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
 Powerful Process Automation
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!

3
Gas Plants Oil and Gas
When process I/O is installed in remote locations, it Matrix is designed
needs to be reliable, environmentally hardened and for use in the
simple to maintain. Matrix’s I/O modules and process difficult environment
controllers meet this challenge by providing the of oil and gas
industry’s most extended temperature range, corrosion operations. Its
protection, and availability. Controllers and modules can –40 °C to +70 °C
be “hot-swapped” under power without taking other (-40 °F to 160 °F)
modules out of service, and they are conformally coated temperature range
to meet ISA’s stringent G3 corrosion standards to and optional
protect your system from harsh chemicals and solvents. intrinsic safety
means that it can be
mounted directly in
these operations’
harsh and hazardous
locations. The Matrix
availability in these
harsh conditions can
be easily increased
by using redundant
controllers, power
supplies and
network cables. Redundant communications are
provided with each controller – it’s not an option!
We also can easily add a redundant controller – just plug
it in – no programming or engineering is required. The
demand for both process and discrete control strategies
typically associated with this type of application is no
challenge for Matrix. The system provides advanced
function block programming in addition to all five
IEC61131-3 languages.

"Gas plant operating staff reductions and high

gas prices make efficient, reliable plant
“Matrix supplied a total solution! The I/O
operation a challenge. The Matrix control
modules with integrated intrinsic safety saved
platform has demonstrated very reliable service
us cost and space. The system’s wide operating
at a remote, unmanned gas plant for more than
temperature range let us mount the control
a year. Matrix also integrates well with the
platform directly in the field. The integrated
existing gathering and pipeline SCADA systems.
Modbus interface made the connection with
Matrix is an effective platform for our Advanced
existing compressor skids very easy. The system
Control applications for enhanced gas processing
supports open standards, simplifying the
performance. Matrix has proven to be well
integration necessary for future expansion
suited for natural gas processing applications."
requirements. We discovered a new very
George Bozant, Sr. Project Consultant,
flexible DCS technology, which is ideal for our
Barry D. Payne & Associates, Inc.
Gas Plant Control Specialist, Houston, TX, USA applications!"
Fusco Luciano, Project Manager,
Edison Gas Company,
Collalto, Italy

