SEALEY DFS91A.V4 Automatic Dust Free System Instruction Manual

: June 12, 2024
: SEALEY

Table of Contents

SEALEY DFS91A.V4 Automatic Dust Free System
Product Information
Safety Instructions
Product Usage Instructions
SAFETY INSTRUCTIONS
GENERAL SAFETY
INTRODUCTION & SPECIFICATION
CONTENTS
ASSEMBLY
OPERATING INSTRUCTIONS
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SEALEY DFS91A.V4 Automatic Dust Free System

SEALEY-DFS91A-V4-Automatic-Dust-Free-System-PRODUCT

Product Information

The Automatic Dust Free System is a high-quality product manufactured by Sealey. It is designed to provide trouble-free performance for many years when used according to the provided instructions and properly maintained. The model numbers for this product are DFS91A.V4 and DFS91B.V2.

Safety Instructions

It is important to read and follow the safety instructions carefully to ensure safe operation and to prevent damage or personal injury. Some important safety instructions include:

Ensure that the electrical safety requirements are met, including using the recommended fuse rating of 10AMP.
Follow all relevant health and safety regulations and guidelines.
Avoid getting the dust free vacuum system wet or using it in damp or wet locations.
Do not use the vacuum system to vacuum combustible, poisonous, or toxic materials.
Avoid operating the vacuum system when tired or under the influence of alcohol, drugs, or intoxicating medication.
Do not leave the vacuum system operating unattended.
Regularly empty the system and clean the filter to prevent damage and maintain warranty validity.
Turn off the mains power supply and air supply when not in use.
Dispose of waste products according to local authority regulations.
Store the vacuum system in a safe, dry, and childproof area.

Introduction & Specification

No specific information is provided in the user manual for the introduction and specification of the product.

Contents

No specific information is provided in the user manual for the contents of the product.

Assembly

The user manual provides assembly instructions, but they are not included in the provided text extract.

Air Supply

No specific information is provided in the user manual for the air supply of the product.

Product Usage Instructions

Operating Instructions

The vacuum system can support a maximum of two air-powered tools together, or one air-powered tool and one electrical tool together.

To operate the vacuum system:

Ensure the power switch (fig.5A) is in the central 0 position.
Connect the air supply to the vacuum system following the provided instructions.
Switch on the mains power supply and turn on the air supply.
To activate the automatic mode, move the power switch to the right (fig.5A) until it clicks into place. The unit will automatically start and stop based on the connected tools’ usage.
To manually operate the vacuum system, move the power switch to the left (fig.5A) until it clicks into place. The unit will continue to operate until you switch it off by moving the power switch back to the central 0 position.

Cleaning the Vacuum System

The dust bag may be emptied as required, but it should not be filled to more than 2/3rd capacity. To clean the vacuum system:

Undo the clips on the side of the vacuum system drum and remove the motor head.
Gently place the motor unit in a safe and clean location.
Remove the filter from the top of the drum and keep it safe and dry.

Thank you for purchasing a Sealey product. Manufactured to a high standard this product will, if used according to these instructions and properly maintained, give you years of trouble free performance.
IMPORTANT: PLEASE READ THESE INSTRUCTIONS CAREFULLY. NOTE THE SAFE OPERATIONAL REQUIREMENTS, WARNINGS, AND CAUTIONS. USE THIS PRODUCT CORRECTLY, AND WITH CARE FOR THE PURPOSE FOR WHICH IT IS INTENDED. FAILURE TO DO SO MAY CAUSE DAMAGE AND/OR PERSONAL INJURY AND WILL INVALIDATE THE WARRANTY.

