Block Control System使用说明书

Printed By: foxm2 Printed On: 2012.04.05.10.31.
29
Block Control System
Installation, Operation, and

Maintenance
REFERENCE REFERENCE DESCRIPTION
This document contains proprietary and confidential information which National OilWell Varco
belongs to National Oilwell Varco, LP; it is loaned for limited purposes
only and remains the property of National Oilwell Varco, LP. 1200 Cypress creek Road
Reproduction, in whole or in part; or use of this design or distribution of Cedar Park, Texas 78613
this information to others is not permitted without the express written
consent of National Oilwell Varco, LP. This document is to be returned to
USA
National Oilwell Varco, LP upon request and in any event upon Phone 512-340-5000
completion of the use for which it was loaned. Fax 512-340-5219
© National Oilwell Varco, LP
DOCUMENT NUMBER REV
60-60 G
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TC Number: 60-60-MAN Printed REV: G Latest REV: G

Printed By: foxm2 Printed On: 2012.04.05.10.31.29
Document number 60-60

Revision G
Page 1 of 136
Revision History
G 01.09.2012 Revised per EC#: 82109-0

F 03.09.2007 Revised per EC#: 62902-161
E 10.06.2006 Revised per EC#: 64726
D 04.06.2006 Revised per EC#: 63054
C 06.22.2005 Revised per EC#: 60774
Rev Date Reason for issue Prepared Checked Approved
Change Description
Revision Change Description

C Revision
D Revision
E Revision
F Revision
G Revision
Suggested Content Improvements
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Or, simply mark your suggested changes on the specific pages, scan, and email them as attachments.
Alternatively, marked-up pages can be mailed to the following address:
National Oilwell Varco
ATTN: Technical Publications
1200 Cypress Creek Road
Cedar Park, TX 78613
USA
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Revision G
Page 3 of 136
Table of Contents
Chapter 1: General Information
Conventions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Notes, Cautions, and Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Illustrations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Safety Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Personnel Training . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Recommended Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
General System Safety Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Replacing Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Proper Use of Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Related Documents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Chapter 2: Overview
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
System Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
DAQ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Brake System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Baylor 2025B Brake Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Eddy Current Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Friction Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Battery Backup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Throttle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Drill/Trip switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Driller Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Sensors & Calibration Switch Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Shaft Encoder Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Drawworks Proximity Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Railmount Proximity Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Hook Load Pressure Transducer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Heave Compensator Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Calibration Switch Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Configuration & Calibration Laptop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
VXC Graphics Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
DAQ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
System Setup Procedures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Chapter 3: Theory of Operation

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
DAQ System Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Brake Controller Functions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
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Revision G
Page 4 of 136
Table of Contents
System Signal Paths . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
Non-Critical Error Condition Signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
Critical Error Condition Signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
Normal Throttle Signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
Reverse Throttle Signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
Current Feedback Signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
Command Feedback Signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
DAQ Alarm Signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
DAQ Alarm Response . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
Zones . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
Alarm Classification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
Alarm Response . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
Matrix Definition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
Alarm Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
System Alarm Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
Acceleration Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
Brake Critical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
Current Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
EDMS Prox Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36
Encoder Alarm (Encoder Operation) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36
Derrick Prox Alarm (Encoder Operation) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36
Position Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36
Velocity Down Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36
Velocity Up Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36
Brake Non-Critical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37
Brake Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37
Friction Brake Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37
Hook Load Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37
UPS Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37
Non-Critical Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37
Set Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38
Corners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38
Battery Backup Enabled . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38
Chapter 4: Installation
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
Hazardous Area Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40
DAQ Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41
Mount the DAQ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41
Ground the DAQ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42
Connect Primary AC Power Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42
Digital Board Dip Switch Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43
DAQ Spectrum I/F Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45
EDMS Board Dip Switch Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46
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Revision G
Page 5 of 136
Table of Contents
I.S. Barrier Box Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Sensor Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Cabling Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Guidelines for Preventing Cable Damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Electrical Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Shielded Cable Splicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Proximity Sensor Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Drawworks Proximity Sensor Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Railmount Proximity Sensors Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Shaft Encoder Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Heave Compensator Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Calibration Switch Box Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Hook Load Pressure Transducer Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
DAQ Sensor Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Friction Brake Solenoid Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Twin Stop Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
DAQ Power Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Chapter 5: Configuration and Calibration

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Calconf Software Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Loading Configuration From Disk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Hook Load Sensor Channel Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Block Height Sensor Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Block Control System Ten Point Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
“Resetting” Block Control System Height Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . 81
System with Calibration Switch Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Systems with a Safe Area CID (SAC) or DataWatch display . . . . . . . . . . . . . . . . . 81
Save Config/Calibration To CD/RW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Saving Data to CD/RW (E:\) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Chapter 6: Setup
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Railmount Proximity Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Set Points Setup. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Chapter 7: Operation
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Green System On LED. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Yellow Alarm LED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Red Friction Brake Enabled LED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
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Revision G
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Override/reset Normal Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .91
Learn Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .92
Emergency Stop Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .92
Lower Speed Potentiometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .92
Drill/Trip Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .92
Alarm Horn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .93
Chapter 8: Maintenance
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .95
Recommended DAQ Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .95
DAQ and Sensor Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .95
General Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .95
Fault Isolation Table: DAQ and Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .96
System Debug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .101
Sensor Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .102
Replacing DAQ Digital Board EPROMs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .102
Power Supply and Wiring Harness Checkout Procedures . . . . . . . . . . . . . . . . . . . . . .104
DAQ Assemblies with 220251-003 & -004 Power Supplies . . . . . . . . . . . . . . . . . . . . .104
EDMS Battery Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .106
AC Power Distribution Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .108
Power Supply and Wiring Harness Checkout Procedures . . . . . . . . . . . . . . . . . . . . . .109
DAQ Assemblies with 220251-005 & -006 Power Supplies . . . . . . . . . . . . . . . . . . . . .109
EDMS Battery Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .111
AC Power Distribution Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .113
Chapter 9: Illustrated Parts Breakdown

Shaft Encoder Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .115
Calibration Switch Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .117
Hookload Transducer Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .119
System Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .120
Proximity Sensors & Laptop. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .120
Baylor System Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .120
Approved Spare Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .121
Appendix A: 2025B Brake Controller

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .123
Firing Board Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .123
Firing Board Switches. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .124
Firing Board Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .124
Auxiliary Board LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .125
Auxiliary Board Interfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .127
Relay Logic. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .128
K1: Emergency Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .128
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Table of Contents
K2: Crownamatic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
K3: Battery Back Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
Brake Controller Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
Appendix B: Brake Monitoring System

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
Safe Area Computer interface Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
Temperature Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
Flow Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
Air Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
“Crownamatic” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
Friction Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
Uninterruptable Power Supply (UPS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
UPS Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
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Table of Contents
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1: General Information
This manual is intended for use by field engineering, installation, operation, and repair
personnel. Every effort has been made to ensure the accuracy of the information contained
herein. National Oilwell Varco (NOV) will not be held liable for errors in this material, or for
consequences arising from misuse of this material.
This manual describes the block control system designed by NOV. The information in this
manual should enable qualified personnel to operate the block control system and to install,
calibrate, troubleshoot and replace parts.
Conventions
Notes, Cautions, and War nings
Notes, cautions, and warnings provide readers with additional information and advise the
reader to take specific action to protect personnel from potential injury or lethal conditions.
They may also inform the reader of actions necessary to prevent equipment damage. Please
pay close attention to these advisories.
Note: The note symbol indicates that additional information is provided about
the current topics.
Caution: The caution symbol indicates that potential damage to equipment or

injury to personnel exists. Follow instructions explicitly. Extreme care
should be taken when performing operations or procedures preceded by
this caution symbol.
Warning: The warning symbol indicates a definite risk of equipment damage

or danger to personnel. Failure to observe and follow proper
procedures could result in serious or fatal injury to personnel,
significant property loss, or significant equipment damage.
ESD The ESD (Electrostatic Discharge) warning symbol indicates that

Warning: static control precautions are needed.
Illustrations
Illustrations (figures) provide a graphical representation of equipment components or screen
snapshots for use in identifying parts or establishing nomenclature, and may or may not be
drawn to scale.
For component information specific to your application, see the technical drawings included
with your NOV documentation.
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Safety Requirements
NOV equipment is installed and operated in a controlled drilling rig environment involving
hazardous situations. Proper maintenance is important for safe and reliable operation.
Procedures outlined in NOV manuals are the recommended methods of performing
operations and maintenance.
To avoid injury to personnel or equipment damage, carefully observe requirements

outlined in this section.
Personnel Training
All personnel performing installation, operations, repair, or maintenance procedures on the
equipment, or those in the vicinity of the equipment, should be trained on rig safety, tool
operation, and maintenance to ensure their safety.
Personnel should wear protective gear during installation, maintenance, and certain
operations.
Recommended Tools
Service operations may require the use of tools designed specifically for the purpose
described. NOV recommends that only those tools specified be used when stated. Ensure that
personnel and equipment safety are not jeopardized when following service procedures or
using tools not specifically recommended by NOV.
General System Safety Practices

The equipment discussed in this manual may require or contain one or more utilities, such as
electrical, hydraulic, pneumatic, or cooling water.
Read and follow the guidelines below before installing equipment or performing
maintenance to avoid endangering exposed persons or damaging equipment.
 Isolate energy sources before beginning work.

 Avoid performing maintenance or repairs while the equipment is in operation.
 Wear proper protective equipment during equipment installation, maintenance, or repair.
Replacing Components
 Verify that all components (such as cables, hoses, etc.) are tagged and labeled during
assembly and disassembly of equipment to ensure correct installment.
 Replace failed or damaged components with genuine NOV parts. Failure to do so could
result in equipment damage or injury to personnel.
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Routine Maintenance
Equipment must be maintained on a routine basis. See the service manual for maintenance
recommendations.
Failure to conduct routine maintenance could result in equipment damage or injury to

personnel.
Proper Use of Equipment

NOV equipment is designed for specific functions and applications, and should be used only
for its intended purpose.
Related Documents
Detailed descriptions and instructions for installing, operating and troubleshooting block
control system devices is presented in separate manuals, as follows:
60-10: Data Acquisition Unit (DAQ) and sensors
60-40: TOTAL System Configuration and Calibration Software
60-24: VXC Graphics Display, Safe Area
220419: Instrument Block Diagram, Basic block control system
220420 Instrument Wiring Diagram, block control system
219569 Installation Control Drawing
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2: Overview
Introduction
The block control system is a backup system for controlling the traveling block. It continually
monitors block speed and position and provides a backup to the operator in controlling block
velocity. The system uses an eddy current brake and friction brake (when needed) to bring the
block to a controlled stop as the crown and rig floor are approached or at any position along its
range of travel.
This chapter describes block control system components and presents an overview of the
procedures for setting up a system.
Note: The block control system is a backup system only. it should not be used in place
of the manual braking controls. Under normal conditions, the operator should use the
manual braking controls at the driller's station to control the block.
System Components
The main components of the block control system are shown in Figure 2.1. These components
can be grouped into the following categories:
 Data Acquisition Unit (DAQ)
 Brake System
 Driller Display
 Sensors and Calibration Switch Box
 Configuration & Calibration Laptop
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Railmount Eddy Current

Proximity Sensors Brake
Drawworks
Throttle
Proximity Sensors
Driller Display
Hook Load Pressure Power Select

Transducer Box
Brake
DAQ
Controller
Drawworks Battery Backup
Shaft Encoder (Optional)
Calibration Friction
Brake Friction Brake
Switch Box
Controller
Heave Sensor Cal/Config

Laptop
UPS
BMS added equipment

Flow Switch
SAC
Temperature
Switch
Figure 2.1: Block Control System Overview
DAQ
The DAQ (Figure 2.2) is the primary Block Control System device. Its main functions are:
 System configuration and calibration - Via a laptop, Configuration/Calibration
software in the DAQ is used to configure the system and calibrate sensors.
 Interface for system components - The DAQ receives and processes rig sensor data
to determine the amount of braking required. The DAQ then sends this braking
information to the brake controller and driller display so that the appropriate action is
taken.
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 Houses the system software -The block control system software in the DAQ
continually calculates the amount of braking required, using data from the shaft encoder
and hook load pressure transducer.
 Issues braking command signals - After each calculation, the DAQ sends command
signals to the brake controller regarding the required current flow in the eddy current
brake and regarding application of friction brake (if needed).
 Monitors the system and issues alarms - Upon initialization of the eddy current brake,
the DAQ checks to insure that the required current is flowing in the brake. If it is not, the
DAQ immediately commands application of the friction brake, if needed. The DAQ also
checks for discrepancies between the shaft encoder and proximity sensors. If a
discrepancy exists, the DAQ issues an alarm that is appropriate for the current error
condition (see the table titled "Alarm Responses" on page 33.)
Figure 2.2: DAQ
Brake System
Brake system components are listed below and described in the paragraphs that follow.
 Baylor 2025B Brake Controller
 Eddy Current Brake
 Friction Brake
 Battery Backup (optional)
 Throttle
 Drill/Trip switch
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Baylor 2025B Brake Controller

During normal operation, the brake controller (Figure 2.3) receives braking command signals
from the throttle and from the DAQ. Throttle signals represent the current to the eddy current
brake that is commanded by the operator. DAQ signals represent the current prescribed by
block control software calculations to safely control block velocity.
The main functions of the Baylor 2025B brake controller are to:
 Compare the throttle braking command signal with that from the DAQ and send the
current associated with the higher signal to the eddy current brake
 House a relay that is activated by the DAQ when the friction brake is required. This
relay, in turn, operates a solenoid at the friction brake to fully engage the brake.
 House a relay that energizes a battery backup unit, if one is installed.
BAYLOR
POWER ON ALARM
Figure 2.3: Baylor 2025B Brake Controller
Eddy Current Brake

The eddy current brake is an electric brake that is attached to the drawworks and driven by
current from the brake controller. The current sent to the eddy current brake is the higher of
the current commanded manually by the operator via the throttle and that commanded by the
DAQ, based upon block control software calculations.
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Friction Brake
The friction brake is attached to the drawworks and can be engaged from the driller's station at
any time with activation of the Emergency Stop Pushbutton. The friction brake solenoid is
installed in a manner which allows any operation by existing crown protector equipment.
However, the brake controller will automatically command activation of the friction brake (via a
solenoid) if any of the following conditions exist:
 Block control software calculations determine that the friction brake is required to safely
stop the block.
 A malfunction is detected in the DAQ, brake controller, eddy current brake or connecting
cable.
 The operator activates the Emergency Stop button on the driller display.
Caution: When the Block Control System commands application of the friction brake, a
one second delay occurs, then the brake is fully engaged. This results in rapid
movement of the brake handle at the driller's station which could cause injury to
personnel and damage to rig equipment.
Batter y Backup
An optional stand-by power supply available from Baylor can be used to power the electric
brake if any of the following conditions occur:
 DC power loss or
 The operator activates the Emergency Stop button on the driller display or
 The current prescribed by the DAQ is not flowing in the eddy current brake.
Throttle
The operator uses the throttle to control the eddy current brake directly. During tripping, the
throttle is used in conjunction with the Drill/Trip switch.
The throttle controls the eddy current brake as long as either of the following conditions exist:
 The braking command signal from the throttle is higher than that from the DAQ
 The Override/Reset Normal switch on the driller display is positioned to Override.
Warning: When the Override/Reset Normal switch is in the Override position, the
block control system is completely unable to provide a back-up to the operator
in controlling the block. It is the full responsibility of the operator to control the
block. Fatal injury to personnel and severe damage to rig may result if the
operator fails to control the block.
Drill/Trip switch
This switch selects the power setting (either drill or trip) for the brake. With a block control
system the switch is incorporated in the driller display.
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Driller Display
The driller display (Figure 2.4) is an enclosure that is mounted at the driller's station. Its main
functions are summarized below. Refer to Chapter 7, titled "Operation" for detailed instructions
on using the display.
 The Override/Reset Normal switch is used to override the block control system, clear
system alarms and select the normal operating mode.
 The Learn button is used to define upper and lower set points.
 The Emergency Stop button is used to command full application of the friction brake
and eddy current brake and to engage the battery backup unit.
 An alarm horn is mounted near the display box and sounds when the system is in alarm.
 Three LED color communicates the current operating condition of the block control
system:
 Friction Brake Enabled (Red);
 Alarm (Yellow); or
 System On (Green.)
 When in override, the green LED will blink. The red or yellow lights may blink alternately
with the green, if an alarm condition exists.
Warning: When the Override/Reset Normal switch is in the Override position, the
block control system is completely unable to provide a backup to the operator in
controlling the block. It is the full responsibility of the operator to control the
block. Fatal injury to personnel and severe damage to rig may result if the
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NORMAL FRICTION BRAKE

