RPM Banner IR Occupancy Sensor Replacement | FRONTLINE Maintenance Tool

Last Updated: 04/24/2025 1:45 AM

The following table lists all the components that make up the document.

Title	Type	Status	Last Updated
Rapiscan VM-250 Vehicle Monitor	Device	Published	10/14/2024 9:50 AM
Rapiscan TM-850 Rail Monitor	Device	Published	09/18/2024 10:28 AM
8468 - 1401 - Establish Initial Conditions; Remark:	Procedure Step	Published	09/16/2023 4:47 PM
1401 - Establish Initial Conditions	Instruction	Published	09/30/2022 3:14 PM
7268 - 7231 - Close lane; Remark:7233	Procedure Step	Published	04/27/2023 7:01 PM
9053 - Warning : Traffic should temporarily be rerouted or halted during conduction of this pr...	Annotation	Published	09/27/2023 9:09 AM
7231 - Close lane	Instruction	Published	04/18/2023 1:00 PM
7233 - Use orange safety (traffic control) cones to setup barriers. Practice establi...	Remark	Published	04/24/2023 12:18 PM
7269 - 7232 - Open RPM door; Remark:7234	Procedure Step	Published	04/27/2023 7:02 PM
7232 - Open RPM door	Instruction	Published	04/18/2023 1:02 PM
7234 - Open all doors needed to access components.	Remark	Published	04/19/2025 7:48 PM
7270 - 7235 - Power off RPM; Remark:7236	Procedure Step	Published	09/01/2023 7:57 PM
7235 - Power off RPM	Instruction	Published	04/24/2023 12:30 PM
7236 - Move LD-260 switch to OFF position. The PWR ON	Remark	Published	04/27/2023 4:25 PM
8623 - 8613 - Uninstall Faulty Sensor; Remark:	Procedure Step	Published	09/19/2023 12:06 PM
8613 - Uninstall Faulty Sensor	Instruction	Published	09/19/2023 11:40 AM
8624 - 8614 - Locate infrared sensors; Remark:8615	Procedure Step	Published	09/19/2023 5:39 PM
8614 - Locate infrared sensors	Instruction	Published	09/19/2023 11:41 AM
8615 - Typical sensor locations are as follows: Control pillar hou...	Remark	Published	09/19/2023 11:43 AM
8625 - 8617 - Disconnect applicable infrared sensors; Remark:8618	Procedure Step	Published	09/19/2023 12:08 PM
8617 - Disconnect applicable infrared sensors	Instruction	Published	09/19/2023 11:49 AM
8618 - To disconnect sensor cable, turn collar counterclockwise and pull away from s...	Remark	Published	09/19/2023 11:51 AM
8626 - 8619 - Unscrew mounting nut; Remark:8620	Procedure Step	Published	09/19/2023 12:09 PM
8619 - Unscrew mounting nut	Instruction	Published	09/19/2023 11:59 AM
8620 - Rotate threaded nut counterclockwise. It may be necessary to hold the infrare...	Remark	Published	09/19/2023 11:58 AM
8627 - 8621 - Remove sensor from back of door; Remark:8622	Procedure Step	Published	09/19/2023 12:09 PM
8621 - Remove sensor from back of door	Instruction	Published	09/19/2023 12:01 PM
8622 - Removal of infrared sensor	Remark	Published	09/19/2023 12:03 PM
8660 - 8658 - Retain sensor O-ring; Remark:8659	Procedure Step	Published	09/19/2023 5:56 PM
8658 - Retain sensor O-ring	Instruction	Published	09/19/2023 5:55 PM
8659 - Retain Sensor O-ring	Remark	Published	09/19/2023 5:55 PM
3397 - 3395 - Label faulty component; Remark:3396	Procedure Step	Published	07/21/2024 6:59 AM
3395 - Label faulty component	Instruction	Published	08/07/2021 11:07 AM
3396 - Use tag or tape. Include date of removal, description of failure symptoms, co...	Remark	Published	08/09/2021 11:35 AM
8641 - 8628 - Install New Sensor; Remark:	Procedure Step	Published	09/19/2023 4:09 PM
8628 - Install New Sensor	Instruction	Published	09/19/2023 12:35 PM
