Ferrule crimping - An easy way to improve reliability of electrical connections.
Crimping a bootlace ferrule to the end of a stranded conductor or fine wire is an easy way to improve the reliability of an electrical connection. In this video, we explore what can happen to conductors when you don't use a ferrule crimp.
Using a ferrule can speed up electrical installations, ensure consistency across connectors. They make life easier for electricians performing maintenance activities in the future by making it easy to remove and replace wires without damaging the conductor or retwisting strands together.
To demonstrate ferrules in this electrical tutorial we are using a Wiha ratchet ferrule crimping tool. This tool can cope with conductors from 0.08mm2 up to 16mm2. A unique feature of the Wiha crimp tool is the guide plate which is sized to allow easy handling of smaller crimp ferrules.
Comments always welcome.
🕐 TIMESTAMPS 🕕
======================
00:00 Introduction to ferrules
00:35 What happens to when you don't use a ferrule
01:30 Using a ferrule on flexible conductors
02:15 Improved connection with a ferrule
03:06 Ferrules stop stray conductor strands
05:22 Ferrule crimp tool - small to large stranded conductors
06:10 Twin conductor ferrules
07:30 Ferrules ideal to improve the quality of electricall connections
=== AD =======================================
Tool featured in this video
Wiha Z62000506SB Crimping Tool
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Uninsulated Ferrule Kit
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Knipex Twin Ferrule Kit
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==
Knipex ferrule starter kits from Rapid Electronics
Uninsulated (no plastic shoulder) - bit.ly/35syeUo
Insulated - bit.ly/3fdT65Y
Twin - bit.ly/3aVsLX3
=============================================
***
This is the first in a series of videos looking at Ferrule crimping.
Part 2 - Ferrule colour codes, types and tips - • Ferrules - Colour code...
Download a printable ferrule colour code - useful for the workshop or your ferrule storage box.
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🎦 Presented by
Gary Hayers - Editor eFIXX
#efixx #electricians #ferrules
In allot of industrial sites I've worked on (oil and gas) the use of ferrules on all connections, ELV or LV is mandated in panels, junction boxes or end devices. They are a good job and don't really take any longer once you get used to using them. They are especially good for connections that get removed now and then for testing or alterations, I think this is the main advantage in using them, you can terminate them multiple times and they still provide a perfect connection, twisted strands are only good for one or two terminations before they need to be restriped and twisted up again and the wire is getting shorter every time you do that!
Wise words!
What ferrule crimper do you use Phil?
@@abdulseaforth6930 I use the Wiha model in the video but also have a cheaper knipex pair for smaller stuff, see link in last comment. For ferrules I normally use RS Pro, same price as others, normally have stock and don’t keep changing part numbers so easy to reorder.
Watching this was so therapeutic. Something about ferrules is so satisfying. Very professional, love the hexagonal crimps too.
I was a HVAC lecturer for 12 years towards the end of my working life and your video was as good as it gets at getting your message across
Wow - Thanks!
I work offshore and all electrical connections are terminated with bootlace ferrules. As long as they fitted correctly and the right size ferrule is used they are excellent.
I came across this video while researching the use of ferrules; as I've always been uncomfortable with the way stranded wire gets chewed up. I didn't know you could get one to connect two wires together. Apart from protecting the wires, it solves the age-old problem of one wire slipping out when you are trying to put two into one connection. Love the video.
Once you go ferrule you can't ever go back. So clean and safe! I didn't know those double ones, though - that's why I subscribed to your channel 🙂
Do ferrules come lose ? I want to start using them but i feel like it will come out .
@@sd-pb6qn they are pretty much secure. But why don't you make a test? It's cheap, and you will see for yourself if it's any good for your needs
A great example of reg 526.1 comes in to play, cheers Gary
i have only recently discovered ferrules no more twisting wires
Really useful video as it shows what some places don’t necessarily teach. Making a more quick and effective job. Especially the earthing ferrules. Also love those Wiha crimpers 😜!
You don’t understand how excited I get about ferrules. You know that feeling when meet the woman of your dreams and your heart skips... this is up there honest 😂
Really good info, i hadn't thought about using them this way.
