Patent Description:
Products may be shipped or stored within a conditioned space, such as a container, truck or trailer. These conditioned spaces utilize a refrigeration unit that circulates cooled air inside the interior volume. In many cases, the refrigeration unit uses a refrigeration cycle to cool the air. Refrigerant from the refrigeration unit may leak and thus it needs to be verified that gas detection systems are operating correctly to successfully detect the leak.

<CIT> discloses a related detector testing system comprising a testing chamber for testing a gas detector.

Viewed from a first aspect, the invention provides a detector testing system for testing a gas detector used in a heating, ventilation, and air conditioning, or refrigeration (HVAC/R) system, the detector testing system comprising: a testing chamber configured to receive the gas detector through an orifice in the detector testing system, the testing chamber being configured to at least partially enclose the gas detector within the testing chamber; a receiving port fluidly connected to the testing chamber; and a target gas cartridge fluidly connected to the receiving port, wherein the target gas cartridge contains a known concentration of a refrigerant as a target gas, wherein the known concentration of the refrigerant within the target gas cartridge is a lower flammability limit of the refrigerant and/or wherein the refrigerant within the target gas cartridge is diluted to a lower flammability limit of the refrigerant prior to the refrigerant entering the testing chamber; wherein the receiving port is configured to deliver the target gas to the testing chamber.

The system may include a door configured to seal against the orifice and fully enclose the gas detector within the testing chamber.

Optionally, the orifice is configured to seal against a mounting surface of the HVAC/R system and enclose the gas detector within the testing chamber.

The system may include a communication device in electronic communication with a communication device of the gas detector.

The system may include a display device configured to display detector readings detected by the gas detector.

Optionally, the target gas is a mildly flammable refrigerant.

Optionally, the target gas is an A2 refrigerant, A2L refrigerant, or an A3 refrigerant.

The system may include: an environmental control configured to adjust an environmental conditions within the testing chamber; and an environmental sensor configured to detect the environmental condition within the testing chamber.

Optionally, the environmental condition is temperature or humidity.

The system may include: a communication device in electronic communication with a communication device of the gas detector, wherein the communication device is configured to receive readings detected by the gas detector and transmit the readings to a cloud server.

The system may include a communication device in electronic communication with a communication device of the gas detector, wherein the communication device is configured to communicate with the gas detector for recalibration of the gas detector.

According to another aspect, the invention provides a method of testing a gas detector of a heating, ventilation, and air conditioning, or refrigeration (HVAC/R) system, the method comprising: inserting the gas detector through an orifice in a detector testing system and at least partially into a testing chamber within the detector testing system, the testing chamber being configured to at least partially enclose the gas detector within the testing chamber; sealing the testing chamber off from external environments; providing a target gas into the testing chamber, wherein the target gas is a refrigerant at a known concentration, and wherein the known concentration is a lower flammability limit of the refrigerant; and receiving one or more readings from the HVAC/R system, a method of testing a gas detector for a heating, ventilation, and air conditioning, or refrigeration (HVAC/R) system is provided.

Optionally, sealing the testing chamber off from external environments further includes: removing the gas detector from the HVAC/R system; inserting the gas detector fully into the testing chamber; and closing a door of the testing chamber, the door being configured to seal against the orifice and fully enclose the gas detector within the testing chamber.

Optionally, sealing the testing chamber off from external environments further includes: sealing the orifice against a mounting surface of the HVAC/R system, the gas detector remaining attached to the mounting surface; and enclosing the gas detector within the testing chamber.

The method may include: displaying the one or more detector readings detected by the gas detector within the detector testing system.

Optionally, the target gas is a flammable refrigerant.

Optionally, prior to providing the target gas into the testing chamber, the method further includes: diluting the target gas to a lower flammability limit of the target gas prior to the target gas entering the testing chamber.

The method may include: detecting an environmental condition within the testing chamber using an environmental sensor; and adjusting the environmental condition within the testing chamber using an environmental control.

The method may include receiving readings from the gas detector; and transmitting the readings to a cloud server.

The method may include: receiving readings from the gas detector; determining a recalibration of the gas detector is required in response to the readings; and transmitting the calibration parameters or adjustments for recalibration of the gas detector to the gas detector.

The method may include: receiving response data from the HVAC/R system; and determining whether the HVAC/R system has performed or is performing an isolation and pump down procedure following the introduction of the target gas into the testing chamber.

The method may include: transporting the target gas from the testing chamber to a target gas tank.

In one possible disclosed arrangement, a detector testing system for testing a gas detector used in a heating, ventilation, and air conditioning, or refrigeration (HVAC/R) system is provided. The detector testing system including: a testing cup having a cup mounting surface with an orifice; a testing chamber extending from the orifice of the cup mounting surface into the testing cup; a target gas delivery hose fluidly connected to the testing chamber; and a target gas tank fluidly connected to the testing chamber through the target gas delivery hose, wherein the target gas delivery hose is configured to deliver a target gas from the target gas tank to the testing chamber.

