RPM +12 VDC Battery Replacement | FRONTLINE Maintenance Tool

Last Updated: 04/24/2025 1:46 AM

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

Title	Type	Status	Last Updated
Rapiscan TM-850 Rail Monitor	Device	Published	09/18/2024 10:28 AM
Rapiscan VM-250 Vehicle Monitor	Device	Published	10/14/2024 9:50 AM
Rapiscan PM-700 Pedestrian Monitor	Device	Published	06/20/2024 11:38 AM
Rapiscan CM-267 Conveyor Monitor	Device	Published	06/27/2024 1:02 PM
1402 - 7927 - Establish Initial Conditions; Remark:	Procedure Step	Published	09/30/2022 1:47 PM
7927 - Establish Initial Conditions	Instruction	Published	07/12/2023 12:23 AM
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
8072 - 10288 - Turn AC Power Off; Remark:	Procedure Step	Published	07/31/2023 11:51 AM
10288 - Turn AC Power Off	Instruction	Published	11/16/2023 6:34 PM
10157 - 10154 - Turn RPM AC power input breaker switch to “OFF” position; Remark:10153	Procedure Step	Published	10/23/2023 11:08 AM
10155 - Warning : 120/240 Vac will still be present at the AC power terminal block and at the A...	Annotation	Published	10/23/2023 11:06 AM
10156 - Note : Normally the “OFF” position will be when the switch is in the down positi...	Annotation	Published	10/23/2023 11:08 AM
10154 - Turn RPM AC power input breaker switch to “OFF” position	Instruction	Published	10/23/2023 11:04 AM
10153 - Note the different styles of AC breakers: 1. Black breaker/green so...	Remark	Published	10/23/2023 11:05 AM
10158 - 10152 - Confirm AC LED on LD-260 is no longer lit once AC breaker ha...; Remark:10151	Procedure Step	Published	04/13/2025 6:14 PM
10152 - Confirm AC LED on LD-260 is no longer lit once AC breaker ha...	Instruction	Published	04/13/2025 5:31 PM
10151 - confirming LD-260 power is off	Remark	Published	10/23/2023 11:32 AM
10150 - 10149 - Uninstall Faulty +12V Battery; Remark:	Procedure Step	Published	10/23/2023 11:35 AM
10149 - Uninstall Faulty +12V Battery	Instruction	Published	10/23/2023 11:34 AM
10142 - 10141 - Disconnect battery at Molex plug; Remark:10140	Procedure Step	Published	10/23/2023 11:42 AM
10141 - Disconnect battery at Molex plug	Instruction	Published	10/23/2023 11:35 AM
10140 - Unplug the 2-conductor Molex by opening latch and separate ends by pulling ap...	Remark	Published	10/23/2023 11:42 AM
10143 - 10139 - Lift battery out of RPM cabinet; Remark:10137	Procedure Step	Published	10/23/2023 11:45 AM
10139 - Lift battery out of RPM cabinet	Instruction	Published	10/23/2023 11:45 AM
10137 - The battery posts may be covered with a protective, non-conductive blanket to...	Remark	Published	10/23/2023 11:45 AM
10144 - 10136 - Disconnect wiring harness from failed battery; Remark:10135	Procedure Step	Published	10/23/2023 11:47 AM
10136 - Disconnect wiring harness from failed battery	Instruction	Published	10/23/2023 11:46 AM
10135 - Remove the wiring harness from the failed battery in preparation for installa...	Remark	Published	10/23/2023 11:46 AM
10145 - 10134 - Attach wiring harness to new battery; Remark:10132	Procedure Step	Published	10/23/2023 11:51 AM
10134 - Attach wiring harness to new battery	Instruction	Published	10/23/2023 11:49 AM
10132 - Install the wiring harness on the new battery.	Remark	Published	10/23/2023 11:50 AM
10133 - If the non-conductive blanket was present on the old battery install it on th...	Remark	Published	10/23/2023 11:50 AM
10146 - 10131 - Place new battery into position in RPM cabinet; Remark:	Procedure Step	Published	10/23/2023 11:51 AM
10131 - Place new battery into position in RPM cabinet	Instruction	Published	10/23/2023 11:51 AM
10147 - 10130 - Reinstall protective cover; Remark:	Procedure Step	Published	10/23/2023 11:52 AM
10130 - Reinstall protective cover	Instruction	Published	10/23/2023 11:52 AM
10148 - 10129 - Reconnect battery; Remark:10128	Procedure Step	Published	10/23/2023 11:54 AM
10129 - Reconnect battery	Instruction	Published	10/23/2023 11:52 AM
10128 - Reconnect the two halves of the Molex connector; slide the two halves togethe...	Remark	Published	10/23/2023 11:54 AM
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
10127 - 10307 - Turn AC Power On; Remark:	Procedure Step	Published	10/23/2023 11:55 AM
10307 - Turn AC Power On	Instruction	Published	11/16/2023 7:01 PM
10125 - 10124 - Turn power ON at AC breaker; Remark:10153	Procedure Step	Published	10/23/2023 12:08 PM
10124 - Turn power ON at AC breaker	Instruction	Published	10/23/2023 12:06 PM
10310 - 10308 - Confirm AC LED on LD-260 is lit; Remark:10309	Procedure Step	Published	04/13/2025 6:13 PM
10308 - Confirm AC LED on LD-260 is lit	Instruction	Published	04/13/2025 5:31 PM
10309 - AC Present	Remark	Published	11/16/2023 7:23 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
7280 - 7250 - Power on RPM; Remark:7251	Procedure Step	Published	04/27/2023 4:14 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
9735 - 319 - Perform operational test; Remark:9733	Procedure Step	Published	04/08/2025 2:22 PM
319 - Perform operational test	Instruction	Published	06/10/2021 8:31 PM
9733 - DET-RPM-RAP-RM03.	Remark	Published	10/13/2023 4:08 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
20 minutes	Duration	Published	05/18/2020 5:44 PM
Upon failure of +12 Vdc battery	Frequency	Published	10/23/2023 9:58 AM
Warning	Annotation Type	Published	03/02/2020 3:25 PM
Note	Annotation Type	Published	03/02/2020 3:25 PM
Technician 2	Skill Level	Published	04/09/2020 1:17 AM
Keys to access RPM	Replacement Parts	Published	04/27/2023 6:56 PM
Phillips screwdriver, medium	Replacement Parts	Published	07/07/2023 11:39 PM
Permanent marker	Tools	Published	10/23/2023 10:07 AM
Orange/yellow safety vest	Replacement Parts	Published	04/27/2023 6:56 PM
Safety shoes	Replacement Parts	Published	04/27/2023 6:56 PM
safety glasses	Replacement Parts	Published	07/02/2023 4:48 PM
Ladder; 2 meters, 6 feet tall; non-conducting if required	Replacement Parts	Published	07/02/2023 4:48 PM
Orange traffic cones	Replacement Parts	Published	04/27/2023 6:56 PM
LD-260 Disconnect Switch Power Off	Image	Published	04/24/2023 12:49 PM
AC Power input breaker	Image	Published	10/23/2023 11:05 AM
LD-260 Power off.png	Image	Published	10/23/2023 2:11 PM
Disconnect battery at Molex plug (1)	Image	Published	10/23/2023 11:39 AM
Disconnect battery at Molex plug (2)	Image	Published	10/23/2023 11:40 AM
Disconnect battery at Molex plug (3)	Image	Published	10/23/2023 11:41 AM
AC power present	Image	Published	10/23/2023 12:20 PM
LD-260 Disconnect Switch Power On	Image	Published	05/04/2023 3:37 PM

