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MTL Open System Technologies (MOST) is committed to
providing the industrial automation market with open hardware
and software technology-based system building blocks for use in
the most demanding real-time system applications.
Open System Components
For The Industrial Automation Market
Open systems are becoming increasingly components, OEMs are able to bring a finished
popular in the industrial automation market. system to market in much less time at a much
Open systems are built from commercially lower cost.
available off the shelf products that conform to
MTL Open System Technologies (MOST)
well-defined standard specifications. Products
provides open hardware and software products
that conform to these standards are easily
to the industrial automation market. Customers
connected to each other, allowing a system to
can choose a single product from the MOST
be quickly assembled. Systems built from open
offering to satisfy their application or they can
components provide different benefits to end
"snap" together several of the available system
users, systems integrators and OEMs.
building blocks to create a comprehensive
Open systems, unlike closed proprietary systems, solution. These open products range from
enable end users to choose a "best of breed" robust Process I/O that has been built to be
solution from competitive offerings at cost- mounted directly in the process plant next to
effective prices. Users are not tied to a single your process transmitters to high performance,
vendor, enabling them to add new products to rugged redundant process controllers to
their system as they emerge on the market. software products for logic, process and hybrid
They can be confident that they can control applications. MOST is actively working
incrementally update their system one product with system integrators and automation
at a time, assuring that it never becomes partners to help provide open control solutions.
obsolete. With its commitment to open control
technology, MOST is providing the "pieces" to
Open systems allow system integrators to
make open control solutions a reality.
choose from many vendors to solve their
problems, and to quickly implement systems MOST products have been widely used in the
from well-known open technology. They can process automation market, including: chemicals
readily recruit engineers that already know the and petrochemicals, oil and gas pipeline, power
open technology, enabling new employees to be generation, water and waste water, cement and
immediately productive with minimal training pulp and paper.
costs. And a vendor that provides open
components can be a great partner for a system
integrator, since he can be confident that the
component vendor will not compete with him
in the market.
OEMs can take advantage of the substantial
existing engineering investment in open
component products to create a world class
solution with much less development expense
than a home grown system. With open
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MOST
Hybrid Control Platform
MOST Hybrid Control is a comprehensive
process automation solution for regulatory and
sequential control applications. With its
concurrent support of both process and logic
control strategies, MOST Hybrid Control is an
ideal solution for process applications that also
require some sequential logic control in a
process environment.
MOST Hybrid Control can be optimized for your
process automation needs today, addressing
applications ranging from a few points to
thousands of points. Its modular design assures
easy upgrades and future expansion, protecting
your investment.
MOST Hybrid Control, built from several MOST
open control components, offers an integrated
project development environment that
coordinates all control project engineering to
design, implement, document, and maintain a
process control system. MOST Hybrid Control
projects can be readily integrated with popular
HMI software to create a true Hybrid Control
solution. MOST Hybrid Control consists of the
MOST Workbench Process Engineering Tools
and the MOST Control platform.
MOST Process Engineering Tools –
The MOST Hybrid Control Workbench provides • MOST Fault Tolerant Ethernet (FTE) –
Foundation Fieldbus (FF593) compliant
an integrated project development environment
software supports fully redundant Ethernet
that centralizes project engineering including I/O
plant networks
and control strategy configuration (process and
• System Management tools, such as the
discrete) and project documentation. The key
Network Configurator and an Import/Export
elements of the Workbench are:
Utility that builds an export table for
• MOST Process Control software - HMI databases
comprehensive self-documenting
• Instrument Maintenance – Process
regulatory control software for process
management tools to control, optimize and
control applications
maintain smart instruments (HART and
• MOST Logic Control software - IEC 61131-3 Foundation Fieldbus)
programming for discrete control applications
3
MOST
Remote I/O
MOST
Logic
MOST
Process
MOST Control Platform –
Designed for process applications, the MOST • MOST Logic Controller – supporting IEC
Control Platform features a rugged field 61131-3 control strategies
mountable controller and I/O system for any • MOST OEM Controller – includes software
process environment, including harsh and tools to port OEM software into controller
hazardous areas, and for virtually any process • MOST Remote I/O – Ethernet interface
signal, including HART and fieldbus. Several connects transparently to all controllers
Controller options are available, enabling you to
All of these capabilities are available in the
choose only the functionality that you need:
comprehensive MOST Hybrid Control Solution.
