May
1977
FORM:
OM-841
COPY
10
~0L..
MODEL
SRPS-1
SRPS-2
STOCK
NO.
040
171
040
172
MODEL/STOCK
NO.
SERIAL/STYLE
NO.
DATE
PURCHASED
ADDITIONAL
COPY
PRICE
25
CENTS
OWNERS
MANUAL
MILLER
ELECTRIC
MFG.
CO.
APPLETON,
WISCONSIN,
USA
54911
v.rto
Effective
With
Style
No.
706-Al
NWSA
CODE
NO.
4579
~s~
~-~~5P
LIMITED
WARRANTY
EFFECTIVE:
NOVEMBER
1,
1976
This
warranty
supersedes
all
previous
MILLER
warranttes
and
is
ex
clusive
with
no
other
guarantees
or
warranties
expressed
or
implied.
LIMITED
WARRANTYMiller
Electric
Mfg.
Co..
Apple-
3.
All
welding
guns
and
feeder/guns
90
days
ton,
Wisconsin
warrants
to
Customer
that
all
new
and unused
4.
All
other
Millermatic
Feeders
I
year
Equipment
furnished
by
Miller
is
free
from
defect
in
workman-
provided
that
the
user
so
notifies
Miller
in
writing
within
thirty
ship
and
material
as
of
the
time
and
place
of
delivery
by
Miller.
(30)
days
of
the
date
of
such
failure.
No
warranty
is
made
by
Miller
with
respect
to
engines,
trade
accessories
or
other
items
manufactured
by
others.
Such
engines,
trade
accessories
and
other items
are
sold
subject
to
the
warran-
ANY
EXPRESS
WARRANTY
NOT
PROViDED
HEREIN
ties
of
their
respective
manufacturers,
if
any.
At
the
present
time,
AND
ANY
IMPLIED
WARRANTY,
GUARANTY
OR
REP-
the
manufacturers
warranty
on
the
Mag-Diesel
engine
on
DEL-
RESENTATION
AS
TO
PERFORMANCE,
AND
ANY
200
is
limited
to
six
months
and
on
all
other
engines
to
one
year.
REMEDY
FOR
BREACH
OF
CONTRACT
WHICH,
BUT
In
the
case
of
Millers
breach
of
warranty
or
any
other
duty
FOR
THIS
PROVISION,
MIGHT
ARISE
BY
IMPLICA
~?t
with
respect
to
the
quality
of
any
goods,
the
exclusive
remedies
TION,
OPERATION
OF
LAW,
CUSTOM
OF
TRADE
OR
therefor
shall
be,
at
Millers
option,
(1)
repair
or
(2)
replace-
COURSE
OF
DEALING,
INCLUDING
ANY
IMPLIED
ment
or,
where
authorized
in
writing
by
Miller
in
appropriate
WARRANTY
OF
MERCHANTABILITY
OR
OF
FITNESS
cases,
(3)
the
reasonable
cost
of
repair
or
replacement
at
an
FOR
PARTICULAR
PURPOSE,
WITH
RESPECT
TO
ANY
authorized
Miller
service
station
or
(4)
payment
of
or
credit
for
AND
ALL
EQUIPMENT
FURNISHED
BY
MILLER
IS
the
purchase
price
(less
reasonable
depreciation
based
upon
EXCLUDED
AND
DISCLAIMED
BY
MILLER.
actual
use)
upon
return
of the
goods
at
Customers
risk
and
cx
pense.
Upon
receipt
of
notice
of
apparent
defect
or
failure,
EXCEPT
AS
EXPRESSLY
PROVIDED
BY
MILLER
IN
Miller
shall
instruct
the
claimant
on
the
warranty
claim
proce-
WRITING,
MILLER
PRODUCTS
ARE
INTENDED
FOR
dures
to
be
followed.
