Wonderware FactorySuite

InBatch

Getting Started Guide

Revision C

October, 2001

Wonderware Corporation
This document contains information for InBatch Premier edition. For information
regarding the Getting Started Guide and tutrorial for InBatch FlexFormula
edition, please visit the following URL:
http://www.wonderware.com/Products/mmi/inbatch.htm
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assume no responsibility for errors or omissions. Neither is any liability assumed
for damages resulting from the use of the information contained herein.
The information in this documentation is subject to change without notice and
does not represent a commitment on the part of Wonderware Corporation. The
software described in this documentation is furnished under a license or
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with the terms of these agreements.

 2001 Wonderware Corporation. All Rights Reserved.

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Trademarks
All terms mentioned in this book that are known to be trademarks or service
marks have been appropriately capitalized. Wonderware Corporation cannot attest
to the accuracy of this information. Use of a term in this book should not be
regarded as affecting the validity of any trademark or service mark.
Wonderware, InTouch and FactorySuite Web Server are registered trademarks of
Wonderware Corporation.
FactorySuite, Wonderware FactorySuite, WindowMaker, WindowViewer, SQL
Access Manager, Recipe Manager, SPCPro, DBDump, DBLoad, HDMerge,
HistData, Wonderware Logger, Alarm Logger, InControl, InTrack, InBatch,
IndustrialSQL, FactoryOffice, FactoryFocus, License Viewer, Scout, SuiteLink
and NetDDE are trademarks of Wonderware Corporation.
Contents
System Requirements ...............................................................................................1-6
Microsoft SQL Server........................................................................................1-6
InBatch Server ..................................................................................................1-6
Batch Runtime Client ........................................................................................1-6
Batch Development Client.................................................................................1-6
InBatch Program Menus...........................................................................................1-7
InBatch Server ..................................................................................................1-7
InBatch Batch Development Client....................................................................1-7
InBatch Batch Runtime Client...........................................................................1-8
Installing InBatch ....................................................................................................1-9
InBatch Server Installation ................................................................................1-9
InBatch Client Installation ................................................................................1-9
Overview of Capabilities ........................................................................................1-10
Flexible Recipes and Process Lines..................................................................1-10
Process Modeling ............................................................................................1-10
Materials Tracking Management .....................................................................1-12
Recipe Management ........................................................................................1-13
Batch Management..........................................................................................1-13
Batch History ..................................................................................................1-14
Batch Reports..................................................................................................1-14
Extensibility...........................................................................................................1-15
Managing InBatch Configurations .........................................................................1-15
InBatch Application Modules.................................................................................1-16
Configuration Modules....................................................................................1-16
Runtime Modules ............................................................................................1-17
Utility Modules................................................................................................1-18
InBatch Configuration Architecture .......................................................................1-19
The Breading Plant Process Area ...........................................................................2-22
Hardware Architecture ...........................................................................................2-22
Hardware Architecture ...........................................................................................2-23
Install the InBatch Software ...................................................................................2-23
Start InBatch Environment Display........................................................................2-24
Configuration Steps................................................................................................2-24
Model the Process ..................................................................................................2-25
Define Units ....................................................................................................2-26
Define Connections .........................................................................................2-27
Define Process Classes ....................................................................................2-28
Define Process Phases .....................................................................................2-29
Define Transfer Classes...................................................................................2-33
Define Transfer Phases....................................................................................2-34
Define Segments .............................................................................................2-35
Validate the Model ..........................................................................................2-37
Use the Tag Linker.................................................................................................2-38
Define Export Configuration ...........................................................................2-39
Perform a Simulation Export ...........................................................................2-40
Update the Runtime Databases ...............................................................................2-41
Define the Process Trains.......................................................................................2-42
Defining the Materials and Material Locations.......................................................2-43
Define Materials..............................................................................................2-44
Define Material Locations ...............................................................................2-45
Build a Recipe........................................................................................................2-46
Recipe Header .................................................................................................2-47
Define Equipment Requirements .....................................................................2-48
Define Formula Inputs.....................................................................................2-49
 Construct the Recipe Procedure....................................................................... 2-51
Validate the Recipe......................................................................................... 2-54
Save the recipe................................................................................................ 2-54
Approve the Recipe for Production.................................................................. 2-55
Create an InBatch Runtime Client (InTouch) Application...................................... 2-56
Create an Operator Interface on InTouch using InBatch Wizards.................... 2-56
Define Windows ............................................................................................. 2-57
Modify Access Name ...................................................................................... 2-72
Set Initial Value for IB_TIM_ACCESS Tag ................................................... 2-73
Define Complimentary Scripts ........................................................................ 2-74
Start the InBatch Runtime System ......................................................................... 2-77
Schedule and Execute Batches ............................................................................... 2-78
From the InBatch Server................................................................................. 2-79
From the InBatch Runtime Client (InTouch)................................................... 2-80
Execute an End-of-Batch Report............................................................................ 2-81
C H A P T E R 1

Welcome to InBatch

InBatch is a “Flexible Batch Management System” that is designed to be quickly

and easily configured once fundamental concepts are understood. It is extremely
important to read this section of the manual before attempting to use InBatch.
Once InBatch concepts are understood, you should be able to quickly build and
edit configurations without using this manual. As with most menu driven
systems, you will become more proficient by using the manual as a reference to
improve your understanding of InBatch and how to apply features that may not be
obvious.
This manual is written for the individuals who will be configuring and applying
the batch control system. Process and control engineers or experienced
technicians, who are very knowledgeable about control system programming and
process control, are the most obvious individuals.
The batch system does not require programming at the PC. However, control
system programming is required. Also, the batch system is a very complex, yet
configurable software product that requires a fundamental knowledge of Windows
NT 4.0 operating system, computer system networking, programmable logic
controllers (PLCs), and process control. Server and client licensing are not
discussed in this section.
Contents
System Requirements
InBatch Program Menus
Installing InBatch
Overview of Capabilities
Extensibility
Managing InBatch Configurations
InBatch Application Modules
InBatch Configuration Architecture
The Breading Plant Process Area
Hardware Architecture
Hardware Architecture
Install the InBatch Software
Start InBatch Environment Display
Configuration Steps
Model the Process
Use the Tag Linker
Update the Runtime Databases
Define the Process Trains
Defining the Materials and Material Locations
Build a Recipe
Create an InBatch Runtime Client (InTouch) Application
Start the InBatch Runtime System
Schedule and Execute Batches
Execute an End-of-Batch Report
n
System Requirements
InBatch system requirements are the same as for InTouch with additional
requirements as described below.

