SUNDYNE

LMC/BMC-311F Compressors

Instruction and Operation Manual

December 2007

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.
2007 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.
 TABLE OF CONTENTS
Text Symbols..................................................................................................................1
Equipment and Safety Precautions..............................................................................1
Explosion / Fire Hazard .................................................................................................2
Using this Manual ..........................................................................................................3
1. Installation..................................................................................................................5
Introduction to the Sundyne Compressor.........................................................................5
Inspection ........................................................................................................................5
Short Term and Long Term Storage ................................................................................6
Installing the Suction and Discharge Piping - Guidelines .................................................7
Seal Environment Control System ...................................................................................7
Baseplate Grouting ..........................................................................................................8
Horizontal Unit Gearbox Support Bracket ........................................................................9
Driver and Coupling .........................................................................................................9
2. Lubricating Oil System..............................................................................................9
3. Start-up .....................................................................................................................13
Compressor Control During Start-Up .............................................................................14
Run-In of the Compressor..............................................................................................14
4. Servicing...................................................................................................................15
Regular Maintenance.....................................................................................................15
5. Maintenance .............................................................................................................16
Gearbox Disassembly................................................................................................16
Diffuser Gap Set-up Impeller/Diffuser Cover Alignment.............................................21
Impeller/Diffuser Clearance Calculation.....................................................................24
6. Gearbox Disassembly .............................................................................................26
7. Gearbox Reassembly ..............................................................................................34
8. Troubleshooting ......................................................................................................47
9. Operation .................................................................................................................50
10. Spare Parts .............................................................................................................51
11. Sundyne Compressor Warranty ...........................................................................53

Reference A
Critical Start-up Checklist ...........................................................................................49
Reference B
Lock-out/Tag-out Guidelines ......................................................................................54

Reference C
Seal Arrangement Drawings for Single, Double, and Tandem Configuraiton ........55

Reference D
Compressor Drawings.................................................................................................59
 INTRODUCTION & SAFETY
Text Symbols
The following symbols may be found in the text
of this manual.
They have the following meanings:
WARNING: Text accompanied by this
symbol indicates that failure to follow
directions could result in bodily harm or
death.
ELECTRICAL HAZARD: Text
accompanied by this symbol indicates
that failure to follow directions could result
in electrical damage to equipment or
electrical shock.
Equipment and Safety Precautions
Sundyne Corporation manufactures
compressors to exacting International Quality
Management System Standards (ISO 9001)
as certified and audited by Lloyds Register
Quality Assurance Limited. Genuine parts and
accessories are specifically designed and
tested for use with these products to ensure
continued product quality and performance.
Sundyne 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 Sundyne compressor parts
and accessories is considered misuse and
damage or failure caused by misuse is not
covered by Sundynes warranty. Additionally,
modification of Sundyne products or removal
of original components may impair the safety
of these products and their effective operation.
1
RECOMMENDED: Text accompanied by
this symbol indicates recommended
usage.
REMINDER: Text accompanied by this
symbol indicates a reminder to perform
an action.
EQUIPMENT USE ALERT: Text
accompanied by this symbol indicates
that failure to follow directions could
result in damage to equipment.
CAUTION
Sundyne compressors may handle hazardous,
flammable, and/or toxic fluids. Proper personal
protective equipment should be worn.
Precautions must be taken to prevent physical
injury. Residual fluid must be handled and
disposed of in accordance with applicable
environmental regulations.
Note: Safety procedures must be applied
prior to any installation, maintenance,
or repair of a Sundyne compressor.
Failure to follow safety precautions
may lead to injury!
Wearing Personal Protective
Equipment
To ensure safety, protective equipment must be
worn at all times when installing, performing
maintenance, or repairing equipment. The following
safety recommendations must be adhered to for
optimum safety:
Safety glasses, with the minimum
requirement of side shields, must be worn at
all times.
Steel-toed shoes must be worn when lifting
equipment greater than 15 pounds (7 kg) or
if pallet jacks or forklifts are operated.
Hearing protection is strongly recommended
at all times when noise levels exceed 85 dB
during an eight (8.0) hour period.
Note: Chemical resistant gloves must be used if
chemicals are utilized (refer to Using
Chemicals for additional information).
Note: A dust mask respirator must be worn if
chemicals have warning labels regarding
fumes, dust, or mists.
When using more than one piece of protective
equipment, consider their compatibility. For
example, safety glasses will not interfere with
hearing protection equipment. Be sure to clean all
pieces of personal protective equipment
immediately after each use.
Using Forklifts
Any persons operating a forklift must have an active
recognized operator license.
Note: Before initializing forklift operation, verify
that the lift is in a safe operating position.
Ensuring Electrical Safety
All electrical sources must be powered-off before
installation, service, or repair of equipment occurs.
Note: Sundyne recommends that a Lock-
out/Tag-out program be followed prior to
altering the equipment. Locks or tags
must be provided to warn employees that
equipment is temporarily unavailable.
Once all work has been completed, the person
installing the lock or tag must remove it according to
company procedure.
2
Testing Equipment
Prior to performing a test on newly installed,
maintained, or repaired equipment; all personnel in
the immediate area must be warned.
Note: Follow company procedures prior to
equipment testing at all times.
Using Chemicals
Any chemicals to be used must be accompanied by
a relevant material safety data sheet (MSDS), in
accordance with government legislation. If
applicable, use chemical proof gloves.
Note: An eye wash station (or equivalent)
should be available in the event of injury.
If any hazardous or flammable chemicals
pass through the equipment, a complete
decontamination of the equipment is
required.
Protection from Falling
Fall protection and associated preventative
measures are required when working on equipment
located six feet or higher from the ground.
Note: Follow company fall prevention
procedures prior to working on
equipment.
Preventative Machine Guards
Preventative guards must remain in place on all
equipment.
Note: Only remove the guards while performing
maintenance or repair.
Replace the guards immediately after working on
the equipment and prior to start up.
EXPLOSION/FIRE HAZARD
Note: Never use an acetylene torch, open flame,
or heat to attempt to remove parts that
have seized together in Sundyne
equipment. Any residual process gas or
liquid that is flammable can result in an
explosion or fire with potential for serious
injury or death.
Using This Manual:
Organization
This manual is part of the final data package for the Sundyne LMC/BMC-311F compressor. In addition to
this manual, the final data package includes such information as the following:

Drawings, Sundyne specification sheet with test performance curves, test data, inspection data, material
certificates if required; and auxiliary equipment information. When using the specification sheet, section 1
of the final data package, and drawings, last section of final data package, in this manual compare the
release date with those in the maintained final data package to ensure that you are using the most
current information. This manual explains procedures for the Sundyne compressor, including how to:
install it, maintain it, service it, troubleshoot problems; and order parts. Whenever you talk or write to your
Sundyne representative, provide your compressors unique serial number.

This manual contains the following sections:

1. Installation
Describes how to install the compressor and how to store it until you install it.

2. Lubricating Oil System

Provides the following information: how to prepare the gearbox for start-up; how the lubricating oil
system works; and specifications for gearbox lubricants.

3. Start-up
Provides a procedure for starting and controlling the compressor. A critical start-up checklist is
included as Reference A.

4. Servicing
Provides procedures for servicing the compressor.

5. Maintenance
Provides procedures for disassembling the LMC/BMC compressor and its seal housings.

6. Gearbox Disassembly
Provides procedures for disassembling & reassembling the gearbox of the compressor.

7. Reassembly
Procedure for Checking High-Speed Shaft End Play

8. Troubleshooting
Provides tables for the following:
a) Looking up a problem.
b) Identifying the possible cause.
c) Selecting the corrective action.

9. Operation
Provides general guidelines for controlling a compressor such as surge control, suction throttling,
discharge throttling, and speed control.

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10. Spare Parts
Contact and reference information.

11. Sundyne Compressor Warranty

Provides a warranty statement for the compressor/gearbox unit.

Reference A
Critical Start-up Checklist

Reference B
Lock-out/Tag-out Guidelines

Reference C
Seal Arrangement Drawings for single, double, and tandem configuration

Reference D
Compressor/Gearbox Drawings

4
1. Installation
This section provides an introduction to the compressor, procedures for inspecting and installing it, and
procedures for storing it if you are not installing it immediately. It contains a subsection on each of the
following:

Introduction: This provides a brief description about the compressor and how it is used.

Inspection: As soon as you receive the compressor, inspect it thoroughly.

Short-term Storage: If the unit will be installed within 6 months follow these procedures.

Long-term Storage: If the unit will not be installed within 6 months follow these procedures.

Suction and Discharge Piping: Follow these procedures to set up the piping for suction and discharge.

Seal Environment Control System: Follow these procedures to set up the seal environment controls,
even if you use the standard system supplied by the factory.

Baseplate Grouting: Use this information for applying grouting to the baseplate.

Horizontal Unit Gearbox Support Bracket: Follow these procedures to drill and pin the gearbox
support bracket on a horizontal unit.

Driver and Coupling: Follow these procedures to align the driver and the compressor. Do this after
grouting, and before you connect the piping for suction and discharge.

Introduction to the Sundyne Compressor

Sundyne LMC/BMC compressors have a single stage with an integral gearbox. It increases the pressure
of a continuous flow gas by applying centrifugal action. Sundyne LMC/BMC compressors are most
commonly used in chemical process plants to increase the pressure in a recycle loop. They are also used
in refineries, petrochemical plants, and power generation plants. Within these facilities, Sundyne
Compressors are used in booster, regeneration, vapor recovery, boil-off, and other gas process
applications.

Sundyne LMC/BMC compressors offer industrial quality in a compact unit that is simple to assemble. It
provides high-energy performance and competitive efficiencies. For detailed specifications for Sundyne
LMC/BMC compressors, see the specification sheet and bill of materials or consult Sundyne
Compressors. For the primary components, see Reference D, compressor /gearbox module
drawings.

Inspection
1. When you receive the Sundyne LMC/BMC compressor, check for any damage. If you find any, inform
the carrier and Sundyne promptly.