SAFETY INSTRUCTIONS

ELECTRICAL SAFETY

WARNING! It is the responsibility of the owner and the operator to read, understand and comply with the following. You must check all electrical products, before use, to ensure that they are safe. You must inspect power cables, plugs, sockets and any other connectors for wear or damage. You must ensure that the risk of electric shock is minimised by the installation of appropriate safety devices.
A Residual Current Circuit Breaker (RCCB) should be incorporated in the main distribution board. We also recommend that a Residual Current Device (RCD) is used. It is particularly important to use an RCD with portable products that are plugged into a supply which is not protected by an RCCB. If in any doubt consult a qualified electrician. You may obtain a Residual Current Device by contacting your Sealey dealer. You must also read and understand the following instructions concerning electrical safety.
The Electricity at Work Act 1989 requires that all portable electrical appliances, if used on business premises, are tested by a qualified electrician, using a Portable Appliance Tester (PAT), at least once a year.
The Health & Safety at Work Act 1974 makes owners of electrical appliances responsible for the safe condition of those appliances and the safety of the appliance operators. If in any doubt about electrical safety, contact a qualified electrician.
Ensure that the insulation on all cables and on the appliance is safe before connecting it to the power supply. See 1.1.1 and 1.1.2 and use a Portable Appliance Tester.
Ensure that cables are always protected against short circuit and overload.
Regularly inspect power supply cables and plugs for wear or damage and check all connections to ensure that none are loose.
Important: Ensure that the voltage marked on the appliance matches the power supply to be used and that the plug is fitted with the correct fuse – see fuse rating at below.
DO NOT pull or carry the appliance by the power cable.
DO NOT pull the plug from the socket by the cable.
DO NOT use worn or damaged cables, plugs or connectors.
Immediately have any faulty item repaired or replaced by a qualified electrician. When a BS 1363/A UK 3 pin plug is damaged, cut the cable just above the plug and dispose of the plug safely. Fit a new plug according to the following instructions (UK only).
a) Connect the GREEN/YELLOW earth wire to the earth terminal ‘E’.
b) Connect the BROWN live wire to the live terminal ‘L’.
c) Connect the BLUE neutral wire to the neutral terminal ‘N’.
d) After wiring, check that there are no bare wires, that all wires have been correctly connected, that the cable outer insulation extends beyond the cable restraint and that the restraint is tight.
Double insulated products, which are always marked with this symbol , are fitted with live (brown) and neutral (blue) wires only. To rewire, connect the wires as indicated in diagram.
DO NOT connect either wire to the earth terminal.
Products which require more than 13 amps are supplied without a plug. In this case you must contact a qualified electrician to ensure that a suitably rated supply is available.
We recommend that you discuss the installation of an industrial round pin plug and socket with your electrician.
If an extension reel is used it should be fully unwound before connection. A reel with an RCD fitted is preferred since any appliance plugged into it will be protected. The cable core section is important and should be at least 1.5mm², but to be absolutely sure that the capacity of the reel is suitable for this product and for others which may be used in the other output sockets, we recommend the use of 2.5mm² section cable.

