9500 System Controller Manual

OPERATION MANUAL
for
9500 System Controller
IMPORTANT
Read this manual carefully before installing,

commissioning or operating this product.
July 1997
Jetline Engineering, 15 Goodyear Street, Irvine, CA 92618

Telephone: (949) 951-1515 ! Fax: (949) 951-9237
ii
LIMITED WARRANTY
Jetline Engineering, of Irvine, California, U.S.A., warrants all new equipment to be free from
defects in material and workmanship for the period of one (1) year, provided that the equipment is
installed and operated according to instructions.
Jetline Engineering's obligation under this warranty is expressly limited to replacing or repairing
any defective part or correcting any manufacturing defect without charge during the warranty period,
if Jetline's inspection confirms the existence of such defects. Jetline's option of repair or replacement
will be F.O.B. factory at Irvine, California, and therefore no compensation for transportation costs of
any kind will be allowed.
The warranty period begins on the date of sale to the original-purchase user of the equipment.
Jetline Engineering will not be liable for any loss or consequential damage or expense accruing
directly or indirectly from the use of equipment covered by this warranty.
This warranty supersedes all previous Jetline warranties and is exclusive with no other guarantees
or warranties expressed or implied.
iii
NOTICE
The installation, operation and maintenance guidelines set out in this manual will enable you to
maintain the equipment in peak condition and achieve maximum efficiency with your welding
operation. Please read these instructions carefully to become aware of every advantage.
CAUTION
Only experienced personnel familiar with the operation

and safe practice of welding equipment should install
and/or use this equipment.
iv
Table of Contents
Section I . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
A. Arc Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
B. Electric Shock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
C. Arc Rays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
D. Fumes and Gases . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
E. Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
F. Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
G. Moving Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
H. EMF Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
I. Principal Safety Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Section II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Section III . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
A. Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
B. Current Sensor Module CSM-I-500 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
C. Gas Solenoid Module GSM-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
D. Motor Control Module MCM-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
E. Limit Switch Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
F. Tach Generator Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
G. Display Screen Abbreviatons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Section IV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
System Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
A. Microprocessor Board (P/N 9500-10) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
v
B. Channel Board (P/N 9500-11) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

C. Auxiliary I/O Board (P/N 9500-12) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
D. Mother Board (P/N 9500-13) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
E. Power Supply (P/N LVS-43E-5) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Section V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Section VI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Operating the System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
A. Sequence of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
B. Weld Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
C. Run Weld Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
D. Selecting a Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
E. Weld Programming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
F. Create/Modify a Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
G. Copy a Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
H. Manual Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Section VII . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
System Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Section VIII . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Process Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
A. Channel Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
B. Auto Touch Retract . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
C. ARC ON WAIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
D. Auto Return Home Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
E. Weld Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
F. Shield Gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
G. Pulse Capability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
vi
H. A.C. Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Section IX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Special Programs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Section X . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Figures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
vii
viii
Section I
Safety Precautions
OSHA 29 CFR 1910.147 (see Safety
Standards).
WARNING 4. Properly install and ground this

equipment according to the operation
manual and national, state and local
codes.
A. Arc Welding 5. Always verify the supply ground-check
and be sure that input power cord ground
Arc Welding can be hazardous. Protect yourself wire is properly connected to ground
and others from possible serious injury or death. terminal in disconnect box or that cord
Keep children away. Pacemaker wearers keep plug is connected to a properly grounded
away until consulting your doctor. receptacle outlet.
In welding, as in most jobs, exposure to certain 6. When making input connections, attach
hazards occurs. Welding is safe when proper grounding conductor first -
precautions are taken. The safety information double-check connections.
given below is only a summary of the more 7. Frequently inspect input power cord for
complete safety information that will be found damage or bare wiring. Replace cord
in the Safety Standards listed at the end of this immediately if damaged - bare wiring can
section. Read and follow all Safety Standards. kill.
Have all installation, operation, maintenance 8. Turn off all equipment when not in use.
and repair work performed only by qualified
people. 9. If earth grounding of the workpiece is
required, ground it directly with a
B. Electric Shock separate cable - do not use work clamp or
work cable.
Touching live electrical parts can cause fatal
10. Do not touch electrode if you are in
shocks or severe burns. The electrode and work
contact with the work, ground, or another
circuit is electrically live whenever the output is
electrode from a different machine.
on. The input power circuit and machine
internal circuits are also live when power is on. 11. Use only well-maintained equipment.
When using mechanized wire feed, the wire, Repair or replace damaged parts at once.
wire reel, drive roll housing and all metal parts Maintain unit according to manual.
touching the welding wire are electrically live.
Incorrectly installed or improperly grounded 12. Wear a safety harness if working above
equipment is a hazard. floor level.
1. Do not touch live electrical parts.

2. Wear dry, hole-free insulating gloves and
appropriate body protection.
3. Disconnect input power before installing
or servicing this equipment.
Lockout/tagout input power according to
1
13. Keep all panels and covers securely in 3. If ventilation is poor, use an approved air-
place. supplied respirator.
14. Clamp work cable with good metal-to- 4. Read the Material Safety Data Sheets
metal contact to workpiece or worktable ( M S D S ) an d t h e m a n u f a c t u r e r ' s
as near the weld as practical. instruction for metals, consumables,
coatings, cleaners, and degreasers.
C. Arc Rays 5. Work in a confined space only if it is well
ventilated, or while wearing an air-
Arc rays can burn eyes and skin; noise can supplied respirator. Always have a trained
damage hearing; flying slag or sparks can injure watch person nearby.
eyes.
6. Do not weld in locations near degreasing,
Arc rays from the welding process produce cleaning, or spraying operations. The heat
intense visible and invisible (ultraviolet and and rays of the arc can react with vapors
infrared) rays that can burn eyes and skin. Noise to form highly toxic and irritating gases.
from some processes can damage hearing.
Chipping, grinding and weld cooling throw off 7. Do not weld on coated metals, such as
pieces of metal or slag. galvanized, lead or cadmium plated steel,
unless the coating is removed from the
1. Use approved ear plugs or ear muffs if weld area, the area is well ventilated, and
noise level is high. if necessary, while wearing an air-
2. Use a welding helmet fitted with a proper supplied respirator. The coatings and any
shade of filter to protect your face and metals containing these elements can give
eyes when welding or watching. off toxic fumes if welded.
3. Wear approved safety glasses with side E. Cylinders

shields.
4. Use protective screens or barriers to Cylinders can explode if damaged.
protect others from flash and glare; warn Shielding gas cylinders contain gas under high
others not to watch the arc. pressure. If damaged, a cylinder can explode.
5. Wear protective clothing made from Since gas cylinders are normally part of the
durable, flame-resistant material (wool welding process, be sure to treat them carefully.
and leather) and foot protection where 1. Protect compressed gas cylinders from
necessary. excessive heat, mechanical shocks, slag,
open flames, sparks, and arcs.
D. Fumes and Gases
2. Install cylinders in an upright position by
Fumes and gases can be hazardous to your securing to a stationary support or
health. cylinder rack to prevent falling or tipping.
Welding produces fumes and gases. Breathing 3. Keep cylinders away from any welding or
these fumes and gases can be hazardous to your other electrical circuits.
health. 4. Never weld on a pressurized cylinder -
1. Keep your head out of the fumes. Do not explosion will result.
breathe the fumes. 5. Use only correct shielding gas cylinders,
2. If inside, ventilate the area and/or use regulators, hoses and fittings designed for
exhaust at the arc to remove welding the specific application; maintain them
fumes and gases. and associated parts in good condition.
2
6. Turn face away from valve outlet when 8. Wear oil-free protective garments such as
opening cylinder valve. leather gloves, heavy shirt, cuffless
trousers, high shoes, and a cap.
7. Keep protective cap in place over valve
except when cylinder is in use or
connected for use.
G. Moving Parts
8. Read and follow instructions on Moving parts, such as fans, rotors, and belts can
compressed gas cylinders, associated cut fingers and hands and catch loose clothing.
equipment, and CGA publication P-1
listed in Safety Standards. 1. Keep all doors, panels, covers, and guards
closed and securely in place.
F. Welding 2. Have only qualified people remove
guards or covers for maintenance and
Welding can cause fire or explosion. troubleshooting as necessary.
Welding on closed containers, such as tanks,
drums, or pipes, can cause them to blow up.
H. EMF Information
Sparks can fly off from the welding arc. The
flying sparks, hot workpiece, and hot equipment Considerations About Welding and the Effects of
can cause fires and burns. Accidental contact of Low Frequency Electric and Magnetic Fields
electrode to metal objects can cause sparks, The following is a quotation from the General
explosion, overheating, or fire. Check and be Conclusions Section of the U.S. Congress,
sure the area is safe before doing any welding. Office of Technology Assessment, Biological
1. Protect yourself and others from flying Effects of Power Frequency Electric &
sparks and hot metal. Magnetic Fields - Background Paper, OTA-BP-
E-53 (Washington, DC: U.S. Government
2. Do not weld where flying sparks can Printing Office, May 1989):
strike flammable material.
".... there is now a very large volume of
3. Remove all flammables within 35 ft (10.7 scientific findings based on experiments at the
m) of the welding arc. If this is not cellular level and from studies with animals and
possible, tightly cover them with people which clearly establish that low
approved covers. frequency magnetic fields can interact with, and
produce changes in, biological systems. While
4. Be alert that welding sparks and hot most of this work is of very high quality, the
materials from welding can easily go results are complex. Current scientific
through small cracks and openings to understanding does not yet allow us to interpret
adjacent areas. the evidence in a single coherent framework.
5. Watch for fire, and keep a fire Even more frustrating, it does not yet allow us
extinguisher nearby. to draw definite conclusions abut questions of
possible risk or to offer clear science-based
6. Do not weld on closed containers such as advice on strategies to minimize or avoid
tanks, drums, or pipes, unless they are potential risks."
properly prepared according to AWSF4.1
(see safety Standards). To reduce magnetic fields in the work place, use
the following procedures:
7. Connect work cable to the work as close
to the welding area as practical to prevent 1. Keep cables close together by twisting or
welding current traveling long, possibly taping them.
unknown paths and causing electric shock 2. Arrange cables to one side and away from
and fire hazards. the operator.
3
3. Do not coil or drape cables around the Recommended Safe Practices for the
body. Preparation for Welding and Cutting of
Containers That Have Held Hazardous
4. Keep welding power source and cables as Substances , American Welding Society
far away as practical. Standard AWS F4.1, from American Welding
5. Connect work clamp to workpiece as Society, 550 N.W. LeJeune Rd, Miami, FL
close to the weld as possible. 33126
About Pacemakers: Safe Handling of Compressed Gases in

