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DDP096
Service guide
18 pgs6.52 Mb0
Data sheet
4 pgs1.92 Mb0
User guide
62 pgs10.57 Mb0
Service guide
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Data sheet
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Danfoss DDP096, DPC12 User guide

Technical Information
Digital Displacement® Pump Gen 1
DDP096 and DPC12
www.danfoss.com
Technical Information
Revision history Table of revisions
Date Changed Rev
June 2021 Added new Gen 1 content; recreated document structure 0201
December 2019 Revised to reflect 420 bar limit and updated software features 0102
October 2019 First edition: 280 bar, industrial 0101
2 | © Danfoss | June 2021 BC306384089197en-000201
Technical Information

Contents

General information
Overview..............................................................................................................................................................................................5
About the DDP.................................................................................................................................................................................. 5
Theory of operation.........................................................................................................................................................................5
Multi-outlet pump...................................................................................................................................................................... 6
Features and benefits..................................................................................................................................................................... 8
General safety warnings.................................................................................................................................................................8
Fluid under high pressure........................................................................................................................................................8
OEM responsibility......................................................................................................................................................................8
Pressure relief............................................................................................................................................................................... 9
Failure and fault states..............................................................................................................................................................9
Intended use.................................................................................................................................................................................9
Improper use.................................................................................................................................................................................9
Personnel qualifications.........................................................................................................................................................10
Technical specifications
DDP096 pump specifications.................................................................................................................................................... 11
DDP general specifications................................................................................................................................................... 11
DDP fluid specifications......................................................................................................................................................... 11
DDP mechanical specifications........................................................................................................................................... 12
DPC12 controller specifications................................................................................................................................................13
DPC12 input power supply...................................................................................................................................................13
Separate coil and logic power supplies...................................................................................................................... 13
Wiring and fuses.................................................................................................................................................................. 14
Pressure sensors for DPC12............................................................................................................................................. 14
Non-volatile memory write/erase ratings........................................................................................................................14
General ratings.......................................................................................................................................................................... 14
Environmental standards and criteria...............................................................................................................................15
LED messages............................................................................................................................................................................ 16
DPC12 housing..........................................................................................................................................................................16
DDP characteristics
Performance.....................................................................................................................................................................................17
Overall pump efficiency......................................................................................................................................................... 17
Idle losses.....................................................................................................................................................................................17
Pump discharged flow and shrinkage.............................................................................................................................. 18
Input torque................................................................................................................................................................................19
Electronic control losses.........................................................................................................................................................20
Noise characteristics..................................................................................................................................................................... 20
Control operation
Control modes, limits, and features........................................................................................................................................ 21
Control modes and sources..................................................................................................................................................21
Limits.............................................................................................................................................................................................21
Other features............................................................................................................................................................................22
Control diagrams......................................................................................................................................................................23
Example use cases....................................................................................................................................................................25
Controller interaction...................................................................................................................................................................25
Overview......................................................................................................................................................................................25
PLUS+1® CAN/USB gateway..................................................................................................................................................25
Configuration and tuning......................................................................................................................................................25
Commissioning mode.............................................................................................................................................................26
Diagnostics and errors............................................................................................................................................................26
Model code
DDP model code............................................................................................................................................................................ 27
DDP part options............................................................................................................................................................................28
Mechanical installation
Pump transport and handling...................................................................................................................................................30
Storage...............................................................................................................................................................................................31
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Technical Information
Contents
Installation requirements............................................................................................................................................................31
Pump arrangement..................................................................................................................................................................31
Pump shaft coupling...............................................................................................................................................................31
Understanding and minimizing system noise............................................................................................................... 31
Air removal..................................................................................................................................................................................32
Removing air with gravity................................................................................................................................................32
Removing air with an auxiliary pump..........................................................................................................................33
Removing air through the DDP outlet port...............................................................................................................33
Removing air by submersion.......................................................................................................................................... 34
Flushing........................................................................................................................................................................................34
Filtration.......................................................................................................................................................................................34
Controller mounting................................................................................................................................................................35
Pump dimensions..........................................................................................................................................................................36
Common dimensions..............................................................................................................................................................36
Shaft end view dimensions..............................................................................................................................................37
Side view dimensions........................................................................................................................................................ 38
Top view dimensions.........................................................................................................................................................39
Rear view dimensions........................................................................................................................................................40
Single-outlet pump dimensions......................................................................................................................................... 41
Multi-outlet pump dimensions............................................................................................................................................43
Multi-outlet pump side view dimensions.................................................................................................................. 44
Multi-outlet pump rear view dimensions...................................................................................................................45
Controller dimensions..................................................................................................................................................................46
Electrical installation
Installation requirements............................................................................................................................................................47
Wiring overview........................................................................................................................................................................ 47
Machine wiring guidelines....................................................................................................................................................47
Machine welding guidelines................................................................................................................................................ 48
CAN bus installation................................................................................................................................................................ 48
System diagnostic connector...............................................................................................................................................49
Fuses..............................................................................................................................................................................................49
Grounding...................................................................................................................................................................................49
Hot plugging..............................................................................................................................................................................49
Connectors....................................................................................................................................................................................... 50
Pump connectors..................................................................................................................................................................... 51
Controller connectors............................................................................................................................................................. 54
Commissioning and troubleshooting
Basic commissioning procedure.............................................................................................................................................. 59
Commissioning and troubleshooting with PLUS+1 Service Tool................................................................................ 59
Initial procedure........................................................................................................................................................................59
Commissioning DDP valves and hydraulic installation.............................................................................................. 59
Further system commissioning and validation............................................................................................................. 60
Symptoms and diagnosis............................................................................................................................................................61
Serviceability....................................................................................................................................................................................61
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Technical Information

