Catalogo Calderas
Catalogo Calderas
Catalogo Calderas
All Thomas C. Wilson, LLC products are designed and manufactured in the U.S.A.
* The warranty is subject to conditions and limitations. Call for details.
Expander Accessories
Tube Clamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 13
Mandrel Drives and Extensions . . . . . . . . . . . . . . . . .Page 24
Taper and Triangle Shanks . . . . . . . . . . . . . . . . . . . . .Page 23
Extension Couplings . . . . . . . . . . . . . . . . . . . . . . . . . .Page 24
Universal Joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 25
Parallel Gear Train Drives . . . . . . . . . . . . . . . . . . . . . .Page 26
Reversible Ratchet Wrench . . . . . . . . . . . . . . . . . . . . .Page 26
Extension Drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 25
Right Angle Gear Drives . . . . . . . . . . . . . . . . . . . . . . .Page 27
1
Series 38 Expanders
Three Roll - Parallel Expanding - Three Flare Roll Type
38 EXPANDERS WITH DRUM MANDREL
Applications
• Water Tube Boilers
• Superheaters
• Fire Tube Boilers
• Economizers
Features
• Self-Feeding
• Three-Roll
• Three Flare Rolls
• Self-Contained Rolls
• Various Mandrels Available:
Drum, Short, Header,
Reverse
Steam/Mud Drum: 38 Series with drum mandrel.
2
(800) 230-2636 or fax (718) 361-2872 or [email protected]
Header Tube Expansion
When water tube boilers do not offer easy access to the tube seat, Thomas C. Wilson, Inc.
offers a variety of solutions. Our Series 38 and Series 114 Expanders are available with a
series of short mandrels. Used with gear trains, right angle drives or universal joints (See
Pages 24-25), they make tube rolling possible through a header or handhole.
Square Header: 38 Series Expander with Round Header: 38 Series Expander with short series
short series mandrels connected to Wilson mandrels connected to Wilson Extension Universal
Right Angle Worm Gear Drive (pg 25). Joint (pg 23).
Features
• Self-Feeding
• Four-Roll
• Double Flare Roll Type
• Self-Contained Rolls
• Various Mandrels
Available: Drum, Short,
Applications Header, Reverse
• Water Tube Boilers
• Fire Tube Boilers Cage Long Roll Mandrel
• Economizers
• Air Heaters
4
(800) 230-2636 or fax (718) 361-2872 or [email protected]
5
Series 114-S Expanders
Four Roll - Parallel Expanding - Straight Roll Type
114-S EXPANDERS WITH DRUM MANDREL
Mandrel Roll
Applications
• Water Tube Boilers
• Fire Tube Boilers
• Economizers
• Air Heaters
6
(800) 230-2636 or fax (718) 361-2872 or [email protected]
7
Tube Expander Lubrication, Care, and Maintenance
The service demanded of tube expanders is severe, therefore, 4. Expanders should be rotated at a speed proportionate to the
these precision tools require a reasonable degree of tube size, Gauge, and the length of the tube seat. Tube metal must
maintenance. For long, trouble-free, and economical service, we also be taken into consideration. The proper speed will provide
suggest: safe cold working of the tube metal without crystallization or
flaking. It will also ensure maximum expander life without undue
1. Remove all rust, mill scale, and other foreign matter from the roll or mandrel breakdown. The ideal speed will keep to a
inside and outside of the tube. Foreign matter on the inside of the minimum mandrel slippage and heating of the mandrels and rolls.
tube will become imbedded in the tube wall and may cause
flaking or galling of the rolls and mandrel. Mill scale or grit left on 5. After rolling each tube, clean and cool the expander in a solvent
the outer wall of the tube can cause damage to the tube seat and or light oil*, then properly lubricate the expander. It is a good
prevent formation of a pressure-tight joint. Cleaning tube ends is practice to use two expanders, if possible, so one can be cooling
best accomplished with a wire brush or a tube end polisher (see while the other is being used.
Page 28).
6. Inspect the rolls and the mandrel after rolling each tube.
2. Before using, the expander should be washed in a commercial Replace a chipped roll or mandrel immediately! A small chip in a
solvent to remove anti-rust, dirt, grease, and other foreign matter. roll can damage the entire set of rolls and the mandrel if not
Inspect the expander to make sure the rolls and mandrels are free replaced at once.
and in good condition.
7. When the job is completed, the expander should be cleaned
3. Before using, an expander should be properly lubricated with a thoroughly with a commercial solvent or light oil*, and it should be
pressure-resistant lubricant, such as Wilson Expander Lube (see stored in a manner which will avoid the possibility of the parts
Page 7). This water soluble lubricant was developed specifically rusting.
for tube rolling and may be mixed with water to the desired
consistency. For small diameter and light Gauge tubes, immerse *CAUTION: The presence of oil in the space between the tube
the expander in Wilson Expander Lube or a light bodied oil*, such and the tube seat can prevent the formation of a leak-tight
as SAE 10 or 20. For large diameter and heavy Gauge tubes, swab joint. Do not allow excess lubrication to run down the face of
or brush the expander with Wilson Expander Lube or a mixture of the sheet, so that it can seep into unrolled joints.
SAE 40* and graphite.
Step 1: Use a Series 65 Expander to “deep roll” the tube, so the area of
expansion is 3/8 inches (9.6mm) beyond the inside edge of the drum.
(see page 10)
Step 2: Use a Series 114 Expander to roll and flare the remaining half
of the tube length within tube seat. (see page 4)
8
(800) 230-2636 or fax (718) 361-2872 or [email protected]
Guidelines for Tube Expansion
Unproperly rolled joints create considerable additional expense: Here is an example of the application of this method for a 2-inch
under-rolled joints must be re-rolled, and over-rolled tubes must Outer Diameter 10 Gauge tube in a boiler.
be removed and replaced. The optimum joint is one that develops
a leak-tight joint with adequate strength for the intended service, 2.010
Tubesheet Hole: __________
but with the minimum amount of cold working (or tube wall -2.000
Tube Outer Diameter : __________
reduction). .010
Clearance: __________
9
Series 65 Expanders
Features
• Three Roll • Self-Feeding
• Parallel Expansion
• Adjustable Thrust Collar
• Non-Flaring
This expander is primarily intended for deep reach expanding. Its
parallel rolling and long, effective roll length make this tool ideal for “touch up”
rolling in thick tubesheets.
