Rockwell Automation FactoryTalk User Manual
Getting Results Guide
Original Instructions
actoryTalk Batch
F
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
FactoryTalk Batch Material Manager
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IMPORTANT
Identifies information that is critical for successful application and understanding of the product.
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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
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In no event will Rockwell Automation, Inc. be responsible or liable for indirect or consequential damages resulting from the use
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2
Table of Contents
Preface
Introducing Material Manager
Introducing the Material Editor
About this manual ....................................................................................... 7
Legal Notices ............................................................................................... 7
Additional resources ................................................................................... 8
Chapter 1
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
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
Introducing material-enabled
phases
Introducing material-based
Running material-based recipes
Using custom code insertion
recipes
Exiting the Material Editor ........................................................................ 43
Summary ..................................................................................................... 43
Chapter 3
Open the area model .................................................................................. 45
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
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
points
4
Chapter 5
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
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
Developing an implementation
plan
Binding material-based recipes
Index
Table of Contents
OnGenerateCustomLotName ................................................................... 81
OnGenerateCustomLabelName ............................................................... 82
AfterSubLotInsert ..................................................................................... 83
AfterSubLotDelete ..................................................................................... 84
AfterLotInsert ............................................................................................ 85
AfterCombinedLotInsert .......................................................................... 86
Chapter 7
Determining the system requirements ................................................... 87
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
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
5
About this manual
Legal Notices
Preface
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
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.
Product Compatibility and Download
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,
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Includes the name of the open source component, its version number,
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citing the license, and the terms of the license.
7
The default location of this file is:
C:\Program Files (x86)\Common Files\Rockwell\Help\<product
name>\Release Notes\OPENSOURCE\oss_licenses.txt
Preface
Resource
Description
Resource
Description
reference for the formulator.
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
FactoryTalk Batch Components Installation and
Upgrade Guide
(BATCH-IN002)
FactoryTalk Batch View Quick Start Guide
(FTBVS-QS001)
FactoryTalk Batch View HMI Controls Quick Start
Guide
(BATCH-QS001D)
FactoryTalk Batch eProcedure® Getting Results
Guide
(BWEPRO-GR011)
FactoryTalk Batch Getting Results Guide
(BATCH-GR011)
FactoryTalk Batch Material Manager Getting
Results Guide
(BWMTR-GR011)
Provides information and procedures for FactoryTalk
Batch system installation. Includes information for
FactoryTalk Batch Material Manager, FactoryTalk Event
Archiver, and associated FactoryTalk Batch Client and
Server components.
Provides information about using FactoryTalk Batch View
to create, view, and command control recipes,
acknowledge prompts and signatures, view equipment
phases and diagnostic information, and view profile
information.
Provides a general overview of FactoryTalk Batch View
HMI Controls.
Explains the basics of FactoryTalk Batch eProcedure.
Introduces the basics of automated batch manufacturing
and the FactoryTalk Batch product components.
Introduces the basics of FactoryTalk Batch Material
Manager.
8
User Guides
FactoryTalk Batch ActiveX Controls User Guide
(BATCH-UM013)
FactoryTalk Batch Material Editor User Guide
(BWMTR-UM001)
Provides information and instructions for using the
FactoryTalk Batch ActiveX Custom Controls.
Provides access to information and procedural
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 materialbased recipes. This information is intended as a
Preface
Resource
Description
Recipe Editor, View, and Phase Simulator.
your Logix 5000 controller.
reference information by the operator.
system administrator and production supervisor.
conjunction with a Human-Machine Interface (HMI).
FactoryTalk Batch Equipment Editor User Guide
(BATCH-UM004)
FactoryTalk Batch PhaseManager™ User Guide
(BATCHX-UM011)
FactoryTalk Batch Recipe Editor User Guide
(BATCH-UM006)
FactoryTalk Batch View HMI Controls User Manual
(FTBVS-UM003)
Provides information on creating and maintaining an
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
Describes the integration of the FactoryTalk Batch
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
Provides instructions on using FactoryTalk Batch Recipe
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.
Provides details about using FactoryTalk Batch View HMI
Controls to monitor and interact with the production
process within a FactoryTalk View SE Display Client.
FactoryTalk Batch View User Manual
(FTBVS-UM002)
FactoryTalk eProcedure Client User Guide
(BWEPRO-UM001)
FactoryTalk Event Archiver User Guide (BATCHUM012)
FactoryTalk Batch View User Guide (legacy)
(FTBVS-UM001)
Provides information and procedural instructions for
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.
Provides information and procedural instructions
required to create and command batches using the
FactoryTalk eProcedure Client, and can be used as a
Provides information and instructions specific to the
FactoryTalk Event Archiver. Intended for use by the
Provides information and instructions on how to use
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
9
Preface
Resource
Description
(BWEPRO-UM011)
Resource
Description
(BATCH-RM001)
(BATCH-RM004)
engineers and the system administrator.
reference by the instruction file author.