These are epic for central heating systems....especially Nests!
Looks like a great idea. I think I saw a video where "My trusted electrician" was using them.
What a brilliant video. I don't know if it's just me, but this is the first video I've seen advocating the the use of ferrules in a domestic situation, inline with industrial standards where reliability is perhaps more important. Very well done sir, a point very well made! Perhaps I could add that the ferrules you are using have plastic end bits that are quite bulky, which is fine for one core, one termination. Where several wires are entering one termination though I find that plain ferrules are handier, and three or more cores can be inserted. I appreciate double type ferrules as you show are available but its not always the best solution. Once again many thanks for the great video.
Can't beat a ferrule for stranded cable!👌 Best thing about them is it gives you the ability to cut down the neutral and functional earth on rcbos, making your boards nice and neat! Those wiha ferrule crimpers look awesome! Another thing added to the wish list!
Nice ferrule crimper. Like the idea of the guide
A very helpful video - thanks
Really informative - great work guys
I learned about them a while back? but decided to buy some for a project I was working on. I built a UPS changeover switch ( after I needed it ) and decided that Ferrell's would be the best way to terminate connections. Changeover switch works great now I just have to repair and rebuild the UPS that decided to die.
Another great video. Will need to start using these.
Nice Video. I just got this tool, it seems to make much better crimps that others I've seen. Hopefully it will solve the issue of multiple wires going into a single breaker where some are getting loose after time due to minute differences in thickness or insertion angle.
Wow ...that Wiha crimper is a beauty. So slick ! ! Gaz 👍.. and i quite agree , ferrule way better connection. ..🌲☃️🎄🎁👍
This video actually made me subscribe !!! Your channel is excellent, i always learn new stuff, i previously used to solder my thinner cables, i never knew ferrells exsisted.. Many thanks
Thanks for the feedback!
Nice one, I’ve used ferrules before but my crimper was crap I’ve just got hex one like yours off eBay however I couldn’t afford one exactly like yours £350. I will use this video for the apprentices to watch many thanks
Good video. Would love to see the difference in performance under a test between twisted and folded and a ferrule. I always use them as it makes like much easier in practical terms.
Not an electrician - I'm even using these in my 3d printers now, and they've made an incredible difference. Easier maintenance, too! Thanks.
Excellent 👍🏼
Very well done.
Great video, going to buy a ferrule crimping tool now.
Go for it!
Excellent demo 👌🍻
Nice video! Well presented and filmed. Great content, I like it, thumbs up and subscribed!
Thanks for the video =)
I like the cupholder.
I only wish all sparks would watch this video . It should be law to use these and the better quality Ferrell s also with the Wiha crimper you can place the Ferrell into the tool then closes the handles till the 1st click and it holds the Ferrell and you can easily insert the wire great video
Great videos guys... anyone who occassionally listens to the radio will surely recognize the voice of Danny Kelly here... has anyone ever said that before?
Nice electronic basics
Just bought a ferrule crimper and I have a CU change tomorrow 😎
Excellent
Best thing to use on flex
Bootlace ferrules are mandatory on fine stranded cables on our jobs, and because I'm picky, I make the lads put them on regular cables at dist boards if they're 2.5mm or smaller. This is to stop the copper crumbling away when the terminals are tightened right up.
thats good practice. im a panel basher, i work site all over. theres been a few times where the cabling guys have asked for some ferrules so i tend to keep extra, just to help out when i can.
These look fantastic and I love the mechanics on that tool, so simple, making electricians lives easier. Is there any limitations though to where these can be used?
Awesome video! I'm an auto electrician by trade and I work out in rural areas, and there is a tool at the start of the video I have not seen before, but been thinking about making! it's that handy wire roll holder on the right side of the screen in the first 30 seconds of the video. I work in a workshop, and I have been lucky enough that the bollards used to keep cars in the workshop at night are a smaller diameter than the inside of my rolls of wire that I work with, however I don't always have access to these bollards due to where the cars are positioned sometimes, and due to being in a workshop with other people. Also, these bollards require a hole in solid ground with a steel pipe inserted into concrete in order to work, and that setup just isn't portable for the times I am having to work outside of the workshop and on somebody's farm. I don't suppose you would have a link to where someone could purchase this product in Australia?
