Troubleshooting SIMATIC BATCH Database Server Compilation and Download Failures in Multiprojects

In SIMATIC PCS 7 multiprojects incorporating SIMATIC BATCH, failures when compiling or downloading batch data from the Batch Configuration Dialog occur when the strict engineering sequence (AS -> OS -> BATCH) is violated, network communication paths in NetPro are incomplete, or temporary transaction cache files in the sbdata directory are corrupted. SIMATIC BATCH requires that all AS controllers and OS servers be compiled and downloaded first to establish consistent message and block type baselines. To resolve compilation and download aborts, execute 'Propagate Batch Types' across all project libraries, verify SQL Server (BSS) service status on the Batch Database Server, clear stale sbdata cache files, and execute a complete Batch compile and download.

Executive Summary

Configuring batch automation in SIMATIC PCS 7 V9.0 SP1 involving redundant Batch Servers, dedicated Batch Database Servers, and distributed Batch Clients requires rigorous adherence to system dependency sequences. Commissioning engineers frequently encounter errors in the SIMATIC Manager 'Batch Configuration Dialog'—such as missing server nodes in the download list, SQL connection failures, or compilation aborts during batch type generation. This guide details the fundamental engineering prerequisites, architectural dependencies between Step 7, WinCC, and SIMATIC BATCH, and the step-by-step troubleshooting workflow to achieve clean compilation and deployment.

Architecture and Fundamental Mechanics

The SIMATIC BATCH engineering architecture relies on multi-tiered database synchronization:
1. Strict Engineering Hierarchy:
- Tier 1: AS Engineering. Technological blocks (EPH, EM, UNIT_FAC) and SFC types are compiled into the controller.
- Tier 2: OS Engineering. OS compilation maps AS block instances, messages, and tags into WinCC Tag Management and Alarm Logging.
- Tier 3: BATCH Engineering. SIMATIC BATCH reads the compiled OS databases, extracts recipe-relevant units and phase interfaces, and compiles process cell data.
Attempting to compile BATCH before completing AS and OS compilation results in missing batch types and broken cross-references.
2. Batch Configuration Dialog Functions:
- Merge / Compile Tab: Merges batch data across individual projects in the multiproject, generates batch types, and transfers batch message definitions into WinCC.
- Download Tab: Synchronizes the compiled batch database files with the physical Batch Database Server and redundant Batch Servers over the Terminal Bus.
3. Communication and Database Layer (BSS & SQL):
The Batch Database Server hosts the master process cell recipes and batch archive databases using Microsoft SQL Server and the Batch Server Service (BSS). If NetPro connections are uncompiled, or if local transaction directories (<ProjectFolder>\sbdata) contain locked temporary files, the Batch Configuration Dialog cannot establish the RPC connection to transfer data.

Step-by-Step Implementation Procedure

Enforce the Mandatory Compilation Sequence:
a. In SIMATIC Manager, compile and download all AS controllers (CPU 416-2DP / CPU 410-5H).
b. Compile all OS Server projects completely ('Entire OS').
c. Download the OS projects to the respective OS servers.
Propagate and Update Batch Types:
a. In SIMATIC Manager, open the master data library.
b. Select Options -> SIMATIC BATCH -> Propagate Batch Types.
c. Ensure that all SFC types and batch interface blocks are synchronized across all project charts.
Verify Network Topology and Station Names in NetPro:
a. Open NetPro and select Network -> Save and Compile (Check consistency).
b. Verify that the ES, Batch Servers, Batch Database Server, and OS Servers are assigned to the identical Terminal Bus subnetwork.
c. Confirm that computer names in the SIMATIC PC Stations match physical Windows hostnames.
Clear Corrupted Batch Temporary Cache Files (sbdata):
a. Close SIMATIC Manager on the ES.
b. On the ES and Batch Database Server, open Windows Services (services.msc) and temporarily stop the SIMATIC BATCH Server service.
c. In Windows File Explorer, navigate to the project directory and locate the sbdata folder.
d. Delete temporary transaction cache files (do not delete the primary database files).
e. Restart the SIMATIC BATCH services.
Execute Batch Compile and Download:
a. In SIMATIC Manager, select Options -> SIMATIC BATCH -> Batch Configuration Dialog.
b. Under the 'Merge / Compile' tab, check 'Generate Batch Types' and 'Transfer messages to OS', then click 'Compile'.
c. Verify that compilation completes without errors.
d. Switch to the 'Download' tab: verify that all Batch Servers and Database Servers appear with green status indicators.
e. Click 'Download' to deploy the process cell configuration.

Verification

In the Batch Configuration Dialog, confirm that the compile status displays 'OK' with 0 errors.
On the Batch Database Server, open SIMATIC BATCH Control: confirm that the process cell appears with all units, phases, and recipes loaded.
Open SIMATIC BATCH Launch Coordinator on the Batch Server: verify that the server state transitions to 'Running' (green).
In WinCC Alarm Control, verify that batch system messages are registered and display without communication errors.

Limitations and Operational Precautions

Performing a Batch download while recipes are executing active batches in the plant can cause recipes to pause or hold; always schedule Batch process cell updates during quiescent process phases or planned turnarounds.

Engineer FAQ

What is the mandatory compilation order when using SIMATIC BATCH?

AS compilation and download must occur first, followed by OS compilation and download, and finally SIMATIC BATCH compilation and download.

Why are my Batch Servers missing from the Download tab?

Batch Servers will not appear if their PC Stations are missing from NetPro, if network connections are uncompiled, or if Simatic Shell is bound to the wrong network card.

What does 'Propagate Batch Types' do in SIMATIC Manager?

It harmonizes batch block types, phase interfaces, and unit definitions between the master data library and all individual project charts within the multiproject.

Which Windows service runs the Batch Database Server backend?

The SIMATIC BATCH Server Service (BSS) along with Microsoft SQL Server.

Can SIMATIC BATCH run on the same PC as an OS Server?

Yes. In smaller architectures, SIMATIC BATCH Server and WinCC OS Server can coexist on a single PC station, provided hardware specifications meet requirements.