UNION TOOL 5 Series User manual

ROLLER COATER
MANUAL
UNION TOOL CORP. Phone: [phone]
1144 North Detroit Street Fax: [phone]
P. O. Box 935 E-Mail: [e-mail]
Warsaw, IN 46580 Web Site: www.uniontoolcorp.com
Date: 7/19/2019 Revised:7/19/2019
The Union Tool Corp.

Page 2
Union Series #5 / #15 / #45 Roller Coaters
STANDARD OPERATING MANUAL
TABLE OF CONTENTS
A
INTRODUCTION
Page 3-4
B
SAFETY
Page 5-7
C
INSTALLATION
Location
Page 8-9
D
WIRING
Page 9
E
OPERATING INSTRUCTIONS
Roll Adjustments/Roll Change Out
Page 10-14
F
ROLL MOUNTINGS
Feeding/Before Starting
Page 14-15
G
PICKOFF FINGERS
Page 16
H
GUARDS
Page 16
I
DOCTOR ROLL SAFETY
FEATURES
Page 16
J
LUBRICATION
Page 17
K
CLEANING
Page 17-18
L
TROUBLE SHOOTING
Page 19-20
M
MAINTENANCE CHECKLIST
Page 21
N
STANDARD FEATURES
Page 22-28

Page 3
INTRODUCTION
This manual was prepared for “standard” Union Roller Coaters. Union Tool
provides standard machines, as well as, special machines for your particular
application. This manual provides “in-general” information on our standard
equipment. Some of the information may not pertain to your particular
machine, but will provide you with a general overall lubrication and
maintenance guide, as well as, troubleshooting.
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.
Eastern Standard Time –Monday through Friday.
Union Roller Coaters are designed to apply a smooth, even, controllable
coating of liquid materials, such as: glue, resinous adhesives, drawing
lubricants, paint, wax, oil, sizing, silicone solutions, etc. to many reasonably flat
surfaced substrates. Roller coating eliminates the human error, wasteful
application, and the poor general coverage of spray or hand coating. “Dry
Spots”and "Squeeze Out" is prevented and quality control is easily maintained.
All of our series #5 / #15 / #45 roller coater frames are manufactured with
welded tubular steel and plate steel construction.

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
#5
4”
2-3/4”
4”
#15
6-1/2”
4-3/8”
6-1/2”
#45
8-3/4”
6-5/8”
8-3/4”
Note: Backup rolls are located on “Model C”Roller Coaters Only
Union Roller Coaters are most versatile in that additions or modifications
can be made to accommodate almost any type of coating problem. Many
coaters have been designed to contain deburring rolls, brush rolls, squeegee
rolls, heated or chilled rolls in addition to coating rolls. Coating rolls can be
chrome plated steel or covered with a number of different coverings including
(but not limited to): Neoprene, Mechanical Neoprene, EPDM, Nitrile, Silicone,
Gelatin, Thiokol, Buna N, Aluminum, etc.
Rolls can be spiral or longitudinally corrugated, depending on the type and
amount of coating material used.
In most cases a smooth ground roll will apply the desired amount of coating
material to the substrate being run.

Page 5
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:
•Safety during Installation;
•Safety during Operation;
•Safety during Servicing;
Failure to follow these recommendations may result in personal injury from
electrocution and/or equipment and property damage.
SAFETY DURING INSTALLATION:
Electrical:
1. A protective electrical ground connection to a reliable earth ground is
essential for safe operation. Without one, all accessible conductive
components (including knobs and controls that appear insulated) can
render an electric shock.
2. A disconnect switch with lockout capability must be provided between the
power source and the equipment.

Page 6
SAFETY (Continued)
SAFETY DURING INSTALLATION (Continued):
3. The power supply wire gauge and insulation must be sufficient to meet the
power requirements for the machine.
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.
Pneumatic: Union Tool has installed a lockout, three-way, manual valve in
the air supply line to the filter/regulator. This valve makes it
possible to relieve air pressure and lock out the pneumatic system
before undertaking maintenance or repairs.
SAFETY DURING OPERATION:
DO NOT operate Union Tool equipment under the following conditions:
1. Near volatile or otherwise explosive gases or materials.
2. Without the covers, panel and safety guards properly installed.

Page 7
SAFETY (Continued)
SAFETY DURING OPERATION (Continued):
3. At atmospheric temperatures below 20F (-6C) or above 120F (50C).
4. In drafty areas with the coating rolls unshielded from the draft.
5. NEVER use Union Tool equipment as a ladder or stepping stool.
SAFETY DURING SERVICING:
1. DO NOT perform internal service or adjustment on any equipment unless
another person capable of rendering first aid and resuscitation is present.
2. Only qualified personnel should service Union Tool equipment.
3. To avoid personal injury, never touch exposed connections and
components while power is ON. Dangerous voltages exist at several
points in the equipment.
4. Disconnect, lock out and tag external electrical power before removing
protective panels or replacing electrical components.
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. Cover exposed terminals and work areas
with rubber sheeting to avoid accidental contact while the power is ON.