General information

Overview

This document contains important information about the safe operation and control of the open circuit hydraulic Digital Displacement® Pump (DDP096) and its partnered electronic controller (DPC12). Throughout this document the complete partnered product will be referred to as the Digital Displacement® Pump or DDP.
Guidance is given on the transportation, commissioning and operation of the pump. For disposal please contact Danfoss.
All safety guidance provided in this document must be followed. Relevant residual risks and control measures are outlined.
This document is not a substitute for appropriate professional training and competency dealing with hydraulic circuits. Only competent persons should install, operate or maintain the pump and controller.

About the DDP

Digital displacement is a new hydraulic pump technology based on a radial piston pump design. An electronic controller selectively enables each piston by actuating a corresponding on/off valve. In this way, the pump displacement is digitally variable resulting in fast and accurate flow control. Digital Displacement® Pumps have high efficiency and very low idle losses because they use only as many pistons as are needed to meet the demand.

Theory of operation

Check valves connect each of the pump’s piston chambers to the inlet and outlet, as shown below.
The outlet check valve is passive. The inlet check valve is actively controlled and is normally open and can be closed by energizing a solenoid coil. As the pump’s input shaft rotates, it turns an eccentric cam which pushes the piston up and down in the piston chamber. The controller determines whether or not the piston will pump fluid to the outlet. If the piston is idling, the inlet check valve is not energized and the inlet check valve remains in the open position. The fluid displaced by the piston moves freely back and forth from the inlet. No fluid is discharged to the outlet.
To pump each piston, the controller closes the solenoid valve when the piston is at bottom dead center. The inlet check valve closes and the piston forces the fluid through the outlet check valve. When the
A Inlet B Inlet check valve C Outlet check valve D Outlet E Piston F Cam G Shaft rotation
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Technical Information
General information
piston reaches top dead center, the inlet check valve reopens and fluid is drawn from the inlet into the piston chamber as the piston moves out to begin another cycle.
The DDP has 12 pistons which each displaces 8cc of fluid per stroke for a total displacement volume of 96 cc/rev. The pump geometry is designed so that the pistons are evenly spaced 30° apart. Every piston is enabled at full displacement (displacement fraction Fd = 1), and every piston is disabled at Fd = 0. For 0 < Fd < 1, the controller uses a sequence of enabled and disabled pistons which are represented by ones and zeros respectively in the following table of examples.
Displacement Fraction Piston Sequence Sequence Length
0.5 01… 2
0.25 0001… 4 7/12 = 0.583 010101101011… 12 19/24 = 0.792 111101111011 110111101110… 24
The desired displacement fraction is achieved as an average over time. Some displacement fractions can be achieved with short sequences like 01… or 001… Other displacement fractions are achieved with longer sequences. For example, Fd = 0.792 = 19/24 has 10 active pistons during the first revolution and 9 active pistons during the second revolution. Fd = 0.51 requires a repeating sequence of length 100 with 51 ones and 49 zeros. Any value of Fd can be achieved with a sufficiently long binary sequence.
The controller does not use fixed or pre-programmed sequences of on and off pistons. At every 30 degrees of shaft rotation, the controller determines whether to enable the next piston based on the current Fd command and the history of pistons enabled. In the preceding table, the commanded displacement is constant, so the piston sequence is periodic. The same pistons are not necessarily enabled or disabled, but can change with each shaft rotation.
The DDP can operate in various control modes including pressure control, load sensing, flow control, displacement control, torque or power control and combinations of these. The control modes are monitored by the DPC12 pump controller based on sensor inputs and configured with parameters and limits at a software level. For instance, to regulate the pump pressure in pressure control mode, the controller compares the measured pressure to the desired pressure and calculates a displacement command with a proportional-integral control algorithm.

