Manual No.

165-31590-AT

INSTALLATION, OPERATION
AND MAINTENANCE
INSTRUCTIONS FOR
BAYLOR EDDY CURRENT
BRAKE, MODEL 6032

EQUIPMENT FURNISHED
BY

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

Rev. A
09/27/04
 SAFETY FIRST!
Before placing this equipment in operation, certain basic rules of safety should be observed. It should
be noted that no safety rules and no amount of safety equipment will make operating this equipment
safe, unless the operator enforces the rules and proper uses of the equipment.

MACHINE OPERATION:
1. Only responsible persons, trained to do so, should operate this equipment.
2. Any person operating this equipment should be thoroughly familiar with the manufacturer's
recommended operating instructions.

CLEANLINESS AND SERVICE

1. Periodic cleaning of the equipment may reveal potential mechanical trouble spots such as loose
or missing bolts, fittings, etc..
2. Keep the area around the equipment clear of loose tools, trash, extraneous matter, etc..
3. Shut the equipment down before servicing or cleaning unless the service work requires the
equipment be operating.
4. Allow only an experienced mechanic to service the equipment.
5. If a mechanical problem or deficiency is found, correct or report it before continuing operation.
6. Before working under or between components that are suspended by hoists or slings, securely
block or crib them.
7. When working in an area of potential head injury, wear an approved safety helmet.

LIFTING NOTE

MANY PARTS ARE HEAVY OR DIFFICULT TO HANDLE.

PLAN LIFTS AND MOVES CAREFULLY TO AVOID SEVERE
PERSONAL INJURY. PROVIDE SAFE SUPPORTS FOR
DISASSEMBLED PARTS.

i
 Table of Contents

Section 1 Introduction and Description

1.1 Scope of Manual .................................................................................................................. 1-1
1.2 General Description of Equipment ....................................................................................... 1-1

Section 2 Summery of Specification

2.1 Specifications....................................................................................................................... 2-1

Section 3 Installation
3.1 General ................................................................................................................................ 3-1
3.2 Brake Alignment .................................................................................................................. 3-6
3.3 Shaft Alignment ................................................................................................................... 3-6
3.4 Cooling Water Quality .......................................................................................................... 3-7
3.4.1 Scope ....................................................................................................................... 3-7
3.4.2 Water Quality Standards .......................................................................................... 3-7
3.4.3 Corrosion Inhibitor.................................................................................................... 3-7
3.4.4 Usage of Antifreeze Standards ................................................................................ 3-8
3.5 Cooling System Capacity Calculation .................................................................................. 3-8
3.6 Brake Field Coil Polarity..................................................................................................... 3-10
3.7 Certification for Hazardous Location.................................................................................. 3-14

Section 4 Theory of Operation

4.1 General ................................................................................................................................ 4-1
4.2 Brake Operation on Rig ....................................................................................................... 4-1
4.2.1 Drill Assist Operation................................................................................................ 4-2

Section 5 Accessories and Options

5.1 General ................................................................................................................................ 5-1
5.1.1 Brake Controller ....................................................................................................... 5-1
5.1.2 Special Brake Shafts................................................................................................ 5-1
5.1.3 Brake Cooling Packages.......................................................................................... 5-1
5.1.4 Cooling Water Alarm ................................................................................................ 5-1
5.1.5 Safety Monitoring Device ......................................................................................... 5-1
5.1.6 Parts and Service..................................................................................................... 5-2

ii
Section 6 Maintenance and Service
6.1 General ................................................................................................................................ 6-1
6.1.1 Lubrication................................................................................................................ 6-1
6.1.2 Breather ................................................................................................................... 6-1
6.1.3 Air Gap ..................................................................................................................... 6-1
6.1.4 Overflow Outlet ........................................................................................................ 6-2
6.1.5 Water Outlet Drain ................................................................................................... 6-2
6.1.6 Preparation of Brake for Storage ............................................................................. 6-3
6.1.7 Removing a Brake from Storage.............................................................................. 6-3
6.2 Maintenance and Repair...................................................................................................... 6-4
6.2.1 Water System Problems .......................................................................................... 6-4
6.2.2 Bearing Removal and Replacement ........................................................................ 6-4
6.3 Electrical Problems and Troubleshooting ............................................................................ 6-7
6.4 Mechanical Problems and Troubleshooting......................................................................... 6-8
6.5 Inspection and Maintenance Schedule ................................................................................ 6-9
6.5.1 Daily Inspection........................................................................................................ 6-9
6.5.2 Weekly Inspection .................................................................................................. 6-10
6.5.3 Monthly Inspection ................................................................................................. 6-10
6.5.4 Quarterly Inspection ............................................................................................... 6-11

Section 7 Parts and Supplies

7.1 General ................................................................................................................................ 7-1

Section 8 Drawing
8.1 Drawing List ......................................................................................................................... 8-1

iii
 Section 1
Introduction and Description

1.1 Scope of Manual

Any alteration or unauthorized repair work to
This manual provides a source of important
the brake or control system will VOID ANY
reference information regarding the installation,
WARRANTY expressed in the terms and
operation, and maintenance of the BAYLOR
Eddy Current Brakes and should be given conditions of sale and will void HAZARDOUS
careful consideration and study before AREA CERTIFICATION. All applicable
schematics, flow diagrams, and major
operating the BAYLOR brake. It is impossible
assembly drawings are contained in SECTION
to anticipate every kind of problem or condition
8 of this manual.
that may be encountered in the use of the
brake, but compliance with the instructions and
suggestions set forth in this operating manual
will assist the operator in successfully
operating this equipment. RISK OF EXPLOSION
Failure to operate and maintain the brake in Only National Oilwells Sugar Land location
accordance with this operating manual may may disassemble, repair, or modify the Eddy
void the warranty covering this equipment. The Current Brake.
information contained in this operating manual
shall not in any way relieve the operator of the
responsibility for exercising reasonable care Magnet Assemblies:
and prudence in the operation of this
equipment. If any other party tampers with these magnet
assemblies ALL HAZARDOUS AREA CERTS
WILL BE VOIDED and a serious risk of
explosion may be created.

WARNING!
1.2 General Description of Equipment
Failure to comply with the instructions in this The BAYLOR Eddy Current Brakes are
operating manual could result in serious auxiliary braking devices for the Drilling Rig
property damage, severe injury, or death! Drawworks. This braking is produced
entirely electrically without the aid of friction
brake devices, slip rings, or other wearing
elements. The brakes are water cooled.

1-1
 Section 2
Summary of Specifications
Model 6032 Eddy Current Brake

2.1 Specifications
Principal of Operation .............................................................................. Induced Eddy Current Braking
Torque-Maximum @ 250 RPM.........................................................................55,000 lb-ft (74,570 n-m)
Torque-@ 50 RPM ...........................................................................................45,000 lb-ft (61,012 n-m)
Number of Magnets ............................................................................................................................... 2
Number of Coils per Magnet.................................................................................................................. 2
Coil Internal Resistance @ 68 F (20 C) ...........................................................................5.9-6.3 Ohms

Total Brake Input Resistance @ 68 F (20 C).......................................................................6.02 Ohms

Brake Excitation:
Voltage....................................................................................................................... 250 Volts DC
Current-Coil Temperature @ 68 F (20 C) ........................................................... 41.53 Amps DC
Power Input @ 68 F (20 C) ........................................................................................... 10.38 kW

Cooling Water Requirements:

Flow @ 100 F (38 Deg. C) At Brake Inlet.......................................................... 75 gpm (284 lpm)
pH ........................................................................................................................................ 7.0-7.5
Maximum Discharge Temperature .......................................................................... 165 F (74 C)
Cooling Water Piping:
Inlet .................................................................................................................................(2) 2 NPT
Outlet ..............................................................................................................................(1) 4 NPT
Overflow.......................................................................................................................(2) 3/4 NPT
Overall Sizes:
Height .................................................................................................................. 60 in (1,524 mm)
Width....................................................................................................................... 32 in (813 mm)
Weight ..................................................................................................................... 12,130 lb (5,502 kg)
Inertia (WK2)-Shaft and Rotor................................................................11,681 lb-ft2 (4,922,387 kg-cm2)
Weight-Shaft and Rotor ............................................................................................. 3,304 lb (1,499 kg)
Shaft Size ................................................................ 7.500 inch Diameter with 1-1/4 inch Taper per foot
(191 mm Diameter with 32 mm Taper per 305 mm) Oilfield Standard
Average Rotor Radial Clearance (Air Gap)
Over Magnets (Without Paint or Other Buildup) ............................................................... 0.040-0.050 in
(1.016-1.27 mm)
Maximum RPM .................................................................................................................................. 600

2-1
2-2
 Section 3
Installation
3.1 General
The BAYLOR Brake should be cradle mounted
on the drawworks structure. The drawworks
manufacturer furnishes the adapter mounting
components as well as the disengaging
coupling between the brake and the drum shaft
of the drawworks. The necessary shifting
mechanism and related accessories should be
furnished by the customer.
CAUTION!
DO NOT USE AN OVERRUNNING TYPE
CLUTCH.
Heat removal from the rotor in the BAYLOR
Brake is accomplished by cooling water. The
movement of the rotor through the water is
necessary to keep the rotor and magnet from
overheating. To avoid damage to the brake, use
a coupling that allows rotation of the rotor in
either direction at all times.
A standard mounting flange on the outboard
bearing cap is provided by National Oilwell for
mounting water and/or air tube assemblies.
The required tube assemblies are furnished by
the drawworks manufacturer and should be
installed in accordance with their instructions.
Electrical control wiring and cooling system
water piping should be installed in accordance
with the drawings contained in this section. A
minimum of five-thread engagement should be
maintained on all threaded connections. Figure
3-1 illustrates a standard Brake cooling
configuration without a heat exchanger. Figure
3-2 illustrates a standard Brake cooling system
with a heat exchanger. A typical closed loop
cooling system which provides the greatest
and best degree of protection against corrosion
/ erosion with adequate flow and temperature
protection for the BAYLOR Brake. These
closed loop systems are manufactured to
provide proper cooling for the particular size
3-1
BAYLOR Brake and can also be capacity sized
to cool other portions of the drawworks drive
Figure 3-3 shows the electrical connections for
the magnet coils and power input to the
junction box.
CAUTION!
The water outlet(s) at the bottom of the brake should
not be hard piped or otherwise restricted. This should
be free-flowing, gravity drain. A funnel-type drain as
illustrated in Figure 3-4 is preferred. Do not plug, pipe,
or connect hoses to, otherwise obstruct the water
overflow outlets, located on the brake just below the
shaft centerline. These overflow outlets provide a
warning of improper water flow conditions.
Removal of heat from the Brake is most
important. Absence of proper cooling water
flow could damage the rotor. Proper cooling
water flow at all times will prolong Brake life for
many years.
As illustrated in Figure 3-4 the BAYLOR Eddy
Current Brake allows cooling water to flow over
the lower sections of the magnets and rotor
before it exits at the bottom. If the cooling
water outlets are restricted, the water level
inside the Brake will increase to a level which
could damage the Bearing grease seals and
permit water to enter the bearing cavity with
ultimate damage resulting to the bearing.
CAUTION!
The BAYLOR Eddy Current Brake is not designed to
operate with the cooling water internal of the brake at
other than atmospheric pressure. For proper brake
operation insure that brake cooling water flows
unrestricted through the brake with gravity discharge
and unrestricted flow back to the cooling water
reservoir.
 Section 3

Figure 3-1
3-2
 Section 3

Figure 3-2
3-3
 Section 3

Figure 3-3

3-4
 Section 3

Figure 3-4
Drain

3-5
 Section 3

3.2 Brake Alignment

The Brake should be aligned to the drum shaft
in keeping with good machinery practice and in
accordance with the recommendations of the
drawworks manufacturer.

NOTE: If the Brake is correctly aligned on the

drawworks, the only loading on the bearings is
the weight of the shaft and assembly since the
magnetic attraction when the brake is
energized is radially equal in all directions.
Improper alignment results in bearing wear and
premature failure.

3.3 Shaft Alignment

Angular misalignment and offset misalignment Figure 3-5
between directly-connected shafts often cause
increased bearing loads and vibration, even Angular Misalignment
when the connection is made by means of
flexible coupling. Shaft alignment is especially
critical if the coupling is to be operated at high
speed.
1. Angular Misalignment
Angular misalignment should not exceed 0.010
inch (0.0025mm) total indicator reading. Refer
to the illustration in Figure 3-5.
2. Offset Misalignment
Total indicator run out of offset misalignment
should not exceed 0.010 inch (0.0025mm).
Refer to the illustration in Figure 3-6.

NOTE: When conditions make it impossible to

check alignment with a dial indicator, a rough
check can be made with a straight edge and
feeler gages. Check angular misalignment by Figure 3-6
inserting feeler gages between the faces of the
coupling hubs at four equi-distant points. Offset Alignment
Check offset misalignment by placing a straight
edge across the machined diameter of both
coupling hubs.

3-6
 Section 3

3.4 Cooling Water Quality 6. A total hardness of 170 parts per

3.4.1 Scope
In order to function properly, the cooling
water used in BAYLOR Eddy Current
Brakes must meet four basic
requirements:
1. It must adequately transfer heat
energy from the rotor to the heat
exchanger used for cooling.
2. It must not form scale or sledge
deposits in the Brake or in the
cooling system.
3. It must not cause corrosion in the
Brake or cooling system.
4. It must not deteriorate any of the
seals or gaskets used in the Brake
or cooling systems.
These requirements are normally met by
combining a suitably demineralized water
with a reliable corrosion inhibitor. Under
extreme operating conditions it may be
necessary to use an antifreeze coolant.
In this case the cooling liquid should be a
mixture of the ethylene glycol type
antifreeze, de-mineralized water, and an
adequate corrosion inhibitor.
3.4.2 Water Quality Standards
The water used in BAYLOR Eddy Current
Brakes should meet the following
requirements:
1. No undissolved particles such as
sand, grit, or silt.
2. A ph level between 7.0 and 7.5.
3. A maximum dissolved chlorides
content of 40 parts per million.
4. A maximum dissolved sulfates
content of 100 parts per million.
5. A total dissolved solids content of
340 parts per million.
million. Water that does not meet
these standards should be treated
by softening, de-mineralization, or
de-ionization before being used to
cool the Brake.
3.4.3 Corrosion Inhibitor
National Oilwell does not recommend the
use of home made type inhibitors. The
ready availability of suitable commercial
products makes these home made
formulations impractical and
unnecessary. The use of soluble oil type
inhibitors is also not recommended due
to the effect they have on ethylene glycol
type antifreeze additives and the fact that
they are detrimental to efficient heat
transfer.
Commercially available corrosion
inhibitors are generally of three types;
chromate based, borate-nitrite based,
and silicate-nitrite based. Of these, the
chromate based and the borate nitrite
based are the most common. It is
important to note that there are
environmental restrictions on the disposal
of these types of inhibitors due to the
chromium and boron content. The
silicate-nitrate inhibitor is basically non-
polluting. Be sure and check with
national, state, and local authorities
before disposing of any water treated
with inhibitors. Be sure to follow the
manufacturers recommendations for
applying the inhibitor, both for new
untreated water and for maintenance of
already treated water.
Due to the successful use in BAYLOR
Eddy Current Brakes, the following
corrosion inhibitor is recommended for
use by National Oilwell:

3-7

NALCOOL 3000
Ondeo Nalco Company
3720 W. Alabama St. #5318
Houston, TX 77027
It is recommended that this inhibitor be
purchased through a local distributor so
that proper field support in its use is
readily available.
NOTE!
If a glycol anti-freeze is used, then
NALCOOL 3000 is recommended due to
possible interaction with the glycol, causing
sludge.
3.4.4 NALCOOL Inhibitor Startup,
Maintenance, and Testing
Standards
Water Quality Standards with
NALCOOL:
1. Insure water quality meets
the water quality standards
in Section 3.4.2.
2. Coolant has a PH level of
8.3 after corrosion inhibitor
is added. (Coolant solution
turns pink).
3. Recommended Nitride level
of 1500 parts per million.
(Add more NALCOOL at
1200 parts per million).
Startup of NALCOOL with fresh
water:
1. Insure water quality meets
the water quality standards
in Section 3.42.
2. Add a 4-1/2% concentration
of NALCOOL.
(Approximately 28 gallons
for a 630 gallon tank or 67
gallons for a 1500 gallon).
3-8
Section 3
Testing:
Coolant Testing should be done
weekly for PH and Nitride levels.
PH and Nitride test kits can be
purchased from National Oilwell in
Sugar Land, Texas or from Nalco
directly.
WARNING!
IF THERE IS A RAPID NITRIDE LOSS
OVER TIME, THEN A BACTERIA IS
SUSPECTED TO BE PRESENT. TO GET
A BACTERIA TEST KIT OR OTHER
PRODUCTS, PLEASE CONTACT NALCO.
3.4.5 Usage of Antifreeze Standards
Only ethylene glycol type antifreezes are
to be used in BAYLOR Eddy Current
Brakes due to the operating temperature
generated.
NOTE: Chromate type rust inhibitors are
not to be used with ethylene glycol
antifreezes. The resulting mixture forms a
sludge. It is recommended that the Brake
cooling fluid not exceed 50%
ethylene glycol. Levels of ethylene glycol
higher than this will lower the freezing
point of the Brake cooling fluid, but will
not provide adequate heat transfer.
If the antifreeze contains corrosion
inhibitors, it is not recommended to add
additional inhibitors to the original mixture
or for maintenance of a used mixture.
This practice can actually cause corrosion
of the Brake. If the corrosion inhibitors in
this type of solution are no longer
effective, the entire content of the cooling
system should be replaced by a fresh
mixture.
 Section 3

National Oilwell does not recommend the

use of antifreezes containing anti-leak
compounds. These compounds can
cause plugging of water passages and
reduction in effective heat transfer rates,
resulting in a Brake that fails from
overheating. Be sure to dispose of used
antifreeze mixtures according to the
manufacturers recommendations and the
applicable environmental authorities
recommendation.

3.5 Cooling System Capacity Calculation

HEAT PRODUCED = BTU/MINUTE =
T X RPM X 42.4
5250
Where T = Torque in FT.-LBS

This may be used directly to size a radiator or

other type of heat exchanger. When the Brake
is not producing torque continuously the heat
produced must be multiplied by the duty cycle.
For example, normal tripping in requires that
the Brake produce torque only one-third of the
time. Therefore the calculated BTU/min would
be multiplied by 1/3.

For a tank or reservoir type cooling system the

storage capacity is calculated by:

LBS of water = BTU/min X t

Temp
Where t = Time in minutes of operation

Temp = 165 Degrees F - Temperature of water

entering Reservoir.
Gallons of water = LBS. of water
8.34

If inlet temperature of cooling water to the

Brake is much higher than 100 Degrees F, note
that the flow required goes up drastically to
cool the Brake, as illustrated in Figure 3-7.

3-9
 Section 3

Eddy Current Brake Coolant Flow

Required to Maintain Outlet Temp of 165 F (74C)

1514 l/mm

1135 l/mm
Required Flow Rate

757 l/mm

379 l/mm

4C 16C 27C 38C 49C 60C 71C

Inlet Temperature (F)

Curve Curve Curve Curve Curve Curve Curve

No. 1 No. 2 No. 3 No. 4 No. 5 No. 6 No. 7
Model Model Model Model Model Model Model
15050 7838 / 9650 19RD130 7040 / 8350 6032 / 5250 5032 / 3550 7RD150
EC Brake EC Brake EC Brake* EC Brake EC Brake EC Brake EC Brake*
Note:
BASED ON MAX TORQUE @ AVG SPD 250 RPM OUTLET TEMP OF 165F (74C)
. ONE-THIRD DUTY CYCLE

* Models 19RD130 & 7RD150 calculations based on average speed of 1000 R.P.M.

Curves are extended only to maximum flow rate capability of the specific brake model water
housing. If higher flow rates are required, contact National Oilwell with specific coolant
requirements.

Figure 3-7

3 - 10
 Section 3

3.6 Brake Field Coil Polarity of time for second joint of drill pipe to pass
through rotary table. Compare the results of
Correct field coil polarity is extremely important
these two tests. If polarity was correct initially,
in obtaining maximum torque from the BAYLOR
then drill pipe would have taken longer to enter
Eddy Current Brake. There are a number of
bore hole during first test. On the basis of these
methods for determining correct field coil
two tests, chose correct junction box coil lead
polarity. None of these methods are totally
connection for correct polarity.
accurate, however, if the following instructions
are closely followed, good results may be
2. Second method of determining correct
obtained. The best method is utilized by
Brake coil polarity. Procedure is as
National Oilwell during coil manufacture. During
follows:
the coil winding process, the starting of the
a. Turn off electrical supply to Baylor Brake.
winding and the ending are tagged. At Brake
Lock out circuit breakers to insure safe
final assembly knowing the start and finish of
conditions while performing work in and
each coil permits accurate determination of
around Brake and Control System.
how to tag each coil lead to insure proper
Remove Brake junction box cover. Make
Brake polarity. It is very important to maintain
record of location of each coil lead on
the coil lead tags during any period of
terminal block in Brake junction box.
maintenance or parts replacement in the field to
Disconnect all coil leads from Brake
insure proper polarity after all work has been
junction box terminal strip.
accomplished.
b. Check resistance of inboard field coil of
inboard magnet as illustrated in Figure 3-
In the field, the following tests may be
14. Set multimeter to lowest resistance
performed to determine correct Brake polarity:
scale (200 ohms or less) and correct
meter leads to F5 and F6. Reading
1. If Brake polarity is not correct, the Brake
should approximately agree with those
will appear weak and not as responsive to
listed in Figure 3-15. If meter readings are
actuation of the Drillers Control. To
lower by 30% or more, a coil problem
obtain a reference point as to the Brakes
may exist. Troubleshoot coil problem
holding capacity, raise the traveling block
before proceeding to next step.
into the derrick so that three joints of drill
pipe are visible. Turn the Brake Drillers
Control full on and allow about 5 OUTBOARD MAGNET INBOARD MAGNET

seconds for full saturation of the Brake

magnetic circuit. Then with the Eddy
Current Brake fully energized, release
drawworks friction brake and allow pipe to
descend into the bore hole. As the
second joint of drill pipe starts through the
rotary table, time the interval of time it
requires for this second joint to progress F1 F8
into the bore hole. F2
F3
F7
F6
F4 F5
Next, turn off electrical supply to BAYLOR
Brake. Lock out circuit breakers to insure safe Figure 3-14
conditions while performing work in and around View of Brake from Junction Box Side
Brake and Control System. Remove cover of
Brake Junction Box. Mark present position of c. Remove meter leads from coil leads F5
coil leads F7 and F8. Reverse the position of and F6. Reconnect coil lead F5 to positive
these two coil leads, that is, disconnect F7 and (+) lead of Control DC in Brake junction
F8,then reconnect F7 where F8 was connected box terminal strip. Reconnect F6 to
and F8 where F7 was connected. Turn negative (-) lead of Control DC in Brake
electrical power on and re-test by timing length junction box terminal strip.

