Standard Dokumentation + SD BUEL G En1!1!00

Standard-Documentation Power Pack BUEL G
Language: English
Content:
Operation manual BUEL G PB-BUEL-G-en5

Declaration of incorporation BUEL G EE-BUEL-G100-240
2018 PINTSCH BUBENZER GmbH

www.pintschbubenzer.de
e-Mail: Info@pintschbubenzer.de
PINTSCH BUBENZER GmbH

Friedrichshüttenstr. 1
57548 Kirchen-Wehbach
Tel.: +49-2741 - 9488 - 0
Fax: +49-2741 - 9488 -44
e-Mail: info@pintschbubenzer.de
Hydraulic Power pack
BUEL® G
Operating manual
- Translation -
Series BUEL® G
State: 05/2018
Version: 5
Index
BUEL® G
1 Basics ............................................................................................................................ 3
1.1 Foreword ....................................................................................................................................................... 3
1.2 Copyright ....................................................................................................................................................... 3
1.3 Guarantee and liability................................................................................................................................... 4
1.4 Conformity ..................................................................................................................................................... 4
1.5 Presentation of hazard warnings ................................................................................................................... 5
1.6 Notices and obligations of the plant operator ................................................................................................ 7
1.7 Personnel training ......................................................................................................................................... 7
1.8 Protective Equipment .................................................................................................................................... 7
2 Safety ............................................................................................................................. 8
2.1 Basics ............................................................................................................................................................ 8
2.2 Use in accordance with the intended purpose .............................................................................................. 9
2.3 Use not in accordance with the intended purpose ........................................................................................ 9
2.4 Residual risks .............................................................................................................................................. 10
2.5 Procedure in the event of Emergency STOP or power failure .................................................................... 10
2.6 Safety notes for assembly, start-up and maintenance ................................................................................ 11
2.7 Notes on waste disposal ............................................................................................................................. 12
3 Product description .................................................................................................... 13

3.1 View of product............................................................................................................................................ 13
3.2 Function ....................................................................................................................................................... 14
3.3 Technical data ............................................................................................................................................. 15
3.4 Type plate .................................................................................................................................................... 17
3.5 Power pack labelling ................................................................................................................................... 17
3.6 State of shipment ........................................................................................................................................ 18
3.7 Storage instructions..................................................................................................................................... 19
3.8 Tool-list ........................................................................................................................................................ 19
4 Mounting of the power pack....................................................................................... 20

4.1 Preparation .................................................................................................................................................. 20
4.2 Mounting at brake unit ................................................................................................................................. 21
4.3 Hydraulic connection ................................................................................................................................... 21
4.4 Electrical connection ................................................................................................................................... 23
4.5 Electrical connection of sensors (Options N / T) ......................................................................................... 25
4.6 Final function check..................................................................................................................................... 25
5 Operation ..................................................................................................................... 26
©2018 PINTSCH BUBENZER GmbH

www.pintschbubenzer.de 1
Telefon +49 (0) 2741 / 9488-0 ∙ Telefax +49 (0) 2741 / 9488-44 ∙ info@pintschbubenzer.de
Index
BUEL® G
5.1 Normal operation mode ............................................................................................................................... 26

5.2 Emergency stop and power failure .............................................................................................................. 26
5.3 Manual operation......................................................................................................................................... 27
5.4 Status-LEDs for operating conditions.......................................................................................................... 28
6 Maintenance ................................................................................................................ 29
6.1 Maintenance schedule ................................................................................................................................ 29
6.2 Lubrication ................................................................................................................................................... 30
6.3 Cleaning ...................................................................................................................................................... 30
6.4 Oilchange .................................................................................................................................................... 31
6.5 Replacement of switches and sensors (Option N / T) ................................................................................. 32
6.6 Refilling ........................................................................................................................................................ 33
7 Troubleshooting .......................................................................................................... 35
8 Putting out of service and disposal ........................................................................... 36

8.1 Putting out of service ................................................................................................................................... 36
8.2 Dismounting of power pack ......................................................................................................................... 37
8.3 Disposal ....................................................................................................................................................... 38
9 Spare part list .............................................................................................................. 39
10 Appendix ...................................................................................................................... 40
10.1 Data sheet ................................................................................................................................................... 40
10.2 Tightening torques for regular threads ........................................................................................................ 41
10.3 Customer support ........................................................................................................................................ 42
10.4 Declaration of Incorporation ........................................................................................................................ 43

Basics
BUEL® G
1 Basics
1.1 Foreword
These Operating Instructions (OI) are an essential aid for the trouble-free assembly, commissioning, safe
operation and maintenance of the product.
Read these Operating Instructions before you assemble the product and put it into operation.
They will help you:
o to avoid danger for the fitter, operator and maintenance personnel
o to get to know the product better
o to avoid faults from incorrect operation
o to extend the service life of the product
o to avoid repair costs and downtimes
o to maintain the product properly
o to use the product efficiently.
1.2 Copyright
To avoid faults in operation and assure the trouble-free use of the product, the Operating Instructions
must always be accessible for the operating personal.
These Operating Instructions are confidential. They may only be used by authorized persons. They may
only be given to third parties with the consent in writing of PINTSCH BUBENZER GmbH.
All documents are protected by the German Copyright Law. The distribution and duplication of
documents, also parts thereof, the use and communication of the contents are prohibited unless
expressly permitted.
The Operating Instructions or even parts thereof may not be saved in a data processing system or
translated into another language.
Any contraventions are punishable and subject to compensation. All rights for the exercise of industrial
property rights are reserved.

