RPM Nano Controller Replacement | FRONTLINE Maintenance Tool

Last Updated: 06/19/2025 1:46 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
8890 - 7292 - Uninstall Faulty Nano Controller; Remark:	Procedure Step	Published	09/25/2023 7:30 PM
7292 - Uninstall Faulty Nano Controller	Instruction	Published	05/01/2023 8:18 AM
8370 - 8369 - Disconnect RJ-45 Ethernet cable; Remark:8368	Procedure Step	Published	09/25/2023 7:21 PM
8369 - Disconnect RJ-45 Ethernet cable	Instruction	Published	09/12/2023 10:46 AM
8368 -	Remark	Published	09/12/2023 10:46 AM
8377 - 8376 - Disconnect occupancy sensor wires; Remark:8375	Procedure Step	Published	09/25/2023 7:23 PM
8376 - Disconnect occupancy sensor wires	Instruction	Published	09/12/2023 10:57 AM
8375 - Use small slotted screwdriver. Remove wires from I1 terminal...	Remark	Published	09/12/2023 11:01 AM
8378 - 8374 - Disconnect power wires; Remark:8373	Procedure Step	Published	09/25/2023 7:24 PM
8374 - Disconnect power wires	Instruction	Published	09/12/2023 11:01 AM
8373 - These wires go to Terminal Block 1 (TB1). Use small slotted screwdriver	Remark	Published	09/12/2023 11:03 AM
8379 - 8372 - Disconnect occupancy output wire; Remark:8371	Procedure Step	Published	09/25/2023 7:26 PM
8372 - Disconnect occupancy output wire	Instruction	Published	09/12/2023 11:03 AM
8371 - Use small slotted screwdriver. Remove green wire from Q1 ter...	Remark	Published	09/12/2023 11:04 AM
8891 - 7297 - Remove faulty Nano Controller; Remark:8380	Procedure Step	Published	09/25/2023 7:31 PM
8382 - Note : Nano Controller installation may differ from configuration shown in this proc...	Annotation	Published	09/12/2023 11:16 AM
7297 - Remove faulty Nano Controller	Instruction	Published	05/01/2023 8:21 AM
8380 - Use slotted screwdriver to pull down tab and rotate Nano Controller up. Use m...	Remark	Published	09/12/2023 11:15 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
8894 - 7298 - Install New Nano Controller; Remark:	Procedure Step	Published	09/25/2023 8:01 PM
7298 - Install New Nano Controller	Instruction	Published	05/01/2023 8:24 AM
8895 - 7299 - Mount new Nano Controller; Remark:8892	Procedure Step	Published	09/25/2023 8:02 PM
7299 - Mount new Nano Controller	Instruction	Published	05/01/2023 8:24 AM
8892 - Hook nano controller to top of mounting rail and rotate down. Nano controller...	Remark	Published	09/25/2023 7:37 PM
8896 - 7300 - Reconnect occupancy output wire; Remark:7338	Procedure Step	Published	09/25/2023 9:37 PM
7263 - Caution : Correct placement of connectors and wiring is critical to proper operation.	Annotation	Published	04/24/2023 2:32 PM
7300 - Reconnect occupancy output wire	Instruction	Published	05/01/2023 8:26 AM
7338 - Insert green wire in Q1 terminal. Use a small slotted screwdriver.	Remark	Published	05/03/2023 10:48 AM
8897 - 7301 - Reconnect power wires; Remark:7339	Procedure Step	Published	09/25/2023 8:04 PM
7301 - Reconnect power wires	Instruction	Published	05/01/2023 8:26 AM
7339 - Use a small slotted screwdriver to reconnect existing power wires on terminal...	Remark	Published	09/25/2023 7:48 PM
8898 - 7302 - Reconnect occupancy sensor wires; Remark:7340	Procedure Step	Published	09/25/2023 8:05 PM
