Lavatec tunnel washer control replacement: PLC-5 to ControlLogix
PLC-5 processor lead times: 14–20 weeks
Refurb PLC-5 processors are scarce. An unexpected processor fault brings the entire tunnel washer line to a standstill. Do not wait for an emergency. Plan the migration while you can still schedule it.
Lavatec tunnel washers and ironers in the LT and LS series almost all ran on Allen-Bradley PLC-5 controls. After Lavatec's 2009 bankruptcy there are no firmware updates, no OEM support, and no new I/O modules. GCG migrates the PLC-5 to a Rockwell Automation ControlLogix platform: including RSLogix 5 ladder conversion, PanelView HMI replacement, and drive integration via EtherNet/IP.
Lavatec machine series
| Series | Year | Tunnel pockets | Control | Status |
|---|---|---|---|---|
| LT-4 / LT-8 | ~1995–2007 | 4 / 8 | AB PLC-5 + PanelView 550 | EOL |
| LT-12 / LT-16 | ~2003–2009 | 12 / 16 | AB PLC-5 + PanelView 600 | EOL |
| LS-serie (enkele trommel) | ~1998–2009 | n.v.t. | AB PLC-5 + DTAM | EOL |
Technical architecture PLC-5 platform
Allen-Bradley PLC-5 processor
1771 backplane with processor types PLC-5/15, PLC-5/25 or PLC-5/40. Program storage on EEPROM cartridge, no cloud backup. Refurb processors are the only replacement, lead times 14–20 weeks, no guarantee on remaining service life.
1771 I/O modules
Analogue modules (thermocouple NiCr, 4–20 mA) and digital I/O for valve control and level sensors. No hotswap: every card change requires control shutdown. Production stop for one faulty card.
PanelView / DTAM HMI
PanelView 550/600 or DTAM module as operator interface. Resistive touchscreen, monochrome or early colour display. Backlight and touch foil have not been available from Rockwell for years, secondhand only.
RS-232 drive communication
Variable frequency drives (Allen-Bradley 1305/1336 or Danfoss VLT) connected via serial RS-232. No remote diagnostics, no network parameter backup. On drive fault: manual reconfiguration at the drive panel.
Installed base Netherlands and Belgium
North Holland / Amsterdam
Hotel laundries (large and five-star segment), Sanquin Blood Bank, AMC/OLVG laundry.
South Holland / Rotterdam-Rijnmond
Port-area hospitality, Erasmus MC central sterilisation, textile rental (Berendsen/CWS).
Gelderland / Goudkuil cluster
Barneveld, Nijkerk, Ede: workwear and hospitality rental. Goudkuil Barneveld acquired Lavatec US assets after the bankruptcy.
Migration platform: Rockwell ControlLogix
GCG migrates to the Rockwell Automation ControlLogix 5580 platform with PanelView Plus 7 HMI and Studio 5000 Logix Designer as engineering environment. Existing wash recipes are fully transferred to FactoryTalk recipe management.
PLC
Allen-Bradley PLC-5 (1771-backplane)
ControlLogix 5580 (1756-chassis)
HMI
PanelView 550/600 of DTAM
PanelView Plus 7 (10"/12")
Engineering software
RSLogix 5
Studio 5000 Logix Designer
Drive communication
RS-232 serieel
EtherNet/IP (PowerFlex 525/755)
Migration steps
- 1
PLC-5 dump & I/O inventory
Complete RSLogix 5 program export, inventory of all 1771 modules (analogue/digital), drive parameter recording, wash recipe documentation.
- 2
Cable audit & ControlLogix chassis engineering
Channel mapping 1771→1756, cabling plan, selection of new I/O modules, control cabinet design (optional renewal). EtherNet/IP switch for drives.
- 3
Studio 5000 engineering & FAT
Ladder conversion RSLogix 5 → Studio 5000, PanelView Plus 7 screens built in FactoryTalk View Studio, drives integrated via EtherNet/IP, Factory Acceptance Test.
- 4
SAT & wash recipe qualification
On-site commissioning, wash recipe verification on production material, operator training, 4-week follow-up. Downtime typically 48–72 hrs (LT-4/LT-8) or 72–96 hrs (LT-12/LT-16 + combination line).
FAQ
Can my PLC-5 program be converted 1:1 to ControlLogix?
RSLogix 5 ladder is largely convertible to Studio 5000. Instructions exclusive to PLC-5 (such as MSG to 1771-SN scanner) are rewritten. Recipe and process logic for wash, rinse, and spin cycles remain unchanged.
What does a Lavatec refit cost?
A standard LT-4/LT-8 migration costs EUR 18,000–28,000 including engineering, hardware, and commissioning. Larger LT-12/LT-16 or combination line installations: EUR 28,000–45,000. Exact quote after I/O audit.
How long is the tunnel washer line down?
Typically 48–72 hrs for LT-4/LT-8. An LT-12 or combination line (tunnel washer + ironer + dryer): 72–96 hrs. GCG always schedules commissioning over a weekend to minimise production loss.
Goudkuil Barneveld services our Lavatec machines. Can you work together?
Yes. Goudkuil Barneveld (purchaser of Lavatec US assets after the 2009 bankruptcy) is an adjacency partner of GCG. Goudkuil provides mechanical maintenance and Lavatec spare parts; GCG provides the control refit. Contact us for a combined approach.
Are our wash recipes preserved after the migration?
Yes. All recipe parameters (temperature, water level, dosing times, rotation profile, spin time) are read out, documented, and transferred 1:1 into the new FactoryTalk recipe system. After migration, operators work with familiar process values.