Field Engineering Bulletin

Bulletin No. 40.20.26

Phoenix 2 Gearbox Upgrade

EFFECTIVE : APRIL 6, 2004 Rev: ORIG
Page 1 of 4

SCOPE
Field experience with the Phoenix gearbox has indicated some instances where the gear life has not met Sundyne’s
expected standard. To address this, the upgraded design changes the upper gear mesh from spur to helical type
gears. In addition, the input bearings were changed to spherical roller type bearings and the lower idler thrust bearing
changed from a thrust washer to a taper land thrust bearing. The lower gearbox housing casting has also been
permanently modified to provide additional clearance to seal housing bolting.

SUMMARY OF CHANGES
• 16 pitch helical input gears replaced 16 pitch input spur gears.
• Cylindrical roller bearings changed to spherical roller type input bearings with minimum 5 year service life.
• Lower idler thrust bearing changed from flat to taper-land type.
• Input bearing lubrication change: lube jet lubrication has been replaced with circulating oil lubrication by
supplying oil through annular groove and lubricating holes.
• Augmented by 50% oil flow to upper and lower idler bearing. Relocated oil supply path to upper idler.
• Casting material heat treat change for both gearbox housings and bearing plate resulted in 20% higher yield and
tensile strength.
• The lower housing was modified to allow use with 7/8” studs and nuts as well as 4” x 6” and 6” x 8” cases,
facilitating unit assembly
• Filter boss was modified to accommodate a vertically mounted filter with typical Sundyne filter manifold:
increased oil passages through filter manifold from ½” to ¾” for increased flow rate.
• Lube pump saddle o-ring changed to ease assembly and minimize possibility of cutting o-ring during assembly.
Increased wall thickness to (.165”) in lube pump discharge cavity (50 Hz type).
• Sump tube fittings were simplified, and tube arrangements were developed for vertical and horizontal
configurations. Sump tube diameter increased from 7/8” to 1”.
• A KMC deflection pad thrust bearing was adopted for high suction pressure applications with allowable thrust up
to 3500 lbf. This is available in addition to the previously available plain thrust and taper-land thrust washers.
• The high speed shaft and thrust runners were redesigned to accommodate high thrust and standard thrust
bearing options. Increased size of shaft shoulders for thrust runners.
• Changed the output seal carbon material from RA to RZ metal filled carbon
• Changed the diameter of the output seal mating ring to more closely match seal diameter and eliminated the
band for RE tungsten carbide mating rings. Changed mating rings to incorporate matte finish.

14845 West 64th Avenue, Arvada, Colorado 80007 USA • Tel: 303-425-0800 • Fax: 303-425-0896 • www.sundyne.com
Title: Phoenix 2 Gearbox Upgrade Rev Orig
Bulletin No. 40.20.26 Page 2 of 4

• Developed modified gearbox with speed ratios and high down thrust capability to accommodate High-Flow
pumps.
• Changed standard lube pump to 10.8 gpm / 40.1 lpm (PU04AW03B) for 60 Hz units and 12.5 gpm / 47.3 lpm
(PU04AW01B) for 50 Hz units. For 60 Hz units with the high capacity KMC thrust bearing the 15 gpm / 56.8 lpm
pump (PU04AW01B) is required.
• Increased relief valve cracking pressure to 100 psi and maximum flow capability to 15 gpm /56.8 lpm.
• “Mistake Proofed” upper and lower high speed bearings to avoid misassembly in incorrect locations.
• “Mistake Proofed” taper land thrust washer and bearing to prevent mis-assembly in standard thrust washer
bearing.
• Simplified the input seal anti-rotation mechanism from two pins to a ‘flat foot’ device.
• Gearbox mounted oil filter capacity increased to 15 gpm / 56.8 lpm.
• Recommend operation with ISO-46 oil for extended bearing life and high ambient temperature applications.

