HALANSM®
HALANSM® HLN-G501 Protection Cap for Kjellberg HiFocus130i/161i/280i – 20–200A
OEM G501 / .11.848.201.081 | Copper Alloy | PerCut210M / PerCut450M "G" Type | Direct Replacement
HALANSM® HLN-G501 is a direct replacement Protection Cap (OEM cross-reference G501 / .11.848.201.081) engineered for Kjellberg HiFocus130i, HiFocus161i, and HiFocus280i plasma systems using PerCut210M and PerCut450M "G" type torches at 20–200A. Constructed from copper alloy, it snaps over the swirl gas cap as the final outermost shield, protecting inner consumables from spatter, molten metal, and arc flash. G501 is the designated low-to-medium amperage protection cap in Kjellberg's PerCut consumable stack. |
What Is HALANSM® HLN-G501?
HALANSM® HLN-G501 is a direct replacement Protection Cap with OEM part number G501 (.11.848.201.081), compatible with Kjellberg HiFocus130i, HiFocus161i, and HiFocus280i plasma cutting systems operating at 20–200A with PerCut210M and PerCut450M "G" type torches. The component is constructed from copper alloy, engineered to Kjellberg's dimensional tolerances for the PerCut "G" type platform. It is rated for 20–200A O₂, N₂, Air, and F5 plasma service, snapping over the swirl gas cap as the final outermost shield to protect inner consumables from spatter, molten metal, and arc flash.
The HLN-G501 is the last component installed in the consumable stack — it snaps into place over the G4020/G4030/G4350 swirl gas cap with no threading required. Its copper alloy construction provides excellent thermal dissipation at the torch face, withstanding the extreme temperatures generated at sustained 20–200A O₂ cutting. The G501's open-front design allows unrestricted plasma gas flow while shielding the G3219 nozzle cap and G4350 swirl gas cap from direct spatter exposure, significantly extending the service life of all inner stack components.
Technical Specifications
Parameter | Specification |
HALANSM® Part Number | HLN-G501 |
OEM Cross-Reference | G501 / .11.848.201.081 (Kjellberg) |
Component Type | Protection Cap (Snap-on Shield) |
Material | Copper Alloy |
Rated Amperage | 20–200A |
Compatible Systems | Kjellberg HiFocus130i, HiFocus161i, HiFocus280i |
Compatible Torch | PerCut210M / PerCut450M "G" type |
Plasma Gas | O₂ (primary), N₂, Air, F5 |
Swirl Gas | O₂, N₂, Air, F5 |
Function | Outermost spatter shield; protects inner consumables from molten metal and arc flash |
Installation | Snap-on (non-threaded); no tools required |
Packaging | 5 pcs/anti-static box |
Supply Capacity | 9,000+ pcs/month |
Certifications | ISO 9001:2015, RoHS |
OEM Cross-Reference
HALANSM® PN | OEM PN | Component | Current | Compatible System |
HLN-G501 | G501 (.11.848.201.081) | Protection Cap | 20–200A | HiFocus130i/161i/280i + PerCut210M/450M |
HLN-G521 | G521 (.11.848.401.081) | Protection Cap (Hi-Amp) | 280–440A | HiFocus360i/440i + PerCut450M |
HLN-G502 | G502 (.11.848.201.082) | Protection Cap (Alternative) | 20–200A | HiFocus130i/161i/280i + PerCut210M |
HLN-G4020 | G4020 (.11.848.201.1520) | Swirl Gas Cap / Shield | 60A | HiFocus130i/161i/280i + PerCut210M |
HLN-G4350 | G4350 (.11.848.401.1550) | Swirl Gas Cap / Shield (Hi-Amp) | 280–360A | HiFocus360i/440i + PerCut450M |
Amperage Boundary G501 is rated 20–200A. For 280–440A high-amperage systems (HiFocus360i/440i), use HLN-G521 (.11.848.401.081) instead. Installing G501 above 200A causes rapid heat degradation and shield failure. |
Complete Consumable Stack (HiFocus130i / PerCut210M, 20–200A O₂)
# | Component | Kjellberg OEM PN | HALANSM® Equivalent |
1 | Cooling Tube | G901Y (.11.848.201.142) | HLN-G901Y |
2 | Cathode (Electrode) | G002Y (.11.848.221.300) | HLN-G002Y |
3 | Gas Guide / Swirl Ring | G101 (.11.848.221.145) | HLN-G101 |
4 | Nozzle (by amperage) | G2010Y(90A)/G2012Y(130A)/G2016Y(200A) | HLN-G201X series |
5 | Nozzle Cap | G3004(20-35A)/G3028(60-200A) | HLN-G3004/G3028 |
6 | Swirl Gas Cap / Shield | G4020(60A)/G4030(90-200A) | HLN-G4020/G4030 |
7 | ▶ Protection Cap ← You are here | G501 (.11.848.201.081) | HLN-G501 |
Nozzle Selection by Amperage (O₂):
Amperage | Nozzle OEM PN | HALANSM® Equivalent |
35A | G2007Y (.11.848.221.407) | HLN-G2007Y |
90A | G2010Y (.11.848.221.410) | HLN-G2010Y |
130A | G2012Y (.11.848.221.412) | HLN-G2012Y |
200A | G2016Y (.11.848.221.416) | HLN-G2016Y |
Installation Note G501 is the final component — it snaps over the swirl gas cap (G4020/G4030) with no threading. No tools required. Hand-inspect for cracks or excessive spatter buildup during every consumable change. Replace immediately if the snap-fit mechanism feels loose or the copper alloy shows heat discoloration. |
Application & Use Cases