2. Use Outline drawings in the final data package to ensure that all auxiliary items are properly included.

3. Check the gearshaft carefully. Seal drag may cause it not to turn freely at first. This is normal. But if
the gearshaft binds, it may be damaged, or it may need adjusting.

5
 Short-term Storage - 1 day to 6 months
1. If the compressor is to be stored near strong chemicals or salt water, protect it immediately. To do
this, follow steps 5 through 11 from the long-term storage procedures below.

2. Protect the unit from moisture and dust.

3. Make sure that the factorys shipping covers for the housing flanges and the seal ports are securely
in place.

4. Carefully follow the instructions provided by the manufacturer of the motor or turbine driver.

Long-term Storage - 6 months or more

If you store the LMC/BMC compressor for a long period of time, the methods you use are very important.
Please contact Sundyne at (303)-425-0800 USA and ask for the Field Service Department for further
instructions.

1. Be sure the storage area has: Humidity below 65%; and temperature range from 45 to 85F
(7C to 29C).

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 factorys 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. Store the unit indoors.

8. Keep the room temperature and humidity constant.

9. Use desiccant bags to absorb moisture.

Either of the following:

10. Purge the internal components with an inert gas.

or
11. Oil flooding of component internals

Review Long Term Storage Instructions supplied with Final Data Package. Should you have any
questions, contact the factory in Arvada, Colorado.

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
manufacturers authorized personnel, at the purchasers expense. Any Field Service work must be
clearly stated at the time of purchase to validate an Extended Warranty.

6
 Because storage location and unknown factors at the site of 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.

Installing the Suction and Discharge Piping - Guidelines

Step 1: Clean the suction line.

Step 2: Install a strainer to protect the impeller from damage by mill scale, welding slag, or other
foreign particles.

Step 3: Make sure that the piping is aligned with the compressor flanges.

Step 4: Support all piping independently of the compressor.

Step 5: When you move the piping into place, never use excessive force at the flanged suction and
discharge connections. This could strain the unit.

Step 6: Use suction pipe that has a diameter at least as large as the diameter of the suction inlet of
the compressor.

Step 7: Make sure that the suction and discharge piping have no unnecessary elbows, bends, and
fittings. These increase the losses caused by friction. Also, be sure that all piping and fittings
are large enough to minimize losses caused by friction.

Step 8: Before you connect the piping to the compressor, tighten the hold-down bolts on the
compressor.

Step 9: Do not use elbow parts near the suction flange. A straight pipe run of at least 3 times the pipe
diameter is desirable between an elbow and the suction flange.

Step 10: Use block valves on both suction and discharge pipes to isolate the compressor
during shutdown, minimize process leakage, and reduce the likelihood of backflow
through the compressor, which can cause reverse rotation.

Seal Environment Control System

For the seal used with the compressor, always maintain the environment shown on the specification
sheet for your unit. For some arrangements and applications, you may need a system to control the seal
environment. For many applications, you can obtain a standard system from the factory. Make sure that
the system is installed properly and that the ports are open or plugged, as applicable. See Outline
drawing in the Final Data Package. Always be sure to leave port 1 free to drain leakage from the
gearbox oil seal and vent the gas seal.

You must vent case drain port 1 to atmospheric pressure and allow it to gravity drain properly. Otherwise
oil could contaminate the outboard gas seal. This port can be attached to a flare line, but should not have
back-pressure in excess of 5 psi.

7
A. GAS BUFFER SYSTEM A gas buffer system must be used with double gas seals to prevent
process gas leakage out of the compressor. The buffer must be a cooled, dry, filtered gas, which is
compatible with the process gas and the compressor metallurgy. The buffer is introduced into seal
port 7 at a pressure range of 40 to 80 psi (2.8 to 5.6 kg/cm2) greater than compressor suction
pressure (max. of 160 psig 11.2 kg/cm2) and at an average temperature no higher than 250F
(121C). Part of the buffer flows across the lower seal into the process gas and part flows across the
upper seal and is vented from port 1. A buffer flow of 1.0 to 2.0 scfm (0.028 to 0.056 Nm3/min) must
be maintained through the seal cavity, and should be regulated by a valve or orifice on port 2. It is
also acceptable to provide a buffer into port 2 and regulate by a valve or orifice out of port 7. The
buffer system must be in operation prior to starting the compressor. Refer to compressor specification
sheet for specific buffer requirements.

A buffer gas may also be used between tandem seals to reduce process leakage when buffer
contamination of the process gas is not permissible. Contact the factory for buffer pressure and flow
requirements.

B. LIQUID BUFFER SYSTEM A liquid buffer system is used with double liquid seals and is functionally
identical to a gas buffer. The buffer liquid is introduced into port 7 or 2, allowed to flow through the
seal cavity, and out the opposing port.

Buffer flow should be 0.5 to 3 gpm (2 to 12 liters/min) with an inlet temperature of 60 to 120F (16 to
49C), and inlet pressure a minimum of 20 psi (1.4 kg/cm2) above process suction pressure.

If a closed loop buffer system is used, the buffer must be cooled prior to returning to port 7.
Otherwise, heat generated by seal friction will build up in the buffer, resulting in shorter seal life. If an
open loop system is used, an orifice or valve on port 2 should be used to regulate flow to proper
value.

NOTE: The compressor casing of units with double liquid seals must be drained prior to starting.

C. SEAL FLUSH An optional seal flush system is available for use with single or tandem gas seal
arrangements when the process gas is contaminated with dust, dirt, or any other types of solid
particles. A clean, cool gas, either from external sources or cooled, filtered gas throttled from the
discharge is introduced into port 5 or 6 at a pressure slightly higher than suction pressure. Thus, only
clean gas will contact the seal face minimizing erosion and seal deterioration.

A flush is not required with a double gas seal due to the flushing action of the buffer leakage across
the lower seal.

D. PORT 1 PIPING Units equipped with gas seals must vent case drain port 1 to atmospheric
pressure and allow it to gravity drain properly. Otherwise oil could contaminate the outboard gas seal.
This port can be attached to a flare line, but should not have back-pressure in excess of 5 psi.

Baseplate Grouting
A rigid concrete mounting base is recommended for all installations. Use a non-shrink grouting to fill the
baseplate grout-fill holes. The concrete foundation should have minimum deflections and freedom from
resonant frequencies in the operating range of the equipment being supported. The stand shall be
secured in position by one inch diameter bolts. The bolts shall be installed in the foundation with sufficient
length to protrude one quarter inch above the nut. The customer shall provide a 4 x 4 x 1/4 steel plate
under each leveling screw.

8
BMC UNITS WITH HORIZONTAL STANDS: The base plate should be leveled prior to grouting. Grout
shall set for the time limit as determined by the grout manufacturer.

LMC UNITS WITH VERTICAL STANDS: The top of the stand (driver mounting surface) should be
leveled by shimming under the base prior to grouting. The channels are to be filled with grout through the
access holes. The nuts on the foundation bolts should not be tightened until the grout has set as
determined by the grout manufacturer.

Horizontal Unit Gearbox Support Bracket

A gearbox support bracket (BK01AW04) is attached to the gearbox bearing plate and provides support to
the gearbox in the horizontally mounted configuration. The bracket is a two-piece slotted hole design
attaching the two pieces to provide adjustability in the field during field installation alignment. A shim (1/4
thickness preferred) should be placed under the bracket and alignment completed. The bracket should
then be drilled and pinned (3/8 minimum pin diameter) in two locations to prevent possible shifting of the
bracket during operation of the unit.

Driver and Coupling

Lock out starting switch on driver prior to working on coupling, following lock-
out/tag-out procedure.
UNITS WITH VERTICAL OR HORIZONTAL STANDS - ALIGNMENT--
If other than Sundyne supplied couplings are used, they must be flexible disc or gear type couplings
capable of tolerating parallel and angular misalignment of .005 inch maximum as well axial end play of
.060 inch maximum. Always refer to the coupling manufacturers recommendations for installation and
maintenance.

The motor and compressor coupling hubs are normally installed at the factory. For alignment
specifications, see Coupling Manufacturers Bulletin in the Final Data Package. Align the driver and
compressor after grouting and before you connect the suction and discharge piping. After you install the
piping, inspect the alignment again.

2. Lubricating Oil System

Oil Specification

The oil used in Sundyne gearboxes must meet the specifications presented in Field Engineering
Bulletin 40.2.04. In general, an ISO viscosity grade 32 oil will meet these specifications. Before using any
oil, you should verify its properties by consulting its manufacturer. Failure to use the proper gearbox
lubricant will void the warranty.

9
 Field Engineering Bulletin

Sundyne & Sunflo & HMP Gearbox Lubricant Recommendations

EFFECTIVE : MAY 2006 Rev: E

For years the preferred gearbox lubricant for Sundyne pumps and compressors has been automotive
automatic transmission fluid (ATF). However, over time the additives in automatic transmission fluid have
changed to coincide with the technical improvements in automobile transmissions. The additives in the
new formulations of ATF, such as Dexron III, have been found to have negative effects on Sundyne
gearboxes and could compromise mechanical integrity and reliability of the equipment.

ISO Viscosity Grade 32 or 46 general purpose or synthetic oils are the recommended lubricants for
Sundyne gearboxes as shown in Table 1 below. ISO VG 46 lubricants are now recommended for high
horsepower gearbox models 33X and 34X with spherical roller bearings and high ambient temperature
installations. Gearbox lube oil should be changed twice yearly or more frequently in severe environments
which may be detrimental to the lubricant. Oxidized oil is frequently characterized by a darkening and/or
thickening of the oil. Operating of gearboxes with oxidized lubricant should be avoided.

Synthetic oils possess different characteristics than conventional mineral oils which make them desirable
for various extreme conditions such as high and low temperature operation. Synthetic oils offer very low
pour points, high temperature oxidation stability and a higher viscosity index.

The operation of Sundyne equipment in high or low ambient conditions may require special consideration
of gearbox lubricant and/or supplemental protective equipment such as heat exchangers or gearbox
heaters.

