HVAC Assembly Line with Evac Loop, Functional Run Test & Cranes
A Leading HVAC Manufacturer needed a new assembly line for residential packaged air conditioning units — one that could build two product footprints at up to 580 lbs., flex between 160 and 300 units per shift, and move every unit through evacuation and functional run testing without leaving the line. J+H Automation Solutions engineered and installed the complete system: an 85-carrier inverted power & free assembly conveyor, a power & free evacuation loop, a 12-station functional run test loop, repair and packaging conveyors, ergonomic lifting, and Allen-Bradley safety controls with a full andon system.
Inside the Functional Run Test Loop
Packaged AC units ride carriers through the test loop while run test panels travel overhead with them — power, Ethernet, and regulated gas stay connected the entire time.
3D design model of the functional run test loop.
The Challenge & the J+H Solution
Launching a new line meant more than moving units from station to station. The manufacturer needed one integrated system to carry heavy units through assembly, evacuation, run testing, repair, and packaging — at a working height that suits operators, with the flexibility to run two product platforms and a wide range of production rates.
The Challenge
- Two product footprints (53" × 48" and 48" × 58") weighing up to 580 lbs. on one line
- Rate flexibility from 160 to 300 units per 8-hour shift at a 90-second takt
- Evacuation and functional run testing had to happen inline, without manual handling
- Operators needed adjustable working height and safe access between moving carts
- Supervisors needed real-time visibility of line status and stoppages
The J+H Solution
- Jervis B. Webb inverted power & free conveyor with 85 scissor-lift carrier carts
- Daifuku Unibilt power & free evacuation loop with 17 evacuation pump carriers
- Functional run test loop with up to 12 overhead-traveling run test panels
- Final repair and packaging conveyors, vertical lifts, and Gorbel jib cranes
- Allen-Bradley CompactLogix safety controls with pull-cord e-stops and a full andon system
How the Line Runs
From the first assembly station to packaging, every unit moves through three coordinated stages engineered as a single system.
Carrier-Based Assembly
Units are built on 85 carrier carts driven by an inverted power & free conveyor at 3–7 FPM on an 8'-9 5/8" work pitch. Each cart has a Southworth hydraulic scissor lift with 24" of travel and foot pedals on both sides, so operators set the right working height at every station.
Evacuation & Run Test
A Daifuku Unibilt power & free evac loop carries 17 evacuation pump carriers alongside the line at 20–40 FPM. Units then enter the functional run test loop, where overhead run test panels stay connected through a rotating slip-ring assembly while exhaust is pulled to the roof.
Repair, Unload & Packaging
A high-speed repair line with 5 stops (6–30 FPM) holds units needing attention, then two high-speed vertical lifts unload carriers onto CDLR conveyor. Chain transfers, repair conveyors, and Southworth lifts feed final repair and packaging, while empty carriers return at up to 60 FPM.
What J+H Engineered, Built & Installed
J+H provided engineering and project management, design runoff in the J+H facility, mechanical and electrical installation (including below-floor pits), PLC and HMI programming, and on-site startup support.
Inverted Power & Free Assembly Conveyor
A Jervis B. Webb inverted power & free system with a variable-speed production line, high-speed repair line, and high-speed carrier return — powered through two 250-ft runs of Vahle 200-amp power rail feeding 85 structural-tube carrier carts with Hamilton casters and Southworth scissor lifts.
Power & Free Evacuation Loop
Approximately 300 ft. of Daifuku Unibilt power & free track — production, transportation, and chain return sections — with 17 evacuation pump carriers, a caterpillar drive, air-operated take-ups, a 4-bar power loop, freestanding support structure, and centralized lubrication.
Functional Run Test Loop
A Unibilt power-only overhead system carrying up to 12 Allen-Bradley CompactLogix run test panels with power monitoring, gas pressure and flow, pressure, and temperature/humidity instrumentation — plus a Moog dual-Ethernet slip ring, Igus cable track, gas supply for up to 12 carriers, and a custom exhaust hood ducted to the roof at 9,260 CFM.