8642 - 8629 - Verify replacement sensor matches function and color of sensor previously rem...; Remark:8630	Procedure Step	Published	09/19/2023 4:10 PM
8629 - Verify replacement sensor matches function and color of sensor previously rem...	Instruction	Published	09/19/2023 12:36 PM
8630 - Infrared sensor identification	Remark	Published	09/19/2023 12:48 PM
8643 - 8631 - Remove nut closest to sensor face; Remark:8632	Procedure Step	Published	09/19/2023 4:11 PM
8631 - Remove nut closest to sensor face	Instruction	Published	09/19/2023 12:48 PM
8632 - Infrared Nut	Remark	Published	09/19/2023 12:50 PM
8644 - 8633 - Add retained O-ring; Remark:8634	Procedure Step	Published	09/19/2023 4:12 PM
8633 - Add retained O-ring	Instruction	Published	09/19/2023 3:52 PM
8634 - Infrared Sensor O-ring	Remark	Published	09/19/2023 3:55 PM
8645 - 8635 - Mount new infrared sensor; Remark:8636	Procedure Step	Published	09/19/2023 4:13 PM
8635 - Mount new infrared sensor	Instruction	Published	09/19/2023 3:57 PM
8636 - Insert sensor through hole on the back side of door.	Remark	Published	09/19/2023 4:01 PM
8646 - 8638 - Add outside nut to front and hand tighten; Remark:8639	Procedure Step	Published	09/19/2023 4:14 PM
8637 - Note : The nut on the outside should be flush with the sensor.	Annotation	Published	09/19/2023 4:01 PM
8638 - Add outside nut to front and hand tighten	Instruction	Published	09/19/2023 4:02 PM
8639 - Use the adjustable wrench to snug the nut up slightly, just enough for the ga...	Remark	Published	09/19/2023 4:05 PM
8647 - 8661 - Reconnect applicable cable previously removed in Step 4-6; Remark:8559	Procedure Step	Published	09/19/2023 4:15 PM
5553 - Caution : Correct placement of connectors and wiring is critical to proper operation.	Annotation	Published	10/28/2022 2:19 PM
8661 - Reconnect applicable cable previously removed in Step 4-4	Instruction	Published	09/19/2023 6:14 PM
8559 - To reconnect sensor cable, align connectors, push towards sensor, and turn co...	Remark	Published	09/29/2023 12:05 PM
7279 - 7249 - Return equipment to normal operating condition; Remark:	Procedure Step	Published	04/27/2023 4:13 PM
7249 - Return equipment to normal operating condition	Instruction	Published	04/08/2025 3:22 PM
8503 - 7250 - Power on RPM; Remark:7251	Procedure Step	Published	09/16/2023 9:00 PM
7250 - Power on RPM	Instruction	Published	05/01/2023 8:31 AM
7251 - Move LD-260 switch to ON position. The LED PWR ON	Remark	Published	05/10/2023 3:14 PM
7281 - 7252 - Verify RPM start-up; Remark:7253	Procedure Step	Published	04/20/2025 3:26 PM
7252 - Verify RPM start-up	Instruction	Published	04/27/2023 2:23 PM
7253 - RPM will perform a power on self-test (POST) and collect a background radiati...	Remark	Published	05/10/2023 3:14 PM
8654 - 8648 - Verify SC-770 display shows OCCUPIED when infrared beams are...; Remark:8651	Procedure Step	Published	09/19/2023 4:52 PM
8648 - Verify SC-770 display shows OCCUPIED when infrared beams are...	Instruction	Published	09/19/2023 4:23 PM
8651 - SC-770 Occupied	Remark	Published	09/19/2023 4:30 PM
8655 - 8649 - Test sensors independently; Remark:8650	Procedure Step	Published	09/19/2023 4:53 PM
8649 - Test sensors independently	Instruction	Published	09/19/2023 4:24 PM
8650 - Disconnect one receiver cable, shut door, and clear sensors for five (5) seco...	Remark	Published	09/19/2023 4:28 PM