The lubricant chosen must be compatible with gearbox elastomers, Viton and Buna N. Any oil that
contains an inert additive such as PTFE, molybdenum disulfide or silicon should not be used in Sundyne
gearboxes. Use of lubricants containing inert additives will void the product warranty.

Use ISO Viscosity Grade 32 Lubricant ** Use ISO Viscosity Grade 46 Lubricant
Models: LMV/BMP-311 Models: LMV/BMP-331 LMV/BMP-341
LMC/BMC-311F LMC/BMC-331F LMC/BMC-341F
LMC-BMC-311 LMC/BMC-331P LMC/BMC-341P
LMV/BMP-313 LMV/BMP-333 LMV/BMP-343
LMC/BMC-313 LMC/BMC-333 LMC/BMC-343
LMV-322 LMC/BMC-337 LMV-346
All Sunflo Gearboxes BMP-338 LMC/BMC-347
HMP-3000 BMP-348
HMP-5000

** Use ISO VG 46 lubricant for high ambient temperatures above 40 C (100 F).

10
 Recommended ISO VG 32 gearbox lube oil specifications:
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 1.5
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.

Recommended ISO VG 46 gearbox lube oil specifications:

Gravity, API 28 - 37
Pour Point, C (F) -7 (20) max.
Flash Point, C (F) 204 (400) min.
Viscosity,
cSt at 40C 41.4 to 50.6
cSt at 100C 6.5 min.
SUS at 100F 217 to 260
SUS at 210F 48.8 min.
Viscosity Index 95 min.
ISO Viscosity Grade 46
Color, ASTM D 1500 2.0
Neutralization Number, Maximum 0.25
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.

11
Lube Oil System

The integral Sundyne lube oil system consists of the following major components: gearbox sump, main
lube pump, oil heat exchanger (if necessary), and oil filter. Oil is taken from the sump by the lube pump,
then passed through internal passages to an external integrally mounted manifold, through the heat
exchanger, then through the filter and back into the gearbox to the bearings. After passing through the
bearings, the oil drains back to the sump.

The gearbox sump holds approximately seven U.S. quarts (7.4 liters) of oil not including auxiliary piping
and heat exchanger. For wet sump gearboxes, fill gearbox within from top of oil level sight glass. DO
NOT overfill gearbox, as this will cause excessive foaming and overheating of the oil.

The main lube pump is a constant displacement gear type pump directly driven by the input shaft.

The standard heat exchanger is a shell and tube water cooled type mounted on the gearbox manifold.
Some low speed or low temperature units do not require a heat exchanger. For units having a heat
exchanger, cooling water should be provided at 150 psig (11 kg/cm2) maximum pressure. See the
specification sheet for cooling water requirements. Coolant flow should be controlled by a hand valve
installed in the cooling fluid discharge line to maintain a gearbox sump temperature between 140F to
200F (60C to 93C). Approximately one hour may be required to stabilize temperature.

The oil filter is a disposable pleated paper element type. Gearbox oil and filter should be changed every
six months.

Optional Lube Oil System Auxiliaries

A. LUBE OIL PRIMING KIT A pre-lube system is required on units operating at high speed, high
pressure, or high horsepower conditions. It is also mandatory with the use of certain auxiliary
equipment. The kit consists of a motor driven positive displacement pump, check valve, gages, and
necessary piping. To start compressor, operate the pre-lube pump at least 30 seconds with a
minimum of 7 psig (0.492 kg/cm2) indication prior to starting the main driver.

The pre-lube pump is to shut down only after main driver is at full operating speed.

B. REMOTE HEAT EXCHANGER Some large water-cooled and all air-cooled heat exchangers are
mounted off the gearbox. Except for packaged units, the interconnecting piping is the purchasers
responsibility. The heat exchanger MUST be mounted lower than the oil filter; otherwise, air pockets
may be present in the lube oil lines at start-up, causing oil starvation at the bearings. Equivalent
length of piping and fitting must not exceed 20 feet (6m), using minimum of 3/4 (19mm) I.D. tubing or
pipe. If greater pipe lengths are required, pipe diameter must be increased accordingly.

C. GEARBOX SUMP HEATER A sump heater is required when ambient temperatures may fall below
the temperature at which the gearbox oil becomes too viscous for proper lube pump operation. Both
steam and electric sump heaters are available. The lube oil priming pump must be operated anytime
the sump heater is in operation.

12
3. Start-up
If a Sundyne supplied control panel is to be used with the Sundyne LMC/BMC compressor, use the
control panel recommended start-up procedure in addition to the steps below. Before starting the
LMC/BMC compressor, complete the following procedure in the order in which the steps are provided:

Step 1: Make sure that the driver has been serviced as per manufacturer recommendations. Check
motor rotation before installing coupling.

Step 2: For the auxiliaries: Check the connections of the utilities; verify that the auxiliary piping
meets the requirements shown in the Outline Drawing.

Step 3: Install flushing screens in all field-assembled piping connections. Clean these screens prior
to commissioning. Check frequently for cleanliness and clean as.needed.

Step 4: Drain any liquids (blow-down) from the compressor and inlet pipe.

Step 5: Prime the lubricating system, as follows:

Fill the oil reservoir with lubricating oil in accordance with the Field Engineering Bulletin
Gearbox Lubricant Recommendations.
Add oil as necessary through the fill opening.
With wet sump compressors, add oil as necessary until the oil level stabilizes at the top
of the bulls eye in the sight glass. With dry sump, check oil level at reservoir sight glass.
Start the auxiliary lubricating pump, and run it until the oil reaches the correct pressure
and temperature. Add oil as necessary until the oil level stabilizes 3/4 of the way from the
bottom of the sight glass.
Allow lube pump to operate for at least 30 seconds with a minimum of 7 psig (0.492
kg/cm2) indication prior to starting the main driver.

Step 6: Turn on the cooling water to lubrication systems heat exchanger (if applicable), or turn on air
cooled heat exchanger. Verify high points (e.g. heat exchanger and filters) have been
vented.

Step 7: For double seal configurations, the buffer system must be pressurized to the pressure
specified on the spec sheet and on outline drawings prior to pressurizing the unit.

Step 8: Charge the compressor with process gas.

Step 9: Start compressor, following process control startup procedures.

Step 10: Once the gearbox oil temperature has stabilized, adjust cooling water supply until the oil
temperature to the bearings is 120 - 160F on units equipped with water cooled heat
exchangers. Maximum recommended temperature is 180F.

13
Compressor Control During Start-Up
Single Units:

A. Suction throttling (preferred method). Start compressor with the discharge valve open while
throttling the suction valve to bring the compressor to the design operating point.

B. Discharge throttling. Start the compressor with the suction valve completely open while
throttling the discharge valve to bring the compressor to the design operating point.

C. Other Methods Insure that the compressor does not go into surge (flow too low) or that the
design horsepower is not exceeded (flow too high) while starting or operating the
compressor. Check unit specification sheet for flow limits.

Series Operation:

In series operation, it is necessary to have a bypass from the discharge of the second stage back
to the suction of the first stage. A check valve should be placed in the discharge line downstream
of the bypass. Typical start-up procedure is as follows:

A. Open the suction and discharge block valves and the bypass valve.

B. Start the second stage unit and maintain stable operation.

C. Start the first stage unit and maintain design flow to both units.

D. When sufficient pressure is being produced to overcome system back-pressure, the check
valve will open and the units will be on stream.

E. Close the bypass valve, being sure that the flow to the compressor is above the surge point.

Parallel Operation:

Check valves must be placed in the discharge piping of each compressor to prevent back-flow
when one unit is started prior to the others. It is advantageous to install separate bypass loops
around each compressor for additional operational flexibility.

The first unit may be started as described above for single units. However, prior to starting the
second unit, it is preferable that the on-stream unit not be operating near its peak head capability.
This will lessen the chance of surging when the second unit is started.

Run-In of the Compressor

If the compressor is to be run-in or mechanically tested under conditions which are considerably
different from those that the unit is designed for (such as gas molecular weight, suction pressure,
flow rate, etc.) Sundyne should be consulted to insure that the run-in conditions are compatible
with the compressor.

14
4. Servicing

General Requirements
To increase the operating life of your compressor and keep it in good operating condition, you should
inspect and service it regularly. Measure all of the operating parameters documented in the specific
maintenance procedures and log your measurements. Make sure that all major equipment, such as
lubricating pumps, heat exchangers, and instrumentation, perform according to the manufacturers
recommendations. Whenever you find a deviation from specifications, identify its source immediately,
and take any corrective steps that are required to bring the unit into manufacturers specifications.

Regular Maintenance
Gearbox Oil
Check the level of the oil in the gearbox immediately before and after initial start-up, and regularly while
the compressor is running. Be sure to keep the level of the oil within the gearbox design limit. The oil level
must be maintained within the MIN/MAX range on the sight glass.

You can add oil to the wet sump gearbox while the compressor is running. See tagging information on
gearbox for where to add oil during operation. This location is different from the initial fill location. Each
must be used for its tagged purpose. Overfilling the gearbox will cause excess foaming and overheating
and should be avoided at all times.

Oil may be added to the external reservoir of the dry sump gearbox at the fill port.

Oil Pressure
The correct oil pressure from the main pump of the gearbox depends on the configuration of the bearings
and the characteristics of the lubricating oil used. In the normal operation, the oil pressure supplied to the
gearbox should be between 18-60 psig (1.2 - 4.2 Kg/cm2 ) (15 psi alarm, 10 psi shutdown).

Changing the gearbox oil and filter

Change the oil in the reservoir and the oil filter elements every 6 months. Sundyne recommends
synthetics may go for a longer period of time before an oil change out is required. For dual oil filter units
with a transfer valve, vent and fill the idle oil filter before operating the transfer valve.

Seal Leakage
Seal leakage out of port 1 should be checked periodically. Seals should be replaced if leakage increases
to an unacceptable level. With double seals, buffer pressure and usage should be monitored to insure
that seals are functioning properly.

