In this interview, AZoCleanTech speaks with Stäubli Electrical Connectors about its BosCon large-format connectors, a revolutionary product for the renewable energy sector in North America.
What is the BosCon connector, and why is it significant?
The BosCon connector is a domestically manufactured connector that is anticipated to set a new standard for reliability and safety in large scale utility grade electric vehicle (EV) and photovoltaic applications.
The large-format (∅ 16 mm) BosCon connector is designed for the North American renewable energy market and is the first of its kind to be completely cULus listed to UL6703 and CSA C22.2 No. 182.5 standards. These standards certify connectors for use in photovoltaic systems.
The BosCon connectors can handle up to 620 A and are rated for up to 1500 V AC/DC, making them perfect for electrical balance of systems (eBOS), trunk cables in battery energy storage systems (BESS), utility-scale systems, and EV charging infrastructure.1
The BosCon connector addresses the need for safety-certified connectors capable of supporting large-scale infrastructure critical for expanding renewable energy systems in North America.1
What are the key features of the BosCon connectors?
The BosCon connectors have a number of key features, some of which I will outline below:
- High Current Capacity: The connectors are rated up to 620 A (depending on the conductor size) and support copper conductors from 3/0 AWG to 500 MCM.2
- Voltage Rating: Can handle up to 1500 V AC/DC, making the connectors suitable for both EV charging and photovoltaic systems.2
- cULus Certification: First in class to receive a full cULus listing to UL6703 and CSA C22.2 No. 182.5, the connectors comply with North American safety standards.1
- Made in the US: Ensures quality control and reduces lead times, meaning improved service to North American customers.1
- Durability: Rated IP65/IP68 when mated, the connectors offer excellent protection against water and dust ingress, making them well-suited for use in harsh and outdoor environments.3
- Color and Mechanical Coding: The unique coding system incorporates seven distinct mechanically keyed and color-coded rings on both socket and plug, ensuring poles and phases cannot be cross-mated during installation.2
Image Credit: Stäubli Electrical Connectors
What challenges do the BosCon connectors solve?
The rapid expansion of renewable energy in North America, especially in large-scale PV installations, has increased the demand for connectors able to handle large-diameter, low conductor strand count cables.
Addressing this need, BosCon connectors provide a certified-safe solution for high-current applications in challenging environments. They are specifically designed for terminating these types of cables in both field and factory environments.
This innovation improves both the safety and reliability of renewable energy systems, while also simplifying the installation and maintenance processes for manufacturers and installers.1
How do the BosCon connectors simplify installation and maintenance?
BosCon connectors are made with user-friendliness in mind. The connectors can be crimped in the factory or field, providing flexibility for pre-assembled leads and on-site installations.2 The color and mechanical coding system guarantees that connectors are mated correctly, decreasing the risk of errors when installing.1
BosCon connectors also require minimal maintenance as their IP65/IP68 rating provides protection against water and dust ingress, reducing the probability of costly, time-consuming repairs, especially in remote locations.2
What are the potential applications for the BosCon connectors?
BosCon connectors are designed primarily for utility-scale PV systems. However, they are suitable for a range of other applications:1
- Battery Energy Storage Systems (BESS): High current and voltage ratings lend the connectors to energy storage systems, critical for stabilizing renewable energy grids.
- Electric Vehicle Charging Infrastructure: Can handle the high currents needed for fast-charging systems and support the modularized design of equipment, allowing for quicker field installation and safer and easier maintenance, repair, and replacement of system devices.
- Future Applications: Expansion of the product line is expected to include solutions for combiner boxes, panel receptacles, and central inverters, widening the range of applications by introducing additional couplers designed for aluminum wire and different cable sizes.
Why is it important that the BosCon connectors are made in the USA?
"Made in the USA" carries a reputation for job creation, high quality, and adherence to strict manufacturing standards. Products with this label must be entirely (or virtually entirely) made in the USA according to the Federal Trade Commission (FTC). This ensures that all significant parts and processing are conducted domestically.
“Made in the USA” not only emphasizes the quality of American craftsmanship, but also the ability to keep local control over production, minimizing lead times, and increasing overall product reliability.
In supplying industries where reliability and safety are non-negotiable, Stäubli ensures strict quality control over processes while expediting production and supporting job creation in the USA.
What can we expect next from Stäubli?
Stäubli’s commitment to driving renewable energy innovation is clear. In the next few months, the company is releasing additional products complementing the BosCon line, including new solutions for central inverters, combiner boxes, aluminum conductors, and other large-format cable applications. These releases will further solidify Stäubli’s position as a renewable energy market leader.1
References and Further Reading
- Stäubli Electrical Connectors (2024). Stäubli Introduces the First UL6703 cULus Listed Large-Format Connectors for North American Renewable Energy Markets. (online). Available at: https://www.prnewswire.com/news-releases/staubli-introduces-the-first-ul6703-culus-listed-large-format-connectors-for-north-american-renewable-energy-markets-302232016.html (Accessed 23 Jan. 2025).
- BosCon connector. Available at: https://www.staubli.com/content/dam/ecs/catalogs-brochures/RE/SOL-BosCon-Connector-11014088-en.pdf.
- IEC (2024). IP ratings | IEC. (online). Available at: https://www.iec.ch/ip-ratings.
This information has been sourced, reviewed and adapted from materials provided by Staubli Electrical Connectors.
For more information on this source, please visit Staubli Electrical Connectors.
Disclaimer: The views expressed here are those of the interviewee and do not necessarily represent the views of AZoM.com Limited (T/A) AZoNetwork, the owner and operator of this website. This disclaimer forms part of the Terms and Conditions of use of this website.