Cylinders , CGA Pamphlet P-1, from
The above procedures are among those also Compressed Gas Association, 1235 Jefferson
normally recommended for pacemaker wearers. Davis Highway, Suite 501, Arlington, VA
Consult your doctor for complete information. 22202
Code for Safety in Welding and Cutting , CSA
I. Principal Safety Standards Standard W117.2, from Canadian Standards
Association, Standards Sales, 178 Rexdale
Reference as applicable
Boulevard, Rexdale, Ontario, Canada M9W
Safety in Welding and Cutting, ANSI Standard 1R3
Z49.1, from American Welding Society, 550
Sales Practices for Occupation and Educational
N.W. LeJeune Rd, Miami, FL 33126
Eye and Face Protection, ANSI Standard Z87.1,
Safety and Health Standards, OSHA 29 CFR from American National Standards Institute,
1910, from Superintendent of Documents, U.S. 1430 Broadway, New York, NY 10018
Government Printing Office, Washington, D.C.
Cutting and Welding Processes, NFPA Standard
20402
51B, from National Fire Protection Association,
National Electric Code, NFPA Standard 70 Batterymarch Park, Quincy, MA 02269
from National Fire Protection Association,
Batterymarch Park, Quincy, MA 02269
4
Section II
Introduction
Congratulations on your purchase of the Jetline The control is compact, requiring little space
Series 9500 System Controller. Its quality on a system control panel. All connections to
workmanship will bring many years of equipment are made through high quality
dependable service. Its modern technology will amphenol type connectors which eases the
help provide you with top quality, repeatable integration of the equipment.
welds.
Calibrating the equipment with the 9500
In today's modern industry, integrated welding controller is at your finger tips through the
systems rarely consist of just a welding power use of the integrated front panel keypad.
supply. Consequently, control of the welding Once set-up is completed, the keypad
sequence is only partially addressed using a becomes your means of setting each
sequence control of the type normally available parameter and adjusting those parameters
with welding power supplies. Even though these once the weld is initiated.
controllers are of micro-processor design, they
can only control the output of the welding power The set parameters are maintained at the
supply and are often limited to a specific weld desired levels because the 9500 system con-
process. An integrated welding system, in troller uses closed-loop feedback to monitor
addition to control of the welding current level, and, if necessary, adjusts the parameters.
requires control of other parameters such as wire An important advantage of the 9500 control-
feed and travel speed. In some weld processes, ler, compared with more conventional units,
control of arc length through arc voltage is also is the incorporation of an easy-to-use menu
required. system to create weld programs and to oper-
The Series 9500 System Controller is a micro- ate the system.
processor based unit designed and built to You are able to key in real numbers, repre-
provide low cost, accurate, repeatable control senting actual values desired, and to review
over the complete weld process. The Series 9500 them, since they are redisplayed. Thus pa-
System Controller is designed to provide rameter levels can be predetermined and
complete closed-loop control of four (4) welding preselected before welding starts.
parameters during the welding process. The
9500 System Controller is also designed to Once the welding starts, the display provides
provide initial sequencing and final sequencing a readout of all four actual weld parameters.
to facilitate the torch positioning and part You can also adjust each parameter during
handling. The unit will control almost any arc the weld.
welding process and, although primarily
designed to integrate with other Jetline
equipment, can be used to control and sequence
other manufacturer's equipment.
5
Section III
Specifications
Inputs (per channel):
A. Control Analog: 0 to 100 VDC (selectable
range)
Digital: 3 (N.O. contact to input
Weight: 22 lbs. (10 kg) common)
Dimensions: Slope (channel 1): 6 segments
Height: 12 in. (305 mm) Pulse Rate Sensing:
Width: 10 in. (255 mm) Automatically detects Pulse when back-
Depth: 6 in. (155 mm) ground signal from power supply is
greater than 50 msec in duration.
Power Requirements:
120/240 Vac, 50/60 Hz., 240 VA Auxiliary Outputs:
6' (1.8 m) power cord Digital: 6 selectable, N.O. or N.C.
contacts
Contact Rating:
NOTE .6 A, 125 Vac
.6 A, 110 VDC
When power is turned off to the control, wait 3 2 A, 30 VDC
seconds before turning power back on. Power can
be turned off in any screen. It is NOT Auxiliary Inputs:
recommended doing so in the middle of a weld. Digital: 3 N.O. contact to input com-
mon
Processor: Intel 80C196KC, 16 MHZ. Digital: 3 selectable, N.O. contact to
Keypad: 20 key, membrane style input common or external 5 to
Display: 4 x 20 Vacuum Fluorescent 12 VDC signal two external
Memory: 25 programs, battery backed-up circuit common.
Programmable Parameters:
Number of parameters: Four (Channels 1-4),
closed-loop
Outputs (per channel):

Analog: 0 to 10 VDC, Isolated
Digital: 3 (2 N.O. contacts, 1 selectable)
6
B. Current Sensor Module D. Motor Control Module

CSM-I-500 MCM-1
Module Weight: ? ( kg) Module Weight: ? ( kg)
Dimensions: Dimensions:
Height: 6" (150 mm) Height: 6" (150 mm)
Width: 5" (127 mm) Width: 6" (150 mm)
Depth: 4" (100 mm) Depth: 8" (205 mm)
Power Requirements: Power Requirements:

120/240 Vac, 60/50 Hz., 5 W 120 Vac, 60/50 Hz.
¾ hp. - 8 amps
Current Range: 5 - 500 amps ½ hp. - 6 amps
¼ hp. - 4 amps
Sensor: Hall Effect type c hp. - 3 amps (and for hp. < c)
Output Analog: 0 - 5 VDC Output:

0 - 90 VDC up to ¾ Hp (600 W) motor
Cables: capability Shunt Motor capability (special
Power - 6' (1.8 m) order)
Control - 25' (7.2 m)
Input:
Analog 0 - 10 VDC, must be isolated signal.
C. Gas Solenoid Module Digital Forward (N.O. contact, close to go).
Reverse (N.O. contact, close to go)
GSM-1
Cables:
Module Weight: ? ( kg) Power - 6' (1.8 m)
Control - 6' (1.8 m)
Dimensions: Motor - 10' (3 m)
Height: 6" (150 mm)
Width: 5" (125 mm)
Depth: 4" (100 mm)
Power Requirements:
120 Vac, 60/50 Hz., 7 W
Input Digital:
On/Off (N.O. contact, close for gas)
Fittings: e" - 18 argon, conical seat.
Cables:
Power - 6' (1.8 m)
Control - 25' (7.2 m)
7
E. Limit Switch Kit G. Display Screen

Linear (Track & Carriage based systems) Abbreviatons
Switches: 3, BZG1-2RN2 type (home, Abbreviation Term
downslope, & end of travel) ACESS Access
ALC Arc Length Control
Cams: 2, SWC-237B
(home & end of travel) AUX Auxiliary
1 _____ (downslope) CHAN Channel
CIRC Circumferential
Cables: 3, 48" (1,220 mm) lengths CONFIG Configuration
20 gauge ( ), 2 conductor, DLY Delay
shielded DIR Direction
EFC Enhanced Function
Circumferential Systems Control
ENC Encoder
Switches: 2, BZE6-2RN2 type (home &
overlap/downslope) FOR Forward
GTAW Gas Tungsten Arc
Cams: 2 _______ Welding
1 _______ Shaft Extension ( ¾ - ID Identification
10 female threaded end) INIT Initial
LANG Language
Cables: 2 - 25' (7.6 m) strips MULTI Multiple
20 gauge ( ) 2 conductor, shielded PAW Purge Arc Welding
(recommend ordering to length)
PDIA Part Diameter Entry
PROG/PGM Program
F. Tach Generator Kit PULS Pulse
Closed loop - Feedback RET Retract
REV Reverse
Tach: B3 generator
Output: 7 VDC per 1000 RPM SEC Second
Rating: Maximum 3000 RPM SEQ Sequence
Mtg Kit: 1 B3 Mounting Bracket SW Switch
1 Adjustable Clamp SYN Synergic
1 Belt TRAV Travel
1 B3 Pulley
1 Motor Pulley (requires ½" (12.7
mm) armature shaft extension, d"
(9.5 mm) diameter)
Cables: 10' (3 m) 20 gauge ( ) 2 conduc-

