HALANSM® Kjellberg® Electrode Nozzle Shield and Cap

HALANSM®

SILVER CUTTING

Kjellberg® Plasma Consumables

HALANSM® Kjellberg® Plasma Consumables — Electrode, Nozzle, Shield & Cap

Aftermarket plasma consumables for Kjellberg® HiFocus neo, FineFocus and PerCut cutting systems — silver cathode electrodes, CoolFlow nozzles, gas guides, swirl gas caps, nozzle caps, protection caps and cooling tubes, engineered to OEM-tolerance dimensions.

HALANSM® Kjellberg® consumables cover the full wear-stack replacement — from the G002Y silver cathode and G2012Y CoolFlow nozzle at 20–200A, to the G032Y electrode and G4350 swirl gas cap at 280–440A — for stable arc initiation, clean cuts and consistent standoff across the full range of HiFocus neo, FineFocus and PerCut torches.

Product Overview

A plasma cutting head wears from the inside out. The electrode (cathode) launches the arc, the nozzle focuses it, the gas guide and swirl gas cap spin the plasma gas into a coherent jet, and the retaining/nozzle cap, protection cap and cooling tube hold the stack in alignment while removing heat. Every component in the HALANSM® Kjellberg® range is dimensioned to seat against the next, so the arc stays centered and the cut stays square.

The range is organized by current class rather than by torch name alone: 20–200A parts use the "G" low-amperage stack (PerCut 210M / 221M), while 280–440A parts use the high-amperage stack (PerCut 370.x / 450M / 451M). Mixing the two classes changes bore, seat and O-ring geometry — always confirm amperage and OEM article number before ordering.

Key Advantages

Silver Cathode, Stable Arc

G002Y / G032Y electrodes use a silver core with hafnium emission point for low ignition voltage, steady arc and predictable cathode wear across oxygen, nitrogen, air and Ar/H₂ gas.

CoolFlow Nozzle Geometry

Nozzles are sized to the amperage step (25A through 400A) with a controlled bore that focuses the plasma jet. Smaller bores for thin sheet, larger bores for thick plate — match to your cutting chart, not guesswork.

Two Current Classes, One Stack Logic

20–200A: G501 / G101 / G2012Y / G3028 / G4020 / G901Y. 280–440A: G521 / G121 / G2330Y / G3219 / G4350 / G931Y. The parallel structure makes kit building and batch ordering straightforward.

Batch Consistency and Inspection

CNC machining and 100% CCD inspection hold bore concentricity and seat flatness. Each batch is packed by SKU with the OEM cross-reference marked on the label for traceability.

Specifications

Coverage: full wear-stack replacement — electrode / cathode, nozzle / tip, gas guide / swirl ring, swirl gas cap / shield, nozzle cap / retaining cap, protection cap, cooling tube.

Model Family: HLN-KJELLBERG (G002Y, G2012Y, G501, G101, G3028, G4020, G901Y, G032Y, G2330Y, G521, G121, G3219, G4350, G931Y, F024, F2628L and full stack)

Compatible Systems: Kjellberg® HiFocus neo (80i–600i), FineFocus 800/900/160 Plus, PerCut 160/170/200/210/370.x/450, CUTFire 100i / Flash 100, PA-S hand torch

Material: High-conductivity copper alloy; silver-cored cathode with hafnium emission point; ceramic / PTFE insulating components where required

Amperage Range: 20–200A (low-current stack) and 280–440A (high-current stack); F-series nozzles rated to 400A for thick mild-steel cutting

Plasma Gas: O₂, N₂, Air, Ar/H₂, F5 — confirm gas and bore per OEM cutting chart

Process: Mechanized CNC plasma cutting; also suits manual / PA-S handheld torches in the listed range

OEM Cross-Reference — HALANSM® Part Number by Function

Selection Guide

Select by current class first, then by function. The part numbering follows the OEM pattern, so the fastest route is to match your existing article number from the table above.

· Step 1 — Confirm current class: 20–200A uses the low-amperage stack (G501/G101/G2012Y/G3028/G4020/G901Y); 280–440A uses the high-amperage stack (G521/G121/G2330Y/G3219/G4350/G931Y).

· Step 2 — Match the function in the stack: electrode first, then nozzle, gas guide, swirl gas cap, nozzle cap, protection cap and cooling tube. Replace as a set when wear is advanced.

· Step 3 — Match bore / amperage: 25–200A nozzles step by 25–40A increments; pick the bore called out in your OEM cutting chart for the material and thickness.