A thrust ball bearing collar gives friction-free operation and long tool life. Rolls
are self-retained in cage and will not fall in or out of cage when mandrel is with-
drawn from expander.
Series 22 Expanders
Features
• Three Roll • Self-Feeding • Non-Parallel Expansion
• Revolving Collar Type • Non-Flaring
The Series 22 Self-Feeding Tube Expander is especially designed for use in boiler rooms, boiler repair
shops, railroads, Scotch Marine boilers and for all general rolling in fire tube boilers where flaring is
not required.
The revolving thrust collar, of hardened steel, bears against the tube seat and provides non-jamming
operation with maximum resistance to abrasive action. Compact design permits working close to wall or
adjacent tubes.
For sizes 2-Inch and up, the rolls are self-retained and the expanders are suitable for far end rolling with
reverse taper mandrel and extension drive.
Spares
Tube Assembly Standard Mandrel Roll Reverse Taper Mandrel Expansion
OD Wall with Mandrel Square Set Square Range*
Inches (mm) GA (mm) Part No. Part No. Inch (mm) Part No. Part No. Inch (mm) Inches
11⁄2 (38.1) 13-18 (2.4-1.2) 30008 30564 30040 – – – 1.281-1.480
2 (50.8) 12-18 (2.8-1.2) 30012 30565 30044 20766 1.718-1.973
1/2 (12.7)
21⁄4 (57.2) 11-18 (3.0-1.2) 30014 3/4 (19.1) 30045 20767 1.973-2.229
30566
21⁄2 (63.5) 30016 30047 20768 2.156-2.478
10-18 (3.4-1.2) 3/4 (19.1)
23⁄4 (69.9) 30018 30567 30048 20769 2.406-2.727
3 (76.2) 9-18 (3.8-1.2) 30020 30049 2.625-2.986
30568 1 (25.4) 21692 1 (25.4)
31⁄4 (82.6) 9-18 (3.8-1.2) 30021 30050 2.875-3.237
10
(800) 230-2636 or fax (718) 361-2872 or [email protected]
Series 116 Expanders
Features
• Four Roll • Self-Feeding • Flaring Type
• Non-Parallel Expansion up to 3/4-Inch Tubesheet
This non-parallel, self-feeding expander features a design embodying four (4) expanding rolls and two (2)
flare rolls. It simultaneously flares and rolls an unusually fine surface with a minimum amount of
indentation by the flare rolls. The flaring operation is ideal for HRT and other fire tube boilers where final
beading of tube ends is the practice.
Mandrels and rolls are made of alloy steel ground after hardening to a fine surface finish. The rolls of
these expanders are self-retained. The self-retained roll feature makes this expander suitable for use
with reverse taper mandrels for far end tube expanding.
Spares
Tube Assembly Standard Mandrel Roll Expansion
Reverse Taper Mandrel
OD Wall with Mandrel Square Set Square Range*
Inches (mm) GA (mm) Part No. Part No. Inch (mm) Part No. Part No. Inch (mm) Inches
11⁄2 (38.1) 11-14 (3.0-2.1) 36607 30064 36653 – – – 1.215-1.389
2 (50.8) 10-16 (3.4-1.7) 36612 30566 3/4 (19.1) 36654 20768 1.680-1.959
3/4 (19.1)
21⁄2 (63.5) 10-18 (3.4-1.2) 36616 30567 36655 20771 2.192-2.453
3 (76.2) 9-18 (3.8-1.2) 36620 30569 1 (25.4) 36656 20774 1 (25.4) 2.654-2.954
* Expander range is taken at front of thrust collar.
Series 28 Expanders
Features
• Three Roll • Self-Feeding • Flaring Type
• Non-Parallel Expansion • Flaring Type to 3/4-Inch Tubesheet
The Model 28 Expander features three flare rolls and three straight self-retained rolls. The use of this
expander simultaneously flares the tube as a preliminary to beading operations. If on close centers, the
revolving thrust collar sets the tube and is notched to clear adjacent tubes. Ideal for most HRT and other
fire tube boilers. The self-retained roll feature also makes this expander a popular one for far end rolling
when used in conjunction with reverse mandrels and extension drives.
Spares
Tube Assembly Standard Mandrel Roll Reverse Taper Mandrel Expansion
OD Wall with Mandrel Square Set Square Range*
Inches (mm) GA (mm) Part No. Part No. Inch (mm) Part No. Part No. Inch (mm) Inches
2 (50.8) 35004 35024 35037 20766 1/2 (12.7) 1.687-2.000
3/4 (19.1)
21⁄2 (63.5) 10-16 (3.4-1.7) 35008 35026 35040 20769 3/4 (19.1) 2.156-2.500
3 (76.2) 35012 35028 1 (25.4) 35043 20772 1 (25.4) 2.625-3.000
Series 92 Expanders
Features
• Three Roll • Self-Feeding
• Non-Parallel Expansion • Non-Flaring Type to 5/8-Inch Tubesheet
The Series 92 Self-Feeding Tube Expander was designed for both boiler erection and boiler repair, either
complete re-tubing or just touching up leaky joints. Tube expansion is recommended in the tubesheet range
from 1/8-inch to 5/8-inch thick. The short mandrel is used for expanding tubes in open tubesheets as found, A B
for example, in most HRT, Scotch Marine, and package boilers and is included with expanders offered. The
header mandrel is offered for expanding through a waterleg or other obstruction which necessitates reach.
Order header mandrel separately.
