Operation and Troubleshooting Guide For The Bromma Twin Twenty Detection System (TTDS)

Twin Twenty Detection System (TTDS)
OPERATION AND
TROUBLESHOOTING
GUIDE FOR THE
BROMMA
TWIN TWENTY
DETECTION SYSTEM
(TTDS)
MARCH 2001
Revised APRIL 2002
Revised AUGUST 2002
Revised AUGUST 2004
Revised OCTOBER 2004
Revised NOVEMBER 2007
Revised DECEMBER 2009
Revised APRIL 2010
BROMMA TTDS Troubleshooting Guide


Table of Content
Introduction ................................................................................................... 3
System Description ........................................................................................................ 3
Sensing The Gap Between Containers ........................................................................ 6
Detecting a Container ................................................................................................... 6
Sensor Settings ............................................................................................................... 7
Interface with Spreader and Crane Control............................................................... 8
Twin Twenty Detection By-Pass ................................................................................ 10
Maintenance ................................................................................................................. 10
False Signals ................................................................................................................. 10
Functional Description ................................................................................................ 11
Limitations ................................................................................................... 13
Procedure To Adjust Photoelectric Sensor On Bromma Twin Twenty
Detection System (TTDS) ........................................................................... 14
Operation Mode Setting.............................................................................................. 14
Distance Setting ........................................................................................................... 14
Indication Lights ......................................................................................................... 14
Testing The Twin Twenty Detection System ............................................ 16

Wiring .......................................................................................................... 17
Pin Layout.................................................................................................... 18
Spares ........................................................................................................... 19
Troubleshooting .......................................................................................... 20
Procedure to Trouble Shoot the Twin Twenty Detection System ........................... 20
Procedure to Replace A Twin-Twenty Detection System Sensor ........................... 23
Procedure to Replace A Twin-Twenty Detection System Controller (TTDC) ...... 24
Procedure to Checking Cable to TTDS Controller .................................................. 25
Procedure to Checking Sensor ................................................................................... 27


Introduction
System Description
The Bromma Twin Twenty Detection System (TTDS) is designed to sense the existence of twotwenty foot containers in a forty foot ships cell by detecting the gap between the two containers
or the sagging of the two containers. The twin twenty detection system is a tool to assist the
operator in detecting the dangerous situation of two twenty foot containers under a spreader
positioned in the 40 foot position.
The majority of twin twenty conditions consist of two typical containers, although there are
several other variables to consider. The Bromma Twin Twenty Detection System was designed
to detect as many types of flatrack and tank containers as possible without unnecessarily shutting
down operations.
Bromma Twin Twenty Detection System uses a seven sensor cluster to avoid many of the false
indications that plague other twin twenty detection systems. Many twin twenty detection systems
cannot differentiate between a twin twenty condition and an open top container, canvas tops, tank
container, and lifts with overheights. The Bromma twin twenty detection system is designed to
give a go signal during these lifts. By reducing the amount of false twin twenty indications that
need to be bypassed, Bromma can offer a more reliable and productive system.
The Bromma Twin Twenty Detection System uses a cluster of seven photoelectric sensors
located in the center of the main frame. See Figure 1. The five inner sensors are used to locate a
gap between two containers. The two outer sensors, S95 and S96, along with the two outer
sensors on the center cluster, S90 and S94 are used to detect the existence of the containers. The
system can detect a 38mm (1-1/2) gap with a range of plus or minus 28mm (1-1/8) from the
center of the spreader.
The Bromma Twin Twenty Detection System can also detect an unsafe twin twenty lift even if
the containers are butted together and there is no gap. The idea is based on the fact that an unsafe
twin twenty lift will lift the ends of the containers that are locked on to the spreader and ends at
the center will not be lifted. By setting the outer sensors lower than the inner sensors, there will
be an area where the TTDS will send an unsafe twin twenty lift even when no gap exists. When
the outer ends of the container are lifted beyond the setting of the inner sensors, the TTDS go
permissive will be switched off. The outer sensors should still detect the presence of the
containers. The TTDS will interrupt the go permissive until the spreader is lifted beyond the
range of the outer sensors. This means when the twistlocks are locked and the TTDS senses an
unsafe lift, the hoisting should stop. Figure 2 shows the condition where the twistlock are locked
and the outer ends of the containers are being lifted, but the ends at the center are not. The TTDS
will determine that this condition is an unsafe twin twenty lift and discontinue the go permissive.
Figure 3 show a typical unsafe twin twenty lift that will be detected by the TTDS.

