Introduction
In modern electrical distribution, reliable and efficient cable connections are non-negotiable. When expanding power lines or branching circuits, engineers need solutions that are fast, safe, and durable—without stripping cable insulation. The Insulation Piercing Connector (IPC) meets this demand by enabling direct, secure contact through the insulation layer. Whether for overhead lines, ABC systems, or low-voltage connections, IPCs simplify installation while improving connection quality.
What is an IPC connector and how does it work? This guide answers the top questions about IPCs, from installation and working principles to the differences between screw-type and spring-loaded variants, ensuring you choose the right product for your project.
What Is an IPC Insulation Piercing Connector?
An IPC Insulation Piercing Connector is a specialised device designed to establish secure electrical connections between a main power cable and a branch conductor without the need to strip away the cable’s insulation. It uses sharp, tin-plated metallic teeth that pierce the insulation layer and make direct metal-to-metal contact with the conductor, while the outer protective sheath remains intact to maintain insulation performance and safety.
These connectors are primarily used in low-voltage distribution networks (≤1kV AC / 600V DC) and, in some designs, in medium-voltage applications, depending on the product model. They play a vital role in aerial bundled cable (ABC) systems, street lighting, residential service connections, and building distribution networks.
A key advantage of IPCs is their compatibility with both aluminium and copper conductors, making them a versatile solution across various electrical infrastructures. To ensure durability, SUNJ IPCs are manufactured with tin-plated copper or aluminium alloy teeth for corrosion resistance, and a glass-fibre reinforced PA66 housing that is UV-resistant, flame-retardant, and weatherproof. Most models are designed to achieve a protection level of IP65–IP68, ensuring reliable performance in outdoor environments exposed to rain, dust, and temperature variations.
Typical Technical Specifications of IPC
| Parameter | Specification |
|---|---|
| Rated Voltage | ≤ 1kV AC / 600V DC |
| Rated Current Range | 41A – 425A (depending on model) |
| Main Conductor Size | 16–95 mm² (up to 400 mm² for some models) |
| Branch Conductor Size | 1.5–16 mm² (up to 300 mm² for some models) |
| Conductor Compatibility | Aluminium & Copper |
| Working Temperature Range | -30°C ~ +90°C |
| Protection Level | IP65 – IP68 (waterproof & dustproof) |
| Contact Material | Tin-plated copper alloy/aluminium alloy |
| Housing Material | Glass-fibre reinforced PA66, UV-resistant & flame-retardant |
| Applicable Standards | EN 50483-4, NFC 33-020, NFC 33-004 |
Ipc Insulation Piercing Connector
How Does an IPC Connector Work?
The core mechanism of an IPC Insulation Piercing Connector lies in its self-piercing blade design. When the connector is tightened, the tin-plated metallic teeth penetrate the insulation layer and embed into the conductor strands, forming a low-resistance, metal-to-metal contact without damaging the cable’s core. This ensures stable conductivity while maintaining the cable’s overall insulation integrity.
Most SUNJ IPCs are equipped with a shear-head torque bolt system. During installation, the bolt applies controlled pressure to the contact teeth. Once the pre-calibrated torque level (typically 12–20 Nm depending on the model) is reached, the head automatically shears off, preventing over-tightening and ensuring a uniform compression force. This design guarantees that the contact resistance remains below 1.2 times the resistance of an equivalent length of conductor, in compliance with IEC 61238-1 testing standards.
To further enhance reliability, IPCs incorporate sealing elements made of UV-resistant elastomer and EPDM gaskets. These seals provide protection up to IP65–IP68, preventing water ingress, dust, and oxidation. As a result, the connector maintains long-term electrical stability, even in outdoor aerial bundled cable (ABC) systems, street lighting, or underground power distribution applications exposed to moisture, temperature fluctuations, and corrosion risks.
Installation & Performance Highlights of IPC
| Feature | Specification / Benefit |
|---|---|
| Torque Range | 12–20 Nm (depending on model) |
| Shear-Head Bolt | Automatic break-off at calibrated torque, prevents over-tightening |
| Contact Resistance | ≤ 1.2 × conductor resistance (IEC 61238-1 compliant) |
| Sealing & Protection | EPDM gaskets, UV-resistant elastomer, IP65–IP68 rating |
| Reliability | Stable performance in outdoor & underground installations |
Components of an IPC Insulation Piercing Connector
An IPC Insulation Piercing Connector is composed of several carefully engineered components that work together to provide a secure, low-resistance electrical connection in power distribution systems. Each part is designed to ensure long-term performance in low-voltage networks, aerial bundled cables (ABC), and street lighting applications.
Shear-head bolt: Ensures the correct torque is applied, preventing over-tightening.
