MTL HART CONNECTION SYSTEMFLEXIBLE SOLUTIONS

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W E L C O M E

T O

M T L

MTL, the world leader in intrinsic safety, has built an outstanding reputation
over 25 years for supplying quality products into the harshest environments.

Where explosive gases are present, MTL's 'intrinsic safety' technique prevents ignition by restricting theenergy available in high-risk areas. MTL's solution is simply the most cost effective and reliable methodof preventing explosions.
When it comes to HART Connections MTL offers the most cost effective, reliable and flexible solutions
for every application and industry. From Siberian oil fields to Mexican power plants, MTL HART
Connections provide the optimum solution.
The world's leading companies rely on MTL to protect their business and their personnel because MTL's
quality and reliability are beyond question. Whatever the client's needs, MTL's holistic, flexible approachdelivers a safe, reliable, total solution that integrates easily with existing components and systems.
The simplicity, quality and robustness of MTL's components and processes contributeto significant cost savings when MTL solutions are compared with less well-engineeredor incomplete approaches.

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IS

H A R TW H AT

HART?

HART is an open protocol that enables two
way digitalcommunication

with Smart fielddevices. It has become the de facto standard

2

for communicating

3

with

SMART devices in

the

full

potential

of

Smart

field

The HART protocol allows additional information to be carried on

devices whilst preserving the traditional

the same pair of wires with the 4-20mA analogue signal.

4-20mA signal.

Simultaneously and Transparently

W H AT

DOES

HART

GIVE

YOU

There are millions of HART devices installed in process plants worldwide and each contains
valuable data which can enable better management of plant assets, helping to help to reduce
commissioning, maintenance and documentation costs.
To communicate with HART devices and extract this data a wide range of powerful Instrument
Management

Softwaremanufacturers i.e

packages

have

been

developedbyanumberofdifferent

AMS, Cornerstone , FieldCare etc. these software packages offer online,

continuous communication with your HART devices simplifying configuration, calibration,
diagnostics, predictive maintenance and automating documentation etc.
To access this information and maximise the benefits of online HART communication you
need HART CONNECTIONS.

HART

CONNECTIONSMTL provide the HART CONNECTION between your fielddevices, your control system and our instrument management
software package.
Our HART CONNECTIONS strip the HART digital signal fromthe

4-20mAsignal(whichpassestothecontrolsystemunscathed) and sends it directly to your maintenance PC. Thus
giving you access to the benefits offered by the latest powerfulconfiguration and predictive
maintenance software.
For process control systems using traditional I/O installations, the MTL4840 HART
Connection System is the ideal HART solution for new installations or upgrades, either
intrinsically safe or general purpose applications.
For process I/O installations, MTL8000 Remote I/O is fully
HART compatible, allowing read-and-write configurationand calibration parameters as well as online monitoring of key variables and status.

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MTL HART CONNECTION SYSTEM

realiseFLEXIBLE SOLUTIONS

the process industry as it allows the user toMTL4840
FOR

HART

CONNECTIONSTRADITIONAL

POINT

TO

POINT

I N S TA L L AT I O N S

A Typical MTL4840 HART Connection System will consist of the following three components.
1. A HART Communication Board

to provide a physical connection - HART Communication Unit for safearea applications or intrinsically safe backplane for hazardous area applications.
2. HART multiplexer to route the communication between the maintenance PC and the HART devices.
3. HART backplane BPHM64 to hold the HART multiplexer modules.
The HART communication board is the link between the HART field devices and the HART
backplane. Normally a 16 channel board, it accepts either AI or AO inputs maintaining
channel to channel isolation between each.
The HART backplane is the backbone of the MTL4840 system. This
small but vitally important board holds the MTL4840 HART modules
which handle the HART multiplexing. Each board can communicate
with up to 64 HART devices.
The HART multiplexer is the brains of the system. Its is a combination of two modules, the MTL4841- HART communications module and MTL4842 - HART interface module. They provide the HART datainterface between smart devices in the field and HART instrument management software running on
a PC. The modules which mount on the BPHM64 HART backplane connect to the field devices via
either HART connection units or IS backplanes depending on the application.
A simple system layout for a 16 channel system is illustrated below:

The MTL4840 system is however completely modular and scalable allowing you to grow the system to the size you require. i.e each
16 channel HART connection board is connected to one MTL interface module and up to 16 of these modules can be connected
to one HART communications module. This enables one multiplexer to communicate with up to 256 different HART devices in the
network. Additionally up to 31 HART Comms modules can be daisy linked giving 7936 HART devices on one network.
See illustration on centre spread.

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H A R T

The flexibility of the MTL4840 and its ability to communicate with any of the instrument management software
packages on the market today allows MTL the ability to offer the optimum solution for any application. Whether for
general purpose or IS applications, retrofit or new installations, the versatile MTL4840 system with its wide rangeof standard or customised backplanes and Hart connection units offers the best connection solution.

A P P L I C AT I O N S

For safe area applications HART field devices are connected to the HART multiplexer via a range of HART
Connection Units, the choice of HCU being dependent on the type and number of the HART field devices. The
generic HART communication boards are generally mounted in series to the existing Field Termination Panel, seediagram 1, but in certain retrofit applications they can be mounted in parallel, see diagram 2 - Discuss with your
MTL representative which is the most appropriate installation for your application.
Dependent on the application see diagrams below:

Diagram 1
HCU installed in series

Diagram 2
HCU installed in parallel

Alternatively, customised HCUs can be utilised to replace the exiting the Field Termination Panel thereby
reducing the number of connections and simplyfying the installation (see Integrated Solutions - page 10)

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FLEXIBLE SOLUTIONS

AREA

5

MTL HART CONNECTION SYSTEM

SAFE

4

I N T R I N S I C A L LYSAFE

A P P L I C AT I O N S

When HART field devices are mounted in the hazardous area the HART signal will have to pass throughthe IS interface that is protecting the loop.
MTL offer a range of HART compatible zener barriers and galvanic isolators including:

MTL4000 -Galvanic Isolators - backplane mounting

MTL5000 -Galvanic Isolators for DIN rail mounting

MTL700 & MTL7700 -Zener barriers

The MTL4840 is designed specifically for use with the MTL4000 range of
backplane mounted galvanic isolators. Connections and integration with thissystem is as simple as safe area applications.
Every IS backplane is fitted with the HART connector to give simple connection to
the HART backplane.
MTL4000 Series backplanes provide both mechanical and electrical connections through the backplane.
The advantages they offer include:

Integrated Solutions
incorporate

Benefits seen

Power distribution
Dual Supply connection
Power fail relay

Saves on wiring and installation timeLess chance of wiring error
Higher reliability
Peace of mind

Optional system connector

Saves money, no marshalling panel needed
Easy integration gives less chance of wiring errors

Removable connectors

Easier maintenance

16mm module width to givehigh packing density

Saves money and panel space

Mechanical and electricalconnection

Saves installation timeLess wiring
Less chance of wiring errors

The following range of HART compatible MTL4000 Series isolators are available:

MTL4041A

Single channel input

4-20mA passive HART input

MTL4041B

Single channel input

4-20mA smart transmitter

MTL4041P

Single channel input

4-20mA smart transmitter

MTL4043

Single channel input

4-20mA smart transmitter

MTL4044

Dual channel input

4-20mA smart transmitter

MTL4046

Single channel output

4-20mA smart positioners + LFD

MTL4046C

Single channel output

4-20mA smart positioners

MTL4046P

Single channel output

4-20mA smart positioners + LFD

For information on HART compatible interfaces from our other ranges please contact you local MTL representative.