Figure 1

Figure 2
Figure 3


The Bromma TTDS can be mounted anywhere along the center of the spreader. It is
recommended that the TTDS be mounted inside the main frame for maximum protection.
The twin twenty detection system is designed so a failure of a sensor will not cause the system to
fail and send a "go" signal during a twin twenty condition. Because the definition of a gap is two
or more sensors, the system will not shut down if one of the gap sensors fails. The system will
become more sensitive to a twin twenty condition. A failure is defined by a failure of the sensor,
the relay wired to the sensor, or a loose connection.
The Bromma Twin Twenty Detection System (TTDS) is not intended nor will it detect all
possible twin twenty conditions. The Limitation Section outlines the situations where the twin
twenty detection system may give a false twin twenty indication or fail to give an indication.
Sensing The Gap Between Containers

The Bromma TTDS can detect a minimum of 38mm (1-1/2) gap between the containers. The
Bromma TTDS defines a gap as two or more consecutive sensors not detecting an obstruction in
their view path. Two consecutive sensors are used to define a gap to avoid false readings due to
damage or variations of the containers.
The center of the gap between containers does not have to fall in the center of the spreader. The
spreader could be as much as 28 mm (1-1/8) from the center of the gap due to the spreader being
landed toward one end of the container, floating twistlocks, or the flexibility of the spreader. For
this reason, the gap sensing cluster is made up of five sensors to achieve a plus or minus 28mm
(1-1/8) range. Because of the physical size of the sensors, the sensors are mounted in two rows.
The two rows are staggered so any one sensor is halfway between the sensors before and after.
Detecting a Container
The two outer sensors, S95 and S96, of the twin twenty detection system are the primary sensors
for detecting the existence of a container. The two outer sensors of the gap cluster, sensors S90
and S94, are used as secondary container sensors for tank containers and flat racks. If these four
sensors do not detect a container, the twin twenty detection system will allow the container to be
locked and lifted. This situation will occur on forty foot open top containers or loose fitting
canvas topped containers.
If any of the four container sensing sensors detects a container, the control is transferred to the
gap sensing sensors. If two consecutive sensors do not detect the container, the TTDS will not
give the go permissive.
The two outer sensors, S96 and S95, are located 114mm (4-1/2) from the center of the spreader
to ensure that two twenty foot containers are detected no matter where they are in the ship cell.


Sensor Settings
The inner sensors should be set low enough to detect sagging canvas tops but not too low where it
will detect the load in an open top container. It is a known fact that two twenty foot containers
can be lifted in a cell by a spreader in single container mode. The bottom of the containers will
ride the cell guide and allow the crane to lift the two containers. Once the containers leave the
cell, the ends at the center will drop and in most cases the container will fall. Even in the cells the
ends of the container at the center will be lower in relation to the ends attached to the spreader.
The inner sensors must be set so they go from high to low state in the event that two twenty foot
containers are lifted in the cells.
When two twenty foot containers are lifted in a cell, the end of the container at the center will be
5.4 inches [137 mm] lower than the ends supported by the spreader. To ensure that the inner
sensors do not detect the container in this configuration, the inner sensors should be set so that the
range is 5 1/4 inches [133.4 mm] below the twistlock housings. Deflection of the spreader and
the 9/16 inch [14 mm] difference between the seated and the loaded position will ensure that the
inner sensor will not detect the container if this condition occurs. Since the TTDS is located in
different positions and the sensors are not mounted at the same elevation, it is best to set the
sensors based on the bottom of the main beam. The type of spreader will determine the range of
the inner sensors. See Table 1 for recommended inner sensor settings for different spreaders.
Since the spreader will travel lower than the theoretical spreader height when it is landed on a
container, the inner sensors will extend approximately 7 inches [178 mm] past the top of the
container when the spreader is landed. On all but canvas top containers, this engagement should
be adequate. The amount of the sag in the canvas top will determine if a canvas top container
will give a false indication.
In the case where an unsafe twin twenty lift occurs outside the cells, the ends at the center will not
be lifted. This means the outer sensors need to be set so that once the go permissive has been
interrupted, the hoist should stop before the containers are lifted out of the range of the outer
sensors. On faster cranes where the stopping distance is too long, logic in the crane should be
added to watch for the interruption of the go permissive with the twistlock locked and the
spreader not landed. Once a predetermined time period without the go permissive has been
reached with the twistlock locked, the hoist should be stopped, even if the go permissive returns.
When the containers have been lifted high enough the outer sensors will no longer be able to
detect the containers and the go permissive will be given. Bromma recommend a sensor setting
of 12 inches [305 mm] greater than the inner sensors. The stopping distance of the crane will
determine if additional crane logic will be needed. The difference between the inner sensor
setting and the outer sensor setting needs to be greater than the stopping distance of the crane, or
additional crane logic will be needed to properly detect the unsafe twin twenty condition. If the
settings are less than the stopping distance of the crane, the hoist will be interrupted and then the
hoist will coast until the containers are outside the range of the outer sensors then the go
permissive will be given and the hoist will be able to rise again. Only a pause will be seen.
See Table 1 for recommended outer sensor settings for different spreaders.


