Installation FAQ's
Classic Car Air Conditioning Kit Installation FAQ's
Upgraded for Australian Conditions
Included is:
Small evaporator box:
1 Evaporator unit
1 Mounting bracket for evaporator
1 Condensation drain hose
1 “T” piece
1 Condensation port drain plug
1 Box – Weight 6kg (400 series) OR Box – Weight 12kg (800 series)
Large external parts box:
1 Instruction with warranty form
1 AC Compressor
1 AC Compressor mounting hardware (plastic bag)
1 AC Compressor generic mount
1 Condenser with fan
1 Receiver drier with bracket
1 Pressure switch (for high powered thermos fans)
1 Power cable for AC Compressor – pre terminated
1 Power cable for condenser fan
1 Power cable to connect to evaporator unit from AC compressor
1 Bag of assorted AC hose fittings to suit compressor, condenser, receiver drier, and evaporator
2m ½” #10 standard barrier air conditioning hose
2m 13/32” #8 barrier air conditioning hose
3m 5/16” #6 barrier air conditioning hose
1 Box 60x60x40cm – Weight 19kg
Before you start, please check the content of the box against the content list we have provided above.
Should any parts be missing, please contact your authorised reseller/agent or place of purchase.
Please complete and return your warranty form within 30 days of installation.
KIT OVERVIEW
Thank you for purchasing our Classic Car Air kit! We have tested many imported budget priced air-conditioning kits and made the best bang for buck kit for you. We have upgraded our kits to meet Australian standards for reliability and ease of service.
Each part has been inspected and tested for your peace of mind.
INDEX
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1 |
Evaporator — Inside heating and air-conditioning unit |
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2 |
AC Compressor — 2A Mechanical | 2B Electric |
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3 |
Condenser |
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4 |
Receiver Drier |
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5 |
Pressure or Trinary Switch — Electric condenser fan control |
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6 |
Vacuum and Gassing |
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7 |
Gas piping diagram |
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8 |
Wiring diagrams |
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9 |
Heater pipe connections |
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10 |
Critical installation checklist |
1. EVAPORATOR HEAD UNIT — INSIDE HEATING & COOLING
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⚠ WARNING Our evaporator head units come vacuum sealed and must NOT be opened until fitting hoses immediately prior to gassing. |
All kits feature both heating and air-conditioning. Key specifications:
• 3-speed fan with dual-axle fan motor and 2 fan blade rotors
• Thermostat control to adjust temperature
• Available in vent or duct configuration — Vent models direct airflow at occupants; duct models connect to existing or new vents and ducts
• Compact dimensions: approx. 400mm × 340mm × 150mm
• Supplied with mounting hardware and drain tube
1A — Air-Conditioning Ports (Left Rear of Unit)
There are 2 air-conditioning ports on the back LEFT of the unit:
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Port #10 OUTPUT |
Top, larger port — connects directly to the INPUT port on the AC compressor |
|
Port #6 INPUT |
Bottom, smaller port — connects to the receiver drier |
1B — Heater Ports (Right Rear of Unit)
The heating circuit runs from your engine's coolant. An external heater tap is required and is not included, as most vehicles already have one fitted. There are 2 heater ports on the back RIGHT of the unit:
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Top INPUT |
Hot water inlet from engine coolant circuit |
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Bottom OUTPUT |
Coolant return to engine |
2A. MECHANICAL AC COMPRESSOR
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⚠ WARNING Our compressors come sealed containing oil and must NOT be opened until fitting, immediately prior to gassing. |
Our mechanical compressor is a dual V-belt, 150cc, 7-cylinder unit that will mount to most V-belt pulley engines using the correct bracket (bracket not supplied). Follow the bracket manufacturer's instructions for mounting.
