GUSTO DRS Dust Reduction System Instruction Manual

GUSTO DRS Dust Reduction System

Product Information

Specifications

• Dust Reduction System
• DRS Unit Template Size: 310mm x 310mm
• Cabinet Vent Template Size: 260mm x 260mm
• Sealant: Sikaflex 227 automotive sealant (not provided)
• Screws: 35mm long self-tapping screws
• Seals: 4x black rubber seals
• Machine Screws: 16x countersunk M4 machine screws
• Air Filter Orientation: Pleats vertically, pull tabs horizontally
• Cutout for Switch Panel: 65mm x 117mm
• Power and Ground Leads: Minimum 8AWG rating, not exceeding 4 meters in length
• Fusible Link: 30 AMP fusible link required (not provided)

Product Usage Instructions

Step 1: Installing the DRS Unit Template

1. Use the DRS unit template on the product packaging to mark and make a cutout of size 310mm x 310mm into the caravan exterior wall.
2. Find the center point of the inside wall of the cabinet and drill a small hole through the external wall.
3. On the exterior of the caravan, align the black dot in the center of the template with the previously drilled hole to ensure correct positioning relative to the inside of the cabinet.
4. Cut and remove the area indicated by the template.

Step 2: Installing Cabinet Vent Template

1. Repeat Step 1 using the 260mm x 260mm cabinet vent template.
2. Position the cutout centrally on the underside of the internal cabinet.

Step 3: Installing the Device

1. Apply a continuous bead of Sikaflex 227 automotive sealant to the rear face of the mounting flange.
2. Install the device, rear vent first, into the previously cut hole from the exterior of the caravan.
3. Orient the unit so that the cables are on the bottom edge.
4. Install the 35mm long self-tapping screws through the holes in the mounting flange, into the caravan wall. If the caravan wall is corrugated, avoid screwing into the troughs and use only holes positioned on the peaks.
5. Support the device from the inside of the cabinet while securing the mounting flange.
6. Use a minimum of 5 screws per side to secure the mounting flange. It is not required to install a screw into every mounting hole on the flange.

Step 4: Installing Rubber Seals and Filter Bucket

1. Ensure that 4x black rubber seals are located on threaded posts located in 4 corners of the mounting flange.
2. If corrugations are present on the caravan wall, apply Sikaflex 227 sealant to the foam seal. Apply a continuous bead around the face that contacts the caravan.
3. Install the Filter Bucket molding into the device and secure using 16x countersunk M4 machine screws. Make sure the Gusto logo is positioned at the bottom when installing.
4. Tighten the screws using a staggered approach to ensure the foam seal is compressed evenly and does not fold as the part is installed.

Step 5: Inserting the Air Filter

1. Insert the Air Filter into the Filter Bucket, ensuring that the pleats are oriented vertically and the pull tabs aligned horizontally.
2. Fasten the Intake vent by securing 4x captive screws. Note : The Intake must face towards the front of the caravan.

Step 6: Mounting the Switch Panel

1. Cut a cabinet panel to match the height and width of the cabinet.
2. Use the Switch Panel template to make a cutout of size 65mm x 117mm into the panel.
3. Include a cutout for the switch panel in the cabinet panel.

Step 7: Routing Power and Ground Leads

1. Neatly and safely route power and ground leads from the caravan’s battery to the interior of the cabinet.
2. The leads must be a minimum of 8AWG rating and should not exceed 4 meters in length.
3. Use wire with red insulation for power and black insulation for ground.
4. Warning: The power lead MUST be fused at the battery with a 30 AMP fusible link to protect against short circuits and fire hazards. The fusible link is not provided and must be obtained separately.

