Reference Manual

Handheld Pressure Calibrator

JOFRA HPC500/HPC502
©Copyright 2009 AMETEK Denmark A/S

...because calibration is
a matter of confidence
HPC500
Reference Manual
1. Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
1.1 Contacting AMETEK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
1.2 Standard Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
1.3 Safety information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
2. Calibrator Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
2.1 Calibrator Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
2.2 Using the Backlight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
2.3 Using the Zero Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
2.4 Menu Controlled Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
3. Measuring Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
3.1 Media Compatibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
3.2 Measuring Pressure with External Modules . . . . . . . . . . . . . . . . . . . . .24
4. Measuring Current . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
5. Measuring Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
6. Measuring Temperature with an RTD . . . . . . . . . . . . . . . . . . . . . . .26
7. Performing a Pressure Switch Test . . . . . . . . . . . . . . . . . . . . . . . . .27
8. Calibrating Transmitters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
8.1 Using the mA Input Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
8.2 Calibrating a Pressure-to-Current Transmitter . . . . . . . . . . . . . . . . . . . .30
8.3 Percent Error Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
9. Minimum and Maximum Storage Capability . . . . . . . . . . . . . . . . . .34
10. Factory Setups . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
11. Custody Transfer / Flow Calibration . . . . . . . . . . . . . . . . . . . . . . .36
12. Remote Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37
12.1 Remote Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37
13. Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38
14. Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40
14.1 Replacing Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40
14.2 Cleaning the Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40
14.3 Service Center Calibration or Repair . . . . . . . . . . . . . . . . . . . . . . . . .40
1. Introduction
The JOFRA HPC500/502 is a high accuracy, full function pressure calibrator.
The calibrator includes the following features and functions:
• Large graphical LCD display. Intuitive menu system for easy operation of the
large number of unique and handy functions and features. The HPC500/502
is available with one or two built-in sensors, to obtain the best possible
solution for your requirements.
• Pressure can be read from an internal sensor or an external module
(JOFRA APM).
• Switch test functionality uses a high speed pressure update rate for superior
performance and repeatability.
• Current measurement, with or without 24 volt loop power.
• Voltage measurement capability.
• Temperature measurement capability (Probe optional).
• An RS232 interface allows complete "hands off" remote control monitoring.
The JOFRA HPC500/502 is well suited for various applications including
calibration of gauges, pressure switches, safety valves, and P/I transmitters.
• The HPC500/502 is available in a great number of pressure ranges, and
types. Please see pressure range/accuracy table for further details (Page 39).
Vacuum is supported in all units up to 35 bar / 500 psi.
• External pressure modules (JOFRA APM´s) may be added for additional
pressure ranges, including the APM S series and higher accuracy APM H
series.
Read this manual carefully before using the instrument and make
sure that all safety instructions and warnings are observed.

1.1 Contacting AMETEK/JOFRA

US, Canada, Latin America AMETEK M&CT 1-800-527-9999
Europe, Africa, Middle East AMETEK Denmark A/S + 45 4816 8000
Asia AMETEK Singapore Pte. Ltd.
At + 65 (64) 842 388

1.2 Standard Equipment

Inspect the unit carefully upon receipt. Save packing carton in case reshipment
is necessary. If there appears to be any damage, equipment missing or if there
are any questions about the unit, contact AMETEK.
Check to see if your calibrator is complete. It should include:
• HPC500/502 Calibrator • Reference Manual
• Test Leads • Pressure Fittings
• Calibration Certificate 1
 1.3 Safety information

Symbols Used
The following table lists the International Electrical Symbols. Some or all of
these symbols may be used on the instrument or in this manual.
Symbol Description

AC (Alternating Current)

AC-DC

Battery

CE Complies with European Union Directives

DC

Double Insulated

Electric Shock

Fuse

PE Ground

Hot Surface (Burn Hazard)

Read the User’s Manual (Important Information)

Off

On

Canadian Standards Association

2
The following definitions apply to the terms “Warning” and “Caution”.
• “Warning” identifies conditions and actions that may pose hazards to the
user.
• “Caution” identifies conditions and actions that may damage the
instrument being used.
Use the calibrator only as specified in this manual, otherwise injury and
damage to the calibrator may occur.

! Warning
To avoid possible electric shock or personal injury:
• Do not apply more than the rated voltage. See specifications for supported
ranges.
• Follow all equipment safety procedures.
• Never touch the probe to a voltage source when the test leads are
plugged into the current terminals.
• Do not use the calibrator if it is damaged. Before you use the calibrator,
inspect the case. Look for cracks or missing plastic. Pay particular
attention to the insulation surrounding the connectors.
• Select the proper function and range for your measurement.
• Make sure the battery cover is closed and latched before you operate the
calibrator.
• Remove test leads from the calibrator before you open the battery door.
• Inspect the test leads for damaged insulation or exposed metal. Check
test leads continuity. Replace damaged test leads before you use the
calibrator.
• When using the probes, keep your fingers away from the probe contacts.
Keep your fingers behind the finger guards on the probes.
• Connect the common test lead before you connect the live test lead.
When you disconnect test leads, disconnect the live test lead first.
• Do not use the calibrator if it operates abnormally. Protection may be
impaired. When in doubt, have the calibrator serviced.
• Do not operate the calibrator around explosive gas, vapor, or dust.
• When measuring pressure, make sure the process pressure line is shut off
and depressurized before you connect it or disconnect it from the
pressure sensor.
• Disconnect test leads before changing to another measure or source
function.
• When servicing the calibrator, use only specified replacement parts.
3
 • To avoid false readings, which could lead to possible electric shock or
personal injury, replace the battery as soon as the battery indicator
appears

! Caution
To avoid possible damage to calibrator or to equipment under test:
• Use the proper jacks, function, and range for your measurement or
sourcing application.

