OPERATION MANUAL

for
9500-FW-MP-SER-PC

9500 to PC Communication Option

With PC Edit Option
October 2004

IMPORTANT

Read this manual carefully before installing,

commissioning or operating this product.

Jetline Engineering, 15 Goodyear Street, Irvine, CA 92618

Telephone: (949) 951-1515 ! Fax: (949) 951-9237
Web site: www.jetline.com ! E-mail: sales@jetline.com
9500-FW-MP-SER-PC

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 9500-FW-MP-SER-PC

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.

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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.

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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
A. Purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
B. Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Section III . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
A. 9500 Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
B. Serial Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
C. Host PC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
D. Load Jetline Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
E. Host PC - Run Jetline Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

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Section IV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Host PC - Assign Passwords . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
A. Password Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
B. Assign Passwords . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
C. Names . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
D. Passwords . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Section V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Serial Port Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Section VI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Create Weld Program Library (Save to PC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
A. Prepare 9500 for Single Pass Upload (Save to PC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
B. Prepare Host PC for Save Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
C. Transfer Program to PC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
D. Edit Host PC Program Title Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

Section VII . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
A. Send Program to 9500 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
B. Send Program to Host PC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
C. Operation Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

Section VIII . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
PC Edit Option - Single Pass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
A. Edit Single Pass Programs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
B. Edit Screen for EFC Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
C. SP Program Timing Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
D. Copy Single Pass Programs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
E. Print Single Pass Programs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

Section IX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76

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PC Edit Option - Multi Pass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76

A. Edit Multi Pass Programs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
B. Edit Selected Pass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
C. Copy Multi Pass Programs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85

Section X . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Electrical Drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89

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Section I
Safety Precautions
WARNING
A. Arc Welding
Arc Welding can be hazardous. Protect yourself and
others from possible serious injury or death. Keep
children away. Pacemaker wearers keep away until
consulting your doctor.
In welding, as in most jobs, exposure to certain
hazards occurs. Welding is safe when precautions
are taken. The safety information given below is
only a summary of the more complete safety
information that will be found in the Safety
Standards listed at the end of this section. Read and
follow all Safety Standards.
Have all installation, operation, maintenance and
repair work performed only by qualified people.
B. Electric Shock
Touching live electrical parts can cause fatal shocks
or severe burns. The electrode and work circuit is
electrically live whenever the output is on. The input
power circuit and machine internal circuits are also
live when power is on. When using mechanized wire
feed, the wire, wire reel, drive roll housing and all
metal parts touching the welding wire are
electrically live. Incorrectly installed or improperly
grounded equipment is a hazard.
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 OSHA 29 CFR
1910.147 (see Safety Standards).
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9500-FW-MP-SER-PC
4. Properly install and ground this equipment
according to the operation manual and
national, state and local codes.
5. Always verify the supply ground-check and
be sure that input power cord ground wire is
properly connected to ground terminal in
disconnect box or that cord plug is connected
to a properly grounded receptacle outlet.
6. When making input connections, attach
proper grounding conductor first - double-
check connections.
7. Frequently inspect input power cord for
damage or bare wiring. Replace cord
immediately if damaged - bare wiring can
kill.
8. Turn off all equipment when not in use.
9. If earth grounding of the workpiece is
required, ground it directly with a separate
cable - do not use work clamp or work cable.
10. Do not touch electrode if you are in contact
with the work, ground, or another electrode
from a different machine.
11. Use only well-maintained equipment. Repair
or replace damaged parts at once. Maintain
unit according to manual.
12. Wear a safety harness if working above floor
level.
13. Keep all panels and covers securely in place.
14. Clamp work cable with good metal-to-metal
contact to workpiece or worktable as near the
weld as practical.
9500-FW-MP-SER-PC
C. Arc Rays
Arc rays can burn eyes and skin; noise can damage
hearing; flying slag or sparks can injure eyes.
Arc rays from the welding process produce intense
visible and invisible (ultraviolet and infrared) rays
that can burn eyes and skin. Noise from some
processes can damage hearing. Chipping, grinding
and weld cooling throw off pieces of metal or slag.
1. Use approved ear plugs or ear muffs if noise
level is high.
2. Use a welding helmet fitted with a proper
shade of filter to protect your face and eyes
when welding or watching.
3. Wear approved safety glasses with side
shields.
4. Use protective screens or barriers to protect
others from flash and glare; warn others not
to watch the arc.
5. Wear protective clothing made from durable,
flame-resistant material (wool and leather)
and foot protection where necessary.
D. Fumes and Gases
Fumes and gases can be hazardous to your health.
Welding produces fumes and gases. Breathing these
fumes and gases can be hazardous to your health.
1. Keep your head out of the fumes. Do not
breathe the fumes.
2. If inside, ventilate the area and/or use exhaust
at the arc to remove welding fumes and gases.
3. If ventilation is poor, use an approved air-
supplied respirator.
4. Read the Material Safety Data Sheets
(MSDS) and the manufacturer's instruction
for metals, consumables, coatings, cleaners,
and degreasers.
5. Work in a confined space only if it is well
ventilated, or while wearing an air-supplied
respirator. Always have a trained watch
person nearby.
2
6. Do not weld in locations near degreasing,
cleaning, or spraying operations. The heat and
rays of the arc can react with vapors to form
highly toxic and irritating gases.
7. Do not weld on coated metals, such as
galvanized, lead or cadmium plated steel,
unless the coating is removed from the weld
area, the area is well ventilated, and if
necessary, while wearing an air-supplied
respirator. The coatings and any metals
containing these elements can give off toxic
fumes if welded.
E. Cylinders
Cylinders can explode if damaged.
Shielding gas cylinders contain gas under high
pressure. If damaged, a cylinder can explode. Since
gas cylinders are normally part of the welding
process, be sure to treat them carefully.
1. Protect compressed gas cylinders from
excessive heat, mechanical shocks, slag, open
flames, sparks, and arcs.
2. Install cylinders in an upright position by
securing to a stationary support or cylinder
rack to prevent falling or tipping.
3. Keep cylinders away from any welding or
other electrical circuits.
4. Never weld on a pressurized cylinder -
explosion will result.
5. Use only correct shielding gas cylinders,
regulators, hoses and fittings designed for the
specific application; maintain them and
associated parts in good condition.
6. Turn face away from valve outlet when
opening cylinder valve.
7. Keep protective cap in place over valve
except when cylinder is in use or connected
for use.
8. Read and follow instructions on compressed
gas cylinders, associated equipment, and
CGA publication P-1 listed in Safety
Standards.

