Stiles Ironwood DSP2500-HS User manual

Ironwood DSP2500-HS
User Manual
general information. features.
operation and adjustments.
machine controls. maintenance.
adjust clearance on guideways.
troubleshooting. digital controller unit.
delivery and installation. inspection.
pre-operation cleaning. assembly.
dust port connections. safety.
technical specifications. safety considerations.

Ironwood DSP2500-HS | User Manual2
1.0 General Information…............................................................... 3
1.1 Thank You
1.2 Before Contacting Stiles
1.3 Features
1.4 Intended Use
1.5 Technical Specications
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
Table of Contents
PLEASE REVIEW AND OBSERVE ALL SAFETY
INFORMATION / DIRECTIVES BEFORE INSTALLING,
OPERATING, OR PERFORMING MAINTENANCE ON
THIS MACHINERY.

Ironwood DSP2500-HS | User Manual 3
1.0 General Information
1.1 Thank You!
Thank you for your purchase of the Ironwood DSP2500-HS double
surface planer. At Stiles Machinery, our goal is to ensure that you are
fully satised with your purchase. This manual is provided so that
you may properly assemble, operate, and maintain your DSP2500-
HS. 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.
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 _____________________________________
1.3 Features
Insert latest drawing with call-outs for features:
• Overlapped pressure-nger conveyor secures workpieces rmly
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
nishing, 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-HS double-surface planer is designed
and manufactured for planing two sides of a workpiece in a single
operation. The lower cutterhead attens 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-nger conveyor
that holds the workpiece rmly 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-HS ensures smooth feeding motion, quiet operation, and
maximum wear resistance.

Ironwood DSP2500-HS | User Manual4
2 heavy duty
spiral cutterheads
Solid cast iron base
Overlapping pressur
e
nger conveyor
Conveniently located
control panel with digital
controller, current meters,
and lighted power switches.
1.5 Technical Specifications
Description Ironwood DSP2500-HS
Max Working Width 25" (635mm)
Max Working Thickness 8" (203mm)
Min Working Thickness 6 / 16" (9.5mm)
Min Length of Cut 12½" (317mm)
Upper Cutterhead Motor 40 hp
Lower Cutterhead Motor 25 hp
Feeding Cutterhead Motor 5 hp
Table Rise/Fall Motor 1/2 hp
Variable Feed Speed 26-131 fpm (8-40 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 177 amps @ 230V / 88 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) 107" x 45" x 68" (2717mm x 1145mm x 1725mm)
Gross Weight 7220 lbs (3275 kg)

Ironwood DSP2500-HS | User Manual 5
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-HS for purposes other than its intended
use. Do not modify or remove any guards or other safety features.
Improper use or modications 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.
LABEL NO. 1 LABEL NO. 2 LABEL NO. 3LABEL NO. 4LABEL NO. 5LABEL NO. 6
LABEL NO. 7 LABEL NO. 8 LABEL NO. 9LABEL NO. 10 LABEL NO. 11 LABEL NO. 12
Clean up anything
on the working
table when it is
getting down.
WARNING
The conveyor will stop by itself
in case of running out of oil.
WARNING
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.
CAUTION
CAUTION
Feed speed adjustment
SLOW FAST
50
40 60
0 100
7030
9010
20 80
Except be authorized,
don’t adjust this device.
Otherwise, it will cause
the inaccuracy of the
machine and damage
the driving mechanism.
WARNING
TURN POWER OFF BEFORE
SERVICING.
HAZARDOUS VOLTAGE
DANGER
VOLTAGE ÉLEVÉ, ENLEVEZ
TOUT POUVOIR ÉLECTRIQUE
AVANT DE FAIRE L’ENTRETIENT
KEEP HANDS AWAY FROM
CUTTERHEAD AND KNIVES
DANGER
ROLLING
KEEP HANDS AND
ANY OBJECT AWAY
DANGER
BE SURE TO ADD SKF LGLT 2 GREASE
FOR HIGH SPEED SHAFT EVERY SIX
MONTHS.
WARNING
Do not adjust the
V belt too tight.
The proper belt
tension is approx.
1 cm by nger
pressure.
CAUTION
1. When the warning lamp lights up, it means an overload caused by the
mechanical feeding system.
3. The feeding system can not be started until the obstacle has been removed.
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.
4. For other types of overload not caused by obstacles, follow the
troubleshooting instructions.
CAUTION