Spares Specifications
Tube Assembly Standard Mandrel Roll Header Mandrel Eff. Roll Range*
OD Wall with Mandrel Square Set Square Length Inches
Inches (mm) GA (mm) Part No. Part No. Inch (mm) Part No. Part No. Inch (mm) Inches Dim. A Dim. B
MADE TO ORDER
1 (25.4) 36019 36054 36064 36093 .681 .937
35⁄16
11⁄4 (31.8) 36021 36055 1/2 (12.7) 36065 36094 1/2 (12.7) .940 1.206
10-13 (3.4-2.4)
11⁄2 (38.1) 36023 36056 36066 36095 4 1.156 1.469
2 (50.8) 36027 36057 3/4 (19.1) 36067 36096 3/4 (19.1) 35⁄8 1.665 1.960
* This self-feeding expander has no collar or flare to prevent the cage from pulling into the tube. Expansion corresponds to movement of tube rolling
from Dim. A to Dim. B. 11
Wilson Combination Beading Expander
Applications
• Expand and Bead 2, 21⁄2 and 3-Inch Tubes in One Operation
• For the Fabrication and Re-tubing of Fire Tube Boilers
Features
• Turn three operations (expanding, beading, and re-rolling) into one.
time-saving, labor-reducing process performed by just one tool!
• Cut labor costs by 50 to 65%!
• Purchase and maintain one tool instead of three.
• Minimal employee training or experience required.
• Produce a perfect, tight bead every time!
• Eliminate all noise for beading operation.
The Wilson Combination Beading Expander is one of our smartest tools! Rather than
expand a tube, then manually bead it, and then re-roll it with a straight roll expander, the
patented Combination Beading Expander (CBE) from Thomas C. Wilson, Inc. does all
three jobs in one seamless process.
And, the Wilson CBE doesn’t just save time, cut labor costs, and reduce your equipment
investment: it produces a perfect bead every time! Designed primarily for the
fabrication and re-tubing of fire tube boilers, the Combination Beading Expander rolls
and beads 2-inch, 21⁄2-inch and 3-inch Outer Diameter tubes, 10 to 13 Gauge.
Combination Beading Expander
Beading Roll in use with 909-Right-Angle
Guide Roll Assembly
Mandrel Pneumatic Tube Roller
* Assembly includes standard mandrel, grease gun (Part No. 53553) and service manual/parts list (SM-140).
† Short Series Mandrels for wet back or tight turnaround are available.
The Wilson CBE for 2-inch Outer Diameter tubes is a 4-roll expander.
For 21⁄2-inch and 3-inch tubes, it is a 5-roll expander. And, the Wilson
Combination Beading Expander is a self-feeding, parallel-rolling unit. Product Recommendations:
For best results, trim the tube to be expanded and beaded to a 3/16- Prolong the life — and improve the efficiency —
inch projection. (See Hydrualic Tube Cutter, P. 14) of the Wilson Combination Beading Expander
with B-Kool! B-Kool dissipates the heat
To order, simply locate your tube Outer Diameter and Gauge. Each CBE
generated by the CBE, increasing this Smart
assembly includes a standard mandrel, a grease gun (to lubricate the
Tool’s longevity, performance, and productivity. B-
tool), and a service manual. You should order extra mandrels, straight
Kool is available as a concentrate. Mix 20-24 parts
rolls, beading rolls, and guide roll assemblies, based on the number of
water to one part B-Kool.
tubes you will be expanding and beading. Your Wilson Product
Application Specialist can help you determine how many spare
Product Description Part No.
mandrels, straight rolls, beading rolls, and guide roll assemblies you
should order. To prolong the life of your Combination Beading Expander, B-Kool (Concentrate) 1 Quart 42161-0001
we recommend B-Kool. B-Kool (Concentrate) 1 Gallon 42161-0004
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(800) 230-2636 or fax (718) 361-2872 or [email protected]
Series 985 Chipping Hammers
Product Description Part No.
#2 Chipping Hammer (2-Inch Stroke) 985-0200
#3 Chipping Hammer (3-Inch Stroke) 985-0300
#4 Chipping Hammer (4-Inch Stroke) 985-0400
Includes:
1- Collar Retainer - 1.970-Inch Dia 53613-0001
1- Lock Spring 53613-0002
1- Rubber Bumper 53613-0003
Service Manual SM-134
COLLAPSING TOOLS
BEADING TOOLS .680 Diameter Straight Shank Tube OD Overall Length Type Shank
Inches (mm) Part No. Inches (mm) Inch
Part No. Radius Bead Tube GA 1 (25.4) 21913 111⁄2 (292.0) .580/.680
42689 9/64 13 and lighter 11⁄8 (28.6) 40514 Round
117⁄8 (301.6)
42690 3/16 10, 11 and 12 11⁄4 (31.8) 21914
.680
42691 7/32 8 and 9 11⁄2 (38.1) 21915 12 (304.8)
Round
2 (50.8) 74010-0800 125⁄8 (320.6)
CHISELS .680 Diameter Straight Shank KNOCKOUT TOOL - For use with No. 80 Boyer Gun
Tube OD Overall Length
Cutter Blade Width
Inches (mm) Part No. Inches (mm)
Part No. Inches (mm)
1 (25.4) 73750 11 (279.4)
53812 3/4 (19.1)
11⁄4 (31.8) 72626 8 (203.2)
53815 7/8 (22.2)
11⁄2 (38.1) 72806
53809 1 (25.4) 10 (254.0)
72230
53839 11⁄2 (38.1) 2 (50.8)
72940 12 (304.8)
Tube Clamp
Applications
To hold on the tubes while rolling at the opposite end.
Features
• Round flat plastic pads.
• Designed to bring the jaws together without turning or twisting. A
• High strength-to-weight ratio.
B
13
Hydraulic Tube Cutters
For 2, 21⁄2 and 3-Inch OD Tubes
Kit Includes:
• Hydraulic Tube Cutter with Guide Rolls
• 3 Sets of Cutter Wheels and Pins
• Hex Keys
• Service Manual – SM146C
The Wilson Hydraulic Tube Cutter quickly and efficiently cuts tubes in front of the This tool needs a minimum 1/2-inch projection to trim tubes, and an adjustable
tubesheet (prior to flaring and/or beading) in seconds. In fact, it cuts a 2-inch Outer collar ensures that tubes are consistently cut at precisely the right position.