F. Welding
Welding can cause fire or explosion.
Welding on closed containers, such as tanks, drums,
or pipes, can cause them to blow up. Sparks can fly
off from the welding arc. The flying sparks, hot
workpiece, and hot equipment can cause fires and
burns. Accidental contact of electrode to metal
objects can cause sparks, explosion, overheating, or
fire. Check and be sure the area is safe before doing
any welding.
1. Protect yourself and others from flying sparks
and hot metal.
2. Do not weld where flying sparks can strike
flammable material.
3. Remove all flammables within 35 ft (10.7 m)
of the welding arc. If this is not possible,
tightly cover them with approved covers.
4. Be alert that welding sparks and hot materials
from welding can easily go through small
cracks and openings to adjacent areas.
5. Watch for fire, and keep a fire extinguisher
nearby.
6. Do not weld on closed containers such as
tanks, drums, or pipes, unless they are
properly prepared according to AWSF4.1 (see
safety Standards).
7. Connect work cable to the work as close to
the welding area as practical to prevent
welding current traveling long, possibly
unknown paths and causing electric shock
and fire hazards.
8. Wear oil-free protective garments such as
leather gloves, heavy shirt, cuffless trousers,
high shoes, and a cap.
G. Moving Parts
Moving parts, such as fans, rotors, and belts can cut
fingers and hands and catch loose clothing.
1. Keep all doors, panels, covers, and guards
closed and securely in place.
2. Have only qualified people remove guards or
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9500-FW-MP-SER-PC
covers for maintenance and troubleshooting
as necessary.
H. EMF Information
Considerations About Welding and the Effects of
Low Frequency Electric and Magnetic Fields
The following is a quotation from the General
Conclusions Section of the U.S. Congress, Office of
Technology Assessment, Biological Effects of
Power Frequency Electric & Magnetic Fields -
Background Paper, OTA-BP-E-53 (Washington,
DC: U.S. Government Printing Office, May 1989):
".... there is now a very large volume of scientific
findings based on experiments at the cellular level
and from studies with animals and people which
clearly establish that low frequency magnetic fields
can interact with, and produce changes in, biological
systems. While most of this work is of very high
quality, the results are complex. Current scientific
understanding does not yet allow us to interpret the
evidence in a single coherent framework. Even more
frustrating, it does not yet allow us to draw definite
conclusions abut questions of possible risk or to
offer clear science-based advice on strategies to
minimize or avoid potential risks."
To reduce magnetic fields in the work place, use the
following procedures:
1. Keep cables close together by twisting or
taping them.
2. Arrange cables to one side and away from the
operator.
3. Do not coil or drape cables around the body.
4. Keep welding power source and cables as far
away as practical.
5. Connect work clamp to workpiece as close to
the weld as possible.
About Pacemakers:
The above procedures are among those also
normally recommended for pacemaker wearers.
Consult your doctor for complete information.
9500-FW-MP-SER-PC

I. Principal Safety Standards

Reference as applicable
Safety in Welding and Cutting, ANSI Standard
Z49.1, from American Welding Society, 550 N.W.
LeJeune Rd, Miami, FL 33126
Safety and Health Standards, OSHA 29 CFR 1910,
from Superintendent of Documents, U.S.
Government Printing Office, Washington, D.C.
20402
National Electric Code, NFPA Standard 70 from
National Fire Protection Association, Batterymarch
Park, Quincy, MA 02269
Recommended Safe Practices for the Preparation for
Welding and Cutting of Containers That Have Held
Hazardous Substances, American Welding Society
Standard AWS F4.1, from American Welding
Society, 550 N.W. LeJeune Rd, Miami, FL 33126
Safe Handling of Compressed Gases in Cylinders,
CGA Pamphlet P-1, from Compressed Gas
Association, 1235 Jefferson Davis Highway, Suite
501, Arlington, VA 22202
Code for Safety in Welding and Cutting, CSA
Standard W117.2, from Canadian Standards
Association, Standards Sales, 178 Rexdale
Boulevard, Rexdale, Ontario, Canada M9W 1R3
Sales Practices for Occupation and Educational Eye
and Face Protection, ANSI Standard Z87.1, from
American National Standards Institute, 1430
Broadway, New York, NY 10018
Cutting and Welding Processes, NFPA Standard
51B, from National Fire Protection Association,
Batterymarch Park, Quincy, MA 02269

4

Section II
Introduction
A. Purpose
This option gives the 9500 Controller the ability to
communicate with a lap top, desk top, or shop
computer, running Jetline PC Option software. This
communication enables Single Pass and Multi Pass
weld programs to be stored on the PC and then be
later recalled by the 9500 one at a time through the
serial port.
These weld programs can be created or modified in
the 9500 in the normal fashion, then sent to the PC
to be renamed in Windows format. Once a library of
programs is created on the PC using Windows long
name, the proper weld program that matches the part
currently being welded can be recalled and sent to
the 9500 just prior to the weld. In this manner, a
virtually unlimited number of programs can be
stored on the host PC and downloaded to the 9500
when needed.
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9500-FW-MP-SER-PC
B. Requirements
• The 9500 controller must be fitted with Ver
4.2 firmware with the 9500-FW-MP-SER-PC
option. This requires that a hardware version
4.0 CPU board is installed.
• A host PC must be located within 8 feet of the
9500 if an unboosted, standard RS-232 serial
cable is to be used (only a 3 wire connection
is required). A serial port protector is
recommended for the PC.
• The host PC must have Windows 98/2000/XP
installed and the Jetline Serial PC Option
program active.
• The host PC should be Pentium based with
1024 x 768 resolution (800 x 600 is
acceptable if slight clipping of the application
screen is tolerable) and 500 Mb of free hard
disk storage available. Speed should be 233
MHZ minimum. CD ROM is required to load
the 9500 application software. One free serial
port is required.
9500-FW-MP-SER-PC
Section III
Installation
A. 9500 Control
Install new EPROM’s. CAUTION: This procedure
WILL erase all weld programs and configuration
data. Existing Upload / Download memory cards
will not be compatible to restore data until data on
cards is reformatted. Only the PCMCIA type
(MEMPEND2) will be compatible with Ver 4.2
firmware (must have the 9500-FW-UD option
installed). Be sure to record information first, as
below:
1) Write down all weld programs
2) Write down all configuration/calibration data.
3) Turn off power
4) Remove the two front door screws
5) Open the 9500 door and locate the 9500-10
CPU board that is mounted on the rear of the
door. This board must be Ver 4.0 to be
compatible with this upgrade option. Verify
that the J1 connector in the lower left corner
is a 4-terminal terminal block (NOT a
metallic 9 pin connector).
6) Make sure to use an anti-static strap or at least
ground yourself to the 9500 enclosure before
handling the EPROM’s.
7) Locate the two EPROM’s in the bottom left
area of the 9500-10 board. They are labeled
U7 (lower) and U8 (upper).
8) With EPROM puller, carefully extract the
EPROM’s. Take note of their orientation.
9) Carefully take the new EPROM’s and insert
them into the sockets. Lower is marked LO
and the upper is marked HI.
B. Serial Cable
6
10) Be sure they are fully seated and that the pins
are in the sockets and are not bent.
11) Close the door and re-install the screws.
12) Turn on power to the 9500.
13) Press the <Enter> key when the welcome
screen comes up.
14) Select “SYSTEM CONFIG” from the menu.
(Press 3).
15) Enter the code “92618" when asked for
access code. This will reset Channel Controls
memory and reset normal password to “0".
NOTE: Do not use the 92618 code again
unless you intentionally want to clear the
memory again.
16) Press the <Prev> key and then select “WELD
SEQUENCE”, then “MODIFY/COPY”.
Enter the code “92618" to clear weld program
memory and reset the weld program access
code to “0". NOTE: Do not use the 92618
code again unless you intentionally want to
clear the memory again.
17) Re-enter/verify all calibration and channel
control data.
18) Re-enter weld program data. NOTE: There is
now a weld program 26 slot. This is the
communication port between the 9500 and
the PC. All data transferred will be to and
from program 26 (See Operation section).
Connect the serial cable between the 9500 9 pin
serial port connector located on the outside of the
 9500-FW-MP-SER-PC

9500 enclosure (or on the front of the vanity panel,

if installed), and a free COMM port on the host PC C. Host PC
(this must be an RS-232 port if no external
converters are being used). This cable should not be
longer than 8 feet and should run well away from The host PC can be any personal computer running
any torch or work leads from the welding power Windows with the Jetline 9500 Serial PC option
source. It is recommended to have a serial port installed. The weld program data will be transferred
isolator installed at the PC to protect the PC from back and forth using this terminal software. Load the
any electrical noise from the welding process. Jetline application program using the screens on the
following pages as a guide.
For extremely high noise environments or long cable
lengths, the RS-232 signal can be converted to a
different interface or to a fiber optic link. Interface
converters can be sourced through companies like
B&B Electronics (www.bb-elec.com) or others.

7
9500-FW-MP-SER-PC

D. Load Jetline Application

Place the Jetline 9500-FW-MP-SER-PC CD ROM

in the host PC CD drive. Make sure all other
applications are shut down then run SETUP.EXE
from the CD drive command line.
Click on OK to continue.

