Phoenix MELANGE Service manual

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Phoenix Mixer India Pvt. Ltd.
MELANGE
Semi Automatic Gyroscopic Mixer
Operating and Service Manual
© 2008 Phoenix Mixer India Pvt Ltd.

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Phoenix Mixer India Pvt. Ltd.
User’s Manual
Gyroscopic l Mixer
MELANGE
Version Phoenix 1.1 _ 15-08-2012
© COPYRIGHT 2008, Phoenix Mixer India Pvt. Ltd. all rights reserved.
No part of this manual may be reproduced in any form, or by any means, electronic or mechanical,
including photocopying and recording, without prior written permission of Phoenix.
Information in this manual is subject to change without notice and does not represent a commitment on
the part of Phoenix.
Unless otherwise indicated, all references to companies, names, data and addresses used in the screens
and / or examples are purely coincidental and serve only to clarify the use of the Phoenix Mixer.
Phoenix shall not be liable for technical or editorial errors or omissions made herein; nor for incidental or
consequential damages resulting from the performance or use of this material.
If you require additional copies of this manual or further technical information about it, please write to:
Phoenix Mixer India Pvt. Ltd.
Plot No 7, Collage Road, Vadkun,
Dahanu Road- 401602
Dist: Palghar, Maharashtra
INDIA
Phone: + 91-2528 221120/223324
www.phoenixmixer.com
An ISO 9001:2015 Certified Company
Printed in India

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Phoenix Mixer India Pvt. Ltd.
1.
INDEX
SAFETY INSTRUCTIONS…………………………………….……………….
4
2. INTRODUCTION………..………………………..………….………………… 5
3. TECHNICAL SPECIFICATIONS………………………………….…………. 6
4. WARRANTY TERMS……………………………………………………..…… 8
5. SAFETY SPECIFICATIONS………………………………….……………….. 9
6. INSTALLATION…………………………………………………………………. 10
7. CONTROLS……………………………………………………………….……… 14
8. OPERATIONS……………………………………………………………….….. 15
9. MAINTENANCE & TROUBLESHOOTING…………..……………….. 17
10. SCHEMATIC DIAGRAM ……………………………………………………… 21
11. SPARE PARTS LIST ……………………………………………………………. 23

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Phoenix Mixer India Pvt. Ltd.
1. SAFETY INSTRUCTIONS
 Read safety instruction carefully and follow them for your own protection.
This Product is use on a nominal 115 or230 Volt circuit, as shown on the Name plate.
Connect the Product to an outlet having the same configuration as the Plug.
Wear safety Shoes when installing or relocating the machine.
Make sure the machine stands securely.
Keep your place clean & tidy. There is risk of accidents at untidy work place.
 Close the Machine when it is not being used.
Machine shall be connected to dedicated electrical circuit- No other device shall be connected
to this circuit.
This product is equipped with a cord having a grounding wire with an appropriate grounding
plug. The plug must be plugged into an outlet that is properly installed and grounded in
accordance with all local codes and ordinances.
This product shall be connected to a dedicated electrical circuit – no other devices shall be
connected to this circuit.
Removal of the plug from the outlet is the means for isolating the mixer from the power
supply. Ensure that the mixer is installed with the plug easily accessible to the operator.
This product is designed to operate only when the door is closed. DO NOT ATTEMPT TO ALTER
ELECTRICAL INTERLOCK MECHANISM
In case of emergency, press the Red Emergency Stop button.
 Do not overload the machine. Check that the weight and dimension of the mixing can are
suitable
Use only undamaged and sturdy Mixing Can, If you don’t, the container may burst.
Never lift large and heavy Can into the machine.
The mixing Can has to be closed completely.
 Make sure that the mixing Can sits in central position on mixing table. Secure the container
handle with rubber bands or adhesive tape.
Take good care of the machine. Make sure that the moving parts move smoothly and without
restriction. Follow the maintenance instruction.
 Do not use high pressure equipment to clean the machine.
Make sure that the safety devices work properly and are clean.
 Do not use the machine if the door or the plastic shutter is damaged. if the shutter strip is
broken, do not reach into the in interior. There is risk of injury from rotating components.
 Do not start the machine with shutter open. Pull out power plug! There is high risk of
accidents!
Before switching on the machine after maintenance work, check that no spanners or setting
tools are left inside the machine.
Examine the machine for signs of damage. Check regularly that all parts are in good working
condition. Have repairs carried out only by the manufacturer or an approved specialist.
Trained and authorized personnel shall use this product.