ULTIMATE
PURCHASE
BY
COMMERCIAL/INDUS
TRIAL
USERS
AND
FOR
OPERATION
BY
PERSONS
As
a
matter
of
general
policy
only,
Miller
may
honor
an
origi-
TRAINED
AND
EXPERIENCED
IN
THE
USE
AND
nal
users
warranty
claims
on
warranted
Equipment
in
the
event
MAINTENANCE
OF
WELDING
EQUIPMENT
AND
NOT
of
failure
resulting
from
a
defect
within
the
following
periods
FOR
CONSUMERS
OR
CONSUMER
USE.
MILLER
from
the
date
of
delivery
of
Equipment
to
the
original
user:
WARRANTIES
DO
NOT
EXTEND
TO,
AND
NO
RE-
I.
Arc
welders,
power
sources,
and
components
...
1
year
SELLER
IS
AUTHORIZED
TO
EXTEND
MILLERS
WAR
2.
Original
main
power
rectifiers
3
years
RANTIES
TO,
ANY
CONSUMER.
,,,
.r
~.
~
,~,
.,-
,,-
,r
~,
~
1-2.
RECEIVING-HANDLING
1-3.
DESCRIPTION
SECTION
1
-
INTRODUCTION
This
Polarity
Switch
is
designed
for
use
with
specific
dc
welding
power
sources.
This
switch
gives
the
capability
of
changing
from
one
polarity
to
another
without
removing
the
leads
from
the
terminals,
The
switch
is
labeled
STRAIGHT
(down)
and
REVERSE
(up)
for
clarity.
1-4.
SAFETY
The
following
definitions
apply
to
CAUTION,
IMPORTANT,
and
NOTE
blocks
found
throughout
this
manual;
I
I
NOTE
Under
this
heading,
explanatory
statements
will
be
found
that
need
special
emphasis
to
obtain
the
most
efficient
operation
of
the
equipment.
I
I
SECTION
2
-
INSTALLATION
2-1.
GENERAL
This
Polarity
Switch
can
either
be
factory
or
field
installed.
If
the
switch
is
factory
installed,
all
connections
to
the
secondary
output
terminals
of
the
welding
power
source
have
been
made,
Therefore,
the
Section
in
the
field
installation
instructions
pertaining
to
secondary
connections
between
the
welding
power
source
and
this
switch
can
be
omitted.
2-2.
LOCATION
This
Polarity
Switch
is
enclosed
in
a
cabinet
and
can
be
mounted
on
the
right
side
of
the
welding
power
source,
or
used
at
a
remote
location,
whichever
is
most
convenient
for
the
operator.
This
switch
has
hangers
(1000
ampere
models)
on
the
top
and
bottom
of
the
case
for
mounting
purposes.
(600
ampere
models
have
four
(4)
9/32
mounting
holes
in
the
left
side
panel
of
the
polarity
switch.)
2-3.
SECONDARY
CABLE
SELECTION
It
is
recommended
that
the
welding
cables
be
kept
as
short
as
possible,
be
placed
close
together,
and
be
of
adequate
current
carrying
capacity.
The
resistance
of
the
welding
cables
and
Connections
cause
a
voltage
drop
which
is
added
to
she
voltage
of
the
arc.
Excessive
cable
resistance
may
result
in
overloading
as
well
as
reducing
the
maximum
current
output
of
the
welding
power
source.
The
proper
operation
of
any
arc
welding
power
source
is
to
a
great
extent
dependent
on
the
use
of
welding
cables
and
connections
that
are
in
good
condition
and
of
adequate
size.
Care
must
be
taken
to
ensure
that
the
electrode
is
properly
insulated
to
protect
the
operator.
Use
Table
2-1
as
a
guide
for
selecting
the
correct
welding
cable
size
for
the
anticipated
maximum
weld
current
that
will
be
used.
Table
2-1
takes
into
account
the
total
cable
length
for
the
weld
circuit.
This
means
the
length
of
the
Electrode
cable
that
connects
the
electrode
to
the
welding
power
source
and
the
Work
or
ground
cable
between
the
welding
power
source
and
the
work.
