Miller KA000000 is an arc hourmeter totalizer designed to work with welding power sources or generators. It helps track welding time accurately, ensuring proper maintenance and monitoring of welding equipment. Its digital display provides clear readings of accumulated arc hours, making it a valuable tool for welding professionals. With its easy installation and compatibility with various welding setups, the Miller KA000000 helps optimize welding operations and maintenance schedules.
September
1990
FORM:
OM-140
107
OWNERS
MANUAL
Use
above
FORM
number
when
orderrng
extra
manuals.
ARC
HOURMETER
TOTALIZER
(Per
NSPR
6626)
SECTION
1
-
SAFETY
PRECAUTIONS
AND
SIGNAL
WORDS
1-1.
GENERAL
INFORMATION
AND
SAFETY
A.
General
Information
presented
in
this
manual
and
on
various
labels,
tags,
and
plates
on
the
unit
pertains
to
equipment
design,
installation,
operation,
maintenance,
and
troubleshooting
which
should
be
read,
understood,
and
followed
for
the
safe
and
effective
use
of
this
equipment.
B.
Safety
The
installation,
operation,
maintenance,
and
troubleshooting
of
arc
welding
equipment
requires
practices
and
proce
dures
which
ensure
personal
safety
and
the
safety
of
others.
Therefore,
this
equipment
is
to
be
installed,
operated,
and
maintained
only
by
qualified
persons
in
accordance
with
this
manual
and
all
applicable
codes
such
as,
but
not
limited
to,
those
listed
at
the
end
of
Section
1
Safety
Rules
For
Operation
Of
Arc
Welding
Power
Source
in
the
welding
power
source
or
generator
Owners
Manual.
1-2.
SAFETY
ALERT
SYMBOL
AND
SIGNAL
WORDS
The
following
safety
alert
symbol
and
signal
words
are
used
throughout
this
manual
to
call
attention
to
and
identify
different
levels
of
hazard
and
special
instructions.
4~
This
safety
alert
symbol
is
used
with
the
signal
words
WARNING
and
CAUTION
to
call
attention
to
the
safety
statements.
a
WARNING
statements
identify
procedures
or
practices
which
must
be
followed
to
avoid
serious
personal
injury
or
loss
of
life.
4A
CAUTION
statements
identify
procedures
or
practices
which
must
be
followed
to
avoid
minor
personal
injury
or
damage
to
this
equipment.
IMPORTANT
statements
identify
special
instructions
necessaty
for
the
most
efficient
operation
of
this
equipment.
SECTION
2-
DESCRIPTION
&
INSTALLATION
2-1.
DESCRIPTION
This
unit
is
an
arc
hourmeter
totalizer
made
for
use
with
welding
power
sources
or
welding
generators.
This
unit
is
installed
in-line
between
the
welding
power
source
(generator)
output
terminal
and
the
electrode
holder,
gun,
or
torch.
This
unit
requires
115
vac,
60
Hz
input
power
for
proper
operation.
If
50
Hz
or
varying
frequency
power
is
supplied,
the
arc
hours
registered
may
not
be
accurate.
2-2.
WELD
CABLE
INSTALLATION
a
WARNING:
ELECTRIC
SHOCK
can
kIll.
Do
not
touch
live
electrical
parts.
Shut
down
welding
powersource
(generator),
and
disconnect
input
power
employing
locko
ut/tagging
pro
cedures
before
inspecting
or
installing.
Lockout/tagging
procedures
consist
of
padlocking
line
disconnect
switch
in
open
position,
removing
fuses
from
fuse
box,
or
shutting
off
and
red-tagging
circuit
breaker
or
other
disconnecting
device.
Stop
engine
and
disconnect
negative
()
battery
cable
from
battery
on
welding
generators.
Two
lengths
of
weld
cable
are
necessary
for
this
installation.
One
weld
cable
is
connected
between
the
welding
power
source
(generator)
positive
weld
output
terminal
and
one
terminal
on
the
arc
hourmetertotalizer.
The
second
cable
is
connected
between
the
arc
hourmeter
totalizer
and
the electrode
holder,
gun,
or
torch.Select
weld
cable
size
and
length
according
to
welding
power
source
(generator)
Owners
Manual.
IMPORTANT:
If
the
two
weld
cable
connections
touch,
arc
hours
will
not
accumulate.
Be
sure
weld
cable
connections
do
not
touch
at
the
arc
hourmeter
totalizer.
2-3.
115
VAC
CONNECTION
Connect
three-prong
polarized
115
vac
plug
to
properly
grounded
receptacle
capable
of
providing
115
vac,
60
Hz
single-phase
power.
SECTION
3-
MAINTENANCE
&
TROUBLESHOOTING
3-1.
