Manual No.

165-60400

INSTALLATION, OPERATION AND

MAINTENANCE INSTRUCTIONS
FOR
BAYLOR EDDY CURRENT BRAKE
MODEL 15050 WITH
KAPTON COILS & LOW
TEMPERATURE SHAFT

EQUIPMENT FURNISHED
BY

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

Rev. A
07/03
 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.

CAUTION!
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

the brake or control system will VOID ANY
This manual provides a source of important
WARRANTY expressed in the terms and
reference information regarding the installation,
conditions of sale and will void HAZARDOUS
operation, and maintenance of the BAYLOR
AREA CERTIFICATION. All applicable
Eddy Current Brakes and should be given
schematics, flow diagrams, and major
careful consideration and study before
assembly drawings are contained in SECTION
operating the BAYLOR brake. It is impossible
8 of this manual.
to anticipate every kind of problem or condition
that may be encountered in the use of the
1.2 General Description if Equipment
brake, but compliance with the instructions and
suggestions set forth in this operating manual The BAYLOR Eddy Current Brakes are
will assist the operator in successfully auxiliary braking devices for the Drilling Rig
operating this equipment. Drawworks. This braking is produced entirely
electrically without the aid of friction brake
Failure to operate and maintain the brake in
devices, slip rings, or other wearing elements.
accordance with this operating manual may
The brakes are water cooled.
void the warranty covering this equipment. The
information contained in this operating manual
shall not in any way relieve the operator of the
responsibility for exercising reasonable care
and prudence in the operation of this
equipment.

WARNING!
Failure to comply with the instructions in this
operating manual could result in serious
property damage, severe injury, or death!

1-1
 Section 2
Summary of Specifications
Model 15050 Eddy Current Brake

2.1 Specifications
Principal of operation ..............................................................................Induced Eddy Current Braking
Torque-Maximum......................................................................................... 185,000 lb-ft @ 175 R.P.M
(250,827 newton-meters)
Torque-@ 50 RPM .............................................................................................................150,000 lb-ft
(203,373 newton-meters)
Number of Magnets ..............................................................................................................................2
Number of Coils per Magnet.................................................................................................................2
Coil Internal Resistance @ 68° F (20° C) ..................................................................... 10.8-11.2 Ohms
Total Brake Input Resistance @ 68° F (20° C).................................................................... 2.38 Ohms
Brake Excitation:
Voltage .....................................................................................................................325 Volts DC
Current-Coil Temperature @ 68° F (20° C)....................................................... 123.22 Amps DC
Power-Input @ 68° F (20° C) ..............................................................................................40 kW
Cooling Water Requirements:
Flow @ 100° F (38° C) At Brake Inlet ....................................................................... 230 Gal/Min
(871 Liters/Min)
pH.......................................................................................................................................7.0-7.5
Maximum Discharge Temperature ........................................................................165° F (74° C)
Cooling Water Piping:
Inlet ........................................................................................................................(2) 2-1/2" NPT
Outlet............................................................................................................................ (2) 4" NPT
Overflow .......................................................................................................................(2) 1" NPT
Overall Sizes:
Height .........................................................................................................92 Inches (2,337 mm)
Width ..................................................................................................................40 in (1,016 mm)
Weight ................................................................................................................... 45,600 lb (20,684 kg)
Inertia (WK²)-Shaft and Rotor ............................................................ 68,471 lb-ft2 (28,853,761 kg-cm2)
Weight-Shaft and Rotor .............................................................................................. 9730 lb (4413 kg)
Shaft Size .............................................................. 11.250 inch Diameter with 1-1/4 Inch Taper per foot
(286 mm Diameter with 32mm Taper per 305 mm) Oilfield Standard
Average Rotor Radial Clearance (Air Gap)
Over Magnets (Without Paint or Other Buildup) ............................................................... 0.063-0.073 in
(1.600-1.854 mm)
Maximum R.P.M. ............................................................................................................................... 450

