The Pataca Fresc 22 is a roof-mounted air conditioning unit designed to provide rapid cooling and a pleasant climate within vehicle cabins. It operates in circulation mode, necessitating that the cabin door and other existing openings remain closed during operation to ensure optimal performance. The unit should not be run if the vehicle is being used for work that requires the cabin door to be open.
Important Technical Specifications:
- Dimensions: The unit has a length of 764 mm, a width of 536 mm, and a height of 179 mm.
- Fastening Holes: The fastening holes for installation are Ø 10 mm.
- Power Supply: The electrical power supply requires a 60 A fuse directly on the battery connection. The battery must be capable of supplying the necessary current and voltage.
- Refrigerant: The system uses R134a refrigerant, with a quantity of 0.45 Kg.
- Compressor Oil: The recommended compressor oil is RL68H.
- Minimum Operating Temperature: The unit should not be operated if the ambient temperature is below 0 °C.
- Installation Height: The installation of the air conditioning roof unit adds 215 mm to the vehicle's height.
Usage Features:
The Pataca Fresc 22 features a control panel with three main knobs for managing its functions:
-
Ventilation Speed Control (Knob 1):
- Turning this knob completely to the left (position 0) switches off the ventilation.
- Rotating it clockwise progressively increases the ventilation speed from 1 to 3.
-
A/C ON/OFF Switch (Switch 2):
- When the switch is pushed to the top, the bottom side turns black, indicating that the A/C, condenser fans, and compressor are off.
- When pushed to the bottom, the upper side turns green, indicating that the A/C is on, and the condenser fans and compressor will activate.
- Note: The A/C system will only operate if the ventilation switch (Knob 1) is set to speed 1 or higher.
- Note: If the ventilation is off (Knob 1 at 0) and the A/C switch is on, the cooling system will not start.
- Note: If the A/C switch is on and the temperature knob (Knob 3) is in the red zone, the A/C system will operate at the lowest cooling power.
-
Temperature Control / Heating System (Knob 3):
- With ventilation on and the A/C switch off, turning this knob to the red zone activates the heating system.
- If the knob is in the blue range, only the ventilation will function.
- If the A/C is switched on, the heating system will be turned off, and the knob can be used to set the desired cooling rate.
- Note: If the ventilation is on and the A/C switch is off, turning the temperature knob to the blue range will not start the cooling system.
Maintenance Features:
The Pataca Fresc 22 requires regular maintenance to ensure optimal performance and longevity.
General Care:
- Clean the housing and outlet panel occasionally with a damp cloth.
- Remove leaves and other dirt from the ventilation grilles regularly, taking care not to damage the system.
- Change the dust filter regularly.
- Regularly check that all elements for the roof air conditioner are fastened.
- Ensure connection leads are undamaged and secure.
- Verify that all through-holes for the roof air conditioner are sealed.
- After approximately 20 hours of operation from installation, perform a general inspection, particularly checking the screws.
Servicing Indications (HVAC Systems):
| Maintenance Check List for HVAC Systems |
Maintenance Interval (Months) |
| Visual system inspection |
3 |
| Manifold gauge check and leak test |
12 |
| Condenser: clean dirt and insects from the wings (more often if severe operating conditions) |
3 |
| Condenser: straighten the wings (wing combs suggested) |
3 |
| Condenser: inspect tubes for leakage (indentation and oil stains) |
3 |
| Receiver drier: check for moisture |
3 |
| Receiver drier: check filter temperature while running (warm to touch) |
3 |
| Receiver drier: replace or clean the filter (or every time refrigerant system is opened) |
12 |
| Evaporator: clean dirt and insects from the wings (more often if severe operating conditions) |
3 |
| Evaporator: check drain holes and drain lines |
3 |
| Air filter: inspect; clean or replace as needed |
3 |
| Pressure switches: check for refrigerant pressure switches with pressure gauges |
12 |
| Expansion Valve: check for leakage (liquid line, gas line) |
12 |
| Compressor: check inlet hose and fitting (cool to touch) |
3 |
| Compressor: check outlet hose and fitting (warm to touch) |
3 |
| Compressor: check compressor working voltage and current |
12 |
Note: Every 30 days, the A/C system should be activated for 5 minutes to circulate the refrigerant system lubrication and verify the proper functioning of the fans.
