Ironwood DSP2500
User Manual
general information.
technical specifi cations. safety considerations.
delivery and installation. inspection.
pre-operation cleaning.
dust port connections. safety.
operation and adjustments.
machine controls.
adjust clearance on guideways.
troubleshooting. digital controller unit.
maintenance.
assembly.
features.
Table of Contents
1.0 General Information… ............................................................... 3
1.1 Thank You
1.2 Before Contacting Stiles
1.3 Features
1.4 Intended Use
1.5 Technical Specifications
1.6 Safety Considerations
2.0 Facility Preparation… ............................................................... 6
2.1 Floor
2.2 Work Space
2.3 Power
3.0 Delivery and Installation … ........................................................... 7
3.1 Receiving Your Machine
3.2 Unpack the Machine
3.3 Inspection
3.4 Move Machine to Final Position
3.5 Remove Machine from Pallet
3.6 Level
3.7 Pre-Operation Cleaning
4.0 Assembly ....................................................................... 11
4.1 Front Roller
4.2 Control Power Switch
4.3 Dust Port Connections
5.0 Connect to Power… ............................................................... 12
6.0 Safety .......................................................................... 13
7.0 Operation and Adjustments ......................................................... 14
7.1 Machine Controls
7.2 Machine Operation
7.3 Tool Adjustments
8.0 Maintenance… ................................................................... 22
8.1 Lubrication
8.2 Inspection
8.3 Periodic Maintenance
8.4 Adjust V-Belt Tension of Cutterhead Motors
8.5 Adjust Clearance on Guideways
8.6 Adjust Clearance for Infeed Table Taper Gib
9.0 Troubleshooting .................................................................. 25
9.1 Machine Operation
9.2 Digital Controller Unit
9.3 Electrical Diagrams
PLEASE REVIEW AND OBSERVE ALL SAFETY
INFORMATION / DIRECTIVES BEFORE INSTALLING,
OPERATING, OR PERFORMING MAINTENANCE ON
THIS MACHINERY.
Ironwood DSP2500 | User Manual2
1.0 General Information
1.1 Thank You!
Thank you for your purchase of the Ironwood DSP2500 double
surface planer. At Stiles Machinery, our goal is to ensure that you are
fully satisfied with your purchase. This manual is provided so that
you may properly assemble, operate, and maintain your DSP2500.
Should you need help, our team of dedicated service personnel
are available to answer your questions and provide any resource
recommendations you may need.
Warranty and Support
All Ironwood machines are designed to meet the exacting standards
demanded by craftsmen like you. Ironwood machines include a
one (1) year parts warranty and two (2) years of free 24/7 technical
support beginning at date of shipment. Standard technical support
remains in effect for free for the lifetime of the machine thereafter.
Warranty service work is not covered by manufacturer’s warranty.
Stiles’ service team is available for an additional charge.
1.2 Before Contacting Stiles
Please have your machine model and serial number available when
contacting Stiles Machinery with questions. The machine’s model
and serial number are listed on the metallic plate located on the
machine’s frame.
Information regarding the electrical system is also listed on the
metallic plate.
1.3 Features
Insert latest drawing with call-outs for features:
• Overlapped pressure-finger conveyor secures workpieces firmly
and uniformly to maintain straightness and prevent movement
• 2 heavy-duty spiral cutterheads have six rows of 16 carbide
inserts, providing high chip-rate removal rate, superior surface
finishing, and reduced noise levels
• Innovative micro-switch enables quick thickness settings
• ½-hp motor raises and lowers table
• 5 hp feed motor has variable speed control (23-65 fpm)
• Heavy-duty 25 hp upper cutterhead motor and 20 hp lower
cutterhead motor
• Digital controller has keypad entry for table positioning
• Powered elevation of feed mechanism allows quick, easy
set-ups.
• Control panel is equipped with digital thickness readout, LED
display (inch/mm), current meters, and lighted power switches
for controls.
1.4 Intended Use
The Ironwood DSP2500 double-surface planer is designed and
manufactured for planing two sides of a workpiece in a single
operation. The lower cutterhead flattens the workpiece and the
upper cutterhead planes the workpiece to the desired thickness for
fast and effective planing results.
The workpiece is fed into the machine by a pressure-finger conveyor
that holds the workpiece firmly for heavy-duty cutting applications.
The feed speed is variable to meet a wide range of workpiece
material requirements.
With hardened chrome-plated and precision ground tables, the
DSP2500 ensures smooth feeding motion, quiet operation, and
maximum wear resistance.
Machine information plate
Stiles Technical Support
616.698.6615
Stiles Parts
800.PARTS.80 (800.727.8780)
Website
www.stilesmachinery.com/ironwood/dsp-2500
Machine Model ____________________________________________
Machine Serial Number _____________________________________
Ironwood DSP2500 | User Manual 3
e
Conveniently located
control panel with digital
controller, current meters,
and lighted power switches.
Overlapping pressur
nger conveyor
2 heavy duty
spiral cutterheads
Solid cast iron base
1.5 Technical Specifications
Description Ironwood DSP2500
Max Working Width 25" (635mm)
Max Working Thickness 8" (203mm)
Min Working Thickness
Min Length of Cut 12½" (317mm)
Upper Cutterhead Motor 25 hp
Lower Cutterhead Motor 20 hp
Feeding Cutterhead Motor 5 hp
Table Rise/Fall Motor 1/2 hp
Variable Feed Speed 26-78 fpm (8-24 m/min)
Cutterhead Speed 5,000 rpm
Cutterhead Diameter 5" (126mm)
Cutter Knives per Head 96
Max Stock Removal ½" (14mm) total / ¼" (7mm) per head
Table adjustment – Lower cutterhead Manual via handwheel
Table adjustment – upper cutterhead Motorized via keypad controller
Table position display Digital
Electrical 230v / 460v (3 phase)
Amperage 125 amps @ 230v / 62.5 amps @ 460v
Dust Port Diameter 2 ports, 6" each (150mm)
Dust Extraction Requirements 1,600 cfm @ 4,500 feet/min
Machine Dimensions (W x L x H) 105" x 45" x 68" (2667mm x 1145mm x 1725mm)
Gross Weight 7000 lbs (3175 kg)
6
/
16" (9.5mm)
Ironwood DSP2500 | User Manual4
1.6 Safety Considerations
For your safety, read these instructions thoroughly before you install
and operate this machine. Always have these instructions available
at the machine for reference.