Diameter tube in just 8 seconds!
We recommend the 909 or 910 Series Air-Driven Rolling Motor (Page 15-17) or the
The Wilson Hydraulic Tube Cutter automatically raises the cutter wheel, cleanly
41238 Electric Rolling Motor (Page 18). The Wilson Hydraulic Tube Cutter is
cutting through the tube. When the rolling motor is reversed, the cutter wheel is
available for rental.
automatically retracted.
U.S. Patent No. 4,424,629
Overall tool length is 22 inches.
Length of
Hydraulic Guide Roll Assembly (2 per set) Tube Cut-Off
Tube Tube Cutter Cutter Wheel Wheel Pin Min Max.
OD Wall
Inches (mm) GA (mm) Part No. Part No. OD Part No. Part No. Inches (mm)
9 (3.8) 42741-0009 42366-0009 1.640 F
10 (3.4) 42741-0010 42366-0010 1.668 L *43⁄4
2 (50.8) 11 (3.0) 42741-0011 42366-0011 1.696 42752 42754 U (120.6)
12 (2.8) 42741-0012 42366-0012 1.718 S
13 (2.4) 42741-0013 42366-0013 1.746 H
9 (3.8) 42742-0009 41735-0009 2.140
10 (3.4) 42742-0010 41735-0010 2.168
21⁄2 (63.5) 11 (3.0) 42742-0011 41735-0011 2.196
12 (2.8) 42742-0012 41735-0012 2.218 F
13 (2.4) 42742-0013 41735-0013 2.246 L 9
42753 42755-0001
9 (3.8) 42743-0009 41771-0009 2.640 U (228.6)
10 (3.4) 42743-0010 41771-0010 2.668 S
3 (76.2) 42743-0011
11 (3.0) 41771-0011 2.696 H
12 (2.8) 42743-0012 41771-0012 2.718
13 (2.4) 42743-0013 41771-0013 2.746
* 6-Inch with modified collar
14
Air-Driven Tube Rollers
Series 909 Right-Angle Tube Rollers: 1 to 4-Inch OD Tubes – Stall Type
Applications
• Rolling ferrous and nonferrous tubes in water and fire
tube boilers and other pressure vessels.
• Ideal for hard-to-reach and confined spaces.
Features
• Lightweight
• Reversible – stall type
• Heavy-duty gear system
• Right-angle design gives users built-in leverage
• Powerful motor
• 3/4-Inch square spindle
Kit Includes:
• Right-Angle Tube Roller
• Quick Connector (3/4-Inch square) 21137-0756
• Operating Hose 8973-0008
• Inline Lubricator 53360
• Carrying Case 44099
• Service Manual SM-156 (909-1600, 1700),
SM-253 (909-1900)
Series 909-1700/with 114 Flare Expander
Series 909-1900
Kit 909
15
(800) 230-2636 or fax (718) 361-2872 or [email protected]
Series 909 Right-Angle Tube Rollers: 2 to 4-Inch OD Tubes – Torque-Controlled
Applications
• Rolling ferrous and nonferrous tubes in water and fire
tube boilers and other pressure vessels.
• Ideal for hard-to-reach and confined spaces.
Features
• Lightweight
• Reversible – torque-controlled
• Heavy-duty gear system
• Right-angle design gives users built-in leverage
• Powerful motor
• 3/4-Inch square spindle
Kit Includes:
• Right-Angle Tube Roller
• Quick Connector (3/4-Inch square) 21137-0756
• Operating Hose 8973-0008
• Inline Lubricator 53360
• Adjusting Tool 909-2127
• Carrying Case 44099
• Service Manual SM-253
Torque
Control Dial
16
Electric-Driven Tube Rollers
Electric Tube Rollers: 1/2 to 3-Inch OD Tubes
Applications
• Rolling ferrous and nonferrous tubes in boilers,
heat exchangers, and other pressure vessels.
Features
• Wilson Electric Tube Rollers are durable, reliable,
and easy to use.
• Both the 41238 and 22488 include dead handles for
added leverage.
• On-Off and reverse switches are conveniently
located on the fixed handle.
• Exceeding their stall points will not damage these
rugged machines.
• Wilson offers a complete line for various tube
sizes and voltages. See chart below for selection.
The 22480 Electric Rolling Motor rolls The 41238 Electric Rolling Motor rolls The 22488 Electric Rolling Motor rolls
tubes to 11/2-inch Outer Diameter. tubes to 2 1/2-inch Outer Diameter. tubes up to 3-inch Outer Diameter.
Tube Overall
Voltage and Motor Free Speed Amps/ Drive Length Service
OD
Inches (mm) Frequency Part No. rpm Wattage Spindle Weight Inches (cm) Manual
110 Volts 22480-7000 10 Amps
60 Hz
⁄2 to 1 1⁄2
1
(12.7-38.1) 750
220 Volts
50 Hz
22480-7220 5 Amps
19 lbs.
110 Volts 41238-0000 10 Amps #3 Morse (8.6 Kg) 18 1⁄2 (47) SM-133
1 to 2 1⁄2 (25.4-63.5) 60 Hz 250 22.7 lbs.
220 Volts 22487-0220 900 Watts Taper Socket (10.3 Kg) 15 ⁄8
5
(40) SM-188
50 Hz
110 Volts
60 Hz 22488-0000 #4 Morse 23 1⁄2 lbs.
2 to 3 (50.8-76.2) 220 Volts 100 900 Watts Taper Socket (10.6 Kg) 16 3⁄4 (42) SM-188
50 Hz 22488-0220
17
(800) 230-2636 or fax (718) 361-2872 or [email protected]
Electronic Torque-Controlled Tube Rollers: 1/2 to 3-Inch OD Tubes
Applications
• Rolling ferrous and non-ferrous tubes in On/Off Switch
boilers, heat exchangers, condensers, and
other pressure vessels with accurate and
repeatable torque control.
