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Stäubli Expands Its BosCon Portfolio with Innovative Solutions

Stäubli, the global leader in industrial and mechatronic solutions, has announced a significant expansion to its BosCon connector portfolio by introducing permanent protective caps and panel receptacles. These new additions are designed to provide enhanced protection and performance for high-power electrical connections, particularly in large-scale applications within the renewable energy sector.

The BosCon series is tailored for demanding environments, particularly in utility-scale photovoltaic (PV) systems, as well as other emerging markets like battery energy storage systems (BESS) and electric vehicle (EV) charging infrastructure. The new products are engineered to enhance flexibility, durability, and safety in trunk cable systems, ensuring they can withstand the rigors of outdoor conditions.

Features of the New BosCon Products

BosCon Panel Receptacles

The recently introduced panel receptacles offer a robust interface for connecting trunk cables to various power equipment, including combiner boxes, load break disconnects, and central inverters. They are rated for AC/DC voltage up to 1500 V and can handle currents of up to 620 A, depending on the size and material of the connected conductor. The engineering of these receptacles supports larger diameter trunk cables, streamlining the power distribution process.

Additionally, there are various termination options available:

• - Fork contact plugs: Suitable for attachment to busbars within electrical enclosures, rated up to 620 A without the need for fasteners.
• - Threaded connectors: Both internal and external thread contacts allow copper or aluminum cables to link via a cable lug, also rated up to 620 A.

These panel receptacles utilize MULTILAM™ contact technology, which ensures minimal contact resistance and consistent contact force, providing stable and efficient performance crucial for high-power applications. They are built to endure harsh environments with up to IP68 sealing, come with mechanical and color coding, and feature tool-assisted locking mechanisms to guarantee secure connections outdoors.

Permanent Protective Caps

Complementing the panel receptacles, the new BosCon permanent protective caps address the need for reliable protection for unused connectors and panel receptacles. They are crafted for long-term durability and safeguard connection points against environmental exposure while ensuring system readiness and safety.

One of the innovative designs of these caps includes an integrated tag loop, serving as a Lock Out / Tag Out (LOTO) device for safe maintenance. Furthermore, they enhance modularity within systems, allowing for more straightforward expansions or reconfigurations of installations over time. These caps are tested for permanent use in live systems, ensuring they can cover unused panel receptacles or be utilized as end-of-line terminations for future expansions on trunk lines.

Meeting Market Demands

"Together, the BosCon Connectors, Panel Receptacles, and Permanent Protective Caps provide a comprehensive solution for both active and inactive connection points," stated Brian Mills, Head of Renewable Energy at Stäubli North America. He emphasized that the BosCon line was developed in response to the growing requirement for large-format, high-power connections in the North American PV market. With these additions, Stäubli aims to deliver not only reliable performance but also long-lasting protection, all while simplifying the installation process and enabling future system growth.

The expanded BosCon portfolio, alongside Stäubli's original MC4 connectors and various cable harness solutions, strengthens the company's position as a pivotal partner in utility-scale PV and large-conductor electrical balance of systems (eBOS). All BosCon products are cULus certified, designed to reduce both installation time and costs while supporting scalable and modular system architectures.

About Stäubli

Founded in 1892, Stäubli is a pioneering global provider of industrial and mechatronic solutions, with a dedicated focus on electrical connectors, fluid connectors, robotics, and textiles. Operating across 28 countries and with a workforce of over 6,000, Stäubli is committed to delivering innovative solutions that enhance productivity across various industries. With a stronghold in renewable energy, the company remains a leader in the photovoltaics market, introducing solutions that significantly contribute to sustainable energy systems worldwide.

As the renewable energy landscape continues to evolve, Stäubli stays at the forefront of innovation, anticipating market needs and serving its clients with high-quality solutions for a sustainable future.