s

Contents

Part 1: Introduction

SIMATIC Part 2: Quick Start

Part 3: Creating an Equipment
Phase with SFC and BATCH
SIMATIC BATCH Interface Blocks

Getting Started Part 4: Creating an Equipment

Phase with an SFC Type
Parts 1 to 4

Manual

Video Sequences
Along with this Getting Started, there are video sequences
in which you can follow the step-by-step instructions
as they are performed.
After installing SIMATIC BATCH, the video sequences
are in the sbvideob.zip file in the
...\SIEMENS\BATCH\Manual folder.
The names of the video sequences match
the chapter numbers in the manual.

Note
The name of the sample project is incorrect in some of the
screenshots: the project name should be "Zen33_01"
instead of "Zdt33_01".

Edition 01/2005
A5E00364255-01
Safety Guidelines

This manual contains notices intended to ensure personal safety, as well as to protect the products and
connected equipment against damage. These notices are highlighted by the symbols shown below and
graded according to severity by the following texts:

Danger
! indicates that death, severe personal injury or substantial property damage will result if proper
precautions are not taken.

Warning
! indicates that death, severe personal injury or substantial property damage can result if proper
precautions are not taken.

Caution
! indicates that minor personal injury can result if proper precautions are not taken.

Caution
indicates that property damage can result if proper precautions are not taken.

Notice
draws your attention to particularly important information on the product, handling the product, or to a
particular part of the documentation.

Qualified Personnel

Only qualified personnel should be allowed to install and work on this equipment. Qualified persons
are defined as persons who are authorized to commission, to ground and to tag circuits, equipment, and
systems in accordance with established safety practices and standards.

Correct Usage

Note the following:

Warning
! This device and its components may only be used for the applications described in the catalog or the
technical description, and only in connection with devices or components from other manufacturers
which have been approved or recommended by Siemens.

This product can only function correctly and safely if it is transported, stored, set up, and installed
correctly, and operated and maintained as recommended.

Trademarks
SIMATIC®, SIMATIC HMI® and SIMATIC NET® are registered trademarks of SIEMENS AG.

Third parties using for their own purposes any other names in this document which refer to trademarks
might infringe upon the rights of the trademark owners.
Copyright Siemens AG 2005 All rights reserved Disclaimer of Liability
The reproduction, transmission or use of this document or its We have checked the contents of this manual for agreement with
contents is not permitted without express written authority. the hardware and software described. Since deviations cannot be
Offenders will be liable for damages. All rights, including rights precluded entirely, we cannot guarantee full agreement. However,
created by patent grant or registration of a utility model or design, the data in this manual are reviewed regularly and any necessary
are reserved. corrections included in subsequent editions. Suggestions for
improvement are welcomed.
Siemens AG
Bereich Automation and Drives
Geschaeftsgebiet Industrial Automation Systems Siemens AG 2005
Postfach 4848, D- 90327 Nuernberg Technical data subject to change.
Siemens Aktiengesellschaft A5E00364255-01
Contents

Part 1: Introduction
1 Batch Processes 1-2
1.1 Technical Process Categories.........................................................................1-2
1.2 Characteristics of Continuous and Batch Processes ......................................1-4
1.3 Practice: Where is this Used? .........................................................................1-5
1.4 Branches for SIMATIC BATCH .......................................................................1-7
1.5 Origins of Batch Production: The Kitchen........................................................1-8
1.6 The Cook - Working Environment and Working Procedures...........................1-9
1.7 Batch Terminology.........................................................................................1-10
1.8 The Kitchen: Master Recipes – Header Data ................................................1-11
1.9 The Kitchen: Master Recipes – Procedure (procedural rules) ......................1-12
1.10 The Kitchen: What is Required of the Automation ........................................1-13
1.11 The Kitchen: Automation Concept.................................................................1-14
1.12 Automation Concept- New Approach ............................................................1-15
1.13 Separation of the Automation Level and Recipe Level .................................1-16
1.14 ISA S88.01 - Physical Model .........................................................................1-17
1.15 Procedural Control Model ..............................................................................1-18
1.16 Implementation – Physical and Procedural Model ........................................1-19
1.17 S88.01 Model – PCS 7 ..................................................................................1-20
1.18 Workflow in the Kitchen: Order - Master Recipe - Process Cell....................1-21
1.19 Classification of Batch Process Cells ............................................................1-22
1.20 SIMATIC BATCH: Customer Benefits ...........................................................1-24

Part 1: Quick Start

Description of the Model..........................................................................................................2-5

Chapter 1 Retrieving the Project....................................................................................2-8
Chapter 2 Configuring the BATCH Server and BATCH Client..................................2-12
Chapter 3 Opening the Plant View...............................................................................2-15
Chapter 4 Creating the Batch Process Cell ................................................................2-16
Chapter 5 Type Definition of the Plant Hierarchy According to ISA S88.01 ...........2-17
Chapter 6 Assigning the "EPH" Batch Category .......................................................2-22
Chapter 7 Generating the Type Description in the Batch Types..............................2-25
Chapter 8 Compiling the PLC, OS and Batch Process Cell Data .............................2-27
Chapter 9 Downloading the Batch Process Cell Data ...............................................2-32
Chapter 10 Downloading the PLC to PLCSim ..............................................................2-34
Chapter 11 Starting the OS.............................................................................................2-38
Chapter 12 Starting the BATCH StartCoordinator .......................................................2-40

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Contents

Chapter 13 Reading in the Supplied Recipes and Materials.......................................2-43

Chapter 14 Updating the Loaded Batch Process Cell Data ........................................2-45
Chapter 15 The Recipe for Piccata Milanese Pasta .....................................................2-46
Chapter 16 Creating an Output Material .......................................................................2-47
Chapter 17 Creating a Master Recipe in the BatchCC.................................................2-48
Chapter 18 Creating the Recipe Structure in the Recipe Editor.................................2-50
Chapter 19 Releasing the Master Recipe for Production............................................2-73
Chapter 20 Creating an Order (Batch)...........................................................................2-75
Chapter 21 Releasing and Starting a Batch (Control Recipe) ....................................2-78

Part 3: Creating an Equipment Phase with

SFC and BATCH Interface Blocks

Chapter 1 Task/Implementation Concept .....................................................................3-5

Chapter 2 Expanding the Plant Hierarchy ....................................................................3-9
Chapter 3 Configuring the Control Module Level (Valve V1)....................................3-11
Chapter 4 Configuring BATCH Interface Blocks for the Control Commands
and Process Value Transfer .......................................................................3-13
Chapter 5 Creating an SFC...........................................................................................3-18
Chapter 6 Connecting the Batch Control Commands with the SFC ........................3-27
Chapter 7 Compiling and Downloading the CPU and OS .........................................3-30
Chapter 8 Generating Batch Types .............................................................................3-33
Chapter 9 Compiling, Transferring the OS and Downloading Batch .......................3-35
Chapter 10 Expanding the Unit Faceplate in the WinCC Explorer .............................3-39
Chapter 11 Expanding a Recipe.....................................................................................3-41

Part 4: Creating an Equipment Phase with an

SFC Type

Chapter 1 Task/Implementation Concept “Ventilate”..................................................4-4

Chapter 2 Creating the SFC Type “Ventilate” ..............................................................4-8
Chapter 3 Creating Sequencers...................................................................................4-13
Chapter 4 Expanding the Plant Hierarchy ..................................................................4-21
Chapter 5 Creating Instances of the SFC Type “Ventilate” for Pot_1 .....................4-25
Chapter 6 Compiling and Downloading PLC, OS, and Batch ...................................4-29
Chapter 7 Expanding the Unit Faceplate in the WinCC Explorer .............................4-30
Chapter 8 Expanding a Recipe.....................................................................................4-32

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Contents

SIMATIC BATCH Getting Started

vi A5E00364255-01
 Introduction

SIMATIC BATCH Getting Started

Part 1

Introduction

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 Introduction

1 Batch Processes

1.1 Technical Process Categories

Technical Process Distribution

Manufacturing Distribution Process Storage process

Process „Transport“ „Saving“
„Transformation“

Process Refinery, Gas distribution, Tank,

engineering Chemical Pipeline Bunker
Reactions

Production Turning, Assembly line, Storage

engineering Milling Packaging

© 2003 SIEMENS AG All Rights Reserved

SIMATIC Process Control System 7

Distinction between Process Engineering and Production Engineering

• The products of industrial processes are normally produce liquid or solid materials
- physical / chemical / biological processes
- safety, complete control of (dangerous) processes
- undetermined (cannot be predicted)
- at times cannot be interrupted
• Production processes are used to produce specific amounts of goods, for example screws,
computers....
- mechanical activities
- throughput, speed
- determined (predictable)
- can be interrupted

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 Introduction

Division within Industrial Processes

• Continuous process
- started up once and then operated continuously over a longer period of time
- Synonym: Continuous flow process
- Examples: Ammonia synthesis, ethylene production
• Discontinuous process (batch process)
- produces the product in individual batches
- Synonym: Batch process
Examples: Production of plastics, paints, fertilizers

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1.2 Characteristics of Continuous and Batch Processes

Conti and Batch Characteristics

Water

Evaporators Chemical
PIC
Reactor Group
Condenser
PT

Vacuum
Pan to Hot Well
Evaporator PIC
LIC LT PT
Steam
Feed
Feed Condensate

DRC

Product
DT
Batch
Conti

✔Continuous Product Flow ✔Limited product amounts

✔Large Product Volumes ✔Low product volumes
✔Set value processing ✔Recipe processing
✔Rarely changes to the system ✔Frequent recipe changes
✔Single product systems ✔Different products on same system
✔Balance states ✔Often only partially automated ->
✔Seldom manual intervention manual intervention
✔Automation contains the ✔Production Know-How is integrated in
Production Know-How the cycles (recipes)

© 2003 SIEMENS AG All Rights Reserved

SIMATIC Process Control System 7

The main difference between batch and continuous processes is in production.

