Leader Evaporator PATRIOT MAX User manual

Leader Evaporator Co., Inc.
49 Jonergin Drive
Swanton, VT 05488
Tel: [phone]
www.leaderevaporator.com
PATRIOT MAX AND STANDARD PAN SETS

PATRIOT MAX & STANDARD EVAPORATOR PAN SET 2019 Page:
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CONTENTS
Contents.............................................................................................................................................................. 2
INTRODUCTION: THEORY OF OPERATION ............................................................................................................. 3
FORMING THE GRADIENT ................................................................................................................................... 3
Firing (if using a wood fired arch) ................................................................................................................... 3
Defoamer ........................................................................................................................................................ 4
Minimize Reversal Effects............................................................................................................................... 4
EQUIPMENT DESCRIPTION...................................................................................................................................... 5
INCLUDED PARTS: ............................................................................................................................................... 5
OPTIONAL SETUP ITEMS AND REPLACEMENT PARTS......................................................................................... 7
DIAGRAM OF THE PATRIOT EVAPORATOR PAN SET............................................................................................... 8
SETUP OF THE PATRIOT EVAPORATOR PAN SET..................................................................................................... 8
RECEIVING YOUR EVAPORATOR: ........................................................................................................................ 8
SUGAR HOUSE SETUP: ........................................................................................................................................ 8
SETTING UP THE PANS: ....................................................................................................................................... 9
OPERATING THE EVAPORATOR............................................................................................................................. 18
SYRUP PAN REVERSAL....................................................................................................................................... 18
MAKING SYRUP ................................................................................................................................................. 20
DAILY SHUTDOWN ............................................................................................................................................ 21
MAINTENANCE...................................................................................................................................................... 22
Daily .................................................................................................................................................................. 22
Periodic ............................................................................................................................................................. 22
End Of Season ................................................................................................................................................... 22
Beginning Of Season Startup ............................................................................................................................ 23
FEEDBACK.............................................................................................................................................................. 23
NOTES.................................................................................................................................................................... 23
ATTACHMENT #1: HYDROMETERS....................................................................................................................... 24
HYDROMETER FUNCTION ..................................................................................................................................... 24
USE OF A HYDROMETER ....................................................................................................................................... 24
Preparing A New Hydrometer For Use ............................................................................................................. 24
Using The Hydrometer...................................................................................................................................... 24

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INTRODUCTION: THEORY OF OPERATION
A maple syrup evaporator works under the principal of a gradient. As the sap boils, it concentrates. As it concentrates,
the volume is reduced and the solids (sugar concentration) increase. As the volume is reduced the liquid works to
maintain the levels across the evaporator so less concentrated sap flows into areas where there is more concentrated
sap. During the evaporation process the percent of sugar will change from the incoming (approximately 2%) to the draw
off (approximately 66%).
FORMING THE GRADIENT
When the evaporator is first filled, the concentration of the sap is the same throughout. The gradient is formed as the
water is evaporated from the sap in the syrup pan and the flue pan, and as the new sap enters the flue pan.
As the sap boils it loses moisture and becomes denser / more concentrated. As it is becoming concentrated it loses
volume. As it loses volume additional sap will try to keep the levels constant and at the same concentration. This is
occurring in both the flue pan and the syrup pan.
In the flue pan less concentrated sap enters through the float box into the first flue pan compartment and begins to
concentrate. As it concentrates it moves toward the second compartment of the flue pan. Early in the boil the second
compartment will become denser as the “fresh” sap entering the first compartment from the float box keeps pushing
the denser sap around.
As the syrup pan boils, the sap continues to become denser. The flue pan sap is pushed into the syrup pan making sap in
the first syrup pan compartment less dense. The sap from the first syrup pan compartment is pushed to the next
compartment where the sap is denser and then to the densest compartment, the “syrup” compartment. The syrup is
drawn off the evaporator from this compartment and more sap flows across all the compartments of the evaporator to
replace the volume of syrup drawn off.
With a good gradient in place there will be a measureable difference in the liquid levels between one side of the syrup
pan and the other. You may note a difference of ½”.
PROPER OPERATIONS TO MAINTAIN GRADIENT:
Firing
Defoamer
Minimize Reversal Effects
During operations you will be working to maintain a consistent gradient. This is done through firing level, control of
foaming, and minimizing the effects of reversal.
Firing (if using a wood fired arch)
During firing you are seeking to maintain the same boil all the time. By doing so, the liquid “push” in the pans will
remain consistent. If the boil reduces, liquid depths in both pans will start to equalize, losing the gradient. In order to
maintain the boil the following should be of concern:
1. Wood to use
a. Mix of hardwood (longer lasting, more BTUs) and softwood (quicker, intense heat).
b. Avoid slabs as they do not allow heat to evenly reach the pan
c. Split wood to the diameter and sized in length to match the length of the grates in use
Width of Evaporator
Diameter to Split Wood
24”
2” to 3”
30” and 36”
2” to 4”
40”and 48”
2” to 5”
60”and 72”
3” to 6”
2. Loading wood into the arch