GENERAL SAFETY

WARNING! Ensure that all relevant Health and Safety, Local Authority, Control of Substances Hazardous to Health (COSHH) and General Workshop Practice Regulations are strictly adhered to when using this equipment.
Familiarise yourself with the applications, limitations and hazards peculiar to the dust free vacuum system.
WARNING! Disconnect dust free vacuum system from mains power and air supply before changing accessories, servicing or performing maintenance.
Maintain the dust free vacuum system in good condition (use an authorised service agent).
Replace or repair damaged parts. Use recommended parts only. Unauthorised parts may be dangerous and will invalidate the warranty.
Locate dust free vacuum system in a suitable work area.
Keep area clean and tidy and free from unrelated materials.
Ensure there is adequate lighting.
WARNING! Ensure correct air pressure is used, maintained, and not exceeded for the sander attachment.
The air supply should be adequate for a minimum of 10.6cfm free air delivery to the sanding tool. There should be a minimum of 14.8cfm free air delivered to the air inlet of the dust free vacuum system. We recommend the use of a 3HP (or more) compressor or twice that rating if two air tools are used.
Air supply must be delivered through a 3/8” internal diameter air hose. If you use a 5/16” internal diameter the performance of the tool may suffer.
Keep air hose away from heat, oil and sharp edges. Check air hose for wear before each use, and ensure that all connections are secure.
Before each use check attached tool for condition. If worn or damaged replace immediately.
WARNING! The maximum wattage of any electrical tool operated from the dust free vacuum system must not exceed 1200 watts.
Ensure there are no flammable or combustible materials near the work area.
WARNING! Always wear appropriate approved eye, face, mask, ear defenders, or protective clothing according to task being undertaken.
Keep hands and body clear of the sanders working parts when operating the dust free vacuum system.
Keep children and unauthorised persons away from the working area, and DO NOT allow untrained persons to operate the dust free vacuum system.
DO NOT use the dust free vacuum system for any purpose other than that for which it is designed.
DO NOT pull or yank the electrical leads, air hoses or vacuum extraction hoses attached to the dust free vacuum system.
DO NOT get the dust free vacuum system wet or use in damp or wet locations.
WARNING! DO NOT use the dust free vacuum system to vacuum combustible, poisonous or toxic materials, including acids, solvents and asbestos.
DO NOT operate the dust free vacuum system when you are tired or under the influence of alcohol, drugs or intoxicating medication.
DO NOT leave the dust free vacuum system operating unattended.
Ensure the system is regularly emptied and the filter is cleaned. Failure to do so may damage the unit and invalidate your warranty.
When not in use turn off the mains power supply and ensure the air supply is turned off.
WARNING! Ensure you turn off the air supply beforedetaching the air hose from the vacuum system.
Dispose of waste products in accordance with local authority regulations.
Store the dust free vacuum system in a safe, dry, childproof area.

INTRODUCTION & SPECIFICATION

Tough, composite bin and motor housing are suitable for industrial/ body shop applications. Fitted with microchip controlled electric and air supply circuit which monitor power/air to the power tool and automatically activates the suction. The same microchip overruns the suction by 10 seconds to clear the hoses of dust. Features vibration function that helps clear dust accumulated on the filter after use. Supplied with a combined air/vacuum hose to minimise trailing hoses. All DFS models require an independent power/air supply. DFS models can be purchased with MA150AS Dust Free Air Sander (‘A’ Versions) or without (‘B’ Versions).

Supply:. ……………………………………………………………………………..230V
Power: . ………………………………………………………………………….1000W
Power Tool Capacity: ………………………………………………………..1200W
Weight (inc. sander): ………………………………………………………..10.4 kg
Replacement Filter: ……………………………………………………. 122.03241
Hose Diameter: . ………………………………………………………………. 28mm
Drum Size: …………………………………………………………………………. 37ltr

Extension Tube.
Extension Tube.
‘Y’ Connector.
Small brush.
Upholstery tool.
Floor tool body.
Floor tool brush insert.
Floor tool carpet insert.
Crevice tool.
Hose connector elbow.
Standard flexible hose.
Combined Air and Dust Extraction Hoses.
Power Head.
Main Body Unit.
Air Sander Model MA150AS.
- (DFS91A.V4 only, not supplied with the DFS91B.V2).

ASSEMBLY

NOTE: The vacuum system will support a maximum of two air powered tools together, or one air powered tool and one electrical tool together.

Connecting an Air Operated Tool.

IMPORTANT: See section 5 for details of external air supply system.
Take the ‘Y’ connector, see 3 in figs 2 & 3 and insert it into the intake socket near the top of the drum as shown in fig.3. Close off one branch of the ‘Y’ connector using the cap on the chain as shown in fig.3-4.
Take the light grey combined suction and air hose (fig.1-13) and push the rubber fitting onto the other branch of the ‘Y’ connector as shown in fig.3-2. Connect the air hose to the units air outlet as shown in fig.3-1.
Connect the other end of the suction hose to the air tool.
Connect the air hose to the tool’s air coupling. See fig.1-16.
Fit an external air line system onto the vacuum system air inlet (fig.1). See section 5 for air supply information. Seal and retain with a hose clip and turn the air supply on.
Take the vacuum system’s electrical cable and plug into the mains power supply and switch the power on.
Press the operating switch to the “Automatic” mode (II). The red standby light will illuminate. See A & B in fig.5.
A second air tool may be connected to the other branch of the air and suction ‘Y’ connectors. See section 5 re air supply.
The unit is now ready for use and will automatically activate when you turn the tool on.

