TE makes two gel-sealed ways to splice or repair 1000 V cable without heat. The GILS is a complete splice kit with the connector included. GelWrap is a wraparound closure that goes over a connector you have already installed, and it also repairs insulation and jackets. This guide covers both, so you can pick by job.
TE describes the GILS as a PowerGel sealant-filled splice for buried, underground and overhead use. It includes a range-taking aluminum connector for aluminum or copper cable, and it meets ANSI C119.1.
| Kit | Use range | Recommended torque | Installed length | Width | Height |
|---|---|---|---|---|---|
| GILS-4/0 | #2 to 4/0 AWG (33 to 107 mm2) | 225 in-lb (25.4 N-m) | 4.25 in. (108 mm) | 2 in. (51 mm) | 1.1 in. (30 mm) |
| GILS-350 | 1/0 to 350 kcmil (50 to 150 mm2) | 225 in-lb (25.4 N-m) | 7.1 in. (180 mm) | 2.75 in. (71 mm) | 1.57 in. (40 mm) |
The GILS-350 is not on our store, but we can order it. Contact Powertech Associates.
| Feature | Detail |
|---|---|
| Sealant | PowerGel, rated to 95 C |
| Cover | Molded UV-stable, impact-resistant polypropylene with a snap-lock closure |
| Cable range | Frangible fingers give a wide range |
| Water seal | Silicone gel gives high dielectric insulation and constant pressure on the cable and connector |
| Re-entry | The gel peels away, leaving a clean connection |
| Approvals | Meets ANSI C119.1. The GILS-4/0 is RUS accepted for secondary connector blocks and splices. |
Tools: a 5/16 in. Allen wrench or torque wrench, and a knife.
| Step | What to do |
|---|---|
| 1 | Remove insulation equal to half the connector length |
| 2 | Insert the conductors, tighten the set screws with the Allen wrench, torque to 225 in-lb (25.4 N-m), flex the cable, then torque again |
| 3 | Center the connector over the GILS gel cover |
| 4 | Snap both locks shut, using pliers if needed |
| 5 | The splice is complete |
TE's GelWrap wrap-around splice cover insulates and seals buried electrical connections rated up to 1000 V. You wrap the sleeve around the cable and snap it shut, over any cable in the use range. It is built for direct burial and manhole use, and TE says it suits insulation and jacket repair. TE's PowerGel is a hydrophobic gel that gives a moisture seal across -40 C to 95 C, and both the gel and the housing are UV resistant for overhead use. TE lists these common uses: LV cable repair splices, MV cable jacket repair, MV splice rejacketing and elbow sealing sleeve. The sleeves are compatible with solid dielectric cable insulations. TE also lists UL listed versions. GelWrap UF splices include the UF connector.
Watch TE install a Raychem GelWrap splice closure.
Minimum seal length on each side of the connector opening or jacket damage: 1.5 in. (38 mm) for the 18/4 series, 2.0 in. (51 mm) for the 33/10 series and 3.0 in. (75 mm) for the 50/20 series.
