ACI Bump Test/Calibration of Q5/B5/Q6/B6 Oxygen Sensors

Introduction

To calibrate oxygen sensors, you will need calibration gas with a known concentration value, 100% nitrogen, a 0.5 LPM regulator, a calibration adapter, and tubing. It is recommended to calibrate the oxygen sensor every 3 months. You will need a cylinder of 100% Nitrogen (Zero Gas) and a cylinder of 20.9% Air (Span Gas).

Note: The typical lifespan of the oxygen sensing element is between 12-18 months. Once sensor lifespan is used up, the raw oxygen sensor must be replaced. If the sensor life is used up, "CAL ERROR" may appear when attempting a SPAN CAL. Other indications include an Error Code: "Sensor Fail", or "Fault" with the R3 LED illuminated.

ACI offers replacement smart sensor assemblies that are factory calibrated. These boards are easily replaced in the field by removing two screws on the previous module and installing the replacement board. All units should be checked for proper functionality and calibration after the replacement sensor module is reinstalled and has had a chance to warm up.

Oxygen Smart Sensor Replacement Part: 85930-016-000

Replacement Smart Sensor Assembly Instructions

Definitions

A "bump test" (function check) is a qualitative check where sensors are exposed to challenge gas for a specific time and concentration to activate all alarms to at least the lower alarm settings. This test confirms that the gas can reach the sensors, that the sensors respond to the gas, that the response time is within normal limits, and that alarms are activated and function properly. However, a bump test does not verify the accuracy of the sensor readings.

A "full calibration" is the adjustment of an instrument's response to match a desired value compared to a known traceable concentration of test gas. The calibration procedure, including gas concentration, application method, and adjustment method, is determined by the manufacturer.

Bump test demonstration: YouTube Video

Calibration demonstration: YouTube Video

Calibration Equipment for O2

• Part: 85930-006-000 (Calibration Adapter for Q5/B5, Q6/B6)
• Part: CAL GAS KIT (Includes: 1ea C10 0.5lpm regulator, 1ea C10 to CGA600 adapter, Carry case, and ten feet of 1/4" tubing.)
• O2 gas for span calibration: Part: H107220.9VN (20.9% Oxygen, 34L, Certified)
• Zero gas for zero calibration only: Part: H1066 (100% Nitrogen, 34L, Certified)

Calibration Gas Kit Datasheet

Calibration Procedure

To enter Q5/B5 menu:

1. Press F3 to get to the Main menu.
2. Press F3 again to access the Password screen.
3. The default password is 4321.
4. Press F2 to select "2. ZERO CAL" and press F3 to enter.
5. The display will ask if you want to continue. Apply zero gas until the output is 0 ppm, then press F3 for YES. The sensor will display "Accepted" and return to "2. ZERO CAL".
6. Remove the Zero gas.
7. Press F2 once to select "3. SPAN CAL" and press F3 to enter.
8. Enter the ppm of the calibration gas and press F3.
9. The display will ask if you want to continue. First, apply the calibration gas and wait until the reading stabilizes.
10. Press the F3 key to confirm the Span Cal and keep the gas flowing.
11. When Span Cal is completed, the display will show "Accepted" and return to "3. SPAN CAL".
12. Remove the Span gas.
13. Press F1 key to get to EXIT MENU.

Once the sensor is in operating mode, apply the Span gas to verify sensor accuracy. If "CAL ERROR" occurs, repeat the Zero or Span Cal. If the error message continues, replace the smart sensor board.