kev,
You will want to consider the following:
It will help if you provided a list of your I/O devices to the forum. From your initial post, there will be four of everything. So, unless this is different, you need only list your devices once.
Based on your information you will need a total of 28 inputs / 20 outputs.
You will need to determine the type of I/O you will require.
Digital I/O can be either AC or DC. From the statement regarding your power, it appears that you will be using all 24 VDC.
With regards to the outputs, you can use either relays or transistors. Much will depend on your load and freqency of switching. The more you switch, you may want to consider the transistor output in that it should last longer then a relay. The difference...A relay uses an arm and contact for completing the circuit. The transistor has no moving parts for making contact to complete the circuit and turn on the output.
You will need to determine your budget for your project. Your budget will include the controller, software and any devices you will require, to accomplish your application.
Software will depend on manufacturer and will range anywhere in price from Free to over $1000.00.
Of note, we provide a free programming software package.
www.entertron.com/software.htm
You will next want to research controllers that meet your requirements.
We offer two different products that will satisfy your application I/O requirements with a few left over.
1. SK1600-RIC configured as 32 DC in / 24 relay out -
www.entertron.com/sk1600ric.htm
2. Elite-2000 configured as 32 DC in / 32 DC transistor out -
www.entertron.com/elite.htm
You will also need to determine if the devices you are driving can be handled by the outputs directly from the PLC or if you will need to use interposing relays that will be turned on by the PLC but will bear the brunt of the load from your devices.
There are many manufacturers you can choose from. Here is a link to the forum's list -
http://www.plcs.net/chapters/links.htm
Hope this information is able to get you started.
God Bless,