Sunflo Pumps

Technical Manual

02.10.11E, 11/02 Visit our website at www.sundyne.com

COPYRIGHT

All rights reserved. No part of this publication may be

reproduced, stored in a retrieval system or transmitted in any
form or by any means, electronic, mechanical, photocopying,
recording or otherwise without the prior permission of Sundyne
Corporation.

2002 Sundyne Corporation

WARRANTY
Sundyne Corporation warrants to Buyer for a period of twelve (12) months from the
date of being placed in service (but not to exceed eighteen (18) months after the
date of shipment) that the equipment at the time of shipment will be free from
defects of design, material and workmanship. If any defects or malperformance
occur during the warranty period, Sundynes sole obligation shall be limited to
alteration, repair or replacement at Sundynes expense, F.O.B. Factory, of parts or
equipment, which upon return to Sundyne and upon Sundynes examination prove
to be defective. Equipment and accessories not manufactured by Sundyne are
warranted only to the extent of and by the original manufacturers warranty.
Sundyne shall not be liable for damage or wear to equipment caused by abnormal
conditions, vibration, failure to properly prime or to operate equipment without flow
or caused by corrosives, abrasives or foreign objects. THE FOREGOING
WARRANTY IS EXCLUSIVE AND IN LIEU OF ALL OTHER WARRANTIES,
WHETHER EXPRESSED OR IMPLIED INCLUDING ANY WARRANTY OF
MERCHANTABILITY OR FITNESS FOR ANY PARTICULAR PURPOSE. In no
event shall Sundyne be liable for consequential or incidental damages.

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Icons Used in this Manual
The following icons (symbols) are used to indicate specific
types of information.

Good ideas to use.

A reminder to do something.

Equipment use alert. Unless you follow

these procedures correctly, the equipment
may be damaged.

Safety alert. Failure to follow these

procedures can endanger the safety of you
or others.

Electrical hazard. Failure to follow these

procedures can endanger the safety of you
or others.

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 TABLE OF CONTENTS
TITLE PAGE

SUGGESTED SAFETY INSTRUCTIONS 4

INTRODUCTION 5
INSPECTION 5
STORAGE 5
LONG-TERM STORAGE 5
MOUNTING 6
FRAME MOUNT DRIVE INSTALLATION 6
FINAL ALIGNMENT 6
SUCTION AND DISCHARGE PIPING 6
SEAL AND ENVIRONMENTAL CONTROL SYSTEM 7
SINGLE SEAL FLUSH SYSTEM 7
DOUBLE SEAL LIQUID BUFFER SYSTEM 7
TANDEM SEAL LIQUID BUFFER SYSTEM 8
GEARBOX AND PROCESS SEAL DRAIN 8
SEAL CAVITY PRESSURE RISE 8
OPERATION 14
GEARBOX OIL FILL 14
START-UP 14
PUMP CONTROL 15
RECOMMENDED CONTROL OF CENTRIFUGAL PUMPS 15
PARALLEL OPERATION 16
TROUBLESHOOTING-GEARBOX, PUMP, MECHANICAL SEALS 18
SPARE PARTS 25

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 Equipment Instruction Manual: Suggested Safety Instructions

During installation, maintenance, or repair operations of Sundyne Corporation pumps or

compressors, systems for safety shall be applied before the commencement of work. Failure to
take responsibility for safety may lead to operator injury.

Personal Protective Equipment (PPE) safety glasses with side shields shall be worn by all
personnel installing or performing maintenance or repair on the equipment. If equipment is to be
manually lifted and the weight is over 15 pounds (7kg), or if pallet jacks or forklifts are to be used,
the person shall wear safety toed shoes. When testing the equipment, hearing protectors (ear
defenders) are recommended to be worn if noise levels exceed 85 dB over the work day.
Chemical resistant gloves shall be used if chemical use is required (see Chemical Use below for
additional information). If chemicals have warnings regarding fumes and/or dust/mists, a dust
mask respirator shall be worn.

When selecting one piece of PPE to be used with another, consider the compatibility between
them. For example, safety glasses should not interfere with the seal from hearing protectors to
protect hearing. Be sure to clean the PPE after each use.

Use of Forklifts: All forklift drivers must have a current recognized license. If using a forklift, first
ensure that the lift is in safe operating condition.

Electrical Safety:

Installation, Service, Repair: Ensure all electrical sources are off and safe to install, service,
and/or repair the equipment. A recognized Lockout/Tagout program should be followed - Locks
and/or tags should be provided warning employees that the equipment is being installed, serviced,
and/or repaired. Once the work is completed, the person installing the lock and/or tag shall
remove it and inform others of start-up. Should there be a shift change, the lock and/or tag shall
be removed by the first authorized person and the lock and/or tag shall be installed by the second
shift authorized person.

Testing Equipment: Persons in the immediate area shall be warned when a test is to be
performed.

Tools: Tools shall be insulated from electrical shock. Ensure all tools are clean and free of oil
and the insulation is not damaged in any way.

Chemical Use: Any chemicals to be used shall be accompanied by a relevant Hazard Data Sheet,
in accordance with your government legislation. If applicable, chemical proof gloves shall be
used. An eye wash station (or equivalent) should be available in the event of injury. Should any
hazardous or flammable chemicals have flowed through the equipment a complete
decontamination of the equipment is required.

Fall Protection: When working over six feet from the ground, fall protection is required.

Machine Guarding: Guards shall remain in place on all equipment. Only during
maintenance/repair can the guards be removed, and prior to start-up, the guard must be replaced.

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INTRODUCTION

This manual presents installation, servicing, starting, pump control, trouble shooting, maintenance, and spare parts
information for Sunflo Pumps.

Information that may be required and is not included herein may be obtained from your Sundyne Corporation
Distributor, or directly from the factory.

Instructions under the heading of NOTE give specific details to ensure satisfactory pump operation and durability of
pump.

Instructions under the heading of WARNING, if ignored, can cause pump damage and void the warranty.

COMPLIANCE WITH APPLICABLE SAFETY REGULATIONS AND THE PROVISION OF REQUIRED PROTECTIVE
DEVICES ARE THE RESPONSIBILITY OF THE USER.

