Heh... funny you should ask...
For my return pump (Dart) I actually have a 2" bulkhead into my sump with a 90 degree corner on it ( to make it able to still work when the sump level gets low). The output is a manifold kinda thing that goes to a 1" line up to my return, and to my chiller (which returns to the sump). And that is the reason that I mentioned the head calculator in my message above, that 1" line really puts up some back pressure, and thus reduces the flow (I had a snapper, and upgraded to the dart impeller). And the actual lift back up to the tank is about 4'. Works great for me, and I actually have it throttled back a little bit just because my overflows are a little to high in the tank for that kind of return flow.
My closed loop is really the problem. It is 1" line run from the tank, and back to the tank. It was a retrofit from an earlier pump. It really restricts that Dart a LOT. I just adapted the 1" up to a 2" with a 2" corner. One of these days I will rip the tank apart (at least partially and replace that 1" plumbing I did. If I had it to do again, I would at least use 1 1/2" plumbing on the intake. It's under the tank so it gets a little tight. But the pump doesn't seem to be too angry with the setup, it just doesn't flow like it could..
Of course the tank is a perpetual project right... I have been thinking about replumbing the entire system one of these days. I just have to bring myself to move some of the rock so that I can plug the return of the closed loop system (which returns to the bottom of the tank).. Crazy idea, but I didn't make the tank, and it was that way when I bought it. The nice thing is it is all self contained in the stand...
If you want a picture, I can see what I can do.. It is jam packed with stuff
Jack