Standard on railway signalling cabinets. Should be able to just see the end of the strands at the front of the crimp. Tools were calibrated daily and pull test results logged in a book that stayed with the tool (both numbered).
Fantastic
Really like these don't know why they are not required everywhere it should be imho
Great video and well presented what size crimps are those that your using?
Nice video, another advantage ist that it also helps to keep moisture away from the copper. Other than that standard German colour scheme would be. White 0.5, grey 0.75, Black 1.5, Blue 2.5
Ferules are great, just need to compare them with their continuety tests between normal terminations to feruled. See if there is a difference.
Use a CK 430029 myself but that WIHA is superb quality & obviously pricey :)
Great video! We use ferrules all time using the single wire connectors similar to what is showed at 7:33. Looking at your example, I can see some of the barrel of the ferrule poking out not allowing the shoulder of the ferrule to butt up against the connector. I like to cut off the end of the ferrule so that none of the barrel shows and the shoulder (the plastic part) is butted up against the connector (if that makes sense). My question is if that is good practice or not to cut the end off? or if you know what the standard is. Any info would be appreciated.
For residential wiring do you use 3 strand thick wire or 40 strand thin wires. Both have same amerage ratings.
Hi. Your video was super useful. I have an arcade joystick to keyboard connector block and the cables are super thin and this tool will do the trick. Many thanks.
Ive always used these, meet loads of sparks that have never seen them. I have wired a good amount of machines
Best use I’ve found is using a twin to get 2x4mm2 in the back of a tight socket.
Danish Name for Ferrules: Terminalerør - tylle. Use them a lot when I do industrial work. 💪🏻🇩🇰
Great to learn the different words people use - Thanks!
Dutch word for it is "adereindhuls".
Pull test it before and see if it comes off I pulled loads off of when no cables were twisted and red faces all around for younger engineers 😷I always twist the cable first never pulled one off when I did that.
Thanks for that Michael
Thanks for the video. I have been using ferrules for several years on all flexible cores. Something to bare in mind, they don't always work. I have had experience with terminating 1mm flex into a spur with a ferrule and they fall out, some spurs terminals can be too big for a small ferrule like 1mm or 0.75mm. So I have had to cut the ferrule off many times, twist and fold over to get my decent connection. This doesn't happen in all spurs depends on the branding, just double check them before screwing back.
Great point 👍
To people who say just tin the wire (solder) I'm not 100% sure, but I heard : - When the wire get hot or whatever... it can melt the solder or soften over time... - Solder will soften overtime under mechanical stress connection This may lead to loose connection which is very bad (arching - overheating - cause fire - etc...) Correct me if I'm wrong... take it with a grain of salt
i use ferrules everywhere i can get them in they’re the best back of light switches where you’ve got one cable going into the terminals or in a consumer unit on circuits where it’s only got one cable for the terminal i wish they’d design one so you could somehow put two conductors in so i could use them on rings and where you’ve got 2 or sometimes 3 cables going into a point
I hope the follow-up video will address the use of Farrell's on solid core cabling and twisting conductor strands together before inserting into Farrell's. The only thing I haven't seen is a way of doing two cables that would later need to be separated for testing? Say rings.
Ferrules are incredible and underused. See them quite often in commercial BMS installations and they make a panel look so tidy and the terminations are much more effective than twisted strands, which often seem to break when the screw has been overtightened. Also, lots of panels use push fit connections, try pushing a twisted stranded cable into a push fit connector:/
been a panel wirer for years, having a ferrule end makes it easier and quicker to wire components. ive seen sparkys trying to put twisted pairs into terminals a couple of times ive let them use mine on site, justa bit shocked some dont use them.
i got irwin vise grip wire strippers how i use it to crimping ferrules?!
Simply fantastic. How do I determine a wire cross section area, gauge and match that with the ferrule type needed?
The easiest way - download our free colour chart - link in the description.
often it's written on the wire if you get a magnifying glass, otherwise measure the diameter with calipers and use a conversion chart
v nice
Would you use ferrules on hard (non-flexible) wires, if not what would you use? Is using ferrules or other crimping connectors needed for solid (non-stranded) wires?