Driver
Inspect the driver to make sure that it performs according to the manufacturers specifications.

Coupling
Inspect the coupling according to the manufacturers specifications. Never operate the compressor
without first checking the coupling guard. A compressor with a missing or incorrectly installed guard could
cause serious or fatal injury.

15
5. Maintenance

The following procedures apply to all configurations of equipment included in your unit. Parenthetical
the Sundyne LMC/BMC-311F centrifugal numbers in the text correspond to item numbers in the
compressors. Refer to the specification sheet to illustrations and parts lists.
determine the specific configuration and optional

Procedure for Disassembling Compressor

The following replacement parts will be required as a result of compressor

disassembly and seal housing removal

Part Item Qty.

Thermal Barrier Gasket 87A 1

O-Ring Seal 936B 1

O-Ring Seal 936C 1

O-Ring Seal 936D 1

O-Ring Seal 936E 1

O-Ring Seal 936F 1

O-Ring Seal 936G 2

O-Ring Seal 936J 3

O-Ring Seal 936K 1

O-Ring Seal 936P 1

Single Seal 1

Double Seal 2

Tandem Seal 3

O-Ring Seal 936H 2

16
 NOTE
An o-ring Repair Kit is available. This kit contains
the o-rings required to replace the gearbox and
compressor mechanical seals.

STEP 1

Vertical units with a driver stand. Remove bolts

(909D) securing the coupling guard. Remove the
coupling guard. Disengage both ends of the spacer
coupling and remove the floating shaft. Remove nuts
(914A) from the compressor casing studs and release
the stiffening brackets. Attach the integral turnbuckles to
the gearbox bearing plate (102). Using the turnbuckles,
lift the gearbox and seal housing from the compressor
casing. Exercise care to prevent damage to the
impeller. Tip and block the gearbox.

Vertical units without a driver stand. Remove

attaching hardware and lift driver from gearbox. Remove
nuts (914A) from compressor casing studs. Lift the
gearbox and seal housing from the compressor casing,
taking care not to damage the impeller. Place the
gearbox on a suitable support with the impeller inclined
upward.

On all BMC units, disconnect the piping between the

heat exchanger and filter. Attach a hoist to the gearbox
housing and eyebolt in the tapped hole on the bearing
plate. Remove nuts (914A) from the compressor casing
studs and disconnect midriff braces. Remove the
gearbox and seal housing from the compressor casing
by moving them toward the driver until the impeller and
inducer (if applicable) clear the casing. Place gearbox
on a suitable support with the impeller facing upward.

Step 2

If diffuser removal is required, insert three eyebolts

(customer furnished 1/2-13 UNC) into tapped holes in
the surface of diffuser (13). Loosely thread a length of
rope through these bolts and tie ends together. Grasp
the rope between bolts and lift the diffuser. This step will
require that o-rings 936B and 936C be replaced.

17
 NOTE
The gearbox can be worked on while in a horizontal
position. However, the diffuser cover must be
supported to prevent it from falling off when the
impeller is removed.

STEP 3

Prevent impeller from rotating and remove impeller (2).

Note that the impeller has a left-hand thread. Anti-
rotation tools for both the input shaft and output shaft are
available through Sundyne.

CAUTION

The impeller is dynamically balanced and should be

replaced or rebalanced if it shows any sign of
damage.

Step 4

Lift diffuser cover (15) from seal housing.

18
 Step 5

Remove shim spacer (936G).

Step 6

Remove the seal rotating face (51A) of single or tandem

seal arrangement or the lower shaft sleeve (50A) on
units equipped with double seals.

Step 7

Remove the single seal (60A) of the single seal

arrangement or the lower mechanical seal (60A) and
seal spacer (52) of the double seal arrangement or the
lower mechanical seal of the tandem seal arrangement.

If the compressor has a single seal arrangement,

remove seal housing (30) and gasket (87A). Remove
hex head cap screws (905F) and washers (916B).
Remove throttle bushing (21B).

19
 Step 7 (continued)

If upper seal of double or tandem seal arrangement

requires removal, detach seal housing (30) and gasket
(87A) from the gearbox by removing hex head cap
screws (905A).

Double Seal Remove hex head cap screws (905F),

washers (916B), upper mechanical seal (60B), and seal
rotating face (51C).

Tandem Seal Remove hex head cap screws (905F),

washers (916B), upper mechanical seal (60B) and seal
rotating face (51C).

Step 8

Carefully inspect the seals for abrasive particles,

excessive seal face wear and any binding of the seal
face washer.

Replace or rebuild a faulty mechanical seal. Seals may

be rebuilt by replacing the seal face washer, wedge
rings, o-ring, and springs. A seal repair kit is available.

Replace or lap the seal rotating face if the wear track is

rough or worn to a depth greater than 0.0002 inch
(0.005mm).

A combined total of 0.010 inch (0.25mm) maximum may

be removed from the surfaces of the compressor and
gearbox seal rotating faces. Excess material removal
will result in incorrect seal face loading causing
increased seal leakage.

Remove any high spots on the end surfaces of the lower

shaft sleeve and impeller hub to insure that the seal
rotating face will not be distorted by clamping force of
the impeller bolt.

Reassemble the seals, throttle bushing, if used, seal

housing, and impeller using an O-ring Repair Kit. All
o-rings that were disturbed by disassembly should be
replaced. During re-assembly, carefully check the
torque values listed in Table 1.

The impeller may rub on the diffuser cover plate (15)

until o-rings (936D and 936E) are compressed by
tightening hex nuts (914A). Check the gearbox input
shaft for freedom of rotation after the compressor is
assembled and all bolts are tightened per Table 1.

20
Diffuser Gap Setup and
Impeller/Diffuser Cover Alignment
The following replacement items will be required
as a result of compressor disassembly and diffuser
removal:
Part Name Item No. Qty.
Impeller Spacer 158C Series As Required
O-ring Packing 936C 1*
O-ring Packing 936E 1
O-ring Packing 936F 1 inch use .125 inch diameter solder. Form a
O-ring Packing 936G 2 ring at the diffuser gap location marked as
*Required only if diffuser is removed.
A. Remove impeller bolt (3) and impeller (2) as
directed under Compressor Mechanical Seal.
B. Inspect impeller and procure a new one if
required.
C. Inspect diffuser for signs of damage (i.e.
gouging in bowl areas due to erosion or
mechanical damage) and procure a new
diffuser if necessary.
D. The diffuser shim (158A) is used to adjust
diffuser gap. The impeller spacer (158C) is
required to align the blade side of the impeller
shroud flush with the diffuser cover (15). See
Figure 2. The impeller spacer (158C) thickness
(D dimension of Figure 3) and diffuser shim
(158A) (B dimension of Figure 3) must be
determined and the correct spacer installed
during the replacement of any of the following
components. (See photos on next page.)
Gearbox Assembly
Gearbox High-Speed Shaft (130)
High-Speed Shaft Bearings (151A or B)
Impeller (2)
Seal Housing (30)
Diffuser Cover (15)
NOTE
The original clearances for your compressors as
shipped from the factory for the impeller and diffuser
are recorded and supplied as part of the final data
package. Figure 3 can be used to record values.
E. Align the impeller (2) with the diffuser cover (15)
and verify diffuser gap as follows:
(1) Remove diffuser cover (15) and set it
impeller side up on a work bench. Set
impeller (2) in place on the diffuser cover
and measure the distance from the outside
flat surface of the diffuser cover to the front
or blade side of the impeller shroud as
close to the outside edge of the shroud as
possible. The impeller should be recessed
into the cover a minimum of 0.025 inch
(0.063mm). If the dimension is less than
21
0.025 inch, please contact the factory. (See
photos on next page.)
(2) Assemble the compressor complete, less
o-rings and mechanical seals 60A, 60B. Do
not install the compressor in the case. Use
original impeller spacer (158C) and all other
components. Dont forget spacer/thermal
barrier gasket (87A).
(3) Record the diffuser gap reading C from
specification sheet and mark on Figure 3.
Procure solder slightly thicker than the stated
gap. For example; if the diffuser gap is .080
C on Figure 3. Install the assembled
compressor, less o-rings and mechanical
seals (60A, B) in the case. Install four nuts
(914A) and torque to
150 ft-lbs. (See photos on next page.)
(4) Remove nuts (914A) and lift compressor
from case. Measure the crushed solder with
a micrometer. Adjust shim (158A) until gap is
within 10% of the value shown on the
specification sheet. (See photos on next
page.)
NOTE
Unless the diffuser (13) or cover (15) have
been changed, the diffuser gap should not
require adjustment.
(5) Turn gearbox bottom side up so that the seal
housing is on top.
(6) Be sure that the high-speed shaft (130) is
pushed in the X direction (see Figure 2) as
far as possible, (i.e. the shaft is pushed
against the upper thrust washer) (155B or tilt
pad thrust bearing 151B). Measure the
distance from the outside flat surface of
diffuser cover to the front or blade side of the
impeller shroud as before. Record this
dimension and not its direction. This is the
E dimension in Figure 2. Record on
Figure 3.
(7) The impeller shroud must be aligned flush
with the diffuser cover or be extended a
maximum of 0.020 inch out from the cover.
As shown in Figure 1, the E dimension is
within tolerance when the original spacer
(158C) is acceptable. If the measured
distance is out of tolerance, remove the
impeller and measure the thickness of the
original spacer.
Determine the thickness of spacer required
and select the size necessary to bring the E
dimension within acceptable limits.
The impeller spacers (158C) listed on page
23 show the various thicknesses that are
available.
Item D (previous page) The diffuser shim (158A) is used to Item D (previous page). The impeller spacer (158C) is required to
adjust diffuser gap. align the blade side of the impeller shroud flush with the diffuser
cover (15).