1.0 INSTALLATION

1.1 INSPECTION

Upon receipt of your Sunflo pump, check visually for any damage which may have occurred during shipment. Notify
the shipping carrier and Sundyne Corporation promptly if damage has occurred. Check packing list to verify receipt of
all items contained in the shipment.

1.2 STORAGE

If pump is not to be installed immediately, it should be stored in a clean, dry area. Care should be taken to protect the
pump from exposure to moisture and dust. Shipping covers installed at the factory (for pump and seal ports) should
be kept securely in place until just prior to installation. Storage instructions provided by the driver (motor or turbine)
manufacturer should be observed.

WARNING
All shipping covers should be removed prior to operation of the pump. Be sure to remove seal drain shipping plugs.

1.3 LONG-TERM STORAGE

Certain long-term storage considerations should be met for any Sunflo pump which will not be operating for a period
of time exceeding six months from date of factory shipment. This action will ensure minimum corrosion damage to
the gearbox and fluid-end components. Because of storage location and other unknown site factors beyond our
control, Sundyne Corporation will not accept any liability for damage to equipment during the storage period, nor will
Sundyne Corporation guarantee the quality of the equipment during and after the storage period.

To ensure the original quality of the Sunflo pump (before commissioning the pump) after storage, all components
must be inspected by an authorized Sundyne Corporation service engineer. Any required replacement will be at the
purchasers expense. Any components not manufactured by Sundyne Corporation (except mechanical seals) must
be inspected by the particular sub-manufacturers authorized service personnel and any component replacement will
be at the purchasers expense.

The method employed for long-term storage is to prevent the humidity/temperature and airborne chemicals from
making contact with the internal components of the equipment.

When the equipment is to be stored in strong chemical environments or near salt water, protection should be initiated
immediately upon receipt of the equipment.

Following is the Sundyne Corporation preferred list of recommended long-term storage procedures:

1. Indoor climate controlled building (maintain constant temperature and humidity).

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2. Inert gas purging of internal components.

3. Oil film on internal components.

4. Desiccant bags in suction and discharge flanges.

1.4 MOUNTING

For both the close coupled and the frame mounted units, the pump, gearbox and driver should be mounted on a rigid
foundation and have minimum deflection freedom from resonant frequencies. The horizontal base or motor feet
should be secured in position using the maximum size bolt accepted by the motor or horizontal base.

Bolts used should have sufficient length to extend at least three threads above the nut after tightening.

When the horizontal base is to be grouted, the horizontal base should be leveled prior to grouting.

1.5 FRAME MOUNT DRIVE INSTALLATION

Alignment of the pump and drive is of extreme importance for trouble-free mechanical operation.

NOTE
If other than Sundyne Corporation supplied couplings are used, they must be a flexible type, vibration dampening
coupling design. Refer to coupling manufacturers recommendations for installation and alignment.

On initial alignment set the motor 0.003-0.004 inches or 0.076 - 0.101 mm higher than the pump.

1.6 FINAL ALIGNMENT

Final alignment can only be accomplished after the unit has been run under actual operating conditions for a sufficient
length of time to bring the unit up to operating temperature.

A. After warm up period has elapsed, stop the unit and immediately disconnect the coupling and check the
alignment.

B. Repeat the alignment procedure.

NOTE
Motor shaft height should be equal to pump shaft height at operating temperature.

C. Reconnect coupling, check final alignment after approximately one week of operation.

1.7 SUCTION AND DISCHARGE PIPING

A. The suction line should be clean and a strainer (40 mesh is suggested) should be installed to protect the impeller
from damage by mill scale, welding slag, or other foreign particles during initial startup.

B. All piping must be supported independently of the pump. The piping should always line up with the pump flanges.

WARNING
Never draw the piping into place by the use of force as this will cause pipe strain which may impose excessive
stress on the unit.

C. The piping, both suction and discharge, should have no unnecessary elbows, bends, and fittings, as they increase
friction losses in the piping. The size of pipe and fittings should be selected carefully and be sufficient to keep the
friction losses as low as practical.

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 NOTE
Piping must not be connected to the pump until after pump hold-down bolts have been tightened.

NOTE
When frame mount units are being used, coupling alignment should be verified after suction and discharge piping has
been connected. If realignment is necessary, pipe strain may be present.

NOTE
Suction pipe should never be of smaller diameter than the pump suction inlet and should have at least 10 pipe
diameters of straight pipe leading into the pump suction flange.

D. Block valves (both suction and discharge) are recommended to isolate the pump during shut-down, to minimize
fluid leakage during the shut-down condition, and to prevent possible reverse rotation due to back flow through
the pump.

E. If reverse flow during shutdown is possible, a check valve should be installed in the discharge piping to protect
the pump from possible reverse rotation.

NOTE
Maximum solid size for the pump is 400 microns. Maximum solid size for the mechanical seal is 5-10 microns.

1.8 SEAL ENVIRONMENTAL CONTROL SYSTEM

Depending upon the pump seal arrangement and application, a seal environmental control system may be required.
The pump seal environment must always be maintained as determined by the seal arrangement. There are three seal
arrangements available for Sunflo Pumps: single, double, tandem (not available for the P-1500). Therefore, its
imperative that the seal environmental control system piping be installed properly and that the seal drain port is open.

A. SINGLE SEAL FLUSH SYSTEM

A seal flush system is available for use with the single seal arrangement when the process fluid is contaminated with
solid particles or if the pump fluid temperature dictates the need to flush. A clean, cool fluid from an external source is
introduced into the seal flush port at 15 psi/103.4 kPa above seal cavity pressure and at a controlled flow of:
3
P-1500 - 1.0 gpm / 0.22 m /hr.
3
P-2000 - 2.0 gpm / 0.45 m /hr.
3
P-3000 - 3.0 gpm / 0.68 m /hr.

See seal cavity pressure, Chart 1.

NOTE
Seal flush ports must be plugged if not in use.

B. DOUBLE SEAL LIQUID BUFFER SYSTEM

A liquid buffer system is used with double liquid seals to prevent process liquid leakage out of the pump. The buffer
must be cool, clean and compatible with the process fluid and pump metallurgy. The buffer liquid is introduced into
2
the buffer in port of the seal housing at a pressure of 15 psi /1.05 kg/cm higher than the seal cavity pressure. See
seal cavity pressure, Chart 1. A small portion of the buffer fluid flows across the front seal into the process fluid and a
small portion flows across the rear seal and is vented from the drain port. A buffer flow of:
3
P-1500 - 1.0 gpm / 0.22 m /hr.
3
P-2000 - 2.0 gpm / 0.33 m /hr.
3
P-3000 - 3.0 gpm / 0.68 m /hr.