8
 9500-FW-MP-SER-PC

If default directory C:\Program files\Jetline is

acceptable, click on OK. If you want to change
target directory, click on CHANGE DIRECTORY.

9
9500-FW-MP-SER-PC

If default group name is acceptable, click on CONTINUE to start copying files

10
 9500-FW-MP-SER-PC

Copying Files . . .

11
9500-FW-MP-SER-PC

When system is done copying, click on OK

12
 9500-FW-MP-SER-PC

In Windows Explorer, go to Program Files then

click on JETLINE (or the alternate preselected
directory). Verify that the Jetline directory exists
and contains the files as above.

13
9500-FW-MP-SER-PC

Now go to the CD ROM drive and select CONFIGURATION.mdb,

then right click and select COPY

14
 9500-FW-MP-SER-PC

Now move the cursor back to the Jetline directory, right click then select Paste.
This installs the correct configuration files for your system

15
9500-FW-MP-SER-PC

To create shortcut from the desktop, right click on the Jetstar.exe icon in the Jetstar directory.
Select CREATE SHORTCUT.

16
 9500-FW-MP-SER-PC

When the shortcut icon appears, right click on it, then select CUT.

17
9500-FW-MP-SER-PC

Close Windows Explorer then right click on the desktop.

Select PASTE

18
 9500-FW-MP-SER-PC

The Jetline icon should now be on the desktop.

See next to rename.

19
9500-FW-MP-SER-PC

To rename, right click on the shortcut icon.

Select Rename.

20
 9500-FW-MP-SER-PC

Type in the desired name

21
9500-FW-MP-SER-PC

E. Host PC - Run Jetline Program

Double click on the new icon to run the 9500-FW-MP-SER-PC program

22
 9500-FW-MP-SER-PC

Click on OK to continue

23
9500-FW-MP-SER-PC

For first time startup, type the password name Grand Master, then the password 12345678.

When typing in the password for the first time as

above, you are considered to be “The Admin-
istrator” with the highest clearance. You may change
the name and/or password once you log in then click
on Edit. When typing in the name you must use
capitals and small case exactly as they are entered
into the User Data screen. There can be only one
space character, this separates first name from last
name.

24
 9500-FW-MP-SER-PC

Section IV

Host PC - Assign Passwords

Note that the default password resides in the User 1

row. This first row is hard coded to be the
Administrator regardless of the Name and Password
assigned to the row. There can be only one
administrator in the system (User 1 only).

25
9500-FW-MP-SER-PC
A. Password Structure
There can be a total of 99 users assigned to the
system. User 1 is the Administrator with highest
security level. Users 2, 3 and 4 are for the
Supervisors with medium security level. Users 5
through 99 are for operators with lower security
level.
FUNCTION USER 1
Change Own Password YES
RESTORE Programs from PC to 9500 YES
SAVE 9500 programs to PC YES
EDIT PC Programs (option) YES
ADD / EDIT / DELETE Passwords YES
Change Administrator Password YES
B. Assign Passwords
Once the administrator is logged in using the Grand
Master name and password, the administrator can
change the administrator name and password by
clicking on EDIT. Make sure that the arrow is in the
User 1 row. After clicking on the appropriate field,
modify the contents as desired. Click on Update
when done.
The administrator can then assign other users to the
system. Procedure is to first click on the User ID
row to select, or, use the left and right arrow keys on
the right half of the screen. Once the desired row is
selected, click on EDIT to re-assign names and
passwords. Click on UPDATE when done changing.
Remember that User 1 is the Administrator, User 2,
3 and 4 are Supervisors who can Save new programs
to the PC and edit the titles and descriptions. Users
5 through 99 are operators who can run the system
(Restore programs from the PC to the 9500), but can
make no changes to the PC weld program data.
To add more users than the 7 defaults provided,
26
USER 2-4 USER 5-99
YES YES
YES YES
YES NO
YES NO
NO NO
NO NO
click on the ADD button and enter new data. To de-
activate a user, click on the user’s row then click
EDIT. Click on the ACTIVE check box to activate
or de-activate, click Update when done. To
completely remove, click on the user’s row then
click on DELETE. There will be a confirmation
dialogue box appear to verify if you are sure.
C. Names
There can be either one or two names assigned to
each user: the first name and the last name. It is also
valid to have only one name (first name only). Each
name can be an alpha-numeric string of characters.
The names are case sensitive meaning that if capital
letters are used in the User Data chart, they must
also be used when entering the name and password
to gain access. When entering two names in the
password screen to gain access, there must be a
space entered between first and last names. Do NOT
use spaces in names in the User Data chart.
 9500-FW-MP-SER-PC

D. Passwords
The assigned password must be an alpha-numeric
string, eight characters long. It can not be longer or
shorter. All users can change their own passwords
and / or comments. The password is also case
sensitive.

27
9500-FW-MP-SER-PC

Section V

Serial Port Configuration

Click on Port Config in the User Data screen:

Now click on Com Port to configure

28
 9500-FW-MP-SER-PC

Configure port in the Input Port Properties Screen:

Port Enter the serial port number of the port to be used
Baud Rate Enter 9600 for Baud Rate
Data Bits Enter 8 data bits
Parity Enter None for parity
Stop Bits Enter 1 for stop bits
Echo Enter Off for echo
Flow Control Enter None for flow control
Click on OK when done

29
9500-FW-MP-SER-PC

Click on
Save Port Settings to save

30
 9500-FW-MP-SER-PC

Click on
Connect before leaving the User Data screen.
This will allow the software to access the serial port for use with the 9500 Serial PC routine.

31
9500-FW-MP-SER-PC

Section VI

Create Weld Program

Library (Save to PC)

The first step is to create a library of weld programs

in the PC to later Restore to the 9500 as needed. If
the user has the multi pass option, both single pass
and multi pass weld programs can be saved to the
PC. These programs go into separate folders. Unless
the PC Edit option is installed, all weld programs
must be created in the 9500, then they are sent to the
PC through the Program 26 slot for storage. When
the programs are saved in the PC, they can be
renamed to what ever the user desires, within the
limits of Windows file names.
Multi pass programs are comprised of from 1 to 25
single pass programs that are chained together to run
in the desired sequence. When creating multi pass
programs in the 9500, all of the single pass programs
that are called in the multi pass sequence must be
programmed, as normal, before saving the multi pass
program to the PC. When saving a multi pass
program, the multi pass sequence is sent to the PC
along with all of the associated single pass programs
as one file. When the multi pass program is sent
from the PC to the 9500, the multi pass sequence is
sent to program 26, overwriting what ever happens
to be in multi pass program 26, and the single pass
programs are sent to their original slot numbers (SP
program numbers), overwriting what ever happens
to be in those slots. The multi pass program can then
be run from the program 26 slot as normal.
NOTE
NOTE: 9500 controllers that do not have the
multi pass option, label the 25 single pass
programs as “Programs”. 9500 controllers that
do have the multi pass option label the single pass
programs as “Passes” and the multi pass
sequences as “Programs”. Due to this, some
nomenclature below may not exactly match your
unit, depending on certain options. Use the
following screens as a guide.
A. Prepare 9500 for Single
Pass Upload (Save to PC)
First, create the programs in the 9500, that you want
to transfer over to the PC. Next, SET the 9500 to
program 26 to get ready for the transfers:
Main Menu
1) RUN PROGRAM
2) SELECT/VIEW
3) MODIFY/COPY

Press <2>, Select / View

32
 9500-FW-MP-SER-PC

“0" during the EPROM installation

Select / View Menu procedure.
1) SET CURRENT PGM 2) Acknowledge the verification screen by
2) VIEW CURRENT PGM pressing the <Enter> key then select Copy
Program (2). In the Copy Pass screen, enter
“12" on the first line and “26" on the second
line:

Select <1>, Set Current Program

Copy SP Program Screen

Select Menu COPY PASS 12

INTO PASS 26
23) PROGRAM 23
24) PROGRAM 24
25) PROGRAM 25
|26) PROGRAM 26
After entering the two numbers, Press <Enter>
once more until the scrolling message appears on
Move cursor to Program 26 then press <Enter> the bottom line. Pressing the <+> key will perform
the copy, pressing the <Enter> key will abort:
Verify Selection Menu
Copy SP Program Screen
CURRENT PGM IS :
COPY PASS 12
26 PROGRAM 26 INTO PASS 26
Press PREV to exit.
Press + to copy, or ENTER to exit

Press <Prev>
Press <+>
The 9500 uses Program 26 as the transfer port when
communicating with the PC. To transfer the first 3) Now press the <Prev> key and select Run
Single Pass (SP) program to the PC, copy the Program (1) from the Main Menu.
desired 9500 weld program to the program 26 slot.
For example, if the SP weld program to be
transferred is program (or pass) 12, copy program 12 Main Menu
into program 26 by selecting Modify/Copy from the
1) RUN PROGRAM
9500 Single Pass main menu:
2) SELECT/VIEW
3) MODIFY/COPY
Main Menu
1) RUN PROGRAM
2) SELECT/VIEW Press <1>
3) MODIFY/COPY

Press <3>

1) Enter the Access Code. This code was reset to

33
9500-FW-MP-SER-PC

4) Now select Load PC Program (2):

Run / Load Screen

1) RUN PROGRAM
2) LOAD PC PROGRAM

Press <2>

Data Transfer Screen

PROGRAM 26 DATA
1) SAVE TO PC
2) RESTORE FROM PC

Stop here and go to next section

34
 9500-FW-MP-SER-PC

B. Prepare Host PC for Save Program

Click on Single Pass Programs (or Multipass, if saving Multipass)

35
9500-FW-MP-SER-PC

Click on ADD, to Add New Program

Type in Program ID,

Program Name, and Program Description for the new program to be added,
in the yellow fields.

36
 9500-FW-MP-SER-PC

After typing in the program

title data, click on UPDATE to record

After updating, note that program title data appears in Program ID slot 2. Also note that the Program ID in
9500 field indicates “EMPTY”. This means that there is no weld data from the 9500 in this program yet.

37
9500-FW-MP-SER-PC

C. Transfer Program to PC

To transfer the data from the program 26 slot in the 9500 to the program 2 slot in the host PC,
click on row 2 to move cursor on to the 2nd row,
then click on the arrow in the OPERATION MODE window,
then select SAVE to PC.

38
 9500-FW-MP-SER-PC

Now click on START. Note that the start button changes to RUNNING.
The host PC program is waiting for data from the 9500

Next, go to the 9500 and press <1>, SAVE TO PC:

Acknowledgement Screen
Data Transfer Screen SAVE COMPLETE
PROGRAM 26 DATA
1) SAVE TO PC Press ENTER to continue
2) RESTORE FROM PC
Press 1, 2, or PREV to exit
Press <Enter>
Press <1>

39
9500-FW-MP-SER-PC

At the host PC, the RUNNING message should have

changed to DONE. Click on Done. Note that the
data in the PROGRAM ID in 9500 column has
changed to whatever the PROGRAM ID data is in
the 9500 program - in this case: “PROGRAM 26".
The transferred weld program data is displayed in
the black window at the bottom of the screen. Note
that the data in this window is not in numerical
format, it has been transferred as an ASCII file and
is not legible (without converting back). Use it for
verification that data has been transferred. If the PC
EDIT option was purchased, this data can be
transferred to an edit screen, where the user can
view and edit the weld program data in the standard
numerical format.

Click on DONE, when done

The 9500 Program 26 has now been transferred to

Program ID slot 2 in the host PC. To add additional
programs, repeat the procedure as in Steps 1 through
4 in Section VI-A above. If the Multi Pass option is
installed, the procedure is the same, using the Multi
pass screens in the 9500 and in the host PC program.

40
 9500-FW-MP-SER-PC

D. Edit Host PC Program

Title Data
To change the program header information on the
host PC, click on the row of the program to be
edited:

Now click on EDIT

41
9500-FW-MP-SER-PC

Click on any of the three yellow fields:

Program ID, Program Name or Program Description and make changes as desired.

42
 9500-FW-MP-SER-PC

Click UPDATE when done

Note that the Program ID in 9500 field and the Date

field can not be modified. The Program ID in 9500
data comes in directly from the 9500, for cross
reference of the 9500 program to the PC program
data. The date in the Date field is the Last Modified
date.

43
9500-FW-MP-SER-PC

Changes are now updated

To add more programs to the PC, copy a different

program in the 9500 to the program 26 slot (or
modify the existing program 26), then repeat above
steps to transfer to the PC. It is recommended to
transfer only a few weld programs to the PC at first,
until experience has been had with all operations of
the Serial Port routine and 9500 weld programs have
been run and tested with the 9500 controller.

44
 9500-FW-MP-SER-PC

Section VII

Operation

A. Send Program to 9500 Run / Load Screen

1) RUN PROGRAM
Once a library of 9500 weld programs has been 2) LOAD PC PROGRAM
established in the PC, as in the Create Weld Library
section above, a weld program can be loaded
(restored) into the 9500 any time it is required.
When sending a file to the 9500, the content will
always be transferred into the Program 26 slot of the Press <2>, Load PC Program:
9500. Procedure as follows:
1) This procedure is done from the active RUN Data Transfer Screen
PROGRAM screen of the 9500 - this is the
normal weld screen for program 26. The host PROGRAM 26 DATA
PC is usually running the Jetline PC 1) SAVE TO PC
program, standing by, if programs are 2) RESTORE FROM PC
frequently downloaded throughout the day. Press 1, 2, or PREV to exit
From the 9500 Run screen, press the <Prev>
key on the 9500 keypad:
Press <2>, Restore from PC:

Run Program Screen

Load Screen
PGM PART NUMBER
26 035 SS
Waiting for PC data
Press START to weld, or PREV
<PREV> to abort

Press the <Prev> key:

45
9500-FW-MP-SER-PC

2) Now go to the PC and select the program to

be Restored from PC. Highlight the program
by clicking on the appropriate row. Make
sure that the Operation Mode is set to
Restore from PC. Click on the Start button.

46
 9500-FW-MP-SER-PC

When transferred, click on the Done button. The

9500 will acknowledge the transfer with the
following message:

Acknowledgment Screen
RESTORE COMPLETE

Press ENTER to continue

Pressing <Enter> will bring up the RUN screen

with the new program:

Run Program Screen

PGM PART NUMBER
26 PROGRAM 26

Press START to weld, or PREV

47
9500-FW-MP-SER-PC
B. Send Program to Host PC
Once the weld program library has been established
in the host PC and a new application comes up,
requiring a new weld program to be created, it can
be added to the PC listing as follows.
The 9500-FW-MP-SER-PC routine uses the 9500
Program 26 as a port to transfer weld program data
between the 9500 and the PC. When sending a file
to the PC, the content will always be whatever is in
program 26. Procedure as follows:
1) First, copy the desired program into Program
26, or Modify program 26 to have the
desired parameters. See 9500 manual for the
normal Copy and Modify functions.
2) From the Main Menu, select Weld Sequence,
Run Program, then Load Program.
48
The next screen will have the heading:
Program 26 Data with two options: 1) Save
to PC, 2) Restore From PC. Stop in this
screen, do not select anything yet.
Data Transfer Screen
PROGRAM 26 DATA
1) SAVE TO PC
2) RESTORE FROM PC
Press 1, 2, or PREV to exit
3) Go to Host PC and select “ADD”. Fill in the
three data fields, Program ID, Program Name
and Program Description. Click on Update
when done with descriptions. Select Save to
PC as the Operating Mode. Click on Start
when ready. Button will change to
“Running”, as below:
 9500-FW-MP-SER-PC

4) Go to 9500 and press 1) Save to PC. The

message “Saving Data” will be briefly Acknowledgment Screen
displayed then “Save Complete.
SAVE COMPLETE

Data Transfer Screen Press ENTER to continue

PROGRAM 26 DATA
1) SAVE TO PC
2) RESTORE FROM PC 5) At the Host PC, click on Done. The transfer
Press 1, 2, or PREV to exit is complete. Press <Enter> on the 9500 to
clear the screen.
Press <1>

49
9500-FW-MP-SER-PC

C. Operation Notes
To EXPAND THE HEIGHT of the rows to view
more information, drag one of the row borders
down, in the first column, until you have the desired
height, as below. You may also EXPAND THE
WIDTH of the columns by dragging the column
borders left or right in the header row.

