SIEMENS NXGPRO PLUS, NXGPRO PLUS DCR 18 CELL NO STO PROGRAM P/N : A5E45508682002
SIEMENS NXGPRO PLUS, NXGPRO PLUS DCR 18 CELL NO STO PROGRAM P/N : A5E45508682002
SIEMENS NXGPRO PLUS, NXGPRO PLUS DCR 15 CELL NO STO PROGRAM P/N : A5E45508681002
SIEMENS NXGPRO PLUS, NXGPRO PLUS DCR 18 CELL NO STO PROGRAM P/N : A5E45508682002
SIEMENS NXGPRO PLUS, NXGPRO PLUS DCR 21 CELL NO STO PROGRAM P/N : A5E45508683002 / A5E45508683001
SIEMENS NXGPRO PLUS, NXGPRO PLUS DCR 24 CELL NO STO PROGRAM P/N : A5E45508684002
WHITE PAPER
NXGPro+ controller
SINAMICS Perfect Harmony GH180
usa.siemens.com/perfectharmony
Executive summary
Since its introduction in 1994, the SINAMICS Perfect Harmony drive has revolutionized power
conversion and continues to set industry standards for reliability and innovation. Advances
in control technology are now being applied to improve reliability, security and processing
performance.
Control evolution – NXG to NXGpro
The NXG control for SINAMICS Perfect Harmony was introduced in 2001. Since then, the NXG hardware
and software have been the basis for SINAMICS Perfect Harmony control. The NXG control is now
operating in more than 22,000 installations with an excellent record for reliability.
In 2005, the NXG control was upgraded with new hardware to reduce the number of circuit boards and
improve the reliability of the control. In addition, the control footprint was reduced to fit into smaller
drives. The result has been known as NXG II. Since that time, the hardware has remained constant
while the software has continually been upgraded.
Figure 1: NXG Control Rack (DCR)
Figure 2: NXG II Control Rack (DCR)
In 2015, Siemens upgraded the NXG II’s hardware to improve the
reliability and ease of maintenance, while keeping the same software
base. The result was NXGPro. This controller reduced the number of
circuit boards, circuit board connections and component count. The
upgraded control was more reliable and easier to maintain than NXG II.
As part of the NXGPro system, the inputs and outputs (I/O) were
transformed using the User I/O Board instead of WAGO and or NXG II’s
System I/O Breakout Board.
NXGPro+
Siemens strives to continuously improve its products to
provide the best value to our customers. Therefore, the
NXGPro+ was developed as another evolutionary step
which increases reliability, maintainability, processing
capability and security.
Underlying the concept for NXGPro+ is the question…
How does Siemens provide a control platform which
will support the Industry 4.0 software evolution with
the most value and minimum impact to existing
customers?
Reliability
For NXGPro+, Siemens made enhancements designed
to increase reliability.
With control systems having such a significant impact
on Mean Time Between Failure (MTBF), improvements
to increase control reliability are a top priority.
First, the number of internal connections were reduced.
This was accomplished by reducing the circuit board
count. Eliminating the single board computer (SBC)
resulted in hundreds of fewer connection points.
Figure 3: NXGPro Control Rack (DCR) Figure 4: NXGPro+ Control Rack (DCR)
2
SINAMICS Perfect Harmony GH180 | NXGPro+ controller
In NXGPro, the fieldbus communication adapters
were not a field replaceable item. A failure of a
fieldbus adapter required replacing the NXGPro
control and sending it in for repair. For NXGPro+,
the fieldbus adapters are field replaceable without
opening the case of the NXGPro+.
Overall drive maintainability and reliability of
systems have been improved by the inclusion
of a hardware based SIL 2 Safe Torque Off (STO)
circuitry. Combined with system level hardware,
this functionality allows the user to create a
system STO at SIL 2 without using circuit breakers.
Maintenance software improvements from the
NXGPro+ support more software systems. The
maintenance software now includes enhanced
troubleshooting aids.
Processing Capability
NXGPro used a SBC with a single core PC processor.