• MOST Hybrid Controller – supporting
concurrent execution of regulatory and IEC Open Control Components –
61131-3 sequential control strategies All of the MOST Hybrid Control capabilities are
• MOST Process Controller – supporting also available as individual open control
regulatory control strategies components that can be integrated into your
control solution, enabling you to choose the
pieces that best fit your needs.
4
MOST Workbench:
Comprehensive Project Management
The MOST Workbench incorporates all of the
tools to create, manage and maintain a process
control project. The Workbench is an integrated
project development environment that
coordinates project engineering activities,
including instrument index, I/O database
configuration, control strategy development
(process and discrete), and process visualization
(export table to build an HMI database). Its
client-server implementation allows multiple
engineers to work on the same project.
Designed using a Microsoft Windows Explorer Centralized Project Development Environment
paradigm, the Workbench’s powerful and
flexible framework significantly reduces project
implementation and maintenance costs.
Workbench capabilities such as drag-and-drop,
right mouse click support and context sensitive
help make developing, testing and maintaining
automation projects easy and straightforward.
Several workbenches are available for you to
choose from, enabling you to choose the
appropriate product for your automation needs:
• MOST Process Workbench, with its
comprehensive self-documenting
regulatory control software for process
control applications
• MOST Logic Workbench, with its
IEC 61131-3 programming for discrete
control applications, and
• MOST Hybrid Workbench, with both
regulatory control software and IEC 61131-3
software for those control applications
that require both process and logic
control software
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MOST Workbench:
Complete Project Engineering Tools
Comprehensive Engineering Tools Enter Project Design Specifications
Only Once
The Workbench provides extensive
management tools for your control project. The Workbench models a process system with
In addition to configuring the control logic, the assignment of module and I/O points. All
the Workbench also: variables are referred to by tagname, simplifying
system configuration. Using a simple "fill in the
• Generates an export table for importing
directly into popular HMI databases, blanks" process, all points are entered into the
including Wonderware, Cimplicity, Citect system and the project I/O configuration
and Intellution database is built.
• Automatically assigns controller network
addresses, optimizes communications and
provides I/O module and individual channel
alarm status
• Configures efficient peer-to-peer capability,
allowing data to be shared between any
controllers on network
• Simulates control strategy before
downloading to the controller
• Incorporates system maintenance
capabilities while documenting the entire
control system from instrument index to
control strategy diagrams
• Provides system-wide security allowing
for multiple levels of access to the
control system
The Workbench eliminates the tedious and
sometimes error-prone manual engineering
work typically required during control projects,
including the manual generation of design
documents, bills of material and control strategy
diagrams. Repetitive programming of control
strategies is no longer necessary, significantly
reducing errors and system configuration time.
Comprehensive I/O Configuration Database
6
MOST
Workbench
Configure Your Control Project
In a Single Step
After your control strategy is developed, the
Workbench cross-links the project diagrams
with the instrument index (I/O database) to
create control programs, operator interface
export table, comprehensive project engineering
documentation and maintenance diagnostics.
Simulate Control Logic or View Real-time Data
There’s no need to review function block codes,
re-enter tags, generate spare parts listings, or
• Controller address, state & communication data
match control logic to operator interface
components. You can concentrate on designing • Controller execution times & control parameters
control strategies and eliminate the repetitive • Detailed controller event log
manual tasks.
