Further System Commissioning And Validation - Danfoss Digital Displacement DDP096 Technical Information

Technical Information
Digital Displacement® DDP096 pump and DPC12 controller
Commissioning and troubleshooting
© Danfoss | October 2023
1. Start the prime mover to spin the pump shaft with a low speed.
2. Check that the speed signal is as expected.
3. Select the Pump 1x commissioning action to pump one specific pumping unit (e.g. A1) once.
4. Repeat the previous step for each pumping unit (A1 to C4) and verify proper pumping function, e.g.
pressure pulsation or pressure increase in the system.
a) If none of the pumping units are providing signs of pumping, stop the prime mover and check that
air has been removed from the case.
b) If one or more pumping units are not pumping or providing different flow characteristics and
additional noise, the wiring harness might be the cause. Stop the prime mover and check the
connections of the wiring harness.
c) If some pumping units (typically from the topmost pumplets) are not providing flow, a small
amount of air might still be trapped in the case. Go to the next step to attempt to clear the
pumping units.
5. Select the Pump 100x commissioning action to pump one specific pumping unit (e.g. A1) a hundred
times.
C
Caution
With the "Pump 100x" action, the DDP displaces a volume of 0.8 L of oil unless the pump outlet
pressure reaches the limit set in the controller. Ensure proper safety precautions to avoid injury.
6. Repeat the previous step for each pumping unit (A1 to C4) and verify proper pumping function.
a) If the pumping units of the topmost pumplet are not delivering flow, wait for outlet pressure to
decrease to a minimum and repeat the Pump 100x action on these pumping units until they are
clear of air. Repeating operation at higher shaft speed (1800+ rpm) can help clear air.
b) If pumping units do not clear after 20 attempts, stop the shaft and double check how to remove air
from the DDP case in Air removal

Further system commissioning and validation

The DDP can be used to provide fixed amount of displacement which can be used to help commissioning
a new system.
1. Use the commissioning action Raw Displacement to provide a fixed flow to the specified service.
When using a multi-service pump in Commissioning mode, Raw Displacement Service 1 and Raw
Displacement Service 2 assume that the pump is set up for a P1 / (P2+P4) split, meaning that Service 1
has 6 pumping units (from P1) and Service 2 has 6 pumping units (from P2+P4). If the application is
plumbed for a (P1+P2) / P4 split, beware of unexpected flow from either service port. For more
information, contact your Danfoss representative.
2. The Raw Displacement commissioning action can be used to help clear air from the pump housing.
a) Increase flow of the pump to full displacement and run up to 3-5 minutes; high speed (1800+ rpm)
may be necessary.
The pump is fully bled once discharged flow is smooth.
b) Ensure that the system can handle this amount of flow.
If flow is going over the relief valve, do not stay in this operating condition for long as it can
significantly heat up the oil.
3. Compare expected discharged flow with actuator speed, or flow measurement.
If issues persist, contact Danfoss for assistance. Do not attempt to disassemble the pump. The pump
is not field serviceable and special tools and procedures are required for assembly and disassembly.
The DDP is now commissioned; use the diagnostic file to return to normal operation mode.
Continue with normal incremental startup procedures for the entire hydraulic system. Test out the
functions being supplied by the DDP to ensure they are working properly.
Tuning the control gains is necessary if operating the DDP in pressure or load sense control modes.
Contact your Danfoss representative for more information.
on page 31 and repeat the current step.
BC306384089197en-000202 | 59