The system may include that the cup mounting surface is configured to seal against a mounting surface of the HVAC/R system and enclose the gas detector within the testing chamber.

The system may include: a target gas metering component located within the target gas delivery hose interposed between the testing chamber and the target gas tank.

The system may include: a target gas return hose fluidly connecting the testing chamber to the target gas tank; and a target gas reclaim component located within the target gas return hose interposed between the testing chamber and the target gas tank.

<FIG> schematically illustrates a detector testing system <NUM> configured to test a gas detector <NUM>. The gas detector <NUM> may contain various components that are tested by the detector testing system <NUM>, such as for example gas sensors, diagnostic algorithms, and mitigation mechanisms such as lights, relays and switches. It should be appreciated that, although particular systems are separately defined in the schematic block diagrams, each or any of the systems may be otherwise combined or separated via hardware and/or software. The gas detector <NUM> may be used in a heating, ventilation, and air conditioning or refrigeration (HVAC/R) system <NUM> to detect a target gas. The target gas is a refrigerant. In an embodiment, the target gas is a flammable and/or a mildly flammable refrigerant. In one embodiment, a mildly flammable refrigerant may be defined as a refrigerant having a greater than <NUM>/m<NUM>, a heat of combustion less than <NUM>,<NUM> kj/kg, and/or a burning velocity of less than <NUM>/s. In an embodiment, the mildly flammable refrigerant may be A2L refrigerant. An A2L refrigerant may include but is not limited to R32, R1234yf, R-1234ze(E), R134A, R454A, and R454B. In another embodiment, the target gas may be a higher flammability refrigerant, such as, for example an A3 refrigerant. In another embodiment, the target gas is an A2 refrigerant, A2L refrigerant, or an A3 refrigerant. An A2 refrigerant may include but is not limited to R-152a. An A3 refrigerant may include but is not limited to R-<NUM> (Propane) and R-600a (isobutene).

The HVAC/R system <NUM> may be a commercial or residential stationary HVAC system or a transport or stationary refrigeration (R) system. The gas detector <NUM> may be utilized in operative association with a transport HVAC/R system, such as, for example, a refrigerated truck, a refrigerated trailer, or a refrigerated container. The gas detector <NUM> may also be utilized in operative association with a stationary HVAC/R system, such as, for example, refrigerated cabinets (e.g., self-serve refrigerated grocery cabinets with and without doors). In the transport refrigeration system or the commercial refrigeration system, the gas detector <NUM> may be used as part of a refrigeration control system to adjust environmental conditions of the perishable goods (e.g., cargo/stock/inventory) in order to control or influence the control of ventilation, humidity, air temperature, and/or contaminant scrubbing systems. In one embodiment, the gas detector <NUM> may be used to activate ventilation to lower the target gas concentration around the gas detector <NUM>, or to alert personnel to the presence of the target gas, or potential damage to property or perishable goods. In another embodiment, the gas detector <NUM> may be utilized independent of a corresponding refrigeration system or commercial refrigeration system to alert personnel to potential damage to perishable goods, alert personnel to the presence of the target gas, and/or to increase or decrease ventilation rates.

The detector testing system <NUM> may be separate and apart from the gas detector <NUM> and may be utilized to test the gas detector <NUM> periodically or intermittently, as required. The detector testing system <NUM> may be brought onsite to test the gas detector <NUM>. The gas detector <NUM> may be removed from the HVAC/R system <NUM> and tested within the detector testing system <NUM> or the detector testing system <NUM> may be brought to the HVAC/R system <NUM> to test the gas detector <NUM> while remaining installed in the HVAC/R system <NUM>, as described herein.

The detector testing system <NUM> includes a testing chamber <NUM> capable of fully and/or partially enclosing the gas detector <NUM>. In the embodiment illustrated in <FIG>, the gas detector <NUM> is removed from the HVAC/R system <NUM> and tested within the detector testing system <NUM>, which fully encloses the gas detector <NUM>. The gas detector <NUM> may be removed from the HVAC/R system <NUM> and placed within the testing chamber <NUM>. The detector testing system <NUM> may include a door <NUM> to environmentally seal the testing chamber <NUM> from external environments <NUM>, thus creating a controlled environment within the testing chamber <NUM>. The door <NUM> is configured to seal against an orifice <NUM> of the detector testing system <NUM>, which opens up into the testing chamber <NUM>.