8656 - 8648 - Verify SC-770 display shows OCCUPIED when infrared beams are...; Remark:8651	Procedure Step	Published	09/19/2023 4:54 PM
8653 - 8652 - Repeat steps 4-4 through 4-6 for other receiver sensors.; Remark:	Procedure Step	Published	04/13/2025 6:16 PM
8652 - Repeat steps 4-4 through 4-6 for other receiver sensors.	Instruction	Published	04/13/2025 6:11 PM
7282 - 7254 - Confirm network connection; Remark:7255	Procedure Step	Published	04/27/2023 4:15 PM
7254 - Confirm network connection	Instruction	Published	04/27/2023 2:22 PM
7255 - Contact operators to confirm communications have been reestablished between RPM ...	Remark	Published	05/10/2023 3:15 PM
7283 - 7256 - Close and lock all RPM doors; Remark:	Procedure Step	Published	09/01/2023 11:45 PM
7256 - Close and lock all RPM doors	Instruction	Published	04/27/2023 2:21 PM
7842 - 7820 - Inform system operators upon completion of maintenance action; Remark:	Procedure Step	Published	07/07/2023 11:15 PM
7820 - Inform system operators upon completion of maintenance action	Instruction	Published	07/07/2023 10:02 PM
322 - 321 - Document maintenance actions; Remark:	Procedure Step	Published	06/17/2021 9:49 AM
321 - Document maintenance actions	Instruction	Published	04/21/2025 11:19 AM
2869 - 2585 - Document maintenance performed; Remark:2866	Procedure Step	Published	06/18/2021 5:58 PM
2585 - Document maintenance performed	Instruction	Published	07/09/2021 12:15 PM
2866 - Record observations, times, and results for the maintenance report.	Remark	Published	04/21/2025 11:39 AM
4706 - 4705 - Submit report; Remark:4864	Procedure Step	Published	06/29/2022 9:50 AM
4705 - Submit report	Instruction	Published	06/29/2022 9:50 AM
4864 - As specified by management or contractual obligations.	Remark	Published	07/28/2022 1:36 PM
Corrective Maintenance Procedure	Document Type	Published	03/02/2020 3:32 PM
30 minutes	Duration	Published	04/01/2020 11:35 AM
If system is locked in continuous occupancy or speed indication does not function	Frequency	Published	09/19/2023 5:28 PM
Warning	Annotation Type	Published	03/02/2020 3:25 PM
Note	Annotation Type	Published	03/02/2020 3:25 PM
Caution	Annotation Type	Published	03/02/2020 3:24 PM
Technician 1	Skill Level	Published	05/14/2020 2:56 PM
Keys to access RPM	Replacement Parts	Published	04/27/2023 6:56 PM
Adjustable wrench	Replacement Parts	Published	06/02/2023 10:08 PM
Ladder: 2 meters, 6 feet tall; non-conducting	Replacement Parts	Published	09/01/2023 9:34 PM
Reflective safety vest if required	Replacement Parts	Published	06/20/2023 4:47 PM
LD-260 Disconnect Switch Power Off	Image	Published	04/24/2023 12:49 PM
Remove Infrared Sensor Nut	Image	Published	09/19/2023 11:57 AM
Mount Infrared Sensors	Image	Published	09/19/2023 5:51 PM
Retained Infrared O-ring	Image	Published	09/19/2023 5:44 PM
Infrared Sensor Identification	Image	Published	09/19/2023 12:39 PM
Outside Nut of Infrared Sensor	Image	Published	09/19/2023 12:49 PM
Tighten Infrared Sensor Nut	Image	Published	09/19/2023 4:03 PM
Infrared Connection	Image	Published	09/29/2023 12:02 PM
Infrared Cable Installation	Image	Published	09/17/2023 10:12 PM
Infrared Sensor Cable	Image	Published	09/17/2023 10:13 PM
LD-260 Disconnect Switch Power On	Image	Published	05/04/2023 3:37 PM
SC-770 Occupied	Image	Published	09/19/2023 4:30 PM

