Abicor Binzel MF1-Rear User manual

T E C H N O L O G Y F O R T H E W E L D E R ´ S W O R L D .
www.binzel-abicor.com
EN Operating instructions
MF1-Rear
EN Master feeder

EN - 2 BAL.0442.0 • 2021-10-21
MF1-Rear
EN English Translation of the original operating instructions
© The manufacturer reserves the right, at any time and without prior notice, to make such changes and amendments to these
operation Instructions which may become necessary due to misprints, inaccuracies or improvements to the product. Such changes
will however be incorporated into subsequent editions of the Instructions. All trademarks mentioned in the operating instructions
are the property of their respective owners.
All brand names and trademarks that appear in this manual are the property of their respective owners/manufacturers.
Our latest product documents as well as all contact details for the ABICOR BINZEL national subsidiaries and partners
worldwide can be found on our website at www.binzel-abicor.com
1 Identification EN-3
1.1 Marking EN-3
2 Safety EN-3
2.1 Designated use EN-3
2.2 Obligations of the operator EN-3
2.3 Personal protective equipment (PPE) EN-3
2.4 Classification of the warnings EN-4
2.5 Warning and notice signs EN-4
2.6 Emergency information EN-4
3 Product description EN-5
3.1 Technical data EN-5
3.2 Abbreviations EN-5
3.3 Nameplate EN-6
3.4 Signs and symbols used EN-6
4 Scope of delivery EN-7
4.1 Transport EN-7
4.2 Storage EN-7
5 Functional description EN-7
6 Commissioning EN-8
6.1 Mounting the feed rollers EN-8
6.1.1 Mounting the pressure rollers EN-9
6.1.2 Mounting the driving rollers EN-10
6.2 Installing the MF1-Rear EN-10
6.3 Establishing connections EN-11
6.3.1 MF1 or MF1 & MF1-Rear EN-11
6.4 Feeding in the wire EN-12
6.5 Pin assignment EN-13
7 Operation EN-14
7.1 Control elements EN-14
8 Decommissioning EN-15
9 Maintenance and cleaning EN-15
9.1 Maintenance intervals EN-16
10 Troubleshooting EN-18
11 Disassembly EN-18
12 Disposal EN-19
12.1 Materials EN-19
12.2 Consumables EN-19
12.3 Packaging EN-19

MF1-Rear 1 Identification
BAL.0442.0 • 2021-10-21 EN - 3
1 Identification
The MF1-Rear is part of the MFS-V3 wire feeder system and is used in industry and the trade for the delivery of welding
wire or solder. The MF1-Rear is a 4-roll wire drive that is solely used as the rear drive for feeding the wire in push-push
mode. All other media (coolant, shielding gas, welding current) required for the joining process must be separately supplied.
These operating instructions only describe the MF1-Rear master feeder. The MF1-Rear must only be operated using
original ABICOR BINZEL spare parts.
1.1 Marking
This product fulfills the requirements that apply to the market to which it has been introduced. A corresponding marking has
been affixed to the product, if required.
2 Safety
The enclosed safety instructions must be observed.
2.1 Designated use
• The device described in these instructions may be used only for the purpose described in these instructions in the manner
described. In doing so, observe the operating, maintenance and servicing conditions.
• Any other use is considered improper.
• Unauthorized conversions or power increase modifications are not permitted.
2.2 Obligations of the operator
• Keep the operating instructions within easy reach at the device for reference and enclose the operating instructions
when handing over the product.
• Putting into operation, operating and maintenance work may only be carried out by qualified personnel. Qualified
personnel are persons who, based on their special training, knowledge, experience and due to their knowledge of the
relevant standards, are able to assess the tasks assigned to them and identify possible dangers
(in Germany see TRBS 1203).
• Keep other persons out of the work area.
• Please observe the accident prevention regulations of the country in question.
• Ensure good lighting of the work area and keep the work area clean.
• Occupational health and safety regulations of the country in question. For example, Germany: Protection Law and the
Company Safety Ordinance
• Regulations on occupational safety and accident prevention
2.3 Personal protective equipment (PPE)
To avoid danger to the user, these instructions recommend the use of personal protective equipment (PPE).
• This consists of protective clothing, safety goggles, a class P3 respiratory mask, protective gloves, and safety shoes.

