OK Industries, the worldwide leader in wire wrapping products, offers a
complete range of manual, electric and battery powered tools, bits & sleeves
and other accessories. For more information, please visit our web site at
www.okindustries.com.
The PTX Series wire wrapping and unwrapping tools have been developed to
address ergonomic requirements and boost operator efficiency. With worker
safety in mind, we consulted a certified ergonomist and added features
including the lightweight, well-balanced construction, a dual-finger short-throw
trigger, and a long handle to mitigate pressure on the palm. These features
result in an industry-leading design from a comfort and safety standpoint. The
recessed wrap/unwrap switch is easy to access at the rear face of
the housing, and is protected from impact if the tool
is dropped. The rugged housing encases
a high-torque planetary gear drive
that can wrap or unwrap 18 to 30
AWG (1.0 to .25mm) wire, and
is compatible with the full range
of industry standard bits and
sleeves. The PTX Series is
available in 115 volt and 230V volt
electric versions, as well as a
battery version that is
powered by a long-life 3.6V
NiMH cell and incorporates
an LED indicator for low
y voltage. Backfor
batter
ce is
an available option, to help
prevent overwrapping caused by
excessive for
ce applied by the
operator; batteries and battery
chargers are sold individually.
2
Product Selection
ItemDescription
PTXBattery Powered Wrap/Unwrap Tool
PTX-1115V Electric Wrap/Unwrap Tool
PTX-1BF115V Electric Wrap/Unwrap Tool with Backforce
PTX-2230V Electric Wrap/Unwrap Tool
PTX-2BF230V Electric Wrap/Unwrap Tool with Backforce
PTX-BBattery for PTX Battery Powered Tool
PTX-BC1115V Charger for PTX Batteries
PTX-BC2230V Charger for PTX Batteries
PTX-KIT1115V kit including: PTX Battery Tool, PTX-BC1 Charger, and two
PTX-KIT2230V kit including: PTX Battery Tool, PTX-BC2 Charger, and two
H-1000Holster (cordura pouch which holds a PTX or a manual squeeze tool;
PTX-48 48V Electric Wrap/Unwrap Tool
PTX-48BF 48V Electric Wrap/Unwrap Tool with Backforce
PTX-2-UK 230V Electric Wrap/Unwrap Tool with UK Plug
PTX-2BF-UK 230V Electric Wrap/Unwrap Tool with Backforce and UK Plug)
PTX-KIT2I
PTX-KIT2-UK230V kit including: PTX Battery Tool, PTX-BC2-UK Charger, and
manual wrap/unwrap tool; bit/sleeve; and 2-3 other misc. tools)
230V kit including:PTX Battery Tool, PTX-BC2 Charger, and one
PTX-B battery)
two (2) PTX-B batteries)
(2) PTX-B Batteries
(2) PTX-B Batteries
The product range includes both battery and electric powered tools, as well as
proprietary batteries and a battery charger. Tool selection is generally determined by
user preference, and includes considerations such as availability of electrical power
outlets and the convenience of cordless operation. The battery powered version (model
# PTX) employs one battery (model # PTX-B) which requires a charger (PTX-BC1, PTXBC2 or PTX-BC2-UK); these are sold separately, but can also be purchased with the tool
in a kit (see models and descriptions above).
All of the tools in the PTX Series have reversible motors, allowing the user
to use the tools to unwrap a wire wrapped termination. (NOTE: unwrapping requires a
separate bit and sleeve or a dedicated manual unwrapping tool; DO NOT attempt to unwrap
with a bit and sleeve that is used for wrapping, this will damage the bit and sleeve and is
detrimental to the reliability of the connection). The Backforce option, available only in the PTX48BF (48V), PTX-1BF (115V) and the PTX-2BF and PTX-2BF-UK (230V) electric power
is a feature that helps to prevent overwrapping. A spring that is mounted internally in the
collet/shaft assembly of the tool helps to absorb pressure that an untrained operator may apply
while wrapping (see page 12 for an illustration of an over
The PTX Series power tools require no assembly and are ready for use out of the
box. The battery powered version (model # PTX) requires an initial charge of the
battery of at least 8 hours. The LED will illuminate to indicate that the battery is
present in the charger. The LED remains lit as long as the battery is present, even
after full charging, but there is no danger in leaving the battery in the charger
for longer than eight hours. Simply plug the charger (115V
model # PTX-BC1 or 230V model # PTX-BC2 or PTX-BC2-UK)
into a power outlet and place the
battery (model # PTX-B) in the charger.