4
2. Calibrator Interface
Figure 1 shows the location of the input and output connections on the
calibrator, while Table 1 describes their use.

Figure 1. Input/Output Terminals

Table 1: Input and Output Terminals

No. Name Description
1, 2 Input Terminals These terminals are used to measure cur-
rent, voltage and a contact closure for switch
test.
3 P1 Pressure Port This is the connection for the internal sensor
[P1]
4 P2 Pressure Port This is the connection for the internal sensor
[P2]
5 RTD Probe Connector This connector is where the RTD probe is
plugged in.
6 External Pressure Sensor This is used to interface to optional external
(JOFRA APM module) modules.

Figure 2 shows the location of the keys on the calibrator. Table 2 lists the
functions of each key.

5
 Figure 2. Keypad

Table 2. Key Functions

No. Name Function
1 Function Keys These keys are used in various ways,
primarily to configure the calibrator
2 ON/OFF Key This key is used to turn the calibrator on
and off
3 ZERO Key This key is used to zero pressure
measurements
4 Backlight Key This key is used to turn the backlight on
and off
5 Cursor Keys This key is for setting user inputed values

Note: When the calibrator is turned on by pressing the ON/OFF key, it will go
through a short startup self-check routine. During that routine, the display
shows the current firmware revision level, auto shutdown status and the ranges
of the internal pressure sensors. The calibrator requires a maximum of 5 min-
utes warm-up to rated accuracy. Large changes in ambient temperature may
require a longer warm-up period. See section 2.3 for instructions on zeroing the
pressure sensor displays. Pressure ranges should be zeroed each time the cali-
brator is started. For aboslute sensors and modules zeroing can only be done
when a barometric reference is available.

6
2.1 Calibrator Display
The Calibrator Display consists of two regions: The menu bar (No. 5 on
Figure 3, located along the bottom of the screen) is used to access a menu
system. The main display (No. 1 on Figure 3) consists of up to three process
measurement sub-regions. These sub-regions will henceforth be referred to
as the UPPER, MIDDLE and LOWER displays. Figure 3 shows the location of
the different display fields while table 3 describes them.

Figure 3. Display

Table 3: Display Functions

No. Name Description
1 Primary Parameters Indicates what is being measured.
2 Span Indicator Indicates the percent of the 4 to 20 mA
span. (For mA and mA Loop functions only)
3 Pressure Units Indicates one of 15 pressure units available
for display.
4 Units Indicates the unit of measure for the display.
5 Menu bar Access to menu systems

2.1.1 Main Menu Functionality

There are three options on the Main Menu, CONFIG, {current display} and
MORE. The Main Menu is home for the menu display.

Current Display

2.1.1.1 Setting the Current Display

The current display is indicated by the center option on the Main Menu,
pressing the F2 key will toggle the current display.
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 2.1.1.2 Setting Current Display Parameters
To set the parameters of the current display use the CONFIG option to get
to the Display Configuration Menu.

Here the SELECT option will toggle through the choices for each parameter.
The first parameter is MODE. Since voltage, current and switch test modes
all use the same jacks, two of these functions cannot be used concurrently.
The ability to select certain functions is limited based on what is already
selected in another active display. The NEXT option is used to change to the
second parameter. Only RTD and Pressure modes have a second
parameter, RTDs can be read in Celsius or Fahrenheit and Pressures can be
read in 15 engineering units.

With a single display the following modes are available:

P[1] = Pressure on left side sensor.
P[2] = Pressure on right side sensor.
[EXT] = Pressure with external pressure module.
P[1] ST = Switch Test with left side sensor.
P[2] ST = Switch Test with right side sensor.
[EXT] ST = Switch Test with external pressure module.
mA = Milliamps measure without loop power.
mA LOOP = Milliamps measure with loop power.
VOLTS = Voltage Measure.
RTD = RTD Temperature Measurement (if a probe is connected).
The following table shows which functions are available concurrently.
An X in a column indicates that the mode in the current display will not be
available for selection if the mode in that row is in use in any other active
display.

8
 Table 4 Mode Concurrency
CURRENT DISPLAY
P[1] P[2] [EXT] P[1] P[2] [EXT] mA mA Volts RTD
ST ST ST Loop
P[1]
OTHER DISPLAYS

P[2]
[EXT]
[∆/Σ]
P[1]ST X X X X X X
P[2]ST X X X X X X
[EXT]ST X X X X X X
mA X X X X X
mA Loop X X X X X
Volts X X X X X
RTD

Note: P2 is only available on the double sensor version of HPC500/502.

2.1.1.3 Accessing Other Menus

Use the MORE option on the Main Menu to access the other menu
functions.

2.2 Using the Backlight

The backlight is controlled by the dedicated backlight key. It toggles on and
off when the key is pressed; There is a user defined timer configuration
settings for the backlight in the functions menu system (2.4.12)

2.3 Using the Zero Function

When the ZERO KEY is pressed, the calibrator will zero the current display if
a pressure mode is selected, and the pressure is within the zero limit. The
zero limits are within 5% of the full scale range of the selected sensor. If the
display indicates "OL," the zero function will not operate."