OVERRIDE RESET ENABLED WARNING
When the OVERRIDE/RESEST NORMAL switch is in the OVERRIDE position, the Block Control System
is completely unable to provide a back-up to the operator in controlling the block. IT IS THE FULL
RESPONSIBILITY OF THE OPERATOR TO CONTROL THE BLOCK. FATAL INJURY TO PERSONNEL
AND SEVERE DAMAAGE TO RIG MAY RESULT IF OPERATOR FAILS TO CONTROL THE BLOCK.
NORMAL FRICTION BRAKE

ENABLE
OVERRIDE RESET
LEARN ALARM
LEARN ALARM
EMERGENCY STOP LOWER SPEED SYSTEM ON

SYSTEM ON
4 5 6
3 7
2 8
1 9
EMERGENCY STOP
DRILL TRIP
LOWER SPEED DRILL TRIP

WARNING
THE BLOCK CONTROL SYSTEM IS A BACK-UP SYSTEM ONLY. IT SHOULD NOT BE USED IN PLACE OF THE
MANUAL BRAKING CONTROLS. UNDER NORMAL CONDITIONS, THE OPERATOR SHOULD USE THE
MANUAL BREAKING CONTROLS AT THE DRILLERS STATION TO CONTROL THE BLOCK.
Panel Mount Box Mount (Typical)

Figure 2.4: Baylor Driller Display
Sensors & Calibration Switch Box

Block control system sensors and the calibration switch box are described in the following
paragraphs.
Shaft Encoder Assembly

The shaft encoder (Figure 2.5) is an optical encoder that attaches to either end of the
drawworks at the rotoseal and is used to determine block position. The encoder measures
drawworks rotation by turning in a one-to-one relationship with the drawworks drum shaft and
providing pulses as the drum rotates. Data from the encoder is sent to the DAQ, where it is
used by the block control software to calculate block position and velocity.
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CCW CW
Figure 2.5: Shaft Encoder Assembly (P/N H12321A)
Drawworks Proximity Sensor

The drawworks proximity sensor (P.N.: 40220378) provides a redundant check on shaft
encoder operation. The sensor is calibrated to detect a metal target placed on the drawworks
and sends a pulse to the DAQ each time it detects the target. The block control software
compares the proximity sensor signals with those from the shaft encoder and, if a discrepancy
exists, the DAQ issues an alarm.
Railmount Proximity Sensors

Two railmount proximity sensors (P.N.: H11094A-01) are used as a redundant check of block
height sensor integrity.
Hook Load Pressure Transducer

The hook load pressure transducer is a hydraulic system transducer with built-in signal
amplifier that is used to determine the weight on the drill line. It senses and converts hydraulic
pressure from the rig weight indicating system into a 4-20 mA DC electrical signal. This signal
is sent to the DAQ, where it is used by the block control software to compute hook load and
maximum allowed block velocity.
Heave Compensator Sensor

The heave sensor is mounted between the traveling block and hook. This isolates the heaving
motion of the vessel from the drill string. It minimizes wear between the drill string and blowout
preventer, marine riser and casing strings. The motion compensation equipment uses the
hydro-pneumatic operating principle and furnished with operating stroke lengths of 15, 18, 20,
or 25 feet depending on the rig design and application.
During operations, the compensator keeps the drill bit on the bottom of the hole within the
weight limits set by the driller. For other operations, the system compensates for rig motion,
maintaining a position relative to the ocean floor.
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As the rig heaves upward, the compensator cylinders retract and the hook moves downward
relative to the drill floor, while remaining at a constant level relative to the earth. The cylinder
piston compresses the air through the hose into the air pressure vessels to maintain the preset
tension level.
As the rig heaves downward, air from the air pressure vessels expands into the compensator
cylinder, and the system works in reverse.
Calibration Switch Box

The calibration switch box (P.N.: 219255-001, Figure 2.6) is a remotely operated, dual-switch
enclosure used to input layer changes (L/C Start button) and block height (Connection
button) during block height channel calibration. Information from the encoder is sent to the
DAQ, where it is used in conjunction with the configuration and calibration software to define
the relationship between block height and sensor counts.
CALIBRATION
CONNECTION L/C START

MADE IN USA
CONNECTED PER DRAWING NO. 21913, 219338,

INTRINSICALLY SAFE FOR CLASS I, DIV. 1, WHEN
DRILLERS CALIBRATION
FOR USE IN HAZARDOUS LOCATIONS
PART NO.
SERIAL NO.
SUBSTITUTION OF COMPONENTS
CURRENT RATING: 100 mA MAX

MAY IMPAIR INTRINSIC SAFETY
− − WARNING − −
VOLTAGE RATING: 10 VDC
SWITCH BOX
IEC 79-11 Ex ia IIB-T4
OR 219569.
219255-001
219273-001
LISTED
11Y8
®
Figure 2.6: Calibration Switch Box
Configuration & Calibration Laptop

A laptop, temporarily connected to the DAQ, is used to configure, calibrate and set up the
block control system.
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VXC Graphics Display

The Safe Area VXC system displays and plots sensor data collected by a Total DAQ. It is
designed for use in non-hazardous locations only. Audio and visual indicators let the operator
know when alarm conditions exist. Refer to Figure 2.7.
T-POT
MODEM
SAFE AREA VXC
COMPUTER & MONITOR
PRINTER
DESKTOP KEYPAD
Figure 2.7: VXC Graphics Display System (SAC)
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Specifications
The following tables list the specifications for the DAQ and sensors. For 2025B brake
controller specifications and other Baylor instruments, consult the appropriate Baylor manual.
DAQ
DAQ Electrical
Parameter Requirements/Limits
Primary Power 90 to 250 VAC, no modifications required
Frequency 47 to 65 Hz
Current 2.0 amperes maximum
Primary Power Fuse Time delay fuse, FLM, 2.0 amperes
DC Power Two 40-watt fused supplies: +/- 15 VDC and +5/+28 VDC
DAQ Environmental
Ambient Operating Temperature -20C to +60C
Ambient Storage Temperature -30C to +85C
Internal Humidity 5% to 90% Non-condensing
DAQ Mechanical
Enclosure Stainless Steel, NEMA Type 4X rating to the standard UL 50
Dimensions 21.5" H x 19.0" W x 13" D (546 mm x 482 mm x 330 mm)
Mounting (from center

19.75" H x 14.0" W (502 mm x 356 mm)
to center)
Mounting Hole 0.406" (10.2 mm) diameter
Door Clearance Area 21.5" H x 48" W (546 mm x 122 mm) @ 90° arc
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Sensors
Analog Channels 23 analog input channels per DAQ
Analog Voltage 0-10 volts maximum in two ranges: 0-5 volts, 0-10 volts
Analog Current 0-20 mA in three ranges: 0-20 mA, 4-20 mA, 12-20 mA
Analog Accuracy 0.5% of full scale, maximum
Digital Channels 14 digital input/output channels
Digital Inputs Maximum frequency - 100 Hz (6000 pulses/minute); Minimum pulse width - 7ms
Proximity sensors: 2- or 3- wire. To use 4-wire sensor, utilize two input channels
Digital Standard Input Sensors
Contact closure: Closed - 500 ohms maximum. Open - 10K ohms minimum
Digital Outputs Maximum frequency: 110 Hz. Output jitter: 0.5% maximum
Pulse-width modulation: 0-100% duty cycle; 0-10 volt output

Maximum frequency response of driven device: 102 Hz, Simulated analog output
Digital Output Functions
voltage range - 0-10 volts. Signal can drive analog chart recorders and meters
with frequency response of less than 40 Hz
User-defined high and low set points

Digital Alarm Outputs 0- and 10-volt levels
Normally high and normally low signal levels available
User-defined trip point

User-defined hysteresis
Digital Discrete Outputs
0- and 10-volt levels
Normally high and normally low signal levels available
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System Setup Procedures

The flow chart below shows the general procedures for setting up a block control system.
Install and connect the block control

system components (Chapter 4, titled
Load the system configuration from the

configuration floppy disk or CD and
modify, if needed (Chapter 5, titled
"Configuration and Calibration").
Calibrate the hook load and block

height sensor channels and save
calibration to floppy (Chapter 5, titled
Set up the railmount proximity sensors

and enter upper and lower extents
(Chapter 6, titled "Setup").
Figure 2.8: Setup Procedure Overview
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3: Theory of Operation
Introduction
This chapter describes the operational theory of the block control system, including the
following:
 System functions of the DAQ and brake controller
 Signal paths between block control system components
 DAQ alarm levels
 System error conditions
 Block operation zones
Figure 3.1 illustrates how the block control system functions as a backup to the operator by
showing the typical communication paths between the throttle, DAQ, brake controller and
eddy current brake.
Operator raises or
lowers block & BCS
provides backup.
DAQ receives block position

Operator uses
and hook load sensor data
throttle to stop or
& computes required
slow block.
current flow in brake.
Throttle signal to DAQ sends required

brake controller current flow in eddy
represents current current brake to brake
operator command. controller.
Throttle and DAQ braking

signals compared. Higher
current sent to eddy
current brake.
Eddy current
brake applied.
Figure 3.1: Block Control System Communication Paths
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Revision G 3: Theory of Operation
Page 28 of 136
DAQ System Functions

During operation of the block control system, the DAQ performs the functions listed below:
 Receives signals from the shaft encoder, drawworks proximity sensor, railmount
proximity sensors and hook load pressure transducer.
 Continually compares signals from the shaft encoder and drawworks proximity sensor to
insure that they agree on drawworks rotation. When applicable, the DAQ compares
block position signals from the railmount proximity sensor with that from the shaft
encoder. If any of the block position sensors disagree, an error condition exists and the
DAQ issues an alarm.
 Continually computes block position, block velocity and hook load and uses these
values, along with the direction of block travel, to determine the braking required.
 Continually sends two pulse-width modulated signals to the brake controller,
representing the required current flow in the eddy current brake (Normal Throttle and
Reverse Throttle).
 If the friction brake is required, the DAQ energizes a relay housed in the brake controller
and issues an alarm.
 When the eddy current brake is utilized, the DAQ receives a signal from the brake
controller (Current Feedback) representing the current flowing in the brake. If the
current required by the block control software is not flowing in the brake, an error
condition exists and the DAQ issues an alarm.
 Sends signals to the driller display regarding block control system status so that the
status can be represented on the display.
 Receives operator input signals from the driller display.
 Monitors the Command Feedback signal.
 Monitors the system for Non-Critical and Critical error conditions.
 Monitors status of input UPS.
Brake Controller Functions

The Baylor 2025B brake controller performs the functions listed below:
 Receives and compares braking command signals from the throttle and DAQ.
 Converts the higher of the throttle and DAQ braking command signals into current
command and sends that current to the eddy current brake.
 When the eddy current brake is utilized, the brake controller sends a signal to the DAQ
(Current Feedback) representing the current flowing in the brake.
 If the current flowing in the brake is less than that required by the block control software,
an error condition exists and the DAQ issues an alarm and takes appropriate action.
 Checks for Non-Critical and Critical error conditions in the brake controller and informs
the DAQ of these conditions, so that the DAQ can issue an alarm.
 When the eddy current brake is controlled by the throttle, the brake controller receives
signals from the Power Select Box restricting the maximum current output to the eddy
current brake (50% or 100% of the rated current excitation) and regulates the output
current accordingly.
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System Signal Paths

Figure 3.2 illustrates the signal paths between block control system components. Signals that
require explanation are described in sections titled, "Non-Critical Error Condition Signal"
through "DAQ Alarm Signal".
Non-Critical Error Condition Signal

This voltage signal is sent to the DAQ when a non-critical error condition is detected in the
brake controller.
Critical Error Condition Signal

This voltage signal is sent to the DAQ when a critical error condition is detected in the brake
controller.
Nor mal Throttle Signal

This pulse-width modulated signal tells the brake controller how much current to send to the
eddy current brake. Zero VDC corresponds to 0 current and ten VDC corresponds to the
maximum rated current excitation.
Reverse Throttle Signal

This pulse-width modulated signal is the inverse of the Normal Throttle signal where zero
VDC corresponds to the maximum rated current excitation and ten VDC corresponds to zero
current. The presence of this signal insures that full application of the eddy current brake will
be commanded if the DAQ loses power or malfunctions.
Current Feedback Signal

This scaled 4-20mA signal (0-160 braking amps) represents the current flowing in the eddy
current brake. If the current flow in the eddy current brake does not reach the rate requested
by the DAQ, the DAQ assumes that a problem exists in the eddy current brake, brake
controller or connecting cables and issues an alarm that commands application of the friction
brake.
Command Feedback Signal

This scaled 4-20mA signal (-10% to 100% current command) represents the percentage of
current command sent by the brake controller to the eddy current brake. It is used to insure
that the Normal Throttle and Reverse Throttle signals sent by the DAQ are in agreement. If
this current is not representative of that intended by the DAQ Normal Throttle and Reverse
Throttle signals, the DAQ assumes that one of the two signals is faulty and issues an alarm.
DAQ Alar m Signal

Whenever the DAQ senses an error condition, it sends a DAQ Alarm signal to the brake
controller auxiliary board, mounted on the brake controller door (Appendix A, titled "2025B
Brake Controller"). Upon receiving this signal, the auxiliary board turns on a red LED,
indicating the error condition and alarm.
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Driller’s Display
Throttle
Alarm
Horn (For configuration
Laptop and calibration)
M/D Totco
M/D Totco DAQ
Barrier Box
Calibration Baylor 2025B

Switch Box Brake Controller
Shaft Encoder
Drawworks
Proximity
Derrick
Proximity
Brake Solenoid
Current Brake
To Friction
To Eddy-
Derrick
Proximity
Heave (optional)
Hookload
Figure 3.2: Block Control System Signal Paths
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DAQ Alarm Response

The brake handle on most drilling rigs is firmly and mechanically linked to the friction brake
bands, assuring the driller is always able to activate the brake. Less understood by those
unfamiliar with drilling equipment, however, is the fact the system can also rapidly and
forcefully move the handle. Hence application of the friction brake can involve movements that
could endanger the driller. Further, application of any braking force, even the relatively slow
acting eddy current brake, when heading upward, could cause line spooling problems and
severely shorten wireline life.
Zones
In the design of the block control system it was decided to divide the operation of the hoisting
equipment into “zones” of operation. These zones relate to when operations would be
endangered by a failure of the eddy current braking ability.
In a Zone “0”, a failure of the eddy current brake would be of no immediate consequence. The
driller and/or system would not need to take immediate action. This was defined to be true,
only when raising, and above 5 feet of the floor, but at a height less than where braking should
be initiated to bring the blocks to a stop at the appropriate Hi setpoint (Corner Up).
Zone “1” is an area of operation where full application of the eddy current brake could (by
itself) bring the block to a minimal safe speed. These areas are:
 Physically anytime the block is headed downward, and the system calculates that
electric brake activation can stop the block before it reaches its lower target.
 When headed upward above the Corner Up, but less than the Hi Setpoint.
Zone “2” is an area where application of the eddy current brake alone might not be sufficient to
bring the blocks to minimal speed before encountering one of the physical setpoints.
Physically these areas are located below the point where the system calculates both brakes
must be applied to avoid block travel beyond the set limits.
Figure 3.3: Block Operation Zones - Block Traveling Up
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Alar m Classification
All alarms originally generated by the 2025B brake control are classified as either “critical” or
“non-critical”. Critical alarms are those that immediately and adversely affect the output of the
brake control and non-critical alarms are those that alert us to a failure of a redundant
component or to a tolerable situation, which allows the controls to fully operate. For example,
the failure of one of the two redundant control power supplies or the grounding of only one
input power phase are non-critical alarms.
These classifications are further extended to non-brake control components. For example, the
Brake Cooling Alarm is non-critical because it should not immediately affect brake
performance, but should be alarmed. Similarly, if the DAQ receives conflicting signals as to
where the block is located, the only sure action is to treat the situation as a critical alarm.
Alar m Response
When the alarm system portion of the block control system is active, it can only take one of the
four predefined actions as described below.
 Alarm response “0” - Take no action, no alarms were activated. The System On LED is
continuously lit, indicating all is OK.
 Alarm response “1” - Sound an audible horn and give a visual alarm. A yellow LED
indicates to the driller that something is wrong with the system.
 Alarm response “2” - Sound an audible horn and give a visual alarm, as in “1” above, but
also command the eddy current brake control to come on fully. The eddy brake will
safely control the block by itself.
 Alarm response “4” - Performs all actions as in “1” and “2” above, but also activates a
solenoid energizes the Crownamatic. This actuates the friction brake and releases any
pressure available to the drawworks clutches.
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Matrix Definition
Figure 3.4: Block Operation Zones - Block Traveling Down
The proper alarm response is determined from whether an alarm is critical or non-critical and
in which zone the alarm has occurred.
Alarm Responses
Alarms
Zone No Alarm Non-Critical Critical