2-1
 Section 2

2-2
 Section 3
Installation

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

3-1
 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

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

3-7
 Section 3

PENCOOL 2000 3.5 Cooling System Capacity Calculation

HEAT PRODUCED = BTU/MINUTE =
(Previously Called Nalcool 2000)
T X RPM X 42.4
The Penray Companies
5250
440 Denniston Court
Where T = Torque in FT.-LBS
Wheeling, Illinois 60090
This may be used directly to size a radiator or
It is recommended that this inhibitor be other type of heat exchanger. When the Brake
purchased through a local distributor so is not producing torque continuously the heat
that proper field support in their use is produced must be multiplied by the duty cycle.
readily available. For example, normal “tripping in” requires that
3.4.4 Usage of Antifreeze Standards the Brake produce torque only one-third of the
time. Therefore the calculated BTU/min would
Only ethylene glycol type antifreezes are be multiplied by 1/3.
to be used in BAYLOR Eddy Current
Brakes due to the operating temperature For a tank or reservoir type cooling system the
generated. storage capacity is calculated by:

NOTE: Chromate type rust inhibitors are LBS of water = BTU/min X t

not to be used with ethylene glycol Temp
antifreezes. The resulting mixture forms a Where t = Time in minutes of operation
sludge. It is recommended that the Brake
cooling fluid not exceed 68% Temp = 165 Degrees F - Temperature of
ethylene glycol. Levels of ethylene glycol water entering Reservoir.
higher than this will lower the freezing
point of the Brake cooling fluid, but will Gallons of water = LBS. of water
not provide adequate heat transfer. 8.34

If inlet temperature of cooling water to the

If the antifreeze contains corrosion Brake is much higher than 100 Degrees F,
inhibitors, it is not recommended to add note that the flow required goes up drastically
additional inhibitors to the original mixture to cool the Brake, as illustrated in Figure 3-7.
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.

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
manufacturer’s recommendations and the
applicable environmental authorities
recommendation.

3-8
 Section 3

Eddy Current Brake Coolant Flow

Required to Maintain Outlet Temp of 165° F.
Required Flow Rate (GPM)

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 165° F. ONE-THIRD
DUTY CYCLE

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

Curves are extended only to maximum GPM 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

3-9
 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 Driller’s Control. To
lower by 30% or more, a coil problem
obtain a reference point as to the Brake’s
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 Driller’s
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 - 10
 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 68°F (20°C) 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 driller’s 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 Driller’s
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 Driller’s 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, 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
Driller’s Control handle to a position as
indicated below:

3 - 11
 Section 3

3 - 12
 Section 3

3 - 13
 Section 3

3.7 Certification for Hazardous Location

The Factory Mutual Certification of BAYLOR
Eddy Current Brakes is reproduced on the
following pages. Note that if a Factory Mutual
Approved Installation is required, a water flow
alarm system must be installed to monitor
water cooling flow in the Brake inlet line in
accordance with drawing B46765 and drawing
D47915 sheets 1 and 2. Copies of these
Drawings are included at the end of this
section.