2.3.01 Internal Sensor and Pressure Module (non-absolute)

When a sensor or module is selected on the current display and the ZERO
KEY is pressed the calibrator subtracts the current reading from the output.
The zero limits are within 5% of the full scale range of the selected sensor. If
the display indicates "OL," the zero function will not operate.

9
 2.3.02 Absolute Internal Sensor or Absolute Pressure Module
When an absolute pressure sensor is selected on the current display and the
ZERO KEY is pressed the calibrator displays the current barometric pressure
on the lower display. At this point the user has two options. With the port
open (vented) to atmosphere, and with access to a high accuracy barometric
reference, the user can utilize the cursor keys to adjust the current value to
the barometric reference pressure and store it in the calibrator using the SET
key. The second option is to use the RESET key to return the barometric
offset to the factory setting. After pressing either the SET or RESET key the
user will be prompted to either confirm or cancel their selection

2.4 Menu Controlled Functions

There are 14 'sub-main' menus that can be accessed through the MORE
option of the Main Menu. A 'sub-main' menu contains three options. The first
option is unique to the function. The second and third options of a 'sub-
main' menu are always the same. The NEXT option leads to the next 'sub-
main' menu and the DONE option returns to main window . For the last 'sub-
main' menu the NEXT option wraps around to home. See Appendix X
(pages 41 & 42) Menu Tree, for a detailed mapping of the menu structure.

A note on naming convention:

If a 'sub-main' menu has subordinate menus, it will henceforth be referred to

as {function} Main Menu. E.g. the display contrast sub-main menu will be
called the Contrast Main Menu. If not it will be called the {function} menu.

10
Menu Functions Overview

2.4.01 %ERROR, on line calculation of sensors error % ….. Page 11

2.4.02 LEAK TEST, automatic leak test timer function……….Page 13
2.4.03 MINMAX, min / max hold……………………………… Page 15
2.4.04 ∆/Σ, delta / summary calculation …………………… Page 16
2.4.05 CONTRAST, display contrast adjustment….……….... Page 17
2.4.06 LOCK CFG, instrument setup lock…………………… Page 18
2.4.07 SETUPS, store or recall of setups………….………… Page 18
2.4.08 AUTO OFF, setup of automatic off timer……………... Page 19
2.4.09 DISPLAY, setup numbers of display windows……..... Page 19
2.4.10 PROBE TYPE, Setup of temperature sensor type…… Page 20
2.4.11 RESULOTION, select display resolution……….…….. Page 21
2.4.12 LIGHT TIMER, setup of backlight timer……………… Page 21
2.4.13 HART, switches hart resistor on and off….………….. Page 22
2.4.14 DAMP, normal or slow display update rate………….. Page 22

2.4.01 %ERROR calculation

The calibrator features a function which can calculate pressure vs. milliamp
error as a percentage of the 4 to 20 mA loop span. The percent error mode
uses all 3 screens and has a unique menu structure. It simultaneously
displays pressure, mA and error percent.
To use the %ERROR function proceed as follows:
1. With the calibrator turned on and operating press the F3 key to activate
the MORE menu option. Now press the F1 key to activate the %ERROR
option.
2. Press the F1 key to select the CONFIG option.
3. The first option is setting the Port, use the select option to scroll through
the port choices, when finished select the NEXT option.

4. LOOP POWER can be toggled on/off, select NEXT when done.

11
 5. Use SELECT to toggle through the UNIT options, and select NEXT to
move on.

6. Use the cursor keys to set the 100% point of the desired pressure range,
select DONE SET when finished.

7. Again, use the cursor keys to set 0% point and select DONE SET when
finished and the %ERROR mode will be ready to use.

12
Note: The 0% and 100% point will be saved in non-volatile memory until
they are changed again by the user for the internal sensors and external
pressure modules. When using an external module the 0% and 100% are
set to low and full scale of the module until the user changes it, or if it was
previously saved.

EXIT leaves the %ERROR mode

2.4.02 LEAK TEST

The calibrator features a leak test function which calculate leak rate. The
timer can be set from 5 to 120 seconds, regardless of the set time the leak
rate is calculated in leak per minute. The function gives a good and
repeatable expression for the leak of a pressure system. This feature might
be used before calibration to document / indicate leak rate.
To use the leak rate function proceed as follows:
1. With the calibrator turned on and operating press the F3 key to activate
the MORE menu option. Press the NEXT button until LEAK TEST
appears in the left text field. Now press the F1 key to activate the leak
test option.
2. Press the F2 key to select the CONFIG option.
3. The first option is setting the Port, use the select option to scroll through
the port choices, when finished select the NEXT option.
13
 4. Use SELECT to toggle through the UNIT options, and select NEXT to
move on.

5. Use cursor keys to set test time, and press DONE SET to confirm.

Note: The units and time will be saved in non-volatile memory until they are
changed again by the user. They may be used at the next leak test without
having to do the configuration each time.

6. To start leak test press F1 button, the time is counted down, and the
Initial, Final and calculated leak rate in pressure pr. Minute is shown.

14
EXIT leaves the leak rate function.

2.4.03 MIN MAX hold

The JOFRA HPC500/502 Pressure Calibrators have a min/max feature for
capturing the minimum and maximum values of any displayed parameter.
To use the MIN / Max storage function proceed as follows:
1. With the calibrator turned on and operating press the F3 key to activate
the MORE menu option. Press the NEXT button until MINMAX appears
in the left text field, now press the F1 key to activate the Min / Max
storage function.