Features
• Wilson Electric Torque-Controlled Tube Rollers
are durable, reliable, and easy to use. In most
cases, you are ready to roll tubes in less than Read-Out Screen
3 minutes.
• The torque control box is adjustable for expanding Motor Connector
torque and will automatically reverse the motor
when selected torque is reached.
• Control boxes are available in 110V or 220V single-
phase supply choices. Motors are on/off reversing
and equipped with dead handle that gives
operator added leverage and maneuverability.
• The system consists of a range of electric motors
and control boxes. See chart below for selection. Control Box Panel
Tube
OD Voltage and Motor Free Speed Amps/ Control Box Control Box
Inches (mm) Frequency Part No. rpm Wattage Part No. Amps
110 Volts
22480-7000 10 Amps 76500-0000
1
⁄2 to 1 1⁄2 (12.7-38.1) 60 Hz
750
220 Volts
50 Hz 22480-7220 5 Amps 76500-0000
110 Volts
41238-7000 10 Amps 76500-0000
1 to 2 1⁄2 (25.4-63.5) 60 Hz
250 20
220 Volts
50 Hz 22487-7220 900 Watts 76500-0000
110 Volts
22488-7000 76500-0000
2 to 3 (50.8-76.2) 60 Hz
100 900 Watts
220 Volts
50 Hz 22488-7220 76500-0000
Control Box Service Manual: SM-281
18
Electronic Tube Expansion
Wils-TronicTM Tube Roller
Electronic Tube Expansion
For 1/2 to 3-Inch OD Tubes
New
Product
Patent Pending
Features
• Two Modes of Operation (Manual and Automatic)
• Constant rpm at Various Torque Settings
• Auto Cycle for Continuous Rolling of Multiple Tubes
• Fully Programmable Keypad
• Security Lockout by Password
• Very Low Noise Level
• Telescopic Shaft Eliminates Operator Fatigue
• Flexible Tool that Allows for a Variety of Tools, including Expanders, Cutters, and
Reamers.
Specifications
Power Requirements: 220V 3 Phase 50 or 60 Hz
- or -
440V 3 Phase 50 or 60 Hz
Speed: Up to 1,400 rpm
Torque (programmable): 1 to 300 ft. lbs.
Weight: 350 lb.
Work Envelope Dimensions: up to 10 ft. x 10 ft.
with standard cart
19
The most important feature of the
Wils-TronicTM is its ability to maintain Mountable Stand, Included
constant speed during the entire with Mobile Base
rolling process, even at various Heavy-Duty Dual Ball
torque settings, making it faster and Bearing Turret Assembly
more efficient than conventional tube
rollers. It also runs much quieter than
any other tool on the market.
100
50
0
Mobile Base
50 75 100 125 150 175 225 300 325
with Casters
Speed (rpm)
How to Order
Wils-TronicTM Model Ultra-Low Torque Low Torque Mid Torque High Torque
Technical Data
Tube Capacity 1/2 to 3/4-Inch Tubes 1/2 to 11⁄2-Inch Tubes 3/4 to 3-Inch Tubes Up to 3-Inch Tubes
rpm 50-1000 rpm 0-1400 rpm 0-400 rpm 0-400 rpm
Torque Ranges 1-10 Ft-lbs. 1-30 Ft-lbs. 15-120 Ft-lbs. 80-300 Ft-lbs.
Accessories
Mobile Stand 48000-7000 46000-5400
Stationary Stand 48000-7010 46000-5010
3/8-Inch Quick Connector 46000-4200 46000-4200 —
1/2-Inch Quick Connector 46000-4250 46000-4250 21489-0500
3/4-Inch Quick Connector 21489-0750
3/4-Inch Extension Coupling 46500-4400
1-Inch Extension Coupling 46500-4500
1/2-Inch Jacobs Chuck 46000-4600 46000-4600 —
#2MT Adaptor 46500-6000
Telescopic Shaft 46000-4000 46000-4000 46500-4000
Service Manual SM-293 SM-287 SM-296
20
Electronic Tube Expansion
Enforcer-500 Tube Expanding Systems
Wilson Enforcer-500 systems offer the latest in electronic • Two Modes of Operation (Manual and Automatic)
torque controll for tube expanding. These systems feature • Constant RPM at Various Torque Settings
an articulating arm mount for reduced operator fatigue. A • Auto Cycle for Continuous Rolling of Multiple Tubes
torque sensing system allows the unit to accurately sense
• Fully Programmable Human-Machine Interface for Parameter Input
torque levels as low as 1 ft/lb and in 1/4 ft/lb increments.
• Pressure Regulation System to Adjust Level of Lifting Assistance for
The unit also includes an automatic lubrication system
Arm and Tool
that feeds lubricant directly to the collar to ensure longer
life of both expanders and tubes. • Automatic Lubrication System (Optional)
• Outstanding Torque Accuracy (+/- 0.5 ft-lbs.)
• Very Low Noise Level
• Low Operator Fatigue
• Holding Fixture Increases Expander Life
Human-Machine Interface
21
Tube Plugs - One Piece - 1 to 3-Inch OD Tubes
Wilson Tube Plugs offer a low-cost, quick, and effective method of sealing off leaky
tubes. They are inserted easily, allowing the return of tubular units back on-stream
without undue interruption of process schedules. Only a minimum amount of driving is
required to accomplish a positive seal without special tools. Plugs may also be welded.
Certification and traceability are provided.
Steel
OD Tube Wall
SA-105
Inches (mm) GA Inches (mm) Part No.
1 (25.4) 11-14 .120-.083 3.0-2.1 39710
1 (25.4) 15-22 .072-028 1.8-0.7 22034
11⁄8 (28.6) 15-22 .072-.028 1.8-0.7 40508
11⁄4 (31.8) 15-22 .072-028 1.8-0.7 42163
13⁄8 (34.9) 15-22 .072-.028 1.8-0.7 42164
11⁄2 (38.1) 15-22 .072-028 1.8-0.7 42162
13⁄4 (44.5) 10-13 .134-.095 3.4-2.4 42606†
2 (50.8) 10-13 .134-.095 3.4-2.4 42600†
21⁄2 (63.5) 10-13 .134-.095 3.4-2.4 42601†
3 (76.2) 10-13 .134-.095 3.4-2.4 42602†
New Applications
• To prepare a uniform projection of
Product tube ends prior to expanding the tubes.
