Resolving SIMATIC BATCH Launch Coordinator 'Intermediate State' and Server Startup Failures

In SIMATIC BATCH (v8.0, v8.1, v8.2, and newer), when the Batch Launch Coordinator becomes stuck in an 'intermediate state' and the Batch Server fails to initialize following an order release on a massive recipe procedure, the failure is caused by runtime database deadlocks or memory corruption within the active batch runtime database (SBRuntime.mdf/.ldf). Releasing an excessively large recipe or experiencing an unhandled transaction abort leaves orphaned database locks, preventing the Batch Control Server (BCS) and Communication Server (CDV) from transitioning from starting to active. To resolve this, engineers must terminate lingering batch processes, perform a structured Batch Runtime Data Reset (purging corrupted active orders while preserving master recipes), and restore the Process Cell data.

SIMATIC BATCH Server Architecture and Launch Coordinator Roles

SIMATIC BATCH manages recipe execution and batch records through a suite of coordinated Windows services overseen by the Batch Launch Coordinator:
- Batch Control Server (BCS): The core execution engine managing recipe state machines, phase transitions, and electronic signatures.
- Batch Data Management (BDM): Manages recipe databases, formula libraries, and system configurations.
- Communication Driver (CDV): Coordinates high-speed S7 communication between the Batch Server and S7-400 / CPU 410 controllers.
- Batch Launch Coordinator: The supervisory watchdog that orchestrates the startup sequence of all BATCH subsystems, verifying database mounts and network socket availability.

During normal startup, the Launch Coordinator advances from Stopped -> Starting -> Active. If any underlying component crashes or hangs on a locked SQL table, the coordinator remains trapped indefinitely in an 'intermediate state'.

Root Causes of 'Intermediate State' Startup Freezes

When this failure follows the release of a massive recipe procedure:

Recipe Parser Buffer Exhaustion: An exceptionally large recipe (e.g., hundreds of parallel steps, complex branch loops, and dozens of equipment operations) can exceed the execution memory buffer allocated to the BCS order parser during compilation.
Corrupted Runtime Transaction (SBRuntime.mdf): When the order release aborted, an uncommitted SQL transaction locked database pages in the active runtime database (SBRuntime.mdf). Upon server restart, the SQL engine attempts an indefinite rollback, blocking the BCS service.
Orphaned Process Locks (bcc.exe / bcs.exe): Lingering background batch processes holding memory locks in Windows task manager prevent clean service initialization.
Mismatched PLC Process Cell Data: If AS blocks were updated while the batch server was in a degraded state, synchronization discrepancies between the controller phase DBs and the BATCH server block the CDV driver.

Step-by-Step Procedure: Resetting Batch Runtime Databases

To recover the SIMATIC BATCH Server from a locked intermediate state:

Step 1: Terminate All Batch Processes

On the primary BATCH Server (and redundant partner), open Windows Task Manager.
Terminate any active BATCH executables: bcs.exe, bcc.exe, cdv.exe, bfmsrv.exe, and BatchLaunchCoordinator.exe.
In Windows Services, ensure all SIMATIC BATCH services indicate Stopped.

Step 2: Clear Corrupted Runtime Data via Batch Advanced Tools

In Windows Start menu, navigate to Siemens Automation > SIMATIC > BATCH > Advanced Tools > BATCH Database Maintenance (or run SBMaintenance.exe).
Select the option 'Clear Batch Runtime Data' (or 'Delete Runtime Data').

[!WARNING]
Clearing runtime data deletes all currently running/active batch orders from the server. Master recipes, equipment properties, and archived completed batches are completely preserved.
Confirm the deletion and allow the tool to reconstruct a clean SBRuntime database structure.

Step 3: Re-Synchronize Process Cell Data from SIMATIC Manager

On the Engineering Station, open SIMATIC Manager.
Select the BATCH object in the project tree, right-click and select Compile.
Select Transfer Messages and Download to Server.
Once download succeeds, open the Batch Launch Coordinator on the BATCH Server; click Start.
Observe the startup sequence; the status will smoothly transition to Active.

Diagnostic Matrix for SIMATIC BATCH Server Startup States

The table below outlines common Launch Coordinator states and corrective actions:

Coordinator StateUnderlying CauseCorrective ActionIntermediate State (Hung)Database deadlock in SBRuntime.mdf or orphaned lockClear runtime data via SBMaintenance.exe; restart servicesFault / Error StateMissing BATCH server license or network card misboundVerify licenses in ALM; check Simatic Shell terminal bus bindingStarting... (Times out)SQL Server BATCH instance stopped or inaccessibleStart SQL Server (BATCH) service in services.mscActive (Normal)All services (BCS, BDM, CDV) running normallyNormal operation

Best Practices for Managing Massive Recipe Procedures

To prevent future recipe release deadlocks:
- Hierarchical Modularization: Break massive monolithic recipes into modular sub-recipes and standardized Equipment Operations (EOPs).
- Avoid Infinite Branching: Restrict complex nested OR/AND divergence loops; use SFC Types on the AS layer to execute repetitive sub-sequences natively in controller firmware.
- Regular Master Recipe Export: Regularly export all approved master recipes to XML/sbx files via Batch Control Center > File > Export to ensure rapid disaster recovery.

Verification

To confirm that the BATCH Server has fully recovered:
1. Launch Coordinator Health: Open Batch Launch Coordinator; confirm that the state indicates 'Active' with a steady green icon.
2. Batch Control Center Access: Launch Batch Control Center (BCC); confirm that the plant process cell hierarchy loads and master recipes are accessible.
3. Test Order Release: Create a small test batch order using a standard recipe; release the order; confirm that the order transitions to 'Released' without error dialogs.

Limitations and Operational Precautions

Engineering teams must observe the following precautions:
- Clearing batch runtime data permanently purges unarchived active batches; if operational records are needed for compliance, export batch data prior to clearing if possible.
- Never manually delete or edit SQL database files (.mdf/.ldf) in Windows Explorer; always use official Siemens BATCH Maintenance tools.
- Always validate final license quantities and MLFBs against the applicable Siemens catalog and authorized distributor quotation when procuring SIMATIC BATCH expansion licenses.

Engineer FAQ

Will clearing runtime data delete my Master Recipes?

No. Master recipes are stored in the engineering database (SBRecipe.mdf), which is entirely separate from the active runtime order database (SBRuntime.mdf). Master recipes remain completely safe.

What should I do if redundant BATCH servers desynchronize during startup?

Stop both servers via Launch Coordinator. Perform the database maintenance on Server 1, start Server 1 to Active, and then start Server 2; Server 2 will automatically synchronize its database from Server 1.

Can SIMATIC BATCH run if the Engineering Station is powered off?

Yes. SIMATIC BATCH Server executes autonomously on dedicated server hardware and does not require the Engineering Station to remain online during production.