ll Find in This Guide
- Why Sensing Technology Matters in Harsh Environments
- Gems Sensors and Setra Systems: Combined Expertise
- Pressure Measurement Solutions
- Level Sensing Technologies
- Flow Measurement and Control
- Cleanroom and Critical Environment Monitoring
- Key Industries and Applications
- Material Compatibility and Selection Guide
- Davis Controls: Your Gems and Setra Partner in Canada
- Frequently Asked Questions
Why Sensing Technology Matters in Harsh Environments
Industrial processes in chemical plants, oil refineries, pharmaceutical production, and semiconductor fabrication depend on precise, real-time measurement of pressure, level, and flow. When the operating environment involves high temperatures, corrosive chemicals, extreme pressures, or strict cleanliness requirements, standard instrumentation simply cannot deliver reliable results. Sensor failure in these conditions leads to unplanned downtime, safety hazards, product contamination, and regulatory violations.
Harsh environment sensing demands instruments built from chemically resistant materials, sealed against ingress, and engineered to maintain accuracy across wide temperature and pressure ranges. The cost of choosing the wrong sensor technology or material is measured in production losses, equipment damage, and compliance failures.
Gems Sensors & Controls and Setra Systems address these challenges with complementary product lines that cover the full spectrum of pressure, level, and flow measurement. Together they provide solutions ranging from simple float switches for tank level indication to high-accuracy pressure transducers for cleanroom differential pressure monitoring.
Gems Sensors and Setra Systems: Combined Expertise
Gems Sensors & Controls and Setra Systems are both part of the Amphenol family, bringing together decades of sensing innovation under a unified engineering philosophy. While each brand has its distinct strengths, their product lines are complementary rather than overlapping, giving engineers access to a broader range of solutions from a single source.
Why Two Brands? Gems Sensors focuses on rugged, versatile sensing for industrial and OEM applications, including level, flow, and pressure measurement in challenging media. Setra Systems specializes in high-accuracy pressure measurement, critical environment monitoring, and cleanroom compliance. Together, they cover virtually every sensing requirement from the factory floor to the cleanroom.
Gems Sensors & Controls: Built for Tough Conditions
Founded in 1955, Gems has earned a reputation for durable sensing products that perform reliably in demanding environments. Their portfolio spans pressure sensors and switches, level sensors using multiple sensing principles (float, ultrasonic, capacitance, conductivity, and optical), flow sensors and switches, and miniature solenoid valves. Gems products are found in oil and gas, chemical processing, food and beverage, marine, and industrial OEM applications worldwide.
Setra Systems: Precision Where It Counts
Setra Systems has been a leader in capacitive pressure sensing technology since 1967. Their core strength lies in extremely accurate, stable pressure transducers and transmitters used in laboratory, cleanroom, pharmaceutical, semiconductor, and HVAC applications. Setra is also the go-to brand for room pressure monitoring, where maintaining precise differential pressure between spaces is critical for contamination control and regulatory compliance.
Core Technology Strengths
Variable Capacitance Sensing (Setra): Setra’s patented capacitive sensing element delivers accuracy as fine as 0.05% of full scale with exceptional long-term stability. Unlike strain gauge designs that drift over time, the capacitive element maintains calibration accuracy, reducing maintenance intervals and improving measurement confidence.
Multi-Technology Level Sensing (Gems): Rather than offering a single level sensing approach, Gems provides float switches, ultrasonic sensors, capacitance probes, conductivity probes, and optical sensors. This breadth ensures the right sensing principle is matched to the application, whether the medium is clean water, corrosive acids, slurries, or hydraulic oil.
Material Versatility: Both brands offer wetted parts in a wide range of materials including 316 stainless steel, Hastelloy C-276, PEEK, titanium, Monel, PVDF, and various elastomers. This allows engineers to select the optimal material for chemical compatibility, temperature range, and cost.
Pressure Measurement Solutions
Pressure measurement is the most widely deployed sensing technology in industrial process control. From monitoring hydraulic systems on heavy equipment to verifying differential pressure across cleanroom walls, selecting the right pressure instrument depends on the application’s accuracy requirements, media compatibility, pressure range, and environmental conditions.