Observe all codes and regulations that apply to the installation and
operation of this machine.
Keep visitors at a safe distance from the workspace.
Keep children away from this and all machines. Childproof your
work area!
Familiarize yourself with the safety notices used in this manual.
CAUTION
If cautions are ignored, personal injury and/or machine damage
may result.
WARNING
If warnings are ignored, serious injury or death may result.
Warning Labels
This machine has warning labels attached to ensure safe operation.
These warning labels are very important and should be kept clean
and never removed. If warning labels become damaged or lost,
contact Stiles Machinery immediately for replacements.
Label 1: Keep work table clean
Label 2: Conveyor will stop if oil is too low
Label 3: Warning lamp: feeding system overload
Label 4: Feed speed adjustment
Label 5: Wear ear protection
Label 6: Keep rollers clean
Label 7: Do not adjust this device
Label 8: Hazardous voltage
Label 9: Keep hands away from cutterhead and knives
Label 10: Keep hands away from rollers
Label 11: Pressure adjustment for feed conveyor
Label 12: Greasing the shaft
WARNING
Never use the DSP2500 for purposes other than its intended use.
Do not modify or remove any guards or other safety features.
Improper use or modifications may affect your warranty or result in
serious injury or death.
Training
This machine is intended for use by authorized, well-trained
operators only.
Do not operate until you have a complete working knowledge of
the machine and have been properly trained for its safe operation,
correct adjustment, and use. All operators should thoroughly read
and understand this manual and the workings of this machine prior
to operation.
It is essential that all operators be aware of the following:
• The dangers associated with the operation of this machine.
• The use of personal protective equipment for ear and eye
protection.
• The proper positioning of the operator and operator’s hands
relative to the cutterheads.
• The principles of machine operation.
• The safe handling of the workpiece when planing.
• The safe stacking of the workpiece before and after planing.
WARNING
Clean up anything
on the working
table when it is
getting down.
LABEL NO. 1 LABEL NO. 2 LABEL NO. 3LABEL NO. 4LABEL NO. 5LABEL NO. 6
WARNING
The conveyor will stop by itself
in case of running out of oil.
1. When the warning lamp lights up, it means an overload caused by the
mechanical feeding system.
2. Fix the trouble by following the instructions below:
(A) Raise the upper mechanism about 100mm.
(B) Remove the bad workpiece or any obstacle.
(C) Return the upper mechanism to its original position.
(D) Start feeding system.
3. The feeding system can not be started until the obstacle has been removed.
4. For other types of overload not caused by obstacles, follow the
troubleshooting instructions.
CAUTION
CAUTION
Feed speed adjustment
50
40 60
7030
SLOW FAST
20 80
9010
0 100
CAUTION
In order to keep the roller smooth, be
sure to clean the wood chip and the
foreign substance in the chasm of the
roller on the worktable.
DANGER
WARNING
Except be authorized,
don’t adjust this device.
Otherwise, it will cause
the inaccuracy of the
machine and damage
the driving mechanism.
LABEL NO. 7 LABEL NO. 8 LABEL NO. 9LABEL NO. 10 LABEL NO. 11 LABEL NO. 12
HAZARDOUS VOLTAGE
TURN POWER OFF BEFORE
SERVICING.
VOLTAGE ÉLEVÉ, ENLEVEZ
TOUT POUVOIR ÉLECTRIQUE
AVANT DE FAIRE L’ENTRETIENT
DANGER
KEEP HANDS AWAY FROM
CUTTERHEAD AND KNIVES
DANGER
ROLLING
KEEP HANDS AND
ANY OBJECT AWAY
CAUTION
Do not adjust the
V belt too tight.
The proper belt
tension is approx.
1 cm by nger
pressure.
WARNING
BE SURE TO ADD SKF LGLT 2 GREASE
FOR HIGH SPEED SHAFT EVERY SIX
MONTHS.
Ironwood DSP2500 | User Manual 5
2.0 Facility Preparation
4'
(1200mm)
*
*
*
4'
(1200mm)
Prior to uncrating your machine confirm that your location can
accommodate the Ironwood DSP2500. Follow these guidelines:
2.1 Floor
• The floor must be flat and level.
• Although no special foundations are required, a concrete floor is
recommended.
• All floors must have a load-bearing strength suitable for the
machine weight of approximately 7,000 pounds (3,175 kg).
• The machine need not be anchored to the floor. However, if you
decide to do so, purchase high quality anchor bolts appropriate
to the floor construction and material.
2.2 Work Space
• Provide adequate work space surrounding the machine.
• Provide proper non-glare, overhead lighting.
• Place the machine so that any potential kickback area is not in
line with aisles, doorways, or other work and traffic areas.
• Provide adequate dust extraction system.
The dust extraction system should have a flow rate with a speed
of 4,500 feet per minute at 1,600 cfm.
2.3 Power
WARNING
A licensed electrician must connect the DSP2500 to the building
power source.
• Do not use extension cords.
• Be sure that the electrical current of the power source is of the
same characteristics as the electrical system supplied with your
machine. If other machine voltage capabilities are required,
contact Stiles Machinery.
DSP2500
Upper cutterhead motor 25 hp
Lower cutterhead motor 20 hp
Feeding cutterhead motor 5 hp
Table rise/fall motor ½ hp
Total required amperage
• Ensure the machine is protected with an external over-current
protective device per your local electrical codes.
• Electrical equipment operating conditions:
Air temperatures between +41ºF (+5ºC) and +113ºF (+45ºC).
Relative humidity not to exceed 50% at a maximum temperature
of +113ºF (+45ºC).