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HART

CONNECTIONBOARDS

I/O Card TypeGP Applications

IS Applications

16ch Analogue inputs

HCU16

BPM16U- Multi way connector

BPSH16 - fitted with screw connectors
As above

HCU16AIOAs above

8ch Analogue inputs

HCU08

As above3 2 ch A na log ue i np uts/ outp uts

B PS H 1 6 / 3 2

A P P L I C AT I O N S

Some applications only require the use of a few HART field devices in a single location i.e pipe line monitoring. For
these applications MTL can mount the HART multiplexer directly onto the HCU or IS Backplane.

HMU16/32 ...
... for General Purpose applications of up to 32 analogue
in or analogue out loops.

BPMH16U/BPSH16 ...
... for IS applications. The interface modules can be mounted
directly on the backplane alongside the IS isolators.

SIL

R AT E D

M U LT I P L E X E R S

Certified by BASEEFA to IEC61508, the MTL HART multiplexers are approved for use as a safety
related sub system in SIL 3 loops.
THE MTL4840 comes with fully certified reliability data fromBASEEFA, thus the safety system designer no longer has theuncertainty of having to use uncertified devices.

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http://www.cooperindustries.jp/

7

FLEXIBLE SOLUTIONSHCU16AO

Mix of Analogue inputs/outputs

6

MTL HART CONNECTION SYSTEM

16ch Analogue outputs

SPECIALH A R T

GENERICHART

SOLUTIONSHART

SYSTEMH A R TMTLOVERVIEW

The MTL4840 HART connection system provides the link between HART field instruments, the control

The MTL systems strips the HART digital signal

INSTRUMENT
MANAGEMENTS O F T WA R E

from the 4-20mA signal (which passes to theSee page 12 for a full listing of compatible software.

10 way ribbon
cable, max
length 1m - 4m

system and the instrument management software package.

89

benefits

offeredconfiguration

by

and

the

latestpredictive

BPHM64powerfulmaintenance

Designed

software.

connected

4.

The illustration right shows the architecture of

RS485/232
Converter

the system and how it can be built to monitor
either a few devices or up to 7936 devices on

3.

one network.
The

connection

boardsdetailed

areofconnection

units

to

full

BPHM64

the}providessignalconditioning

and

thus

providingasimpleandcost

effective way to customise the backplane forconnectionsforprovide

an

alarm

if

BPM16Urequirements.

Each

BPHM64either

HCU16AO

filters for use in systems where the analogue output
signal interferes with the HART data or may become

Eachfilterpresentsalow

impedance

d.c.

thus

to add series or parallel conditioning to provide theRemovable screw terminal strips are provided for field

HART Connection
Unit 16ch AI

correct impedance characteristics to enable the HARTand system connections in groups of 4 channels.

signals to function. Three screw terminals per channel

20 way ribbon
cables, max 12m
4 - 20mA
HART signal
RS485 Network

are provided to allow through connection for the Tx+,

Connection to the BPHM64 is made via a 20 way

input

ribbonandreturnConnection

to

the

HART data is routed from each isolator via a

BPHM64 is made via a

20-way ribbon cable to the MTL4842 HART

20 way ribbon cable.

multiplexer mounted on the backplane.

Channel

http://www.cooperindustries.jp/

cable

provided.

signals.

tochannelisolation is provided.

MTL-JP@eaton.com

may be linked via expansion cables.

HCU16

16ch backplane

power feed fails.

Cooper Industries Japan K.K.

system

A 16ch analogue input or output interface with options

dual

power feeds and power supply monitoring.
contacts

themaintaining good current drive capability.

I/O connectors and cables.

Relay

meet

HART Connection
Unit 16ch AO

HCU16

mounting posts, giving a solid support for the

has

an

HCU16AO

The interface board is held in place with six

backplanewithunstable with the presence of the HART data signal.

different applications.

Each

user

A 16 channel analogue output interface with HART

routing is designed onto a plug-in interface
board

the

HART Interface
Unit

Upto 31 off 4841 canbe connected to the
HART RS485 network

userwith a common backplane for all input andAllprovidesHART

modules to each comms module, up to 3 BPHM64

1.

types.

interface

ribbon

BPHM64

backplanes, each with four MTL4842 modules fitted,

BPM16Uoutputvia

theSince it is possible to connect a total of 16 MTL4842

See page 12 for further details.

backplaneunitscables,and up to four MTL4842 HART interface modules.

