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Q: Do you believe the swapping of the Current SD card to the new PLC will transfer the program over?   A:  It depends on how it was setup when programmed/last accessed   https://www.youtube.com/watch?v=ddb7rCPPMtI   If needed we know of a few local integrators that may be able to help if required.

The Most Cost effective CompactLogix System is the 1769-L16ER-BB1B   1769L16ERBB1B L1, 384KB, 6 I/O Expansion via 1734 POINT I/O, 4 Ethernet IP Nodes, 24VDC https://www.plcgear.com.au/products/allen-bradley-1769-compactlogix-l23x-and-l3x-controllers?variant=36765061070   Software Required to Program these is Studio 5000 (Can Purchase Directly from Rockwell) https://www.rockwellautomation.com/en-gb/products/software/factorytalk/designsuite/studio-5000.html   See Ordering guide for Options https://literature.rockwellautomation.com/idc/groups/literature/documents/qr/9324-qr001_-en-p.pdf   Note There is also the Micro800 Series of PLCs that uses its own software (Connect Components Workshop) – These are more budget PLCs   And Older Models Like MicroLogix and SLC that Use RSLogix 500 Software but these are being phased out and soon to be obsolete

The L16 can have up to 8 Point IO Expansion modules (Any of the 1734 Point IO Modules can be used)   See here for all the options https://www.plcgear.com.au/products/ab1734-pointio   With the base you will want the either the 1734-TB (Screw Terminal) or 1734-TBS (Spring Terminals)  

If Needing to switch the loads directly could use a Relay Output Model, but if going to use PWM this may mean a high amount of switching on and off (Relay wont last as long) so would be better to go with transistor output and an SRR to switch the 48V loads

For S7-1200 memory card is optional and used to store user data or backup of the program