Alarm Alarm
0 0 1 1
1 0 1 2
2 0 1 3
Alarm Summary
The system will alarm with only an audible and visual indication to those alarm conditions that
do not immediately adversely affect the ability of the system to bring about a safe stopping, or
near stopping, of the block. If in a situation where only the eddy current brake is required to
bring about a safe condition of the block, then only the eddy current brake should be
energized. If, on the other hand, the eddy current brake alone is not sufficient to safely bring
about the stopping of the blocks, then the friction brake will be applied.
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Page
Envelope Over-Ride Emergency
Reset Stop
Revision
Learn
Printed By: foxm2
V Dn Man
Emer Stop
Document number
TC Number: 60-60-MAN
Block Speed
2025B
Friction Brake
G
-
+ PID III
60-60
34 of 136
Blinker R
Critical Alarms
EDMS Prox
3
Electric
Encoder 0, 1 Brake
Alarm Summary
38
Hookload
Figure 3.5: Brake Control System Signal Flow

Position 2
Blinker Y
Non-Critical Alarms
EDMS Prox
Printed REV: G
1
Encoder
0, 1
Alarm Summary
Hookload 0
Position Blinker G
System ON
Zone Alarm Response

0, 1, 2, 3
2 HI
1 85'
0, 1, 2
1 25'
0 2
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Latest REV: G
Printed On: 2012.04.05.10.31.29

Revision G
Page 35 of 136
System Alarm Conditions

An alarm is issued by the DAQ when an error condition or sensed malfunction exists. The
DAQ uses these error conditions in conjunction with block operation zones to determine the
proper alarm response. The DAQ alarms are determined on channels available for viewing on
the laptop with CALCONF or with a SAC or DataWatch, if the system is so equipped. Normal
system operation is indicated by a “0” alarm value while a “1” indicates an alarm.
There are also two associated summary channels, a critical summary and a non-critical
summary, each of which will be a 1 if any of the respective critical or non-critical alarms are
high. As a further aid in troubleshooting, there is a channel within the DAQ called Last Alarm
# the value of which is the alarm number of the last alarm. This channel is not usually erased
(except by system restart) so that the last offending alarm is recorded. This is true even if the
system is reset by the operator before the maintenance personnel can connect the laptop.
Alarms names described below have a 14 character limit. The descriptions of the DAQ alarms
are:
• Accelerated • Derrick Prox • Brake Cooling

• Brake Critical • Position • Friction Brake Pressure Switch
• Current • Velocity Down • Hook Load Alarm
• EDMS Prox • Velocity Up • UPS
• Encoder • Brake Non-Critical • Non-Critical Position
Acceleration Alar m
This alarm indicates an inability of the block control system to keep the downward acceleration
of the block within previously defined limits. This alarm might occur if the allowed acceleration
is quite low because of a low maximum allowed velocity (as when the speed limit
potentiometer is turned down quite low) or if the brake is quite hot and ineffective. If the electric
brake is not impaired, alarm avoidance could be done by having the driller pull on the electric
brake prior to mechanical brake release, and then slow electric brake release. Note that this is
the normally recommended method of operation of the electric brake.
Brake Critical
This alarm condition is the result of the brake control sending a signal to the DAQ indicating a
critical alarm that seriously affects the brake or brake control ability to absorb torque. Critical
alarms within the brake control include, SCR Misfire, Over-Current, Over-KW, Throttle
Mismatch, Battery Back-Up In Use, Coil Fuse, and Input Power Quality. Any of these
alarms should turn the appropriate LED indicator on the brake control mimic panel from green
to red and also sink the available source voltage on the appropriate DAQ analog channel,
announcing the alarm.
Current Alar m
This alarm is essentially a DAQ backup of the brake control throttle mismatch alarm. If the
DAQ senses that it is commanding near full output current, but does not have sufficient
response, this alarm will occur. Consistent occurrence with a properly acting brake control
might indicate improper calibration of the current feedback signal.
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EDMS Prox Alar m

This alarm will go high (become a 1) if there is a sensed discrepancy between the counts
recorded from the encoder and the counts sensed by the prox switch mounted to detect the
target on the drawwork drum clutch (the EDMS proximity sensor.) An alarm could indicate that
the prox switch or its target is improper or that the encoder is inactive. An inactive encoder
could trip this alarm and the Encoder Alarm.
Encoder Alar m (Encoder Operation)

This alarm indicates that the system has detected drum rotation via the EDMS prox switch, yet
has sensed no rotation of the drawworks encoder itself. Possible causes of this alarm include
unscrewing the encoder assembly from the drawworks shaft assembly, and/or a severance of
the encoder cabling.
Derrick Prox Alar m (Encoder Operation)

This alarm indicates that the system has sensed the position of the derrick prox switches at a
point outside the allowable range (Derrick Prox Lo to Derrick Prox Hi.) The most frequent
cause for this is system miscalibration after the drill crew has cut and slipped the line without
resetting the system zero point. Note that this alarm does not reset with system Reset or
Override because it indicates a serious system miscalibration. The alarm will clear itself when
the derrick prox switches are sensed within the allowable range.
Note: that during system commissioning, allowable range should be determined. This
range will account for normal line stretch, movement, and variances as a result of a
retractable block and/or a crown or block mounted heave compensator.
Position Alar m
This is the most common alarm. It will occur anytime the elevators go beyond the allowable
range, i.e. above the Hi Setpoint, or below the Lo Setpoint. This alarm will also occur on
systems with the ZMS option whenever the elevators go below a ZMS target that has been
activated. It is important to realize that this alarm does not necessarily indicate system
malfunction, but may be an indication that the driller should redefine the allowable area of
operation. Pushing the Learn button (sometimes called the HI-LO Limit Set) redefines the
allowable limits.
Velocity Down Alar m

This alarm indicates an inability of the block control system to control the downward velocity of
the block. The alarm may indicate the brake has over-heated, de-clutched, or become
ineffective.
Velocity Up Alar m
This alarm indicates an inability of the block control system to control the upward velocity of
the block. This alarm most frequently occurs when the driller mistakenly continues powering
upward past the Hi setpoint, usually occurring just before the position alarm.
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Brake Non-Critical
This alarm condition is the result of the brake control sending a signal to the DAQ indicating
that a non-critical alarm has been sensed by the brake control. Non-critical alarms are those
that do not immediately and adversely affect the ability of the brake or brake control to control
the block. These include AC ground, DC ground, loss of one of the two control power sources,
or phase rotation. Any of these alarms should turn the appropriate LED indicator on the brake
control mimic panel from green to red and also sink the available source voltage on the
appropriate DAQ analog channel, signaling the alarm.
Brake Cooling
This alarm is on those systems that have the brake monitoring system option. It indicates a
high temperature has been sensed for the outlet cooling water, or a loss of cooling water flow
on the input. There is a two second delay of the alarm activation with the flow sensors, to
account for flow fluctuations, and a disarming of the alarm after five minutes of no brake use.
This is to allow the driller to stop the cooling water for a period of time without the alarm
sounding. Note however that the alarm is immediately reactivated if the brake is used without
proper cooling water flow.
Friction Brake Pressure Switch

This alarm is on those systems that have the brake monitoring system option, monitoring the
air pressure used to set the friction brake (the pressure to the Crownamatic activation
solenoid). This must be available to back up operation of the electric brake, and is sensed to
comply with requirements for North Sea operation. This alarm and/or pressure switch can be
eliminated if there is a battery back-up available. Note that occurrence of this alarm will
frequently occur if the driller over-rides the Crownamatic.
Hook Load Alar m

This alarm indicates that the sensed hookload is below a value of zero, usually indicating that
the hydraulic pressure has been lost to the cell.
UPS Alar m
This alarm is on most systems including the brake monitoring system option, and indicates
that the system UPS is running on its battery reserve. This alarm might also be on other
systems, and possibly not on some with the brake monitoring system option that utilize a rig
central UPS system.
Non-Critical Position
This alarm indicates that a critical position alarm is about to occur. It serves as a warning for
some operators of impending friction brake activation.
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Set Points
The operator programs an upper and lower set point into the block control system using the
Learn button on the driller display (Chapter 6). Upper and lower set points are defined below.
 Upper Set Point - the highest working position that the block should reach
 Lower Set Point - the lowest working position that the block should reach
Each set point has a prescribed buffer, or distance above and below the set point. The function
of the block control software is to stop the block within the buffer zone. Buffer zones are part of
the block control software and cannot be changed by the operator.
Note: The operator can change the upper and lower set points, but not the buffers.
Cor ners
The block control software continually calculates upper and lower corner values and uses
them to determine when and how to apply the brakes. Upper and lower corners are defined
below.
 Upper Corner - When the block is traveling up at maximum velocity, the upper corner is
that point at which the block should begin to slow down, or decelerate. The upper corner
exists only when the block is traveling up.
 Lower Corner - When the block is traveling down at maximum velocity, the lower corner
is that point at which the block should begin to slow down, or decelerate. The lower
corner exists only when the block is traveling down.
Battery Backup Enabled

When the battery backup is enabled, the brake controller auxiliary board's battery backup LED
comes on. The battery backup is enabled by either of the conditions below:
 The brake controller throttle mismatch alarm or
 The Emergency Stop button on the driller display is activated.
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4: Installation
Introduction
This chapter contains the following:
 Location requirements for block control system components
 DAQ installation
 MDT barrier box installation
 Sensor installation
 Sensor and block control system component connections to the DAQ
 Driller's display, Drill/Trip switch connections to the 2025B brake controller
 Friction brake solenoid installation
Refer to the engineering drawings supplied with the manual for detailed installation
dimensions. Refer to Baylor Company manuals for procedures on installing all Baylor
instruments.
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Hazardous Area Locations

Figure 4.1 shows the location requirements for block control system components. Before
beginning installation, the installer should be thoroughly familiar with the code requirements
and hazardous area classifications for all areas of the installation site and should be
experienced in the common methods of installing intrinsically safe equipment.
CLASS I DIVISION 1 NON-HAZARDOUS

GROUPS C& D LOCATIONS
(Only connected
for calibration) M/D Totco
DAQ
Calibration
Switch Box Intrinsically Safe
Sensors Barriers
Driller
Display Bylor 2025B
Brake Controller
Throttle
Eddy
Current
Brake
Friction
Brake
Solenoid
Figure 4.1: System Component Location Requirements
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4: Installation
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DAQ Installation
To install the DAQ follow the steps below.
1. Mount the DAQ (page 41).
2. Earth ground the DAQ ("Ground the DAQ" on page 42).
3. Connect the primary AC power cord to the DAQ and to the AC source (page 42).
4. Ensure that the switch positions on the DAQ digital board are properly set (page 43).
5. Ensure that the switch positions on the DAQ communications board are properly set
(page 45).
6. Ensure that the switch positions on the DAQ EDMS board are properly set (see "EDMS
Board Dip Switch Settings" on page 46.)
Mount the DAQ
Mount the DAQ as close to the brake controller as possible, using the four mounting holes on
the DAQ rear door (Figure 4.2). The DAQ may be bolted directly to a rigid structure or bolted to
mounting brackets and then clamped securely to a rigid structure. A clearance of
approximately 30 inches (76.2 cm) in front and on the left side is required to allow the door and
case to swing fully open. Clearance below the DAQ should be adequate for service loops that
allow opening of the case to access the rear compartment.
14.00 13.40
21.56
18.56
19.76
19.06
Figure 4.2: DAQ (Permanent Location) Installation Dimensions
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Page 42 of 136
Ground the DAQ

Connect the eight-gauge ground conductor, P/N 230017, from the DAQ to earth ground as
follows:
Caution: All earth ground connections must be made in non-hazardous areas. Ensure
that all connecting surfaces are bare metal and completely free of grease, paint or
oxidation and that the distance between the DAQ and ground connection is minimal.
Do not solder earth ground connections.
1. Connect one end of the ground conductor to the DAQ ground lug (Figure 4.3).
2. If a grounding rod will be used, proceed to Step 3. Otherwise, use an appropriate-sized
ground clamp to make a secure compression connection between the free end of the
ground conductor and rig substructure.
3. Drive a clean, copper-clad grounding rod that is eight feet long and 1/2-inch in diameter
into the ground so that just enough of the rod is exposed to attach a 1/2-inch ground
clamp.
4. Use a 1/2-inch ground clamp to make a secure compression connection between the
free end of the ground conductor and the grounding rod.
Sensor Cable Glands
Ground Lug
Spectrum Display Spectrum Display Configuration/Calibration

T-Pot BNC Connector Laptop Connector
Figure 4.3: DAQ Ground, Power, and Signal Connectors
Connect Primar y AC Power Cable

To connect the primary AC power cable from the rig power source to the DAQ, refer to Figure
4.4 and follow the steps below.
Caution: Ensure that the ground wire is properly installed before connecting primary
AC power cable
5. Open DAQ rear cover door.

6. Ensure that DAQ ON/OFF switch is set to OFF position.
7. Remove the protective cover which encloses the power terminals and power supply.
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8. Route end of AC power cable (PN 219531-002) with terminals through DAQ cable
gland.
9. Observe wire color coding and connect terminals to terminal block and ground lug.
10. Tighten cable gland nut until cable is secured.
11. Connect other end of AC cable to rig power source.
12. Roll and tie excess cable away from rig traffic and working space.
13. Replace AC power protective cover.
+/- 15VDC
Power Supply
On/Off
Switch
+5/+28VDC
Power Supply
Isolator
WARNING GND
Ground
Fuse Terminal
(2 Amp) Block
AC Power Cable/
Cable Gland
Figure 4.4: AC Primary Power Connections
Digital Board Dip Switch Settings

The digital board contains two dip switches. Figure 4.6 shows how SW2 should be set for the
block control system. Refer to this figure to insure that the switch positions on SW2 are
properly set. For information on alternate settings for SW2 and on other features of the DAQ
digital board, refer to Manual 60-10. SW3 is currently not used
Note: Switch position 2 on SW2 must be set to the OFF position. Otherwise, the DAQ
will not communicate with the EDMS board to receive block height data.
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Main
Main Processor Analog
Main Processor Processor
Processor RESET
RESET
LED
D2
SW1
SW4
J11
J4
J3
U1
U16
A
B
C
B
D1
Main Programs
EPROMs
U15
U19
BT1
Watchdog
ON
SW2
Timer LED
SW2
OFF
J8
1 2 3 4 5 6 7 8
D3
U17
J9
Analog Processor LED Analog Processor
Figure 4.5: DAQ Digital Board Dip Switch Settings
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DAQ Spectrum I/F Board

220660-002
Com V 3.31
JP1
JP2
JP3
JP4
JP6
JP5
219952-404
SIF V 1.58
Figure 4.6: DAQ Spectrum I/F (SIF) Board
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SIF Board Jumper Settings
Jumpe Default Jumper Setting Description

r
JP1 Not Used
Installed between pins 15 and 16 Used to select the T-Pot network baud rate
JP2
for 42.8K baud (default = 42.8K)
JP3 Not Used
JP4 Not Used
JP5 Not Used
JP6 Not Used
EDMS Board Dip Switch Settings

The EDMS board contains one dip switch, as shown in Figure 4.7. This switch is currently not
used.
220206-002
v 1.04
Figure 4.7: EDMS Board Dip Switch Settings
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I.S. Barrier Box Installation

The intrinsically safe(I.S.) barrier box provides safety barriers for connecting the block control
system to I.S. devices. Point-to-point wiring is specified in the installation drawing.
I.S. barrier box wiring must meet the local regulatory code requirements of the installation
location. Examples of local regulatory codes are NFPA-70, BS5345 Part 4 and ANSI-ISA 12.6.
Check for local requirements, if necessary.
Barrier Assignments
Barrier Channel Barrier Function Barrier PN
1 BCS system on LED
1 951540-073
2 BCS alarm LED
1 24 volt horn power
2 951540-076
2 Alarm horn
1 24 volt LED power
3 951540-073
2 Drill/Trip switch
1 Learn pushbutton
4 951540-078
2 10 volt switch power
1 BCS E-stop push button
5 951540-078
2 DVRD/Norm/Reset switch
1 Baylor throttle
6 951540-074
2 Baylor throttle
1 Baylor Drill/Trip switch
7 951540-038
2 Baylor switch power
1 Baylor override switch
8 951540-038
2 Lowering speed signal
1 Friction brake LED
9 951540-038
2 Baylor E-stop
1 Encoder power
10 951540-035
2 Encoder power
1 Encoder signal A
11 951540-040
2 Encoder signal B
1 Calibration switch box EXE
12 951540-078
2 Calibration switch box communication
1 Calibration switch box layer
13 951540-078
2 Calibration switch box calibration
1 Hookload
14 951540-076
2 Hookload
15 951540-078
2 10 volt Pot power
16 951540-078
2 Flow switch
17 951540-078
2 Water temperature in
1 Water temperature out
18 951540-078
2 Spare
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Barrier Assignments (Continued)

