Resolving WARNING! WinCC Messages Are Not Included in the Report in SIMATIC BATCH

The banner 'WARNING! WinCC messages are not included in the report!' in SIMATIC BATCH occurs when the Charge Data Viewer (CDV) background service has not yet finalized message extraction from the WinCC Message Archive, or when technological measuring blocks lack mandatory batch interconnections. In SIMATIC BATCH, messages and limit violations are only consolidated into the final Electronic Batch Record (EBR) when the batch reaches the 'Closed' lifecycle state and the CDV service successfully executes its SQL query. To resolve this, ensure technological blocks are interconnected to BatchEn, BatchID, BatchName, StepNo, and Occupied, transition the batch to 'Closed', and verify that the CDV service and Microsoft SQL Server instance are running.

Architecture of SIMATIC BATCH CDV Service and Message Archiving

In SIMATIC PCS 7, SIMATIC BATCH (e.g., V8.1, V8.2, or V9.0, 6ES7657-0AX58-0YB0) manages recipe execution, unit allocation, and batch record archiving in strict compliance with ISA-88 and FDA 21 CFR Part 11. The generation of the Electronic Batch Record (EBR) relies on the Charge Data Viewer (CDV) service (sbcdv.exe).

The CDV engine performs three critical operational functions:
1. Message Collection: Queries the WinCC Message Archive (Alarms) via SQL Server OLE-DB to extract all alarms, warnings, operator inputs, and limit violations stamped with the specific BatchID.
2. Measured Process Value Archiving: Extracts historical process curves and continuous trend values configured for active batch phases from WinCC Tag Logging.
3. Batch State Transition: Drives the final state transition from 'Completed' through 'Closing' to 'Closed', permanently sealing the cryptographic XML batch report into the BATCH archive database (sbdata).

If the CDV service is stalled, if the underlying SQL Server instance is paused, or if the batch report is previewed while the batch is still in an open state, SIMATIC BATCH prints the warning banner across the top of the report: WARNING! WinCC messages are not included in the report!.

Mandatory CFC Interconnections for Technological Block Message Logging

For WinCC alarms (such as high temperature alarms from an analog monitoring block MonAnL or valve feedback faults from VlvL) to appear in the batch report, the technological block must know which batch is currently occupying its equipment unit.

SIMATIC BATCH provides batch context via Unit Allocation blocks (UNIT_STATUS / UNIT_PLC) and Equipment Phase blocks (EPH / BPH). These blocks dynamically broadcast batch tracking parameters during recipe execution:
- BatchEn (Batch Enable): Boolean enabling message collection for this measuring point.
- BatchID (Batch ID): 32-bit integer identifying the unique batch run.
- BatchName (Batch Name): String containing the user-defined batch name.
- StepNo (Step Number): Integer identifying the active recipe phase/step.
- Occupied (Unit Allocation Flag): Boolean indicating that the technological unit is currently allocated to a batch.

If an engineer manually inserts technological blocks into CFC charts without cross-connecting these inputs from the unit allocation block, the WinCC alarm server generates messages with empty batch attributes (BatchID = 0). Consequently, the CDV SQL query returns zero matching records for that batch report.

Batch Lifecycle States and Message Ingestion Timing

A widespread misconception is that WinCC messages stream continuously into the batch report in real time while the batch is executing. In reality, the CDV service operates on a defined lifecycle schedule:

While a batch is in state Running or Held, messages are logged normally inside the WinCC SQL message archive, but the BATCH report preview will display the warning banner because the CDV has not yet performed its final consolidation query.
When recipe execution finishes, the batch transitions to state Completed.
The operator or automated recipe schedule must then command the batch to state Closed. During the Closing transitional state, the CDV service locks the batch, connects to WinCC Alarm Logging, extracts all correlated events, compiles the final XML report, and transitions the batch to Closed.
Once the batch reaches Closed, the warning banner disappears completely.