3 - 11
 Section 3

d. Observing meter lead polarity, connect For the following Brake Models, move the
meter leads to a pair of Field Coil Leads handle half way through its total travel:
as indicated in Table I.
3630 3550
Brake Model Coil Internal Resistance 5032 5250
at 68F (20C) 6032 19RD130
15050 10.8 OHMS TO 11.2 OHMS
For the following Brake Models, move the
*7838 13.4 OHMS TO 13.9 OHMS handle full on position:
9650 15.5 OHMS TO 16.4 OHMS
7040 15050
7040 13.0 OHMS TO 13.5 OHMS
8350 7RD150
8350 13.0 OHMS TO 13.5 OHMS
7838 9RD130
6032 5.9 OHMS TO 6.3 OHMS
5250 6.1 OHMS TO 6.5 OHMS 9650
5032 5.1 OHMS TO 5.4 OHMS NOTE: Those brakes requiring only half on
3550 4.9 OHMS TO 5.2 OHMS position of drillers control have coils which are
3630 4.8 OHMS TO 5.2 OHMS connected series-parallel and therefore require
only half value of applied control voltage for full
19RD130 6.7 OHMS TO 7.1 OHMS saturation. Reference drawing D56772, sheets
9RD130 6.7 OHMS TO 7.1 OHMS 1 and 2.
7RD150 4.4 OHMS TO 4.8 OHMS
g. Observe positive meter deflection. If in
*NOTE: For Model 7838 brakes manufactured
agreement with Table I, move Drillers
prior to July 1985, coil resistance will
Control handle to off position. Turn off
be 11.0-11.5 ohms.
AC power to Brake Control System, lock
out circuit breakers. Remove meter leads
FIGURE 3-15 and move to next pair of Field Coil Leads.
If not in agreement, with Table I, move
e. Set meter scale as indicated in Table I for Drillers Control handle to off position.
specific Field Coil Leads selected. Turn off AC power to Brake Control
System, lock out circuit breakers. Swap
Table I Field Coil identification tags on Field Coil
being measured, and connect meter
Field Coil leads to another pair of Field Coil Leads
F1 - F2 F3 - F4 F7 - F8
Leads for polarity test per Table I.
Meter Lead F1 - F2 F3 - F4 F7 - F8
Polarity + - + - + - h. Repeat steps d, e, f, and g until all Field
Meter Scale 1 10 1 10 1 50 Coil Leads have been tested and are in
VDC VDC VDC agreement with Table I.
Meter Positive Positive Positive
Deflection i. Turn off AC power to Brake Control
System and lock out circuit breakers.
f. Insure that disconnected coil leads not Reconnect Field Coil Leads to junction
being tested are not in contact with each box terminal strip per drawing D56772,
other or surrounding surfaces. Unlock Sheets 1 and 2.
circuit breakers for Brake Control and
energize the Control circuit. Move the
Drillers Control handle to a position as
indicated below:

3 - 12
 Section 3

3 - 13
 Section 3

3 - 14
 Section 3

3.7 ATEX Directive 94/9/EC Compliance Information

The EC Type Examination Certificate for the Eddy Current Brake to the ATEX Directive 94/9/EC
included in the following section as well as the Examination Certificates for all ATEX approved
components on the brake. When certificates are not yet available from Notified Bodies, Declarations
of Conformity have been provided indicating the certification number.
The following Certificates are included:

National Oilwell Declaration of Conformity to Directive 94/9/EC

Certificate not available at time of publication. This certificate will be provided separately.

Adalet Model XCEX Junction Box Certificate # DEMKO 01 ATEX 0129472U

Stahl Conduit Union Model BFF Certificate # CESI 99 ATEX 034U

Stahl Declaration for Conformity to Directive 94/9/EC for Conduit Open Elbow model LBH

Stahl Declaration for Conformity to Directive 94/9/EC for Conduit Seal model EYS

Reference D43428 as depicted in Figure 3-1 in Section 3 of this manual.

3 - 15
 Section 3

3 - 16
 Section 3

3 - 17
 Section 3

3 - 18
 Section 3

3 - 19
 Section 3

3 - 20
 Section 3

3 - 21
 Section 3

3 - 22
 Section 3

3 - 23
 Section 3

3 - 24
 Section 3

3 - 25
 Section 3

3 - 26
 Section 3

3 - 27
 Section 3

3 - 28
 Section 3

3 - 29
 Section 4
Theory of Operation
4.1 General
When the steel rotor rotates through the
stationary magnetic field, currents are induced
in the rotor. These currents, commonly called
eddy currents, produce a magnetic field
which interacts with the stationary field. This
field interaction produces a force, which
opposes rotor rotation, and provides the
braking torque for the BAYLOR Brake.
The Eddy Current Brake provides high braking
torque at low rotor speeds. This is a distinct
advantage over other types of braking systems
such as the water brake. The braking torque of
the Eddy Current Brake is dependent on the
strength of the stationary magnetic field, rotor
speed, and rotor temperature. Torque
increases with magnetic field strength and with
rotor speed. Torque decreases as rotor
temperature rises and the rotor expands which
widens the air gap. The strength of the
stationary magnetic field is controlled by the
field coil in proportion to the braking
requirements.
The eddy currents induced in the rotor produce
heat. This rotor heat must be kept within
acceptable limits or braking torque will be
reduced. To maintain rotor temperature within
acceptable limits, a cooling system is required.
A steady flow of water is directed into the area
containing the rotor, as illustrated in Figure 3-4.
The movement of the rotor through this water
as it turns provides uniform cooling of the rotor
surface. If the flow of cooling water fails while
the brake is in operation the rotor will become
overheated. In this state the rotor will be
damaged if a safe cooling procedure is not
followed. Consult Section 6 of this manual for
the proper procedure to use.
4.2 Brake Operation on Rig
When a BAYLOR Eddy Current Brake is
installed on a rig its response may vary
depending upon the following items:
4-1
Brake torque capacities may vary + or
5% between individual units.
When the brake becomes overheated it
will lose some of its torque capacity.
Normal reaction time for the brake to
reach maximum braking torque is
approximately 2 seconds. This may vary
depending upon the Brake Control
System employed.
Normal reaction time for the brake to
decay to zero braking torque is
approximately 1-2 seconds. This may
vary depending upon the Brake Control
System employed.
As the brake ages, the air gap between
the rotor and the magnets may increase
due to rust or erosion which will cause a
decrease in brake output torque.
With all these factors in mind, the operator
must learn and get a feel for the brake
response time during the early stages of
tripping when the loads are lighter.
When the load exceeds the brake capacity
note that the brake will not be able to control or
properly decelerate the load.
Proper operation of the brake is to apply the
Eddy Current Brake before releasing the main
drawworks friction brake when tripping into the
bore hole.
CAUTION!
When the brake is being used close to its
Maximum torque capacity, apply the Eddy
Current Brake before releasing the main
drawworks friction brake when tripping into
the bore hole.

