FEL3 · Class 3 · target ±10%

Controls Cost Estimator

I/O schedule

Hardwired = terminated in a panel. Soft = read over the network (drive, instrument, remote device data).
Point typeHardwiredSoft / networkedHardware $/hardwired pt
Discrete inputs (DI)A·Basm
Discrete outputs (DO)A·Basm
Analog inputs (AI)A·Basm
Analog outputs (AO)A·Basm
Networked device nodesVFDs, smart instruments, remote adapters, packaged skids on the networkA—asm
Spare I/O allowanceExtra hardwired points in hardware only%asm
Soft-point programming factorSoft point hours as a fraction of a hardwired point×asm

Panels

Per-panel hardware, fabrication and design allowances.
Panel typeQtyPLC / adapter $Enclosure, power, wiring $Fab & assembly $Design h
Main control panelCPU, chassis, power supply, comms
Remote I/O panelNetwork adapter, local I/O
Include design & drawingsSchematics, panel layouts, network drawings. Not covered by either source.
Hardware markupSource A: hardware × 1.30×A

Visualization

Screens drive hours; units and servers drive hardware.
ElementQtyHours each (A / B)
Standard HMI screensPanelView-class operator pagesA·B—
Alarm pagesB—
Trend / historical displaysB—
Recipe screensB—
SCADA screensWonderware / InTouch / FactoryTalk View SE classA—
HMI terminals (hardware)×asm
SCADA servers incl. licensing×asm

Logic elements

Counted separately from I/O in both sources.
PID loopsA: 4 h config · B: 35 min config + 1–2 h site tuningA·B
Motor starters / VFDs with logicA: 2–3 h eachA×asm
Function blocks / AOIsB: 25–30 min eachB
Major state machines / sequencesB: 4–8 h eachB
Recipe managementB: 8–16 hB
Data logging / historianB: 16–24 hB
High-speed counter modulesB: 4–8 h eachB
Servo axesB: 8–16 h each incl. tuningB
Sequential share of discrete logicB: sequential logic takes 2× equivalent discrete logicB%

Method & rates

Complexity picks a position inside each source's published range.
ComplexityLow / mid / high end of each range
Contingency classA: 1.5–2 / 2–3 / 3–5× · B: 1.5–2×
Contingency overrideLeave 0 to use the class value×
Estimate basisWhich programming-hours method carries the total
Blend weight toward AOnly used when basis is Blend
Site commissioningB: 20–30% of programming hoursB%
Programming / design rate$/hasm
Commissioning rate$/hasm
Total installed project valueOptional. Cross-checks B's 7–15% rule.$

Cost breakdown

CategoryLineQtyUnitHoursCostSource

Cross-checks

Independent top-down rules from the two sources.

Basis of estimate

Source A — Industrial Monitor Direct, PLC Programming Estimation: Hours per I/O, HMI, SCADA. Digital I/O 1.0–2.0 h × 1.0–1.5; analog I/O 1.5–2.5 h × 1.2–1.8; PID 4 h × 1.0–2.0; HMI screen 4–6 h × 1.0–1.5; SCADA screen 6–10 h × 1.2–2.0; comms setup 2–4 h per node; motor/VFD logic 2–3 h × 1.0–1.3. Debug/FAT +15–25%, documentation +20–30%. Contingency 1.5–2× well-defined, 2–3× moderate, 3–5× new technology. Turnkey cross-check: ((HW × 2.5) + (HW × 1.30)) × 1.10.

Source B — Industrial Monitor Direct, PLC Programming Project Cost Estimation Based on I/O Count. DI 10 min, DO 15 min, AI 20 min, AO 35 min; PID 35 min config + 1–2 h site tuning; function block 25–30 min; state machine 4–8 h; recipe 8–16 h; historian 16–24 h; HSC 4–8 h; servo 8–16 h; sequential logic 2× discrete. HMI page 5 h, alarm page 4–6 h, trend 3–4 h, recipe screen 6–10 h. Logic × 1.5–2.0 contingency, HMI × 1.5 (per its worked example). Commissioning 20–30% of programming hours. Programming should land at 7% (well-defined) to 15% (undefined) of total project value.

How the two methods are reconciled. Source A's per-point hours are an order of magnitude above Source B's. Treat A as the conservative envelope and B as the lean floor. The Blend basis interpolates between them. Neither source distinguishes hard from soft I/O, so soft points are scaled by the soft-point factor and each networked device adds A's comms-setup hours. Elements one source lacks borrow the other's mid-range value (marked in the breakdown).

Assumptions marked asm are not from either source: unit hardware costs, panel fabrication, design hours, labor rates, spares, drive hardware. They are placeholders to be replaced with your vendor quotes and shop rates.

Reaching ±10%. Both sources' methods are Class 4/5 in nature. Source A's own guidance is to track actual vs. estimated hours across 5–10 projects and tune the unit hours. Use the Method A / B spread flag as the signal: while the two methods disagree by more than about 25%, treat the band shown as indicative and calibrate the complexity, contingency and blend settings against a comparable completed project before carrying the number into an FEL3 package.