Basics
BUEL® G
1.3 Guarantee and liability
These Operating Instructions must be thoroughly read before the assembly and commissioning of the
product.
A general exclusion applies to guarantee and liability claims:
o if the product is not used in accordance with its intended purpose,
o in the case of incorrect commissioning, operation or upkeep,
o in the case of non-observance of the notes in these Operating Instructions,
o in the case incorrect repairs,
o in the case of faulty monitoring of wearing parts,
o in the case of the structural changes without the prior agreement of PINTSCH BUBENZER GmbH,
o if damage is caused by foreign bodies.
We accept no liability for damage and operating faults resulting from operating faults or incorrect repairs
and upkeep.
Any liability is excluded for damage resulting from the failure to use genuine spare parts and accessories.
All technical information, data and notes on the operation and maintenance of the product in these
Operating Instructions correspond to the current state of the art at the time of printing. They take account
of our experience and findings up to now to the best of our knowledge.
Technical changes in the course of the further development of the product presented in these Operating
Instructions are reserved. No claims may therefore be inferred from the data, illustrations or descriptions.
1.4 Conformity
The conformity assessment is based on the applicable directives (with their relevant amending directives)
in the version at the time of commissioning. The particular directives in question can be found from the
Declaration of Conformity or Manufacturer’s Declaration.
The Declaration of Conformity or Manufacturer’s Declaration is enclosed with the product documentation.

Basics
BUEL® G
1.5 Presentation of hazard warnings
In these Operating Instruction, use is made of the following symbols for the presentation of hazard
warnings and notices:
DANGER!
Indicates a dangerous situation, which leads to serious injury or death.
WARNING!
Indicates a dangerous situation, which can lead to serious injury or death.
CAUTION!
Indicates a dangerous situation, which can lead to minor or fairly serious injuries and
to damage to property.
NOTICE!
Indicates a situation which can lead to damage to property. Additional important
information is also given here.

Basics
BUEL® G
Symbols of hazard warnings
Warning of a danger point
Warning of dangerous voltage
Warning of automatic start
Warning of cut and crush injuries
Warning of hot surfaces
Warning of environmental pollution
Warning of falling loads

Basics
BUEL® G
1.6 Notices and obligations of the plant operator
The Operating Instructions constitutes an important part of the product. E g. if the product is installed in a
plant the Operating Instructions are to be made available to the operator of the plant. The plant operator
must ensure that these Operating Instructions are always available to the operating personnel!
To protect operating personnel from health hazards and to assure the operational reliability of the
product, the plant operator is obliged to instruct its personnel in the safe operation, upkeep/maintenance
and correct operation of the product. Due attention has to be paid to supervisory and reporting obligations
and special operating features.
The instructions and details in these Operating Instructions must be known and familiar to the operating
and maintenance personnel employed.
In addition to the Operating Instructions, universally valid, legal and other mandatory rulings on accident
prevention and environmental protection as well as basic safety and health requirements are to be
observed.
1.7 Personnel training
Assembly, commissioning, operating and upkeep/maintenance personnel must be adequately qualified

and trained. The responsibility for this lies exclusively with the plant operator.
1.8 Protective Equipment
During all work on the product

o safety footwear is to be worn,
o close-fitting clothes are to be worn,
o long, loose hair is to be tied back or a hair net worn,
o the wearing of jewellery is prohibited,
o for work in the port, reflective clothing in compliance with ISO 471 is to be worn.
o A protective helmet and protective goggles have to be worn.
The safety measures necessary for all tasks concerning the hydraulic fluid can be found in the
corresponding safety-data sheet.

Safety
BUEL® G
2 Safety
2.1 Basics
The product has been developed and built according to the state of the art and recognized safety rules.
Nevertheless, hazards can result from the product for the operator or damage to the product and other
assets if:
o the product is operated by untrained personnel or personnel not instructed in its use,
o the product is not used in accordance with its intended purpose,
o the product is not correctly maintained or serviced,
o the safety notes in these Operating Instructions are not observed,
o the product is improperly modified or converted,
o the maintenance and inspection jobs described above are not properly carried out.
NOTE
Any person operating, maintaining or repairing the product must have read and understood the
Safety Regulations. The Safety Regulations must be observed.
Attention must also be paid to the observance of the following regulations and provisions which can also
be additionally supplemented by Works or Internal Regulations:
o the relevant labour safety regulations,
o recognized safety rules in general use,
o country-specific regulations,
o documentations of other manufacturers accompanying the product,
o use in accordance with the intended purpose.
o Operating manual of the brake.
o Operating manual of the installation
o safety-data sheet of the hydraulic medium

Safety
BUEL® G
2.2 Use in accordance with the intended purpose
The PINTSCH BUBENZER BUEL® G power pack is meant exclusively as a hydraulic pressure generator
for hydraulic brakes. In case of a power failure the unit is idle. The power pack is designed for the
operation in combination with a corresponding spring-actuated brake. It is meant to open the brake
hydraulically.
Use in accordance with the intended purpose includes the observance of the following notes and
warnings:
o on safety,
o on operation,
o on upkeep/maintenance,
o concerning technical specifications as described in the Operating Instructions.
o All electric components of the BUEL® G-power pack are mounted inside the housing and are
environmentally sealed.
o The only interface is the terminal box.
o Protective class of the terminal box: IP 65.
2.3 Use not in accordance with the intended purpose
Any use other than the above or exceeding such is considered as not in accordance with the intended
purpose. The plant operator bears the sole liability for damage resulting from such use.
Hazards may result from the product if it is operated incorrectly or not for the intended purpose by
personnel who have not been trained and familiarized with it.
WARNING
The product is not designed for operation in a potentially explosive environment and does not
have ATEX certification.

Safety
BUEL® G
2.4 Residual risks
All technical information, data and notes on the operation and maintenance of the product in these
Operating Instructions correspond to the current state of the art at the time of printing. Account is taken of
our experience and findings up to now to the best of our knowledge.
Even when all the safety regulations are observed, there remain residual hazards in the operation of the
product.
For all jobs on the brake, make sure that
o all potentially dangerous movements have completely stopped;
o the unintentional and unexpected start-up of the brake is excluded by appropriate measures;
o when there is a load on the brake, the braking and stopping action is assumed by other devices.
There are the following dangers:
o risk of crushing by moving parts
o draw-in points,
o parts such as the housing in particular can become hot after braking.
2.5 Procedure in the event of Emergency STOP or power failure
o In case of a power failure or after the EMERGENCY-STOP has been activated, the supply voltage of
the BUEL® G-power pack is cut off.
o Due to the fail-safe principle, the des BUEL® G-power pack is idle and the brake automatically closes
via spring force.
o A controlled opening of the brake is now only possible by means of the manual release device of the
brake.
o In case of a power down the brake also sets automatically.
IMPORTANT!
The installation has to be secured against uncontrolled starting in case the supply voltage is
switched on again.
o The pre-set setting time of the brake does not change in case of an Emergency-stop or a power
failure.

