IPC Connectors

KW10 Insulation Piercing Connector

The KW10 Insulation Piercing Connector is designed for 1/0 AWG trunk cable with #10 and #8 AWG lead wires in 1500V DC PV systems. Certified to UL 9703, this connector helps create fast, secure field-installed connections for solar trunk bus and harness cable applications while supporting reliable performance in demanding utility-scale environments.

KW1000 Insulation Piercing Connector
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Specifications

Model KW10
Product Code 32KW10
Product Type Insulation Piercing Connector
Trunk Cable Size 1/0 AWG
Lead Wire Size #10, #8 AWG
Max System Voltage 1500V DC
Max Current 55 Amps
Overcurrent Fuse Amps 40
Tap Type Single
Number of Bolts 1
Bolt Size M6 x 60
Torque Value 10 ft-lbs
Weight 5 oz
Dimensions 2.63" W x 3.38" D x 2.87" H
Cable Compatibility AL9CU Class 2 stranded PV certified cables per UL4703 type PV
Material V0-rated body and cover material
Installation Temperature -28°C to +43°C
Max Operating Temperature 90°C
Certification UL 9703

Product Details

KW10 Insulation Piercing Connector

The KW10 Insulation Piercing Connector is designed for photovoltaic wiring applications that require a reliable field-installed connection between trunk bus cable and lead wire. Built for use with 1/0 AWG trunk cable and compatible with #10 and #8 AWG lead wires, this connector is a practical solution for organized 1500V DC solar wiring systems. In utility-scale and large-format PV installations, a dependable insulation piercing connector helps create repeatable electrical connections while supporting cleaner wire management and more standardized installation practices.

This KW10 insulation piercing connector is certified to UL 9703 and rated for 1500V DC photovoltaic applications. It is intended for use with AL9CU Class 2 stranded PV certified cables per UL4703 type PV, making it suitable for solar infrastructure where component compatibility and certified performance are important. The connector is built with a single-bolt design that helps simplify installation, and the body and cover are manufactured from V0-rated material for dependable use in demanding PV environments.

Designed for Solar Trunk Bus and Harness Cable Connections

The KW10 is used in PV systems where trunk bus cable and harness cable need to be connected efficiently in the field. In these layouts, an insulation piercing connector helps create a secure tap connection without requiring more complex wiring arrangements across the row. This can support a more repeatable and standardized installation process, which is especially valuable on larger projects where labor efficiency, wire organization, and system consistency all matter.

In utility-scale solar applications, trunk bus style wiring architectures can help reduce unnecessary jumper and harness wire use while simplifying the overall DC wiring layout. The KW10 insulation piercing connector supports that kind of design by providing a practical field-installed connection point for lower cable range applications. This makes it useful for solar contractors, EPC teams, and installers looking for a connector that fits into structured PV wiring systems built around repeatable processes and standardized components.

Built for 1/0 AWG Trunk Cable and #10 or #8 AWG Lead Wire

The KW10 is sized for 1/0 AWG trunk cable and supports #10 and #8 AWG lead wire. This cable range makes it a strong choice for specific solar connection points where a compact IPC is needed while still maintaining certified performance. By matching the connector to the correct cable sizes, installers can support proper fit, secure installation, and dependable electrical continuity in the finished assembly.

Because photovoltaic installations often involve repeated connection points across long cable runs, having a connector matched to the intended conductor size is important for both installation consistency and long-term system reliability. The KW10 gives installers a connector option that is purpose-built for this cable range while still fitting into the broader 1500V DC solar system design.

1500V DC Performance and Certified Construction

This KW10 insulation piercing connector is rated for 1500V DC, making it suitable for modern photovoltaic system architectures that require high-voltage DC components. It also carries UL 9703 certification, which is important for projects that depend on listed components for permitting, inspection, and compliance. In addition to voltage performance, the KW10 supports a maximum current rating of 55 amps and is associated with a 40 amp overcurrent fuse value.

The connector body and cover are made from V0-rated material, helping support dependable use in PV environments where material performance is an important part of product selection. For compliance with listing requirements, the IPC must be installed with the matching cover. That matching cover is an important part of the complete assembly and should always be used according to installation requirements.

Single-Bolt Installation for Repeatable Field Use

The KW10 uses a single M6 x 60 bolt and has a required torque value of 10 ft-lbs. This single-bolt design helps keep installation straightforward while still providing the secure mechanical hold needed in field wiring applications. In large PV installations, repeatable hardware and clear installation values can make a noticeable difference in jobsite efficiency and overall consistency.

