OpenPLC vs RSLogix 500/5000
Comprehensive comparison of two leading PLC programming platforms
OpenPLC
OpenPLC Project (Open Source)
Completely FREE - no costs ever
RSLogix 500/5000
Rockwell Automation / Allen-Bradley (Legacy)
Massive installed base - many jobs still require it
Overall Winner
RSLogix 500/5000 leads with an overall score of 76/100
RSLogix 500/5000 is the stronger overall choice with better community support. However, OpenPLC may be preferable if you prioritize pricing or if you're already committed to the OpenPLC Project (Open Source) ecosystem.
Score Breakdown
| Category | OpenPLC | RSLogix 500/5000 |
|---|---|---|
| Overall | 55 | 76✓ |
| Pricing | 100✓ | 70 |
| Ease of Use | 50 | 60✓ |
| Features | 63 | 74✓ |
| Industry Adoption | 18 | 85✓ |
| Community Support | 94 | 100✓ |
| Career Value | 23 | 74✓ |
Real-World Scenario Recommendations
See how OpenPLC and RSLogix 500/5000 perform in specific industry scenarios to help guide your decision.
Small Machine Builder
OEM building compact machines with 50-200 I/O points, typically for niche markets or specialized applications
OpenPLC
Interesting for proof-of-concept or extremely budget-constrained startups, but risky for commercial machines. The appeal is obvious: completely FREE, runs on Raspberry Pi ($35-$100 hardware cost), zero licensing restrictions. Perfect for: (1) Building your first prototype to secure investor funding, (2) Educational machines or demonstration units, (3) Very simple control tasks with forgiving indus...
RSLogix 500/5000
Legacy platform, but potentially viable for budget-conscious small OEMs targeting North American markets with older infrastructure. RSLogix 500 with MicroLogix hardware can cost significantly less than Studio 5000 with ControlLogix ($1,000-$5,000 vs $10,000-$30,000). If your machines have modest I/O counts (under 256 points) and don't require advanced features, MicroLogix may suffice. The installe...
Key Considerations:
- •Per-machine software licensing cost vs expected production volume
- •Time-to-market pressure - can you afford 6+ month learning curves?
- •Target customer geography and brand preferences
- •Hardware cost optimization - some platforms offer cheaper controllers
Automotive Tier 1 Supplier
Tier 1 automotive supplier providing systems and components directly to OEM vehicle manufacturers (VW, BMW, GM, Ford, Toyota, etc.)
OpenPLC
Not viable for automotive Tier 1 production equipment. Automotive OEMs have strict certification, safety, and vendor support requirements that OpenPLC cannot meet. Insurance, liability, and customer acceptance issues eliminate this option. Possibly acceptable for internal R&D labs, proof-of-concept demonstrations, or training junior engineers before expensive platform licenses. Otherwise, avoid fo...
RSLogix 500/5000
Obsolete for new automotive production lines. While MicroLogix PLCs are still produced, Rockwell is clearly phasing this out. Automotive production lines have 15-20 year lifecycles - starting new designs on sunset platforms is risky. The only justification: Cheap expansions of existing RSLogix 500-based lines where full system replacement isn't economically viable. For greenfield automotive projec...
Key Considerations:
- •Customer-specified platforms are non-negotiable - verify before any engineering investment
- •Long-term parts availability (15-20 years) is critical for automotive
- •Safety certifications (SIL 2/SIL 3) must be well-established and accepted
- •Customer's plant maintenance teams must be trained on your platform
Process Industry (Chemical, Oil & Gas, Pharma)
Continuous process control in chemical plants, refineries, pharmaceutical manufacturing, and other process industries requiring high reliability and regulatory compliance
OpenPLC
Completely unsuitable for process industries. The lack of safety certifications, redundancy, regulatory compliance documentation, and vendor support eliminates OpenPLC from consideration. Process industries cannot accept uncertified control systems due to safety, environmental, and regulatory requirements. Not viable even for non-critical applications in regulated environments.
