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Siemens SIMATIC BATCH Operating Manual

Process control system pcs 7.
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SIMATIC
Process Control System PCS 7
SIMATIC BATCH V8.2
Operating Manual
02/2016
A5E35958174-AA
Preface
Security information
Product introduction and
installation
What's new?
Technological basics
complying with ISA-88.01
Introduction to SIMATIC
BATCH
Engineering
Rational engineering
BATCH Control Center
BATCH Recipe Editor
BATCH OS controls
Recommended procedure
Appendix
Context help references
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   Summary of Contents for Siemens SIMATIC BATCH

  • Page 1 Preface Security information Product introduction and installation SIMATIC What's new? Process Control System PCS 7 SIMATIC BATCH V8.2 Technological basics complying with ISA-88.01 Introduction to SIMATIC BATCH Operating Manual Engineering Rational engineering BATCH Control Center BATCH Recipe Editor BATCH OS controls...
  • Page 2 Note the following: WARNING Siemens products may only be used for the applications described in the catalog and in the relevant technical documentation. If products and components from other manufacturers are used, these must be recommended or approved by Siemens. Proper transport, storage, installation, assembly, commissioning, operation and maintenance are required to ensure that the products operate safely and without any problems.
  • Page 3 3.4.5 Recipe processing in runtime....................48 Possible configurations......................48 3.5.1 System software architecture....................48 3.5.2 Distribution of the SIMATIC program packages..............50 3.5.3 Client / server architecture of SIMATIC BATCH..............51 3.5.4 Interface to MES/ERP......................53 3.5.5 Redundancy...........................54 3.5.5.1 Introduction..........................54 3.5.5.2 Example configuration - Fault-tolerant Batch Control............55 3.5.5.3...
  • Page 4 Table of contents Security aspects........................75 Configuring the security settings on the SIMATIC BATCH server.........77 Installation..........................79 3.9.1 Delivery type of SIMATIC BATCH..................79 3.9.2 SIMATIC BATCH Basic......................80 3.9.3 Requirements for installation....................81 3.9.4 Readme file with the latest information..................82 3.9.5 Authorizations........................83 3.9.6 Installing the components of SIMATIC BATCH..............86 3.10...
  • Page 5 ANSI/ISA-88.01 models ......................112 5.9.1 Overview of the ISA-88 standard models................112 5.9.2 Procedural control model.....................114 5.9.3 Physical model........................115 5.9.4 Process model........................117 Introduction to SIMATIC BATCH......................119 Getting started........................119 Process cell configuration....................120 Permission management.....................120 Recipe creation........................120 Process mode........................120 Engineering..............................121 Basic engineering for PCS 7....................122 7.1.1 Using the PCS 7 Wizard......................123...
  • Page 6 Multiproject engineering ......................224 8.3.1 General information......................224 8.3.2 Importing remote process cells....................225 8.3.3 Preparing ES data for SIMATIC BATCH................226 8.3.4 PCS 7 - change project type....................226 Central multiproject engineering..................227 8.4.1 Flow chart: Engineering procedure for a multiproject............227 Distributed multiproject engineering ..................230 SIMATIC BATCH V8.2...
  • Page 7 8.5.5 Step 4: Restoring and inserting project(s) in the CMP............236 8.5.6 Errors sources in distributed multiproject engineering with SIMATIC BATCH.....238 Operation of SIMATIC BATCH with more than one PCS 7 OS...........240 BATCH Control Center..........................243 Starting and operating......................243 9.1.1 Information on the BATCH Launch Coordinator..............243 9.1.2...
  • Page 8 9.6.2.1 How to configure batches.....................348 9.6.2.2 Creating a new production order..................350 9.6.2.3 Assigning batches to a production order................351 9.6.2.4 Displaying the properties of a production order..............353 9.6.2.5 Adding batches to a production order..................354 SIMATIC BATCH V8.2 Operating Manual, 02/2016, A5E35958174-AA...
  • Page 9 Commands for controlling batches..................414 9.8.5.2 Operator commands for recipe steps...................416 9.8.5.3 Manual jump.........................420 9.8.5.4 Time out when transmitting operator commands..............422 9.8.5.5 Entering comments on a running batch................422 9.8.5.6 Displaying operator dialogs during runtime................423 SIMATIC BATCH V8.2 Operating Manual, 02/2016, A5E35958174-AA...
  • Page 10 Requirements for working with the BATCH Recipe Editor...........491 10.2.3 User interface and operation....................492 10.2.3.1 Layout of the main window (Recipe Editor)................492 10.2.3.2 Possibilities for adapting the edit window................495 10.2.3.3 Project and user settings......................496 SIMATIC BATCH V8.2 Operating Manual, 02/2016, A5E35958174-AA...
  • Page 11 Supplemental information about online assignment of a unit for flat recipes.......532 10.4.5 Inserting and labeling recipe elements.................532 10.4.5.1 Recipe procedural element (Insert menu)................532 10.4.5.2 Recipe phase/operation (Insert menu).................533 10.4.5.3 Library reference (Insert menu)....................534 10.4.5.4 Operator instruction (Insert menu)..................534 SIMATIC BATCH V8.2 Operating Manual, 02/2016, A5E35958174-AA...
  • Page 12 Displaying two BATCH process cells in one process picture ..........592 11.2.6 Simple batch creation......................596 11.3 Operations in process mode ....................597 11.3.1 Control: SIMATIC BATCH OS Master .................597 11.3.2 Control: SIMATIC BATCH OS Process Cell................600 11.3.3 Control: SIMATIC BATCH OS Allocation ................605 SIMATIC BATCH V8.2...
  • Page 13 Table of contents 11.3.4 Control: SIMATIC BATCH OS Properties ................610 11.3.5 Control: SIMATIC BATCH OS Batch Creation..............619 11.3.6 Control: SIMATIC BATCH OS Monitor.................621 11.4 Applications in process mode....................624 11.4.1 Display actual quantity......................624 11.4.2 Showing tooltips........................625 11.4.3 Color text boxes........................625 11.4.4 User settings........................626...
  • Page 14 ToolbarVisible........................653 11.5.3.9 ParametersListColumnOrderAndVisibility................653 11.5.3.10 ParametersListColumnWidth....................654 11.5.3.11 ParametersListColumnResizeEnabled................655 11.5.3.12 ParametersListColumnFilterVisible..................655 11.5.3.13 AllocationsListColumnWidth....................656 11.5.3.14 AllocationsListColumnOrderAndVisibility................656 11.5.3.15 AllocationsListColumnResizeEnabled..................656 11.5.3.16 AllocationsListColumnFilterVisible..................657 11.5.4 SIMATIC BATCH OS Batch Creation..................657 11.5.4.1 CommunicationChannel.......................657 11.5.4.2 OrderCategoryName......................657 11.5.4.3 OrderName..........................657 11.5.4.4 FilterRecipeEnabled......................657 11.5.4.5 FilterFormulaEnabled......................658 11.5.4.6 FilterUnitName........................658 11.5.4.7 FilterClassName........................658 11.5.4.8 FilterGroupName........................658 11.5.4.9 FilterProductName.......................658...
  • Page 15 11.5.6.10 ToolbarOrderAndVisibility....................671 11.5.6.11 ToolbarVisible........................672 Recommended procedure........................673 12.1 How do I restore a SIMATIC BATCH server to its original state?........673 12.2 What should I know about the BATCH project database?...........674 12.3 How does SIMATIC BATCH stop automatically on specific events?........674 12.4 What effects do changes to SFC types have on SIMATIC BATCH?........676...
  • Page 16 "Product" tab (Recipe procedure properties)...............787 14.1.6 BCC Formula Properties dialog box..................789 14.1.6.1 "General" tab (Formula property)..................789 14.1.6.2 "Product" tab (formula property)...................789 14.1.7 BCC Order (Batch) Properties dialog box................790 14.1.7.1 "Add batch" dialog box (creating batches)................790 SIMATIC BATCH V8.2 Operating Manual, 02/2016, A5E35958174-AA...
  • Page 17 "General" tab (jump properties)....................823 14.1.10.10 "General" tab (Command step properties)................824 14.1.10.11 "General" tab (RUP properties)....................825 14.1.10.12 "General" tab........................826 14.1.10.13 "Instruction" tab (operator instruction properties)..............827 14.1.10.14 "Condition" tab (transition properties)..................829 14.1.10.15 "Allocation list" tab (library reference properties)..............833 SIMATIC BATCH V8.2 Operating Manual, 02/2016, A5E35958174-AA...
  • Page 18 "View permissions of the logged in user" tab...............838 14.1.11.9 "Permissions management" dialog..................838 14.1.11.10 "Configure roles" dialog box....................841 14.1.11.11 Dialog box "SIMATIC BATCH: Sign"..................841 14.1.11.12 "Select unit" dialog box......................843 14.1.11.13 Create SQL Server database dialog box................844 14.1.11.14 "Export" dialog box.......................844 14.1.11.15 Select PCell, Recipe, Library dialog..................845 14.1.11.16 "Save as..."...
  • Page 19 14.1.12.58 "OS objects" tab........................945 14.1.12.59 "Project languages" tab......................946 14.1.12.60 "System characteristics" tab....................946 14.1.12.61 "Process cells" tab.......................947 14.1.12.62 "Chart folder" tab........................949 14.1.12.63 "Connections" tab.........................951 14.1.12.64 "External process cells" selection..................953 14.1.12.65 "Process cell" selection......................954 14.1.12.66 Control strategies of......................955 SIMATIC BATCH V8.2 Operating Manual, 02/2016, A5E35958174-AA...
  • Page 20 Table of contents 14.1.12.67 Parameter groups of the batch process cell.................956 14.1.12.68 "Batch types" selection......................956 14.1.12.69 "Batch instances" selection....................957 14.1.13 SIMATIC BATCH configuration dialog (Pcell Control Center)..........959 14.1.13.1 "Batch types" selection, PCC....................959 14.1.13.2 "Data types (General)" selection, PCC................962 14.1.13.3 "Data type" selection, PCC....................965 14.1.13.4...
  • Page 21 14.2.2.53 Delete order category (Edit menu)..................1061 14.2.2.54 Delete library operation (Edit menu)..................1061 14.2.2.55 Delete batch (Edit menu)....................1061 14.2.2.56 Delete formula category (Edit menu).................1061 14.2.2.57 Delete formula (Edit menu)....................1062 14.2.2.58 Delete quality (Edit menu)....................1062 SIMATIC BATCH V8.2 Operating Manual, 02/2016, A5E35958174-AA...
  • Page 22 Set order of batches (Planning menu)................1074 14.2.4.6 Production order list (Planning menu)................1075 14.2.4.7 Unit allocation (Planning menu)..................1075 14.2.5 Options menu........................1075 14.2.5.1 Log off (Options menu)......................1075 14.2.5.2 Permission management (Options menu)................1075 14.2.5.3 Roles management (Options menu)..................1075 SIMATIC BATCH V8.2 Operating Manual, 02/2016, A5E35958174-AA...
  • Page 23 New > Library element: Recipe operation (Recipe menu)..........1093 14.3.1.4 New > Library element: Substructure (Recipe menu)............1093 14.3.1.5 Open... (Recipe menu).......................1093 14.3.1.6 Open library object... (Recipe menu).................1093 14.3.1.7 Close (Recipe menu)......................1094 14.3.1.8 Save (Recipe menu)......................1094 14.3.1.9 Save as... (Recipe menu)....................1094 SIMATIC BATCH V8.2 Operating Manual, 02/2016, A5E35958174-AA...
  • Page 24 Logged-on user........................1105 14.4.3 Print preview........................1105 14.4.4 Exit.............................1105 14.5 BCC and RE Edit menu.....................1106 14.5.1 Cut (Edit menu)........................1106 14.5.2 Copy (Edit menu).......................1106 14.5.3 Insert (Edit menu).......................1107 14.5.4 Select all (Edit menu)......................1107 14.5.5 "Find" dialog........................1108 SIMATIC BATCH V8.2 Operating Manual, 02/2016, A5E35958174-AA...
  • Page 25 14.10.23 Current job being processed....................1121 14.10.24 Cancel queued jobs......................1121 14.11 Transition wizard........................1122 14.11.1 "General" transition condition (1/5) dialog box..............1122 14.11.2 "Operand 1/2" parameter (2/5) dialog box.................1122 14.11.3 "Operand1/2" dialog box process tag (2/5)................1123 SIMATIC BATCH V8.2 Operating Manual, 02/2016, A5E35958174-AA...
  • Page 26 Properties (Edit menu).......................1127 14.12.10 Export (Edit menu)......................1127 14.12.11 Find (Edit menu).........................1127 14.12.12 Copy the object (Edit menu)....................1127 14.12.13 Delete (Edit menu)......................1127 14.12.14 New (Edit menu)........................1127 14.12.15 Open (Edit menu).......................1127 14.12.16 Renaming ..........................1127 Glossary..............................1129 Index...............................1141 SIMATIC BATCH V8.2 Operating Manual, 02/2016, A5E35958174-AA...
  • Page 27 ● What is SIMATIC BATCH? ● What are the software components that make up SIMATIC BATCH? ● Which areas of application is SIMATIC BATCH suitable for in the SIMATIC environment? ● How is SIMATIC BATCH planned, configured and operated in the PCS 7 environment? ●...
  • Page 28 Documentation relating to SIMATIC BATCH The following table shows the documentation relating to SIMATIC BATCH at a glance. You can find the documentation in PDF format after installation of SIMATIC BATCH under Start > SIMATIC > Documentation > Language selection.
  • Page 29 Siemens recommends strongly that you regularly check for product updates. For the secure operation of Siemens products and solutions, it is necessary to take suitable preventive action (e.g. cell protection concept) and integrate each component into a holistic, state-of-the-art industrial security concept.
  • Page 30 Security information SIMATIC BATCH V8.2 Operating Manual, 02/2016, A5E35958174-AA...
  • Page 31 Possible applications of SIMATIC BATCH SIMATIC BATCH is suitable for batch processes of any complexity. It provides simple support for batch applications ranging from small to extremely large. The outstanding features of SIMATIC BATCH are as follows: ●...
  • Page 32 BATCH interface blocks Introduction SIMATIC BATCH uses the new functionality of the SFC types in the engineering system to define operation and phase types. As an alternative, SIMATIC BATCH continues to provide special interface blocks as the communications interface to the processing programs on the automation system.
