Coordinating multiple axes, managing production data and integrating safety functions requires a control platform sized for the machine’s requirements. Allen-Bradley CompactLogix 5390 controllers from Rockwell Automation combine machine control, integrated motion, safety capabilities and local PointMax I/O in a compact architecture.
For machine builders, system integrators and manufacturers, the family provides an option for both new industrial automation projects and control system upgrades. A choice of memory sizes, network capacities and axis counts allows the system to match the application while maintaining a common control platform.
CompactLogix 5390 performance and controller capacity
Rockwell Automation specifies performance up to twice that of CompactLogix 5380 controllers. User memory ranges from 400 KB to 10 MB, with each model also providing an equal amount of dedicated safety memory.
The main capacities fall into three groups:
| User memory | Maximum EtherNet/IP nodes | Maximum position-loop drive axes | Maximum local I/O modules |
|---|---|---|---|
| 400 KB to 1 MB | 60 | 8 | 16 |
| 2 MB to 5 MB | 200 | 32 | 32 |
| 10 MB | 300 | 128 | 32 |
These limits depend on the model and are not available on every controller. System sizing requires a combined assessment of program execution, communications, I/O and motion: individual maximum capacities are not necessarily achievable simultaneously under full load.
For an OEM developing machines of different sizes, this scalability supports controller selection for each configuration while maintaining consistent design principles across the machine family.
Local PointMax I/O for compact control panels
CompactLogix 5390 controllers use local 5034 PointMax I/O modules, installed on the same DIN rail as the controller. Remote I/O connects through EtherNet/IP, allowing inputs and outputs to be distributed across different areas of the machine.
This architecture allows local signals to be concentrated in the cabinet, with remote connections used where the layout requires them. It can support a more organised, compact system with less integration complexity. Actual reductions in footprint and wiring depend on the configuration.
Configurations exceeding 16 local modules require the appropriate PointMax expansion module. Overall assembly dimensions must also account for power supplies, terminal blocks and installation clearances.
Integrated motion and functional safety
The platform supports Integrated Motion on EtherNet/IP, including synchronised multi-axis applications with compatible Kinetix drives. Depending on the model, the maximum number of drive axes configured for position-loop control is 8, 32 or 128.
All CompactLogix 5390 models can be enabled for safety applications up to SIL 2 / PL d, Category 3, using the appropriate safety task and safety I/O. Communication with networked safety devices uses CIP Safety over EtherNet/IP.
Managing machine logic, motion and safety on a common platform can simplify engineering and maintenance. The application’s safety performance still depends on the correct design, configuration and validation of the complete system.
Connectivity and programming with Studio 5000
Two embedded Gigabit Ethernet ports support Dual-IP configurations and linear, star and Device Level Ring (DLR) topologies. OPC UA capabilities enable machine data exchange, while CIP Security and Syslog provide functions for integration into the wider industrial cybersecurity architecture.
Programming uses Studio 5000 Logix Designer version 39 or later. Standard tasks support Ladder Diagram, Structured Text, Function Block Diagram and Sequential Function Chart; the safety task uses Ladder Diagram.
For teams already working with Logix, the common development environment supports continuity between engineering and technical support. Migration projects require a review of the existing program, I/O architecture, firmware and connected devices.
Industrial applications and controller selection criteria
Potential applications include packaging machines, material handling systems, assembly lines and dosing systems. These are application examples: controller suitability depends on cycle times, axis count, signals and operating conditions.
Standard versions operate at ambient temperatures from −25 to +60 °C. XT variants extend the range to −40 to +70 °C and provide additional protection in corrosive gas environments.
Selection therefore considers both performance requirements and installation conditions, together with expansion needs and compatibility between the components in the architecture.
Technology BSA support for CompactLogix 5390 controllers
Technology BSA, a Rockwell Automation Value-Added Distributor, supports machine builders, system integrators and industrial companies in selecting automation components and solutions.
When evaluating a CompactLogix 5390 system, the starting point is the application: I/O types and quantities, axes to coordinate, network architecture, safety functions and environmental conditions. For upgrade projects, the assessment also covers the installed system and migration requirements.
Technology BSA’s automation and PLC technical support helps assess the configuration and associated components. Commercial availability and lead times require verification for the specific project.
Would you like more information about CompactLogix 5390?
To learn more about CompactLogix 5390 controllers or assess their suitability for a project, complete the form below. The Technology BSA team provides technical and commercial support for selecting the configuration and associated components.
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