Leader Evaporator WSE User manual

Leader Evaporator Co., Inc.
49 Jonergin Drive
Swanton, VT 05488
Tel: [phone]
www.leaderevaporator.com
WSE Evaporator Manual

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Contents
INTRODUCTION: THEORY OF OPERATION ........................................................................................................................... 3
FORMING THE GRADIENT........................................................................................................................................................ 3
Firing............................................................................................................................................................................................. 3
Defoamer..................................................................................................................................................................................... 4
Minimize Reversal Effects .................................................................................................................................................... 4
EQUIPMENT DESCRIPTION .......................................................................................................................................................... 5
DIAGRAM OF THE WSE EVAPORATOR .................................................................................................................................... 8
SETUP OF THE WSE EVAPORATOR ........................................................................................................................................... 9
SUGGESTED TOOLS:.................................................................................................................................................................... 9
RECEIVING YOUR EVAPORATOR:.......................................................................................................................................... 9
SUGAR HOUSE SETUP: .............................................................................................................................................................10
FOUNDATION FOR THE ARCH ..............................................................................................................................................12
SETTING THE ARCH ON THE FOUNDATION:..................................................................................................................12
INSULATING THE ARCH:.........................................................................................................................................................13
Cementing of Insulation Board and Bricks ..................................................................................................................14
Insulation Board.....................................................................................................................................................................15
Install The Grates...................................................................................................................................................................16
Bricks..........................................................................................................................................................................................18
SETTING UP THE PANS:...........................................................................................................................................................24
INSTALL TAPER AND STACK.................................................................................................................................................29
THE FIRST BOIL ..........................................................................................................................................................................32
OPERATING THE WSE EVAPORATOR.....................................................................................................................................33
SYRUP PAN REVERSAL ............................................................................................................................................................33
MAKING SYRUP...........................................................................................................................................................................35
DAILY SHUTDOWN....................................................................................................................................................................36
MAINTENANCE ...........................................................................................................................................................................37
DAILY..........................................................................................................................................................................................37
PERIODIC ..................................................................................................................................................................................37
END OF SEASON.....................................................................................................................................................................37
BEGINNING OF SEASON STARTUP .................................................................................................................................38

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FEEDBACK.....................................................................................................................................................................................38
NOTES .............................................................................................................................................................................................38
ATTACHMENT #1: HYDROMETER USAGE............................................................................................................................39
HYDROMETER FUNCTION......................................................................................................................................................39
USE OF A HYDROMETER .........................................................................................................................................................39
Preparing A New Hydrometer For Use: ........................................................................................................................39
Using The Hydrometer ........................................................................................................................................................39
ATTACHMENT #2: INSTALLATION AND USAGE OF THE WSE UPGRADE BUTTERFLY.....................................41
INSTALLATION............................................................................................................................................................................41
USAGE .............................................................................................................................................................................................43

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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 becomes 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 compartment s 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
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, the syrup pan flow will reverse and flow to the flue pan. 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 2” to 3” in diameter and approximately 24” in length
2. Loading wood into the arch
a. Wood should stay on the grates and 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

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3. When
a. Keep stack temperature in range of 650oF to 800oF
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.
2. Add defoamer primarily to the flue pan. Modify this only under certain conditions.
3. The estimated usage for a 2 foot wide WSE is 3 drops. The usage may need to be changed as the sap
characteristics change. NOTE: This is based on the use of ATMOS 300 Defoamer
4. NEVER add defoamer to the center compartments of the syrup pan. Use one drop at a time in the syrup (draw-
off) compartment.
Minimize Reversal Effects
Reversal occurs when the boil in the flue pan is reduced (when firing is inconsistent, end of day, change pan flow
direction). As the flue pan boil reduces, the level is reduced so more fresh sap is added and sap will flow back from the
syrup pan. This causes the “sweet” in the syrup pan to mix back across the syrup pan and increases the volume of sap in
the flue pan. To minimize this effect:
1. Maintain a consistent boil
2. After the last syrup draw of the day, draw 1 to 1 ½ gallons of “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.

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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. The flue pan and the syrup pan are tig welded of 20 gauge
bright annealed stainless steel which is the same as the larger evaporators.
NOTE: Pictures, sketches and drawings presented in this document are not to scale.
A left draw evaporator is defined, as the draw off assembly will be on the left front of the syrup pan when standing
facing the firing door. A right draw evaporator is defined, as the draw off assembly will be on the right front of the syrup
pan when standing facing the firing door.
The Leader WSE Evaporator consists are the following parts:
ITEM
LEADER
ORDER #
DESCRIPTION / PHOTO
ITEM
LEADER
ORDER #
DESCRIPTION / PHOTO
Arch
302406LN
2X6
3 Sided SS
Splash Guard
58974
Flue Pan
372404LW
2X4
Syrup Pan (2X2)
372402LWL
(for Left)
372402LWR
(for Right)
Float Box
Regulator
Arm
(Included –
part of float
box)Regulato
r Bridge
(Included –
part of box)
Special
Order
59048
59061
Regulator
Packing
(included with
regulator arm)
59065
Float with
Collar (10
½” X 5 ½” X
2”)
59024
float
SS “U”
Connection
Special Order
1–½” SS
Clamps (qty:
4)
72245
1–½” Teflon
Gasket (qty: 4)
65621
¼” SS Thumb
Screws (qty:
2)
72422
Draft Door Latch
Wire tied to
draft door of
arch
75169
1-½” #24 SS
Band Clamps
(qty: 2)
60046
1-½” X 2” Hose
Connection
Special Order