  • Page 33 Product introduction and installation 3.3 Components of SIMATIC BATCH Functions Using the BATCH interface blocks along with SIMATIC BATCH, makes the following functions available: ● Controlling the running of the process: The IEPH/IEOP blocks are used for this purpose. These provide the commands (for example start or hold) of the recipe control steps from the batch control to the processing blocks (for example: SFC_CTL or user blocks).
  • Page 34 Software components in the SIMATIC Manager The BATCH configuration dialog is opened in the SIMATIC Manager using the Options > SIMATIC BATCH menu. As an alternative, you can also open it using the "SIMATIC BATCH" shortcut menu of any object in the SIMATIC Manager.
  • Page 35 Starting the BatchCC The BATCH Launch Coordinator creates the preconditions for starting BatchCC. BatchCC cannot be connected to the database of the loaded batch process cell until SIMATIC BATCH displays the status "running". BatchCC will display a corresponding information dialog on startup until SIMATIC BATCH is ready.
  • Page 36 3.3.4 BATCH control server Definition The BATCH Control Server is a component of SIMATIC BATCH. The BATCH Control Server handles communication with the process and controls and monitors execution of the current batches. The BATCH Control Server does not have its own user interface. The BATCH Control Server is started using the Launch Coordinator on the BATCH server or, in a redundant system, on both BATCH servers.
  • Page 37 Generating the batch report After a batch is started, the batch data is saved in the online data storage of SIMATIC BATCH. In order to display and/or print out batch data, a print preview window and the batch report are available.
  • Page 38 Batch Control Center (BatchCC) Definition The BATCH Control Center (BatchCC) is the central component in SIMATIC BATCH for batch planning and batch control. The BATCH Control Center manages all the data relevant to SIMATIC BATCH. This means all BatchCC data can also be displayed in reports.
  • Page 39 Product introduction and installation 3.3 Components of SIMATIC BATCH Functions With the BATCH Control Center, you can do the following: ● Read in the process cell data from the basic control ● Specify the user permissions for all functions of BATCH ●...
  • Page 40 BATCH Recipe Editor Definition The BATCH Recipe Editor (RE) is part of SIMATIC BATCH and provides you with a graphical user interface for creating and modifying master recipes and library operations. Recipe creation is based on the BATCH objects from the BATCH process cell configuration in the engineering system (ES) of SIMATIC PCS 7, for example, by ISA-88 type definition of the process cell, units and equipment modules.
  • Page 41 BATCH OS controls OLE custom controls (OCX) for SIMATIC BATCH We provide you with SIMATIC BATCH OS controls for operating and monitoring batch processes on a PCS 7 OS client. In a template screen that is available after installing SIMATIC BATCH, you will find all the BATCH OS controls for operator control and monitoring of a Batch process cell.
  • Page 42 Which functions are not supported in the AS-based operating mode? ● Flat recipes are not available. ● The "online structure changes (OSC)" from SIMATIC BATCH version 7.1 SP1 with which structure changes could be made to the recipe logic during the running of a batch is not possible in AS-based mode.
  • Page 43 Product introduction and installation 3.4 Operating modes in SIMATIC BATCH Memory allocations Description Memory required in KB Dynamic part. Occupied by settings in per unit the BATCH configuration dialog. per recipe unit procedure (RUP) The following table shows the runtimes of the most important recipe structures that result from the processing of a recipe unit procedure and are required to calculate a cycle time.
  • Page 44 3.4 Operating modes in SIMATIC BATCH Characteristics of SIMATIC BATCH When compared with previous versions of SIMATIC BATCH, this version allows faster batch control. The following features characterize SIMATIC BATCH in AS-based mode: ● Shifting of the recipe logic to the automation system (BATCH block UNIT_PLC) ●...
  • Page 45 Product introduction and installation 3.4 Operating modes in SIMATIC BATCH separate communication channel (S7DOS). The result is shorter and simplified communication paths. Communication path between BATCH control server and automation system The new concept in AS-based mode uses a direct communication channel for faster and more stable data exchange between the BATCH control server and the automation system.
  • Page 46 Operator control of the process on a PCS 7 OS using BATCH OS controls To create and operate batches including visualization of the control recipes of currently running batches, SIMATIC BATCH provides a template screen on a PCS 7 OS with all the necessary BATCH OS controls.
  • Page 47 Recipe levels and sequence of a recipe Recipe levels and recipe logic In AS-based mode, SIMATIC BATCH allows a reduction and a reproducibility of step change times with the following recipe control runtime functions that have been shifted to the automation system: ●...
  • Page 48 The following figure shows the hardware components involved in the system (colored gray) that are interconnected via bus systems (colored brown) Software program packages or parts of software program packages (colored white) of SIMATIC BATCH are shown for each SIMATIC BATCH V8.2...
  • Page 49 Product introduction and installation 3.5 Possible configurations hardware component involved in the process. Blue lines with directional arrows roughly show the interaction of the components of the software packages. SIMATIC BATCH V8.2 Operating Manual, 02/2016, A5E35958174-AA...
  • Page 50 PC as OS server, single PC as RC server, single PC as BATCH client, OS client and RC client, Data storage systems SIMATIC BATCH operates with the following three databases: ● Project DB: Storage of user permissions ● Offline DB: Storage of recipes, formulas, materials ●...
  • Page 51 ● BATCH Recipe Editor (RE) ● BATCH OS controls ● API interface Additional information You will find a detailed description of the possible distribution of the SIMATIC BATCH program Process Control System PCS 7; PC Configuration and Authorizations packages in the manual 3.5.3...
  • Page 52 To accelerate a step change, for example, switch to next signals are set in the control recipe and therefore in the automation system. SIMATIC BATCH V8.2 Operating Manual, 02/2016, A5E35958174-AA...
  • Page 53 You will find the online help named "bfapicm_a.chm" in the following path ".. \SIEMENS\BATCH\Api_Example\BFApi\_doc". Double-click on the file to open the online help. The manual can be opened as a PDF file under Start > All Programs > Siemens Automation > SIMATIC > Documentation > English > SIMATIC BATCH - COM API.
  • Page 54 To increase the availability of the batch control and to allow a software update during operation, SIMATIC BATCH provides the option of installing a redundant BATCH server. If there is a failure in the redundant system, there is a standby/master failover between the redundant BATCH servers.
  • Page 55 The redundancy of the PCS 7 operator stations ensures that the batch processes will continue uninterrupted even if one of the two OS servers fails. The operator remains informed about the status of the process cell and can still intervene in the process. SIMATIC BATCH V8.2 Operating Manual, 02/2016, A5E35958174-AA...
  • Page 56 BATCH server. ● Failure of a BATCH server application, e.g. BATCH Control Server, batch data management (CDV), SIMATIC BATCH Server (SBS). Failover of the BATCH clients If the BATCH server (master) fails, the BATCH clients automatically fail over to the standby BATCH server.
  • Page 57 ● An interruption of the replication connection (extra network adapter in both redundant SIMATIC BATCH server PCs with network cable) affects the communication between the AS and the BATCH server. The communication is blocked for approximately 20 s. This means that the process (batch) continues running but its visualization in the BATCH Control Center or in the BATCH OS controls is updated after a delay of up to 20 s.
  • Page 58 ● The additional network adapters must be installed in your PCs (redundant BATCH server pair) in free PCI slots. ● Make sure that you read the information in the relevant SIMATIC PCS 7 documents, PCS 7 - PC Configuration and Authorization . especially the document SIMATIC BATCH V8.2 Operating Manual, 02/2016, A5E35958174-AA...
  • Page 59 Check that a log is not selected in the adapter settings for the plant bus (file and print sharing). 6. Repeat steps 1-5 for the redundancy partner. Result You have now configured the required communication for the redundancy partners and can no perform database replication for SIMATIC BATCH. SIMATIC BATCH V8.2 Operating Manual, 02/2016, A5E35958174-AA...
  • Page 60 Configuration of applications on objects WARNING Computer names Configuring applications (WinCC, SIMATIC BATCH, ...) on separate "SIMATIC PC station" objects and then merging them to create one PC station by assigning the same computer name to the "SIMATIC PC station" objects is not permitted.
  • Page 61 – Insert a batch application from the hardware catalog: Path in the hardware catalog: Standard > SIMATIC PC-Station > BATCH > BATCH application (stby). Select the menu command Station > Save and compile. SIMATIC BATCH V8.2 Operating Manual, 02/2016, A5E35958174-AA...
  • Page 62 – Connection to redundant partner via serial interface: Select "none". – Connection to redundant partner via network adapter (MAC address): Select the network adapter you used for data replication and close the dialog using the "OK" button. SIMATIC BATCH V8.2 Operating Manual, 02/2016, A5E35958174-AA...
  • Page 63 BATCH process cell still not created". ● In a distributed system (WinCC server and batch server on different PCs), the "Start SIMATIC BATCH automatically after starting WinCC" setting is blocked. ● When starting a redundant BATCH server or during a redundancy switchover, the databases of the standby server are synchronized with the databases of the master server.
  • Page 64 ● Isolation of SIMATIC BATCH server in an error state ● Isolation of the server applications in an error state ● Automatic hot restart of a SIMATIC BATCH server after status check of the partner server Prevention on exiting a SIMATIC server application...
  • Page 65 – SIMATIC BATCH V6.1 SP3 HF18 ● Requirements for configuration: – Automatic hot restart and isolation of the SIMATIC BATCH server are only supported in a redundant configuration. – All the mechanisms are available for the following redundant environments: Redundant WinCC server, redundant BATCH server, redundant Process Historian, redundant maintenance server and redundant Route Control server.
  • Page 66 BATCH server. The situation still remains that if there is a sudden failure of the SIMATIC BATCH standby PC (hardware defect, power failure, network connection to the database broken down), the BATCH server can no longer store the AS frames in the database of the standby PC (redundant storage for data backup/replication).
  • Page 67 For example, batches with a short duration (minutes up to a few hours) with large numbers of setpoints put significantly more load on a SIMATIC BATCH server (PC-based operation) or an automation system (AS-based operation) than batches with few setpoints and a duration of several days.
  • Page 68 3.6 Configuration limits 3.6.2 Structures of batch process cells Process cell configuration with SIMATIC BATCH One possible structure of a complex SIMATIC BATCH process cell is shown in the following figure. Image 3-3 Process cell configuration Operating batch process cells The "Process cell configuration"...
  • Page 69 ● The PC used for the measurements is equipped with the hardware recommended by SIMATIC PCS 7 ● In PC-based mode, the blocks relevant to SIMATIC BATCH are installed in OB32 (1 second cycle), recommendation from the section "Introduction" (Page 143) SIMATIC BATCH V8.2...
  • Page 70 Number of opened batches (control recipes) on all BATCH clients Number of batches to be completed simultaneously Number of batches to be archived simultaneously Number of batches to be deleted simultaneously Number of active BATCH clients (BATCH Control Center) SIMATIC BATCH V8.2 Operating Manual, 02/2016, A5E35958174-AA...
  • Page 71 As an average value, approximately 5-7 recipe objects are assumed per step change. Action Runtime Start batch < 3 s HOLD command < 2 s! SIMATIC BATCH V8.2 Operating Manual, 02/2016, A5E35958174-AA...
  • Page 72 UNIT_PLC and the user blocks are installed. ● Take into account all the CPU requirements relating to the cycle time (you should also refer to the documentation for the automation system S7-400 CPU Data). SIMATIC BATCH V8.2 Operating Manual, 02/2016, A5E35958174-AA...
  • Page 73 To determine the amount of required memory for a CPU, you need to add the standard BATCH blocks (SFC type, SFC, IEPH etc.) and the blocks for process control (drivers, actuators, sensors etc.). SIMATIC BATCH V8.2 Operating Manual, 02/2016, A5E35958174-AA...
  • Page 74 300 active equipment phases/operations. Report creation and archiving SIMATIC BATCH can process data (XML archive file) up a maximum of 200 MB in a report. This applies only when using the XML format with SIMATIC BATCH version V7.0 or earlier.
  • Page 75 With the increasing networking of processes in automation, matters concerning all aspects of IT security are becoming more and more important. Consider all security aspects before commissioning the hardware and software. You will find information about this with the following link: www.siemens.com/pcs7-documentation (http://www.automation.siemens.com/ mcms/industrial-automation-systems-simatic/en/manual-overview/tech-doc-pcs7/Pages/ Default.aspx) SIMATIC BATCH V8.2 Operating Manual, 02/2016, A5E35958174-AA...
  • Page 76 ● Protecting backup files (Backup (Page 1076)/Restore) (Page 1076) and Export/Import (Page 321) You must protect these files (.sbx) because SIMATIC BATCH does not provide recognized protection mechanisms for these files at present. One possibility is to create access permissions for accessing the directory.
  • Page 77 Requirements for manual configuration ● In Windows a user account (login) incl. password has been created. ● The user is a member of the SIMATIC BATCH group and a member of the administrators group.. ● The user has the right "Login as service" (1).
  • Page 78 Result The SIMATIC BATCH server system uses the NTLM mode. Note If the password elapses, the user is disabled or deleted, the SIMATIC BATCH server system does not operate. "Compatible" mode If the "NTLM" mode does not work correctly, change the mode to "Compatible".
  • Page 79 Delivery type of SIMATIC BATCH Program packages SIMATIC BATCH is delivered in different program packages for engineering and process mode (Runtime). Within the setup of SIMATIC PCS 7, you choose the appropriate programs for installation depending on the intended use of the PC.
  • Page 80 Basic, the higher authorization is used with full functionality. Functional scope of SIMATIC BATCH Basic The following functions are not available or only available in restricted form in SIMATIC BATCH Basic: ● The "Libraries" and "Formulas" folders are not displayed in the project tree of BatchCC.
  • Page 81 Display of the reduced range of functions in the user interfaces If you authorize SIMATIC BATCH Basic, the functions described above are either not displayed in the interface menus and dialogs, or they are grayed out. In both cases, the functions are not available.
  • Page 82 PCS 7 plants in the manual "PCS 7 - PC Configuration and Authorization". 3.9.4 Readme file with the latest information Readme file Note Make sure that you read the latest information on SIMATIC BATCH in the SB readme file on the software DVD. SIMATIC BATCH V8.2 Operating Manual, 02/2016, A5E35958174-AA...