A connector like the KW10 is intended to help installers work through repeated trunk bus connection points with a more uniform process. That can support faster installation workflows, cleaner organization, and a more structured approach to field DC wiring. For crews working on utility-scale solar or similar PV projects, having the right connector size and hardware configuration helps reduce variation from one connection point to the next.

Compact Size for Targeted PV Applications

The KW10 has a compact overall size of 2.63 inches wide, 3.38 inches deep, and 2.87 inches high. It weighs approximately 5 ounces, making it one of the lighter IPC options in the product range. Its smaller footprint can be useful in layouts where a lower cable range connector is needed without moving into larger dual-tap models intended for bigger conductors.

This size profile helps make the KW10 a practical option for project teams that need a compact insulation piercing connector for 1/0 AWG cable while still maintaining the same general product family, certification standard, and solar application focus found across the broader IPC lineup.

Common Uses for the KW10 Insulation Piercing Connector

  • PV trunk bus cable to harness cable connections
  • 1500V DC solar electrical systems
  • Field-installed connection points in utility-scale PV layouts
  • Solar projects using standardized trunk bus wiring architecture
  • Applications requiring a UL 9703 certified insulation piercing connector

The KW10 Insulation Piercing Connector is a strong choice for solar projects that need a certified, compact, and field-ready IPC for 1/0 AWG trunk cable and #10 or #8 AWG lead wire. With 1500V DC performance, UL 9703 certification, and a design intended for repeatable field installation, it fits well into photovoltaic systems that prioritize organized wiring, dependable connections, and practical installation efficiency.

IPC Connectors Products

Product Model Product Code Product Type Trunk Cable Size Lead Wire Size Max System Voltage Max Current Overcurrent Fuse Amps Tap Type Number of Bolts Bolt Size Torque Value Weight Dimensions Cable Compatibility Material Installation Temperature Max Operating Temperature Certification
KW10 Insulation Piercing Connector KW10 32KW10 Insulation Piercing Connector 1/0 AWG #10, #8 AWG 1500V DC 55 Amps 40 Single 1 M6 x 60 10 ft-lbs 5 oz 2.63" W x 3.38" D x 2.87" H AL9CU Class 2 stranded PV certified cables per UL4703 type PV V0-rated body and cover material -28°C to +43°C 90°C UL 9703
KW40 Insulation Piercing Connector KW40 32KW40 Insulation Piercing Connector 4/0 AWG #10, #8 AWG 1500V DC 55 Amps 40 Single 1 M6 x 60 10 ft-lbs 5 oz 2.63" W x 3.38" D x 2.87" H AL9CU Class 2 stranded PV certified cables per UL4703 type PV V0-rated body and cover material -28°C to +43°C 90°C UL 9703
KW350 Insulation Piercing Connector KW350 32KW350 Insulation Piercing Connector 350 kcmil #8, #6 AWG 1500V DC 55 Amps 40 Single 1 M6 x 60 10 ft-lbs 5 oz 2.63" W x 3.38" D x 2.87" H AL9CU Class 2 stranded PV certified cables per UL4703 type PV V0-rated body and cover material -28°C to +43°C 90°C UL 9703
KW500 Insulation Piercing Connector KW500 32KW500 Insulation Piercing Connector 500 kcmil #8, #6 AWG 1500V DC 175 Amps 75 Dual 1 M10 x 100 25 ft-lbs 14.1 oz 3.15" W x 4.30" D x 4.52" H AL9CU Class 2 stranded PV certified cables per UL4703 type PV V0-rated body and cover material -28°C to +43°C 90°C UL 9703
KW600 Insulation Piercing Connector KW600 32KW600 Insulation Piercing Connector 600 kcmil #8, #6 AWG 1500V DC 175 Amps 75 Dual 1 M8 x 100 20 ft-lbs 20.5 oz 3.62" W x 4.13" D x 4.41" H AL9CU Class 2 stranded PV certified cables per UL4703 type PV V0-rated body and cover material -28°C to +43°C 90°C UL 9703
KW750 Insulation Piercing Connector KW750 32KW750 Insulation Piercing Connector 750 kcmil #8, #6 AWG 1500V DC 175 Amps 75 Dual 1 M8 x 100 20 ft-lbs 20.5 oz 3.62" W x 4.13" D x 4.41" H AL9CU Class 2 stranded PV certified cables per UL4703 type PV V0-rated body and cover material -28°C to +43°C 90°C UL 9703
KW1000 Insulation Piercing Connector KW1000 32KW1000 Insulation Piercing Connector 1000 kcmil #8, #6 AWG 1500V DC 175 Amps 75 Dual 1 M8 x 100 20 ft-lbs 20.5 oz 3.62" W x 4.13" D x 4.41" H AL9CU Class 2 stranded PV certified cables per UL4703 type PV V0-rated body and cover material -28°C to +43°C 90°C UL 9703

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Common Questions

Frequently asked questions featured across the site.

