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Unplated copper split-bolt connector, square head, 1.77 in long, 0.73 in wide

Burndy

Burndy KS25 Split-Bolt Connector 4 AWG to 1/0 AWG

SKU CH-AY7Y-8MKMA

Copper split-bolt connector joins 4 AWG to 1/0 AWG conductors at up to 35 kV

  • TypeElectrical Connectors
  • Connects 4 AWG to 1/0 AWG copper conductors
  • Accepts tap wires from 14 AWG to 1/0 AWG
  • Rated for 35 kV maximum voltage
  • Requires 385 in-lb installation torque
  • CSA certified and UL 486A, 486B, 486D listed

Burndy KS25 Split-Bolt Connector

The Burndy KS25 is a copper split-bolt connector designed for joining solid or stranded copper conductors in electrical installations. It accommodates run wires from 4 AWG to 1/0 AWG and tap wires from 14 AWG up to 1/0 AWG. The unplated body and square-head hex nut allow a secure mechanical connection rated for up to 35 kV maximum voltage.

Replaces crimp or compression lugs

This connector replaces permanent crimp-style lugs when a separable, reusable joint is preferred for maintenance or future changes. The jump is worth it when the installation requires a torque-controlled mechanical bond rated at 385 in-lb and compliance with UL 486A, UL 486B and UL 486D standards. It suits applications where CSA certification and RoHS compliance are specified.

Mechanical split-bolt limits

The split-bolt design relies on proper torque to maintain contact pressure across the conductor range. It does not suit conductors smaller than 14 AWG or larger than 1/0 AWG, nor does it accept aluminium wire. The 1.77 in overall length and 0.73 in width set the physical space needed, while the 0.94 in hex nut dictates the tool clearance required for installation.

Highlights

  • Connects 4 AWG to 1/0 AWG copper conductors
  • Accepts tap wires from 14 AWG to 1/0 AWG
  • Rated for 35 kV maximum voltage
  • Requires 385 in-lb installation torque
  • CSA certified and UL 486A, 486B, 486D listed

Specifications

BrandBURNDY
TypeElectrical Connectors

Questions about this item

What is the hex nut size and overall length of the KS25 split-bolt connector?

The connector has a hex nut size of 0.94 in and an overall length of 1.77 in, which determines the wrench clearance and space required inside the enclosure.

How do I torque the square-head bolt correctly, and what is the common mistake?

Tighten the square-head bolt to 385 in-lb using a calibrated torque wrench; the common error is using an adjustable wrench and guessing the force, which can under-tighten or strip the threads.

When should the KS25 connector be replaced after installation?

Replace the connector if the copper body shows corrosion, the square head rounds off, or the connection exceeds the 35 kV rating during service inspections.

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