  • Page 83 See the table below for SIMATIC BATCH client authorizations. In ALM, you can configure which PC in the network should be searched for licenses. SIMATIC BATCH server authorizations must be located on the SIMATIC BATCH server concerned, as the employed SIMATIC BATCH software will search for them there.
  • Page 84 If you require a larger number of units due the requirements of your project, you will need to use ALM to transfer a new, extended authorization from the authorization data medium to the relevant PC. Licenses for units for SIMATIC BATCH are derived from the number of "UNIT_PLC" unit blocks used.
  • Page 85 Example: With a BATCH 10 UNITs and a BATCH 50 UNITs, you can operate a BATCH process cell with 60 units. SB client products: The SIMATIC BATCH client authorizations are searched for both locally on a specified PC and on a PC specified in the network. The method of searching for authorizations in the network must be configured in the Automation License Manager.
  • Page 86 Make sure that you read the information on installing SIMATIC BATCH in the The readme file is on the same DVD as SIMATIC BATCH. You will find detailed information on installing and configuring the PC stations for SIMATIC PCS 7 process cells in the manual Process Control System PCS 7;...
  • Page 87 Installation of Client Options Only one selection is possible during installation. If one variant is already installed, SIMATIC BATCH setup only offers an update for this variant. However, you can convert to the other variant at any time after you have uninstalled the previous variant.
  • Page 88 ● Delete the previous web plugin manually in the following path C:\Program Files\SIEMENS \WINCC\Webnavigator\Server\Web\install\custom Uninstalling Note If you remove SIMATIC BATCH, you must always do this before removing the plant hierarchy (SIMATIC PH). Installation in a redundant system Note A few particular requirements must be observed in a redundant PCS 7 system. A detailed description of the installation can be found in section "Redundancy (Page 54)".
  • Page 89 ● If applicable, the installation of new operating systems, such as Windows 7 and Windows Server 2008 R2 64-bit ● Installation or reinstallation of SIMATIC PCS 7 with SIMATIC BATCH = software update. For the update, there are two possible options: –...
  • Page 90 Product introduction and installation 3.10 Plant update ● As of SIMATIC BATCH V7.0, enumerations are supported for the BOOL data type. If you use this type, now it will be interpreted as ENUM and no longer as BOOL. This results in a type change during generation, which means that the plausibility check will mark the release of such recipe objects as invalid when you update the plant in BatchCC.
  • Page 91 The SB server data on the standby server are compared completely with the master server when the standby server reports the status "Listening". You can check the status of the SIMATIC BATCH server using the symbol of the BATCH start coordinator or using the shortcut menu command "BATCH status...”.
  • Page 92 The SB server data on the standby server are compared completely with the master server when the standby server reports the status "Listening". You can check the status of the SIMATIC BATCH server using the symbol of the BATCH start coordinator or using the shortcut menu command "BATCH status...”.
  • Page 93 ● Visualization and operator control of batches with flat recipes is not supported in the BATCH OS controls. ● The interface blocks from SIMATIC BATCH V4.x contained in your project can continue to be used in SIMATIC BATCH. A reconfiguration is not possible, however.
  • Page 94 ● In batch logs, process values are always output for the configured control strategy in the master recipe. If there is a control strategy discrepancy between SIMATIC BATCH and the function or operation type (EPH/EOP), the process values for the parameters are not fully logged.
  • Page 95 ● SIMATIC BATCH installation instructions Open SIMATIC BATCH help ● In the BATCH Control Center or in the recipe editor open the SIMATIC BATCH online help via the "Help Topics" menu item in the "Help" menu. Alternatively you can open the SIMATIC BATCH online help via the <F1>...
  • Page 96 To search for words with similar spelling, enable "Search for similar words". ● Example: When "Search for similar words" is enabled, the search string "Mayor" returns all topics containing the words "Mayer," "Moyer," and "Meyor". SIMATIC BATCH V8.2 Operating Manual, 02/2016, A5E35958174-AA...
  • Page 97 To search for terms within a topic, press <Ctrl+F>. You can search for whole words only, define the search direction, or case-sensitive. When "Whole words only" is disabled, the search string "Process" returns the term "ProcessValue" also. When "Whole words only" is enabled, only the word "process" is found. SIMATIC BATCH V8.2 Operating Manual, 02/2016, A5E35958174-AA...
  • Page 98 Meaning Contents In the table of contents you have direct access to every topic of the SIMATIC BATCH online help. Index Use keywords to find specific topics in the index. The string entered must match one of the keywords in the index.
  • Page 99 Navigation bar in the display window The SIMATIC BATCH online help has a navigation bar that is located at the top of the display window. The navigation bar provides links to other topics. The links are organized by link type.
  • Page 100 Moves one row down in the table of contents. <Page up> Scrolls upwards in the table of contents. <Page down> Scrolls downwards in the table of contents. <Enter> or <Input> Open or close the selected chapter SIMATIC BATCH V8.2 Operating Manual, 02/2016, A5E35958174-AA...
  • Page 101 Additional information Control: SIMATIC BATCH OS Process Cell (Page 600) Batch status symbol "Completed" at order folder In addition to the existing symbols at the order folder for the processing status of the included batches, an additional symbol is now displayed when batches in the order folder have the status "Completed", "Closed", "Stopped", "Archived"...
  • Page 102 Display actual quantity in BATCH OS Controls (Page 624) Expansions in the "Batch properties" dialog The additional elements Order and Order category are listed in the "Properties" dialog of a batch in the BATCH Control Center. SIMATIC BATCH V8.2 Operating Manual, 02/2016, A5E35958174-AA...
  • Page 103 Configured conditions are shown in the control recipe in the tooltip of the transition. Additional information "Condition" tab (transition properties) (Page 829) 4.10 Increasing security for communication To increase security in communication of the SIMATIC BATCH system, you can configure the "NTLM" mode. SIMATIC BATCH V8.2 Operating Manual, 02/2016, A5E35958174-AA...
  • Page 104 What's new? 4.12 Archiving method "SQL Server" Additional information Configuring the security settings on the SIMATIC BATCH server (Page 77) 4.11 Connecting automatically to a project You can connect to a project automatically. Additional information You will find further information in the section "AutoConnect (Page 646)".
  • Page 105 Technological basics complying with ISA-88.01 Which standards is SIMATIC BATCH based on? Standards SIMATIC BATCH was developed on the basis of the ISA-88 (1995) Batch Control, Part 1: Models and Terminology standard. Use of SFC In the "Technical Report" ISA-TR88.0.03-1996, the use of SFC (Sequential Function Charts, DIN/IEC 1131) as a graphic language for describing recipe procedures is also recommended.
  • Page 106 Recipe The necessary set of information that uniquely defines the production requirements for a specific product. A recipe is the set of rules and information required to define how a product is manufactured. SIMATIC BATCH V8.2 Operating Manual, 02/2016, A5E35958174-AA...
  • Page 107 Technological basics complying with ISA-88.01 5.2 Introduction of technological terms Two types of recipe are used in SIMATIC BATCH: ● Master recipe ● Control recipe Master recipe A type of recipe that accounts for equipment capabilities and may include process cell-specific information.
  • Page 108 Basic structure of a recipe Components of a recipe Recipes contain the following four categories of recipe information: See also Material and production data (formula) (Page 109) Basic structure of a recipe procedure (Page 110) SIMATIC BATCH V8.2 Operating Manual, 02/2016, A5E35958174-AA...
  • Page 109 Process parameters are physical parameters such as speed, pressure or temperature. Process parameters can also be logic parameters and character chains: For example, release number of loop of type integer or material information HCL of type string or Boolean values e.g., releases. SIMATIC BATCH V8.2 Operating Manual, 02/2016, A5E35958174-AA...
  • Page 110 By assigning formulas to a master recipe, a variety of control recipes can be created for a process cell or a grouping of equipment belonging to a process cell. The schematic below illustrates this relationship. SIMATIC BATCH V8.2 Operating Manual, 02/2016, A5E35958174-AA...
  • Page 111 ISA-88 does not mention the formula category. However, the formula category does not contradict the formula definition in ISA-88, instead it expands it (see also "Models of the ISA-88 Standard"). SIMATIC BATCH V8.2 Operating Manual, 02/2016, A5E35958174-AA...
  • Page 112 Introduction The following sections describe those models of the ISA-88 standards that relate directly to the use of SIMATIC BATCH. You will find information on other topics in the standard itself. Models of the ISA-88 standard The following models of the ISA-88 standard provide the foundation for batch-oriented control strategies with SIMATIC BATCH: ●...
  • Page 113 ● You structure the recipes for batch control with the BATCH Recipe Editor based on the procedural control model. See also Structure of the plant hierarchy (Page 130) Implementation of the hierarchy in the BATCH Recipe Editor (Page 504) SIMATIC BATCH V8.2 Operating Manual, 02/2016, A5E35958174-AA...
  • Page 114 ● The execution of an equipment phase can result in: – Commands to basic control – Commands to other equipment phases (either in the same or another equipment entity) – The collection of data SIMATIC BATCH V8.2 Operating Manual, 02/2016, A5E35958174-AA...
  • Page 115 ● A unit often contains a complete batch of material at some point in the processing sequence of the batch. ● A unit cannot process more than one batch at the same time. SIMATIC BATCH V8.2 Operating Manual, 02/2016, A5E35958174-AA...
  • Page 116 Control modules are not included in the procedural model or in the process model. This means that they cannot be addressed in SIMATIC BATCH either. See also Overview of the ISA-88 standard models (Page 112) SIMATIC BATCH V8.2...
  • Page 117 Technological basics complying with ISA-88.01 5.9 ANSI/ISA-88.01 models 5.9.4 Process model Process model with example – What do we want to produce? SIMATIC BATCH V8.2 Operating Manual, 02/2016, A5E35958174-AA...
  • Page 118 Technological basics complying with ISA-88.01 5.9 ANSI/ISA-88.01 models SIMATIC BATCH V8.2 Operating Manual, 02/2016, A5E35958174-AA...
  • Page 119: Getting Started

    BATCH OS (BATCH server, BATCH clients) and those of the engineering system. Basic procedure If you are working with SIMATIC BATCH for the first time, the following table gives you an overview of the most important steps. Process cell configura‐...
  • Page 120 Permission management SIMATIC BATCH uses the central user management of PCS 7. You define user roles for SIMATIC BATCH (for example operator) and their assignment to the defined Windows user groups using the SIMATIC Logon software. Within SIMATIC BATCH (BatchCC), you can restrict the user permissions of a user role even further - for a specific computer and for a specific unit.
  • Page 121 SIMATIC Manager. For SIMATIC BATCH, specified hierarchy levels must be complied with. Additional information Structure of the plant hierarchy (Page 130) SIMATIC BATCH V8.2 Operating Manual, 02/2016, A5E35958174-AA...
  • Page 122 – Set up AS network connections – Adapt local data. – Copy blocks from the SIMATIC BATCH block library to your user project. – Specify reserved areas for data blocks and functions in the CFC. – Adapt the plant hierarchy to the specific project.
  • Page 123 Settings for SIMATIC BATCH In the 3rd dialog box "Which objects will be used in the project?", the "SIMATIC BATCH" option is available. Select this option and three further options appear on the right in the same dialog box.
  • Page 124 BATCH client in the Component view of SIMATIC Manager. Note Configuring applications (WinCC, SIMATIC BATCH, ...) on separate "SIMATIC PC station" objects and then merging them to create one PC station by assigning the same computer name to the "SIMATIC PC station" objects is not permitted.
  • Page 125 "BATCH application [stdby]" stands for the redundant applications: ● DB server project: Storage of user permissions ● DB server offline: Storage of the recipes, formulas, materials ● DB server online: Storage of the batches ● BATCH control server (BCS) SIMATIC BATCH V8.2 Operating Manual, 02/2016, A5E35958174-AA...
  • Page 126 WARNING Configuring applications (WinCC, SIMATIC BATCH, ...) on separate "SIMATIC PC station" objects and then merging them to create one PC station by assigning the same computer name to the "SIMATIC PC station"...
  • Page 127 ● A SIMATIC PC station must be created and configured with a "BATCH application client" in HW Config for every PC on which a BATCH client application runs. ● BATCH clients can also run on PC stations on which no OS client (multiclient) is installed. SIMATIC BATCH V8.2 Operating Manual, 02/2016, A5E35958174-AA...
  • Page 128 WinCC application if the BATCH client is operated along with an OS client on one PC. Path in the hardware catalog: Standard > SIMATIC PC Station > HMI > BATCH application client. 6. Select the menu item Station > Save and Compile. SIMATIC BATCH V8.2 Operating Manual, 02/2016, A5E35958174-AA...
  • Page 129 10.Adapt the amount of memory for the local data in accordance with the displayed local data referred to in point 4. Note Optimization of local data Use the procedure described above to optimize your local data within the priority classes SIMATIC BATCH V8.2 Operating Manual, 02/2016, A5E35958174-AA...
  • Page 130 In multiproject engineering, the top level is the "Multiproject" object, below that you will find the individual projects and the process cell below these projects. For the configuration data for SIMATIC BATCH, the three hierarchy folders shown in the schematic below are necessary (these are generally known as batch hierarchy folders): ●...
  • Page 131 BATCH hierarchy folders. You can also extend the structure specified by SIMATIC BATCH for the general function blocks using neutral hierarchy folders so that you produce the ideal plant structure for your requirements.
  • Page 132 For detailed information on creating, modifying and setting the properties of the plant hierarchy, Process Control System PCS 7; Engineering System . refer to the manual Only the additional and special settings for the batch configuration are described in the following. SIMATIC BATCH V8.2 Operating Manual, 02/2016, A5E35958174-AA...
  • Page 133 You can decide whether the name of an individual hierarchy folder will be included in the HID in the operator control and monitoring attributes of each individual hierarchy folder (menu command Edit > Object Properties > Control and Monitoring Attributes"). 4. Confirm your settings with OK. SIMATIC BATCH V8.2 Operating Manual, 02/2016, A5E35958174-AA...
  • Page 134 (SFC) required for the automation task can also be stored in these BATCH hierarchy folders. ● You can also extend the hierarchy specified by SIMATIC BATCH for the general function blocks using neutral hierarchy folders so that you produce the ideal plant structure for your requirements.
  • Page 135 Engineering 7.1 Basic engineering for PCS 7 Example SIMATIC BATCH V8.2 Operating Manual, 02/2016, A5E35958174-AA...
