Manual No.

165-55850-2

INSTRUCTION, OPERATION AND

SERVICE MANUAL
FOR
MODEL 2025A BRAKE CONTROL
WITH BATTERY BACK-UP

EQUIPMENT FURNISHED
BY

National Oilwell Varco

500 INDUSTRIAL BLVD.
SUGAR LAND TEXAS 77478-2898
TELEPHONE: (281) 240-6111
FAX: (281) 274-0426

04/05
Rev. C
 TABLE OF CONTENTS

Paragraph Page
SECTION 1
INTRODUCTION AND DESCRIPTION

1.1 SCOPE OF MANUAL 1-1

1.2 GENERAL DESCRIPTION 1-1

SECTION 2
DESCRIPTION OF OPERATION

2.1 THEORY OF OPERATION 2-1

2.2 DRILL FLOOR COMPONENTS 2-1
2.2.1 Driller's Control (Drawing 55858) 2-1
2.2.2 Rig Floor Selector Switch (Drawing 55860) 2-2
2.3 SAFE AREA COMPONENTS 2-3
2.3.1 SCR Power Converter Model 2025A
(Drawing 55850-2) 2-3
2.3.2 Auxiliary Printed Circuit Board 2-7
2.3.3 System Block Diagram 2-11
2.3.4 Intrinsic Safety 2-13

SECTION 3
SPECIFICATIONS
3.1 GENERAL 3-1
3.2 INPUT POWER REQUIREMENTS 3-1
3.2.1 Brake Power Controller Input AC 3-1
3.3 INPUT SIGNAL REQUIREMENTS 3-1
3.4 BRAKE CONTROLLER OUTPUT POWER 3-1

i
TABLE OF CONTENTS (Cont'd) Page
Paragraph

SECTION 4
INSTALLATION
4.1 GENERAL 4-1
4.2 HAZARDOUS AREA COMPONENTS 4-1
4.2.1 Driller's Control (Drawing #55858) 4-1
4.2.2 Rig Floor Selector Switch (Drawing #55860) 4-2
4.3 SAFE AREA COMPONENTS 4-2
4.3.1 General 4-2
4.3.2 Power Transformers 4-3
4.4 INITIAL SYSTEM POWER-UP 4-3
4.4.1 Test Equipment Required 4-3
4.4.2 Installation Checkout 4-3
4.4.3 Functional Test 4-9
4.5 HAZARDOUS AREA CONSIDERATIONS AND APPROVALS 4-11
4.5.1 General 4-11
4.5.2 Driller’s Control (Drawing #55858) 4-11
4.5.3 Rig Floor Selector Switch (Drawing #55860) 4-12
4.6 APPROVALS 4-12

SECTION 5
OPERATING INSTRUCTIONS

5.1 SCR POWER CONVERTER 5-1

SECTION 6
MAINTENANCE
6.1 BRAKE AND CONTROL 6-1

ii
TABLE OF CONTENTS (Cont'd) Page
Paragraph

SECTION 7
PARTS AND SERVICE
7.1 GENERAL 7-1
7.2 PARTS AND SERVICE 7-1
7.3 RECOMMENDED SPARE PARTS 7-2
7.3.1 SCR Assembly – 25KW Model 55850-2 7-2
7.3.2 Miscellaneous 7-2

SECTION 8
DRAWINGS

iii
 SECTION 1
INTRODUCTION AND DESCRIPTION

1.1 SCOPE OF MANUAL

This manual provides information pertaining to the installation, operation and
maintenance of the following component parts of the Baylor Brake Control
System:

• SCR Power Controller

• Intrinsic Safety Barrier
• Hazardous Area Components

The manual is divided into sections giving a narrative description of the theory of
operation, function of controls, operating instructions, maintenance and service.
Also recommended spare parts and supplies are listed along with schematics,
block diagrams, and major assembly drawings.

Operators are requested to read and thoroughly familiarize themselves with this
manual before attempting to operate the equipment.

1.2 GENERAL DESCRIPTION

The Eddy Current Brake Control System (referred to in the balance of this
Manual as CONTROL SYSTEM), provides a variable DC voltage and current
input to an Eddy Current Brake. Braking control is accomplished through the
movement of a single driller’s control handle. The movement of this control
handle increases or decreases the level of the direct current excitation voltage
input to the field coils of the Eddy Current Brake. The system is designed to
operate any of the several BAYLOR Eddy Current Brakes, as well as other
systems having like voltage and current requirements.

1-1
 SECTION 2
DESCRIPTION OF OPERATION

2.1 THEORY OF OPERATION

The Baylor Brake Control System consist of a power conversion circuit and a circuit
that processes, shapes and compares the driller’s control handle position input and
the resulting current supplied to the Brake. Since the handle position is a function of
the amount of braking effort the driller desires, and the output current determines
the amount of Braking effort the Brake will supply, (within it’s rated torque
capability), the circuit continuously checks for any discrepancies in the Brake
Control System.

Due to the inductive nature of the eddy current brake, the rise time of brake current
as a result of an instantaneous change in driller’s input, may vary from
approximately 3 seconds to 6 seconds. This variance in output current rise time is a
function of the position of the Brake Control power selector switch. In the “DRILL”
position when in the Current mode, approximately one half of the maximum current
is supplied by the Brake Controller and in the “TRIP” position maximum current is
supplied by the Brake Controller. When in the Voltage mode and in the “DRILL”
position, approximately one half of the maximum voltage is supplied by the Brake
Controller and in the “TRIP” position, maximum voltage is supplied by the Brake
Controller. The electronic circuit automatically modifies scale factors internally to
match system operation when the power selector switch is in the “DRILL” position.
The circuitry provides an adjustable window comparator for determination of proper
brake controller operation.