Table 1 Sensor Settings for Different Spreaders
Type of Spreader
New Type ASX-7 & BSL-6, AST-6, & BST-6

(12 1/4 from Bottom T/L Housing to Gable Tube)
AST-6SCH
(12 1/4 from Bottom T/L Housing to Gable Tube)
Old Style ASX-7 and BSL-6
(9 from Bottom T/L Housing to Gable Tube)
ASX-7 & BSL-6, AST-6, & BST-6 Spreaders with INRS
Gable Ends
AST-6SCH
with INRS Gable Ends
SSX40, SSX45, STR40, STR45 & STS45 with Standard
Gable ends (6 3/4 [172 mm] from Bottom T/L Housing to
Gable Tube)
SSX40, SSX45, STR40, STR45 & STS45 with Bromma
Classic Gable ends (12 3/4 [342 mm] from Bottom T/L
Housing to Gable Tube)
SSX40, SSX45, STR40, STR45 & STS45
with INRS Gable Ends
EH170U, EH5U with Standard End Beams
Inner Sensor Setting

(Inches from Bottom of
Main Beam)
[Millimeters]
16
[405 mm]
15 1/8
[384 mm]
13
[337 mm]
18
[457 mm]
17 1/8
[435 mm]
16
[425 mm]
Outer Sensor Setting

(Inches from Bottom
of Main Beam)
[Millimeters]
28
[710 mm]
27 1/8
[689 mm]
25
[640 mm]
30
[762 mm]
29 1/8
[740 mm]
28
[730 mm]
22 3/8
[568 mm]
34 3/8
[873 mm]
23 7/8
[606 mm]
35 7/8
[911 mm]
13 5/8
[345 mm]
25 5/8
[650]
Interface with Spreader and Crane Control

The Bromma Twin Twenty Detection System should be tied into the spreader position circuit to
deactivate the system when the spreader is in the 20 or 45 foot position. In the case of a twin
twenty spreader, the system should also be tied into the center housing down circuit so the system
is deactivated when the housings are down. The TTDS should be tied into the hoisting circuit. In
the event the system is fooled by a small gap between the containers, the twistlocks can be locked
and the containers could be lifted. As the two containers are lifted, the outer ends of the container
are lifted beyond the setting of the inner sensors, the TTDS go permissive will be switched off.
The hoist should then stop, only if the system is tied into the locked hoist permit. The twin
twenty detection indication should not affect the lowering of the spreader or the unlocking of the
twistlocks.
The stopping distance of the crane determines if the hoisting of the container will stop within the
range of the outer sensors. The stopping distance of the crane is based on a number of
parameters, acceleration rate, deceleration rate and the hoist speed. Since each crane is set up
differently, testing the actual crane may be the only way to determine if the 12 inches [305 mm]
difference between the inner and outer sensors will be enough to stop the hoist. A test to


determine if only the difference in sensor settings will be enough to stop the hoist is described
below.
On faster cranes the sensor settings may not be enough to stop the hoist. When the TTDS is
fooled by the two containers butted together and the two containers are lifted, the go permissive
will be interrupted, but since the crane can not stop quickly, the spreader will be lifted passed the
range of the outer sensors and the go permissive will be sent again. If no other logic is in the
crane PLC, the hoist will start again. To avoid this, one of the two crane logic options should be
added to the PLC.
The first option would be to place TTDS latching logic to stop the hoist and keep it
stopped if the go permissive is interrupted for a half a second to one second when the
twistlocks are locked. The only way to hoist would be to cycle the twistlocks to the
unlock position or active the Twin Twenty Detection bypass. The TTDS latching logic
would need to be added in the PLC. It should be noted that is not a good idea to stop the
hoist and keep it stopped based on just the interruption of the go permissive. As the
spreader is landing or the containers are lifted, the TTDS will interrupt the go permissive
momentarily as the sensors adjust to a different status. The interruption of the go
permissive should be continuous over a period of time from 0.5 to 1 seconds.
The second option would be to keep the hoist in slowdown mode for 2 second after lifting
the containers. This would allow the hoist to be stopped within the range of the outer
sensors.
Testing the Stopping Distance of the Crane

The following test can be done to check if the TTDS sensor setting and crane controls are
properly set to stop an unsafe twin twenty lift.
The first test should be performed without addition TTDS latching logic in the PLC to check if
the sensor settings would be all that is necessary.
Properly set the TTDS sensors.