• Trim boiler tube ends to a consistent
Adjustable Thrust projection before they are bead-rolled.
Bearing Collar • De-burr tubes after they are cut
or rolled.
Features
• Adjustable Thrust Bearing Collar
• Quickly trim tube ends to desired
projection
• Interchangeable, reversible cutter
Cutter Bits bits are easily replaced
• High Speed Steel Tool Bit
• Recommended speed: 150 rpm
Pilot
NOTE 1: Alternate Morse taper shanks are interchangeable on all tools and may be selected in place of the listed standard shanks.
#2 M.T., No. 39671 #3 M.T., No. 39672 #4 M.T., No. 39673
NOTE 2: The pilots are furnished in a diameter to suit the specific Tube Inner Diameter.
When ordering, either specify pilot diameter desired or the Outer Diameter and Gauge or wall thickness of the tube or pipe with which
the cutter is to be used.
23
(800) 230-2636 or fax (718) 361-2872 or [email protected]
Mandrel Drives
Mandrel drives serve the purpose of adapting tube expander mandrels to existing air Extra Inserts
or electric drills. Loosening the knurled nut releases the square insert type of socket Morse Taper Insert Square Assembly Square
for the introduction of another size. No. Size Inches Part No. Size Inches Part No.
3/8 20112-0037 3/8 20123
2
1/2 20112-0050 1/2 20124
3/8 21288-0037 3/8 21059
1/2 21288-0050 1/2 20113
3
3/4 21288-0075 3/4 20125
1 21288-0100 1 20126
3/8 20115-0037 3/8 20159
1/2 20115-0050 1/2 20113
Assembly includes one insert only. 4
3/4 20115-0075 3/4 20125
Specify catalog numbers. 1 20115-0100 1 20126
Drive Extensions
Male Square Overall Diameter
Size Inches Length Inches Inches Part No.
6 20041
3/8 12 1/2 20043
18 20197
4 20044
6 20045
9 20046
1/2 5/8
12 20047
18 20048
24 20339
4 20049
General purpose drive extensions are used with 15/16
6 20050
universal joints and parallel gear trains, as well as with
3/4 12 20052
couplings for extending expander mandrels through 18 3/4 20053
water legs, header, etc. 24 20054
6 11⁄4 20056
12 20058
1
14 1 20196
24 20060
24
(800) 230-2636 or fax (718) 361-2872 or [email protected]
Extension Couplings
Universal Joints
“GP” Universal Joints Square Size Square Size Overall Major
The Model GP is a female square type, smoothly rotating Female Female Length Dia.
and deflecting upon a common axis. It has unusual strength Inches Inches Inches Inches Part No.
for its size and is popular with all boilermakers. Minimum 3/8 3/8 21⁄4 7/8 42853
working angle is 135°. 1/2 1/2 23⁄8 1 20186
3/4 3/4 31⁄4 11⁄2 20187
1 1 33⁄4 13⁄4 20188
9 21015
1/2
16 21236
6 21242
Wilson Extension Universal Joints are useful for many 12 20008
1/2 1/2 15⁄16
applications when expanding tubes through waterwall 16 20009
20 20010
headers, superheaters, water legs, etc. The integral design
9 21244
eliminates coupling an extension with a separate universal 3/4 3/4 15⁄8
16 20019
joint. The 140° working angle matches the standard location 9 21246
of many tubes from the accessible handhole. 1 1 21⁄4
16 20028
25
Parallel Gear Train Drives
Wilson Parallel Gear Drives are suitable for many expanding
applications in various types of boiler headers. The inner gears have
individual bronze bushings, rotating on shafts that are an integral part of
the steel housing. These rigid gear shafts cannot come loose, hence
gears are maintained in perfect alignment under any operating
conditions. The alloy steel gears are specially heat-treated for maximum
strength. All parts are readily replaceable. For maximum service,
lubricate with Texaco Starfak grease M or equivalent. Select the proper
square hole size when ordering.
Extension Drives
This telescopic extension is suitable for the far end
rolling of tubes in such HRT types of boilers as
Fitzgibbons, Pacific, and similar types. It is used with
the same expander used for the front sheet. The
extension can be as short as 49" or extend as far as
desired. It will perform in a space as small as 7" at
the back end.
Female Added
Square Sizes Inches Adjustable Diameters Inches Reach Inches Square Plain Square Reach For Use With Reach Inches
Male Driven Female Driven Telescopic Drive Dim. “A” Dim. “B” Max Min Inches Extension Inches Assembly Max Min
3/4 1/2 20405 11⁄16 11⁄16 1/2 20471 20405
3/4 21581 13⁄16 11⁄4 49 92 3/4 21588 47 21581 96 139
1 1 20412 2 17⁄8 1 20473 20412
26
(800) 230-2636 or fax (718) 361-2872 or [email protected]
Right Angle Gear Drives
Right Angle Worm Gear Drive Features:
• One piece, steel housing with knurled shank.
Wilson Worm Gear Drives were designed for maximum duty and service life and • Replaceable bronze bushings and thrust washers.
are expressly suitable for operating in very confined areas of boiler headers. The • One piece worm and shaft.
gear housing is specially shaped and the knurled shank is small enough to • Hardened and ground alloy steel worm and shaft.
provide for expander feed movement when working through a handhole. They • Gear ratio - see chart.
will conveniently “reach in” for expanding tubes at right angles to, but offset • Handhole entrance - see chart.
from, a handhole.
The Wilson exclusive one piece steel housing and one piece worm shaft assures
complete rigidity, continued gear alignment, and extended service life. For
maximum service, lubricate with Vital E.P. SAE 250 oil or equivalent. Select the
proper square hole size when ordering.