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ITEM
LEADER
ORDER #
DESCRIPTION / PHOTO
ITEM
LEADER
ORDER #
DESCRIPTION / PHOTO
WSE ¾” SS
Draw Off
Valve
390000
4” X 24”
Ceramic Pan
Gasket
65158
Base Taper
24” X 3’ X
10”
502410L
(Galvanized)
542410L
(Stainless
Steel)
Stack 10” X 3’
(qty: 3)
5210
(Galvanized)
5210S
(stainless
Steel)
25” Full
Leader Grate
(qty: 4)
75021
Pipe legs (Qty:
2)
Wire tied to
inside rear of
arch
77021
Flue Brush
Rod (8’ )
60069 (6’)
60071 (8’)
Rod end is
threaded to allow
mounting of flue brush
Flue Brush
60058
OPTIONAL SETUP MATERIAL, ADDITIONAL SPARE PARTS AND OPERATIONAL SUPPLIES
Fire Door
24”
75241
Draft Door 30”
75111
Front Only
24” No
Doors
75240
10” Stack Cover
5410
10” Leader
Style Roof
Jack
Peak Style
OR
Side of Roof
Style
INSULBOARD 1”
–1’X3’ (3 sq. ft)
qty. 14
65000
3000oFull
Brick (2X6
qty: 14)
65003
3000oHalf Brick
(2X6 qty: 98)
65006
Refractory
Cement qty:
2
65001
Jaco Firestop
Plus (10.5 oz
tube)
65196

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ITEM
LEADER
ORDER #
DESCRIPTION / PHOTO
ITEM
LEADER
ORDER #
DESCRIPTION / PHOTO
Rail Gasket
65154
(1/2” X 2” X
25’)
Thermometer
3” or 5” face, 6”
stem
61022
3” Face/6”
Stem
61028
5” Face/6”
Stem
Two are recommended –one
for each side of the syrup pan
Stainless
Steel Smoke
Stack 3’ x
10”
5210S
Stainless Steel
Base Stack
542410L
Upgrade
Butterfly 1
½” WSE
390002
Valve allows for isolating
the flue pan from the syrup
pan so the flue pan does
not need to be drained
when you change sides of
the syrup pan.
Stack
Thermometer
61052
Install at
shoulder to eye level in the
smoke stack
4 oz
Defoamer
(Organic
defoamer
available
Order #
63010)
63015
Firing Gloves
63123
Green
Gloves
63125
Short Syrup
Hydrometer
61040
Short Test
Cup 2”
Diameter
59007

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DIAGRAM OF THE WSE EVAPORATOR

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SETUP OF THE WSE EVAPORATOR
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.
The following documentation is pertinent to the setup of the WSE evaporator. Information about the
setup and use of other equipment can be found on the Leader Evaporator website –
www.leaderevaporator under the Information Resources option.
SUGGESTED TOOLS:
7/16” box/open-end wrench
Phillips screwdriver
Utility knife
Plumb bob
Drill
Drill bits
Bricking trowel
Measuring tape
Marker (mark roof material)
Level 4’
Brick saw
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.

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SUGAR HOUSE SETUP:
Prior to setup of the sugar house, it is suggested future needs be considered. The requirements for the setup of the
WSE 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 the dimensions of the evaporator:
2 X 6 WSE

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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 WSE arch.
SETTING THE ARCH ON THE FOUNDATION:
5. 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.
c. Center the firebox on the Ash Pit foundation.
2. The pipe legs are wire tied to the inside rear of the
arch for transport. Remove the pipe legs from the
arch
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.

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INSULATING THE ARCH:
3. 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. The order is as follows:
1. Left Side Insulation
2. Right Side Insulation
3. Back Insulation
4. Insert the grates
5. Front Insulation
6. Top View Insulation starting with under the Grate Shelf then the Incline then the Rear Floor
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. Prior to insulating the arch it is recommended
high temperature caulking (ex. JACO Firestop
Plus) be used to seal all joints, rivets and
bolts. This is to prevent sparks and smoke
from exiting the arch.
2. Obtain the right number of 3000ofire bricks,
refractory cement containers and insulation
board:
14 full bricks
98 half bricks
2 - 30 lb. buckets of refractory cement
14 sheets of 1’ X 3’ insulation board