After approximately 500-750 uses,
the battery should be disposed of
and replaced.
Charger
(shown with Battery)
TTeerrmmiinnaallss
ooff BBaatttteerryy
When the battery is not mounted in the tool or charger, it is important to ensure
that the terminals are not shorted by any metal or other conductive object. The
battery could otherwise short circuit, potentially causing fire, burns or battery
damage. The PTX-B is an environmentally friendly NiMH battery which can be
disposed of along with normal refuse.
CAUTION!
Do not attempt to use any other manufacturer’s battery with the PTX, as it will not
perform properly and can damage the tool. Always use model # PTX-B batteries,
employing the model # PTX-BC1, PTX-BC2 or PTX-BC2-UK battery charger, both
manufactured by OK Industries.
Do not use the battery charger with a damaged cord or plug, or in wet or damp or
any outdoor environments, or in the vicinity of sinks or basins or other water
sources. Do not disassemble charger, there are no consumer serviceable parts
inside.
4
When the battery is charged, remove it from the charger, insert it into the
handle of the PTX tool and rotate the end cap of the battery 90 degrees in the
counterclockwise direction to engage the cap (see below);
then pull back slightly to lock it into the handle of the
tool. To remove battery from tool, press inward
on battery end cap, rotate battery
Tool Handle
90 degrees clockwise and pull out.
Battery
Rotate Counter-clockwise to
engage battery
End Cap
Rotate Clockwise to Remove
Battery
When the battery begins to lose its charge (at about 3.3V), the red LED indicator
located on the top surface of the tool will begin to glow. At this point,
depending on the application, the battery should still contain enough charge for
several hundred additional wrapping or unwrapping operations.
BB)) WWiirree WWrraappppiinngg
Wire wrapping technology, when properly used, provides an interconnection
that is superior in reliability than one made using alternative methods, yet is
easily removed if necessary. It is a process by which a bare end of a wire is
wrapped in a tight helix around a metal terminal. This requires the use of a
proper bit and sleeve in conjunction with the power tool. The selection of the
bit and sleeve should follow the process outlined below:
BIT & SLEEVE SELECTION PROCESS:
1. Determine wire gauge: 18 to 30 AWG
2. Determine terminal post dimensions:
a) Telecom: usually .045” X .045” or .030” X .060”
b) Other: usually .025” X .025”
3. Decide on regular vs. modified wrap:
a) Telecom: usually regular wrap, 22-26 AWG wire
b) Electronics: usually modified wrap, 26-30 AWG wire
4. Once bit is identified, sleeve is listed alongside bit part number in
the Bit & Sleeve Chart (see page 9 -10)
Additional infor
mation r
egar
ding r
egular vs. modified wraps, and
other technical aspects relating to the wrapping process and the resulting
interconnection, can be found in the Section below entitled “Wire
Wrapping Technology.”
5
BIT & SLEEVE INSTALLATION:
1. Loosen collet nut by rotating it in the clockwise direction (see below).
Loosen Collet Nut
in Clockwise Direction
2. Insert the bit into the chuck, and rotate the bit while pushing it into
the chuck, until the bit is seated in the drive mechanism. At this point,
the smaller of the two holes in the face of the bit will be at the
twelve o’clock position.
Small hole in bit face in twelve
o’clock position
3. Place the sleeve over the bit and slide the sleeve into the collet. Rotate the
sleeve as you are sliding it into the chuck until the sleeve has engaged with
the locating pin (internal to the collet); the sleeve will then slide further in
and, when fully seated, will be such that the spouted portion of the sleeve
end is in the twelve o’clock position.
Spouted portion of sleeve in
twelve o’clock position
Sleeve
Bit
4. Tighten the collet by rotating the collet nut in the counterclockwise
direction. The tool is now ready for use. To make a wire wrapped
connection, follow the instructions and helpful hints on the pages ahead.
Tighten Collet Nut in Counterclockwise
6
Direction
MAKING A WIRE WRAP CONNECTION:
Step 1
Select the Proper Bit and
Sleeve (see above).
Step 1
Bit, Sleeve and
Pre-Stripped Wire
Step 2
Insert the wire into the
Wire Slot.
Step 2
Wire Insertion
Step 3
Anchor the Wire.
Step 3
Wire Anchoring
Step 4
Insert terminal into
large center hole of bit.
