Morris Auger Chiller

High Flow Auger Poultry Chiller Service Manual for Models:

MAT-7W; MAT-8W; MAT-10W;
MAT-HS-8W; MAT-HS-10W; MAT-HS-12W
 Table of Contents
I. INTRODUCTION ____________________________________________________________ 2
A Brief History of Our Company ________________________________________________________ 2
Mission Statement___________________________________________________________________ 2
II. PRODUCT PREVIEW ______________________________________________________ 2
III. RECEIPT OF YOUR MACHINE______________________________________________ 4
Inspection __________________________________________________________________________ 4
Description of Your Auger Chiller _____________________________________________________ 4
Table 3.1 Customized Running Levels _________________________________________________________ 4
Safety Tags and Labels ______________________________________________________________ 4
IV. THEORY OF OPERATION __________________________________________________ 5
Water Chilling _______________________________________________________________________ 5
Air Agitation ________________________________________________________________________________ 5
Antibacterial Intervention Point________________________________________________________________ 5
Table 4-1 Rate at which Bacteria Double _______________________________________________________ 6
Counter Flow Water _________________________________________________________________ 6
Moisture Control ____________________________________________________________________ 6
Patented Integrill™ Flights ___________________________________________________________ 7
Figure 4-1 Integrill™ Enabled Water Circulation____________________________________________________ 7
Figure 4-2 Integrill™ Flights ___________________________________________________________________ 7
V. SAFETY____________________________________________________________________ 8
Important Safety Notice ______________________________________________________________ 8
Safety Symbols and Meanings________________________________________________________ 8
Figure 5-1 Safety Symbols ___________________________________________________________________ 8
Figure 5-2 Warning Labels ___________________________________________________________________ 9
Special Safety Precautions and Notes_________________________________________________ 9
Installation _________________________________________________________________________________ 9
Start-Up and Operation ______________________________________________________________________ 9
Clean-Up __________________________________________________________________________________ 9
Maintenance _______________________________________________________________________________ 9
VI. INSTALLING YOUR AUGER CHILLER ______________________________________ 10
Supervision ________________________________________________________________________ 10
Custom Designed for Installation ____________________________________________________ 10
Transporting Equipment to Location _________________________________________________ 10
Proper Lifting Points________________________________________________________________________ 10
Unloading Equipment from the Truck _________________________________________________________ 10
Transporting Equipment to Final Location _____________________________________________________ 10
Figure 6-1 Lifting Points_____________________________________________________________________ 11
Leveling ___________________________________________________________________________ 12
Determining Grade _________________________________________________________________________ 12
Adjusting the Feet _________________________________________________________________________ 12
Keys to Success ___________________________________________________________________________ 12
 Figure 6-1 Adjustable Feet __________________________________________________________________ 12
Connecting Sections _______________________________________________________________ 13
Bolting Sections Together ___________________________________________________________________ 13
Figure 6-4 Bolt Connections _________________________________________________________________ 13
Weld Joints _______________________________________________________________________________ 13
Keys to Success ___________________________________________________________________________ 13
Figure 6-5 Hanger Bearings _________________________________________________________________ 14
Air Piping __________________________________________________________________________ 14
Installing Blowers __________________________________________________________________________ 14
Piping ____________________________________________________________________________________ 14
VII. START-UP AND OPERATION OF YOUR AUGER CHILLER ____________________ 18
Start-Up Sequence _________________________________________________________________ 19
Water Levels ______________________________________________________________________________ 20
Table 7-1 Water Levels for Optimally Functioning Machine ______________________________________ 20
Figure 7-1 Water Level for MAT-HS __________________________________________________________ 20
Figure 7-2 Water Level for MAT Standard _____________________________________________________ 21
Shut-Down Procedure ______________________________________________________________ 21
VIII. CLEAN-UP_____________________________________________________________ 22
Clean-in-Place Procedure ___________________________________________________________ 22
IX. MAINTENANCE __________________________________________________________ 23
Preventative Maintenance Chart _____________________________________________________ 23
X. TROUBLESHOOTING _______________________________________________________ 24
XI. PARTS AND ORDERING DETAILS__________________________________________ 27
Suggested Spare Parts List _________________________________________________________ 27
Contact Information ________________________________________________________________ 27
Equipment Drawings _______________________________________________________________ 27
Figure 11-1 MAT-HS Top View ______________________________________________________________ 28
Figure 11-2 MAT-HS Side View ______________________________________________________________ 28
Figure 11-3 MAT-HS Inlet View ______________________________________________________________ 28
Figure 11-4 MAT-HS Outlet View ____________________________________________________________ 28
Figure 11-5 MAT Top View __________________________________________________________________ 29
Figure 11-6 MAT Side View _________________________________________________________________ 29
Figure 11-7 MAT Inlet View _________________________________________________________________ 29
Figure 11-8 MAT Outlet View ________________________________________________________________ 29
XII. TRAINING _______________________________________________________________ 30
Classes ____________________________________________________________________________ 30
Access to Materials_________________________________________________________________ 30
XIII. WARRANTY ______________________________________________________________ 31

