Configuring SIMIT Virtual Controller for SIMATIC BATCH and Route Control Simulation

In SIMATIC PCS 7 simulation environments using SIMIT Virtual Controller (VC), SIMATIC BATCH recipe unit reservation failures (indicated by a pink 'U' icon and 'Recipe element is waiting for a unit occupancy' status) and Route Control connection faults occur when Named Connections (S7 H-connections) are not properly mapped over the virtual network interface. Unlike standard OS clients that can communicate via plain TCP/IP, SIMATIC BATCH (BA_NA FB255 / EPH FB260) and Route Control (RC_IF_CFG) require active S7 Named Connections to exchange recipe phase allocations and heartbeat tokens. To resolve, configure the SIMIT Virtual Controller coupling to use ISO-on-TCP with exact NetPro S7 connection IDs, enable SIMATIC BATCH communication routing in SIMIT VC settings, and ensure controller time synchronization matches the BATCH server.

Executive Summary

Testing complex batch recipes and material routing sequences prior to commissioning requires full co-simulation of the AS automation logic, WinCC OS, SIMATIC BATCH, and SIMATIC Route Control (RC). When using SIMIT Virtual Controller to emulate the controllers, engineers frequently encounter a roadblock: while standard WinCC OS screens communicate normally, SIMATIC BATCH recipes fail to allocate equipment units (displaying a persistent pink 'U' occupancy wait), and Route Control reports disconnected routes. This technical article details the underlying communication mechanics, explains why Named Connections behave differently in virtual environments, and provides the step-by-step configuration workflow to enable seamless BATCH and Route Control virtual commissioning.

Architecture and Fundamental Mechanics

The communication architecture between SIMATIC BATCH, Route Control, and SIMIT Virtual Controller relies on multi-layered protocol bindings:
1. The Named Connection Requirement:
- SIMATIC BATCH relies on dedicated high-speed communication blocks (BA_NA FB255, EPH FB260, UNIT_BLOCK FB267) embedded within the AS CFC charts.
- These blocks do not communicate over raw TCP/IP sockets; they require S7 Named Connections defined in NetPro between the AS station and the BATCH Server application.
2. SIMIT Virtual Controller (VC) Networking Layer:
- SIMIT VC emulates S7-400 / CPU 410-5H controllers as software instances on the Windows host.
- By default, SIMIT VC binds to a virtual network adapter using ISO-on-TCP (RFC 1006). If the NetPro S7 connection database is compiled with named endpoints that point to physical CP 443-1 MAC addresses or ISO protocols without IP routing, the BATCH communication server cannot bind to the Virtual Controller.
3. Unit Allocation and State Machine Handshake:
- When BatchCC starts a recipe phase, it transmits an allocation request to the AS UNIT_BLOCK.
- The AS verifies that the unit is not locked (U_STATE = Free) and returns an occupancy confirmation.
- If the communication telegrams between BATCH Server and SIMIT VC are dropped, time-skewed, or blocked by firewall rules, BatchCC never receives the confirmation token, causing the phase to hang indefinitely with the pink 'U' (Unit waiting) status.
4. Route Control Heartbeat Mechanics:
- SIMATIC Route Control exchanges continuous heartbeat frames with RC_IF_CFG blocks in the AS.
- Latency jitter or time drift between SIMIT VC's virtual clock and the physical PC clock can cause Route Control to declare connection loss and abort path requests.

Step-by-Step Implementation Procedure

Configure NetPro Connections for Virtual Emulation:
a. In SIMATIC Manager, open NetPro for the Multiproject.
b. Inspect the connection table between the BATCH Server PC station and the AS station.
c. Ensure the connection type is configured as S7 connection (Named Connection) utilizing the Industrial Ethernet (TCP/IP) interface rather than ISO transport.
d. Note the exact 'Local ID' and 'Partner ID' assigned to the BATCH connection.
e. Execute Network -> Save and Compile (Compile and check everything).
Configure SIMIT Virtual Controller Network Coupling:
a. Open SIMIT V10.x / V9.1 and open the simulation project.
b. In Project Navigation, open the Virtual Controller coupling.
c. Under 'Network Configuration', select the host network adapter connected to the BATCH Server (or select the loopback adapter if running on a single PC).
d. Set the communication protocol to ISO-on-TCP (RFC 1006).
e. Ensure that 'Enable S7 Named Connections' is checked in the VC coupling advanced properties.
Synchronize Time Settings in SIMIT and BATCH:
a. In SIMIT, open Simulation Settings: set the 'Time Factor' strictly to 1.00 (real-time execution).
b. In Windows Date and Time on the BATCH Server and Engineering Station, verify that both systems utilize UTC or identical local time zones with automatic daylight saving disabled.
Compile and Propagate SIMATIC BATCH Engineering Data:
a. In SIMATIC Manager, select the BATCH object and execute Compile / Download.
b. Execute: Merge -> Generate -> Propagate.
c. Execute Download to AS and Download to Server.
d. Open BatchCC, select System -> Update Process Cell Data.
Verify Route Control Communication Blocks:
a. In the AS CFC charts, confirm that block RC_IF_CFG is placed in OB35 with module drivers generated.
b. In Route Control Wizard on the ES, execute a full Route Control compilation and server download.
c. Start Route Control Server and verify green communication status.

Verification

In BatchCC, open the Unit Overview: verify that all process units report status 'Available' without communication fault overlays.
Start a test batch: confirm that when the recipe reaches the unit allocation step, the unit status shifts from 'Available' to 'Allocated' (blue/green icon) without displaying the pink 'U' wait icon.
In Route Control Center (RCC), execute a route search and request: verify the route is found, reserved, and activated with live feedback from SIMIT VC.

Limitations and Operational Precautions

Accelerated simulation (Time Factor > 1.0) is not supported when co-simulating with live SIMATIC BATCH and Route Control servers, as communication timeouts will trigger heartbeat failures.

Engineer FAQ

What does the pink 'U' symbol indicate in BatchCC?

It indicates that the recipe element is waiting for unit occupancy because the AS unit block has not confirmed reservation to the BATCH Server.

Why do WinCC OS screens work with SIMIT VC while SIMATIC BATCH fails?

WinCC OS can connect via basic TCP/IP tags, whereas SIMATIC BATCH requires active S7 Named Connections configured in NetPro.

Can SIMATIC Route Control run with SIMIT Virtual Controller?

Yes, provided S7 Named Connections are properly configured and SIMIT is running in real time (Time Factor = 1.00).

Does SIMIT VC support redundant BATCH Server configurations?

Yes, but both BATCH Server instances must have routable network access to the host PC running SIMIT Virtual Controller.

What block manages unit allocation in PCS 7 CFC for BATCH?

The UNIT_BLOCK (FB267) or technological equipment phase blocks (EPH FB260).

Technical References

Related Tags

SIMATIC BATCH
Route Control
SIMIT VC
Virtual Controller
Named Connections
Unit Occupancy

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Configuring SIMIT Virtual Controller for SIMATIC BATCH and Route Control Simulation