Administrator Guides
FactoryTalk Batch Administrator Guide
(BATCH-UM003)
FactoryTalk Batch eProcedure Administrator Guide
(BWEPRO-UM011)
FactoryTalk Batch Material Manager Administrator
Guide
Reference Guides
FactoryTalk Batch ActiveX Controls Library
Reference Guide
FactoryTalk Batch Material Server API Technical
Reference
(BWMTR-RM001)
FactoryTalk Batch PCD Programming Reference
Manual
FactoryTalk Batch Server API Reference Manual
(BATCH-RM003)
Provides instructions for configuring security and
services, and implementation and use of components not
typically accessed or used by batch operators, such as
the FactoryTalk Batch Server.
Provides procedures specific to FactoryTalk Batch
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.
Provides information and instructions specific to
FactoryTalk Batch Material Manager. Intended for use by
the system administrator and database administrator.
Provides reference information and procedural
instructions for the FactoryTalk Batch ActiveX Custom
Controls.
Provides access to information regarding the interface
between the FactoryTalk Batch Material Server and the
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.
Provides information and instructions about the
FactoryTalk Batch PCD interface design. It is intended to
be used as a reference guide.
Provides information regarding the interface between the
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.
10
FactoryTalk Batch System Files Reference Manual
(BATCH-RM005)
FactoryTalk Batch eProcedure Instruction File
Design Reference Manual
(BWEPRO-RM001)
Provides the technical information for configuration and
maintenance of a FactoryTalk Batch system. It can be
used as a reference information for implementation
Includes information about the building of instruction
files for use in equipment database creation and recipe
development. This information is intended to be used as a
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.
What is Material Manager?
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
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.
11
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
Chapter 1 Introducing Material Manager
FactoryTalk Batch
FactoryTalk Batch Server
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.
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.
12
Chapter 1 Introducing Material Manager
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
FactoryTalk Batch Recipe Editor
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 read-
only, 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
FactoryTalk Event Archiver
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
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.
14
See also
FactoryTalk Batch Components on page 12
FactoryTalk Batch Network
Editor
FactoryTalk eProcedure
FactoryTalk Batch Material
Chapter 1 Introducing Material Manager
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.
See also
FactoryTalk Batch Components on page 12
FactoryTalk eProcedure Client
Server
Manager
The FactoryTalk eProcedure Client computer uses Internet Explorer to enable
operators to run batch recipes.
See also
FactoryTalk Batch Components on page 12
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.
15
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.
Chapter 1 Introducing Material Manager
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
FactoryTalk Batch View
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.
16
you follow the directions for using this demonstration step by step.
Material data
Introduction to the Material
Chapter 1 Introducing Material Manager
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 dayto-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.
Server
Looking at the Material Server
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
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
r
Material Client
(Client Interface)
Material Server
(Server Interface)
Material
Database
(SQL Server)
FactoryTalk Batch
Material Editor
FactoryTalk Batch
Recipe Editor &
Equipment Editor
FactoryTalk
Batch Server
Third-Party
Solutions
Material Server also interacts with SQL Server to read to and write from the
material database.
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:
Material Server Communications
• 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
IMPORTANT
IMPORTANT
Chapter 1 Introducing Material Manager
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.
Set up the sample demonstrations
Configure the Network Editor
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.
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.
Administrator privileges are required to perform this procedure.
19
Chapter 1 Introducing Material Manager
IMPORTANT
Add sample FactoryTalk
2. Select the Material Server.
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.
Security users
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.
Administrator privileges are required to perform this procedure.
20
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.
Chapter 1 Introducing Material Manager
21
Chapter 1 Introducing Material Manager
Configure sample
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.
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.
22
2. Right-click Access Modes, and then select Properties. The Access
Modes Properties dialog box opens.
Chapter 1 Introducing Material Manager
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.
23
Chapter 1 Introducing Material Manager
Configure the sample
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.
FactoryTalk Batch Server
24
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.
IMPORTANT
IMPORTANT
instructions on defining instruction-based phases.)
Chapter 1 Introducing Material Manager
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).
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.
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
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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Chapter 1 Introducing Material Manager
Options dialog box.)
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
See also
Rebuild the recipe directory on page 27
26
IMPORTANT
privileges.
for more information.
IMPORTANT
Rebuild the recipe directory
Start the FactoryTalk Batch
Chapter 1 Introducing Material Manager
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.
Administrator privileges are required to perform this procedure.
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
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.
and Material Manager
Servers
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
To start or restart the FactoryTalk Batch Server:
1. Select Start > Rockwell Software > Batch Service Manager.
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.
27
2. In the FactoryTalk Batch Service Manager, select the FactoryTalk
Batch Server if it is not listed in the Service box.
Chapter 1 Introducing Material Manager
displays.
Guide for installation instructions.
Cold Boot
Warm Boot
on the batch list when the server previously terminated.
Warm All Boot
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
28
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
7. To start the FactoryTalk Batch Server in Demo mode, select Allow
Demo Mode.
8. Select the method to use for booting the server.
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
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.
Phase Simulator for more information.
see if the Phase Simulator is started.
IMPORTANT
Start the sample
FactoryTalk Batch Phase
Simulator
Chapter 1 Introducing Material Manager
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
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
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.
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
29
Chapter 1 Introducing Material Manager
IMPORTANT
Verify PCD communications
Use the following instructions to verify PCD communications.
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.
Summary
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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