SIMATIC BATCH, scalable from single-user up to client/server system

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. Both the SIMATIC PCS 7 ES/OS Single Station and the SIMATIC PCS 7 BOX are suitable as a single station. Both can be combined with modular automation systems from the S7-400 series as well as with compact SIMATIC PCS 7 AS RTX.

Client/server configuration

However, characteristic for the automation of batch processes using SIMATIC BATCH are client/server architectures with which one Batch server and multiple Batch clients running a plant project in unison. The batch server in such a configuration can also be configured with redundancy in order to increase availability.

BATCH clients and OS clients can run on separate or common basic hardware. In addition to the SIMATIC PCS 7 Industrial Workstations, the more compact SIMATIC PCS 7 Box OS Clients 627D and SIMATIC PCS 7 OS Clients 427D/477D are also suitable as a Batch client.

The Batch server software provided for configuration of a Batch server (SIMATIC BATCH Basic or SIMATIC 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/CP 1613 A2 communication module or via a simple Fast Ethernet 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 communication module with the SIMATIC NET HARDNET?IE S7 communications software. When using redundant automation systems, the SIMATIC PCS 7 workstation requires SIMATIC NET HARDNET?IE S7?REDCONNECT communications software instead of the SIMATIC NET HARDNET?IE S7 communication software. The SIMATIC NET HARDNET?IE S7?REDCONNECT PowerPack is suitable for upgrading the communications software (for ordering data, see section "Communication", section "Industrial Ethernet, System Connection of PCS 7 systems").

The 10/100/1000 Mbps Ethernet RJ45 port is already onboard and can be used for connecting to the terminal bus.

Redundancy

SIMATIC BATCH supports the Batch server redundancy. The two batch servers in a redundant pair of servers have identical configurations. A separate redundant connection 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 environmental conditions and the distance between the two batch servers, e.g. up to 100 m per crossover network cable (RJ45 connectors). For details, refer to Manual "Fault-tolerant process control systems"; for appropriate cable material and further accessories, refer to Catalog IK PI.

For information and components for the redundant bus connection (plant bus and terminal bus), see the section "Communication", "Industrial Ethernet" and "System connection of PCS 7 systems".

Note:

Licenses for the server, API and UNITs 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 section "Industrial Workstation/IPC" as well as the SIMATIC PCS 7 BOX from the section "Compact systems" 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 or reject the existing SIMATIC PCS 7 installation, and restore it for the operating system using the restore DVD.

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 operator system's message system, the use of a signal module is only recommendable with multi-function OS/batch stations (clients, single stations).