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Industrial Automation & Network Hardware
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Micro PLC comparison from Allen Bradley, Mitsubishi, Omron

April 30, 2025

A Programmable Logic Controller (PLC) is an industrial control system that continuously monitors input devices and makes logic-based decisions to control output devices. While full-sized PLCs are standard for large-scale industrial control, micro PLCs offer a compact and cost-effective alternative for smaller or embedded automation applications. This article compares leading micro PLCs from Allen-Bradley, Mitsubishi, and Omron, focusing on features, construction, specifications, and applications.

Features and Connectivity

Allen-Bradley Micro800 Series

  • Compact design with Nano-sized footprint (Micro820 models).

  • Up to 36 I/O points.

  • Embedded smart relay function blocks.

  • Optional LCD/keypad interface.

  • USB port (via adapter), embedded Ethernet, serial communication.

  • MicroSD slot for data logging and program transfer.

  • Expansion through plug-in modules.

  • High-speed counters and Pulse Train Outputs (PTO).

  • Analog I/O capabilities enhance application flexibility.

Mitsubishi FX Series

  • Dual system-bus architecture improves speed and functionality.

  • Compact, space-saving design.

  • Built-in analog I/O and Ethernet connectivity.

  • Connector-type I/O for faster setup.

  • Modular expansion support.

  • High-speed processing for precise control.

Omron CP Series

  • Program capacity from 2K to 10K steps.

  • Flexible I/O expansion up to 160 points.

  • High-speed counter and interrupt inputs.

  • Trapezoidal/S-curve pulse control.

  • Two analog input channels (1/1000 resolution).

  • Serial communication boards and built-in Ethernet.

  • Battery-backed flash memory.

  • Modular programming with up to 128 function blocks.

Design and Construction

Allen-Bradley Micro800 Series

  • Rugged, compact enclosure.

  • Optional display and keypad interface.

  • Easy-to-navigate programming environment.

Mitsubishi FX Series

  • All-in-one compact architecture (CPU, I/O, power in one unit).

  • Strong mechanical structure.

  • Integrated Ethernet ports.

  • Connector-style wiring minimizes installation errors.

Omron CP Series

  • Robust housing resistant to dust and moisture.

  • Integrated cooling system.

  • Compact size for panel/machine integration.

Input/Output and Memory Specifications

Allen-Bradley Micro800 Series

  • I/O Points: 12 (Micro810) to 36 (Micro820).

  • Analog Input: 4 channels (0-10V), 1 analog output.

  • Communication: Ethernet, USB, RS-232/RS-485.

  • Expandable via microSD.

Mitsubishi FX Series

  • I/O Points: 30 to 384 (with expansion).

  • Support for digital, analog, temperature I/O.

  • Fast instruction execution.

  • Expandable memory via cassettes.

Omron CP Series

  • Input: 40 built-in, expandable to 160.

  • Analog Inputs: 2 channels (0-10V).

  • Pulse Control: 2 adjustable pulse outputs.

  • Memory: 2K to 10K steps, support for data/index/trace memory.

  • Communication: Ethernet, USB, RS-232/RS-485.

Applications

Allen-Bradley Micro800 Series

  • Standalone machine control.

  • Small/medium automation systems.

  • HVAC, pump/motor control.

  • Material handling, energy-efficient lighting.

Mitsubishi FX Series

  • Manufacturing and process control.

  • Motion control (CNC, packaging systems).

  • Energy management and smart home automation.

  • Building automation.

Omron CP Series

  • Conveyor and robotic arm control.

  • CNC and servo motor motion control.

  • Industrial IoT and energy monitoring.

  • Safety systems and predictive maintenance.

Conclusion Micro PLCs from Allen-Bradley, Mitsubishi, and Omron each offer distinctive advantages for different industrial use cases. Allen-Bradley's Micro800 Series emphasizes user-friendliness and integrated smart features for compact, cost-effective automation. Mitsubishi's FX Series excels in processing speed and modular connectivity, making it ideal for dynamic and motion-intensive applications. Omron's CP Series stands out for its high program capacity, versatile I/O expansion, and robust industrial performance, making it well-suited for complex automation environments. As industrial automation evolves, these micro PLCs remain crucial to enabling smarter, more adaptable systems worldwide.

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