Safety
BUEL® G
2.6 Safety notes for assembly, start-up and maintenance
Assembly, start-up and maintenance work on the mechanical and electrical devices may only be carried
out by authorized specialists with due observance of the safety regulations and accident prevention
regulations.
The assembly and maintenance jobs specially explained in these Operating Instructions must be carried
out in a professional manner. Only then is the trouble-free operation of the product assured.
Before starting any work at all on the brake, make sure that the drive is switched off and protected against
switching on again.
Before starting any work at all on the brake, make sure that the electrical connection of the power pack is
switched off and protected against switching on again.
Electrical tasks must only be carried out by trained and instructed electricians.
For all repairs and maintenance work, use only genuine PINTSCH BUBENZER spare parts!
The power pack must not be opened, while it is still hot. Let it cool down to at least room-temperature
before working on it to avoid burns.
On completion of any maintenance work as described in these instructions, adjust the brake again to the
necessary values.
Due to their weight and construction, the components of the brake can cause serious injury if they fall.
During work on the brake, all dismantled parts must be secured against falling.
The power pack may only be taken apart to the extent prescribed by these Operating Instructions. Any
further dismantling of assemblies is prohibited.
If unusual changes at the power pack are noticed, switch off the supply voltage immediately. Report the
unusual changes, e.g., a strange smell from the brake, immediately to your superior or contact the After-
Sales Service!
Always heed the information and advices on the handling given in the safety data sheet of the hydraulic
medium.

Safety
BUEL® G
2.7 Notes on waste disposal
In the use and handling of the product, due attention must be paid to the national and communal legal
regulations concerning environment protection and waste disposal. Internal regulations are to be
compared with the corresponding data issued by the manufacturer and upgraded if necessary.
WARNING!
Risk of environmental pollution.
Due attention is to be paid to the environmental-friendly disposal of consumables, lubricants,

auxiliaries and oily components.
Electrical waste is to be collected separately and passed on for recycling.

Product description
BUEL® G
3 Product description
3.1 View of product

TK
FKT 13
10
7
A 10.1
11
21.1
11.1
11.2
20
Pos. Item Pos. Item

7 Shutoff-valve 20 Mounting base
10 Handpump 21.1 Connection - bracket
10.1 Extension lever A Hydraulic connection
11 Terminal box FK Fluid level control
11.1 Cover T Tank
11.2 Cable gland TK Temperature control
13 Filler plug

Product description
BUEL® G
3.2 Function
Pos. Item Pos. Item

1 Pressure limiting valve 11 Filter
2 Check valve A Hydraulic connection
3 Way-valve DS Pressure switch
4 Way-valve M Motor
7 Shutoff-valve MA Measuring connection
8 Pressure limiting valve P Pump
9 Check valve T Tank
10 Handpump
Release brake
 When the supply voltage is switched on, the redundant way-valves (3) and (4) are energized and
close of the return line back into the tank. The motor is switched on, too.
 The pump (P) draws the hydraulic medium out of the tank (T) and generates a pressure- and volume-
flow releasing the brake (s).
 The pressure-limiting valve (1) protects the pump from overload.
 After the pre-set pressure is reached, the motor (M) is switched off by the pressure switch (DS).
 The check-valve (2) prevents the oil from flowing back through the pump (P).
 The check-valve (2) and the seated valves (3) and (4) maintain the pressure at the cylinder.
 The brake remains open.
 The hydraulic pressure may drop due to micro-leakages.
 In this case, the inductive sensor emits a signal to restart the pump for a short period to compensate
the pressure drop.

Product description
BUEL® G
 In case the temperature of the hydraulic fluid rises when the brake is released the pressure in the
system may rise, too. The excessive pressure is released into the tank via the pressure-limiting valve
(17), while the brake remains open.
Set brake
 When the supply voltage is switched off, the two way-valves (3) and (4) are switched off
simultaneously and allow the oil to flow back into the tank (T).
 The hydraulic pressure is released and the brake sets by spring force.
 The redundant execution of the way-valves (3) and (4) helps a safe setting even when one valve
should be blocked.
3.3 Technical data
NOTE!
Please also refer to the data sheet in the appendix.
The technical data refers to an operation with a supply voltage of: 3 ~ 400 V, 50 Hz
Op.mode S1
Pmax Pel I Weight Volume-flow
Type andS3 up to
[bar] [kW] [A] [kg] [l/min]
[c/h]
100 (L) 100 1.7 4.4 39 (42) 180 6
210 (L) 210 3.2 6.0 39 (42) 180 6
240 (L) 240 3.8 6.5 39 (42) 180 6
Operating conditions
Ambient temperature -30°C - + 60°C*
Protection class* IP 65 (IP 67)
Class of insulation (Motor) F
Class of insulation (Coil) H
Class of insulation (Transformer) F
Hydraulic medium Pentosin CHF 11S
Mounting position Vertical
Duty cycle Intermittent duty.
S1 /S3 Up to 180 c/h
NOTE!
Different temperature ranges require special hydraulic fluids.
Please contact PINTSCH BUBENZER!

