Which I/O System is right for your simulator?

As many nuclear power plant simulators worldwide are reaching 30+ years of age, input/output (I/O) system replacements are becoming more common. Hardware engineers tire of complicated repairs, obsolete parts, and maxed-out racks. Trainers and operators are tired of weekly downtime where they cannot train on the simulator due to I/O problems.

In this industry, there used not to be a choice of I/O systems. Ever since simulators were required back in 1991, nuclear power plants have routinely used proprietary systems. Their promise of “plug n’ play” functionality and a quick turnaround for implementing technology and obsolescence upgrades have kept the industry largely captive to the hefty price tag. Until now, that is.

Commercial, off-the-shelf I/O system providers with decades of proven experience in industrial, building, and marine automation offer independent, modular solutions at a lower price point. Which solution is best for you?

Legacy vs. New Modular I/O Systems: Pros and Cons

Before you compare suppliers, it is important to consider why you may want to choose a modular I/O system in the first place.

Here is a chart of the pros and cons of upgrading legacy proprietary systems versus replacement with a new modular I/O solution.

IO Solution	Advantages	Disadvantages
Custom	Typically, faster to implement	Expensive Obsolete parts
Modular	Standardized IO interface.  The actual IO vendor does not matter as much as long as the vendor supports the IO interface standard Lower cost, easily obtained in the market Large installed base Easy to maintain & troubleshoot Easier to run wires Small footprint Draws less electricity Generates less heat Fully distributed and easy to expand the IO where needed	Time required to implement. (For new builds and expansions, less time than custom) For most solutions, when removing modules with power on, downstream modules are temporarily affected

 

The major barrier to choosing modular I/O solutions has always been the time required to implement versus their custom counterpart. However, along with advancements in the systems themselves, GSE has reduced implementation time to a couple of weeks for a typical simulator.

The picture below demonstrates the vast difference in accessibility between the legacy I/O systems currently at most plants and a replacement modular I/O solution. You guessed it! The one on the right is the replacement I/O, a modern, modular implementation where you can actually access everything without stepping over wires!

Modular I/O Vendor Comparison

If you’ve read this far, you’re likely interested in learning more about the modular solution providers available today and how their solution stacks up against the competition.

As an experienced simulator I/O replacement partner, GSE has extensively researched and implemented some of the top names in modular I/O. The chart below compares a handful of the most prominent modular I/O solution providers; Beckoff, Wago (750), and Weidmuller (u-Remote).

 

Vendor	Advantages	Disadvantages
Beckoff	overall cost, easily obtained in the market Higher analog density High voltage power distribution module available Large installed base	When removing modules with power on, downstream modules are affected
Wago	Low-cost, easily obtained in the market. (Currently experiencing longer delivery times) High voltage power distribution module available Large installed base	When removing modules with power on, downstream modules are affected
Weidmuller (u-Remote)	Electronics modules can be replaced with power on – truly the best hot-swappable I/O on the market. Removing a module with power on does not affect any other part of the system Electronic module is sold and replaced separately if needed.  No wiring is required to replace the electronics Discrete wiring (toolless wiring/removal) also has removable connector options. Overall LED light status at the top of the module and a LED at each point Analog module supports all voltage/current standards on a point-by-point basis.  Programmable and scalable Analog Outputs (Point by Point) Native Wi-Fi/web browser/ iPhone/ Android control/ override/ troubleshooting on a node/ module basis Newest design	Keying is not supported on these connectors No alternative power distribution modules available

I/O Interface Standardization (The Holy Grail of Modern I/O systems)

All the modern modular I/O system vendors support multiple standard I/O interfaces. With the advent of the I/O interface software standardization, you are no longer bound to the original I/O Vendor. In fact, it is possible to have all the IO systems listed above and others not even developed yet simultaneously operating in the same I/O system. This is the Holy Grail of Modern I/O systems. The advantages of this cannot be overstated. You are no longer bound to any one I/O vendor for spare parts or support. You are future-proofed.

Conclusion

If you’re tired of the headaches caused by I/O failures, simulator downtime, and obsolete parts, one of the above modular systems might be the best solution.

GSE can help you determine which I/O solution is best for your plant’s simulator. We’ve implemented modular systems on over a dozen simulators. Contact us to schedule a consultation.