charnwood DS10 Drum Sander Owner’s Manual

charnwood DS10 Drum Sander

Product Information

The Charnwood DS10/20 is a drum sander designed for woodworking enthusiasts and weekend DIY’ers. It is a lighter weight machine with a maximum width of 255mm (10 inches) in one pass or 505mm (20 inches) in two passes. The maximum workpiece thickness is 75mm (3 inches), while the minimum workpiece thickness is 5mm (1/5 inch). The drum sander comes with sandpaper wrap measuring 82mm x 1550mm and features a drum motor with an induction power of 1100w (1.5hp), running at 1440rpm. The drum size is 132mm in diameter and 260mm in length. It also has a conveyor motor with a variable speed of 0-3.5m/min and a dust port diameter of 100mm. The dust collection system requires a minimum airflow of 1000m3/hour (50 Litres per second). The assembled dimensions of the drum sander are 900 x 590 x 1140mm, and the shipping dimensions are 800 x 640 x 640mm. The product weighs 72kg and has a hobby rating, suitable for up to 100 hours of annual use. It comes with a 1-year guarantee.

Product Usage Instructions

1. Read the owner’s manual carefully and thoroughly before operating the drum sander.
2. Ensure all tools are properly earthed.
3. Keep guards in place and in working order. If a guard needs to be removed for maintenance or cleaning, make sure to properly replace it before using the machine again.
4. Remove adjusting keys and spanners from the machine before turning it on.
5. Keep the work area clean and free from clutter to reduce the risk of accidents.
6. Avoid using the drum sander in damp or wet locations or exposing it to rain. Ensure the work area is well illuminated.
7. Keep children and visitors at a safe distance from the work area.
8. Childproof the workshop by using padlocks, master switches, and removing starter keys.
9. Do not force the machine. Operate it at the rate for which it is designed to ensure better performance and safety.
10. Always use the right tools and attachments for the job. Do not force them to perform tasks they are not designed for.
11. Never reach into a rotating drum to avoid the risk of injury. Always keep hands and fingers clear.
12. Wear eye protection to shield your eyes from flying debris.
13. Wear ear protection to protect your hearing from the noise generated by the machine.

Note: Exceeding the maximum rating of the product will void the manufacturer’s free warranty. Make sure to use the drum sander within its specified limits.

Unpacking

To unpack the Charnwood DS10/20 drum sander:

1. Open the crate that contains the product. It is packed into 1 wooden crate.

Open The Crate
This product is packed into 1 wooden crate.
To open the wooden crate:
Cut the vertical straps Use a pry bar to release the nails around the base Lift off the complete lid.

Remove Loose Items
Remove the plastic cover and the carton of loose parts.

Unbolt From The Base
The machine is fixed to the pallet base with 2 bolts. Use a pair of 13mm spanner to undo the 2 securing nuts. This part of the assembly requires 2 people: Lift the machine off the pallet base. Do not dispose of any of the packaging until the machine has been completely assembled and tested. In the unlikely event that the product needs to be returned, the original packaging will be required.

GENERAL SAFETY RULES

WARNING: Do not attempt to operate the machine until you have read thoroughly and understood completely all instructions, rules, etc. contained in this manual. Failure to comply may result in accidents involving fire, electric shock, or serious personal injury. Keep this owner’s manual and review frequently for continuous safe operation.

1. Know your machine. For your own safety, read the owner’s manual carefully. Learn its application and limitations, as well as specific potential hazards pertinent to this machine.

2. Make sure all tools are properly earthed.

3. Keep guards in place and in working order. If a guard must be removed for maintenance or
   cleaning, make sure it is properly replaced before using the machine again.

4. Remove adjusting keys and spanners. Form a habit of checking to see that all keys and adjusting spanners are removed from the machine before switched it on.

5. Keep your work area clean. Cluttered areas and workbenches increase the chance of an accident.’

6. Do not use in dangerous environments. Do not use power tools in damp or wet locations, or expose them to rain. Keep work areas well illuminated.

