
Wire Ferrules
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Wire connectors (ferrules) are used to facilitate wire insertion into a terminal clamp. They ensure reliable electrical connections and prevent the unraveling of stranded wire. Ferrules are sized according to the conductor size and the barrel length. The conductor size is the cross-section of the wire it will be connected to and the barrel length indicates the stripping length of the wire. Ferrules are available in insulated and uninsulated designs. Insulated ferrules have a sleeve made of polyamide or PVC that covers part of the tin-plated copper tube. The sleeves are color-coded according to the wires size the ferrule is connected to. Uninsulated ferrules do not come with a plastic sleeve. The shorter length and uninsulated body makes them a better choice for printed circuit board terminal blocks and other terminal blocks with smaller clamps and narrow widths.
When installing a ferrule, the wire should be cut as squarely and evenly as possible. The stripped length of the wire will depend on the barrel length of the ferrule. The wire insulation should be stripped to a length that allows the conductor end to reach the tip of the ferrule when inserted. Many wire strippers have a device that allows the user to set the strip length. After the insulation is stripped, the strands of the conductor should be twisted to ensure that there are no stray strands. The wire can then be inserted in the ferrule so that the insulation edge is fully covered by the plastic collar (when using an insulated ferrule). Finally, the wire and ferrule are crimped using an appropriately sized ratcheted crimper.
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Top 5 reasons to use ferrules.
- Using ferrules can make wire terminations safer. When terminating stranded wire, the wire can fray or bird cage, which can lead to short circuits and potential shock hazards at termination points. Crimping and securing the strands of wire with a ferrule can prevent this from happening.
- Using ferrules creates a more consistent connection point. It can be difficult sometimes to get consistent results when stripping wire by hand, even when using tools that are designed for it. One benefit of using ferrules is that there will be a consistent connection point on all of the wires. When a panel or any electrical system is wired using ferrules, all of the termination points will be the same, reducing any chances of failure at the various termination points throughout the system.
- Using ferrules creates a safe and clean wiring option when two different wires need to be terminated into one single point. It is not uncommon to see situations where two separate conductors needs to be terminated at one location and share a terminal.
- Ferrules come in all shapes and sizes to meet almost any application. This versatility allows ferrules to be used on very small wires that might be needed for more intricate control work, as well as much larger wire that might be used to distribute or switch high amounts of power.
- Using ferrules greatly increases the overall quality of the work. While ferrules can increase the overall cost of a job, the quality and consistency of the work provided can far outweigh that cost in most cases. They can also greatly reduce the chance of having to come back at a later date to fix troubled connections.