tor, shielded
8
Section IV
System Overview
The 9500 System Controller is a micro-processor When the system is connected to hardware which
based unit designed to provide accurate and allows closed-loop feedback to be used, each of
repeatable control over the complete welding the four parameters is closely monitored (50
process. times per second) and automatically adjusted (4
times per second) to maintain the set value which
The unit is designed to store 25 separate welding has been programmed.
programs and a unique programmable calibration
schedule in its 8 year battery backed memory. The closed-loop feedback guarantees an accuracy
Each program contains a program number to help of 1% of the set value under normal operating
you choose the correct program for the right part. procedures (dependant upon the connected hard-
ware).
The programs can hold information for four
channels. This information includes the desired Once the 9500 is programmed and calibrated for
output level and timing sequencing for each a particular system, the battery-backed memory
channel. For the GTAW and PAW processes, insures the configuration data will be there the
the channels are usually welding current control, next time you turn on the unit.
arc voltage control, travel speed and direction,
and wire feed speed. The control comes equipped with Start, Stop and
Emergency Stop buttons for operator control.
Each program can also have some control of the The unit has a 20 entry keypad and an 80
torch movement and placement before and after character fluorescent display.
the weld. In the same fashion, the control can
acquire a home position after each weld. Inside, the unit has a micro-processor board, four
channel boards, an auxiliary Input/Output board,
The 9500 also has the capability of manual a mother board, and a 5 VDC power supply. The
control. Manual control can be used to help set- function of these items are described below.
up welding parameters or to jog a certain motion,
such as the wire, the travel device or the torch. If
gas control circuitry is used, you can also purge A. Microprocessor Board (P/N
the gas system in the manual mode of operation. 9500-10)
Each program allows complete control over four
welding parameters of the process as well as The Micro-processor board is mounted on the
some on/off control over other parameters such rear of the enclosure door. The board is the brain
as shielding gas. of the control. It handles all of the sequencing
and timing functions involved in programs. It
controls the level of analog output, monitors the
analog feedback level, and compensates accord-
ingly.
9
B. Channel Board D. Mother Board (P/N 9500-13)

(P/N 9500-11)
The 9500-13 Mother board provides power to,
and houses the four channel boards and the
The 9500 control is equipped with four Channel
auxiliary I/O board. The board also provides
boards. These boards are plugged into the
easy terminal connections to bring the signals to
mother board.
and from the amphenol type filter assemblies
These boards generate the isolated analog output located on the enclosure.
control voltage, condition and isolate the
The mother board is also equipped with a pulse
incoming feedback signal, isolate the digital
detection circuit. This circuit monitors the
input signals, and house the output relays. They
welding current feedback signal. If it detects a
condition the signals, both analog and digital,
significant and consistent drop in current
between the processor and the actual channel
(background level), longer than 50 msec. in
being controlled.
duration, then it generates a pulse lockout signal.
This signal prevents the 9500 control from
C. Auxiliary I/O Board reacting to the background as the normal weld
(P/N 9500-12) current level. This signal can also be distributed
to the wire feeder and arc length control so
appropriate action can be taken by that
The Auxiliary I/O board is plugged into the equipment during the background current period.
mother board and next to the channel boards.
This board is necessary to handle the complete
weld sequence associated with GTAW, GMAW E. Power Supply
and PAW processes. (P/N LVS-43E-5)
This board helps control torch position, gas flow,
pulse control if pulsing, clamp or finger release, The 9500 System Controller is designed to
and remote stop/start signals. operate on a single + 5 VDC power supply. This
power supply is capable of delivering all the
The board has the capability of handling and power necessary to operate all six boards and the
providing 6 digital inputs to the processor. It can display, yet operate at an efficient temperature.
also provide 6 digital outputs, relay type, to the
outside of the control. The power supply also has the capability of
sensing the input voltage and automatically
adjusting for it. Thus if the input power is 110-
130 Vac or 220-240 Vac, the only adjustment to
the control is to change the fuses.
10
Section V
Functions
The 9500 System Controller has the following Emergency Stop:
operator controls: They include the Start button,
Stop button, Emergency Stop button, Power The emergency stop button is used to stop any
On/Off switch, and the twenty digit keypad. activity instantly. When pressed, all action is
See Figure 22 in the Figures section of this stopped and can not be restarted until after the
manual for a complete view of the front panel of button has been disengaged.
the 9500 control. The controls are as follows: To protect the weld area and torch, post flow of
Power On/Off: gas is enabled.
This white rocker switch turns the input power 20 Digit Keypad:
on or off to the 9500 control. The power goes The keypad provides the main method of
only to the + 5 VDC power supply. The switch controlling the 9500 control. The number keys
is electrically located before the fuses. There are exclusively for numerical input. Other keys
are two fuses on the right side of the enclosure. may have multi-purposes according to the
Normally only one fuse is required, but since particular program activity.
the control can be operated on 240 Vac, both
legs of the input line are protected. To enable you to use the 9500 control as easily
as possible, certain key operations always have
Power can be turned off in most screens. If you the same action irrespective of the particular
are in the midst of modifying a program, the old screen display in use at the time. Standard key
values will be retained. You should not turn operations are:
power off in the middle of a weld, external
equipment may be damaged or continue its PREV From any point in any screen display,
operation uncontrolled. pressing PREV will take you to the
previous screen (except when you are in
Start Button: the middle of a data entry and have not
The green start push button is used to initiate the yet entered the value).
weld sequence. It is also used in the manual NEXT Once you have chosen a programming
mode to start a maintained "jog" motion or to option, pressing the NEXT key at any
start a gas purge. point in a screen display will take you
Stop Button: immediately to the next screen display.
The red stop push button is used to sequentially REV During the entry of a value, the REV
stop the weld sequence. When pressed, it will key, when pressed, will erase the
begin the downslope portion of the weld. It is entered value to allow a revised value to
also used in the manual mode to stop a be entered.
maintained jog motion, to stop the gas purge, on
to stop the weld.
11
8 This key will move the cursor or select

arrow (6) up to the previous line of the
screen display. When the top line of a
display is the one at which the cursor is
positioned, the 8 key will take you to
the start of the previous screen (just like
the PREV key).
9 This key will move the cursor or the
select arrow (6) down to the next line of
the screen display. When the cursor is
at the end of the last line of a screen
display, this key will take you to the
next screen (in the same way as the
NEXT key).
ENTER This key is used during programming to
enter the data into memory. When you
have inputted the appropriate number,
pressing the ENTER key will record the
number and move you to position for
the next data entry. At the last line of a
display, after the last data has been
inputted and entered a second press of
the ENTER key will move you to the
next screen display.
12
Section VI
Operating the System
The 9500 system controller has been designed The sequence of operation is as follows:
for ease of use. The following instructions will
lead you through the various steps (screen Switch on power to the unit. The first screen to
displays) needed to produce a weld or program be displayed is:
a weld sequence, but if you would like to try it 1. Screen 1
for yourself, go ahead. You cannot cause any WELCOME SCREEN
damage to the system by trying out the various
screens and moving backwards and forwards
through them. Jetline Engineering
9500 Controller
So, feel free to experiment, you'll be amazed Model GTAW - 2.0
how easy it is to operate the 9500. Many
screens have a bottom line of wording that is
...Press ENTER to cont...
"scrolling", in other words it is moving from
right to left. If you read this text, you will find The screen shows the software version in use.
that it gives you the necessary instruction of
what to do or what your choices are. Press Enter to proceed to the next screen ...Go
to Screen 2
2. Screen 2
A. Sequence of Operation MAIN OPTIONS
The following sequence descriptions take you 1) WELD SEQUENCE

all the way through the various stages in run-
2) MANUAL CONTROL
ning, selecting or programming a weld. Any
values used are for explanation only, they are 3) SYSTEM CONFIG
not meant to be used as actual weld program ...Press 1, 2, 3, or ...
numbers.
A number of abbreviations are used to save The main options screen allows you to choose
space in the various screen displays, most of and run a weld program, operate the 9500
these are self-explanatory. If there are any system under manual control, or set up the
which are confusing to you, a complete list of system using the configuration routine.
abbreviations can be found in the section titled Press 1 to enter the Weld Sequence section. ..Go
"Specifications". to Screen 3
Press 2 to enter the Manual Control section.
....Go to Screen 45
Press 3 to enter the System Configuration
section....
13
From this screen, you can run a weld program,

