ABB - Installation Products 54015 - Copper Two-Way Splice, Long Barrel, Max 35kV, Wire Size 350 kcmil, Die Set 15CA71R, Die Color Code Red
ABB - Installation Products

54015

UPC: 786210540153

Documents & Media
Installation InstructionsSpecification SheetManufacturer Product Website

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Minimum Qty: 10

Multiplier: 10

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Overview

The ABB Copper Two-Way Splice (SKU: 54015) is a precision-engineered copper splice designed for high-voltage applications up to 35kV. This long-barrel splice accommodates stranded copper conductors sized at 350 kcmil, ensuring robust mechanical and electrical connections in power distribution, transmission, and industrial wiring systems. The splice features a die set 15CA71R with a red color code for easy identification and tool compatibility, meeting stringent industry standards for performance and safety. Key specifications include a maximum voltage rating of 35kV and a temperature rating of 90°C when installed with compatible crimping tools and dies. The long barrel design maximizes crimp points, enhancing wire pull-out strength and long-term reliability. The splice is tin-plated to inhibit corrosion, making it suitable for demanding environments where moisture and chemical exposure are concerns. Engineered for compatibility with copper conductors, the 54015 splice is ideal for splicing two wires of equal or different sizes within its specified range. It is UL Listed and CSA Certified, ensuring compliance with North American electrical standards. The splice’s design includes an inspection window for visual confirmation of full conductor insertion, reducing installation errors and improving reliability. Applications include power distribution networks, utility substations, industrial machinery, and renewable energy systems where high-voltage copper conductors require secure, long-lasting splices. The splice’s compatibility with standard crimping tools and dies simplifies installation, reducing downtime and maintenance costs. For optimal performance, always follow the manufacturer’s installation guidelines and voltage stress relief instructions for applications exceeding 2000V.
  • Rated for 35kV maximum voltage and 90°C temperature
  • Accommodates 350 kcmil stranded copper conductors
  • Long barrel design for enhanced wire pull-out strength
  • Tin-plated for corrosion resistance and low contact resistance
  • UL Listed and CSA Certified for compliance and reliability

Specifications

Application
Applications certified to 600 V and recommended up to 35 kVÂ¥
Application
Applications certified to 600 V and recommended up to 35 kV¥
Color
Red
Finish
Tin-Plated
Material
Copper
Special Features
Two-way connectors provide high pullout values, are easy to insulate and provide a low-resistance connection of high quality and low installed cost
Standard
UL E9809
Standard
UL E9809 / UL E9809
Type
Splice Connector
Voltage Rating
600 V
Package Dimensions (L x W x H)
5 IN x 4.5 IN x 3 IN
Package Dimensions (L x W x H)
12.7 cm x 11.43 cm x 7.62 cm
Package Weight (Imperial)
0.320 L
Package Weight (Metric)
0.145 kg
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How to Install the High Voltage Two Way Splices

This guide provides step-by-step instructions for properly installing high voltage two way splices, ensuring safe and effective connections.

Estimated time: 30m

Tools needed:

Crimping tool, Wire strippers, Multimeter

Supplies needed:

High voltage connectors, Hose clamps, Cable ties

  1. Prepare the cable

    Train the cable into its final position, mark the splice center line, and cut excess cable from each end.

  2. Strip the cable

    Remove the cable jacket, shield, and insulation from the conductors for a distance of 1/2 connector length plus a minimum of 1/2 inch.

  3. Insert the conductor

    Fully insert the conductor into the connector, ensuring it is seated properly.

  4. Crimp the connector

    Make the first crimp at one end of the connector next to the taper, then make a second crimp at the other end of the connector next to the taper.

  5. Overlap crimping

    Crimp in overlapping steps, starting from the 'start overlap' line towards the connector ends, ensuring no ridges are left.

  6. Final crimping

    To ensure the connector is round and to avoid flash and ridges, repeat the crimping steps with the tool rotated 90 degrees.

  7. Safety check

    Verify that all connections are secure and that there are no exposed conductors. DO NOT CRIMP ON HOT ENERGIZED WIRES; disconnect power before installation.

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