How to calibrate a pressure sensor on-site?

 

Why is on-site calibration important?
In industrial processes, pressure sensors are essential – they monitor safety-critical operations, regulate processes, and provide key measurements for control and quality assurance. Regular calibration of these sensors ensures that the readings are reliable, accurate, and compliant with relevant standards.
The on-site calibration, also known as “field calibration,” offers a decisive advantage over lab-based calibration: it saves time, minimizes downtime, and reduces costs, as sensors do not need to be removed and sent away. Instead, calibration takes place directly in the installed position – without interrupting plant operation or requiring complex disassembly.

---

Typical application areas
On-site calibration is primarily used where continuous measurement and control are required and high system availability is essential. Typical applications include:

• Process industry (e.g. chemical, petrochemical, food production): regular testing cycles during ongoing operations

• Energy supply & power plants: safety-relevant pressure measurement points

• Water and wastewater sector: distributed measurement points, difficult accessibility

• Maintenance & servicing of industrial plants: mobile calibration equipment saves time and personnel

• Aerospace & defense industries: mobile test benches for complex measurement systems

---

Challenges of field calibration
Despite its advantages, field calibration comes with specific requirements:

• Harsh environmental conditions such as dust, humidity, extreme temperatures, or confined spaces

• Logistical complexity: The right equipment must be mobile, rugged, and highly accurate at the same time

• Time pressure: Downtime must be kept to a minimum – the calibration process must be efficient

• Documentation requirements: Even in the field, traceability, test protocols, and compliance with standards (e.g. ISO 9001, ISO 17025) must be ensured

To meet these challenges, portable calibrators are needed that combine precise measurement, intuitive operation, and digital documentation – such as the DPI610E pressure calibrator and the PV624 pressure source. When combined with the 4Sight2 software, this results in a complete, audit-ready workflow – from planning to digitally signed test certificates.

 

→ Requirements for calibration

For on-site calibration to be efficient, safe, and compliant with standards, certain requirements must be met. These include not only technical conditions but also organizational and documentation-related aspects.

---

Technical conditions

Before calibration can begin, a detailed assessment of the technical environment is essential:

• Sensor pressure range:
  The calibrator (e.g. DPI610E) and pressure source (e.g. PV624) must cover the pressure range of the sensor to be tested. Over- or underdimensioning can result in inaccurate readings or even damage.

• Process medium:
  Calibration directly on the installed sensor is only possible if the medium (gas, water, oil, etc.) poses no danger or can be safely isolated. For hazardous media, either a shut-off valve or sensor removal is required.

• Ambient conditions:
  Temperature, humidity, dust, and vibrations affect measurement accuracy and calibration stability. Calibrators such as the DPI610E are built for field use (e.g. IP-rated), but the environment must still allow for stable measurement conditions.

---

Safety requirements

Safety is the highest priority during calibration – especially when performed during operation:

• Pressure relief & safety:
  Before starting, it must be ensured that no uncontrolled pressure changes occur. Overpressure valves, shut-off mechanisms, and controlled depressurization are mandatory.

• Explosion protection (ATEX, IECEx):
  Only approved devices may be used in hazardous areas. For example, the DPI610E is available in an intrinsically safe version.

• Personnel training:
  Only qualified personnel may carry out calibration at safety-critical measurement points. Proper instruction on the equipment used is essential.

---

Required documentation

A standard-compliant calibration does not end with the measurement – it must also be thoroughly documented:

• Calibration certificate / test report:
  The calibration results must be documented with all relevant data (measurement deviation, tolerance, equipment used, date, technician). Software such as 4Sight2 generates these reports automatically and traceably.

• Traceability to national standards:
  All reference devices used must be regularly calibrated and traceable – ideally with ISO 17025 certification.

• Archiving requirements:
  In many industries, calibration records must be stored for several years. A centralized digital archive improves auditability and significantly reduces administrative effort.

Meeting these requirements is essential to ensure measurement integrity, compliance with standards, and operational safety. Only when the technical, safety, and documentation-related conditions are in place can on-site calibration be carried out efficiently and reliably.

 

→ Device solution for field use

Reliable on-site calibration requires robust, portable, and precise equipment. With the DPI610E and the PV624, Druck offers a perfectly matched system for mobile use – even in harsh environments.

 

With the DPI610E calibrator and the PV624 pressure source, a powerful, mobile calibration solution is available that delivers reliable results even under harsh conditions. Both devices are perfectly matched and can be seamlessly integrated with the 4Sight2 software – enabling digital logging, standards compliance, and maximum efficiency in field operations.