EN - 4 BAL.0442.0 • 2021-10-21
2 Safety MF1-Rear
2.4 Classification of the warnings
The warnings used in the operating instructions are divided into four different categories and appear prior to potentially
dangerous work steps. Arranged in descending order of importance, they have the following meanings:
2.5 Warning and notice signs
The following warning and notice signs can be found on the product:
These markings must always be legible. They may not be covered, obscured, painted over or removed.
2.6 Emergency information
In the event of an emergency, immediately disconnect the following supplies:
• Electrical power supply
Further measures can be found in the operating instructions for the power source or the documentation of further peripheral
devices.
DANGER
Describes an imminent threatening danger. If not avoided, this will result in fatal or extremely critical injuries.
WARNING
Describes a potentially dangerous situation. If not avoided, this may result in serious injuries.
CAUTION
Describes a potentially harmful situation. If not avoided, this may result in slight or minor injuries.
NOTICE
Describes the risk of impairing work results or potential material damage to the equipment.
Symbol Meaning
Crushing of fingers!

MF1-Rear 3 Product description
BAL.0442.0 • 2021-10-21 EN - 5
3 Product description
3.1 Technical data
3.2 Abbreviations
WARNING
Hazards caused by improper use
If improperly used, the device can present risks to persons, animals and material property.
• Use the device according to its designated use only.
• Do not convert or modify the device to enhance its performance without authorization.
• The device may only be used by qualified personnel (in Germany, see TRBS 1203).
Ambient temperature -10°C to +40°C
Relative humidity Up to 90% at 20°C
Tab. 1 Ambient conditions during operation
Storage in a closed environment, ambient temperature -10°C to +40°C
Ambient temperature for shipment -25°C to +55°C
Relative humidity Up to 90% at 20°C
Tab. 2 Ambient conditions for transport and storage
MF1-Rear
Supply voltage 24 VDC
Standard roll diameter 20 mm
Drive 4 rollers
Protection rating IP 23
Weight 2.9 kg
Tab. 3 MF1-Rear
MFS-V3 Complete wire feeder system comprising an eBOX, MF1-Rear and a process-side drive plus all
necessary media leads and control leads
MF1-Rear Rear wire drive on push-push systems
MF1 Process-side wire drive
Quickconnector Interface for wire guidance
Tab. 4 Abbreviations

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3 Product description MF1-Rear
3.3 Nameplate
The MF1-Rear is labelled with a nameplate as follows:
When making enquiries, please note the following information:
• Device type
• Device number (1)
3.4 Signs and symbols used
The following signs and symbols are used in the operating instructions:
1Device number 2Reduction ratio
Fig. 1 Nameplate
Standard reduction ratio
Laser applications i= 30:1
Tab. 5 Marking
XXXXXXXX
1
I = XXXX
2
Symbol Description
• Bullet symbol for instructions and lists
Cross-reference symbol refers to detailed, supplementary or further information
1Step(s) described in the text to be carried out in succession

MF1-Rear 4 Scope of delivery
BAL.0442.0 • 2021-10-21 EN - 7
4 Scope of delivery
Order the equipment parts and wear parts separately.
The order data and ID numbers for the equipment parts and wear parts can be found in the current product catalog. Contact
details for support and placing orders can be found online at www.binzel-abicor.com.
4.1 Transport
Although the items delivered are carefully checked and packaged, it is not possible to fully exclude the risk of damage during
transport.
4.2 Storage
Physical storage conditions in a closed environment:
Tab. 2 Ambient conditions for transport and storage on page EN-5
5 Functional description
The MF1-Rear is mechanically and electronically aligned with the master feeder system in push-push mode.
The 4-roll wire drive feeds the wire synchronously with the front drive MF1 in line with the target value setting.
•Assembly MF1-Rear • Operating instructions
Tab. 6 Scope of delivery
• Insulating plate (only with hot wire applications)
Tab. 7 Options
Goods-in inspection Use the delivery note to check that everything has been delivered.
Check the delivery for damage (visual inspection).
In case of complaints If the delivery has been damaged during transport, contact the last carrier immediately.
Retain the packaging for potential inspection by the carrier.
Packaging for
returns
Where possible, use the original packaging and the original packaging material. If you have
any questions concerning the packaging and/or how to secure an item during shipment,
please consult your supplier.
Tab. 8 Transport

