C135 PCS 7 (PCS7)
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Why a Second AS Station is Missing in SIMATIC BATCH Configure Process Cell and How to Add It

Why a Second AS Station is Missing in SIMATIC BATCH Configure Process Cell and How to Add It

When a second Automation System (AS) controller is added to an existing SIMATIC PCS 7 multiproject but fails to appear in the "Configure Batch Process Cell" dialog, the cause is typically an incomplete Plant Hierarchy OS/BATCH assignment or an unmerged Plant Bus network in NetPro. For SIMATIC BATCH to recognize an AS controller, the technological hierarchy folders within that AS project must have their "OS/BATCH Assignment" explicitly linked to the multiproject's central OS/BATCH server. Furthermore, the Industrial Ethernet subnet of the new AS must be merged across multiproject boundaries in NetPro, followed by compiling the S7 connections and running a full "Generate, Propagate, Merge" compilation in SIMATIC BATCH.

Table of Contents

Architecture of Multi-AS Plant Models in SIMATIC BATCH

In large chemical, pharmaceutical, and food-and-beverage manufacturing facilities, batch processes frequently span across multiple Automation Systems:
- Distributed Equipment Units: Unit 1 (Reactor A) executes on AS 1, while Unit 2 (Blender B) and Unit 3 (Storage Tanks) execute on AS 2.
- Central BATCH Coordination: A single redundant SIMATIC BATCH Server pair coordinates recipe phase transitions seamlessly across both controllers.
- The Process Cell Model: SIMATIC BATCH aggregates all participating AS controllers into a single unified technological model known as the Process Cell.
- Multiproject Structure: In STEP 7, each AS is housed in its own project folder under a shared Multiproject, while OS and BATCH servers reside in a dedicated station project.

Prerequisites for Cross-Project BATCH Integration in a Multiproject

Before an AS station can participate in batch recipes, four engineering requirements must be satisfied:
1. Unique AS Station Names: Controller stations across all sub-projects must possess unique names (e.g., AS_01 and AS_02).
2. Standardized Plant Hierarchy: The plant hierarchy folders must follow the ISA-88 hierarchy: Process Cell -> Unit -> Equipment Module -> Control Module.
3. Common Plant Bus (Industrial Ethernet): The CP or onboard PROFINET interfaces of both controllers must attach to the same physical and logical Plant Bus subnet.
4. Shared Server Assignment: The plant hierarchy folders in both AS projects must point to the identical WinCC OS and SIMATIC BATCH application.

Root Causes: Missing Plant Hierarchy Assignment vs. Network Merging

When opening the "Configure Batch Process Cell" dialog and observing that only the original AS appears, engineers typically encounter one of two missing links:

MisconfigurationTechnical MechanismObservable SymptomMissing OS/BATCH Hierarchy AssignmentThe top-level Plant Hierarchy folder of the new AS project has its "OS/BATCH assignment" set to [None] or pointed to an isolated local OS instead of the shared multiproject OS/BATCH server.The BATCH generator skips the entire chart folder of the second AS because it does not recognize it as part of the managed process cell.Unmerged Subnet in NetProThe Industrial Ethernet subnet in the new AS sub-project has the same visual name as the existing plant bus, but has not been merged using NetPro's Merge Subnets function.NetPro cannot route S7 named connections between the central BATCH server PC station and the second AS CPU.Missing BATCH Blocks in AS ProgramThe second AS does not contain the mandatory BMASTER (FB41/FB42) communication block and equipment phase blocks (IEPH).BATCH compiler detects an invalid technological interface and excludes the station.

Method: Step-by-Step Procedure to Integrate a Second AS into BatchCC

Follow this comprehensive workflow to incorporate the new AS controller into the active BATCH configuration:

Step 1: Merge Industrial Ethernet Subnets in NetPro

  1. In SIMATIC Manager, select the multiproject root and open NetPro.
  2. Select menu Edit -> Merge Subnets -> Industrial Ethernet.
  3. Select the Industrial Ethernet subnet from the first project and the subnet from the new AS project.
  4. Click Merge. The two subnets merge into a unified logical network.
  5. In NetPro, select the WinCC/BATCH PC station: insert a new S7 Connection pointing to the CPU of the second AS.
  6. Save, compile, and download network connections to both the AS and the PC station.

