301 - Solderless Wrapped Electrical Connections-Wire Wrap.pdf

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DISCRETE WIRING
SOLDERLESS WRAPPED ELECTRICAL CONNECTIONS - WIRE WRAP
WIRE WRAPPING
Solderless wrapped terminations are made by
helically wrapping a solid uninsulated wire,
around a specially designed termination post,
to produce a mechanically and electrically
stable connection.
Class A:
Class A
provides improved vibration
characteristics, and is the required wrap style
for spaceflight hardware applications. This
wrap configuration, requires 1/2 to 1-1/2 turns
of insulated wire be in contact with a minimum
of three (3) corners of the wrappost, in addition
to the uninsulated wraps.
Class B:
Class B
wraps are prohibited.
DISCRETE WIRING
SOLDERLESS WRAPPED ELECTRICAL CONNECTIONS - WIRE WRAP
(cont.)
UNACCEPTABLE
OVERWRAP
Overlapping wraps reduce the reliability of the
termination and may result in severed wraps.
MIL-STD-1130B [ 5.3.2.1 j ]
UNACCEPTABLE
SPIRAL WRAP
The space between adjacent wrap turns shall not
exceed one-half uninsulated conductor diameter.
The sum of all gaps shall not exceed one wire
diameter, excluding the first and last turn.
MIL-STD-1130B [ 5.3.2.1 f ]
ACCEPTABLE
CLASS A – SINGLE TERMINATION
The termination has the required number of
insulated and uninsulated turns of wire, and is
clean and free of foreign material.
MIL-STD-1130B [ 4.1 ]
ACCEPTABLE
CLASS A – MULTIPLE TERMINATIONS
The terminations are properly spaced, with each
having the required number of insulated and
uninsulated turns of wire, and are clean and free
of foreign material.
MIL-STD-1130B [ 4.1 ]
UNACCEPTABLE
OPEN WRAP
An open wrap is an indicator of an improper
termination process and may reduce the
reliability of the termination.
MIL-STD-1130B [ 5.3.2.1 f ]
UNACCEPTABLE
IMPROPER ROUTING
The wire shall not be routed in any manner that
will tend to unwrap the termination, and shall be
routed around and between the wrapposts in a
manner that prevents shorting to adjacent
wrapposts.
MIL-STD-1130B [ 5.3.2.1 g ]
ACCEPTABLE
OVERLAPPED TURNS
The insulated conductor overwrap does not
exceed one (1) turn, and the termination wrap is
tight.
MIL-STD-1130B [ 5.3.2.1 b ]
UNACCEPTABLE
CLASS B
Class B terminations, characterized by the
absence of insulated turns, are prohibited.
Best Workmanship Practice
UNACCEPTABLE
DAMAGED WRAPPOST
The wrappost shall not exhibit evidence of
cracking, flaking plating, bending, excessive
twisting, gouging, or exposed base metal.
MIL-STD-1130B [ 5.3.2.1 a ]
UNACCEPTABLE
DAMAGED WRAPPOST
The wrappost shall not exhibit evidence of
cracking, flaking plating, bending, excessive
twisting, gouging, or exposed base metal after
wire wrapping.
Best Workmanship Practices
NASA WORKMANSHIP STANDARDS
Released:
Revision:
Revision Date:
NASA WORKMANSHIP STANDARDS
Released:
Revision:
Revision Date:
03.31.2000
Book:
A
Section:
03.30.2001
Page:
03.31.2000
Book:
A
Section:
03.30.2001
Page:
3
3.01
1
3
3.01
3
DISCRETE WIRING
SOLDERLESS WRAPPED ELECTRICAL CONNECTIONS - WIRE WRAP
(cont.)
DISCRETE WIRING
SOLDERLESS WRAPPED ELECTRICAL CONNECTIONS - WIRE WRAP
(cont.)
UNACCEPTABLE
DAMAGED CONDUCTOR
After removal of the insulation, the conductor
shall not exhibit nicks, cuts, exposed base metal,
ringing, or reduction of cross-sectional area.
Burnishing of the wire surface is acceptable.
MIL-STD-1130B [ 5.3.2 ]
UNACCEPTABLE
DAMAGED CONDUCTOR
After wrapping, the conductor shall not exhibit
nicks, cuts, exposed base metal, ringing, or
reduction of cross-sectional area. Burnishing of
the wire surface is acceptable.
Best Workmanship Practice
UNACCEPTABLE
INSUFFICIENT INSULATION WRAP
The insulated section of the termination must be
in contact with a minimum of three (3) corners of
the wrappost.
MIL-STD-1130B [ 5.3.2.1 a ]
UNACCEPTABLE
OVERLAPPING WRAPS
The overlapping wrap must not exceed one (1)
complete turn over the last turn of uninsulated
wire in a termination directly below it on the
wrappost.
MIL-STD-1130B [ 5.3.2.1 b ]
UNACCEPTABLE
DAMAGED INSULATION
Cut, crushed, gouged, damaged, or nicked
insulation may result in reduced electrical
isolation and/or short circuits. Slight scuffing or
discoloration is acceptable.
Best Workmanship Practice
UNACCEPTABLE
CONTAMINATION
Contamination reduces the reliability of the
termination.
Best Workmanship Practice
UNACCEPTABLE
IMPROPER POSITION – SINGLE WRAP
The first wrap should be located as low on the
post as practical, providing sufficient space for
additional terminations later.
MIL-STD-1130B [ 5.3.2.1 b ]
UNACCEPTABLE
IMPROPER POSITION – MULTIPLE WRAP
Terminations in a multiple wrap configuration
must be properly positioned to ensure the wraps
are completed within the defined termination area
of the wrappost.
MIL-STD-1130B [ 5.3.2.1 b ]
UNACCEPTABLE
STRANDED CONDUCTOR
The use of stranded conductor for wire wrapping
is prohibited.
Best Workmanship Practice
UNACCEPTABLE
SILVER UNDERPLATING
The use of wrapposts with silver underplating is
prohibited. Gold plating over nickel is preferred.
MIL-STD-1130B [ 5.3.2.1 a ]
UNACCEPTABLE
INSUFFICIENT TURNS
The uninsulated section of the termination shall
have the minimum number of complete turns, as
specified by MIL-STD-1130B, or as noted on the
engineering documentation.
MIL-STD-1130B [ 5.3.2 ]
UNACCEPTABLE
END TAIL
An end tail is the end of the last turn of wire that
is protruding in a tangential direction from the
surface of the wrappost. End tails present a risk
of shorting.
MIL-STD-1130B [ 5.3.2.1 d ]
NASA WORKMANSHIP STANDARDS
Released:
Revision:
Revision Date:
NASA WORKMANSHIP STANDARDS
Released:
Revision:
Revision Date:
03.31.2000
Book:
A
Section:
03.30.2001
Page:
03.31.2000
Book:
A
Section:
03.30.2001
Page:
3
3.01
4
3
3.01
2

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