B. Weld Sequence select and view another program, create a new
program, or return to screen 2.
The following screens are displayed when you Press 1 to run a selected weld program.
need to carry out a weld which has previously ...Go to Screen 4
been programmed and recorded. You are led
through the screens on a step by step basis so Press 2 to select and view a program.
you will find it easy to follow the procedure. ...Go to Screen 16
If you have not selected the correct weld Press 3 to modify/copy a weld program.
sequence (as shown on screen 4), refer to the ...Go to Screen 28
section titled "Selecting a Sequence" (screen 16)
Press PREV to return to the previous screen.
and follow the instructions to allow you to
...Go to Screen 2
change the selected sequence.
Once you have selected the correct weld se-
quence, you can go through the following steps, C. Run Weld Sequence
to start your weld. When the weld has started,
it will continue automatically from one stage to 1. Screen 4
another according to the times which have been RUN WELD PROGRAM
pre-programmed. The final weld sequence will
be initiated either based upon the elapsed weld
time (if weld time has been enabled) or by an PGM PART NUMBER
external signal such as may be provided by an 01 0123456789
end of travel limit switch. You can initiate this
sequence yourself at any time during the weld ...Press START to weld ...
by pressing the sequence stop button. This will
immediately initiate downslope.
This screen informs you which weld program
During the weld sequence, you may need to (for the particular part) is loaded and ready to
make some adjustment to one or other of the run.
weld parameters, e.g. increase current. You can
Press START to initiate the weld .
do this by first selecting the parameter to be
...Go to Screen 5
changed and then increasing or decreasing it.
Please note that the maximum adjustment you Press PREV to return to the previous screen.
can make is to go 10% higher or 10% lower ...Go to Screen 3
than the set (programmed) value.
2. Screen 5
1. Screen 3 RUN WELD PROGRAM
WELD SEQUENCE
WAITING FOR
1) RUN WELD SEQUENCE
2) SELECT/VIEW SEQ TOUCH RETRACT
3) MODIFY/COPY SEQ
...Press 1, 2, 3, or ...
14
The system waits for external equipment to set System waits until an arc on signal is received
the initial arc gap before continuing. This is a from external equipment.
programmable feature and has to be enabled in ...Go to Screen 8.
the program.
5. Screen 8
System waits for "sequence ready" signal from INITIAL WELD
external equipment (usually an arc length
control) before continuing.
6 CURR 75.0 I TIME
Press STOP if no signal is received. ARC L 9.0 2
...Go to Screen 4. TRAV DELAY
WIRE DELAY
Or
Engage EMERGENCY STOP This screen indicates initial settings and values
...Go to Screen 4. for the four controlled parameters.
(Remember to reset the emergency stop button by The "I" on the first line indicates current is at
pulling it out). the initial level.
3. Screen 6 The "L" on the second line indicates the arc
PROGRAMMED GAS PREFLOW voltage control is in lockout, remaining in
manual/locked-out mode until the programmed
5.0 ALC START DELAY times out.
GAS The TRAV and WIRE channels show the word
PREFLOW "DELAY", denoting that the parameter is in its
start delay period.
The number under WELD TIME indicates the
The screen informs you how much gas preflow total "arc on" time that has elapsed in seconds.
time remains before the arc will start.
When initial current time elapses, the system
When the preflow time reaches 00.0, the system proceeds to the next section of the weld pro-
will continue to the next display. ...Go to gram.
Screen 7. ...Go to Screen 9
4. Screen 7 6. Screen 9
ARC ON UPSLOPE WELD
6 CURR 6 CURR 99.0 U TIME

ARC 9.0 5
WAITING FOR ARC ON TRAV DELAY
WIRE 21.0
The system operates the weld contactor and This screen indicates the upslope settings and
waits until an "arc on" signal is established. values for the four controlled parameters.
The feature to wait for an "arc on" signal is
programmable. The "U" indicates that current is in upslope
phase.
The TRAV channel shows the word "DELAY",
denoting that the parameter is in its start delay
period.
15
When upslope current time has elapsed, the Note: If weld time is disabled, weld taper is not
system proceeds to the next section of the weld available.
program.
When weld taper time elapses, the system
...Go to Screen 10
proceeds to the next section of the weld pro-
7. Screen 10 gram.
MAIN WELD ...Go to Screen 12
9. Screen 12
6 CURR 125.0 W TIME DOWNSLOPE WELD
ARC 9.0 15
TRAV 15.0 6 CURR 85.0 D TIME
WIRE 21.0 ARC L 9.0 62
TRAV STOP
This screen indicates the main weld settings and WIRE 21.0
values for the four controlled parameters.
To select the channel you want to change, move This screen indicates the downslope settings and
the "6" by pressing the " 8" or "9" keys. When values for the four controlled parameters.
the channel is selected, you can increase its
output by pressing "+" or decrease it using the The "D" indicates that current is in downslope
"-" key. If the key is pressed intermittently, stage.
each press will change the value by 1%. If The "L" indicates the arc voltage control is in
maintained pressure is applied, the channel will lockout, remaining in manual/locked-out mode
increase or decrease up to the preset limits as until the weld is finished.
dictated in the SYSTEM CONFIGURATION
section. The TRAV channel shows the word "STOP",
denoting that the parameter has stopped
When main weld time elapses, the system following the programmed stop delay.
proceeds to the next section of the weld pro-
gram. When downslope time elapses, the system
...Go to Screen 11 proceeds to the next section of the weld pro-
gram.
If weld time is not enabled, the sequence STOP ...Go to Screen 13
push button or an external stop signal takes you
to the next section of the weld program. 10. Screen 13
...Go to Screen 12 FINAL WELD
8. Screen 11
6 CURR 85.0 F TIME
TAPER WELD
ARC L 9.0
83
6 CURR 120.0 T TIME
TRAV STOP
ARC 9.0 35
TRAV 15.0
WIRE 21.0 This screen indicates the final settings and
values for the four controlled parameters.
This screen indicates the weld taper settings and The "F" indicates that the current is in the final
values for the four controlled parameters. stage.
The "T" indicates that the current is in the taper The "L" indicates the arc voltage control is in
stage. lockout, remaining in manual/locked-out mode
until the weld is finished.
16
The TRAV and WIRE channels show the word

"STOP", denoting the parameters have stopped D. Selecting a Sequence
following their programmed stop delays.
When the final weld time has elapsed, the If you are changing the system to make a weld
system proceeds to the next section of the weld on a different part, you will need to call up a
program. new weld program. The 9500 system controller
...Go to Screen 14 stores 25 weld sequences in its memory, you
can select any of these by following these steps.
11. Screen 14 You can also browse through any of the
PROGRAMMED GAS POSTFLOW sequences without making changes.
1. Screen 16
15.0
SELECT/VIEW PROGRAM
GAS
POSTFLOW
1) SELECT NEW SEQ
2) VIEW CURR SEQ
The screen informs the operator how much time ...Press 1, 2, or PREV...
remains for gas postflow.
When the postflow time reaches 00.0, the From this screen, you can select a different weld
system will continue according to the following program and/or view a weld program
options:
Press 1 to select a new weld program.
If home sequence is enabled in the program. ...Go to Screen 17
...Go to Screen 15
Press 2 to view a weld program.
If home sequence is disabled in the program. ...Go to Screen 18
...Go to Screen 4
12. Screen 15 ...Go to Screen 3
RETURN HOME
2. Screen 17
CHOOSE PROGRAM
PGM PART NUMBER

RETURN HOME... 6 1 0123456789
2 9876543210
3 UNUSED
The screen informs you that the travel
equipment is returning to a home position. This screen allows you to select and load a new
weld program.
This screen will be displayed until a home
signal is received. The " 6" indicates the currently selected pro-
...Go to screen 4 gram. Press " 8" or "9" to move the " 6" pointer
up or down to the program desired.
Press FWD or REV to move the pointer up or
down a group (full screen) at a time.
Press ENTER to choose the program when the
"6" pointer is at the program desired.
...Go to Screen 16
17
VIEW PROGRAM VIEW GAS TIMES
PGM PART NUMBER PREFLOW 5.0 SEC

1 0123456789 POSTFLOW 15.0 SEC
This screen allows you to view all the This screen allows you to view the times set for
parameters of the selected weld program. gas preflow and postflow.
Press NEXT to advance to the next screen. ...Go Press NEXT to advance to next screen.
to Screen 19 ...Go to Screen 22
Press PREV to return to the previous screen. Press PREV to return to the previous screen.
...Go to Screen 17 ...Go to Screen 20
VIEW CHANNEL STATUS VIEW INITIAL WELD
CHANNEL STATUS INIT CURR 30.0 A

O TRAV ENABLE INIT TIME 2.0 SEC
G WIRE DISABLE UPSLOPE 10.0 SEC
WELD CURR 95.0 A
This screen allows you to view the status of the This screen allows you to view the initial weld
travel & wire channels. and main weld current settings and times.
Press NEXT to advance to next screen.
...Go to Screen 20
...Go to Screen 18 Press NEXT to advance to next screen.
...Go to Screen 23
5. Screen 20
VIEW FEATURE STATUS Press PREV to return to the previous screen.
...Go to Screen 21
O TOUCH RET ENABLE 8. Screen 23
O ARC WAIT ENABLE VIEW WELD TIME
O HOME SEQ ENABLE
G WELD TIME ENABLE WELD TIME 105.0 SEC
TAPER CURR 70.0 A
This screen allows you view the status of the TAPE TIME 20.0 SEC
optional features.
Press NEXT to advance to next screen.
...Go to Screen 21 This screen allows you to view the weld and
taper current settings and times.
...Go to Screen 19 Press NEXT to advance to next screen.
...Go to Screen 24
18
VIEW FINAL WELD VIEW WIRE
FINAL CURR 45.0 A WIRE 20.0 IPM