Product description
BUEL® G
Pentosin CHF 11S

Colour Green DIN 10964
Density at 15 °C kg/m³ 830 DIN EN ISO 12185
Kinematic viscosity at 100°C mm²/s 6,0 DIN EN ISO 3104
Kinematic viscosity at 40°C mm²/s 18,7 DIN EN ISO 3104
Kinematic viscosity at -40°C mm²/s 1100 DIN EN ISO 3104
Viscosity-index 313 DIN ISO 2909
Flash point °C 156 DIN EN ISO 2592
Pourpoint °C -57 ISO 3016
Water endangering class WGK 2
Storage class 10
Type - Brake Nr. of cylinders / BUEL G Type BUEL® G

BSC 50.2, BSC 95.5 2/4 100
BSC 100.5 2/4 210
SF 10 2/4 210
SF 15 2/4 210
2 210
SF 24
4 210 L
2 240
SF 26
4 240 L
2 240 L
SF 30, SF 32
4 240 L
2 240 L
SF 40
4 240 L
SF 50 4 210 L
SFRA5 - 12 2/4 210
Note:
o The SFRA-brakes are equipped with one cylinder per brake.
o The SF 50-brakes are equipped with two cylinders per calliper half, i.e. four per brake.
o The other brakes are equipped with one cylinder per calliper half, i.e. two per brake.

Product description
BUEL® G
3.4 Type plate
 If you have any questions about the brake or when ordering spare parts, please give us the
complete brake type and the serial number according to the type plate.
 The typeplate is mounted at the terminal box.
3.5 Power pack labelling
o The BUEL® G power pack is labelled as follows:
BUEL Max. pressure Options Operation voltage Frequency

G in bar See below in V in Hz
Example:
BUEL® G 210C 400V, 50 Hz stands for:
o Buel Green Power Pack
o max. pressure 210 bar
o Special equipment: Increased corrosion protection
o Connect to a supply voltage of 400 V 50 Hz

Product description
BUEL® G
Index Available options

A Heater
C Enhanced corrosion-protection.
D Pressure monitoring
I Protection class IP 67
K Acc. to special demands of the customer
L Long housing
M Shutoff valve - locking and self-resetting
N Oil level indicator
O Optical status monitoring
R Shutoff valve - locking
T Temperature sensor
W High temperature execution
X External certification
3.6 State of shipment
o Die BUEL® G power packs are shipped either as part of a brake system or separately.
o In case the units are delivered as part of a ready mounted brake-unit, they are filled with hydraulic
fluid and the unit is bled.
o In case the units are delivered separately, they have to be connected to the existing brake-system. In
this case, the Buel-units are not filled with hydraulic fluid. They have to be filled and bled before the
start-up.
o BUEL® G-power packs have to be safely stored for the transport. Make sure neither the power pack
nor other components may be damaged.
o The transportation device has to be executed in a way that any danger for the shipped power packs
or other components can be avoided.
o A safe loading to guarantee a safe transport is mandatory.
o The BUEL® G-power pack should preferably be transported in vertical position

Product description
BUEL® G
3.7 Storage instructions
IMPORTANT!
The electrohydraulic power pack has a weight of over 39

/ 42 Kg, depending on the type. Always use proper
lifting devices and attach the brake at the lifting ore.
The lifting ore is designed to hold the weight of the Buel

G unit. In case the Buel G unit is mounted to a brake
unit, this lifting ore must not be used to lift the complete
unit-
Heed the following instructions and notes for the correct storage:
o Store and / or transport the power pack dust- and waterproof with drying agent until installation.
o Protect the power pack against external damages during the complete storage- / transport-period.
In case of additional painting, do NOT contaminate:
o Electrical components
o Hydraulic components
o Signs and plates
3.8 Tool-list
NOTE!
Please note, that you need a torque wrench to tighten some of the screws and bolts correctly.
Function Tool
Terminal-box Allen key 4 mm
Cable-glands Wrench 27 mm
Cable-clips Flat screwdriver - width 3 mm
Closure stud at tank Allen key 6 mm
Fluid level sensor Wrench 32 mm
Temperature sensor Wrench 19 mm

Mounting of the power pack
BUEL® G
4 Mounting of the power pack
WARNING
A sudden start-up of the installation endangers the life of the maintenance personnel!
Secure the drive and the installation against any accidental movement before starting any work!
4.1 Preparation
Check before mounting the power pack:

o Cleanliness and state of the mounting area
o Availability of correct power supply.
o Installation is secured
o Correct earthing
IMPORTANT!
The electrohydraulic power pack has a weight of over 39 / 42

Kg, depending on the type. Always use proper lifting devices
and attach the brake at the lifting ore.
The lifting ore is designed to hold the weight of the Buel G

unit. In case the Buel G unit is mounted to a brake unit, this
lifting ore must not be used to lift the complete unit-

BUEL® G
4.2 Mounting at brake unit
IMPORTANT!
Danger of injury from moving parts of the brake (e.g. when the brake sets).
Stay clear of the danger zone of the brake while the installation is running. It is the duty of the
operator to close off or enclose this area properly.
Mounting position:
 The BUEL® G-units are to be mounted in vertical position (tank 21.1
up).
 A deviation of +/- 10% is possible,
 Dismount mounting bracket (21) for easier mounting of the 21.1
power pack, if necessary.
 Mount power pack onto mounting base.
21
 Insert mounting bolts.
 Tighten mounting bolts with a torque wrench to nominal
torque.
 Tighten screws (21.1) at mounting bracket. (21).
4.3 Hydraulic connection
IMPORTANT!
Always heed the information and advices on the handling given in the safety data sheet of the
hydraulic medium.
IMPORTANT!
In case the power pack is used with SF-brakes, make sure the transportation safety bolts are
removed according to the manual, before the system is bled.
 The BUEL® G–unit is equipped with two hydraulic connections

(A) G ½“
 The hydraulic connections have to be fastened to nominal
torque. MA = 60 Nm
 In case more than one calliper pair is connected to the power
pack install T-connectors, if necessary. A A

BUEL® G
Fill up hydraulic system 13

 Slowly fill clean hydraulic fluid with a funnel into the filler plug
(13) to the top edge of the overfill-protection.
7
 Actuate shutoff-valve (13).
 Pump hydraulic fluid into brake cylinders using the hand pump
(10). 10
 Refill oil into the funnel, if necessary.
 When a continuous, bubble-free oil stream runs through the
transparent hose at the brake, pump the oil remaining in the
funnel into the tank to the top edge of the overfill-protection.
 Close plug (13).
IMPORTANT!
After finishing the setup and adjustment of the brakes, the fluid level of the system has to be
checked, while the brakes are set. Refill, if necessary.