In the embodiment illustrated in <FIG>, the gas detector <NUM> is not removed from a mounting surface <NUM> of the HVAC/R system <NUM> and tested within the detector testing system <NUM> while still being mounted to the mounting surface <NUM>. As shown in <FIG>, the gas detector <NUM> is inserted into an orifice <NUM> of the detector testing system <NUM>. The orifice <NUM> opens up into the testing chamber <NUM>. The orifice <NUM> is configured to seal against the mounting surface <NUM> of the HVAC/R system <NUM>, while the testing chamber <NUM> encloses the gas detector <NUM>. The orifice <NUM> sealing against the mounting surface <NUM> of the HVAC/R system <NUM> environmentally seals (i.e., isolates) the gas detector <NUM> within the testing chamber <NUM> and prevents gas leakage between the testing chamber <NUM> and an external environment <NUM> outside of the testing chamber <NUM>.

When the gas detector <NUM> is sealed within the testing chamber <NUM>, the detector testing system <NUM> is configured to emit a known concentration of the target gas into the testing chamber <NUM> to test a state of health of the gas detector <NUM>. The detector testing system <NUM> may be in wired and/or wireless communication with the gas detector <NUM> when the gas detector <NUM> is located within the testing chamber <NUM> to receive detector readings from the gas detector <NUM>. The detector testing system <NUM> may include a communication device <NUM> and the gas detector <NUM> may include a communication device <NUM>. In one embodiment, the communication device <NUM> of the gas detector <NUM> may be hardwired to the communication device <NUM> of the detector testing system <NUM> through a removable connecting wire (not shown). In another embodiment, the communication device <NUM> of the gas detector <NUM> may be in wireless communication with the communication device <NUM> of the detector testing system <NUM> through a short-range wireless transmissions, such as, for example, Bluetooth, Wi-Fi, Infrared, etc..

In one embodiment, a memory <NUM> of a controller <NUM> of the detector testing system <NUM> or any other memory device within the detector testing system <NUM> may be utilized to locally store testing data, including, but not limited to, building name, building number, room number, HVAC/R identification number, station number, time, test number, target gas name, target gas concentration, detector name, detector location, detector baseline, readings from the gas detector <NUM>, detector response as function of time, the known concentration of the target gas within the target gas cartridge <NUM>, the concentration of target gas delivered into the testing chamber <NUM>, the humidity within the testing chamber <NUM>, and the temperature within the testing chamber <NUM>, and the like.

In one embodiment, the controller <NUM> of the detector testing system <NUM> may be configured to locally analyze the testing data, determine a pass or fail decision for the gas detector <NUM>, and display the pass or fail decision back on the detector testing system <NUM>.

In another embodiment, the communication device <NUM> of the gas detector <NUM> may be in wireless communication with a cloud server <NUM> through a wireless transmissions, such as, for example, Bluetooth, Wi-Fi, Infrared, cellular, satellite, or other network communication. The communication device <NUM> may be configured to transmit the testing data to the cloud server <NUM>. The cloud server <NUM> may be configured to analyze the testing data, determine a pass or fail decision for the gas detector <NUM>, and transmit the pass or fail decision back to the detector testing system <NUM> for local display.

In another embodiment, the communication device <NUM> of the gas detector <NUM> may be in wired communication with another device, such as, for example, for example a phone, a laptop. In addition to determining a pass or fail, the controller <NUM> and/or the cloud server <NUM> may alternatively determine that the gas detector <NUM> needs to be recalibrated using the detector testing system <NUM>. The communication device <NUM> of the detector testing system <NUM> may be in wireless communication with the communication device <NUM> of the gas detector <NUM> through a short-range wireless transmissions, such as, for example, Bluetooth, Wi-Fi, Infrared, etc.. The communication device <NUM> of the detector testing system <NUM> may be in wired communication with the communication device <NUM> of the gas detector <NUM> through a USB cable, Ethernet, fiber-optics, etc. Through the communication devices <NUM>, <NUM>, the detector testing system <NUM> may be able to pass to the gas detector <NUM> calibration parameters or adjustments thereto for recalibration of the gas detector <NUM>, which may be an automatic process. For example, once connected with the gas detector <NUM>, the detector testing system <NUM> can pair with the gas detector <NUM> to start a calibration test where it delivers a known concentration of target gas into the testing chamber <NUM>. Upon receiving the readings from the gas detector <NUM> in response to the target gas then the detector testing system <NUM> can send updated calibration parameters to the gas detector <NUM> and then rerun the test to confirm that the gas detector <NUM> has been successfully recalibrated. This recalibration process can be done at various temperature levels and humidity levels as discussed herein.

The controller <NUM> may be configured to control entry of the target gas into the testing chamber <NUM>. The controller <NUM> may be an electronic controller including a processor <NUM> and an associated memory <NUM> comprising computer-executable instructions that, when executed by the processor <NUM>, cause the processor <NUM> to perform various operations. The processor <NUM> may be, but is not limited to, a single-processor or multi-processor system of any of a wide array of possible architectures, including field programmable gate array (FPGA), central processing unit (CPU), application specific integrated circuits (ASIC), digital signal processor (DSP) or graphics processing unit (GPU) hardware arranged homogenously or heterogeneously. The memory <NUM> may be but is not limited to a random access memory (RAM), read only memory (ROM), or other electronic, optical, magnetic or any other computer readable medium.