2.2 DRILL FLOOR COMPONENTS

2.2.1 Driller's Control (Drawing 55858)
The Driller’s Control has been designed to give a maximum of trouble free
operation in the rugged drill floor environment. It consists of a spring loaded
handle which rotates a cam. These are the only moving parts in the Driller’s
Control assembly. A sensor (P/N 6575-95-0011) is positioned in the lower

2-1
2.2.1 Driller's Control (Drawing 55858) (Cont’d)
section of the assembly in such a manner that the cam surface is approximately
0.020” from the top surface of the sensors. As the cam is rotated, an increasing
air gap is created between the cam and the sensor top. The sensor is able to
measure this air gap change and convert it into an electrical analog. The
electrical analog is a linear DC voltage that is directly proportional to the handle
movement of the Driller’s Control and thus the amount of braking effort the Driller
requires. The sensor electrical signal is connected to the Brake Controller
through zener type barriers to establish intrinsic safety.

The handle is arranged in such a manner that the output voltage is at maximum
when the Driller’s Control is in the spring-returned “OFF” position. As the handle
is pulled on, the output voltage reduces. This is done in case of a sensor failure
or the Driller’s Control cable has be cut/disconnected, the brake controller’s
output will be full on going to the brake. The typical voltage levels are from
approximately -9.0 Vdc (“OFF” position) to 0.0 Vdc (“FULL ON”).

2.2.2 Rig Floor Selector Switch (Drawing 55860)

The Selector Switch divides the maximum braking capability into two ranges;
“DRILL” and “TRIP”. “DRILL” is 50 percent of braking capability. When in the
Current mode, it is 50 percent of the Brake’s maximum rated current. When in the
voltage mode, it is 50 percent of the Brake’s maximum rated voltage. This selector
switch is connected through a zener type barrier to establish an intrinsic safe circuit.

NOTE!

“TRIP” position provides more braking than “DRILL”

position.

2-2
2.3 SAFE AREA COMPONENTS
2.3.1 SCR Power Converter Model 2025A (Drawing 55850-2)
The SCR Power Converter is a three-phase, full wave silicon controlled rectifier
bridge. It requires a nominal 240 volt three-phase 50/60 Hz input from the
secondary of a delta connected transformer source. The transformer primary
voltage must be specified at the time of purchase to match the rig power source.
The power converter is an SCR Bridge that requires properly timed gating or firing
pulses. The firing pulses are generated in a firing circuit (P/N 55854).

The Firing Circuit is connected to the SCR Power Controller through multi-conductor
plugs and a terminal strip. These are listed as follows:
J1 - AC Current Input
J2 - DC Voltage Sensing
J3 - AC Voltage Sensing
J4 - External Metering and Reset
J5 - Activation of Throttle (2 Sets of Dry Contact)
J6 - Firing PCB General Alarm SCR (2 Sets of Dry Contact)
J101 - SCR Firing for A Phase SCR Module
J201 - SCR Firing for B Phase SCR Module
J301 - SCR Firing for C Phase SCR Module
J-10 - Auxiliary Board Interconnection (Ribbon Cable)
FTB1-1 - Common
FTB1-2 - 33% Power Selection - N/A
FTB1-3 - 67% Power Selection - N/A
FTB1-4 - Driller's Control Signal Input
FTB1-5 - 50% Power Selection (+15V drill, -15V trip)
FTB1-6 - Open
FTB1-7 - -15 Vdc
FTB1-8 - +15 Vdc
FTB1-9 - Open
FTB1-10 - +15 Vdc

2-3
2.3.1 SCR Power Converter Model 2025A (Drawing 55850-2) (Cont’d)
The Firing Circuit P.C. Board will come to the customer already set-up and
adjusted. A minor adjustment may be needed to match the Driller's Control
output with the Firing Circuit Board.
Perform the following set up instructions for the Firing Circuit P.C. Board:

1. Verify that all connectors are properly plugged in and TB1 fanning
strip is connected to FTB1.

2. Verify and/or set the following switches on the Firing Circuit PCB.
S1 - REV position.
S2 - to the LEFT (OFF).
NOTE: See Schematic (DWG. #56041) for full
explanation of this switch’s function.
S3 - VOLT position.
S5 - to the LEFT (OFF). Both switches for 315 Vdc max.
- to the RIGHT (ON) Both switches for 250 Vdc max
position. This switch is to match the information on the Eddy
Current Brake nameplate in the box indicated “Input Volts”.
S6 - to the LEFT (OFF). All three switches.
S7 - Select switch position based on Eddy Current Brake model.
The correct position for this switch is indicated on Drawing
56041, Sheet 5 of 6 in Section 8 of this manual.
S8 - Select switch position based on Eddy Current Brake model.
The correct position for this switch is indicated on Drawing
56041, Sheet 4 of 6 in Section 8 of this manual.

2-4
2.3.1 SCR Power Converter Model 2025 (Cont’d)
3. Adjust the “ZERO” and “SPAN” Potentiometer.
A. With the Driller’s Control in the OFF
position, adjust R6 for +0.45 Vdc at TP29
with respect to TP22 (GND).
B. With the Driller’s Control “FULL ON”, adjust
R5 for –8.00 Vdc +/-0.50 Vdc at TP29 with
respect to TP22 (GND).
4. Set up is now complete.

