C135 PCS 7 (PCS7)
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How to Correctly Interconnect SIMATIC BATCH Recipes with SFC Types and Setpoints in PCS 7

How to Correctly Interconnect SIMATIC BATCH Recipes with SFC Types and Setpoints in PCS 7

To correctly pass recipe setpoints from SIMATIC BATCH into SFC Types in SIMATIC PCS 7, engineers must define setpoints within the SFC Type Characteristic Overview rather than creating generic block parameters or manual CFC inputs. In the SFC Type editor, configuring a setpoint under the 'Setpoints' characteristic automatically instantiates the standardized batch interface variables—including SP (active automatic setpoint), SP_OP (operator manual setpoint), SP_AI (actual process value input), and SP_Q (validated actual value). Setpoints must then be assigned to specific Control Strategies (CS). After compiling the AS and OS, running 'Update BATCH Project' in BATCH CC imports these characteristics, allowing Master Recipe phases to manipulate setpoint values dynamically during recipe execution.

Table of Contents

Architectural Difference: SFC Type Setpoints vs Parameters

In SIMATIC PCS 7 and SIMATIC BATCH, SFC Types represent reusable state transition logic for Equipment Modules (EM) and Equipment Phases (EPH).

A critical design distinction exists in how values are routed into the SFC Type:

1. Setpoints (Batch-Relevant Recipe Inputs)

Setpoints are dynamic variables intended to be specified by a higher-level recipe system (SIMATIC BATCH) or manually by an operator. They influence the execution of the SFC sequencer (e.g., target temperature, agitation speed, transfer volume) and are assigned to individual Control Strategies. When configured, SIMATIC BATCH recognizes them as recipe parameters.

2. Parameters (Instance-Specific Configuration)

Parameters are fixed or semi-static values used to modify the behavior of an SFC Type on a specific instance (e.g., sensor calibration offsets, physical vessel volume limits, maximum heating duration). They are not manipulated dynamically by SIMATIC BATCH recipe steps during runtime.

The Auto-Generated Setpoint Interface Variable Structure

When an engineer defines a setpoint (e.g., named TempSP) within the SFC Type Characteristic Editor, the compiler automatically generates a standardized suite of interconnected interface pins:

  • TempSP: The active valid setpoint value in Automatic mode, directly commanded by SIMATIC BATCH.
  • TempSP_OP: The setpoint value entered by the operator in Manual mode.
  • TempSP_OPP: The prepared setpoint value in Manual mode, transferred to TempSP_OP on the next Start command.
  • TempSP_AI: The actual process value input from the plant instrumentation (e.g., temperature transmitter PV_Out).
  • TempSP_Q: The actual valid process value utilized internally by the SFC sequencer comparison transitions.
  • TempSP_QP: The prepared actual valid value.
  • TempSP_AO: The actual process value output (mirrors TempSP_AI for external routing).

Within the SFC Type sequencer transitions and steps, engineers evaluate TempSP against TempSP_AI to determine phase completion (e.g., transition condition: TempSP_AI >= TempSP).

Configuring Setpoints and Assigning Control Strategies in SFC Types

Follow this engineering sequence to configure batch-controllable setpoints:

Step 1: Define Setpoints in SFC Type

  1. In SIMATIC Manager, open the target SFC Type in the SFC Editor.
  2. In the navigation tree, open the Characteristics window.
  3. Right-click Setpoints -> Insert Characteristic.
  4. Define the setpoint name (e.g., AgitSpeed), data type (e.g., REAL), unit of measure (e.g., rpm), and default limits.
  5. In the setpoint properties, assign the setpoint to one or more configured Control Strategies (e.g., 'Gentle Agitation' or 'High Shear Mixing').

Step 2: Interconnect Actual Values in CFC

  1. Instantiate the SFC Type into an Equipment Phase CFC chart.
  2. Interconnect the plant sensor output (e.g., speed transmitter PV_Out) to the auto-generated input pin AgitSpeed_AI.
  3. Interconnect the control command output pin (or write logic in SFC steps) to drive the downstream motor block SpdAut pin.