7. Keep children away. All visitors should be kept a safe distance from the work area.

8. Make workshop childproof. Use padlocks, master switches and remove starter keys.

9. Do not force the machine. It will do the job better and be safer at the rate for which it is designed.

10. Use the right tools. Do not force the machine or attachments to do a job for which they are not designed. Contact the manufacturer or distributor if there is any question about the machine’s suitability for a particular task.

11. Wear proper apparel. Avoid loose clothing, gloves, ties, bracelets, and jewellery which could get caught in moving parts. Non-slip footwear is recommended. Wear protective hair covering to contain long hair.

12. Always use safety glasses. Normal spectacles only have impact resistant lenses. They are not safety glasses.

13. Do not over-reach. Keep proper footing and balance at all times.

14. Maintain the machine in good condition. Keep the machine clean for best and safest performance. Follow instructions for lubrication and changing accessories.

15. Disconnect the machine from power source before servicing and when changing the blade.

16. Never leave the machine running unattended. Turn the power off. Do not leave the machine until it comes to a complete stop.

17. Do not use any power tools while under the effects of drugs, alcohol or medication.

18. Always wear a face or dust mask if operation creates a lot of dust and/or chips. Always operate the tool in a well ventilated area and provide for proper dust removal. Use a suitable dust extractor.

    • Risk of Injury! Never reach into a rotating drum
    • Wear Eye Protection
    • Wear Ear Protection

Rating Description
Hobby: Suitable for Weekend DIY’ers and woodworking enthusiasts.
Generally lighter weight machines with lower power ratings and smaller tooling capacities. Typically only ever used by one person for short periods of time or longer periods of time infrequently. Machinery should be well maintained in a clean, dry environment such as a home workshop, garage or timber shed. Expected maximum use of 100 hours annually.
Please Note: Using a product in excess of its rating will void the manufacturer’s free warranty.

Charnwood DS10/20 Specification

Identify The Loose Parts

• A) Long Top Frame
• B) Short Top Frame
• C) Leg – Wheel Kit End
• D) Leg – Lifitng Handle End
• E) Lifting Handles
• F) Hand Wheel
• G) Dust Extractor Elbow
• H) Short Cross Brace
• I) Long Cross Brace
• J) Wheel Kit
• K) Rubber Feet
• L) Service Tools
• M) Fixing Bolts

Assembly

Assemble The Stand
Identify the 2 legs, C, which have 2 additional holes near the bottom for the wheel kit. Assemble these with the Short Cross Brace H and the Short Top Frame B, to form one end of the stand.
Note: The legs go on the outside. Use 2 square head bolts and nyloc nuts for each joint. Leave all nuts finger tight for now.
Repeat for the other 2 legs which have additional holes for the lifting handles. Now assemble the 2 end frames with the Long Cross Brace I and Long Top Frame A. One end of the Long Top Frame A, has a slotted hole. This end goes towards the Wheel Kit end of the stand. Place the stand on a flat surface and tighten all the nuts with a 13mm spanner.

Fit The Feet
Push the 4 rubber feet onto the ends of the legs.

Attach The Wheel Kit
Use 4 bolts and nyloc nuts to attach the Wheel Kit. Tighten with a pair of 13mm spanners.

Attach The Handles
The lifting handles attach  using  countersunk screws and nuts. Tighten using a cross head screw driver and 10mm spanner. The handles fold down when not in use.

Using The Drum Sander

Operating The Sander
Drum Sander Vs Thicknesser
Drum sanding gradually removes material in increments of 0.8mm or less depending on sanding grit, stock hardness, stock width, etc. Thicknessing, on the other hand, is for quick, bulk material removal at rates up to 3mm per pass. If you have used a planer thicknesser to smooth and dimension timber you will quickly learn to work with the drum sander, but do not over work it. Be patient, let the drum sander do the work: 0.8mm or less per pass for best results. The most common mistake made with a drum sander is forcing it to remove too much material too fast. Variables such as sandpaper grit, stock width, wood type, feed rate, and moisture content all influence how much material can be removed in a single pass.