DET-RPM-RAP-CM28

Replace +12 Vdc [Volts direct current] battery

Equipment Hierarchy

Rapiscan TM-850 Rail Monitor

Rapiscan VM-250 Vehicle Monitor

Rapiscan PM-700 Pedestrian Monitor

Rapiscan CM-267 Conveyor Monitor

Frequency

Upon failure of +12 Vdc battery

Technician Level

Technician 2

x 1

Duration

Time increment

20 minutes

Notes

20 minutes (30 minutes with retest)

Length of time

Tools Required

Keys to access RPM

Phillips screwdriver, medium

Permanent marker

Orange/yellow safety vest

Safety shoes

safety glasses

Ladder; 2 meters, 6 feet tall; non-conducting if required

Orange traffic cones

Materials Required

+12 Vdc battery (Rapiscan Part# 6456B, or equivalent)

RPM Maintenance Guide Rev 2.0

Originators

David Alexander

Originating Organization

PNNL

Approver

Craig Stinson

Safety Concerns

Traffic

Electrical

Retest Requirements

RPM Operational Test

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

1.00

Version #

Revision Description

Updated pillar names

Revision Date

2020-11-30

Revision Author

Angela Moore

Step 1

Main Step

1402 - 7927 - Establish Initial Conditions; Remark:

Step 00

7927 - 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.