2. After the Min / Max have been activated, pressing the F1 key will toggle
the display through the min/max values that are stored in the min/max
registers. These readings are live so that the new min/max values will be
recorded while in this mode. To reset the min/max registers simply press
the clear key. These registers are also cleared at power-up, when
pressure is zeroed or when the configuration is changed.

The Min / Max mode is cancelled by pressing F3

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 2.4.4 ∆/Σ mode (Delta / Sum mode)
The calibrator features the ability to subtract or add two specified pressure
readings. An application of the ∆ function is differential measurements.
Either two on board sensors or an on board sensor and a pressure module
can be used. An application for the Σ function is pseudo absolute
measurement. Where the barometric pressure can be taken by an absolute
sensor/module and added to the value of another gauge sensor/module
giving you an absolute pressure reading.
To use the ∆/Σ function proceed as follows:
1. With the calibrator turned on and operating press the F3 key to activate
the MORE menu option. Press the NEXT button until SET∆/Σ appears in
the left text field. Now press the F1 key to activate the function. Please
note ∆ function is [port1] - [port2] and Σ function is [port1] + [port2].
2. The first option is setting either ∆ or Σ, use select option to chose, when
finished select the NEXT option.
The 2nd option is setting the 1st Port, use select option to scroll through the
port choices, when finished select the NEXT option.

3. The 3rd option is selecting the 2nd port, use select option to scroll
through the port choices, when finished select the NEXT option.

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4. The ∆/Σ function is now configured, and can be chosen in the main
menu, for the desired display via the normal CONFIG / SELECT
procedure.

Note: The setup will be saved in non-volatile memory until it is changed

again by the user. It may be used at the next leak test without having to do
the configuration each time.

2.4.05 Setting the Display Contrast

1. With the calibrator turned on and operating press the F3 key to activate
the MORE menu option. Press the NEXT button until CONTRAST
appears in the left text field, now press the F1 key to activate the
contrast adjustment function.
2. Use the cursor keys to adjust the display contrast to the desired level
and then use the CONTRAST DONE option to return home.

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 2.4.06 Locking and Unlocking Configurations
When the LOCK CFG option is chosen the menu display returns home and
the CONFIG option on the Main Menu indicates that it is locked. Also all
menus are locked out with the exception of the %ERROR, LEAK TEST,
MINMAX, SET ∆/Σ and CONTRAST menus and the Configuration Lock
Menu. When the UNLOCK CFG option is chosen the configuration is
unlocked and the menu display continues to the next sub-main menu.
To use the Locking function proceed as follows:
1. With the calibrator turned on and operating press the F3 key to activate
the MORE menu option. Press the NEXT button until LOCK CFG
appears in the left text field. Now press the F1 key to activate the
function. To reactivate the function use UNLOCK CFG in the same way.

2.4.07 Saving and Recalling Setups

The calibrator will automatically save the current set-up for recall at power-
up. Additionally 5 set-ups can be accessed through the SETUPS menu.
To use the Locking function proceed as follows:
1. With the calibrator turned on and operating press the F3 key to activate
the MORE menu option. Press the NEXT button until SETUPS appears
in the left text field. Now press the F1 key to enter the function.

2. Choose SAVE to save a set-up , RECALL to recall the set-up, or DONE

to do nothing and return home.

If SAVE or RECALL is selected use the cursor keys to select the set-up
location. Then use the save option to store the current set-up into the
selected location or the recall option to recall the set-up stored in the
selected location. The display menu will automatically go home.

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2.4.08 Setting AutoShut-off Parameters
The calibrator can be set to automatically shut-off after a selected number of
minutes; this function can also be disabled.

To change parameters proceed as follows:

1. With the calibrator turned on and operating press the F3 key to activate
the MORE menu option. Press the NEXT button until AUTO OFF appears
in the left text field. Now press the F1 key to enter the setup.
2. To set the auto shut off parameters select the AUTO OFF option on the
Auto Shut Off Main Menu.

3. Use the cursor keys to select the number of minutes before the calibrator
turns off or disable auto shut-off by scrolling all the way down to 0.

4. Use the AUTO OFF DONE option to set the parameters and return home.
The auto shut off time is reset whenever a key is pressed.

2.4.09 Activating and Deactivating a Display

This is where the number of active measuring windows / channels are
selected, 1, 2 or 3 windows can be selected, to give the optimal mix between
text size, overview and amount of information.

To use the number of windows, pressed as follows:

1. With the calibrator turned on and operating press the F3 key to activate
the MORE menu option. Press the NEXT button until DISPLAY appears in
the left text field. Now press the F1 key to enter the function.

19
 2. The NEXT option can be used to select which display to act upon. The
ON/OFF option turns the selected display on or off. The selected display
and current on/off state are displayed in the lower display.

3. Use the DONE option to save the changes and return home. When a
display is deactivated its configuration is retained. When the display is
activated its configuration is checked against the configurations of the
other currently active displays, if the configurations are in conflict the
recalled display's configuration is modified to avoid the conflict. If all three
displays are deactivated the LOWER display will come on automatically

2.4.10 Setting the RTD probe type

The JOFRA HPC500/502 have a built in high accuracy RTD thermometer, it
works with an RTD sensor (optional).