4.2.1 Drill Assist Operation
If the brake is used for drill assist where
the rotor speed is very limited, it is
recommended that no more than half of
full rated DC voltage be applied to the
field coils continuously. The brakes
primary purpose as an auxiliary brake is
to dissipate the energy of drill pipe or
casing being lowered into the bore hole.
For this specific purpose, the field coils
are designed to accommodate a duty
cycle of full DC voltage on time of 20
seconds out of every 60 seconds. To
increase the duty cycle to 100%, or an
on time of 60 seconds out of 60
seconds will create excessive heat
buildup within the individual conductors of
the field coils. As the electrical insulation
system of the field coil has excellent
dielectric characteristics, it also is an
excellent thermal insulator. The heat
produced internal of the field coil due to
the DC current passing through each
conductor will continue to rise until, within
a short period of time, the insulation
system will de-grade and turn-to-turn
shorting will occur with ultimate failure of
the field coil. It is also interesting to note
that the torque curves for BAYLOR Eddy
Current Brakes all have a similar
characteristic. The torque produced at
very low drum shaft speeds (0-20 r.p.m.)
is approximately the same for various
excitation values. In other words, the
brake torque produced at 15 r.p.m. is
about the same, at full applied excitation,
as the torque with 33% applied excitation.
Therefore, the brake, utilized for drill
assist, will perform at the low speed
drum requirements of feed off at 1/3 of
excitation as well as performance at full
excitation. This can reduce the excitation
to the larger capacity brakes from 21 kW
to 7 kW with the obvious fuel savings and
reduction of thermal load of field coils.
4-2
Section 4
Operation of the brake at very low
speeds during drill assist, with full
excitation, will also contribute to
excessive wear to the I.D. of the rotor
and the O.D. of the magnets. At very low
rotor speeds, with full excitation to the
field coils, the magnetic attraction
between magnets and rotor is greater
than the collapse strength of the rotor
material. Pull over will occur where the
outer circumference of the rotor drum will
pull down and contact the O.D. of the
magnet. The resultant contact, at slow
speed, will gall and gouge the surfaces of
rotor and magnets. This mechanical
contact will increase the air gap between
the rotor I.D. and the magnet O.D. such
that maximum torque of the brake will be
reduced.
In conclusion, to utilize the BAYLOR
Eddy Current Brake in the drill assist
mode requires specific attention to how
much excitation is applied to the field
coils. Continuous operation at full
excitation can significantly shorten the life
of the field coils and increase the air gap
dimension such that reduced torque
output will result.
NOTE
National Oilwell manufactures several
different types of Control Systems for use
with the BAYLOR Eddy Current Brakes.
Each Control System design incorporates a
different method of supplying reduced
voltage to the brake during drill assist
operations. Consult your Brake Control
System Manual to determine the proper
operational technique for drill assist
conditions.
 Section 5
Accessories and Options

5.1 General
5.1.3 Brake Cooling Packages
In striving to satisfy the needs of all customers,
Each Eddy Current Brake needs a
National Oilwell offers the following
cooling system to remove the heat from
accessories and options.
the brake while the brake is being used.
5.1.1 Brake Controller National Oilwell builds brake water
cooling systems to meet a variety of
Each Eddy Current Brake requires a
operational and regulatory requirements.
brake controller which supplies voltage to
In addition to cooling water for the
the field coils. The brake controller is a
BAYLOR Eddy Current Brake, extra
variable DC voltage power supply which
capacity can be designed into the system
controls the amount of excitation
for the main drawworks friction brake, top
delivered to the brake field coils as a
drives, electric drive motors, and other rig
function of the position of a drillers
cooling requirements.
control lever. A complete controller
system consists of an isolated power 5.1.4 Cooling Water Alarm
transformer, a power control unit, and a
A cooling water alarm system is available
drillers control.
to monitor flow and temperature of the
5.1.2 Special Brake Shafts coolant to the brake. This system warns
the operator whenever cooling to the
Certain applications may require an
brake has been impaired. It can prevent
optional special shaft on the brake.
the need for expensive repairs.
Double-ended shafts and special
coupling features have been 5.1.5 Safety Monitoring Device
manufactured in the past. If the brake is
A safety monitor system manufactured by
required to operate in highly regulated
National Oilwell which signals the
areas such as the North Sea, then
potentially dangerous loss of control of
special shafts may be required to
brake excitation is available for BAYLOR
conform to low temperature
Brakes.
requirements. One of these may fit your
needs; if not, a new special can be
designed to your specifications.

If there is a need for further information about any of the aforementioned items,
or if you have other special requirements, please contact National Oilwell Sales
Department or Service Department.
Telephone Number in the U.S.A. ....................................................(281) 240-6111
Fax Number: ...................................................................................(281) 274-0426

These Numbers are in operation 24 hours/day, 7 days/week

5-1
 Section 5

5.1.6 Parts and Service

Parts and service are available from the factory:

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

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

Factory Engineering personnel may also be directly contacted at the following

e-mail address:
Baylor.engr@natoil.com

For a list of worldwide National Oilwell locations and Service Centers go to

www.natoil.com and click Contact Us

5-2
 Section 6
Maintenance and Service
6.1 General
An Inspection and Maintenance Schedule is
provided at the end of this section.
6.1.1 Lubrication
To maintain the lubricant volume, add
approximately 2 ounces (59 ml) of grease
to each bearing cavity each 24-hour
period, or before each trip into the hole
with pipe. There is a grease fitting for
each of the two bearings, and each must
be independently lubricated (See Figure
6-1). The recommended grease is a NLGI
No.2, water resistant (Lithium base)
grease. A good grade of lithium or sodium
base ball and roller bearing grease may
be used. The bearings and seals will not
be harmed by excess grease. It will simply
enter the cooling water stream by
momentarily lifting the seal lip to relieve
pressure. Drawworks manufacturers and
users may connect the grease inlet holes
in the bearing caps to lubrication header
blocks with tubing to facilitate lubrication
from a remote point. This is satisfactory if
the tubing is regularly inspected, and it is
determined that the required amount of
grease is actually reaching the bearing.
6.1.2 Breather
Figure 6-1 shows a breather on the upper
and / or lower exterior face of each
magnet assembly. These breathers
should be inspected periodically to insure
that they are clean and have free access
to air to minimize condensation and to
prevent any accumulation of moisture in
the coil cavity. They should be removed
and cleaned with kerosene at least once a
month.
6-1
CAUTION!
The accumulation of moisture in the coil
cavities caused by plugged breathers will
result in early deterioration of the coils. These
breathers should be cleaned as outlined above
and must always be pointed downward for
proper drain.
GREASE FITTING BREATHER / VENT
(TYPICAL BOTH SIDES) TO P & BOTTO M OR
MAY BE BOTTOM ONLY
ON SO ME MODELS
(TYPICAL BOTH SIDES)
Figure 6-1
Inboard Side
6.1.3 Air Gap
If there is erosion/corrosion in the air gap
between the rotor I.D. and the magnet
O.D. due to the use of poor quality cooling
water, this gap distance may gradually
increase to a point where rated torque will
be reduced. In making any field check of
this gap distance, it is necessary to allow
for any pitting and for any scale build-up
to determine the effective gap distance.
Any scale present does not provide an
effective magnetic path so it must be
deducted from the gap distance
measurement. This air gap should be
checked monthly. The effective air gap is
the average of all measurements taken.
 Section 6

Measurements should be taken at each OVERFLOW

air gap inspection hole (both inboard and (TYPICAL BOTH SIDES)
outboard) and recorded. Then rotate rotor
assembly 90 degrees clockwise. Again
record all readings. Rotate rotor
assembly 90 degrees clockwise and
record all readings. Rotate rotor 90
degrees clockwise and record readings.
Finally, rotate rotor assembly 90 degrees
clockwise. This will bring you back to
original position and readings should
agree with first position readings.
Normally, a 50% increase in the air gap Figure 6-3
will produce a 70% decrease in rated Inboard Side
torque. For original air gap dimensions 6.1.5 Water Outlet Drain
see SECTION 2 of this manual.
Located underneath the brake are one or
two NPT threaded water outlet drains.
AIR GAP
INSPECTION PORTS The preferred method of installation is
(TYPICAL BOTH SIDES) use of an open, free-flowing funnel on
each water outlet as indicated in Section
3.1. Check these funnels daily for any
obstructions. The water should flow freely
back to the supply reservoir.

