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W I R E W R A P P I N G O V E RV I E W
Wire Wrapping is a method of making a wire connection by coiling the bare wire around the sharp corners of a
terminal under mechanical tension. The technology was developed as an alternative to soldering, which presents
various safety and reliability problems in many applications. A principal advantage of wire wrapping is that it
provides a high-reliability connection that is also easily removed to correct or modify a wiring layout. Wire wrapping
subjects the wire to tremendous tension and compression forces, causing the oxide layer on both wire and terminal
to be crushed or sheared, resulting in a clean, oxide-free metal-to-metal contact. A standard wrap is generally used
for 24 AWG and larger diameter wires; a modified wrap is typically used for 26 AWG and smaller wires, and is used
almost exclusively for 28 to 30 AWG wires. In either case, the wrap style affects only the connection’s mechanical
stability; both styles provide suitable electrical connections.
METAL - TO - METAL CONTACT
By bending the wire around the sharp corner
of the terminal, the oxide layer on both wire
and terminal is crushed or sheared, and a clean,
STRIP FORCE CHART*
Wire Size Min. number Min. strip
AWG Dia. Dia. of turns force
inches mm (Bare Wire) lbs. gms
oxide-free metal-to-metal contact is obtained.
A
16 .051 1.30 4
18 .0403 1.00 4
15 6800
15 6800
TYPES
OF
WRAP
B
20 .032 0.80 5
22 .0253 0.65 5
8 3600
8 3600
A “Regular” bit wraps the bare wire around the terminal.
24 .0201 0.50 6
7 3200
A “Modified” bit wraps a portion of insulation around
the terminal in addition to the bare wire.This
greatly increases the ability to withstand vibration.
HOW
TO MAKE WIRE
Regular
Modified
26 .0159 0.40 7
28 .0126 0.32 7
30 .0100 0.25 7
*Conforms to MIL-STD-1130B
6 2700
5 2200
3.3 1500
WRAPPED CONNECTIONS
SOME HINTS ON MAKING WRAPPED CONNECTIONS
Step 1: Bit, Sleeve and
Pre-Stripped Wire
Step 2: Wire Insertion
Step 3: Wire Anchoring
Step 4: Terminal
Insertion
Step 5: Finished
Connection
OVERWRAP
Do not press too hard. Let the OK
tools do the work. Excessive
pressure can lead to overwrapping.
Backforce "BF" to prevent
overwrapping is available on most
power tools and is recommended
for use with 26 through 30 AWG
wire.
INSUFFICIENT TURNS
It’s easy to feed wire into the slot in
the OK bit correctly. Be sure the
stripped end of the wire is “pushed-
in” all the way.
OPEN WRAP & SPIRAL
WRAP
Just keep the OK tool on the
terminal until the wrap is
complete. Early removal can
result in spiral and open
wraps.
PIGTAIL
Wire wrapping is a precision
technique and the wrong bit and
sleeve just cannot do the job.
Improper selection can cause
problems ranging from “Pigtails”
to loose wraps.
TERMINAL DIAGONAL CHART
DIMENSION B
In.
.010
.015
.020
.025
.030
.035 .040 .045
.050 .055 .060 .065
.070
.075
.080
.085
.090
.095
.100
mm 0.25 0.38 0.51 0.64 0.76 0.89 1.02 1.14
.010 .014 .018 .022 .027 .032 .036 .041 .046
0.25 0.36 0.46 0.56 0.69 0.81 0.91 1.04 1.17
.015 .018 .021 .025 .029 .033 .038 .043 .047
0.38 0.46 0.53 0.64 0.74 0.84 0.97 1.09 1.19
.020 .022 .025 .028 .032 .036 .040 .045 .049
0.51 0.56 0.64 0.71 0.81 0.91 1.02 1.14 1.25
.025 .027 .029 .032 .035 .039 .043 .047 .050
0.64 0.69 0.74 0.81 0.89 0.99 1.09 1.19 1.27
.030 .032 .033 .036 .039 .042 .046 .050 .054
0.76 0.81 0.84 0.91 0.99 1.07 1.17 1.27 1.37
. 035 .036 .038 .040 .043 .046 .049 .052 .056
0.89 0.91 0.97 1.02 1.09 1.17 1.25 1.32 1.42
.040 .041 .043 .045 .047 .050 .052 .056 .060
1.02 1.04 1.09 1.14 1.19 1.27 1.32 1.42 1.52
.045 .046 .047 .049 .050 .054 .056 .060 .063
1.14 1.17 1.19 1.25 1.27 1.37 1.42 1.52 1.60
.050 .051 .052 .053 .056 .058 .060 .064 .067
1.27 1.30 1.32 1.35 1.42 1.47 1.52 1.63 1.70
1.27 1.40 1.52 1.65
.051 .056 .061 .066
1.30 1.42 1.55 1.68
.052 .057 .062 .067
1.32 1.45 1.58 1.70
.053 .058 .063 .068
1.35 1.47 1.60 1.73
.056 .060 .065 .069
1.42 1.52 1.65 1.75
.058 .062 .067 .071
1.47 1.58 1.70 1.80
.060 .064 .069 .073
1.52 1.63 1.75 1.85
.064 .068 .072 .076
1.63 1.73 1.83 1.93
.067 .071 .074 .078
1.70 1.80 1.88 1.98
.071 .074 .078 .082
1.80 1.88 1.98 2.08
1.78
.071
1.80
.072
1.83
.073
1.85
.074
1.88
.076
1.93
.078
1.98
.080
2.03
.083
2.11
.086
2.18
1.91
.076
1.93
.077
1.96
.078
1.98
.079
2.01
.080
2.03
.082
2.08
.084
2.13
.087
2.21
.090
2.29
2.03
.081
2.06
.082
2.08
.083
2.11
.084
2.13
.085
2.16
.087
2.21
.089
2.26
.091
2.31
.094
2.39
2.16
.086
2.18
.087
2.21
.088
2.24
.089
2.26
.090
2.29
.091
2.31
.092
2.34
.096
2.44
.098
2.49
2.29
.091
2.31
.092
2.34
.093
2.36
.094
2.39
.095
2.41
.096
2.44
.097
2.46
.101
2.57
.103
2.62
2.41
.096
2.44
.097
2.46
.098
2.49
.099
2.52
.100
2.54
.101
2.57
.102
2.59
.105
2.67
.107
2.72
2.54
.101
2.57
.102
2.59
.103
2.62
.104
2.64
.105
2.67
.106
2.69
.107
2.72
.109
2.77
.111
2.82
Example: If “A”=.020”. “B”=.060”. The terminal diagonal is .063" as shown on chart.
4
INDUSTRIES CORP.
134 Marbledale Road, Tuckahoe, NY 10707
? www.jonard.com
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