Item E. 1 (previous page) Item E. 3 (previous page)

Item E. 3 (previous page) Item E. 4 (previous page)

22
Figure 1. Compressor Cross Section

Figure 2. Compressor Clearances

23
 Part No. Thickness Impeller/Diffuser Clearance
SP01AD02XXF 0.018 (0.046mm) Calculation
SP01AD02XXA 0.030 (0.075mm) The clearance between the impeller and
SP01AD02XXG 0.040 (0.105 mm)
diffuser must be checked and, if necessary,
adjusted after the replacement of any of the
SP01AD02XXB 0.050 (0.127mm) following parts:
SP01AS02XXH 0.060 (0.152 mm) Gearbox Assembly
SP01AD02XXC 0.075 (0.178 mm) Gearbox High-Speed Shaft (130)
SP01AD02XXD 0.090 (0.230 mm) Gearbox High-speed Shaft Bearings (151A-
SP01AD02XXE 0.105 (0.279 mm) 151B)
Diffuser (15)
(8) Replace the impeller spacer (158C) Impeller (2)
with the new spacer if required. Compressor casing (1)
Again, check the alignment of the
impeller (2) shroud to the diffuser Seal Housing (30)
cover (15). A. The required impeller to diffuser clearance
(9) When alignment is correct, torque is obtained by adjusting spacers (158C)
the impeller bolt (3) per Table 1. between the impeller and mating ring. The
recommended procedure for determining
(10) Record the new impeller spacer spacer requirements is as follows:
(158C) thickness (D dimension)
and impeller shroud to diffuser (1) Invert the gearbox assembly, carefully
cover alignment (E dimension) on protecting the low-speed shaft (120),
Figure 2 for future records. so that the impeller is on top.
(2) Torque the impeller bolt per Table 1

24
 Customer

S/N

Model

Date Shift

Assembled By:

Name (Not Clock #)

A. Impeller Clearance

B. Shim Thickness

C. Diffuser Gap

D. Spacer Thickness

E. Shroud Ht.

F. Impeller Blade Ht.

Impeller Diameter

Figure 3. Sundyne Full Emission Compressor Build Record

(3) Make four solder clips and bend them
over the tips of the impeller blade near
the outside of the impeller. They may
be held in place by tape. It is
acceptable to use a ring of solder in
the case instead of clips on the
impeller. Install the completed
compressor less seals and o-rings
into the compressor case. Install four
nuts (914A), in the seal housing and
torque to 150 ft.-lbs. This will crush
the solder between the impeller and
the diffuser and indicate the gap,
dimension A. Again, the solder will
force the shaft up into the running
position. Remove the seal housing
bolts and pull the compressor from the
case. Using a micrometer, measure
the crushed area of the solder. This
value should be .035-.055 inch. The
impeller gap A is changed by
adjusting the impeller shim thickness,
(158C). However, this change must
not result in lowering the impeller to
the point where the face of the shroud
is below the cover. If the adjustment
required would recess the impeller
below the cover, additional impeller
blade gap (A) can be obtained by
making the diffuser shim (158A)
thinner. Since you are using two
shims to change three dimensions,
some compromise may be necessary.
NOTE
The purpose of this step is to set the
clearances between the impeller and
the diffuser such that it will not rub,
but is close enough that the
machine will run efficiently. When
the compressor is not running and
no suction pressure is supplied, the
high-speed shaft will be sitting
against the lower thrust bearing.
The gap must be sufficient to insure
that the impeller will not touch the
diffuser. If the compressor is set up
with too large a clearance, the
efficiency will be low.
When all gaps and clearances, A, E
and C are within specifications, check
Figure 3 to be sure all values are
recorded. Disassemble compressor
and reinstall all o-rings, mechanical
seals, etc. Reassemble and install
compressor into case.

25
6. Procedure for Disassembling Gearbox
The following replacement items will be required as a result of the gearbox disassembly:

Part Item No. Qty.

Gearbox Oil Filter 185 1

Input Shaft Lip Seal 115 1

Housing O-Ring 936AG 2

O-ring Seal 936M 2

O-ring Seal 936N 2

O-ring Seal 936P 1

O-ring Seal 936T 2

* Shim Spacers 158 Series As Required

* Available in sets of five 0.005 inch (0.13mm), 0.010 inch (0.25mm), .05 inch
(0.38mm), 0.020 inch (0.51mm), 0.030 inch (0.76mm)

NOTE:

In order to disassemble the gearbox, it is

necessary to complete steps one through seven
under Procedure for Disassembling
Compressor.

Step 1

Drain oil from the gearbox.

Step 2

Remove upper shaft sleeve (50B) on double or

tandem seal arrangements or sleeve (50) on single
seal equipped units.

26
 STEP 3
Remove gearbox seal screws and gearbox
seal.

Removing three hex head screws.

Note: The gearbox mechanical seal can be

replaced or rebuilt.

STEP 4
Remove gearbox seal O-ring.

Use extraction tool to remove O-ring.

STEP 5
Remove gearbox seal mating ring.

Remove mating ring with extraction tools.

STEP 6
Invert the gearbox and remove fill and vent
fitting.

Use a pipe wrench to remove the inch

pipe elbow first. Next, use the pipe wrench
to loosen the pipe and remove from the
gearbox.

27
 Slide the fill and vent pipe out of gearbox.

STEP 7
Loosen and remove gearbox bolts, (7 total).

STEP 8
Loosen close tolerance alignment pin.

STEP 9
Drive close tolerance alignment pins out, (2
pins).

Use hammer to tap pin out.

28
 STEP 10
Remove upper gearbox housing.

A mallet can be used to tap around the

edges of the housing to loosen the idler
shaft and assist the housing in lifting off.

Note: Use hooks or eyebolts and a hoist

when possible to avoid personal
injury.

STEP 11
Remove idler shaft assembly.

Removing the idler shaft assembly

disengages the upper idler and input shaft
gears.

Technician is pointing to idler shaft.

STEP 12
Remove input shaft assembly.

STEP 13
Remove the lube pump spring and the lube
pump.

29
 STEP 14
Inspect the condition of the lube pump anti-
rotation pin.

Extraction tool is touching anti-rotation pin.

STEP 15
Remove bearing plate.

STEP 16
Remove and inspect upper thrust washer.

Washer will slide off of the shaft.

STEP 17
Remove idler shaft assembly.

30
 STEP 18
Remove high-speed shaft assembly.

STEP 19
Remove and inspect lower thrust washer.

STEP 20
Remove and inspect upper journal bearing
after removing from bearing plate.

Unscrew three hex head screws.

Use fingers to remove journal bearing.

Inspect the upper journal bearing for

damage or signs of excessive wear.

31
 STEP 21
Remove input shaft lip seal.

STEP 22
Remove the sump tube.

Remove lower journal bearing.

Repeat step 20 for removal of lower journal

bearing.

STEP 23
Remove lower bearing shims.

STEP 24
Remove lower bearing shims.

Use hex key to remove the lube jets.

32
 STEP 25
Blow out lube passage.

Using air tool to blow out lube passages.

Blowing out lube passages.

33
7. Gearbox Reassembly
The following replacement items will be required as a result of the gearbox disassembly:

Part Item No. Qty.

Gearbox Oil Filter 185 1

Input Shaft Lip Seal 115 1

Housing O-Ring 936AG 2

O-ring Seal 936M 2

O-ring Seal 936N 2

O-ring Seal 936P 1

O-ring Seal 936T 2

* Shim Spacers 158 Series As Required

* Available in sets of five 0.005 inch (0.13mm), 0.010 inch (0.25mm), .05 inch
(0.38mm), 0.020 inch (0.51mm), 0.030 inch (0.76mm)

STEP 1
Insert shim under lower journal bearing.

STEP 2
Install lower journal bearing.
Insert 3 hex head screws.

Note: Torque to 40 in-lbs

Note: Above picture has thrust washer

already installed over journal bearing.

Note: Using a torque wrench to tighten

screws.

34
STEP 3
Install lower thrust washer if not already in
place.

STEP 4
Install high-speed shaft assembly.

STEP 5
Re-install the sump tube into the bearing
plate.

STEP 6
Re-install the upper journal bearing into the
bearing plate.

Note: Tighten hex head screws to 40 in-lbs.

35
STEP 7
Install new thrust washer.

Thrust washer is silver disc in center.

STEP 8
Install bearing plate without gasket using
alignment pins.

Using alignment pin to install the bearing

plate temporarily.

STEP 9
Clamp bearing plate to the lower gearbox
housing.

Clamping the bearing plate to housing.

Note: C clamps can be utilized to perform

this task.

36
STEP 10
Inspect endplay of the high-speed shaft.

Note: Endplay must fall within these

tolerances, 0.015 +/- 0.002
Measuring endplay of High Speed Shaft.
Note: For complete instructions for checking
endplay refer to the Procedure for Checking
High Speed Shaft Endplay later in this manual

STEP 11
Remove bearing plate and install lower housing
gasket and o-ring at oil passage

STEP 12

Lubricate the journal bearings, high-speed

shaft, journal/thrust face with standard
gearbox lubricant.
Lubricating the high-speed shaft.

37
STEP 13
Lubricate the lower idler bearing.

STEP 14
Install idler shaft assembly.

Note: The idler shaft assembly sits at a

slight tilt to allow installation of the
bearing plate.

STEP 15
Install the bearing plate.

38
STEP 16
Install lube pump.

STEP 17
Install lube pump spring.

The lube spring sits inside the lube pump.

STEP 18
Lubricate the lube pump.

STEP 19
Install input shaft assembly.

Note: Notice the input slots for the oil pump

drive pins.

39
STEP 20
Push on input shaft to verify engagement of
drive pins.

STEP 21
Set idler shaft assembly in place and
engage input gears.

STEP 22
Lube input shaft bearings and upper idler
bearings.

STEP 23
Install upper housing gasket and o-ring.

40
STEP 24
Install upper gearbox housing.

Note: Lower carefully in order to slide

bearings into bearing liners.

Note: Use hoist when available to prevent

personal injury.

STEP 25
Install close tolerance alignment pins.

Note: Install first pin as noted on the bearing

plate.