3 - 14
 Section 3

3 - 15
 Section 3

3 - 16
 Section 3

3 - 17
 Section 3

1
2

3 - 18
 Section 3

3 - 19
 Section 3

3 - 20
 Section 4
Theory of Operation

4.1 General 4.2 Brake Operation on Rig

When the steel rotor rotates through the When a BAYLOR Eddy Current Brake is
stationary magnetic field, currents are induced installed on a rig its response may vary
in the rotor. These currents, commonly called depending upon the following items:
“eddy currents”, produce a magnetic field
• Brake torque capacities may vary + or –
which interacts with the stationary field. This
5% between individual units.
field interaction produces a force, which
opposes rotor rotation, and provides the • When the brake becomes overheated it
braking torque for the BAYLOR Brake. will lose some of its torque capacity.
• Normal reaction time for the brake to
The Eddy Current Brake provides high braking reach maximum braking torque is
torque at low rotor speeds. This is a distinct approximately 2 seconds. This may vary
advantage over other types of braking systems depending upon the Brake Control
such as the water brake. The braking torque of System employed.
the Eddy Current Brake is dependent on the
• Normal reaction time for the brake to
strength of the stationary magnetic field, rotor decay to zero braking torque is
speed, and rotor temperature. Torque approximately 1-2 seconds. This may
increases with magnetic field strength and with vary depending upon the Brake Control
rotor speed. Torque decreases as rotor System employed.
temperature rises and the rotor expands which
widens the air gap. The strength of the • As the brake ages, the air gap between
stationary magnetic field is controlled by the the rotor and the magnets may increase
field coil in proportion to the braking due to rust or erosion which will cause a
requirements. decrease in brake output torque.
With all these factors in mind, the operator
The eddy currents induced in the rotor produce must learn and get a feel for the brake
heat. This rotor heat must be kept within response time during the early stages of
acceptable limits or braking torque will be tripping when the loads are lighter.
reduced. To maintain rotor temperature within When the load exceeds the brake capacity
acceptable limits, a cooling system is required. note that the brake will not be able to control or
A steady flow of water is directed into the area properly decelerate the load.
containing the rotor, as illustrated in Figure 3-4.
The movement of the rotor through this water Proper operation of the brake is to apply the
as it turns provides uniform cooling of the rotor Eddy Current Brake before releasing the main
surface. If the flow of cooling water fails while drawworks friction brake when tripping into the
the brake is in operation the rotor will become bore hole.
overheated. In this state the rotor will be
damaged if a safe cooling procedure is not
followed. Consult Section 6 of this manual for CAUTION!
the proper procedure to use. 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.

4-1
 Section 4

4.2.1 Drill Assist Operation

Operation of the brake at very low
If the brake is used for “drill assist” where speeds during drill assist, with full
the rotor speed is very limited, it is excitation, will also contribute to
recommended that no more than half of excessive wear to the I.D. of the rotor
full rated DC voltage be applied to the and the O.D. of the magnets. At very low
field coils continuously. The brake’s rotor speeds, with full excitation to the
primary purpose as an auxiliary brake is field coils, the magnetic attraction
to dissipate the energy of drill pipe or between magnets and rotor is greater
casing being lowered into the bore hole. than the collapse strength of the rotor
For this specific purpose, the field coils material. Pull over will occur where the
are designed to accommodate a duty outer circumference of the rotor drum will
cycle of full DC voltage “on time” of 20 pull down and contact the O.D. of the
seconds out of every 60 seconds. To magnet. The resultant contact, at slow
increase the duty cycle to 100%, or an speed, will gall and gouge the surfaces of
“on time” of 60 seconds out of 60 rotor and magnets. This mechanical
seconds will create excessive heat contact will increase the air gap between
buildup within the individual conductors of the rotor I.D. and the magnet O.D. such
the field coils. As the electrical insulation that maximum torque of the brake will be
system of the field coil has excellent reduced.
dielectric characteristics, it also is an
In conclusion, to utilize the BAYLOR
excellent thermal insulator. The heat
Eddy Current Brake in the drill assist
produced internal of the field coil due to
mode requires specific attention to how
the DC current passing through each
much excitation is applied to the field
conductor will continue to rise until, within
coils. Continuous operation at full
a short period of time, the insulation
excitation can significantly shorten the life
system will de-grade and turn-to-turn
of the field coils and increase the air gap
shorting will occur with ultimate failure of
dimension such that reduced torque
the field coil. It is also interesting to note
output will result.
that the torque curves for BAYLOR Eddy
Current Brakes all have a similar
characteristic. The torque produced at NOTE
very low drum shaft speeds (0-20 r.p.m.)
is approximately the same for various National Oilwell manufactures several
excitation values. In other words, the different types of Control Systems for use
brake torque produced at 15 r.p.m. is with the BAYLOR Eddy Current Brakes.
about the same, at full applied excitation, Each Control System design incorporates a
as the torque with 33% applied excitation. different method of supplying reduced
Therefore, the brake, utilized for “drill voltage to the brake during drill assist
assist”, will perform at the low speed operations. Consult your Brake Control
drum requirements of feed off at 1/3 of System Manual to determine the proper
excitation as well as performance at full operational technique for drill assist
excitation. This can reduce the excitation conditions.
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 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 driller’s
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
driller’s 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
Or from the following Service Centers:

NATIONAL OILWELL - HITEC

266 Auchmill Road
Bucksburn, Aberdeen
Scotland AB21 9NB
Phone: 44 1224 714499 Fax: 44 1224 714599

NATIONAL OILWELL – NORWAY AS

Lagerveien 16
P.O. Box 8181
N-4069 Stavanger
Norway
Phone: 01147 51 818181 Telex: 01147 51 800547

GE KEPPLE ENERGY SERVICES PTE LTD

No.2, Pioneer Sector 3,
Jurong, Singapore 2262
Phone: 65 551 9500 Fax: 65 861 2054

INTERSEL ENGINEERING SERVICES

P.O. Box 18092
Jebel Ali
Dubai, United Arab Emirates
Phone: 011-971 488 33 661 Telex: 011-971 488 33 662

RIMES ELECTRO MECANICA, C.A.

Av. Intercomunal
Ciudad Ojeda 4019
Zulia, Venezuela
Phone: 58 65 411 763 Fax: 58 65 413 261

5-2
 Section 6
Maintenance and Service

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

6-1
 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
 Section 6

6.1.6 Preparation of Brake for Storage 6.1.7 Removing a Brake from Storage
If a brake is to be stacked, stored, or If a brake has been in storage, either after
inactive for any long period, proper field use or as shipped from the plant, for
precautions should be taken to prevent more than three months, it will need a
the rotor assembly from becoming stuck through inspection to make sure it has not
to the magnet assemblies because of been damaged in any way and all parts
scale, rust, or salt growth. As an initial are properly in place. Failure to observe
step, both bearing cavities should be the following points can result in serious
pumped completely full of grease to damage.
protect the bearings during storage.
1. Remove all plugs and drain
If water of doubtful nature had been preservative fluid from the brake.
circulated in the brake before being
2. Rotate shaft and verify that the rotor
inactivated, it should first be flushed with
turns freely.
good clean water. The interior of the
brake should then be sprayed with a fluid 3. Check the bearings and seals.
which will inhibit rust and/or salt growth. 4. Replace seals if they have been in
Clean oil, kerosene, diesel fuel, or other place for more than three years.
similar petroleum products will serve this
purpose if a specific inhibitor is not 5. Check and tighten all the bolts.
available. Spraying the interior of the 6. Grease the bearings and seals.
brake can be accomplished by inserting a
spray gun nozzle into each of the air gap 7. Remove clean magnet breathers
inspection holes which are equally and re-install. Replace if unable to
spaced in each of the end rings at the clear breather obstructions.
rotor diameter, as illustrated in If the brake has been in storage for
Figure 6-2. approximately one year or more, megger
the windings and check coil internal
resistance before energizing the coils.
CAUTION! Coil internal resistance values may be
obtained from values listed in Section 3,
Do not remove coil breather / vents and
Figure 3-15. Coil resistance to ground
introduce any fluid or substance into the coil
should not be less than 5 megohms
cavity. This could attack the coil insulation
(tested with 500 VDC megger and with all
and greatly reduce the life expectancy of the
interconnecting wires disconnected from
brake coils. See Figure 6-1.
coil leads).
Note: Coil leads will normally read low
due to humidity or other moisture which
Plug all ports and continue to spray until can accumulate in the brake junction box.
the rotor is well coated with the preserving If readings are low enough to cause
fluid. Rotate the shaft once each month to concern, use heat source such as hair
distribute the bearing grease and blow drier to reduce moisture in leads. If
preserving fluid internal coating. Spray this process does not help resistance
more preserving fluid into the brake air readings, call National Oilwell or licensed
gap inspection holes if necessary. Service Companies listed in Section 5.
Additionally, all exposed surfaces of the
shaft should be coated with Rust-Ban 373
or an equivalent rust preventative.

