ABB - Installation Products 54809 - Copper Two-Way Splice, Long Barrel, Max 35kV, Wire Size 1/0 AWG, Length 2.0 Inches, Diameter 0.54 Inch, Tin Plated, Die Code 42, Die Color Code Pink
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ABB - Installation Products

54809

UPC: 786210548098

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Overview

The ABB Copper Two-Way Splice (SKU: 54809) is a precision-engineered electrical connector designed for reliable splicing of stranded copper conductors in high-voltage industrial and utility applications. This splice features a long barrel design optimized for wire sizes up to 1/0 AWG and supports maximum voltages of 35kV, making it ideal for power distribution systems, substations, and industrial wiring where robust electrical and mechanical performance is critical. Key specifications include a compact 2.0-inch length and 0.54-inch diameter, allowing installation in tight spaces without compromising connection integrity. The tin-plated finish provides superior corrosion resistance, extending service life in harsh environments. The splice is color-coded pink with Die Code 42, ensuring proper die selection for crimping tools and compliance with industry standards. Certified by UL and CSA for use up to 35kV and temperature-rated to 90°C, this splice delivers premium electrical and mechanical performance when crimped with Panduit and specified competitor tools. The long barrel maximizes crimp points, enhancing wire pull-out strength and long-term reliability. Its design includes an inspection window for visual verification of conductor insertion, reducing installation errors. Applications include power distribution systems, substations, industrial wiring, and utility installations requiring high-voltage splicing of copper conductors. The splice's wide wire range-taking capability minimizes inventory requirements, while its UL Listed and CSA Certified status ensures compliance with stringent safety and performance standards. For service and technical support, contact ABB at 1-800-777-3300.
  • Long barrel design for secure splicing of 1/0 AWG copper conductors
  • Supports maximum voltage of 35kV and temperature-rated to 90°C
  • Tin-plated finish for superior corrosion resistance
  • Color-coded pink with Die Code 42 for proper tool/die selection
  • Compact 2.0" length and 0.54" diameter for tight-space installations

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
Pink
Connection Type
Splice
Finish
Tin-Plated
Material
Copper
Material
Copper, Tin Plated
Size
1/0 AWG, 2.0 Inches Length, 0.54 Inch Diameter
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, CSA 4503
Standard
UL E9809, CSA 4503 / UL E9809, CSA 4503
Type
Splice Connector
Voltage Rating
600 V
Voltage Rating
35 kV
Package Dimensions (L x W x H)
3.3 IN x 2.8 IN x 2.3 IN
Package Dimensions (L x W x H)
8.382 cm x 7.112 cm x 5.842 cm
Package Weight (Imperial)
0.060 L
Package Weight (Metric)
0.027 kg
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How to Install the 54809 Long Barrel Two Way Splicer

This guide provides step-by-step instructions for installing the 54809 Long Barrel Two Way Splicer for 600V applications, ensuring a secure and reliable connection.

Estimated time: 30m

Tools needed:

Wire strippers, Crimping tool, Wire brush, Multimeter

Supplies needed:

54809 Long Barrel Two Way Splicer, Cable (appropriate size), Shrink tubing (if needed)

  1. Prepare the cable

    Strip the insulation from the cable end to the length specified in the installation table. Be careful not to nick the cable strands.

  2. Clean the cable end

    Ensure the cable end is clean. Use a wire brush or emery cloth to remove any dirt or oxidation.

  3. Insert and crimp the connector

    Insert the cable into the 54809 connector until it stops. Use the appropriate crimping tool and die to compress the connector between the markings, starting near the center.

  4. Remove sharp edges

    After crimping, carefully remove any sharp edges, flash, or burrs from the connector to ensure safety.

  5. Verify the connection

    Use a multimeter to check the continuity of the connection and ensure it meets the required specifications.

Frequently Asked Questions about ABB - Installation Products

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