Step 5
Step 4
Terminal Insertion
Actuate the wrapping tool.
The connection is completed.
Unwrapping and backforce are special features for wire wrapping, and are
available with the PTX Series. All models of the tool, whether battery or electric
powered, have the unwrapping feature built in; the backforce feature is optional,
and is found in models PTX-1BF, PTX-2BF, PTX-2BF-UK and PTX-48BF.
USING THE UNWRAPPING FEA
TURE:
Install unwrapping bit/sleeve in the collet. Flip the switch on the rear face of the
tool into the down position, which reverses the motor direction to change from
‘wrap’ to ‘unwrap.’ Place the unwrapping bit/sleeve over the terminal so that
the hook-shaped portion of the unwrapping bit is positioned to engage the top
end of the wire coil that is to be unwrapped. Squeeze the trigger of the tool
and hold it stationary, allowing the bit to do the work of unraveling the wire coil.
Be sure to remove all of the unwrapped wire from the bit and the work area prior
to proceeding to additional unwrap operations.
CAUTION!
Unwrapping requires a special bit and sleeve or a dedicated manual
unwrapping tool; DO NOT attempt to unwrap with a bit and sleeve that is used
for wrapping only, this will damage the bit and sleeve and is detrimental to the
reliability of the connection.
7
USING THE BACKFORCE FEATURE:
‘Backforce’ is a feature that compensates for the unnecessary application of downward
pressure on the tool during wire wrapping. A wire wrapping tool will perform the
wrapping function properly without any downward pressure applied, in fact, such
pressure results in a tendency to ‘overwrap’ (refer to Section entitled Wire Wrapping
Technology for further details). A tool with the backforce option contains a spring
mechanism to absorb downward pressure that an unskilled operator might apply.
Product Specifications:
PPoowweerr TToooollss**
ItemVoltageSizeWeightRPM
PTX3.6V battery powered 1.5" W X 6" H X 6.5" L0.74 lb. 3700
PTX-1115V electric1.5" W X 6" H X 6.5" L0.86 lb.3700
PTX-1BF115V electric1.5" W X 6" H X 6.5" L0.86 lb.3700
PTX-2230V electric1.5" W X 6" H X 6.5" L1.0 lb.4200
PTX-2BF230V electric1.5" W X 6" H X 6.5" L1.0 lb.4200
PTX-2-UK230V electric1.5" W X 6" H X 6.5" L1.0 lb.4200
PTX-2BF-UK230V electric1.5" W X 6" H X 6.5" L1.0 lb.4200
PTX-4848V electric1.5" W X 6" H X 6.5" L0.86 lb.3700
PTX-48BF48V electric1.5" W X 6" H X 6.5" L0.86 lb.3700
*Typical operating cycle is 2 seconds on and 18 seconds off (varies with application).
BBaatttteerryy CChhaarrggeerrss
ItemVoltageSizeWeightCord
PTX-BC1115V electric4.0" round X 2.7" high0.7 lb.6.0” long
PTX-BC2230V electric4.0" round X 2.7" high0.7 lb.6.0” long
PTX-BC2-UK230V electric4.0" round X 2.7" high0.7 lb.6.0” long
BBaatttteerryy
ItemVoltageSizeWeight
PTX-B3.6V 1" diameter X 4.5" L0.36 lb.
CAUTION! — ALL PTX TOOLS
This equipment is for indoor industrial/laboratory use only at altitudes up to 2000 m, maximum RH of 80% up to 31°C
decreasing to 50% RH at 40°C. Pollution degree 2 in accordance with IEC644. Installation category II. Temperature range:
5°C to 40°C. The user must be aware that, if the equipment is used in any manner not specified by the manufacturer, safety
may be impaired. When using electric tools, basic safety precautions should be used to reduce the risk of fire, electric shock
and personal injury. Keep work areas clean, well lit, off limits to children and visitors. Disconnect unused tools and store them.
Never use accessories or attachments unless recommended by the original manufacturer. If the supply cord is damaged, or
servicing is required, this work must be carried out by the manufacturer or its service agent or a similarly qualified person in
order to avoid a hazard.
