Refrigeration Connector Tailored Swiftly to Meet Application Requirements

jxl custom handle


A leading global manufacturer of HVAC equipment.


Refrigeration system processing on air conditioning units traveling down a high volume, multi-station assembly line.


The manufacturer was converting an existing line to a new design utilizing a new A2L refrigerant. A new processing connector solution was needed that was compatible with A2L refrigerant and provided “poka yoke” capability. At each station the line operator connects processing lines to the AC unit, and then disconnects them when the process is complete prior to the unit moving on to the next station. The AC units are mounted to a “base plate” as they travel down the line, and the connectors could not project outside of the base plate to avoid being damaged during transit between stations. Finally, each AC unit has two different line sizes, one size for the low-pressure line and another for the highpressure line; the solution would need to work for both sizes.

Project Goals

  • “Poka yoke” connectors to prevent accidental use of old tooling/refrigerant on the new air conditioner model
  • Compatible with A2L refrigerant, compressor lubricant, and processing fluid
  • Increase processing flow capacity to decrease takt time
  • Fit within the AC unit base plate space constraints
  • Common connector design for both high and low pressure lines
  • Automatic refrigerant shut-off upon disconnect


FasTest engineers worked with the customer to modify an existing FasTest JXL refrigeration connector to meet the unique needs of the application. The handle design was highly modified to minimize overall length and featured a separable handle. Also, FasTest developed a special molded seal compound that was compatible with the A2L refrigerant being used as well as the customer’s unique combination of compressor lubricant and processing fluid.     


The custom JXL cam handle design met all the requirements and performed well in the new application. The customer achieved the increased flow capability they required and the new seal compound has been approved for use at several manufacturing locations.