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How to choose the right PLC and Control System for the job
Choosing the right PLC and control system can greatly affect how reliably and efficiently a machine or broader industrial process operates. Different requirements place very different demands on a control system, and with a wide range of platforms available, understanding what the application actually needs is the best place to start.
So, how do you choose the right system?
There are a few key factors to consider when choosing the right control system, starting with what the system needs to do, the scale of the application and how your requirements may change in the future.
Consider the use of the Control System
As we all know, a system controlling a single machine will have very different requirements to one managing a larger production process with multiple motors, temperature control or several pieces of connected equipment. Understanding elements such as:
- the number and type of inputs and outputs
- the level of automation required
- how operators will interact with the system
This helps narrow down which PLC and control platform is suitable for the application.
Consider your future plans
It is also important to consider how your system may need to change and evolve alongside your business into the future. If additional machinery, production lines, sensors or monitoring are likely to be introduced later, choosing a PLC and control system that has the capability to expand becomes essential.
In short, planning for future requirements from the beginning can help avoid replacing or heavily reworking a control system simply because the original setup no longer has enough capacity.
Consult a PLC and Control Panel Specialist
If you are unsure which PLC or control system is best suited to the job, we always recommend speaking to a control panel specialist as early as possible in the project. They can assess the equipment being controlled, the required inputs and outputs, communication requirements, operating environment and future expansion plans before recommending a suitable platform. This helps make sure the system is designed around the actual needs of the job rather than simply choosing a controller based on familiarity or price.
There are many PLC and Control Systems to choose from…
At Electric Technics Ltd, we work with a range of manufacturers and controller families across commercial and industrial environments. Below are some of the main platforms our experts regularly work with and the types of applications they are suited to.
Allen Bradley PLCs and Controllers
Allen-Bradley offers a wide range of PLCs for different levels of industrial automation, from simple standalone machinery through to larger and more complex control systems.
MicroLogix – A compact PLC range commonly found in smaller and older automation applications.
Micro800 – Designed for standalone machines and smaller control applications where a compact and flexible controller is required.
SLC 500 – A well-established legacy PLC platform still found across many industrial sites and existing control systems.
CompactLogix – Suited to small and medium-sized automation systems requiring greater processing, networking and expansion capabilities.
ControlLogix – Designed for larger and more complex industrial applications involving extensive I/O, communications and interconnected processes.
B&R Automation Control Systems
B&R offers modular control systems designed for a wide range of industrial automation applications, including machinery, process control and mobile equipment.
X20 System – A modular control and I/O platform suited to a wide range of machine and industrial automation applications.
X20 System Coated – A protected version of the X20 platform designed for use in harsher environments where additional resistance to moisture and contaminants is required.
X90 Mobile Control System – Designed for mobile machinery and off-highway applications where control equipment needs to cope with demanding operating conditions.
Siemens PLCs and Automation Systems
Siemens offers a broad range of PLCs and automation systems used across everything from compact machinery through to larger industrial and process control applications.
S7-300 – A proven modular PLC platform still widely found in existing industrial installations and suitable for a broad range of automation tasks.
S7-400 – Designed for larger and more demanding applications where high processing capability, scalability and system availability are required.
S7-1200 – A compact PLC range suited to smaller machines and straightforward automation applications.
S7-1500 – A higher-performance platform designed for more advanced machine and plant automation, with greater processing, networking and expansion capabilities.
ET 200 – A distributed control and I/O platform suited to applications where control equipment needs to be positioned closer to machinery or spread across a larger system.
Danfoss Control Systems
Danfoss control systems are commonly used within heating, ventilation, air conditioning and refrigeration applications, with platforms ranging from programmable controllers through to wider system management.
Alsmart – A modular programmable controller platform designed for HVAC applications such as chillers, air handling units, heat pumps and rooftop units.
MCX – A flexible range of programmable controllers used across HVAC and refrigeration systems, from standalone equipment through to more complex control applications.
AK-SM – A system management platform used particularly within refrigeration and HVAC environments to monitor and coordinate controllers, temperatures, alarms and other system functions.
Resource Data Management Control Systems
Resource Data Management, or RDM, provides control and monitoring systems commonly used across HVAC, refrigeration, lighting and wider building management applications.
TDB – A programmable control platform used to create bespoke control strategies across HVAC, refrigeration, lighting and energy applications.
TouchXL – A touchscreen interface that can be used for local control, monitoring and alarm management within an RDM system.
DMTouch – A front-end control and monitoring platform used to manage HVAC, refrigeration and other connected building systems across a site.
CAREL Control Systems
CAREL control systems are widely used within HVAC, refrigeration and building management applications, with solutions covering equipment control, electrical load management and wider system supervision.
pCO – A programmable controller platform designed for HVAC and refrigeration applications, including chillers, heat pumps, air handling units and other building services equipment.
pChrono – A programmable controller used to manage lighting and other electrical loads, with time-based control helping to manage how and when equipment operates.
BOSS – A web-based supervision system used to centrally monitor and manage HVAC, refrigeration and other connected building systems, including alarms, operating data and system performance.
Speak to our PLC and Control System Experts
Choosing the right control system starts with understanding exactly what the application needs, both now and in the future. At Electric Technics Ltd, we work with a wide range of PLC and control platforms and can help assess your requirements, recommend a suitable system and support everything from programming and modifications through to complete control panel projects. Whether you are planning a new installation or need support with an existing system, speak to our team to discuss the best approach for your application.
