DVD-61C Splicing Wires - IPC Training Home Page

DVD-61C TranscriptNow, we’ll make the wrap splice. The first step is to position the wires in an “X” pattern. Thensecure one wire firmly and begin the wrap motion of the opposite wire until one turn iscompleted. Perform the same step with the remaining wire – by firmly securing it and wrappingit in the opposite direction. With one wrap completed in each direction, you can finish thewrapping process to obtain the three wrap minimum requirement.Now, we’ll cut any remaining wire flush to the wrap. This will eliminate any wire protrusion thatcould extend beyond the outer circumference of the wrap. A wire protrusion that extends beyondthe splice may cause damage to the insulation or tubing – possibly resulting in a short circuit. Asyou can see, the proper wrap splice interlocks the two wires smoothly -- for a minimum of threewraps.Now we can solder the connection. Add just enough solder so it can penetrate the splice area,but leave the outline of the strands visible. At this point, we clean the freshly soldered splice.Then we inspect it. An acceptable wrap splice is where the solder is wetted to both wires and youcan see the outline of the wire strands underneath the solder.To complete the wrap splice, we position the heat shrink tubing over the spliced area. Then weapply enough heat to shrink the tubing to a snug fit -- over the splice and the wire insulation.The wrap splice is considered defective if there are any sharp points or projections covered by theheat shrink tubing; if the conductor strands pierce the tubing; if the wire splice area is exposed; orif the tubing doesn’t overlap the wire insulation on both ends -- for a minimum of three wirediameters.Now, we’ll examine the hook splice. A hook splice is similar to a wrap splice in that the splicetakes up a lot of space. The wires are first stripped and then pre-tinned in the same manner as thewrap splice. Next, we place the heat shrink tubing onto the wire.Now, we’re ready to make the splice. We start by forming a 180 degree bend in each wire –making sure that the tinned wire strands do not separate during this process. Then secure onewire firmly and begin the wrap motion of the opposite wire -- until one full turn is completed.Perform the same step with the remaining wire – by firmly securing it and wrapping in theopposite direction.With one wrap completed in each direction, you can finish the wrapping process to obtain thethree wrap minimum requirement. Now, we’ll cut any remaining wire flush to the wrap. As youcan see, the proper hook splice interlocks the two wires smoothly for a minimum of three wraps.Now, we solder the connection. Add just enough solder so it can penetrate the splice area, butleave the outline of the strands visible. At this point, we clean the soldered splice. Then weinspect it. An acceptable hook splice is where the solder is wetted to both wires and you can stillsee the outline of the wire strands underneath the solder.To complete the hook splice, we position heat shrink tubing over the spliced area. Then applysufficient heat to shrink the tubing to a snug fit over the splice and the wire insulation.5