The flow should be regulated by a valve or orifice on the buffer out port.

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 WARNING
The buffer system must be in operation prior to flooding the pump casing.

C. TANDEM SEAL LIQUID BUFFER SYSTEM

(Not applicable to P-1500 nor P-1000)

A liquid buffer system is used with tandem seal arrangement to cool and lubricate the outboard seal and to contain
process fluid leakage from the inboard seal. The buffer fluid must be cool, clean, and compatible with the process
fluid and pump materials of construction. The buffer liquid is introduced into the buffer in port of the seal housing at
3
atmospheric pressure and must maintain a flow of 0.5 to 3.0 gpm (0.10 to 0.70 m /hr) through the buffer cavity to
properly lubricate and cool the outboard (secondary) seal.

D. GEARBOX AND PROCESS SEAL DRAIN

Seal drain must be open, free to drain. Ensure all shipping plugs have been removed.

E. SEAL CAVITY PRESSURE RISE

Whenever a single seal with external flush, double, or tandem seal arrangement is used, the seal cavity pressure rise
must be known to determine the seal flush or buffer pressure. The area behind the impeller, near the seal, is referred
to as the seal cavity. Suction pressure plus the seal cavity pressure rise plus a safety margin of 15 psi/103.4 kPa
equals the required double seal buffer pressure or the single seal flush pressure.

The required seal flush/buffer pressure may be determined for your pump model by using the appropriate values in
the Seal Cavity Pressure Rise Tables (1 through 6) and the method provided below:

1. Find the pump model which is applicable to your pump.

2. Determine the seal cavity pressure rise (based on water with a specific gravity of 1.0).
3. Multiply this seal cavity pressure rise value by the specific gravity of the process fluid.
4. Specify the seal flush/buffer pressure to equal the sum of the suction pressure, the specific gravity corrected seal
cavity pressure rise determined in Step E-3, and 15 psi/103.4 kPa.

EXAMPLE

Model: Sunflo P3-AJG

Suction Pressure: 19 psig
Seal Cavity Pressure Rise: 20 psig (from the P3 Table)
Process Specific Gravity: 0.95
Required Seal Flush/Buffer Pressure (RSFBP) = Suction Pressure + Seal Cavity Pressure Rise + 15 psig
RSFBP = 19 psig + (20 psig)(0.95) + 15 psig
RSFBP = 53 psig

EXAMPLE
Model: Sunflo P3-AJG
Suction Pressure: 131 kPa
Seal Cavity Pressure Rise: 138 kPa (from the P3 Table)
Process Specific Gravity: 0.95
Required Seal Flush/Buffer Pressure (RSFBP) = Suction Pressure + Seal Cavity Pressure Rise + 103.4 kPa
RSFBP = 131 kPa + (138 kPa)(0.95) + 103 kPa
RSFBP = 365.1 kPa

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 P-1500/P-1000 Seal Cavity Pressure Rise P-2000 Seal Cavity Pressure Rise (Based on
(Based on Water: S.G. = 1.0) Water: S.G. = 1.0)
60 HZ Pump 60 HZ Pump

Model Pressure Rise Model Pressure Rise

(psi / kPa) (psi / kPa)
P1-Axx 17 / 117 P2-Axx 5 / 35
P1-Bxx 20 / 138 P2-Bxx 10 / 69
P1-Cxx 40 / 276 P2-Cxx 10 / 69
P1-Dxx 60 / 414 P2-Dxx 15 / 103
P1-Exx 85 / 586 P2-Exx 15 / 103
(Table 1) P2-Fxx 20 / 138
P2-Gxx 30 / 207
(Table 3)

P-1500/P-1000 Seal Cavity Pressure Rise

(Based on Water: S.G. = 1.0) P-2000 Seal Cavity Pressure Rise (Based on
50 HZ Pump Water: S.G. = 1.0)
50 HZ Pump
Model Pressure Rise
(psi / kPa) Model Pressure Rise
(psi / kPa)
P1-Lxx 16 / 110
P1-Mxx 28 / 193 P2-Hxx 5 / 35
P1-Nxx 47 / 324 P2-Jxx 10 / 69
P1-Pxx 60 / 414 P2-Kxx 10 / 69
P1-Qxx 114 / 786 P2-Lxx 15 / 103
(Table 2) P2-Mxx 20 / 138
P2-Nxx 30 / 207
(Table 4)