4
Boiler Control
Matrix combines industry-leading open components –
operator interface (HMI), engineering tools and
industrial control hardware with pre-written advanced
boiler control functions such as combustion control,
steam, O2 trim, and water header pressure controls to
provide a cost-effective solution. Matrix has successfully
replaced many installations that had used single loop
and mature DCS solutions. With our boiler control
expertise, your control system will be quickly
commissioned, significantly reducing the engineering
time required on the project. Your boiler will operate
more efficiently with an optimum air/fuel mix, reducing
your fuel costs and providing a rapid system payback.
"Advanced Boiler Control Services (ABCS)
chose Matrix for boiler control at the
Crawfordsville Electric Light and Power because
it enabled us to cost effectively deliver a
redundant control system with advanced boiler
control strategies, which has significantly
reduced operating costs."
Robert Burrink, President,
Advanced Boiler Control Services,
Orland Park, IL, USA
5
Biotech and Pharmaceutical
Matrix meets the demands of regulated industries that
must comply with U.S. Food & Drug Administration
(FDA) requirements, specifically 21 CFR Part 11. The
advanced function block control strategies included
with the system support the Wonderware InBatch
Flexible Batch Management System thus eliminating
countless hours of engineering and programming
associated with phase and unit operations, saving
considerable time and money. Detailed audit tracking of
users and software revision control combined with the
advanced reporting and documentation features of the
Matrix programming environment eliminate the many
issues faced by end users and system auditors.
"Matrix is really easy to work with. Our
requirements called for a "single-point" of data
entry. With an easy single step configuration,
the Matrix Workbench, incorporating
Wonderware's .NET-based ArchestrA, seamlessly
configured the Control Application, HMI and
Historian. This helped us complete our testing
quicker, which helped us achieve 21 CFR Part 11
compliance faster."
Guhan Prabhu, Systems Engineer
MAVERICK Technologies
Houston, TX, USA
Chemical and Petrochemical
Processing
Matrix is environmentally hardened to withstand the
harsh and hazardous areas of chemical and
petrochemical plants. The control platform meets ISA’s
stringent G3 corrosion requirements and incorporates
intrinsic safety when required. Matrix’s batch software
provides a cost effective and flexible recipe
management solution for specialty chemical plants.
For Class I Division 1 hazardous areas, Matrix provides
the most cost effective solution available by integrating
intrinsic safety and sensor signal conditioning in a
single module, eliminating costly barriers and
significantly reducing wiring, engineering and
installation costs.
"We were looking for an open system for a
hybrid application at our specialty chemical
plant and selected the Matrix system as the best
of breed solution. Matrix ensures reliable
operation in a harsh process environment and is
a cost saving solution, not only in initial
hardware and engineering cost but also with
ongoing maintenance costs."
Mr. Yin Zuwei, Vice General Manager,
Wuxi He Cheng Chemical Industry Co. Ltd.
Wuxi, China
6
Cement Plants
Matrix is used in cement plants that require special
functionality for cement manufacturing, including
specialized motor control. Application specific control
blocks have been created to optimize performance in
cement plants and further accelerate the program
development time. Matrix’s robust environmental
specifications are essential in this environment, where
its extensive corrosion resistance is needed to withstand
the ever-present dust particles.
"Matrix Process Software's advanced
functionality enabled us to quickly implement
our system. Motor Control function blocks
enabled us to quickly set up our plant
operations with safety interlocks while the
process control blocks enabled us to readily
control all of the ingredients needed in cement
manufacturing. This control software saved us
significant program development time and has
also been easy to maintain."
Jeff Meurin, Process Software-Electronics Technician
Texas Industries, Inc. (TXI)
New Braunfels, TX, USA
Water and Waste
Distributed field mounting makes Matrix ideal for use
in the water industry where I/O is clustered in each
part of the process. Its wide temperature range means
that I/O cabinets do not need heating and ensures
that the control platform can be mounted directly in
the process, providing significant savings in field
wiring. Matrix supports the Modbus RTU protocol
for easy interface to remote mounted RTUs and
provides dual redundant RS-485 connections for
reliable serial communications.
"We need to provide a redundant control
solution in our large water and waste water
applications. We prefer Matrix because it
provides an easy-to-use and cost effective
redundancy solution. Also, we like the fact
that Matrix is designed around Wonderware's
FactorySuite A2 for all HMI and plant historian
functions."
Sam Vandivort
TMV Systems Engineering
Phoenix, AZ, USA
7
Safety Systems
Matrix is TüV approved for use in SIL 2 applications, in
compliance with IEC 61508, enabling you to use the
same control platform for process control, emergency
shutdown (ESD) and fire and gas (F&G) systems.
Matrix’s common platform for these applications greatly
reduces commissioning and ongoing maintenance
costs. Matrix incorporates several test tools to evaluate
your control logic, including an integrity analyzer and a
cross reference analyzer. These productivity tools help
users reduce the time and effort required developing
IEC 61508 safety applications.
"We used Matrix controllers on a British
Petroleum training center in the Caspian Sea
because it not only combined shutdown logic
with DCS functionality in one controller, but
the system’s rugged design enabled it to be
remote mounted, which reduced
commissioning time and did not require
additional environmental protection.”
Steve Coates, Engineering Manager
Petrofac Engineering Ltd.,
Surrey, England
Matrix Total Control
Matrix provides a comprehensive solution for both
your process automation and functional safety needs.
Matrix provides process automation solutions for
regulatory, sequential and batch control applications
while Matrix Safety Net, certified to IEC 61508 by
TüV, provides safety related solutions for Emergency
Shut Down and Fire and Gas applications.
Matrix 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, while protecting your investment.

Control Room

Single Monitor
Operator Station
Multi Monitor Multi Monitor
Operator Station Operator Station
Network
Printer

Matrix Process Matrix

Modbus RTU
Device
RS485
Half-Duplex

8
 The Matrix Workbench is integrated with
Wonderware’s Industrial Application Server,
ArchestrA®’s core application development platform.
This architecture extends the life of legacy systems by
leveraging the latest software technologies and
enables applications to be developed more quickly,
providing an easy interface to the open Matrix system.
Matrix offers extensive redundancy choices,
including system servers, controllers, control
networks and system power supplies. You can
choose some or all of these options for increased
system availability.
Business
LAN

Server/Network Equipment Room

Network connection to handle
server redundancy

Industrial
Application Server
Engineering
Workstation
Primary Real Backup Real
Time Industrial Time Industrial InSQL Server
Application Application Historian/Reporting
Server Server
Server

DATA

Redundant Control System Network

(Fault Tolerant Ethernet)

