Leader Evaporator 2X6 User manual

Leader Evaporator Co., Inc.
49 Jonergin Drive
Swanton, VT 05488
Tel: [phone]
www.leaderevaporator.com
LEADER EVAPORATOR STANDARD 2X6 / 2X8 WOOD FIRED ARCH

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TABLE OF CONTENTS
EQUIPMENT DESCRIPTION ................................................................................................................................................................4
DIAGRAM OF THE STANDARD WOOD FIRED ARCH ............................................................................................................................6
SETUP OF THE STANDARD WOOD FIRED ARCH..................................................................................................................................6
RECEIVING YOUR ARCH: ........................................................................................................................................................................6
SUGAR HOUSE SETUP: ...........................................................................................................................................................................6
FOUNDATION FOR THE ARCH ................................................................................................................................................................7
SETTING THE ARCH ON THE FOUNDATION:...........................................................................................................................................7
INSTALL THE FRONT DRAFT DOOR ADJUSTMENT LATCH....................................................................................................................... 8
INSULATING THE ARCH:.....................................................................................................................................................................9
General Notes................................................................................................................................................................................... 9
Cementing of Insulation Board and Bricks ...................................................................................................................................................... 11
Bricks...............................................................................................................................................................................................................11
Standard Wood Fired Arch Design..................................................................................................................................................................12
Considerations For A MAX/COMBO Flue Pan ................................................................................................................................................. 12
Insulating a Drop Flue Arch ............................................................................................................................................................12
Insulating a 2X6 Arch ...................................................................................................................................................................................... 12
Insulation Board ........................................................................................................................................................................................ 13
Cut Out Diagram...................................................................................................................................................................................13
Front..................................................................................................................................................................................................... 14
Left Side................................................................................................................................................................................................14
Right Side ............................................................................................................................................................................................. 15
Back...................................................................................................................................................................................................... 15
Rear Grate Shelf to Top of Incline ........................................................................................................................................................16
Ash Pit Rear .......................................................................................................................................................................................... 16
Bricking ......................................................................................................................................................................................................17
Floor behind Top of Incline .................................................................................................................................................................. 17
Back...................................................................................................................................................................................................... 17
Left Side................................................................................................................................................................................................18
Right Side ............................................................................................................................................................................................. 18
Ash Pit Rear .......................................................................................................................................................................................... 19
Install the Grates .................................................................................................................................................................................. 19
Front..................................................................................................................................................................................................... 20
Grate Shelf to Top of Incline................................................................................................................................................................. 20
Insulating a 2X8 Arch ...................................................................................................................................................................................... 21
Insulation Board ........................................................................................................................................................................................ 22
Cut Out Diagram...................................................................................................................................................................................22
Front..................................................................................................................................................................................................... 23
Left Side................................................................................................................................................................................................23
Right Side ............................................................................................................................................................................................. 24
Back...................................................................................................................................................................................................... 24
Rear Grate Shelf to Top of Incline ........................................................................................................................................................25
Ash Pit Rear .......................................................................................................................................................................................... 25
Bricking ......................................................................................................................................................................................................26
Floor behind Top of Incline .................................................................................................................................................................. 26
Back...................................................................................................................................................................................................... 26
Left Side................................................................................................................................................................................................27
Right Side ............................................................................................................................................................................................. 27
Ash Pit Rear .......................................................................................................................................................................................... 28
Install the Grates .................................................................................................................................................................................. 28
Front..................................................................................................................................................................................................... 29
Grate Shelf to Top of Incline................................................................................................................................................................. 29
Insulating a Raised Flue Arch (Not Max Combo) ............................................................................................................................30
Insulating a 2X6 Arch ...................................................................................................................................................................................... 30
Cut Out Diagram...................................................................................................................................................................................31
Left Side................................................................................................................................................................................................32
Right Side ............................................................................................................................................................................................. 33
Back...................................................................................................................................................................................................... 34
Ash Pit Rear .......................................................................................................................................................................................... 34
Front..................................................................................................................................................................................................... 32
Rear Grate Shelf to Top of Factory Baffle............................................................................................................................................. 35