Really good and looks professional.only problem would be that it would take you twice as long on a house rewire. I only use them on a consumer unit at the moment
Why would you need multi-stranded wire for a house rewire anyway?
At 4.40. Is that Ferrell too long if you have a cable coming in the other side?
I've always used the practise of using ferrules in panel wiring.
Is there anyway or better type of ferrule to buy, that will not break over time? Tried to use these in our company projects, but overtime, with minimal movement, the ferrules break where it becomes plastic... I love the look and feel of the ferrules, but it can't come the cost of functionality.
Thanks for the video. At first, this topic is a bit of a minefield with such enormous variation in a number of variables for the process of crimping. May be doing a detailed look at all the different types would be helpful such as self adjustable square vs. hexagonal crimping tools etc...Also, the variation in quality of these tools is enormous from cheap chinese designs up to what I could see as one of the best manufacturers being Weidmuller. I would imagine there is also quite a variation in quality due to the standard of ferrules themselves. What could have given clarity to this video would have been taking measurements on a voltmeter to prove the ferrule was a better connection in comparison to the bare wire... may be one for the future! : )
Problem beeing you would probably not see a difference when measuring resistance, even if only one strand of the bunch was connected, as the higher resistance path would be very short. However you would still have that high resistance spot, which would create a hotspot at higher currents. Quite misleading if you are measuring resistance and thought its alright, while in fact it isnt. Though you could pass a few amps through it and measure voltage drop, that would work better.
You don’t need to twist when using ferrules it can make it harder to insert the conductors into the ferrule Helps keep cable numbers from falling off too 👍
Great #electricians #toptips - thanks
efixx : would ferrules be suitable for a marine environment? I am thinking about a 220v/16 amp shore-power connection.
@@ianrobinson6788 Yes they would, we use them offshore and onboard ships all the time.
Uther : Thanks for your reply. Would they need to be A2 stainless steel (not sure if you could crimp stainless or not?) or are just standard ones OK?
Can you please explain ( helps keep cable numbers from falling off too ) ? As I always twist the strands in any crimp or connection.
Great video giving examples. Had the debate with our qs when I put on an EICR that neutral fly leads on rcbos had been shortened and only twisted in terminal. I gave it a c2 and said its a regulation to use them. 526.9.1 he said that must be a new reg so I continued to show him it in the 17th and in the 16th. But yes all who don't use them when using screw terminals should really change as soon as its pointed out to them. However the guys on site will call it a specialist tool and expect company to supply it. That said I have 4 in van 1. 25,35,50. 2. 6,10,16 3. 0.5-6 and 4. 0.25-10. Number 4 is favorite as is a clone of knipex on amazon costing £12.
We would be keen to see an example used on the flexible 19 strand 25mm meter tails!
I am a dinosaur when it comes to tech despite 18 years as a sparky but I could email some photos of before and after into a Henley block if any use
I didn't realise it was in the regs! Also tinning is NOT permitted in the regs.
@@lucidlx I'm guessing you looked it up. There can be confusion on screw type connectors as some have a little plate which separates the screw tip from the conductors. That said if you have the tool its a good habit to get in to regardless on type of connection. I personally wouldn't use them on lever wagos though as they aren't as solid as a typical crimp lug
Thomas, what make is that Knipex look alike?
This Wiha crimper is nice but super expensive. Got the Knipex 9772180 myself for about 30 euros 0.25 to 16mm2 cables.
Where did youu get that wire stripper....mske??
I’m not even an electrician but makes sense 👍🏻👍🏻 good learning video!
Just been watching this video. Is there any "Electrical Measurement " that can show the practical benefit of using ferrules?
I was waiting for that. A resistance reading with and without...
Excellent demo. Even an amateur DIY'er like me can see the sense of using these ferrules.
Yet a professional electronics engineer thinks it's nonsense. Go figure!
Geoff Brown I noticed when I was training in electronics some engineers were “old school” but as you say, go figure.
... Great vid. Would using this ,on a actual UK plug socket be ok?. (I have a set various sizes/crimper).
