I use a 50g tall under my 135g at about 1000gph currently, but it will eventually be about 1400gph when I install my new pump...
Here is a few pictures for ya.
BTW this is on a fresh/semi brackish aquarium...
i love your set up! im thinking of copying this design - with a couple of minor changes - and making a spare 10 gallon i have into a sump for my 29 gallon. would you mind posting pics of your overflow, or atleast telling me what kind you use? iv never used a sump before and im a little scared i might do it wrong and have it overflow everywhere.
The size of the sump is practically meaningless in regards to how much flow it can handle through it. The physical properties of the drainage side of the system, ie diameter of pipe, bends, valves etc are what determines the max amount of water that can move through the system. Size does matter greatly in regards to evaporation and handling back siphoning, but even these issues can be overcome with things like an auto top-off system and a bit of planning in the design of the plumbing. To set the proper safe running level fill the tank until water goes down the overflow into the sump. Let the sump fill until the water is a couple of inches from overflowing and then turn on the pump. The water level in the sump will drop. When it's stable draw a line at the water level. That is the maximum level for water in the sump with the pump running. As long as you take care to prevent back-siphoning through the return plumbing as previously mentioned it won't overflow if the power goes out.For saltwater tanks, generally speaking, should be 1/3 of the display tank. Freshwater doesn't matter as much. For freshwater I have used them as small as 10% to the current size of 35%.
Since you have posted this in the FW section, I am assuming that is it's application. You want it large enough you aren't having to top off daily (there are ways around that), as well as large enough for filtration of the water. If it can handle water volume of 5x the main tank size it should work, (ex: Display tank of 100gallons=500gph flow) most commercial ones only handle 300-600 gph on average but can goes as high as 1200.
Ya no problem. The overflow is an Eshopps PF-1800 rated at 1600gph. It does not flow what it is rated at, but I suspect this is only an issue on this model, being the largest model they sell and has had some noise on the Internet about issues with this model in particular.
As far as making it safe where no overflowing problems will occur, just follow instructions and it's pretty much idiot proof. Also keep in mind the overflow is not the only thing that will siphon. The return plumbing will also syphon back to the sump if the power cuts out, so either have a tall enuff sump to handle the volume(like I did) or put a syphon break on the return plumbing above the water line.
I'm terrible at linking videos, but here is a few YouTube videos of it running...
http://www.youtube.com/watch?v=Mf4qix8kgTU
http://www.youtube.com/watch?v=_vuZkQSdfAE