  • Page 136 ● When creating a master recipe in SIMATIC BATCH, the data of this process cell are made available. This means that all the units and equipment phases required in a master recipe must be created below the process cell folder.
  • Page 137 "Equipment module" object type afterwards in the properties of the hierarchy folder in the "S88 type definition" tab. A hierarchy folder that was type defined as equipment module has the following icon in the plant view in the SIMATIC Manager: SIMATIC BATCH V8.2 Operating Manual, 02/2016, A5E35958174-AA...
  • Page 138 The "<neutral>" object type deactivates the BATCH hierarchy for the "process cell" object. The lower-level BATCH hierarchy folders retain their object type but are no longer relevant for the SIMATIC BATCH configuration. In "Object type", the nested hierarchy folders no longer relevant for SIMATIC BATCH are displayed in round brackets, for example: (unit).
  • Page 139 Extending the plant hierarchy by adding neutral folders Neutral folders As already mentioned, the three-stage hierarchy for SIMATIC BATCH can be extended by adding neutral folders to improve the structuring of the project, for example to divide units into groups. The neutral folders can be created at any level. The total number of possible levels (batch hierarchy levels, levels with neutral folders) is limited to eight.
  • Page 140 No BATCH interface blocks (or EPAR blocks) should be located in the charts of neutral folders. Example Levels in the example: Process cell: Production Area: Branches1 to 7, Buffer, Filter, Capacitor, Overview, PCS 7, Premixer, Reactor, Silo, Tankfarm SIMATIC BATCH V8.2 Operating Manual, 02/2016, A5E35958174-AA...
  • Page 141 For recipe creation and processing, the process cell and unit levels must exist at least once. Whether or not you require the equipment module level depends on how you define the equipment procedural elements. SIMATIC BATCH V8.2 Operating Manual, 02/2016, A5E35958174-AA...
  • Page 142 Batch hierarchy folder of a process cell: ● Process Cell ● Unit ● Equipment Module ● Neutral folders Block instances IEOP Equipment operation interface IEPH Equipment phase interface UNIT_PLC Unit status and allocation interface TAG_COLL Collection of process values SIMATIC BATCH V8.2 Operating Manual, 02/2016, A5E35958174-AA...
  • Page 143 Introduction Interface to unit and to equipment module In SIMATIC BATCH, each unit and each recipe phase of a control recipe communicates at runtime with a unit and an equipment module in the automation system. Both setpoints and process values as well as the current status or control commands are exchanged. An equipment module may be an equipment phase (EPH) or an equipment operation (EOP).
  • Page 144 The status may be lost in the BATCH control server if this condition is violated. Setpoints Setpoints are updated by the recipe control of SIMATIC BATCH to influence the equipment module. Control strategies Different and (in terms of the same run) mutually exclusive equipment phases/operations of the same equipment module are known as control strategies of this equipment module.
  • Page 145 ● MemIDB64 The BATCH configuration dialog searches the S7 project for the block names listed above in order to be able to make internal project settings. If the names are changed, SIMATIC BATCH cannot be configured correctly. In CFC charts, only blocks from the "BATCH" block family in the SIMATIC BATCH library may be used and, therefore, imported.
  • Page 146 The "UNIT_NAME" input cannot be modified in the block. Every recipe operation (ROP), equipment phase (EPH) or transition in the assigned unit is checked by this block and the specifications for further processing steps are defined. SIMATIC BATCH V8.2 Operating Manual, 02/2016, A5E35958174-AA...
  • Page 147 QAvgRecProTime = 50 to 60 ms* Not OK * Recipe processing cannot be undertaken in a processing cycle but must instead be split over two processing cycles. The system thereby extends the batch runtime by one processing SIMATIC BATCH V8.2 Operating Manual, 02/2016, A5E35958174-AA...
  • Page 148 80 ms. 7.1.4.4 Self-terminating equipment phases Definition Self-terminating equipment phases are sequences that end with a process condition, in other words, the end of the RUN sequence independently starts the COMPLETING sequence. SIMATIC BATCH V8.2 Operating Manual, 02/2016, A5E35958174-AA...
  • Page 149 The end of the RUN sequence is only reported (Ready_TC) so that this equipment phase can be completed by an external command. This command can given either by the operator using the "Close" in the SFC faceplate or by SIMATIC BATCH with the "Close" command.
  • Page 150 RUN sequence ends and the equipment phase reports that it has completed. The "COMPLETING" step can only be started by external command from the operator or from SIMATIC BATCH. As long as no external complete command has been issued, the equipment phase remains in the RUN sequence (RUN status), which means that the RUN sequence is started once again.
  • Page 151 Setting up the equipment module with interface blocks IEPH and IEOP SIMATIC BATCH block library All the necessary BATCH blocks for the two modes are contained in the SIMATIC BATCH block library. The documentation in the form of a PDF file is available under START > SIMATIC >...
  • Page 152 In terms of timing, optimum processing of step changes can only be achieved in conjunction with an SFC type or an IEPH/SFC pair. SIMATIC BATCH supports the use of a user block with the IEPH, but this can lead to a longer step change time under certain circumstances.
  • Page 153 ● In all IEPAR blocks (apart from the BOOL and ENUM type) the high and low limit value and the default setpoint must be specified. The default value must be within the limits. SIMATIC BATCH V8.2 Operating Manual, 02/2016, A5E35958174-AA...
  • Page 154 Interconnect the "EPE_CONN" output of the IEPH/IEOP block with the input of the same name on the IEPAR block. 5. Open the "SP_VAL" input object properties of the ENUM block I/O and select the enumeration and values. SIMATIC BATCH V8.2 Operating Manual, 02/2016, A5E35958174-AA...
  • Page 155 7.1.4.7 Setting up the equipment module with SFC types You create SFC types and their instances in the CFC charts for SIMATIC BATCH using SFC/ CFC standard tools. SIMATIC BATCH does not need to be installed. Configuring an SFC instance Below, you will find a recommended order for creating an SFC type (equipment phase) and an instance in the CFC chart.
  • Page 156 6. Select the menu command Edit > Open object. Result: SFC opens with the new SFC type. 7. Here you can use the standard SFC tools to edit the sequential control of the equipment operation/phase. Overview of the parameters relevant for SIMATIC BATCH Parameter Where to edit Meaning Setpoint Under Characteristics >...
  • Page 157 No entries can be made in the "Enumeration" column. The enumerations available for selection are those previously created in the SIMATIC Manager under the "Shared Declarations" object. The enumerations are then available for operator control and monitoring of SFC instances in SIMATIC BATCH. SIMATIC BATCH V8.2 Operating Manual, 02/2016, A5E35958174-AA...
  • Page 158 7.1 Basic engineering for PCS 7 Creating parameters or setpoints for the SFC type You create setpoints (parameters) that are relevant for SIMATIC BATCH in the characteristics view in SFC: 1. Select the created object "SFC type" in the chart folder.
  • Page 159 3. Change to the "Characteristics" view with the menu command of the same name. The "Characteristics" view opens. 4. Here, you edit all the setpoints relevant for SIMATIC BATCH To do this, select "Setpoints" in the left-hand column. On the right, you can now set the setpoint with all the relevant attributes.
  • Page 160 Batch data. The faceplates on the PCS 7 OS then indicate whether this equipment procedural element is being used by SIMATIC BATCH and which batch is running. The batch name and the batch ID are included in the messages to the PCS 7 OS.
  • Page 161 ● The process tag type name is derived from the F_TYPE input of the TAG_COLL block. ● The process tag parameter name is derived from the IEPAR_xxx block name. SIMATIC BATCH V8.2 Operating Manual, 02/2016, A5E35958174-AA...
  • Page 162 Dynamic unit parameters allow you to define and evaluate properties of units. They are used as parameter steps and as transitions in basic recipes, and are evaluated or further used during the runtime of a batch. SIMATIC BATCH transfers parameter values to the unit and can react to them during batch execution.
  • Page 163 The "UnitStatus" input can be modified by a PCS 7 OS or by means of the SIMATIC BATCH batch control. The "L_UnitStatus" input is coupled with the user program in the AS and you can use it with its own logic.
  • Page 164 ● Using the BATCH interface block TAG_COLL (as in BATCH ● Using the standard function block TAG_COLL, given the name TAG_COLLECT below to distinguish the two (new in SIMATIC BATCH as of V6.0) Individual measured values are created in the interface or standard function block. The process tag types are then generated in the BATCH configuration dialog within the context of the batch types ("Generate"...
  • Page 165 3. Here, you can edit all the values to be be collected as measured values as input parameters. Note Use only the data types permitted with SIMATIC BATCH: Bool, Int, Dint, Real and String. 4. Assign the parameters the following attributes: –...
  • Page 166 BATCH configuration dialog. 12.Open the BATCH configuration dialog with the menu command Options > SIMATIC BATCH. 13.Select the "Batch types" object in the left window. SIMATIC BATCH V8.2 Operating Manual, 02/2016, A5E35958174-AA...
  • Page 167 2. Select the CFC chart and select the menu command Edit > Open Object. 3. Open the I/O table with View > Chart Inputs/Outputs. 4. Here, you can edit all the values that will be collected as measured values as input parameters under IN. SIMATIC BATCH V8.2 Operating Manual, 02/2016, A5E35958174-AA...
  • Page 168 7. Select the menu command Chart > Compile > Chart as Block Type. 8. In the "General" tab, specify the following: FB name, symbolic name and the family (for example, BATCH) 9. Change to the "Attribute" tab. SIMATIC BATCH V8.2 Operating Manual, 02/2016, A5E35958174-AA...
  • Page 169 In previous versions, you selected the possible unit candidates statically. This meant that selecting the available units in which a recipe procedure was to be executed in the recipe editor when creating a recipe. You can continue to use this procedure. SIMATIC BATCH V8.2 Operating Manual, 02/2016, A5E35958174-AA...
  • Page 170 MP with the command Shared Declarations > Update in Multiproject. 7.1.7.3 Assigning equipment properties to the units Requirements ● The equipment properties have been created. ● The Plant view is displayed in the SIMATIC Manager. SIMATIC BATCH V8.2 Operating Manual, 02/2016, A5E35958174-AA...
  • Page 171 6. In the name box, select the newly created equipment property from the drop-down list, in our example "Pcell Group". 7. Select a process group in the "Value" box. 8. Open the configuration dialog "Configure batch process cell ...". SIMATIC BATCH V8.2 Operating Manual, 02/2016, A5E35958174-AA...
  • Page 172 BATCH does not record these measured value sequences, but fetches the values from the WinCC measured value archives. For each instance parameter to be recorded as a measured value, ● the "Archive measured variable" option must activated and ● a WinCC archive tag must be assigned. SIMATIC BATCH V8.2 Operating Manual, 02/2016, A5E35958174-AA...
  • Page 173 BATCH configuration dialog with the SFC types for operation, function and process tag types (not with SFC instances). This may lead to validation errors and therefore errors in the compilation. SIMATIC BATCH V8.2 Operating Manual, 02/2016, A5E35958174-AA...
  • Page 174 4. Display the individual hierarchies in the WinCC tag browser. 5. Select the required WinCC archived tag. 6. Click the "Apply" button. Result: After compiling and downloading the process cell, you can use the archive tags in your recipes. SIMATIC BATCH V8.2 Operating Manual, 02/2016, A5E35958174-AA...
  • Page 175 CFC charts (for example UNIT_PLC, MemIDB64, EventSend, IEOP, IEPH, IPAR…). All other blocks from the SIMATIC BATCH library that are not used in a CFC chart are removed from the CFC data management using the "Clean up" button in this dialog. The blocks must not, however, be deleted from the block folder of the project.
  • Page 176 Compiling the OS Introduction SIMATIC BATCH communicates with the automation system via the defined PCS 7 OS (message OS). As a result, on completion of PCS 7 basic configuration and following every change to the batch process cell data, the PCS 7 OS must be compiled. This downloads all the BATCH objects as WinCC tags to the appropriate PCS 7 OS.
  • Page 177 6. In the next Wizard dialogs, follow the normal procedures for PCS 7. Select the operator stations, the S7 programs and then the scope of the compilation. There are no specific SIMATIC BATCH settings necessary. Note The default compilation mode for PCS 7 is area-oriented compilation (OS area). This setting can be changed by calling the menu command Options >...
  • Page 178 The BATCH configuration dialog is the Control Center for BATCH engineering. The aim of configuration is to make available all necessary data from the PCS 7 basic configuration and the BATCH configuration to the SIMATIC BATCH server for the automation task. Image 7-1 BATCH configuration dialog SIMATIC BATCH V8.2...
  • Page 179 Project data from the PCS 7 basic engineering is collected in the form of objects in a structure in the navigation area for SIMATIC BATCH. When you select an object in the navigation area, its properties are then displayed and special context-dependent functions are offered.
  • Page 180 Access protection Access protection for projects configured for PCS 7 engineering also affects the BATCH configuration dialog. For functions that affect changes in basic engineering, you need to authenticate yourself with SIMATIC Logon. SIMATIC BATCH V8.2 Operating Manual, 02/2016, A5E35958174-AA...
  • Page 181 Engineering 7.3 BATCH engineering Overview of the dialog landscape for the BATCH configuration dialog Image 7-3 BATCH configuration dialog SIMATIC BATCH V8.2 Operating Manual, 02/2016, A5E35958174-AA...
  • Page 182 Engineering 7.3 BATCH engineering Image 7-4 Settings in the multiproject or project SIMATIC BATCH V8.2 Operating Manual, 02/2016, A5E35958174-AA...
  • Page 183 Engineering 7.3 BATCH engineering Image 7-5 Stations, CPU memory configuration SIMATIC BATCH V8.2 Operating Manual, 02/2016, A5E35958174-AA...
  • Page 184 Engineering 7.3 BATCH engineering Image 7-6 Generating batch types SIMATIC BATCH V8.2 Operating Manual, 02/2016, A5E35958174-AA...
  • Page 185 Engineering 7.3 BATCH engineering Image 7-7 Merge batch instances SIMATIC BATCH V8.2 Operating Manual, 02/2016, A5E35958174-AA...
  • Page 186 Engineering 7.3 BATCH engineering Image 7-8 Downloading a batch process cell SIMATIC BATCH V8.2 Operating Manual, 02/2016, A5E35958174-AA...
