What Is an Insulation Piercing Connector?

What is an Insulation Piercing Connector?

An insulation-piercing connector (IPC) is a specialized electrical component designed to create a secure and reliable connection by penetrating the insulation of a wire without the need for stripping. This innovative design ensures a seamless electrical link while preserving the insulation's integrity.

These connectors are widely utilized in various industries, including power distribution, telecommunications, and automotive systems. Their robust construction and ability to maintain insulation protection make them an essential solution for ensuring durable and efficient electrical connections in demanding environments.

What Are the Components of an Insulation Piercing Connector?

An insulation-piercing connector (IPC) is composed of multiple components that work synergistically to establish a reliable electrical connection while preserving the wire's insulation.

Key components of JERA LINE insulation tap connectors include:

• Shearhead
• Nut
• Stainless steel washer
• Upper body
• Blade teeth
• Waterproof sealing
• Lower body
• Stainless steel bolt
• End cap

These elements are designed to form a secure and durable connection without the need to strip insulation. This feature is particularly beneficial in applications where insulation integrity is critical.

Applications of Insulation-Piercing Connectors

Insulation-piercing connectors are versatile and find use in various electrical applications, such as:

1. Power Distribution:

   • Ideal for connecting overhead lines, underground cables, and transformers in distribution networks.

2. Telecommunications:

   • Used for splicing and connecting telephone wires, fiber optic cables, and coaxial cables in distribution and junction boxes.

3. Street Lighting:

   • Commonly applied in pole-mounted setups to connect wires securely and efficiently.

4. Automotive Systems:

   • Utilized in wiring harnesses, battery connections, and electrical sensors within vehicles.

5. Industrial Applications:

   • Found in motor control centers, switchgear, and industrial equipment to ensure robust wire connections.

This broad range of applications highlights the connector's adaptability and reliability across industries.

What Are the Advantages of Using Insulation Piercing Connectors?

Insulation-piercing connectors (IPCs) offer numerous benefits, making them an efficient and versatile solution in various electrical applications:

1. Time-Saving Installation

   • IPCs eliminate the need for wire insulation stripping, significantly reducing installation and maintenance time.

2. Reliable Connections

   • They ensure secure and durable connections, minimizing the risk of wire damage or loose connections.

3. Waterproof Design

   • JERA ENERGY IPCs feature a waterproof seal, making them ideal for outdoor and underground installations where moisture resistance is critical.

4. Versatility

   • Compatible with a wide range of wire sizes and types, IPCs provide flexibility for diverse electrical setups.

5. Enhanced Safety

   • Their design reduces the risk of electric shocks and injuries during installation by maintaining insulation integrity.

6. Space-Saving

   • The compact structure of IPCs makes them suitable for applications with limited space for connections.

7. Cost-Effective

   • By simplifying the installation process and reducing the need for additional components, IPCs help lower material and labor costs.

8. Durability

   • Designed to withstand harsh environmental conditions, IPCs ensure long-lasting performance in outdoor and industrial settings.

How Do You Install an Insulation Piercing Connector?

Key installation steps:

-- Insert the branch cable in the connector as shown.
-- Insert the main cable. Put on the cable end cap
-- Gradually tighten the nut, until it shears off.
          

How to Test Performance of IPCs?

Testing insulation-piercing connectors (IPCs) involves conducting a series of rigorous evaluations to ensure their performance, safety, and compliance with industry standards. These tests are categorized as type tests and routine tests:

Type Tests

Type tests assess IPCs under various conditions to validate their suitability for specific applications. These include:

• Visual inspection test and dimentional and material verification test
• Test of permanent marking
• Dielectrical voltage test in water
• Corrosion aging test (salt fog chamber test)
• Climatic aging test (UV radiation test)
• Test for mechanical damage of the main conductor
• Branch cable pull-out test
• Connector bolt tightening test
• Shear head functions test
• Low temperature impact test
• Low temperature assembly test
• Complete electrical ageing test (1000 cycles) with short circut test

JERA ENERGY’s ZOP Series IPCs have passed the NFC 33-020 type tests, certified by an EU-independent laboratory.

What is NFC 33-020 standard for Insulation piercing connector?

    1.The NFC 33-020 standard is a French standard that specifies the requirements for insulation piercing connectors (IPCs) used in low-voltage electrical installations. The standard covers the design, materials, testing, and performance of IPCs, as well as the requirements for installation and use.

    2.The NFC-33020 standard defines the characteristics of IPCs, including their size, shape, and piercing depth, as well as their electrical and mechanical properties. It also specifies the tests that IPCs must undergo to ensure their compliance with the standard, including tests for electrical resistance, mechanical strength, and environmental resistance.

    3.The standard also provides guidelines for the installation and use of IPCs, including the recommended torque values for fasteners, the minimum and maximum wire sizes that can be used with the connector, and the maximum current-carrying capacity of the connector.

Routine Tests

Routine tests for insulation piercing connectors (IPCs) are conducted to ensure the quality, safety, and performance of the connectors before they are put into service. These tests are typically carried out during the manufacturing process and may include the following:

• Visual inspection test 
• Test of permanent marking
• Dielectrical voltage test in water
• Shear head functions test

Jera Line has own factory laboratory with test equipment and measuring tools, to ensure our insulation piercing connectors meet the required standards and specifications for quality, safety, and performance before they are installed in electrical systems.
       

What’s the Advantages of JERA’s Insulation Tap Connector?

• Wide Compatibility: Suitable for both aluminum (AL) and copper (CU) cables.
• Stainless Steel Components: Equipped with stainless steel bolts and washers for superior rust and corrosion resistance.
• Durable Rubber Cap: Ensures a long service life, even in challenging conditions.
• UV-Resistant Polymer Body: Protects against degradation from sunlight and harsh environments.
• Certified Performance: Fully compliant with NFC 33-020, with type test reports from EU-independent laboratories.

JERA Energy provides a comprehensive range of overhead cable tap connectors for 1KV power lines, including the ZOP series insulation piercing connectors.

Learn more about our products here.

Why Is JERA Energy a Leading Manufacturer of Insulation Piercing Connectors?

Jera Line established from 2012, produces the insulation piercing connectors from year 2015, and have experience in many international projects.
Here are some factors that why JERA is one of the best manufacturers and why to purchase IPCs from Jera Energy:

1. Product Quality and Reliability: Jera Energy produces high-quality insulation piercing connectors that are reliable, durable.
2. Compliance and Certification: Jera Energy ensures insulation piercing connetors comply with relevant inductry standards, such as NFC 33-020, EN-50483,providing customers with confidence in the quality and safety of the products.
3. Range of Offerings: Jera Energy offers a diverse range of insulation piercing connectors for 1kv power lines, to meet various application requirements
4. Research and Development: Jera Energy invests in research and development to continually improve the design, performance, and reliability of their insulation piercing connectors, ensuring they remain competitive in the market.
5. Customer Support: Jera Energy provides strong customer support, including technical assistance, flexible OEM with stickers , and after-sales service, which can be important for customers seeking reliable solutions for their applications.
6. Competitive price: Jera Line located in a small city in Yuyao Ningbo, scale production facility casued the competitive price.

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Summary

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