Barrier Channel Barrier Function Barrier PN
19 1 Drawworks proximity switch 951540-007
20 1 Derrick proximity 951540-007
21 1 Derrick proximity 951540-007
Sensor Installation
This section contains installation procedures for the proximity sensors, shaft encoder and hook
load pressure transducer, as follows:
 Installing the sensors onto the rig.
 Connecting the sensor signal cables to the DAQ field termination board.
Cabling Guidelines
The following paragraphs describe guidelines to follow when connecting sensor signal cables.
Guidelines for Preventing Cable Damage

Observe the following practices when routing sensor signal cables to the DAQ termination
board:
 Route cables so that they are out of walkways and not exposed to sharp corners that
could wear through the insulation.
 Plan signal cable runs to avoid wet areas and close proximity to power cables.
 Use nylon (land rig) or stainless steel (offshore rig) tie wraps to dress, secure, and
support the cables.
 Take special care to protect splices from moisture and excessive strain.
Electrical Interface
When signal cables must be run such that power cables could cause electrical interference,
use shielded cables instead of the non-shielded cables. This prevents induced noise from
causing erratic sensor channel values.
Shielded Cable Splicing

Sensor cables must typically be spliced in the field.
Warning: Plan each rig up so that splices are not located in hazardous areas.
Follow the guidelines below when splicing shielded cable:

 When joining two pieces of cable, always cut the individual conductors.
 Stagger the butt splices along the length of the cable splice.
 Observe color code when cutting and splicing conductors.
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 Use a crimping tool and apply enough pressure on each butt splice connector to ensure
a good compression connection between the conductor and the connector.
 Always seal and protect each splice with a strip of mastic tape that extends up the cable
about one inch past both sides of the splice and wrap the mastic tape securely with
black electrical tape.
Warning: Check local electrical codes. Splicing is not allowed in some offshore
areas. Any cable termination or junctions must be protected by junction boxes
in these applications.
Proximity Sensor Installation
The following paragraphs describe how to install the drawworks and railmount proximity
sensors.
Drawworks Proximity Sensor Installation

To install the drawworks proximity sensor and target, refer to Figure 4.8 through Figure 4.10
and follow the steps below.
1. Measure the circumference of the drawworks high clutch assembly.
2. Mount the supplied target, P/N 220605-001.
3. Weld the sensor's metal mounting bracket to the rig floor.
4. Place the sensor into the bracket; then slowly rotate the drawworks drum one revolution
to insure that the sensor is not struck by the target and that the gap between the sensor
and target is 1/8" to 1/4".
5. Connect the sensor cable to the DAQ ("DAQ Sensor Connections" on page 59).
6. After the sensor is connected to the DAQ, refer to engineering drawing numbers 220416
and 220420, if needed, and verify the following voltages:
DAQ, barrier side:
 No target, less than 3.40 V (J7 DIGITAL IN (+) and J7 GROUND)
 With target, more than 8 V
At sensor:
 No target, estimated 4.5 VDC
 With target, estimated 8.0 VDC
At DAQ:
 No target, less than 1 VDC
 With target, 10 VDC
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Drawworks
High Clutch
Assembly
Target
4"
Target Drawworks
Proximity Frame
Sensor
6%
of
Circumference
Figure 4.8: Drawworks Proximity Sensor and Target
Metal Target
Hole Diameter 31mm
C C A
Adjustable
Proximity Sensor Metal Mounting Bracket

Welded to Rig Floor
Mounting Bracket
Rig Floor (Enlarged View)
A = Distance between metal mounting bracket and top of proximity sensor (min. 1 inch).
B = Distance between proximity sensor and meta target (min. 1/8 inch, max 1/4 inch).
C = Distance between proximity sensor and any metal object (min. 1.25 inch).
Figure 4.9: Mounting Dimensions - Drawworks Proximity Sensor
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Railmount Proximity Sensors Installation

The railmount proximity sensors detect two metal targets on the traveling block when the
targets pass the sensor. Follow the steps below to mount the sensors and targets.
Note: BCS Cal/Conf is preset to Lo = 15’ and Hi = 25’. If sensors are not in this range,
adjust limits in Cal/Conf.
1. Select the mounting position for the targets and sensors by referring to Figure 4.10 and
Figure 4.11 and honoring these two requirements:
 The location of the proximity sensors must be such that, when the block is traveling
down, the sensor activates before the block assembly base is close to the rig floor.
 The mounting location should be at a height maintenance personnel can easily
access at any time. This is typically head high on the level of the doghouse.
2. Attach a metal target to the traveling block assembly.
(If the rig has heave compensation device, the target should be mounted on the
uncompensated side of the dolly.)
3. Weld the proximity sensor mounting bracket to the rail.
4. Insert the sensor and adjust as needed; then tighten the screws to hold it in place.
5. Slowly move the block so that it passes the sensor and insure that the sensor is not
struck by the target.
Refer to "DAQ Sensor Connections" as indicated on the system drawings, to connect
the sensor cables to the DAQ.
6. After the sensor is connected to the DAQ, refer to engineering drawing numbers 220416
and 220420, if needed, and verify the following voltages:
Note: Railmount proximity sensors are not connected to 2 channels. Sensors are
wired in series (DAQ connector J9D).
At DAQ:
 No target, less than 1 VDC
 With target, more than 3.4 VDC
At sensor:
 No target, 3.40 VDC
 With target, 8.5 VDC
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Figure 4.10: Railmount Proximity Sensor Installation
Note: It is not imperative that the A and B proximity switches are at the same height.
But, It is imperative that the targets mounted on the dolly activate both switches
simultaneously.
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Proximity Sensor
Top Drive Rail
Block
Assembly Target
Mounting Bracket
Proximity Sensor
Top Drive Rail
Mounting Bracket Side View
Adjustable
Front View
Mounting Bracket Top View

A = Distance from back of sensor to mounting bracket (min. of 1.5 inches).
B = Distance from sensor to any other metal object (min. of 6 inches).
C = Distance between sensor and target (min. of 0.5 inch).
D = Distance between sensor and any other metal in absence of target (min. of 4.8 inches).
Figure 4.11: Mounting Locations - Railmount Proximity Sensors & Target
Figure 4.12: Traveling Block Target Dimensions
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Shaft Encoder Installation

Refer to Figure 4.14, then follow the procedure below to attach the encoder to either end of the
drawworks at the rotoseal.
Caution: Never install the encoder with the conduit adapter pointed up. If the conduit
adapter is pointed up, water will accumulate in the electrical connections causing
corrosion and electrical shorts
1. Ensure that rotoseal thread diameter is 1"- 14 and correctly mates with encoder. Use
adapters to match the threads, if needed.
Note: The encoder is designed to fit common drawworks configurations. If the

drawworks must be modified in order to mount the encoder, obtain approval from rig
personnel before making any modifications.
2. Check rotoseal area for possible interference with rig hardware, such as shields or bolts.
3. Turn off rotoseal air supply.
4. Unscrew rotoseal from drawworks drum shaft.
5. Screw encoder onto drawworks drum shaft, using loctite compound.
6. Reinstall rotoseal on threaded end of encoder.
7. Turn rotoseal air on, then check assembly for leaks.
8. Fabricate a mounting bracket to hold encoder in a fixed position (Figure 4.14); then weld
bracket to the rig floor.
6.41 [162.71] 3.14 [79.76]
CCW CW
.50 NPT CONDUIT

ADAPTER ENCODER SHOWN WITH
COVER REMOVED
Figure 4.13: Shaft Encoder Dimensions
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9. Connect the cable, Part Number 219343, to the encoder.

10. Refer to "DAQ Sensor Connections" and the engineering drawings supplied with this
manual to connect the encoder cable to the DAQ.
Drawworks
Encoder
Drawworks Encoder
Mounting
Bracket
Mounting
Bracket
Front View
Figure 4.14: Encoder Mounting Bracket
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Heave Compensator Sensor

The heave sensor is mounted to the hook and traveling block as shown below. The output of
the motion compensator sensor is connected to DAQ channel JA10. See the interconnect
drawings for connection details.
Traveling Block
M/D Totco Motion

Compensator Sensor
Hook
Figure 4.15: Heave Compensator Sensor Mounted
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Calibration Switch Box Installation

The calibration switch box should be stored inside the J-box near the driller's station so that
the driller can use it to calibrate block height. Figure 4.16 shows the switch box dimensions.
Refer to "DAQ Sensor Connections" and the engineering drawings supplied with the system to
connect the switch box to the DAQ field termination board.
Figure 4.16: Calibration Switch Box Dimensions
Hook Load Pressure Transducer Installation

The hook load pressure transducer is connected to the rig's hydraulic weight indicator system
between the weight indicator and the load cell on the deadline anchor. It should be located as
close to the weight indicator or load cell as possible. Follow the guidelines below to connect
the pressure transducer.
 Choose the transducer assembly to match the rig's weight indicator system. Use the
table titled "Suggested Transducer Ranges" on page 58 to determine the appropriate
transducer.
 Before connecting the transducer into the hydraulic line, make sure that no air is trapped
in the transducer assembly by connecting the transducer to a hydraulic pump and filling
the reservoir with hydraulic fluid.
 Before connecting the transducer into the hydraulic line, advise the driller, tool pusher
and company man that a connection will be made in the weight indicator system.
 Make the hydraulic line connection when hook load is at a minimum, so that the
hydraulic pressure will be low. To accomplish this, ask the driller to put the drill string on
the slips while the connection is made.
 Hook load transducer assemblies are available with two types of hydraulic connectors.
Check the rig's hydraulic system and refer to Chapter 9, titled "Illustrated Parts
Breakdown" to determine which connectors are required. Figure 4.17 shows a typical
transducer installation with a load cell.
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 After making the hydraulic line connection, connect the transducer signal cable to the
DAQ, as described in "DAQ Sensor Connections" on page 59 and the engineering
drawings supplied with the system.
 Insure that the transducer assembly and signal cable do not interfere with the movement
of the deadline or anchor.
 Check for leaks in the hydraulic system after installing the transducer assembly.
Caution: It is critical to insure that there are no leaks in the hydraulic system
after installation.
Suggested Transducer Ranges

Type of Weight Indicator Max Deadline Max Load Cell X-ducer Range
Load (lbs) Output (psig) (psig)
30 or equivalent 30,000 970 0-1000
40 or equivalent M/D type F,26 S 40,000 1408 0-2000
50 or equivalent M/D type D 50,000 816 0-1000
75 or equivalent M/D type E 75,000 816 0-1000
100 or equivalent M/D type EB 100,000 1088 0-2000
type EH with Hercules 122A 120,000 1304 0-2000
120 & Hercules 150 120,000 1440 0-2000
150 & Hercules 150 150,000 1800 0-2000
Figure 4.17: Typical Hook Load Transducer Installation
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DAQ Sensor Connections

Each sensor cable must be connected to the DAQ field termination board (Figure 4.18). The
main features of the field termination board are summarized below:
 Analog Sensor Terminal Blocks - J1A through J23A; used to receive input from
current- or voltage-type sensors.
 Analog Sensor Voltage/Current Switches - located to the right of J1A through J23A,
these red rocker switches are used to identify each analog sensor input as current or
voltage. A 24th rocker switch is present; however, it serves no function and should be
ignored.
 Digital Sensor Terminal Blocks - J1D through J14D; used to receive input from digital
sensors. These terminal blocks are also used if the DAQ is used to drive other
instruments, such as chart recorders.
 EDMS Sensor Terminal Block - J1E; used to receive input from EDMS sensor.
 Calibration Switch Box Terminal Block - J1S; used to receive block height input from
the calibration switch box.
 Power Terminal Blocks - J1P - J6P; supplies 12 VDC to power other instruments.
 E-DEPTH™ Terminal Blocks - J2S, J1R; used when E-DEPTH is part of the system.
Refer to the engineering drawings supplied with the system for block control system
installation and point-to-point wiring diagrams for rigs with and without existing brake
monitoring systems. To connect sensor cables, use the DAQ sensor cable screwdriver (PN
999701-005) to open the wire connector slot and then insert the wire. For analog sensors, set
the corresponding DAQ analog board rocker switch to “Current” or Voltage”, to reflect the
sensor type.
Note: Set the red rocker switch to “Current” for the hook load transducer.
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Analog Sensor
Voltage/Current Switches
Depressed
Positions: Digital Sensor

Current = Depressed toward Terminal Blocks
DAQ center (Digital Out = +10V)
Voltage = Depressed away from SOURCE 1
DAQ center DIGITAL IN 1
J1D
GROUND
DIGITAL OUT 1
SHIELD
SOURCE 3
DIGITAL IN 3
J3D
GROUND
DIGITAL OUT 3
SHIELD
SOURCE 5
Analog Sensor DIGITAL IN 5
J5D
Terminal Blocks GROUND
DIGITAL OUT 5
(Source = +24V) SHIELD
SOURCE 1
SIGNAL 1 1 of 6 Power
J1A
GROUND 1
SHIELD Out Terminal
SOURCE 3 Blocks (12 VDC)
SIGNAL 3
J3A
POWER1
GROUND 3
SHIELD
GROUND
SHIELD
SOURCE 5
J5A
SIGNAL 5
GROUND 5
SHIELD
EDMS Input
SOURCE 7
Terminal Blocks
J7A
SIGNAL 7
GROUND 7
SHIELD EXC
SOURCE 9
CONN
LAYER
J9A
SIGNAL 9
GROUND 9 CAL
SHIELD DAQ, Front View SHIELD
SOURCE 11
J11A
SIGNAL 11
GROUND 11
SHIELD
Figure 4.18: DAQ Field Termination Board
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Friction Brake Solenoid Installation

The 2025B brake controller commands activation of the friction brake via a solenoid valve
generally supplied by . The specifications for this solenoid are given below.
 Explosion Proof, NEMA 7, 9 Groups A and B
 150 PSI or greater
 Normally closed 3 way valve
 Brass ports or equivalent
 Nominal 11 watt coil
 Coil voltages available in 120 volt or 240 volt, 60 Hz, 240 Volts 50 Hz, and 24 VDC.
The most frequently used solenoid is P/N 221431-001 (120 V, 50/60 Hz).
Follow the steps below for installation.
1. Start with a Crownamatic that is already fully operational. A “typical” schematic for such
is shown in Figure 4.19. The hose connections for a conventional Crownamatic are
frequently numerous and difficult to follow, hence the reason for starting with a known
good unit. There is often work being done on a Crownamatic simultaneous with
installation of the block control system but it is imperative that the Crownamatic be
operational beforehand.
2. Locate the “actuating” line that will go from the “toggle valve” located above the
drawworks to some assortment of actuators and/or relays. In every system there will be
a high pressure supply to the toggle valve, and a line from the toggle valve that will be
the “actuating” line.
3. Locate a source of usually high rig air pressure. The most commonly used source is that
just downstream of the Crownamatic override valve. This is so that if the block control
system sets the friction brake, over-ride with the Crownamatic releases the friction brake
regardless. Note however that it is also acceptable to supply the solenoid valve with
constant rig air pressure, thus insuring the capability of the block control system even if
the Crownamatic system is in override.
4. Physically mount the solenoid so as to have convenient access to both of the above
lines. Hookup the electrical connections to the explosion-proof coil.
5. Remove rig air from the Crownamatic system. Referring to Figure 4.20, install a “T” in
the high pressure line, from the Crownamatic override valve and reconnect the line, so
as to have one available port. From that port run a hose to the “HP” or high pressure
port of the friction brake activation solenoid.
6. Break the connection of the “actuating” line between the toggle valve and whatever
other equipment might exist (air cylinders, air relays, etc.).
Run a connection from the toggle valve port to the “A” or “LP” input of the friction brake
solenoid valve. Connect the hose that had previously gone to the toggle valve to the
“Out” port of the friction brake activation solenoid.
7. If the system has a BMS option, a friction brake pressure switch must be installed in the
high pressure air available to the friction brake solenoid valve. Connect the electrical
wires as per the system drawing.
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8. Test the system in the following manner:

a. Restore air pressure to the Crownamatic system.
b. Ensure that the Crownamatic is not activated, i.e. that the brake handle can be
operated, and that the clutches have air pressure available to them.
c. Activate the Crownamatic by manually activating the toggle valve. Ensure proper
operation as normal. Reset the toggle valve, override the system if necessary, and
restore the system to normal.
d. Activate the friction brake solenoid valve by pushing the Emergency Stop button.
The coil should pick, and air should be placed on the actuating line bringing into play
all the responses as per normal Crownamatic activation seen in step c.
e. Return the emergency stop button to normal. Ensure return of the Crownamatic
system to normal status.
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Figure 4.19: Typical Crownamatic Type Installation
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Low Drum Clutch
Air Relay
Valve High Drum Clutch
Alternate
Tee Friction Brake
Location Pressure Switch
Override Valve (for BMS Option)
Friction Brake Solenoid
Port 3 HP or IN
Rig Air
Inlet
Tee Port 2 (A) Out
Port 1
LP or EX
Toggle Valve
Air Cylinder To Friction Brake
Vent
Figure 4.20: Friction Brake Solenoid Installation
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Twin Stop Connection