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Bricking ......................................................................................................................................................................................................36
Arch Floor Behind Factory Baffle.......................................................................................................................................................... 36
Left Side................................................................................................................................................................................................37
Right Side ............................................................................................................................................................................................. 37
Back...................................................................................................................................................................................................... 38
Ash Pit Rear .......................................................................................................................................................................................... 38
Install the Grates .................................................................................................................................................................................. 39
Front..................................................................................................................................................................................................... 39
Grate Shelf to Top of Factory Baffle ..................................................................................................................................................... 40
Rear Baffle............................................................................................................................................................................................40
Baffle Area Completion ........................................................................................................................................................................ 41
Insulating a 2X8 Arch ...................................................................................................................................................................................... 42
Insulation Board ........................................................................................................................................................................................ 43
Cut Out Diagram...................................................................................................................................................................................43
Left Side................................................................................................................................................................................................44
Right Side ............................................................................................................................................................................................. 45
Back...................................................................................................................................................................................................... 45
Ash Pit Rear .......................................................................................................................................................................................... 46
Front..................................................................................................................................................................................................... 44
Rear Grate Shelf to Top of Front Factory Baffle ................................................................................................................................... 46
Bricking ......................................................................................................................................................................................................47
Rear Floor Behind Front Factory Baffle ................................................................................................................................................ 47
Left Side................................................................................................................................................................................................47
Right Side ............................................................................................................................................................................................. 48
Back...................................................................................................................................................................................................... 48
Ash Pit ..................................................................................................................................................................................................49
Install the Grates .................................................................................................................................................................................. 49
Front..................................................................................................................................................................................................... 50
Rear Grate Shelf to Top of Front Factory Baffle ................................................................................................................................... 50
Behind Rear Factory Baffle...................................................................................................................................................................51
Baffle Area Completion ........................................................................................................................................................................ 51
INSTALL TAPER AND STACK .................................................................................................................................................................52
Roof Penetration and the Type of Roof Jack:..................................................................................................................................52
Install the Taper and Stack .............................................................................................................................................................52
THE FIRST BOIL ...............................................................................................................................................................................55
OPERATING THE EVAPORATOR .......................................................................................................................................................55
DAILY SHUTDOWN ..............................................................................................................................................................................56
MAINTENANCE ....................................................................................................................................................................................56
DAILY.....................................................................................................................................................................................................56
PERIODIC................................................................................................................................................................................................ 56
BEGINNING OF SEASON STARTUP................................................................................................................................................................ 56
FEEDBACK........................................................................................................................................................................................56
NOTES .............................................................................................................................................................................................56

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EQUIPMENT DESCRIPTION
A standard wood fired arch from Leader Evaporator is designed to have a deeper and wider firebox to increase firing
capacity. There is a large draft door to maximize airflow. Grates are designed with a double “V” to give the strongest
and most warp resistant properties.
NOTE: Pictures, sketches and drawings presented in this document are not to scale.
The Leader Standard Wood Fired Arch consists of the following parts:
ITEM
LEADER
ORDER #
DESCRIPTION / PHOTO
ITEM
LEADER
ORDER #
DESCRIPTION / PHOTO
Arch
As Ordered
Grates
(Qty: 4)
75021
Base Stack
512410L
(stainless
steel)
Smoke stack
2X6 Qty: 3
2X8 Qty: 4
5210S
(stainless steel)
Draft Door
Latch
Wire tied to
draft door of
arch
75169
Flue Brush Rod
(8’ )
60071 (6’)
60072 (8’)
Rod end is threaded
to allow mounting of flue brush
Pipe legs
(Qty: 2)
Wire tied to
inside rear of
arch
77021

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OPTIONAL SPARE PARTS, SETUP PARTS AND OPERATIONS EQUIPMENT AND SUPPLIES
ITEM
LEADER
ORDER #
DESCRIPTION / PHOTO
ITEM
LEADER
ORDER #
DESCRIPTION / PHOTO
Upper Half
24”
75170
Lower Half 24”
75171
10” Leader
Style Roof
Jack
Peak or
Side of Roof
Style
INSULBOARD 1”
–1’X3’ (3 sq. ft)
65000
3000oFull
Brick
65003
3000oHalf Brick
65006
Refractory
Cement
65001
Jaco Firestop
Plus (10.5 oz
tube)
65196
10” Stack
Cover
5410

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DIAGRAM OF THE STANDARD WOOD FIRED ARCH
SETUP OF THE STANDARD WOOD FIRED ARCH
NOTE: The following information pertaining to setup of an arch is to be considered one suggested method. Installations
should meet all applicable governmental regulations and standards.
RECEIVING YOUR ARCH:
Upon receipt of the arch, it is recommended the following tasks be performed:
1. Protect all incoming materials from damage and the environment. If possible place the arch at the location
where it will be setup (See section titled SUGAR HOUSE SETUP).
2. Unpack all materials and check the received materials against the Equipment Description list provided
above.
3. Immediately notify Leader Evaporator or your local dealer if there are questions on the received equipment.
SUGAR HOUSE SETUP:
Prior to setup of the sugar house, it is suggested future needs be considered. The requirements for the setup of the
standard arch may not be adequate if in the future additional or larger equipment will be needed. If assistance is
needed in determining possible future requirements please contact Leader Evaporator Sales or your local dealer.
The following are minimum clearances recommended for around the arch. When determining the clearances, keep in
mind any additional items/equipment (ex. packaging supplies, canner, table(s), chairs) and where they will be located in
the sugar house:
1. Front of the arch: six (6) feet
a. Allows room for firing and cleaning out of ashes
2. Back of the arch: three (3) feet
a. Allows for cleaning and removal of the stack
3. Sides of the arch: four (4) feet
a. Allows for draw off and movement