The target gas may be received from a target gas cartridge <NUM>. The target gas cartridge <NUM> may include an output port <NUM> that fluidly connects to a receiving port <NUM> of the detector testing system <NUM>. The receiving port <NUM> is fluidly connected to the testing chamber <NUM> and configured to deliver the target gas into the testing chamber <NUM>. The target gas cartridge <NUM> contains a known concentration of the target gas, such as, for example, <NUM>%, <NUM>%, <NUM>%, <NUM>%, <NUM>%, <NUM>%, <NUM>%, <NUM>%, <NUM>%, <NUM>%, <NUM>%, or any concentration therebetween. In one embodiment, the target gas cartridge <NUM> may contain a known concentration of the target gas equal to <NUM>% and the detector testing system <NUM> may include a flow meter to adjust flow of the target gas from the target gas cartridge <NUM> into the testing chamber <NUM>.

Although only one is shown, the detector testing system <NUM> may include multiple receiving ports <NUM> that connect to multiple target gas cartridges <NUM> and/or a dilution gas cartridge <NUM>. In the event multiple target gas cartridges <NUM> are utilized, each of the multiple target gas cartridges <NUM> may contain a different known concentration of the target gas. The dilution gas cartridge <NUM> may also include an output port <NUM> that fluidly connects to a receiving port <NUM> of the detector testing system <NUM>. In an embodiment, the detector testing system <NUM> may include a flow meter to help dilute the target gas. The flow meter is not shown for simplification of illustration.

In one embodiment, the detector testing system <NUM> may introduce the target gas from the target gas cartridge <NUM> directly into the testing chamber <NUM> without diluting the target gas received from the target gas cartridge <NUM>. In another embodiment, the detector testing system <NUM> may dilute the target gas received from the target gas cartridge <NUM> prior to entering into the testing chamber <NUM> using external air or a gas from the dilution gas cartridge <NUM>. In an embodiment, the known concentration of the target gas within the target gas cartridge <NUM> is a lower flammability limit (LFL) of the target gas. In another embodiment, the known concentration of the target gas within the target gas cartridge <NUM> may be diluted to the LFL of the target gas prior to entering the testing chamber <NUM>.

The detector testing system <NUM> may also be configured to test a responsiveness of the gas detector <NUM> to a non-target gas. The non-target gas may be received from a non-target gas cartridge <NUM>. The non-target gas cartridge <NUM> may include an output port <NUM> that fluidly connects to a receiving port <NUM> of the detector testing system <NUM>. The non-target gas cartridge <NUM> contains a known concentration of a non-target gas, such as, for example, <NUM>%, <NUM>%, <NUM>%, <NUM>%, <NUM>%, <NUM>%, <NUM>%, <NUM>%, <NUM>%, <NUM>%, <NUM>%, or any concentration therebetween. In one embodiment, the detector testing system <NUM> may introduce the non-target gas from the non-target gas cartridge <NUM> directly into the testing chamber <NUM> without diluting the non-target gas received from the non-target gas cartridge <NUM>. In another embodiment, the detector testing system <NUM> may dilute the non-target gas received from the non-target gas cartridge <NUM> prior to entering into the testing chamber <NUM> using external air or a gas from a dilution gas cartridge <NUM>. Advantageously, utilizing a non-target gas allows the detector testing system <NUM> to test cross sensitivity of the gas detector <NUM> to gases other than the target gas.

The detector testing system <NUM> may also be configured to test a responsiveness of the gas detector <NUM> to a target gas at various temperatures and humidity levels. The detector testing system <NUM> may include environmental controls <NUM> configured to adjust the environmental conditions within the testing chamber <NUM> and environmental sensors <NUM> configured to detect the environmental conditions within the testing chamber <NUM>. The environmental controls <NUM> may include but are not limited to a heater 510a and a humidifier 510b. The environmental sensors <NUM> include but are not limited to a temperature sensor 520a and a humidity sensor 520b. Advantageously, by including environmental controls <NUM> and environmental sensors <NUM>, the detector testing system <NUM> could test accuracy of the gas detectors <NUM> at multiple other temperature or humidity conditions rather than at the one environmental condition that occurred during the test. The controller <NUM> of the detector testing system <NUM> would be configured to establish environmental testing conditions within the testing chamber <NUM> using the environmental controls <NUM> and the environmental sensors <NUM> prior to reading the gas detector <NUM> output and comparing it to the target gas composition. Advantageously, adjusting the temperature and the humidity within the testing chamber <NUM> could be used to test gas detectors <NUM> having multipoint calibrations over a range of temperature and humidity levels.

