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End-of-life module / CPU replacement, keeping the existing program
Replace end-of-life Allen-Bradley controllers or modules with current replacement catalog numbers, convert and test the program, with no change to the operating logic.
Scope
- Survey of old catalog numbers, proposal of replacements and required accessories
- Backup of program and configuration before replacement
- Project conversion to the new firmware/version, checking tags, I/O, comms
- Replacement at the plant, I/O testing and trial run with operations
- Handover of the new backup + sign-off record
Not included
- Changes to control logic
- Replacement of hardware beyond the agreed module list
What the plant prepares
- Original program file available, or a PLC that can still be uploaded
- Shutdown window decided by the plant
| Duration | Confirmed after a survey — TDL states the scope and number of days before work starts |
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| Price | Quoted per scope after the survey |
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An end-of-life catalog number does not mean the program has to be rewritten. For most Allen-Bradley controllers, Rockwell publishes replacement catalog numbers and migration paths (the lifecycle page for each catalog number on rockwellautomation.com and the equivalence tables in the selection guides; for example, per 1769-SG003A: 1769-L31 and 1769-L32E → 1769-L30ER, 1769-L23E-QB1B → 1769-L24ER-QB1B; the L30ER takes no more than eight expansion modules, so larger systems need an L33ER or above). Before the replacement day, check the catalog numbers in use against those paths, check firmware and companion-module compatibility on the Product Compatibility and Download Center (PCDC), and convert the project in Studio 5000 in advance; the shutdown window is then left for removal, installation, I/O testing and the trial run with operations. Handover includes a new backup and a test record. Quick reference of migration paths for SLC 500, MicroLogix, 1768, PanelView, FLEX I/O and ControlNet: Upgrade paths for legacy Allen-Bradley systems.
Related project: Phu My Fertilizer Plant – demineralization system, redundant ControlLogix program migrated to new ControlLogix hardware.
Related services:
Lifecycle review and spare parts Rockwell Automation upgrades
Related technical articles
- MicroLogix 1500 faults: FAULT LED, S:6 major error code and how to get back to RUN
- Upgrade Paths for Legacy Allen-Bradley Systems: SLC 500, MicroLogix, 1768, PanelView, FLEX I/O, ControlNet
- CompactLogix 1769-L31, L32E, L35E, L23E end of life — migration path to 5370/5380
- 1756-ENBT end of life — replace with 1756-EN2T, EN2TR or EN4TR?
- Major faults on ControlLogix, CompactLogix and GuardLogix: reading Type/Code and what to check
All service packages (11)
