Insulation Piercing Connector

Ask the cable manufacturers to recommend a suitable IPC.

Get a well experienced technician to check the connection

Check the connection. May be loose contact is causing the problem.

Something doesn't sound right. If you're working for a utility/contractor you should be able to present your problem to the IPC supplier who will work with you to understand the nature of your problem. If not then start searching for an alternate vendor who can supply something like this.

On the other hand if you're using a tap rated for ABC but not supporting it properly, then anything that allows either of the conductors to move (wind, street vibration, people, etc.) will accelerate the creeping of the al and ultimately cause a poor connection leading to heat cycling and ultimate failure.

Thanks for the info on Michaud.

The IPCs are properly tightened on installation (using shear heads ). The connections are not subject to wind or other vibration

However my main question asks if there is a suitable alternative to using IPCs for these tap connections.

The most reliable method of joining two conductors together is called a CAD Weld.It melts the 2 conductors together to form one solid piece.No vibration or temperature issues with this connection.

Then there is the old but reliable split-bolt or parallel clamp connection.If properly installed can give years of trouble free service.

Reliability is paramount in your case, and repairs cost much more than doing it properly the first time.

Insofar as insulation-piercing connectors go, I would consult with the current manufacturers engineering dept to determine why their connectors are failing.I am sure they are as equally interested in learning the failure mode of the connectors as you are.

Good Luck!

I tried to get this in under the edit time limit, but failed to do so.

Here is a link to the man that wrote the specs on IPC connectors, with instructional video.

http://www.youtube.com/watch?v=n75qR-eBx0c