RPM Banner IR Occupancy Sensor Replacement | FRONTLINE Maintenance Tool

Last Updated: 06/18/2025 1:43 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	06/05/2025 11:26 AM
Rapiscan TM-850 Rail Monitor	Device	Published	06/05/2025 11:31 AM
7264 - 1401 - Establish Initial Conditions; Remark:	Procedure Step	Published	04/27/2023 7:00 PM
1401 - Establish Initial Conditions	Instruction	Published	09/30/2022 3:14 PM
7622 - 7592 - Inform system operators; Remark:11335	Procedure Step	Published	04/20/2025 10:15 AM
7592 - Inform system operators	Instruction	Published	06/29/2023 3:20 PM
11335 - Upon arrival, brief system operators on expected work, duration, anticipated ...	Remark	Published	04/20/2025 10:14 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
7755 - 7679 - Disconnect Ethernet; Remark:11336	Procedure Step	Published	04/20/2025 11:18 AM
7680 - Caution : Make sure to press release button on back of Ethernet cable before removing.	Annotation	Published	07/01/2023 11:54 PM
7679 - Disconnect Ethernet	Instruction	Published	05/16/2025 8:03 PM
11336 - Locate Ethernet connector on top of SC-770 controller. Press release button o...	Remark	Published	04/20/2025 11:21 AM
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
7454 - 7290 - Disable tamper switches; Remark:7416	Procedure Step	Published	06/02/2023 5:25 PM
7290 - Disable tamper switches	Instruction	Published	05/01/2023 8:14 AM
7416 - Use a magnet to disable tamper switches for all open doors. Use adhesive tape...	Remark	Published	06/02/2023 1:18 PM
8561 - 7291 - Disable both infrared occupancy sensors; Remark:8514	Procedure Step	Published	09/18/2023 12:05 AM
5291 - Note : It is good practice to verify all cables and connectors are labeled prior to ...	Annotation	Published	10/24/2022 8:35 AM
7291 - Disable both infrared occupancy sensors	Instruction	Published	05/01/2023 8:15 AM
8514 - Verify sensors mounted in control pillar door are receivers.	Remark	Published	09/29/2023 11:52 AM
9205 - To disconnect sensor cable, turn collar counterclockwise and pull away from s...	Remark	Published	09/29/2023 11:52 AM
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
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
8587 - 7305 - Enable both infrared occupancy sensors; Remark:8559	Procedure Step	Published	09/17/2023 11:03 PM
5553 - Caution : Correct placement of connectors and wiring is critical to proper operation.	Annotation	Published	10/28/2022 2:19 PM
7305 - Enable both infrared occupancy sensors	Instruction	Published	05/01/2023 8:33 AM
8559 - To reconnect sensor cable, align connectors, push towards sensor, and turn co...	Remark	Published	09/29/2023 12:05 PM
7474 - 7310 - Enable tamper switches; Remark:7451	Procedure Step	Published	06/02/2023 5:41 PM
7310 - Enable tamper switches	Instruction	Published	05/01/2023 8:36 AM
7451 - Remove magnets and/or adhesive tape from door tamper switches.	Remark	Published	04/13/2025 5:46 PM
7781 - 7730 - Reconnect Ethernet; Remark:7731	Procedure Step	Published	04/20/2025 11:00 AM
7730 - Reconnect Ethernet	Instruction	Published	07/02/2023 2:34 AM
7731 - Insert Ethernet connector at top of SC-770 module. Connector will audibly "cl...	Remark	Published	07/02/2023 2:36 AM
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
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
9385 - 319 - Perform operational test; Remark:9347	Procedure Step	Published	06/16/2025 5:15 PM
319 - Perform operational test	Instruction	Published	06/10/2021 8:31 PM
9347 - DET-RPM-RAP-RM03 RPM Operational Test.	Remark	Published	10/03/2023 12:11 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
8260 - 8250 - Reopen Lane; Remark:8249	Procedure Step	Published	09/07/2023 3:09 PM
8250 - Reopen Lane	Instruction	Published	09/07/2023 3:09 PM
8249 - Remove orange safety (traffic control) cones	Remark	Published	09/07/2023 3:09 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
Caution	Annotation Type	Published	03/02/2020 3:24 PM
Note	Annotation Type	Published	03/02/2020 3:25 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
Disconnect Ethernet cable on top of SC-770 box	Image	Published	10/04/2023 2:59 PM
LD-260 Disconnect Switch Power Off	Image	Published	04/24/2023 12:49 PM
Disable tamper switch	Image	Published	09/07/2023 8:22 PM
Disable Tamper Switch	Image	Published	06/02/2023 2:28 PM
Infrared Receiver	Image	Published	09/17/2023 7:09 PM
Infrared Receiver DC	Image	Published	09/29/2023 11:47 AM
Infrared Disconnect Sensor Cable	Image	Published	09/17/2023 7:11 PM
Infrared Sensor Disconnect	Image	Published	09/17/2023 7:12 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
LD-260 Disconnect Switch Power On	Image	Published	06/04/2025 1:28 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
Remove Magnet from Tamper.PNG	Image	Published	09/28/2023 9:37 AM
Remove Magnet on Tamper Switch	Image	Published	06/02/2023 4:31 PM
SC-770 Occupied	Image	Published	09/19/2023 4:30 PM

