Boiler make-up: automatic and manual

Maintaining the efficiency and comfort of your home’s heating system, particularly in the winter, depends on keeping it operating at peak performance. The boiler, which heats the water that runs through radiators and underfloor heating systems, is an essential part of this setup. Homeowners can choose between automatic and manual boiler make-up when it comes to maintaining the water level in their boiler.

The purpose of automatic boiler make-up systems is to keep an eye on the boiler’s water level and add water automatically when necessary to keep it at the appropriate level. These systems frequently have sensors that, when the water level falls below a predetermined threshold, detect it and start adding water from a connected water source. Homeowners may find this hands-free method convenient as it guarantees constant water levels without requiring constant supervision and requires little effort.

However, with a manual boiler make-up, the homeowner must constantly check the boiler’s water level and manually add more water as needed. This could entail adding water using a designated filling system or opening a valve to let water enter the boiler. Although manual make-up calls for more work and attention from the homeowner, it offers a chance to visually inspect the boiler and spot any possible problems before they become serious.

The decision between an automatic and manual boiler make-up is influenced by a number of variables, such as the heating system’s complexity, budget, and personal preferences. Automatic systems provide comfort and assurance, especially for time-pressed homeowners who would rather not be involved in maintenance. For those who want to actively interact with their heating system, manual make-up may be preferred as it provides more control over the system.

In conclusion, homeowners who want to properly maintain their heating systems must comprehend the distinctions between automatic and manual boiler make-up systems. Homeowners can maintain the functionality and efficiency of their heating systems for a long time by making educated decisions by analyzing the advantages and disadvantages of each option and taking into account their unique needs.

Why make-up in the heating system?

It is impossible to totally prevent water leaks from the system, even in the best-designed heating systems with premium boiler and heating network piping.

As a result, a make-up unit is installed, and the boiler owner should be aware of the circumstances under which using regular tap water to refuel hot water boilers is permitted.

The following are the primary causes of the internal boiler circuit’s decreased water volume:

1. Technological discharge of coolant in the process of heating the boiler from a cold state, caused by thermal expansion of water and the need to reduce the pressure.
2. Operation of Maevsky valves.
3. Performing emergency or preventive repairs.
4. Emergency leaks from the boiler, at rupture or corrosion damage of internal heating surfaces.
5. Leakage of the safety valve, in case of emergency water discharge.
6. Violation of the boiler maintenance schedule.
7. Poor water quality and scaling in pipes.
8. Poor quality of heating circuit installation.

A specialized unit that typically comes with the boiler is used to perform boiler make-up using raw water. If it isn’t there, the manufacturer has to tell the customer about the required piping layout, the equipment’s minimum capacity calculation, and the equipment specifications.

In closed systems, normal leakage is defined as 0.75% of the actual water volume in the network, boiler circuit, and heating appliances. In open systems, this value is increased by one.2 of the DHW needs’ estimated hourly volume. Chemical pretreatment is required for make-up water in heavy-duty hot water and steam boilers.

When it comes to insulation and heating for your house, the important boiler make-up deserves consideration, offering options for manual and automatic systems. The boiler make-up system, which keeps water levels stable and guarantees effective operation, is your heating system’s lifeline. While manual systems provide more hands-on control and allow for customized adjustments, automatic systems are more convenient as they regulate water levels without the need for constant supervision. For homeowners hoping to maximize comfort, efficiency, and peace of mind from their heating systems, it is imperative that they comprehend the distinctions between these options.

Signs that there is insufficient water in the heating system

Without making any mistakes, the boiler unit’s owner or operating staff must ascertain the coolant deficit in its circuit. Initially, with the aid of a pressure gauge, as a leak will cause the medium’s pressure within the network to drop.

Modern autonomous systems with multifunctional automation include a mandatory indicator for the boiler’s protection that includes the leakage of the water heating network. If this happens, staff members will be alerted through both visual and auditory cues.