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Phoenix Mixer India Pvt. Ltd.
2. INTRODUCTION
MELANGE is a revolutionary mixer, which is ideal for all your mixing requirements. MELANGE Mixer
performs gyroscopic action, which enables in effective mixing, uniform blending and making
homogeneous mixer.
The MELANGE mixer is specifically designed for point-of-sale color mixing applications as well as for semi-
industrial applications.
This mixer is ideal for mixing small, medium, large cans up to 35kgs.
MELANGE is user friendly.
The MELANGE has been designed to meet the demands of the retail market.
The dimension of the machine makes it versatile and suitable for use in all environments.
The unique design results in reduced maintenance and in color mixing at the lowest cost per liter
produced.
MELANGE is a rugged and reliable mixer which performance and design exhibits the qualities of a strong
and sturdy engineering product and low maintenance.
Phoenix shall not be liable for any damage or injury incurred by non-
compliance with these regulations, or by not taking the usual and accepted
precautions in handing, operation or repair, even if not expressly stated in
this manual.

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3. TECHNICAL SPECIFICATIONS
PERTICULAR
SPECIFICATION
MAXIMUM CAN WEIGHT
40 KG
MAXIMUM CAN HEIGHT
400 MM
MAXIMUM CAN DIAMETER
240 MM
OVAL AND MULTIPLA CANS
YES
CAN LOADING
MANUAL
CAN MIXING (MIN
-
MAX) 1 LIT
.
1
-
5 NOS(Ad
a
ptor Disc)
CAN MIXING (MIN
-
MAX) 4 LIT
.
1 NO
CAN MIXING (MIN
-
MAX) 10 LIT
.
1 NO
CAN MIXING (MIN
-
MIX) 20 LIT
.
1 NO
MINIMUM CAN HEIGHT
70 MM
GYRO OPEN (MAX)
410 MM
GYRO CLOSE (MIN))
65 MM
GYRO RPM
120
RPM
BOTTOM DISC RPM
240 RPM
CLAMPING
MANUAL
VERTICAL POSITIONING
MANUAL
MACHANICAL LOCK
-
PIVOT
MAIN MOTOR
1 HP,SINGLE PHASE,230/110Vac,50/60 Hz
.1440
RPM
MAXIMUM NOISE LEVEL
55
Db
POWER SUPPLY
230V/50
-
60 Hz
POWER SUPPLY (OPTIONAL)
110 V/60Hz
ELECTRONICS
BOARD
TIMER
MACHANICAL TIMER (5 Min.)
LOCKING DOOR DEVICE(Saf
e
ty Door
S/W
)
AVAILABLE
GYROSCOPIC MOTION
CLOCKWISE
EMERGENCY SWITCH
AVAILABLE
TRANSPORT ROLLER(Cust
e
r Wheel)
AVAILABLE
MACHINE DIMENSION (W
x
D
x
H)
815
x
690
x
1085 MM
PACKING DIMENSION (WxDxH)
965x890x1315 MM
MACHINE NET WEIGHT
155 KG
MACHINE GROSS WEIGHT
175 KG

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EN 292 Part 1 and 2: 1991 Safety of Machinery – Basic concepts, general
Principles for design
EN 418: 1992 Safety of Machinery – Emergency stop
equipment, Functional aspects
EN60204 Part 1: 1997 Safety of machinery – Electrical equipment of
Machines -Specifications for general requirements.
EN 954-1: 1996 Safety of Machinery – Safety related parts of control
Systems- Part 1: General principles for design
EN 1088: 1995 Safety of machinery-Interlocking devices associated
with guards.
EN 294: 1992 Safety of machinery – Safety distances to prevent danger
zones being reached by the upper limbs.
EN 953: 1997 Safety of machines – Guards-General requirements for the
design and construction of fixed and movable for coating
materials.
PrEN 12757-1 Mixing machinery for coating materials
- Materials used by Phoenix to manufacture the machine doesn’t undergo corrosions or
deteriorations (They are compatible) with the paints which have to be mixed.

