Siemens Robicon BH Fan Perfect Harmony VFD_GenIII(630V Cell ) with NXGI Old Controller, DCR Compitibility A5E33065979 New & A1A461R57.00 Old
Siemens Robicon BH Fan Perfect Harmony VFD_GenIII(630V Cell ) with NXGI Old Controller, DCR Compitibility A5E33065979 New & A1A461R57.00 Old
Siemens Robicon BH Fan Perfect Harmony VFD_GenIII(630V Cell ) with NXGI Old Controller, DCR Compitibility A5E33065979 New & A1A461R57.00 Old
Siemens Robicon DCR Box PN: A1A461R57.00
Includes Boards:
Robicon A1A461D85.00M
Siemens A1A10000350.00M
ASI Robicon A1A363818.00M
Siemens A1A10000423.00M
Siemens: A1A10000283.01M
Secure your Perfect Harmony MV Drive
Investment with the latest technology
NXGpro Digital Control System Upgrade
Industry Services
NXGpro is the latest generation of control for
SINAMICS PERFECT HARMONY GH180
medium voltage drives. NXGpro is easily
retrofitted into existing NXGI and NXGII
drives while utilizing the same software and
software tools.
NXGI/NXGII hardware and software are currently
controlling over 10,000 SINAMICS PERFECT
HARMONY GH180 medium voltage variable
frequency drives with an excellent history of
reliability. The NXGI control was introduced in
2001 and followed by the NXGII control in 2005.
NXGpro is the latest evolution in control systems
and is smaller, more powerful, reliable, and
efficient than previous generations.
NXGpro software has the same basic
functionality as NXGII but with an additional
Tamper Resistant Input Protection feature. The
purpose of this new feature is to ensure
protection of the drive by verifying that the
upstream input circuit breaker is functioning
properly. NXGpro also uses the same compiler
and operating system as NXGII, so maintenance
tools such as ToolSuite remain virtually
unchanged.
Existing drives with NXGI or older control
systems may contain parts which are no longer
available and could result in extended downtime
in the event of a failure. Retrofitting your
SINAMICS PERFECT HARMONY medium voltage
variable frequency drive with the NXGpro
control provides you with maximum reliability,
simplifies maintenance, and increases
performance. To learn more about the NXGpro
control or to discuss an upgrade program to
transition your fleet, please contact your local
Siemens representative.
The NXGpro Digital Control is standard in new drives and is also designed to
quickly and economically upgrade your existing control
This state-of-the-art upgrade
package has been developed for
your Perfect Harmony Drive to
improve its control performance
and reliability while minimizing
the issues with obsolescence.
Description NXGpro Improvements Benefits
Input Protection • Enhanced Control Feature with Tamper Resistant Input
Protection function
• Better input protection scheme through the addition of
Tamper Resistant Input Protection function. This feature
tests the timing of the opening of the contactor in the
input circuit breaker to ensure that the breaker functions
properly
Serviceability
and Maintenance
• Test board available for fast and easy test access
• Smaller footprint for easier service
• Moved flash disk for access without disassembly
• Designed to update software and firmware without special tools
• Shorter downtime for testing, troubleshooting, and
maintenance service due to improved accessibility and
the ability to quickly swap the complete unit if needed
Reliability • Reduced number of circuit boards by as much as 50%
• Reduced the number of inter board connections by as much as 80%
• Reduced active DCR electronic components and bulk capacitors by 40%
• Reduced DCR external electrical connections by 50%
• Eliminated ISA bus card edge connections that can become misaligned
• Eliminated use of ribbon cables within the control rack
• Eliminated the need for control rack cooling fans
• Built in support for redundant power supplies
• Improved reliability by eliminating and reducing
components, reducing possibilities for connection
failures, and simplifying the overall complexity of the
control system
Communications • NXGpro supports NXGI/NXGII standard Communication protocols
• Also supports EtherNet/IP™ communication protocol
• If other Communication methods are needed, please contact the
factory
• Easy transition since NXGpro is compatible with NXGI
and NXGII standard communication protocols
• Increased communication capability with the addition
of EtherNet/IP™ on NXGpro
Evolution of the NXG Control System
NXGI Control NXGII Control NXGpro Control
Benefits when Upgrading from NXGI/NXGII to NXGpro
www.usa.siemens.com/services
EtherNet/IP™ is a registered trademark of ODVA, Inc.
This brochure contains only general descriptions or performance
features, which do not always apply in the manner described
in concrete application situations or may change as the products
undergo further development. Performance features are valid only
if they are formally agreed upon when the contract is closed.
Siemens is a registered trademark of Siemens AG. Product names
mentioned may be trademarks or registered trademarks of
their respective companies. Specifications are subject to change
without notice.
Siemens Industry, Inc.
3333 Old Milton Parkway
Alpharetta, GA 30005
1-800-333-7421
Order No. CSSS-NXGP-1015
© 2015 Siemens Industry, Inc.
www.usa.siemens.com/services
Let us help you plan your migration. Our on-site service is never more than a phone call away and we’re available 24/7.
