HALANSM®

Kjellberg HiFocus® / PerCut450M® Plasma Consumables

Product Data Sheet — HLN-G521

HALANSM® HLN-G521 Protection Cap for Kjellberg HiFocus280i/360i/440i – 280–440A

OEM Cross-Reference: G521 / .11.848.401.081  |  Material: CrNi (Chrome-Nickel Stainless Steel)  |  Torch: PerCut450M® “G” Type

SUMMARY: HALANSM® HLN-G521 is a direct replacement protection cap (OEM G521 / .11.848.401.081) for Kjellberg HiFocus280i, HiFocus360i, and HiFocus440i plasma systems using PerCut450M “G” type torches at 280–440A. Made from CrNi (chrome-nickel stainless steel), it is the outermost shield component that protects inner consumables from spatter, molten metal, and heat radiation during sustained high-amperage O₂ cutting.

What Is HALANSM® HLN-G521?

HALANSM® HLN-G521 is a direct replacement protection cap (OEM: G521 / .11.848.401.081) for Kjellberg HiFocus280i, HiFocus360i, and HiFocus440i plasma systems using PerCut450M “G” type torches at 280–440A. Constructed from CrNi (chrome-nickel stainless steel), it is the final outermost component threaded onto the torch body after the G4350 swirl gas cap, providing a protective barrier against spatter, molten metal, and heat radiation during sustained high-amperage O₂ cutting.

The HLN-G521 snaps over the G4350 swirl gas cap as the last step of the PerCut450M consumable stack. Its CrNi construction offers superior high-temperature strength and oxidation resistance versus standard copper protective caps, maintaining dimensional stability at the extreme face temperatures generated during 360–440A O₂ production cutting. Unlike the G501 protection cap (.11.848.201.081) rated for 20–200A, G521 is engineered for the high-amperage “G” type stack and must be paired with G931Y cooling tube, G032Y/G034Y cathode, G2330Y nozzle, and G4350 swirl gas cap.

Technical Specifications

OEM Cross-Reference

Complete Consumable Stack (HiFocus440i / PerCut450M, 280–440A O₂)

Assembly sequence per Kjellberg service documentation:

INSTALLATION NOTE: G521 is the FINAL component — snapped onto the torch body AFTER the G4350 swirl gas cap is seated. It is not threaded; it slides over the G4350 body and locks into place. No tools required for installation or removal. Inspect for spatter buildup and cracking during every consumable change.

Application & Use Cases

 ✅  IDEAL FOR

• Sustained 360–440A O₂ cutting on HiFocus440i — 50–80mm mild steel at 300–500mm/min; G521’s CrNi body withstands extreme face temperatures without deforming, protecting the G4350 swirl gas cap and G2330Y nozzle from spatter accumulation.

• HiFocus360i 280–360A production cutting — 25–50mm mild steel at 600–1000mm/min; G521 + G4350 + G032Y/G034Y stack maintains 100% duty cycle with consistent ISO 9013 cut quality.

• Heavy fabrication with 100% duty cycle — shipbuilding, pressure vessels, structural steel where sustained high-amperage cutting demands reliable outermost shielding against molten metal fallout and UV radiation.

 ❌  NOT RECOMMENDED FOR

• HiFocus130i/160i at 20–200A — G521 is rated 280–440A. For these systems, use HLN-G501 (.11.848.201.081), the designated 20–200A protection cap. Installing G521 on a low-amperage stack creates gaps in the shield geometry and reduces spatter protection.

• PerCut451M with Ar/H₂ gas — G521 is engineered for O₂/Air/F5 plasma. For Ar/H₂ HiFinox cutting on PerCut451M, use HLN-G502 (.11.852.201.081) protection cap, which is specified for Ar/H₂ gas chemistry and PerCut451M torch design.

Why Choose HALANSM® HLN-G521

Frequently Asked Questions

Is HALANSM® HLN-G521 compatible with Kjellberg HiFocus440i?

Yes. HALANSM® HLN-G521 is a direct replacement for Kjellberg G521 (.11.848.401.081), fully compatible with HiFocus280i, HiFocus360i, and HiFocus440i plasma systems using the PerCut450M “G” type torch at 280–440A. It installs as the final outermost component: G931Y cooling tube → G034Y cathode → G121 gas guide → G2330Y nozzle → G3219 nozzle cap → G4350 swirl gas cap → G521 protection cap.

Is G521 the same as G501?

No. G521 (.11.848.401.081) is the high-amperage protection cap rated 280–440A for PerCut450M “G” type torches. G501 (.11.848.201.081) is the standard protection cap rated 20–200A for the same PerCut450M platform. They are not interchangeable — G501 is too small for the high-amperage stack geometry, and G521 creates shield gaps on low-amperage stacks.

What material is the G521 protection cap made from?

CrNi — chrome-nickel stainless steel. This alloy offers superior high-temperature strength and oxidation resistance compared to standard copper protective caps. At the extreme face temperatures generated during 360–440A O₂ cutting (often exceeding 400–600°C), CrNi retains dimensional stability without softening, ensuring consistent shield coverage and consumable protection throughout its service life.

How do I install HLN-G521?

No tools required. G521 is the final component of the PerCut450M stack — it slides over the G4350 swirl gas cap and snaps into place on the torch body. To install: (1) Complete stack assembly through G4350 swirl gas cap, (2) Align G521 notches with torch body slots, (3) Push firmly until it clicks into locked position. To remove: pull straight off. Inspect for spatter buildup and hairline cracks during every consumable change.

When should I replace the G521 protection cap?

Replace when: (1) Spatter accumulation inside the cap cannot be removed with a wire brush; (2) Hairline cracks appear on the CrNi body from thermal cycling; (3) The locking mechanism no longer seats firmly on the torch body; (4) Visible heat discoloration (blue/brown oxidation) covers >50% of the surface. Typical lifespan: 500–1000 arc starts under standard 280–440A O₂ cutting conditions.

Can I use HLN-G521 on HiFocus130i?

No. HLN-G521 is rated 280–440A. HiFocus130i operates at 20–130A — installing a high-amperage protection cap on a low-amperage stack creates shield geometry mismatch, reducing spatter protection for inner consumables. For HiFocus130i/160i, use HLN-G501 (.11.848.201.081), the designated 20–200A protection cap.

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