125 amps @ 230v / 62.5 amps
@ 460v
Machine clearance requirements*
*Actual clearance requirements may vary depending on length of
material to be cut.
• Electrical equipment is designed and protected to withstand the
effects of transportation and storage temperatures within a range
of -13ºF (-25ºC) to +131ºF (+55ºC), and for short periods of time
not exceeding 24 hours at up to +158ºF (+70ºC).
• Ensure connection to factory ground system is wired correctly
(IAW local electrical codes and NEC) and not connected to any
electro magnetic interference source such as welders.
Ironwood DSP2500 | User Manual6
3.0 Delivery and Installation
to crate.
sides.
3.1 Receiving Your Machine
You will be contacted to arrange delivery. Your machine will be
delivered by truck to your location. If there is no loading dock, be
sure that you have informed the carrier in advance so that they
deliver using a truck with a lift gate to lower the machine to
ground level.
Before accepting the machine and signing the bill of lading from the
carrier, please inspect crating and machine condition, note potential
damage on the bill of lading, take pictures of potential damage, and
contact Stiles Machinery immediately at 616.698.7500 and ask to
speak with the traffic department.
The machine will arrive fully crated and secured to a pallet. Use a
fork lift or crane to move the machine on its pallet as close to its final
position as possible.
If you do not intend to install the machine immediately after delivery,
store it in a protected, cool, and dry location.
3.2 Unpack the Machine
TOOLS REQUIRED:
• Hammer
• Crowbar
Unpack as follows:
Do not remove the machine from the pallet.
1. Remove and save all paperwork attached to the outside of the
crate.
2. Remove the crating, starting with the top, then remove the four
sides. Use caution to avoid personal injury and prevent damage
to the machine’s finish.
3. Remove the protective plastic from the machine, starting at the
bottom.
The machine arrives
fully crated. Remove
and save the
paperwork attached
Remove the crating,
starting with the top,
then remove the four
Do not remove the machine from the pallet while uncrating.
4. Remove the hardware, accessories, and tool kit that are
shipped with the machine. If additional accessories are ordered,
they are delivered separately.
Ironwood DSP2500 | User Manual 7
3.3 Inspection
Use a fork lift to move
3.4 Move Machine to Final Position
Save all containers and packing materials until you are satisfied
that your machine has arrived in good condition. If you discover the
machine is damaged after you’ve signed for delivery, immediately
call Stiles Customer Service at 616.698.7500.
When you are completely satisfied with the condition of your
equipment, you should inventory its parts.
Open and check the contents of all containers to ensure all tools,
hardware, and accessories are included. The tool kit should contain
the following items:
1. Adjustable wrench
2. Open end wrench set (12mm/4mm and 19mm/21mm)
3. Allen wrench set
4. 4 leveling pads
5. 3 leveling bolts and nuts (a fourth bolt is preinstalled)
6. 5 T-handle wrenches (5mm)
7. 5 knife jibs
8. 10 carbide insert knives
9. Gauge block for setting table rollers
10. Paint brush
11. Oil can
12. Touch-up paint (2-color set)
13. User manual
Be sure the site is properly prepared. Refer to section 2.0 for details.
Be sure the cabinet door is closed and locked before transporting.
TOOLS REQUIRED:
• Fork lift or crane
Use a fork lift or crane to move the machine on its pallet to its final
location.
the machine on its pallet.
If using a fork lift, insert forks through the slots at the machine
bottom. Make sure fork travel is clear of any obstacles or wiring.
Ironwood DSP2500 | User Manual8
Hoist hooks for
straps to place machine
bolted to the pallet
crane lift
If using a crane, use a hoist hook and lift strap (suitable to lift more
than 7,000 lbs) secured to the four red lifting hooks to move and
place the machine. Make sure travel is clear of any obstacles or
wiring.
3.5 Remove Machine from Pallet
CAUTION
The DSP2500 weighs approximately 7,000 lbs (3,175 kg). For this
procedure, we recommend using a fork lift or crane.
TOOLS REQUIRED:
• Adjustable wrench
When the machine has been placed at its final location, carefully
remove the machine from the pallet.
The machine is
for transport.
Use a crane and
in its nal position.
1. Remove the bolts that secure the machine to the pallet at the
corners.
2. Lift the machine from the pallet by one of two methods:
a. Forklift
b. Crane with hoist hook and lift strap
3. Carefully place the machine in final position.
Ironwood DSP2500 | User Manual 9
3.6 Level
preinstalled.
3.7 Pre-Operation Cleaning
TOOLS REQUIRED:
• Bubble Level
• Adjustable wrench
WARNING
Use proper cleaning agents and methods described below. Do not
use gasoline or other petroleum-based solvents. There is a risk of
explosion and burning if these products are used. Serious personal
injury may occur.
Machine Tabletop Surface
After the machine is unpacked, remove the rust preventative oil that
coats the machine. Use a soft cloth and nonflammable degreasing
agent, such as Simple Green or other orange/citrus-based cleaner.
Do not use abrasive pads.
Table Rollers, Feed Rollers, and Cutterheads
CAUTION
Use extreme care when cleaning the cutterheads. The knives are
very sharp.
Be sure to level the
machine. The circled
leveling bolt is
Use a bubble level along the length and width of the tabletop surface
to check for level. Use an adjustable wrench to adjust the 3 leveling
bolts to level the machine. A fourth bolt is preinstalled under the
infeed table rise/fall motor as shown.
Ironwood DSP2500 | User Manual10
4.0 Assembly
oller
Dust hood
To be assembled:
• Front roller
• Control power switch
• Dust port connections
4.1 Front Roller
The front roller attaches at the infeed end of the table for smooth
feeding.
Front r
4.2 Control Power Switch
The control power switch is not mounted on the machine during
shipping. It is shipped inside the electrical control cabinet.
