Rockwell Automation FactoryTalk User Manual

FactoryTalk Batch

Material Manager

Getting Results Guide

FactoryTalk Batch Components 14.00

Rockwell Automation Publication BWMTR-GR011E-EN-P - October 2020

Supersedes Publication BWMTR-GR011D-EN-P - February 2017

Getting Results Guide

Original Instructions

FactoryTalk Batch Material Manager

Important User Information

Read this document and the documents listed in the additional resources section about installation, configuration, and operation of this equipment before you install, configure, operate, or maintain this product. Users are required to familiarize themselves with installation and wiring instructions in addition to requirements of all applicable codes, laws, and standards.

Activities including installation, adjustments, putting into service, use, assembly, disassembly, and maintenance are required to be carried out by suitably trained personnel in accordance with applicable code of practice.

If this equipment is used in a manner not specified by the manufacturer, the protection provided by the equipment may be impaired.

In no event will Rockwell Automation, Inc. be responsible or liable for indirect or consequential damages resulting from the use or application of this equipment.

The examples and diagrams in this manual are included solely for illustrative purposes. Because of the many variables and requirements associated with any particular installation, Rockwell Automation, Inc. cannot assume responsibility or liability for actual use based on the examples and diagrams.

No patent liability is assumed by Rockwell Automation, Inc. with respect to use of information, circuits, equipment, or software described in this manual.

Reproduction of the contents of this manual, in whole or in part, without written permission of Rockwell Automation, Inc., is prohibited.

Throughout this manual, when necessary, we use notes to make you aware of safety considerations.

WARNING: Identifies information about practices or circumstances that can cause an explosion in a hazardous environment, which may lead to personal injury or death, property damage, or economic loss.

ATTENTION: Identifies information about practices or circumstances that can lead to personal injury or death, property damage, or economic loss. Attentions help you identify a hazard, avoid a hazard, and recognize the consequence.

IMPORTANT Identifies information that is critical for successful application and understanding of the product.

Labels may also be on or inside the equipment to provide specific precautions.

SHOCK HAZARD: Labels may be on or inside the equipment, for example, a drive or motor, to alert people that dangerous voltage may be present.

BURN HAZARD: Labels may be on or inside the equipment, for example, a drive or motor, to alert people that surfaces may reach dangerous temperatures.

ARC FLASH HAZARD: Labels may be on or inside the equipment, for example, a motor control center, to alert people to potential Arc Flash. Arc Flash will cause severe injury or death. Wear proper Personal Protective Equipment (PPE). Follow ALL Regulatory requirements for safe work practices and for Personal Protective Equipment (PPE).

2

	Table of Contents
Preface	About this manual.......................................................................................	7
	Legal Notices ...............................................................................................	7
	Additional resources ...................................................................................	8
	Chapter 1
Introducing Material Manager	What is Material Manager?.......................................................................	11
	FactoryTalk Batch Components ...............................................................	12
	FactoryTalk Batch Server.....................................................................	12
	FactoryTalk Batch Recipe Editor.........................................................	13
	FactoryTalk Batch Equipment Editor.................................................	14
	FactoryTalk Event Archiver .................................................................	14
	FactoryTalk Batch Network Editor .....................................................	15
	FactoryTalk eProcedure Client............................................................	15
	FactoryTalk eProcedure Server ...........................................................	15
	FactoryTalk Batch Material Manager .................................................	15
	FactoryTalk Batch View .......................................................................	16
	Material data...............................................................................................	17
	Introduction to the Material Server...........................................................	17
	Looking at the Material Server ..................................................................	17
	Set up the sample demonstrations ...........................................................	19
	Configure the Network Editor ............................................................	19
	Add sample FactoryTalk Security users.............................................	20
	Configure sample permissions for FactoryTalk Security users ......	22
	Configure the sample FactoryTalk Batch Server ..............................	24
	Rebuild the recipe directory ...............................................................	27
	Start the FactoryTalk Batch and Material Manager Servers..................	27
	Start the sample FactoryTalk Batch Phase Simulator ............................	29
	Verify PCD communications....................................................................	30
	Summary....................................................................................................	30
	Chapter 2
Introducing the Material Editor	Start the Material Editor ...........................................................................	31
	Adding material states...............................................................................	32
	Adding material types ................................................................................	34
	Adding a material class ..............................................................................	35
	Adding a material .......................................................................................	37
	Adding containers .....................................................................................	38
	Associating materials with containers ....................................................	40
	Creating lots................................................................................................	41
	Distributing lots to containers .................................................................	42

3

Table of Contents
	Exiting the Material Editor........................................................................	43
	Summary.....................................................................................................	43
	Chapter 3
Introducing material-enabled	Open the area model..................................................................................	45
phases	Naming the area .......................................................................................	46
	Viewing enumeration sets .......................................................................	46
	Creating material-enabled phases ............................................................	47
	Adding material-enabled phase parameters.....................................	50
	Adding material-enabled phase report parameters .........................	52
	Defining equipment modules ............................................................	52
	Restart the FactoryTalk Batch server ........................................................	53
	Setting material container priorities........................................................	54
	Programming a material-enabled phase..................................................	54
	Summary.....................................................................................................	55

Introducing material-based recipes

Chapter 4
Create a material-based operation ...........................................................	57
Creating recipe formula parameters........................................................	59
Assigning formula values ..........................................................................	59
Creating a unit procedure .........................................................................	61
Enabling dynamic unit allocation............................................................	62
Create a procedure ....................................................................................	62
Linking phase groups................................................................................	68
Verifying the recipe...................................................................................	69
Summary....................................................................................................	70