Blade teeth / Piercing Elements: Made of corrosion-resistant metal, they pierce the insulation to establish a secure contact with the conductor.
Upper and lower body: Constructed from glass-fibre reinforced PA66 engineering plastic, the insulated body provides mechanical protection, flame retardancy (UL94 V-0), UV resistance, and stability under varying temperatures. This ensures that the connector housing performs reliably in outdoor electrical installations.
Waterproof sealing: Equipped with EPDM rubber gaskets and elastomeric seals, the connector achieves a protection rating of IP65–IP68. This prevents water ingress, dust, and oxidation, making the connector suitable for outdoor distribution lines, underground cable networks, and harsh environmental conditions.
Stainless steel washer: Adds structural integrity and prevents rusting.
End cap: Provides additional insulation at the cable end to maintain safety.
Together, these components allow the IPC Insulation Piercing Connector to deliver secure, conductive, and weather-resistant connections, with a service life exceeding 20 years in real-world distribution networks.
Advantages of IPC Connectors Over Traditional Crimp Connectors
Compared to traditional crimp connectors, IPC Insulation Piercing Connectors offer a range of benefits that make them a superior choice in many applications.
Time efficiency: No stripping, no crimp die selection, no re-insulation. Typical field installs can be completed in about 5 minutes with SUNJ’s waterproof JJC series, streamlining branch-tap work on overhead distribution lines.
IPC Connector 16 951.5 16mm² For low voltage wire accessories 2
Enhanced safety: Since IPC connectors do not require insulation stripping, the risk of accidental conductor damage or electric shock is minimized.
Waterproof and corrosion-resistant: The sealing mechanisms ensure long-term durability, making them ideal for outdoor applications.
Consistent torque application: The shear-head bolt design guarantees a uniform and optimal connection pressure, reducing the risk of poor electrical contact.
Compatibility: IPC connectors are suitable for aluminum-to-aluminum, copper-to-copper, and aluminum-to-copper connections, whereas traditional crimp connectors often require additional compatibility considerations.
Space efficiency: Their compact design allows for easy integration into power grids with limited space.
Why this matters: In modern power distribution projects, IPC insulation-piercing connectors cut install time, improve repeatability, and maintain long-term conductivity in outdoor service—often making them the preferred branch-tap solution over traditional crimp connectors for LV-ABC, street lighting and residential service drops.
Top 6 Applications of an IPC Insulation Piercing Connector
IPC connectors are widely used across multiple industries and electrical applications due to their adaptability and efficiency.
Street Light Connections
One of the most common applications of IPC connectors is in street lighting systems. They allow quick and secure branching from main power lines to individual streetlights, ensuring a consistent power supply.
Tap-off/Multi-Tap Connection to Households
IPC connectors play a crucial role in residential electricity distribution. They enable direct connections from aerial bundled cables to homes, making it easier to expand power networks without extensive cabling modifications.
Distribution Box Charging Connection
In low-voltage distribution systems, IPC connectors help facilitate reliable power transfer to distribution boxes, ensuring steady electrical flow for multiple circuits.
Jumper Connection
Jumper connections require secure and low-resistance links between two cables of the same size. IPC connectors provide an efficient solution for T-connections and high-angle turns in electrical networks.
Automotive Systems
In the automotive industry, IPC connectors are used in wiring harnesses, battery connections, and sensor integrations, ensuring stable electrical connections without extensive modifications.
Insulation Piercing Connector for ABC Cable
IPC Insulation Piercing Connectors are crucial in Aerial Bundled Cables (ABC), widely used in modern power distribution networks for their safety, efficiency, and ease of installation. These connectors enable secure, reliable, and maintenance-free branch connections by piercing the cable insulation without the need for stripping, enhancing installation speed and reducing maintenance needs. As a leading manufacturer, we offer high-quality insulated piercing connector for abc cable solutions, ensuring optimal performance and longevity in various electrical systems.
Screw-Type vs Spring-Loaded IPCs
When selecting an IPC Insulation Piercing Connector, understanding the differences between screw-type and spring-loaded variants is crucial. Below is a detailed comparison based on six key dimensions:
| Feature | Screw-Type IPCs | Spring-Loaded IPCs |
| Installation | Requires a tool to tighten the shear-head bolt, ensuring precise torque and a secure connection. | Uses internal spring tension to pierce and hold the conductor, allowing faster, tool-free installation. |
| Connection Strength | Highly stable and rigid, ideal for long-term installations. | Less rigid, may loosen over time due to spring fatigue. |
| Cost Consideration | Higher upfront cost, but better long-term reliability. | Lower initial cost, but may require more frequent replacements. |
| Torque Control | Shear-head bolts prevent over-tightening, ensuring consistent pressure. | Spring tension varies, which may lead to inconsistent contact pressure. |
| Durability & Lifespan | Extremely durable, resistant to vibration and movement, ideal for harsh environments. | May degrade as the spring loses elasticity, requiring periodic checks. |
| Best Use Cases | Suitable for permanent installations, overhead networks, and street lighting where reliability is key. | Ideal for quick installations, testing applications, and temporary power setups. |
| Environmental Resistance | Stronger sealing against moisture and corrosion, better for outdoor use. | Still weather-resistant but may have weaker sealing. |
Which One Should You Choose?
