Transform every connection point on your test station into an intelligent data source. ICON™ integrates seal verification, process automation, and real-time data output directly into FasTest’s industry-leading connection tools.
Modern manufacturing demands more from leak testing than a simple pass/fail result. Production engineers need to know that every connection was sealed before the test began, that every step in a multi-port test sequence was completed in order, and that every test cycle is documented for traceability and process optimization. Traditional connectors can’t provide any of that information—they’re passive mechanical components with no intelligence.
ICON™ changes that. By integrating sensing, SURE SEAL™ seal confirmation, and real-time data output into the connector itself, ICON™ makes every FasTest connection tool an intelligent connection tool that communicates with operators, PLCs, and data systems. The result is automated leak testing that’s smarter, safer, and faster—with verifiable data at every connection point.
ICON™ intelligent connection tools are available across 10 FasTest connector families, covering external threads, internal threads, tubes, flanges, and custom geometries. Whether your test station is manual, semi-automated, or fully robotic, ICON™ provides the intelligence layer that turns a mechanical connection into a verified, documented, automation-ready process step.
Yellow indication of a miss-connect or short-connect. Reconnect for green indication.
User controllable white indication allows user’s to tailor to their testing process. Examples include setting a signal to operators to use a specific tool, or an indication that a test is running and to not remove connector.
Blue heartbeat indication that power is connected.
Manufacturers invest heavily in leak test instruments, PLCs, automation hardware, and data systems—but the physical connection between the test system and the part being tested is often the least intelligent component on the station. Here’s what that costs:
ICON™ intelligent connection tools solve every one of these problems by putting intelligence at the point of connection—exactly where automated leak testing needs it most.
At the heart of every ICON™ intelligent connection tool is SURE SEAL™—FasTest’s patented seal verification technology. SURE SEAL™ uses integrated sensors to detect whether the connector has achieved a complete, leak-tight seal on the port.
Sense: When the operator or actuator engages the connector, internal sensors detect the position and engagement state of the sealing mechanism.
Evaluate: The ICON™ module evaluates the sensor data against stored calibration parameters to determine whether the seal meets the required threshold.
Signal: If the seal is confirmed, the connector signals “good connection” via a green LED (for operators) and a digital output (for PLCs). If the seal is incomplete, a yellow LED signals a short-connect, prompting reconnection.
Record: The seal status data is available in real time for PLC integration, data logging, traceability, and SPC analysis. Calibration parameters are stored in non-volatile memory on the connector itself.
For automated test stations, SURE SEAL™ provides the digital handshake that the PLC needs to confirm the connection is sealed before initiating the test cycle. For manual stations, it gives operators immediate visual confirmation (green LED) that eliminates guesswork. For quality systems, it generates the documented seal verification record that traceability requirements demand. In every case, SURE SEAL™ removes the connection as a source of test variability, false failures, and undocumented process steps.
| Industry | ICON™ Application Examples |
|---|---|
| Automotive & EV | Multi-port engine block leak testing with PLC-verified seal confirmation at every connection. Battery pack seal testing with automated connection sequencing. Motor housing coolant circuit testing with CoBot-mounted intelligent connection tools. |
| HVAC-R | Coil leak testing with SURE SEAL™ confirmation on automated rotary indexing stations. Compressor test stations with actuator-mounted ICON™ connectors. Automated evacuation and charge stations with verified processing connections. |
| Compressed Gas | Fill plant automation with ICON™ seal verification on cylinder connections. Data logging of connection status for fill quality documentation. Multi-point fill manifold monitoring. |
| Fluid Power | Hydraulic hose assembly proof testing with PLC-interlocked ICON™ connections at high pressures. Automated cylinder test stations with multi-port seal confirmation before pressurization. |
| Medical / Life Science | High-volume automated catheter and luer testing with ICON™ seal confirmation. Traceability data output for FDA-regulated manufacturing. Step-completion verification on multi-connection test sequences. |
| Aerospace | High-pressure tube assembly proof testing with verified seal status before pressurization. Engine component test cells with robotic ICON™ connector placement and multi-point verification. |
| Appliance | End-of-line refrigerant circuit leak testing with actuator-mounted ICON™ connectors. Gas burner test stations with seal-confirmed connections. Multi-system test stations (refrigerant + plumbing + gas) with step-completion tracking. |
ICON™ intelligent connection tools are available across a broad range of FasTest connector families, covering the most common connection types in manufacturing leak testing:
| Series | Connection Type & Application |
|---|---|
| 60 ICON | External threaded connections to 750 psi (51 bar). The most widely used ICON™ connector for threaded port leak testing across automotive, HVAC-R, fluid power, and general manufacturing. |