STEP 26
Install new lip seal.

Note: Use lip seal installation tool #T-

H006AA-47 to install lip seal.
Putting lip seal onto lip seal installation
tool.

Installing the lip seal.

41
STEP 27
Install remainder of gearbox hex head bolts.

Installing washers and nuts onto gearbox

bolts.

Note: Torque to 65 ft-lbs.

STEP 28
Install fill and vent fitting.

Note: Use pipe dope on all pipe threads.

Use pipe wrench to tighten fitting after
sliding into place.

STEP 29
Install shaft anti-rotation device to prevent
the impeller from spinning.

42
STEP 30
Turn gearbox over.

STEP 31
Install gearbox-mating ring.

STEP 32
Install gearbox-mating ring o-ring

43
STEP 33
Install gearbox seal o-ring onto gearbox
seal.

STEP 34
Install gearbox seal.

STEP 35
Install three gearbox seal hex head screws.

Note: Torque screws to 75-80 in-lbs.

44
Table 1. Torque Values
Gearbox
Sundyne Standard Steel Screws & Bolts and NACE Compliant Steel Screws/Bolts (BG Material)
Torque Values
Item # Location Size English Metric
905H Oil Filter Manifold 3/8 - 16 x 1/2 22 - 25 ft-lbs 30 - 34 N-m
905L Gearbox Seal 1/4 - 20 x 1/2 75 - 80 in-lbs 8.5 - 9.0 N-m
905M, N Journal Bearings #10 - 24 x 1 35 - 40 in-lbs 4.0 - 4.5 N-m
905T Chemical Barrier Gasket 1/4 - 20 x 5/8 75 - 80 in-lbs 8.5 - 9.0 N-m
909B Gearbox Halves 1/2 - 13 x4 60 - 65 ft-lbs 81 - 88 N-m
909C Gearbox Halves, Alignment 5/8 - 18 x 4 17/64 60 - 65 ft lbs 81 - 88 N-m
906B Sight Glass #8 - 32 x 1/2 10 - 12 in-lbs 1.0 - 1.4 N-m
Pumps & Compressors*
Sundyne Standard Steel Screws and Bolts
Torque Values
Item # Location Size English Metric
3 Impeller Bolt/Inducer:
LMV/BMP-801, 802, 806, 322, 311, 331 1/2 - 20 36 - 40 ft-lbs 49 - 54 N-m
LMV/BMP-341, 346 1/2 - 20 65 - 70 ft-lbs 88 - 95 N-m
LMV-313, 343, BMP-338, 348 (High 3/4 - 10 85 - 90 ft-lbs 115-122 N-m
Flow)
LMC/BMC 3X1P, 3X1F, 3X3, 3X6P, 3X7 1/2 - 20 36 - 40 ft-lbs 49 - 54 N-m
906D Diffuser Attaching Screws 1/4 - 20 95 - 102 in-lbs 11 - 11.5 N-m
905E Mechanical Seal No. Spacer 1/4 - 20 x 12 95 - 102 in-lbs 11 - 11.5 N-m
905F Throttle Bushing/Mechanical Seal 1/4 - 20 x 12 9 5- 102 in-lbs 11 - 11.5 N-m
905G Double Seal with Spacer 1/4 - 20 x 3/4 95 - 102 in-lbs 11 - 11.5 N-m
914A Case Nuts 3/4 - 10 250 - 275 ft-lbs 340 - 375 N-m
914A Case Nuts 7/8 - 9 300 - 330 ft-lbs 405 - 445 N-m
905A Seal Housing to Gearbox 3/8 - 16 x 1 3/4 35 - 40 ft-lbs 47 - 54 N-m
905P Separator 1/4 - 20 x 5/8 95 - 102 in-lbs 11 - 11.5 N-m
Pumps & Compressors
NACE Compliant Steel Screws / Bolts (BG Material)
Torque Values
Item # Location Size English Metric
3 Impeller Bolt/Inducer:
LMV/BMP-801, 802, 806, 322, 311, 331 1/2 - 20 36 - 40 ft-lbs 49 - 54 N-m
LMV/BMP-341, 346 1/2 - 20 65 - 70 ft-lbs 88 - 95 N-m
LMV-313, 343, BMP-338, 348 (High 3/4 - 10 85- 90 ft-lbs 115 - 122 N-m
Flow)
LMC/BMC 3X1P, 3X1F, 3X3, 3X6P, 3X7 1/2 - 20 36 - 40 ft-lbs 49 - 54 N-m
906D Diffuser Attaching Screws 1/4 - 20 70 - 75 in-lbs 8.0 - 8.5 N-m
905E Mechanical Seal No. Spacer 1/4 - 20 70 - 75 in-lbs 8.0 - 8.5 N-m
905F Throttle Bushing/Mechanical Seal 1/4 - 20 70 - 75 in-lbs 8.0 - 8.5 N-m
905G Double Seal with Spacer 1/4 - 20 70 - 75 in-lbs 8.0 - 8.5 N-m
914A Case Nuts 3/4 - 10 160 - 200 ft-lbs 217 - 270 N-m
914A Case Nuts 7/8 - 9 225 - 245 ft-lbs 305 - 332 N-m
905A Seal Housing to Gearbox 3/8 - 16 x 1 3/4 27 - 30 ft-lbs 47 - 54 N-m
905P Separator 1/4 - 20 x 5/8 70 - 75 in-lbs 8.0 - 8.5 N-m
* When using Teflon o-rings, allow 15 minutes between torquing for the Teflon to cold flow. Repeat torquing
until there is no change in torque.

45
 Parts List
1. General
Assemblies, subassemblies and
components of the Sundyne
LMC/BMC-311F compressors are
illustrated on the following exploded and
cross sectional views. Refer to your
Sundyne specification sheet for those
options applicable to your compressor. The
corresponding parts lists, keyed to each
part by item number, identify detail parts by
part name, quantity and location.
2. Recommended Spare Parts
Refer to pages 68 and 69 for
recommended spares. The quantities listed
are intended as general guidelines; actual
quantities for a specific application will vary
with operating conditions, process liquid,
critical nature of service, and inventory
considerations. You can obtain assistance
for planning an adequate supply of spare
parts from your Sundyne Corporation
representative.
3. Gearbox Exchanger
A gearbox exchange can be arranged for a
fixed price. A replacement gearbox,
completely tested and with a full one year
warranty can be shipped to anywhere in
the continental United States within 48
hours after receipt of the expedited order in
Arvada.
46
4. Repair Kits
Seal and o-ring repair kits are not
illustrated herein, but may be purchased
directly from Sundyne Corporation. Seal
repair kits contain all normally wearing
parts (springs, washers, o-rings, carbon
faces, etc.) of the compressor or gearbox
mechanical seals.
O-ring repair kits contain all o-rings
necessary for maintenance on overhaul
of the compressor. The use of these kits
reduces maintenance time, prevents
assembly mistakes, simplifies stocking
and inventory, and reduces delivery time.
5. Ordering Spare Parts
When ordering spare parts, give the
compressor serial number and list each
part by part number as shown on the parts
list which is included with each compressor
shipment (preferred method), or list each
part by item number (as listed in this
manual), part name and compressor
model. Specify quantities desired.
Order parts from your Sundyne
representative or directly from Sundyne
Corporation:
Sundyne Corporation
14845 West 64th Avenue
Arvada, CO 80007 (USA)
Phone: +1-303-425-0800
or
refer to www.sundyne.com
for your local representative
8. Troubleshooting
Gearbox and Compressor
Many factors affect the performance of your compressor. Among them are suction pressure,
temperature, molecular weight, driver speed, flow rate, and discharge control. You need to check all
of these when there is a problem with the compressor and when you are analyzing the performance
of the system. For details on the performance of the compressor including the performance curve.
See final data package.
Table 2 provides information for analyzing gearbox and compressor problems.
Table 2 Troubleshooting for Gearbox and Compressor
Trouble Possible Cause
The compressor produces no flow and A component of the drive, such as the
no pressure at start-up coupling or the impeller spline, has
failed, or an item is missing from the
assembly
The drive shaft rotates in the wrong
Direction
The suction valve or the discharge
valve is closed.
The head rise is insufficient. The flow is too high.
The driver shaft is rotating in the
wrong direction.
The suction pressure is low.
Recirculation from the discharge to
the inlet is excessive.
The molecular weight is not that for
which the compressor was designed.
The driver speed is too low.
The pressure gauges or the flow
meters are in error
The oil pressure in the gearbox is low. The pressure gauge is faulty.
The main lubricating pump has failed.
Driver overloaded. Molecular weight higher than values
listed on specification sheet
Electrical failure in electric power unit.
47
Investigative and Corrective Action
Disassemble and inspect the component.
Make sure that the drive shaft is rotating in
the direction shown by the arrow on the
compressor gearbox.
Check the valving (see section 3. Startup
instructions).
Check the head rise and the flow rate against
the performance curve.
Make sure that the drive shaft is rotating in
the direction shown by the arrow on the
compressor gearbox.
Check the Sundyne specification sheets.
Check the flow through the external piping,
such as the bypass
Check the molecular weight against the value
given on the specification sheet. Low
molecular weight will cause low discharge
pressure.
Check the speed against the value listed on
the Sundyne specification sheets.
Calibrate the instrumentation.
Check the accuracy of the gauge.
Remove the pump and coupling, and check
them for damage.
Check actual molecular weight against value
listed on specification sheet.
Check circuit breaker heater size and setting.
Check voltage.
Current for each phase should be balanced
within three percent.
Trouble
Driver overloaded.
(continued)
Excessive discharge pressure
pulsation.
Change of gearbox automatic
transmission fluid color from normal
color to milky pink or yellow.
Shaft sleeve rubs on inside diameter
of seal.
Excessive gearbox automatic
transmission fluid consumption.
Excessive oil foaming.
Possible Cause
Mechanical failure in driver, gearbox,
or compressor.
Corrosion pitting on surface of diffuser
adjacent to impeller blades. Head rise
is reduced by this condition.
High suction pressure.
Flow rate too low (surge).
Defective flow control valve.
Gearbox oil contaminated with water
or process fluid.
Gearbox journal bearing failure.
Low speed shaft seal (115) leakage.
High speed shaft mechanical seal
(60C) leakage.
Leakage through heat exchanger into
cooling fluid.
High oil level.
Low gearbox temperature.
48
Investigative and Corrective Action
Disconnect spacer coupling and check for
freedom of rotation of compressor, driver, and
gearbox shafts.
Drain oil and remove gearbox oil level sight
glass and inspect bottom of sump for wear
particles. Bearings are probably not damaged
if no wear particles are present.
Disassemble compressor end and search for
any mechanical failure.
Disassemble and inspect. Check diffuser
bowl area, cover plate and diffuser throat for
material buildup. Clean these areas of all
obstructions and restore surfaces to a smooth
polished finish (use emery cloth) free of all
corrosion pitting. Edge of diffuser throat must
be sharp. If damage is more severe (i.e.
impeller is deformed or has come in contact
with diffuser) replace the damaged parts.
Check specification sheet. Increase suction
pressure and corresponding mass flow rate
will result in high horsepower consumption.
Increase flow rate through compressor. Add
controlled bypass to suction, if necessary.
Check control valve.
Inspect gearbox heat exchanger for leakage.
Check for excessive compressor seal
leakage.
Inspect shaft sleeve O rings.
Install replacement exchange gearbox or
repair gearbox as outlined under
MAINTENANCE.
Check drain port for leakage. Replace shaft
seal if required.
Check for fluid leakage from port 1.
Pressure test heat exchanger and replace if
required.
Shut down the unit and check oil level.
Adjust coolant to heat exchanger, keeping oil
temperature above 140F. (60C).
 Compressor Mechanical Seals
Table 3 provides information on problems with single units, as well as double and tandem seal units.
Table 3 Troubleshooting for Gearbox and Compressor
Trouble
Leakage around the seal suddenly
increases
Possible Cause
The system is operating at a low flow
rate or a low inlet pressure, causing
vibration of the high-speed shaft,
bouncing on the face of the seal, and
chipping on the nose of the carbon
seal.
The action of the stationary face
spring on the seal is rough and sticky
The seal is worn or damaged.
The wear pattern on the rotating faces
of the seal is not uniform.
The rotating face of the seal is
cracked or broken. This may have
been caused by damage at the
assembly or by heating due to lack of
leakage (cooling) past the seal.
The seal faces, seal parts, or o-rings
have become chemically attached.
The seal on a low-temperature
compressor is icing, or there is heavy
condensation on the atmospheric side
of the seal.
49
Investigative/Corrective Action
Make sure that the compressor always
operates above the specified minimum
flow rate and/or inlet pressure.
If contamination in the process gas
(from entrained solids) causes a sticky
seal, there may be need for a seal
flush, double seals, or tandem seals.
Disassemble the seal and rebuild or
replace it by the instructions in Section
5.
Lightly lap the surfaces on the shaft
sleeve and the impeller hub that
contact the rotating face of the seal, to
remove high spots. Install new seal
faces. Do not remove more than 0.005
in. (0.12mm) from any surface.
Make sure that the system operates
above the specified minimum flow rate
at all times.
Check the seal environment to make
sure that there is a leakage path of
process or buffer fluid across the
compressor seal(s) and that there is a
differential across the seal(s) to force
this leakage. Replace the damaged
seal.
Investigate the properties of the
process gas, and replace the
components with chemically resistant
materials.
Purge the atmospheric side of the seal
with dry nitrogen gas.
9. Operation
Some form of control is required for the majority of SUNDYNE compressor applications. The purpose
of control is twofold: 1) to achieve the desired performance as required by process conditions, and 2)
to protect the compressor from mechanical damage due to surge or overload conditions.