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Phoenix Mixer India Pvt. Ltd.
4. WARRANTY
LIMITED WARRANTY: Phoenix warrants each unit manufactured to be free of defects in material and
workmanship for a period of twelve months. This warranty applies to single-shift operation and is counted
from the date of initial start-up. It cover all defects arising from faulty material or workmanship.
Please Note that all warranty claims must be accompanied by the original delivery note or initial start – up
report.
All essential warranty repair work must only be carried out by trained service engineers or by third parties
authorization form Phoenix. Unauthorized repair may render the warranty null and void.
Please return any defective parts or machines carriage-paid to our factory. Phoenix reserves the rights to
decide on whether cost-free parts replacement is applicable. Parts and labour covered by the warranty
will be supplied free of charge. The warranty does not cover travel cost, expenses or possible overnight
accommodation resulting from warranty repairs carried out off our premises.
Any other responsibility, with particular reference to damage claims, including foregone profit or other
material losses on the part of the customer, is expressly excluded.
Warranty and liability claims for personal or material damage are excluded if attributable to one or more
of the following causes.:
The part unit shall be returned with transportation charges prepaid. If the fault has been caused by misuse
or abnormal conditions of operation, repairs will be billed at a normal cost. In this case, an estimate will
be submitted before works is started, if requested.
Always include serial number in any correspondence concerning the part unit.
The warranty expires: Twelve month after date of invoicing
 Operation of the machine with defective safety or protection device.
 Incorrect operation of the machine, as define in the operation instructions.
 Failure to observe the instruction in the operating manual with respect to set up, initial start
up, operation and maintenance of the machine.
 Fault and damage cause by dirt or incorrect cleaning schedules, with particular reference to
leaks and damaged Cans.
 Unauthorized structural modification to the machine.
 Incorrect monitoring of parts subject to wear and consumables.
 Unauthorized repairs or fitting of non original parts.
 Damage caused by the impact of foreign bodies or majeure force.
We reserve the right to make amendments as a result of on going advance in the technical field.

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5. SAFETY SPECIFICATIONS
Compliance with safety requirements:
This mixer must be used and serviced by authorized and trained personnel only. Improper use or
servicing may result in dangerous situations or accidents.
Risk to personnel is possible in two areas:
Operator area
Maintenance area
Maintenance area
Operator area
THIS EQUIPMENT MUST BE GROUNDED.
Attention!!!
Connect this product to a dedicated electrical circuit – no other devices shall be
connected to this circuit. Do not use extension cords to connect this product.
Attention!!!
Only trained personnel shall be permitted access to the electrical wiring within the
machine. DO NOT USE THIS PRODUCT IF THE BACK PANEL IS NOT IN PLACE.

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The machine is equipped with a power supply cable having the following specifications:
Length: 8 FT
Size: 14 AWG
The machine shall be connected to a dedicated, grounded circuit, protected by a 15 A circuit breaker.
All wiring shall be in accordance with local codes
Important:
The power supply cable conductors are color-coded as follows:
GREEN or GREEN/YELLOW — GROUND
WHITE or BLUE/BLACK — NEUTRAL
BLACK or BROWN/RED — LINE
Service safety rules:
1. Prior to performing any maintenance or inspection of the MELANGE disconnect the power plug
from the electrical outlet in order to ensure that the MELANGE cannot start unexpectedly.
2. To prevent injuries to personnel ensure that all removable panels are in place and properly
secured except for any necessary inspections or maintenance.
3. Do not disable or override any of the installed safety features such as the door lock system.
4. The MELANGE shall be installed in an environment conforming to the appropriate local
regulations. A permit issued by the local authority may be required. Keep the number of paint
cans in the immediate area of the machine to a minimum.
5. Do not store flammable materials or other materials inside the machine. The area in which the
MELANGE is installed must be kept free of exposed flames, incandescent fixtures or other
devices that might create sparks.
6. It is recommended that a ventilation system, guaranteed to maintain the concentration of
dangerous vapors around electrical components at less than 30%, be installed.
7. When the MELANGE is not being used for a period of time (such as at the end of the work day),
ensure that it is empty (no paint can inside), close the door and unplug the power plug from
the outlet.
8. Ensure that all tools are removed from inside the machine after any maintenance work.
RESIDUAL RISK
Residual risks list for the user:
The MELANGE, and its operating and service instructions, have been developed giving careful
consideration to the safety of the user and service technician. However, there are situations
where risks can be reduced but not eliminated completely.
RISK PRECAUTION
Injury or
crushing during loading and
unloading operations.
Use protective gloves and safety shoes during loading
and unloading operations.
Abrasions and injuries caused by sharp edges
on the cans being used
Use protective gloves during loading and unloading
operations.
Liquid leakage form the cans being used
Thoroughly clean the operator and maintenance areas.
Keep these areas clean.

