Matrix

Matrix Total Control

A m e m b e r o f T h e M T L I n s t r u m e n t s G r o u p p l c

MTL has been a leading supplier of process I/O and intrinsic safety products to many of the

world’s top process automation companies for over thirty years. MTL Open System

Technologies (MOST), a member of the MTL Instruments Group, has combined this experience

with leading open market technologies to provide Matrix, an open process automation system

that’s both powerful and flexible.

Matrix Total Control delivers the performance that you expect from a distributed control

system at a price that is normally associated with a programmable logic controller. Matrix has

been successfully deployed worldwide in many diverse process applications, including power

generation, gas plant control, chemicals and petrochemicals, pulp and paper, water and waste

water, pharmaceutical, oil and gas pipeline, cement, and food and beverage.

Matrix’s rugged open control platform is tightly integrated with Wonderware’s market leading

FactorySuite A2, providing a field proven solution. Matrix’s comprehensive process

management tools provide a unified environment for visualization, plant historian, batch

management, device communications and instrument maintenance.

While many systems only provide proprietary communication networks, Matrix incorporates

Modbus TCP with built-in Fault Tolerant Ethernet (FTE) for redundant communications and

interfaces with popular asset management software packages for regular status monitoring of

smart plant instruments. Matrix’s open architecture enables you to cost effectively upgrade

your system as new technologies emerge on the market. You no longer need to make critical

business decisions based on traditional proprietary solutions that are costly and lock you into a

single solution from a single vendor.

Matrix is a compelling alternative to the DCS and PLC solutions that are being considered in

today’s process applications. Matrix’s robust field mountable control platform incorporates

interfaces with smart field devices and an elegant redundancy solution, providing a superior

approach to most DCS and PLC solutions. Unlike other systems that determine software

licensing by complicated and costly tag structures, Matrix has a single one-time affordable

license for its control software that is independent of tag count, providing significant value to

end users and system integrators in both small and larger applications.

Customers worldwide are choosing Matrix for their process control needs. We offer extensive

post installation support ranging from simple upgrade services, hotline support to 24/7

assistance. See how Matrix can provide a compelling advantage for your next project. Your

satisfaction is not only our goal, it is our guarantee!

Powerful Process Automation

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Gas Plants When process I/O is installed in remote locations, itneeds to be reliable, environmentally hardened andsimple to maintain. Matrix’s I/O modules and processcontrollers meet this challenge by providing theindustry’s most extended temperature range, corrosionprotection, and availability. Controllers and modules canbe “hot-swapped” under power without taking othermodules out of service, and they are conformally coatedto meet ISA’s stringent G3 corrosion standards toprotect your system from harsh chemicals and solvents.

"Gas plant operating staff reductions and highgas prices make efficient, reliable plantoperation a challenge. The Matrix controlplatform has demonstrated very reliable serviceat a remote, unmanned gas plant for more thana year. Matrix also integrates well with theexisting gathering and pipeline SCADA systems.Matrix is an effective platform for our AdvancedControl applications for enhanced gas processingperformance. Matrix has proven to be wellsuited for natural gas processing applications."

George Bozant, Sr. Project Consultant, Barry D. Payne & Associates, Inc.

Gas Plant Control Specialist, Houston, TX, USA

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Oil and Gas Matrix is designedfor use in thedifficult environmentof oil and gasoperations. Its –40 °C to +70 °C (-40 °F to 160 °F)temperature rangeand optionalintrinsic safetymeans that it can bemounted directly inthese operations’harsh and hazardouslocations. The Matrixavailability in theseharsh conditions canbe easily increasedby using redundantcontrollers, powersupplies andnetwork cables. Redundant communications are provided with each controller – it’s not an option! We also can easily add a redundant controller – just plugit in – no programming or engineering is required. Thedemand for both process and discrete control strategiestypically associated with this type of application is nochallenge for Matrix. The system provides advancedfunction block programming in addition to all fiveIEC61131-3 languages.

“Matrix supplied a total solution! The I/Omodules with integrated intrinsic safety savedus cost and space. The system’s wide operatingtemperature range let us mount the controlplatform directly in the field. The integratedModbus interface made the connection withexisting compressor skids very easy. The systemsupports open standards, simplifying theintegration necessary for future expansionrequirements. We discovered a new very flexible DCS technology, which is ideal for ourapplications!"