  • Page 187 Engineering 7.3 BATCH engineering Image 7-9 Downloading a batch process cell is not possible SIMATIC BATCH V8.2 Operating Manual, 02/2016, A5E35958174-AA...
  • Page 188 Online help for STEP 7> What you need to know about access protection 7.3.2 BATCH engineering overview Requirement for the BATCH engineering All the relevant points from the PCS 7 basic engineering have been performed and the PCS 7 OS was compiled and downloaded. SIMATIC BATCH V8.2 Operating Manual, 02/2016, A5E35958174-AA...
  • Page 189 DBs and FCs in the current S7 program. As a result the DB and/or FC information saved internally for SIMATIC BATCH has to be updated. Following a change to the reserved areas you will need to run the SIMATIC BATCH engineering again. Additional information Memory configuration of the CPU being used (Page 198) SIMATIC BATCH V8.2...
  • Page 190 Phase type, operation type based on SFC type Phase type, operation type based on SFC type with control strategy Process tag types Process tag type Equipment properties Unit of measure Enumeration as control strategy Floating point number Integer String Boolean SIMATIC BATCH V8.2 Operating Manual, 02/2016, A5E35958174-AA...
  • Page 191 UNIT_PLC block contains the functionality of the IUNIT interface block including the AS-based runtime system. Automatic parameter setting of BATCH blocks in the BATCH configuration dialog The SIMATIC BATCH configuration dialog reads and writes parameters at the blocks during configuration: ● Determination of all instance data blocks (IDB).
  • Page 192 CFC can create messages with the "Alarm_8P" block. 7.3.5 How to compile and download the process cell data Basic procedure Compile OS See chapter "PC station", paragraph "Compile OS (Page 176)". SIMATIC BATCH V8.2 Operating Manual, 02/2016, A5E35958174-AA...
  • Page 193 OS servers in the process cell that do not have any batch-relevant data. This means that the batch-relevant operator stations must be specified for SIMATIC BATCH. To achieve an optimum load distribution, you can select a message OS to which SIMATIC BATCH sends its messages.
  • Page 194 Display number of units If you want to know how many available units (UNIT_PLC instances) are in your project, for example, to be able to order the required authorization for SIMATIC BATCH, open the corresponding report in the BATCH configuration dialog.
  • Page 195 SFC type will be passed on to the SFC instances. Procedure for SFCs In the SFC, you create the following SFC types for SIMATIC BATCH with the following characteristics: ● EOP (equipment operation) ●...
  • Page 196 CFC chart. Procedure without a PCS 7 project (BATCH configuration dialog) 1. Open the BATCH configuration dialog with the Options > SIMATIC BATCH menu command. 2. For operation/phase type, create a new parameter, for example fw_param an. Select the required "Phase type"...
  • Page 197 (enumeration type with control strategy parameters). The "Edit" button is displayed in the properties under control strategy parameters. The "Control strategies of equipment properties" dialog opens when you click this button. Image 7-11 Control strategy assignment SIMATIC BATCH V8.2 Operating Manual, 02/2016, A5E35958174-AA...
  • Page 198 Allocation of work memory The figure shows the dialog for individually setting the allocation of work memory with data blocks for storing of recipe logic. Blocks cannot be created and fitted during the AS runtime. SIMATIC BATCH V8.2 Operating Manual, 02/2016, A5E35958174-AA...
  • Page 199 A master recipe executed on the AS requires at least 2 data blocks. Twenty batches running simultaneously with this control recipe require 40 data blocks in the "@ASB_Mem" CFC chart. Result: The 20% allocation of the data area in work memory is adequate. SIMATIC BATCH V8.2 Operating Manual, 02/2016, A5E35958174-AA...
  • Page 200 If the data are not plausible they will not be complied. Procedure in the SIMATIC Manager 1. Open the BATCH configuration dialog with the Options > SIMATIC BATCH menu command. 2. In the left window under process cell data select the "Batch instances" folder.
  • Page 201 Batch-relevant when the settings were made in the "OS objects" tab. 9. Press the "Start" button. Result: All Batch-relevant data (messages and user data types) is downloaded to the appropriate operator stations. SIMATIC BATCH V8.2 Operating Manual, 02/2016, A5E35958174-AA...
  • Page 202 After configuring for the first time in the BATCH configuration dialog, you have the option of performing the entire BATCH engineering in this dialog using the function SIMATIC BATCH > Compile/Download function in the SIMATIC Manager. The dialog consists of two tabs in which you can make the required settings.
  • Page 203 Manager prior to downloading the BATCH process cell data. The following sequence should be followed: 1. Compile and download the automation systems 2. Compile and download the PCS 7 OS server 3. Merge/compile and download the BATCH server and BATCH clients SIMATIC BATCH V8.2 Operating Manual, 02/2016, A5E35958174-AA...
  • Page 204 Procedure in the "Settings" dialog in the SIMATIC Manager 1. In the "Settings" dialog, open the "Download" tab with the menu command Options > SIMATIC BATCH > Compile/Download. 2. In the "Merge/Compile" tab, you can decide whether or not the batch types are generated prior to merging/compiling and whether the messages should be transferred to the PCS 7 3.
  • Page 205 Multiple instantiation of the same block types within a unit Introduction As of SIMATIC BATCH version 8.1, multiple instances of the same SFC type can be addressed within a unit. To distinguish between multiple block instances of an SFC type within a unit, the block instance names must be different.
  • Page 206 Multiple instances with the same name within a unit are not permitted. ● If there are multiple instances within a unit: Has a common block instance name been assigned in all other units where this SFC type is used? SIMATIC BATCH V8.2 Operating Manual, 02/2016, A5E35958174-AA...
  • Page 207 Only the instance name is displayed in the recipe report and in the batch report for instance mode. SIMATIC BATCH COM API The associated instance name and not the type name is displayed at the instances for the "GetObjectData" XML functions in instance mode.
  • Page 208 Communication monitoring Communication monitoring With SIMATIC BATCH, you have the ability to monitor the communication between BATCH server, PCS 7 OS server and the AS. The communication monitoring is performed by the unit block, UNIT_PLC (FB 266). You define the configuration in the BATCH configuration dialog under the settings in the "System characteristics"...
  • Page 209 Several process cells of different S7 projects With SIMATIC BATCH, it is also possible to create BATCH servers and BATCH clients in several S7 projects. It is, for example, possible to run three S7 projects each with three PCS 7 operator stations and the same multiclient (with BATCH Client).
  • Page 210 When delta loading in the CFC, you must ensure that the "Include user data blocks" option button is selected. You make this setting in the "S7 Download" tab when you load the S7 program in the CFC from the BATCH configuration dialog or from the SIMATIC Manager. SIMATIC BATCH V8.2 Operating Manual, 02/2016, A5E35958174-AA...
  • Page 211 Type description of the process cell Introduction As the basis for creating recipes in SIMATIC BATCH, the type description of the process cell must be generated or edited and, where necessary, synchronized with the block instances of the CFC charts. The following types can be defined for creating recipes.
  • Page 212 Batch types that depend on the language (user data types, for example) are displayed in SIMATIC BATCH in the language with which they were created during the configuration of the type descriptions. Switching the language of the Batch application has no effect in this regard.
  • Page 213 Display log command in the shortcut menu, the object-related text for errors and warnings can be displayed: Error Warning If errors/warnings cannot be determined, for example, after a migration, a question mark is shown on the object icon. SIMATIC BATCH V8.2 Operating Manual, 02/2016, A5E35958174-AA...
  • Page 214 ● Equipment properties Batch types Display of the logs of the executed "Generate" function To do this you must select the executed function in a drop-down selection list and then click on the "Display" button. SIMATIC BATCH V8.2 Operating Manual, 02/2016, A5E35958174-AA...
  • Page 215 You configure the type description in the BATCH configuration dialog. You open this dialog in the Component view and in the Plant view: ● using the Options > SIMATIC BATCH menu command ● by selecting the multiproject and then the SIMATIC BATCH command in the shortcut menu SIMATIC BATCH V8.2 Operating Manual, 02/2016, A5E35958174-AA...
  • Page 216 Display log command in the shortcut menu, the object-related text for errors and warnings can be displayed: Error Warning If errors/warnings cannot be determined, for example, after a migration, a question mark is shown on the object icon. SIMATIC BATCH V8.2 Operating Manual, 02/2016, A5E35958174-AA...
  • Page 217 You will find a description of editing SFC types in the section ● Process tag types "Creating a new SFC type (Page 155)". Additional functions Batch types Printing: Print all batch types of the process cell in tabular form. Print SIMATIC BATCH V8.2 Operating Manual, 02/2016, A5E35958174-AA...
  • Page 218 Updating the batch types in this project (importing the batch types of the multiproject). Check validity Batch process cell The validity of the project is checked. Compile Batch instances Compiles the batch instances. SIMATIC BATCH V8.2 Operating Manual, 02/2016, A5E35958174-AA...
  • Page 219 ● Process tag types ● Equipment properties Batch types Display of the logs for the executed functions "Generate" First select the executed function in the drop-down list and then click the "Display" button. SIMATIC BATCH V8.2 Operating Manual, 02/2016, A5E35958174-AA...
  • Page 220 3. Activate all the projects to be propagated. 4. Click the "Start" button. Result: The complete type description is distributed to the projects of the multiproject. After running this function, the batch types are consistent in all selected projects. SIMATIC BATCH V8.2 Operating Manual, 02/2016, A5E35958174-AA...
  • Page 221 "Remove for editing". You can completely configure the project there. Preciously, you could only edit batch types in a removed project. As of SIMATIC BATCH V7.0, you can now remove any project from a multiproject for editing. The batch types can still be edited in each project.
  • Page 222 The basic control has been created; in other words, the PLC hardware is configured, the CFC and SFC charts have been created and compiled. The information below relates only to the supplementary ES configuration for creating recipes and batch control with SIMATIC BATCH. Example of a configuration for single project engineering SIMATIC BATCH V8.2...
  • Page 223 Rational engineering 8.2 Single project engineering What is involved in the ES configuration for SIMATIC BATCH? SIMATIC BATCH V8.2 Operating Manual, 02/2016, A5E35958174-AA...
  • Page 224 You will find further information in the online help in PCS 7 in the topic "What you Should Know about Multiprojects". The following information relates to the additional engineering steps involved in configuring batch processes with the components of SIMATIC BATCH. Uniqueness of the names Note Please note that if you distribute the configuration work on several ES PCs, the project names and the names of the project objects contained must be unique on all ES PCs.
  • Page 225 All projects in multiprojects must be configured in the same language. If a project is removed and then configured in another language, SIMATIC BATCH will not be able to compile it correctly when the project is reinserted. The reason for this is the lingually differing display names for the parameters of enumerations.
  • Page 226 ● The ES data are copied to the corresponding project directory of Batch with the "Download" function. ● The ES data are transferred to the SIMATIC BATCH database using the "Update process cell" action in the BATCH Control Center (BCC).
  • Page 227 8.4.1 Flow chart: Engineering procedure for a multiproject Example configuration for centrally managed multiproject for SIMATIC BATCH The first step is to create a "Multiproject" object on a central ES PC in the SIMATIC Manager. You set up all the S7 projects along with drive information relating to the ES PCs on which the S7 projects will be configured below the multiproject.
  • Page 228 Rational engineering 8.4 Central multiproject engineering SIMATIC BATCH V8.2 Operating Manual, 02/2016, A5E35958174-AA...
  • Page 229 Rational engineering 8.4 Central multiproject engineering What is involved in the ES configuration for SIMATIC BATCH in a multiproject? SIMATIC BATCH V8.2 Operating Manual, 02/2016, A5E35958174-AA...
  • Page 230 8.5.1 Overview and important initial considerations Introduction In this section, we explain distributed multiproject engineering with SIMATIC BATCH. This involves the exchange of projects between central and several distributed multiprojects. These projects can only contain SIMATIC AS stations. These projects are exchanged by removing them from a central multiproject, inserting them into a distributed multiproject, editing them in the distributed multiproject, removing them from the distributed multiproject and finally inserting them back into the central multiproject.
  • Page 231 PC on which the SIMATIC PCS 7 configuration software is used. Requirements for distributed multiproject engineering with SIMATIC BATCH The following requirements must be fulfilled to perform DMPE with SIMATIC BATCH. ● The projects to be exchanged may only contain AS stations.
  • Page 232 ● Recipes, batch sequences ● Process pictures Up to which point in time can DMPE be performed? The point in time at which the commissioning phase for DMPE with SIMATIC BATCH is completed, depends on your own decision for the most part. Note You determine the point in time at which any reconfigured data can lead to inconsistencies in the Batch database when you perform the "Update process cell"...
  • Page 233 ZIP file. There, the project of the CMP is adapted to the local environment to allow further configuration and subsequent testing (AS, OS and BATCH process mode). SIMATIC BATCH V8.2 Operating Manual, 02/2016, A5E35958174-AA...
  • Page 234 Select the top hierarchy folder and, in the shortcut menu, click "Object properties" > In the "ISA-88 type definition" tab of the properties dialog, select "Process cell" as the object type and click "OK". The folder of the batch process cell is given a light green background. SIMATIC BATCH V8.2 Operating Manual, 02/2016, A5E35958174-AA...
  • Page 235 File > Archive > select project > OK > select archive and path > Save. Result You have continued editing of the project(s) and performed testing in process mode. You then archived the project as a user project to reinsert into the CMP. SIMATIC BATCH V8.2 Operating Manual, 02/2016, A5E35958174-AA...
  • Page 236 Did you remove the project from the CMP earlier? Were all the Batch IDs removed first? Is the name of the top hierarchy folder the same in all projects? Does the MAC address of the AS match the CMP settings? SIMATIC BATCH V8.2 Operating Manual, 02/2016, A5E35958174-AA...
  • Page 237 13.Update the batch data in the Batch Control Center (BCC). Result You have integrated the project back into the original CMP. You have made all the preparations to start process mode in you project. SIMATIC BATCH V8.2 Operating Manual, 02/2016, A5E35958174-AA...
  • Page 238 Rational engineering 8.5 Distributed multiproject engineering 8.5.6 Errors sources in distributed multiproject engineering with SIMATIC BATCH Introduction If the procedures and requirements for individual configurations are not adhered to, the following errors may occur: ● The batch data in the CMP and all projects may become invalid ●...