Connecting an Electrically operated tool.

IMPORTANT: If a compressor or a workshop air supply is connected to the unit disconnect it now.
Take the ‘Y’ connector, see 3 in figs. 2 & 3 and insert it into the intake socket near the top of the drum as shown in fig.3. Close off one branch of the ‘Y’ connector using the cap on the chain as shown in fig.3-4.
Take the light grey combined suction and air hose (fig.1-13) and push the rubber fitting onto the other branch of the ‘Y’ connector as shown in fig.3-2. DO NOT connect the air line hose to the unit.
Connect the other end of the suction hose to the electric tool as shown above in fig.4. If necessary, tie or tape the redundant air line to the suction hose to keep it out of the way.
Lift the socket cover and plug the tool’s electrical cable into the vacuum system’s power socket as shown in fig.5-C.
WARNING! DO NOT plug the tool into any electrical supply other than the vacuum system’s.
Take the vacuum system’s electrical cable and plug into the mains power supply and switch the power on.
Press the operating switch to the “Automatic” mode (II). The red standby light will illuminate. See A & B in fig.5.
The unit is now ready for use and will automatically activate when you turn the tool on.

To use as an ordinary vacuum cleaner.

Firstly attach the hose connector elbow (fig.2-11) to the plain end of the black flexible hose (fig.2-12). To do this, push the hose into the open end of the elbow and turn the rotating sleeve anti-clockwise until it threads tightly onto the hose end.
Referring to fig.6, assemble either the carpet insert (7) or the brush insert (8) into the floor tool body (5). Place the insert into the lower opening of the floor tool body and snap the tabs at either end into place to secure it.
If still in place detach the “Y” connector from the unit by using the red ribbed release catch. See 5 in fig.3. Insert the black vacuum hose directly into the unit intake until it snaps into place.
Attach the required accessories to the hose connector elbow.
Plug the unit into the mains power supply.
When the switch is set to manual (I), see fig.5A, this will start the suction.

AIR SUPPLY

The recommended hook-up procedure is shown in fig.7.
WARNING! Ensure correct air pressure is used, maintained and not exceeded for the sander attachment.
Air supply should be adequate for a minimum of 10.6cfm free air delivery to the sanding tool. This should be a minimum of 14.8cfm free air delivered to the air inlet of the dust free vacuum system. We recommend use of a 3hp (or more) compressor to operate one air tool and twice that compressor rating to operate two air tools..
Air supply must be delivered through a 3/8” internal diameter air hose and fittings must have the same inside dimensions.
If you use a 5/16” internal diameter the performance of the tool may suffer.
Ensure the air valve is in the “off” position before connecting to the air supply.
WARNING! Ensure the air supply does not exceed 90psi while operating the sander. Too high an air pressure and unclean air will shorten the product life due to excessive wear, and may be dangerous causing damage and/or personal injury.
Drain the air tank daily. Water in the air line will damage the tool.
Clean the air inlet filter screen weekly.
Line pressure should be increased to compensate for unusually long air hoses (over 8 metres).
Keep hose away from heat, oil and sharp edges. Check hoses for wear and make certain that all connections are secure.

OPERATING INSTRUCTIONS

NOTE: The vacuum system will support a maximum of two air powered tools together, or, one air powered tool and one electrical tool together.
WARNING! Ensure you have read and understood and adhere to Section 1 safety instructions. Ensure you are using the personal protection items appropriate to the task before operating the unit and before opening the vacuum system drum.