• Module location & type
The Workbench simulation functions will test • I/O Channel configuration & troubleshooting data
your programs before startup. Control logic
diagrams are animated with either simulated
Instrument Maintenance
data or live, real-time process data. Verification
of control loop integrity and troubleshooting Well-maintained process instrumentation is
loop issues can be quickly completed, critical to optimizing plant performance. The
significantly accelerating system start-up and instrument maintenance module manages the
reducing downtime. Simulation also helps train key configuration, calibration and monitoring
your operators, assuring they are familiar with data as well as diagnostic history for HART and
the control system exactly as it has been Foundation Fieldbus devices.
designed to operate the plant process.
On-line Maintenance, Diagnostics
and Troubleshooting
Project savings are not limited to initial
development and start-up. Other Workbench
tools include tuning capabilities, on-line system
diagnostic tools, and real-time control diagrams
to help maintain your system.
Diagnostic capabilities include network
configuration, controller statistics and individual
module details. Operators are alerted of any
device or I/O channel failure, and have access to
technical diagnostic data for the actual failure
state and statistical data. This data can include:
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MOST
Process Control
Use Standard Drawing Forms Comprehensive Self-Documentation
and Commands
MOST Workbench automatically generates
The MOST Process Strategy Builder develops the as-built system documentation, I/O
process control logic diagrams, which builds the configuration reports, cross-reference analysis,
control specification scheme by selecting the bill of materials, instrument index, system
appropriate blocks, assigning symbolic tags, and startup, testing and maintenance information,
then connecting the blocks with analog or and control strategy diagrams. The instrument
digital lines – all using standard drawing forms index provides instrument details such as
and commands. Control strategy drawings manufacturer, model number, group number,
define all the functions and parameters that shift and day log, panel wiring information
form the process loop. including panel in/out terminal block and panel
in/out position, and field wiring information
Function block choices include manual/auto
including cable color, size and type.
station interface, function generators, pulse
controllers, sequencers, bumpless transfers, PID As the system documentation is generated
and other standard function blocks. The automatically, from the initial engineering
algorithms provide the logic and analytic phases through subsequent system
functions for complex control strategies such as modifications, the Workbench maintains the
feed forward, cascade, and adaptive control. project documentation in the as-built state. In
Functions are provided for easily configuring other words, project documentation from
biased multi-output loops as found in steam configuration database to control strategies is
and water header pressure controls. continually kept current to the operating
control system.
Further reducing development time, template
diagrams can be created and reused within the
current project or future projects. As an
example, a sample cascade loop can be created
and saved for repetitive use to generate
additional loops.
Sequential step functions with interlocks and
first out functionality are easily configured, and
tuning functions for PID control are also
supported. Two and three-state device drivers
provide the functionality for motor and valve
operations with failure alarms, local and remote
operation, and interlocks.
Graphical Control Strategy Development
8
MOST
Logic Control
The MOST Logic
Control Workbench
contains a powerful
project management
tool that graphically
represents and
organizes programs,
resources,
configurations, and networks within a
project. The Workbench provides powerful
and intuitive graphical and textual editors. IEC 61131 Control Logic
MOST Logic Control supports the five IEC
61131-3 automation languages: Ladder
Diagram, Sequential Function Chart, Function
Block Diagram, Structured Text, Instruction List, procedures that cannot be easily expressed with
plus Flow Chart to develop, download, simulate, graphical languages.
debug, monitor, and edit application programs.
Instruction List is a low-level language, similar to
This offers users the versatility to mix
the simple textual PLC languages. IL is a register-
programming languages on the same project.
level programming language. MOST Logic
Ladder Diagram is one of the most familiar Control has a set of more than 60 IEC functions
methods of representing logic equations and and function blocks. Users can enlarge this set
simple actions. Contacts represent input by writing functions and function blocks in the
arguments and coils represent output results. It LD, FBD, ST, and IL languages.
is well suited for discrete control and
Sequential Function Chart divides the process
interlocking logic.
cycle into well-defined steps, providing an
Structured Text is a high level structured overall structure to your program. Graphical
language with a syntax similar to Pascal, but function chart programming is also supported.
more intuitive to the automation engineer. This
Function Block Diagram allows the user to build
language is mainly used to implement complex
complex procedures by taking existing function
blocks from the Workbench library, and wiring
them together on screen.