DOWNSLOPE 11.0 SEC START DELAY 5.0 SEC
FINAL TIME 3.0SEC STOP DELAY 5.0 SEC
WIRE RETRACT 1.0 SEC
This screen allows you to view the final weld This screen allows you to view the wire setting
current setting and times. and start/stop delay times.
Press NEXT to advance to next screen. Press NEXT to advance to next screen.
10. Screen 25
VIEW ARC VOLTAGE E. Weld Programming
ARC VOLT 8.0 V The 9500 system controller has two ways of
START DELAY 10.0 SEC making new programs. When you receive a
STOP DELAY 8.0 SEC new unit, it will have been fully tested by Jetline
at its facility. A test program will have already
been written, this will be program #1. You will
want to go through this program and change all
This screen allows you to view the arc voltage the values to suit your application. This is the
setting and delay times. first way of programming weld schedules.
Press NEXT to advance to next screen. Once you have a satisfactory weld schedule,
...Go to Screen 26 you will probably find that the second, third and
Press PREV to return to the previous screen. subsequent programs are just variations of the
...Go to Screen 24 first, perhaps a little more current or wire and a
different travel speed. For this reason, we have
11. Screen 26 provided a "copy" routine. You can create a
VIEW TRAVEL new weld schedule by copying one you already
use and then just changing those values you
TRAVEL 15.0 IPM need to change. In this way you can create new
weld schedules quickly and accurately.
START DELAY 7.0 SEC
STOP DELAY 5.0 SEC Modifying weld schedules can affect your part
quality and your QA procedures and should not
therefore be done casually. To avoid this
happening, we have set up a password entry
This screen allows you to view the travel setting routine which you must follow to allow access
and start/stop delay times. to weld program modification. Like the cash
Press NEXT to advance to next screen. machine at your bank you only have access if
...Go to Screen 27 you enter the correct "password".
19
PROGRAM ACCESS MODIFY/COPY PROGRAM
MODIFY/COPY SEQ
REQUIRES ACCESS CODE 1) MODIFY SEQUENCE
2) COPY SEQUENCE
...Enter code then ENTER...
To modify or copy a program, you must type in You can choose to create a new program,
the correct access code. modify an existing program or copy one
program to another.
Type in the valid access code, maximum 7
digits, and press ENTER
Press 1 to create or modify a weld program.
If the code is correct, ...Go to Screen 32
...Go to Screen 29
Press 2 to copy an existing weld program into
If the code is incorrect, another program.
2. Screen 29 Press PREV to return to previous screen. ...Go
PROGRAM ACCESS OK to Screen 3
F. Create/Modify a Program
ACCESS CODE VERIFIED
If you want to write a new weld schedule from
...Press ENTER to cont... scratch or if you want to make changes to an
existing weld schedule, the routine is the same
Correct access code was entered. and is as follows:
Press ENTER to proceed to next screen. 1. Screen 32

...Go to Screen 31 MODIFY PROGRAM
Press PREV to return to previous screen.
..Go to Screen 3
PGM PART NUMBER
6 1 0123456789
3. Screen 30 2 9876543210
PROGRAM ACCESS DENIED 3 UNUSED
This screen allows you to choose the weld pro-

INVALID ACCESS CODE gram to be modified.
...Press ENTER to cont... Press "9" or " 8" to move the "6" up or down to
the program desired (this can be an existing or
a new program).
Incorrect access code was entered.
Press FWD or REV to move the pointer up or
Press ENTER to continue, you cannot modify or down a whole screen at a time.
copy a program.
...Go to Screen 3 Press ENTER to choose program when the " 6"
pointer is at the weld program desired.
20
...Go to Screen 33 4. Screen 35

MODIFY FEATURE STATUS
...Go to Screen 31
O TOUCH RET ENABLE
2. Screen 33 O ARC WAIT ENABLE
MODIFY PART NUMBER O HOME SEQ ENABLE
G WELD TIME DISABLE
PGM PART NUMBER

This screen allows you to modify the status of
1 0123456789 the optional features.
Press "8" or " 9" to move the "6" pointer up or
down to the feature desired.
This screen allows you to modify the part
number associated with the weld program. Press • to enable or disable the feature.
Press REV to move the flashing cursor to the Press NEXT to advance to the next screen.
left. ...Go to Screen 36
Type in the part number desired, any number of Press PREV to return to the previous screen.
digits up to a maximum of ten digits. ...Go to Screen 34
Press ENTER to enter the new part number into 5. Screen 36
the program. MODIFY GAS TIMES
...Go to Screen 34
...Go to Screen 32 PREFLOW 3.0 SEC
POSTFLOW 10.0 SEC
3. Screen 34
MODIFY PART NUMBER
CHANNEL STATUS This screen allows you to modify the times set
for gas preflow and postflow.
O TRAV ENABLE Type in the time desired for preflow and press
G WIRE DISABLE ENTER to enter the value into the program.
Type in the time desired for postflow and press
This screen allows you to modify the status of ENTER to enter the value into the program.
the travel & wire.
Press NEXT or ENTER to advance to next
Press " 9" or "8" to move the "6" pointer up or screen.
down to the channel desired. ...Go to Screen 37
Press M to enable or disable the channel. When 6. Screen 37
the channel is enabled, that parameter will be MODIFY INITIAL WELD
active during welding. If you do not want to
use a channel (e.g. wire), disable it now. INIT CURR 20.0 A
Press NEXT to advance to next screen. INIT TIME 2.0 SEC
...Go to Screen 35 UPSLOPE 10.0 SEC
WELD CURR110.0 A
...Go to Screen 33
21
This screen allows you to modify the initial Press PREV to return to the previous screen.
weld and main weld current settings and times. ...Go to Screen 38
Type in the value desired for each parameter 9. Screen 40
and press ENTER to enter the value into the MODIFY ARC VOLTAGE
program.
Press NEXT to advance to the next screen. ...Go ARC VOLT 8.5 V
to Screen 38 START DELAY 10.0 SEC
STOP DELAY 8.0 SEC
...Go to Screen 36
7. Screen 38 This screen allows you to modify the arc
MODIFY WELD TIME voltage setting and delay times.
WELD TIME 200.0 SEC Type in the value desired for each parameter
and press ENTER to enter the value into the
TAPER CURR 85.0 A
program.
TAPE TIME 10.0 SEC
Press NEXT to advance to the next screen. ...Go
to Screen 41
This screen allows you to modify the weld and Press PREV to return to the previous screen.
taper current settings and times. ...Go to Screen 39
This screen will appear only if WELD TIME is 10. Screen 41
ENABLED in screen 35. MODIFY TRAVEL
Type in the value desired for each parameter
and press ENTER to enter the value into the TRAVEL 10.0 IPM
program. START DELAY 5.0 SEC
STOP DELAY 4.0 SEC
to Screen 39
Press PREV to return to the previous screen. This screen allows you to modify the travel set-
...Go to Screen 37 ting and delay times.
8. Screen 39 Type in the value desired for each parameter
MODIFY FINAL WELD and press ENTER to enter the value into the
program.
FINAL CURR 40.0 A
DOWNSLOPE 12.0 SEC
to Screen 42
FINAL TIME 3.0SEC
...Go to Screen 40
This screen allows you to modify the final weld 11. Screen 42
current setting and times. MODIFY WIRE
and press ENTER to enter the value into the WIRE 18.0 IPM
program. START DELAY 6.0 SEC
STOP DELAY 7.0 SEC
Press NEXT to advance to the next screen. ...Go WIRE RETRACT 1.5 SEC
to Screen 40
22
This screen allows you to modify the wire 2. Screen 44

setting and start/stop delay times. VERIFY COPY
and press ENTER to enter the value into the COPY 1) 0123456789
program. INTO 3) UNUSED
Press NEXT to advance to the next screen. ...Go ...Press + to copy, or ...
to Screen 32
Press PREV to return to the previous screen. This screen allows you to verify if programs se-
...Go to Screen 41 lected are correct before copying.
Press + to verify and complete the copying.
G. Copy a Program ...Go to Screen 31
Press ENTER to by-pass the copy.
If you already have in the system a weld ...Go to Screen 31
schedule for a weld which is similar to the one
you now want to set up, you can use the copy
routine to save you having to go through all the H. Manual Control
tedious routine of creating a program from
scratch.
If you choose option 2 from the main selection
The procedure is as follows: screen (Screen 2) you will now be in manual
control. This feature of the 9500 System
1. Screen 43 Controller provides you with the ability to set
COPY PROGRAM up welding parameters for applications where
you are not sure what the actual levels should
be. It allows you to start a weld and then
COPY PROGRAM 1 individually adjust each channel until you are
INTO PROGRAM 3 satisfied with the weld quality. You would then
be able to take a note of the weld settings and
use them to create or modify a weld program.
This screen allows you to copy one program The manual control routine is also useful for
into another program. moving or jogging any of the connected equip-
ment which is capable of movement, e.g. travel
Type in the program number you wish to copy or wire. Using this feature you can return a
from and press ENTER. travel carriage to a start point or feed wire.
Type in the number of the new program you The manual system control proceeds according
want to create and press ENTER. Press ENTER to the following sequence:
or NEXT to confirm copy.
...Go to Screen 44 1. Screen 45
MANUAL CONTROL OPTIONS
Press PREV to exit copy routine.
...Go to Screen 31 1) MANUAL SETUP
2) MANUAL WELD
3) JOG CHANNEL
...Press 1,2,3 or ...
23
From this screen, you can select to set up and Press NEXT to advance to next screen.
perform a manual weld, or jog a device which is ...Go to Screen 45
available.
4. Screen 48
Press 1 to setup a manual weld. MANUAL WELD
...Go to Screen 46.
Press 2 to perform the manual weld. G CURR 50.0 STOP
...Go to Screen 48. G VOLT 9.0
G TRAV > 10.0
Press 3 to jog a device, such as wire and travel. G WIRE 20.0
...Go to Screen 52.
Press PREV to return to previous screen. This screen allows you to perform a manual
...Go to Screen 2. weld. Any or all of the channels can be "en-
abled" so they are active during welding.
2. Screen 46
MANUAL WELD SETUP Press ENTER to enable the parameter. The
telltale block will become solid to indicate an active
PREFLOW 00.0 SEC channel.
POSTFLOW 00.0 SEC Press "8" or "9" to move the "6" pointer up or
WIRE RETRACT 0.0 SEC down to the channel desired.
Press • to disable the parameter.
This screen allows you to program the gas set- Note that you can enable or disable the parameter
tings and wire retract time. during welding in the manual mode.
Type in the value desired for each and press Press + or - to increase or decrease the pa-
ENTER to enter the value into the program. rameter setting until the level you require is
reached.
Press PREV to return to previous screen. ...Go
to Screen 45. Press START push button to start the weld.
...Go to Screen 49
Press NEXT to advance to next screen. ...Go to
Screen 47.
3. Screen 47 Press PREV to return to the previous screen.
MANUAL WELD VALUES ...Go to Screen 47.
5. Screen 49
CURR 0000.0 A MANUAL PREFLOW
ARC 00.0 V
TRAV 000.0 IPM G CURR 0000.0 GAS
WIRE 000.0 IPM G ARC 00.0 PREF
G TRAV 000.0
This screen allows you to set the values for the G WIRE 000.0 5
four channel parameters.
Type in the value desired and press ENTER for This screen informs you how much time is left
each parameter to be set. on the gas preflow.
Press the PREV to return to previous screen. The arc is initiated when the gas preflow time
...Go to Screen 46 has elapsed.
...Go to Screen 50
24
6. Screen 50 This screen allows you to select which device is

