As Rockwell Automation phases out the MicroLogix family of controllers, many industries are migrating to the modern Micro800 series. This migration not only ensures long-term support and spares availability, but also unlocks new capabilities and cost savings for small to mid-size control applications.
Upgrading from MicroLogix to Micro800 offers multiple advantages:
| Benefit | Description |
|---|---|
| π οΈ Product Lifecycle | MicroLogix is nearing end-of-life; Micro800 is the long-term supported platform |
| β‘ Performance Boost | Faster processing, better memory, enhanced I/O and communication options |
| π° Cost Optimization | Micro800 offers modular designs at competitive pricing |
| π Flexible Programming | Uses Connected Components Workbench (CCW) β intuitive and versatile |
| π Communication Ready | Native support for Ethernet/IP, USB, Serial, and remote I/O configurations |
| π Enhanced Security | Password protection, user access levels, and better firmware management |
Before planning your Micro800 migration, consider the following:
Identify all existing MicroLogix units (1100, 1200, 1400, 1500)
Note I/O types (analog/digital), expansion modules, and comms configuration
Backup all MicroLogix programs (*.RSS format from RSLogix 500)
Document key logic sequences, hardware dependencies, and data types
Match MicroLogix I/O specs with Micro800 models (e.g., 850, 820, 810)
Check availability of required expansion modules and communication adapters
MicroLogix uses RSLogix 500; Micro800 uses CCW
Reprogramming or conversion using RSLogix to CCW logic mapping is often needed (no direct import available)
Evaluate control panel layout and DIN rail space
Plan for rewiring or signal adaptation, especially for I/O point changes
Hereβs a step-by-step approach to implement a smooth migration:
Create a detailed list of all MicroLogix units and I/O configurations.
Record firmware versions, network settings, and wiring diagrams.
Choose a Micro800 model (Micro820 for compact, Micro850 for modular, etc.)
Select matching plug-in modules and communication interfaces
Start a new project in Connected Components Workbench (CCW)
Recreate ladder logic using reusable function blocks
Validate all timers, counters, analog scaling, and PID blocks
Simulate logic in CCW with hardware test bench (if possible)
Verify I/O status, comms, and controller behavior before deployment
Replace or rewire terminals, I/O, and power supply as needed
Install and mount the new Micro800 controller and modules
Download program, establish communications
Conduct I/O verification, interlock checks, and safety tests
Brief plant staff on new interface, troubleshooting methods, and maintenance best practices
Save the final CCW project and upload backup to a secure location
Update control schematics and panel documentation
Use the MicroLogix-to-Micro800 Selection Guide from Rockwell for accurate hardware matching
Where applicable, use plug-in analog or communication modules to save space
Plan migration during scheduled downtime or phased equipment upgrades
Maintain spare Micro800 controllers for faster replacements
Migrating from MicroLogix to Micro800 is a strategic move for future-proofing your control systems. With proper planning, the right tools, and structured execution, your plant can benefit from improved flexibility, performance, and long-term support.
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