· Step 4 — Confirm gas: O₂, N₂, Air, Ar/H₂ and F5 all run across the range, but the electrode and nozzle life vary by gas. Use the chart — do not extrapolate.

· If your article number is not listed, or you run a PerCut 450M / 451M or hand-held PA-S torch, provide your torch model and original part number for fitment check.

Compatible Equipment / Application

HALANSM® Kjellberg® consumables are aftermarket / compatible replacements for the systems below. They are not manufactured by Kjellberg Finsterwalde and are not represented as OEM original parts.

· HiFocus neo: 80i, 100i, 130i, 160i, 161i, 280i, 360i, 440i, 600i — PerCut 210M / 221M torches (20–200A stack).

· HiFocus 280i, 360i, 440i — PerCut 370.x / 450M / 451M "G" type torches (280–440A stack).

· FineFocus 800, 900, 160 Plus; CUTFire 100i, Flash 100; PA-S hand-held torch.

· Smart Focus / PerCut 2000 / PerCut 4000 with F-series electrodes and nozzles (F024, F2628L and range).

Kjellberg®, HiFocus®, FineFocus®, PerCut®, SilverLine® and CoolFlow™ are third-party trademarks of their respective owners, referenced here only for compatibility identification. For unlisted configurations, provide your torch model and original part number for fitment check.

Installation and Handling

· Cut power to the plasma system and relieve gas pressure before opening the torch assembly.

· Remove worn parts in stack order. Inspect the electrode tip, nozzle bore, swirl ring holes and O-rings for pitting, deformation and clogging.

· Clean the torch body and seat. Lightly lubricate O-rings where the OEM service manual specifies — do not over-lubricate, as excess grease carbonizes in the arc zone.

· Assemble the new HALANSM® stack by hand in the correct order; seat each part flush before torquing to the OEM-specified value. Do not cross-thread.

· Perform a test pierce and a short cut at low current to confirm arc stability, gas flow and standoff.

· Store spares in sealed original packaging in a dry place, away from moisture and metal debris.

Frequently Asked Questions

What Kjellberg systems do HALANSM® consumables fit?

They fit HiFocus neo (80i through 600i), FineFocus 800/900/160 Plus, PerCut 160/170/200/210/370.x/450, CUTFire 100i / Flash 100 and PA-S hand torches. Provide your torch model and original part number for fitment check.

Are these OEM Kjellberg parts?

No. HALANSM® parts are aftermarket / compatible replacements, not OEM original. Kjellberg®, HiFocus® and PerCut® are third-party trademarks referenced only for compatibility.

What is the difference between the 20–200A and 280–440A stacks?

The low-current stack (G501/G101/G2012Y/G3028/G4020/G901Y) seats differently from the high-current stack (G521/G121/G2330Y/G3219/G4350/G931Y). Bore, seat and O-ring geometry differ — never interchange them.

How do I choose the correct nozzle for my amperage?

Nozzles step by amperage: G2006Y at 25A through G2330Y at 360A and F2628L at 400A. Match the bore to your OEM cutting chart for the material, thickness and gas you run.

What does the silver cathode do, and when should I replace it?

The silver-cored electrode with hafnium emission point launches and stabilizes the arc. Replace it when the pit depth exceeds the OEM limit, arc ignition becomes inconsistent, or cut quality drops.

How should I store and handle the consumables?

Store sealed, dry and away from debris. Inspect each part before assembly, lubricate O-rings per the service manual, and replace the full stack as a set when wear is advanced.

Related Products

From the official HALANSM® Kjellberg consumables catalog:

· HLN-G501 — Protection Cap for HiFocus 130i/161i/280i, OEM G501 (.11.848.201.081), 20–200A.

· HLN-G101 — Swirl Ring / Gas Guide for HiFocus 130i/160i/280i, OEM G101 (.11.848.221.145), up to 130A.

· HLN-G2012Y — CoolFlow Nozzle for HiFocus 130i/161i/280i, OEM G2012Y (.11.848.221.412), 130A O₂.

· HLN-G4020 — Swirl Gas Cap / Shield for HiFocus 130i/161i/280i, OEM G4020 (.11.848.201.1520), 60A.

· HLN-G901Y — Cooling Tube for HiFocus 130i/160i/280i, OEM G901Y (.11.848.201.142), 20–200A.

· HLN-G002Y — Silver Electrode for HiFocus & PerCut, OEM G002Y (.11.848.221.300), 20–200A O₂.

All models above are real HALANSM® products. Match the window size and power rating to your specific head before ordering.

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