MTL Open System Technologies (MOST) is committed to providing

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MTL Open System Technologies (MOST) is committed to providing Powered By Docstoc
					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

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

                                                                                     Remote I/O



    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.

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

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


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:

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

Logic Control

The MOST Logic
Control Workbench
contains a powerful
project management
tool that graphically
represents and
organizes programs,
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.

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
                                                      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

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
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

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

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

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
export file that can be used to build an HMI
database, it provides an easy interface to all
popular HMI applications.

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.

The Americas                                  Europe, Middle East & Africa                            Asia
United States                                 England                                                 Singapore
MTL Incorporated                              MTL Instruments Group plc                               MTL Instruments Pte Limited
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