Place two empty twenty foot containers on the ground so that the ends are butted
together.
Land the spreader on the containers with the center housings up.
Tape a large piece of cardboard (18 by 24) to the top of the containers directly under
the TTDS sensors.
Lock the twistlocks to the outside ends of the containers.
The operator should lift the containers at full stick. (Note: The containers should only be
lifted about two to three feet)
If the TTDS is set properly and the proper hoist interrupts are in place, the TTDS will
stop the hoist and it should remain stopped.
Activate the Twin Twenty Detection Bypass to see if it is working properly.
Check to see if the crane can hoist the containers with the Twin Twenty Detection Bypass
active. (Only lift the containers slightly).


If the test properly stops the hoisting of the containers, repeat the test two more times. If all three
attempts are successfully, then additional logic in the PLC is not needed.
If any of the attempts fail to stop the hoist, the TTDS latching logic or the hoist slowdown needs
to be included in the PLC logic and the test should be repeated. If the TTDS latching logic is
used, start with a timer set for 1 second. Continue to reduce the time setting until the TTDS
properly stops the hoisting of the containers.
Twin Twenty Detection By-Pass

Since there is a possibility that the TTDS will indicate a twin twenty condition when it is landed
on a forty foot container or flat rack, the system must be equipped with a method to override the
system. To do this, a twin twenty bypass should be placed either on the crane or on the spreader.
The bypass should be keyed and only operated by authorized maintenance personnel. The bypass
should be used only after the situation has been checked thoroughly. When the twin twenty
bypass is activated, an audible alarm should be sounded to warn the workers that the bypass is
active. It is the customers responsibility to determine if a twin twenty condition exists when the
bypass is activated.
Maintenance
Normal maintenance of the system includes testing the system according to the Testing the Twin
Twenty Detection System Section (attached) and cleaning the lenses. The operation of the system
should be checked at every maintenance period to ensure the proper operation of the system. The
lenses should also be cleaned at every maintenance period. The sensor will become more
sensitive as the lens become dirty and the system will indicate a twin twenty condition where
there is none.
False Signals
Some ports have encounter false twin twenty indications during heavy rains. A puddle can form
directly beneath the sensor cluster and the wind and rain can produce ripple in the puddle. The
reflective nature of the puddle and the ripples abnormally disperses the light from the sensors,
leading to the TTDS indicating a twin twenty condition. The system should be bypassed until the
container is unloaded.

10

Functional Description
The twin twenty detection system (TTDS) is designed to stop the twistlocks from locking if a
twin twenty condition is detected. The system is also tied into the locked hoist permissive to stop
the hoist if the system is fooled and the twistlocks are locked. The twin twenty detection signal
should only stop the twistlocks from locking when the spreader is in the 40 foot position or the
position of the spreader is unknown and the center housings are up. A keyed bypass switch
labeled TWIN TWENTY DETECTION BYPASS, should be installed in a convenient location to
bypass the twin twenty detection system. The bypass should only be used after the twin twenty
situation has been checked. An alarm should sound when the bypass switch is activated to warn
the worker that a bypass is active.
The crane logic must contain the following interlocks for proper use of the TTDS:
The crane logic must block the operator from locking the twistlocks when a TTDS go
permissive is not given.
The crane logic must block the operator from hoisting the spreader and container when the
twistlocks are locked and a TTDS go permissive is not given.
The TTDS is bypassed under certain condition and a TTDS go permissive will be sent from the
spreader. The logic in the crane should also include the bypasses to mimic the spreader. The
valid TTDS go permissives that need to be supplied by the crane logic are as follows.
Valid TTDS go permissives supplied by crane control:
Spreader in 20 foot position.
Spreader in 45 foot position.
Center Housings are down.
The Twin Twenty Detection Bypass is activated
The twin twenty detection indication should not affect anything when the spreader is in the 20 or
45 foot position, the twistlocks are unlocked or the center housings are down. The twin twenty
detection indication should not effect the lowering of the spreader or the unlocking of the
twistlocks.
If the twin twenty detection indication effects the lowering of the hoist, then the crane may be
stuck in a position it cannot recover. If the system is fooled and the twistlocks are locked, the
TTDS can sense the sagging of the container at the center of the spreader and interrupt the go
permissive and stop the hoist. Without the ability to lower the spreader and unlock the twistlocks,
the containers will be stuck partial lifted.