Fusco Luciano, Project Manager, Edison Gas Company,

Collalto, Italy

Biotech and PharmaceuticalMatrix meets the demands of regulated industries thatmust comply with U.S. Food & Drug Administration(FDA) requirements, specifically 21 CFR Part 11. Theadvanced function block control strategies includedwith the system support the Wonderware InBatchFlexible Batch Management System thus eliminatingcountless hours of engineering and programmingassociated with phase and unit operations, savingconsiderable time and money. Detailed audit tracking ofusers and software revision control combined with theadvanced reporting and documentation features of theMatrix programming environment eliminate the manyissues faced by end users and system auditors.

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"Advanced Boiler Control Services (ABCS)chose Matrix for boiler control at theCrawfordsville Electric Light and Power becauseit enabled us to cost effectively deliver aredundant control system with advanced boilercontrol strategies, which has significantlyreduced operating costs."

Robert Burrink, President, Advanced Boiler Control Services,

Orland Park, IL, USA

"Matrix is really easy to work with. Ourrequirements called for a "single-point" of dataentry. With an easy single step configuration,the Matrix Workbench, incorporatingWonderware's .NET-based ArchestrA, seamlesslyconfigured the Control Application, HMI andHistorian. This helped us complete our testingquicker, which helped us achieve 21 CFR Part 11compliance faster."

Guhan Prabhu, Systems EngineerMAVERICK Technologies

Houston, TX, USA

Boiler Control Matrix combines industry-leading open components –operator interface (HMI), engineering tools andindustrial control hardware with pre-written advancedboiler control functions such as combustion control,steam, O2 trim, and water header pressure controls toprovide a cost-effective solution. Matrix has successfullyreplaced many installations that had used single loopand mature DCS solutions. With our boiler controlexpertise, your control system will be quicklycommissioned, significantly reducing the engineeringtime required on the project. Your boiler will operatemore efficiently with an optimum air/fuel mix, reducingyour fuel costs and providing a rapid system payback.

Cement Plants Matrix is used in cement plants that require specialfunctionality for cement manufacturing, includingspecialized motor control. Application specific controlblocks have been created to optimize performance incement plants and further accelerate the programdevelopment time. Matrix’s robust environmentalspecifications are essential in this environment, whereits extensive corrosion resistance is needed to withstandthe ever-present dust particles.

Chemical and PetrochemicalProcessing Matrix is environmentally hardened to withstand theharsh and hazardous areas of chemical andpetrochemical plants. The control platform meets ISA’sstringent G3 corrosion requirements and incorporatesintrinsic safety when required. Matrix’s batch softwareprovides a cost effective and flexible recipemanagement solution for specialty chemical plants. For Class I Division 1 hazardous areas, Matrix providesthe most cost effective solution available by integratingintrinsic safety and sensor signal conditioning in asingle module, eliminating costly barriers andsignificantly reducing wiring, engineering andinstallation costs.

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"We were looking for an open system for ahybrid application at our specialty chemicalplant and selected the Matrix system as the bestof breed solution. Matrix ensures reliableoperation in a harsh process environment and isa cost saving solution, not only in initialhardware and engineering cost but also withongoing maintenance costs."

Mr. Yin Zuwei, Vice General Manager, Wuxi He Cheng Chemical Industry Co. Ltd.

Wuxi, China

"Matrix Process Software's advancedfunctionality enabled us to quickly implementour system. Motor Control function blocksenabled us to quickly set up our plantoperations with safety interlocks while theprocess control blocks enabled us to readilycontrol all of the ingredients needed in cementmanufacturing. This control software saved ussignificant program development time and hasalso been easy to maintain."

Jeff Meurin, Process Software-Electronics TechnicianTexas Industries, Inc. (TXI)

New Braunfels, TX, USA

Water and Waste Distributed field mounting makes Matrix ideal for usein the water industry where I/O is clustered in each part of the process. Its wide temperature range meansthat I/O cabinets do not need heating and ensures that the control platform can be mounted directly inthe process, providing significant savings in field wiring. Matrix supports the Modbus RTU protocol for easy interface to remote mounted RTUs andprovides dual redundant RS-485 connections forreliable serial communications.