Gems Industrial Pressure Transducers and Transmitters
Gems offers a broad line of pressure transducers and transmitters for industrial and OEM applications. These instruments use piezoresistive and thin-film sensing elements housed in rugged stainless steel or Hastelloy bodies. Available in gauge, absolute, and sealed gauge configurations, they cover pressure ranges from vacuum to 60,000 psi. Output signals include 4-20 mA, 0-5 VDC, 0-10 VDC, and digital protocols.
Key Products
- 3100 Series compact pressure transmitters (general industrial, 0-15 to 0-10,000 psi)
- 3200 Series heavy-duty transmitters with conduit connection for harsh environments
- 3500 Series high-performance transmitters for OEM and process applications
- IS Series intrinsically safe transmitters for hazardous locations
- Customizable configurations for specific media, pressure range, and output requirements
Gems Pressure Switches
For applications requiring simple on/off control or alarm annunciation rather than continuous measurement, Gems pressure switches provide reliable, repeatable switching at a set pressure point. Available with adjustable or factory-set setpoints, these switches use proven diaphragm and piston sensing elements. Wetted materials include brass, 316SS, and elastomers selected for the target media.
Key Products
- PS Series compact OEM pressure switches with adjustable setpoints
- PS71 high-pressure switches rated to 7,500 psi
- PS75 low-pressure switches for HVAC and building automation
- Explosion-proof and submersible configurations available
Setra High-Accuracy Pressure Transducers
Setra’s capacitive pressure transducers deliver accuracy levels that set the industry standard for laboratory, pharmaceutical, and semiconductor applications. Their patented variable capacitance sensing technology provides 0.05% to 0.25% full-scale accuracy with outstanding long-term stability, eliminating the drift problems common in strain gauge-based instruments. These transducers are ideal for applications where measurement confidence directly affects product quality or regulatory compliance.
Key Products
- Model 205-2 ultra-high-accuracy industrial transducer (0.05% FS accuracy)
- Model 209 general-purpose transducer for HVAC and building automation
- Model 512 OEM miniature pressure sensor for space-constrained applications
- Model 270 barometric pressure transducer for weather and altitude measurement
- Multi-range and configurable output options available across the lineup
Level Sensing Technologies
Accurate level measurement is essential across virtually every process industry. Whether monitoring chemical storage tanks, detecting coolant levels in machine tools, or managing wastewater in treatment plants, the sensing principle must be matched to the application. Gems Sensors provides one of the broadest portfolios of level sensing technologies in the industry, ensuring the right fit for every medium and environment.
Float Level Switches and Sensors
Float-based level sensing is the simplest and most reliable technology for point-level detection and continuous level measurement in compatible liquids. Gems float switches use reed switch or solid-state outputs actuated by a magnetic float riding on a stem. Available in single-point and multi-point configurations, they handle temperature ranges from cryogenic to over 400°F and pressures up to 3,000 psi. Wetted materials include 316SS, polypropylene, PVDF, and Buna-N, making them suitable for water, oils, fuels, mild chemicals, and many other media.
Gems Float Level Products
From compact side-mount switches for hydraulic reservoirs to multi-point sensors for large storage tanks, Gems float technology covers a wide range of requirements. The LS-700 Series provides continuous level measurement with a 4-20 mA output, while the ELS-1100 and ELS-1150 Series offer economical single-point switching for OEM applications.
Ultrasonic Level Sensors
For non-contact level measurement, Gems ultrasonic sensors use sound pulses to determine distance to the liquid surface. This makes them ideal for corrosive, viscous, or contaminated liquids where a submerged sensor would be impractical or would foul quickly. Ultrasonic sensors provide continuous level output without any moving parts or media contact, reducing maintenance to near zero.
Capacitance Level Sensors
Capacitance-based level sensing works by measuring the change in electrical capacitance as the medium level changes around a probe. Gems capacitance probes can detect level in both conductive and non-conductive liquids, slurries, and granular solids. With no moving parts and robust construction, they are well suited for challenging media including adhesive liquids, coatings, and process chemicals.
Conductivity Level Sensors
For conductive liquids such as water, acids, and caustic solutions, conductivity probes offer a simple, low-cost approach to multi-point level detection. Gems conductivity sensors use electrodes that detect the presence of a conductive liquid to trigger relay outputs. They are commonly deployed in boiler level control, chemical dosing tanks, and wastewater systems.