  • Page 239 Procedure on the OS servers Delete the batch messages on the OS servers involved. Note Consult with your Siemens service engineer. Make sure you do not lose any Batch data whatever you do. Potential problems and solutions, FAQ 1. Central settings of the configured equipment properties are lost when attaching and detaching.
  • Page 240 Operation of SIMATIC BATCH with more than one PCS 7 OS In standard cases, SIMATIC BATCH can be used either as a single station system (SB server with SB clients and OS server with OS client) on one computer or as a distributed system (multiple station system) with multiple OS servers (single or redundant).
  • Page 241 Rational engineering 8.6 Operation of SIMATIC BATCH with more than one PCS 7 OS Configuration example SIMATIC BATCH V8.2 Operating Manual, 02/2016, A5E35958174-AA...
  • Page 242 Rational engineering 8.6 Operation of SIMATIC BATCH with more than one PCS 7 OS SIMATIC BATCH V8.2 Operating Manual, 02/2016, A5E35958174-AA...
  • Page 243 BATCH server. If WinCC is installed on the BATCH server then the start mode "Automatic start of Simatic Batch after start of WinCC" is set, if WinCC is not installed on the BATCH server, then the start mode "Automatic start of Simatic Batch independently of WinCC"...
  • Page 244 Coordinator is started, a dialog opens showing all loaded batch process cells. Once you have selected a batch process cell, the Launch Coordinator icon appears showing the status of its process cells in the status bar of the BATCH client. SIMATIC BATCH V8.2 Operating Manual, 02/2016, A5E35958174-AA...
  • Page 245 BATCH Control Center 9.1 Starting and operating Status icons of the BATCH Launch Coordinator The icon contains a status display for SIMATIC BATCH. The potential states are listed in the table below. Symbol Meaning No status icon. No connection to the BATCH project. The BATCH project is not loaded and SIMATIC BATCH is waiting for BATCH data.
  • Page 246 "Running" status must be displayed in the information bar. The symbol looks like this: To start BatchCC: 1. Select the Start > Siemens Automation > SIMATIC > Batch > BATCH Control Center menu command in the Windows Start menu.
  • Page 247 The main window shows the BATCH objects, for example, in list form. You can control the view or windows with the "View" menu. There you will find commands for displaying and hiding additional windows. SIMATIC BATCH V8.2 Operating Manual, 02/2016, A5E35958174-AA...
  • Page 248 You can individually arrange windows in BatchCC. The following windows are offered: ● Control recipe. Arranged in the main window. ● Overview of the control recipe. Floating to the right next to the main window. SIMATIC BATCH V8.2 Operating Manual, 02/2016, A5E35958174-AA...
  • Page 249 In some situations, a progress indicator is also displayed in the status bar for processes that require longer. In the left part of the status bar, you will see context-sensitive information, for example explanations of menu commands, operator prompts or error messages. SIMATIC BATCH V8.2 Operating Manual, 02/2016, A5E35958174-AA...
  • Page 250 The BATCH Con‐ trol Center is not ready to use. The BATCH Control Center is not ready to use. See also Objects and object hierarchy (Page 270) Overview lists (Page 259) SIMATIC BATCH V8.2 Operating Manual, 02/2016, A5E35958174-AA...
  • Page 251 9.1.4.2 Project and user settings The graphic user interface of SIMATIC BATCH can be configured and customized completely according to your specific needs. You decide on the appearance and range of functions. You can make the required settings centrally in the "Project settings" and "User settings" dialogs in BatchCC and the recipe editor.
  • Page 252 ● If you do not use SIMATIC Logon, the applications use the user logged on in Windows. ● If you use SIMATIC Logon, the applications use the user logged on in SIMATIC Logon. SIMATIC BATCH V8.2 Operating Manual, 02/2016, A5E35958174-AA...
  • Page 253 ● Position, size and visibility of the menu bars. ● The last directory set in all SIMATIC BATCH dialogs where this selection is possible. ● Window settings for batches (size and position).
  • Page 254 This means that tabs are hidden if they do not contain any configuration settings. This behavior applies to the following tabs: ● Transfer parameters ● Process parameters ● Input material ● Output material ● Electronic signature ● Synchronization SIMATIC BATCH V8.2 Operating Manual, 02/2016, A5E35958174-AA...
  • Page 255 BATCH Control Center 9.1 Starting and operating System behavior with the SIMATIC BATCH OS controls In the properties dialogs for the BATCH OS controls in process mode, you have the option of hiding or showing tabs for the following elements in the OS Master control tab using the "PropertiesTabOrderAndVisibility"...
  • Page 256 All important functions relating to an object are available in the shortcut menu. As an alternative, the same functions are also available in the "Edit" menu. Functions that cannot be executed in the current status of an object are grayed out in the "Edit" menu. SIMATIC BATCH V8.2 Operating Manual, 02/2016, A5E35958174-AA...
  • Page 257 Selecting the functions General functions Some basic functions are common to all objects. These common functions are listed below. The descriptions of other functions assume that you know how to use these functions. SIMATIC BATCH V8.2 Operating Manual, 02/2016, A5E35958174-AA...
  • Page 258 Deleting is permanent and cannot be undone. If you are not sure whether or not you still need an object, it is advisable to archive the entire project before deleting. SIMATIC BATCH V8.2 Operating Manual, 02/2016, A5E35958174-AA...
  • Page 259 ● Batch overview list ● Material overview list To select overviews: Select a folder in the navigation window, for example, a master recipe folder, and then select the menu command Edit > Details. SIMATIC BATCH V8.2 Operating Manual, 02/2016, A5E35958174-AA...
  • Page 260 The content of the batch planning list is updated once you open it again, and the batch moved to the batch status list is no longer displayed. SIMATIC BATCH V8.2 Operating Manual, 02/2016, A5E35958174-AA...
  • Page 261 A new arrangement in a list is automatically saved when the list is closed and retained the next time the list is opened. SIMATIC BATCH V8.2 Operating Manual, 02/2016, A5E35958174-AA...
  • Page 262 With CRTL+A or the menu command Edit > Select all, you can select all the objects of a list, for example, to release all batches using the shortcut menu. Additional information Status of the batches (Page 372) SIMATIC BATCH V8.2 Operating Manual, 02/2016, A5E35958174-AA...
  • Page 263 ● User settings are entered in the global database and restored the next time you start BatchCC. Certain settings that are essential for SIMATIC BATCH are exceptions to this, for example selection of BATCH messages.
  • Page 264 Symbol Meaning Error status: Completed Error status: Reset Error status: Outgoing Error status: Outgoing and acknowledged Error status: Pending Error status: Pending and acknowledged Error type: Error Error type: Information Error type: Warning SIMATIC BATCH V8.2 Operating Manual, 02/2016, A5E35958174-AA...
  • Page 265 Some examples are described below: ● Errors in the equipment module such as pending external error, for example. ● Errors due to lack of licenses, for example, to few UNIT licenses, no SIMATIC BATCH Server license ● Errors in the allocation, for example, recipe element awaiting unit allocation.
  • Page 266 The shortcut window displays a type of fast access for frequently used objects. This eliminates the need to navigate through folder structures in the BatchCC navigation window. You can show or hide the shortcut window. SIMATIC BATCH V8.2 Operating Manual, 02/2016, A5E35958174-AA...
  • Page 267 Process cell data activated by server. Process cell data cleaned up Library element Library element deleted Master recipe Master recipe deleted Formula category Formula category Formula Formula deleted Order category Order category deleted SIMATIC BATCH V8.2 Operating Manual, 02/2016, A5E35958174-AA...
  • Page 268 A. With "?" in a name, you search for all objects with this name and a variable at the location of the "?" character. If the search result is displayed as a table, further filtering in the columns is possible by clicking the desired column header. This sorts the list entries accordingly. SIMATIC BATCH V8.2 Operating Manual, 02/2016, A5E35958174-AA...
  • Page 269 SIMATIC BATCH V8.2 Operating Manual, 02/2016, A5E35958174-AA...
  • Page 270 BatchCC in much the same way as the folder structure of the Windows Explorer with folders and files. The following figure shows a possible structure in the project window within the BatchCC. SIMATIC BATCH V8.2 Operating Manual, 02/2016, A5E35958174-AA...
  • Page 271 BATCH objects for the objects selected in the BatchCC (library operations and master recipes) and the configured unit allocations. Additional information ● Libraries with library operations (Page 272) ● Master recipes (Page 273) SIMATIC BATCH V8.2 Operating Manual, 02/2016, A5E35958174-AA...
  • Page 272 Position of the objects Available functions ● Opening and editing recipes (Page 302) ● Specifying the properties of library operations (Page 576) ● Validating recipes (Page 315) ● Releasing recipes for testing (Page 316) SIMATIC BATCH V8.2 Operating Manual, 02/2016, A5E35958174-AA...
  • Page 273 There are both flat and hierarchical master recipes. If you have large numbers of master recipes, these can be stored in different folders (without semantics) to achieve a better structure. Position of the objects SIMATIC BATCH V8.2 Operating Manual, 02/2016, A5E35958174-AA...
  • Page 274 If you have large numbers of formulas of a category, these can be stored in different folders (without semantics) to achieve a better structure. Position of the objects SIMATIC BATCH V8.2 Operating Manual, 02/2016, A5E35958174-AA...
  • Page 275 In this area, you create the production order categories with the lower level production orders. You can create batches for a production order. You also make the settings for batch processing, for example the Start mode. SIMATIC BATCH V8.2 Operating Manual, 02/2016, A5E35958174-AA...
  • Page 276 BATCH Control Center 9.1 Starting and operating Position of the objects Legend for figure: ① Order category ② Production orders with batches SIMATIC BATCH V8.2 Operating Manual, 02/2016, A5E35958174-AA...
  • Page 277 BatchCC and the BATCH Recipe Editor. This is only possible if the PCS 7 SIMATIC Logon software is installed. Without this additional product, every user in SIMATIC BATCH has all permissions comparable with the "Super user" role.
  • Page 278 User groups and roles When a user is a member of several Windows user groups that have been assigned a variety of roles in SIMATIC BATCH, this user has a union set of the individual permissions from all assigned roles.
  • Page 279 Creating and modifying recipes Super user The administrator of SIMATIC BATCH takes on the role of "Super user". A user with the super user role has all user permissions in SIMATIC BATCH and only this user can make changes in the permission management. The following icon identifies a super user: Rules for super users ●...
  • Page 280 ● As well as always having all permissions by definition, roles with super user status also have additional permissions that cannot be assigned to other users. For this reason, the permissions of these roles cannot be edited: all check marks are always set in the permission management. SIMATIC BATCH V8.2 Operating Manual, 02/2016, A5E35958174-AA...
  • Page 281 ● SIMATIC Logon Service (logon dialogs) Basic requirements for working with SIMATIC Logon: ● To configure SIMATIC Logon for use in SIMATIC BATCH, there must be a Windows user who is a member of the "Extended_Logon_Administrator" group. You can log on with this membership (Start >...
  • Page 282 The "SIMATIC Logon roles management" dialog is displayed: – You can create user roles for SIMATIC BATCH in the upper half of the dialog box and then assign Windows user groups/Windows users to these user roles. As a result, Windows users in SIMATIC BATCH have the assigned permissions of the BATCH user roles.
  • Page 283 BATCH Control Center 9.2 Specifying user permissions 3. In the "Individual permissions" tab, specify the user permissions for each user role: SIMATIC BATCH V8.2 Operating Manual, 02/2016, A5E35958174-AA...
  • Page 284 BatchCC), double-click on the logon display on the bottom right of the status line of the BATCH application. Alternatively, you can click the key symbol or use the "Log off" command in the "Options" menu. SIMATIC BATCH V8.2 Operating Manual, 02/2016, A5E35958174-AA...
  • Page 285 You cannot edit individual permissions of the "super user" role. Requirement To change or adapt the user permissions of the various roles, you need to be logged on as a user with the super user role in the BatchCC. SIMATIC BATCH V8.2 Operating Manual, 02/2016, A5E35958174-AA...
  • Page 286 To do this, navigate through the tree structure of the user roles or user groups / functions. 3. In the "Computers and units" tab, you can see which user roles are possible on which computer or on which unit. SIMATIC BATCH V8.2 Operating Manual, 02/2016, A5E35958174-AA...
  • Page 287 Structure of the info file The SIMATIC BATCH version, the generation date of the html file, and a note about ID numbers used which do not reference SIMATIC BATCH appear in the header.
  • Page 288 Setting up the emergency operator Automatic logon of standard user or emergency operator You can set up an emergency operator in SIMATIC BATCH using SIMATIC Logon. When a logged-on user logs off in BatchCC, the specified user is automatically logged on as an emergency operator in BatchCC.
  • Page 289 To be able to use the batch-relevant process cell data created in the engineering system (ES), this data must first be read into SIMATIC BATCH. To do this, create a new process cell in the BATCH Control Center. Requirement The batch process cell data created in the engineering system (ES) has been downloaded from the engineering station to the PCS 7 OS (runtime PC) of the BATCH server.
  • Page 290 (ES) or have entered new data, for example a new unit, you must also make such changes known in SIMATIC BATCH by reading the process cell data into the BATCH Control Center again. When you do this, all the BATCH data is updated.
  • Page 291 You can only delete it. Additional information "Assignment" tab in the "Updating the process cell" dialog (Page 800) "Preview" tab in the "Updating the process cell" dialog (Page 804) Updating a BATCH process cell (Page 292) SIMATIC BATCH V8.2 Operating Manual, 02/2016, A5E35958174-AA...
  • Page 292 SIMATIC BATCH are checked. If incorrect assignments are found, objects used in SIMATIC BATCH can fail validation. In this case, you must adapt and re-release BATCH objects such as master recipes, library operations, or formulas that have the "Release invalid"...
  • Page 293 9.4.1 Editing materials Purpose At the start of batch planning, you must define the following in SIMATIC BATCH for materials (products, by-products, waste products): ● The materials for input materials and output materials ● The quality of the main product You define the materials in the list boxes displayed in the subsequent dialogs for recipe creation and batch planning.
  • Page 294 4. Save you new entries with "OK". Note Context menu for the "Quality" object As an alternative, you can also perform this settings in the tree using the command Properties in the context menu of the object SIMATIC BATCH V8.2 Operating Manual, 02/2016, A5E35958174-AA...