Double Pass
The maximum sanding width in a single pass is 255mm. When working with stock up to this width, the drum height lock should be engaged once the drum height has been set.
It is possible to work with stock up to 510mm wide by making 2 passes. Firstly, remove the End Plate to make the end of the sander open. Use a 13mm spanner to remove 2 bolts then remove the locking knob. Wider stock can now be fed through the drum, with only the first 255mm being sanded. The stock can then be rotated 180 degrees and fed back into the sander with the remaining area being sanded to the same depth.

Abrasive Grit Selection
Smoothing wood, or sanding, is the process of making finer and finer scratches until they become so small they are no longer visible to the human eye. The grit size of the sandpaper designates the coarseness of the abrasive. The lower the grit number, the coarser the sandpaper and the larger the scratches made to the surface. Thus 80 grit sandpaper is coarser (bigger scratches) than 120 grit sandpaper, and 120 grit is coarser than 240 grit, and so on. With coarser grit papers, such as 80 grit, very aggressive material removal and surface scratching occurs, whereas with 240 grit, very little surface material is removed and a buffed like look begins to appear. Typically, you begin sanding with a coarse grit and progressively work through finer grits until the desired finish or thickness is achieved. Choosing which grit to begin sanding with is a subjective judgment based on your assessment of stock condition (rough, smooth, etc.), thickness, hard/soft wood, and the desired outcome. Below are some general guidelines regarding sanding grits. Pre-cut wraps in each listed grit size are available.

smoothing, planer mark removal
120| Medium fine: light surfacing and stock removal, thin stock dimensioning
150| Fine: minimum stock removal, finish sanding surface preparation, thin stock dimensioning
180| Fine: finish sanding
240| Very fine: finish sanding

Drum Height
The height of the drum is raised by turning the handwheel in a clockwise direction. To lower the drum, turn the handwheel in a counterclockwise direction. The depth of the movement is approximately 0.4mm per 1/4 turn in either direction. One complete turn is 1.6mm. Depth settings can be measured using the height reading scale. Depth settings used during surface sanding of stock are adjusted by considering several variables. The hardness of the material, the width of the material being surfaced, and the feed rate selected are all considered when determining the amount of material to be removed on each pass. Never remove more than 0.8mm of material in one pass.

Conveyor Feed Rate
The variable feed rate is set to prevent burning and provide a smooth sanded surface on different types and widths of materials. As a general rule: 1/4 turn or 0.4mm or less is recommended stock removal for coarser grits and softer woods, while 1/8 of a turn or 0.2mm may be more desirable with harder woods and/or finer grits. Some experimenting and practice will be required to become familiar with the sanding performance of your Drum Sander. When selecting the rate of feed for the material being surfaced:

• Wider material – slow the feed rate.
• Harder wood – slow the feed rate.

To Begin Sanding

1. With power off, place stock on the feed table and advance the stock to a point so that you can adjust height of sanding drum to equal thickness of stock at its greatest point.

2.  Connect and turn on the dust extractor.

3.  Adjust feed rate to match sanding requirements and width of stock.

4. Turn on unit and place stock on the feed conveyor table allowing the feed belt to carry the stock into and engage the sanding action of the drum. Support long stock as necessary during the feed operation. Once the sanding operation feed allows, reposition yourself to the out feed side of the machine to accept, support, and control the board as it exits the Sander.
   NOTE: Do not apply upward or downward pressure when supporting and guiding stock through the sander. To do so may induce snipe (sander drum dig- in) into the sanded stock.

5. Reverse the feed direction of the stock on successive passes, while adjusting the depth of cut using the height adjustment hand wheel.

Sanding Wrap Replacement

The most convenient way to buy sandpaper wraps is to use the precut type which come with the tapered ends ready to install. The other option is to buy a roll of 82mm wide sandpaper and cut the tapers yourself. The template below gives the dimensions for the tapers.