To select type of temperature sensor proceed as follows:

1. With the calibrator turned on and operating press the F3 key to activate
the MORE menu option. Press the NEXT button until PROBE TYPE
appears in the left text field. Now press the F1 key to enter the function.

2. There are four probe types to select from P100-385, P100-392, P100-JIS
and CUSTOM. Use the SELECT option to select the desired probe type
and the DONE option to store the change and return home.
Note: The default probe type is PT100-385.

3. Pressing DONE leaves the temperature selection function

20
2.4.11 Low resolution function.
Due to the high accuracy of the JOFRA HPC500/502 the measured values
are displayed with many digits, this might be an disadvantage in some
cases, therefore the HPC has a low resolution function. The function takes
away the last digit.

To turn the function on or off, proceed as follows:

1. With the calibrator turned on and operating press the F3 key to activate
the MORE menu option. Press the NEXT button until RESOLUTION
appears in the left text field. Now press the F1 key to enter the function.

2. The select ON or OFF to turn the low resolution function on or off.

3. Pressing DONE returns to main menu.

2.4.12 Setting display Light-off Parameters

The calibrator will automatically shut-off the display back light after a
selected number of minutes.

To change parameters proceed as follows:

1. With the calibrator turned on and operating press the F3 key to activate
the MORE menu option. Press the NEXT button until LIGHT TIMER
appears in the left text field. Now press the F1 key to enter the setup.

21
 2. Use the cursor up/down keys to select the number of minutes before the
light turns off.

3. When the desired time has been reached, press DONE SET to return to
main menu.

2.4.13 Switching HART resistor on or off.

The calibrator has a built in 250 ohms serial "HART" resistor, to prevent
communication errors on live HART networks, while calibrating 4-20 mA
output from pressure transmitters. The resistor is switched into the loop, as a
serial resistor.

To change switch in or out the HART resistor proceed as follows:

1. With the calibrator turned on and operating press the F3 key to activate
the MORE menu option. Press the NEXT button until HART appears in the
left text field. Now press the F1 key to enter the setup.

2. Switches the resistor on or off.

3. DONE returns to main menu.

2.4.14 Switching damping on or off.

To give a more stable reading on fluctuating readings, the HPC500/502 has a
damping function. This function applies to internal sensors only. When
damping is ON, the calibrator displays a running average reading of ten
measurements. The calibrator takes approximately 3 readings per second.

22
 To switch in or out damping proceed as follows:
1. With the calibrator turned on and operating press the F3 key to activate
the MORE menu option. Press the NEXT button until DAMP appears in
the left text field. Now press the F1 key to enter the setup.

2. Switches damping on or off.

3. DONE returns to main menu.

3. Measuring Pressure
To measure pressure, connect the calibrator using an appropriate fitting.
Choose a pressure setting for the display being used. The calibrator is
equipped with one or two internal sensors and many optional external
sensors (JOFRA APMs) are available. Be sure to choose the sensor based
on working pressures and accuracy.
Note:
Pressure sensors may be damaged and/or personnel injury may occur due
to improper application of pressure. Please refer to the table of ranges and
resolutions at the back of this manual for information on overpressure and
burst pressure ratings. Vacuum should not be applied to any gauge
pressure sensor. The calibrator display will indicate "OL" when an
inappropriate pressure is applied. If "OL" is observed on any pressure
display, the pressure should be reduced or vented immediately to prevent
damage or possible personnel injury. "OL" is displayed when the pressure
exceeds 120% of the nominal range of the sensor or when a vacuum in
excess of 2 PSI is applied on gauge range sensors.

23
 Figure 4
Use the (ZERO) key to zero the pressure sensor when vented to
atmospheric pressure.
Important NOTE: To protect sensor integrity and prevent damage to the
sensor, the calibrator will display OL [overload] when the applied pressure
exceeds 120% of the full scale calibrated range of the sensor.
Important NOTE: To ensure accuracy of the calibrator it is critical to zero
the calibrator before a device is calibrated.

3.1 Media Compatibility

The calibrator utilizes a media isolated sensor to prevent sensor
contamination. Whenever possible clean, dry air is the media of choice. If
that is not always possible, make sure that the media is compatible with
Nickel Plated Brass and 316 Stainless Steel.

3.2 Measuring Pressure with External Modules

The calibrator provides a digital interface to JOFRA APMs. These modules
are available in various ranges and types including gauge, vacuum,
differential and absolute. The modules work seamlessly with the calibrator.
Simply plug them into the interface and select [EXT] (external sensor). Since
the interface between the calibrator and the module is digital all the
accuracy and display resolution is derived from the module.

24
 Figure 5
4. Measuring Current
To measure current use the input terminals on the top of the calibrator.
Select the mA function on one of the displays. Current is measured in mA
and percentage of range. The range on the calibrator is set to 0% at 4 mA
and 100% at 20 mA.
Note: The display will indicate "OL" when the measured current exceeds the
nominal range of current measurement (24 mA).
For example:
If the current measured is displayed as 75% then the mA value is 16 mA.

Figure 6
25
5. Measuring Voltage
To measure voltage use the input terminals on the top of the calibrator.
Select the Volts function on one of the displays. The calibrator can measure
up to 30V.
Note: The display will indicate "OL" when the measured voltage exceeds the
nominal range of voltage measurement (30 VDC).