Some rigs do not have a crownmatic system, but use a twin stop instead. When this occurs,
refer to the following illustration and instructions for installation.
Solenoid J-box CAM Enclosure
Lo Out
Air Supply
Hi
Rig Control
Brake Cylinder Console
Brake Set Brake Override

Valve Valve
Working Line - 1/2” ID Hose

Pilot Line - 1/4” ID Hose
1. Somewhere close to the mounting of the cam enclosure assembly (CEA), permanently
mount the explosion proof solenoid supplied by .
2. Remove the line going to the CEA fitting labeled Cam Air Supply and install a 1/4” T with
one end of the T top attached to the just removed line.
3. Connect the other end of the T top to the CEA fitting for the Cam Air Supply.
4. Connect a line from the body of the T to the Hi pressure input of the Solenoid.
5. Remove the line going to the CEA fitting labeled Set Pilot and connect it to the solenoid
Lo input.
6. Connect a line from the Out of the solenoid to the CEA Set Pilot fitting.
7. Install junction box and make electrical connections with the solenoid as required.
DAQ Power Up
After all block control system components have been installed, apply primary power to the
DAQ as follows:
1. Open DAQ rear door.
2. Set power ON/OFF switch to ON position (Figure 4.4).
3. Close DAQ rear door.
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5: Configuration and Calibration
Introduction
This chapter contains procedures for the following:
 Block control system configuration and calibration software start-up
 Hook load and block height sensor channel calibration
 Saving the calibration (and configuration, if modified) to floppy
Figure 5.1: Recommended Configuration & Calibration Procedure
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Calconf Software Startup

The configuration and calibration software is downloaded via a laptop connected to the DAQ.
Follow the steps below to connect a laptop to the DAQ and initialize the software. The block
control software is preloaded from the factory. the supplied CD may be used to reload the
block control software from the CD ROM drive (E:\). Copy the complete CD contents to
C:\BCS. The batch file setup to start the block control software from the “C:\BCS” directory.
Place the Override/reset Normal switch on the driller display to Override.
1. Connect the calibration cable assembly (part number 40220082) to the laptop 9-pin
serial port and to the DAQ connector labeled “CAL.CONFIG” (Figure 5.2).
2. Turn the laptop on and follow the startup instructions.
3. The CalConf laptop is a dual boot system (Windows XP and DOS). Select DOS
operating system at the prompt.
4. Select Load Block Control and Calibration.
The computer will boot to C:\BCS>.
5. Initialize the software by typing the following:
 TYPE CALCONF C C: to start the block control calibration program with the laptop
connected to the DAQ.
 TYPE CALCONF C C: DX to start the block control calibration program without the
DAQ.
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6. The configuration and calibration main menu is displayed (Figure 5.3).
WARNING
Calibration Cable
Assembly
DAQ
Laptop
Figure 5.2: Laptop PC Connection to DAQ
Figure 5.3: Configuration & Calibration Main Menu Screen
Loading Configuration From Disk

The block control system configuration disk contains a complete description of all system
components connected to the DAQ, including the following:
 All sensors
 All brake controller outputs to the DAQ
 All Driller's Display outputs to the DAQ
 All DAQ outputs to the brake controller
 All algorithms and numerical constants used by the block control software
Follow the steps below to download the configuration to the DAQ from the C:\ drive.
1. Select [Load All] from the Configuration and Calibration main menu screen (Figure
5.3). A submenu listing the configuration by name is displayed (for example, BLKCTRL
in Figure 5.4).
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2. Use the arrow keys to highlight the configuration name and then press [Enter].
Downloading begins and a series of messages like those shown below is displayed.
NOTICE
SENDING ALGORITHMS
When downloading is complete, the Configuration and Calibration main menu screen is
displayed again.
Figure 5.4: Floppy: [Load All] Menu Screen
Configuration
The configuration must be edited if:
 The block control system components were not connected to the DAQ field termination
board exactly as specified in the engineering drawing, or
 The manual value for any channel differs from that on the floppy configuration. For
example, if the number of lines strung on the floppy configuration is 12 and the actual
number of lines strung is 14.
Refer to Manual 60-40, Total System Configuration and Calibration Software Version 3.10, for
instructions on editing the configuration.
Warning: The configuration must be updated if there are any differences

between the configuration downloaded from floppy and the actual rig
configuration. Not updating the configuration invalidates block control system
operation and may result in fatal injury to personnel and severe damage to the
rig.
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Calibration
Under most circumstances, the hook load pressure transducer and EDMS sensor are the only
sensors that require calibration. The following paragraphs explain how to calibrate the Hook
Load and Block Height sensor channels.
Hook Load Sensor Channel Calibration

The hook load pressure transducer output is continuous and proportional to the quantity being
measured. Calibration defines the relationship between transducer output in raw AD counts
and data values in engineering units. This is accomplished by specifying the four values listed
below:
 Raw Minimum - the raw value of the A/D converter when the transducer is set to
minimum output (Note: A/D counts vary from 0–4095 counts)
 Value Minimum - the engineering units value corresponding to the raw minimum
 Raw Maximum - the raw value of the A/D converter when the transducer is set to
maximum output (Note: A/D counts vary from 0–4095 counts)
 Value Maximum - the engineering units value corresponding to the raw maximum
In the analog calibration procedure presented here, raw minimum is determined first, then
value minimum, then raw maximum, then value maximum; however, these values may be
determined in any order.
Follow the steps below to calibrate the hook load sensor channel.
1. Ensure that the hook load sensor cable is properly connected to the DAQ (Check the
engineering drawings provided with this manual.)
2. From the Configuration & Calibration main menu, use the arrow keys to highlight
[Calibration] and press [Enter]. The System Calibration Software screen (Figure 5.5)
is displayed.
Figure 5.5: Software Calibration Software Screen
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3. Highlight [Channels] and press [Enter]. A submenu of channels is displayed.
Figure 5.6: [CHANNELS] Submenu
4. Use the arrow keys to highlight [Hookload] and press [Enter]. The hook load calibration
screen is displayed (Figure 5.7), with default minimum and maximum values listed. The
current sensor reading in raw counts and in engineering units is presented on the line
labeled Current Reading. The Calibration Min. and Calibration Max values are used
to calculate the current sensor reading in engineering units.
Note: Hookload calibration is done on a per line basis. For example, if you have 10
lines, and the value max for the dead line is 100K pounds, this will correspond to a 1M
pound hookload capacity.
5. Calibrate the raw minimum by setting the sensor to its zero point and viewing the raw
counts displayed next to Current Reading.
6. When the reading stabilizes, or you have a good estimate of what the minimum reading
should be, record the raw sensor minimum by highlighting Raw Min. and pressing
[Enter]. The Raw Minimum Calibration screen is displayed (Figure 5.8). The New Raw
Minimum Value field lists the sensor output, in raw counts, at the time Raw Min. was
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selected. The Current Raw Minimum Value field lists either raw counts from the
previous calibration or the default minimum raw counts.
Figure 5.7: Hook Load Calibration Screen
Figure 5.8: Raw Minimum Calibration Screen
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7. To accept the New Raw Minimum Value, press [Enter].To enter a different New Raw
Minimum Value, type in the value, up to six numerals, and press [Enter]. The following
messages are displayed:
NOTICE:
SENDING CALIBRATION DATA
REQUESTING CALIBRATION DATA
To disregard the New Raw Minimum Value, press [Esc]. The following message is
displayed:
NOTICE:
8. The Hook Load Calibration Screen is displayed and the value accepted in step 7 is
displayed on the Calibration Min line.
9. Enter the value minimum by selecting Value Min from the Hook Load Calibration
screen and pressing [Enter]. The Value Minimum screen is displayed (Figure 5.9.)
Figure 5.9: Value Minimum Calibration Screen
10. The New Minimum Value field lists the current value sent from the DAQ, in engineering
units, that corresponds with the raw minimum. The Current Minimum Value lists either
the value minimum from the previous calibration or the default value minimum.
11. To accept the New Minimum Value, press [Enter]. To enter a different New Minimum
Value, type in the new value and then press [Enter]. The following messages are
displayed:
NOTICE:
To disregard the NEW MINIMUM VALUE default, press <Esc>. The following message is
displayed:
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NOTICE
12. The Hook Load Calibration screen is displayed and the value accepted in step 11 is
displayed on the Calibration Min line.
13. To calibrate the raw maximum, set the sensor to maximum output and view the raw
counts displayed next to Current Reading.
14. When the reading stabilizes, or you have a good estimate of what the maximum reading
should be, record the raw sensor maximum by highlighting Raw Max and pressing
[Enter]. The Raw Maximum Calibration screen is displayed (Figure 5.10). The New Raw
Maximum Value field lists the output, in raw counts, at the time Raw Max was selected.
The Current Raw Maximum Value field lists either the raw counts from the previous
calibration or the default maximum raw counts.
Figure 5.10: Raw Maximum Calibration Screen
15. To accept the New Raw Maximum Value, press [Enter].To enter a different New Raw
Maximum Value, type in the value, up to six numerals, and press [Enter]. The following
messages are displayed:
NOTICE:
To disregard the New Raw Maximum Value, press [Esc]. The following message is
displayed:
NOTICE:
16. The Hook Load Calibration Screen is displayed and the value accepted in step 14 is
displayed on the Calibration Max line.
17. Enter the maximum value by selecting VALUE MAX and pressing ENTER. The Value
Maximum Calibration screen is displayed (Figure 5.11). The NEW MAXIMUM VALUE field
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lists the output, in engineering units, at the time CURRENT MAXIMUM VALUE was
selected. The CURRENT MAXIMUM VALUE field lists either the value maximum from the
previous calibration or the default.
Figure 5.11: Value Maximum Calibration Screen
18. To accept the NEW MAXIMUM VALUE, press ENTER.

To enter a NEW MAXIMUM VALUE, type in the new value and press ENTER. The
following messages are displayed:
NOTICE:
To disregard the NEW MAXIMUM VALUE, press ENTER. The following message is
displayed:
NOTICE
19. The Hook Load Calibration screen is displayed and the value accepted in Step 18 is
displayed on the CALIBRATION MAX line.
20. When the channel is calibrated, highlight QUIT and press ENTER. The SYSTEM
CALIBRATION SOFTWARE Menu is displayed.
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21. To calibrate the Block Height sensor channel, proceed to "Block Height Sensor
Calibration" on page 77. To exit Calibration, highlight Quit from the System
Calibration Software screen and press [Enter]. The following message is displayed:
22. Highlight SEND and press ENTER. A series of messages is displayed as the calibration
data is sent to the DAQ.If the calibration is unsatisfactory, highlight ABORT, press
ENTER and begin calibration again.
23. The Configuration & Calibration Main Menu screen is displayed.
Block Height Sensor Calibration
Block height sensor calibration defines the relation between shaft encoder sensor counts and
block height. There are two calibration procedures used with the block control system. They
are the simple “block control system Two Point Calibration” and the more involved “block
control system Ten Point Calibration”. There is also a procedure for resetting the calibration
system after a cut and slip operation. Before these are explained, a description of the goals of
the block control system in regards to block height determination and measurement should be
given.
The normal TOTAL EDMS system used for tracking and displaying the block height does an
outstanding job with great accuracy. The system does however require operator input to a
keypad and a several step process to maintain that accuracy after the initial calibration. With
the block control system this was considered to be too great a trouble and expense. For block
control needs, the absolute accuracy in the block height is not as stringent, but of greater
importance is the ability to return to the same position repeatably. This is done with the high
resolution incremental encoder used by the block control system. Thus the block control
system is calibrated and then reset in the simplest possible means that insures adequate
accuracy for the task.
For our purposes the following terms are defined:
“Calibration” of the EDMS system means to input to the EDMS system values of encoder
counts versus block height that allow it to generate a set of values for “table 4" of the ten point
tables. This table is then used by the DAQ to interpolate and extrapolate all other values. This
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must be done, by the maintenance personnel with the assistance of the driller, during initial
commissioning or if the rig has changed the number of lines strung.
“Resetting” of the EDMS system is done after cut and slip operations. It's intent is to
communicate to the DAQ when the elevators are at the rig floor, so that it knows the proper
place to begin. This is generally done by the driller and his crew and is covered in "System
with Calibration Switch Box" on page 81.
Block Control System Ten Point Calibration

On those systems that require better accuracy throughout the full block travel range, for
example those with ZMS, the following procedure builds into the calibration table a “bow” so as
to compensate for the increasing effective diameter of the drawworks drum with increasing
block height.
1. Ensure that the normally used drilling bails are on the Top Drive. If not, remove the
existing bails and replace with the drilling bails.
2. Lock the Top Drive heave compensator (if present) in closed (OFF) position (i.e. lock the
pin in the heave compensator).
3. Lower elevator so that it is barely touching the rig floor. The amount of line on the drum
should be the minimum acceptable amount to the drilling crew, with many wraps before
the first layer change. If not, ask the drill crew to spool line back onto the reel to arrive at
such a point.
4. Attach a 100’ tape measure to the bottom of the elevator.
5. Remove the calibration switch box from the J-Box and begin calibration by
simultaneously pressing the L/C START and CONNECTION buttons; the red LED
should come on. Press just the CONNECTION button and on the calibration data sheet,
record 0’.
6. Raise the blocks to 11' and stop. Press CONNECTION and record 11'.
7. Raise the block another 11', to 22' and stop. Press CONNECTION and record 22'.
8. Continue raising the block in 11' increments, pressing CONNECTION each time and
recording the height until the block is at 99', or the highest point possible in that
particular derrick. Press the CONNECTION button once more.
9. Simultaneously press L/C START and CONNECTION. The red LED on switch box
should go out.
10. At laptop PC, select [CALIBRATION] from the Configuration & Calibration software
Main Menu (Figure 5.3). The system calibration software screen (Figure 5.5) is
displayed.
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11. Use the arrow keys to highlight [EDMS] and press ENTER. The data gathered in Steps
4 through 8 is downloaded and displayed on the EDMS Calibration Screen.
Figure 5.12: EDMS Calibration Screen
The events recorded in Steps 5 through 8 are numbered in the order they were recorded
beginning with 0. For each event, the event type (block height) and sensor counts are listed.
Note: The events Care always numbered in the order they were recorded (0 = the first
event recorded, 1 - the second event, etc.). "CONN" events are labeled block heights.
12. Ensure the following:

 Output is TEN POINT TABLE # 4. If it is not, use the arrow keys to highlight
[Output] and press ENTER. A submenu of output tables is displayed. Then use
arrow keys to highlight TEN POINT TABLE #4 and press ENTER.
 CALIBRATION FACTORS is FEET. If it is not, use the arrow keys to highlight
CALIBRATION FACTORS and press ENTER. A submenu is displayed. Use arrow
keys to highlight FEET and press ENTER.
 The correct value is entered for lines strung. If not, use the arrow keys to highlight
[LINES STRUNG], then type in correct value and press ENTER.
 0 for [CABLE DIAMETER]
 9999 for [COUNTS PER WRAP]
 99 for [AVERAGE WRAPS PER LAYER]
13. Using the arrow keys highlight the footage figures and, if necessary, change them to
read 0, 11, 22, 33, etc. up to 99, as was recorded.
14. To insure readings are given outside of the normal range of travel, make the following
two changes to the ten point table:
 Edit the "0" counts - "0" feet entry so as to be the negative of the 11 foot entry. In
other words, for the number of counts that represent 11 feet in the table, negate that
number and enter it instead of the "0" counts entry. Then enter "-11" feet instead of
the "0" feet entry.
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 Edit the 99 feet entry by multiplying both the feet and counts by ten. Figure 5-15
shows what Figure 5-14 would look like after the modifications.
Figure 5.13: EDMS Calibration Screen
15. Use the arrow keys to highlight [CALCULATE] and then press ENTER.
16. To exit EDMS calibration, highlight [QUIT] and press ENTER. The SYSTEM
CALIBRATION SOFTWARE screen is displayed.
17. To exit CALIBRATION, highlight [QUIT] from the SYSTEM CALIBRATION
SOFTWARE screen and press ENTER. The following message is displayed:
18. Highlight [SEND] and press ENTER. A series of messages is displayed as the
calibration data is sent to the DAQ.If the calibration is unsatisfactory, highlight ABORT,
press ENTER and begin calibration again.
19. The Configuration & Calibration Main Menu screen is displayed.
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“Resetting” Block Control System Height

Calibration
After the block control system has been calibrated, there has effectively been a “yard stick”
placed in the derrick with the graduations placed on it by the procedure. After a “cut and slip”
operation, this yardstick still remains but the entire length has been moved. It is necessary to
“reset” the yardstick, that is re-align the bottom “zero point” with the rig floor. This is described
in the next two sections. The system should only have to be “reset” after a cut and slip
operation or a period of time where the DAQ has lost power long enough to have lost its
memory of block position. The “Calibration” should only need to be redone if the number of
lines have changed.
Note: The “HI” and “LO” setpoints input by the driller are “marked” on the yardstick.
Hence resetting the system does not change the setpoints.
System with Calibration Switch Box

1. Connect the Calibration Switch Box as described in "Calibration Switch Box" on page
21. Note that the switch box should always be kept convenient for the driller so as to do
this resetting in a timely manner with each “cut and slip” operation. Often the switch box
is left hooked up permanently, as long as the buttons would not be inadvertently or
accidentally pushed.
2. Lower the elevators until they just touch the floor. It might be necessary to place the
system in OVER-RIDE.
3. Push both the “L/C” and the “CONN” buttons on the switch box simultaneously. Observe
that the red LED comes on.
4. Again push both the “L/C” and the “CONN” buttons on the switch box simultaneously.
Observe that the red LED goes off on.
5. Return the switch box to a secure location. The system should now be recording a "0"
block height. After lifting above the LO Setpoint the driller can place the system in
NORMAL.
Systems with a Safe Area CID (SAC) or DataWatch display
1. Lower the elevators until they just touch the floor. It might be necessary to place the
system in OVER-RIDE.
2. On the SAC or DataWatch display, call up the “EDMS CALIB” screen.
3. There should be at least two channels displayed, Block Position or Elevator Position,
and EDMS Counts. Choose the “Zero Channel” option and zero first one channel and
then the other. If, while zeroing the second channel, the first channel's value changes,
re-zero it. You are seeking both the EDMS Counts channel and the Elevator Position
simultaneously reading “0”.
4. Exit from the menu, saving the changes. The system should now be recording a “0”
Elevator Position and, after lifting above the LO Setpoint, the driller can place the
system in NORMAL.
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Save Config/Calibration To CD/RW

Follow the steps below to save configuration and calibration data to a CD.
1. Select [SAVE ALL] from the Configuration and Calibration Main Menu screen. A
message similar to the following is displayed, where BLKCTRL is the name of the
configuration loaded from the disk:
2. Type in the new name (maximum of eight characters) to assign to the data file and press
ENTER. We recommend using the rig name as the file name.
Note: Always assign a new name to the modified data file.
A series of messages is displayed as the calibration data file is copied to disk.