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6 Commissioning MF1-Rear
6 Commissioning
6.1 Mounting the feed rollers
DANGER
Risk of injury due to unexpected start-up
The following instructions must be followed during all maintenance, servicing, assembly, disassembly, and repair work:
• Switch off the power source.
• Close off the gas supply.
• Disconnect all electrical connections.
WARNING
Risk of crushing
Hands can be drawn in and crushed.
• Do not reach into moving wheels.
NOTICE
• Please take note of the following instructions:
3 Product description on page EN-5
• The system may be installed and commissioned only by qualified personnel (in Germany, see TRBS 1203).
NOTICE
• Ensure that the feed rollers (4), (12) are correctly installed.
• Always replace or reverse the feed rollers (4), (12) in pairs.
• Before installing the feed rollers (4), (12) remove any oil and grease residues from the running surfaces.
• Pay attention to the groove geometry and wire diameter; use smooth feed rollers only as pressure rollers (12).
• All grooved feed rollers (4), (12) have two guide grooves. Should one be worn out, the roll can be reversed once and
re-used.
• Adjust the contact pressure using the pressure screw (8).
• When assembling the pressure rocker (10) make sure that the axles (9) (anti-twist protection pin) are positioned in the
lower longitudinal groove.
• Check that the pressure rollers (12) run smoothly once installed.
• Ensure that the knurled screws are correctly assigned/installed in the correct position:
• Red knurled screws (7) = pressure rocker
• Blue knurled screws (3) = gear side

MF1-Rear 6 Commissioning
BAL.0442.0 • 2021-10-21 EN - 9
6.1.1 Mounting the pressure rollers
1Lift off the cover (5).
2Press on the rocker (10) then rotate the eccentric bolt (1) and remove it upwards.
3Unscrew the knurled screw (6) and lift off the rocker (10).
4Loosen the knurled screws (7) and press out the axle (9) downward.
5Remove the drive gears (11).
6Place the feed rollers (12) on the drive gears (11).
7Insert the drive gears (11) and axles (9) and secure in place using knurled screws (7).
8Place the rocker (10) on the bolt and secure with the knurled screw (6).
9Swivel the rocker (10) into position, insert the eccentric bolt (1) and turn it over.
10 Put on the cover (5).
1Eccentric bolt
2Drive gears (2 pcs.)
3Knurled screws (2 pcs.)
4Feeder drive rollers (2 pcs.)
5Cover
6Knurled screw
7Knurled screws (2 pcs.)
8Pressure screw
9Axles (2 pcs.)
10 Rocker
11 Drive gears (2 pcs.)
12 Feeder pressure rollers (2 pcs.)
Fig. 2 Mounting the feed rollers
1 2 43
89
12
6
11
10 7
5

EN - 10 BAL.0442.0 • 2021-10-21
6 Commissioning MF1-Rear
6.1.2 Mounting the driving rollers
1Unscrew and remove the knurled screws (3).
2Place the drive rollers (4) on guide pins on the drive gears (2) and secure with knurled screws (3).
6.2 Installing the MF1-Rear
Due to the different installation situations in systems, the system constructor/operator is responsible for ensuring that the
MF1-Rear is duly installed. Mount the MF1-Rear on a mounting plate of a suitable size.
NOTICE
• Red drive rollers = V-groove / blue drive rollers = U-groove
DANGER
Electric shock
Dangerous voltage during hot wire applications.
• All MF drives must be installed so as to be electrically insulated from other peripheral devices.
• Use insulating sleeves to fasten the screws on the robot.
NOTICE
• Ensure clear access to the control elements and connections.
• Select a location that allows a short and rectilinear wire feed.
• The dimensions of the following mounting holes are identical for the MF1 and MF1-Rear.
Fig. 3 Mounting hole dimensions in mm
36,40
43,90

MF1-Rear 6 Commissioning
BAL.0442.0 • 2021-10-21 EN - 11
6.3 Establishing connections
6.3.1 MF1 or MF1 & MF1-Rear
Establish the connections as shown in the following diagram:
1Wire end sensor
2Wire drum
3 eBOX
4Control lead for wire end sensor
5Control lead MF1-Rear - MF1/ MF1DIG.
/sensor
6Flex supply
7 MF1
8 MasterLiner
9 MF1-Rear
10 MasterLiner
Fig. 4 MF1 or MF1 & MF1-Rear
1 2
3
4
56
7
8
9
10

EN - 12 BAL.0442.0 • 2021-10-21
6 Commissioning MF1-Rear
6.4 Feeding in the wire
1Lift off the cover (3).
2Press on the rocker (7) then rotate the eccentric bolt (8) and remove it upwards.
3Fold away the rocker (7) to the side.
4Insert the wire (4) from the wire drum or spool through the MasterLiner (1) to the inlet tube (2).
5Swivel the rocker (7) into position, insert the eccentric bolt (8) and turn it over.
6Press the inching trigger (6) until wire comes out of the MF1 (process-side wire drive).
NOTICE
• Each time you change the wire, make sure that the start of the wire is free of burrs.
1 MasterLiner
2Inlet tube
3Cover
4Wire
5 MasterLiner
6Inching trigger (green)
7Rocker
8Eccentric bolt
Fig. 5 Feeding in the wire
1
5
8 7
3
6
2 4
CAUTION
Risk of injury
Physical injury caused by the start of the wire.
• Keep the process-side drive away from the body.
NOTICE
• For further steps, please see the MF1 operating instructions.