For
example:
If
the
Electrode
cable
is
75
feet
long
and
the
Work
or
ground
cable
is
25
feet
long,
select
the
size
cable
from
Table
2-1
that
is
recom
mended
for
100
feet
at
the
maximum
amperage
that
will
be
used.
In
the
case
of
a
maximum
anticipated
weld
current
of
1000
amperes.
2-3/0
weld
cable
would
be
recommended
for
both
the
Electrode
and
Work
cables.
NOTE
When
selecting
the
proper
size
cables
to
route
to
and
from
the
polarity
switch,
use
Table
2-1
in
conjunction
with
the
following
examples:
For
1000
ampere
models
where
1000
amperes
is
the
selected
weld
current,
2
-
3/0
cables
would
normally
be
required,
but
since
the
amperage
load
must
be
equally
divided
between
the
four
(4)
sets
of
contacts
in
the
polarity
switch,
4
-
1/0
cables
would
be
appropriate
for
routing
to
and
from
the
switch.
For
600
ampere
models
where
600
amperes
is
the
selected
weld
current,
1
-
4/0
cable
would
normally
be
required,
but
since
the
amperage
load
must
be
equally
divided
between
the
two
(2)
sets
of
contacts
in
the
polarity
switch,
2
-
2/0
cables
would
be
appropriate
for
routing
to
and
from
the
switch.
Figure
1-1.
Specification
1-1.
GENERAL
This
manual
has
been
prepared
especially
for
use
in
familiar
izing
personnel
with
the
design,
installation,
operation,
main
tenance,
and
troubleshooting
of
this
equipment.
All
informa
tion
presented
herein
should
be
given
careful
consideration
to
assure
optimum
performance
of
this
equipment.
CAUTION
A..
this
heading,
installation,
operating,
and
main
tenance
procedures
or
practices
will
be
found
that
if
not
carefully
followed
may
create
a
hazard
to
per.
I
Prior
to
installing
this
equipment,
clean
all
packing
material
from
around
the
unit
and
carefully
inspect
for
any
damage
that
may
have
occurred
during
shipment.
Any
claims
for
loss
or
damage
that
may
have
occurred
in
transit
must
be
filed
by
the
purchaser
with
the
carrier.
A
copy
of
the
bill
of
lading
and
freight
bill
will
be
furnished
by
the
carrier
on
request
if
occasion
to
file
claim
arises.
When
requesting
information
concerning
this
equipment,
it
is
essential
that
Model
Description
and/or
Stock
Number
and
Serial
(Or
Style)
Numbers
of
the
equipment
be
supplied.
sonnel.
I
rTANT
I
Under
this
heading,
installation,
operating,
and
main
tenance
procedures
or
practices
will
be
found
that
if
not
carefully
followed
may
result
in
damage
to
equip
ment.
I
OM~841
Page
1
Table
2-1.
Secondary
Cable
Size
Welding
Amperes,
DC
Total
Length
Of
Cable
(Copper)
In
Weld
Circuit
50
100
150
200 250
300
350
400
100
4
4
2
2
2
1
1/0
1/0
150
2
2
2
1
1/0
2/0
3/0
3/0
200
1
1
1
1/0
2/0
3/0
4/0
4/0
250
1/0
1/0
1/0
2/0
3/0
4/0
2-2/0
2-2/0
300
2/0
2/0
2/0
3/0
4/0
2-2/0
2-3/0 2-3/0
350
3/0
3/0
3/0
4/0
2-2/0
2-3/0
2-3/0 2-4/0
400
3/0
3/0
3/0
4/0
2-2/0
2-3/0
2-4/0
2-4/0
500
410
4/0
4/0
2-2/0
2-3/0
2-4/0
500MCM
1000MCM
600
4/0
4/0
2-2/0
2-3/0
2-4/0
500MCM
1000MCM
1000MCM
700
4/0 4/0
2-3/0
2-4/0
500MCM
1000MCM
1000MCM
1000MCM
800
2-2/0 2-2/0
2-3/0
2-4/0
1000MCM
1000MCM
1000MCM
1000MCM
900
2-3/0
2-3/0
2-4/0
500MCM
1000MCM
1000MCM
1000MCM
1000MCM
1000
2-3/0
2-3/0
2-4/0
1000MCM
1000MCM
1000MCM
1000MCM
1250
2-4/0 2-4/0
500MCM
1000MCM
1000MCM
1000MCM
1500
500MCM 500MCM
1000MCM
1000MCM
1000MCM
1750
1000MCM
1000MCM
1000MCM
1000MCM
2000
1000MCM
1000MCM
1000MCM
NOTE:
A.