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FOUNDATION FOR THE ARCH
The following is one suggested method of preparing a foundation for the arch. The example shown is for a 2 foot wide
arch.
SETTING THE ARCH ON THE FOUNDATION:
1. Place the arch on the foundation.
a. The firebox of the arch should be centered on the foundation of the Ash Pit.
b. The front of the arch should be on the open side of the Ash Pit.
3. Move the pipe leg nuts to a position approximately half
way on the threads.
4. Place a pipe leg into each socket. The sockets are located
at the rear of the arch. The threaded end of the pipe leg
should be inserted into the sockets.
a. Seat the pipe legs in the Leg Support.
2. The pipe legs are wire tied to the inside rear of
the arch for transport. Remove the pipe legs from
the arch.

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INSTALL THE FRONT DRAFT DOOR ADJUSTMENT LATCH
5. Level the arch on the foundation.
a. Place a 4-foot level on the rail of the
arch front to back. (The rail is the part
where the pans are rested).
b. Adjust the level of the arch by raising
or lowering the pipe leg nuts. The use
of two pipe wrenches is suggested.
Metal shims may be needed on the
front of the arch..
c. Place the level on the rail of the arch
side-to-side.
d. Adjust the level of the arch by raising
or lowering the pipe leg nuts.
1. Install the draft door adjustable latch
a. The latch is wire tied to the front of the draft door. Remove
the wires to free the latch. Remove the wire securing the
draft door.
b. Remove the draft door adjuster bolt. The draft door adjuster
bolt is located on the rear of the draft door across the latch
slot.
c. Slide the latch into the slot until the mounting hole in the
latch is in line with the bolt holes in draft door. Ensure
the “teeth” of the latch are pointed down. Insert the bolt
through the bolt holes and the latch and tighten the nut.

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INSULATING THE ARCH:
General Notes
2. Each of the presented drawings is accompanied by a table of approximate dimensions for cutting and fitting
pieces. The ID for each piece to be cut can be cross referenced between the drawing and the table.
3. Layout of the insulation of the arch will be dependent on the type of evaporator pan set to be used. Arches are
built for dropped flue and raised flue pan sets. The difference will be in the factory and user installation of
baffles for the raised flue pan sets. Dropped flue pan sets do not use baffles. Raised flue pan sets have factory
baffles installed. With the exception of a 2X6 (or smaller), arches for raised flue pans have 2 factory installed
baffles. The diagrams below illustrate the arches:
1. Prior to insulating the arch it is
recommended high temperature
caulking (ex. JACO Firestop Plus LEADER
Order #65196) be used to seal all joints,
rivets and bolts. This is to prevent
sparks and smoke from exiting the arch.

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4. Obtain the right number of 3000ofire bricks, refractory cement containers and insulation board:
NOTE: The quantities on the table are approximate usages. Actual quantities will vary depending on the actual
techniques and layouts employed.
Dropped Flue
Arch
Half Bricks
Full Bricks
Insulation Board
Refractory Cement
(30 lbs. buckets)
2 X 6
97
14
11
2
2 X 8
115
23
13
2
Raised Flue
Arch
Half Bricks
Full Bricks
Insulation Board
Refractory Cement
(30 lbs. buckets)
Vermiculite (bags)
2 X 6
109
16
13
2
1
2 X 8
112
16
12
2
1
5. Begin by fitting the insulation board and bricks in the arch “dry” (no cement). This will allow you to cut and fit all
the insulation board and bricks into the arch so the cementing can be done in one continuous application.
NOTE: The use of a wet saw or masonry blade in a circular saw is
recommended to cut the bricks where required.
NOTE: The use of a mini hacksaw is suggested for cutting the
insulation board.
The following sections are the outline for the preparing and sequencing of the fitting of the insulation board and brick
into the arch. Adjustments to shown sizes will be required as the installation proceeds. The rule of “Measure twice and
cut once” will reduce waste in fitting the pieces. As you go through each of the following pages, cut, “dry fit” then
cement the parts into place.
When fitting pieces in the arch there will be bolts and rivets where the pieces are being fit. In order to properly fit for
the bolts and rivets either:
Measure the locations on the sheet and cut out the necessary area for clearance of the rivets/bolts
OR
Place the sheet in position and press it against the rivets/bolts in order to mark the rear of the sheet then cut
out the marked area to allow for clearance of the rivets/bolts.