Not on solid wires.
Definitely a good idea for the typical 7 copper core house wiring. The problem is that electricians have a bad habit of leaving barely any slack inside fittings and screws in the terminals nick the cores, so that when replacing a fitting invariably some of the cores snap while trying to insert or screw the wire into the new fitting. Once the wire is stripped back a bit to expose intact cores the wire is so short it is almost impossible to get it inserted with the fitting out of the wall. A ferrule protecting the cores would hopefully solve this.
"The problem is that electricians have a bad habit of leaving barely any slack inside fittings..." That's called bad practice, or a plasterer who cut 'those annoying unnecessary long cables' between first and second fixing. Good electricians leave enough slack on their cable to reach the end of the fitting opposite of where the cable enters and then bend back to the terminal, or even a bit more than that.
I absolutely Love the idea, but all the ferrels are in MM's instead of AWG... do you know if they are made for the N. America market?
Hi John, You can get ferrules in the NA market. When I worked in NJ we used to get them from Digikey - www.digikey.co.uk/en/product-highlight/a/american-electrical/crimp-wire-ferrules - listed in AWG Cheers *Gordon
Haven't seen on comercial sites that someone are using them, although it is a must. Totally mess on the electrical installations on sites even it is passed testing and certification, who will do the maintenance is gonna cry
Can you make a video showing how to use ferrils to make wiring easy in connecting and preparing an electrical plug for a stove or any plug.
Like this 👉kzhead.info4HvLTNy_uyw?feature=share
The ferrele kit I have has a mixture of French and German colour code. Was getting confused at first trying to follow one chart
Can't you use the flat blade type crimp instead of ferrules? This one works with the most common crimping tool
When shortening rcbo leads i almost only ever use a 4mm grey bootlace ferrule. Now as the size of the neutral for the 6A and 32A differ i should probably be using a blue 2.5mm for the 6A but i find the larger grey gets crimped very tightly although its not a perfectly square crimp. The screw terminations torqued to 2Nm further compress and tighten the ferrule. The only time id be concerned with getting a compressed slightly distorted ferrule is if it were being used in a square clamp and the square edge was required for contact. Anyone disagree?
goid.. toit.... love the accent
The correct answer is you should use whatever the electrical code specifies in the locality where you are! Having done high-tech installations in over 20 countries, I can tell you what is “required” in one place is specifically disallowed in another. Interestingly, it’s in the UK where I have seen these ferrules disallowed, because the wire can actually slip out of them, even when you think you’ve got a great, snug connection. All is not always what it seems, so go by the book, and never assume the way you learned, or the way you think is best is the way to do it wherever you are.
When it slips out it wasn't crimped properly. If you make a good crimp connection and try to pull it off the wire, the copper wire itself will fail before the crimped connection. I've seen guys trying to crimp ferrules with their combination pliers because they hadn't the proper crimping tool. No wonder that such crimps will fail...
The issue that I have had is that a cable that will fit into a conection with out . Some times will no longer fit into the connection after you have crimped a ferule on to it .
@@hotrex7779 It depends also on the shape of the crimp, the square shaped crimps don't make so much trouble. It also depends on the type of connector and it's current rating. You can't put a 1.5mm² with a ferrule in a 10A terminal, but in a 16A one they'll fit.
youve seen these disallowed in the uk. what industry was that in. think youll find many panel companies use these. its not hard to use the right crimping tool for the job. plus dont put a 2.5 ferral on a 1mm cable.
I use the insulated type and the non insulated type . And different length of the crimp .
one big issue tho - someone thinks crimping is a good idea so they choose a crimp, its slightly too big, gets a poor crimp, the screw grips the crimp but the wires fall out of the crimp. very important to get the right crimp for the cable csa
Ferrules should not be used to make a bad idea better, they are not the "Answer" as you say to good workmanship.
I want one!
👍
I would make 2 comments here, which may have been addressed in other comments or videos, but no harm in repeating them. Firstly you should always make sure that the conductor strands reach the full length of the ferrule and secondly that crimping is only suitable for stranded conductors.
You don't really need to put a ferrule on solid copper wire anyways. The purpose of a ferrule designed specifically to make the stripped ends of stranded wires mimic the properties of solid ones.