1. Remove the paper covering the mounting hole.
2. Mount the switch using the supplied hardware.
4.3 Dust Port Connections
1. Remove the 2 Allen bolts from each side of the infeed table.
2. Attach the roller using the Allen bolts removed in step 1.
3. Tighten the Allen bolts to secure the roller.
The machine has two dust exhaust ports to remove dust from the
upper and lower cutterheads.
Fit flexible hoses to the two dust hoods and connect them to the
dust collector. The outlet diameter for each dust hood is 6".
Ironwood DSP2500 | User Manual 11
5.0 Connect to Power
L1
L2
L3
• Voltage – Steady state voltage +/- 10% of nominal voltage.
• Machine needs steady voltage at all times.
WARNING
Before connecting power to the machine, make sure all screws and
fasteners are tightened, all mechanical functions work freely, and the
cutterhead and rollers turn freely without touching the machine.
WARNING
A licensed electrician must complete all connections to electrical
power.
Before connecting to a power source, confirm that the electrical
current of the power source is the same as the electrical system
supplied with your machine. Ensure the machine is protected with
an external over current protective device per your local regulating
authorities.
Machine must be properly grounded to prevent electric shock.
Never connect the yellow/green wire to a live terminal.
Once connected to power source, terminals are electrified even
while the power switch is off.
To connect power source to the machine:
5. Replace the clear plastic insulator and the power box cover.
6. Close and secure the electrical cabinet door.
WARNING
Always shut off power at source before removing terminal box cover.
Failure to comply with this action may result in electric shock.
CAUTION
We have covered some basic electrical requirements for the safe
installation of your machine. These requirements may not cover
all installation requirements. You must confirm that your particular
electrical configuration complies with all local codes. Ensure
compliance by checking with your local municipality and a licensed
electrician.
Proper wiring inside electrical cabinet
1. Open electrical cabinet
2. Remove clear plastic insulator that covers the terminals.
3. Insert source power cables through opening of electrical cabinet
using the grommet on the electrical cabinet to prevent dust
from getting inside.
4. Connect the three power cables to terminals L1, L2, and L3,
and the yellow/green ground wire to ground terminal.
Ironwood DSP2500 | User Manual12
6.0 Safety
WARNING
Like all power equipment, there is danger associated with the
Ironwood DSP2500. Use caution and follow all safety instructions.
Take every precaution to protect yourself, others around you, and
the machine itself from improper use. Safety is a combination of
common sense, training, and being alert at all times while operating
your machine. If instructions, warnings, and cautions are not
followed, serious personal injury or death may occur.
EYE PROTECTION: Always wear approved safety glasses, or a
face shield when operating this machine. Only use eye protection
that meets or exceeds the standards of the American National
Standards Institute (ANSI).
EAR PROTECTION: Always wear ear protection during machine
operation.
DRESS CODE: Do not wear loose clothing, neckties, jewelry, or
gloves that can get caught in moving parts. Confine long hair and
keep sleeves above the elbow.
ELECTRICAL GROUNDING: Your machine must be electrically
grounded. If a cord and plug are used, make certain the machine is
properly grounded. Follow the grounding procedure indicated by the
National Electric Code and local regulating authorities.
POWER: Make sure that the starter is in an “OFF” position before
connecting power to the machine.
Make certain the machine is either unplugged or electrically
disconnected and locked out when performing all maintenance,
cleaning, or machine adjustments. Never leave the machine running
unattended. Always turn the power off and stay by the machine until
the cutterheads come to a complete stop.
HOUSEKEEPING: Before turning machine on, remove all extra
items on or around the machine. Keep the work area clean and free
of scrap material, sawdust and other debris to minimize the danger
of slipping. Use compressed air or a brush to remove chips or
debris. NEVER use your hands.
GUARDS: Make certain that machine guards are in place and in
good working order. The machine should never be operated without
the safety guards in place.
TOOLING AND ACCESSORIES: Use only recommended tooling
and accessories. Improper tooling and accessories may cause
damage to your machine or personal injury. Always run at the correct
speed and feed rate. Regularly maintain your tools and accessories.
Knives should be sharpened and cleaned for safe, optimal
performance. Follow instructions for lubricating and changing tooling
and accessories.
Ironwood DSP2500 | User Manual 13
7.0 Operation and Adjustments
1
2 8 3 4 5 6
7 9 1011
WARNING
Do not attempt to operate machine if you are not completely familiar
with its operation. Obtain immediate advice from a supervisor,
instructor, or other qualified personnel.
Use of this machine requires that you give your work your undivided
attention, and careless acts or not paying close attention to work
being performed may result in serious injury to yourself and/or
others. Never operate this or any machine under the influence of
drugs, alcohol, or any medication that may impair judgment.
Dust created by manufacturing activities may be harmful to your
health.
Your risks from exposure may vary. Always work in a well-ventilated
area and wear safety approved, protective dust masks specifically
designed to filter out microscopic particles. Utilize wood dust
collection systems appropriate to your machine type.
Avoid Kickback
It is very important that each workpiece be carefully inspected for
stock condition and grain orientation before running through the
machine. The danger of kicked back material can occur when the
workpiece has knots, holes, or foreign materials such as nails. It
can also occur when the material is fed against the grain on the
cutterheads.
CAUTION
During certain applications, it may be necessary to plane against the
grain. This application requires that the operator use a shallow depth
of cut and a slower feed rate.
7.1 Machine Controls
Controls are conveniently located on the machine. Familiarize
yourself with the controls before operating the machine.
A
GTM-525
150
75
50
25
0
The control panel is located at the infeed end of the machine.
1. Power switch: Turns machine power on and off.
2. Emergency stop: In case of emergency, press the red
emergency stop switch to stop all machine function. Turn
switch to the right to release the stop before restarting the
machine.
3. Lower cutterhead start switch: Press to start lower cutterhead.
4. Lower cutterhead stop switch: Press to stop lower cutterhead.
5. Upper cutterhead start switch: Press to start upper cutterhead.
6. Upper cutterhead stop switch: Press to stop upper cutterhead.
7. Feed conveyor start switch: Press to start feed conveyor
running forward to feed workpieces into machine. The switch
light turns on.