50
FEET
OR
LESS.
*B.
CABLE
SIZE
IS
BASED
ON
DIRECT
CURRENT
(DC),
100%
DUTY
CYCLE
AND
EITHER
A
4
VOLTS
OR
LESS
DROP
OR
A
CURRENT
DENSITY
OF
NOT
OVER
300
CIRCULAR
MILS
PER
AMP.
C.
WELD
CABLE
INSULATION
WITH
A
VOLTAGE
RATING
TO
WITHSTAND
THE
OPEN-
CIRCUIT
VOLTAGE
(OCV)
OF
THE
WELDING
POWER
SOURCE
MUST
BE
USED.
WHILE
MOST
WELDING
POWER
SOURCES
HAVE
AN
OPEN-CIRCUIT
VOLTAGE
OF
LESS
THAN
100
VOLTS,
SOME
WELDING
POWER
SOURCES
OF
SPECIAL
DESIGN
MAY
HAVE
HIGH
ER
OPEN-CIRCUIT
VOLTAGE.
2-4.
FIELD
INSTALLATION
INSTRUCTIONS
Before
making
electrical
connections
to
the
polarity
switch,
ensure
that
the
primary
input
power
to
the
welding
power
source
is
disconnected
by
employing
machinery
lockout
procedures.
If
the
welding
power
source
is
connected
to
a
line
disconnect
switch,
padlock
the
switch
in
the
open
position.
If
the
connection
is
made
from
a
fuse
box,
remove
the
fuses
from
the
box
and
padlock
the
cover
in
the
closed
position.
If
the
unit
is
connected
to
a
circuit
breaker,
or
other
disconnecting
device
without
locking
facili
ties,
attach
a
red
tag
to
the
device
to
warn
others
that
the
circuit
is
being
worked
on.
1.
Disconnect
the
welding
cables
from
the
welding
power
source.
2.
Mount
the
polarity
switch
to
the
welding
power
source
(or
remote
fixture,
if
desired,
in
which
case
skip
Steps
a,
b,
and
c)
as
follows:
a.
Open
hinged
doors
on
right
side
of
welding
power
source,
or
remove
right
side
panel
where
applicable.
b.
Examine
inside
of
welding
power
Source
in
relation
to
the
door
(or
panel),
and
select
a
suitable
location
for
mounting
the
polarity
switch.
1~TAN~_
1000
Ampere
Models
~
This
polarity
switch
has
two
(2)
separate
switch
plates.
Each
plate
has
two
(2)
sets
of
contacts
and
terminals.
The
terminals
are
labeled
ELECTRODE
and
WORK.
One
of
these
sets
of
termina!s
is
also
labeled
TO
WELDER.
Since
the
polarity
switch
has
four
(4)
sets
of
contacts,
ensure
that
the
load
is
equally
divided
between
them
(connections
must
be
made
to
both
sides
of
the
two
(2)
switch
plates)
as
illustrated
in
Figure2-1
U
I
RK
(Positive)
TO
WELDER
*600
ampere
models
have
only
one
(1)
mounting
board
(1000
ampere
models
shown)
TD-040
172
Figure
2-1.