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P-3 SEAL CAVITY PRESSURE RISE (BASED ON WATER: SG = 1.0 and 60 Hz)
MODEL SCPR* MODEL SCPR* MODEL SCPR* MODEL SCPR* MODEL SCPR*
P3-AJG 20/ 138 P3-AJH 20/138 P3-AMJ 20/138 P3-AMK 20/138 P3-ARL 20/138
P3-AKG P3-AKH P3-ANJ P3-ANK P3-ASL
P3-ALG P3-ALH P3-APJ P3-APK P3-ATL
P3-AMG P3-AMH P3-AQK P3-AVL
P3-ANG P3-ANH P3-ARK
P3-APG P3-APH P3-ASK
P3-ATK
P3-AVK
P3-AWK
P3-ARM 25/172 P3-BNE 25/172 P3-BLF 25/172 P3-BMG 25/172 P3-BLH 25/172
P3-ASM P3-BPE P3-BMF P3-BNG P3-BMH
P3-BQE P3-BNF P3-BPG P3-BNH
P3-BRE P3-BPF P3-BQG P3-BPH
P3-BSE P3-BQF P3-BRG P3-BQH
P3-BTE P3-BRF P3-BSG P3-BRH
P3-BVE P3-BSF P3-BTG P3-BSH
P3-BWE P3-BTF P3-BVG P3-BTH
P3-BVF P3-BWG P3-BVH
P3-BWF P3-BWH
P3-BLJ 25/172 P3-BMK 30/207 P3-BRL 30/207 P3-CMD 30/207 P3-CJE 35/241
P3-BMJ P3-MNK P3-BSL P3-CND P3-CKE
P3-BNJ P3-BTK P3-CPD P3-CLE
P3-BPJ P3-BVK P3-CQD P3-CME
P3-BQJ P3-BWK P3-CRD P3-CNE
P3-BRJ P3-CSD P3-CPE
P3-BSJ P3-CTD P3-CQE
P3-BTJ P3-CVD P3-CRE
P3-BVJ P3-CWD P3-CSE
P3-BWJ P3-CTE
P3-CVE
PE-CWE
P3-CJF 35/241 P3-CHG 40/276 P3-CJH 40/276 P3-CMJ 45/310 P3-CMK 45/310
P3-CKF P3-CJG P3-CKH P3-CNJ P3-CNK
P3-CLF P3-CKG P3-CLH P3-CPJ
P3-CMF P3-CLG P3-CMH P3-CQJ
P3-CNF P3-CMG P3-CNH
P3-CPF P3-CNG P3-CPH
P3-CQF P3-CPG P3-CQH
P3-CRF P3-CQG P3-CRH
P3-CSF P3-CRG P3-CSH
P3-CTF P3-CSG
P3-CVF
P3-CWF
P3-DGB 50/345 P3-DFC 50/345 P3-DED 50/345 P3-DDE 50/345 P3-DFF 50/345
P3-DHB P3-DGC P3-DFD P3-DEE P3-DGF
P3-DJB P3-DHC P3-DGD P3-DFE PG-DHF
P3-DKB P3-DJC P3-DHD P3-DGE P3-DJF
P3-DLB P3-DKC P3-DJD P3-DHE P3-DKF
P3-DMB P3-DLC P3-DKD P3-DJE P3-DLF
P3-DNB P3-DMC P3-DLD P3-DKE P3-DMF
P3-DPB P3-DNC P3-DMD P3-DLE
P3-DPC P3-DND P3-DME
P3-DPD
P3-DGG 60/414 P3-DJH 60/414 P3-EDB 70/483 P3-ECC 70/483 P3-ECD 70/483
P3-DHG P3-EEB P3-EDC P3-EDD
P3-DJG P3-EFB P3-EEC P3-EED
P3-DKG P3-EGB P3-EFC P3-EFD
P3-EHB P3-EGC P3-EGD
P3-EJB P3-EHC P3-EHD
P3-EKB P3-EJC P3-EJD
P3-ELB P3-EKC P3-EKD
P3-EMB P3-ELC
P3-ENB
* Seal Cavity Pressure Rise (SCPR) in psi / kPa
(Table 5)

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P-3 SEAL CAVITY PRESSURE RISE (BASED ON WATER: SG = 1.0 and 60 Hz) (cont)
MODEL SCPR* MODEL SCPR* MODEL SCPR* MODEL SCPR* MODEL SCPR*
P3-EEE 70/483 P3-EGF 70/483 P3-FCB 75/517 P3-FEB 80/552 P3-FCC 80/552
P3-EFE P3-EHF PE-FDB P3-FFB P3-FDC
P3-EGE P3-FGB P3-FEC
P3-EHE P3-FHB P3-FFC
PE-EJE P3-FJB P3-FGC
P3-FHC
P3-FCD 80/552 P3-FEE 80/552
P3-FDD P3-FFE
P3-FED
P3-FGD
* Seal Cavity Pressure Rise (SCPR) in psi / kPa
(Table 5 cont)

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P-3 SEAL CAVITY PRESSURE RISE (BASED ON WATER: SG = 1.0 and 50 Hz)
MODEL SCPR* MODEL SCPR* MODEL SCPR* MODEL SCPR* MODEL SCPR*
P3-HJG 17/117 P3-HJH 17/117 P3-HMJ 17/117 P3-HMK 20/138 P3-HRL 20/138
P3-HKG P3-HKH P3-HMJ P3-HNK P3-HSL
P3-HLG P3-HLH P3-HPJ P3-HPK P3-HTL
P3-HMG P3-HMH P3-HQK P3-HVL
P3-HNG P3-HNH P3-HRK
P3-HPG P3-HPH P3-HSK
P3-HTK
P3-HVK
P3-HWK
P3-HRM 20/138 P3-JNE 25/172 P3-JLF 25/172 P3-JMG 27/186 P3-JMH 27/186
P3-HSM P3-JPE P3-JMF P3-JNG P3-JNH
P3-JQE P3-JNF P3-JPG P3-JPH
P3-JRE P3-JPF P3-JQR P3-JQH
P3-JSE P3-JQF P3-JRG P3-JRH
P3-JTE P3-JRF P3-JSG P3-JSH
P3-JVE P3-JSF P3-JTG P3-JTH
P3-JWE P3-JTF P3-JVG P3-JVH
P3-JVF P3-JWG P3-JWH
P3-JWF
P3-JLJ 30/207 P3-JLK 30/207 P3-JRL 30/207 P3-KMD 35/241 P3-KJE 36/248
P3-JMJ P3-JMK P3-JSL P3-KND P3-KKE
P3-JNJ P3-JTK P3-KPD P3-KLE
P3-JPJ P3-JVK P3-KQD P3-KME
P3-JQJ P3-JWK P3-KRD P3-KNE
P3-JRJ P3-KSD P3-KPE
P3-JSJ P3-KTD P3-KQE
P3-JTJ P3-KVD P3-KRE
P3-JVJ P3-KWD P3-KSE
P3-JWJ P3-KTE
P3-KVE
P3-KWE
P3-KJF 36/248 P3-KHG 40/276 P3-KJH 40/276 P3-KLJ 48/331 P3-KMK 48/331
P3-KKF P3-KJG P3-KKH P3-KMJ P3-KNK
P3-KLF P3-KKG P3-KLH P3-KNJ
P3-KMF P3-KLG P3-KMH P3-KPJ
P3-KNF P3-KMG P3-KNH P3-KQJ
P3-KPF P3-KNG P3-KPH
P3-KQF P3-KPG P3-KQH
P3-KRF P3-KQG P3-KRH
P3-KSF P3-KRG P3-KSH
P3-KTF P3-KSG
P3-KVF P3-KTG
P3-LGB 50/345 P3-LFC 50/345 P3-LED 50/345 P3-LDE 50/345 P3-LFF 50/345
P3-LHB P3-LGC P3-LFD P3-LEE P3-LGF
P3-LJB P3-LHC P3-LGD P3-LFE P3-LHF
P3-LKB P3-LJC P3-LHD P3-LGE P3-LJF
P3-LLB P3-LKC P3-LJD P3-LHE P3-LKF
P3-LMB P3-LLC P3-LKD P3-LJE P3-LLF
P3-LNB P3-LMC P3-LLD P3-LKE P3-LMF
P3-LPB P3-LNC P3-LMD P3-LLE
P3-LPC P3-LND P3-LME
P3-LPD P3-LNE
P3-LGG 70/483 P3-LJH 70/483 P3-MDB 70/483 P3-MCC 70/483 P3-MCD 70/483
P3-LHG P3-MEB P3-MDC P3-MDD
P3-LJG P3-MFB P3-MEC P3-MED
P3-LKG P3-MGB P3-MFC P3-MFD
P3-LHB P3-MGC P3-MGD
P3-LJB P3-MHC P3-MHD
P3-LKB P3-MJC P3-MJD
P3-LLB P3-MKC P3-MKD
P3-LMB P3-MLC
P3-LNB
*Seal Cavity Pressure Rise (SCPR) in psi / kPa
(Table 6)