BUEL® G
4.4 Electrical connection
DANGER!
The applied electrical voltages are dangerous to life!
Make sure the power supply is switched off and secured against switching on again.
The electrical connection and all other electrical tasks must only be done by a trained electrician!
NOTE!
If the unit is protected by a protective motor switch, insure that the thermal value which triggers
the switch is at least 1.5 times of the nominal lifting current (refer to type plate)!
IMPORTANT!
Connect a right handed field at the terminals L1, L2, L3
The phases must not be interchanged during the operation of the unit.
Terminal box
LEDs for the

surveillance
Terminal
Option
A, O, D / K
Terminals for
supply voltage

BUEL® G
 Unscrew cover (11.1) of terminal box (11).
11
11.1
 The cable glands (11.2) M25 on either sides of the terminal

box or the bottom side may be used for the connection to the
power supply.
 The possible diameter at the clamp for the supply cable is 9 –
17 mm.
 Keep terminal box (11) clean. 11.2 11.2
 Make sure that gasket is correctly positioned and intact.
 Lock terminal box securely, tighten cable entry and seal it if
necessary.
11.2
 Also check the wiring diagram inside the cover of the terminal
box.
 The BUEL® G-power packs are operated with a 3-phase

current voltage of 220 V - 690 V at 50 Hz or 60 Hz.
 The connection to the power supply is done at the terminals
L1, L2, L3 and PE inside the terminal box of the BUEL® G-
power pack.
 Connect according to wiring diagram on the previous page / on
the inside of the cover of the terminal box.
 The BUEL® G -power pack is switched on / off via the main
power supply.

BUEL® G
4.5 Electrical connection of sensors (Options N / T)
 The sensors are ready mounted.

o FK – Sensor Fluid level monitoring
o SK – Sensor Temperature monitoring
FK
 The sensors are to be connected acc. to the data sheets
included in this set of documentation.
TK
4.6 Final function check
WARNING!
The correct setting of the power pack is essential for a safe operation of the brake!
Make sure the brake settings are correct, especially after commencing a full running in procedure
Item
Function check
Release time correct
Tubing correct
Installation bled
Check for leakages
Fluid level correct
Signals correct (option)

Operation
BUEL® G
5 Operation
CAUTION!
Stay clear of the danger zone of the brake while the installation is running. It is the duty of the
operator to close off or enclose this area properly.
CAUTION!
Danger of burning due to hot oil and / or hot surfaces
Let the power pack cool down at least to room temperature before commencing any work on the
power pack.
5.1 Normal operation mode
o BUEL® G-power packs work in intermittent duty independent of the operation mode of the brake.
o In normal operation mode the following states are possible:
State of power pack State of brake

Power pack not energized Brake set
Power pack energized Brake opens and remains open
Power pack is being switched off Brake sets automatically
Power down or emergency stop Brake sets automatically
5.2 Emergency stop and power failure
 In case of a power failure or after the EMERGENCY-STOP has been activated, the supply voltage of
the BUEL® G-power pack is cut off by the installation.
 Due to the fail-safe principle, the BUEL® G-power pack is idle and the brake automatically closes via
spring force.
 A controlled opening of the brake is now only possible by means of the manual release device of the
brake.
 In case of a power down the brake also sets automatically.
 The pre-set setting times are still valid.

Operation
BUEL® G
5.3 Manual operation
The shutoff-valve is executed as self-resetting (dead mans-valve-function).Alternative options:

R – Locking (no dead-mans-valve-function.
M - Locking or non-locking, depending on the sense of rotation
 Attach extension lever (10.1) to hand pump lever (10).

 Always watch the load (2nd operator) so you do not miss the
10
point, where the brake releases.
 After finishing all tasks:
 Let go of shutoff-valve (7).
 Dismount extension lever (10.1) and store it properly. 7
10.1
Standard-version (Dead-mans valve)

 Turn shutoff-valve (7) clockwise until stop and hold it.
 Dead-mans valve-function 7
 If the shutoff-valve (7) is released, the brake automatically
closes.
 Operate hand pump (10) until the brake opens.
 The pressure may be released in a controlled way by slowly
releasing the shutoff-valve (7), so the brake sets slowly.
Option R: Manual operation w/o dead-mans-valve function

 Turn shutoff-valve (7) counter-clockwise until stop.
 Brake remains open, even if you let go of the shutoff-valve. 7
 No dead-mans valve-function
 Operate hand pump (10) until the brake opens.

 Let go of shutoff-valve (7).
 Dismount extension lever (10.1) and tore it properly.

Operation
BUEL® G
Option M - Locking or non-locking, depending on the sense of rotation
The Option M allows – depending on the application – to execute both of the functions described before.
The mode of operation can be chosen by turning the shutoff-valve in the corresponding direction.
The „neutral position“ is marked in terms of colour, respectively it is shown on the front of the shutoff
valve as shown below.
Locking-position Neutral position Self-resetting

 Turn shutoff-valve (7) back to neutral position.
 Dismount extension lever (10.1) and tore it properly.
5.4 Status-LEDs for operating conditions
o H1 –green LED
o H2 - yellow LED
o H3 –red LED
LED red, yellow, green off o Power pack idle
LED yellow on o Motor type relay on
LED yellow off: o Motor type relay off
LED green flashing o Normal operation
LED red flashing: o Motor switched off via timer