To SCROLL THROUGH THE PROGRAMS, you

may use the Arrow keys. Right arrow moves cursor
down one program, left arrow moves cursor up one
program, right arrow/line moves cursor to the end of
the list, left arrow/line moves cursor to the beginning
of the list.

50
 9500-FW-MP-SER-PC

To SORT by Program Name, click on the Program

Name header. You may also sort by Date,
Description, etc.

51
9500-FW-MP-SER-PC

To DELETE a program, click on the program row,

then click on Delete. A warning message will appear
- click on YES to delete, NO to Abort.

You may OVERWRITE a program by clicking on

the program row, Save to PC, then Start. A warning
message will appear - click on YES to overwrite,
NO to abort. This will place the 9500 program
information that is currently in the Program 26 slot
of the 9500 into the selected program slot in the PC
(assuming that the 9500 is also set to Save to PC).

52
 9500-FW-MP-SER-PC

Section VIII

PC Edit Option - Single Pass

If the PC Edit option was purchased, the user will

have the ability to edit weld programs at the PC, for
downloading to the 9500 controller later. At least
one weld program will have to be uploaded to the
PC before the Edit function can be fully utilized.
A. Edit Single Pass
Programs
Once a program library has been started as in
Section VI, a program can be selected from the
Single Pass screen for editing by clicking on the
Program ID line, then clicking on the Edit Program
button (in the upper right corner) as below:

Click on EDIT PROGRAM to go to the editing screens for Program ID 61

53
9500-FW-MP-SER-PC

Setup Parameters for Program ID 61

The first editing screen is called the Setup Channel Status – In this column the various channels
Parameters screen, as shown above. Some of these can be enabled or disabled for the current weld
parameters may be absent or greyed-out if the program. Clicking on each box will produce or
configuration of your 9500 controller does not remove the check mark. A checked box means the
support them (if certain options were not purchased). channel is enabled, unchecked is disabled. NOTE: if
The functions of these parameters are more fully a channel is disabled here, it will not be active in the
described in the 9500 operation manuals but a brief weld program even if there are valid parameter
description follows: entries in the weld program.
The information in the Program Name field, near the
top of the screen, is the information contained in the
“Program ID in 9500" column in the Single Pass
Program listing on the previous page. This is the
Program Name as seen on the 9500 in the 9500
program listing screen. Changing the data in this
field will change the program name that the operator
sees when operating the 9500 controller.

54

Feature Status – Here, various features can be
enabled or disabled. Any greyed-out boxes mean
that the feature is not available with your
configuration.
Touch Retract – When this is enabled, the ALC
controller will do a “touch retract” at the
beginning of the weld sequence, automatically
setting the starting arc gap. An ALC controller
must be installed and interfaced to the 9500 in
order to use this feature.
Arc Wait – When this feature is enabled, the
weld program will wait for an “arc on” signal
after sending the start command to the welding
power supply, before starting any auxiliary
channels or start delays. This signal can come
from an external device eg an ALC controller or
can be derived from the hall effect current
transducer on the weld cable, depending on the
9500 configuration code.
Weld Time – When this feature is enabled the
weld length will be controlled by the 9500 weld
timer. Weld Time and Taper Time fields will
appear in the 9500 fields when the weld timer is
enabled. NOTE: When weld time is enabled, it
over rides the downslope limit switch and Weld
Distance (encoder) values.
Home Seq – When home seq is enabled, the
travel device will return to home automatically
In the right hand column are other setup values:
after the weld.
Linear – If Linear is checked, it enables the
encoder for Weld Distance if system is
configured to be Linear. If system is a
circumferential type, this box will be greyed-out.
Pulse – If this box is checked, the values in the fields
below it will be active. This activates the pulsing
feature which pulses the weld current during the
weld. Note: If this box is not checked, there will be
no pulsing even if there are valid entries in the pulse
parameters fields below. The Peak current is the
programmed value for weld current (as in the Weld
Parameters screen), the Background current is a
percentage of the weld current value as below:
Start Delay – This timer starts timing with the
Arc On signal and when it times out, pulsing will
commence. Valid entry range is 0.0 to 99.9
seconds.
55
9500-FW-MP-SER-PC
Stop Delay – This timer starts timing with the
Downslope signal (when Weld Timer times out,
or when downslope limit switch is engaged, or
when encoder count is reached, or when Stop
button is pressed). While timing, the pulsing
function will continue, when timed out the
pulsing function will stop. Valid entry range is
0.0 to 99.9 seconds.
Frequency – This is the pulsing frequency in
Hertz. Valid entry range is 0.5 to 300.0 Hz.
Pulse On % – This value determines the Peak
time as a percentage of the period of the pulse
cycle. In other words, if the frequency is 10 Hz,
the period is 100ms:
1
Period (in secs) = --------------------
Frequency (in Hz)
If the Pulse On%=70%, the Peak time will be
70ms and the Background time will be the
remainder, or 30ms. Valid entry range is 5% to
95%.
Pulse Back % – This value determines the
Background current level as a percentage of the
weld current set in the weld program (as in the
Weld Parameters screen). Valid entry range is
5% to 95%.
Preflow – This is preflow time of gases
controlled by the 9500 Gas output. Typically,
preflow time starts after touch retract and when
preflow times out, contact signal to start welding
power supply is issued. If touch retract is not
programmed, preflow will start when Start button
is pressed. Valid entry range is 0.0 to 99.9
seconds.
Postflow – This is postflow time of gases
controlled by the 9500 Gas output. Valid entry
range is 0.0 to 99.9 seconds.
Wire Retract – This is the filler wire retract time.
When the filler wire is stopped near the end of
the program, the wire will retract out of the weld
puddle at full speed for the amount of time in this
field. Valid entry range is 0.0 to 99.9 seconds.
9500-FW-MP-SER-PC

Part Diameter – For circumferential systems,

enter the part diameter in this field. The 9500
will use this value to calculate surface speed of
the piece part during the weld so that the Travel
values can be programmed in inches per minute
(IPM) or centimeters per minute (CPM) instead
of entering RPM values. If a zero (0) is entered
here, the programmed travel values (as in the
Weld Parameters screen) WILL BE in RPM
instead of surface speed. If a 0 is entered then the
travel parameters will have to be changed to
RPM values (in the Weld Parameters screen) or
the travel speed could go out of control due to
the high surface speed values.
Although the 9500 controller will automatically
recalculate these numbers as the part diameter
value is changed to 0, this program will not do
that, it only transfers the recorded values into the
9500 weld program data base. So anytime the
part diameter value is changed from or to 0, the
travel values in the Weld Parameters screen must
be changed accordingly.
Travel Direction – This value can be either Forward
or Reverse. Please note that for both Linear and
Circumferential 9500 systems using limit switches,
the system may not work as expected if
programming the travel direction in reverse. For
systems with cold wire feeders, the wire guide
positioner must be rotated 180 degrees around torch
when reversing travel direction.
Click on the “X” in the upper right to exit this screen
or click on the “Weld Parameters” button to go to
the Weld Parameters Edit screen.

CAUTION
If you have made changes, always click on the
“Save” button before leaving this screen or the
changes will be lost.