MANUAL WELD to be jogged.
Press 1 to jog the travel channel.
G CURR 0000.0 WELD ...Go to Screen 53.
G ARC 00.0 TIME
G TRAV 000.0 Press 2 to jog the wire channel.
G WIRE 000.0 15 ...Go to Screen 55.
Press 3 to jog the torch position.
This screen allows you to monitor and adjust the ...Go to Screen 57.
parameters for manual welding.
Press 4 for gas purge.
Press "9" or "8" to move the " 6" pointer up or ...Go to Screen 59.
down to the parameter desired.
Press + or - to increase or decrease the param- ...Go to Screen 45.
eter setting.
9. Screen 53
Press ENTER to enable the parameter where the JOG TRAVEL
pointer is located.
Press • to disable the parameter. TRAVEL
Speed Factor (1-9) 5
Note: No arc on signal is used in manual control. Maintained Dir FWD
Thus each parameter which is enabled will imme- ...Press FWD or REV to...
diately become active when the preflow times out.
Press the STOP push button to stop the weld. You can jog the travel equipment from this
...Go to Screen 51. screen. This screen has many options.
7. Screen 51 Press any number key from 1-9 to set the jog
MANUAL POSTFLOW speed. (Represents 10% to 90% of full speed,
defaults to 5.)
G CURR 0000.0 GAS
Press the FWD or REV keys to momentarily jog
G ARC 00.0 POST the travel device. Motion will continue as long
G TRAV 000.0 as the key is depressed. "FWD" will jog the
G WIRE 000.0 15 channel forward and "REV" will jog the channel
in reverse.
This screen informs you how much time is Press + to set the "maintained" jog direction as
remaining on the gas postflow. forward.
System continues to the next screen when the Press - to set the "maintained" jog direction as
gas postflow time has elapsed. reverse.
...Go to Screen 48.
Press the START push button to start a main-
8. Screen 52 tained jog in the selected direction. ...Go to
JOG OPTIONS Screen 54.
1) TRAVEL 3) TORCH
2) WIRE 4) GAS ...Go to Screen 52.
Press 1, 2, 3, 4 or ...
25

JOG TRAVEL ACTIVE JOG WIRE ACTIVE
TRAVEL WIRE
Speed Factor (1-9) 3 Speed Factor (1-9) 7
Maintained Dir REV Maintained Dir FWD
...Press STOP to end... ...Press STOP to...
The travel equipment is in a maintained jog The wire feeder is in a maintained job mode
mode when in this screen. when in this screen.
Press the STOP push button to stop the main- Press the STOP push button to stop the main-
tained jog motion. tained jog motion.
...Go to Screen 53. ...Go to Screen 55.
JOG WIRE JOG TORCH
WIRE
Speed Factor (1-9) 5 TORCH
Maintained Dir FWD
...Press FWD or REV to... ...Press FOR to lower...
You can jog the wire feeder equipment from this

screen. This screen has many options.
You can jog the torch up or down from this
Press any number key from 1-9 to set the jog screen.
speed. (Represents 10% to 90% of full speed,
defaults to 5.) Press FOR to lower (move forward) the torch.
Press the FWD or REV keys to momentarily jog Press REV to raise (move backwards) the torch.
the wire feed device. Wire will continue to feed ...Go to Screen 58.
as long as the key is depressed. "FWD" will jog Press PREV to return to the previous screen.
the wire forward and "REV" will retract the ...Go to Screen 52.
wire.
14. Screen 58
Press + to set the "maintained" jog direction as JOGGING TORCH
forward. (Used for feeding a new spool of wire).
Press - to set the "maintained" jog direction as
reverse. TORCH
Press the START push button to start a main-
tained jog in the selected direction. ...Go to ...Release REV to end...
Screen 56.
Press PREV to return to the previous screen. You are jogging the torch up (out) or down (in)
...Go to Screen 52. from this screen.
Release REV to stop raising the torch. ...Go to
Screen 57.
26
15. Screen 59
GAS PURGE
GAS
...Press START to pur...
This screen allows you to purge the gas.

Press the START push button to start the purge.
...Go to Screen 60.
...Go to Screen 52.
16. Screen 60
PURGING GAS
GAS
...Press STOP to end...
This screen informs you that the gas is purging.

Press the STOP to stop the gas purge. ...Go to
Screen 59.
27
Section VII
System Configuration
When the 9500 control is first installed, the unit This screen informs the operator that access to
should be calibrated and configured to fit the the configuration is permitted. The operator may
overall system as close as possible. This is also change the access code.
accomplished through the use of the System
Configuration option. Pressing 3 places you into Press + to change the access code.
the configuration section of software. ...Go to Screen 64
1. Screen 61 Press ENTER to by-pass the change and enter the

SYSTEM ACCESS system configuration section.
...Go to Screen 68.
* System Configuration Press PREV to return to the previous screen.

* Requires Access Code ...Go to Screen 2.
*
3. Screen 63
*...Enter Code then ENTER, or...
SYSTEM ACCESS DENIED
*
The operator must enter an access code, up to 7 * INVALID ACCESS CODE
digits, to gain access into the system configura- *
tion. * ...Press ENTER...
Type in valid access code, maximum 7 digits,
and press ENTER.
NOTE: When the unit first arrives, the access code An invalid access code was entered.
is 0.
Press ENTER to continue, the operator has no
If the code is correct, other option.
...Go to Screen 62. ...Go to Screen 2.
If the code is incorrect, 4. Screen 64
...Go to Screen 63 MODIFY ACCESS CODE
2. Screen 62
SYSTEM ACCESS OK * CHANGE SYSTEM
* ACCESS CODE
*
* * ...Enter code then ENTER....
* ACCESS CODE VERIFIED
*
*...Press + to change, or ENTER
The operator may change the access code
through this screen.
28
Enter up to a seven digit number as a new access ...Go to Screen 68.

code. Press ENTER when complete.
7. Screen 67
...Go to Screen 65.
NEW CODE DENIED
The numbers will not show on the screen, only
*'s will. Press REV to backup a number when
entering the code. * CONFIRMATION
* FAILED
Press NEXT to skip changing the access code *
...Go to Screen 68. * ... Press ENTER...
...Go to Screen 2.
This screen informs the operator the new access
5. Screen 65 code has not been accepted. The old code is still
VERIFY NEW CODE valid.
Press ENTER to continue.
* RE-ENTER NEW CODE ...Go to Screen 64.
* TO CONFIRM
8. Screen 68
*
* ...Enter code then ENTER, or... CONFIGURATION OPTIONS
* 1) SENSITIVITY
Before the system accepts the new code, the * 2) CLOSED LOOP DELAY
operator must enter the code again. * 3) CALIBRATION
* ...Press 1, 2, 3, or PREV...
To verify the code is what the operator believes
it to be, re-enter the new code and press ENTER.
If the code is the same, From this screen, the operator can choose to set
...Go to Screen 66. the closed loop sensitivity for each channel, set
the delay time for closing the feedback loop, or
If the code is not the same,
setup the 9500 control calibration.
...Go to Screen 67.
Press 1 to set the sensitivity of each channel.
Press NEXT to skip changing the access code
...Go to Screen 69.
...Go to Screen 68.
Press 2 to set the close loop delay time.
...Go to Screen 70.
...Go to Screen 2.
Press 3 to setup the calibration of the control.
6. Screen 66 ...Go to Screen 71.
NEW CODE ACCEPTED
...Go to Screen 2.
* NEW ACCESS CODE
* ACKNOWLEDGED
*
* ...Record new code, then...
The operator is requested to record the new code

before it is forgotten.
Press ENTER to continue.
29

SYSTEM SENSITIVITY CLOSED LOOP DELAY
* SENSITIVITY * CLOSED LOOP DELAY

* CHAN % CHAN % * CHAN SEC CHAN SEC
* CURR 2.0 TRAV 5.0 * CURR 2.0 TRAV 7.0
* ARC 2.0 WIRE 4.0 * ARC 3.0 WIRE 3.0
This screen allows the operator the ability to set