Figure 7

6. Measuring Temperature with an RTD

To measure temperature using an RTD probe you must select the RTD
function on one of the displays. Make sure the proper probe type is
selected. There are 4 probe types supported, P100-385, P100-392, P100-JIS
and CUSTOM.
Note: The factory default type is PT100-385 so if the HPC500/502 is being
used with the AMETEK/JOFRA sensor you do not have to set the probe
type. Simply plug the probe into the HPC500/502 and configure the display
to read temperature.
Note: The display will indicate "OL" when the measured temperature is
outside the nominal measurement range of the RTD function (below -40°C or
above 105°C).
If a custom probe is being used, the entering of R0 and coefficients is
handled through the serial interface (see section 11 and communication
manual).

26
 Figure 8

7. Performing a Pressure Switch Test

Figure 9
To perform a switch test, follow these steps:
1. Change the setup to Setup 4 (default switch test).
Setup 4: The upper display is set to [P1] ST, all other displays are off.
Important NOTE: The pressure Switch Test can be performed with the
following functions[P1] ST, [P2] ST, or EXT ST.
27
 2. Connect the calibrator to the switch using the pressure switch terminals.
The polarity of the terminals does not matter. Then connect the pump to
the calibrator and the pressure switch.
3. Make sure the vent on the pump is open. Zero the calibrator if
necessary. Close the vent after zeroing the calibrator.
4. The top of the display will read "CLOSE".

5. Apply pressure with the pump slowly until the switch opens.
Important NOTE: In the switch test mode the display update rate is
increased to help capture changing pressure inputs. Even with this
enhanced sample rate pressurizing the device under test should be done
slowly to ensure accurate readings.
6. Once the switch is open, "OPEN" will be displayed, bleed the pump
slowly until the pressure switch closes.

7. At the top of the display it will now read, "SW OPENED AT" and give you
the pressure that the switch opened at.

28
8. Press the "NEXT" option to view when the switch closed, and the dead
band.

9. Press the "NEW TEST" option to clear the data and perform another
test.
10. Press the "DONE" option to end the test and return to the standard
pressure setting.
Important NOTE: The following example uses a normally closed switch.
The basic procedure is still the same for a normally open switch, the display
will just read "OPEN" instead of "CLOSE".
Example:
[P1] ST will return to [P1].
29
8. Calibrating Transmitters

8.1 Using the mA Input Function

The mA input function allows the user to read back the 4-20 mA output from
the device being calibrated. This can be done in one of two ways.
1) Passively - Where the device under test directly generates 4-20 mA and
can be read by the calibrator.
2) Actively - Where the calibrator supplies 24 VDC loop power to the device
under test to power the device while reading the resulting 4-20 mA
signal.

8.2 Calibrating a Pressure-to-Current Transmitter

To calibrate a pressure-to-current transmitter (P/I), perform the following
steps:
1. Connect the calibrator and the pump to the transmitter.
2. Apply pressure with the pump.
3. Measure the current output of the transmitter.
4. Ensure the reading is correct. If not, adjust the transmitter as necessary.

30
 Figure 10.

8.3 Percent Error Function

The calibrator features a unique function which can calculate pressure vs.
milliamp error as a percentage of the 4 to 20 mA loop span. The percent
error mode uses all 3 screens and has a unique menu structure. It
simultaneously displays pressure, mA and percent error.

Figure 11. 31
 Example:
Suppose a pressure transmitter under test is 30 psi (2 Bar) Full Scale and
outputs a corresponding 4 to 20 mA signal. The user can program in a 0 to
30 psi pressure span into the calibrator and the calibrator will calculate and
display the deviation or % Error from the expected 4 to 20 mA output. This
eliminates the need for manual calculations and also helps if it becomes
difficult to set an exact pressure with an external pump.
To use the %ERROR function proceed as follows:
1. With the calibrator turned on and operating press the F3 key to activate
the MORE menu option. Now press the F1 key to activate the %ERROR
option.
2. Press the F1 key to select the CONFIG option.
3. The first option is setting the Port, use the select option to scroll through
the port choices, when finished select the NEXT option.

4. LOOP POWER can be toggled on/off, select NEXT when done.

5. Use SELECT to toggle through the UNIT options, and select NEXT to
move on.

32
6. Use the cursor keys to set the 100% point of the desired pressure
range, select DONE SET when finished.

7. Again, use the cursor keys to set 0% point and select DONE SET when
finished and the %ERROR mode will be ready to use.

Note: The 0% and 100% point will be saved in non-volatile memory until
they are changed again by the user for the internal sensors, and external
pressure modules. When using an external module the 0% and 100% are
set to low and full scale of the module until the user changes it, or if it was
previously saved.

33
9. Minimum and Maximum Storage Capability
The JOFRA HPC500/502 Pressure Calibrators have a min/max feature for
capturing the minimum and maximum values of any displayed parameter.
The min/max function can be accessed by stepping through the menu
options until "min/max" is shown on the display above the F1 key. At this
time, pressing the F1 key will toggle the display through the min/max values
that are stored in the min/max registers. These readings are live so that the
new min/max values will be recorded while in this mode.

To reset the min/max registers simply press the clear key. These registers
are also cleared at power-up or when the configuration is changed.

34
10. Factory Setups
The Calibrator is loaded with five factory setups. These setups are shown
below.

Setup 1: The upper display is set to [P1] mode and the middle is set to mA,
lower is off.

Setup 2: The upper display is set to [P2] mode and the middle is set to mA,
lower is off.

