WEG PLC500 Controllers

High-Availability Control for Demanding Automation Cells

The WEG PLC500 family delivers modular, high-performance automation with redundant CPUs, remote I/O, and extensive networking. Pair PLC500 hardware with WEG drives, HMIs, and SCADA software to orchestrate complex machinery, process skids, and plant-wide control systems. Gross Automation engineers design, program, and commission PLC500 architectures every day.

Request PLC500 Quote PLC500 Quick Reference Search PLC500 Parts

WEG PLC500 Modular Controller Illustration

Controller Performance

Dual-core CPUs with scan times down to 0.6 ms and dedicated motion tasks
Redundant hot-standby processor and power modules for critical uptime
Integrated SoftPLC blocks for pump, HVAC, and positioning applications
High-speed counters, PTO outputs, and PID loops with autotuning

Modular Architecture

Scalable base racks from 4 to 16 slots with remote expansion over fiber or copper
Plug-in digital, analog, temperature, and specialty modules with per-channel diagnostics
Redundant power supply options plus built-in isolation for mixed voltage I/O
Hot-swappable modules simplify maintenance without disrupting production

Industrial Networking

Native Modbus TCP/RTU, EtherNet/IP, PROFINET, and CANopen support
Cybersecurity with user roles, encrypted protocols, and audit trails
Time-synchronized data logging with onboard historian buffers
Integrated OPC UA server for Industry 4.0 analytics and SCADA

Engineering Toolset

WLP and SoftPLC programming with IEC 61131-3 Ladder, FBD, ST, and SFC
Online changes, trace diagnostics, and simulation for faster FAT
Library management with reusable function blocks and project versioning
Integrated motion configuration and drive parameterization utilities

Engineered for Mission-Critical Control

Redundant Architectures

Deploy primary/secondary CPUs, network paths, and power supplies to meet water, utility, and heavy industrial availability targets.

Integrated Safety

SIL-rated safety I/O and safe motion interlocks coordinate with WEG drives for comprehensive machine protection.

Data & Diagnostics

Embedded web server, trend capture, and event logs provide immediate visibility for maintenance teams and remote support.

Cybersecure by Design

Role-based authentication, encrypted protocols, and secure boot help harden automation assets against unauthorized access.

Flexible System Building Blocks

Gross Automation helps you construct PLC500 topologies tailored to each project. Start with a compact rack for OEM equipment, add remote I/O for field devices, and integrate motion or safety modules when your application demands it.

Central Racks: CPU, power, and communication modules with high-density I/O.
Remote Nodes: Fiber or copper remote racks with environmental ratings up to IP67.
Network Gateways: Protocol conversion for legacy PLCs, MCCs, and SCADA masters.
Visualization: TPW HMIs or web dashboards for operators and maintenance teams.

Drive Integration

Native function blocks exchange diagnostics and control words with CFW500, CFW700, and CFW900 drives over Ethernet or fieldbus networks.

Remote I/O Segments

Distribute PLC500 I/O closer to equipment to reduce wiring costs. Each node supports local diagnostics, fused outputs, and safe-off relays.

Edge Analytics

Leverage embedded OPC UA and MQTT to publish operating data to plant historians, MES layers, and cloud dashboards.

Where PLC500 Delivers Results

Water & Wastewater

Coordinated pump stations with redundant control, secure remote telemetry, and on-board reporting for compliance.

Process Skids

Batching, blending, and CIP systems that require modular I/O, recipe management, and integration with plant PLCs.

Material Handling

Conveyors, sorters, and AS/RS systems with synchronized drives, safety zones, and uptime monitoring.

Energy & Utilities

Microgrids, CHP plants, and substations that rely on secure networking, historian integration, and NERC-compliant designs.

Delivered with Gross Automation Expertise

Our engineering team architects PLC500 systems from discovery through commissioning. We evaluate I/O requirements, redundancy needs, cybersecurity posture, and lifecycle support to deliver a complete automation package.

Front-end design reviews, P&ID mapping, and functional specification development
Panel fabrication with UL508A certification and documented FAT procedures
PLC, HMI, and drive programming with version control and validation
Onsite start-up, training, and remote monitoring services

Schedule Design Session Automation Solutions Overview

Associated WEG Platforms

CFW500 & CFW700 Drives

High-performance VFDs with embedded PLC500 communication profiles and diagnostics.

Explore CFW500

TPW HMIs & SCADA

Operator interfaces with secure remote access, alarming, and historian dashboards.

See TPW Panels

CLIC Micro PLCs

Cost-effective edge controllers that share WLP programming and networking with PLC500.

View CLIC PLCs

PLC500 Resources

PLC500 Quick Reference

Frame sizes, I/O capacities, and communication options at a glance.

Download PDF

I/O Architecture Guide

Topology examples for redundant CPUs, remote racks, and fiber backbones.

Download Guide

WLP Programming Manual

Complete IEC 61131-3 reference for WEG PLCs and drive-based SoftPLC.

Download Manual

Project Discovery Worksheet

Document I/O, network, and redundancy requirements for a PLC500 proposal.

Request Worksheet