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NOTE: Insulating sheets at the top of the arch may leave a ¾” gap between the sheet top and the bottom of the arch
rail. If this occurs, after the cement has dried, fill the gap with rail gasket material.
Cementing of Insulation Board and Bricks
1. Skim coat a layer of refractory cement to the inside arch wall covering the approximate area of the piece of arch
board to be mounted. Place the board against the cement.
2. The cement does not need to dry prior to installing the bricks.
3. To install brick, skim coat the rear of the brick and apply a heavier coat to the sides of the brick. Place it into
position. As more bricks are added the cement will be forced from the joints. Scrape and smooth off the excess
cement. Make sure all openings between the bricks are filled with cement..
4. Allow the cement to dry for 36 hours at room temperature (65°F or higher).
NOTE: THE LAYOUTS AND DIMENSIONS PRESENTED IN THE FOLLOWING PAGES ARE FOR USE AS GUIDELINES.
ALWAYS MEASURE AND“DRY FIT” BOARD AND BRICKS PRIOR TO FINAL PLACEMENT.
Bricks
In the drawings standard bricks are labelled as follows:
LABEL
BRICK TYPE
FB
Full Brick (9” X 4.5” X 2.5”)
HFB
Half a Full Brick (4.5” X 4.5” X 2.5”)
HB
Half Thickness Brick(9” X 4.5” X 1.25”)
HHB
Half a Half Thickness Brick (4.5” X 4.5” X 1.25”)
The top row of bricks should be cut so they do not prevent the heat from reaching the pans. The bricks will need to be
tapered on the top. See the illustration below.

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Standard Wood Fired Arch Design
Leader standard wood fired arches have two different overall designs. They are divided by widths; 24” and
greater than 24”. The generalized design for a 24” is shown in the following pictures.
Two Foot Wide Front Two Foot Wide Rear
Considerations For A MAX/COMBO Flue Pan
In order to properly direct the heat into the flues of a MAX/COMBO flue pan, additional bricking must be
added to form baffles at certain locations.
Baffles should be located as indicated in the following table. The measurements are from the front of the
stack collar to the front of the brick baffle. Each baffle requires 3 full bricks.
Flue Pan Length (FT)
Qty of Baffles
Location of Baffles (inches in front of stack collar)
3
1
20
4
2
20
30
5
2
20
42
6
2
20
54
1. Begin by bricking the arch as described for a dropped flue arch.
2. At the locations specified in the table run a row of full thickness bricks across the arch.
a. The front of the row of bricks will be at the location specified in the table.
b. The bricks should be laid face down on the bricks on the floor of the arch.
Insulating a Drop Flue Arch
Insulating a 2X6 Arch
The order of insulation is as follows:
1. INSULATION BOARD
a. Front
b. Left Side
c. Right Side
d. Back Board
e. Rear Grate Shelf to Top of Incline
f. Ash Pit Rear Board
2. BRICKING
a. Floor behind Top of Incline
b. Left Side
c. Right Side
d. Back
e. Ash Pit Rear
f. Install the Grates
g. Front
h. Grate Shelf to Top of Incline

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Insulation Board
Cut Out Diagram
The following are suggested cutout diagrams for use with the insulation board. The sizes for each piece can be found on
the section diagrams of the arch.

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Front
Left Side

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Right Side
Back

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Rear Grate Shelf to Top of Incline
Ash Pit Rear

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Bricking
Floor behind Top of Incline
Back

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Left Side
Right Side

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Ash Pit Rear
Install the Grates
Place the four arch grates evenly spaced into the arch with the grates
touching the front of the arch. Obtain a piece of “C flute” cardboard
(most common type of cardboard) approximately 20” x 18”. Fold it
into thirds along the length and tape with a non-plastic tape (ex.
masking tape). Place it behind the grates toward the rear of the
arch. The cardboard will provide the spacing needed to remove the
grates after the bricks have been fit in place. The cardboard can be
left in place after installation of the insulation –it will burn out
during firing.
NOTE: Arch insulation not shown.
PROPER ORIENTATION OF GRATES
Grates should be installed so the
“V” groove is up. In other words
the opening of the “V” will be in a
position to catch and fill with
ashes.

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Front
Grate Shelf to Top of Incline