This section is a general guideline on controls. A control system should be selected only after
completion of a detailed analysis of the specific installation.
Surge Control
It is recommended that a surge control system be installed whenever there is any chance
that the process flow could decrease appreciably from design flow. In most surge control
systems, a flow sensor is placed in the suction line to the compressor. The signal from this
sensor is input to a controller which controls a valve in the bypass loop. When the minimum
safe flow is reached, this valve opens and the flow through the compressor is kept above the
surge point. Again, the recycled gas must be cooled to prevent heat build-up. Both pneumatic
and electrical surge control systems are available.

Suction Throttling

Suction throttling is generally the most economical control method with a constant speed
drive. Throttling the control valve on the suction side causes a reduction of inlet pressure to
the compressor. Although the compressor creates the same compression ratio as if it were
unthrottled, the discharge pressure is reduced. The net result is to lower the total head output
to the system. The reduction of inlet pressure correspondingly decreases inlet gas density,
and thus, power consumption. Suction throttling also has the advantage of slightly lowering
the compressor surge point.

Discharge Throttling

Discharge throttling is controlled by means of a valve placed at the compressor discharge. A

constant speed compressor will always operate on its design head-flow curve. For a given
system operating point, the compressor will operate at the system flow rate, thus producing
more head than the system requires. This excess head is throttled by the discharge valve.
Since the throttling occurs downstream of the compressor, there are no power savings by this
method. Discharge throttling offers no real advantages over suction throttling, but is
nonetheless an acceptable control method.

Speed Control

Speed control is the most efficient means of compressor control. To operate at points below
the design head-flow curve, the driver speed may be reduced accordingly. This creates an
infinite family of head-flow curves on which the compressor may operate. Since consumed
horsepower, assuming constant inlet conditions, varies as the cube of the speed, substantial
power savings can be realized. Also, the compressor surge point is lowered proportional to
the speed decrease. This method is used mainly on turbine driven units although variable
speed motors or mechanical drives are available. Since the main lube oil pump in the
SUNDYNE compressor is driven by the gearbox input shaft, provision must be made so the
speed is not reduced to a point where adequate lube oil pressure is no longer present.

Flow Bypass

Flow bypass requires a recycle line from the compressor discharge to suction. The
compressor is operated at the desired flow or discharge pressure and the excess flow not
50
 required by the process is recycled through the bypass. A cooler is required in the loop to
cool the recycled gas to normal suction temperature. This method is generally less efficient
than other methods discussed, but may be warranted in some special situations.

Other aspects which should be considered in compressor operation are:

Series Compressor Control - Inlet throttling on the first stage is the most practical method of
controlling compressor in series. It is necessary to throttle only the first stage, which in turn
acts as a throttle for the second stage. Inlet throttling between stages offers no advantages
and should be avoided. Efficiency gains by variable speed control of series units will seldom
justify its cost and complexity.

Surge control on series units consists of a flow sensor and controller in the suction line of the
first stage. This sends a signal to the control valve in a bypass loop around both
compressors. It must be determined which compressor surges at the lowest inlet flow to the
first unit so the flow controller can be set such that neither compressor will surge. A more
complex system which offers maximum machine protection consists of separate bypass
loops for each unit which are operated by separate flow controllers.

Parallel Compressor Control - The control of two or more compressors operating in parallel
would appear to be relatively simple. More than likely, though no two compressors ever
operate identically across their flow range. To produce identical discharge pressures, one
compressor could be operating at a different flow than the unit in parallel with it. As a result,
the control system would have to include a separate flow controller for each unit. Either
suction or discharge throttling may be used, but again, suction throttling is the preferred
method. If variable speed drivers are used, extreme care must be taken to insure that the
speeds can be precisely controlled. In any case, check valves must be installed in the
discharge line of each compressor to prevent possible back flow due to any slight imbalance
in the characteristics of the compressors. Separate surge control systems for each
compressor should be considered for maximum unit protection.

10. Spare Parts

1. General

Assemblies, subassemblies and components of the Sundyne compressor are illustrated on

the exploded and cross sectional views in Reference D. Refer to your Sundyne Compressor
Specification Sheet for those options applicable to your compressor. The corresponding parts
lists, keyed to each part by item number, identify detail parts by part name, quantity and
location. A complete bill of materials list for the compressor and gearbox end is included in the
final data package. Refer to the unit outline drawing for a list of the major kit bills of material.

2. Recommended Spare Parts

Refer to your final data package for recommended spare parts identified for your particular unit.
These are provided as guidelines only.

51
3. Repair Kits

Seal and o-ring repair kits are not illustrated herein, but may be purchased directly from
Sundyne Corporation. Seal repair kits contain all normal wearing parts (springs, washers,
o-rings, carbon faces, etc.) of the compressor or gearbox mechanical seals.

O-ring repair kits contain all o-rings necessary for maintenance or overhaul of the compressor.
The use of these kits reduces maintenance time, prevents assembly mistakes, simplifies
stocking and inventory, and reduces delivery time.

4. Ordering Spare Parts

When ordering spare parts, give the unit serial number and list each part by the part number as
shown on the Bill of Material which is included with each compressor shipment (preferred
method), or list each part by item number (as listed in this manual), part name and compressor
model. Specify quantities desired.

Order parts from your Sundyne representative or directly from Sundyne Corporation at one of
the following locations.

Sundyne Corporation Phone Number: +1-303-940-2989

14845 West 64th Avenue Fax Number: +1-303-940-2826
Arvada, Colorado 80007, USA

Sundyne Corporation Europe Phone Number: +011-333-80-38-3300

(13-15 Boulevard Eiffel Fax Number: +011-333-80-38-3366
Zone Industrielle De Dijon-Sud 21600)
B.P. 30
21604 Dijon (Longvic)
France

Or visit our Genuine Service and Parts site at www.sundyne.com.

52
11. Sundyne Compressor Warranty
Sundyne Compressors warrants to Purchaser for a period of 12 months from the date the line
mounted compressor (LMC) is placed in service (not to exceed 18 months after shipment date) that
the equipment at the time of shipment is free from defects of material and workmanship.

If any defects occur during the warranty period, Sundynes sole obligation is limited to alteration,
repair, or replacement at Sundynes expense, F.O.B. factory, of parts and equipment, which upon
Sundynes examination prove to be defective.

