In order to protect the stripped ends of stranded wires, wire end sleeves are often used. This allows the stranded wire cables to be connected easily and without damaging the individual wires in the terminals or clamps.
Wire end sleeves are available in insulated or uninsulated versions. Wire end sleeves with protective collar (colored) also offer additional kink protection for the connected wire. The color coding of the protective collar also provides information about the maximum wire or conductor cross-section. There are three different, partly contradictory identification colors. The color coding according to DIN standard 46228 is becoming more and more common in specialized trade.
Here is a list of the three different identification colors:
Another variant of the ferrules is the twin ferrule. This is used to insert 2 conductors into one ferrule. The twin variant is available for conductor cross-sections from 2 x 0.25 mm² to 2 x 16 mm², whereby the color identification of the conductor cross-section can be taken from the table above. If a slightly thicker cable is to be reduced, as the connection possibility is designed for a thinner cable, pin cable lugs can be used. Pin cable lugs are therefore an alternative to wire end ferrules.
The inquiry form for stranded cables can be found here.
Processing of ferrules
Using the color code table, the matching ferrule can be selected exactly to the conductor cross section and applied to the stranded wire with the designated use of the crimp tool. The standard DIN EN 60352-2:2006-11 defines the requirements for crimp connections. An essential quality feature of the connections is the achieved tensile strength of the connection. However, typical errors can also occur during the crimping process. These would be, for example:
Crack formation on the longitudinal edges and stamp impressions
Bursting of the ferrule
Asymmetrical crimp form
Strong burr formation on the longitudinal edges
Sleeve not filled by the conductor
Wire inserted too short or too far into contact area
Plastic collar damaged by crimp stamp
Conductor insulation not pushed into the plastic collar
Wire end ferrule bent lengthwise after crimping
Fields of application
In order to guarantee a perfect connection of a fine-stranded copper conductor (stranded wire), ferrules are used. A further advantage of the sleeves is that conductivity is improved. Insulated ferrules also contribute to the operational safety of electrical systems, switch cabinets, electronic assemblies and the like. Even if the terminal block or screw terminal is changed several times, cable breaks and vibration damage are avoided and a good contact resistance is guaranteed.
Wire end ferrule ready made
Wire end ferrules
Wire end ferrules are available in insulated or uninsulated versions. Wire end ferrules with protective collar (colored) also offer additional kink protection for the connected wire. The color coding of the protective collar also provides information about the maximum wire or conductor cross-section. We use the color coding according to DIN standard 46228.
Wire end ferrules completely assembled with matching wire / cable in the following cross sections:
(Length of the ferrule from protective collar in mm)