 

→ Step-by-step: On-site calibration of a pressure sensor

An efficient and standards-compliant on-site calibration follows a clearly structured process – especially when performed using digital tools like DPI610E, PV624, and the calibration software 4Sight2. The following guide illustrates how modern calibration technology can be combined with automated documentation:

---

1. Preparation

Before calibration begins, all required data and specifications are centrally managed via the 4Sight2 software:

• • • Device identification (e.g. serial number, location, medium)

    • Inspection interval

    • Specifications for test points, tolerances, limits

    • Traceable reference instruments (e.g. DPI610E as reference standard)

      Plan calibration task:
      In 4Sight2, the calibration task is created for the respective device – including:

• • Transfer task to DPI610E:
    The calibration task is transferred to the field device DPI610E via USB, Wi-Fi or Bluetooth. This ensures unambiguous identification of the device under test – avoiding manual input errors.

---

2. Connection & Pressure Generation

After digital preparation, the physical setup of the test system takes place:

• Connect sensor:
  The pressure sensor to be tested is connected to the DPI610E pressure port using suitable adapters. The electrical connection is made via the calibrator’s multifunction terminals (e.g. for 4–20 mA, mV, RTD).

• Generate pressure with PV624:
  The PV624 pressure source is connected to the DPI610E. The desired pressure level is now automatically generated and precisely regulated – either manually via the calibrator menu or automatically using the test sequence previously defined in 4Sight2.

---

3. Performing the Calibration

The calibration process now runs in a structured and largely automated manner:

• • Execute test steps:
    The DPI610E performs the calibration according to the transferred task – e.g. a 5-point test with increasing and decreasing pressure levels. Reference and actual values are displayed simultaneously.

  • • Timestamp

    • Device identification

    • Measurement results

    • Deviations

      Automatic evaluation:
      The calibrator compares the measured values with the target values and tolerance limits. Deviations are highlighted.
      At the same time, 4Sight2 automatically records:

---

4. Evaluation of Results

• Live pass/fail evaluation:
  During the test, the DPI610E already displays whether the measurement deviations are within the specified tolerance limits.
  This saves time and reduces documentation effort.

• Digital signature:
  If desired, the test engineer can electronically sign the calibration result directly on the device – a crucial aspect for audit-compliant processes.

---

5. Logging & Traceable Documentation

Once calibration is complete, a digital calibration certificate is generated and archived:

• • Transfer of measurement results:
    The data is transferred back to 4Sight2 – either instantly (with online connection) or later via USB/Wi-Fi synchronization.

  • Automatic test report:
    4Sight2 automatically generates a complete, traceable calibration certificate from the results – including all legally and normatively required details:

    • Test results and tolerance evaluation

    • Used reference instruments with calibration certificate

    • Electronic signature (optional)

    • Export as PDF, XML or CSV for digital archiving

     

---

The integrated workflow with DPI610E, PV624 and 4Sight2 enables fast, standards-compliant, and error-free on-site calibration. At the same time, digital logging ensures complete traceability and significantly reduces administrative effort – especially when dealing with large volumes or regular inspection intervals.

 

→ Digital calibration processes with 4Sight2 in the field

Requirements for efficiency, traceability, and compliance are increasing – especially for field calibrations. 4Sight2 is a powerful calibration software developed specifically for this purpose: it supports companies in planning, execution, evaluation, and archiving of calibrations – fully digital and audit-ready.

---

Example workflow: Planning → Calibration → Documentation → Release

1. Office planning:

   • Create test equipment, define tolerances, set calibration intervals

   • Generate calibration orders (e.g. for 100 pressure sensors per site)

2. Synchronization & field execution:

   • Transfer calibration plan to mobile devices such as the DPI610E

   • Automatic guidance through test steps and tolerance evaluation

   • Direct entry of observations or error codes

3. Automated documentation:

   • Measurement results, reference data, responsible personnel, and timestamps are automatically recorded

   • Calibration certificates can be generated as PDF, XML or CSV

   • Digital signatures and release workflows possible

4. Central archiving & analysis:

   • Test reports are stored in an audit-proof manner

   • Monitor trends, anomalies, and calibration history

   • Notifications for upcoming calibration due dates

 

---

Supported Devices (excerpt)

4Sight2 supports a wide range of pressure calibrators and reference instruments from the pressure portfolio, including:

---

Seamless integration into maintenance processes

• Integration with existing maintenance and quality systems (e.g. SAP, Maximo, Infor)

• Interfaces for data export and automatic test equipment monitoring

• User and role-based permission system

• Mobile workflows available for maintenance teams

---

Flexible licensing model: Cloud or On-Premise

4Sight2 flexibly adapts to your IT strategy:

• Cloud version for quick start, automatic updates, and remote access

• On-premise installation for companies with their own IT infrastructure and individual compliance requirements

• Scalable licenses for small teams up to enterprise-wide maintenance units

---

With 4Sight2, calibration becomes a fully digital process – from preparation and execution to audit-proof documentation. This not only reduces manual errors but also increases efficiency and test equipment safety – especially for frequent calibration cycles in the field.