3. When all data is copied to disk, the Configuration and Calibration Main Menu screen is
displayed.
4. If system set-up has not yet been completed, proceed to Chapter 6, titled "Setup"
without exiting the configuration and calibration software. If system set-up has been
performed, highlight [QUIT] and press ENTER to exit the Configuration and Calibration
software.
Saving Data to CD/RW (E:\)

1. Exit Calconf and restart computer in XP operating system mode.
2. Use the Direct CD software to write the complete BCS directory to a blank CD for future
use.
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6: Setup
Introduction
Before the block control system is engaged, perform the two setup procedures described
below:
1. Railmount Proximity Sensor Setup - A two-part procedure that consists of: 1)
determining the allowable sensor activation range for each railmount sensor and then,
2) moving the block to insure that the sensor activates within that range.
2. Set Points Setup - Using the Driller's Display LEARN button to enter the upper and
lower set points.
Warning: Do not engage the block control system until the setup procedures
described in this chapter have been performed. Only after completing these
procedures is the system ready to provide a backup to the driller.
Railmount Proximity Sensor

To set up the railmount proximity sensors follow the steps below.
1. Place OVERRIDE/RESET NORMAL switch on Driller's Display to OVERRIDE position.
Warning: When the OVERRIDE/RESET NORMAL switch is in the OVERRIDE

position, the block control system is completely unable to provide a backup to
the operator in controlling the block. IT IS THE FULL RESPONSIBILITY OF THE
OPERATOR TO CONTROL THE BLOCK. FATAL INJURY TO PERSONNEL AND
SEVERE DAMAGE TO THE RIG MAY RESULT IF THE OPERATOR FAILS TO
CONTROL THE BLOCK.
2. Hook up the laptop and have the block control system CALCONF running and
communicating with the DAQ. Use F3 to see the channel values and find the “Derrick
Prox Position” channel (Drk Prx Psn).
3. Lock the heave compensator (if present) in the OFF position, (i.e. lock the pin in the
heave compensator).
4. Ensure the block height system has been calibrated as described in Section 5 and the
normal (drilling) bails are on.
5. Run the block past the derrick prox switches several times in both the upwards and
downwards direction. Each time the block moves past the derrick prox switches, the
value displayed on the DAQ “Derrick Prox Position” channel should change slightly.
Note and record each of the values.
6. If there is a block retract system, retract the block and again run the block past the prox
switches several times, again recording the value of the “Derrick Prox Position” each
time.
7. Determine both the highest and lowest values seen from the above movements. Add 2
feet to the highest value and subtract 2 feet from the lowest.
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8. At the laptop PC, press the “ESCAPE” key to return to the MAIN MENU and then use
the arrow keys to highlight [CONFIGURATION] (Figure 5.3 on page 69) and then press
ENTER. The submenu shown in Figure 6.1 is displayed.
Figure 6.1: CONFIGURATION Submenu
9. Highlight SYSTEM/DAQ and press ENTER. The SYSTEM/DAQ configuration screen

(Figure 6.2) is displayed.
10. Highlight CHANNEL, SENSOR, & OUTPUT: [EDIT] and press ENTER. A submenu of
channels is displayed (Figure 6.3).
11. Use Page Down and arrow keys to scroll through menu and highlight DRK PROX LOW;
then press ENTER. The DRK PROX LOW configuration screen is displayed (Figure
6.4).
12. Use arrow keys to highlight Manual value; then type in the (lowest-2) value calculated in
Step 7 and press ENTER. The new value is displayed.
13. Highlight [QUIT] and press ENTER. The EDIT Channels submenu is displayed (Figure
6.3).
14. Repeat Steps 11, 12 and 13 to enter values for DRK PROX HI and the channel entering
the (highest+2) value determined in step 7. When all values are entered, press [Esc]
from EDIT Channels screen to close submenu.
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Figure 6.2: SYSTEM/DAQ Configuration Screen
Figure 6.3: EDIT Channels Submenu
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Figure 6.4: PROX LOW Channel Configuration Screen
Figure 6.5: DIAGNOSTIC CHANNEL VALUES Screen–Page 1
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15. From EDIT Channels screen, highlight [QUIT] and press ENTER. The following
message is displayed.
16. Highlight SEND and press ENTER. Messages are displayed as the configuration is sent
to the DAQ. When the configuration has been sent, the Configuration and Calibration
Main Menu is displayed.
17. Select FLOPPY: [SAVE ALL] from Configuration and Calibration Main Menu screen. A
message similar to the following is displayed, where BLKCTRL is the name of the
configuration loaded from floppy:
MENU
ENTER FILENAME: BLKCNTRL
18. Type in the same name (typically the rig name) used when saving to floppy after
configuration and calibration (Figure 5.5 on page 71) and press ENTER.
Caution: Always assign the same name used in "Save Config/Calibration To CD/RW"
on page 82.
A series of messages is displayed as the data is copied to floppy.
19. When all data is copied to floppy, the Configuration and Calibration Main Menu screen is
displayed. Highlight [QUIT] and press ENTER to exit the
Configuration and Calibration software.
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Set Points Setup

The upper set point is the highest working position that the block should reach and the lower
set point is the lowest working position that the block should reach. Use the LEARN button on
the Driller's Display and follow the steps below to define the upper and lower set points.
1. Slowly raise block until upper set point is reached and then press LEARN
button.
2. If the new upper set point is above the current upper set point, select OVERRIDE on the
OVERRIDE/RESET NORMAL selector switch to avoid an alarm.
3. Lower block until lower set point is reached and then press LEARN button.
4. If the new lower set point is below the current low set point, select OVERRIDE on the
OVERRIDE/RESET NORMAL selector switch to avoid an alarm.
Warning: When the override/reset normal switch is in the override position, the
block control system is completely unable to provide a backup to the operator in
controlling the block. It is the full responsibility of the operator to control the
block. Fatal injury to personnel and severe damage to the rig may result if the
Note: Upon detection of learn button activation, the system assumes that if the block
height is above 25’, you are setting an upper set point. Likewise, if the block height is
less than 25’, it is assumed you are setting a lower set point.
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7: Operation
Introduction
The Driller's Display contains three LED's, an override/reset normal switch, a learn button, an
emergency stop button and alarm horn button (Figure 2.4 on page 19). The following
paragraphs describe these features.
Green System On LED

When the block control system is operating and no error conditions are present, the green
System On LED is on steady.
Yellow Alarm LED

When the block control system is operating and there is an error condition requiring a Level 1
or Level 2 DAQ alarm, the yellow Alarm LED is on steady and the alarm horn sounds.
Red Friction Brake Enabled LED

When the block control system is operating and an error condition exists that requires a Level
3 DAQ alarm (Table 3-2), the red Friction Brake Enabled LED is on steady and the alarm
horn sounds. This tells the operator that the friction brake is enabled.
Override/reset Normal Switch

The functions of the Override/Reset Normal switch are summarized below.
Normal - When this switch is in the normal position, the operator controls the eddy current
brake and/or friction brake and the block control system operates as a backup. In this mode,
the green, yellow or red LEDs indicate the block control system status.
Override - When this switch is in the override position, the block control system is ignored and
only the operator is in control of both brakes. In override, green always blinks alternately with
yellow or red if in alarm condition.
Warning: When the Override/Reset Normal switch is in the override position, the
block control system is completely unable to provide a back-up to the operator
in controlling the block. It is the full responsibility of the operator to control the
block. Fatal injury to personnel and severe damage to the rig may result if the
System Reset - When the block control system is operating under a system error condition,
the override switch is used to reset the system and turn the alarm horn off. To do this, position
the switch from normal to override/reset and then back to normal.
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Learn Button
The Learn button is used to define the upper and lower set points ("Set Points" on page 38).
The set points are initially defined during system set-up (Chapter 6, titled "Setup") but may be
redefined at any time, if needed. To define the set points, follow the steps below:
1. From normal block control system operation (green LED is on and OVERRIDE/RESET
NORMAL switch is in NORMAL position) set the OVERRIDE/RESET NORMAL switch
to OVERRIDE.
Warning: When the OVERRIDE/RESET NORMAL switch is in the OVERRIDE

position, the block control system is completely unable to provide a back-up to
the operator in controlling the block. It is the full responsibility of the operator to
control the block. Fatal injury to personnel and severe damage to the rig may
result if the operator fails to control the block.
2. Move the block to the new set point and then press the Learn button.
3. To change the other set point, repeat Step 2. Position the Override/reset Normal switch
to Normal. The green LED comes on and normal system operation resumes.
Emergency Stop Button

The Emergency Stop button can be activated any time during block control system operation.
When the emergency stop button is activated, the DAQ issues a Level 3 alarm. The results
are:
 The eddy current brake and friction brake are fully engaged.
 The alarm horn near the Driller's Display sounds.
 The red LED on the Driller's Display comes on.
To disable the friction brake, eddy current brake and alarm horn, press and turn the
emergency stop button in the direction of the arrow on the button (clockwise).
Then position the override/reset normal switch to override and then back to normal.
Emergency Stop button will set friction brake in override mode.
Lower Speed Potentiometer

The lower speed potentiometer can be adjusted any time during block control system
operation. Turning the dial to a higher number allows the block to lower more quickly. If a
slower speed of block lowering is desired, turn this dial to a lower number.
Drill/Trip Switch
When drilling, set this switch to DRILL. When tripping, set this switch to TRIP. This switch
setting is monitored by the BCS, and must be set correctly for proper operation of the block
control system.
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Alarm Horn
An alarm horn near the Driller's Display sounds when either of the conditions listed below
occurs:
 The DAQ issues a Level 1, Level 2 or Level 3 alarm or
 The red EMERGENCY STOP button on the Driller's Display is pulled.
To silence the alarm horn, position the Override/reset Normal switch to Override and then
back to Normal.
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8: Maintenance
Introduction
This chapter contains the following:
 Procedures for inspecting and troubleshooting the DAQ and sensors
 Procedure for replacing DAQ EPROMs
 Procedure for checking the EDMS battery
 DAQ interface cabling diagram
Refer to Chapter 9, titled "Illustrated Parts Breakdown" for parts lists and illustrations depicting
component locations, assembly and disassembly. For maintenance information regarding the
2025B brake controller and all other Baylor instruments, refer to the appropriate Baylor
manuals.
Recommended DAQ Inspection

Perform the following checks periodically, or each time the DAQ is opened:
 Ensure that all component mounting bolts are securely fastened; tighten if necessary.
 Check enclosure for moisture ingression; correct as necessary.
DAQ and Sensor Troubleshooting

The following paragraphs list general checks and a fault isolation table for identifying and
repairing problems in the DAQ.
General Checks
Field experience indicates that most electronic equipment failures can be corrected or avoided
by performing the general checks listed below. These checks should always be completed
prior to performing more extensive repairs.
1. Verify that primary power is supplied to the unit and that it is the power required by the
unit (table titled "DAQ Electrical" on page 23).
2. Check for loose, crushed, frayed, cut or otherwise damaged cables.
3. Check wiring connections for loose or broken leads.
4. Verify that all components are properly interconnected and seated in their mating
connector or socket (see Chapter 4, titled "Installation").
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Fault Isolation Table: DAQ and Sensors

For system alarms, refer to "Alarm Response" on page 32 for alarm descriptions and
troubleshooting suggestions.
Use the table below to isolate and correct malfunctions associated with the DAQ and sensors.
For each malfunction, the table lists probable causes and corrective actions. Refer to Figures
8-1 through 8-4 as needed for interface wiring, cabling and component locations. Note that
after replacement of any circuit board or related component, the system must be recalibrated.
Refer to Figure 8.1, if needed, to identify DAQ components.
Fault Isolation Table: DAQ and Sensors
Problem Probable Cause Corrective Action
System inoperative No power to the system Check and correct power source.
Blown fuse Replace fuse (Figure 4.4 on page 43).
Perform power supply checkout

Defective power supply
(Section).
Digital board failure Replace digital board
DAQ digital board “analog” Analog processor malfunction 1. Press analog processor reset SW4
LED off (Figure 4.5 on page 44).
2. If problem persists, press both
processor resets, SW1 and SW4
(Figure 4.5).
3. If problem persists, set switch 8 on
SW2 to OFF (Figure 4.5). Press both
processor resets, SW1 and SW4;
then set switch 8 on SW2 to ON.
Digital board failure Replace board (Figure 8.1).
Analog board failure Replace board (Figure 8.1).
DAQ digital board “analog” Analog processor malfunction 1. Press analog processor reset, SW4
LED on steady (not blinking) (Figure 4.5 on page 44).
processor resets SW1 and SW4
(Figure 4.5).
3. If problem persists, set switch 8 of
processor resets SW1 and SW4; then
set switch 8 on SW2 to ON.
Digital board failure. Replace board (Figure 8.1).
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Fault Isolation Table: DAQ and Sensors (Continued)
DAQ digital board “watch- Check voltages and replace supply, if

dog timer” LED off. needed.
Main processor malfunction 1. Turn main power to DAQ off and wait
5 seconds; then turn main power to
DAQ on.
2. If problem persists, set switch 8 on
SW2 to OFF (Figure 4.5 on page 44).
Press both processor resets SW1
and SW4; then set switch 8 on SW2
to ON.
DAQ digital board “watch- Main processor malfunction 1. Turn main power to DAQ off and wait
dog timer” LED blinking (not 5 seconds. Then turn main power to
on steady) DAQ on.
2. If problem persists set switch 8 on
SW2 to OFF (Figure 4.5 on page 44).
Press both processor resets SW1
and SW4; then set switch 8 on SW2
to ON.
DAQ digital board

No malfunction indicated. No action required.
“communications” LED off
All three DAQ digital board No power to system Check and correct power source.
LEDs off
Blown fuse Replace fuse (Figure 4.5).
Perform power supply checkout

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Erratic indication from Analog processor malfunction 1. Press analog processor reset SW4
sensor channel (Figure 4.5).
(Figure 4.5).
3. If problem persists set switch 8 on
processor resets SW1 and SW4; then
set switch 8 on SW2 to ON.
“Raw” input counts OK, but engineering 1. Verify channel is configured properly.
units erratic. 2. Recalibrate the channel.
Analog board voltage/current switch set Verify that switch is set correctly for
incorrectly sensor type (Section 4-5-6).
Sensor connected improperly or not at all Ensure that all sensor connections are
secure correct and to the proper
connector.
Faulty channel on analog board Connect sensor to different connector;

then reconfigure and recalibrate the
channel.
Sensor malfunction Replace sensor
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No indication from sensor Analog processor malfunction 1. Press analog processor reset SW4
channel (Figure 4.5).
(Figure 4.5).
3. Set switch 8 on SW2 to OFF (Figure
4.5). Press both processor resets
SW1 and SW4; then set switch 8 on
SW2 to ON.
“Raw” input counts OK, but engineering 1. Verify channel is configured properly.
units not changing 2. Recalibrate channel.
Analog board voltage/current switch set Verify that switch is in correct position
incorrectly for sensor type
(Section 4-5-6).
Sensor connected improperly or not at all Ensure that all sensor connections are
secure correct and to the proper
connector.
Faulty channel on analog board Connect sensor to a different channel;

then reconfigure and recalibrate the
channel.
Sensor malfunction Replace sensor.
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Front View
Field Termination Board Analog I/O Board
EDMS Board
Located between Communications
communications Board
Rear View
and digital boards
Digital
Board
Battery Pack
(Optional)
Modem Power Supplies

Figure 8.1: DAQ Main Components
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System Debug
DAQ software version 4.0 enables you to use position 7 of SW2 on the DAQ digital board to
display debug screens containing information about the system's internal operation. The
debug screens present information regarding the conditions listed below:
 Analog task failure. Caused by analog processor malfunction or digital board failure.
This failure will cause the system to be RESET as the message indicates.
 Copies of data stored in nonvolatile RAM are corrupted.
 Copies of data stored in the EEPROM are corrupted.
 Current time being sent to the T-POT network is 0.
 A channel value is being zeroed.
 Laptop PC polling responses
 EEPROM write errors are detected.
 T-POT device polling responses
 Polling time for EDMS processor
 EDMS processor is not responding.
 Analog processor is not responding.
 T-POT processor is not responding.
 BLOW WORLD AWAY switch (DIP SW2, position 8) is OFF at power up.
To view these screens, follow the steps below:
1. From any point in the Configuration & Calibration software, press the F7 key. If position
7 of DIP SW2 is ON, the following message is displayed:
Note: DEBUG output can be enabled by setting DIP SW2 (SW7) to OFF.
2. On DIP SW2, change the setting of position 7 to OFF.