| 70 ICON | External connections for tubes and barbed fittings. Grip-and-seal with ICON™ intelligence for tube assembly and hose barb applications. |
| ME ICON | External sealing connectors for smooth tubes and cylindrical ports. ICON™-equipped for automated tube sealing applications. |
| FE ICON | Pneumatically operated external seal-only connectors for fixtured automated leak testing. Seal confirmation via ICON™ for PLC-controlled actuator-mounted stations. |
| FI ICON | Pneumatically operated internal seal-only connectors for fixtured applications. Internal bore sealing with ICON™ verification for automated test stations. |
| FEG ICON | External cradle connectors for flanges and irregular port geometries. ICON™-equipped for turbocharger, manifold, and housing face sealing applications. |
| FIG ICON | Internal cradle connectors for sealing inside irregular port openings. ICON™ intelligence for custom internal sealing applications. |
| FN ICON | FasMate® FN internal high-pressure connectors to 5,000 psi (345 bar). ICON™ seal confirmation for high-pressure threaded bore applications. |
| FX ICON | FasMate® FX external connections for high-pressure applications. ICON™-equipped for demanding fluid power and aerospace testing. |
| ZGNP ICON | EZ-Connect™ ZGN series for quick tube connections. ICON™ intelligence for fast push-to-connect tube sealing. |
A: ICON™ (Intelligent Connection) is FasTest’s technology platform that integrates sensing, SURE SEAL™ seal confirmation, and real-time data output into FasTest connection tools. ICON™ turns standard connectors into intelligent connection tools that communicate seal status, enable process automation, and generate traceability data for automated leak testing and manual test operations.
A: SURE SEAL™ is FasTest’s patented seal verification technology built into ICON™ connectors. It uses integrated sensors to detect whether a complete, leak-tight seal has been achieved, then signals the result via LED (for operators) and digital output (for PLC integration). SURE SEAL™ is the foundation of ICON™’s ability to verify connections in automated leak testing systems.
A: Intelligent connection tools are sealing connectors with built-in sensing, seal confirmation, and data output capabilities. Unlike traditional passive connectors, FasTest’s ICON™-equipped intelligent connection tools actively verify seal status, communicate with PLCs and operators, and generate real-time process data. They transform the connection from a mechanical step into a verified, documented, automation-ready process event.
A: ICON™ provides the digital signals that automated leak testing systems need: verified seal confirmation before pressurization (safety interlock), step completion handshakes for multi-port sequences, and real-time connection status data for PLC-controlled test logic. ICON™ intelligent connection tools work with linear actuators, collaborative robots, and full industrial robot cells.
A: ICON™ supports four levels of automation: manual operation with visual seal confirmation, linear actuator-mounted connectors with PLC handshakes, collaborative robot (CoBot) integration for complex motion paths, and full industrial robot cells for multi-port automated leak testing. The same ICON™ connector works across all levels.
A: ICON™ is currently available in 10 connector families: Series 60, 70, ME, FE, FI, FEG, FIG, FN (FasMate®), FX (FasMate®), and ZGNP (EZ-Connect™). These cover external threads, internal threads, tubes, flanges, and custom geometries. Custom ICON™ configurations are also available.
A: The SSR (Solid-State Relay) version provides a simple normally-open dry-contact output for easy PLC integration and is suitable for most applications. The Analog version provides 0–10V proportional output for advanced users who need detailed actuation position data and full LED control via PLC. The SSR version is recommended for most customers; Analog is for specialized applications.
A: False failures occur when an incomplete seal causes the test system to detect a “leak” that is actually at the connector, not in the part. ICON™’s SURE SEAL™ verification confirms the seal is complete before the test begins. If the seal is incomplete, a yellow LED and digital signal prompt reconnection rather than running a doomed test. This eliminates the single largest source of false failures in manufacturing leak testing.
A: In most cases, yes. ICON™ intelligent connection tools use the same physical form factor and mounting as standard FasTest connectors, so upgrading typically requires no changes to fixtures or mechanical hardware. Integration involves wiring the ICON™ output to a PLC input and configuring the test logic to use the seal confirmation signal. FasTest provides integration guidance and technical support.
A: ICON™ outputs real-time connection status (sealed/not sealed), seal verification confirmation, actuation state, and LED status. This data can be used for PLC safety interlocks, step completion tracking, process traceability documentation, SPC analysis, and predictive maintenance (identifying connectors approaching seal replacement before they cause failures).
A: Yes. ICON™ connectors are calibrated during setup to establish the seal verification threshold for your specific application. For SSR versions, calibration parameters are stored in non-volatile memory on the connector, making maintenance and replacement straightforward. For FE and FI connectors, calibration may require gauge pins sized to the device under test. FasTest provides calibration procedures and tools.
A: ICON™ intelligent connection tools are used in automotive and EV manufacturing, HVAC-R, compressed gas, fluid power, medical device, aerospace, and appliance industries—anywhere that automated leak testing, process traceability, or false failure reduction is a priority.