The 2025 SCR Power Converter operates in either “VOLTAGE” or “CURRENT

REGULATED” modes. The “VOLTAGE” mode allows the voltage to rise to the
commanded set point, based on the brake’s maximum rated voltage. Switch S5
selects the brake’s voltage to the brake’s maximum rated voltage. The
“CURRENT” mode allows the voltage to rise to as much as 310 Vdc to force the
current to the brake’s maximum rated current and then the voltage decays to a level
to maintain the commanded brake current.

The Voltage/Current modes of operation will, if unchecked, force current through a

Hot Brake, making it get even hotter and thus accelerate the breakdown of coil
insulation. This is checked by a Brake Coil KW limiting circuit (See schematic Dwg.
#56041 for proper setting). This circuit works to insure that the brake never
dissipates more energy than it's coils can handle. This may result in the brake
current being less than the full rated current. Also, operating at maximum rated Coil
KW for extended periods of time can cause excessive heating if the Brake Rotor is
turning less than 2 or 3 RPM’s. This happens when the Driller’s Control handle is
moved to “FULL ON” and left there for prolonged periods of time to assist in
drilling. There is additional circuitry which allows the Brake Control to operate in the
“DRILL ASSIST” mode. After approximately two minutes at full current command,
the maximum allowed power to the brake coils will be slowly reduced from 100% to
50% over a period of approximately 10 minutes. Note that 50% power to the Brake
still results in approximately 85% of full braking.

2-5
2.3.1 SCR Power Converter Model 2025A (Drawing 55850-2) (Cont’d)
Full Current command is restored by simply returning the Driller's Control handle to
the "OFF" position and then back "ON".

If a Brake Coil does fail and must be removed from the circuit until time permits a
repair or replacement, Switch S2 (Applies to only Brakes that have all of the coils
connected parallel, see Schematic Drawing 56041) allows for removal of one or two
coils. The remaining coils will be properly current limited and controlled. The Brake
should be overhauled as soon as possible if a coil has failed.
OFF ON
4 Coils (Normal) S2-1 [X] [ ]
Operational S2-2 [X] [ ]

3 Coils Only S2-1 [X] [ ]

Operational S2-2 [ ] [X]

2 Coils Only S2-1 [ ] [X]

Operational S2-2 [ ] [X]

NOTE!

“OFF” is toggle to the left.

2-6
2.3.1 SCR Power Converter Model 2025A (Drawing 55850-2)(Cont’d)
In summary, under normal conditions, the Control System would respond as
follows:
1. Driller's Control handle "FULL ON"
2. Input to the Firing Circuit PC Board Terminal FTB-1-1 to FTB-1-4 should be
approximately 0.5 Vdc at "FULL ON".
3. Gate pulses for power SCR’s expanded fully into firing zone giving maximum
output.

The circuit approaches linearity, and linear output readings can be expected. (i.e.
Driller's Control 50% "ON" and gate pulses expanded halfway into the firing zone
giving 50% output.)

2.3.2 Auxiliary Printed Circuit Board

The Auxiliary Printed Circuit Board attached to the door of the cabinet, provides two
functions. It provides circuits to monitor and alarm under certain conditions and
L.E.D.'s arranged in a mimic panel to show the status of various parts of the Brake
Controller. (Reference Figure 2-1). The monitored conditions are as follows:

The indicating L.E.D.'s will be Green in the Normal or Non-Alarm Condition and will
be Red in the Alarm Condition except as noted.

1. “PHASE ROTATION”
The 240V, 3 Phase AC has the proper phase rotation (ABC).

2. “DRILL/TRIP” Power Select Switch

The Drill Floor Power Selector Switch is in a reduced range position.
(L.E.D. is Yellow when in the “DRILL” position.)

2-7
2.3.2 Auxiliary Printed Circuit Board (Cont’d)
3. “DRILL ASSIST”
L.E.D. indicates the SCR Bridge has “TIMED OUT” and gone into the Drill
Assist mode of operation. (L.E.D. is Yellow when activated.)

4. “STANDBY CP” Normal

The 120V Single Phase AC Power provides backup power to the monitor
circuits but cannot provide DC power to the Brake.

5. “MAIN CP” Normal

The 240V, 3 Phase AC power is available. This power must be present in
order for the SCR Bridge to provide DC power to the Brake.

6. “POWER QUALITY”
The Input AC Power is satisfactory.

7. “THROTTLE SIGNAL MISMATCH”

The commanded current is below the acceptable window of acceptability.
This will turn the SCR to full “ON” and provide contact closure to activate
any backup brake supply.

8. “OVERCURRENT”
L.E.D. indicates current to the Brake is under or over the set limit.

9. “OVER KILOWATT”
L.E.D. indicates the Kilowatt output to the Brake is under or over the set
limit.

10. “SCR FAILURE”

The six (6) SCR’s in the Bridge are each monitored for proper gating
control.

2-8
2.3.2 Auxiliary Printed Circuit Board (Cont’d)
11. “DC CABLE GROUNDED”
L.E.D. indicates a ground condition on the (+) DC Power conductor.
L.E.D. indicates a ground condition on the (-) DC Power Conductor.

12. “AC PHASE GROUND”

One of the 3 phases of the AC input power is grounded.

13. “OPEN COIL FUSE”

L.E.D. indicates one or more of the fuses in F-1, F-2, F-3 and F-4 has
blown or is open.