DET-RPM-RAP-CM14

Remove and replace Banner Infrared (IR) occupancy sensor

Equipment Hierarchy

Rapiscan VM-250 Vehicle Monitor

Rapiscan TM-850 Rail Monitor

Frequency

If system is locked in continuous occupancy or speed indication does not function

Technician Level

Technik 1

x 1

Duration

Time increment

30 minutes

Length of time

Tools Required

Keys to access RPM

Adjustable wrench

Ladder: 2 meters, 6 feet tall; non-conducting

Reflective safety vest if required

Materials Required

THRU BEAM EMITTER Yellow (Part Number: 6660A1)

THRU BEAM RECEIVER Yellow (Part Number: 6660A2)

THRU BEAM EMITTER Black (Part Number: 6660B1)

THRU BEAM RECEIVER Black (Part Number: 6660B2)

Originators

Mike Papp

Originating Organization

Rapiscan System

Approver

Craig Stinson

Safety Concerns

Traffic

Final Documentation

Corrective Maintenance Report

Departmental Coordination

Prior to arrival, notify operators concerning expected work, duration, and anticipated alarms and fault indications.

Date of Origin

2020-11-30

Version

2.00

Version #

Revision Description

Updated pillar names

Revision Author

Angela Moore

Revision Description

Typographical corrections in 2-1

Revision Author

John Dorian

Przygotowanie

Step 1

Main Step

8468 - 1401 - Establish Initial Conditions; Remark:

Step 00

1401 - Establish Initial Conditions

Establish Initial Conditions

7268 - 7231 - Close lane; Remark:7233

9053 - Warning : Traffic should temporarily be rerouted or halted during conduction of this pr...

Type

Warning

Traffic should temporarily be rerouted or halted during conduction of this procedure to ensure maintenance provider safety and to prevent unscreened vehicles from passing.

Step 00

7233 - Use orange safety (traffic control) cones to setup barriers. Practice establi...

Use orange safety (traffic control) cones to setup barriers. Practice established safety protocols.

7269 - 7232 - Open RPM door; Remark:7234

Step 00

7234 - Open all doors needed to access components.

Open all doors needed to access components.

7270 - 7235 - Power off RPM; Remark:7236

Step 00

7236 - Move LD-260 switch to OFF position. The PWR ON

Move LD-260 switch to OFF position. The PWR ON LED will turn off.

Obsługa

Step 2

Main Step

8623 - 8613 - Uninstall Faulty Sensor; Remark:

Step 00

8613 - Uninstall Faulty Sensor

Uninstall Faulty Sensor

8624 - 8614 - Locate infrared sensors; Remark:8615

Step 00

8614 - Locate infrared sensors

Locate infrared sensors

8615 - Typical sensor locations are as follows: Control pillar hou...

Typical sensor locations are as follows:

Control pillar houses both "RECEIVERS"
Auxiliary pillar houses both "EMITTERS"

8625 - 8617 - Disconnect applicable infrared sensors; Remark:8618

Step 00

8617 - Disconnect applicable infrared sensors

Disconnect applicable infrared sensors

8618 - To disconnect sensor cable, turn collar counterclockwise and pull away from s...

To disconnect sensor cable, turn collar counterclockwise and pull away from sensor.

8626 - 8619 - Unscrew mounting nut; Remark:8620

Step 00

8620 - Rotate threaded nut counterclockwise. It may be necessary to hold the infrare...

Rotate threaded nut counterclockwise. It may be necessary to hold the infrared sensor from the back.

8627 - 8621 - Remove sensor from back of door; Remark:8622

Step 00

8621 - Remove sensor from back of door

Remove sensor from back of door

8622 - Removal of infrared sensor

8660 - 8658 - Retain sensor O-ring; Remark:8659

Step 00

3397 - 3395 - Label faulty component; Remark:3396

Step 00

3396 - Use tag or tape. Include date of removal, description of failure symptoms, co...

Use tag or tape. Include date of removal, description of failure symptoms, country, site, and lane number. Dispose per Nuclear Smuggling Detection and Deterrence (NSDD) guidance or contractual requirements.

Obsługa

Step 3

Main Step