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P-3 SEAL CAVITY PRESSURE RISE (BASED ON WATER: SG = 1.0 and 50 Hz) (cont)
MODEL SCPR* MODEL SCPR* MODEL SCPR* MODEL SCPR* MODEL SCPR*
P3-MEE 70/483 P3-MGF 70/483 P3-NCB 77/531 P3-NEB 81/558 P3-NCC 81/558
P3-MFE P3-MHF P3-NDB P3-NFB P3-NDC
P3-MGE P3-NGB P3-NEC
P3-MHE P3-NHB P3-NFC
P3-MJE P3-NJB P3-NGC
P3-NHC
P3-NCD 81/558 P3-NEE 81/558
P3-NDD P3-NFE
P3-NED
P3-NFD
P3-NGD
* Seal Cavity Pressure Rise (SCPR) in psi / kPa
(Table 6 cont)

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2.0 OPERATION

2.1 GEARBOX OIL FILL

Remove the fill plug and fill the gearbox until fluid reaches the designated level on the sight glass.

Oil Capacities:

P-1500 - 1.0 quart / 0.946 liters

P-2000 - 2.5 quarts / 2.4 liters
P-3000 - 8.0 quarts / 7.6 liters

WARNING
Overfilling the gearbox will cause seal leakage, excess foaming and excessive use of horsepower.

The following lube oil specifications must be met by any oil used in Sunflo gearboxes:

Gravity, API 28 37
Pour Point, C (F) -7 (20) max.
Flash Point, C (F) 204 (400 min.
Viscosity,
cSt at 40C 28.8 to 35.2
cSt at 100C 5.2 min.
SUS at 100F 150 to 180
SUS at 210F 44 min.
Viscosity Index 95 min.
ISO Viscosity Grade 32
Color, ASTM D 1500 1 to 5
Neutralization Number, Maximum 0.20
Rust Protection, ASTM D 665, A & B Pass
Demulsibility, ASTM D 1401
Time to 0 ml emulsion
At 54C (130F) after 30 min. Pass
At 82C (180F) after 60 min. Pass
Foam Limits, ASTM D 892
Sequence 1 25/0 max.
Sequence 2 50/0 max.
Sequence 3 25/0 max.

NOTE: NO other additives are recommended.

Table 7. Recommended Gearbox Lube Oil Specifications

2.2 START-UP

Perform the following steps to start the Sunflo pump:

A. Review pump specification sheet noting design parameters and possible seal system requirements.

B. Check to ensure that the driver has been serviced per instructions provided by the driver manufacturer.

C. Check to ensure suction screen has been installed on inlet side for initial start-up (40 Mesh Recommended).

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D. If buffer fluid or external seal flush is required, this system should be pressurized prior to admitting process fluid
into the pump casing. If the buffer fluid is not pressurized, process fluid will contaminate the buffer fluid. If the seal
flush is not pressurized, contaminants may cause seal face damage.

E. Check oil level in gearbox.

F. Open suction and discharge block valve fully.

WARNING
Never start the pump against a closed discharge valve.

G. Adjust control valve so that pump will operate near the design point when pump is started.

H. Insure that the motor shaft rotation is in the same direction as the arrow on the gearbox marked MOTOR
ROTATION. To determine shaft rotation, observe the motor shaft or fan while jogging the motor in a
short, one-second interval. Rotation of the high speed shaft must be in the same direction as the arrow on the
gearbox housing marked PUMP ROTATION.

NOTE
Three-phase motor rotation may be reversed by interchanging any two motor leads. Motor and pump rotate in
opposite directions due to the single step gear arrangement.

NOTE
P-3000 Journal Bearing Units - On initial start-up or after extended shutdown time, (periods in excess of one week)
jog the motor for several one-second intervals to pre-lubricate the bearings prior to full speed operation.

WARNING
Reverse rotation may cause damage to the pump.

I. Start the motor and adjust the discharge throttle valve to the proper operating condition.

WARNING
Do not overload the pump or motor (an ammeter is recommended to determine motor load).

3.0 PUMP CONTROL

3.1 RECOMMENDED CONTROL OF CENTRIFUGAL PUMPS

A. Obtaining satisfactory performance from any centrifugal pump requires that the pump be operated in the following
manner:

1. A flow range where the system head curve and pump performance curve intersect at a significant angle.
2. The pump is not operated below the recommended minimum flow. Minimum flow considerations are
discussed further in the Sunflo Pump Control Bulletin. Actual minimum hydraulic stable flow must be
determined during system commissioning.
3. The pump is not operated beyond the recommended maximum flow. Maximum flow considerations are
discussed further in the Sunflo Pump Control Bulletin.

B. The flow at which a centrifugal pump operates depends upon the point of intersection of the system head and
pump characteristic curves. In order for control to be steady, the system curve must intersect the pump
characteristic curve at a significant angle. Examples of satisfactory and unsatisfactory angles of intersection are
shown in Figures 1 and 2.