DRAINS

Figure 6-2
Inboard Side
6.1.4 Overflow Outlet
Located on both sides of the brake, just
below the centerline of the shaft and to
one side is a 90 degree elbow for water
overflow. This elbow should always be
pointing down and be clear of any
obstructions. Should the cooling water Figure 6-4
level, internal of the brake, rise to the Inboard Side
point that water could penetrate into the
shaft bearings, this overflow outlet would
allow the excess water to run off. If the
drains are partially blocked or piped with
too much resistance to flow, the water
level in the brake could rise above the
shaft height and get into the bearings. In
normal operation, there should never be
any water coming out of these overflows.
These overflows should be checked
daily.

6-2

6.1.6 Preparation of Brake for Storage
If a brake is to be stacked, stored, or
inactive for any long period, proper
precautions should be taken to prevent
the rotor assembly from becoming stuck
to the magnet assemblies because of
scale, rust, or salt growth. As an initial
step, both bearing cavities should be
pumped completely full of grease to
protect the bearings during storage.
If water of doubtful nature had been
circulated in the brake before being
inactivated, it should first be flushed with
good clean water. The interior of the
brake should then be sprayed with a fluid
which will inhibit rust and/or salt growth. A
solution of 50% corrosion inhibitor and
50% clean water should be used to
protect the internal surfaces. Spraying the
interior of the brake can be accomplished
by inserting a spray gun nozzle into each
of the air gap inspection holes which
are equally spaced in each of the end
rings at the rotor diameter, as illustrated in
Figure 6-2.
CAUTION!
Do not remove coil breather / vents and
introduce any fluid or substance into the coil
cavity. This could attack the coil insulation
and greatly reduce the life expectancy of the
brake coils. See Figure 6-1.
Plug all ports and continue to spray until
the rotor is well coated with the preserving
fluid. Then plug both water inlets, both
vents, as well as the water outlets. Rotate
the shaft once each month to distribute
the bearing grease and preserving fluid
internal coating. Spray more preserving
fluid into the brake air gap inspection
holes if necessary. Additionally, all
exposed surfaces of the shaft should be
coated with Rust-Ban 373 or an
equivalent rust preventative.
6-3
Section 6
6.1.7 Removing a Brake from Storage
If a brake has been in storage, either after
field use or as shipped from the plant, for
more than three months, it will need a
through inspection to make sure it has not
been damaged in any way and all parts
are properly in place. Failure to observe
the following points can result in serious
damage.
1. Remove all plugs and drain
preservative fluid from the brake.
2. Rotate shaft and verify that the rotor
turns freely.
3. Check the bearings and seals.
4. Replace seals if they have been in
place for more than three years.
5. Check and tighten all the bolts.
6. Grease the bearings and seals.
7. Remove clean magnet breathers
and re-install. Replace if unable to
clear breather obstructions.
If the brake has been in storage for
approximately one year or more, megger
the windings and check coil internal
resistance before energizing the coils.
Coil internal resistance values may be
obtained from values listed in Section 3,
Figure 3-15. Coil resistance to ground
should not be less than 5 megohms
(tested with 500 VDC megger and with all
interconnecting wires disconnected from
coil leads).
Note: Coil leads will normally read low
due to humidity or other moisture which
can accumulate in the brake junction box.
If readings are low enough to cause
concern, use heat source such as hair
blow drier to reduce moisture in leads. If
this process does not help resistance
readings, call National Oilwell or licensed
Service Companies listed in Section 5.

6.2 Maintenance and Repairs
6.2.1 Water System Problems
If the cooling water supply fails while the
BAYLOR Brake is being used, the heat
generated in the rotor may build very
quickly. The rotor will expand if the heat is
not properly carried away. As a result, the
braking action will be below normal due to
this expansion and the consequent
widening of the air gap between the rotor
and magnet assemblies. If the rotor
overheating continues beyond a short
period of time, the rotor may suffer severe
distortion and require replacement. The
presence of any cooling water at all and
the temperature of the water will affect the
length of time before which irreversible
damage occurs. It can be simply said that
a sufficient flow of cool water will yield a
long operating life for the Eddy Current
Brake.
If overheating of the rotor occurs, do not
immediately turn on or increase water flow
to the brake. First, let the rotor air-cool to
200 to 250 degrees F. The driller should
then run the drawworks so that it turns the
brake rotor at a uniform slow speed as the
cooling water supply is slowly
reintroduced into the brake. In this way
the rotor will be cooled evenly, and any
out-of-round condition or eccentricity of
the rotor may possibly be avoided.
However, once a rotor becomes severely
overheated, permanent warping of the
rotor cylinder is a distinct probability, even
if the above steps are taken to cool it. On
many rigs, the cooling water systems of
the BAYLOR Brake and the drawworks
mechanical friction brake are paralleled
from a common source of adequate
capacity for the two systems. Any failure
of the cooling water supply then becomes
noticeable promptly.
6-4
Section 6
NOTE!
Do not connect the two brake cooling
systems in series; that is, where the outlet
from the friction brake system is fed to the
inlet of the BAYLOR Brake System.
6.2.2 Bearing Removal and
Replacement (Figure 6-5)
Initially, before attempting to remove the
old bearing, remove any external
components, which have been added to
the basic brake on the side from which the
bearing is to be removed. This would
include such items as the hub of the
disengaging coupling, any components of
a drill feed control drive, any water/air
tube components, guards, brackets, etc.,
which may have been added by the
drawworks manufacturer or user and
which would interfere with the removal of
the bearing involved. In addition, it is
necessary to move the brake out of
position on the drawworks if an inboard
bearing is to be removed, but it is often
possible to change an outboard bearing
with the brake in place. Refer to the
assembly drawing showing the cross
section of the brake included in Section 8
of this manual for a better understanding.
To remove a bearing, proceed as follows:
1. Remove the bearing cap: Loosen
and remove the cap screws which
fasten the bearing cap to the inner
seal retainer.
2. Remove the retaining ring or locknut
and lockwasher. (Note: To remove
the inboard bearing on a model
7838 brake, reverse the order of
steps 1 & 2 above.)
3. Remove the center plate: Loosen
and remove the cap screws which
fasten the center plate to the inner
flange of the magnet assembly.