MF1-Rear 6 Commissioning
BAL.0442.0 • 2021-10-21 EN - 13
6.5 Pin assignment
Fig. 6 Pin assignment
Gas test Inching
CAT normally open switch
CAT base point
CAT normally closed switch
3-pole
Socket board
10-pole
emergency stop
Pin base 10-pole
16-pole circular
Master feeder
connector
Encoder motor
300 lines
bushing

EN - 14 BAL.0442.0 • 2021-10-21
7 Operation MF1-Rear
7 Operation
1Switch on the robot control.
7.1 Control elements
DANGER
Shortness of breath and poisoning caused by inhaling phosgene gas
When welding workpieces that have been degreased with chlorinated solvents, phosgene gas is formed.
• Do not inhale fumes and vapours.
• Ensure a sufficient supply of fresh air.
• Rinse workpieces with clean water prior to welding.
• Do not place degreasing baths containing chlorine in the vicinity of the welding area.
NOTICE
• The MF1-Rear may only be operated by qualified personnel (in Germany see TRBS 1203).
• As the MF1-Rear is integrated into a welding system, the operating instructions of the welding components, such as
welding torch and power source, must be observed during operation.
1CAT socket 2Control lead port 3Gas test trigger 4Inching trigger
Fig. 7 Overview of control elements
Symbol Description
Control lead port (2). Connect the connection plug to the control lead port (2) to establish signal
transmission.
Optional: only when using safety cut-out CAT2.
Connect the CAT socket (1) to the helix cable of the CAT emergency stop safety cut-out. The integrated
control lead will transmit the signal to peripheral devices.
Gas test trigger (black) (3). Press the trigger: gas flows. Check the gas volume.
Inching trigger (green) (4). Press the trigger once: wire is fed.
1
42
3 2

MF1-Rear 8 Decommissioning
BAL.0442.0 • 2021-10-21 EN - 15
8 Decommissioning
1Switch off the power to the robot control system.
9 Maintenance and cleaning
Scheduled maintenance and cleaning are prerequisites for a long service life and trouble-free operation.
NOTICE
• As the MF1-Rear is integrated into a welding system, the process for putting it out of operation depends on the robot
control system. Please make sure that the shutdown procedures for all components integrated in the welding system are
strictly observed.
DANGER
Risk of injury due to unexpected start-up
The following instructions must be followed during all maintenance, servicing, assembly, disassembly, and repair work:
• Switch off the power source.
• Close off the gas supply.
• Disconnect all electrical connections.
DANGER
Electric shock
Dangerous voltage due to defective cables.
• Check all live cables and connections for proper installation and damage.
• Replace any damaged, deformed or worn parts.
WARNING
Risk of crushing
Hands can be drawn in and crushed.
• Do not reach into moving wheels.
WARNING
Risk of injury
Serious injuries may be caused by parts swirling around.
• When cleaning the wire guide with compressed air, wear suitable protective clothing, in particular safety goggles.
NOTICE
• Maintenance and cleaning work may be carried out only by qualified personnel (in Germany see TRBS 1203).
• Observe the provisions of EN 60974-4 Inspection and testing during the operation of arc welding equipment plus any
national laws and regulations.
• Always wear your personal protective clothing when performing maintenance and cleaning work.

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9 Maintenance and cleaning MF1-Rear
9.1 Maintenance intervals
When using arc welding equipment, always observe the provisions of EN 60974-4 Inspection and testing, as well as any
national laws and regulations.
NOTICE
• The specified maintenance intervals are standard values and refer to single-shift operation.
1Cover
2Clamp lever
3Wire outlet nipple
4Grub screw
5Toothed wheels (2 pcs.)
6Drive gear
7Wire guide nipple
8Pressure screw
9Pressure spring
10 Full-floating axles (2 pcs.)
11 Toothed wheels (2 pcs.)
Fig. 8 Maintenance intervals
1 2 5
6
4
7
11
10 8
3
9