DET-RPM-RAP-CM13

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

Příprava

Step 1

Main Step

7264 - 1401 - Establish Initial Conditions; Remark:

Step 00

1401 - Establish Initial Conditions

Establish Initial Conditions

7622 - 7592 - Inform system operators; Remark:11335

Step 00

7592 - Inform system operators

Inform system operators

11335 - Upon arrival, brief system operators on expected work, duration, anticipated ...

Upon arrival, brief system operators on expected work, duration, anticipated alarms, and fault indications before starting work.

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.

7755 - 7679 - Disconnect Ethernet; Remark:11336

7680 - Caution : Make sure to press release button on back of Ethernet cable before removing.

Type

Caution

Make sure to press release button on back of Ethernet cable before removing.

Step 00

11336 - Locate Ethernet connector on top of SC-770 controller. Press release button o...

Locate Ethernet connector on top of SC-770 controller. Press release button on back of connector. Pull connector.

Disconnect Ethernet cable on top of SC-770 box

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.

7454 - 7290 - Disable tamper switches; Remark:7416

Step 00

7290 - Disable tamper switches

Disable tamper switches

7416 - Use a magnet to disable tamper switches for all open doors. Use adhesive tape...

Use a magnet to disable tamper switches for all open doors. Use adhesive tape to disable older mechanical switches.

8561 - 7291 - Disable both infrared occupancy sensors; Remark:8514

5291 - Note : It is good practice to verify all cables and connectors are labeled prior to ...

Type

Note

It is good practice to verify all cables and connectors are labeled prior to disconnection.

Step 00

7291 - Disable both infrared occupancy sensors

Disable both infrared occupancy sensors

8514 - Verify sensors mounted in control pillar door are receivers.

Verify sensors mounted in control pillar door are receivers.

9205 - To disconnect sensor cable, turn collar counterclockwise and pull away from s...

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

Provoz

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 - Označte vadnou součástku; Remark:3396

Step 00

3395 - Označte vadnou součástku

Označte vadnou součástku

3396 - Použijte štítek nebo pásku. Uveďte datum odstranění, popis známek vady, zemi, mí...

Použijte štítek nebo pásku. Uveďte datum odstranění, popis známek vady, zemi, místo a číslo pruhu. Zlikvidujte v souladu s pokyny organizace NSDD (Nuclear Smuggling Detection and Deterrence) nebo smluvními požadavky.

Provoz

Step 3

Main Step