Comparison of Batch States and CDV Data Collection Status

The following table compares the operational status of WinCC message collection across SIMATIC BATCH states:

Batch Lifecycle StateWinCC Message LoggingCDV Extraction StatusReport Warning Banner Displayed?Report Finalized?Planning / ReadyIdleNot startedYes (if previewed)NoRunningActive in WinCC SQL ArchiveBuffered in memoryYes (WinCC messages not included)NoHeld / PausedActive in WinCC SQL ArchiveBuffered in memoryYes (WinCC messages not included)NoCompletedCompleted for active recipePending final archive sweepYes (until Closing state executes)NoClosingSealedActive SQL query executingIntermittentIn progressClosedRead-only in BATCH databaseCompleted and verifiedNo (Warning removed; messages displayed)Yes (Audited EBR)ArchivedRead-only long-term backupDetached to archive directoryNoYes

Step-by-Step Procedure to Restore WinCC Messages in BATCH Reports

Follow this procedure to resolve the warning and restore complete message integration in SIMATIC BATCH:

Verify CFC Interconnections on Technological Blocks:
- Open the CFC charts containing technological blocks associated with the batch unit (e.g., MonAnL, PIDConL, MotL).
- Check that inputs BatchEn, BatchID, BatchName, StepNo, and Occupied are interconnected to the corresponding outputs of the UNIT_STATUS or EPH block (QBA_EN, QBA_ID, QBA_NA, QSTEP_NO, QOCCUPIED).
- If missing, make the interconnections, compile CFC changes (Changes only), and download to the AS controller.
Check WinCC Alarm Logging Message Configuration:
- In WinCC Explorer on the OS Server, open Alarm Logging.
- Verify that the message blocks include the system attributes: Batch ID, Batch Name, and Step Number.
- Ensure that the WinCC Message Archive is configured to retain alarms for a duration exceeding your longest batch run.
Verify the CDV and SQL Server Service Status:
- On the BATCH Server IPC, open Windows Start Menu -> Microsoft SQL Server -> SQL Server Configuration Manager.
- Verify that SQL Server (WINCC) and SQL Server (BATCH) services are in state Running.
- Ensure SQL Server Agent is set to Automatic startup and is currently Running.
- In Windows Task Manager (Services tab), verify that sbcdv.exe (SIMATIC BATCH CDV Service) is running.
Properly Close the Batch in BATCH Control Center (BCC):
- In BATCH Control Center, navigate to the completed batch in the batch overview.
- Right-click the batch and select Close (or let recipe automatic closure execute).
- Wait until the batch status icon updates from 'Completed' (blue) to 'Closed' (green checkmark).
- Open the batch report: verify that the warning banner is gone and all process alarms and limit violations are populated.

Verification

Verify the complete report generation process:
1. Execute a test batch in SIMATIC BATCH BCC with a deliberate process limit violation (e.g., temporary high alarm on an analog transmitter).
2. Verify that the alarm appears in the active WinCC Alarm banner with the populated BatchID.
3. Conclude the recipe and command the batch to Closed state.
4. Open the generated batch report PDF / print preview. Confirm that the header banner WARNING! WinCC messages are not included in the report! is completely absent.
5. Navigate to the 'Limit Violations and Alarms' section of the report and verify that the test alarm is recorded with its exact timestamp, tag name, message text, and acknowledgment time.

Limitations and Operational Precautions

Never Reopen a Closed Batch: Once a batch is transitioned to state 'Closed', its electronic batch record is digitally signed and sealed in accordance with 21 CFR Part 11. It cannot be edited, appended, or reopened.
WinCC Archive Retention Time: If the WinCC Message Archive max size or retention duration is set too short, older alarms from long-running multi-day batches may be purged before the batch reaches 'Closed' state, permanently losing records.
Redundant BATCH Server Synchronization: In redundant BATCH server architectures, both primary and secondary BATCH servers must be synchronized. A failover during CDV archiving requires verifying that the standby server resumes CDV processing cleanly.

Engineer FAQ

Why does the report say 'Limit Violations: 0' even though alarms occurred?

Limit violations report 0 if the technological block's BatchEn or BatchID inputs were not interconnected to the Unit block, or if the report was previewed while the batch was still in 'Running' state before the CDV sweep executed.

Does the input QOCCUPIED need to be connected on technological blocks?

Yes. The Occupied input (QOCCUPIED) informs the block that the physical unit is allocated to a batch. Certain APL blocks suppress non-critical maintenance messages or route alarms specifically to the active batch based on this flag.

Can I force the CDV service to run manually without closing the batch?

No. The CDV service architecture enforces data integrity by consolidating and auditing records only upon batch closure. To view intermediate messages while a batch is running, operators must use the WinCC Alarm Control filtered by BatchID.