Fresair S6 User manual

!
S6 - VAN CONVERSION KIT
MANUAL

Congratulations on your new purchase! As a Fresair Air Conditioning Unit owner,
you’re about to enjoy the fruits of an innovative, high quality product designed
exclusively to provide you with extreme comfort in hot climates.
We take pride in our products and want you to feel confident installing and operating
the Fresair Air Conditioning unit, that’s why we prepared this manual.
Here you will find simple instructions for step-by-step installation, optimal
performance, and operational procedures so you can get the most out of your Fresair.
Main Components
3
Safety Information
4
Technical Data
5
Technical Assistance
7
Operation Information
8
Warranty Information
9
Parts: Maintenance
10
Parts: Installation
12
How to Install
13
Cleaning & Care
22
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Dear User
Table of Contents

•FAN ON/OFF: Press button ➎to turn the fan on and off.
•FAN SPEED: Press button ➑to cycle through fan power levels (5 fan speeds.)
•PUMP ON/OFF: Press button ➏to turn water circulation on and off. Note: When
you turn the fan on the water pump automatically starts (if there is water in the
reservoir.)
•LOW WATER: When the water tank level is low the “LOW WATER” LED ➋starts
blinking. The light will remain solid when water is completely depleted at which
point pumps will shut off. Refill the water tank to resume normal cooling operation.
•INTERIOR LIGHT: Press button ➐to turn the interior light on and off.
➊Remote Control IR receiver
➋Low Water LED
➌Water Pump on LED
➍Fan on LED
➎Fan On/Off
➏Water Pump On/Off
➐Interior Light On/Off
➑Cycle through Fan Speeds (5 Fan
speeds)
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Main Components

EXPLANATION OF SYMBOLS
SAFETY
The manufacturer accepts no liability for damage in the following cases:
•Damage to the product resulting from mechanical influences and incorrect
connection voltage.
•Alterations to the product without express permission from the manufacturer
•Use for purposes other than those described in the operating manual.
HANDLING THE PRODUCT
WARNING!
•Only use the Fresair Air Conditioning Unit for the purpose specified by the
manufacturer and do not make any alterations or structural changes to
the device.
•Do not use the Fresair Air Conditioning Unit if it is visibly damaged.
•Installation and repairs to the Fresair Air Conditioning Unit may only be
carried out by qualified personnel who are familiar with the risks involved
and the relevant regulations. Inadequate repairs may cause serious
hazards.
•People (including children) whose physical, sensory or mental capacities or
whose lack of experience or knowledge prevent them from using this
product safely should not use it without the supervision or instruction of a
responsible person.
•Electrical devices are not toys.
•Children must be supervised to ensure that they do not play with the
product.
•Do not undo the upper cover of the Fresair Air Conditioning Unit in case of
a fire. Use approved extinguishing agents instead. Do not use water to
extinguish fires.
•Do not reach into air vents or insert any foreign objects in the system.
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CAUTION!
Safety instruction: Indicates a hazardous situation that, if not avoided,
could result in serious, minor or moderate injury.
NOTICE!
Indicates a situation that, if not avoided, can results in property damage.
NOTE
Supplementary information for operating the product.
Safety Information

CAUTION!
•Disconnect all power supply lines when working on the unit (cleaning,
maintenance, etc.)
INTENDED USE
The Fresair Air Conditioning Unit is used to supply the interior with cool air.
The system is designed for stationary use. It can be used while driving.
The Fresair unit uses minimal 12V power to pull air from the outside of the vehicle,
through an anti-bacterial and anti-fungal pine straw filter, delivering strong
directional air through the four adjustable air vents. With the cooling mode on, the
pine filter is gradually wetted through a drop system, by repetitive injection and
return of circulating water from the water reservoir. The pine straw filter is never over-
saturated and water usage is conserved by this regular flow of water between the
reservoir and the unit. The resultant air flowing into the vehicle is cooled by an
evaporative process.
The unit will continue to produce cool air until it is turned off, the connected power
source is depleted, or the water reservoir is exhausted.
The unit can be used both with or without water circulation. To use it without, power
on the Fresair unit and power off the pump on the control panel. With no water
circulating the system acts like a simple directional fan without cooling.
The system is controlled using the control panel or the included remote control.
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NOTE
Only install the Fresair Air Conditioning Unit using the installation
instructions provided in the manual.
Technical Data
NOTE
The Fresair Air Conditioning unit can lower the temperature within the
vehicle to a certain level. The temperature depends on the type of vehicle,
the ambient temperature and the cooling capacity of your unit. For the
cooling capacity of your unit, see “Technical data on page 9.

