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MicroLogix 1400 and Micro800 are Allen-Bradley MicroLogix family controllers from Rockwell Automation. These Programmable Logic Controller Systems are launched under the label of Micro Control Systems. Micro800 controllers are further comprised of Micro810, Micro820, Micro830, Micro850, and Micro870 models. This guide will discuss the features of the controllers mentioned above, the scope of their applications, specifications, and software capabilities, along with differences among these models.
MicroLogix 1400 is a small Programmable Logic Controller (PLC) which extends the MicroLogix family of small PLCs by combining the features of MicroLogix 1100, such as online editing, Ethernet/IP, and a built-in LCD, with enhanced features like faster High-Speed Counter/PTO, increased I/O, and communication capabilities. MicroLogix 1400 boosts the MicroLogix family by expanding the scope of applications while facilitating great features at a reasonable price. Applications, where MicroLogix 1400 can be used, are general industrial machinery, including material handling, packaging, and assembly operations. MicroLogix 1400 can easily encircle larger applications like building automation, oil and gas, water and wastewater, electrical power, food and beverage, pharmaceutical industry, and commercial machinery like vending industrial washers, and dryers.
Micro800 controllers provide a scalable and cost-effective control solution for standalone micro applications. These controllers are especially good for such control systems where companies are adopting automation incrementally, they might have a small process cycle or are interested in automating individual machines. Micro800 controllers with compact size can be used in applications having low I/O requirements, for increasing productivity and efficiency, with an additional benefit of Ethernet communication and a powerful yet friendly programming environment. The applications for these controllers include packaging, material handling, process, heavy industrial equipment, manufacturing, and assembly.
The MicroLogix series uses a well-known programming languages. This software enables programmers to make changes while the program is running and readily spot program modifications that differ from the original while debugging. The complete Micro800 family is equipped with Connected Components Workbench software (CCW) for programming needs, reflecting the family’s grasp of today’s connection requirements. System designers and end-users may utilize the CCW software to program the controller, set up devices, and interface with the Human Machine Interface (HMI) devices.
Perhaps the most significant distinction between MicroLogix 1400 and Micro800 is in their software. Both software systems support ladder logic and workflow programming. In addition, they each include special data types, Common Industrial Protocol (CIP) messaging, and example codes. The software in the Micro800 series includes function block diagram (FBD), structured text (ST), motion control, variable-based addressing, and controller stored comments. The Micro800 line of controllers has a flat Program Organizational Unit (POU) structure. A user must first specify the program as a ladder, function block, or structured text before beginning to write the program in the controller. The software includes a wizard converter for customers considering a migration to Micro800 that enables a seamless transition. It transforms around 95% of the original software and keeps track of any remaining errors. All of the Micro800 models also support user-defined function blocks, 32-bit and 64-bit floating-point, and PID loop control, whereas, MicroLogix 1400 additionally offers data logging and recipe storage, which have a memory capacity of 128 KB and 64 KB, respectively.
With the world’s manufacturing and warehousing sectors becoming more sophisticated and connected, the necessity for standardization to enable interchangeable and adaptable control unit components implies that CCW coincides with this trend.
One lead of MicroLogix 1400 over Micro800 is the number of I/O ports available. The MicroLogix 1400 has 32 embedded I/O ports, which can expand to as many as 256 I/O ports. The Micro800 family has a smaller number of embedded I/O ports. Micro810 has 12-points (or pins), and Micro820 has 20-points. Micro830 offers 4 options with 10, 16, 24, and 48-points. Micro850 also has two variations having 24 and 48-points, whereas Micro870 offers 24-points. The Micro820, Micro830, and Micro850 have the capability to expand the number of I/Os through plug-in modules to allow additional digital I/O ports. Only Micro870 supports the expansion I/O option, which at full capacity supports up to 304 digital I/O ports, maximum in the Micro800 family. Talking about analog I/O pins, Micro810 and Micro820 have four digital inputs shared as analog inputs. This number can be increased in Micro820 using plug-in modules. Micro820 also supports one embedded analog output. In Micro830, Micro850, and Micro870 models, analog I/O can be added using plug-in modules, whereas analog I/O can also be installed using expansion I/O for the latter two.
The MicroLogix family is older than Micro800 and has less data capacity. The MicroLogix 1400 has 10K/10K (configurable) program steps/data byte of memory size. Micro810 can store 2K/2K program steps/data byte. Two variants of Micro830 (10 and 16-point) have 4K/8KB, the other two models of Micro830 (24 and 48-point), Micro820, and Micro850 have 10K/20K steps/data byte memory. The Micro870 possesses the maximum amount of memory in the entire family, which is 20K/ 40K.
MicroLogix 1400 controller has a memory module port. A memory module can be externally installed in it, which can be used as a backup or transfer medium for the user program and user data between controllers. Memory modules also feature auto-recovery, program comparisons, security, and data write protection.
All MicroLogix controllers, including MicroLogix 1400 have a 120/240V AC or 24V DC power supply integrated into the controller. Micro810 has 120/240V AC and a 12/24V DC embedded power supply. Base units of the remaining models have a 24V DC power supply, whereas a 120/240 V AC power supply is optional.
MicroLogix 1400 has a single eight-pin Mini-DIN connector and a single 9-pin D shell. MicroLogix 1400 provides a single 8-pin mini-DIN for RS-485 connections. USB connection is not available on MicroLogix 1400. Micro800 models come with essential embedded communication ports. A USB 2.0 is installed in all models by default except Micro820, which can attain the same features through a remote LCD (2080-REMLCD). RS232/RS485 non-isolated combo serial port is available in all Micro800 models except Micro810, whereas Micro820, Micro850, and Micro870 are additionally equipped with a 10/100 Base T Ethernet port (RJ-45).
