Managed End-of-Life PLC Upgrades

End-of-Life PLC Controls for Data Centers, Hospitals, and Other Critical Facilities

Micrologix 1100 PLCs EOL March, 1 2022

Micrologix 1000 PLCs EOL March 1, 2017

Hundreds of Dot-Com Era (1998 – 2002) data centers are still in service throughout the US and world.  Many of these facilities are very valuable because they occupy locations close to large cities and fiber optic infrastructure.  Earthsafe built fuel systems for many of these facilities, and our systems have operated reliably over that time with very little maintenance.

Allen Bradley is our standard PLC for our controllers.  One of the primary reasons is their back integration, meaning that new PLC, HMIs, and Networks will integrate to the older model PLCs.  Now we are at the second generation of their micro PLCs from the Dot-Com era Micrologix 1000 / 1500 > Micrologix 1100 / 1400 > Micro 820 / 850.  After more than 20 years in service, Allen Bradley has stopped production of the Micrologix 1000 / 1500.

End of Life for Micrologix 1000/1500: There are several million Micrologix 1000 and Micrologix 1100 PLCs in service around the world, including thousands in critical service in data center equipment.

Hundreds of Dot‐Com Era (1998 – 2002) data centers are still in service throughout the US and world. Many of these facilities are very valuable because they occupy locations close to large cities and fiber optic infrastructure. Earthsafe built fuel systems for many of these facilities, and our systems have operated reliably over that time with very little maintenance.

Allen Bradley PLC Migration: Allen Bradley is our standard PLC for our controllers. One of the primary reasons is their back integration, meaning that new PLC, HMIs, and Networks will integrate to the older model PLCs.

Now we are at the second generation of their micro PLCs from the Dot‐Com era Micrologix 1000 / 1500 > Micrologix 1100 / 1400 > Micro 820 / 850. After more than 20 years in service, Allen Bradley stopped production of the Micrologix 1000 / 1500, in 2017.

Not Just a Hardware Swap: It is not simply a matter of a hardware swap:

1. Application Software Changes: The new Micro 800 PLCs and HMI use a new application software called Connected Components Workbench (CCW), replacing RS Logix 500/5000 on the old PLCs. The software change requires that the programming for the replacement PLCs must be re‐written on the new platform.
2. Network Standard: The obsolete ML1000/1100s typically used an RS‐485 based network for communication. The new Micro 800s have built‐in Ethernet for peer‐to‐peer networking, although they still maintain an RS232/485 Port.
3. Room‐to‐Improve Redundancy: System upgrades include a performance review to address any inadequacies. This may be an opportunity to get full dual control, rather than a single element + bypass.

Ethernet Built-In:  The Micrologix 1100 was the first Allen Bradley Micro-controller to have built-in ethernet capability for peer-to-peer data communication.  The older Micrologix 1000 had only serial communication RS-232, with even RS-495 requiring an adaptor module.  

The 1100 allowed for some great modular control systems so that day tanks, duplex pump sets, filter polishers, fill stations, and promary control panels could all talk to each other with fast simple ethernet connection.

Hundreds of mission critical fuel systems for data centers, hospitals, and secure facilities were installed with Micrologix 1100 controllers.

The reason for migration from end-of-life PLCs is to handle the what-ifs.  Our systems typically are designed with modularity and bypass systems to allow operation with some fault tolerance.  But end of life means that a quick fix of swapping out a PLC is not an option.

Thinking ahead, let us review your system and provide a proposal for a planned transition.  Contact: tech@earthsafe.com 

End of Life for Siemens S7‐200: There are several million Siemens S7‐200 PLCs in service around the world, including thousands in critical service in data center equipment.

Hundreds of Dot‐Com Era (1998 – 2002) data centers are still in service throughout the US and world. Many of these facilities are very valuable because they occupy locations close to large cities and fiber optic infrastructure.

Siemens PLC Migration: After more than 18 years in service, Siemens stopped production of the S7‐200, in 2017. The replacement PLC is the S7‐1200.

Not Just a Hardware Swap: It is not simply a matter of a hardware swap:

1. 1. Application Software Changes: The new S7‐1200 PLCs and HMI use a new application software called TIA – Total Integrated Automation, replacing Step 7 on the old PLCs. The software change requires that the programming for the replacement PLCs must be re‐written on the new platform.
2. 2. Network Standard: The obsolete S7‐200s typically used an RS‐485 based network for communication. The new St‐1200s have built‐in Ethernet for peer‐to‐peer networking, although they still maintain an RS232/485 Port.
3. 3. Room‐to‐Improve Redundancy: System upgrades include a performance review to address any inadequacies. This may be an opportunity to get full dual control, rather than a single element + bypass.

Earthsafe Technical Services

We can design upgrade solutions for existing controllers by replacing PLCs within existing cabinets or removing and replacing existing control panels.  In either case existing networks can remain in place, and work sequences can assure no interruption of service.

Besides End-of-Life planning there are a number of reasons to upgrade. New PLCs are cheaper, better, faster as you would expect. New color touch-screen HMIs are much less expensive, and can replace the hassle of maintaining the older panel incandescent lamps with lamp test pushbuttons. And industrial grade ethernet networks can replace RS-485 networks.

Upgrade / Replace Any Control Brand

Earthsafe has excellent experience upgrading and replacing controls of other manufacturers.  We have trained personnel for control panel PLCs / HMIs / Networking based on:

• Allen Bradley
• Schneider
• Siemens
• GE Fanuc
• Automation Direct / Toyo
• IDEC / Panasonic / Mitsubishi

Representative Experience

Data Center USA-TX: Replaced an existing Mitsubishi fuel control system for 6 generators and expanded to 12 generators.  Replaced existing RS-485 network with industrial ethernet.  Maintained full operation of existing system throughout.

Data Center USA-IL: Replaced an existing Single-Point-of-Failure fuel systems control based on Panasonic PLCs.  Installed redundant PLC controls based on new Allen Bradley PLCs and HMI.  Maintained system operation for the 4 existing generators.

Data Center USA-CA: Expanded an existing fuel system from 4 to 8 generators with integration to existing PLCs – HMIs based on Siemens. Maintained existing service throughout transition.

Data Center: USA-CA: Replaced existing End-Of-Life PLCs with new Allen Bradley PLCs-HMIs for a 6 generator, 4 bulk tank system.  Sequenced work to assure continuous operation.

Data Center: USA-SC: Designed, programmed and commissioned fuel system controls for 12 generators based on Automation Direct PLCs – HMIs.

Data Center: Dublin-IE: Designed, programmed, and commissioned fuel system controls for 6 generators based on Schneider PLC-HMI.

Data Center: Dharan-SA: Designed, programmed, and commissioned fuel system controls for 4 additional generators based on existing IDEC PLC-HMI.  Integrated to an existing master controller based on Schneider PLC-HMIs.