Non-Sundyne equipment and accessories are warranted only to the extent of and by the original
manufacturers warranty. Sundyne is not liable for damage or wear to equipment caused by abnormal
conditions, vibration, improper lubrication, failure to provide proper inlet conditions or flow, corrosives,
abrasives, or foreign objects.

This warranty is exclusive and in lieu of all other warranties, whether expressed or implied,
including any warranty of merchantibility or fitness for any purpose. In no event shall Sundyne
be liable for consequential or incidental damages.

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 Compressors.

EUROPEAN UNION MACHINERY DIRECTIVE

(CE Mark System)
(where applicable)

This document incorporates information relevant to the Machinery Directive 89/392/EEC. It should be
read prior to the use of any of our equipment. Individual maintenance manuals which also conform to
the EU Directive should be read when dealing with specific models.

SAFETY WARNING
Sundyne Compressors manufactures centrifugal process gas compressors 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 Compressors 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 Sundyne
Compressor parts and accessories is considered misuse and damage or failure caused by misuse is
not covered by Sundynes warranty. Additionally, modification of Sundyne Compressor products or
removal of original components may impair the safety of these products and their effective operation.

53
Reference A

Critical Start-up Checklist

Know Your Machine
Before servicing and starting up the Sundyne line mounted compressor (LMC), carefully review the
specification sheet, the outline drawings, the performance curves, and this instruction manual. You
should be familiar with the configuration of the compressor before you start and operate it.

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 Sundynes drawings.
3. Verify the connections of the switches, the instruments, and the set points.
4. Calibrate the flow instruments and the other transmitters.

Environmental Control System

Install a system to control the environment of the seal, if required, and verify that port 1 is properly
vented. Drain the compressor casing. (Maximum back pressure = 10 psig)

Pressurize Fluid Loop

Pressurize double seal buffer fluid loop or external seal flush, if required, prior to admitting fluid into
compressor casing.

Check Driver Rotation

Make sure that the gear shaft rotates in the direction indicated by the arrow stamped on the gearbox
of the compressor.

Start Compressor
1. Suction throttling (preferred method): Start the compressor with the discharge valve open while
throttling the suction valve, to bring the compressor to the design operating point. See
specification sheets for the inlet conditions and flow rate.

2. Discharge throttling: Start the compressor with the suction valve completely open while throttling
the discharge valve, to bring the compressor to the design operating point.

3. Variable speed (as applicable): Start the compressor with the suction valve and the discharge
valve open. Check the pressure in the system. If it exceeds the surge point of the compressor
(see the specification sheet and the performance curve), you will need a bypass to protect the
compressor from surging during ramp-up to speed. Never operate the compressor above the
maximum design speed.

Heat Exchanger
If a heat exchanger for the gearbox is installed, adjust the cooling flow to keep the temperature of the
gearbox sump at 120-180F (49-82C).

54
Check
Check the following items. Each of these parameters significantly affects the performance of the
system. Head rise, Flow rate, Power consumption, Inlet pressure, Temperature; and Molecular
weight.

Coupling
There are two types of connections between the motor and gearbox; a splined shaft or a coupling.
For splined connections, the splined shaft must be lubricated with the supplied spline grease and the
two
o-rings installed prior to mounting the motor. It is recommended that the input shaft be rotated by
hand prior to mounting the motor. If the unit has a coupling, be sure coupling gap is correct and
bolting between coupling halves is tight. The instruction manual contains coupling set-up information.

Process Conditions
Do process conditions; suction pressure, suction temperature, discharge header pressure, and mole
weight agree with specification sheet information? Check with your Sundyne Corporation
representative if you must test a different gas 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. Compressor flange bolts?
b. Seal environment piping and port connections?
c. Cooling water connections to heat exchanger? (if applicable)
d. Gearbox oil drain plug?
e. Compressor case drain plug?

Reference B
Lock-out/Tag-out Guidelines
Follow Your Companys Lock-Out / Tag-Out Procedure When Servicing Sundyne
Compressors.

Never remove a lock or tag applied by someone else. Additional locks or tags should be applied if
multiple groups are working on the equipment. Each responsible work group leader should apply a
lock or tag. Always treat conductors and equipment as if they are energized.

Reference C
Seal Arrangement Drawings for Single, Double and Tandem Configurations

55
Item Item
No. Part Name Qty. No. Part Name Qty.
21B Throttle Bushing 1 158C Shim Spacer 1
50 Slinger Sleeve Assembly 1 905E Hex Head Cap Screw 3
51A Sal Rotating Face 1 905F Hex Head Cap Screw 3
51D Seal Rotating Face (Gearbox) 1 905L Hex Head Cap Screw 3
60A Mechanical Seal (Lower) 1 916A Washer 3
61A Retainer & Drive Sleeve Assembly 1 916B Washer 3
62A Seal Face Washer 1 916K Washer 3
65A Coil Spring Set 1 936G O-Ring Packing 2
68A Backing Ring 2 936H O-Ring Packing 2
69A O-ring Packing 1 936J O-Ring Packing 1
60C Mechanical Seal (Gearbox) 1 936K O-Ring Packing 1
61C Retainer & Drive Sleeve Assembly 1 936P O-ring Packing 1
62C Seal Face Washer 1
64C Seal Retaining Ring 1
65C Coil Spring Set 1
69C O ring Packing 1

Figure 4. SINGLE SEAL ARRANGEMENT

56
Item Item
No. Part Name Qty. No. Part Name Qty.
50A Shaft Sleeve (Lower) 1 60B Mechanical Seal (Liquid Seal) 1
50B Shaft Sleeve (Upper) 1 61B Retainer & Drive Sleeve Assembly 1
51C Seal Rotating Face 1 62B Seal Face Washer 1
51D Seal Rotating Face (Gearbox) 1 63B Seal Spring Backup Disc 1
52 Seal Spacer 1 64B Seal Retaining Ring 1
65B Coil Spring Set 1
60A Mechanical Seal (Gas Seal) 1 68B Seal Wedge Ring 1
61A Retainer & Drive Sleeve Assembly 1
62A Seal Face Washer 1 60C Mechanical Seal (Gearbox) 1
65A Coil Spring Set 1 61C Retainer & Drive Sleeve Assembly 1
63A Backing Ring 2 62C Seal Face Washer 1
68A Seal Retaining Ring 1 64C Seal Retaining Ring 1
69A O-Ring Packing 1 65C Coil Spring Set 1
69C O-Ring Packing 1
60A Mechanical Seal (Liquid Seal) 1
61A Retainer & Drive Sleeve Assembly 1 158C Shim Spacer 1
62A Seal Face Washer 1 905F Hex Head Cap Screw 3
63A Seal Spring Backup Disc 1 905G Hex Head Cap Screw 3
64A Seal Retaining Ring 1 905L Hex Head Cap Screw 3
65A Coil Spring Set 1 916A Washer 3
68A Seal Wedge Ring 1 916B Washer 3
916K Washer 3
60B Mechanical Seal (Gas Seal) 1 936G O-Ring Packing 2
61B Retainer & Drive Sleeve Assembly 1 936H O-Ring Packing 2
62B Seal Face Washer 1 936J O-Ring Packing 1
65B Coil Spring 1 936K O-Ring Packing 1
63B Backing Ring 2 936P O-Ring Packing 1
68B Seal Retaining Ring 1
69B O-Ring Packing 1

Figure 5. DOUBLE SEAL ARRANGEMENT

57
Item Part Name Qty. Item Part Name Qty.
No. No.
50A Shaft Sleeve (Lower) 1 60C Mechanical Seal (Gearbox) 1
50B Shaft Sleeve (Upper) 1 61C Retainer & Drive Sleeve Assembly 1
51A Seal Rotating Face 1 62C Seal Face Washer 1
51C Seal Rotating Face 1 64 C Seal Retaining Ring 1
51D Seal Rotating Face (Gearbox) 1 65C Coil Spring Set 1
69C O-Ring Packing 1
60A Mechanical Seal (Lower) 1
61A Retainer & Drive Sleeve Assembly 1 158C Shim spacer 1
62A Seal Face Washer 1 905E Hex Head Cap Screw 3
64A Seal Retaining Ring 1 905F Hex Head Cap Screw 3
65A Coil Spring Set 1 905L Hex Head Cap Screw 3
68A Backing Ring 2 916A Washer 3
69A O-Ring Packing 1 916B Washer 3
916K Washer 3
60B Mechanical Seal (Upper) 1 936G O-Ring Packing 2
61B Retainer & Drive Sleeve Assembly 1 936H O-Ring Packing 2
62B Seal Face Washer 1 936J O-Ring Packing 3
64B Seal Retaining Ring 1 936K O-Ring Packing 1
65B Coil Spring Set 1 936P O-Ring Packing 1
68B Backing Ring 2
69B O-Ring Packing 1

Figure 6. TANDEM SEAL ARRANGEMENT

58
Reference D
Compressor/Gearbox

Figure 7

59
Figure 8. Compressor Exploded View

60
Figure 9. 200 HP Gearbox Exploded View

61
 Item Item
No. Part Name Qty. No. Part Name Qty.
116 Coupling 1 914G Hex Nut 4
117 Input Coupling 1 914H Hex Nut 4
118 Coupling Housing 1 916E Washer 4
119 Hub 1 916M Washer 4
904A Screw 4 916N Washer 4
905J Hex Head Cap Screw 4 916P Washer 4
905R Hex Head Cap Screw 4 916R Washer 4
909D Hex Head Bolt 4 916AC Washer 4
914D Hex Nut 4 920E Key 4

Figure 10. Flexible Coupling

Item
No. Part Name Qty.
106 Chemical Barrier Gasket 1
107 Seal Spacer 1
905T Hex Head Cap Screw 3
916V Seal Washer 3
See Pages 56 and 57 for Recommended Spare
Parts.

Figure 11. Chemical Barrier Gasket

62
Figure 12. Flexitalic Gasket

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