ADDENDUM
MAT-7W, 8-W, 10W & MAT-HS-8W, 10W, 12W Service Manual
I. INTRODUCTION
A. A Brief History of Our Company
In 1949, Morris & Gorrell was
founded by William F. Morris, Jr. and C.R.
Farinholt in Raleigh, N.C as a company.
dealer/distributor and contractor in air
conditioning, heating and refrigeration.
Today, Morris & Associates, Inc. is one of
the most trusted names in the poultry
industry.
For 56 years, Morris & Associates
has remained a company of “firsts”- first in
refrigeration technology for poultry
processing and for ice making. The growth
of the poultry industry in the United States
and around the world can be attributed in
part to Morris & Associates innovations.
The company created the first continuous
line poultry chilling equipment, the first
efficient rechilling system, the first giblet
chilling system, the first high speed chilling
system, and the first clean-in-place (CIP)
systems, among other groundbreaking
achievements.
A collateral benefit of the company’s
ingenuity in poultry processing was being
first with ice making innovations: the high
volume ice makers that poultry processors
need have been adapted specifically for
other industries. Ice makers thus became
an additional specialization of the
company, and over the years Morris has
created some of the finest high volume ice
equipment now used for fish processing,
the produce industry and especially among
packaged ice retailers.
Through the years, the business has
remained all in the family as Bill Morris, III,
who has been on the company’s board of
directors for over twenty years, purchased
a controlling interest in the company in
1
INTRODUCTION
2003 to become President and CEO of
Morris & Associates, Inc. and created an
Employee Stock Ownership Plan where
employees own the majority of the
B. Mission Statement
To be a refrigeration-equipment
development and manufacturing company,
utilizing our particular business and
manufacturing strengths.
To service the needs of customers,
through innovation, with the best solutions
brought about through our people and our
experience.
To serve and be sensitive to the personal
lives and goals of employees and their
families, encouraging and accommodating
them whenever possible.
To provide for those less fortunate in our
community and beyond by striving to give
ten percent of net profits to support God-
centered outreach.
To strive to be efficient, responsive, and
profitable in order to support these goals
and provide a fair return for shareholders.
To strive to create solutions for more
difficult challenges in our chosen field and
to develop a reputation for doing so.
To build and sustain a work environment
that is on the whole fulfilling, enjoyable,
and fun for employees and customers
alike.
MAT-7W, 8W, 10W & MAT-HS-8W, 10W, 12W Service Manual 2
PRODUCT PREVIEW

II. PRODUCT PREVIEW

MAT-7W, 8W, 10W & MAT-HS-8W, 10W, 12W Service Manual 3
PRODUCT PREVIEW
MAT-7W, 8W, 10W & MAT-HS-8W, 10W, 12W Service Manual 4
RECEIPT OF YOUR MACHINE

III. RECEIPT OF YOUR MACHINE

A. Inspection mechanical and electrical components are

functioning properly.
Directly following receipt of your machine,
inspect it for any visible or hidden damage. Your auger chiller - ) has been
If damage is suspected, note it in the designed to run at these levels:
shipper’s papers (i.e, the trucker’s Bill of (Please contact your Morris representative
Lading). Immediately make a separate for the following information).
written request for inspection by the freight Line Speed: birds/minute
line’s agent. Any repair work or alteration Avg. WOG: lbs.
to the machine without the permission of Residence Time: minutes
Morris & Associates, Inc. can void the Load Capacity: lbs.
machine’s warranty. You should also TABLE 3.1
notify your Morris sales representative. Customized Running Levels