Setup 3: The upper display is set to [P1] mode and the middle is set to
[P2], lower is off.
35
 Setup 4: The lower display is set to [P1] switch test, the other displays are
off.

Setup 5: The upper display is set to [P1], the middle display is set to [P2]
and the lower display is set to RTD.

11. Custody Transfer / Flow Calibration

The HPC500/502 is ideal for flow computer calibration. Every manufacturer
of flow computers has a different calibration procedure, but most call for
calibration of three parameters: static pressure, differential pressure and
temperature. To facilitate these measurements recall setup #5 on the
HPC500/502.
Note: The pressures in the UPPER, and MIDDLE displays can be changed
to [P1], [P2], and EXT.
1. Connect the calibrator to your static and differential pressures. ([P1],
[P2], EXT) Then connect the RTD sensor to the calibrator.
2. Using the reading of your RTD, static, and differential pressures, make
sure the flow computer has the correct reading. If not, adjust the flow
computer as necessary.

36
12. Remote Operation

12.1 Remote Interface

The calibrator can be remotely controlled using JOFRACAL software, or by a
computer program running the calibrator in an automated system. It uses an
RS232 serial port connection for remote operation. NOTE: The special
RS232 cable is an option (Communication kit with cable and JOFRACAL
software), and are used for adjustment procedures too. A detailed
communication manual can be downloaded on www.jofra.com.
Typical RS232 remote configurations are shown in Figure 12.

Figure 12. Calibrator-to-Computer Connection

37
13. Specifications (18 °C to 28 °C unless otherwise noted.)

General
Instrument Setup Recall 5; last used on power-up
Environmental
Operating Temperature -10 °C to +50 °C
Storage Temperature -20 °C to +60 °C
Ingress Protection IP54
Power Requirements 6.0 VDC
Battery Four (4) standard AA cells
Battery Life > 35 hours, typical usage
Physical
Dimensions 8.3" H x 3.9" W x 2.0" D (200.9 x 99.1 x 50.1 mm)
Weight 1 lb. 7 oz. (0.651 kg) with batteries installed
EMI/RFI Conformance EN61326
Connectors/Ports Pressure (HPC500) - one, 1/8" BSP female
Pressure (HPC502) - two, 1/8" BSP female
Pressure module/Serial port;
RTD probe
Included Accessories
Item HPC 500 and HPC 502
1/8" male BSP to ¼" female BSP Standard 2 pcs. if dual sensor or differential
1/8" male BSP to ¼" male NPT Standard 2 pcs. if dual sensor or differential
1/8" sealed gasket2 type washer Standard 2 pcs. if dual sensor or differential
Read + Black test lead and clips Standard
Hand strap w/clip Standard
NIST traceable calibration certificate Standard
User manual Standard
RS232 cable Option
Soft case Option

38
 Ranges
Gauge: 70 bar (1000 psi)
200 bar (3000 psi)
350 bar (5000 psi)
700 bar (10,000 psi)
Absolute: 1.1 bar (16 psi)
2 bar (30 psi)
7 bar (100 psi)
20 bar (300 psi)
Differential: +/- 25 mbar (+/- 0.4 psi)
+/- 70 mbar (+/- 1psi)
+/- 350 mbar (+/- 5psi)
Compound: +/- 1 bar (-14 to 15 psi)
-1 to 2 bar (-14 to 30 psi)
-0.82 to 7 bar (-12 to 100 psi)
-0.82 to 20 bar (-12 to 300 psi)
-0.82 to 35 bar (-12 to 500 psi)
mA 0 to 24.000 mA
Volts 0 to 30.000 VDC
RTD -40.0°C to 105.0°C
(-40.0°F to 220.0°F)
Engineering Units psi, bar, mbar, kPa, MPa, kg/cm2, mmH2O @ 4°C,
mmH2O @ 20°C, cmH2O @ 4°C, cmH2O @ 20°C,
inH2O @ 4°C, inH2O @ 20°C, inH2O @ 60°F, mmHg @
0°C, inHg @ 0°C

Accuracy 18°C to 28°C (unless otherwise noted)

HPC500 and HPC502
+/- 25 mbar ± 0.1% F.S. (± 0.15% F.S. 0°C to 50°C)
Vacuum same as above
+/- 70 mbar, +/- 350 mbar ± 0.05% F.S. (± 0.1% F.S. 0°C to 50°C)
Vacuum same as above
All compound ranges ± 0.025% Reading ± 0.01% F.S.
not listed above (± 0.04% Rdg ± 0.01% F.S. 0°C to 50°C)
Vacuum ± 0.025% F.S. (± 0.05% F.S. 0°C to 50°C)
Absolute ranges ± 0.025% Reading ± 0.01% F.S.
(± 0.04% Rdg ± 0.01% F.S. 0°C to 50°C)
Gauge ranges ± 0.025% Reading ± 0.01% F.S.
(± 0.04% Rdg ± 0.01% F.S. 0°C to 50°C)
All ranges - Temperature Effect -10°C to 0°C is ± 0.005% FS/°C

39
Electrical
mA ± 0.015% of rdg ± 0.002mA
Volts ± 0.015% of rdg ± 0.002 VDC
RTD (ohms) ± 0.015% of rdg ± 0.02 ohms;
or ± 0.1°C @ 0°C for Pt100
Switch-Test 5 VDC (< 1mA)
Hart Resistor 250 ohm
Transmitter Supply 24 VDC ± 10%
Temperature Effect - Electrical Ranges
Add ± 0.001% F.S./°C for temps below 18°C and temps above 28°C unless specified
otherwise.
Optional Probe Meets PT-100 ALPHA 385/EN751 Class "A"
Specifications

14. Maintenance

14.1 Replacing Batteries

Replace batteries as soon as the battery indicator turns on to avoid false
measurements. If the batteries discharge too deeply the JOFRA
HPC500/502 will automatically shut down to avoid battery leakage.
Note: Use only AA size alkaline batteries or optional rechargeable battery
pack.