Multi-outlet pump

The DDP096 is composed of 12 pistons and valves (i.e. 12 pumping units). These pumping units are divided into four groups called pumplets. The DDP can be perceived as a combination of four independent pumplets producing each up to 24cc/rev, given its unique radial design and digital control.
The DDP096 is available either as a single-outlet endcap or a multi-outlet endcap. The single-outlet DDP has one inlet and one outlet like other conventional hydraulic pumps. However, the multi-outlet DDP leverages the four pumplets to offer multiple outputs from a single pump with independent flows, pressures, and control modes.
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2 services 2 services
Ganging
manifold
48-24-24 cc/rev
endplate
Pumplets
48 cc/rev
48 cc/rev
P1 P2
P4
24 cc/rev
24 cc/rev24 cc/rev
24 cc/rev
1
2 3
4
72 cc/rev
24 cc/rev
P1 P2
P4
24 cc/rev
24 cc/rev 24 cc/rev
24 cc/rev
1
2 3
4
Technical Information
General information
Three-outlet DDP096 exploded view
The current multi-outlet endcap provides three outlets to the DDP:
•
2 outlets producing up to 24 cc/rev each
•
1 outlet producing up to 48 cc/rev
With this multi-outlet endcap, different displacements are achievable with a ganging manifold to suit an application using two services. A service is one level higher than the pump outlet and represents the number of fluid consumers of the DDP. A service is essential to control the DDP096 with the DPC12.
Services diagram
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Currently, only 2-service operation (Service 1 and Service 2) is available. There are two settings possible for 2-service operation:
Technical Information
General information
•
P1 / (P2 + P4) [48 / 48 cc/rev]
•
(P1 + P2) / P4 [72 / 24 cc/rev]
P1, P2, and P4 represent the outlet ports of the multi-outlet DDP096 endcap. (P2+P4) means that the P2 and P4 ports must be connected with a ganging manifold. Refer to Pump dimensions for more information on ports.
Service 1 (S1) and Service 2 (S2) must be selected at the software level and configured accordingly. Refer to Software manual for more information.

Features and benefits

Features and benefits of the DDP are as follows.
•
High efficiency radial piston pump with exceptional part-load performance
•
Low idle losses even when pressurized
•
Near-silent operation for pressure-holding applications
•
Fast response, low displacement hysteresis
•
CAN bus interface with performance and diagnostic information, sensored outputs, tunable parameters, PLUS+1® Compliant
•
Virtually no leakage at zero flow output
•
Zero to full displacement (or the reverse) in half a revolution
•
Options for multiple independent outlets from a single pump, through-shaft capability and auxiliary mounting
*

General safety warnings

The DDP has been manufactured according to the generally accepted rules of hydraulic machine design and uses the latest advanced valve concepts to maximize operating efficiency and user controllability.

Fluid under high pressure

Escaping hydraulic fluid under pressure can have sufficient force to penetrate skin causing serious injury and/or infection. Additionally, the fluid may cause burns. Use caution when dealing with hydraulic fluid under pressure. Always relieve pressure in the system before removing hoses, fittings, gauges, or other components. Never use hands or any other body parts to check for leaks in a pressurized component; seek medical attention immediately if you are cut by hydraulic fluid.

