Allen Bradley vs ABB PLCs

When selecting the right PLC controller for your industrial needs, two names frequently rise to the top of the list: ABB and Allen Bradley. Both manufacturers are industry leaders in industrial automation. ABB, based in Switzerland, provides a broad range of control products, including PLCs and HMIs, and is widely known for its robotics expertise. On the other hand, Allen Bradley, a US-based company, is one of the most well-regarded brands in control solutions, both domestically and globally. 

This blog post provides a comparison on the popular PLC products and features from both brands to make your industrial automation decisions easier:

Large Control Systems

For large-scale operations that require extensive control, both ABB and Allen Bradley offer highly capable PLC controllers, but they approach this from different angles. 

ABB’s AC500 series is known for its modularity. This means businesses can customize their PLC controller systems to meet specific needs, making it an excellent choice for industrial automation solutions that require flexibility and scalability. Whether it’s managing complex motion control or integrating with existing systems, the AC500 can be expanded by adding extra ABB electrical parts as needed. This modular design not only allows for growth but also offers a high level of customization, ensuring that the system is tailored to the exact requirements of each project.

In comparison Allen-Bradley PLC systems, specifically the ControlLogix family, focuses on seamless integration across large-scale operations. The ControlLogix 5580 and 5570 models are designed for factory-wide industrial automation operations. One standout feature of Allen Bradley’s PLCs is their ability to reduce installation time by allowing users to manage I/O, cabling, and motion control through a unified interface. This makes them highly efficient in complex environments where coordination and reducing downtime is essential. 

Both brands serve automation companies in industries like food and beverage, oil and gas, and mining, where high-speed and high-volume control is necessary. However, the choice between them often comes down to whether you priorities flexibility (ABB) or seamless integration (Allen Bradley).

Small & Medium Control Systems

While both companies excel at large-scale solutions, they also offer a range of PLCs for medium sized and smaller control systems. Allen-Bradley’s CompactLogix family is designed for mid-range operations but with the same robustness found in larger systems. The CompactLogix 5480 runs on a Windows-based operating system, making it ideal for industrial automation solutions that incorporate IIoT (industrial internet of things). This controller can handle real-time data capture, analytics, and predictive maintenance—an attractive feature for automation companies looking to leverage digital transformation.

For those not yet ready to dive into IIoT, the CompactLogix 5370 offers an efficient alternative. The 5370 simplifies the design and implementation process for smaller systems without sacrificing performance. Additionally, for operations that require enhanced safety, Allen Bradley offers the GuardLogix 5380, a powerful solution that manages both standard and safety control in one system.

ABB caters to smaller operations with its AC500eco, a more compact and cost-effective version of the larger AC500. What sets this PLC controller apart is its modularity—it can either serve as a standalone controller or integrate into a larger AC500 system. Programming the AC500eco is also simplified, as it allows for configuration via an SD card. 

In simpler operations that do not require extensive motion or safety controls, Allen-Bradley PLC systems, like the MicroLogix 800 family, provide an affordable, streamlined solution. These PLC controllers are designed to manage basic automation tasks and support communication protocols like EtherNet/IP and DeviceNet. For smaller systems, Allen-Bradley ensures high performance without the need for excessive complexity.

While ABB doesn’t have a direct competitor to the MicroLogix 800, the AC500eco can serve similar functions, offering businesses an adaptable solution for simpler applications. The flexibility of ABB’s PLC controllers allows them to meet a wide variety of needs, from standalone operations to scalable systems that can grow alongside your business.

Safety Control & Operating in Extreme Environments

A significant point of difference between ABB and Allen Bradley lies in how they handle safety and harsh environments. Allen Bradley takes a streamlined approach, offering safety models such as the GuardLogix within the same family of products. For example, the GuardLogix 5580 provides enhanced safety features for automation companies working in high-risk environments. While still being part of the broader ControlLogix family. This PLC controller simplifies the process for industries that need both standard control and safety protocols within a single system.

ABB, however, offers distinct models for safety and extreme conditions. The AC500-S is ABB’s dedicated safety PLC controller, specifically designed for high-risk industries like heavy machinery and robotics. This controller comes with a separate CPU for safety tasks, ensuring maximum protection for critical operations. Additionally, ABB offers the AC500-XC series for extreme environments, where conditions such as high vibrations, hazardous gases, or extreme temperatures (-40°C to +70°C) are common. The rugged design of the AC500-XC makes it a standout option for industries like offshore oil and gas or renewable energy, where robust equipment is essential.

Pricing Considerations

When it comes to price, Allen Bradley PLC systems are generally known to be more expensive than ABB’s PLC controllers. This higher cost can be attributed to Allen Bradley’s advanced integration features, their strong reputation for reliability, and their extensive support network—particularly in North America, where Allen Bradley has a dominant market presence.

ABB, by contrast, often offers a more cost-effective option, especially in regions outside the U.S. and for businesses that priorities flexibility and customization. The modularity of ABB’s PLCs, like the AC500 series, allows users to build systems tailored to their specific needs, without the higher upfront costs typically associated with Allen Bradley’s more integrated offerings.

Ultimately, choosing between ABB and Allen-Bradley PLC controllers depends on your business needs and budget. Allen-Bradley is the go-to choice for businesses looking for seamless integration, while ABB’s electrical parts are ideal for companies seeking flexible, customizable, and budget-friendly options in the world of industrial automation.

At Mizen Automation, we specialize in providing all the parts you need for your industrial automation solutions, including HMIs, PLCs, drives, robots, and more. Reach out to our sales executive team today for personalized assistance.