8. Feed conveyor stop switch: Press to stop feed conveyor. The
switch light turns off.
9. Current meter: Indicates lower cutterhead motor current.
10. Current meter: Indicates upper cutterhead motor current.
11. Digital controller: Keypad entry enables automated rise/fall of
the upper head for desired workpiece thickness. See section
6.2, Step 3.
A
200
100
80
60
40
20
0
Ironwood DSP2500 | User Manual14
WARNING
Warning light
1
2
3
1
2
Do not start lower and upper cutterheads simultaneously to prevent
overload. The machine is wired Star-Delta and starts slowly to avoid
an overload. When starting machine, start one motor at a time and
wait for amperage to drop on the current meter for each motor
before starting additional motors.
Table Height
Warning Lamp: If the light is on, the conveyor chain may be
overloaded.
Outfeed End Controls
Feed Conveyor
The feed conveyor can be controlled from the outfeed side of the
machine.
1. Feed conveyor start switch: Press to start the feed conveyor;
when started, the conveyor runs forward to feed workpieces
into machine.
2. Feed conveyor stop switch: Press to stop the feed conveyor.
3. Emergency stop: In case of emergency, press the emergency
stop switch to stop all machine function. Turn the switch to the
right to release the stop before restarting the machine.
A manually operated upper table height controller is located at the
outfeed side of the machine.
1. Manual rise switch: Press to raise the upper table to increase
workpiece thickness.
2. Manual lower switch: Press to lower the upper table to
decrease workpiece thickness.
7.2 Machine Operation
Prior to machine set-up or performing any adjustments, repair work,
or troubleshooting, it is very important to check the applicable safety
functions to ensure they are all in proper working condition.
To operate and adjust the machine, follow these steps.
Step 1: Check the Cutterheads
WARNING
The planing knives in the cutterheads are very sharp. Handle with
extreme care when cleaning, sharpening, or replacing.
Each spiral cutterhead is equipped with 6 rows of 16 carbide inserts
that house the planing knives.
The cutterheads should be inspected before each operation. Be
sure the carbide inserts are secure and not fractured in any place.
Loose or damaged inserts may be thrown from the machine and
pose extreme danger.
Check the knives for sharpness. The knives are two sided and can
be rotated when dull. Once both sides of a knife are dull, the carbide
inserts should be replaced. To obtain replacements, call Stiles Parts
Dept. at 1-800-727-8780. Reference part # 56-010-12005.
Ironwood DSP2500 | User Manual 15
Changing Knives
screw
A
plate
plate
The lower cutterhead can be easily slid out for access to the
cutterhead.
1. Open the v-belt guard.
2. Loosen the hand lever.
3. Shift the v-belt tension lever to release the v-belt tension.
4. Remove the v-belt from the cutterhead pulley.
5. Loosen the cutterhead lock bolts and nuts located at both ends
of cutterhead block.
6. Slide the cutterhead out to access the cutterblock.
NOTE: It is important to blow out the machine and remove loose
dust before pulling out the cutterhead. This ensures the cutterhead
stays level and is free of debris when reconnected.
To remove and replace inserts, proceed as follows:
Step 2: Machine Alignment
NOTE: The DSP2500 comes pre-aligned from the factory. Do
not adjust unless you are experiencing cutting issues. Call Stiles
Machinery Technical Support at 616.698.6615 prior to attempting
any machine adjustments.
Rollers and chipbreakers should be positioned in proper relation to
the cutterhead. Use a dial indicator if necessary to check positions
and make proper adjustments.
1. The cutterhead is used as the zero line reference on the
dial indicator. Check both sides of cutterhead to ensure the
cutterhead is level, and set the dial indicator to 0.
2. Move the dial indicator to the segmented infeed roller. The roller
should be 0.1mm below the cutterhead. To adjust, loosen lock
nut A and turn bolt B.
Adjustment nut
1. Loosen the knife gib by turning the Allen head screw into
the gib.
2. Remove the gib and knife.
3. Remove the remaining knives in the same manner.
4. Thoroughly clean the knife slots and knife gibs.
5. Check the screws. If they appear worn or stripped replace
them.
6. In sequence, insert the knife and knife gib into the slot of the
cutterhead.
7. Fasten the knife and gib with a spacer and Allen head screw.
8. Repeat process until all knives are set in position and tight.
Cutterhead
Knife
Lock nut B
Outfeed rollers
Rear pressure
Cutterhead
Front pressure
Infeed roller
3. The front segmented chip breaker is set at the factory and
should not be adjusted.
4. Move the dial indicator to the rear chipbreaker. The bar should
be 0.3mm below the cutterhead. To adjust, turn the two rear
screws in the back of the machine.
5. Move the dial indicator to the outfeed rollers. Each roller should
be 1mm below the cutterhead. To adjust, loosen lock nut A and
turn bolt B.
Ironwood DSP2500 | User Manual16
Knife gib
Allen head
Step 3: Adjust Workpiece Thickness
planing table buttons
Handwheel for positioning
Adjust the table height and lower cutterhead position to plane the
workpiece to the desired thickness. For most applications, the lower
cutterhead remains in the same position and doesn’t need to be
adjusted.
Upper Cutterhead Adjustment (automated)
Use the digital controller with keypad entry located on the front
of the machine to set upper cutterhead height for the desired
workpiece thickness. The controller automatically adjusts upper
cutterhead height according to the thickness value entered.
A limit switch defines how far the tables will raise or lower. When a
limit switch stop on the table comes in contact with a limit switch,
the table motor switches off to prevent damage in maximum high
and low positions.
Before entering the thickness value, be sure the controller is set
as desired for inches or millimeters. Press the Unit key to change
between inches and millimeters.
To set workpiece thickness, use the digital controller keypad.
1. Press the Set key.
2. Enter the desired cutterhead height by entering the numerical
value.
3. Press the green On button. The upper feed and cutterhead
assembly will raise or lower to the desired height.
If a planed workpiece is not the correct size, calibrate the controller:
Upper Cutterhead Adjustment (Manual)
The upper table height can be adjusted manually.