B. Description of Your Auger Chiller C. Safety Tags and Labels

A Morris Auger Style Poultry Chiller is a Be sure to read and adhere to all special
continuous poultry chiller requiring tags and labels attached to valves or
electrical connection, and connection to a applied to various areas of the machine.
chilled water supply such as the Morris They provide important information
Red Water Chiller. necessary for safe operation of your
equipment.
The machine has been partially factory
tested hours prior to shipment to ensure
MAT-7W, 8W, 10W & MAT-HS-8W, 10W, 12W Service Manual
IV. THEORY OF OPERATION
A. Water Chilling
The MAT uses water chilling because it
is the most cost effective, quickest, and
safest way to chill poultry.
Water chilling has many striking
advantages compared to air-chilling
poultry. Chilled water systems operate on
a steady refrigeration cycle at moderate
evaporator temperatures – about 20 °F.
While retaining relatively simple operating
procedures, Morris chillers employ a
carefully designed and highly effective
system to circulate cooling water around
each bird. In contrast, air-cooled systems
require lower evaporator temperatures
and complex refrigeration cycles for
defrosting of the air-cooling surfaces.
Because of the low density of air
compared to water, air-cooled systems
require high air velocities past the bird and
sub-freezing air temperatures. Application
of mist to the birds reduces but does not
eliminate the tendency of this very cold air
to desiccate and freeze the skin
a. Air Agitation
Air agitation is used to further enhance
circulation of cold water around and
through the product. Air from a blower is
introduced through holes in the bottom of
the chiller tank and allowed to bubble up
through the water and birds. As the
bubbles rise, they create a circulation of
water up through the birds in the tank.
This circulation increases the rate at which
heat is removed from the bird and
provides improved uniformity of product
temperature.
5
THEORY OF OPERATION
In addition, careful manipulation of the
air flow can help manage distribution of
the product in the chiller tank. Finally, as
the air moves past a bird, it massages the
skin and encourages moisture retention in
the product.
Air agitation is critical for two reasons:
moisture pickup and bird temperature.
Bird chillers are normally sold with multiple
10 HP blowers. This gives the customer
the ability to run however many are
necessary for the application. A general
rule of thumb is two blowers for the first 20
feet of chiller and one blower for every 20
feet after that.
Air is used to move the birds around in
the chiller. This does two things. It
causes the birds to pick up moisture and
also keeps the birds from packing
together. When birds are not packed
together too tightly or lying on the best
bottom of the chiller you get the best heat
transfer from the water flowing through the
chiller.
b. Antibacterial Intervention Point
Studies conducted in 2002 and 2004
found that when properly managed,
immersion chilling systems, such as the
Morris Auger Style Poultry Chiller
represent, represent the most effective
means of antibacterial intervention.
While additional methods of
intercession are undoubtedly necessary in
the process of eliminating microbial
contamination from poultry, the most
significant drop in carcasses positive for
salmonella or campylobacter occurred
prior to submersion in a chiller.
MAT-7W, 8W, 10W & MAT-HS-8W, 10W, 12W Service Manual 6
THEORY OF OPERATION

These studies were funded by the U.S.

Poultry and Egg Association and the
National Turkey Federation. To read the
reports of these studies in their entireties,
refer to the December 2003 and
December 2004 issues of Watt Poultry
USA.
To further reduce the occurrence of
bacteria, Morris & Associates, Inc.
recommends keeping water temperature
as low as possible. As water temperature
goes up or the time grows longer, or both,
bacteria double and re-double. If they
double too many times, they will destroy
the flavor of your product. To slow the
growth of bacteria, keep the temperature
of your product at 35 degrees or lower, or
as cold as possible.
B. Counter Flow Water
Morris chillers are set up in a counter-
flow arrangement in which cold water is
generally introduced at the outlet end of
the chiller and flows through to the inlet
end. This assures that the product is
exposed to the coldest water just prior to
being removed from the chiller.
C. Moisture Control
Moisture is a function of residence
time, water temperature, pH, air agitation,
flight pitch, loading and other factors.
Consult your Morris representative for the
best combinations to optimize your
moisture pick-up.

At 90 ° bacteria doubles every 30 min.

70 1 hour
60 2 hours
50 3 hours
40 6 hours
35 12 hours
32 20 hours
28 60 hours
TABLE 4-1
RATE AT WHICH BACTERIA DOUBLE
MAT-7W, 8W, 10W & MAT-HS-8W, 10W, 12W Service Manual 7
THEORY OF OPERATION

D. Patented Integrill™ Flights cold water channels through the chiller

A feature that sets Morris auger chillers
apart from the competition is the patented
Integrill™ flights. In competing models
the only flow path for the water is through
a narrow gap between the auger flights
and the tank wall. This can lead to a
situation where flow rate is restricted and
without circulating around the individual
birds. The Morris Integrill™ allows
circulation around the shaft, between
flights and tank and through the grills,
assuring that a strong flow of cold water
reaches every bird in the chiller – not just
those near the wall.

FIGURE 4-2
Integrill™ Flights
MAT-7W, 8W, 10W & MAT-HS-8W, 10W, 12W Service Manual 8
SAFETY

V. SAFETY

A. Important Safety Notice B. Safety Symbols and Meanings

This information is intended for use by Prior to installation or operation of your

individuals possessing adequate MAT machine, please read this manual.
backgrounds in electrical and mechanical Are you familiar with the installation, start-
experience. Any attempt to repair major up, and operation of a MAT machine?
equipment may result in personal injury Before you operate, adjust or service this
and/or property damage. The machine, you should read this manual,
manufacturer cannot be responsible for the understand the operation of this machine,
interpretation of this information, nor will it and be aware of possible dangers.
assume any liability in connection with its
use.

These safety symbols will alert you when special care is needed.
Please heed them!

! DANGER !
Indicates an immediate hazard and that special precautions are
necessary to avoid severe personal injury or death.

WARNING:
Indicates strong possibility of a hazard and that an unsafe
practice could result in severe personal injury.

CAUTION:
Means hazards or unsafe practices could result in personal
injury or product or property damage.