Microsoft SQL Server

InBatch utilizes Microsoft SQL Server 7.0 on a separate Information Server
machine for database storage and retrieval.
• Allow at least 200-300 MB free hard disk space for your InBatch databases.

InBatch Server
• InBatch Server (only) requires 40 MB free hard disk space.
• InBatch Server with a Batch Runtime Client requires 70 MB free hard disk
space.
• SVGA(1024X768) display and adapter w/2MB Video RAM.

Batch Runtime Client

• Wonderware InTouch.
• Microsoft Windows 95, 98 or NT 4.0.
• Client requires 30 MB free hard disk space.
• SVGA Monitor, 2MB Video RAM.

Batch Development Client

• Microsoft Windows NT 4.0.
• SVGA(1024X768) display and adapter w/2MB Video RAM.
InBatch Program Menus
InBatch Server
When you install the InBatch Server, the Wonderware FactorySuite menu is
created which contains the InBatch Server submenu. The contents of the
InBatch Server sub-menu are summarized below.

Environment Display - starts the Environment Display and initializes the

background processes necessary to access InBatch configuration and runtime
applications.
History Admin. - starts the History Administration utility, and is used to define
the user account that will be used to access the historical database.
History Archive - starts the History Archive utility, and is used to set when
InBatch will create archival databases of completed batch information.
Release Notes - starts a Windows Help file that contains a summary of
enhancements, user documentation that was unable to be included in this User’s
Guide, and known problems with, and work-arounds for InBatch.
The UnInstall - allows you to remove the InBatch server. Use this only if you
want to remove InBatch from your computer.

InBatch Batch Development Client

When you install a Batch Development Client, the Wonderware FactorySuite
menu is created which contains the InBatch Development Client sub-menu and
the items described below.
Process Modeling Editor - starts the InBatch Process Modeling Editor on the
client.
Tag Linker - starts the InBatch Tag Linker on the client.
Train Editor - starts the InBatch Train Editor on the client.
Material Editor - starts InBatch Material Editor program on the client.
Recipe Editor - starts InBatch Recipe Editor program on the client.
Report Editor - starts the InBatch Report Editor on the client.
Security Editor - starts InBatch Security Editor program on the client.
Process Log Editor - starts InBatch Process Log Editor program on the client.
UnInstall - allows you to remove the Batch Development Client. Use this only if
you want to remove InBatch from your computer.
InBatch Batch Runtime Client
When you install a Batch Runtime Client, the Wonderware FactorySuite menu
is created which contains the InBatch Runtime Client sub-menu and the items
described below. InTouch 7.0 is required in order to install the Batch Runtime
Client.
Batch Display - starts InBatch Batch Display program on the client.
Batch Scheduler - starts InBatch Batch Schedule program on the client
Report Display - starts InBatch Report Display on the client.
UnInstall - allows you to completely remove the Batch Runtime Client. Use this
only if you want to remove InBatch from your computer.
In addition to these items, the following items are added to the InTouch
installation.
InBatch Wizards – loads batch wizards into InTouch.
ActiveX Objects – loads the Batch ActiveX object and the SFC ActiveX object
onto the client system.
Alarm/Event Interface – loads the wwextalm.dll and the ibhist.dll into InTouch.
Script Add-On Functions – loads several script add-on functions that can be
used with InBatch into InTouch.
? For more information on using InTouch, see your online InTouch User’s
Guide.
Installing InBatch
InBatch is installed from the FactorySuite CD-ROM. The installation program
provides the capability to install various Batch Server and Batch Client
configurations. A summary of the server and client configuration options specific
to InBatch is provided below.

InBatch Server Installation

n Configuration and runtime components
n Redundancy

InBatch Client Installation

n Batch Development Client (InBatch configuration applications) for NT 4.0
only
n Batch Runtime Client (InBatch runtime applications, Batch Wizards,
ActiveX objects, etc.) for NT 4.0
n Batch Runtime Client (InBatch runtime applications, Batch Wizards,
ActiveX objects, etc.) for Windows 95
n Redundancy
Overview of Capabilities
Wonderware InBatch is flexible batch management software designed to automate
and provide a complete production history for batch processes. Consistent with
the Instrument Society of America (ISA) S88.01 standard, InBatch allows you to
quickly and easily create recipes and simulate their execution against a model of
the process – all before writing one line of control code. InBatch also provides
complete production history and materials genealogy. InBatch's powerful batch
engine, combined with its integration with FactorySuite, means that you can
reduce the cost and time to implement your batch-related processes by up to 40 to
60% over competitive solutions.
InBatch provides "Out of the box" batch management functionality that
eliminates the need for unsustainable custom code in the PLC or DCS and
dramatically reduces the life-cycle engineering effort. The sophisticated batch
engine is responsible for Unit-to-Unit Material Tracking, Short Term Scheduling,
Dynamic Batch and Equipment Management, and Batch History and Reporting.
The batch management system also supports redundancy for mission-critical
applications.

Flexible Recipes and Process Lines

In the batch control system, recipe procedures can be changed and new formula
and process lines can be easily re-configured, not re-engineered, for new product
introductions. The batch system is flexible because it lets you model your plant,
create new process lines, manage recipes, schedule and execute batches, and keep
a history of all batch processing activity.
Flexibility in a batch process will make a plant more competitive. Improvements
will result because of faster line changeovers, faster time-to-market for new
products, quick response to customer orders, accurate batch history, and
consistent product quality.