The detector testing system <NUM> may also include a display device <NUM> configured to display detector readings from the gas detector <NUM>, the concentration of the target gas or non-target gas being detected by the gas detector <NUM> enclosed within the testing chamber <NUM>, a temperature within the testing chamber <NUM>, and humidity conditions within the testing chamber <NUM>. The display device <NUM> may include detector readings such as whether the sensor within the gas detector <NUM> being tested passes the accuracy level required or not (e.g., pass or no pass), whether relays or other system-level mitigation mechanisms including in the gas detector <NUM>, such as, for example, lights or switches are operating or operating correctly. The detector testing system <NUM> may also include different relay indicator lights <NUM> that may illuminate when different relay signals are activated by the gas detector <NUM> in response to a target gas or non-target gas. For example, when the gas detector <NUM> detects a target gas of a certain concentration then the gas detector <NUM> may produce a relay signal to the HVAC/R system <NUM> to perform a task (e.g., switches, fan on/off switches, activate an alarm, shut off the HVAC/R system, etc.) and the relay signal from the gas detector <NUM> will be communicated to the detector testing system <NUM> through the communication devices <NUM>, <NUM> and a relay indicator light <NUM> may illuminate, and the results may be displayed in the display device <NUM>.

Referring now to <FIG>, with continued reference to <FIG>, a flow chart of a method <NUM> of testing the gas detector <NUM> for an HVAC/R system <NUM> is illustrated, in accordance with an embodiment of the present disclosure. In an embodiment, the method <NUM> is performed by the detector testing system <NUM>. At block <NUM>, the gas detector <NUM> is inserted through an orifice <NUM> in a detector testing system <NUM> and at least partially into a testing chamber <NUM> within the detector testing system <NUM>. The testing chamber <NUM> being configured to at least partially enclose the gas detector <NUM> within the testing chamber <NUM>. In an embodiment, the testing chamber <NUM> is configured to at least totally or completely enclose the gas detector <NUM> within the testing chamber <NUM>.

At block <NUM>, the testing chamber <NUM> is sealed off from external environments <NUM> external to the testing chamber <NUM> and/or the detector testing system <NUM>. The testing chamber <NUM> may be sealed off from external environments <NUM> by: removing (e.g., detaching) the gas detector <NUM> from the HVAC/R system <NUM>; inserting the gas detector <NUM> fully into the testing chamber <NUM>; and closing a door <NUM> of the testing chamber <NUM>. The door <NUM> is configured to seal against the orifice <NUM> and fully enclose the gas detector <NUM> within the testing chamber <NUM>. The testing chamber <NUM> may also be sealed off from external environments <NUM> by: sealing the orifice <NUM> against a mounting surface <NUM> of the HVAC/R system <NUM> while the gas detector <NUM> remains attached to the mounting surface <NUM>; and partially enclosing the gas detector <NUM> within the testing chamber <NUM>.

At block <NUM>, a target gas is provided into the testing chamber <NUM> from a target gas cartridge <NUM> containing a known concentration of the target gas. In an embodiment, the target gas is a refrigerant. In another embodiment, the target gas is a mildly flammable refrigerant. In another embodiment, the target gas is an A2 refrigerant, A2L refrigerant, or an A3 refrigerant. In another embodiment, the known concentration of the target gas within the target gas cartridge is a lower flammability limit of the target gas.

At block <NUM>, one or more readings are received from the gas detector <NUM>. The method <NUM> may further comprising displaying the one or more detector readings detected by the gas detector <NUM> either through the display device <NUM> or relay indicator lights <NUM>. Additionally, the method <NUM> may further comprise: diluting the target gas to a lower flammability limit of the target gas prior to entering the testing chamber <NUM>.

The method <NUM> may also comprise: detecting an environmental condition within the testing chamber <NUM> using an environmental sensor <NUM> and adjusting the environmental condition within the testing chamber <NUM> using an environmental control <NUM>. The method <NUM> may further comprise: receiving readings from the gas detector <NUM> and transmitting the readings to a cloud server <NUM>. The method <NUM> may also further comprise: receiving readings from the gas detector <NUM>; determining a recalibration of the gas detector <NUM> is required in response to the readings; and transmitting the calibration parameters or adjustments for recalibration of the gas detector to the gas detector <NUM>.

While the above description has described the flow processes of <FIG> in a particular order, it should be appreciated that unless otherwise specifically required in the attached claims that the ordering of the steps may be varied.

