O2 / Air / N2 / ArH2 (match gas type to electrode and nozzle)
OD / Height / Thread
Confirm exact specs with us.
HALANSM®
SILVER CUTTING
HLN-Z4030
HALANSM® Kjellberg Z4030 Swirl Gas Cap .11.835.201.1591
Aftermarket Shield (Swirl Gas Cap), 3.0mm Bore, Copper Alloy
HALANSM® HLN-Z4030 is an aftermarket plasma shield, also known as a swirl gas cap, with a 3.0mm bore and copper alloy body, built for Kjellberg HiFocus 80i, 100, 130, 160i and PerCut 170 torches to deliver stable vortex gas flow and clean cuts.
Product Overview
The Z4030 swirl gas cap sits at the front of the plasma torch, directly behind the nozzle. It forms and stabilizes the swirling gas vortex around the arc, which focuses the plasma jet and expels molten material. The precision-machined copper body dissipates heat effectively, protecting the electrode and nozzle during continuous cutting.
Key Advantages
3.0mm Precision Bore: Stable Vortex Gas Flow: The 3.0mm bore produces a consistent swirl pattern for focused arc energy and minimal dross.
Durable Copper Alloy: Copper Alloy Body: High thermal conductivity for fast heat dissipation and longer wear life under sustained operation.
Direct Fit Replacement: Exact OEM Geometry: Machined to the .11.835.201.1591 reference dimensions for a direct drop-in fit on PerCut 170.
Batch Consistency: Batch Inspected: Every cap is checked for bore accuracy and sealing surface finish to ensure repeatable cut quality.
Specifications
Part Type:Shield / Swirl Gas Cap
Original Reference: Original Reference: Z4030 / .11.835.201.1591
Bore Size:3.0 mm
Material:Copper Alloy (copper / steel for O2 service)
Gas:O2 / Air / N2 / ArH2 (match gas type to electrode and nozzle)
OD / Height / Thread:Confirm exact specs with us.
Note: Note: Select bore size and gas type to match your nozzle and electrode; mixing ranges causes gas-flow mismatch and premature wear.
Compatible Equipment and Application
Compatible with Kjellberg HiFocus 80i, HiFocus 100, HiFocus 130, and HiFocus 160i plasma systems using the PerCut 170 torch. Suitable for mild steel, carbon steel, stainless steel, and aluminum. Provide your torch model and original part number for fitment check if unsure.
Selection Guide
Bore by Current Range: The Z-series swirl gas caps are sized by bore diameter. Select the bore that matches your current and gas type:
Higher current requires a larger bore to maintain correct gas velocity. Do not substitute a Z4030 3.0mm cap into a stack specified for 2.0mm or 4.0mm; the gas dynamics and seal seat will not match, leading to arc instability and rapid wear.
Installation and Handling
Power off the plasma system and fully depressurize all gas lines.
Remove the worn swirl gas cap and inspect the seat and threads for slag or damage.
Clean the seat, threads, and contact surfaces with compressed air.
Install the electrode, nozzle, and swirl ring first in the correct order.
Seat the Z4030 swirl gas cap squarely, then hand-tighten the retaining cap.
Do not over-tighten; excessive force damages the seat and sealing surfaces.
Run a low-current test cut to verify arc stability and gas flow before production.
Frequently Asked Questions
What Kjellberg systems fit the Z4030 swirl gas cap?
It fits HiFocus 80i, 100, 130, 160i and the PerCut 170 torch. Send your torch model and OEM part number for fitment confirmation.
What is the bore size of the Z4030?
The Z4030 has a 3.0mm bore. This is fixed by the .11.835.201.1591 reference and must match your nozzle and current setting.
What material is the Z4030 made of?
It is copper alloy with a radial-lathed finish. Copper provides high thermal conductivity, which extends wear life under continuous cutting.
How does the swirl gas cap affect cut quality?
It creates the vortex gas flow around the arc. A worn or wrong-bore cap causes unstable arc, more dross, and poor edge quality. Clean the seat and install squarely.
Can I use a different bore size, like Z4020 or Z4140?
No. Each bore is matched to a current and gas range. Using Z4030 where 2.0mm or 4.0mm is specified causes gas-flow mismatch, seal failure, and arc instability.
How should I store these consumables?
Store in a dry, clean environment away from moisture and contaminants. Keep sealing surfaces protected so the cap seats correctly on first use.
Related Products
From the official HALANSM® Kjellberg consumables catalog:
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