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Figure 1
In Figure 1, the angle of intersection between the system curve and the pump performance curve is small. Note that
System Curve C intersects the pump performance curve resulting in Pressure Pc and Flow Qc. System Curve C
could represent a system curve in which the control valve is wide open. As the control valve is closed, the additional
pressure moves the system curve to that of System Curve D resulting in Pressure Pd and Flow Qd. Note that for a
very small change in pressure, there is a large change in flow.

Figure 2

In Figure 2, the angle of intersection between the system curve and the pump performance curve is much larger than
that shown in Figure 1. The pump performance curve shown in Figures 1 and 2 are identical. In this example, note
that System Curve A intersects the pump performance curve resulting in Pressure Pa and Flow Qa. As was the case
in Figure 1, Curve A could represent a system curve in which the control valve is wide open. As the control valve is
closed, the additional pressure moves the system curve to that of Curve B resulting in Pressure Pb and Flow Qb.
Since the angle of intersection between the system curve and the performance curve is much larger, a larger change
in pressure is required to provide the same change in flow as shown in Figure 1.

C. Because of the characteristic flat pump performance curve shape of Sunflo pumps, flow control rather than
pressure control is recommended. Pressure and flow control schemes both operate by throttling a discharge flow
valve. The control signal to the valve comes from either a flow or pressure controller. When trying to operate the
Sunflo pump in the flat area of the performance curve, a small change in pressure will result in a large change in
flow. Since a flow controller responds to changes in flow rather than pressure, pump control is more stable in this
region of the curve.

D. As the pump is operated closer to BEP, the Sunflo pump performance curve provides a more responsive change
in flow for a given change in pressure. Either pressure or flow control of the Sunflo pump is suitable in this area.
However, flow control is still recommended because of the problems associated with pressure control that were
discussed in the previous paragraph.

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E. In the portion of the performance curve beyond BEP, the Sunflo pump performance curve shape provides for
small changes in flow for large changes in pressure. Operation in this portion of the performance curve is
discouraged because of control problems and the potential to exceed the driver capabilities and to exceed the
NPSH requirements.

F. If the user requires that the pump be operated on pressure control, contact Sunflo or your local sales
representative. It is possible to modify the pump to steepen the pump performance curve so that pressure control
is more practical.

PARALLEL OPERATION

G. When centrifugal pumps are operated in parallel, their control becomes more critical because one pump may
tend to overpower the other pump in terms of head at total lower flows. If pumps are connected together at
discharge by a simple, unrestricted manifold, the discharge head of one pump is upon another; all pumps see the
same discharge head at any given moment in time. This situation is shown on the following curves and
discussion.

Figure 3

Figure 3 shows that the characteristic curves of 2 duplicated pumps designated as Pump A and Pump B. Since no 2
pumps will have exactly the same performance, the curves in Figure 6 shows that Pump A produces a very slight
more amount of head than Pump B. The pumps arranged with a manifold having a common control valve are as
shown in Figure 4.

Figure 4

With the manifold pressure set at P1, the flow through Pump A is indicated as A1 and the flow through Pump B is
indicated as B1. If the throttle valve is closed to set the manifold pressure at P2, the flow through pumps A and B are
A2 and B2 respectively. If the control valve were closed even further, then Pump B would cease to flow entirely
resulting in damage for deadheading the unit. This situation can be avoided through the proper selection of the
control system.

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H. The best way of ensuring that one of the pumps in a parallel pump system is not deadheaded is to provide a
separate control valve for each pump as Shown in Figure 5. Sunflo also recommends that individual minimum
flow lines be installed for each pump operated in parallel.

Figure 5

4.0 TROUBLESHOOTING

4.1 GEARBOX, PUMP, AND MECHANICAL SEAL

Pump performance characteristics are shown in the pump selection procedure. Tables 8 and 9 present information
which is useful in the analysis of gearbox, pump performance, and seal problems.

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TROUBLESHOOTING
GEARBOX AND PUMP
PROBLEM POSSIBLE CAUSE
No flow, no pressure at Pump not completely primed.
startup.
NPSH available actually lower
than requirement specified on
specification sheet.
Failure of drive component
such as missing drive gear,
sheared or missing impeller
key, or failed high-speed shaft
bearing.
Wrong direction of rotation on
motor.
Pump starts and then Improperly primed pump.
stops pumping.
Suction screen plugged.
Air or vapor pockets in suction
line.
(Table 8) PUMP AND GEARBOX TROUBLESHOOTING
02.10.11E,2/00 Visit our website at www.sundyne.com
INVESTIGATIVE/CORRECTIVE ACTION
Bleed all vapors and gases from system. Also bleed
vapor or air from the seal flush port.
Allow more cool-down time if pumping a low
temperature fluid.
Verify that pump and suction line are full of liquid.
Suction line blocked. Check suction strainer and
valves.
Excessive pressure drop through suction piping.
Flow restricted by vapor pockets in high points of
suction and discharge piping.
Inability to vent past a check valve in the discharge
piping.
Suction tank level or pressure too low.
Entrained gases in pumped liquid.
NPSH reduced by a more volatile process liquid.
Replace as necessary with Genuine Sundyne Parts.
Direction of driver shaft rotation is as shown by arrow
on gearbox housing. Note: Impeller and driver rotate
in different directions. Rotation can be checked by
viewing driver fan or input shaft on frame-mounted
units. Reverse any 2 leads on motor to change
direction of rotation.
Attempt to prime pump. If priming is not possible,
inspect suction piping for obstructions.
Determine if there is a check valve on the discharge.
If so, determine if the vapors between the pump and
the check valve are being vented.
Suction line blocked. Check suction strainer and
valves.
Vent suction piping at the highest point. Determine if
the piping must be redesigned to eliminate the
formation of air or vapor pockets.
19
GEARBOX AND PUMP