Height
3.7 inches
Width
33 inches
Depth
25 inches
Weight
25 pounds
Average Water Consumption
500 to 1500 ml/h depending on the external
moisture and temperature
Capacity
18L water tank
Autonomy
15-22 hours
Fan
Double fan with ohmic resistance
Voltage
12V
Maximum Nominal Current
12V/10A
Fan Speed
4000 rpm
Weight Maximum Air Flow
400 m³/h
Insulation Class
1Ω
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Technical Data

Fresair is committed to providing guidance to ensure optimal performance,
understanding routine maintenance and preventative care.
Should you need any assistance or guidance on performance, preventative care,
maintenance or general questions please contact an authorized dealer or reach out to
us directly at [e-mail].
Additionally, we have outlined some of our go to resources for questions and/or
troubleshooting remedies that can help to answer your questions.
FAQ: https://www.fresair.com/faq/
Support: https://www.fresair.com/support/
Installation Videos: https://www.fresair.com/videos/
Installation Guide: https://www.fresair.com/installation-guide/
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Technical Assistance

Observe the following instructions to ensure your Fresair Air Conditioning Unit is used
properly and efficiently.
It is recommended that you
•Park your vehicle in the shade when possible.
•If you leave your vehicle and your unit is in off mode and the vehicle is not
ventilated, make sure to open a window, door, or vent when you return in order to
release hot air and more quickly introduce cool air.
•Select a suitable fan speed by increasing or decreasing the speed until the desired
speed is achieved.
•Use the any or all of the 4 directional vents to point the airflow to the desired areas.
•Ensure water reservoir is full.
•The water pump automatically turns on when the unit is turned on provided there
is water present in the reservoir.
•Keep the water pump on for maximum cooling performance.
•The best cooling capacity is achieved when the fan is at maximum speed, the
pump is on and the directional vents are directed toward you.
OPERATION
✓With the system switched off, press the button.
✓The Power LED and Water Pump LED light up.
✓The fan and water pump starts.
✓If you wish for the unit to operate without the water press the button to turn the
water pump off.
✓To increase or decrease the airflow press the button.
✓To turn the interior light on or off press the button.
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NOTICE!
•The manufacturer assumes no liability for non-observance of this
operating manual, in particular for any consequential damage(s),
especially consequential damage(s) caused by failure of the Fresair Air
Conditioning unit.
•Do not insert foreign objects into the system.
Operation Information

The warranty period begins on the purchase date and ends 12 months from the
purchase date with exceptions to certain replacement parts as outlined in the
manual.
If the product is defective, please contact the dealer you purchased from or contact
Fresair directly by emailing [e-mail]. For repair and warranty processing,
please include a copy of the receipt with purchase date and a reason for the claim
and/or description of the fault.
In no case will Fresair exchange the product for a replacement solely due to a
defective component.
A. Damages caused by accidents;
B. Plastic items: superior cover in ABS plastic, main panel, finishing frame and base;
C. Electric harness or hoses cut or damaged;
D. Control panel with any sign of modification or use with other brand;
E. Fan with broken or damaged airscrew or with normal brush wear and tear;
F. Air filter obstructed by dirt or dust;
G. Any component in which the label with the date of manufacture is removed or not
legible;
H. Use of unauthorized parts, unauthorized modifications, or unauthorized repairs
made by technicians or individuals who are not licensed or not qualified to modify
or repair Fresair units;
I. Off road application;
J. Unsatisfactory product performance due to improper installation;
K. Damage caused by unexpected circumstances (ex: accident, fall, wear and tear,
violent weather conditions, use of chemical abrasive products inside and outside
the product, etc.);
L. If the product is switched on at a different voltage than it was intended for;
M. Removal of and/or modification of the serial number or the product identification
label.
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Warranty Information
NOTICE!
•If kept in off mode for an extended period of time, there may be an odor
when turning it on again as a result of the absence of water cycling
through the straw filter. You may remedy this by running a few cycles
and the odor will naturally subside.
NOTICE!
•This model has exclusive application for on road uses. We do not
recommend extreme off road uses at this time.
NOTICE!
•Never add anti-freeze, softener, perfume, fragrance or any other
substance than pure water in the reservoir. Adding substances could
create foam or potentially cause leaks.