The Flow Chart is an easy to read decision
diagram where actions are organized in a
graphic flow.
9
MOST
Control Platform
The MOST Control Platform is a field-mountable efficiently shared between controllers instead of
distributed control system that offers concurrent requiring data to be passed to each controller
execution of process and logic control (IEC through a central control room. MOST
61131-3) applications, harsh environment controllers support full redundancy and
operation, "hot swappable" I/O modules, peer-to-peer communications between other
extensive redundancy options, peer-to-peer MOST controllers.
communications and smart device integration
For OEMs, MOST provides software tools to
for connecting to HART field devices. The
enable an OEM to readily port application
controllers execute control strategies and
software into the OEM controller. This control
manage all control activities including network
solution enables the OEM to incorporate its
communications.
engineering expertise in a new comprehensive
Four MOST Controllers are available: control solution in significantly less time than it
• MOST Hybrid Controller – supporting would take to develop a completely new system
concurrent execution of regulatory and and save substantial development money in
IEC 61131-3 sequential control strategies the process.
• MOST Process Controller – supporting MOST Process I/O is a distributed I/O solution
regulatory control strategies that provides an intelligent interface between
• MOST Logic Controller – supporting field-mounted instrumentation and the MOST
IEC 61131-3 control strategies Controllers. It has the accuracy, reliability and
• MOST OEM Controller, with software tools to ruggedness required for continuous operation in
facilitate porting an OEM’s application process environments. There are MOST I/O
software into this powerful controller modules available for virtually any process signal,
including smart modules for process busses such
MOST Controllers and I/O as HART.
MOST Controllers can communicate with each
other on a peer-to-peer basis, enabling
controllers to share data with each other. This
capability assures that critical information can be
10
MOST
Control Platform
A Cost Saving Solution A Robust Control Platform
One of the most significant benefits of the Beyond general-purpose applications, the MOST
MOST control platform is the cost saved by Control Platform has been designed to operate
replacing many hundreds of separate cable in harsh environments under the rigors of
pairs with a single or dual communication bus extreme temperature (-40°C to +70°C),
cable. System design, installation and vibration, shock and ISA’s stringent G3 corrosion
commissioning are faster and, by moving the resistance requirements. The MOST Control
control platform into the field, less space is Platform can be mounted directly in Division
required in the control room. Further savings 2/Zone 2 hazardous areas and, when required,
are made by terminating low-level signal can provide intrinsic safety interfaces for field
sensors at the node, eliminating transmitters devices located in Class I, Division 1 and Zone 0
for each input. Indirect savings are derived and Zone 1 hazardous areas. Intrinsic safety is
from improved diagnostics, live maintenance built into the front end of the I/S I/O modules,
data and the use of an open bus. eliminating the need for external safety barriers
and providing a space saving cost-effective
MOST Process I/O carriers enable you to power
solution.
field circuits with a minimum of wiring and
termination effort. A single power supply The MOST Control Platform is designed to
connection to the module carrier can power operate safely in potentially explosive
two I/O modules (up to 32 channels), atmospheres, such as those found in
eliminating the need for additional wiring and petrochemical refineries, natural gas plants,
separate terminal blocks. pharmaceutical plants and offshore drilling
platforms. The control platform can be
mounted in the existing junction boxes without
further environmental protection, and the
system can be connected to off-the-shelf
SCADA and HMI systems using industry
standard protocols such as Modbus over
Ethernet.
11
Extensive Redundancy Options
The MOST Control Platform offers extensive area network (LAN) can be provided where each
redundancy choices including: controllers, controller has two independent Ethernet ports
control networks and system power supplies. that are connected to two separate independent
Redundant controller pairs check status multiple networks. The controller monitors the networks’
times through the processing loop enabling the health and will switch between networks when
standby controller to continuously monitor the a problem is detected.
health of the master controller, assuring a rapid
Redundant power supplies are available to
and bumpless transfer to the standby controller
provide power for critical applications. An N+1
when required. The MOST controller redundancy
redundancy scheme is used for power supply
model supports on-line configuration and on-
redundancy where N power supplies are backed
line firmware changes, where the updates are
up by a single power supply, providing a cost-
shared between controllers in real-time, resulting
effective redundancy solution.
in an easy-to-use redundant system.