PROBLEM POSSIBLE CAUSE INVESTIGATIVE/CORRECTIVE ACTION

Insufficient flow or Flow rate is higher than pump Check head rise and flow rate against performance
pressure. design allows. curve.
Wrong direction of driver shaft Direction of driver shaft rotation is as shown by arrow
rotation. on gearbox housing. Note: Impeller and driver rotate
in different directions. Rotation can be checked by
viewing driver fan or input shaft on frame-mounted
units. Reverse any 2 leads on motor to change
direction of rotation.
Air trapped in pump or Check shutoff pressure. If deficient, vent pump.
pumping entrained vapors or
gases.
Determine if there is a check valve on the discharge.
If so, determine if the vapors between the pump and
the check valve are being vented.
Available NPSH actually lower Refer to solutions provided under No Flow, No
than required NPSH listed on Pressure at Startup.
pump specification sheet.
Flow too low causing Increase pump flow rate.
overheating of fluid and loss of
NPSH after a short period of
satisfactory operation.
Increase bypass flow rate or use seal cavity bypass
to continuously increase inlet flow rate. Vent to the
highest point of the pump.
Install bypass to recirculate part of pump discharge
back to the supply tank.
Impeller damage by passage Inspect impeller for nicked, bent, or worn blades.
of solid particles. Replace impeller if damaged.
Process fluid specific gravity or Check actual viscosity and specific gravity at the
viscosity different from what operating temperature. A viscosity higher than 5
was specified. centipoise will cause reduced head and flow and
increased power consumption. A specific gravity
higher than what was specified will cause increased
power consumption.
Pressure gauges or flow Remove and replace with calibrated instrument.
meters in error.

(Table 8 cont) PUMP AND GEARBOX TROUBLESHOOTING

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GEARBOX AND PUMP

PROBLEM POSSIBLE CAUSE INVESTIGATIVE/CORRECTIVE ACTION

Corrosion pitting on pump
casing.
Corrosion and/or erosion of
diffuser throat (may also be
accompanied by corrosion
and/or erosion of diffuser
surface adjacent to the
impeller).
Pump discharge throat partially
plugged.
Driver speed too low.
Driver Overloaded. Fluid specific gravity or
viscosity is higher than what
the pump was initially designed
for.
Electrical Failure in Motor.
Mechanical failure in driver,
gearbox, or pump.
Pump operating beyond design
flow.
Minor pitting may be polished with emery cloth.
Major pitting indicates a failed part and should be
replaced.
Inspect remainder of pump to determine if other
areas of pump are damaged from corrosion.
Replace damaged parts.
Establish corrosion mechanism. Determine if
process conditions can be changed. Consult your
authorized Sunflo sales representative for assistance
on different pump materials of construction.
If edge of throat has opened in size, head-rise may
be reduced. Opening of the throat will result in
higher flow rate and horsepower consumption.
Corrosion and/or erosion of the diffuser and cover
surfaces will also result in a significant increase in
horsepower consumption.
Disassemble pump and inspect pump casing for any
obstructions. Replace hardware with Genuine
Sundyne Parts if necessary.
Check driver speed against value provided on the
pump specification sheet.
Decrease specific gravity and/or viscosity.
Reduce pump flow to the level that will reduce driver
power consumption to an acceptable level.
Check circuit breaker heater size and setting.
Check motor voltage.
Check motor current in each phase. The current
should be balanced within 3 percent.
Remove casing and check for impeller rub on cover
plate and pump casing.
Rotate high speed shaft assembly and check for
ease of rotation.
Inspect ball bearings and journal bearings. Replace
failed parts with Genuine Sundyne Parts.
Check actual pump flow and head against the values
provided on the pump specification sheet.

(Table 8 cont) PUMP AND GEARBOX TROUBLESHOOTING

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GEARBOX AND PUMP

PROBLEM POSSIBLE CAUSE INVESTIGATIVE/CORRECTIVE ACTION

Driver Overloaded Corrosion pitting on surface of Disassemble pump and inspect. Rough or pitted
(contd) diffuser adjacent to impeller surfaces can cause additional friction losses which
blades. will significantly increase driver horsepower
consumption. Clean these areas of all obstructions
and use emery cloth to restore all surfaces to a
smooth, polished finish. Check the diffuser throat.
Erosion and corrosion will cause roughness that will
increase horsepower consumption. Note: A larger
than designed diffuser throat will allow for a higher
flow and horsepower consumption for a given head
rise.
Excessive Discharge Flow rate too low Increase flow through pump. Add bypass If required.
Pressure Pulsation
(May be associated
with a hammering
sound or may sound
like gravel being
pumped).
Insufficient NPSH Refer to solution for insufficient NPSH under No
Flow, No Pressure at Startup.
Defective flow control valve. Repair or replace valve.
Change of gearbox oil Gearbox lubricant is Check for excessive pump or seal leakage. Change
from normal color to contaminated with water or gearbox oil and replace all worn or damaged parts
milky pink or yellow. process fluid. with Genuine Sundyne Parts.
Inspect shaft sleeve o-rings. Replace if necessary.
Check for restricted seal drain port. Change gearbox
oil and remove restriction.
Shaft sleeve rubs on Gearbox bearing failure. Inspect and replaced damaged hardware with
inside diameter of seal. Genuine Sundyne Parts.
Excessive gearbox oil Gearbox seal leakage. Check for fluid leakage from drain port. Disassemble
consumption. and replace worn or damaged hardware.
High lube oil Heat exchanger fouled or no Clean heat exchanger.
temperature coolant flow to heat exchanger.
Check coolant flow.

(Table 8 cont) PUMP AND GEARBOX TROUBLESHOOTING

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GEARBOX AND PUMP

PROBLEM POSSIBLE CAUSE INVESTIGATIVE/CORRECTIVE ACTION

Excessive oil foaming. High oil level. Check oil level. If too high, shut down the unit a
drain the oil to the correct level.
Incorrect lubricant.
Excessive noise and Rotation incorrect. Direction of driver shaft rotation is as shown by arrow
vibration. on gearbox housing. Note: Impeller and driver rotate
in different directions. Rotation can be checked by
viewing driver fan or input shaft on frame-mounted
units. Reverse any 2 leads on motor to change
direction of rotation.
Worn or damaged bearings. Disassemble pump and replace damaged
components with Genuine Sundyne Parts.
Insufficient NPSH Refer to solution for insufficient NPSH under No
Flow, No Pressure at Startup.
Damaged impeller or shaft. Replace as required with Genuine Sundyne Parts.
Partially clogged impeller Back-flush pump to clean impeller. Determine cause
causing imbalance. of clogging.
Foundation not rigid. Tighten down hold-down bolts of pump and motor.
Suction or discharge piping not Anchor piping per the Hydraulic Institute Standards
anchored or properly Manual recommendations.
supported.
Damaged drive or pinion gear. Disassemble pump and replace damaged gear with
Genuine Sundyne Parts.
Improper pump & driver Align pump and driver shafts.
alignment.
Resonance of pump Perform vibration testing to determine if there is a
foundation. natural frequency of the installation close to that of
the driver. Modify installation to dampen the natural
frequency.
Improper location of discharge Install discharge control valve within 5 feet of the
control valve. pump discharge.