2.

or PLC is used on site.

BPM16Uremoteaccommodates one MTL4841 communications module

integration of the system whatever DCS, ESD

The

connection

to

our

allow

to

be

interface easily configurable and expandable

generic solution, however we offer a wide
varietytoandchanneltochannelisolationis

MTL HART CONNECTION SYSTEM

to a maintenance PC, thus giving access to the

FLEXIBLE SOLUTIONS

control room unscathed) and sends it directly

INSTRUMENT

MANAGEMENTS O F T WA R EPowerful instrument management software is being widely adopted
by the process industry to provide detailed process and maintenanceinformation for a broad range of HART field devices.
The online access to the information contained within HART devices
allows users to diagnose field device troubles before they lead to costly
problems. Software such as AMS, PRM and Cornerstone can capture
and use diagnostic data from HART field instruments via the MTL HART
connection hardware. This allows users to realise the full potential of
their field devices to optimise plant assets, which results in significant
operations improvement and direct maintenance savings.
IMS products provide essential configuration, calibration, monitoringand maintenance history functions for conventional analog (4-20 mA)
and HART protocol compatible smart process instruments and field devices. They deliver powerful tools to meet the need forstandardised instrument maintenance procedures and record keeping mandated by some quality standards and regulatory bodies.
The benefits of utilising these powerful software packages online include:

Reduced commissioning time and costs
Reduced maintenance costs
Reduced documentation
Reduced process downtime
The MTL HART Connection System offers connectivity to a comprehensive range of both...
general instrument management software packages anddedicated software packages for optimising Valve positioner performance and maintenance including...

Software

Manufacturer

4841 Version

AMS Device
Manager v7

Emerson Process Management

MTL4841-AMSv7

Cornerstone

Applied System Technologies

MTL4841

FDM

Honeywell

MTL4841

FieldCare

Endress & Hauser/Metso Automation

MTL4841-AMS with Comms DTM

HART OPC Server

HART Communication Foundation

MTL4841

PACTware

PACTware Consortium

MTL4841-AMS with Comms DTM

PDM

Siemens

MTL4841

PRM

Yokogawa

MTL4841-PRM

SmartVision

ABB

MTL4841-AMS with Comms DTM

SoftTools

Flowserve

MTL4841

ValveLink

Emerson Process Management

MTL4841

ValvueMasoneilan

MTL4841

For software packages that are based on an FDT frame i.e FieldCare, PACTware etc. communication with the MTL HART multiplexer
system requires the MTL Generic Communications DTM. This can be downloaded free of charge from www.mtl-inst.com.

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So

CONNECTIONS

you’ve‘future-proofed’

your

FOR

processplant

PROCESS

I/O

with

I/O

field-mounted

and

smart

field

devices... but are you making the most of your HART?
The high accuracy offered by HART transmitters is used to

the I/O to the controlling host. The controller can accessthe status of each smart field devices, providing greater
diagnostic information on the health and operation of theassociated sensor.
For HART valve positioners, the travel of the control
valve dictated by the 4-20mA drive signal can be monitored by the controller as one of the HART process
variables, allowing the valve position to be displayed on the HMI face plate.
MTL8000 Process I/O ™ system has been designed to be transparent to HART signals, thus allowing the hostcontrol software and any field instruments to communicate directly with each other. In addition MTL8000 systems
provide on line access from a PC to the HART field devices for monitoring device performance. HART devices may
be selected for regular status monitoring and alerts can be issued if the status changes.
The benefits of this approach are:
Reduced commissioning time and costs
Reduced process downtime through status monitoring
Lower loop maintenance costs by using field device diagnostics