Chapter 5
Running material-based recipes Run in simulation mode............................................................................	71
Running a material-based recipe .............................................................	71
Checking inventory levels..........................................................................	73
Using manual phase control......................................................................	74
Binding a material-enabled phase manually ...........................................	75
Handling split feeds ...................................................................................	76
Summary.....................................................................................................	77

Using custom code insertion points

4

Chapter 6
When would I customize an insertion point?	.........................................79
What library can be customized?..............................................................	79
Creating a custom ramscustom.dll .........................................................	80
Material manager insertion points...........................................................	81

		Table of Contents
	OnGenerateCustomLotName ...................................................................	81
	OnGenerateCustomLabelName...............................................................	82
	AfterSubLotInsert .....................................................................................	83
	AfterSubLotDelete.....................................................................................	84
	AfterLotInsert ............................................................................................	85
	AfterCombinedLotInsert ..........................................................................	86
	Chapter 7
Developing an implementation	Determining the system requirements...................................................	87
plan	Configuration requirements..............................................................	87
	Hardware and operating systems requirements..............................	87
	Security requirements ........................................................................	88
	Questions to ask about system requirements.........................................	88
	Questions to ask about the material database ........................................	88
	Questions to ask about equipment data..................................................	89
	Questions to ask about master recipe data .............................................	89
	Appendix A
Binding material-based recipes	Unit binding ..............................................................................................	92
	Static binding ......................................................................................	92
	Creation binding .................................................................................	92
	Dynamic unit allocation ......................................................................	93
	Manual binding ...................................................................................	94
	Material requirements........................................................................	94
	Material requirements: material ..................................................	95
	Material requirements: material and lot.....................................	96
	Container type................................................................................	97
	Distributions .................................................................................	98
	Recipe phase binding ................................................................................	99
	Container binding type ....................................................................	100
	Feed type .............................................................................................	101
	Automatic container binding process ..............................................	101
	Summary...................................................................................................	103
Index

5

Preface

About this manual

Legal Notices

This manual introduces the basics of FactoryTalk Batch Material Manager. It is one of a set of related manuals that describe installing, programming, and operating the FactoryTalk Batch system.

To review FactoryTalk Batch release notes and latest information regarding product compatibility refer to the Product Compatibility and Download Center (PCDC).

Rockwell Automation publishes legal notices, such as privacy policies, license agreements, trademark disclosures, and other terms and conditions on the Legal Notices page of the Rockwell Automation website.

End User License Agreement (EULA)

You can view the Rockwell Automation End User License Agreement (EULA) by opening the license.rtf file located in your product's install folder on your hard drive.

The default location of this file is:

C:\Program Files (x86)\Common Files\Rockwell\license.rtf

Open Source Software Licenses

The software included in this product contains copyrighted software that is licensed under one or more open source licenses.

You can view a full list of all open source software used in this product and their corresponding licenses by opening the oss_license.txt file located your product's OPENSOURCE folder on your hard drive. This file is divided into these sections:

•Components

Includes the name of the open source component, its version number, and the type of license.

•Copyright Text

Includes the name of the open source component, its version number, and the copyright declaration.

•Licenses

Includes the name of the license, the list of open source components citing the license, and the terms of the license.

The default location of this file is:

C:\Program Files (x86)\Common Files\Rockwell\Help\<product name>\Release Notes\OPENSOURCE\oss_licenses.txt

7

Preface

Additional resources

You may obtain Corresponding Source code for open source packages included in this product from their respective project web site(s). Alternatively, you may obtain complete Corresponding Source code by contacting Rockwell Automation via the Contact form on the Rockwell Automation website: http://www.rockwellautomation.com/global/aboutus/contact/contact.page. Please include "Open Source" as part of the request text.

Following is a comprehensive list of documentation for the FactoryTalk® Batch products from Rockwell Automation.

Installation, Quick Start, and Getting Results Guides

Resource	Description
FactoryTalk Batch Components Installation and	Provides information and procedures for FactoryTalk
Upgrade Guide	Batch system installation. Includes information for
(BATCH-IN002)	FactoryTalk Batch Material Manager, FactoryTalk Event
	Archiver, and associated FactoryTalk Batch Client and
	Server components.
FactoryTalk Batch View Quick Start Guide	Provides information about using FactoryTalk Batch View
(FTBVS-QS001)	to create, view, and command control recipes,
	acknowledge prompts and signatures, view equipment
	phases and diagnostic information, and view profile
	information.
FactoryTalk Batch View HMI Controls Quick Start	Provides a general overview of FactoryTalk Batch View
Guide	HMI Controls.
(BATCH-QS001D)
FactoryTalk Batch eProcedure® Getting Results	Explains the basics of FactoryTalk Batch eProcedure.
Guide
(BWEPRO-GR011)
FactoryTalk Batch Getting Results Guide	Introduces the basics of automated batch manufacturing
(BATCH-GR011)	and the FactoryTalk Batch product components.
FactoryTalk Batch Material Manager Getting	Introduces the basics of FactoryTalk Batch Material
Results Guide	Manager.
(BWMTR-GR011)

User Guides

Resource	Description
FactoryTalk Batch ActiveX Controls User Guide	Provides information and instructions for using the
(BATCH-UM013)	FactoryTalk Batch ActiveX Custom Controls.
FactoryTalk Batch Material Editor User Guide	Provides access to information and procedural
(BWMTR-UM001)	instructions required to configure materials and the
	containers to hold them. The material data is stored in the
	material database, which is used to create material-
	based recipes. This information is intended as a
	reference for the formulator.

