Stac SS500P User manual

MODEL 500P
HYDRAULIC COOLER & TANK STABILIZER
PROPANE USE ONLY
Serial #:
Installation Date:
Resource Manual
Installation Guide Operating Procedures Parts Breakdown
STAC INC  ST PAUL MN 800-334-7699
®

MODEL 500P
HYDRAULIC COOLER & TANK STABILIZER
PROPANE USE ONLY
INDEX
STEP DESCRIPTION PAGE
Index 1
Introduction 2
1 Positioning & Mounting 3
2 Installing the PTO & Hyd Pump 3
3 Hydraulic Plumbing 4
4 Product Line Plumbing 5
5 Final Assembly 6
6 Start-Up Procedures 7
7 Operating Procedures 7
System Maintenance 8
Troubleshooting 9
Specifications 10
Parts Breakdown 11
Parts List 12
Product Offering 13
Warranty Policy
INSTALLATION GUIDE, OPERATING PROCEDURES & PARTS BREAKDOWN
STAC INC  ST PAUL MN 800-334-7699
PAGE 1
NOTICE
PURCHASER/INSTALLER before proceeding be sure to check the following:
1) Do you have a valid CT License? Proceed no further unless you have supplied STAC, INC. with
a copy of your CT License.
2) This system must be installed and operated in accordance with all DOT regulations and
according to the instructions contained inside this manual.
3) PURCHASER/INSTALLER must have adequate training on how to operate this system.
4) Failure to follow these instructions will void any product warranty and subject the PURCHASER/
INSTALLER to any and all potential liabilities associated with this product and/or its use.
®

Please read this guide carefully before installing and operating the Model 500P
THERMAFLOW system.
HYDRAULIC FUNCTION
The Model 500P THERMAFLOW assembly is designed to cool and filter the
oil required to operate your hydraulic system by using the product which is being
pumped. This is accomplished via a special heat exchanger which is designed to
transfer the heat of the hydraulic oil into the product which is being pumped. The
amount of heat which is transferred into the product is safely limited only to the
amount of cooling which is required. The product supplied to the heat exchanger by a
pressure line which is tee’d into the pressure discharge line. STAC, INC. provides an
orifice fitting to be installed in the THERMAFLOW unit to limit the amount of product
being pumped through the heat exchanger. The exhausting product is then pumped
back into the supplying vessel through a suitable port (ex. motor fuel port).
Optional hydraulic controls for this system allow for easy integration with off-
truck remote controls for either electric or air shut-offs.
And as with all hydraulic drive systems, this system will also eliminate the need
for a driveline. This will reduce maintenance and downtime associated with shaft
driven pumps.
TANK STABILIZER FUNCTION
The Model 500P THERMAFLOW is also a tank stabilizer. As the propane is
pumped through the heat exchanger it is vaporized. Reintroducing this vaporized
product back into the supplying vessel gives the added benefit of maintaining pump
performance, reducing pump noise and prolonging pump life.
Because different product pump applications require different speed and power
requirements, your THERMAFLOW system was custom engineered for a particular
application. If the system is operated beyond its designed capacity, overheating and/
or component damage could result.
PAGE 2
INSTALLATION GUIDE, OPERATING PROCEDURES & PARTS BREAKDOWN
STAC INC  ST PAUL MN 800-334-7699
®

STEP 1 POSITIONING & MOUNTING
The Model 500P is required to be mounted in a position that meets the DOT’s requirements
for roll-over-protection. See diagram below for proper mounting bracket and shock mount
installation.
NOTE: The THERMAFLOW Model 500P can be mounted either from the rear
or bottom mounting holes.
NOTE: Please contact your local DOT representative if you have any
questions concerning the DOT’s requirements on mounting of equipment that
require roll-over-protection.
NOTE: STAC, INC. does not assume any liability for its products if they are
mounted or plumbed in a way that does not meet the DOT’s requirements.
STEP 2 INSTALLING THE PTO & HYDRAULIC PUMP
A) Install the PTO to the transmission and mount the hydraulic pump according to
the instructions included with the PTO.
HELPFUL HINT: If you are using a direct mount hydraulic pump/PTO combination,
be sure that the pump splines are well lubricated with a heavy grease. This grease will
prevent premature spline wear on the PTO and pump shafts. A small packet of this
grease is available through STAC, INC. P/N 300980.
INSTALLATION GUIDE, OPERATING PROCEDURES & PARTS BREAKDOWN
PAGE 3
STAC INC  ST PAUL MN 800-334-7699
IN MOUNTING
KIT 500550
IN MOUNTING
KIT 500550
IN MOUNTING
KIT 500550
IN MOUNTING
KIT 500550
500200500200
500032
THE 500P CAN BE MOUNTED
USING METHOD A OR B
METHOD A
METHOD B
MOUNTING BRACKET
500130
®