3. Reset the DAQ by turning the main power to the DAQ off, waiting five seconds and then
turning the main power on. The debug screen assigned to position 7 of DIP SW2 is
displayed. This screen lists the error conditions being checked and presents messages
if any of the error conditions exist.
4. To exit this screen, change position 7 of DIP SW2 to ON.
5. To view the other debug screen, change the setting of position 1 on DIP SW2. The
debug screen assigned to position 1 is displayed. This screen lists the conditions being
checked and their values at the time that position 1 was changed. To view an updated
version of this screen, change the setting of position 1 on DIP SW2. Change the setting
of SW2 position 1 as needed to view updated versions of this screen.
6. To exit debug mode, press the F7 key.
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Sensor Problems
Sensor problems are generally caused by one of the following:
 Improper installation
 Improper alignment
 Faulty cables or connections
 Faulty sensor
If the sensor is properly installed, aligned and connected, and if the sensor cables are in good
condition, repair or replace the sensor; then recalibrate the sensor channel using a laptop PC
and the Configuration & Calibration software.
Replacing DAQ Digital Board EPROMs

Digital board EPROMs may require replacement either as a result of failure or routine software
updates. The EPROM chips (U15 and U16) are located on the digital board shown in Figure
8.2. Follow the steps below to replace the chips.
1. Open DAQ rear door.
2. Set power ON/OFF switch to OFF.
Caution: STATIC DISCHARGE CAN DAMAGE INTEGRATED CIRCUITS. Do not

handle integrated circuits or component boards unless properly grounded. Do not
allow clothing or plain plastic materials in close proximity to these static-sensitive
devices.
3. Observe CAUTION, note direction of integrated circuit notch, and carefully remove chip
from socket using an IC extractor tool.
4. Carefully install replacement chip. Make sure notch in chip faces same direction as
previous chip.
5. Set power ON/OFF switch to ON.
6. Close DAQ rear door.
7. Reload configuration from floppy and recalibrate system.
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Main
Main Processor Analog
Main Processor Processor
Processor RESET
RESET
LED
D2
SW1
SW4
J11
J4
J3
U1
U16
A
B
A
C
B
D1
Main Programs
EPROMs
U15
U19
BT1
Watchdog
ON
SW2
Timer LED
SW2
OFF
J8
1 2 3 4 5 6 7 8
D3
U17
Analog Processor LED Analog Processor J9
Figure 8.2: DAQ Digital Board Main Components
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Power Supply and Wiring Harness

Checkout Procedures
DAQ Assemblies with 220251-003 & -004
Power Supplies
Note: The following procedure tests both power supply outputs and associated wiring
for DAQs that have 220251-003 and 220251-004 power supplies.
These DAQs use DC power distribution cable P/N 219962-002 for power supply output
connections.
Figure 8.3 is a DC power distribution schematic that includes interfaces, connector pins, signal
names and wire color-coding. Follow the steps below to check the power supply and wiring
harness.
1. Remove four screws securing power supply ON/OFF switch protective cover (Figure
8.4). Remove cover and set aside.
2. Using digital voltmeter (DVM), measure voltages from power supply connectors to
chassis ground, as follows:
Connector-Pin
From (+) To (-) Volts DC
P4-J5 Ground -15
P4-J2 Ground +15
P4-J1 Ground +15
P14-J1 Ground +28
P14-J2 Ground +5
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3. If any voltages are incorrect, replace associated power supply. If voltages are all correct,
measure for the following voltages:
Connector-Pin
From (+) To (-) Volts DC
P8-J1 Ground +5
P8-J2 Ground +15
P11-J1 Ground +28
P11-J5 Ground +15
P11-J8 Ground -15
P3-J9 Ground +28
P3-J10 Ground +15
4. If any of the above voltages are not present, repair or replace wiring between power
supply and associated connector.
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EDMS Batter y Test

Refer to Figure 8.3 and measure battery output voltage from connector-pin P3-J4 (+) to P3-J2
(-). A reading between 10.5 and 12.0 VDC should be obtained. If the measured voltage is less
than 10.5 VDC, replace the battery.
Figure 8.3: DC Power Distribution Wiring Diagram (Cable Assembly 219962-002)
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P11
P4
P3
(EDMS)
P8 P1
+/- 15Power Supply
P1
+5/+28 Power Supply
P14
SW1
P2 L1 ISLATROL L1
GND
L2 L2
P1
TB1
2
1
F1 3 AMP
Battery Pack Power Switch

12VDC (EDMS)
Figure 8.4: DC Power Distribution
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AC Power Distribution Wiring Diagram

Figure 8.5 shows the AC power distribution wiring. Refer to it as needed for troubleshooting
and maintenance.
BLK
WHT
BLK
WHT
LOAD
LINE
Figure 8.5: AC Power Distribution Wiring Diagram (Power Supplies 220251-003 & -004)
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Power Supply and Wiring Harness

Checkout Procedures
DAQ Assemblies with 220251-005 &
-006 Power Supplies
Note: The following procedure tests both power supply outputs and associated wiring
for DAQs with 220251-005 and 220251-006 power supplies.
These DAQs use P/N 219962-004 for power supply output connections.
A schematic of the DC power distribution that includes interfaces, connector pins, signal
names, and wire color coding is shown in Figure 8.6 on page 111. Perform the procedure in
the following sequence:
1. Refer to Figure 8.7 on page 112 and remove four screws securing power supply on-off
switch protective cover. Remove cover and set aside.
2. Using digital voltmeter (DVM), measure voltages from power supply connectors to
chassis ground as follows:
Connector\Pins
Volts DC Color
From (+) To (-)
P4 - J6 Gnd -15 Vdc Yellow
P4 - J2 Gnd +5 Vdc Red
P4 - J1 Gnd +15 Vdc Orange
P14 - J1 Gnd +28 Vdc Purple
3. If any voltages are incorrect, replace associated power supply. If voltages are all correct,
measure for the following voltages:
Connector Pins
Volts DC Color
From (+) To (-)
P8 - J1 Gnd +5 Vdc Red
P11 - J1 Gnd +28 Vdc Purple
P11 - J8 Gnd -15 Vdc Yellow
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4. For EDMS option, measure for the following voltages:
Connector Pins
Volts DC Color
From (+) To (-)
P3 - J9 Gnd +28Vdc Purple
5. If any above voltages are not present, repair or replace wiring between power supply
and associated connector.
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EDMS Batter y Test

Refer to Figure 8.6 and measure battery output voltage from connector-pin P3-J4 (+) to P3-J2
(-). A reading between 10.5 and 12.0 VDC should be obtained. If the measured voltage is less
than 10.5 VDC, replace the battery.
Connector Pins
Volts DC
From (+) To (-)
P3-J4 P3-J2 10.5 to 12.0 Vdc *
* If voltage reading is below 10.5 Vdc, replace battery.
P4 PIN OUT KEY - (END VIEW) P14

1 P11 1
2 P7 P8 1 2 2
3 2 4 6 3 1 3 4 Key
4 Key 3 5 Key 2 5 6 4
5 Key 8 5
Key 6
Figure 8.6: DC Power Distribution Wiring Diagram (Cable Assembly 219962-004)
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P11
P4
P3 (EDMS)
P8 P1
Power Supply
P1
Power Supply
P14
SW1
P2 L1 ISLATROL L1
GND
L2 L2
P1
TB1
2
1
F1 3 AMP
Battery Pack Power Switch

12VDC (EDMS)
Figure 8.7: DAQ DC Power Distribution
DAQ DC Connections
Pin Description
P1 Battery Pack Connector (+)
P2 Battery Pack Connector (-)
P3 Connector to EDMS Board
P4 Power Supply Connector
P8 Connector to Digital Board
P11 Connector to Digital Board
P14 Power Supply Connector
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AC Power Distribution Wiring Diagram
AC Power Plug (P1) N

(To +5, -15, -15 VDC
L
Power Supply)
N
AC Power Plug (P1)
(To +28 VDC Power Supply) L
BLK
L1 L1
BLK
Load
Line
Isolatrol
WHT
L2 L2
WHT
WHT
2
2A
DAQ BLK
On-Off
1
Switch BLK
Fuse Block
Terminal Block
Hot Ground
Neutral
AC Primary
Power Unit
Figure 8.8: AC Power Distribution Wiring (Power Supplies 220251-005 & -006)
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9: Illustrated Parts Breakdown
This chapter contains the illustrated parts breakdown, parts lists, and recommended spare
parts lists for use in maintaining the shaft encoder, calibration switch box and hook load
transducer.
For an illustrated parts breakdown of the DAQ, see the Permanent Location DAQ manual
document number 60-11.
Shaft Encoder Assembly

H12321A- RG2087A- Orientation Thread Size
01 01 Right Hand 1-14 UNS
02 02 Left Hand 1-14 UNS
03 03 Right Hand 1.5-12 UNF
04 04 Left Hand 1.5-12 UNF
05 05 Right Hand 1.5 NPT
1 33
06 06 Left Hand 1.5 NPT
27
29 31 27 33 26
CCW CW
28 32 30
34
27 26 30
Figure 9.1: Shaft Encoder Assembly (PN: H12321A-series)
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Shaft Encoder Parts List
Index Qty.
No. Part Number Description
1 RG2087A-series R.O.P. Assembly (see table above illustration) 1
24 H52-1 Terminal Ring #6 X #22-16 6
25 220468 Drawworks Encoder ID Label 1
26 220626-125A Optical Encoder 125P/R, ATEX 1
27 40220464 Drawworks Optical Encoder Mounting Plate 1
28 M10260A-002 Coupling Shaft 0.25" ID (3-PC) 1
29 40220463 Drawworks Optical Encoder Shaft Adapter 1
30 J814-4RB #6-32X.50 Screw Round-head, Cad-plated Steel 2
31 J812-4FB #10-32X.50 Screw Flat-head Cad-plated Steel 4
32 999324-051 #10-32X.31 Setscrew, Socket Head-Hex, 1
33 J813-4RB #8-32X.50 Screw Round-head, Cad-plated Steel 2
34 H12390A-01 Adapter CND, .50"NPT X M20, Brass 1
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Printed On: 2012.04.05.10.31.29
Latest REV: G
15
7
14
23
6
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26
60-60
20
G
21
Document number
Figure 9.2: Calibration Switch Box (PN: 219255-001)

4
8
5
2
3
Calibration Switch Box
Revision
Page
Printed REV: G
22
19
18
27
10
11
24
21
LISTED
L/C START
CALIBRATION
11Y8
®
DRILLERS CALIBRATION
SWITCH BOX
9
FOR USE IN HAZARDOUS LOCATIONS

PART NO. 219255-001
SERIAL NO.
VOLTAGE RATING: 10 VDC
CURRENT RATING: 100 mA MAX
INTRINSICALLY SAFE FOR CLASS I, DIV. 1, WHEN
25
CONNECTED PER DRAWING NO. 21913, 219338,
CONNECTION
12 13
OR 219569.
IEC 79-11 Ex ia IIB-T4
− − WARNING − −
SUBSTITUTION OF COMPONENTS
MAY IMPAIR INTRINSIC SAFETY
MADE IN USA 219273-001
TC Number: 60-60-MAN
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Calibration Switch Box Parts List
Index Part Description Qty.

No. Number
2 949808-004 Box Receptacle Connector, 14 Square, 4 Socket 1
3 970118-008 Nut Ring, #4-40, MS-14, Self-locking 1
4 999449-034 Screw, #4-40 X .50, Stainless Steel, Pan Head Slotted 4
5 235386-002 Gasket, MS, #14, Bulkhead, Corprene 1
Switch, Push button, Momentary Single Pole Double

6 932520-001 2
Throw
7 996857-024 Heat Shrink Tubing, .125", Black 0.5
8 999442-001 Seal Washer, #6, .15 X .25 X, Neoprene/Stainless Steel 4
9 950859-024 Receptacle Cap, MS-14S With Chain 1
10 946613-029 Wire, 24 AWG, IPVC, White/Black 1
11 946613-021 Wire, 24 AWG, IPVC, Red 1
12 946613-020 Wire, 24 AWG, IPVC, Brown 1
13 946613-028 Wire, 24 AWG, IPVC, White 1
14 40220099 Guard, Push button E-Depth 2
15 932520-003 Switch, Push button, Black 2
18 219277-005 Label "CONNECTION" 1
19 219277-006 Label "START L/C" 1
20 923302-009 Red LED, LD-R2R-50-1, 20MA 1
21 100125-00193 RES, MF, 1K, 1%, .25W, RN60C 1
22 219277-004 Label "CALIBRATION" 1
23 923302-008 LED Lamp Holder, 2004-9002 1
24 946613-019 Wire, 24 AWG, IPVC, Black 5
25 946613-022 Wire, 24 AWG, IPVC, Orange 5
26 219260-001 Enclosure, Drillers Calibration, EDMS Switch Box, LED 1
27 219273-001 Label, ID, Calibration Box, UL Version 1
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Hookload Transducer Assembly
6 5 2 3 2
8
Figure 9.3: Hook Load Transducer Assembly
Hookload transducer assembly part number 221503-001 for 1000 psig capacity; or
221503-002 for 2000 psig capacity. See index number one in the table below.
Transducer Assembly Parts List
Index Part Number Description Qty.