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a. Wood should stay on the grates and a minimum of 2” to 5” inside from the door so wood fire does not
heat the arch face
b. Criss-cross the wood as best possible so oxygen can reach all wood efficiently
c. Do not hit the flues when loading wood
3. When to fire
a. Keep a consistent stack temperature with less than 150°F range
b. Maintain the arch ½ to ⅔full
c. Fire consistently with small amounts of wood to maintain level of heat
d. Use timer to stay on schedule with firings
e. Adjust firing intervals as needed to maintain an even boil
Defoamer
The purpose of defoamer is to prevent foam build up in the pans. Foam build up will prevent proper evaporation of the
water from the sap. It will give a false liquid level to the float not allowing the incoming sap to flow in a consistent
manner. Inconsistent defoamer usage will create large volume adds of sap into the pans as the foam is reduced (when
you do add defoamer) and the float seeks to replace the level with incoming sap. The following items should be of
concern in the use of defoamer:
1. Use defoamer on a regular basis. It is suggested you add defoamer to the flue pan each time you fire the
evaporator or every 5 to 10 minutes.
2. Add defoamer primarily to the flue pan. Modify this only under certain conditions.
3. The estimated usage is as follows: NOTE: This is based on the use of ATMOS 300 Defoamer
Pan Set Width (Inches)
Drops of Defoamer
24
3
30
4
36
4 to 5
40
5 to 6
48
6 to 8
60
7 to 9
72
8 to 11
If using sap that has been concentrated by an RO, use an additional drop for each foot of pan width
4. NEVER add defoamer to the center compartment of the syrup pan. Use one drop at a time in the syrup (draw-
off) compartment only.
Minimize Reversal Effects
Reversal occurs when the boil in the pans is reduced (when firing is inconsistent, end of day, change pan flow direction):
1. Maintain a consistent boil
2. After the last syrup draw of the day, draw “sweet” from the syrup pan into a clean container. This will be added to
the boiling syrup pan at the beginning of the next boil and aid in setting up the gradient. The guideline for the
amount of “sweet” to draw is as follows:
Pan Set Width (Inches)
Gallons of “Sweet”
24
1 to 1 ½
30
1 ½ to 2
36
2 to 2 ½
40
2 ½ to 3 ½
48
3 ½ to 5
60
4 to 7
72
6 to 9

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EQUIPMENT DESCRIPTION
The PATRIOT set of evaporator pans have dual level controls allowing a deeper level in the syrup pan and a shallower
level in the flue pan. The PATRIOT also offers a flow reversing system comprised of two valves and a single plug. The
pans are constructed of 20 gauge stainless steel.
The LEADER MAX flue pan has an 11-½”flue giving 50% more surface area for more fuel efficient performance with a
higher evaporation rate. It is available as a raised flue or a combination raised and drop flue pan. The LEADER standard
flue pan offers 7 ½”raised flues. Both styles allow for expansion with a parallel flow preheater, a Steam-Away or reverse
osmosis unit.
NOTE: Pictures, sketches and drawings presented in this document are not to scale.
A left feed evaporator is defined, as the regulator float box assembly will be on the left side of the flue pan when
standing facing the firing door. A right feed evaporator is defined, as the regulator float box assembly will be on the
right side of the flue pan when standing facing the firing door.
INCLUDED PARTS:
The Leader PATRIOT Evaporator pan set consists are the following parts:
ITEM
LEADER
ORDER #
DESCRIPTION / PHOTO
ITEM
LEADER
ORDER #
DESCRIPTION / PHOTO
Standard or
MAX Flue Pan
Available
from 2’X4’ to
6’X10’
Syrup Pan
Available in
2’X2’ to 6’X6’
Regulator Box
59078 (For
Right Feed)
59079 (For
Left Feed)
Regulator Packing
(included with
regulator arm)
59065
Float (10-¾” X
5 ½” X 2”)
59025
Hot Sap Float (4” x
8 ½”)
59028
Regulator Z-
arm
59051
Stainless Steel Plug
2”
59013
Flue Brush (for
standard flue
pan)
60061
Flue Brush (for
MAX style flue
pans)
60056
Stainless Steel
Machine Screw
RH ¼-20 X 3”
(qty.: 2)
72454
Stainless Steel Hex
Nut ¼-20 (qty.: 6)
72551
2-3/4” #36 SS
Band Clamps
(qty.: 6)
60049
2” X 2-1/4” Hose
Connection (qty.:
3)
60004
4” X 24”
Ceramic Pan
Gasket
65158
Distribution Pipes
(may already be
installed in flue
pan)

