Understanding the Rockwell PLC Family: From Micro to ControlLogix

When it comes to industrial automation, selecting the right PLC can significantly impact your system’s performance. Rockwell Automation offers one of the most comprehensive ranges of programmable logic controllers on the market, designed to serve everything from small, standalone machines to large, plant-wide control systems.

But with so many models and capabilities, it can be tricky to know which controller fits your needs. At HESCO, we help facilities of every size choose and support the right PLCs for their operations. Let’s walk through Rockwell’s three main controller families–Micro800™, CompactLogix™ 5380, and ControlLogix® 5590–and how each is designed for a specific kind of automation challenge.

Micro800™ Series: Compact Power for Standalone Machines

If you’re running smaller, standalone machines, the Micro800 family is your ideal starting point. Designed with OEMs and small facilities in mind, these controllers deliver reliable performance at an approachable price point, with enough flexibility to handle diverse applications from packaging to water treatment skids to simple process control.

Within the Micro800 line, there’s a clear progression of capability. The Micro810® functions as a smart relay; think of it as the bridge between a timer relay and a full PLC. It’s built for straightforward applications like pump control or lighting automation and can even be programmed directly from its front display without any software.

The Micro820® steps things up with built-in Ethernet connectivity, data logging via microSD card, and analog I/O support for small process applications or remote monitoring. For OEMs who need more flexibility, the Micro850® adds expandable I/O, motion control via pulse train output (PTO), and EtherNet/IP support for communication with other devices.

At the top of the lineup sits the Micro870®, offering more memory, expanded communication options, and the ability to control larger systems, all within the same familiar Connected Components Workbench™ (CCW) programming environment.

Altogether, the Micro800 family strikes the right balance for operations that need scalable control in a compact, cost-effective package without sacrificing Rockwell’s reliability or support ecosystem.

CompactLogix™ 5380: Scalable Control for Smart Manufacturing

When your operation demands more than standalone control, and your machines need to talk to each other, share data, and coordinate safety, it’s time to step up to the CompactLogix 5380.

This series bridges the gap between smaller Micro800 systems and high-end ControlLogix platforms, combining high-speed processing, modular architecture, and integrated safety in one streamlined package. The CompactLogix 5380 is purpose-built for today’s “smart machine” environments, offering a single controller that manages standard, motion, and safety functions without separate hardware or software systems.

The benefits are tangible. With dual Gigabit Ethernet ports, the 5380 supports integrated motion control for up to 32 axes and communication with up to 180 EtherNet/IP nodes. Certain models include up to 10 MB of user memory, giving you faster scan times and tighter process control for high-performance applications.

For safety-critical environments, the Compact GuardLogix® 5380 variant offers SIL 2 and SIL 3 capability, combining safety and standard logic on the same controller while maintaining compliance and reducing hardware complexity.

The CompactLogix family is also built for longevity and resilience, with conformal-coated options for harsh environments and enhanced cybersecurity features like encrypted firmware and role-based access control.

In practical terms, CompactLogix is the sweet spot for mid-sized automation systems: packaging lines, material handling cells, or process skids where precision and uptime are critical but a full ControlLogix system would be excessive. It’s a controller that can handle today’s challenges while preparing your facility for future expansion.

ControlLogix® 5590: The Flagship for Complex Systems

When your automation demands peak performance, scalability, and security, the ControlLogix 5590 family–part of Rockwell’s Logix5000™ control platform–sits at the top of the hierarchy.

This platform integrates process, motion, safety, and batch control within a single architecture, delivering the highest performance and flexibility in Rockwell’s PLC lineup. Compared to the previous generation, the 5590 delivers 10 to 40 times faster performance than the 5570 series and up to three times faster than the 5580. It supports up to 80 MB of user memory, 12 MB of safety memory, and more than 600 EtherNet/IP nodes, making it a powerhouse for large, distributed automation systems.

Every 5590 controller comes standard with integrated safety and CIP Security™, meeting global cybersecurity standards like IEC 62443-4-2. Redundancy and high-availability options make it ideal for mission-critical operations that can’t afford downtime.

For engineers and controls managers, ControlLogix offers a unified platform that simplifies architecture, streamlines integration, and enables enterprise-wide visibility. It’s the go-to choice for large manufacturing systems, oil and gas operations, life sciences, and other process-intensive industries where reliability and speed are paramount.

Choosing the Right PLC for Your Facility

Each Rockwell PLC family is designed to meet you where you are in your automation journey.

If your goal is to automate smaller standalone systems, the Micro800 family offers reliable control at an accessible cost. For mid-sized operations that demand faster performance and integrated safety, CompactLogix delivers a powerful balance of capability and scalability. And for large facilities managing complex, connected systems across multiple processes, the ControlLogix 5590 provides the processing power and intelligence needed to tie everything together.

No matter which platform you choose, all three share Rockwell’s Studio 5000 Logix Designer® environment, allowing engineers and maintenance teams to move seamlessly between systems without retraining or rewriting code. Whether you’re starting small or managing global operations, the Rockwell PLC ecosystem scales with you, protecting your investment and simplifying future growth.

Bringing It All Together

At HESCO, we understand that selecting the right PLC isn’t simply about technical specs; it’s about matching capability to your goals, your production demands, and your long-term strategy. Rockwell’s PLC lineup gives you a clear path forward, from cost-effective micro control to high-performance enterprise automation, all under one unified platform.

Every great automation system starts with the right controller, so let’s make sure yours is the perfect fit. If you’re planning a system upgrade, expansion, or migration, our team can help you evaluate your current infrastructure and identify the best Rockwell solution for your operation. Reach out and talk to an expert at HESCO today.