Page 81 - Jonard Tools - Catalog 2021_0

jonard.com | Wire Wrap Tools

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 18 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 Strip Force Chart*
By bending the wire around the sharp corner of the WIRE SIZE MIN NUMBER OF MIN. STRIP FORCE
terminal, the oxide layer on both wire and terminal is AWG DIA. DIA. TURNS
A crushed or sheared, and a clean, oxide-free metal-to- INCHES MM (BARE WIRE) LBS. GMS
metal contact is obtained. 16 .051 1.30 4 15 6800
B 18 .0403 1.00 4 15 6800
20 .032 0.80 5 8 3600
Types of Wrap 22 .0253 0.65 5 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 26 .0159 0.40 7 6 2700
the terminal in addition to the bare wire. This greatly 28 .0126 0.32 7 5 2200
increases the ability to withstand vibration. 30 .0100 0.25 7 3.3 1500
Regular Modified *Conforms to MIL-STD-1130B
How to Make Wire Wrapped Connections Some Hints on Making Wrapped Connections

Step 1: Bit, Sleeve and Pre-Stripped Wire OVERWRAP OPEN WRAP & SPIRAL WRAP
Do not press too hard. Let the Just keep the OK tool on the terminal
OK tools do the work. Excessive until the wrap is complete. Early
pressure can lead to overwrapping. removal can result in spiral and
Step 2: Wire Insertion Backforce “BF” to prevent open wraps.
overwrapping is available on most
power tools and is recommended for
use with 26 thought 30 AWG wire.
Step 3: Wire Anchoring
INSUFFICIENT TURNS PIGTAIL
It’s easy to feed wire into the slot Wire wrapping is a precision
Step 4: Terminal Insertion in the OK bit correctly. Be sure the technique and the wrong bit and
stripped end of the wire is “pushed- sleeve just cannot do the job.
in” all the way. Improper selection can cause
problems ranging from “Pigtails” to
Step 5: Finished Connection 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 1.27 1.40 1.52 1.65 1.78 1.91 2.03 2.16 2.29 2.41 2.54
.010 .014 .018 .022 .027 .032 .036 .041 .046 .051 .056 .061 .066 .071 .076 .081 .086 .091 .096 .101
0.25 0.36 0.46 0.56 0.69 0.81 0.91 1.04 1.17 1.30 1.42 1.55 1.68 1.80 1.93 2.06 2.18 2.31 2.44 2.57
.015 .018 .021 .025 .029 .033 .038 .043 .047 .052 .057 .062 .067 .072 .077 .082 .087 .092 .097 .102
0.38 0.46 0.53 0.64 0.74 0.84 0.97 1.09 1.19 1.32 1.45 1.58 1.70 1.83 1.96 2.08 2.21 2.34 2.46 2.59
Dimension A .025 .027 .029 .032 .035 .039 .043 .047 .050 .056 .060 .065 .069 .074 .079 .084 .089 .094 .099 .104
.020 .022 .025 .028 .032 .036 .040 .045 .049 .053 .058 .063 .068 .073 .078 .083 .088 .093 .098 .103
0.51 0.56 0.64 0.71 0.81 0.91 1.02 1.14 1.25 1.35 1.47 1.60 1.73 1.85 1.98 2.11 2.24 2.36 2.49 2.62
0.64 0.69 0.74 0.81 0.89 0.99 1.09 1.19 1.27 1.42 1.52 1.65 1.75 1.88 2.01 2.13 2.26 2.39 2.52 2.64
.030 .032 .033 .036 .039 .042 .046 .050 .054 .058 .062 .067 .071 .076 .080 .085 .090 .095 .100 .105
0.76 0.81 0.84 0.91 0.99 1.07 1.17 1.27 1.37 1.47 1.58 1.70 1.80 1.93 2.03 2.16 2.29 2.41 2.54 2.67
.035 .036 .038 .040 .043 .046 .049 .052 .056 .060 .064 .069 .073 .078 .082 .087 .091 .096 .101 .106
0.89 0.91 0.97 1.02 1.09 1.17 1.25 1.32 1.42 1.52 1.63 1.75 1.85 1.98 2.08 2.21 2.31 2.44 2.57 2.69
.040 .041 .043 .045 .047 .050 .052 .056 .060 .064 .068 .072 .076 .080 .084 .089 .092 .097 .102 .107
1.02 1.04 1.09 1.14 1.19 1.27 1.32 1.42 1.52 1.63 1.73 1.83 1.93 2.03 2.13 2.26 2.34 2.46 2.59 2.72
.045 .046 .047 .049 .050 .054 .056 .060 .063 .067 .071 .074 .078 .083 .087 .091 .096 .101 .105 .109
1.14 1.17 1.19 1.25 1.27 1.37 1.42 1.52 1.60 1.70 1.80 1.88 1.98 2.11 2.21 2.31 2.44 2.57 2.67 2.77
.050 .051 .052 .053 .056 .058 .060 .064 .067 .071 .074 .078 .082 .086 .090 .094 .098 .103 .107 .111
1.27 1.30 1.32 1.35 1.42 1.47 1.52 1.63 1.70 1.80 1.88 1.98 2.08 2.18 2.29 2.39 2.49 2.62 2.72 2.82
Example: If “A”=.020”. “B”=.060”. The terminal diagonal is .063" as shown on chart.
Example: If “A”=.020”. “B”+.060”. The Terminal diagonal is .063” as shown on chart.
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