56
 9500-FW-MP-SER-PC

Weld Parameters for Program ID 61 (No EFC)

In this screen, the weld parameters can be edited.

The above example is for firmware not configured
for Enhanced Function (EFC). This means that there
is a single entry for the voltage channel (channel 2)
and that the travel channel and wire channel
(channels 3 and 4) have start and stop delay times
instead of sloping capability.
NOTE
It is up to the user to be certain that the entries for
the various weld parameters do not exceed the limits
of calibration for the particular system. This
program is not tied into the calibration section of the
9500 controller. If a parameter entry exceeds the
calibration limit, the 9500 defaults to the system
maximum or minimum value as set in the calibration
section.

57
9500-FW-MP-SER-PC
Auxiliary Status – There are two auxiliary outputs
on the 9500 (aux 1 and aux 2) that can be
programmed to turn on during the weld. What these
outputs control depends on how the system is wired.
In some cases there may not be anything connected
to these outputs. Common functions are magnetic or
mechanical oscillator, auxiliary drive axis, hot wire
power supply, etc.
AUX 1 – A check in this box enables the aux 1
contact to come on during the weld. When it
turns on and off is determined by the delay times
below.
Start Delay – This timer start timing with the Arc
On signal and when it times out, Aux 1 contact
will turn on. Valid entry range is 0.0 to 99.9
seconds.
Stop Delay – This timer starts timing with the
Downslope signal (when the Weld Timer times
out, or Taper timer if programmed, or when the
downslope limit switch is engaged, or when the
encoder count is reached, or when the Stop
button is pressed). While timing, the Aux 1
output will remain active, when timed out the
Aux 1 contact will drop out. Valid entry range is
0.0 to 99.9 seconds.
AUX 2 – A check in this box enables the aux 1
contact to come on during the weld. When it
turns on and off is determined by the delay times
below.
Start Delay – This timer starts timing with the
Arc On signal and when it times out, Aux 2
contact will turn on. Valid entry range is 0.0 to
99.9 seconds.
Stop Delay – This timer starts timing with the
Downslope signal (when the Weld Timer times
out, or Taper timer if programmed, or when the
downslope limit switch is engaged, or when the
encoder count is reached, or when the Stop
button is pressed). While timing, the Aux 2
output will remain active, when timed out the
Aux 2 contact will drop out. Valid entry range is
0.0 to 99.9 seconds.
58
ALC Start Delay – This timer starts timing with the
Arc On signal and when it times out, the ALC
controller will go into the Auto mode. Normally this
time should be equal to or greater than the Initial and
Upslope periods of the weld current, so the ALC is
not active while the weld current is changing and
until the arc has stabilized. Valid entry range is 0.0
to 99.9 seconds.
ALC Stop Delay – This timer starts timing with the
Downslope signal (when the Weld Timer times out,
or Taper timer if programmed, or when the
downslope limit switch is engaged, or when the
encoder count is reached, or when the Stop button is
pressed). While timing, the ALC controller will
remain active, when timed out the ALC will switch
back to the Manual mode. Normally, this time is 0
seconds so that the ALC will lock out (switch to
Manual) as soon as the downslope of weld current
commences. Valid entry range is 0.0 to 99.9
seconds.
Limit Sw Delay – This timer starts timing with the
Arc On signal and when it times out, the Downslope
(or Switchpass) limit switch input will become
active. This is used primarily in circumferential
systems where it is possible to start the weld with
both the Home and Downslope limit switches
engaged, when set to do a 360 degree weld. The
time normally entered here should be greater than
the time it takes the positioner to rotate past the
downslope limit switch after the arc strikes. If set for
too short a time, the weld (or pass) will end
prematurely. Valid entry range is 0.0 to 99.9
seconds.
Weld Monitor Delay – If this box is checked, the
Weld Monitoring option (if installed) will be
invoked for this weld or pass. Each channel has it’s
own monitoring start delay, as below, and can be
different from program to program or pass to pass.
The weld monitor Limits and Tolerance are global
and set in the System Config, Channel Controls
section in the 9500 firmware.
Current – Channel 1 – This timer starts timing
with the Arc On signal and when it times out,
Weld Monitoring on the Current channel will
commence. Valid entry range is 0.0 to 99.9
seconds.

Volts – Channel 2 – This timer starts timing with
the Arc On signal and when it times out, Weld
Monitoring on the Volts channel will commence.
Valid entry range is 0.0 to 99.9 seconds.
Travel IPM – Channel 3 – This timer starts
timing with the Arc On signal and when it times
out, Weld Monitoring on the Travel channel will
commence. Valid entry range is 0.0 to 99.9
seconds.
Wire IPM – Channel 4 – This timer starts timing
with the Arc On signal and when it times out,
Weld Monitoring on the Wire channel will
commence. Valid entry range is 0.0 to 99.9
seconds.
In the center column are the values for Weld
Current, Channel 1
Init Current Amps – This is the Initial Current field
which is the current that the arc will strike at. Valid
entry is a value between the system min and max
values for weld current, as dictated by the limits set
in the calibration section.
Init Time – This is the Initial Time field which is
how long the weld current will remain at the initial
value after Arc On. Valid entry range is 0.0 to 99.9
seconds.
Upslope Time – This is the amount of time that the
weld current will take to ramp from the Initial value
to the Weld value. Valid entry range is 0.0 to 99.9
seconds.
Weld Current Amps – This is the main welding
current value. The welding current will be at this
value throughout the Weld segment until the Taper
segment (if Weld Time is enabled) or Downslope
segment. When pulsing, this is considered to be the
Peak current. Valid entry is a value between the
system min and max values for weld current, as
dictated by the limits set in the calibration section.
Weld Time – This field is only displayed when the
Weld Time is enabled in the Setup screen. If the
weld time is not enabled, the end of the weld is
determined by when the downslope limit switch is
engaged, or when the encoder count is reached, or
when the Stop button is pressed). Enter the amount
of time for the main course of the weld. Valid entry
range is 0.0 to 9999.9 seconds.
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9500-FW-MP-SER-PC
Taper – This field is only displayed when the Weld
Time is enabled in the Setup screen. This is the
value of weld current that the program will ramp to
when the weld time expires. This is used primarily
for circumferential applications where it is desired to
taper down the weld current near the end of the
revolution, as the part is heating up from the weld.
Valid entry is a value between the system min and
max values for weld current, as dictated by the limits
set in the calibration section.
Taper Time – This field is only displayed when the
Weld Time is enabled in the Setup screen. This is
the amount of time it will take for the weld current
to ramp from the Weld current value to the Taper
value. Valid entry range is 0.0 to 9999.9 seconds.
Final Current Amps – This is the weld current value
that the main weld current will ramp down to at the
end of the weld (during downslope). Valid entry is
a value between the system min and max values for
weld current, as dictated by the limits set in the
calibration section.
Downslope Time – This is the amount of time the
weld current will take to ramp down from Weld
current to Final current. Valid entry range is 0.0 to
99.9 seconds.
Final Time – This is the time that the weld current
will stay at the final value after the Downslope
segment. Valid entry range is 0.0 to 99.9 seconds.
In the right column are the parameters for the Arc
Voltage, Travel and Wire channels (channels 2, 3
and 4, respectively, with the configuration in the
example).
Volts – Channel 2 – Enter the arc voltage value that
the program is to be at during the Weld segment
here. The ALC Start and Stop delays will override
arc voltage values during the upslope and downslope
portions of the weld. The ALC controller is usually
“locked out” (force manual mode) during these
periods where the weld current is changing
significantly. When pulsing with Background times
of more than 50 ms (equivalent to 10 Hz or less,
50/50 symmetry), the ALC controller will be locked
out during the background periods. At faster pulse
rates (less than 50 ms background periods), the ALC
controller will not be locked out during Background
periods and will average the acquired voltage
measurement.
9500-FW-MP-SER-PC
Travel IPM – This is the travel speed, during the
weld. Travel will start and stop as per the delays
below. For circumferential systems, this value is
surface speed in IPM (or CPM, if metric) IF the Part
Diameter field (in the Setup screen) has a non-zero
value. If a “0" is entered for Part Diameter, this
value will be in RPM. For linear systems, this value
is always linear travel speed in IPM (or CPM). If
Travel is disabled in the Setup screen, these values
are disregarded.
Start Delay – This timer starts timing with the
Arc On signal and when it times out, travel will
commence. Valid entry range is 0.0 to 99.9
seconds.
Stop Delay – This timer starts timing with the
Downslope signal (when the Weld Timer, or
Taper timer if programmed, times out, or when
the downslope limit switch is engaged, or when
the encoder count is reached, or when the Stop
button is pressed). While timing, the Travel will
continue, when timed out the Travel will stop.
Valid entry range is 0.0 to 99.9 seconds.
60
Wire IPM – This is wire feed speed, during the
weld. Enter this value in IPM, or CPM, if metric.
The wire will start and stop as per the delays below.
If wire is disabled in the Setup screen, these values
are disregarded.
Start Delay – This timer starts timing with the
Arc On signal and when it times out, the wire
feeder will start feeding. Valid entry range is 0.0
to 99.9 seconds.
Stop Delay – This timer starts timing with the
Downslope signal (when the Weld Timer, or
Taper timer if programmed, times out, or when
the downslope limit switch is engaged, or when
the encoder count is reached, or when the Stop
button is pressed). While timing, Wire will
continue, when timed out the Wire will stop and
retract, if retract time is programmed in Setup
screen. Valid entry range is 0.0 to 99.9 seconds.
CAUTION
If you have made changes, always click on
the “Save” button before leaving this screen
or the changes will be lost.
 9500-FW-MP-SER-PC