<FIG> schematically illustrates a detector testing system <NUM> configured to test a gas detector <NUM> and an associated HVAC/R system <NUM>. The gas detector <NUM> may contain various components that are tested by the detector testing system <NUM>, such as for example gas sensors, diagnostic algorithms, and mitigation mechanisms such as lights, relays and switches. It should be appreciated that, although particular systems are separately defined in the schematic block diagrams, each or any of the systems may be otherwise combined or separated via hardware and/or software. The gas detector <NUM> is used in the HVAC/R system <NUM> to detect a target gas. The target gas is a refrigerant. In an embodiment, the target gas is a flammable and/or a mildly flammable refrigerant. In one embodiment, a mildly flammable refrigerant may be defined as a refrigerant having a greater than <NUM>/m<NUM>, a heat of combustion less than <NUM>,<NUM> kj/kg, and/or a burning velocity of less than <NUM>/s. In an embodiment, the mildly flammable refrigerant may be A2L refrigerant. An A2L refrigerant may include but is not limited to R32, R1234yf, R-1234ze(E), R134A, R454A, and R454B. In another embodiment, the target gas may be a higher flammability refrigerant, such as, for example an A3 refrigerant. In another embodiment, the target gas is an A2 refrigerant, A2L refrigerant, or an A3 refrigerant. An A2 refrigerant may include but is not limited to R-152a. An A3 refrigerant may include but is not limited to R-<NUM> (Propane) and R-600a (isobutene).

The detector testing system <NUM> may be separate and apart from the gas detector <NUM> and may be utilized to test the gas detector <NUM> periodically or intermittently, as required. The detector testing system <NUM> may be brought onsite to test the gas detector <NUM>. The detector testing system <NUM> may be brought to the HVAC/R system <NUM> to test the gas detector <NUM> while remaining installed in the HVAC/R system <NUM>, as described herein.

The detector testing system <NUM> includes a testing cup <NUM> with a testing chamber <NUM> capable of partially enclosing the gas detector <NUM>. The testing chamber <NUM> originates on a cup mounting surface <NUM> of the testing cup <NUM> and extends into the testing cup <NUM>, as illustrated in <FIG>.

In the embodiment illustrated in <FIG>, the gas detector <NUM> is not removed from a mounting surface <NUM> of the HVAC/R system <NUM> but rather gas detector <NUM> is tested within the testing chamber <NUM> of the testing cup <NUM> while still being mounted to the mounting surface <NUM>. As shown in <FIG>, the gas detector <NUM> is inserted into an orifice <NUM> of the detector testing system <NUM>. The orifice <NUM> opens up into the testing chamber <NUM>. The cup mounting surface <NUM> is configured to seal against the mounting surface <NUM> of the HVAC/R system <NUM>, while the testing chamber <NUM> encloses the gas detector <NUM>. The cup mounting surface <NUM> sealing against the mounting surface <NUM> of the HVAC/R system <NUM> environmentally seals (i.e., isolates) the gas detector <NUM> within the testing chamber <NUM> and prevents gas leakage between the testing chamber <NUM> and an external environment <NUM> outside of the testing chamber <NUM>.

When the gas detector <NUM> is sealed within the testing chamber <NUM>, the detector testing system <NUM> is configured to emit a known concentration of the target gas into the testing chamber <NUM> to test a state of health of the gas detector <NUM> and a response of the HVAC/R system <NUM>.

The detector testing system <NUM> may be in wired and/or wireless communication with the HVAC/R system <NUM> when the gas detector <NUM> is located within the testing chamber <NUM> to response data of the HVAC/R system <NUM>. The detector testing system <NUM> may include a communication device <NUM> and the HVAC/R system <NUM> may include a communication device <NUM>. In one embodiment, the communication device <NUM> of the HVAC/R system <NUM> may be hardwired to the communication device <NUM> of the detector testing system <NUM> through a removable connecting wire (not shown). In another embodiment, the communication device <NUM> of the HVAC/R system <NUM> may be in wireless communication with the communication device <NUM> of the detector testing system <NUM> through a short-range wireless transmissions, such as, for example, Bluetooth, Wi-Fi, Infrared, etc. Alternatively, there may be no communication between the detector testing system <NUM> and the HVAC/R system <NUM>, a technician may verify a response of the HVAC/R system <NUM> to testing by the detector system testing system <NUM>.

In one embodiment, a memory <NUM> of a controller <NUM> of the detector testing system <NUM> or any other memory device within the detector testing system <NUM> may be utilized to locally store testing data, including, but not limited to, building name, building number, room number, station number, time, test number, target gas name, target gas concentration, detector name, detector location, detector baseline, readings from the gas detector <NUM>, detector response as function of time, the known concentration of the target gas within the target gas tank <NUM>, the concentration of target gas delivered into the testing chamber <NUM>, the humidity within the testing chamber <NUM>, and the temperature within the testing chamber <NUM>, and the like. In an embodiment, the controller <NUM> is configured to dispense a correct quantity of target gas for testing.

In one embodiment, the controller <NUM> of the detector testing system <NUM> may be configured to locally analyze the testing data, determine a pass or fail decision for the gas detector <NUM>, and display the pass or fail decision back on the detector testing system <NUM>. In another embodiment, the communication device <NUM> may be in wireless communication with a cloud server <NUM> through a wireless transmissions, such as, for example, Bluetooth, Wi-Fi, Infrared, cellular, satellite, or other network communication. The communication device <NUM> may be configured to transmit the testing data to the cloud server <NUM>. The cloud server <NUM> may be configured to analyze the testing data, determine a pass or fail decision for the gas detector <NUM>, and transmit the pass or fail decision back to the detector testing system <NUM> for local display. Testing data may be downloaded from the HVAC/R system <NUM> to the controller <NUM> or any other computing device for analysis.

