Conversions Tech™ Insulated Tap & Splice Connectors – In-Depth Installer FAQ

General Information

1. What is a Conversions Tech insulated tap connector?

An insulated tap—also called an IPC or insulated piercing connector—is a dual-rated, mechanical splice that lets you add a branch circuit without stripping the main run conductor. Precision set-screws bite through insulation and reseal the joint with a molded plastisol sleeve, giving a 600 V, 90 °C, NEC-compliant connection in seconds.

2. Which conductor sizes do the taps accommodate?

The family covers 14 AWG–4 AWG, 6 AWG–250 MCM, and heavy-duty 1/0 AWG–750 MCM ranges, making them ideal for everything from rooftop PV strings to utility feeders.

3. Are they dual-rated for aluminum and copper?

Yes. A high-strength 6061-T6 aluminum body filled with oxide-inhibiting grease earns them a CU9AL dual-rating, so they bond flawlessly to copper and aluminum conductors.

4. What voltage and temperature ratings apply?

All models are UL 486A/B listed for 600 V, with a continuous operating window from –45 °C to 90 °C (–49 °F to 194 °F).

Installation & Handling

5. Do I need to strip the main conductor?

No stripping is required. The tap’s cutting ridge pierces the run insulation as you torque the screw—only the branch conductor is stripped.

6. What torque values should I apply?

Each connector includes a removable plug with the exact torque spec. For instance, the 6 AWG–250 MCM size torques to 225 in-lb (25.4 N·m). Always verify before energizing.

7. Which tools are recommended?

A 3⁄8-in drive torque wrench and the correct hex bit (3⁄16-in or 1⁄4-in) assure code compliance—no crimping dies or heat guns needed.

8. Can I re-enter or reuse the connector?

One re-torque is permissible if strands are undamaged and the plastisol jacket remains intact. For critical systems, replace rather than reuse.

9. Are Conversions Tech taps suitable for outdoor or direct-burial use?

Yes. The UV-stabilized jacket resists sunlight and moisture. For direct-burial, backfill with non-hydroscopic sand or potting compound for extra longevity.

10. Are they submersible?

They pass a 72-hour, 10-ft immersion test without dielectric breakdown. For permanent submersion (e.g., marinas), encapsulate with waterproof resin per NEC 110.11.

Code & Compliance

11. Which NEC articles govern insulated taps?

Key clauses include NEC 300 (General), 310.104 (Conductors), 250.148(B) (bonding), and 230.46 for line-side service splicing.

12. Are they suitable for service-entrance line-side splicing?

Yes—the heavy-duty 1/0-750 MCM model is factory-marked for line-side use, satisfying NEC 230.46. Always confirm with your AHJ.

Applications & Selection

13. Where are insulated taps most beneficial?

• LED lighting retrofits
• Solar combiner boxes
• EV charging branches
• Panelboard feeders
• Dock and marina circuits

14. How do I choose between single-entry and dual-entry?

Single-entry taps work best when all conductors approach from one side. Dual-entry zig-zag models keep the main run straight while the tap exits opposite the set-screw, minimizing bend radius.

Troubleshooting & Maintenance

15. The screw bottoms out before reaching torque—what now?

Ensure wire size matches the catalog range and strands are fully seated. If bottoming persists, step down to the next-smaller tap size.

16. How do I confirm a good connection?

• Visual check: plastisol jacket flush with insulation.
• Torque witness mark engaged.
• Optional megger at 1 kV for 60 s; leakage ≤ 1 mA.

17. What is the shelf life of unused connectors?

Up to 10 years in sealed bags below 110 °F and out of direct sunlight.

18. Where can I get replacement plugs?

Order plug kit PK-IP-10 (pack of 10) free with any PO over $250 or add separately.

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