STEP 3 HYDRAULIC PLUMBING
The following diagram shows the proper plumbing for the Model 500P THERMAFLOW
assembly. Please carefully read the helpful hint and notes listed below before beginning.
HELPFUL HINT
We recommend the use of 1 1/2” suction hose for all applications, especially if the
THERMAFLOW assembly will be operated in cold weather. If the suction hose is too
small the hydraulic pump will cavitate and fail prematurely.
NOTE: Be careful not to over tighten NPT threads. It is very easy to crack these types
of ports when tightening fittings.
NOTE: When mounting the THERMAFLOW Model 500P across the frame rails and
behind the cab, make sure that the suction and pressure hoses are properly plumbed
and secured away from the driveline.
INSTALLATION GUIDE, OPERATING PROCEDURES & PARTS BREAKDOWN
PAGE 4
STAC INC  ST PAUL MN 800-334-7699
DIAGRAM A
Hydraulic plumbing diagram for THERMAFLOW Model 500P
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®

DIAGRAM B
Product plumbing diagram for THERMAFLOW Model 500P
INSTALLATION GUIDE, OPERATING PROCEDURES & PARTS BREAKDOWN
PAGE 5
STAC INC  ST PAUL MN 800-334-7699
STEP 4 PRODUCT LINE PLUMBING
The following diagram shows the proper product plumbing for the Model 500P
THERMAFLOW assembly. Please carefully read the helpful hint and notes listed below before
beginning.
NOTE: We have provided the proper orifice fitting installed into the THERMAFLOW
cooler assemblies Product Inlet Port. Failure to use the orifice fitting provided could
cause your THERMAFLOW cooler assembly to improperly cool the hydraulic oil. Please
consult STAC, INC. with any questions regarding this orifice fitting.
NOTE: Always use UP Approved hoses and fittings.
PRODUCT PRESSURE LINE
PRODUCT RETURN LINE
RETURN INTO TANK VIA MOTOR FUEL
PORT OR OTHER SIMILAR PORT.
USE UL APPROVED HOSE AND
FITTINGS ONLY.
PLUMB FROM POINT DOWN-STREAM
OF THE PRODUCT PUMP BUT BEFORE
THE METER OR DIFFERENTIAL VALVE.
®

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DIAGRAM C
Filter assembly procedures for THERMAFLOW Model 500P
INSTALLATION GUIDE, OPERATING PROCEDURES & PARTS BREAKDOWN
PAGE 6
STAC INC  ST PAUL MN 800-334-7699
STEP 5 Final Assembly
A) Complete all hydraulic and product plumbing.
B) Fill the reservoir until the oil level gets to the top black line on the site level gauge.
NOTE: After the initial start up procedure you will need to add oil due to the hydraulic
lines filling up to capacity.
NOTE: Over-filling the reservoir will cause the oil to expand up through the breather
assembly when the oil warms up.
NOTE: We recommend using a high grade of hydraulic oil with a Pour Point of -50°F.
This will ensure proper oil flow during extreme cold weather operation. Use of synthetic
hydraulic oils is also recommended. Recommended Oil: MOBIL DTE 10-32 or
equivalent.
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®