Compressor Maintenance (DC Scroll Compressor):
Compressors are generally maintenance-free products and are typically not replaced until the vehicle is scrapped. Warranty periods are set separately. For detailed work content, refer to the existing vehicle manufacturer's maintenance manual.
Compressor Removal:
- If operable:
- Perform oil return operation.
- Perform refrigerant recovery operation.
- Remove the compressor.
- Drain oil from compressor suction and discharge port.
- Insert a photo with oil removal from crankcase.
- Check oil quantity and contamination.
- If inoperable:
- Perform refrigerant recovery operation.
- Remove the compressor.
- Drain oil from compressor suction and discharge ports.
- Check oil quantity and contamination.
Oil Return Operation:
The oil is mixed with refrigerant in the refrigeration system. To return oil to the compressor before removing components:
- Open doors and operate blower motor at maximum speed.
- Operate the compressor at minimum speed (blower min, temperature setting at 22 °C) for at least 20 minutes.
Cleaning of the AC Loop:
If the compressor is inoperable (locked, seized, etc.) and contaminates the AC loop (confirmed by oil quality), the complete AC loop (condenser, expansion valve, evaporator, pipes, and hoses) must be cleaned.
- There is a risk of repetitive contamination and seizure.
- The filter dryer must be exchanged. If not exchangeable, the condenser must be exchanged.
- The AC loop must be flushed without the compressor installed. During flushing, the expansion valve must be opened. Flushing should be done via pipe connection at the compressor on the high and low sides.
Oil Amount Control:
If a new compressor is installed without flushing, check the amount of oil discharged during refrigerant recovery and the amount of oil remaining in the removed compressor, then adjust the total oil amount to the specified amount.
Refrigerant Safety (R134a):
- Always wear eye protection.
- Wear gloves for hand/skin protection; R134a contact can cause frostbite.
- Do not expose refrigerant containers to open flames, red-hot surfaces, or temperatures above 5°C.
- Provide adequate ventilation when charging or recovering refrigerant as it is heavier than air. Avoid breathing R134a vapor.
- Use caution when hot water steam cleaning the engine, as hot water on A/C pipes and tubes can cause thermal expansion of refrigerant.
- Do not transfer refrigerant from cylinder to cylinder using a pump without knowing when the bottle being filled has reached 80% capacity (20% is for thermal expansion).
- Do not transport refrigerant containers in the passenger compartment of a vehicle.
- Do not puncture or incinerate refrigerant containers.
Safety Instructions:
- Read the entire manual thoroughly and carefully.
- Reliability is guaranteed only if instructions are adhered to.
- The manufacturer accepts no liability for damage from faulty assembly/connection, mechanical influences/excess voltage, unauthorized alterations, or use for purposes other than described.
- The travel range of superstructures (telescopic arms, booms, side forks, etc.) must not be restricted.
- Use the unit only for its specified purpose; do not make alterations.
- Do not use if visibly damaged.
- Install safely to prevent tipping or falling.
- Protect from overturning or falling parts.
- Installation, maintenance, and repair work must be carried out by qualified personnel from a specialist company.
- Do not use near flammable fluids and gases.
- Do not undo the upper cover in case of fire; use approved extinguishing agents (not water).
- Inquire with the vehicle manufacturer about potential changes to vehicle documentation due to the added height (215 mm).
- Disconnect all power supply lines when working on the unit (cleaning, maintenance, etc.).
Handling Electrical Cables:
- Use cable ducts for cables through walls with sharp edges.
- Complete wiring to avoid damage from sharp-edged vehicle components.
- Do not lay loose or bent cables next to electrically conductive materials.
- Do not pull on cables.
- Attach and lay cables to prevent tripping or damage.
- Electrical power supply must be connected by a specialist workshop.
- Never lay power supply lines near signal or control cables.