No.
220759-130, or 1K/0K Transducer assembly, 4-20 mA 1

1
220759-140 2K/0K Transducer assembly, 4-20 mA 1
2 210367 Stainless Steel Tee, Hex Street, 1/4" NPT 2
3 J234-5 Hose Assembly, 1/4" X 5', 5K PSI 1
4 J10900A-20 Coupler, Male, 17K PSI, 1/4" FNPT 1
5 J996 Stainless Steel Nipple, Hex, 1/4" NPT X 1.5" 1
6 J10900A-02 Coupler, Female, 17K PSI, 1/4" FNPT 1
7 999279-005 Stainless Steel Self-locking Nut, 1/4-20 Hex 4
8 J811-5Ys Button Head Socket Screw, 1/4-20 x .625 4
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System Cables
Part No Description Qty
40220082 Calibration (RS232) Cable Assembly 1
221562-003 Encoder to J-Box Cable Assembly 1
221564-001 Calibration Switch Box to J-Box Cable Assy 1
Proximity Sensors & Laptop

40220893 Laptop Computer XT with Power Supply 1
40220378 Drawworks Proximity Sensor 1
H11094A-01 Railmount Proximity Sensor 2
Baylor System Components

Baylor PN Description Qty
55852 Brake Controller 1
55858 Throttle 1
55862 Driller's Display 1
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Approved Spare Parts

The following table lists part numbers of approved spare parts for components of the block
control system. Refer to Baylor documentation for approved spare parts for Baylor
components.
220426-201 PCB Assembly, DAQ digital board 1
40219509 PCB Assembly, DAQ Field Termination board 1
220442-001 PCB Assembly, Analog I/O Board 1
221034-104 Spectrum PCB Assembly, without software 1
40219770-101 PCB Assembly, EDMS Board 1
938203-021 Fuse, 3 Amp 5
220251-005 Power Supply, 5V ±15 1
220251-006 Power Supply, Dual Output, 28V 1
40219908 Battery Pack, EDMS 1
220626-125A Shaft Encoder Assembly 1
H11094A-01 Proximity Sensor-Derrick 1
40220378 ProximitySensor-Drawworks 1
Valve, Solenoid, 3-way, Normally Closed, 120V, 1/

976756-007 1
4”
Caution: To replace power supply P/N 220251-003 or 220251-004, a

replacement supply of the same part number MUST be used or equipment failure
will result. As an alternative, both supplies, 220251-003 and 220251-004 may be
replaced as a set with 220251-005 and 220251-006, ONLY if DC power
distribution cable P/N 219962-002 is replaced with cable P/N 219962-004. Power
supplies and cable are a matched set and MUST be used together.
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A: 2025B Brake Controller
Introduction
This chapter describes the interface of the 2025B brake controller. For a thorough description
of the brake controller, refer to the Instruction, Operation, and Service Manual for Baylor Brake
Control Model 2025B, Baylor document number 165-56300.
Firing Board Connections

The firing board is located inside the brake controller rectifier assembly. The following table
lists the interfacing connectors for this board.
Firing Board Interfacing Connectors
Connect Description
or
J1 AC current transformer inputs
J2 DC voltage input
J3 AC voltage input
J101 Trigger pulses to A phase SCR module
J201 Trigger pulses to B phase SCR module
J301 Trigger pulses to C phase SCR module
J4 External (i.e. door) reset and meters (if used)
J5 Throttle relay for cooling pump or cooling alarm operation (if used)
J6 Alarm relay to operate the light on the door
FTB-1 Pinouts
Pin Description
1 System ground
2 33% Maximum Current Limit (Not used)
3 67% Maximum Current Limit (Not used)
4 Throttle Signal Input
5 50% Maximum Current Limit
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Pin Description
6 No Connection
7 -15 VDC for system use
8 +15 VDC for system use
9 No Connection
10 +15 VDC for system use
Firing Board Switches

The brake controller Firing Board contains the switches summarized below:
 “Current - Volts” Slide Switch - Used to designate the brake as voltage- or current-
regulated.For the block control system, this switch should always be set to “Current”.
 “Normal - Reverse” Switch - Used to designate the throttle as reverse-acting. This
voltage is used to hold off the brake so that a cut cable will result in full application of the
brake. This switch should always be set to “Reverse”, unless installed in an existing
1025 system.
 Unlabeled Dip Switches - There are two unlabeled dip switches, which are used to
reduce maximum power to the brake by 25% or 50%, in the event that one or two coils
to the brake burn out and must be disconnected. Contact The Baylor Company in
Houston for details on using these switches.
Firing Board Setup

For a reverse-acting throttle, the firing board should be set so that it commands from zero up
to the prescribed maximum amperage, as the throttle varies from its maximum to minimum
output. To set the firing board for a reverse-acting throttle, follow the steps below:
1. Set the “Normal-Reverse” switch to “Normal”.
2. With the throttle at maximum output, turn the “Zero” pot until both LED's associated with
the pot begin to turn on.
3. Fully release the throttle and adjust the "Gain" pot until both LED's are on.
4. Repeat Steps 2 and 3 several times to double check settings.
5. Set the “Normal-Reverse” switch to “Reverse”.
For a normal-acting throttle, the firing board should be set so that is commands from zero up
to the prescribed maximum amperage, as the throttle varies from its minimum to maximum
position. To set the firing board for a normal-acting throttle, follow the steps below:
1. Set the “Normal-Reverse” switch to “Normal”.
2. With the throttle at minimum output, turn the “Zero” pot until both LED's associated with
the pot begin to turn on.
3. Turn the throttle on full and adjust the "Gain" pot until both LED's are on.
4. Repeat Steps 1 and 2 several times to double check settings.
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Auxiliary Board LEDs

The Auxiliary Board (Figure B-1) is mounted on the brake controller door. It contains 26 LED's,
which identify alarm conditions by changing color from green to red or from off to yellow. When
an alarm condition exists, the auxiliary board also communicates a critical or noncritical alarm
to the DAQ. Each alarm LED is illustrated in Figure A.1 and detailed in the table titled
"Auxiliary Board LED Summary".
M/D T
A
Override 19 2 Drill/Trip
Phase
Rotation
1 DAQ Alarm 18 3 Drill Assist
C B
AØ BØ CØ Standby CP
4 17 15 16 7 Throttle Mismatch
Main CP 5 8 Overcurrent
Power Quality
6 9 Over Kilowatt
11
10 10 10
Auxiliary
Eddy
Current
14 Battery Backup
12 12 12 10 10 10 Brake
13 Coil Fuse
11
Figure A.1: Brake Controller Auxiliary Board
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Auxiliary Board LED Summary

LED Indication Result
Red if the phase rotation of the supply is
1: Phase Rotation Sends a noncritical alarm to the DAQ*
counter clockwise
the drill floor power selector switch is in a
2: Drill/Trip reduced range position. Yellow when in the --
Drill position
Yellow if the driller has commanded full Power to brake is reduced to half linearly
3: Drill Assist
current for 2 minutes or more over a ten-minute period
4: Standby CP Red if Auxiliary Board power supply fails Sends a noncritical alarm to the DAQ
5: Main CP Red if the main firing board power supply fails Sends a noncritical alarm to the DAQ
6: Power Quality Red if input voltage drops below 80% Sends a critical alarm to the DAQ
Generates a critical alarm and causes the
Red if the actual brake current is less than
7: Throttle Signal battery backup unit to come on. To reset,
50% of that commanded for a period
Mismatch deactivate the battery back up and then
exceeding.5 second
reset
Red if the brake current exceeds 150% of the Sends a critical alarm to the DAQ and
8: Overcurrent
rated current for 20 milliseconds must be reset
Red if a control puts out 125% of the rated Trips the control, sends a critical alarm to
9: Over Kilowatt
KW to the brake for two seconds the DAQ and must be reset
10: SCR Failure Red if any of six SCRs are not turning on Sends a critical alarm to the DAQ
Indicates a ground condition on the (+) and (-)
11: DC Ground Sends a noncritical alarm to the DAQ
DC power conductors
Red if the incoming 240 V phase line is
12: Phase AC Ground Sends a noncritical alarm to the DAQ
grounded
Red if turned on by the switch in the fuse
13: Open Coil Fuse Sends a critical alarm to the DAQ
holder
Red if the battery back up is ON and
14: Battery Back Up Sends a critical alarm to the DAQ
supplying DC current to the brake
18: DAQ Alarm Red if the DAQ has issued an alarm --
Bar Graph Shows. . .

The current commanded by the driller, amended, if applicable, by the Power Select or Drill
15: Driller
Assist mode
The actual current flowing to the brake, which should match the higher of the M/D T or
16: Actual
DRILLER bar graphs
17: M/D T The current commanded by the DAQ
* The 2025B brake controller is phase rotation sensitive on the input, and attempted operation
with such is forbidden and would normally be considered “critical”. However, in recognition of
the fact that phase rotation should be checked upon start-up and then remain correct, the
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alarm is categorized as “noncritical” to prevent inadvertent Crownamatic and Battery Backup

energizing when power is first applied to the unit.
Auxiliary Board Interfaces

Table B-4 lists interface connectors and Table B-5 lists the pinouts for the auxiliary board TB-1,
located in the brake controller rectifier assembly.
Auxiliary Board Interface Connectors
Connect Description
or
J1 Auxiliary Power
J2 Override Switch
J3 Coil Fuse Switch
J4 “Battery Backup In Use” Switch
J5 DAQ Alarm Connection
J6 Auxiliary Use Connector (interface to Baylor equipment)
J7 DAQ Alarm Connector
J10 Firing Board Interface Connector
Auxiliary Board TB-1 Pinouts
Pin Description
1 DAQ Normal Throttle current loop input
2 DAQ Normal Throttle current loop return
3 DAQ Reverse Throttle current loop input
4 DAQ Reverse Throttle current loop return
5 Current Command Feedback to DAQ input (4-20 ma for -10 to 100%)
6 Current Command Feedback to DAQ return (4-20 ma for -10 to 100%)
7 Current Feedback to DAQ input (4-20 ma for 0 to 160 amps DC)
8 Current Feedback to DAQ return (4-20 ma for 0 to 160 amps DC)
9 Input for reverse throttle defeat
10 Return for reverse throttle defeat
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Relay Logic
The brake controller contains three relays. The function of each relay is as follows:
K1: Emergency Relay

As a fail-safe measure, upon de-energizing of this relay, the friction brake is activated and the
battery back up unit is enabled. See Figure A.2.
Figure A.2: Emergency Relay Schematic
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K2: Crownamatic
Upon energizing of this relay, the friction brake is activated.
Figure A.3: Friction Brake Relay Schematic
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K3: Batter y Back Up

Upon energizing of this relay, the battery back up unit is enabled.
Figure A.4: Battery Backup Relay (K3) Schematic
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Brake Controller Troubleshooting

Refer to Figure B-1 and use the procedure below as a guide for troubleshooting the brake
controller.
1. Check the Auxiliary Board display on the front of the brake controller. If all LED's are off,
check for both main input power and auxiliary board power input. Either should power
the display.
2. If there is power to the LED's (or after restoring power in Step 1), clear any red LED
indications as directed below:
 Power Quality LED - Red if input power is not adequate - either the voltage level is too
low or one phase is missing. Measure all three phases and correct.
 Rotation LED - If red, check to see if input power LED is red and correct input power, if
needed. If input power LED is green, then remove power to the brake controller and
correct rotation.
 Normal Control Power LED - If red, check for blown fuse on firing board and replace
fuse, if needed. If fuse blows a second time, replace firing board.
 Auxiliary Control Power - If red, check for the following: removal of auxiliary 120 VAC
to Auxiliary Board, disconnection of J-1 or blown fuse on Auxiliary Board. Replace fuse,
if needed. If fuse blows a second time, replace Auxiliary Board.
 A Phase, B Phase or C Phase Ground - If any of these LED's are red, correct the
ground as soon as possible.
 SCR Misfire LED's (6) - If any of these LED's are red, the representative SCR did not
carry current as required. Check the wiring to the gates, including the J-01 connectors
and push on connectors on the rectifier assemblies. These LED's will reset to green
when the circuit senses normal current flow.
Note: These circuits are sensitive and may alarm when first turned on.
 (+) or (-) DC Bus Grounded - These LED's are red when the DC bus has been
grounded. Because of the regenerative nature of this control, a ground on the (+) DC
connection will indicate on the (-) during the short period of regeneration (turning off).
 Coil Fuse LED - Red if one or more of the coil fuses has blown. Measure the coil
resistance. If it is approximately 13 ohms, then check the associated selenium surge
protector and then replace the fuse. If the coil is shorted, contact Baylor Company
before leaving coil disconnected and continuing operation.
Caution: Operation of the block control system is not recommended with less
than four coils.
Battery Backup LED - Red if the battery backup unit is enabled and is sending battery power
to the brake. Manual reset of the battery backup unit will be necessary.
DAQ Alarm LED - Red if the DAQ has calculated or sensed a serious condition and is taking
appropriate action.
OverKW Led - Red if the brake controller has shut itself off because excess power was sent to
the coils, indicating brake control failure. To clear this, press the RESET switch
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located either on the firing board or on the front door of the brake controller. If after resetting,
the brake controller immediately turns on and the OverKW led turns red, replace the firing
board.
Overcurrent LED - Red if the brake controller has shut itself off due to a momentary 150%
over current condition, typically caused by a shorted DC load, SCR failure or firing board
failure.
Throttle Mismatch -Red if the actual brake current is less than 50% commanded for a period
exceeding 0.5 seconds will generate a critical alarm to the DAQ and cause the battery backup
unit to come on. To clear, push the RESET switch on either the firing board or on the front door
of the brake controller. Then manually reset the battery backup unit.
1. If after clearing any LED condition described above (i.e. all LED.s are green), there is
still no braking current, look at the bar graphs displayed on the Auxiliary Board. If neither
the DAQ throttle command nor the driller’s manual input is requesting current, verify that
one should be and follow the troubleshooting flow diagram in the Baylor 2025B manual.
2. If the DAQ or the driller’s control is requesting current but the actual braking current bar
graph is not showing current, determine if the brake controller is actually outputting
current through the use of a this means (i.e. clamp on DC meter, shunt, etc.). If current is
being output, the problem lies with the current-sensing elements, the CT’s, interconnect
cabling, J2 or input burden resistors. If no current is coming from the brake controller
with a legitimate input, change the firing board.
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Revision G
Page 133 of 134
B: Brake Monitoring System
Introduction
The Brake Monitoring System is a collection of new and pre-existing rig components that,
when combined with the DAQ computational and monitoring capabilities, satisfy the U.K.’s
Department of Energy Offshore Installations: Guidance on Design, Construction and
Certification, paragraph 46.5.2.
Figure B.1: Brake Monitoring System Overview
Components
The following sub-sections describe each of the individual components of the BMS.
Safe Area Computer interface Device

the Safe Area Computer (SAC) interface device is a personal computer designed to interface
with the DAQ and serve as a display for any information the DAQ gathers. Preformatted
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Revision G B: Brake Monitoring System
Page 134 of 134
screen displays will call up information for the Brake Monitoring System, the Zone
Management System, BCS Alarms, BCS Operation and System Inputs and Outputs.
Note: In RLC configurations of the block control system, a DATAWATCH unit is

typically substituted for a SAC to display gathered information.
Temperature Switch
This item is used to monitor the temperature of the cooling water coming from the eddy current
brake. A high reading will signal an alarm to the SAC and the Driller’s Display.
Flow Switches
These monitor the flow of cooling water to the eddy current brake and alarm with loss of flow.
Because of transient surges in most cooling flow systems, the alarm has a time delay, and
even disables if the brake is not used for 5 minutes. It is, however, reactivated with a current
command from either the driller of the DAQ.
Solenoid
This is used to activate the “Crownamatic” function which will immediately apply the friction
brake and remove air from the drawwork clutches.
Air Pressure
This is taken from the rig air supply, and is used by the “Crownamatic” to activate the friction
brake.
Pressure Switch
This is used to insure that the friction brake activation and back up of the electric brake is
possible. The pressure switch is inserted to monitor the air pressure available to energize the
“Crownamatic.”
“Crownamatic”
This trade name is used here to denote any of a family of products which have been
developed and which activate a pneumatic actuator that applies the friction brake and also
releases air to the drawwork clutches.
Friction Brake
This is the positive torque device used to hold the drilling load. It can be of either a disk or
band type. Its proper operation and strength are assumed.
Uninterruptable Power Supply (UPS)

Used to insure electrical power to activate the solenoid in the event of complete power failure.
UPS Switch
Connected from the UPS to the DAQ, it tells the system that the UPS is operating on battery
power. This allows the system to generate a non-critical alarm, identifying a situation that
might otherwise go unnoticed until the battery power was depleted.
134
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Block Control System使用说明书

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Block Control System使用说明书

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Printed By: foxm2 Printed On: 2012.04.05.10.31.

Block Control System

Installation, Operation, and

REFERENCE REFERENCE DESCRIPTION

TC Number: 60-60-MAN Printed REV: G Latest REV: G

Document number 60-60

G 01.09.2012 Revised per EC#: 82109-0

Revision Change Description

Suggested Content Improvements

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Document number 60-60

Chapter 3: Theory of Operation

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Chapter 5: Configuration and Calibration

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Chapter 9: Illustrated Parts Breakdown

Appendix A: 2025B Brake Controller

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Appendix B: Brake Monitoring System

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Caution: The caution symbol indicates that potential damage to equipment or

Warning: The warning symbol indicates a definite risk of equipment damage

ESD The ESD (Electrostatic Discharge) warning symbol indicates that

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To avoid injury to personnel or equipment damage, carefully observe requirements

General System Safety Practices

 Isolate energy sources before beginning work.

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Failure to conduct routine maintenance could result in equipment damage or injury to

Proper Use of Equipment

60-10: Data Acquisition Unit (DAQ) and sensors

60-40: TOTAL System Configuration and Calibration Software

60-24: VXC Graphics Display, Safe Area

220419: Instrument Block Diagram, Basic block control system

220420 Instrument Wiring Diagram, block control system

219569 Installation Control Drawing

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Railmount Eddy Current

Hook Load Pressure Power Select

Heave Sensor Cal/Config

BMS added equipment

Figure 2.1: Block Control System Overview

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Figure 2.2: DAQ

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Baylor 2025B Brake Controller

Figure 2.3: Baylor 2025B Brake Controller