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ℹ MOUNTING ORIENTATION Mount the compressor with its outlet ports within the 10 o'clock to 2 o'clock position (measured from vertical). The optimal range is 11 o'clock to 1 o'clock. Mounting in the 3 to 9 o'clock range will cause improper oil lubrication, leading to premature compressor failure. |
Port Connections
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Port #10 LARGE |
Connects directly to the large #10 port on the evaporator head unit |
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Port #8 SMALL |
Connects directly to the top port on the condenser |
2B. ELECTRIC AC COMPRESSOR
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⚠ WARNING Our compressors come sealed containing oil and must NOT be opened until fitting, immediately prior to gassing. Do NOT operate the compressor if oil has been spilt or leaked from the unit. |
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ℹ MOUNTING ORIENTATION Electric compressors must be mounted upright, with a maximum operating tilt of 15°–20°. Mounting greater than 20° will cause oil starvation, poor lubrication, and premature failure. A basic mounting bracket is provided. Always mount the compressor on the rubber feet to reduce vibration and noise. |
Port Connections
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Port #10 LARGE |
Connects directly to the large port on the evaporator head unit |
|
Port #8 SMALL |
Connects to the larger top port on the condenser |
Condenser Fan Wiring Limit
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⚡ ELECTRICAL LIMIT The electric compressor can directly power a condenser fan up to a MAXIMUM of 120 watts (12V @ 10A). Fans larger than 120W must NOT be wired directly from the compressor — connect them via a relay to the pressure or trinary switch on the receiver drier. |
3. CONDENSER
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⚠ WARNING Our condensers come vacuum sealed and must NOT be opened until fitting, immediately prior to gassing. |
The condenser cools refrigerant gas back into a liquid, keeping gas pressure within compressors safe working range. It must be mounted vertically with adequate airflow.
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Port #8 TOP |
Always at the top. #8 hose and fitting must always connect here. |
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Port #6 BOTTOM |
Always at the bottom. #6 hose and fitting must always connect here. |
Mount the condenser anywhere with sufficient airflow. Tilting up to 45° is permissible but may reduce performance.
Fan & Shroud
The fan and shroud come pre-fitted to the condenser. By default, airflow pulls air through the condenser and out through the fan.
• The supplied fan is rated at 120W — it can run directly from the electric compressor.
• For larger fans, use the pressure switch supplied and connect via a relay.
• Mechanical kits must use the Trinary switch, connected via relay to the fan(s).
4. RECEIVER DRIER
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⚠ WARNING Our receiver driers come vacuum sealed and must NOT be opened until fitting, immediately prior to gassing. |
The receiver drier performs four critical functions:
• Filters contaminants from the refrigerant circuit
• Removes moisture that causes internal corrosion
• Acts as a reservoir to hold refrigerant
• Provides a sight glass for visual inspection of refrigerant charge
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ℹ MOUNTING & FLOW DIRECTION Your receiver drier must be mounted either vertically or horizontally, according to the type label on your unit. The drier has a direction of flow — always follow the arrows or markings on the unit. Input (from condenser): #6 hose and fitting | Output (to evaporator TX valve): #6 hose and fitting |
5. PRESSURE & TRINARY SWITCH
Pressure Switch (Electric Systems)
The pressure switch controls high-powered engine or condenser fans. When refrigerant pressure reaches the compressor threshold, the switch activates a relay to power the fan(s).
• Always use a relay (not supplied) with the pressure switch.
• Has 1 connector — can switch negative or positive depending on your vehicle's wiring.
Trinary Switch (Mechanical Systems)
The trinary switch protects the compressor against very high or very low pressures and controls the condenser or engine fan via relay (not supplied).
It has two connectors:
1. Red & Black wire plug - High/low pressure control — disables the compressor if gas pressure goes out of range.
2. Blue wire plug - Condenser or engine fan relay output.
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ℹ IMPORTANT These systems are designed for 12V negative earth vehicles only. 24V and 48V systems are available on request. |
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ℹ IMPORTANT Due to the custom nature of higher powered thermo and condenser fans, we do not supply a wiring harness for these types of configurations. If you are unsure, please contact your auto electrician. |
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ℹ IMPORTANT The use of a pressure or trinary switch is only required when controlling fans of 120watts or greater. IT IS NOT NECESSARY TO USE A PRESSURE OR TRINARY SWITCH WHEN USING THE FAN IN THE KIT PROVIDED. Please connect as per the wiring diagram below. |
6. VACUUMING & GASSING
Before charging the system with refrigerant, the circuit must be pressure tested and vacuumed to remove all moisture and air. The longer any components are left open and exposed to air, the longer the vacuum process must run.
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ℹ VACUUM & GAS PROCEDURE Pressure test for leaks prior to vacuum. Do not remove the vacuum pump until the pump has stopped rattling Always use R134a refrigerant only. Use of any other refrigerant will void the warranty. Always gas by gauges and observe sight glass on the drier for bubbles — never estimate refrigerant charge by weight alone. Ensure high side does not exceed 195psi for electric AC compressors and 280psi for Mechanical AC compressors. |
7. GAS PIPING DIAGRAM
The diagram below shows the refrigerant flow circuit for the electric compressor kit. Refer to this diagram when routing and connecting all hoses.