8

		Preface
	Resource	Description
	FactoryTalk Batch Equipment Editor User Guide	Provides information on creating and maintaining an
	(BATCH-UM004)	equipment database (area model). The area model is
		stored in a file with a .cfg file extension and is available
		to all other FactoryTalk Batch programs, including the
		Recipe Editor, View, and Phase Simulator.
	FactoryTalk Batch PhaseManager™ User Guide	Describes the integration of the FactoryTalk Batch
	(BATCHX-UM011)	software with the Studio 5000 Logix Designer®
		application and the Logix 5000™ family of controllers.
		The integration simplifies the configuration and
		maintenance of the FactoryTalk Batch automation
		system, provides better communication between the
		FactoryTalk Batch Server and the Logix 5000 controller,
		and significantly reduces the programming effort
		required to develop the phase logic code that resides in
		your Logix 5000 controller.
	FactoryTalk Batch Recipe Editor User Guide	Provides instructions on using FactoryTalk Batch Recipe
	(BATCH-UM006)	Editor to create and configure master recipes for use in
		batch automation. The interface is based on IEC 61131-3
		sequential function charts to graphically organize recipes
		into procedures, unit procedures, operations, and phases.
		Build recipes using either the SFC format or a table-based
		format.
	FactoryTalk Batch View HMI Controls User Manual	Provides details about using FactoryTalk Batch View HMI
	(FTBVS-UM003)	Controls to monitor and interact with the production
		process within a FactoryTalk View SE Display Client.
	FactoryTalk Batch View User Manual	Provides information and procedural instructions for
	(FTBVS-UM002)	using FactoryTalk Batch View in a modern and intuitive
		portal into a comprehensive batching solution for
		effective operations, leveraging its own web server using
		HTML5 technology to provide native connectivity into a
		FactoryTalk Batch Server.
	FactoryTalk eProcedure Client User Guide	Provides information and procedural instructions
	(BWEPRO-UM001)	required to create and command batches using the
		FactoryTalk eProcedure Client, and can be used as a
		reference information by the operator.
	FactoryTalk Event Archiver User Guide (BATCH-	Provides information and instructions specific to the
	UM012)	FactoryTalk Event Archiver. Intended for use by the
		system administrator and production supervisor.
	FactoryTalk Batch View User Guide (legacy)	Provides information and instructions on how to use
	(FTBVS-UM001)	FactoryTalk Batch View to initiate and execute
		FactoryTalk Batch automation processing. FactoryTalk
		Batch View secured objects are located in the FactoryTalk
		Diagnostics and are modified using the FactoryTalk
		Administration Console. A system administrator can
		customize FactoryTalk Batch View security to meet the
		needs of the facility. FactoryTalk Batch View is used in
		conjunction with a Human-Machine Interface (HMI).

9

Preface

Administrator Guides

Resource	Description
FactoryTalk Batch Administrator Guide	Provides instructions for configuring security and
(BATCH-UM003)	services, and implementation and use of components not
	typically accessed or used by batch operators, such as
	the FactoryTalk Batch Server.
FactoryTalk Batch eProcedure Administrator Guide	Provides procedures specific to FactoryTalk Batch
(BWEPRO-UM011)	eProcedure, such as implementing security and
	configuring the user-defined area Active Server Page.
	Included are instructions for tasks specific to FactoryTalk
	Batch, such as configuring security and services to
	support FactoryTalk Batch eProcedure. Provides
	instructions on the implementation and use of
	components not typically accessed or used by batch
	operators, such as the FactoryTalk Batch Server.
FactoryTalk Batch Material Manager Administrator	Provides information and instructions specific to
Guide	FactoryTalk Batch Material Manager. Intended for use by
(BWEPRO-UM011)	the system administrator and database administrator.

Reference Guides

Resource	Description
FactoryTalk Batch ActiveX Controls Library	Provides reference information and procedural
Reference Guide	instructions for the FactoryTalk Batch ActiveX Custom
(BATCH-RM001)	Controls.
FactoryTalk Batch Material Server API Technical	Provides access to information regarding the interface
Reference	between the FactoryTalk Batch Material Server and the
(BWMTR-RM001)	FactoryTalk Batch Material Editor and FactoryTalk Batch.
	It is intended to be used as a reference information by
	those who want to develop custom interfaces.
FactoryTalk Batch PCD Programming Reference	Provides information and instructions about the
Manual	FactoryTalk Batch PCD interface design. It is intended to
(BATCH-RM004)	be used as a reference guide.
FactoryTalk Batch Server API Reference Manual	Provides information regarding the interface between the
(BATCH-RM003)	FactoryTalk Batch Server and FactoryTalk Batch View —
	the Server Application Programming Interface (API). It is
	intended to be used as a reference guide by those who
	want to develop custom interfaces.
FactoryTalk Batch System Files Reference Manual	Provides the technical information for configuration and
(BATCH-RM005)	maintenance of a FactoryTalk Batch system. It can be
	used as a reference information for implementation
	engineers and the system administrator.
FactoryTalk Batch eProcedure Instruction File	Includes information about the building of instruction
Design Reference Manual	files for use in equipment database creation and recipe
(BWEPRO-RM001)	development. This information is intended to be used as a
	reference by the instruction file author.

View or download publications at http://www.rockwellautomation.com/literature. To order paper copies of

technical documentation, contact your local Allen-Bradley® distributor or sales representative.