Controls, Safety & Andon
A CompactLogix safety processor with CIP Safety I/O, a remote VFD panel, 35 PowerFlex 525 drives, Allen-Bradley HMIs, and Balluff EtherNet/IP I/O blocks — with Keyence and Turck sensing, overhead e-stop pull cords on every pitch, 67 andon pull cords and tower lights, and 8 andon scoreboards.
Results: One Integrated Line from Assembly to Packaging
Assembly, evacuation, testing, repair, and packaging run as one coordinated system instead of separate islands.
System Capability
- Built for 160–300 units per 8-hour shift at a 90-second takt at max rate
- Two product footprints and unit weights up to 580 lbs. on one line
- Inline evacuation and functional run testing on the moving line
- Variable line speeds for production, repair, and carrier return
Business Impact
- Better ergonomics, with adjustable working height at every carrier
- Faster response to issues through andon pull cords, tower lights, and scoreboards
- Safer operator access, with e-stop pull cords reachable between every cart
- Less handling, with Gorbel jib cranes and air hoists at heavy-lift points
Built for HVAC Manufacturing — and Beyond
This project reflects the assembly line systems J+H delivers for HVAC manufacturers across the United States: carrier-based assembly conveyors, evacuation and run test loops, repair and packaging conveyors, and safety controls engineered around the plant's products, rates, and people.
The same capabilities extend across J+H's overhead and power & free conveyor work, serving manufacturers nationwide from facilities in Hackett, Arkansas and Hockley, Texas.
Frequently Asked Questions
What did J+H build for this HVAC manufacturer?
J+H Automation Solutions engineered and installed a complete material handling system for a new residential packaged air conditioning assembly line: an 85-carrier inverted power & free assembly conveyor with high-speed repair and carrier return lines, a Daifuku Unibilt power & free evacuation loop, a 12-station functional run test loop, final repair and packaging conveyors, Gorbel jib cranes with Harrington air hoists, and Allen-Bradley CompactLogix safety controls with a full andon system.
What production rate is the HVAC assembly line designed for?
The line is designed for 160 to 300 units per 8-hour shift, with a 90-second takt time at the maximum rate. Production line speed is variable from 3 to 7 feet per minute, and the system handles two product footprints — 53 by 48 inches and 48 by 58 inches — at unit weights up to 580 pounds.
How does the functional run test loop work?
Run test panels ride a Unibilt power-only overhead system above the carriers, so each unit can be connected and tested while it travels the loop. A rotating three-arm support with a Moog dual-Ethernet slip ring and an Igus cable track keeps power, data, and the regulated gas supply connected, and a custom exhaust hood ducted to the roof with a 9,260 CFM fan removes exhaust during testing. J+H supplied up to 12 run test panels built on Allen-Bradley CompactLogix with power monitoring, gas pressure and flow, and temperature and humidity instrumentation.
How are operators protected on a moving carrier assembly line?
The line uses overhead e-stop pull cords with dropped ropes on every carrier pitch along both sides, so operators can stop the system from anywhere — including between carts. Safety is managed by an Allen-Bradley CompactLogix safety processor with CIP Safety I/O, and 67 andon pull cords, three-color tower lights, horns, and andon scoreboards give operators and supervisors real-time line status.
Does J+H Automation Solutions build assembly lines for HVAC manufacturers?
Yes. J+H Automation Solutions designs, builds, installs, and commissions turnkey assembly lines, power & free and overhead conveyor systems, evacuation and run test loops, and controls for HVAC manufacturers nationwide from facilities in Hackett, Arkansas and Hockley, Texas — with design runoff in the J+H facility before installation. Contact sales@jhautomationsolutions.com or call (479) 638-8398 to discuss your application.
Launching a New Line or Rebuilding an Old One?
From carrier-based assembly conveyors to inline evacuation and run test loops, J+H Automation Solutions engineers complete assembly systems built around your products, your rates, and your people.
Request a Consultation Call (479) 638-8398