7302 - Reconnect occupancy sensor wires	Instruction	Published	05/01/2023 8:27 AM
7340 - Connect black wire from black infrared occupancy sensor to I1	Remark	Published	09/25/2023 7:53 PM
8899 - 7303 - Reconnect RJ-45 Ethernet cable; Remark:8893	Procedure Step	Published	09/25/2023 8:06 PM
7303 - Reconnect RJ-45 Ethernet cable	Instruction	Published	05/01/2023 8:28 AM
8893 - Nano Controller RJ45 Connection	Remark	Published	09/25/2023 7:57 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
8433 - 8432 - Close all RPM doors; Remark:	Procedure Step	Published	09/14/2023 9:14 AM
8432 - Close all RPM doors	Instruction	Published	09/14/2023 9:14 AM
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
8434 - 8431 - Generate speed message; Remark:8430	Procedure Step	Published	09/14/2023 9:15 AM
8431 - Generate speed message	Instruction	Published	09/14/2023 9:14 AM
8430 - Stand to side of control pillar. Open door with infrared sensors.	Remark	Published	09/14/2023 9:15 AM
8606 - 7308 - Verify Nano Controller response; Remark:8599	Procedure Step	Published	09/18/2023 12:49 PM
7308 - Verify Nano Controller response	Instruction	Published	05/01/2023 8:35 AM
8599 - Nano Controller LEDs will illuminate (IN1, IN2	Remark	Published	09/18/2023 12:36 PM
8437 - 8425 - Verify speed message in CAS; Remark:8424	Procedure Step	Published	09/14/2023 9:37 AM
8425 - Verify speed message in CAS	Instruction	Published	09/14/2023 9:36 AM
8424 - Contact CAS operator to verify “SP” appears in RAVEN [Radiation Alarm and...	Remark	Published	09/14/2023 9:37 AM
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
Upon failure of Nano Controller	Frequency	Published	09/25/2023 8:49 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 2	Skill Level	Published	04/09/2020 1:17 AM
Keys to access RPM	Replacement Parts	Published	04/27/2023 6:56 PM
Magnets and adhesive tape to disable door tamper switches	Replacement Parts	Published	06/02/2023 10:08 PM
Medium Phillips (PH2) screwdriver	Tools	Published	04/24/2020 4:40 PM
Small slotted (flathead) screwdriver	Tools	Published	09/11/2020 11:23 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
Gloves	Replacement Parts	Published	05/10/2023 3:28 PM
Protective headwear: glasses, hard hat	Replacement Parts	Published	05/10/2023 3:31 PM
Orange traffic cones	Replacement Parts	Published	04/27/2023 6:56 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
nanocontroller - Disconnect RJ-45 Ethernet cable	Image	Published	09/12/2023 10:40 AM
Disconnect occupancy sensor wires	Image	Published	09/12/2023 10:50 AM
Disconnect power wires	Image	Published	09/12/2023 10:52 AM
Disconnect occupancy output wire	Image	Published	09/12/2023 10:55 AM
Remove Nano Controller	Image	Published	09/12/2023 11:07 AM
Remove Nano Controller 2	Image	Published	09/12/2023 11:08 AM
Install Nano Controller	Image	Published	09/25/2023 7:36 PM
Nano Controller Output Wire	Image	Published	09/25/2023 9:33 PM
Power to Nano Controller	Image	Published	09/25/2023 7:47 PM
Connect Occupancy Sensor Wires	Image	Published	06/04/2025 1:29 PM
Connect RJ45 in Nano Controller	Image	Published	09/25/2023 7:56 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
Open door with infrared sensors	Image	Published	09/14/2023 9:01 AM
PLC Response	Image	Published	09/18/2023 12:35 PM

