Gas Sensor Calibration - Things to Bear in Mind

Whether developing a gas sensor and testing its sensitivity and repeatability, or calibrating a sensor for quality compliance, you likely will need a traceable reference test gas. Manufacturers of sensors and process regulators require calibration of sensors from time to time.

Regular calibration assures the detection of conditions such as unwanted, flammable, or toxic gas exposure. Depending on the risks, compliance can prevent process disruption—or even catastrophe.

Running the mandatory tests using premixed gases is essential to maintaining the integrity of your measurement devices, thus the efficacy, safety, and reliability of your gas flow system.

Many gas sensor calibration procedures standardize a technique that verifies the sensor at less than 5 points in its span. A 2‑point calibration procedure involves two steps: setting the offset reading and calibrating the sensor’s span. Increasing the number of calibration points assures the sensor is performing well across its span. The trade‑off, however, is that it requires multiple pre‑mixed atmospheres which come at a cost.

Gas sensor calibration can often be carried out based on standardized models using readily‑available pre‑mixed gas species. This can be a cost‑effective solution for single‑ and few‑point gas sensor calibration, but it rapidly becomes prohibitively costly when dynamic, multi‑point calibration is required. Made to order m ixtures may also be difficult to find at a reasonable price.

Often, premixed gases remain an attractive solution for single‑ and few‑point gas calibration. Multi‑point gas sensors, however, often require a more precise solution than premixtures when it comes to calibration.

Dynamic gas mixers offer much greater performance capabilities when sensors need to be calibrated with a variety of atmospheres, rather than to a single reference standard. This empowers researchers, providing consistent and precise control of gas sensor calibration parameters.

For instance, gas mixers provide greater levels of control with intuitive firmware. Gas sensor calibration can subsequently be carried out to the parts per million (ppm) range accurately and much more cost‑effectively than with pre‑mixed cylinders. Simply program the gas mixer and run the process for fully automated, reliable gas sensor calibration.

Accurate and repeatable gas mixtures are essential for calibration routines, especially in demanding research and industrial environments. For low‑flow ppm and ppb gas blending, several universities and laboratories have turned to the FusionFlow™ team at Alicat^® Scientific.

FusionFlow specializes in both turnkey and modular gas mixing systems tailored to meet the specific needs of each client. Our flagship products—the MXM gas blending platform and the IMX industrial gas mixer—are engineered to deliver repeatable, high‑accuracy gas mixtures that support critical calibration and QA processes.

Whether you’re developing a new process or optimizing existing protocols, FusionFlow is here to help you achieve reliable, accurate results—every time.

Contact one of our engineers with your application details or visit our website to explore our full range of solutions.