OEM responsibility

The OEM of a machine or vehicle in which Danfoss products are installed has the full responsibility for all consequences that might occur. Danfoss has no responsibility for any consequences, direct or indirect, caused by failures or malfunctions.
*
Half a revolution plus 8.5 ms for communication and processing time. For example, at 1800 rpm, processing time is 16.2 ms + 8.5 ms = 24.7 ms.
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W
Technical Information
General information
•
Danfoss has no responsibility for any accidents caused by incorrectly mounted or maintained equipment.
•
Danfoss does not assume any responsibility for Danfoss products being incorrectly applied or the system being programmed in a manner that jeopardizes safety.
•
All safety critical systems shall include an emergency stop to switch off the main supply voltage for the outputs of the electronic control system. All safety critical components shall be installed in such a way that the main supply voltage can be switched off at any time. The emergency stop must be easily accessible to the operator.
•
The hydraulic system must also be designed to withstand an emergency shutdown where hydraulic flow will stop, and pressure may drop significantly.
Warning
There is the potential to cause personal injury or damage to equipment if the following instructions and warning are not followed.
•
Please read these instructions thoroughly before commissioning the pump.
•
Keep these instructions in an accessible location and always pass them on to the end user of the pump.
•
Consult with Danfoss if there are any questions about the intended use of the pump or safety implications from operating the pump.
•
Operating conditions and technical data given in the data sheet must be followed at all times.

Pressure relief

The pump is not supplied with any mechanical pressure limiting device as standard. Pressure transducers present on the pump are for pressure compensation and can not substitute as a safety device. A pressure relief valve rated for full flow in the hydraulic circuit is important in protecting the product and personnel. The OEM is responsible for designing the system to mitigate potential unsafe situations, such as providing adequate pressure relief.

Failure and fault states

If electrical power to the DPC12 controller is lost, the DDP096 pump will output zero flow. Some software faults also cause the DDP096 to stop providing flow. If zero output flow is an undesirable failure/fault mode in the application, means of providing backup flow must be designed into the system.

Intended use

Digital Displacement® pumps are components in terms of the EU machinery directive 98/37/EC. Hydraulic pumps are not ready to use machines as described in the EU machine directive. Digital Displacement pumps are produced with the sole intention of being incorporated within a machine or further assembly to form a machine or system. The product may only be fully commissioned after it has been installed in the machine or system for which it is intended.
The Digital Displacement® pump produces and controls the flow of hydraulic fluid most commonly with the function of regulating the output pressure. It is assumed that a flow control device, such as a closed center proportional valve, is present in the system between the pump and the controlled load. Other applications may be acceptable but should be discussed with Danfoss first.
®

Improper use

Warning
Digital Displacement® pumps may not be used in explosive environments. Digital Displacement® pumps may not be used in life critical applications.
Please contact Danfoss for further information on use in specific applications.
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Technical Information
General information

Personnel qualifications

The system operates with high pressure fluid. Assembly and disassembly of the pump for maintenance purposes is only to be carried out by Danfoss or a qualified service technician authorized by Danfoss.
Installation of the pump and electrical equipment must be carried out by suitably qualified personnel with experience and knowledge of working with hydraulic and electrical systems.
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Technical Information

