PLC · Allen-Bradley · ControlLogix 5590 · L9 · Studio 5000 · EtherNet/IP
ControlLogix 5590 PLC (L9): Specifications, Features, Four Operating Modes and How It Compares to the 5580
The Allen-Bradley ControlLogix 5590 (L9) is Rockwell Automation's newest generation of ControlLogix controllers, launched in late 2025. It delivers up to 80 MB memory, 512 motion axes, 600+ EtherNet/IP nodes, dual gigabit Ethernet ports, built-in SIL 2/PLd safety in every variant, and OPC UA connectivity, all in a single-slot chassis-based design that is backward-compatible with the 5580 (L8) generation.
What Is the ControlLogix 5590 PLC?
The ControlLogix 5590 is the latest generation of Allen-Bradley ControlLogix programmable logic controllers from Rockwell Automation, designated the L9 family. It replaces the ControlLogix 5580 (L8) as the flagship controller in the ControlLogix platform, which has been the dominant large-scale PLC platform in North American process and manufacturing industries for over two decades.
Where the 5580 (L8) was designed for high-performance control in the mid-2010s, the 5590 (L9) is designed for the demands of the mid-2020s: larger programs, more connected devices, integrated safety without a separate safety controller, OPC UA and MQTT connectivity for cloud and MES integration, and cybersecurity built into the hardware from the start. It is the first ControlLogix generation that includes SIL 2/PLd functional safety capability in every controller variant, not just in a separate GuardLogix model.
The 5590 is programmed using Studio 5000 Logix Designer version 38 or higher, and from November 2025, also supports FactoryTalk Design Studio v2.03 for cloud-based engineering workflows. It supports the same five IEC 61131-3 programming languages as all Logix controllers: Ladder Diagram (LD), Function Block Diagram (FBD), Structured Text (ST), Sequential Function Chart (SFC), and Instruction List (IL). For context on how PLCs fit in industrial automation, see our guide on PLC vs RTU differences.
ControlLogix 5590 Key Specifications
| Parameter | ControlLogix 5590 (L9) | Notes |
|---|---|---|
| Product family designation | 1756-L9xx series | Example: 1756-L980 = 80 MB model. Memory size visible in catalog number. |
| User memory | 2 MB to 80 MB | Double the maximum of the 5580 (40 MB max). More memory supports larger programs, more tags, richer diagnostics and complex logic. |
| Motion axes supported | Up to 512 real and virtual axes | Supports CIP Motion over EtherNet/IP. Suitable for large packaging lines, robotics cells and coordinated motion applications. |
| EtherNet/IP nodes | 600+ per controller | Double the node capacity of the 5580 (300+ nodes). Supports large-scale I/O architectures and distributed control. |
| OPC UA nodes | Up to 100,000 | Native OPC UA server for vendor-neutral data access from SCADA, MES, historians and cloud platforms without OPC bridges. |
| EtherNet/IP ports | 2 x 1-Gigabit RJ45 | Both ports can be used simultaneously. Supports Dual IP mode, Device Level Ring (DLR) and linear topologies. |
| Local programming port | USB-C | Replaces the USB-A port of the 5580. Used for firmware flashing, project download/upload, online monitoring. |
| Removable storage | 8 GB MicroSD card (included) | Supplied with every 5590. Used for firmware storage, project backup, and datalog archiving. |
| Safety rating | SIL 2/PLd standard; SIL 3/PLe with 1756-L9SP safety partner | SIL 2/PLd built into every variant. No separate GuardLogix controller needed for SIL 2 applications. |
| Redundancy | 1756-RM3 redundancy module required | Bumpless switchover between primary and secondary controller. Front Ethernet ports now usable for crossloading in redundancy mode (improvement over 5580). |
| Cybersecurity | IEC 62443-4-2 compliant | CIP Security (TLS/DTLS encryption and device authentication), secure boot, role-based access control. |
| Modern protocols | OPC UA, MQTT, REST | MQTT and REST supported via machine builder libraries. Enables direct IoT connectivity without middleware. |
| Chassis slots | Single slot | Same physical form factor as 5580. Compatible with existing 1756 chassis. |
| Scan time improvement | 2x faster than 5580, 40x faster than 5570 | Based on Rockwell Automation internal testing. Significant for large programs and tight motion control loops. |
| Variants available | Standard, XT, P (Process) | XT: corrosion-resistant for harsh environments. P: optimised for process control with integrated safety and redundancy. |
| Backward compatibility | Compatible with 5580 and 5570 I/O modules and chassis | Upgrade without replacing I/O infrastructure. Same Studio 5000 toolchain. |
New Physical Hardware Features on the ControlLogix 5590
Beyond the performance numbers, the 5590 introduces several visible hardware changes compared to the 5580. Field engineers and technicians upgrading from the L8 generation will notice these immediately on the front face of the controller.