•FAN: Located in the center of the tray, the fan draws in external air
and blows internal air through the 4 directional vents.
•EVAPORATIVE STRAW FILTER: Located in the tray, external air is
pulled through the moistened straw causing evaporation over a
large surface area resulting in the cooling of the passing air which is
delivered to the internal vents. It also filters out dust, insects, and
acts as a humidifier in very low humidity environments.
•TRAY INTERNAL FILTER: An internal filter located in the tray which
is responsible for filtering the excess water descending from the
straw filter. The water is then recycled and returned to the water
reservoir.
•TRAY PRE-FILTER: Also located in the tray and is responsible for a
second filtering process, avoiding the entry of dirt into the pump,
protecting the pump from clogging and breaking down.
WATER PUMPS
•INJECTION: The injection pump is located on the outside of the
water reservoir and sends water to the Fresair unit.
•RETURN: The return pump is located in the tray and returns excess
water to the reservoir.
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Parts: Maintenance
NOTE
The fan contains carbon brushes that can degrade over time. We recommend
replacing every 4 years.
NOTE
We recommend inspecting the filter and washing with a hose every 3-6 months
to remove dirt and debris. Depending on usage we recommend replacing the
filter every 12 months.
NOTE
We recommend inspecting and gently washing the filter every 6 months. Excess
amounts of dirt could prevent water from cycling through, possibly cause water
leakage.
NOTE
We recommend inspecting and gently washing the filter every 6 months. Dirt
can gradually accumulate which overtime lowers the equipment’s performance
and can cause eventual water leakage.
NOTE
We recommend removing the pumps every 6 months and cleaning them with
an air blast. Additionally, we recommend changing the pumps every 12 months.

•FLOAT SENSOR: The sensor buoy is attached to the water tank and
monitors the water level. If the tank is full and the low water warning
light remains on, check that the sensor is inserted correctly in the
reservoir with the green dot facing up. If the sensor is inserted
correctly and the light remains on it should be replaced.
•CONTROL PANEL: The control panel controls all the product
functions. The panel is equipped with an internal safety circuit
against motor and pump short-circuits. Should your unit stop
working, always check the fan motor and pumps first. The control
panel may turn off, protecting itself against some other electrical
defects. If the control panel is completely dead, check the main fuse
to the battery.
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Parts: Maintenance
NOTICE!
Periodical maintenance is essential for optimal performance and
prolonging the life of your Fresair Air Conditioning unit. We recommend
preventative maintenance and replacing of wearable parts annually or as
outlined in the manual, coinciding with your yearly vehicle maintenance.

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Parts: Installation
UNIT
(1) Fresair Unit
(1) Fresair Finishing Frame
LOOSE
(1) Cardboard Mounting
Template
(1) 3/4” (Thick) x 76” Reel Self-
Sticking Sealing Foam (inner
seal around airbox)
(1) 3/8” (Thin) x 110” Reel Self Sticking Sealing Foam (Outer Edge of Unit)
BAG #1
(10) 8” Black Zip Tie Straps
(5) 1” x 1” Tie Mounting Pads
(2) 4mm x 50mm Washer
Head Screws (Secure
Underside Finishing
Frame to Unit)
(2) M5 x 10mm Screws (Front
Screws to Secure Top Cover)
(4) M5 x 15mm (Side and
Rear Screws to Secure Top
Cover)
(1) Fresair Owner’s Manual
(2) Fresair Decals (Color
and White)
(1) Remote Control

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WATER RESERVOIR & BUBBLE WRAPPED BRACKETS
(1) 18L Horizontal or
Vertical Mount Water
Reservoir (Horizontal
Default)
(2) Mounting Brackets
(4) Bolts
(2) Water Reservoir End Caps
BAG #2
(2) VDO Water Pumps
(Preventative
Maintenance Spares)
(1) Rubber Grommet for Water
Pump (Preventative
Maintenance Spare)
BAG #3
(4) Rubber O Rings (Insert
Between Bolt Head and
Top of Unit)
(4) M8 x 40mm Bolts
(4) M8 x 60mm Bolts
(4) M8 x 80mm Bolts
(4) M8 x 100mm Bolts
(8) M8 Flat Washers (4 - Unit, 4 -
Reservoir)
(8) M8 Self Locking Nylon
Nuts (4 - Unit, 4 -
Reservoir)
*NOTE: Use only 4 bolts to secure (Bold head ➔
Rubber ‘O’ Ring ➔Unit/Roof ➔Washer ➔Nut. "
Choose bolt length best suited to specific installation.
Parts: Installation