14. “BATTERY BACKUP” (Optional)

Battery Backup is in use.

15. “BAR GRAPH DISPLAY”

Display of relative magnitude of commanded braking current.

16. “BAR GRAPH DISPLAY”

Display of relative magnitude of commanded braking current.

2-9
Figure 2-1 System Status and Mimic Display Panel

2-10
2.3.3 System Block Diagram
The System overall block diagram is shown in Figure 2-2. The control signal paths
are marked by arrows showing also the direction of information flow.

The Driller's Control command signal is the input to the firing board on TB1-4 with
respect to TB1-1 (Common). This will be a negative DC voltage. The signal is then
scaled to be +.0 Vdc to -7.5 Vdc representing a 0 to 80 Amps DC current command
with a 10% deadband at the start. With Switch S1 in the "REVERSE" position, the
voltage changes from Driller's Control "OFF" to "FULL ON", even though the
Driller’s Control commanded voltage will be declining from its maximum to its
minimum. The current command is then processed through the command reduction
circuitry, where the signal is reduced to 50% of its input value, if the Drill Floor
Power Selector is in the "DRILL” position. This "CURRENT COMMAND" is the
input to the current regulating loop.

The current feedback is sensed from the AC current transformers. The AC current
signals are then rectified and summed to create an analog signal that represents the
DC current flowing to the Brake. This signal is scaled 1 volt for 10 Amps of DC
current and is the feedback for the current regulating loop.

The output of the loop is called the “CONTROL VOLTAGE” and ranges from about
–4 Vdc to about +7 Vdc. This produces an output from the SCR Bridge that ranges
from –240 Vdc to +310 Volts. This range allows the current excitation to the brake
to be changed as rapidly as possible to follow the current command from the
Driller’s Control.

2-11
2-12
2.3.4 Intrinsic Safety
The Zener type barriers used with the Brake Control are energy limiting devices to
limit the available energy to a level that cannot ignite the hazardous atmospheres
likely to be present at the device being protected. Therefore the circuits on the drill
floor are classified as intrinsically safe.

Device spacing is used to ensure that protected wiring is segregated from non-
protected wiring and from protected wiring of different potential.

The panel layout and wiring is designed to comply with the recommended practices
set forth in the ISA RP 12.6 publication.

The assembly is designed to act as an interface between safe area equipment and
the equipment located in hazardous locations.

2-13
 SECTION 3
SPECIFICATIONS

3.1 GENERAL
The Brake Controller is designed to meet the special requirements of an offshore
drilling rig service. The material and workmanship will satisfy the service demands
of normal drilling operations. The System is rated for 50ºC maximum ambient
temperature in a NEMA Type 4 (IP42 rating) enclosure. All drill floor control circuits
are designed to satisfy the requirements of intrinsically safe classification as set
forth in ISA-RP 12.6 and NEPA 493.

3.2 INPUT POWER REQUIREMENTS

3.2.1 Brake Power Controller Input AC

Input AC Power required: (Reference TABLE 3-1.)
Note: See ABS Table 4/5.2 for proper cable sizing.

3.3 INPUT SIGNAL REQUIREMENTS

There is no external input signals required that are not generated by Sensors and
Transducers supplied with the Brake Control.

3.4 BRAKE CONTROLLER OUTPUT POWER

DC voltage to the Brake is adjustable to match Brake nameplate requirements.
(Reference TABLE 3-2.)

3-1
 TABLE 3-1
Supply Voltage, Circuit Breaker and Cable Size for Brakes

3-2
 BRAKE COILS COIL
BRAKE CURRENT
DC PER CONNECTIONS
MODEL PER COIL
VOLTS BRAKE PARALLEL SER/PAR SERIES
15050 325 4 30.2 #
9650 310 4 19.9 #
7838 250 4 18.5 #
8350 258 4 20.2 #
7040 250 4 19.5 #
6032 250 4 20.8 #
5250 310 4 24.6 #
5032 250 4 23.3 #
3550 254 4 24.6 #
19RD130 310 2 22.7 #
9RD130 155 1 22.7 #
7RD150 90 2 20.7 #

TABLE 3-2
DC Voltage and Current for Brakes

3-3
 SECTION 4
INSTALLATION

4.1 GENERAL
The 2025A Brake Controller System has two components mounted in the
hazardous area and a Brake Controller enclosure mounted in the safe area.

All initial installation and startup should be performed by a qualified technician.

All components mounted in the hazardous area are either designed for use in such
areas or protected by devices that render them intrinsically safe.

CAUTION!

Interconnecting cables must be of size and type to comply

with standards and practices in effect. Total cable inductance
and capacitance must not exceed values published by
certifying groups for intrinsic safety at voltages used.

4.2 HAZARDOUS AREA COMPONENTS

4.2.1 Driller's Control (Drawing #55858)

Install the Driller's Control so a downward movement of the handle advances the
control toward the “FULL ON” position. The return spring will bring the handle
back to the “OFF” position when the driller releases the handle. This arrangement
seems most natural to drillers since it gives the Control System the same direction
and sense as the drawworks mechanical friction brake lever.

The Rig Floor Selector Switch is designed to be mounted in sight of and easily
accessible by the Driller.

4-1
4.2.2 Rig Floor Selector Switch (Drawing #55860)
The enclosure is water-tight, and the device inside is rendered intrinsically safe by
means of a zener barrier in the circuit. The zener barrier is located in the Brake
Controller #55850-2 cabinet.