230V Tools (PTX-2 & PTX-2BF)
If required, replace the fuse in the main unit with the correct type: T250mA. If a fused mains plug is to be used, ensure
the fuse is of the high breaking capacity type and has a value of no more than: 1A 250V. Any mains plug that requires
emoval or r
r
plug with bar
eplacement must be destr
es is hazardous if engaged in a live socket.
ed wir
emoval of any fuse and fuse car
oyed by r
rier and disposed of immediately, as a
48V PTX Tools
The 48V tools include cor
ce.
sour
ds without plugs, and must never be connected to anything but a 48V A/C or D/C power
16746 Motor, PTX-1 or PTX-1BF
16772 Motor, PTX-2 or PTX-2BF
16771 Motor, PTX-48 or PTX-48BF
3 21363 Wrap-Unwrap switch assembly,
PTX battery tool
21403 Wrap-Unwrap switch assembly,
PTX electric tools
4 21676 Clutch assembly, PTX tools w/backforce
21677 Clutch assembly, PTX tools w/out backforce
5 16765 Gear box assembly, PTX-1, PTX-1BF,
PTX-48 or PTX-48BF
ITEM PART DESCRIPTION
6 21406 Trigger switch assembly, PTX battery
tool
20419 Trigger switch, electric wrap tools
7 21407 Collet assembly (Collet, collet nut
and set screw)
8 16762 Power PCB assembly, PTX-1 or
PTX-1BF (not shown)
18416 Power PCB assembly, PTX-2 or
PTX-2BF (not shown)
18217 Power PCB assembly, PTX-48 or
PTX-48BF (not shown)
9 12446 Power cord, PTX-1 or PTX-1BF
(not shown)
21402 Power cord, PTX-2 or PTX-2BF
(not shown)
21475 Power cord, PTX-2BF-UK or PTX-2BF-UK
(not shown)
10
Warranty, Repair and Technical Support
Each PTX power wrapping and unwrapping tool, as well as the battery chargers, are covered with
a six-month warranty from date of purchase.
Repair service and technical support are available from OK Industries, Tuckahoe, NY 10707, phone:
914-793-0700, fax: 914-793-4527. Service and repair may be obtained from one of our many
worldwide facilities, and technical support can be provided by our representatives and distributors.
Please visit our web site at www.okindustries.com to contact a representative in your region.
ire Wrapping Technology
W
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 requires a rotating tool, called a bit. The bit has a large central hole in the face for
slipping the tool over the terminal, and it marks the point around which the bit rotates. The top of
the bit has a slot which accepts the wire to be wrapped. The front or face of the bit is shaped to
apply the proper tension to the wire during the wrap. This
contour also guides the wire into a helix that is tightly
spaced and uniform. During use, the bit is housed in a
metal tube called a sleeve. The sleeve retains the bit in the
collet of a wire-wrapping tool, which drives the bit as it
spins. It also keeps the wire in the slot during the wrapping
process and protects the worker from the rotating bit.
Wire wrapping subjects the wire to tremendous tension
and compression forces, typically 100,000 PSI at the
terminal’s edge. The wrapping action causes the oxide layer on both wire and terminal to be
crushed or sheared, resulting in a clean, oxide-free metal-to-metal contact. The number of turns is a
function of the length of uninsulated wire. Pre-stripped wire saves time and improves reliability, since
there is a specified minimum number of’ turns required for each particular wire size. These relate
directly to electrical conductivity and mechanical strength. However, if a manufacturing specification
requires a wrap with more turns, wire with correspondingly longer lengths of bare wire or further
hand stripping may be required.
There are two types of wire-wrapped connections: regular and modified. In a “regular” connection,
only bare (uninsulated) wire is wrapped around the terminal. A “modified” wrap, which requires a
modified bit, coils about 1.5 turns of insulated wire around the terminal in addition to the bare wire.
This method greatly improves a connection’s mechanical stability, such as resistance to vibration, in
cases where the wire diameter is small and its mechanical strength is low. The most important
element to consider when choosing either wrap method, then, is the size wire being used. A
standard wrap is generally used for 24 AWG and larger diameter wires; a modified wrap is
sometimes used for 26 AWG and smaller wires, and is used almost exclusively for 28 to 30 AWG
wires.
The four most common wire wrapping mistakes are (a) pressing too hard, which can lead to
wrapping; (b) not pushing the stripped end of the wir
over
emoving the tool befor
ficient tur
insuf
open wraps; and (d) choosing the wrong bit and sleeve, which can cause problems ranging from
pigtails to loose wraps.