14.2 Cleaning the Unit

Warning
To avoid personal injury or damage to the calibrator, use only the specified
replacement parts and do not allow water into the case.
Caution
To avoid damaging the plastic lens and case, do not use solvents or
abrasive cleansers. Clean the calibrator with a soft cloth dampened with
water or water and mild soap.

14.3 Service Center Calibration or Repair

Only qualified service personnel should perform calibration, repairs, or
servicing not covered in this manual. If the calibrator fails, check the
batteries first, and replace them if needed.
Verify that the calibrator is being operated as explained in this manual. If the
calibrator is faulty, send a description of the failure with the calibrator. Be
sure to pack the calibrator securely, using the original shipping container if it
40 is available.
Appendix X

41
42
 AMETEK JOFRA™ HPC500/502 Ranges and Resolutions
Range (Bar) 25mBar 70mBar 350mBar 1 1.1 2 7 20 35 70 200 350 700
Burst Pressure (Bar) 1.4 1.4 7 20 20 20 70 133 133 677 677 677 1000
Proof Pressure (Bar) 70mBar 200mBar 1 2 2 4 14 40 67 200 400 677 1000
Static Pressure (Bar) 70mBar 7 7 NA NA NA NA NA NA NA NA NA NA
Range (PSI) 0.4 1 5 15 16 30 100 300 500 1000 3000 5000 10000
Burst Pressure (PSI) 10 10 100 300 300 300 1000 2000 2000 10000 10000 10000 15000
Proof Pressure (PSI) 1 3 15 30 30 60 200 600 1000 3000 6000 10000 15000
Static Pressure (PSI) 1 100 100 NA NA NA NA NA NA NA NA NA NA
Psi 1 0.4000 1.0000 5.0000 15.000 16.000 30.000 100.00 300.00 500.00 1000.00 3000.0 5000.0 10000.0
bar 0.06894757 0.0689 0.0689 0.3447 1.0342 1.1032 2.0684 6.8947 20.684 34.474 68.947 206.84 344.74 689.47
mbar 68.94757 27.579 68.948 344.74 1034.2 1103.2 2068.4 6894.8 20684 34474 68948 N/A N/A N/A
kPa 6.894757 2.7579 6.8948 34.474 103.42 110.32 206.84 689.48 2068.4 3447.4 6894.8 20684 34474 68948
MPa 0.00689476 0.0028 0.0068 0.0344 0.1034 0.1103 0.2068 0.6894 2.0684 3.4474 6.8948 20.684 34.474 68.948
kg/cm2 0.07030697 0.0281 0.0703 0.3515 1.0546 1.1249 2.1092 7.0307 21.092 35.153 70.307 210.92 351.53 703.07
cmH2O @ 4°C 70.3089 28.124 70.309 351.54 1054.6 1124.9 2109.3 7030.9 21093 35154 70309 N/A N/A N/A
cmH2O @ 20°C 70.4336 28.173 70.434 352.17 1056.5 1126.9 2113.0 7043.4 21130 35217 70434 N/A N/A N/A
mmH2O @ 4 °C 703.089 281.24 703.09 3515.4 10546 11249 21093 70309 N/A N/A N/A N/A N/A N/A
mmH2O @ 20°C 704.336 281.73 704.34 3521.7 10565 11269 21130 70434 N/A N/A N/A N/A N/A N/A
inH2O @ 4°C 27.68067 11.072 27.681 138.40 415.21 442.89 830.42 2768.1 8304.2 13840 27681 83042 N/A N/A
inH2O @ 20°C 27.72977 11.092 27.730 138.65 415.95 443.68 831.89 2773.0 8318.9 13865 27730 83189 N/A N/A
inH2O @ 60°F 27.70759 11.083 27.708 138.54 415.61 443.32 831.23 2770.8 8312.3 13854 27708 83123 N/A N/A
mmHg @ 0°C 51.71508 20.686 51.715 258.58 775.73 827.44 1551.5 5171.5 15515 25858 51715 N/A N/A N/A
inHg @ 0°C 2.03602 0.8144 2.0360 10.180 30.540 32.576 61.081 203.60 610.81 1018.0 2036.0 6108.1 10180 20360
• Proof pressure - maximum allowable pressure without a shift in calibration
• Burst pressure - sensor damaged or destroyed; some risk of personnel injury
• Static pressure - Differential units only. Maximum allowed common mode pressure between both ports.
• Compound ranges - the data for the 1 Bar range also applies to the -1 to +1 Bar compound range; the data for the 2 Bar range also applies to the -1 to +2 Bar
compound range.
• Absolute ranges - the data for the 1.1, 2, 7 and 20 Bar ranges also applies to the absolute pressure versions of those ranges.

43
 AMETEK Calibration Instruments
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M&G Pressure Testers

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