In the case of older boiler modifications, the following indicators indicate when coolant pressure drops because of inefficient leaks:

• overheating of the supply coolant, while the radiators cool down quickly due to disruption of water circulation in them;
• the water in the network starts to gurgle, especially in the heating risers;
• The process of boiler cycling starts, when the burner of the gas unit is frequently switched on/off;
• triggering of the safety valve of the solid fuel boiler unit due to overheating of the coolant.

Leaks are particularly dangerous in solid fuel boilers because of the high inertia of the combustion process, which means that the boiler cannot stop until all of the fuel is burned. As a result, there is a high risk that the furnace’s heat exchangers or pipes will overheat, burst, and release an open source of fire into the furnace room.

How the make-up valve works

Through the addition of water from the municipal water supply system, the valve is installed to maintain the working pressure in the internal circuit of the heating system. The number of floors in the house and the internal head losses in the network determine the standard pressure for the heating network; typically, 2 to 2 atm is adequate. five atm.

An automated make-up mechanism is employed, which is a pressure-reducing valve. Simultaneously, if the water pressure decreases, the valve’s pressure stops, the spring pushes the stem downward and opens the seat hole. Water from the tank or mains enters the network through it. As the system fills up, the diaphragm and orifice will close due to an increase in pressure.

Utilized most frequently in systems with an automated air vent that expels air from the network, is the pressure reducing valve. Install a check valve to safeguard the system against the medium moving through the reducer in the water mains in the opposite direction.

Which tap to choose

Nearly all modifications of both domestic and foreign boilers have boiler boilers installed, including Vaillant boiler make-up taps, Immergas, Baxi, Ariston, and Ferroli boilers. These valves are typically required to be replaced by the user in the event that the factory model malfunctions. In this instance, installing the one that came with the boiler is preferable. It is important to consider the dimensions, working pressure, and flow rate of the water to be supplied when selecting an alternative model.

Typical make-up valves for gas boilers:

• Ariston electromagnetic boiler make-up tap, price: 1780 rubles.;
• boiler make-up tap Baxi Main, price: 1590 rub.;
• boiler make-up tap Bosch ZW23-1KE/AE, price: 1090 rubles.;
• boiler make-up tap Daewoo Gasboiler 100-300 ICH, price: 1820 rub.;
• make-up tap for boiler Vaillant Max, Pro, Plus, price: 590 rubles.;
• make-up tap Immergas Mini 1.015093, price: 320 rubles.;
• make-up tap of the two-circuit gas boiler Ferroli Divatech, Divatop, price: 800 rubles.;
• Protherm Panther v18, price: 560 rubles.

Elements of the make-up device

The hourly capacity of the normative make-up will determine the heating network’s make-up scheme. Large main heating networks typically consist of an electric pump, automation, chemical water treatment, water tank, shut-off and control valves, and a water make-up that can reach hundreds or even thousands of cubic meters per hour. The number of scheme elements can be altered significantly when performance is reduced.

Boiler reducer

In order to provide make-up water to the network circuit, a reducer is installed on the return line upstream of the boiler. Due to leaks or air lock discharge, water from the water mains enters the valve at a pressure drop in the network pipeline. If the plan calls for installing a circulation pump, it is installed after everything else. If not, there’s a chance the entire heating system won’t work.

Without the need for service staff, the reducer runs automatically. It is not always convenient because there are situations when the leak cannot be stopped and it gets large enough to be an emergency. As a result, a lot of users favor manual make-up mode or set up systems with high leakage level alarms.

Pump group

Upstream of the boiler units, make-up water is supplied by one or more pumps at a pressure greater than that of the return mains water. A pressure sensor activates the pump, which removes water from the make-up water tank.

There are systems that can draw water from a borehole or well using a submersible pump. The normative make-up’shourlycapacity is used to calculate the pumping group; a minimum of two electric pumps are required, one of which is a reserve.

Executive mechanism

It is put in place to operate a make-up line gate valve. It typically comes with a shut-off valve and a check valve as part of a make-up unit. It can communicate with the pump to control it via electrical contacts. The mechanism’s operating pressure is set to the allowable limit. Typically, an electric motor-powered valve serves as the executive device.