OK Industries, le leader mondial des outils de câblage par fil enroulé (wire wrapping), offre une
gamme complète d'outils manuels, électriques et sur batterie, de douilles et guide-fil et autres
accessoires. Pour plus d'informations, visitez notre site Web: www.okindustries.com.
La série d'outils de câblage et de décâblage à fil enroulé PTX a été développée pour répondre aux
demandes d'ergonomie et augmenter l'efficacité de l'opérateur. Ayant la sécurité du travailleur à
l'esprit, nous avons consulté un ergonomiste certifié et ajouté des caractéristiques comme une
construction légère et bien équilibrée, un déclencheur à faible course à deux doigts et une grande
poignée pour répartir la pression dans la paume. Ces caractéristiques conduisent à une conception
leader de l'industrie du point de vue du confort et de la sécurité. L'interrupteur
d'enroulement/déroulement en retrait est facile à manipuler en face arrière du boîtier et
est protégé contre les impacts si l'outil tombe. Le boîtier robuste
comporte une boîte de vitesse à engrenages
planétaires qui peut enrouler ou dérouler du
fil de diamètre 1,0 mm à 0,25 mm (18 à
30 AWG), et est compatible avec la
gamme complète de douilles et guide-fil
standards de l'industrie. La série PTX est
disponible en versions électriques 115
volts et 230 volts ainsi que sur batterie
longue durée NiMH 3,6 V et intègre un
indicateur DEL de tension de batterie
faible. Une limitation de force est
disponible en option pour éviter un
enroulement excessif causé par une
force excessive appliquée par
l'opérateur. Les batteries et les chargeurs
de batteries sont vendus séparément.
12
Choix du produit
RéférenceDescription
PTXOutil Wrap/Unwrap alimenté sur batterie
PTX-1Outil Wrap/Unwrap 115V
PTX-1BFOutil Wrap/Unwrap 115 V avec limiteur de force
PTX-2Outil Wrap/Unwrap 230 V
PTX-2BFOutil Wrap/Unwrap 230 V avec limiteur de force
PTX-BBatterie pour outil PTX alimenté sur batterie
PTX-BC1Chargeur 115 V pour batteries PTX
PTX-BC2Chargeur 230 V pour batteries PTX
PTX-KIT1Kit 115 V comprenant : outil PTX alimenté sur batterie, chargeur
PTX-KIT2Kit 230 V comprenant : outil PTX alimenté sur batterie, chargeur
H-1000Holster (pochette cuir pour un outil PTX ou un outil de serrage manuel,
PTX-48 Outil Wrap/Unwrap 48 V
PTX-48BF 4Outil Wrap/Unwrap 48 V avec limiteur de force
PTX-KIT2I Kit 230 V comprenant:outil PTX alimenté sur batterie, chargeur PTX-
PTX-BC1 et deux (2) batteries PTX-B
PTX-BC2 et deux (2) batteries PTX-B
outil manuel Wrap/Unwrap, douille et guide-fil et 2 ou 3 autres outils).
BC2 , et une (1) batterie PTX-B)
La gamme de produits comporte des outils alimentés sur batterie et sur secteur, ainsi que
des batteries et un chargeur de batteries spécifiques. Le choix des outils est
généralement déterminé par la préférence de l'utilisateur et prend en compte des
éléments comme la disponibilité de prises de courant et la facilité du fonctionnement sur
batterie. La version alimentée sur batterie (modèle PTX) utilise une batterie (modèle PTXB) et nécessite un chargeur de batterie (PTX-BC1 ou PTX-BC2) qui sont vendus
séparément mais qui peuvent aussi être achetés avec l'outil sous forme de kit (voir
modèles et descriptions plus haut).
Tous les outils de la série PTX ont des moteurs réversibles, permettant à l'utilisateur de
démonter une connexion enroulée. (Note : ce démontage nécessite une douille et un
guide-fil séparés ou un outils manuel spécial de déroulement. NE PAS essayer de
déconnecter avec une douille et un guide-fil qui sont utilisés pour l'enroulement, ceci
pourrait endommager la douille et le guide-fil et compromettre la fiabilité de la
connexion. L'option de limitation de force (Backforce) disponible uniquement sur les
outils sur secteur PTX-1BF (115 V) et PTX-2BF (230 V), est une fonction qui per
t monté à l'intérieur de l'assemblage
d'éviter un enr
bague/axe de l'outil permet d'absorber la pression qu'un opérateur peu entraîné peut
appliquer lors de l'enroulement.
oulement excessif. Un r
essor
13
met
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