Upper raise/lower
1. Press the upper planing table raise or lower switch to position
the upper cutterhead for desired workpiece thickness.
2. Workpiece thickness can be read using the analog scale for
precise positioning.
Lower Cutterhead Adjustment
In general, the amount planed from the top and bottom of the
workpiece should be roughly equal. This may require an adjustment
of the lower cutterhead.
1. Press Set button on control.
2. On the keypad enter the actual value for workpiece.
3. Press and hold the Set button until “.” on the display stops
blinking. When the blinking stops, the height is calibrated.
the lower cutterhead
Use the handwheel to position the lower cutterhead.
To adjust, use the handwheel. The depth scale indicates thickness.
A full turn raises the table by 1.5mm.
Ironwood DSP2500 | User Manual 17
Step 4: Set Feed Speed
Speed control knob
C
Feed conveyor
The speed selector controls the rate of feed through the planer.
The DSP2500 is equipped with a 5 hp feed motor and variable feed
speed control system that is controlled by a frequency inverter.
Turn the speed selector adjustment knob to control the speed.
Set the feed rate between 23 fpm-65 fpm to meet the different
requirements of your material:
• Turn the variable speed adjustment dial clockwise to increase the
feed rate
• Turn counterclockwise to decrease the feed rate
NOTE: Feed rates will vary based upon stock removal rate and
workpiece characteristics.
Step 5: Adjust Hold-Down Pressure for Feed Conveyor
CAUTION
Too much hold down pressure can cause wood to stop in the
machine.
Step 6: Check Feed Conveyor Chain Tension
Maintain proper chain tension to the upper feed assembly. Make
sure both chains are always tensioned uniformly.
chain tension
Turn the nut clockwise to increase tension. Turn counterclockwise to
decrease tension.
Step 7: Adjust Table Rollers
Adjust the table rollers so they project about 0.1-0.2mm above the
table surface.
1. Place the supplied block gauge over the roller. The four sides of
the gauge have different values (0, 0.1, 0.2 and 0.3mm).
2. Turn the adjustment screws under both ends of the roller until it
touches the gauge.
3. Ensure both sides of the table roller are equally set to ensure
the roller is parallel to the table surface.
A
B
Use the adjustment lever (A) to adjust the hold-down pressure on
the workpiece for the feed conveyor.
1. Loosen the hand lever (C).
2. For normal hold-down pressure, set the adjustment lever at
the highest position in the groove (B). If the wood thickness is
varied, set the adjustment lever at a lower position to increase
hold down pressure on feed conveyor.
3. Tighten the hand lever.
Ironwood DSP2500 | User Manual18
Step 8: Leveling Lower Cutterhead and Outfeed Table
A
Workpiece E
D
B
C
The lower cutterhead must be adjusted so that the knives are the
same height as the outfeed table. The cutterhead and table must
also be parallel. To adjust:
1. Place the flat side of a supplied gauge (A) on the outfeed table
and across the knife on the lower cutterhead.
2. Turn the cutterhead slowly and carefully until the knife-edge
just touches the gauge. If the cutterhead is pushing up on the
gauge block, the cutterhead needs to be adjusted down. If the
cutterhead does not touch the gauge block, the cutterhead
needs to be adjusted up.
3. To adjust the lower cutterhead, loosen the lock screws (B) and
lock nuts (D) at both ends, then turn the adjustment screw (C).
4. Tighten the lock screws (B) and lock nuts (D).
Step 9: Adjust the Rear Pressure Plate
Adjustment screw F
Fix nut H
Bracket G
Pressure plate B
Knife edge D
Cutterhead C
Pressure plate A
The front pressure plate has been adjusted by the manufacturer.
The rear pressure plate must be positioned .03mm lower than the
workpiece.
1. With power off to the machine, place a workpiece under the
front (A) and rear (B) pressure plates.
2. Slowly turn the upper cutterhead (C) so that the knife edge (D)
just touches the workpiece (E).
3. Loosen the lock nut (H).
4. Turn the adjustment screw (F) until it touches the bracket (G).
Then turn the adjustment screw (F) again about 1/4 turn.
5. Tighten the lock nut (H).
Ironwood DSP2500 | User Manual 19
Step 10: Check Adjustment of Outfeed Pressure Rollers
e
pressure roller E
Thickness gauge
Adjustment nut A
Adjustment nut F
1mm
gap
to show 1mm gap
Adjustment
nut D
Step 12: Oiler
The oiler requires adjustment to properly lubricate the feed conveyor
chain.
The oil rate can be changed according to the video instructions
found in the following link: http://www.youtube.com/
watch?v=xT6QS2uxX-E
Cutterhead B
Infeed pressur
roller C
Rear outfeed
Workpiece A
1. With all functions running, place a workpiece (A) through the
machine.
2. Observe how much the nuts (F) lift off the holding bracket when
the workpiece passes the outfeed rollers (E).
3. Manually adjust the lock nuts (F) until a 1mm gap is achieved.
Step 11: Adjust Pressure for Outfeed Pressure Roller
Lock nut B
Step 13: Feed the Workpiece Through the Planer
WARNING
Make sure the workpiece is free of nails, loose knots, and other
defects that could cause personal injury or damage the knives.
Keep fingers and hands away from the cutting area. Keep hands
away from the top surface of the board near the feed rollers.
Remove wood chips and shavings only with the power off. The
main on/off power switch should be turned to the off position before
any maintenance is performed on machine.
Stand to the side of the workpiece when feeding it through the
planer to avoid potential injury from kickback and loose chips.
If it is necessary to stop a workpiece before it is entirely fed
through the machine, hit the emergency stop button. WAIT until
the cutterheads have completely stopped. Reset the emergency
stop button to allow lowering the table to remove material. Do not
attempt to start the feed or the cutterheads until material has been
removed from the planer. Attempted removal while cutterheads are
turning may cause kickback.
Never start the machine with the workpiece in contact with the
cutterhead.