Insert four pusher bolts into the
threaded holes located at four
equidistant positions about the outer
edge of the center plate. Screw in
these (4) pusher bolts, evenly, to
remove the center plate.
NOTE!
Care should be taken to exert even
pressure on the four pusher bolts. This will
move the plate out evenly and avoid
damage. The model 6032 brake center
plate is cast iron. Be especially careful not
to exert uneven pressure on the pusher
bolts or the center plate may crack due to
its brittle, cast iron, and construction. The
bearing is now clear and may be removed
by conventional procedures.
Figure 6-5
Bearing Assembly
Item No. Description
1 Rotor with Shaft Installed
2 Cylindrical Brake Housing
3 One of the two Magnets
4 End Ring
Center Plate with Jacking
5 Insure that seal lip is turned in right
Screws
Inner Seal Retainer with all
6
threads installed
7 Bearing Cap
6-5
Section 6
8 Spherical Roller Bearing
Bearing Lock Nut and
9
Lockwasher
10 Grease Seal
Machined areas requiring
11
sealant when assembling
12 Sleeve, Seal
The inner race of the bearings has an
interference fit with the shaft, and
hydraulic pulling equipment is usually
required to remove the bearing when cold.
If the bearing is to be discarded, it may be
removed by other methods if proper care
is taken to insure that the shaft is not
damaged. The outer race may be cut off
and the rollers removed. The inner race
may then be heated and removed. Any
time a bearing is replaced, it is
recommended that the related seal be
replaced as well as its seal sleeve in order
to provide adequate protection for the new
bearing.
To remove a bearing, proceed as follows:
1. Install new seal sleeve on shaft.
Note: never heat seal sleeves or
bearings with heating torch. The
point source of heat of a heating
torch is in the range of 6000 degrees
F. This high temperature small area
contact with bearing tempered alloy
steel will cause a micro structure
change to occur which will greatly
reduce the life expectancy of the
bearing or seal sleeve. Heat
bearings and seal sleeves in an
oven or a container of clean oil. Heat
range is 200-250 degrees F. After
heating the seal sleeve and
installing on the shaft, place a good
quantity of clean bearing grease on
the seal sleeve. Before installing the
seal retainer with the seal over the
seal sleeve, also hand-coat the seal
with clean bearing grease. Install
retainer and seal over seal sleeve.
direction with respect to bearing
cavity. (If in doubt, look at assembly
drawing in this manual. Some brake
models have more than one seal.)

2. Heat and install new bearing.
3. Install the snap ring or bearing
lockwasher and locknut.
Note: The tightness of the locknut
should be checked after the bearing
has cooled.
4. Prior to replacing the center plate,
Care should be taken to insure that the pilot
hand pack the bearing and seal with
diameters of the inner seal retainer and the
clean bearing grease. Screw guide
bearing cap have entered the bore of the
pins into two of the tapped holes in
center plate straight and both of these parts
the inner seal retainer to align the
are straight and firmly affixed to the center
corresponding through holes in the
plate.
center plate and bearing cap.
5. Thoroughly clean the machined
mating surfaces between the inner
seal retainer and the center plate,
and the inner flange of the magnet
assembly. Apply a coating of Part
No. 1885-11-0015, non-hardening,
silicone sealant to these surfaces.
No gasket is used here since the
cavity is not pressured and a sealer
serves quite satisfactorily.
6. Install the center plate and pull it
firmly into position by tightening the
cap screws which hold it to the inner
flange of the magnet assembly.
Care should be taken to insure that
the center plate is drawn up straight
and evenly. The rotor shaft should
be supported while the center plate
is replaced. A cheater pipe may be
used with a hoist to support it.
7. Install the bearing cap and position
the cap screws, which hold the
bearing cap in place. Tighten these
cap screws firmly. Remove the (2)
guide pins and replace with the
remaining (2) cap screws and
tighten firmly.
8.
6-6
Section 6
NOTE!
Prior to replacing external parts,
remove air gap inspection plugs
(Figure 6-2) and check air gap at all
three inspection holes. Rotate
rotor 90 degrees and take three
more readings (this is to check
concentricity of rotor). Compare air
gap readings. If center plate O.D.
and/or magnet pilot diameter is
worn, gap at vertical top of brake will
be less than (2) gap readings at
lower quadrant of brake. If difference
is greater than 0.010" (0.25 mm),
then it will be necessary to shim
between O.D. of center plate and
I.D. of magnet assembly. This can
be accomplished by loosening the
cap screws, which retain the center
plate to the magnet by two full turns.
Using the cheater pipe mentioned
in 6.2.2.6 lift weight of shaft and
rotor assembly such that shim may
be inserted between center plate
O.D. and magnet pilot diameter (at
bottom vertical center line). Tighten
cap screws, which retain center
plate to magnet assembly. Remove
cheater pipe. Recheck air gaps as
outlined previously. Shimming
should correct concentricity between
magnet O.D. and rotor I.D. and
insure equal magnet attraction and
reduce rotor pull over.
Add sufficient grease to the bearing
cavity with a grease gun to insure
that the cavity is at least two-thirds
filled. The external parts which may
 Section 6

have been removed can be replaced There is no difference in the inboard and
after it is determined that the shaft outboard magnets. The leads are numbered for
and rotor assembly rotates freely. If convenience in wiring and to assist in proper
it was necessary to move the brake coil lead connection to insure proper coil
from its position on the drawworks, it polarity. Outboard magnet leads are F1, F2, F3,
should be reinstalled and aligned and F4. Inboard magnet leads are F5, F6, F7,
with the same care as when initially and F8. If there is a need to convert an inboard
installed. magnet to outboard or vice-a-versa the
following table should be used:
6.3 Electrical Problems and Leads F1 = F8, F3 = F6
Troubleshooting F2 = F7, F4 = F5
All electrical problems must be in one or more Therefore, the inboard and outboard magnets
of these components. are mechanically and electrically
1. Interconnect cables and wiring. interchangeable. Refer to Figure 3-3
2. Brake (coils, lead wires, or terminations). Most problems can be solved with the
preceding information. Additional checks which
3. Control System (Refer to Control System
may be useful are included in the voltage and
Manual).
resistance checklist in the BAYLOR Brake
Experience has shown that about 90% of all Control System Manual.
problems can be traced to interconnect cables
and wiring, therefore it is suggested that these
be checked first.
With power removed, use a 500 VDC megger
to check for grounds. Wiring and interconnect
cables should be a minimum 1 megohm to
ground.
Individual magnet coils should be a minimum of
5 megohms to ground. An ohmmeter should be
used to check the coils for open or short
circuits. Coil resistance is listed in the
specifications summary in Section 2.

6-7

6.4 Mechanical Problems and Troubleshooting
All mechanical problems eventually lead to noticeable loss of braking. There are four general
categories of mechanical problems which result in braking loss. These categories and their one or
more causes are listed in the following pages.
Troubleshooting Chart
Symptom
Rotor is dragging on the magnet
or the bearings are noisy
Water coming out of the overflow
piping.
Gradual loss of torque capacity
due to increase of magnet / rotor
gap
Section 6
Trouble Shooting Hint
1. The brake shaft may be misaligned with the drawworks
or automatic feed shaft. If this is the case, align the
shafts correctly. Check for damage to the bearings
before tripping.
2. The bearings may be worn because of poor grease
maintenance. If this is the problem, replace the bearings
and maintain the proper bearing grease service.
An incorrect water level may have been maintained inside the
brake housing causing an overflow. This may result in seal and
bearing failure.
1. If the output water flow rate is excessive, then limit the
flow rate as shown in the brake specifications.(Section 2)
2. If the water outlet is restricted, check for any restrictions.
NOTE: Do not reduce the pipe size of water outlet (s).
3. If the outlet water back pressure is excessive, the water
tank is not sufficiently below the brake water outlet level
or a long return line does not have a sufficient increase
in pipe diameter to allow the flow to pass. NOTE:
Allowing the water to drain into a funnel not mechanically
connected to the brake prevents backpressure problems.
The surface of the magnets and rotor may have an
accumulated layer of rust and scale due to a cooling
water system with a high salinity content or high pH
factor. This build-up will eventually decrease the brake
torque capacity.
1. If the brake is cooled with saltwater, the life expectancy
of the brake may be as short as 3 years. It is
recommended not to use saltwater for cooling, but to
maintain a clean fresh water system.
2. If the brake cooling water is shared with other remote
machines, freshwater should be added to prevent
acquiring too much acid content. Also add corrosion
resistant chemical as recommended by a water
treatment specialist.
3. If iron oxide flakes off the magnet and rotor, the air gap is
increased. This decreases the brake torque capacity.
The air gap should be as listed in the specifications. If
the air gap increases beyond 0.100 inch (2.54 mm),
consult the factory for repairs. Remember to remove rust
and scale before measuring the air gap. NOTE: Life of
the brake with proper cooling system care can be as long
as 15 years.
6-8
 Section 6

Loss of torque capacity due to
overheating the brake.
Overheating the rotor will increase the magnet/rotor gap.
This decreases the brake output torque. Overheating the
magnet will increase the coil resistance. This decreases
the coil current, and this reduces magnetic flux. This will
also reduce the torque.

