Xpress Seal AC Leak Sealant | Direct Inject XPS- mini, SS, 5T, 10T, 15T, 30T, 60T
The Formula That Built The Category. Millions of Leaks Sealed.
Built specifically for HVACR service, Xpress Seal is an organosilane-based refrigerant leak sealant that circulates as inert monomers inside the closed system — carried by the refrigerant to every point in the circuit. It does nothing inside the system. At a leak point, atmospheric exposure triggers polymerization from outside the system only— sealing the leak without forming anything inside the circuit.
No pre-formed polymer macromolecules enter the system. This is the distinction that matters: legacy polymer sealants injected macromolecules large enough to obstruct TXV valves and metering devices, this was the problem with early formulations that caused system failures. Xpress Seal does not. The seal forms where the leak is, nothing forms anywhere else.
The result: reduced callbacks, eliminated refrigerant loss, and a permanent pinhole repair — across residential, light commercial, and heavy commercial applications up to 60 tons. (125 and 250 ton available upon request).
Vapco Tech Note — How It Works: Think of Xpress Seal the way you think about platelets in your bloodstream. Platelets circulate harmlessly through a healthy system — completely inert, doing nothing, causing no obstruction. The moment there’s a breach, they activate at the site of injury and form a seal. Not throughout the system. Only where the leak is.
This makes Xpress Seal effective for older systems already losing refrigerant — and as a preventative maintenance option for newer systems that will more than likely develop a pinhole leak at some point in their service life.
Pre-Injection Check: Before injection, confirm a small nitrogen bubble is present and moving freely in the inject tube — this is your quality indicator that the formula is intact and ready to perform.
Installation Note: If the product is not dispensing after connecting to the low-side service port, the Xpress Inject tube depressor may not be making full contact with the Schrader valve core. Using channel-lock pliers or grips, continue tightening the connection until the valve core is fully depressed and flow begins. This is the most common installation issue and is resolved by ensuring a fully seated connection before assuming a product or system problem.
| KEY FEATURE / SPECIFICATION | TRADE BENEFIT / RESULT |
|---|---|
| TXV, Gauge & Metering Device Safe | No Obstruction Risk: no pre-formed polymer macromolecules enter the system. Nothing large enough to obstruct a TXV, piston, capillary tube, or EEV at any point. The seal forms outside the system at the leak site only. |
| No Pump Down Required | Install Into a Running System: No pump down required regardless of refrigerant type. Connect to the low-side service port, inject using high-side system pressure, manifold gauges, or the Xpress Inject CO2 Gun. Disconnect. Let the system run 60 minutes. |
| Full Refrigerant Compatibility | Every Refrigerant on Your Truck: Compatible with all refrigerants in active HVACR service — R-410A, R-22, R-32, R-134a, R-404A, R-407C, A2L (R-454B, R-32), and A3 hydrocarbons. Ready for the full A2L transition in new residential equipment. Not compatible with ammonia (NH3) systems. |
| Recovery Equipment Safe | No Contamination Risk: Unreacted monomers circulate with the refrigerant and exit normally during recovery — the same way any refrigerant-miscible additive behaves. Nothing is left behind that wouldn’t already come out in a standard recovery process. |
| Full Size Coverage — One Brand | Stocking Advantage: Seven standard SKUs cover every system your techs are working on — from appliances 0.75-tons through 60-ton commercial systems. |
| Industrial Sizes Available | 125 and 250-Ton On Request: For large commercial and industrial applications — chillers, industrial refrigeration, large VRF systems — 61–125 ton and 126–250 ton sizes are available on request.