Technical specifications

DDP096 pump specifications

DDP general specifications

The below table contains information for displacement, pressure, torque, and temperature.
Description Value Units
Maximum displacement 96 [5.86] cm3/rev [in3/rev] Available rotation (viewed from shaft end of the pump) Clockwise (CW) [R] Outlet pressure Maximum peak 450 [6530] bar [psi]
Maximum continuous 420 [6090] Minimum continuous 20 [290] Minimum intermittent11 [15]
Inlet pressure (absolute)
Input speed Minimum 1450 min-1 (rpm)
Maximum power 45 [60] kW [hp] Flow at rated speed and maximum displacement (theoretical)
Torque at full displacement, 1500 rpm & ∆p=400 bar Mass Single outlet 51.6 [114] kg [lb]
Approximate filling capacity 2.3 [0.61] L [US gal] Mass moment of inertia of internal rotating components (single pump without through shaft) 0.001037 [0.00076] kg·m2 [slug·ft2] Ambient temperature Minimum 0 [32] °C [°F]
1
Performance degradation expected.
2
Size hoses or piping appropriately to ensure the minimum pressure condition is satisfied.
3
For more information, refer to Input torque on page 19.
2
3
Minimum 0.8 [12] bar [psi] Maximum 3.5 [50]
Maximum 1850
144 [38] @1500 rpm 173 [45.6] @1800 rpm
600 [5310] N·m [lbf·in]
Multi outlet 53.9 [119]
Maximum 70 [158]
L/min [US gal/min]
Maximum power and speed specifications represent the current qualification. Wider speed operation and/or higher power limit may be possible. Check with your Danfoss representative.

DDP fluid specifications

Description Value Units
Viscosity Minimum continuous 10 cSt
Recommended range 16 - 40 Maximum for cold start 1000
Temperature Minimum for cold start 0 [32] °C [°F]
Maximum continuous 60 [140] Maximum intermittent 70 [158]
Cleanliness per ISO4406:1999 Recommended 17/15/12
Minimum 18/16/13
Viscosity and temperature specifications represent the current qualification. Wider temperature and/or viscosity operation may be possible. Check with your Danfoss representative.
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Technical specifications

DDP mechanical specifications

Description Value Notes
Front mounting flange SAE C 4-bolt Flange 127-4 adhering to ISO 3019-1 (SAE
Front input shaft 23 tooth 16/32 pitch Spline per ANSI B92.1b-1996 class 6e Inlet/Suction port S DN 51 (Ø 51 mm) Shipped with steel cover. For more information, Outlet/Pressure port(s) Single outlet P DN 25 (Ø 25 mm)
Multi outlet P1 DN 19 (Ø 19 mm)
P2 DN 13 (Ø 13 mm)
P4 DN 13 (Ø 13 mm) Bleed port plugs M14 x 1.5 per ISO 6149-1 Steel plugs Lifting brackets Two brackets on endcap bolts, and another
Pump wiring harness connectors
Sensors included in DDP
aligned with outlet port(s)
DTM04-12PC (green) – C3
DTM04-12PA (grey) – C4
DTM04-12PB (green) – C5
1 speed and temperature sensor
1 (to 3) pressure sensor(s)
J744:1996)
see pump dimensions.
Only intended for lifting pump and Danfoss supplied sensors/wiring
C3 is for the sensor harness C4 is for the coil harness “A” C5 is for the coil harness “B”
The DDP has a pressure sensor (0-600 bar) on each service.
Substituting the factory supplied speed/temperature or pressure sensors will void the warranty. Only replace sensors with genuine Danfoss replacements parts. Contact your Danfoss representative for more details.
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Technical Information
Technical specifications

