Low voltage (LV) overhead ABC aerial bundled cable grids form the core infrastructure of residential power supply, municipal street lighting, rural grid renovation and distributed photovoltaic power systems worldwide. Reliable branch tapping is the key to stable grid operation, while single-bolt insulation-piercing connectors (IPC) often suffer from uneven clamping force, loose contact after long-term wind vibration and overheating faults on large-section aluminum cables. To solve these industry pain points, Jera Line, a professional manufacturer of LV cable accessories founded in 2012, has developed a complete two-bolt IPC product lineup including ZOP-257 and ZOP-258, specially designed for all kinds of 1kV LV ABC grids. Different from single-bolt structures, the symmetric double shear-head bolt design delivers uniform compression, full IP68 waterproof sealing and universal compatibility for copper and aluminum wires. This blog will introduce product definition, unified technical parameters, structural material advantages, typical LV grid application scenarios and core strengths of cooperating with Jera Line as your IPC supplier.
Jera Line double-bolt IPC is a special tap fitting exclusively developed for 0.6/1kV LV aerial bundled cable distribution grids. Unlike single-bolt connectors that only apply one-way extrusion pressure, ZOP-257 and ZOP-258 adopt two independent shear-head torque bolts arranged symmetrically on both sides of the plastic housing. When tightened with a standard hex wrench, the dual bolts evenly wrap the cable outer sheath, avoiding partial separation between piercing teeth and wire cores caused by unbalanced stress after long-term thermal expansion and contraction.
The integrated structure is filled with high-viscosity silicone sealing gel inside, equipped with tin-plated aluminum bimetal piercing teeth. Electricians do not need to strip cable insulation, cut conductors or wrap insulating tape during live-line tapping. The serrated metal teeth automatically pierce the cable jacket and form tight conductive contact, while built-in elastomer seals fully block rainwater, coastal salt fog and dust intrusion. Calibrated shear-off aluminum alloy nuts break once the preset torque is reached, eliminating installation errors caused by under-tightening or over-tightening by new workers. The shell adopts UV-resistant composite polymer through two-component insert molding, stably operating between -40℃ and +55℃ to adapt to cold northern, hot desert and humid tropical LV grids. All models fully pass EN-50483:4 routine type tests in Jera Line' s in-house laboratory, with SGS and BV third-party certification reports available for global LV grid tender projects.
|
Product code |
Cable size , mm² |
|
|
Main |
Top |
|
|
ZOP-257 |
25–150 |
25–95 |
|
ZOP-258 |
35–185 |
35–185 |
All Double-Bolt Insulation-Piercing Connector adopt stainless steel anti-rust bolts and washers, IP68 integrated waterproof structure, and support mixed copper-aluminum cable connection without electrochemical corrosion risks. Each finished batch is issued SGS or BV third-party inspection certificates to meet overseas tender document requirements.
1. Balanced Dual-Bolt Clamping Prevents Loose Joint Failures on LV Grids
Single-bolt Insulation-Piercing Connector only squeeze cables from one side, leading to contact gaps after years of wind shock. The double symmetrical bolt structure distributes pressure evenly around the cable circumference. Lab vibration cycle tests verify that Jera Line Double-Bolt Insulation-Piercing Connector maintain consistent contact resistance after 1000 vibration cycles, drastically reducing hidden heating risks for overhead LV grid lines.
2. IP68 All-Weather Waterproof & Anti-Corrosion Performance
The fully enclosed cavity is tightly locked by dual bolts, with integrated silicone sealant filling all gaps. It works reliably in coastal salt areas, rainy mountainous zones and farmland LV grids where ordinary connectors easily fail due to moisture erosion.
3. Universal Cu & Al Cable Compatibility for Mixed LV Grids
Tin-plated aluminum contact teeth form an isolation buffer between copper and aluminum conductors, effectively eliminating electrochemical overheating at branch joints. Contractors only need one series of Jera Line Double-Bolt Insulation-Piercing Connector to complete mixed aluminum main line + copper service line LV grid construction, cutting inventory costs and wrong model selection risks .
4. Shear-Head Bolts Ensure Standardized LV Grid Installation
No professional torque measuring tools are required. The shear nut automatically breaks at the rated torque value, unifying construction quality of all LV grid tap points and lowering project rework rate by over 70%.