| Catalog number | Sleeve length in. (mm) | Connector conductor size | Max. opening in. (mm) | General use diameter in. (mm) | Std. pack |
|---|---|---|---|---|---|
| GelWrap-18/4-100 | 4.0 (100) | #12 to 4/0 | 1.0 (25) | 0.15 to 0.70 (4 to 18) | 6 |
| GelWrap-18/4-150 | 6.0 (150) | #12 to 4/0 | 3.0 (75) | 0.15 to 0.70 (4 to 18) | 6 |
| GelWrap-18/4-200 | 8.0 (200) | #12 to 4/0 | 5.0 (125) | 0.15 to 0.70 (4 to 18) | 6 |
| GelWrap-18/4-250 | 10.0 (250) | #12 to 4/0 | 7.0 (175) | 0.15 to 0.70 (4 to 18) | 6 |
| GelWrap-18/4-300 | 12.0 (300) | #12 to 4/0 | 9.0 (225) | 0.15 to 0.70 (4 to 18) | 6 |
| GelWrap-33/10-150 | 6.0 (150) | #2 to 500 | 2.0 (50) | 0.40 to 1.30 (10 to 33) | 6 |
| GelWrap-33/10-200 | 8.0 (200) | #2 to 500 | 4.0 (100) | 0.40 to 1.30 (10 to 33) | 6 |
| GelWrap-33/10-250 | 10.0 (250) | #2 to 500 | 6.0 (150) | 0.40 to 1.30 (10 to 33) | 6 |
| GelWrap-33/10-250-I350M4 (includes a four-screw mechanical connector) | 10.0 (250) | #6 to 350 | 5 (125) | 0.40 to 1.30 (10 to 33) | 12 |
| GelWrap-33/10-300 | 12.0 (300) | #2 to 500 | 8.0 (200) | 0.40 to 1.30 (10 to 33) | 12 |
| GelWrap-33/10-350 | 14.0 (350) | #2 to 500 | 10.0 (250) | 0.40 to 1.30 (10 to 33) | 10 |
| GelWrap-50/20-200 | 8.0 (200) | 250 to 750 | 2.0 (50) | 0.80 to 1.50 (20 to 38) | 12 |
| GelWrap-50/20-250 | 10.0 (250) | 250 to 750 | 4.0 (100) | 0.80 to 1.50 (20 to 38) | 12 |
| GelWrap-50/20-300 | 12.0 (300) | 250 to 750 | 6.0 (150) | 0.80 to 1.50 (20 to 38) | 12 |
| GelWrap-50/20-350 | 14.0 (350) | 250 to 750 | 8.0 (200) | 0.80 to 1.50 (20 to 38) | 12 |
| GelWrap-50/20-400 | 16.0 (400) | 250 to 750 | 10.0 (250) | 0.80 to 1.50 (20 to 38) | 12 |
| GelWrap-UF-200 | 8.0 (200) | 14/2 to 8/3 with ground | N/A | N/A | 10 |
| Catalog number | Sleeve length in. (mm) | 1000 V cable range | Max. connector opening in. (mm) |
|---|---|---|---|
| GelWrap-18/4-150UL | 6.0 (150) | #14 to 4/0 AWG | 2.0 (50) |
| GelWrap-18/4-200UL | 8.0 (200) | #14 to 4/0 AWG | 4.0 (100) |
| GelWrap-18/4-250UL | 10.0 (250) | #14 to 4/0 AWG | 6.0 (150) |
| GelWrap-18/4-300UL | 12.0 (300) | #14 to 4/0 AWG | 8.0 (200) |
| GelWrap-18/4-350UL | 14.0 (350) | #14 to 4/0 AWG | 10.0 (250) |
| GelWrap-18/4-400UL | 16.0 (400) | #14 to 4/0 AWG | 12.0 (300) |
| GelWrap-18/4-450UL | 18.0 (450) | #14 to 4/0 AWG | 14.0 (350) |
| GelWrap-18/4-500UL | 20.0 (500) | #14 to 4/0 AWG | 16.0 (400) |
| GelWrap-18/4-550UL | 22.0 (550) | #14 to 4/0 AWG | 18.0 (450) |
| GelWrap-18/4-600UL | 24.0 (600) | #14 to 4/0 AWG | 20.0 (500) |
| GelWrap-UF-250UL | 10.0 (250) | 14/2 to 8/3 with ground | N/A |
TE gives the UL 18/4 connector as up to 0.85 in. (22 mm) in diameter, 1.2 in. (30 mm) high and 1.1 in. (28 mm) wide.
| If you need | Look at |
|---|---|
| A complete splice with the connector in the box | GILS-4/0 or GILS-350 |
| A closure over a connector you already installed | GelWrap |
| To repair damaged insulation or a jacket | GelWrap |
| A splice for cable up to 4/0 or up to 350 kcmil | GILS |
| Cable over 350 kcmil, up to 750 | GelWrap-50/20 |
#2 to 4/0 AWG. The GILS-350 fits 1/0 to 350 kcmil.
Yes, TE lists the connector as range taking for either.
TE lists manholes and direct burial as applications.
TE says the gel peels away on re-entry and leaves a clean connection.
1000 V for both.
Contact Powertech Associates at info@powertech-upsc.com or (860) 678-8772. Tell us the cable and connector and we will pick the kit.
Last updated: November 2026.