Safety Systems Matrix is TüV approved for use in SIL 2 applications, incompliance with IEC 61508, enabling you to use thesame control platform for process control, emergencyshutdown (ESD) and fire and gas (F&G) systems.Matrix’s common platform for these applications greatlyreduces commissioning and ongoing maintenancecosts. Matrix incorporates several test tools to evaluateyour control logic, including an integrity analyzer and across reference analyzer. These productivity tools helpusers reduce the time and effort required developing IEC 61508 safety applications.

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"We used Matrix controllers on a BritishPetroleum training center in the Caspian Seabecause it not only combined shutdown logicwith DCS functionality in one controller, butthe system’s rugged design enabled it to beremote mounted, which reducedcommissioning time and did not requireadditional environmental protection.”

Steve Coates, Engineering Manager Petrofac Engineering Ltd.,

Surrey, England

"We need to provide a redundant controlsolution in our large water and waste waterapplications. We prefer Matrix because itprovides an easy-to-use and cost effectiveredundancy solution. Also, we like the factthat Matrix is designed around Wonderware'sFactorySuite A2 for all HMI and plant historianfunctions."

Sam VandivortTMV Systems Engineering

Phoenix, AZ, USA

NetworkPrinter

Single MonitorOperator Station

Multi MonitorOperator Station

Multi MonitorOperator Station

Control Room

Matrix Matrix Process

Modbus RTUDevice

RS485Half-Duplex

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Matrix Total ControlMatrix provides a comprehensive solution for bothyour process automation and functional safety needs.Matrix provides process automation solutions forregulatory, sequential and batch control applicationswhile Matrix Safety Net, certified to IEC 61508 byTüV, provides safety related solutions for EmergencyShut Down and Fire and Gas applications.

Matrix can be optimized for your processautomation needs today, addressing applicationsranging from a few points to thousands of points. Itsmodular design assures easy upgrades and futureexpansion, while protecting your investment.

DATA

IndustrialApplication Server

EngineeringWorkstation

Server/Network Equipment Room

BusinessLAN

Primary RealTime Industrial

ApplicationServer

InSQL ServerHistorian/Reporting

Server

Redundant Control System Network(Fault Tolerant Ethernet)

Matrix SafetyNetDiscrete

Network connection to handleserver redundancy

Backup RealTime Industrial

ApplicationServer

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The Matrix Workbench is integrated withWonderware’s Industrial Application Server,ArchestrA®’s core application development platform.This architecture extends the life of legacy systems byleveraging the latest software technologies andenables applications to be developed more quickly,providing an easy interface to the open Matrix system.

Matrix offers extensive redundancy choices,including system servers, controllers, controlnetworks and system power supplies. You canchoose some or all of these options for increasedsystem availability.

Matrix Process Engineering Tools

Process Engineering - The Workbench

• Centralizes and coordinates all system engineering

• Consistent Windows Explorer "Look and Feel"

• Easy-To-Use Hierarchy of objects and folders

• Comprehensive context sensitive help files

The Matrix Workbench provides an integratedproject development environment that centralizesproject engineering including I/O and controlstrategy configuration (process and discrete) and

project documentation. Matrix fully supports all fiveIEC 61131-3 programming languages and offers acomprehensive function block library for addressingadvanced process control needs.

Matrix Process

• Build process control logic diagrams using graphic interface - easy transition from P&IDs

• Select the appropriate function blocks, assign symbolic tags, and connect them

• Complete, proven library of function blocks provides powerful control logic capability

• Resulting control logic diagrams provide self documentation of control strategies

• Compile and download control program to control platform

• On-line programming and troubleshooting

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Matrix Discrete (IEC 61131-3)

• Supports all five IEC 61131-3 languages (Ladder Diagram, SequentialFunction Chart, Function Block Diagram, Structured Text, Instruction List) plus Flow Chart

• Concurrently executes programs in different languages – IEC 61131-3 andfunction block programming

• Supports multiple configurations in a single programming environment

• Supports user-defined function blocks, enabling users to create custom blocksthat can be easily reused

