S-4000H Jumper Wire Inserter: Cut Jumper Material & Labor Cost

Jumper wires appear on most through-hole boards as configuration links, EC straps and routing jumpers, yet many DIP lines still insert them by hand. The S-4000H Jumper Wire Inserter feeds jumper wire straight from feeder to board - no sequencer pass, and up to one-third less JW material.

What is this machine used for?

Automatic jumper wire (JW) insertion on through-hole PCBs with direct JW feeder support.

• Jumper links, option straps and EC changes on power, appliance and automotive boards
• High-mix EMS batches and inline THT lines with SMEMA handshaking

Why automate jumper wire insertion?

• Direct feeder feed - no separate sequencer pass
• Vendor-cited saving of up to 1/3 JW material
• 20 inputs standard, expandable to 100
• Repeatable 0/90/180/270 deg placement replaces hand work

Verified specifications

| Parameter | Specification |

|---|---|

| Spec speed | 20,000 CPH |

| Inputs | 20, expandable to 100 |

| Insertion directions | 0, 90, 180, 270 deg |

| Lead span | 5.0-25 mm |

| PCB size | Max 450x390 mm, Min 50x50 mm |

| Process width | 50-285 mm, adjustable |

| Conveyor | Inline, SMEMA communication |

| Drive | Panasonic servo motors, Hi-win ballscrew |

| Power / air | 220 VAC 1-ph 50/60 Hz, 2.0 kW; 0.8 MPa, 0.3 m3/min |

| Certification | CE |

Values from the smthelp.com product page; confirm at quotation.

Line integration

After SMT reflow, boards enter the S-4000H; jumper links are inserted with SMEMA handshaking, then the panel moves to wave soldering, lead cutting and AOI/AVI.

ROI

Each S-4000H replaces several hand-insertion operators and removes sequencer capital cost. Direct feeding also cuts material waste - the ~1/3 JW saving compounds daily on high-volume panels. ROI modeled case by case.

About Southern Machinery

Founded 2011 in Shenzhen, China; 237+ global customers. Cost-effective SMT/THT automation: insertion, wave soldering, board handling, inspection, spare parts and modular upgrades with global support.

FAQ

Q: What components can the S-4000H insert?

A: Jumper wire, fed directly - no sequencer needed.

Q: Inline or offline?

A: Inline, with SMEMA communication upstream/downstream.

Q: What PCB sizes fit?

A: Max 450x390 mm, min 50x50 mm; width 50-285 mm adjustable.

Q: How many inputs?

A: 20 standard, expandable to 100.

Q: Power and air requirements?

A: 220 VAC single phase, 2.0 kW; air 0.8 MPa, 0.3 m3/min.

Next steps

Contact: jasonwu@smthelp.com | WhatsApp: +86 13602562576

Catalog: https://file.autoinsertion.com | Images: https://ph.smthelp.com

Watch jumper wire auto-insertion in action: https://www.youtube.com/watch?v=sBRMRw-gaHI

Product page: https://www.smthelp.com/s-4000h-jumper-wire-inserter-machine.html

Southern Machinery - cost-effective SMT/THT automation with global support. Founded 2011, Shenzhen. 237+ customers worldwide.