Figure 1: ControlLogix 5590 (L9) front panel. Key hardware changes from the 5580 (L8): vertical lift door hiding QR code and USB-C port, replacement of the traditional 3-position key switch with a mode switch, addition of a second 1-Gigabit EtherNet/IP port, and an 8 GB MicroSD card included with every unit.
Four ControlLogix 5590 Operating Modes
Every ControlLogix 5590 controller can be configured for one of four operating modes. This is a significant advance over the 5580 generation, where safety applications required a separate GuardLogix controller and redundant safety required a separate Logix SIS architecture. With the 5590, all four modes are available from the same hardware variant, selected through firmware configuration rather than hardware purchase.
Discrete, process, motion and drive control. No safety task enabled. The controller executes standard tasks with full performance and access to all 600+ EtherNet/IP nodes and 512 motion axes. For applications with no functional safety requirement or where safety is handled by a separate dedicated SIS system. Compatible with Modbus TCP and other third-party protocols via add-on instructions.
Safety task enabled alongside standard tasks. SIL 2/PLd (Category 3) is achieved using the safety task alone with safety I/O modules connected via CIP Safety over EtherNet/IP. SIL 3/PLe (Category 4) requires the 1756-L9SP safety partner module installed in the same chassis. This eliminates the need for a separate GuardLogix controller for most process and machine safety applications.
Two 5590 controllers paired with a 1756-RM3 redundancy module achieve bumpless switchover between primary and secondary controllers. The primary executes standard tasks and crossloads data to the secondary via the dual front Ethernet ports (new in L9: the L8 could not use front ports in redundancy mode). Designed for non-safety high-availability applications.
Both primary and secondary controllers simultaneously execute the safety task, with all safety data synchronised. Standard tasks execute on the primary only. Achieves up to SIL 3/PLe in a redundant configuration. Designed for safety-critical process applications requiring both high safety integrity and high availability, replacing traditional separate SIS/ESD hardware in some applications.
ControlLogix 5590 vs 5580: What Changed in the L9 Generation
| Feature | ControlLogix 5580 (L8) | ControlLogix 5590 (L9) | Improvement |
|---|---|---|---|
| Maximum user memory | 40 MB | 80 MB | 2x more memory |
| Scan time | Baseline | Approximately 2x faster than L8 | 2x faster (40x faster than L7/5570) |
| EtherNet/IP nodes | 300+ per controller | 600+ per controller | 2x node capacity |
| Motion axes | 256 axes | 512 axes | 2x motion capacity |
| OPC UA nodes | Limited OPC UA support | Up to 100,000 OPC UA nodes | Major expansion for IIoT connectivity |
| Built-in safety | Requires separate GuardLogix for SIL 2 | SIL 2/PLd in every variant standard | Eliminates separate safety controller |
| Front Ethernet ports in redundancy | Not usable in redundancy mode | Usable for crossloading in redundancy | Reduces need for additional comms modules |
| Local programming port | USB-A | USB-C | Modernised connector |
| Front door | Standard bezel | Vertical lift door with QR code | Easier access to QR resource links |
| Removable storage | SD card (optional) | 8 GB MicroSD (included standard) | Storage included with every unit |
| MQTT / REST support | Not native | Via machine builder libraries | Direct IoT/cloud connectivity |
| Cybersecurity standard | CIP Security supported | IEC 62443-4-2 compliant + CIP Security + secure boot | Higher security certification level |
| Chassis compatibility | 1756 chassis | Same 1756 chassis | Backward compatible: reuse existing chassis |
ControlLogix 5590 Connectivity and IIoT Integration
The 5590 is Rockwell Automation's most connected controller to date. The dual 1-Gigabit EtherNet/IP ports support linear and Device Level Ring (DLR) topologies, reducing the need for separate managed switches in many network architectures. The EtherNet/IP network carries both I/O data (CIP I/O) and message-based communication (CIP Connected and CIP Unconnected messaging) to remote I/O, drives, smart instruments and other controllers.