This setup had several drawbacks including:
1) Hundreds of connections
2) A PCI bus between the processor and the
logic devices
3) An ISA bus to the communication boards
With NXGPro+, a dual core ARM processor is
included with a single SOC device which allows
the processors direct access to the logic within
the same device. This SOC arrangement reduces
hardware latency.
The dual core processors allow for a logical
separation of tasks with one processor core
dedicated for drive control and the other for
support functions.
With NXGPro+, the PCI / ISA bus is replaced with
PCIe. This improves performance of communications
connections. The results are more efficient code
execution and reduced power consumption.
Connections were further reduced by changing
the communication interface bus between the
main processor and the communications circuit
board from a parallel bus to a modern Peripheral
Component Interconnect Express (PCIe) connection.
This change reduced 20+ connections.
For connections which were unavoidable, various
types of connections and driver combinations were
investigated to improve the connection between the
main board and fiber optic board. As a result, the
fiber optic board connection to the main board was
changed from single ended to differential signals
connected through high quality connectors versus
the NXGPro’s old style header connectors.
Second, the control’s reliability was enhanced by
reducing the integrated circuit (IC) count and
internal circuit board connections. A modern System
on a Chip (SOC) was selected to replace the previous
single board computer and the Field Programmable
Gate Array (FPGA) logic device. This eliminated
hundreds of circuit board connections, as well
as, reduced the chip count.
Third, power supply reliability and complexity were
addressed by eliminating the complex integrated
supply which provided many voltages using a single
24V industrial supply. This improved MTBF and
reduced possible failure modes.
Finally, power consumption was reduced. By
reducing power consumption, less heat is released
into the drive’s control section. Reducing heat is a
reliability goal as heat ages most components.
Additionally, a heat sink was eliminated. This
change reduces assembly complexity and low
frequency vibration response.
Maintainability
Maintainability was improved by reducing unique
spare parts, improving accessibility and by
enhancing maintenance software.
With NXGPro, up to four different varieties of the
power supply were needed depending upon the
drive and its environment. Now, standard Siemens
industrial power supplies are used making spare
parts less expensive and easier to get.
3
SINAMICS Perfect Harmony GH180 | NXGPro+ controller
NXGPro+ has fiber optic channels with four times
the bandwidth of the NXGPro. The additional
improvements in core system design allow for
increased utilization of the improved bandwidth.
This improved bandwidth supports new diagnostics
and maintenance features.
New fieldbus adapters are used which have more
processing capabilities and support more fieldbus
protocols.
Security
NXGPro used a software system designed in the year
2000. This was before software security was seen as
a crucial item. NXGPro+ has been designed with
software security as a major factor of design.
NXGPro+ stores its control code internally. This
allows for a continuous chain of trust from the
time of manufacture to the present.
All software / firmware is controlled to inhibit
any unauthorized modifications.
All settings and other files are all encrypted
and accepted only when the correct passwords
are provided.
Encrypted connections ensure authenticated
tool operation.
Summary
The latest NXGPro+ control offers many enhancements:
• Enhanced reliability
• Simplified spare parts
• More communications capability
• More diagnostics capability
• Support for Safe Torque Off (STO)
• Improved security
• Support for future diagnostic capabilities
Legal Manufacturer
Siemens Industry, Inc.
100 Technology Drive
Alpharetta, GA 30005
United States of America
Telephone: +1 (800) 333-7421
lda-portal.siemens.com
Order No: LAWP-04600-0833
© 2022, Siemens Industry, Inc.
In order to protect plants, systems, machines and networks against cyber threats, it is necessary
to implement – and continuously maintain – a holistic, state-of-the-art industrial security
concept. Siemens’ products and solutions constitute one element of such a concept. For more
information about industrial security, please visit https://www.siemens.com/industrialsecurity.
This document contains a general description of available technical options only, and its
effectiveness will be subject to specific variables including field conditions and project
parameters. Siemens does not make representations, warranties, or assurances as to the
accuracy or completeness of the content contained herein. Siemens reserves the right to modify
the technology and product specifications in its sole discretion without advance notice.
SINAMICS Perfect Harmony GH180 | NXGPro+ controller
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