Ironwood DSP2500-HS | User Manual6
2.0 Facility Preparation
Prior to uncrating your machine conrm that your location can
accommodate the Ironwood DSP2500-HS. Follow these guidelines:
2.1 Floor
• The oor must be at and level.
• Although no special foundations are required, a concrete oor is
recommended.
• All oors 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 oor. However, if you
decide to do so, purchase high quality anchor bolts appropriate
to the oor 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 trafc areas.
• Provide adequate dust extraction system.
The dust extraction system should have a ow rate with a speed
of 4,500 feet per minute at 1,600 cfm.
4'
(1200mm)
*
*
*
4'
(1200mm)
Machine clearance requirements*
*Actual clearance requirements may vary depending on length of
material to be cut.
2.3 Power
WARNING
A licensed electrician must connect the DSP2500-HS 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-HS
Upper cutterhead motor 40 hp
Lower cutterhead motor 25 hp
Feeding cutterhead motor 5 hp
Table rise/fall motor ½ hp
Total required amperage 132 amps @ 230v / 66 amps
@ 460v
• 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).
• 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-HS | User Manual 7
3.0 Delivery and Installation
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 trafc 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 nal
position as possible.
If you do not intend to install the machine immediately after delivery,
store it in a protected, cool, and dry location.
The machine arrives
fully crated. Remove
and save the
paperwork attached
to crate.
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 nish.
3. Remove the protective plastic from the machine, starting at the
bottom.
Remove the crating,
starting with the top,
then remove the four
sides.
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-HS | User Manual8
3.3 Inspection
Save all containers and packing materials until you are satised
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 satised 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
3.4 Move Machine to Final Position
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 nal
location.
Use a fork lift to move
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-HS | User Manual 9
Hoist hooks for
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.
Use a crane and
straps to place machine
in its nal position.
3.5 Remove Machine from Pallet
CAUTION
The DSP2500-HS 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 nal location, carefully
remove the machine from the pallet.
The machine is
bolted to the pallet
for transport.
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 nal position.

Ironwood DSP2500-HS | User Manual10
3.6 Level
TOOLS REQUIRED:
• Bubble Level
• Adjustable wrench
Be sure to level the
machine. The circled
leveling bolt is
preinstalled.
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.
3.7 Pre-Operation Cleaning
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 nonammable 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.

Ironwood DSP2500-HS | User Manual 11
4.0 Assembly
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
oller
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.
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
Dust hood
The machine has two dust exhaust ports to remove dust from the
upper and lower cutterheads.
Fit exible hoses to the two dust hoods and connect them to the
dust collector. The outlet diameter for each dust hood is 6".

Ironwood DSP2500-HS | User Manual12
5.0 Connect to Power
• 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, conrm 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 electried even
while the power switch is off.
To connect power source to the machine:
L1
L2
L3
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.
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 conrm that your particular
electrical conguration complies with all local codes. Ensure
compliance by checking with your local municipality and a licensed
electrician.

Ironwood DSP2500-HS | User Manual 13
6.0 Safety
WARNING
Like all power equipment, there is danger associated with
the Ironwood DSP2500-HS. 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. Conne 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.
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.
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.

Ironwood DSP2500-HS | User Manual14
7.0 Operation and Adjustments
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 qualied 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 inuence 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 specically
designed to lter 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
150
75
50
25
0
A
200
100
40
20
0
60
80
GTM-525
1
2 8 3 4 5 6
7 9 1011
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.

Ironwood DSP2500-HS | User Manual 15
WARNING
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.
Warning light
Warning Lamp: If the light is on, the conveyor chain may be
overloaded.
Outfeed End Controls
1
2
3
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.
Table Height
1
2
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-HS | User Manual16
Changing Knives
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:
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
Allen head
screw
Knife gib
Knife
Step 2: Machine Alignment
NOTE: The DSP2500-HS 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
A
Lock nut B
Infeed roller
Front pressure
plate
Cutterhead
Rear pressure
plate
Outfeed rollers
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-HS | User Manual 17
Step 3: Adjust Workpiece Thickness
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 denes 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:
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.
Upper Cutterhead Adjustment (Manual)
The upper table height can be adjusted manually.
Upper raise/lower
planing table buttons
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.
Handwheel for positioning
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-HS | User Manual18
Step 4: Set Feed Speed
Speed control knob
The speed selector controls the rate of feed through the planer.
The DSP2500-HS 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
A
B
C
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.
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.
Feed conveyor
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.

Ironwood DSP2500-HS | User Manual 19
Step 8: Leveling Lower Cutterhead and Outfeed Table
A
D
C
B
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 at 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
Pressure plate A
Workpiece E
Pressure plate B
Bracket G
Adjustment screw F
Fix nut H Cutterhead C
Knife edge D
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-HS | User Manual20
Step 10: Check Adjustment of Outfeed Pressure Rollers
Infeed pressur
e
roller C
Workpiece A
Rear outfeed
pressure roller E
Adjustment nut F
1mm
gap
Adjustment
nut D
Thickness gauge
to show 1mm gap
Cutterhead B
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
Adjustment nut A
Lock nut B
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).
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
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 ngers 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.