scubanimal:
I opened my new 02 sensor to plug into my Drager Oxy gauge. I reads 25-26 O2 in an open room. Not attached to a lung or any tank.
Is this normal? Is there a burn in time or something? Or is this a defective gauge?
Sounds right spot on. I agree with Caveseeker here; sounds like all you need to do is calibrate the OxyGauge. I don't have one (although I've played with 'em a few times.) I think it's either five or six pushes of the switch to set it to calibration mode, within the first few moments after you turn on the OxyGauge. Then you need to do the usual confirmation presses. The OxyGauge manual is clearer... I've never dived on the unit - I use a VR3 with mine, and, in the past, used an Oxy2. The procedures are similar, though, in that all of them need calibration. If I remember, the OxyGauge can only be calibrated with air as the calibration gas.
It actually sounds like almost all the sensors you tried were just fine. Each sensor's output will be slightly different, and varies a bit as to age of cell, time that it's been exposed to air, pressure (yes, changing weather patterns will affect surface readings), etc.
The very high reading (135%?) might be due to using the wrong cell type, if they weren't all the same. Generally, there are 10mV and 20mV (nominal, in air) cells. The Drager unit takes the lower of the two, IIRC. Don't know if you were using a batch of the same cell types or not. 10 mV cells should generally read anywhere from about 7 mV at the end of their lives to almost 13 mV at the beginning, when they're fresh, if you were to check the voltage with a multimeter (read the outside two pins of the three, if it's a molex connector type...) Verification with a multimeter is the only true way to check cell behavior. Verify that it's 7 - 13 mV in air, then, optionally, put it in pure O2 (at 1 ATA) and verify that it's _roughly_ five times as great in value as your air reading. Cell response is linear, more or less, with oxygen content.
Remember to do your calibration, for the Drager, in air, and not when connected up to the bag. The bags, if assembled, might be under pressure, and could contain residual gas from setting up the loop, if you've been checking flows, or may cause too low a reading (if you've sucked the loop down to a negative pressure test, then you'll actually find the Oxygauge reads a little low if you calibrated properly - about .19 on the surface...)
When using new cells, it takes several hours after opening the sealed package, or removing the cell from an inert environment, for the cell to begin reading correctly. Personally, I never trust a cell that's been exposed to air for less than 6 - 8 hours, from personal experience, regardless of what the manufacturer's literature says. Generally, if I can, I open cells the day before I install them into any equipment I'll actually dive. The one hour or so on the package is simply not enough time to let the readings stablize after the cell has been "sleeping." Sure, it'll read
something, but not stably enough to trust.