5 Critical Rockwell Automation End Of Life Deadlines And Your Urgent 2025 Migration Strategy

The clock is ticking for many industrial facilities relying on legacy Rockwell Automation hardware and software. As of December 10, 2025, a wave of critical End of Life (EOL) and Discontinuation dates is approaching, most notably for the iconic RSLogix 5 software platform and a range of Allen-Bradley components. Ignoring these deadlines poses a severe risk to operational stability, leading to potential catastrophic downtime, unsupportable systems, and escalating maintenance costs in the near future.

Proactive migration planning is no longer optional; it is a critical business imperative. This comprehensive guide breaks down the most urgent Rockwell EOL announcements, details the hidden risks of delaying an upgrade, and outlines the official and most effective migration paths to modern platforms like ControlLogix, ensuring your facility remains secure, supported, and future-ready.

The Rockwell Automation Product Lifecycle: Understanding EOL Statuses

Rockwell Automation uses a clear, four-stage lifecycle status to help customers manage their assets. Understanding these statuses is the first step in creating a forward-looking maintenance and upgrade strategy. The most critical statuses signal an impending need for action.

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• Active: The product is the current offering and is fully supported.
• Active Mature: The product is fully supported, but a newer product or family exists. This is the ideal time to start budgeting and planning a migration to gain value from newer technology.
• End of Life (EOL): The product is still available for sale, but a discontinued date has been announced. Migration planning must be prioritized.
• Discontinued: The product is no longer manufactured or sold by Rockwell Automation. Support is severely limited or non-existent, making the product a major operational risk.

5 Critical End of Life Deadlines You Must Know for 2025

While the PLC-5 controller has been officially Discontinued for some time, several other major components and software platforms are hitting final, hard deadlines in 2025. These are the most urgent items on the industrial automation EOL calendar:

1. RSLogix 5 Software (Final Discontinuation): The programming software for the PLC-5 platform reaches its final lifecycle phase on December 31, 2025. After this date, new activations for RSLogix 5 will no longer be available for purchase. For systems still running on this software, this is the final warning to convert to the modern Studio 5000 Logix Designer platform.
2. 800F-AFAU2CE152 22mm Accessory: This Allen-Bradley accessory for push buttons is scheduled for Discontinuation on June 30, 2025. A replacement product, the 800F-AFAU2CE100G, is available, making this a straightforward, necessary hardware swap.
3. 7703E-FS1FX Product Line: A specific Allen-Bradley product line (7703E-FS1FX) is scheduled for Discontinuation on February 28, 2025, with no planned direct Rockwell replacement. Customers must remove references to this product and seek an alternative solution.
4. FactoryTalk VantagePoint EMI Server: While the exact 2025 date is variable, FactoryTalk VantagePoint has announced its End of Life. This manufacturing intelligence software requires a migration to a modern data analytics platform to maintain reporting and historical data capabilities.
5. PLC-5 Control Platform (Ongoing Risk): Although officially Discontinued, the operational risk of the PLC-5 skyrockets as its associated software, RSLogix 5, is retired. The scarcity of replacement parts and the lack of vendor support mean a single hardware failure can result in days or weeks of costly, unscheduled downtime.

The Hidden Risks of Delaying Migration

The cost of replacing a controller or software license can seem high, but it pales in comparison to the financial and operational risks of running Discontinued equipment. These risks represent the true cost of inaction:

• Unscheduled Downtime and Production Loss: The most significant risk. When a Discontinued component fails, replacement parts are often only available on the volatile third-party market, leading to extended lead times and massive production halts.
• Security Vulnerabilities: Legacy software like RSLogix 5 and outdated hardware do not receive security patches, leaving your control network vulnerable to modern cyber threats and breaches.
• Lack of Technical Support: Rockwell Automation will not provide technical support, firmware updates, or bug fixes for Discontinued products. Troubleshooting a complex issue without manufacturer support is incredibly difficult.
• Limited Integration: Older platforms cannot easily integrate with modern Industrial Internet of Things (IIoT) technologies, cloud services, or advanced analytics, preventing your facility from benefiting from digital transformation initiatives.

Strategic Migration Paths: Your Upgrade Roadmap

The goal of any EOL migration is not just to replace an old part, but to upgrade your entire control system to a modern, scalable, and fully supported platform. Rockwell’s migration strategy primarily focuses on moving to the ControlLogix platform, which offers superior performance, security, and integration capabilities.

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1. PLC-5 and RSLogix 5 to ControlLogix Migration

The most common and critical migration involves moving from the PLC-5 and its associated RSLogix 5 software to the ControlLogix platform, programmed using Studio 5000 Logix Designer. Rockwell offers a structured approach to minimize risk and downtime:

A. Hardware Conversion Options

• The Conversion Rack Method: This is often the lowest-risk and quickest path. It involves installing a 1756 Conversion Rack, which allows a new ControlLogix processor to be installed while utilizing the existing PLC-5 I/O wiring and chassis. This significantly reduces wiring time and field work.
• The Scanner Card Method: An alternative is to replace the PLC-5 processor with a scanner card (e.g., a ControlLogix Processor with a scanner) that turns the existing PLC-5 rack into an I/O rack for the new ControlLogix system.

B. Software Conversion

The existing PLC-5 logic must be converted to the Logix-based logic used by ControlLogix. Rockwell provides tools and resources within the RSLogix 5 software itself (like a "Save As" function) to help initiate the conversion process, although a full code review and optimization are always necessary.

2. FactoryTalk VantagePoint Replacement Strategy

For users of the FactoryTalk VantagePoint EMI Server, the migration involves moving to a modern manufacturing intelligence or data historian platform. Rockwell’s recommended pathway is often the ThingWorx platform, which offers advanced IIoT and analytics capabilities.

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However, many companies also look at third-party alternatives that specialize in data analysis and reporting, such as TrendMiner for self-service analytics or XLreporter for Excel-based reporting, depending on their specific needs. Choosing the right replacement ensures continuity of historical data and reporting functionality.

3. General Component EOL (e.g., 800F-AFAU2CE152)

For individual component EOLs, the strategy is straightforward: identify the official replacement product listed by Rockwell Automation and schedule a direct swap. These migrations are typically low-risk and can be performed during scheduled maintenance windows, but they must be planned before the Discontinuation date to ensure parts availability.

Conclusion: The Future is ControlLogix and Studio 5000

The year 2025 marks a definitive turning point for many legacy Rockwell Automation users. The impending final discontinuation of RSLogix 5 and the ongoing obsolescence of the PLC-5 platform are clear signals that the era of older control systems is ending. By embracing a proactive, phased migration approach to the modern ControlLogix platform and Studio 5000 Logix Designer, businesses can drastically reduce their operational risk, lower long-term maintenance costs, and unlock the full potential of IIoT and advanced manufacturing technologies. Start your migration planning today to secure your future tomorrow.