CAUTION!

Use caution while working on the Intrinsically Safe Circuits

since shorting the cables may destroy the Zener Barriers and
render the System inoperative.

4.3 SAFE AREA COMPONENTS

4.3.1 General
The Brake Controller Cabinet should be mounted in a space for ease of
maintenance and economy of cable runs.

The Controller can be mounted in any convenient non-hazardous location. Usual

practice is to mount the Controller System at the nearest convenient safe location
to the drill floor, since this minimizes cable inductance and capacitance
considerations in the intrinsically safe wiring, and may allow shorter runs for less
cable expense.

NOTE!

After completion of initial installation of the System, Proceed

to Section 6 of this manual and make measurements
required to establish a record for this Brake and Monitor
System.

4-2
4.3.2 Power Transformer
The Power Transformer provided is to be wired in a 3 phase delta-delta bank to feed
the SCR Brake Power Controller. Mount the transformer in any convenient location.
Once the installation is accomplished, frequent access to the transformer should not
be required.

4.4 INITIAL SYSTEM POWER-UP

After all system components are properly installed and all cables are connected
using wiring information supplied in this manual, proceed as follows to confirm that
all components and circuits are within acceptable tolerances. These tests are
intended as a basis for acceptance in terms of operational performance as
measured at selected test points.

4.4.1 Test Equipment Required

1. Digital Multimeter with: 0-300 Volt, 0-20 Volt and 0-1 Amp range
2. Ammeter: 0-100 Amp range
3. Ohmmeter or continuity meter
4. Oscilloscope
5. Two (2) Decade Resistance boxes

4.4.2 Installation Checkout

4.4.2.1 "No Power" Checks

For the Model 2025 control system, the following resistance measurements
should be made and recorded at the time of installation, without any power
applied to the unit. Use a VOM or digital meter for the measurements. (Not a
megger!)

4-3
4.4.2.1 "No Power" Checks (Cont’d)
Measuring Resistance Expected
Point to Ground Value

Transformer Pri A Phase __________ Inf.

Transformer Pri B Phase __________ Inf.

Transformer Pri C Phase __________ Inf.

Transformer Sec A Phase __________ 3.3K

Transformer Sec B Phase __________ 3.3K

Transformer Sec C Phase __________ 3.3K

Brake + DC leads __________ 500K

Brake - DC leads __________ 500K

Firing board TB1-4 __________ 30K

Firing board TB1-1 __________ 0 Ohms

4.4.2.2 "Powered" Checks (No current commanded)

Before energizing the control, check that the power supply jumpers on the firing
board are correct for the supplied voltage (240 Vac or 120 Vac). Upon
energizing the control, there should be some L.E.D.'s turned "ON" in the top
left corner of the firing board. If they are not, then turn "OFF" the control and
investigate power integrity. All measurements are made with respect to TP22,
electronics common, which should also be connected to ground. Proceed with
the following power checks as measured with a VOM or digital meter:

4-4
4.4.2.2 "Powered" Checks (No current commanded) (Cont’d)

POWERED STATIC MEASUREMENTS

Measuring Measured Expected
Point Value to TP22 Value

TP6 - Electronics +15 __________ +15±.15 Vdc

TP7 - Electronics -15 __________ -15±.15 Vdc

240 Vac A Phase __________ 135 Vac

240 Vac B Phase __________ 135 Vac

240 Vac C Phase __________ 135 Vac

TP2 (A Phase scaled) __________ 3.20 Vac

TP3 (B Phase scaled) __________ 3.20 Vac

TP4 (C Phase scaled) __________ 3.20 Vac

TP14 (Vin) __________ 9.50 Vdc

TP8 - Cb firing ramp __________ approx 5 Vac

TP9 - Bc firing ramp __________ approx 5 Vac

TP10 - Ba firing ramp __________ approx 5 Vac

TP11 - Ab firing ramp __________ approx 5 Vac

4-5
4.4.2.2 "Powered" Checks (No current commanded) (Cont’d)
TP12 - Ca firing ramp __________ approx 5 Vac

TP13 - Ac firing ramp __________ approx 4 Vac

Firing Board TB1-4 __________ approx -9 Vdc

4.4.2.3 "Powered" Checks - Current commanded

Make sure the controls are calibrated as indicated in Section 2.3.1 and then the
following checks can be made as the control is varied from full "OFF" to full
"ON". Please note these reading are based upon a nominal full output, and with
no power reduction ("TRIP" mode):

Measured Measured Expected

Point Variance Variance

Firing Board TB1-4 _____ to _____ -9.00 to -0.50 Vdc

TP1 - Current Command _____ to _____ +0.45 to -8.00 Vdc

TP29 - DC Signal _____ to _____ +0.45 to -8.00 Vdc

TP5 - Control Voltage _____ to _____ -5.00 to +5.00 Vdc

TP15 - A Phase Current _____ to _____ 0 to 2.50 Vac

TP16 - B Phase Current _____ to _____ 0 to 2.50 Vac

TP17 - C Phase Current _____ to _____ 0 to 2.50 Vac

TP21 - Current Feedback _____ to _____ 0 to 8.00 Vdc

4-6
4.4.2.3 "Powered" Checks - Current commanded (Cont’d)
TP24 - Vout _____ to _____ 0 to 7.5 Vdc

TP23 - Coil KW _____ to _____ 0 to 6.0 Vdc

4.4.2.4 "Auxiliary Board" Checkout

One of the main functions of the Auxiliary board is to monitor the circuit operation
of the rest of the controls.