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How does an IPC trunk bus system replace combiner boxes?

Instead of routing individual string cables to a central combiner box, IPCs connect strings directly to a trunk bus cable that runs along the array. This eliminates combiner box hardware, reduces underground conduit runs, lowers voltage drop, and cuts total connection points dramatically — resulting in less labor, less material, and fewer potential failure points.

Why UL 9703 instead of UL 486?

UL 9703 was developed specifically for wiring harnesses in distributed generation systems. It requires more aggressive testing — including freeze cycles, thermal chamber, wet high-pot, and impact tests — than UL 486, which covers a broader range of general-purpose connectors. It’s the highest standard available for solar EBOS connections.

What sizes do your IPCs support?

Our IPC product line covers trunk bus sizes from 1/0 AWG through 1000 KcMil, with tap cable support from #10 AWG up. Available in dual-tap and multi-tap configurations to match your array string count and inverter layout.

What is an insulation piercing connector?

An IPC connects string-level DC wiring to a trunk bus cable by piercing through the cable insulation with tinned copper teeth. This eliminates wire stripping in the field, reduces connection time, and creates a sealed, weather-resistant joint. The result is fewer failure points and faster array commissioning.

What does NPDesign do?

NPDesign engineers and delivers EBOS infrastructure for utility-scale solar projects, with a strong focus on Solar IPC trunk bus systems, connectors, engineering support, and project-specific kitting and logistics.

What is an IPC connector?

An IPC connector is an insulation piercing connector designed to create a field-installed electrical tap connection without requiring wire stripping at the tap point. NPDesign presents IPC connectors as a faster and more efficient solution for solar trunk bus systems.

Do NPDesign IPC connectors require wire stripping?

No. NPDesign IPC connectors are designed to make the connection without stripping the cable insulation first. This helps speed up installation, reduce extra cable prep in the field, and create a more consistent connection process across large solar projects.

How fast do the IPC connectors install?

NPDesign IPC connectors are designed to install in under two minutes per tap. That faster install time helps crews move more efficiently across the array while keeping the process simple and repeatable.

What cable sizes do NPDesign IPC connectors support?

The IPC product line covers trunk bus sizes from 1/0 AWG through 1000 KcMil, with tap cable support starting at #10 AWG depending on the model. This gives project teams options across a wide range of utility-scale solar layouts.

Why use an IPC trunk bus system in solar?

An IPC trunk bus system can reduce connection points, simplify array wiring, and lower field labor compared with more traditional DC wiring layouts. It also helps create a cleaner, more standardized installation process across large solar projects.

How does an IPC trunk bus system replace combiner boxes?

Instead of routing individual string cables back to a central combiner box, IPCs connect strings directly to a trunk bus cable along the array. This can reduce hardware, lower conduit needs, cut total connection points, and help reduce both labor and material costs.

Does NPDesign provide engineering support or only products?

NPDesign provides both products and engineering support. That includes site plan review, single-line review, IPC sizing, array layout support, field guidance, and other services that help customers apply the right EBOS solution to the project.

Does NPDesign offer project-specific kitting?

Yes. NPDesign can kit connectors, trunk cable, harnesses, and accessories by site zone and construction schedule. This helps crews receive materials in a more organized way for the work being done on site.

Why is UL 9703 important?

UL 9703 is a photovoltaic connector standard that supports safety, inspection confidence, and project compliance. Using listed components can also help give developers, EPCs, and contractors more confidence in the connection system being installed.

Why UL 9703 instead of UL 486?

UL 9703 is tailored specifically to photovoltaic and distributed generation wiring applications, with more aggressive testing for solar use conditions. That makes it a stronger fit for solar EBOS connections than a broader general-purpose connector standard.

How does it work to start a project with NPDesign?

The process starts with sharing the site plan and single-line diagram. From there, NPDesign reviews the EBOS requirements, develops the connector and trunk bus approach, and helps move the project toward kitting, delivery, installation, and energization.

How can I contact NPDesign?

Customers can reach out through the contact and quote request options on the site, and NPDesign also lists in**@*********lc.com as a direct contact email.

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