Maintenance
BUEL® G
6 Maintenance
DANGER!
Make sure the power supply is switched off and secured against switching on again.
The electrical connection and all other electrical tasks must only be done by a trained electrician!
WARNING!
CAUTION!
Danger of burning due to hot oil and / or hot surfaces
Let the power pack cool down at least to room temperature before commencing any work on the
power pack.
NOTE!
Also heed the corresponding sections of the operating instructions of the brake.
NOTE!
All maintenance tasks must only be executed by trained and designated personnel!
6.1 Maintenance schedule
 Being a closed hydraulic system the BUEL® G-power pack is a low maintenance system. Check the
power pack during the regular maintenance schedule of the brake.
 Contact the customer support service in case of a leakage.
 Please refer to the maintenance section of the operating manual of the brake.
Maintenance tasks Interval [operating hours]
Visual check for leakages During the regular maintenance schedule of the brake
Check for unusual noise emission During the regular maintenance schedule of the brake
Setting- and opening speed During the regular maintenance schedule of the brake
Check for corrosion During the regular maintenance schedule of the brake
Check correct earthing During the regular maintenance schedule of the brake
Replacement of hydraulic fluid 2 Million cycles / every 5 years

Maintenance
BUEL® G
Check the power pack / brake system outside the regular inspection intervals if:
o Prolonged braking times or -distances appear
o Extreme operating conditions appear:
o Overspeeding of the brake disc
o And/or excessive braking times
o A sensor indicates an incorrect stroke
o After a longer period of brake-standstill or drive standstill.
o An emergency stop occurred.
6.2 Lubrication
No lubrication or greasing is needed or allowed.
6.3 Cleaning
WARNING!
Danger due to chemical substances
Do not use corrosive or acidic agents to clean the brake. Only use fat-dissolving cleaners (e.g.
brake cleaner) and proper cleaning materials like cloth.
The cleaning must be carried out with proper tools and agents. Never use tools like high-pressure
cleaners or a wire brush.
WARNING!
The Installation has to be shut down during the cleaning process and has to be secured against
switching on again.
 Make sure the power pack is free from fat, oil, rust and other contaminations.
 Keep all movable parts clean
 The brake itself has to be kept clean as well.

Maintenance
BUEL® G
6.4 Oilchange
NOTE!
hydraulic medium.
NOTE!
Make sure the correct hydraulic fluid is used. Please refer to specification.
Different temperature ranges may require special hydraulic fluids. Please contact PINTSCH
BUBENZER!
WARNING!
Escaping hot oil may cause burns!
Before repair or refilling, let the unit cool down to room temperature!
Never open the power pack when it is hot!
WARNING!
Risk of environmental pollution

The BUEL® G-power packs are filled with synthetic high performance fluid Pentosin CHF 11S for a use in
the temperature range of -30°C to +60°C.
o Lifetime: 2 Million cycles / 5 years
o Depending on the installation about 5 litres of hydraulic fluid are necessary per unit.
Release oil 13
 Unscrew plug (13) G1/4 with 6 mm Allen-key.
 Fit a transparent hose to the conical part of the brakes bleeder
valve.
 Provide a proper container for the hydraulic fluid.
 Attach extension lever (10.1) to handpump (10).
 Actuate shutoff-valve and pump down hydraulic fluid.

Maintenance
BUEL® G
Refill brake system 13

 Pump hydraulic fluid into brake cylinders using the hand pump
(10). 7 10
 When the oil has reached the upper edge of the overfill
protection (upper arrow) the oil level of the tank is correct
(lower arrow).
 The overfill protection thus also helps ensuring the correct oil
level.
 Wipe away remaining oil at power pack, if necessary.
6.5 Replacement of switches and sensors (Option N / T)
NOTE!
o Please also refer to the data sheets of the sensors.
o These data sheets are part of the documentation package.
Fluid level sensor (Option N) FK.1

 Switch off power supply and secure against switching on.
 Disconnect sensor (FK.1)
 Pull of plug (FK.1).
 Unscrew sensor (FK) at hexagon (wrench size 32 mm).
 Screw in new sensor (FK). FK
 Tighten sensor (FK) with a torque wrench to the nominal
torque of 40 Nm.
 Connect new sensor (FK) electrically according to data sheet.
 Remount plug (FK.1).
 Screw on plug (FK.1).
 Check function.

Maintenance
BUEL® G
Temperature sensor (Option T)

 Switch off power supply and secure against switching on.
 Disconnect sensor (TK.1) TK.1
 Pull of plug (TK.1).
 Unscrew sensor (TK) at hexagon (wrench size 19 mm). TK
 Screw in new sensor (TK).
 Tighten sensor (TK) with a torque wrench to the nominal
torque of 35 Nm.
 Connect new sensor (TK) electrically according to data sheet.
 Remount plug (TK.1).
 Screw on plug (TK.1).
 Check function.
6.6 Refilling
NOTE!
hydraulic medium.
NOTE!
Make sure the correct hydraulic fluid is used. Please refer to specification.
Different temperature ranges may require special hydraulic fluids. Please contact PINTSCH
BUBENZER!
WARNING!
Escaping hot oil may cause burns!
Before repair or refilling, let the unit cool down to room temperature!
Never open the power pack when it is hot!
WARNING!
Risk of environmental pollution

The BUEL® G-power packs are filled with synthetic high performance fluid Pentosin CHF 11S for a use in
the temperature range of -30°C to +60°C.
o Lifetime: 2 Million cycles / 5 years
o In case the sensor fluid-level emits a signal, hydraulic fluid has to be refilled:
o Standard execution – about 0.25 l
o Version L – about 1.5 l

Maintenance
BUEL® G
Refill brake system 13

 Unscrew plug (13) G1/4 with 6 mm Allen-key.
 Pump hydraulic fluid into brake cylinders using the hand pump 7 10
(10).
 When the oil has reached the upper edge of the overfill
protection (upper arrow) the oil level of the tank is correct
(lower arrow).
 The overfill protection thus also helps ensuring the correct oil
level.
 Wipe away remaining oil at power pack, if necessary.