Hose Colour Guide
|
Colour |
Size |
Description |
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BLUE |
#10 |
Thickest hose — Evaporator to Compressor (suction line) |
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RED |
#8 |
Medium hose — Compressor to Condenser (discharge line) |
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ORANGE |
#6 |
Thinnest hose — Condenser to Receiver Drier, and Drier to Evaporator TX valve |
8. WIRING DIAGRAMS
Overall Wiring Diagram
Type A Evaporator wiring (note the single plug to evaporator)
This diagram shows the use of the supplied condenser fan connected directly to the AC compressor.
Type B Evaporator Wiring (Note the individual wires and ground bolt)
Note the type B evaporator wiring.
IMPORTANT: The bolt on the back of the evaporator must be connected to the car’s negative.
This bolt must be tight.
The RED WIRE connects to a 10amp switched ignition source
The Green Wire connects to the start stop wire of either the electric or clutch of the mechanical AC Compressor
Electric Compressor & Pressure Switch Wiring
The pressure switch diagram above is configured in negative switching mode. Positive switching mode is also supported. If unsure, consult a qualified auto electrician.
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⚠ NOTE Relay and wiring for the pressure switch are NOT supplied. |
Status LED Indicator
A status LED is located next to the wire terminals on the back of the compressor. Use this table to diagnose compressor status:
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Status |
LED Behaviour |
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Standby |
Flash once for 1 second, pause 1 second — on power-up |
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Working (Normal) |
Light is always off |
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Under-voltage |
Flash 0.2s, pause 0.2s — repeating; pause 1s after 4 cycles |
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Overcurrent / Phase loss |
Flash 0.2s, stop 0.2s — repeating; pause 1s after 2 cycles |
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Damaged / Short MOS transistor |
Flash 0.2s, pause 0.2s — repeating; pause 1s after 5 cycles |
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Over-voltage |
Flash 0.2s, pause 0.2s — repeating; pause 1s after 6 cycles |
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Over-temperature |
Flash 0.2s, pause 0.2s — repeating; pause 1s after 13 cycles |
Mechanical Compressor Wiring
Please connect the GREEN START/STOP WIRE from the Evaporator unit to the CLUTCH WIRE on the mechanical compressor.
Classic Car Air mechanical air-conditioning compressor draws 6 Amps and can be connected directly to the GREEN START/STOP WIRE from the evaporator
The evaporators GREEN START/STOP WIRE and thermostat have a maximum rating of 10 amps.
Please check the specifications of your air conditioning compressor before connecting.
A relay is required (not supplied) with any compressor that requires 10Amps or more.
9. HEATER PIPE CONNECTIONS
All Classic Car Air kits include a heater core. This conventional core uses engine coolant to heat the cabin.
• Typically the top pipe is the inlet (hot water in) and the bottom pipe is the outlet (return to engine).
• A heater tap (not supplied) is required. It can be connected to either side, but works best on the inlet side.
• It is recommended not to use a radiator cap above 14 psi
10. CRITICAL INSTALLATION CHECKLIST
Before commissioning, confirm ALL of the following steps have been completed and adhered to.
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★ ALWAYS — CRITICAL CHECKLIST ✔ Ensure all O-rings are lubricated before fitting hose ends ✔ Use R134a refrigerant ONLY — any other refrigerant voids the warranty ✔ Leak and pressure test the complete system ✔ Vacuum the system for a minimum of 1 hour before gassing ✔ Apply an initial gas charge before final gassing ✔ Gas the system using gauges ✔ Complete in full and submit the warranty form within 30 days of installation. |
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⚠ WARNING NEVER use any refrigerant other than R134a. NEVER kink, damage or use sharp bends in air-conditioning hose. NEVER open vacuum-sealed components until immediately prior to fitting and gassing. |
LEGAL DISCLAIMER Australian law requires that installation, repair, gassing, and maintenance of this automotive air-conditioning system be performed by a qualified automotive air-conditioning technician. Classic Car Air accepts no liability for loss or damage arising from incorrect installation including use of non-approved refrigerants, incompatible components or installations by unqualified persons.