STEP 6 START-UP PROCEDURES
The following steps are to ensure that the THERMAFLOW assembly is operating properly.
NOTE: Before engaging the PTO, make sure that all hydraulic and product lines are
plumbed and properly tightened.
1) Connect product hose to proper location so that system can circulate product back into the
tank.
2) Engage the PTO with engine at idle speed.
NOTE: Watch the oil level in the reservoir. Be ready to add more oil as needed to
maintain the oil level between the black and red lines on the site level gauge.
3) Check for hydraulic and product leaks and repair as needed.
4) Carefully Tach the product pump speed.
5) Slowly increase the engine speed until desired product pump speed is obtained.
6) Run system for at least five minutes to ensure that system is sufficiently cooling the
hydraulic oil. You should see approximately a 10-20°F rise in the hydraulic oil temperature
above the product temperature. This oil temperature should then be maintained throughout
the entire pumping cycle depending how long the system is run.
NOTE: If the hydraulic oil temperature is higher or lower than the 10-20°F rise, please
consult STAC, INC. at 800-334-7699. DO NOT OPERATE THIS SYSTEM UNTIL AFTER
YOU HAVE CONSULTED STAC, INC.
7) Slow engine to idle and disengage the PTO.
8) System is ready for operation.
STEP 7 OPERATING PROCEDURES
1) Engage PTO.
2) Set engine speed with the throttle control to the correct RPM.
NOTE: This system is self contained and there is no fan motor to operate.
3) To disengage the product pump either disengage any installed control valve or disengage
the PTO.
INSTALLATION GUIDE, OPERATING PROCEDURES & PARTS BREAKDOWN
PAGE 7
STAC INC  ST PAUL MN 800-334-7699
®

System Maintenance
Hydraulic
Fluid:
 Drain and replace hydraulic oil every 6 to 12 months depending on use.
 Recommended Fluid: Mobil DTE 10-32 or equivalent.
Filter:
 Remove 3 cap screws on top of filter housing.
 Remove filter cartridge and spring.
 Replace with new filter cartridge and spring Part Number 934331.
 Apply anti-seize to cap screws and tighten.
Pump:
 Inspect periodically for leaks.
 Check hoses for signs of wear.
Motor:
 Inspect periodically for leaks.
 Check hoses for signs of wear.
PTO
 Grease output shaft every 6 to 12 months depending on use.
 If PTO does not have a grease zerk on output shaft, remove direct mount
hydraulic pump and grease the output shaft using a high quality gear lube.
INSTALLATION GUIDE, OPERATING PROCEDURES & PARTS BREAKDOWN
PAGE 8
STAC INC  ST PAUL MN 800-334-7699
®

Troubleshooting
Safety First!
Think about it before you do it. Our systems use controlled fluid pressure and converts it to rotational
movement. This means that the system pressure operates around 2000 psi. A pin hole leak of fluid at this
pressure can be dangerous. Use caution when loosening fittings, system pressure can be maintained for a
period of time after shutdown.
Troubleshooting
Always inspect the things easiest to eliminate first. Look for faulty linkage or wiring that controls the PTO,
pump or motor. Look at the fluid level and appearance of the oil. Check temperatures and pressures.
Excessive Heat:
Clean air passages through heat exchanger.
Check fan operation.
Check setting of relief valve.
Check temperature of suction line vs outlet line temperature. If the outlet temperature is noticeably hotter,
the pump is cavitating.
Check for contamination in relief valve. Clean and replace.
Check for added flow controls. If a flow control has been added to the system, excess heat can be
generated by the added restriction to flow.
Loss of Motor Speed:
Check oil level.
Ensure recommended engine idle speed is maintained.
Check output pressure of the pump. If system pressure cannot be maintained, attempt to adjust the relief
valve setting to max system pressure. If this does not make a noticeable change, make sure to return relief
setting to original position and bring the pump and motor to a hydraulic specialist for bench testing and
possible replacement.
Excessive Noise:
Check oil level. Fill to proper level.
Ensure use of recommended oil type and weight.
Ensure suction line to pump is at least 1 1/2”.
Ensure there is no restriction in suction line.
Oil Discoloration:
Ensure suction line connections are tight.
Ensure oil is free from water and contaminants. Drain and refill with recommended oil and replace filter.
Ensure use of recommended oil type and weight.
INSTALLATION GUIDE, OPERATING PROCEDURES & PARTS BREAKDOWN
PAGE 9
STAC INC  ST PAUL MN 800-334-7699
®

Specifications
Max Flow Rate: 25 gpm
Max Pressure: 3000 psi
Reservoir: 2.5 gal
Weight: 50 lbs
Suction Line: 1.5 Inch
Pressure Lines: ¾ Inch
Warranty: 2 years
Oil - The recommended oil is
Mobil DTE 10-32 or equivalent. Mobil
DTE 10-32 is a supreme performance
anti-wear hydraulic oil engineered for
wide temperature range applications. It
exhibits optimum flow characteristics at
sub-zero temperatures and is resistant
to shearing and viscosity loss so that
system efficiency is maintained and
internal pump leakage is minimized
at high operating temperatures and
pressures.
INSTALLATION GUIDE, OPERATING PROCEDURES & PARTS BREAKDOWN
PAGE 10
STAC INC  ST PAUL MN 800-334-7699
®

