Aftermarket Water Tube Replacement — Copper, for HiFocus 280i / 360i / 440i neo
HALANSM® HLN-G902Y is an aftermarket plasma cooling tube in copper, built for Kjellberg HiFocus 280i / 360i / 440i neo torches to carry cooling water through the electrode seat and keep the arc front stable at 280–400A.
Replacing a Kjellberg G902Y water tube with HALANSM® HLN-G902Y means the same copper body and the same seat geometry, so cooling water reaches the electrode without leaking past the torch neck — one of the first things to check when a torch overheats between nozzle changes.
Product Overview
The cooling tube sits inside the torch body behind the electrode. Cooling water flows through it, out across the electrode base, and back through the return path. Its job is to carry heat away from the arc root before the copper softens.
On HiFocus 280i / 360i / 440i systems the tube also sets the electrode seating depth. A tube that sits too deep or too shallow moves the electrode off the gas-guide centerline, and the arc wanders from the first pierce.
Three things the tube controls:
Electrode seat cooling — keeps the hafnium insert from overheating
Water sealing — no drip at the torch-neck joint
Electrode concentricity — sets how straight the arc column runs
This is a water tube, not an electrode, nozzle, shield or swirl ring. Mixing it up with the nozzle cap is the most common fitment error on this stack.
Key Advantages
Copper Body, Same as the Original
Copper carries heat at the electrode seat. The HALANSM® HLN-G902Y uses copper alloy to match the thermal load at 280–400A on HiFocus class systems.
Seat Geometry Matches .11.852.201
The shoulder, tube length and end form follow the G902Y format, so the electrode seats at the correct depth and the water seal sits where the torch neck expects it.
Batch-Checked for Leaks
Every batch is pressure-checked before dispatch. A tube that leaks at the neck joint ruins more than cut quality — it takes the torch out of service.
Aftermarket, Not Original
HALANSM® parts are aftermarket consumables compatible with Kjellberg references. They are not sold as original Kjellberg parts and no original manufacturer authorization is claimed.
Specifications
Label
Value
Part Type
Cooling tube / water tube
OEM Reference
G902Y / .11.852.201.142
Material
Copper alloy
Install Position
Inside torch body, behind the electrode
Length
Confirm exact specs with us
Inner Diameter
Confirm exact specs with us
End Form
Confirm exact specs with us
Working Pressure
Confirm exact specs with us
Temperature Range
Confirm exact specs with us
Coating
Confirm exact specs with us
Brand Marking
Confirm exact specs with us
Compatible Equipment
Verified stack match — the supplier listing calls out these three systems directly:
Kjellberg HiFocus 280i neo
Kjellberg HiFocus 360i neo
Kjellberg HiFocus 440i neo
Provide your torch model and original part number for fitment check before ordering. The G902Y shares the .201 prefix family with other low-to-mid current consumables, but that does not make every .201 part interchangeable.
Selection Guide: Which Water Tube for Which Current Band
Part
Ref Prefix
Current Band
Use
G901Y
.11.848.201
35–200A
Water tube for 20–200A stack
G902Y
.11.852.201
280–400A
Water tube for HiFocus 280i / 360i / 440i
G931Y
.11.848.401
280–360A
Water tube for .401 family stacks
G971
.11.848.411
280–400A
Water tube for Ar/H2 and O2 stacks
Do not fit a .201 family tube into a HiFocus 440i stack, and do not assume G902Y and G971 are the same part — the ref prefix and end form differ. Confirm exact specs with us for your torch before choosing.
For 360A swap the electrode to G034Y and the nozzle to G2330Y. For 400A use G2331Y. The water tube stays G902Y across the 280–400A band on this stack.
Installation and Handling
Replacing a cooling tube is not the same as swapping a nozzle. Water and gas lines must be isolated before the torch is opened.
Power down the plasma system and isolate the torch from the power source.
Shut off the cooling-water supply and release pressure from the lines.
Release gas pressure from the plasma and swirl gas lines.
Remove the nozzle cap, gas guide and electrode, then pull the worn cooling tube from the torch body.
Inspect the torch-neck seal and the electrode seat for scale or scoring.
Insert the new HLN-G902Y, seat the electrode, gas guide, nozzle and caps in order, hand-tight only — then run a low-current test cut before full 280–400A production.
Storage and Service Life
Store tubes dry, away from cutting dust and moisture
Keep the tube ends capped so scale does not build up inside
Replace if the copper shows green corrosion, the end form is deformed, or the neck joint weeps
A tube that looks clean but the torch overheats usually has internal scale — replace it
Batch inspection and consistent tolerance are how HALANSM® keeps these parts reliable. No life-multiple or pass-rate claim is made, and no original manufacturer grade is implied.
Frequently Asked Questions
Is the HLN-G902Y a water tube or a nozzle?
It is a cooling tube — the copper pipe that carries water behind the electrode. It is not the nozzle, the nozzle cap or the swirl gas cap, even though all four sit close together in the stack.
Which Kjellberg systems use the G902Y water tube?
The supplier listing verifies HiFocus 280i, 360i and 440i neo. FineFocus, PerCut, CUTFire and PA-S are listed in the full catalog but not confirmed for this exact part — provide your torch model and original part number for fitment check.
Can I use G902Y instead of G901Y?
Only if your torch runs the .11.852.201 high-current front end. On 35–200A stacks use G901Y — the prefixes and end forms differ, so they are not interchangeable.
What goes wrong when the cooling tube fails?
The electrode overheats first: the hafnium insert pits faster, the arc wanders off-center and piercing becomes unstable. A leaking neck joint can also take the torch out of service entirely.
Why does my torch overheat even with a new nozzle?
Check the cooling tube before the nozzle. Internal scale blocks water flow while the outside still looks clean. Replace the tube and confirm the water path is clear.
How should spare cooling tubes be stored?
Dry cabinet, both ends capped, no cutting dust. Inspect the end form and the neck seal before fitment — do not fit a tube that has been dropped on either end.
Related Products
From the official HALANSM® Kjellberg consumables catalog:
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