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Personal protection for user:
The MELANGE, when properly operated and maintain, presents minimal risk to the user. However, it is
recommended that the user wear suitable protective equipment (safety glasses, safety shoes with non-
slip soles and gloves), in particular when loading and unloading the mixer.
General danger situations:
There are no specifically identified hazard related to the operation and maintenance of the MELANGE (e.g.
fire risk, issue or dispersion of dangerous products). However, it is recommended that a powder type fire
extinguisher, suitable for electrical fires, be readily accessible.
Safety devices:
The machine is equipped with the following safety devices:
 Emergency Stop Button
 Door Lock and sensor
Emergency Stop Button:
For safety reasons, all users should know the location of the Emergency Stop button, and how to use it.
The RED Emergency Stop push button is located on the Left Hand control panel on the top front of the
mixer – to the left of the door. Pushing the button will immediately cut power to the motor control relay,
stopping the motor. To reset the button and restore the mixer to normal operation mode, rotate the
button clockwise.
Door Lock and sensor:
The MELANGE is equipped with a safety device which prevents start up of the mixing cycle when the door
is in the open position. It also locks the door in the closed position during the mixing cycle.

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Phoenix Mixer India Pvt. Ltd.
6. INSTALLATION
INSTALLATION CONDITIONS:
Before unpacking and installing the MELANGE Mixer, please make sure of the following:
 The crate/packaging in which the MELANGE was shipped has not been damaged in any way.
 The floor on which the MELANGE is to be located is firm and level
 An electrical receptacle on a properly grounded, dedicated, 15 A, 115 or 230 V circuit is
available in the immediate vicinity. The circuit shall be installed in accordance with local codes.
The receptacle shall be of a configuration appropriate for the voltage and current rating of the
circuit.
INSTALLATION:
It is recommended that, during the installation of the mixer, protective gloves be worn in order to prevent
hand injuries.
 Unpack the MELANGE Mixer.
 Ensure the machine has not been damaged in any way
 Position the mixer in the desired location. It is equipped with rollers to aid in positioning.
 Using the four leveling feet, level the machine, ensuring that all four feet are properly
supporting the machine. Lock the leveling legs in place by tightening the jam nuts.

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Phoenix Mixer India Pvt. Ltd.
7. CONTROLS
LEFT HAND CONTROL PANEL
RIGHT HAND CONTROL PANEL
STOP Button
- Illuminated RED - door is unlocked
Mechanical Timer
-
sets mixing time
Emergency Stop Button
START Button
-Illuminated Green – when mixer running

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Phoenix Mixer India Pvt. Ltd.
LOGIC CARD AS670-101-ME

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8. OPERATIONS
TURN ON MACHINE (Connect to power) :
Note: The door will not open until the MELANGE mixer is connected to the building power.
 Ensure the Emergency Stop button is engaged – push to engage if necessary
 Plug the mixer into the appropriate electrical receptacle. Ensure the circuit breaker on
the left hand side the mixer, near the top rear corner, is ON.
Mechanical Timer: The STOP button will light up RED For few second. Release the
Emergency Stop button by turning it clockwise. The stop button will continuously
illuminated RED and the door will unlock.
CAN LOADING:
1. Open the MELANGE Mixer door to its fully open position.
2. Ensure the Can Holder Assembly is in the vertical, top dead center (TDC) position, with
the Clamp Mechanical Mechanism at the top, and locked in place. If it is not, use the two
handles on the front of the Can Holder Assembly, to rotate it to the TDC position. Ensure
the lock mechanism engages and the Can Holder Assembly is locked in place.
3. Referring to the illustrations, open the Can Clamping Plates as follows:
 Rotate Handle for spocket (X).
 Using the tapper knob, rotate the mechanism anti-clockwise to open the
clamping plates.
 Position the can on the bottom Disc. Using the concentric rings on the bottom
Disc as a guide, ensure the can is properly centered.
X