Installation Instructions

1. Use the DRS unit template on the product packaging to mark and make a cutout 310mm x 310mm into the caravan exterior wall. To do so, find the center point of the inside wall of the cabinet and drill a small hole through the external wall. On the exterior of the caravan, align the black dot in the center of the template with the previously drilled hole, this will ensure the cutout will be correctly positioned relative to the inside of the cabinet. Neatly cut and remove the area indicated by the template.
2. Repeat Step 1 using the 260mm x 260mm cabinet vent template. The cutout should be positioned centrally on the underside of the internal cabinet.
3. Apply a continuous bead of Sikaflex 227 automotive sealant (not provided) to the rear face of the mounting flange. Install the device, rear vent first, into the previously cut hole from the exterior of the caravan. The unit must be oriented so that the cables are on the bottom edge. Install the 35mm long self-tapping screws through the holes in the mounting flange, into the caravan wall. The device may need to be supported from the inside of the cabinet while the mounting flange is being secured. If the caravan wall is corrugated, do not screw into the troughs of the corrugations, and instead use holes only that are positioned on the peaks.
   • Note : It is not required to install a screw into every mounting hole on the flange a minimum of 5 screws per side should be used.
4. Ensure 4x black rubber seals are located on threaded posts located in 4 corners of the mounting flange. If corrugations are present on the caravan wall, sealant (Sikaflex 227) must be applied to the foam seal, apply a continuous bead around the face that contacts the caravan. Install the Filter Bucket molding into the device and secure using 16X countersunk M4 machine screws. Ensure the Gusto logo is positioned at the bottom when installing. Tighten screws using a staggered approach to ensure the foam seal is compressed evenly and does not fold as the part is installed.
5. Insert the Air Filter into the Filter Bucket, ensuring that the pleats are oriented vertically and the pull tabs aligned horizontally. Insert and fasten the Intake vent by securing 4x captive screws
   • Note : Intake must face towards the front of the caravan.
6. A cabinet panel should be cut to match the height and width of the cabinet and mount the switch panel within the cabinet. Use the Switch Panel template to make a 65mm x 117mm cutout into the panel.
7. Power and ground lead with no less than an 8AWG rating need to be routed neatly and safely from the caravan’s battery to the interior of the cabinet. The leads must not exceed 4 meters in length. Use wire with red insulation for power and black insulation for ground.
   • Warning : The power lead MUST be fused at the battery to protect the power leads from causing a fire hazard in the event of a short circuit. A 30 AMP fusible link is required (not provided).
8. Pass the power and ground leads through the previously cut switch panel hole and terminate the power leads using crimped ring terminals (not provided). Fasten the power and ground wires into the Terminal Block using the two outer screws. Connect ground to the left position and power to the right.
   • Warning : Do not solder the ring terminals to the wires, crimp only.
9. Feed the Switch Panel connectors through the hole in the cabinet panel and connect them to the connectors protruding from the rear of the DRS unit, ensure the connectors are fully engaged.
10. Secure the previously cut panel into the cabinet cavity, the method of fastening is up to the installer and will depend on the material of the panel and surrounding cabinet. Ensure that the panel is set back from the front of the cabinet by at least 15mm this will prevent the switch from contacting the cabinet door when closed. Using 4 of the supplied, 22mm long self-tapping screws, fasten the switch panel in place.
11. Fasten the Cabinet Vent into the previously cut hole on the underside of the cabinet (see step 2). The vent should be secured using 4 of the supplied 22mm long self-tapping screws (the same screws as the Switch Panel).

Instructions for use

To turn on/off device:
Switch the device on by toggling the circular switch down. Wait 15 seconds for a fan to reach full speed. If the red filter warning light does not turn off after 15 seconds, clean filter. Leave the device on when driving, and turn off when the tow vehicle is parked.

To Clean Filter:
Remove 4x screws retaining intake assembly, remove Intake Vent Assembly, remove filter using 2x pull tabs, wash filter with soapy water, and let dry fully. Installation is the reverse of removal.

Safety Precautions

• DO NOT switch the device on when the Intake Vent and/or Air Filter are not present.
• The Gusto DRS device is designed to work in all conditions but is not recommended to operate during heavy rain when the risk of dust ingress is low.
• Power to the device MUST be fused at 30A.
• Installation of the wiring MUST be completed by a licensed electrician.

FAQ

What size is the DRS Unit Template?
The DRS Unit Template size is 310mm x 310mm.

What size is the Cabinet Vent Template?

The Cabinet Vent Template size is 260mm x 260mm.

What type of sealant should be used?
Sikaflex 227 automotive sealant should be used. Please note that the sealant is not provided with the product.

How many screws should be used to secure the mounting flange?
A minimum of 5 screws per side should be used to secure the mounting flange. It is not required to install a screw into every mounting hole on the flange.

How should the Air Filter be inserted into the Filter Bucket?
The Air Filter should be inserted with the pleats oriented vertically and the pull tabs aligned horizontally.

How should the power and ground leads be routed?
The power and ground leads should be neatly and safely routed from the caravan’s battery to the interior of the cabinet. The leads must not exceed 4 meters in length and should have a minimum 8AWG rating. Use wire with red insulation for power and black insulation for ground.

Is a fusible link required for the power lead?
Yes, a 30 AMP fusible link is required for the power lead. The fusible link is not provided with the product and must be obtained separately. It is important to fuse the power lead at the battery to protect against short circuits and fire hazards.

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