DPC12 controller specifications

DPC12 input power supply

Description Minimum Typical Maximum Unit Notes
Supply voltage 21.6 24 26.4 VDC For both coil and logic power
Cranking voltage 6 VDC Minimum voltage before the logic
Voltage disabling coil outputs
DPC12 power-on time 1.5 s Time from power-on to completing
Supply voltage range represents the current qualification. Wider supply voltage range may be possible. Check with your Danfoss representative.
Coil power consumption
Description Typical Unit
Approximate coil power vs theoretical flow, full displacement
Full displacement @ 1500 rpm
Full displacement @ 1800 rpm
*
Tests performed at full displacement Fd=1 (most power consuming condition); 24 VDC power supply; 34 mΩ for each pump-to-controller coil cable @ 20°C (2 meter cable with a 1 mm2 CSA). Refer to Wiring and fuses on page 14 for recommendations.
*
*
*
9 VDC Minimum voltage before coil outputs
supplies
resets
turn off
address claim procedure, ready to pump
51 mA/(L/min)
1.2 W/(L/min)
8.0 A 192 W
8.8 A 211 W
Power consumption values are reported as mean values. The DPC12 draws a variable pulsed load from the coil power supply, so the power supply must be able to handle higher peak currents. If operating from a switch-mode converter, consult Danfoss on recommended parts.
Logic power consumption
Description Typical Maximum Unit
Logic power consumption (with 24 VDC
power supply)
100 220 mA 2 5 W
The maximum logic power consumption is with 6 pressure sensors (4-20 mA).
Separate coil and logic power supplies
The controller coil and logic supply inputs (i.e. power) are internally separated, while the supply returns (i.e. ground) are internally connected (see Grounding on page 49). This means that supply inputs and returns must be supplied to both to produce flow. The separation allows the coil circuitry to be de­energized while the logic remains powered, thus providing communication with the controller while the coils can no longer cause pumping. Any switching device used must be on the supply inputs. The coil and logic supply returns must always be connected to system ground and all supply return pins must be used in order to provide the appropriate current sinking. Due to higher power requirements of the coil circuitry compared to the logic circuitry, different gauges of wire may be needed.
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Technical Information
Technical specifications
Wiring and fuses
Description Value Unit Notes
Pump-to-controller coil cable resistance 25 - 55 @ 20 °C mΩ One-way resistance of pump-to-controller cable (from pump
Coil supply fuse requirements (24V system)
Logic supply fuse recommendations 3 Fuse recommended for system protection. Fuse not required for
30 A Use fast acting fuses of I2t ≤ 3500 A2s. A fused coil power supply
connector C4/C5 to controller connector C4/C5, excluding pins and crimps). Any additional connections between the pump connector and controller connector should be included in the resistance calculation. Contact your Danfoss representative if your application requires pump-to-controller cables that cannot satisfy this rule.
is essential to protect the DPC12 against reverse polarity conditions. Without a fuse, the DPC12 can be damaged. Multiple or sustained reverse polarity events can also damage the DPC12.
reverse polarity protection.
Warning
When powering the DPC12 from a current limited power supply, use special consideration to ensure power supply has enough margin to blow the chosen fuse. For example, pairing a 40A fuse with a current limited power supply of 40A is potentially dangerous. The fuse current must be exceeded by a large margin to guarantee the fuse blows before hardware damage.
Pressure sensors for DPC12
While the DDP096 pump is already equipped with pressure sensor(s), additional pressure sensor(s) may be required for load sensing operation. The DPC12 is only compatible with 4-20 mA pressure sensors. The controller supplies a minimum supply voltage of 12V to pressure sensors. The receiver has a maximum load resistance of 160 Ω. A 4-20 mA sensor that accepts a minimum supply voltage of 8V or less is recommended. Contact your Danfoss representative for recommended pressure sensors.

Non-volatile memory write/erase ratings

Description Value Unit
EEPROM write/erase cycles
*
Minimum valid cycles over entire operating temperature range
*
4 x 10
6

General ratings

Environmental
Description Minimum Maximum Unit
Ambient operating temperature -40 [-40] 70 [158] °C [°F] Electronics temperature shut down Storage temperature -55 [-67] 85 [185] °C [°F] Humidity 80 % Ingress Protection (IP) ratings
1
Internal electronics temperature monitoring will error in extreme temperatures.
2
Documented IP ratings are valid only when the mating connectors are in place and unused connector pin positions
have sealing plugs installed.
1
2
-40 [-40] 105 [221] °C [°F]
IP69K
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Technical Information
Technical specifications
Product compliance
Description EU Directive
CE rating -
EMC 2014/30/EU
RoHS 2011/65/EU
REACH (EC) No 1907/2006
CAN port
Description Value Unit
Available baud rates 125 kbps
*
Default value; see the DPC12 software manual for more information.