Optical Level Sensors
Gems optical level sensors use an infrared LED and phototransistor in a compact prism-tipped probe. When the prism tip is in air, the light reflects internally and reaches the detector. When the tip is submerged, the light refracts into the liquid and the detector signal changes, providing a precise point-level indication. These sensors are immune to foam, vibration, and coating, making them excellent for applications where float switches or conductivity probes would give false readings.
| Sensing Technology | Best For | Measurement Type | Key Advantage |
|---|---|---|---|
| Float | Clean to moderately viscous liquids | Point or Continuous | Simple, reliable, cost-effective |
| Ultrasonic | Corrosive, viscous, or fouling liquids | Continuous (non-contact) | No media contact, no moving parts |
| Capacitance | Conductive and non-conductive liquids, slurries | Point or Continuous | Handles challenging media, no moving parts |
| Conductivity | Water, acids, caustic solutions | Multi-Point | Low cost, simple multi-point detection |
| Optical | Foaming, coating, or vibrating environments | Point | Immune to foam, vibration, coatings |
Flow Measurement and Control
Monitoring and controlling fluid flow is fundamental to process efficiency, product quality, and safety. Gems Sensors offers a range of flow sensing and control products designed for reliable operation in demanding industrial environments.
Flow Switches
Gems flow switches detect the presence or absence of flow in a pipeline, triggering an alarm or control action when flow drops below or exceeds a setpoint. Using paddle, piston, or thermal sensing elements, these switches are available in brass, stainless steel, and engineered plastic bodies for compatibility with water, oils, coolants, and chemicals. They protect pumps from dry-run conditions, verify cooling flow in equipment, and confirm flow in safety-critical systems.
Gems Flow Switches
The FS-925 Series uses a rugged piston design for reliable flow detection in water and oil-based fluids. The FS-380 Series provides economical paddle-style flow detection for larger pipe sizes. For applications requiring hazardous area certification, explosion-proof versions are available across the product line.
Flow Sensors
For continuous flow measurement, Gems flow sensors provide analog or digital output proportional to flow rate. Turbine-style sensors are well suited for clean, low-viscosity fluids, while positive displacement designs handle higher viscosity oils and fuels with excellent accuracy. These sensors integrate with PLCs, SCADA systems, and process controllers for closed-loop flow control and monitoring.
Miniature Solenoid Valves
Gems miniature solenoid valves provide precise on/off or proportional flow control for liquids and gases. Their compact size, low power consumption, and wide material compatibility make them ideal for analytical instruments, medical devices, fuel cells, and OEM equipment where space and weight are constrained. Available in 2-way and 3-way configurations with orifice sizes from 0.025″ to 0.187″, they handle pressures from vacuum to 150 psi.
Gems Miniature Solenoid Valves
The D-Series and B-Series valves are industry standards for miniature fluid control. With wetted materials including 316SS, PTFE, and PEEK, they are compatible with aggressive chemicals, high-purity fluids, and medical-grade media. Response times as fast as 5 milliseconds support high-speed sequencing applications.
Cleanroom and Critical Environment Monitoring
In pharmaceutical manufacturing, semiconductor fabrication, hospital isolation rooms, and laboratory environments, maintaining precise room pressure differentials is not optional. It is a regulatory requirement and a fundamental element of contamination control. Setra Systems is the recognized leader in room pressure monitoring, with products specifically designed for these demanding applications.
Setra Room Pressure Monitors
The Setra SRIM (Setra Room Isolation Monitor) and SRPM (Setra Room Pressure Monitor) series are purpose-built for monitoring and displaying differential pressure between adjacent spaces. These wall-mounted units feature bright, easy-to-read displays visible from a distance, configurable alarm setpoints, and relay outputs for integration with building management systems. They meet the monitoring requirements of USP 797/800, CDC/HICPAC guidelines for healthcare facilities, and cGMP standards for pharmaceutical manufacturing.
Setra SRIM and SRPM Room Pressure Monitors
The SRIM provides room-to-room or room-to-corridor differential pressure monitoring with a large LCD display, audible and visual alarms, and BACnet or Modbus communication. The SRPM adds multi-room monitoring capability with up to 8 channels in a single unit. Both products deliver the 0.001″ W.C. resolution required for critical environment compliance.