NOTE:
Indicates recommendations for an optimally functioning machine

FIGURE 5-1
Safety Symbols
MAT-7W, 8W, 10W & MAT-HS-8W, 10W, 12W Service Manual
FIGURE 5-2
Warning Labels
C. Special Safety Precautions and
Notes
a. Installation

When moving, multi-section chillers,
use caution to insure the unit stays
level. Although the auger is braced for
shipping, the auger shaft and bearing
assemblies are not designed to hold the
auger from sliding, and it is possible the
auger could slide out of the tank if the
section is pitched downward towards
the open end.

Do not remove shipping braces on the
shell until the unit is located in its final
position and all sections are welded
together and cooled.

The bolts on mating sections are not
designed for drawing the sections
together; their function is for alignment
only.

Mating sections are labeled for
proper sequence of assembly.

The chiller must be aligned before
welding.
9
SAFETY

Final welding must be liquid tight
using filler wire compatible with 304
stainless steel.
b. Start-Up and Operation

Only a qualified electrician should
do any electrical work. Failure to
follow these instructions could result
in permanent injury or loss of life.

The air blowers should always be
“on” when water is in the chiller in
order to keep water out of the air
lines.

Make sure all personnel are clear of
paddles, chain, and all mechanically
operated components before
operating chiller.
c. Clean-Up

Disconnect and lock out power to all
drive motors before entering the
chiller. Failure to follow these
instructions could result in
permanent injury or loss of life.
MAT-7W, 8W, 10W & MAT-HS-8W, 10W, 12W Service Manual
VI. INSTALLING YOUR AUGER CHILLER
A. Supervision
Installation should be supervised by a
Morris Certified Technician (MCT). Morris
offers both supervised and full turn-key
installation. A MCT must be onsite to
ensure proper installation as well as to
validate warranty.
B. Custom Designed for Installation
Each section of your Morris Auger Style
Chiller has been specially designed for
ease of installation.
Proper planning and plant layouts should
be completed at time of order to fit
equipment in allotted space and determine
point of entry and equipment transport path
into plant in order to minimize installation
time.
C. Transporting Equipment
a. Proper Lifting Points (See Figure 6-1)
Connect to Chiller legs as illustrated,
minimum of 4 points.
Spreader bars should be a minimum of
2 feet longer than the widest point of chiller
to prevent damage to sides of tank when
lifting.
CAUTION:
Always locate lifting points as far apart
as possible for stability. Special lifting
considerations may be required as not
to damage accessories such as air
headers, recirculation and overflow
boxes that may come in contact with
lifting devices.
10
INSTALLATION
b. Unloading Equipment from the Truck
CAUTION:
When transporting multi-sections chillers,
unit should always stay level. Failure to
keep unit level may cause auger shaft and
hanger bearings to slide out of tank and
cause personal injury and/or severe
damage to product and property.
When moving, multi-section chillers,
use caution to insure the unit stays level.
Although the auger is braced for shipping,
the auger shaft and bearing assemblies
are not designed to hold the auger from
sliding, and it is possible the auger could
slide out of the tank if the section is pitched
downward towards the open end.
(See Figures 6-1 and 6-2 for proper lifting
points.)
CAUTION:
Do not remove shipping braces on the shell
until the unit is located in its final position
and all sections are welded together and
cooled.
After the unit has been lifted from the
trailer, locate the adjustable legs, and
install them into the threaded hole on each
leg of the chiller. Screw the legs all the
way into the chiller to insure the most rigid
assembly for rolling into final position.
Set all chiller sections with the adjustable
legs fully retracted. Insure a jam nut is on
each adjustable leg.
c. Transporting Equipment to Final
Location
Using rollers of sufficient capacity,
position the chiller section(s) into place.
MAT-7W, 8W, 10W & MAT-HS-8W, 10W, 12W Service Manual 11
INSTALLATION

Do not drag the chiller into position as this could damage the unit.

FIGURE 6-1
Lifting Points

Notes:
1- Connect to Chiller legs as illustrated
2- Spreader bars should be a minimum of 2 feet longer than the widest point of the chiller to prevent damage to
sides of chiller when lifting
3- Always locate lifting points as far apart as possible for stability of load, preferably the legs at either end of chiller
section
4- Special lifting considerations may be required as not to damage accessories such as air headers, recirculation and
overflow boxes on chiller that may come in contact with lifting devices
5- Chiller must be level when unloading to prevent auger from sliding out of open end of chiller section
MAT-7W, 8W, 10W & MAT-HS-8W, 10W, 12W Service Manual 12
INSTALLATION

D. Leveling
a. Determining Grade
Using jacks under the structural
members, raise the outlet end of the chiller
such that the entire unit is pitched ¼ inch
per 10 feet of length, down towards the
inlet end.
b. Adjusting the Feet
Screw each adjustable leg down until it
firmly contacts the floor, and secure its
position with the jam nut.
c. Keys to Success
The entire length of the chiller must be
level side to side. Level side to side should
be confirmed at each set of legs.

