EC: Jumpflex 857-402 Universal Signal Conditioner

Network integration – Signal conditioning, diagnostics: Just 6 mm wide, Wago's Jumpflex 857-402 Universal Signal Conditioner supports 456 signal combinations with industry-leading input range, class-exclusive Signal Clipping, and overcurrent protection via unique auto-reset fusing. This is a Control Engineering 2012 Engineers’ Choice honorable mention.


Jumpflex 857-402 Universal Signal Conditioner. Just 6 mm wide, Wago's Jumpflex 857-402 Universal Signal Conditioner supports 456 signal combinations with industry-leading input range, class-exclusive Signal Clipping, and overcurrent protection via unique auto-reset fusing. This is a Control Engineering 2012 Engineers’ Choice finalist.Wago's 857-402 Jumpflex Universal Signal Conditioner (USC) is unique. It isn’t 12.5 mm like traditional devices; it’s only 6 mm. The USC isn’t limited to 100 V, and its input spans from ± 0.3 mA to ± 100 mA, and ± 60 mV to a segment-leading ± 200 V. This USC, the industry’s slimmest, frees panel space within increasingly compact industrial electronics. Technically advanced, it simplifies BOMS, streamlines inventory, and reduces ordering errors by supporting 456 different signal combinations, the most in 6 mm.

Wago’s USC is configurable via on-unit DIP switches. Factory-calibrated, laser-capable resistors within the DIP switch maintain precise, constant values, even after multiple configurations. This provides signal transmission error of ± 0.1%, despite adjusting signal ranges, to eliminate time-consuming recalibration. The USC employs a momentary rocker-style switch (MRS), not a traditional potentiometer, for limit-free signal settings and enhanced vibration resistance. The MRS can be disabled via DIP switch to maintain signal settings or make them tamper-proof.

Jumpflex USC’s exclusive, auto-reset fuse protects input circuits against overload without impacting input value. When the overload is removed, the fuse instantly resets, with no in-the-field resetting or fuse replacement required. USC’s class-exclusive Signal Clipping protects PLCs by switching between analog and limiting behavior to clip signals that exceed set limits. For example, if a transducer’s input exceeds 20 mA, output signal is clipped at 20 mA, and the output will continue normal operation, preventing PLC errors and time-consuming troubleshooting.

Beyond offering the most signal combinations in the slimmest unit, the USC simplifies commissioning with flexible color-coded push-in jumpers, jumper slots at every connection point, marking tag holder, ribbon cable interface adapter, three-way 2.5 kV isolation, and maintenance-free CAGE CLAMPS terminations for reliability in temperatures of -25 to +70 C.


Return to the list of the 2012 Engineers' Choice honorable mentions.

View the list of the 2012 Engineers' Choice winners.

View the complete list of the 2012 Engineers' Choice finalists.

No comments
The Top Plant program honors outstanding manufacturing facilities in North America. View the 2013 Top Plant.
The Product of the Year program recognizes products newly released in the manufacturing industries.
The Engineering Leaders Under 40 program identifies and gives recognition to young engineers who...
A cool solution: Collaboration, chemistry leads to foundry coat product development; See the 2015 Product of the Year Finalists
Raising the standard: What's new with NFPA 70E; A global view of manufacturing; Maintenance data; Fit bearings properly
Sister act: Building on their father's legacy, a new generation moves Bales Metal Surface Solutions forward; Meet the 2015 Engineering Leaders Under 40
Cyber security cost-efficient for industrial control systems; Extracting full value from operational data; Managing cyber security risks
Drilling for Big Data: Managing the flow of information; Big data drilldown series: Challenge and opportunity; OT to IT: Creating a circle of improvement; Industry loses best workers, again
Pipeline vulnerabilities? Securing hydrocarbon transit; Predictive analytics hit the mainstream; Dirty pipelines decrease flow, production—pig your line; Ensuring pipeline physical and cyber security
Upgrading secondary control systems; Keeping enclosures conditioned; Diagnostics increase equipment uptime; Mechatronics simplifies machine design
Designing positive-energy buildings; Ensuring power quality; Complying with NFPA 110; Minimizing arc flash hazards
Building high availability into industrial computers; Of key metrics and myth busting; The truth about five common VFD myths

Annual Salary Survey

After almost a decade of uncertainty, the confidence of plant floor managers is soaring. Even with a number of challenges and while implementing new technologies, there is a renewed sense of optimism among plant managers about their business and their future.

The respondents to the 2014 Plant Engineering Salary Survey come from throughout the U.S. and serve a variety of industries, but they are uniform in their optimism about manufacturing. This year’s survey found 79% consider manufacturing a secure career. That’s up from 75% in 2013 and significantly higher than the 63% figure when Plant Engineering first started asking that question a decade ago.

Read more: 2014 Salary Survey: Confidence rises amid the challenges

Maintenance and reliability tips and best practices from the maintenance and reliability coaches at Allied Reliability Group.
The One Voice for Manufacturing blog reports on federal public policy issues impacting the manufacturing sector. One Voice is a joint effort by the National Tooling and Machining...
The Society for Maintenance and Reliability Professionals an organization devoted...
Join this ongoing discussion of machine guarding topics, including solutions assessments, regulatory compliance, gap analysis...
IMS Research, recently acquired by IHS Inc., is a leading independent supplier of market research and consultancy to the global electronics industry.
Maintenance is not optional in manufacturing. It’s a profit center, driving productivity and uptime while reducing overall repair costs.
The Lachance on CMMS blog is about current maintenance topics. Blogger Paul Lachance is president and chief technology officer for Smartware Group.