Ferrules/Pins Question

[hogback]

I've crimped my share of lugs onto pretty fat wire, but not done any ferrules. Looking around at ferrulesdirect, I see mention of 'true awg' and 'awg.' what does this mean? Also, are there standard pin thicknesses for a given wire awg? I've removed some ferrules that were installed by others, and they are flattened a bit. Are the ferrules supposed to be pre-flattened or do round ones just squish a bit once torqued down?

 

[hogback]

I see that 'true' ones are supposed to be a bit tighter.... why wouldn't you want that? Too hard to jam strands in there without splaying?

 

[hogback]

So it looks like the ferrulesdirect ferrules have no pin - the crimped connection is itself what is inserted to the terminal. Can my temco lug crimper do ferrules, or do ferrules require a separate tool?

 

[hogback]

Now I'm seeing that any crimping just needs to hold things in place until the terminal actually does the final crimp. Any merit to this?

 

[wpns]

Now I'm seeing that any crimping just needs to hold things in place until the terminal actually does the final crimp. Any merit to this?

There's no ferrule that'll do as good a job as a crimped lug and compress the individual strands into a single piece of copper. It just needs to hold the strands together so the terminal you put it in applies the appropriate force for that connection.

 

[hogback]

So using my lug crimper first is not recommended, right? The ferrules crimps look like they leave a series of ridges.

 

[SomethingAppropriate]

I have crimped ferules and tightened a breaker down to the point of it splitting open.

I was still able to yank the cable out of the ferule.

I would crimp them next time.

 

[hogback]

Ok thanks I ordered a dedicated ferrule crimper from ferrulesdirect. They only had one that overlapped 4-6awg, so hope it is quality for $69. The ferrule collar specs seem to indicate that the insulation on the polarwire I'm using might not fit. This is all for connecting inverter #2 (xwpro) to pdp and also from sccs to the dc breakers in the pdp. Mix of 4 and 6awg.

 

[wpns]

P

insulation on the polarwire I'm using might not fit

Put the ferrule on backwards and cut the plastic off after crimping it

 

[meetyg]

The best of both worlds:

https://www.aliexpress.com/item/1005003106792200.html

or some beefier ones:

https://www.aliexpress.com/item/1005004895902843.html

These are great (from experience) because they are crimped, but they can be used on screw terminals (depending on the size of the screw terminal and the lug you choose).
I think thinner ones are also available, if the screw terminal is smaller (like in many SCCs or PV inputs of an all-in-one inverter), but you get the idea.

Specifically, I used the beefier ones to connect my battery to my MUST inverter, which has screw terminals for the battery connection.

 

[robbob2112]

I have ferrule crimpers for the smaller stuff..and above 2awg I use the regular temco hydraulic crimper... makes a solid piece of copper that you can torque down hard on

 

[hogback]

Thanks for all the tips. The ferrulesdirect ones were pretty cheap for qty100, so no biggie if I have to not use them (or do the backwards insert as suggested). Will report back!

 

[robbob2112]

The thing about ferrules direct verse other places is you can get the right length so when they go in they are full depth. And ideally they are full length and they are squeezed into a cold welds lump.

 

[hogback]

I guess there's no harm in using bare ferrules with heat shrink if need be. Stuff arrives Friday so insulating collar fit will be what I check first.

 

[robbob2112]

I actually prefer the ferrules without the collars for anything above 10awg to be honest... a lot of times the collars prevent the ferrule from being fully inserted a lot of the time.

 

[hogback]

Good point. I'll check the ferrule collars against the actual terminals.

 

[robbob2112]

Best us to use the other end of a caliper and measure the depth of the terminal opening then compare that to your ferrule length -- you want it to bottom out if possible without leaving the ferrule metal sticking out where it is unsupported