the closed loop sensitivity of each channel. This screen allows the operator the ability to
enter in a time delay before the system starts to
The flashing cursor can be moved to the channel close the loop.
desired by using the 8 or 9 keys.
The flashing cursor can be moved to the channel
Enter a number between 00.0 to 99.9 and then desired by using the 8 or 9 keys.
press ENTER.
Enter a number between 00.0 to 99.9 and then
The number entered is a percentage, from 0 to press ENTER.
99.9. Note, if 0 is entered, the effect is to run the
channel as open loop . Recall that each channel is During the delay, the channel operates as an open
monitored 50 times per second and modified if loop channel. Once it times out, the channel
necessary 4 times per second. The percentage becomes closed loop at the sensitivity set in the
which is entered at this screen informs the soft- previous screen. This allows the overall system
ware what percent of the error should be adjusted to settle just after starting.
for with each modification.
Once the desired delays have been entered, press
We recommend trying a sensitivity value be- PREV to return to the previous screen. ...Go to
tween 2% and 10% as an initial value. At 10%, Screen 68.
up to 40% of the error will be added each second.
11. Screen 71
At this rate, overshoot and oscillation will be
avoided due to acceleration and de-acceleration SYSTEM CALIBRATION,
times. CURRENT FEEDBACK
* CURRENT CALIBRATION
NOTE * ACTUAL INPUT
* HI 300.0 A 715
Entering a value of 0.0% in the sensitivity setting * LO 5.0 A 25
causes the channel to become an OPEN loop
channel. No error factor is added or subtracted to
compensate the output for its error. This screen allows the operator to calibrate the
analog feedback signal for welding current with
Once the necessary values have been entered, the 9500 control.
press PREV to return to the previous screen.
...Go to Screen 68. The flashing cursor can be moved to the value
Enter the values and press NEXT.
...Go to Screen 72
...Go to Screen 68
30
The values (HI and LO) entered under actual As stated earlier, the current transducer produces
relate to the specifications of the current trans- __ volts at ___ amps. Since the maximum value
ducer. allowed after the first stage in the 9500-11 is 10
volts, the "Gain" of ___ should be chosen.
For example, the CSM-1 provided by Jetline uses (__*__ = __, which is ok) The 9500-11 should
a hall-effect type device. This device has a have jumper at location ___.
current range of ___ amps to ___ amps. The ___
rating would be entered as Actual/Hi. The ___ The 9500-11 board automatically reduces the
rating would be entered as Actual/Lo. The feedback signal by one-half to be acceptable for
numerical values under INPUT are not as straight the 9500-10 board. Thus a 10 volt signal after
forward. These values correspond to the maxi- the first stage will be 5 volts when it leaves the
mum input allowed by the 9500 control. The 9500-11 board.
number is binary in nature. To arrive at this
number carefully read the following. The maximum numerical value that can be
entered is 1024 and represents a 5.0 VDC input
The first bit of information necessary to calibrate into the 9500-10 micro-processor control board.
the input is the transducer's output signal. For The minimum value of 0 represents an input
example the Jetline transducer is rated for __ signal of approximately 0.0 VDC.
volts at ___ amps. If unknown, please contact
Jetline or the manufacturer of the transducer to To arrive at the number to be entered, follow the
determine the exact voltage output it produces. formula below:
Once the maximum and minimum output volta- HI numerical value will be:
ges of the transducer have been determined, the Max. Feedback Volt. * Gain * 1024/10 = INPUT
next step is to select the correct gain factor for HI Value.
the 9500-11 board per jumpers J1, J2, J3, and J5.
See Figure 19, in the Figures section for the Likewise, the initial LO number will be:
9500-11 board layout and position of the
jumpers. Min. Feedback Volt. * Gain * 1024/10 = INPUT
LO Value.
For the current transducer, the HI Input value can
now be calculated as:
NOTE (21/3) * 1024/10 = 717
This value can be entered as an initial value.
After this initial gain stage, the feedback voltage You can use the same calculation for finding the
must be between 0 and 10 volts. The closer the LO input value.
maximum signal is to 10 volts, the better. (better
signal to noise ratio). In most cases, these numbers will have to be
modified as you finish the calibration, but it
The "Gain" corresponds to the jumper setting on serves as a good starting reference.
the 9500-11 board. The "Gain" will be 2/1, 1/1,
1/3, or 1/10 per the jumper location. Check your 12. Screen 72
9500-11 board for the current channel, location SYSTEM CALIBRATION,
H9, to determine the gain value. (Reference ARC VOLTAGE FEEDBACK
Figures 19 and 21, in the Figures section).
* ARC VOLT CALIBRATION
* ACTUAL INPUT
* HI 50.0 V 610
* LO 5.0 V 61
31
This screen allows the operator to calibrate the 14. Screen 74

analog feedback signal for arc voltage with the SYSTEM CALIBRATION,
9500 control. WIRE FEEDBACK
The flashing cursor can be moved to the value
desired by using the 8 or 9 keys. * WIRE CALIBRATION
Enter the values and press NEXT. * ACTUAL INPUT
...Go to Screen 73 * HI 135.0 IPM 935
* LO 2.5 IPM 18
...Go to Screen 71
As with the current calibration, the actual range This screen allows the operator to calibrate the
of the equipment needs to be entered. Then the analog feedback signal for the wire feed device
feedback signal strength must be known and the with the 9500 control.
correct gain jumper installed on the 9500-11
board. Finally, convert the feedback signal to a The flashing cursor can be moved to the value
percentage of the "1024" number via the calcula- desired by using the 8 or 9 keys.
tion provided above. Enter the values and press NEXT.
13. Screen 73 ...Go to Screen 75
SYSTEM CALIBRATION, Press PREV to return to the previous screen.
TRAVEL FEEDBACK ...Go to Screen 73
As with the current calibration, the actual range
* TRAVEL CALIBRATION of the equipment needs to be entered. Then the
* ACTUAL INPUT feedback signal strength must be known and the
* HI 150.0 IPM 910 correct gain jumper installed on the 9500-11
* LO 3.0 IPM 18 board. Finally, convert the feedback signal to a
percentage of the "1024" number via the calcula-
tion provided above.
This screen allows the operator to calibrate the When the NEXT key is pressed again, the
analog feedback signal for the travel device with operator is brought to a similar set of screens.
the 9500 control. However, these are for the analog output signal
from the 9500 control which control the pa-
The flashing cursor can be moved to the value rameter.
15. Screen 75
Enter the values and press NEXT. SYSTEM CALIBRATION,
...Go to Screen 74 CURRENT OUTPUT SIGNAL
...Go to Screen 72 * CURRENT CALIBRATION
* ACTUAL OUTPUT
As with the current calibration, the actual range * HI 300.0 A 1480
of the equipment needs to be entered. Then the * LO 5.0 A 25
feedback signal strength must be known and the
correct gain jumper installed on the 9500-11
board. Finally, convert the feedback signal to a
percentage of the "1024" number via the calcula-
tion provided above. This screen allows the operator to calibrate the
analog output signal for welding current with the
9500 control.
32
The flashing cursor can be moved to the value As an example, a 9500 unit in our demo area is
desired by using the 8 or 9 keys. connected to a Hobart unit. The Hobart unit has
a specified range of 300 to 5 amps. To obtain
Enter the values and press NEXT. 300 amps, the voltage input to the Hobart unit is
...Go to Screen 76 specified to be 5.0 volts.
Press PREV to return to the previous screen. Thus 5/10 * 3000 = 1500
...Go to Screen 74
The number 1500 would be entered under
With the output signal, the equipment you are OUTPUT next to the ACTUAL/HI number in the
interfacing into must be familiar to you. The travel channel. (When the final calibration was
equipment requirements need to be known com- complete, the value ended up being 1445, or 4.82
pletely. Knowledge on how to make the system volts.)
go and stop is required (for example, momentary
versus maintained contact closure). Also, the 16. Screen 76
analog signal required to control the parameter SYSTEM CALIBRATION,
must be known. ARC VOLTAGE OUTPUT SIGNAL
The "ACTUAL" number you enter is the range of
the equipment. For example, a welding power * ARC VOLT CALIBRATION
supply may have a welding current range of 5 to * ACTUAL OUTPUT
300 amps. These would be the values you need * HI ***.* V ****
to enter. * LO ***.* V ****
The second part of information you need is the
analog signal requirement for the power supply
you are connecting up with the control. The
manufacturer of the equipment can usually This screen allows the operator to calibrate the
provide the analog signal specifications. analog output signal for arc voltage with the
9500 control.
If you are unsure of the analog signal required to
feed into your equipment, contact Jetline Engi- The flashing cursor can be moved to the value
neering. We will need the complete model and desired by using the 8 or 9 keys.
serial number of the equipment. We will attempt
to locate the values needed. Enter the values and press NEXT.
...Go to Screen 77
The 9500 control can produce an isolated analog
signal from 0 to 10 volts DC. The number Press PREV to return to the previous screen.
entered across from each value, under OUTPUT, ...Go to Screen 75
will be between 3000 and 30. The number 3000 Again the operating range of the equipment
represents 10 volts DC. To calculate your value, needs to be entered under ACTUAL. The
use the following formula: OUTPUT number has to be calculated based on
Analog signal required ÷ 10 * 3000 = the OUT- the formula above.
PUT number to be entered. For example, a Jetline ALC is specified to
This will work for both the HI and LO values. operate with arc voltages from 50 to 5 volts. For
a 50 volt arc length, a 5.0 volt analog signal
As you tune the system in, you may find you would need to supplied. For a 5 volt arc length,
have to increase or decrease the OUTPUT a .5 volt analog signal would need to be supplied.
number to obtain the correct analog output signal Using the above formula, you get:
needed.
5 ÷ 10 * 3000 = 1500, which is entered under
OUTPUT/HI.
.5 ÷ 10 * 3000 = 150, which is entered under
OUTPUT/LO
33

SYSTEM CALIBRATION, SYSTEM CALIBRATION,
TRAVEL OUTPUT SIGNAL WIREFEED OUTPUT SIGNAL
* TRAVEL CALIBRATION * WIRE CALIBRATION

* ACTUAL OUTPUT * ACTUAL OUTPUT
* HI ***.* IPM **** * HI ***.* V ****
* LO ***.* IPM **** * LO ***.* V ****
This screen allows the operator to calibrate the