• Peer to peer communications links together multiple applications running in separate controllers

Matrix SafetyNet

• IEC 61508 certified by TüV for use in SIL 2 functional safety applications, including Emergency Shutdown and Fire & Gas

• SIL 2 rating without requiring use of redundant I/O or redundant controllers

• Add a second controller to provide greater system availability

• Develop both process control and functional safety applications with the same control platform on a single workbench

• Static analysis tools assist verification and validation of safety strategy

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Project Documentation

• Automatically generates as-built documents from control strategy diagrams, dramatically reducing project documentation time

• Standard reports include:

- System startup and testing information

- I/O configuration reports

- Cross reference analyses

- Instrument index

• User configurable reports address specific requirements

I/O Database Configuration

• Uses "Fill-In-The-Blanks" Template or Excel spreadsheet import, providing anopen interface to other systems

• Configure instrument I/O tags, field and panel wiring information

• Configure controller and assign tags to I/O modules

• Allows on-line configuration changes during testing, start-up, and maintenance phases

• Eliminates expensive, laborious, and sometimes error prone manual engineering

• Eliminates manual generation of design documents, bill of materials, wiring diagrams, and operator interface database

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Simulation and Tuning

• View control logic diagram animation with simulated data or real-time process data

• On-line and off-line control configuration and intelligent control schematics for modification and maintenance

• Quick and easy verification of control loop integrity quickens system startup

• Simulation accelerates operator training

System Diagnostics

• Diagnostic tools for network configuration, controller statistics and individual modules

• Extensive Process I/O diagnostics include module and channel status, high and low alarms and open circuit detection

• Event logs provides detailed diagnostic data

• On-Line Diagnostic Tools for evaluating system configuration, communications, execution times and control parameters

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Operator Interface (HMI)

Plant Historian

• Utilizes Wonderware’s InTouch, the market leading operator interface

• Integrated with Industrial Application Server, an ArchestrA® software component

• Provides a single integrated view of allcontrol and information resources

• Performs visualization, data access, extensibility to external components/systems, history, event handling, alarm logging, reporting and analysis

• Connect to your process via standard Internet-enabled applications

• Ease of use and power dramatically reduce commissioning and maintenance timing, with significant cost savings

• Integrated with IndustrialSQL Server Plant Historian

• Integrates plant data with event, summary, production and configuration data

• Acquires process data at full resolution including hourly, daily, weekly, monthly, etc.

• Powerful suite of data analysis and reporting tools, including real-time andhistorical trending, database queries and report generation

The system features process management tools and applications needed to control, optimize andmanage process performance including operator

interface (HMI), plant historian, batchmanagement and instrument maintenance (HART and Foundation Fieldbus).

Matrix Process Management Tools

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Batch Management

• Integrated with InBatch flexible batch system

• Integrated phase logic consistent with ISA S88.01 standard

• Manages recipes, batches and complex decisions

• Assigns process units to the recipe and sets schedule

• Redundant servers for critical applications

• Dynamic batch and equipment management

• Batch history and reporting

Instrument Maintenance

• Manages instrument configuration and calibration information

• Monitors instrument status – alerts when status changes

• Preventative maintenance will lower overall operating costs

• Maintains maintenance and diagnostichistory

• Performs online and offline configuration

• Supports conventional and HART devices – 4-20mA, 4 process variables and status

• Modules with HART “passthrough” connect directly to asset management software

Matrix Control Platform

Power Supplies (not shown)

• AC power or 24V dc input versions

• Supplies power for I/O and controllers

• Redundant power supply options

• External mounting allows easy panel layout and simple installation

• Power supply monitor alerts controller when a power supply fails

Controllers

• Controls up to 64 sixteen channel modules

• Redundant controllers with dual redundant Ethernet® and redundant RS-485 connections

• Wide range of protocols including Modbus TCP and Modbus RTU

• Regulatory and IEC 61131-3 software execute concurrently providing both process and discrete control

• Provides process automation, sequential control and functional safety from a single control platform