11

If the twin twenty detection indication effects the hoisting of the crane with the twistlocks
unlocked, the operator will not be able to raise the spreader to put down the center housing or the
spreader will not be able to be removed to check to see if there are two twenty foot containers.
Both of these conditions can be overcome using the twin twenty indication bypass, but frequent
use of the bypass will be a nuisance. If the use of the bypass becomes routine, then the operator
may use the bypass when there is a twin twenty condition just out of habit. Bromma strongly
recommends that each twin twenty occurrence be thoroughly checked before the bypass is used.
The logic for the twin twenty detection system is contained on the spreader. The logic on the
spreader should be imitated in the PLC. The logic must be installed and maintained to ensure the
safe operation of the spreader.
There may be a momentary loss of the twin twenty detection permissive during the landing of the
container as the photosensors adjust to their new status.

12

Limitations
The limitations of the twin twenty detection system are (see Figure 4):
1. There must be a 1-1/2 inch gap between the containers where the twin twenty detection
system is sensing.
2. There must be a support between the end corner castings near the top of the container or flat
rack. The support must be at least 3 inches thick and the side of the support cannot be more
than 2 inches from the end of the corner castings.
3. The maximum recess along the top of a container between the corner castings is 2".
4. The twin twenty detection system has given false twin twenty indications during heavy rains.
Figure 4
13

Procedure To Adjust Photoelectric Sensor On Bromma Twin
Twenty Detection System (TTDS)
Use the attached Figure 5 as reference
Operation Mode Setting

1.
The operation mode screw is mounted on the front face of the sensor.
2.
Rotate the mode screw to D for Dark On or to L for Light On.
3.
Photoelectric Sensors S90 thru S94 are set Light On. Photoelectric Sensors S95 and 96 are
set Dark On.
Distance Setting
1.
Determine the type of spreader. Using Table 1, find the settings for the inner and outer
sensors for the spreader.
2.
Place a black mat object the proper distance +/- inches [6 mm] from the bottom of the
main beam for setting the inner sensors.
3.
Rotate the sensor distance adjustment screw on the inner sensors until the photoelectric
sensor is activated.
4.
Repeat the procedure until all five inner photoelectric sensors are set.
5.
Place a black mat object the proper distance +/- inches [6 mm] from the bottom of the
main beam for setting the outer sensors.
6.
Rotate the sensor distance adjustment screw on the outer sensors until the photoelectric
sensor is activated.
7.
Repeat the procedure until both the outer photoelectric sensors are set.
Indication Lights
The green indicating light is illuminated when there is a stable light or dark condition.
The red indicating light is illuminated when the output is active.

14
Figure 5

15

Testing The Twin Twenty Detection System
Items in parenthesis are for Twin Twenty Spreaders Only
Accepted
(Initials)
Description
Check each sensor individually to see if the green LED lights on each
sensor are illuminated.
Check each sensor individually to see that the red LED lights changes state
when an object is place 150 mm (6") below the sensor.
With the twistlocks unlocked, (the center housings up) and the spreader in
the 40-foot position, place an object about 150 mm (6") below all the
sensors. The LED lights on each sensor should be checked to make sure the
sensor is tripped. The twistlocks should lock and the twin twenty light
should not light.
Clear the area 1020 mm (40") inches from the bottom of the Main Beam.
With the twistlocks unlocked, the plungers up, (the center housings up) and
the spreader in the 40-foot position, check to see if the twistlocks will lock.
The twistlocks should lock and the twin twenty light should not light.
the spreader in the 40-foot position, place an object approximately 150 mm
(6") directly below one of the outer sensors. Check to see if the twistlocks
will lock. The twistlocks should not lock and the twin twenty light should
light.
(6") directly below the other outer sensors. Check to see if the twistlocks
will lock. The twistlocks should not lock and the twin twenty light should
light.
(6") directly below all of the sensors. Check to see if the twistlocks will
lock. The twistlocks should lock and the twin twenty light should not light.
(6") directly below one of the outer sensors. Check to see if the twistlocks
will lock. The twistlocks should lock and the twin twenty light should not
light.
With the twistlocks unlocked, the plungers up, (the center housing up) and
spreader in the 45-foot position, place an object approximately 150 mm (6")
directly below one of the outer sensors. Check to see if the twistlocks will
With the twistlocks unlocked, the plungers up, the center housing down and
spreader in the 40-foot position, place an object approximately 150 mm (6")
directly below one of the outer sensors. Check to see if the twistlocks will
(This step is for Twin Twenty Spreaders Only)
16
Date

