Table of Contents
Summary of Contents for UNION TOOL 5 Series
- Page 1 The Union Tool Corp. ROLLER COATER MANUAL UNION TOOL CORP. Phone: 574/267-3211 1144 North Detroit Street Fax: 574/267-5703 P. O. Box 935 E-Mail: sales@uniontoolcorp.com Warsaw, IN 46580 Web Site: www.uniontoolcorp.com Date: 7/19/2019 Revised: 7/19/2019...
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Page 2: Table Of Contents
Union Series #5 / #15 / #45 Roller Coaters STANDARD OPERATING MANUAL TABLE OF CONTENTS INTRODUCTION Page 3-4 SAFETY Page 5-7 INSTALLATION Page 8-9 Location WIRING Page 9 OPERATING INSTRUCTIONS Roll Adjustments/Roll Change Out Page 10-14 ROLL MOUNTINGS Feeding/Before Starting Page 14-15 PICKOFF FINGERS Page 16... -
Page 3: Introduction
Should your company or operator have any questions regarding this manual, please do not hesitate to contact the Union Tool Corporation, Technical Sales Department at 574-267-3211. Our hours are 8:00 A.M. through 5:00 P.M. - Page 4 INTRODUCTION (Continued) All rolls are supported in antifriction, self-aligning bearings. The diameter of our series of coating rolls and doctor rolls can be found in the chart below: Series # Coating Roll Doctor Roll Backup Roll 4” 2-3/4” 4” 6-1/2” 4-3/8”...
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Page 5: Safety
SAFETY SAFETY INTRODUCTION: Here you will find safety guidelines for use with Union Tool equipment. These guidelines apply to anyone working with Union Tool equipment, including operations and service personnel. These guidelines are repeated throughout the manual, along with specific warnings and cautions not included here. These safety guidelines cover: •... - Page 6 4. Only fuses of the correct type voltage rating and current rating should be used. Refer to the Union Tool wiring diagram equipment parts list for fuse recommendations. Using incorrect or non-recommended fuses can present a fire hazard.
- Page 7 5. Remove all jewelry (rings, watches, etc.) before servicing equipment. 6. If possible, stand on a rubber mat when servicing Union Tool equipment. DO NOT work on equipment if standing water is present. Avoid working in a high-humidity atmosphere.
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Page 8: Installation
INSTALLATION Your Union Tool Roller Coater is easy to install. 1. Remove the coater from the skid. Depending on the size, the coater could be very heavy so please make a note of the shipping weight and use the proper equipment. Lift from the bottom of the frame. Be sure that the lift forks are against the frame when lifting the coater from the wooden skid. -
Page 9: Location
Location The machine should be located with due consideration for the movement of materials in and out of the machine and the ease of movement required by the operator. Mounting holes are provided in the "feet" of the machine for the purpose of leveling. -
Page 10: Operating Instructions
OPERATING INSTRUCTIONS Roll Adjustments The vertical adjustment assembly raises and lowers the upper roll assembly to accommodate various thickness of substrates being ran. Generally, this upper roll assembly is the only one that requires vertical adjustments; however, in special cases the lower roll assembly has been made adjustable. These rolls should never be allowed to be forced together so as to cause damage to the surface of the rolls. - Page 11 OPERATING INSTRUCTIONS Roll Adjustments (Continued) The doctor roll adjustment assembly is the movement of the doctor roll in relationship to the coating roll. This adjustment governs the thickness of the coating being applied. The unifeed single handwheel located at either the infeed or offbearing end of the machine (depending on the model of coater) are used to move the doctor roll bearing slide plates, to which the doctor roll is mounted, in and out from the coating roll.
- Page 12 OPERATING INSTRUCTIONS Roll Adjustments (continued) A trough is formed by the doctor roll and coating roll. This trough is where the coating material will sit within the “coating head assembly” with the ends sealed by UHMW seal plates. These seal plates should be hand tightened by either the hex nut or thumb screw located with the seal plate assembly.
- Page 13 OPERATING INSTRUCTIONS Roll Adjustments / Roll Change Out (continued) So, 0.002" x 5 = 0.010" which is the gap required between the doctor and coating roll. This may not give you the dry finished thickness required due to the possibility that not all the coating material passing through the gap is deposited on the stock being run.