DET-RPM-RAP-CM11

Replace the VersaMax Nano Controller on the radiation portal monitor (RPM).

Equipment Hierarchy

Rapiscan VM-250 Vehicle Monitor

Rapiscan TM-850 Rail Monitor

Frequency

Upon failure of Nano Controller

Technician Level

Technician 2

x 1

Duration

Notes

Minutes

Length of time

Tools Required

Keys to access RPM

Magnets and adhesive tape to disable door tamper switches

Medium Phillips (PH2) screwdriver

Small slotted (flathead) screwdriver

Orange/yellow safety vest

Safety shoes

Gloves

Protective headwear: glasses, hard hat

Orange traffic cones

Materials Required

GE VersaMax Nano Controller, Model #IC200NDR010 (Rapiscan Part #6661N)

Originators

Brian Tucker

Yavor Andreev

Vasil Vasilev

Originating Organization

PNNL; Theta Consult

Approver

Cody Hostick

Safety Concerns

Traffic

Electrical

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

2021-07-01

Version

0.00

Preparation

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.

Operation

Step 2

Main Step

8890 - 7292 - Uninstall Faulty Nano Controller; Remark:

Step 00

7292 - Uninstall Faulty Nano Controller

Uninstall Faulty Nano Controller

8370 - 8369 - Disconnect RJ-45 Ethernet cable; Remark:8368

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

8369 - Disconnect RJ-45 Ethernet cable

Disconnect RJ-45 Ethernet cable

8377 - 8376 - Disconnect occupancy sensor wires; Remark:8375

Step 00

8376 - Disconnect occupancy sensor wires

Disconnect occupancy sensor wires

8375 - Use small slotted screwdriver. Remove wires from I1 terminal...

Use small slotted screwdriver. Remove wires from I1 terminal and I2 terminal.

8378 - 8374 - Disconnect power wires; Remark:8373

Step 00

8373 - These wires go to Terminal Block 1 (TB1). Use small slotted screwdriver

These wires go to Terminal Block 1 (TB1). Use small slotted screwdriver

8379 - 8372 - Disconnect occupancy output wire; Remark:8371

Step 00

8372 - Disconnect occupancy output wire

Disconnect occupancy output wire

8371 - Use small slotted screwdriver. Remove green wire from Q1 ter...

Use small slotted screwdriver. Remove green wire from Q1 terminal.

8891 - 7297 - Remove faulty Nano Controller; Remark:8380

8382 - Note : Nano Controller installation may differ from configuration shown in this proc...

Type

Note

Nano Controller installation may differ from configuration shown in this procedure.

Step 00

7297 - Remove faulty Nano Controller

Remove faulty Nano Controller

8380 - Use slotted screwdriver to pull down tab and rotate Nano Controller up. Use m...

Use slotted screwdriver to pull down tab and rotate Nano Controller up. Use medium Phillips (PH2) screwdriver if Nano Controller is mounted with screws.

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.

Operation

Step 3

Main Step

8894 - 7298 - Install New Nano Controller; Remark:

Step 00

7298 - Install New Nano Controller

Install New Nano Controller

8895 - 7299 - Mount new Nano Controller; Remark:8892

Step 00

7299 - Mount new Nano Controller

Mount new Nano Controller

8892 - Hook nano controller to top of mounting rail and rotate down. Nano controller...

Hook nano controller to top of mounting rail and rotate down. Nano controller will snap into place.

8896 - 7300 - Reconnect occupancy output wire; Remark:7338

7263 - Caution : Correct placement of connectors and wiring is critical to proper operation.

Type

Caution

Correct placement of connectors and wiring is critical to proper operation.

Step 00

7300 - Reconnect occupancy output wire

Reconnect occupancy output wire

7338 - Insert green wire in Q1 terminal. Use a small slotted screwdriver.

Insert green wire in Q1 terminal. Use a small slotted screwdriver.

8897 - 7301 - Reconnect power wires; Remark:7339

7263 - Caution : Correct placement of connectors and wiring is critical to proper operation.

Type

Caution

Correct placement of connectors and wiring is critical to proper operation.

Step 00

7301 - Reconnect power wires

Reconnect power wires

7339 - Use a small slotted screwdriver to reconnect existing power wires on terminal...

Use a small slotted screwdriver to reconnect existing power wires on terminal block TB1 to Nano Controller:

Red wire - (+)

Black wire - (-)

8898 - 7302 - Reconnect occupancy sensor wires; Remark:7340

7263 - Caution : Correct placement of connectors and wiring is critical to proper operation.

Type

Caution

Correct placement of connectors and wiring is critical to proper operation.

Step 00

7302 - Reconnect occupancy sensor wires

Reconnect occupancy sensor wires

7340 - Connect black wire from black infrared occupancy sensor to I1

Connect black wire from black infrared occupancy sensor to I1 terminal. Connect black wire from yellow infrared occupancy sensor to I2 terminal. Use a small slotted screwdriver.