Synchronizing the Engineering System with SIMATIC BATCH CC

To make the newly configured setpoints available in recipe design:

  1. Compile AS: In SIMATIC Manager, compile the CFC charts containing the SFC instances.
  2. Compile OS: Perform an OS compile to generate WinCC tags and SIMATIC BATCH messages.
  3. Compile and Download SIMATIC BATCH:
    * Open the SIMATIC BATCH configuration dialog (Configure BATCH).
    * Compile the BATCH engineering data.
    * Download the BATCH project to the BATCH Server.
  4. Update BATCH Control Center (BATCH CC):
    * Open BATCH CC.
    * Execute System -> Update BATCH Project.
    * BATCH CC reads the updated SFC Type catalog.
  5. Assign in Master Recipe:
    * Open the Master Recipe in BATCH Recipe Editor.
    * Insert the Equipment Phase.
    * In the phase properties dialog, the configured setpoints appear under the Parameters tab, allowing recipe designers to enter target values and tolerances.

SFC Type Characteristic and Recipe Interface Reference Matrix

The following table outlines the characteristic types, auto-generated variables, and BATCH relevance:

Characteristic TypeAuto-Generated PinsBATCH RelevancePrimary Operational PurposeSetpoint (SP)SP, SP_OP, SP_AI, SP_QYes (Recipe Parameter)Dynamic process target specified by recipeMaterial Input (PI)PI, PI_OP, PI_AI, PI_QYes (Material Tracking)Ingredient identification and dosage quantityMaterial Output (PO)PO, PO_OP, PO_AI, PO_QYes (Material Tracking)Produced batch material and yield volumeParameter (PAR)Single static parameter pinNo (Static Instance)Fixed engineering limit, timeout, or gainControl Strategy (CS)QCS, CS_OP, CSYes (Recipe Strategy)Selects specific operating behavior in phase

Proper characteristic structuring ensures clean parameter handshakes between BATCH CC and the controller.

Verification

To verify that recipe setpoints transfer correctly to the SFC Type:
1. In BATCH CC, create a batch order using the modified master recipe and specify a test setpoint (e.g., AgitSpeed = 450 rpm).
2. Release and start the batch.
3. In SIMATIC Manager, open the active SFC Type instance online in test mode.
4. Verify that when the phase activates, the input pin AgitSpeed changes from its default to 450.0.
5. Verify that the SFC transition evaluating AgitSpeed_AI >= AgitSpeed successfully advances the recipe sequencer upon reaching setpoint.

Limitations and Operational Precautions

  • Never manually create inputs or outputs with _AI or _OP suffixes in the SFC Type I/O view; always use the Characteristic Editor to avoid internal naming collisions.
  • Modifying setpoints or control strategies on an active SFC Type requires an AS compilation and Type Change in RUN (TCiR) or controller STOP.
  • Ensure unit of measure (UoM) strings match exactly between the SFC Type characteristic and the SIMATIC BATCH engineering repository.
  • When using redundant BATCH servers, verify database synchronization before downloading updated batch project types.

Engineer FAQ

Why does my setpoint not appear in BATCH Recipe Editor after creating it in SFC Type?

You must compile the AS, compile the OS, execute 'Compile BATCH', and then run 'Update BATCH Project' in BATCH CC. Without these steps, the BATCH database remains unaware of new SFC characteristics.

What is the difference between SP and SP_AI in an SFC Type?

SP is the commanded target value received from SIMATIC BATCH or the operator. SP_AI is the actual process feedback signal from field instrumentation connected to the block.

Can a single SFC Type have multiple control strategies with different setpoints?

Yes. Each setpoint can be independently assigned to specific control strategies. In the recipe phase, selecting a control strategy automatically filters the available setpoints to match that strategy.

Technical References

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Related Tags

  • SIMATIC BATCH
  • SFC Types
  • Recipe Setpoints
  • Characteristic Editor
  • Control Strategies
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