10

Chapter 1

Introducing Material Manager

FactoryTalk® Batch Material Manager is an integral part of the FactoryTalk Batch suite of software components. As part of the FactoryTalk family, the FactoryTalk Batch components increase overall plant efficiency by delivering the visibility, control, and reporting you need to optimize manufacturing. With coordinated execution, you can reduce scrap and rework and improve product quality and consistency. Through real-time management of equipment utilization, you can maximize your return on assets. By implementing optimized recipes and procedures, you can increase your plant capacity. By using electronic, paperless operations, you can improve your productivity. You also reduce compliance costs by using electronic batch record implementation, paperless manufacturing, and quality sign-offs. By lifting the compliance burden from manufacturing, you reduce inventory levels and cycle times, which greatly improves customer service.

The FactoryTalk Batch components ensure that plant floor operations are optimized, giving you quick return on your net assets. New product definitions are deployed quickly into manufacturing. Production order information is accurate. Business and plant-level control systems are tightly coordinated and multiple sites operate as a team. Our completely open, configurable set of products helps you define, manage, monitor, and control manufacturing at local, remote, or contractor plants. Best of all, you can deploy any of the FactoryTalk Batch components wherever you need them — one at a time or all at once — to improve productivity and plant control.

The FactoryTalk Batch components include:

•FactoryTalk Batch

•FactoryTalk eProcedure®

•FactoryTalk Batch Material Manager

What is Material Manager? As one of the FactoryTalk Batch components, Material Manager provides plant-level material management and tracking that is tied to corporate material management systems. Material Manager manages and tracks the use of materials by material type, lot, and sublot. It manages and tracks vessels, containers and pallets, as well as permanent and transient storage. It also provides automatic support for bulk containers with multiple lots either as composites or plug flow separated.

Material Manager adds material definitions to the recipes, significantly reducing the number of recipes needed for flexible storage facilities. Material consumption, production, and association of materials to containers and

11

Chapter 1

Introducing Material Manager

FactoryTalk Batch

Components

FactoryTalk Batch Server

12

vessels are automatically logged, providing complete information for forward and backward material tracking within and across process cells.

The material recipes, called material-based recipes, allow you to define recipes in terms of materials used, not just by plant equipment. A material-based recipe uses material-enabled phases, which are configured in the Equipment Editor and stored in the area model. Material-enabled phases support the specification of a material as a means to find appropriate equipment and bind to that equipment in a control recipe.

The following figure is a conceptual diagram of the elements of the materialbased recipe function and illustrates the relationships among the functional components.

FactoryTalk Batch comes with several components that interact with each other to design, create, configure and run batch recipes.

See also

FactoryTalk Batch Server on page 12

FactoryTalk Batch Recipe Editor on page 13

FactoryTalk Batch Equipment Editor on page 14

FactoryTalk Event Archiver on page 14

The FactoryTalk Batch Server is the engine that runs FactoryTalk Batch. It is the component that controls system information, phases and recipes. The server allows integration with process-connected devices (PCDs) and thirdparty software packages. Prior to opening FactoryTalk Batch View, the FactoryTalk Batch Server must be running and remain active during all batch functions.

Chapter 1

Introducing Material Manager

FactoryTalk Batch Recipe

Editor

The FactoryTalk Batch Server operates as a Windows service, which means that the FactoryTalk Batch Server can be configured to start automatically and that control of the FactoryTalk Batch Server can be given to the Windows Service Manager. Because the FactoryTalk Batch Server runs as a service, it does not require an operator to log on to run. Therefore, logging on or off Windows during operation does not disrupt the performance of the FactoryTalk Batch Server.

See also

FactoryTalk Batch Components on page 12

The FactoryTalk Batch Recipe Editor is used to graphically create and configure recipes.

•The interface is based on IEC 61131-3 sequential function charts (SFC) that graphically organizes recipes into procedures, unit procedures, operations and phases along with any applicable comments.

•In addition to the SFC view, the FactoryTalk Batch Recipe Editor offers a table view. Table-based recipes provide a mechanism for creating simple recipes that do not require a complex recipe structure or elaborate transition expressions. Additionally, you can view tablebased recipes and edit all recipe parameters without having to navigate between steps.

•The FactoryTalk Batch Recipe Editor allows you to specify sequences of phases. The actual phase logic must be configured in the processconnected device (PCD) while the interface to the PCD must be configured in the FactoryTalk Batch Equipment Editor.

•Recipe reports can be generated in SFC and/or descriptive format.

•If Recipe Approvals are enabled in the underlying area model, approval signoffs are executed in the FactoryTalk Batch Recipe Editor.

•When Recipe Version Control is enabled, a version of a recipe (a readonly, numbered snapshot of a recipe) can be saved and protected from further editing. New work-in-progress (WIP) copies of a version allow the recipe author to continue to make changes and updates to a recipe. When a versioned recipe no longer matches the underlying area model, or references a deleted or non-existent sub-recipe, it is marked as obsolete.

See also

FactoryTalk Batch Components on page 12

13

Chapter 1

Introducing Material Manager

FactoryTalk Batch

Equipment Editor

The FactoryTalk Batch Equipment Editor is a graphical interface through which a database of process equipment is defined and maintained (an area model).

•Components defined in the FactoryTalk Batch Equipment Editor are used to interface with process-connected devices (PCDs) in the facility. During recipe configuration, the area model provides a list of available units and phase classes.

•Configure phases and commands to trigger an electronic signature request when a report or recipe parameter is out of range (parameter deviation), or when specific commands are executed on a batch (such as Abort Batch or Active Step Change).

•During recipe verification, the area model confirms that the designated equipment is capable of executing the procedures.

•During recipe execution, resource arbitration functions use the area model to allocate equipment based on recipe and operator requests.