Contact Vapco for availability and to put you in contact with a wholesaler near you for pricing. |
| Minimum System Pressure: 15 PSI | Moisture Risk Threshold: System must maintain a minimum of 15 PSI to qualify for standard sealant application. If system pressure has dropped below 15 PSI, moisture contamination is likely — acid formation and internal corrosion may already be present. In this case, use Xpress Seal & Protect or Xpress Protect to neutralize acids and eliminate moisture before or concurrent with sealant injection. |
| Right Application: 24-Hour Hold Test | Qualify the System First: Xpress Seal is engineered for pinhole leaks in evaporator coils, condenser coils, copper line sets, steel lines, and solder joints. If the system can maintain operating pressure and continue running for 24 hours, the leak or leaks are small enough for sealant. If the system loses charge fast enough to become non-functional within 24 hours, the leak is too large for sealant and requires mechanical repair. In that case, use Xpress Seal with UV Dye or UV Dye only to rapidly locate the leak site and perform the mechanical repair. |
| Preventative Maintenance Application | Proactive Service Upsell: Xpress Seal is not only a reactive repair — it’s a proactive maintenance option. Every system will develop micro-leaks at some point in its service life, particularly at solder joints and coil connections subject to thermal cycling. A single application on a healthy system provides ongoing protection against refrigerant loss before it becomes a callback or a coil replacement conversation. |
Vapco Field Guide: Xpress Seal Application Matrix
| SITUATION | WHAT TO DO |
|---|---|
| Pinhole leak, system still running | If it holds operating pressure for 24 hours — inject Xpress Seal or Xpress Inject Combo. |
| Can’t Find Leak | Use Xpress Seal & UV Dye — seal and locate simultaneously. |
| System below 15 PSI | Moisture is likely in the system. Use Xpress Protect or Seal & Protect to neutralize acid and eliminate moisture before or with sealant injection. |
| Preventative maintenance | No active leak? One application protects against micro-leaks before they become a coil replacement conversation. |
| Leak too large to locate or hold charge | Use UV Dye only to find it. Mechanical repair required. |
| ⚠ Do Not Use | Physical cracks, separated fittings, failed Schrader cores, or ammonia systems. |
Select Your Size
Match the tube to your system tonnage. Every SKU is labeled — no guessing. Sold in case quantities.
Xpress Seal Direct Inject Tubes
| PART # | SYSTEM SIZE | PACK |
|---|---|---|
| XPS-MINI | Appliances & Small Systems — Up to 0.75 Ton | Case of 6 |
| XPS-SS | Mini Splits & Small Systems — Up to 1.5 Ton | Case of 6 |
| XPS-5T | Residential — 1.5 to 5 Ton | Case of 6 — Most popular residential size |
| XPS-10T | Light Commercial — 2 to 10 Ton | Case of 4 |
| XPS-15T | Mid Commercial — 6 to 15 Ton | Case of 4 |
| XPS-30T | Large Commercial — 16 to 30 Ton | Case of 4 |
| XPS-60T | Heavy Commercial — 31 to 60 Ton | Case of 4 |
| XPS-125T & XPS-250T | Industrial — Available on Request | Contact Vapco for pricing and availability |
Injection Tools & Accessories
| Inject Gun | Xpress Inject Gun (XPS-GUN) CO2-powered injection gun for installations without manifold gauges. Dry, high-quality CO2 ensures safe, clean injection every time. |
| Inject Hose | Xpress Injector Hose (XPS-HOSE) Connects the high-side service port to the inject tube — uses system refrigerant pressure for installation. No additional equipment needed. |
| CO2 Refills | CO2 Cartridge Refills (CO2-5) Replacement CO2 cartridges for the Xpress Inject Gun. Sold in packs of 5. |
Contractors: Contact your local Vapco distributor for pricing and availability.
Why Carrier Chemistry Matters – AC Leak Sealant
| THE PROBLEM | THE XPRESS SEAL DIFFERENCE |
|---|---|
| Pre-Formed Polymers Large polymer chains injected into the system — big enough to obstruct TXV valves and metering devices. Why the category has a reputation problem. | Monomers Only Circulates inert. Polymerizes outside the system at the leak point only. Nothing forms inside. |
| Oil-Carrier Sealants Don’t mix with refrigerant. Non-miscible mass hits the compressor — you can hear the compressor strain. Can’t scale beyond light commercial due to volume limitations. | Refrigerant-Carried Fully miscible. Travels with refrigerant to every point in the circuit. No compressor impact. Scales from window unit to 60 tons. |
| Can’t Scale Oil-carrier products hit a ceiling at larger tonnages. No oil-carrier sealant covers commercial applications effectively. | Appliances to 250 Ton Same formula, every size. No other sealant formula covers this range under one product family. |