BENEFITS OF THE MODIFICATIONS

The benefits of the change to Helical gears are that helical gears are less susceptible to the effects of misalignment,
multiple teeth share the load at any given moment, and a higher gear power rating is possible with Helical gears of a
given width. Noise levels are also typically lower with Helical gears.
The change to the lower gearbox housing provides better accessibility to seal housing bolting and the phoenix gearbox
can now be used with 7/8” studs and nuts as well as the High-Flow pump case and 343/347 compressor cases.

APPLICABILITY OF CHANGES
After Jan 1, 2003 exchange gearboxes for Phoenix field units will be available in the new configuration. Highly loaded
units returned for Overhaul & Repair will also be provided in the new configuration. All lower gearbox housings as of
this date will be to the new configuration.
Title: Phoenix 2 Gearbox Upgrade Rev Orig
Bulletin No. 40.20.26 Page 3 of 4

PERFORMANCE CHANGES

The change to Helical gears inherently results in a change to the overall gearbox speed ratio. Since the speed
changes resulting from the modification are typically less than 1.5 %, impacts to performance and NPSH are minimal
and it is expected that no process end hardware changes will be necessary. The table below provides a comparison of
the old and new gear ratios and speeds for reference. If the customer believes that this change would cause them an
operating problem the matter should be brought to the attention of Field Service for resolution.

GEAR RATIO 60 HZ * OUTPUT RPM 50 HZ ** OUTPUT RPM

APPLICABILITY
OLD NEW
OLD NEW OLD NEW
SPUR HELICAL
GEAR GEAR

Pump & Compressor 2.7932 2.8201 9916 10011 N/A N/A

Pump & Compressor 3.1695 3.2164 11252 11418 N/A N/A

Pump & Compressor 3.3288 3.3609 11817 11931 9853 9948

Pump & Compressor 3.7774 3.8333 13410 13608 11181 11346

Pump & Compressor 4.1663 4.1219 14790 14633 12332 12201

Pump & Compressor 4.5404 4.6076 16119 16357 13440 13639

Pump & Compressor 4.8706 4.9175 17291 17457 14417 14556

Pump & Compressor 5.1847 5.1080 18406 18133 15347 15120

Pump & Compressor 5.6067 5.5471 19904 19692 16596 16419

Pump & Compressor 6.0379 6.0960 21435 21641 17872 18044

Pump & Compressor 6.4274 6.5054 22817 23094 19025 19256

Compressor 6.7927 6.9528 24114 24683 20106 20580

Pump 6.9420 6.9528 24644 24683 20548 20580

Pump 7.4000 7.5095 N/A N/A 21904 22228

Compressor 7.7859 7.7079 27640 27363 23046 22815

Pump 7.8237 7.7079 N/A N/A 23158 22815

Pump 8.4501 8.3250 N/A N/A 25012 24642

Compressor 8.4501 8.3250 29998 29554 25012 24642

Compressor 9.0887 8.9402 32265 31738 26903 26463

Compressor 9.7273 9.6237 34532 34164 28793 28486

Compressor 10.6763 10.5399 N/A N/A 31602 31198

Compressor 11.4679 11.3458 N/A N/A 33945 33584

* Based on 3550 input rpm

** Based on 2960 input rpm
Title: Phoenix 2 Gearbox Upgrade Rev Orig
Bulletin No. 40.20.26 Page 4 of 4

PIPING INTERFACE CHANGES

The lube oil piping interface to the gearbox has changed. As an aid to make the required piping adjustments, the
sketches below show the lube oil connection locations for old and new Phoenix designs. Typical sketches are shown
for units with gearbox mounted and remote filters. The routing of the piping may differ from what is shown below
depending on the scope and location of auxiliary equipment, however the connections at the gearbox will be as shown
on these drawings. All connections are ¾” NPT.

Old Design: Old Design:

Units with Gearbox Mounted Filter Units with Remote Filter

NEW DESIGN NEW DESIGN

Units with Gearbox Mounted Filter Units with Remote Filter