OVERLOAD
PROTECTION
a
WARNING:
ELECTRIC
SHOCK
can
kill.
Do
not
touch
live
electrical
parts.
Shut
down
welding
power
source
(generator),
and
disconnect
input
power
employing
lockout/tagging
pro
cedures
before
inspecting
or
installing.
Lockout/tagging
procedures
consist
of
padlocking
line
disconnect
switch
in
open
position,
removing
fuses
from
fuse
box,
or
shutting
off
and
red-tagging
circuit
breaker
or
other
disconnecting
device.
Stop
engine
and
disconnect
negative
()
battery
cable
from
battery
on
welding
generators.
INCORRECT
FUSE
can
damage
unit.
Use
only
replacement
fuse
of
same
size,
type,
and
rating
(see
Parts
List).
Fuse
Fl
is
used
to
protect
the
hourmeter
against
overload.
If
Fuse
Fl
opens,
the
115
vac
input
is
interrupted
and
the
hourmeter
will
not
total
arc
time.
To
replace
Fl,
proceed
as
follows:
1.
Press
and
rotate
fuse
holder
cover
counterclockwise.
2.
Pull
out
fuse
with
cover
when
fuse
holder
cover
is
free.
3.
Insert
new
fuse
into
fuse
holder
cover.
4.
Reinstall
fuse
with
fuse
holder
cover.
5.
Press
and
rotate
fuse
holder
cover
clockwise
until
cover
is
secure.
3-2.
TROUBLESHOOTING
a
WARNING:
ELECTRIC
SHOCK
can
kill.
Do
not
touch
live
electrical
parts.
Shut
down
welding
power
source
(generator),
and
disconnect
input
power
employing
lockout/tagging
pro
cedures
before
inspecting,
servicing
or
maintaining.
Lockout/tagging
procedures
consist
of
padlocking
line
disconnect
switch
in
open
position,
removing
fuses
from
fuse
box,
or
shutting
off
and
red-tagging
circuit
breaker
or
other
disconnecting
device.
Stop
engine
and
disconnect
negative
()
battery
cable
from
battery
on
welding
generators.
It
the
arc
hourmeter
totalizer
is
not
working,
there
are
few
causes.
1.
Check
to
be
sure
the
weld
cable
lug
from
the
welding
power
source
is
not
touching
the
weld
cable
lug
from
the
electrode
holder.
2.
Be
sure
fuse
Fl
is
not
open.
3.
One
of
the
internal
relays
may
not
be
working.
Contact
the
nearest
Factory
Authorized
Service
Station.
4.
The
hourmeter
may
not
be
working.
Contact
the
nearest
Factory
Authorized
Service
Station.
OM-140
107
Page
2
FROW
POWER
SUPPLY
POS.
TO
POS.
ELECTRODE
SECTION
4
ELECTRICAL
DIAGRAMS
PLC
5
Diagram
41.
CIrcuit
Diagram
Circuit
Diagram
No.
SA-140
064
SECTION
5
PARTS
LIST
Dia.
Part
Mkgs.
No.
.
Description
Quantity
Complete
Assembly
CR1
CR2
Fl
034
857
059
266
*012
653
046
432
HM1
1142710006626
PLG1
073690
604 825
010476
039 047
601
976
039 049
601
880
039
044
601
879
0937270006626
019663
1065360006626
010828
RELAY,
reed
RELAY,
end
1
2OVAC
OPOT
FUSE,
mintr
gi
.5A
HOLDER,
fuse
mintr
.250
x
1
.250
METER,
elapsed
time
hours
I
2OVAC
60Hz
PLUG,
str
grd
armd
2P3W
15A
125V
CABLE,
port
No.
18
3/c
(order
by
if)
BUSHING,
strain
relief
.625
ID
x
.57Omtg
hole
TERMINAL,
pwr
output
red
(consisting
of)
SCREW,
cap
stl
hexhd
.500-13
x
1.500
TERMINAL
BOARD,
red
NUT,
stl
hex
jam
.500-13
BUS
BAR,
term
bd
NUT,
sti
hex
full
fnsh
.500-13
CASE
SECTION,
frontJbottom/rear
MOUNT,
nprn
15/16
00
x
3/8rec
CASE
SECTION,
top/sides
HANDLE
*Recommended
Spare
Parts.
BE
SURE
TO
PROVIDE
MODEL
AND
SERIAL
NUMBER
WHEN
ORDERING
REPLACEMENT
PARTS.
<
I
CR
J
CR2
1
1
1
1
1
1
lOft
1
2
1
1
1
1
1
1
4
1
1
OM-140
107
Page
3
1
2
3
4
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