Process Modeling
A batch processing plant is made up of units and connections. Units process
and/or hold materials while connections transfer materials between units.
A unit is defined as any vessel that can hold and/or process materials. Some units
have no processing capabilities, as is the case with bulk storage vessels, manual
add stations, and hold tanks. Other units have significant processing capabilities,
as is the case with most reactors, blenders, mixers, dryers, retorts, and washers.
Examples of processing capabilities are agitating, mixing, heating, cooling,
blending, and packaging. Other examples of units are storage tanks, silos, ovens,
fillers, washers, retorts, molders, bottlers, wrappers, cartoners, and palletizers.
Connections are defined as the equipment, i.e. pumps, valves, separators,
condensers and flow meters, that is necessary for transferring a product from one
unit to another. Many plants have units that are connected to more that one unit
and some plants have multiple connections between the same two units.
All units that have the same processing capabilities or perform the same function
are grouped into one process class. All the connections between the same two
process classes are grouped into one transfer class. Process Classes and Transfer
Classes define a family of units and connections, respectively. The ability to group
units and connections into classes is the essence of a true flexible batch system.
Processing and transferring capabilities are defined by Phases. Each phase is an
independent action that may contain a unique set of Parameters. Parameters
configure the phase based on a recipe’s requirements. Phases can be automatically
executed by the control system. The can also be manually executed by an
operator. The execution of automatic phases is performed by the control system
using Phase Logic.
 Units, Process Classes (Processes), Connections, Transfer Classes (Transfers),
and Processing Capabilities are the five main components of the Process Model.
Defining the plant processing capability is called Process Modeling and involves
the steps listed below.
1. Identify each unit and its attributes.
2. Group units into process classes.
3. Identify all connections between units.
4. Define all equipment segments and assign to connections.
5. Group connections into transfer classes.
6. Define the processing capabilities of each process class (phases and
parameters).
7. Define the transferring capabilities of each transfer class (phases and
parameters).
8. Define equipment statuses.
9. Define trains.
10. Develop phase logic.
An integral part of Process Modeling involves defining specific data points, called
Tags, for Units, Processes, Connections, and Transfers. Tags allow data to move
between the batch system and the control system. Tags must be defined prior to
configuring any of the batch system application modules. The number of tags
allowed in the batch system is only limited by the amount of mass storage in the
system.

Materials Tracking Management

Materials Tracking Management includes the ability to define materials as
ingredients, intermediates, finished goods, by-products, and others. The ability to
define characteristics is provided for each material entered in the system.
The Materials Editor is used to track the location of materials that are stored in
units. This usually pertains to bulk ingredients and work in process materials.
The batch management system uses the ingredient location data to determine
where to get ingredients when a batch is to be produced. This capability allows
ingredient locations to be independent of recipes and control programs, and
permits ingredients to change locations with no effect on recipe execution.
The materials database is used by the Recipe Editor in the construction of recipes.
Only materials in the materials database can be used in recipes.
When new bulk ingredients are received, the unit location may be entered into the
materials database by plant personnel. A lot identification can also be assigned to
the material. Multiple lots of the same ingredient may be stored in the same
vessel. The batch management system updates the database when ingredients are
used and when intermediates or finished goods are produced. The database
provides for easy access to WIP information and can be used to update higher
level material management and material resource planning (MRP) systems with
ingredient usage information, WIP, and finished goods production. The Materials
Editor is not an inventory management system, but may be used to complement
existing systems.
Recipe Management
The batch control system manages and constructs recipes according to the
guidelines outlined in the Instrument Society of America (ISA) SP88 Flexible
Batch Specification.
The batch control system provides a recipe management system that enables
Master Recipes to be constructed and edited. Master recipes are not process line
specific, but rather are equipment independent. They can be assigned to any
process line (train) that has units belonging to the classes of process equipment
defined in the recipe. A master recipe becomes a Control Recipe as the units
defined in the train are dynamically allocated and used in producing a batch.
A master recipe is not size specific, but is scalable to the batch size defined by
production scheduling. All formula quantities for ingredients, intermediates, by-
products, and finished goods are entered as either actual quantities or can be
expressed as a percent of the total batch size. Quantities expressed in percentages
are scaled by the batch management system when the batch is executed.
The Recipe Editor provides several text and graphical editors to construct and
alter recipes. Recipes can be saved, retrieved, and printed. A revision control
system provides an accurate time stamped history of all changes and revisions
that have been made to the recipe.

Batch Management
Batch Management consists of scheduling batches, initializing batches,
coordinating the execution of batches with the control system, interfacing with
operators, and storing all batch activity. This functionality is achieved through the
Batch Manager, Batch Scheduler, and Batch Display programs. The final result is
a flexible, reliable, and intuitive approach to the management of a batch process.
Scheduling: The Batch Manager’s scheduling capability is that of dispatching
batches that are ready to run to plant floor operators. Scheduling involves the
manual entry of the batch identification, master recipe, batch size, and Train
(Process Line) into the Batch Scheduler. Once entered, the batch can be
initialized.
Initialization: Each batch must be initialized before it is executed. The
initialization process involves validation of the recipe, checking if the Train
exists, checking if the bulk materials defined in the recipe are available in the
Train, ensuring that the recipe’s equipment requirements are satisfied by the
Train, and verifying that the Process Model database is compatible with the
recipe.
Batch and Unit Management: Batch Manager directs and supervises the
execution of each batch. The Batch Manager interprets recipes and enables the
control system. Based on the recipe’s procedure, blocks of control software,
referred as phase blocks, are signalled to execute by the Batch Manager. Phase
block control logic, located in the control system, is responsible for controlling
the process. Prior to enabling each phase block, the Batch Manager verifies that
the phase block is ready to be executed. If so, phase parameter values are
downloaded to the block, then the block is started.
Batch Manager also interfaces with Batch Display programs. The Batch Display
programs provide operators with information on all batches initialized and/or
executing in the system. Through these displays, operators can put a batch or
phase in hold, as well as restart and abort batches or phases. In addition,
operators can change phase parameter values, acknowledge the execution of
phases, review phase interlock statuses, and enter comments while the batch is
executing.
 The Batch Manager coordinates the usage of process units for each batch. The
Batch Manager is capable of running a large number of batches simultaneously.
Each batch is a separate entity and contends along with other batches to possess
the process units it needs. Batch Manager allocates ownership of units to batches
as units become available, and releases units when the batch no longer requires
the unit.
Flexible batch systems using controllers must take the approach in which the
supervisory workstation becomes an active participant in executing a batch. The
reason for this is that unit management is very sophisticated in a flexible batch
system. Most controllers do not have the ability to program a unit manager
capable of interpreting and executing the recipe procedures that can be
constructed in the batch control system.
A Master Recipe uses classes of process units, not specific units. This means
phases pertain to a class of units not a specific unit. When the Batch Manager
executes a Master Recipe, each phase encountered is converted into a unit specific
phase. This process is called Master Recipe to Partial Control Recipe conversion.
The Train assigned to produce the batch specifies all the units that can be used.
The Batch Manager automatically converts the Master Recipe to a Control Recipe
based on the units found in the Train.
History: Batch Manager captures and stores all processing and operator activity
during the execution of a batch.