  • Page 295 BATCH Control Center 9.5 Recipes Recipes 9.5.1 Flow chart: How to create and edit a master recipe How to create and edit a master recipe SIMATIC BATCH V8.2 Operating Manual, 02/2016, A5E35958174-AA...
  • Page 296 BATCH Control Center 9.5 Recipes 9.5.2 Flowchart: How to create/edit a library operation How to create / edit library operations and insert them in master recipes SIMATIC BATCH V8.2 Operating Manual, 02/2016, A5E35958174-AA...
  • Page 297 Internal and external formula must not be congruent, this means, all recipe header parameters must not be interconnected to an external formula. and not all the parameters of an external formula need to be used in a master recipe. SIMATIC BATCH V8.2 Operating Manual, 02/2016, A5E35958174-AA...
  • Page 298 After assigning a formula category to a master recipe, you specify the reference to the parameters in the formula category in the properties dialog. Parameters of the same data type and same physical unit are made available from the formula category. SIMATIC BATCH V8.2 Operating Manual, 02/2016, A5E35958174-AA...
  • Page 299 You create the actual recipe structure and set the properties of the recipe elements (Step 2) in the BATCH Recipe Editor. All the other steps can be made in BatchCC. SIMATIC BATCH V8.2 Operating Manual, 02/2016, A5E35958174-AA...
  • Page 300 BATCH Control Center 9.5 Recipes reference to formula category reference to new formula category reference to master recipe SIMATIC BATCH V8.2 Operating Manual, 02/2016, A5E35958174-AA...
  • Page 301 As an alternative to the tree, the "master recipe" objects can also be edited in the recipe overview. You can open the recipe overview with the menu command "Details". First, select the folder with the desired master recipes in the tree. ● Validating recipes (Page 315). SIMATIC BATCH V8.2 Operating Manual, 02/2016, A5E35958174-AA...
  • Page 302 You can recognize parameters or settings that can still be modified by the white editing fields. 3. Make the settings you require in the tabs and confirm with "OK". SIMATIC BATCH V8.2 Operating Manual, 02/2016, A5E35958174-AA...
  • Page 303 After assigning a formula category to a master recipe you specify the reference to the parameters in the formula category in the properties dialog ("input materials", "output materials" and "parameters" tabs). See also section: Interconnecting parameters between the master recipe and formula (Page 307) SIMATIC BATCH V8.2 Operating Manual, 02/2016, A5E35958174-AA...
  • Page 304 (only for process parameters) and physical unit and confirm with OK. Result: With the formula category, you can now create formulas with the same raw material and production data structure by creating new formulas under this formula category in the tree. SIMATIC BATCH V8.2 Operating Manual, 02/2016, A5E35958174-AA...
  • Page 305 |The parameters of the higher level formula category are displayed in each case. If parameters are missing, the formula category needs to be adapted. SIMATIC BATCH V8.2 Operating Manual, 02/2016, A5E35958174-AA...
  • Page 306 If the required master recipe is not listed, change to the properties dialog of the master recipe and enter the reference to the formula category there. SIMATIC BATCH V8.2 Operating Manual, 02/2016, A5E35958174-AA...
  • Page 307 Perform the parameter interconnection for the master recipe in the properties dialog, provided the formula category was assigned there (see also section Specifying the properties of the master recipe (Page 302)). SIMATIC BATCH V8.2 Operating Manual, 02/2016, A5E35958174-AA...
  • Page 308 Display of parameter interconnection The interconnection is displayed in the properties dialog of the formula with a connection icon in the "Usage" column: : interconnected : not interconnected (or no longer interconnected) SIMATIC BATCH V8.2 Operating Manual, 02/2016, A5E35958174-AA...
  • Page 309 Using the shortcut menu for the list object, you can select the available functions in the same way as in the tree structure (alternative editing method). SIMATIC BATCH V8.2 Operating Manual, 02/2016, A5E35958174-AA...
  • Page 310 Using the context menu for the list object, you can select the available functions in the same way as in the tree structure (alternative editing method). SIMATIC BATCH V8.2 Operating Manual, 02/2016, A5E35958174-AA...
  • Page 311 BATCH Control Center 9.5 Recipes Selecting the formula overview Select the required area by first selecting a formula folder in the tree and then selecting the menu command Edit > Details. SIMATIC BATCH V8.2 Operating Manual, 02/2016, A5E35958174-AA...
  • Page 312 In the BATCH Recipe Editor, you store the library operations created in this way in the "Libraries" folder in BatchCC using a menu command. SIMATIC BATCH V8.2 Operating Manual, 02/2016, A5E35958174-AA...
  • Page 313 A results list or error list is displayed that indicates, for example, which parameter settings are missing. Requirement: The master recipe or library operation has header pa‐ rameters and a recipe structure. SIMATIC BATCH V8.2 Operating Manual, 02/2016, A5E35958174-AA...
  • Page 314 Recipes released for testing can also be edited directly after revoking the release. If recipes are released for production, editing is possible only with certain settings in BatchCC (Options > Settings > Project settings). SIMATIC BATCH V8.2 Operating Manual, 02/2016, A5E35958174-AA...
  • Page 315 Only test batches (for example, test mode with water) can be created with the master recipes and library operations released for testing . 9.5.6.2 Validation of recipes Definition The validation covers the consistency of the library operations and process cell data used in the created recipe. SIMATIC BATCH V8.2 Operating Manual, 02/2016, A5E35958174-AA...
  • Page 316 Validation is possible based on modules that can be created and modified externally (plug-in modules). SIMATIC BATCH; Plugin Concept documentation describes how to program these modules. How to register these modules and activate their functions in SIMATIC BATCH is explained in the section "Working with externally created modules for validation (Page 319)". 9.5.6.3...
  • Page 317 Requirements: ● A master recipe released for testing or production is assigned. ● The formula parameters were interconnected successfully ● The formula parameters are within the upper and lower limit values SIMATIC BATCH V8.2 Operating Manual, 02/2016, A5E35958174-AA...
  • Page 318 "Release inva‐ lid". A recipe that is already open and being edited is locked to prevent access by other operators. This is indicated as locked by the additional symbol SIMATIC BATCH V8.2 Operating Manual, 02/2016, A5E35958174-AA...
  • Page 319 SIMATIC BATCH; Plugin How you program these modules is described in the documentation Concept . Below, you will learn how these modules are registered in SIMATIC BATCH and how to activate their functions. Follow the steps outlined below: 1.
  • Page 320 2. To navigate within the report, click the corresponding functions in the control bar located at the top. 3. You can print out the displayed report data for documentation purposes with the Edit > Print > 1 Standard menu command. SIMATIC BATCH V8.2 Operating Manual, 02/2016, A5E35958174-AA...
  • Page 321 When exporting/importing large recipes, you should only export one large recipe at a time into a file or import one large recipe at a time out of file otherwise performance will be affected. SIMATIC BATCH V8.2 Operating Manual, 02/2016, A5E35958174-AA...
  • Page 322 In the subsequent dialogs, the import wizard compares the process cell data of the file to be imported with the process cell data of the batch process cell open in BatchCC (target process SIMATIC BATCH V8.2 Operating Manual, 02/2016, A5E35958174-AA...
  • Page 323 Select the type you want to import here. 3. Confirm your selection of the desired file with "OK". Result: The import wizard starts. SIMATIC BATCH V8.2 Operating Manual, 02/2016, A5E35958174-AA...
  • Page 324 This command is only in the shortcut menu if the check box is selected and renaming is permitted. Using this command, you can give the element a new name under which the element will be imported. SIMATIC BATCH V8.2 Operating Manual, 02/2016, A5E35958174-AA...
  • Page 325 With BatchML (BATCH Markup Language) and BATCH COM API, we offer you the capability to import and use external manufacturer data for batch processes in SIMATIC BATCH. BatchML is a standardized recipe format. Source data must be structured for the data exchange according to rules.
  • Page 326 You use imported batches via COM API in the BATCH Control Center or in the BATCH OS controls. Additional information ● Manual for BATCH COM API: Start > SIMATIC > Documentation > English > SIMATIC BATCH - COM API ● World Batch Forum (WBF) SIMATIC BATCH V8.2 Operating Manual, 02/2016, A5E35958174-AA...
  • Page 327 The following elements are displayed in the result window with the default setting for the filter: ● Changed ● Inserted ● Deleted SIMATIC BATCH V8.2 Operating Manual, 02/2016, A5E35958174-AA...
  • Page 328 Changes the comparison direction. As a result, the comparison object of the left column is swapped with that of the right column in the display and the "Show only elements present on the right/left" symbols are also swapped. SIMATIC BATCH V8.2 Operating Manual, 02/2016, A5E35958174-AA...
  • Page 329 The basic principle of the comparison of recipe objects in terms of display and interpretation of results is explained using the following recipes: ● Recipe named Recipe example - V1.0 ● Recipe named Recipe example - V2.0 SIMATIC BATCH V8.2 Operating Manual, 02/2016, A5E35958174-AA...
  • Page 330 The master recipe named Recipe example - V1.0 is structured as follows and contains the following elements. Image 9-7 Master recipe V1.0 In the master recipe named Recipe example - V2.0 to be compared, changes have been made as follows. Image 9-8 Master recipe V2.0 SIMATIC BATCH V8.2 Operating Manual, 02/2016, A5E35958174-AA...
  • Page 331 01.06.2015 11:06:05 (UTC (UTC +2:00) +2:00) <Additional attributes> … … RUP_1 Recipe unit procedure <Absolute path> Name <Additional attributes> … … Recipe_operation_2 Recipe operation <Absolute path> Name Recipe operation <Additional attributes> … … SIMATIC BATCH V8.2 Operating Manual, 02/2016, A5E35958174-AA...
  • Page 332 The value before the change is located in the left column, and the value after the change is located in the right column (here, left column: "ROP"; right column: "Recipe operation"). SIMATIC BATCH V8.2 Operating Manual, 02/2016, A5E35958174-AA...
  • Page 333 9.5.9.3 Special displays and interpretations Because the explanations in the "Basic principles of the display and interpretation" section are not sufficient for the following SIMATIC Batch constructs, the particularities for these are described in this section: ● Simultaneous branch ● Alternative branch ●...
  • Page 334 Property Value (left side) Value (right side) Recipe_example_1 Recipe <Absolute path> Recipe Recipe example Recipe example Version V1.0 V2.0 Last change 08.06.2015 14:36:58 01.06.2015 11:06:05 (UTC +2:00) (UTC +2:00) <Additional attributes> … … SIMATIC BATCH V8.2 Operating Manual, 02/2016, A5E35958174-AA...
  • Page 335 Recipe example Recipe example Version V1.0 V2.0 Last change 08.06.2015 14:36:58 01.06.2015 11:06:05 (UTC +2:00) (UTC +2:00) <Additional attributes> … … OR_11 Alternative branch <absolute path> Number of subelements Elements that were added SIMATIC BATCH V8.2 Operating Manual, 02/2016, A5E35958174-AA...
  • Page 336 Property Value (left side) Value (right side) Recipe_example_1 Recipe <absolute path> Recipe Recipe example Recipe example Version V1.0 V2.0 Last change 08.06.2015 14:36:58 (UTC 01.06.2015 +2:00) 11:06:05 (UTC +2:00) <Additional attributes> … … SIMATIC BATCH V8.2 Operating Manual, 02/2016, A5E35958174-AA...
  • Page 337 Comment (node ID1) SyncNode-2.1 Com‐ ment Blocking (node ID1) Synchronization point (node ID2) ROP_4 - ROP_6 Comment (node ID2) SyncNode-2.2 Com‐ ment Blocking (node ID2) Monitoring container A monitoring container has been added. SIMATIC BATCH V8.2 Operating Manual, 02/2016, A5E35958174-AA...
  • Page 338 08.06.2015 14:36:58 (UTC 01.06.2015 11:06:05 +2:00) (UTC +2:00) <Additional attributes> … … Monitoring_8 Monitor <Absolute path> Number of elements in the monitoring container Elements that were added The number of monitored elements has been changed. SIMATIC BATCH V8.2 Operating Manual, 02/2016, A5E35958174-AA...
  • Page 339 (UTC +2:00) <Additional attributes> … … Loop_11 Loop <Absolute path> Comment Loop Number of subelements Elements that were integrated in the loop The number of elements in the recipe loop has been changed. SIMATIC BATCH V8.2 Operating Manual, 02/2016, A5E35958174-AA...
  • Page 340 Transition <absolute path> Number of conditions Logic (C1 OR C2) (C1 OR C2 OR C3) Condition_12 Condition <Absolute path> Description Operator <> Right value ERROR Left value U3_String (RUP_2:Uni‐ tParameter) Effective immediately (left) SIMATIC BATCH V8.2 Operating Manual, 02/2016, A5E35958174-AA...
  • Page 341 V1.0 V2.0 Last change 08.06.2015 14:36:58 (UTC 01.06.2015 11:06:05 +2:00) (UTC +2:00) ESIG activated <Additional attributes> … … ESIG that are available for this recipe ESIG Remove check mark at global attribute "Activate" SIMATIC BATCH V8.2 Operating Manual, 02/2016, A5E35958174-AA...
  • Page 342 Last change 08.06.2015 14:36:58 (UTC 01.06.2015 11:06:05 +2:00) (UTC +2:00) <Additional attributes> ESIG ESIG Electronic signature/Abort batch Number of configured roles Configured roles Operator Operator; Superuser Control strategy The control strategy has been changed. SIMATIC BATCH V8.2 Operating Manual, 02/2016, A5E35958174-AA...
  • Page 343 01.06.2015 11:06:05 +2:00) (UTC +2:00) <Additional attributes> … … Lib_reference_Test_27 Recipe operation <Absolute path> Comment Name LibReferenceTest Description Planned run time 00 S Monitoring time 00 S Overwrite runtime Scaling the runtime ESIG activated SIMATIC BATCH V8.2 Operating Manual, 02/2016, A5E35958174-AA...
  • Page 344 00 S Overwrite runtime Scaling the runtime ESIG activated LibReferenceTest Library reference <Absolute path> Comment Library reference LibReferenceTest1 Description Planned run time 00 S Monitoring time 00 S Scaling runtime Overwrite runtime ESIG activated SIMATIC BATCH V8.2 Operating Manual, 02/2016, A5E35958174-AA...
