Lincoln Electric SPIRIT II 400 User Manual (English)

Questions and Answers:

M
Michelle ShieldsAug 16, 2025
Why is there no arc at the torch of my Lincoln Electric SPIRIT II 400?
- J
  Jermaine HallAug 16, 2025
  If there is no arc at the torch of your Lincoln Electric Welding System, several factors could be responsible: * Incorrect torch consumables might be installed. Ensure you install the correct torch consumables. * Incorrect gas pressure settings may be in place. Check and adjust the gas pressure settings. * The pilot arc transistor (PAT) may not be operating correctly. Check the PAT LED (D43) on the DSP microprocessor board. * There might be damaged or loose torch lead connections. Inspect and secure these connections. * The torch or torch leads could be shorted. Check the continuity between the Electrode lead and the Nozzle lead. * The torch or torch leads could be open. Check the continuity from the Electrode lead to the torch electrode.
E
Ellen ColeAug 19, 2025
How to fix a Lincoln Electric Welding System when the power supply indicator won't illuminate?
- M
  Mr. David SimsAug 19, 2025
  If the power supply indicator on your Lincoln Electric Welding System does not illuminate, here are several things to check: * A blown primary disconnect fuse. You should check and replace the primary disconnect fuse. * A blown internal power supply fuse (F1A, F1B). Check and replace the internal power supply fuse. * A burned-out power supply indicator light or bad associated wiring. Inspect and replace the power supply indicator light or repair the wiring. * A bad Control Transformer or associated wiring. Inspect and repair the Control Transformer or wiring.
D
derek69Aug 22, 2025
What to do if the Lincoln Electric Welding System power supply won't energize?
- K
  Karen HortonAug 22, 2025
  If your Lincoln Electric Welding System's power supply won't energize after moving the pointer to ON and pressing the select button on the MGC, consider these potential causes: * The ASC door may be open. Ensure the ASC door is closed. * The coolant level might be low. Check and refill the coolant level. * A fuse may be blown (F1-F6). Check and replace any blown fuses. * The Off Button or its wiring could be faulty. Inspect and repair the Off Button or wiring. * The Off Relay might be faulty. Replace the Off Relay.
M
mthomasAug 25, 2025
Why gas pressures will not adjust properly on Lincoln Electric SPIRIT II 400 Welding System?
- A
  Anna DavisAug 25, 2025
  If the gas pressures on your Lincoln Electric Welding System will not adjust properly, consider the following: * Incorrect consumables installed in torch. Replace consumables with the correct type. * Loose pressure transducer cable on PC board in the MGC. Inspect and secure the pressure transducer cable. * Check connectors on the MGC valve associated with the malfunction. Inspect and secure connectors on the MGC valve.
J
Jennifer GonzalezAug 27, 2025
How to troubleshoot arc transfer issues to the workpiece with a Lincoln Electric Welding System?
- J
  Jill WoodAug 28, 2025
  If the arc will not transfer to the workpiece when using your Lincoln Electric Welding System, consider the following: * A loose work ground connection. Ensure the work ground connection is secure. * The pierce height being too high. Adjust the pierce height. * Incorrect, damaged, or worn consumables. Inspect and replace any incorrect, damaged, or worn consumables.
N
Nathan CarneyAug 30, 2025
What causes a Lincoln Electric SPIRIT II 400 power supply to not stay on?
- K
  Keith Taylor MDAug 30, 2025
  If the power supply of your Lincoln Electric Welding System does not stay on after moving the pointer to ON and then pressing the select button on the MGC, the issue may be: * A faulty DSP board. Replace the faulty DSP board. * A faulty Off Relay. Replace the Off Relay.
A
Aaron JohnsonSep 2, 2025
Why is the manual gas console screen blank on my Lincoln Electric SPIRIT II 400 Welding System?
- N
  Nicole OrozcoSep 2, 2025
  If the manual gas console screen is blank on your Lincoln Electric Welding System, check the following: * Verify the connection of the power/communications CAN cable on the back of the manual gas console. * Inspect and replace any blown DIN rail fuses. * Measure and ensure 120v is present on the CAN cable pins at the back of the manual gas console.
P
Patrick KingSep 5, 2025
What to do if the manual gas console screen is on, but the screen doesn't work on Lincoln Electric SPIRIT II 400?
- S
  Sarah CamposSep 5, 2025
  If the manual gas console screen is on but not working on your Lincoln Electric Welding System, try these steps: * Power cycle the Spirit system. * Inspect and reconnect the ribbon cable that connects the keypad to the DSP PCB in the manual gas console.
R
Richard KnightSep 7, 2025
Why is liquid leaking from the torch handle of my Lincoln Electric SPIRIT II 400 Welding System?
- A
  Allison MillsSep 7, 2025
  If you observe liquid or torch coolant leaking from the drain hole in the torch handle of your Lincoln Electric Welding System: * Infrequent dripping may be condensation, requiring no action unless the leakage worsens. * Noticeable flow indicates a problem with the torch leads and/or connections. Check for damaged or loose torch lead connections within the torch handle.
J
Jonathan WigginsSep 10, 2025
What causes a low pressure error on a Lincoln Electric SPIRIT II 400 Welding System?
- J
  Jennifer Wright DDSSep 10, 2025
  A low pressure error on your Lincoln Electric Welding System can be caused by: * Supply gas pressure(s) less than 120 psi. Verify and increase supply gas pressure to at least 120 psi.