Batch History
InBatch uses Microsoft SQL Server as its historical repository to provide open
and easy access to all batch history data
The Batch Management System is responsible for writing all information related
to the production of a batch to the history database. This includes events, process
data, production information, material usage, operator comments, operator
actions, and equipment used.

Batch Reports
InBatch uses Seagate Crystal Reports Professional for report development. This
provides a flexible and open platform so that the user can easily build custom
reports. Retrieval of historical data in the form of reports is provided by the
runtime Reporting System. Reports can be automatically triggered during the
execution of a batch or at the end of a batch. InBatch is supplied with a set of
predefined reports.
Extensibility
InBatch offers a rich set of ActiveX objects and API functions for integrating
external applications such as ERP or scheduling systems and allowing exchange
of formulas/recipes, materials and production results. InBatch also uses Microsoft
SQL Server as its historical repository to provide open and easy access to all batch
history data. These interfaces make it easy to integrate with ERP and Advanced
Planning Systems, allowing InBatch to be a key link in a successful supply chain
management initiative.

Managing InBatch Configurations

When the InBatch Server is installed, the following folder structure is created.
The folders and files shown must never be modified, except for one notable
exception, the configuration folder.
The InBatch configuration that you create is stored in the
“…/FactorySuite/InBatch/cfg/config_A” folder. The InBatch system looks for
your configuration and must find it in config_A. If you want to work on a
different configuration, you can create a different folder. For example, create a
folder named “ AnotherConfig,” and then move the configuration files from
“config_A” into it. An empty set of default database files can be copied from the

dflt_cfg folder to “config_A.”

InBatch Application Modules
The following section is a summary of the applications that are available within
the Environment Editor.

Configuration Modules
Environment Editor (EnvEdit)
(Required) The Environment Editor is used to define the batch configuration and
runtime applications that are to be executed.

Process Modeling Editor (ModelEdit)

(Required) Provides the capability for a user to create a process model database.
Only one Process Modeling Editor can run in a system at a time.

Tag Linker Editor (TagLinker)

(Required) The Tag Linker Editor associates InBatch tags with a control system.
It is also capable of associating InBatch tags with InTouch tags. Tag Linker also
exports InBatch tags to a comma separated variable file that will ultimately
populate the InTouch tag dictionary with memory and IO tags.

Train Editor (TrainEdit)

(Required) The Train Editor is used to create production lines on which batches
are scheduled.

Materials Editor (MaterialEdit)

(Required) Provides the capability for a user to create and edit a materials
database both on and off-line. Multiple Materials Editors can run in a system
enabling multiple users to edit the same database simultaneously.

Recipe Editor (RecipeEdit)

(Required) Provides the capability for a user to create and edit a recipe database
both on and off-line. Multiple Recipe Editors can run in a system enabling
multiple users to edit the same database simultaneously.

Report Editor (ReportEdit)

(Optional) The Report Editor is used to create, edit, and print report
configurations.

Process Log Editor (LogEdit)

(Optional) The Process Log Editor is used to create, edit, and print batch-related
data logging configurations.

Security Editor (SecEdit)

(Optional) Provides the capability for a user to define the users of the system,
security levels for each user, appropriate workstation access for each user,
appropriate recipe access for each user, and enable/disable applications and
functions requiring security.
Runtime Modules
Environment Manager (EnvMngr)
(Required) The Environment Manager manages the execution of the batch
runtime applications defined with the Environment Editor.

Environment Display (EnvDspl)

(Required) The Environment Display is a client of the Environment Manager and
provides a single interface for starting and stopping all batch system GUI
applications.

Unilink Manager (UnilinkMngr)

(Required) Manages inter-process communications between all of the batch
system applications.

InBatch Client (IBCli)

(Required for Runtime) Runtime client application which allows InBatch to
access tag data from SuiteLink and DDE Servers.

Memory Tag Manager (MemTagMngr)

(Required) The Memory Tag Manager is responsible for generating all of the tags
configured as InBatch Memory Tags in the Tag Linker application.

Simulation Manager (SimMngr)

(Required for Simulation) The Simulation Manager replaces the communication
drivers for a batch system and allows the system to be executed without control
system hardware present.

Information Manager (InfoMngr)

(Required) Provides general batch server information to client applications.

InBatch Server (IBServ)

(Required) Runtime server application, which allows SuiteLink and DDE client
applications (e.g. InTouch), to use InBatch TIM tags and Control System tags.

InBatch Function Server (IBFServ)

(Required if you are using Batch Function Tags) Runtime server application,
which allows SuiteLink and DDE client applications (e.g. InTouch), to use
InBatch Batch Function Tags.

Batch Manager (BatchMngr)

(Required) Interfaces with the process model, recipe, and materials databases.
The Batch Manager works in conjunction with the Batch Scheduler and Batch
Display programs. The Batch Manager executes all recipes, manages unit
allocation, moves batch information to the History Manager, and triggers reports.

Batch Scheduler (BatchSched)

(Optional) Interfaces with the Batch Manager and is used to construct a schedule
of batches to be executed. Multiple Batch Schedulers can run in a system.
 Batch Display (BatchDspl)
(Optional) The Batch Display is a client of the Batch Manager, and provides all
of the runtime information concerning the execution of a single batch. Multiple
Batch Displays can run in a system.

Report Manager (ReportMngr)

(Optional) The Report Manager interfaces with the Batch Manager for report
triggers. In addition, the Report Manager will retrieve historical data from the
Historical Database. Only one Report Manager can be run in a system.

Process Logger Manager (LogMngr)

(Optional) The Process Logger Manager controls the data logging of any tag in
the system according to the logging configuration.

Security Manager (SecMngr)

(Optional) Security Manager is used in batch and external applications to evaluate
and respond to requests for security clearance.

Tag Interface Management (TIM) System Batch

Process (TIMBatch)
(Optional) The TIM System Batch Process manages the runtime tag interface
between the batch management system and the computers and/or controllers
defined in the system.

Tag Interface Management (TIM) System Function

Library Process (TIMFunc)
(Optional) The TIM System Function Library Process manages the runtime tag
interface between the batch functions and the computers and/or controllers
defined in the system.

