Harmonized Automation System – Dependable Open

Openness and reliabil ityfoster harmonization.

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3

Discover Harmonas-DEOTM, the proven

automation system from Yamatake.

Based on open architecture and standard

protocols, it offers the powerful

functionality and robust reliability of the

best distributed control systems (DCS).

■ Dependable OpenArchitecture

■ Information on Demand

■ Automation Suite

■ Cost-effective Solutions

■ Scalability

❑ Dependable Open Architecture In today’s global market, the demand is

growing for worldwide standards, including

preferences for open operating systems

and commodity components. At the same

time, customer requirements are diversify-

ing. Harmonas-DEO was conceived to

solve this puzzle: it offers the highest level

of flexibility as well as an open architecture

(Microsoft Windows and Ethernet). This

openness helps to integrate design,

engineering and operations with a single,

powerful human-machine interface (HMI).

Connectivity is improved, facilitating

access to Windows application data files,

databases, and documentation that has

been developed on other computers.

Engineering and troubleshooting can be

performed from remote locations using the

Internet as part of a secure networking

strategy. It’s no wonder that Harmonas-

DEO can outperform a conventional DCS

in terms of flexibility, connectivity, and

openness.

On top of these qualities, Harmonas-DEO

ensures very high reliability for process con-

trol. To ensure full customer satisfaction, it

incorporates several technologies that

enhance overall dependability. In addition

to Ethernet redundancy, node redundancy

and failover systems, EDAC* is employed

for memory integrity in individual parts.

Naturally there is also redundancy for the

high-reliability controllers, including the

CPU, power source, network and I/O

modules. In addition, system reliability has

been further raised by enhancing

maintainability, operability and safety. The

result is an open automation system that

offers unprecedented dependability:

Harmonas-DEO.*EDAC (Error Detection and Correction) ensures automatic 1-bit error correction and 2-bit error detection.

❑ Information on Demand

The architecture of Harmonas-DEO is

designed to harmonize everything from

the field level up to production control,

bringing it all together around an open

network. Employing integrating drivers,

all of the data from intelligent Fieldbus

instruments and controllers,

programmable logic controllers (PLCs)

and sub-systems are consolidated in an

information processing device. The

human interface and history applications

exchange data using the same

protocols. Since control management

has been built from such modules as

the Fieldbus instruments base, the

control system base and the logic

controller base, it is easy to add new

functions to the system. Moreover, the

data consolidated in the Harmonas-DEO

system can be accessed from anywhere

over open networks. Staff at every level

– from on-site engineers to management

executives – can benefit from a real-time

picture of operational status.

❑ Automation SuiteHarmonas-DEO offers a wide range of

the solution software required for plant

automation. At the heart of this

Automation Suite are such components

as the Human Interface Engine, History

Engine, Batch Engine and Control Engine.

On top of these are various solution

templates provided in the form of client

software. For example, the Human

Interface Engine is accessed via analytic

software and a multipurpose software

interface, while the Control Engine is

furnished with a range of control logic

parts. Turning to field communications, in

order to exchange information with the

PLC network and Fieldbus instruments,

there is a data exchange system that

complies with standard communications

protocols. Naturally, connections with the

host system are made using standard

protocols and this ensures operational

support. The Automation Suite also

includes a large number of application

enablers for the host system.

❑ Cost-effective SolutionsDCS users face new challenges that

demand expertise and innovative

technologies. And investment is essential

to improve productivity and efficiency, but

while new equipment may be too costly,

Harmonas-DEO can provide the

functionality, reliability and scalability of a

conventional DCS – but for far less

investment. Harmonas-DEO offers excellent

maintainability: individual modules can be

replaced without incurring downtime, and

system diagnosis can be performed

remotely via the Internet. Moreover, network

connections are made via common

components and topologies that facilitate

expansion without depending on

proprietary systems.

