Resolving PDF Batch Report Archiving Failures in SIMATIC BATCH

In SIMATIC BATCH (v8.1 SP1 and v8.2), an error archiving completed batches to PDF while XML archiving succeeds indicates a breakdown in the Microsoft SQL Server Reporting Services (SSRS) pipeline. XML export is written directly by the BATCH Server, whereas PDF generation requires Report Definition Language templates (.rdl), active SSRS web services, and synchronized database versions between the Engineering Station and BATCH Server. To resolve this, re-download the BATCH project from the ES to align database versions, verify that standard .rdl report templates exist in the RSTemplates folder, and validate user credentials in BATCH Options.

Architecture of Batch Archiving: XML vs PDF Report Generation

In SIMATIC BATCH (6ES7657-0XX08-1YB0), completed production batches are archived from the active runtime database to external long-term storage according to life-cycle compliance rules (e.g., ISA-88, FDA 21 CFR Part 11).

The Batch Control Center (BCC) supports two primary archive formats:
1. XML Archive: A structured data interchange format containing raw recipe execution trees, phase transitions, process values, and operator comments. XML files are serialized directly by the local SIMATIC BATCH Control Server service without external dependencies.
2. PDF Batch Report: A formatted, human-readable document containing recipe charts, electronic signatures, trend graphs, and alarm summaries. PDF generation relies on Microsoft SQL Server Reporting Services (SSRS) and the SIMATIC BATCH Report Server.

Why PDF Archiving Fails While XML Export Succeeds

When an operator attempts to close and archive a completed batch, the system may report an archiving error for PDF while XML archiving finishes cleanly:

Operational CheckpointXML Archiving MechanismPDF Archiving MechanismFailure Impact on PDFRendering EngineNative BATCH C++ serializerMicrosoft SQL Server Reporting Services (SSRS)SSRS service stopped or DCOM permissions rejected.Template DependencyNo template requiredRequires .rdl templates in BATCH\RSTemplatesMissing standard template halts PDF rendering.Database SynchronizationDirect SQL queryBATCH Report Server database syncSchema mismatch between ES and Server aborts report.User AuthenticationLocal Windows userBATCH Service credentials (Options > User Credentials)Invalid service credentials reject SSRS execution.

Table 1: Technical dependencies comparing XML and PDF batch archiving.

Verifying Report Server Templates (.rdl) and SSRS Dependencies

To ensure the Report Server can render PDF reports:

Inspect Template Directory:
* Navigate to the BATCH installation directory on the BATCH Server: C:\Program Files (x86)\Siemens\BATCH\RSTemplates (or Template).
* Verify the presence of standard report template files: standard_batch_en-US.rdl, standard_recipe_en-US.rdl, etc.
* If the folder is empty, reinstall the SIMATIC BATCH Report Server component or copy default templates from the PCS 7 installation media.
Verify Reporting Services Status:
* Open Windows Services (services.msc).
* Verify that SQL Server Reporting Services (WINCC) is running and set to Automatic startup.
* Open Internet Explorer on the server and browse to the SSRS report manager URL: http://localhost/Reports_WINCC to confirm the report web service is responsive.
Validate Service Credentials:
* Open SIMATIC BATCH Control Center.
* Select Options > User Credentials.
* Re-enter the domain/local automation user account and password.
* Ensure this user belongs to the Windows groups SIMATIC BATCH, SIMATIC HMI, and Administrators.

Aligning SIMATIC BATCH Project Database Versions via ES Download

A frequent root cause occurs when SIMATIC BATCH software is upgraded on the server (e.g., from v8.1 to v8.1 SP1) without re-downloading the engineering database:
* The upgraded BATCH Report Server binary expects updated database stored procedures and schema definitions.
* Because the server database retains legacy v8.1 tables, report generation queries fail with database access exceptions.
* Resolution:
1. On the Engineering Station, open the project in SIMATIC Manager.
2. Open the BATCH engineering application (Configure BATCH).
3. Execute Generate followed by Compile.
4. Perform a complete Download of the BATCH project to the BATCH Server.
5. In BATCH Control Center, open Batch > Update System Data.
6. Re-attempt batch archiving: PDF generation now completes cleanly.

Verification

To confirm successful PDF archiving:

In SIMATIC BATCH Control Center, select a completed batch.
Right-click the batch and select Print / Archive > Archive to PDF.
Confirm that the progress bar executes through data collection, SSRS rendering, and file generation without error prompts.
Navigate to the configured archive target folder: verify that the .pdf file is present, has a non-zero file size, and opens cleanly in Adobe Acrobat displaying all recipe phases and trend charts.
In BATCH Control Center, verify that the batch status transitions to Archived (PDF).

Limitations and Operational Precautions

Never modify standard .rdl template files directly without creating a project-specific copy; future software updates will overwrite modifications.
Ensure the target archive network share has sufficient disk space and grants Full Control permissions to the SIMATIC BATCH Windows service account.
If a plant uses electronic signatures compliant with 21 CFR Part 11, ensure audit trail logging is active before archiving batches to PDF.

Engineer FAQ

Can I convert existing XML batch archives to PDF after the fact?

Yes. In SIMATIC BATCH Control Center, you can retrieve an archived XML batch back into the system database and then execute Archive to PDF once the Report Server is repaired.

Where are BATCH PDF rendering errors logged?

Inspect the BATCH diagnostic directory: C:\ProgramData\Siemens\Automation\Logfiles\BATCH\ and the SQL Reporting Services log folder: ...\Microsoft SQL Server\MSRS11.WINCC\Reporting Services\LogFiles\.

Does SIMATIC BATCH require Microsoft Office to generate PDF reports?

No. Report generation is handled entirely by Microsoft SQL Server Reporting Services (SSRS) and does not require Microsoft Office or third-party PDF printer drivers.