FIGURE 6-1
Adjustable Feet
MAT-7W, 8W, 10W & MAT-HS-8W, 10W, 12W Service Manual
E. Connecting Sections
a. Bolting Sections Together
NOTE:
Mating sections are labeled for proper
sequence of assembly.
Once all chiller sections are positioned,
start from the inlet end and draw the
sections together with clamps.
NOTE:
The bolts on mating sections are not
designed for drawing the sections
together; their function is for alignment
only.
Once each section is clamped together,
secure all alignment bolts with lock
washers and nuts provided.
After each shell section is secured
tightly together, connect each auger
section completely, and secure with the
bolts and lock washers provided.
FIGURE 6-4
Bolt Connection
Auger sections are marked for proper
alignment. If the marks are not visible,
13
INSTALLATION
proper auger section alignment is to have
the ends of the flights as close as possible
with no overlap as to create a continuous
spiral.
Once all shell sections are rigidly
clamped together, and all auger sections
are bolted together, welding may begin.
NOTE:
The chiller must be aligned before welding.
b. Weld Joints
After the entire chiller is level and
straight, the sections can be welded
together.
Tack weld the inside of each joint, then the
outside.
NOTE:
Final welding must be liquid tight using
filler wire compatible with 304 stainless
steel.
c. Keys to Success
Final welding must be liquid tight,
using filler wire compatible with 304
stainless steel. Use good welding
practices to prevent applying too much
localized heat, which could cause
distortion. A pulsed MIG process is ideal.
Once all sections are welded and cool,
remove shipping braces.
MAT-7W, 8W, 10W & MAT-HS-8W, 10W, 12W Service Manual 14
INSTALLATION

The entire length of the chiller must

be straight using a taut line or transit to
confirm each side of the chiller is straight.
Confirm alignment of the auger in a similar
manner. The auger has been aligned at
the factory during testing, and should not
require much (if any) adjustment.
Shipping and handling can cause the pre-
set alignment to move. Side to side
adjustment of the auger can be made at
each hanger bearing.

FIGURE 6-6
KEY FOR FIGURES 6-6, 6-7, 6-8

HI. Clean and Sanitize Chiller

Using necks and backs of poultry

carcasses, hand scrub inside of chiller tank
and all metal components that will come in
contact with product. This removes all
residual metal findings to assure sanitary
FIGURE 6-5 initial operation.
Hanger Bearing
Proceed with clean-up as outlined in
F. Air Piping Section VIII. Clean-Up.

a. Installing Blowers WARNING:

Blower skid should be leveled horizontally Disconnect and lock out power to chiller
and vertically. controls before entering the chiller.

b. Piping

Blower piping should match the header

size on skid. ! DANGER !
Make sure all drive assemblies covers
Avoid excessive bends or distance are properly installed.
between blowers and chiller.

G. Electrical Connections For your protection, the Morris Certified

Technician will print a summary sheet
Connect electrical according to stating that all equipment is installed and
Figures 6-7, 6-8 and 6-9. operating correctly to your satisfaction.
MAT-7W, 8W, 10W & MAT-HS-8W, 10W, 12W Service Manual 15
INSTALLATION

Figure 6-6
MAT WIRING DIAGRAM LEFT SIDE CONTROL PANEL
MAT-7W, 8W, 10W & MAT-HS-8W, 10W, 12W Service Manual 16
INSTALLATION

FIGURE 6-7
MAT WIRING DIAGRAM RIGHT SIDE CONTROL PANEL
MAT-7W, 8W, 10W & MAT-HS-8W, 10W, 12W Service Manual 17
INSTALLATION

