Discover the Power of Micro850 Controllers for Standalone Machine Control, Motion, and Ethernet Connectivity

Introduction to Allen-Bradley Micro850 PLC

The Allen-Bradley Micro850 programmable logic controller (PLC) by Rockwell Automation is engineered for standalone machine applications requiring flexible communication, robust I/O capabilities, and embedded motion control. Designed to replace legacy systems like MicroLogix, the Micro850 supports up to 192 I/O points and integrates seamlessly with Rockwell’s Connected Components Workbench (CCW) software. Its versatility makes it ideal for OEMs and industrial automation applications, including material handling, packaging, and solar panel positioning. With built-in Ethernet, pulse train output (PTO) motion control, and expandable I/O modules, the Micro850 balances performance and cost-effectiveness for mid-range automation tasks.

Key Features and Technical Specifications

The Micro850’s standout features include ​high-density I/O scalability, supporting up to five plug-in modules and four expansion I/O modules. This allows users to customize functionality with additional serial ports, analog I/O, or microSD cards for data logging. The controller also delivers ​embedded motion control, enabling up to three axes of PTO-based motion for stepper or servo drives. Predefined function blocks (e.g., homing, velocity control) simplify programming for single-axis applications.

For connectivity, the Micro850 offers an ​embedded Ethernet port​ for EtherNet/IP communication, enabling seamless integration with HMIs, SCADA systems, and drives like PowerFlex 520 and Kinetix 5100. It also includes USB programming ports, RS-232/RS-485 serial interfaces, and 100 kHz high-speed counter inputs (on 24V DC models). The controller operates in temperatures from -20°C to +65°C, ensuring reliability in harsh environments.

Applications in Industrial Automation

The Micro850 excels in ​standalone machine control​ for sectors such as manufacturing, renewable energy, and logistics. Typical applications include:

• ​Material Handling Systems: Controlling conveyors and sortation systems with precise I/O monitoring.

• ​Packaging Machinery: Managing vertical form-fill-seal machines and shrink sleeve labelers via motion and I/O coordination.

• ​Solar Tracking: Adjusting solar panel positioning using PTO motion commands.

• ​Cut-to-Length Systems: Synchronizing fly shear and stamping presses with high-speed inputs.

Its ability to handle digital/logic control while integrating motion makes it a cost-effective alternative to larger PLCs.

Advantages Over Competing PLCs

A key advantage of the Micro850 is its ​unified software environment. The Connected Components Workbench provides a single platform for configuring PLCs, drives, and HMIs, reducing development time versus using separate tools. The controller’s ​backward compatibility​ with Micro800 series I/O modules and PCCC command support eases migration from MicroLogix systems. Additionally, the newer 2080-L50E model (replacing discontinued LC50 variants) offers faster Ethernet communication, improved I/O response times, and Class 1 implicit messaging for optimized HMI/SCADA connectivity.

Selection and Migration Guidelines

When selecting a Micro850, consider:

• ​I/O Requirements: Choose 24-point or 48-point models, and expand with modules for analog/digital needs.

• ​Motion Axis Count: Opt for the Micro850 if applications require ≤3 axes; complex motion may need higher-end controllers.

• ​Communication Protocols: Ensure compatibility with EtherNet/IP, DF1, or serial devices.

For users upgrading from MicroLogix, Rockwell Automation provides migration tools in CCW (v20.01 or later), including predefined tags and familiar programming workflows resembling MicroLogix 1400.

Conclusion: Enhancing Machine Performance

The Allen-Bradley Micro850 PLC combines scalability, embedded motion, and industrial Ethernet in a compact platform. By simplifying control architecture and reducing integration costs, it empowers OEMs to optimize standalone machines for productivity. With awards like the 2023 Plant Engineering Product Award, the Micro850 demonstrates its value in modern automation. Engineers can leverage its flexibility to build future-ready systems while maintaining compatibility with Rockwell’s broader ecosystem.