• On-line configuration and reconfiguration

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Carriers

• Tough polycarbonate base – protects against shock and vibration

• Choice of four module, eight module and controller versions

• Cable ground and shield terminals along front edge

• Reliable – no active components - so there is nothing to fail

• Replacement modules are configured automatically, so maintenance is simplicity itself

• Field power can be supplied through connectors on the back of the carrier

Field Terminals

• Unique, removable terminals for fast wiring and field replacement

• Optional fuses and disconnects – no interposing terminals required

• Field power provided at terminals – no daisy chained power connections

• Integral tagging system

I/O Modules

• Wide range of I/O for virtually any process signal, including HART®

Smart analog, thermocouple, RTD, potentiometer, high-speed counter, frequency, quadrature and sequence of events

• Suitable for safe-area, non-incendiveand intrinsically safe applications

• Remote configuration and interrogation of smart devices

• Maximum packing density – 1/4” (6mm) per channel

• “Hot swapping” does not affect adjacent modules

• Keying stops modules from being fitted in the wrong position

• Isolation between I/O bus and field wiring

• Diagnostic services for each channel,including status and alarms

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Matrix Total Control is the cost effective automationsolution for both process, discrete, batch andfunctional safety applications. A PLC is cost effective insmall discrete applications while a DCS is well suited forlarge process control applications, but neither areeffective solutions for complex process applications thatalso need discrete control. Users often have to use botha PLC and DCS to address these two differentrequirements. This is a difficult solution since it requiresthe user to manage different programming approaches,different communications protocols and an extensiveintegration effort to get data from one system into the other.

Now there’s no longer the need to struggle with thesedifficult solutions. Matrix Total Control combines thebest application features of a PLC and a DCS to addressthese complex applications.

Matrix is a superior choice over traditional solutions inprocess applications. The Matrix control platform is afield-mountable distributed control system that offersconcurrent execution of process and discrete controlapplications, harsh environment operation, "hotswappable" I/O modules, extensive redundancyoptions, peer-to-peer communications and fieldbus

integration for connecting to HART and FoundationFieldbus devices. Matrix control strategies, HMI andhardware are configured through a single unifiedengineering tool unlike HMI and PLC systems, whichoften require that the HMI and controller be configuredseparately.

Matrix is a scalable solution, able to address both smalland large applications, which provides significantflexibility over DCS systems that are optimized for largeapplications. Its advanced function block programmingcombined with the IEC 61131-3 languages enablesprocess control applications to also address discretelogic needs when required. The single MatrixEngineering Workbench is tag count independent,which provides you with a more cost effective solutionthat is easier to use – you will never have to buy moreWorkbench tags to complete your application.

Matrix is a rugged process automation system that canbe mounted much nearer the process plant than everbefore, providing users with benefits of increasedflexibility, greater scalability and a significantly lowercost of ownership. Why settle for traditional solutions?Matrix provides value across the entire automationspectrum.

MATRIX Total Control – The Cost Effective Automation Solution for Process and Discrete Applications

MATRIX SOLUTIONS DCS BASED SOLUTIONSPLC BASED SOLUTIONS

IEC 61131-3 Programs/Advanced Function Blocks

Tight Peer-to-Peer Communications

Integrated HMI

Quality for I/O andCommunications

Harsh EnvironmentalSpecifications

Low Initial Investment

Scaleable

Open Protocols

Seamless Redundancy

Intrinsic Safety Available

Integral Hart Capability

Advanced Function Blocks

Tight Peer-to-Peer Communications

Integrated HMI

Quality Flags for I/Oand Communications

Requires ControlledEnvironment

High Initial Investment

Not Very Scaleable

Propriety Protocols

Seamless Device Redundancy

IEC 61131 Programs

Loose Peer-to-Peer Communications

Minimal HMI Integration

Minimal IntegratedI/O and Diagnostics

Harsh EnvironmentalSpecifications

Low Initial Investment

Scaleable

Open Protocols

Safety and Process Controlby same control platform

Independent SIL 2-3 Safety SystemWorkable Safety System

MATRIX - Providing the Best of What a PLC and DCS Have to Offer

Workable Device Redundancy

MTL Open System Technologies

MTL Open System Technologies (MOST), a member of the MTL

Instruments Group, provides industrial automation and information

technologies to the process industries. Solutions encompass process

automation systems including process controllers and robust I/O

systems, operator interfaces, supervisory control and data acquisition

(SCADA) systems, plant historians and batch management

applications. Our solutions are proving themselves in many

industries, including: oil and gas, petrochemical and petroleum

refining, food and beverage, pulp and paper, power generation and

utilities, metals and mining, water and wastewater, manufacturing

and others.