Wiring
Figure 6 shows the typical wiring scheme for the TTDS. See the electrical schematic of the
spreader to determine the actual wiring.
Figure 6

17

Pin Layout
10 m
Main Cable with Plug
Male Socket on TTDS
The following is the pin layout for the main cable.
Wire No.
1
2
YL/GR
3
4
5
6
7
8
9
Pin No.
A
B
C
D
E
F
G
H
I
J
Function
Power
Neutral
Equipment Ground
Common Supply Relay 1
TTDS Fault Relay 1 (N.C.) (TTDS Fault)
TTDS Fault Relay 1 (N.O.) (TTDS Permissive)
TTDS Fault Relay 2 (N.C.) (TTDS Fault)
TTDS Fault Relay 2 (N.O.) (TTDS Permissive)
Fault Override (115 VAC)

18

Spares
The following is a list of typical spares. See the electrical wiring diagram of the spreader to
determine the actual parts used.
Part No.
38272
38273
38271
38274
RST3RKWT4/3-631/.6M
UZD355A
Description
Twin Twenty Detection Controller (TTDC) for 120 VAC
Twin Twenty Detection Controller (TTDC) for 220 VAC
Twin Twenty Detection Controller (TTDC) for 24 VDC
Main Cable
Cable Between TTDC and Sensors
Photoelectric Sensor

19

Troubleshooting
Procedure to Trouble Shoot the Twin Twenty Detection System
This procedure is used for Twin Twenty Detection Systems with the Bromma TTDS controller
another procedure is used to troubleshoot the TTDS with relays.
Position the spreader so it is raised at least three (3) feet from the ground in the area of the twin
twenty detection system. There will be one relay mounted in the main junction box that is the
go permissive for the twin twenty detection system. Check the electrical schematic for the
spreader to determine the relay number for the go permissive. For this document, the go
permissive relay will be called R100. When Relay 100 is powered, the go permissive is given. If
Relay 100 is not on, then the twin twenty detection system is indicating a twin twenty condition.
See Figure 1 for the sensor configuration.
Check to see that the cables number corresponds to the sensor number. See Figure 1 for the
sensor configuration. Cable S90 is on sensor S90, Cable S91 is on sensor S91, Cable S92
is on sensor S92, Cable S93 is on sensor S93, Cable S94 is on sensor S94, Cable S95 is on
sensor S95 and Cable S96 is on sensor S96.
Reconnect the cables to the proper sensors if the cabling is not correct.
When there is no object under the sensor cluster, the green LED lights should be lit on all
the sensors. The red LED light should be illuminated on sensors S95 and S96. The LED
light on Relay 100 should be illuminated.
If the green LED light on some sensors is not illuminated and illuminated on other
sensors, the cable to the sensor may be bad, the sensor may be bad or the controller
may be bad. First, check the sensor according to the attached, Procedure For Checking
Sensors. If the sensor is not bad, check the cable to the bad sensor according the
attached, Procedure For Checking Sensor Cable. If the cable to the sensor is not bad,
replace the TTDS controller according to the attached, Procedure to Replace Twin
Twenty Detection System Controller.
If none of the green LED lights on the sensors are illuminated, the cable to the
controller may be bad or the controller is bad. First, check the wiring to the
controller according to the attached, Procedure For Checking Cable to
Controller. If the wiring is not bad, replace the TTDS controller according
attached, Procedure to Replace Twin Twenty Detection System Controller.
TTDS
TTDS
TTDS
to the
Place masking tape over the face of the outside sensor S95. The red LED light should go
off. The LED light in Relay 100 will not be illuminate.
If the red LED light does not go out, check the sensor according to the attached,
Procedure For Checking Sensors.