✅ Ideal for the Following Applications • 20–130A precision cutting on HiFocus130i — 0.5–12mm mild steel at 1500–3500mm/min; G501's copper alloy body dissipates torch-face heat effectively, enabling ISO 9013 Class 1–2 cut quality with minimal dross on thin-sheet fabrication. • 90–200A medium-duty cutting on HiFocus161i/280i — 6–25mm mild steel, stainless steel, and aluminum at 800–2000mm/min; automotive components, HVAC ductwork, electrical enclosures, and agricultural equipment manufacturing. • Job shop mixed-material production — G501 + PerCut210M stack handles mild steel, stainless (304/316), and aluminum from 0.5mm to 25mm with a single set of consumables, reducing inventory complexity for small-to-medium fabricators. |
❌ Not Recommended For • HiFocus360i/440i at 280–440A — G501 is rated 20–200A. For high-amperage systems, use HLN-G521 (.11.848.401.081, 280–440A) which has reinforced copper alloy construction for sustained high-heat operation. • Underwater plasma cutting — G501 is designed for above-water operation. Submerged cutting requires specialized underwater shielding components to prevent water ingress into the torch body. |
Why Choose HALANSM® HLN-G501
Differentiator | HALANSM® Advantage |
Copper alloy construction | Optimal thermal dissipation at torch face; withstands sustained 20–200A O₂ cutting temperatures without warping or heat degradation |
Snap-on design (no threading) | Installs and removes in seconds without tools; eliminates cross-threading risk and reduces consumable change downtime |
OEM-equivalent dimensions | Machined to G501 (.11.848.201.081) tolerances for direct drop-in fit on PerCut210M/450M torch; seamless integration with G4020/G4030 swirl gas caps |
Inner consumable protection | Absorbs the brunt of spatter and molten metal fallout, significantly extending the lifespan of G3028 nozzle cap, G4020 swirl gas cap, and G201X nozzle |
High-volume supply | 9,000+ pcs/month production capacity; 5–10 business day lead time for in-stock orders; MOQ 5 pcs |
Quality inspection | Every HLN-G501 undergoes dimensional gauge inspection and visual defect check before shipment; ISO 9001:2015 certified manufacturing |
Frequently Asked Questions
### Is HALANSM® HLN-G501 compatible with Kjellberg HiFocus130i?
Yes. HALANSM® HLN-G501 is a direct replacement for Kjellberg G501 (.11.848.201.081), fully compatible with HiFocus130i, HiFocus161i, and HiFocus280i plasma systems using PerCut210M and PerCut450M "G" type torches at 20–200A. It installs as the final outermost component, snapping over the swirl gas cap (G4020/G4030) with no threading or tools required.
### Is G501 the same as G521?
No. G501 (.11.848.201.081) is the Protection Cap rated 20–200A for PerCut210M/450M "G" type torches. G521 (.11.848.401.081) is the high-amperage Protection Cap rated 280–440A for PerCut450M on HiFocus360i/440i. They are not interchangeable — G501 will fail under sustained high-amperage heat loads. Match the protection cap to your system's amperage range.
### How do I install the G501 protection cap?
G501 requires no tools. After installing the swirl gas cap (G4020/G4030), simply snap the G501 protection cap over it until it clicks into place. The snap-fit mechanism holds it securely during cutting. To remove, pull it straight off — no unscrewing needed. Inspect the snap-fit tabs for wear during every consumable change; replace if the cap feels loose.
### What does the G501 protection cap actually protect?
Three critical functions: (1) Spatter shield — absorbs molten metal droplets and slag that would otherwise accumulate on the G3028 nozzle cap and G4020 swirl gas cap; (2) Arc flash barrier — copper alloy body deflects radiant heat away from inner components; (3) Gas flow preservation — open-front design allows unrestricted plasma/swirl gas exit while blocking debris ingress. A worn G501 causes accelerated failure of all inner stack components.
### When should I replace the G501 protection cap?
Replace when: (1) Snap-fit mechanism feels loose or fails to click securely; (2) Visible cracks, warping, or heat discoloration (blue/brown staining) on the copper alloy body; (3) Excessive spatter buildup inside the cap that cannot be removed with a wire brush; (4) The cap no longer fully covers the swirl gas cap, leaving gaps. Typical lifespan: 400–800 arc starts under standard 20–200A O₂ cutting conditions.
### Can I reuse a G501 protection cap after removing it?
Yes, if it passes inspection. The G501 is designed for multiple reuse cycles — unlike the electrode and nozzle, it does not experience direct plasma arc erosion. As long as the snap-fit tabs are intact, the copper alloy body shows no cracks or warping, and spatter buildup is minimal, you can reinstall the same G501 across multiple consumable change cycles. This makes it one of the most cost-efficient components in the PerCut stack.
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