In addition to determining a pass or fail, the controller <NUM> and/or the cloud server <NUM> may alternatively determine that the gas detector <NUM> needs to be recalibrated using the detector testing system <NUM>. The communication device <NUM> of the detector testing system <NUM> may be in wireless communication with the communication device <NUM> of the gas detector <NUM> through a short-range wireless transmissions, such as, for example, Bluetooth, Wi-Fi, Infrared, etc.. The communication device <NUM> of the detector testing system <NUM> may be in wired communication with the communication device <NUM> of the gas detector <NUM> through a USB cable, Ethernet, fiber-optics, etc. Through the communication devices <NUM>, <NUM>, the detector testing system <NUM> may be able to pass to the gas detector <NUM> calibration parameters or adjustments thereto for recalibration of the gas detector <NUM>, which may be an automatic process. For example, once connected with the gas detector <NUM>, the detector testing system <NUM> can pair with the gas detector <NUM> to start a calibration test where it delivers a known concentration of target gas into the testing chamber <NUM>. Upon receiving the readings from the gas detector <NUM> in response to the target gas then the detector testing system <NUM> can send updated calibration parameters to the gas detector <NUM> and then rerun the test to confirm that the gas detector <NUM> has been successfully recalibrated.

The controller <NUM> may be configured to control entry of the target gas into the testing chamber <NUM> using a target gas metering component <NUM> or removal of the target gas from the testing chamber <NUM> using a target gas reclaim component <NUM>. The controller <NUM> may be an electronic controller including a processor <NUM> and an associated memory <NUM> comprising computer-executable instructions that, when executed by the processor <NUM>, cause the processor <NUM> to perform various operations. The processor <NUM> may be, but is not limited to, a single-processor or multi-processor system of any of a wide array of possible architectures, including field programmable gate array (FPGA), central processing unit (CPU), application specific integrated circuits (ASIC), digital signal processor (DSP) or graphics processing unit (GPU) hardware arranged homogenously or heterogeneously. The memory <NUM> may be but is not limited to a random access memory (RAM), read only memory (ROM), or other electronic, optical, magnetic or any other computer readable medium.

The detector testing system <NUM> may also include a target gas delivery hose <NUM> fluidly connected to the testing chamber <NUM>. The target gas tank <NUM> may be fluidly connected to the testing chamber <NUM> through a target gas delivery hose <NUM>. The target gas metering component <NUM> may be located within the target gas delivery hose <NUM> interposed between the testing chamber <NUM> and the target gas tank <NUM>. The target gas metering component <NUM> may be a metering valve, solenoid valve, stepper motor valve or similar component known to one of skill in the art. The target gas metering component <NUM> may adjust or meter how much of the target gas is delivered from the target gas tank <NUM> to the testing chamber <NUM>. In one example, the target gas metering performed by the target gas metering component <NUM> may be done with a controller that opens a solenoid valve for a specific time, which is correlated to a quantity of refrigerant. In another example, the target gas metering performed by the target gas metering component <NUM> may be done by opening a stepper motor valve, measuring the flow rate with a flow-meter, and correlating that the flow rate to a quantity of refrigerant.

The target gas delivery hose <NUM> is configured to deliver the target gas into the testing chamber <NUM>. The target gas tank <NUM> contains a known concentration of the target gas, such as, for example, <NUM>%, <NUM>%, <NUM>%, <NUM>%, <NUM>%, <NUM>%, <NUM>%, <NUM>%, <NUM>%, <NUM>%, <NUM>%, or any concentration therebetween. In one embodiment, the target gas tank <NUM> may contain a known concentration of the target gas equal to about <NUM>%. The detector testing system <NUM> includes target gas metering component <NUM> to adjust flow of the target gas from the target gas tank <NUM> into the testing chamber <NUM>.

The detector testing system <NUM> may also include a target gas return hose <NUM> fluidly connected to the testing chamber <NUM>. The target gas tank <NUM> may be fluidly connected to the testing chamber <NUM> through a target gas return hose <NUM>. A target gas reclaim component <NUM> may be located within the target gas return hose <NUM> interposed between the testing chamber <NUM> and the target gas tank <NUM>. The target gas reclaim component <NUM> may be a valve, a pump, a hermetic pump rated for flammable refrigerant, or any similar device known to one of skill in the art. The target gas reclaim component <NUM> may be configured to pump the target gas from the testing chamber <NUM> to the target gas tank <NUM> through the target gas return hose <NUM> once testing is completed. The pressure of the testing chamber <NUM> will be measured and pumped down to <NUM> psig.

