Insulated and bare wire end sleeves in various designs

Perfect current connection with wire end ferrules

Wire end ferrules are tin-plated copper tubes that are inserted into the end of power cables and fixed there by crimping. They are ideal for multi-stranded cables. By bundling the strands, the current connection at terminals is optimized. The bundling of the strands prevents short circuits.

Structure of a wire end ferrule with plastic collar

Wire-end ferrules consist of a plastic insertion funnel and a copper tube. The plastic funnel is color-coded. This allows the user to know at a glance which ferrule belongs on the cable in question. In addition to a wide range of single-action sleeves, Hilpress also offers "doubleaction" sleeves. These are used to accommodate two power cables. This makes the production of Y-guided cables or branches particularly convenient and safe. In addition, "Doubleaction" ferrules make it easier to clamp two conductors in one clamp.

TIP: Use only the appropriate tools to install your ferrules. These are the wire stripper and the crimping tool. You can find both in our store in first-class quality!

Function of wire end ferrules

Connecting flexible, multi-wire power cables to Lüsterklemmen or WAGO terminals is a challenge. Luster terminals tend to squeeze the inserted copper strands. This can change their cross-section and decrease their ability to carry current. The result can be overheating of the point. With WAGO terminals, inserting the loose copper wires is difficult. It is best to twist the conductors beforehand.

In doing so, it is very easy to overlook a protruding wire. If this happens, a live stranded wire will permanently protrude from the connection point. All it takes is a slight contact or a little moisture, and a short circuit is triggered. Many users help themselves by tinning or twisting the ends. However, only ferrules offer optimum safety when connecting flexible, multi-wire power cables. Tinning of stranded conductors is prohibited, as the tin can detach from the conductor when heated and this can lead to short circuits.

Use of ferrules

Wire end ferrules are used as standard in manual work on flexible power lines. Their main functions are to summarize the wire package of these cores. Therefore, they are not in use for single-core, rigid cables. In addition to preventing short circuits, ferrules ensure that the defined cross-section of the core is reliably continued to the contact tip. Overheating due to the flat crimping of the wire tip is thus ruled out.

Wire end ferrules are therefore used in the following areas of electrical engineering:

  • Manual series production
  • Repair work
  • general electrical construction
  • Hobby and do-it-yourself work.
  • Switchgear construction
  • Control and apparatus engineering

The use of ferrules is an effective contribution to the professionalization of electrical work and to functional safety.

Defects on wire end ferrules

Ferrules can fail if mistakes are made during their installation. These can be:

  • use of incorrect ferrules
  • mechanical stress
  • faulty assembly
  • incorrect/ poor crimping

If ferrules that are too large are used, no firm connection can be made between the ferrule and the cable. Sleeves that are too small will suffer damage during assembly. In addition, it becomes difficult to insert the wire into the sleeve.

Ferrules are used to ensure a safe flow of current between the cable and the connection point. Their task is not to secure the cable against high tensile loads. It is therefore neither necessary nor sensible to tighten the sleeve in the luster terminal with excessive torque. Above all, the tube should be clamped, not the plastic collar!

TIP: Luster terminals are still widely used, but they are considered obsolete. WAGO clamps are much easier to handle. However, their greatest advantage is that they fix the wires with a defined clamping force. Crushing, which can easily happen with luster terminals, therefore does not occur with WAGO terminals.

Wire end ferrules consist of thin copper (tinned) at their current-carrying part. The professional uses terminal blocks from various manufacturers (Wago, Weidmüller, Phoenix, Conta-Clip, etc.) Wire end ferrules should always be used here.

This metal is flexible and corrosion resistant. However, it is sensitive to kinking or vibration. Strain relief and mechanical decoupling are therefore very important when installing ferrules in areas subject to mechanical stress.

Wire-end ferrules should only be crimped with the appropriate tools. These ensure a clean and safe result. The use of cutter knives for stripping and universal pliers for fastening therefore only provides poor connections. Wire end ferrules are assembled with wire strippers and crimping pliers. Only their use leads to the desired goal. Defective ferrules cannot be repaired. They are simply cut off behind the clamping point. The wire is then stripped again and a new sleeve is crimped.

Correct assembly of ferrules

The assembly of ferrules is done in the following steps:

  1. Stripping the wire
  2. Selection of the ferrule
  3. Inserting the wire into the sleeve
  4. Crimping the sleeve

For stripping a cable, the stripper is the ideal tool. These can be adjusted to the cross-section of the core. This ensures that no inner wire of the core is cut along with it when removing the insulation. You can also adjust the length of the insulation removed on the wire stripper. This should correspond to the length of the sleeve.

When inserting the core, make sure that no wires stick out to the side! It is essential that the ferrule matches the core. The connection is only optimal if the wire and sleeve fit together. Finally, the sleeve is attached to the core using the crimping tool. After a strong pressure with the crimping pliers, the connection is made.

Selection of wire end ferrules

Hilpress offers ferrules in the following selection:

The products we offer are certified and comply with DIN 46228-4. The polypropylene sheathing is halogen-free. We offer ferrules with plastic collars up to 16 N cross-section. You can order these products from us in any quantity. We supply you with packaging units from 100 pieces. With our assortments you receive a selection of the most common ferrules in a practical package. This solution is ideal for do-it-yourselfers and craftsmen.

Buy ferrules at Hilpress

Buy safe and high quality ferrules at Hilpress. We offer you a comprehensive selection and the right tools. Rely on quality and prevent unnecessary risks. With our products, best results, efficient work and safe connections are guaranteed!