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.

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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.

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