Page 8
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.
2. Place the coater in the chosen position.
3. Level the coater.
4. Make the power drop to the disconnect box. The voltage should be clearly
marked on the front of the disconnect box and on the electrical print inside the
box.
5. Make an air drop to the coater if the coater is equipped with a filter and
regulator. Please do not reduce the size of the lines of the air drop
smaller than the supplied filter and regulator.
Make a visual check between the coating rolls and doctor rolls; look for any
loose objects that may have fallen between the rolls. Check the rotation of the
coating and doctor rolls in the reverse mode. All guards and covers must be in
position for the coater to operate.

Page 9
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. The machine must be on a solid, level surface and a spirit level
should be used longitudinally on the channel at the top of the machine and on
the lateral top section of the frame. The machine must be secured to the floor
by bolts or equal to ensure stable running.
WIRING
Make sure proper wiring is carried out to prevent damage to the circuit. Refer
to packing list or wiring diagram inside the electrical control box. This will
ensure correct voltage to all motors.
MACHINE SHOULD BE GROUNDED FOR SAFETY OF OPERATOR.

Page 10
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. A handwheel located at one end of the coater connects two
gear box arrangements and is the means of operating this assembly. Turning
this handwheel in the direction as indicated by the tag will adjust the gap
between the upper coating roll and lower coating roll (or lower back-up roll). This
assembly is mounted on top of the machine at the end housing and includes a
coupling to allow the top roll to be adjusted parallel to the bottom roll within a
thousandth of an inch. To parallel the roll, pull the spring-loaded portion of the
coupling back and either turn the single handwheel or turn the shaft to move
either side up and down independently.
NEVER ALLOW COATING ROLLS TO TOUCH. Sharp materials or
burrs should never be run through the machine with rubber rolls. This would cut
& gouge 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. These slide plates are machined to slide freely
within the containment of the full length gib plates. A finely threaded screw is
utilized to slide this bearing plate. This screw is located through a graduated
collar to give you a precise degree of accuracy and control when turning the
hand knob. The unifeed is supplied with a mechanical digital indicator to give a
precise reading of the doctor roll position in relationship to the coating roll. This
whole assembly is mounted on the upper bearing plates on Models “A”, “B” and
“C”. The Model “D” is a bottom coater and this assembly is mounted to the
housing ends, as is the lower assembly on the Models “A” and “B”. The Model
“A” doctor roll hand knob adjustments or single handwheel unifeed are located at
the top infeed side and the bottom offbearing side. In the “B”, “C” and “D”
Models, these adjustments are located all on the infeed side. The clockwise
movement of the handwheel means moving the doctor roll toward the coating
roll; a counterclockwise movement will move it away 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. Only
tighten these seal plates when the machine is due to operate; before the
machine is turned on and the coating material is filled into the trough. When the
machine is not in use, loosen the seal plates ensuring that they are not touching
the rolls. The seal plates are a wear item and overtime will begin to leak. When
this occurs you will need to replace with new seal plates.
Before attempting to fill the trough, feeler gauges should be used between
the rolls at each end to ensure an even coat. In theory, to set a staring gap
between these rolls, the solids in the coating material and the desired dry film
thickness should be known. With these two factors, a setting for the gap
between the rolls can be determined by multiplying the dry finish thickness by the
percentage of solids, divided into 100. For example, the desired dry film
thickness is 0.002" and the solids in the coating material is 50% or 100/50 = 2.
Then 0.002" x 2 = 0.004 which is the gap required. Or, if the dry film thickness
required is 0.002" and the solids in the coating material is 20% then 100/20 = 5

Page 13
OPERATING INSTRUCTIONS
Roll Adjustments (continued) / Roll Change Out
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. A small adjustment of the doctor roll may be necessary
to produce the required dry finish thickness.
ROLL CHANGE OUT:
To remove the coating and doctor roll (s) follow these procedures:
1. Remove seal plates.
2. Remove “end”covers on both housings
3. Remove chain and sprockets from rolls to be replaced.
4. Loosen roll bearings (4 bolts per bearing) and collars which hold
bearings in place.
5. Slide bearings toward center of roll along journal; keep the roll
supported by overhead hoist and straps. Care should be taken
not to damage the roll face or the steel journals while removing
the roll.
6. Shift the roll toward one end housing and tilt the opposite end out.
7. Shift entire roll out of the machine
8. Installation of a new roll is the same sequence in reverse

Page 14
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.
ROLL MOUNTINGS
All rolls are mounted in self-aligning ball bearings. Self-aligning seals
effectively keep grease in and prevent entry of dirt regardless of alignment. All
bearings are mounted on smooth surfaces to ensure proper mounting and
alignment.