The native OPC UA server capability supporting up to 100,000 nodes is the most significant connectivity advance for IIoT applications. OPC UA (IEC 62541) is the vendor-neutral, secure, platform-independent communication standard for industrial data exchange. With native OPC UA, any SCADA, MES, historian or cloud platform that supports OPC UA can read and write directly to the 5590 controller without an OPC bridge, gateway or middleware server. This directly supports data-driven operations where the PLC becomes a transparent data node rather than a closed-system logic engine.
MQTT and REST protocol support via machine builder libraries allows the 5590 to publish data directly to MQTT brokers (for cloud platforms such as AWS IoT, Azure IoT Hub or on-premise MQTT brokers) and interact with REST APIs. This makes the 5590 capable of participating in Industry 4.0 architectures where control-layer data flows directly to analytics and digital twin platforms without additional hardware gateways.
ControlLogix 5590 Variants: Standard, XT and P
| Variant | Catalog prefix | Environment rating | Typical use | FactoryTalk Design Studio support |
|---|---|---|---|---|
| Standard | 1756-L9xx | Standard industrial temperature and humidity | General manufacturing, process control, machine automation, motion, packaging | From v2.03 (November 2025) |
| XT (Extended Temperature / Corrosion Resistant) | 1756-L9xxXT | Extended temperature range, corrosive gas environments (ISA-71.04 G3) | Offshore platforms, chemical plants, wastewater treatment, outdoor enclosures in harsh climates | From v2.03 (November 2025) |
| P (Process) | 1756-L9xxP | Standard industrial (same as Standard variant) | Process control applications requiring integrated safety and redundancy. Oil and gas, refining, chemical manufacturing, power generation | Future release after v2.03 |
All three variants support safety, redundancy, secure communications and all four operating modes. The difference is environmental protection rating (XT) and application optimisation (P variant for process control with tighter integration to process-specific function block libraries). All are backward compatible with the existing 1756 chassis, I/O modules and power supplies from the 5580 generation.
Quick FAQs: ControlLogix 5590
- PLC vs RTU: Differences, When to Use Each, and Selection Guide
- Ladder Logic Programming: How PLCs Execute Rungs and Scan Cycles
- Modbus RTU vs Modbus TCP: Protocol Differences and When to Use Each
- PLC Analog Scaling: Raw Count to Engineering Units Formula and Calculator
- Cold Loop and Hot Loop Testing: Commissioning Procedures for PLC and DCS Systems
External References
- Rockwell Automation: ControlLogix 5590 Official Product Page
- Rockwell: ControlLogix 5590 Selection Guide (1756-SG900)
- RealPars: ControlLogix 5590 New Features Explained
- AutomationForum: ControlLogix 5590 PLC Guide
What we learn today
- The ControlLogix 5590 (L9) doubles the 5580 (L8) in memory (80 MB), EtherNet/IP nodes (600+), motion axes (512) and adds a second 1-Gigabit Ethernet port. Scan time is approximately 2x faster than the L8. SIL 2/PLd safety is built into every variant without needing a separate GuardLogix controller.
- Four operating modes from the same hardware: Standard, Safety (SIL 2/PLd or SIL 3/PLe with safety partner), Redundancy (high availability with 1756-RM3), and Logix SIS (safety plus redundancy for SIS applications). Mode is selected through Studio 5000 configuration, not hardware.
- Key IIoT features: native OPC UA server (up to 100,000 nodes), MQTT and REST via libraries, IEC 62443-4-2 cybersecurity compliance, CIP Security with mutual authentication and encrypted communication, and secure boot. Three variants: Standard, XT (harsh environments), and P (process control).