Sizes of DINSE Plugs, Connectors, and Sockets

[MC5W]

I looked up DINSE SKS 120 plug and found on the American website 2 different versions of the same PDF document and on their European website 2 different PDF files one of which explains some things about sizes.

There are 3 different diameter pins for the plugs and male power inlets. The smallest is 9 millimeters diameter, the medium is 13 mm diameter, and the large 120 size is 15 mm. The largest plug is the SKS 120 and the corresponding panel socket socket BES 95/120.

There are 3 different size adapters. The RSS 50/25 is 13mm female 9 mm male. The RSS S50/B25 is 9mm female 13 mm female. These are sold by Everlast as well as a number of other vendors. The RSS 95/120 13 mm female 15 mm male so that cables 2/0 copper or smaller can be plugged into the BES 95/120 female panel mounted socket.

If you really need to use 3/0 or 4/0 copper welding cables ( and I doubt that you would need to do this ) with Everlast welders there are 3 options. One of them is to retrofit the welder with the BES 95/120 socket. Then, use 15 mm male 13 mm female adapter for smaller welding cables. The second is that the SKK 95 plug and the BKS female cord connector will both take 3/0 copper. The third if you believe in using antioxidant compound such as Ilsco Deox(R) that is listed for use on copper is to put 2/0 copper into the plug, 3/0 copper into the large connector, then use a split bolt connector to put the 2 together. Then, tape with Scotch 88 electrical tape which has a broader range temperature than Scotch 33.

The probably cheaper option would be to use a 6 or better yet 4 gauge extension cord and move the welding machine. This would put the voltage drop on the higher voltage lower current side of the machine.

Mike Cole, Ohio Electrical Contractor License No. EL45,008.

[performance]

First, We do not recommend you retrofit anything to our welders. That can and will void the warranty, especially when it is damaged.

The DINSE configuration is the most widely used plug adapters in the world. I'm not sure what all you are talking about. I think you are making it overly complicated and likely will confuse many people. It's not that hard.

I've been around a long time and DINSE are defined in multiple ways, but the most common way they are defined is by the cross section of the cable. With that said, they are two common sizes, 3/8" diameter pin, and a 1/2" diameter pin. (nominal). These are often listed by the pin size too. These pin sizes are generally related to amperage with the 3/8" used on less than 200 amp equipment, and the 1/2" diameter is used on up to 400 amp capacity machines. The back end of the cable connection is the only difference. That is why you'll see it often as DINSE 15/25 or DINSE 35/50 or DINSE 50, or DINSE 50/70. Every manufacturer deals with the numbers a bit differently. All of which we use, but really doesn't matter that much unless you need to change a cable out, which isn't recommended

Miller, and Lincoln also use these. The word "type" is often accompanied by the use of the word DINSE as there are many manufacturers that will typically interchange with one another, but DINSE is the biggest and frankly, it is an open source design that has been around for 30 or 40 years.

The best resource is here, on page 18. And if a person wants "aftermarket" DINSE type, this is the place to go. https://profax-lenco.com/catalog/

[MC5W]

Hi Mark,

First of all, I would NOT retrofit a new DINSE panel socket to anybody's welder until it is at least twice as old as the warranty. Even then, I would rather use the same size panel socket as before and use an external adapter for heavier welding cables. I will probably NEVER get to do a Big Project where I need to run the ouput cables of a welder 150 feet but then I never know what God's angles named Fate and Fortune might do. They might surprise me.

I would prefer the second and third options that I put up anyways. I do not have to do anything inside the welder other than to blow out dust.

You are right that the 2 most common DINSE plugs have either a 9 mm pin or a 13 mm pin. 3/8 and 1/2 inch are only approximations. I doubt that I will ever go into a weld shop or factory that has the DINSE plugs that are 15 mm pin but then I cannot predict the future.