For long-term stability and harsh environments, go with screw-type IPCs. Their use of shear-head bolt connectors ensures consistent torque control and better environmental sealing. According to the comparison table:
- Screw-type models offer stronger sealing against moisture and corrosion, ideal for outdoor cable tap solutions.
- They provide consistent contact pressure due to precise torque from the shear-head bolt, reducing failure risk.
- The longer lifespan of screw-types makes them ideal for low-voltage connectors in street lighting or permanent overhead line installations.
For quick installations and flexibility, choose spring-loaded IPCs. They excel in temporary connections or test setups, offering tool-free installation and cost efficiency. However, note that their performance may degrade over time due to spring tension loss, particularly in high-vibration or outdoor environments.
How Do You Install an IPC Insulation Piercing Connector?
Source: electrical.theiet
Proper installation of an IPC Insulation Piercing Connector ensures a secure and long-lasting electrical connection. Following the correct procedure reduces the risk of connection failure and enhances system reliability.
Installation Steps
1.Preparation
Identify the main cable and branch cable that will be connected.
Ensure that the IPC connector is compatible with the conductor sizes and material (aluminum or copper).
Inspect the IPC and cables for any visible defects before installation.
2.Positioning
Place the main cable into the designated groove of the IPC.
Insert the branch cable into the secondary groove to ensure proper alignment.
Verify that both cables are properly positioned without twisting or overlapping.
3.Pre-Tightening
Lightly tighten the bolts by hand to secure the cables in place.
Ensure that the cables are firmly seated within the IPC without excessive movement.
Double-check alignment to prevent improper piercing during the next step.
4.Piercing the Insulation
Use a torque wrench or the appropriate tightening tool.
Gradually tighten the IPC bolts according to the recommended torque settings to ensure proper piercing.
Continue tightening until the shear-head bolt snaps off, indicating that the optimal torque has been reached.
Avoid over-tightening, as it may damage the conductor.
5.Inspection & Verification
Visually inspect the IPC to confirm there are no gaps between the connector and the cables.
Check that the bolts are properly sheared, leaving a flush and secure connection.
Lightly tug both cables to ensure they are firmly held in place.
6.Sealing and Protection
Verify that the self-sealing waterproof mechanism is engaged, protecting the connection from moisture and corrosion.
If applicable, apply additional insulation covers or protective coatings for extreme environmental conditions.
Ensure the IPC is securely fastened to prevent vibration-related loosening.
Installation Considerations
Avoid installation in heavy rain or extreme cold, unless the IPC is specifically rated for such conditions.
If used outdoors, ensure the IPC has UV-resistant properties to prevent degradation.
Regularly inspect IPC connections for any signs of corrosion, loosening, or wear.
Perform periodic maintenance and re-tighten connections if necessary to maintain long-term performance.
Following these guidelines ensures a durable and efficient IPC connection, minimizing the risk of failure while optimizing electrical performance.
How to Test Performance of IPCs?
The reliability of an IPC connector is determined through rigorous testing procedures. Some of the most common tests include:
Dielectric voltage test in water: Evaluates insulation resistance under wet conditions.
Corrosion resistance test: Assesses long-term exposure to environmental elements.
Mechanical strength test: Measures the connector’s ability to withstand external forces.
Short circuit endurance test: Determines performance under high electrical loads.
By passing these tests, IPC connectors demonstrate their reliability in real-world applications.
Industry Standards & Certifications
Ensuring compliance with industry standards is essential for safe and efficient electrical installations. IPC connectors typically adhere to the following certifications:
IEC 61238-1-2: Covers mechanical and electrical durability.
BS EN 50483-4: Specifies test requirements for low-voltage ABC cable accessories.
NFC 33-020: French standard for insulation piercing connectors in power networks.
These certifications confirm the quality, durability, and safety of IPC connectors in various electrical applications.
How to Choose an IPC Connector?
Selecting the right IPC connector depends on various factors, including:
Cable material and size compatibility
Environmental conditions (outdoor, underground, marine, etc.)
Voltage and current capacity
Installation method and ease of use
Ensuring that the chosen IPC meets project-specific requirements is key to long-term performance and reliability.