Light Duty
Right Angle Bevel Gear Drive - Maximum 2-Inch Outer Diameter Tube
Features:
• All steel one piece housing.
• Alloy steel gears.
• Replaceable bronze bushing and thrust washer.
• Exceptionally compact.
• Gear ratio: 1-to-1.
• Will enter minimum 23⁄4-Inch round handhole.
This small, all steel, bevel gear drive is used in small headers. It is Male Female Overall
generally used in conjunction with a universal joint and extension Square Square Length Width Thickness
Inches Inches Inches Inches Inches Part No.
for tubes located approximately 100° radially from a handhole. Its
3/8 3/8 21601
use is restricted to a maximum 2-inch diameter tube and for 1/2 1/2
6 ⁄8
3
1 ⁄4
3
2 ⁄32
13
21602
extended service life it should be rotated in the slower ranges of
speed.
27
Handhole Seat Cleaning Kit
The Wilson Handhole Seat Cleaning Kit includes all the tools you
need to remove rust, deposits, torn gaskets, and other encrustations
from boiler drums, sectional headers, plug seats, handholes and pipe
flanges. It is also suitable for the surfacing of corners, as well as flat
areas of tanks, stacks, and bulkheads, prior to painting.
28
(800) 230-2636 or fax (718) 361-2872 or [email protected]
Handhole Seat Grinding Kit
The Wilson Handhole Seat Grinding Kit restores to a
smooth flat surface the gasket seal of any size handhole,
ensuring a perfect seal when the hole is closed. And the
unique Wilson Alignment Indicator eliminates guesswork
as to proper alignment of the grinding wheel with the seat to
be ground.
The unique Wilson Alignment Indicator (Part No. 1043) is Handhold Seat Grinding Kit (Part No. 1041-1601)
available as optional equipment and is included in the includes:
Handhole Seat Grinding Kit No. 1041-2601.
Product Description Part No.
Air Motor (90 psi, 22 SCFM Max) 1041-0088
2-Inch Grinding Wheel (Coarse Grit) 1041-0029
Optional Grinding Wheels 2-Inch Grinding Wheel (Fine Grit) 1041-1029
Extension Arm Assembly 1041-0093
Product Description Part No. 2-Inch Cup Brush 8340
21⁄4-Inch Diameter-Coarse Grit 1041-0081 Guide Roller (15⁄8-Inch diameter) 1041-0025
21⁄4-Inch Diameter-Fine Grit 1041-1081 Guide Roller (19⁄16-Inch diameter) 1041-0026
21⁄2-Inch Diameter-Coarse Grit 1041-0082 Guide Roller (11⁄2-Inch diameter) 1041-0027
21⁄2-Inch Diameter-Fine Grit 1041-1082 Guide Roller (17⁄16-Inch diameter) 1041-0028
23⁄4-Inch Diameter-Coarse Grit 1041-0083 MF Adapter (1-Inch-8M x 7/8-9F) 1041-0035
23⁄4-Inch Diameter-Fine Grit 1041-1083 MF Adapter (1-Inch-8M x 3/4-10F) 1041-0036
5/16-Inch Hex Key 52147
Optional Carbide Surfacers 3/16-Inch Hex Key 51254
Product Description Part No. 5/64-Inch Hex Key 52142
2-Inch Diameter 62524 Filter/Lubricator 8596
21⁄4-Inch Diameter 62525 Offset Socket Wrench (9/16-Inch x 7/16-Inch) 1041-0072
21⁄2-Inch Diameter 62526 Wheel Dressing Stone 1041-0066
Inspection Mirror 1041-0030
Mounting Assembly 1041-3067
Tool Box/Carrying Case 24939
Service Manual SM-121
Air Motor Specifications Handhole Seat Grinding Kit (Part No. 1041-2601)
includes items in Kit No. 1041-1601 plus
12,600 rpm
90 psi Product Description Part No.
Alignment Indicator 1043
22 SCFM
Motor Clamp Assembly 1041-0087
0.25 HP Service Manual SM-122
3/8-Inch NPT Inlet
29
Boilermaker’s Grinding Kit
The Wilson Boilermaker’s Grinding Kit includes a
variety of the tools and accessories that are needed on
most boiler repair projects. Many combinations of tools
are possible from the accessories supplied with the kit, so
many boiler repair tasks can be performed with this
comprehensive and affordable kit.
30
(800) 230-2636 or fax (718) 361-2872 or [email protected]
Pneumatic Beveling Machines: 5/8- to 3 7/8-Inch ID Tubes
Applications
• The removal of weld, the preparation of tube ends
prior to welding, and for facing operation.
• For light or heavy wall tubes or pipes.
• Two models covering 5/8-inch (12.7mm) Inner
Diamater to 3 7/8-inch (102mm) Outer Diameter tubes.
Features
• Compact and lightweight.
• Simultaneously bevel inside or outside and for
facing cuts.
• Heavy-duty bevel gear set.
• Reliable pneumatic motor.
• Internal locking holds tool securely in position
for safety and accuracy.
• Choice of crank feed (for 74805) or wrench feed.
• Dual swivel air connection eliminates hose
twisting and binding.
Kit Includes:
• Beveling Machine
• Complete Set of Inner Diameter Locking Wedges
• Wedge Rods
• 6 Cutter Bits
• 1 Hose Whip with Oiler
• Service Wrenches
• Carrying Case
• Service Manual - SM-308(74802), SM-309(74805)
Beveling
Machine
74802
Beveling
Machine
74805
Kit 74802
Cutter Bits:
The cutter bits illustrated at the right cover the
standard machining applications. Standard bits
are made from high-quality tool steel. Custom bits
are available with carbide and titanium materials,
and for other machining configurations.
Plain End Facing 37 1/2˚, 30˚
#74806 Outside Bevel
#74807 (37 1/2˚)
#74808 (30˚)
31
Pneumatic Accessories
It is very important to provide every air-operated tool with clean, lubricated, and
properly pressurized air. Many job sites lack such conditions and the air provided
may actually harm these air-operated tools. These popular assemblies, the Filter- Portable Type
Regulator-Lubricator and Filter-Lubricator, are offered as portable units.