Polarity
Switch
Connections
Ensure
that
when
the
doors
of
the
welding
power
source
are
closed
or
panel
replaced
no
contact
is
made
between
the
mounting
bolts
and
internal
electrical
or
mechanical
components.
c.
Close
the
doors,
or
replace
the
side
panel
of
the
welding
power
source.
3.
Remove
the
Outer
enclosure
from
the
polarity
switch.
OM.841
Page
2
IMPORTANT
2-1
).
Connect
the
other
ends
of
these
cables
to
the
polarity
switch
ELECTRODE
terminals
labeled
TO
WELDER.
600
Ampere
Models
This
polarity
switch
has
one
(1)
switch
plate.
This
plate
has
two
(2)
sets
of
contacts
and
terminals.
The
terminals
are
labeled
ELECTRODE
and
WORK.
One
of
these
sets
of
terminals
is
also
labeled
TO
WELDER.
Since
the
polarity
switch
has
two
(2)
Sets
of
contacts,
ensure
that
the
load
is
equally
divided
between
them
(connections
must
be
made
to
both
sides
of
the
switch
plate)
as
illustrated
in
Figure
2-1.
5.
Connect
four
(4)
(1000
ampere
models;
two
(2)
600
ampere
models)
welding
cables
to
the
terminal(s)
labeled
WORK
(POSITIVE)
on
the
welding
power
source.
Connect
the
other
ends
of
these
cables
to
the
polarity
switch
WORK
terminals
labeled
TO
WELDER.
6.
Connect
four
(4)
(1000
ampere
models;
two
(2)
600
ampere
models)
welding
cables
to
the
terminals
labeled
ELECTRODE
on
the
polarity
switch.
Connect
the
other
ends
of
these
cables
in
a
proper
method
to
the
Electrode.
4.
Connect
four
(4)
(1000
ampere
models;
two
(2)
600
ampere
models)
welding
cables
of
adequate
size
(see
Section
2-3)
to
the
terminal(s)
labeled
ELECTRODE
(NEGATIVE)
on
the
welding
power
source
(see
Figure
7.
Connect
four
(4)
(1000
ampere
models;
two
(2)
600
ampere
models)
welding
cables
to
the
terminals
labeled
WORK
on
the
polarity
switch.
Connect
the
other
ends
of
these
cables
in
a
proper
method
to
the
Work.
8.
Replace
the
outer
enclosure
Onto
the
polarity
switch.
SECTION
3
-
SEQUENCE
OF
OPERATION
3-1.
STRAIGHT
POLARITY
Straight
Polarity
means
that
the
electrode
is
negative
()
and
that
the
work
is
positive
(+).
To
select
this
condition,
place
the
polarity
switch
handle
completely
down
to
the
STRAIGHT
position.
ETAN~1
3-2.
REVERSE
POLARITY
Reverse
Polarity
means
that the
electrode
is
positive
(+(
and
that
the
work
is
negative
((.
To
select
this
condition,
place
the
polarity
switch
handle
completely
up
to
the
REVERSE
position.
Do
not
change
the
position
of
the
Polarity
switch
while
welding
or
under
load,
as
this
causes
arcing
across
the
contacts
of
the
switch.
This
arcing
causes
the
contacts
to
become
pitted
and
eventually
moper
ative.
SECTION
4
-
MAINTENANCE
4-1.
WELDING
CABLES
The
welding
cables
should
be
inspected
frequently,
and
all
breaks
in
the
insulation
repaired
with
electrical
insulating
tape
or
the
cables
replaced.
Frayed
and
broken
wires
should
be
replaced.
4-2.
WELDING
CABLE
CONNECTIONS
The
welding
cables
should
be
inspected
periodically.
The
connections
should
be
kept
clean
and
tight.
Loose
connec
tions
will
cause
overheating
of
the
cables
and
arcing
at
the
terminals.