True. Just thought it was worth a mention as I have seen people putting crimps on solid wires. They inevitably come off with very little effort.
I am an electrician in Brazil, I only use terminals, even if in a service I "lose a few cents" I prefer to lose than to make poor quality connections, in BR is totally widespread flexible cables, so for better connection are the terminals, I know many and many electricians even who were stopped in the time they do not use, I particularly think very pig
i was always taught , to only crimp things on stranded conductors and not solid conductors. i tend to use them on meter tails, there was a time when hager consumer units came with a pair for the meter tails. And that was when hager were seen as a cheap brand totally different from todays image of hager.
There is a good thread on IEE about this and one chap is adament they should not be used on solid core conductors. Others whom worked on MOD projects also said the same!
I've wondered since I was kid ( a v. long time) how poor the contact area is on a stripped conductor.
Use Ferrules for bms
Hi I was looking to get a crimper. Would the sleeves you crimp on be OK for a 3 pin plug. Thank you.
Absolutely
it would be better to use UNinsulated ferrules though, because the plastic sleeve will cause the bend radius to be too large for the tight corners in the plug! Also the screw clamps are not very deep, so you might need to snip off a few mm of the ferrule after crimping.
@@unclefatbloke687 yeah absolutely
KNIPEX do ferrule crimp pliers and are a lot easier to wield than those ridonculous ratchets which are totally unnecessary. I also think that the ferrules can bend and snap more easily, probably best to use an uninsulated, shroudless style. However, the booted ferrules are better in terminal blocks as it stops screwing onto the insulation rather than the conductor as you can't push it in that far.
OK, cool, nice cool crimper there. even though this is a uk vid, I think its applicable to what I do in Chicago here in US. When I did electronics we just tin the leads after stripping and twisting, this is too much to do in an electrical installation in a house of course but in controls I think it would be added value. I work in commercial HVAC so I'm constantly troubleshooting problems in controls and much of the time its poor terminal terminations. These are very small poorly positioned terminal blocks with small wiring often twisted shielded wire. I like the idea of using crimped pins like this however I don't think its practical on small gauge wiring like in control wiring, so I'd like to see a way or process in fast reliable bulk tinning to be used in control wiring installations. I think its value added considering I've spent 2 full days pulling ceiling tiles and crawling around above ceilings on planks to get to every micro control in a Victoria Secret to perform a "tug test" on each and every wire termination only to find one single poorly done wire causing the whole system not to work.
Thanks for some info from across the pond. The crimped we used will go down to 0.08mm2 - and the ferrules start at 0.14mm2 - so will work on the smallest of control wiring.
NEVER EVER tin connections that will be used in screw terminals. The solder will "cold flow" and the connection will ALWAYS become loose over a few months. I have been to many jobs where this has happened and caused arcing. Obviously this is a massive fire risk. Also it's against the UK electrical regs to tin wire (526.9.2). Ferrules are just the right way to terminate stranded wire.
Johnny B most all issues come down to the workmanship. Think about this. There was a time when pulling a ground wire was not required. Sloppy workmanship like not tightening set screws and lock nuts gave us that. Arc fault breakers would not be needed if not for bad splices
@@gerhardschemel3565 agree, In Chicago, or whats called the 6 county area of Chicago, we have some of the strictest electrical codes. I'm not an electrician but I have worked as one and I do commercial HVAC so I'm always working on electrical and controls. We are required to pull a ground wire on every piece of equipment and it has to be landed in the panel. My biggest head ache is control wiring, one little wire not landed tight, can cause an intermittent program execution error that can be nearly impossible to find. compounded by the owners don't want to spend a lot of money troubleshooting on a hunch its a loosely landed wire. I looked up the equivalent american product and I think I want to get a kit when I get back to work after the pandemic, if I survive it.
Great vid👍. Splayed not sprayed though, sorry. Thanks for the vid.
🤦♂️
You use the terms ‘nice and tight’ and “firmly and securely” for tightening the screws on ferrule. I’ve invested in a torque screw driver, what torque do I use?
The one specified by the equipment manufacturer