Error-free and fast connection of I/O modules


Osman Gazi Bridge  

The now completed Osman Gazi Bridge is the fourth largest suspension bridge in the world

  • The Osman Gazi Bridge is the central element of the planned 420 km-long highway connection between Istanbul and Izmir.
  • The signals from the around 4500 I/Os installed in the bridge are processed by I/O modules of the S7-300/ET 200M controllers.
  • System cabling from Phoenix Contact connects the modules quickly and without errors to the field wiring.

Customer profile

Project Manager Alper Arifoǧlu  

Siemens Project Manager Alper Arifoǧlu was responsible for selecting the electrical components

The Japanese Group IHI Corporation, tasked with building the bridge, assigned various aspects of the work to subcontractors.

The SCADA (Supervisory Control and Data Acquisition) solution needed to monitor and control the processes and the bridge’s power supply system were implemented by Siemens AG.


Container with control cabinets  

Sectional model of a roof segment with the control cabinet containers on the maintenance level

Main supply buildings were erected at the northern and southern termini of the bridge, each of which houses the high, medium, and low-voltage network. Both subsystems are connected to one another redundantly in order to prevent system failure.

Signal processing takes place on the maintenance levels of the bridge. As such, this level houses special containers in which the individual control cabinets are set up. The different signal lines for data acquisition converge in the containers, as permanent monitoring is necessary to maintain the bridge’s infrastructure.

Moreover, the proper lighting and signaling for vehicle, air, and ship traffic must be ensured at all times. The signals of the subsystems are evaluated using I/O modules of the S7-300/ET 200M controllers. Siemens uses the system cabling solution from Phoenix Contact to connect the modules.


VIP-Power front adapter  

VIP-Power front adapter for quick and easy connection

The VIP-Power Cabling product range offers a plug-in terminal block that supports the quick and easy Plug and Play connection of the individual I/O modules of the S7-300 controller. The time-consuming single-wire cabling required in traditional systems and the I/O function test for checking proper signal routing are therefore no longer required. One of the advantages of the pre-assembled VIP adapters is that they are subjected to a high-voltage test at the end of the production process. At the same time a check is performed to ensure that the wires between the front adapter and the terminal block connector are connected properly. This provides the user with an error-free and safe connection. When combined with plug-in Push-in double-level terminal blocks, the 40 terminal points of the controller can be routed on a piece of hardware only 70 mm wide.

According to Project Manager Alper Arifoǧlu, the decision-makers were particularly impressed with the space and time saved when combining system cabling with the direct connection technology of the terminal blocks. Normally, around ten working days are scheduled for setting up a large control cabinet with marshalling level, as is required for the application at hand. One working day is needed for mechanical installation work, while the remaining nine days are used to implement the electrical components and perform the field acceptance test (FAT). “At first, the control cabinet implementation really threatened our time schedule,” says Alper Arifoǧlu. “Thanks to the use of system cabling, our control cabinet manufacturing contractor managed to do the same job in just two days, which helped us to stick to the schedule.”


A further criterion for opting for the VIP-Power Cabling product range is its easy handling. 20- or 40-pos. versions are available that are suitable for all I/O modules of the ET 200M. It doesn't matter whether it's an analog module or a relay output card here. Owing to the large conductor cross section and the terminal block connectors, weak switching signals and loads of up to 250 V AC and 6 A can be routed. A total of 24 control cabinets were wired on the Osman Gazi bridge using system cabling from Phoenix Contact.


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