Discrete Matrix SafetyNet

9
Matrix Process Engineering Tools
The Matrix Workbench provides an integrated
project development environment that centralizes
project engineering including I/O and control
strategy configuration (process and discrete) and
Process Engineering - The Workbench
Matrix Process
10
project documentation. Matrix fully supports all five
IEC 61131-3 programming languages and offers a
comprehensive function block library for addressing
advanced process control needs.
• 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
• 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
Matrix Discrete (IEC 61131-3)
• Supports all five IEC 61131-3
languages (Ladder Diagram, Sequential
Function Chart, Function Block
Diagram, Structured Text, Instruction
List) plus Flow Chart

• Concurrently executes programs in

different languages – IEC 61131-3 and
function block programming

• Supports multiple configurations in a

single programming environment

• Supports user-defined function blocks,

enabling users to create custom blocks
that 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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I/O Database Configuration
• Uses "Fill-In-The-Blanks" Template or
Excel spreadsheet import, providing an
open 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

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

12
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

13
Matrix Process Management Tools
The system features process management tools interface (HMI), plant historian, batch
and applications needed to control, optimize and management and instrument maintenance
manage process performance including operator (HART and Foundation Fieldbus).

Operator Interface (HMI)

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

• Integrated with Industrial Application

Server, an ArchestrA® software
component

• Provides a single integrated view of all

control 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

Plant Historian
• 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 and
historical trending, database queries
and report generation

14
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 diagnostic
history

• 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

15
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

16
 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-incendive

and 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
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

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

17
MATRIX Total Control – The Cost Effective Automation Solution
for Process and Discrete Applications

Matrix Total Control is the cost effective automation
solution for both process, discrete, batch and
functional safety applications. A PLC is cost effective in
small discrete applications while a DCS is well suited for
large process control applications, but neither are
effective solutions for complex process applications that
also need discrete control. Users often have to use both
a PLC and DCS to address these two different
requirements. This is a difficult solution since it requires
the user to manage different programming approaches,
different communications protocols and an extensive
integration effort to get data from one system into
the other.
Now there’s no longer the need to struggle with these
difficult solutions. Matrix Total Control combines the
best application features of a PLC and a DCS to address
these complex applications.
integration for connecting to HART and Foundation
Fieldbus devices. Matrix control strategies, HMI and
hardware are configured through a single unified
engineering tool unlike HMI and PLC systems, which
often require that the HMI and controller be configured
separately.
Matrix is a scalable solution, able to address both small
and large applications, which provides significant
flexibility over DCS systems that are optimized for large
applications. Its advanced function block programming
combined with the IEC 61131-3 languages enables
process control applications to also address discrete
logic needs when required. The single Matrix
Engineering Workbench is tag count independent,
which provides you with a more cost effective solution
that is easier to use – you will never have to buy more
Workbench tags to complete your application.

Matrix is a superior choice over traditional solutions in
process applications. The Matrix control platform is a
field-mountable distributed control system that offers
concurrent execution of process and discrete control
applications, harsh environment operation, "hot
swappable" I/O modules, extensive redundancy
options, peer-to-peer communications and fieldbus
Matrix is a rugged process automation system that can
be mounted much nearer the process plant than ever
before, providing users with benefits of increased
flexibility, greater scalability and a significantly lower
cost of ownership. Why settle for traditional solutions?
Matrix provides value across the entire automation
spectrum.

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

PLC BASED SOLUTIONS MATRIX SOLUTIONS DCS BASED SOLUTIONS

IEC 61131 Programs IEC 61131-3 Programs/ Advanced Function Blocks

Workable Safety System
Loose Peer-to-Peer Communications
Minimal HMI Integration
Minimal Integrated
I/O and Diagnostics
Harsh Environmental
Specifications
Low Initial Investment
Advanced Function Blocks
Safety and Process Control Independent SIL 2-3 Safety System
by same control platform
Tight Peer-to-Peer Communications Tight Peer-to-Peer Communications
Integrated HMI Integrated HMI
Quality for I/O and Quality Flags for I/O
Communications and Communications
Harsh Environmental Requires Controlled
Specifications Environment
Low Initial Investment High Initial Investment

Scaleable Scaleable Not Very Scaleable

Open Protocols Open Protocols Propriety Protocols
Workable Device Redundancy Seamless Redundancy Seamless Device Redundancy
Intrinsic Safety Available
Integral Hart Capability

18
 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.
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