Tag Interface Management (TIM) System Security

Process (TIMSec)
(Optional) The TIM System Security Process manages the runtime tag interface
between the security system and the computers and/or controllers defined in the
system.

Utility Modules
Phase Logic Testing Tool (PhaseLogic)
(Optional) The Phase Logic module permits individual phase execution
independent of any batch operation.

Change Password (ChgPwd)

(Optional) The Change Password application permits the user to interact with the
security system from the command line in order to change a user’s password. The
Change Password utility is part of the security system.

Tag View (TagView)

(Optional) The Tag View application permits monitoring and changing any of the
InBatch equipment or TIM tags.
InBatch Configuration Architecture
ModelEdit TrainEdit MaterialEdit RecipeEdit ReportEdit

CfgModelDB MaterialDB RecipeDB ReportDB

TagLinker EnvEdit SecEdit LogEdit

LinkDB Imp/Exp

CfgLinkDB CfgTIMDB DBLoad Files EnvDB SecurityDB LogDB

 InBatch Runtime Architecture

RecipeEdit MaterialEdit EnvMngr

EnvDB

Lock Manager
(lm_tcp)

RecipeDB MaterialDB BatchDB .BatchWR

BatchSched
(OCXBatch) InSQL
InfoMngr BatchMngr
BatchDspl
(OCXBatch, LogMngr
SFCOCX)
SQLServer
TIMBatch
TIMSec
TIMFunc
TrainEdit UnilinkMngr

ModelDB SysTagMngr
LogDB
IBHist

SimMngr

IBCli IBServ

LinkDB TIMDB

WindowMaker/Viewer
IO Server InControl
SFC Batch InBatch Wizards InBatch Tag
Alarm/Event
ActiveX ActiveX and Script Browser
Interface (.dlls)
Object Object Functions Server
C H A P T E R 2

Discovering InBatch - A Tutorial

This chapter guides you through the process of developing actual InBatch Server
and Client applications using a generic Breading Plant process as a reference.
The purpose of the tutorial is to show you the ease with which you can configure
InBatch and the power that InBatch provides as a design, engineering and
simulation tool. Additionally, it familiarizes you with all other InBatch
capabilities associated with configuration and control system logic, material
management, recipe management, history, reporting, and operator interface. As
you work through this tutorial, you will develop a complete understanding of what
InBatch is and how it is configured.
This tutorial assumes that the user has a properly configured, operational
hardware system and strong working knowledge of InTouch.
Contents
The Breading Plant Process Area
Hardware Architecture
Hardware Architecture
Install the InBatch Software
Start InBatch Environment Display
Configuration Steps
Model the Process
Use the Tag Linker
Update the Runtime Databases
Define the Process Trains
Defining the Materials and Material Locations
Build a Recipe
Create an InBatch Runtime Client (InTouch) Application
Start the InBatch Runtime System
Schedule and Execute Batches
Execute an End-of-Batch Report
The Breading Plant Process Area

Bulk1 Bulk2 BulkTks Process Phases

(Flour) (Salt) None

Blk1_Dis Common Blk2_Dis

Bulk_Mix Transfer Phases/Parameters
BulkAdd Qty_Kgs (Input)
Mix1_Chg Mix2_Chg

Mixers Process Phases/Parameters

Mixer1 Mixer2 Mix Time_Min, Speed_%
ManAdd Qty_Kgs (Input)
Instruct

Mix_Hold Transfer Phases/Parameters

Discharg Qty_Kgs (Output)

HoldTks Process Phases

Hold1 Hold2
None
Hardware Architecture
Our example architecture is shown below. MERCURY is the name of the InBatch
Server. MIXER1 is the name of the InBatch Development Client and MIXER2 is
the name of the InBatch Runtime Client.

InBatch Server
"MERCURY"
Windows NT 4.0

InBatch InBatch
Development Client Runtime Client
"MIXER1" "MIXER2"
Windows NT 4.0 Windows NT or 95

Install the InBatch Software

l Install the InBatch Server software on MERCURY.
l Install and Configure Microsoft SQL Server on MERCURY. This can be
done by installing IndustrialSQL Server.
l Install the InBatch Development Client software on MIXER1.
l Install the InBatch Runtime Client software on MIXER2.
Note The MIXER1 node is used for illustration purposes only. This node is
portrayed as an InBatch Development Client. All configuration information
presented can be performed from the InBatch Server or the InBatch Development
Client. This example refers to the server.
Start InBatch Environment Display
Select the Environment Display option from the Start/Programs/Wonderware
FactorySuite/InBatch Server folder. The InBatch Environment Display will be
displayed. This application is used to start the InBatch configuration and runtime
applications.

Configuration Steps
1. Model the Process
2. Use the Tag Linker
3. Update the Runtime Databases
4. Define the Process Trains
5. Defining the Materials and Material Locations
6. Build a Recipe
7. Create an InBatch Runtime Client (InTouch) Application
8. Start the InBatch Runtime System
9. Schedule and Execute Batches
10. Execute an End-of-Batch Report
Model the Process
Double-click the ModelEdit icon on the Environment Display window. The
Process Modeling Editor main window is displayed.
Define Units
Units are equipment entities that hold, process and/or package materials.
Select the Units tab to display the Units editor. Use the Units editor to enter the
units as shown below.
Define Connections
Connections are defined by a source and a destination unit. If materials can move
between two units, then the connection must be defined. The way in which
materials move is not important at this time.
Select the Connections tab to display the Connections editor. Use the
Connections editor to enter the connections as shown below.
Define Process Classes
A Process Class is a group of one or more units that perform the same functions.
Select the Processes tab to display the Processes editor. Use the Processes editor
to enter the process classes and assign all of the units as shown below.
Process Class Name Assigned Units
BulkTks Bulk1, Bulk2
Mixers Mixer1, Mixer2
HoldTks Hold1, Hold2
Define Process Phases
Only define process phases for the classes of equipment that actually process
material. In our example, only the Mixers process material. The BulkTks and
HoldTks classes do not.
Select the Mixers process class and then click the Phases… button from the
Processes tab dialog. This displays the Edit Phases dialog. Enter the process
phases shown below.
Phase Name Phase Type
Mix Automatic
ManAdd Manual
Instruct Manual
In the Save History pane, select the Control/Status Activity and Parameter
Status check boxes for each phase in the Mixers class. If you do not set these
check boxes, then phase events and parameters will not be stored in the history
database.
Note You must select the Change button following any phase modifications.
Create Phase Control/Status Tags
All Automatic phases must have Phase Control and Status tags. These are the
tags that would ultimately be linked to the control system memory/register
addresses.
There is only one automatic phase in the Mixes class. Select the Mix phase from
the Phases list and then click Phase Control/Status... The Edit Phase
Control/Status dialog is displayed. Click Select All and then click Create Tags.
All tags needed to control and monitor the status of the Mix phase will be