The platform supports LAN redundancy utilizing
MOST Fault Tolerant Ethernet, a Foundation
Fieldbus compliant software
product. A fully redundant local
12
MOST
Process I/O
MOST Process I/O is a completely modular
distributed I/O solution for both general
purpose and hazardous area applications. It
is built to be mounted in the entire spectrum
of process plant environments, especially the
user’s most demanding applications.
Now users no longer need to run sensors to
central systems in a benign, safe area,
dramatically reducing system installation time
and expense. MOST Process I/O can be
mounted directly in harsh and hazardous
applications and is capable of withstanding the
extreme temperatures and corrosive 'HART-ability'
environments of process applications.
The use of 'smart' instruments on process plants
MOST Process I/O’s operating temperature is is growing, but this investment has not always
-40°C to + 70°C. The product meets ISA’s been fully exploited. Smart Process I/O modules
stringent G3 corrosion resistance requirements are available to take full advantage of HART
and withstands extensive shock and vibration. instruments. They have been designed to be
Process I/O modules are available for virtually transparent to HART signals, allowing the host
any process signal, including analog, control software and any HART field
thermocouple, RTD, potentiometer, discrete, instruments to communicate directly with each
high-speed counter, frequency and quadrature. other, enabling asset management programs to
And for hazardous applications, it provides the access critical device information for calibration,
most cost-effective intrinsically safe I/O available configuration, and predictive maintenance.
by integrating intrinsic safety and sensor signal HART devices can be selected for regular status
conditioning in one package. monitoring and alerts can be issued if the status
changes. HART can provide your plant with
several benefits, including:
• Reduced commissioning time and cost
• Reduced process downtime through
status monitoring
• Lower loop maintenance costs by using field
device diagnostics
13
Ethernet Connectivity De facto Standard
MOST Process I/O is an open I/O platform, MOST Process I/O has become the de facto I/O
connecting to the popular distributed I/O standard for major automation suppliers. It is
networks including Ethernet, Modbus and the standard platform for several major DCS
Profibus. It connects to a group of field devices, systems, providing the I/O solution for both safe
of virtually any type, and connects them to a area and hazardous area I/O needs in their
single remote node. The remote nodes can systems. Several PLC vendors are using MOST
then be connected together to build a fast, Process I/O for their PLC applications in harsh
powerful and open I/O solution. process environments. You can be confident
with MOST Process I/O in your application.
Each Process I/O Node requires a Bus Interface
Module (BIM) to connect to a host system. The
Ethernet BIM provides a high-speed
MTL Open System Technologies
communication interface to any remote I/O Whether you use MOST Process I/O as a
application. When used with a MOST component in your control system or you use
Controller, the Ethernet BIM’s remote I/O and the comprehensive MOST Hybrid Control, you
the controller’s local I/O are configured in the have chosen open technology components that
same way by the Workbench, providing a fully can be readily integrated into your complete
integrated Remote I/O solution. system. MTL Open System Technologies (MOST)
provides open hardware and software
When used as remote I/O to a third party
technology-based components for the process
controller, the Ethernet BIM provides a high
automation market. For more information about
speed interface to communication interface to
MOST and its open system building blocks,
that controller. The Ethernet BIM supports the
contact your local MTL office or visit our web
MODBUS TCP protocol and, since it provides an
site at www.mtl-most.com.
export file that can be used to build an HMI
database, it provides an easy interface to all
popular HMI applications.
Redundancy
The Ethernet BIM offers the same extensive
redundancy options as the MOST controllers,
including redundant BIMs, control networks and
system power supplies. For critical applications,
these redundancy choices allow you to add
redundant elements to increase system
availability to the necessary level.
14
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