Please read the instructions thoroughly prior to installing the Fresair unit. We are not
responsible for damages and/or improper installation due to user error.
Step 1 - Tracing the Mounting Template
Prep Tip: It is very important that the roof surface is clean to ensure a weather-tight
seal between the base of the Fresair unit and your roof. Take time to determine
where you wish to install your Fresair. Ensure that the unit is placed between roof
support bars so you don’t compromise roof integrity. Plan how the internal harness
will run to power and reservoir.
What you’ll need: Cardboard Mounting Template, *Masking Tape, *Permanent Marker
•Place the Cardboard Mounting Template over the exact roof area where you plan to
mount your Fresair Unit.
•Ensure the larger notch (side A) is positioned toward the front of the vehicle and the
Cardboard Mounting Template is placed between roof supports.
•*We recommend taping the Cardboard Mounting Template to the roof to eliminate
movement while tracing the outline and hole cutouts for bolt placement.
•Simply trace the open area of the Cardboard Mounting Template.
•*We recommend using a permanent marker so the outline is clearly visible.
•Once the outline has been drawn, remove the template (and tape.)
IMPORTANT: For Van Conversion you do not need to cut the exact template
shape. For ease you should just cut an opening of 14.5” wide (side to side of roof)
and 13” tall (front to back of roof).
Step 2 - Cutting the Opening for the Fresair Unit
Prep Tip: In order to keep the vehicle free from debris, we recommend temporarily
securing a plastic drop cloth around the cutout area inside the vehicle so that
debris will land inside of the drop cloth and not in your vehicle.
What you’ll need: Angle Grinder/Jigsaw (Cordless tools are strongly recommended),
File, Sealant/Anti-Rust Paint, *Plastic Drop Cloth, *Safety Glasses
•Make sure to wear appropriate safety gear to protect yourself from sparks, metal
ricochet, etc. such as safety glasses, gloves, long sleeves, etc.
•Cut the opening of 14.5” wide (side to side of roof) by 13” tall (front to back of roof)
along the outline as closely as possible.
•File any newly cut edges and ensure edges are smooth to the touch.
•Seal the newly cut edges with anti-rust paint or sealant and allow to dry for the
recommended time.
•Clean away any remaining debris from the roof to prevent rust.
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How to Install

Step 3 - Testing the Fit
What you’ll need: Fresair Unit
•Test the fit of the Fresair Unit by lowering it in the area you’ve just cut out and make
any necessary adjustments accordingly. Be careful not to crimp or damage the
water hoses
Step 4 - Drop in the Bolts
What you’ll need: Fresair Unit, Screwdriver, 8MM/5/16” drill bit
•Remove the cover of the Fresair unit and locate the black push tabs that release the
pine filter (note how the filter slots into the front channel of the base.) (See figure 1)
•Next, rotate the pine filter gently to reveal the “Universal” mounting holes. (See
figure 2)
•With the unit in place and secure, drill through the plastic base and roof using an
8MM/5/16” drill bit in the first “Universal” hole.
•Drop a bolt into the newly drilled hole to hold the unit in place.
•Then drill the second, third and fourth holes in a similar fashion.
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How to Install
Figure 1
Black Push Tabs

Step 5 - Adhering the Sealing Foam Tape
What you’ll need: Fresair Unit, Sealing Foam Tape
•With the unit still in place and secure, use a permanent marker to draw an outline
around the outside base of the unit on the roof.
•Remove the unit from the roof and turn the unit over.
•Stick the thicker sealing foam tape around the airbox up to the honeycomb plastic
line. Cut the sealing foam tape to the correct length ensuring there are no gaps
where the sealing foam tape ends meet. (See figure 3)
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Figure 3
Sealing Foam Tape
Figure 2
Universal Bolt Hole
How to Install