•The area model is available to all other FactoryTalk Batch applications.

In addition to the area model, the FactoryTalk Batch Equipment Editor allows configuration of the following:

•Communication functions

•Electronic signatures

•Enumeration sets

•Data servers

•Recipe approvals

•Recipe version control

•FactoryTalk Event Archiver functions

	See also
	FactoryTalk Batch Components on page 12
FactoryTalk Event Archiver	The FactoryTalk Event Archiver’s purpose is to translate the FactoryTalk Batch
	tab-delimited ASCII electronic batch record files to a user-specified file type.
	These electronic batch record files are maintained separately for each batch
	created and viewed with a word processor or spreadsheet. Many plants have
	standardized on one of the many commercially available Relational Database
	Management System (RDBMS) software packages. We recommend using a
	high-performance database, such as SQL Server, due to their better
	robustness and performance. The Archiver collects data from each electronic
	batch record file and stores it in the specified RDBMS database format.
	See also
	FactoryTalk Batch Components on page 12

14

Chapter 1

Introducing Material Manager

FactoryTalk Batch Network

Editor

The FactoryTalk Batch Network Editor is a utility that indicates where other FactoryTalk Batch and FactoryTalk Batch Material servers are located on the network. This network configuration allows for ease of integration with other FactoryTalk Batch components and simplifies the process of reconfiguring a multi-computer system. If FactoryTalk Batch Material Manager is also installed the FactoryTalk Batch Network Editor is also used to indicate the location of the material database.

FactoryTalk eProcedure

Client

See also

FactoryTalk Batch Components on page 12

The FactoryTalk eProcedure Client computer uses Internet Explorer to enable operators to run batch recipes.

See also

FactoryTalk Batch Components on page 12

FactoryTalk eProcedure

Server

FactoryTalk Batch Material

Manager

The FactoryTalk eProcedure Server provides the services to the FactoryTalk Batch Server to enable the use of HTML instruction files. Prior to opening FactoryTalk eProcedure Client, FactoryTalk eProcedure Server must be running and remain active during all batch functions.

See also

FactoryTalk Batch Components on page 12

FactoryTalk Batch Material Manager is used to track material consumption in batch recipes. It consists of two components: Material Server and Material Editor.

The Material Editor provides an interface to help you create the material database, which consists of material, lot, sublot, container, and storage location data. The Material Server provides the communication between the material database and the FactoryTalk Batch Server. During a batch run, information about available containers is presented to the operator for binding decisions. Binding is the process of mapping steps within a control recipe to actual equipment in a plant. After a batch is run, quantities consumed or distributed are updated in the material database for use in inventory tracking.

15

Chapter 1

Introducing Material Manager

FactoryTalk Batch View

16

The Material Server consists of a group of components that work together to service various applications. The primary applications that the Material Server services are the Material Editor, FactoryTalk Batch Server, FactoryTalk Batch Recipe Editor, and FactoryTalk Batch Equipment Editor. Any third-party application can also use custom solutions based on the exposed Material Object Model (MOM).

See also

FactoryTalk Batch Components on page 12

This topic describes FactoryTalk Batch View on a Windows desktop system.

Tip: The modern FactoryTalk Batch View is an innovative and intuitive user interface for your comprehensive batch solution. It leverages state-of-the-art web technologies with scalable graphics for consistent visualization across all devices and form factors. The zero-install browser simplifies administration and maintenance. As the only native client application that supports the new features in FactoryTalk Batch and eProcedure, it is the client of the future for modern batch solutions.

For more information about the new FactoryTalk Batch View mobile solution, view the FactoryTalk Batch View User Manual (FTBVS-UM002).

FactoryTalk Batch View is the batch recipe initiation and execution program used by the operator of the FactoryTalk Batch Automation Solution system to:

•Initiate and control the batch process

•Display a graphical representation of a running batch and its associated data

Typically, FactoryTalk Batch View is intended to be used in conjunction with an HMI.

Each FactoryTalk Batch View window can be customized to suit the needs of a specific station:

•Specify the columns to display

•Specify the size of columns and rows

•Sort and filter on one field in certain windows

•Set the font for each FactoryTalk Batch View window

If the security is enabled for FactoryTalk Batch View, a system administrator can use the password protection option to:

•Limit the information that is displayed

•Specify the commands that are allowed at a particular station

Using FactoryTalk Batch View, an operator can respond to electronic signature requests that have been generated by report and recipe parameter deviations or by a command execute request.

Chapter 1

Introducing Material Manager

Material data

Introduction to the Material Server

To implement material-based recipes, you must configure three types of data:

•Material Data

Use the Material Editor to add the materials, lots, sublots, and the containers that hold them. This data is stored in the material database.

•Equipment Data

Use the FactoryTalk Batch Equipment Editor to create materialenabled phases and then associate the resultant equipment module with a container.

•Recipe Data

Use the FactoryTalk Batch Recipe Editor to define the materials and amounts to use in a recipe.

There are two stages to configuring material data. First is the initial system configuration which is the process of adding elements, such as material types, materials, material storage containers, and storage locations that are unique to the given installation. Once these initial elements are defined, configured, and tested, the process of initial system configuration is considered complete. The second stage is the on-going system upkeep, which is the process of day- to-day activities that keep the material-based recipe system current and operational. An example of the upkeep process is the addition or distribution of a new lot of a given material to the database.