Always turn on the upper and lower cutterheads before starting the
feed conveyor.
Do not start the upper and lower cutterheads simultaneously to
prevent overload and tripping the breakers.
Never push or pull the board once the feed conveyor has taken the
board into the machine.
To adjust the load pressure of the outfeed pressure roller on the
workpiece:
1. Loosen the lock nut (B).
2. Turn the adjustment nut (A).
3. Tighten the lock nut (B).
Ironwood DSP2500 | User Manual20
Do not place hands under the feed conveyor.
R
O
T
A
T
Step 14: Normal Machine Stop
1. Turn the power selector switch to ON.
2. Inspect the feed bed to ensure no parts or foreign objects are in
the machine before starting cutterheads.
3. Press the upper cutterhead motor START switch. The needle
on the meter moves all the way up, then down the current level.
4. Press the lower cutterhead motor START switch as in step 1.
5. Press the feed conveyor forward START switch.
6. Feed the workpiece. Always feed the workpiece against the
cutter rotation.
I
O
N
The maximum depth of cut is 1/4" (7mm) per head, so it may be
necessary to pass the workpiece through several times to achieve
the desired depth of cut.
Torque Adjustment
The warning lamp light may turn on during normal operation due to
a slipping clutch. This can be corrected by resetting the torque.
WARNING
Do not stop the machine until the workpiece is completely planed
and removed from the machine.
1. Press the upper cutterhead OFF switch.
2. Press the lower cutterhead OFF switch.
3. Press the conveyor feed STOP switch.
4. Turn power switch to OFF.
5. Make sure the work area is clean.
7.3 Tool Adjustments
WARNING
Tools are extremely sharp. Be careful when working with tooling as
serious injury may occur.
CAUTION
Always disconnect the machine from its power source before
making any adjustments.
To reduce kickback, use only tools that conform to EN 848-1:2005
and EN 848-2:2001, and that are marked MAN.
Refer to the tool manufacturer’s recommendations for clamping and
setting of tools.
To ensure safe and efficient cutting, the tooling should be suitable for
the material being cut. The tools should be sharp and properly set.
Use extra precautions when handling tools and always use tool
carriers.
1. Open the transmission guard.
2. Turn the adjustment screws (A) clockwise 180-360 degrees.
3. Close the transmission guard.
Ironwood DSP2500 | User Manual 21
8.0 Maintenance
WARNING
Before performing any type of maintenance or adjustments, make
certain that the machine is disconnected from its power source and
completely shut off.
WARNING
Never operate the machine until it has been properly lubricated and
all necessary maintenance work has been completed.
Clean all machine parts and surrounding areas daily.
Keep a maintenance record and perform recommended
maintenance checks.
8.1 Lubrication
Lubricate at the points indicated in the chart below.
Lubrication Point # Color Lubrication Point Lubricant Interval Quantity
1 Red Cutterhead bearing SKF [LGLT 2/1] 720 hrs. 5cc
2 Yellow Feed conveyor bearings Mobil [Mobilux 2]
or lithium sponified
Rear brackets
3 Blue Front pressure trunnion
shaft
Infeed table guideways
4 Blue Electric lubricator: Feed
conveyor chain
5 Blue Hand lubricator: Upper
planing table guideways
Infeed table (option)
6 Magenta FRL Unit (option) ISO VG 32 ---
7 Green Conveyor gear reducer Mobil [Gear 630] or
Elevation gear reducer
NLGI No. 2
Mobil [DTE oil
medium] or ISO
VG 68
Mobil [DTE oil
medium] or ISO
VG 68
1 week check oil
level
ISO VG 220
1 week check oil
level
240 hrs. 3cc
1500 hrs.Elevation unit bearings
1500 hrs.
720 hrs. Full oil cap
720 hrs.
--- Up to sight glass
240 hrs.
---
1 year replace
Ironwood DSP2500 | User Manual22
8.2 Inspection
B
8.4 Adjust V-Belt Tension
Feature Interval/Situation
Cutterheads Every use
Belt Every 1,000 hours of use or check belt
whenever it becomes frayed
Chains Every day
Emergency stop Every day: functional test-press
Safety guard Every day
Roller tension Every day
Electrical cabinet/system Monthly check: wiring terminals loose,
insulation deterioration
NOTE: After changing a setting, making an adjustment, performing
repair/maintenance work, or troubleshooting, please check that all
applicable safety functions are working properly before performing
another operation.
8.3 Periodic Maintenance
It is important to periodically vacuum the inside of the machine, as
wood shavings, dust or other debris will accumulate. Care should
be taken to prevent dust from embedding on moving parts in the
machine. Periodic machine cleaning increases the life of the machine
and its performance.
Over time, v-belt tension on the cutterheads motor may gradually
loosen. The normal tension on the v-belt is 8mm deflection when
pressed on its center position.
To adjust the lower cutterhead v-belt:
Loosen
A
Tighten
1. Loosen the adjustable hand lever clamp (B).
2. Turn the adjustable hand lever (A) counterclockwise to increase
v-belt tension.
3. Tighten the hand lever clamp.
CAUTION
Never blow out the electrical cabinet with air.
To replace ball bearings, please contact Stiles Machinery’s Parts
Dept at 1-800-727-8780.
To adjust the upper cutterhead v-belt:
C
B
A
1. Loosen the fixing nut (B).
2. Turn the screw (A) clockwise to increase v-belt tension.
3. Tighten the fixing nut.
Ironwood DSP2500 | User Manual 23
8.5 Adjust Clearance on Guideways
b
Infeed table
Gi
B
A
8.6 Adjust Clearance for Infeed Table Taper Gib
taper gib
Over time, there will be a clearance on the guideways due to wear
on the gib. To adjust the gibs:
1. Loosen the lock nut (A) on the gib.
2. Tighten the adjustment screw (B) to enable smooth guideways
movement.
Over time, there will be a clearance on the infeed table due to wear
on the taper gib. To adjust:
1. Loosen the lock nuts (A) on the gib.
2. Tighten the gib adjustment screw (B) to enable a smooth infeed
table movement.
