Wire end ferrules with plastic collar

Information about the intended use of wire end ferrules with plastic collar

Wire end ferrules with plastic collar

Wire end ferrules with plastic collar offer additional ease of insertion due to the conical shape that is integrated in the inner diameter of the collar. Additionally, avoids that the rough insulation edges of the conductor getting caught when connecting at the clamping point. The different color codes offer a visual aid for cross-section identification.

The requirements for wire end ferrules are defined in DIN 46228. Therefore, this standard is decisive for basic conditions and key parameters.

Clean, squeeze- and burr-free cut

Contrary to the common opinion the plastic collar of the wire end ferrule does not offer kink protection, unlike insulated cable lugs. Neither is the plastic collar of the ferrule a mechanical insulation support and therefore should not be stressed by excessive pulling or bending. Additionally to this, during the assembly, all relevant standards must always be complied with. According to DIN VDE 0298-300 conductors must only be installed in certain bending radius. For instance a PVC insulated wire with conductor diameter ≤ 20 mm should have a bend radius of no less than 6 times that of the conductor diameter. In practice this means that no significant pull should stress the plastic collar of the wire end ferrule!

Perfectly stripped conductor

In order to create an optimal crimped connection the standard DIN 46228 recommends to use tools andcontacts of the same supplier (e.g. Weidmüller). Only by doing this can a constantly high processing quality be guaranteed. Weidmüller offers a matching product portfolio that enables you to process conductors from an electrical and a mechanical point of view providing safe, long-lasting and reliable connections.

Start with a clean, non-squeezed and burr-free cut (e.g. with KT 8; Art.: 9002650000), then the conductor needs to be perfectly stripped (e.g. with Stripax; Art.: 9005000000) in order to guarantee that the entire cross-section is being crimped in the tube of the ferrule. In case of fanned out conductors ends and referring to DIN EN 60352 it is only allowed to twist the single strands slightly (re-establishing the original condition).

Strands looking out of the tube

During crimp process it must also be noted that wire end ferrules are only meant for the usage of finestrandedconductors according to VDE 0295 class 5. Deviations must be evaluated. For crimpedconnections with wire end ferrules and conductors with a cross-section up to 6 mm2 (AWG 10) it isrecommended that the single strands should be visible 1 mm out of the copper tube. For cross-sections larger than > 6 mm2 up to 2mm.

Examples of different crimp geometries

Additionally, it is essential to select the crimping tool with a suitable crimping shape for the connection point. When conducting the crimp it is important to note that the crimp should be placed close to the plastic collar.

When considering all aspects of this technical information a high quality, non-detachable connection is established between conductor and wire end ferrule.