INSTALLATION GUIDE, OPERATING PROCEDURES & PARTS BREAKDOWN
PAGE 11
STAC INC  ST PAUL MN 800-334-7699
MODEL 500P PARTS BREAKDOWN
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®

INSTALLATION GUIDE, OPERATING PROCEDURES & PARTS BREAKDOWN
PAGE 12
STAC INC  ST PAUL MN 800-334-7699
Parts List
Item No. Part # Description QTY.
1 150710 16FJIC SWIVEL X16MORB 90° ELBOW 1
2 150712 16MJIC X12MORB 90° ELBOW 1
3 934330 FILTER ASSEMBLY 1
4 300334 SITE GLASS 1
5 300412 12MORB PLUG 1
6 300702 3000 PSI RELIEF VALVE 1
7 300708 12MJIC-12MORB 90° 3
8 300748 12MORB-12MORB ADJUSTABLE 1
9 500001 500P TANK 1
10 500030 500P LID 1
11 500032 SPACER 4
12 500130 MOUNTING BRACKET 2
13 500200 500P/100P SHOCK MOUNT 4
14 500412 6MSAE-6MP STRAIGHT 1
15 500418 6MSAE-08MP STRAIGHT 1
16 600332 BREATHER 1
®

Product Offering
Fans
Spal
Multi-Wing
Fittings
Tompkins
Stucci
Ryco
Heat Exchangers
Thermal Transfer
Flat Plate
AKG
Hydraulic Motors
Eaton/Charlynn
Muncie
Permco
Hydro Leduc
PTO’s
Muncie
Pumps
Muncie
Parker
Permco
Hydro Leduc
INSTALLATION GUIDE, OPERATING PROCEDURES & PARTS BREAKDOWN
PAGE 13
STAC INC  ST PAUL MN 800-334-7699
®

The THERMAFLOW 500P Hydraulic Cooler & Tank Stabilizer is warranted against
any defect in material and workmanship which existed at the time of sale by STAC,
Inc. according to the following provisions, subject to the requirements that the Cooler
must be used only in accordance with the catalogue and package instructions.
The Cooler is warranted for a period of TWO Years from the date of installation. If
during the warranty period the cooler fails to operate to STAC’s specifications due
to a defect in any part in material or workmanship that existed at the time of sale by
STAC, Inc., the defective part will be repaired or replaced, at STAC, Inc.’s discretion,
at no charge, if the defective part is returned to STAC, Inc. with transportation
prepaid.
The above warranty shall terminate if any alterations or repairs are made to the
System other than at an authorized dealer or if the cooler is used on any equipment
other than the equipment upon which it is first installed.
THE FORGOING WARRANTIES ARE IN LIEU OF ALL OTHER OBLIGATIONS
AND LIABILITIES, INCLUDING NEGLIGENCE AND ALL WARRANTIES OF
MERCHANTABILITY AND SUITABILITY, EXPRESSED OR IMPLIED AND STATE
STAC, INC.’S ENTIRE AND EXCLUSIVE LIABILITY AND BUYER’S EXCLUSIVE
REMEDY FOR ANY CLAIM OF DAMAGES IN CONNECTION WITH THE SALE,
REPAIR OR REPLACEMENT OF THE ABOVE GOODS, THEIR DESIGN,
INSTALLATION OR OPERATION. STAC, INC. WILL IN NO EVENT BE LIABLE
FOR ANY DIRECT, INDIRECT, SPECIAL, INCIDENTAL OR CONSEQUENTIAL
DAMAGES WHATSOEVER, AND OUR LIABILITY UNDER NO CIRCUMSTANCES
WILL EXCEED THE CONTRACT PRICE FOR THE GOODS FOR WHICH
LIABILITY IS CLAIMED.
60 West Sycamore Street • St. Paul, MN 55117
800-334-7699 • 763-235-7822 Fax
Web: www.thermaflow.com
Inc.
THERMAFLOW WARRANTY
Thermaflow is a registered trademark of STAC, Inc. All Rights Reserved. Form 500901 Rev: 04/18
®