---

Reference:
4Sight2 Datasheet (PDF)

 

→ Typical sources of error in on-site calibration

Even with modern calibration equipment like the DPI610E and the PV624, measurement quality strongly depends on environmental conditions and preparation care. The following typical sources of error can affect results – but can be reliably avoided with the right approach:

---

Practice note:
A common mistake in on-site calibration is the use of makeshift connections such as Teflon tape or quick adapters without proper sealing. While these may work in the lab, they are often the cause of slow leaks in the field – especially during vacuum or low-pressure tests.

---

Tip:
Leaks can be detected early with the DPI610E – for example, using the leak test function under stable pressure. Combined with the precise regulation of the PV624, pressure loss can be quickly localized and eliminated.

 

→ Benefits of on-site calibration with DPI610E, PV624 and 4Sight2

The combination of the mobile calibrator DPI610E, the pneumatic pressure source PV624, and the 4Sight2 calibration software offers a powerful all-in-one system for precise, documented on-site calibrations. Users benefit not only technically, but also organizationally and economically.

---

1. Time savings through automated test steps

The DPI610E enables the execution of fully defined calibration sequences – controlled by test specifications stored in 4Sight2. The user no longer needs to manually perform or document each step. Typical time savings: up to 50 % compared to conventional, paper-based calibrations.

• Automatic control of pressure points (via PV624)

• Guided measurement grids with immediate tolerance evaluation

• No post-processing or manual calculation required

---

2. No handwritten protocols required

Traditional calibrations often require manual recording – which is prone to error. With digital data capture using the DPI610E and automatic logging in 4Sight2, this effort is completely eliminated.

• Measurements are stored and evaluated directly

• Test reports are automatically generated (PDF, XML, CSV)

• Digital signatures and user identification possible

• No media disruptions between testing and documentation

---

3. Centralized data management & traceability according to ISO 17025 / ISO 9001

4Sight2 ensures seamless traceability of all calibration processes – including complete history, device records, reference instruments used, and calibration intervals.

• Traceable calibration records in accordance with ISO 17025

• Audit-proof storage of all test protocols with timestamp and responsible person

• Avoidance of duplicate testing through centralized test planning

• Automatic reminders for due calibrations

---

4. Integration into existing maintenance or quality systems

Thanks to open interfaces, 4Sight2 can be easily integrated into existing company systems:

• Connection to maintenance software (e.g. SAP PM, Maximo, Infor)

• Export of calibration data for further processing in QA systems

• Integration into internal approval workflows or test equipment management

This turns calibration into an integrated part of the quality process – rather than an isolated work step.

---

5. Transparency and traceability during audits

Whether for ISO certification, internal audits, or customer inspections – with 4Sight2, all calibration processes can be traced and presented at any time. Each calibration includes:

• Device data and measurement values

• Reference devices used and their calibration status

• Deviation assessment and release history

• User, location, and date of calibration

This significantly reduces audit workload and builds confidence in your measurement processes.

The combination of DPI610E, PV624 and 4Sight2 offers not only high-precision measurement technology, but also a continuous, paperless and standards-compliant calibration process. Users benefit from increased efficiency, reduced error rates and full transparency – both in the field and in the office.

 

→ Summary

On-site calibration of pressure sensors is now more than just a practical alternative to lab calibration – in many applications, it is the most economical, efficient, and flexible solution.

---

When is on-site calibration especially worthwhile?

• In time-critical processes where downtime must be avoided (e.g. chemical plants, power stations, utility companies)

• At decentralized or hard-to-reach measuring points, such as in the water or energy sector

• In harsh industrial environments requiring robust and mobile measuring equipment

• When many sensors require regular verification, e.g. as part of standardized maintenance plans according to ISO 9001 or ISO 17025

• When digital records and documentation are mandatory, e.g. for external audits or customer requirements

---

DPI610E + PV624: The robust complete solution for field use

With the DPI610E pressure calibrator and the PV624 pressure source, users have access to a powerful, portable calibration system specifically designed for demanding field applications. In combination with the 4Sight2 calibration software, this becomes a fully digital workflow – including planning, execution, evaluation, and documentation.

Key benefits at a glance:

• Mobile, precise, robust – for daily use in real-world conditions

• Time savings through automated test steps and digital logging

• Standards-compliant traceability according to ISO 9001 / ISO 17025

• Less paper, fewer errors, greater efficiency

---

Further information

• DPI610E Datasheet (PDF)

• PV624 Datasheet (PDF)