49V30 - HW-27 Replacement TIG Torch Body Assembly 500A

Technical Overview of the ESAB 49V30 HW-27 Body & Tube Assembly

The ESAB 49V30 is a critical replacement component designed specifically for the Heliarc HW-27 series of water-cooled TIG torches. This assembly, commonly referred to as the torch body and tube assembly, serves as the structural and electrical core of the welding torch. It is engineered to handle extreme industrial welding applications, boasting a current rating of 500 Amps DC and 350 Amps AC at a 100% duty cycle. This high-performance specification makes it the standard choice for automated and manual welding of heavy-walled pipe, thick plate aluminum, and structural stainless steel.

Technically, the 49V30 assembly integrates the main torch head with the necessary conductive tubes that route shielding gas and cooling water to and from the front end. The body is constructed from high-grade copper alloys to minimize electrical resistance and heat buildup, ensuring that the full welding current is delivered to the tungsten electrode. The exterior is encased in a durable, high-temperature silicone rubber insulation that protects the operator from electrical shock and withstands the radiant heat generated during high-amperage arcs. This insulation also provides mechanical protection against impact and abrasion common in heavy industrial environments.

Compatibility is a key feature of the 49V30. While manufactured by ESAB for the Heliarc line, this body style adheres to the industry-standard "27 series" geometry. This means it is dimensionally interchangeable with the Weldcraft WP-27, CK Worldwide CK510, and other PTW-500 style torches. It accepts standard 27-series consumables, including heavy-duty collets, collet bodies, and gas lenses. The rear connections for power, water, and gas are designed to mate perfectly with standard cable assemblies used in water-cooled setups. For maintenance and repair operations (MRO), stocking the 49V30 ensures that downtime is minimized when a torch body fails due to thread wear, coolant leaks, or accidental arcing.

Installation of the 49V30 requires disconnecting the power cable, water, and gas hoses from the old torch handle. The assembly includes the rigid tubes that slide into the torch handle (sold separately), providing the backbone for the torch's ergonomic grip. Precision machining on the front threads ensures a tight seal with gas cups and back caps, preventing atmospheric contamination of the weld pool. This part is essential for maintaining the integrity of Class A welds in aerospace, power generation, and shipbuilding sectors.