B. Edit Screen for EFC Option

From t h e
Single Pass Program List, Program 67 has been selected for Editing

This program has been uploaded from a 9500 with

the EFC (Enhance function Control option installed.

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Setup Screen for Program 67

Setup screen, Encoder option installed, no Weld

Monitoring, all channels active.

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Weld Parameters Screen for Program 67 (with EFC)

Note that with the EFC option, all channels have

upslope and downslope capabilities. There are no
Start and Stop Delays, but by putting “0" values in
the Initial or Final fields, the parameter will delay
for the period of time in the Initial Time or Final
Time fields.

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Timing Diagram for Program 67

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C. SP Program Timing Chart

To graph a single pass program, or at least create a
timing diagram of the beginning and ending values,
go to the Single Pass Programs listing, select the
program number, then click on the Edit Program
button:

In the example above, program ID 61 has been selected for graphing. Click on Edit Program, Weld
Parameters, then Timing Chart, as in the following:

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Click on WELD PARAMETERS Button

Click on TIMING DIAGRAM Button

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Sin gle
Pass Program ID 61 Timing Diagram

In the above diagram, the first four charts are for the This screen is meant for a simple quick view of the
four main channels, in this case, Weld Current, startup and ending of the main weld parameters. It is
Voltage, Travel and Wire. Below that are the Aux not designed for high accuracy representations. No
channels, “10" indicating aux output on and “0" editing or modifications are allowed from this
indicating aux output off. If compared to the editing screen.
screens the charts show the beginning and ending
segments, relative to each other, in seconds. The
main Weld segment is truncated so as to allow a
clearer view of the relatively shorter upslope and
downslope segments. 1024 X 768 resolution is
required to fully view this screen.

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D. Copy Single Pass

Programs
Programs can be copied in the Single Pass Programs
listing screen. To copy the contents of an existing
program into another existing program (overwriting
it), click on the “Copy” button.

Click on the COPY PROGRAM Button

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To Copy Contents of Program ID 62 into Existing Program ID 53, enter the Source and Destination Numbers
and Click on Copy.
This will copy the contents of program 62 into 53, overwriting all weld parameters in program 53.

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Click on YES to Overwrite

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Note that the Program ID, Program Name, To change the Names and Descriptions of 53, click
Description and Date remain the same for Program on the EDIT button in the lower half of the screen.
53. Only the Program ID in 9500 is transferred over
from 62 as part of the weld parameters. All other
weld parameters from 62 have now been copied into
53.

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9500-FW-MP-SER-PC

Make the changes in the yellow fields near the top of the screen, then click on UPDATE

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New names and descriptions have been entered and saved

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9500-FW-MP-SER-PC

E. Print Single Pass

Programs
Single Pass Programs can be printed using the
Windows default printer. All information in the
Names, Description, Setup and Weld Parameters
screens are printed out in a single report. Select the
desired program to print from the Single Pass
Program listing, then click on Edit Program:

Single Pass Program 61 Setup screen. Click on PROGRAM REPORT to print the report

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Single Pass Program 61 Print Preview

The print preview screen appears before the printing.

From this screen you can zoom the preview in or out
by clicking on the Zoom option pulldown. To print,
click on the Print icon in the upper left corner.
This data may also be exported as an HTML (.hml)
or Text (.txt) file by clicking on the Export icon (to
the right of the print icon). The HTML file may be
opened later using an Internet browser. The Text file
can be used by various word processor programs or,
with a little work by the user, can be imported into
Excel for program record storage and further
graphing ability.

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9500-FW-MP-SER-PC

Section IX

PC Edit Option - Multi Pass

What CAN be edited in the Multi Pass PC Edit
A. Edit Multi Pass Programs program are the pass transition types and transition
times, Auxiliary delays, Auto Start times and the
ability to completely edit each of the passes
If the multi pass option is installed, the multi pass including Setup values, Weld Parameter values with
programs can be edited in a similar, but limited print out and timing diagram, similar to the Single
fashion to the single pass programs in Section VIII. Pass editing section above.
A multi pass weld program is simply an index of
single pass weld programs that is used to provide the Once a multi pass program library has been started
9500 with instructions on what order to run single as in Section VI, a Program can be selected from the
pass programs and whether the program will stop Multi Pass screen for editing by clicking on the
between passes or continue welding from pass to Program ID line, then clicking on the Edit Program
pass without stopping. The single pass programs can button (in the upper right corner) as below:
be scheduled to run in any order and any single pass
program can be run more than once in each multi
pass schedule. There is a limit of 25 passes in each
multi pass program. All of this program information
must be established in the 9500 controller before
uploading to the 9500 SERPC program.
When the multi pass program is uploaded to the
9500 SERPC program, the multi pass index AND all
of the related Single Pass programs are uploaded
from the 9500 into a single file contained in the
Multi Pass portion of the 9500 SERPC program. In
the PC Edit program it is not possible to change the
order of the passes or add or delete passes. In
addition, the weld parameters in the multi pass
structure are NOT related to any of the programs in
the Single Pass portion of the PC Edit program. The
Multi Pass portion is completely separate from the
Single Pass portion. No data is ever transferred
between the two sections, they are separate.

