HOW TO WIRE-WRAP

27-mar-00

Wire wrapping is a means for making connections between circuit components using 30g Kynar wire wrap wire and a special wrap tool. The tool forms the wire in a tight spiral around the 0.025 inch square wire post. The post must be square in cross-section because the corners of the square dig into the wire to form a gas-tight connection.

We use two brands of wrap tools. The "blue tool", Model WSU-30M is made by OK Industries. The "silver tool", Catalog No. 276-1570, is made by Radio Shack. Instructions for both tools are similar. The figures in our writeup were taken from the instructions provided with the tools

1. Blue tool instructions

1. Strip the insulation by inserting wire approximately 1 inch into the slit. Pull wire down into the slot, then pull the wire 2. Insert wire into the small opening on the bottom of the tool, the one near the edge. Insert until the insulation bottoms out. Bend the wire 90 degrees and hold. Place tool over terminal (the terminal goes into the center opening). Turn clockwise about 10 turns, neither lifting up nor pushing down.
3. To unwrap, place short end of tool over terminal. Turn tool counterclockwise.

 

 

2. Silver tool instructions

1. Remove wire stripper from handle. Insert wire approximately 1 inch. Pull down into slot. Pull wire. 2. Insert wire into the small opening on the bottom of the tool, the one near the edge. Insert until the insulation bottoms out. Bend the wire 90 degrees and hold. Place tool over terminal (the terminal goes into the center opening). Turn clockwise about 10 turns, neither lifting up nor pushing down.
3. To unwrap, place end of tool over terminal. Turn tool counterclockwise.

 

Quality Control

A quality wrap will have the following attributes:

  1. Five to 10 tightly spaced wraps
  2. Insulation wrapped 1/2 to 1-1/2 times around post
  3. No bare wire extending away from the post