FIGURE 20a. Insert the
pre-stripped wire into
the wire slot of the
FIGURE 20b. Anchor the
wire in the notch of the
FIGURE 20c. Insert the terminal
into the center hole of the
FIGURE 20d. Activate the
wire wrapping tool. This
rotates the wrapping bit
and wraps the wire
around the terminal.
FIGURE 21a. Insert the
insulated wire into the
bit and sleeve.
FIGURE 21b. Place the
tool over the terminal
to be wrapped.
FIGURE 21c. The wire wrapping
tool. Excess wire is cut off as
the tool starts to wrap.
FIGURE 21d. Insulation
stripping and wire wrapping
FIGURE 22a. Don’t
press too hard on the
tool during the wire
This results in
which one or more turns
of wire can slip over
the preceding turns.
device is helpful in
FIGURE 22b. Push the
wire all the way into
the wire slot. Improper
feeding of the wire
into the slot of the bit
results in insufficient
turns of wire for regular
wraps or insufficient
insulation turns for
FIGURE 22c. Don’t remove the tool
too quickly before you complete the
wrap. This results in “spiral” or
“open” wraps where one turn of
wire is more than 0.005” from
another turn. Pigtails, are where
the final turn of wire is not completely
wrapped. Too rapid removal of
the wrapping tool can cause this.
An anti-backforce device will help
reduce this problem.
FIGURE 22d. Select the proper bit
and sleeve. The particular wire
wrapping bit and sleeve depend
upon the size (terminal diagonal)
of the terminal you are wrapping.
An improperly matched terminal
hole diameter or bit to the
terminal diagonal causes defects
ranging from loose turns to
to a connection that you have poorly
wrapped. Unwrap it and start again! Never
use pliers of any kind on a wrap post. Use
an unwrapping tool (see Figure 19). Do
not use the bit and sleeve of the wrapping
tool as a pry. If possible, avoid placing more
than two wrap connections on a single post.
Figure 20 shows the four steps in a
standard mechanical wrap connection.
Figure 21 shows the four steps in a cut,
strip, and wrap connection. If you follow
these procedures, you will avoid four
common problems (see Figure 22).
And, that’s a wrap! NV
• Wire-Wrap Bits and Sleeves.
Gardner Denver Co., Pneutronics
Division, Grand Rapids, MI 49417.
• “The Wrap-Up: Connections
Without Solder,” W.H. Long. Electronic
Engineering Times, July 1977.
• “Wire Wrapping Wrap Up” Vaughn
D. Martin CQ Amateur Radio
Magazine October 1980.
• Military Standard 1130A. US
Department of Defense.
• EIA Standard RS-280-B. Electronic
Industries Association, January 1977.
• Wire-Wrapping Technology and
Production Equipment. David
Weltman, OK Machine & Tool Corp.,
3455 Conner St., Bronx, NY 10475
resource/ tech_wire.html. JDV
Products Inc.’s Standard Pneumatic
& Electronic Tool Company — wire
Acknowledgement: A special
thanks to Mike Crawl of Standard
Pneumatic for technical support
and permission to use their
artwork in this article.
June 2009 51