5. Wide Cable Coverage for Medium & Large LV Trunk Lines
ZOP-257 covers medium-size 25–150 mm² main cables for residential and commercial three-phase LV grids; ZOP-258 adapts 35–185 mm² large-section trunk cables for industrial parks and large photovoltaic microgrids, forming a complete size matching solution for medium and heavy-load LV overhead networks.
1. Multi-Family & Commercial Three-Phase LV Distribution Grids
ZOP-257 is the preferred tapping fitting for apartment blocks, shopping malls and community three-phase ABC overhead grids, realizing power branch without cutting off mains supply to reduce resident complaints.
2. Municipal Highway & Park Street Lighting LV Grids
The anti-vibration dual-bolt structure resists long-term vehicle vibration along roads, greatly extending the service life of street lamp branch joints and lowering routine grid maintenance workload.
3. Industrial Park Large-Capacity LV Trunk Grids
ZOP-258 matches 35–185 mm² thick aluminum trunk cables for factory power supply, stably transmitting heavy industrial current under day-night temperature alternation.
4. Distributed Photovoltaic Overhead LV Microgrids
Suitable for rooftop and ground PV station grid-connected branch lines, adapting frequent temperature changes of outdoor new energy LV grids with stable long-term conductivity.
5. Rural Power Grid Renovation Overhead Lines
Most rural LV grids adopt large-section aluminum ABC cables; balanced dual-bolt clamping solves the poor contact defect that frequently occurs when single-bolt clamps are applied on oversized aluminum conductors.
1. Direct Factory R&D & Production Located in Ningbo Yuyao
Founded in 2012, Jera Line owns full-automatic injection molding, CNC metal processing and assembly production lines. All molds of ZOP-257 and ZOP-258 are independently developed by our in-house engineering team, removing middleman markup to provide competitive bulk pricing for global LV grid contractors. Standard models keep permanent stock to guarantee stable 7–15 working day delivery cycles.
2. Complete OEM & ODM Customization Support for Regional LV Grid Standards
We provide one-stop customization including laser customer logo marking, exclusive color box packaging, torque parameter adjustment and special-size mold development for different country LV grid specifications. Free product samples are offered for project testing with low minimum order quantities for trial bulk orders.
3. Strict Full-Process QC & Independent Professional Laboratory
Jera’s on-site testing laboratory is equipped with dielectric water bath testers, temperature-humidity aging equipment and salt spray testing machines. Every batch of two-bolt IPCs completes visual inspection, dimensional verification, shear function test and water voltage withstand test according to EN-50483:4 standards before shipment. All products carry a 5-year factory warranty, with free replacement for non-artificial manufacturing defects.
4. Over Ten Years Global Export Experience in LV Grid Fittings
Our LV cable accessories have been exported to more than 30 countries across Europe, Africa, Southeast Asia and the Middle East. The multilingual foreign trade team is fully familiar with local LV grid standards, tender document requirements and customs clearance procedures, providing one-stop service from model selection to after-sales technical guidance.
5. One-Stop Sourcing for Full Set Overhead LV Grid Hardware
Besides ZOP series double-bolt IPCs, Jera Line manufactures supporting anchor clamps, suspension clamps, pole brackets and surge arresters. Clients can purchase all required LV grid fittings from a single manufacturer, reducing multi-supplier communication and comprehensive logistics costs.
For medium and large capacity overhead LV grids that demand long-term stable tapping performance, anti-vibration structure and all-weather durability, Jera Line ZOP-257 and ZOP-258 double-bolt insulation-piercing connectors are a comprehensive upgrade compared with traditional single-bolt IPCs and stripped wiring terminals. With balanced dual-side clamping, universal copper-aluminum compatibility, full international standard compliance and factory-direct cost advantages, this two-bolt IPC series becomes the preferred branch fitting for global LV grid distributors, EPC contractors and new energy integrators.
If you are sourcing reliable tapping solutions for residential, industrial or photovoltaic LV grids, feel free to contact the Jera Line team to apply for free samples, download complete technical datasheets and obtain exclusive quotations tailored to your project order volume.
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