Call 1-800-333-7421 to find a local service representative near you.
The NXGpro Digital Control unit improves performance, simplifies maintenance, and enhances reliability by:
• Adding a control feature to better protect the drive
• Changing the physical design to allow faster and easier service
• Simplifying complexity of assembly and number of components
• Increasing microprocessor capability to enable future software enhancements
Unrestricted lda-portal.siemens.com/services
Common questions and answers related to the new
SINAMICS Perfect Harmony GH180 NXGPro+
digital control system
1. Q: Can all drives be upgraded to the NXGPro+ control platform?
A: Yes, all drives can be upgraded (including those with legacy controls) with the exception of frame 325 HA (High Availability).
Please note NXGPro+ software is only available for air-cooled drives starting 2021, and water-cooled drives starting 2022.
2. Q: If I upgrade to the NXGPro+, what would the impact be for my existing drive?
A: The NXGPro+ is designed to facilitate upgrades without changing the functionality of the drive. It enforces the use of an upstream trip
able device, which must be connected so that the drive may disconnect the main power. This is done by testing the input medium voltage
interruption time. This test must pass before the drive can operate. The customer must be able to guarantee that their trip able device can
open the contactors within 100 ms. This feature enhances protection for the drive. Contact the factory in the event the customer cannot
guarantee the functionality of the proper input trip able device.
3. Q: What are the primary differences between the NXGpro and the NXGPro+ controls?
A: The NXGPro+ is an evolutionary change to the control for the purpose of improved maintainability, reliability, and security. It uses the
same tools and algorithms as NXGpro and does not alter the drive functionality. Most functionality is combined into a main circuit board
eliminating many connectors and cables within the controller. The obsolete operating system had to be changed to a Linux and FreeRTOS
based platform. The data storage and program are now internal with no external compact flash. The original combined power supply is
now three separate power supplies in an effort to reduce cost and risk of failure. Communications cards are now mounted
externally avoiding the need to expose internal components. Improved security by encryption of customer drive data.
4. Q: How much time will it take to upgrade the current control to the NXGPro+?
A: Installation downtime varies by control version, drive configuration, and site peculiarities. A Siemens Sales representative will work with
your plant personnel to determine the actual requirements for your specific application.
5. Q: Is the NXGPro+ software compatible with all drives?
A: No, the software is only compatible with drives with NXGPro+ control (new or upgraded product) with the exception of frame 325 HA
(High Availability).
6. Q: How does the NXGPro+ control upgrade affect the drive logic parameters?
A: For NXGpro drives only the existing System Operating Program (SOP) can be reused for all other previous control platforms SOP will
need to be rewritten. Parameter configuration functionality will remain largely unchanged with the exception of few additional parameters
no related to configuration but related to customer drive data security. Configuration checks are performed as part of the upgrade service.
NXGPro+ Control System FAQ
Unrestricted lda-portal.siemens.com/services
7. Q: Will the reporting I receive from the Fieldbus/DCS system remain the same with the new NXGPro+
Control System?
A: The logic and setup of Fieldbus network interfacing for the NXGPro+ remains the same as NXGII and NXGpro.
8. Q: Does the HMI have to be upgraded during an NXGPro+ upgrade or is that part of the new NXGPro+
control?
A: No, it is not necessary to upgrade the HMI hardware. However, the software will require an update to the latest NXGPro+ compatible
versions. The customer interface remains unchanged.
9. Q: Will my staff require additional training to use the NXGPro+?
A: Drive operation and drive interface remain unchanged, except for newly added parameters and diagnostic messages. These parameters
and message additions are described within the NXGPro+ Control Manual and Drive Operating Instructions. Training classes are available
upon request.
10. Q: When did Siemens begin installing the NXGPro+ digital control on production units?
A: In New Kensington, PA location, the NXGpro digital control unit has been installed on production units since November 2020. The
transition to NXGPro+ will occur globally via a staging process by manufacturing location and product variation.
11. Q: Why does the NXGPro+ not support the SINAMICS Perfect Harmony GH180 frame 325 HA (High
Availability)?
A: The SINAMICS Perfect Harmony GH180 frame 325 HA is system approach to facilitate the utmost availability. Although NXGPro+ does
provide enhanced reliability via hardware changes and reduced components, Siemens is studying control options for frame 325 HA to
ensure maximum availability and redundancy. At this time, the frame 325 HA will continue to be provided with the NXGII control. New
diagnostic messages enforce the use of an upstream trip able device, which must be connected so that the drive may disconnect the main
power.
12. Q: How long will Siemens offer spare parts support for the NXGpro control?
A: Siemens generally plans support for a minimum of 10 years after obsolescence of a product. This timeframe could be affected by
availability of components. Customers are always advised to have spares parts available onsite. For spare parts availability please
contact your Siemens sales representative.
Legal Manufacturer
Siemens Industry, Inc.
100 Technology Drive
Alpharetta, GA 30005
United States of America
lda-portal.siemens.com/contact
Order No: CSFAQ-00100-0921
All rights reserved
©2021, 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.
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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