3. Tighten the lock nuts.
Ironwood DSP2500 | User Manual24
9.0 Troubleshooting
9.1 Machine Operation
Trouble Possible Cause Solution
Machine will not start. V-belt guard open.
Dust hood in wrong position.
Emergency stop not reset.
Infeed trip device not reset.
Overload. Poor contact on power wire terminals.
Partial loss of a single phase.
Cutting overload.
Poor magnetic switch.
Warning lamp lights up. Feed conveyor overload.
Check for error on inverter display
Board jammed during feeding. Incorrect feed conveyor tension.
Table roller too low.
Too much cut for each pass.
Feed speed too fast.
Uneven wood thickness and front and rear
end.
Incorrect position of outfeed rollers.
Poor surface cut. Dull cutterhead blades.
Board not firmly clamped.
Table loose.
Bottom cutterhead not level with table.
Poor hold-down on front and rear pressure
plates.
Table roller too high.
Wood is warped.
Machine vibrates excessively. Damaged tooling.
Stand or bench is on uneven floor.
Bad v-belt.
V-belt does not have proper tension.
Improper motor mounting.
Edge splits off on cross-grain cut. Quality of cut. Make cross-grain cuts first then finish with grain.
Clip or snip appears on end of stock. Pressure bar is set too high.
Outfeed roller is set too high.
Upper outfeed roller is set too low.
Stock not butted.
Grain running against knives.
Check all safety switches.
Close all guards.
Reset emergency stop/infeed trip device.
Tighten terminal screw securely.
Reduce cutting load.
Reduce feed speed.
Replace magnetic switch.
Raise the upper mechanism about 100mm; remove the bad
workpiece or obstacle; return the upper mechanism to its original
position; start the feed conveyor.
Call Stiles Machinery Technical Support Dept
Adjust feed conveyor tension.
Adjust table roller position.
Reduce cutting load.
Reduce feed speed.
Do not feed again.
Adjust roller position.
Sharpen or replace blades.
Adjust feed conveyor tension.
Fix the table firmly.
Adjust bottom cutterhead.
Adjust hold-down on pressure plates.
Adjust table roller.
Do not use excessive warped wood.
Inspect, replace tooling.
Reposition on flat, level surface.
Replace v-belt.
Adjust belt tension.
Check and adjust motor mounting.
Use scrap block to support at end of cut.
Adjust pressure bar and rollers.
Work in the direction of the grain whenever possible.
Continued
Ironwood DSP2500 | User Manual 25
Trouble Possible Cause Solution
Knives tear out stock. Feed is set too fast.
Moisture content is not ok.
Cut is too heavy.
Cutting angle is too large.
Grain running against knives
Knives are dull.
Knives raise the grain. Feed is set too fast.
Cutting angle is too large.
Moisture content is too high
Cut is too heavy.
Knives are dull.
Variation in height of cut. Variation in pressure that holds workpiece
down on table.
Uneven cuts (cuts not smooth). Feeding stock too quickly.
Grain running against knives.
Cutting too deep.
Chip marks on stock. Blower system not strong enough. No
suction.
Feed is set too fast.
Knives are dull.
Exhaust pipe is connected with too large on
angle to main blower pipe.
Panels are tapered across width. Planer bed is out of parallel with cutterhead.
Knives not set evenly in cutterhead.
Undesired glossy finish. Knives are dull.
Feed is set too slow.
After cut, wave mark appears at the
front end of the wood.
After cut, wave mark appears at rear
end of the wood
Overcut at front end. Wood is warped. Use a light cut.
Poor hold-down on the front pressure plate. Adjust the front pressure plate position.
Poor hold-down on rear pressure plate. Adjust the rear pressure plate position
Adjust feed speed.
Ensure you measure the moisture content of the wood.
Sharpen or replace knives.
Work in the direction of the grain whenever possible.
Sharpen or replace knives.
Adjust feed speed.
Be sure stock is dry.
Sharpen or replace knives.
Adjust roller pressure.
Adjust feed speed.
Adjust feed speed.
Work in the direction of the grain whenever possible.
Make several passes on deep cuts.
Increase suction on blower system.
Adjust feed speed.
Sharpen or replace knives.
Reinstall exhaust pipe.
Adjust using a dial indicator.
Check cutterhead carbide inserts and reinstall if not set evenly.
Replace or sharpen knives.
Adjust feed speed.
Cut twice.
Ironwood DSP2500 | User Manual26
9.2 Digital Controller Unit
Trouble Possible Cause Solution
The display fails to show figures. Electric pressure of the power 220V or
AC110V is not normal.
Fuse is burned out and fused or
broken.
If the above two conditions are normal
then the control unit is broken and
needs repair.
The display shows figures but the
figures are abnormal.
The display shows figures but
when the up-down motor is in
operation the figure fails to change
accordingly.
If you cannot resolve your issue, contact Stiles Technical Support at 616.698.6615.
Figures shown are incorrect. Correct the dimension of the control unit in accordance
Parameter is incorrect. Calculate correct parameter and input again.
If the above 2 points do not provide a
solution, then the controller needs to
be reset.
The proximity switch is failing. If the instruction lights fail, change the proximity switch.
Distance between the induction unit
and induction sheet is more than 1mm.
Re-input correct electric voltage.
Replace with new 1A fuse.
Contact the supplier for repair.
with the actual dimension.
Turn off machine power and turn on again. If the problem
persists contact the supplier for repair.
Adjust the distance between the induction unit and
induction sheet to less than 1mm.
Ironwood DSP2500 | User Manual 27
9.3 Electrical Diagrams
Ironwood DSP2500 | User Manual28
9.3 Electrical Diagrams (Continued)
Ironwood DSP2500 | User Manual 29
Version A
September 2013
© 2013 Stiles Machinery Inc.
Stiles Machinery Inc.
3965 44th St. SE
Grand Rapids, MI 49512
p. 616.698.7500
f. 616.698.9411
www.stilesmachinery.com
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