The Expanded-Tube Connector Built for Real Production Tube Ends

The FasTest XT is the expanded tube connector — a sleeve-actuated, ball-grip tool that grips and seals onto the expanded (flared) ends of copper and aluminum refrigeration tubes for fast, repeatable leak testing and processing. Where a straight-tube connector needs a smooth, prepared tube, the XT is built specifically for the flared tube end, and built to handle it as it actually comes off a production line.

That is the XT’s real advantage: it connects to a broad range of flared ends, including rough-cut ends. Production tube ends are not perfect — they vary, and they are often rough-cut — and a connector that only seals on a clean, precise flare forces extra tube preparation or rejects good assemblies. The XT’s ball-grip design seals across that range, so it connects to the tubes a line actually produces, not only the ideal ones. For a manufacturer, that is fewer rejects, less rework, and a faster line.

It is a leak-test connector at heart, designed for helium leak testing, run testing, proof testing, and pressure decay, with deep vacuum capability down to 10 millitorr (micron) — the deep vacuum a helium leak test needs. The sleeve actuation makes the connection instantly and locks under pressure to prevent accidental disconnection, and the tool is rated from that deep vacuum up to 750 psi (51.7 bar).

Two more things set the current XT apart. Its base connector is now made of stainless steel for durability, and it is available with the SurConnect© sleeve, whose “Green to Go” ring gives the operator visual confirmation of a secure connection — error-proofing on a busy line — on a lightweight aluminum body that reduces operator strain. It can be fitted with Hansen® or PCU® processing tips, and is compatible with standard industry quick-connect tips.

The Problem the FasTest XT Solves

Leak testing an expanded-tube refrigeration assembly, in production, runs into problems the XT is shaped to solve:

• Real tube ends are imperfect: Production flared ends vary and are often rough-cut. A connector that seals only on a clean flare means extra prep or rejected assemblies. The XT seals across a broad range of flared ends, rough-cut included.

• Helium leak testing needs deep vacuum: A meaningful helium leak test pulls a deep vacuum. The XT reaches 10 millitorr (micron), so it supports the test rather than limiting it.

• The connection must be fast and repeatable: On a line testing every assembly, the connection has to be instant and consistent. The sleeve-actuated ball grip connects fast and the same way every time.

• A missed connection is a bad test — or a hazard: A connection that is not fully secure can fail the test or release under pressure. The sleeve locks under pressure, and the SurConnect© “Green to Go” ring gives visual confirmation the connection is secure.

The FasTest XT answers each: a broad flared-end range including rough-cut, deep vacuum to 10 micron, an instant sleeve ball-grip that locks under pressure, and optional visual confirmation of a secure connection.

Key Features 

Broad Flared-End Range — Including Rough-Cut

The XT connects to a broad range of flared ends on copper and aluminum refrigeration tubes, including rough-cut ends. This is the feature that matters most in production: the tool seals on the tubes a line actually makes, so it reduces the tube preparation and the rejected assemblies that a less tolerant connector forces.

Sleeve-Actuated Ball Grip — Instant, Locks Under Pressure

A sleeve-actuated ball-grip mechanism makes the connection instantly and grips the flared end securely. The sleeve locks under pressure to prevent accidental disconnection, so the connection stays put through the test.

Deep Vacuum to 10 Millitorr (Micron)

The XT reaches deep vacuum down to 10 millitorr (micron), the level a helium leak test requires. Combined with the up-to-750 psi rating, it covers deep-vacuum and pressure testing on one tool.

SurConnect© — “Green to Go” Visual Confirmation

The optional SurConnect© sleeve gives a “Green to Go” ring that visually confirms a secure connection — error-proofing for the operator — on a lightweight aluminum body that reduces strain, colour-coded for easy recognition. It installs on existing XT connectors or comes fully assembled, and is compatible with standard industry quick-connect tips.

Stainless Base, Hansen® / PCU® Tips

The base connector is now stainless steel for durability, and the XT is available with Hansen® or PCU® processing tips to match the processing system in use. (A seal-material improvement has also been announced — see the seal change note.)

Technical Specifications

Where the FasTest XT Is Used

Helium Leak Testing of Expanded-Tube Assemblies

Its core use is helium leak testing refrigeration assemblies with expanded / flared tube ends — pulling deep vacuum through the XT to 10 micron and running the test, on copper or aluminum tubes.

Run, Proof, and Pressure-Decay Testing

Beyond helium leak testing, the XT is designed for run testing, proof testing, and pressure decay — the range of tests a refrigeration assembly goes through, all on the same flared-tube connection.

Copper and Aluminum Refrigeration Tubes

It connects to both copper and aluminum flared tubes, the common refrigeration tube materials, across a broad range of flared-end conditions including rough-cut.

HVAC-R Manufacturing Lines

Its home is HVAC-R manufacturing — air conditioning, refrigeration, and heat pump assembly lines — where expanded-tube joints are tested in volume and tolerance to real tube ends keeps the line moving.

FasTest XT vs. a Conventional Manual Expanded-Tube Connection

Frequently Asked Questions

Q: What is the XT Expanded Tube Connection Tool?

A: It is FasTest’s expanded tube connector — a sleeve-actuated, ball-grip tool that seals onto the expanded (flared) ends of copper and aluminum refrigeration tubes for helium leak testing, run testing, proof testing, and pressure decay. It reaches deep vacuum to 10 micron and is rated to 750 psi.

Q: Does the XT work with rough-cut tube ends?

A: Yes — that is one of its main strengths. It connects to a broad range of flared ends, including rough-cut ends, so it seals on the tubes a production line actually makes rather than only clean, precisely prepared flares. That reduces tube preparation and rejected assemblies.

Q: What tests is the XT designed for?

A: Helium leak testing, run testing, proof testing, pressure decay, and other related processes — the tests an expanded-tube refrigeration assembly goes through in manufacturing.

Q: How deep a vacuum can the XT pull?

A: Down to 10 millitorr (micron) — the deep vacuum a helium leak test needs — and it is rated up to 750 psi (51.7 bar) for pressure testing.

Q: What is SurConnect?

A: SurConnect© is an optional sleeve for the XT with a “Green to Go” ring that visually confirms a secure connection — error-proofing for the operator. It has a lightweight aluminum body that reduces strain, is colour-coded, installs on existing XT connectors or comes fully assembled, and is compatible with standard industry quick-connect tips.

Q: What tubes does the XT connect to?

A: Copper and aluminum flared (expanded) refrigeration tube ends, across a broad range of conditions including rough-cut. See the XT Series Tube Tolerances document for supported dimensions.

Q: How is the XT different from the ST, JXL, and JNL connectors?

A: They are for different tube ends. The XT is for expanded / flared tube ends. The ST is a sleeve-actuated connector for smooth straight tubes; the JXL is a lever-actuated connector for smooth straight and swaged tubes; the JNL is a lever-actuated internal connector for smooth straight tubes and bores. Choose by the tube end you are sealing — flared: XT.

Q: Is it a quick connect?

A: It makes an instant sleeve-actuated connection to the flared tube end and releases when done — a reusable quick-connecting test tool, not a permanent coupling. It is also compatible with standard industry quick-connect tips.

Q: What processing tips are available?

A: The XT is available with Hansen® or PCU® processing tips, and is compatible with standard industry quick-connect tips, so it can match the processing system in use.

Q: What industries use the XT?

A: HVAC-R manufacturing — air conditioning, refrigeration, and heat pump assembly — wherever expanded-tube refrigeration joints are leak tested and processed in volume.