Denford Mirac conversion help

[m_c]

Something with enough inputs and outputs!
I used the small Click PLC range from Automation Direct for my turret, but had to buy an additional Input/output module to get enough inputs. They also do a slightly more featured range (DL series?) that might have more inputs/outputs on the base modules.
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Good thing about the Click range though, is the programming software is free and has no limits. The DL software has a limit on program size, above which you have to buy a license.
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As for communicating between the PLC and controller, the less complicated option is via Modbus, but that can sometimes be problematic to setup. In my lathe, I use Modbus to transfer the desired position to the PLC, and continually read the actual position back. I then have an output from the KFlop to the PLC telling the PLC if it's ok to change position, and an output from the PLC back to the KFlop telling the KFlop that the tool changer is locked, and on the correct position. The KFlop then monitors that input, and if it deactivates when a change hasn't been requested, it triggers an E-stop.