6-3
 Section 6

6.2 Maintenance and Repairs

6.2.2 Replacement (Figure 6-5)
6.2.1 Water System Problems
Initially, before attempting to remove the
If the cooling water supply fails while the old bearing, remove any external
BAYLOR Brake is being used, the heat components which have been added to
generated in the rotor may build very the basic brake on the side from which the
quickly. The rotor will expand if the heat is bearing is to be removed. This would
not properly carried away. As a result, the include such items as the hub of the
braking action will be below normal due to disengaging coupling, any components of
this expansion and the consequent a drill feed control drive, any water/air
widening of the air gap between the rotor tube components, guards, brackets, etc.,
and magnet assemblies. If the rotor which may have been added by the
overheating continues beyond a short drawworks manufacturer or user and
period of time, the rotor may suffer severe which would interfere with the removal of
distortion and require replacement. The the bearing involved. In addition, it is
presence of any cooling water at all and necessary to move the brake out of
the temperature of the water will affect the position on the drawworks if an inboard
length of time before which irreversible bearing is to be removed, but it is often
damage occurs. It can be simply said that possible to change an outboard bearing
a sufficient flow of cool water will yield a with the brake in place. Refer to the
long operating life for the Eddy Current assembly drawing showing the cross
Brake. section of the brake included in Section 8
If overheating of the rotor occurs, do not of this manual for a better understanding.
immediately turn on or increase water flow
To remove a bearing, proceed as follows:
to the brake. First, let the rotor air-cool to
200 to 250 degrees F. The driller should 1. Remove the bearing cap: Loosen
then run the drawworks so that it turns the and remove the cap screws which
brake rotor at a uniform slow speed as the fasten the bearing cap to the inner
cooling water supply is slowly seal retainer.
reintroduced into the brake. In this way 2. Remove the retaining ring or locknut
the rotor will be cooled evenly, and any and lockwasher. (Note: To remove
out-of-round condition or eccentricity of the inboard bearing on a model
the rotor may possibly be avoided. 7838 brake, reverse the order of
However, once a rotor becomes severely steps 1 & 2 above.)
overheated, permanent warping of the
rotor cylinder is a distinct probability, even 3. Remove the center plate: Loosen
if the above steps are taken to cool it. On and remove the cap screws which
many rigs, the cooling water systems of fasten the center plate to the inner
the BAYLOR Brake and the drawworks flange of the magnet assembly.
mechanical friction brake are paralleled Insert four pusher bolts into the
from a common source of adequate threaded holes located at four
capacity for the two systems. Any failure equidistant positions about the outer
of the cooling water supply then becomes edge of the center plate. Screw in
noticeable promptly. these (4) pusher bolts, evenly, to
remove the center plate.

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.

6-4
 Section 6

The inner race of the bearings has an

NOTE! interference fit with the shaft, and
hydraulic pulling equipment is usually
Care should be taken to exert even pressure required to remove the bearing when cold.
on the four pusher bolts. This will move the If the bearing is to be discarded, it may be
plate out evenly and avoid damage. The removed by other methods if proper care
model 6032 brake center plate is cast iron. is taken to insure that the shaft is not
Be especially careful not to exert uneven damaged. The outer race may be cut off
pressure on the pusher bolts or the center and the rollers removed. The inner race
plate may crack due to its brittle, cast iron, may then be heated and removed. Any
construction. The bearing is now clear and time a bearing is replaced, it is
may be removed by conventional procedures. 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
Figure 6-5 bearing or seal sleeve. Heat
Bearing Assembly bearings and seal sleeves in an
oven or a container of clean oil. Heat
Item No. Description range is 200-250 degrees F. After
1 Rotor with Shaft Installed heating the seal sleeve and
installing on the shaft, place a good
2 Cylindrical Brake Housing quantity of clean bearing grease on
3 One of the two Magnets the seal sleeve. Before installing the
4 End Ring seal retainer with the seal over the
seal sleeve, also hand-coat the seal
Center Plate with Jacking
5 with clean bearing grease. Install
Screws
retainer and seal over seal sleeve.
Inner Seal Retainer with all
6 Insure that seal lip is turned in right
threads installed
direction with respect to bearing
7 Bearing Cap cavity. (If in doubt, look at assembly
8 Spherical Roller Bearing drawing in this manual. Some brake
Bearing Lock Nut and models have more than one seal.)
9
Lockwasher 2. Heat and install new bearing.
10 Grease Seal
3. Install the snap ring or bearing
Machined areas requiring lockwasher and locknut.
11
sealant when assembling
12 Sleeve, Seal Note: The tightness of the locknut
should be checked after the bearing
has cooled.