20
Remove the masking tape from sensor S95. Place masking tape over the face of sensor
S96. The red LED light should go off. The LED light in Relay 100 will not be illuminate.
If the red LED light does not go out, check the sensor according to the attached,
If the LED light in Relay R100 does not go out, the cable to the sensor may be bad, the
cable to the TTDS controller may be bad, or the controller may be bad. First, check the
wiring to the TTDS controller according to the attached, Procedure For Checking
Cable to TTDS Controller. If the wiring to the TTDS controller is not bad, check the
cable to the bad sensor according the attached, Procedure For Checking Sensor
Cable. If the cable to the sensor is not bad, replace the TTDS controller according to
the attached, Procedure to Replace Twin Twenty Detection System Controller.
Place the masking tape back onto sensor S95, then individually add masking tape to sensors
S90, S91, S92, S93 and S94. When the tape is placed on the sensor, the red LED light on
the sensor should illuminate.
If the red LED light does not illuminate, check the sensor according to the attached,
After all the sensors have been covered. The LED light on Relay 100 should illuminate.
If the LED light in Relay R100 does not illuminate, the cable to the TTDS controller
may be bad, or the controller may be bad. First, check the wiring to the TTDS
controller according to the attached, Procedure For Checking Cable to TTDS
Controller. If the wiring to the TTDS controller is not bad replace the TTDS
controller according to the attached, Procedure to Replace Twin Twenty Detection
System Controller.
Check the logic in the TTDS controller by removing the tape from two sensors. See the list
below for the proper pair of sensors. The LED light in Relay 100 should go out. If the
LED light in Relay 100 goes out, replace the tape and uncover the next pair.
Sensors S90 and S91
Sensors S91 and S92
Sensors S92 and S93
Sensors S93 and S94

21
If everything has worked properly to this point and the system is still not functioning
properly on the spreader, check the wirings to the relay according to the attached
Procedure to Check the Wiring to the Go Permissive Relay

22

Procedure to Replace A Twin-Twenty Detection System Sensor
Remove the sensor cluster from the spreader by removing the bottom locknuts on the
cluster shock mounts (See Figure 1).
Remove cluster from mounting brackets.
Remove screws and wiring from sensor. The sensors are held in place by two screws.
Separate the bad sensors from the other sensors. Note the location of sensors in cluster.
Unscrew the sensor cable form the sensor.
Reinstall the sensor cable onto the new sensor.
Reinstall the sensor back into the cluster and make sure all sensors are back in their proper
order.
Place the sensor cluster back on the support brackets and replace the shock mount nuts.
Set the new sensor according to Procedure To Adjust Photoelectric Sensor On Bromma
Retest the Twin Twenty Detection System according to Procedure to Trouble Shoot TwinTwenty Detection System.

23

Procedure to Replace A Twin-Twenty Detection System Controller (TTDC)
Disconnect the cables to the sensors at the TTDC.
Disconnect the main cable to the TTDC.
Remove the nut holding the TTDC.
Remove the TTDC.
Place the new TTDC on the shock mounts.
Reinstall the nut on the shock mounts.
Reinstall the main cable to the TTDC.
Reinstall the sensor cable to the TTDC. Make sure the cables are connected to the proper
connections.
Retest the Twin Twenty Detection System according to Procedure to Trouble Shoot TwinTwenty Detection System.

24

Procedure to Checking Cable to TTDS Controller
Before checking the cable, check all the connections of the cable to the terminal strips.
Look for loose screws, bad crimps and frayed strands.
If a spare cable is available, temporarily wire the cable in the junction box. Disconnect the
existing cable and plug in the spare cable. Retest the TTDS.
If the meter does not show any voltage, measure and verify with the voltmeter that the
proper voltage in on the wire terminations in the junction box. If not repair the problem
in the junction box. If the proper voltage exists on the wire terminations, replace the
cable.
If the meter reads the proper voltage, Carefully with an voltmeter meter, place one probe on
Pin G and the other to Pin B. The ohm meter should read the proper voltage (24 VDC, 115
VAC or 220 VAC). See the electrical schematic to determine the proper voltage.
If the TTDS operates properly, then replace the existing cable. If the TTDS is not
functioning properly, reconnect the existing cable and follow the Procedure to Trouble
Shoot the TTDS to determine the cause of the problem.
If a spare cable is not available, unplug the cable from the TTDC with the power off. Turn
on the power. Carefully with a voltmeter meter, place one probe on Pin A and the other to
Pin B. The voltmeter meter should read the proper voltage (24 VDC, 115 VAC or 220
VAC). See the electrical schematic to determine the proper voltage.
If any bad connections are found, repair and retest the TTDS
If the meter does not show any voltage, measure and verify with the voltmeter that the
proper voltage in on the wire terminations in the junction box. If not repair the problem
in the junction box. If the proper voltage exists on the wire terminations, replace the
cable.
If the meter reads the proper voltage, remove the power on the spreader. With the ohm
meter set to check for continuity, check each of the wires for continuity. The following
chart shows the pin out for the cable.
Wire No.
1
2
YL/GR
3
4
5
6
7
Pin No.
A
B
C
D
E
F
G
H

