HALANSM® HLN-G4020 Swirl Gas Cap / Shield for Kjellberg HiFocus130i/161i/280i – OEM G4020 (.11.848.201.1520) 60A Equivalent

HALANSM®

Kjellberg Plasma Consumables — PerCut210M / PerCut450M Series

HALANSM® HLN-G4020 Swirl Gas Cap / Shield for Kjellberg HiFocus130i/161i/280i – 60A

OEM Equivalent: G4020 / .11.848.201.1520  |  PerCut210M “ G” Type  |  CrNi + Steel Construction

Summary: HALANSM® HLN-G4020 is a direct replacement swirl gas cap / shield (OEM G4020 / .11.848.201.1520) for Kjellberg HiFocus130i, HiFocus161i, and HiFocus280i plasma systems using PerCut210M torches at 60A O₂. Constructed from CrNi (chrome-nickel stainless steel) and steel, it generates the swirling gas flow that stabilizes the plasma arc, protects inner consumables from spatter, and delivers ISO 9013-compliant cut quality on mild steel, stainless steel, and aluminum from 0.5mm to 25mm.

1. What Is HALANSM® HLN-G4020?

HALANSM® HLN-G4020 is a direct replacement swirl gas cap / shield with OEM part number G4020 (.11.848.201.1520), compatible with Kjellberg HiFocus130i, HiFocus161i, HiFocus280i, HiFocus360i, HiFocus440i, and HiFocus600i neo plasma cutting systems operating at 60A with PerCut200, PerCut201, PerCut210M, and PerCut211M torches. The component is constructed from CrNi (chrome-nickel stainless steel) and steel, engineered to Kjellberg’s dimensional tolerances for the PerCut210M “G” type platform. It is rated for 60A O₂, N₂, Air, and F5 plasma service, generating the swirling gas flow that stabilizes the plasma arc, improves energy density, and focuses the cut.

The HLN-G4020 threads onto the torch body as the outermost component of the 20–200A consumable stack — installed after the G3004/G3028 nozzle cap, and working in conjunction with the G501 protection cap to shield inner components from spatter and molten metal. Its swirl gas channel geometry is precision-machined to Kjellberg’s gas flow specifications, ensuring arc stability and ISO 9013-compliant cut quality at low-to-medium amperage production loads.

2. Technical Specifications

⚠ Amperage Boundary: G4020 is rated 60A. For 20A use HLN-G4015; for 90–130A use HLN-G4025; for 90–200A use HLN-G4030; for 200A Contour Cut use HLN-G4035/G4040; for 280–360A high-amperage use HLN-G4350. Installing G4020 above 60A causes gas flow mismatch and rapid component wear.

3. OEM Cross-Reference

4. Complete Consumable Stack (HiFocus130i / PerCut210M, 35–60A O₂)

Nozzle Selection by Amperage (O₂):

Installation Note: G4020 is the outermost threaded component of the PerCut210M stack. It must be threaded onto the torch body after the nozzle cap (G3004/G3028) is in place. Hand-tight only — overtightening cracks the CrNi/steel body and disrupts gas channel geometry. The G501 protection cap then snaps over G4020 as the final spatter shield.

5. Application & Use Cases

✅ Ideal for

• 35–60A precision cutting on HiFocus130i — 0.5–6mm mild steel at 2000–3500mm/min; G4020’s swirl gas channel generates the vortex flow that constricts and stabilizes the plasma arc at low amperage, delivering ISO 9013 Class 1–2 cut quality with minimal dross.

• Medium-thin sheet metal fabrication at 60A — 3–12mm mild steel, stainless steel, and aluminum on HiFocus161i/280i; HVAC ductwork, electrical enclosures, agricultural equipment manufacturing where clean, narrow-kerf cuts are mandatory.

• Robotic 3D plasma cutting — G4020 + PerCut210M is Kjellberg’s designated stack for robot-mounted plasma at 35–60A; 0.5–25mm mixed metals at speeds up to 7000mm/min with consistent arc stability.

❌ Not Recommended For

• 90–200A cutting — G4020 is rated 60A. For 90–130A use HLN-G4025; for 90–200A use HLN-G4030; for 200A Contour Cut use HLN-G4035 / HLN-G4040.

• 280–360A high-amperage systems — G4020’s bore and gas channel geometry are optimized for low-to-medium amperage. For HiFocus360i/440i at 280–360A, use HLN-G4350 (.11.848.401.1550) on PerCut450M “G” type torch.

6. Why Choose HALANSM® HLN-G4020

7. FAQ

1. Is HALANSM® HLN-G4020 compatible with Kjellberg HiFocus130i?

Yes. HALANSM® HLN-G4020 is a direct replacement for Kjellberg G4020 (.11.848.201.1520), fully compatible with HiFocus130i, HiFocus161i, HiFocus280i, HiFocus360i, HiFocus440i, and HiFocus600i neo plasma systems using PerCut200, PerCut201, PerCut210M, and PerCut211M torches. It installs as the outermost threaded component: G901Y cooling tube → G002Y cathode → G101 gas guide → G2008Y nozzle → G3028 nozzle cap → G4020 swirl gas cap → G501 protection cap. —

2. Is G4020 the same as G4350?

No. G4020 (.11.848.201.1520) is the 60A swirl gas cap for PerCut210M “G” type torches, constructed from CrNi and steel. G4350 (.11.848.401.1550) is the 280–360A swirl gas cap for PerCut450M “G” type torches, constructed from copper alloy. They serve different amperage platforms — installing G4020 in a high-amperage stack causes gas flow mismatch and rapid failure.

3. What does the G4020 swirl gas cap actually do?

Three critical functions: (1) Generates swirling gas flow — internal vortex mechanism imparts rotational momentum to swirl gas (O₂/N₂/Air/F5), creating a constricted, high-energy-density plasma arc; (2) Stabilizes the arc — focused gas dynamics reduce arc root wander, ensuring ISO 9013-compliant cut quality; (3) Shields inner components — G4020 absorbs spatter and molten metal fallout, protecting the nozzle, electrode, and gas guide from premature wear.

4. What gas should I use with HLN-G4020?

Any Kjellberg-certified HiFocus gas. G4020 supports O₂, N₂, Air, and F5 as plasma gases, with O₂, N₂, Air, and F5 as swirl gases. Required purity: O₂ ≥ 99.5%, N₂ ≥ 99.99%. At 60A O₂ cutting: O₂ plasma at 0.8–1.0 MPa, 1250–2000 L/h; swirl gas at 0.6 MPa, 1750 L/h. No component modification needed. —

5. Can I use HLN-G4020 at 200A?

No. HLN-G4020 is rated 60A. Running it at 90–200A causes gas flow mismatch, arc instability, and accelerated bore wear. For 90–130A use HLN-G4025 (.11.848.201.1525); for 90–200A use HLN-G4030 (.11.848.201.1530); for 200A Contour Cut use HLN-G4035 / HLN-G4040. Match the swirl gas cap to your actual cutting amperage. —

6. When should I replace the G4020 swirl gas cap?

Replace when: (1) Thread damage prevents finger-tight seating; (2) Spatter accumulation inside the bore cannot be cleaned with wire brush; (3) Visible cracks, heat discoloration, or corrosion on the CrNi/steel body; (4) Cut quality drops — increased dross, wider kerf, or arc instability. Typical lifespan: 300–600 arc starts under standard 35–60A O₂ cutting. Continuing with a worn G4020 causes rapid degradation of the G2008Y nozzle and G002Y cathode.

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