6-5
 Section 6

4. Prior to replacing the center plate, Prior to replacing external parts,

hand pack the bearing and seal with remove air gap inspection plugs
clean bearing grease. Screw guide (Figure 6-2) and check air gap at all
pins into two of the tapped holes in three inspection holes. Rotate
the inner seal retainer to align the rotor 90 degrees and take three
corresponding through holes in the more readings (this is to check
center plate and bearing cap. concentricity of rotor). Compare air
gap readings. If center plate O.D.
5. Thoroughly clean the machined
and/or magnet pilot diameter is
mating surfaces between the inner
worn, gap at vertical top of brake will
seal retainer and the center plate,
be less than (2) gap readings at
and the inner flange of the magnet
lower quadrant of brake. If difference
assembly. Apply a coating of Part
is greater than 0.010" (0.25 mm),
No. 1885-11-0015, non-hardening,
then it will be necessary to shim
silicone sealant to these surfaces.
between O.D. of center plate and
No gasket is used here since the I.D. of magnet assembly. This can
cavity is not pressured and a sealer be accomplished by loosening the
serves quite satisfactorily. cap screws which retain the center
6. Install the center plate and pull it plate to the magnet by two full turns.
firmly into position by tightening the Using the “cheater pipe” mentioned
cap screws which hold it to the inner in 6.2.2.6 lift weight of shaft and
flange of the magnet assembly. rotor assembly such that shim may
Care should be taken to insure that be inserted between center plate
the center plate is drawn up straight O.D. and magnet pilot diameter (at
and evenly. The rotor shaft should bottom vertical center line). Tighten
be supported while the center plate cap screws which retain center plate
is replaced. A “cheater pipe” may be to magnet assembly. Remove
used with a hoist to support it. “cheater pipe”. Recheck air gaps as
outlined previously. Shimming
7. Install the bearing cap and position should correct concentricity between
the cap screws which hold the magnet O.D. and rotor I.D. and
bearing cap in place. Tighten these insure equal magnet attraction and
cap screws firmly. Remove the (2) reduce rotor pull over.
guide pins and replace with the
remaining (2) cap screws and 8. Add sufficient grease to the bearing
tighten firmly. cavity with a grease gun to insure
that the cavity is at least two-thirds
filled. The external parts which may
have been removed can be replaced
NOTE! after it is determined that the shaft
Care should be taken to insure that the pilot and rotor assembly rotates freely. If
diameters of the inner seal retainer and the it was necessary to move the brake
bearing cap have entered the bore of the from its position on the drawworks, it
center plate straight and both of these parts should be reinstalled and aligned
are straight and firmly affixed to the center with the same care as when initially
plate. installed.