FIGURE 6-8
MAT ALARM WIRING DIAGRAM
MAT-7W, 8W, 10W & MAT-HS-8W, 10W, 12W Service Manual
VII. INITIAL START-UP
A. Inspect electrical wiring
Make sure proper voltage is available at
the chiller motors. Measure voltage at line
side of starter. Must be plus or minus 10%
motor rating.
! DANGER !
Only a qualified electrician should do
any electrical work. Failure to follow
these instructions could result in
permanent injury or loss of life.
B. Balance Phases
Make sure all three voltage phases are
balanced.
18
INITIAL START-UP AND OPERATION
C. Check Overload Settings
Check for proper overload settings on
starters.
D. Ensure Proper Rotation
Check for proper rotation of drive
motors.
Insert drawings of LH and RH and how to
inspect for proper rotation.
E. Inspect Piping
Inspect water and air piping to ensure
that it is installed according to specification.
Check air piping for leaks.
MAT-7W, 8W, 10W & MAT-HS-8W, 10W, 12W Service Manual
VIII. DAILY START-UP AND OPERATION
A. Start-Up Sequence
1. Make sure air blower valves at
chiller are open.
2. Turn desired amount of blowers to
“on” position.
NOTE:
Remote “on/off” may be used for entire
bank of blowers.
3. Fill the prechiller with tap and chilled
water up to overflow. See Table 7-1.
(If using ice, load ice into entrance
end of chiller.)
4. Fill the final chiller with chilled water
up to overflow. (If using ice, load ice
into entrance end of chiller.)
NOTE:
The air blowers should always be “on”
when water is in the chiller in order to
keep water out of the air lines. It is
recommended to leave one blower on
24 hours a day to ensure air lines stay
clean.
WARNING:
Make sure all personnel are clear of
paddles, chain, and all mechanically
operated components before
operating chiller.
5. Turn outlet wheel to “on” position.
Outlet wheel must be turned on
before the chiller auger can operate.
6. Turn Auger “on”.
Note:
These water levels are for a fully loaded chiller.
Partially loaded chillers do not require high water levels.
These views are water levels on the ENTRANCE end of auger chiller.
19
INITIAL START-UP AND OPERATION
7. Verify that your inverter is set
predetermined setting.
NOTE:
The inverter gives you the flexibility to
fine-tune dwell time as well as
increase auger speed at the end of a
shift. Your MCT will determine proper
settings at initial start-up.
NOTE:
In a multi-stage chilling system, the
prechiller outlet wheel will not operate
unless the final stage is operating and
is switched to the “on” position. This is
done by electrically interlocking the
prechiller to the final chiller
8. Before birds enter the chiller, water
level should be at overflow level and
water temperature below 35
degrees.
9. Eviscerated birds going into chiller
should be dropped into the entrance
end of the first stage chiller.
NOTE:
If equipped with suction box, do not
drop birds directly in front of suction
box.
10. As birds come into chiller,
displaced water will exit the
overflow of the chiller.
MAT-7W, 8W, 10W & MAT-HS-8W, 10W, 12W Service Manual 20
INITIAL START-UP AND OPERATION

fresh water on at a rate of ½

11. If equipped with a transfer pump, it gallon per bird.
should be turned on when the
birds begin to enter the final
chiller.

12. When the birds start to exit the

final chiller, put the make up or
MAT Standard MAT-HS-8W MAT-HS-10W MAT-HS-12W
Water Level
above Shaft/
Overflow Level 0” 14 ½ “ 18” 20 ½ “
at Entrance
End of Chiller
TABLE 7-1
Water Levels for an Optimally Functioning Machine

FIGURE 7-1
Water Level Above Shaft (Overflow Level) at Entrance End of MAT-HS-8W, 10W, 12W

Note:
These water levels are for a fully loaded chiller.
Partially loaded chillers do not require high water levels.
These views are water levels on the ENTRANCE end of auger chiller.
MAT-7W, 8W, 10W & MAT-HS-8W, 10W, 12W Service Manual 21
INITIAL START-UP AND OPERATION

FIGURE 7-2
Water Level (Overflow Level) at Entrance End of MAT-7W, 8W, 10W

B. Shut-Down
NOTE:
Once all birds are out of the prechiller it can In multi-stage chilling processes, the
be turned off by switching the auger and the above sequences are repeated for
unloader to the “off” position. the final chiller.

Note:
These water levels are for a fully loaded chiller.
Partially loaded chillers do not require high water levels.
These views are water levels on the ENTRANCE end of auger chiller.
MAT-7W, 8-W, 10W & MAT-HS-8W, 10W, 12W Service Manual
IX.
A. Clean-in-Place Procedure
! DANGER !
Disconnect and lock out power to all
drive motors before entering the
chiller. Failure to follow these
instructions could result in permanent
injury of loss of life.
1. Using hot water, start at the
top with a high-pressure water hose
and wash off entire chiller to remove
as much grease and chicken solids as
possible.
22
CLEAN - UP
CLEAN-UP
2. Using cleaning foam, cover
auger and main chiller tank, starting
at one end and working to the
opposite end.
NOTE:
Take special care to clean hanger
bearings as these can be a source of
bacterial growth.
3. After soaping, using 120°,
high-pressure water, start at the same
end where foaming was started and
rinse of all foam and soap. Clean all
drains and outlet wheel chutes using
foam and then rinse. Any piping
should be cleaned with soap and a
brush, and then thoroughly rinses.
MAT-7W, 8-W, 10W & MAT-HS-8W, 10W, 12W Service Manual 23
MAINTENANCE

