What Is HVAC Leak Testing?

HVAC leak testing verifies that components such as evaporators, condensers, radiators, heat exchangers and air conditioning hoses meet the required leak rate before they leave production.

For HVAC manufacturers, HVAC leak testing systems help detect very small leaks that could affect refrigerant containment, product performance, warranty risk and regulatory compliance.

VES designs HVAC leak testing systems around the component, required leak rate, production volume, cycle time and test method, with options including hard vacuum, accumulation and PURE helium recovery systems. For a deeper technical overview, read our helium leak testing guide.

HVAC Components and Applications VES Can Test

VES designs HVAC leak testing systems for automotive, residential, air conditioning, refrigeration and thermal management components.

Automotive HVAC

Leak testing for production components used in vehicle heating, ventilation, air conditioning and thermal management systems.

  • Evaporators and condensers.
  • Radiators and heat exchangers.
  • Air conditioning hoses.
  • Refrigeration and thermal management assemblies.

Residential HVAC

Leak testing for components used in residential HVAC, air conditioning, heating and heat pump manufacturing.

  • Condensers and evaporators.
  • Radiators and heat exchangers.
  • Heat pump components.
  • Air conditioning hoses and assemblies.

Refrigeration and Thermal Management

Leak testing for refrigeration circuits, cooling systems and bespoke HVAC assemblies where leak integrity is critical.

  • Refrigeration coils and cooling circuits.
  • Pressure-tested components.
  • Thermal management assemblies.
  • Bespoke HVAC components.

10 Helium Leak Testing Challenges With HVAC

Production capacity depends not only on volumes of products out of the door, but also on minimising waste. All VES machines are designed and manufactured to ensure a CPK of 1.67. This means that you can be confident that your passes are passes, your fails are fails, and your line is running at full optimisation.

VES have refined our design system, down to the last screw. We aim to ensure the machine we build for you is comprised of proven quality components whilst maintaining the most cost effective procurement strategy. This means we can pass our advantages on to the end user. VES will never compromise on quality. Our reputation is based on providing trouble free and long lasting operation at a fair price. We are confident this will allow your organisation to thrive with the best in quality assurance. With production capacity maximised, your output will be as high as possible with a VES machine in your arsenal.

Founded in 1986, VES have been through many changes in legislation spanning industry types worldwide. We have experienced team members with the knowledge to navigate our way through the sometimes tumultuous world of legislation. Built on the requirement to ensure our skies are clear and the environment as clear of hydrocarbons as possible, we gained an unrivalled understanding in the world of fuel systems, HVAC and harmful gas industries. We ensure products tested on our systems both conform to the required standards, and contribute to a safe environment for future generations. VES are proud to be involved in making the world a better place.

Finding the smallest leaks means our machines require technology that changes the pressures both inside and outside of the test piece. This causes issues with overstressing products and potentially causing catastrophic failures after the test has completed. VES control, monitor and maintain this pressure differential, ensuring your product is tested safely and efficiently, time and time again.

VES understand that our Helium Leak Testers need to smoothly integrate into the production line in order to maintain productivity and efficiency. Therefore we work with automation experts to integrate state of the art conveyor systems. This allows parts to transition efficiently in and out of our machines and onto the next production cycle.

We understand that floor space is at a premium in most places of work. Due to our modular machine design, we are able to customise the layout of the machine to fit your footprint requirements. VES have also developed our OptVol leak detector. OptVol is a volume optimised leak detector where the vacuum chamber size is kept to a minimum which in turn reduces the vacuum pump sizes. This keeps the footprint of the machine to a minimum.

With manufacturing techniques constantly improving, industries can now utilise high pressure applications and benefit from their advantages. CO2 is now commonplace as a refrigerant in HVAC systems at a working pressure over 200 bar. This makes testing safely a priority. VES have developed robust designs and unique safety mechanisms. We have worked with 3rd party safety experts to analyse and approve our designs. This enables us to assure the customer we are a safe pair of hands when it comes to high pressure testing.

With customers expecting more from their product than ever, the industry is having to adapt and become more flexible. We now have to offer a larger product range, which comes with different demands and testing requirements. Our modular designs enable us to accept and test multiple products.

In the past two years we have seen an increase in the price of helium by 30-40%. For the leak detection industry this brings great concern to the running costs associated with helium. VES produce multiple products which can reduce your helium usage. Solutions include: PURE helium recovery systems, helium re-purification and gas mixing.

We understand the pressures of the large scale production environment. Our reputation has been built on ensuring your product has not only the highest quality, but is produced in the largest quantity. Our proposal process considers required cycle times and we will not quote a machine unless we are able to hit these requirements.

VES HVAC Systems

VES offer a complete range of HVAC leak testing systems for manufacturers of automotive HVAC, residential HVAC, air conditioning, heat exchanger and refrigeration components.

Hard vacuum helium leak detection system

HardVac

The VES range of HardVac helium leak detection systems is the ultimate solution and the last word in helium leak detection. Our systems offer a fully bespoke solution, tailored to your specific requirements. This means that the solution we supply will be fully optimised to ensure you get the best in design, highest quality, long-lasting components, and a machine that will ensure complete peace of mind. By minimising waste and maximising production, you can have confidence in your product. Our hardvac systems have been used worldwide for decades with unparalleled success due to our extensive knowledge in this complex field. VES are incredibly proud of this world-beating technology and consider our HardVac systems to be our flagship product.

OptVol

VES' Optimised Volume range of helium leak detection equipment is the ultimate compact all-in-one solution. They  utilise the proven technology found in our flagship range of bespoke test equipment. Our machines built using OptVol Technology boast maximum features housed within a convenient and compact package. Ideally suited to shop floors where space is a premium, OptVol is a one size fits all solution.

OptVol features a single size chamber that can be loaded with a machined block profiled to your specific product. This ensures the minimum machine cycle time whilst also enabling a futureproof design. OptVol can be used to test a range of products with a simple tooling change, rather than needing a whole new vessel module or even a dedicated machine.

VES - OptVol helium leak detection machine

Accumulation

Our accumulation machine utilises mass spectrometry technology, helium or hydrogen tracer gas, and airflow generators to accurately measure the total leak rate of a product down to 1.0 x 10-3 mbar*L/sec. This is done without the need for a vacuum pumping system or leak-tight chamber, as tests are conducted at atmosphere. The lack of a pumping system and vacuum chambers reduces the price of the machine when compared to traditional Hard Vacuum machines.

Helium Recovery for HVAC Leak Testing

For HVAC manufacturers using helium leak testing at production scale, helium cost and availability can become a major operating consideration. PURE helium recovery systems can help recover, repurify and reuse helium from suitable HVAC leak testing processes. This can reduce helium waste, improve long-term operating costs and support a more sustainable test strategy.

HVAC leak testing machine service

Speak to VES About HVAC Leak Testing

Talk to VES about your HVAC component, leak rate, cycle time and production requirements. Our team can advise on the most suitable leak testing system and whether helium recovery could support your operation.