automatically created.
Define Formula Parameters
Formula parameters are used to provide phases with information they need to do
their job. Parameter values are defined in the recipe and written to the control
system when the phase is executed. The recipe procedure determines when each
phase is executed.
Select the appropriate phase from the Phases list, then click the Formula
Parameters… button. The Edit Formula Parameters dialog will be displayed.
Enter the following parameters for each of the defined process phases.
Phase Parameter Parameter Type
Mix Speed_% Process Variable
Time_Min Process Variable
ManAdd Qty_Kgs Input
Configure both Mix formula parameters as follows:
1. Create tags for the Target and Actual elements by enabling the check box for
each and selecting the Create Tags button.
2. Set the Edit Allowed check box for the Target element.
3. Set the Enable Display check box for the Actual element.
Configure the ManAdd formula parameter as follows:
1. Set the Enable Display check box for the Target and Material ID elements.
2. Set the Edit Required check box for the Actual and Lot Code elements.
Note You do not have to create tags for the ManAdd phase.
Define Transfer Classes
A Transfer Class is a group of one or more connections that perform the same
functions. Within a Transfer Class, all of the source units are in the same process
class and all of the destination units are in the same process class. The source and
destination process classes can be the same.
Select the Transfers tab to display the Transfers editor. Use the Transfers editor
to enter the transfer classes and assign all of the connections as shown below.
Transfer Class Name Source Process Destination Process
Bulk_Mix BulkTks Mixer
Mix_Hold Mixer HoldTks

Transfer Class Name Assigned Connections

Bulk_Mix Blk1Mix1, Blk1Mix2, Blk2Mix1, Blk2Mix2
Mix_Hold Mix1Hld1, Mix2Hld2
Define Transfer Phases
Each transfer class should have at least one transfer phase defined. The phase is
responsible for moving material from a source unit to a destination unit.
Select a transfer class and then click the Phases… button from the Transfers tab
dialog. This displays the Edit Phases dialog. Enter the transfer phases shown
below.
Transfer Class Name Phase Name Phase Type
Bulk_Mix BulkAdd Automatic
Mix_Hold Transfer Automatic
In the Save History pane, select the Control/Status Activity and Parameter
Status check boxes for each phase. If you do not set these check boxes, then phase
events and parameters will not be stored in the history database.
Note You must select the Change button following any phase modifications.

Create Phase Control/Status Tags

As previously discussed for process phases, all Automatic phases require control
and status tags. These are the tags that would ultimately be linked to the control
system memory/register addresses.
Select the appropriate transfer class. Select the automatic phase defined for the
class from the Phases list and then click Phase Control/Status... button. The
Edit Phase Control/Status dialog is displayed. Click Select All and then click
Create Tags. All tags needed to control and monitor the status of the Mix phase
will be automatically created.

Define Formula Parameters

Select the appropriate phase from the Phases list, then click the Formula
Parameters… button. The Edit Formula Parameters dialog will be displayed.
Enter the following parameters for each of the defined transfer phases.
Transfer Class Name Phase Parameter Type
Bulk_Mix BulkAdd Qty_Kgs Input
Mix_Hold Transfer Qty_Kgs Output
Configure each of the formula parameters as follows:
1. Create tags for the Target and Actual elements by enabling the check box for
each and selecting the Create Tags button.
2. Set the Edit Allowed check box for the Target element.
3. Set the Enable Display check box for the Actual element.
4. Set the Enable Display check box for the Material ID element.
Define Segments
A segment is a subsection, that is, part of a connection. Segments are the lowest
equipment entities that are managed by InBatch. The segments that make up a
connection are allocated to a batch when a transfer is executed. This prevents
other transfers from using the same segments associated with their connection.
This permits the batch engine to provide some automatic process interlocking.
Select the Segments tab to display the Segments editor. Use the Segments editor
to enter the segments as shown below.
Assign Segments to Connections
Select the Connections tab to display the Connections editor. At the bottom of the
Connections tab dialog assign the required segments to appropriate connections.
Select the connection and then click the Assign Segments… button to display the
Assign Segments to Connection dialog. Select the required segments from the
Segments list and Apply to the connection as shown below.
Connection Name Segments
Blk1Mix1 Blk1_Dis, Common, Mix1_Chg
Blk1Mix2 Blk1_Dis, Common, Mix2_Chg
Blk2Mix1 Blk2_Dis, Common, Mix1_Chg
Blk2Mix2 Blk2_Dis, Common, Mix2_Chg
 Define Equipment Status
Equipment statuses apply to all units and segments in the system. The status of a
unit or segment is evaluated before it is allocated to a batch. The status must be
Available before it is allocated.
Select the Equipment Status tab to display the Equipment Status editor. Use the
Equipment Status editor to enter the segments as shown below.

Validate the Model

Select the File/Validate… menu option from the Process Modeling Editor main
window to check for modeling errors. Correct any discrepancies.
Use the Tag Linker
Double-click the TagLinker icon on the Environment Display window. The Tag
Linker main window is displayed. The Tag Linker is used to configure tags to
point to the control system and to export tags to a .csv file for use in InTouch.
Define Export Configuration
Select the Edit/Export… menu option. This displays the Export Editor dialog.
Configure this dialog as shown below.
Perform a Simulation Export
Select the File/Simulation Export… menu option. An Export Results dialog will
be displayed telling you what is being exported and when it is complete. The
Simulation Export performs two primary functions. First, it creates a .csv file for
the client type. Secondly, the InBatch Server creates a set of Tag Interface
Management (TIM) System tags using the Client Type name and the declared
Number of Clients, and creates a unique topic name for MIXER2.
Update the Runtime Databases
The InBatch Environment system provides the user with the ability to make off-
line changes to the process model and link databases. The Environment Display
Update/Runtime menu option copies the contents of the process model, link, and
TIM configuration databases to the corresponding runtime databases. This option
must be performed before the runtime system will recognize the latest changes.
Note This option is not permitted in a running system.
Define the Process Trains
Double-click the TrainEdit icon on the Environment Display window. The Train
Editor main window is displayed.
Enter train names and assign units to the trains as shown below.
Train Name Assigned Units
Mixer 1 Train Bulk1, Bulk2, Mixer1, Hold1
Mixer 2 Train Bulk1, Bulk2, Mixer2, Hold2
Defining the Materials and Material
Locations
Double-click the MtlEdit icon on the Environment Display window. The
Materials Status main window is displayed.
IMPORTANT You MUST select the Update/Runtime from the Environment
Display as described at the end of the previous section before continuing.
Define Materials
Select the Edit/Materials Editor… menu option on the Material Status main

window. The Materials Editor dialog is displayed.