Harmonas-DEO is the ideal choice no

matter what the scale of your operations –

from the largest industrial plants to small

facilities involving nothing more than PLCs

and simple loops, for which a conventional

DCS is not a viable option. It offers the

benefits of the latest supervisory

technologies to improve plant and factory

productivity via highly reliable control.

Through integration of process control and

data management with an affordable PC-

based system, Harmonas-DEO can perform

as well if not better than a conventional DCS.

❑ ScalabilityHarmonas-DEO combines the

advantages of both PLC SCADA

(Supervisory Control And Data

Acquisition) and DCS packages, thus

enabling continuous, batch and discrete

process control. Since Windows,

Ethernet and other standard and/or open

technologies have been used for the

backbone of the system, Harmonas-DEO

can be easily adapted for information

sharing. It also has improved links with

general-purpose applications, using

DCOM/Active-X/.net framework/XML and

OPC for interfacing executive software.

What this means is that there is greater

portability for applications that the

customer has developed; it is now easy

to make adjustments when the platform

needs to be upgraded.

Harmonas-DEO ensures seamless

connections to the host executive

system, and application software is not

dependent on the scale of the system.

Accordingly, the customer can

accommodate, using the same system,

everything from partial optimization of

manufacturing facilities to the complete

upgrading of a large-scale production

executive system. The system can

always be expanded at a later date.

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OperationAnywhere

■ Hardware: Standard Components

■ Software:Windows OS

■ Operation: Focus on HMI

■ Engineering: Object-oriented

44 5

❑ Hardware: Standard Components

Harmonas-DEO is effectively a PC-

based DCS in which design priority has

been placed on the human-machine

interface (HMI). Instead of producing

proprietary hardware for operation and

control, Yamatake makes use of familiar

commodity components – such as

computers, monitors and keyboards.

This approach offers options for lower

cost, both at time of installation and in

terms of life-cycle ownership.

For example, the open architecture

means faster upgrades. When installing

a more powerful CPU, Harmonas-DEO

customers can immediately utilize it,

rather then waiting for their DCS

supplier to adopt it. This is increasingly

important, considering the accelerated

development cycles of computer

hardware. Using off-the-shelf

components does not compromise on

dependability, because at the controller

level, Harmonas-DEO offers high-

reliability, high-availability hardware

circuitry and processing design.

❑ Software: Windows OS

The robust client-server software that is

now available for process control

system runs on Windows, a true

multitasking operating system. With

built-in Ethernet also now functioning at

the controller level, Harmonas-DEO

joins seamlessly to existing networks,

and with minimal additional investment.

Thanks to the use of standard

architecture and Windows, off-the-shelf

applications can be used without

modification; examples include Excel

for reporting and Word for system

documentation. Developing new

programs is greatly simplified with

Windows-based development software.

Of course, security is an important

consideration for any network control

system, especially with the trend

toward Internet-based remote access,

but thanks to the open architecture of

Harmonas-DEO it is easy to install the

latest security measures as soon as

they become available.

❑ Operation: Focus on HMI

Yamatake places high priority on the

human-machine interface, which is a

key factor in determining the

performance and reliability of a control

system. Efficient GUI (Graphical User

Interface) displays, such as those for

groups and trends, are all equipped as

standard. Familiar point and click

mouse operations, the optional touch

screen and dedicated operator

keyboard all contribute to superb ease

of operation.

Furthermore, Harmonas-DEO

demonstrates a new, global approach

to operations – “OperationAnywhere™” – that frees

the customer from restrictions of place and time. A

full-fledged DCS environment can be realized using a

web-based approach, which may well make the

conventional control room obsolete.

At the same time, Yamatake is committed to

enhancing the efficiency of on-site operations,

realizing improved safety and better staff support so

that all necessary work can be carried out by small

teams on site.