MicroLogix 1400 analog inputs and outputs have a resolution of 12-bit with an overall accuracy of ±1.0% and a maximum analog output setting time of 3ms. Micro810 is a low-performance model, Micro830 gives a medium performance with plug-ins equipped models, and, Micro850 and Micro870 reside in the high-performance category with analog expansion I/O integrated. Micro810 has a 10-bit of resolution with 5% nominal accuracy, Micro830 with plug-ins has a 12-bit of resolution and 1% of nominal accuracy. With analog expansion I/O enabled for Micro850 and Micro870, the resolution goes to 14-bit and 12-bit, and nominal accuracy improves to ±0.1% and 0.133%, respectively. The input update rate of Micro810 and Micro820 depends on the program scan only. For Micro830 with plug-ins enabled, the input update rate is 200ms and 8ms for Micro850 and Micro870 with expansion I/O included. Recommended shielded cable length for Micro810, Micro820 and Micro830 are 10 m, and for Micro850 and Micro870, it is 100 m. The shielded cable length for MicroLogix 1400 is suggested to be 30 m.
In MicroLogix 1400, the expansion module can be either panel mounted or DIN rail. Screw mounting and DIN latches are part of the package design. Digital, analog, and specialty modules are available for the controller. Digital modules comprise different variations like 8-point AC input, up to 32-point DC input, up to 16-point sink/source dc input, up to 16-point AC/DC relay output, up to 16-point sourcing DC output, up to 32-point solid-state sink or source output and 8-point AC Triac output modules. For analog input modules, a catalog lists 4-channel voltage/current analog input and output modules and a combination module. In the category of specialty modules, 4-channel RTD/Resistance and Thermocouple/mV input modules are available.
All expansion I/O modules are only available for Micro850 and Micro870 in the Micro800 family controllers. The Micro800 expansion I/O modules deliver superior performance in a small, low-cost package. Many digital and analog modules expand the capabilities of the Micro850 and Micro870 controllers. There are 9 discrete I/O modules that provide point extensions ranging from 8-point to 32-point. There are solid-state output modules available that are recommended for applications that require more switching cycles than relays. Triac outputs are available for use with AC loads. For DC loads, sink and source transistor outputs are available. Then there are 3 analog modules with up to 8-channel voltage/current inputs and 4-channel voltage/current outputs. A specialty expansion I/O temperature and thermocouple input module with 4-channel is also in the expansion modules list, and a bus terminator expansion module is also offered. The power supply module is only available for the Micro870 model, which can supply power for up to four expansion I/O modules.
For the MicroLogix 1400, there are no plug-in modules available. In Micro810, the only external addition can be an LCD with a keypad and a USB adapter. The Micro820 model also has a unique extension, which is a remote LCD (2080-RELCD). A memory module with RTC is available in Micro830 and Micro850 only. An additional power supply is supported with all Micro800 controllers. All other plug-in modules are supported by Micro800 family controllers except Micro810, which does not support any. Plug-in modules and accessories include RS232/485 isolated serial port, digital input, output, relay, combination modules, high-speed counter, DeviceNet scanner, non-isolated unipolar analog input/output, non-isolated thermocouple, non-isolated RTD, and a 6-channel trim potentiometer analog input. The Micro800 controllers, except the Micro810, can have a high-speed counter (HSC) plug-in module, 2080-MOT-HSC. This module offers the same functionality as the embedded high-speed counter, but it can also drive up to 250 kHz 5V differential line drivers for better noise immunity and has an additional dedicated I/O.
Base instruction speed in Micro800 is 2.5 µs for Micro810 and 0.3 µs for other models. The minimum scan or cycle time for Micro810, Micro30, Micro850, and Micro870 is <0.25 ms, and for Micro820, it is <4ms.
The operating temperature for MicroLogix 1400 is -20 to 60 °C. For Micro810, the operating temperature range is 0 to 55 °C, and for the rest of the family controllers, it is -20 to 65 °C. Non-operating or storage temperatures for MicroLogix 1400 and Micro800 range from -40 to 85 °C. Recommended relative humidity range for all controllers under discussion is the same, which is 5 to 95%, non-condensing. MicroLogix 1400 can bear a vibration of 3 g @ 10 to 500 Hz, 0.015 in. max peak-to-peak, whereas, Micro800 controllers can bear vibration of 2 g @ 10 to 500 Hz. During machine operation, MicroLogix 1400 can withstand three pulses of shock in each direction at 30 g. Micro810 has an operating shock limit of 30 g, which reduces to 25 g for the other members of the family.
MicroLogix 1400 controllers have received several regulatory agency approvals for the global market, which include CE, EAC, RCM, UL, and c-UL, including Class 1 Division 2 (for Hazardous Location). Micro800 controllers also hold many certifications, which are c-UL, CE, RCM, and EAC. Additionally, Micro830 holds KC certification, and Micro820, Micro850, and Micro870 possess both KC and EtherNet/IP certifications.
While both MicroLogix 1400 and Micro800 families are intended to be small and adaptable, the comparison above demonstrates noticeable differences. The Micro800 is designed for compactness, affordability, and modularity to meet the complex and expanding connectivity requirements for machine control in today’s world with versatile programming software. On the other hand, the MicroLogix 1400, with a small controller size, can fit into tight spaces and operate in potentially more rugged environments. It comes loaded with a wide range of features which make it useful for some applications as a single device to cope with all the needs while it makes it less flexible and less affordable for applications suited for Micro800 controllers.
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