Step 2

Main Step

8072 - 10288 - Turn AC Power Off; Remark:

Step 00

10157 - 10154 - Turn RPM AC power input breaker switch to “OFF” position; Remark:10153

10155 - Warning : 120/240 Vac will still be present at the AC power terminal block and at the A...

Type

Warning

120/240 Vac will still be present at the AC power terminal block and at the AC voltage input to the +12 Vdc power supply.

10156 - Note : Normally the “OFF” position will be when the switch is in the down positi...

Type

Note

Normally the “OFF” position will be when the switch is in the down position; however, confirm the correct off position for the specific RPM where the procedure is performed.

Step 00

10154 - Turn RPM AC power input breaker switch to “OFF” position

Turn RPM AC power input breaker switch to “OFF” position

10153 - Note the different styles of AC breakers: 1. Black breaker/green so...

Note the different styles of AC breakers:

1. Black breaker/green socket style has a light (green circle) that will be lit when power is present

2. White breaker/socket style has a bar below the switch that is green when the breaker is OFF and red when the breaker is ON.

10158 - 10152 - Confirm AC LED on LD-260 is no longer lit once AC breaker ha...; Remark:10151

Step 00

10152 - Confirm AC LED on LD-260 is no longer lit once AC breaker ha...

Confirm AC LED on LD-260 is no longer lit once AC breaker has been switched off

10151 - confirming LD-260 power is off

Step 3

Main Step

10150 - 10149 - Uninstall Faulty +12V Battery; Remark:

Step 00

10149 - Uninstall Faulty +12V Battery

Uninstall Faulty +12V Battery

10142 - 10141 - Disconnect battery at Molex plug; Remark:10140

Step 00

10141 - Disconnect battery at Molex plug

Disconnect battery at Molex plug

10140 - Unplug the 2-conductor Molex by opening latch and separate ends by pulling ap...

Unplug the 2-conductor Molex by opening latch and separate ends by pulling apart. Avoid pulling on the wire to separate the Molex connector.

10143 - 10139 - Lift battery out of RPM cabinet; Remark:10137

Step 00

10139 - Lift battery out of RPM cabinet

Lift battery out of RPM cabinet

10137 - The battery posts may be covered with a protective, non-conductive blanket to...

The battery posts may be covered with a protective, non-conductive blanket to prevent accidental contact with conductive surfaces and objects to prevent arcing. If so, retain this cover for installation on the new battery.

10144 - 10136 - Disconnect wiring harness from failed battery; Remark:10135

Step 00

10136 - Disconnect wiring harness from failed battery

Disconnect wiring harness from failed battery

10135 - Remove the wiring harness from the failed battery in preparation for installa...

Remove the wiring harness from the failed battery in preparation for installation on the new battery.

10145 - 10134 - Attach wiring harness to new battery; Remark:10132

Step 00

10134 - Attach wiring harness to new battery

Attach wiring harness to new battery

10132 - Install the wiring harness on the new battery.

Install the wiring harness on the new battery.

10133 - If the non-conductive blanket was present on the old battery install it on th...

If the non-conductive blanket was present on the old battery install it on the new battery.

10146 - 10131 - Place new battery into position in RPM cabinet; Remark:

Step 00

10131 - Place new battery into position in RPM cabinet

Place new battery into position in RPM cabinet

10147 - 10130 - Reinstall protective cover; Remark:

Step 00

10130 - Reinstall protective cover

Reinstall protective cover

10148 - 10129 - Reconnect battery; Remark:10128

Step 00

10129 - Reconnect battery

Reconnect battery

10128 - Reconnect the two halves of the Molex connector; slide the two halves togethe...

Reconnect the two halves of the Molex connector; slide the two halves together until they lock in place.

3397 - 3395 - Label faulty component; Remark:3396

Step 00

3395 - Label faulty component

Label faulty component

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.

Step 4

Main Step