Key Capabilities
- 0.001″ W.C. resolution for precise differential pressure monitoring
- Large, high-visibility LCD display with backlight
- Configurable high/low alarm setpoints with audible and visual indicators
- BACnet MS/TP, Modbus RTU, and analog outputs for BMS integration
- Meets USP 797/800, CDC/HICPAC, and cGMP requirements
- Wall-mount or panel-mount installation options
Setra HVAC and Building Pressure Sensors
Beyond cleanroom-specific monitors, Setra offers a line of low-range differential pressure transmitters designed for HVAC applications including filter monitoring, duct static pressure control, and VAV box control. The Model 264 and Model 265 transmitters provide the accuracy and long-term stability needed for energy-efficient building automation while maintaining the rugged construction required for field installation.
Compliance Matters: Healthcare and pharmaceutical facilities must maintain documented, continuous pressure monitoring to satisfy regulatory audits. Setra room pressure monitors provide data logging, alarm history, and communication outputs that streamline compliance documentation and reduce audit preparation time.
Key Industries and Applications
The combined Gems and Setra portfolio addresses sensing requirements across a wide range of industries. The following table highlights key application areas and the recommended products for each environment.
| Industry | Typical Applications | Recommended Products | Key Requirement |
|---|---|---|---|
| Oil & Gas | Wellhead pressure, separator level, pipeline flow | Gems 3200 Series, IS Series, FS-925 | Hazloc certification, high pressure, corrosion resistance |
| Chemical Processing | Reactor pressure, tank level, chemical dosing | Gems capacitance probes, Hastelloy transducers | Chemical compatibility, corrosive media resistance |
| Pharmaceutical | Cleanroom pressure, process vessel level, pure water flow | Setra SRIM/SRPM, Gems optical level sensors | cGMP compliance, high accuracy, sanitary design |
| Semiconductor | Cleanroom differential pressure, gas flow, chemical level | Setra 205-2, Gems miniature solenoid valves | Ultra-high accuracy, contamination prevention, compact size |
| Food & Beverage | Tank level, CIP flow monitoring, process pressure | Gems 316SS float switches, flow switches | Sanitary materials, washdown resistance, reliability |
| HVAC & Buildings | Duct pressure, filter monitoring, room pressurization | Setra 264/265, SRPM, Model 209 | Low-range accuracy, BACnet/Modbus, energy efficiency |
| Water & Wastewater | Wet well level, filter pressure drop, chemical feed flow | Gems ultrasonic level, conductivity probes, FS-380 | Submersible, non-contact options, fouling resistance |
Material Compatibility and Selection Guide
Selecting the correct wetted materials is one of the most important decisions in harsh environment sensor specification. The wrong material choice leads to corrosion, sensor failure, process contamination, and safety hazards. Gems and Setra offer a wide selection of wetted materials to match virtually any process medium.
| Material | Chemical Resistance | Temperature Range | Typical Applications |
|---|---|---|---|
| 316 Stainless Steel | Good resistance to most industrial chemicals and mild acids | Cryogenic to 800°F | General industrial, food/bev, water treatment |
| Hastelloy C-276 | Excellent resistance to strong acids, chlorides, and oxidizers | Cryogenic to 1250°F | Chemical processing, flue gas, acid handling |
| Titanium | Outstanding resistance to seawater, chlorides, and bleach | Cryogenic to 600°F | Marine, desalination, chlor-alkali |
| Monel 400 | Excellent in seawater and reducing acids (HF, H2SO4) | Cryogenic to 1000°F | Marine, hydrofluoric acid service |
| PEEK | Broad chemical resistance, including strong acids and solvents | -76°F to 480°F | Semiconductor, pharmaceutical, ultra-pure water |
| PVDF (Kynar) | Excellent resistance to halogens, acids, and oxidizers | -40°F to 300°F | Chemical processing, water treatment, plating |
| PTFE (Teflon) | Near-universal chemical resistance | -328°F to 500°F | Aggressive chemicals, pharmaceutical, laboratory |
Selection Tip: When in doubt about material compatibility, consult the Gems or Setra chemical resistance guides, or contact Davis Controls’ application engineering team. They can recommend the optimal material based on your specific process chemistry, temperature, and pressure conditions. Getting this right at specification time prevents costly failures in the field.