1. If the water flow rate is below the recommended level,

then raise the input flow rate to the specified level.
2. If the amount of cooling water is not sufficient to maintain
the system at or below 165F (74C) maximum brake
discharge temperature, then add water to the tank. Be
sure the volume of the tank is at or above the
recommended capacity. NOTE: In extremely hot working
areas, additional volume may be required.
3. If no water is applied to a brake that is full on, damage to
the coils or rotor will occur.

No cooling water to brake
cooling on overheated rotor.
If this happens, the rotor will be overheated in a matter of
minutes. If cold water is turned on an overheated rotor the
rotor will distort and may lock up on the magnets. To cool an
overheated rotor:
a) Let the rotor air cool to 200 to 250F (93C to 121C).
b) Then turn the water on while turning the rotor slowly. This
procedure may salvage the rotor.

Torque not at full capacity due to If coils are connected incorrectly, refer to Section 3 of this
incorrect coil polarity manual. Check for coil polarity and connections.

Torque reduced due to loss of 1. If an over-voltage is applied to a coil, see electrical

one or more coils troubleshooting in brake controller manual.
2. The coils may have an insulation failure due to
condensation in the coil cavity. To prevent condensation
from becoming a problem, remove the coil cavity drain
plugs and/ or breather plugs and clean them periodically.

NOTE: Undue flow from the drain plugs and/ or breather plugs
would indicate the magnets not working properly.

6.5 Inspection and Maintenance Schedule If cutting back on flow rate results in
too high temperature on brake water
6.5.1 Daily Inspection
at outlet 165F (74C), check on
1. Cooling Water Flow Rate brake discharge water line to see if it
Inspection has become restricted. Flow rates
Observe brake water overflow vent from brake should be unrestricted.
while lowering drill string into hole. If
constant flow is observed coming
from vent, slowly begin to reduce
rate until constant flow is no longer
observed coming out of vent.

6-9

2. Lubrication
Grease each brake bearing with 2 to
4 ounces of lithium base ball and
roller bearing grease (See page 6-1
paragraph 6.1.1) Each brake has two
grease fittings, one on inboard
bearing cap and one on outboard
bearing cap.
3. Electrical Wiring Inspection
CAUTION!
All electrical checks and inspections must be
conducted by qualified personnel. Proper lock
out/tag out procedures must be followed when
powered testing is not being conducted.
Testing while the equipment is
powered must be done in a manner to
minimize the inherent risk of electrical
shock. Inspect control system wiring
with visual inspection for cut wires,
snags, or other accidental damage.
Turn off main power, unplug any
in-line disconnects, and inspect for
oxidation, moisture, and signs of
arcing. Clean as required and
return to service.
6.5.2 Weekly Inspection
1. DC Voltage Check
Check DC voltage to brake under full
load condition (electrical full load,
Drillers Control in FULL ON position).
See Section 2, Summary of
Specifications.
6.5.3 Monthly Inspection
1. Drain/ Breather Inspection
Remove brake magnet coil cavity
drain and brake junction box drain
from fitting. Clean with kerosene.
This drain / breather should be open
for passage of air or liquid. Replace
drain/ breather into fitting after
inspection.
6 - 10
Section 6
IMPORTANT!
To protect the full life of the coils the
condensation that may form in coil cavities
must be drained. To assure free flow, these
drain / breathers must be inspected every
month and cleaned if necessary.
2. Air Gap Inspection
Inspect and record brake air gap,
remove 1-1/4 inch N.P.T. pipe plugs
from brake and rings. Using feeler
gauges which are a minimum of 6
inches long, insert gauges into the
air gap between the brake magnet
and the rotor.
NOTE!
Disengage brake shaft from drum shaft by
using disconnect clutch before making any air
gap measurements.
Air gap measurements should be
taken as far in on magnet as feeler
gauge length will permit. (7 inches
8 inches is recommended) Try to
approximate the thickness of any
scale, (Rust and Calcium) if cleaning
is not possible. This figure must be
added to basic feeler gauge reading.
If rotor is pitted, an additional pit
estimate must be added to air gap
measurement. Remember, multiple
readings are required and their
average is used in establishing the
condition and performance of the
Brake.
3. Disconnect Clutch Inspection
While the brake shaft is coupled to
the drum shaft and while the brake
 Section 6

is being slowly rotated (preferable

under loaded conditions) observe
the brake disconnect clutch. Verify
that if fully engaged the clutch hub
on the brake shaft does not move
with respect to the shaft. Check that NOTE!
the clutch is being properly
lubricated. (Refer to drawworks Remove only one set of leads at a time, for
manufacturer for lubrication example, F1 and F2. Mark their position
specifications.) carefully; check the coil and then return the
leads to their exact same position. Failure to
6.5.4 Quarterly Inspection return all leads to their correct position could
result in incorrect polarity which would
1. Voltage and Resistance Check seriously decrease the braking effort.
Readings for the individual coils should be as
Check brake coil voltages at brake listed under coil resistance in summary of
junction box as described in voltage specifications. See Section 2.
check. After voltage check is
complete (see 6.5.2), turn off main
supply voltage to brake control
system. Disconnect each coil from
the electrical control system by
removing coil leads from their
installed position in brake junction
box. The coils should read 5
megohms or higher to ground when
checked with a 500 Volt DC megger
electrical insulation tester.

6 - 11
 Section 6

Cut here and place near Maintenance area Cut here and place near Maintenance area Cut here and place near Maintenance area

BAYLOR Eddy Current Brake

Maintenance Schedule

DAILY SCHEDULE
1. INSPECT COOLING SYSTEM.
2. LUBRICATE BEARINGS.
3. INSPECT ELECTRICAL

WEEKLY SCHEDULE
1. DC VOLTAGE CHECK

MONTHLY SCHEDULE
1. DRAIN / BREATHER INSPECTION
2. AIR GAP INSPECTION
3. DISCONNECT CLUTCH INSPECTION

QUARTERLY SCHEDULE
1. VOLTAGE AND RESISTANCE CHECK

6 - 12
 Section 7
Parts and Supplies

7.1 General
The recommended spare parts and supplies for the 6032 BAYLOR Brake are provided in the
following table:

Recommended Spare Parts

BAYLOR Eddy Current Brake

Qty. Part No. Description

1 1030-20-0002 Bearing, Inboard

1 1030-20-0001 Bearing, Outboard

1 1555-10-0001 Seal, Inboard

1 1555-10-0007 Seal, Outboard

1 07939 Sleeve, Seal, Inboard

1 07940 Sleeve, Seal, Outboard

1 1420-20-0040 Locknut, Inboard

1 1420-20-0028 Locknut, Outboard

1 1690-20-0040 Lockwasher, Inboard

1 1690-20-0028 Lockwasher, Outboard

5 1075-10-0003 Breather/Drain

4 06614 Housing, Breather

7-1
 Section 8
Drawings 6032 Brake

8.1 Drawing List

D31590-AT ....................................................................... Assembly Model 6032 Eddy Current Brake
B/M31590-AT .......................................................Bill of Material 6032 Eddy Current Brake Assembly
D46102 ......................................................................Outline and Mounting 6032 Eddy Current Brake
C10711 ................................................................................. Schematic Brake Water Cooling System

8-1