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7. Left Side Brick
8. Right Side Brick
9. Front Brick
10. Back Brick
11. Top View Brick starting under the Grate Shelf then the Grate Shelf then the Incline then the Rear Floor
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.
NOTE: All drawings for the insulating board are illustrated as the board “white” face up.
NOTE: Insulating sheets at the top of the arch are cut to leave a ¾” gap between the sheet top and the bottom of the
arch rail.
Cementing of Insulation Board and Bricks
1. Place a temporary support at the bottom of the arch to hold the brick in place as you are bricking.
2. 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.
3. The cement does not need to dry prior to installing the bricks.
4. 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..
5. Allow the cement to dry for 36 hours at room temperature (65°F or higher).
DECIMAL
FRACTION
0.125
1/8
0.250
1/4
0.375
3/8
0.500
1/2
0.625
5/8
0.750
3/4
0.875
7/8

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Insulation Board
The following are dimensions for the parts labeled above. Always “dry fit” the parts prior to cementing to ensure proper
fit.
Print ID
Length
Width
Notes
L1
36"
9.25"
L2
12"
9.5"
L3
31.5"
9.75"
L4
Top: 36" Bottom: 29.5"
12"
Down 2" from Top then cut on angle to 29.5"
L5
25"
9.5"
Top cutout 1.5" L, 0.5" W / Bottom cutout 1" L, 0.5" W
The following are dimensions for the parts labeled above. Always “dry fit” the parts prior to cementing to ensure proper
fit.
Print ID
Length
Width
Notes
R1
36"
9.25"
R2
12"
9.5"
R3
31.5"
9.75"
R4
Top: 36" Bottom: 29.5"
12"
Down 2" from Top then cut on angle to 29.5"
R5
25"
9.5"
Top cutout 1.5" L, 0.5" W / Bottom cutout 1" L, 0.5" W

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The following are dimensions for the parts labeled above. Always “dry fit” the parts prior to cementing to ensure proper
fit.
Print ID
Length
Width
Notes
B1
13.375"
8.5"
B2
8.75"
8.5"
Install The Grates
Place three of the arch grates evenly spaced into the arch with the
grates touching the front of the arch. Place the grates so one is on
each side of the arch and the other is approximately in the middle.
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.
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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The following are dimensions for the parts as labelled. Always “dry
fit” the parts prior to cementing to ensure proper fit.
NOTE: The insulation board will fit above the grates.
.
The following are dimensions for the parts labeled above. Always “dry fit” the parts prior to cementing to ensure proper
fit.
Print ID
Length
Width
Notes
TV1
22.25"
9.25"
Not Shown - under the grate support shelf
TV2
10.5"
4.5"
TV3
12"
4.5"
TV4
10.5"
14.5"
TV5
12"
14.5"
TV6
22.5"
5"
TV7
36"
10.25"
TV8
36"
12"
Print ID
Length
Width
Notes
F1
4.5"
9.0"
F2
24" Arc cutout 16" W
6"
Cutouts top corners 2.5" L
0.5" W
F3
4.5"
9.0"

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Bricks
The following are dimensions for the bricks labeled above. Always “dry fit” the parts prior to cementing to ensure
proper fit
Brick ID
Brick
Type
Length
Width
Thickness
Quantity
Needed
NOTES
FB
Full
9.000"
4.500"
2.500"
4
HB
Half
9.000"
4.500"
1.250"
22
HHB
Half
4.500"
4.500"
1.250"
3
BL1
Half
6.625"
4.500"
1.250"
1
BL2
Half
9.000"
4.500"
1.250"
1
Cutout 1" L
0.625" W
BL3
Half
top - 6.125"
bottom -
4.25"
2.750"
1.250"
1
BL4
Half
top - 6.5"
bottom -
3.75"
4.500"
1.250"
1
BL5
Half
4.25"
4.500"
1.250"
1
BL6
Half
top - 2.5"
bottom -
5.25"
4.500"
1.250"
1
Use part of
brick left
from BL5
BL7
Half
3.000"
4.500"
1.250"
1
BL8
Half
6.375"
4.500"
1.250"
1

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The following are dimensions for the bricks labeled above. Always “dry fit” the parts prior to cementing to ensure
proper fit
Brick ID
Brick
Type
Length
Width
Thickness
Quantity
Needed
NOTES
FB
Full
9.000"
4.500"
2.500"
4
HB
Half
9.000"
4.500"
1.250"
22
HHB
Half
4.500"
4.500"
1.250"
3
BR1
Half
6.625"
4.500"
1.250"
1
BR2
Half
9.000"
4.500"
1.250"
1
Cutout 1" L
0.625" W
BR3
Half
top - 6.125"
bottom -
4.25"
2.750"
1.250"
1
BR4
Half
top - 6.5"
bottom -
3.75"
4.500"
1.250"
1
BR5
Half
4.25"
4.500"
1.250"
1
BR6
Half
top - 2.5"
bottom -
5.25"
4.500"
1.250"
1
Use part of
brick left
from BR5
BR7
Half
3.000"
4.500"
1.250"
1
BR8
Half
6.375"
4.500"
1.250"
1