For Zone 2 applications the MTL8000 2/x Series modular I/O system provides direct communication with thecontroller via an open bus to an I/O ‘node’ located close to field instruments often in harsh and hazardous
environments. Process I/O uses MTL8000 Series AI and AO with HART modules to regularly scan up to four HART
process and device status variables. These are accessible to the controller via the Modbus or Profibus link and thecontrol system can be configured to use this important data to improve overall process control.
MTL8000 1/1 Series is an innovative remote I/O system targeted at applications which require installation in
Zone 1 hazardous areas and connection to Profibus-DP hosts while maintaining a low installed cost. Analog
modules ‘with HART’ can obtain information from HART instruments of revision 5.0 or later. Each channel cancommunicate with a single HART instrument. The ‘with HART’ modules regularly scan up to four HART process anddevice status variables which are communicated over Profibus-DP for easy integration in the controller.
HART over Profibus functionality enables the HART information to bepassed through the system direct to Asset Management Packages such

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11

FLEXIBLE SOLUTIONStransmitted in digital form from the field instrument through10

MTL HART CONNECTION SYSTEM

its maximum potential when the process variables are

as AMS Device Manager.

H A R T

HART

MTL

HART

I N T E G R AT E D

SOLUTIONSOne of the simplest and most cost effective methods of integrating HART CONNECTIONS into a
traditional point to point Process I/O solution is to install a customised HART connection board in placeof the normal DCS Field Termination Panel.
MTL manufacture a wide range of customised backplanes and HART connection units to replace the standard DCS termination
boards and provide direct pickup of the HART signal.
The MTL HART connection units have all the features of the standard DCS termination board with the addition of the HART
multiway connector which links the board to the HART backplane. Additional features can be added as required.
Channel to channel isolation
Customised field and system connectors
HART signal conditioning
HART filters for use in systems where the analogue output signal either interferes with HART data or
may become unstable with the presence of the HART signal
Variable number of channels
Channel labelling
Whatever the application, MTL have, or can design, an integrated solution to allow simple, flexible and space effective
connection to your control system. Installations worldwide show that users everywhere recognise the quality and reliability of
MTL Integrated Solutions
The range of integrated options is too extensive to list. Please contact your local MTL representative for full details.

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H A R T

CONNECTING HART
When connecting any HART device, be it an instrument, hand held configurator or HART
connection system there are a few rules to follow concerning the impedance of the loop.
Customised

backplanes

and

HCUs

are

designed

with

these

rules

in

mind

makingHART

FLEXIBLE SOLUTIONSANALOGUEINPUTSAs HART devices monitor the HART signal in a voltage form, theimpedance at the monitoring point must be >240 ohms or theamplitude of the signal will be insufficient for the input circuits inthe monitoring device to detect the data. Where the HART signal
is monitored within the loop is not important, as long as there issufficient impedance. This can be at the transmitter or across the
DCS input if it has a 250 ohm input resistor.
Where HART is to be detected on inputs of <240 ohms, either in
IS or safe area applications, a series resistor must be added to theloop to raise the impedance to >240 ohms. Various versions of the
HCU16 are available to add the necessary resistance to the loop.
Custom backplanes for IS applications are already fitted withcomponents to raise the impedance where necessary.

ANALOGUE

OUTPUTSWith analogue outputs there is more to consider. As with inputs, the impedance in the loop for HART to operate mustbe >240 ohms. Very few DCS analogue outputs present a high impedance to the loop. Most analogue outputs
monitor the current in the loop and control a voltage source to obtain the correct current. Voltage sources are
generally low impedance so connecting a HART signal will limit the amplitude of that signal to a point where it canno longer work.
In IS applications, fitting a simple resistor between the
output +ve and the input to the isolator will raise theimpedance up to the required level. In some cases it may
be necessary to add additional filtering between the output
and the isolator if:

1. the HART signal affects the stability of the current signal or:
2. the noise generated by the analogue output interfereswith the HART data.
Talk to MTL for full installation details and advice.

