Kannegiesser tunnel washer modernisation: Siemens S5 to S7-1500
Siemens S5: no firmware updates, no CPU replacement via Siemens
Siemens officially ended S5 support in 2013. Replacement S5 CPUs come exclusively from the secondhand market, lead times undefined. Any unexpected CPU failure stops the tunnel washer until a replacement is found.
Kannegiesser (based in Vlotho, Westphalia) is an active industrial laundry equipment manufacturer, but the POWER-TRANS and PERMALOC tunnel washers from the S5 generation are no longer supported. GCG migrates the Siemens S5 control to S7-1500 via TIA Portal, including energy optimisation with variable-speed drives for pumps and drums. The Polish hospitality and healthcare sector is growing rapidly: a modern control extends machine service life by 10–15 years and reduces energy consumption by 15–25%.
Kannegiesser machine series
| Series | Year | Control | Status |
|---|---|---|---|
| POWER-TRANS classic | ~1985–2005 | Siemens S5-115U | EOL |
| PERMALOC / Warmpress | ~1990–2008 | S5-135U | EOL |
| ECOSTAR (vroeg) | ~2005–2012 | S5/S7 mix | Partial EOL |
| ECOSTAR+ / nieuw | 2012+ | S7-300/400 | Active |
Technical architecture S5 platform
Siemens S5-115U / S5-135U CPU
EPROM/RAM memory cards, proprietary STEP 5 programming language. Siemens officially ended support in 2013. The secondhand market is the only source for replacement CPUs: lead time undefined, quality uncertain.
S5 I/O modules (digital + analogue)
Central rack with digital I/O for valve control, level sensors, and temperature measurement. No hotswap; every I/O module change requires control shutdown. Analogue modules for wash temperature and water level.
Siemens OP panel / TD200
Early operator panels (OP5/OP7/OP17/TD200) with text display and function keys. No touchscreen, no colour, no Ethernet. Firmware updates are no longer available; dead pixels or backlight failure means operating blind.
Drives without feedback loop
Pumps and drums driven at fixed speed via direct motor starters or early VFDs without network coupling. No energy metering, no remote diagnostics. Energy consumption 15–25% higher than with modern variable-speed drives.
Installed base Poland and surrounds
Masovian / Warsaw
Hotel laundries (Marriott, Hilton, IHG), hospital central laundries (WUM, CSK MCS), textile rental.
Lesser Poland / Kraków
Heritage and congress hotels, Szpital Uniwersytecki central laundry, growing wellness sector.
Lower Silesia / Wrocław
Hospitality boom driven by tech industry presence, medical sector (4 Wojskowy Szpital), workwear laundries.
Migration platform: Siemens S7-1500 + TIA Portal
GCG migrates to the Siemens S7-1500 platform with TIA Portal V18 engineering and a modern KTP or TP Comfort Panel HMI. Customers preferring a vendor-independent platform can choose a B&R X20 migration with mapp View HMI.
PLC
Siemens S5-115U / S5-135U
S7-1500 (1511 / 1515)
HMI
OP5/OP7/OP17/TD200
KTP700 / TP1200 Comfort
Engineering software
STEP 5
TIA Portal V18
Drives
Fixed speed / RS-232
SINAMICS G120 via PROFINET
Migration steps
- 1
S5 dump & energy measurement (baseline)
Complete STEP 5 program export via PG (programming unit), I/O module inventory, wash recipe documentation, energy consumption measurement as baseline for post-migration comparison.
- 2
S7-1500 chassis engineering & cable audit
S5 → S7-1500 I/O channel mapping, SINAMICS G120 drive selection per motor, control cabinet design, PROFINET network plan, on-site cabling audit.
- 3
TIA Portal engineering & FAT
STEP 5 ladder conversion to TIA Portal structured text/ladder, HMI screens built in WinCC Comfort, SINAMICS drives parameterised via PROFINET, Factory Acceptance Test.
- 4
SAT + energy verification
On-site commissioning, wash recipes verified on production material, energy consumption measured and compared with baseline, operator training, 4-week follow-up. Expected energy savings: 15–25%.
FAQ
Can the STEP 5 program be converted to TIA Portal?
Yes. Siemens provides an S5 conversion tool in TIA Portal, but the result must always be manually reviewed and tested. GCG fully converts wash logic, recipe management, and alarms, and optimises drive parameters for energy savings.
What are the costs of a Kannegiesser refit?
A standard POWER-TRANS tunnel washer migration costs EUR 19,000–30,000 including engineering, hardware, and commissioning. Combination lines with ironer or dryer: EUR 28,000–45,000. Exact quote after S5 dump and I/O audit.
How much energy do we save after the migration?
Typically 15–25% energy savings through variable-speed drives (pumps and drums) and optimised drive parameters. Exact savings depend on the wash pattern and machine type. GCG measures before and after migration.
How long is the line down during migration?
Typically 48–72 hrs for a single tunnel washer. Combination lines (tunnel washer + ironer + dryer): 72–96 hrs. GCG always plans commissioning over a weekend to minimise production loss.
Are the wash recipes preserved?
Yes. All recipe parameters (temperature, water level, dosing times, rotation speed, spin time) are read out, documented, and transferred 1:1 into the new WinCC Comfort recipe system. Operators recognise all process values after migration.