Step 2: Configure Plant Hierarchy OS/BATCH Assignment

  1. In SIMATIC Manager, switch to the Plant View.
  2. Navigate to the root plant hierarchy folder of the second AS project.
  3. Right-click the folder and select Object Properties.
  4. Select the OS/BATCH Assignment tab.
  5. In the drop-down menu, select the shared WinCC OS Server project (e.g., OS_SRV::OS(1)).
  6. Ensure the option Pass assignment down to subordinate hierarchy folders is enabled.
  7. Click OK.

Step 3: Insert BMASTER and Equipment Phase Blocks in CFC

  1. In the chart folder of the second AS, insert the mandatory BMASTER block (FB41) into a central diagnostic chart.
  2. Verify that unit allocation blocks and equipment phase blocks (IEPH, IEPAR) are instantiated in the technological charts corresponding to each process unit.
  3. Execute Chart -> Compile -> Charts as Program.

Step 4: Execute BATCH Data Compilation in SIMATIC Manager

  1. Select the multiproject root, right-click, and select SIMATIC BATCH.
  2. In the BATCH configuration window, click Generate:
    - Verify that the compiler log reports scanning both AS_01 and AS_02.
  3. Click Propagate: distributes phase types across all AS controllers.
  4. Click Merge: merges equipment properties into the unified process cell model.
  5. Select Compile / Download: select Entire Scope and download the compiled BATCH database to the active BATCH Server.

Step 5: Update Process Cell in BatchCC

  1. Launch BatchCC on the engineering station or client.
  2. Select Process Cell -> Update Process Cell.
  3. In the tree view, expand the Process Cell: confirm that units, equipment phases, and tags from both the first and second AS controllers appear in green.

Verification

To verify that multi-AS batch execution is operational:
- In BatchCC, open Configure Process Cell: verify that both AS stations display status Configured and Connected.
- Open a test Master Recipe in the Recipe Editor: confirm that units from AS_01 (e.g., Reactor 1) and units from AS_02 (e.g., Blender 2) can be placed within the same recipe procedure.
- Create and release a batch order that requires transfer between AS_01 and AS_02: confirm that BatchCC releases the batch without connection errors.
- Start the batch: confirm that execution handshakes (IEPH.START, ACT_STATE) update synchronously across both controllers in their respective CFC charts.

Limitations and Operational Precautions

  • Unique Block Numbers: Ensure that user-defined function block (FB) and data block (DB) numbers do not collide between the two AS projects, particularly if third-party libraries are utilized.
  • Controller Time Synchronization: All AS controllers and BATCH servers must be synchronized to an identical central NTP master clock (such as a SICLOCK or central network time server). Time discrepancies exceeding 1,000 ms cause batch recipe phase validation timeouts.
  • Process Cell Download Requires Safe State: While propagating and merging data does not stop controllers, downloading the process cell to the BATCH Server briefly locks recipe release. Perform this action during stable operating conditions.

Engineer FAQ

Can SIMATIC BATCH coordinate units across three or more AS controllers?

Yes. SIMATIC BATCH supports multi-AS architectures encompassing dozens of automation stations, provided all controllers communicate over the merged Plant Bus and share a common BATCH engineering compilation.

Why is BMASTER required in every AS controller?

The BMASTER block serves as the communication coordinator between the controller's local equipment phases (IEPH) and the BFW server application. Each controller participating in batch control must host its own BMASTER instance.

What should I do if NetPro refuses to merge the subnets?

Ensure that both subnets share identical communication parameters (Transmission rate: 100 Mbps or 1 Gbps, Full Duplex, and matching IP subnet masks). Mismatched subnet masks prevent NetPro from completing the merge.

Does adding a second AS require additional SIMATIC BATCH licenses?

SIMATIC BATCH licensing is based on the total number of Units (e.g., SIMATIC BATCH Unit License for 10, 20, or 50 units) and Batch Clients, not on the physical count of AS controllers. If adding the second AS increases your unit count beyond your licensed tier, an additional unit package license is required.

Technical References

  • Siemens Industry Online Support: SIMATIC BATCH Operating Manual (A5E38012658).
  • SIOS Entry 109742323: PCS 7 Compendium Part A - Configuration Guidelines (Section: SIMATIC BATCH Architecture).
  • SIOS Entry 109809264: SIMATIC Process Control System PCS 7 Multiproject Engineering.
  • Siemens Engineering Manual: SIMATIC NET NetPro Network Configuration.

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Related Tags

  • SIMATIC BATCH
  • Multiproject
  • Process Cell
  • NetPro
  • Subnet Merge
  • Plant Hierarchy
  • Industrial Automation
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