The detector testing system <NUM> may also include a display device <NUM> configured to display response data of the HVAC/R system <NUM>. The response data may indicate whether the HVAC/R system <NUM> has performed (or is performing) an isolation and pump down procedure following the introduction of the target gas into the testing chamber <NUM>. The display device <NUM> may be controlled with a computing program, such as, for example, Vissim or MATLAB. The display device <NUM> may be a computer monitor or one or more lights with different meanings (e.g., red = test failed; green = test passed).

Referring now to <FIG>, with continued reference to <FIG>, a flow chart of a method <NUM> of testing the gas detector <NUM> for an HVAC/R system <NUM> is illustrated, in accordance with an embodiment of the present disclosure. The method <NUM> may indicate a pass or fail of a safety system test. In an embodiment, the method <NUM> is performed by the detector testing system <NUM>. At block <NUM>, the gas detector <NUM> is inserted through an orifice <NUM> in a detector testing system <NUM> and at least partially into a testing chamber <NUM> within the detector testing system <NUM>. The testing chamber <NUM> being configured to at least partially enclose the gas detector <NUM> within the testing chamber <NUM>. In an embodiment, the testing chamber <NUM> is configured to at least totally or completely enclose the gas detector <NUM> within the testing chamber <NUM>.

At block <NUM>, the testing chamber <NUM> is sealed off from external environments <NUM> external to the testing chamber <NUM>. The testing chamber <NUM> may be sealed off from external environments by sealing the cup mounting surface <NUM> against a mounting surface <NUM> of the HVAC/R system <NUM> while the gas detector <NUM> remains attached to the mounting surface <NUM>; and partially enclosing the gas detector <NUM> within the testing chamber <NUM>.

At block <NUM>, a target gas is provided into the testing chamber <NUM> from a target gas tank <NUM> containing a known concentration of the target gas. In an embodiment, the target gas is a refrigerant. In another embodiment, the target gas is a mildly flammable refrigerant. In another embodiment, the target gas is an A2 refrigerant, A2L refrigerant, or an A3 refrigerant. In another embodiment, the known concentration of the target gas within the target gas cartridge is a lower flammability limit of the target gas.

At block <NUM>, response data is received from the HVAC/R system <NUM>. The response data may indicate whether the HVAC/R system <NUM> has performed or is performing an isolation and pump down procedure following the introduction of the target gas into the testing chamber <NUM>. If the HVAC/R system <NUM> has performed (or is performing) an isolation and pump down procedure following the introduction of the target gas then the HVAC/R system <NUM> is considered to have passed a safety system test. If the HVAC/R system <NUM> has not performed (or is not performing) an isolation and pump down procedure following the introduction of the target gas then the HVAC/R system <NUM> is considered to have failed the safety system test.

The method <NUM> may further comprise that the target gas is transported from the testing chamber <NUM> to a target gas tank <NUM>. The target gas may be transported from the testing chamber <NUM> to a target gas tank <NUM> using the target gas reclaim component <NUM> through the target gas return hose <NUM>.

As described above, embodiments can be in the form of processor-implemented processes and devices for practicing those processes, such as processor. Embodiments can also be in the form of computer program code (e.g., computer program product) containing instructions embodied in tangible media, such as floppy diskettes, CD ROMs, hard drives, or any other non-transitory computer readable medium, wherein, when the computer program code is loaded into and executed by a computer, the computer becomes a device for practicing the embodiments. Embodiments can also be in the form of computer program code, for example, whether stored in a storage medium, loaded into and/or executed by a computer, or transmitted over some transmission medium, loaded into and/or executed by a computer, or transmitted over some transmission medium, such as over electrical wiring or cabling, through fiber optics, or via electromagnetic radiation, wherein, when the computer program code is loaded into and executed by a computer, the computer becomes an device for practicing the exemplary embodiments.

Claim 1:
A detector testing system for testing a gas detector (<NUM>) used in a heating, ventilation, and air conditioning, or refrigeration (HVAC/R) system (<NUM>), the detector testing system comprising:
a testing chamber (<NUM>; <NUM>) configured to receive the gas detector through an orifice (<NUM>; <NUM>) in the detector testing system, the testing chamber being configured to at least partially enclose the gas detector within the testing chamber;
a receiving port (<NUM>) fluidly connected to the testing chamber; and wherein the receiving port is configured to deliver the target gas to the testing chamber,
a target gas cartridge (<NUM>) fluidly connected to the receiving port, characterized by that the target gas cartridge contains a known concentration of a refrigerant as a target gas, wherein the known concentration of the refrigerant within the target gas cartridge is a lower flammability limit of the refrigerant and/or wherein the detector testing system is configured to dilute the refrigerant within the target gas cartridge to a lower flammability limit of the refrigerant prior to the refrigerant entering the testing chamber.