•Stick the thinner foam on the roof along where you traced the outside of the base.
Overlap the outline slightly to ensure a conservative amount of foam sticks out from
the base of the unit. Again, cut the foam to length ensuring there are no gaps where
the ends meet.
•Apply a single bead of silicone along the middle of both the foam on the unit and
the foam on the roof.
•Carefully lower the unit back onto the roof being careful to align the bolt holes first
so the foam and silicone form a weathertight seal.
•At the same time, make sure to bring wiring and tubing through the opening on
the predetermined side the wiring and tubing will run to meet their connections.
Step 6 - Mounting the Fresair Unit
What you’ll need: Fresair Unit, 4 Bolts, 4 Washers, 4 Nuts, 4 Waterproof Bolt Caps, 6
Cover Screws, 2 Finishing Frame Screws, *Screwdriver, *Crescent Wrench(es), *Self-
leveling lap sealant/Silicone
•Choose the ideal bolt length for your installation and roof finish. (Excess bolt length
can always be removed with an angle-grinder later.) The bolts you choose will need
to be long enough to secure the unit to the roof and have enough thread for the
washer and nut to be secured to the end of the bolt of the roof’s interior.
•Place a small rubber washer onto the bolt and drop in each of the four bolts into the
universal bolt holes.
•Place the provided red rubber caps over each universal hole in the base to further
weatherproof the bolt holes.
•Inside the vehicle, place a metal washer onto each bolt, followed by a nut.
•Tighten each of the 4 bolts gradually and evenly until the sealing foam tape
compresses evenly over the roof lines or ridges.
•Inspect how well the foam has compressed over roof ridge lines. If there are any
gaps you need to run self leveling lap-sealant around the outside of the base and
outer edge of the sealing foam tape and onto the roof for a better weatherproof seal.
Please allow for drying time so as not to remove any of the seal.
•On the roof, twist and latch the pine filter back into place (ensure the front of the
filter is slotted below the channel at the front of the base.)
•Attach the top cover using the 4 longer cover screws on the back and sides and the
two shorter cover screws at the front of the unit. Attaching the cover makes it easier
starting at the front first.
•Attach the finishing frame inside the vehicle using the two finishing frame screws
(This step can be skipped if you are building custom trim to match your vehicle’s
interior.)
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NOTE
Be careful not to over tighten the bolts as this can warp or crack the base.
How to Install

Step 7 - Electrical
What you’ll need: Supplied Electrical Wiring, *Screwdriver
•Please remember to take any safety precautions when working with electrical wire.
We recommend disconnecting the main power supply until the wires are
connected for safety purposes.
•Run the electrical wiring from the unit to the 12V DC fuse block ensuring it is
completely concealed so that the wire is not exposed to elements or incidental
damage.
•Connect the positive wire (red) to the positive terminal of your fuse block.
•Connect the negative wire (black) to the negative terminal of your fuse block.
•Ensure both wire connections are tightened properly and completely secured to the
fuse block.
•Next, test the power (using the Fresair power button on the unit) to ensure your unit
turns on.
Step 8 - Plumbing
What you’ll need: Supplied Water Lines/Tubes, Water Reservoir, Zip Ties, Water,
*Plumbing tape
•Out of the box the reservoir is set up for horizontal mounting but can also be
mounted vertically by moving the float sensor and injection pump.
•Choose an orientation that supports easy access so that you can connect the water
lines, easily fill the water reservoir, easily change the float sensor and pump when
needed and drain the reservoir if/when necessary.
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Figure 4
Electrical Wiring
How to Install

• IMPORTANT: None of the barbs on the reservoir are pre-drilled. You must drill
out the return barb depending upon whether you are mounting horizontally or
vertically.
•Using the provided mounting brackets, mount the reservoir in the desired area.
•Run water lines/tubes to the reservoir according to the figure 5/6. The return water
line is marked with a small red dot at the end
•Pre-drill the Water Return barb on the reservoir. Slide the water return hose onto the
barb. The water return hose has a little red dot on the end.
•Attach the Water Injection hose to the barb on the pump.
•NOTE: Optionally you can use plumbers tape and a hose clamp or zip-tie to secure
the hoses to the barbs.
•Test the connections by lightly pulling them to ensure the connection is secured.
•Connect the electrical connectors to the float sensor and injection pump.
•Once you’re ready, fill your reservoir with water and seal with the provided cap.
•Finally, power on your Fresair and ensure there are no leaks.
•Additionally, test all functions to ensure your Fresair is working properly.
NOTE: There are many ways that you could plumb up the reservoir to be filled from
the main freshwater tank which is beyond the scope of this manual. The simplest
installation described here assumes that you can access the filling cap with a hose.
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How to Install
How to InstallHow to Install

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Figure 5
Vertical Reservoir
Water return line
Negative connection
Fuse
Positive connection
Water injection line
Water pump & connector
Float Sensor
How to Install