Lincoln Electric SPIRIT II 400 Specifications

General

Brand	Lincoln Electric
Model	SPIRIT II 400
Category	Welding System
Language	English

Summary

Section 1: Safety

General Precautions

Ensures operator and bystander safety during plasma cutting operations. Requires qualified personnel for installation and service.

Toxic Fume Prevention

Highlights the need for ventilation and breathing equipment when cutting hazardous materials.

Electric Shock Prevention

Warns about high voltages and provides guidelines for safe electrical connections and handling.

Fire Prevention

Advises on maintaining safe distances from flammable materials and ensuring fire extinguisher accessibility.

Explosion Prevention

Covers safe handling of compressed gases and potential hazards with specific gas mixtures.

Section 2: Specifications

System Description

System Components

Lists all standard and optional components included in the Spirit II 400 system.

Power Supply Specifications

Details electrical specifications, input voltage, current, and physical dimensions of the power supply.

Cooling System Specifications

Manual Gas Console (MGC) Specifications

Gas Supply Requirements

Outlines the required gas types, flow rates, and pressures for plasma cutting operations.

Arc Starting Console (ASC) Specifications with Remote High Frequency (RHF)

Arc Starting Console (ASC) Specifications with CleanStrike™ Technology

Section 3: Installation

Component Placement

Provides instructions on properly positioning and installing the plasma power supply.

Manual Gas Console (MGC) Placement

Arc Starting Console (ASC) Placement

Torch Installation

Cooling System Installation

System Interconnection

Explains how to plan and connect system components using diagrams and cable identification.

Power Supply Primary Power Connections

Details how to safely connect the primary power supply, including disconnect switch and fuse sizing.

Power Supply Output Connections

Guides the connection of power supply output leads to the arc starting console and work table.

ASC Control Cable and ASC Ground Connections

Cooling System Connections

Torch Leads to Arc Starting Console Connections

Explains how to connect torch leads, including braided shield, to the arc starting console.

Torch Leads to Torch Base Connections

Provides instructions for connecting torch leads to the torch base components.

Torch Gas Connections

Guides the connection of torch gas hoses to the manual gas console, torch base, and manifolds.

Gas Supply Connections

CNC Machine Interface Connections

Filling the Cooling System

Provides a step-by-step procedure for filling the system's cooling reservoir with coolant.

Section 4: Operation

Operating the Manual Gas Console (MGC)

Explains the function of the MGC, its display, buttons, and regulator knobs.

Setting up to Cut

Guides the user through setting up the system parameters for cutting operations.

Setting up to Mark

Details the procedure for configuring the system for marking operations.

Verifying Input Gas Pressures

Describes how to check and verify input gas pressures are within acceptable ranges.

Input Gas Pressure Error Messages

Making a Cut or Mark

Explains the final steps and sequence initiation for starting a cut or mark.

Piercing Thick Materials

Moving Pierces and Edge Starts

Cut Quality

Offers guidelines for achieving optimal cut quality and adjusting parameters.

Section 5: Torch Consumables and Cutting Charts

Installing / Removing the Torch Head

Provides instructions and safety precautions for attaching and detaching the torch head.

Installing / Replacing Consumables

Details the process for installing and replacing torch consumables like nozzles and electrodes.

Maximizing Consumable Life

Offers guidelines to extend the lifespan of torch consumable parts.

Inspecting for Damage

Selecting Consumables

Presents charts for selecting the correct consumables based on material, amperage, and gas type.

Cutting Charts

Provides recommended cutting parameters for various materials, thicknesses, and amperage settings.

Section 6: Maintenance & Troubleshooting

Routine Maintenance

Power Supply Maintenance

Details cleaning and connection checks for the power supply unit.

Cooling System Maintenance

Covers checking the coolant filter and flushing the cooling system.

Manual Gas Console (MGC) Maintenance

Describes cleaning and checking connections for the manual gas console.

Torch, Torch Leads, and Gas Hoses Maintenance

Covers verifying connections, inspecting leads, and checking torch base integrity.

Arc Starting Console (ASC) Maintenance

Details checking ASC leads, hoses, and spark gap electrodes.

Replacing the Torch Coolant and Filter

Provides a procedure for flushing and replacing the torch coolant and filter cartridge.

Power Supply Microprocessor (DSP) Status Indicators

Lists LEDs on the DSP board and their corresponding indications for troubleshooting.

Power Supply Microprocessor (DSP) Sequence of Operation

Error Codes

Lists comprehensive error codes for the Spirit system and their descriptions.

General Troubleshooting

Provides common troubleshooting guidelines for system issues like power or arc problems.

Chopper Test Procedure

Section 7: Parts List

Power Supply (BK300234 - BK300239) Right Side View

Power Supply (BK300234 - BK300239) Left Side View

Power Supply (BK300234 - BK300239) Top View

Cooling System (BK300275)

Manual Gas Console (BK300610) Right Side View

Manual Gas Console (BK300610) Left Side View

Arc Starting Console (BK284500) with Remote High Frequency (RHF)

Lists components of the ASC with RHF, including fittings, transformers, and capacitors.

Arc Starting Console (BK300505) with CleanStrike™ Technology

Details components of the ASC with CleanStrike™ Technology, including fittings and PCBs.

Torch and Manifold Assemblies

PCB Assemblies – Component Reference Locations

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Lincoln Electric SPIRIT II 400 User Manual

Table of Contents