The Wire-Wrap wrapping technique

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WRAPPING BITS AND SLEEVESWrapping bits and sleevesSelection of wrapping bits and sleevesApplication:Wire diameter, Dimensions of terminal, Grid system,Connection styleExample:Solid wire with conductor 0,25 mm (AWG 30) and insulation0,55 mm diameter to be wrapped on a terminal a x b= 0,75 x 0,50 mm, terminal length 13,50 mm on a spacingof 2,54 mm - a modified connection is required.Solution:In the table „Technical features of wrapping bitsand sleeves“ locate column (1): Conductor diameter,and column (2): wrap type.Example:Conductor diameter 0,25 mm (AWG 30) and „MOD“.Check maximum insulation diameter - column 5 -(applicable only to MODIFIED connections)The insulation diameter is 0,55 mm. The bit 507573 canaccept a maximum insulation diameter of 0,60 mm.Clearance between sleeve and adjacent wrapped terminaluse the formula:Effective Radius + Wire diameter + a / 2 Spacing.The bit 507573 with the sleeve 507100 has an effectiveradius of 1,55 mm. So: 1,55 + 0,55 + 0,375 < 2,54 mm.Determine that the Strip Length (column 7) gives therequired number of turns (column 8). This relationshipdepends on the wire diameter and the dimensions of theterminal.In our example: strip length: 25 mm is correct.Find:„Terminal Diagonal” (column 3) in the chart on page 21:Using side „a“ = 0,75 mm and side „b“ = 0,50 mm calculatethe theoretical diagonal = 0,90 mm.The actual diagonal is 0,90 - 0,04 = 0,86 mm (0,04 mm isthe terminal corner radius allowance). For bit 507573 theterminal diagonal is from 0,84 to 0,92 mm.MOD. = MODIFIEDA connection is called MODIFIED whenthere is a turn of insulationat the base of the wrap. This turn ofinsulation will reinforce the connectionagainst shocks and vibrations.spacinghalf ofterminal widthSTD. = STANDARDA connection is called STANDARD whenthere is no turn of insulation at the baseof the wrap. The use of STANDARD connectionsmakes the wrapping of thickerwires in a determined spacing possible(e.g. power supply lines).Conductor Ø (for STD.)Insulation Ø (for MOD.)= Wire ØEffective Radius (R) is the radius of the circle covered bythe bit + sleeve combination when the tool rotates. Asmany bits have an excentric terminal hole axis, the (R) isnot always half of the sleeve outside diameter.>R< + Wire-Diam.+ a / 2 Spacing20
WRAPPING BITS AND SLEEVESWrapping bits and sleevesChart for terminal diagonalsAWG Diameter Cross sectionSize mm mm 2side arealdiagonalbittheoreticaldiagonal34 0,16 0,02132 0,202 0,03231 0,227 0,04030 0,2555 0,05029 0,286 0,06428 0,321 0,08027 0,361 0,10226 0,405 0,12825 0,455 0,16324 0,511 0,20523 0,573 0,25922 0,644 0,32521 0,723 0,41220 0,813 0,51919 0,912 0,65218 1,024 0,82617 1,151 1,03916 1,290 1,30915 1,450 1,65214 1,628 2,08413 1,829 2,62712 2,053 3,30811 2,304 4,16810 2,588 5,262theoreticaldiagonalside b21
Page 1: Wrapping Technique
Page 4 and 5: The Wire-Wrap wrapping techniqueWRA
Page 6 and 7: VorgehensweiseThe Wire-Wrap wrappin
Page 12 and 13: Electric powered toolsTOOLSMicro Wi
Page 14 and 15: Battery powered toolsTOOLSThis tool
Page 16 and 17: TOOLSHand squeezed toolsThese tools
Page 18 and 19: TOOLSManual wrapping toolsWRAP 3 F
Page 22 and 23: Wrapping Pointed Tips bits Straight
Page 24 and 25: Wire specifications for C.S.W. conn
Page 26 and 27: Hand squeezed tool used as unwrappi
Page 28 and 29: UNWRAPPING TOOLSManual unwrapping t
Page 30 and 31: VARIOUS ACCESSORIESStrip force gaug
Page 32 and 33: TEST SHEETTest sheetName:Company:De
Page 34 and 35: 14YB3EXPLODED DRAWINGS / SPARE PART
Page 36 and 37: Pointed 14YP1 Tips StraightEXPLODED
Page 38: Index bits and sleevesINDEXBitsOrde

The Wire-Wrap wrapping technique

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