Function
Power
Neutral
Equipment Ground
TTDS Fault Relay 1 (N.O.)
TTDS Fault Relay 1 (N.C.)
TTDS Fault Relay 2 (N.O.)
25

8
9
I
J
TTDS Fault Relay 2 (N.C.)

Fault Override (115 VAC)
If the meter shows any breaks in the cable, replace the cable.
If no breaks are found, follow the Procedure to Trouble Shoot the TTDS to determine the
cause of the problem.

26

Procedure to Checking Sensor
If a spare cable is available, remove the suspected cable and install the spare cable. Retest
the TTDS.
If a spare cable is not available, unplug the cable from the TTDC and the sensor.
With the ohm meter set to check for continuality, check each of the wires for
continuity.
If the TTDS operates properly, then keep the spare cable installed. If the TTDS
is not functioning properly, reconnect the existing cable and look for another
problem.
If the meter shows any breaks in the cable, replace the cable.
If no breaks are found, follow the Procedure to Trouble Shoot the TTDS to determine the
cause of the problem.

27

Operation and Troubleshooting Guide For The Bromma Twin Twenty Detection System (TTDS)

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Operation and Troubleshooting Guide For The Bromma Twin Twenty Detection System (TTDS)

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Twin Twenty Detection System (TTDS)

BROMMA TTDS Troubleshooting Guide

Twin Twenty Detection System (TTDS)

Testing The Twin Twenty Detection System ............................................ 16

BROMMA TTDS Troubleshooting Guide

Twin Twenty Detection System (TTDS)

BROMMA TTDS Troubleshooting Guide

Twin Twenty Detection System (TTDS)

BROMMA TTDS Troubleshooting Guide

Twin Twenty Detection System (TTDS)

BROMMA TTDS Troubleshooting Guide

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Sensing The Gap Between Containers

BROMMA TTDS Troubleshooting Guide

Twin Twenty Detection System (TTDS)

BROMMA TTDS Troubleshooting Guide

Twin Twenty Detection System (TTDS)

New Type ASX-7 & BSL-6, AST-6, & BST-6

Inner Sensor Setting

Outer Sensor Setting

Interface with Spreader and Crane Control

BROMMA TTDS Troubleshooting Guide

Twin Twenty Detection System (TTDS)

Testing the Stopping Distance of the Crane

Properly set the TTDS sensors.

BROMMA TTDS Troubleshooting Guide

Twin Twenty Detection System (TTDS)

Twin Twenty Detection By-Pass

BROMMA TTDS Troubleshooting Guide

Twin Twenty Detection System (TTDS)

Spreader in 20 foot position.

Spreader in 45 foot position.

Center Housings are down.

The Twin Twenty Detection Bypass is activated

BROMMA TTDS Troubleshooting Guide

Twin Twenty Detection System (TTDS)

BROMMA TTDS Troubleshooting Guide

Twin Twenty Detection System (TTDS)

Twin Twenty Detection System (TTDS)

Operation Mode Setting

Rotate the mode screw to D for Dark On or to L for Light On.

BROMMA TTDS Troubleshooting Guide

Twin Twenty Detection System (TTDS)

BROMMA TTDS Troubleshooting Guide

Twin Twenty Detection System (TTDS)

Twin Twenty Detection System (TTDS)

BROMMA TTDS Troubleshooting Guide

Twin Twenty Detection System (TTDS)

Main Cable with Plug

Male Socket on TTDS

The following is the pin layout for the main cable.

BROMMA TTDS Troubleshooting Guide

Twin Twenty Detection System (TTDS)

BROMMA TTDS Troubleshooting Guide

Twin Twenty Detection System (TTDS)

BROMMA TTDS Troubleshooting Guide

Twin Twenty Detection System (TTDS)

BROMMA TTDS Troubleshooting Guide

Twin Twenty Detection System (TTDS)

BROMMA TTDS Troubleshooting Guide

Twin Twenty Detection System (TTDS)

Remove cluster from mounting brackets.