(Table 8 cont) PUMP AND GEARBOX TROUBLESHOOTING

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PUMP MECHANICAL SEALS
PROBLEM POSSIBLE CAUSE
Sudden Increase in Severe cavitation or loss of
Seal Leakage suction pressure causing
vibration and bouncing of seal
face.
Seal icing on low temperature
pumps or icing when handling
fluids which have high vapor
pressures at a temperature of
less than 32 DegF (0 DegC).
Solid particles in seal cavity or
seal spring area.
Seal stationary spring action is
rough and sticky.
Worn or damaged seal.
Wear pattern on seal rotating
faces not uniform in the
circular direction.
Wear pattern on stationary
face of seal is smooth but not
uniform.
(Table 9) MECHANICAL SEAL TROUBLESHOOTING
02.10.11E,2/00 Visit our website at www.sundyne.com
INVESTIGATIVE/CORRECTIVE ACTION
Correct pump suction condition causing cavitation.
Bleed vapor from seal cavity and restart pump.
Install double seal system if loss of suction cannot be
prevented.
Replace seal and rotating face with Genuine
Sundyne Parts if either part is shown to be worn or
damaged.
Use purge of dry nitrogen gas into seal drain area.
Install double seal system and use a compatible,
nonaqueous, nonvolatile external seal flush.
Replace seal and rotating face.
Supply clean, external seal flush or install double
seal system if particles cannot be removed by a
separator or filter.
If parts are corroded, check for material compatibility.
Check for the accumulation of solids in the seal
retainer area. If solids are found, consider the
installation of a double seal system.
Disassemble high speed shaft assembly and replace
worn or damaged components with Genuine
Sundyne Parts.
Inspect shaft sleeve and impeller hub for high spots.
Replace if necessary. Install new seal and rotating
face.
Shaft sleeve not parallel causing rotating face to be
cocked. Dirt or debris caught between sleeve,
rotating face, or adjacent parts.
Replace seal and rotating face.
24
PUMP MECHANICAL SEALS

PROBLEM POSSIBLE CAUSE INVESTIGATIVE/CORRECTIVE ACTION

Edges of stationary face
chipped and seal face is worn.
(Usually caused by vapor
formation in the seal cavity)
Seal rotating face is cracked or
broken. This may be caused
by damage during assembly or
by thermal shock from running
the seal dry.
Wear on seal rotating face
near the area where the
outside of the stationary face
contacts. (Usually cause by
icing from air in drain).
Chemical attack of seal faces,
seal parts, or o-rings.
Prevent loss of pump suction. Install double seal
system if loss of suction cannot be prevented.
Supply cool seal flush. Consult with your authorized
Sunflo sales representative to see if a heat
exchanger is required.
Prevent loss of pump suction. Install double seal
system if loss of suction cannot be prevented.
Supply cool seal flush. Consult with your authorized
Sunflo sales representative to see if a heat
exchanger is required.
Install nitrogen purge in drain area.
Install a double seal system.
Investigate process fluid properties and change seal
and o-ring materials if needed.

(Table 9 cont) MECHANICAL SEAL TROUBLESHOOTING

5.0 SPARE PARTS

When ordering replacement parts, give the pump serial number, and list each part required by item number and part
name along with quantities desired. When requesting information concerning your Sunflo Pump, always refer to the
pump model number and pump serial number as they appear on the nameplate.

All SUNFLO products are available on an expedited basis. The factory should be contacted prior to order placement
to ensure part availability. Stock spare parts requiring no machining will be shipped 24 hours after receipt of order at
the factory and parts requiring additional machining will be shipped within 96 hours after receipt of order at the factory.

The kits shown below simplify maintenance and inventory control. They are available through your Sunflo distributor.

O-RING REPAIR KITS

Packages all o-rings in one kit.

Color coded o-ring material.

Easy-to-read instructions describe exact location of each o-ring.

SEAL REPAIR KITS

Custom tailored for the specific pump and seal type.

Single and double seal options.

Easy-to-read instructions prevent installation mistakes.

Eliminates misplacement of parts and simplifies inventory control.

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EXCHANGE HIGH SPEED SHAFT ASSEMBLIES

Easier to perform routine seal and bearing maintenance.

Normal delivery is 2 weeks.

Same quality construction, testing and warranty as new shaft assemblies.

Can ship on an expedited 3-day basis when needed. Old shaft assembly returned for credit within 60 days.

Order kits through your Sunflo distributor.

NOTE
A HIGHLY RECOMMENDED OPTION TO NORMAL PUMP MAINTENANCE IS THE PURCHASE OF A SPARE
HIGH SPEED SHAFT ASSEMBLY WHICH CAN BE REPLACED QUICKLY AND EASILY AS A COMPLETE UNIT.

6.1 ORDERING REPLACEMENT PARTS

Order parts through your Sunflo distributor. For information or assistance contact:

Sundyne Corporation
th
14845 West 64 Avenue
Arvada, Colorado 80007
Telephone: 303-425-0800
Fax: 303-425-0896
Attention: Parts Order Coordinator

or

Sundyne Corporation - Europe

13-15 Blvd. Eiffel
Zone Industrielle de Dijon SUD (21600)
B.P. 30
21600 Longvic Cedex
France

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Sundyne Corporation Arvada, CO 80007 USA +1-303-425-0800 FAX: +1-303-425-0800 www.sundyne.com
Sundyne Europe Longvic Cedex, France +33-380-383300 FAX: +33-380-383371

ANSIMAG ANYSPEED CASTER HMD/KONTRO MASO/SINE SCMP COMPRESSORS SUNDYNE SUNFLO