BIZOMAT MAKEOS · Maintenance
Coolant Top-up Balance
How much make-up fluid reaches the target within sump capacity?
Calculate the addition needed to correct an existing coolant concentration using a specified make-up mixture.
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How this tool works
Inputs, units and where to find them
| Input | Unit | Typical source |
|---|---|---|
| Existing working volume | L | Measured volume before correction, excluding unusable tank space. |
| Existing concentration | % | Representative measured concentration after the refractometer correction. |
| Make-up concentration | % | Actual concentration of compatible prepared make-up fluid. |
| Target concentration | % | Required final concentration within product instructions. |
| Maximum working volume | L | Maximum permitted working level with operating headroom, not brim capacity. |
What each input means
Open an input to see what it is, its units, the worked example and the common mistakes, with a small diagram.
What this means: Existing working volume
- What it is
- The volume of coolant now in the system before topping up, measured or estimated from the tank level.
- Units and format
- Enter a number in L: litres. The form accepts 0.001 L to 1000000 L. Required: the tool does not calculate until every input is valid.
- Example
- The form opens with 100 L as a worked example. It is an illustration, not a recommended value: replace it with your own figure.
- Effect on the result
- The required make-up volume is directly proportional to the existing volume.
- Get it right
- Exclude dead volume that cannot circulate; it does not take part in the mix.
What this means: Existing concentration
- What it is
- The concentration by volume of the coolant now in the sump, measured on a representative sample after it has circulated.
- Units and format
- Enter a number in %: percent: the number is read as a percentage, so type 8 for 8 %. The form accepts 0% to 100%. Required: the tool does not calculate until every input is valid.
- Example
- The form opens with 3% as a worked example. It is an illustration, not a recommended value: replace it with your own figure.
- Effect on the result
- The further it is from target, the more make-up is needed.
- Get it right
- Apply the product’s refractometer correction factor; a raw Brix reading is not the concentration.
What this means: Make-up concentration
- What it is
- The concentration by volume of the prepared make-up fluid you will add, such as a premix or neat concentrate.
- Units and format
- Enter a number in %: percent: the number is read as a percentage, so type 8 for 8 %. The form accepts 0% to 100%. Required: the tool does not calculate until every input is valid.
- Example
- The form opens with 20% as a worked example. It is an illustration, not a recommended value: replace it with your own figure.
- Effect on the result
- Make-up further from the target means less volume is needed.
- Get it right
- To raise concentration the make-up must be stronger than the target; to lower it, weaker.
What this means: Target concentration
- What it is
- The concentration by volume the system should reach after topping up, within the product instructions.
- Units and format
- Enter a number in %: percent: the number is read as a percentage, so type 8 for 8 %. The form accepts 0% to 100%. Required: the tool does not calculate until every input is valid.
- Example
- The form opens with 5% as a worked example. It is an illustration, not a recommended value: replace it with your own figure.
- Effect on the result
- A target further from the current concentration needs more make-up.
- Get it right
- Enter the same value as the current concentration if no correction is needed; the tool then returns zero.
What this means: Maximum working volume
- What it is
- The largest volume the system may hold while working, leaving headroom for drain-back, chips and foaming.
- Units and format
- Enter a number in L: litres. The form accepts 0.001 L to 1000000 L. Required: the tool does not calculate until every input is valid.
- Example
- The form opens with 150 L as a worked example. It is an illustration, not a recommended value: replace it with your own figure.
- Effect on the result
- It does not change the make-up volume, only the capacity check and margin.
- Get it right
- Use the safe working level, not the brim or nominal tank capacity.
Method and formulas
- Added volume = existing volume × (target − current concentration)/(make-up − target concentration).
- A target already equal to current needs no addition. Make-up at the target cannot bring a different initial concentration exactly to target in finite volume.
- Example: 100 L at 3%, corrected to 5% with 20% make-up, needs 13.333333 L and ends at 113.333333 L.
Limitations
- Compatible fluids, volume fractions, additive volumes and complete mixing are assumed. No removal or evaporation occurs during addition.
- The make-up concentration must be beyond the target in the required direction. Unattainable targets are rejected.
- Capacity exceedance is reported without clipping the quantity. Drain-and-replace planning is excluded.
- Default values are worked examples, not recommended settings or material properties.
Typical uses
- sump top-up
- coolant correction
- tank capacity
Who it is for
- Maintenance teams
- Machinists
What you get
- Required addition
- Final working volume
- Capacity margin
Interpreting the result
- Confirm working level before adding; if capacity fails, develop a separate supplier-approved correction plan.
- Circulate and recheck condition and concentration.
References
- Machinery’s Handbook, 29th edition (Industrial Press, 2012), printed pp. 1182–1187. Topic reference; implementation and examples are original, and no source tables are reproduced.
- Blaser Swisslube: Measuring coolant concentration — https://blaser.com/measuring-the-coolant-concentration/
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