❑ Engineering: Object-oriented

The combination of a graphical interface with an

object-oriented approach to development gives

Harmonas-DEO a simplicity that contrasts with the

complexity involved in building continuous, batch

and discrete control strategies. This is made

possible only because of a unique, real-time

coherent and cooperative system engineering

environment (RTC). Engineers can create and

modify strategies with click & drop simplicity from an

icon-based floating menu bar. As well as enjoying

access to a large library of pre-built function parts

and other shared resources, developers can also

perform application simulations via function

simulator without engaging actual I/O. Smart

debugging further speeds development.

All of these factors – hardware, software, operation

and engineering – combine to realize a complete

system that assures DCS-level functionality for only

a fraction of the cost.

Control Design Graphics

RTC Engineering Tools

Supervisory Station (DOSS)

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PREXION Client Custom Graphics Group Display

66 7

• Process Controller III (DOPC III)

• Distributed I/O Module

• PLC Linker II (DOPL II)

• General Purpose Linker II (DGPL II)

Ethernet/PLC Network

• Fieldbus Controller (DOFC)

Control LAN (Ethernet)

• I/O

• Fieldbus Devices

Information LAN (Ethernet)

• Supervisory Station (DOSS)with Software Simulator • History Station (DOHS™)

• Business PC

• OPC Interface (DOGS)

❑ Harmonas-DEO System Architecture

In essence Harmonas-DEO consists of a Control

LAN (Ethernet) connecting a Supervisory Station

(DOSS), Process Controller (DOPC™ III), Open

Database (DOHS™) and Fieldbus Controller

(DOFC). This architecture can be expanded to meet

the needs of large-scale operations.

❑ Process Operation

The Supervisory Station (DOSS) is the core of

Harmonas-DEO. It is an optimized HMI that

provides accurate information in an easy-to-

understand form to the engineers monitoring

process data, their supervisors and the

management.

Process Operation Engine

The tools that supply operational information,

both for the plant and for the system, are all

supplied in one application package. The

Process Operation Display, which is principally

graphical, offers a standard monitor display. The

System Monitoring Display is a status/diagnostic

display for system malfunctions, failures, etc.,

enabling the engineer to check on the status of

system operations.

Harmonas-DEO System Architecture

Data Distribution Engine

Monitoring of such process events as alarms and

messages is provided as part of the standard

application package. Moreover, using the standard

protocols of DCOM/ActiveX, it is possible to send

event information to remote nodes.

• Web Based Supervisory Station/PREXION Client/Data Analysis

• Web Based Supervisory Station/PREXION Client/Data Analysis

• Web Based Supervisory Station/PREXION Client/Data Analysis

• I/O

HI Fieldbus

• PLC sub-system

• Third party sub-system

• MODBUS-TCP slave devices

• DCS

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❑ Historian

To facilitate smooth process control, all information

required for evaluating plant status is collected

automatically for long-term storage. Included are the

operational audit trail required for analyzing

production quality and gauging production efficiency,

the production log needed for tracking, and the

operation management log. There are 3 types of

History Engine, and the PREXION™ Client makes it

possible to display the three types of data formatted

in a variety of ways using the DOSS or an office PC.

Continuous History Engine

This assures periodic gathering of process data

for continuous, long-term storage, offering a data

source for production log management.

Event-driven History Engine

Using process/production events, this brings

together and stores necessary data sets by

process/production event, offering another data

source for production log management.

Journal History Engine

This ensures long-term event history storage for

process/system alarms, messages and actions

taken by staff, offering a data source for

performing analyses of how the facility is

operating.

❑ Process Controller

Playing a crucial role in ensuring the reliable

operation of Harmonas-DEO is the DOPC III

process controller, which offers SOE support.

Unbeatable performance is assured thanks to its

high capacity (max. 640 regulatory loops, I/O

connections for 120 units) and high speed (max.

100msec.). In addition to regulatory point

configuration, logic block base configuration is

also available. For installing and debugging, a

software simulator allows multiple virtual

controllers to be evaluated. And, once running,

the 2-out-of-3 redundancy architecture of

Harmonas-DEO ensures that even if one

controller fails, the remaining two will keep the

system operating so that downtime is minimized.