Page 15
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. An outfeed table can also be
substituted for our pickoff fingers.
BEFORE STARTING:
Two areas must be checked before operating this machine. Be sure the
rolls are apart; be sure the pickoff fingers/outfeed table and infeed table are not
touching the rolls. Serious damage to the rolls or the machine will occur if
these points are not checked and corrected before operation. Careful reading
of these instructions will ensure you of satisfactory operation. Tighten all bolted
pieces to the machine (jarring and jolting during shipment may cause loosening
of parts or assemblies).
Move all rolls away from each other. Steel roll contact with each other
may cause a galling action and will ruin the finish of these rolls.
Roll rotation should be checked. If it is wrong recheck circuit for proper
wiring.

Page 16
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.
DOCTOR ROLL SAFETY FEATURES
The adjusting screw on the doctor roll assembly is spring loaded. In
event of a large object being caught in the trough of the rolls, the pressure can
be relieved by vigorously pushing the adjusting screw out of the slotted bracket
on the bearing slide block, towards the center of the machine.

Page 17
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.
The most efficient way to clean the coating head is to use as much of the
coating material within the rolls while coating product. Any material left in the rolls
when production is over will be wasted. If both coating heads (top and bottom) were
being used, you do not need to move the top vertical adjustment. If only the top
coating head was used, raise the top coating assembly to about 3”; stop the coater
and insert the cleanup pan. The cleanup pan and catch pan may be lined with
plastic or paper; this will make it easier to clean up when the wasted coating
material and clean up material have been dumped. If you are cleaning both the top
and bottom coating heads, do not make any vertical adjustments. Stop the coater by
moving the reversing switch to neutral and raise lexan hood for access on the
backside of the coater. Once the lexan hood is open, the machine will not be able

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. Allow the cleanup material to revolve with the
coating material for several minutes. After several minutes, reverse the direction of
the coating rolls by moving the reversing drum switch to reverse. This will allow all
material between the rolls to be squeezed out from the bottom of the rolls into the
cleanup pans or catch tray.
Repeat adding the cleanup material approximately 2-3 more times at which
time all rolls should be cleaned of any coating material and only have a small
amount of residue of cleanup material on them. IMPORTANT: Adjust doctor roll
away from the coating roll to ensure they are not touching. This may be done while
rolls are still revolving. Leaving rolls together will cause a flat spot on rubber coating
rolls.
STOP/POWER DOWN THE MACHINE TO PREVENT AN ACCIDENT. Wipe
the rolls clean and loosen the seal plates.
NEVER WIPE THE ROLLS WHILE THEY ARE ROTATING.

Page 19
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).
TROUBLE SHOOTING DOCTOR ROLL DRIVE CLUTCH
Problem
Possible Cause
Corrective Action
1. The doctor roll stops
rotating.
1. Seal plates are too tight.
2. Clutch needs adjusting to
apply more torque.
1. Loosen spring tension on
seal plates.
2. Straighten the tab on the
lock washer and turn the
nut by hand clockwise to
apply more torque.
1. The doctor roll drive chain
jumping.
1. Clutch needs adjusting to
apply less torque.
2. Spring tension needs to
be increased on chain
tightner, or the spring is
broken or weak and
needs to be replaced.
1. Straighten the tab on
the lock washer and turn
the nut counter clockwise
to apply less torque.

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
Corrective Action
Seal plate adjustment
1. The correct tension is to
hand tighten the nut or
thumb screw and if
needed one or two extra
turns to apply more spring
tension to the seal plate.
1. Seal plates leaking coating
material.
1. The seal plate spring
tension may be too loose.
2. You will need to check
that the coating roll ends
are flush with the doctor
rolls, as far as left to right.
3. Check if the seal plates
are grooved deeply or
damaged and have been
leaking, you will need to
replace the seal plates at
this time.
4. Check for damage on the
rubber on the end of the
roll.
5. Check that the doctor roll
is level with the coating
roll.
1. Tighten the nut or
thumbscrew to apply more
spring tension.
2. Loosen the setscrews in
the coating or doctor roll
bearings and move the roll
that has shifted to the left
or right; retighten the set
screws.
3. Replace the seal plates.
4. Replace the coating
roll.
5. There are adjustments on
the doctor roll bearing gibs.