X. MAINTENANCE
A. Preventative Maintenance Chart

Bi-
Task Daily Weekly Monthly Monthly Quarterly Yearly
Auger Drive and Unloader Drive
* Check oil level in gear reducers X
Lubrication
* Grease main bearing and unloader bearing X
Pulley and Belt
* Check and replace if worn X
Sprocket, Tension Arm, and Chain
* Check for wear. Replace worn parts and make
X
necessary adjustment on tension arm.
Pumps
* Check strainer and clean if necessary X
Motors
* Check operating AMPS while motors are
X
under full load.
* Check to make sure ball bearing is lubricated
sufficiently. As needed, regrease with Shell Oil
X
“Dollum R,” Chevron “SRI No. 2,” and Texaco
“Premium RB.”
Air Blower System
* Check Filters. Filters can be washed and dried
X
to extend life.
* Check air hoses for cleanliness. Use only clear X
vinyl tubing.
Controls
* Check operation and starters for contact wear. X
Reducers
* Visually check to oil level gauge on the vertical
unit, forced-lubrication type. Check lubrication X
flow by viewing piping set and oil signal.
MAT-7W, 8-W, 10W & MAT-HS-8W, 10W, 12W Service Manual
XI. TROUBLESHOOTING
Symptom: Chiller won’t start
Motor starter is tripped
There is no power to the panel
Outlet wheel is not running
Starter is not closing
Motor is running, Auger is not turning
Symptom: Chiller stops running
Possible Cause
Birds are backed up
No power
Shear pin
Symptom: Birds are backing up
Possible Cause
Machine is in clean-up mode
Pull cable safety switch is tripped
Flights spirals are assembled incorrectly
Tank is overloaded
Auger is not running
24
TROUBLESHOOTING
See Symptom: Motor starter is tripped.
Check for the 3 phase incoming power, check for
control voltage or blown fuse or tripped breaker.
Check that the position switch is in the on
position. Check drive chain to assure its on.
Check motor for operation. Check gearbox that
the gearbox is turning. Check for missing key in
drive shaft.
Check for tripped overloads and check control
safeties, also check starter coil or replace starter.
Check drive chain on motor drive. Check shear
pin on drive shaft.
Possible Remedy
Low water level. Check chiller speed. Outlet wheel
not running or Outlet wheel turning to slow
Check for blown fuse or breaker tripped or could
be turned off.
Replace broken shear pin in the main drive shaft.
Check why pin broke possible overload condition.
Possible Remedy
Turn switch to Chill Mode
Check tank to ensure that personnel has not fallen
into tank. After tank has been deemed clear of any
personnel, reset pull cable switch
Reassemble auger flights so that flights are
continuous at hanger bearings (note: we need an
illustration of this in the installation section)
Refer to table 1.2 for load capacities
Check to make sure unloader is turned on.
MAT-7W, 8-W, 10W & MAT-HS-8W, 10W, 12W Service Manual 25
TROUBLESHOOTING

Symptom: Motor is not running

Possible Cause Possible Remedy
Belt is bad Belt should be in one piece, not slipping and is on
and tightened to specification.
Sheer Pin is Broken Replace sheer pin and restart motor check for
overloading conditions.
Key Stock broke Replace key stock and restart
Chain Repair or replace broken chain.
Gear Reducer Check for loose set screws or missing key way.

Symptom: Flights are pushing birds out of the tank

Possible Cause
Water level is too high
Tank is filled past capacity
Possible Remedy
Increase bleed-off to return to proper level.
Check for failures elsewhere in system, correct
problem, repair damage and restart unit. Check for
proper flow rates on the overflow water decease as
needed.

Symptom: Motor Starter is Tripped

Possible Cause Possible Remedy
Motor Failure Replace motor and check for loose wiring
connections.
Motor overloaded Restart and check amps and possible overload
conditions on chiller. Check for foreign material that
could hang up the chiller. Check for low water level
Lose Wire Connection Check and secure all wiring connections.

Problem with the Reducer Possible Cause Suggested Remedy

Load exceeds the
Refer to Table 3-1 for recommended
Overloading capacity of the
load level.
reducer
Insufficient Check lubricant level and adjust up to
Runs Hot lubrication recommended levels
Improper Check lubricant level and adjust down
Excessive lubricant
Lubrication to recommended level
Flush out and refill with correct
Wrong lubricant
lubricant as recommended
MAT-7W, 8-W, 10W & MAT-HS-8W, 10W, 12W Service Manual 26
TROUBLESHOOTING

Problem with the Reducer Possible Cause Suggested Remedy

Cont.
Inspect mounting of reducer. Tighten
Weak mounting
Loose loose bolts and/or reinforce mounting
structure.
Foundation & structure.
Bolts Loose hold down
Tighten bolts.
bolts.
Overloading unit
Disassemble and replace disc.
Worn Disc may result in
Recheck rated capacity of reducer.
damage to disc.
Replace bearing. Clean and flush
May be due to lack
Runs Noisy reducer and fill with recommended
Failure of of lubricant.
lubricant.
Bearings
Refer to Table 3-1 for recommended
Overload.
load level.
Level of lubricant in
Insufficient Check lubricant level and adjust to
the reducer not
Lubricant factory-recommended level.
properly maintained
Replace ring gear pins and rollers.
Damaged Pins Overloading of
Contact Morris & Associates, Inc. for
& Rollers reducer.
replacement parts.
Overloading of Replace broken shaft. Contact Morris
reducer may cause & Associates, Inc. for replacement
Input Shaft damage. parts.
Broken Key missing or
sheared off on Replace key.
Output Shaft
input shaft.
Does Not
Replace eccentric bearing. Contact
Turn
Morris & Associates, Inc. for
Lack of lubricant.
Eccentric replacement parts. Flush and refill
Bearing Broken with recommended lubricant.
Coupling loose or Properly align reducer and coupling.
disconnected Tighten coupling.
Replace seals. Breather filter may be
Caused by dirt or clogged. Replace or clean filter.
grit entering seal Contact Morris & Associates, Inc. for
replacement parts.
Oil Leakage Worn Seals Check lubricant level and adjust to
Overfilled reducer.
recommended level.
Vent clogged. Clean or replace element, being sure
to prevent any dirt from falling into the
reducer.
MAT-7W, 8-W, 10W & MAT-HS-8W, 10W, 12W Service Manual 27
PARTS

XII. PARTS AND ORDERING DETAILS

A. Suggested Spare Parts List

The following is a suggested spare parts list only. It in no way is a complete list of
machine components.

