Bootlace Ferrules

Crimp bootlace ferrules are metal tubes crimped (compressed for the purpose of joining) over a stranded wire to allow for a reliable connection with screw or spring clamps. Their use is often misunderstood, yet they play a critical role in ensuring secure and dependable electrical connections.

Most bootlace ferrules have a colour-coded insulation collar to protect the connection. These ferrules are essential for achieving a high degree of contact reliability across various applications. Available in different designs to suit varying wire sizes, bootlace ferrules are versatile and can be used with different types of cables, including PVC wires and electrical wires.

How Do Bootlace Ferrules Work?

With crimp bootlace ferrules, you crimp the component's metal tube rather than the insulation, whereas with a standard terminal, you do the opposite.

Once you have stripped your wire or cable, push it into the ferrule through the plastic collar so that the conductor insulation covers the entire collar, and the stripped part is in the metal tube.

You then use a crimping tool to crimp the metal tube to hold the wire or cable in place for a stable connection.

Understanding the Benefits of Bootlace Ferrules

Using bootlace ferrules offers several benefits in electrical installations. Firstly, ferrules prevent the splaying of wire strands, ensuring a neat and secure connection within terminal blocks. This not only enhances the electrical contact but also increases the mechanical strength of the connection.

Secondly, the insulated collars provide additional safety by preventing electrical shorts between adjacent terminals. Ferrules also simplify maintenance and troubleshooting by ensuring that cable joints are uniform and easily identifiable. Moreover, their use can lead to improved performance of electrical systems by ensuring consistent conductivity and protecting against corrosion over time.

Where are They Used?

• Control units
• Switching cabinets
• Function units
• Equipment with poke-in clamp or row clamp connectors

How are Bootlace Ferrules Used in Industrial and Electronic Devices

Bootlace ferrules, also known as wire end ferrules or crimp ferrules, are copper sleeves used to terminate stranded electrical wires. They provide a secure and reliable connection by capturing the individual wire strands and creating a solid conductor-like termination. Bootlace ferrules are commonly used in various applications, including:

• Control Units: Bootlace ferrules are used as terminal connectors in control systems and programmable logic controllers (PLCs), terminating wires connected to input/output modules, power supplies and communication interfaces. They ensure a reliable connection for data transmission and control signals.
• Switching Cabinets: Electrical cabinets housing switches, relays, and other control equipment often utilise bootlace ferrules to terminate the wiring. Ferrule connectors are the preferred option as they prevent loose wire strands, improve the appearance of the cabinet, and facilitate easier maintenance and troubleshooting.
• Function Units: Various industrial and electronic devices, such as drives, sensors, and actuators, employ bootlace ferrules to terminate the wiring. The use of insulated wire ferrules improves the reliability and durability of the connections, reducing the risk of failures and malfunctions.
• Equipment with Poke-in Clamp or Rail-Mount Connectors: Many industrial devices feature poke-in clamp or rail-mount connectors that are designed to work seamlessly with bootlace ferrule-terminated wires. These connectors provide a quick and secure connection method, making installation and maintenance easier. Examples include terminal blocks, I/O modules, and power supplies.

Common Types of Bootlace Ferrules

Bootlace ferrules come in various forms, each designed to enhance the safety and reliability of wire terminations in electrical installations.

Insulated Ferrules

Insulated bootlace ferrules feature a plastic or nylon collar that covers the crimped area, enhancing safety by preventing electrical shorts. They are typically used in power distribution panels and consumer electronics where additional protection is crucial.

Non-Insulated Ferrules

Uninsulated bootlace ferrules consist of a simple metallic tube without an insulation collar. Their minimalistic design is suited for applications where space is limited, and insulation is not necessary, commonly used in the internal wiring of electronic devices.

Twin Wire Ferrules

Twin wire ferrules are designed to terminate two wires in a single ferrule, effectively doubling the connection capacity. This feature is particularly useful in applications requiring neat wire management and space conservation, such as in control panels.

Colour-Coded Wire Ferrules

Colour-coded wire ferrules simplify installation by indicating the wire size or function through different colours. This visual aid helps in quickly identifying and matching wires during installation and maintenance, enhancing workflow efficiency.

Insulation Materials Used in Bootlace Ferrules

The insulation materials used in bootlace ferrules play a crucial role in ensuring safety, durability, and performance in various applications. Below is an overview of the different insulation materials commonly used in ferrule connectors.

1. Polypropylene

Polypropylene is one of the most common insulation materials used in bootlace ferrules as it offers excellent electrical insulation properties and is resistant to moisture, chemicals, and UV radiation while being lightweight and cost-effective. Polypropylene-insulated ferrule connectors are suitable for outdoor and industrial applications where exposure to harsh environments is likely.

2. Nylon

Nylon insulation is known for its durability and resistance to abrasion, making it ideal for applications where mechanical stress may occur. Nylon-insulated bootlace ferrules provide good electrical insulation and can withstand higher temperatures compared to polypropylene. They are often used in automotive and aerospace applications, where reliability and performance are critical.

Decoding Colour Codes in Ferrule Systems

The colour coding of bootlace ferrules is essential for identifying wire sizes and ensuring correct installation, following standards like the French Telemecanique system, the German Weidmuller system, and the German DIN standard. Each system uses a distinct colour palette to represent various conductor sizes, aiding in quick identification and reducing errors during wiring. Here’s an overview of the different colour codes used:

French Telemecanique Conductor Size and Colour Codes

In the French Telemecanique system, the most common conductor sizes and their corresponding colour codes include:

• 0.14 mm²: Brown
• 0.5 mm²: White
• 1.00 mm²: Red
• 1.50 mm²: Black
• 2.50 mm²: Grey
• 4.00 mm²: Orange

German Weidmuller Conductor Size and Colour Codes

The most common conductor sizes and colour codes for the German Weidmuller system are:

• 0.14 mm²: Grey
• 0.5 mm²: Orange
• 1.00 mm²: Yellow
• 1.50 mm²: Red
• 2.50 mm²: Blue
• 6.00 mm²: Black
• 10.00 mm²: Ivory

German DIN

In the German DIN system, common conductor sizes and colour codes include:

• 0.14 mm²: Grey
• 0.25 mm²: Yellow
• 1.00 mm²: Red
• 1.50 mm²: Black
• 2.50 mm²: Blue
• 6.00 mm²: Yellow
• 10.00 mm²: Red
• 16.00 mm²: Blue

Trusted Supplier of Ferrule Connectors

RS is your reliable source for high-quality ferrule connectors, including the versatile bootlace ferrule. We stock an extensive range from industry leaders like Phoenix Contact, TE Connectivity, Schneider Electric, and our own RS PRO. Our selection spans various types and sizes at competitive prices, ensuring you find the perfect ferrule type connector for your application.

Whether you're looking for electrical ferrule connectors, cable lug ferrules, electrical cable joint ferrules, or insulated wire ferrules, RS has you covered with premium products and expert support. For more details on our ordering process, delivery services and delivery fees, please refer to our Delivery Page.