Define the following ingredients.
Material ID Material Name UOM Hi Dev Low Dev
Flour 100 Pure White Flour LBS 1.0 1.0
Salt 200 Pure Salt LBS 1.0 1.0
CS102 Chicken Spice LBS 1.0 1.0
PS102 Pork Spice LBS 1.0 1.0
Define the following finished goods.
Material ID Material Name UOM Hi Dev Low Dev
CB1000 Chicken Breading LBS 1.0 1.0
PB1000 Pork Breading LBS 1.0 1.0
Define Material Locations
Select the Edit/Material Locations… menu option on the Material Status main

window. The Material Location Assignment Editor dialog is displayed.

Assign the bulk materials to the appropriate bulk tanks and define Lot Tracking
Information as shown below.
Material ID Material Name Unit Lot
Quantit
y
Flour 100 Pure White Flour Bulk1 Flour Vendor 1 50,000
Salt 200 Pure Salt Bulk2 Salt Vendor 3 30,000
Build a Recipe
Double-click the RecipeEdit icon on the Environment Display window. The
Recipe Editor main window is displayed. This editor is used to define a recipe.
Recipe Header
Select the Edit/Recipe Header… menu option on the Recipe Editor main window.
The Recipe Header dialog is displayed. Enter the Header information for the
Chicken Breading recipe as shown below.
Define Equipment Requirements
Select the Edit/Equipment Requirements… menu option on the Recipe Editor
main window. The Equipment Requirements Editor dialog is displayed. Select
the Add Processes… button and add the process classes as shown below.
Define Formula Inputs
Select the Edit/Formula Inputs… menu option on the Recipe Editor main
window. The Formula Inputs Editor dialog is displayed. Select the Add
Inputs… button and add the ingredients as shown below.
Define Formula Outputs
Select the Edit/Formula Outputs… menu option on the Recipe Editor main
window. The Formula Outputs Editor dialog is displayed. Select the Add
Outputs… button and add the finished goods as shown below.
Construct the Recipe Procedure
Construct the recipe procedure for the Chicken Breading product as shown on the
following pages.

Add Materials Operation

WaitSec(35)
Material: Flour 100
Qty_Kgs: 40%

Material: Salt 200

Qty_Kgs: 15%
Speed_%: 40
Time_Min: 8
Material: CS102
Qty_Kgs: 5%
 Mix Materials Operation
Speed_%: 10
Time_Min: 4
Material: Flour 100
Qty_Kgs: 40%

Speed_%: 10
Time_Min: 4

Ask(“ Mix Again?”)

Instruction: “Take Sample for

QA Test. Wait for Results.”

Ask(“Test OK?”)

Enable “ Ack On Entry”

Instruction: “Enter Speed and
Time, then Acknowledge.”
Discharge Operation

Material: CB1000
Qty_Kgs: 100%
Validate the Recipe
Select the File/Validate… menu option from the Recipe Editor main window to
check for configuration errors. Correct any discrepancies.
Note The recipe must be valid in order to schedule and execute.

Save the recipe

Select the File/Save… menu option from the Recipe Editor main window to save
the recipe. Enter the information shown below.
Approve the Recipe for Production.
Select the File/Approvals… menu option from the Recipe Editor main window to
approve the recipe. Enable the Approved for Production check box as shown

below.
Create an InBatch Runtime Client (InTouch)
Application
This section will describe the steps required to create the batch client application
using InTouch. Several windows will be created that use wizards, ActiveX
objects, and InBatch tags to represent the batch activity.
Note There are two alternatives to making batch tags available within the
InTouch application. The first involves importing the .csv file that was created by
selecting the File/Simulation Export… menu option in the Tag Linker into
InTouch using the DBLOAD utility. The second makes use of the tag browsing
and remote referencing capabilities on InTouch. The latter option will be used in
this example.

Create an Operator Interface on InTouch using InBatch

Wizards
Use the InTouch – Application Manager program to create a new InTouch
application named IB_Client. After the application has been created, select the
new application and start WindowMaker.
Note This example assumes that a screen resolution of 800x600 is used for the
InBatch Runtime Client application.
Define Windows
Create a new Popup window named Questions as illustrated below.

Insert the Batch Questions (w/Close) wizard in the center of this window with
the font settings of Courier New, 8pt, Bold.

Save the Questions window.

The Questions window should look similar to the one shown below.
Create a new Popup window named Equipment as illustrated below.

Insert the Equipment Allocation wizard in the center of this window with the

font settings of Courier New, 8pt, Bold.

Save the Equipment window.
The Equipment window should look similar to the one shown below.
Create a new Popup window named Errors as illustrated below.

Insert the Errors wizard in the center of this window with the font settings of

Courier New, 8pt, Bold.

Save the Errors window.
The Errors window should look similar to the one shown below.
Create a new full-screen, Replace window named Schedule as illustrated below.

Insert the Batch Scheduler/Dispatcher wizard at the top of this window with the
font settings of Courier New, 8pt, Bold.

Double-click the schedule wizard and change the List Size to 4.

Below the schedule wizard, insert the Active Batch List wizard with the font
settings of Courier New, 8pt, Bold.
Double-click the batch list wizard and change the List Size to 4.
To the right of the Active Batch List wizard, add a column of four
Batch/Phase/Misc Button wizards with font settings of Courier New, 8pt, Bold.
Double-click each of the buttons and configure each to have the following name
and action assignments.
Label Button Action
Batch Start Batch Start
Batch Hold Batch Hold
Batch Restart Batch Restart
Batch Abort Batch Abort
Below the schedule wizard, insert the Batch Comments wizard with the font
settings of Courier New, 8pt, Bold.