For ease of understanding, and for tutorial purposes, this guide refers to configuring and using the sample files that are installed with FactoryTalk® Batch. The SampleDemo folders contain complete area models and recipes for a simulated plant. Before running the demonstrations:

•Configure the Network Editor to recognize the material database

•Add a FactoryTalk Security user

•Configure the FactoryTalk Batch Server to recognize the required project directories

•Select the initialization path and file name

•Start the FactoryTalk Batch Server and the FactoryTalk Batch Phase

Simulator

Tip: This guide outlines the configuration and use of the SampleDemo2 demonstration files. Because these files are used as an example throughout the guide, it is recommended that you follow the directions for using this demonstration step by step.

Looking at the Material

Server

The FactoryTalk Batch Material Server is a group of components that work together to service various client applications. The primary clients that the Material Server services are the Material Editor, FactoryTalk Batch Server, Storage Container ActiveX control, FactoryTalk Batch Recipe Editor, and FactoryTalk Batch Equipment Editor. Also, any third-party application can use custom solutions based on the exposed Material Object Model (MOM). The

17

Chapter 1

Introducing Material Manager

Material Server also interacts with SQL Server to read to and write from the material database.

	FactoryTalk Batch	FactoryTalk Batch	FactoryTalk	Third-Party
	Material Editor	Recipe Editor &	Batch Server	Solutions
		Equipment Editor

r

Material Client

(Client Interface)

Material Server

(Server Interface)

Material

Database

(SQL Server)

Material Server Communications

The Material Server runs with the context of a COM+ component, which is an extension to the Component Object Model (COM). This component resides on the client workstations and provides a rich programming model. See the

FactoryTalk Batch Material Server API Technical Reference for more information about the material object model.

The Material Server coordinates the following functions:

•Records actions to the material database that occur during configuration and run-time in the Activity Journal.

•Loads the material and container lists from the material database to the Batch Server at startup for population of the area model material and container enumeration sets.

•Loads the equipment module/container associations from the area model into the material database.

•Communicates with the FactoryTalk Batch Server during binding.

•During Unit Binding, the FactoryTalk Batch Server communicates with the Material Server to determine if the required materials can be satisfied by the containers within a unit.

•During Phase Binding, the FactoryTalk Batch Server communicates with the Material Server to get a list of containers and equipment modules based on the material to add or distribute in the step. In Prompted Phase Binding, the Operator selects the binding solution

18

Chapter 1

Introducing Material Manager

Set up the sample demonstrations

Configure the Network

Editor

from a list of container-equipment pairs. In Automatic Phase Binding, phases are selected based on current container priority.

•In Manual Phase Binding, the FactoryTalk Batch Server communicates with the Material Server to obtain a list of containers, lots and equipment modules that support the required material. The list is presented to the operator for selection of the equipment module to bind to the material step.

•Updates the material database with actual amounts consumed or distributed during a batch run. During an addition or distribution, when the Feed Complete is true, the FactoryTalk Batch Server communicates the actual amount to the Material Server. When the Feed Complete is not true, the FactoryTalk Batch Server communicates the actual amount to the Material Server, which in turn calculates the difference between the promise amount and the actual amount and sends this back to the FactoryTalk Batch Server. The FactoryTalk Batch Server uses this difference to update the setpoint for the split feed.

This guide also describes the different binding methods and how to handle split feeds.

The installation process placed the SampleDemo1 and SampleDemo2 folders in the BATCHCTL share on your hard drive. Within each of these SampleDemo folders are four subfolders that contain the files for the area model. To run the sample demonstrations, configure the Network Editor to locate the material database, add a FactoryTalk Security user, configure the FactoryTalk Batch Server to locate the area model, and then verify the recipes in the area model.

IMPORTANT The default databases MaterialBasedRecipe and SAMPLE2_Materials cannot be removed from SQL Server. You are free to add another database and use it for production or test, but you must keep the originally installed databases intact even though they are not being used.

Configure the Material Server with the location of the SQL database that contains the materials for the SampleDemo2 recipes.

1.Select Start > Rockwell Software > Material Manager, and then select

Network Editor. The Network Editor window opens.

IMPORTANT Administrator privileges are required to perform this procedure.

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2. Select the Material Server.

Add sample FactoryTalk Security users

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3.Select Configure. The Configure MaterialTrack dialog box opens.

4.In the MaterialTrack Database box, type SAMPLE2_MATERIALS, and then select OK.

5.Select Synchronize.

6.Select File > Exit, and then click Yes to exit the Network Editor.

See also

Set up the sample demonstrations on page 19

For the sample demonstrations file, create FactoryTalk user accounts for an operator and an engineer. Create these user accounts in the FactoryTalk Directory.

To add sample FactoryTalk Security users:

1.Select Start > Rockwell Software > FactoryTalk Administration Console. The Select FactoryTalk Directory dialog box opens.

IMPORTANT Administrator privileges are required to perform this procedure.

Chapter 1

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2.Select Network to add this user account to the FactoryTalk Network Directory, and select OK.

3.If not already logged on to the FactoryTalk Network Directory, the Log On to FactoryTalk dialog box opens. In User name, type the user name for the Administrator that was configured when the FactoryTalk Services Platform was installed.

4.In Password, type the password for the Administrator.

5.Verify the Directory and select OK. The FactoryTalk Administration Console window opens and displays the specified FactoryTalk Directory.

6.Expand Users and Groups.

7.Right-click the Users folder, and select New > User to create a new FactoryTalk Security user account in FactoryTalk Directory.

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8.The New User dialog box opens and displays the General tab. In the

User name box, type OPER.

9.In Full name, type Operator.

10.In Password, type password, and confirm it by re-entering password in the Confirm Password box.

11.Select Create.