4.4.2.4.1 Overall
If the Auxiliary Board is operating correctly, the L.E.D. side of the Auxiliary Board
will have all L.E.D.'s showing in Green. There are 2 L.E.D.’s that should not be
"ON" at this time. They are identified as No. 2 and 3 in Figure 2-1. They are
single color (Yellow) L.E.D.’s. They will turn "ON" as their function is activated.
If any of the bicolor L.E.D.'s (identified as being frosted Grey or White) are not
turned "ON" at all, the board is defective. Replace with the spare board.

4.4.2.4.2 Control Power

If either of the control power L.E.D.'s are Red, verify proper operation of the plus
and minus 15 volt power supplies. Make sure the fuse on the PC board is good.

4.4.2.4.3 Input Quality

If the input voltage drops too low or loses a phase this L.E.D. will turn from Green
to Red. If so, check TP14 - Vin for about 2.40 Vdc for an input of 240 Vac. An
excessive amount of AC ripple would indicate a possible phase loss. Determine
which by measuring TP's 2, 3, 4 looking for any irregularity.

4.4.2.4.4 AC Ground
If any of the input voltages are reduced as the result of a ground, the respective
L.E.D. turns from Green to Red. Measure test points 2, 3, 4 to make sure and
then measure the phase voltages A, B, and C to insure there is a ground. Then
turn off power and clear the ground. Note that disconnecting R1, R2, and R3

4-7
4.4.2.4.4 AC Ground (Cont’d)
from ground inside the 2040 SCR enclosure and disconnecting J3 from the firing
board should result in the input terminals being almost infinite resistance above
ground.

4.4.2.4.5 SCR Misfiring

This alarm works by comparing the current going through the individual SCR's to
the average carried by all of the SCR's. Once set, the alarm turns the L.E.D. from
Green to Red and stays that way until it again sees the proper level of current in
the SCR's.

4.4.2.4.6 Coil Fuse

This bicolor L.E.D. turns Red by unplugging J5 on the Auxiliary PCB.

4.4.2.4.7 Over Kilowatt

This L.E.D. turns Red by the sensing of the electronics of 125% of brake coil
allowed KW for a period exceeding a 20 second time interval. It is intended to
signal the failure of the overall control signal. Resetting can be done with the
door mounted or firing board mounted, reset switch. If the L.E.D. continually
turns RED, replace the firing board.

4.4.2.4.8 Overcurrent
This L.E.D. turns Red when the electronics senses a current level 150% that of
normal, for a period of about 25 milliseconds. Such will usually result if an SCR
shorts, a brake coil shorts, an input transient suppressor shorts, or two input
power phases are grounded inside the rectifier cubicle.

4.4.2.4.9 Throttle Mismatch

This L.E.D. turns Red when the electronics senses the brake control is putting
out less than one half the current it should be putting out at that moment. This
activates a relay that is used to enable the Battery Back Up unit, if one is
installed. It will in any event, activate the alarm relay.

4-8
4.4.2.4.10 Power Select and Drill Assist
Power Select L.E.D. will turn "ON", Yellow, when the brake control is in a
reduced "power selected" mode. When the driller selects "DRILL", this L.E.D.
will turn "ON". The Drill Assist L.E.D. will turn "ON" Yellow after a period of
approximately 2 minutes.

4.4.2.4.11 Battery Back Up

This L.E.D. will turn Red when J4 on the Auxiliary PCB is unplugged.

4.4.3 Functional Test

Turn on the main circuit breaker that supplies 240 Volts, 3 Phase AC to the SCR
Brake Control. Measure the power supply output at TP6 (Test Point 6) with
respect to common TP22. The voltage should be +15.00 (+/-0.15 Vdc).

Record reading TP6 Vdc

Place the Power Selector Switch on the "TRIP" position. Confirm that the Driller's
Control is working by measuring a varying voltage at FTB1-4 with respect to
FTB1-1. This voltage should vary from "OFF" equal to -9 (+/-1.0 Vdc) to -.50 (+/-
0.5 Vdc) at full "ON" with switch S1 in the "REVERSE" position.

Record: Control "OFF" Vdc

Control "FULL ON" Vdc

Change Switch S3 on the Firing Circuit Board to "VOLT". Slowly increase the
Driller's Control while measuring the DC output voltage at the input to the eddy
current brake. At maximum Driller's Control movement, the meter indication
should be 320 + 5 volts DC. Connect the oscilloscope at the same place and
view the rectified wave shapes of the DC output as the Driller's Control slowly
increased. The oscilloscope trace should be uniform and its level of magnitude
should change smoothly as the voltage increases. Measure the voltage at TP24
with respect to TP22. It should be proportional to the DC output voltage in the

4-9
4.4.3 Functional Test (Cont’d)
ratio of 1.0 Volt to 32.4 Volts. Measure the voltage at TP28 with respect to TP22.
It should remain at 0.0 + 0.2 Vdc as the output voltage goes from minimum to
maximum signifying there are no DC Cable or Brake Coil grounds. Check the
voltage at TP21 with respect to TP22. It is related to the DC current being
supplied to the Brake and is scaled as 1.0 Volt per 10.0 Amps DC.

Move the Drill Floor Power Selector Switch to the "DRILL" position and check
that the maximum Driller's Control input produces approximately 50% of the
current measured in the previous step.