I
I
I
I
Page
3
May
1977
FORM:
OM-841
Effective
With
Style
No.
706-Al
MODEL
STOCK
NO.
External
Polarity
Switches
MODEL/STOCK
NO.
SERIAL/STYLE
t~JO.
DATE
PURCHASED
PARTS
LIST
MILLER
ELECTRIC
MFG.
CO.
APPLETON,
WISCONSIN,
USA
54911
SRPS-1
SRPS-2
040
171
040
172
NWSA
CODE
NO.
4579
Item
Factory
No.
Part
No.
Figure
A
Main
Assembly
Description
Quantity
Models
SRPSl
j
SBPS-2
1
014
937
2
021
859
2
021
893
3
021919
4
010
800
4
021
880
5
017
055
5
014
934
6
021
921
7
021
892
8
038
768
9
010
801
10
017
058
10
014
935
11
12
013
602
13
010
803
13
010
804
14
021
860
15
602 267
16
019
616
3
1
1
2
2
6
1
6
1
2
3
1
1
1
1
1
1
1
2
2
1
1
BE
SURE
TO
PROVIDE
STOCK,
MODEL
AND
STYLE
NUMBERS
WHEN
ORDERING
REPLACEMENT
PARTS.
1
WRAPPER
SPACER,
steel
5/8
x
13/8
SPACER,
steel
5/8
x
13/8
threaded
STUD,
steel
5/1618
x
2-~3/4
SPACER,
steel
5/8
x
2
threaded
SPACER,
steel
5/8
x
2
PANEL,
side
PANEL,
side-left
STUD,
steel
5/1618
x
15/8
SPACER,
steel
5/8
x
2-3/4
SWITCH
ASSEMBLY,
polarity
(See
Figure
B
Page
2)
SPACER,
steel
5/8
x
4
ENCLOSURE
PANEL,
side-right
NAMEPLATE
(order
by
model
and
style
number)
LABEL,
polarity
switch
BAR,
connecting
switch
BAR,
connecting
-
switch
STUD,
steel
3/8-24
x
3-1/8
LATCH,
barrel
bolt
2
KNOB
1
1
1
Figure
A
Main
Assembly
TD-040
172
OM-841
Page
1
Item
No.
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
010
805
024
694
021
920
038
770
010
799
601
840
010
797
010
798
038
654
604
318
011
080
038
769
103 632
011
645
011
074
011
953
011
075
011
948
011
644
010
133
010
796
104
981
BE
SURE
TO
PROVIDE
STOCK,
MODEL
AND
STYLE
NUMBERS
WHEN
ORDERING
REPLACEMENT
PARTS.
2
2
2
1
2
16
4
2
4
1
4
2
1
2
1
2
1
2
8
24
4
4
Factory
Part
No.
Description
Quantity
Figure
B
038
768
Switch
Assembly
(See
Fig.
A
Page
1
Item
8)
~
HANDLE
BEARING
GUIDE,
molded
BOARD,
mounting
-
components
CABLE,
braided
si/sleeving
10
lg
NUT,
hex
-
brass
1/2-13
BAR,
bus
1
x
4~i
CABLE,
braided
w/sleeving
12
lg
STUD,
brass
1/213
x
25/8
NUT,
lock
elastic
1/4-20
SPACER,
copper
PLATE
ASSEMBLY,
movable
(consisting
of)
BOARD,
mounting
-
components
CONTACT
ASSEMBLY
(consisting
of)
,SPRING
CONTACT,
copper
-
movable
SPRING
GUIDE,
molded
CONTACT,
copper
-
stationary
SPACER,
copper
1/8
thick
BAR,
bus
copper
1
x
13
SPACER
Figure
B
Switch
Assembly
Tc-o38
768
OM-841
Page
2
-
1
-
2
-
3
-
4
-
5
-
6
-
7
-
8
-
9
-
10
Miller HH000000 Owner's manual
- Category
- Welding System
- Type
- Owner's manual
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