2025-04-30

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.

Contact PLG Automation today:
Email: sales@plgautomation.com
Phone: 800-906-9271