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Allen-Bradley's CompactLogix 5380 and 5480 controllers look similar on paper — same 5069 I/O platform, same Studio 5000 programming environment, same EtherNet/IP connectivity. But they serve different roles in your automation architecture.
The 5380 is a pure real-time controller. The 5480 adds a full Windows 10 IoT Enterprise operating system alongside the Logix engine. Understanding when you need that Windows layer — and when it just adds cost and complexity — is the key to making the right choice.
Quick comparison
| Feature | CompactLogix 5380 | CompactLogix 5480 |
|---|---|---|
| Operating System | Logix real-time OS only | Logix real-time OS + Windows 10 IoT Enterprise |
| Controller Models | 5069-L306ERM through 5069-L380ERM | 5069-L406ERMW through 5069-L4200ERMW |
| User Memory (Logix) | 0.6–20 MB | 0.6–20 MB |
| Windows Storage | N/A | 64 GB SSD (Windows partition) |
| Ethernet Ports (Logix) | 2 × 1 Gbps | 2 × 1 Gbps (Logix) + 1 × 1 Gbps (Windows) |
| Display Output | None | DisplayPort (for local Windows desktop) |
| USB Ports | 1 (programming) | 1 (programming) + 2 (Windows peripherals) |
| Local 5069 I/O | Up to 31 modules | Up to 31 modules |
| CIP Motion Axes | Up to 256 | Up to 256 |
| Safety Option | Yes (Compact GuardLogix 5380) | No |
| Approximate CPU Cost | $1,200–$6,000 | $5,000–$8,000+ |
CompactLogix 5380: pure control, nothing extra
The 5380 is Allen-Bradley's current-generation workhorse for machine and cell-level control. It does one thing well: executing Logix control programs with deterministic, real-time performance.
Strengths
- Wide range of CPU sizes: From the entry-level L306ERM (0.6 MB, 4 axes) to the high-end L380ERM (20 MB, 256 axes), you can right-size the controller to your application.
- Compact GuardLogix safety option: The 5069-L3xxERMS2 models combine standard and safety control in one controller — no need for a separate safety PLC.
- CIP Security: TLS/DTLS encryption for controller-to-device communications, protecting against man-in-the-middle attacks.
- Lower cost and complexity: No Windows updates, no antivirus, no OS patches to manage.
- Proven reliability: No Windows blue screens or crashes to worry about — it is a dedicated real-time control engine.
Typical applications
- OEM packaging, filling, and labeling machines
- Conveyor and material handling systems
- Machine tool cells
- Safety-integrated machine control (GuardLogix variant)
- Any application where "just control" is all you need
CompactLogix 5480: control + edge computing
The 5480 is a hybrid platform. Inside the same physical housing, you get a dedicated Logix real-time controller and an independent Windows 10 IoT Enterprise PC, connected via a high-speed internal link.
What Windows enables
- Local SCADA/HMI: Run FactoryTalk View SE, Ignition, or any Windows-based SCADA directly on the controller — no separate PC required.
- Data analytics at the edge: Run Python, MATLAB, or custom analytics applications that process production data locally before sending summaries to the cloud.
- Machine learning inference: Deploy trained ML models (TensorFlow, ONNX) that run on the Windows side and exchange data with the Logix controller in real time.
- Custom applications: Run any Windows application — database clients, OPC UA servers, custom protocol converters, REST API endpoints.
- Local historian: Run FactoryTalk Historian or OSIsoft PI locally for data logging without network dependency.
Architecture detail
The Logix engine and Windows OS run on separate, isolated processors. The Logix side has dedicated memory, a dedicated Ethernet port pair, and its own real-time OS. Windows cannot interfere with or delay the real-time control program. Data exchange between the two sides happens through a high-speed internal connection using standard tag read/write operations.
This is fundamentally different from a PC-based soft PLC. The 5480's Logix side provides the same deterministic, scan-based execution as a standalone 5380 — Windows is a passenger, not the driver.
When the 5480 makes sense
- You currently run a separate industrial PC alongside your PLC and want to consolidate
- Edge computing requirements: local analytics, ML inference, or custom application logic
- Remote or hard-to-access machines where minimizing hardware simplifies maintenance
- Applications that need local HMI/SCADA without a panel PC
When the 5480 does not make sense
- You just need a PLC — adding Windows adds cost, management overhead, and attack surface
- Safety applications — there is no GuardLogix 5480 variant
- Budget-constrained projects where a 5380 covers the control requirements
- Environments where IT/OT policy restricts Windows devices on the plant floor
Decision framework
| Question | If Yes → 5480 | If No → 5380 |
|---|---|---|
| Do you currently run a PC alongside the PLC? | Consolidate into 5480 | 5380 is sufficient |
| Do you need local data analytics or ML inference? | 5480 runs Windows apps natively | 5380 + cloud analytics |
| Do you need integrated safety (SIL 2)? | N/A — 5480 has no safety variant | 5380 GuardLogix |
| Is IT willing to manage Windows on the plant floor? | Proceed with 5480 | Stick with 5380 |
| Is controller cost the primary concern? | 5480 costs $2,000–$4,000 more | 5380 saves budget |
Related resources
- Allen-Bradley PLC Buyer's Guide: ControlLogix vs CompactLogix vs Micro800
- Allen-Bradley 5069 Compact I/O: Complete Module Selection Guide
- Allen-Bradley Catalog Number Decoder
Browse our CompactLogix 5380 and 5480 inventory →
Frequently asked questions
Can I run the same Logix program on both the 5380 and 5480?
Yes. The Logix engine in the 5480 is identical to the 5380. You can develop a program on a 5380, then deploy it to a 5480 (or vice versa) without modification — as long as the target controller has sufficient memory and I/O configuration matches.
Does the Windows side affect Logix real-time performance?
No. The Logix engine and Windows OS run on separate, isolated processors with dedicated memory and network interfaces. A Windows crash or heavy CPU load on the Windows side does not affect the Logix scan time or I/O processing. They are architecturally independent.
Can I use the 5480 as a replacement for a panel PC?
In many cases, yes. The 5480 has a DisplayPort output and USB ports for keyboard/mouse, so you can connect a monitor directly. However, the 5480 is an industrial controller — not a full desktop PC. It runs Windows 10 IoT Enterprise (LTSC), which receives fewer updates but also has some application limitations compared to full Windows 10 Pro.
Is there a GuardLogix version of the 5480?
No. As of 2026, Allen-Bradley does not offer a safety-rated 5480 controller. If your application requires integrated functional safety (SIL 2 / PLd), you must use the Compact GuardLogix 5380 (5069-L3xxERMS2 models). You can pair a 5480 with a separate GuardLogix controller on the same network if you need both edge computing and safety control.