To the right of the Batch Comments wizard, add two button wizards using the
directions provided earlier with font settings of Courier New, 8pt, Bold.
Double-click each of the buttons and configure each to have the following label
and action assignments.
Label Button Action Window
Name
Batch Display Window Show: Show ‘Window Name’; Batch
Display
Equipment Window Show: Show ‘Window Name’; Equipment

Note The Batch Display window will be defined later. This step will have to be
completed after the Batch Display window is defined.
Save the Schedule window.
The Schedule window should look similar to the one shown below.
Create a new full-screen, Replace window named Batch Display as illustrated

below.
Insert the Active Phase List wizard at the top of this window with the font
settings of Courier New, 8pt, Bold.
Double-click the schedule wizard and change the List Size to 3.
Insert the Phase Parameter List wizard below the Active Phase List wizard with
the font settings of Courier New, 8pt, Bold.
Double-click the schedule wizard and change the List Size to 3.
Insert the Phase Instructions wizard below the Phase Parameter List wizard with
the font settings of Courier New, 8pt, Bold.
Double-click the schedule wizard and change the List Size to 3.
Insert the Phase Message Display wizard to the right of the Phase Instructions
wizard with the font settings of Courier New, 8pt, Bold.

To the right of the phase wizards, add a column of six Batch/Phase/Misc Button
wizards with font settings of Courier New, 8pt, Bold.
Double-click each of the buttons and configure each to have the following label
and action assignments.
Label Button Action
Phase Start Phase Start
Phase Hold Phase Hold
Phase Restart Phase Restart
Phase Abort Phase Abort
Ack On Entry Phase: Ack On Entry
Ack On Exit Phase: Ack On Exit
Add another Batch/Phase/Misc Button wizard with font settings of Courier New,
8pt, Bold.
Double-click each of the buttons and configure each to have the following label
and action assignments.
Label Button Action Window
Name
Schedule Window Show: Show ‘Window Name’; Schedule
Add the InBatch SFC Control to the bottom of the window and position

accordingly.
Save the Batch Display window.
The Batch Display window should look similar to the one shown below.
Modify Access Name
A default Access Name is created when an InBatch wizard is used in an
application. This access must be modified to point the InTouch batch client
application to the InBatch Server for runtime wizard data. Select the
Special/Access Names… menu option to display the Access Names dialog.
Modify the IB_TIM_TAGS access as shown below.
Set Initial Value for IB_TIM_ACCESS Tag
There are several tags created in the InTouch Tagname Dictionary when an
InBatch wizard is used in an application. One tag in particular must be modified
to point the InTouch batch client application to the InBatch Server for runtime
wizard data. Select the Special/Tagname Dictionary… menu option to display the
Tagname Dictionary. Modify the initial value of the IB_TIM_ACCESS_TAG

tag as shown below.

Define Complimentary Scripts
In order to complete the batch client application, several scripts are required.
These scripts will use several of the InBatch tags. These tags will be remotely
referenced from the InTouch tag browser.

Define Tag Sources

In order to use the InBatch tags within the scripts defined on the next few pages,
an InTouch tag source must be defined that points to the InBatch Tag Interface
Management (TIM) System tags. These are the wizard tags that provide access to
the runtime batch information from InTouch. Create the tag source shown below
from any script entry dialog. The Location will correspond to the configuration
directory (config_A) on the InBatch Server (MERCURY) node.
Questions Condition Script
Condition: IB_TIM_TAGS:BTRQ-QUES-NUMITEMS > 0
Condition Type: On True
Script: Show “Questions”;
Condition Type: While True (Every 5000 Msec)
Script: Show “Questions”;

Errors Data Change Script

Tagname: IB_TIM_TAGS:BTEE-MSG-NUMITEMS
Script:

Window Script
Window: Batch Display
Condition Type: On Show
Script: #InBatchSFCCtrl1.Host = "mercury";

Condition Type: On Hide

Script: #InBatchSFCCtrl1.Term();

InBatch SFC ActiveX Control Event Script

Double-click the InBatch SFC ActiveX control object to display the
InBatchSFC1 Properties dialog. Select the Events tab. Select the
SystemShuttingDown event and define the following script.
Script Name: TermControl
Script: #InBatchSFCCtrl1.Term();
Batch Focus Data Change Script
Tagname: IB_TIM_TAGS:BTB-SEL-SCHFOCUSOK
Script:
Start the InBatch Runtime System
Click the Runtime… button on the Environment Display window. The Runtime
Application Display dialog is displayed.
Select the Start All button in this dialog to start all of the runtime applications.
After the Server Applications are started, start the InTouch WindowViewer.
Schedule and Execute Batches
Double-click the BatchSched icon on the Environment Display window. The
Batch Scheduler main window is displayed.
Schedule the following batches.

Select the Initialize/All menu option from the Batch Scheduler main window to
change the status of all of the batches from Open to Ready.
From the InBatch Server
Double-click the BatchDspl icon on the Environment Display window. The Batch
Display main window is displayed.

Select the Windows/Schedule… menu option from the Batch Display main
window. This displays a list of available batches. Select a batch from the list. Start
the batch by clicking the Batch Start button.
Monitor the execution of the batch, answering any question, entering data for
manual phases and acknowledging phases when necessary.
From the InBatch Runtime Client (InTouch)
Make sure the InTouch WindowViewer application is running and displaying the
Schedule window.
Enter the information shown below and then click Add.
Campaign: C001
Lot: L002
Batch: 1
Recipe: CB1000
Quantity: 5000
Train: Mixer 1 Train
Click the Init Batch button to initialize the new batch. The batch status will
change from Open to Ready.
Select a batch from the list at the bottom of the Schedule window and click the
Batch Start button. After the batch status changes to Run, click the Batch
Display button to activate the Batch Display window.
Monitor the execution of the batch, answering any question, entering data for
manual phases and acknowledging phases when necessary until the batch is done.
Execute an End-of-Batch Report
Double-click the ReportDspl icon on the Environment Display window. The
Report Display main window is displayed.
Select the File/Open… menu option from the Report Display main window. This
displays a list of available reports. Select the B_Journal.rpt file.

Upon opening, the search criteria dialog will be displayed. Enter the information
shown below to generate a report for the batch executed.
After defining the search criteria, the report will be displayed containing all batch
information.