"DRILL" Position Vdc Adc

"TRIP" Position Vdc Adc

With the Drill Floor Power Selector Switch in the "TRIP" position hold the Driller's
Control full "ON". After approximately 2 minutes the Yellow "DRILL ASSIST"
L.E.D. on the mimic panel will turn on and the DC voltage to the Brake will start
to ramp down.

After approximately 10 minutes the voltage will level off at approximately 50% of
the maximum or starting value. Releasing the Driller's Control handle will return it
to zero or the "OFF" position. This will reset the Ramp Circuit and the next time
the Control is moved to maximum the output will also go to maximum.

To check an "OVER KILOWATT" indication, you must simulate the condition by

temporarily connecting a decade resistance box, set to 250K ohms of resistance,
between TP30 and TP31 on the Firing Circuit Board. Slowly increase the current
using the Driller's Control and verify that the "OVER POWER" L.E.D. on the
Firing Circuit Board and "OVER KILOWATT" L.E.D. on the Mimic Panel turns
"ON" (Red). This simulates an abnormally high kilowatt requirement
(approximately 125% of normal). Disconnect the Decade Box and push the reset
button on the Firing Board. The "OVER KILOWATT" L.E.D. should reset to
Green.

4-10
4.4.3 Functional Test (Cont’d)
To check an "OVER CURRENT" limit condition, you must simulate the condition
by temporarily connecting a decade resistance box between TP21 and TP32
located on the Firing Circuit Board. Set the decade box to 20k ohms of
resistance. Slowly increase the Driller's Control. When the Firing Circuit "OVER
CURRENT" L.E.D. turns Red, the current limit (150% of normal current) has
been reached. Disconnect the Decade Resistance Box and push the reset
button on the Firing Circuit Board. The "OVER CURRENT" L.E.D. should reset
to Green.

The system should be in operating condition. A final check of the Mimic Panel to
see that all of the L.E.D.’s are Green will confirm that the system is operational.

4.5 HAZARDOUS AREA CONSIDERATIONS AND APPROVALS

4.5.1 General
Brake Control System components intended for installation in hazardous areas are
rendered intrinsically safe by virtue of being connected to the safe area portion of
the System through approved zener barriers which are physically located in the
Intrinsic Safety Barrier Assembly. Interconnecting cables must be of size and type
to comply with regulations, standards and practices in effect for the particular
installation. Total cable inductance and capacitance must not exceed values
published by certifying groups for intrinsic safety at voltages used.

Caution should be used while working on equipment, as shorting of interconnect

cables could destroy zener barrier devices and render portions of the system
inoperative.

4.5.2 Driller’s Control (Drawing #55858)

The Baylor Driller’s Control is rendered intrinsically safe by means of operating
through a zener type barrier installed in the SCR Assembly (Drawing #55850-2).

4-11
4.5.3 Rig Floor Selector Switch (Drawing #55860)
The Rig Floor Selector Switch is rendered intrinsically safe by means of operating
through a zener type barrier installed in the SCR Assembly (Drawing #55850-2).

4.6 APPROVALS
• Factory Mutual OV2HO.AX
• Underwriters Laboratories E152169
• Canadian Standards Association LR 77661-3
• PTB Certificate of Conformity NR.EX-83/2053X

(See the following pages)

4-12
 SECTION 5
OPERATING INSTRUCTIONS

5.1 SCR POWER CONVERTER

The Eddy Current Brake, controlled by this Control System, provides an actual
braking effect controlled as required, rather than a speed regulation which is limited
to a certain pre-selected degree of braking effect.

The Power Selector allows the operator to select the proper range of braking effect
for his drilling conditions. The Selector divides the Control System's maximum
braking capability into two ranges: "DRILL" and "TRIP".

The mechanical friction brake lever on most drawworks is located at the driller's
right hand. It is usually convenient for the driller to transfer his left hand from the
drum clutch controls to the eddy current brake control since these two controls are
normally operated alternately during tripping cycles.

The operator should have complete control, with his left hand, of the braking effect
from zero to fully applied, while his right hand is on the mechanical friction brake
lever.

As the Driller's Control is advanced toward "FULL ON", the voltage excitation to
the brake magnet coils increases toward a maximum. The Control System thus
provides the driller with controlled braking that is easily varied during any rotation of
the drawworks. By modulating the Driller's Control, the maximum safe controlled
speed of descent of each stand of pipe into the hole is assured.

5-1
5.1 SCR POWER CONVERTER (Cont’d)
In the "TRIP" position of the Selector Switch, a small variation of the Driller's
Control effects a large change in descent speed. This control effect is reduced in
the Drill Selector Switch position. For instance, with a light load on the drawworks,
operating in the “DRILL” Selector Switch position, gives the operator better speed
control.
For typical operation proceed as follows:
1. Select the desired Selector Switch position for the drawworks load
conditions.
2. Pick the pipe up off the slips and start the downward travel into the
hole with the Driller's Control left slightly "ON" until the load
accelerates.
3. Keep the rate of descent under control by moving the control handle
in the "FULL ON" direction to decrease pipe speed or if the descent
speed is too slow, by moving the control handle in the "OFF"
direction.

CAUTION!

Since the load conditions may vary the amount of braking

required, even during the downward travel of one stand of
pipe, it is normal for the driller to advance the control handle
toward “FULL ON” and return it towards “OFF” position
several times during the downward descent of a stand of drill
pipe to maintain a uniform safe speed of descent.