- Lay electric cables at least 15 mm from rotating parts and 150 mm from very hot parts.
- Attach cable sets using supplied cable binders.
- Fix compact plug connections at snap-in points.
- Protect plug connections in areas with high splashing risk (engine compartment, underbody) with protective wax spray, insulating tape, or similar.
Installation Notes:
- The air conditioning roof unit may only be installed by qualified personnel from a specialist company.
- Ensure all electrical components are electrically discharged before working on them.
- Always check for potential damage or impaired operation of vehicle components before installation. Use Fig. 1 (page 3) to check dimensions.
- Supplied assembly parts must not be modified.
- Ventilation slots (grill) must not be covered (minimum distance: 10 cm).
- Adhere to corresponding rules of technology for installation and repair.
- Observe guidelines from the body manufacturer for electrical connections.
- Use appropriate tools.
- Note the location of existing cable harnesses, cables, and components before and during drilling.
- Disconnect vehicle battery power supply before installation to prevent electrocution.
- Improper installation can cause irreparable damage and risk user safety. The manufacturer is not liable for claims if the unit is not installed according to this manual.
- The manufacturer is only liable for parts included in the scope of delivery; warranty expires if third-party parts are used.
- Check if the vehicle roof can support a person's weight before climbing; ask the manufacturer about permitted roof loads.
- Protect the upper part of the cabin with a cloth or blanket before installing the unit to prevent scratches or damage.
Checking Installation Conditions:
- Consult the vehicle manufacturer to ensure the construction is designed for the static weight and dynamic loads of the unit. The manufacturer assumes no liability otherwise.
- Cabins with sunroofs generally have robust structures. If not, check if the cabin roof needs strengthening (e.g., for fiberglass roofs or pre-existing cut-out sections).
- Check minimum requirements: vehicle voltage, power consumption, generator power, and cabin size/load bearing capacity.
- Check output voltage of the three-phase generator.
- Check efficient functioning of all electrically operated vehicle components.
- Report any deviations to workshop management or the vehicle owner.
Preparing Unit Fastening:
- Place the unit's bracket on the roof, ensuring the roof area is level (Fig. 3,4,5,6).
- Check if cut-out sections for air inlet/outlet and cover installation can be completed inside the cabin.
- Mark fastening holes (Ø 10 mm) (Fig. 4).
- Mark rectangular openings for air inlet and outlet (Fig. 4).
- Notice: Check for electric wires, lining, or vehicle facilities under the roof plate near the holes.
- Perform holes and openings (Fig. 4).
- Protect holes and openings with antioxidant.
Attaching the Seal:
- Notice: Ensure the adhesive surface for the seal between the unit and the cab roof is clean (free of dust, oil, etc.).
- Lay sealing silicone around holes and openings to prevent water ingress (Fig. 5).
Installing the Unit on the Cab:
- Place the unit on the roof, aligning the holes (Fig. 6A).
- Fasten the unit with M8 screws and washers (Fig. 6B).
- Notice: Do not exceed the specified torque to prevent thread inserts from tearing out.
- Fasten the condensate drain hose to the system (Fig. 7).
- Align the condensate drain hose by turning to ensure proper drainage.
Connecting Electrically:
- Warning: Electrical power supply must be performed by qualified personnel.
- Ensure no voltage is present on electrically operated components before working on them.
- Notice: Fit a 60 A fuse to the vehicle's power supply connection.
- The battery must supply the required current and voltage.
Attaching Ventilation Panel:
- Notice: Check for electrical cables or hoses between the roof and ventilation panel before installation.
- Place the ventilation panel in the cabin under the roof (Fig. 8).
- Position the panel so the air inlet grill is under the air inlet opening (Fig. 8) and the three air outlet nozzles are under the air outlet opening of the unit.
- Note: The length of fastening bolts depends on the roof interior lining thickness. Ensure bolts do not interfere with the unit when screwing the ventilation plate.
- Select fastening bolts (not included) appropriate for roof thickness and bodywork strength.
- Attach the ventilation plate.
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