Aftermarket electrode, nozzle, shield, swirl ring and retaining cap kit for Kjellberg HY200A-400A plasma cutting torches.
HALANSM® HY200A-400A kit is an aftermarket, full-wear-stack replacement for Kjellberg® HY200A through HY400A plasma torches, covering 35-400A across low-current and high-current builds. It includes the silver-core cathode, copper-alloy nozzle, brass shield cap, swirl gas guide and retaining cap so maintenance teams can restore arc stability and cut quality from one order.
Product Overview
The consumables mount at the front of the HY200A-400A torch and form the plasma arc together. The silver-core electrode initiates and sustains the arc, the copper nozzle focuses the gas jet, the swirl ring spins the gas into a stable vortex, and the shield cap protects the assembly from molten spatter. A worn stack shows up immediately as wider kerf, dross, arc misfire or shortened electrode life.
Replacing the full stack together keeps the seat geometry and O-ring sealing consistent, which matters more at 300-400A where thermal load is highest.
Key Advantages
Silver-Core Electrode
Hafnium emission point on a copper body with a silver contact face improves conductivity and ignition stability across 35-400A.
Focused Copper Nozzle
Precision bore channels the plasma jet coaxially, giving clean edges on mild steel, stainless and aluminium.
Vented Brass Shield
The shield cap dissipates heat through its body and perimeter while deflecting spatter away from the nozzle seat.
Current-Matched Stack
Low-current (35-200A) and high-current (300-400A) parts use different bore, seat and O-ring geometry; selecting the right set prevents poor cuts and rapid wear.
Copper alloy, brass, hafnium, silver; O2, N2, Air, Ar/H2 (select by gas type)
Individual bore size and thread pitch vary by OEM part number; provide your torch model and original part number for an exact match.
Compatible Equipment / Application
Verified for Kjellberg® HY200A, HY280A, HY360A and HY400A mechanised plasma cutting systems. These aftermarket parts are commonly used on CNC tables cutting mild steel, stainless steel and aluminium plate.
If your torch is a different sub-model, provide your head model and original part number for fitment check.
Selection Guide
35-200A low-current stack
Electrode F012/F005/F006, nozzle F2007-F2017, shield F4020/F4030/F4040, cap F3028, swirl ring G101C, cooling tube F902.
300-400A high-current stack
Electrode F022/F024, nozzle F2227/F2230/F2231/F2628(L), shield F4250/F4255, cap F3209/F3219/F3249, swirl ring G121C, cooling tube F921/F963.
Warning: low-current and high-current parts differ in bore, seat and O-ring geometry. Do not mix them, and choose O2 versus Air/N2/ArH2 nozzles by your gas.
Installation and Handling
· Power down the plasma source and bleed all gas pressure from the torch.
· Remove the worn cap, nozzle, electrode and swirl ring as one assembly.
· Clean the seat and threads with compressed air; check O-rings for dryness or damage.
· Fit the new silver-core electrode, seat the swirl ring and align the nozzle coaxially.
· Hand-tighten the retaining and shield caps without over-torquing the brass threads.
· Run a low-amperage test cut and confirm arc stability before full production.
Frequently Asked Questions
Are HALANSM® HY200A-400A parts original Kjellberg® products?
No. They are aftermarket compatible replacements. Kjellberg® is a third-party trademark used here only for fitment identification; no original-equipment authorisation is claimed.
What is the difference between the 200A and 400A stacks?
The 400A set uses a larger vented shield, heavier cooling tube and wider nozzle bore for higher thermal load. Mixing the two causes poor cuts and fast electrode wear.
Why does the electrode use a silver core?
The silver contact face improves conductivity and heat transfer, while the hafnium tip sustains the arc. This combination extends service life under continuous cutting.
How do I choose the correct nozzle?
Match nozzle bore to material thickness, amperage and cutting gas. O2 nozzles are not interchangeable with Air/N2/ArH2 nozzles. Share your setup and we will cross-reference it.
Which torch models accept this kit?
Kjellberg® HY200A through HY400A torches are verified. For other sub-models, send your head model and original part number for a fitment check.
How should consumables be stored?
Keep them dry and clean, with O-rings lightly lubricated. Inspect for dents, corrosion and non-round holes before installation.
Related Products
From the official HALANSM® Kjellberg consumables catalog:
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