4. As the stand nears the end of its downward travel and the elevator
approaches the rotary table, advance the Driller's Control toward "FULL
ON" to decelerate the pipe. The mechanical brake is then used to hold
the load under complete control until the slips are set.

5-2
5.1 SCR POWER CONVERTER (Cont’d)
By keeping the load under control with the BAYLOR Eddy Current Brake
Control System, the driller is able to go into the hole with optimum safe
speed and with minimum wear of the mechanical friction brake system on
the drawworks.

5-3
 SECTION 6
MAINTENANCE
6.1 BRAKE AND CONTROL
The Control System should not require any maintenance other than a periodic
inspection for loose terminals or broken or damaged wires.

NOTE!

Any inspection or preventive maintenance other than

operational checks should be performed with power removed.

For the BAYLOR Brake Control System, one set of resistance measurements
(Table 6.1), and the following operational voltage checks should be made and
recorded at time of installation:

Power Input Phase A to B = (240 Vac)

Power Input Phase A to C = (240 Vac)

Power Input Phase B to C = (240 Vac)

Terminal TB10-1 to TB10-2 = (120 Vac)

With the Brake Power Selector Switch in each of the two positions and the Driller's
Control at "FULL ON", the DC voltage to the Brake should be recorded:

“DRILL” Positions: ___________ Vdc

“TRIP” Positions: ___________ Vdc
Max Driller’s Control input
(FTB1-4 to FTB1-1): ___________ Vdc

6-1
6.1 BRAKE AND CONTROL (Cont’d)
Because the output DC voltage is a function of the AC input voltage, some
variance will be noted for AC voltages other than 240 Vac.

The above listed measurements should be made on a periodic basis and at any
time abnormal Brake operation is suspected. Any difference in the measurements
will be clues to use in the trouble shooting of the Control System.

6-2
BRAKE MODEL NUMBER:
BRAKE SERIAL NUMBER: START DATE:________________
NOTE: Measurements should be made at the brake junction box with the coil leads disconnected
from the terminals.
DATE COIL RESISTANCE RESISTANCE TO GRD. COMMENTS
(OHMS) (MEG. OHM)

F1-F2 F3-F4 F5-F6 F7-F8 F1 F4 F5 F8

TABLE 6.1

6-3
 SECTION 7
PARTS AND SERVICE
7.1 GENERAL
The recommended spare parts and supplies for the Control System are provided
in the following tables.

7.2 PARTS AND SERVICE

Parts and service are available from the factory:

NATIONAL OILWELL VARCO

500 Industrial Blvd.
Sugar Land, Texas 77478-2898
Telephone: (281) 240-6111
Fax: (281) 274-0426

Factory Sales and Services personnel may also be directly contacted at the
following e-mail address:
Baylorsales-service@nov.com

Factory Engineering personnel may also be directly contacted at the following

e-mail address:
Baylorengr@nov.com

For a list of worldwide National Oilwell Varco locations and Service Centers go to
www.nov.com and click “Contact Us”

7-1
7.3 RECOMMENDED SPARE PARTS

7.3.1 SCR Assembly - 25 KW, Model 55850-2

QUANTITY PART NUMBER DESCRIPTION

1 55854
1 55856-2
3 6500-13-0003
3 55988
1 6425-05-0152
8 6525-25-0208
2 6525-25-0211
2 6525-25-0205
1 6425-06-0004
10 6375-10-0058
Firing Circuit P.C. Board
Auxiliary, P.C. Board
Semi Pak SCR Assembly
Dv/Dt Network Assembly
Relay, 2PDT, 1.0K ohm Coil
Fuse, 25 Amp
Fuse, 1/2 Amp (Firing Ckt. P.C.B.)
Fuse, 750ma Amp (Auxiliary P.C.B.)
Zener Barrier (CH)
Lamp, Pilot Light

7.3.2 Miscellaneous

QUANTITY PART NUMBER DESCRIPTION

1 6575-95-0011 Driller’s Control Sensor
1 6525-75-1052 Operator, 2 Position
1 6525-51-0002 Contact, Normally Close

7-2
 SECTION 8
DRAWINGS

Description Drawing Number

Outline and Mounting, 2025 Brake Control System ................................................ 56280

Assembly, 2025A Brake Control .......................................................................... 55850-2

Bill of Material .....................................................................................B/M 55850-2

Assembly, Panel, Inside Back SCR Mounting......................................................... 56018

Bill of Material ....................................................................................... B/M 56018

Assembly, Heatsink 2025........................................................................................ 56022

Bill of Material ........................................................................................ B/M 56022

Assembly, Panel, Right Side 2025A........................................................................ 56024

Bill of Material ........................................................................................ B/M 56024

Wiring Diagram ....................................................................................................... 56043

Cable Diagram, Brake Control ................................................................................ 55846

Interconnection System Diagram, 2025A ................................................................ 56353

Schematic, PCB SCR Firing 2025........................................................................... 56041

Schematic, PCB Firing Auxiliary........................................................................... 55856-2

Outline & Mounting, 55858 Driller’s Control ............................................................ 56165

8-1
DRAWINGS (Cont'd)
Description Drawing Number
Assembly, Model 55858 Driller’s Control................................................................. 55858
Bill of Material ........................................................................................ B/M 55858

Wiring Diagram, Driller’s Control ............................................................................. 55859

Outline & Mounting, Power Selector Switch ............................................................ 56483

Assembly, Rig Floor Selector Switch....................................................................... 55860

Bill of Material ........................................................................................ B/M 55860

8-2