Manifold
Type
32
(800) 230-2636 or fax (718) 361-2872 or [email protected]
Superheater Tube Cutters
Seal Weld Facing or Counterbore Cutter - Flat Cut Type
MULTI-TOOTH - Without Swivel
1/2-Inch Square
Drive Motor
100-125 rpm
1/2-Inch Square
Drive Motor
100-125 rpm
Swivel accessories are ball bearing for tubes 11⁄4-inch Outer Diameter and up.
Cutter Cutter Cutter Assembly Parts Swivel Assembly Parts
Tube Pilot Diameter Assembly Cutter Shank Pilot Swivel Assembly Swivel Washer Screw Bearing
OD
Inches (mm) Diameter Inches Part No. Part No. Part No. Part No. Part No. Part No. Part No. Part No. Part No.
1 (25.4) .805 1 ⁄2
1
72601-8053 72464-0001 72464-8053 72544-0002 72544-0008 72544-0007 38070 –
1.035 13⁄4 72546-0353 72537-0001 72464-0353
11⁄4 (31.8) 15⁄8 72914-0103 72914-0001
1.010 72464-0002 72464-0103
2 73292-0103 73292-0001 72951 72951-0001 – 39523 72951-0004
17⁄8 72555-2623 72555-0001
11⁄2 (38.1) 1.262 72464-2623
23⁄32 73510-2623 72906
1/2-Inch Square
Drive Motor
100-125 rpm
1/2-Inch Square
Drive Motor
100-125 rpm
Seal Weld Groove and Tube End Outside Chamfer - Miscellaneous Angles
1/2-Inch Square
Drive Motor
100-125 rpm
1/2-Inch Square
Drive Motor
100-125 rpm
Swivel accessories are ball bearing for tubes 11⁄4-inch Outer Diameter and up.
34
(800) 230-2636 or fax (718) 361-2872 or [email protected]
Superheater Tube Cutters
Tube End Outside Chamber
Fly-Cutter - Miscellaneous Angles
CHAMFER
1/2-Inch Square
Drive Motor
100-125 rpm
1/2-Inch Square
Drive Motor
100-125 rpm
35
Flo-Breaker - Safely Cuts Off Excess Air Flow
The powerful force of compressed air escaping from a Standard Model –
broken air hose causes the hose to whip, creating a Inserts Between
dangerous hazard to personnel and equipment. The Flo- Male Pipe Threads
Breaker safely cuts off excess air flow, so the hose will not
whip.
Features
• Non-Clogging
• Automatic Reset
• No Adjustment Necessary
• Stainless Steel Springs (unaffected by temperature)
• Low Pressure Drop-means high productivity
New York State BSA approved-patent no. 3,561,471
Pipe Size Shut-Off Flow Shut-Off Flow Rates at Selected Air Pressures
NPT Rate @90psi Standard Model Weight 60psi 90psi 110psi 130psi 150psi
Inches SCFM Part No. Pounds SCFM SCFM SCFM SCFM SCFM
3/8 45 1050-1040 38 45 49 52 56
65 1051-1030 1/4 55 65 71 76 82
1/2
80 1051-1040 68 80 87 94 100
115 1052-1020 97 115 125 135 144
3/4 135 1052-1030 3/8 114 135 147 159 169
180 1052-1040 152 180 196 212 226
1 250 1053-1020 3/4 211 250 273 294 314
11⁄4 450 1054-1020 51⁄4 380 450 491 529 564
11⁄2 650 1055-1020 7 549 650 709 764 815
2 1200 1056-1200 13 845 1050 1120 1190 1250
32
(800)
(800)
230-2636 or faxor(718)
230-2636 fax (718)
361-2872
361-2872
or [email protected]
or [email protected]
33
Thickness of Wall in Birmingham Wire GA in Millimeters
34
(800)
(800)
230-2636 or faxor(718)
230-2636 fax (718)
361-2872
361-2872
or [email protected]
or [email protected]
Inch
35
Visit tcwilson.com
VISIT OUR NEW WEBSITE AND USE OUR PRODUCT SELECTOR FEATURE TO
DETERMINE THE BEST TOOL FOR YOUR APPLICATION, QUICKLY AND EASILY
36
Trusted to Perform
Thomas C. Wilson, LLC services many In Stock:
markets such as:
Thomas C. Wilson has
• OEM pressure vessel manufacturers tremendous in-house
• Petro Chemical quantities and a global
• Power Generation network ensures that a wide range of products
• Marine and Shipyards are readily available. Our expanded inventory
• Food Processing includes equipment that not only helps you to
• Industrial HVAC perform but make your job easier as well. We
• Public Institutions and Municipalities also specialize in tube cutting, trimming facing,
• Paper and Sugar Mills beading tools, reaming rolling motors,
• General Manufacturing collapsing tools, pneumatic tools, shaft and
casings, cutter heads and accessories and
Thomas C. Wilson offers more than supplies. Additionally, Thomas C. Wilson
just products: understands that not every job requires a
purchase and not every budget can afford
MANUFACTURING: equipment ownership. We offer
a range of equipment rental options to get the
Our skilled personnel process new models right tool in your hands as quickly and
and specials to suit your needs. For some, cost-effectively as possible.
a catalog solution fits the bill. For others,
a more custom approach is needed. FACTORY
ENGINEERING:
• Raw Material - Only the best grades of
certified alloy steels are used to meet Tools are engineered
the rugged services need for to meet the rigorous
tube expanding. conditions in the
• Heat Treating - Accomplished in modern industry. State-of-
instrument controlled furnaces, the the-art designs are
instruments are constantly checked incorporated with a
to assure the accurate control proven tradition of
of temperature. excellence and
• Inspection ~ Thomas C. Wilson employs manufactured with
a range of inspection procedures and the best materials available. Our engineering
devices to ensure the highest possible department is constantly testing and
quality of every product. developing the tools for better equipment.
BE-2014