Preparation for use.

Ensure that the vacuum system is unplugged from the mains power supply and the air supply.
Check that dust bag will accommodate dust generated and that the filter is in good condition (see section 6.3 for bag and filter removal).
Check the vacuum system and attached tools are in good working order and condition and all air and electrical connections are sound.
Check that the operating switch is moved to the automatic mode (II) when using as a dust free system.
Turn the electrical mains power on and the external air supply if required.
Operating the system.
Make the tool ready for use and operate the tool which in turn will automatically activate the dust vacuum system. When the tool is activated the red standby light will go out. Whilst performing the task the vacuum system will draw the dust up into the unit.
When you turn off the tool, the vacuum system will continue to operate for approximately a further 10 seconds drawing up any remaining dust.
After a further 10 seconds the filter shaking mechanism will operate to clear dust which has accumulated on the filter. The filter shaker may also be operated manually by pressing the red button to the right of the 3 pin socket. See fig.5D.
Any dust that still remains in the work area may be collected by using the system as an ordinary vacuum cleaner. To do so switch the operating button (fig.5A) to “Stop” “0” mode, turn off the air supply system (if connected) and remove all air hoses.
Disconnect the mains power lead and transport the vacuum system to appropriate area for use. Set up as a vacuum cleaner as described in section 4.3.
Plug into the mains power supply. Move the operating switch (fig.5A) to the manual mode (I). The unit will continue to operate until you switch it off by moving the power switch back to the central “0” position.

Cleaning the vacuum system.

The dust bag may be emptied at any time as required (follow steps below). It is important to ensure however that the dust bag is not filled to more than 2/3rd capacity.
Undo the clips on the side of the vacuum system drum and remove the motor head. Gently place the motor unit in a safe clean location. Remove the filter from the top of the drum and keep safe and dry.
Check that the dust collection bag has enough free space to collect the dust that will be generated by the next task (the bag is designed to accommodate dust up to a maximum of 2/3 of total capacity and this must not be exceeded). To remove the bag, hold the cardboard and rubber retainer that fits around the inlet socket and gently pull the bag away from it. Dispose of the bag and contents according to local regulations. If the vacuum system is in constant use, we recommend that the paper bag is checked everyday and automatically replaced at the end of each operating week. To refit the dust bag ensure the inlet collar is pushed fully onto the inlet socket.
To clean the filter, first operate the built in filter shaker by manually pressing the red button to the right of the 3 pin socket. See fig.5D. If necessary remove the drum filter and shake it in an appropriate safe area to expel any remaining dust particles thus prolonging the life of your equipment. We recommend that the filter is cleaned after every 10 hours operation. Check filter is in good condition and replace it into the drum. Replace the motor head with power switch (fig.5) aligned with the suction inlet socket and secure it with the side clips.
NOTE: Blocked filters and/or over filled bags may damage the motor and will invalidate your warranty.
WARNING! DO NOT operate the system without a filter or dust bag. Always ensure you use authorised spares, filters and bag. Contact your Sealey dealer for details.
WARNING: The warnings, cautions and instructions discussed in this instruction manual cannot cover all possible conditions and situations that may occur. It must be understood that common sense and caution are factors which cannot be built into this product, but must be applied by the operator.
NOTE: It is our policy to continually improve products and as such we reserve the right to alter data, specifications and component parts without prior notice.
IMPORTANT: No liability is accepted for incorrect use of this product.
WARRANTY: Guarantee is 12 months from purchase date, proof of which will be required for any claim.
INFORMATION: For a copy of our latest catalogue and promotions call us on 01284 757525 and leave your full name and address, including postcode.
Sole UK Distributor, Sealey Group, Kempson Way, Suffolk Business Park, Bury St. Edmunds, Suffolk,
IP32 7AR
01284 757500
01284 703534
www.sealey.co.uk sales@sealey.co.uk