Sundyne Sunflo P-3000 Series Installation instructions manual

02.10.02E, 6/2000 Visit our website at www.sundyne.com
Effective: 6/2000
Supersedes: 6/97
P-3000
with Journal Bearings
Instruction & Operation Manual
SUNFLO

02.10.02E, 6/2000 Visit our website at www.sundyne.com 1
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.
©2000 Sunyne 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, Sundyne’s sole obligation shall be limited to
alteration, repair or replacement at Sundyne’s expense, F.O.B. Factory, of parts or
equipment, which upon return to Sundyne and upon Sundyne’s 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.
NOTES:
Sunflo P-3000 = High Speed Centrifugal Pumps

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USING THIS MANUAL:
This manual presents installation, servicing, starting, pump control, troubleshooting, maintenance, and
spare parts information for the Sunflo P-3000 centrifugal pump.
Parenthetical numbers included in the text correspond to item numbers located on the illustrated figures.
Information that may be required and is not included herein may be obtained from your Sundyne
Corporation distributor, or directly from the factory.
i. Introduction to the Sunflo P-3000 Pump
ii. Safety Precautions
iii. Critical Startup Checklist
1. Receiving Your Unit
Inspection, Storage, Long-Term Storage
2. Installation
Mounting, Frame mount Drive Unit Installation, Final Alignment, Suction and Discharge Piping
3. Auxiliary Piping and Seal Environment
Single Seal Flush System, Double Seal Liquid Buffer System, Tandem Seal Liquid Buffer System,
Process Seal Drains, Seal Cavity Pressure Rise
4. Pre-startup
Gearbox Oil Fill
5. Startup
6. Pump Operation
Suction Conditions, Discharge Conditions, Minimum Flow Conditions, Maximum Flow Conditions,
Drivers, Entrained Gases
7. Pump Control
Parallel Operation
8. Troubleshooting
Gearbox and Pump, Pump Mechanical Seals
9. Maintenance
Servicing – Driver, Gearbox Oil Change, Seal Leakage, Radial Ball Bearings, Coupling
Torque Values

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10. Pump Disassembly
Provides a detailed disassembly procedure for the gearbox and pump
11. Pump Assembly
Provides a detailed re-assembly procedure for the gearbox and pump
12. Tool Drawings
13. Parts List
General, Recommended Spares

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i. Introduction to the Sunflo P-3000 Pump
The Sunflo P-3000 pump is a high pressure/high speed centrifugal pump which provides multi-stage
performance from a single-stage unit. The frame mounted configuration offers a greater degree of
performance diversity and added driver flexibility such as the use of standard electric motors, steam
turbines, and internal combustion. The close-coupled design incorporates the proven Sunflo design in an
integral pump and motor package. This configuration provides a compact lightweight unit that does not
utilize bedplates, couplings or belts. Installation is simplified and alignment of the pump and motor is not
necessary. Close-coupled pumps are ideal for OEM packages and other industrial applications where a
frame unit is not desired.
Common uses include pollution control, chemical, petrochemical, power system services, pulp and paper,
vehicle manufacturing, mining, food and beverage, and oil products.
ii. Safety Precautions
Safety Warning
Sundyne Corporation manufactures centrifugal pumps to exacting International Quality Management
System Standards (ISO 9001 - 1987) as certified and audited by Lloyd's Register Quality Assurance
Limited. Genuine parts and accessories have been specifically designed and tested for use with these
products to ensure continued product quality and performance. As Sundyne Corporation cannot test all
parts and accessories sourced from other vendors, incorrect design and/or fabrication of such parts and
accessories may adversely affect the performance and safety features of these products. Failure to
properly select, install or use authorized Sunflo pump parts and accessories is considered misuse and
damage or failure caused by misuse is not covered by Sundyne’s warranty. Additionally, modification of
Sunflo products or removal of original components may impair the safety of these products and their
effective operation.
Suggested Safety Instructions:
During installation, maintenance, or repair operations of a Sunflo pump, systems for safety shall be
applied before the commencement of work. Failure to take responsibility for safety may lead to injury of
operator or others.
Personal Protective Equipment (PPE): Safety glasses with side shields, as a minimum, shall be worn
by all personnel installing or performing maintenance or repair on the equipment. If equipment is over 15
pounds (7 kg) and is to be manually lifted, or if pallet jacks or forklifts are to be used, steel-toed safety
shoes shall be worn. When testing the equipment, hearing protection is highly recommended if noise
levels exceed 85 dB during an eight (8.0) hour period. 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 as a minimum.
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 protection. 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 a safe operating condition.

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Electrical Safety: During installation, service, or repair ensure all electrical sources are off and it is safe
to operate the equipment. A recognized Lock-out/Tag-out 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 complete, the person installing the lock and/or tag shall remove it following
your company’s procedure for Lock-out/Tag-out and inform others of start-up.
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 material safety data sheet
(MSDS), 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 passed 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 Guards: 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.
Lock-Out/Tag-Out Guidelines:
Follow Your Company’s Lock-Out / Tag-Out Procedure When Servicing Sunflo Pumps.
iii. Critical Startup Checklist
Know Your Machine
Before servicing and starting up the Sunflo P-3000 pump, carefully review the specification sheet, the
outline drawings, performance curves, and this instruction manual. It is important you become familiar
with the pump configuration before starting and operating the pump.
Driver Instructions
Carefully follow the installation and starting instructions provided by the manufacturer of the driver. This is
included in the final data package.
Auxiliaries
1. Check the utility connections.
2. Verify that the auxiliary piping conforms to Sundyne’s drawings.
3. Verify the connections of the switches, the instruments, and their settings.
4. Calibrate all measurement equipment (Flow meters, Current or Ampere meters, Pressure meters, etc.).
Environmental Control System
Install a system to control the environment of the seal, if required, and verify that Port 1 is properly
vented.
If required install overhead drain piping.