❑ Digital Field Integration

The industry’s standard, FOUNDATION Fieldbus™,

is integrated into the Harmonas-DEO system by

the DOFC Fieldbus Controller. Visualizing the

status of plant equipment using various types of

real-time information from field sensors and

actuators creates an information environment

that can directly contribute to better production

control, plant device management, and business

management.

❑ Sub-system Integration

There are two methods available for sub-system

integration; one uses the controllers’ serial

communications modules, and the other

employs DOPL™ II/DGPL II. The use of serial

communications modules is recommended for

feeding the controller with small amounts of data

88

Process Controller III (DOPC III)

– for example, control-level integration for

initiating a controller’s sequence control with a

trigger signal supplied by a sequencer. Of

course, you can connect the measuring sub-

system of an electronic weighing device.

Alternatively, DOPL II/DGPL II provides a

gateway function to the PLC network or

Ethernet; once PLCs and other devices are

integrated with the DOPC III, PLC data (from

coils, resistors, etc.) can be treated as

Harmonas-DEO tags, allowing peer-to-peer

communication between DOPC III and third-

party subsystems.

❑ Asset Management

The monitoring and management of digital field

devices is possible using Supervisory Stations for

Harmonas-DEO system operation, engineering

and maintenance. In addition to providing device

status monitoring, malfunction alerts and journal

recording, such a system can be used to tune

devices and change calibration parameters. With

the history of individual device operation,

calibration, and replacement at hand, and with

the ability to list devices by function, the efficient

maintenance and management of devices can

be achieved.

❑ Versatility

Harmonas-DEO can be configured to serve in a

wide range of applications, whether small- or

large-scale.

■ Pharmaceuticals

■ Fine chemicals

■ Food & beverages

■ Metals & minerals

■ Semiconductors (clean room control)

■ Oil & gas plants

■ Fuel supply systems

■ Utility & boiler control

■ Garbage incineration

■ District cooling systems

■ Water/wastewater treatment

■ Automated assembly operations

■ Automobile & related plants

Control Valve Diagnosis and Maintenance Support

Asset Management

Maintenance OperationEngineering

ConfigurationSetting of Parameters

Operating StatusAlarm Monitoring

Device DiagnosisCalibration

Maintenance

Field Devices

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❑ Global Presence, Global Support

For over 100 years, the azbil Group has pioneered

new technologies in measurement and control,

providing innovative solutions in the field of both

process automation and factory automation. In

addition to control management systems, Yamatake

is renowned for its smart field instruments, such as

control valves, flowmeters and transmitters. Such

leading-edge technologies work together to boost

productivity, safety, and convenience while reducing

energy use and running costs. Yamatake has the

expertise and experience to offer comprehensive

process automation systems tailored to your

requirements.

The azbil Group combines global presence with local

know-how to offer unsurpassed service to our

customers worldwide. Our business network gives us

the ability to conduct sales, engineering, consulting

and support activities wherever there is a need. You

will find our representatives close at hand, always

ready and willing to provide support, wherever and

whenever you want it. The integrity that underlines the

Yamatake name is your guarantee of satisfaction.

Whatever the size or nature of your business, contact

us and find out what Harmonas-DEO can offer. We

can help you achieve new levels of efficiency and

reliability that will allow you to adapt and grow your

business. For a partnership you can rely on, choose

Yamatake.

• Harmonas-DEO, OperationAnywhere, PREXION, DOPC, DOHS, and DOPL aretrademarks of Yamatake Corporation in Japan.

• FOUNDATION Fieldbus is a registered trademark of the Fieldbus Foundation.

• Windows is a registered trademark of Microsoft Corporation in the United States andother countries.

• Ethernet is a registered trademark of XEROX Corporation.

• MELSEC is a registered trademark of Mitsubishi Electric Corporation, Ltd.

• Other product names, model nos., and company names may be trademarks of therespective company.

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