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ITEM
LEADER
ORDER #
DESCRIPTION / PHOTO
ITEM
LEADER
ORDER #
DESCRIPTION / PHOTO
Distribution
Box (qty.: 2 –
may already be
installed at the
end of the
distribution
pipes))
¾” Stainless Steel
Ball Valve
60104
2’ Wide Pan set:
Qty.: 3
30” Wide and 36”
Wide pan set: Qty.:
1
¾” Close
Stainless Steel
Nipple
72106
2’ Wide Pan
set: Qty.: 3
30” Wide and
36 Wide” pan
set: Qty.: 1
1” Stainless
Steel Ball Valve
60106
1” Close Stainless
Steel Nipple
72111
30” Wide and
above pan set:
Qty.: 2
30” Wide and
above pan set:
Qty.: 2
1 ¼” Stainless
Steel Ball Valve
60108
1 ¼” Close
Stainless Steel
Nipple
72340
40” Wide and
above pan set:
Qty.: 1
40” Wide and
above pan set:
Qty.: 1
There are two angle valve assemblies supplies with the pan set. The following listing of parts are the components for each
1” Stainless
Steel Street
Elbow
72126
1” X 2 ½” Running
Thread Nipple
72118
1” Close
Stainless Steel
Nipple
72111
1” Stainless Steel
Ball Valve
60106
1” Stainless
Steel Special
Street Elbows
72234
1 3/8” Rubber
Washer
760045
1 3/8” Stainless
Steel Washer
760055
1” Stainless Steel
Hex Nut (qty:2)
760065

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OPTIONAL SETUP ITEMS AND REPLACEMENT PARTS
ITEM
LEADER
ORDER #
DESCRIPTION / PHOTO
ITEM
LEADER
ORDER #
DESCRIPTION / PHOTO
Pan Gasket
Holder
59210
1 ¼” Stainless
Steel Ball Valve
60108
1 ¼”
Stainless
Steel Close
Nipple QTY: 2
72340
1 ¼” Stainless
Steel Tee
72316
½” Stainless
Steel Ball
Valve
60100
½” Stainless
Steel Close
Nipple
72101
1 ¼” to ½”
Stainless
Steel Close
Adapter
72344
Sight Level
60156
Hot Sap Float
(4” x 8 ½”)
59028
Regulator Z-
arm
59051
Thermomete
r 3” or 5”
face, 6” stem
61022
3” Face/6”
Stem
61028
5” Face/6”
Stem
Rail Gasket
65154
(1/2” X 2” X
25’)
65157
(1” X 2” X 25’)
65156 Woven
¼” X 1 ½” X
50’

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DIAGRAM OF THE PATRIOT EVAPORATOR PAN SET
SETUP OF THE PATRIOT EVAPORATOR PAN SET
NOTE: The following information pertaining to setup of an evaporator is to be considered one suggested method.
Installations should meet all applicable governmental regulations and standards.
RECEIVING YOUR EVAPORATOR:
Upon receipt of the evaporator, it is recommended the following tasks be performed:
1. Protect all incoming materials from damage and the environment. If possible place the evaporator 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
PATRIOT evaporator 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 around the evaporator. 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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SETTING UP THE PANS:
NOTES:
All arch side directions are as if you were facing the fire door of the arch.
Prior to setting up the pans, level the arch.
Prior to setting up the pans, insulate the arch per the instructions provided for that arch.
1. Prior to placing the pans on the arch, line the rails and
the top of the baffle(s) with ceramic rail gasket (not
included). Use a utility knife to cut the gasket to make a
square fit with no gaps.
2. Place the flue pan onto the lined baffle and arch rails.
Slide the pan tight to the back collar.
3. Install the drain valve on the right rear corner of the
flue pan:
a. For a 24” to a 36” wide evaporator - Teflon tape
both ends of the ¾” stainless steel close nipple.
Thread a ¾” stainless steel ball valve onto one end
of the nipple. Thread the other end of the nipple
onto the drain coupling of the flue pan. Tighten.
b. For an evaporator over 36” side - Teflon tape both
ends of the 1 ¼” stainless steel close nipple.
Thread a 1 ¼” stainless steel ball valve onto one
end of the nipple. Thread the other end of the
nipple onto the drain coupling of the flue pan.
Tighten.
4. Put two #36 band clamps loosely onto each of three 2” x 2
¼” hose connectors.
5. Place the rubber connectors onto the three regulator
connection pipes on the flue pan with the clamp screws
facing down.
6. Push each of the rubber connectors tight to the flue pan.
Make sure the band clamp closest to the flue pan is over
the flue pan regulator connector pipe and tighten the
band clamp.

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7. Insert a supplied ¼ - 20 X 3” stainless steel machine screw RH
through each of the mounting holes in the flue pan located
above the regulator box connection pipes. The head of the
screw will be inside the flue pan.
8. Thread a supplied ¼ - 20 stainless steel nut onto each of the
machine screws. Turn the nut towards the flue pan until the
screw is held into position –do NOT tighten the nut.
9. Thread a second supplied ¼ - 20 nut onto each screw and
turn the nut until it is approximately 1 ½” down on the
machine screw.
10. Align the regulator box connections with the rubber
connectors on the flue pan.
11. Tilt the regulator box top slightly away from the flue
pan and while straightening the regulator box, slide the
regulator box connectors into the rubbers connectors
on the flue pan and the machine screws in the flue pan
into the mounts on each side of the regulator box.
12. Thread a supplied ¼ - 20 nut onto each of the machine
screws and finger tighten against the nut on the
machine screw. This will hold the regulator box in
place.
13. Press the regulator box into the rubber connectors.
Ensure the band clamps on each connector are located
over the connector pipe on the regulator box and face
screw down then tighten the clamps.