MF1-Rear 9 Maintenance and cleaning
BAL.0442.0 • 2021-10-21 EN - 17
Check the following:
Weekly Every other week Monthly
• Remove the cover (1) and use dry compressed air to clean the
drive unit.
• Lightly lubricate the
full-floating
axles (10) and
toothed wheels (11)
with: K3N-30
Lithium NL GI
class 3
• Check the contact
pressure setting and
correct using the
pressure screw (8) if
necessary.
• Check the drive gear (6) for wear and replace if necessary. • Check the wire
guide nipple (7) for
wear and replace if
necessary.
• Check the pressure
spring (9) for wear
and replace as
follows if necessary:
Unscrew the pressure
screw (8), replace the
pressure spring (9)
and screw in the
pressure screw (8).
• Check the full-floating axles (10) and toothed wheels (11) for
wear and replace if necessary.
• Check the wire
outlet nipple (3) for
wear and replace if
necessary.
• Check the feed rollers for wear and replace if necessary.
6.1 on page EN-8
• Check the clamp
lever (2) for wear and
replace if necessary.
Tab. 9 Maintenance and cleaning

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10 Troubleshooting MF1-Rear
10 Troubleshooting
Please observe the attached document ‘Warranty’. Please consult your retailer or the manufacturer in case of any doubts
and/or problems.
11 Disassembly
1Disconnect the cable assembly from the wire feeder.
2Remove the parts to be disconnected.
3Disassemble the MF1-Rear.
Disassemble the MF1-Rear in the reverse order. In doing so, please note: 6.2 Installing the MF1-Rear on page EN-10
DANGER
Risk of injury and device damage when handled by unauthorized persons
Improper repair work and modifications to the product may lead to serious injuries and damage to the device. The
product warranty will be rendered invalid if work is carried out on the product by unauthorized persons.
• Operating, maintenance, cleaning and repair work may be carried out only by qualified personnel
(in Germany see TRBS 1203).
NOTICE
• Please also consult the operating instructions for the welding components, such as the power source, welding torch
system, re-circulating cooling unit etc.
Fault Cause Solution
Unit is not
ready for
operation
• Control system or component defective • Ask a Binzel specialist to replace the defective control
system or component
Wire is not fed
• Motor defective See eBOX
• Motor control card fault. Fault cannot be
eliminated by pressing the RESET trigger.
See eBOX
• When the wire feed trigger is pressed again, the
motor control card shows again a fault.
See eBOX
Tab. 10 Troubleshooting
DANGER
Risk of injury due to unexpected start-up
The following instructions must be adhered to during all maintenance, servicing, assembly, disassembly, and repair work:
• Switch off the power source.
• Close off the gas supply.
• Switch off the entire welding system.
• Disconnect all electrical connections.
NOTICE
• Disassembly may be carried out only by qualified personnel (in Germany see TRBS 1203).
• Please consult the operating instructions for the welding components, such as the power source, welding torch system,
re-circulating cooling unit etc.
• Observe the information provided in the following section:
8 Decommissioning on page EN-15.

MF1-Rear 12 Disposal
BAL.0442.0 • 2021-10-21 EN - 19
12 Disposal
When disposing of the system, local regulations, laws, provisions, standards and guidelines must be observed. To correctly
dispose of the product, it must first be disassembled.
Please note the following information:
11 Disassembly on page EN-18
12.1 Materials
This product is mainly made of metallic materials, which can be melted in steel and iron works and are thus almost infinitely
recyclable. The plastic materials used are labelled in preparation for their sorting and separation for later recycling.
12.2 Consumables
Oil, greases and cleaning agents may not contaminate the ground or enter the sewage system. These substances must be
stored, transported and disposed of in suitable containers. Observe the relevant local regulations and disposal instructions
in the safety data sheets specified by the manufacturer of the consumables. Contaminated cleaning tools (brushes, rags, etc.)
must also be disposed of in accordance with the information provided by the consumables’ manufacturer.
12.3 Packaging
ABICOR BINZEL has reduced the transport packaging to the necessary minimum. The ability to recycle packaging
materials is always considered during their selection.

T E C H N O L O G Y F O R T H E W E L D E R ´ S W O R L D .
www.binzel-abicor.com
Manufacturer:
Alexander Binzel Schweisstechnik GmbH & Co. KG
Kiesacker • 35418 Buseck • GERMANY
T +49 64 08 / 59–0
F +49 64 08 / 59–191
[e-mail]
BAL.0442.0 • 2021-10-21
Importer UK:
ABICOR BINZEL (UK) ltd.
Binzel House, Mill Lane, Winwick Quay
Warrington WA2 8UA • UK
T [phone]
F [phone]
[e-mail]