  • Page 345 Recipe example Version V1.0 V2.0 Last change 08.06.2015 14:36:58 01.06.2015 11:06:05 (UTC +2:00) (UTC +2:00) <Additional attributes> … … Sub_17 Library element <absolute path> Comment Name <Additional attributes> Elements hidden in the substructure SIMATIC BATCH V8.2 Operating Manual, 02/2016, A5E35958174-AA...
  • Page 346 Input material 001 Input material 002 Material code E001 E002 Output material 1 Output material <Absolute path> Setpoint Material name Product 001 Product 002 Material code P001 P002 Parameter1 Recipe parameters <Absolute path> Setpoint SIMATIC BATCH V8.2 Operating Manual, 02/2016, A5E35958174-AA...
  • Page 347 A production order specifies which product will be manufactured. Batches can be assigned to a the production order manually or automatically. The recipe on which the batch is based specifies the production process and the duration of the unit allocation. SIMATIC BATCH V8.2 Operating Manual, 02/2016, A5E35958174-AA...
  • Page 348 The procedure is identical in both cases. The procedure for working with formulas is described below. Configuring batches With SIMATIC BATCH, you can schedule batches and specify the chronological order of several batches without having to release the batches immediately for production. Batches can be derived from production orders.
  • Page 349 To make sure that batches do not block each other while they are running, configure start allocations or work with chains in the "End" mode. This is particularly important when using synchronization functions. Additional information "Allocation" tab (Page 756) SIMATIC BATCH V8.2 Operating Manual, 02/2016, A5E35958174-AA...
  • Page 350 See also section: Adding batches to a production order (Page 354) 2nd option You move on immediately to the "Batches" tab. For further settings: See section: Assigning batches to a production order (Page 351) SIMATIC BATCH V8.2 Operating Manual, 02/2016, A5E35958174-AA...
  • Page 351 – Automatic: Using the "Automatic" button is a convenient method of calculating batches for a specific amount of material. SIMATIC BATCH V8.2 Operating Manual, 02/2016, A5E35958174-AA...
  • Page 352 In the "Batches" tab, you can also create batches automatically using the "Automatic" button. How to create batches automatically: 1. Select a batch as the master batch. 2. Click the "Automatic" button. Result: The dialog for selecting the formula/master recipe is displayed. SIMATIC BATCH V8.2 Operating Manual, 02/2016, A5E35958174-AA...
  • Page 353 9.6.2.4 Displaying the properties of a production order Procedure in BatchCC: 1. Select the production order in the "Orders" folder in BatchCC. 2. Select the menu command Edit > Properties. SIMATIC BATCH V8.2 Operating Manual, 02/2016, A5E35958174-AA...
  • Page 354 There are several ways you can add batches to the production order: ● When creating a new production order: see section: "Assigning batches to a production order". (Page 351) ● By adding batches to an existing production order: described below. SIMATIC BATCH V8.2 Operating Manual, 02/2016, A5E35958174-AA...
  • Page 355 (Page 351). ● When supplementing a batch for the production order: see section Adding batches to a production order (Page 354). ● Later for an existing batch. This option is described below. SIMATIC BATCH V8.2 Operating Manual, 02/2016, A5E35958174-AA...
  • Page 356 3. Make all the settings you require for the batch and confirm with "OK". Result: After it is enabled, the batch can be processed depending on the selected Start mode and the unit allocation. SIMATIC BATCH V8.2 Operating Manual, 02/2016, A5E35958174-AA...
  • Page 357 Result: The dialog "Properties of <batch name>" is displayed. 3. In the "Start mode" input field, select "Operator", "Immediate" or "Time-driven". 4. You must also set a start time and date. 5. Confirm with "OK". SIMATIC BATCH V8.2 Operating Manual, 02/2016, A5E35958174-AA...
  • Page 358 5. Confirm your changes with "OK". Overview of the unit allocations You can also open an overview (read only) of the unit allocations with the menu command Planning > Unit allocation. SIMATIC BATCH V8.2 Operating Manual, 02/2016, A5E35958174-AA...
  • Page 359 If you want to make sure that a batch is only started after a previous batch has been completed, you can also chain planned and not yet released batches. You can specify a predecessor batch and then specify whether the predecessor batch is to be started or already completed. SIMATIC BATCH V8.2 Operating Manual, 02/2016, A5E35958174-AA...
  • Page 360 The planned starting time is updated for all the batches that are shifted to the right by this action. ● In the start mode "immediately", only the first batch of a batch chain can be shifted to the left or right. SIMATIC BATCH V8.2 Operating Manual, 02/2016, A5E35958174-AA...
  • Page 361 ● End chain: This batch starts running only after the predecessor batch is completed. If the batch is aborted or stopped, a query is displayed asking whether the next batch should be started. SIMATIC BATCH V8.2 Operating Manual, 02/2016, A5E35958174-AA...
  • Page 362 "Run time" box. Note These batch run times can be used to optimize planning. Please remember that these times are not exactly the same as the actual times required for batch control. SIMATIC BATCH V8.2 Operating Manual, 02/2016, A5E35958174-AA...
  • Page 363 The time conflict is indicated by a red lightning icon. Time conflicts can be eliminated in this overview dialog by simply moving the batches in the right-hand time window. SIMATIC BATCH V8.2 Operating Manual, 02/2016, A5E35958174-AA...
  • Page 364 ● Yellow bar: Unit without conflict ● Gray bar: Batches with a run time longer than six hours. The icon to the left of the bar indicates the current status of the batch. SIMATIC BATCH V8.2 Operating Manual, 02/2016, A5E35958174-AA...
  • Page 365 Such limit violations are generally caused by adjusting the volume of the setpoint parameters when creating a control recipe from a basic recipe. Definitions Recipe A recipe is comprised of the recipe header, recipe steps and transitions. SIMATIC BATCH V8.2 Operating Manual, 02/2016, A5E35958174-AA...
  • Page 366 (limit value violations) on release of the batch, the creator of the recipe is already supported by the system when working within the recipe editor and possible conflicts are shown for prepared amounts within the set recipe limits. SIMATIC BATCH V8.2 Operating Manual, 02/2016, A5E35958174-AA...
  • Page 367 Reference quantity 1000 liter Recipe ② Minimum quantity 100 liter Recipe ③ Maximum quantity 5000 liter Recipe Unit Unit A Unit B Lower limit of nominal value Upper limit of nominal value 1500 Setpoint SIMATIC BATCH V8.2 Operating Manual, 02/2016, A5E35958174-AA...
  • Page 368 (see Figure 2). To make recipe design easier for the recipe creator, the limit values within which the nominal value can be without violating the nominal value limits for mix quantities between the lowest SIMATIC BATCH V8.2 Operating Manual, 02/2016, A5E35958174-AA...
  • Page 369 ● Adjusted parameter of lower limit = (1000 / 100) * 0 = 0 ● Adjusted parameter of upper limit = (1000 / 5000) * 100 = 20 Image 9-11 Fig 3: Display of nominal limits in candidate mode with preferred unit "UNIT_B" SIMATIC BATCH V8.2 Operating Manual, 02/2016, A5E35958174-AA...
  • Page 370 The incorrect behavior of this batch can be prevented by making a change to the configuration at the upper limit of the single step from 1500 Kg to 1250 kg. Engineering and the creator(s) of the recipe must work together on this. Please carry out the test runs. SIMATIC BATCH V8.2 Operating Manual, 02/2016, A5E35958174-AA...
  • Page 371 The complete control recipe is always shown in the overview window. The overview window is used for more complex control recipes that you display enlarged in the control recipe window. You use this function to visualize details in large recipes. SIMATIC BATCH V8.2 Operating Manual, 02/2016, A5E35958174-AA...
  • Page 372 The batch was started and is now wait‐ ing for the unit or units required at the start of the recipe to become free. Running The batch was started or resumed and is being processed. SIMATIC BATCH V8.2 Operating Manual, 02/2016, A5E35958174-AA...
  • Page 373 The batch is archived. The batch can now be deleted. Error At least one recipe phase in the control recipe of the batch has reported an error or the batch control itself is in an exceptional state. SIMATIC BATCH V8.2 Operating Manual, 02/2016, A5E35958174-AA...
  • Page 374 To prevent a released batch from being started (by operator command or automatically), you can lock it. Procedure 1. Select the batch in the tree structure in the BatchCC or in the planning list. 2. Select the Control > Lock menu command. SIMATIC BATCH V8.2 Operating Manual, 02/2016, A5E35958174-AA...
  • Page 375 Electronic signature 9.7.1 Specifying electronic signatures SIMATIC BATCH supports the function "Electronic signature" according to the requirements as regards FDA or 21 CFR Part 11. The "electronic signatures" function allows you to enter one or more electronic signatures in the form of dialogs similar to the logon prompts normal in Windows when defined actions are taken with BATCH objects such as batches, recipes, recipe elements etc.
  • Page 376 2. Change to the "ESIG" tab (in the figure below, this is for a batch) and select the "Activate" check box. Result: A table with possible operator actions for the object is displayed. SIMATIC BATCH V8.2 Operating Manual, 02/2016, A5E35958174-AA...
  • Page 377 4. When completed, confirm the configuration with the "OK" button. Result At runtime of the object (batch, RPH, ROP, RUP, transition), after the action is complete, the dialog box "SIMATIC BATCH: Sign" opens. For information on entering electronic signatures, refer to section "Signing operator actions (Page 378)". Note Once electronic signatures have been created, they can be deactivated but not deleted.
  • Page 378 With a right-mouse click on the object to be signed and the shortcut menu command "Sign", this dialog box can also be opened here. With the "Sign" button of the dialog box "SIMATIC BATCH: Sign", the entry of the signatures can be started. assuming that you have configured electronic signatures for the object.
  • Page 379 An icon indicating a signature request is displayed at the step and an icon indicating an operator prompt is displayed at the batch. Icon Description Signature request at the recipe step. Operator prompt on the batch in the BCC SIMATIC BATCH V8.2 Operating Manual, 02/2016, A5E35958174-AA...
  • Page 380 Requirements for batch processing Requirements Batch control with SIMATIC BATCH requires the PCS 7 OS (WinCC) system. Before a batch can be processed, the following requirements must be met: ● The PCS 7 OS system must be operating in runtime mode (online).
  • Page 381 Flow chart: How is a batch started and controlled? How do I start and control a batch? The activities involved in batch control are as follows: Opening the control recipe (Page 409) Starting production of a batch (Page 412) SIMATIC BATCH V8.2 Operating Manual, 02/2016, A5E35958174-AA...
  • Page 382 UNIT_PLC blocks, a check is made to find out whether the units have been released for use by SIMATIC BATCH and are not allocated to other batches. If the units are free and released, the batch can be started, otherwise the relevant parameters are reported for monitoring.
  • Page 383 For each planned batch, you can specify which batch must be started and which batch must be completed before the planned batch is started. Additional information: Chaining of batches (Page 359) SIMATIC BATCH V8.2 Operating Manual, 02/2016, A5E35958174-AA...
  • Page 384 Executing a batch Execution of a recipe in SIMATIC BATCH AS based The following recipe is intended to illustrate execution of a recipe in As-based SIMATIC BATCH: Image 9-12 Online view of the control recipe in the BCC, status planned...
  • Page 385 BATCH control server within 34 ms via the direct communication channel of the BATCH control server (BCS) and the AS. Image 9-13 Online view of the control recipe in the BCC, status completed and completing SIMATIC BATCH V8.2 Operating Manual, 02/2016, A5E35958174-AA...
  • Page 386 Online view of the control recipe in the BCC, status running Note Control recipe is run through once Once a batch has been started, the entire control recipe is run through once without consideration of the time set in the "MaxCyclRun" parameter. SIMATIC BATCH V8.2 Operating Manual, 02/2016, A5E35958174-AA...
  • Page 387 (in different RUPs) can be started at the same time. Within a recipe operation, the individual steps (recipe phases -> EPHs) and transitions (step enabling conditions) are also executed sequentially. SIMATIC BATCH V8.2 Operating Manual, 02/2016, A5E35958174-AA...
  • Page 388 9.8.3.5 Status changes of equipment phases SIMATIC BATCH uses so-called equipment phases (EPE, Equipment Procedural Elements) for the recipe sequence. This can be of the type EPH or EOP. To ensure problem-free cooperation with the overlying control, the equipment phase must...
  • Page 389 ● A non-self-terminating equipment phase. Once it has run, such a phase changes to the READY TO COMPLETE status. In the READY TO COMPLETE status, an EPE signals that it must be completed actively by the control. SIMATIC BATCH V8.2 Operating Manual, 02/2016, A5E35958174-AA...
  • Page 390 Control in manual mode (batch "Operation" start mode) With commands for recipe steps, you can execute these status changes manually, for example, during commissioning. Additional information Operator commands for recipe steps (Page 416) SIMATIC BATCH V8.2 Operating Manual, 02/2016, A5E35958174-AA...
  • Page 391 BATCH Control Center 9.8 Batch control 9.8.3.6 Status changes with batches Statuses of a batch The schematic below shows the possible statuses and status changes of a batch depending on the existing status. SIMATIC BATCH V8.2 Operating Manual, 02/2016, A5E35958174-AA...
  • Page 392 BATCH Control Center 9.8 Batch control SIMATIC BATCH V8.2 Operating Manual, 02/2016, A5E35958174-AA...
  • Page 393 5. The additional label "archiving" is used only in connection with the "Prompt archiving" technology. Additional information Status of the batches (Page 372) States of the batch steps (Page 427) States of a transition (Page 426) PH Archive server - Prompt archiving (Page 471) SIMATIC BATCH V8.2 Operating Manual, 02/2016, A5E35958174-AA...
  • Page 394 All external clients, such as API clients, must comply with this diagram to ensure compatibility with future versions. All clients that receive recipe results, must be prepared for the optional statuses for future software versions. SIMATIC BATCH V8.2 Operating Manual, 02/2016, A5E35958174-AA...
  • Page 395 BATCH Control Center 9.8 Batch control Image 9-15 Status changes with recipe steps SIMATIC BATCH V8.2 Operating Manual, 02/2016, A5E35958174-AA...
  • Page 396 When a recipe step takes on the additional status "manual operation" and is occupied by SIMATIC BATCH, the status can be changed from inactive to any other status. This means that the recipe phase takes on the status of the SFC, for example.
  • Page 397 As so