12.Repeat steps 7-11, but this time in the User Name field, enter ENG and in the Full Name field, enter Engineer.

13.Keep the FactoryTalk Administration Console open to configure permissions for these FactoryTalk Security users in the next exercise.

Configure sample permissions for FactoryTalk Security users

See also

Configure sample permissions for FactoryTalk Security users on page 22

After creating the FactoryTalk security users, set up access modes for each FactoryTalk Batch component to specify which users are permitted to view or perform actions. Configure security settings in the FactoryTalk Administration Console. To tighten security in the eProcedure Client, remove the All Users group from the Full Edit policy setting.

To configure sample permissions for FactoryTalk Security users:

1.In the FactoryTalk Administration Console Explorer pane, navigate to

System > Policies > Product Policies > Batch > Equipment Editor > Access Modes.

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2.Right-click Access Modes, and then select Properties. The Access Modes Properties dialog box opens.

3.In the Full Edit row, select the Configure Security browse button. The

Configure Securable Action dialog box opens.

4.Select Add. The Select User and Computer dialog box opens.

5.In the Filter Users box, select Show All.

6.In Users, select ENG.

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Configure the sample FactoryTalk Batch Server

7.Select OK. The Configure Securable Action dialog box is updated, showing ENG in the list of Users with the Allow checkbox selected.

8.Select OK to close the Configure Securable Action dialog box.

9.In the Access Modes Properties dialog box, select View Only.

10.In the View Only row, select the Configure Security browse button. The Configure Securable Action dialog box opens.

11.Select Add. The Select User and Computer dialog box opens.

12.In the Filter Users box, select Show All.

13.In Users, select OPER.

14.Select OK. The Configure Securable Action dialog box is updated, showing OPER in the list of Users with the Allow checkbox selected.

15.Select OK to close the Configure Securable Action dialog box.

16.Select OK to close the Access Modes Properties dialog box.

See the FactoryTalk Batch Administrator Guide for more information on security.

See also

Configure the sample FactoryTalk Batch Server on page 24

To set up the sample demonstrations, configure the FactoryTalk Batch Server to locate the folders that contain the demonstration files and to the \Restart and bin folders where the FactoryTalk Batch Server writes data upon system failure. Configure the FactoryTalk Batch Server in the FactoryTalk Batch Equipment Editor.

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To configure the sample FactoryTalk Batch Server:

1.Select Start > Rockwell Software > Equipment Editor. The FactoryTalk Batch Equipment Editor opens (log on to FactoryTalk if prompted).

IMPORTANT Administrator privileges are required to perform this procedure.

2.Select Options > Server Options. The Server Options dialog box opens to the Project Settings tab.

3.In the Project Directories area, select the Primary Journal browse button. The Select Directory dialog box opens.

4.From the Look in list, select the SampleDemo1\Journals folder, and then select Open.

5.Select the Error Logging browse button. The Select Directory dialog box opens.

6.From the Look in list, select the SampleDemo1\Logs folder, and then select Open.

7.Click the Instructions browse button. The Select Directory dialog box opens.

IMPORTANT In order for the eProcedure Server to start, you must define the instruction path and an instruction file for each instruction-based phase in the area model. (See the FactoryTalk Batch Equipment Editor User Guide for instructions on defining instruction-based phases.)

8.Select the Equipment Database browse button. The Select Equipment Database dialog box opens.

9.From the Look in list, open the SampleDemo1\ Recipes folder, select the ice_cream1.cfg file, and then select Open.

10.In the Store Recipes Using area, select Binary Files, and then select the

Recipe Directory browse button. The Select Directory dialog box opens.

11.From the Look in list, select the SampleDemo1\Recipes folder, and then select Open.

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12. Select the Restart Control tab.

13.Select the Primary Path browse button. The Select Directory dialog box opens.

14.From the Look in list, select the SampleDemo1\Restart folder, and then select Open.

15.Select the Secondary Path browse button. The Select Directory dialog box opens.

16.From the Look in list, select the Bin folder.

17.Select the Batch Reporting tab. Leave Never (No Queue) as the default reporting application.

18.Select OK to close the Server Options dialog box.

19.Select File >Exit to exit the FactoryTalk Batch Equipment Editor.

Tip: These steps set up the FactoryTalk Batch Server to run the tutorial steps in this manual. There are many other settings to consider when setting up the FactoryTalk Batch system. (See the FactoryTalk Batch Administrator Guide for more information on the Server Options dialog box.)

See also

Rebuild the recipe directory on page 27

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Rebuild the recipe directory	To run the demonstration recipes, you must rebuild the recipe directory and
	verify the recipes in the area model using the FactoryTalk Batch Recipe
	Editor.
	IMPORTANT Administrator privileges are required to perform this procedure.

Start the FactoryTalk Batch

and Material Manager

Servers

To rebuild the recipe directory:

1. Select Start > Rockwell Software > Recipe Editor. The FactoryTalk Batch Recipe Editor reads the area model.

Tip: If you are logged in with an account that does not have administrator privileges, rightclick Recipe Editor and select More > Run as administrator to run under elevated privileges.

2.If prompted, log on to FactoryTalk. If a message displays asking you to verify the recipes, select Cancel.

3.Select File > Rebuild Recipe Directory. When the rebuild is complete, select OK, and then select Yes to verify the recipes.

4.When the recipe verification is complete, select Accept to save the recipes, and then select Close.

5.Select File > Exit to exit the FactoryTalk Batch Recipe Editor.