Troubleshooting
BUEL® G
7 Troubleshooting
NOTE!
Also refer to section 6.4.
Please also refer to the troubleshooting-list of the brake.
Problem: No hydraulic pressure

Possible reason Action Section
Motor runs with wrong direction Re-connect supply voltage correctly 4.4
Power supply malfunctioning Check supply voltage 4.4
Not enough hydraulic fluid Check filling level and refill, if necessary. 6.4
Check LED
Sensor malfunctioning 5.4 / -
Contact customer support
Coil damaged. Contact customer support
Problem: BUEL® G power pack does not set

Brake is mechanically blocked Check -
Supply voltage still switched on Check supply voltage 4.4
Problem: Setting time to long

Unit is soiled / blocked Clean Brake manual

Putting out of service and disposal
BUEL® G
8 Putting out of service and disposal
8.1 Putting out of service
DANGER!
The electrical connection and all other electrical tasks must only be done by a trained electrician.
WARNING!
WARNING!
Danger due to heavy loads!
Always lift the brake with a proper lifting device.
o The brake must only be put out of service and disposed by trained and qualified personnel.
o Always heed the applying laws and regulations!

BUEL® G
8.2 Dismounting of power pack
WARNING!
The Installation has to shut down during the cleaning process and has to be secured against
switching on again.
 Disconnect power supply (11).

 Please also refer to section 4.3.
 Dismount BUEL® G-unit.
 Please also refer to the manual of the brake.
11
 Unscrew hydraulic connection (A) at BUEL® G-unit
IMPORTANT!
The mounting situation may vary, depending on the mounting base, especially when it is not
provided by Pintsch Bubenzer. Please always heed the local conditions.
 Loosen screws (21.1) at mounting bracket (21).

 Dismount mounting bracket (21) for easier mounting of the
power pack, if necessary. 21.1
 Remove mounting bolts.
 Attach unit to lifting device at eyebolt. 21.1
21

BUEL® G
8.3 Disposal
WARNING!
Danger of pollution.
Take care that the hydraulic fluids, lubricants and other used substances as well as oil-soiled
parts are disposed environmental friendly and in compliance with the corresponding laws and
regulations!
Electronic scrap has to be disposed separately and recycled.
 Always heed the corresponding laws and regulations, when disposing the product and its
components.
 Always check which operating fluid is used in the power pack.
 Drain the tank acc. to section 7.4 and dispose of the oil according to the corresponding laws and
regulations.

Spare part list
BUEL® G
9 Spare part list
NOTE!
The use of spare parts, not meant for this power pack, can lead to a malfunction of the power
pack or damage the power pack!
Only use original PINTSCH BUBENZER spare parts!
NOTE!
In case of ordering, please indicate the type and the serial no. of the brake, which is located on
the type plate of the power pack!
Please note, that the brake has a separate type plate.
Pos. Nr. Item
1 Piston rod with joint head and cotter pin

1 Seal-kit for piston rod incl. protective rod
1000 ml Hydraulic fluid Pentosin CHF 11S
1 Sensor - Fluid level monitoring (Option N)
1 Sensor – Temperature monitoring (Option T)

Appendix
BUEL® G
10 Appendix
10.1 Data sheet

Appendix
BUEL® G
10.2 Tightening torques for regular threads
NOTE!
The following values apply, unless another torque is given at a specific point in the manual.
These tightening torques apply for:

compl. = 0.12 (black or bonderd, slightly oiled)
NOTE!
Used Nordlock-washers must not be used again!
Size Tightening Torques M A Wrench size [mm]
8.8 10.9 12.9

M4 3,0 4,6 5,1 7
M5 5,9 8,6 10,0 8
M6 10,1 14,9 17,4 10
M8 24,6 36,1 42,2 13
M10 48 71 83 17 (16)
M12 84 123 144 19 (18)
M14 133 195 229 22 (21)
M16 206 302 354 24
M18 295 421 492 27
M20 415 592 692 30
M22 567 807 945 32 (34)
M24 714 1017 1190 36
M27 1050 1496 1750 41
M30 1428 2033 2380 46
M36 2482 3535 4136 55

Appendix
BUEL® G
10.3 Customer support
Our customer service department is at your disposal should you require technical information on any of
PINTSCH BUBENZER GmbH's products and how to use these correctly. See below for the address and
telephone number.
Should you have any questions of this device, please contact our customer service department.
If you have any questions concerning the product or this manual, please contact PINTSCH BUBENZER
quoting the type and serial number of the product as given on the typeplate (also refer to section 1).This
allows us to supply you with the correct data and / or spare parts for your product.
Plant Kirchen
Germany
Tel.: +49 (0) 27 41/94 88-0

Fax: +49 (0) 27 41/94 88-44

Appendix
BUEL® G
10.4 Declaration of Incorporation

PB-BUEL-G-en5.docx PINTSCH BUBENZER GmbH
D-57548 Kirchen-Wehbach
Telefon +49 (0) 27 41/94 88-0
MADE IN GERMANY
EG-Einbauerklärung
EC Declaration of Incorporation
Hersteller:
Manufacturer:

Friedrichshüttenstraße 1
In der Gemeinschaft ansässige Person, die bevollmächtigt ist, die relevanten technischen Unterlagen zusammenzustellen:
Person residing within the Community authorized to compile the relevant technical documentation:
Richard Steinmeier
Friedrichshüttenstraße 1
Beschreibung und Identifizierung des Sicherheitsbauteils:

Description and Identification ofthe safety component:
Produkt/Producf: BUEL G
Typ/Type: 100-240
Funktion /Function: Bei dem obengenannten Produkt handelt es sich um einen elektrohydraulischen Druckerzeuger zur Betätigung
von hydraulischen Bremsen, welcher bestromt über eine Pumpe den erforderlichen Druck aufbaut und unbe-
stromt bzw. bei Ausfall der Energiequelle automatisch drucklos geschaltet wird.
Above mentioned product is an electrohydraulic pressure generator for the actuation ofhydrauiic brakes. When
energized, its pump builds up the needed pressure. When de-energized or in the event of a power failure, it is
depressurized automatically.
Es wird ausdrücklich erklärt, daß das obengenannte Sicherheitsbauteil allen einschlägigen Bedingungen der folgenden Richtli
nien entspricht:
We declare explicitly that the above mentioned safety component corresponds to all the relevant regulations of the following
directives:
2006/42/EG:2006-05-17 Richtlinie 2006/42/EG des europäischen Parlaments und Rates vom 17. Mai 2006 über Maschinen
und zur Änderung der Richtlinie 95/16/EG (Neufassung)
2006/42/EG:2007-03-16 Berichtigung der Richtlinie 2006/42/EG des Europäischen Parlaments und des Rates vom 17. Mai
2006 über Maschinen und zur Änderung der Richtlinie 95/16/EG
2006/42/EC:2006-05-17 Directive 2006/42/EC of the European Parliament and of the Council of 17 May 2006 on machin-
ery, and amending Directive 95/16/EC (recast)
2006/42/EC:2007-03-16 Corrigendum to Directive 2006/42/EC of the European Parliament and of the Council of 17 May
2006 on machinery, and amending Directive 95/16/EC
2014/30/EU:2014-02-26 Richtlinie 2014/30/EU des Europäischen Parlaments und Rates vom 26. Februar 2014 zur Har
monisierung der Rechtsvorschriften der Mitgliedstaaten über die elektromagnetische Verträglich
keit
Directive 2014/30/EU of the European Parliament and of the Council of 26 February 2014 on the
harmonization of the laws of the Member States relating to electromagnetic compatibility
2014/35/EU:2014-02-26 Richtlinie 2014/35/EU des Europäischen Parlaments und Rates vom 26. Februar 2014 zur Har
monisierung der Rechtsvorschriften der Mitgliedsstaaten über die Bereitstellung elektrischer Be
triebsmittel zur Verwendung innerhalb bestimmter Spannungsgrenzen auf dem Markt
Directive 2014/35/EU of the European Parliament and of the Council of 26 February 2014 on the
harmonization of the laws of the Member States relating to the making available on the market of
electrical equipment designed for use within certain voltage limits
Fundstelle der angewandten harmonisierten Normen:

Reference to the harmonized Standards used:
DIN EN ISO 12100:2011-03 Sicherheit von Maschinen - Allgemeine Gestaltungsleitsätze - Risikobeurteilung und Risikomin
derung
Safety of machinery - General principles for design - Risk assessment and risk reduction
Einbauhinweis:
Installation details:
Die BUEL G sind zum Einbau in hydraulische Bremsanlagen bestimmt. Ihre Inbetriebnahme darf erst dann erfolgen, wenn sicherge
stellt wurde, daß die gesamte Anlage, in der das BUEL G eingebaut wurde, den Bestimmungen der EG-Maschinenrichtlinie
2006/42/EG entspricht. Der Hersteller verpflichtet sich, die speziellen Unterlagen der unvollständigen Maschine einzelstaatlichen
Stellen auf begründetes Verlangen elektronisch zu übermitteln. Die speziellen Unterlagen gemäß Anhang VII, Teil B erstellt.
The „BUEL G" is intended for the Installation in hydraulic brake Systems. The commissioning of the "BUEL G" is prohibited until it has
been demonstrated that the whole System in which the "BUEL G" is incorporated complies with the EU Machinery Directive
2006/42/EG. The manufacturer undertakes to electronically transmit all specific documents ofthis incomplete machine to national
authorities upon a reasoned request.

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Standard-Documentation Power Pack BUEL G

Operation manual BUEL G PB-BUEL-G-en5

2018 PINTSCH BUBENZER GmbH

PINTSCH BUBENZER GmbH

3 Product description .................................................................................................... 13

4 Mounting of the power pack....................................................................................... 20

©2018 PINTSCH BUBENZER GmbH

5.1 Normal operation mode ............................................................................................................................... 26

8 Putting out of service and disposal ........................................................................... 36

9 Spare part list .............................................................................................................. 39

©2018 PINTSCH BUBENZER GmbH

©2018 PINTSCH BUBENZER GmbH

1.3 Guarantee and liability

©2018 PINTSCH BUBENZER GmbH

1.5 Presentation of hazard warnings

©2018 PINTSCH BUBENZER GmbH

Symbols of hazard warnings

Warning of a danger point

Warning of dangerous voltage

Warning of automatic start

Warning of cut and crush injuries

Warning of hot surfaces

Warning of environmental pollution

Warning of falling loads

©2018 PINTSCH BUBENZER GmbH

1.6 Notices and obligations of the plant operator

1.7 Personnel training

Assembly, commissioning, operating and upkeep/maintenance personnel must be adequately qualified

1.8 Protective Equipment

During all work on the product

©2018 PINTSCH BUBENZER GmbH

©2018 PINTSCH BUBENZER GmbH

2.2 Use in accordance with the intended purpose

2.3 Use not in accordance with the intended purpose

©2018 PINTSCH BUBENZER GmbH

2.4 Residual risks

2.5 Procedure in the event of Emergency STOP or power failure

©2018 PINTSCH BUBENZER GmbH

2.6 Safety notes for assembly, start-up and maintenance

©2018 PINTSCH BUBENZER GmbH

2.7 Notes on waste disposal

Due attention is to be paid to the environmental-friendly disposal of consumables, lubricants,

Electrical waste is to be collected separately and passed on for recycling.

©2018 PINTSCH BUBENZER GmbH

3.1 View of product

Pos. Item Pos. Item

©2018 PINTSCH BUBENZER GmbH

Pos. Item Pos. Item

©2018 PINTSCH BUBENZER GmbH

3.3 Technical data

©2018 PINTSCH BUBENZER GmbH

Pentosin CHF 11S

Type - Brake Nr. of cylinders / BUEL G Type BUEL® G

©2018 PINTSCH BUBENZER GmbH

3.4 Type plate

3.5 Power pack labelling

o The BUEL® G power pack is labelled as follows:

BUEL Max. pressure Options Operation voltage Frequency

©2018 PINTSCH BUBENZER GmbH

Index Available options

3.6 State of shipment

©2018 PINTSCH BUBENZER GmbH

3.7 Storage instructions

The electrohydraulic power pack has a weight of over 39