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Pressurized Fluid Loop:
Pressurize double seal buffer loop or external seal flush, if required, prior to admitting fluid into pump
casing.
Check Driver Rotation
Rotation must be in the same direction as the arrow stamped or cast on the pump casing.
Gearbox Servicing:
Where applicable, operate auxiliary lube pump to fill heat exchanger and filter. Add oil as necessary
through fill fitting until oil level stabilizes in sight glass. The gearbox alone requires approximately eight
U.S. quarts (7.5 liters).
Starting Pump
Start pump with suction valve completely open while throttling discharge valve, to bring pump to design
operating point.
Heat Exchanger
If a heat exchanger for the gearbox is installed, adjust the cooling flow to keep the temperature of the
gearbox sump at 120°-170°F (49°-77°C).
Check
Check total head, flow rate, and power consumption against pump specification sheet. Check that
specific gravity, viscosity and NPSH are in accordance with specification sheet. These conditions will
significantly alter performance of the pump.
Process Conditions
Do process conditions; suction pressure, suction temperature, discharge pressure, agree with
specification sheet information? Check with your Sunflo representative if you must test or run a different
fluid/specific gravity than shown on the specification sheet.
Auxiliary Lube Pump
If you have an auxiliary lubrication pump, unlock the electrical circuit and start it in the “hand” position.
Check for oil leaks and recheck the oil level.
Piping Connections
Are the following bolted/threaded connections tight:
a. Pump flange bolts?
b. Seal environment piping and port connections?
c. Cooling water connections to heat exchanger? (if applicable)
d. Gearbox oil drain plug?
e. Pump case drain plug?

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1. Installation
This section contains the following:
Introduction: Provides a brief description of the pump and how it is used.
Inspection: Important items to inspect as soon as you receive your pump.
Short-term Storage: Procedure for units installed within 6 months.
Long-term Storage: Procedure for units installed after 6 months.
Mounting
Final Alignment
Suction and Discharge Piping: Procedures to set up the suction and discharge piping.
Auxiliary Piping and Seal Environment: Procedures to set up the seal environment controls,
even if you use the standard system supplied by the factory. Gas buffer system procedures are
included.
Baseplate Mounting and Grouting: Use this information for grouting the baseplate.
Driver and Coupling: Procedures to align the driver and pump. Do this after grouting, and before
connecting the piping for suction and discharge. Once the suction and discharge piping is
connected, confirm the final alignment.
Inspection
1. When you receive the Sunflo P-3000 Pump, check for any damage. If you find any, inform the carrier
and Sundyne Corporation promptly.
2. Use Outline drawings in the last section of final data package, and reference the Pump and Gearbox
bill of material to ensure that all auxiliary items are properly included.
3. Check the gear shaft carefully. Seal drag may cause it not to turn freely at first; this is normal. If the
gear shaft binds, it may be damaged, or may need adjusting.
Short-term Storage - 1 day to 6 months
1. If the pump is to be stored near strong chemicals or salt water, protect it immediately. To do this,
follow steps 5 through 10 from the long-term storage procedures below.
2. Protect the unit from moisture and dust.
3. Make sure that the factory’s shipping covers for the housing flanges and the seal ports are securely
in place.
4. Carefully follow the storage instructions provided by the manufacturer of the motor or turbine driver.

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Long-term Storage - 6 months or more
If you store the Sunflo P-3000 Pump for a long period of time, the following methods are very important.
If you require further instructions, please contact Sundyne Corporation at (303)-425-0800 USA and ask
for the Field Service Department.
1. Be sure the storage area is indoors and has: Humidity below 65%; and temperature range from 45°F
to 85°F (7°C to 29°C).
2. Do not allow contact of airborne chemicals with the internal components of the unit.
3. If the unit is being stored near strong chemicals or salt water, protect it immediately.
4. Protect the unit from moisture and dust.
5. Make sure that the factory’s shipping covers for housing flanges and seal ports are securely in place.
6. Prevent corrosion to the components of the gearbox and the fluid-end.
7. Use desiccant bags to absorb moisture.
8. Purge the internal components with an inert gas.
9. Flood component internals with oil.
10. After long-term storage, have an authorized Sundyne service engineer inspect all components and
supervise any necessary repair to be sure that they work properly. Any components not made by
Sundyne (except mechanical seals) must be inspected or replaced as determined by the
manufacturer’s authorized personnel, at the purchaser’s expense. Any Field Service work must be
clearly stated at the time of purchase to validate an Extended Warranty.
Because storage location and unknown factors at the site or storage are beyond our control,
Sundyne does not accept any liability for damage to the equipment during storage, nor do we
guarantee the quality of the equipment during and after the storage period. An Extended Warranty
will be null and void if the proper equipment preparation is not maintained.
Mounting
A. During pump installation, ensure that adequate surrounding space is available for inspection,
operation, and maintenance requirements.
B. The pump and driver for both the close-coupled and the frame mounted units should be bolted to a
concrete foundation or an adequately supported structure substantial enough to absorb any vibration
and to form a rigid support. If the pump and driver are mounted on a bedplate, the bedplate should
be mounted on a concrete foundation and grouted.
1. Choose a solid ground location and build the foundation form 3 inches larger overall than the
bedplate.
2. Use bedplate anchor bolts of the same size specified in the outline drawing. Provide pipe sleeves
with an I.D. 2.5 to 3.0 times the bolt diameter. Provide flat washers between the bolt head and pipe
sleeve to keep the bolt from slipping through the pipe sleeve.