Insulated and bare wire end ferrules in various designs

What are wire end ferrules?

Wire end ferrules are tinned copper tubes that are plugged onto the end of power cables and crimped into place. They are ideal for multi-stranded cables. Bundling the strands optimizes the electrical connection at terminals. Bundling the strands prevents short circuits.

How are wire end ferrules constructed?

Wire end ferrules consist of a plastic insertion funnel and a copper tube. The plastic funnel is color-coded. This means that the user knows at a glance which ferrule belongs on the cable in question. In addition to a large selection of single ferrules, Hilpress also offers twin ferrules. These are used to accommodate two power cables. This makes the production of Y-guided cables or branches particularly convenient and safe. Twin ferrules also make it easier to clamp two conductors in one terminal.

How do wire end ferrules work?

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

It is very easy to overlook a protruding wire. If this happens, a live 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 wire end ferrules offer optimum safety when connecting flexible, multi-wire power cables. The tinning of stranded conductors is prohibited, as the tin can detach from the conductor when heated, leading to short circuits.

Where are ferrules used?

Ferrules are used as standard for manual work on flexible power cables. Their main task is to join the wire bundle of these cores. They are therefore not used for single-core, rigid cables. In addition to preventing short circuits, wire end ferrules ensure that the defined cross-section of the wire continues reliably to the contact tip. This prevents overheating due to the flat crimping of the wire tip.

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

• Manual series production
• Repair work
• General electrical construction
• Hobby and DIY 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.

What errors can occur during installation?

Wire end ferrules can fail if errors are made during installation. These can be

• Use of incorrect ferrules
• Mechanical stress
• Incorrect assembly
• Incorrect or 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 be damaged during installation. It will also be difficult to insert the wire into the sleeve.

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

Wire end ferrules consist of thin copper (tinned) on their current-carrying part. Professionals use terminal blocks from various manufacturers (Wago, Weidmüller, Phoenix, Conta-Clip and many others). Wire end ferrules should always be used here.

This metal is flexible and corrosion-resistant, but 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 using suitable tools. These ensure a clean and reliable result. The use of cutter knives for stripping and universal pliers for fastening therefore only produces poor connections. Wire end ferrules are fitted using wire strippers and crimping pliers. Only their use leads to the desired result. Defective wire end 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.

How are wire end ferrules fitted correctly?

Wire end ferrules are installed in the following steps:

1. Stripping the cable
2. Selecting the wire end ferrule
3. Inserting the wire into the ferrule
4. Crimping the sleeve

Stripping pliers are the ideal tool for stripping a cable. These can be adjusted to the cross-section of the wire. This ensures that no inner wire of the core is cut when the insulation is removed. You can also set the length of the removed insulation on the wire stripper. This should correspond to the length of the sleeve.

When inserting the core, make sure that no wires are sticking out to the side! The ferrule must always fit the wire. The connection is only optimal if the wire and ferrule match. Finally, the ferrule is attached to the wire using the crimping pliers. After applying firm pressure with the crimping pliers, the connection is made.

How do you choose the right wire end ferrule?

Hilpress offers you the following selection of wire end ferrules:

• Single ferrules without plastic collar
• Single ferrules with plastic collar
• Twin ferrules

The products we offer are certified and comply with DIN 46228-4. The polypropylene sheathing is halogen-free. We offer wire end ferrules with plastic collars up to 16 mm² 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 wire end ferrules in a practical container. This solution is ideal for DIY enthusiasts and tradesmen.

Where can you buy wire end ferrules?

Buy safe and high-quality wire end ferrules from Hilpress. We offer you a comprehensive selection and the right tools . Rely on quality and prevent unnecessary risks. Our products guarantee the best results, efficient work and safe connections!