In a batch process, specific quantities of product are produced so that they can be uniquely identified.
Recipes contain not only the setpoints of the relevant process variables and product quantities but also
describe the method or procedure used to make the product.
In a continuous process, the sections of plant are specialized for their particular task.
In a batch process, the same section of plant can be used more than once by different batches (shared
resources).
Quite often, you will find a mixture of these two processes in which continuous and batch processes are
linked together or in which smaller sections of a batch process are handled by an intermediate stage
operating continuously.

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 Introduction

1.3 Practice: Where is this Used?

Practice: Where is this used ?

are written in "Recipes"
Chemical
Reactor Group
can be modified for new
products

are continuously
optimized
Production cycles

are logged
Batch
are created / modified by operating personnel

can run on different units

Consider examples
Manage various products (on the same for Batch / Conti Processes
plant)

© 2003 SIEMENS AG All Rights Reserved

SIMATIC Process Control System 7

The production sequences are described in recipes that reflect the manufacturing process. In contrast to
typical continuous applications or production engineering applications, the production sequence is not
expressed in the automation solution but is described in a "Recipe".
The production sequences can be adjusted to new products. It is by no means the case that automated
production always produces the same thing, but rather various end products can be produced whose
manufacturing processes are specified in different recipes. These are constantly optimized both in terms
of parameter settings and the production sequences themselves.
In production, it is often vital that the sequences can be documented to allow them to be reconstructed.
This is important for quality assurance and to identify defects.
For many end customers it is decisive that they can adapt the production sequences themselves to
different products allowing them to introduce new products or to modify existing workflow sequences. This
should be possible for the operating personnel without needing to call in system specialists. It should not
be necessary to make changes to the programmable controller itself but rather in the recipes describing
the manufacturing process.
During actual production as described in a recipe, the following question often arises: "Where will
production take place?“. Generally there is more than one production facility capable of performing the
same production sequence (for example several production lines). It should therefore be possible to
assign the production sequences to different production facilities. This ability must also be included in the
system functionality and must not require modifications to the automation program.

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 Introduction

Notes:

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 Introduction

1.4 Branches for SIMATIC BATCH

SIMATIC BATCH Application Branches

Biotechnology Food and

Luxury Stuffs

Pharmaceuticals Washing and

Cleaning Agents

Paint / Dye Plastic /

Adhesive

Fertilizer / Chemical and

Pesticides Mineral Fiber

© 2003 SIEMENS AG All Rights Reserved

SIMATIC Process Control System 7

Typical branches that use batch processes are listed above.

One example is the production of beer in the foodstuffs and luxuries industries.

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 Introduction

1.5 Origins of Batch Production: The Kitchen

Origin of Batch Production:

The Kitchen

© 2003 SIEMENS AG All Rights Reserved

SIMATIC Process Control System 7

The best example from daily life is the "Kitchen“ production plant.
Various products are created here. The production method is described in recipes. These can be
constantly optimized and improved and completely new recipes are added.
The cooks are perfectly capable of doing this themselves without needing help from the kitchen
manufacturer. The recipe is often "secret" and contains the know-how for the production of a dish.
When cooking, cooks want to be able to decide which equipment will be used to implement a recipe. If
there are several kitchens (for example in an industrial kitchen), the user can decide which kitchen will be
used to make the recipe. Regardless of the kitchen selected, the same product should result and the
actual production location should only be decided during production scheduling.
It may also be important to document the production sequences (for example for quality assurance for the
health authorities and for guests who want to know how the product they are consuming was actually
produced).

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 Introduction

1.6 The Cook - Working Environment and Working Procedures

The Cook
Working Environment and Working Procedures
Ingredients+directions (1 portion) for:
-Spaghetti Bolo
-Spaghetti Carbonara
-Beef Stew
-.........

Master Recipes Material

Order
For table 1:
8 portions of Spaghetti Bolo
For 12:30 pm
production order 8 portions of Spaghetti Bolo:
Produce on range 1
4 batches of 2 portions
According to master recipe for
"Spaghetti Bolo"
by 12:30 pm

Production System Product

© 2003 SIEMENS AG All Rights Reserved
SIMATIC Process Control System 7

The working environment of a cook is as follows. The cook has recipes available containing both the
instructions as well as the required ingredients and quantities. These recipes are known as master
recipes.
To produce the product, materials are required that will be used during production.
Before production can be started, an order is necessary. This contains at least the information about what
should be created in which quantity and by when.
To deal with the order, the cook works according to the relevant recipe. The cook must also decide where
(for example on which stove) the dish will be cooked. Normally, several orders are being processed at the
same time so that some production equipment is occupied and not currently available.
The result is the finished product.

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 Introduction

1.7 Batch Terminology

Batch Terminology

„ Master recipe
A type of recipe wich taks into account the equipment
capabilities and may include process cell-specific
information.
„ Control recipe
A type of recipe witch, through its execution, defines the
manufacture of a single batch of a specific product.
„ Batch
Apparatus dependent amount of a product, which is
manufactured discontinuously in a defined production
cycle.
„ Process
Sequence of chemical, physical or biological processes to
recover, produce or eliminate materials or products.

© 2003 SIEMENS AG All Rights Reserved

SIMATIC Process Control System 7

Up to now, we have used terms taken from everyday language. Such terms are, however, liable to
subjective interpretation. The same word may mean different things to different people. This is particularly
the case when people with different occupations talk to each other (for example system engineers,
chemists, production engineers). A chemist might understand a recipe to be the chemical composition of
a product (which should not be revealed at any cost) whereas the system engineer considers it to be an
automated sequence (for example a sequencer).
To create a production facility that operates as required, people from various walks of life must be able to
work together. It is therefore important that everyone speaks the same "language". Definition and
unification of the terminology was the aim of NAMUR and ISA SP88.
We will gradually replace everyday language with the terminology from the standard.
In our kitchen, we will therefore be able to derive a control recipe from the "Spaghetti" recipe for Fred's
kitchen that will decide the production sequences and that will produce a batch of spaghetti after it has
been processed.
This illustrates that the control recipe derived from the master is responsible for production. The control
recipe must therefore know which production facilities it will be using while the master recipe remains
neutral in this respect.

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 Introduction

1.8 The Kitchen: Master Recipes – Header Data

The Kitchen
Master Recipes - Header Data:

The cook's language S88-Terminology

Dish Spaghetti Product

Bolognese

Servings 4 (Standard servings) Reference

quantity
Ingredients 1 kg Ground meat
100 g Mushrooms Ingredient
1kg Noodles
A pinch of salt
1 Onion
4 Tomatoes
: :
: :

© 2003 SIEMENS AG All Rights Reserved

SIMATIC Process Control System 7

What do master recipes contain in detail? Typically, they contain two parts:
A recipe header with general information on the product (name, reference quantity, ingredients,
quantities).
A recipe was also include instructions or procedural rules for production. This is known as a recipe
procedure.
This does not yet contain any information about the equipment that will be used for production.

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 Introduction

1.9 The Kitchen: Master Recipes – Procedure (procedural rules)

Master Recipes – Procedure (procedural rules)

The Kitchen
Instructions Procedural Rules
1. Make Bolognese Partial recipe 1

Onions and tomatoes ROP 1: Preparations

Chop
and put in Pan,
Weigh the ground meat and
add it
ROP 2: Heating
Pan to Setting 6
heat
ROP 3: Simmer
Put the lid on the pan
and let simmer for 1 hour
2. Cook noodles Partial recipe 2
.....
.....
3. Add spices Pot Partial recipe 3
.....
.....
4. Taste Pan Sample

© 2003 SIEMENS AG All Rights Reserved

SIMATIC Process Control System 7

The recipe procedure forms the instructions for production. It is divided into various sections (unit
recipes). The unit recipes themselves are made up of recipe operations.
We could, for example describe the production of Bolognese sauce required to produce Spaghetti
Bolognese in a unit recipe for Bolognese. We can further refine this procedure by detailing the steps in
recipe operations. In the unit recipe for Bolognese sauce, would therefore start with the "Prepare“ recipe
operation. During the preparation, the input materials onions and tomatoes are chopped, ground meat is
weighed and put in a pan.
At this stage, use of the term pan or pot is still generalized. These are references to the production
facilities that will be required. In the language of the standard, these are known as unit classes. The
master recipe itself is nevertheless "neutral" in terms of the units; in other words there is still no mention
of the unit that will actually be used for production (for example Fred's kitchen and, Fred's favorite pot).

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 Introduction

1.10 The Kitchen: What is Required of the Automation

What is required of the Automation

The Kitchen
are written in "Recipes" Cooking recipes for spaghetti, ...

can be modified for new The cook must create new dishes
products

are continuously Refinements, Recipe modifications

optimized
Production cycles
Dish production should be recorded
are logged
and be able to be traced

are created / modified by Recipes are made by the cook, not

operating personnel by the appliance supplier

can run on different units Recipes can be used in different

kitchens
Manage various products (on the same Spaghetti, schnitzel, baked potatoes,…
plant)

© 2003 SIEMENS AG All Rights Reserved

SIMATIC Process Control System 7

The characteristics of batch processes are illustrated in the example of a kitchen above.
When automating such processes, the above requirements must therefore be met.

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 Introduction

1.11 The Kitchen: Automation Concept

Automation Concept
The Kitchen
are written in "Recipes" Could be extremely complex
in some cases, if possible
with AWL.SCL.SFCs WinCC

can be modified for new AWL,SCL,SFCs could be

modified
products

AWL,SCL,SFCs could be
are continuously modified
optimized
Production cycles
AWL,SCL,SFCs could be
are logged modified

are created / modified by Doesn't work anymore

operating personnel

can run on different units Doesn't work anymore

Manage various products (on the same

plant) Could be extremely complex
in some cases, if possible
with AWL.SCL.SFCs WinCC
© 2003 SIEMENS AG All Rights Reserved
SIMATIC Process Control System 7

What do these requirements mean when formulating an automation concept ? We can think of PCS 7 as
a system platform.
How can we describe the production sequences in recipes ? –
It is conceivable to structure all possible sequences using CFC and SFC and to map these to "recipes"
using parameters stored on the OS. Structuring the sequences could, however, be extremely complex
since all possibilities must be taken into account. It should also be possible to modify the recipes or to
create new recipes. This could mean that the automation program (CFC, SFC) would have to be
changed. The operating personnel would not be capable of doing this and the automation technician
would have to be called in.
It would be possible to log the sequences using messages output on the OS in the form of reports. This
would have to be implemented separately for each specific project. New and modified recipes would once
again cause problems.
The complexity of the automation solution increases yet again if the sequences need to be extended to
include various units. This would mean that the SFCs would also have to include the unit to be used.

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 Introduction

1.12 Automation Concept- New Approach

Automation Concept
New Approach
✔Separation of Automation and Recipe

Process Cell Recipes

Instructions
1. Make Bolognese

Control recipe Onions and Tomatoes

Chop
2. Cook noodles and put in Pan,
Weigh the ground meat and add
it as well
3. Add spices

4. Taste

© 2003 SIEMENS AG All Rights Reserved

SIMATIC Process Control System 7

A new approach is required to reduce the complexity, and this is achieved by separating the automation
level from the recipe level.
We assume that the physical structure of the process cell remains the same and that only the sequences
change. We can therefore implement the process cell-specific parts in the program or controller and map
the sequences in a "recipe system" that can be manipulated during operation. This is where the master
recipes are created and maintained.
Control recipes are derived from the master recipes and these access the programmable controller.

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 Introduction

1.13 Separation of the Automation Level and Recipe Level

Automation Concept
New Approach
✔Separation of the Automation level and Recipe level

Process Cell (Kitchen) Master Recipes

Dosing weighing instrument

Weigh (amount)
Material dosing (amount) Instructions
1. Make Bolognese Cooking machine:
Insert 1 onion and 4
tomatoes
Chop for 1 min. ...
control recipe
Pan Heat (Temp.)
Fill... 2. Cook noodles Pan:
Fill with water
Heat to (90°)
Insert noodles
Wait 10 min.
Drain

3. Add spices Manual

Cooking machine
Fill (amount) intervention
Mix (duration) 4. Taste Manual
Chopping (duration)
intervention

© 2003 SIEMENS AG All Rights Reserved

SIMATIC Process Control System 7

In the process cell, we can create a structure consisting of units (scales, pan, mixer,..). These, in turn,
have equipment phases such as weighing dosing etc.
The phases can have parameters such as the quantity parameter of the dosing equipment phase.
This is all mapped in the programmable controller. Here, the term process cell model is used. This
represents the "tool box" for the author of the master recipe.
Within the master recipe, the units along with their equipment phases are used to compose the sequence.
Based on the example of Bolognese sauce, this means that the mixer is necessary. This provides the
equipment phases filling, mixing, chopping. The first step is to put an onion into the machine. This is
followed by four tomatoes. These are then chopped for one minute, etc.

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 Introduction

1.14 ISA S88.01 - Physical Model

ISA S88.01
Physical Model
Pizza Hut Pizza Hut Company
Company
What should be
Karlsruhe
can contain
used for
Works
manufacturing?
Works

can contain
System-
System-
Storage, Kitchen, complex
complex Outside
Delivery.. can contain of S88
Kitchen
Process cell
Process cell

must contain

Unit
Unit
Cooking pot
can contain
Equipment In PCS7:
Equipment EPH / EOP
Module
Module
can contain can contain
Control
Control
Module
Module can contain

© 2003 SIEMENS AG All Rights Reserved

SIMATIC Process Control System 7

The hierarchical structure is shown once more in overview above.

The model has seven levels. The top three levels are not dealt with in the standard since these go
beyond the framework of batch control.
The lower four levels are also known as the process cell model.
The term "equipment module“ here means the "equipment phase“ (dosing, weighing,..). In the PCS 7
environment, the term “EPH (equipment phase)“ is used. All three terms mean the same.

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 Introduction

1.15 Procedural Control Model

Procedure Control Model

(Procedural Model)

How should it be produced?

Recipe
Recipe
Procedure (RP) Spaghetti production
Procedure (RP) Spaghetti production
consists of a
defined amount of

Recipe Unit Cook noodles

Recipe (RUP)
Unit Cook noodles
Procedure Prepare Bolognese Sauce
Procedure (RUP) Prepare Bolognese Sauce
consists of a
defined amount of Preparations: Fill with water, add salt and oil,
Preparations: Fill with water, add salt and oil,
bring up to temperature
Recipe
Recipe bring up to temperature
Operation (ROP) Fill: Add noodles
Operation (ROP) Fill: Add noodles
Preparation: Cook noodles, while stirring,
Preparation: Cook noodles, while stirring,
consists of a sample, drain off water
sample, drain off water
defined amount of

Recipe
Recipe
Function (RF) Fill with water, heat, stir, ...
Function (RF) Fill with water, heat, stir, ...

© 2003 SIEMENS AG All Rights Reserved

SIMATIC Process Control System 7

In keeping with the physical model, a hierarchical model to describe the procedures is specified.

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 Introduction

1.16 Implementation – Physical and Procedural Model

Implementation – What runs Where

Physical and Procedural Model

Implementing
the physical
ES:
ES: model
SIMATIC
SIMATIC
OS Manager
Manager

TC

LI

t
po
g Implementing
in 0
k
o 51 SIMATIC
SIMATIC the
Co T
BATCH
BATCH procedural
model

PLC

© 2003 SIEMENS AG All Rights Reserved

SIMATIC Process Control System 7

The two models are mapped in the architecture of PCS 7 as shown in the picture. The physical model is
implemented in the PCS7 ES. The program structures produced run on the PLC.
The procedural model is implemented in SIMATIC BATCH. The control recipe is also run in SIMATIC
BATCH and operates on the PLC systems.

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 Introduction

1.17 S88.01 Model – PCS 7

S88.01 Model – PCS7

Recipe
Process cell Recipe
Procedure
Process cell Procedure

Recipe Unit
Unit Recipe Unit
Procedure
Unit Procedure

Equipment Recipe
Equipment Recipe
Operation
Module Operation
Module

Control Recipe
Control Recipe
Function
Module Function
Module

© 2003 SIEMENS AG All Rights Reserved

SIMATIC Process Control System 7

ISA S88.01 describes various models that can be fully covered with PCS 7 and SIMATIC BATCH.
The process cell model describes the process cell, unit, equipment module and control module level that
is mapped using the plant hierarchy in the plant view of the SIMATIC Manager.
The process cell model is prepared for SIMATIC BATCH so that the procedural model in the form of
recipes can be mapped on it.
• A recipe procedure runs on a process cell to control a process and to create a batch of a product.
• A recipe unit procedure runs on a unit to control a recipe stage. A unit can only be allocated to one
batch at any one time.
• A recipe operation or a recipe phase runs on an equipment module to perform a industrial process
task or function.
• The device control level is not within the scope of the Batch system and is addressed over the
equipment module. The device control level is located completely within the PLC system.

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1.18 Workflow in the Kitchen: Order - Master Recipe - Process Cell

Working Procedures in the Kitchen

Task-Master Recipe-Process Cell
Process cell Order Master recipe

Pans 1-6 Pans 7-12

For Mary: Spaghetti Bolognese, Picatta...

3x Picatta Milanese for table 5
in 40 min Instructions
1. Make
Bolognese Onions and
Tomatoes
For Peter:4x
Recipe "Picatta" makes 1 Chop
Spaghetti for portion in 2 pans and put in Pan,
table 1 2. Cook Weigh the ground
Start control noodles meat and add it
recipe For 3 Picatta, I need 3 batches
in 6 pans as well
Pans 13-18 3. Add
Pans 19-24
Pans 7-18 are free spices
-> Portion1-> Pan 7,8
-> Portion2-> Pan 9,10
-> Portion3-> Pan 11,12
= 3 batches which corresponds
with 3 control recipes 4. Sample
For Paul:4x Wiener
Schnitzel for table 3

© 2003 SIEMENS AG All Rights Reserved

SIMATIC Process Control System 7

Mike puts in an order for three portions of Piccata Milanese. The order is for table 5 and should be ready
in 40 minutes.
The master recipe "Piccata“ is available for production. It describes the process for one portion. Two pans
are required.
To create three portions at the same time, six pans are therefore needed. This means that three control
recipes must be created (each occupying two pans). Each control recipe produces one batch of Piccata.
If six pans are free, the cook can start the three control recipes at the same time (as shown in the
picture).
If only two pans are free, the three batches can only be produced one after the other.

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1.19 Classification of Batch Process Cells

Classification of Batch Systems

Single line - Single product system Single line - Multi-product system

Ingredients

Line

Product

Multi-line - Single product system Multi-line - Multi-product system

Ingredients

Line

Product

© 2003 SIEMENS AG All Rights Reserved

SIMATIC Process Control System 7

The first criterion in the categorization is the number of products being produced in the process cell:
• Single-product process cells
• Multi-product process cells
The second criterion is the number of production lines allowing simultaneous product flow.
• Single-line structure
• Multi-line structure
• Network structure (all paths fully flexible)

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Classification of Batch Systems

complex
Simple to complex ...

CH
AT
B
IC
AT
M
SI

Small to large
simple
CH n
AT io
C
B lut
I So small medium large
AT 7
M S
SI PC © 2003 SIEMENS AG All Rights Reserved
or SIMATIC Process Control System 7

With its scalability, SIMATIC BATCH is suitable both for smaller process cells as well as for large
complexes that are now possible with V6. While the previous version was restricted in terms of the
numbers of servers (only one OS server), V6 allows up to 11 OS servers to be used.
The complexity increases with the number of products and the number of lines. With SIMATIC BATCH,
you can automate multi-line, multi-product process cells.
For small process cells that manufacture only one product on one line and do not require flexible recipes,
the user has the choice between a PCS 7 solution and the use of SIMATIC BATCH.
The essential issue here is the license costs compared with the engineering effort to create the solution.

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1.20 SIMATIC BATCH: Customer Benefits

SIMATIC BATCH
Customer Benefits

Production cycles are described in master recipes, which are created / changed by operating personnel at any
time
-> Greater flexibility of production, reduced "Time to market"

Unit allocation can be planned. The allocation planning can be changed right up to the actual allocation.
Simatic Batch supports automatic unit selection.

-> Improved efficiency

Production procedures are documented in a batch log (paper or electronic). The production cycles can be
reproduced using recipes.

-> Easy quality management

With compulsory validation / FDA is especially interesting

Version control, access control, audit trails (21CFR Part11) are supported

-> Low validation-/compliance-costs, traceable recipe changes

Utilization of a standard Siemens product

-> Reduced operation and life-cycle costs

© 2003 SIEMENS AG All Rights Reserved

SIMATIC Process Control System 7

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SIMATIC BATCH Getting Started

Part 2

Quick Start

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Getting Started SIMATIC BATCH

Quickstart

Chap. 1
Retrieving the Project

Configuring the BATCH Server and Chap. 2

BATCH Client

Chap. 3
Opening the Plant View

Chap. 4
Creating the Batch Process Cell
SIMATIC Manager
Working with the

Type Definition of the Plant Hierarchy Chap. 5

According to ISA S88.01

Chap. 6
Assigning the "EPH" Batch Category

Generating the Type Description in the Chap. 7

Batch Types

Compiling the PLC, OS and Batch Chap. 8

Process Cell Data

Downloading the Batch Process Cell Chap. 9

Data

Chap. 10
Downloading the PLC to PLCSim

Chap. 11
Starting the OS

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Getting Started SIMATIC BATCH

Quickstart

Chap. 12
Starting the BATCH Start Coordinator

Reading in the Supplied Recipes and Chap. 13

Materials
Working in the BATCH Control Center (BatchCC)

Updating the Loaded Batch Process Chap. 14

Cell Data

Chap. 15
The Recipe for Piccata Milanese Pasta
and Recipe Editor (RP)

Chap. 16
Creating an Output Material

Creating a Master Recipe in the Chap. 17

BatchCC

Creating the Recipe Structure in the Chap. 18

Recipe Editor

Releasing the Master Recipe for Chap. 19

Production

Chap. 20
Creating an Order (Batch)

Releasing and Starting a Batch Chap. 21

(Control Recipe)

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Description of the Model

Process cell

Unit

Desk Pan Pot 1 Pot 2 Pot 3 Oven

Equipment modules

Drain Drain Drain Drain Drain Drain

Fill_Solid Fill_Solid Fill_Solid Fill_Solid Fill_Solid Fill_Solid

Turn Temp Temp Temp Temp Temp

Add_Ingredient Add_Ingredient Add_Ingredient Add_Ingredient

Stir Stir Stir Stir

Turn

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PH View in the SIMATIC Manager

The process cell model is prepared for SIMATIC BATCH so that the procedural model in the form of
recipes can be mapped on it.
A recipe procedure runs on a process cell to control a process and to create a batch of a product.
A recipe unit procedure runs on a unit to control a recipe stage. A unit can only be allocated to one batch
at any one time.
A recipe operation or a recipe phase runs on an equipment module to perform a industrial process task or
function.
The device control level is not within the focus of the Batch system and is addressed over the equipment
module. The device control level is located completely within the PLC system.

Process cell Recipe Procedure

Unit Recipe
Unit Procedure

Equipment
modules Recipe
Operation

Control Module
Recipe Phase

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Requirements:

PCS 7 V6.1 basic installation

• + BATCH server
• + BATCH client
• + Batch Engineering
• + PLCSim
• one network card

Note:
If SIMATIC Logon is installed, you have to log on every time SIMATIC Batch is started

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Chapter 1 Retrieving the Project

1. Retrieve the project (the archived project is called zEn33_01.zip and is located in
..\Siemens\STEP7\examples) and save the project in ..\Siemens\STEP7\S7Proj.

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2. Select the “Server” PC station in the component view and open the object properties. Enter the actual
name of your computer in “Computer name”.
You can check the name of your computer as shown below

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The batch process cell data for the entered computer name generated on the ES will be loaded later.

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3. Change the computer name in the WinCC Explorer to the name of your computer.

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Chapter 2 Configuring the BATCH Server and

BATCH Client
• A SIMATIC PC station has to be created and configured with a "BATCH application" in HW Config for
every computer on which a BATCH server application runs.
• If you want to work locally on the ES computer with BATCH server/clients (single project
engineering), only one PC station with a server and client application needs to be set up. In this case,
the runtime computer name remains empty (or the local computer name is entered).
• BATCH clients can also run on PC stations on which no OS client is installed.
1. Select the “Server” PC station in the component view and open its configuration.

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2. Select the “BATCH Application” and drag it to or insert it at position 2.

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3. Select the “BATCH Application Client” and drag it to or insert it at position 3.

4. Save and compile the hardware configuration of the “Server” PC station with the newly added BATCH
applications.

5. Close HW Config.

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Chapter 3 Opening the Plant View

1. Open the plant view of the project in the SIMATIC Manager and place the views side by side.

Plant View Component View

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Chapter 4 Creating the Batch Process Cell

1. Assign the "Process cell" S88 type definition to the “Kitchen” hierarchy folder. The "Kitchen" folder
then becomes green and has the "process cell" type according to ISA S88.

Result: After you have performed these steps successfully, a new Batch process cell is created
automatically at the project level (Level 1). The name of the Batch process cell is adapted automatically.

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Chapter 5 Type Definition of the Plant Hierarchy

According to ISA S88.01
Assign the S88 type definition “Unit”, “Equipment module” to the existing hierarchy folders.

Level 2:
Process cell

Level 3: Level 4:
Unit class Equipment modules

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1. Assign the “Desk_1” hierarchy folder the object type “Unit” in the S88 type definition. The “Desk_1”
folder is then displayed green identifying it as a unit according to the ISA S88.01 standard.
2. At the level of the unit, you will also find the corresponding “Unit block” for the unit
“Desk_1”

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3. Assign the object type "Unit" to the hierarchy folders “Oven”, “Pan”, “Pot_1”, “Pot_2” and “Pot_3”, as
described in step 1 in S88 type definition.

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4. Assign the object type "Equipment module" to the “Drain” hierarchy folder below
Kitchen/Stove_1/Oven in S88 Type Definition. The “Drain” folder is then displayed green and
identified as an equipment module according to the ISA S88.01 standard.
At the level of the equipment modules, you will find the instances of the SFC types and/or the Batch
interface blocks (IEPH, IEPO, IEPAR_xxx).

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5. Assign the object type "Equipment module" to the hierarchy folders shown on page 5 (Description of
the model) as equipment modules in the S88 type definition as explained in step 3.

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Chapter 6 Assigning the "EPH" Batch Category

Assign the "EPH" Batch category to the existing SFC types. As a result, the information relevant to
S88.01 is created automatically during subsequent type generation.
You will find the existing SFC types (Heat, Stir, Drain, Fill_Solid, Turn and Add_Ingredient) in the
component view in the chart folder of the PLC.

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1. Open the “Heat” SFC type.

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2. Assign the "EPH" Batch category to the “Heat” SFC type.

3. Assign the "EPH" Batch category to the remaining SFC types “Stir”, “Drain”, “Fill_Solid”, “Turn” and
“Add_Ingredient” as explained in steps 1 and 2.
4. Close the SFC Editor.

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Chapter 7 Generating the Type Description in the

Batch Types
As the basis for creating recipes in SIMATIC BATCH, the type description of the process cell must be
generated and synchronized with the block instances of the CFC charts.

Type Description of a Process Cell

Type Editing Options and Results

Data types The system specifies the standard data types floating point number, integer, string,
input material, output material, material (V4), and Boolean.
You can also create your own data types and modify their properties.

Units of measure You can create new units of measure and change their properties.

Operation types, To allow recipe creation purely on the basis of types, types have to be specified
phase types and process tag without existing block instances.
types 1. Operation types: Type information of the equipment operations (EOP)
2. Phase types: Type information of the equipment phases (EPH)
3. Process tag types: Type information of the TAG_COLL blocks
Operation types, phase types and process tag types can be assigned control strategy
parameters.

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1. Open SIMATIC BATCH and select Batch types. Then generate the Batch types and exit the window
with OK.

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Chapter 8 Compiling the PLC, OS and Batch Process

Cell Data
1. Open any CFC chart and compile the entire program for the PLC.

2. Close the CFC Editor.

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3. Compile the entire OS with memory reset.

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4. Compile the Batch process cell data. Select your project (Kitchen) in the plant view and select
SIMATIC BATCH > Batch instances >Compile.

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5. Transfer Batch (ISA S88.01)-relevant data to the OS .

The Batch compilation can take several minutes because the Batch OS messages are transferred to
the OS and generated the first time you compile.

This activity can take several minutes

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Chapter 9 Downloading the Batch Process Cell Data

1. Update the status of the entire process cell in the configuration window for the Batch process cell with
Settings > OS objects tab > Update
and then exit the window with OK.

Update the entries.

Following this, your computer name is
displayed in "Target system".

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2. Download the generated Batch process cell data to the BATCH server and BATCH client. In your
case, the BATCH server and BATCH client are on the same computer.

3. Exit the "Configure Batch process cell" dialog with OK.

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Chapter 10 Downloading the PLC to PLCSim

Download the PLC data compiled in the SIMATIC Manager to the “PLCSim” simulation program.

For this Getting Started, the “Station Configuration Editor” is ignored, because the PLC is
simulated with PLCSim and the ES, the OS server, and the BATCH server are located on a single
workstation (on the same computer).
1. Start PLCSim from the SIMATIC Manager.

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2. Download the hardware configuration to PLCSIM.

3. Close HW Config.

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4. Open a chart from the project and download the charts to PLCSim.

5. Close the CFC Editor.

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6. Start PLCSim with “RUN-P”.

7. Save the simulation you have downloaded so that it is not lost when you close PLCSim.
If you close PLCSim without saving, you have to repeat steps 1 to 5 the next time you work with PLCSim.
Saved PLCSim data can be put directly into Run by opening the saved file.

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Chapter 11 Starting the OS

1. Open the WinCC Explorer of the OS. Create a user with suitable privileges in the User Administrator.

Note
Open the OS-ProjectEditor and click on "OK". This serves to configure the WinCC
runtime interfaces and the alarm system.

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2. Start the OS in runtime; the first startup can take several minutes.

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Chapter 12 Starting the BATCH StartCoordinator

The BATCH Start Coordinator starts automatically when you log in. It does not have its own graphic user
interface, rather it is visible as a pictograph on the lower right hand side of the taskbar.
If the BATCH Start Coordinator has been closed, you can start it from the Windows Start menu with Start
> Simatic > BATCH > BATCH Start Coordinator.
Starting the BATCH Start Coordinator also starts the Batch Control Server (BCS) and the Batch Data
Management (BDM) and these change to the “Ready“ status.

Batch Start Coordinator

Batch BDM
BATCH Control Server

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Using the system tray icon, you can configure the start-up behavior of SIMATIC BATCH.
There are three different start-up options for the Batch Start Coordinator (right-click on the Start
Coordinator):

• “start SIMATIC BATCH automatically after starting WinCC“,

• “start SIMATIC BATCH independent of WinCC“ and
• “start SIMATIC BATCH manually”
1. Select the “start SIMATIC BATCH automatically after starting WinCC” option.
The BATCH applications (BCS, BDM) start up automatically after WinCC starts and they change to
the “Running“ status.

All Batch applications are started

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Update the entries.

Following this, your computer name is
displayed in "Target system".

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Chapter 13 Reading in the Supplied Recipes and

Materials
Read in the supplied recipe database for this project.
1. Open the Batch Control Center (BatchCC).

After restarting the BatchCC, the window looks different. The windows Shortcuts, Control and Message
window are opened.
The Batch Control Center is the central component for
• batch scheduling
• batch control
• management of all Batch-relevant data
• libraries, master recipes, formulas, materials
• permission management

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2. In Batch Control Center, restore the supplied XML file.

Browse to the supplied

sb_gs1_b.XML file

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Chapter 14 Updating the Loaded Batch Process Cell

Data
1. Update the Batch process cell data you loaded in the Batch Control Center.

Depending on the date on which

the process cell was created, this
window can appear differently.

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Chapter 15 The Recipe for Piccata Milanese Pasta

Meal Piccata Milanese

Quantity 2.9 Kg (reference quantity)

Ingredients 100 ml oil

1.9 kg pasta

50 g salt

50 g pepper

1 kg tomato sauce

Instructions

Fill a pot with 3 liters of water, add 100 ml of oil and a pinch of
1. Prepare water salt, heat to 100°

2. Cook pasta Put 1.9 kg of pasta in the boiling water and cook for 6 minutes

Put 1 kg of tomato sauce in a pot, heat to 40° and stir for 5

minutes
3. Prepare sauce (while cooking pasta)
Add salt and/or pepper to flavor
…
Serve pasta and sauce
…

7. Completed

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Chapter 16 Creating an Output Material

At the beginning, you have to define the materials and as an option the qualities for input materials/output
material for SIMATIC BATCH once.
Define the materials in the list boxes displayed in the subsequent dialogs for recipe creation and batch
planning. Materials and qualities have to also be assigned a unique code (for example an internal
company code). This code can, for example, be used to specify setpoint output and process value input
at the interface blocks or SFC types to identify the material or product. To write recipes, data about the
materials have to be defined. Input and output materials with various qualities can be created. These are
created in the BatchCC in the Materials folder in the process cell you have read in.
1. Create a new output material with the name “Piccata Milanese” and the material code “47” and place
it in the "Dish/Product" folder.

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Chapter 17 Creating a Master Recipe in the BatchCC

1. Create a new hierarchical master recipe for the product “Piccata Milanese” with the reference quantity
2.9 kg (all other information in the recipe for “Piccata Milanese” refers to this amount). The minimum
quantity for production is 1 kg and the maximum quantity 10 kg (maximum and minimum quantity that
can be cooked in this process cell, in our case the kitchen).

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2. Define the main product (here Piccata Milanese) as output material

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Chapter 18 Creating the Recipe Structure in the

Recipe Editor

Layout of the Main Window in the Recipe Editor

The basic layout of the user interface of the BATCH Recipe Editor is shown in the figure below which
illustrates an example of a hierarchical recipe. You can create or modify recipes in the editing windows
using the structure elements of the Insert menu.

Zoom bar
Title bar Menu bar Toolbar Buttons for
changing the view

Status bar with Editing window with recipe Editing window with a ROP
context-sensitive structure of a hierarchical sequence (editing level 2)
information master recipe with ROPs
(editing level 1)

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Basic Representation of the Hierarchy in the BATCH Recipe Editor

The schematic below shows the basic representation of the hierarchical structure when editing with the
BATCH Recipe Editor. The structure of a hierarchical recipe is edited at two levels (editing level 1 and 2).
Editing Level 1
Editing level 1 is intended for the plant view in which the processes of several cells can be synchronized.
A recipe unit procedure (RUP) is made
Editing Level 1 Editing Level 2
up of recipe operations (ROPs). To Recipe Procedure (RP) Recipe Operation
structure the process, you can use (with Recipe unit procedure (RUP 1 ...)) (ROP)
double lines to synchronize. This
allows you to synchronize the timing of
STA
ROPs in different units. STA
RT
RUP 1 RUP 2 RT
Editing Level 2
RPH
Editing level 2 is used to create ROP ROP ROP
sequences. An ROP sequence begins
RPH RPH
with a Start step. The Start step is
ROP ROP
followed by a transition that defines the
start conditions. Every ROP sequence
ends with an End step. A transition that END
ROP ROP
defines the end condition precedes
every end step.
END

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Implementation in the BATCH Recipe Editor

Synchronization
line between
RUPs

1. Recipe unit procedure 2. Recipe unit procedure ROP sequence with the SFC
(RUP 1) with recipe (RUP 2) with recipe structure elements, steps,
operations (ROPs) operations (ROPs) transitions, branches etc.

A RUP is always shown within a column,

i.e. the ROPs are arranged vertically.

Editing level 1 Editing level 2

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Tools for Creating the Recipe Structure

The recipe editor has tools for the simple creation of recipe structures such as:
• Inserting S88 procedure elements such as recipe unit procedures (RUP), recipe operations (ROP)
and recipe phases (RPH)
• Instead of a recipe operation, a referenced library operation (Lib-ROP) can also be inserted
• Inserting operator instructions or operator dialogs
• Inserting transitions
• Inserting simultaneous sequences
• Inserting alternative sequences
• Inserting synchronization lines
• Inserting loops

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Creating the Recipe Structure in the Recipe Editor According to the Description in the
Recipe
1. Open the Recipe Editor with your master recipe “Training_Recipe”.

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2. Using the tools and the recipe description, create the dish “Piccata Milanese”.
The diagram on this page and the accompanying video will help you (Notes on storing and labeling
videos are available on the first page of this manual).

Unit (RUP) Unit (RUP)

Pot_1 Pot_3

ROP: Prepare water (while

frying)

Put 3 liters of water in a pot and add

100 ml of oil and a pinch of salt.
Then heat to 100 °C.

ROP: Cook Pasta ROP: Prepare sauce (while

boiling pasta)
Put 1.9 kg of pasta into boiling water Put 1 kg of tomato sauce into a pot.
and boil for 6 minutes.
Heat to 40 °C for 5 minutes
while stirring.
Add salt and pepper to flavor.

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3. Create two RUPs (recipe unit procedures) [units].

4. Assign the "Pot_1" unit and the "Preferred unit" strategy to the left RUP.

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5. Assign the "Pot_3" unit and the "Preferred unit" strategy to the right RUP.

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6. Insert the relevant ROPs (recipe operations).

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7. Assign the texts "Prepare Water", "Cook Pasta" and "Prepare Sauce" to the ROPs (recipe
operations).

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8. By double-clicking on the "Prepare Water" ROP, insert a recipe phase or NOP (No Operation).

9. Assign the “Add_Ingredient” phase and the “Add_Water” control strategy to the NOP (No Operation)
or recipe phase.

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10. Assign the values and information for the input materials and parameters of the “Add_Ingredient”
phase.
The input material “Li_quantity” has to be assigned the material, in this case water, and the amount to
be filled, here 3 l.

Note:
Here, and in all the phases, the "Simutime" parameter is used for simulation (it
has no influence on the runtime behavior of phases in a batch).

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11. Insert a simultaneous sequence and 3 NOPs.

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12. Add the “Add_Ingredient” recipe phase with the “Add_Oil” control strategy and assign the "Oil"
material to the “Li_quantity” input material and a quantity of “0.1 l”. For the simulation time specify
value of “5” sec.
13. Add the “Heat” recipe phase and assign the value "100 °C" to the "Temp" parameter. For the
simulation time specify value of “300” sec.
14. Within the simultaneous sequence, and a further “Add_Ingredient” recipe phase with the "Add_Salt"
control strategy below the "Add_Ingredient" recipe phase and assign the material "Salt" and the
quantity "0.01 kg" to the "Li_quantity" input material. For the simulation time, specify a value of “5”
sec.

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15. Complete the "Cook Pasta" ROP according to the recipe description for “Piccata Milanese.”

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16. Complete the "Prepare Sauce" ROP according to the recipe description for “Piccata Milanese.”

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17. Insert a synchronization line by selecting the starting position with the mouse and moving to the enter
position while holding down the mouse button.

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18. Add the “Serve Pasta” and “Serve Sauce" ROPs (recipe operations) and complete them according to
the recipe description for "Piccata Milanese“.

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19. Save the master recipe you have created.

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20. Validate the recipe.

21. Close the Recipe Editor.

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Chapter 19 Releasing the Master Recipe for

Production
Before you can use your master recipe “Training_Recipe V1.0” to create a batch, the recipe must be
released for production or testing.
1. Release your recipe for production.

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Note:
To be able to edit recipes that have already been released, the release has to be
revoked. To do this, open the properties dialog in the BATCH Control Center with
Options > Settings and select the “Allow editing of recipes in the "Release
revoked" status“ check box.

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Chapter 20 Creating an Order (Batch)

1. Create an order category with the name “order_category_GS”.

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2. Create an order with the name "Order_GS" under “order_category_GS”.

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3. Create a batch for "Order_GS” with the master recipe “Training_Recipe V1.0”.

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Chapter 21 Releasing and Starting a Batch

(Control Recipe)
1. Open the batch (control recipe) “Batch1”.

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2. Release the “Batch1” control recipe. The icon of the control recipe becomes light blue.

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3. Start the released control recipe. The icon changes to green and the units are occupied and started
according to the recipe structure.

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SIMATIC BATCH Getting Started

Part 3

Creating an Equipment Phase with

SFC and BATCH Interface Blocks

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Getting Started SIMATIC BATCH

Creating an equipment phase
using SFC and BATCH interface blocks (IEPH, IEPAR_xxx)

Task/Implementation Concept Chap. 1

Chap. 2
Expanding the Plant Hierarchy

Configuring the Control Module Level Chap. 3

(Valve)
Working in the SIMATIC Manager

Configuring BATCH Interface Blocks

for the Control Commands and Chap. 4
Process Value Transfer

Chap. 5
Creating an SFC

Connecting the Batch Control Chap. 6

Commands with the SFC

Compiling and Downloading the CPU Chap. 7

and OS

Generating Batch Types Chap. 8

Chap. 9
Compiling, Transferring the OS and
Downloading Batch

Expanding the Unit Faceplate in the Chap. 10

WinCC Explorer

Chap. 11
Expanding a Recipe

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Chapter 1 Task/Implementation Concept

An additional equipment phase is required for the pan: It has to be extended by adding the “Quench”
phase. A selectable quantity of a material (for example, red wine) will be added via a quench valve.
To simplify matters, the process of reaching the set quantity will be simulated by a selectable time. If the
batch is held or aborted, the valve will close.
To implement the equipment phase, we will select blocks from the Batch library.

Process cell

Unit

Desk Pan Pot 1 Pot 2 Pot 3 Oven (Unit

(Unit class Desk) (Unit class Pan) (Unit class Pot) (Unit class Pot) (Unit class Pot) class Oven)

Equipment Modules

Drain Drain Drain Drain Drain Drain

Fill_Solid Fill_Solid Fill_Solid Fill_Solid Fill_Solid Fill_Solid

Turn Temp Temp Temp Temp Temp

Add_Ingredient Add_Ingredient Add_Ingredient Add_Ingredient

Stir Stir Stir Stir

Turn

Quench

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Process values
Process value name Block Data type Comment
string
Quantity IEPAR_PI
real
Duration IEPAR_REAL real

Block contacts
Block name Block Comment

V1 VALVE

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Outline of the “RUN” Sequencer (RUN=1)

Start
V1.LIOP_SEL = TRUE
V1.AUT_L = TRUE

Valve in AUTO
V1.QMAN_OUT=TRUE

Open Valve Start Timer

V1.AUTO_OC = TRUE Duration_Timer.I0 = TRUE

Timer ended?
V1.QOPEND=TRUE
Duration _Timer_Q0=FALSE

Close Valve
V1.AUTO_OC = FALSE

Valve closed
V1.QCLOSED=TRUE

End
V1.AUTO_OC = FALSE
Duration_Timer.I0 = FALSE

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Outline of the “Hold/Abort/Complete” Sequencer (Holding=1 or Aborting=1 or

Completing=1)

Start

Close Valve
V1.AUTO_OC = FALSE

Valve closed
V1.QCLOSED=TRUE

End

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Chapter 2 Expanding the Plant Hierarchy

1. Open your edited SIMATIC BATCH Getting Started “Quick Start”.
2. Expand the “Pan” unit by adding a hierarchy folder with the name “Quench”.
The newly added hierarchy folder is automatically declared as an equipment module and therefore
also as Batch-relevant (folder is green).
At this level, you will find the Batch interface block (IEPH, IEPAR_xxx).

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3. Expand the “Quench” hierarchy folder by adding a hierarchy folder with the name “Quench_Valve”;
this level also contains the control modules (here, the appropriate valve).

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Chapter 3 Configuring the Control Module Level

(Valve V1)
1. Create a CFC chart with the name “Valve” in the "Quench_Valve" hierarchy folder.

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2. Open the “Valve” CFC chart and insert a valve block. Give the valve block the block name “V1”.
3. Make the inputs and outputs “QCONTROL”, “BA_EN”, “BA_ID”, “OCCUPIED”, “BA_NA”, and
“STEP_NO” visible.
4. Interconnect the “QCONTROL” output with the “FB_OPEN” and “FB_CLOSE” inputs and invert
“FB_CLOSE”.

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Chapter 4 Configuring BATCH Interface Blocks for

the Control Commands and Process Value
Transfer
1. Create a CFC chart with the name "Quench_EPH" in the “Quench” hierarchy folder.

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2. Open the “Quench_EPH” CFC chart and add the “IEPH”, “IEPAR_PI” and “IEPAR_REAL” blocks
from the “SIMATIC BATCH Blocks” library. For the IEPH block, assign the name “Quench”, and
assign the same name to the “F_TYPE” input. Assign the name "Quantity" to the IEPAR_PI block and
the name "Duration" to the IEPAR_REAL block.

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3. Assign the IEPH “Quench” interface block to the IEPAR_PI “Quantity” and IEPAR_REAL “Duration”
parameter blocks.
Interconnect the “EPE_CONN” output of the IEPH block (Quench) with the “EPE_CONN” inputs of
the EPAR blocks (Quantity, Duration).

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4. Add a TIMER_P block for the simulation of the “Duration” process value and assign the name
"Duration_Timer" to the block and also assign MODE 1.
Interconnect the IEPAR_REAL block “Duration” with the TIMER_P block as follows.

Duration / Q_SP_VAL with Duration_Timer / TIMER0

Duration_Timer / PTIME with Duration / ACT_VAL

5. Interconnect the IEPAR_PI block “Quantity” to the simulation as follows.

Quantity / Q_SP_VAL with Quantity / ACT_VAL

Quantity / QMAT_SP with Quantity / MAT_SP
Quantity / QBAID_SP with Quantity / BA_ID_SP

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6. To have the BATCH name, Batch ID, Batch step number, Batch enable, occupied available at the
valve block "V1", the valve block has to be interconnected with the Batch control block IEPH
“Quench”.
Make interconnections as shown below.

Quench / QBA_EN with V1 / BA_EN

Quench / VSTEP_NO with V1 / STEP_NO
Quench / VBA_ID with V1 / BA_ID
Quench / VBA_NAME with V1 / BA_NA
Quench / Q_OCCUPI with V1 / OCCUPIED

CFC chart "Quench_EPH" CFC chart "Valve"

As an alternative, BA_EN, BA_ID, BA_NA , OCCUPIED and STEP_NO can be supplied by the Unit
block.

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Chapter 5 Creating an SFC

1. Create an SFC chart with the name "Quench_SFC" in the "Quench" hierarchy folder.

2. Open the SFC chart and configure the RUN sequencer listed in Chapter 1 "Implementation Concept”.

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Step: START

Transition: Valve in AUTO

Step: Open Valve

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Step: Start Timer

Transition: Timer ended

Step: Close Valve

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Transition: Valve Closed

Step: END

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3. Insert a new sequencer in “Quench_SFC“.

- Open the properties window of SEQ1 (double-click on the SEQ1 tab).
- In the “General“ tab, enter the name “Abort-Hold-Comp”. Then apply the settings.

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4. Configure the start conditions of the sequencer

- Make the "Inputs/Outputs" view visible.
- Insert the parameters “HOLDING” ,”ABORTING” and “COMPLETING” as start conditions in the
"Start condition" tab by dragging them with the mouse (these parameters are located in OUT).
- Apply the settings and close the "Properties" window.

2
1

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5. Configure the Abort-Hold-Complete sequencer as described in Chapter 1 "Implementation Concept".

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Step: Close Valve

Transition: Valve Closed

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6. Select the "AUTO" mode in the “Quench_SFC” SFC chart.

7. Close the SFC Editor.

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Chapter 6 Connecting the Batch Control Commands

with the SFC
1. Open external view of the “Quench_SFC” SFC chart.

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2. Open the “Quench_EPH” CFC chart with the “Quench” interface block.
3. Interconnect the “Quench” interface block with the external view of the “Quench_SFC” SFC chart as
follows.

Note:
First, make all parameters of the following list visible.

.
Quench / QSTART with Quench_SFC / START
Quench / QHOLD with Quench_SFC / HOLD
Quench / QSTOP with Quench_SFC / STOP
Quench / QABORT with Quench_SFC / ABORT
Quench / QRESET with Quench_SFC / RESET
Quench / QTERM with Quench_SFC / COMPLETE
Quench / QCONT with Quench_SFC / CONT
Quench / QBA_EN with Quench_SFC / BA_EN
Quench / VSTEP_NO with Quench_SFC / STEP_NO
Quench / VBA_ID with Quench_SFC / BA_ID
Quench / VBA_NAME with Quench_SFC / BA_NA
Quench / Q_OCCUPI with Quench_SFC / OCCUPIED
Quench / USTAT_L with Quench_SFC / BA_STATE

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Chapter 7 Compiling and Downloading the CPU and

OS
1. Run a changes only compilation of the CPU and then download the newly compiled data to PLCSim
with a changes only download.
You can only do this after the runtime OS has ended.

After downloading,
check the CPU state. It
has to be in RUN_P.

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2. Run a changes only compilation of the OS.

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Chapter 8 Generating Batch Types

1. Open the “Configure Batch process cell“ dialog in the plant view in your project. Select “Batch types“.

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2. Generate the Batch types.

Your batch data newly configured in the "Quench_EPH“ CFC chart is now read in.

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Chapter 9 Compiling, Transferring the OS and

Downloading Batch
1. Compile the Batch process cell data.
To do this, select "Batch instances" and select the "Compile" button.

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2. Transfer the Batch process cell data to the OS.

To do this, select the Batch process cell (in this case, Kitchen) and click "Transfer to OS”.
Start the transfer in the "Transfer BATCH-relevant data" dialog (WinCC has to first be closed).

Update the entries.

Following this, your computer name is
displayed in "Target system".

3. Close the dialog.

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4. Download the Batch process cell data.

To do this, select the Batch process cell (in this case, Kitchen) and click "Download".
- Save the changes (confirm the dialog box with Yes).
- Download the generated Batch process cell data to the BATCH server and BATCH client.
- In this case, the BATCH server and BATCH client are on the same computer.

5. Close the dialog.

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6. Close the “Configure Batch process cell“ dialog.

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Chapter 10 Expanding the Unit Faceplate in the

WinCC Explorer
1. Open the WinCC picture "Kitchen.PDL” from the WinCC Explorer.

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2. Select the "Pan" unit block icon and double-click on it to open its properties. In the “Configuration“
box, select the "Pan" unit with the "Browser" button. In the “Selected functions/EPH” field, you will see
the previously configured “Quench” phase. If you double-click with the left mouse button with the
“Quench” phase selected, you add it to the configuration.

If you double-click on the block

icon, you open the Configuration
window

Select Quench and

double-click to insert it
in the Configuration list

3. Save the picture.

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Chapter 11 Expanding a Recipe

1. Start the OS in runtime.

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The unit faceplate “Pan“ now also includes the “Quench“ phase.

2. The Start Coordinator starts automatically as soon as your WinCC project is in runtime. Wait until it
has started all applications completely (BCS, BDM).

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3. Start the Batch Control Center and update the newly downloaded Batch process cell data.

Depending on the date on which

the process cell was created, this
window can appear differently.

After the update, your newly configured “Quench” phase is available for recipe creation.

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4. Open the “Template_Recipe_Getting_Started” master recipe and save it with the name
“Recipe_Quench”.

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5. In the “Recipe_Quench” recipe you have just created, insert the newly configured “Quench” phase.

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6. Save the recipe and validate it. Then close the Recipe Editor.

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7. Release the recipe for production in BatchCC. Then create a new batch with the “Recipe_Quench“
recipe, then release and start it.

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SIMATIC BATCH Getting Started

Part 4

Creating an Equipment Phase with an

SFC Type

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Getting Started SIMATIC BATCH

Creating an equipment phase with a SFC type

Task/Implementation Concept Chap. 1

“Ventilate”

Chap. 2
Creating the SFC Type “Ventilate”
Working in the SIMATIC Manager

Chap. 3
Creating Sequencers

Chap. 4
Expanding the Plant Hierarchy

Creating Instances of the SFC Type Chap. 5

“Ventilate” for Pot_1

Compiling and Downloading PLC, OS, Chap. 6

and Batch

Expanding the Unit Faceplate in the Chap. 7

WinCC Explorer

Expanding a Recipe Chap. 8

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Chapter 1 Task/Implementation Concept “Ventilate”

An additional equipment phase is required for the pots: They must be extended by adding the “Ventilate”
phase. A ventilation valve must be opened for a selectable time. If the batch is held or aborted, the valve
will close.
Since the same phase is necessary for Pots 1-3, select the SFC type to implement it.

Process cell

Unit

Desk Pan Pot 1 Pot 2 Pot 3 Oven

(unit class desk) (unit class pan) (unit class pot) (unit class pot) (unit class pot) (unit class oven)

Equipment modules

Drain Drain Drain Drain Drain Drain

Fill_Solid Fill_Solid Fill_Solid Fill_Solid Fill_Solid Fill_Solid

Turn Temp Temp Temp Temp Temp

Add_Ingredient Add_Ingredient Add_Ingredient Add_Ingredient

Stir Stir Stir Stir

Turn Ventilate Ventilate Ventilate

Quench

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Implementation Concept for SFC Type “Ventilate”

Control strategies
Control strategy name Comment

Ventilate First control strategy, QCS=1

Setpoints
Setpoint name Data type Comment

Duration real Unit of measure seconds

Process values
Process value name Data type Comment

none

Times
Name Data type Comment

T_Leng Time Timer for setpoint “Duration”, Mode=1

Block contacts
Block name Block Comment

V1 VALVE Ventilation valve

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Outline of the “Run” Sequencer (Run=1) for “Ventilation” Control Strategy (QCS=1)

Start

V1 Auto
V1_LIOP_SEL=1
V1_AUT_L=1

Set Timer
Open Valve T_Leng_Time0=Durati_Q
V1_Auto_OC=1

Start Timer
T_Leng_IO=1

Valve Opened?:
V1_QOPENED=1
and
Timer started?: Reset Timer Trigger
T_Leng_Q0=1 T_Leng_IO=0

Time over:
T_Leng_Q0=0
Close Valve
V1_Auto_OC=0

Valve closed?:
V1_QCLOSED=1
End
T_Durati_IO=0

The timer of the SFC type behaves like the standard block “Timer_P”.

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Outline of the “Hold/Abort/Complete” Sequencer (Holding=1 or Aborting=1 or

Completing=1)

Start

Close Valve
V1_Auto_OC=0

Valve closed?:
V1_QCLOSED=1
END

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Chapter 2 Creating the SFC Type “Ventilate”

1. Open the component view and insert the new SFC type “Ventilate”.

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2. Open the characteristics dialog of the “Ventilate” SFC type shown below by double-clicking on it.
Select the "Characteristics" menu.

3. Select the “Control strategies” characteristic and enter the name “Ventilate” in the right-hand box.

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4. Now select the “Setpoints” characteristic and enter the setpoint name “Duration” in the right-hand
field. Select “REAL” as the data type for duration. Enter "sec" as the unit of measure for duration.

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5. In the next step, we will define the timer. Select the “Timers” characteristic. In the right-hand field,
enter the name “T_Length”. The timers that can be used in this way within SFC types, behave like the
standard block “Timer_P” from the PCS 7 library.

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6. In the final step, we will create the valve. Select the “Block contacts” characteristic and enter the
name “V1” in the right-hand field. Select the corresponding block types in the “Block” column. In our
case, the block type is “VALVE”.

We have now specified all the characteristics required for the “Ventilate” example. The sequencers now
have to be created and configured.

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Chapter 3 Creating Sequencers

The Run sequence path that is processed in the “Run“ status has already been created. The sequencer
that is processed in the “Holding”, “Aborting”, “Completing” statuses does not yet exist. Since the content
is the same in all three sequencers in our case, we will only create one sequencer and call it “Abort-Hold-
Comp”.

1. To insert a new sequencer, click with the right mouse button while the mouser pointer is over the
“RUN” tab. Select “Insert Sequence at End”.

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2. A new tab is created called “SEQ1”. Set the properties for SEQ1. In the general properties, enter the
name Abort-Hold-Comp.

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3. We now configure the start conditions of the sequencer in the properties. In our case, the start
condition is:
- Aborting=True or Holding=True or Completing=True.
- Change to the "Inputs/Outputs" view. The I/Os Aborting, Holding and Completing are located in
“OUT”.
- Drag the I/Os from the upper part to the dialog for configuring the start condition.

Apply the changes and then close the properties window

Chart I/Os

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4. The next step is to configure the sequence of the “RUN“ sequencer.

Remain in the "Inputs/Outputs" view.

In the left-hand part of the window, you will see the I/Os of the SFC type “Ventilate” grouped according to
inputs, outputs and in_outs. In the right-hand part, you see the list of corresponding I/Os.
The control outputs for the V1 valve or the T_Leng timer are located in “OUT”.
The feedback messages of the V1 valve are created in “IN”.

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5. Drag the I/Os from the upper part to the dialog for configuring the steps/transitions. The Run and the
Abort-Hold-Complete sequencer are structured as shown in Chapter 1.

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6. Set the start value for the timer mode used to “1“ (extended pulse).

7. Set the start value for the CS parameter (control strategy) to the default value 1.

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8. Select the SIMATIC BATCH category “EPH”.

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9. Set the CPU operating parameter to “Auto“ as the default mode.

This completes all the steps for configuring the “Ventilate” type.
10. Exit the SFC Editor.

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Chapter 4 Expanding the Plant Hierarchy

1. Open the plant view of the project in the SIMATIC Manager. We want to insert a new equipment
phase "Ventilate" for Pot_1. Create a new hierarchy folder. Call the folder “Ventilate”.

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2. Create a CFC chart in the “Ventilate” hierarchy folder. This chart “Ventilate_Pot1” is required for the
instance of the SFC types. Create a further folder "Val_Ventilate" in the “Ventilate” folder. Here, you
create the “Pot1_Valve”. In this chart, you configure the valve required to ventilate Pot_1.

You then have the following screen:

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3. Create the “Pot1_Valve” chart.

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4. Open the “Pot1_Valve” chart. Insert a VALVE block with the name P1_V1. To simulate the feedback
messages, interconnect the QCONTROL output with the FB_OPEN input and invert with the
FB_CLOSE input (QCONTROL has to first be made visible). You then get the following screen:

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Chapter 5 Creating Instances of the SFC Type

“Ventilate” for Pot_1
1. Open the chart “Ventilate_Pot1“. You will find the previously created type in Catalog/Blocks/Other
blocks. Insert a block with the name “T1_Ventilate“ of the type “Ventilate” in the chart.
You then get the following screen:

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2. Now open the chart “Pot1_Valve” as well and arrange the two windows side by side as shown below.

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3. The valve T1_V1 now has to be interconnected with T1_Ventilate.

- Select the V1_AUTO_OC output of T1_Ventilate. Select the corresponding valve input
AUTO_OC of the valve P1_V1. All the relevant interconnections to the valve are now created
automatically (eight in total).
- So that all the batch-relevant information that SIMATIC BATCH writes to the block instance of
“Ventilate“ also arrives at the corresponding valve, the batch-relevant outputs (five) also have to
be interconnected with the valve. First, the following parameters have to be made visible:
- On the valve P1_V1:
BA_EN, BA_ID, BA_NA, STEP_NO,OCCUPIED
- On the “Ventilate“ T1_Ventilate phase:
QBA_EN, QBA_ID, QBA_NA, QSTEP_NO, QOCCUPIED
- Interconnect the five outputs of T1_Ventilate (QBA_EN, QBA_ID, QBA_NA, QSTEP_NO,
QOCCUPIED) with the corresponding inputs of the valve P1_V1 (BA_EN, BA_ID, BA_NA,
STEP_NO,OCCUPIED).
- Interconnect the output “T_Leng_PTIME“ with the input “Duration_AI“. This is important for the
displaying in the OS faceplate and for reading the process values with SIMATIC BATCH. The
process value input on “T1_Ventilate“ is called “Duration_AI” (Actual Value Input).
- Check the interconnection based on the following screen.

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Chapter 6 Compiling and Downloading PLC, OS, and

Batch
Run a changes only compilation of the CPU and then download the newly compiled data to PLCSim with
a "changes only" download.

Note:
You can only do this after the runtime OS has ended.

Then run a changes only compilation of the OS.

Open the “Configure Batch process cell“ dialog in the plant view in your project. Select “Batch types“.
Generate the Batch types, compile and download the process cell.
Follow the steps as described in Chapters 7 through 9 in Part 3.

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Chapter 7 Expanding the Unit Faceplate in the

WinCC Explorer
1. Open the WinCC picture "Kitchen.pdl" from the WinCC Explorer.
2. Select the unit block icon “Pot1“ and double-click on it to open its properties.

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3. In the Configuration box, select the "Pot_1" unit using the “Browser“ button.
In the “Selected functions/EPH" field, you will see the previously configured “T1_Ventilate" phase.

4. If you double-click with the left mouse button with the “T1-Ventilate" phase selected, you add it to the
configuration.

Doubleclick

5. Enter "Pot_1" as the WinCC runtime name.

6. Save the picture and close the Graphics Designer.

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Chapter 8 Expanding a Recipe

1. Start the OS in runtime.

2. The Start Coordinator starts automatically as soon as your WinCC project is in runtime. Wait until it
has started all applications completely (BCS, BDM).

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3. Start the Batch Control Center and update the newly downloaded Batch process cell data.

4. After updating, your newly configured “Ventilate” phase is available in the “Pot_1” unit.

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5. Open the “Template_Recipe_Getting_Started” master recipe and save it with the name
“Recipe_Ventilate”.

Note:
If you cannot modify the recipe, select the option "Allow editing of recipes in the
"Release revoked" status in Options - Settings in the Batch Control Center.

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6. Open “the “Recipe_Ventilate” recipe you have just created and insert the newly configured “Ventilate”
phase in the recipe.

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7. Save the recipe and validate it. Then close the Recipe Editor.

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8. Release the recipe for production in BatchCC. Then create a new batch with the “Recipe_Ventilate“
recipe, then release and start it.

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