RSLogix 500/5000
Obsolete for new process plants. Some older chemical or water treatment plants have legacy RSLogix 500/PLC-5 systems requiring maintenance, but starting new process designs on sunset platforms is unacceptable. Process plants have 20-30+ year lifecycles - legacy platforms won't have adequate support. For greenfield process projects, use Studio 5000/PlantPAx. For retrofits of existing RSLogix 500 sy...
Key Considerations:
- •Redundancy and high availability are mandatory for critical processes
- •Safety certifications (SIL 2/SIL 3) for emergency shutdown systems
- •Long-term vendor support (20-30 year plant lifecycles)
- •Integration with process instrumentation and field devices
💰Pricing Comparison
OpenPLC (free) is significantly more affordable than RSLogix 500/5000 ($$). OpenPLC costs between $0 and $0, while RSLogix 500/5000 ranges from $1 000 to $10 000.
📚Learning Curve
RSLogix 500/5000 (rated 5/10) is easier to learn than OpenPLC (rated 6/10). RSLogix 500/5000 typically takes 2-4 months to learn, while OpenPLC requires 3-6 months. This makes RSLogix 500/5000 better for beginners.
⚙️Features & Capabilities
OpenPLC offers 11 key features. RSLogix 500/5000 provides 10 key features with safety programming, motion control. OpenPLC offers a comprehensive feature set for industrial automation.
🏭Industry Adoption
RSLogix 500/5000 has 75% market adoption compared to OpenPLC's 10%. RSLogix 500/5000 dominates in North America, Latin America, while OpenPLC is strongest in Global (primarily education and research). RSLogix 500/5000's higher adoption means more job opportunities and community resources.
🔌Hardware Compatibility
OpenPLC is designed specifically for Generic/Open Hardware hardware, while RSLogix 500/5000 works with Allen-Bradley, Rockwell Automation PLCs. Both are vendor-specific solutions optimized for their respective hardware ecosystems.
💼Career Prospects
RSLogix 500/5000 offers stronger career prospects with 75% market adoption and official certification programs. OpenPLC has 10% adoption and is growing in market presence. For maximum employability, RSLogix 500/5000 expertise is more in-demand.
OpenPLC Overview
Key Strengths
- ✓Completely FREE - no costs ever
- ✓Open source - fully customizable
- ✓Runs on inexpensive hardware (Raspberry Pi)
- ✓Perfect for learning without financial investment
Limitations
- ✗Not suitable for commercial/industrial use
- ✗No official support (community only)
- ✗Limited features compared to commercial PLCs
Best For
RSLogix 500/5000 Overview
Key Strengths
- ✓Massive installed base - many jobs still require it
- ✓Well-understood and documented
- ✓Stable, mature platform
- ✓Simpler interface than Studio 5000 for basic tasks
Limitations
- ✗No longer actively developed (legacy software)
- ✗Being phased out in favor of Studio 5000
- ✗Won't work with newer PLC hardware
Best For
Recommendations
For Beginners
Both are suitable
For Professionals
RSLogix 500/5000
Budget-Constrained
OpenPLC
Enterprise Use
RSLogix 500/5000
Frequently Asked Questions
Which is better: OpenPLC or RSLogix 500/5000?
RSLogix 500/5000 is the stronger overall choice with better community support. However, OpenPLC may be preferable if you prioritize pricing or if you're already committed to the OpenPLC Project (Open Source) ecosystem.
What is the price difference between OpenPLC and RSLogix 500/5000?
OpenPLC (free) is significantly more affordable than RSLogix 500/5000 ($$). OpenPLC costs between $0 and $0, while RSLogix 500/5000 ranges from $1 000 to $10 000.
Which is easier to learn: OpenPLC or RSLogix 500/5000?
RSLogix 500/5000 (rated 5/10) is easier to learn than OpenPLC (rated 6/10). RSLogix 500/5000 typically takes 2-4 months to learn, while OpenPLC requires 3-6 months. This makes RSLogix 500/5000 better for beginners.
Which has better career prospects?
RSLogix 500/5000 offers stronger career prospects with 75% market adoption and official certification programs. OpenPLC has 10% adoption and is growing in market presence. For maximum employability, RSLogix 500/5000 expertise is more in-demand.