Davis Controls: Your Gems and Setra Partner in Canada
Davis Controls is an authorized Gems Sensors and Setra Systems distributor, providing Canadian industry professionals with expert product selection, application engineering, and technical support. As a full-service instrumentation distributor with decades of experience, Davis Controls delivers more than products. They provide complete sensing solutions.
Application Engineering Support: Choosing between five different level sensing technologies, dozens of pressure transducer configurations, and multiple material options can be complex. Davis Controls’ application engineers work directly with your team to evaluate your process conditions, media chemistry, accuracy requirements, and budget to recommend the right product for the job.
What Davis Controls Brings to Your Project
- Expert product selection across the full Gems and Setra portfolio of pressure, level, flow, and valve products
- Application engineering support to match sensing technology and materials to your specific process
- Inventory and fast delivery across Canada, with stocking programs for high-volume OEM accounts
- Technical documentation including chemical compatibility guides, wiring diagrams, and installation manuals
- Cross-referencing assistance to identify Gems or Setra replacements for discontinued or competing products
- Calibration and service coordination to keep your installed instruments performing to specification
Frequently Asked Questions
What is the difference between Gems Sensors and Setra Systems?
Both brands are part of the Amphenol family but serve different primary markets. Gems Sensors specializes in rugged pressure, level, and flow sensors for industrial and OEM applications, with a focus on versatility and material compatibility. Setra Systems specializes in high-accuracy pressure measurement and critical environment monitoring, including cleanroom room pressure monitors and HVAC sensors. Together, they cover virtually every sensing application from the factory floor to the cleanroom.
Which level sensing technology should I choose?
The best technology depends on your medium and application. Float switches are the most reliable and cost-effective for clean, non-viscous liquids. Ultrasonic sensors are ideal when you need non-contact measurement in corrosive or fouling media. Capacitance probes handle conductive and non-conductive liquids plus slurries. Conductivity probes are simple and low-cost for conductive liquids like water. Optical sensors resist foam and coating that cause false readings with other technologies. Davis Controls’ engineers can help match the right technology to your application.
What accuracy can I expect from Setra pressure transducers?
Setra’s capacitive pressure transducers offer accuracy ranging from 0.25% of full scale on their standard models to 0.05% of full scale on their high-accuracy models like the 205-2 Series. This is significantly better than most strain gauge-based instruments, and Setra’s capacitive sensing technology maintains this accuracy over time with minimal drift, reducing the need for frequent recalibration.
Can Gems sensors handle corrosive chemicals?
Yes. Gems offers wetted materials specifically selected for chemical compatibility, including 316 stainless steel, Hastelloy C-276, titanium, Monel, PEEK, PVDF, and PTFE. The right material depends on the specific chemical, its concentration, temperature, and pressure. Davis Controls provides chemical compatibility guidance to ensure the sensor materials are appropriate for your process media.
Do Setra room pressure monitors meet pharmaceutical compliance requirements?
Yes. Setra’s SRIM and SRPM room pressure monitors are designed specifically to meet USP 797/800 compounding pharmacy requirements, CDC/HICPAC guidelines for healthcare isolation rooms, and cGMP standards for pharmaceutical manufacturing cleanrooms. They provide the 0.001″ W.C. resolution, alarm functionality, and data logging/communication capabilities required by these standards.
Are Gems products available with hazardous location certifications?
Yes. Gems offers intrinsically safe (IS) pressure transmitters, explosion-proof pressure switches, and hazardous location rated flow switches for installation in Class I and Class II hazardous areas. Specific certifications include CSA, FM, ATEX, and IECEx depending on the product family. Contact Davis Controls for help specifying the correct certification for your hazardous area classification.
Can Davis Controls help with cross-referencing from other sensor brands?
Yes. Davis Controls regularly assists customers in identifying Gems or Setra replacements for sensors from other manufacturers that have been discontinued, have extended lead times, or are not performing satisfactorily. Their application engineers can evaluate your current sensor specifications and recommend a compatible Gems or Setra product with equivalent or better performance.
What is the typical lead time for Gems and Setra products?
Many standard Gems and Setra products are available from Davis Controls’ inventory with same-day or next-day shipping. Custom configurations, including special materials, pressure ranges, or output signals, typically ship within 2 to 6 weeks depending on complexity. Davis Controls also offers stocking programs for OEM customers with recurring volume requirements to ensure consistent availability.
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