6-6
 Section 6

6.3 Electrical Problems and There is no difference in the inboard and

Troubleshooting outboard magnets. The leads are numbered for
convenience in wiring and to assist in proper
All electrical problems must be in one or more
coil lead connection to insure proper coil
of these components.
polarity. Outboard magnet leads are F1, F2, F3,
1. Interconnect cables and wiring. and F4. Inboard magnet leads are F5, F6, F7,
and F8. If there is a need to convert an inboard
2. Brake (coils, lead wires, or terminations).
magnet to outboard or vice-a-versa the
3. Control System (Refer to Control System following table should be used:
Manual).
Leads F1 = F8, F3 = F6
Experience has shown that about 90% of all F2 = F7, F4 = F5
problems can be traced to interconnect cables
Therefore, the inboard and outboard magnets
and wiring, therefore it is suggested that these
are mechanically and electrically
be checked first.
interchangeable. Refer to Figure 3-3
With power removed, use a 500 VDC megger
Most problems can be solved with the
to check for grounds. Wiring and interconnect
preceding information. Additional checks which
cables should be a minimum 1 megohm to
may be useful are included in the voltage and
ground.
resistance checklist in the BAYLOR Brake
Individual magnet coils should be a minimum of Control System Manual.
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
 Section 6

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 Trouble Shooting Hint

Rotor is dragging on the magnet 1. The brake shaft may be misaligned with the drawworks
or the bearings are noisy 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.
Water coming out of the overflow An incorrect water level may have been maintained inside the
piping. 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.

Gradual loss of torque capacity The surface of the magnets and rotor may have an
due to increase of magnet / rotor accumulated layer of rust and scale due to a cooling
gap 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, 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 rotor will increase the magnet/ rotor gap.
overheating the brake. 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 GPM to the specified level.
2. If the amount of cooling water is not sufficient to maintain
the system at or below 165°F 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 – If this happens, the rotor will be overheated in a matter of
cooling on overheated rotor. 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 250°F
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 (165 degrees Fahrenheit),
1. Cooling Water Flow Rate check on brake discharge water line
Inspection to see if it has become restricted.
Observe brake water overflow vent Flow rates from brake should be
while lowering drill string into hole. If unrestricted.
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
 Section 6

2. Lubrication 2. Air Gap Inspection

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

6 - 10
 Section 6

6.5.4 Quarterly Inspection

NOTE!
1. Voltage and Resistance Check
Remove only one set of leads at a time, for
Check brake coil voltages at brake
example, F1 and F2. Mark their position
junction box as described in voltage
carefully; check the coil and then return the
check. After voltage check is
leads to their exact same position. Failure to
complete (see 6.5.2), turn off main
return all leads to their correct position could
supply voltage to brake control
result in incorrect polarity which would
system. Disconnect each coil from
seriously decrease the braking effort.
the electrical control system by
Readings for the individual coils should be as
removing coil leads from their
listed under coil resistance in summary of
installed position in brake junction
specifications. See Section 2.
box. The coils should read 5
megohms or higher to ground when
checked with a 500 Volt DC megger
electrical insulation tester.

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 - 11
 Section 7
Parts and Supplies

7.1 General
The recommended spare parts and supplies for the 15050 BAYLOR Brake are provided in the
following table:

Recommended Spare Parts

BAYLOR Eddy Current Brake

Qty. Part No. Description

1 1030-20-0053 Bearing, Inboard

1 1030-20-0002 Bearing, Outboard

2 1555-10-0128 Seal, Inboard

2 1555-10-0127 Seal, Outboard

2 006-03-3002 Sleeve, Seal, Inboard

2 010-03-3002 Sleeve, Seal, Outboard

1 1420-20-0071 Locknut, Inboard

1 1420-20-0040 Locknut, Outboard

1 1690-20-0049 Lockwasher, Inboard

1 1690-20-0040 Lockwasher, Outboard

3 1075-10-0003 Breather/Drain

2 06614 Housing, Breather

7-1
 Section 8
Drawings - Brake

8.1 Drawing List

60400.............................................................................. Assembly – Model 15050 Eddy Current Brake
B/M 60400 ..........................................................Bill of Material – 15050 Eddy Current Brake Assembly
006-08-0015 ............................................................Outline and Mounting – 15050 Eddy Current Brake
006-06-0006 ................................................Water Piping Diagram – Model 15050 Eddy Current Brake

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 Section 8

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 Section 8

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 Section 8

8-4
 Section 8

8-5
 Section 8

8-6
 Section 8

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 Section 8

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