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HALANSM® Gas Guide G102 Swirl Ring .11.848.221.146 for Kjellberg Plasma Cutting Torch Consumables Replacement
HALANSM® HLN-G102 Gas Guide Swirl Ring .11.848.221.146 for Kjellberg® HiFocus
Aftermarket G102 gas guide / swirl ring, 60-200A, vespel insulator
HALANSM® HLN-G102 is an aftermarket plasma gas guide / swirl ring with copper body and vespel insulator, built for Kjellberg® HiFocus 280i, 360i and 440i torches to deliver stable arc and clean cuts.
Product Overview
HALANSM® HLN-G102 is the gas-guide element in the Kjellberg® HiFocus front stack, referenced as G102 / .11.848.221.146. It sits between the electrode and the nozzle, spins the plasma-forming gas into a controlled vortex, keeps the arc column centred in the nozzle bore and isolates the gas path from the electrode body. Its job is arc stabilisation, not workpiece shielding - fit the correct swirl gas cap separately.
G102 covers 60-200 amp. Published materials include both vespel and ceramic types, so confirm the exact insulator type with us before ordering. Note the related G101C gas guide: that part covers 20-200A and carries a different insulator type, so the two are not interchangeable even though both sit in the same stack position.
Key Advantages
Stable Swirl at 60-200A
G102 is the 60-200A gas guide in the HiFocus 20-200A stack. Its swirl geometry holds the arc column coaxial in the nozzle bore, which controls kerf width and edge squareness on medium-thickness plate.
Vespel or Ceramic Insulator
The insulator is offered in both vespel (high-temperature polyimide) and ceramic. Vespel stays dimensionally stable at temperature and has low wear and friction; ceramic gives higher temperature resistance. The two are not interchangeable, so name the type you need when ordering.
Coaxial Seat Tolerance
The seat and bore are checked by lot for consistent tolerance. A square seat is what lets the electrode, gas guide and nozzle stay coaxial after reassembly - the single biggest factor in clean restart cuts.
Aftermarket, Not Original Equipment
HALANSM® HLN-G102 is an aftermarket replacement supplied against the original G102 reference. It is not an original Kjellberg® part and no original-equipment authorisation is claimed.
Specifications
Specification
Value
Part type
Gas Guide / Swirl Ring
OEM reference
G102 / .11.848.221.146
Body material
Copper alloy
Insulator material
Vespel or ceramic (confirm exact type with us)
Amperage
60-200A (G101 / .11.848.221.145 is 20-35A; G101C / .11.848.221.145C is 20-200A)
Gas
O2; N2 and Air nozzles are separate gas-specific SKUs
HALANSM® HLN-G102 is verified for the Kjellberg®HiFocus 280i, 360i and 440i plasma systems, with cross-reference support for PerCut 210M and 450M and Smart Focus 300 / 400. Duty range is 60-200A on O2; matching nozzles also cover N2 and Air paths, but those are separate gas-specific SKUs. For other sub-models, provide your torch model and original part number for fitment check.
Typical applications:
· CNC plasma tables running 60-200A on mild steel, stainless and aluminium.
· Medium-thickness plate where 60-200A nozzle bores from 0.8 mm to 1.7 mm are used.
· Fabrication shops standardising on one gas guide across the 60-200A range instead of stocking two.
Selection Guide: Pick the Right Gas Guide for the Current
Three parts sit in the same stack position and look similar, but they are not interchangeable. The split is by current band, not by torch model.
Current band
Gas guide
Cooling tube
Electrode
20-35A
G101 .11.848.221.145
G901Y .11.848.201.142
G002Y .11.848.221.300
20-200A
G101C .11.848.221.145C
G901Y .11.848.201.142
G002Y .11.848.221.300
60-200A
G102 .11.848.221.146
G901Y .11.848.201.142
G002Y .11.848.221.300
280-400A
G121C .11.848.421.145C
G931Y .11.848.401.142
G032Y .11.848.421.310
400A Ar/H2
G125 .11.848.421.149
G931Y .11.848.401.142
G034Y .11.848.421.330
Nozzle bore by amperage on the G102 stack: 0.8 mm at 60A (G2008Y), 1.0 mm at 90A (G2010Y), 1.2 mm at 130A (G2012Y), 1.4 mm at 160A (G2014Y), 1.7 mm at 200A (G2017Y). Nozzle cap is G3028 (.11.848.201.1628) for 60-200A; the 20-35A range uses G3004 (.11.848.201.1604).
G102 must not be swapped for G101, G101C or G121C. Mixing them changes the gas-path geometry and accelerates electrode wear. Do not confuse G102 with Z101 (.11.835.221.153) either - that is a different HALANSM® SKU, a 3-hole swirl ring, not the same part.
Installation and Handling
Replace the full front stack as one assembly. A worn nozzle or electrode will defeat a fresh gas guide within minutes, so mixing old and new parts is false economy.
· Power down the plasma source and bleed all gas pressure from the torch before disassembly.
· Remove the worn cap, nozzle, electrode and gas guide together; inspect each for arc scarring.
· Clean the seat and threads with compressed air. Check O-rings for dryness, flat spots or damage.
· Seat HALANSM® HLN-G102 squarely, then fit the electrode and nozzle coaxially in that order.
· Hand-tighten the retaining and shield caps. Brass threads strip easily - no wrench, no over-torque.
· Run a low-amperage test cut and confirm arc stability and gas flow before full production.
Frequently Asked Questions
What is the amperage range of G102?
G102 is rated 60-200A. It is not the same as G101, which covers 20-35A, or G101C at 20-200A. Match the gas guide to your actual cutting current before ordering.
Which Kjellberg® torches use G102?
G102 fits HiFocus 280i, 360i and 440i, with cross-reference support for PerCut 210M and 450M and Smart Focus 300 / 400. Send your torch model and original part number if your head is a different sub-model.
What insulator does the G102 gas guide use?
Published materials include both vespel and ceramic types. G101C uses a different insulator type. The two are not interchangeable, so confirm the exact insulator type with us before ordering.
Can I use an O2 nozzle with Air plasma?
No. O2 nozzles have a different bore and cooling geometry from Air and N2 nozzles. Running Air through an O2 nozzle accelerates electrode burn-off. Pick the nozzle by gas type as well as amperage.
What nozzle bore matches my cutting current?
On the G102 stack, bores run 0.8 mm at 60A through 1.7 mm at 200A: G2008Y, G2010Y, G2012Y, G2014Y and G2017Y. A bore that is too large for the current gives a ragged edge; too small and the electrode burns back.
How should G102 be stored?
Keep spares dry and clean, away from workshop dust and moisture. Leave O-rings lightly lubricated with oxygen-suitable lubricant and inspect the insulator for chips before fitting. A chipped insulator ruins swirl immediately.
Related Products
From the official HALANSM® Kjellberg consumables catalog:
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