To Change The Sandpaper Wrap Disconnect from the power supply. Identify the wider (15mm) end of the wrap. Make a fold around 30mm in from the end.

On the left side of the drum, press the spring loaded clip up towards the rim of the drum. Insert the tip of the wrap through the slot in the drum and into the teeth of the clip. Approximately 30mm of material should be inserted into the clip.

Stand in front of the drum and radially wrap the abrasive material. Roll the drum away from you, whilst keeping some tension on the abrasive wrap and guide it onto the drum. The edge of the taper should be parallel to the edge of the drum.

Continue along the length of the drum: Do not let the sandpaper overlap, it should be flush or slightly gapped.

On the right hand end of the drum, press the clip and tensioning device towards the slot in the drum. Insert the end of the wrap into the clip whilst keeping tension on the wound part of the wrap. When the clip is released it will grip the wrap and apply tension to it.

The tensioning device will hold tension in the event the wrap stretches during use.
TIP: The final part can be quite fiddly. You may find it helpful to place a wedge of timber into the open end of the drum to prevent it from rotating whilst inserting the tail end of the wrap.

Servicing And Maintenance

Troubleshooting

down
| Faulty switch| Replace switch
| |
Only starts when Green button is held down| Faulty switch| Replace switch
| |
MCB trips on Start up| Short circuit in cable or plug| Repair the damage
Machine hums but does not start| Start capacitor failed| Replace start capacitor
| |
Motor running but drum is not rotating| Broken or coupling or spider| Inspect and replace rubber spider
Motor slows down during the cut| Depth of cut is too great| Take a smaller cut
| Dust & Chip collector hood is blocked| Clear the blockage and ensure the extractor is functioning correctly
Conveyor belt slipping| Build up of dust and sap on the belt| Clean the belt
---|---|---
| Insufficient tension on belt| Increase tension on belt
| Rubber drive roller is worn out| Replace drive roller
Long lines or ridges along the length of planed timber| Damaged sanding wrap| Re-wrap or replace the sandpaper
Conveyor running, but speed not changing| Failed PCB| Replace the PCB inside the switch housing

Declaration of Conformity for CE Marking

Charnwood Declare that Woodworking Drum Sander, Model DS10/20
Conforms with the following EU Directives: Machinery Directive 2006/42/EC
Electromagnetic Compatibility Directive 2014/30/EU
Conforms with the following UK Regulations: Supply of Machinery (Safety) Regulations 2008 Electromagnetic Compatibility Regulations 2016
And further conforms to the machinery example for which the EC type examination Certificate No. TA 385213771 & AE 50390138 have been issued by TUV Rheinland LGA Products GmbH, Tillystrasse 2, 90431, Nurnberg, Germany. I hereby declare that equipment named above has been tested and found to comply with the relevant sections of the above referenced specifications. The machinery complies with all essential requirements of the directives and regulations.
Signed:
Richard Cook, Director
Dated: 04/01/2023
Location: Leicestershire

• Please dispose of packaging for the product in a responsible manner. It is suitable for recycling. Help to protect the environment, take the packaging to the local amenity tip and place into the appropriate recycling bin.
• Only for EU countries
  Do not dispose of electric tools together with household waste material!
  In observance of European Directive 2002/96/EC on waste electrical and electronic equipment (EEE) and its implementation in accordance with national law, electric tools that have reached the end of their life must be collected separately and returned to an environmentally compatible recycling facility.

Your local refuse amenity will have a separate collection area for EEE goods

Charnwood DS10/20 Parts Diagrams

Drawing A:

Drawing B:

DS10/20 WIRING DIAGRAM

Last Updated January 2023
Charnwood Machinery, Cedar Court, Walker Road, Hilltop Industrial Estate, Bardon, Leicestershire, LE67 1TU
Tel. 01530 516 926
email: sales@charnwood.net
website: www.charnwood.net

References

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