SIMATIC BATCH

In the process industry, discontinuous processes – so-called batch processes – are of great significance. Permanently shorter product lifecycles as well as the versatility required by consumers are two of the reasons for this.

Product quality that stays the same even in the umpteenth batch, quick response to changed market conditions, traceability for production (FDA compliance), fulfillment of legal standards, as well as the economic and technical necessity to utilize production plants flexibly and optimally – all of this places high demands on plant automation.

The SIMATIC PCS 7 process control system with the SIMATIC BATCH software package offers the right solution for low-cost and effective automation of batch processes.

SIMATIC BATCH is completely integrated in SIMATIC PCS 7, both in the visualization and in the engineering system. Thanks to the modular design and the flexible scaling, it can be used in small test centers as well as in production plants of any size.

Scalability

SIMATIC BATCH is configured as a single station system or as a client/server system and can be used in plants of any size due to its modular architecture and scalability in cumulative SIMATIC BATCH UNITs (sets of 1, 10 and 50 plant unit instances).

Single-user system for small applications

For small batch applications, SIMATIC BATCH can be installed together with the OS software on a Single Station system.

Client/server configuration

However, a characteristic feature of the automation of batch processes using SIMATIC BATCH is client/server architectures in which one Batch Server and multiple Batch Clients together process a plant project. The Batch Server in such a configuration can also be configured with redundancy in order to increase availability.

SIMATIC BATCH Clients and OS Clients can run on separate or common basic hardware. In addition to the SIMATIC PCS 7 Industrial Workstations, SIMATIC PCS 7 OS Clients 427E/477E are also suitable as Batch Clients.

The Batch Server software, SIMATIC BATCH Basic or SIMATIC BATCH Server, provided for configuration of a Batch Server usually runs on dedicated server hardware (Batch Server). Depending on the load on the Operator System, the OS Server and Batch Server software can also be run on shared server hardware (OS/Batch Server).

The hardware configuration of the Batch Server depends on the SIMATIC BATCH operating mode:

• In PC mode, the complete recipe logic is executed in the batch server. If SIMATIC BATCH is only executed in PC mode, the Batch Server does not require a connection to the plant bus. Communication with the automation system is via the Operator System.
• In AS mode, the recipe unit logic is executed in the automation system. Mixed operation with PC operating mode is also possible within a batch where recipe units are run on both the Batch Server and on the automation system. In AS mode, the Batch Server requires a connection to the plant bus for communication with the automation system.

System connection

Batch Single Station and Batch Server can be connected to the Industrial Ethernet plant bus via a CP 1623/CP 1628 communications module or via a simple FastEthernet network adapter with BCE (suitable for communication with up to 8 automation systems; not redundant systems).

The IE versions of the SIMATIC PCS 7 Workstation for Single Stations and Servers are equipped with a CP 1623 communications module with the SIMATIC NET HARDNET‑IE S7 communication software. When using redundant automation systems, the SIMATIC PCS 7 workstation requires SIMATIC NET HARDNET‑IE S7‑REDCONNECT communication software instead of the SIMATIC NET HARDNET‑IE S7 communication software. SIMATIC NET HARDNET-IE S7-REDCONNECT PowerPack can be used to upgrade the communication software. For order data on this, see "Industrial Communication" section, "Industrial Ethernet, System Connection PCS 7 Systems" subsection.

The 10/100/1 000 Mbps Ethernet RJ45 port is already onboard and can be used for connecting to the terminal bus.

Redundancy

SIMATIC BATCH supports Batch Server redundancy. The two Batch Servers in a redundant pair of servers have identical configurations. A separate Ethernet connection via separate network adapters/connectors between these servers is used to optimize the internal communication. This must always be provided as an Ethernet connection. This also applies if SIMATIC BATCH software and SIMATIC PCS 7 OS software are installed together on the redundant pair of servers. The serial RS 232 connection described in the section "OS redundancy" is not possible in this case.

A redundant optical or electrical connection can be used depending on the ambient conditions and the distance between the two Batch Servers, for example up to 100 m per crossover network cable (RJ45 plug). For details, refer to the "High-availability process control systems" manual; for appropriate cable material and further accessories, see Catalog IK PI.

Note:

Licenses for the server, API and UNITs and for SIMATIC BATCH OS Control Web Client must be installed on both servers for the redundant version.

Basic hardware

The modularity and flexibility of SIMATIC BATCH are optimally supported by the hardware available. The basic hardware from the "Industrial Workstation/IPC" section can be used for SIMATIC BATCH. Please note that the operating system and the ES/OS software of the SIMATIC PCS 7 process control system are pre-installed as standard on the SIMATIC PCS 7 Industrial Workstations of version Single Station, Server and Client. If these basic devices are used for SIMATIC BATCH, it is possible to extend the existing SIMATIC PCS 7 installation or restore it for the operating system using the Restore DVD set.

Expansion options

OS/Batch Single Station and Batch client can be optionally expanded for multi-monitor mode with up to 4 monitors. Using multi-monitor mode, the visualization of a plant/unit can be divided among 2 to 4 process monitors per operator station using different views. These plant sections can all be operated using just one keyboard and one mouse.

Note:

Since all messages from SIMATIC BATCH are processed in the message system of the Operator System, the use of a signal module is only recommendable with multi-function OS/Batch stations (Clients, Single Stations).

Process picture with integrated OS Control

Integration in SIMATIC PCS 7

SIMATIC BATCH is completely integrated in SIMATIC PCS 7. The plant data can be configured entirely using the engineering system. The engineering system transfers all data required for creating recipes to the Batch server. It is therefore possible to edit recipes separate from the engineering system. Changes to the configuration which are made in the engineering system are available to the Batch server using an update function (online/offline).

SIMATIC BATCH supports the operation and monitoring of batch processes by means of standard faceplates (faceplates and OS controls integrated in the process picture). With SIMATIC PCS 7 V9.1, operation is also possible using OS controls configured on a Web client.

The SIMATIC Logon integrated in SIMATIC PCS 7 uses SIMATIC BATCH for the following functions:

• Central user administration with access control
• "Electronic Signature" function
  This means that actions cannot be performed until enabled by authorized users/user groups.

A smart card reader suitable as a logon device is offered in section "Industrial Workstation/IPC", under "Expansion components, smart card reader".

Communication with the automation systems

Depending on the operating mode, SIMATIC BATCH communicates with the automation systems via the Operator System or directly via S7-DOS.

SFC instances derived from a SFC type template are generally used as the interface to the subordinate automation level. The properties of the SFC type can be defined in a properties dialog, including:

• Control strategies
• Setpoint/actual value
• Instance parameters
• Timers

In addition to the SFC instances, individual unit parameters can be described by parameter steps of the recipe.