Environmental standards and criteria

250 500 1000
*
Climate environmental standards
Description Applicable standard
Storage operating IEC 60068-2-1, test Ab
Operating temperature IEC 60068-2-1, test Ab
Thermal cycle IEC 60068-2-2, test Na
Humidity IEC 60068-2-78,
Solar radiation (UV exposure) ASTM G154
Degree of protection (IP) IEC 60529
IEC 60068-2-2 test Bb
IEC 60068-2-2, test Bd
IEC 60068-2-38 (partial)
IEC 60068-2-30, test Db
Chemical standards
Criteria Applicable standard
Ice water shock ISO 16750-4
Chemical resistance ISO 16750-5
Mechanical and electrical connection standards
Criteria Applicable standard
Random vibration (Level 2)
Bump IEC 60068-2-29, test Eb
Shock IEC 60068-2-27, test Ea
Free fall IEC 60068-2-32, test Ed
Wire force IEC 60730-1 section 11.7
IEC 60068-2-6, test Fc IEC 6008-2-64, test Fh
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Technical Information
Technical specifications
Electrical and electromagnetic standards
Criteria Applicable standard Additional information
EMC emissions ISO 13766 Electromagnetic compatibility for earth moving
EMC immunity ISO 13766 Electromagnetic compatibility for earth moving
Electrostatic discharge
Auto electrical transients
For more information about criteria and standards please contact your Danfoss representative.

LED messages

LED characteristics meaning
Characteristic LED Indication
Magenta; blink rate 1.5 Hz Device is in BOOT-LOADER mode
EN 61000-4-2 SAE J1113-13
ISO 7637-2 ISO 7637-3
machinery
machinery Electrostatic discharge immunity test
Road vehicles — Electrical disturbances from conduction and coupling
Blue; fast irregular blinking Device is downloading application software
Yellow; blink rate 1.5 Hz Device is in COMMISSIONING mode
Yellow; continuous Device is either waiting for DM13 message to enable the
Green; continuous Device is in ACTIVE state
Red; continuous Device is in ERROR or ERROR_HOLD state
Red; blinking J1939 address claim fault
Alternating red/green Device is in LIMP mode and there is no severe error
pump, in INIT state directly after power up, or in DISABLED state
Refer to the DPC12 Software manual for details on operation modes.

DPC12 housing

The DPC12 housing features a snap together assembly. The controller weighs 2.8 kg [6.2 lbs]. Once assembled at the factory, the housing cannot be opened for service.
The DPC12 controller is not field serviceable. Opening the DPC12 housing voids the factory warranty.
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Technical Information

DDP characteristics

Performance

Overall pump efficiency

The overall pump efficiency is the ratio of the hydraulic output power to the mechanical input power.
Inlet pressure 1.0 bar abs – inlet temperature 49°C with ISO VG46 oil.

Idle losses

In a Digital Displacement® pump each piston chamber is isolated from the outlet line by a high-pressure valve, acting as a check valve. As a result, the idle losses of the DDP096 are independent from the outlet pressure.
While in idling mode, the discharge flow of the pump is exactly 0 L/min.
See Theory of operation on page 5 for more information.
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Technical Information
DDP characteristics

Pump discharged flow and shrinkage

Pump shrinkage
The DDP096 output flow rate is proportional to the displacement fraction as the number of valves being enabled increases linearly with the displacement fraction. The discharged flow rate will also decrease as the pressure increases. In conventional machines, such a decrease in flow is normally associated with volumetric efficiency, as the energy is lost as leakage. With Digital Displacement® pumps, this decrease is due to pump shrinkage and is mostly caused by the compression of oil. Most of the energy stored in the compressed oil is then transferred back to the crankshaft when the piston chamber is depressurized after top dead center.
The conventional definition of volumetric efficiency (defined by ISO4409:2019) is therefore inappropriate for Digital Displacement® pumps. For a more accurate definition of the DDP’s volumetric efficiency, please refer to A More Accurate Definition of Mechanical and Volumetric Efficiencies for Digital Displacement Pumps from Christopher Williamson and Noah Manring.
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Technical Information
DDP characteristics
Discharged flow
To estimate the actual DDP096 discharged flow rate at a given pressure and shaft speed, the shaft speed should be multiplied by the “Flow rate / Shaft Speed” (i.e. pump displacement) presented in the graph below. For example, at 400 bar and 2500 rpm the DDP096 pump displaces a maximum of 88.5 cc/rev, equivalent to 177 L/min.
As each valve actuation is done independently, the pump shrinkage ratio is independent of the pump displacement demand. Therefore, when requesting 25% of pump output flow, the pump will displace exactly 25% of maximum flow in the same condition of pressure speed and viscosity.

Input torque

Due to internal compressed energy recovery, the torque and input power follow the same rule as the pump discharge flow; the input torque and power increases less with pressure than would be expected from the theoretical value.
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