Cable Terminals, Lugs and Ferrules Selection Guide
Selection criteria for wire ferrules, copper and bimetal cable lugs, insulated/non-insulated ring and fork terminals, faston connectors and splice sleeves.
What are cable terminals, lugs and ferrules? Cable terminals, tubular lugs, and wire ferrules are crimp-on termination components that secure stranded copper or aluminum conductors into terminal blocks, circuit breakers, contactors, and busbars without strand fraying, loosening, or hot spots.
This guide explains how to select products in the Cable Terminals, Lugs and Ferrules category by conductor cross-section ($ ext{mm}^2$) and stud size.
Main product groups
- Cable ferrules: Single-entry and twin-entry (dual wire) insulated and uninsulated bootlace ferrules for terminating fine-stranded wires into DIN-rail terminals, MCBs, and PLC I/O blocks.
- Cable lugs: Tinned electrolytic copper tubular lugs (6–400 $ ext{mm}^2$) for bolting power cables onto MCCBs and busbars.
- Bimetal lugs: Friction-welded aluminum-barrel / copper-palm lugs for connecting aluminum cables (NAYY, NA2XH) to copper busbars without galvanic corrosion.
- Insulated cable terminals and non-insulated cable terminals: Ring, fork (spade), pin, and blade crimp terminals for 0.5–6 $ ext{mm}^2$ control wiring.
- Faston and connection terminals: Male/female quick-disconnect blade terminals (2.8 mm, 4.8 mm, 6.3 mm).
- Splice joints and end closure parts: Butt-splice sleeves and twist-on wire caps.
Termination type comparison table
| Termination Type | Cross-Section Range | Material / Insulation | Connection Target | Crimping Tool |
|---|---|---|---|---|
| Wire Ferrule (Single / Twin) | 0.5 – 50 mm² | Tinned Cu + PP collar | DIN terminal blocks, MCBs, PLC cages | Ferrule crimping pliers |
| Insulated Ring / Fork Terminal | 0.5–1.5 mm² (Red), 1.5–2.5 mm² (Blue), 4–6 mm² (Yellow) | Tinned Cu + PVC/PA sleeve | Screw-clamp relay and instrument terminals | Ratchet insulated-terminal crimper |
| Tubular Copper Lug | 6 – 400 mm² | Tinned Electrolytic Copper | MCCB terminals, copper busbars, transformers | Mechanical or hydraulic hex crimper |
| Bimetal Cable Lug | 16 – 400 mm² | Al barrel + Cu palm | Aluminum feeder cable → Copper busbar | Hydraulic hexagonal die crimper |
Frequently asked questions
What do the two numbers on a tubular cable lug (such as 35-8 or 50-10) indicate?
The first number specifies the conductor cross-section in $ ext{mm}^2$, and the second number specifies the metric stud hole diameter in mm (for example, `35-8` fits a 35 $ ext{mm}^2$ cable and an M8 bolt).
What do red, blue, and yellow insulation sleeves signify on crimp terminals?
Standard insulated ring, fork, and faston terminals use color coding for wire gauge: Red fits 0.5–1.5 $ ext{mm}^2$, Blue fits 1.5–2.5 $ ext{mm}^2$, and Yellow fits 4–6 $ ext{mm}^2$.
How should two wires be terminated into the same terminal block clamping point?
Use a twin (double-entry) cable ferrule that crimps both conductors inside a single metal sleeve rather than inserting two separate single ferrules into one clamp.