This screen allows the operator to calibrate the
analog output signal for travel device with the
analog output signal for travel device with the
9500 control.
9500 control.
...Go to Screen 68
...Go to Screen 78
...Go to Screen 77
...Go to Screen 76
Again the operating range of the equipment
Again the operating range of the equipment
needs to be entered under ACTUAL. The
needs to be entered under ACTUAL. The
OUTPUT number has to be calculated based on
OUTPUT number has to be calculated based on
the formula above.
the formula above.
This concludes the calibration section, and also
the screens involved with the 9500 control. If
you have questions, please contact Jetline.
34
Section VIII
Process Options
A. Channel Status C. ARC ON WAIT

The 9500 control has the capability of enabling Each weld program has the capability of enabling
or disabling the two motion channels, typically or disabling the ARC ON WAIT option. If en-
wire and travel. Each weld program allows the abled, the start delays for the channels will not
operator to choose if the channel is enabled or start timing until an arc on signal is received.
disabled.
The arc on signal can be brought into the 9500
If enabled, the channel will operate per the values control in two places. One is on the current
entered for that particular channel. If disabled, channel connector, the other is on the arc voltage
the channel will remain idle, no matter what val- channel connector.
ues are entered for that channel.
Either arc on signal needs to be a normally closed
If disabled, the outputs for that channel are not contact or switch which changes to a maintained
activated and associated input signals are not open condition when an arc exists.
monitored.
On the current channel, the signal goes across
pins __ and __. On the arc voltage channel, the
B. Auto Touch Retract signal goes across pins __ and __. See Figures 15
and 16, in the Figures Section, for details.
Each weld program has the option to enable or If the ARC ON WAIT is enabled, the arc on
disable the auto sequence start. If enabled, the signal is monitored continuously. If the signal is
9500 control will automatically send a drive lost, the 9500 control immediately shuts the
signal to the arc length control to drive its actu- whole system down.
ator down. The down drive signal is continued
until a signal is received that the ALC has com- If the ARC ON WAIT option is disabled, the
pleted its touch retract for initial starting arc gap. start delays on the channels begin timing out
when the contactor signal is sent to the welding
Typically, when the touch retract is complete, the power supply. Also, the arc on signal is not
preflow gas automatically begins. When preflow monitored. Thus the 9500 control will not shut
is finished, the 9500 control sends the welding down the system if the arc on signal is lost.
power supply a start signal.
35
Weld time in this section is not to be confused

D. Auto Return Home with the "weld time" which is shown on the dis-
play. The "weld time" on the display is total arc
Sequence on time. The display "weld time" is the sum of
the initial, up-slope, weld, taper, downslope, and
Each weld schedule has the capability to enable final current times.
or disable the return home option. The return
If the weld time is disabled, weld time, taper
home option is typically used when the weld
current and taper time is NOT available. As a
starting point has to occur at the same position
result, the 9500 can not cycle itself based on time
every time. This may be due to part
alone. It must receive some type of downslope
configuration or tooling or due to the way the
signal to initiate downslope.
equipment must be operated.
When enabled, the 9500 control will reverse the
travel channel at high speed at the end of the post F. Shield Gas
flow. The travel channel is reversed until a
"home" signal is received. Each weld program allows you to control the gas
flow (on/off) for the system. The 9500 control
The "home" signal is a normally closed contact
provides the ability to set the preflow and
or switch across pins __ and __ on the travel
postflow times for the gas flow.
channel connector.
The 9500 control provides a set of normally open
When home is achieved, the contact or switch
contacts for the shield gas flow. When the gas
should open. The signal is acknowledged and the
flow sequence is active, the relay closes and
reverse travel will quit.
remains so until the gas flow sequence is over.
The shield gas relay contacts can be found on the
E. Weld Time auxiliary connector, pins __ and __. See Figure
19 for details.
Each weld program has the capability of enabling
Jetline offers a gas solenoid module for con-
or disabling the weld time section of program-
trolling the gas flow (on/off). The module has a
ming. The weld time is considered to be the
part number GSM-1.
amount of time the 9500 control remains at the
weld current level.
When the weld time timer times out, the control G. Pulse Capability
will proceed to taper to the taper current level
which you must enter. The time it takes to go The 9500 has built in pulse sensing ability,
from the weld current level to the taper current is assuming the system is equipped with current
the taper time. feedback capability. As the weld current pulses
per the setting on the welding power supply, the
If the weld time is enabled, the control will
9500 control has circuitry which detects the
completely cycle itself based on time alone.
change.
Once a start signal is received, the 9500 can auto-
matically cycle based on initial, up-slope, weld, As a result, the circuitry provides two "lockout"
taper, downslope, and final weld times. signals. The signals are active during the low or
background current level. When the current
returns to high or weld current level, the signals
are deactivated.
36
Jetline uses the two "lockout" signals for use The arc voltage feedback signal may have to be
with its equipment. One signal is used to prevent rectified as well. If an arc length control is being
the arc length control from following the used in the system and provides the feedback
changing current. The other signal can be sent to signal, the signal is probably rectified already.
a pulsed wire feeder. Usually this signal is used
to prevent wire from being fed into the weld If you are pulling the arc voltage from another
during the low or background current level. source, that signal may not be rectified. As with
the current, the signal will have to pass through
The circuitry can detect up to 10 pulses per a full wave rectification stage before entering the
second with a 50/50 duty cycle. When pulsing at 9500 control.
high rates, the ALC will not be able to chase the
changing current and the wire feed unit will not
be able to pulse fast enough. Thus the lockout NOTE
signal is not necessary.
We strongly recommend contacting the technical

H. A.C. Welding support personnel at Jetline before considering AC
welding with a 9500 system.
The standard 9500 control is designed to
accommodate AC welding. However, the
standard transducers are not designed to handle
AC welding.
The current transducer will detect the alternating
current and produce an alternating feedback
signal. This type of signal can not be handle by
the 9500 control. In order to provide an
acceptable signal, the current transducer must
provide a rectified DC signal. The standard
Jetline current transducer must be equipped with
a full wave rectifier stage.
37
Section IX
Special Programs
The Series 9500 System Controller is a pro- There is an additional cost for special programs.
grammable control because it is a microprocessor The cost will include the programming and the
based control. The microprocessor is driven by testing of the special program.
the software provided with the unit.
Please contact Jetline for the current cost of
The software is contained within the two special programs. The cost will be estimated on
EPROMs located on the microprocessor control the time deemed necessary to perform the pro-
board, P/N 9500-10 (a high and low bank). gramming and testing. Please have the details of
the complete weld sequence you require on paper
The EPROMs can be specially programmed to before contacting us.
accommodate special applications. The program
can be altered to provide different sequencing for Jetline will need to know as much information as
the output relays and respond differently to digi- possible on the timing and the necessary re-
tal inputs. quirements to achieve the timing (sequence).
For example, the output relays are programmed The delivery on special programs is very
to be maintained. If necessary, one or more dependent on the availability of our software
outputs could be programmed to become engineers. Please consider this when requesting
momentary. The software could also be pro- special programming.
grammed to sequence more of the auxiliary
outputs and respond to more of the auxiliary Details for installing new EPROMs are included
digital inputs. This would enable the user to se- with the EPROMs. The instructions offered will
quence more devices. help insure the chips are installed without
damage to them or their content.
The 9500 control is only capable of controlling
four devices (channels) with an analog signal.
Jetline cannot provide a fifth analog signal at this
time. Requests to do so will be turned down.
38
Section X
Figures
39

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OPERATION MANUAL

Read this manual carefully before installing,

Jetline Engineering, 15 Goodyear Street, Irvine, CA 92618

Only experienced personnel familiar with the operation

B. Channel Board (P/N 9500-11) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

WARNING 4. Properly install and ground this

1. Do not touch live electrical parts.

3. Wear approved safety glasses with side E. Cylinders

About Pacemakers: Safe Handling of Compressed Gases in

Outputs (per channel):

B. Current Sensor Module D. Motor Control Module

Module Weight: ? ( kg) Module Weight: ? ( kg)

Power Requirements: Power Requirements:

Output Analog: 0 - 5 VDC Output:

Fittings: e" - 18 argon, conical seat.

E. Limit Switch Kit G. Display Screen

Cables: 10' (3 m) 20 gauge ( ) 2 conduc-

B. Channel Board D. Mother Board (P/N 9500-13)

8 This key will move the cursor or select

Operating the System

The following sequence descriptions take you 1) WELD SEQUENCE

From this screen, you can run a weld program,

6 CURR 6 CURR 99.0 U TIME

The TRAV and WIRE channels show the word

PGM PART NUMBER

PGM PART NUMBER PREFLOW 5.0 SEC

CHANNEL STATUS INIT CURR 30.0 A

FINAL CURR 45.0 A WIRE 20.0 IPM

Press ENTER to proceed to next screen. 1. Screen 32

This screen allows you to choose the weld pro-

...Go to Screen 33 4. Screen 35

PGM PART NUMBER

This screen allows you to modify the wire 2. Screen 44

6. Screen 50 This screen allows you to select which device is

10. Screen 54 12. Screen 56

You can jog the wire feeder equipment from this

...Press START to pur...

This screen allows you to purge the gas.

...Press STOP to end...

This screen informs you that the gas is purging.

1. Screen 61 Press ENTER to by-pass the change and enter the

* System Configuration Press PREV to return to the previous screen.

Enter up to a seven digit number as a new access ...Go to Screen 68.

The operator is requested to record the new code

9. Screen 69 10. Screen 70

* SENSITIVITY * CLOSED LOOP DELAY

This screen allows the operator the ability to set

This screen allows the operator to calibrate the 14. Screen 74

17. Screen 77 18. Screen 78

* TRAVEL CALIBRATION * WIRE CALIBRATION

This screen allows the operator to calibrate the

A. Channel Status C. ARC ON WAIT

Weld time in this section is not to be confused

We strongly recommend contacting the technical

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