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Page 14: Roll Mountings
OPERATING INSTRUCTIONS Roll Change Out When installing new rolls, care should be taken to ensure that the vertical coating roll springs are firmly positioned on the screw shoulder and screw thrust bearing. This adjustment is done by the hex nut on the lower end of the elevating screw. Minimum tension prevents damage to the rolls should a varied substrate thickness be passed through. -
Page 15: Feeding/Before Starting
ROLL MOUNTINGS Feeding On the basic coaters, feeding is done on an infeed table of solid sheet metal fabrication, mounted level with the roll pass line. A series of adjustable pickoff fingers are mounted on the offbearing side of the machine to ensure positive pickoff of the substrates being run. -
Page 16: Pickoff Fingers
PICKOFF FINGERS The series of pickoff fingers should never be moved while the machine is running; any adjustment should have been done while the machine was idle. Serious damage could occur if these fingers come into contact with the rolls. GUARDS Proper guards are installed and care should be taken to see that all guards are securely in place before the power is turned on. -
Page 17: Lubrication
LUBRICATION Lubrication of the machine has been checked at the factory during the testing period. However, a double check of all the lubrication fittings should be made to familiarize the maintenance staff of all the lubrication points. Be sure to check the oil level in the reducer gear box before power is applied. CLEANING Clean all equipment whenever it will be idle for a period in excess of the usable life of the coating material, or at last once daily. - Page 18 Cleaning (continued) to be started. Add cleanup material to one or both coating assemblies in between the doctor and coating rolls. Close the lexan hood and move the doctor roll against the coating roll, just as you would to apply a minimum coating. Start the roller coater in the forward position.
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Page 19: Trouble Shooting
TROUBLE SHOOTING (DOCTOR ROLL DRIVE CLUTCH) If the torque is too high or too low readjust toque limiter by tightening or loosening the adjusting nut as required. First straighten the tab on the lock washer before adjusting nut after adjusting the nut bend the tab on the lock washer locking the tab into place (SEE CHART BELOW). - Page 20 TROUBLE SHOOTING (SEAL PLATE PROBLEMS AND LEAKING) Note: Running the coater with the seal plates tight, without adhesive or cleanup or coating material to lubricate the seal plates, can damage the rubber on the end of the rolls (SEE CHART BELOW). TROUBLE SHOOTING SEAL PLATE PROBLEMS AND LEAKING Problem Possible Cause...
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Page 21: Maintenance Checklist
MAINTENANCE CHECK LIST The two covers will need to be removed on the offbear end to gain access to the drive components. Remove the seal plates from the machine. The drive chain will need be removed from equipment as well as the doctor roll drive chain. -
Page 22: Standard Features
The Union Tool Corp. SERIES #5 / #15 / #45 ROLLER COATER “STANDARD FEATURES” Page 22... - Page 23 VARIABLE SPEED DRIVES Union Tool coaters include AC variable speed drive controllers that control the speed of the rollers. The controllers are labeled to indicate the roll in which each controller is maneuvering. Variable speed ratios will depend on the specific series of roller coater.
- Page 24 E-STOP PUSH-PULL CORD All coaters are equipped with a push-pull emergency cable that extends around the perimeter of the coater. This cable can be pushed or pulled to be activated. Once activated, this will stop all powered rolls and will not allow the rolls to function until the blue safety switch has been re-set to the center position.
- Page 25 SINGLE HANDWHEEL ADJUSTMENT The single hand wheel adjustment allows the gap between the coating roll and lower back-up roll (or lower coating roll for a double-sided coater) to be adjusted for the thickness of the substrate to be coated. Depending on the unit, this hand wheel is turned either clockwise or counter clockwise to open or close the gap.
- Page 26 UNIFEED ADJUSTMENT The doctor roll(s) is adjustable on a horizontal plane in relationship to the coating roll to control the amount of coating being applied. As the doctor roll is adjusted into the coating roll, less coating will be applied. As the doctor roll is moved away from the coating roll, more coating will be applied.
- Page 27 Depending on the set up of the machine, if you turn the coupling clockwise/or counterclockwise, it will move the doctor roll side that is furthest away from the unifeed handle either closer or farther away from the coating roll. Likewise, if you only turn the unifeed handle you can move the side closest to the handle either closer or farther away from the coating roll.
- Page 28 SEAL PLATES (Cont.) The metal core of the coating roll and of the doctor roll should be parallel and square so that the UHMW seals the ends of the rolls. If a straight edge is not flush against the steel cores of both the coating roll and doctor roll, one roll will need to be moved horizontally, so that the steel ends are flush.