Fresair S6 User manual

S6 - VAN CONVERSION KIT MANUAL
© Fresair, LLC. | All Rights Reserved

Main Components
Safety Information
Technical Data
Technical Assistance
Operation Information
Warranty Information
Parts: Maintenance
Parts: Installation
How to Install
Cleaning & Care
3
4
5
8
9
10
11
13
15
24
Table of Contents
Congratulations on your new purchase! As a Fresair Air Cooling 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 Cooling 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.
Dear User
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➊ Remote Control IR receiver
➋ Low Water LED
➌ Water Pump on LED
➍ Fan on LED
➎ Fan On/Off
➏ Water Pump On/Off
➐ Interior Light On/Off
➑ Cycle through Fan Speeds (5 Fan speeds)
Pump On/Off:
5
Press button ➎ to turn the fan on and offFan On/Off:
8
Press button ➑ to cycle through fan power levels (5 fan speeds.)Fan Speed:
Low Water:
Interior Light:
Press button ➏ to turn water circulation on and off.
When the water tank level is low the “LOW WATER” LED ➋ starts
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.
Press button ➐ to turn the interior light on and off.
Note: When you turn the fan on the water pump automatically starts (if there is
water in the reservoir.)
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Main Components

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Explanation of Symbols
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.
The manufacturer accepts no liability for damage in the following cases:
Safety
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
Only use the Fresair Air Cooling 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 Cooling Unit if it is visibly damaged.
Installation and repairs to the Fresair Air Cooling 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 Cooling 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.
WARNING!
Safety Information

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Technical Data
CAUTION!
Disconnect all power supply lines when working on the unit (cleaning,
maintenance, etc.)
Intended Use
The Fresair Air Cooling Unit is used to supply the interior with cool air.
The system is designed for stationary use. It can be used while driving.
NOTE
Only install the Fresair Air Cooling Unit using the installation
instructions provided in the manual.
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 oversaturated 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.
NOTE
The Fresair Air Cooling 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

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Technical Data
NOTE
These figures are estimates based upon aggregated data. Fresair is not
responsible for exact achievable temperatures or comfort zones as
installations differ.
Comfort
Cool with air flow (ceiling fan or window.) Use directional air from vents on the body.
Daytime cooling only. For enclosed RV/VAN/Trailer sleeping you will need traditional AC.
.
.
.

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Technical Assistance
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 [email protected].
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/
https://www.fresair.com/installation-guide/
https://www.fresair.com/support/ Support:
Installation Videos:
Installation Guide:
https://www.fresair.com/videos/

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.
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.
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Operation Information
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
Cooling unit. • Do not insert foreign objects into the system.
It is recommended that you:
Observe the following instructions to ensure your Fresair Air Cooling Unit is used
properly and efficiently.
Operation

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Warranty 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 [email protected]. 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.
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.
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.
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.

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Parts: Maintenance
NOTE
The fan contains carbon brushes that can degrade over time. We
recommend replacing every 4 years.
Fan:
Located in the center of the tray, the fan draws in external air
and blows internal air through the 4 directional vents.
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.
Evaporative Straw 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 Internal 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.
Tray Pre-Filter:
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.
Water Pumps
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.

NOTICE!
Periodical maintenance is essential for optimal performance and prolonging
the life of your Fresair Air Cooling 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: Maintenance
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.
Float Sensor:
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.
Control Panel:

(10) Zip Ties (2) 4mm x 50mm
Washer Head
Screws
(2) M5 x 10mm
Screws
(4) M5 x 15mm
Screws
(5) Tie Mounting
Pads
Fresair Owner's
Manual
(2) Fresair Decals (1) Remote Control
Fresair Unit Self-Sticking
Sealing Foam
(Inner Edge Use)
Self-Sticking
Sealing Foam
(Outer Edge Use)
Cardboard
Mounting
Template
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Parts: Installation
Loose Components
Bag #1
18L Water
Reservoir Mini Reservoir
Water Reservoir
—OR—

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Parts: Installation
Bubble Wrapped Brackets (18L)
Bag #2
Bag #3
18L Water
Reservoir (2) Mounting Brackets (4) Bolts (2) Water
Reservoir End
Caps
(2) VDO
Water Pumps (1) Rubber
Grommet for
Water Pump
(4) Rubber O Rings (4) M8 x 40mm Bolts (4) M8 x 60mm Bolts (4) M8 x 80mm Bolts
(4) M8 x 100mm Bolts (8) M8 Self
Locking Nylon
Nuts
(8) M8 Flat
Washers
(4) Red End Caps

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How to Install
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).

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How to Install
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.
Step 2 - Cutting the Opening for the Fresair Unit
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

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How to Install
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.
Black Push Tabs
Figure 1
Universal Bolt Hole
Figure 2
Red End Cap
Bolt
Rubber O Ring
Washer
Nut
Fresair Unit
Roof

Universal Bolt Hole
Figure 3
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How to Install
Step 5 - Adhering the Sealing Foam Tape
What you’ll need:
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)
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.
Fresair Unit, Sealing Foam Tape
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.

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How to Install
Step 6 - Mounting the Fresair Unit
What you’ll need:
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.
Fresair Unit, 4 Bolts, 4 Washers, 4 Nuts, 4 Waterproof Bolt Caps, 6
Cover Screws, 2 Finishing Frame Screws, *Screwdriver, *Crescent Wrench(es),
*Selfleveling lap sealant/Silicone
NOTE
Be careful not to over tighten the bolts as this can warp or crack the base.
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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How to Install
Step 7 - Electrical
What you’ll need:
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.
Supplied Electrical Wiring, *Screwdriver
Main Electrical
Harness
fuse block
—or—
18L Reservoir Mini Reservoir
Electrical
Plug
Electrical
Plug
positive
wire
negative
wire
Float Sensor &
Injection Harnesses
Electrical Diagram
Figure 4