For increased efficiency, and to reduce instance of down-time, Morris recommends

that you keep the following parts on hand at all times:

B. Contact Information

Morris & Associates, Inc. Parts Department

919.779.1250 ext. 239
MAT-7W, 8-W, 10W & MAT-HS-8W, 10W, 12W Service Manual 28
PARTS

C. Equipment Drawings

FIGURE 11-1
MAT-HS TOP VIEW

FIGURE 11-2
MAT-HS SIDE VIEW

FIGURE 11-3 FIGURE 11-4

MAT-HS INLET VIEW MAT-HS OUTLET VIEW
MAT-7W, 8-W, 10W & MAT-HS-8W, 10W, 12W Service Manual 29
PARTS

FIGURE 11-5
MAT TOP VIEW

FIGURE 11-6
MAT SIDE VIEW

FIGURE 11-7 FIGURE 11-8

MAT INLET VIEW MAT OUTLET VIEW

MAT OUTLET VIEW

MAT-7W, 8-W, 10W & MAT-HS-8W, 10W, 12W Service Manual 30
TRAINING

XIII. TRAINING

A. Classes B. Access to Materials

Morris & Associates, Inc. offers Coming soon to the Morris &
extensive training beyond the scope of this Associates, Inc. website:
manual.
Helpful training information featuring links
For information on how to receive to websites, printed text, and CD training.
continued on-site training on this or other
Morris equipment, contact us at: Check www.morris-associates.com
919-582-9200. frequently for updates.
 Standard 1 Year Manufacturer’s Warranty
Morris & Associates, Inc., hereinafter referred to as
SELLER, warrants to the original Purchaser from SELLER or
the original end user, hereinafter referred to as
PURCHASER, every Morris Auger Style Poultry Chiller
Model MAT-7W, MAT-8W, MAT-10W, MAT-HS-8W, MAT-
HS-10-W, MAT-HS-12W, to be free of defects in
workmanship, if properly installed, maintained and operated,
for a period of eighteen (18) months from the date of
shipment from the SELLERS plant or for twelve (12) months
from the date of original installation in the PURCHASERS
plant, whichever occurs first.
SELLERS obligation under this warranty shall be strictly
limited, at SELLERS option, to: (i) repairing or furnishing
replacement OEM parts F.O.B. point of manufacture, such
parts proven defective upon examination by SELLER. On
parts furnished to SELLER but manufactured by others,
SELLER will extend the same warranty to PURCHASER as
is granted to SELLER by the manufacturer thereof.
Any alteration in material or design of SELLERS product
or any component parts thereof by PURCHASER or others
without written authorization by SELLER voids all obligations
of SELLER regarding the product and any associated
warranty herein stated or implied.
SELLER shall not be liable for any incidental or
consequential damages or delays due to defects, beyond
making such repairs or furnishing duplicate parts, nor shall
SELLER be liable for any defective material repaired or
replaced without SELLER’S consent, nor shall SELLER be
liable for damages caused by corrosion.
SELLER DOES NOT MAKE AND DOES NOT
AUTHORIZE ANY OTHER PERSON TO MAKE ANY
WARRANTY OF ANY KIND WHATSOEVER, EXPRESS
OR IMPLIED, ORALLY OR IN WRITING, OTHER THAN AS
SPECIFICALLY STATED HEREIN; AND THERE ARE NO
WARRANTIES OF MERCHANTABILITY AND/OR
FITNESS FOR A PARTICULAR PURPOSE WHICH
EXCEED THE OBLIGATIONS AND WARRANTIES
SPECIFICALLY STATED HEREIN.
Parts furnished without charge as replacements for original
parts under warranty are warranted only for that period of
time during which the original parts warranty is effective.
Damage to any component due to water quality, CIP
detergents or Antimicrobial additives is specifically excluded
from this warranty.
Standard Procedure will be to furnish replacement parts
as requested on a charge basis, f.o.b. factory, with credit to
be issued to PURCHSER after inspection and approval of
parts or materials returned for adjustment, freight prepaid.
It is understood that PURCHASER must obtain
advanced approval before returning any material to
PURCHSER regardless of whether it is in or out of warranty.
This warranty will not apply to any material or part
thereof that is subject to accident, misuse or unauthorized
alteration.
Notes:
Notes: