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How to Resolve SIMATIC BATCH Control Center (BatchCC) Startup Failures on OS Clients

How to Resolve SIMATIC BATCH Control Center (BatchCC) Startup Failures on OS Clients

When SIMATIC BATCH Control Center (BatchCC) fails to open on a single OS Client workstation—while operating normally on other clients and the BATCH Server—the failure is caused by missing local Windows user permissions, corrupt local database client cache files, or mismatched DCOM security endpoints. BatchCC does not store process recipes locally; it establishes a distributed Microsoft .NET/DCOM remoting channel to the central BATCH Server database. If the logged-in Windows user is missing from the local SIMATIC BATCH user group, if Simatic Shell binds to an incorrect network adapter, or if the client's local cached database descriptor (*.bcr) is corrupted, the BatchCC executable hangs or terminates silently. To restore operation, verify user group membership, confirm DCOM permissions, clear local client cache directories, and rejoin the station via Simatic Shell.

Table of Contents

SIMATIC BATCH Client-Server Communication Architecture

In recipe-driven batch processing plants running SIMATIC PCS 7, SIMATIC BATCH manages recipe execution, batch scheduling, and 21 CFR Part 11 compliant audit trails:
* Central BATCH Server: Hosts the core database services (BFW.exe, BServer.exe) running Microsoft SQL Server and managing the shared project folder (sbdata).
* BATCH Control Center (BatchCC): The primary operator client interface (bcc.exe) used to create control recipes, allocate equipment units, and release batches.
* Client Architecture: BatchCC on an OS Client acts as a thin presentation layer. It communicates with the BATCH Server over the Terminal Bus using:
- DCOM / .NET Remoting: For command dispatching and state updates.
- SMB Shared Folder Access: To read compiled recipe objects and report definitions from the server's sbdata share.
- SQL Native Client: For direct query execution during batch archive retrieval.

Root Cause Analysis: Why BatchCC Fails on Isolated Clients

When BatchCC operates reliably across all stations except for one isolated workstation, the central server database is healthy. The fault resides strictly in local client configuration:

  1. Missing User Group Membership: The active Windows domain user logged into the problem client is not a member of the local Windows group SIMATIC BATCH on the client PC.
  2. Local Cache File Corruption: BatchCC maintains a local client cache of recent recipes and server connection tokens in %APPDATA%\Siemens\SIMATIC BATCH. If a client PC suffers an abrupt power loss or network disconnection while BatchCC is closing, this cache corrupts, causing bcc.exe to crash upon subsequent launches.
  3. Simatic Shell Adapter Mismatch: If the client PC has multiple network cards and Simatic Shell is bound to the wrong adapter, BatchCC cannot locate the BATCH Server via UDP broadcast.
  4. DCOM Access Permissions: Microsoft Windows security updates (specifically DCOM Hardening guidelines KB5004442) frequently block unauthenticated RPC requests if authentication level settings are misaligned.

Windows User Group and DCOM Security Requirements

To allow BatchCC to communicate with the BATCH server, the workstation must meet strict security configurations:

Security ComponentRequired Configuration on OS ClientFailure Symptom if MissingLocal User GroupUser must belong to SIMATIC BATCH and SIMATIC HMI.BatchCC terminates immediately with 'Access Denied' or silent crash.DCOM ConfigurationDefault Launch and Activation Permissions granted to SIMATIC BATCH.BatchCC hangs indefinitely on splash screen showing 'Connecting to Server...'.SMB Share AccessRead/Write access to \\<BatchServer>\sbdata.BatchCC opens but reports 'Cannot open batch project database'.

Method: Step-by-Step Diagnostic and Resolution Workflow

Follow this procedure to resolve the single-client startup failure:

Step 1: Verify Windows User Group Memberships

  1. On the problem OS Client, right-click the Windows Start menu and select Computer Management.
  2. Expand Local Users and Groups > Groups.
  3. Inspect the group SIMATIC BATCH:
    - Verify that the active user account (or domain user group) is listed as a member.
    - If missing, click Add, enter the user account, and click OK.
  4. Inspect the group SIMATIC HMI: ensure the user is also a member.
  5. Log out of Windows and log back in to apply updated security tokens.

Step 2: Clear Corrupted Local Client Cache Directories

  1. Ensure all SIMATIC applications are terminated on the client.
  2. Open Windows Explorer and navigate to:
    text C:\Users\<Current_User>\AppData\Roaming\Siemens\SIMATIC BATCH
  3. Locate the client cache folder and temporary session files (*.tmp, *.bcr).
  4. Rename the SIMATIC BATCH directory to SIMATIC BATCH_Old.
  5. Upon the next launch, BatchCC will automatically generate a clean cache directory and retrieve fresh descriptors from the BATCH Server.

Step 3: Verify Simatic Shell Binding

  1. In Windows Explorer, right-click Simatic Shell and select Settings.
  2. Confirm that the selected network adapter is the physical network card connected to the Terminal Bus.
  3. Confirm that the BATCH Server appears in the Simatic Shell navigation tree with an active blue computer icon.

Step 4: Re-initialize DCOM Permissions via dcomcnfg

  1. Open the Windows Run dialog, type dcomcnfg, and press Enter.
  2. Expand Component Services > Computers > My Computer.
  3. Right-click My Computer and select Properties.
  4. On the Default Properties tab:
    - Ensure Default Authentication Level is set to Connect.
    - Ensure Default Impersonation Level is set to Identify.
  5. On the COM Security tab, under Access Permissions and Launch and Activation Permissions, click Edit Limits and confirm that SIMATIC BATCH has full local and remote permissions enabled.

Verification

To verify that BatchCC is fully restored on the client:

  1. Double-click the BatchCC desktop shortcut.
  2. Verify that the splash screen appears, authenticates against the server within 3 to 5 seconds, and opens the main user interface.
  3. Expand the project tree in BatchCC:
    - Confirm that all master recipes, control recipes, and plant units load properly.
  4. Open a control recipe and execute a test batch release:
    - Confirm that the batch releases without 'Communication error' popups.
  5. Inspect the BATCH Server diagnostic monitor: confirm that the client workstation is listed under active connected client sessions.

Limitations and Operational Precautions

  • Operating System Version Matching: SIMATIC BATCH clients are supported strictly on Windows 10 Enterprise LTSC and Windows Server. Installing BATCH client software on consumer Windows 10 Home or Pro editions causes unpredictable DCOM authentication dropouts.
  • Do Not Modify Server Database Directly: Never attempt to resolve client connection faults by altering SQL Server tables inside the BATCH database (sbdata). All configuration must be performed through official PCS 7 engineering tools.
  • Simultaneous Recipe Editing: While multiple BatchCC clients can view recipes simultaneously, only one client can open a specific master recipe in edit mode at a time to prevent concurrent database overwrite conflicts.

Engineer FAQ

Why does BatchCC work when I log in as the local Administrator but fail for standard operators?
Local Administrators automatically bypass certain DCOM security checks. If it fails for standard operators, the operator's Windows account is missing from the local SIMATIC BATCH group.

Can I run BatchCC on an OS Client if WinCC Runtime is not running?
Yes. BatchCC communicates directly with the BATCH Server database services and does not require active WinCC Graphics Runtime to view or release recipes.

What is the function of the BFW.exe service on the BATCH Server?
BFW.exe (BATCH Framework) manages background communication, coordinates controller phase execution via AS-OS message drivers, and orchestrates client connections.

Technical References

  • Siemens Industry Online Support Entry ID 109742323: SIMATIC BATCH Operating Manual
  • SIMATIC BATCH Client-Server Configuration Guide (Document No. A5E38012658)
  • Siemens Industry Online Support Entry ID 109809264: DCOM Hardening and SIMATIC PCS 7 Security Guidelines

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Related Tags

  • https://industrialautomation.net/search?query=simatic-batch
  • https://industrialautomation.net/search?query=batchcc
  • https://industrialautomation.net/search?query=simatic+pcs7
  • https://industrialautomation.net/search?query=dcom-configuration
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