RSLogix 500/5000 vs TwinCAT
Comprehensive comparison of two leading PLC programming platforms
RSLogix 500/5000
Rockwell Automation / Allen-Bradley (Legacy)
Massive installed base - many jobs still require it
TwinCAT
Beckhoff Automation
FREE engineering software - only pay for runtime
Head-to-Head Match
Both RSLogix 500/5000 and TwinCAT are excellent choices with different strengths. RSLogix 500/5000 excels in community support, while TwinCAT leads in community support. Your choice should depend on your specific requirements, budget, and target hardware platform.
Score Breakdown
| Category | RSLogix 500/5000 | TwinCAT |
|---|---|---|
| Overall | 76 | 77✓ |
| Pricing | 70 | 95✓ |
| Ease of Use | 60✓ | 40 |
| Features | 74 | 86✓ |
| Industry Adoption | 85✓ | 70 |
| Community Support | 100✓ | 99 |
| Career Value | 74 | 75✓ |
Real-World Scenario Recommendations
See how RSLogix 500/5000 and TwinCAT 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
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...
TwinCAT
Intriguing choice for engineering-savvy small OEMs, particularly if you need exceptional motion control. The licensing model is perfect for small builders: Engineering software is completely FREE - you only pay for runtime licenses on target hardware ($0-$3,000 per machine). This means zero upfront investment to develop your first machine. If you build 10 machines, you pay 10 runtime licenses. Bui...
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.)
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...
TwinCAT
Specialized choice for automotive Tier 1 suppliers focused on testing equipment, dynamometers, or advanced motion control applications rather than assembly lines. Beckhoff TwinCAT excels in: engine test stands (precise motion and data acquisition), suspension testing rigs, battery testing systems, and automated quality inspection with high-speed vision. The PC-based architecture provides computing...
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
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...
TwinCAT
Niche applications in process industries, primarily for specialized high-speed data acquisition, advanced process analytics, or precision motion control in pharmaceutical packaging. The PC-based architecture provides computing power for real-time process calculations and optimization algorithms that exceed typical PLC capabilities. The MATLAB/Simulink integration enables model-based control strate...
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
TwinCAT ($) is significantly more affordable than RSLogix 500/5000 ($$). TwinCAT costs between $0 and $3 000, while RSLogix 500/5000 ranges from $1 000 to $10 000.
📚Learning Curve
RSLogix 500/5000 (rated 5/10) is easier to learn than TwinCAT (rated 7/10). RSLogix 500/5000 typically takes 2-4 months to learn, while TwinCAT requires 6-12 months. This makes RSLogix 500/5000 better for beginners.
⚙️Features & Capabilities
RSLogix 500/5000 offers 10 key features including safety programming, motion control. TwinCAT provides 11 key features with safety programming, motion control, robotics integration. TwinCAT offers a comprehensive feature set for industrial automation.
🏭Industry Adoption
RSLogix 500/5000 has 75% market adoption compared to TwinCAT's 60%. RSLogix 500/5000 dominates in North America, Latin America, while TwinCAT is strongest in Europe, North America, Asia-Pacific. RSLogix 500/5000's higher adoption means more job opportunities and community resources.
🔌Hardware Compatibility
RSLogix 500/5000 is designed specifically for Allen-Bradley, Rockwell Automation hardware, while TwinCAT works with Beckhoff PLCs. Both are vendor-specific solutions optimized for their respective hardware ecosystems.
💼Career Prospects
Both RSLogix 500/5000 and TwinCAT offer similar career value with certification programs. Knowledge of either platform will open automation career opportunities.
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
TwinCAT Overview
Key Strengths
- ✓FREE engineering software - only pay for runtime
- ✓Exceptional motion control capabilities
- ✓PC-based architecture provides high performance
- ✓Excellent real-time performance with EtherCAT
Limitations
- ✗Steep learning curve
- ✗Requires strong PC/Windows knowledge
- ✗Less common than Siemens/Rockwell (fewer jobs)
Best For
Recommendations
For Beginners
RSLogix 500/5000
For Professionals
TwinCAT
Budget-Constrained
TwinCAT
Enterprise Use
RSLogix 500/5000
Frequently Asked Questions
Which is better: RSLogix 500/5000 or TwinCAT?
Both RSLogix 500/5000 and TwinCAT are excellent choices with different strengths. RSLogix 500/5000 excels in community support, while TwinCAT leads in community support. Your choice should depend on your specific requirements, budget, and target hardware platform.
What is the price difference between RSLogix 500/5000 and TwinCAT?
TwinCAT ($) is significantly more affordable than RSLogix 500/5000 ($$). TwinCAT costs between $0 and $3 000, while RSLogix 500/5000 ranges from $1 000 to $10 000.
Which is easier to learn: RSLogix 500/5000 or TwinCAT?
RSLogix 500/5000 (rated 5/10) is easier to learn than TwinCAT (rated 7/10). RSLogix 500/5000 typically takes 2-4 months to learn, while TwinCAT requires 6-12 months. This makes RSLogix 500/5000 better for beginners.
Which has better career prospects?
Both RSLogix 500/5000 and TwinCAT offer similar career value with certification programs. Knowledge of either platform will open automation career opportunities.