In safe area applications it’s important not to significantly
increase the resistance to the loop. A simple resistive filter
will reduce the available voltage to the loop by up to 5V.
This in many applications will cause the loop to 'run out of
volts'

towards

20mA.

The

filtercircuit

used

on

the

HCU16AO presents a very low series resistance to dc but ahigh impedance to the HART signal. This filter circuit should
be used in these applications and will maintain the full
output drive specification of the control system.

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13

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MTL HART CONNECTION SYSTEM

connections simple and reliable.

12

HART

A P P L I C AT I O N S
MTL HART maintenance systems are utilised in a wide variety of applications around the world. The
system is extremely flexible allowing communication between the host and HART device to be carriedby copper, optical fibre, wireless or ethernet.
One application in the North Sea required HART devices situated on a number of unmanned platforms to be connected to
the Instrument Management Software system running on a nearby manned platform.
An underground fibre optic network had been installed to connect the various platforms and this was utilised to carry the HART
signals. On each of the unmanned platforms the HART devices were connected to a standard MTL HART Maintenance System.
The RS485 connection from each of the HART backplanes was then connected to a Guard Data Fibre Optic Node Tap Modem.

HART devices on the manned platform were connected via the
HART backplanes to the copper RS485 network. All HART
devicesonmannedandunmanned

platforms

were

now

connected to the serial port on one PC running Cornerstone
software.

This

configured

without

enabledthealldevices

need

for

to

an

be

monitored

engineer

to

and

visit

the

unmanned platform.
Similarly on large plants where HART devices may be scatteredover a very large area, the use of a copper RS485 network is
impractical. At a recent installation in Kazakhstan there was arequirement to connect up to 20,000 HART devices to a
Predictive Maintenance software package.
The site had been designed to include a full Ethernet network,
and

the

brief

from

the

contractor

was

to

offer

a

HART

maintenance system which would run over the Ethernet LAN.
AMS Device Manager from Emerson has the ability to run on
an Ethernet network allowing secure access from a number ofclient stations.

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H A R T

The site will eventually have 20 operating areas and cover approx 400 square kilometers. The MTL HART
Maintenance System will link all the HART devices from each of these areas into a single database running on
the AMS server, giving the ability to check a device status, configure, re-range and perform diagnostics fromSTROKEVA LV ETESTING

WITH

HART

An increasingly popular application for HART is for the partial stroke testing of Emergency
Shut Down (ESD) valves. Unlike normal process valves which are continuously moving, ESD
valves can stay in one position for a long time. Therefore they can become stuck and may

not operate when needed.
Connecting a SMART positioner such as the DVC6000 to the MTL HART Maintenance System allows the software to
perform a Partial Stroke test on the ESD valve without the need for a disruptive process shutdown.

N O M E N C L AT U R E :ITEM 1 - Safety system DO card
ITEM 2 - Repeater power supply barrier - MTL5042
ITEM 3 - MTL HCU16-P250 HART Connection Unit (with 250 ohm parallel resistor)
ITEM 4 - MTL BPHM64 HART backplane with MTL4842 HART interface module and MTL4841 HART

communication module
ITEM 5 - RS485/232 converter - Westermo MA45
ITEM 6 - Max 10m signal cable
ITEM 7 - Instrument Management Software workstation
ITEM A - Cable connection from MTL isolator to MTL HART Connection Unit

The system can be used for intrinsically safe, Exd or safe area applications. The diagram above shows an IS
application with a MTL5042 IS isolator connected between the Safety System DO card, the SMART positioner andthe HART maintenance system. For Exd or safe area applications the Isolator can be removed from the circuit.

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FLEXIBLE SOLUTIONSPA RT I A L

15

MTL HART CONNECTION SYSTEM

the PC without going into the field.

14

Cooper Industries Japan K.K., 7th Floor Jowa Nogizaka Building, 8-11-37 Akasaka,Minato-ku, Tokyo 107-0052
TEL . +81(0)3 6434 7890 FAX. + 81(0)3 6434 7871 EMAIL M TL- J P@ eaton.c om