MTL Instruments Group PLC

MTL Instruments Group PLC is recognized as a world leader in the

development and supply of Process Control, Hazardous Area, and

Surge Protection products aimed at process and discrete control

spanning a wide range of industries, applications, and geographical

regions. Many of the world’s safety-critical processes are monitored,

controlled or protected by MTL products. The Group is distinguished

by its global network of sales and support centers and by its

acknowledged position as a leader in this high technology

marketplace.

©2005 MTL Open System Technologies LP. All rights reserved.All brand names and product names are trademarks or registered trademarks of their respective companies.

The Americas

United StatesMTL Open System Technologies LP2450 South Shore Blvd.League City, TX 77573 USATel +1 281 334 3293Fax +1 281 334 4324Email: [email protected]

CanadaMTL Canada Safety InstrumentationStonegate Plaza511 Edinburgh Road, SouthSuite 202Guelph, OntarioN1G 4S5 CanadaTel +1 800 835 7075Email: [email protected]

Latin AmericaMTL Open System Technologies LP9 Merrill Industrial DriveHampton, NH 03842 USATel +1 603 926 0090Fax +1 603 926 1899Email: [email protected]

Europe, Middle East & Africa

EnglandMTL Instruments Group plcPower Court, Luton, Bedfordshire,England LU1 3JJTel +44 (0) 1582 723633Fax +44 (0) 1582 422283Email: [email protected]

FranceMTL Instruments sarlBâtiment 4, Parc d’Activités deLimonest1rue des Vergers, 69760 Limonest,FranceTel +33 (0)4 78 64 98 32Fax +33 (0)4 78 35 79 41Email: [email protected]

GermanyMTL Instruments GmbHAn der Gümpgesbrücke 17,D-41564 Kaarst, GermanyTel +49 (0)2131 718930Fax +49 (0)2131.7189333Email: [email protected]

ItalyMTL Italia srlVia Fosse Ardeatine, 4, I - 20092Cinisello Balsamo MI, ItalyTel +39 (0)2 61802011Fax +39 (0)2 61294560Email: [email protected]

The NetherlandsMTL Instruments BVde Houtakker 33,6681 CW Bemmel,The NetherlandsTel +31 (0)48 1450250Fax +31 (0)48.1450260Email: [email protected]

United Arab EmiratesMTL InstrumentsP.O. Box 53234, Abu Dhabi, UAETel +971 2 645 2620Fax +971 2 645 2630Email: [email protected]

Asia

SingaporeMTL Instruments Pte Ltd128 Joo Seng Road#07-00 DP Computers BuildingSingapore 368356 Tel +65 6 487 7887Fax +65 6 487 7997E-mail: [email protected]

AustraliaMTL Instruments Pty Limited9 Vinnicombe Drive,PO Box 1441,Canning Vale, Perth,WA 6155, AustraliaTel +61 (0)8 9455 2994Fax +61 (0)8 9455 2805Email: [email protected]

China

The People’s RepublicMTL Instruments Pte LimitedRoom 07-05A, The Gateway,No. 10 Yaobao Road, Chaoyang District,Beijing, 100020

People’s Republic of ChinaTel +86 10 85625718/20/21Fax +86 10 85625725E-mail: [email protected] www.mtlmost.com/cn

IndiaMTL India Pvt Limited36, Nehru Street, Off OldMahabalipuram Road,Sholinganallur, Chennai - 600119,IndiaTel +91 (0)44 2450 1660Fax +91 (0)44 2450 1463Email: [email protected]

JapanMTL Instruments KK3rd Floor, Gotanda Masujima Building,1-8-13 Higashi-Gotanda,Shinagawa-Ku, Tokyo 141-0022,JapanTel +81 (0)3 5420 1281Fax +81 (0)3 5420 2405Email: [email protected]