See also

Set up the sample demonstrations on page 19

The FactoryTalk Batch and Material Manager Servers may start automatically when the computer starts. By default, the FactoryTalk Batch Server starts in production mode. If FactoryTalk Batch has not been activated, the tutorial can run in demo mode. While in demo mode, the FactoryTalk Batch Server runs for a two-hour period and then stops.

Tip: The FactoryTalk Batch Server does not start in production mode without activation. The Material Manager Server starts automatically when the FactoryTalk Batch Server starts. See

Activating Material Manager for more information.

To start or restart the FactoryTalk Batch Server:

1. Select Start > Rockwell Software > Batch Service Manager.

IMPORTANT If you are logged in with an account that does not have administrator privileges, right-click Batch Service Manager and select More > Run as administrator to run under elevated privileges.

2.In the FactoryTalk Batch Service Manager, select the FactoryTalk Batch Server if it is not listed in the Service box.

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3. If the FactoryTalk Batch Server is running, select Stop.

4.If the name of the computer where the FactoryTalk Batch Server is installed does not display in the Computer box, select the Select Computer button.

5.In the Select Computer dialog box under Enter the object name to select, type the name of the computer where the Batch Server is

installed (or select Advanced to search for a computer). Select OK.

Tip: The FactoryTalk Batch Service Manager must communicate with the Windows Service Manager of the selected computer to determine what services are available. There may be a noticeable delay when establishing communications. If the Service Manager cannot communicate with the Windows Service Manager of the selected computer, a message displays.

6. From the Service list, select FactoryTalk Batch Server.

Tip: If No Batch Services displays in the list, the FactoryTalk Batch Server is not installed on the selected computer. See the FactoryTalk Batch Components Installation and Upgrade Guide for installation instructions.

7.To start the FactoryTalk Batch Server in Demo mode, select Allow Demo Mode.

8.Select the method to use for booting the server.

Cold Boot

Warm Boot

Warm All Boot

Restarts the FactoryTalk Batch Server in a cold state. All journal data or recipe content is erased upon startup.

Restarts the FactoryTalk Batch Server, restoring the set of batches that were on the batch list when the server previously terminated.

Restarts the FactoryTalk Batch Server only if it is able to restore all of the batches to the batch list.

9.Select the Start/Continue button. The Service State area changes from STOPPED to START PENDING. After a few moments, RUNNING displays and the light changes to green. The Material Server starts automatically with the FactoryTalk Batch Server.

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Start the sample FactoryTalk Batch Phase Simulator

The FactoryTalk Batch Phase Simulator starts automatically. Minimize the window.

10. Select Close to close the FactoryTalk Batch Service Manager.

Tip: If conversation becomes LOST while running in Demo mode, make sure that the Simulator is running and try starting the server(s) again. See Starting the FactoryTalk Batch Phase Simulator for more information.

FactoryTalk Batch comes with a phase logic simulation program, referred to as the FactoryTalk Batch Phase Simulator used to simulate the batch process without connecting to a PCD. The Phase Simulator imitates the functionality of a data server and can communicate with the FactoryTalk Batch Server using OPC communication protocol. The Phase Simulator is a powerful tool for testing, experimentation and demonstration purposes. In this guide, run the sample demonstration using the Phase Simulator.

Tip: If the Phase Simulator is required and OPC protocol is used for communications, the FactoryTalk Batch Server automatically starts the Phase Simulator. Check the Windows taskbar to see if the Phase Simulator is started.

To run the sample demonstration correctly, open the ice_cream1.sim file in the Phase Simulator.

To start the sample FactoryTalk Batch Phase Simulator:

1.If the Phase Simulator is already running, maximize it from the Windows taskbar. If the Phase Simulator is not running, select Start > Rockwell Software > Simulator. The FactoryTalk Batch Phase Simulator opens.

IMPORTANT Administrator privileges are required to perform this procedure.

2.Select File > Open. The Open Simulator Configuration File dialog box opens.

3.From the Look in list, open the Program Files > Rockwell Software > Batch > SampleDemo1 > Recipes folder. Select the ice_cream1.sim file, and then select Open.

4.Minimize the FactoryTalk Batch Phase Simulator window.

See also

Verify PCD communications on page 30

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Verify PCD communications

Summary

Use the following instructions to verify PCD communications.

IMPORTANT Administrator privileges are required to perform this procedure.

To verify PCD communications:

1.Select Start > Rockwell Software > Batch Service Manager. The FactoryTalk Batch Service Manager opens.

2.Make sure FactoryTalk Batch Server is selected in the Service box.

3.Select Server Details. The FactoryTalk Batch Server Details dialog box opens.

4.Select the PCD Communications tab. The Data Server Status area displays the status of the conversation with the OPC_SIM data server (Phase Simulator), which should be PHASES GOOD.

5.In the Tag Verify area, select Start to begin the verify process. The tag verification process takes several minutes.

6.When the Status box shows COMPLETED, select OK to close the

FactoryTalk Batch Server Details dialog box.

In this chapter, you:

•Set up the Network Editor and the FactoryTalk Batch Server to run the sample demonstration

•Started the FactoryTalk Batch Server in demo mode

•Opened the .sim file in the FactoryTalk Batch Simulator to run the sample demonstration

This chapter provided a brief overview of the capabilities of the Material Server. (See the FactoryTalk Batch Administrator Guide for more information about the FactoryTalk Batch Server. See the FactoryTalk Batch Material Manager Administrator Guide for more information about the Material Server.)

The rest of this document is designed to give you a tour through Material Manager using the sample demonstration. Follow the step-by-step instructions to learn how to define and run material-based recipes using Material Manager and FactoryTalk Batch software.

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