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Click o n
the EDIT PROGRAM button to edit

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9500-FW-MP-SER-PC

Multi Pass Editing Screen (Pass Wait Disabled)

This is the editing screen for the multi pass weld single pass programs 1, 3 and 5 will be overwritten
programs. Description of fields follow: with the data contained in this multi pass schedule,
in order to support the list in this field.
Program Name – This is the program name that was
entered into the 9500 at the time the program was When running this schedule in the 9500, Single Pass
created. This name is displayed in the program list program 1 will run in the first pass, SP program 5
of the 9500 controller and is also displayed in the will run in the second pass, and SP program 3 will
“Program ID in 9500" column in the Multi pass run in the third and final pass. Up to 25 passes can
portion of the 9500 SERPC program, as on the page be listed here.
above. This field can be edited here.
Click on the desired program number to see the
Total Single Pass Programs – This field is a related information on the rest of the screen. This
calculation and can not be changed here. This is selects the pass. Note that in the screen above, pass
simply indicating the number of passes in the multi 1 is selected. The information in this field can not be
pass program, as it was created in the 9500. In the edited in the PC program.
example above, it is a 3 pass program.
Single Pass ID in 9500 Controller – This list is
showing the order in which the Single Pass
programs will be run in the Multi Pass schedule. The
numbers in this list are the 9500 program numbers in
which the single pass programs were stored when
the program was uploaded to the PC software. Any
time that this multi pass program is downloaded to
the 9500 (Restore to 9500), these single pass
programs will be put back into these slots,
overwriting anything that happens to reside in them
at the time. When restoring to 9500 in this case,

78

Pass Wait – Checking this box will Enable Pass
Wait meaning that at the end of the selected pass,
downslope and final values will be followed and the
arc will extinguish. In this mode the next pass is
automatically called up and the 9500 waits for the
operator to press the Start button to start the next
pass or, with the Autostart feature, a timer can be
called up which, when it times out, the next pass will
automatically start. The initial and upslope values
will be followed in the next pass.
If the box is unchecked it means that the Pass Wait
is Disabled. In this mode the it means that the weld
will not stop at the end of the pass (unless it is the
last pass) and will not follow the downslope and
final segments of the selected pass nor will it follow
the initial and upslope values of the next pass. The
weld will go from the weld segment of this pass
directly to the weld segment of the next pass.
Transition Output Contact – There is a relay contact
output from the 9500 that can be programmed to
turn on during the transition time. This contact is not
used in all systems, but can be connected to a linear
drive unit that can move the torch over slightly
during the transition period for overlay welding, or
move the torch up at the end of each pass for
multipass deep groove welding, etc. Checking the
box will enable the relay, it will be on for the
transition time programmed below.
Transition Time – The transition time is the period
of time for all of the weld parameters to go from the
main weld segment of the selected pass to the weld
segment of the next pass. For instance, if the weld
current is 100 amps in the selected pass and is 200
amps in the next pass, the weld current will go from
100 to 200 amps in the amount of transition time
entered. If the transition time is 0, the weld current
will step from 100 to 200 instantly. If the transition
time is 3 seconds, the weld current would slope from
100 amps to 200 amps in 3 seconds. The same is
true for all of the channels programmed (voltage,
travel, etc). Valid entry range is 0.0 to 999.9
seconds.
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9500-FW-MP-SER-PC
AUX 1 Delay – Because in the Pass Wait Disabled
mode the beginning and ending segments are
skipped, any auxiliary start and stop delays
programmed in the Weld Parameters screen will not
be valid due to the fact that they are tied to Arc On
and Downslope points. In this field the Aux output
can be toggled at a time starting at the beginning of
the transition period. For example, if the Aux 1
output is off in the selected pass and on in the next
pass, and the transition period is 3 seconds, entering
1.5 seconds for the Aux 1 Delay will cause the
auxiliary 1 output to turn on half way through the
transition from current pass to next pass. Entering 0
will turn on Aux 1 at the beginning of transition,
entering 4 seconds will turn on Aux 1 one second
after the program is in the next pass.
If the Aux 1 output is on in the selected pass and off
in the next pass, the Aux 1 output will stay on until
the Aux 1 Delay times out, then turn off.
If the Aux 1 output is off in the selected pass and off
in the next pass also, it does not matter what is
entered here. Same thing if Aux 1 is on in both
passes. Valid entry range is 0.0 to 999.9 seconds.
AUX 2 Delay – See the AUX 1 Delay description
above.
CAUTION
If you have made changes, always click on
the “Save” buttons before leaving this screen
or the changes will be lost.
9500-FW-MP-SER-PC

M ult
i Pa
ss Editing Screen (Pass Wait Enabled, No Auto Start)

Description of fields for the Pass Wait Enabled

without Auto Start is the same as the descriptions
above for Pass Wait Disabled except, because there
is not timed transition between passes, all of the
fields relating to transition have been removed.
When the pass is programmed in this manner, the
current pass ends normally with downslope, final
and postflow segments, then calls up the next pass
and waits for the operator to push the Start button.

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Multi Pass Editing Screen (Pass Wait Enabled, with Auto Start)

Description of fields for the Pass Wait Enabled with Inter Pass – This timer starts timing at the end of
Auto Start is the same as the descriptions above for postflow in the selected pass. When it times out, a
Pass Wait Enabled without Auto Start except, now start command will be issued to start the next pass.
there is an Inter Pass time field. Note that the second Advise caution if programming this mode, as if the
pass is now selected (SP ID #5). At the end of the operator is not careful the arc could strike when he
second pass in the example the weld will stop is not ready. The Transition Output Relay could be
normally using the downslope, final and postflow used to trigger a signaling device. Valid entry range
segments. After postflow times out, the Inter Pass is 0.0 to 999.9 seconds.
timer will start timing. When this times out, the third
pass will automatically start. In this example, there
is a 30 second delay.
Auto Start – Checking this box will call up the Auto
Start routine for the end of the selected pass (second
pass in example) and beginning of next pass (pass 3
in example). When checking this box the Transition
Output Contact and Inter pass fields will appear.
Advise caution if programming this mode, as if the
operator is not careful the arc could strike when he
is not ready. The Transition Output Relay could be
used to trigger a signaling device.

Transition Output Contact – Checking this box will

turn on the Transition Output Relay during the Inter
Pass period.

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B. Edit Selected Pass

Select Pass Number to Edit, then click on EDIT SELECTED PASS

Each of the single pass programs that are called up
in the multi pass schedule can be edited in the same
manner as in the Edit Single Pass section earlier.
Remember that these three passes in the example
above are NOT associated with any of the single
pass programs in the Single Pass section. All three
of these passes will be downloaded to the 9500
when the multi pass program is downloaded
(Restore 9500), overwriting what ever is in the 9500
#1, #3 and #5 program slots.
Although each pass may be edited completely, the
order of the passes can not be changed and no new
passes can be added or any passes deleted from this
program unless it is downloaded to the 9500 for
editing.
Following are editing screens for Pass 3, above:

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Setup Screen for Pass 3, Cap Pass

Edit this pass as you would any pass in the Single

Pass section. This is the 3rd and final pass of the
example program called the Cap Pass. All channels
enabled, feeding wire, no pulsing, weld time
enabled. Program Report is available (for each pass).
Click on the WELD PARAMETERS button to edit
weld parameters for this pass.

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9500-FW-MP-SER-PC

Weld Parameters Screen for Pass 3, Cap Pass

Edit weld parameters of pass 3, Cap Pass here, as

you would in the Single Pass editing section.

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 9500-FW-MP-SER-PC

C. Copy Multi Pass

Programs
Multi Pass programs can be copied in the same
manner as in the Single Pass editing section. From
the Multi Pass listing screen, click on the COPY
PROGRAM button:

Click on the COPY PROGRAM button to copy Multi Pass Program

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9500-FW-MP-SER-PC

Enter the Source and Destination Program ID Numbers

Click on COPY

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 9500-FW-MP-SER-PC

Click on YES to Verify the Overwrite

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9500-FW-MP-SER-PC

Click on the X on the Copy Subscreen to Clear (do not click on COPY again)

Multi Pass Program 100 has now been copied over

to MP Program 50, overwriting the contents of the #
50 program. All of the multi pass data and all of the
related Single Pass weld parameters data have been
copied over. As in the Single Pass editing screens,
the “Program ID in 9500" data has been copied over
with the weld parameters and the Program ID,
Program Name and Description fields remain as
original. To make changes in the names and
description fields, select the program to be changed
by clicking on the row, then click on the EDIT
button in the lower half of the screen.

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Section X

Electrical Drawings

89
 9500-FW-MP-SER-PC

DB9 FEMALE DB9 FEMALE

P1 P2

2 3
TO 3 2 TO

90
9500 5 5 PC