The electric motor begins to rotate when the return pressure drops by 10% below the allowed pressure. This opens the make-up valve, allowing water from the mains water supply or the water tank with a pressure higher than the return to enter the internal heating circuit.

When it fills and the pressure reaches the operating level, the sensor signals for the valve to be closed, which causes the electric motor to start rotating in the other direction.

Check valve

This component is essential to any make-up circuit because it keeps network water out of the main water supply and water tank, which could contaminate tap water and cause the boiler unit to shut down unexpectedly.

When the shut-off and control valves don’t close tightly, or if the mains’ pressure is lower than the return’s, water backflow can happen even during make-up. After the actuator, the check valve is installed downstream.

There are variations in the trade network when it is integrated into the pressure-reducing valve’s body. These days, a "flow interrupter" or a check valve up front are installed on the make-up unit.

Make-up water treatment filters

Impurities in raw water have a detrimental effect on the functioning of thermal equipment, particularly the boiler. They can deposit themselves as scale and sludge on the boiler’s heating surfaces, slowing the coolant’s flow and increasing the risk of overheating, which can lead to pipe rupture.

Equipment for treating extra-pure water is installed for this reason.

Sand or activated carbon-filled mechanical filters are used for a more basic cleaning. It is also possible to arrange simpler devices, such as strainers, which have a larger body diameter than the return pipes and in which mesh filters are installed. As water enters the strainer, suspended solids precipitate out as its velocity drops. Specialized softener filters should be used to remove harder salts that are more complex.

How to make a manual make-up

When filling the heating circuit with water, manual make-up is frequently the simplest and most appropriate method. This is particularly true if the heating networks are inside and have no leaks along their entire length.

In this instance, the network’s water circulates within a regulated, enclosed area, and water is added to the circuit no more frequently than once every ten days or less. Recharges for well-established in-home heating networks typically occur once per season.

Manual make-up scheme

Making a manual make-up is the simplest way to add water back into the heating circuit. To do this, a pipeline from the municipal water supply system must be extended and connected to the heating network’s return line. At this point, a water purification filter and a cut-off tap are installed.

The plan works flawlessly in modestly sized one-story homes with basic heat supply systems. Since the pressure and temperature of the mains water are lowest in this section, the line is connected to the return up to the circulation pump.

The make-up system arranges the water supply for open heating networks so that it goes straight into the expansion tank rather than the return. It’s not required to check the make-up level by going to the attic. The plan is to connect the expansion tank to three separate outputs—the supply, return, and make-up pipelines.

By opening the valve on the control pipe leading to the sewerage system, the level in the tank can be adjusted. The make-up valve is opened and left open until there is no overflow from the control pipe; if water flows after the valve is opened, it indicates that the system is full.

The decision between manual and automatic boiler make-up systems is influenced by a number of variables, such as your lifestyle, preferences, and financial situation. By lowering the need for manual intervention, automatic systems provide convenience by automatically replenishing the water levels in the boiler. They work especially well in busy homes or businesses where it may not be possible to keep an eye on everything all the time. However, manual make-up systems offer greater control and might be chosen by people who have particular needs for water quality or who wish to keep a close eye on water levels.

It’s important to evaluate your unique needs and circumstances when deciding which kind of boiler make-up system to install. Because they require less manual oversight, automatic systems can save time and effort over time, even though they can be more expensive initially due to installation and component costs. Although manual systems offer more flexibility and control over the process, they may need to be monitored and adjusted more frequently.

Consideration must also be given to each system type’s maintenance needs and dependability. In order for automatic make-up systems to continue working effectively, they may need routine maintenance because they depend on sensors and valves for proper operation. Despite having a simpler design, manual systems might need more frequent maintenance and observation to avoid problems like contamination or low water levels.

The choice between manual and automatic boiler make-up systems ultimately comes down to your needs and priorities. If simplicity of use and convenience are your top priorities, an automatic system might be the best option. A manual system, however, might be more appropriate for you if you would rather have more control over the procedure and are prepared to put in the time and effort necessary for manual monitoring. Whichever option you select, safe and effective boiler operation depends on correct installation and ongoing maintenance.

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