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Phoenix Mixer India Pvt. Ltd.
 U Rotate the mechanism in clockwise direction to securely clamp the can between the plates.
 Rotate the Lock Unlock Handle (Y) in clockwise direction to lock Handle for spocket.
 Close the door to the fully closed position.
Note: Do not force the door. If the Handle for Spocket (X) and Lock Unlock Handle (Y) is unclamped.
MIXING:
Mechanical Timer:
 Set the desired mix time by turning the knob on the mechanical timer to the appropriate
position.
 Push the “START” button to start the mixing cycle.
The “START” button will be illuminated GREEN and the light on the “STOP” button will
turn OFF. The door will lock, the Can Hold Assembly Lock will disengage and the Can
Holder Assembly will spin for the set time to mix the paint.
Once the set time has expired, the “STOP” button will illuminated RED, the light in the “START”
button will turn OFF and the Can Holder Assembly will come to a stop. The light in the “STOP”
button staying on and the door will unlock.
To STOP the mixer during an emergency situation, push the Emergency Stop button. Once the
machine has stopped, release the Emergency Stop button by turning it clockwise. The door will
unlock.
USE THE EMERCENCY STOP BUTTON IN AN EMERGENCY SITUATION ONLY
Y
X

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Phoenix Mixer India Pvt. Ltd.
Note: Always remove the can from the mixer after the mix cycle has been completed. Follow
the UNLOADING instructions. Below.
UNLOADING THE CAN:
1. Open the MELANGE Mixer door to its fully open position.
2. Using the two handles on the front of the Can Holder Assembly, slowly rotate the
Assembly to the vertical, top dead center (TDC) position, with the Clamp Mechanical
Mechanism at the top. When it reaches this position the Clamp Assembly Lock will
engage, locking it in place.
Note: If, for some reason, it is necessary to rotate the Can Holder Assembly after the lock has
engaged, Pull Shutter and Rotate the assembly off the TDC position. The lock will remain in the
disengaged position until the assembly is returned to the TDC position.

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Phoenix Mixer India Pvt. Ltd.
9. MAINTENANCE & TROUBLESHOOTING
Monthly Maintenance:
1) Apply grease on Guide shaft of EP 90 Lithium base
2) Apply grease also on Spine (Below the Bottom Disc)
Troubleshooting:
PROBLEM
TROUBLE SHOOTING
Machine is not turning on

Check the Mains supply.
 Check MCB Position, it should be ON.
 Check the Power supply
 Check plug or lose wire.
 Check motor belts.
Gyro vertical position not locked

Check Pivot mechanism back side of the
machine.
 Check shutter end stripe whether it’s broken or
not.
 Check slot at pulley.
Main Motor not running / working

Check Emergency switch
 Check Motor mechanism and
 Motor capacitor.
 Check supply on card.
Machine vibrates during operation

Check the floor flatness. If the floor surface is
not plain, then shift the Machine on a plain /
flat surface.
Machine makes a loud noise after every
revolution

Check the foundation of the Motor.
 Check the tension of the belt joining the Motor
pulley and the Main Wheel. If found loose,
adjust it to the proper tension.
 Check whether the belt has worn out.
 If yes, then replace the same with a new one.
Container clamped does not rotate along
its axis even though the machine is
rotating.

Check the “V” belt for proper tension.
 If the belt is found loose then replace the same
with a new one.
Clamped container becomes loose

Tight handle for sprocket properly.
 Tight Lock / Unlock handle.
Aluminum
Plates
does not slide smoothly.

Clean the Guide Shafts and apply the general-
purpose grease
Machine is giving shock while in operation

Check for proper grounding. If the earthing is
not proper consult an Electrician.
Timer Failure

Check Power ON
 Rotate Timer Knob
 Reset Knob

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Note: Shutter will not open when the Power is OFF
System Error :
Emergency Press

Turn the emergency push button to Clockwise
direction.
 Check the wire connection on the emergency
push button.
 Defective emergency push button cable.
System Error :
Door Switch Faulty

Check Position of Door.
 Check the cable connection of Door Switch.(If
its Photo sensor Check reflector light)
 Check Reflector
Adjusting Transmission Belts:
Remove Cover for Motor from the
machine.
Check belt tension, which should bend 5 –
10mm while pressed with fingers in its
side.
To Correct the tension, set the bolt with
motor as shown in the picture.
Check the belt by rotating the main
pulley. The belt should not be worn.
Put the back panel in its original position.
Pivot Assembly
Remove back panel from the machine to
view the Pivot assembly.
It has been used to work as vertical
position at Gyro assembly.

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10. SCHEMATIC DIAGRAM