The TC Wilson WTC-1000 is an electronic torque control system for tube expanding operations in boilers, heat exchangers, condensers, and other pressure vessels where consistent, repeatable tube-to-tubesheet joints are critical. Unlike manual or pneumatic rolling motors that rely on operator feel, the WTC-1000 measures torque electronically and automatically reverses the motor the instant the preset torque value is reached — eliminating both under-rolled joints (which leak) and over-rolled joints (which distort the tubesheet ligament).

How does auto-reverse torque control prevent over-rolling?

The operator sets the desired expanding torque on the electronic controller. As the rolling motor drives the expander into the tube, the controller continuously monitors motor torque draw. When torque reaches the target setpoint, the controller instantly cuts forward power and reverses the motor, withdrawing the expander at exactly the correct expansion level. This closed-loop control removes operator variability — every tube in the vessel receives the same degree of expansion regardless of who is operating the equipment or how many tubes have been rolled that shift. A dead-handle switch on the motor provides positive operator control and added leverage during positioning.

Which tube sizes and materials can the WTC-1000 handle?

The system accommodates tubes from 1/2″ to 3″ (12.7 to 76.2 mm) outside diameter, covering the most common heat exchanger and boiler tube sizes. It works with both ferrous (carbon steel, stainless steel, duplex) and non-ferrous (copper, brass, copper-nickel, titanium) tube materials. Three motor speed options — 100, 250, or 500 RPM — allow the operator to match rolling speed to tube material and wall thickness: lower speeds for hard alloys and thin walls, higher speeds for soft materials and production rolling. The control box operates from 110 or 220 VAC single-phase input and includes a portable carrying case for transport between job sites.