Ferruel Crimping Sizes

[aKO]

Just bought an inexpensive crimper , never needed one before but i have some connections that might benefit from having Ferrules . Can someone advise how to select the correct adjuster when its supposed to be self adjusting . Had no instructions with it and nothing came up on Google to explain . I assume that you would select the smallest ferrule that the cable fits into but not sure about the 6 position adjuster wheel ? .

 

[BobT]

Having no idea of what brand/model crimper you have, here's a screenshot of the one I use. Each position of the die is marked with the wire size in mm^2 and a conversion table to AWG. I suspect yours probably covers the same range of sizes since most of that stuff comes out of the same Chinese factory.

 

[hybe022]

Just bought an inexpensive crimper , never needed one before but i have some connections that might benefit from having Ferrules . Can someone advise how to select the correct adjuster when its supposed to be self adjusting . Had no instructions with it and nothing came up on Google to explain . I assume that you would select the smallest ferrule that the cable fits into but not sure about the 6 position adjuster wheel ? .

I watched the Deye 5kW install video of EEVblog on Youtube.
He used the same battery lug crimper.

Set it one size smaller.
Use 2AWG setting for 0AWG

 

[robbob2112]

That is just to adjust how hardie presses. That will vary depending in how close the ferrule matches the wire.

Post in thread 'Robbob2112 Answer thread'

May 24, 2024

#6 - Ferrule usage

When to use ferrules and when not to use them. This is sometimes hotly debated depending on the type of terminal block

Use them when -

• The screw terminal just has the screw directly contacting the wire and the wire is fine stranded.
• When the mfg calls for them

When not to use them -

• On stranded THHN when the screw pushes on the wires directly unless the mfg calls for it
• When the mfg says NO - like the victron MPPT Changed 8/24 - see wiring unlimited.
• In any sort of spring push connection like wego unless they are called for
• On...

• robbob2112

 

[aKO]

This is the type of crimper

 

[robbob2112]

Yup, I probably have exactly that crimper - your problems are as mentioned in your other thread asking the same/similar question --- you need to extend the wires past the end of the ferrule and trim after ... the wires should totally fill the ferrule - if it doesn't then try the next size down or order a "true awg" type ferrule off ferrulesdirect.com -- they run more true to size.

the end result won't be as tight as a crimped lug that does a cold weld, but they will be tight.

And Victron explicitly states to use fine stranded wire and NOT to use ferrules in their MPPT --- if you do use a ferrule on a Victron MPPT you can expect the connection to get hot and possibly damage the terminal block ... and Victron will reject the warranty claim.

And one thing - on ferrulesdirect you can buy them at different lengths -- either measure the depth of the terminal block or look around here - several have reported it. I have a 250/100 and a 150/35 I can measure if yours is either series.

 

[SolarReaper]

Victron's 'Wiring Unlimited' guide Section 4.3 'Cable Connections' now has a section on Ferrules, they say use them everywhere if you feel like it, just ensure they are fitted correctly. Definitely use them on screw terminals where stranded wire is being used, definitely don't use them on solid core wire.

Wiring Unlimited

www.victronenergy.com

 

[robbob2112]

Victron's 'Wiring Unlimited' guide Section 4.3 'Cable Connections' now has a section on Ferrules, they say use them everywhere if you feel like it, just ensure they are fitted correctly. Definitely use them on screw terminals where stranded wire is being used, definitely don't use them on solid core wire.

Wiring Unlimited

www.victronenergy.com

Victron's MPPT manuals explicitly forbid the use of ferrules and it will void the warranty if there is any sort of heat damage on the terminal connections. This is because their terminals have interlocking cup shaped teeth to gather and compress loose wires in for a good connection. A ferrule will not let them work correctly.

Do what you want yourself, but giving advice against the mfg manual for a product isn't good.

 

[featherlite]

Victron's MPPT manuals explicitly forbid the use of ferrules

The 2022 and 2024 versions of the manual for my Victron 100/50 MPPT solar chargers does not mention ferrules.

Does your manual mention ferrules? If so, which manual.

Thanks

 

[SolarReaper]

I'm looking at the Rev.09 02/2025 manual online for my 250/60 charge controllers and there's no mention of not using ferrules in there either.
It does mention the Wiring Unlimited book I referenced earlier though.

8.8.4. PV connections burned or melted
Burned or melted PV cables or connections are not covered under warranty. This can occur due to the following reasons:
• Loose screw connections.
• Using cables with rigid core wire or rigid strands.
• Soldering the core wire ends of the cables.
• Using thin cables may result in higher currents when the PV voltage is lower. Refer to the Wiring Unlimited book for more
information.
• Inserting cable insulation too deeply into the connector.
• Exceeding 30A per MC4 connector pair.
• Incorrectly crimping MC4 connectors.
• Using low-quality MC4 connectors.

 

[robbob2112]

Using ferules, pros and cons…

Hi Everyone, I have recently updated the ferule chapter in the Wiring Unlimited book, see the Electrical Connection chapter. I know that ferrules remain a topic of discussion, and many people have their own vision on them. The main rule is to ALWAYS use a correct crimping tool to achieve a...

community.victronenergy.com

Apparently updated in Aug 2024 - the stress is on gas tight crimp on the ferrule as well as inserting to full depth. This means the right length ferrule and using a crimper on the ferrule that makes it gas tight prior to insertion... so proper size ferrule, proper length ferrule, real ferrule crimpers of the right size and shape or hydraulic crimpers.... Just getting it straight in my head.


Yer right, I'm wrong.... it happens.

 

[robbob2112]

Updated my info post on ferrules

Post in thread 'Robbob2112 Answer thread'

May 24, 2024

#6 - Ferrule usage

When to use ferrules and when not to use them. This is sometimes hotly debated depending on the type of terminal block

Use them when -

• The screw terminal just has the screw directly contacting the wire and the wire is fine stranded.
• When the mfg calls for them

When not to use them -

• On stranded THHN when the screw pushes on the wires directly unless the mfg calls for it
• When the mfg says NO - like the victron MPPT Changed 8/24 - see wiring unlimited.
• In any sort of spring push connection like wego unless they are called for
• On...

• robbob2112